Rock Breaker

Ref No.
V-0607
NOVEMBER 2006
JCB
Hydraulic Breaker
Operation & Service

Manual
D&A V-S01
INDIA eries
D&A Heavy Industries Co., Ltd.

www.yesbreaker.com
TABLE OF CONTENTS
1 Information
1.1 NOT structure
Main APPLICABLE
8V to 20V hyd.breaker
1.2 Main structure 30V to 550V hyd.breaker
1.3 Recommended Spare Parts
2 Operating
2.1 Specifications
2.2 Safety
2.3 Safety Instructions
2.4 Machine signs (decals)
2.5 Removal & installation of hydraulic breaker
2.6 Removaling the hydraulic breaker
2.7 Storing
2.8 Operation
2.9 Proper way of operation
2.10 Precaution for operation
2.11 Oil & lubrication
2.12 Working in high-temperature conditions
2.13 Working in low-temperature conditions
2.14 Chisel
2.15 Replacement of the chisel
2.16 Essential points in use
2.17 Chisel type by shapes
2.18 Cause of tool damage
2.19 Chisel warranty guide
3 Servicing
3.1 Inspection & maintenance
3.2 Bolts
3.3 Gas pressure and charging nitrogen gas
3.4 Wearing Parts
3.5 Working Pressure
3.6 Oil Temperature
3.7 Accumulator
3.8 Oil leakage
3.9 The contamination of working oil
3.10 Charging gas into back head & accumulator
3.11 Mounting & installation
2
3.12 General view of breaker installation to base machine
3.13 Precaution of installation
3.14 Hydraulic system
3.15 Adjusting adjuster valve to control impact blows
3.16 Hydraulic pipe line and controls
3.17 Dissembly & reassembly
3.18 Disassembling
3.19 Assembling
3.20 Repairing
3.21 Maintenance by the operator
3.22 Troubleshooting guide
3.23 Malfunction
3.24 Oil leaking
3.25 Poor operation of breaker
3.26 Torque
3.27 Torque to each bolt
3.28 Spanner size to each model
4 Auto lubrication system
5 Warranty registration card
6 Service report
7 Warranty policy
3
1-1.MAIN STRUCTURE OF D&A
D&A 8V~20V
D&A Hydraulic Breaker consists of five main

sections. Such as Cylinder, Piston, Control
Valve, Front Head, Head Cap.
Cap
1. The cylinder contains piston & valve.
2. Four through bolts are assembled and hold

cylinder & head cap together with front head.
3. Piston strikes the chisel by oil & gas

pressure.
4. Control valve is inside of cylinder to regulate

piston movement.
5. Chisel Pin is inside of front head to stops

the chisel from coming out.
6. Head cap has charged Nitrogen gas.
4
1-2.MAIN STRUCTURE OF D&A
D&A 30V~550V
INDIA 01
5
1-3. RECOMMENDED SPARE PARTS FOR EACH MODEL
D&A 8V D&A 15V
NO PARTS NAME PARTS NO Q’TY NO PARTS NAME PARTS NO Q’TY
1 CHISEL PIN B008-12600 1 1 CHISEL PIN B015-12600 1
2 SEAL KIT B008V-SK002 1 2 SEAL KIT B015V-SK002 1
3 GAS VALVE SET B008-13200 1 3 GAS VALVE SET B008-13200 1
D&A 20V D&A 30V
4 DIAPHRAGM B032V-14300 1
D&A 50V D&A 70V
2 T/BOLT SET B050-12200 1 2 T/BOLT SET B080-12200 1
5 DIAPHRAGM B032V-14300 1 5 FRONT COVER B070-12300 1
6 ROUND BUSH B070-12400 1
6
D&A 80V D&A 100V
2 T/BOLT SET B080V-12200 1 2 T/BOLT SET B102V-12200 1
5 FRONT COVER B080-12300 1 5 FRONT COVER B100-12300 1
6 ROUND BUSH B080-12400 1 6 ROUND BUSH B100-12400 1
7 DIAPHRAGM B032V-14300 1 7 DIAPHRAGM B132V-14300 1
D&A 130V
NO PARTS NAME PARTS NO Q’TY
1 CHISEL PIN B130V-12600 2
2 T/BOLT SET B131V-12200 1
3 SEAL KIT B132V-SK001 1
4 GAS VALVE SET B080-13200 1
5 FRONT COVER B130-12300 1
6 ROUND BUSH B130-12400 1
D&A 150V D&A 180V
1 STOPPER PIN B180-12650 2 1 STOPPER PIN B180-12650 2
2 RUBBER PLUG B030-12620 2 2 RUBBER PLUG B030-12620 2
3 CHISEL PIN B152V-12600 1 3 CHISEL PIN B180-12600 1
4 GREASE NIPPLE 004013-10400 2 4 GREASE NIPPLE 004013-10400 2
5 HOLLOW PLUG 004014-10200 1 5 HOLLOW PLUG 004014-10200 1
7 DIAPHRAGM B18V-14300 1 7 DIAPHRAGM B18V-14300 1
7
D&A 200V INDIA-01
D&A 220V
3 CHISEL PIN B180-12600 1 3 CHISEL PIN B221V-12600 1
7 DIAPHRAGM B22G-14300 1 7 DIAPHRAGM B22G-14300 1
D&A 300V D&A 360V
3 CHISEL PIN B300V-12600 1 3 CHISEL PIN B360V-12600 1
6 DIAPHRAGM B300-14300 1 6 DIAPHRAGM B300-14300 1
D&A 450V D&A 550V
6 DIAPHRAGM B450-14300 1 6 DIAPHRAGM B450-14300 1
7 T/BOLT SET B450-12201 1 7 T/BOLT SET B552V-12201 1
8
2.OPERATING
2-1. SPECIFICATIONS
Models
D&A 8V D&A 15V D&A 20V D&A 30V D&A 50V D&A 70V D&A 80V D&A100V D&A130V
Items
Operating Kg 120 140 175 245 310 480 540 800 900
Weight lb 265 309 386 540 683 1058 1,191 1,764 1,985
Overall mm 1135 1,259 1,317 1,513 1,597 1,894 2,062 2,125 2,234
Length Inch 44.7 49.6 51.9 59.6 62.9 74.6 81.2 83.7 88,0
mm 45 57 57 70 70 80 90 95 105
Hammer Tool
Inch 1.77 2.44 2.44 2.75 2.75 3.14 3.54 3.74 4.13
Setting Kg/cm2 175 175 175 175 175 175 175 175 210
Pressure Psi 2,500 2,500 2,500 2,500 2,500 2,500 2,500 2,500 3,000
2
Kg/cm 90~120 90~120 100~140 110~165 110~165 140~170 140~170 140~180 140~180
Working
1,305~ 1,305~ 1,450~ 1,595~ 1,595~ 2,030~ 2,030~ 2,030~ 2,030~
Pressure Psi
1,740 1,740 2,030 2,393 2,393 2,465 2,465 2,610 2,610
Oil LPM 15~30 23~45 26~50 30~60 35~70 45~90 50~100 75~120 80~140
Flow GPM 3.9~7.9 6.0~11.8 6.8~13.2 7.9~15.8 9.2~18.8 11.8~23.7 13.9~26.4 19.8~31.8 21.1~36.9
Blow Rate BPM 550~1,100 450~800 450~800 550~1,100 380~1,000 400~1100 350~1000 350~800 350~900
Head Cap
Kg/cm2 10~14 ( 142~200psi)
Gas Pressure
Accumulator
Kg/cm2 - 40~50 ( 570 ~ 710 psi) 55~60 (780~850psi)
Gas Pressure
Models
Items
D&A 150V D&A 180V D&A 200V INDIA-01
D&A 220V D&A 300V D&A 360V D&A 450V D&A 550V
Operating Kg 1150 1,450 1,580 1,800 2,400 2,700 3,300 3,800

Weight lb 2,535 2,999 3,374 3,969 5,292 5,954 7,277 8,379
Overall mm 2,441 2,522 2,589 2,775 3,016 3,085 3,508 3,580

Length Inch 96.1 99.3 101.9 109.3 118.7 121.5 138.1 141.0
mm 115 125 125 135 150 155 165 175

Hammer Tool
Inch 4.52 4.92 4.92 5.31 5.90 6.10 6.49 6.88
Setting Kg/cm2 210 210 210 210 210 210 210 210
Pressure Psi 3,000 3,000 3,000 3,000 3,000 3,000 3,000 3,000
Working Kg/cm2 160~190 160~190 160~190 160~190 160~190 160~190 160~190 160~190
Pressure Psi 2,275~2,702 2,275~2,702 2,275~2,702 2,275~2,702 2,275~2,702 2,275~2,702 2,275~2,702 2,275~2,702
Oil LPM 100~150 100~155 120~170 140~190 180~240 200~260 220~280 240~320
Flow GPM 26.4~39.6 26.4~40.9 31.6~44.8 36.9~50.1 47.6~63.3 52.8~68.6 58.0~73.9 63.3~84.5
Blow Rate BPM 350~900 320~800 320~800 340~800 250~650 230~600 230~600 230~550
Head Cap
Kg/cm2 14~16 (200~230psi) 10~14 14~16
Gas Pressure
Accumulator
Kg/cm2 55~60 (780~850 psi)
Gas Pressure
9
2-2. SAFETY
2-3. SAFETY INSTRUCTIONS
SAFETY IS THE OPERATION’S RESPONSIBILITY
D&A Hydraulic Breaker is designed to give maximum safety, but no machine design can prevent operator
JCB
error or carelessness.
READ
READTHIS
THISMANUAL
MANUALBEFORE
BEFOREYOU
YOUOPERATE D&A
OPERATE A HYDRAULIC BREAKER
JCB HYDRAULIC BREAKER
Untrained operators and failure to obey warnings can cause injury or death.
SAFE OPERATION NEEDS A QUALIFIED OPERATOR
A QUALIFIED OPERATOR MUST DO THE FOLLOWING BEFORE OPERATING:
1. UNDERSTAND THE WRITTEN INSTRUCTIONS, RULES AND REGULATIONS:
• The written instructions from D&A Company

the JCB include the delivery report, Operation & Maintenance
COMPANY
Manual,
and machine signs (decals).
• Check the rules and regulations at your locations. The rules may include an employer’s work safety
requirements. Regulations may identify a hazard such as an underground utility line.
2. HAVE TRAINING WITH ACTUAL OPERATION
• Operation training must consist of a demonstration and verbal instruction. The D&ADEALER
The JCB dealer give thisthis
will give
training before the hydraulic breaker is delivered.
• The new operator must start in an area without bystanders and use all the controls until he can control
the excavator with hydraulic breaker safely under all conditions of the work area.
A QUALIFIED OPERATOR MUST DO THE FOLLOWING WHEN OPERATING:
1. SAFETY FIRST
• When leaving the hydraulic excavator, lower the breaker to the ground and turn the engine off.
• Never attach a cable or sling to the breaker to hoist a load. Doing so is extremely dangerous.
• Remove the chisel before transporting the breaker.
• Keep all people and equipment away from the breaker during operation. Rock flying from the breaker can
cause serious accident.
10
2. PRIOR INSPECTION
• Check that there is sufficient hydraulic oil and that it is not contaminated.
• Check that hoses, bolts and nuts are secure.
• Grease the shank part of the chisel.

3. ATTACHING THE HYDRAULIC BREAKER
• When attaching the hydraulic breaker, the assistant is required who must be instructed by an excavator
driver. All directions, signals etc. must agreed on beforehand.
• The hydraulic breaker should only be attached to an excavator with sufficient load capacity. If the
excavator is too light it may become unstable under load and fall over.
• Do not touch any parts when the boom is moving.
• Check the pressure relief valve on the hydraulic system.
• Do not run any hydraulic lines through the driver’s cab. These lines may start to leak or even burst.
During operation, the hydraulic oil becomes very hot. Never touch the breaker.
4. FITTING / REMOVING THE CHISEL
• Always wear protective glasses and helmet when fitting or removing the chisel.
Metal splinters may chip off when the spring dowel sleeves are hammered out.
• Never use your fingers to check alignment of the recesses on chisel to the slots for the retaining bars.
5. BREAKER OPERATION
• If the noise level exceeds 90 dB(A), all workers in the immediate area, including the excavator driver,
Must were hearing protection.
• Stop the breaking immediately if any one moves into the danger area, which is much large for breaker
operation than for excavator operation due to the risk of flying rock splinters.
0
• Check the oil temperature constantly. Temperature of the hydraulic oil must never exceed 80 C.
If higher temperatures are measured in the tank, oil cooler must be fitted.
0
• At temperatures lower than minus 20 C, the hydraulic breaker should not be put into operated with cold
hydraulic oil, the seals in the hydraulic breaker may be damage.
Have warming the engine up and moving the boom to higher temperature before operate hydraulic
breaker.
• Only approved hydraulic oils should be used.
11
※ For an operator to be qualified, he must not use drugs or alcoholic drinks which change his alertness or
coordination while working. An operator who is taking prescription drugs must get medical advice to
determine if he can safely operate a machine.
2-4. MACHINE SIGNS (DECALS)
Reference Image Content Signs
Hearing protection must be

Head wearing ear protection
worn.
Consult manual for proper

Technical manual
service procedures.
Keep away the breaking area A working breaker with

while the breaker works. diagonal slash
Inject grease into the hole

Grease gun
with grease gun periodically.
“HIGH PRESSURE” is charge

Accumulator
prior to disassembly.
Keep away as the breaker is

High Temperature
so “HOT”
12
2-5. REMOVAL & INSTALLATION OF THE HYDRAULIC BREAKER
WARNING:
• The assistant must be instructed by the excavator operator and all signals and directions agreed upon
beforehand.
• The hydraulic breaker should only be attached to an excavator with sufficient load capacity. If the excavator
is too light, it may become unstable under load and fall over.
• Do not touch any parts when the boom is moving.
• Collect any oil which leaked out and dispose of it correctly.
• Check that the pressure relief valve on the hydraulic system has been approved by the relevant authorities.
• Check that the hydraulic pipe lines which connected on from the base machine the hydraulic breaker.
• Do not touch any parts for a while when the hydraulic oil keeps on being hot.
It may cause your hands to be burned.
• Never use your fingers to check the alignment of the bores.
2-6. REMOVALING THE HYDRAULIC BREAKER
1. Remove the hydraulic hose connected with the stop valve on the boom and the breaker.
2. Shut off the hose and the stop valve with caps in the toolbox.
3. Replace the breaker and the bracket by the bucket in the same order of the bucket replacement.
4. Follow the reverse order when installs the breaker.
13
2-7. STORING
1. Be sure to shut the caps of the dismounted breaker’s hoses.
2. Avoid getting wet in the rain.

Preserve inside or put on the tie with covering.
3. Apply enough grease to the chisel.
4. Follow these to prevent getting rust on the piston for long preservation:
• Dismount the chisel from the front cover.
• Deflate the nitrogen gas of head cap completely from the gas valve of head cap.
• Push up the piston after arranging the round stick with the stroke piston by light hammering from the
front cover.
• Let the residuary gas pressure out of head cap.

• Apply grease to the inside of front cover and chisel then attach to the front cover.
The hydraulic breaker should be stood vertically. Secure the hydraulic breaker during lengthy periods of non-
use to ensure that it cannot fall over.
14
2-8. OPERATION
First of all, precautionary measures should be taken to the rule out the rule out the risk of accident.
• Only operate the hydraulic breaker from the driver’s seat in the excavator cab.
• Close the front screen / splinter guard on the drivers cab to avoid injury from flying rock splinters.
• Wear ear protection to prevent hearing impairment. Anyone in the immediate vicinity of breaker operations
should also wear ear protection.
• Switch off the hydraulic breaker immediately if any one moves into the danger zone, that is within a radius
of at least 7 metres around the hydraulic hammer. Depending on the application greater distances may
have to be observed.
2-9. PROPER WAY OF OPERATION
1. Proper thrust
To break effectively, a proper thrust force has to be applied to the breaker. If a thrust is insufficient, a
hammering energy of the piston is not efficiently for breaking rocks. Then, the hammering force is
transferred to the breaker body, arm and boom of the base machine etc. to result in damage of those
parts.
On the other hand, if a thrust is excessive or breaking is performed with boom of the base machine
raised, the machine may suddenly tilt toward the movement, rocks are broken and the breaker body
may violently hit against rocks to result in damage.
15
If hammering is performed under such a condition, vibrations may also be transmitted to the tracks therefore,
hammering in such a manner should be avoided to also protect the tracks.
Further, during hammering, always take care of applying a thrust to the breaker. Do not hammer without
proper applied thrust.
2.Direction of thrust
Apply a thrust in a straight line with the tool place the tool on a rock with the hammering side as
vertically as possible. If the hammering side is oblique, the tool may slip during hammering to cause the
chisel and piston to be broken, or seized. When breaking, select the point of a rock on which hammering
can be performed stably and fully stabilize the chisel to hammer.
16
2-10. PRECAUTION FOR OPERATION
The operator should pay attention to the following points during operation.
2-10-1. Stop the operation as soon as the hoses vibrate excessively.
Check to see if the high and low pressure hoses of the breaker vibrate excessively. If that, the accumulator
may be defective and then contact with the service shop appointed by D&A JCB dealer in your territory for
repair. Further check oil leakage at the hose fitting points, if oil oozes, retighten them. Visually inspect
whether there is a surplus of tool, during operation as illustrated (See below). If not, the tool must be
seized in the front head.
Disassemble the front head, and inspect the components and repair or replace defective parts.
17
2-10-2.Chisel Stroke
Chisel Stroke Chisel Stroke

Hammer model
mm mm
D&A 8V 25 1.28
D&A 15V 41 1.61
D&A 20V 41 1.61
D&A 30V 48 1.89
D&A 50V 45 1.5
D&A 70V 43 1.7
D&A 80V 45 1.77
D&A 100V 50 1.97
D&A 130V 49 2.21
D&A 150V 46 2.21
D&A 180V 59 2.32
D&A 200V 59 2.32
D&A 220V
INDIA 63 2.48
D&A 300V 71 2.8
D&A 360V 72 2.87
D&A 450V 74 2.9
D&A 550V 75 2.95
2-10-3 Stopping (Avoid idle hammering to the utmost)
As soon as rocks are broken, stop the hammering. If idle hammering is continued, the accumulator may be
damaged, the bolts loosened or broken and, further more, the base machine also affected adversely.
When a proper thrust is not applied to the breaker or the chisel used as a lever, the state of idle
hammering will be brought. (In idle hammering, the hammering sound is not normal.)
2-10-4 Never use to move the rocks.
As shown on the picture, do not roll or throw down a rock with the end of the chisel or the side of the
bracket using the oil pressure for the base machine boom, arm, bucket, swing or traveling because the
bolts of breaker may be broken, the bracket damaged, the chisel broken or scuffed, and the boom or arm
damaged. Avoid moving rocks. Especially, never travel the machine with the tool in a rock.
18
2-10-5 Never lever with the breaker.
Never attempt to use the hydraulic breaker as a crowbar, as this will cause the working tool to break.
19
2-10-6 Never breaking to exceed 30 seconds.
When rocks are hardened, do not hammer the same place for such a long time to exceed 30 seconds but
change the point to be hammered. The long time hammering raises the oil temperature to result in the
damaged accumulator and cause the chisel to be excessively worn.
2-10-7 On a hard, large rock, start breaking at the end point. (Advance)
Beginning to hammer at the crack or the end will enable even a big rock to be broken comparatively easily.
Advancing in large steps will not improve working results. Advancing in small steps is more effective.
2-10-8 Operate the breaker at a proper engine speed.
Breaker rocks at the specified engine speed. Raising the engine speed more than necessary does not
increase the hammering force but raises the oil temperature to result in the damaged equipment.
20
2-10-9 Must never be used in or under water also in mud without prior conversion.
If water were to penetrate the percussion chamber, each blow would create a pressure wave. These
pressure waves would cause irreparable damage to the stripper and seals on the hydraulic breaker, and in
addition the lower percussion piston zone would rust. Water could also penetrate the carrier’s hydraulic
system.
In order to avoid damage to the hydraulic breaker, JCB
D&A has developed a special kit for operating for under
water.
2-10-10. Never use as a sledgehammer.
Before starting up, rest the breaker on the ground. Never attempt to use the breaker and excavator boom as
a sledgehammer to beak material. This will cause each part of the base machine to be damaged.
21
2-10-11. Never breaking with the cylinders of base machine extended to the end of stroke.
The excavator may easily damage when the break material is broken with the cylinders of base machine
stretched to the end.
2-10-12. Never use for transport or lift purposes.
The hydraulic breaker is not designed to lift or transport loads. The breaker may easily damage and it is
very dangerous.
2-10-13. Needs Warming up the base in winter.
If the breaker is operating with low oil temperature in winter, the piston & seals may easily be damaged.
It is required that warming up the engine of base machine from five to twenty minutes and moving the
o
boom. Oil temperature must reach to min. 30 C.
(Referto
(Refer “Instruction Book for
Carrier Machine Base Machine”)
Manual)
22
2-11. OIL & LUBRICATION
D&A
A JCBhydraulic
hyraulic breaker
breaker required proper viscosity of hydraulic oil & grease as below when using oil extremely
cold or hot weather.
Lubricate to the contact faces in the lower breaker part between the working tool and the wear bushes.
Hydraulic Oil Grease
High Temperature Low Temperature

NLGI No.2
ISO VG 68 ISO VG 46 (265-295)
(61.2-74.8 cst) (41.4-51.6 cst)
Grease gun application
Model No. of Pump
D&A 8V - D&A 80V 5–7
D&A100V - India
D&A220V 11 - 15
D&A300V - D&A360V 17 - 20
D&A450V - D&A550V 20 - 25
2-12. WORKING IN HIGH-TEMPERATURE CONDITIONS
o
The temperature of the hydraulic oil must be monitored to ensure it does not exceed 80 C. If higher
temperatures are measured in the tank, oil cooler must be fitted. Only use hydraulic oils of sufficient viscosity.
In summer and tropical climates, the minimum requirement is a hydraulic oil type HLP 68.
2-13. WORKING IN LOW-TEMPERATURE CONDITIONS
o
The temperature down to 20 C below freezing there are no special regulations, the hydraulic oil must be
warmed up before operating. This is achieved by
-Starting up the excavator motor.
carrier engine
-Moving the boom.
o
This raises the oil temperature. Once it has risen above 0 C, the hydraulic breaker can be start up. Leave the
motor and the pumps of the excavator running during breaker I n work.
carrier
Please note:
The hydraulic breaker and excavator
carrier do not operate to full capacity until the oil temperature has reached at
o
least 60 C.
WARNING:
Feeding hydraulic oil to an extremely cold hydraulic breaker will cause internal stresses in the unit resulting
in its failure. If the breaker is used without preheating the hydraulic oil, the hammer seals may fracture and
the diaphragm in the high-pressure accumulator may tear. (Please observe the excavator manufacturer’s
carrier machine
regulations.)
23
2-14. CHISEL (TOOL)
WARNING: For safety reason, the carrier must be switched off before performing the following work.
• Never use your fingers to check whether the recesses on the working tool shaft are aligned to the slots for
the chisel pin.
• Always wear protective glasses when fitting or removing the tool, since metal splinters may fly off when
hammering out the stopper pins.
• Clean away any dirt adhering to the working tool in the insert zone.
• Lubricate to the contact faces in the lower breaker part between the working tool and the wear bushes.
• The chisel should only be fitted correctly.
24
2-15. REPLACEMENT OF THE CHISEL
1. •D&A 8V~80V: Push the spring pin back into the hole is being spring with the pin punch.
•D&A 100V~550V: Knock the stopper pin & rubber plug of the upper for chisel pins out with hammer And
1. INDIA
pin punch.
2. Take the chisel pin out by using a pin punch to push the chisel pin out from under of the breaker.
3. Replace the new chisel after removed.

The chisel is heavy, so careful attention needed.
▶ ▶
D&A 8V~80V
▶ ▶
D&A 100V~550V
INDIA
2-16. ESSENTIAL POINTS IN USE
Follow these warning to prevent of failure or crack on the chisel and holder bushing.
• Avoid lifting, twisting and hitting.

• Avoid getting wet in the rain.
• Avoid getting injured from hitting between the chisels or to other hard things.
• Avoid heating.
25
2-17. CHISEL TYPES
Type of Chisel Application
Conical Breaking concrete, rock and

(Universal) pavement
Moil Breaking concrete, rock and

(Pyramid) pavement
Wedge H
Mining, foundation, trenching,
demolition, finishing slopes
Wedgh V
Flat end
Mining, breaking oversize, demolition
(Blunt)
※Use the genuine

JCB JCB our
chisel for D&A hydraulic breaker if not use CANproduction
TAKE NO we have no
responsibility for even other parts.
2-18. CAUSE OF TOOL DAMAGE
1. Continuous side pressure due to leverage, incorrect driving angle and using the hammer to pull the heavy
objects.
2. Free running leading to the damage on the chisel pin.
3. Low temperature causing the tool to be more susceptible to fatigue failure.
4. Overheating of tool by the friction caused by improper lubrication and excessive bending.
5. Excessive wear of front cover making piston blow on the top face of the chisel by inclined direction
causing the damage on the tool head as well as on the bottom of the piston.
26
27
2-19. CHISEL WARRANTY GUIDE
The purpose of this guide is to enable you to advise your customer as to the correct application of D&A
JCB
chisels and assist you to resolve complaints immediately they occur.
GUIDE TO WARRANTY CLAIMS
1. Bending or breakage of rods due to incorrect operation:

Operator always has to hammer rod in vertical on breaking objectives.
Rejected for Warranty Claim.
2. Normal wear due to hammering:

Wear is influenced by ground conditions.
3. Softening of rod point (Mushrooming) due to hammering on the same point for a longtime:
Do not hammer more than 30 seconds on the same point.
4. Chipping of rod point:

Mishandling by hammering at unstable setting.
5. When rods are deformed due to overheating with welding.

6. Damaged on the impact area, breakage and bending of rods due to abnormal wear of bush (has wornover
has worn over
8mm)
8mm.
7. Breakage and abnormal wear in F area due to blank firing.

28
8. Typical of high stress fracture, usually caused by using the machine to “pull”.
9. Typical fractures caused by excessive bending of the demolition tool.

10. Typical fracture caused by levering tool while buried in the burden.
11. Mushrooming; this is caused by driving the point into hard dense material for too long a period of time
without penetration. This generates intense heat, softening the point, thus causing it to ‘mushroom’.
29
12. A chisel fatigue failure will generally occur approximately 100mm(4”) either side of the chuck front face.
13. The polished semi-circular are in the blow picture is the fatigue area and generally starts from a damage
mark or other stress raiser on the outside of the chisel and spreads inwards.
14. Note fatigue lines originate from internal point, not outer diameter:
Caused by manufacturing defects.
Accepted for Warranty Claim.
30
SERVICING
3-1. INSPECTION & MAINTENANCE
WARNING:
• When dissembling the head cap: It may spring out of the head cap very suddenly due to gas pressure in
the head cap:
-Be sure to release gas out from the head cap before disassembly.
-Be sure to completely tighten the through bolts with the specified torque before gas charging.
• When dissembling the gas valve: There is being inflate nitrogen gas in head cap.
If discharged gas pressure before disassembles the gas valve, spring the gas valve up and it will be very
dangerous.
-Be sure to release gas out from the head cap before disassembles gas valve.
It may spring the chisel out When charge the nitrogen gas into head cap.
Do not stand in front of the chisel to avoid accidents.
• Discharge the gas pressure with “L” wrench(5mm) from gas valve after released the plug of gas valve.
31
3-2. BOLTS
In case the breaker is working for long time, easy to the bolts is to be loosened. Required regular checking.
If retighten loosen bolt, should be better retighten all together the bolts that it play a same roll.
In case of frequent loosing, ask for help of the service shop of D&AJCBdealer.
3-3. GAS PRESSURE AND CHARGING NITROGEN GAS
D&A hydraulic breaker operates with hydraulic oil & gas pressure.
JCB
WARNING:
Fill with nitrogen only. Filling with air or oxygen runs the RISK OF AN EXPLOSEN!
• If gas pressure becomes over than optimum gas pressure, the breaker gets overload.
But if the gas pressure is lower than optimum gas pressure, the breaker becomes low performance.
• The gas pressure is different in accordance with the working conditions. So, the gas pressure should be
within optimum gas pressure while operating the breaker.
• Check the O-ring, even If recharged gas pressure, it is decreased in gas pressure.
• If the working oil leaked into head cap from cylinder, replace the gas seal or O-rings which are cylinder
bush has held and check if there is a scratch on the piston.
• The pressure in head cap should be set according to the chart as follows.
D&A30V & 50V for

Gas Pressure D&A 8V - D&A 20V D&A30V~130V D&A150V-
INDIA D&A 550V
Skid Steer Loader
10 – 14 10 – 14 10 – 16 10 – 14
Head Cap(㎏/㎠)
(142~200psi) (142~200psi) D&A450V is 10~14 (142~200psi)
D&A30V & 50V for

Gas Pressure D&A 8V - D&A 20V D&A30V~80V D&A100V- D&A 550V
INDIA
Skid Steer Loader
40~50 55 –60 75
Accumulator(㎏/㎠) -
(570~710psi) (780~850psi) Return line : 20
※ Gas pressure should only be checked with the chisel protecting from the front cover to its full extent.
32
3-4. WEARING PARTS
The following items are considered as wearing to exchange these items.

: When damaged or worn, your attention is highly recommended to exchange these items and
recommended the user to stock wearing parts as follows.
① Chisel
② Front Cover and Round Bush
③ Chisel pins
④ Hydraulic Seals
⑤ Through Bolts
⑥ Hydraulic Hoses
Replace hydraulic seals every 500 hours of actual operation as well as just kept over 6months in storage.
Chisel Pins: When each chisel pin is excessively deformed, it is difficult to replace chisel. Therefore, every
100 to 150 hours of operation, change the face of each pin that comes in contact with the
chisel (The two faces of each pin can be used).
If the chisel use is not the genuine part, we cannot guarantee the breaker parts for their
good performance.
3-4-1. FRONT COVER
Wear Limit of Chisel and Front Cover:
When the clearance between the chisel and

Holder bush becomes large, it is
strongly recommended to replace
these parts to prevent from wear.
Exceeding the following value may
damage other component parts, such
as the piston and cylinder.
33
Model D&A8V-50V D&A70V-180V D&A220V-360V
INDIA D&A450V-550V
Wear mm 6 8 10 12
Limit Inch 0.23 0.315 0.394 0.472
3-5. WORKING PRESSURE
As the working pressure of breaker is regular pressure and if the pressure of the excavator itself is regular
pressure, it does not need to apply pressure by attaching relief valve to the high-pressure line of breaker.
Please get the help of your D&A
JCB dealer.
If the pressure is over regular pressure the breaker gets more impact that makes a problem on the breaker
and the excavator.
Model D&A8V-100V D&A130V-550V

INDIA
175 ㎏/㎠ 210 ㎏/㎠

Relief Valve Setting Pressure
( 2500psi) ( 3000psi)
3-6. OIL TEMPERATURE
o o
The oil temperature is different according to working condition but it is usually 50~80 C. If it is over 80 C it
makes the accumulator rubber and the life of O-ring span be shorter.
Be cautions of the following to avoid the rise of oil temperature.
1. Avoid continuous blowing at the same point over 30’ seconds.
2. The amount of oil needed in the breaker within the using pressure is regular. In spite of more engine
rotation the blow frequency does not increase, rather the oil flows out by the relief valve. So the oil
temperature rise and the continued ratio become high. While hammering the breaker, if the engine
rotation increases to some degree, the increase happens no more.
3. Keep clean the cooler to avoid falling a cooling effect.
3-7. ACCUMULATOR INDIA

(D&A 30V~550V)
Replace the accumulator if there is big tremor on the hose of high-pressure line. Ask for your JCB
D&A dealer
when replace the accumulator and the O-ring and back up ring as well. And check whether oil is leaking or
not around accumulator. After replacement and inspection, the socket bolts that fix the accumulator should
be tightened by the torque wrench.
34
3-8. OIL LEAKAGE
Check of oil leakage from connected parts. But a little oil leakage, out of between chisel and front cover, can
be disregarded as it helps smooth the chisel. In case of a lot of leakage check and replace the seals, apply
the working oil to the seal kit and the seal groove.
The Followings Should Be Inspected When Replace the Packing.
1. Check if there is any scratch on the seals are well pressed or they are not pushed out.
2. Be cautions of dirt of flow.
3. If the seal gets damaged, check the seals and stroke piston.
4. When the seals that placed in cylinder bush get injured, lots of oil leaks out. Then replace each seal &
O-ring.
Require the service of your JCB
D&A dealer, even if replaced new seals, oil leaks out continue.
3-9. THE CONTAMINATION OF WORKING OIL
The contamination of working oil becomes the cause of problems control valve, and flows in the stroke piston,
keep clean the working oil. Replace the filter of excavator per 100 hours and the working oil 600 hours.
When install the breaker in the old excavator, replace the working oil and recharge the working oil if
necessary.
3-10. CHECKING GAS PRESSURE IN THE ACCUMULATOR / BACK HEAD AND CHARGING
The gas in back head & accumulator may only be filled with nitrogen.
When filling the gas, ensure no one is standing in the area of the working tool. If the tool has jammed, it may
spring out of the lower hammer part very suddenly.
How to charge accumulator with nitrogen gas
35
1. Remove gas valve cap ⑥ screwed in the accumulator and tighten the adaptor⑫ completely which
is connected to insert nozzle(2).
2. Remove needle cap ⑧ screwed side of accumulator and loosen needle pin⑦ about one turn.
3. Charge the accumulator with nitrogen gas by controlling the gas cylinder valve(4). Check whether
the gas pressure is correct or not
4. Tighten the needle pin ⑦ completely and needle pin cap.⑧
5. Remove the adaptor⑫ and tighten gas valve cap⑥.
Please note!
When filling the gas, the hammer must be lying flat with no contact pressure applied to the working tools as
well in cold condition as at operating temperature.
1. Pressure relief valve
2. Insert nozzle
3. Press gauge (regulator)
4. Gas cylinder valve
5. Gas valve cap
How to connect gas charging kit

1. Connect gas regulator with nitrogen gas cylinder.
2. Remove the gas valve cap(5) on back head and connect the adaptor⑫ & insert nozzle (2)to the gas
regulator.
3. Check whether the gas pressure is correct ornot.
☞ Must put the cap on gas bottle to avoid damage to valve of gas bottle and check the valve of gas has
closed while keeping. Especially, do not expose the gas to the sun for a long time
Back head gas charging pressure
Hammer model D&A8V ~ D&A130V D&A150V~D&A550V

INDIA D&A 450V
Back head gas bar 10 ~ 14 14~ 16 10 ~ 14
charging pressure (psi) (140~200) (200 ~ 230) (140 ~ 200)
Accumulator gas charging pressure
Hammer model D&A30V ~D&A80V D&A100V~D&A550V

INDIA D&A30~50V for Skid
Accumulator gas bar 40~50 55~60 75
charging pressure (psi) (570~710) (780~850) Return line : 20
36
3-11. MOUNTING & INSTALLATION OF HYDRAULIC BREAKER
3-12. GENERAL VIEW OF BREAKER INSTALLED TO BASE MACHINE
Hydraulic Breaker is not self-powered. So it makes use of hydraulic power systems of the carriers on which it
is mounted, such as excavator, mini-excavators, backhoe loaders etc. To enable carriers to operate with
such attachments, the hydraulic power system has to be converted accordingly.
D&A hydraulic breaker requires a proper oil flow and pump pressure.
JCB
2
They are required Setting Pressure to operate D&A
JCB hydraulic breakers as below, which is 10kg/cm less than
main relief pressure.
* D&A 8V~100V: 175 ㎏/㎠

㎠
130V~550V: 210 ㎏/㎠
* D&AINDIA ㎠
37
3-13. PRECAUTIONS OF INSTALLATION
When the bucket and breaker operation are performed alternately, the hydraulic breaker is connected to the
base machine with the two pins, therefore the bucket and breaker can easily be replaced with each other.
However as the hydraulic circuit is easily apt to be damaged by contamination, remove and install in the
following procedures with care.
SELECT A LEVEL GROUND WHERE IS FREE FROM MUD, DUST AND DIRT. A SERVICE SHOP IS
MOST AVAILABLE.
After move the base machine to the place, stop the engine and turn off the main switch. Further, if the
hydraulic tank of base machine may be pressurized, bleed pressurized air from the oil tank. At this time, the
base machine is positioned as shown the picture; the breaker and bucket can easily be replaced.
CAUTION:
Must shut the stop valve off before remove the breaker from excavator
38
3-14. HYDRAULIC SYSTEM
1. Proper input oil flow
Have to attach a package valve for breaker or equivalent valve to control output flow from pump so as to
acquire appropriate number of blows and reduce peak pressure to control output flow.
2. Pressure pulse (Pump to Breaker input line)
▪ Average operating pressure of pump
Indispensable condition:
The average value of operating pump pressure is
much less than that of compensating pressure.
Purpose:
Prevent an abrasion of regular and swash
plate supporter of pump.
▪ Outlet pressure pulse of pump (Pmin. to Pmax.)
Indispensable condition:
Pressure displacement is within 80bar in 1
cycle of blow except an instantaneous peak
pressure within 10m/s.
INDIA
(Ex: D&A 220V)
Purpose:
Acquiring durability of pump.
▪ Outlet pressure pulse of pump (Pmin)
39
Indispensable condition: In datum of average operating pressure an instantaneous peak pressure drop to
negative pressure direction is within 40bar, when measuring at supply line.
Purpose: Acquiring durability of pump.
▪ Pressure pulse (Pmin, Pump & Pmin, Breaker)
Indispensable condition: On operating breaker, minimum value of peak pressure of pump outlet is higher
than that of breaker inlet or so. ( Pmin, Pump ≥ Pmin, Breaker)
Purpose: Checking control valve load and protecting valves.
▪ Inlet pressure pulse of breaker (Pmin, Breaker)
Indispensable condition: On operating breaker, minimum valve of peak pressure of breaker inlet keep on
higher than diaphragm pre-charge pressure (60bar) or so.
(Pmin, Breaker ≥ 60 bar)
Purpose: Protecting hydraulic components as to achieve efficiency of diaphragm.
3-15. ADJUSTER VALVE TO CONTROL IMPACT BLOWS
The blow of breaker is adjusted by oil flow of excavator, and reducing pressure valve in control valve at
breaker line controls oil flow of excavator.
(D&A INDIA
70V~550V)
The blows of breaker can be adjusted with following procedure.
1. Release the nut of adjuster.
2. High speed (Low power): turn adjuster to counter-clockwise.

Low speed (High power): turn adjuster to clockwise.
3. Tighten the nut of adjuster after setting.
CAUTION:
The max, effect of high speed is just one turning of adjuster to counter-clock wise. Never effect, if over
turning than one. One eighth of a rounding to adjuster can be blowing about 10~15bpm, so a little bit turn
adjuster with care.
40
3-16 HYDRAULIC PIPE LINES AND CONTROLS
1. Following devices and equipment of the base machine are used in common for breaker.
• Hydraulic oil tank.

• Oil pump
• Hydraulic control valve(When a spare valve is available in control valve bank of base machine.)
2. Following devices and equipment have to be newly installed for breaker.
• Hydraulic control valve (When a spare valve is not available in control valve bank of a base machine.)
• Control pedal or lever: For breaker control.
• High pressure pipe lines: For supply of high pressure oil to breaker.
• Low pressure pipe lines: For return of low pressure oil to hydraulic oil tank.
• Stop valve: For shutting off oil lines when breaker is replaced with bucket etc.
CAUTION:
• If excavator has a suitable hydraulic system, check the normal width of the hydraulic lines.
• Check the connections on the hydraulic breaker and the breaker hoses.
• The connecting threads must be undamaged and free of sand or similar foreign bodies.
• Check that the pressure relief valve on the hydraulic system has been approved by the relevant authorities.
• Ensure that the pressure relief valve has been set correctly, i.e. to the maximum permissible operating
pressure of the hydraulic breaker, and then leaded. (Operating pressure + min 30bar)
• Do not run any hydraulic lines through the driver’s cap, since they may start to leak or even burst.
• The hydraulic oil becomes very hot during operation.
• As the hydraulic circuit varies with the base machine, hydraulic pressure, oil capacity pressure loss, etc. of
the base machine are inspected and the hydraulic circuit is provided by D&A
JCB dealer’s service engineer.
• As the hydraulic pipe lines (hoses, pipes and fittings) are made of materials carefully selected in
consideration of durability use genuine parts when replacing the parts.
41
3-17. DISASSEMBLY & REASSEMBLY
WARNING:
If there is any gas in the hydraulic breaker, it could be very dangerous.
3-18. DISASSEMBLING
1. Put body on wooden supports with the equivalent size.
2. Deflate N2 gas in head cap to avoid the risk.
3. Release nuts of through bolts from main body.
4. Disassemble head cap with hoist or chain block.
42
5. Disassemble cylinder with eyebolt and using hoist or chain block to arrow direction as shown picture.
6. Disassemble piston with eyebolt toward upper vertically using hoist or chain block to arrow direction as
shown picture.
JCBstander
7. Release the through bolts from front head with D&A standard spanner
spanner.
(D&A 8V~10
8V~100V)
(D&A 13
13INDIA
0V~550V)
43
8. Remove of seals & O-rings
Using a screw driver carefully, remove dust seal, u-packing, buffer ring, step seal, and gas seal from in the
lower sealing zone of the cylinder and cylinder bush.
WARNING:
Excessive kinking will cause cracks and subsequent failure.
CAUTION:
• Once seals and O-rings are removed, they should not be used again.
• Use only new and genuine JCB

D&A parts.
• After snapping into the groove, check the fit of the seal is facing the oil side.
• Lightly coat sealing elements with oil before fitting.
MODEL CYLINDER CYLINDER BUSH DESCRIPTION
D&A
INDIA8V
8V
D&A 15V
15V
D&A 20V
20V
D&A 30V
30V
① Dust Seal
D&A 50V
50V
D&A 70V ② U-Packing
70V
D&A 80V
80V ③ Buffer Ring Set
D&A 100V
100V (Buffer Ring
+Back Up Ring
D&A 130V
130V
or Step Seal)
D&A 15
150V
④ Step Seal
D&A 180V
180V
D&A 200V ⑤ Gas Ring Set
D&A 220V (Gas Ring
220V
+Back Up Ring)
D&A 300V
300V
D&A 360V
360V
D&A 450V
450V
D&A 550V
550V
44
※The part no. & shape of seals & O-rings differ from each model. Therefore, please refer to part lists in this
manual for detail review.
9. Inspection
① Seals
While seals are still in there original position, check for scratches and deformation. Do not remove to
check. Even a small scratch will lead to oil leakage.
Damaged Seals
※ Replace hydraulic seals every 500 hours of actual operation as well as just kept over 6months in
storage.
② Control Valve
Inspect valve for signs of seizure or scuffing. If marks left by the seizure are even small, polishes by using
the fine oilstone or sand paper (#1000~1200).
The corresponding marks on the valve bush or valve cap should be removed in the same manner.
If seizure or scratch is excessive, replace immediately with a new control valve assembly.
③ Piston
Periodically the lower end of piston deformed must be checked.
45
Check piston for seizure marks and scuffing. If such marks are on the section, remove by polishing with
an oilstone or sand paper (#1000~1200). Corresponding marks on the mating part should also be treated in
the same manner.
3-19. ASSEMBLING
1. Assemble the seals.
Once cylinder bush and cylinder bore

have been washed clean and lightly
coat sealing elements with hydraulic oil
before fitting.
2. Assembly of the round bush and front cover.
① Knock out the rubber plugs and

stopper pins using hammer & pin
punch.
② Disassemble the worn front cover & worn round bush, choice a disassemble method among 3 kinds of
the followings.
WARNING: Wear Safety Approved Eye Protection.
A. Remove the bushes using oxy-arc cutting.

Require a skilled worker not to allow too much hitting effect to front head.
46
B. Press out the bushes after the removal plate welded into front cover and round bush as shown picture.
This work can only be performed in a well-equipped workshop with a hydraulic press of 200tonnes
or more capacity.
C. If no oxy-arc cutting & press are available to remove the bushes, the following procedure is possible.
-Apply thick axial or radial welding beads inside the worn wear bush using an electrode welder
-Upon cooling the wear bush contracts and loosens in it seat.
47
③ Before fitting the round bush and front cover, heat the around of front cover to make oversize or super-
cool bushes in liquid nitrogen (N2) to make undersize for fitting.
CAUTION: • Do not allow overheating the front cover, it can become weak.
1. Keep clean contact face lower
front cover
2. Replace the stopper pins &
rubber plugs
3. General assembly
① Screw the through bolts to front head.
② Replace the seals in lower sealing of the cylinder & cylinder bush.
D&A8V~100V D&A130V~550V
48
③ Put piston into cylinder after lubricating piston & cylinder thoroughly
④ Put cylinder bush onto piston as shown picture using a rubber hammer
⑤ Let the hydraulic oil about 40~700CC into inside of head cap.
Model Qantity of hyaulic oil (cc)
D&A 8V
INDIA 340cc
40 cc
D&A 15V 50 cc
D&A 20V 50 cc
D&A 30V 60 cc
D&A 50V 80 cc
D&A 70V 150 cc
D&A 80V 220 cc
D&A 100V 200 cc
D&A 130V 220 cc
D&A 150V 230 cc
D&A 180V 300 cc
D&A 200V 380 cc
D&A 220V 340 cc
D&A 300V 500 cc
D&A 360V 500 cc
D&A 450V 500 cc
D&A 550V 700 cc
⑥ Connect the cylinder, Front head and Head cap with through bolts, and tighten the nuts of through bolts
to their specified torque.
⑦ Fill the hydraulic oil up through ports on cylinder into cylinder.
⑧ Tighten the hose adapters to ports on cylinder.
⑨ Tighten gas valve to its specified torque.
⑩ Inflate nitrogen gas into inside of head cap.
49
⑪ Fitting the Assembled main body into the bracket.
4. Disassembling bracket (Box Type)

① Take upper urethane out after removed the plate on bracket.
② Take the main body out from bracket using crane or hoist.
③ To assemble bracket, perform the above procedure in the reverse manner.
5. Replace of the chisel
① D&A 8V~130V: Push the spring pin back into the hole is being spring with the pin punch.
D&A 150V~550V: Knock the stopper pin & rubber plug of the upper for chisel pins out with hammer And
1.INDIA
pin punch.
② Take the chisel pin out by using a pin punch to push the chisel pin out from under of the breaker.
③ Replace the new chisel after removed.
The chisel is heavy, so careful attention needed.
6. Breaker lifting point
50
7. Suitable Eyebolt for breaker main body
Weight Allowed
Model Eyebolt
(kg) Weight (kg)
INDIA
D&A 8V 950
60 M24
M10 950
150
D&A 15V 75 M10 150
D&A 20V 100 M10 150
D&A 30V 130 M10 150
D&A 50V 180 M12 220
D&A 70V 250 M16 450
D&A 80V 310 M16 450
D&A 100V 406 M20 630
D&A 130V 517 M20 630
D&A 150V 602 M20 630
D&A 180V 725 M24 950
D&A 200V 800 M24 950
D&A 220V 950 M24 950
D&A 300V 1,280 M30 1500
D&A 360V 1,500 M30 1500
D&A 450V 1,720 M36 2300
D&A 550V 1,960 M36 2300
51
3-20. REPAIRING PARTS
When correcting faults on sliding surfaces, finish surfaces as smooth as possible. Using an oilstone, emery
paper and flex hone. Keep in mind that overworking may cause malfunctioning.
Tool for correction
Grain size or Type

Name of Tool Operating Method
Rough Finish Finish
Rough and
Oilstone Fine Grain
medium grain
Polish perpendicular to a sliding direction.
Emery Paper #100, #160, #240 #400, #600
1. Cylinder bush
When using the buffering grindstone, apply the grinder correctly to

the circumference. If the grinder is led straight ahead, circularity will
be spoiled. Wash the parts after finishing them.
2. Cylinder
Faults on the sliding surface may cause malfunctioning and
oil leakage of the cylinder, and disable the breaker in worst
cases if did not left remedy.
Correct faults at an early stage, using an oilstone and
emery paper.
CAUTION ON USING THE BUFFER GRINDER
52
Kind of Fault Condition Remedy
Vertical
Scratch
If burrs stick out above labyrinth grooves,
A stripped fault running in the sliding remove burrs and correct vertical faults
direction of the blow piston. with oil stone and/ or emery paper.
Galling
A localized fault that is wider than the Finish galling with an oil stone till no step
vertical scratch and is caused by sliding exists on the outer surface and then finish
motion. with fine emery paper.
Chipping
Corner of sliding section is chipped. Finish an edge produced by chipping

smoothly with an oilstone.
Vermin
A vermin-like fault by cavitations located at A vermin causes galling if left uncorrected.

the corner of a sliding part. Remove it with an air grinder and finish it
smoothly with an oilstone.
3. Piston
Correct faults at an early stage, using an oilstone and
emery paper.
CAUTION ON USING THE BUFFER GRINDER
53
Kind of Fault Condition Remedy
Vertical
Scratch
Striped scratches caused by sliding Remove burrs on the surface by polishing

motion. in the circumferential direction.
Scratch in
labyrinth
grooves
Correct scratches at an early stage as Removes burrs sticking above labyrinth

scratches in this area may develop into a grooves and finish edges and finish edges
fatal failure of the cylinder. and remedy vertical scratches.
Reparation
vertical
scratch
and/ or Taking piston on polishing machine.
rust pit Remove burrs on surface by polishing in
circumferential direction for max. 0.05mm
less of normal diameter. If scratches and/
or rust pit still remain replace piston by
new one.
54
4. Damage on the blowing surface
Damage on the blowing surface has adverse effect on the chisel. Correct it at an early stage on replace the
blowing piston with a new one.
① Collapse:
If the blowing surface has collapse of 2.0mm or over in depth, replace the piston with a new one.
If the blowing surface has a step of less than 1.0mm in depth, smooth the area.
② Chipping an peeling-off
If the blowing surface shows a localized shipping or a peeling-off,

correct the area smoothly to prevent the progress of the peeling-off.
③ Chipping-off at edge of blowing surface
Replace piston quickly with a new one.
55
3-21. MAINTENANCE CARRIED OUT BY THE OPERATOR
DAILY MAINTENANCE;
• Tighten loose connections.

• Grease chisel shank and chisel bushings.
• Observe oil temperature, all lines and connections as well as impact efficiency and evenness of operation.
WEEKLY MAINTENANCE;
• Remove retaining pin(s) and check condition.

• Remove chisel and check chisel shank for wear.
• Remove burrs from retaining pin groove of the chisel.
• Check that the chisel has received sufficient greasing.
MONTHLY MAINTENANCE;
• Check chisel bushings for wear.

• Check condition of vibration damping mechanism.
• Check condition of other wear parts and hoses.
WHEN CHANGING CHISEL OR APPROX. 4TIMES PER YEAR MAINTENANCE;
• Check wear to working chisel.

• Check wear to lower wear bushes.
• Check adapter and breaker bracket for cracks.
• Check impact face of piston for wear or damage.
• Check impact face of working chisel for damage.
• Check retainer bars for burring.
• Check chisel for burring.
AS REQUIRED
• Replace bent and squashed pipes.

• Replace damaged hoses.
• Check pressure in piston accumulator.
• Check adapter bolts for wear.
56
3-22. TROUBLE SHOOT
3-23. MALFUNCTIONS
Prerequisites for the normal operation and long life of D&A

JCB Hydraulic Breaker series:
-Supply of rates (Pressure ‘P’ and flow rate ‘Q’) to hydraulic breaker of this series.
-Use of clean hydraulic oil.
-Proper operation as per operating & maintenance manual.
Dealers concerned are requested to take prompt actions when they receive trouble reports from their
customers. Skilled technicians of dealers should grasp condition of troubles exactly and set forth adequate
countermeasures by checking their possible causes. The repair of minor troubles would be better entrust to
customer, and appropriate steps should be taken if their causes cannot be detected.
If the hydraulic breaker is not working correctly, check the hydraulic system of the excavator thoroughly
before making any repairs on the breaker. Hydraulic breaker problems can be affected by a hydraulic system
that is not operating to specifications or such problems as a plugged fuel filter or hydraulic filter in the
excavator. Connect a flow meter to the excavator to check the hydraulic pump output, relief valve setting and
tube lines to check flow and pressure.
The following tabulation on the causes and countermeasures of troubles may help for a good disposition of
troubles encountered.
57
1. Base machine (Excavator, Backhoe, Skid loader) and piping
Conditions Causes Countermeasures

Check and control set pressure on
Breaker does not work Low set pressure on relief valve.
slow side.
Check and control set pressure on
High set pressure on relief valve.
Breaker easily damaged due to slow side.
too strong impact power.
Gas pressure is too high. Check the gas pressure.
Poor heat radiation of base Have excavator manufacturer

machine. check.
Rapid increase in oil Have excavator manufacturer
Premature were of pump.
temperature check.
Clogged piping. Required flushing.
Hose pulsation on the return

The amount of oil flow is too low. Check oil flow.
side
Hose pulsation on the high-
Gas pressure is too low or high Check the gas pressure.
pressure line
Emulsification of hydraulic oil Entering of water into oil. Immediately replace hydraulic oil.
Decrease the gas pressure and

Insufficient output of engine.
increase RPM.
Excessive decrease in engine Have excavator manufacturer
Drop of engine performance.
RPM check.
Excessively low temperature of
Required warming-up.
oil.
2. Main body (Breaker)
Conditions Causes Countermeasure
Insufficient power (PｘQ) Check power.

Insufficient down pressure on
Proper instructions.
chisel.
Clogged piping. Check and repair (Flushing).
Breaker will not work
Seizure of breaker. Repair or replace worm parts.
Filling –up of hydraulic oil in head Replace gas seal and check the
cap. piston.
Lack of hydraulic oil. Refill oil.
58
Clogged piping. Check and repair (Flushing).

Stop hammering or erratic action
Gas pressure is too high. Check gas pressure.
in approx. 30~90min. operation
Damaged seals. Replace seals.
Filling –up of hydraulic oil in head Replace gas seal and check the
cap. piston.
Use of hammering chisel in bent
Apply down force in tool direction.
condition.
Breakage of chisel
Use of chisel as lever, move rocks Check if any excessive play on
with chisel. arms, link & pins.
Long time continuous hammering
Melting of chisel point Relocate.
in one place.
Full power operation from the Low speed operation for first 30
Cracking of chisel point
outset. minutes.
Difficulty in attach and removing
Deformation of chisel pin. Regular check & grinding needed.
chisel point
Excessively worn urethane
Replace.
Excessive plays between bracket (Box type).
and breaker body
Loose the side bolts (Side type). Retighten bolts.
Premature wear of front cover Lack of grease. Proper instruction.

Low number of blow Proper instructions.
chisel.
Gas pressure is too low. Recharge the N2 gas.

Proper instructions.
chisel.
Weak impact force
Insufficient power (PｘQ) Proper instructions.
Breakage of chisel in front cover. Replace tool and check the piston.
59
3-24. OIL LEAKAGE
Even if oil leaks, there is no need replacing at all times. Check the following point listed in the below.
The user can check the remedy before calling dealer.
Area of Oil Leakage Conditions Causes & Remedies
-Seals are damaged:

Between the chisel and front cover A large amount of oil is leaking.
Replace.
Oil leaking from hose adapter -Loose breaker hoses and adapter:
Upper part
portion. Replace.
Oil leakage from reassembly of -Check that O-ring is damaged:

Valve or Ro-plug after overhaul. Replace.
-Loosed through bolts & nuts

Oil leakage
Between the cylinder & head cap Retighten.
-Check that gas seal and O-ring are

damaged and oil & piston
Oil leakage (also gas leakage)
condition:
Replace.
-Check that seals of cylinder are

Between cylinder & front head Oil leakage damaged.
Replace.
60
3-25. POOR OPERATION OF BREAKER
Conditions Major causes Remedies

Required warming up the engine
of base machine from five to
twenty minutes and moving the
Oil temperature is too low.
boom.
Oil temperature must reach to
o
min. 30 C.
Does not impact Main control valve (Excavator) Check conditions of M.C.V and
does not operate properly. power cable.
N2 gas pressure is too high in
Check gas pressure and relief
head cap and setting pressure of
valve.
relief valve is low.
Poor performance of hydraulic Contact excavator manufacturer
pump. (Excavator) immediately.
Oil temperature increased due to
Supplement of hydraulic oil.
lack of hydraulic oil.
Gas pressure in head cap is too
Check gas pressure.
high.
Relief valve is set too low. Check pressure of relief valve.
Not enough down pressure on Apply enough down pressure with
chisel. arm or boom of base machine.
The clearance between the chisel Check the clearance between
Irregular blows it operates
and front cover are too large. chisel and front cover.
normally at the beginning.
Wear on top of chisel. Disassemble chisel to check.
Poor performance of hydraulic
Have excavator manufacturer
JCB Service
pump and backpressure are too
check.
high.
Foreign material inside main
Disassemble and clean.
valve.
Seizure of piston & cylinder. Overhaul and check.
Low gas pressure in back head. Check gas pressure.

Not enough down pressure on Apply enough down pressure with
chisel. arm and boom.
Lack of blow Setting pressure of relief valve is
Check pressure of relief valve.
too low.
Poor performance of hydraulic Have excavator manufacturer
JCB Service
pump. check.
Check setting pressure or gas
Operating pressure is too high.
pressure.
61
3-26. TORQUE
Before starting work, check all the bolts tightness and also be sure to retighten loose bolts to the specified
torque referring to the manual. The tightening torque of each bolt is as follows.
62
3-27. TORQUE FOR EACH PARTS
TOP
ACC’ BODY ACC’ COVERS
THROUGH BOLT MOUNTING
MODELS BOLT BOLT
(kg.m / N.m ) BOLT
(kg.m / N.m ) (kg.m / N.m )
(kg.m / N.m )
D&A 8V
INDIA 35~40 / 343~392
390-400 / 3822-3920 4548/ 410
/ 470 None
60 / 588 None
60 / 588
D&A 15V 35~40 / 343~392 45 / 410 None None
D&A 20V 40~45 / 392~441 45 / 410 None None
D&A 30V 80~85 / 784~833 45 / 410 30 / 588 20 / 196
D&A 50V 80~85 / 784~833 45 / 410 30 / 588 20 / 196
D&A 70V 95~100 / 931~980 48 / 470 30 / 588 20 / 196
D&A 80V 95~100 / 931~980 48 / 470 35 / 343 20 / 196
D&A 100V 180~190 / 1764~1862 48 / 470 35 / 343 35 / 343
D&A 130V 220~230 / 2156~2254 48 / 470 60 / 588 35 / 343
D&A 150V 250~260 / 2450~2584 48 / 470 60 / 588 35 / 343
D&A 180V 330~340 / 3234~3332 48 / 470 60 / 588 35 / 343
D&A 200V 330~340 / 3234~3332 48 / 470 60 / 588 60 / 588
D&A 220V 390~400 / 3822~3920 48 / 470 60 / 588 60 / 588
D&A 300V 470~480 / 4606~4704 48 / 470 105 / 1029 105 / 1029
D&A 360V 470~480 / 4606~4704 48 / 470 105 / 1029 105 / 1029
D&A 450V 590~600 / 5782~5880 45 / 410 105 / 1029 105 / 1029
D&A 550V 590~600 / 5782~5880 45 / 410 105 / 1029 105 / 1029
63
3-28. SPANNER SIZE FOR BOLTS OF D&A HYDRAULIC BREAKERS
mm
THE SIZE OF
MODELS THROUGH BULK CAPS SIDE BOLTS ACC’ BODIES ACC’ COVERS
NUT
D&A 8V
INDIA 27
75 2732 27
NON 19(L) 14(L)
D&A 15V 27 27 27
D&A 20V 30 27 NON
D&A 30V 36 27 32 14(L) 12(L)
D&A 50V 36 27 32 14(L) 12(L)
D&A 70V 46 27 NON 14(L) 12(L)
D&A 80V 46 27 NON 14(L) 12(L)
D&A 100V 55 30 NON 17(L) 14(L)
D&A 130V 60 30 NON 17(L) 14(L)
D&A 150V 65 32 NON 19(L) 14(L)
D&A 180V 70 32 NON 19(L) 14(L)
D&A 200V 70 32 NON 19(L) 14(L)
D&A 220V 75 32 NON 19(L) 14(L)
D&A 300V 75 32 NON 22(L) 17(L)
D&A 360V 80 32 NON 22(L) 17(L)
D&A 450V 90 50 NON 22(L) 17(L)
D&A 550V 90 50 NON 22(L) 17(L)
Remark; “L” → L Wrench
64
AUTOGREASE
4. AUTO LUBRICATION SYSTEM (Option - Applied D&A INDIA-01
100V~550V)
Lubricating of the chisel and bushings can be made very easy automatically with a D&A
JCB Auto Lubrication
AUTOGREASE
System.
Benefits:
• Longer life for chisel bushing.

• Longer life for tool.
• Higher utilization rate of D&A
JCB hydraulic breaker.
JCB
By JCB
D&A Auto Lubrication System is fed along an internal channel to the chisel bushing and the chisel shank.
AUTOGREASE
* The above drawing is based on LINCOLN and other maker of automatic lubrication system can be
installed as an option.
65
JCB ATTACHMENTS
The Warranty becomes effective in accordance with the terms shown below for a period of twelve months from the date of
purchase by the original user.
IMPORTANT
Read the JCB Hammermaster Owner’s Manual BEFORE operating the Hammermaster. Ensure that the Hammermaster is
filled with an approved oil before starting.
Where a JCB Hammermaster is to be operated by a non JCB carrier machine, ensure that the machine has been
certified as acceptable by JCB Attachments BEFORE FITTING the Hammermaster. Your JCB Distributor will carry
out the necessary tests on your machine. The warranty card will be stamped by your Distributor on approval from
JCB Attachments.
See approved lubricants in the JCB Hammermaster Owner’s Manual. The use of non-approved oil will invalidate the
Warranty.
WARRANTY POLICY
This JCB Hammermaster is guaranteed against defects in workmanship and/or material when properly maintained and
operated under conditions laid down in the WARRANTY AND PROCEDURE.
Should any defect develop in the unit during the warranty period you are advised to contact your JCB Dealer. In the event of
the fault being attributed to bad workmanship or defective manufacture or material, the dealer will take the appropriate
warranty action. (The Warranty does not apply to chisels or other types of breaker steels, diaphragms, seals or hoses used
with the equipment.)
For conditions of warranty, please see overleaf.

WARRANTY AND PROCEDURE
Examination of the goods has been made by, or on behalf of the Purchaser and no warranty condition, description or
representation on the part of the Manufacturer is given or is to be implied or has been given or is to be implied from anything
said or written in the negotiations between the parties or their representatives beyond those mentioned below. Any statutory or
other warranty condition, description or representation expressed or implied as to the state quality of fitness for any purpose of
the goods is hereby expressly excluded.
In lieu thereof the Manufacturer undertakes to make good by repair or replacement at its option free of all charges other than
labour costs any defects in the goods arising, in the Manufacturer’s opinion, from faulty design, materials or workmanship
which shall become apparent within a period of twelve months in the case of units and three months in the case of parts or
equipment from the date or receipt of the goods at the termination of which periods all liability on the Manufacturer’s part
ceases. Provided always and the above warranty is subject to the following conditions:
a e j
The Manufacturer’s liability extends In the event of the rejection by the This warranty shall cease to have
only to repair or replacement and it Manufacturer of any claim, the part or effect if the Purchaser removes or
accepts no liability for any parts returned will be destroyed defaces or alters the Manufacturer’s
consequential or other loss, damage unless specific instructions to the Number or Name Plates or any other
or injury resulting directly or indirectly contrary were given when the part or numbers or marks affixed to any JCB
from any defect in the goods. parts were returned. Product.
b f k
The Manufacturer’s warranty does not The registration card must be returned In respect of machines sold which
extend to failures, defects or damage to the Manufacturer within seven days have been used since the date of
attributable to wear and tear, improper of the receipt of any new manufacture by the Manufacturer for
adjustment, neglect, alteration of Hammermaster. demonstration purposes the term of
specification, or accident. this warranty shall be three months.
g
c No claim will be considered if other l
Defective parts must be returned to than genuine parts manufactured by No warranty shall be given in respect
the Main Dealer when requested the Manufacturer or to its order and of JCB Hammermaster Rockbreakers
together with full particulars of the listed in its catalogue are used or if when used with non JCB carrier
defects, the serial number, the hours other than JCB ‘Special’ Hydraulic machines unless authorised by JCB
worked and the date the unit was Fluid is used where specified. Attachments.
supplied to the Main Dealer who will
claim on your behalf. h m
This warranty should be construed as The warranty registration card must
d strictly limited in its application to new be returned to JCB Attachments after
The Manufacturer’s warranty does not JCB Products and if the goods shall the installation inspection is carried
extend to proprietary or other change hands during the period of this out and the card is filled out with the
components not of its manufacture, warranty shall cease to have any corresponding information. No
but will as far as possible pass to the effect. warranty claims will be handled until
Purchaser the benefits of any this is done. If the carrier is replaced
guarantee given to the Manufacturer i during the warranty time with another,
in respect of such components. The Manufacturer accepts no the installation to the new carrier must
responsibility for damage by fires or be inspected and approved and the
accident of any kind to any goods corresponding information sent to JCB
returned to it under the terms of this Attachments.
warranty nor does the Manufacturer
accept responsibility for any accident
occurring to such goods whilst on the
premises.
JCB Attachments
Riverside WARRANTY REGISTRATION CARD
Rugeley
Staffordshire PRODUCT
WS15 2WA, England
SERIAL NUMBER
DEALER
Company Delivery Date
City Country
CUSTOMER
Company
Address
Contact Person Phone
INSTALLATION INSPECTION
Made by Company
Excavator Make Model
Year of manufacture Total Weight
Serial Number Service meter hours
Max. total output of pumps supplying the attachment 1/min
Main relief setting in carrier’s hydraulic circuit bar
Measured relief valve setting in attachment line bar
Measured oil flow to hammer at hammer’s operating pressure 1/min
Measured return line back pressure at operating oil flow bar
Measured hammer operating pressure in HP and LP circuits / bar
Hydraulic oil type and grade
Special flow regulator for attachment yes no setting 1/min
Oil coolers in carrier’s circuit yes no
Oil filter in attachment line yes no
INSTALLATION INSPECTION COMPLETED / 20
DELIVERY ACCEPTED BY CUSTOMER / 20
Tel: 01889 - 572700 Fax: 01889 - 570043

From outside UK all numbers preceded by +44 1889
P
STAM
Fax to Warranty Department JCB
to receive WARRANTY APPROVAL
JCB Attachments Tel: 01889 - 572700
Riverside Fax: 01889 - 570043 HAMMERMASTER
Rugeley From outside UK all INSTALLATION
Staffordshire numbers preceded
WS15 2WA, England by +44 1889 CHECKLIST
R
CUSTOMER HAMMERMASTER
DISTRIBUTOR SERIAL No
DEPOT CARRIER MACHINE
SERIAL No
✔ ACTIONED ✘ NOT APPLICABLE
1 Review of Operators Handbook contents including sections on safety
2 Familiarisation of Operator with correct breaker operating techniques
3 Maintenance
i) Daily (Including correct method of greasing)
ii) Weekly
iii) Monthly
iv) Regular Service Requirements (500 hours/1 year)
4 Correct Breaker grease (graphite, high dropping point)
5 Machine installation and Warranty Registration documents completed
6 Review Terms and Conditions of Warranty
7 E.C. Certificate of Conformity
8 Service and Parts contacts

(including normal and out of hours telephone numbers)
Service Manager/Department
Parts Manager/Department
This Rockbreaker has been delivered in satisfactory condition and necessary information for
operation, maintenance and safety has been received together with the Operator’s Manual.
Customers Signature........................................................... Installers Signature ...............................................................
Print Name........................................................................... Print Name............................................................................
Date:
JCB Attachments Tel: 01889 - 572700
Riverside Fax: 01889 - 570043
Rugeley From outside UK all TOOL REPORT
Staffordshire numbers preceded
WS15 2WA, England by +44 1889
DISTRIBUTOR WARRANTY CLAIM NO. DATE
HAMMER TYPE TYPE OF TOOL PART NUMBER TOOL CODE NO.
DATE OF INSTALLATION DATE OF FAILURE WORKING HOURS OTHER TOOL ID:S
APPLICATION TYPE OF MATERIAL TYPE OF LUBRICANT FAILURE
Broken Worn out
ORIGINAL LENGTH LENGTH BEFORE FAILURE LENGTH OF UPPER PART FRACTURE TYPE
mm L1 mm L2 mm A B C D
MAX DIAMETER MIN DIAMETER
Dmin mm Dmin mm
Diameter measurement
point
A B
L2
L1
C D
Dmax
Dmin
1002A
IF TOOL IS BROKEN, DRAW APPROXIMATE FAILURE LINE IN PICTURE OF THE TOOL, PLEASE!
PHOTOS ENCLOSED SIGNATURE
TOOL STORED AT:

NAME:

Rock Breaker

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Rock Breaker

Uploaded by

Copyright:

Available Formats

Ref No.

Operation & Service

D&A Heavy Industries Co., Ltd.

D&A Hydraulic Breaker consists of five main

1. The cylinder contains piston & valve.

2. Four through bolts are assembled and hold

3. Piston strikes the chisel by oil & gas

4. Control valve is inside of cylinder to regulate

5. Chisel Pin is inside of front head to stops

6. Head cap has charged Nitrogen gas.

D&A 8V D&A 15V

NO PARTS NAME PARTS NO Q’TY NO PARTS NAME PARTS NO Q’TY

1 CHISEL PIN B008-12600 1 1 CHISEL PIN B015-12600 1

2 SEAL KIT B008V-SK002 1 2 SEAL KIT B015V-SK002 1

3 GAS VALVE SET B008-13200 1 3 GAS VALVE SET B008-13200 1

D&A 20V D&A 30V

NO PARTS NAME PARTS NO Q’TY NO PARTS NAME PARTS NO Q’TY

1 CHISEL PIN B015-12600 1 1 CHISEL PIN B030-12600 1

2 SEAL KIT B021V-SK002 1 2 SEAL KIT B031V-SK001 1

3 GAS VALVE SET B008-13200 1 3 GAS VALVE SET B008-13200 1

D&A 50V D&A 70V

NO PARTS NAME PARTS NO Q’TY NO PARTS NAME PARTS NO Q’TY

1 CHISEL PIN B050-12600 1 1 CHISEL PIN B070-12600 2

2 T/BOLT SET B050-12200 1 2 T/BOLT SET B080-12200 1

3 SEAL KIT B051V-SK001 1 3 SEAL KIT B070V-SK002 1

4 GAS VALVE SET B008-13200 1 4 GAS VALVE SET B008-13200 1

5 DIAPHRAGM B032V-14300 1 5 FRONT COVER B070-12300 1

6 ROUND BUSH B070-12400 1

NO PARTS NAME PARTS NO Q’TY NO PARTS NAME PARTS NO Q’TY

1 CHISEL PIN B070-12600 2 1 CHISEL PIN B100-12600 2

2 T/BOLT SET B080V-12200 1 2 T/BOLT SET B102V-12200 1

3 SEAL KIT B080V-SK001 1 3 SEAL KIT B102V-SK001 1

4 GAS VALVE SET B008-13200 1 4 GAS VALVE SET B080-13200 1

5 FRONT COVER B080-12300 1 5 FRONT COVER B100-12300 1

6 ROUND BUSH B080-12400 1 6 ROUND BUSH B100-12400 1

7 DIAPHRAGM B032V-14300 1 7 DIAPHRAGM B132V-14300 1

NO PARTS NAME PARTS NO Q’TY

1 CHISEL PIN B130V-12600 2

2 T/BOLT SET B131V-12200 1

3 SEAL KIT B132V-SK001 1

4 GAS VALVE SET B080-13200 1

5 FRONT COVER B130-12300 1

6 ROUND BUSH B130-12400 1

D&A 150V D&A 180V

NO PARTS NAME PARTS NO Q’TY NO PARTS NAME PARTS NO Q’TY

1 STOPPER PIN B180-12650 2 1 STOPPER PIN B180-12650 2

2 RUBBER PLUG B030-12620 2 2 RUBBER PLUG B030-12620 2

3 CHISEL PIN B152V-12600 1 3 CHISEL PIN B180-12600 1

4 GREASE NIPPLE 004013-10400 2 4 GREASE NIPPLE 004013-10400 2

5 HOLLOW PLUG 004014-10200 1 5 HOLLOW PLUG 004014-10200 1

6 T/BOLT SET B152V-12201 1 6 T/BOLT SET B181V-12201 1

7 DIAPHRAGM B18V-14300 1 7 DIAPHRAGM B18V-14300 1

8 SEAL KIT B152V-SK001 1 8 SEAL KIT B181V-SK001 1

9 GAS VALVE SET B008-13200 1 9 GAS VALVE SET B008-13200 1

NO PARTS NAME PARTS NO Q’TY NO PARTS NAME PARTS NO Q’TY

1 STOPPER PIN B180-12650 2 1 STOPPER PIN B220-12650 2

2 RUBBER PLUG B030-12620 2 2 RUBBER PLUG B030-12620 2

3 CHISEL PIN B180-12600 1 3 CHISEL PIN B221V-12600 1

4 GREASE NIPPLE 004013-10400 2 4 GREASE NIPPLE 004013-10400 2

5 HOLLOW PLUG 004014-10200 1 5 HOLLOW PLUG 004014-10200 1

6 T/BOLT SET B201V-12201 1 6 T/BOLT SET B221V-12201 1

7 DIAPHRAGM B22G-14300 1 7 DIAPHRAGM B22G-14300 1

8 SEAL KIT B201V-SK001 1 8 SEAL KIT B221V-SK001 1