SERVICE INFORMATION

To : DHI subsidiaries/Dealers Ref. No : EX0503-03 (OS)

Attn: Service/Parts Managers Date : Mar. 7th. 2005
Model : Hydraulic Excavator of 13 ton or over
Subject : Breaker Piping Installation and Operation Manual

This information supplies proper way to install Breaker(Hammer) piping and

instruction how to set pressure to obtain recommended operating condition for those who
need to install Breaker(Hammer) on Daewoo Excavator and who wants to maintain
optimum condition of Machine & Breaker.
Improper installation or misuse incurred by misunderstanding might lead to serious
damage to both Machine and Breaker. You are kindly requested to follow our instruction
herein.
See attached instruction and Manual.

Sincerely Continued..

Y. H. Yoon / Y. J. Lee
Customer Support Team / C.E. Division
Daewoo Heavy Industries and Machinery Ltd. .

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Ansan office : 85-1 Palgok Ei-Dong, Ansan Kyungki,Korea/ Tel : 82-31-400-2163
Fax: 82-31-400-2169 , e-mail: yjlee@dhiltd.co.kr
BREAKER PIPING INSTALLATION AND
OPERATION MANUAL

contents

1. Recommendation of BREAKER PIPING

1) BREAKER Piping circuit & components

2) Adjusting PUMP flow

3) Pressure setting of BEAKER RELIEF VALVE

4) Hydraulic circuit of the SWITCH VALVE

5) Pressure check & solution of abnormal pressure in BREAKER

2. Ckecking points

1) Piping Installation

2) Operation

Daewoo Heavy Industries & Machinery Ltd

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1. Recommendation of BREAKER piping
1) BREAKER piping circuit & the components
The followings are the piping circuit & the components delivered by DHI as option
The customer who installs it on the vehicle which is not delivered by DHI will follow the
identical procedure

no part name remark

① OPTION SPOOL
② BREAKER PACKAGE V/V
③ BREAKER RELIEF V/V Part installation by DHI
④ SWITCH VALVE
⑤ BREAKER switch
⑥ ACCUMULATOR Installed by end user

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2) Adjusting PUMP flow
① close the stop valve on the end of front pipe before using BREAKER
and adjust the flow in conformity with the standard flow
② install pressure meter(50Kg/㎠) at "C4" PORT of BREAKER PACKAGE VALVE (ref. Fig 1)
③ Extract the value of Pi of respective model in reference of below Pi-Q graph
& Pi value TABLE.(refer Table1)
④ after selecting breaker mode on breaker select switch, pressing BREAKER SWITCH
on right side JOYSTICK LEVER, adjust Pi pressure turning the screw of PACKAGE VALVE.
(pressure ascending 0.3Kg/㎠ when you turn SCREW 90t̊o the right)

Curve

C4 pressure
Pump flow

Fig 1 Hydraulic Circuit Fig 2. Pi-Q Graph

Table 1 : Pi Value Table for Each Model

Model Pi Formula
S140LC-V Pi = (143.8-Q)/2.98
S140W-V Pi = (222.1-Q)/6.45
S175LC-V Pi = (247.2-Q)/7.72
S180W-V Pi = (236.2-Q)/8.62
S225LC-V Pi = (281.7-Q)/7.07
S210W-V Pi = (325.7-Q)/8.57
S300LC-V Pi = (350-Q)/8.66
S340LC-V,S370LC-V Pi = (471-Q)/13.45
S420LC-V Pi = (444-Q)/13.79
S470LC-V Pi = (510-Q)/16.2

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3) Pressure setting of BREAKER Relief Valve
① close the stop valve on the extreme of BREAKER hydraulic.(fig 1 )

② activate breaker by pushing the upper switch of joystick lever and adjust the pressure
of the relief valve for breaker(located on the BOOM ; Fig 2) into the standard pressure.
(reference : Daewoo factory install specification : 220kgf/cm ^2)
(pressure going up 80kg/㎠ by turning to the right SCREW 90˚)

Stop valve
close

Fig.1

relief valve

Fig.2

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4) Hydraulic circuit of SWITCH Valve

① check as below whether return flow of the SWITCH VALVE is connected to CONTROL VALVE
and OIL COOLER

②when the direction is not correct, adjust with hexagonal spanner (spanner 27mm)

1.5mm slot line should be

positioned to each 3 ports
to Breaker

to Control valve

to Oil cooler

Switch

※In 2-WAY OPTION , it is possible to use it by changing the direction of SWITCH VALVE.

To use 2-WAY OPTION, it is necessary to modify circuit and install the additional hydraulic components.

In that case, please contact us.

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5) pressure check and the solution of abnormal pressure in BREAKER.
It is important to prevent the damage & durability

Check the pressure as below and adjust it to the standard

① Pressure check

- Use the TEST instrument which can record the waves of the pressure(oscillograph).

- eliminate the pressure sensor at the side of main pump(FRONT or REAR pump ;

refer to the circuit of respective model) and install the tester A

- install the tester at the entrance side of OIL COOLER (PLUG PORT at the lower pipe

of cooler ) B
- install the tester between the return port of CONTROL VALVE & RESTRICTOR. C

- starting the BREAKER, measure the pressure of the 3 places.

B
A

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② pressure standard

- main pump prrsure with breaker operation A

pressure

operating pressure
pressure

time

- pressure at the entrance of OIL COOLER B

pressure

Po : peak pressure of oil cooler

inlet

time

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 - RETURN pressure C

pressur pressur
e
between control valve & restrictor

time

② solution of abnormal pressure

- In case of high pressure line which means the output of the pump is beyond the standard,
install appropriate accumulator
- when the peak pressure at the entrance of OIL COOLER and at BREAKER return line is over
the standard, you must install appropriate accumulator (on low pressure piping of Boom).
- when the abnormal pressure gets not resolved with the above method, you must contact the specialist.

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2. Checking point
1) Piping installation
① You must not use the OVER LOAD RELIEF VALVE of Control Valve as relief valve for breaker.

You have to install the relief valve for breaker separately as recommended circuit.
② after installation of the BREAKER, you must measure the pressure wave & adjust it to
obtain the standard instructed by DHI.

③ Breaker return line must be connected to the Control valve and to Oil cooler,

both of which will be connected ultimately to the Tank.

(Breaker return Contol Valve Tank

Oil cooler

2) Operation
① hydraulic oil and filter service interval
When using a hydraulic breaker, the viscosity breakdown and contamination of hydraulic oil
is faster because the working condition is more severe than during normal digging work.
To prevent the hydraulic components (especially pump) from having a shortened life-cycle,
replace the hydraulic oil and main hydraulic oil filter using the following schedule.

attachment operation rate maintenance interval

hydraulic oil filter

250 Hours
(First replacement)
bucket work 100% 2000 Hours
500 Hours
(After first replacement)

hydraulic breaker
100% 500 Hours 100 Hours
work

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 mach Hydraulic oil & Filter service interval
2000 0 10 20 30 40 50 60 70 80 90 100
oper
hyd oil 2000 1658 1400 1196 1028 893 782 692 614 551 500
filter svc 500 370 300 250 210 180 150 130 110 105 100
1500
Machine operating hour

1000

500

0
0 10 20 30 40 50 60 70 80 90 100

Breaker operating ratio(%)

② If a hydraulic breaker and piping is installed without Daewoo's authorization,

it might create a serious malfunction which will not be covered under the warranty.

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