Disassemble

Repair

Disassemble

Disassemble

Removing working tool

  1. 1.
    Place the hydraulic breaker on timber support blocks.
  2. 2.
  3. 3.
  4. 4.
  5. 5.
  6. 6.
  7. 7.

Removing DustProtector

  1. 1.
  2. 2.
    The guide ring (E) may stick in the centrical bore due to dust accumulation. Strike the guide ring (E) a few times with the hand hammer until it comes loose.
  3. 3.
    The guide ring (E) with floating ring (D) and counter-ring (C) can now be removed.
  4. 4.
  5. 5.
    Remove wiper (B) and base for wiper (A).

Note: To facilitate removal of the wiper: Press the sealing lip of the wiper inward using your thumb. This presses the wiper out of the annular grove in the seat.

Removing adapter plate

  1. 1.
    Stand the hydraulic breaker vertically and secure against falling over.

    WARNING

    Hydraulic hose flailing about

    Pressurised hydraulic hoses will flail about when bolted connections have come loose or have been loosened. A hydraulic hose flailing about may cause serious injuries.

    1. Depressurise the hydraulic system before disconnecting a hydraulic hose (see chapter Depressurising the hydraulic system).

  2. 2.
    Remove the hydraulic breaker from the carrier according to the Safety and operating instructions of the hydraulic breaker.
  3. 3.

    WARNING

    Hoist tipping over / hydraulic attachment falling

    The hydraulic attachment is heavy. The hoist/lifting equipment and/or hydraulic attachment tipping over or falling may cause serious injury and material damage.

    1. Only transport the hydraulic attachment with lifting equipment with the right load-bearing capacity for the weight of the hydraulic attachment.

    2. Only lift and secure the hydraulic attachment with lifting gear (ropes, chains, links etc.) with the right load-bearing capacity for the weight to be lifted.

    3. Make sure that there is nobody near or under the suspended hydraulic attachment.

    4. Stand breaker box with percussion unit vertically and secure against falling over.

  4. 4.
  5. 5.

Removing cover and ContiLube

  1. 1.
    Make sure the hydraulic system is depressurised.
  2. 2.
  3. 3.
    Remove grease/oil line from the percussion unit.

    Note: The fittings are fixed with Loctite.

     

     

     

     

     

     

     

     

  4. 4.
    Lock connection boring “PCL” (connection oil line for ContiLube® II) so that no oil runs out (threaded plug Part No. 3363 0669 63).
  5. 5.
    Note: The fixing screws of the ContiLube® II are fixed with Loctite.

Removing percussion unit from breaker box

WARNING

Rupturing washers become projectiles

When loosen the tensioning bolts the washer under the head of the tensioning bolts may rupture and become projectiles. Rupturing parts may cause serious injuries.

  1. Only lift the percussion unit out of the breaker box with fitted dismantling rings.

  2. For safety reasons the dismantling rings are removed only if the tensioning bolts are dismounted.

  1. 1.
    Make sure the hydraulic system is depressurised.
  2. 2.
    Place dismantling rings (Part No. 3363 0979 01) over the heads of all tensioning bolts before lifting the percussion unit out of the breaker box.
  3. 3.
    Screw two adjustable eyebolts M20 x 30 (Part No. 3363 1032 48) into the two threaded borings on the upper face of the cylinder cover (see chapter Adjustable eyebolts).

     

     

     

     

     

     

     

     

     

  4. 4.
    Using a hoist/crane, lift the percussion unit of the hydraulic breaker out of the breaker box.

    WARNING

    Abruptly loosen parts cause injuries

    Using the hoist as a pulling device if the percussion unit has jammed in the breaker box can cause serious injuries.

    1. You must not use the hoist as a pulling device.

    2. Contact the Eprioc Customer Center / Dealer in your area, when the percussion unit has jammed in the breaker box.

    3. Secure breaker box against falling over.

    4. Stand percussion unit vertically and secure against falling over.

  5. 5.
    Remove plastic parts and plugs from the breaker box.

Removing filling valve

WARNING

Component coming loose abruptly

The piston accumulator is under pressure, even when the hydraulic system has been depressurised. The filling valve might come loose unexpectedly and cause injuries.

  1. Never unscrew the filling valve »G« from the pressurised piston accumulator.

NOTICE

Damage to the filling valve

Nails, screwdrivers or similar objects can damage the filling valve.

  1. Never use nails, a screwdriver or similar objects to release nitrogen gas from the piston accumulator.

  1. 1.
    Make sure the hydraulic system is depressurised.
  2. 2.
    Unscrew screw plug from filling valve port.
  3. 3.
    Push the hose end of the test pressure gauge into the filling valve and let gas escape until the piston accumulator is depressurized.
  4. 4.
    Unscrew the filling valve from cylinder cover.

     

     

     

     

  5. 5.
    Check the filling valve and replace if necessary.

Removing stop valve

  1. 1.
    Make sure the hydraulic system is depressurised.
  2. 2.

    Note

    To remove the stop valve you can use a bar magnet.

  3. 3.
  4. 4.
    Check the stop valve for scores.
  5. 5.
    Check that the valve piston can move easily in the valve housing.
  6. 6.
    Replace the stop valve if you detect scores or if the valve piston sticks.

Removing tensioning bolts

Note

Mark the tensioning bolts and borings for later remounting. This ensures remounting to borings with matching threaded inserts in the lower breaker part.

  1. 1.
    Make sure the hydraulic system is depressurised.
  2. 2.
    Release tensioning bolts using a power wrench and unscrew from the lower breaker part.
  3. 3.
    Remove all tensioning bolts, washers and dismantling rings.
  4. 4.
    Check the plastic collar of each tensioning bolt.
  5. 5.
    Replace the tensioning bolt if the plasic collar is loosened or defectiv.
  6. 6.
    Check the thread of each tensioning bolt.
  7. 7.
    Replace the tensioning bolt if the thread is defectiv.

Removing cylinder cover

NOTICE

Environmental damage due to hydraulic oil

Hydraulic oil is environmentally harmful and must not penetrate the ground or enter the water table or water supplies.

  1. Collect any hydraulic oil which escapes.

  2. Dispose of it in accordance with the applicable environmental regulations.

  1. 1.
    Screw two adjustable eyebolts M20 x 30 (Part No. 3363 1032 48) into the two threaded borings on the upper face of the cylinder cover (see chapter Adjustable eyebolts).
  2. 2.
    Lift off the cylinder cover using a hoist/crane.
  3. 3.
    Remove locking pin (A) and save it for future use.
  4. 4.
    Remove o-ring and seals from the cylinder cover.

Removing control valve

  1. 1.
    Make sure the hydraulic system is depressurised.
  2. 2.
    Remove o-ring.
  3. 3.
    Turn a screw M6 into the threaded boring on the upper face of the cover.
  4. 4.
  5. 5.
  6. 6.
    Remove control valve from boring and observing direction of removal.
  7. 7.

Removing percussion piston

Note

Remove the percussion piston in vertical position.

NOTICE

Environmental damage due to hydraulic oil

Hydraulic oil is environmentally harmful and must not penetrate the ground or enter the water table or water supplies.

  1. Collect any hydraulic oil which escapes.

  2. Dispose of it in accordance with the applicable environmental regulations.

WARNING

Uncontrolled flailing parts, heavy parts falling

The adjustable eyebolt can be torn out of the piston’s screw thread if the load is too high. When the adjustable eyebolt tears out, it shoots out of the piston uncontrollably and can lead to serious injuries. The piston and/or other heavy parts can fall down.

Due to the special design of the piston’s screw thread, the adjustable eyebolt can only be loaded to a maximum of 700 kg (1545 lbs), although a load of up to 2.3 t is approved.

  1. If the piston is jammed in the cylinder, you must never firmly hold the cylinder to release the piston from it with greater force.

    The higher pulling force would result in the adjustable eyebolt being impacted with more than 700 kg (1545 lbs).

  2. Never use the jammed piston to lift the cylinder.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Note

If the piston cannot be removed from the cylinder, the cylinder and piston must be replaced.

  1. 1.
    Screw an adjustable eyebolt into the threaded boring on the percussion piston (see chapter Adjustable eyebolts).

    Version A:

    3/4“ - 16 UNF-2B (Part No. 3363 1067 21)

    Version B: M20 x 30 (Part No. 3363 1032 48)

  2. 2.
    Pull out the percussion piston using a hoist / crane.

Removing cylinder

NOTICE

Environmental damage due to hydraulic oil

Hydraulic oil is environmentally harmful and must not penetrate the ground or enter the water table or water supplies.

  1. Collect any hydraulic oil which escapes.

  2. Dispose of it in accordance with the applicable environmental regulations.

  1. 1.
    Screw two adjustable eyebolts

    Version A: M16 x 24 (Part No. 3363 1032 49)

    Version B: M20 x 30 (Part No. 3363 1032 48)

    into the two threaded borings on the upper face of the cylinder (see chapter Adjustable eyebolts).

  2. 2.
    Lift off the cylinder using a hoist / crane.
  3. 3.
    Remove locking pin (A) and save it for future use.

Checking lower breaker part

  1. 1.
    Check the treaded inserts of the tensioning bolts and replace if necessary.

Removing locking pins for wear bushes

  1. 1.
    Knock out the locking pin (A) for the upper wear bush using the pin punch and a hand hammer.
  2. 2.
    Knock out the locking pin (B) for the lower wear bush using the pin punch and a hand hammer.

Removing locking bushes

Note

Locking pins for retainer bars, DustProtector system and wear bushes are secured with locking bushes. A locking bush must be replaced if the locking pin can be pushed out of the bore by pressing on it firmly with a finger.

  1. 1.
    Insert a screwdriver behind the locking bush and lever it out of the bore.