Assemble

Repair

Assemble

Assemble

Tightening torques

Connection point

Pos.

Type of spanner

Size / Torque

Adapter plate* (fastening screws)

A

Allen key

17 mm / 390 Nm

(0.687 in. / 288 ft lbs)

Tensioning bolts**

B

Torque wrench / power wrench

50 mm (1.97 in.)

Filling valve »G« (threaded plug)

C

Socket spanner

Allen key

22 mm / 130 Nm

(0.87 in. / 96 ft lbs)

5 mm / 20 Nm

(0.20 in. / 15 ft lbs)

Ports »P« and »T«

D

Open-ended wrench

50 mm / 275 Nm

(1.97 in. / 203 ft lbs)

Hose connections ContiLube® II

E

Various open-ended spanners with different spanner sizes

Valve »HV«

F

Allen key

12 mm / 100 Nm

(0.47 in. / 74 ft lbs)

Percussion chamber ventilation

G

Open-ended wrench

41 mm / 200 Nm

(1.61 in. / 148 ft lbs)

*  Apply anti-seize compound to the Allen screw threads before inserting them.

   The contact faces of the screw head and the lock washers must not be lubricated

**   1. Pre-tighten the tensioning bolts to 200 Nm (148 ft lbs) crosswise,

   2. retighten 120° (2 hexagons) crosswise,

   3. retighten 90° (1½ hexagons) crosswise

Fitting cylinder

  1. 1.
    Stand lower breaker part upright and secure against falling over.
  2. 2.
    Clean contact faces on lower breaker part and cylinder.
  3. 3.
    Check locking pin (370) and replace if necessary.
  4. 4.
    Fit locking pin (370).
  5. 5.
    Fit new seals and wiper to the cylinder (see chapter Changing seals).
  6. 6.
    Screw two adjustable eyebolts

    Version A: M16 x 24 (Part No. 3363103249)

    Version B: M20 x 30 (Part No. 3363103248)

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

  7. 7.
    Position the cylinder on the lower breaker part using a hoist/crane.
  8. 8.
    Remove the adjustable eyebolts.

Fitting percussion piston

  1. 1.
    Clean percussion piston and coat with hydraulic oil.
  2. 2.
    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)

  3. 3.
    Using a crane, insert percussion piston into cylinder as far as it will go, avoiding tilting.
  4. 4.
    Remove the adjustable eyebolt.

Fitting control valve

  1. 1.
    Check the control valve (301) and replace if necessary.
  2. 2.
    Lubricate control valve (301) with hydraulic oil.
  3. 3.
    Fit control valve (301) in bore in cylinder.

    Note

    Ensure valve is fitted the right way round.

  4. 4.
    Grease new o-ring(s) (303) with Parker O-Lube and insert in the cover (302).
  5. 5.
    Turn a screw M6 into the threaded boring on the upper face of the cover.
  6. 6.
    Fit the cover (302), ensuring it is straight and not tilted.
  7. 7.
    Remove the screw M6 from the cover.
  8. 8.
    Grease new o-ring (304) with Parker O-Lube and insert in the cover (302).

Fitting cylinder cover

  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.
    Clean the upper face of the cylinder and the lower face of the cylinder cover.
  3. 3.
    Fit new seals and o-rings to the cylinder (see chapter Changing seals).
  4. 4.
    Check locking pin (370) and replace if necessary.
  5. 5.
    Position the cylinder cover on the cylinder using a hoist/crane.
  6. 6.
    Remove the adjustable eyebolts.

Fitting tensioning bolts

Note: Washers are conical on one side. When fitting, the conical side must be facing the head of the tensioning bolt.

  1. 1.
    Treat the threads of the tensioning bolts and the washers with anti-seize agent.
  2. 2.
    Provide tensioning bolts (191) with one washer each (192) and insert into the marked bore (in matching pairs).

    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.

  3. 3.
    Place dismantling rings (Part No. 3363 0979 01) over the heads of all tensioning bolts before tightening.

     

     

     

     

     

     

     

     

     

     

     

     

     

  4. 4.
    Use a power wrench to tighten the tensioning bolts following the tightening procedure:

    1. Pre-tighten the tensioning bolts to 200 Nm (148 ft lbs) crosswise,

    2. retighten 120° (2 hexagons) crosswise

    3. retighten 90° (1½ hexagons) crosswise.

Note: After assembling the percussion mechanism the piston accumulator must be filled with nitrogen (see chapter Filling the piston accumulator).

Fitting stop valve

  1. 1.
    Check the stop valve and replace if necessary.
  2. 2.
    Fit the valve piston (321) to the valve housing (320).
  3. 3.
    Check that the valve piston (321) can move easily in the valve housing (320).
  4. 4.
    Insert stop valve in bore (marked HV) provided in cylinder.
  5. 5.
    Coat the threaded plug (322) with Loctite 243 and place it in bore (marked HV).
  6. 6.
    Fasten threaded plug (322) with an Allen key.

Fitting filling valve

  1. 1.
    Check the filling valve (181) and replace if necessary.
  2. 2.
    Fit new o-ring (183) to filling valve (181).
  3. 3.
    Use a socket spanner to screw the filling valve (181) into the cylinder cover (boring marked G).

Prefilling the piston accumulator

DANGER

Danger of explosions

The integrated piston accumulator is filled with nitrogen (N2). Filling it with any other gas may trigger an explosion and lead to serious, possibly fatal, injuries.

  1. Only fill the piston accumulator with nitrogen (N2).

If a country-specific adapter (E) is required, it has to be installed between the nitrogen bottle and the pressure relief valve (D).

  1. 1.
    Connect the pressure relief valve (D) to the nitrogen bottle.
  2. 2.
    Open the valve of the nitrogen bottle (F).
  3. 3.
    Push the free filling hose end (H) into the filling valve (G).
  4. 4.
    Slowly open the pressure relief valve (D) to let the nitrogen flow into the piston accumulator.
  5. 5.
    Read out the pressure increase from the pressure gauge (B).
  6. 6.
    Close the pressure relief valve (D) when the piston accumulator has reached the minimum gas pressure of 9.6 bar (139 psi).
  7. 7.
    Pull the filling hose out of the filling valve (G).
  8. 8.
    Close the nitrogen bottle valve (F).
  9. 9.
    Fit the threaded plug (183) in the filling valve (181) and tighten using an Allen key.

Checking if connections are gastight

  1. 1.
    Check if the connections at the filling valve and the seal flange are gas-tight.
  2. 2.
    Spray leak detection spray or soap water onto the filling valve and the connection between cylinder cover and seal flange.
  3. 3.
    Look for bubbles detecting a leak.
  4. 4.
    If a connection is not gas-tight disassemble again and change the seals.
  5. 5.
    Only finish the assembly of the hydraulic breaker when all connections are gas-tight.

Filling the piston accumulator

Note

After installation of the hydraulic breaker to the carrier the piston accumulator has to be filled to the required gas pressure of 11.6 bar (168 psi). This has to be done at operating temperature 60-70 °C (140-158 °F) and without exerting pressure of the working tool.

WARNING

Unexpected movement

If the working tool has got stuck, it might come loose unexpectedly if the pressure in the piston accumulator is increased. The unexpected impact may lead to serious injury.

  1. When filling the piston accumulator make sure that there is nobody within the direct vicinity of the working tool.

  1. 1.
    Remove the threaded plug (183) from the filling valve (181) using an Allen key.
  2. 2.
    Repeat the steps 1 to 5 from chapter Prefilling the piston accumulator.
  3. 3.
    Close the pressure relief valve (D) when the piston accumulator has reached the required pressure of 11.6 bar (168 psi) +10 %.
  4. 4.
    Push the hose end of the test pressure gauge into the filling valve again.

    This will cause gas to escape from the piston accumulator.

  5. 5.
    Check the pressure in the piston accumulator and repeat this until the required gas pressure of 11.6 bar (168 psi) has been reached.
  6. 6.
    Repeat the steps 7 to 9 from chapter Prefilling the piston accumulator.

Fitting the percussion unit in the breaker box

  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.
    Stand breaker box vertically and secure against falling over.
  3. 3.
    Replace any defective shock absorbers (3) and guide plates (4, 5 and 7) (see chapter Checking plastic parts).
  4. 4.
    Fit plastic elements and fix in position using double-sided adhesive tape.
  5. 5.
    Lift up percussion mechanism using a crane/ hoist.
  6. 6.
    For hydraulic breaker with DustProtector: Snap the base for wiper in the inner support groove of the lower wear bush.

    WARNING

    Hands and fingers being cut off or hurt

    Bores and surfaces can act like a pair of scissors and cut off or hurt parts of your body.

    1. Never use your fingers to check bores or fitting surfaces.

     

     

     

     

     

     

     

     

     

     

     

     

     

     

     

     

     

     

  7. 7.
    Lower the percussion unit into breaker box.
  8. 8.
    Remove the adjustable eyebolts.
  9. 9.
    Remove the dismantling rings.
  10. 10.
    Fit adapter plate or transport safety device.

Fitting cover and ContiLube II

  1. 1.
    To fix the ContiLube® II on the plate (35) fit four Allen screw (554) with a pair of lock washers (556).

    Note

    The grease line and oil line must be routed as shown in the Spare parts list. It must be ensured that grease line and oil line can move freely in the breaker box and do not come into contact with the breaker box at any point.

    The ports for the grease line (marked CL) and the oil line (marked PCL). These thread sizes are almost identical and can lead to mix-ups.

    For this reason:

    Never use force during assembly as the threads could be damaged. Screw couplings will leak. It must be possible to tighten the hose connections on the appropriate couplings by hand.

  2. 2.
    Remove the threaded plug locking the connection boring “PCL”.
  3. 3.
    Coat the thread of fitting (568) of grease line with Loctite 243 and connect to the appropriate boring (marked CL) in the cylinder cover.
  4. 4.
    Coat the thread of fitting (566) of oil line with Loctite 243 and connect to the appropriate boring (marked PCL) in the cylinder cover.

     

     

     

     

     

     

     

     

  5. 5.
    Tighten the fitting using open-ended spanners.
  6. 6.
    To fix plate (34) and plate (35) on the breaker box fit all four Allen screws (38) with a pair of lock washers (39).

Fitting adapter plate

NOTICE

The adapter plate can come loose

The adapter plate can come loose if the fastening screws are not designed for local high loads.

  1. Only use the Allen screws of strength category 8.8 and the pairs of lock washers included in the delivery to attach the adapter plate or the base plate.

  1. 1.
    Fit elastic pad (2).
  2. 2.
    Check threads and/or threaded inserts and rework or replace if necessary.
  3. 3.
    Place the adapter plate on the hydraulic breaker.
  4. 4.
    Apply Anti-Seize to the Allen screw threads before inserting them.

    The contact faces of the screw head and the lock washers must not be lubricated.

  5. 5.
    Fit a pair of lock washers onto every screw.

     

     

  6. 6.
    Tighten the Allen screws with an Allen key.

Fitting working tool

Note

When assembling a hydraulic breaker with Dust- Protector first fit the base for wiper. The wiper may not be fitted before the working tool is mounted. If working tool is fitted without first removing the wiper, the latter will be turned the wrong way out and will no longer be functional.

  1. 1.
    Place the hydraulic breaker on timber support blocks.
  2. 2.
    Clean any dirt from the insertion zone of the working tool and grease with chisel paste.
  3. 3.
    For hydraulic breaker with DustProtector (DP): snap the base for wiper (18) in the inner support groove of the lower wear bush.
  4. 4.
    Insert working tool.
  5. 5.
    Grease the two retainer bars with chisel paste.
  6. 6.
    Insert retainer bars in the appropriate oblong holes and turn the working tool until the retainer bars slide into oblong holes in lower breaker part.
  7. 7.
    Fit new spring dowel sleeves (487), if they has been removed or are worn.
  8. 8.
    Position the retainer bars so that the recesses of the retainer bars and the holes for the locking pins align.
  9. 9.
    Drive in pins (486) using a pin punch and hand hammer.
  10. 10.
    Fit the plugs (33) into the openings in the breaker box.
  11. 11.
    Remove the screws from the retainer bars.
  12. 12.
    Fit the plugs (32) into the openings in the breaker box.

Fitting DustProtector

  1. 1.
    Push wiper (19) over the working tool by hand and snap into the groove in the base for wiper.
  2. 2.
    Use an auxiliary tool (hammer handle) to press in the stripper where necessary.
  3. 3.
    Run your thumb around the circumference to complete fitting.
  4. 4.
    Grease floating ring (11) and counter ring (12), insert in guide ring (13) and fit in the lower breaker part of the breaker box.
  5. 5.
    Position the guide ring (13) in such a way that the bores in the breaker box and in the guide ring are aligned.
  6. 6.
    Fit new locking bushes (15), if they has been removed or are worn.
  7. 7.
    Drive in locking pins (14) using a pin punch and hand hammer.