DXB Breakers:

Service Training

2011. 12 – V2
GLOBAL Construction Equipment BG
AM D
Department
t t

© copyrights 2011. Doosan Infracore Co. Ltd. All rights reserved.

Important dates for Montabert

2009
Montabert launches DXB
range breakers

2004
SC range (Silver
Clip)

1969
1st hydraulic breaker
1970
1st hydraulic drifter 1987
Invention of
Variable speed
b k
breaker
Table of Contents
Introduction Chapter IV: Breaker Maintenance
1. Maintenance schedule
Chapter 1: Breaker Basics 2. Auto g
grease device ((Option)
p )
1. Hydraulic breaker 3. Warning
2. Applications 4. Storage
3. Doosan Breaker Line up
4 Technical background.
4. background Chapter V: Trouble Shooting
5. Breaker operation principle 1. Major cause and trouble
6. Blank Firing 2. Breaker dose not start
7. The Golden Rules 3. Too low impact
p rate
4. Too low impact force
Chapter II: Breaker Installation 5. Oil temperature too high
1. Mechanical Mounting 6. Oil or Gas Leakage
2 Relief pressure
2. 7 Others
7.
3. Oil Flow 8. Major Phenomenon
4. Nitrogen gas inflating 9. Typical Tool Failure

Chapter III: Breaker Operation Closing Remarks

1. Working application
2. Tool Choice
3 Two speed impact frequency
3.
4. How to operate properly
2
 Introduction:

The wonderful world of

Attachments

3
Why Attachments?

Attachments:
 Get the – dirtyy – jjob done!
 Are the natural extension of the machine (like a hand is to
the body)
 Increase
I th versatility
the tilit off the
th machine
hi
 Impact directly the productivity and efficiency of the machine
 Boost business opportunities
pp / applications,
pp , thus $ !
 Address regional needs and demands
 Give a competitive edge (over some competitors)
 Increase
I th One-Stop-Shop
the O St Sh solution l ti for
f your customers
t
 Reinforce the Doosan brand and value
 Enhance machine residual value
…
 small investment, great return !
Without an attachment,
attachment the machine offers only a bumpy ride!
4
Why Attachments?

Wrong attachments:

 May damage the machine vital circuits or structure

 Will create disputes with the Warranty Dpt.
 Will immediately affect ff productivity and customer
satisfaction
 Will deteriorate the overall Doosan brand and image

 small investment, great return… or great risks!

The attachment is determinant in the performance of the machine!

5
What is Attachments?

“Tools, implements, assemblies, etc. which are used on and

enhance the productivity
p y and versatilityy of construction
equipment”
Association of Equipment Manufacturers

6
Breaker basics: Applications
Applications:

7
Breaker basics: Applications
Applications:

8
Breaker basics: Applications
Applications:

9
Breaker basics: Applications
Applications:

10
Breaker basics: Applications
Applications:

11
Our Mission

Global Attachments Team

Committed to develop integrated attachments that optimize
carrier versatility, productivity and utilization.

Our focus in 2012 are on:

 Increasing the Attachment offering (new products)
 Developing marketing tools and support
 Improving training material (Sales and Service)
 Increasing Field presence

Our Vision is to be your “preferred

preferred partner
partner”!!
12
Our Message

Doosan delivers:
 Quality
 Performance
 Best Fit
 Service

We thrive to enhance our services to you!

13
Chapter
p I:

Definition of a breaker

14
Table of Contents

Chapter 1: Breaker Basics

1. Hydraulic breaker

2 Applications
2.

3. Doosan Breaker Line up

4. Technical background.

5 Breaker
5. B k operation
ti principle
i i l

6. Blank Firing

7. The Golden Rules

15
Breaker basics: Definition of a breaker
Definition:
A breaker is a powerful percussion hammer fitted to an excavator for demolishing
concrete structures or rocks. It is ppowered by
y an auxiliary
y hydraulic
y system
y from the
excavator. Additionally, demolition crews employ the hoe ram for jobs too large for jack
hammering or areas where blasting is not possible due to safety or environmental issues.
Breakers are often referred to as "hammers", "hoe rams" or "hoe rammers.“ These terms
are popular and commonly used amongst construction/demolition workers.
Source: wikipedia

ALL Hydraulic Hammers work by

transmittingg a shock wave ((created by y
the piston striking the tool) through the
tool into the material to be broken!

16
Definition

Hydraulic
A
Aux. Li
Line
Hoses
Mounting cap
(Also called Fixing Cap)

Quick Breaker
Coupler Check application!
(Optional)

Tools
(Also called Bits or Points)
Check application!

17
 Breaker basics: Definition of a breaker
3 technologies:
Tech. Technology Advantages Disadvantages Leaders
Type Explanation
Gas type • Piston falls down only by gas • Fewer components • Gradual gas leak NPK
pressure • High hammer efficiency • Cavitation in ham
• N accumulator
No l t mer
• High pressurized gas on upside
piston
yp
Oil type • Piston falls down by
y hydraulic
y • Easyy to start without • Many y components
p Montabert
force. pre-load • High pressure fluct Sandvik
• Acc. Located on the upside of • No cavitation in breaker uation Indeco
breaker.
• Atmospheric
p p
pressure on
upside piston
Gas • Piston falls down by Hyd. + Gas • Fewer components • Gradual gas leak Doosan
assisted pressure. • Very high breaker • Light cavitation in Krupp
Type • Normally Acc.
Acc located in front of efficiency the breaker Furukawa
breaker. • Stable operating Everdigm
• No Acc. on small breaker Soosan
• Pressurized gas on upside
piston

18
 Definition
Nitrogen Fired vs. Fully Hydraulic
NITROGEN PISTON DIAPHRAGM
GAS CHAMBER ENERGY CHAMBER
Nitrogen
Approximately two thirds
of energy per blow Energy per blow is
Seals
comes from nitrogen constant:
pressure. Oil
Between each nitrogen
refill the energy per
refill,
blow is constantly Piston
decreasing. low
When breaker is not in Piston seals maintenance,
use, nitrogen causes the
seals to dry up and constant
crack. These seals will performance
then allow nitrogen to
escape.
Tool

Example: Doosan DXB

19
Definition
Nitrogen Fired vs. Fully Hydraulic
NITROGEN PISTON DIAPHRAGM
GAS CHAMBER
vs. ENERGY CHAMBER
Example: Example:
Nitrogen

Seals
Oil

Piston

Piston seals

Tool

Example: Doosan DXB

20
 Breaker basics: Definition of a breaker
DXB Parts Identification:
SC36 DXB20 DXB170 DXB260

Fully Hydraulic (SC36) vs. Nitrogen Fired (DXB series)

21
 Breaker basics: Definition of a breaker
Parts Identification:
No. Part Name Description Application

DXB260 DXB90 DXD20 4EA. Through bolts, Long bolts. Assembling Back
1 Tie rod bolt All
head,, Cylinder,
y , Front g
guide
2 Nut Back head Nuts. Tightening with tie rod bolts. All
1 3 Back Head Nitrogen chamber with “Valve type” inflating system All
Back 2 4 Valve Back-head gas charging valve All
3 5 Valve Distributor All
head
Cylinder bush. Sealing between Hydraulic passage
4 6 Seal group
andd N2 gas chamber
h b
All
5 7 In port 1EA. High pressure port All
6 8 Out port 1EA. Return pressure port All
Cylinder 9 Grease port For Lubrication All
7 10 Cylinder Cylinder included. All
8 11 Piston Strike Piston All
9 DXB160,
12 Accumulator DXB190,
10 DXB260
11 13 Scraper seal To protect dust coming into the cylinder. All
Front 12 4EA Assemble back head, Cylinder
y and front g
guide
14 Front guide Nut All
with the Tie rod bolt
Guide 13 All, except
14 15 Upper bussing 1EA Upper chuck busing, Chisel bush.
DXB10,
DXB20,
15 DXB35
16 16 Retainer pin Tool pin, pin.
pin Chisel pin All
17 All, except
DXB10,
18 17 Lower busing 1EA, Lower chuck busing. Front bush.
DXB20,
19 DXB35
1-piece
p Tool DXB10,
18 Single busing
bush DXB20,
19 Tool Chisel. All

22
 Breaker basics: Operation principle
Piston strike operation cycle

① Start
Piston Raising ② Piston Up
Valve Raising ③ Valve up
Piston falling ④ Piston Down
Valve falling

HP HP HP HP
LP LP LP LP

Breaker requires one high pressure line (in- When the striking piston Strike piston is falling down due to Strike piston hit the tool, and
line from pump) and one low pressure line fully moved upside, the compressed gas pressure + High impact energy is transmitted
(out line to tank). When high oil pressure is oil path on the bottom oil pressure + Weigh of piston. to the rock through the tool.
supplied, the oil pressure is built up on the side of valve become Strike piston upper chamber = When the piston is down, the
bottom side of piston. high pressure line. Compressed gas pressure + High lower area of the valve is
Hydraulic pressure on the bottom side of Force = Area X Pressure oil pressure (Large Area) + changed to low pressure, and
piston (Relief pressure > Back head gas Weight of piston >Piston lower the valve is falling down
pressure + Weight of piston ( Operating chamber = simultaneously.y
pressure) High oil pressure (Small area)

23
 Breaker basics: Definition of breaker
DXB Feature:

Compact DXB Mid-Size DXB

High pressure Accumulator with

diaphragm
Hydraulic
 In order to reduce peak
HP Hydraulic
energy from LP energy from HP pressure.
Carrier Carrier LP
 DXB160 and DXB260

Anti blank blow (Anti start &

Anti-blank-blow
stop)
 DXB160

2 speed impact frequency

2-speed
 DXB190, DXB260

Blank firing protection shape

DXB 170,
170 DXB190
DXB190, DXB260

Air compressor port for under

water working
 DXB190,
DXB190 DXB260

24
 Breaker basics: terms of flow and pressure.
Start
Transient State Steady State
Qsupplyy

Δ QS

QS
T BU
Psupply

Δ PS

PS peaak
TC
PS
P R peak
P return

PR

25
Breaker basics: terms of flow and pressure.

26
Breaker basics: Operation principle
The condition associated with breaker performance

B oilil ttemperature
By t

Oil temperature
p increased

Gas pressure on back head increased

Operating pressure
(Pressure to lift up the striking piston) increased

27
Breaker basics: Operation principle
The condition associated with breaker performance

Impact Ratte

Operating
g
Pressuree
Min Max
Oil flow Oil Flow
Operating Peak
Performance Frequency Operating
Energy Pressure Pressure on Remarks
Condition (BPM) Pressure Variation return line

Decreased oil flow     Min. at Frequency is directly

rated oil proportional to supplied
Increased oil flow     flow oil flow

Decreased back head gas pressure      Energy is directly to

proportional to back head
gas pressure
Increased back head gas pressure     
Oil flow from pump is
Increased oil temperature      decreased simultaneously.

28
Breaker basics: Operation principle
The condition associated with breaker performance

Operating Peak
Performance Impact Impact Operating
Pressure Pressure on Remarks
Condition Rate Energy Pressure Variation return line

Increased back pressure     

Acc. Installation on high Initial operating time is
pressure line   —  delayed
Acc. Installation on high
pressure line — — — — 
Lost accumulator function   —   Damaged diaphragm

Increased clearance Piston cylinder wear

between piston and      After polishing piston and
cylinder cylinder
Piston-cylinder or valve
stuck   Irregular Irregular Irregular Irregular blow

Increased tool settlement Wear of stopper on tool bush

height     or thrust ring
Increased piston repulsive
Breaking strong object     power
Decreased piston repulsive
Breaking soft object     power

29
Breaker basics: Blank Firing
What is the blank firing?

30
Breaker basics: Blank Firing
Blank firing protection

Damping throttle

Blank firing is the enemy of breaker! DXB Breakers have optimized design for blank firing protection.
Blank firing leads to a lot of troubles on some breaker parts such as tool
tool, bushing
bushing, etc
etc..

Applied Model: DXB170, DXB190 and DXB260. 31

Breaker basics: Blank Firing
Blank firing protection

If the tool is not applied on the shank thrust,

the piston will go in his damping stroke, that
will generate a pressure increase and the
piston slows down  Dash Pot Damping stroke

Applied Model ; DXB170

DXB170, DXB190
DXB190, DXB260
DXB260.

Pressure
increases

The piston will not kick into the cylinder.

Bl k fifiring
Blank i protection
t ti = protection
t ti off ththe piston
i t and d cylinder.
li d

32
Breaker basics: DXB Range
Bracket mounting type

Direct Top
Side Mounting Top Mounting Housing type
Mounting

Mounting Mounting cap separately need for

Direct mounting type (without Mounting cap)
Method mounting

All except DXB10, DXB10 All except DXB10, All except DXB10,
Applied Model
DXB20 DXB20 DXB20, DXB260 DXB20

Illustration

33
 Definition

3 frames can be found:

• Housing (also know as silenced) breakers are recommended for
professional contractors
p workingg in urban zones,, where noise
level must be maintenanceled and/or where local regulation may
require silenced breakers.

• Top mount versions,

versions because of their simplified design,
design offer easy
access to the power cell for easy on‐site maintenance.

• Side mount versions offer similar characteristics as the Top Mount

versions, yet the mounting on the arm of the excavator is made at an
angle.
Housing

Top
Mounting
Side
Mounting
34
 Breaker basics: DXB Range

Facts:
- 16 models
- For carrier weight from 1t up to 38t.
- For breaker weight from 90kg to 2550kg
A range of breakers in Housing
35
and/or Top Mount versions for every DX machine (from 1t up to 38t)! 35
Ch t II :
Chapter

DXB IInstallation
t ll ti

2011. 11
GLOBAL Construction Equipment BG
AM D
Department
t t

36
Table of Contents

Chapter II: DXB Installation

1. Matching the carrier and Breaker.

2 Mechanical Mounting
2.

3. Auxiliary piping line flushing.

4. Oil Flow

6. Relief pressure

7. Nitrogen
g g gas inflating
g

37
Beaker Installation.
Hydraulic circuit for breaker

The location of the Hi

Hi-pressure
pressure an and Low
Low-pressure
pressure (Return line) auxiliary piping are not switchable
switchable.

38
Breaker basics: Technical background
Terminology

C i W
Carrier Weight
i ht The total operation weight of all attachment such as actuator at end of arm
arm, load on the
actuator and quick coupler to should be less then 80% of tipping load at least. (ton)
Total attachments weight ≤ 80% at least of carrier tipping load

The pump of the machine discharges the oil in the circuit and delivers a flow expressed in litre
Flow
per minute. (l/min)

Rated attachment oil flow ≤ 100% of Main pump discharge flow

Back pressure Measured at the breaker outlet, this pressure represents the difficulties the oil has to go
Counter pressure back to the tank through the return circuit. (adaptor shape and size + hose length + hose
Low pressure(LP) diameter + …)

Working pressure Piston weight, N2 gas pressure, Back pressure.

High pressure(HP)

This device placed on the auxiliary line deviate the flow directly to the tank when the
Relief valve pressure reaches a pre-adjusted value.

Relief Setting pressure = [max operating pressure + 40 bar]

At pump pressure compensation ≥ [ Max operation pressure + 70 bar]  refer to the
f ll i page
following

39
Matching the carrier and Breaker.

 Weight (kg)
① Total attachments weight: 1680 + 450 (quick
coupler) = 2130 kg
② Tipping load ; (2500 + 1000(bucket) ) X 80% =
2800
■ Total attachments weight (①)≤ 80% at least of
carrier tipping load (②)

 Oil Flow (liter/min)

( )
① Rated flow ; 150.
② Main pump discharge flow ; 206.5
■ Rated attachment oil flow (①)≤ 100% of Main
pump discharge flow (②)

40
 Matching the carrier and Breaker.
Excavator weight base
Carrier Weight (tons)
DXB Range 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
DXB10 X

DXB20 X

DXB35 X X

DXB45 X

DXB90 X

DXB170 X X X

DXB190 X

DXB260 X X
(X) Most suitable fit

Important note:
DXB Line has been developed specifically to best fit with Doosan excavators. DXB Line is primarily designed for
Doosan machines.
Montabert breakers (green and blue lines) are to be mounted on all other excavator brands.
brands Exceptions may be
considered for the green line. Point discussed later.

Select the right breaker for the right machine! 41

 Matching the carrier and Breaker.
Discharge oil flow base.
DXB10 X

DXB20 X

DXB35 X

DXB45 X

DXB90 X

DXB160 X

DXB170 X

DXB190 X

DXB260 X

0 50 100 150 200 250

Flow
X = recommended oil flow (l/min)

Doosan recommends min. oil flow +15% for best performance! 42

 Mechanical Mounting
Mounting type & Mechanical kit

Side mounting &

Direct top mounting

Mechanical kit (Option)

Side Mounting, Direct Top Mounting - Pins
- Busing, Shims

Top mounting &

Housing

Mounting Cap Mechanical kit (Option)

Top Mounting Housing - Cap, - Pins
- Bolts & Nuts - Busing, Shims

Once the breaker is connected (hoses included) and

the Nitrogen chamber loaded… You’re ready to start! * 43
(*) Please refer to the Operation Manual for proper set up and first time installation.
 Mechanical Mounting
Mounting type

Direct Top
Side Mounting Top Mounting Housing
Mounting
Mounting Model
Method Direct mounting type Mounting cap separately need
(without Mounting cap) for mounting
DXB10 No  No No DX27
DXB20 No  No No DX30Z, DX35Z
DXB35*  No   DX55,DX55W, DX60R
DXB45**
DXB45  No   S75,, DX80R
DXB90  No   DX140, DX140W, DX170W
DXB160  No  No DX180LC, DX190W, S180W, S210W
DXB170  No   S180W, S210, S220, S255, DX180, DX21DX225, DX255

DXB190  No   DX300LC.
DXB260  No No  S300LC, S340LCDX300LC, DX340LC,

* DXB35: Universal pin set and Mounting cap for SSL and Backhoe loader are available
available.
** DXB45: Universal pin set and Mounting cap for SSL.
All the parts number for each Mounting kit are announced in the Part catalog as one of spare parts.

44
 Mechanical Mounting

Bracket only part

DXB Model * Mounting cap kit part number Applicable Excavator.
number

DXB170 86698982 86694940d DX210W, DX225LC, DX260LC

86698982 86694940d DX210W DX225,

DX210W, DX22 DX260
DXB190
To be confirmed 86684222b DX300LC

160626-00113 86635968 EC3300LC

160626-00114 86637535 Solar300

DXB260
160626 00115
160626-00115 86632551 S l 340
Solar340
160626-00116 86684388b DX300LC
160626-00117 86699931b DX340LC

* Kit detail ; Bracket (1EA), Bolts (12EA), Nut (12EA), Washer (12EA)
Please note that we reserve the right to change the part numbers without prior noticification.

45
Auxiliary piping line oil flushing
Auxiliary piping line flushing.

In order to clean up in the Auxiliary piping line,

The flushing must to be done before connect the
hoses to breaker.

Flushing procedure.
1) Connect the HP and LP line.
If you don’t
don t have the flow check kit ()
(), you can
also connect the hose () to the check valve.
2) Keep activate the breaker switch for 15 minutes


46
Oil Flow
Hydraulic oil flow maintenance in Doosan excavator.

Main pump generates hydraulic oil flow for auxiliary line

Pump type Description Applicable Doosan excavator
Fixed discharge pump The volume of discharge flow is only No
maintenanceled by Engine speed.

Variable discharge axial piston The volume of discharge flow is maintenanceled All Models
pump by engine speed and power maintenance signal.

Flow maintenance device (Breaker package or flow maintenance valve) for

auxiliary line
Compact breakers Mid and large size breakers.

There are no additional flow maintenance Breaker package valve; Manually adjust Flow maintenance proportional
device . The volume of discharge flow is the oil flow valve ; Operator can adjust the oil
Explanation
determined by only engine rpm. flow through the Monitor panel in
the cabin
Applied model ; Solar 010, Solar 015, Applied Doosan Excavator ; S130LC-III, Applied Doosan Excavator ;
Solar 030, Solar 030Pluls, Solar 035, S170LC-III, S220LC-III, S280LC-III, DX180LC, DX225LC, DX225NLC,
Applied Solar 55, Solar 55 W, Solar 75-V, DX15, S330LC-III, S130LC-V, D175LC-V, DX225LC, DX300LC, DX340LC
model DX18, DX27Z, DX30Z, DX35Z, DX55, S220LC-V, S225LC-V, S255LC-V,
DX55W, DX60R, DX80R S290LC-V, S300LC-V, S330LC-V,
S340LC-V

47
 Oil Flow
Hydraulic oil flow maintenance in Solar series excavator

Related part:
- Main pump () ; Generate discharge oil flow.
- Breaker package valve () ; maintenance discharge oil

Applicable excavators: mid and larger size Solar Exc.

Flow maintenance valve: maintenance main pump

discharge oil flow.

 How to adjust the frequency?

Fl
Flow (l/
(l/m)) 1.
1 Engine rpm constant.
constant 
2. Breaker switch ON.
3. Pump P-Q curve maintenanceled by
breaker package valve ()
4. The reducing valve on the breaker


package
k valve
l maintenances
i t Pil
Pilott
Pressure
5. Pilot Pressure ↑ pump discharge flow ↓
Breaker Frequency ↓
6. Pilot Pressure ↓ pump discharge flow ↑
Breaker Frequency ↑
Frequency
(bpm)
Eg: S220LC-V 48
Breaker basics: Technical background
Solar Series Exc.: Pump P-Q curve

Flow curve for S220LC-V

49
Oil Flow
Solar Excavators: Flow curve

Reducing valve
Solenoid valve

The mechanical flow maintenance device is equipped on Solar series excavators. The operator needs
to adjust the bolt (1) as shown in the graph, to meet the correct breaker flow.

Note: This adjustment method is efficient only for the original installation of the Doosan breaker pipeline!

50
Oil Flow
DX Serie Exc.: Hydraulic oil flow

Flow maintenance proportional

valve
From
From
C/V Pilot
Pumpp

EPOS
To
Pump
regulator EPPR 2nd oil flow
Bar
[mA] press[k] [l/min]
Oil maintenance 0 615 32.8 34.0
through monitor 1 519 30 6
30.6 48 9
48.9
panel 2 482 28.4 66.9

3 446 26.1 85.5

4 409 23.6 105.4

5 389 21 3
21.3 124 0
124.0

6 371 18.8 143.9

7 353 16.5 162.5

8 335 14.0 182.4

9 317 11.4 203.0

10 300 7.2 206.5

51
 Oil Flow
Mid to Large Excavators: How to set oil flow?

Bar oil flow [l/min]

0 34.0
1 48.9
2 66.9
3 85.5
4 105.4
5 124.0
(1) On the instrument panel, press flow maintenance valve ( ) , then oil flow maintenance 6 143.9
screen will be shown as below.
7 162.5
(2) Select breaker mode (see the mode selection marked in the “red circle” above).
8 182.4
(3) Use Up (▲) or Down (▼) buttons to adjust oil flow rate.  Output oil flow is marked on DX
manual
manual. 9 203 0
203.0
(4) After oil flow is adjusted, press “APPLY” button ( ) to return to Normal Display. 10 206.5
(5) After finishing oil flow settings, please turn off engine, then start again the excavator. DX225LC at Rated Engine: 1900 rpm
(6) Please check oil flow again to check if oil flow is set correctly
correctly.

52
 Oil Flow
Flow check device
Installation location
Flow check kit.
Buyable from Doosan
warehouse.

Flow check kit:

CPN: 86694957 for DXB170 and DXB190.
- A flow test device is needed CPN: 86718590 for DXB260 only
for g
general service activities. p
Composition;
- There are various suppliers - Pressure gauge (400bar)
Dealer can find in the market. - O-ring (2EA)
the kit in the market Users can purchase it - Orifice Adaptator
according g to buyer
y ‘s liking.
g

53
Oil Flow
Oil Flow verification: Flow check kit
Pressure  Flow
Pressure (bar) Flow (l/mn) Remark

75 180

60 163

DXB170 Maximum
50 150
flow

45 142

40 135

DXB170
30 120
Recommendable flow

*Temperature condition ; 50℃

Never exceed the specified flow!

54
 Oil Flow
Oil Flow verification: Flow specification

Doosan Breaker DXB10 DXB20 DXB35 DXB45 DXB90 DXB170 DXB190 DXB260

min
min. l/min 15 25 35 45 80 100 120 150
Flow max. l/min 30 45 65 90 140 150 180 240
ROF*
ROF l/min 20 30 40 55 95 115 140 175
(*) ROF: Recommendable Oil Flow to use.

Operating
O ti att maximum
i fl
flow iis lik
like d
driving
i i a car att maximum
i speed.
d
The wear and tear is faster! It may lead to overload on the breaker.

W strongly
We l recommend
d min.
i flflow + 15%
1 % ffor the
h bbest performance!
f !
55
Oil Flow
Compact Excavators: Hydraulic oil flow maintenance

S55-V (DXB35): Related parts in the breaker system

Breaker sol valve beside main maintenance

valve

Since there are no flow maintenance valve in compact Excavators, the pump flow are fixed only depend
on engine rpm
rpm. (Applicable Model ; DXB10
DXB10, DXB20
DXB20, DXB35
DXB35, DXB45)

56
 Relief pressure

Relief valve

Location
- The Relief valve is mounted at the right of the cabin.
- The setting pressure can be found in the operator’s manual.

Breaker Doosan excavator

DXB90 DX140 DX140W,
DX140, DX140W DX170W
DXB160 DX180LC, DX190W, S180W, S210W
DXB170 S180W, S210, S220, S255, DX180, DX21DX225, DX255
DXB190 DX300LC.
DXB260 S300LC,, S340LCDX300LC,, DX340LC,,

57
Relief pressure
How to adjust relief pressure?

 Beforehand:
Install the pressure gauge between High and Low
auxiliary piping as shown in the next illustration
illustration. 
 Note: Some of mid to large excavators are provided
for the display of the pressure through the monitor panel.
In this case, it is not necessary to proceed with the 
above settings
settings.

 Procedure:
1. Close the stop valve at return line () and open the high
pressure line ()
2. Activate the breaker switch.
3. Check how much pressure on the system through the
gauge or monitor panel.
4. Adjust the pressure by relief valve (refer page 47)

58
Relief pressure
Compact range excavators

1
1. Install the pressure gauge
gauge, as explain earlier
earlier.

2. Push breaker operation switch and read pressure

3. Adjust relief valve and check pressure repeatedly until you read
the correct pressure.

Boom2 / Aux. block at the

main maintenance valve
Applicable Model and Doosan Excavator located under the cabin.

Breaker Doosan excavator

DXB10 DX27
Location: under the cabin.
DXB20 DX30Z, DX35Z
DXB35 DX55,DX55W, DX60R Mostly there is no additional breaker relief valve.
DXB45 S75, DX80R The overload relief valve function as breaker relief valve.

59
Relief pressure
Relief setting pressure.

DXB10 DXB20 DXB35 DXB45 DXB90 DXB170 DXB190 DXB260

150 170 220 220 220 250 250 250

※ The wrong relief pressure Lower than spec pressure.

- Operating pressure too low.
- Damage
g the relief valve
- Impact force too low

Higher than spec pressure .

- Damage hydraulic system.

60
Nitrogen gas inflating
Oil Flow: composition No. Description
1 Regulator
A 2
3
Adaptor
Mi i
Mini-mess coupling
li I
4 Exhaust valve I
5 Cap nut
6 Coupling
7 Hose
8 Adaptor
8 Adaptor
9 Handle
9 Handle
10 Gas valve
11 Accumulator gauge
B C D E 12 Back-head gauge
13 Back-head mini-mess coupling
14 Acc m lator charging pl
Accumulator plug
g
15 O-ring
16 Accumulator charging valve
22 23 24 21 12 23 17 Gas charging port
18 Back-head
Back head
A : Regulator - All models 19 Accumulator
B : Adaptor - DXB170, DXB190, DXB260 (Option), connection at breaker back head. 20 Mini-mess coupling II
C : Adaptor - DXB170, DXB190, DXB260 (Option), connection at breaker back head
D : Back-head mini-mess coupling - DXB10, DXB20, DXB35, DXB45, DXB90, DXB160.
21 Exhaust valve II
E : Accumulator - DXB160, DXB190, DXB260 22 Mini-mess coupling
23 Adapter
24 maintenance knob
61
Nitrogen gas inflating
Nitrogen gas inflating: before inflating…

Only
y use nitrogen
g to inflate the back head.

Breaker position: 2 conditions:

1) The strike piston must be imperatively (completely) down as shown by the
illustration ()
().

2) The breaker must be in horizontal position, with tool fully “extended” as


shown by the illustration ().

The piston position must be down

down.
62
Nitrogen gas inflating

63
 Nitrogen gas inflating
Back-Head Inflating Table A - Primary
(Depend of the temperature of the back head surface)

Nitrogen setting pressure (bar)

Temperature
-20 0 20 40 60
at °C
DXB10 B 8 9 10 11 12

DXB20 B 10 11 12 13 14

A 14 16 17 18 19 B - Secondary stone or building

DXB35
B 12 13 14 15 16

A 15 16 17 18 19
DXB45
B 12 13 14 15 16

A 15 16 17 18 19
DXB90
B 10 11 12 13 14

A 15 16 17 18 19
DXB160
B 10 11 12 13 14

DXB170 A 13 14 15 16 17
DXB190
DXB260 B 9 10 11 12 13

64
 Nitrogen gas inflating
Nitrogen setting pressure (bar)
With temperature at 20°C of breaker

Pressure
Applicable Model
(bar)
DXB160 60
DXB260 35 1. Connect the right hand hose port 2. Install the mini mess coupling on
of the regulator. the accumulator.
Applicable model: DXB160

For further details, please refer to

the service or operation manual.

3 Install
3. sta tthe
e adapto
adaptor
Applicable model: DXB260
And connect the hose.

6. Drain and adjust if over 5. Inflating nitrogen. 4. Open the plug

charging Applicable model: All. Applicable model: DXB160 65
Close the plug as shown step 4.
DXB Operation: 2-Speed maintenance
Instructions of two speed
maintenance

Impact power and frequency change by maintenanceling piston stroke which can be regulated by oil
Function
path blocking and opening. Manual impact speed and power change.

➀ Low speed mode: Quarry, Trenching  High power required

Application
➁ High speed mode: Concrete breaking, soft rock, reducing boulders  High speed required.

66
DXB Operation: 2-Speed maintenance
How to select the speed?

Applicable Model: DXB190, DXB260.

1 Take the cover (①) out

1. out.

2. Take the screw (②) out with 3/16” L-wrench. ②

3 Turn the stock opposite position and turn
3. ①
into the cylinder. Tightening torque: 100Nm.

67
Ch t III :
Chapter

O
Operation
ti

2011. 11
GLOBAL Construction Equipment BG
AM D
Department
t t

68
Table of Contents

Chapter III: Breaker Operation

1. Working application

2 Tool Choice
2.

3. Two speed impact frequency

4. How to operate properly

69
DXB Operation: Appropriate applications
Appropriate working application: (beware recommendations may vary!)

Application Work site DXB10 DXB20 DXB35 DXB45 DXB90 DXB160 DXB170 DXB190 DXB260
Demolition buildings 
(inside)
X X X X
Demolition
Demolition building 
(outisde)
(outisde) 
X X X X X
Breaking up 
concrete pavement 
X X X X X X X
Secondary breaking 
(concrete and alike)
(concrete and alike)
X X X X X X
Chiseling rock beds  X X X X X
Cutting slopes  X X X X
Civil engineering 
Trenching  X X X X X X X
Digging and 
breaking tunnels 
X X X X X
Breaking up piers 
etc
X X X X
L
Large‐scale work 
l k X
Primary Breaking X X X X
Quarry & Mining
Secondary breaking X X X X
p
Steel plants  Splitting slag
p g g X X X X

70
DXB Operation: Tool type
Tool Type

M il point
Moil i Universal
U i l tool
t l for
f demolition
d liti workk
and block splitting low abrasive
Conical material, concrete.
• DEMOLITION
• HARD GROUND
• HARD GROUND WITH FAILURES
• CONCRETE
MOST COMMON TOOL FOR A BREAKER

Chisel

Flat wedge – Horizonal. Excavation of trenches, building

• TRENCHING pits, breaking of reinforced concrete.
• GENERAL EXCAVATION
• MASS EXCAVATION IN QUARRY
• SOFT GROUND WITH FAULTS
• CONCRETE
• REINFORCED CONCRETE

71
DXB Operation: Tool type
Tool Type

Bl
Blunt tooll
Blok splitting in quarries.
Flat End.
• BLOCK SPLITTING
• COMPACT ABRASIVE
• DIFFICULT TO POSITION
• CONCRETE SLAB ON DEMOLITION

Pyramidal point
Hard reinforced concrete
Moil wedge. flooring, sedimentary materials
• DEMOLITION
• HARD GROUND
• HARD GROUND WITH FAILURES
• CONCRETE

72
DXB Operation: How to operate properly
Hose length

Ensure appropriate hose length to avoid damages

73
DXB Operation: How to operate properly
Perpendicular to the ground

Ensure appropriate perfomance degree to avoid damages

74
DXB Operation: How to operate properly
Cut rocks in the right sequence & size

Ensure blocks are broken in the right sequence and size

75
DXB Operation: How to operate properly
Breathing intervals

Keep the breaker less than 15 seconds in the same position

76
DXB Operation: How to operate properly
Distance between frame and material

Keep a correct distance between the frame and the material

77
DXB Operation: How to operate properly
Put the tool on the material tenderly
Do not activate the breaker with excessively hose vibration

Stop the breaker when hoses vibrate excessively and avoid blank firing

78
DXB Operation: How to operate properly
Piston position

Ensure pistons don’t

don t reach the end of their front stroke

79
DXB Operation: How to operate properly
Working Temperature

Ensure the oil temperature to be appropriate to avoid damage

80
DXB Operation: How to operate properly
Underwater application:

Never use the hydraulic breaker in and

under water without air pressurisation!
DXB10, DXB20, DXB35, X45, DXB90,
DXB170.

Air
pressurization
port

Available on DXB160, DXB190 , DXB260.

Fits only DXB160,

DXB160 DXB190 and DXB260 – with option and compressor !

81
DXB Operation: How to operate properly
Don’t use it as a lifting device!

Please don’t
don t lift items using the tool
tool. It can cause severe damages!

82
Ch t IV :
Chapter

M i t
Maintenance

2011. 11
GLOBAL Construction Equipment BG
AM D
Department
t t

83
Table of Contents

Chapter
p IV: DXB Maintenance

1. Maintenance schedule

2. Auto grease device (Option)

3 Warning
3.

4. Storage

84
DXB Maintenance: Maintenance Schedule
Maintenance point and interval time

Service Interval
No Item of Check Qty 10 hr 50 hr 100 hr 600 hr
2 hr
(daily) (weekly) (monthly) (6monthly)
1 Tool 1 G I I
2 Tool Bush 1 G I I
3 Piping & Connection 2 I, T I, M I, M
4 Back Head Gas 1 I, F
5 Accumulator Gas 1 I, F
6 Front Bush 1 I
8 Piston Lower Parts I
9 Hose 2 I I, M I, M
10 Through
g Bolt 4 I
11 Oil Filter 1 I, M
12 Seal R, M
13 Accumulator Diaphragm 1 I, M
14 Power Cell 1 I, M
15 Breaker case 1 I, M

*G: Greasing *T: Tightening *F: Refill *R: Replacement *I: Inspection *M: Maintenance by DXB dealer

85
 DXB Maintenance: Maintenance Schedule
Maintenance in time base
Grease the tool and tool bush.
We recommend Lithium EP Grease MoS2 additive, consistency grade NLGI 2.
Every 2 hours
Check hydraulic oil temperature, piping & connection and impact efficiency.
Tighten loose connections.
Remove the retaining pin and the tool and check their condition. Grind off any burrs that may be present.
Every
y 10 hours or daily
y
Check that the tool has been receiving sufficient grease.
grease Grease more frequently
frequently, if needed
needed.
Check gas pressure in the back-head. Refill the gas if necessary.
Every 50 hours or weekly Check for wear of the tool, front bush, tool bush, tool wiper and piston lower part.
(Main inspection) Check the hydraulic hoses. Replace if necessary
Check through bolts.
bolts Replace and/or re-tighten
re tighten if necessary.
necessary
It is recommended to have the main inspection done by a local Doosan DXB official dealer.
Every 100 hours or
Check all hydraulic hoses and pipe connections.
monthly
Check interference between hoses with carrier.
It is recommended that the annual maintenance be carried out by DXB official dealer
dealer, or after
600 operating hours.
Every 600 hours or Check all hydraulic pipe, hose connections and conditions of oil filters
6 monthly Check through bolts for cracks on the threads and shanks.
Change all seals including the accumulator diaphragm.
Check the conditions of the power cell and breaker case.

86
 DXB Maintenance: Tool box
Too box:
For your convenience, a tool box is included, standard, in the DBX breaker configuration!
Eg: Eg:
DXB35 DXB260

87
DXB Maintenance: Maintenance Schedule
How to check limit worn out of service part

Checking tool is one of spare part contained

in Breaker Tool box in DXB170, DXB190,
DXB260.

※ Grease Every 2hours, 10

times pumping during operation.
We recommend Lithium EP Grease MoS2 The other breakers (DXB10, DXB20, DXB35, DXB45, DXB90),
additive,
dditi consistency
i t grade
d NLGI 2
2.
the tolerance are identified per each part
Further detail you can find at the Service Manual. 88
DXB Maintenance: Maintenance Schedule
Hydraulic oil replace interval time.
Attachment Operation Rate Hydraulic Oil Filter
250 Hours (First Replacement)
Bucket Work 100% 2,000 Hours
1,000 Hours (After First Replacement)
Hydraulic Breaker Work 100% 500 Hours 100 Hours

▶ These service intervals only apply

apply, when a
genuine DOOSAN oil and filter are used. If any
other brands are used, the guaranteed
changed interval should be reduced in half.

▶ Hydraulic oil.
Optimal viscosity range : 20 ~ 60cSt
* Too Thick oil :
- Slow
Sl and d irregular
i l bl
blow
- Difficult to start
- Damage parts by Cavitation
- Low impact power
* Too Thin oil :
- Decrease flow delivery form pump
- Low impact rate; low breaking efficiency
- Insufficient lubrication on hydraulic parts
- Damage on sealing parts

89
DXB Maintenance: Maintenance Schedule
Breaker filter.

Implemented Doosan Excavators are middle

and large
g class DX series as the option.
p

Replace interval hours ; Every 100hr of only breaker

operation.

90
DXB Maintenance: Maintenance Schedule

1st Click

2nd Click

Accumulated
breaker working
hours.

91
 DXB Maintenance: Auto-Greasing Devise
Auto grease device: a recommended option!

Applicable model: DXB170,

DXB170 DXB190 and DXB260
Auto greasing device kit part number
DXB170, DXB190 ; 86702537, Grease cartridge (12ea/box) ; 86617222
DXB260 ; 86708278, Grease cartridge (12ea/box) ; 86617222 92
DXB Maintenance: Warning

Warning These parts are fragile!

Even light shocks can damage them and induce breaker malfunctioning
Inspect the parts. If necessary, you can
smooth small marks. But it is forbidden
to smooth on the whole surround.
YES NO
If the parts are too much damaged,
replace them!

Warning Smoothing can increase the clearance between parts and cause
seizing or breaker trouble.

93
DXB Maintenance: Storage
General Conditions:
 Environment conditions around the breaker should be clean, dry and well-ventilated.
 Hydraulic passage (High pressure and return pressure) must be sealed.
 Breaker must be safely covered with plastic sheeting or tarpaulins to protect them
against the weather, dust, humidity, etc.
 Remove the tool and ensure the retaining pins, bushings, and piston bottom are well
greased.
d

Short term storage Long term storage

(Less than 3 weeks stock) (Exceed 3 weeks stock)

Vertical Position
Piston should be positioned
at the end of its upper stroke by the
buttress.
Lying position.
position

94
 DXB Maintenance: Storage
Long Term storage risks:

① Seal deformation:
If the
h bbreaker
k was storedd more than
h 1 year, seals l might
i h be
b deformed
d f d by
b weight
i h off the
h piston.
i If the
h seals
l were
deformed or damaged, the piston and cylinder will contact directly (metal to metal contact). It can cause serious
damage not only to the piston but also to the cylinder.

② Damage by rust
The lower parts of the piston are always in contacts with air that contains moisture and oxygen. Piston might be
damaged by rust. Corrosion can be the reason of oil leakage or serious damage.

Piston ① Seal deformation

weight - Seal deformation by weight of the piston
- Hardened
H d d seall b
by contact
t t with
ith air
i or h
heatt

②
Moisture
+ Oxygen

② Rust damage by Moisture + Oxygen

95
 DXB Maintenance: Storage
Storage condition

If the storage period is less than 4 weeks

weeks, the following procedure must be followed:
Short term storage
(less than 4 weeks  The breaker must be stored in a dry and well ventilated room
stock)  The hydraulic connections must be sealed
 Remove the tool and ensure the retaining pins
pins, bushings
bushings, and piston bottom are well greased.
greased
 Grease the tool and reinstall it
 Cover the breaker (including the tool) with a protection cover

If the storage period is likely to exceed 4 weeks, the following procedure must be followed:
Long term storage
(exceed 4 weeks  The tool must be removed and protected again corrosion (use grease)
stock)  The gas in the back-head must be discharged completely
 Ensure the retaining pins, bushings, and piston bottom are well greased.
 The breaker must be stored in vertical position and a specific bar in order to push the piston into
upper dead end position
 The breaker must be stored in a dry and well ventilated room
 The hydraulic connections must be sealed
 Cover the breaker and the tool with a protection cover

96
DXB Maintenance: Storage
Inspection after long term storage before delivery to the customer

To prevent a breaker from failing at early hours after long term storage
(12month or more),
more) the breaker must be checked as described:
 The breaker must be dismantled
 Parts subjected to corrosion (piston
(piston, cylinder
cylinder, distributor
distributor, ….)) must be checked
checked.
 If needed parts must be repaired or replaced.
 All the seals must be replaced

 Long
g term stocking
g = Inspection
p / Servicing!
g

97
Ch t V
Chapter V:

T
Troubleshooting
bl h ti

2011. 11
GLOBAL Construction Equipment BG
AM D
Department
t t

98
Table of Contents

Chapter V: Troubleshooting
1 Major cause and trouble
1. trouble.
2. Breaker dose not start
3 T
3. Too llow iimpactt rate
t
4. Too low impact force
5. Oil temperature too high
6. Oil or Gas Leakage
7. Others
8. Major Phenomenon
9. Typical Tool Failure

99
DXB Troubleshooting: root causes & troubles
4 root causes and 6 major troubles

Four root cause Six common trouble

1. Breaker does not start

2. Breaker hits slowly

1. Carrier / Excavator
3. Breaker has no power
2. Hoses & Fittings
4. Operating temperature
3. Breaker
is too high
4. Driver
5 Oil leakage
5.

6. Vibrations

100
 DXB Troubleshooting:
1- Breaker does not start:
• The pressure line High & Return contact right port.
• Stop valve is closed.
Breaker dose not Hyd oil flows in auxiliary line NG • Breaker electric circuit out of order.
• Piping (hose) connections are incorrectly.
start at all • Spool in the Main maintenance valve is not switched
Normal
completely

Hydr.
y Pressure if it is too high g or NG • Wrong relief pressure.
pressure
too low. • Malfunction of main pump
Normal
N2 gas pressure at the back NG • Check the pressure.
head if it is too high or too low ※ Refer to the N2 p
pressure specification
p table.
Normal
There must not be the Hyd oil at NG
the back head • Replace the step, gas, o-ring.
Normal
NG • Remedy
R d th
the ffaultlt on th
the surface.
f
The piston and cylinder is seized • Check the oil filter in the carrier.
※ Contact Doosan service.

The return line piping connected NG • Stop valve is closed.

No response after
to the hyd
hyd. tank
tank. • Hydr.
H d hose
h iinside
id bl
blocked.
k d
first single blow
Hyd. oil level in the hydr. tank of NG
Working with carrier • Refill Hydr. oil into the tank.
g
irregular blow

Legend: NG = If not good, then check… 101

 DXB Troubleshooting:
2- Too low impact rate:
Oil flow constantly meet breaker NG
Constantly low demand. • Refer to the oil flow section of the training
g section.
impact rate
Normal
Hyd Pressure if it is too high or NG • Wrong relief pressure.
too low. • Malfunction of main pump
Normal
N2 gas pressure at the back NG • Check the pressure.
head if it is too high or too low ※ Refer to the N2 pressure specification table.
Normal

Counter back pressure NG • Check the hydraulic device on the return circuit.
Stop valve, oil cooler, hydraulic filets.

Hydraulic
H d li oilil viscosity
i it meett NG
It happens in high specification • Replace with appropriate oil.
temperature
Normal
The oil temperature is within NG
normal range. • Service
S i th the oilil cooler
l and
d oilil cooling
li system.
t
Normal
All of the exterior condition is in NG • Need to check internal leaking due to excessively
normal. worn out internal part (valve
(valve, seal
seal, piston or cylinder)

Legend: NG = If not good, then check… 102

 DXB Troubleshooting:
3- Too low impact force:
Clearly understand breaker NG • Particularly with new breakers, the customer need
New breaker feature. adaptation
adap a o to o the
e feature
ea u e o
of Doosan
oosa pproduct.
oduc
Normal
The relief setting pressure NG • Adjust the relief pressure to be within specification.
(Refer to the attached specification table)
Normal
The back-head N2 gas pressure NG • Adjust the back-head N2 gas pressure to be within
specification. (Refer to the attached specification table)
Normal
N2 gas pressure in ACC. NG • Adjust the back-head N2 gas pressure to be within
specification (Refer to the attached specification table)
specification.
Normal

Counter pressure (return line) NG • Find out a cause of high return line pressure and fix
it. Contact carrier manufacturer service center.

Too low working pressure NG

As time goes on • Check if there is an internal leakage.
Normal
g condition  In-line
Diaphragm NG
G
hose abnormal vibration • Replace
R l the
h necessary parts.
Normal
The hydraulic oil temperature NG • Check oil cooling system - Oil cooler, restriction
valve.

Legend: NG = If not good, then check… 103

 DXB Troubleshooting:
4- Oil temperature is too high:
Too long continuous activating NG
Operation breaker • Operate the breaker in sequences of 15sec. or less
Normal
NG
Oil level in the tank is too low • Refill to fit the oil level in the tank.
Carrier
Normal
NG
Oil cooler • Check the cooler condition and do necessary action.
Normal
NG
Restriction valve • Check the cooler condition and do necessary action.
Normal

Relief setting pressure is too low NG • Check the cooler condition and do necessary action.
Refer to the specification.
Normal
Back head gas pressure is too NG
Breaker high. • Reset the pressure.

Legend: NG (No Good) = If not good, then check… 104

 DXB Troubleshooting:
5- Oil or gas leakage:
Clearly understand breaker • Small leakage is a normal phenomenon
Oil leakage shown feature. (Compact breakers: 50 CC/ hr, Mid to large
at tool or pin breakers: 100CC/hr)
NG
The amount of oil leakage is • Check the piston or cylinder condition and fix it with
increasing as time goes by. replacement of seal kit.

Oil leakage between Tie-rod bolts (Though bolts ) NG

tightening. • Check if the loosen the tie rod bolts or nuts
cylinder & back
head Normal
The amount of oil leakage is
increasing as time goes by. • Replace seal kit

• 10% / 100hr of N2 pressure NG

Back head N2 gas leakage is normal condition. • Replace seal kit
leakage

Air bubble between NG

• Back head N2 gas leakage • Replace seal kit
cylinder & beak
head.

Legend: NG = If not good, then check… 105

 DXB Troubleshooting:
6- Other:

N2 gas pressure in
i ACC or NG
Hydraulic hose Back-head • Check the pressure and re-set
excessive vibration
Normal

Diaphragm condition • Replace necessary

necessar parts.
parts

Legend: NG = If not good, then check… 106

DXB Troubleshooting: Major Phenomenon
Piston, Busing, Tool damage:

• If broken pieces of the tool and piston go

through the gab of piston, piston and related
major parts can be scored.
scored

• Piston and tool damage : the piston and

tool must be contacted face to face. Linear
or point contacts can cause the tool head
damage or piston damage

• Upper & lower bushing damage : the

inclined tool head can hit the upper part of
thrust ring.

• Tool pin damage : Wrong angled contact

can cause tool pin and related parts damage

Blow force
direction
107
 DXB Troubleshooting: Piston or cylinder scratch.
With
Wi h the
h scratch
h ffailure
il on the
h piston
i and
d cylinder,
li d what
h are the
h points
i
must need to be observed at initial inspection on the field.

① Hydraulic oil condition.

② The
Th lower
l and
d upper bushing
b hi condition
diti whether
h th outt off worn out.
t

③ Bottom surface of piston condition.

④ Whether any of those tool, bushings, retainer pin, seals are not genuine parts.

⑤ Breaker working with over specification in frequency and Nitrogen gas.

⑥ Whether the breaker has been leaking anywhere

anywhere.

⑦ The breaker has worked in water even short period time.

Note ; Breaker working with improper tool type is a little concerned. 108
DXB Troubleshooting: Major Phenomenon
Piston and cylinder broken:

Due to dust seals out of order,

the dust passed into the system and caused to scratch the piston and the cylinder.

109
DXB Troubleshooting: Major Phenomenon
Piston and cylinder broken:

Missing
g seal replacement
p
schedule !!

Seal breakage by over

h t ffrom oilil !!
heat

Vertical crack around scratched area

 Lost
os heat
ea treatment
ea e su surface
ace a
and
d irregular
egu a su
surface
ace
 Stress concentration by notch effect!!

110
DXB Troubleshooting: Major Phenomenon
Long storage in poor condition:

111
Piston & Shank stop inspection

Have a look inside the breaker, in order to maintenance the piston, the
greasing ….

GOOD STOP

112
DXB Troubleshooting: Major Phenomenon
No Warranty

Failure
located on
tool retaining Breaking the
area material but
continually
activating the
breaker

Breaking point

- Too much vibration.

- Blank firing

113
DXB Troubleshooting: Major Phenomenon
No Warranty

Crack starting point

Chisel break

Crack development &

spread

Abusing

114
 DXB Troubleshooting: Major Phenomenon
No Warranty

Failure located
Outside front bushing
90
°

T i l failure
Typical f il due
d tot bending
b di force
f
115
DXB Troubleshooting: Major Phenomenon
No Warranty

Failure located on tool

retaining area Breaking the material but
continually
ti ll activating
ti ti th the
breaker

- Blank
Bl k fi
firing
i
- Not genuine parts

116
DXB Troubleshooting: Major Phenomenon
No Warranty

Failure located on tool

retaining area

- Not genuine parts

- Too much worn out the busing.
- Excessive hydraulic adjustment
(over pressure
pressure, over flow)

117
DXB Troubleshooting: Major Phenomenon
No Warranty

Excessive run

118
DXB Troubleshooting: Major Phenomenon
No Warranty

90°

Material to material contact due

to no grease.

119
 DXB Troubleshooting: Major Phenomenon
No Warranty

T l (Chi
Tool (Chisel)
l)

Retainer pin

Chisel twisting torque.

120
DXB Troubleshooting: Major Phenomenon
Typical failures in abuse operation:

Blank Firing Metal to metal contact Tip melt and breakage

Breakage pattern by external stress

121
DXB Troubleshooting: Typical tool failure

 Failure in this area are usually the result of blank firing, worn bushing or
wrong hydraulic adjustment (overpressure – overflow)

Inside  Failure in this area are usually the result of worn shank stop (upper bushing)
Front or blank firing
guide
 Failure in this area are usually the result of worn retainer or blank firing

 Failure in this area are usually the result of twisting torque (chisel)

 Failure in this area are usually the result of metal-to-metal contact (lack of
grease) or corrosion
Outside  Failure in this area are usually the result of bending force, incorrect breaking
Front angle, or shocks
guide
 Failure in this area are usually the result of excessive run

122
DXB Troubleshooting: Major Phenomenon
Warranty

90° Failure can

be located all
tool length

90°

Typical failure due to a material defect.

defect

123
Ch t VI :
Chapter

W
Warranty
t condition
diti

2011. 11
GLOBAL Construction Equipment BG
AM D
Department
t t

124
Warranty condition in period base.

12 m The warranty cover period date

DXB10
DXB20 since the breaker’s delivery
DXB30 date to customer.
DXB45 6m
DXB90

3m
DXB170
DXB190
DXB260
DXB35

125
Warranty condition in period base.

Applicable Model ; DXB170, DXB190, DXB260

3 month or 200 Operation hours after

delivered to customer whichever
A comes first

A ; 75mm
A

B ; 45mm
45
A

B
126
CLOSING REMARKS

For more details, please consult the DXB

Service Training Material or Ops Manual. 127
 Breaker basics: The Golden Rules
G ld rules
Golden l for
f dealers:
d l
1. Check the excavator
2 Flushing
2. Fl hi off the
th auxiliary
ili line
li ((minimum
i i i t )  use flow
15 minute) fl checking
h ki kit
3. Adjustment of the excavator relief valve
4 Adjustment of the flow regulation valve
4.
5. Adjustment of the inflating pressure
6 Check the mechanical and the hydraulic installation (no interference
6. interference, hoses
length …)
7 Explain to the end-user
7. end user how to use the breaker
8. Explain to the end-user the importance of the greasing operation (quality of the
grease, frequency,...)
9. Explain to the end user how to make the maintenances (tool, retaining pins,
bushing)
g) and the frequency
q y
10. Send back the warranty registration
128
 Breaker basics: The Golden Rules
G ld rules
Golden l for
f customers:
t
1. Never change the setting of the excavator relief valve

2. Never change the setting of the flow regulation valve

3. Never exceed the recommended inflating pressure

4. Never hammer continuously more than 15 seconds, and avoid blank firing!

5. Use the breaker in right condition; correct operation method

6. Grease every 2 hours

7. Every 50h, maintenance the retaining pin

8 Every 50h,
8. 50h maintenance the tool

9. Every 50h, maintenance the bushing

10.Every 50h, have a look at the piston strike surface (look inside the breaker)
129
Questions?

130
 Thank you for your support
And Attachments commitment

131