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Sizing the Hydraulic Breaker

1. 20 Starp Up hesseepoe a eqq 21 Typical Hydraulic Circuit 21 Carrier with Auxiliary Hydraulic Circuit 21 Carrier without Auxiliary Hydraulic Circuit 22 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Operation 23 Suggestions for Efficient Operation 23 End Of Shitbsssesea e enda ekeen eda SEM R annar HE ture i eene 24 Improper Use of Breaker 24 Blank FIrIng sesssesssessssescsessseesc e ESS 25 Breaking Oversize Material 26 Trenching and Excavation 26 Breaking Concrete 26 Breaking on a Grizzly 27 Guide to Too Choice tiea sa 27 Underwater Operation 28 Installing the Air Supply Kit 28 Air flow rate for underwater operation 28 Illustration for Installing the Underwater Breaker
2. 47 Rear Head Removal aedes viesenss pen dsbeedus eee ene ee 48 Accunmulator RemovallssssEsssssEesIREdRSERHBUEE RESTE OBRIdE RH oe eae EE EAS 48 Diaphragm Replacement 49 Accumulator Assembly 49 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Charging the Accumulator 50 Control Valve Removal and Disassembly 51 Control Valve Inspection 51 Piston Removal 52 Cylinder Removal 52 Cylinder Inspection 52 Cylinder Clean up 53 Seal Bushing Inspection 54 Breaker Body Assembly 54 Tie Rod Installation 54 Cylinder Installation 54 Seal Bushing Re sealing 55 PISTON Installati n ss ssa a S
3. SHEARFORCE Se PMENT Inward Valve Type gt SB10 gt SB20 gt SB30 gt SB35 gt SB40 gt SB43 gt SB45 gt SB50 7 j far Hydraulic Breakers SB60 gt SB OA SB81A SB100 SB121 SB130 gt SB151 X X x VAN mA 4 t he er TTA PELI raed ELI es ATTACHMENT SPECIALISTS shearforce ca 1 800 255 5211 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Contents Introduction 1 To our custom r 4 soso os es tse sess oases 1 PORE ec E 1 Product IIIIIIIlIIIIIlTlIl00lMMTMM 2 Specification 2 External Dimension 3 General Information 4 How the Tool Breaks Rock es255 aec 2535s so ears See aise ea ues eee 4 Sizing the Hydraulic Breaker 5 Based on Carrier Weight 6 Based on the Type of Work 7 Recommended Hydraulic Oils 8 Oll is Too Thick ot Too lalla ere ee eee eee g Hydraulic
4. Do not use the breaker to pry pick pound or lift This can cause serious damage to the breaker as the tool is side loaded or binds in the bushing The tool must always move freely straight up and down in the bushing gt Do not PUSH incorrectly Use breaker wear plate and reinforced rock claws 25 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL gt Bad alignment BENDS the tool Always break at 90 to surface of rock A CAUTION Excessive down force will not make breaking easier in fact the carrier will be lifted too far off the ground and this can damage your equipment Not enough down force and the tool will bounce on the material resulting in blank firing gt Do not POUND or PRY with the breaker Blank Firing A CAUTION Avoid blank firing Premature failure of parts in the breaker lower end can result Stop the movement of the breaker s piston when full contact to the target material is lost This reduces the strain on the tool retainers and front head during normal operation Blank firing emits a distinct metallic ringing sound and most often occurs in hard rock just as the rock shatters under the tool With no material under the tool the piston smashes the tool and retainers into the front head transferring the breaking force back through the breaker and excavator This can cause premature failure of the parts in the lower end of the breaker To prevent blank firing learn to anticipa
5. Tool Rod 662 913 500 New Part SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Changing the Breaker Tool Check the wear width between the tool and tool bushing See table on the previous pages for maximum and minimum permissible wear limit Tool and Front Tool Bushing Clearance Check the clearance between the tool and the front tool bushing every 100 hours Worm parts may cause misalignment between the tool and the piston If the value exceeds those shown in the following table both front and rear tool bushings must be replaced to prevent damage A CAUTION Exceeding the following values may damage other component parts such as the piston and cylinder Tool Removal 1 To remove the tool drive out the retainer pin and stopper plug using the drift supplied in the tool kit 2 Use the drift to drive out the tool retainers Inspect them for cracks or deformities and wear on the edge that rests against the tool NOTE Models SB10 SB20 SB30 SB35 SB40 and SB43 have spring tool retainer pins whereas larger models have round tool retainer pins Ensure tool retainer pins SB45 and larger model are rotating properly Check for hash mark where pin contacts front head pin 3 Remove any burrs on the retainer pins and the tool with a grinder Check for mushrooming on the top of tool 4 If rotating the retainer pins make sure the marked surface is towards the tool as shown 36 1 Drift 2
6. A CAUTION The accumulator is charged with nitrogen N2 a non explosive inert gas Use only N2 when refilling it Charging it with any other gas could trigger an explosion and lead to serious or possibly fatal injuries IMPORTANT Incorrect nitrogen gas pressure in the accumulator can damage the breaker and cause poor or erratic breaker behavior IMPORTANT Hydraulic oil pressure MUST be fully vented inside the breaker before charging the accumulator Residual pressure will result in an incorrect N2 charge pressure fem me oy We cas crargng Set 1SET_ SRS Nz Gas Cylinder E Rg 9 11 O Ring Cap r Handle e le ejeje mI 40 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Accumulator Gas Pressure Checking 1 Make sure if the cap and valve of the 3 way valve assembly 5 are fully tightened 2 Remove the cap 11 from the accumulator and tighten the charging valve 12 fully 3 Check if O rings 6 8 are installed to the adapter 7 Remove the plug 9 and screw in the adapter 4 Install the adapter 7 to the 3 way valve assembly 5 5 Loosen the charging valve 12 gradually The charging pressure is indicated on the pressure gauge 6 Close the valve clockwise when the gas pressure is normal If the gas pressure is higher repeat loosening and tightening the relief valve of 3 way valve assembly The pressure is lowered gradually 7 Loosen the relief valve of the 3 way v
7. gt Always keep the tool 90 to the surface of the rock to reduce side loading on the tool bushings gt If the rock or stone shows no sign of breaking within 20 seconds reposition the breaker gt Breaking along a rocks natural faults and seams makes breaking easier gt When breaking on a wall or steep incline use a combination of the carriers stick cylinder and tilt cylinder to provide the necessary force to hold the breaker against the material Always work the tool at 90 to the material being broken gt As down force is applied on the breaker the carrier will lift slightly indicating breaker tool is properly pressed onto the material ACAUTION The breaker should not be fired when the carrier s boom hydraulic cylinders are fully extended or fully retracted The cylinders may be damaged from the breaker s shock pulses A CAUTION When hydraulic oil temperature exceeds 158 F 70 C stop breaking If the carrier s operating temperature runs too high it will actually decrease the breaking power 24 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL gt Rake ONLY with breaker wear plate and reinforced rock claws Do not use the tool to rake materials gt Push ONLY with breaker wear plate and reinforced rock claws End of Shift If the breaker is not removed from the carrier at the end of the day it should be left standing vertical with the tool pushed up into the breaker Improper Use of Breaker A CAUTION
8. 1 Relieve all pressure before disconnecting hoses or tubes 2 Use a lifting crane of suitable capacity to remove the breaker from the carrier NOTE Breaker disassembly must be carried out in a clean shop environment 3 Remove the tool from the breaker Measure and record the clearance value between the tool and the tool bushing 4 Position the breaker upright on a clean level shop floor surface 5 Brace the breaker upright in this position while keeping the crane in place Restrain the breaker with chains straps or other suitable method to prevent it from tipping over if knocked or hit from an external load forklift cranes loads on cranes etc A CAUTION Be aware of worn housings As the breaker is used the lower portion of the housing becomes worn Worn housings can be unstable 6 Ensure breaker is supported and restrained to prevent tipping over 7 The breaker housing must also be restrained against upward movement produced by the lift crane 8 Remove crane rigging from the breaker housing only AFTER the breaker housing has been fully restrained 46 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL A CAUTION Upper and lower isolators inside the breaker housing are compressed to provide a preload on the breaker body to support it within the housing Loosen bolts gradually and equally to remove pre load and prevent injury 9 Loosen top mount bracket bolts gradually and equally to reduce spring pre load from isolators O
9. 29 High Low Speed Selector Valve 30 Maintenance 31 Greasing the Breaker 31 Automatic Greasing Systems 31 i EE EE 31 Comparison of Automatic Lubrication Systems to Manual Lubrication 32 Seal amp O Ring 32 Wear Toletariee ieina a ee a 33 Changing the Breaker Tool 35 Tool and Front Tool Bushing Clearance 35 Tool Removdl a enei tt aes ee eS oe eee 35 Tool mtaona e S 36 Cushion Chamber Gas Pressure Checking 37 Cushion Chamber Gas Pressure Adjusting 38 Nitrogen Charging Pressure versus Ambient Temperature 41 Maintenance Schedule se essse esce sec sees eae ee etce doses 42 Torque and Gas Pressure Table AA Service c neeetisdarede EUH a 45 Breaker Disassembly 45 Removing Breaker Body from Housing 46 Breaker Body Disassembly
10. Retainer Pin 4 Tool Retainer 5 Drift 6 Tool SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Tool Installation To install the tool reverse the above procedure 1 First grease the inside of the lower bushings When the tool is inserted it will take the grease with it 2 Cover the sides of the tool s top section with grease and insert the tool into the front head 3 Grease and insert the tool retainers then grease and insert the retainer pins T 3 1 Tool 2 Tool Retainer 3 Retainer Pin 37 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Cushion Chamber Gas Pressure Checking IMPORTANT Incorrect nitrogen gas pressure in the cushion chamber can damage the breaker and cause poor or erratic breaker behavior A CAUTION Stay clear of the tool when charging the breaker cushion chamber Gas pressure may cause unexpected piston movement and force the tool to jump against the retainer pins A CAUTION The cushion chamber is charged with nitrogen N2 a non explosive inert gas Use only N2 when refilling it Charging it with any other gas could trigger an explosion and lead to serious or possibly fatal injuries f RN T ee gt Ve tuc ON al e BD 4 oo EL Hose connection p a rt Handle Cap IMPORTANT Before charging the cushion chamber make sure the tool is NOT pushed up inside the breaker Lay the breaker down in a horizontal position mem
11. The relative movement of various parts should be prevented using ties supports blocks etc 10392 DO NOT OPERATE A CAUTION Use only original ShearForce spare parts Transporting Safety Precautions gt Use a pressure washer to remove any loose gravel mud or debris from the breaker and or carrier Load and unload the machine on a level surface Ensure that the combined height of the trailer bed and the top of the machine cab is lower than local height restrictions or any bridges overpasses or overhead obstructions expected to be encountered during transport Ensure that the transporting equipment is adequate to hold the weight and size of the machine Place chocks against the truck and trailer wheels Use a ramp or loading dock Ensure that the ramp is strong enough and has a low angle of rise to the height of the trailer bed Do not place tie down cables or chains over or against hydraulic tubes hoses cylinders or valves etc Fasten chains or cables to machine frame Obey all local laws concerning loading unloading or transporting the machine Keep the trailer bed clean Always keep bystanders clear of the area 19 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Installation General To obtain the best performance from a ShearForce hydraulic Breaker it must be installed correctly and the carrier machine supplying the hydraulic power must be operating properly The following checklist will assist in
12. 4A 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 L 2 2 2 2 2 2 2 2 2 2 2 4 Back Head Gas Pressure kg cm psi 15 5 220 16 228 156 591235 17 242 17 5 249 Back Head Cushion Chamber Gas Pressure Adjusting Increasing the Pressure 1 Connect the charging hose 4 to N2 gas cylinder 1 after screwing the bombe adapter 3 onto adapter nut 2 and installing them to the N2 gas cylinder 2 Connect the 3 way valve assembly 5 to the charging hose 4 after unscrewing the cap on the 3 way valve 3 Install the 3 way valve assembly 5 to the charging valve of the Back Head At this time the handle of the 3 way valve assembly must be up position to prevent the gas from coming out 4 Push the handle of the 3 way valve assembly fully and turn the handle of the N2 gas cylinder counter clockwise gradually to charge gas 5 When the gas pressure exceeds 1096 higher than the specified pressure close the N2 gas cylinder by turning the handle clockwise 6 Leave the handle of 3 way valve assembly up Generated pressure makes it return back to original position naturally 7 In order to discharge N2 gas in the charging hose 4 and the 3 way valve assembly turn the relief valve counter clockwise 8 Remove the charging hose 4 from the N2 gas cylinder 1 and the 3 way valve assembly 5 and screw the cap into the 3 wa
13. 52 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Cylinder Removal A CAUTION Handle this component with care Damage will cause breaker malfunction 1 Install lifting eyes into the top of the cylinder 2 Lift the cylinder straight up off the tie rods 3 Loosen and remove the tie rods It may be necessary to secure the front head to prevent it from rotating 4 Loosen the tie rods by rotating them counter clockwise Use an adjustable wrench and a soft faced mallet or a sledge wrench on the tie rod flats to loosen them 10330 The cylinder should slip out of the front head If not tap the front head with a soft faced mallet until the cylinder and front head come apart Cylinder Inspection gt Thoroughly clean the cylinder bore and remove the dust seal oil seal and slide ring Check the seals for signs of extension and excessive wear both before and after removal gt Thoroughly inspect inside walls of the cylinder for corrosion cavitation or scoring Check grooves above seal area for small pieces of metal due to galling If these are not cleaned out they will chip off and go between the piston and cylinder and galling will occur again gt Check for any damage to the heliserts that secure the control valve Repair or replace as necessary to ensure the valve can be installed properly gt Inspect the main inlet and outlet adapter threads for damage Always replace the seals if they are removed A CAUTION Do no
14. Flat High Risk Fatigue Area Low Risk Fatigue Area 10283 B Ne m op Typical fractures caused by excessive bending of the tool Fractures like this are not covered by warranty 10282 Typical fracture caused by prying with the tool while it was buried in the work piece Fractures like this are not covered by warranty 10287 68 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Mushrooming Hammering the tool too long in hard dense material without penetrating through causes mushrooming This generates intense heat that softens and mushrooms the point This is not a fault of the tool If the rock or stone shows no sign of breaking within 20 seconds reposition the breaker Warranty claims made for mushrooming on the ends of the tool sli will be rejected Steel Defect Failure This failure has fatigue lines originating from an internal point and not from the outer surface This is a very rare failure caused by a defect in the steel This type of defect is covered under the normal warranty period Mushrooming from operating with worn bushings orfinngthe breakertoo long at one time No Warranty Failure from blank firing or excessive wear to bushings and or fronthead No Warranty Failure from operating with worn out retainer pins blank firing or twisting the tool No Warranty Failure caused by misalignment of down pressure breaker and the tool prying levering etc No Warranty Tool Break
15. PartName Qy We Gas Charging Set ist 2 Adapter ut Synflex Hose 3 Way Valve Assembly 2 1 Cushion Chamber Back Head Gas Pressure Checking 1 Make sure if the cap and valve of the 3 way valve assembly 5 are fully tightened Screw the 3 way valve assembly 5 into the charging valve of the back head after removing the plug 2 At this time the handle must stand up to prevent the gas from coming out 3 Push the handle into the charging valve fully so the gas pressure inside the back head is indicated on the pressure gauge 38 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL 4 When the gas pressure is normal unscrew the 3 way valve assembly after discharging gas inside the 3 way valve assembly 5 When the gas pressure is higher or lower charge it as described below NOTE Be careful to connect the hose as quickly as possible Once the hose end is starting to thread on the valve will unseat and gas pressure can be lost Refer to Specifications below table for back head gas pressure values m Conversion Table for charging nitrogen gas pressure to Back Head Depends on the temperature of Back Head surface Back Head 3 3 m 0 32 10 50 20 68 30 86 40 104 surface Temperature C F L
16. covered with rock use the breaker s reinforced rock claws and the wear plate of the box housing to rake the material This will get most of the finer material through the bars and let the larger pieces rest directly on the grizzly Large pieces are easier to break if they rest directly against the grizzly bars All the energy from the breaker is then applied directly to the rock Breaking oversize is less effective when there is material under the rock that can absorb energy If rocks are hanging on the edge of the bars use short bursts of the breaker to hammer them through Guide to Tool Choice 1 Moil used for penetration in low abrasive materials of similar make up 2 Chisel X used for splitting material made of substances that have a different make up 3 Chisel Y use for asphalt cutting 4 Blunt used for impact in hard crumbly rock ACAUTION Use of after market tools not approved by ShearForce Equipment and may void warranty 28 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Underwater Operation Optional A CAUTION Do not operate the breaker underwater or in mud Permanent damage to the breaker may result ShearForce breakers require specific modifications for underwater applications gt Underwater operation of the breaker is possible if air is supplied into the striking area between the piston and the rod gt An adapter is available for underwater operation gt Underwater usage of the br
17. cylinder seal bushing The seal bushing carries several specially designed seals Pay attention to the condition and orientation of the old seals as they are removed This may help to identify any operating problems that the breaker had before it was dismantled If burrs are found on the seal bushing use a buffing grindstone to remove them IMPORTANT When using a buffing grinder apply the flap wheel around the inside diameter of the part only If applied along the axis roundness will be affected ACAUTION Handle this component with care Damage will cause breaker malfunction All parts should be thoroughly washed in clean solvent and dried with compressed air Once the seal bushing is clean and dry protect it from dirt and set it aside Tie Rod Installation Inspect the tie rod threads If they are damaged beyond repair the tie rod must be replaced 1 Lubricate the tie rods and threads thoroughly using grease 2 Install the tie rods and tighten until they bottom out in the front head 3 The tie rods should turn in smoothly and easily until they seat themselves If they do not bottom out or there is excessive resistance the threads on the tie rods may be damaged NOTE As a reference tie rod torque can be found in Torque Specifications 55 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Cylinder Installation 1 Check the cylinder for burrs 2 Liberally oil the inside surface of the cylinder and the new seals then ins
18. may cause a malfunction Circulating the oil will remove air and other foreign substances from the system If the breaker was stored lying down seals can deform Follow these steps to circulate the hydraulic oil and correct these problems 1 First recharge cushion chamber with nitrogen gas With the breaker mounted and oil warmed to operating temperatures 2 Lift the unit of the ground 3 Press the Start button or pedal to fire the breaker momentarily 4 Continue to turn the breaker ON and OFF in this manner for ten minutes The breaker is now ready to be put in to service 71 SHEARFORCE Y Cae us Sales and Rentals Product Support Repairs and Installations ATTACHMENT SPECIALISTS 107 2707 Progressive Way Abbotsford BC V2T OA7 shearforce ca 1 800 255 5211
19. replace all seals Replace upper and lower breaker isolators inside the housing Measure the wear limit on the Front and Rear Bushings Replace each bushing if the allowable tolerances are exceeded Check hydraulic flow to breaker and operating pressure Adjust as necessary 44 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL asset ser Jojemumooy amssalg SED emesal Ser peH Jeg FLPD FAD L6 0T andog d og dej 3unoyq jexoelq i Ja f roa os oe ms e oe ee OF SE at 3E e qej w 6 gt eainssaig sey 79 wi by anbioly Torque and Gas Pressure Table SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Breaker Disassembly A WARNING Hydraulic breakers and their components are heavy Plan carefully how you will handle them when removing disassembling or installing the breaker Stand clear when slinging the breaker off the ground ACAUTION Use extreme care to prevent dirt from entering the hydraulic circuit when disconnecting or reconnecting hydraulic lines Cap or plug lines when disconnecting clean thoroughly before reconnecting Even the smallest dirt particles will cause damage to the internal workings of the breaker AWARNING Risk of personal injury Wear safety glasses boots and protective gloves Relieve all trapped pressure in the breaker hydraulic circuit Pressure can be maintained in hydraulic circuits long after the power source and pump have been shut down
20. section of this manual gt Stay clear of the tool when charging the breaker cushion chamber Gas pressure may cause unexpected piston movement and force the tool to jump against the tool retainer pins gt Use only lifting devices with sufficient capacity to safely support the expected weight you are lifting gt All lifting devices straps slings chains ratchet blocks etc must comply with applicable local regulations and certifications ShearForce Equipment cannot accept responsibility for the use of sub standard equipment and work practices gt When lifting or supporting the breaker or its parts use equipment with a sufficient lifting capacity gt Use the lifting eyes or lifting points that are located on certain breaker components gt Do not work under a hanging or suspended load gt If a jack is used the floor or ground must be flat and of sufficient strength to support the expected load Precautions for Working on Hydraulic Systems A WARNING Risk of personal injury Wear safety glasses and use protective gloves Relieve all trapped pressure before performing any service to the hydraulic system Pressure can be maintained in the hydraulic circuits long after the power source and pump have been shut down gt A Relieve all pressure before disconnecting hoses or tubes gt Tighten all connections before applying pressure It is important that each person who comes in contact with the machine be alert to any fault
21. the Breaker 1 Clean the inner surfaces of the breaker attachment bracket with a cloth 2 Draw the carrier machine near inserting the STICK boom into the breaker attachment bracket 3 Carefully clean any dirt from the pins and bushing Insert the bucket pin checking its alignment and securing it with the collars and locking bolts ACAUTION Do not force the pin re check its alignment instead 4 Move the LINK cylinder to line up the hole of the connecting rod with the second mounting bracket attachment hole Insert the pin and secure it with the collars and locking bolts Setting Flow and Pressure See Specifications below for operating pressure and oil flow requirements for all SB models a 7SB50 150 170 1849 2276 2134 2418 ems JSBISI 160 180 2276 2560 2276 2560 ITE JSB50 Umin 15 25 20 30 25 50 30 60 40 70 50 90 60 100 80 110 Oil flow emi 4 8 5 10 5 6 5 13 8 16 10 5 18 5 13 24 16 16 5 21 29 JSB60 JSB70 JSB81 JSB100 JSB121 JSB130 JSB151 requirements min 90 120 100 150 120 180 150 210 180 240 200 260 210 290 gal min 24 32 27 40 32 48 40 56 48 63 51 69 55 77 DO NOT operate the breaker below its minimum flow rate Internal damage to the breaker may result DO NOT operate the breaker at a pressure near to or above the relief valve setting Internal damage to the relief valve may result Ensure the relief valve is set 400 600 psi 27 41 bar above the actual operating pressure of the breaker Setting the Flo
22. the installation 1 Make sure the hydraulic circuit targeted for the breaker matches the requirements for hydraulic flow and pressure relief settings 2 The hydraulic tubing and hose size must match the requirements of the breaker 3 The hydraulic oil and filter must be clean Be sure the hydraulic reservoir is full at all times 4 Make sure any hoses or tubes that are used are routed to prevent rubbing or chafing during operation It is beneficial for the tank return line to pass through a filter This ensures dirt introduced into the system by connecting and disconnecting the breaker is caught before entering the carrier s pump Quick disconnects on the pressure and return lines are not recommended If they fail metal particles can cause internal damage in the breaker such as accelerated component wear blockages and seizing They will also cause a pressure drop and flow restrictions A CAUTION Make sure the hose fittings are clean and dust free ACAUTION Be sure the operating pressure values do not exceed those instructed in this manual AWARNING It is advisable to provide clearly marked shut off valves in the breaker pressure and return line circuits Shut off valves will enable them to be isolated when removing or installing the breaker This will overcome the risk of releasing high pressure oil and limit the discharge of oil from the hydraulic lines 20 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Mounting
23. two cubic yard piece of limestone 20 000 psi or less needs to be broken in half a 3 000 5 000 ft lb breaker is required Trenching When trenching the breaker is expected to fracture a solid mass of rock into manageable pieces The size of the material could be hundreds of cubic yards and the energy will be quickly absorbed This is why it Is recommended to work from a bench so the rock has somewhere to break out When trenching in limestone or medium hard rock use a 3 000 5 000 ft lb breaker When working in hard material use a 7 500 10 000 ft lb breaker and if high production is critical a 13 500 ft lb breaker would be beneficial SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Breaking Concrete When breaking concrete the breaker is expected to penetrate the material allowing it to crack and shake loose from the reinforcing steel High frequency breakers tend to provide better performance in this application It is not the energy per blow but the fast blows per minute rate that destroys the concrete s structural integrity On concrete walls footings and floors use a 750 1 500 ft lb breaker With larger projects consisting of footings greater than four cubic yards use a 2 000 5 000 ft lb breaker The high production demand of bridge and building demolition requires a 7 500 10 000 ft lb breaker Recommended Hydraulic Oils Oil is Too Thick or Too Thin Thick oil may cause gt Difficult start up Stiff opera
24. units be sure the Installation Notice is properly completed and submitted Typical Hydraulic Circuits For a hydraulic breaker to function it needs hydraulic flow and pressure in one direction only The supply line should be directed out the left side of the carrier and the return line on the right as viewed by the operator ShearForce Equipment breakers operate within a specified flow range The operating pressure will depend on the amount of oil flow the return line pressure and internal efficiency of the individual attachment Carrier with Auxiliary Hydraulic Circuit The carrier will often be equipped with an auxiliary control valve In this case the auxiliary control can be used to control the supply of oil It can usually be adjusted to provide the correct amount of flow and a relief cartridge can be installed to protect the hydraulic circuit A CAUTION When using the carrier s existing auxiliary control valve for the hydraulic breaker circuit do not route the return line back through its return port High back pressures may result It is recommended to send the oil directly back through the cooler return filter to the tank If it is necessary to plumb the circuit using both ports on the auxiliary valve the return line should have a drain line connected to the tank This will reduce back pressure in the hydraulic circuit and protect the control valve from return line pressure spikes 22 SHEARFORCE HYDRAULIC BREAKER USER
25. AWARNING The operator of this machine must have sufficient knowledge and instructions before he she operates the machine Untrained operators may cause severe injuries or even fatalities Therefore it is important that you read and follow the instructions of this operator s manual gt Never use a machine that does not have an operator s manual available Learn and understand the safety signs and symbols on the machine and the operator instructions before you begin to use the machine Wear protective clothing Know and use the protective equipment that is to be worn when operating or servicing the hydraulic breaker Hard hats protective glasses protective shoes gloves reflector type vests respirators and ear protection are types of equipment that may be required Prolonged exposure to loud noise can cause hearing damage Operate the machine only when physically fit and not under the influence of alcohol or drugs Avoid loose fitting clothing loose or uncovered long hair jewelry and loose personal articles These can get caught in moving parts Keep all personnel well away from the hydraulic breaker when it is operating Small pieces of stone or concrete can fly off causing serious injury to bystanders Keep a first aid kit and a multi purpose fire extinguisher on or near the machine and know how to use them Know where to get help Before starting up the hydraulic breaker perform a daily inspection and include it
26. Disassembly A CAUTION Handle these components with care Damaging them will cause breaker malfunction The control valve is responsible for directing oil within the breaker to move the piston within the cylinder The SB Model has an internal control valve contained within the cylinder body The control valve is housed within the cylinder body Once the back head is removed it can be accessed from the upper end of the cylinder body 1 Remove the O rings then the valve plug 2 The valve spool and valve sleeve can then be slid out If spool is not seized it can be easily removed 1 Valve Sleeve A puller can assist in removing a seized spool 2 Valve Spool 3 Valve Cap Control Valve Inspection gt If the valve spool surface is scuffed remove it with 800 1200 grit emery cloth If the area is extremely damaged replace the valve gt If the valve body has flaws in area D smooth the surface with 800 1200 grit emery cloth Do not use a buffing grinder on this area gt In case of scuffing on the inner diameter G finish by buffing with a flap wheel gt Clean all parts of the control valve in clean solvent and dry them with compressed air 51 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Piston Removal A CAUTION Handle these components with care Damaging them will cause breaker malfunction 1 2 NOTE Avoid scratching the piston s polished surface Tapping the cylinder with a soft faced mal
27. Oil Purity g Hydraulic Oil Cooling 9 Safety Rules 10 General Safety Precautions 11 Practice Safe Maintenance 11 Precautions for Working on Hydraulic Systems 12 Precautions for Handling Hydraulic Oil 13 Fire Prevention 13 Welding and Grinding Work 14 Work on Painted Surfaces 14 Rubber and Plastics esssesssescesenscsetdsectone a ee 15 Hazard AJene s 5 225s eae ae ae eee eee ee 15 Transporting Safety Precautions 18 Installation 19 GPC Tall ss ce ae a te 19 Mounting the Breaker 20 Setting Flow and Pressure 20 Setting the Flow 20 Setting the Relief Pressure
28. RTANT When it comes to safety nothing will ever replace a careful operator This operator s manual is the primary source in maintaining optimum performance from the hydraulic breaker It is imperative that the operator reads and understands all the safety information in this manual before proceeding Failure to follow the instructions or heed the warnings could result in injury or death Proper care is your responsibility We cannot anticipate every possible circumstance that might involve a hazard The hazard alerts in this publication and on the product are therefore not all inclusive If a tool procedure work method or operating technique not specifically recommended by ShearForce is used you must be confident that it is safe for yourself and others You should also ensure the hydraulic breaker will not be damaged or made unsafe by the operation maintenance or repair procedures you choose gt It is the obligation of the operator to make sure that all warning decals are in place on the machine and that they are readable Accidents may otherwise occur Contact ShearForce Equipment for replacement manuals or decals gt Should there be any information or instructions in this manual that are not in compliance with local laws and regulations in force in the country or region where this equipment is operated the local laws and regulations must take precedence 11 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL General Safety Precautions
29. S MANUAL Typical Hydraulic Circuits From ES Electric Pilot Circuit Foot Switch Hydraulic Oil Supply On Off Breaker Valve 6 0 Aux Spool Swing R Track R Track Example of a carrier hydraulic circuit with an auxiliary hydraulic circuit Carrier without Auxiliary Hydraulic Circuit If the carrier is not equipped with an auxiliary control valve install a priority flow control valve to direct the correct flow away from the normal circuit and operate the attachment The priority flow control valve is usually equipped with a flow adjustment and pressure relief These valves often need a check valve on the regulated port to completely close the flow If dividing too much flow this circuit can generate heat and may require additional cooling capacity Priority Flow Hydraulic Electric Control Valve Breaker Foot Switch 6 9 gt Valve Case Drain Example of a carrier hydraulic circuit without an auxiliary hydraulic circuit SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Operation Suggestions for Efficient Operation A CAUTION Do not operate the breaker continuously in one spot for more than 20 seconds Doing so will cause excessive heat that could mushroom the end of the tool On large rocks take a smaller bite Do not start in the middle gt For large rocks start at the edge and work toward the center breaking off small chunks each time
30. age improper contadt with tool tip and material to be broken No Warranty Mushrooming fast wear caused by breaking too long on the same spot No Warranty 69 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Removal and Storage A CAUTION Use extreme care to prevent dirt from entering the hydraulic circuit when disconnecting or reconnecting hydraulic lines Cap or plug lines when disconnecting clean thoroughly before reconnecting Even the smallest dirt particles will cause damage to the internal workings of the breaker Short term Storage Storing your breaker up to a week is considered Short term Storage Follow this procedure 1 If shut off valves are used with the breaker turn them to the OFF position 2 Disconnect the pressure and return lines Plug the lines and the breaker ports to prevent contamination 3 Use your excavator to lay the breaker on wooden blocks with the mounting bracket end lying higher than the tool end Support the breaker before proceeding 4 Remove the pins to disconnect the breaker from the carrier 5 Remove the tool and ensure the retaining pins bushings and piston bottom inside breaker are well greased 6 Reinstall the tool and cover the breaker with a tarp Use a waterproof cover if storing outdoors Long term Storage Storing the breaker over a week is considered Long term Storage Breaker Stored Lying Down Use the following procedure 1 Release the cushion chamber gas pressure 2 Re
31. alve assembly to discharge the N2 gas in the 3 way valve assembly 5 8 Remove the 3 way valve assembly 5 and tighten the plug 9 and cap 11 IMPORTANT To determine the correct pressure in relation to ambient temperatures refer to the below table m Conversion Table for charging nitrogen gas pressure to Accumulator Accumulator Surface Temperature C j F 0 32 10 50 20 68 30 86 40 104 Accumulator i i Gas Pressure kg cm psi j i H 51 730 53 755 55 780 j 57 815 59 830 i i i Accumulator Gas Pressure Adjusting Increasing the Pressure 1 Connect the charging hose 4 to N2 gas cylinder 1 after screwing the bombe adapter 3 onto adapter nut 2 and installing to the N2 gas cylinder 2 Connect the 3 way valve assembly 5 to the charging hose 4 after unscrewing the cap on the 3 way valve assembly 3 Remove the cap 11 form the accumulator and tighten the charging valve 12 fully 4 Check if O rings 6 8 are installed to the adapter 7 Remove the plug 9 and screw in the adapter 5 Loosen the accumulator charging valve 12 after checking if adapter 7 is installed to the 3 way valve assembly 6 Turn the handle of the N2 gas cylinder counter clockwise slowly to charge gas 7 Charge gas in accordance with the conversion table for charging N2 gas pressure to accumulator 8 Turn the handle of the N2 gas cylinder clockwise to close the accumulating charging val
32. and O rings Periodical replacement should be carried out every three months without external leakage of breaker Even if the breaker is not operated for a substantial amount of time replace seals periodically to prevent rust corrosion of oil and transformation of seals 33 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Wear Tolerance Wear tolerance of each replaceable part is listed in the charts below Exceeding the wear tolerance of each part can cause serious damage to breaker Prevent damage through the regular inspection and exchange of expendable parts including seals and bushings Minimum and Maximum Diameters for Wear Bushings Tools and Pistons Wear Tolerance Unit mm NEW REJECT Inside Dia Inside Dia JsB10 40 42 S820 S830 JsB35 60 62 JsB40 68 71 JSB45 85 89 Ring Bush Wear Tolerance Unit mm NE REJECT Inside Dia Inside Dia W JSB10 40 JSB35 60 JSB40 68 Front Cover Lower Bush 175 5 3 5 5 3 JSB81 5 5 5 5 5 5 5 89 dd bh hh La a Wear area F F sPFPPMF SB10 43 Measure at 30mm SB10 45 FRONT COVER Measure at 10mm 34 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Minimum and Maximum Diameters for Wear Bushings Tools and Pistons Piston Wear Tolerance Unit mm 168 167 251 250 JSB50 2 5 2 4 324 Wear Limit New Part 35 Wear Tolerance Unit mm
33. aree esas e oes eee teers 55 Control Valve Installation 56 Installing the Rear Head 56 Charging the Cushion Chamber 57 Breaker Assembly 57 High Low Speed Selector Valve Adjusting 59 High Speed Setting 59 Low Speed Setting 59 Troubleshooting Guide 60 Oil Leakage 60 Hydraulic Breaker 61 Breaker fore C 65 Normal Breaker Tool Wear 65 Breaker Tool Fatigue Failures 65 Cause and Effect of Fatigue 66 Other Causes of Increased Tool Fatigue Stress 66 Area of Typical Tool Failures 67 Guide to Warranty Claims 67 Mushroomlng sese eesseeeeeh
34. ation of all machine functions Grease breaker tool bushing Pump grease in until it is visible around tool and retainer Check general condition of machine and surrounding work area Check all screw connections for tightness during first 50 hours of operation Refer to Torque Specifications Check hydraulic oil level in carrier reservoir Check torque on all fasteners Check mounting pins for wear Check impact surface of tool for deformation Inspect the tool retainer pins Remove the pins rotate 180 degrees and reinstall After initial 100 hours of operation change hydraulic pressure and return line filter elements Check tool bushing clearance Check that the pressure return filter indicators on the carrier hydraulic system are functioning correctly and not in by pass 43 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Every 500 Hours Take a sample of the hydraulic oil Review the results and determine if an increase in filter change interval and or oil change is required File the results Check cushion chamber nitrogen gas pressure Refer to Cushion Chamber Gas Pressure Checking Perform all breaker checks above as required Check that the retainer pins cross pins and stopper plugs are not damaged and are in Check that the upper isolator and tie rod nuts are in place and tight Check for wear Replace the retainer pins Perform all breaker checks listed above as required Disassemble the breaker to
35. ator is set too low Set the relief valve to correct pressure setting Poor performance of the hydraulic pump on the excavator Lack of down pressure on the tool Nitrogen gas pressure in the rear head is too low Back pressure too high in circuit Control valve bolts loose Blows min decreased Have the hydraulic excavator manufacturer check the pump performance If the performance is poor repair or replace Operate the arm and bucket so that pressure is applied to the tool Adjust the nitrogen gas to the correct pressure Find source causing increased back pressure in return circuit and remove Tighten bolts to correct torque in a staggered pattern Nitrogen gas pressure in the rear head is too high Lack of down pressure on the tool Pressure setting for the relief valve is too low Poor performance of the hydraulic pump on the excavator Clogged or restricted hoses and or pipes Back pressure too high in circuit Tool Breaking Adjust the nitrogen gas to the correct pressure Operate the boom and bucket cylinders so that pressure is applied to the tool Set the relief valve to the correct pressure setting Have the excavator manufacturer check the pump performance Investigate the blocked area and repair or replace Find source causing increased back pressure in return circuit and remove Abuse of tool and prying with tool Apply down force in the direction of tool only Check fo
36. broken rock away from the work area In some cases the excavator can sit on top of the trench and the broken material can be back filled under the excavator For best performance apply the down force in line with the tool repositioning every 10 to 15 seconds or when no penetration is evident gt Keep the breaker well greased at all times Breaking Concrete Begin by penetrating the concrete several times in one area with the breaker tool This should loosen the concrete and separate the reinforcing steel This rebar may need to be cut to keep the concrete pieces manageable for removal gt When breaking concrete floors use the down force from the carrier s boom cylinder to follow the tool through the concrete gt For vertical walls force must be maintained using a combination of boom stick and tilt cylinders A fast blow rate gives the best performance in breaking concrete so ensure your carrier is providing the breaker with the maximum recommended oil flow Generally a chisel point gives the best splitting action when breaking concrete However if breaking hard concrete with lots of rebar a moil point may be better The moil tip helps deflect the tool off the steel as it breaks the concrete 27 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Breaking on a Grizzly NOTE Breaking on a grizzly can cause excessive blank firing It is recommended the breaker be configured for anti blank firing mode If the grizzly is
37. cal wiring and connections and hydraulic hoses to ensure they are secure and not 14 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL V V V V rubbing against other components Clean up any excess grease and oil accumulation and spillage immediately Use only non flammable solutions for cleaning the machine or components Store rags and other combustible materials in a safe fireproof location Before starting repair work such as welding clean the surrounding area and place a fire extinguisher close by Store flammable fluids away from fire hazards Do not incinerate or puncture pressurized containers Welding and Grinding Work IMPORTANT A fire extinguisher should be easily accessible during all welding work Welding repairs are to be performed by a trained welder with proper service instructions Know the material to be welded and select the correct welding procedure and materials electrodes rods wire that will provide a weld metal strength equivalent to the parent material gt Move the machine to a clean safe area before welding grinding or using an oxy acetylene torch on it This type of work should only be done in a clean area and not in places that contain combustible liquids such as fuel tanks hydraulic pipes or similar Consult the carrier operator s manual before starting welding procedures Sensitive equipment may require disconnecting machine electronics If welding the breaker side plates or box housing
38. d higher than the normal factory setting turn clockwise 2 turns or more A valve adjuster 1 found on the upper side of the breaker cylinder body is used to switch between high speed and low speed 31 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Maintenance Lubrication is the single most important procedure for sustaining the life of a hydraulic breaker To keep your breaker in top operating condition perform the maintenance procedures outlined in this section Greasing the Breaker A CAUTION Use proper grease Always use JSB chisel Paste or a molybdenum disulfide based MoS2 grease to lubricate the tool The use of GP general purpose grease is not recommended It will melt and run down the tool providing very poor lubrication Use only as a last resort MT Pressing the tool up inside the breaker prevents excessive grease NUS Z entering the impact chamber The excessive grease will cause a V6 V y cushioning effect and a lack of breaker power when the breaker is fired 0 Excessive grease could contaminate the oil and cause seal failure Q 1 The breaker must be in a vertical position to grease with m enough down pressure to push the tool up inside the R housing S 2 2 Grease until clean grease oozes out around the tool and retainer pins 3 Grease the breaker after every two hours of continuous use or when the tool appears shiny where it rides inside the front head A CAUTION Grea
39. eaker is put into service the cushion chamber must be recharged with N2 nitrogen gas 1 Cross Damper Upper Isolator Breaker Assembly Installing body into boxed frame A WARNING Hydraulic breakers and their components are heavy Plan carefully how you will handle them when removing disassembling or installing the breaker Stand clear when slinging the breaker off the ground The ShearForce breaker uses upper and lower isolators to support the breaker body within the housing IMPORTANT After the top mount bracket is installed the upper and lower isolators must compress to form a spring pre load on the 58 2 Lower Damper Lower Isolator SHEARFORCE HYDRAULIC BREAKER USER S MANUAL breaker body within the housing If the breaker body has been disassembled to be rebuilt replace the Isolators NOTE The upper lower isolators and wear pads are considered wear parts and HN are not covered under the breaker warranty It is recommended that they be replaced after every 1 000 hours of operation or as required A CAUTION Check to make sure the housing is upright secure and fully restrained 1 Install the wear pads and lower isolator into the breaker housing NOTE Do not lubricate the wear pads to ease installation of the breaker body NOTE If the breaker body is new check to make sure nothing is protruding to hinder insertion into the housing 2 Lift the breaker body up and center it for entry
40. eaker without the underwater kit and air compressor will cause serious damage to the hydraulic breaker Installing the Air Supply Kit 1 Clean the air check valve hole on the left side of the cylinder Except SB40 the air check valve hole is located on the right side 2 Remove the air check valve with the standard tool 3 Apply the O ring to the cylinder s air check valve hole and install it 4 Connect the hose to the air check valve hole and install it Air flow rate for underwater operation Air capacity levels are in the following chart Supply appropriate air flow rate in accordance with the breaker model and operating depth Depth Pressure m Ibar i nu JSB10 JSB43 JSB20 jeg 7 m fJSB30 ft SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Illustration for Installing the Underwater Breaker SB10 SB151 30 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL High Low Speed Selector Valve Breaker models SB50 and larger can operate at two speeds The higher speed setting is obtained by shortening the piston stroke At the higher speed the breaking power is somewhat lower but higher production rates can be achieved in softer materials such as concrete It is not available on models smaller than SB50 To set the lower speed turn valve adjuster counter clockwise 2 1 2 turns To set the spee
41. ee c cepe suci eHeei eee eMe nues ee ELE EAS 68 Steel Defect Failure 68 Removal and Storage 69 mC mat OS 1 0 8 a medendi amie 69 Eo ao Fai ARS CO 6 0 aaa 69 Breaker Stored Lying Down 69 Breaker Stored Standing Up 69 Initial Start up after Storage 70 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Introduction To our customer Thank you for choosing a ShearForce product for your application At ShearForce Equipment we pride ourselves in the equipment we distribute to our customers We believe this product is without exception the industry standard Using state of the art CAD modeling software complemented with finite element analysis meticulous care has been taken to ensure that this product will meet your rigorous requirements Our support team consists of knowledgeable long term dedicated employees They are able to respond quickly to any questions or concerns you may have Foreword This book is intended as a guide to the use and maintenance of the ShearForce Hydraulic Breakers Please keep it with the operator at all times Replace it immediately if it becomes lost The design of the ShearForce Hydraulic Breaker pr
42. er Oil ooze after overhaul of breaker between Loosen tie rod nuts and retighten Damaged the joining surfaces of cylinder and rear head O ring replace New oil leaking from surface between cylinder and front head Between the cylinder and hose adapter Leakage at stroke adjuster cap Leakage at pilot valve cap Loosen plugs on face of the cylinder then re tighten Damaged seals in the cylinder replace as necessary Replace worn or damaged O ring Check and re tighten the hose adapter to the specified torque Replace worn or damaged O ring Loosen the stroke adjuster cap then re tighten to specified torque Replace worn or damaged O ring Loosen the pilot valve cap then re tighten to specified torque Control valve bolts loose Tighten bolts to correct torque in a staggered pattern Gas Leakage Probable Cause Gas leakage from the gas valve Leakage from gas valve body Gas leakage from between the cylinder and the cylinder cover Tie rods loose Replace worn or damaged seals Check gas Worn or damaged O ring Replace Tighten to correct torque value in a cross pattern 64 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Erratic Blows After Breaker has been Operating Normally Probable Cause Correction Seizure of control valve Repair or replace control valve Seizure of piston and cylinder Remove and inspect piston and inside of cylinder body Relief valve for the excav
43. ers hydraulic breakers that are designed to break any material that the machine can handle Sizing the breaker by carrier hydraulics gives the operator a carrier breaker combination designed to optimize system efficiency thereby reducing heat generation and eliminating power loss The following steps will ensure a smooth installation This manual will not cover all types of applications so for assistance in any unusual situations please contact your ShearForce Equipment representative Based on Carrier Weight By using the Carrier Sizing Chart below you can narrow your hammer choice Normally the breaker s production rate is the most crucial factor when choosing a breaker size It is a good idea to do some research and understand your hydraulic system capabilities and the material size and hardness before determining an expected production rate This rate will also be affected by breaking conditions and the operator SHEARFORCE HYDRAULIC BREAKER USER S MANUAL BREAKER Carrier Weight in Metric Ton MODEL SB10T 175 ft lb SB20T 250 ft lb SB30T 350 ft lb SB35T 550 ft lb SB40S 750 ft lb SB43S 875 ft lb SB45S 1500 ft lb SB50S 2000 ft lb SB60S 3000 ft lb SB70AS 4000 ft lb SB81S 5000 ft lb BREAKER MODEL SB100S 6000 ft lb SB121S 7500 ft lb SB130S 8500 ft lb SB151S 12000 ft Ib Skidsteer dim Backhoe va Mini excavator aa Excavator 5 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Based
44. ess applied to the tool i e the smaller the fatigue area the higher the stress level Once a fatigue crack begins it takes less stress to make it grow 66 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Cause and Effect of Fatigue In normal operation a cycle of compressive and tensile stresses Incorrect flow up and down the tool with each piston blow as the breaker S Breaking Angle fires The main cause of increased tool fatigue stress is any side force applied during operation that bends the tool Prying with the tool using the incorrect working angle or attempting to break ground using the pull of the carrier machine will shorten tool life and must be avoided Anything that interferes with these normal stresses increases the risk of early tool fatigue failure Other Causes of Increased Tool Fatigue Stress EM Prying with Breaker Blank Firing S Blank firing is any situation where the breaker piston strikes the top of the tool but the tool is not in proper contact with the material This can happen when the tool slides off the work and also when breaking through thin concrete slabs or boulders Cold Low temperature makes the tool more susceptible to fatigue failure Warm the tool first with moderate or light breaking Mechanical and Thermal Damage Any type of damage to the tool surface makes it more likely to suffer fatigue failure Care must be taken to fand gt Prevent scratches gouges and weld marks g
45. ethane and rubber without first protecting them from the heat gt Never burn polymer materials when scrapping them gt Be careful when handling machines that have been exposed to fire or other intense heat Always use gloves protective safety glasses and breathing protection Hazard Alerts AWARNING The breaker should only be mounted to excavators whose lifting capacity is greater than the minimum value AWARNING When working overhead always be aware of the possibility of falling blocks or material fragments Ensure that the machine is equipped with the necessary protection and that the cab is of the 10010 F O P S Falling Object Protective Structure type A WARNING Keep a minimum distance of 100 ft 30 5 m from the excavator operating area Protect bystanders from the working area to prevent injuries Proceed carefully when moving the excavator 16 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL AWARNING The breaker must only be used by a skilled operator who has read and understood the operator s manual AWARNING Do not allow any unauthorized person to operate or carry out any type of maintenance AWARNING The breaker must be used only on the condition that it has been installed correctly using the attachment bracket and pins AWARNING Do not use the breaker for lifting hammering or transporting materials AWARNING If the breaker becomes entangled in the reinforce
46. higher than the last time it was charged indicates the diaphragm may have ruptured Pressurized oil may exist in the accumulator Proceed with caution 2 Bleed off the nitrogen gas with the charging kit hose Fully vent the accumulator Confirm with the gauge in the charging kit 3 Loosen the 4 bolts in a staggered pattern Use multiple steps 4 Remove the accumulator from the breaker body Diaphragm Replacement 4A CAUTION Nitrogen gas must be fully vented before disassembly 1 Confirm the gas pressure has been fully vented with the charging kit 2 Loosen the bolts holding the accumulator halves together in a staggered pattern 3 Loosen the bolts off in 1 8 in 3mm increments watch for movement Movement of the halves may mean residual pressure remains 4 Continue loosening the bolts in a staggered pattern 5 Remove the cover to replace the diaphragm Accumulator Assembly 1 Install the accumulator diaphragm into the accumulator base Make sure the groove is clean and free of any debris 2 Lubricate the cover bolt threads 3 Install the cover bolts and washers Tighten in stages in a staggered pattern For information on accumulator bolt torque see Torque amp Gas pressure table 50 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Charging the Accumulator Before the breaker is put into service the accumulator must be recharged with N2 gas Refer to Accumulator Gas Pressure Adjusting Control Valve Removal and
47. housed within the cylinder body It is installed from the upper end of the cylinder body Lightly oil the control valve spool valve sleeve plug and O rings with clean hydraulic oil 1 Insert the valve sleeve first then insert the spool Insert the small end of the spool first 2 Insert the plug and ensure the O rings are placed correctly before installing the rear head Installing the Rear Head The cushion chamber in the rear head needs a small amount of oil to function properly Just before installing the rear head make a circular dam of grease on the top of the piston just high enough to contain the required amount of oil see table below l Lower the rear head over the tie rods The gas valve must face the same direction as the control valve on the cylinder 2 Install the tie rod washers 3 Lubricate the tie rod nuts with grease and tighten them in a crossing pattern to draw the breaker components together evenly 4 Finish tightening the nuts to the correct torque in four stages 4096 60 8096 and 100 using the same crossing pattern 57 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Tie Rod Through Bolt Nut Torque smos 3 5 Pour the required amount of oil for the cushion chamber through the gas valve port Use a medium viscosity hydraulic oil Cushion Chamber Oil Volume SB10 43 SB45 50 SB60 70 SB81 SB100 151 7 wo 53 2 3o Charging the Cushion Chamber Before the br
48. in the daily machine walk around Pay special attention to hoses and electrical connections Make repairs before operating the breaker Practice Safe Maintenance gt Only trained mechanics should repair or disassemble the hydraulic breaker Be sure you understand a service procedure before beginning any work if you are uncertain contact your ShearForce Equipment representative Avoid unauthorized machine modifications never substitute alternate parts not intended for the application This could create hazardous situations or machine failure ShearForce s engineering team must approve all machine modifications as they can affect product reliability and machine stability Before performing any work on the machine attach a DO NOT OPERATE or similar tag in the operator s cab to alert others of service work being performed Remove engine key and master key switch Unexpected machine movement can cause serious injury The cushion chamber back head is charged with nitrogen N2 a non explosive inert gas Only use N2 when refilling it Charging it with any other gas could trigger an explosion and lead to serious or possibly fatal injuries 12 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL gt Relieve all gas pressure in the cushion chamber before beginning disassembly procedures to avoid the potential for accidents or injury It remains under pressure even after the hydraulic system is depressurized Refer to the Maintenance
49. into the housing Check the orientation of the body the pressure and return ports must face the control valve side 3 Slowly lower the breaker into the housing The breaker may have to be slightly tapped in using a dead blow If the breaker binds or seizes in the housing remove it and determine the cause 4 Keep the lower isolator centered nylon side up 5 Lower the breaker until it fully bottoms out in the housing Check by comparing the position of the retaining pins and the clearance holes in the bottom of the housing The retaining pins should be just above the centerline of the clearance holes 6 Position the upper isolator on the rear head Verify it protrudes above the finished face of the breaker housing See previous page 7 Position the mounting bracket on the top of the breaker Ensure bracket is not put on backwards and install bolts 8 Lubricate the bolts with MoS2 grease 9 Tighten bolts in a cross pattern to provide even loading to the upper isolator Top Mount Bracket Bolt Torque Model Torque Value Torque Value kg m kg m SB35 43 SB81 120 SB45 50 SB100 151 160 Reinstall the tool Refer to Tool Installation 59 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL A CAUTION Use extreme care to prevent dirt from entering the hydraulic circuit when disconnecting or reconnecting hydraulic lines Cap or plug lines when disconnecting clean thoroughly before reconnecting Even the smallest dir
50. ion chamber Adjust pressure Too much grease in the impact chamber Remove tool and clean out excess grease Follow proper greasing instructions Excessive clearance between tool and tool Check clearance and replace worn parts bushing Excess wear at top of tool Remove and inspect the tool Replace if necessary Foreign matter in the breaker control valve Disassemble and clean Seizure of piston and cylinder Overhaul the breaker Back pressure too high in circuit Find source causing increased bacle pressure in return circuit and remove Control valve bolts loose Tighten bolts to correct torque in a staggered pattern Tool Mushrooming Continuous hammering in one place Use short bursts Re position breaker every 20 seconds Rapid Increase in Oil Temperature Insufficient oil cooling Check oil cooler Insufficient oil flow Check pump output Incorrect oil pressure Check relief valve setting Emulsification of Oil Oil contaminated with water Locate source of water and repair Replace oil 63 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Leakage The space between the tool and bushing has Damaged seals Re seal as necessary Possible loose hoses or adapter fittings cause Check condition of hoses and fittings tighten oil on the surface of the breaker as necessary Oil oozing after overhaul of breaker between Normal oozing of assembly lubricants the control valve and surface of the cylind
51. lead to a fire or explosion Operation of the breaker may create sparks that could ignite highly flammable gases gt Never operate the breaker in an environment where highly explosive gases could be present gt Make sure there are no sources of flammable gases in the work area gt Always provide sufficient ventilation when working in buildings or confined areas AWARNING Never operate the breaker in the vicinity of explosives gt Make sure there are no explosives hidden in the rock or stones being broken The impact of the tool could cause them to explode AWARNING Avoid all overhead cables and electrical wiring when operating the breaker to prevent the risk of electrical shock gt Any contact with sources of electricity can lead to an electric shock resulting in serious injury or death Check the worksite for hidden electrical circuits Fire Prevention IMPORTANT Maintain a charged fire extinguisher on the machine at all times and KNOW HOW TO USE IT Prevent combustible debris from collecting in tight corners of the machine This debris by itself may not cause a fire however when mixed with fuel oil or grease in a hot or confined space the danger of fire increases dramatically To reduce the chance of a fire starting follow these instructions Clean dust and debris from the machine daily gt Inspect the machine daily for potential fire hazards and make any necessary repairs immediately gt Inspect electri
52. let may ease the removal of the piston The seal bushing will come out with the piston 3 4 2 6 7 8 9 Install a lifting eye into the top of the piston Lift the piston straight up and out of the cylinder Place the piston and seal bushing on a clean protective surface The piston should be carefully cleaned and inspected for corrosion cavitation pitting and scoring Check the grooves in the piston for metal that has been pulled in due to galling If this has occurred clean the grooves Small marks can be removed with an oilstone or fine emery cloth and oil Check the corresponding mating part as well and treat in the same manner Look for pitting and deformation of the impact face This indicates that the tool has been operated with too much 1 Normal Impact Face wear on the tool bushings 2 Impact Face with Deformation If the face is dished carefully measure the amount of deformation Thoroughly clean and dry the piston to protect it from dirt then set it aside If the piston is not going to be installed immediately coat it with oil and store it protected in a clean dry place If the piston face is scuffed finish it with a buffing grinder then 800 1200 grit emery cloth IMPORTANT When using a buffing grinder apply the flap wheel around the circumference of the part only If applied along the axis roundness of the part will be affected Wash the parts after finishing them
53. ment bars of the structure being demolished free it before proceeding AWARNING Do not begin demolition work from lower parts of a structure The upper part could collapse A WARNING Do not use the breaker to hammer against the structure being demolished 17 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL AWARNING The excavator boom must be moved safely with slow accurate movements Avoid sudden movements AWARNING Ensure that the structure supporting your machine is strong enough to support its weight A WARNING Stay a minimum of 30 ft 9 1m away from overhead wires with any pe part of the machine X T4 P 10389 AWARNING To keep dust at a minimum during operation spray the work area with water AWARNING No adaptations or modifications to the breaker are allowed unless agreed upon by ShearForce engineering Written approval must be received beforehand Check the carrier owner s manual Further precautions may be required 18 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL A WARNING All operations of adjustment maintenance repair or cleaning must be made with the engine OFF and the attachment resting firmly on the ground als h Fasten a DO NOT OPERATE or similar tag in the cab A WARNING When carrying out maintenance or transporting procedures take care to place the breaker in a stable position
54. move the tool and liberally grease the piston bottom retaining pins and inside the front head 3 Ensure inlet ports are open to allow the piston to move up to the top 4 Push the piston up inside the breaker and reinstall the tool 5 Lay the breaker on wooden blocks using your excavator Mounting bracket end should lie higher than the tool end 6 Cover the breaker with a tarp waterproof if outdoors Breaker Stored Standing Up If the breaker is to be stored standing up place in a safety stand Use the following procedure 1 Release the cushion chamber gas pressure 2 Remove the tool and liberally grease the piston bottom retaining pins and inside the front head 3 Ensure inlet ports are open to allow piston to move up to top 70 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL 4 Reinstall the tool and place the breaker in the vertical stand This will allow the breaker s weight to push the tool and piston up inside the breaker 5 Cover the breaker with a tarp waterproof if outdoors Initial Start up after Storage A CAUTION Use extreme care to prevent dirt from entering the hydraulic circuit when disconnecting or reconnecting hydraulic lines Cap or plug lines when disconnecting clean thoroughly before reconnecting Even the smallest dirt particles will cause damage to the internal workings of the breaker Storage can introduce air into the hydraulic circuit If air is present in the hydraulic circuit during operation it
55. nce all bolts have been loosened the spring pre load will be gone and it is safe to remove the bolts 10 Remove top mount bracket bolts and bracket Store in a safe place away from the work area If the upper or lower isolators are not thick enough it should be replaced 11 Remove the upper isolator from the breaker and check for cracking heat damage wear etc If the isolator is in poor condition it must be replaced NOTE Upper and lower isolators must be replaced after 1 000 hours of operation Removing Breaker Body from Housing NOTE All lifting eyes required for breaker disassembly are found in the breaker tool kit Wear Pads Besides the upper and lower isolators the breaker body has wear pads between it and the inside of the housing to keep it supported Wear pads can be reused also if in good condition 1 Upper Isolator Crosse Damper 2 Lower Isolator Lower Damper 3 Wear Plate 4 Wear Plate 5 Wear Plate 6 Back Head Holding Block 47 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Weight of Main body Model Weight Model Weight Kg Ib Kg Ib Sas 280669 sB206 500519 seso 471951 sexG sso a919 ACCAUTION Ensure breaker is restrained to prevent tipping over 1 Insert the appropriate lifting eyes into the rear head 2 Using an overhead crane pull the breaker body straight up out of the housing 3 Carefully lower the bare breaker onto a smooth clean level su
56. oduces stable high speed percussion and exceptional value and durability for all construction demolition and rock breaking requirements The manufacturers use sophisticated technology to produce a simple design With only two internal moving parts this line of breakers makes the equipment operation easy flexible and reliable Field proven and customer sanctioned ShearForce breakers are enthusiastically accepted as the standard for the industries they serve Some typical applications include gt Construction Demolition Recycling Mining Quarrying Trenching V V V VV V Tunneling SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Specification SB 43 SB 45 SB 50 SB 60 SB 70 Weight Ibs 1259 1898 2897 3306 mers o es m xw s Required Oil Flow gpm 10 6 212 11 9 22 5 21 1 29 1 23 8 31 7 26 4 39 6 Operate Pressure psi 1885 2176 1885 2176 2176 2466 2176 2466 2321 2611 Impact Rate bpm 400 800 400 800 350 700 350 650 350 600 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL External Dimension in sei see qme mes me se sas mm me me m ow mom om x a se ex ws ES sad p 5A HN Jg Ll 03 as _ 7 I VEZ I E I Fen ll s sm sme sum seo sms p re as as amir ne SHEARFORCE HYDRAULIC BREAKER USER S MANUAL How the Tool Breaks Rock The following paragraphs describe the process of breaking rock when the piston strikes the to
57. ol A Contact Initial Compression Stress Wave When the piston 1 strikes the top of the tool 2 it sends a compressive stress wave 3 down to the working end of the tool If the tool is touching a rock this force compressive stress wave travels out the tool directly into the rock 4 fracturing it B Recoil Reflected Stress Wave Immediately following the initial compressive stress wave a reflected stress wave forms 5 which travels back up the tool bouncing the piston off the top of the tool This cycle of compressive and tensile stresses flowing up and down the tool is repeated with each piston blow E amp F C Bending Anything interfering with the strength of the compressive stress waves 7 during operation such as blank firing free running or prying with the tool can lower breaker performance and cause tool fatigue The breaker must be at a 90 angle to the face of the rock D Blank firing Blank firing the breaker without the chisel point pressing on a rock causes the energy that normally travels through the tool into the rock 8 to impact the retainer pins 9 and front head causing excess stress to these components SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Sizing the Hydraulic Breaker When sizing the breaker to the machine two key points should be given careful consideration gt Machine operating weight gt A Hydraulic system capabilities With the correct carrier weight ShearForce off
58. oles gt Rapidly accelerated wear on cylinders and seals gt Reduced breaker efficiency accelerated wear of moving parts and seals piston seizing up oil leakage gt Shortened working life and reduced efficiency of hydraulic oil overheats ages electrochemical changes Excessive large particle contamination can cause severe damage to the piston and piston cavity A CAUTION After a major component failure the hydraulic system must be flushed Component damage is only a symptom The issue itself cannot be resolved by removing the symptom Hydraulic Oil Cooling A CAUTION The maximum permitted hydraulic oil temperature in continuous breaker use is 120 158 F 50 70 C depending on the viscosity of the oil in the system It is essential the carrier has a reliable hydraulic oil temperature sensor installed The temperature of the hydraulic oil will depend upon ambient conditions efficiency of the cooling system and the amount of breaker use Additional cooling may be required SHEARFORCE HYDRAULIC BREAKER USER S MANUAL 10 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Safety Rules Our policy is to produce products that are safe and reliable However even when using well engineered equipment there will always be an element of risk To minimize risk and promote safety at all times this section of the operator s manual details a number of safety rules that must always be followed and obeyed IMPO
59. on the Type of Work The Production Rate is the next factor to consider in sizing the breaker Most situations call for the largest breaker that your carrier could handle and therefore the largest breaker is the best option The lifting capacity of your machine then becomes the limiting factor The carrier machine must be able to safely handle the breaker at any distance out from the machine where you are working Small Breakers Smaller sized breakers up to 1 000 ft lb class 1350 joule are typically used in concrete and other light duty work Medium Breakers Medium sized breakers 1 500 4 000 ftlb class 2000 5400 joule are used in both concrete and rock applications with limitations on the size and amount of material to be broken Large Breakers Larger breakers greater than the 4 000 ftlb class 5400 joule are typically used in hard rock high production applications Breaking Oversize When breaking oversize material the breaker is expected to break the material down quickly into multiple pieces This is optimum production If the operator has to re position the breaker towards the edge of the rock and gradually downsize the material the production rate slows down To assess which breaker will effectively handle this application the size and hardness of the material must be known For example if a 4 cubic yard piece of hard rock 20 000 psi or greater needs to be broken in half a 7 500 ft lb or larger breaker is required If a
60. place Cushion chamber filled with oil Replace seals Seizure of breaker Overhaul and replace worn parts Back pressure too high in circuit Find source causing increased back pressure in return circuit and remove Control valve bolts loose Tighten bolts to correct torque in a staggered pattern Check all ball valves Open ball valve Does not impact Temperature of the hydraulic oil is too low Warm up the hydraulic excavator The nitrogen gas pressure in the cushion Adjust the nitrogen gas to the correct chamber is too high pressure Pressure setting for the relief valve is too low Set the relief valve to the correct pressure setting Poor performance of the hydraulic pump on Have the hydraulic excavator manufacturer the excavator check the pump performance If the performance is poor repair or replace Back pressure too high in circuit Find source causing increased back pressure in return circuit and remove Lack of power Insufficient oil flow or oil pressure Check hydraulics of the base carrier Broken tool Replace tool check piston for damage Cushion chamber gas pressure is too low Check and adjust Back pressure too high in circuit Find source causing increased back pressure in return circuit and remove 62 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Erratic hammering Not enough down force on the tool Increase the down pressure acting on the tool Pressure too high in cush
61. r excess play in arms links and pins SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Breaker Tool Normal Breaker Tool Wear Wear depends on rock conditions Hard abrasive rock wears the tool down faster Working in softer materials will keep the point shape longer Blunt tools A will wear back 1 3 of the diameter to be shaped as shown Moil and Chisel tools B amp C will wear back 2 inches 51mm or more to be shaped as shown As a general guide this is considered normal wear and reasonable tool life Warranty claims are not accepted for normal wear Breaker Tool Fatigue Failures Metal Fatigue Metal fatigue is the sudden fracture of a component This effect occurs on metal after a period of repeated cycles of 1 stress Normally there will be no obvious warning A crack 9 forms without any visual change making it difficult to detect the presence of growing cracks Fractures usually start from 2in 5mm 10288 small nicks or scratches that cause a localized concentration 19284 of stress The fracture face itself normally appears as a semi circular polished area with the remainder looking uneven and rough The polished semi circle is the fatigue area originating from a damage mark or other stress event outside of the tool The fatigue area spreads slowly into the tool until the stress causes sudden failure to the section Generally the size of the fatigue area indicates the level of str
62. remove them from the breaker assembly This prevents the possibility of internal damage to the breaker resulting from internal arcing between the cylinder and piston Work with extra care when welding grinding or torch cutting near flammable objects Welding on painted surfaces releases dangerous fumes and results in a poor weld joint that can result in failure and potential accidents Always remove paint from areas to be welded Work on Painted Surfaces Heated paint emits poisonous gases Therefore paint must be removed from an area with a radius of at least 4 inches 10 cm before carrying out welding grinding or gas cutting In addition to health hazards the weld will be of inferior quality and strength if the paint is not removed Methods and precautionary measures when removing paint gt gt Blasting use respiratory protective equipment and protective goggles Paint remover or other chemicals use a portable air extractor respiratory protective equipment and protective gloves Grinding use a portable air extractor respiratory protective equipment and protective gloves and goggles 15 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Rubber and Plastics A WARNING When heated rubber and plastics can give off substances that are hazardous to personal health and the environment The following safety instructions must be followed gt Do not weld or cut with a torch near polymer materials plastics ur
63. rface 4 Clean inside of the housing Inspect for weld cracks damage etc inside and outside of the housing Repair as required 5 Clean and inspect the front head area of the bare breaker Clean and inspect the wear pads NOTE The upper lower isolators and wear pads are considered wear parts and are not covered under the breaker warranty It is recommended that they be replaced after every 1 000 hours of operation or as required Breaker Body Disassembly The breaker body can be disassembled standing up or laying down The following instructions describe the standing method A WARNING Release cushion chamber gas pressure before disassembly The cushion chamber in the back head contains nitrogen gas under pressure Do not remove the tie rod nuts or gas valve until this pressure is released A WARNING DO NOT use impact tools to disassemble or reassemble the breaker body The tie rods and control valve bolts use heliserts steel threaded inserts that can be 1 Back Head Charging Valve damaged by the use of impact tools 48 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Rear Head Removal 1 2 3 4 2 6 7 8 Use the charging hose in tool kit to fully vent the N2 gas from the cushion chamber Insert lifting eyes into the rear head and stand the breaker on a safety stand Remove the back head charging valve to avoid accidental damage during bushing replacement Put it in a safe place for reu
64. rts Check the following points in the table below before calling your ShearForce Equipment representative A slight amount of oil seepage around the breaker connecting parts is normal during the first 200 hours of operation Area of Leakage Probable Cause The space between the tool Damaged seals Re seal as necessary and the bushing Large amounts of oil coming out Oil over the surface of the Loose hydraulic hoses or Check condition of hydraulic breaker adapters hoses and adapters Tighten as necessary Joining surface of cylinder and Loose tie rod nut Damaged Tighten tie rod Replace rear head Oil oozing New oil O ring damaged O ring leaking Joining surface of cylinder and Loose plugs on face of Tighten loose plugs Replace front head cylinder Damaged seals damaged seals as necessary New oil leaking High low speed selector Loose locknut Tighten loose locknut Oil running down breaker Damaged O ring Replace damaged O ring 61 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Hydraulic Breaker Does not hammer Anti blank fire has activated Push breaker down on tool to disengage blank fire mode Base carrier selector valve does not operate Check connection from cab controls to correctly selector valve Poor performance of the hydraulic pump Check pump outlet Repair or replace Pressure relief valve set too low Check relief settings and adjust Clogged or restricted hoses Clean or re
65. s Follow these basic precautions gt Never adjust a pressure relief valve or other pressure limiting device to a higher pressure than specified gt Check to make sure hydraulic hoses are not worn or damaged and are routed to avoid chafing gt Replace any hydraulic hose immediately that shows signs of swelling wear leaks or damage before it bursts gt A Hydraulic fluid escaping under pressure can penetrate the skin causing serious injury Do not use your hand to check for hydraulic oil leaks use a piece of cardboard If skin penetration occurs seek medical attention immediately Relieve all pressure before disconnecting hoses gt Do not bend or strike high pressure lines tubes or hoses or reinstall them in a bent or damaged condition 13 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Precautions for Handling Hydraulic Oil AWARNING Risk of burns Use protective work gloves gt A Hot oil can cause painful burns Use caution when changing the hydraulic oil gt Oils can irritate and damage the eyes throat and other sensitive skin Avoid contact gt Petroleum based oils are hazardous to the environment Take special care not to spill or discharge these fluids Use approved containers and methods to handle and dispose of them gt Use an authorized disposal and recycling company Work Site Precautions A WARNING Know the location of any flammable gas lines in the construction area Damaged gas lines could
66. se later Back off the tie rod nuts a couple of turns This can be done using a torque multiplier if the breaker is standing up If the breaker is lying down use the sledge wrench method Using a hoist jerk the assembly upwards slightly which should loosen the rear head from the cylinder Place the rear head on a clean protective surface If the rear head is stuck it may be necessary to tap the cylinder cover on alternate sides with a soft faced mallet Remove the nuts and washers from the four tie rods Remove the rear head from the cylinder using lifting eyes l Lifting Eye 2 Back Head Charging Valve In some cases the nuts may be seized onto the tie rod and may come out as a unit Accumulator Removal AWARNING Release accumulator gas pressure before disassembly The accumulator contains nitrogen gas under pressure Do not remove the bolts until this pressure is released 1 Accumulator body bolt 2 Accumulator cover 3 Accumulator hex plug 4 O Ring 5 Accumulator cover bolt SHEARFORCE HYDRAULIC BREAKER USER S MANUAL AWARNING DO NOT use impact tools to remove the accumulator from the breaker body The accumulator mounting bolts use heliserts steel threaded inserts that can be damaged by the use of impact tools 1 Take an initial reading of the nitrogen gas pressure in the accumulator A higher than normal reading may indicate a problem AWARNING A gas pressure reading in the accumulator
67. se often Failure to lubricate regularly reduces the life of the tool bushings and front head If the tool becomes dry and shiny during the shift apply additional grease Automatic Greasing Systems A provision hole for automatic greasing systems is provided for SB50 and larger models When greasing with an automatic greasing system the grease should only be injected into the breaker when it s firing This will allow the breaker to consume the grease correctly Set the flow rate so there is a continuous new grease shine near the top of the tool coming from the breaker If the tool appears shiny the greasing flow rate may need to be increased This rate may change due to specific operating conditions 32 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Comparison of Automatic Lubrication Systems to Manual Lubrication gt Constant lubrication gt Inconsistent lubrication gt Lube while machine runs gt Cannot lubricate while operating gt Closed system no contamination gt Constant contamination gt Extended bearing life gt Premature bearing failure gt Less downtime gt Labor expense gt Quick payback on investment Seal and O Ring Since hydraulic breakers operate at high pressure and high temperature leakage or scratches could be results of friction wear and breakage of seals Poressure temperature viscosity of oil and a little leakage is accepted as normal But in case of abnormal leakage replace seals
68. t Keep tool well lubricated gt Operate properly and avoid excessive bending of the tool P or Lubrication S Pulling with Carrier Metal to metal contact causes material pick up that can scrape deep damage marks These will develop into fatigue cracks causing tool failure Ensure the tool shank is well lubricated before inserting into the tool holder Molybdenum disulfide grease or ShearForces own brand of Chisel Paste containing copper graphite and silica is recommended at two hour intervals gt Make sure tool is pushed up fully inside the breaker gt Grease until clean grease runs freely from cavities Corrosion Keep spare tools well greased and sheltered from the weather when not in use A rusty tool is more prone to fatigue failure 67 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Area of Typical Tool Failures NN Guide to Warranty Claims ShearForce tools are manufactured from top quality materials and heat treated to produce a fatigue and wear resistant tool When a tool fails to give satisfactory service life a brief visual 1 inspection usually reveals the cause P gt A tool metal fatigue failure generally occurs within 4 in 100 4 in mm above and below the face of the front head or at the 100 mm 3 retainer pin flat A in gt A less common failure area is about 8 in 200 mm from the 100 mm face of the front end depending on the work the breaker is doing Front Head Retainer Pin
69. t install the hydraulic adapters in the wrong port The pressure adapter has a smaller through hole than the tank adapter The cylinder is marked IN beside the pressure adapter and OUT beside the tank adapter 53 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Cylinder clean up Any slight galling and other irregularities on the cylinder wall must be removed before reassembly Use a cylinder hone to ensure the cylindricity of the bore is maintained After using a hone deburr the edges of the bore The preferred method to remove irregularities is to use a blade fixed type hone A second method is to use a flexible hone The amount of deburring required will be reduced with the flexible hone A die grinder should only be used for deburring edges and severe local points of galling If damage is too great call your ShearForce Equipment representative gt Check the slide areas A B and C for flaws If there are scuffing flaws finish the surface smooth with a cylinder hone gt If there are flaws in area D use 800 1200 grit emery cloth Never use a buffing grinder in this area Area E can be finished by buffing with a grinder Wash the parts after finishing them fnt 54 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL IMPORTANT When using a buffing grinder apply flap around the inside diameter of the part only If applied along the axis roundness will be affected Seal Bushing Inspection Clean and inspect the
70. t particles will cause damage to the internal workings of the breaker gt Install the breaker onto the carrier and reconnect the pressure and return lines Start up Air may have been introduced to the hydraulic circuit and may cause a malfunction Warm the carrier hydraulic system up to operating temperature then cycle the oil to remove the air 1 Lift the unit off the ground 2 Press the start button or pedal to fire the breaker momentarily On 3 Continue to turn the breaker ON and OFF in this manner alee hd aster Positi n for 10 minutes 4 Work the breaker in soft material in short bursts for 10 minutes 5 Check for any loose bolts or oil leakage The breaker is now ready to operate High Speed and Low Speed Valve Adjusting Valve Adjuster The manual High Low Speed Selecting Valve Adjuster is on upper right side on the Cylinder 2 Valve Adjuster Nut High Speed Stroke Setting 1 Turn the valve adjuster screw 1 three complete turns counter clockwise from normal factory setting 1 Valve Adjuster Low Speed Stroke Setting 1 Turn the valve adjuster screw 1 to bottom out tight If it is hard to turn the valve adjuster because the valve nut 2 is too tight please loosen the valve adjuster nut 2 slightly to make the valve adjuster turn easily 60 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Troubleshooting Guide Oil Leakage If oil leakage develops it may not be necessary to replace pa
71. tall the seals and rings into the grooves at the lower end of the cylinder 3 Lower the cylinder carefully onto the tie rods The control valve mounting holes on the cylinder must face the same direction as the grease fitting on the front head gt Pay close attention to the correct placement and orientation of the seals Improper seal installation will cause premature leakage and premature wear Seal Bushing Re sealing Ensure the bushing is clean and there are no burrs gt Oil the seal bushing and seals gt Install the seals and O rings in the correct positions and orientations 56 1 Lower Cylinder 2 Buffer Seal 3 U Packing 4 Dust Seal 6 Gas Seal 7 Step Seal 8 O ring 9 Back up ring SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Piston Installation 1 Lubricate the top end of the piston and slide the seal bushing into place with the chamber or step towards the center of the piston 2 Lift the piston with the lifting eye lubricate it thoroughly and lower it carefully into the cylinder It may need a tap to push it through the lower seals 3 When the piston is all the way into the cylinder bore use a soft mallet to tap the seal bushing into position in the cylinder The bushing will stop when it reaches the support flange on the front head Replace the O rings and back up rings on the top of the cylinder where the rear head makes contact Control Valve Installation The control valve is
72. te when the material will break Predicting this moment is probably best done by listening to the sound of the tool hitting the rock A change in the hammering sound is noticed as the tool breaks through This is the point to stop firing the breaker 26 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Breaking Oversize Material With practice the best place to begin breaking will be learned by just looking at the rock gt Position the tool on flat areas of the rock or look for a seam or crack which may allow easier splitting gt To fully absorb all of the breaker s energy make sure the rock is resting on a solid base Trenching and Excavation Before trenching remove all top level material exposing the rock surface to be broken gt To begin penetrate the breaker tool deep into the material splitting and loosening the rock gt Repeat this penetration several times within a small area excavating a hole When excavating a deep trench it is more effective to use steps or benches allowing a place for the rock to break out to gt Maintain the benches as the trench advances gt Slope the sides of the trench to accommodate the width of the breaker The larger the breaker and the deeper the trench the wider the opening at the top will need to be gt For most situations the excavator will sit to the side of the trench allowing you to keep steeper slopes However the carrier swing function may not have the strength to push
73. tion gt Danger of cavitation in the pumps gt Accelerated wear of pumps and breaker gt Sticky valves gt Filter bypasses oil impurities not removed contamination in hydraulic tank Thin oil may cause gt Efficiency losses internal leakage gt Breaker strikes slowly and irregularly gt Damage to gaskets and seals leaks gt Accelerated wear of parts from decreased lubrication Hydraulic Oil Purity It is beneficial for the tank return line to pass through a filter This ensures dirt introduced into the system by connecting and disconnecting the breaker is caught before entering the carrier s pump Dirt destroys the hydraulic system so ensure the breaker hose connections are protected when the breaker is not in use Impurities also heat and age the hydraulic oil Air and water are also considered impurities in oil not all impurities can be seen with the naked eye Impurities can enter the hydraulic system gt When components are repaired or serviced gt During hydraulic oil changes and refilling SHEARFORCE HYDRAULIC BREAKER USER S MANUAL gt gt When the breaker is operated with worn cylinder and seals When hoses are disconnected during breaker removal installation Results of damage by hydraulic oil impurity gt Working life of pump s significantly shortened rapid wear of parts and corrosion gt Valves do not function properly spools bind accelerated wear of parts blocking of small h
74. ve 9 Close the accumulator charging valve 12 10 Loosen the relief valve of the 3 way valve assembly to discharge the N2 gas remaining in the charging hose 11 Remove the charging hose 3 way valve assembly and bushing and tighten the plug 9 and cap 11 41 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Nitrogen Charging Pressure vs Ambient Temperature Conversion table for charging The following table is a guide to accumulator pressure values N gas pressure to accumulator J gt bats G Mate L3 c am me 3 ACC i Oo D ale pt A5 adjusted to ambient temperature differences gt Allow the hydraulic breaker and the nitrogen bottle temperatures to normalize to room temperature in a 80 shop environment gt Adjust the accumulator and cushion chamber pressure as indicated in the tables below for the 40 ambient temperature expected N gas sealing pressure kg cm Cc e Accumulator Surface Temperature C 42 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Maintenance Schedule Pre Shift Verify correct operation of all machine functions Check for leaks damaged hoses or clamps Check that all electrical components are in operational condition Grease the breaker tool retainer pins and plugs with Chisel Paste If equipped with auto lube system ensure there is adequate grease in the reservoir Verify correct oper
75. w 1 Install an in line flow meter in place of the breaker 2 Adjust the flow on the flow control valve to the maximum permitted for the breaker The highest flow will permit the most blows per minute 3 Ensure the flow is within the permitted range Setting the Relief pressure 1 Connect a flow and pressure meter in place of the breaker Bypass the hydraulic breaker and route the return line directly to the tank 2 Measure the flow under no load and verify it is in the range for the breaker 3 Slowly increase the pressure and at the same time verify the flow remains constant right up to the predetermined relief setting 21 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL 4 Adjust accordingly Double check both relief pressure and flow settings 5 When the breaker is installed and the oil is warmed to operating temperature use a pressure gauge in the pressure line to verify the average operating pressure is within the specification Start up Before putting the breaker to work in hard material it is necessary to remove air from the hydraulic system and allow the new seals to work in properly 1 Lift the breaker unit off the ground 2 Press the start button or pedal to fire the breaker momentarily 3 Continue to turn the breaker ON and OFF in this manner for 10 minutes 4 Work the breaker in soft material in short bursts for 10 minutes 5 Check for any loose bolts or oil leakage The breaker is now ready to operate On new
76. y valve assembly 9 Push the handle of the 3 way valve assembly fully and the gas pressure inside the Back Head is indicated on the pressure gauge When the pressure is higher discharge a small amount of gas from the Back Head by repeatedly opening and closing the valve and the gas pressure falls to the specified pressure 10 When the gas pressure reaches the specified pressure close the valve and release the handle 11 Open the valve completely and discharge gas inside the 3 way valve assembly Remove the 3 way valve assembly from the charging valve of Back Head and install the plug to the charging valve 39 SHEARFORCE HYDRAULIC BREAKER USER S MANUAL Nitrogen Charging Pressure vs Conversion table for charging Ambient Temperature N gas pressure to back head l 22 ap The following table is a guide to back head cushion chamber e pressure values adjusted to ambient temperature differences 5 LT O 20 ee ee a gt Allow the hydraulic breaker and the nitrogen bottle PM s cet G temperatures to normalize to room temperature in a shop o 18 4 ad se aet T environment 17 L T eg e beet gt Adjust the cushion chamber pressure as indicated in the 2 16 fe table below for the ambient temperature expected S 15 i o 14 anl Z 12 11 Accumulator Gas Pressure Checking 0 2 40 60 80 Back Head Surface Check accumulator gas pressure every 500 hours of operation Temperature C

Sizing the Hydraulic Breaker

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