HYDRAULIC BREAKERS - Gearmore

1 HYDRAULICBREAKERSS ervice ManualFor ModelsG10, G20, G30, G40,G50, & G60 June 2007 Form: OF CONTENTSSECTIONDESCRIPTION PAGE1 Introduction .. Number Location .. 12 Safety .. Safety .. 33 Specifications .. Machine Weights .. Specifications .. 44 Structural Layout .. Layout Drawing .. Description .. Principles of BREAKERS .. Stroke of Piston .. Stroke of the Valve Spool .. Stroke .. Stroke of the Valve Spool .. 75 Nitrogen Gas Chargins .. the Gas Pressure .. Nitrogen Gas Pressures .. the Gas Pressure .. Charging Procedure .. 96 Maintenance & Inspection .. Item List .. Inspection .. Bolts .. of HYDRAULIC Hose .. & Deformation of breaker Tool .. of breaker Tool .. of HYDRAULIC Oil .. on Nitrogen Gas Pre-Charge.

2 Limits Between Tool & Bushing .. Bolts .. Tie Rods .. Rod Replacement .. breaker .. Hoses & Fittings .. Oil Changing Intervals .. HYDRAULIC Oil & Grease .. Oil .. Storage of Seal Kits .. of HYDRAULIC BREAKERS .. 157 Troubleshooting Guide .. Leaks .. Leaks .. breaker Problems .. 188 Replacing breaker Seals .. 189 Rebuilding HYDRAULIC The Main Cylinder Body .. the Valve Housing .. 23-251 INTRODUCTIONThis service manual should provide service personnel with instructions necessary for servicing andmaintaining Gearmore HYDRAULIC any additional information or for help with any complicated problems encountered, please contact yournearest authorized Gearmore repairs or replacement of component parts are required only genuine Gearmore parts should beused.

3 Use of non-genuine parts may cause the breaker to work improperly and performance of the machinemay be seriously affected. Please note Gearmore will not warrant replacement parts that are not supplied SERIAL NUMBER LOCATIONA lways give your dealer the serial number of your HYDRAULIC breaker when ordering parts or requestingservice or other serial number plate is located where indicated. Please mark the number in the space provided for OF PURCHASE: _____MODEL NUMBER: _____SERIAL NUMBER: _____serial numberplate2 SAFETYSAFETY ALERT SYMBOLWhy is SAFETY important to you?The Safety Alert symbol identifiesimportant safety messages on theTandem Discs and in the you see this symbol, be alertto the possibility of personal injuryor death. Follow the instructionsin the safety Safety Alert symbol meansATTENTION!

4 BECOMEALERT! YOUR SAFETY ISINVOLVED!Accidents Disable and KillAccidents CostAccidents Can Be Avoided3 Big ReasonsDANGER -Indicates an imminently hazardoussituation that, if not avoided, will resultin death or serious injury. This signalword is to be limited to the mostextremesituations typically formachine components which, forfunctional purposes, cannot be -Indicates a potentially hazardoussituation that, if not avoided, couldresult in death or serious injury, andincludes hazards that are exposedwhen guards are removed. It mayalso be used to alert against -Indicates a potentially hazardoussituation that, if not avoided, mayresult in minor or moderate may also be used to alert againstunsafe WORDS:Note the use of the signal words DANGER,WARNING and CAUTION with the safetymessages.

5 The appropriate signal word foreach message has been selected using thefollowing guide-lines:SI NO LEE INGLES, PIDA AYUDAA AIGUIEN QUE SI LO LEA PARAQUE LE TRADUZCA LASMIDIDAS DE you have any questions not answered in this manual or require additional copies or the manual isdamaged, please contact your GENERAL SAFETYIMPORTANT SAFETY INFORMATION WHEN USING OUR HYDRAULIC and service personnel must read and thoroughly understandthis operators manual before using your Gearmore all people clear of breaker while in not operate the breaker without suitable shielding between the breakerand the operator to protect the operator from flying TO PREVENT INJURY OR DEATH, do not disassemble a breaker beforedischarging the nitrogen gas not hardface or sharpen a tool with a cutting torch.

6 Excessive heat fromtorching or welding causes embrittlement breakage, and flying only with a lathe or milling machine using sufficient extend tool while charging the breaker with nitrogen. STAY CLEAROF TOOL WHILE precharging the Gearmore HYDRAULIC breaker use nitrogen gas not operate the breaker unless the operator is in full control of the the breaker from the operators seat safety decals are provided with each breaker . Keep them clean andvisible. Gearmore will provide decals free of charge as is very important to have compatibility between the breaker and themachine. Please refer to the Recommended Machine Weight section of the proper lifting equipment and tools when handling or servicing thebreaker or any of it's ear protection if conditions personnel must take care handling pins and bushings whenexchanging the bucket for the breaker .

7 The machine operator must movethe arm or boom only when directed by service it is necessary to hammer the pins in or out, beware of flying metal protection should be not make any alterations to the Gearmore BREAKERS . Only trained servicepersonnel must make replacement parts only sold by MACHINE WEIGHTSM achine weight ranges are intended as a guideline only. Other factors, such as arm length, counterweights,undercarriage, etc., must be taken into A breaker THAT IS TOO HEAVY FOR THE MACHINECAN BE DANGEROUS AND A breaker THAT IS TOO SMALL FOR THE MACHINECAN DAMAGE THE breaker AND VOID THE WARRANTYBREAKER MODELRECOMMENDED MACHINE WEIGHT RANGEG10 .. 1560 to 2250 .. 2250 to 6750 .. 4450 to 8890 .. 5600 to 11,000 .. 8200 to 16,800.

8 9000 to 18,700 SPECIFICATIONSB reakerOperatingRequired Oil Blows PerNitrogenOverallOverallModelPressureFl owsMinutePressureWeightLength(psi)(gal / min)(bpm)(psi)(Lbs)(Inches)G1015254-7650 - 110029016842G2013505-10650 - 115033022046G3016008-13700 - 125033030351G4016508-16550 - 125029050557G50170012-21650 - 140029057560G60180014-26550 - 120036072563 Please note working weights may vary with bracket/side plate configuration. Specifications subject tochange without STRUCTURAL LAYOUT OF Gearmore LAYOUT DESCRIPTIONThe Gearmore HYDRAULIC breaker consists primarily of the cylinder section and main valve cylinder section consists of the chisel, chuck housing, tool retainer, impact ring, piston, cylinderbushings, main cylinder body, and head cap.

9 These are secured with tie rods. The piston reciprocateswithin the cylinder bushing, striking the chisel end. The impact ring fixes the relative position betweenthe piston and chisel. The head cap is charged with nitrogen gas through an valve housing contains the plunger and valve spool and is fixed from both sides with the upper valveend and lower valve end. The plunger reciprocates within the upper valve end, forcing down the mainbody. The valve spool reciprocates within the valve liner, switching over the oil PRINCIPLES OF HYDRAULIC BREAKERS2 LIFT STROKE OF MAIN VALVE3 I MPACT STROKEC2C35C424 OUTINPISTONCHISEL1 LI FT STROKE OF PI STONC3C2 MAI N VALVE16 INC1NI TROGEN GASC4 PLUNGER234 OUT4 DOWN STROKE OF MAI N VALVEC2C3C1 OUTINC4C3 MAI N VALVEINC4 OUTPLUNGER3 LIFT STROKE OF PISTONLIFT STROKE OF MAIN VALVEIMPACT STROKEDOWN STROKE OF MAIN LIFT STROKE OF PISTONAs the control valve is opened, the IN port is opened to allow the high-pressure oil to act on the chamber(C3) and top of the plunger.

10 The action of the plunger forces the valve spool against the bottom plate. Sincethe plunger cannot move any further the oil can only act on the piston. The piston is forced up, overcomingthe nitrogen gas pressure. At this time the oil in the chamber (C2) is forced through the OUT LIFT STROKE OF THE VALVE SPOOLAs the piston lifts and the chamber (C3) is opened to the oil passage (3), oil flows into the chamber (C4).Since the sectional area of the chamber (C4) is larger than that of the plunger, the up force overcomes theplunger s down force and the valve spool is moved IMPACT STROKEWith the valve spool rising, the oil passage (1) is opened to the oil passage (6) so that the nitrogen gaspressure pushes down the piston. When the oil passage (1) is totally opened to the oil passage (6), the routebetween the oil passage (1) and the IN port is shut off while the route between the oil passage (2) and INport is opened.