Vulcan Attachments V3GS Manual
Hydraulic Breaker
Vulcan V3GS
Operation
&
Maintenance Manual
1
CONTENTS
1. Specifications
1.1 General specifications for the V3GS
1.2 Tool specification
1.3 Structure
2. Operation
2.1 Product numbers
2.2 Tool Selection
2.3 Breaking Principles
2.4 Correct working methods
2.5 Operating Temperature
2.6 Important Operation Points
2.7 Storage
2.8 Mounting and Dismounting the Hammer
2.9 Operation Pressure Settings
2.10 Hose and Pipe Specification
2.11 Hydraulic Circuit
3. Lubrication
3.1 Manual Lubrication
3.2 Hydraulic Oil
4. Maintenance
4.1 Removal and Installation of Tools and Tool Bushings
4.2 Wear Limits of Tools and Tool Bushings
4.3 Disassembling and Assembling the Hammer Assembly
4.4 Disassembling and assembling the back head
4.5 Nitrogen gas charging device and method
4.6 Loosening and tightening side rods
4.7 Torques
4.8 Workshop tool list
2
CONTENTS
5. Troubleshooting Guide
5.1 Oil leakage
5.2 Irregular blows after normal beginning
5.3 No Impact
6. Generals and Safety Information
6.1 General
6.2 Safety
7. Parts List
7.1 Housing
7.2 Hammer Assembly
3
1Specifications
1.1 General specifications for the V3GS (Box)
Item
Specifications
Working weight
170 kg (374 lb)
Impact frequency
600 ~ 1000 bpm
Operating pressure
90 ~ 120 bar (1300 ~1740 psi)
Relief pressure
140 ~ 160 bar
Oil Flow
20 ~ 40 l/min (5.3 ~ 10.5 gpm)
Back pressure
10 bar (145 psi)
Tool diameter
53 mm (2.08 in)
Oil temperature
-20 ~ +80 °C (-4 ~ +176 °F)
Hydraulic oil viscosity
1000 ~ 15 cSt (131 ~ 2.35 °E)
Pressure line size
12 mm (½in)
Return line size
12 mm (½in)
Back head pressure
16 bar (230 psi)
Carrier weight
2.0 ~ 3.5 ton
4
1.2 Tool specifications for the V3G
Name
Length
mm (in)
Weight
kg (lb)
Diameter
mm (in)
Notes
Cone tool
(A)
500(19.69)
7.3(16.1)
53(2.09)
Chisel tool
(B)
500(19.69)
7.3(16.1)
53(2.09)
Blunt tool
(C)
500(19.69)
7.3(16.1)
53(2.09)
Moil tool
(D)
500(19.69)
7.3(16.1)
53(2.09)
5
1.3 Structure
1) SIDE ROD
The front head, cylinder and the back head of the breaker body are secured with four side
rods.
2) BACK HEAD
The gas charging valve is built in and charged with N2gas to improve the hammering power.
3) CONTROL VALVE
The control valve is built into the cylinder and it controls the piston‟s hammering action.
4) CYLINDER
The cylinder is the heart of the breaker body.
5) PISTON
The kinetic energy of the piston is converted into hammering energy when the piston hits the
tool; this consequently breaks the material.
6) FRONT HEAD
The front head supports the entire breaker with the thrust ring and the built in upper bushing
protects the carrier from the shock transmitted by the tool.
7) TOOL
The cone, chisel, blunt and moil tools are used for breaking different types of material.
6
2. Operation
2.1 Product numbers
The serial number is stamped on the back head.
It is important make correct reference to the serial number of the attachment when making
repairs or ordering spare parts. Identification of the serial number is the only proper means of
identifying parts for each specific unit.
2.2 Tool Selection
Vulcan Attachments offers a wider selection of
standard and special tools to suit your every
need. The correct tool should be selected for
each application to ensure you are getting the
best possible results and the longest working life
of your tool.
1) Blunt
For igneous (e.g. granite) and tough
metamorphic rock (e.g. gneiss) into which
the tool does not penetrate.
Concrete.
Boulders.
2) Chisel, cone, and moil
For sedimentary (e.g. sandstone) and
weak metamorphic rock into which the
tool can penetrate.
Concrete.
Trenching and benching.
2.3 Breaking Principles
There are two general ways of breaking with
a gas-type breaker.
1) Penetrative (or cutting) breaking
In this form of breaking the cone point or
chisel tool is forced inside of the material.
This method is most effective in soft,
layered, low abrasive, or plastic material.
2) Impact breaking
In impact breaking, the material is broken by
transferring very strong mechanical stress
from the tool into the material.
The best possible energy transfer between
the tool and the object is achieved with a
blunt tool.
Impact breaking is most effective in hard,
brittle and very abrasive materials.
a
2.4 Correct working methods
1) Prepare the carrier as you would for normal
excavation work.
a. Move the carrier to work location.
b. Engage the parking brake.
c. Put the carrier in neutral gear.
d. Disengage the boom lock (if fitted).
2) Set the engine speed to the recommended
engine RPM.
3) Place the tool against the object at a 90°
angle.
a. Avoid small irregularities on the object
which will break easily and cause either
idle strokes or incorrect working angles.
b. Incorrect working methods may cause
failure in the operation of the breaker or the
housing.
4) Use the excavator boom to press the breaker
tool firmly against the object.
a. Do not use the breaker tool as a pry bar to
pry the breaker with the boom.
b. Do not press down too much or too little
with the boom.
5) Start the breaker.
6) Do not let the tool move outwards from the
breaker when it penetrates.
* Feed the breaker at all times with the
excavator boom.
7) Keep the tool at 90° at all times.
a. If the object moves or its surface breaks,
correct the angle immediately.
b. Keep the feed force and tool aligned.
8) Stop the breaker quickly.
a. Do not allow the breaker to fall off the
object or make idle strokes when the object
breaks. Constant idle strokes have a
deteriorating effect on the breaker.
b. If the breaker falls off the object ,side
pressure could occur, and side plates will
be worn down more quickly
9) Chisel, cone, and moil
If the object does not break after fifteen
seconds, stop the beaker and change the
position of the tool. Leaving the tool in the
same position for more that fifteen seconds
will only make an indentation, which will fill
with dust and dampen the impact effect. This
will cause the tool to overheat.
10) When breaking concrete, hard ground, frozen
ground, or any similar material, never strike and
pry with the tool at the same time. This could
break the tool.
2.5 Operating Temperature
The operating temperature is -20°C~80⁰C. If the
temperature is lower than -20°C (-4°F), the
breaker and tool must be preheated before
starting to operate, in order to avoid breakage of
the accumulator membrane and the tool.
During operation they will remain warm.
2.6 Important Operation Points
a. Listen to the breaker‟s sound while you are
working.
If the sound becomes thinner and the impact
is less efficient, the tool is misaligned with
the material and/or there is not enough
“pressing” force on the tool.
Realign the tool and press the tool firmly
against the material.
b. The breaker, as a standard assembly must
not be used underwater.
If water fills the space where the piston
strikes the tool, a strong pressure wave is
generated and the breaker could be
damaged.
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