BREAKER
TABLE OF CONTENTS
FOREWORD WS 88
ESSENTIAL EQUIPMENT WS 89
ENVIRONEMENT WS 90
SEALS PACKAGE WS 91
WS 87 2010
FOREWORD
The contents of this manual are considered
to be proprietary and confidential for the
manufacturer and should not be reproduced
without the prior written permission of the
manufacturer.
WS 88
ESSENTIAL EQUIPMENT
Travelling crane
(mini 3,5 tons) Crane jib
Hydraulic press
(50 tons) Nitrogen bottle
Blackboard
Washbasin
Bench
(hard rubber)
Support
WS 89
Operators and service personnel must
wear appropriate safety equipment,
including hearing protection, respirator,
hardhat, safety shoes, eye protection,
heavy gloves etc......
OK
Always use clean tools for
maintenance work or inspection.
OK
OK
All damaged parts , seals spoiled
or used must be thrown in the
dustbin.
WS 90
86694171
86714748
86706405 86694163
86706371 86694155
86706389
86706397
86240389
86718103
86724754
86709383
86709383
86703758
86703758
WS 91 DOOSAN
DXB190 06 / 2011
DISMANTLING
IMPORTANT !
Take the
nitrogen out.
DOOSAN WS 92
06 / 2011 DXB190
DISMANTLING
Center of gravity
860
1655 daN
1 Sling and lift the breaker.
WS 93 DOOSAN
DXB190 06 / 2011
DISMANTLING
200 840
DOOSAN WS 94
06 / 2011 DXB190
DISMANTLING
WS 95 DOOSAN
DXB190 06 / 2011
DISMANTLING
DOOSAN WS 96
06 / 2011 DXB190
DISMANTLING
WS 97 DOOSAN
DXB190 06 / 2011
DISMANTLING
DOOSAN WS 98
06 / 2011 DXB190
DISMANTLING
M20
946 daN
WS 99 DOOSAN
DXB190 06 / 2011
DISMANTLING
6,9 daN
150 daN
DOOSAN WS 100
06 / 2011 DXB190
DISMANTLING
M20
796 daN
WS 101 DOOSAN
DXB190 06 / 2011
DISMANTLING
DOOSAN WS 102
06 / 2011 DXB190
DISMANTLING
M20
97 daN
WS 103 DOOSAN
DXB190 06 / 2011
DISMANTLING
DOOSAN WS 104
06 / 2011 DXB190
DISMANTLING
101 daN
WS 105 DOOSAN
DXB190 06 / 2011
DISMANTLING
DOOSAN WS 106
06 / 2011 DXB190
DISMANTLING
3 4 1
2
1
3
2
35 Mark each side rod, nut, and their mounting position in the
front guide and the cylinder.
--- Rod 1, Nut 1, Hole 1.........
3 1
3 1
2
2
WS 107 DOOSAN
DXB190 06 / 2011
DISMANTLING
2
3
9 daN
1
In case of seizing
WS 109
DOOSAN WS 108
06 / 2011 DXB190
DISMANTLING
35
37 By drilling.
60
Ø 12
38 By cutting.
Ø 230
22
WS 109 DOOSAN
DXB190 06 / 2011
DISMANTLING
H M6
DOOSAN WS 110
06 / 2011 DXB190
DISMANTLING
M20
245 daN
WS 111 DOOSAN
DXB190 06 / 2011
DISMANTLING
27
DOOSAN WS 112
06 / 2011 DXB190
DISMANTLING
WS 113 DOOSAN
DXB190 06 / 2011
DISMANTLING
M20
253 daN
DOOSAN WS 114
06 / 2011 DXB190
DISMANTLING
WS 115 DOOSAN
DXB190 06 / 2011
DISMANTLING
T1 Page : WS 269
T2 Page : WS 269
DOOSAN WS 116
06 / 2011 DXB190
DISMANTLING
23 daN
Page : WS 268
38
WS 117 DOOSAN
DXB190 06 / 2011
DISMANTLING
T3 Page : WS 269
Page : WS 268
OR
DOOSAN WS 118
06 / 2011 DXB190
INSPECTION
Strike piston
WS 119 DOOSAN
DXB190 06 / 2011
INSPECTION
OK
351,5
New
DOOSAN WS 120
06 / 2011 DXB190
INSPECTION
Distributor
Distribution box
Lower bushing
OK
Ø 143
OK
Ø 148
OUT OF USE
WS 121 DOOSAN
DXB190 06 / 2011
INSPECTION
Upper bushing
205,48
New
202,5
New tool
DOOSAN WS 122
06 / 2011 DXB190
INSPECTION
Retaining pin
OK
41
45 43
180°
New
= =
WS 123 DOOSAN
DXB190 06 / 2011
ASSEMBLING
DOOSAN WS 124
06 / 2011 DXB190
ASSEMBLING
Down
Up
45°
FRONT GUIDE
BUSHING HOLES
WS 125 DOOSAN
DXB190 06 / 2011
ASSEMBLING
M20
DOOSAN WS 126
06 / 2011 DXB190
ASSEMBLING
253 daN
WS 127 DOOSAN
DXB190 06 / 2011
ASSEMBLING
3
3 1
1
2
OK
DOOSAN WS 128
06 / 2011 DXB190
ASSEMBLING
300 Nm
WS 129 DOOSAN
DXB190 06 / 2011
ASSEMBLING
Oil
DOOSAN WS 130
06 / 2011 DXB190
ASSEMBLING
245 daN
WS 131 DOOSAN
DXB190 06 / 2011
ASSEMBLING
Oil
DOOSAN WS 132
06 / 2011 DXB190
ASSEMBLING
AIR
Oil
WS 133 DOOSAN
DXB190 06 / 2011
ASSEMBLING
DOOSAN WS 134
06 / 2011 DXB190
ASSEMBLING
WS 135 DOOSAN
DXB190 06 / 2011
ASSEMBLING
UP
Grease
DOWN
DOOSAN WS 136
06 / 2011 DXB190
ASSEMBLING
UP
WS 137 DOOSAN
DXB190 06 / 2011
ASSEMBLING
M20
Oil
DOOSAN WS 138
06 / 2011 DXB190
ASSEMBLING
97 daN
36 Oil.
Oil
OK
Oil Oil
WS 139 DOOSAN
DXB190 06 / 2011
ASSEMBLING
2
3
9 daN
1
3 1
2
3
1
2
DOOSAN WS 140
06 / 2011 DXB190
ASSEMBLING
Do not use a hammering wrench.
WS 141 DOOSAN
DXB190 06 / 2011
ASSEMBLING
EM10
Grease
3 1
2
43 Mount each nut in its original position and in
correspondance with number on the back head.
3 1
2
DOOSAN WS 142
06 / 2011 DXB190
ASSEMBLING
1
2
Contact!
Get free!
WS 143 DOOSAN
DXB190 06 / 2011
ASSEMBLING
No
No
OK
DOOSAN WS 144
06 / 2011 DXB190
ASSEMBLING
No
No
OK
WS 145 DOOSAN
DXB190 06 / 2011
ASSEMBLING
3 1 400 Nm
2
DOOSAN WS 146
06 / 2011 DXB190
ASSEMBLING
4
35
3 1
Anticlockwise
360°
52 Check that the tie rod do not touch the front guide.
Clearence
200 Nm
WS 147 DOOSAN
DXB190 06 / 2011
ASSEMBLING
Mark
Make a mark on one of faces of each nut, on the
54 back head and on the tool socket.
DOOSAN WS 148
06 / 2011 DXB190
ASSEMBLING
3 1
Tighten in 2 steps
1---Pre---constraint
55 Tighten in a criss---cross pattern the 4 nuts for 1 flat.
Before
After
WS 149 DOOSAN
DXB190 06 / 2011
ASSEMBLING
4
2---Finition
3 1
56 Tighten in a criss---cross pattern the 4 nuts for
2 2 flats + 5 mm.
2 fats
+ 5mm
--- 5 mm
DOOSAN WS 150
06 / 2011 DXB190
ASSEMBLING
WS 151 DOOSAN
DXB190 06 / 2011
ASSEMBLING
796 daN
840
DOOSAN WS 152
06 / 2011 DXB190
ASSEMBLING
326 daN
WS 153 DOOSAN
DXB190 06 / 2011
ASSEMBLING
321 daN
DOOSAN WS 154
06 / 2011 DXB190
ASSEMBLING
EM10
Grease
WS 155 DOOSAN
DXB190 06 / 2011
ASSEMBLING
38
350 Nm
DOOSAN WS 156
06 / 2011 DXB190
ASSEMBLING
Top plate tightening procedure
6 2 8 4
5 3 7 1
600 Nm
Mark
WS 157 DOOSAN
DXB190 06 / 2011
ASSEMBLING
After Before 6 2 8 4
5 3 7 1
2nd Cycle
After
6 2 8 4
Before
5 3 7 1
OK
The nut mark must be in line with the plate mark.
DOOSAN WS 158
06 / 2011 DXB190
ASSEMBLING
WS 159 DOOSAN
DXB190 06 / 2011
ASSEMBLING
150 daN
Grease
DOOSAN WS 160
06 / 2011 DXB190
ASSEMBLING
WS 161 DOOSAN
DXB190 06 / 2011
ASSEMBLING
STROKE ADJUSTMENT
High frequency
1
21
2
OR 100 Nm
1 Low frequency
3/16”
100 Nm
DOOSAN WS 162
06 / 2011 DXB190
INFLATING PROCEDURE
IMPORTANT !
NITROGEN ONLY
Before inflating :
The strike piston must be imperatively in
down position, the tool (rod) must not
push the piston upward (contact) or,
dismantle the tool (rod).
WS 249 DOOSAN
DXB190 06 / 2011
INFLATING PROCEDURE
DOOSAN WS 250
06 / 2011 DXB190
INFLATING PROCEDURE
3/16”
DANGER !
The back head is full of nitrogen.
WS 251 DOOSAN
DXB190 06 / 2011
INFLATING PROCEDURE
24
DOOSAN WS 252
06 / 2011 DXB190
INFLATING PROCEDURE
10 bar
9 Adjust the pressure to 10 bar.
WS 253 DOOSAN
DXB190 06 / 2011
INFLATING PROCEDURE
DOOSAN WS 254
06 / 2011 DXB190
INFLATING PROCEDURE
16 bar
16 Adjust until the specified pressure.
See TABLE (pressure according
to the temperature).
WS 255 DOOSAN
DXB190 06 / 2011
INFLATING PROCEDURE
3 mn
17 Wait 3 mn to stabilyze the
pressure.
DOOSAN WS 256
06 / 2011 DXB190
INFLATING PROCEDURE
WS 257 DOOSAN
DXB190 06 / 2011
INFLATING PROCEDURE
25 Clean correctly.
3/16”
37 Nm
DOOSAN WS 258
06 / 2011 DXB190
INFLATING PROCEDURE
3/16”
DANGER !
The back head is full of nitrogen.
WS 259 DOOSAN
DXB190 06 / 2011
INFLATING PROCEDURE
15
DOOSAN WS 260
06 / 2011 DXB190
INFLATING PROCEDURE
WS 261 DOOSAN
DXB190 06 / 2011
INFLATING PROCEDURE
11 Turn off the nitrogen bottle plug cock.
+
+
DOOSAN WS 262
06 / 2011 DXB190
INFLATING PROCEDURE
3 mn
WS 263 DOOSAN
DXB190 06 / 2011
INFLATING PROCEDURE
DOOSAN WS 264
06 / 2011 DXB190
INFLATING PROCEDURE
WS 265 DOOSAN
DXB190 06 / 2011
INFLATING PROCEDURE
29 Clean correctly.
3/16”
37 Nm
DOOSAN WS 266
06 / 2011 DXB190
INFLATING PROCEDURE
BACK HEAD INFLATING TABLE
(depend of the temperature of the back head surface)
Temperature in ° C -- 20 -- 10 0 10 20 30 40 50 60 70
A A
B B
C C
WS 267 DOOSAN
DXB190 06 / 2011
TOOLING
86693983 86485802
ORFS
86718590
M 20 HM6
86677846
Ø 25 -- lg : 250 mm
86705332
86704624
86697851
86626017
1’’
1’’ 1/2
70 86697844
DOOSAN WS 268
06 / 2011 DXB190
TOOLING
T1
Ø 238 ' 240
T2
Ø 300 ' 350
800
T3 58
70¦ 5 138
WS 269 DOOSAN
DXB190 06 / 2011
TOOLING
Support
To make
Ø 132
U : 175 x 70
Ø 135
100 4 x Ø 30
200
270
600
600
DOOSAN WS 270
06 / 2011 DXB190
TOOLING
86697943
To order
Ø 132
90
+0,2
Ø 95,2 0
Ø 135
100
0
--- 0,2
Ø 95
WS 271 DOOSAN
DXB190 06 / 2011
BREAKER