SECTION IV

MAINTENANCE

Revised: August 2018

Section IV - Page # 1
LONG TERM STORAGE MORE THAN THREE (3) WEEKS

 Place breaker onto blocks with the top of the breaker elevated.

 Remove the working steel (Refer to the Working Steel section of this manual)
and apply rust preventive oil to the inside of the breaker.

 Remove the plug from the backhead charge port and discharge the gas.

 Push the piston completely into the cylinder, this will prevent the piston
from rusting.

 It is recommended that the breaker be stored indoors, in a dry, warm

environment, but if that is not possible, store the breaker on a raised
platform and cover it with a water-proof cloth, secured so as to protect it
from wind and rain.

Section IV - Page # 2
 DAILY BREAKER INSPECTION

BEFORE OPERATING THE BREAKER: CHECK FOR LOOSE, MISSING OR

DAMAGED BOLTS, NUTS, VALVES, FITTINGS & HOSE WHIPS.

Section IV - Page # 3
 Maintenance Schedule
Daily - Every 8 hours
Grease breaker every 2-3 hours, grease more frequently if needed. (Do not over-load the tool
with grease)
(10-20 Shots with 0.9 cc/stroke grease gun; See Section IV page 7, for recommended
Grease)
Check for loose, missing or damaged bolts, nuts, valves, charge port plugs & caps.
Check the hydraulic hoses and fittings for leaks or damage.
Check for oil leaking around the working steel.
Check for loose or missing rubber plugs and caps.

Weekly - Every 50 hours

Check hydraulic oil level in the carrier's reservoir.
Check torque on all bolts, nuts plugs, caps and valves.
Check the working steel for cracks and/or other damage.

Monthly - Every 150 hours

Check front bushing for wear.
(See Section V page 2, for procedure)
Remove the rod pins and working steel, inspect the wear surfaces. Remove burrs.
(See Service Manual for detailed instructions)
Check backhead charge.
(See Section IV page 8, for charging procedure)
Check the operating pressure and change the carriers return filter.
(See section II for detailed instructions)

Section IV - Page # 4
Semi Annual - Every 600 hours
Check the hydraulic oil condition and change the carriers return filter.
(See Section IV page 8, for procedure)
Replace rod and stop pins. (See Section V page 4, for procedure)

Annual - Every 1200 hours

Disassemble and reseal breaker.
(See Service Manual for detailed instructions)
Check piston, liner, valve & seal retainer for wear.
(See Service Manual for detailed instructions)
Check the front bushing for wear.
(See Service Manual for detailed instructions)
Replace the backhead bolts.
(See Service Manual for detailed instructions)
Check all bolts and nuts for damage.

Section IV - Page # 5
 HYDRAULIC FLUIDS and GREASES
The life-blood of the breaker is the hydraulic oil. In order to maintain peak
performance from the breaker, it is essential to use the correct oil as well as
maintain a clean hydraulic system.

SELECTION OF HYDRAULIC OIL

To select the proper oil, refer to the following table:

ISO VG 68 ISO VG 46
MANUFACTURER ( HOT WEATHER ) (COLD WEATHER) ( EXTREME COLD )
SHELL TELLUS S2 MX 68 TELLUS S2 MX 46
ESSO NUTO H68 NUTO H46
MOBIL DTE 26 DTE 25 DTE 13
** NOTE: IF A PHOSPHATE ESTHER FLUID IS USED, SPECIAL SEALS ARE
REQUIRED. CONSULT YOUR FURUKAWA ROCK DRILL USA
REPRESENTATIVE.

HYDRAULIC OIL CONTAMINATION

Oil contamination can result in malfunctions and unsatisfactory

performance of both the hydraulic breaker and the base machine. Special
attention must be paid to the hydraulic system. The base machine's hydraulic
system may become contaminated faster when using a breaker than when
using a bucket or other attachment. The following guidelines should be
followed when using a hydraulic breaker:

 When installing the breaker onto a machine for the first time, drain the base
machine's hydraulic system completely. Flush the reservoir, cylinders and
piping as thoroughly as possible. Replace the main line oil filter cartridge.
Add new hydraulic oil. If the base machine is brand new, this step may be
omitted.

 The main return filter element should be replaced after the first 50 hours of
operation, and every 125 hours thereafter.

 Change the hydraulic oil after the first 250 hours of operation, and every
600 hours thereafter, or sooner in accordance with the carrier
manufacturer’s specifications.

Section IV - Page # 6
 Oil temperature should be between 100°F and 140°F during normal hammer
operation.
 Oil contamination should be kept to NAS NO.9 class / ISO 20/18/15.
Field determination of contamination is as follows:

Place a sample of the base machine's hydraulic oil in a transparent

container. Also place a sample of unused oil in another transparent
container. Compare the two containers. If there is a visual difference in the
color, the base machine's oil is presumed to be contaminated.

GREASE

Furukawa Rock Drill USA’s Fx Series hydraulic breakers are equipped with
one (1) grease fitting. This fitting is located on the front bushing, down by the
working steel (refer to the illustration below). Lack of lubrication can cause
failure of the working steel, piston or shorten the life of the seals. An NLGI
NO.2 grease is recommended. The following is a list of the recommended
greases:

SHELL GADUS S2 G 220-2

ESSO LITHTAN EP2
MOBIL MOBILPLEX 48

 The fronthead should be

lubricated every 2 - 3 hours of
operation. Grease more
frequently, if needed, but do
not over-load the tool with
grease.

 When greasing the hammer,

hold it in an upright, vertical,
position, being sure that the
working steel is fully engaged
into the chuck.

 Avoid getting rock or cement

chips into the fronthead when
replacing working steels.
Particles which may have
adhered to the grease can
cause scratches and scaring
inside the hammer.
Section IV - Page # 7
 BACKHEAD CHARGING PROCEDURE
To receive the optimum performance from the hydraulic breaker, care must be
taken to maintain the proper nitrogen charge in the backhead of the breaker. To
assist with this, Furukawa Rock Drill USA can supply a charge kit as illustrated on
the opposite page.
The following is a step-by-step procedure that should be used to properly
charge the backhead. (Note: These instructions are written for Furukawa Rock Drill
USA’s charge kit. If you are not using Furukawa Rock Drill USA’s charge kit, use the
same procedure only disregard the reference to item numbers.

STEP 1 The breaker should be charged at the temperature of the breaker and in
a horizontal position with the working steel all the way out.
STEP 2 The customer must supply a nitrogen tank complete with a regulator.

! USE EXTREME CAUTION WHEN HANDLING PRESSURIZED VESSELS!!

STEP 3 Attach charge adapter (1) to swivel elbow (18). Be sure that O-ring (2) is
installed on charge adapter (1). The charge kit is shipped partially
assembled. Assemble as shown in the illustration. A charge adapter (1)
and O-ring (2) can also be found in the tool box included with the
hammer.
STEP 4 Connect hose assembly (15) to the regulator on your nitrogen tank.
STEP 5 Turn shut-off valve (12) clockwise until it is completely closed.
STEP 6 Connect the 0 - 300 PSI pressure gauge (11) and Q.D. coupler (9), to the
Q.D. nipple (8).
STEP 7 Adjust your regulator to its lowest setting before opening the valve on
your nitrogen tank. Open the valve on your tank and adjust your
regulator to the appropriate backhead charge.
(Refer to the table shown on the opposite page to select the appropriate charge.)
STEP 8 Remove the external plug located in the backhead charge port.
STEP 9 Insert the charge adapter (1) into the charge port. Push the charge
adapter (1) into the charge port until it is fully seated. It will be
necessary to hold the charge adapter in place until charging is
completed.
STEP 10 Open shut-off valve (12) to allow the gas to enter the backhead chamber.
STEP 11 Wait about 15 seconds while holding the charge adapter (1) into the
charge port. The pressure reading on gauge (11) should now be correct.
If the reading is not the proper charge pressure as shown in the table,
adjust your regulator accordingly.

Section IV - Page # 8
 BACKHEAD CHARGING PROCEDURE

STEP 12 Once the correct pressure reading is achieved, turn the shut-off valve
(12) clockwise until it is fully closed.
STEP 13 Quickly remove the charge adapter (1) from the charge port. Replace the
plug into the charge port.

Section IV - Page # 9
 CHARGE KIT BACKHEAD
PART NO. BM-21805 PRESSURE TABLE

ITEM PART NO. QTY DESCRIPTION

1 K15587 1 CHARGE KIT ADAPTER BREAKER CHARGE
2 K03034 1 O-RING TEMPERATURE PRESSURE
3 K15588 1 CHARGE KIT ADAPTER 185° ~ 203° F 160~188 PSI
4 K01829 1 O-RING 167° ~ 185° F 155~183 PSI
5 K21806 1 HOSE ASSEMBLY 149° ~ 167° F 149~177 PSI
6 K08897 1 1/4" NPT FEMALE TEE 131° ~ 149° F 145~173 PSI
7 K08977 1 1/4" NPT PIPE NIPPLE 113° ~ 131° F 141~169 PSI
8 K15341 1 1/4" NPT Q.D. NIPPLE 95° ~ 113° F 135~163 PSI
9 K15340 2 1/4" NPT Q.D. COUPLER 77° ~ 95° F 131~159 PSI
10 K15351a 1 1500 PSI PRESSURE GAUGE 59° ~ 77° F 126~154 PSI
11 K15350a 1 300 PSI PRESSURE GAUGE 41° ~ 59° F 120~148 PSI
12 K15348 1 1/4" NPT SHUT-OFF VALVE 23° ~ 41° F 116~144 PSI
13 K04692 1 1/4" NPT X 4 JIC ADAPTER 5° ~ 23° F 112~140 PSI
14 K15339 1 4 JIC CAP -13° ~ 5° F 107~135 PSI
15 K21373 1 HOSE ASSEMBLY
18 K15374 1 4 JIC SWIVEL ELBOW

Section IV - Page # 10
Notes

Section IV - Page # 11
 TORQUE SPECIFICATIONS
Note: Some external box, plates, or weldments have been removed for clarity.
This drawing is representative of a number of models and might
not match your hammer.

As a general rule, all bolts should be torqued in sets, so that the

load is divided equally among any bolts that function as a group.
Torques listed refer to lubricated threads. Apply anti-sieze compound to
all threads, nuts, and washers prior to assembly. All bolts in a group
should first be loosened, and then re-tightened in stages, alternately
bringing opposing bolts up to the same torque level, until all bolts in the
group share the load equally. Continue in the same way, bringing all
bolts in that group up to the final torque level specified.


Section IV - Page # 12
 TORQUE SPECIFICATIONS
Fx55a Series Breakers

1) Back Head Bolt Torque: 440 ft-lbs. (61 kg-m)

Every 50 hours of operation

2) Charge Valve Plug Torque: 18 ft-lbs. (2.5 kg-m)

Every 50 hours of operation

3) Charging Valve Torque: 90 ft-lbs. (12 kg-m)

Every 50 hours of operation

4) Port Adapter Torque: 400 ft-lbs. (55 kg-m)

Every 50 hours of operation

5) Valve Adjuster Seal Nut Torque: 30 ft-lbs. (4 kg-m)

Every 50 hours of operation

6) Cross Bolts Torque: 560 ft-lbs. (77 kg-m)

Every 50 hours of operation

7) Cross Bolts Torque: 560 ft-lbs. (77 kg-m)

Every 50 hours of operation

8) Top Cap Mounting Bolts Torque: 330 ft-lbs. (46 kg-m)

Every 50 hours of operation

Section IV - Page # 13
 TROUBLE SHOOTING GUIDE
If a problem occurs with the breaker, it is important to first get a flow and
pressure reading of the breaker circuit. To do this, plumb a flow meter and
pressure gauge into the pressure line going to the breaker, locate them as close
to the breaker as possible. Once the readings are taken, refer to the following
list of problems and possible causes:
Condition Problem Remedy
Does not hammer... Control valve does not Check connections between
operate. foot switch and valve solenoid.

Supply hoses have been Pressure line from pump must

reversed. be connected to pressure port
marked "P".
The return line connects to
tank port marked "T".

Oil flow is not sufficient to Flow test pump circuit.

cycle breaker. Replace or repair pump,
Adjust hammer valve.

Operating pressure not Check and/or adjust relief

sufficient to cycle breaker. settings. Adjust hammer
valve.

Supply hoses collapsed, Replace hose.

plugged, or leaking.

Backhead chamber filled Replace all breaker seals.

with oil.

Shuttle valve stuck. Disassemble and clean all

valve ports. Replace worn
valve.

Quick disconnects are Check Q.D. connectors and

faulty replace as needed.

Screw couplings are faulty Check fillings and replace as

needed.

Section IV - Page # 14
Continued...

Condition Problem Remedy

Breaker is slow or Hydraulic oil temperature Oil temperature should not
erratic... is too high. exceed 176F If an oil cooler
needs to be installed, an
inline accumulator is needed
to protect cooler.

Low oil flow or pressure. Test and repair hydraulic

system. Adjust hammer valve.

Too little down pressure Increase down pressure, or

between steel and reposition carrier closer to
material. work.

Too much grease in Remove steel, and clean

fronthead. fronthead cavity. Do not over-
grease.

Steel is galled or sticking. Breaker should be greased

every 2 to 3 hours of
operation. Grease the
fronthead with breaker
upright, and steel engaged
fully.

Working steel is not fully Use correct down pressure.

engaged. Be sure the steel and front
cover are not worn, and have
been properly greased.

Working steel does not Check carrier oil pressure.

stay engaged, or extends Adjust to specifications.
under load.

Continued...

Section IV - Page # 15
Continued...

Condition Problem Remedy

Hammering is weak... Insufficient oil flow. Adjust control valve to rated
specifications.

Operating pressure is low Check the pump and pressure

relief valve.

Oil is contaminated, Change hydraulic oil, and

discolored, or cloudy in filters.
appearance

Oil level is low Refill to proper levels.

Return line back pressure Check filter and hose

is too high connections.

Filter element is clogged. Clean or replace.

Excessive amounts of oil Replace seal kit if oil

are leaking out from consumption is greater than 1
chuck area. Oil flows off pint per hour.
end of working steel.

 If the cause of the problem still cannot be isolated, contact your Furukawa
Rock Drill USA distributor for additional assistance.

Section IV - Page # 16