Hydraulic Breaker

Vulcan V40GS
Operation
&
Maintenance Manual
 CONTENTS
1. Specifications
1.1 General specifications for V40GS
1.2 Tool specifications
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 Other important points
2.7 Storage
2.8 Mounting and Dismounting the Hammer
2.9 Operating 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 Delivery Precautions
4.2 Inspection of the nitrogen gas charging in the back head
4.3 Inspection of nitrogen gas in the accumulator
4.4 Side Rod Inspection and Replacement
4.5 Adjusting Control Methods
4.6 Regulating oil flow rate of valve adjuster
4.7 Wearing parts
4.8 Wear limit of tool and tool bushing

1
 CONTENTS
5. Disassembling and Assembling
5.1 Disassembling
5.2 Assembling
5.3 Torques
5.4 Workshop tool list
6. Troubleshooting Guide
6.1 Oil leakage
6.2 Irregular blows after normal beginning
6.3 No Impact
7. Generals and Safety Information
7.1 General
7.2 Safety
8. Parts List
8.1 Housing
8.2 Hammer Assembly (Standard)
8.3 Hammer Assembly (Auto-Grease)
9. Auto Grease Pump
9.1 Specifications
9.1.1 Models
9.1.2 Diagrams
9.1.3 General Specifications
9.2 Operation
9.2.1 Grease Filling Procedure – Option 1
9.2.2 Grease Filling Procedure – Option 2
9.2.3 Reinstallation and Operation of Grease Pump
9.3 Features
9.3.1 Benefits
9.3.2 Comparison to Manual Greasing
9.4 Installation
9.4.1 Model: HL11CU
9.4.2 Model: HL11CD

2
1. Specifications
1.1 General specifications for V40GS

Item Specifications
Working weight 2995 kg (6602 lbs)
Impact rate 250 ~ 400 BPM
Operating pressure 160 ~ 180 bar (2320 ~ 2610 psi)
Relief pressure 200 ~ 210 bar (2900 ~ 3045 psi)
Oil flow 170 ~ 230 l/min (44 ~ 60 gpm)
Back pressure 10 bar (145 psi)
Tool diameter ø153 mm (6.02 in)
Oil temperature -20 ~ +80 °C (-4 ~ +176 °F)
Hydraulic oil viscosity 1000 ~ 15 cSt (131 ~ 2.35 °E)
Pressure line size 25 mm (1 in)
Return line size 32 mm (1¼ in)
Air (Under water) PF ½’’
Accumulator pressure 60 bar (870 psi)
Backhead pressure 9 bar (130 psi)
Carrier weight 28 ~ 35 tons

3
1.2 Tool specifications

Length Weight Diameter

Name Notes
mm (in) kg (lbs) mm (in)
Cone tool
1400 (55.11) 175 (385) 153 (6.02)
(A)
Chisel tool
1400 (55.11) 175 (385) 153 (6.02)
(B)
Blunt tool
1400 (55.11) 179 (394) 153 (6.02)
(C)
Moil tool
1400 (55.11) 170 (374) 153 (6.02)
(D)

4
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 N2 gas to improve the hammering power.
3) CONTROL VALVE
The control valve is bolted onto 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.

5
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.

6
2.2 Tool Selection 2.3 Breaking Principles

Vulcan Attachments offers a wider selection of  There are two general ways of breaking with a gas-
standard and special tools to suit your every need. type breaker.
The correct tool should be selected for each
application to ensure you are getting the best 1) Penetrative (or cutting) breaking
possible results and the longest working life of your
 In this form of breaking the cone point or chisel
tool.
tool is forced inside of the material. This
1) Blunt method is most effective in soft, layered, low
 For igneous (e.g. granite) and tough abrasive, or plastic material.
metamorphic rock (e.g. gneiss) into which 2) Impact breaking
the tool does not penetrate.
 In impact breaking, the material is broken by
 Concrete. transferring very strong mechanical stress
 Boulders. from the tool into the material.
2) Chisel, cone, and moil  The best possible energy transfer between the
 For sedimentary (e.g. sandstone) and weak tool and the object is achieved with a blunt
metamorphic rock into which the tool can tool.
penetrate.  Impact breaking is most effective in hard,
 Concrete. brittle and very abrasive materials
 Trenching and benching.

7
2.4 Correct working methods

1) Prepare the carrier as you would for normal 4) Use the excavator boom to press the breaker
excavation work. tool firmly against the object.
a. Move the carrier to work location. a. Do not use the breaker tool as a pry bar to
b. Engage the parking brake. pry the breaker with the boom.
c. Put the carrier in neutral gear. b. Do not press down too much or too little with
d. Disengage the boom lock (if fitted). the boom.
2) Set the engine speed to the recommended 5) Start the breaker.
engine RPM. 6) Do not let the tool move outwards from the
3) Place the tool against the object at a 90° angle. breaker when it penetrates.
a. Avoid small irregularities on the object which
* Feed the breaker at all times with the
will break easily and cause either idle
excavator boom.
strokes or incorrect working angles.
b. Incorrect working methods may cause failure 7) Keep the tool at 90° at all times.
in the operation of the breaker or the a. If the object moves or its surface breaks,
housing. correct the angle immediately.
b. Keep the feed force and tool aligned.

8
8) Stop the breaker quickly. 2.5 Operating Temperature
a. Do not allow the breaker to fall off the object
 The operating temperature of the hammer is -
or make idle strokes when the object breaks.
20°C~80⁰C. If the temperature is lower than -
Constant idle strokes have a deteriorating
20°C (-4°F), the breaker and tool must be
effect on the breaker.
preheated before starting operation. Preheating of
b. If the breaker falls off the object ,side
the breaker reduces the likelihood of breaking the
pressure could occur, and side plates will be
accumulator membrane and the tool. During
worn down more quickly
operation they will remain warm.
9) Chisel, cone, and moil
 If the object does not break after fifteen 2.6 Important Operation Points
seconds, stop the beaker and change the b. Listen to the breaker’s sound while you are
position of the tool. Leaving the tool in the working.
same position for more that fifteen seconds will  If the sound becomes thinner and the impact is
only make an indentation, which will fill with less efficient, the tool is misaligned with the
dust and dampen the impact effect. This will material and/or there is not enough “pressing”
cause the tool to overheat. force on the tool.
10)When breaking concrete, hard ground, frozen  Realign the tool and press the tool firmly against
ground, or any similar material, never strike and pry the material.
with the tool at the same time. This could break the c. The breaker, as a standard assembly must not be
tool. 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.
 .

9
2.7 Storage

Long term storage

Observe the following points when the hammer is stored for a long period of time. This will protect the
vital parts of the attachment from rusting, and keeps the breaker ready for use whenever it is needed.

1. The storage area must be dry.

2. The tool must be removed from the hammer.
3. The lower end of the piston, tool and the tool bushing must be well protected with grease.
4. Connections must be sealed with clean plugs to prevent oil leakage and dirt from getting into the
couplings.
5. The breaker must be stored in the vertical position.
6. Ensure that the breaker cannot fall over.

10
2.8 Mounting and Dismounting the Hammer
Removal from the carrier
1. Position the hammer horizontally on the floor and remove the tool.
2. Stop the carrier engine. Operate boom and hammer controls to release the trapped pressure inside
of the hoses. Wait ten minutes for the oil pressure to drop.
3. Close the hammer inlet and outlet lines. If quick couplers are used, disconnection automatically
closes the hammer lines.
4. Disconnect the hoses and plug them as well as the hammer inlet and outlet ports.
5. Remove the bucket pins and other parts.
6. The carrier can now be moved aside.

Installation
1. Install the hammer in the same manner as mounting a bucket, install bucket pins.
2. Connect the hoses. Hammer inlet port is marked on the back head with “IN” and the outlet port is
marked with “OUT”.
3. Open the hammer inlet and outlet lines.

11
2.9 Operating Pressure Settings

Model Operating Pressure V40G 200 ~ 210 bar

V40G 160 ~ 180 bar
2) Relief Valve
1) Operating Pressure a. The relief valve is a safety device which is used to
a. Stop the carrier engine. protect the breaker when the pressure rises in the
b. Assemble the high pressure gauge to the hydraulic circuit.
high pressure test port. Start the engine. b. The operating pressure of the breaker determines
c. Set the tool of the breaker on something the setting of the relief valve in the pressure line.
stable (e.g. a thick steel plate). c. The relief valve setting should be adjusted to the
d. Adjust the operating engine revolution and specifications of each Vulcan model
start to operate the breaker.
e. Read the average pressure from the high
pressure gauge.
f. Operating pressure is pre-adjusted at the
factory and there should be no reason to
adjust it.
g. Stop the carrier and remove the gauge.
h. Tighten the plug of the pressure measuring
point.

Model Relief Pressure

12
2.10 Hose and Pipe Specification

Hose Assembly Piping Line Size

Model Notes
IN OUT IN OUT
V40G PF 1’’ PF 1 ¼’’ PF 1 ¼’’ PF 1 ¼’’

2.11 Hydraulic Circuit

13
3. Lubrication
3.1 Manual Lubrication
* Grease interval
1. The tool shank and tool bushing must be well lubricated before installing the tool.
2. Apply 40 – 50 strokes from the grease gun to the tool bushing and the tool at regular intervals.
3. Adapt the interval and amount of grease to minimize tool wear and keep it in good working condition.
Greasing should be done every hour.
Insufficient greasing or improper grease could cause:
- Abnormal wear of the tool bushing and the tool.
- Tool breakage.
Technical data:
- NLGI grade 2.
- Synthetic oil base with aluminum complex soap.
- Approximately 15% graphite copper solids to reduce metal to metal contact damage.
- Dropping point 260°C (500°F).
- Viscosity 15 cSt.
- Temperature range -30° ~ 230°C (-20°F ~ 450°F).

14
3.2 Hydraulic Oil
 When the breaker is used continuously, the 2) When the oil is too thin, the following
temperature of the hydraulic oil normalizes at problems may occur.
a certain level, depending on the conditions a. Efficiency losses (internal leaks).
and the carrier. At this temperature, the b. Damage to gaskets and seal leaks.
viscosity of the hydraulic oil should be 20 ~ 30 c. Accelerated wearing of parts, caused
cSt (2.90~5.35°E). by decreased lubrication efficiency.
 The Vulcan hydraulic breaker must not be 3) Special oils
started if the viscosity of the hydraulic oil is  In some cases special oils (e.g. biological
above 1000 cSt (131°E) or operated when the oils and non-inflammable oil) can be used.
viscosity of the hydraulic oil is below 15 cSt Please observe following aspects when
(5.35°E). considering the use of special oil:
1) When the oil is too thick, the following  The viscosity range in the special oil must
problems may occur. be within the range of 15 ~ 1000cSt
 Difficulty starting. (2.35~131°E).
 Stiff operation.
 Irregularly and slow striking.
 Danger of cavitations in the pumps and
hydraulic breaker.
 Sticky valves.
 Filter bypass, impurities in the oil not
removed.

15
4) Cleanliness of the hydraulic oil 7) Damage caused by hydraulic oil
 The hydraulic oil filter of the carrier will contamination in the carrier and breaker
clean the oil flowing through the circuits causes:
breaker. a. The working life of the pumps to be
 The purpose of the oil filter is to significantly shortened.
remove impurities from the hydraulic - Premature wear of the parts.
oil since they accelerate component - Cavitation.
wear, cause blockages and even b. Valves to not function properly.
seizure. - Spools bind – premature wear of the
 Impurities also cause the oil to parts.
overheat and deteriorate. - Blocking of small holes.
 Air and water are impurities in oil. c. Wear of the cylinders.
5) Oil filter d. Reduced breaker efficiency.
 When working with the hydraulic - Premature wear of moving parts and
breaker, the carrier oil filter must fulfill seals.
the following specifications: - Danger of the piston seizing and
a. The oil filter must be rated at 25 the oil overheating.
microns maximum. e. Shortened working life and reduced
b. The oil filter must be a standard efficiency of hydraulic oil.
return line filter rated to maximum - Oil overheats and the oil quality
working pressure. deteriorates.
c. The oil filter must have a volume - Electro-chemical changes in the
flow capacity of at least twice the hydraulic oil.
breaker’s maximum flow.
d. The cooler must withstand a
dynamic pressure of 290 psi (20
bar).
6) If the carrier’s oil cooler is too small, the
original cooler must be replaced with a
larger one or an auxiliary cooler must be
installed. The auxiliary hydraulic cooler
can be installed:
a. In front of the radiator, in which case
an additional fan is not required, i.e.
maximum rise of cooling air is 5°C
(40°F).
b. Any other suitable place, using a fan
either hydraulically of electrically
driven
16
4. Maintenance
4.1 Delivery Precautions 8) If the gas pressure is low, perform steps 1)
through 6) again, until the gas pressure has
When a Vulcan hydraulic breaker is shipped increased to the specified pressure.
from the factory, the back head is not charged 9) If the gas pressure is excessive, slowly turn
with Nitrogen gas. the adjustment valve of the charging block
If the back head were charged with Nitrogen counter-clockwise, while pressing down on
gas, the front head of the piston is left protruding the plunger. This relieves the pressure from
from the cylinder. the back head. When the correct amount of
gas pressure is shown, release the plunger
4.2 Inspection of the nitrogen gas and close the adjustment valve by turning it
charging in the back head clockwise. When the gas pressure is
higher than the recommended setting
the breaker will not operate.
WARNING! 10) Ensure that the gas pressure is at the
specified pressure and install the plug with
the o-ring on the back head
1) Remove the gas plug on the back head.
Make sure you keep the o-ring in the plug.
2) Connect the charging block to the gas
charging valve on the back head.
3) Connect the N2 cylinder to the charging
block hose.
4) Ensure that the adjustment valve on the
charging block is closed.
5) Charge the pressure of the back head to
specifications by turning the handle on the
N2 cylinder counter-clockwise to open.
Increase the pressure shown on the
charging block by opening and closing the
N2 cylinder, close the cylinder when the
desired pressure is shown. Check the
charged pressure in the back head by
pressing the push rod on the charging
block.
6) Wait 2 minutes for pressure to stabilize
after closing the N2 cylinder.
7) Recheck the charged pressure in the back
head by pressing the push rod on the
charging block.
17
4.3 Inspection of nitrogen gas in the accumulator
f. Turn the handle of the N2 cylinder
clockwise to close.
WARNING! g. Loosen Screw 1 on the charging block to
discharge the remaining N2 in the hose.
h. Remove the gas hose from the charging
Never use anything but Nitrogen gas to charge
block and N2 cylinder.
the accumulator.
i. After removing the gas hose, adjust the
1) Inspecting the charging pressure.
pressure, refer to 1) Inspecting the
a. Install the adapter and the pressure
charging pressure.
gauge on the charging block.
j. After charging the accumulator with N2,
b. Turn the handle of the charging block
check for gas leakage from the valve.
counter-clockwise.
Then plug the hole of the accumulator
c. Remove the plug on the accumulator and
body.
install the charging block.
d. Turn the needle valve (2)
counter-clockwise slowly, and observe
the charging pressure on the pressure
gauge.
e. Ensure the charging pressure is correct
and tighten the needle valve (2)
completely.
f. Loosen Screw 1 to discharge the N2 gas
from the charging block.
g. Remove the charging block and tighten
the plug and the cap. Ensure that the
o-rings are installed in the plug and cap.
2) Charging the accumulator with N2 gas.
a. After performing the inspection of the
charging pressure, remove the cap of the
charging block.
b. Connect the gas hose to the charging
block and the N2 cylinder.
c. Turn the handle of the charging block
clockwise.
d. Slowly turn the handle of the N2 cylinder
counter-clockwise to charge the
accumulator with Nitrogen gas.
e. Tighten the needle valve (2) completely.

18
4.4 Side Rod Inspection and Replacement

CAUTION!

Release the back head pressure completely before loosening the side rods. Not releasing the pressure in
the back head before removing the side rods can cause damage to the unit and serious bodily harm.

1) Discharge the N2 in the back head completely before loosening the side rods.
2) Remove all of the side rods, and inspect them for any cracks or damage.
3) When installing the side rods, tighten the bolts one turn at a time in a diagonal sequence, not each nut
completely before the next.
4) Use the torque wrench to tighten each nut to their specified torque range.

19
4.5 Adjusting Control Methods
An adjuster which regulates the number of blows is standard in Vulcan hydraulic breakers.

For the most effective breaking, change the number of blows depending on the working condition.

By using an adjuster, piston stroke and frequency can be controlled, meanwhile keeping the working
pressure and flow rate of the oil fixed.

The adjuster is installed on the right side of the cylinder.

To change the impact frequency, rotate the adjusting screw by first loosening the lock nut from the
adjustment screw.
Rotating the adjustment screw clockwise to the end makes the longest stroke and minimum number of
blows, while rotating the screw counter-clockwise two (2) turns makes the shortest stroke and gives the
maximum number of blows.

After adjustment, tighten the lock nut completely.

20
4.6 Regulating oil flow rate of valve adjuster

When the base machine supplies insufficient hydraulic oil to the breaker, this adjusting valve can obtain
the rated working pressure by reducing the number of blows; even though the working pressure is
continuously the same, if the oil flow to the hammer is increased the number of blows would also be
increased.

Vulcan breakers are being sent out with adjuster’s preset at 3 to 4 turns counter-clockwise as the
standard specification.

21
4.7 Wearing parts

1) When damaged or worn, it is highly 4) Tool pin

recommended to replace the following - When each tool pin is excessively
wearable parts: deformed, it is difficult to replace the tool.
- Tool Therefore, every 100 to 150 hours of
- Tool bushing (must be removed at the operation, change the face of each pin
service centre) which comes in contact with the tool. The
- Tool pins two faces of each pin can be used. If the
- Stopper pin, bushing pin tool you use is not a genuine part, we
- Rubber plug, bushing pin plug cannot guarantee the breaker unit and
- Hydraulic seals part’s performance.
- Side bolts - When replacing each part, check for wear,
- Hydraulic hoses breakage, scours, etc., especially after
removing burrs and swelling on tool pins.
2) We recommend the user to stock wearable - Replace the tool after grinding the worn
parts such as tool pins, stoppers, rubber parts of the tool pin. Insert a new tool pin
plugs, bolts and hydraulic hoses. after grinding the scuffed parts of the tool
and tool pins in use.
3) Replace hydraulic seals after every 600
hours of actual operation.

22
4.8 Wear limit of tool and tool bushing

When the clearance between the tool and the tool bushing becomes excessive, it is strongly
recommended that these parts are replaced to prevent further wearing of the components.

To use the tool and tool bushing past their wear limit of 8mm, can cause damage to other parts of the
breaker such as the piston or the cylinder.

23
5. Disassembling and Assembling
5.1 Disassembling

WARNING!
Do not attempt to disassemble or assemble the hammer before reading this chapter of the manual.

1. Disassembly
1) Put the hammer on wooden supports of equivalent size.
2) Release the N2 from the back head. Not releasing this gas makes disassembly very dangerous!
3) Remove the side rods bolts from the hammer.
4) Disassemble the back head by using a hoist or chain block.

24
5) Disassemble the cylinder with the eye bolt and by using a hoist or chain block in the
direction indicated by the arrow.

6) Disassemble the piston with the eye bolt vertical, in the direction
indicated by the arrow.

7) Loosen and disassemble the side rod from the front head by screwing
out the quadrangle part with the lower nut by using a spanner.

25
5.2 Assembling

1) Seal assembly d) Using a rubber hammer assemble the seal

Using a brush apply lubrication oil to the seal housing into the cylinder.
groove in order to put in the seals. A lot of care e) Assemble the back head.
should be taken when installing seals. f) Tighten the side rod nuts to their specified
torque.
2) General assembly g) Assemble the removed gas charging valve
and fill the cushion chamber with hydraulic
a) Assemble the side rods to the front head
oil.
with the lower nuts.
h) Tighten the gas charging valve to its
b) Assemble the cylinder.
specified torque.
c) Lubricate the piston thoroughly and
i) Assemble the hose adapter.
carefully assemble the piston and the seal
housing. Ensure that the seals are installed
correctly in the cylinder and the seal CAUTION!
housing.

26
5.3 Torques

Item N.m kg.m ft.lb Description Q’ty

A 3,050 311 2,249 Side rod nut 4
B 390 39 287 Accumulator cover bolt 12
C 650 66 479 Accumulator bottom bolt 4
D 390 39 287 Valve block bolt 8
E 390 39 287 Valve block cover bolt 8
F 200 20 150 Flange adapter bolt 8
G 3,050 305 2,250 Joint nut 8
H 2,100 214 1,548 Top cover bolt 12

24
5.4 Workshop tool list

NO. Part Name Specifications Q’ty Notes

1 Tool Box Large Size 1
2 Single Spanner 19mm 1
3 Single Spanner 22mm 1
4 Single Spanner 24mm 1
5 Hammer Wrench 65mm 1
6 Hammer Wrench 75mm 1
7 L. - Wrench 5mm 1
8 L - Wrench 8mm 1
9 L - Wrench 10mm 1
10 L – Wrench 12mm 1
11 L – Wrench 14mm 1
12 L – Wrench 17mm 1
13 L – Wrench 19mm 1
14 Driver (+) 1 pc
15 Driver (-) 1 pc
16 Installation Card 2 set
17 Warranty Claim Report 2 set
18 Hammer Card 1 set
19 Gas Charging Kit 1 set Option Part
20 Gas Cylinder 3.4 liter Option Part

25
6. Troubleshooting Guide
6.1 Oil leakage

Probable cause Remedy

a. Oil leakage between the tool and the tool - Replace the damaged seals.
bushing.

b. Oil leakage on the surface of the breaker. - Retighten the loose breaker hoses and bolts.

c. Oil leakages on the valve block and bolts. - This is normal, during assembly lubrication and
antirust oil is applied.

d. Oil leakage between the cylinder and the back - Tighten to specified torque.
head.
6.2 Irregular blows after normal beginning

Probable Cause Remedy

a. Oil temperature increased due to lack of - Supplement the hydraulic oil.
hydraulic oil.

b. Pressure in the back head is too high. - Check the gas pressure.

c. Relief valve is set too low. - Check the pressure of the relief valve.

d. Not enough down pressure on the tool. - Apply enough down pressure with the arm or the
boom of the carrier.

e. The clearance between the tool and the tool - Check the clearance between the tool and the
bushing is too large. tool bushing.

f. Wear on the top of the tool. - Disassemble the tool and check.

g. Poor performance of the hydraulic pump and - Have the excavator manufacturer check the
the back pressure is too high. hydraulic piping.

h. Foreign material in the side valve. - Disassemble and clean.

i. Seizure of the piston and cylinder. - Overhaul and check.

26
6.3 No Impact

Probable Cause Remedy

a. Oil temperature is too low. - Oil temperature must reach a minimum of
30⁰C.

b. Valve does not operate properly - Check the breaker operating button in the
cabin.

c. Pressure in the back head and setting - Check the pressure of the nitrogen gas and
pressure of the relief valve is too low. the relief valve.

d. Poor performance of the hydraulic pump - Contact the excavator manufacturer.

e. Gas pressure is too low or too high. - Check the gas pressure.

f. Not enough down pressure on the tool. - Apply enough down pressure with the arm or
boom of the excavator.

g. Setting pressure of the relief valve is too low. - Check the pressure of the relief valve.

h. Poor performance of the hydraulic pump. - Check the relief valve on the excavator.

i. Hydraulic oil operating pressure is too low. - Check the setting pressure.

j. Malfunction of hydraulic quick couplers. - Check to ensure that the oil is flowing through
the quick couplers. If it is not repair or replace
malfunctioning couplers.

k. Couplers are not fully engaged. - Connect couplers securely.

27
7. Generals and Safety information
7.1 General b. Attempting to dismantle the accumulator
without first releasing the pressure can cause
Do not use or install the breaker until you can use
serious injury.
the carrier. Do not rush the learning process. Take
c. Do not try to dismantle the pressure
your time and learn how to operate the breaker
accumulator, contact your Vulcan service
safely and efficiently.
center first.
 If there is anything you do not understand, ask
6) Hydraulic pressure
your Vulcan service center for advice.
a. Hydraulic fluid at system pressure is very
 The breaker serial number is stamped on a metal
dangerous.
plate which is located on the back head near the
b. Before disconnecting or connecting the
inlet connection.
hydraulic hoses, stop the carrier engine and
 Correct reference to the serial number of the operate the controls to release the pressure
breaker is important when ordering spare parts. trapped in the hoses.
Identifying parts for specific breakers is only c. Keep all personnel away from the hydraulic
possible through the serial number. hoses during breaker operation.
7.2 Safety - Regulation –
1) Manuals  Observe all of the laws, work site and local
a. Read this manual before installing, operating, regulations which affect you and your equipment.
or maintaining the breaker. If there is anything - Practice –
that you do not understand ask your employer  Carrying out unfamiliar actions without practice
or your local Vulcan dealer. could cause serious injury to the operator and
b. Keep this manual in good condition for future any others on site.
reference.  Practice away from the job site in a clear area.
2) Clothing  Keep other people away.
a. Proper clothing is important to prevent injury.  Do not perform new operations until you are
Loose clothing can get caught in the machinery confident you can carry them out safely.
and cause bodily harm. - Equipment condition –
3) Work site  Defective equipment can cause injury to yourself
a. Inspect the working site before starting work. and others. Do not operate equipment that is
b. Check for potholes, weak ground, hidden rocks defective or has missing parts.
etc.  Make sure that the maintenance procedures in
c. Check for utilities like water pipes, power lines, this manual are completed before operation.
and gas lines. - Equipment limits –
4) Metal splinters  Operating the equipment beyond it’ design limits
a. Injury can be caused by flying splinters when can cause damage and be hazardous.
driving metal pins in and out.  Do not operate the equipment beyond its limits.
b. Always wear safety glasses.  Do not try to upgrade the equipment’s
5) Accumulator performance with non-approved modifications.
a. The accumulator is pressurized even when
there is no hydraulic pressure in the breaker.

28
8. Generals and Safety information
8.1 V40GS Housing

32
 V40GS Housing Parts List

No. Part No. Part Name Q’ty Note

301 - Hammer Assembly 1
302 A3003510 Housing Assembly 1 S/No. : 1003 ~ up
303 A3002030 Top Plate 1
304 A3003690 Plate (Cover 3) 1
305 A3003660 Plate (Cover 2) 1
306 A3003650 Plate (Cover 1) 1
307 A3002050 Wearing Plate 1
308 A3002060 Wearing Plate 2
309 A3002070 Wearing Plate 1
310 A2002020 Wearing Plate 3
311 A2500180 Buffer (Top) 1
312 A3000300 Buffer (Base) 1
A3000220 Plug (Rubber) (Old) 3
315
A3000280 Plug (Rubber) 3
316 B4000130 Plug (Rubber) 8
317 B2500110 Plug (Rubber) 4
318 A3000250 Rubber (In, Out) 2
319 B400W270 Rubber 2
320 HB1015030 Cover Bolt 14
321 SW100000 Washer 14
326 HB3640160 Top Cover Bolt 12
NN364000 Top Cover Nut (Old) 12
327
HN364000 Top Cover Nut 24

33
No. Part No. Part Name Q’ty Note
329 PW360000 Flat Washer (Top Cover) 24
330 B3200040 Rubber Grease 1
331 HB1217530 Cover Bolt 4
332 SW120000 Washer 4
333 A3000520 BLOCK W.A 1
A3000560 Side Buffer 1
334
A2003820 Side Buffer 1
SB2430100 Socket Bolt (old) 4
335
SB2430110 Socket Bolt 4
336 PW240000 Plain Washer 4
337 HN243000 Hex. Nut 4
339 B6000130 Rubber Plug 4
340 B4000140 Rubber Plug 1
341 A5002330 Wearing Plate 2
342 HL11CD-400 Grease Pump 1
343 SB12175100 Bolt 4 Optional
344 BHSSG100 Hose 1

34
8.2 V40GS Hammer Assembly (Standard)

35
V40GS Hammer Assembly (Standard) Parts List

No. Part No. Part Name Q’ty Note

1 A3006480 Back Head 1
2 A3006020 Cylinder 1
3 A3006030 Front Head 1
4 A3006040 Seal Housing 1
5 A3006050 Piston 1
6 A3006060 Accumulator Cover 1
7 A3006070 Accumulator Bottom 1
8 A3006080 Upper Bushing 1
9 A3006090 Tool Bushing 1
11 A3006110 Side Rod 4
12 A3006120 Nut – Side Rod Lower 4
13 A3006130 Nut – Side Rod Upper 4
14 A3006140 Washer – Side Rod 4
15 A3006150 Valve Block 1
16 A3006160 Valve Cover (Upper) 1
17 A3006170 Valve Guide 1
18 A3006180 Valve Spool 1
19 A3006190 Valve Cover Lower 1
21 A3006210 Tool Pin 2
22 A3006220 Bushing Pin 2
23 A3006230 Stop Pin 2
24 A3006240 Upper Bushing Pin 1
25 A3006250 Connection Bushing 2
26 A3006260 Plug Bushing 1
27 A3006270 Air Vent Plug 1
28 A3006280 Tool – Cone 1
29 A3006290 Tool – Chisel 1
30 A3006300 Tool – Blunt 1
31 A3006311 Adjust Bolt 1 1
32 A3006320 Adjust Nut 2

36
No. Part No. Part Name Q’ty Note
33 A3006330 Adjust Bolt 2 1
34 A3006340 Accumulator Inner Valve Assembly 1
35 A3006350 Gas Charging Bolt 1
36 A3006360 Gas Charging Cap 1
A3006370 Gas Charging Valve (Old) 1
37
A3006590 Gas charging Valve Assembly 1
38 A3006380 Heli – Coil 14
39 A3006390 Heli – Coil 8
40 A3006400 Hex. Plug 2
46 A3007200 Membrane 1
47 B4006450 Socket Plug 2
48 B2506530 Socket Plug 4
49 B4006530 Socket Plug 1
52 B4006560 Grease Nipple 1
53 B1806570 Snap Ring 2
54 B3006570 Snap Ring 2
55 B4006370 Guide Pin 1
56 B4006310 Guide Pin 4
57 B1806580 Rubber Plug 2
58 B3006580 Rubber Plug 2
59 A2006510 Bolt 1
61 SB1420040 Socket Bolt 8
66 SB2015060 Socket Bolt 12
69 SB2025070 Socket Bolt 8
71 SB2430060 Socket Bolt 4
75 A2006430 Flange 1
76 A3006450 Flange 1
77 A3006800 Tool – Moil 1
SB2015045 Hex. Bolt (Old) 4
78
HB2015055 Hex. Bolt 4

37
No. Part No. Part Name Q’ty Note
SB2015045 Hex. Bolt (Old) 4
79
HB2015045 Hex. Bolt 4
80 B4006890 Hex. Socket Plug 1
3
101 A3007010 O - Ring 1
102 A3007020 Gas Seal 2
103 A3007030 Step Seal 1
104 A3007240 Buffer Ring 1
105 A3007220 U – Packing 1
106 A3007230 Wiper 1
107 A3007070 O - Ring 1
108 A3007080 Backup Ring 1
109 A3007090 O - Ring 1
110 A3007100 Backup Ring 1
111 B4007190 O - Ring 1
112 A3007110 Backup Ring 1
113 B2507200 O - Ring 1
114 B2507190 O - Ring 2
115 A2007110 O - Ring 2
116 A3007200 O - Ring 1
117 A3007130 Backup Ring 1
118 A3007140 O – Ring 6
119 A1807310 O – Ring 5
120 A3007160 Backup Ring 1
121 A3007170 O - Ring 1
122 A3007180 Backup Ring 1
123 A3007190 O - Ring 1
124 B6007330 O – Ring 2
125 B4007340 O – Ring 1

38
8.3 V40GS Hammer Assembly (Auto-Grease)

39
V40G Hammer Assembly (Auto grease) Parts List

No. Part No. Part Name Q’ty Note

1 A3006490 Back Head 1
2 A3006500 Cylinder 1
3 A3006510 Front Head 1
4 A3006040 Seal Housing 1
5 A3006050 Piston 1
6 A3006060 Accumulator Cover 1
7 A3006070 Accumulator Bottom 1
8 A3006080 Upper Bushing 1
9 A3006090 Tool Bushing 1
11 A3006110 Side Rod 4
12 A3006120 Nut – Side Rod Lower 4
13 A3006130 Nut – Side Rod Upper 4
14 A3006140 Washer – Side Rod 4
15 A3006150 Valve Block 1
16 A3006160 Valve Cover Upper 1
17 A3006170 Operational Valve Guide 1
18 A3006180 Operational Valve Spool 1
19 A3006190 Operational Valve Cover 1
21 A3006210 Tool Pin 2
22 A3006220 Bushing Pin 2
23 A3006230 Stop Pin 2
24 A3006240 Upper Bushing Pin 1
25 A3006250 Connection Bushing 2
26 A3006260 Plug Bushing 1
27 A3006270 Air Vent Plug 1
28 A3006280 Tool – Cone 1
29 A3006290 Tool – Chisel 1
30 A3006300 Tool - Blunt 1
31 A3006311 Adjust Bolt 1 1
32 A3006320 Adjust Nut 1

40
No. Part No. Part Name Q’ty Note
33 A3006330 Adjust Bolt 2 1
34 A3006340 Accumulator Inner Valve Assembly 1
35 A3006350 Gas Charging Bolt 1
36 A3006360 Gas Charging Cap 1
A3006370 Gas Charging Valve (Old) 1
37
A3006590 Gas charging Valve 1
38 A3006380 Heli – Coil 4
39 A3006390 Heli – Coil 8
40 A3006400 Hex. Plug 2
46 A3007200 Membrane 1
47 B4006450 Socket Plug 3
48 B2506530 Socket Plug 4
49 B4006530 Socket Plug 1
52 B4006560 Grease Nipple 1
53 B1806570 Snap Ring 2
54 B3006570 Snap Ring 2
55 B4006370 Guide Pin 1
56 B4006310 Guide Pin 4
57 B1806580 Rubber Plug 2
58 B3006580 Rubber Plug 2
59 A2006510 Bolt 1
61 SB1420040 Socket Bolt 8
66 SB2015060 Socket Bolt 12
69 SB2025070 Socket Bolt 8
71 SB2430070 Socket Bolt 4
75 A2006430 Flange 1
76 A3006450 Flange 1
77 A3006800 Tool – Moil 1
SB2015045 Hex. Bolt (Old) 4
78
HB2015060 Hex. Bolt 4

41
No. Part No. Part Name Q’ty Note
SB2015045 Hex. Bolt (Old) 4
79
HB2015045 Hex. Bolt 4
80 B4006910 Hex Socket Plug 1
101 A3007010 O - Ring 3
102 A3007020 Gas Seal 1
103 A3007030 Step Seal 2
104 A3007240 Buffer Ring 1
105 A3007220 U - Packing 1
106 A3007230 Wiper 1
107 A3007070 O – Ring 1
108 A3007080 Backup Ring 1
109 A3007090 O – Ring 1
110 A3007100 Backup Ring 1
111 B4007190 O – Ring 1
112 A3007110 Backup ring 1
113 B2507200 O – Ring 1
114 B2507190 O – Ring 2
115 A2007110 O – Ring 2
116 B3007200 O – Ring 1
117 A3007130 Backup Ring 1
118 A3007140 O – Ring 6
119 B1807310 O – Ring (old) 5
120 A3007160 Backup Ring 1
121 A3007170 O – Ring 1
122 A3007180 Backup ring 1
123 A3007190 O – Ring 1
124 B6007330 O – Ring 2

42
9. Auto Grease Pump
9.1 Specifications
9.1.1 Models
Model: HL11CU-RC400

Cartridge Capacity: 400cc

Mounting direction: Up
(Cartridge Up Type)

43
 Model: RC400

Cartridge Capacity: 400cc

Model: RC300

Cartridge Capacity: 300cc

44
9.1.2 Diagrams

Model: HL11CU – RC400 Diagram

45
Model: HL11CU – RC300 Diagram

46
Adjustment & Grease Refilling Diagram

Grease Filling Port – Option 2

47
9.1.3 General Specifications

Model: HL11CU – RC400

Item Specifications
Output Pressure about 10bar
Cylinder Capacity 400 ml
Exterior Size 140mm x 89mm x 361mm
Weight (Without Grease) 6.2 kg
Output Port PF ¼’’
0.2cc – 1cc /min
Output Quantity
12cc – 60cc /hr
MO2 Grease
NLGI NO.2 (Normal Condition)
Recommended Grease
NLGI No.1 (Under 10C)
NLGI No.0 (Under 0C)
Available Temperature Range -10C ~ 50C
Permissible Main Body Temperature -20C ~ 90C

Model: HL11CU – RC300

Item Specifications
Output Pressure about 10bar
Cylinder Capacity 300 ml
Exterior Size 140mm x 89mm x 306mm
Weight (Without Grease) 5.0 kg
Output Port PF ¼’’
0.2cc – 1cc /min
Output Quantity
12cc – 60cc /hr
MO2 Grease
NLGI NO.2 (Normal Condition)
Recommended Grease
NLGI No.1 (Under 10C)
NLGI No.0 (Under 0C)
Available Temperature Range -10C ~ 50C
Permissible Main Body Temperature -20C ~ 90C

48
9.2 Operation
9.2.1 Grease Filling Procedure – Option 1

1. Insert an injection port into the Grease. 2. Pull the Handle and wait for 2 seconds
(Grease has time to move into the pump)

3. Insert the Handle (Grease becomes 4. Repeat 2 & 3 until the grease is filled.
compressed in the refilling cartridge) Fasten the handle by turning it clockwise.

49
 9.2.2 Grease Filling Procedure – Option 2

Refilling the Auto Grease Pump can be accomplished one of two ways, the first
way was described on page 8. The second method involves using a manual or
automatic (electric or pneumatic) grease gun and filling the unit through the
Grease Filling Port pictured below.

NOTE: When using the second grease filling method it is extremely important to
ensure that you only fill it up to the fill line, over-filling the unit can cause damage
and failure of the Auto Grease Pump as well as possible personal injury.

33
 9.2.3 Reinstallation and Operation of Grease Pump
After the charged cylinder is installed on the main body of the pump check to ensure that the valve of
the cylinder is open and grease is coming out.
The grease moves out of the pump automatically when the breakers operation vibrates the unit.

34
9.3 Features
9.3.1 Benefits
There are many benefits to using the Auto Grease Pump on Vulcan hydraulic breakers, the
following table lists those.

Vulcan Auto Grease Pump

The rechargeable cartridge decreases maintenance costs.

The installation of the Vulcan Auto Grease pump is simple; there is no need
for separate hydraulic lines, and no need for separate connections to pre-
existing hydraulic lines.

The Vulcan Auto Grease Pump is extremely durable, made of aluminum

alloy it protects the internal parts and keeps the unit safe from impact.

The Auto Grease Pump was specifically designed for the Vulcan Hydraulic
Breaker so it fits perfectly with the unit and provides ideal lubrication for
each unit equipped.

The Auto Grease Pump provides grease to the breaker via a powerful
spring, it does not interfere with the performance of the breaker in any way.

Adjusting the output quantity of the Auto Grease Pump from 0.2cc to 1cc
per minute makes it useful in many different applications, when little or a lot
of lubrication is needed.

35
9.3.2 Comparison to Manual Greasing

Manual Filling
- Manual filling is inconvenient
and wastes the operators time
- Deficient filling causing
excessive injections
- Shortened life of the device
due to improper lubrication
- Environmental pollution
caused by grease spills

Automatic Filling
- Automatic filling is convenient
and does not need constant
attention from the operator
- The pump automatically
dispenses the right amount of
grease to keep the device well
lubricated.
- Increased life of the device
because of proper lubrication
- Less environmental pollution
due to less grease spills

36
9.4 Installation
9.4.1 Model: HL11CU

37
 9.4.2 Model: HL11CD

*Vulcan Attachments Inc. is not responsible for errors and omissions to the content of this manual. Specifications are subject to change without notice

38
39
Version: 0711