HB20-II / HB30-II / HB40-II: Operation and Maintenance Manual

Operation and Maintenance Manual
HB20-II / HB30-II / HB40-II
DOOSAN and the DOOSAN logo are registered

trademarks of DOOSAN Corporation in the United
States and various other countries around the
world. April 2019
Copyright DOOSAN 2020© Original Instructions

Table of Contents
Foreword .................................................................................. 1-1
Symbols.................................................................................... 2-1
Safety ....................................................................................... 3-1

Safety Signal Words ..........................................................................3-1
Safety Precautions .............................................................................3-1
General Information ........................................................................... 3-2
Mounting on Carrier ...........................................................................3-2
Hydraulic Fluids .................................................................................3-3
Energy Chamber ................................................................................ 3-4
Operation ........................................................................................... 3-4
Maintenance and Repairing ...............................................................3-5
Products and Structure ........................................................... 4-1

Products ............................................................................................. 4-1
Structure ............................................................................................4-1
Information ............................................................................... 5-1

Specification of Breakers ...................................................................5-1
Usage of Breaker ...............................................................................5-2
Installation and Operation ....................................................... 6-1

Flushing Before Install Breaker .......................................................... 6-1
Tool Installation .................................................................................. 6-2
Tool Removement.............................................................................. 6-2
Hose Installation ................................................................................ 6-3
Check Setting Pressure ..................................................................... 6-4
Check Operating Pressure .................................................................6-4
User Instruction ....................................................................... 7-1
HB20-II/HB30-II/HB40-II Table of Contents

I
For the Working Position ....................................................................7-1
For the Working Time ........................................................................ 7-2
For the Breaker Position ....................................................................7-2
Working Temperature ........................................................................7-7
Impact Effect on Tool ......................................................................... 7-9
Origin of Breakages ......................................................................... 7-10
Nitrogen Inflating Procedure ............................................................ 7-11
Charging N2 Gas Instruction - Back head ........................................ 7-13
Back Head Inflating Table ................................................................ 7-17
Charging N2 Gas Instruction - Accumulator ..................................... 7-18
Accumulator Inflating Table.............................................................. 7-24
Stroke Adjustment............................................................................ 7-25
Front Cover Removement ................................................................ 7-26
Innerbush Removement ................................................................... 7-28
Innerbush Assembly ........................................................................ 7-30
Frontcover Assembly ....................................................................... 7-32
Front Cover & Innerbush Removement Tools .................................. 7-34
Front Cover & Innerbush Assembly Tools........................................ 7-35
External Dimensions ............................................................... 8-1

Housing Type Dimension ...................................................................8-1
Top Type Dimension ..........................................................................8-2
Side Type Dimension .........................................................................8-3
Mountcap Plate Dimension ................................................................ 8-4
Torque ...................................................................................... 9-1

Through Bolt ...................................................................................... 9-1
Mountcap Bolt ....................................................................................9-1
Accumulator Body Bolt ....................................................................... 9-1
Accumulator Cover Bolt ..................................................................... 9-2
Valve Housing Bolt.............................................................................9-2
Valve Cover_A Bolt ............................................................................9-2
Valve Cover_B Bolt ............................................................................9-2
Bracket Side Bolt ...............................................................................9-3
Maintenance and Trouble Shooting ..................................... 10-1

Maintenance Schedule .................................................................... 10-1
Wear Limit of Parts .......................................................................... 10-1
Trouble Shooting.............................................................................. 10-3

I
Storage ................................................................................... 11-1
Caution for Long Term Storage........................................................ 11-1
Storage Method ............................................................................... 11-2
Before Operating.............................................................................. 11-2
The Auto Lubrication Kit (Option) ........................................ 12-1

Adjustment of Auto Lubrication Kit ................................................... 12-1
Air Discharge Method ...................................................................... 12-1
Air Discharge Method ...................................................................... 12-2
Grease Refill Method (Only Have Grease Power Pump) ................. 12-3
* Specifications and features presented in this document are subject to change without notice.

I
Table of Contents HB20-II/HB30-II/HB40-II
IV
Foreword
1. The contents of this manual are considered to be
proprietary and confidential to the manufacturer and
should not be reproduced without the prior written
permission from the manufacturer.
2. Nothing contained in this document is intended to extend
any promise, warranty or representation, expressed or
implied regarding the manufacturer products described
herein. Any such warranties or other terms and conditions
of sale of products shall be in accordance with the
standard terms and conditions of sale of such products,
which are available upon request.
3. This manual contains instructions and technical data to
cover all routine operations and scheduled maintenance
tasks by operation and maintenance staff. Major overhauls
are outside the scope of this manual and should be referred
to an authorized manufacturer service department.
4. The manufacturer reserves the right to make changes and
improvements to products without notice and without
incurring any obligation to make such changes or add such
improvements to products sold previously.
HB20-II/HB30-II/HB40-II Foreword
1-1
Foreword HB20-II/HB30-II/HB40-II
1-2
Symbols
Danger; Caution
DS1600838
Figure 1
Read Operation Manual
Figure 2
Check; Examine
DS1901080
Figure 3
HB20-II/HB30-II/HB40-II Symbols
2-1
Read Maintenance Manual
Figure 4
Hydraulic Oil
DS1901081
Figure 5
Hydraulic Oil Pressure
DS1901082
Figure 6
Hour Meter
DS1901083
Figure 7
Symbols HB20-II/HB30-II/HB40-II
2-2
Mass
DS1901084
Figure 8
General Prohibition Signal
DS1901085
Figure 9
Lubricant Grease
DS1901086
Figure 10
Lock; Tighten
DS1901087
Figure 11
HB20-II/HB30-II/HB40-II Symbols
2-3
Obligation: to Wear Safety Equipments
DS1901088
Figure 12
Symbols HB20-II/HB30-II/HB40-II
2-4
Safety
Safety Signal Words
WARNING
WARNING implies that instructions must be followed strictly
to avoid injury or death.
CAUTION
CAUTION means instructions must be followed strictly to
avoid damaging the product, process or its surroundings.
NOTE: NOTE" are used for supplementary information.
Safety Precautions
All mechanical equipment can be dangerous when used without
care or if in bad condition.
Ensure that the operator reads and understands the labels and
consults the manuals before maintenance or operation.
Ensure that the operation and maintenance manual remains at
operator’s disposal.
Ensure that maintenance personnel are adequately competent
and have read the maintenance manuals.
Safety is not only a matter of warnings.
Every time the operator is working with the breaker, he must
foresee any risks which might occur and how to avoid them.
WARNING
AVOID DEATH OR SERIOUS INJURY
Never undertake a new job or maintenance operations
without being sure you and other people in the environment
will be safe.
HB20-II/HB30-II/HB40-II Safety
3-1
General Information
The Breaker is an attachment for excavators, or back- hoes
according to the model.
The operator must have the necessary knowledge, and must be
qualified to operate such carriers.
He must know the safety instructions concerning the carrier and
comply with them.
In addition to the usual safety equipment such as helmet, safety
shoes, the operator will, if need be, have available.
• Safety glasses
• Industrial gloves
• Dust mask
• Ear protector
Ample, loose clothing, watch bracelet, can in some
circumstances be dangerous.
The operator must not absorb any alcoholic drinks or medicine
liable to generate sleepiness.
WARNING
It is imperative to be informed and comply with all local
laws and regulations concerning the breakers and their use.
Mounting on Carrier
Each model of breaker is suited to a specific carrier.
The operator must be informed of the technical instructions
given by the manufacturer such as
• Carrier minimum weight
• Working pressure
• Flow rate
• Hoses
• Dimensions and connection to carrier’s hydraulic circuit
WARNING
Failure to follow these instructions could result in
permanent damage to hydraulic hammer!
Safety HB20-II/HB30-II/HB40-II
3-2
When someone helps to install the breaker, make sure any hand
signals will be well understood.
When connecting the breaker hoses to the carrier circuit, be
sure the circuit is not under pressure (check the hydraulic tank is
not pressurized) or at high temperature.
WARNING
The cier engine must be stopped.
Check that IN and OUT return hoses are well connected.

Take all necessary steps to prevent oil- leakages when
connecting the breaker.
Hydraulic Fluids
Hydraulic fluids and lubricants can be dangerous for heath if not
used properly.
WARNING
Avoid ingestion, skin contact and inhalation.
Safety data sheets for oil and lubricants should be obtained from
the lubricant supplier.
Should hydraulic oil come into contact with eyes, rince them
abundantly, then consult a doctor.
Fine jets of hydraulic fluids at high pressure, can penetrate the
skin, causing serious injury.
3-3
Energy Chamber
The breakers incorporate one or two energy chambers,
containing nitrogen under pressure.
WARNING
Never attempt to open the covers.
If an energy chamber needs to be repaired, contact your

distributor.
Operation
If the carrier is in a work area where there are risks of falling
objects or rocks, the cabin must be equipped with an approved
FOPS protection.
Prior to starting work, the operator must ensure there are no
buried electricity, gas or water pipes or lines.
The operator must take every step to indicate or light up his
working area and ensure that the ground on which the carrier is
operating, is stable.
The rock breaker will be used on a clear working area,
orientated in such a way that inevitable rock chips produced by
the contact of tool with the ground are not dangerous for the
operator or any bystanders.
WARNING
Stand clear from a breaker in operation.
According to the job done with the breaker a large quantity of

dust could be produced.
Then, use water spraying to drop dust and avoid inhalation.
Do not use the breaker for any other application than that which
it is intended for : splitting blocks, trenches digging, demolition,
excavations.
Never use the breaker as a lever or use the breaker to lift loads.
Using a breaker without tool pins is forbidden.
Do not use any other tools than those recommended by the
manufacturer.
After a certain working time, the rock breaker temperature could
be high: avoid therefore all contact with any parts until it has
3-4
completely cooled down and the pressure relieved in the
hydraulic circuit.
Do not touch the rock breaker while it is in operation.
Do not leave any object on the breaker.
Maintenance and Repairing

All components, accessories, pipes and connectors added to the
rock breaker should be
• Of good quality, procured from a reputable manufacturer
and, wherever possible, be of a type approved by the
manufacturer.
• Compatible with the breaker maximal working pressure.
• Accompanied by instructions for safe installation, operation
and maintenance.
When replacing IN and OUT return hoses only use hoses
compatible with the maximum working pressure.
The use of spare parts other than those included in the
manufacturer approved parts list may create hazardous
conditions over which the manufacturer.
Therefore the manufacturer cannot be held responsible for
equipment on which non approved spare parts are installed.
3-5
3-6
Products and
Structure
Products
1. HB20-II top, housing, side
2. HB30-II top, housing, side
3. HB40-II top, housing type 1
2
Structure
1. Through Bolt 3
Front head, cylinder and back head of breaker body are

tightly fixed with through bolts.
4
2. Back Head
N2 Gas charging valve is built in and the inside is changed
with the nitrogen gas.
3. Cylinder 5
The cylinder is the heart of the breaker containing
hydraulic circuit for piston reciprocation.
4. Control Valve
6
Cylindrical control valve is built in the valve housing to
control piston reciprocation.
5. Accumulator
The accumulator compensates the pressure in the hydraulic 7
circuit and prevents pulsation. It is not usually necessary to
refill. Use nitrogen gas only.
6. Piston
8
Kinetic energy of the piston is converted into blowing
energy after hitting the tool.The lowing energy is
transmitted to the tool to break rocks.
7. Front Head
The front head supports the whole breaker components.
Upper bushing prevents shock from the tool.
9
8. Tool pins
9. Tool
The specially heat-treated tool is directly applied to break
rocks. It has various forms of a wedge, moil point, blunt Figure 1
and conechisel appropriate to the application.(optional)
HB20-II/HB30-II/HB40-II Products and Structure

4-1
Products and Structure HB20-II/HB30-II/HB40-II
4-2
Information
Specification of Breakers
Description Unit HB20-II HB30-II HB40-II
kg 1,862 2,498 3,160
Top
lb 4,105 5,507 6,966
kg 1,693 2,263 2,796
Operating Weight Housing
lb 3,732 4,989 6,164
kg 1,630 2,340 -
Side
lb 3,594 5,159 -
kg 720 920 1,105
Main Body Weight
lb 1,582 2,024 2,429
L/min 130 ~ 150 150 ~ 190 190 ~ 250
Required Oil Flow
gal/min 34 ~ 40 40 ~ 50 50 ~ 66
bar 210 230 240
Setting Pressure
psi 3,045 3,335 3,480
bar 170 ~ 210 180 ~ 220 190 ~ 230
Operating Pressure
psi 2,465 ~ 3,045 2,610 ~ 3,190 2,755 ~ 3,335
Impact Rate bpm 200 ~ 350 150 ~ 250 150 ~ 250
inch 1" 1 1/4" 1 1/4"
Hose Diameter
mm 25 32 32
Tool Diameter mm 135 150 160
Applicable Carrier Weight ton 18 ~ 25 28 ~ 35 35 ~ 48
HB20-II/HB30-II/HB40-II Information
5-1
Usage of Breaker
Use Safety Equipment
Helmet Protective Glasses
Ear Protectors
Well Fitting Cloths
Gloves
Safety Shoes
Figure 1
DS1901089
Safety Distance
Figure 2
DS1901090
Information HB20-II/HB30-II/HB40-II
5-2
Tool Type
Classification Contents
Universal tool for demolition work

Moil and block splitting low abrasive
material, concrete.
Excavation of trenches, building

Wedge pits, breaking of reinforced
concrete.
Blunt Block splitting in quaries
Hard reinforced concrete flooring,

Corn
sedimentary materials
HB20-II/HB30-II/HB40-II Information
5-3
Information HB20-II/HB30-II/HB40-II
5-4
Installation and
Operation
Flushing Before Install Breaker
HP (Pressure Line)
LP (Return Line) 2 Open
2 Open
3 Operate Pedal (10 min)
Flushing Connector
DS1901095
Figure 1
HB20-II/HB30-II/HB40-II Installation and Operation

6-1
Tool Installation
Figure 2 DS1901001
Tool Removement
DS1901002
Figure 3
Installation and Operation HB20-II/HB30-II/HB40-II

6-2
Hose Installation
DS1901003
Figure 4
HB20-II/HB30-II/HB40-II Installation and Operation

6-3
Check Setting Pressure
3 Pressure Guage 1 C
Cllo
C loossseee (((B
Booottthhh sssiid
B iddeee)))
2 Operate Pedal
Figure 5 DS1901005
Check Operating Pressure
Open (((B
1 C Booottthhh S
B Siididdeee)))
S
3 Pressure Guage
2 Operate Pedal
Figure 6 DS1901004
Installation and Operation HB20-II/HB30-II/HB40-II

6-4
User Instruction
For the Working Position
Pressure on tool will always be correct if breaker remains
perfectly perpendicular.
OK
90°
Figure 1 DS1901096
OK
HB20-II/HB30-II/HB40-II User Instruction

7-1
User Instruction HB20-II/HB30-II/HB40-II
7-2
For the Working Time
Do not keep the breaker more than 15 seconds in the same
position especially when the material is rather hard and resilient.
(No warranty)
STOP
15s
OK
DS1901097
Figure 2
For the Breaker Position
6° 6°
>2° >2°
OK
DS1901098
Figure 3

7-2
Push with the reinforced plate.
OK
DS1901099
Figure 4
Do not push with tool or casing.
DS1901100
Figure 5
Do not push with tool or casing. (No warranty)
DS1901120
Figure 6

7-3
Push in lateral direction with the reinforced plate.
OK
DS1901121
Figure 7
Do not push in lateral direction with the casing. (No warranty)
DS1901122
Figure 8
Cut small blocks of material.
OK OK
1 2
DS1901124
Figure 9

7-4
Do not cut big blocks of material
1
Figure 10 DS1901123
Make sure to keep a distance between casing and material.
OK
Figure 11 DS1901125
Work without vibration.
OK
Figure 12
DS1901126

7-5
Avoid blank firing.
OK
DS1901127
Figure 13
Stop the breaker immediately when hoses vibrate excessively.
OK
DS1901128
Figure 14

7-6
If piston have reached the maximum stroke, the excavator boom
and arm cylinders will be damaged.
OK
DS1901129
Figure 15
Working Temperature
Stop if oil temperature is too high.
60˚C 80˚C
`W `W
_W _W
^W ^W
]W ]W
\W \W
[W [W
ZW ZW
YW YW
XW XW
W W W W
TX W TX W
TY W TY W
TZW
T[W
OK TZW
T[W
T\W T\W
T]W T]W
T^W T^W
STOP
DS1901130
Figure 16

7-7
If the weather is too coil, don't start to work. Pre-heat the
excavator oil.
5min
-10˚C +
`W
`W _W
`W
^W
_W ]W
_W
\
W
^W ^W
[
]W W
]W
Z
\W W \W
Y
[W W [W
ZW ZW
YW YW
XW XW
W W W W
TX W TX W
TY W TY W
TZW TZW
T[W T[W
T\W T\W
T]W
T^W
T]W
T^W
OK
DS1901131
Figure 17
Never use the tool as a lever or to lift heavy loads.
DS1901132
Figure 18
Do not use the breaker underwater without under water system.
DS1901133
Figure 19

7-8
Impact Effect on Tool
Tool reacts differently to repeated impacts:
• When piston hits tool: compression effect
• After transmission of impact to the rock: expansion,
compression or stress release
Stresses variations subject tool to fatigue. Therefore, it is
recommended to replace a tool, when totally worn out, even if
used correctly, rather than waiting for a fatigue failure.
Fatigue breakages occur perpendicularly to the tool axis. They
develop from an incipient breakage, with progressive fissuring
similarly to ripples at the surface of the water.
Comment: a similar phenomenon appears when there is a
defect in steel. In this case, the fatigue lines develop from the
weak point.
Fatigue breaking due to damages

causes from outside.
Breaking point following

a cut or a damage.
Lines of fatigue.
(fatigue breaking area) Sudden breaking surface.
Fatigue breaking surface

with typical fatigues lines
due to steel defect.
Figure 20 DS1901134

7-9
Origin of Breakages
WARNING
Corrosion: Corrosion causes a superficial alteration of the
steel, which may result in an incipient breakage. Tool
should then be protected with grease during storage or
when unused for a long time, to avoid rust formation.
WARNING
Cold: Cold may cause brittleness of tool. (temperature lower
than 5° C).
To prevent it:
• Store tool in a temperate place
• Operate the breaker at a low pressure during 5 to 10
minutes to heat the tool
Tool bending
To reduce frictions due to bending, apply sufficient pressure in
the axis of the breaker and tool, and whenever possible,
perpendicularly to the surface to be hit.
The breaker orientation must be constantly adjusted to keep up
with tool motion or any possible tool slipping.
Tool twisting
This problem is specific to tool. When tool is in a fault or
deviated by a rock, seizing may occur at the level of the retaining
pins.These tool, more stressed, have generally a shorter life
than standard moil point.

7-10
Nitrogen Inflating Procedure
IMPORTANT
Do not use other gas. Use N2 Gas only.
CAUTION
AVOID SERIOUS INJURY
Do not stay close to the tool, during the inflating operation.
Before inflating:
The strike piston must be imperatively in down
position, the tool must not push the piston
upward (contact) or, dismantle the tool.
DS1901135
Figure 21

7-11
WARNING
Waring Notice for N2 gas 3-way charging kit.
1. Check the two O-Rings exists in right place.
2. Be sure the adapter nut (N) is locked before assemble
the kit.
3. Be sure the release valve (RV) is locked before
assemble the kit.
4. Check the amount of nitrogen gas remaining.
5. Keep fastening handle and tools always around you.
6. Must use the N2 charging kit for N2 charging purpose.
7. Avoid facing the kit when connecting the N2 cylinder
and charing kit.
8. Check the points and maintenance.
A. Check interval valve leakage.
B. Check pressure gauge operate normally.
C. Check adapter nut (N) thread is damaged or not.
D. Check the dent on the charging kit.
Gas Gauge Regulating Button

- 50 bar to Backhead
- 100 bar to Accumulator
Nulling Handle
Release Valve
Gas Duct
Coupler
Adapter Nut
Adapter Connector
DS1901136
Figure 22

7-12
Charging N2 Gas Instruction - Back head
1. Assemble the 50 bar gas gauge (G).
• Pull the coupling and assemble it
WARNING
• Check adapter nut (N) is be locked.
• Check release valve (RV) is be locked.
DS1901026
Figure 23
2. Unscrew the charging plug with 17 mm spanner.
DS1901027
Figure 24
3. Assemble the charging kit on the back head by hand.

• Use the knurling to lock tightly with your hands.
DS1901028
Figure 25

7-13
4. Press regulating button (RB) to check remaining nitrogen
gas.
DS1901029
Figure 26
5. If there is no nitrogen gas, remove the adapter nut (N) with

22 mm spanner.
DS1901030
Figure 27
6. Connect the nitrogen cylinder to the hose with 30 mm

spanner.
DS1901031
Figure 28
7. Connect the charging kit to the hose with 22 mm spanner.
DS1901032
Figure 29

7-14
8. Turn counterclockwise the nitrogen cylinder handle slowly.
WARNING
• If you turn fast, you risk exploding.
• Keep your eyes on the gas gauge (G).
DS1901033
Figure 30
9. When the nitrogen gas reaches the setting pressure, turn

and lock the nitrogen cylinder handle.
DS1901034
Figure 31
10. Turn counterclockwise the release valve (RV) for residual

pressure removal.
DS1901035
Figure 32
11. Disconnect the hose from the charging valve and nitrogen
cylinder.
DS1901036
Figure 33

7-15
12. Be fasten the adapter nut (N).
DS1901037
Figure 34
13. Be fasten the release valve (RV).
DS1901038
Figure 35
14. With the regulating button (RB) pressed, loosen the

release valve (RV) gradually to adjust the specific
pressure.
• Do not loosen the release valve (RV) quickly.
DS1901039
Figure 36
15. When setting is completed, loosen the release valve (RV)

to remove residual pressure.
WARNING
• During in this working, the button must be not
pressed.
DS1901040
Figure 37

7-16
16. Disassemble the charging kit on the back head by hand.
DS1901041
Figure 38
17. Screw and lock the charging plug.
DS1901042
Figure 39
Back Head Inflating Table

(Unit: kg/cm2)
Model HB20-II HB30-II HB40-II
Back head Gas Pressure 6 6 9
Depends on the temperature of the back head surface.
(Unit: kg/cm2)
Pressure
Temperature (°C)
HB20-II HB30-II HB40-II
-10 5.1 5.1 8.1
0 5.4 5.4 8.4
10 5.7 5.7 8.7
20 6 6 9
30 6.3 6.3 9.3
40 6.6 6.6 9.6
50 6.9 6.9 9.9
60 7.2 7.2 10.2
70 7.5 7.5 10.5

7-17
Charging N2 Gas Instruction - Accumulator
1. Assemble the 100 bar gas gauge (G).
• Pull the coupling and assemble it
WARNING
DS1901043
• There is a risk of explosion if you don't use a Figure 40
100 bar gauge.
2. Unscrew the plug with 22 mm spanner
DS1901044
Figure 41
3. Assemble the charging kit on the accumulator by hand.

• Use the knurling to lock tightly with your hands.
DS1901045
Figure 42

7-18
4. Unscrew the accumulator adjust nut with 22 mm spanner.
DS1901046
Figure 43
5. Turn the accumulator adjust in the counterclockwise

direction with 5 mm L-wrench. (1/2 ~ 1 turn)
WARNING
• Do not turn the accumulator adjust over 1 turn.
There is a possibility that if you turn it over than 1
turn, you will be serious injured. DS1901047
Figure 44
6. Press regulating button (RB) to check remaining nitrogen

gas.
DS1901048
Figure 45

7-19
7. If there is no nitrogen gas, remove the adapter nut (N) with
22 mm spanner.
DS1901049
Figure 46
8. Connect the nitrogen cylinder to the hose with 30 mm

spanner.
DS1901031
Figure 47
9. Connect the charging kit to the hose with 22 mm spanner.
DS1901050
Figure 48

7-20
10. Turn counterclockwise the nitrogen cylinder handle slowly.
WARNING
• If you turn fast, you risk exploding.
DS1901051
Figure 49
11. When the nitrogen gas reaches the setting pressure, turn
and lock the nitrogen cylinder handle.
DS1901052
Figure 50
12. Turn counterclockwise the release valve (RV) for residual

pressure removal.
DS1901053
Figure 51

7-21
13. Disconnect the hose from the charging valve and nitrogen
cylinder.
DS1901054
Figure 52
14. Be fasten the adapter nut (N).
DS1901055
Figure 53
15. Be fasten the release valve (RV).
DS1901056
Figure 54

7-22
16. With the regulating button (RB) pressed, loosen the
release valve (RV) gradually to adjust the specific
pressure.
• Do not loosen the release valve (RV) quickly.
DS1901071
Figure 55
17. When setting is completed, loosen the release valve (RV)

to remove residual pressure.
WARNING !

• During in this working, the button must be not
pressed.
DS1901072
Figure 56
18. Turn the accumulator adjust in the clockwise direction for

lock.
DS1901073
Figure 57
19. Screw the nut for lock.
DS1901074
Figure 58

7-23
20. Disassemble the charging kit on the back head by hand.
DS1901075
Figure 59
21. Be fasten the plug.
DS1901076
Figure 60
Accumulator Inflating Table

(Unit: kg/cm2)
Accumulator Gas Pressure 58 58 58
Depends on the temperature of the accumulator surface.
(Unit: kg/cm2)
Pressure
Temperature (°C)
HB20-II HB30-II HB40-II
-10 50 50 50
0 52 52 52
10 55 55 55
20 58 58 58
30 60 60 60
40 62 62 62
50 65 65 65
60 66 66 66
70 68 68 68

7-24
Stroke Adjustment
WARNING
• Do not turn over 2 turns in the counterclockwise
direction.
• It can be exploded and got serious injured or die.
1 2
Figure 61 DS1901077
High Frequency Low Frequency

Low Power High Power
DS1901078
Figure 62

7-25
Front Cover Removement
WARNING
• Must be removed first the tool and tool pins.
1. Remove the snap rings with snap ring plier.
DS1901138
Figure 63
2. Remove the rubber plugs with snap ring plier or vise pliers.
DS1901139
Figure 64
3. Remove the stop pins from the opposite side with hammer
DS1901140
Figure 65

7-26
4. Lay the jig_a up as shown in the fig.4
DS1901141
Figure 66
5. Lay the jig_b up as shown in the fig.5
DS1901142
Figure 67
6. Hit the jig_b hard with a hammer until remove the front
cover.
DS1901143
Figure 68

7-27
Innerbush Removement
WARNING
1. Remove the rubber plug with snap ring plier or vise pliers.
DS1901144
Figure 69
2. Remove the stop pin from the opposite side with hammer.
DS1901145
Figure 70
3. Lay the jig_c up as shown in the fig.9
DS1901146
Figure 71

7-28
4. Hit the jig_c hard with a hammer until remove the
innerbush.
DS1901147
Figure 72

7-29
Innerbush Assembly
WARNING
1. Insert the innerbush in the front head as shown in fig.11
DS1901148
Figure 73
2. Lay the jig_d up as shown in the fig.12
DS1901149
Figure 74

7-30
3. Hit the jig_d hard with a hammer until innerbush is fully
assembled.
DS1901213
Figure 75
4. Insert the stop pin in a hole like fig.14
DS1901214
Figure 76
5. Assemble the rubber plug in a hole like fig.5 with snap ring
plier or vise pliers.
DS1901215
Figure 77

7-31
Frontcover Assembly
WARNING
• Must be innerbush assembled first.
1. Insert the front cover in the front head as shown in fig.16

At this time, be careful about the right angle between the
front head pin holes and the front cover pin holes.
Figure 78 DS1901216
2. Lay the jig_e up as shown in the fig.17
Figure 79 DS1901217
3. Hit the jig_e hard with a hammer until front cover in fully
assembled.
DS1901218
Figure 80

7-32
4. Insert the stop pins in holes like fig.19
DS1901219
Figure 81
5. Assemble the rubber plugs in holes like fig.20 with snap

ring plier or vise pliers.
DS1901220
Figure 82
6. Assemble the snap rings in holes like fig.21 with snap ring
plier.
DS1901221
Figure 83

7-33
Front Cover & Innerbush Removement Tools
Unit: mm
Jig_a A B C
HB20-II 160
HB30-II 180 40 60
HB40-II 200
A C
B
Unit: mm
Jig_b A B C
HB20-II
HB30-II 110 30 700
C
HB40-II
B
A
DS1901223
Figure 85
Unit: mm
Jig_c A B C
HB20-II 118 30 250
HB30-II 135 30 300 C
HB40-II 140 30 330
B
A
DS1901223
Figure 86

7-34
Front Cover & Innerbush Assembly Tools
Unit: mm
Jig_d A B C
HB20-II 135 30 380
HB30-II 150 30 450
C
HB40-II 160 30 490
B
A
DS1901223
Figure 87
Unit: mm
Jig_e A B C
HB20-II
HB30-II 300 40 60
HB40-II
A C
B
DS1901222
Figure 88

7-35
7-36
External Dimensions
Housing Type Dimension
DS1900998
Figure 1
(Unit: mm)
Model A B C D E F
HB20-II 2,790 2,040 1,610 410 495 75
HB30-II 3,060 2,285 1,820 440 515 80
HB40-II 3,250 2,510 1,990 472 550 100
HB20-II/HB30-II/HB40-II External Dimensions

8-1
Top Type Dimension
C
A
E D
F
DS1900997
Figure 2
(Unit: mm)
Model A B C D E F
HB20-II 2,820 2,060 1,625 447 625 75
HB30-II 3,080 2,285 1,815 495 668 80
HB40-II 3,320 2,560 2,020 536 725 100
External Dimensions HB20-II/HB30-II/HB40-II

8-2
Side Type Dimension
D C
B
A
F E
G
DS1900999
Figure 3
(Unit: mm)
Model A B C D E F G
HB20-II 2,310 1,550 1,185 500 545 460 75
HB30-II 2,540 1,745 1,355 600 620 540 80
HB40-II - - - - - - -

8-3
Mountcap Plate Dimension
C D C E
H
F
G
B
12-X
F
T
DS1901000
Figure 4
(Unit: mm)
Model Type A B C D E
HB20-II 510 680 150 150 30
HB30-II Housing 630 745 180 190 40
HB40-II 700 800 190 215 40
Model Type F G H T X
HB20-II 210 200 30 27 26
HB30-II Housing 220 225 40 33 32
HB40-II 240 240 40 37 32

8-4
A
C D C E
H
F
G
B
12-X
F
T
DS1901000
Figure 5
(Unit: mm)
Model Type A B C D E
HB20-II 550 670 160 170 30
HB30-II Top 640 712 150 270 35
HB40-II 780 780 240 220 40
Model Type F G H T X
HB20-II 170 170 30 27 26
HB30-II Top 180 182 35 33 32
HB40-II 240 220 40 37 32

8-5
8-6
Torque
Through Bolt
Unit: Nm
Torque 2719 3630 4238
DS1901010
Figure 1
Mountcap Bolt
Unit: Nm
Torque 690 1470 1470
DS1901011
Figure 2
Accumulator Body Bolt

Unit: Nm
Torque 1300 1350 1350
DS1901013
Figure 3
HB20-II/HB30-II/HB40-II Torque
9-1
Accumulator Cover Bolt
Unit: Nm
Torque 805 805 1000
DS1901012
Figure 4
Valve Housing Bolt

Unit: Nm
Torque 1000 1000 1000
DS1901014
Figure 5
Valve Cover_A Bolt

Unit: Nm
Torque 855 1000 1000
DS1901015
Figure 6
Valve Cover_B Bolt

Unit: Nm
Torque - 1000 1000
DS1901016
Figure 7
Torque HB20-II/HB30-II/HB40-II
9-2
Bracket Side Bolt
Unit: Nm
Torque 2719 3023 3630
DS1901017
Figure 8
HB20-II/HB30-II/HB40-II Torque
9-3
Torque HB20-II/HB30-II/HB40-II
9-4
Maintenance and
Trouble Shooting
Maintenance Schedule
Description Substance
• Greasing on fronthead for tool, and tool pin.
Every 2 hours • Check hydraulic oil temperature.
• Check hose and piping connection.
Every Every • Check oil leakage.
day 10 hours • Check the tool and tool pins surface.
• Check gas pressure.
Every Every • Check the side dampers and upper/lower damper’s thickness.
week 50 hours
• Check each bolts tightening torque.
Every Every • Check the clearance between tool and tool pins.
4 weeks 200 hours • Check the clearance between tool and front cover.
• Change the seals.
Every Every
• Change accumulator diaphragm.
6 month 1,000 hours
• Factory inspection by authorized service personnel recommended.
Wear Limit of Parts

1. Front Cover
(Unit: mm)
Model New Part (A) Usage Limit (B)

HB20-II 135 141
A
B
HB30-II 150 158

HB40-II 160 168
DS1901018
Figure 1
HB20-II/HB30-II/HB40-II Maintenance and Trouble Shooting

10-1
2. Tool Pin
(Unit: mm)

HB20-II 80 77
HB30-II 89 86
HB40-II 100 97 B
DS1901019
Figure 2
3. Tool
(Unit: mm)

HB20-II 765 450
HB30-II 780 460
B
HB40-II 825 480
A
DS1901020
Figure 3
4. Innerbush A
(Unit: mm)
B
HB20-II 34 31
HB30-II 40 37
HB40-II 40 37
DS1901137
Figure 4
5. Upper damper

HB20-II 130 126
HB30-II 145 141
HB40-II 150 146
Figure 5
Maintenance and Trouble Shooting HB20-II/HB30-II/HB40-II

10-2
6. Lower damper

HB20-II 40 38
HB30-II 40 38
HB40-II 40 38
Figure 6
7. Side damper

HB20-II 20 18.5
HB30-II 20 18.5
HB40-II 20 18.5
Figure 7

10-3
Trouble Shooting
1. The breaker does not work.
DS1901021
Figure 5
Condition Cause Solution

Pressure and return line mixed up Connect breaker hoses correctly
Ball valves on pressure and
Open valves
/ or return lines closed
Does not work Oil level in tank to low Check and refill oil
Abnormal performance of hydraulic pump Repair and replace
Pressure relief valve set too low Check and refill oil
Failure on the breaker Check if the piston moves

10-3
2. Too low impact power of breaker.
DS1901022
Figure 6

Insufficient oil flow and pressure Check hydraulic of the excavator
Check coupling, oil filter, cooler and return
Flow resistance to high in return line
line diameter
Hydraulic oil delivery (flow, pressure) from
Lack of power Check engine speed
carrier not conform
Relief valve setted too low Adjustment of the setting
Breken tool Replace tool and check piston damage
Gas pressure in backhead too high or too low Check gas pressure and reset to correct value

10-4
3. Abnormal operating of breaker.
DS1901023
Figure 7

Hydraulic oil temperature too high Oil temperature must not exceed 80 deg.C
Float position Never use float position
Insufficient thrust Increase thrust on breaker
Irregular Suspension (Housing model) check the
Suspension (Housing model)
breaking damper
Clogged or restricted hoses or pipes Clean and replace
Down force on the tool too low Increase the down pressure acting on the tool
Abnormal movement of piston and cylinder Overhaul the breaker

10-5
4. Operating temperature too high
`W
_W
^W
]W
\W
[W
ZW
YW
XW
W W
TXW
TYW
TZW
T[W
T\W
T]W
T^W
DS1901024
Figure 8

Insufficient oil cooling Check oil cooler
Insufficient oil flow Check pump output
High
Incorrect oil pressure check relief valve setting
temperature
Oil level in tank is too low Check and refill oil
Too long continuous working Never exceed 15 s

10-6
5. Leakage
DS1901025
Figure 9

Leakage on fittings Tighten the fittings
Leakage on IN & OUT port Tighten the fittings
Oil leakage
Leakage on bottom of the piston Contact to dealer
Leakage between main body Contact to dealer

Loosen bolts Tighten the bolts
Back head Broken bolts Replace the bolts
N2 gas leakage Defect back head charging valve Replace charging valve
Defect O-ring or gas seal Replace O-ring and gas seal

10-7
10-8
10-8
Storage
Caution for Long Term Storage
1. Breaker Storage
• Do net store outside when not in use
DS1901007
Figure 1
2. Long Term Storage

• Must be stored inside
• Removed the tool
• Upright (in safety stand)
DS1901008
Figure 2
3. Short Term Storage

• Lay down (inclined at tool end)
• Grease the tool
• Cover with like tarpaulin
DS1901009
Figure 3
HB20-II/HB30-II/HB40-II Storage
11-1
4. Boom Positioning (not in use)
• Breaker vertical
• Retract tool
DS1901006
Figure 4
Storage Method
Term Solution
Every 3 months Change up side down the body for good state of seal
Every 6 months Check the internal cylinder & corrosion condition
Before Operating
Term Solution
Every 3 months Check the seals
Every 6 months Check the seals and corrosion states
Storage HB20-II/HB30-II/HB40-II
11-2
The Auto Lubrication
Kit (Option)
Adjustment of Auto Lubrication Kit
Adjuster
Grease Refilling Port
L
Max. Output L = 7 mm
Min. Output L = 0 mm
Grease Nipple for ManualGreasing
Figure 1
Air Discharge Method

When air and grease are mixed, push the check valve.
Grease
Air
Push
Air
Push
Figure 2
HB20-II/HB30-II/HB40-II The Auto Lubrication Kit (Option)

12-1
Air Discharge Method
1. Insert an injection port into the grease and pull the handle
and then wait for 2 seconds. (Grease gets inside the pump)
GREASE
Figure 3
2. Insert the handle. Then grease becomes compressed in

the refilling cartridge.
GREASE
Figure 4
3. Repeat 1, 2
GREASE GREASE
Figure 5
The Auto Lubrication Kit (Option) HB20-II/HB30-II/HB40-II

12-2
4. When the grease injection is complete, turn handle
clockwise direction for lock.
Figure 6
Grease Refill Method (Only Have Grease

Power Pump)
Put the injection port of an auto power grease gun into the
refilling port of an auto grease device and refill the cartridge.
Power Pump
Figure 7
HB20-II/HB30-II/HB40-II The Auto Lubrication Kit (Option)

12-3
The Auto Lubrication Kit (Option) HB20-II/HB30-II/HB40-II
12-4

HB20-II / HB30-II / HB40-II: Operation and Maintenance Manual

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Operation and Maintenance Manual

HB20-II / HB30-II / HB40-II

DOOSAN and the DOOSAN logo are registered

Copyright DOOSAN 2020© Original Instructions

Safety ....................................................................................... 3-1

Products and Structure ........................................................... 4-1

Information ............................................................................... 5-1

Installation and Operation ....................................................... 6-1

User Instruction ....................................................................... 7-1

HB20-II/HB30-II/HB40-II Table of Contents

External Dimensions ............................................................... 8-1

Torque ...................................................................................... 9-1

Maintenance and Trouble Shooting ..................................... 10-1

HB20-II/HB30-II/HB40-II Table of Contents

The Auto Lubrication Kit (Option) ........................................ 12-1

HB20-II/HB30-II/HB40-II Table of Contents

Read Operation Manual

Hydraulic Oil Pressure

General Prohibition Signal

NOTE: NOTE" are used for supplementary information.

Check that IN and OUT return hoses are well connected.

If an energy chamber needs to be repaired, contact your

According to the job done with the breaker a large quantity of

Maintenance and Repairing

Front head, cylinder and back head of breaker body are

HB20-II/HB30-II/HB40-II Products and Structure

Use Safety Equipment

Helmet Protective Glasses

Well Fitting Cloths

Universal tool for demolition work

Excavation of trenches, building

Blunt Block splitting in quaries

Hard reinforced concrete flooring,

LP (Return Line) 2 Open

3 Operate Pedal (10 min)

HB20-II/HB30-II/HB40-II Installation and Operation

Installation and Operation HB20-II/HB30-II/HB40-II

HB20-II/HB30-II/HB40-II Installation and Operation

Check Operating Pressure

Installation and Operation HB20-II/HB30-II/HB40-II

HB20-II/HB30-II/HB40-II User Instruction

For the Breaker Position

User Instruction HB20-II/HB30-II/HB40-II

Do not push with tool or casing.

Do not push with tool or casing. (No warranty)

HB20-II/HB30-II/HB40-II User Instruction

Do not push in lateral direction with the casing. (No warranty)

Cut small blocks of material.

User Instruction HB20-II/HB30-II/HB40-II

Make sure to keep a distance between casing and material.

Work without vibration.

HB20-II/HB30-II/HB40-II User Instruction

Stop the breaker immediately when hoses vibrate excessively.

User Instruction HB20-II/HB30-II/HB40-II

HB20-II/HB30-II/HB40-II User Instruction

Never use the tool as a lever or to lift heavy loads.

Do not use the breaker underwater without under water system.

User Instruction HB20-II/HB30-II/HB40-II

Fatigue breaking due to damages