12-0009 -IB

Brokk 250
Part. no: 3136 8012 51
Issue: A
Valid for machine no:
910785
910813
Operator´s manual

Distributor:
Brokk AB
PO Box 730
SE-931 27 Skellefteå • Sweden
Tel: +46 910 711 800
Fax: +46 910 711 811
E-mail: [email protected]
www.brokk.com
12-0384-GB
 portant! About this m a n u al
Im We hope it will help you
work more
the Brokk.
Thank you for choosing
efficiently.
d this manual
supervisors and operators rea
It is extremely important that service
be for e usi ng the ma ch ine . Following the operating and
carefully ll as
po rta nt bo th for the saf ety of operators and others as we
instructions is im
and machines.
to avoid damaging buildings
main sections:
The manual consists of three
machine with technical data
• General description of the
ting instructions
• Safety regulations and opera
ctions
• Service schedule and instru
especially carefully!
Read the safety regulations
bols are found in the text:
The following warnings sym

Attention!
Indicates risks that can
cause injury if misused.

Warning!
Indicates risks that can
cause serious injury if
misused.

WARNING!
Indicates risks that can
cause fatal injury if
misused.

ious tasks
can be esp eci ally ada pte d during manufacture for var
As the machine slightly from the
nm ent s, som e dia gra ms in this manual might differ
and env iro ption of the
usi ng. If you r ma chi ne has been modified, a descri
machine you are .
ns wil l be fou nd in the chapter "Special adaptations"
modifica tio s" or in
ng acc ess ori es can be fou nd in the chapter "Accessorie
Directions for usi
ls.
separate instruction manua

Brokk AB

08-1220-GB
 Table of contents
Important notes about this ma- Moving the machine
Operating the outriggers
nual! Moving during operation
Moving on uneven ground
Safety regulations Folding the outrigger brackets when moving
through narrow passages
General
Removing wheels and hubs
Range of uses Operating the machine
Personal protective equipment Operating the upper part with arm
Risks factors when demolishing Operating with different kinds of tools
Warning signs Operating near shafts
Supervisor and operator responsibility Operating in confined spaces
Work environment Changing tools
Stability Lower pressure level
Electrical safety
Radio Maintenance
Transporting and moving General notes
Before operation Cleaning
Important notes on the electric system
During operation Important notes on the hydraulic system
After operation Hydraulic fluid and lubricants
Safety during servicing and maintenance Daily Inspection and lubrication
Lubrication points
Description Maintenance instructions
General notes Regular maintenance
Technical Data Brokk 250 Check points
Description of weight distribution with hydraulic Maintenance instructions
hammer
Product description Trouble shooting
Upper part General notes
Lower part Motor and electricity supply
Hydraulic system Operation
System parts
Working temperature Circuit diagrams
The Electric System Cable marking
Power Supply Electric circuit diagram, control box
High voltage part Electric circuit diagram, electronics unit
Low-voltage part Electric circuit diagram, light current
Control system Electric circuit diagram, light current
Control box Electric circuit diagram, heavy current
Hydraulic diagram
Handling
Operating in difficult environments. Accessories
Heat Central greasing
Cold Forced draft cooling equipment
Water
Risk of fire and explosion
Transport and hoisting
Hoisting
Transport
Starting and stopping
Before starting
Starting
Stopping

12-0377- GB
 Safety regulations
General
• The operator must read and understand the
instruction manual and the directions on signs
and labels before putting the machine in service.
• The operator must have the relevant training and
experience in order to carry out the task safely.
• The employer and operator are responsible for
ensuring that national and local legislation,
regulations and other directions are followed
when the machine is being used.

Range of uses
Brokk machines are designed exclusively for
demolishing work with attachments designed for
this specific purpose. The manufacturer cannot be
held responsible for damage caused by incorrect
use, unsuitable attachments or the use of non-origi-
nal spare parts.
The machine must not be used for purposes for
which it was not intended or that are unsuitable, i.e.
handling that causes damage to property or persons.
The machine must not be operated in premises
classed as an ”explosion hazard”.
Since Brokk machines can be used for many
different applications, it is essential that the
operator’s protective equipment is adapted to the
conditions in question in each case. Examples of
fields of work demanding specialist knowledge and
special protective measures:
• working on ladles and kilns in extremely hot
environments
• demolishing refractory brick linings
• demolishing radioactive installations in nuclear
power plants.
It is essential that working methods be adapted to
the actual conditions.

09-0574G-GB
 Safety Regulations

In the example above, demolishing refractory linings,

the machine will directly affect the risk of collapsing.
The refractory lining above and to the side of the
operator may vibrate loose a long way from where
the actual cutting is taking place. In addition, the
work is often carried out in narrow and hot
environments where bricks or sharp splinters of
brick can fly around in an uncontrolled manner.

Personal protective
equipment
Always use personal protective equipment consis-
ting of:
1 protective helmet
2 hearing protectors, earmuffs
3 helmet face shield
4 breathing apparatus suited to the environment
5 rugged overalls
6 protective gloves
7 safety shoes
8 safety equipment.
We recommend using a helmet of type
Airstream in dusty environments. Use special
protection in warm environments. Certain
environments may require the use of a gas mask.

09-0575G- GB
 Safety Regulations

Risks factors when

demolishing
It is essential that the operator is familiar with the
machine functions and characteristics. The
demanding tasks performed by the machine also
means that it is essential to always ”think safety”
while working.
Since the machines are used in many different
environments, it is impossible to give general
Illustration 1
guidelines and warnings for all possible risks. This
means that a great responsibility rests on the opera-
tor and supervisor and their judgement and ability to
identify possible risks before and during the job.
Experience of demolishing work, prudence and
thinking safety are decisive for working with
demolishing equipment without exerting personnel
and equipment to unnecessary risks.
The environment the machine is working in often
Illustration 2
involves various risk factors:
• demolition of structural elements with associated
risks.
• placing a heavy machine on floors of doubtful
strength or close to shafts, see illustration 1
• placing the machine on rubble where it can tip
over, see illustration 2
• moving up or down stairs or ramps, see illustra- Illustration 3
tion 2
• demolition where hazardous electrical, gas and
fluid lines may be concealed in walls or floors,
see illustration 3
• falling objects
• cutting material that splinters and flies around in
an uncontrollable manner, see illustration 4, etc.

Illustration 4

09-0576G- GB
 Safety Regulations

Warning signs
Warning signs are located on the machine, see the
chapter ”description, Technical Data” for their
locations. Warning symbols on the signs are grouped
in pairs: The symbol on the left, in the warning
triangle, indicates the danger that exists. The symbol
on the right describes how the danger can be fore-
stalled and avoided.
The warning symbols on the signs have the
following meanings:
1. General hazard – Use personal protective
equipment.
2. General hazard – read the instruction manual.
3. Warning, high voltage – Always connect the
machine through an earth fault relay.
4. Risk for collapsing, falling machine, falling opera-
tor – Check surface, stabilise surface, anchor the
machine and operator, separate the operator from
the control box by using a stand.
5. Risk for tipping/sliding machine – Anchor the
machine, keep your distance and stand above the
level of the machine.
6. Risk for being run over, fastening in cables –
Keep your distance.
7. Risk for splintering, falling objects – Keep your
distance, use personal protective equipment.

Warning signs for Brokk Diesel

1. Warning for rotating fan blades, can cause
serious injury to fingers and hands.
2 Warning for hot surfaces, can cause serious
burns if touched.
1.

2.

09-0577G-A- GB
 Safety Regulations

Supervisor and operator

responsibility
Constructional aspects must be taken into conside-
ration by the supervisor/operator when commencing
demolishing work.
• Make sure the surface is able to withstand the
weight of the machine and the forces arising
from the attachments being used.
• Investigate the consequences of pulling down
structural elements.
Take necessary safety precautions: bracing,
trussing and correct order when pulling down
structural elements.
• Plan the order in which to perform the various
demolishing procedures.
• Check and mark where cables are run and make
sure cables in walls/floors being demolished are Illustration 1
disconnected, see illustration 1.
• Ensure the mobility of the machine in
the workplace.
• When moving/operating the machine on a ramp
or staircase, the machine must always be
secured. Make also sure that the ramp/staircase
is strong enough to support the weight of the
machine, see illustration 2.
• The operator must have access to personal
protective equipment, including a safety line and Illustration 2
stand, if there is the slightest risk of falling, see
illustration 3.
• The operator must be informed of any risks
(location of structural elements, floor strength,
live power cables).

Illustration 3

09-0578G- GB
 Safety Regulations

The operator must observe safety precautions at all

times while operating the machine and always think
ahead.
The most important safety aspects for the opera-
tor are to:
• read and understand the instruction manual
• use the necessary personal protective equipment
• stay outside the working range and risk zone of
the machine.
• stand in a position that is not affected by the
demolishing work (splinters, falling objects, risk
of collapsing, etc.)
• make sure nobody comes within the working
range and risk zone of the machine or where
there is risk of falling or flying objects.

09-0579G- GB
 Safety Regulations

Work environment
National and local regulations must always be
followed. This can apply to e.g. demands for spe-
cial protective equipment, sound and vibration levels,
the use of breathing apparatus, cordoning off, etc.
Local regulations can be checked with the safety
representative.
Other important aspects include observing and
attending to the work environment that arises during
demolishing in the best way possible. Naturally,
personal protective equipment must be used.
Remember that the dust that arises may be a health
hazard - always use breathing apparatus.
The air in confined areas or in hollows may
deteriorate rapidly due to exhaust fumes. Provide
good ventilation. A good working light can be a
decisive factor with respect to working safely and
with good vision.

Stability
The machine stability can vary considerably
depending on how it is standing and on the weight of
the attachment being used.
During operation, the machine must be
standing as level as possible and the outriggers
must be fully lowered.
However, it may be impossible to work with the
outriggers fully lowered on certain occasions. This
can apply in confined areas, when moving or when
working close to an obstruction. It is essential to be
aware of the fact that machine stability deteriorates
when the outriggers are not fully lowered. The
working range will be limited and procedures must
be adapted to these circumstances. The machine
can tip over if the arm is slewed outside the range of
the outriggers/tracks, i.e. the arm may only work in
a forward direction, not to the side.

09-0580G- GB
 Safety Regulations

The same problem may occur when machines with

track drive are working with narrow track width or
with the outriggers folded back. Safety in these
circumstances is greatly affected by the operator
and his judgement.
There is a risk of the machine tipping while
working with the machine standing on debris and
rubble when not all the outriggers are on stable
ground.
Always anchor the machine when working on
inclines.

Electrical safety
• Handle electric equipment with great
respect. This applies also to cables and
connectors.
• Always connect the machine through an
earth fault relay, 30mA.
• The machine must never be moved into deep
water so that the water reaches up to and enters
connectors, power cables, the electric motor or
any other electric equipment that may then be
damaged.
• Check that the voltage and fuse values are
correct before connecting the machine’s supply
cable.
• Make sure the supply cable is not damaged.
• Damage to electric cables may interfere with the
machine function and cause mechanical parts to
become live.
• The electric cabinet must not be opened while
the machine is connected to the mains. Certain
parts of the electric cabinet are always live.

Radio
If several radio-controlled machines are working in
close proximity to each other and transmitting on the
same frequency, they may block out each other.

09-0581G- GB
 Safety Regulations

Transporting and
moving
• Lifting devices may be used only on specified
points, see chapter ”Handling, Transporting and
lifting”. The machine may not be lifted by the arm
system, see illustration 1.
Ill. 1
• Check that the lifting device and the lifting tools
that are used are free from faults and are
approved for the weight of the machine.
• Make sure nobody is under the machine or in its
vicinity when it is suspended.
• Always secure the machine when transporting it
on a vehicle as described in the section on hand- Ill. 2
ling, see illustration 2.
• Check local regulations concerning the fastening
of loads.
• Connecting equipment to the machine, e.g. a
diesel generator, and towing it is forbidden (does
not apply to MiniCut).
• The arm must be folded when the outriggers are
raised. Ill. 3

• When moving the machine, the arm may be used

in certain circumstances to lift the driving wheels
over uneven surfaces. Due to the risk of tipping,
the arm must never be slewed or lifted high, see
illustration 3.
• Lower the outriggers so they are positioned just
above the surface when moving on uneven
surfaces.
• Certain machines have a pair of freewheels.
These machines must not be operated with the
freewheel pair first down stairs or ramps.
• Use the arm as extra support when moving on
inclining surfaces (in the direction of travel), see Ill. 4

illustration 4.

09-0582G- GB
 Safety Regulations

• Anchor the machine when operating on

inclined planes/ramps.
Always stand above the line of the machine
when working on an incline to avoid the risk
of being crushed. The machine may slip on
the surface.
• Always concentrate on the machine while
the control circuit is on. Wait until the
control circuit has turned off (indicator H3
goes out) before entering the working range
of the machine.

Moving the control cables

or any other actions that
may inadvertently move the
control levers and thereby
also the machine while the
control circuit is on may
cause fatal injury.

• The operator must always be separated from

the control box when moving the machine
where there is risk of the machine falling
over.

Before operation
• Always connect the machine through an earth
fault relay, 30mA.
• Check that the voltage and fuse values are
correct before connecting the machine’s supply
cable.
• Check that the supply cable is not damaged
before connecting it and while work is being
carried out.
• Make sure nobody is standing within the working
range of the machine.
• Make sure the machine is standing firmly.
• Follow the instructions carefully when changing
attachments.

Changing attachments
manually while the control
circuit is active may cause
fatal injury.

09-0583G- GB
 Safety Regulations

During operation
• Note that the operator is always responsible for
ensuring that the correct part of the building is
demolished and that vibration from the hydraulic
breaker does not cause cracks to form in other
places in the building or that loose stone or other
material does not come loose and cause damage
to property or person.
• Never stand within the working range of the
machine, see illustration 1. A burst hydraulic hose
Ill. 1
or an incorrect manoeuvre can have serious
consequences.
• Always concentrate on the machine while the
control circuit is on. Wait until the control circuit
has turned off (indicator H3 goes out) before
entering the working range of the machine.

Moving the control cables

or any other actions that Ill. 2
may inadvertently move the
control levers while the
control circuit is on may
cause fatal injury.

• Always operate the machine with the outriggers

lowered, see illustration 2.
• Do not stand on the control or power supply
cables.
• Always keep the power and control cables away Ill. 3
from the working zone.
• Make sure the control and power cables are not
run over while moving the machine, see illustra-
tion 3.
• The operator must always be separated from the
control box when working where there is risk of
the machine falling over, see illustration 4.
• Never stand under a raised arm.
• Stand in a position that is not affected by the
demolishing work (splinters, falling objects, risk
of collapsing, etc). Ill. 4

09-0584G- GB
 Safety Regulations

• Observe the risk of flying splinters.

• When cutting at an inclined angle, the demolition
waste can be spread over an area roughly as
large as the distance up to the spot being cut.
• Never stand where there is a risk of being
jammed between the machine and a wall or
pillar, for example. Note that the position of
the machine can change rapidly due to
unforeseen external forces.
• Observe the risk of being jammed in the machine’s
moving parts, under wheels/tracks or under
outriggers when the machine is being turned
round and when changing attachments.
• On certain models, it is possible to angle in the
outriggers slightly or reduce the track width when
working in confined areas. On these occasions,
the arm must not be slewed outside the outriggers/
tracks.
• Note that machine stability changes depending on
the weight of the attachment being used and the
overhang of the arm.
• Always stand above the line of the machine
when working on an incline. The machine may
slip on the surface.
• Press down the safety stops before taking off the
control box and when leaving the machine
unattended.

After operation
• Always place the attachment on the floor or the
ground after finishing work.
• Press down the safety stops before taking off the
control box and when leaving the machine
unattended.
• Turn off the power supply to the machine.
• Always store the control box safely to prevent
operation of the machine by unqualified persons.

09-0585G- GB
 Safety Regulations

Safety during servicing and maintenance

• The machine must be checked regularly, daily
inspections must be carried out and any defects
attended to. The machine must be kept in such a
condition that the operator or other people are
not exposed to danger or accidents.
• Never carry out repairs on the machine without
the necessary knowledge. Only trained service
personnel may carry out work on the electric
and hydraulic systems.
• Any faults or damage must be rectified
immediately. Do not operate the machine until
such faults have been rectified.
• Use safety goggles during servicing and
maintenance.
• Check the function and condition of the control
box regularly. Change malfunctioning control lev-
ers and buttons immediately.
• Pipe and hose couplings may be under pressure
even though the motor has been turned off.
Always be careful when dismantling
connections.
• Never disconnect a hydraulic hose before ma-
king sure it is not under pressure.
• Always secure moving parts mechanically
before disconnecting a hydraulic hose.
• Never attempt to stop a leaking or damaged
hydraulic hose with your hand. Atomised fluid
can penetrate the skin at high pressure and cause
serious injury.

09-0589G- GB
 Safety Regulations

• The electric cabinet must not be opened while

the machine is connected to the mains.
• Work on the machine’s high-voltage circuitry
must only be carried out by a qualified personnel.
• Cut the power to the machine before any cables
or other components containing electric current
are removed or opened.

09-0590G- GB
 Description
General notes

The Brokk 250 is an electrically driven all-hydrau- The machine is equipped with four outriggers that
lic workhorse especially suitable for excavating as can be run in pairs in order to get a stable working
well as demolishing concrete constructions and position. It can easily be moved through narrow
furnace linings. The compact design combined with openings since the outriggers may be folded. In
the electric drive and remote control makes the extremely narrow openings, the wheels may also be
machine well-suited for working in confined areas removed along with driving gears and free wheel
indoors as well as in hazardous environments. hubs.
The machine can be mounted with different The arm may be rotated 360° and can therefore
hydraulic tools such as glazing hammer, concrete work in every direction. It is controlled from a
crusher and drilling equipment. Different kinds of portable control box connected to the machine by a
buckets may of course also be used. The machine is control cable. The hydraulic functions are
equipped with a tool hitch for rapid changes of work proportionally controlled by means of electric
tools. valves, which enables fine and delicate manœuvres.
The Brokk 250 has got two-wheel drive with In additon to adapting the machine for diffeent
separate wheel drive. The steering is controlled by working conditions and environments at the
running the drive wheels with different speed or production stage, there is a number of accessories
with reversed direction of rotation. available through your local supplier. The Brokk
250 is also available with caterpillar tracks.

08-1360-GB
 Description

Technical Data Brokk 250

Dimensions in mm Dimensions in meter
7

2210
4
1760

2
1000
3600 *
1

* Depends on mounted tool 0

3
1200
2450

780

4
0 1 2 3 4 5 6 7

R 730 ∠ 2000

3000

Dimension Weights
Transport length, excl. of attachment 3600 mm Weight, complete, excl of attachment 3060 kg
Transport height, lowest 1760 mm Weight, undercarriage complete 1870 kg
Transport width Weight, undercarriage without wheels 1620 kg
• outriggers folded 1530 mm Revolving table with arm 1190 kg
• outriggers retracted 1200 mm
• no wheels 780 mm
Operating width, outriggers extended 2450 mm
Wheel base 1000 mm Performance
Ground clearance 200 mm Maximum slewing arm speed 14 s/360°
Working radius 5-7 m Maximum transport speed 0.8 m/s
(depending on tool) Maximum gradient 30°

08-1361-GB
 Description

Electric motor Machine plates

Type ABB type MTB 180 L4
Warning signs
Output 22 kW
Rotation speed indicated by machine plate
Voltage/frequency indicated by machine plate
Amperage indicated by machine plate Machine plate
Starting device Y/D-starter or D-starter

Control system
Type Individual speed control of left
and right drive wheels
Control unit Portable operating box
Transmission Control cable
Signal code Analogue
Warning sign on
electric cabinet
Hydraulic system
Volume hydraulic tank 120 litres
Type of pump Variable load-sensing
piston pump
Standard system pressure 16.5 MPa
Flow 0-100 l/min

Description of weight distribution with hydraulic hammer

Please note that the weight distribution varies
Total weight 3360 kg
depending on tool. All weight declarations are
Hammer weight approx. 300 kg
approximative and the table may only be used as a
guidance.

Wheel pressure, front 2650 kg

Wheel pressure, rear 710 kg

Wheel pressure, front 3360 kg

Wheel pressure, rear 0 kg

Outrigger pressure, front 2890 kg

Outrigger pressure, rear 470 kg

Inner outrigger, min working radius 2760 kg

Inner outrigger, max working radius 3280 kg
Outrigger foot, min working radius 600 kg

08-1362-GB
 Description

Product description
To give a simplified picture of the Brokk 250, it
consists of a lower part and a revolving upper part.
The machine is controlled from a portable control
box connected to the machine by a control cable.

Arm 2

Upper direction valve

Slewing unit

Arm 1

Revolving table
Arm 3
Swivel Filling pump

Upper part
The upper part consists of a revolving table and a On the revolving table there is also a manual filling
system of arms. pump for hydraulic oil as well as a filling filter. The
revolving table is covered by a protective casing.
Revolving table
The revolving table is operated by means of a System of arms
hydraulic slewing unit that cams into the slew ring The arm is in three parts and designed to endure the
on the machine itself. In the middle of the revolving extremely heavy load it may be exposed to when
table there is a special swivel construction that both e.g. using a hydraulic hammer.
transmits the hydraulic flow and the electric control
signals between the lower and the upper part. This
enables the driver to rotate the upper part without
limiting the number of revolutions.

08-1363-GB
 Description

Lower part
The lower part consists of the machine body, four
wheels and four outriggers.

Lifting eye bolt

Machine body Slew ring
Hydraulic pump
Outrigger bracket
Electric motor

Outrigger

Free-wheels
Wheel gears
Lower direction valve

Machine body Wheels

The machine body is a self-contained box type The front wheels are equipped with built-in separate
design with high turning rigidity. In the machine hydraulic motors that control the wheels via crypto-
body there is an electric motor, hydraulic tank, oil gears. During transport, the machine is controlled
pump, oil filter, oil cooler and valves for controlling by driving the wheels at different speeds. By using
wheels and outriggers. reversed direction of rotation, the machine can
On the left side of the machine body there is an handle very sharp turns.
electric cabinet where both mains voltage and the The driving wheels are equipped with passive
control cable are connected. On top of the breaks, which means that they lock automatically
machine body there is a slew ring for fastening the when the drive is disconnected. The rear wheels
upper machine part. have got free-wheeling which enables the machine
to pass obstacles by using the arm.
Outriggers The wheels are of the massive type for extra long
The outriggers are run in pairs which simplifies life. If the machine has to be moved through narrow
compensating for sloping ground. The outtrigger openings, the wheels with drive gears and free-
feet may be equipped with rubber shoes that protect wheel hubs may be removed. The width will then be
the floor and improve the friction. During transport, just 780 mm.
the outriggers may be folded which enables the
machine to enter narrow openings.

08-1364-GB
 Description

Hydraulic system
The main parts of the hydraulic system are shown in
the picture. See also section: "Circuit diagrams".

Cylinder 3
Cylinder 2

Upper direction valve

Swivel Filling pump with filter

Cylinders for outriggers
Slew unit

Cylinder 4

Hydraulic tank

Hydraulic pump with regulator

Dump valve, low
Hydraulic motor with planetary
pressure valve
gearing
Oil cooler
Lower direction Return oil filter
valve

In the rear part of the machine body there is a By adjusting the low pressure valve, the machine’s
hydraulic tank that holds both hydraulic oil and a operating pressure can be matched to the operating
hydraulic pump with regulator. From the pump, the pressure of the hydraulic tool.
oil is led to a valve core at the front of the machine, On the upper part there is also a manual filling
and then back to the tank via a cooler and an oil pump that, via a filter, a shut-off cock and the
filter. swivel, leads the oil to the hydraulic tank.
Direction valves for the outriggers and drive In order to equalize the air pressure in the
wheels, and a dump valve and low pressure valve hydraulic tank, an air filter is connected to the upper
are fitted in the machine body. part of the tank. The air filter keeps constant
The dump valve increases the cooling capacity overpressure in the tank.
by directing the flow through the cooler when no
functions are being used.

08-1370-GB
 Description

System parts Working temperature

The ideal working temperature of the hydraulic
Hydraulic pump system is around 70°C. It may not exceed 90°C for
The electrically driven hydraulic pump is of axial more than short moments. This means that extra
piston type with variable deplacement. This cooling may be necessary when the environmental
produces a flow of between 0 and 100 l/min. The temperaure exceeds 25° C. All these temperature
pump is equipped with pressure and flow regulators, recommendations refer to using the oil ISO VG 46.
for effective use of the motor power. Whether extra cooling is necessary depends on
The maximum pump pressure has been set at the several factors; type of job, way of driving, the state
manufacturing plant. If necessary, authorized ser- of the machine, air circulation and altitude where
vice personnel may adjust the pressure. the machine is working. For more information about
working at high environmental temperatures, see
CAUTION! section 3: Handling.
Incorrect setting of the An extra oil cooler which may be mounted at the
maximum pump pressure may back of the machine is available as an optional
endanger the function of the extra.
machine or cause serious
damage on the hydraulic
system.

Extra oil cooler

Hydraulic motors
Both front wheels are driven by hydraulic motors
that are integrated in a hub reduction cone. The hub
reduction cones consist of a selfcontained unit that
also holds an automatic hydraulic parking brake.
The brake is activated when the function switch on
the control box is put in operating position.
The motor and brake unit must not be opened,but
the whole unit may be removed if the machine
needs to move through a narrow opening.
Should the environmental temperature exceed
40° C, cooled compressed air must be blown into
the machine body. Should the altitude of the
worksite exceed 1000 m, this temperature limit
drops to 35°C, and at 2000 m the limit is 30°C.
A cooling kit using compressed air may be orde-
red as an optional extra.

08-1371-GB
 Description

The Electric System

The electric system consists of a high-voltage and a
low-voltage part. The figure below shows the most
important components of the electric system as well
as the main cabling.

Upper direction
valve pilot valves

Junction box
Electric valve

Electric swivel

Mains cable

Lower direction valve

pilot valves Control cable
Electric motor

Power Supply Electric cabinet Control box

The machine must be connected for voltage feed
from an electricity supply system or a generator that
gives off 3-phase alternating voltage. Neutral wire
is not needed. The connecting cable supplied with
the machine is 1 metre long, and an extension cable
must be dimensioned according to the following
(applies to 380V or higher voltage):

Cable length max 75 m min 10 mm2 conductor

Cable length max 125 m min 16 mm2 conductor

When using voltages below 380V, one must always

consult the manufacturing plant. Please note that
the mains cable must run through the ring on the left
outrigger, since the flexible lead connector may
otherwise drag on the ground.

08-1367-GB
 Description

Fuses Electric cabinet

The power points used must have the proper fuses Most electric components, both for the high- and
as regards the diametre of the mains cable. the low-voltage part, are assembled in an electric
Recommended minimum fusing at maximum cabinet on the left side of the machine. The cabinet
effective output is 50A at 380V/50 Hz may be removed to increase accessibility at service
or repair.
Mains voltage Recommended fusing At the front of the cabinet there is an hour meter
Y/D-start Directstart showing the number of working hours. There are
also two reset buttons for the automatic fuses of the
220V 50Hz 85A 100A
low-voltage part. There is also an indicator light
380V 50Hz 50A 63A
indicating when the voltage feed to the machine has
415V 50Hz 45A 63A
the wrong phase sequence.
440V 50Hz 45A 63A
500V 50Hz 40A 50A
660V 50Hz 30A 50A CAUTION!
440V 60Hz 50A 63A The front of the electric
480V 60Hz 40A 50A cabinet must not be
removed when the machine
is connected to the mains
High voltage part power supply.
The high-voltage part is used for voltage feed to the Work on the high-voltage
main motor and the low-voltage circuit. part of the machine may
only be carried out by
The motor authorized personnel.
The motor is a 3-phase induction motor. Technical
data are clear from the machine plate.

Lamp for indication of wrong phase

sequence.

Hour meter

Automatic fuse 8A/19,5V

Automatic fuse 10A/24V

08-1368-GB
 Description

THE START SWITCH The lighting circuit may be used for mounting lights.
The motor is connected by a Y/D-starting connector Headlamps are an optional extra,but the machine
(or a direct starting connector) with automatic check has been prepared electrically and has got holes for
of rotation direction. headlamp attachments.
When starting, the phase sequence of the power
outlet is checked by a phase sequence relay. If the Electric cabinet
phase sequence is incorrect, an LED will light up See also section: "Circuit diagrams".
indicating that S1 must be switched over.
TRANSFORMER
THERMAL OVERLOAD RELAY In the electric cabinet there is a transformer with
The motor is protected from overloading by means two outlets on the secondary side, one for the
of a thermal overload relay which is set for the rated lighting circuit and one for the control circuit.
current of the motor multiplied by 0.58
FUSES
Mains voltage Setting of overload relay
The mains voltage transformer is protected by two
Y/D-start Directstart
automatic fuses on the secondary side. The rated
220V 50Hz 45A 78A current for the control circuit fuse is 8A, and for the
280V 50Hz 26A 45A lighting circuit 10A.
415V 50Hz 24A 41A
440V 50Hz 22A 39A
Please note!
500V 50Hz 20A 34A
A released fuse should
660V 50Hz --A 26A
always be regarded as a
440V 60Hz 25A 43A
warning that something is
480V 60Hz 23A 34A
wrong with the machine.
Therefore, always look for the
cause and attend to the
The overload relay is reset automatically. Should
problem!
the protection device be released, one has to wait a
couple of minutes before the machine can be re-
started. Should the device release a second time
after re-starting, this means that something is wrong. TEMPERATURE GAUGE
The temperature gauge on a radio controlled
machine is located in the electric cabinet
Low-voltage part
The low-voltage part consists of a control circuit
and a lighting circuit - both supplied with 24V direct Electric swivel
current. The control circuit is used for all kinds of The electric swivel is placed inside the hydraulic
signal transmission between the control unit and the swivel in the middle of the revolving table. It has
machine. got 15 coals that run on an electric circuit each.

The hydraulic direction valves are controlled by

pilot valves which in turn convert the electric sign- Control box
als to a hydraulic control pressure that regulates the The control box is only supplied with 24V DC
spool position in the direction valves. control voltage. Work on the box may only be
carried out by authorized personnel.
The control signals to the upper direction valves are
transmitted by an electric swivel (a revolving
electric connection) in the middle of the revolving
table. This means that the upper part may be
revolved any number of times.

08-1369-GB
 Description

Control system
Brokk has an advanced control system to NB Note that both the control levers must be in
simplify operation and also to prevent accidents. neutral position before the control circuit can be
All the machine functions are operated from a activated.
control box which can be carried on a waist When the current has been turned off, the
harness or placed on a stand (optional extra). drive system, outriggers, revolving table, arm
system and attachments will be disconnected.
Control circuit switch
Once the control current has been switched on,
the operator must always pay attention to the
Control box
machine since the slightest lever movement will The layout of the control box is shown in the
affect the machine. illustration. All the functions are shown with
symbols on the panel.
After 3 seconds of inactivity, the control voltage
will be automatically disconnected.

Left control lever Right control lever

Left top cap Right top cap

LL LR RL RR
S1 H1 H3

S4 S2 H2 S3 R1 S6 S5

12-0372-GB 1/3
 Description

S1 Stop and safety stop button. S5 Switch used for obtaining

Turn the stop button clockwise different functions with hydrau-
to reset after use. lic tools. (Top switch on left
control lever.) The switch is
locked and must be lifted in
order for it to be put in the
different positions.
S2 Press once: Starting the control
box.
Press twice: Activate horn Double-acting position for e.g.
Two rapid presses: Change hydraulic shears.
radio frequency.
Used also for programming and
testing the control box.
Spring back return to middle
position.
Single-acting position for
hydraulic breaker.
Connecting on/off function 1.

S3 Reset to normal speed on all

Double-acting position with
functions (from micro-opera-
increased working pressure.
tion). Control levers must be in
*This position may only be
neutral position.
used with the Brokk hydraulic
Springs back to middle position.
shears.
** Option.
*** No function
Micro operation. Pressing the
button results in reduced speed
on all functions.
5 steps. NB! Single-acting hydraulic tools
Used also for programming. can be damaged if the
Springs back to middle position. working pressure is fed on the
return side.
Increased working pressure
S4 Starting the electric motor. is 25.0 MPa, which may
Springs back to middle position. damage tools that are not
designed for such pressure
levels.

Connecting on/off function 2

* Valid for Brokk 110/150/180/250

** Valid for Brokk 330
*** Valid for Brokk 90

12-0372-GB 2/3
 Description

S6 Working mode, control levers

operate the upper machine
section.

H1 H3
S1 S5

Drive mode, control levers S6

operate the undercarriage.

S4
S2 S3 R1
R1 Adjustment of fluid flow to H2
hydraulic tools. Works only
when top switch B1.LL on left
control lever has been pressed.

H1 Green LED which lights up

when stop button S0 is
released. Shows that there is
supply voltage to the control
box.

H2 Yellow LED which lights up

when control box is started by
pushing S1.

H3 Orange LED which lights up

when control circuit is
connected to the control levers.

12-0372-GB 3/3
 Description

Control levers
Switch S6 in working mode

Left control lever Right control lever

Arm 3 up Arm 2 down

Slew Slew Tilt in Tilt out

anticlockwise clockwise

Arm 3 down Arm 2 up

Switch S6 in drive mode

Left control lever Right control lever

Left track drive forward Right track drive forward

Outrigger down Outrigger up

Left side Right side
Outrigger up
Outrigger down
Left side
Right side

Left track drive reverse Right track drive reverse

12-0374-GB
 Description

Right control lever B2, right top switch RR

Extending boom
Right lever function with the top
switch RR pressed: Running
cylinders 1 & 2 jointly.

Retracting boom

Right control lever B2, left top switch RL

RL Connecting the control circuit. LED H3 lights up.

Note! The control voltage disconnects, should the control levers be left in neutral
position for more than 3 seconds.

Left control lever B1, left and right top switch, LL and LR
Setting the switch S6 on the control box as illustrated will give the pushbuttons on the left-hand control
lever, B1.LL and B1.LR, the following functions.

Switch S6 B2.RR

B2.RL

B1.LR
H3
B1.LL

B1.LR Full flow to the hydraulic

tool.
R1

B1.LL Oil flow to the hydraulic

tool can be varied with
potentiometer R1.

12-0375-GB
 Description

Electronic box

The electronic box made of aluminium, is LEDs for operating status

equipped with attachments and contacts for On the electronec box there are i.a LEDs for
connecting e.g. control box, radio receiver box operating status.
and on/off-functions. In addition there are POWER: Indicates voltage feed.
connections and contacts for voltage feed,
electric adjustment device/sliding controls and DV: Voltage feed to contactors.
dumping valve. The box may be exposed to ON/OFF: The on/off-function is activated. The
severe conditions; therefore it is embedded to LED is connected and integrated, i.e.
protect it against humidity, heat, cold, dust, only one switch at a time can be
vibrations and corrosive environments. activated from the control box, in or-
The electronic box is protected against polar- der for checkup to be possible.
ity reversal, it has got short circuit-proof inlets DIR.A: DIR.A indicates whether the A-side of
and outlets, and is protected against high the valve receives a signal when the
incoming voltage transients, EMC/RF. Thanks control lever is moved outwards. With
to this, the electronic box may be connected an increased angle deflection of the
without posing the risk of injuries. control lever, the intensity of the LED
The electronic box is designed for voltage increases.
feed +12/+24 VDC (+/- 10%) with negative DIR.B: DIR.B indicates whether the B-side of
grounding. Inside the box, standard car fusing is the valve receives a signal when the
placed. control lever is moved outwards. With
Positive fusing: 10 Amp, negative fusing: 30 an increased angle deflection of the
Amp. control lever, the intensity of the LED
increases.
By means of the LEDs on the electronic box, simple
error messages may be read.
LEDs 1-4 are i.a. used for error messages. In the
event of error, LED 1 will start flashing first, then a
combination of LEDs 1-4.

08-1646-GB 1/2
 Description

Switch ON/OFF Switch radio Type plate

Change-over switch, operating mode

LEDs, operating status

Switch, cable control

08-1646-GB 2/2
 Handling
Operating in difficult environments.
Heat Wheels
The temperature of the hydraulic oil must not exceed The solid rubber tyres must not be exposed to tempe-
90°C for more than short moments. The capacity of ratures above 80°C. Special wheels for higher
the machine will be impaired and some parts may be temperatures are available as an optional extra.
seriously damaged if the machine is operated for
long periods of time with overheated hydraulic oil. Cold
The lower temperature limit of the machine depends
Consider the following when working in hot on the kind of hydraulic oil used. With standard oil
environments: (ISO VG 46) the limit is -10°C.
• The temperature of the oil is primarily influenced Please note that maximum pump flow may not
by type of job. Continuous chiselling of concrete be used when the oil temperature is below +10°C.
with a hydraulic hammer generates the most
heat.
• Should the mounted tool not be adapted to the Water
machine, this also generates unnecessary heating The machine may be used outdoors and on wet
of the oil. premises, but never in deeper water than 10 cm.
Should water reach and penetrate the machine body,
• Place control levers in a neutral position when
the electric motor and equipment may be damaged.
any function reaches its end position, since pas-
sage via the shock valves raises the temperature. Should water penetrate the machine body at
downtime, the motor must not be started. It must be
• If possible, increase the air circulation when
dismantled and oven-dried. The transformer and
working indoors.
contactors must usually be replaced. Please contact
• Check the state of the machine. Inner leakage in your machine supplier or a motor electrician.
the pump and valves makes the machine warm
and inefficient.
• Remember that there is a decreased cooling Risk of fire and explosion
effect at higher altitudes (5% for every 1000 m). On condition that cables and connections are
approved, the machine may be used in environments
rated as ”flammable”, but not on premises rated as
Extra cooling
”explosive room”.
Should the environmental temperature exceed 25°C,
an extra oil-cooler may be necessary. At
environmental temperatures exceeding 40°C, the
machine must be equipped with air-pressure
cooling. Contact your machine supplier for more
information.

08-1376-GB
 Handling

Transport and hoisting

Hoisting Transport
1. Place the arm in folded-in position to get the When transporting the machine on a lorry, place the
point of gravity as close to the centre of the machine on the wheels and with the arm against the
machine as possible. wagon-bridge. Use the outrigger eye bolts to secure
2.Connect a chain with a safety hook to each lifting the machine.
eye bolt on the outriggers as shown in the figure In order to make sure that the outriggers do not
below. slide down and damage other load, lock them in
folded-up position by means of a screw or bolt
Each chain should be dimensioned for hoisting
at least 4000 kg and have a minimum length of 2 (length 250 mm, 12 mm) put through the holes in
the brackets according to the figure below.
m.
3.Check for damages when the chain tightens.
Locking screws

Strap
Min
2m

CAUTION!
Never walk underneath or
near a suspended machine.
Never hoist the machine by
the arm system.

08-1377-GB
 Handling

Radio
(Valid for machines equipped with radio control, Important information on
which can be ordered as optional extra.)
radio control!
Approvals Interference
This device complies with part 15 of the FCC-rules, If several radio-controlled Brokk machines,
and I-ETS 300 220. Operation is subject to the construction cranes or other radio-controlled
following two conditions: machinery are working in close proximity to each
1. This device may not cause harmful interference. other and transmitting on the same frequency, they
2. This device must accept any interference may block out each other. To prevent this, it is
received, including interference that may cause possible to choose between 12 different radio
undesired operation. channels on the Brokk.
Note that the radio will restart on its base channel
WARNING! each time the safety stop has been depressed. The
Changes or modifications operator must set the desired channel manually
to this unit not expressly each time the machine is restarted.
approved by the party Observe the yellow indicator H2 on the control
responsible for compliance box if interference is suspected of causing bad
could void the user's performance. The fault will be found in the control
authority to operate the box if the lamp goes out. The fault will be found in
equipment. the transmission or on the machine if the light stays
on. Always test with cable control to limit the scope
of troubleshooting.
There is a label specifying the approval number in
the control box battery holder under the battery. The radio may be blocked by changes in the
electromagnetic field when radio control is used in
conjunction with work where the breaker impacts
on steel sheet. If the operator has problems with the
chisel hitting steel, try using cable control.

12-0370G- GB
 Handling

Safety
To limit the risk of operating the wrong machine
with radio control, each control box has been given
a unique ID-code that allows operation only of the
machine with the same ID-code programmed in the
electronic unit.
The operator must ensure that the correct control
box is being used for the machine in question and
carefully observe the reaction of the machine during
the starting procedure. This is especially important
when there are two or more radio-controlled
machines on the same work site.
After the control box has been turned off longer
than two minutes, the machine must be reset, i.e.
the power supply to the electronic unit in the electric
cabinet must be cut and then reset before the
machine can be started. This function is used to
ensure the operator always has eye contact
with the machine before starting it.

Power supply to control box

The battery will give a warning 30 minutes before it
is completely discharged, see ”Battery status”. To
prolong the service life of the battery, use the radio
until the machine stops completely and then put the
battery on charge immediately.
Check and clean the battery terminals regularly
to avoid bad contact.
The control box is turned off automatically if the
machine is left inactive for more than five minutes
to save the battery. The electric motor will also
stop.

Troubleshooting
Using cable control during troubleshooting will sup-
press the ID-code so that any control box can be
used, provided it has the correct control system
version.

12-0371G- GB
 Handling

Battery chargers and battery charging

The battery charger must be mounted in a

shakeproof place indoors, in order to protect it
against moisture and temperature changes. For a
discharged battery, the normal charging time is 12 -
14 hours. The charger has been adapted so that the
battery casettes will not be damaged by long,
continuous charging.
There are two indicating LED´s on the char-
ger:
• Red LED (POWER) indicates voltage feed.
• Green LED (CHARGING) indicates charging
in progress.
The connecting voltage of the charger must be
110-240 VAC. Beside the connecting cable there
is a fuse holder with a glass fuse, 3 amp (time
fuse), the size of 5 x 20 mm.

LED RED CONNECTING CABLE

(VOLTAGE FEED)

FUSE

LED GREEN
(CHARGING)
MOUNTING HOLE ø4,5 [4x]

08-1401-B-GB 1/4
 Handling

Programming of identity code will automatically be disconnected when

using cable control.
code
Each control box has got its individual identity
code, which has to be programmed into the
Before starting
electronic box before the radio control can be The following points must be checked every
used. morning and before starting work on a new job
site.
1. Run the system by cable control.
1. Carry out the daily inspection according to the
2. Keep the cable control connected between
maintenance instructions. Also check that the oil
the control unit and the electronic box.
used has the right viscosity.
3. Press the emergency stop button on the
2. Check that there is no transport damage.
control box.
3. Check that the control and power cables are
4. Turn the stop button on the control box, so
intact.
that it pops up.
4. Check that the electric power point has the correct
5. Press switch S2 and keep it pressed for voltage and fusing.
about 15 seconds. LED H2 will light up.
5. Connect the power and control cables.
As an indication that programming is in pro-
gress, the control unit will beep rapidly, and
LED´s 1, 2, 3 and 4 on the electronic box will Starting
flash.
1. Press the emergency stop button on the control
6. The programming is complete, remove the box. Check that the switch on the electronic box
cable control. is in mode REMOTE. LED POWER will light
7. Should this not work, repeat points 2 - 6 of up and LED 4 on the electronic box will flash.
the programming steps. In the event of it still The green LED on the radio receiver will light
not working, please contact Brokk AB. up.
When using cable control , the battery will auto- 2. Put a battery in the battery holder on the control
matically be charged. At cable control usage, all box.
control units can be used on the Brokk, i.e. radio
transmitter and receiver boxes as well as the identity

RL
S1
S4
S2 H1
H2
H3

08-1401-B-GB 2/4
 Handling

3. Turn switch 48 on the electric cabinet in posi- disconnected and the electric motor switched
tion 1 or 2 for connection of voltage feed and off.
choice of the right phase sequence. At the Should the machine be left with the control
wrong phase sequence, yellow indicator H1 box switched off for 60 seconds, the switch on the
will light up. Should this happen, turn the electronic box must be put in position "OFF"
switch in the opposite direction to turn off the and then "REMOTE", before the machine can
indicator. be re-started.
4. Turn stop button S1 clockwise to make it pop
up. Green indicator H1 VDC will light up to Warming up
indicate voltage feed to the control box. 10. Warm up the machine with light work
5. Start the control box by pressing switch S2 until the temperature of the oil is at least
upwards. Yellow indicator H2 will light 20°C. Check that all the functions run
up, as well as LED´s DV2 and 3 on the electronic smoothly.
box.
6. Start the electric motor by pressing switch S4 Starting in cold weather
upwards. When the temperature of the hydraulic oil is below
Should the electric motor not start, the phase 10°C, it is important to make small lever movements
sequence may be wrong, which is indicated by LED and not start e.g. a hydraulic hammer. This is in
H1 on the electric cabinet lighting up. Should this order to avoid damage on the hydraulic system.
occur, turn the switch for phase sequence to the When starting at temperatures below 0°C, the
opposite position. hydraulic oil and the machine should be warmed up
Please note that when the electric motor starts, it the following way:
will always be in Y-position in order to decrease the 1. Place the machine on the outriggers and run both
starting voltage. In this position, the machine may track motors for 10 - 15 mins.
NOT be operated. When the electric motor has 2. Switch to operating mode and run all cylinders
picked up after about 10 seconds, it is automatically in the arm system without loading them with
switched to D-position and the machine is ready to work. Rotate the upper part a couple of turns.
use.

Connecting the control circuit

8. Make sure that neither yourself, nor other
personnel are standing within the working area
of the machine.
9. Connect the control circuit by pressing the left
top cap on the right control lever (RL). Red
indicator H3 will light up.
After 3 seconds of inactivity, the control circuit will
automatically be disconnected as a precaution, so
that the operator does not leave the control box
connected by mistake. Please note that both control
levers have to be in neutral position in order to
reconnect the control circuit.
Should the control box be left inactive for 5
minutes, the box will automatically be

08-1401-B-GB 3/4
 Handling

Stopping
1. Put the control levers in neutral position.
2. Press the stop button.
Leave the stop button in a depressed position
until starting the next time.
3. Put the phase sequence switch on the electric
cabinet in position 0 if the machine is not to be
used immediately.
Please note that the stop button also works as an
emergency stop.

Battery status
When using radio control, the battery is placed on
the outside of the control box, and can easily be
changed. When the battery needs charging, the
control box will beep three times as a warning, at
the same time as the yellow LED H2 will start
flashing. Use the battery until the LED goes out,
then change the battery. Should the capacity of the
battery run down too low, the control box will be
impossible to activate.
The effective operating time of the battery is 8 -
10 hours on one charging. At extremely cold
weather, the capacity and operating times are
reduced. When using cable control the battery will
automatically be charged.

Changing radio channels

Concurrently with the increasing use of radio
control, frequency clashes are becoming more and
more common. This will occur as interference or
interruption in the operation. To prevent this, you
can easily switch between 12 channels in the control
system.
For switching channels, press switch S2 twice
rapidly upwards.
You may switch channels at any time during
operation.

08-1401-B-GB 4/4
 Handling

Moving the machine

Operating the outriggers Attention!

Make sure no cables or leads
1. Make sure the arm and the tool are retracted
get jammed while raising and
(see illustration).
lowering the outriggers.
2. Switch to drive mode by pushing switch S5
(S6 Brokk 250) downwards.
3. Connect the control circuit by pressing the top
button (B2.RL).
WARNING!
4. Raise the outriggers by pushing the right
The arm system must not
control lever to the left.
be operated while the
Lower the outriggers by pushing the right outriggers are raised, as the
control lever to the right. machine can then easily tip
over.

B2.RL

S5
(S6 Brokk 250)

09-0615-GB
 Handling

Moving during operation

1. Retract the arm and the tool (see illustration).
Attention!
The arm must not be extended while the out-
When reversing, be careful
riggers are raised as the machine can then
not to let cables and leads get
easily tip over.
jammed.
2. Raise the outriggers according to the adjacent
instructions.
3. Make sure the switch S5 is in drive mode
WARNING!
(down).
Always stop the tracks and
4. Connect the control circuit by pressing the wait until the control circuit
push-button (B2.RL). has switched off before
5. Carefully push both control levers forward. moving cables and leads or
Make sure no cables or leads get caught or do anything else that may
stretched so they are pulled out of their sock- cause the levers to be
ets. inadvertently moved.
Steer the machine by driving the left and right
tracks at different speeds. To make sharp
turns, the direction of one of the tracks can be
reversed by pulling back on the lever.

Note!
As the front and rear of the
track undercarriage look
similar and the revolving table
can be rotated, it is difficult to
determine in which direction
the machine will move when
the control levers are pushed.

09-0563-GB
 Handling

Moving on uneven ground Folding the outrigger

When moving over heaps of building debris or brackets when moving
other obstacles, the arm may be used to pull the
drive wheels and the machine on the freewheeling through narrow passages
rear wheels. When passing openings with a width of 1200 mm to
1. As a security measure, put down the outriggers 1530 mm, the outriggers must be folded in.
just above ground level. 1. Fold up the outriggers completely.
2. Pull the machine forward with cylinder 3 (left 2. Remove the middle hexagon-headed screw that
lever forward/ backward) and balance the height holds the outrigger brackets and unfold them.
with cylinder 2 (right lever forward/ backward). Repeat in the front and rear.

CAUTION!
Note the risk of tipping!
When moving by means of
the arm, do not use the
slewing outside the body of
the machine.

3. Push in the outriggers manually.

Do not forget to unfold the outriggers and fasten the
brackets after passing the obstacle.

08-1380-GB
 Handling

Removing wheels and hubs Procedure:

1. Unscrew the rim nuts a bit on all wheels.
When passing openings with a width of 780 mm to 2. Fold the outriggers out and run them down until
1200 mm, the outriggers must be folded in and the the wheels lift from the ground.
wheels removed. After that, the machine has to be 3. Unload the arm by putting it in forward position
pulled by means of the arm. on the ground.
4. Remove all wheels.
Please note!
5. Unscrew the rim nuts on the free-wheels (rear)
Place battens under the
from the machine body.
machine to protect the floor,
and the underbody of the 6. Drain possible excess pressure from the hydrau-
machine. lic tank by opening any of the tank cover screws.
That way you will avoid oil spill from the hoses.
7. Unscrew the hydraulic hoses from the wheel
motors (2 on each motor) and plug the
CAUTION!
connections on both hoses and motors.
Note the risk of tipping
when the wheels are
removed. Never lift the arm
high and avoid slewing. Hydraulic motor

Pressure hoses
Please note that removing the wheels requires
interference with the hydraulic system. Follow the
instructions carefully and take great care to keep
your hands clean.
Necessary tools:
”Draw shank (1/2”)
”Extender (1/2”)
Hexagonal casings 19, 24 and 27 mm
Socket head casing 10 mm
U-wrench 17, 19, 21 and 24 mm
Necessary hydraulic plugs:

Number Design Order no

4 PNTXS 12 3176 5563 00

4 FNTXS 12 3136 5313 00

08-1381-GB
 Handling

8. Unscrew the hub unit (i.e. the unit consisting of Remounting of wheels and hubs
the hydraulic motor, planetary gear, brake and Follow the instruction for removing wheels and
hub) and carefully remove it. hubs, but do it in the reversed order.
Use a hoist or blocks under the hub unit. The unit Do not mix the hydraulic hoses up (causes
weighs approximately 60 kg. reversed rotation direction). Do not forget to fasten
the tank cover screws.
Rim and wheel hub screws must be fastened
with tightening torque as in the table below:

Flange screws (M12) 100-120 Nm

Rim screws 150-200 Nm

Start the motor and test run the drive. Check all the
Wheel centre flange
couplings you have touched and make sure there is
no leakage.

Hub unit

9. Start the machine and fold up the outriggers.

10.Remove the middle hexagon-headed screw that
holds the outrigger steering arms and fold out
the arms. Repeat in the front and rear.
11.Fold in the outriggers.
12.Check the oil level in the hydraulic tank and
refill if necessary.

08-1047-GB
 Handling

Operating the machine

Please note! Operating with different
The machine must be parked
steadily with all four outriggers
kinds of tools
on firm ground. Place thick Read the individual instructions and safety
battens under the machine if regulations that apply to each tool.
the ground is soft or unveven.

Operating the upper part

with arm
The function switch must be in operating mode
( ) and the control voltage connected. The
function of the control levers is clear from section:
"Description". Operating system and the symbols
on the control box.
The operation of the arm is totally dependent on
the task. Practice manœuvering until you know all
lever movements backwards!

CAUTION!
Never carry out demanding
jobs or work in hazardous
environments until you can
control the machine
completely!

08-1382-GB
 Handling

Operating near shafts Operating in confined

Be very careful when parking the machine and spaces
operating near a shaft. Check at regular intervals
In order for the machine to work in confined spaces,
that the machine does not slide on the ground and
the outriggers on one side can be folded and locked.
move closer to the shaft. If the machine has to be
Please note that all jobs must be carried out with the
parked very close to a shaft, it must be anchored. Be
greatest caution when the outriggers are folded.
cautious about the risk of landslip.
1. Remove the middle hexagon-headed screw that
Be cautious about the tipping risk if the arm is
holds the outrigger brackets.
mounted with a heavy tool and is completely
extended. Study the figure in section: "Description" 2. Fold out one bracket and fasten the screw again.
showing weight distribution. 3. Push in the outrigger manually and fasten the
Please note that you, being the driver, are bracket in the hole on the opposite outrigger.
responsible for the operation, and it is your duty to
know the limitations of the machine.

CAUTION!
Always anchor the machine
when working near shafts.
When working where there
is risk of tipping, the driver
must be disconnected from
the control box.
Never stand on the control
or voltage cable. Never
stand in a cable loop or
between a cable and a
Please note!
shaft.
Check that both brackets are
fastened.
A collapsible stand for the control box can be orde-
red as an optional extra.
CAUTION!
Do not place the arm in a
position over the folded-in
outriggers due to the risk of
tipping.

08-1383-GB
 Handling

Changing tools
Please note! Tool mounting
Only use tools designed for Follow the instructions below carefully. Items 10
this machine. and 11 do not apply when mounting buckets and
other non-hydraulic tools.
1. Place the tool facing the machine as in the figure.
The tool holder has got one fixed and one flexible Please note that the pressure port of the hydraulic
hook. The flexible hook automatically locks the hammer should be on the left side seen from the
tool when the piston rod of cylinder 4 is pressed out. machine.
Then the tool is secured with a wedge and a lock
pin. 2. Remove the wedge from the tool holder.
3. Run in the piston rod on cylinder 4 in order to pull
in the flexible hook at the maximum.
4. Attach the fixed hook to the brackets on the tool.

Flexible hook
Wedge with
lock pin

On the hydraulic hammer and other hydraulic tools,

both hoses can be connected. In order to prevent
dirt from getting into the sytem, the hoses must
always be connected if the tool is not mounted on 5. Run out the piston rod on cylinder 4 until the
the machine. flexible hook holds the tool. If necessary, raise
arm 2 slightly in order to facilitate the mounting.

08-1384-GB
 Handling

6. Run the arm in order to turn the tool forwards.

CAUTION!
7. Switch off the control voltage, stop the motor
Undo the flange coupling
and put down the control box.
carefully since hot oil may
squirt out. This is most
CAUTION! likely if there is air in the
It is highly dangerous to hose.
carry out the above
described manual
operations without 11. Clamp the hoses on the arm.
switching the control
voltage and the motor off.

Quick-coupling

Hose clamp

8. Insert the lock wedge until it butts against the Tool removal
tool The procedure is exactly the opposite of the one
9. Secure the wedge with the lock pin in the inner- when mounting. Take great care to attach the rubber
most hole. covers to the quick-couplings of the arm and to
connect the hoses on the tool as soon as they have
10.Disconnect the connected hoses on the tool,
been removed from the machine.
check that the hydraulic couplings are clean.
Remove the rubber covers on the quick coupling
of the arm and connect the hoses of the tool.
Please note! Should there be closed-in pressure
in the hoses, the quick-couplings may not be
connected. In this case, wait a moment until the
pressure decreases or undo the quick-couplings
on the return side.
In order to avoid high pressure in the pressure
pipe when working with crushed concrete, the
jaws should not be run to end position just before
removing the tool.

08-1385-GB
 Handling

Lower pressure level

For use of different hydraulic tools without
running the risk of overloading the electric mo-
tor, hydraulic pressure and oil flow have to be
adapted so that the power output does not exceed
the maximum effective output of the motor. The
function makes it possible to choose an lower
pressure level on the hammer circuit. When
using a tool, for instance a hammer which
demands large oil flow but a lower pressure than
16,5 MPa, a lower pressure level must be used.
To find out if lower pressure level must be
used, put the switch in position crusher Switch for lower
measure the current consumption on the pressure level.
incoming phase to the motor when operating the
hydraulic hammer simultaneously with an arm
function in end position. Shold the current
consumption exceed the maximum value
according to the table, lower pressure level must
be used.
Lower pressure level must always be used
when using hydraulic hammer Montabert BRH
125 and BRP 130.
To choose lower pressure level, you turn the
switch (see figure) into position hammer . When
using other tools, that demand maximum pressure
of the machine, the switch must be in position
crusher .

Caution!
If the switch is in postion
crusher when using the
hydraulic hammer, the
machine could be
overloaded.

Rated voltage Maximum current consumption

220 V 76 A
380 V 44 A
415 V 40 A
440 V 38 A
500 V 33 A

08-1386-GB
 Maintenance

General notes Important notes on the

The maintenance instructions must be followed to electric system
ensure the safety of the driver and the life of the It is essential that the state of all electric wiring is
machine. Maintenance work must be carried out by checked regularly. Please note that only qualified
authorized personnel. personnel may work with the high-voltage system
Copying the enclosed maintenance record and of the machine.
making notes when measures are taken on the
machine, both give a good overview of the status of CAUTION!
the machine and a check that no service time is Damaged electric wires may
forgotten. lead to functional disorder
and to electrically charged
Take immediate measures should faults or
machine parts.
damage occur. Even small problems may cause
serious secondary damage.
Usually the electric cabinet does not need to be
Please note! opened. Should this be necessary when repairing,
Only use genuine parts when the electric cabinet may be removed from the
repairing or servicing the machine body. The cabinet is charged with high-
machine voltage and may only be opened by qualified
personnel.

CAUTION!
Cleaning The control voltage must be
Clean the machine regularly inside and outside. It is disconnected before
nicer to work with a clean machine and easier to removing or opening a
spot possible faults or damage. Besides, clean cable or any other part with
surfaces are cooled more easily than dirty ones. electric voltage!

08-1387-GB
 Service

Hydraulic system • Important

Important notes on hydrau-
lic system
Warning! Air in the system
Never loosen a hydraulic hose Air in the system can disrupt its function. Normally
before making sure it is any air in the system will disappear through
depressurized. Always circulation.
mechanically secure moving If air enters the system while running the machine
parts before loosening the suction hose is leaking. The pump will be
hydraulic hoses. damaged if the leakage is not rectified immediately.

Wrongly adjusted pressure

Contamination Wrongly adjusted pressure can damage the hydrau-
The hydraulic system is extremely sensitive to con- lic system. The maximum pressure of the pump/
tamination. Particles only a few µm (0,001 mm) big system must not be increased without the
can jam a valve and cause serious disruptions and manufacturer's permission.
accidents. Contamination also increases component
wear and damages seals, valves and other moving
parts. Hydraulic liquid
Never fill the machine with used liquid. Think of the
Damaged piston rods are a main source of con- environment and avoid liquid spills. Always let an
tamination in a hydraulic system. Contaminants can approved waste treatment plant take care of used
also enter the system when replacing hoses and liquid.
pipes or carrying out other repairs if sufficient
cleanliness is not practised. Contaminants in the Always read the manufacturers instructions for
hydraulic system can damage pumps, cylinders and handling liquid. Avoid contact with the skin for long
other moving parts which can be the source of periods and keep away from eyes.
metal particles entering the system.

NOTE! The hydraulic filter must be

changed at least at the
intervals stated in the
maintenance instructions.
Only original parts may be
used.

Overheating
Overheating causes insoluble precipitates, sediment
and solid particles to form. Overheated hydraulic
fluid is a bad lubricant and causes bad performance
and wear. It can also ruin seals and cause leaks.

08-1192G-B- GB
 Service

Hydraulic system • Important

Preventive maintenance • Keep the system free from water.
Preventive maintenance is essential for the • Change hydraulic fluid according to the service
functioning of the hydraulic system. Faults can be schedule.
discovered at an earlier stage or avoided altogether
• Make sure the hydraulic lines are connected
if the steps below are followed.
correctly and do not vibrate during operation.
• Keep hydraulic fluid clean.
• Make sure lines are not damaged or split.
• Check the hydraulic fluid level regularly.
• Make sure hoses do not chafe against sharp
• Check the hydraulic fluid temperature often and edges.
follow instructions concerning correct working
• Do not operate the machine if unusual noises are
temperature.
heard from the hydraulic system.
• Use hydraulic fluid of correct viscosity.

Hydraulic fluid and lubricants

The following grades are recommended:

Grade Lowest start temp. Operating temp.

Hydraulic fluid* Mineral oil ISO VG32 -10ºC. +5°-+75°C (Ideal 40-60°C)
Mineral oil ISO VG46 0ºC. +10°-+85°C (Ideal 50-70°C)
Water-glycol UltraSafe 620S -20ºC. max +60°C
Biological oil HF-E46 -30ºC. 0°-+75°C (Ideal 40-60°C)
Quintolubric N850. -10ºC. -10°-+90°C. (Ideal 40-60°C)
Slew transmission SAE 80W-90 API GL 5
Drive transmission SAE 80W-90 API GL 5
All lubricating points
with nipples NLGI 2

* The hydraulic fluid grade used in the machine is specified on a label on the machine's hydraulic tank.
The hydraulic fluids should apply to the following standards: DIN 51524 HVLP, ISO 6743-4 HV and
SS 15 54 34 AV.

Caution! Using other hydraulic fluid

Mixing different hydraulic The maker of the machine must always be consulted
liquides can cause before using any other type of hydraulic fluid than
functional disruptions. those recommended in the above table.
Therefore, before attaching a
NOTE! The service life of the cylinder seals and
new tool, always make sure
the pump will be reduced if water and glycol is used
that the hydraulic system on
as hydraulic fluid. Extra cooling must be used.
the new tool contains the
same type of oil as that in the
machine.

09-0674G-C- GB
 Maintenance

Daily Inspection and lubrication

Inspections must also be carried out after transportation.

● Inspection Lubrication

Check point Measure taken Note

Stickers ● Must be readable, otherwise replace immedlately

Control cable ● Take immediate measures against possible damage
Mains voltage cable ● Take immediate measures against possible damage
Arm ● Check for signs of cracks
Shaft locks ● Check that they are secured
Hydraulic cylinders ● Check for damage and leakage
Hoses and couplings ● Chack for damage and leakage
Hydraulic oil ● Check the level. Refill if necessary 1)
Slew ring 1 nipple
Arm joints 19 nipples
Outrigger joints 5 nipples on each outrigger

1) Please note that the hydraulic oil must match the working temperature of the machine. If the working
temperature does not match the one recommended for the oil used, the oil must be changed.

Lubrication points

08-1390-GB
 Maintenance

Maintenance instructions

Inspection of hydraulic cylinders

Please note!
1. Check that the piston rods are completely
Immediately change damaged
straight and intact, and that the cylinder
or blocked nipples.
attachments are free from defects.
2. Check that there is no leakage.

Lubricating the slew ring

Please note!
1. Connect the grease gun to the nipple on the
Damaged scraper rings and
right side of the revolving table under the
piston rods may cause large
slew gear (see figure below).
quantities of dirt to enter the
hydraulic system, which in 2. Pump 3-5 times.
turn leads to secondary 3. Start the machine, rotate the upper part and
damage and breakdown. stop the motor.
4. Repeat the lubrication according to item 1-3
on at least 6 points spread out around the
CAUTION! slew ring. Lubricate extra carefully in the
Never remove a hydraulic area where the slew reduction gear unit opera-
cylinder or cylinder hose tes most of the time.
without first mechanically
locking or securing
concerned parts.

CAUTION!
Pipes and hose couplings
may be under pressure
despite the motor being
switched off. Always undo
couplings with the greatest
care.
Slew gear unit

Grease nipple Slew ring

Lubrication of arm joints, hydraulic
cylinders and outriggers
Thoroughly lubricate all nipples as in figure: Refill and change of hydraulic oil
"Lubricating points". See below for directions.

There is a total of 19 nipples on the arm and 5 on

each outrigger.
1. Wipe the nipple clean.
2. Connect the grease gun and pump 3-5 times.
3. Continue until you have lubricated all check
points.

08-1391-GB
 Maintenance

Regular maintenance
The maintenance diagram is based on the operating
Please note!
time of the machine. Since operating conditions
Do not forget the items on the
may vary considerably, you may have to adapt the
daily checklist!
intervals to the work situation and environment at
hand.
l Inspection Lubrication m Change

Check point Service intervals, Notes

Operating time (hours)
Week 500 1500

Oil cooler l Clean when necessary

Slew gear l m Check the oil level and change oil
l Fixing screws
Slew bearing 2 nipples
l Fixing screws
Return oil filter m
Wheel transmission l m Check the oil level and change oil
Hydraulic oil m
Filling filter m
Servo filter m
Air filter in hydraulic tank m
Hydraulic pressure l Adjust when necessary
Control voltage l

Check points
Servo filter

Slew gear

Filling filter

Slew bearing

Slew ring

Hydraulic tank

Hydraulic pump
Servo filter Air filter on hydr tank
Return oil filter (breathing filter)
oil cooler
Wheel transmission

08-1392-GB
 Maintenance

Maintenance instructions
Inspection and cleaning of oil cooler 3. Fill oil until it pours out of the hole where the
(Week) level plug was earlier.
1. Check that the shields around the electric motor 4. Put back the level plug and the filling plug.
are intact in order to get the best possible air
change rate in the machine body.
Filling plug
2. Wash the oil cooler clean with water or pressure
air.
Suggestion!
When operating, check regularly that air is
streaming out through the gills of the side panel.

Slew gear threaded union

Drain plug

Lubricating the slew bearing

(Week)
1. Undo the cover (see figure below) on the
Inspection of the slew gear threaded revolving table by removing one of the screws.
unions 2. Start the motor and carefully revolve the upper
(Week) part until one lubricating nipple is visible in the
hole.
1. Tighten the screws that hold the slew reduction
gear unit (see figure) with tightening torque 120 3. Cut the control voltage and stop the motor.
Nm. 4. Connect the grease gun and pump 3-5 times.
5. Revolve the upper part another 180° and repeat
Inspection of oil level in the slew gear the lubrication with the second nipple.
(Week)
1. Check the hydraulic oil level with the gauge rod
under the filling plug (see figure).

Change of oil in the slew gear

(500 h)
1. Remove the drain plug, the level plug and the
filling plug.
2. Put back the drain plug when all the oil has run
out.
Lubricating nipple

08-1393-GB
 Maintenance

Inspection of the slew gear threaded

unions
(500 h)
1. Tighten all 18 screws in the upper threaded 6. Remove the cover underneath the machine body.
unions with tightening torque 200 Nm. Place a collecting vessel under.
2. Undo the covers on the revolving table.
Caution!
3. Tighten any visible screws with tightening
Hot oil may cause burn
torque 200 Nm.
injuries.
4. Start the machine and carefully revolve the up-
per part until the next screw on the slew bearing
is visible.
5. Cut the control voltage and stop the motor.
6. Continue tightening until all 18 screws have
been checked.
Please note that two of the screws are not
threaded in the casting but have a bolt
underneath. If necessary, take out the electric
cabinet and press against the underside.

7. Unscrew the filter holder.

8. Drain the oil and remove the old filter insert.
Seal the old one in the plastic bag.
9. Check for large particles of metal or sealing
Upper threaded union
Cover material. If any are found, the machine must be
Lower threaded union taken in for trouble shooting and repair without
delay.
10.Clean the holder with degreasing agent, rinse
Change of return oil filter with hot water and dry with pressure air.
(500 h)
11.Fit the new insert, change the old seals and
1. Slew the upper part of the machine 90° to allow fasten the filter holder manually.
free scope above the air inlet cover.
12. Wipe up any spilled oil. Mount the cover
2. Relieve the arm system by lowering the arm on underneath the machine body.
the ground and stop the motor.
13.Fasten the cover again and the tank cover screws
3. Undo some of the tank cover screws to release that were undone.
the additional pressure in the tank.
14.Start the motor and check that there is no leakage
4. Remove the air inlet cover on top of the machine around the filter.
body.
5. Clean the filter holder and surrounding items
meticulously.

08-1394-GB
 Maintenance

Inspection of oil in the wheel gear Oil change in wheel gear

(500 h) (1500 h)
1. Run the machine until one of the plugs reaches 1. Run the machine until one of the plugs reaches
exactly the same level as the hub centre and the exactly the same level as the hub centre and the
second plug is in the highest position. second plug is in the lowest position.
2. Stop the motor. 2. Stop the motor.
3. Unscrew the level plug and check the oil level. 3. Put a container under the hub and unscrew the
4. Fill oil until it pours through the hole. drain plug.

5. Fasten the plug. 4. Turn the wheel so that one of the plugs will be in
the highest position and the second one level
See under heading: "Hydraulic oil and lubrication"
with the hub centre.
for choice of oil".
5. Fill oil through the filler plug until the oil pours
through the level hole.
6. Fasten the plugs.
See under heading: "Hydraulic oil and lubrication"
for choice of oil.

Filler plug

Level plug

Drain plug

08-1395-GB
 Maintenance

Change of hydraulic oil

(1500 h)

DRAINING OF HYDRAULIC OIL 7. Fasten the cover. Check that all seals are
1. Run the machine so that all cylinder piston rods positioned. Fasten all screws.
are retracted.
2. Place the machine in inclined position so that the Please note!
drain plug is at a low point. On no account may the motor
be started when the hydraulic
3. Put a container under the drain plug and open it.
tank is empty, as this will
cause serious damage to the
Caution! hydraulic pump.
Hot oil may cause burn
injuries.
FILLING OF HYDRAULIC OIL
The motor must always be switched off when
4. Clean thoroughly around the tank cover.
filling hydraulic oil. Use fluid of the grade
5. Undo all screws and remove the tank cover. specified on the label affixed to the hydraulic
tank.
Caution! 1. Clean the suction hose of the filling pump
Make sure that no dirt gets carefully before putting it into the oil keg.
into the tank.
2. Open the shut-off cock (position O) and start
pumping.
3. Check the amount of oil by looking at the glass
gauge on the left side of the machine.
4. Close the shut-off cock (position C) and tighten
the screws of the tank cover.
Tank cover 5. Start the machine and run the cylinders to their
end positions several times to evacuate air that
may have entered the hydraulic system when
Label indicating grade filling.
of hydraulic fluid
Shut-off cock

Open
Glass gauge Drain plug

6. Clean the tank inside with white spirit. Wipe dry Closed

with lint-free rag and vacuum clean the tank.

09-0947-GB
 Maintenance

Changing the filling filter Changing the hydraulic tank air filter
(1500 h) (1500 h)
1. Clean the area around the filter. The filter is in the machine body above the front of
2. Remove the old one and insert a new filter. the motor.
Fasten manually. 1. Open the left side panel and remove the electric
3. Wipe off any oil spill. cabinet.
2. Unscrew the old filter and insert the new one.
Changing the servo filter 3. Put back the electric cabinet and fasten the cover
(1500 h) again.
The direction valve servo circuit is equipped with a
strainer for cleaning the hydraulic oil. The strainer
is fitted in the end sections of the direction valve,
Air filter
behind the servo circuit test nipple. A 6 mm Allen
key is required.
1. Release any additional pressure in the hydraulic
system by running out the arms with the parallel
function switched on. Relieve the arm by putting
it on the ground.
2. Stop the motor.
3. Clean the area around the filter carefully.
4. Put a container under the valve.

Caution!
Hot oil may cause burn
injuries.

5. Unscrew the filter from the valve core.

6. Wash the filter with white spirit and blow clean
with pressure air.
7. Put back the filter and fasten the line again.

08-1397-GB
 Maintenance

Maximum pressure of the pump

Checking the hydraulic pressure The pressure level may be adjusted with the
(1500 h) adjusting screw on the regulator of the hydraulic
Pump pressure is measured at the outlet on the left pump after slackening off the locking nut. The
side of the upper direction valve (PX). Measure correct pressure level is 16.5 MPa.
both static pressure and maximum pressure.
Caution!
STATIC PRESSURE OF PUMP Maladjusted maximum pump
The pressure can be adjusted with the adjusting pressure may endanger the
screw on the hydraulic pump regulator after function of the machine or
loosening the lock nut. Correct pressure is 1.6 - 2.0 cause serious damage on the
MPa. The control circuit must be turned on for the hydraulic system.
pump to deliver its static pressure.
1. Turn off the motor. 1. Put the function switch in drive mode and turn
2. Unscrew the cover of the measuring point and on the control voltage.
fasten the manometer with measuring range 0-6 2. Run the outriggers on one side against their stop
MPa. position and keep the control lever in its actual
3. Start the motor. position. Read the pressure on the manometer.
4. Turn the function switch to operating mode ( ). 3. If necessary, adjust with the adjusting screw on
NB! Make sure the control circuit is turned on by the regulator. Clockwise movement increases
pressing the left top switch of the right control lever. pressure. Remember to lock the adjusting screw
The operating voltage will break after being inactive after adjustment.
for 3 seconds and the pump will then deliver its 4. Stop the motor, remove the manometer and fas-
maximum pressure. ten the cover on the measuring point.
5. Check the pressure on the manometer. 5. Fasten the tank cover.
6. If necessary, adjust with the adjusting screw on
the regulator. Clockwise movement increases
pressure. Remember to lock the setting screw
after adjustment.

Setting screw for

static pressure

Adjusting screw for

maximum pressure

7. Change manometer to the one with measuring

range 0-25 MPa.
8. Continue to measure the maximum pressure.

08-1398-GB
 Maintenance

Lower pressure level - adjusting the

pressure
1. Connect the manometer at the outlet on the left
side of the upper direction valve. (PX) The
measuring range of the manometer must be 0-
25,0 Mpa. The hammer hoses shold not be
connected when measuring (the hammer
function is operated against plug).
2. Turn switch (A) located on the electric cabinet,
in postition hammer . Adjust the pressure on A
the pressure limiter (B). Unscrew the locking nut
(C) and adjust with the adjustment screw (D).
Unscrew it to obtain lower pressure and screw it B
in to obtain higher pressure. Activate the top
botton on the left lever and read the positioned C
pressure D
The pressure shold be:
Hammer Montabert BRP 130 13,5 MPa
Hammer Montabert BRH 125 12,5 MPa

3. Mount the locking nut.

4. After the hammer has been used for a couple of
minutes it is prefearble to do point 1-3 again
depending on that it could be air in the pipes the
first time the pressure is adjusted and that could The valve is mounted on the
affect the adjusted pressure. lower directionvalve.

Measurement points, upper direction

valve

PL Signal pressure
PS Servo pressure
PT
PT Tank pressure
PX Pump pressure

PS PX
PL

08-1399-GB
 Trouble shooting
General notes
CAUTION!
Apart from external damage to machine parts,
The following items are very
damage and faults that may occur on the machine
important:
can be divided into three groups:
• Faults in the high-voltage circuit or the mains • Always disconnect the
power supply mains voltage to the
• Faults in the control circuit machine before repairing
• Faults in the hydraulic system • Work on the high-voltage
When trouble shooting, it is important to think part of the machine may
logically and to work methodically. Try to only be carried out by a
remember in what situation the fault appeared or in qualified electrician
what order different faults appeared. • Always lock machine
Try to identify the problem, then go through the parts that may move
trouble shooting diagram. The diagram does not unintentionally when
cover all possible faults, but it should be helpful working with the
concerning details that need to be checked. hydraulic system
• Only qualified service
personnel may work with
the electric or hydraulic
system.

08-1633-GB
 Trouble shooting

Motor and electricity supply The motor stops when it switches from
Y-to D-connection
1. Contact your machine supplier.
The electric motor does not start
1. Check that the stop-button has been pulled up
and that the control cable is properly connected The motor hums
at both ends. One phase is missing.
2. Check that all fuses, electric cables and 1. Check that the fuses, electric cables and
contactors are connected correctly. connectors are correctly connected.
3. Check that the voltage on all three phases reaches 2. Check the voltage with a potential tester.
the machine. Connect some other electric
equipment or check with a potential tester. CAUTION!
Testing on the high-voltage
CAUTION! part may only be carried out
Testing on the high-voltage by a qualified electrician.
part may only be carried out
by a qualified electrician.

The electric circuit fuses trip when

4. Check if the automatic fuse for the control circuit trying to start the machine
has tripped. 1. The fuses in the outlet are either rated too low, or
5. Contact the machine supplier. they are too fast. Change to time fuse according
to the diagram in section: "Description". First
Please note! If the thermal overload relay has
check if the electric circuit can cope with this
tripped, you must wait a moment before the
fusing.
machine can be started again.
2. Contact your machine supplier. The engine or
the rotation direction mechanism is broken.
The electric motor stops when the
start button is released Please note! When the electrical power is supplied
1. Change the control cable. by a diesel-driven plant, this must be dimensioned
for coping with the high-voltage current demand at
the moment of start: 3 times the rated current of the
The contactors tap continuously when motor when Y-/D-starting, and 7 times the rated
the start button is pressed or when the current when direct starting.
motor runs
(A clattering sound can be heard from the electric
cabinet. Please note that this will damage the
contactors very quickly.)
1. Check the supply voltage.
2. Check that the mains cable is not undersized.
3. Contact your machine supplier.

08-1634-GB
 Trouble shooting

The thermal overload relay of the mo- Operation

tor trips repeatedly
1. Check that the overload relay is correctly set. The motor runs, but none of the
See the diagram in section: "Description". hydraulic functions work
1. Check that the control circuit is connected.
CAUTION! 2. Check the control cable and the contactors at
The electric cabinet may both ends.
only be opened by 3. Check the level of hydraulic oil in the tank.
authorized personnel.
4. Check the dump valve.
5. Contact your machine supplier. The problem
2. Check the mains cable and cable connections in may be faulty static pressure, leakage in the
the connectors with respect to damages. The signal circuit, defective pressure reducing valve,
thermal overload relay has got a phase break pump or pump regulator.
protector that trips at defective contact in one of
the phase conductors. The machine is powerless on all
functions
CAUTION! 1. Contact your machine supplier. The problem
Always remove the main may be too low signal pressure, internal leakage
cable from the wall socket in the swivel, faulty pump regulator or worn out
before inspection. A pump.
damaged cable is highly
dangerous! All functions work with full power, but
boom cylinders move slowly and
hammer frequency is reduced
3. Contact the machine supplier. The motor may be 1. Contact your machine supplier. The problem
overloaded due to defects in the hydraulic sys- may be too low control voltage, static pressure
tem; the motor or the thermal overload relay may of the pump may be set too low or there may be
be defective. a leakage from the pressure line of the pump.
The machine works, but the revs. drop
markedly when any function is Only one of the boom functions moves
engaged slowly
1. Check the supply voltage. 1. Contact your machine supplier. A control lever
or a valve may be maladjusted, or there may be
2. Check that the mains cable is not undersized.
restriction in a hose due to an incorrectly pressed
3. Contact your machine supplier. hose connection.

08-1635-GB
 Trouble shooting

Both boom-arm and wheels fail to Overheating in the hydraulic system

respond when the control lever is If the ambient temperature is too high:
pushed into a certain position 1. Cool the machine by blowing cooling air into the
1. Measure the resistance in the cable with an machine body. If the machine will be used for
ohmmeter and lubricate the contacts with contact long periods in a hot environment, an extra
oil or replace the control cable. (Could be rupture cooler must be mounted.
in the control cable or defective contact in any
If the ambient temperature is not extremely high:
connector).
1. Always bring the control levers back to neutral
2. Contact your machine supplier.
when a movement goes to the end position.
Incorrect machine operation causes passage in
A particular boom or wheel function the shock-valves which heats the oil.
does not work 2. Check that the static and maximum pressure of
1. Contact your machine supplier. the pump is correctly set. (See maintenance
instructions.)
A particular function can only be 3. Check that there is not faulty restriction in a
activated with the control lever pushed hydraulic hose or quick-coupling (e.g. due to
to the maximum position incorrectly fitted brace.)
1. Contact your machine supplier. The control le- 4. Contact your machine supplier. The power
ver may be defective. consumption may be excessive due to defect
hydraulic hammer, worn-out hydraulic pump or
Jerky arm movements a leakage on any hydraulic pipe.
1. Contact your machine supplier. The control
voltage may be too high or there is poor contact CAUTION!
in the control lever. Beware of high-pressure oil
jets if a hydraulic pipe is
The machine sinks down on the damaged.
outriggers or some other cylinder
sinks
1. Contact your machine supplier. There may be a Noise in the hydraulic system
leaking check-valve, a defective shock-valve or
1. Check the oil level. Please note that the pump
internal cylinder leakage.
will be severely damaged if it is run with too
little oil in the system.
Together with another function, an 2. If the noise appears directly after filling hydrau-
unselected arm function is activated lic oil or changing tools, there may be air in the
1. Contact your machine supplier. A pilot valve system. Run the machine on low load until the
may be defective, or there is short-circuiting in air has separated from the oil.
the control cable or the electric swivel.
3. Contact your machine supplier. The pump may
be defective.
Please note the difficulty in identifying and analy-
sing unfamiliar noise. Machine noise can be
perceived differently depending on the working
environment.

08-1636-GB
 Circuit diagrams
Cable marking
The cables are colour marked and have identification
numbers. See illustration 1.
The cables are identified in the wiring diagram with
a designation consisting of the colour and number of
the cable. See illustration 2.
There are two versions of this cable marking sys-
Illustration 1
tem. The machine and the control box may have
different versions. Compare the designations on the
relevant wiring diagram to determine the version
used on your machine.

Version 1

Colour Designation

Grey GR
Illustration 2
Black SB
Brown BN
Red R
Green GN
Version 2
Yellow Y
White W Blue/white BL/W Low voltage connected to
Blue BL earth
Pink PI Blue BL Low voltage 24V
Orange OR Yellow/green Y/GN Protective earth connected to
Violet VI earth
Yellow/green Y/GN
Cables with numerical designations starting with 0
go from one unit to another within the same
equipment cabinet.
Cables with numerical designations starting with
any other number go from a unit to a terminal block.

07-0722G-A-GB
 Circuit diagrams

Electric circuit diagram, control box 3136 1136 92

Not. Name Function
B1 Control lever Control lever LH
B1.LL Switch Push button on LH control lever. Hydraulic tool with
variable flow
B1.LR Switch Push button on LH control lever. Hydraulic tool with
full flow
B2 Control lever Control lever RH
B2.RL Switch Push button on RH control lever. Opens lever gate
B2.RR Switch Push button on RH control lever. Parallel function,
coordination of movements CY1 and CY2.
D2 Circuit board Transmitter logic board, circuit board in control box
D3* Radio transmitter Radio transmitter
G4* Battery Battery for radio control
H1 Indicator lamp Green indicator lamp lights when power is supplied to
control box.
H2 Indicator lamp Indicator lamp yellow, lights when control box starts.
H3 Indicator lamp Indicator lamp orange, lights when lever gate is open
and operating current is supplied to control levers.
R1 Potentiometer For setting oil flow to Hydraulic tool. Functions only
when switch B1.LL is depressed.
S0 Safety switch Safety switch on control box for stopping electric mo-
tor.
S1 Switch Switch has two functions:
-start of control box
-connects extra On/Off 1
S2 Switch Switch has two functions:
-start of electric motor
-connects extra On/Off 2
S3 Switch Switch to select lower max. machine speed, 5 levels.
Also used for programming control system.
S4 Switch Switch determines which function switchB1.LL
andB1.LR is to have.

* Optional extra.
* * Not valid for all types of machines.

1136-92G-1-A- GB
 Circuit diagrams

Electric circuit diagram, control box 3136 1136 92

Not. Name Function

S5 Switch Switch functions:

-Use arm in transport mode, not Brokk 40.
-Manoeuvre upper section, working mode.
-Manoeuvre lower section, transport mode.
S6* Switch Extra On/Off 3.
S7* Switch Extra On/Off 4.
W1* Aerial Radio transmitter aerial.
X4 Connection point Chassis connector for control cableW4
X7* Connection point Chassis connector for radio aerial.
X24 Connection point Connector for coupling left control lever. Proportional
functions.
X25 Connection point Connector for coupling right control lever. Proportio-
nal functions.
X26 Connection point Connector for coupling left control lever. On/off
functions.
X27 Connection point Connector for coupling right control lever. On/off
functions.

* Optional extra.
* * Not valid for all types of machines.

1136-92G-2-A- GB
 Circuit diagrams

Electric circuit diagram, electronics unit 3136 1104 93-B

Not. Name Function
K7 Relay Relay for holding voltage to the contactors K1, K2, K3
and time relay P1.
K8 Relay Relay gives start impulse to contactor 1 for direct star-
ting
K10 Relay
S3 Switch The S3 switch is for selecting remote control or
emergency operation .
X5 Framing plug To connect the control cable to the controlbox
X6 Framing plug To connect the radio
X7 Framing plug To connect the control cable to the machine

* Optional extra.
** Not valid for all types of machines.

1104-93-B-GB
 3136 1104 93-B

1104-93-B
 Circuit diagrams

Electric circuit diagram, light current 3136 1138 93

Not. Name Function
18 Terminal block Low voltage only
21 Connection
42 Thermal overload relay Protect electricmotor on overload
45 Phase sequence relay
56 Hour meter Hour meter registers motor operating hours
H1 Indicator lamp Lights when phase sequence wrong.
K1 Contactor Contactor 1 couples in power supply to electric motor.
K2 Contactor Contactor 2, connects motor to star connection for start.
K3 Contactor Contactor 3, connects motor to delta connection when
operating
K9 Time relay Controls timing for switching motor from star
connection to delta connection

* Optional extra.
** Not valid for all types of machines.

1138-93-GB
 Circuit diagrams

Electric circuit diagram, light current 3136 1135 56

Not. Name Function
A1 Electrical cabinet
A3 Terminal box
17 Diode bridge Prevents feedback
18 Terminal block Low voltage only
19 Relay Switches negative lead between upper section and
undercarriage. Controlled from selector knob 9 on the
control box.
21 Connection
23 Temperature sensor Registers hydraulic oil temperature.
25 Diode bridge Prevents feedback
26 Terminal block
47 Relay For logic control of parallel unit.
47.2
51* Lighting
70* Motor Central greasing. Optional extra
71 Valve Low pressure
75 Switch Low pressure
76 Dump valve
A1 Directional valve Right outriggers up
B1 Directional valve Right outriggers down
A2 Directional valve Left outriggers down
B2 Directional valve Left outriggers up
A3 Directional valve Left wheel motor forwards
B3 Directional valve Left wheel motor backwards
A4 Directional valve Right wheel motor forwards
B4 Directional valve Right wheel motor backwards
A5 Directional valve Cylinder 2 in
B5 Directional valve Cylinder 2 ut
A6 Directional valve Cylinder 3 ut
B6 Directional valve Cylinder 3 in

* Optional extra.
** Not valid for all types of machines.

1135-56-1-GB
 Circuit diagrams

Electric circuit diagram, light current 3136 1135 56

Not. Name Function

A7 Directional valve Cylinder 4 ut

B7 Directional valve Cylinder 4 in
A8 Directional valve Slew clockwise
B8 Directional valve Slew anti-clockwise
A9 Directional valve Hydraulic tool
B9 Directional valve Optional extra
A14* Directional valve Slew brake. Optional extra
K6 Relay Low pressure
K7 Relay Central greasing
K8 Relay Slew brake
XR1 Swivel Rotating coupling for hydraulics between upper and lower
sections.
V10 Directional valve Parallel unit
V15* Directional valve Directional valve used for water flushing . Extra equipment.
V16 Directional valve Release parking brake
W1 Control cable

* Optional extra.
** Not valid for all types of machines.

1135-56-2-GB
 Circuit diagrams

Electric circuit diagram, heavy current 3136 1085 53

Not. Name Function
18 Terminal list Low woltage only
27 Capacitor Smoothes the rectified current It increases the current 1,4
times
28 Rectifier Rectifies the transformed alternating current (25 A, 50 V)
29 Transformer Features two ancillary coils, one for illumination circuit
and the other for the control circuit
Max output illumination circuit 10 A, 24 V
Max output control circuit 8 A, 19,5 V
30 Automatic fuse For the control circuit, 8 A
31 Automatic fuse For the illumination circuit 10 A
36 Plug For connection to the main cable
42 Thermal overload relay Safeguards the electric motor against overload
45 Phase rotation relay Controls the phase sequence of the supply voltage. When
wrong phase sequence the lamp H1 on the electric cabinet
will light up.
48 Phase inverter If the lamp H1 lights up , change the position of the switch
K1 Main contactor Always activated when the motor is running
K2 Y-contactor Only activated during start
K3 D-contactor Activates by K9, after that always activated when the
motor is running
F3* Earth fault relay Optional extra

* Optional extra.

1085-53-GB
 Circuit diagrams

Hydraulic diagram 3136 1135 55

Not. Name Function

1 Hydraulic cylinder Arm 2 cylinder C1

2 Hydraulic cylinder Arm 2 cylinder C2
3 Hydraulic cylinder Arm 3 cylinder C3
4 Hydraulic cylinder Arm 3 cylinder C4
5 Hydraulic motor Hydraulic motor for slew function
8 Pressure relief valve Parallell function
9 Load holding valve
10 Direction valve Parallell function
11 Flow divider Parallell function
12 Slewing brake Optional extra
13 Directional valve Upper direction valve.
17 Swivel The swivel conveys both hydraulic pressure and
electric current between the upper and the lower body of the
machine
18 Air-oil cooler
19 By pass valve
20 Return filter The return filter is for purification of the hydraulic oil.
21 Hydraulic pump Main pump
22 Pump regulator
28 Filling pump For filling hydraulic oil.
29 Ball valve
30 Filter For oil purification when refilling
33 Direction valve Lower direction valve.
35 Hydraulic motor Hydraulic motor for wheel drive.
36 Hydraulic motor Hydraulic motor for wheel drive.
37 Pilot op check valve
38 Hydraulic cylinder Outrigger cylinder
39 Electric motor
40 Breathing filter The breathing filter is for the hydraulic tank.
54 Pressure limiting valve and Reduces the signal pressure.
dump valve

1135-55-1-GB
 Circuit diagrams

Hydraulic diagram 3136 1135 55

Not. Name Function

AV20 Valve block Slew brake
AV22 Valve block Track angling / Extra On/Off 1
AV24 Valve block Extra On/Off 2
RY1 Rotator Side-angling of breaker
RY2 Rotator Extra equipment
V16 Directional valve Release parking brake
VF1 Pressure relief Main pressure relief that protects system against
unallowably high pressure.
VF8 Pressure relief
VY5 Directional valve The directional valve is used to control extra hydraulic
functions on the undercarriage / Extra On/Off 1. Accessory.
VY9 Directional valve On/Off 2. used for extra function
Y5 Actuator Extra 1 on/off.
Y9 Actuator Solenoid on directional valve -VY9
PL Measuring connection To gauge the maximum pressure at port A or B
PS Measuring connection PS measuring connection for gauging the servo pressure.
PX Measuring connection PX measuring connection for gauging the pump pressure
and pressure at rest
TPB Measuring connection For guaging the pressure at rest.

1135-55-2-GB
 Accessories
Central greasing
Description of the Before start
lubrication system. Before using the lubricating pump, the grease con-
The lubrication system consists of an electrically tainer must be filled with fresh lubricating grease
driven lubricating pump with a lubricant container via the grease nipple (B). All hoses must then be
taking 2000 ccm grease. completely filled with grease to remove all air from
the system.
At the outlet of the pump a pressure reducer is
mounted. It will open if the pressure exceeds 14,0 Refilling of grease
MPa. When the lubricant is pumped out at the by- Continue pumping until grease comes out from all
pass valve (A), one of the lubrication passages is the lubricating points.Use a hand operated grease
silted up so that the grease can not reach the gun, or carefully use a larger lubricating pump, to
lubricating points. A lubricating hose leads from the fill the whole system with lubricating grease.
lubricating pump to a quick coupling, which makes
a simple partition of the lubricating hose possible Note. Dirt and foreign matter are detrimental to
when exchanging tools. the lubricating system. Strict cleanliness is
essential in all servicing operations.
When the quick coupling is parted the lubricating
pump must be shut off. If the lubricating pump is Shutting off the lubricating
run with the quick coupling parted, the pressure
incrases to 14,0 MPa and the lubricant pumpes out
pump
at the pressure reducer. With pressure in the Shut off the lubricating pump by turning the switch
lubricating hose and the quick coupling it is (C).
impossible to couple the quick coupling.
The lubricating pump must also be shut off when
using a tool, for instance a concrete crascher,which
uses the dubble acting hammer function.
In order to reduce the pressure in the quick
coupling, disconnect the hose nipple from the quick
coupling. Then the pressure in the hose and the C
quick coupling will increase.

08-1400-GB
 Accessories

Forced draft cooling equipment

Description of forced draft cooling Connecting
equipment Forced draft cooling equipment is connected to the
The forced draft cooling equipment increase the machine by a 1/2" claw coupling. The claw coupling
existing coolers refrigerating capacity. is located on the back of the machine body. Pos 1.
When compressed air is connected, the air is
distributed through a nozzle to existing cooler in the
machine body.

Cleaning
Clean the machine regularly inside and outside,
clean surfaces are cooled more easily than dirty
ones.

08-1402-GB