NEXGEN IMPULSE 100L User manual

OPERATION MANUAL & PARTS LIST
HYDRAULIC BREAKER
IMPULSE 100L/S

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СONTENTS
01 GENERAL INFORMATION ON THE PRODUCT
02 SAFETY INSTRUCTIONS
03 TECHNICAL SPECIFICATIONS
04 DESIGN AND COMPONENTS OF BREAKER
05 CONNECTION AND DISMOUNTING
06 MAINTENANCE
07 OPERATION
08 TROUBLESHOOTING
09 SERVICE TOOLS
10 WORKING TOOL SELECTION
11 WARRANTY
12 REGISTRATION PAGE 36

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01 GENERAL INFORMATION ON THE PRODUCT
Hydraulically operated breakers can be used as attachments to different models of hydraulic
excavators of both domestic & foreign origin, as well as with other hydraulic machines (such as
loaders, manipulators etc.) with relevant weights & load capacities, subject to compliance with
the requirements of hydraulic circuit of excavator and breaker.
Hydraulic breakers can be used in construction, road work, quarrying, tunneling and other
projects to break solid materials and other structures.
Hydraulic breakers can also be used for soil compaction in confined areas and for hammering in
pillars, piles and other similar objects, if the special working tool is installed.
Hydraulic breakers can be operated in any position, ranging from horizontal to vertical, and in
ambient temperatures of -40°C to +40°C.
Before operating the breaker, the instruction and safety manual should be read and understood.
Adhering to all the requirements of the instructions in this manual, the manufacturer guarantees
high-productivity, reliability and safe operation.
WARNING!
Breaker’s operator must read and understand this manual before installation,
operation or maintenance of the hydraulic breaker.
This manual must be kept on hand; operator as well as anyone else working
within proximity should read this manual on an intermittent basis. When the
breaker is either sold or given to third parties this manual must be given with it.
Improper operation can result in serious injury. If this manual is lost or damaged,
please contact your dealer.
Digital manual can be obtained on www.nexgenattachments.ca website,
product documentation page.

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02 SAFETY INSTRUCTIONS
Before operation
Most accidents involving machine operation and maintenance are caused by failure to observe
basic safety rules of connection, operation or neglecting visual inspection of the hydraulic
breaker.
Before operation or service of the breaker, make sure that you read and understand the safety
precautions in this manual as well as safety stickers and plates on the breaker itself.
Warning messages are classified below, so that the operator can read and learn them either in
this manual or on the breaker itself.
DANGER!
Points at hazards. This shows the most dangerous situation.
CAUTION!
Points at a potentially hazardous situation.
WARNING!
Points at a potentially hazardous situation, which may cause a minor injury.
NOTIFICATION!
Indicates a situation that is directly or indirectly related to personal safety or
property protection

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CAUTION!
This hydraulic breaker is not to be used for any other activity other than the
work mentioned in the product designation section.
CAUTION!
Observe all safety precautions.
Observing safety precautions
•Adhere to all the rules, precautions and safety procedures while operating or servicing the breaker
•Perform work in accordance with local requirements
Required PPE
•Wear properly fitted clothing, as loose clothing can get caught in the machinery
•Wear a safety helmet, safety boots etc. When required wear a dust-proof mask, protective
glasses and industrial gloves
•Use ear-protection
Safety precautions after operation is completed
•Before the operator leaves the equipment, make sure the breaker is moved down to the
ground level and the equipment’s engine is turned off
•Clean your attachment and equipment regularly, keep your work area organized
Be careful with the hydraulic oil pressure
•Before disconnection or connection of hydraulic hoses, stop the equipment engine, release oil
pressure in the hoses (turn breaker control lever into the start position 2–3 times and hold it for
2–3 seconds each time) and wait for 2 minutes to release pressure.
Be aware of projectile rock chips
•To avoid accidents, the operator is strictly prohibited from getting out of the excavator cab and
must keep the cab windows and doors closed during operation. Make sure there is nobody in
proximity of the projectile rock chips

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03 TECHNICAL SPECIFICATIONS
Specications Impulse 100S
Breaker’s weight, with mounting plate and working tool, kg / lb 275kg / 606lb
Excavator’s weight, t / lb 1–6,5t / 2204-14330lb
Impact energy, J / ft-lbs 630j / 464 ft-lbs
Impact rate, bpm 800–1600
Operating pressure, bar / psi 90–130 bar / 1305-1885 psi
Max pressure, bar / psi 160–180 bar / 2320-2610 psi
Oil ow, l/min 30–50
The purity class of the hydr. oil by Russian ISO 4406:1999 no less than -/19/16
Working tool’s diameter, mm / in 68mm / 2.67in
Working tool’s useful length, mm / in 345mm / 13.58in
DN hoses, mm (tting) 13 (1/2’’BSP)
Nitrogen chamber charging pressure, bar / psi 16–17 bar / 232-246 psi
Breaker’s length without tool and mounitng plate, mm / in 970mm / 38.18in
Breaker’s length without tool and with mounitng plate, mm / in 1195mm* / 47 in
Breaker’s length with tool and with mounitng plate, mm / in 1540mm* / 60.62in
* Depending on conguration.

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04 DESIGN AND COMPONENTS OF BREAKER
4.1. Components of Impulse 100S breaker
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№ Part number Part description Qty, pcs
1 ТК 296.07.200 Breaker housing 1
2 ТК 296.07.100 Main body 1
3 ТК 296.07.005 Pressure plate 1
4 Mounting plate for excavator 1
4-1 Mounting plate for loader 1
5 Working tool 1
6 ТК 296.07.004 Bottom buer 1
7 ТК 297.22.003 Upper buer 1
8 ТК 297.22.002 Upper buer ring 1
9 Seal S01-P 99--66-/18 1
10 Screw М16х55 10.9 12
11 Locking washer 16Т DIN 127 12
12 Nut М16 10.0 DIN 985 12

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4.2. Main body components of 100S breaker
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№ Part number Part description Qty, pcs
1 ТК 296.07.110 Breaker housing 1
2ТК 296.01.102-01 Control block housing 1
3 ТК 296.03.102 Piston 1
4 ТК 296.03.101 Sleeve 1
5 ТК 296.01.103 Bushing 1
6 ТК 296.01.104 Spacer 1
7 ТК 296.01.105 Screw cap 1
8ТК 296.01.106-01 Cap (M20) 1
9 ТК 296.01.113 Thrust washer 1
10 ТК 296.01.107 Solid tool bushing 1
11 ТК 296.01.114 Tool pin 1
12 DF05-3000 Directional control valve 1
13 ТК 296.07.119 Charging valve adaptor 38 mm 1
14 DF03B-1110 Charging valve (with plug) 1
15 ТК 080.00.147 Buer ring ST08 92,40x98,00-1,5 1
16 ТК 080.00.188 Buer ring ST08 94,40х100,00-2 1
17 Screw М14х100 8.8 (DIN 912) 8
18 Screw М20х40 10.9 (DIN 912) 2
19 Adapter 1/2»х1/2» 2
20 Locking washer 14 DIN 127 8
21 Locking washer20 DIN 127 2
22 Spring pin 12х60 1
23 Oiler М10 1
24 Plug М10 1
25 Plug VHR 90-3/8 ED 4
26 O-ring 1/2» 2
27 Plug (blind nut AB08) 1/2» 2
28 DF05D-0040 Seal ISI 70х80х6 1
29 DF05D-0050 Seal DSI 70х80х6х8 1
30 DF05D-0020 Seal SPNS 68 2
31 DF05D-0010 Seal GAS SEAL IKH 68х78х6 1
32 092-098-36 O-ring 1
33 094-100-36 O-ring 5
34 096-102-36 O-ring 1
35 11A281K6 O-Ring 19,5х3,0 (020-025-30 O-ring) 3
36 11A476K6 O-Ring 37,3х3,6 (038-044-36 O-ring) 2
37 O-ring 1BG 25 (025-030-30 O-ring) 1
38 O-ring 1BG 40 (040-045-30 O-ring) 1
39 Spring pin 12х60 DIN 1481 1
40 018-022-25 O-ring 1

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05 ASSEMBLING & DISASSEMBLING
5.1. Breaker’s connection to excavator’s hydraulic circuit
This schematic shows one of the simplest hydraulic circuits when the breaker is connected to
the backup distributor of the equipment
Shut-o˜ valves (or quick coupler)
Hydraulic breaker
Return line
Pressure line
Relief valve
Relief valve
Pump
Hydraulic
distribution valve
Operating сontrol block
NOTE!
If the hydraulic circuit of your machine differs from scheme 5.1, contact
your dealer or the equipment manufacturer
5.2. General view
NOTE!
Check all oil supply lines for compliance with the hydraulic pressure of the
breaker. A pressure release valve should be mounted if there is no pressure
release valve in the hydraulic circuit of the equipment.

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Standard breaker installation is shown in the diagram below.
Stop valves
(or Quick Release Valves)
Oil output line
Oil input line
Oil supply
pressure line
Oil output pipeline
Hydraulic tank
Air heater
Hydraulic pump
Operating
control block
Directional
valve
Intput pipeline
(pressure line)
Output pipeline
(drain line)
5.3. Installation of the breaker on an excavator
WARNING!
Never put your hands or ngers into the pin holes!
WARNING!
During arm hole adjustment, ensure there is no one under the arm of the
equipment or excavator bucket. Moving the equipment while installing the
breaker is dangerous.
Wear safety boots to protect your feet.

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CAUTION!
Be careful not to allow any dust, mud or sand into the breaker and its hydraulic
circuit. Perform connection and disconnection of the breakers on a clean,
horizontal surface.
Wooden bars
1. Set breaker on the wooden bars in a horizontal position
2. Take out pins from the excavator’s arm and linkage, take the bucket off.
3. Move equipment closer to the breaker; connect pin holes of the arm with the pin holes of
hammer’s adapter plate (hitch), put pins into the excavator arm.
4. After the arm pin is installed, take the bucket cylinder out, move the excavator bucket linkage
and put the linkage pin in.
5. Stop the equipment’s engine, turn off directional control valves and release air pressure from
the hydraulic tank.
6. Take plugs off of the hydraulic hoses at the end of the excavator’s arm; connect the breaker to
the hydraulic circuit using high-pressure hoses.
NOTE!
Be careful to avoid oil leakage onto the ground.
Keep the plugs from the hydraulic circuit in the toolbox when they are not in
use. Every time you install or remove plugs and high-pressure hoses, clean them
and keep them away from dust and mud which can get into the hydraulic circuit
of the breaker or base machine.
7. Open the stop valves at the pressure lines if they are installed in the hydraulic circuit, turn
them to the “Open” position
8. Start the equipment’s engine and check the high-pressure hoses connections
9. Start warming up the equipment

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NOTE!
Run excavator boom and arm for 5 minutes after the engine starts to raise oil
temperature in the hydraulic circuit.
WARNING!
Stay away from the hydraulic breaker.
5.4. Dismounting breaker from excavator
CAUTION!
Be careful not to be injured by falling pins or tool during dismantling.
WARNING!
Wear safety boots to protect your feet.
1. Set the breaker on a clean, horizontal surface. Block the brake pedal of the equipment.
2. Stop engine.
3. Set stop valves in the “closed” position.
4. Disconnect high-pressure hoses and shut-off valves and make sure there is no oil leakage.
5. Connect plugs to high-pressure hoses.
6. Take off excavator’s arm and linkage pins.
7. Take equipment’s arm out of the breaker’s mounting plate.
8. Cover the dismounted hydraulic breaker with a protective shroud and store it in a dry, indoor
area.

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06 MAINTENANCE
6.1. Machine markings and numbers
The equipment’s serial number is marked on the label plate on the breaker’s body. It is
important to make the correct reference to the serial number of the attachment when making
repairs or ordering spare parts.
6.2. Informational stickers & plates
Tag «Charge pressure»
Tag «High-pressure hose connections»
«Greasing points tag»
Tag «Check pressure before operation»
Warning tag «High noise level, ear protection is required» Warning tag «Read and understand manual before operation»
Tag «Discharge pressure before dismounting»
Machine marks and numbers
Warning tag «Projectile rock chips»
Model
Serial Number
Manufacuring Date
Working Weight
Nexgen Attachments Inc.
[phone]
(kg)

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6.3. Maintenance
NOTE!
Before using the hydraulic breaker, make sure you have checked the
following points:
Every 3 hours
•Add grease into the front head of the hammer (working tool greasing)
•Check oil temperature, pipelines and high-pressure connections, working conditions.
•Check all connections
Every 10 hours or daily
•Should any burrs be found on the working tool, they should be removed.
•Check the mounting plate’s bolts tightness.
•Check the breaker’s body – should there be any visible damage, found immediately stop
operating the breaker and find the source of the damage and eliminate it.
Every 50 hours or weekly
•Check the gap between the working tool and tool bushing
•Check the working tool’s condition
•Check the nitrogen pressure in the breaker’s gas chamber.
Every 200 hours or every month
•Check the working tool’s pins condition
Every 1000 hours or every 6 months
•An inspection of the breaker in authorized service station is recommended.
Every 1500 hours or once every two years
•Change all seals
•Check piston, sleeve and bushing for wear
6.4. Hydraulic oil requirements
Hydraulic oil is recommended. The hydraulic oil used in the equipment circulates in the breaker
circuit as well.
Oil Manufacturer
Hydraulic Oil
ISO VG 46 ISO VG 32
All-weather (for temperate climate) For cold weather in temperate
climate, All-weather for cold climate)
Esso Nuto H46, Univis N46 Nuto H32, Univis N32

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Shell Tellus V46 Tellus V32
Mobile DTE Excel 46 DTE Excel 32
Gulf Harmony 46 Harmony 32
Russian
Oil МГЕ-46В
(МГ46-В)
ТУ 38-001347-83
Oil ВМГЗ
(МГ-15В)
ТУ 38-101479
Changing oil and oil filters
The hydraulic breaker is advanced and high precision equipment. Internal components move
at high speeds and operate within the smallest gaps, so oil purity and viscosity should be
carefully measured and controlled.
Oil contamination can not only damage the hydraulic breaker but can also cause problems in
the equipment which could result in damaged components. We recommend an oil and filter
change as shown in the chart below, which provides the breaker’s maximum performance.
Hydraulic oil Initial 250 hours. Every 600 hours or as per the equipment’s manual
-whichever comes first
Oil lters Initial 50 hours. Every 100 hours, or as per the equipment’s manual -
whichever comes first
Oil temperature
The oil temperature depends on environmental conditions, the efficiency of the cooling system,
the connection scheme and the operating mode of the hydraulic breaker.
The normal operating oil temperature range is -20°C +80°C. If the temperature falls lower than
-20°C, the oil should be preheated before starting the breaker. To heat the oil, you should start
the equipment and let it run (without starting the breaker), as long as it takes to raise the oil
temperature to the required level. While operating, the oil will remain warm.
When operating the breaker continuously, the hydraulic oil temperature range should be 50–80
°C (120–175°F), depending on the oil viscosity.
A special thermometer is required to measure the oil temperature. If there is no such
thermometer on the equipment, you must install one.
Oil cooling
When the breaker is used continuously, it is necessary to have a cooling system with an
additional cooling function, because when working with a hydraulic breaker, the oil heats up
much more than while in excavating mode.

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NOTE!
Equipment’s parameters should always be monitored. Oil temperature in the
hydraulic circuit should not exceed 80°C. If the temperature exceeds the maximum
allowed, stop the breaker and don’t start it until the oil temperature drops to
normal.
Oil viscosity
Viscosity is an especially important parameter of hydraulic oil. Typically, the temperature of the
hydraulic breaker oil and the equipment is between 40 °C (cold season) and 60 °C (warm season).
At these temperatures, the viscosity of the oil should be 20-40 cSt. The breaker must not be
started if the oil viscosity exceeds 1000 cSt, or falls down to 15 cSt.
If the oil is too thick:
•difficult start up
•breaker strikes slowly
•unstable breaker performance
•danger of cavitation in pumps and hydraulic breaker
•sticky valves
•if the filter is too dirty, the hydraulics of the equipment may be
damaged
If the oil is too thin:
•efficiency losses (internal leakages)
•damage of gaskets, seals or O-rings
•accelerated parts wear due to lack of
lubrication.
Oil purity
Oil filters as per the filtration specifications, should comply with the excavator or any other
equipment requirements mentioned in the base machine’s manual. When working with the
breaker, we recommend installing oil filters in the inlet lines with filtration no less than 10 mkm.
NOTE!
Oil purity must be no less than recommended by code -/19/16 according to ISO
4406:1999 (neither water nor any other dirt are allowed in the oil) otherwise the
warranty on your breaker will be void.
6.5. Lubrication
CAUTION!
Insufficient or improper greasing may cause abnormal wear of the tool bushing
and tool itself, or tool damage.

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Apply tool grease with a grease gun to the greasing points marked with stickers every 3 hours of
operation.
Grease stickers
NOTE!
Grease the tool shank properly before installation. The breaker must stand
upright resting on the tool to ensure that the grease will penetrate downwards
between the tool and the bushing to avoid implosion and gasket damage.
Recommended grease
Manufacturer Lubrication
Esso Beacon Q2
Shell Retinax AM | Grease S 5826 | Kuggfett | Albida HLS 2
Mobile Special Grease Mobile
ASPO Molycent MP Grease
TEBOIL Tebo Gear-Grease MDS
UNION Texaco Molytex Grease
Delta Marathon DM-3000
RAMMER TOOL GREASE, part no. 902045
FUCHS Meisselpaste
KENDALL Tough TAC
KLUBER Craoscon C-SG 0 Ultra
LE 3751/3752 Almagard varipurpose lubricant
WYNNS GS80
Russian ГОСТ 3333-55 УСсА | ГОСТ 3333-80 23258-78-СКа 2/6-23
6.6. Nitrogen level control (N2)
WARNING!
Do not stand in front of the working tool while nitrogen is being filled into the
breaker’s gas chamber.
Make sure that gas chamber is fully depressurized before disassembling the
breaker.