Dozco D135 Op - PM

D Series
HYDRAULIC ROCK BREAKER
D series
D135 Operation and Maintenance
Manual
D Series D135 Operation and Maintenance Manual
OREWORD
Thank you for purchasing DOZCO Rock Breaker.

DOZCO pursues a policy of continuing improvement in design and performance of Breaker. The right
is therefore reserved to change the part in this list without prior notice or obligation.
This Breaker gives our customer, the maximum in performance and durability. Should you have any
question regarding this breaker or catalogue, please contact the sales person /nearest branch to your
area. A satisfied customer is our goal.
NOTICE
 Pictures in this broacher are for reference purpose only.

 Use DOZCO Rock Breaker genuine parts when replacing some part.
Instructions for Use

Instructions for ordering
This spare parts catalogue contains no safety
measures for operation and is only intend to When ordering a part, refer to the
assist in placing spares order. For detailed illustrations, lists in this parts catalogue, and
information on operation, maintenance and then inform DOZCO of the following items.
safety regulations refer operation manual (1) Model name
provided along with the breaker. (2) Machine No. (Serial No.)
(3) Part No.
(4) Part name
(5) Quantity
It is very easy to find what kind of part to be ordered and replaced using this parts catalogue. And it is
also a guideline for our customer to order the parts they want.
* ALL RIGHTS RESERVED
DOZCO 2
COMPONENTS OF BREAKER
Model: DOZCO D135

(Outward valve type with Accumulator)
Advantages and Benefits of DOZCO ROCK BREAKER
* Operator friendly * Lower maintenance cost with good

durability
* Well-balanced bracket with fewer component * Easy to use
* World best quality main valve and piston * Quicker and better after-sales services
* Outstanding power to weight ratio * Prompt on-the-site support
* High performance with latest technology main valve * Effective Buyer technical support Program
* Top class " Less Noise" (Box Type Bracket)
DOZCO 3
D135 Rock Breaker Technical Specifications

A. Frame Outline Dimensions
DOZCO 4
B. Technical Specifications
Description Specifications
Excavator Weight Class 18~26 Ton
Operating Weight (*) 1725 Kg
Overall Length 2666 mm
Tool Diameter Ø135 mm
Tool Length 1200 mm
Setting Pressure 220 bar
Operating Pressure 160~190 bar
Optimal Oil Flow 120~180 lpm
Impact rate 300~550 bpm
Back Head Pressure 14~16 Kg/cm²
Anti-Blank Firing Yes
Stroke Control Yes
Auto Greasing Optional
Accumulator Yes
Frame Bottom Plate Thickness 50 mm
 The Operating Weight include the MC + Body + Tool Weight

 The Above Specifications are subjected to change without prior notice for the quality
enhancement
DOZCO 5
CONTENT PAGE NO
OPERATION & MAINTENANCE MANUAL
1 Safety Information --------------------------------------------------------------------------------- 8
2 Working Principle ---------------------------------------------------------------------------------- 10
3 Installation and Removal ------------------------------------------------------------------------- 11
3.1 Fundamental Circuits ----------------------------------------------------------------------------- 11
3.2 General View ---------------------------------------------------------------------------------------- 12
3.3 Installation ------------------------------------------------------------------------------------------- 13
3.4 Removal ---------------------------------------------------------------------------------------------- 16
4 Maintenance ---------------------------------------------------------------------------------------- 17
4.1 Serial numbering system ------------------------------------------------------------------------- 17
4.2 Safety label ------------------------------------------------------------------------------------------ 18
4.3 Moving and Lifting --------------------------------------------------------------------------------- 19
4.4 Care and Maintenance schedule ---------------------------------------------------------------- 20
4.5 Hydraulic Oil ----------------------------------------------------------------------------------------- 21
4.6 Greasing ---------------------------------------------------------------------------------------------- 23
4.7 Inspection and Charging of Nitrogen gas ---------------------------------------------------- 24
4.7.1 Back Head -------------------------------------------------------------------------------------------- 24
4.7.2 Accumulator ---------------------------------------------------------------------------------------- 27
4.8 Pressure setting ------------------------------------------------------------------------------------ 29
4.9 Seal Inspection ------------------------------------------------------------------------------------- 30
4.10 Wear Inspection ------------------------------------------------------------------------------------ 31
4.11 Inspection and replacement of through bolt ----------------------------------------------- 34
4.12 Torque table ---------------------------------------------------------------------------------------- 35
4.13 Storage ----------------------------------------------------------------------------------------------- 38
5 Operation -------------------------------------------------------------------------------------------- 39
5.1 Tool Installation ------------------------------------------------------------------------------------ 39
5.2 Safety Operation ----------------------------------------------------------------------------------- 41
5.3 Function of Adjuster ------------------------------------------------------------------------------ 44
5.3.1 Cylinder Adjuster ----------------------------------------------------------------------------------- 44
5.3.2 Valve Adjuster -------------------------------------------------------------------------------------- 45
DOZCO 6
6 Trouble shooting ----------------------------------------------------------------------------------- 46

7 Tool Selection --------------------------------------------------------------------------------------- 48
7.1 Guide for Tool Selection -------------------------------------------------------------------------- 48
7.2 Tool claim Judgment ------------------------------------------------------------------------------ 49
8 Parts Catalogue ---------------------------------------------------------------------------------------- 53
8.1 Frame Assembly--------------------------------------------------------------------------------------- 54
8.2 Frame Assembly Parts List--------------------------------------------------------------------------- 55
8.3 Hydraulic Body ---------------------------------------------------------------------------------------- 56
8.4 Hydraulic Body Parts List ---------------------------------------------------------------------------- 57
8.5 Acc. Assembly ------------------------------------------------------------------------------------------ 59
8.6 Valve Housing Assembly Parts --------------------------------------------------------------------- 60
8.7 Valve Housing Assembly Parts List ---------------------------------------------------------------- 61
8.8 Nitrogen Gas Charging Kit -------------------------------------------------------------------------- 62
9 Tool Box Parts List ------------------------------------------------------------------------------------ 63
DOZCO 7
1. Safety Information
 Before operation
Many accidents are caused by disregarding the basic rule of installation,

operation and repair or by neglecting the inspection before operation.
Before operating or repairing this hydraulic breaker, be sure to read and fully
understand the preventive methods and warnings described on the breaker and in
this manual.
Safety labels and messages are classified as below so that the user may
understand the warnings on the breaker and in this manual.
DOZCO 8
 Specified works
This hydraulic breaker can be used for breaking, demolishing and drilling in mines, stone
breaking or building engineering work.
 Observance of safety rules in workplace

- Observe all the rules, cautions and procedures for safety when the hydraulic
breaker is operated or repaired.
- Fulfil the work according to the signals already decided when cooperative work or
work by guide is done.
 Inspection for safety devices
- When the work is stopped or finished, be sure to set the safety lock of
operations in locked position.
- When the operator gets out from the base machine, be sure to put the hydraulic
breaker on the ground and stop the engine of base machine.
 Be careful of the hydraulic oil pressure
- Before disconnecting or connecting hydraulic hoses, stop the engine of base
machine, close stop valves “IN” and “OUT” connections and then operate the
control lever to release pressure trapped in the hoses and wait ten (10)
minutes.
 Safety from flying chips of rock during hydraulic breaker operation
- Protect yourself and your neighbourhood against flying chips of rock. Do not
operate the hydraulic breaker or base machine if someone is too close.
- Keep the base machine’s cab doors and windows closed during operation.
Window bars are recommended to protect the windows from flying chips of
rock.
DOZCO 9
2. Working Principle
1) Cylinder
This contains the moving piston which strikes the tool. The seals for both end of
the piston is also located in the cylinder. The seals for the upper end of the piston
are located in a removable seal retainer while the seals for the lower end of the
piston are located in proves machined directly into the cylinder.
2) Piston
The piston transfers impact power to the tool, generated by hydraulic power.
3) Seal Retainer
The seal retainer has oil seal and Gas seal to seal Nitrogen (N2) gas back
head, and to prevent hydraulic oil leakage.
4) Valve
The valve controls reciprocate piston action with hydraulic fluid distribution.
5) Front Head Assembly
This retains the tool, using the tool pins. By removing these pins, the tool can
be changed.
6) Ring Bush
This guides the tool; inner bush limits the uppermost position of the tool. It is
consumable part, which should be checked for wear limits. If needed, they
should be replaced.
7) Tool
This transfers piston impact power to the objects. We recommend various tool
shapes according to working circumstance.
8) Tool Pin
This is installed on the front head, and prevents the tool from coming off.
9) Back Head Assembly
This contains the cushion chamber charged with nitrogen (N2) gas that is
compressed during upward strokes of the piston, and serves to provide
maximum absorption of piston recoil, efficiency storing this energy for the next
blow.
10) Through bolt Assembly
These are used to assemble front head, cylinder and back head. They have to
be constantly tightened to specified torque. Inspect the bolts for loosening and
re-tighten them weekly.
DOZCO 10
3. Installation and Removal

3.1 Fundamental Circuit
When piping the hydraulic lines on base machine, it is important to know the
fundamental circuit to which the piping belongs. Then the piping can be
connected correctly, properly and quickly.
(Fig.3-1)
Fig.3-1 Showing one of simplest Hydraulic circuit in case of installing a service port into the main
control valve of base machine.
NOTICE
 If the piping method is different with Fig.3-1, consults.
DOZCO 11
3-2. General view
NOTICE
 Check the piping lines for correctness pressure, flows or pressure loss, once hydraulic
pipes are installed in the base machine.
 A pressure control valve has to be installed, if there is no pressure control valve on the
main control valve of base machine.
Standard view of installation is as shown in Fig. 3-2
(Fig.3-2)
DOZCO 12
3-3. Installation
NOTICE
1) Set the hydraulic breaker on horizontal ground.

2) Remove the bucket from the base machine after disassembling the two pins.
NOTIC
3) Move the base machine in the vicinity of hydraulic

breaker, and align the pin hole of arm with the pin hole
of hydraulic breaker, and then, insert the pins.
4) After the arm pin is inserted, lift the boom, insert the
hydraulic breaker on the wood blocks and extend the
bucket cylinder, fit it to the bucket link’s hole and insert
the pins.
5) Install the stop rings, align the bolt holes and insert the
bolts, mutually lock double nut.
DOZCO 13
NOTICE
 If the stop rings are secured with

one nut only, the service life of the
bolt may be shortened or the bolt
maybe loosened out very quickly.
6) Stop the engine of the base machine, turn off the main switch and discharge the air
pressure in the hydraulic oil tank.
7) Remove the union caps from the hydraulic breaker pipe of the arm end, and connect the
hoses after disassembling the hose plug.
NOTICE
NOTICE
 Do not allow the oil to drop onto the ground.
 Store the removed union cap and hose plug in the toolbox.
 When installing or removing the oil hose
and union cap, clean them fully to prevent
the dust and mud from entering the
hydraulic breaker or the base machine.
8) Connect the hoses to stop valve at both sides of Arm.
9) Turn on the Engine of the base machine, lift the boom,

operate the bucket cylinder and check the hose connections
of hydraulic breaker.
10) Start and warm up the base machine.
DOZCO 14
NOTICE
 Warm up the base machine by idling for
5 minutes after starting the engine.
 Move the boom and arm for approx. 5
minutes after warm up operation to
raise the hydraulic oil temperature
of base machine.
11) Turn the stop valves to “ON” position.
NOTICE
 The tool may come out under oil pressure in the pipe line. Do not stand near to
hydraulic breaker.
DOZCO 15
3-4. Removal
TION
1) Set the Hydraulic breaker on clean and horizontal ground.

2) Stop the Engine.
3) Turn stop valve to “OFF "position.
4) Disconnect hoses from stop valves.
Ensure no leakage occurs from hoses
and stop valves.
5) Apply union cap and plug to hose
ends fit- tings to prevent
contamination.
6) Remove pins fixing fasteners.
7) Remove Pins
8) When Pins have been withdrawn,
move operation joysticks lightly, to
take weight off remaining link pin.
9) Lift arm away from hydraulic breaker
so that hydraulic breaker can be
carried away or another attachment
can be mounted on base machine.
NOTICE
 Cover the hydraulic breaker already removed with sheet,

 And then store it in indoor.
DOZCO 16
4. Maintenance
4-1. Serial Numbering System

The Unit Serial number is stamped on the bracket left side by steak name plate; It is
very important for management of repairing or spare parts ordering.
Structure of Serial number is as follows:
DOZCO 17
4-2. Safety label
Stop! Personal protective equipment

Read and understand technical manual
must be worn in this area. Consult your
before servicing the machine
supervisor for instruction.
 Pressurized Container!
 Do not open without
reading operating
manual or consulting the
service personnel!
 Use Nitrogen gas only!
Optimum Pres- sure: 50-
60 kg/cm2 (at20°C)
Noise Hazard wears approved noise

protection in this area.
Greasing label Consult manual warning label
DOZCO 18
4-3. Moving and Lifting
WARNING
MODEL Lifting Bolt
DOZCO D135 4T Capacity
DOZCO 19
4.4 Care and Maintenance Schedule
- Change Hydraulic Oil: Every 600 hrs.

- Line Oil Filter: Every 100 hrs.
Period Every Every 3 Every 4 Every 4

Every Day
Every 2 Week Week's Week's Months
Remarks
Hours Every 8 Every 50 Every 150 Every 250 Every 800
Item hours hours hours hours hours
Tool
O
Grease
Oil
O(V)
Leakage
Tightening
O(V) Spec.
torque
Refer to
Tightening Instruction
torque (T- O Manual
Bolts)
Gas
O(W)
Pressure
Change
Tool Pin the
O
Wear contacting
face
Wear
between
tool & O
Front
Cover
Seals * O
V: Visual Check,
W: Only at Weak Power
* If Breaker not commissioned for 6 months from date of supply, all seals to be
changed before Commissioning.
DOZCO 20
4.5 Hydraulic Oil
 Recommended Hydraulic Oil
Normally, any hydraulic oil originally intended for base machine can be used in the hydraulic
breaker. However, oil viscosity must be checked timely, because the oil may be heated much
more in the breaker works than in normal excavator works.
When hydraulic breaker is used continuously the oil temperature normalizes at certain levels,
depending on conditions and carrier.
At such temperatures, hydraulic oil viscosity should be 20-40 cST (Centistokes)
DOZCO recommends use of DOZCO Genuine oil for better and long-life performance of the
breaker and base machine.
NOTICE
 Usually, the hydraulic oil temperature of hydraulic breaker and base machine must
be controlled between 40°C to 60°C.
 When you operate the hydraulic breaker while the oil temperature exceeds 80°C,
you must check the seals.
Hydraulic Oil
Maker
For Hot Weather For Cold Weather
use use
ISO VG 68 ISO VG 68 For European countries use

SAE equivalent Oil grade/
ESSO Nuto H68 Univis N46 Carrier manufacturers
recommended oil grade For
European countries use SAE
SHELL Tellus Oil 68 Tellus Oil 46 equivalent Oil grade/ Carrier
manufacturers recommended
MOBILE DTE 16 DTE 15 oil grade
GULF Harmony 68 Harmony 46
DOZCO 21
 Replacement of Hydraulic Oil& Oil filter
Contamination of hydraulic oil may result in part damage, not only in hydraulic breaker, but
also in carrier main components. We recommend hydraulic oil and filters replacement as
shown in the following table, which is based on 100% hydraulic breaker operation.
Hydraulic Oil Every 600 hours-Standard Oil

Every 1000 hours-long life Oil Based on 100% Hydraulic Breaker
Every 100 hours-Standard filters Operation
Oil Filter
Every 200 hours-long life filters
 Hydraulic Oil Viscosity
Hydraulic breaker must not be started if hydraulic oil viscosity exceeds 1000cST, do
not operate when hydraulic oil viscosity falls 15cST.
Oil Viscosity too High
- Startup difficulty.
- Operation stiffness.
- Irregular hydraulic breaker impact.
- Danger of cavitations’ in pumps and hydraulic breaker.
- Valve sticking.
- If the filter is very contaminated, hydraulic components could be
damaged, due to open bypass valve.
Oil Viscosity too Low
- Efficiency losses from internal leakage.

- Damage to seals & O-rings.
- Accelerated wearing of parts, because of decreased lubrication efficiency.
 Cooling
Maximum permitted hydraulic oil temperature range in continuous hydraulic breaker
use in 50- 800C (120-1750F), depending on viscosity of oil in the system. Therefore, a reliable
hydraulic oil thermometer is necessary. If there is no thermometer on the carrier, one must
be installed. Hydraulic oil temperature depends on ambient conditions, carrier cooling system
efficiency, and on hydraulic breaker use. When hydraulic breaker is used continuously, it is
necessary to have a cooling system with extra cooling capacity, as compared with normal
excavation work.
 Hydraulic oil temperature
Thenormaltemperatureofhydraulicoiloperatingis-200C-800C (-40F–1750F),if the temperature
is lower than -200C (-40F), the hydraulic oil has to be preheated before operation, in order to
avoid breakage of the accumulator diaphragm.
To preheat hydraulic oil, operate the base machine (without running hydraulic
breaker), until oil temperature rises to specified temperature range. During operation, oil will
remain warm. If hydraulic oil temperature exceeds specified limits, please stop equipment and
do not restart Operation until oil has cooled to specified operating temperature range.
DOZCO 22
4.6 Greasing
WA RNING
- Apply grease at grease nipple on front head every2 hours.
- Adopt grease interval and amounts to tool wear rates and working conditions.
WARNING
Recommended lubricant Grease (NIGI NO.3)
Maker Grease
DOZCO Moly Graf- HTCM
DOZCO 23
4-7. Inspection and Charging of Nitrogen (N2) Gas
4-7-1. Back Head
(Fig.4-7-1)
(1) Connect gas hose to N2 gas, Cylinder.
(2) Turn the handle of charging gauge counter clockwise before installing the charging
gauge.
(3) Install charging gauge to charging valve. (Make sure that O-rings are installed
on charging gauge).
DOZCO 24
(4) Connect other end of gas hose to charging gauge.

(5) Slowly turn the handle of charging gauge clockwise and handle of N2 gas cylinder
clockwise to set charging pressure.
(6) Turn the handle of charging gauge counter clockwise, and then turn the handle of N2
gas cylinder counter clockwise to close.
NOTICE
 For N2 gas sealing pressure, refer to Fig.4-7-2.
(7) Close the cap of charging gauge after gas hose is relieved from gauge.
(8) Recheck charging pressure in back head as turning the handle of charging gauge counter
wise.
NOTICE
When nitrogen gas is charged in back head completely by following procedures (1) through
(8), disconnectcharginggaugefromchargingvalveofbackheadafterthehandleofcharging
gauge counterclockwise, but, if need to adjust the pressure of charging gas in back head by
following procedures (9) through (13) mentioned below.
(9) Disconnect the gas hose from charging gauge.

(10) Install charging gauge on charging valve of back head completely.
(11) When turn the handle of charging gauge clockwise, gas pressure in back head is
indicated on pressure gauge.
(12) If gas pressure is low, again perform operations (1) through (8), repeat until gas pressure
rises to specified pressure.
(13) If gas pressure is excessive, slowly turn the adjuster of charging gauge counter
clockwise, and then gas pressure leaks from back head. When correct amount of gas
pressure is shown, close the adjuster clockwise.
When gas pressure is excessively high, breaker will not operate.

Ensure that gas pressure is at specified pressure and O-ring in charging gauge is installed.
DOZCO 25
(Fig.4-7-2)
Model Charging Pressure (bar)
DOZCO D135 14~16
DOZCO 26
4-7-2. Accumulator
(Fig.4-7-3)
DOZCO 27
A) Inspection of charging pressure
(1) Turn the handle of charging gauge counterclockwise.

(2) Remove the A plug on the accumulator and charging gauge completely.
(3) Remove the cap of adjuster from accumulator.
(4) Remove charging gauge and tighten plug and cap. (Ensure O-rings must be installed in
plug and cap).
(5) Turn the adjuster counter clockwise slowly to indicate accumulator charging pressure.
B) Charging Accumulator with Nitrogen gas.
(1) After performing steps same inspection of charging pressure.

(2) Connect gas hose charging gauge and N2 gas cylinder.
(3) Turn the adjuster counterclockwise after remove the cap from adjuster.
(4) Slowly turn handle of N2 gas counterclockwise to charge accumulator with N2 gas
charging pressure.
(5) When accumulator is charged with N2 gas completely, close the adjuster fully.
(6) Turn the handle of N2 gas cylinder clockwise to close.
(7) Loosen adjuster of charging gauge discharge N2 gas remaining in gas hose.
(8) Remove the gas hose from charging gauge to N2 gas cylinder.
(9) After removing gas hose, adjuster the pressure referring
Inspection of Charging Pressure
Model Charging Pressure (bar)
DOZCO D135 56~60
(10) After charged accumulator with N2 gas, check gas leakage from adjuster, plug hole
of accumulator.
DOZCO 28
(Fig.4-7-4)
4-8. Pressure Setting
The pressure setting for hydraulic breaker must be lower than the base machine pressure
setting in order to protect the pump of base machine.
Normally, set the pressure for hydraulic breaker about 5-10 Kg/cm2 lower than base
machine pressure setting, when the main pressure of base machine is lower than below
table.
If hydraulic breaker setting pressure higher than below table:

That will be shorten durable of main pump and shorten service life of seals
& tool in hydraulic breaker.
If hydraulic breaker setting pressure higher than below table:

Hydraulic breaker performance will be downed.
Recommended setting pressure for Hydraulic breaker (bar)
D 135 220
DOZCO 29
4-9. Seal Inspection
WARNING
1) If any hydraulic oil leakage from hydraulic breaker is discovered, faulty seals should
be replaced.
To figure where seals are bad, refer to following drawings:
Backup Ring-Worn
Distorted O-Ring & Dust Seal Worn, U-Packing & Buffer Ring
Deteriorated Deformed, Worn,
Deteriorated
2) When bad seal is found, the cause of the damage must be determined
and rectified. When seals changed, apply grease to seal and seal seat,
and hold seal firmly with thumb, index and middle fingers, as per
marking.
Be careful not to break seal through excessive deformation.
DOZCO 30
4-10. Wear Inspection
4-10-1. Front Cover
If the clearance between tool and front cover is too big, this could cause of damage or
breakage of tool through piston irregular contact.
The following table is shown the wear limit of hydraulic breaker tool and front cover for
reference purposes
Model Wear Limit (mm)
DOZCO D135 6
DOZCO 31
4-10-2. Ring Bush
Model ØA Wear Limit (mm) B Wear Limit (mm)
DOZCO D135 4 3
DOZCO 32
4-10-3. Tool Pin
NOTICE
 Change the face of tool pins every 50 to 100 hours of actual operation.
 Replace pins every 500 hours of actual operation or based on wear condition.
A) When each tool pin is excessively deformed, it is difficult to replace the

tool, therefore, after operating the hydraulic breaker every 50 to 100
hours, change the face of each pin which comes in contact with the tool
(The faces of each pin can be used).
B) When replacing each tool pin, check each part for wear, breakage,
scores, etc. especially. And remove burrs and swelling on tool pins.
C) Replace tool after grinding the worn parts of front cover and tool pins.
DOZCO 33
4-11. Inspection and replacement of through bolt
C AUTION
1) Discharge nitrogen (N2) gas in back head completely prior to loosen through bolts.
2) Remove all through bolts, and inspect for presence of any cracks and damages on
through bolts.
3) When through bolts are assembled, tighten bolts one turn at a time in diagonal
sequence; not each nut completely all at once turn of times, not completely at
once.
4) Use torque wrench of specified range. (Refer to torque table)
DOZCO 34
4-12. Torque Table
1) Before starting the hydraulic breaker operation, check all kind of bolts and nuts for
tightness including the through bolts, socket bolts for accumulator, valve housing
socket bolts, valve cover socket bolts and bracket bolts.
Also be sure while tightening of any loose bolts and nuts according to the specified
torque. Using the hydraulic breaker with loose bolts and nuts will cause not only oil
leakages but also damages to the screw threads and breakage to the bolts. These can
lead also defective operation.
2) After first 10 hours of operating, retighten the bolts and nuts of all components and
sections.
3) At first, lightly tighten the bolts and nuts by referring to the following torque force.
The bolts and nuts should be screwed down, alternately and diagonally until the
bolts and nuts are tightened to the uniform torque.
 Through Bolt
NOTE
 Every 250 Hours, Tighten the Through bolts
Torque(kg-m)
Through Bolt
280
DOZCO 35
Torque(kg-m)
Damper Holder Bolt
85~90
Torque(kg-m)
Hose Adapter
12~16
Socket Bolt - Valve Torque(kg-m)

Cover 75
DOZCO 36
Socket Bolt - Valve Torque(kg-m)

Housing 65
Socket Bolt – Torque(kg-m)

Accumulator Cover 55
Socket Bolt – Torque(kg-m)

Accumulator Body 80
Torque(kg-m)
Bolt – Mount Cap
85~90
DOZCO 37
4-13. Storage
 When operation is interrupted or finished

When Operation is interrupted or after finished move the base machine on level ground
Remove mud from the hydraulic breaker and set the hydraulic breaker on wood blocks.
CAUTION
- Check whether oil leaks from hydraulic system and whether the tool oil is damaged.
- If the hydraulic breaker is operated in river, dry the hydraulic breaker body and apply
the grease to the front head.
 When hydraulic breaker is not used for a long time-3 week or more
CAUTION
- Discharge the nitrogen gas with the back head and accumulator, and then push the
piston to avoid rust the cylinder.
- Assemble the tool and store the hydraulic breaker indoors after applying the grease to
every part, especially internal parts of front head.
DOZCO 38
5.Operation
Before starting the base machine which, the hydraulic breaker is mounted, check to use the
machine safety and to prevent any trouble
5-1. Tool Installation

INSTALLATIONNG
1) Set the hydraulic breaker horizontally on wood blocks so that the accumulator may be
upper side.
2) Remove the snap ring ① rubber plug ②and the stop pin ③ in the front head from
opposite side by using a hammer and a pin bar. (Pin Bar is stored in toolbox)
DOZCO 39
NOTICE
3) Lift the tool pins ④ after insert the pin bar into the hole of tool pin from bottom side,
and remove the tool pins from front head.
4) Insert the tool front head.
ICE
5) Inset tool pins, and then assemble the stop pin and rubber plug or spring pin in front
head.
6) Using a hammer and a press pin, fasten the rubber plug or spring pin into front head.
 Removal
The Removal of tool in reverse order of installation.
DOZCO 40
5-2. Safety Operation

1) Precautions for safety operationON
Inspection
Check the base machine and the hydraulic breaker to uses safely and to prevent
any trouble before operation.
Warming up the machine
Especially in winter or cold area, warm up the base machine a first before the
breaker operation.
Safety maintenance
Before starting the work, examine the geological and geographical features of
work site and be careful of the ground crack or the building collapse.
2) Cautions, when driving or stopping base machine
Driving
Carry out driving while the hydraulic breaker is kept horizontally with
ground and is 40 to 50cm above ground.
Cautions on slope driving
When driving down on the slope, decrease the engine rpm and keep the
angles with boom and arm 900 to 1100.
Stopping
When the machine is stopped, the hydraulic breaker stands vertically

and set the tool end on the ground.
DOZCO 41
3) Safe Operation
Stop working the hydraulic breaker, if hydraulic hoses

vibrate excessively.
Check the N2 Gas Pressure in Accumulator and Back head

of hydraulic breaker
Stop the hydraulic breaker operation as soon as the object

is broken. if operation continued, idle blows, could result in
excessive wear of major components, or parts damage such
as inner bush or piston.
Do not use hydraulic breaker to move rocks with end of

tool or with hydraulic breaker.
Do not use tool as a lever.
Hydraulic breaker could be damaged at through bolt, tool,

front head, inner bush and front cover.
Move impact point of object, if the object does not break

within 30 Seconds.
Do not use hydraulic breaker in water. Corrosion of

hydraulic breaker, non-lubrication, cloud result in further
damage of the hydraulic components.
Under water kit must be installed when hydraulic breaker

for working in water.
Please contact to our dealer, if your need.
DOZCO 42
Do not use hydraulic breaker as hammering. Because of

hydraulic breaker is much heavier than excavator bucket,
such usage could result in damage of the front head or
swing mechanism of the base machine.
Do not operate hydraulic breaker with boom or arm

cylinders fully extended (bottomed out).
This may result in hydraulic breaker shock, and damage to

the base machine.
Maintain 100mm cylinder stroke of base machine at least.
Do not curl the tool tip into arm or boom of base machine
when travelling or parking carrier.
Do not strike in one spot for more than 30 seconds.
If object close not break, stop breaking after than change

the spot of object.
Working tool in one spot will create excessive stone dust

under tool. Dust dampens impact effect, and can be
damage piston seal.
Never use hydraulic breaker as a transporter. This could

result tipping carrier, or damaging on base machine.
Operate the hydraulic breaker only to the front and rear of

base machine.
Do not use hydraulic breaker at either side of base

machine. This may result in tipping excavator, or damaging
carrier swing device.
DOZCO 43
5-3. Function of Adjuster

(DOZCO D135)
5-3-1. Cylinder Adjuster / 2-Stroke Controller
The DOZCO hydraulic breaker is designed so that the bpm (blows per minute) can be
adjusted with the operating pressure and oil consumption kept constant by changing the
piston stroke, enabling the hydraulic breaker to be used widely.
However, when the bpm is increased, the impact force will decrease.
Therefore, the bpm must be adjusted in accordance with job condition.
The Cylinder adjuster is adjusted to the right side of the cylinder
NOTICE
 The cylinder adjuster is fully tightened when the breaker is delivered.
When the cylinder adjuster is tightened fully, the piston stroke become maximum and the
Impact blows (bpm) becomes the minimum.
The other way, when the adjuster is loosened about two turns, the piston stroke becomes
the minimum and the impact blows (bpm) becomes the maximum.
NOTICE
 Even the adjuster is loosened over two turns, the impact blows does not increase.
DOZCO 44
5-3-2. Valve Adjuster
The valve adjuster is installed on the valve housing.

The impact blows and the oil consumption increase when the adjuster is
opened and when it is closed, the impact blows and the oil consumption
decrease.
When the oil flow from base machine is lower or when the hydraulic
breaker has been installed on large base machine, the valve adjuster can control
amount of oil flow artificially.
NOTICE
NOTICE
 The hydraulic breaker does not operate if the valve adjuster is fully closed.
DOZCO 45
6. Trouble Shooting
This trouble-shooting guide has been prepared to aid the operator to locate the problem
cause and then remedy when trouble has occurred. If trouble has been caused, obtain
details as following check points and contact your local service shop or distributor.
NOTICE
 Check below mentioned items and contact service shop to check and repair any
item which operator cannot remedy.
 Check Point
Check Point (Cause) Remedy

1. Spool stroke is insufficient. After stop
engine, depress the pedal and check if spool * Adjust pedal link and control cable joint.
moves full stroke.
2. Hose vibration becomes bigger at
hydraulic breaker operation. * Recharge with nitrogen gas or check.
* High pressure line oil hose vibrates * Recharge with gas.
excessively. (Accumulator gas pressure
is lowered). If accumulator or back head is recharged
* Low pressure line oil hose vibrates but gas leaks at once, diaphragm or
excessively (Back head gas pressure is charging valve may be damaged.
lowered).
* Pull out tool and check.
3. Piston operates but does not strike tool.
If the tool is seizing, repair with grinder or
(Tool shank is damaged or seizing).
change the tool and/or tool pins.
4. Hydraulic oil is insufficient. * Refill hydraulic oil.
5. Hydraulic oil is deteriorated or
contaminated.
* Change all hydraulic oil in hydraulic
* Hydraulic oil color change to white or no
system of base machine.
viscous (White colored oil contain air
bubbles or water).
6.Line fitter element is clogged. * Wash or replace the filter element.
7. Impact rate increases excessively.
* Adjust or replace damaged part and
(Breakage or miss-adjustment of valve
check nitrogen gas pressure in back
adjuster or nitrogen gas leakage from back
head.
head.)
8. Impact rate decreases excessively. (Back * Adjust nitrogen gas pressure in back
head gas pressure is excess.) head.
9. Base machine meander or weak at
traveling. (Base machine pump is defective * Contact base machine service shop.
or improper set of main relief pressure.)
DOZCO 46
 Trouble Shooting Guide
Symptom Cause Required action

1. Excessive nitrogen gas pressure of back 1. Re-adjust nitrogen gas pressure in
head. back head.
2. Stop valve(s)closed. 2. Open stop valve.
3. Lack of hydraulic oil. 3. Fill hydraulic oil.

No blow out 4. Wrong pressure adjustment from relief
4. Re-adjust setting pressure.
valve.
5. Faulty hydraulic hose connection. 5. Tighten or replace.
6. Replace back head O-ring, or seal
6. Hydraulic oil in back head infection.
retainer seals.
1. Line leakage or blockage. 1. Check lines.
2. Clogged tank return line filter. 2. Wash filter, or replace.
3. Lack of hydraulic oil. 3. Fill hydraulic oil.

4. Hydraulic oil contamination or heat
4. Replace hydraulic oil.
deterioration.
Low impact power
5. Poor main pump performance. 5. Contact authorized service shop.
6. Nitrogen gas in black- head lower. 6. Refill nitrogen gas.

7. Low flow rate by mis- adjustment of valve
7. Re-adjust valve adjuster.
adjuster.
8. Push down tool by excavator
8. Tool out of range for blowing Position.
operation.
1. Refill nitrogen gas and check
1. Low nitrogen gas pressure in accumulator. accumulator. Replace diaphragm if
need.
Irregular Impact 2. Bad piston or valve sliding surface. 2. Contact authorized local distributor.
3. Push down tool by Excavator
3. Piston moves down/up to
operation.
Blank blow hammer chamber.
1. Tool diameter incorrect. 1. Replace tool with genuine parts.

2. Tool and tool pins would be jammed by tool
2. Smoothen rough surface of tool.
pins wear.
Bad tool movement
3. Smoothen rough surface of inner
3. Jammed inner bush and tool.
bush. Replace inner bush if need.
4. Deformed tool and piston impact area. 4. Replace tool by new.

Sudden reduction 1. Gas leakage from accumulator.
power and pressure 1. Replace diaphragm if need.
line vibration 2. Diaphragm damage.
Oil leakage from
1.Cylinder seal worn 1.Replace seals by new
front cover
Gas leakage from
1.O-ring and/or gas seal damage 1. Replace related seals by new.
back head
DOZCO 47
7. Tool Selection
7-1. Guide for tool Selection
WARNING
 The correct choice of the most suitable tool for as certain job is crucial not only in
increasing hydraulic breaker productivity, but also for the lift of the tool itself.
A: Wedge Tool
-Suitable for all kinds of digging or narrow trenching on soft/medium stratified
rocks.
B: Moil Point Tool

-Suitable for fine/medium concrete demolition or for soft, non-stratified rocks.
-Second mining of soft/medium hard blocks.
C: Blunt Tool
-Suitable for breaking blocks of up to medium hardness or to reduce the size of
small blocks.
DOZCO 48
7-2. Tool Claim Judgment

Hence, to help users use our products correctly, and ensure long operating life, these
claim judgment criteria present defect examples that can occur during use, and the
disposition standards applicable in each case.
 Breakage of piston impact area or tool pins contact corners (Fig.1 and 2)
Breakageofpistonimpactingpointoroftoolpinscontactcornersisextremelyrare.Thisphe
nomenon
occursorwhenstrikingforceisbeingconcentratedonthetoolcornersduetounsatisfactor
yflatness of piston and tool impacting point. If such defect occurs, affected tools
may not be accepted under warranty.
 Plastic deformation of piston impact area (Fig.3)
The possibility of tool tip plastic deformation occurring due to piston is extremely
slim. Such defects may occur due to material strength deficiency, or brittleness,
resulting from unsatisfactory heat- treatment. If such defect occurs, affected
products may be accepted under warranty.
 Breaking inside basic line (Fig.4 and 5)
DOZCO 49
Should product breakage occur in any direction occur in any direction at a point inside
the front cover, as shown in <Fig.5>, from the basic line shown in <Fig.4>, this may be due to
defective material, defective heat-treatment; tool deformation, or unsatisfactory shaping of
tool neck. Should such defect occur, affected products may be adopted under warranty.
In addition to the causes described above, product breakage inside the basic line may
also occur if the interval between the front cover and tool widens due to excessive wear of
front cover, coupled with excessive bending load being applied to hydraulic breaker, If any
trace of seizure, caused by friction between the front cover and tool, is observed on the
surface of the tool body, and if it is clear that product breakage is centered around the area
of such seizure, affected products may be rejected under warranty.
 Breakage outside basic line (Fig.6, 7 and 8)
Should product breakage occur at a point outside the front cover, as shown in <Fig.6>,
from the basic line shown in <Fig.4>, this may be due to excessive bending load being applied
to the tool. Such bending load occurs when, after tool has been inserted into material, the
tool is struck and pushed when it is not perfectly perpendicular to the surface of the material
being worked on. Fractures, in general, are of the form shown in <Fig.7>. Fatigue breakage, of
clamshell form, develops in the areas near breakage start points, caused by stress
concentration resulting from bending loads, and then quickly radiates outward, such type of
breakage may also occur due to scarring of the tool body during use, as breakage occurring
outside the basic line are caused by improper working habits, as explained above, products
incurring such defects shall not be accepted under warranty. However, if a fatigue fracture
start point occurs within the tool body, instead of on the surface of tool as shown in <Fig.8>,
affected products will be accepted under warranty, as such breakage indicates material
defect.
DOZCO 50
DOZCO 51
 Crushing of tool tip (Fig.9)
Breaker tools are heat-treated to exhibit high breakage-and wear-resistance; and

defects such as crushing of the tool tip <Fig.9> are not to be expected under normal operating
conditions. However, if a tool is hammering continuously for a long period of time without
crushing or puncturing the material being worked on, the temperature of the tip rises
extremely high, inducing annealing of the heat-treated material, and bringing on plastic
deformation (crushing), rather than wear, as explained above, crushing of the tool tip is caused
by improper working methods, and therefore affected products will be rejected under
warranty.
 Tool tip wear (Fig.10)
Theratesandtypesoftooltipwearvarywithworkmaterialandworkmethod.Ifthediameter
ofthe worn tip of a chisel point tool is less than 2/3 of the tool body diameter, as shown in
<Fig.10>; and if the tip of a new pointed tool is worn down in excess of 5mm length wise
from the tip, this is considered normal tool wear, Hence, tools exhibiting such normal wear,
as shown in <Fig.10>, will be rejected warranty claim.
DOZCO 52
D Series D135 Parts Manual
HYDRAULIC ROCK BREAKER
D series
D135 Parts manual
DOZCO 53
8.2 Frame Assembly Parts List
S. No Part number Part Name Q'ty Remarks

1 D135-3-000 Frame 1
2 000-9-310 Bottom Damper 1
3 000-7-007 O-Ring 8 K1, K3
4 200-0-222 Mc-Plate (BT-Front) 2
5 D135-0-221 Mc-Plate (BT-Side) 2
6 T135-0-225 Mc-Plate (BT-Front2) 3
7 203-0-233 Mc-Plate (Up-Side2) 1
8 D135-2-001 Hydraulic Body Assy 1
9 000-9-116M Upper Damper 1
10 200-0-204 Mc-Plate Spacer 2
11 200-0-215 Mc-Plate (BH-Support) 2
12 000-8-238 Hex Head Bolt 2
13 000-8-508 Plan Washer 26
14 200-0-216 Mc-Plate Washer-H1 2
15 000-8-608 Spring Washer 14
16 000-8-408 Hex Nut 28
17 000-9-231 Rod Pin Rubber Plug 2
18 000-9-269 Grease Rubber Plug 1
19 000-9-204 Stop Pin Rubber Plug 6
20 000-9-162 Spanner Rubber Plug 2
21 000-9-451 Adjuster Rubber Plug 2
22 - Cap Bracket 1 Optional
23 000-8-230 Socket Head Bolt 12
DOZCO 55
8.4 Hydraulic Body Parts List

D135-2-001 Hydraulic Body Assy. 1
1 D135-B-001 Back Head 1
2 200-B-013 BH-Charging Valve Assy 1
2a 000-6-157 O-Ring 2 K1, K3
2b - BH-Charging Valve 1
2c 000-6-146 O-Ring 1 K1, K3
2d - Charging Valve Cap 1
3 000-6-178 O-Ring 2 K1, K3
4 000-9-062 Cy-Hose Adapter 2
5 000-9-067 Union Cap 2
6 - O-Ring 3 K1, K2, K3
7 - Gas Seal 1 K1, K2
8 - Step Seal 2 K1, K2
9 - Step Seal O-Ring 2 K1, K2
10 200-C-006 Seal Retainer 1
11 000-7-270 Backup-Ring 3 K1, K2, K3
12 200-C-004 Piston 1
13 200-C-012 Knock Pin 2
14 - Grub Screw 3
15 200-C-013 Teflon Bush 2 K1
16 000-7-064 O-Ring 2 K1, K2, K3
17 - ED-Ring 4
18 D135-C-003 Cylinder 1
19 000-6-163 O-Ring 1 K1, K2, K3
20 - Socket O-Ring Plug 1
21 - Buffer Seal 1 K1, K2
22 - U-Packing 1 K1, K2
23 - Dust-Seal 1 K1, K2
25 - O-Ring 4 K1, K2, K3
26 200-C-021 Cylinder Adjuster Set 1
26a 000-6-152 O-Ring 1 K1, K3
26b 000-6-572 Backup Ring 1 K1, K3
26c - Cy Adjuster 1
26d - Hex Nut 1
27 T135-C-017 ABF-Plug 1
29 000-6-150 O-Ring 1 K1, K2, K3
30 200-C-018 Air Check Valve Assy 1
DOZCO 57

31 000-8-981 Heli-Coil 8
32 200-V-000 Valve Housing Assy 1
34 200-J-000 Acc-Assy 1
36 000-8-982 Heli-Coil 4
37 D135-F-002 Front Head 1
38 000-9-080 Grease Nipple 1
39 D135-F-008 Rod Pin 2
40 D135-F-009 Stop Pin 4
41 000-9-552 Rubber Plug 4 K1
42 000-8-901 Snap Ring 4
43 D135-F-003 Ring Bush 1
44 D135-F-006 Front Cover-B 1
D135-F-010 Tool (Moil) 1
45 D135-F-013 Tool (Wedge) 1
D135-F-016 Tool (Blunt) 1
46 200-T-000 Through Bolt Assembly 4
46a - T-bolt Rdx Nut 4
46b - T-Bolt 4
46c - T-bolt Washer 4
46d - T-bolt Hex Nut 4
K1 D135-S-001 Seal kit Assy 1
K2 D135-C-022 Seal kit, cylinder 1 6~9,11,16,19,21~23,25,29
K3 D135-S-008 O-Ring Kit 1
DOZCO 58
8.5 Accumulator Assy
Accumulator Assy Parts List

200-J-000 Accumulator Assy 1
1 000-6-207 O-Ring 1 K1, K4
2 000-7-375 Back Up Ring - Flange 1 K1, K4
3 - Acc Body 1
4 200-J-016 Acc Holder Set 1
4a - Acc Hex Nut 1
4b - Acc Holder-A 1
4c - Acc Holder-B 1
4d - Acc Holder-C 1
4e - Acc Pin 1
4f - Acc Holder Bolt 1
5 200-J-004 Acc Diaphragm 1
6 -- Acc Cover 1
7 000-8-042 Socket Bolt 12
8 200-J-015 Acc Hex Plug Set 1
8a -- Acc Hex Plug 1
8b 000-6-154 O-Ring 2 K1, K4
9 200-J-014 Acc Charging Valve Set 1
9a 000-6-143 O-Ring 1 K1, K4
9b -- Acc Charging Valve 1
9c -- Acc Charging Valve Cap 1
K4 D135-J-017 Seal Kit, Acc. Assy 1 1,2,8b,9a
DOZCO 59
8.6 Valve Housing Assy
DOZCO 60
8.7 Valve Housing Assy Parts List

200-V-000 Valve Housing Assy 1
2 - Valve Cover 1
3 000-7-248 Backup-Ring 1 K1, K5
4 000-7-068 O-Ring 1 K1, K5
5 T135-V-012 Valve Assy 1
5a - Valve Plug 1
5b - Valve 1
6 - Valve Housing 1
7 200-V-009 Valve Adjuster Assy 1
7a 000-6-574 Backup-Ring 1 K1, K5
7b 000-6-154 O-Ring 1 K1, K5
7c - Valve Adjuster 1
7d - Hex Nut 1
8 000-6-163 O-Ring 1 K1, K5
9 000-8-840 Socket O-Ring Plug 1
10 000-8-863 ED-Ring Plug 1
11 - O-Ring 2 K1, K5
12 - O-Ring 2 K1, K5
13 - O-Ring 1 K1, K5
14 - Backup-Ring 1 K1, K5
15 - O-Ring 1 K1, K5
K5 D135-V-013 Seal Kit, Valve housing Assy. 1 3,4,7a,7b,8,11~15
DOZCO 61
8.8 Nitrogen Gas Charging Kit
Nitrogen Gas Charging Kit Parts List
S. No PART NO PART NAME Qty Remarks

1 DOZCO-020-002-02-000-3002 Nitrogen Cylinder 1
2 - N2 Charging Key 1
3 - N2 Cylinder Adapter 1
4 - N2 Hose Adapter 1
5 - N2 Hose Hex Nut 1
6 - N2 Hose 1
7 - N2 Charging Kit Cap 1
8 - N2 Pressure Gauge 1
9 DOZCO-020-001-02-000-0011 N2 Charging Kit 1 3~8
DOZCO 62
9. Tool Box Parts List

Q’t
S. No Part Name Part No Q’ty Size S. No Part Name Part No Size
y
Tool Box
1 000-3-201 1 - Sledge offset

Spanner
18 000-3-565 1 75mm
3 000-3-261 1 6mm
4 000-3-262 1 8mm
5 000-3-264 1 12mm
6 000-3-265 1 14mm
7 000-3-266 1 17mm
8 000-3-267 1 19mm
T-Wrench SE Spanner
19 000-3-362 1 17mm
9 000-3-820 1 14mm 20 000-3-367 1 32mm
21 000-3-371 1 50mm
Pin Bar
10 000-3-763 1 Ø14.5 22 Grease Gun 000-3-220 1 1Kg
Circlip plier
DOZCO-020-
11 000-3-795 1 230 23 Male Dummy 002-02-000- 2 -
3001
Cutting Plier
12 000-3-805 1 - 24 Union Cap 000-9-067 2 -
13 DE Spanner 000-3-463 1 19x22 Hose

14 000-3-465 1 24x27 1" BSP
25 2000A938H 2 FWS
15 000-3-467 1 36x41 L2300
16
T-Screw
M12x
17 000-3-825 1 26 Charging Kit Ref.Page 62 1 -
P1.75
DOZCO 63
Notes:
*Accessories and features shown may not be a part of standard equipment. Picture Shown is for representation purpose only.
DOZCO 64
DOZCO 65

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D Series

HYDRAULIC ROCK BREAKER

Thank you for purchasing DOZCO Rock Breaker.

 Pictures in this broacher are for reference purpose only.

Instructions for Use

* ALL RIGHTS RESERVED

Model: DOZCO D135

Advantages and Benefits of DOZCO ROCK BREAKER

* Operator friendly * Lower maintenance cost with good

D135 Rock Breaker Technical Specifications

 The Operating Weight include the MC + Body + Tool Weight

6 Trouble shooting ----------------------------------------------------------------------------------- 46

Many accidents are caused by disregarding the basic rule of installation,

 Observance of safety rules in workplace

5) Front Head Assembly

9) Back Head Assembly

10) Through bolt Assembly

3. Installation and Removal

 If the piping method is different with Fig.3-1, consults.

3-2. General view

Standard view of installation is as shown in Fig. 3-2

1) Set the hydraulic breaker on horizontal ground.

3) Move the base machine in the vicinity of hydraulic

 If the stop rings are secured with

8) Connect the hoses to stop valve at both sides of Arm.

9) Turn on the Engine of the base machine, lift the boom,

10) Start and warm up the base machine.

11) Turn the stop valves to “ON” position.

1) Set the Hydraulic breaker on clean and horizontal ground.

 Cover the hydraulic breaker already removed with sheet,

4-1. Serial Numbering System

Structure of Serial number is as follows:

4-2. Safety label

Stop! Personal protective equipment

Noise Hazard wears approved noise

Greasing label Consult manual warning label

4-3. Moving and Lifting

MODEL Lifting Bolt

DOZCO D135 4T Capacity

4.4 Care and Maintenance Schedule

- Change Hydraulic Oil: Every 600 hrs.

Period Every Every 3 Every 4 Every 4

4.5 Hydraulic Oil

 Recommended Hydraulic Oil

At such temperatures, hydraulic oil viscosity should be 20-40 cST (Centistokes)

ISO VG 68 ISO VG 68 For European countries use

GULF Harmony 68 Harmony 46

 Replacement of Hydraulic Oil& Oil filter

Hydraulic Oil Every 600 hours-Standard Oil

- Efficiency losses from internal leakage.

Recommended lubricant Grease (NIGI NO.3)

DOZCO Moly Graf- HTCM

4-7. Inspection and Charging of Nitrogen (N2) Gas

4-7-1. Back Head

(4) Connect other end of gas hose to charging gauge.

 For N2 gas sealing pressure, refer to Fig.4-7-2.

(9) Disconnect the gas hose from charging gauge.

When gas pressure is excessively high, breaker will not operate.