Breaker 6720280 enUS sm 06-12 (3)

ServiceManual

1250 (S/N 157000101 AND ABOVE)1250X (S/N 157800101 AND ABOVE)1560 (S/N 702000101 AND ABOVE)2500 (S/N 229800101 AND ABOVE,

S/N 693200101 AND ABOVES/N 705200101 AND ABOVE,S/N 780900101 AND ABOVE,S/N 896708001 AND ABOVE)

2560 (S/N 617900101 AND ABOVE)2570 S/N 573306139 AND ABOVE)3500 (S/N 006500101 AND ABOVE,

S/N 705400101 AND ABOVE,S/N 897200101 AND ABOVE)

3560 (S/N 615800101 AND ABOVE)3570 (S/N 573500878 AND ABOVE)5060 (S/N 754400101 AND ABOVE)

(S/N 754600101 AND ABOVE)5500 (S/N 154700101 AND ABOVE)6560 (S/N 166500101 AND ABOVE,

S/N 472900101 AND ABOVE)

HydraulicBreaker

Doosan purchased Bobcat Company from Ingersoll-Rand Company in2007. Any reference to Ingersoll-Rand Company or use of trademarks,service marks, logos, or other proprietary identifying marks belongingto Ingersoll-Rand Company in this manual is historical or nominativein nature, and is not meant to suggest a current affiliation betweenIngersoll-Rand Company and Bobcat Company or the products ofeither.

6720280 (6-12) Printed in U.S.A. © Bobcat Company 2006

MAINTENANCE SAFETY

WARNING

Never service attachments without instructions. SeeOperation & Mainte nance Manual and Attachment ServiceManual.

Cleaning and maintenance are required daily.

Never service or adjust attachment with the engine runningunless instructed to do so in manual.

Always lower the attachment to the g round beforelubricating or servicing.

Avoid contact with leaking hydraulic fluid or diesel fuelunder pressure. It can penetrate skin or eyes.

Stop, cool and clean engine of flammable materials beforechecking fluids.

Keep body, loose objects and clothing away from movingparts, electrical contacts, hot parts and exhaust.

Safety glasses are needed for eye protection from electricalarcs. battery acid, compressed springs, fluids underpressure and flying debris or when tools are used. Use eyeprotection approved for type of welding.

MSW30-0805

B-10731a

CORRECT

WARNINGInstructions are necessary before operating or servicing machine. Read andunderstand the Operation & Ma intenance Manual, Operator’s Handbook andsigns (decals) on machine. Follow warnings and instructions in th e manualswhen making repairs, adjustments or servicing. Check for correct function afteradjustments, repairs or service. Untrained operators and failure to followinstructions can cause injury or death. W-2003-0903

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

ALPHABETICAL INDEX

1250, 1250X HYDRAULIC BREAKER SERVICEACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01TROUBLESHOOTING THE HYDRAULIC BREAKER. . . . . . 10-01

1560 HYDRAULIC BREAKER SERVICECHECKING MOUNTING BOLT TORQUE. . . . . . . . . . . . . . . 20-01HYDRAULIC BREAKER LUBRICATION. . . . . . . . . . . . . . . . 20-01NITROGEN CHAMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01TROUBLESHOOTING THE HYDRAULIC BREAKER. . . . . . 20-01

2500/3500 HYDRAULIC BREAKER SERVICECHECKING MOUNTING BOLT TORQUE. . . . . . . . . . . . . . . 30-01DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-01HYDRAULIC BREAKER LUBRICATION. . . . . . . . . . . . . . . . 30-01NITROGEN CHAMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01SPECIFICATIONS (2500) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01SPECIFICATIONS (3500) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01TROUBLESHOOTING THE HYDRAULIC BREAKER. . . . . . 30-01

2560/3560 HYDRAULIC BREAKER SERVICEDISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 40-01NITROGEN CHAMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01TROUBLESHOOTING THE HYDRAULIC BREAKER. . . . . . 40-01

2570/3570 HYDRAULIC BREAKER SERVICECHECKING MOUNTING BOLT TORQUE. . . . . . . . . . . . . . . 50-01DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 50-01HYDRAULIC BREAKER LUBRICATION. . . . . . . . . . . . . . . . 50-01NITROGEN CHAMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01TROUBLESHOOTING THE HYDRAULIC BREAKER. . . . . . 50-01

CONTINUED ON NEXT PAGE

Hydraulic Breaker10-01 Service Manual

ALPHABETICAL INDEX (CONT’D)

5060 HYDRAULIC BREAKER SERVICEBOB-TACH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 60-01HYDRAULIC BREAKER LUBRICATION . . . . . . . . . . . . . . . . 60-01HYDRAULIC BREAKER MOUNT INSPECTION. . . . . . . . . . 60-01LOADER MOUNT REMOVAL AND INSTALLATION . . . . . . . 60-01NITROGEN CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01TOOL BIT REMOVAL AND INSTALLATION . . . . . . . . . . . . . 60-01TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

5500 HYDRAULIC BREAKER SERVICECHECKING MOUNTING BOLT TORQUE. . . . . . . . . . . . . . . 70-01HYDRAULIC BREAKER LUBRICATION . . . . . . . . . . . . . . . . 70-01NITROGEN CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01TROUBLESHOOTING THE HYDRAULIC BREAKER. . . . . . 70-01

6560 HYDRAULIC BREAKER SERVICECHECKING MOUNTING BOLT TORQUE. . . . . . . . . . . . . . . 80-01HYDRAULIC BREAKER LUBRICATION . . . . . . . . . . . . . . . . 80-01NITROGEN CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01TROUBLESHOOTING THE HYDRAULIC BREAKER. . . . . . 80-01


CONTENTS

SERIAL NUMBER LOCATIONS & HYDRAULIC BREAKER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III

1250, 1250X HYDRAULIC BREAKER SERVICE . . . . . . . . . . . . 10-01

1560 HYDRAULIC BREAKER SERVICE . . . . . . . . . . . . . . . . . . 20-01

2500/3500 HYDRAULIC BREAKER SERVICE. . . . . . . . . . . . . . 30-01






1250, 1250X

CALIFORNIAPROPOSITION 65 WARNING

Diesel engine exhaust and some of itsconstituents are known to the State of California

to cause cancer, birth defects and otherreproductive harm.

HYDRAULICBREAKER SERVICE

1560 HYDRAULICBREAKER SERVICE

2500/3500 HYDRAULICBREAKER SERVICE






Hydraulic BreakerI Service Manual

Hydraulic BreakerII Service Manual

SERIAL NUMBER LOCATIONS & HYDRAULIC BREAKER IDENTIFICATION

Serial Number Locations (1250, 1250X)

Figure 1

Always use the serial number of the machine whenrequesting service information or when ordering parts.Early or later models (identification made by serialnumber) may use different parts, or it may be necessaryto us a different procedure in doing a sp ecific serviceoperation [Figure 1].

The breaker serial number plate is on the front of themain body [Figure 1].

There are 2 different breakers. Be sure to use the correctbreaker on the correct machine. The 1250X Breaker isfor excavators. The 1250 Breaker is for Bobcat Loadersand loader mounted backhoes.

Hydraulic Breaker Identification (1250, 1250X)

N-06610

Charge Fitting

Nitrogen Chamber

Hose Fitting Port

Breaker Body

Breaker Foot

Tool Point

Mounting Bracket

Grease Fitting

Mounting Holes

Breaker shown is mounted in excavator bracket B-12480

Hydraulic BreakerIII Service Manual

SERIAL NUMBER LOCATIONS & HYDRAULIC BREAKER IDENTIFICATION (CONT’D)

Serial Number Locations (1560)

Figure 2


The 1560 Hydraulic Breaker is approved for the followingmachines:

Oil cooler equipped 400 Series and 500 Series loaders

Oil cooler equipped 220 & 225 excavators

All 453 & 553 Bobcat Loaders and 320 & 325 excavators

Hydraulic Breaker Identification (1560)

P5589

Mounting Bracket

Charge Fitting

Hose Fittings

Lower Body

Tool Point

MainBody

MountingBolts

P-5745

Hydraulic BreakerIV Service Manual


Serial Number Locations (2500/3500 & 5500)

Figure 3


The 1560 Hydraulic Breaker is approved for the followingmachines:

Oil cooler equipped 400 Series and 500 Series loaders

Oil cooler equipped 220 & 225 excavators

All 453 & 553 Bobcat Loaders and 320 & 325 excavators

Hydraulic Breaker Identification (2500/3500 & 5500)

B-9608

B-09923

Nitrogen Chamber

Main Body

Mounting Bolts

Lower Body

Grease Fitting

Accumulator

Hose Fitting Ports

Charge Fitting

Tool Point

Hydraulic BreakerV Service Manual


Serial Number Locations (2560/3560)

Figure 4

Always use the serial number of the machine whenrequesting service information or when ordering parts.Early or later models (identification made by serialnumber) may use different parts, or it may be necessaryto use a different procedure in doing a specific serviceoperation [Figure 4].

The breaker serial number plate is located on the front ofthe nitrogen chamber [Figure 4].

Hydraulic Breaker Identification (2560/3560)

P1854

Mounting Bracket

Nitrogen ChamberCharge

Fitting

Main Body

MountingBolts

Tool Point

Lower Body

Grease Fitting

Hose Fitting Ports

N-00221N-00224

Hydraulic BreakerVI Service Manual


Serial Number Locations (2570/3570)

Figure 5


Hydraulic Breaker Identification (2570/3570)

P1854

Mounting Bracket

Nitrogen Chamber

Main Body

Charge Fitting

Mounting Bracket

Hose Fitting Ports

Grease Fitting

Tool PointMounting

Bolts

Accumulator

Tool Point

Accumulator

Two Position Frame

N-00221P-10953P-10958

Hydraulic BreakerVII Service Manual



Figure 6



P1854

P-12815P-12814

Tool Bit

Quick Couplers

Wear Plate Bolts

Steps

Steps

Hydraulic BreakerVIII Service Manual



Figure 7



P10516

P-12815

Tool Bit

Grease Fitting

Bob-Tach Mounting

Frame

Auxiliary Hydraulic Couplers

Hydraulic BreakerIX Service Manual

Hydraulic BreakerX Service Manual

1250, 1250X HYDRAULIC BREAKER SERVICE

ACCUMULATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1Charging The Accumulator . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1Checking Mounting Bolt Torque. . . . . . . . . . . . . . . . . . . . . 10-10-2Hydraulic Breaker Lubrication . . . . . . . . . . . . . . . . . . . . . . 10-10-1

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-10

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1Accumulator Removal and Installation. . . . . . . . . . . . . . . . 10-20-6Breaker Frame Removal and Installation. . . . . . . . . . . . . . 10-20-1Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-9Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-8Charge Valve Removal and Installation . . . . . . . . . . . . . . . 10-20-7Checking Breaker Bushings. . . . . . . . . . . . . . . . . . . . . . . . 10-20-8Diaphragm Removal and Installation . . . . . . . . . . . . . . . . . 10-20-7Flow Sleeve Removal and Installation . . . . . . . . . . . . . . . . 10-20-5Lower Body Removal and Installation . . . . . . . . . . . . . . . . 10-20-5Return Pressure Compensating (RPC) Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2Upper Body Removal and Installation . . . . . . . . . . . . . . . . 10-20-3

PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-4

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

TROUBLESHOOTING THE HYDRAULIC BREAKER . . . . . . 10-10-3


ACCUMULATOR

Use charging kit (P/N 6568037) to charge theaccumulator.

Charging The Accumulator

Figure 10-10-1

Remove the valve cap assembly (Item 1) [Figure 10-10-1] from the breaker.

Remove the protective cap from the charging valve andloosen the hex locknut 2 to 3 turns.

Figure 10-10-2

Thread the charge hose fitting onto the charging valve onthe breaker [Figure 10-10-2].

Adjust the regulator to the charging pressure of 600 PSI(4137 bar).

NOTE: It may be necessary to set the regulator at 600to 700 PSI (41,38 to 41,28 bar) to overcomeany pressure drop through the chargingsystem.

When the accumulator is fully charged close the valve onthe charging assembly hose.

Remove the charging tool.

Tighten the hex locknut on the charge valve.

Install the breaker charging valve cap on the protectivevalve cap.

Hydraulic Breaker Lubrication

Put the breaker in the vertical position so the point is onthe ground and the point is pushed up inside the breakeras far as possible.

Figure 10-10-3

Stop the engine and have a second person add grease tothe fitting (Item 1) [Figure 10-10-3].

Apply grease (4 to 5 pumps) to the upper end of the toolat the grease fitting (Item 1) [Figure 10-10-3] every 4 to 8hours of operation, or when the tool bit looks dry.

Always apply grease to the top 8 in. (203 mm) of the toolpoint before reinstalling it in the breaker bore.

IMPORTANTUnderwater use of the breaker will cause internaldamage. No por tion of th e breaker may besubmerged.

I-2053-0589

6533396A

Nitrogen 600 PSI (41,38 bar)

Torque400 ft.-lb.

(542,4 N•m)

Torque28 ft.-lb.

(38,0 N•m)

Grease4-5 PumpsTwice Daily

Torque400 ft.-lb.

(542,4 N•m)

Pressure Line Return

Line

2

1

Hydraulic Breaker10-10-1 Service Manual

ACCUMULATOR (CONT’D)

Checking Mounting Bolt Torque

Check the mounting bolts (Item 2) [Figure 10-10-3 onPage 10-10-1] daily.

Tighten the bolts to 37 5 to 42 5 ft.-lb. (508 to 675 N•m)torque.


TROUBLESHOOTING THE HYDRAULIC BREAKER

WARNINGInstructions are necessary before operating orservicing machine. Read Operation & M aintenanceManuals, Handbook and signs (decals) on machine.Follow warnings and instructions in t he manualswhen making repairs, adjustments or servicing.Check for correct function after adjustments, repairsor service. Failure to follow instructions can causeinjury or death.

W-2003-1289

If the Hydraulic Breaker is not working correctly, check the hydraulic system of the Bobcat Loader or excavator thoroughlybefore making any repairs on the breaker. Hydraulic Breaker performance can be affected by a hydraulic system that isnot operating to specifications or such problems as a plugged fuel filter or hydraulic filter in the loader or excavator.Connect a flow meter to the loader or excavator to check the hydraulic pump output, relief valve setting and tubelines tocheck flow and pressure. (See the loader/excavator Service Manual for the correct procedure to connect the flow meter.)

If the loader or excavator operation is found to be correct, use the following troubleshooting chart to locate and correctproblems with the Hydraulic Breaker which most often occur.

PROBLEM CAUSE CORRECTION

Breaker will not fire. Hydraulic flow is reserved. Check hose for correct connection.

Supply has high restriction to return fluid flow. Warm up hydraulic fluid to 75° F/24º C to reduceviscosity.

Hoses or couplings are restricting flow. Check hoses and couplings. Repair or replace.

Failure of breaker piston or automatic valve. If circuit test is within limts, dissassemble andinspect for damaged parts.

Breaker does not hit effectively. Supply pressure, return pressure or flow rateare incorrect.

Test circuit for 4 to 9 gpm/15 to 34 lpm flow andpressure is within 1600 to 2250 psi/113 to 158bar.

Hoses or couplings are restricting flow. Check hoses and couplings for damage. Repairor replace.

Accumulator not properly charged. Test and recharge. Replace diaphragm ifrecharge was inneffective.

Hydraulic fluid too hot. Install a cooler.

Tool bit is binding in breaker foot bushings. Add grease to fitting on breaker foot more often(at least twice daily).Do not pry with control.Damaged tool bit or bushing. Remove andinspect.

Breaker hits slowly. Low circuit flow Test valve loading near relief setting. If flowreduces with pressure rising, pump and/or valveworn. Repair or replace. Fluid contaminated.Flush and replace with clean fluid. Check forproper filtration.

Relief pops during operation. Test supply circuit. Make sure the flow rate andpressure ratings are within manufacturer'sspecifications.

Trigger switch or solenoid valve not operating (ifused).

Check wiring and valve operation.Repair asrequired.

Inadequate down force. Refer to operating instructions.


PARTS IDENTIFICATION


PARTS IDENTIFICATION (CONT'D)


DISASSEMBLY

Breaker Frame Removal and Installation

WARNINGWear safety glasses to prevent eye injury when anyof the following conditions exist:• When fluids are under pressure.• Flying debris or loose material is present.• Engine is running.• Tools are being used.

W-2019-1285

The tool listed will be needed to s ervice the hydraulicbreaker:

6652471 - Charging Kit

Read and understand the complete disassembly andassembly procedure before beginning the operation.

NOTE: Always replace O-rings and seals whenservicing the breaker.

Before removing the breaker from the Bob-Tach, loosenthe 4 main bolts. Loosen the 8 bolts from the cradle.

Figure 10-20-1

Remove the hoses from the breaker [Figure 10-20-1].

Put the breaker in a stand.

Figure 10-20-2

Have a se cond person remove the mounting pin clip(Item 1) [Figure 10-20-2] and pin.

Figure 10-20-3

Have a se cond person remove the pivot pin bolt andpivot pin [Figure 10-20-3].


DISASSEMBLY (CONT'D)

Return Pressure Compensating (RPC) Valve Removal and Installation

Put the breaker in a vise.

Figure 10-20-4

Loosen the swivel fittings bolt (Item 1) [Figure 10-20-4].

Figure 10-20-5

Remove the O-rings and split back-up rings from theswivel fitting [Figure 10-20-5].

Figure 10-20-6

Remove the 4 bolts and lock washers [Figure 10-20-6].

Installation: Tighten the bolts to 27 to 30 ft.-lb. (36 to 40N•m) torque.

Figure 10-20-7

Remove the return pressure compensating (RPC) valve[Figure 10-20-7].

Remove the RPC valve O-rings.

IMPORTANTDo not completely discharge the accumulator at thistime.

I-2037-0788



Return Pressure Compensating (RPC) Valve Removal and Installation (Cont'd)

Place the RPC valve in a soft jaw vise.

Figure 10-20-8

Remove the O-ring boss plug [Figure 10-20-8].

Figure 10-20-9

Remove the valve assembly internal parts [Figure 10-20-9].

NOTE: Do not lose the parts in the RPC valve.

The RPC valve is blocked open and not used in theloader mounted 1250 Breaker [Figure 10-20-9].

The RPC valve is used when 1250X Breaker is mountedon the excavator [Figure 10-20-9].

Upper Body Removal and Installation

Figure 10-20-10

Remove the valve cap [Figure 10-20-10].

Loosen the locknut on the charging valve 1-1/2 turns.

Discharge the accumulator down to 20 PSI (137,9 bar).

Figure 10-20-11

Loosen the 4 breaker body bolts [Figure 10-20-11].

Loosen each bolt 1 turn and move to the next bolt. Thiswill insure no binding of the breaker body.

Remove the bolts.

Installation: Put anti-sieze compound on the boltthreads and tighten the bolts equally working up to 400ft.-lb. (542 N•m) torque.



Upper Body Removal and Installation (Cont'd)

Figure 10-20-12

Tap around the to p flange with a r ubber hammer toseparate the breaker body [Figure 10-20-12].

Figure 10-20-13

Separate the body halves [Figure 10-20-13].

Do not drop any internal parts.

Figure 10-20-14

Remove the rod wiper, washer and cup seal from thepiston [Figure 10-20-14].

Use a r ubber hammer to tap around the lower bodyflange [Figure 10-20-14].

Figure 10-20-15

Remove the lower body from the piston [Figure 10-20-15].



Lower Body Removal and Installation

Figure 10-20-16

Remove the piston from the flow sleeve [Figure 10-20-16].

If the automatic valve body remains in the flo w sleeveassembly, remove it as follows:

Figure 10-20-17

Place the split ring (from the k it) between the automaticvalve body and flow sleeve assembly [Figure 10-20-17].

Flow Sleeve Removal and Installation

Figure 10-20-18

Put the assembly on the Flow Sleeve Removal Tube withthe automatic valve body facing down [Figure 10-20-18].

Figure 10-20-19

Use a p ress to remove the flow sleeve from theautomatic valve body [Figure 10-20-19].

IMPORTANTPut a rag in the bottom of the removal tube to protectthe automatic valve body when it drops out.

I-2038-0788



Flow Sleeve Removal and Installation (Cont'd)

Figure 10-20-20

The automatic valve, flow sleeve, 4 long push pins fromthe flow sleeve and 2 long push pins from the automaticvalve body will drop out [Figure 10-20-20].

Accumulator Removal and Installation

Figure 10-20-21

Put a 3/4 inch deep socket over the charging valve andtap it with a so ft hammer to r emove the a ccumulatorassembly [Figure 10-20-21].

Remove the accumulator cylinder using the puller (fromthe kit).

Figure 10-20-22

Drive out the cylinder by tapping on a rod that extendsthrough the charge valve hole in the breaker body[Figure 10-20-22].

Figure 10-20-23

Lift the breaker body to remove the outer keeper, discand pilot springs to fall out [Figure 10-20-23].



Charge Valve Removal and Installation

Figure 10-20-24

Put the accumulator chamber in a soft jaw vise andloosen the lo cknut to completely discharge theaccumulator assembly [Figure 10-20-24].

IMPORTANTThe machined surfaces of the accumulator canbecome damaged if a soft jaw vise is not used.

I-2039-0788

Figure 10-20-25

Remove the charge valve (Item 1) [Figure 10-20-25].

Diaphragm Removal and Installation

Put the accumulator assembly on the accumulatordisassembly tool and flow sleeve removal tube.

Put a rag in the bottom of the removal tool to protect theaccumulator chamber.

Figure 10-20-26

Remove the accumulator chamber and diaphragm fromthe accumulator cylinder by pressing on the charge valveend [Figure 10-20-26].

Squeeze the accumulator diaphragm and slide it off theaccumulator chamber at the charge valve end.

NOTE: Avoid damage to the inside wall of theaccumulator chamber.

Figure 10-20-27

Remove the cup seal and back-up washer from theaccumulator chamber [Figure 10-20-27].



Checking Breaker Bushings

The bushings can be checked with a new tool installedand the breaker mounted on the carrier.

Figure 10-20-28

Put the br eaker in a hor izontal position with the toolagainst a solid object [Figure 10-20-28].

Move the breaker up, then down. If there is more than 1/2in. movement of the tool in either direction the bushingsmay be worn or damaged [Figure 10-20-28].

NOTE: A cracked bushing may have caused thebreaker lower body bore to become enlarged.If this happens, a new bushing may fit tooloose. Replace the breaker lower body ifnecessary.

Bushing Removal

Figure 10-20-29

NOTE: The removal tools are to be made from 2-3/4inch bar stock [Figure 10-20-29].

Always replace both bushings as a set.

Figure 10-20-30

Remove the rod wiper, washer and O-ring at the top ofthe breaker foot [Figure 10-20-30].

NOTE: Be sure the tool retainer pin ha s beenremoved.

Put the breaker lower body in a press.

Figure 10-20-31

Use the removal tool shown [Figure 10-20-29] to p ushboth bushings out of the bottom of the breaker lowerbody at the same time [Figure 10-20-31].



Bushing Installation

Put the new bushings in dry ice for about 1 hour beforeinstallation.

Lubricate the outer edge of the bore in the breaker lowerbody with SAE 30 oil.

Use the installation tool shown [Figure 10-20-29] to firstpress the upper bushing in the breaker, then the lowerbushing [Figure 10-20-31].


ASSEMBLY

Clean all parts in solvent and inspect before assembly.

Install the tool retainer pin.

Figure 10-20-32

Install the r od wiper (lip first) in the counterbore of thebreaker foot [Figure 10-20-32].

Figure 10-20-33

Install the washer [Figure 10-20-33].

Figure 10-20-34

Install the cup seal (lips up) [Figure 10-20-34].

Figure 10-20-35

Install the 4 l ong pins in the holes in the flow sleeve[Figure 10-20-35].

NOTE: Push pins must be installed with the groundflat-end face pointing toward the flange of theautomatic valve.


ASSEMBLY (CONT'D)

Lubricate the bore of the flow sleeve cover then put in apress with the small end facing up.

The flow sleeve has a wide groove around the outside of1 end. Install this end first.

Use the accumulator cylinder puller to p rotect the flowsleeve.

Figure 10-20-36

Press the flow sleeve into the cover flush with the top[Figure 10-20-36].

Figure 10-20-37

Install the 2 long push pins into the automatic valve body[Figure 10-20-37].

Figure 10-20-38

Install the automatic valve (small diameter first) into theautomatic valve body [Figure 10-20-38].

Figure 10-20-39

Align the roll pin and then place the automatic valve body(side holes up) on top of the flow sleeve [Figure 10-20-39].

NOTE: This allows the automatic valve to drop andpilot into the bore of the flow sleeve.


ASSEMBLY (CONT'D)

Use the accumulator cylinder puller to press theautomatic valve body into the flow sleeve until the flo wsleeve bottoms out on the press.

Coat the O-ring with grease and put it in the pilotdiameter against the machined surface of the breakerlower body.

Figure 10-20-40

Put the flow sleeve and automatic valve assembly on thebreaker lower body and push down until they are seatedin the breaker lower body bore [Figure 10-20-40].

Figure 10-20-41

Install the piston (large end first) through the automaticvalve body and flow sleeve [Figure 10-20-41].

Be sure the large end of the piston goes through the cupseal and sits flat inside the pilot diameter of the breakerlower body.

Figure 10-20-42

Put the washer (small diameter first) on the piston stemagainst the automatic valve body [Figure 10-20-42].

Figure 10-20-43

Install the nitrogen charge valve (Item 1) [Figure 10-20-43] in the accumulator chamber.

IMPORTANTThe machined surfaces of the accumulator canbecome damaged if a soft jaw vise is not used.

I-2039-0788


ASSEMBLY (CONT'D)

Figure 10-20-44

Put a th in coat of gr ease on th e inside surface of th eaccumulator diaphragm [Figure 10-20-44].

Figure 10-20-45

Slide the diaphragm onto the accumulator chamber fromthe charging valve end [Figure 10-20-45].

Put grease on the inside of the accumulator cylinder andthe outside diameter of the diaphragm.

Figure 10-20-46

Push the accumulator chamber and diaphragm (chargingvalve end first) halfway into the accumulator cylinder[Figure 10-20-46].

The parts are assembled from the end of the cylinder withthe chamfer on the outside diameter.

IMPORTANTDo not use a hammer or electrically powered press toassemble the accumulator diaphragm.

I-2042-0788

NOTE: Make sure the accumulator diaphragm is freeof wrinkles and the seal bead is in its groovebefore completing the assembly.

NOTE: A ha nd powered press may be needed tocomplete the accumulator assembly. Applyshort strokes during the last 12 inch (12 mm)of travel to gently seat the diaphragm.


ASSEMBLY (CONT'D)

Figure 10-20-47

Put the assembly in a soft jaw vise by the ends of thechamber and loosen the nitrogen charging valve locknut1-1/2 turns [Figure 10-20-47].

Figure 10-20-48

Charge the accumulator with nitrogen to 600 PSI (4137bar) [Figure 10-20-48]. (See Charging The Accumulatoron Page 10-10-1.)

NOTE: It may be necessary to charge the accumulatoran additional 50 to 75 PSI (345 to 517 bar) dueto the pressure drop in the charging system.

Test the accumulator for any visible leaks by immersingin oil and checking for bubbles.

If no leaks are found, discharge the accumulator.

If leaks are found, disassemble and correct the cause ofthe leak.

Install the valve cap on the charging valve.

Install the back-up washer and cup seal (lips facing out)in the accumulator chamber counterbore.

Install a greased O-ring in the groove around the upperend of the flow sleeve cover and ing the groove on theautomatic valve body.

Figure 10-20-49

Put the accumulator assembly (charge valve end up) onthe automatic valve body [Figure 10-20-49].

Carefully seat it into place.

IMPORTANTThe disc springs must have their center holesdepressed toward the pilot spring shoulder. Do notstack them with gaps in between or with their insidediameters facing toward the breaker body end.

I-2043-0788


ASSEMBLY (CONT'D)

Figure 10-20-50

Seat the outer keeper spring (Item 1) [Figure 10-20-50](beveled end facing up) on the accumulator cylinder.

Lubricate the 4 disc spring washers; then stack them(Item 2) [Figure 10-20-50] (inside diameter up andoutside diameter sloping down) in the outer keeperspring.

Figure 10-20-51

Insert the pilot spring (large end facing up) into the centerhole of the disc springs [Figure 10-20-51].

Be sure it is squarely seated.

Grease the outside diameter of th e accumulatorassembly.

Clean the interior of the breaker body.

Figure 10-20-52

Carefully place the breaker body over the accumulatorassembly [Figure 10-20-52].

Figure 10-20-53

Press the breaker body into place [Figure 10-20-53].

Put lock washers on the 4 long bolts and put anti-siezecompound on the threads and under the washers.


ASSEMBLY (CONT'D)

Figure 10-20-54

Install the bolts through the holes in the breaker body andinto the tapped holes in the breaker lower body [Figure10-20-54].

Tighten the bolts until they begin to compress the lo ckwashers.

Figure 10-20-55

Tightening sequence must be followed to preventdamage to the components [Figure 10-20-55].

IMPORTANTThe bolts must be tightened using equal turns and inthe order shown to avoid distorting the assembly ordestroying internal parts.

I-2044-0788

Figure 10-20-56

Put the breaker assembly in a soft jaw vise and tightenthe bolts equally working up to 400 ft.-lb. (542 N•m)torque [Figure 10-20-56].

Charge the accumulator. ( See Charging TheAccumulator on Page 10-10-1.)

Clean the flat surfaces of the RPC valve and the breakerbody.

Figure 10-20-57

Lubricate and install the 3 O-rings in the grooves on theRPC valve surface [Figure 10-20-57].


ASSEMBLY (CONT'D)

Figure 10-20-58

Put the RPC against the breaker body surface [Figure10-20-58].

NOTE: Be sure the O-rings are in place.

Install the bolts and lock washers.

Figure 10-20-59

Tighten the bolts to 27 to 30 ft.-lb. (36 to 40 N•m) torque[Figure 10-20-59].


SPECIFICATIONS

* 1250X Only: Operating pressure below 1200 PSI (120 bar) and return pressures above 200 PSI (14 bar) arecompensated for by the operation of the return pressure compensating (RPC) valve.

NOTE: The 1250, 1250X Hydraulic Breaker is unique in design and only 1250, 1250X tools will fit the breaker.

DIMENSIONS AND WEIGHT

Weight 235 lb. (107 kg)

Length (A) 41 in. (1041 mm)

Width Inside Bracket (B) 8.125 in. (206 mm)

Tool Diameter (C) 1.75 in. (44 mm)

Tool Working Length (D) 9 in. (229 mm)

Mounting Pin Diameter 1.5 in. (38 mm)

HYDRAULIC REQUIREMENTS

Flow Requirements 4 to 9 GPM (15 to 34 LPM)

Minimum Operating Pressure 1700 PSI * (11721 bar)

PERFORMANCE

Impact Energy Class 125 ft.-lb. (170 J) Impact Class

Blows Per Minute 500 to 1300


1560 HYDRAULIC BREAKER SERVICE

CHECKING MOUNTING BOLT TORQUE . . . . . . . . . . . . . . . 20-10-5

DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 20-20-1Breaker Frame Removal and Installation. . . . . . . . . . . . . . 20-20-1Bushing Removal and Installation . . . . . . . . . . . . . . . . . . . 20-20-8Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6Seal Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2Sleeve Removal and Installation . . . . . . . . . . . . . . . . . . . . 20-20-7Upper Section Removal and Installation . . . . . . . . . . . . . . 20-20-5

HYDRAULIC BREAKER LUBRICATION . . . . . . . . . . . . . . . . 20-10-4

NITROGEN CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1Checking The Nitrogen Chamber Charge Pressure . . . . . 20-10-1Charging The Nitrogen Chamber. . . . . . . . . . . . . . . . . . . . 20-10-3Releasing Pressure From the Nitrogen Chamber . . . . . . . 20-10-1


SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1




NITROGEN CHAMBER

Releasing Pressure From the Nitrogen Chamber

The nitrogen chamber valve is located on the hose fittingside of the hydraulic breaker.


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NOTE: Release the charge pressure when storing thehydraulic breaker for an extended period oftime.

Figure 20-10-1

Remove the pl ug (Item 1) [Figure 20-10-1] from thecharge valve using a 3/16 in. (4,67 mm) allen wrench.

Figure 20-10-2

Using a small shaft (Item 1) [Figure 20-10-2], push thevalve inward to release the gas pressure.

Install the plug in the charge valve hole.

Checking The Nitrogen Chamber Charge Pressure

Use the nitrogen accumulator charge pressure gaugeMEL1523B to check pressure.

Remove the plug (Item 1) [Figure 20-10-1].

Figure 20-10-3

Install the correct adapter (Item 1) [Figure 20-10-3] onthe gauge.

P18084

1


NITROGEN CHAMBER (CONT’D)

Checking The Nitrogen Chamber Charge Pressure (Cont’d)

Figure 20-10-4

With the adapter (Item 1) tig htened on the ga uge,measure the pin (Item 2) [Figure 20-10-4] protrusion.

Manually extend or retract the pin until the pin measures0.125 in. (3,2 mm) from pin tip to adapter face.

Figure 20-10-5

Loosen the adapter until the pin is flush with the end ofthe adapter as shown [Figure 20-10-5].

Install the gauge/adatper on the breaker.

Figure 20-10-6

Tighten the adapter (Item 1) [Figure 20-10-6] on th ebreaker.

Figure 20-10-7

Slowly turn the gauge valve body (Item 1) [Figure 20-10-7] clockwise until the gauge shows a reading. If th epressure is low, recharge the breaker using charging kitnumber 6568037.

NOTE: The correct charge pressure is 250 PSI (17,24bar).

P-42758

2

1

0.125”(3,2 mm)

P-42759



Charging The Nitrogen Chamber

NOTE: When in doubt of nitrogen charge pressure orwhen recharging a hot breaker, release thenitrogen pressure completely and rechargethe nitrogen chamber.

Raise the breaker until the tool is hanging freely. The toolmust not touch the piston during charging.

Use kit #6568037 to charge the hydraulic breaker.

Figure 20-10-8

Figure 20-10-9

Using the adapter, install the charging tool in the chargevalve [Figure 20-10-9].

NOTE: Be sure to use the correct side of the chargingtool [Figure 20-10-8].

Connect the nitrogen hose to th e charging tool [Figure20-10-9].

Slowly open the valve on the nitrogen tank and fill the1560 breaker nitrogen chamber to 250 PSI (17,24 bar).Close the valve on the nitrogen tank.

Disconnect the hose and charging tool.

Install and tighten the plug (Item 1) [Figure 20-10-1 onPage 20-10-1].

B-07196250 PSI (17,24 BAR)

Connect Hose FromNitrogen Bottle Here

Connect This End ToNitrogen Chamber


HYDRAULIC BREAKER LUBRICATION


Figure 20-10-10


Apply grease (4 to 5 pumps) to the upper end of the toolat the grease fitting (Item 1) [Figure 20-10-10] every 4 to8 hours of operation or when the tool bit looks dry.


IMPORTANTUnderwater use of the breaker will cause internaldamage. No por tion of th e breaker may besubmerged.

I-2053-0589


CHECKING MOUNTING BOLT TORQUE

Figure 20-10-11

Check the snap rings and breaker mounting bolts (Item1) [Figure 20-10-11] every day.

If the snap rings and lock plates are missing, tighten thebolts to 300 ft.-lb. (407 N•m) torque. Lock plates can beturned 180° for a different alignment if necessary.



WARNINGInstructions are necessary before operating orservicing machine. Read Operation & M aintenanceManuals, Handbook and signs (decals) on machine.Follow warnings and instructions in the manualswhen making repairs, adjustments or servicing.Check for correct function after adjustments, repairsor service. Failure to follow instructions can causeinjury or death.

W-2003-1289




Breaker will not fire. Loader or excavator main relief valve set tolow.

Adjust main relief valve to correct setting.

Loader or excavator fluid reservoir is low. Add hydraulic fluid to the fluid reservoir onthe loader or excavator.

No hydraulic flow to the breaker. Check the hydraulic flow to the breaker.

Loader or excavator hydraulic pump notworking.

Check flow of loader hydraulic pump.Repair or replace as needed.

Nitrogen chamber not at correct pressure. Charge to required pressure.

Damaged electrical connection to breakervalve (backhoe mounted unit only).

Check wiring harness and switch.

Damaged quick couplers. Replace quick couplers.

Breaker runs very slowly orblow per minute reducing.

Loader or excavator main relief valve set tolow.


Not enough hydraulic flow. Test loader or excavator hydraulics forcorrect flow and pressure.

Excessive heat build up. Check oil cooler for debris and air flow.Check loader or excavator relief valvepressure.


Nitrogen chamber over-pressurized. Remove gas and refill to correct pressure.

Internal leakage. Check seals and O-rings in the breaker.Check piston, sleeve and seal carrier forwear.

Excessive back pressure. Check for plugged or bent return lines


TROUBLESHOOTING THE HYDRAULIC BREAKER (CONT’D)


Breaker fires erratically. Loader or excavator main relief valve set tolow.


Excessive back pressure. Check for plugged or kinked return lines.

Low fluid level. Add fluid to the reservoir as needed.


Tool binding. Add grease to the tool shank fitting.



Excessive heat build up. Blank firing. Refer to the hydraulic controls section forcorrect operating procedure.


DISASSEMBLY AND ASSEMBLY



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The tool listed will be needed to s ervice the hydraulicbreaker:

6568037 - Charging Kit

Read and understand the complete Disassembly andAssembly procedure before beginning the operation.


NOTE: Before removing the breaker from the framedo the following:

Disconnect the hydraulic quick couplers from the loaderor excavator and remove them from the hose guide onthe boom arm.

Release the pressure from the nitrogen chamber. (SeeReleasing Pressure From the Nitrogen Chamber onPage 20-10-1.)

Loosen the 2 bolts in the upper section of the breaker. Donot remove the bolts.


Figure 20-20-1

Have a second person remove the mounting pin clip andpin [Figure 20-20-1].

Have a second person remove the pivot pin bolts and thepins (inset) [Figure 20-20-1].

Slowly move the machine away from the breaker.

Figure 20-20-2

Use a chain hoist [Figure 20-20-2] to control the framewhile removing or installing the mounting bolts.


DISASSEMBLY AND ASSEMBLY (CONT'D)

Breaker Frame Removal and Installation (Cont’d)

Figure 20-20-3

Remove the retaining clips and washers (Item 1) [Figure20-20-3] from the fr ame mounting bolts. Remove thebolts from both sides of the breaker frame.

Installation: Use anti-seize on the bolt threads duringassembly. Tighten the bolts to 300 ft.-lb. (406 N•m)torque.

Figure 20-20-4

Lower the frame (Item 1) and use a hoist (Item 2) [Figure20-20-4] to lift the breaker and remove the s tand.Reinstall the breaker in the stand for repairs.

Shuttle Valve

NOTE: Check the machined surfaces of the shuttlevalve for scratches or wear. The shuttle valveparts can be replaced individually.

NOTE: Apply hydraulic oil to the O-rings andmachined surfaces during assembly.

Figure 20-20-5

Remove the bolts from the shuttle valve cap (Item 1)[Figure 20-20-5].

Installation: Tighten the b olts to 20 ft.-lb. (27 N•m)torque.

Figure 20-20-6

Install 2 of the mounting bolts (Item 1) [Figure 20-20-6]into the threaded holes in the s huttle valve cap andtighten evenly to remove the cap.



Shuttle Valve (Cont’d)

Figure 20-20-7

Remove and replace the O-ring (Item 1) [Figure 20-20-7]from the cap.

Figure 20-20-8

Remove the shuttle valve (Item 1) [Figure 20-20-8] fromthe shuttle valve sleeve.

A light scuffing or burnishing of the surfaces is normal.Check for cracks and see that the spool moves freely inthe valve sleeve.

If small burrs are found, remove them with 200 grit emerycloth.

DO NOT break or buff the sharp edges of the valvesleeve or valve spool. This will cause the valve tomalfunction.

Figure 20-20-9

The sleeve (Item 1) [Figure 20-20-9] is a press fit. Do notremove it.

If sleeve is damaged, replace the upper body of th ebreaker (replacement body will include a new sleeve).


DISASSEMBLY AND ASSEMBLY (Cont'd)

Charge Valve

Figure 20-20-10

Remove the p lug (Item 1) [Figure 20-20-10] to gainaccess to the charge valve.

Figure 20-20-11

Use a slotted screwdriver to remove the charge valve(Item 1) [Figure 20-20-11].

Figure 20-20-12

Inspect the charge valve for cracks, scratches, or wear[Figure 20-20-12].

Replace the O-rings (Items 1 & 2) [Figure 20-20-12] onthe charge valve assembly.



Upper Section Removal and Installation

Figure 20-20-13

Remove the 2 tie rods (Item 1) [Figure 20-20-13] andwashers (Item 2) [Figure 20-20-13] from the uppersection of the breaker.

The washers must be installed with the internal chamferUP.

Installation: Put anti-seize on the tie rod threads, tie rodnuts, and washers. In an alternating pattern, tighten thebolts to 150 ft.-lb. (203 N•m) torque, then to 500 ft.-lb.(678 N•m) torque.

Check the tie rods for wear or cracks.

NOTE: If a tie rod is broken, both must be replaced.

Figure 20-20-14

Use a chain hoist (Item 1) [Figure 20-20-14] to removethe upper section.

Install a lar ge punch (Item 2) [Figure 20-20-14] in thelower section, lift the breaker slightly with the hoist andstrike the punch with a l arge rubber hammer to helpseparate the sections

Continue to raise the hoist to remove the upper section.



Piston

Figure 20-20-15

Install a lifting eye in the piston and use the hoist (Item 1)[Figure 20-20-15] to remove the piston from the sleeve.

Installation: Lubricate the piston with hydraulic oil andpush it into the sleeve by hand.

Seal Carrier

Figure 20-20-16

Remove the seal carrier (Item 1) [Figure 20-20-16] fromthe piston.

Check the seal carrier and piston for wear, galling, orcracks [Figure 20-20-16].

A light scuffing or burnishing of surfaces is normal.

Figure 20-20-17

Remove the O-rings from the seal carrier [Figure 20-20-17].

Figure 20-20-18

Remove the q uad ring (Item 1) and the seal (Item 2)[Figure 20-20-18] from inside the seal carrier.

Installation: Put oil on the quad ring and seal. Install theseal with the lips DOWN.

Remove small burrs with 220 grit emery cloth.



Sleeve Removal and Installation

Installing a shaft (screwdriver, etc.) through the sleeveholes and pu ll while twisting should remove the s leevefrom the lower section.

Figure 20-20-19

If the sleeve is tight, install a bolt (Item 1) through theholes in th e sleeve. Using a s lide hammer (Item 2)[Figure 20-20-19] slowly remove the s leeve from thelower section.

Check the s leeve for scratches, damaged O-rings andseals.

Figure 20-20-20

Remove the O-rings from the sleeve [Figure 20-20-20].

Figure 20-20-21

Remove the quad ring (Item 1) and the inner seal (Item 2)[Figure 20-20-21] from the sleeve.

Installation: Put hydraulic oil on the quad ring and seal.Install the seal with the lips up.

A light scuffing or burnishing of the surfaces is normal.Check for cracks and see that the piston moves freely inthe sleeve.




Sleeve Removal and Installation (Cont’d)

Figure 20-20-22

Put oil on the outside and inside surface of th e sleeveand install the sleeve in the lower section [Figure 20-20-22].

Check the condition of the O-rings (Item 1) [Figure 20-20-22] on top of the lower section.

Bushing Removal and Installation

Check the bushings for cracks or excessive galling.

Install a new tool bit into the bushings and check the sidemovement. There should be no m ore than 1/4 in. (6.4mm) side movement at the tool point.

Replace the bushings if out of tolerance.

Lay the hydraulic breaker on it's side for bushing removaland installation.

Clean the lower body before service.

Figure 20-20-23

Remove the tool retaining pin (Item 1) and the 2 rubberholders (Item 2) [Figure 20-20-23].

Remove the tool (Item 3) [Figure 20-20-23].

Figure 20-20-24

Use a hammer and punch to remove the roll pins [Figure20-20-24].



Bushing Removal and Installation (Cont'd)

Figure 20-20-25

Remove the r oll pin (Item 1) and dowel pin (Item 2)[Figure 20-20-25].

Figure 20-20-26

Drive the remaining roll pin flush with the outside of thelower section to remove the bushing [Figure 20-20-26].

Repeat the procedure to remove the upper bushing rollpin.

Figure 20-20-27

Remove the bushings from the lower section [Figure 20-20-27].


SPECIFICATIONS

NOTE: The 1560 Hydraulic Breaker is unique in design and only 1560 tools will fit the breaker.

DIMENSIONS AND WEIGHT

Weight, Breaker wtih Cradle 210 lb. (95 kg)

Two Position Frame (453) 315 lb. (140 kg)

(553) 360 lb. (160 kg)

Length (A) 39 in. (990 mm)

Tool Diameter 1.75 in. (44 mm)

Tool Working Length 9 in.

HYDRAULIC REQUIREMENTS

Flow Requirements 6 to 14 GPM (23 to 53 LPM)

Minimum Operating Pressure 1800 PSI (12409 bar)

PERFORMANCE

Impact Energy Class 150 ft.-lb. (203 J)

Blows Per Minute (Hyd. Oil @ 200°F) (93.3°C) 1250 @ 8 GPM (30 LPM)


2500/3500 HYDRAULIC BREAKER SERVICE

CHECKING MOUNTING BOLT TORQUE . . . . . . . . . . . . . . 30-10-10

DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-20-1Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-9Breaker Frame Removal and Installation. . . . . . . . . . . . . . 30-20-1Lower Body Bushings Removal . . . . . . . . . . . . . . . . . . . . . 30-20-7Main Body Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-6Manifold Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4Nitrogen Chamber Disassembly and Assembly. . . . . . . . . 30-20-8Nitrogen Chamber Removal and Installation . . . . . . . . . . . 30-20-3Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4Seals Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-11Start Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-12Valve Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-6Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . 30-20-5


PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-12

NITROGEN CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1Charging the High Pressure Accumulator . . . . . . . . . . . . . 30-10-2Charging the Low Pressure Accumulator . . . . . . . . . . . . . 30-10-5Charging the Nitrogen Chamber . . . . . . . . . . . . . . . . . . . . 30-10-8Checking The High Pressure Accumulator Pressure. . . . . 30-10-1Checking The Low Pressure Accumulator Pressure . . . . . 30-10-4Checking The Nitrogen Chamber Charge Pressure . . . . . 30-10-6

SPECIFICATIONS (2500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

SPECIFICATIONS (3500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-2

TROUBLESHOOTING THE HYDRAULIC BREAKER . . . . . 30-10-11



NITROGEN CHAMBER

Checking The High Pressure Accumulator Pressure


Figure 30-10-1

Remove the charge valve plug [Figure 30-10-1].

Figure 30-10-2


Figure 30-10-3

With the adapter (Item 1) ti ghtened on the g auge,measure the pin (Item 2) [Figure 30-10-3] protrusion.


Figure 30-10-4



B-7047

P18084

1

P-42758

2

1

0.125”(3,2 mm)

P-42759



Checking The High Pressure Accumulator Pressure (Cont’d)

Figure 30-10-5


Figure 30-10-6

Slowly turn the gauge valve body (Item 1) [Figure 30-10-6] clockwise until the gauge shows a reading. If thepressure is low, recharge the breaker using charging kitnumber 6568037.


Use charging kit (P/N 6568037) to charge the hydraulicbreaker.

Charging the High Pressure Accumulator


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Figure 30-10-7


Figure 30-10-8


B-23394

1

B-23394

1




Figure 30-10-9

NOTE: Use the high pressure side of the charging tool[Figure 30-10-9].

Figure 30-10-10

Install the charging tool into the accumulator [Figure 30-10-9].

Connect the n itrogen hose to the high pressure side ofthe charging tool [Figure 30-10-10].

SLOWLY open the valve at the nitrogen tank and fill thehigh pressure accumulator to 850 PSI (58,6 bar) [Figure30-10-10]. DO NOT EXCEED THIS PRESSURE

Close the valve at the nitrogen tank when accumulatorpressure is reached.

B-7077

B-7196


Connect This EndTo High Pressure

Accumulator &Nitrogen Chamber



Checking The Low Pressure Accumulator Pressure


Figure 30-10-11


Figure 30-10-12


Figure 30-10-13



Figure 30-10-14



B-7078

P18084

1

P-42758

2

1

0.125”(3,2 mm)

P-42759



Checking The Low Pressure Accumulator Pressure (Cont’d)

Figure 30-10-15


Figure 30-10-16

Slowly turn the gauge valve body (Item 1) [Figure 30-10-16] clockwise until the gauge shows a r eading. If th epressure is low, recharge the breaker using charging kitnumber 6568037.


Charging the Low Pressure Accumulator

The low pressure accumulator is located on the front sideof the main body.

Remove the charge valve plug.

Figure 30-10-17


Figure 30-10-18

NOTE: Use the low pressure side of the charging tool[Figure 30-10-18].


B-23393

1

B-23393

1

B-7196


Connect This EndTo Low Pressure

Accumulator



Charging The Low Pressure Accumulator (Cont’d)

Figure 30-10-19

Connect the nitrogen hose to the low pressure side of thecharging tool [Figure 30-10-19].

SLOWLY open the valve at the nitrogen tank until the gasescapes from the relief valve (Item 1) [Figure 30-10-19]on the charging tool.

Close the valve at the tank. Disconnect the nitrogen hoseand charging tool.

Install and tighten the plug.



Figure 30-10-20


Figure 30-10-21


B-7077

B-8887

1

P18084

1




Figure 30-10-22



Figure 30-10-23



Figure 30-10-24

Tighten the a dapter (Item 1) [Figure 30-10-24] on th ebreaker.

Figure 30-10-25


NOTE: The correct charge pressure is:

2500 - 400 PSI (27,58 bar)3500 - 500 PSI (31,71 bar)

P-42758

2

1

0.125”(3,2 mm)

P-42759

B-23395

1

B-23395

1



Charging the Nitrogen Chamber

The nitrogen chamber charge valve is located on theback side of the breaker above the hydraulic inlet andoutlet ports.

Figure 30-10-26

Remove the charge valve plug (Item 1) [Figure 30-10-26].

Using a small shaft push the valve inward to release thegas pressure.

Figure 30-10-27

Install the charging tool in the charge valve [Figure 30-10-27].

Figure 30-10-28


Connect the nitrogen hose to the hi gh pressure side ofthe charging tool.

SLOWLY open the valve at the nitrogen tank and fill thenitrogen chamber.

2500 - Fill the chamber to 400 PSI (27,58 bar)3500 - Fill the chamber to 500 PSI (31,71 bar)Close the valve on the nitrogen tank.

Disconnect the hose and the charging tool.


B-7196






Figure 30-10-29


Apply grease (4 to 5 pumps) to the upper end of the toolat the grease fitting (Item 1) [Figure 30-10-29] every 4 to8 hours of operation, or when the tool bit looks dry.


IMPORTANTUnderwater use of the breaker will cause internaldamage. No por tion of t he breaker may besubmerged.

I-2053-0589

B-11927

1



Figure 30-10-30

Check the mounting bolts (Item 1) [Figure 30-10-30]daily.

Tighten the bolts to 900 ft.-lb. (1200 N•m) torque.

B-11927

1



WARNINGInstructions are necessary before operating orservicing machine. Read Operation & M aintenance

Manuals, Handbook and signs (decals) on machine.Follow warnings and instructions in the manualswhen making repairs, adjustments or servicing.Check for correct function after adjustments, repairsor service. Failure to follow instructions can causeinjury or death.

W-2003-1289




Breaker will not fire. Loader fluid reservoir is low. Add hydraulic fluid to the fluid reservoiron the loader.

No hydraulic flow to the breaker. Check the hydraulic flow to thebreaker.

Loader main relief valve set too low. Adjust main relief valve to correctsetting.

Loader hydraulic pump not working. Check flow of loader hydraulic pump.Repair or replace as needed.

Nitrogen chamber not at correctpressure.

Charge to required pressure.


Breaker runs very slowly. Not enough hydraulic flow. Test loader hydraulics for correct flowand pressure.

Excessive heat build up. Check oil cooler for debris and air flow.Check loader relief valve pressure.

Nitrogen chamber over-pressurized. Remove gas and refill to correctpressure (400 PSI maximum).

Internal leakage. Check seals and O-rings in thebreaker.Refer to Service Letter 10 May 1996.

Breaker fires erratically. Excessive back pressure. Check for plugged or kinked returnlines.



Damaged electrical connection tobreaker valve (backhoe mounted unitonly).


Defective push pins. Replace push pins.





W-2019-1285

The tools listed will be nee ded to do the fol lowingprocedure:

6568037 - Charging Kit (purchased from Bobcat Sales)OEM6106 - Torque MultiplierMEL1214 - Hex Bit DriverMEL1308 - Lower Bearing Removal PlateMEL1310 - Remover HandleRead and understand the complete disassembly andassembly procedure before beginning the operation.

NOTE: Different colored seals have been used in thebreakers in the past. Do not identify the sealsby their colors, instead each seal is n owindividually packaged with an identificationnumber. These identification numbers will berefered to in this manual for seal replacement.There may b e extra seal(s) and/or O-ring(s)included with the seal kit, discard unusedseals and/or O-rings.

Before removing the breaker from the B ob-Tach frame,do the following:

Loosen the 4 main body bolts. DO NOT REMOVE THEBOLTS.

MEL1307 - Hex Bit Driver

Figure 30-20-1

Loosen the 6 bolts which fasten the breaker to the frame[Figure 30-20-1]. DO NOT REMOVE THE BOLTS.


Remove the 3/ 16 in. hex plug at the accumulatorchamber. Release the nitrogen gas from the chamber.

Figure 30-20-2

Loosen the hex bolt (use a 2-1/16 inch socket) on the topof the nitrogen gas chamber [Figure 30-20-2]. DO NOTREMOVE THE BOLT.

Assembly: Tighten the bolts to 600 ft.-lb. (813 N•m)torque.


DISASSEMBLY AND ASSEMBLY (CONT’D)


Figure 30-20-3

Install the eye bolt in the bo lt at th e top of th e breaker[Figure 30-20-3]. Install a chain hoist at the eye bolt.

Figure 30-20-4

Have a second person remove the mounting pins (Item1) [Figure 30-20-4] and the washers.

Have a second person lift the breaker from the Bob-Tachframe. Put the breaker in th e vertical position in th estand.

Install a chain hoist on the frame of the breaker.

Figure 30-20-5

Remove the 6 bolts [Figure 30-20-5].

Use MEL1214 - Hex Bit Driver

Assembly: Put anti-sieze lubricant on the threads andtighten the bolts to 900 ft.-lb. (1220 N•m) torque.

Remove the frame from the breaker.

Figure 30-20-6

Remove the hydraulic hoses from the hydraulic breaker[Figure 30-20-6].

Remove the 3/1 6 inch hex plug at the accumulatorchamber. Release the nitrogen gas from the chamber.




Figure 30-20-7

Using a small shaft (Item 1) [Figure 30-20-7], push thevalve inward to r elease the nitrogen gas from thechamber.

Nitrogen Chamber Removal and Installation

Figure 30-20-8

Remove the 4 main socket head bolts [Figure 30-20-8].

Use MEL1214 - Hex Bit Driver

NOTE: When the 4 main bolts are removed, thenitrogen chamber, main body and lower bodyare independent of each other. Be careful soparts do not fall.

Assembly: Put anti-sieze lubricant on the threads of thebolts and tighten to 600 ft.-lb. (814 N•m) torque.

Figure 30-20-9

Use a ch ain hoist and remove the nitrogen chamber[Figure 30-20-9].



Manifold Removal

Figure 30-20-10

Lift the manifold assembly from the main body [Figure30-20-10].

Piston Removal

Figure 30-20-11

Remove the piston (Item 1) [Figure 30-20-11] from themain body.

Check the piston for wear.

Later model breakers have a cross hatch pattern (Item 2)[Figure 30-20-11] on the piston. Early model pistons aresmooth. This cross hatch pattern is used to trap oil on thepiston shaft to help lubricate the new style seals used inthe breakers.

If there is no cross hatch pattern on the piston or if thecross hatch is worn smooth on part of the piston, apply across hatch pattern as follows:

Use an emery cloth and move the emery cloth up anddown in th e area (Item 2) [Figure 30-20-11] whilerotating the piston.

This will produce a very fine surface scratching in a crosshatched pattern (Item 2) [Figure 30-20-11].

NOTE: The new style seals (See Seals Installation onPage 30-20-11.) must be used with the crosshatch pattern pistons. Both old and new styleseals are included in the breaker seal kit. Werecommend crosshatching the old style(smooth) piston and using the latest designseals.



Valve Removal and Installation

Figure 30-20-12

Remove the valve with the push pins [Figure 30-20-12].

Assembly: Align the timing marks on the valve and valvecylinder [Figure 30-20-12].

Figure 30-20-13

Remove the push pins and inspect for wear [Figure 30-20-13].

Inspect oil holes in the valve. Be sure they are notplugged.

Figure 30-20-14

NOTE: The manifold will not s eat correctly if thetiming marks (Item 1) [Figure 30-20-14] are notaligned.



Valve Cylinder Removal

Figure 30-20-15

Remove the valve cylinder with the valve seat from themain body [Figure 30-20-15].

Figure 30-20-16

Remove the valve cylinder from the valve seat [Figure30-20-16].

NOTE: The valve cylinder and valve seat are indexedby a roll pin (Item 1) [Figure 30-20-16].

Main Body Removal

Figure 30-20-17

Remove both disc springs from the main body [Figure30-20-17].

NOTE: The disc springs help maintain tolerancebetween components by keepingcomponents tightly against 1 another.

Figure 30-20-18

Assembly: Install the disc springs with the convexsurface facing away from the lower bearing [Figure 30-20-18].

Install the socket head bolts into the body at bothaccumulator sides.



Main Body Removal (Cont’d)

Figure 30-20-19

Install a chain hoist and lift the main body from the lowerbody [Figure 30-20-19].

Figure 30-20-20

Turn 2 b olts, equally into the main body to r emove thelower bearing [Figure 30-20-20].

Lower Body Bushings Removal

Figure 30-20-21

NOTE: A bead of weld may have to be put around theI.D. of the tool stop (Item 1) [Figure 30-20-21]bearing for easier removal.

Disassembly of the lower body internal parts requires apress for removal of the tool bearing (Item 2) and toolstop (Item 1) [Figure 30-20-21]. Replace the parts asneeded.

MEL1308 - Lower Bearing Removal PlateMEL1310 - Remover HandleClean in solvent and air dry them.

Inspect all parts for scratches, wear or damage. Replacethe parts as needed.



Nitrogen Chamber Disassembly and Assembly

Disassembly: Remove the large bolt and the top plate.

Figure 30-20-22


Clean and inspect the charge valve.

Turn the chamber over, install the large bolt. Use a softhammer and hit the bo lt to remove the diaphragm andscreen.

Remove the O-ring from the s creen and inspect thediaphragm for wear.

DO NOT store the diaphragm in direct sunlight.

Figure 30-20-23

Assembly: Put approximately 1 teaspoon of cleanhydraulic oil on the outside of the diaphragm. Lubricatethe sealing surface of th e nitrogen chamber. Install thediaphragm [Figure 30-20-23].

Figure 30-20-24

Install the screen [Figure 30-20-24].

Figure 30-20-25

Install the O-ring on the screen [Figure 30-20-25]. (TheO-ring identification number is 350724.)



Nitrogen Chamber Disassembly and Assembly (Cont'd)

Figure 30-20-26

Install the O-ring (Item 1) on the top and bottom of thechamber.(The O-ring (Item 1) [Figure 30-20-26]identification number is 350754.)

Install the top plate and bolt. The bolt must be tightenedafter the chamber is installed on the main body.

Tighten the bolt to 600 ft.-lb. (814 N•m) torque.

Figure 30-20-27

Install the O-ring (Item 1) [Figure 30-20-27] on th echarge valve. (The O-ring identification number is01605.)

Install the charge valve and tighten to 80 ft.-lb. (108 N•m)torque[Figure 30-20-27].

Accumulator

Figure 30-20-28

Remove the hex socket bolt at the accumulator chamber[Figure 30-20-28].


Disassembly: Put the accumulator body in a vise.

Figure 30-20-29

Loosen the accumulator plug [Figure 30-20-29].

Remove the accumulator plug and diaphragm [Figure30-20-29].

Inspect the diaphragm for wear and replace as needed.



Accumulator (Cont’d)

Figure 30-20-30

Remove the charge valve [Figure 30-20-30].


Install the O-ring (Item 1) [Figure 30-20-30] on th echarge valve. (The O-ring identification number is01605.)

Install the charge valve and tighten to 80 ft.-lb. (108 N•m)torque[Figure 30-20-30].

Figure 30-20-31

Assembly: Install the diaphragm in the accumulator[Figure 30-20-31].

Figure 30-20-32

Put the accumulator body in a vise [Figure 30-20-32].

Put approximately 1 teaspoon of clean oil in the cover.

Put the plug into the body and tighten to 600 ft.-lb. (814N•m) torque.

Install the charge valve and tighten to 80 ft.-lb. (108 N•m)torque.



Seals Installation

NOTE: New and old style seals are include in eachseal kit. Not all of the seals will be used torebuild the breaker. The following procedurewill describe the usages of both the old andthe new seals. But, we recommend modifyingthe piston and using the new style seals. (SeePiston Removal on Page 30-20-4.)

NOTE: Heating the seal to 150°F (68°C) in hot waterwill ease the installation.

NOTE: Do not use a screwdriver or any sharp tool forinstallation of the seals.

The type of seal to be u sed is depended on the type ofpiston in the breaker. (Early pistons are smooth, laterpistons are cross hatched.) We recommend using thelastest style piston or modifing the early piston to use thelastest style seals. (See Piston Removal on Page 30-20-4.)

Figure 30-20-33

When installing the wiper seal into the lower body, makesure the lip is facing down [Figure 30-20-33]. (The sealidentification number is :

For 2500 Breakers with smooth piston is 500000. For2500 Breakers with cross hatch piston is 24999.

For 3500 Breakers with smooth piston is 12851. For 3500Breakers with cross hatch piston is 25000.

Figure 30-20-34

Install the seal (Item 1) [Figure 30-20-34] into the lowerbearing. Make sure the s eal lip faces up ( toward thenitrogen chamber). (The seal identification number is :

For 2500 Breakers with smooth piston is 350832. For2500 Breakers with cross hatch piston is 24893.

For 3500 Breakers with smooth piston is 12852. For 3500Breakers with cross hatch piston is 24932.

Install the O-ring (Item 2) [Figure 30-20-34]. The sealidentification number for both 2500 and 3500 breakers is350833.)

Figure 30-20-35

When installing the seal (Item 1) [Figure 30-20-35] intothe groove at the valve seat, make sure the seal lip facesdown. (The seal identification number for 2500 or 3500Breakers with either smooth or cross hatch piston is27221.)

Install the O-ring (Item 1) [Figure 30-20-35]. The sealidentification number for both 2500 and 3500 breakers is350835.)



Seal Installation (Cont'd)

Install the seal on the valve cylinder as follows:

Figure 30-20-36

Install the sm aller seal (5-3/16 inch O.D.) (Item 1)[Figure 30-20-36] in the low er groove.(The sealidentification number is 27222.)

Install the larger seal (5-5/16 inch O.D.) (Item 2) [Figure30-20-36] in th e upper groove.(The seal identificationnumber is 27223.)

The open side (O-ring side) of the seals must face towardeach other [Figure 30-20-36].

Start Up Procedure

Install the hydraulic breaker on the Bobcat (or backhoe).

Connect the quick couplers.

Start the engine. Engage the auxiliary hydraulics andraise the tool off the work object.

Run the breaker above the object in the BLANK FIREposition to he lp remove the air from the breaker. (SeeHydraulic/Hydrostatic Flow Chart Blank FiringOperation.)

It may take several minutes for all the air to be removedfrom the system.


SPECIFICATIONS (2500)

WEIGHT

Total Weight 390 lb. (177 kg)

ENERGY 250 ft.-lb. (339 J) CLASS

BLOWS PER MINUTE (Hyd. Oil @ 200°F)(43.3°C) 780 @ 12.5 GPM (47 L/min.)

RECOMMENDED HYDRAULIC OIL FLOW (For OptimumPerformance)

10 to 15 GPM (23 to 57 L/min.)

MINIMUM OPERATING PRESSURE 1800 PSI (12411 bar)


SPECIFICATIONS (3500)

NOTE: The same tools will fit the 2500 and 3500 breaker.

WEIGHT



BLOWS PER MINUTE (Hyd. Oil @ 200°F)(43.3°C) 480 @ 12.9 GPM (47 L/min.)

RECOMMENDED HYDRAULIC OIL FLOW (For OptimumPerformance)

13 to 18 GPM (49 to 68 L/min.)




DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 40-20-1Installing Piston Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-8Lower Section Bushings Removal and Installation . . . . . . 40-20-9Main Body Removal and Installation . . . . . . . . . . . . . . . . . 40-20-8Nitrogen Chamber Removal and Installation . . . . . . . . . . . 40-20-2Piston and Seal Carrier Installation . . . . . . . . . . . . . . . . . 40-20-11Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-3Piston Sleeve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-4Start Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-11Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . 40-20-5


NITROGEN CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1Charging the Nitrogen Chamber . . . . . . . . . . . . . . . . . . . . 40-10-3Checking The Nitrogen Chamber Charge Pressure . . . . . 40-10-1Releasing Pressure From The Nitrogen Chamber. . . . . . . 40-10-1

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1




NITROGEN CHAMBER

Releasing Pressure From The Nitrogen Chamber


W-2019-1285

Figure 40-10-1

Remove the pl ug (Item 1) [Figure 40-10-1] from thecharge valve.

Figure 40-10-2





Figure 40-10-3


Figure 40-10-4


P-1828

1

P18084

1




Figure 40-10-5



Figure 40-10-6



Figure 40-10-7


Figure 40-10-8


NOTE: The correct charge pressure is 350 PSI (24,13bar)

P-42758

2

1

0.125”(3,2 mm)

P-42759

P-65363

1

P-65363

1




Use charging kit (P/N 6568037) to charge the nitrogenchamber.

The nitrogen chamber charge valve is located on thefront side of the nitrogen chamber housing.


W-2019-1285

Figure 40-10-9


Figure 40-10-10

NOTE: Be sure to use the adapter (P/N 6661802) (Item1) [Figure 40-10-10] and the correct side of thecharging tool.

Connect the nitrogen hose to the charging tool.

SLOWLY open the charging valve on th e nitrogen tankand fill the nitrogen chamber on the breaker to 350 PSI(24,14 bar).

Close the valve on the nitrogen tank.



B-7196350 PSI (24,14 BAR)



1



WARNINGInstructions are necessary before operating orservicing machine. Read Operation & M aintenanceManuals, Handbook and signs (decals) on machine.Follow warnings and instructions in the manualswhen making repairs, adjustments or servicing.Check for correct function after adjustments, repairsor service. Failure to follow instructions can causeinjury or death.

W-2003-1289




Breaker will not fire. Loader main relief valve set too low. Adjust main relief valve to correct setting.

Loader fluid reservoir is low. Add hydraulic fluid to the fluid reservoir onthe loader.


Loader hydraulic pump not working. Check flow of loader hydraulic pump.Repair or replace as needed.





Breaker runs very slowly or blow perminute reducing.

Loader main relief valve set too low. Adjust main relief valve to correct setting.

Not enough hydraulic flow. Test loader hydraulics for correct flow andpressure.

Excessive heat build up. Check oil cooler for debris and air flow.

Check loader relief valve pressure.

Nitrogen chamber over-pressurized. Remove gas and refill to correct pressure(400 PSI maximum).

Internal leakage. Check seals and O-rings in the breaker.




TROUBLESHOOTING THE HYDRAULIC BREAKER (CONT'D)


W-2003-1289


Breaker fires erratically. Loader main relief valve set too low. Adjust main relief valve to correctsetting.

Excessive back pressure. Check for plugged or bent return lines.



Damaged electrical connection tobreaker valve (backhoe mounted unitonly).



Excessive pressure pulsations. Incorrect hoses. Refer to Serviceletter 13 May 1996.

Quick coupler failure. Refer to Serviceletter 13 May 1996.

Nitrogen chamber pressureinsufficient.

Refer to Serviceletter 13 May 1996.

Breaker valve seal pressure. Refer to Serviceletter 13 May 1996.



TS1153

1

3

38

3

6

3

4

3

5

5

9

3

8

3

7

21

3

8

11

26

27

3

12

13

3

223

322

223

322 8

314

3

83 16

3

3

8

4

17

4

44

4

10

24

24 23

25

18

19

20

2324

23

2423

1. Accumulator2. Charge Valve Assembly3. O-ring4. Seal5. Rod Seal6. Seal Carrier7. Manifold8. O-ring Plug9. Piston

10. Piston Sleeve11. Valve Cap12. Spool Sleeve13. Valve Sleeve14. Valve Spool15. Main Body16. Grease Fitting17. Rod Wiper18. Lower Body Assembly19. Upper Bushing20. Lower Bushing21. Bolt22. Backup Ring23. Roll Pin24. Pin25. Dowel Pin26. Bolt27. Washer




W-2019-1285

The tools listed will be needed to service the breaker:

MEL1430 - Hydraulic Breaker Sleeve Puller 6568037 -Charging Kit or MEL1523A

Read and understand the complete disassembly andassembly procedure before beginning the operation.


Before you remove the breaker from the frame do th efollowing:

Release the pressure from the ac cumulator. (SeeReleasing Pressure From The Nitrogen Chamber onPage 40-10-1.)

NOTE: It is recommended that the hydraulic hoses beloosened at the breaker fittings to release anytrapped hydraulic pressure.

Have a s econd person assist in the h ydraulic breakerremoval while the operator remains in the operator seat.

Figure 40-20-1

Remove the mounting pin clip and pin [Figure 40-20-1].

Figure 40-20-2

Put the breaker in a stand [Figure 40-20-2].

Figure 40-20-3

Loosen the top 4 bolts (Item 1) [Figure 40-20-3]. Do notremove the bolts.

Remove the s nap ring from the bolts [Figure 40-20-2].Loosen the 4 bol ts from the breaker frame. Do no tremove the bolts.



Have a second person disconnect the hydraulic quickcouplers from the loader and remove them from the hoseguide on the boom arm.

Remove the pivot pin bolts and the pins.

Slowly move the loader away from the breaker.

Use a chain hoist to control the frame while removing orinstalling the mounting bolts (Item 1) [Figure 40-20-3 onPage 40-10-1].

Figure 40-20-4

Remove the lock plates [Figure 40-20-4].

Figure 40-20-5

Remove the 4 mounting bolts from the b reaker [Figure40-20-5].

Installation: Put anti-sieze on the bolt threads and theshank of the bolt. Tighten the bolts to 300 ft.-lb. (407N•m) torque.

Lower the frame to the floor and remove the chain.

NOTE: For clarity purposes, the breaker frame isremoved. However, most of the breakerservicing can be done with frame installed.

NOTE: The frame can be left in the breaker standduring repair if needed.

Nitrogen Chamber Removal and Installation

Figure 40-20-6

Remove the to p 4 bol ts from the n itrogen chamber[Figure 40-20-6].

Installation: Put anti-sieze on th e bolt threads andwasher (Item 1) [Figure 40-20-6]. Tighten the bolts to200 ft.-lb. (271 N•m) torque in a cross pattern.

Repeat the tightening pattern to 5 00 ft.-lb. (678 N•m)torque.

Figure 40-20-7

Remove the nitrogen chamber [Figure 40-20-7].

Replace the large O-ring (Item 1) [Figure 40-20-7] on thenitrogen chamber.



Nitrogen Chamber Removal and Installation (Cont'd)

Figure 40-20-8

Replace the small O-ring (Item 1) [Figure 40-20-8] fromthe bottom surface of the nitrogen chamber.

Piston Removal

Figure 40-20-9

Install an eye bolt in the end of the piston and remove thepiston [Figure 40-20-9].

Remove the piston slowly to prevent damage to the sealcarrier (Item 1) [Figure 40-20-9] and the piston.

NOTE: If the piston is clean or slightly discolored it isan indication that the seal carrier is in goodcondition.

Figure 40-20-10


NOTE: Check the seal carrier for scratches, damagedseals, back-up washers or oil seals. Check thepiston for wear areas.

Figure 40-20-11

Check the piston shaft and grooves for wear [Figure 40-20-11].



Piston Removal (Cont'd)

Figure 40-20-12

Remove the O-rings from the carrier [Figure 40-20-12].

Installation: Put oil on the O-rings during assembly.

Figure 40-20-13

Remove the back-up washer from the lower o-ringgroove [Figure 40-20-13].

NOTE: The back-up washer is located only in groove(Item 1) [Figure 40-20-13].

Installation: Put oil on the back-up washer and install onthe upper side of the O-ring.

Figure 40-20-14

Remove the 2 inner seals [Figure 40-20-10].

Installation: Put oil on the se als and install with the lipsdown.

Piston Sleeve Removal

Use MEL1430 (Hydraulic Breaker Sleeve Puller) for thefollowing procedure:

Figure 40-20-15

Install the puller hooks until the spring loaded pins (Item1) [Figure 40-20-15] are under the sleeve lip.

NOTE: Rotate the puller to be sure the puller pins arein the sleeve holes to prevent damage duringsleeve removal.

B-15066



Piston Sleeve Removal (Cont'd)

Figure 40-20-16

Remove the O-rings from the carrier [Figure 40-20-16].

Tighten the nut until the s leeve pulls free from the mainbody [Figure 40-20-16].

Figure 40-20-17

Remove the sleeve [Figure 40-20-17].

Figure 40-20-18

Remove the seals from the sleeve [Figure 40-20-18].

Valve Removal and Installation

Figure 40-20-19

Remove the bolts from the valve manifold [Figure 40-20-19].

Installation: Put anti-sieze on th e bolt threads andtighten to 70 to 75 ft.-lb. (95 to 102 N•m) torque.



Valve Removal and Installation (Cont'd)

Figure 40-20-20

Replace the O -rings (Item 1) [Figure 40-20-20] on thebottom of the manifold.

Figure 40-20-21

Remove the plug from the valve [Figure 40-20-21].

Install a bolt in the hole of the valve cap.

Figure 40-20-22

Use a puller to remove the valve [Figure 40-20-22].

A pry bar used with a wooden block will also work toremove the valve.

NOTE: Be careful not to damage the face of the mainbody.

NOTE: The spool should slide freely when the valve isshaken.

Figure 40-20-23

Remove the O-rings and back-up washers from the valve[Figure 40-20-23].

NOTE: The position of the O-rings and back-upwashers are VERY important duringassembly. Use insert for O-ring and back-upwasher location [Figure 40-20-23].




Figure 40-20-24

Remove the cap from the valve [Figure 40-20-24].

Figure 40-20-25

Pry the sleeve from the cap [Figure 40-20-25].

NOTE: Rotate the sleeve to remove or install in thecap.

Figure 40-20-26

Remove the O-ring (Item 1) [Figure 40-20-26] from thecap.

Figure 40-20-27

Remove the spool from the valve [Figure 40-20-27].

NOTE: Rotating the spool while holding the valve willaid during removal and installation.

NOTE: Check the valve and spool for scratches.

Install the spool in the valve.

Install the c ap and hand tighten only. DO NOT overtighten.

Install the valve in the upper section.




Figure 40-20-28

Use a s oft hammer to tap the valve until it s eats inposition [Figure 40-20-28].

Main Body Removal and Installation

Figure 40-20-29

Remove the main body from the lower body [Figure 40-20-29].

Figure 40-20-30

The upper section and the lower section are aligned witha dowel (Item 1) [Figure 40-20-30].

Installing Piston Sleeve

Put the upper section in a press.

Put oil on the O-rings, the outside of the sleeve and theinside of the main body before installation.

Figure 40-20-31

Install the sleeve in the upper section [Figure 40-20-31].

NOTE: Lower sleeve slowly into upper section beingcareful not to damage O-rings.



Installing Piston Sleeve (Cont'd)

Figure 40-20-32

Press the sleeve slowly until it seats [Figure 40-20-32].

Lower Section Bushings Removal and Installation

NOTE: The lower bushings are not interchangeable.

Figure 40-20-33

Drive out the roll pin (Item 1) [Figure 40-20-33] for thelower bushing.

Figure 40-20-34

Tip the lower section to remove the inner pin [Figure 40-20-34].

Figure 40-20-35

Drive the other roll pin back [Figure 40-20-35].



Lower Section Bushings Removal and Installation (Cont'd)

Figure 40-20-36

Remove the lower bushing [Figure 40-20-36].

Figure 40-20-37

Repeat the same procedure to remove the upper bushing[Figure 40-20-37].

Figure 40-20-38

The bushings are grooved in di fferent locations [Figure40-20-38].

NOTE: The bushing pin holes and grooves will line upin their original position and location only.

Figure 40-20-39

The pins (Item 1) [Figure 40-20-39] are rubber mountedand hold the breaker tool retaining pin in position.

The pins usually do no t need replacing until they arevisibly worn out [Figure 40-20-39].



Piston and Seal Carrier Installation

After the upper section and lower section have beenrepaired do the following:

Set the lower section on the point in the stand.

Align the dowel and put the main body on the lowersection.

Figure 40-20-40

Slowly lower the piston in the sleeve, being careful not todamage the piston or the sleeve [Figure 40-20-40].

Figure 40-20-41

Install the seal carrier in the upper section as s hown[Figure 40-20-41].

Figure 40-20-42

Use a soft hammer and a tool of the same diameter asthe seal carrier to tap the seal carrier into position[Figure 40-20-42].

Start Up Procedure

Install the Hydraulic Breaker on the Bobcat Loader,backhoe or excavator. Connect the quick couplers.

Start the engine. Raise the tool off the work surface andengage the auxiliary hydraulics.

Run the breaker for several minutes until the air isremoved from the breaker.

Figure 40-20-43

The extent of wear in the upper and lower bushings ischecked by installing a new bit ( Item 1) [Figure 40-20-43] in the hydraulic breaker and checking the ga pbetween the lower bushing and the tool bit shaft.

There can be no more than 0.25 in. (6,35 mm) gapbetween the lower bushing and a new tool bit [Figure 40-20-43].


SPECIFICATIONS

NOTE: The same tools will fit both the 2560 and 3560 breakers.

WEIGHT

Breaker With Cradle 470 lb. (210 kg)

Two Position Frame 360 lb. (160 kg)

ENERGY

2560 300 ft.-lb. Class


BLOWS PER MINUTE (Hyd. Oil @ 200°F) (93.3°C)

2560 1000 @ 13 GPM (49 L/min.)

3560 1080 @ 15 GPM (57 L/min.)

RECOMMENDED HYDRAULIC FLOW (For Optimum Performance)

2560 11 to 18 GPM (42 to 68 L/min.)

3560 13 to 18 GPM (49 to 68 L/min.)

RECOMMENDED SYSTEM RELIEF (Min) 2500 PSI (17235 bar)




DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 50-20-1Accumulator Removal And Installation . . . . . . . . . . . . . . 50-20-16Breaker Frame Removal And Installation . . . . . . . . . . . . . 50-20-1Bushing Removal And Installation . . . . . . . . . . . . . . . . . . 50-20-18Nitrogen Chamber Disassembly And Assembly . . . . . . . . 50-20-6Nitrogen Chamber Removal And Installation. . . . . . . . . . . 50-20-5Piston Removal And Installation . . . . . . . . . . . . . . . . . . . . 50-20-7Piston Sleeve Installation. . . . . . . . . . . . . . . . . . . . . . . . . 50-20-10Piston Sleeve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-9Start Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-21Tool Bit Retaining Pins Removal And Installation . . . . . . 50-20-21Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . 50-20-10Upper Housing Removal And Installation . . . . . . . . . . . . 50-20-14



NITROGEN CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1Charging The Accumulator . . . . . . . . . . . . . . . . . . . . . . . . 50-10-8Charging The Nitrogen Chamber. . . . . . . . . . . . . . . . . . . . 50-10-3Checking The Accumulator Charge Pressure . . . . . . . . . . 50-10-5Checking The Nitrogen Chamber Charge Pressure . . . . . 50-10-1Releasing Pressure From The Accumulator . . . . . . . . . . . 50-10-7Releasing Pressure From The Nitrogen Chamber. . . . . . . 50-10-1

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

TOOL BIT REMOVAL AND INSTALLATION. . . . . . . . . . . . . 50-10-11




NITROGEN CHAMBER


The nitrogen chamber valve is located on the front side ofthe hydraulic breaker.


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Figure 50-10-1


Figure 50-10-2

Using a small shaft, push the valve (Item 1) [Figure 50-10-2] inward to release the gas pressure.

Install the plug in the charge valve.




Figure 50-10-3


P18084

1




Figure 50-10-4

With the adapter (Item 1) tig htened on the ga uge,measure the pin (Item 2) [Figure 50-10-4].


Figure 50-10-5


Install the gauge/adapter on the breaker.

Figure 50-10-6


Figure 50-10-7



P-42758

2

1

0.125”(3,2 mm)

P-42759





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Figure 50-10-8

Block up the breaker so the tool bit (Item 1) [Figure 50-10-8] is not under pressure and is not in contact with thepiston.

Figure 50-10-9


Figure 50-10-10

Install the adapter (Item 1) [Figure 50-10-10] on the"Above 100 PSI" side of the charging tool.



Charging The Nitrogen Chamber (Cont'd)

Figure 50-10-11

Install the charging tool (Item 1) [Figure 50-10-11] on thebreaker.

Remove the cap (Item 2) [Figure 50-10-11] from thecharging tool.

Figure 50-10-12

Connect the nitrogen hose (Item 1) to the charging tool(Item 2) [Figure 50-10-12].

Slowly open the v alve on the nitrogen tank and fill thenitrogen chamber to 350 PSI (24,14 bar). Close the valveon the nitrogen tank.


Figure 50-10-13

Install and tighten the plug (Item 1) [Figure 50-10-13].



Checking The Accumulator Charge Pressure


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Figure 50-10-14


Figure 50-10-15


Figure 50-10-16

With the adapter (Item 1) ti ghtened on the g auge,measure the pin (Item 2) [Figure 50-10-16].


P-29454

1

P-42758

2

1

0.125”(3,2 mm)



Checking The Accumulator Charge Pressure (Cont’d)

Figure 50-10-17


Figure 50-10-18

Install the gauge adapter on the breaker.

Tighten the adapter (Item 1) [Figure 50-10-18] on thebreaker.

Figure 50-10-19



P-42759



Releasing Pressure From The Accumulator

Figure 50-10-20

Remove the plug (Item 1) [Figure 50-10-20] from thecharge valve.

Figure 50-10-21

Using a small shaft, push the valve (Item 1) [Figure 50-10-21] inward to release the gas pressure.




Charging The Accumulator

Use kit 6568037 to charge the accumulator.

To gain access to the accumulator, put the hydraulicbreaker in the horizontal operating position.

Figure 50-10-22

Remove the plug (Item 1) [Figure 50-10-22] from thecharge valve on the accumulator.

Figure 50-10-23

Install the charge tool (Item 1) [Figure 50-10-23] in thecharge valve.

NOTE: Be sure to install the side of the charging toolwhich reads "above 100 PSI".

Connect the hose (Item 2) to the charge tool fitting (Item1) [Figure 50-10-23].

SLOWLY open the valve on the nitrogen tank until thegauge reads 1000 PSI (68,97 bar). Close the valve onthe nitrogen tank.

Remove the hose, charge tool, and adaptor.





Figure 50-10-24


Apply grease (4 to 5 pumps) to the upper end of the toolat the grease fitting (Item 1) [Figure 50-10-24] every 4 to8 hours of operation or when the tool bit looks dry.



I-2053-0589



Figure 50-10-25

Check the snap rings, lock plates and breaker mountingbolts (Item 1) [Figure 50-10-25] every day.

If the snap rings and lock plates are missing, tighten thebolts to 300 ft.-lb. (407 N•m) torque. Lock plates can beturned 180° for a different alignment if necessary.


TOOL BIT REMOVAL AND INSTALLATION

Figure 50-10-26

Use a punch and a hard rubber hammer to remove theretaining pin from the tool [Figure 50-10-26].

NOTE: The retaining pin can be driven out or installedfrom either side.

WARNINGAVOID BURN INJURYBreaker bit can be hot after use. Let breaker bit coolbefore removing bit or servicing breaker.

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Put grease on the top 8 in. (203 mm) of the tool beforeinstalling the tool.

NOTE: During normal operation, the grease will heatup and run down the tool shaft.

NOTE: Grease the fitting every 4 to 8 hours ofoperation or if the tool bit looks dry.

Figure 50-10-27

Install the tool bit and align the notch (in the tool) with theretaining pin hole [Figure 50-10-27].

Figure 50-10-28

Use a har d rubber hammer to in stall the retaining pin[Figure 50-10-28].



WARNINGInstructions are necessary before operating orservicing machine. Read and understand theOperation & Maintenance Manual, Handbook andsigns (decals) on machine. Follow warnings andinstructions in the manuals when making repairs,adjustments or servicing. Check for correct functionafter adjustments, repairs or service. Untrainedoperators and f ailure to follow instructions cancause injury or death.

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If the Hydraulic Breaker is not working correctly, check the hydraulic system of the Bobcat Loader or excavator thoroughlybefore making any repairs on the breaker. Hydraulic Breaker problems can be affected by a hydraulic system that is notoperating to specifications or such problems as a plugged fuel filter or hydraulic filter in the loader or excavator. Connecta flow meter to the loader or excavator to check the hydraulic pump output, relief valve setting and tubelines to check flowand pressure. (See the loader Service Manual for the correct procedure to connect the flow meter).



Breaker will not fire. Loader or excavator main relief valve set too low. Adjust main relief valve to correct setting.

Loader or excavator fluid reservoir is low. Add hydraulic fluid to the fluid reservoir on theloader or excavator.


Loader or excavator hydraulic pump not working. Check flow of lo ader hydraulic pump. Repair orreplace as needed.



Breaker runs very slowly orlow blow energy.

Loader or excavator main relief valve set too low. Adjust main relief valve to correct setting

Not enough hydraulic flow. Test loader or excavator hydraulics for correct flowand pressure.

Excessive heat build up. Check oil cooler for debris and air flow. Checkloader or excavator relief valve pressure.


Nitrogen chamber pressure incorrect Check and fill to correct pressure.

Internal leakage. Check seals and O-rings in the breaker. Checkpiston, sleeve and seal carrier for wear.


Breaker fires erratically. Loader or excavator main relief valve set too low. Adjust main relief valve to correct setting.








Excessive heat build up. Blank firing. Refer to the hydraulic controls section of theOperation And Maintenance Manual forcorrect operating procedure.


Excessive breaker inlethose pulsations.

Accumulator charge pressure low or accumulator damaged.

Check and fill to correct pressure or serviceaccumulator.


PARTS IDENTIFICATION (CONT’D)



Breaker Frame Removal And Installation


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The tools listed will be needed to service the breaker.

MEL1430-Hydraulic Breaker Sleeve Puller6568037-Charging KitMEL1523B

Figure 50-20-1

Place the hydraulic breaker on blocks (Item 1) [Figure50-20-1].

Release the pressure from the nitrogen chamber andaccumulator. (See Releasing Pressure From TheNitrogen Chamber on Page 40-10-1.)

Figure 50-20-2

Install a hoist (Item 1) [Figure 50-20-2]. Raise the hoistuntil the weight of the breaker is supported by the hoist.

Figure 50-20-3

Remove the pin (Item 1) and washer (Item 2) [Figure 50-20-3].

Figure 50-20-4

Remove the pin (Item 1) [Figure 50-20-4].



Breaker Frame Removal And Installation (Cont'd)

Mark the hoses for correct installation.

Figure 50-20-5

Remove the hoses (Item 1) [Figure 50-20-5] from theframe. Install caps and plugs.

Figure 50-20-6

Remove the bolts (Item 1) [Figure 50-20-6] and nutsfrom the pivot pins.


Figure 50-20-7

Install a puller (Item 1) in the pivot pins (Item 2) [Figure50-20-7].

Remove the pivot pins (both sides).

Figure 50-20-8

Install an additional hoist (Item 1) [Figure 50-20-8] on theframe.




Figure 50-20-9

Raise the hoist (Item 1) [Figure 50-20-9] that is attachedto the breaker.

Remove the frame (Item 2) [Figure 50-20-9].

Figure 50-20-10

Set the breaker down on blocks (Item 1) [Figure 50-20-10].

Figure 50-20-11

Mark the hoses for correct installation. Remove thehoses (Item 1) [Figure 50-20-11]. Install caps and plugs.

Remove the tool bit (Item 2) [Figure 50-20-10]. (SeeTOOL BIT REMOVAL AND INSTALLATION on Page 50-10-11.)

Figure 50-20-12

Install a lift eye (Item 1) and hoist (Item 2) [Figure 50-20-12] on the end of the breaker.




Figure 50-20-13

Raise the hoist and stand the breaker on end [Figure 50-20-13].

Figure 50-20-14

Figure 50-20-15

Remove the snap ring (Item 1) and retainer (Item 2) fromthe 4 bolts (Item 3) [Figure 50-20-14] and (Item 1)[Figure 50-20-15] (2 on each side).

Remove the 4 bolts (Item 1) [Figure 50-20-15].

Installation: Apply anti-seize to the bolt threads. Tightenthe bolts to 300 ft.-lb. (407 N•m) torque.

Figure 50-20-16

Remove the 2 bolts (Item 1) (1 on each side) and spacer(Item 2) [Figure 50-20-16] from the frame.





Figure 50-20-17

Raise the breaker and remove the frame [Figure 50-20-17].

Stand the breaker on the work surface.

NOTE: Do not disassemble or assemble the breakerwhile it is laying on its side.

Nitrogen Chamber Removal And Installation

NOTE: Do not us e an impact wrench to loosen ortighten the tie rods.

Figure 50-20-18

Remove the 4 t ie rods (Item 1) and washers (Item 2)[Figure 50-20-18].

Installation: Apply anti-seize to the threads of the tierods and both sides of the washers.

Tighten the tie rods to 150 ft.-lb. (203 N•m) pretorque.Final tighten to 500 ft.-lb. (678 N•m) torque.

NOTE: If 1 tie rod was broken replace all 4 tie rods.

Figure 50-20-19

Remove the nitrogen chamber (Item 1) [Figure 50-20-19].



Nitrogen Chamber Disassembly And Assembly

Figure 50-20-20

Remove the O-ring (Item 1) [Figure 50-20-20].

Figure 50-20-21


Figure 50-20-22

Remove the charge valve assembly (Item 1) [Figure 50-20-22].

Figure 50-20-23

Remove the O-ring (Item 1) [Figure 50-20-23] from thecharge valve assembly.

Figure 50-20-24




Nitrogen Chamber Disassembly And Assembly (Cont'd)

Figure 50-20-25

Remove the spool (Item 1) and O-rings (Item 2) [Figure50-20-25] from the charge valve and spool.

Piston Removal And Installation

Figure 50-20-26

Install an eye bolt (Item 1) [Figure 50-20-26] on thepiston.

Figure 50-20-27

Install a hoist (Item 1) [Figure 50-20-27] on the eye bolt.

Figure 50-20-28

Raise the hoist slowly to pr event damaging the sealcarrier (Item 1) [Figure 50-20-28].

Use a s oft faced hammer to di slodge the piston ifnecessary.

Remove the piston (Item 2) [Figure 50-20-28].



Piston Removal And Installation (Cont'd)

Figure 50-20-29


NOTE: Check the seal carrier for scratches, damagedseals, back-up washers or oil seals. Check thepiston for wear areas.

NOTE: If the piston is clean or slightly discolored it isan indication that the seal carrier is in goodcondition.

Figure 50-20-30

Check the piston shaft and grooves for wear [Figure 50-20-30].

Figure 50-20-31

Remove the 2 seals (Item 1) [Figure 50-20-31] from theinside of the seal carrier.

Figure 50-20-32

Remove the 3 O-rings (Item 1) and backup ring (Item 2)[Figure 50-20-32] from the outside of the seal carrier.



Piston Sleeve Removal

Use MEL1430 (Hydraulic Breaker Sleeve Puller) for thefollowing procedure:

Figure 50-20-33

Install the puller hooks until the spring loaded pins (Item1) [Figure 50-20-33] are under the sleeve lip.

NOTE: Rotate the puller to be sure the puller pins arein the sleeve holes to prevent damage duringsleeve removal.

Figure 50-20-34

Tighten the nut until the s leeve pulls free from the mainbody [Figure 50-20-34].

Figure 50-20-35

Remove the sleeve [Figure 50-20-35].

Figure 50-20-36

Remove the seals from the sleeve [Figure 50-20-36].



Piston Sleeve Installation

Put the upper section in a press.

Put oil on the O-rings, the outside of the sleeve and theinside of the main body before installation.

Figure 50-20-37

Install the sleeve in the upper section [Figure 50-20-37].

NOTE: Lower sleeve slowly into the upper sectionbeing careful not to damage O-rings.

Figure 50-20-38

Press the sleeve slowly until it seats [Figure 50-20-38].

Valve Removal And Installation

Figure 50-20-39

Remove the 2 fittings (Item 1) [Figure 50-20-39].

Figure 50-20-40

Remove the O-ring (Item 1) [Figure 50-20-40] from thefittings.



Valve Removal And Installation (Cont'd)

Figure 50-20-41

Remove the 8 bolts (Item 1) [Figure 50-20-41] from thevalve manifold.

Installation: Apply anti-seize to the bolt threads andtighten to 70 to 75 ft.-lb. (95 to 102 N•m) torque.

Figure 50-20-42

Remove the valve manifold (Item 1) [Figure 50-20-42].

Figure 50-20-43

Remove the 2 O -rings (Item 1) [Figure 50-20-43] fromthe valve manifold.

Figure 50-20-44

Remove the 2 plugs (Item 1) [Figure 50-20-44].




Figure 50-20-45

Remove the O-ring (Item 1) [Figure 50-20-45] from theplugs.

Figure 50-20-46

Remove the plug (Item 1) [Figure 50-20-46] from thevalve.

Remove the O-ring (Item 1) [Figure 50-20-45] from theplug.

Figure 50-20-47

Install a lift eye (Item 1) [Figure 50-20-47] in the valve.

Figure 50-20-48

Use a block of wood (Item 1) and punch (Item 2) to prythe valve (Item 3) [Figure 50-20-48] from the housing.

Remove the valve.

Installation: Totally submerge the valve in c leanhydraulic fluid. Saturate the v alve bore with cleanhydraulic fluid and with 1 motion, as quickly as possible,install the valve from the container of hydraulic fluid intothe valve bore. Apply additional hydraulic fluid, ifnecessary, to the valve and valve bore during installationto prevent damage to the O-rings.




Figure 50-20-49

Remove the c ap (Item 1) [Figure 50-20-49] from thevalve.

Installation: Hand tighten the cap.

NOTE: Do not overtighten the cap.

Prior to i nstalling the valve in the valve bore, place thevalve in a clean container and add clean hydraulic fluiduntil the valve is completely submerged.

Figure 50-20-50

Remove the O-ring (Item 1) [Figure 50-20-50] from thecap.

Figure 50-20-51

Remove the sleeve (Item 1) [Figure 50-20-51].

Figure 50-20-52





Figure 50-20-53

Remove the s pool (Item 1) [Figure 50-20-53] from thevalve.

Figure 50-20-54

Remove the O-rings (Item 1) and backup rings (Item 2)[Figure 50-20-54].

Installation: Saturate the O-rings and seals duringassembly with clean hydraulic fluid.

Upper Housing Removal And Installation

Figure 50-20-55

Remove the upper housing (Item 1) [Figure 50-20-55].

Figure 50-20-56

Installation: Align the dowel (Item 1) with the hole (Item2) [Figure 50-20-56].



Upper Housing Removal And Installation (Cont'd)

Figure 50-20-57

Remove the plugs (Item 1) [Figure 50-20-57].

Figure 50-20-58

Remove the O-rings (Item 1) [Figure 50-20-58] from theplugs.

Figure 50-20-59

Remove the plugs (Item 1) [Figure 50-20-59].


Figure 50-20-60

Remove the seals (Item 1) [Figure 50-20-60].



Accumulator Removal And Installation

Figure 50-20-61

Remove the snap ring (Item 1) [Figure 50-20-61].

Figure 50-20-62

Remove the retainer lock (Item 1) [Figure 50-20-62].

Figure 50-20-63

Remove the retainer (Item 1) [Figure 50-20-63].

Figure 50-20-64

Remove the cap (Item 1) [Figure 50-20-64].

Installation: Tighten the ca p to 600 ft.-lb. (814 N•m)torque.



Accumulator Removal And Installation (Cont'd)

Figure 50-20-65

Remove the charge valve assembly (Item 1) [Figure 50-20-65] from the cap.

Figure 50-20-66

Remove the O-ring (Item 1) [Figure 50-20-66] from thecharge valve assembly.

Figure 50-20-67


Figure 50-20-68

Remove the spool (Item 1) and O-rings (Item 2) [Figure50-20-69] from the charge valve.



Accumulator Removal And Installation (Cont'd)

Figure 50-20-69

Remove the diaphragm (Item 1) [Figure 50-20-69].

Figure 50-20-70

Remove the screen (Item 1) [Figure 50-20-70].

NOTE: The screen cannot be removed withoutdamage.

Remove the O-ring (not shown), under the screen if thescreen has been removed.

Bushing Removal And Installation

Figure 50-20-71

Figure 50-20-72

Use a hammer and punch to dr ive the roll pins (Item 1)[Figure 50-20-71] in until the roll pins (Item 1) [Figure50-20-72] on th e other side of th e housing can beremoved.

Remove the roll pins (Item 1) [Figure 50-20-72].



Bushing Removal And Installation (Cont'd)

Figure 50-20-73

Remove the retaining pins (Item 1) [Figure 50-20-73].

Figure 50-20-74

Drive the roll pins (Item 1) [Figure 50-20-74] back untilthe end of the roll pins are flush with the housing.

Figure 50-20-75

Figure 50-20-76

Remove the lower bushing (Item 1) [Figure 50-20-75] &[Figure 50-20-76].

Installation: Align the slot (Item 2) with the hole (Item 3)[Figure 50-20-76] in the housing.




Figure 50-20-77

Use a brass or aluminum bushing driver (Item 1) [Figure50-20-77] to remove the upper bushing.

Figure 50-20-78

Remove the upper bushing (Item 1) [Figure 50-20-78].

Figure 50-20-79

Installation: Align the slot (Item 2) [Figure 50-20-78] inthe upper bushing with the hole (Item 1) [Figure 50-20-79] in the housing.



Tool Bit Retaining Pins Removal And Installation

Figure 50-20-80

The pins (Item 1) [Figure 50-20-80] are rubber mountedand hold the breaker tool retaining pin in position.

The pins usually do not need replacing until they arevisibly worn out [Figure 50-20-80].

Wash the breaker parts in clean solvent and dry withcompressed air.

Inspect the p arts for burrs, scratches, cracks or otherdamage. Use fine emery cloth to r emove any burrs orscratches. Replace any parts that are cracked.

Lubricate the parts with clean hydraulic fluid duringassembly. Always install new O -rings and seals duringassembly.

Start Up Procedure

Install the Hydraulic Breaker on th e Bobcat Loader,backhoe or excavator. Connect the quick couplers.




SPECIFICATIONS

• Dimensions are given for loader equipped with standard tires. Dimensions may vary with other types. All dimensionsare shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

• Where applicable, specifications conform to SAE or ISO standards and are subject to change without notice.

WEIGHT

Breaker With Cradle and Tool 470 lb. (210 kg)

Two Position Frame 360 lb. (160 kg)

ENERGY



BLOWS PER MINUTE (Hyd. Oil @ 200°F) (93.3°C) 2570 1000 @ 12.5 GPM (47 L/min.)

3570 1020 @ 15 GPM (57 L/min.)

RECOMMENDED HYDRAULIC OIL FLOW

(For Optimum Performance) 2570 11 to 18 GPM (19 to 68 L/min.)

3570 13 to 18 GPM (26 to 68 L/min.)



BOB-TACH INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5

DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8

DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 60-20-1Breaker Frame Removal And Installation . . . . . . . . . . . . . 60-20-1Bushing Removal And Installation . . . . . . . . . . . . . . . . . . 60-20-11Center Housing Disassembly And Assembly. . . . . . . . . . 60-20-10Center Housing Removal And Installation . . . . . . . . . . . . . 60-20-8Charge Valve Removal And Installation. . . . . . . . . . . . . . . 60-20-5Lower Bumper Removal And Installation. . . . . . . . . . . . . . 60-20-4Lower Housing Disassembly And Assembly . . . . . . . . . . 60-20-14Lower Housing Removal And Installation . . . . . . . . . . . . 60-20-15Nitrogen Chamber Removal And Installation. . . . . . . . . . . 60-20-4Piston Removal And Installation . . . . . . . . . . . . . . . . . . . . 60-20-6Start Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-15Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-20-8Wear Plate Removal And Installation . . . . . . . . . . . . . . . . 60-20-3


HYDRAULIC BREAKER MOUNT INSPECTION . . . . . . . . . . 60-10-6

LOADER MOUNT REMOVAL AND INSTALLATION . . . . . . 60-10-12

NITROGEN CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1Charging The Nitrogen Chamber. . . . . . . . . . . . . . . . . . . . 60-10-3Checking The Nitrogen Chamber Charge Pressure . . . . . 60-10-2Releasing Pressure From The Nitrogen Chamber. . . . . . . 60-10-1


SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

TOOL BIT REMOVAL AND INSTALLATION. . . . . . . . . . . . . . 60-10-9

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-14

X-CHANGE MOUNT REMOVAL AND INSTALLATION . . . . 60-10-13



NITROGEN CHAMBER



The nitrogen chamber charge valve is located on thefront side of the hydraulic breaker.


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Figure 60-10-1


Figure 60-10-2

Using a small shaft, push the charge valve (Item 1)[Figure 60-10-2] in to release the gas pressure.

Install the plug (Item 1) [Figure 60-10-1] in the chargevalve after the pressure has been released.





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Figure 60-10-3


Figure 60-10-4


Figure 60-10-5



Figure 60-10-6



P-29454

1

P-42758

2

1

0.125”(3,2 mm)

P-42759



Checking The Nitrogen Chamber Charge Pressure (Cont'd)

Figure 60-10-7


Figure 60-10-8





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NOTE: When in doubt of nitrogen charge pressure orwhen recharging a hot breaker, release thenitrogen pressure completely and rechargethe piston.

Figure 60-10-9

Block up the breaker so the tool bit (Item 1) [Figure 60-10-9] is not under pressure and is not in contact with thepiston.



Charging The Nitrogen Chamber (Cont’d)

Figure 60-10-10


Figure 60-10-11

Install the adapter (Item 1) [Figure 60-10-11] on th e"Above 100 PSI" side of the charging tool.

Figure 60-10-12

Install the charging tool (Item 1) [Figure 60-10-12] on thebreaker.

Remove the cap (Item 2) [Figure 60-10-12] from thecharging tool.

Figure 60-10-13


Slowly open the valve (Item 3) [Figure 60-10-13] on thenitrogen tank and fill the n itrogen chamber to 230 PSI(15,86 bar). Close the valve on the nitrogen tank.


Figure 60-10-14

Install and tighten the plug (Item 1) [Figure 60-10-14]


BOB-TACH INSPECTION

Figure 60-10-15

Move the Bob-Tach levers to engage the wedges [Figure60-10-15]. The levers and wedges must move freely.

The wedges must extend through the holes in th eattachment mounting frame (Item 1) [Figure 60-10-15].

WARNINGBob-Tach wedges must extend through the holes inattachment. Lever(s) must be fully down and locked.Failure to secure wedges can allow attachment tocome off and cause injury or death.

W-2102-0497

Figure 60-10-16

Figure 60-10-17

The spring loaded wedge (Item 1) [Figure 60-10-15]must contact the lower edge of the hole in the attachment(Item 1) [Figure 60-10-16] and [Figure 60-10-17].

If the wedge does not contact the lower edge of the hole[Figure 60-10-16] and [Figure 60-10-17], theattachment will be loose and can come off the Bob-Tach.

Figure 60-10-18

Inspect the mounting frame on th e attachment and theBob-Tach, linkages and wedges for excessive wear ordamage [Figure 60-10-18]. Replace any parts that aredamaged, bent, or missing. Keep all fasteners tight.

Look for cracked welds.

Lubricate the wedges (See the correct loader ServiceManual for LUBRICATION OF THE BOBCAT LOADER).


HYDRAULIC BREAKER MOUNT INSPECTION

Figure 60-10-19

Inspect the Bob-Tach wedge mounts (Item 1), mountingflange (Item 2) [Figure 60-10-19] and all welds on th emount for wear and damage each time the hydraulicbreaker is removed from the loader.

Figure 60-10-20

Inspect the X-Change™ mount (Item 1) [Figure 60-10-20] and all welds on the mount for wear and damageeach time the hydraulic breaker is removed from theexcavator.



Put the breaker in the vertical position so the tool bit is onthe ground and the tool bit is pushed up inside thebreaker as far as possible.

Figure 60-10-21

Stop the engine and have a second person apply grease(4 to 5 pumps) to the upper end of the tool at the greasefitting (Item 1) [Figure 60-10-21] every 4 to 8 ho urs ofoperation or when the tool bit looks dry.


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DAILY INSPECTION

Figure 60-10-22

Check the 4 wear plate retaining screws (Item 1) [Figure60-10-22] everyday.

Tighten the screws to 250 ft.-lb. (339 N•m) torque.

Figure 60-10-23

The extent of wear in the upper and lower bushings ischecked by installing a new bit ( Item 1) [Figure 60-10-23] in the hydraulic breaker and checking the ga pbetween the lower bushing and the tool bit shaft.

There can be no more than 0.354 in. (9 mm) gapbetween the lower bushing and a new tool bit [Figure 60-10-23].

P-12836

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1


TOOL BIT REMOVAL AND INSTALLATION


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NOTE: Tool bit removal and installation is shown on aloader. The procedure is t he same for anexcavator mounted hydraulic breaker.

Figure 60-10-24

Place the hydraulic breaker in the position shown andinstall blocks (Item 1) [Figure 60-10-24] under thehydraulic breaker.

Fully lower the hydraulic breaker to the blocks.

Stop the engine.

WARNINGBefore you leave the operator's seat:• Lower the lift arms, put the attachment flat on the

ground.• Stop the engine.• Engage the parking brake.• Raise seat bar.• (Foot Pedal Controls) Move pedals until both

lock.• (Mechanical Hand Controls) Move the hand

controls until both lock. The seat bar systemmust lock the lift and tilt controls in neutral whenthe seat bar is u p. Service the system if handcontrols do not lock correctly.

• (Advanced Hand Controls) Move the handcontrols to the NEUTRAL POSITION to make surethat both lift and tilt fu nctions are deactivated.The seat bar system must deactivate the lift andtilt control functions when the seat bar is up.Service the system if hand controls do notdeactivate.

W-2323-0698


TOOL BIT REMOVAL AND INSTALLATION (CONT’D)

Figure 60-10-25

Remove the roll pin (Item 2) [Figure 60-10-24 on Page60-10-9] and (Item 1) [Figure 60-10-25].

Figure 60-10-26

Drive the tool retaining pin (Item 1) [Figure 60-10-26] outthe bottom of the hydraulic breaker.

Figure 60-10-27

Measure the outside diameter of the pin [Figure 60-10-27].

Replace the pin if the measurement is 1.12 in. (28 mm) orless at any location along the length of the pin.

Figure 60-10-28

Remove the tool bit (Item 1) [Figure 60-10-28].


TOOL BIT REMOVAL AND INSTALLATION (CONT’D)

Figure 60-10-29

When installing the tool bit apply grease to the top 10 in.(250 mm) of the tool bit shaft [Figure 60-10-29].

Inspect the tool bit for excessive galling or cracks.

Replace the bit if worn or damaged.


LOADER MOUNT REMOVAL AND INSTALLATION

Figure 60-10-30

Install blocks (Item 1) [Figure 60-10-30] under the bodyof the hydraulic breaker.

Figure 60-10-31

Remove the hydraulic hoses (Item 1) from the hose guide(Item 2) [Figure 60-10-31].

Figure 60-10-32

Install a h oist (Item 1) [Figure 60-10-32] on the loadermount.

Remove the 8 bolts (Item 2 [Figure 60-10-32].

Installation: Tighten the bolts to 475 to 525 ft.-lb. (645 to710 N•m) torque.

Remove the loader mount (Item 3) [Figure 60-10-32]from the hydraulic breaker.


X-CHANGE MOUNT REMOVAL AND INSTALLATION

NOTE: The breaker shown is not the 5060 hydraulicbreaker. The procedure is the same.

Install blocks under the body of the hydraulic breaker.

Figure 60-10-33

Remove the eight bolts (Item 1) [Figure 60-10-33].

Installation: Tighten the bolts to 475 to 525 ft.-lb. (645 to710 N•m) torque.

Remove the X-Change mount (Item 2) [Figure 60-10-33]from the hydraulic breaker.


TROUBLESHOOTING

WARNINGInstructions are necessary before operating orservicing machine. Read and understand theOperation & Maintenance Manual, Handbook andsigns (decals) on machine. Follow warnings andinstructions in the manuals when making repairs,adjustments or servicing. Check for correct functionafter adjustments, repairs or service. Untrainedoperators and f ailure to follow instructions cancause injury or death.

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If the Hydraulic Breaker is not working correctly, check the hydraulic system of the loader or excavator thoroughly beforemaking any repairs on the breaker. Hydraulic Breaker problems can be affected by a hydraulic system that is not operatingto specifications.



Breaker will not fire. No hydraulic flow to the breaker. Check the hydraulic flow to the breaker.


Loader or excavator fluid reservoir is low. Add hydraulic fluid to the reservoir on the loaderor excavator.

Nitrogen chamber pressure incorrect. Charge to required pressure.

Loader or excavator main relief valve set too low. Adjust main relief valve to correct setting.

Loader or excavator hydraulic pump not working. Check flow of hydraulic pump. Repair or replaceas needed.

Breaker runs very slowly or lo wblow energy.



Nitrogen chamber pressure incorrect. Check and fill to correct pressure.

Excessive heat build up. Check oil cooler for debris and air flow.Check loader or excavator relief valve pressure.

Not enough hydraulic flow. Test loader or ex cavator hydraulics for c orrectflow and pressure.


Internal leakage. Check seals and O-rings in the breaker.Check piston sleeve and seal carrier for wear.

Breaker fires erratically. Low fluid level. Add fluid to the reservoir as needed.





Excessive heat buildup. Blank firing. Refer to the hydraulic controls section of theOperation and Maintenance Manual for correctoperating procedure.

Loader or excavator fluid reservoir is low. Add hydraulic fluid to the reservoir on the loaderor excavator.


PARTS IDENTIFICATION (CONT'D)



Breaker Frame Removal And Installation

Remove the tool bit. (See TOOL BIT REMOVAL ANDINSTALLATION on Page 60-10-9.)

Remove the mount frame. (See TOOL BIT REMOVALAND INSTALLATION on Page 60-10-9.)


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Release the pressure from the nitrogen chamber. (SeeReleasing Pressure From The Nitrogen Chamber onPage 60-10-1.)

Figure 60-20-1

Mark the h oses for correct installation. Remove thehoses (Item 1) [Figure 60-20-1].

Figure 60-20-2

Remove the fittings (Item 1) [Figure 60-20-2].

Figure 60-20-3

Remove the bumper (Item 1) [Figure 60-20-3].

Figure 60-20-4

Install a hoist (Item 1) [Figure 60-20-4].




Figure 60-20-5

Raise the hoist and stand the hydraulic breaker on end[Figure 60-20-5].

Figure 60-20-6

Reinstall the hoist as shown in [Figure 60-20-6].

Figure 60-20-7

Install an additional hoist (Item 1) in the th readed holes(Item 2) [Figure 60-20-7] on each side of the breaker.

Figure 60-20-8

Raise the hoist (Item 1) [Figure 60-20-7] & [Figure 60-20-8] and remove the breaker from the housing [Figure60-20-8].

Lower the breaker and remove the hoist.

NOTE: Do not lay the breaker on it's side fordisassembly or assembly.



Wear Plate Removal And Installation

Figure 60-20-9

Figure 60-20-10

Remove the 2 flange bolts (Item 1) [Figure 60-20-9] andnuts (Item 1) [Figure 60-20-10] from the wear plate (frontand rear).

Installation: Install the flange nuts into the wear plate,ensure the flange (Item 1) is flush with the wear plate(Item 2) [Figure 60-20-10].

Install the bolts finger tight.

Use a spanner wrench to hold the nut and tighten thebolts to 250 ft.-lb. (339 N•m) torque.

Figure 60-20-11

Remove the wear plate (Item 1) and shim (if installed)(Item 2) [Figure 60-20-11] from both the front and rear ofthe housing.

Figure 60-20-12

Installation: Install the wear plate with the beveled side(Item 1) [Figure 60-20-12] toward the inside of the frame.

NOTE: The front wear plate and shim have a hole(Item 3) [Figure 60-20-11] that must be alignedwith the hole in the frame (Item 2) [Figure 60-20-9] to provide access to a grease fitting inthe breaker.



Lower Bumper Removal And Installation

Figure 60-20-13

Remove the l ower bumpers (Item 1) [Figure 60-20-13]from the housing.

Nitrogen Chamber Removal And Installation

Make sure the nitrogen chamber is discharged beforedisassembly.

Figure 60-20-14

Remove the nuts (Item 1) [Figure 60-20-14].

NOTE: Do not use an impact wrench to remove orinstall the nuts.

Installation: Apply anti-sieze to the threads of the nuts.Tighten the nuts to 290 ft.-lb. (393 N•m) torque.

Figure 60-20-15

Remove the 4 washers (Item 1) [Figure 60-20-15].

Installation: Apply anti-sieze to both sides of thewashers.

Figure 60-20-16

Remove the tie rods (Item 1) [Figure 60-20-16].

Installation: Clean and inspect the threads of the tierods for burrs or damaged threads. If any of the tie rodswere broken, replace all 4 tie rods.

Apply anti-sieze to the threads of the tie rods. Install thetie rods by hand until they are fully seated in the bottomhousing.

NOTE: Use care to prevent the breaker sections fromfalling after removing the tie rods.



Nitrogen Chamber Removal And Installation (Cont’d)

Figure 60-20-17

Remove the nitrogen chamber (Item 1) [Figure 60-20-17].

Figure 60-20-18

Remove the O-ring (Item 1) [Figure 60-20-18] from thenitrogen chamber.

Charge Valve Removal And Installation

Figure 60-20-19

Remove the charge valves (Item 1) [Figure 60-20-19]from both front and rear of the nitrogen chamber.

Installation: Clean the threads and apply thread lockadhesive (LOCTITE 242).

Figure 60-20-20

Remove the O-rings (Item 1) [Figure 60-20-20] from thecharge valves.



Piston Removal And Installation

Figure 60-20-21

Install a lift eye (Item 1) in the top of the piston, attach ahoist (Item 2) [Figure 60-20-21] to the lift eye.

Figure 60-20-22

Carefully raise the hoist and remove the piston (Item 1)[Figure 60-20-22].

Use a rubber hammer to dislodge the piston if necessary.

Figure 60-20-23

Remove the O-ring (Item 1) [Figure 60-20-23] from theseal carrier.



Piston Removal And Installation (Cont'd)

Figure 60-20-24


Figure 60-20-25

Inspect the piston for burrs, scratches and other damage.Measure the end of the piston. Replace the piston if thedimension [Figure 60-20-25] is 7.40 in. (188 mm) or less.

Figure 60-20-26

Remove the 2 se als (Item 1) and wiper (Item 2) [Figure60-20-26] from the seal carrier.

Figure 60-20-27

Remove the 2 O-rings (Item 1) [Figure 60-20-27].



Center Housing Removal And Installation

Figure 60-20-28

Install a h oist (Item 1) [Figure 60-20-28] on the c enterhousing. Raise the hoist and remove the center housing.

Figure 60-20-29


Valve Removal And Installation

Figure 60-20-30

Remove the O-ring (Item 1) [Figure 60-20-30] from thevalve plug.

Figure 60-20-31

Install a l ift eye (Item 1) [Figure 60-20-31] in the valveplug.




Figure 60-20-32

Use a punch (Item 1) and block of wood (Item 2) to prythe valve plug (Item 3) [Figure 60-20-32] out of thecenter housing.

Remove the valve plug.

Figure 60-20-33

Remove the O-ring (Item 1) [Figure 60-20-33] from thevalve plug.

Figure 60-20-34

Remove the valve (Item 1) [Figure 60-20-34].

Installation: Make sure the valve moves freely in theport.

Figure 60-20-35

Do not remove the valve sleeve (Item 1) [Figure 60-20-35].



Center Housing Disassembly And Assembly

Figure 60-20-36

Remove the 4 plugs (Item 1) [Figure 60-20-36].

Figure 60-20-37


Figure 60-20-38

Remove the seals (Item 1) [Figure 60-20-38].

Figure 60-20-39

Remove the vent (Item 1) [Figure 60-20-39].

Installation: Clean the threads of the vent and applythread lock adhesive (LOCTITE 242).



Center Housing Disassembly And Assembly (Cont'd)

Figure 60-20-40

Remove the O-ring (Item 1) [Figure 60-20-40] from thevent.

Bushing Removal And Installation

Figure 60-20-41

Figure 60-20-42

Use a hammer and punch to dr ive the roll pins (Item 1)[Figure 60-20-41] in until the roll pins (Item 1) [Figure60-20-42] on th e other side of th e housing can beremoved.

Remove the rollpins (Item 1) [Figure 60-20-42].

Figure 60-20-43

Remove the retaining pins (Item 1) [Figure 60-20-43].




Figure 60-20-44

Measure the outside diameter of the pins [Figure 60-20-44], replace the pins if the measurement at any locationalong the length of the pins is .56 inch (14 mm) or less.

Figure 60-20-45

Drive the rollpins (Item 1) [Figure 60-20-45] back untilthe end of the rollpins are flush with the housing.

Figure 60-20-46

Remove the lower bushing (Item 1) [Figure 60-20-46].

Installation: Align the slot (Item 2) with the hole (Item 3)[Figure 60-20-46].

Figure 60-20-47

Measure the inside diameter of the lower bushing .40 in.(10 mm) in from the bottom of the bushing [Figure 60-20-47].

Replace the bushing if the measurement is 3.56 inch (89mm) or more.




Figure 60-20-48

Use a brass or aluminum bushing driver (Item 1) [Figure60-20-48] and hammer to remove the upper bushing.

Figure 60-20-49

Remove the upper bushing (Item 1) [Figure 60-20-49].

NOTE: Early models have a thrust ring located abovethe upper bushing.

Installation: Install the up per bushing (Item 1) with theslot (Item 2) aligned with the hole (Item 3) [Figure 60-20-49].

Figure 60-20-50

Measure the inside diameter of the upper bushing, .40inch (10 mm) in from the top of the bushing [Figure 60-20-50]. Replace the bushing if the measurement is 2.84inch (71 mm) or more.

Figure 60-20-51

On older models measure the thrust ring [Figure 60-20-51] from the wear areas to the bottom of the ring.Replace the ring if the measurement is .30 inch (7,5 mm)or less.




Figure 60-20-52

Measure the inside diameter of the upper bushing[Figure 60-20-52], on older models, midway between theends of th e bushing. Replace the bushing if th emeasurement is 2.84 inch (71 mm) or more.

NOTE: The thrust ring and upper bushing for oldermodels is no longer available. Use the newer1 piece upper bushing for replacement.

Lower Housing Disassembly And Assembly

Figure 60-20-53

Remove the snap rings (Item 1) from the bolts (Item 2)[Figure 60-20-53] on both sides of the lower housing.

Figure 60-20-54

Remove the retainers (Item 1) [Figure 60-20-54].

Figure 60-20-55

Remove the bolts (Item 1) [Figure 60-20-55] (bothsides).

Installation: Tighten the bolts to 600 ft.-lb. (813 N•m)torque.



Lower Housing Removal And Installation

Figure 60-20-56

Remove the stop blocks (Item 1) [Figure 60-20-56] (bothsides).

Wash the breaker parts in clean solvent and dry withcompressed air.

Inspect the p arts for burrs, scratches, cracks or otherdamage. Use fine emery cloth to r emove any burrs orscratches. replace any parts that are cracked.

Lubricate the parts with clean hydraulic fluid duringassembly. Always install new O -rings and seals duringassembly.

Start Up Procedure

Install the Hydraulic Breaker on th e Bobcat Loader,backhoe or excavator. Connect the quick couplers.




SPECIFICATIONS

• All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.• Where applicable, specifications conform to SAE or ISO standards and are subject to change without notice.

WEIGHT

Breaker With Tool; Loader 940 lb. (426 kg)

Breaker With Tool; Excavator 780 lb. (354 kg)

ENERGY 750 ft.-lb. (1017 N•m) Class

BLOWS PER MINUTE (Hyd. oil @ 200°F [93.3°C]) 800 to 900 @ 18.6 GPM (69.9 Lpm)

RECOMMENDED HYDRAULIC FLOW 15 to 22 GPM (57 to 83 L/min.)




DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 70-20-1Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-8Lower Body Bushings Removal . . . . . . . . . . . . . . . . . . . . . 70-20-6Main Body Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-5Manifold Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-3Nitrogen Chamber Disassembly and Assembly. . . . . . . . . 70-20-6Nitrogen Chamber Removal . . . . . . . . . . . . . . . . . . . . . . . 70-20-3Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-4Seals and Poly-Pak Installation . . . . . . . . . . . . . . . . . . . . . 70-20-9Start Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-10Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-4



NITROGEN CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1Charging the High Pressure Accumulator . . . . . . . . . . . . . 70-10-2Charging the Low Pressure Accumulator . . . . . . . . . . . . . 70-10-5Charging the Nitrogen Chamber . . . . . . . . . . . . . . . . . . . . 70-10-7Checking The High Pressure Accumulator Pressure. . . . . 70-10-1Checking The Low Pressure Accumulator Pressure . . . . . 70-10-3Checking The Nitrogen Chamber Charge Pressure . . . . . 70-10-6

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1




NITROGEN CHAMBER

Checking The High Pressure Accumulator Pressure


Figure 70-10-1


Figure 70-10-2


Figure 70-10-3



Figure 70-10-4



B-7047

P18084

1

P-42758

2

1

0.125”(3,2 mm)

P-42759




Figure 70-10-5


Figure 70-10-6



Charging the High Pressure Accumulator

Use charging kit (P/N 6568037) to charge the hydraulicbreaker.


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Figure 70-10-7


Figure 70-10-8


B-23394

1

B-23394

1



Charging The High Pressure Accumulator Pressure (Cont’d)

Figure 70-10-9


Figure 70-10-10


Connect the n itrogen hose to the high pressure side ofthe charging tool [Figure 70-10-9].

SLOWLY open the valve at the nitrogen tank and fill thehigh pressure accumulator to 850 PSI (58,6 bar) [Figure70-10-9]. DO NOT EXCEED THIS PRESSURE

Close the valve at the nitrogen tank when accumulatorpressure is reached.

Checking The Low Pressure Accumulator Pressure


Figure 70-10-11


Figure 70-10-12


B-7049

B-7196


Connect This EndTo High Pressure

Accumulator &Nitrogen Chamber

B-7078

P18084

1



Checking The Low Pressure Accumulator Pressure (Cont’d)

Figure 70-10-13



Figure 70-10-14



Figure 70-10-15

Tighten the a dapter (Item 1) [Figure 70-10-15] on th ebreaker.

Figure 70-10-16



P-42758

2

1

0.125”(3,2 mm)

P-42759

B-23393

1

B-23393

1



Charging the Low Pressure Accumulator

The low pressure accumulator is located on the front sideof the main body.

Remove the charge valve plug.

Figure 70-10-17


Figure 70-10-18

NOTE: Use the low pressure side of the charging tool[Figure 70-10-18].


Figure 70-10-19

Connect the nitrogen hose to the low pressure side of thecharging tool [Figure 70-10-19].

SLOWLY open the valve at the nitrogen tank until the gasescapes from the relief valve (Item 1) [Figure 70-10-19]on the charging tool.

Close the valve at the tank. Disconnect the nitrogen hoseand charging tool.


B-7196


Connect This End To LowPressure Accumulator

B-7077





Figure 70-10-20


Figure 70-10-21


Figure 70-10-22



Figure 70-10-23



B-8887

1

P18084

1

P-42758

2

1

0.125”(3,2 mm)

P-42759




Figure 70-10-24


Figure 70-10-25


NOTE: The correct charge pressure is 500 PSI (34,48bar)


The nitrogen chamber charge valve is located on theback side of the breaker above the hydraulic inlet andoutlet ports.

Figure 70-10-26

Remove the charge valve plug (Item 1) [Figure 70-10-26].

Using a small shaft push the valve inward to release thegas pressure.

Figure 70-10-27


B-23395

1

B-23395

1



Charging the Nitrogen Chamber (Cont'd)

Figure 70-10-28


Connect the n itrogen hose to the high pressure side ofthe charging tool.

SLOWLY open the valve at the nitrogen tank and fill thenitrogen chamber.

Fill the chamber to 500 PSI (34,48 bar)


Disconnect the hose and the charging tool.


B-7196






Figure 70-10-29


Apply grease (4 to 5 pumps) to the upper end of the toolat the grease fitting (Item 1) [Figure 70-10-30] every 4 to8 hours of operation, or when the tool bit looks dry.



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Figure 70-10-30

Check the mounting bolts (Item 1) [Figure 70-10-30]daily.

Tighten the bolts to 900 ft.-lb. (1200 N•m) torque.

1




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Breaker will not fire. Loader hydraulic pump not working. Check flow of loader hydraulic pump.Repair or replace as needed.

Loader fluid reservoir is low. Add hydraulic fluid to the fluid reservoir on theloader.


Nitrogen chamber not at correct pressure. Charge to required pressure of 500 PSI (3448bar).

Damaged electrical connection to brea kervalve. (Backhoe mounted unit only.)



Breaker runs very slowly. Loader hydraulic pump not working. Check flow of loader hydraulic pump.Repair and replace as needed.

Not enough hydraulic flow. Test loader hydraulics for correct flow andpressure.

Excessive heat build up. Check oil cooler for debris and air flow.Check loader relief valve pressure.


Nitrogen chamber over-pressurized. Remove gas and refill to correct pressure of500 PSI (3448 bar) maximum.

Internal leakage. Check seals and O-rings in the breaker.

Breaker fires erratically. Loader hydraulic pump not working. Check flow of loader hydraulic pump.Repair or replace as needed.





Damaged electrical connection to brea kervalve. (Backhoe mounted unit only.)





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The tools listed will be nee ded to do the fol lowingprocedure:

6568037 - Charging KitOEM6106 - Torque MultiplierMEL1306 - Hex Bit DriverMEL1309 - Lower Bearing Removal PlateMEL1310 - Remove HandleRead and understand the complete disassembly andassembly procedure before beginning the operation.

Before you remove the Breaker from the Bob-Tachframe, have a second person assist with the following:

Loosen the 4 main body bolts. DO NOT REMOVE THEBOLTS.


Remove the 3/ 16 in. hex plug at the accumulatorchamber. Release the nitrogen gas from the chamber.

Figure 70-20-1

Loosen the eight bolts which fasten the b reaker to th eframe [Figure 70-20-1]. DO NOT REMOVE THE BOLTS.


Figure 70-20-2

Loosen the hex bolt (use a 2-1/16 inch socket) on the topof the nitrogen gas chamber [Figure 70-20-2]. DO NOTREMOVE THE BOLT.

Figure 70-20-3

Install the eye bolt in the bo lt at th e top of th e breaker[Figure 70-20-3].

Install a chain hoist on the hydraulic breaker.



Figure 70-20-4

Remove the mounting pins [Figure 70-20-4].

Lift the breaker from the Bob-Tach frame. Put the breakerin a vertical position in a stand.

Install a chain hoist on the frame of the breaker.

Figure 70-20-5

Remove the eight bolts [Figure 70-20-5].



Remove the frame from the breaker.

Figure 70-20-6

Remove the hydraulic hoses from the hydraulic breaker[Figure 70-20-6].

Figure 70-20-7

Remove the 3/1 6 inch hex plug at the accumulatorchamber. Put a phillips screwdriver in the hex plug holeand release the nitrogen gas from the chamber [Figure70-20-7].



Nitrogen Chamber Removal

Figure 70-20-8

Remove the 4 main socket head bolts [Figure 70-20-8].


NOTE: When the 4 main bolts are removed, thenitrogen chamber, main body and lower bodyare independent of each other. Be careful soparts do not fall.

Assembly: Put anti-sieze lubricant on the bolt threadsand washers. Tighten to 600 ft.-lb. (814 N•m) torque.

Figure 70-20-9

Use a cha in hoist and remove the nitrogen chamber[Figure 70-20-9].

Manifold Removal

Figure 70-20-10

Lift the manifold assembly from the main body [Figure70-20-10].



Piston Removal

Figure 70-20-11

Remove the pi ston from the main body [Figure 70-20-11].

Valve Removal

Figure 70-20-12

Remove the valve with the push pins [Figure 70-20-12].

Assembly: Align the timing marks on the valve and valvecylinder [Figure 70-20-12].

Remove the push pins and inspect for wear [Figure 70-20-12].

Figure 70-20-13

NOTE: The manifold will not s eat correctly if thetiming marks (Item 1) [Figure 70-20-13] are notin alignment.

Figure 70-20-14

Remove the valve cylinder with the valve seat from themain body [Figure 70-20-14].



Valve Removal (Cont'd)

Figure 70-20-15

Remove the valve cylinder from the valve seat [Figure70-20-15].

NOTE: The valve cylinder and valve seat are indexedby a roll pin (Item 1) [Figure 70-20-15].

Main Body Removal

Figure 70-20-16

Remove both disc springs from the main body [Figure70-20-16].

Figure 70-20-17

Assembly: Install the disc springs with the convexsurface facing away from the lower bearing [Figure 70-20-17].

Install the socket head bolts into the body at bothaccumulator sides.

Figure 70-20-18

Install a chain hoist and lift the main body from the lowerbody [Figure 70-20-18].



Main Body Removal (Cont'd)

Figure 70-20-19

Turn 2 b olts, equally into the main body to r emove thelower bearing [Figure 70-20-19].

Lower Body Bushings Removal

Figure 70-20-20

NOTE: A bead of weld may have to be put around theI.D. of the tool (Item 1) [Figure 70-20-20]bearing for easier removal.

Disassembly of the lower body internal parts requires apress for removal of the tool bearing (Item 1) and toolstop (Item 2) [Figure 70-20-20]. Replace the parts asneeded.

MEL1309 - Lower Bearing Removal PlateMEL1310 - Remover HandleRemove all the O-rings, seals and Poly-Pak seals fromthe breaker parts.

Clean in solvent and air dry them.

Inspect all the parts for scratches, wear or damage.Replace the parts as needed.

Nitrogen Chamber Disassembly and Assembly

Disassembly: Remove the large bolt and the top plate.

Figure 70-20-21



Turn the chamber over, install the large bolt. Use a softhammer and hit the bolt to remove the diaphragm (Item2) [Figure 70-20-21] and screen.

Remove the O-ring from the s creen and inspect thediaphragm for wear.

Figure 70-20-22

Assembly: Lubricate the sealing surface of the nitrogenchamber. Install the diaphragm [Figure 70-20-22].



Nitrogen Chamber Disassembly and Assembly (Cont'd)

Figure 70-20-23

Install the screen [Figure 70-20-23].

Figure 70-20-24

Install the O-ring on the screen [Figure 70-20-24].

Figure 70-20-25

Install the O-rings (Item 1) [Figure 70-20-25] on the topand bottom of the chamber.

Install the top plate and bolt. The bolt must be tightenedafter the chamber is installed on the main body.

Tighten the bolt to 600 ft.-lb. (814 N•m) torque.

Figure 70-20-26

Install the charge valve and tighten to 80 ft.-lb. (108 N•m)torque [Figure 70-20-26].



Accumulator

Figure 70-20-27

Remove the hex socket bolts at the accumulatorchamber [Figure 70-20-27].


Disassembly: Put the accumulator body in a vise.

Figure 70-20-28

Loosen the accumulator plug [Figure 70-20-28].

Remove the accumulator plug and diaphragm [Figure70-20-28].

Inspect the diaphragm for wear and replace as needed.

Figure 70-20-29

Remove the charge valve [Figure 70-20-29].


Figure 70-20-30

Assembly: Install the diaphragm in the accumulator[Figure 70-20-30].



Accumulator (Cont'd)

Figure 70-20-31

Put the accumulator body in a vise [Figure 70-20-31].

Put approximately 1 teaspoon of clean oil in the cover.

Put the plug into the body and tighten to 600 ft.-lb. (814N•m) torque.

Install the charge valve and tighten to 80 ft.-lb. (108 N•m)torque.

Seals and Poly-Pak Installation

NOTE: Heating the Poly-Pak to 1 50°F (68°C) in hotwater will ease the installation.

Figure 70-20-32

When installing the wiper seal (Item 1) [Figure 70-20-32]into the lower body, make sure the lip is facing down[Figure 70-20-32].

Figure 70-20-33

Install the Poly-Pak into the lower bearing. Make sure theseal lip faces up (toward the nitrogen chamber) [Figure70-20-33].

NOTE: Do not use a screwdriver or any sharp tool forinstallation of the Poly-Pak.

Figure 70-20-34

When installing the Poly-Pak into the groove at the valveseat, make sure the lip faces down [Figure 70-20-34].



Seals and Poly-Pak Installation (Cont'd)

Install the Poly-Pak on the valve cylinder as follows:

Figure 70-20-35

Install the smaller seal (5.81 inch O.D.) in the lowergroove [Figure 70-20-35].

Install the larger seal (5.94 inch O.D.) in the upper groove[Figure 70-20-35].

The open side of the seals must face toward each other[Figure 70-20-35].

Start Up Procedure

Install the Hydraulic Breaker on the Bobcat (or backhoe).Connect the quick couplers.

Start the engine. Engage the auxiliary hydraulics, andraise the tool off the work object.

Run the breaker above the object in the Blank Fireposition (See Hydraulic/Hydrostatic Flow Chart BlankFiring Operation) to help remove the air from the breaker.

It may take several minutes for air to be removed fromthe system.


SPECIFICATIONS

WEIGHT

Breaker W/Moil & Breaker Mount 627 lb. (285 kg)

Bob-Tach Adapter 441 lb. (200 kg)



BLOWS PER MINUTE 900 @ 25 GPM (95 L/min.)

HYDRAULIC FLOW REQUIRED 25 GPM (95 L/min.)


MOIL DIAMETER 2.75 in. (69,8 mm)

MOIl WORKING LENGTH 18.0 in. (457,2 mm)



CHECKING MOUNTING BOLT TORQUE . . . . . . . . . . . . . . . 80-10-6

DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 80-20-1Breaker Frame Removal and Installation. . . . . . . . . . . . . . 80-20-1Bumper Pad Removal and Installation. . . . . . . . . . . . . . . 80-20-10Bushing Removal and Installation . . . . . . . . . . . . . . . . . . 80-20-10Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-4Piston and Seal Carrier Installation . . . . . . . . . . . . . . . . . 80-20-13Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-8Seal Carrier Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-6Seal Carrier Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-7Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-12Sleeve Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-9Tie Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-14Tool Retaining Pin Removal and Installation . . . . . . . . . . 80-20-12Upper Body Removal and Installation . . . . . . . . . . . . . . . . 80-20-5



NITROGEN CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1Checking The Nitrogen Chamber Charge Pressure . . . . . 80-10-3Charging The Nitrogen Chamber. . . . . . . . . . . . . . . . . . . . 80-10-2Releasing Pressure From The Nitrogen Chamber. . . . . . . 80-10-1

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1




NITROGEN CHAMBER


The nitrogen chamber charge valve is located on thefront side of the hydraulic breaker.


W-2019-1285


Remove the plug from the charge valve.

Figure 80-10-1

Using a s mall shaft push the charge valve inward torelease the gas pressure [Figure 80-10-1].






Position the breaker horizontal, charging valve will befacing up. The tool must not touch the piston duringcharging.

Use kit (P/N 6568037) to charge the hydraulic breaker.

Figure 80-10-2

Figure 80-10-3

Using the adapter (Item 1) [Figure 80-10-2], install thecharging tool (Item 2) [Figure 80-10-3] in the chargevalve.

NOTE: Be sure to use the correct side of the chargingtool [Figure 80-10-3].


SLOWLY open the charging valve on th e nitrogen tankand fill the 6560 breaker nitrogen chamber to 35 0 PSI(24,14 bar).




B-7196



350 PSI (24,14 bar)

1


NITROGEN CHAMBER (CONT'D)



W-2019-1285


NOTE: The hydraulic breaker shown is not the 6560.The procedure is the same.

Figure 80-10-4


Figure 80-10-5


Figure 80-10-6



Figure 80-10-7



P-29454

1

P-42758

2

1

0.125”(3,2 mm)

P-42759


NITROGEN CHAMBER (CONT'D)

Checking The Nitrogen Chamber Charge Pressure (Cont'd)

Figure 80-10-8


Figure 80-10-9



1



Put the breaker in the vertical position so the tool bit is onthe ground and the tool bit is pushed up inside thebreaker as far as possible.

Figure 80-10-10


Apply grease (4 to 5 pumps) to the upper end of the toolat the grease fitting (Item 1) [Figure 80-10-10] every 4 to8 hours on operation or when the tool bit looks dry.



I-2053-0589

P-10520

1



Figure 80-10-11

Check the 4 wear plate retaining screws (Item 1) [Figure80-10-11] everyday.

Tighten the screws to 250 ft.-lb. (339 N•m) torque.

P-10520

1




W-2003-0797




Breaker will not fire. Loader or excavator main relief valve set toolow.




Loader or excavator hydraulic pump notworking.

Check flow of loader hydraulic pump.Repair or replace as needed.


Damaged electrical connection to br eakervalve (backhoe mounted unit only).



Breaker runs very slowlyor blow per minutereducing.

Loader or excavator main relief valve set toolow.


Not enough hydraulic flow. Test loader or excavator hydraulics for correctflow and pressure.

Excessive heat build up. Check oil cooler for debris and air flow. Checkloader or excavator relief valve pressure.


Nitrogen chamber over-pressurized or loss ofpressure.

Remove gas and refill to correct pressure.

Internal leakage. Check seals and O-rings in the breaker.Check piston, sleeve and seal carrier for wear.





Breaker fires erratically. Loader or excavator main relief valve set toolow.






Damaged electrical connection to br eakervalve (backhoe mounted unit only).


Excessive heat build up. Blank firing. Refer to the hydraulic controls section of theOM for correct operating procedure.


PARTS IDENTIFICATION (CONT’D)





W-2019-1285

NOTE: Before removing the breaker from the framerelease the nitrogen pressure from thebreaker. (See Releasing Pressure From TheNitrogen Chamber on Page 80-10-1.)

Remove the hydraulic breaker from the loader orexcavator. (See the Operation & Maintenance Manual forthe procedure.)

Lay the hydraulic breaker and frame on the floor.

Figure 80-20-1

Figure 80-20-2

Use a hoist and chains to support the weight of the Bob-Tach mounting frame [Figure 80-20-1] or the excavatorX-Change [Figure 80-20-2]. Remove the eight bolts(Item 1) [Figure 80-20-1] or [Figure 80-20-2] andremove the mounting frame or X-Change.

Installation: Apply liquid adhesive (LOCTITE #242) tothe threads. Tighten the bolts and nuts to 474 to 525 ft.-lb. (645 to 710 N•m) torque.

Remove the hydraulic hoses from the breaker fittings.

Figure 80-20-3

Remove the upper bumper (Item 1) [Figure 80-20-3].




Figure 80-20-4

Remove the fi ttings (Item 1) [Figure 80-20-4], install aneyelet in the top of the breaker, and use a hoist to slidethe breaker from the frame.



Shuttle Valve

NOTE: Check the machined surfaces of the shuttlevalve for scratches or wear. The shuttle valveparts are not replaceable.

NOTE: Apply hydraulic oil to the O-rings andmachined surfaces during assembly.

Figure 80-20-5

Remove the bolts from the shuttle valve cap (Item 1)[Figure 80-20-5].

Installation: Tighten the bo lts to 85 ft.-lb. (115 N•m)torque.

Figure 80-20-6

Rotate the cap until 1 edge (Item 1) [Figure 80-20-6]clears the upper body.



Tap on the cap to remove it from the bore.

Shuttle Valve (Cont’d)

Figure 80-20-7

Remove and replace the O-ring (Item 1) [Figure 80-20-7]from the cap.

Check the cap machined surfaces for scratches or wear.

Figure 80-20-8

Remove the shuttle valve (Item 1) [Figure 80-20-8] fromthe shuttle valve sleeve.

A light scuffing or burnishing of the surfaces is normal.Check for cracks and see that the spool moves freely inthe valve sleeve.


DO NOT break or buff the sharp edges of the valvesleeve or valve spool. This will cause the valve tomalfunction.

Figure 80-20-9

The sleeve (Item 1) [Figure 80-20-9] is a press fit. Do notremove it unless it is damaged.

Use MEL1545 to remove it from the housing.

If the sleeve was removed, install the replacement sleeveas follows:

Freeze the s leeve for 2 hours in liquid CO2, then installthe sleeve into the main body. The prongs of the sleevemust contact the end face of the bore [Figure 80-20-9].

Allow the sleeve to warm before continuing.



Charge Valve

Figure 80-20-10

Remove the p lug (Item 1) [Figure 80-20-10] to gainaccess to the charge valve.

Figure 80-20-11

Use a slotted screwdriver to remove the charge valve(Item 1) [Figure 80-20-11].

Figure 80-20-12

Inspect the charge valve for cracks, scratches, or wear[Figure 80-20-12].

Replace the O-rings (Items 1 & 2) [Figure 80-20-12] onthe charge valve assembly.



Upper Body Removal and Installation

Figure 80-20-13

Remove the protective vinyl caps (Item 1) from the tie rodnuts (Item 2) [Figure 80-20-13].

Figure 80-20-14

Remove the 4 tie rod nuts (Item 1) and lock plates (Item2) [Figure 80-20-14].

NOTE: Do not use an impact wrench to remove the tierod nuts.

Figure 80-20-15

Use MEL1544 to remove the tie rods (Item 1) [Figure 80-20-15].

Lift the tie rods from the upper body.

Figure 80-20-16

Remove the nuts from the slots in the lower body [Figure80-20-16].



Upper Body Removal and Installation (Cont’d)

Figure 80-20-17

Install a lifting eyelet (Item 1) [Figure 80-20-17] in the nutof the upper body.

Use an overhead hoist to lift the upper body from thelower body [Figure 80-20-17].

NOTE: Use a rubber hammer to strike the bumpers(Item 2) [Figure 80-20-17] if sections sticktogether.

Inspect the upper body for cracks or other damage (Seeyour dealer for repair or replacement.)

NOTE: The seal carrier and piston sleeve may b elifted out with the upper body. If this happens,the parts may fall out. Use caution to protectthese parts when sections are separated.

Lay the upper body on its side.

If the piston sleeve lifts out with the upper body it can beremoved by pulling it from the body.

Seal Carrier Removal

If the seal carrier stays in the upper body, use MEL1542and a slide hammer to remove the carrier.

Figure 80-20-18

Position the tool (Item 1) [Figure 80-20-18] to passthrough the seal carrier.

Figure 80-20-19

Seat the tool securely against the seal carrier flange anduse the slide hammer to remove the carrier [Figure 80-20-19].



Seal Carrier Repair

Check the seal carrier and piston for wear, galling, orcracks .

A light scuffing or burnishing or surfaces is normal.

Figure 80-20-20

Remove the O-rings from the seal carrier [Figure 80-20-20].

Figure 80-20-21

Remove the quad ring (Item 1) and the seal (Item 2)[Figure 80-20-21] from inside the seal carrier.

Remove small burrs with 220 grit emery cloth.

Lubricate the seal and seal carrier with hydraulic oil.

Figure 80-20-22

Position the oil seal on the tool MEL1033 [Figure 80-20-22]. Lips must face away from the tool.

Figure 80-20-23

Install the seal with the lips DOWN [Figure 80-20-23].



Piston Removal

Figure 80-20-24

Install a lifting eye (Item 1) [Figure 80-20-24] in thepiston and us e the hoist to r emove the piston from thesleeve.

Figure 80-20-25

Check the piston for wear, galling, or cracks [Figure 80-20-25].

Figure 80-20-26

Check the condition of the annual groves (Item 1)[Figure 80-20-26].

A light scuffing or burnishing of surfaces is normal.



Sleeve Removal

Figure 80-20-27

If the sleeve stays in the lower body use MEL1541 toremove the sleeve. Install the slide hammer (Item 1)[Figure 80-20-27] on the tool.

Align the tool with the holes in the sleeve and install thepin (Item 2) [Figure 80-20-27] through the sleeve andtool.

Use the slide hammer until the sleeve is free from thelower body.

Check the s leeve for scratches, damaged O-rings andseals.

A light scuffing or burnishing of the surfaces is normal.Check for cracks and see that the piston moves freely inthe sleeve.


Figure 80-20-28

Remove the O-rings from the sleeve [Figure 80-20-28].

Installation: Apply grease to the O-rings before installingthem on the sleeve.

Figure 80-20-29

Remove the wiper seal (Item 1) and the rod seal (Item 2)[Figure 80-20-29] from the sleeve.

Installation: Put grease on the rod seal (Item 2) [Figure80-20-29]. Install the seal with the lips up.

Installation: Put grease on th e wiper seal (Item 1)[Figure 80-20-29]. Install the seal with the beveled sidedown.



Bumper Pad Removal and Installation

NOTE: Do not remove the bumper pads unless theyare damaged.

Figure 80-20-30

The pins (Item 1) [Figure 80-20-30] can be removed forrepair.

Install a bolt in the threaded hole of the bumper pad pins(Item 1) [Figure 80-20-30]. Use the bolt to pull the pinsfrom the lower body.

Installation: Install the bumper pads (Item 2) [Figure 80-20-30] so the angle is facing up. Install the pins so thethreaded hole is facing up.

Bushing Removal and Installation

Before the lower body is lifted from the stand, the pointretaining pin can be removed and the point will remain inthe stand.

Figure 80-20-31

Install chains through the tie rod holes. Use a bolt (Item1) [Figure 80-20-31] to connect the chains together.

Use an overhead hoist to lift the lower body.

Lay the lower body on it's side.



Bushing Removal and Installation (Cont'd)

Check the bushings for cracks or excessive galling.Check tool bit for metal shavings

Install a new tool bit into the bushings and check the sidemovement. There should be no more than 1/4 inch (6.4mm) side movement at the extreme end of the tool point.

Replace the bushings if out of tolerance.

Clean the lower body before service.

Figure 80-20-32

Install a punch (Item 1) [Figure 80-20-32] through the rollpin. Use a hammer to remove the roll pin and retainingpin.

Repeat the procedure for both roll pins and retainingpins.

Figure 80-20-33

The roll pins and retaining pins fit o nly 1 s et of holes(Item 1) [Figure 80-20-33].

Figure 80-20-34

Remove the bushings from the lower section [Figure 80-20-34].

Clean the bushings and inside of the lower body.

Check the condition of the bushings and the inside of thelower body.

Align the retaining pin grooves (Item 1) [Figure 80-20-34] in the bushings with the holes in the lower body.

Install the bushings, retaining pins, and roll pins.

Drive the roll pins flush with the outside surface of th elower body.



Tool Retaining Pin Removal and Installation

Figure 80-20-35

Remove the pl ugs (Item 1) [Figure 80-20-35] from thelower body.

Installation: Apply LOCTITE #242 on th e plug threadsduring assembly. Tighten the plugs to 150 ft.-lb. (203N•m) torque.

Figure 80-20-36

Pry the retainer rubbers and retaining pins from the lowerbody [Figure 80-20-36].

Clean the holes and threads of de bris before installingrubbers and reataining pins.

Sleeve Installation

Lubricate the lower body bore and all sleeve surfaceswith hydraulic oil before installation.

Figure 80-20-37

Use MEL1543 and a hammer to install the sleeve in thelower body bore [Figure 80-20-37].



Piston and Seal Carrier Installation

Figure 80-20-38

Be sure to install new O-rings (Item 1) [Figure 80-20-38]in the lower body before installing the upper body.

Figure 80-20-39

Lubricate the piston (Item 1) [Figure 80-20-39] andinstall it in the sleeve.

Lubricate the seal carrier (Item 2) [Figure 80-20-39]before installing it on the piston.

Use MEL1543 (Item 3) [Figure 80-20-39] and a hammerto install the seal carrier on the piston.

Install the upper body. (See Upper Body Removal andInstallation on Page 80-10-5.) Align the dowel pin (Item4) [Figure 80-20-39] with the mating hole in the upperbody during assembly.



Tie Rod Installation

Apply anti-sieze to the following locations duringassembly:

Thread surfaces of tie rodsTop and bottom surfaces of the nutsTie rod nutsTop and bottom surfaces of the lock plates

Figure 80-20-40

Install the nuts in the slots of the lower body [Figure 80-20-40].

Figure 80-20-41

Use Mel1544 to install the tie rods (Item 1) [Figure 80-20-41] in the upper body.

Screw the 4 tie rods into the nuts finger tight. Loosen thetie rods 1/4 turn.

Figure 80-20-42

Install the 4 lock plates (Item 1) [Figure 80-20-42] on thetie rods.

If necessary loosen the tie rods to align the lock plates.

Install the tie rod nuts (Item 2) [Figure 80-20-42].

In a cr ossing pattern, tighten the tie rods to 200 f t.-lb.(271 N•m) torque, then to 650 ft.-lb. (881 N•m) torque.

Figure 80-20-43

Install the vinyl caps (Item 1) [Figure 80-20-43] on the tierod nuts.

Charge the nitrogen chamber. (See Charging TheNitrogen Chamber on Page 80-10-2.)


SPECIFICATIONS

WEIGHT

Breaker With Tool 850 lb. (385 kg)

ENERGY 875 ft.-lb. (1186 J) Class

BLOWS PER MINUTE 600 to 1000

HYDRAULIC PRESSURE 1700 to 1900 PSI (117 to 131 bar)

RECOMMENDED HYDRAULIC FLOW 16 to 24 GPM (60 to 90 L/min.)

RECOMMENDED SYSTEM RELIEF 2500 PSI (172.4 bar)


Revision No: HB-1Date: 5 September 1997Product: Bobcat AttachmentModel: Hydraulic BreakerManual No: 6720280 (9-96)

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PARTS MANAGER

SERVICE MANAGER XSALES MANAGER

SERVICE MANUALREVISION

Insert This Sheet With The Below Listed Manual For Future Reference.NOTICE

The following sections are a revision to the above Service Manual.

Take out the existing sections and put in the new sections as listed below:

TAKE OUT PUT IN

i, ii i (Revised Sept. 97), iiiii, iv iii (Revised Sept. 97), iv

ix (Revised Sept. 97), x (Revised Sept. 97)1-1, 1-2 1-1 (Revised Sept. 97), 1-21-5, 1-6 1-5, 1-6 (Revised Sept. 97)1-7, 1-8 1-7, 1-8 (Revised Sept. 97)1-9, 1-10 1-9, 1-10 (Revised Sept. 97)

1-11 (Added Sept. 97), 1-12 (Revised Sept. 97)3-5, 3-6 3-5, 3-6 (Revised Sept. 97)3-7, 3-8 3-7 (Revised Sept. 97), 3-83-9, 3-10 3-9 (Revised Sept. 97), 3-10

Hydraulic/Hydrostatic Flow Chart2560

(Printed September 1993)

Hydraulic/Hydrostatic Flow Chart1560, 2560/3560, 6560

(Printed September 1997)5-5, 5-6 5-5, 5-6 (Revised Sept. 975-9, 5-10 5-9 (Revised Sept. 97), 5-105-11, 5-12 5-11 (Revised Sept. 97), 5-126-13, 6-14 6-13 (Revised Sept. 97), 6-14Section 7 7-1 thru 7-8 (Revised Sept. 97)

7-9 thru 7-18 (Revised Sept. 97)Section 8 (Revised Sept. 97)

Printed in U.S.A.

Revision No: HB-2Date: 7 March 2001Product: Bobcat AttachmentModel: 1250, 1560, 2500/3500, 2560/3560, 5500 & 6560Manual No: 6720280 (9-96)

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TAKE OUT PUT IN REVISION DESCRIPTION

4-1 - 4-14 4-1 - 4-14 Revised seal identification information. 2500/3500seals are no longer identified by colors, seals are nowpackaged in the seal kit with identification numbers.

Printed in U.S.A.

Revision No: HB-3Date: 18 February 2002Product: Bobcat AttachmentModel: 1250, 1560, 2500/3500, 2560/3560, 2570/3570, 5060 5500 & 6560Manual No: 6720280 (9-96)

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TAKE OUT PUT IN REVISION DESCRIPTION

ALPHABETICAL INDEX ALPHABETICAL INDEX Revised pageiii, iv iii, iv Revised contents page

ix thru xii ix thru xii Added models 2570/3570 and 50601-1, 1-2 1-1, 1-2 Revised contents page

1-9 thru 1-12 1-9 thru 1-30 Added models 2570/3570 and 50606-1 thru 6-14 6-1 thru 6-26 Added models 2570/35707-1 thru 7-18 7-1 thru 7-20 Added model 50608-1 thru 8-8 8-1 thru 8-14 Move model 5500 to section 8

9-1 thru 9-18 Moved model 6560 to section 9

Printed in U.S.A.

Revision No: Breaker - 4Date: 19 October 2005Product: Bobcat AttachmentModel: Hydraulic BreakerManual No: 6720280 (10-04)

Please remove the existing Hydraulic / Hydrostatic Flow Charts from Hydraulic Breaker Service Manual (P/N6720280) Dated 9-96 and save these Flow Charts.

After the Hydraulic / Hydrostatic Flow Charts have been removed, discard your old Hydraulic Breaker ServiceManual (P/N 6720280) Dated 9-96 and replace it with the revised Hydraulic Breaker Service Manual (P/N 6720280)Date 10-05.

Insert the existing Hydraulic / Hy drostatic Flow Charts into t he new Hydraulic Breaker Service Manual (P/N6720280) Date 10-05.

This Service Manual is in a new format with added updates.

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Printed in U.S.A.

Revision No: Breaker-5Date: 23 March 2006Product: AttachmentModel: Hydraulic BreakerManual No: 6720280 (10-05)

Hydraulic Breaker Service Manual (P/N 6720280) Dated (2-06) contains updated service information whichreplaces the previous Hydraulic Breaker Service Manual (P/N 6720280) Dated (10-05).

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Printed in U.S.A.

SERVICE MANUAL REVISION

Revision No: Breaker-6Date: 15 June 2012Product: AttachmentModel: Hydraulic BreakerManual No: 6720280 (2-06)

The following Sections are a revision to the above Service Manual.

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SERVICE MANAGER X

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