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Hydraulic

Breaker Service
Manual
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 ABOVE

Dealer Copy -- Not for Resale


S/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)

Doosan purchased Bobcat Company from Ingersoll-Rand Company in


2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Bobcat Company or the products of
either.

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

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Dealer Copy -- Not for Resale
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Ma intenance Manual, Operators Handbook and
WARNING
WARNING signs (decals) on machine. Follow warnings and instructions in th e manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions 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.

CORRECT

Dealer Copy -- Not for Resale


B-10731a

Never service attachments without instructions. See


Operation & Mainte nance Manual and Attachment Service
Manual.

Cleaning and maintenance are required daily.

Never service or adjust attachment with the engine running


unless instructed to do so in manual.

Always lower the attachment to the g round before


lubricating or servicing.

Avoid contact with leaking hydraulic fluid or diesel fuel


under pressure. It can penetrate skin or eyes.

Stop, cool and clean engine of flammable materials before


checking fluids.

Keep body, loose objects and clothing away from moving


parts, electrical contacts, hot parts and exhaust.

Safety glasses are needed for eye protection from electrical


arcs. battery acid, compressed springs, fluids under
pressure and flying debris or when tools are used. Use eye
protection approved for type of welding.

MSW30-0805

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Dealer Copy -- Not for Resale
ALPHABETICAL INDEX

1250, 1250X HYDRAULIC BREAKER SERVICE


ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
TROUBLESHOOTING THE HYDRAULIC BREAKER. . . . . . 10-01

1560 HYDRAULIC BREAKER SERVICE


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

2500/3500 HYDRAULIC BREAKER SERVICE


CHECKING MOUNTING BOLT TORQUE . . . . . . . . . . . . . . . 30-01
DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-01

Dealer Copy -- Not for Resale


HYDRAULIC BREAKER LUBRICATION . . . . . . . . . . . . . . . . 30-01
NITROGEN CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
SPECIFICATIONS (2500) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
SPECIFICATIONS (3500) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
TROUBLESHOOTING THE HYDRAULIC BREAKER. . . . . . 30-01

2560/3560 HYDRAULIC BREAKER SERVICE


DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 40-01
NITROGEN CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
TROUBLESHOOTING THE HYDRAULIC BREAKER. . . . . . 40-01

2570/3570 HYDRAULIC BREAKER SERVICE


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

CONTINUED ON NEXT PAGE

Hydraulic Breaker
10-01 Service Manual
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ALPHABETICAL INDEX (CONTD)

5060 HYDRAULIC BREAKER SERVICE


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

5500 HYDRAULIC BREAKER SERVICE


CHECKING MOUNTING BOLT TORQUE . . . . . . . . . . . . . . . 70-01
HYDRAULIC BREAKER LUBRICATION . . . . . . . . . . . . . . . . 70-01
NITROGEN CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

Dealer Copy -- Not for Resale


TROUBLESHOOTING THE HYDRAULIC BREAKER. . . . . . 70-01

6560 HYDRAULIC BREAKER SERVICE


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

Hydraulic Breaker
10-02 Service Manual
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CONTENTS

SERIAL NUMBER LOCATIONS & HYDRAULIC BREAKER


IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III

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


HYDRAULIC
1560 HYDRAULIC BREAKER SERVICE . . . . . . . . . . . . . . . . . . 20-01 BREAKER SERVICE
1560
2500/3500 HYDRAULIC BREAKER SERVICE. . . . . . . . . . . . . . 30-01 HYDRAULIC
BREAKER SERVICE
2560/3560 HYDRAULIC BREAKER SERVICE. . . . . . . . . . . . . . 40-01
2500/3500
2570/3570 HYDRAULIC BREAKER SERVICE. . . . . . . . . . . . . . 50-01 HYDRAULIC
BREAKER SERVICE
5060 HYDRAULIC BREAKER SERVICE . . . . . . . . . . . . . . . . . . 60-01 2560/3560
HYDRAULIC
5500 HYDRAULIC BREAKER SERVICE . . . . . . . . . . . . . . . . . . 70-01 BREAKER SERVICE

6560 HYDRAULIC BREAKER SERVICE . . . . . . . . . . . . . . . . . . 80-01 2570/3570


HYDRAULIC

Dealer Copy -- Not for Resale


BREAKER SERVICE

5060
HYDRAULIC
BREAKER SERVICE
5500
HYDRAULIC
BREAKER SERVICE
6560
HYDRAULIC
BREAKER SERVICE

CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the State of California
to cause cancer, birth defects and other
reproductive harm.

Hydraulic Breaker
I Service Manual
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Dealer Copy -- Not for Resale

Hydraulic Breaker
II Service Manual
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SERIAL NUMBER LOCATIONS & HYDRAULIC Always use the serial number of the machine when
BREAKER IDENTIFICATION requesting service information or when ordering parts.
Early or later models (identification made by serial
Serial Number Locations (1250, 1250X) number) may use different parts, or it may be necessary
to us a different procedure in doing a sp ecific service
Figure 1 operation [Figure 1].

The breaker serial number plate is on the front of the


main body [Figure 1].

There are 2 different breakers. Be sure to use the correct


breaker on the correct machine. The 1250X Breaker is
for excavators. The 1250 Breaker is for Bobcat Loaders
and loader mounted backhoes.

N-06610

Hydraulic Breaker Identification (1250, 1250X)

Dealer Copy -- Not for Resale


Mounting Bracket

Charge Fitting

Nitrogen Chamber

Hose Fitting Port Grease Fitting

Breaker Body

Breaker Foot
Mounting Holes

Tool Point

B-12480
Breaker shown is mounted in excavator bracket

Hydraulic Breaker
III Service Manual
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SERIAL NUMBER LOCATIONS & HYDRAULIC Always use the serial number of the machine when
BREAKER IDENTIFICATION (CONTD) requesting service information or when ordering parts.
Early or later models (identification made by serial
Serial Number Locations (1560) number) may use different parts, or it may be necessary
to us a different procedure in doing a sp ecific service
Figure 2 operation [Figure 2].

The 1560 Hydraulic Breaker is approved for the following


machines:

Oil cooler equipped 400 Series and 500 Series loaders

Oil cooler equipped 220 & 225 excavators

All 453 & 553 Bobcat Loaders and 320 & 325 excavators

P5589

Hydraulic Breaker Identification (1560)

Dealer Copy -- Not for Resale


Mounting
Bracket

Charge
Fitting
Main
Body

Hose
Fittings

Lower
Mounting Body
Bolts

Tool
Point

P-5745

Hydraulic Breaker
IV Service Manual
10 of 260
SERIAL NUMBER LOCATIONS & HYDRAULIC Always use the serial number of the machine when
BREAKER IDENTIFICATION (CONTD) requesting service information or when ordering parts.
Early or later models (identification made by serial
Serial Number Locations (2500/3500 & 5500) number) may use different parts, or it may be necessary
to us a different procedure in doing a sp ecific service
Figure 3 operation [Figure 3].

The 1560 Hydraulic Breaker is approved for the following


machines:

Oil cooler equipped 400 Series and 500 Series loaders

Oil cooler equipped 220 & 225 excavators

All 453 & 553 Bobcat Loaders and 320 & 325 excavators

B-9608

Hydraulic Breaker Identification (2500/3500 & 5500)

Dealer Copy -- Not for Resale


Nitrogen Chamber

Charge Fitting

Hose Fitting Ports

Main Body
Accumulator

Grease Fitting
Mounting Bolts
Lower Body

Tool Point

B-09923

Hydraulic Breaker
V Service Manual
11 of 260
SERIAL NUMBER LOCATIONS & HYDRAULIC Always use the serial number of the machine when
BREAKER IDENTIFICATION (CONTD) requesting service information or when ordering parts.
Early or later models (identification made by serial
Serial Number Locations (2560/3560) number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
Figure 4 operation [Figure 4].

The breaker serial number plate is located on the front of


the nitrogen chamber [Figure 4].

P1854

Hydraulic Breaker Identification (2560/3560)

Dealer Copy -- Not for Resale


Mounting Bracket

Nitrogen
Charge Chamber
Fitting

Hose
Main Fitting
Body Ports

Grease
Fitting
Mounting
Bolts Lower
Body

Tool
Point

N-00221
N-00224

Hydraulic Breaker
VI Service Manual
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SERIAL NUMBER LOCATIONS & HYDRAULIC Always use the serial number of the machine when
BREAKER IDENTIFICATION (CONTD) requesting service information or when ordering parts.
Early or later models (identification made by serial
Serial Number Locations (2570/3570) number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
Figure 5 operation [Figure 5].

P1854

Hydraulic Breaker Identification (2570/3570)

Dealer Copy -- Not for Resale


Hose
Fitting
Mounting Ports
Mounting Bracket
Bracket
Nitrogen
Chamber
Charge
Fitting
Main
Accumulator
Body

Grease
Fitting

Tool
Mounting Point
Bolts

Tool
Point
Two
Position
Frame
Accumulator
N-00221
P-10953
P-10958

Hydraulic Breaker
VII Service Manual
13 of 260
SERIAL NUMBER LOCATIONS & HYDRAULIC Always use the serial number of the machine when
BREAKER IDENTIFICATION (CONTD) requesting service information or when ordering parts.
Early or later models (identification made by serial
Serial Number Locations (5060) number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
Figure 6 operation [Figure 6].

P1854

Hydraulic Breaker Identification (5060)

Dealer Copy -- Not for Resale


Wear
Plate
Bolts

Tool Quick
Bit Couplers

Steps

Steps

P-12815
P-12814

Hydraulic Breaker
VIII Service Manual
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SERIAL NUMBER LOCATIONS & HYDRAULIC Always use the serial number of the machine when
BREAKER IDENTIFICATION (CONTD) requesting service information or when ordering parts.
Early or later models (identification made by serial
Serial Number Locations (6560) number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
Figure 7 operation [Figure 7].

P10516

Hydraulic Breaker Identification (6560)

Dealer Copy -- Not for Resale


Auxiliary
Bob-Tach
Hydraulic
Mounting
Couplers
Frame

Grease
Fitting

Tool
Bit

P-12815

Hydraulic Breaker
IX Service Manual
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Dealer Copy -- Not for Resale

Hydraulic Breaker
X Service Manual
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1250, 1250X HYDRAULIC BREAKER SERVICE

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

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

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

Dealer Copy -- Not for Resale


Upper Body Removal and Installation . . . . . . . . . . . . . . . . 10-20-3

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

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

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

Hydraulic Breaker
10-01 Service Manual
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Hydraulic Breaker
10-02 Service Manual
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ACCUMULATOR When the accumulator is fully charged close the valve on
the charging assembly hose.
Use charging kit (P/N 6568037) to charge the
accumulator. Remove the charging tool.

Charging The Accumulator Tighten the hex locknut on the charge valve.

Figure 10-10-1 Install the breaker charging valve cap on the pr otective
valve cap.

Hydraulic Breaker Lubrication

Put the breaker in the vertical position so the point is on


the ground and the point is pushed up inside the breaker
as far as possible.

Figure 10-10-3
Nitrogen 600 PSI (41,38 bar)

Torque
400 ft.-lb.
(542,4 Nm)
Pressure
Return
Line

Dealer Copy -- Not for Resale


Remove the valve cap assembly (Item 1) [Figure 10-10- Line
1] from the breaker. Torque
2 28 ft.-lb.
Remove the protective cap from the charging valve and (38,0 Nm)
loosen the hex locknut 2 to 3 turns. Torque
400 ft.-lb. 1
Grease
Figure 10-10-2 (542,4 Nm) 4-5 Pumps
Twice Daily
6533396A

Stop the engine and have a second person add grease to


the fitting (Item 1) [Figure 10-10-3].

Apply grease (4 to 5 pumps) to the upper end of the tool


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

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

Thread the charge hose fitting onto the charging valve on


IMPORTANT
the breaker [Figure 10-10-2].
Underwater use of the breaker will cause internal
Adjust the regulator to the charging pressure of 600 PSI damage. No por tion of th e breaker may be
(4137 bar). submerged.
I-2053-0589

NOTE: It may be necessary to set the regulator at 600


to 700 PSI (41,38 to 41,28 bar) to overcome
any pressure drop through the charging
system.

Hydraulic Breaker
19 of 260 10-10-1 Service Manual
ACCUMULATOR (CONTD)

Checking Mounting Bolt Torque

Check the mounting bolts (Item 2) [Figure 10-10-3 on


Page 10-10-1] daily.

Tighten the bolts to 37 5 to 42 5 ft.-lb. (508 to 675 Nm)


torque.

Dealer Copy -- Not for Resale

Hydraulic Breaker
20 of 260 10-10-2 Service Manual
TROUBLESHOOTING THE HYDRAULIC BREAKER

WARNING
Instructions are necessary before operating or
servicing machine. Read Operation & M aintenance
Manuals, Handbook and signs (decals) on ma chine.
Follow warnings and instructions in t he manuals
when making repairs, adjustments or servicing.
Check for correct function after adjustments, repairs
or service. Failure to follow instructions can cause
injury or death.
W-2003-1289

If the Hydraulic Breaker is not working correctly, check the hydraulic system of the Bobcat Loader or excavator thoroughly
before making any repairs on the breaker. Hydraulic Breaker performance can be affected by a hydraulic system that is
not 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 to
check 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 correct
problems with the Hydraulic Breaker which most often occur.

Dealer Copy -- Not for Resale


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/24 C to reduce
viscosity.
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 and
inspect for damaged parts.
Breaker does not hit effectively. Supply pressure, return pressure or flow rate Test circuit for 4 to 9 gpm/15 to 34 lpm flow and
are incorrect. pressure is within 1600 to 2250 psi/113 to 158
bar.
Hoses or couplings are restricting flow. Check hoses and couplings for damage. Repair
or replace.
Accumulator not properly charged. Test and recharge. Replace diaphragm if
recharge 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 and
inspect.
Breaker hits slowly. Low circuit flow Test valve loading near relief setting. If flow
reduces with pressure rising, pump and/or valve
worn. Repair or replace. Fluid contaminated.
Flush and replace with clean fluid. Check for
proper filtration.
Relief pops during operation. Test supply circuit. Make sure the flow rate and
pressure ratings are within manufacturer's
specifications.
Trigger switch or solenoid valve not operating (if Check wiring and valve operation.Repair as
used). required.
Inadequate down force. Refer to operating instructions.

Hydraulic Breaker
21 of 260 10-10-3 Service Manual
PARTS IDENTIFICATION

Dealer Copy -- Not for Resale

Hydraulic Breaker
22 of 260 10-10-4 Service Manual
PARTS IDENTIFICATION (CONT'D)

Dealer Copy -- Not for Resale

Hydraulic Breaker
23 of 260 10-10-5 Service Manual
Dealer Copy -- Not for Resale

Hydraulic Breaker
24 of 260 10-10-6 Service Manual
DISASSEMBLY Figure 10-20-2

Breaker Frame Removal and Installation

WARNING
Wear safety glasses to prevent eye injury when any
of 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 hydraulic Have a se cond person remove the mounting pin clip
breaker: (Item 1) [Figure 10-20-2] and pin.

6652471 - Charging Kit Figure 10-20-3

Read and understand the complete disassembly and


assembly procedure before beginning the operation.

Dealer Copy -- Not for Resale


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

Before removing the breaker from the Bob-Tach, loosen


the 4 main bolts. Loosen the 8 bolts from the cradle.

Figure 10-20-1

Have a se cond person remove the pivot pin bolt and


pivot pin [Figure 10-20-3].

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

Put the breaker in a stand.

Hydraulic Breaker
25 of 260 10-20-1 Service Manual
DISASSEMBLY (CONT'D) Figure 10-20-6

Return Pressure Compensating (RPC) Valve Removal


and Installation

Put the breaker in a vise.

Figure 10-20-4

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

Installation: Tighten the bolts to 27 to 30 ft.-lb. (36 to 40


Nm) torque.

Figure 10-20-7

Dealer Copy -- Not for Resale


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

Figure 10-20-5

Remove the return pressure compensating (RPC) valve


[Figure 10-20-7].

Remove the RPC valve O-rings.


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

IMPORTANT
Do not completely discharge the accumulator at this
time.
I-2037-0788

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26 of 260 10-20-2 Service Manual
DISASSEMBLY (CONT'D) Upper Body Removal and Installation

Return Pressure Compensating (RPC) Valve Removal Figure 10-20-10


and Installation (Cont'd)

Place the RPC valve in a soft jaw vise.

Figure 10-20-8

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).

Dealer Copy -- Not for Resale


Remove the O-ring boss plug [Figure 10-20-8].
Figure 10-20-11
Figure 10-20-9

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


Remove the valve assembly internal parts [Figure 10-20-
9]. Loosen each bolt 1 turn and move to the next bolt. This
will insure no binding of the breaker body.
NOTE: Do not lose the parts in the RPC valve.
Remove the bolts.
The RPC valve is blocked open and not used in the
loader mounted 1250 Breaker [Figure 10-20-9]. Installation: Put anti-sieze compound on the bolt
threads and tighten the bolts equally working up to 400
The RPC valve is used when 1250X Breaker is mounted ft.-lb. (542 Nm) torque.
on the excavator [Figure 10-20-9].

Hydraulic Breaker
27 of 260 10-20-3 Service Manual
DISASSEMBLY (CONT'D) Figure 10-20-14

Upper Body Removal and Installation (Cont'd)

Figure 10-20-12

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

Use a r ubber hammer to tap around the lower body


Tap around the to p flange with a r ubber hammer to flange [Figure 10-20-14].
separate the breaker body [Figure 10-20-12].
Figure 10-20-15

Dealer Copy -- Not for Resale


Figure 10-20-13

Remove the lower body from the piston [Figure 10-20-


Separate the body halves [Figure 10-20-13]. 15].

Do not drop any internal parts.

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28 of 260 10-20-4 Service Manual
DISASSEMBLY (CONT'D) Flow Sleeve Removal and Installation

Lower Body Removal and Installation Figure 10-20-18

Figure 10-20-16

Put the assembly on the Flow Sleeve Removal Tube with


the automatic valve body facing down [Figure 10-20-18].
Remove the piston from the flow sleeve [Figure 10-20-
16]. Figure 10-20-19

Dealer Copy -- Not for Resale


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

Figure 10-20-17

Use a p ress to remove the flow sleeve from the


automatic valve body [Figure 10-20-19].

Place the split ring (from the k it) between the automatic
valve body and flow sleeve assembly [Figure 10-20-17]. IMPORTANT
Put a rag in the bottom of the removal tube to protect
the automatic valve body when it drops out.
I-2038-0788

Hydraulic Breaker
29 of 260 10-20-5 Service Manual
DISASSEMBLY (CONT'D) Figure 10-20-22

Flow Sleeve Removal and Installation (Cont'd)

Figure 10-20-20

Drive out the cylinder by tapping on a rod that extends


through the charge valve hole in the breaker body
[Figure 10-20-22].

The automatic valve, flow sleeve, 4 long push pins from Figure 10-20-23
the flow sleeve and 2 long push pins from the automatic
valve body will drop out [Figure 10-20-20].

Dealer Copy -- Not for Resale


Accumulator Removal and Installation

Figure 10-20-21

Lift the breaker body to remove the outer keeper, disc


and pilot springs to fall out [Figure 10-20-23].

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

Remove the accumulator cylinder using the puller (from


the kit).

Hydraulic Breaker
30 of 260 10-20-6 Service Manual
DISASSEMBLY (CONT'D) Diaphragm Removal and Installation

Charge Valve Removal and Installation Put the accumulator assembly on the accumulator
disassembly tool and flow sleeve removal tube.
Figure 10-20-24
Put a rag in the bottom of the removal tool to protect the
accumulator chamber.

Figure 10-20-26

Put the accumulator chamber in a soft jaw vise and


loosen the lo cknut to completely discharge the
accumulator assembly [Figure 10-20-24].

Dealer Copy -- Not for Resale


Remove the accumulator chamber and diaphragm from
the accumulator cylinder by pressing on the charge valve
IMPORTANT end [Figure 10-20-26].

Squeeze the accumulator diaphragm and slide it off the


The machined surfaces of the accumulator can accumulator chamber at the charge valve end.
become damaged if a soft jaw vise is not used.
I-2039-0788
NOTE: Avoid damage to the inside wall of the
accumulator chamber.
Figure 10-20-25
Figure 10-20-27

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


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

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31 of 260 10-20-7 Service Manual
DISASSEMBLY (CONT'D) Always replace both bushings as a set.

Checking Breaker Bushings Figure 10-20-30

The bushings can be checked with a new tool installed


and the breaker mounted on the carrier.

Figure 10-20-28

Remove the r od wiper, washer and O-ring at the top of


the breaker foot [Figure 10-20-30].

NOTE: Be sure the tool retainer pin ha s been


removed.

Dealer Copy -- Not for Resale


Put the br eaker in a hor izontal position with the tool
against a solid object [Figure 10-20-28]. Put the breaker lower body in a press.

Move the breaker up, then down. If there is more than 1/2 Figure 10-20-31
in. movement of the tool in either direction the bushings
may be worn or damaged [Figure 10-20-28].

NOTE: A cracked bushing may have caused the


breaker lower body bore to become enlarged.
If this happens, a new bushing may fit too
loose. Replace the breaker lower body if
necessary.

Bushing Removal

Figure 10-20-29

Use the removal tool shown [Figure 10-20-29] to p ush


both bushings out of the bottom of the breaker lower
body at the same time [Figure 10-20-31].

NOTE: The removal tools are to be made from 2-3/4


inch bar stock [Figure 10-20-29].

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32 of 260 10-20-8 Service Manual
DISASSEMBLY (CONT'D)

Bushing Installation

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

Lubricate the outer edge of the bore in the breaker lower


body with SAE 30 oil.

Use the installation tool shown [Figure 10-20-29] to first


press the upper bushing in the breaker, then the lower
bushing [Figure 10-20-31].

Dealer Copy -- Not for Resale

Hydraulic Breaker
33 of 260 10-20-9 Service Manual
ASSEMBLY Figure 10-20-34

Clean all parts in solvent and inspect before assembly.

Install the tool retainer pin.

Figure 10-20-32

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

Figure 10-20-35

Install the r od wiper (lip first) in the counterbore of the

Dealer Copy -- Not for Resale


breaker foot [Figure 10-20-32].

Figure 10-20-33

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 ground


flat-end face pointing toward the flange of the
automatic valve.

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

Hydraulic Breaker
34 of 260 10-20-10 Service Manual
ASSEMBLY (CONT'D) Figure 10-20-38

Lubricate the bore of the flow sleeve cover then put in a


press with the small end facing up.

The flow sleeve has a wide groove around the outside of


1 end. Install this end first.

Use the accumulator cylinder puller to p rotect the flow


sleeve.

Figure 10-20-36

Install the automatic valve (small diameter first) into the


automatic valve body [Figure 10-20-38].

Figure 10-20-39

Dealer Copy -- Not for Resale


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

Figure 10-20-37

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 and


pilot into the bore of the flow sleeve.

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

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35 of 260 10-20-11 Service Manual
ASSEMBLY (CONT'D) Figure 10-20-42

Use the accumulator cylinder puller to press the


automatic valve body into the flow sleeve until the flo w
sleeve bottoms out on the press.

Coat the O-ring with grease and put it in the pilot


diameter against the machined surface of the breaker
lower body.

Figure 10-20-40

Put the washer (small diameter first) on the piston stem


against the automatic valve body [Figure 10-20-42].

Figure 10-20-43

Dealer Copy -- Not for Resale


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

Figure 10-20-41

Install the nitrogen charge valve (Item 1) [Figure 10-20-


43] in the accumulator chamber.

IMPORTANT
The machined surfaces of the accumulator can
become damaged if a soft jaw vise is not used.
I-2039-0788
Install the piston (large end first) through the automatic
valve body and flow sleeve [Figure 10-20-41].

Be sure the large end of the piston goes through the cup
seal and sits flat inside the pilot diameter of the breaker
lower body.

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36 of 260 10-20-12 Service Manual
ASSEMBLY (CONT'D) Figure 10-20-46

Figure 10-20-44

Push the accumulator chamber and diaphragm (charging


valve end first) halfway into the accumulator cylinder
Put a th in coat of gr ease on th e inside surface of th e [Figure 10-20-46].
accumulator diaphragm [Figure 10-20-44].
The parts are assembled from the end of the cylinder with
Figure 10-20-45 the chamfer on the outside diameter.

Dealer Copy -- Not for Resale


IMPORTANT
Do not use a hammer or electrically powered press to
assemble the accumulator diaphragm.
I-2042-0788

NOTE: Make sure the accumulator diaphragm is free


of wrinkles and the seal bead is in its groove
before completing the assembly.

NOTE: A ha nd powered press may be needed to


complete the accumulator assembly. Apply
Slide the diaphragm onto the accumulator chamber from short strokes during the last 12 inch (12 mm)
the charging valve end [Figure 10-20-45]. of travel to gently seat the diaphragm.

Put grease on the inside of the accumulator cylinder and


the outside diameter of the diaphragm.

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37 of 260 10-20-13 Service Manual
ASSEMBLY (CONT'D) Install the back-up washer and cup seal (lips facing out)
in the accumulator chamber counterbore.
Figure 10-20-47
Install a greased O-ring in the groove around the upper
end of the flow sleeve cover and ing the groove on the
automatic valve body.

Figure 10-20-49

Put the assembly in a soft jaw vise by the ends of the


chamber and loosen the nitrogen charging valve locknut
1-1/2 turns [Figure 10-20-47].

Figure 10-20-48

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

Carefully seat it into place.

IMPORTANT
The disc springs must have their center holes
depressed toward the pilot s pring shoulder. Do not
stack them with gaps in between or with their inside
diameters facing toward the breaker body end.
I-2043-0788

Charge the accumulator with nitrogen to 600 PSI (4137


bar) [Figure 10-20-48]. (See Charging The Accumulator
on Page 10-10-1.)

NOTE: It may be necessary to charge the accumulator


an additional 50 to 75 PSI (345 to 517 bar) due
to the pressure drop in the charging system.

Test the a ccumulator for any visible leaks by immersing


in oil and checking for bubbles.

If no leaks are found, discharge the accumulator.

If leaks are found, disassemble and correct the cause of


the leak.

Install the valve cap on the charging valve.

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38 of 260 10-20-14 Service Manual
ASSEMBLY (CONT'D) Figure 10-20-52

Figure 10-20-50

Carefully place the breaker body over the accumulator


assembly [Figure 10-20-52].
Seat the outer keeper spring (Item 1) [Figure 10-20-50]
(beveled end facing up) on the accumulator cylinder. Figure 10-20-53

Lubricate the 4 disc spring washers; then stack them


(Item 2) [Figure 10-20-50] (inside diameter up and

Dealer Copy -- Not for Resale


outside diameter sloping down) in the outer keeper
spring.

Figure 10-20-51

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

Put lock washers on th e 4 l ong bolts and put anti-sieze


compound on the threads and under the washers.

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

Be sure it is squarely seated.

Grease the outside diameter of th e accumulator


assembly.

Clean the interior of the breaker body.

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39 of 260 10-20-15 Service Manual
ASSEMBLY (CONT'D) Figure 10-20-56

Figure 10-20-54

Put the breaker assembly in a s oft jaw vise and tighten


the bolts equally working up to 400 ft.-lb. (542 Nm)
Install the bolts through the holes in the breaker body and torque [Figure 10-20-56].
into the tapped holes in the breaker lower body [Figure
10-20-54]. Charge the accumulator. ( See Charging The
Accumulator on Page 10-10-1.)
Tighten the bolts until they begin to compress the lo ck

Dealer Copy -- Not for Resale


washers. Clean the flat surfaces of the RPC valve and the breaker
body.
Figure 10-20-55
Figure 10-20-57

Tightening sequence must be followed to prevent


damage to the components [Figure 10-20-55]. Lubricate and install the 3 O-rings in the grooves on the
RPC valve surface [Figure 10-20-57].

IMPORTANT
The bolts must be tightened using equal turns and in
the order shown to avoid distorting the assembly or
destroying internal parts.
I-2044-0788

Hydraulic Breaker
40 of 260 10-20-16 Service Manual
ASSEMBLY (CONT'D)

Figure 10-20-58

Put the RPC against the breaker body surface [Figure


10-20-58].

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

Dealer Copy -- Not for Resale


Install the bolts and lock washers.

Figure 10-20-59

Tighten the bolts to 27 to 30 ft.-lb. (36 to 40 Nm) torque


[Figure 10-20-59].

Hydraulic Breaker
41 of 260 10-20-17 Service Manual
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Hydraulic Breaker
42 of 260 10-20-18 Service Manual
SPECIFICATIONS

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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

* 1250X Only: Operating pressure below 1200 PSI (120 bar) and return pressures above 200 PSI (14 bar) are
compensated 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.

Hydraulic Breaker
43 of 260 10-30-1 Service Manual
Dealer Copy -- Not for Resale

Hydraulic Breaker
44 of 260 10-30-2 Service Manual
1560 HYDRAULIC BREAKER SERVICE

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

DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 20-20-1


Breaker Frame Removal and Installation. . . . . . . . . . . . . . 20-20-1
Bushing Removal and Installation . . . . . . . . . . . . . . . . . . . 20-20-8
Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6 1560
Seal Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6 HYDRAULIC
Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2 BREAKER SERVICE
Sleeve Removal and Installation . . . . . . . . . . . . . . . . . . . . 20-20-7
Upper Section Removal and Installation . . . . . . . . . . . . . . 20-20-5

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

NITROGEN CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1


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

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PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-8

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

TROUBLESHOOTING THE HYDRAULIC BREAKER . . . . . . 20-10-6

Hydraulic Breaker
20-01 Service Manual
45 of 260
Dealer Copy -- Not for Resale

Hydraulic Breaker
20-02 Service Manual
46 of 260
NITROGEN CHAMBER Figure 20-10-2

Releasing Pressure From the Nitrogen Chamber

The nitrogen chamber valve is located on the hose fitting


side of the hydraulic breaker.

WARNING
Wear safety glasses to prevent eye injury when any
of 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 Using a sm all shaft (Item 1) [Figure 20-10-2], push the
valve inward to release the gas pressure.

NOTE: Release the charge pressure when storing the Install the plug in the charge valve hole.
hydraulic breaker for an extended period of
time. Checking The Nitrogen Chamber Charge Pressure

Dealer Copy -- Not for Resale


Figure 20-10-1 Use the nitrogen accumulator charge pressure gauge
MEL1523B to check pressure.

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

Figure 20-10-3

Remove the pl ug (Item 1) [Figure 20-10-1] from the


charge valve using a 3/16 in. (4,67 mm) allen wrench.

P18084

Install the correct adapter (Item 1) [Figure 20-10-3] on


the gauge.

Hydraulic Breaker
47 of 260 20-10-1 Service Manual
NITROGEN CHAMBER (CONTD) Figure 20-10-6

Checking The Nitrogen Chamber Charge Pressure


(Contd)

Figure 20-10-4

0.125
(3,2 mm) Tighten the adapter (Item 1) [Figure 20-10-6] on th e
breaker.

P-42758 Figure 20-10-7

With the adapter (Item 1) tig htened on the ga uge,


measure the pin (Item 2) [Figure 20-10-4] protrusion.

Dealer Copy -- Not for Resale


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

Figure 20-10-5

Slowly turn the gauge valve body (Item 1) [Figure 20-10-


7] clockwise until the gauge shows a reading. If th e
pressure is low, recharge the breaker using charging kit
number 6568037.

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


bar).
P-42759

Loosen the adapter until the pin is flush with the e nd of


the adapter as shown [Figure 20-10-5].

Install the gauge/adatper on the breaker.

Hydraulic Breaker
48 of 260 20-10-2 Service Manual
NITROGEN CHAMBER (CONTD) Slowly open the valve on the nitrogen tank and fill the
1560 breaker nitrogen chamber to 250 PSI (17,24 bar).
Charging The Nitrogen Chamber Close the valve on the nitrogen tank.

NOTE: When in doubt of nitrogen charge pressure or Disconnect the hose and charging tool.
when recharging a hot breaker, release the
nitrogen pressure completely and recharge Install and tighten the plug (Item 1) [Figure 20-10-1 on
the nitrogen chamber. Page 20-10-1].

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

Use kit #6568037 to charge the hydraulic breaker.

Figure 20-10-8

Connect This End To


Nitrogen Chamber

Dealer Copy -- Not for Resale


Connect Hose From
Nitrogen Bottle Here

250 PSI (17,24 BAR) B-07196

Figure 20-10-9

Using the adapter, install the charging tool in the charge


valve [Figure 20-10-9].

NOTE: Be sure to use the correct side of the charging


tool [Figure 20-10-8].

Connect the nitrogen hose to th e charging tool [Figure


20-10-9].

Hydraulic Breaker
49 of 260 20-10-3 Service Manual
HYDRAULIC BREAKER LUBRICATION

Put the breaker in the vertical position so the point is on


the ground and the point is pushed up inside the breaker IMPORTANT
as far as possible.
Underwater use of the breaker will cause internal
Figure 20-10-10 damage. No por tion of th e breaker may be
submerged.
I-2053-0589

Dealer Copy -- Not for Resale


Stop the engine and have a second person add grease to
the fitting (Item 1) [Figure 20-10-10].

Apply grease (4 to 5 pumps) to the upper end of the tool


at the grease fitting (Item 1) [Figure 20-10-10] every 4 to
8 hours of operation or when the tool bit looks dry.

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

Hydraulic Breaker
50 of 260 20-10-4 Service Manual
CHECKING MOUNTING BOLT TORQUE

Figure 20-10-11

Check the snap rings and breaker mounting bolts (Item


1) [Figure 20-10-11] every day.

If the snap rings and lock plates are missing, tighten the
bolts to 300 ft.-lb. (407 Nm) torque. Lock plates can be

Dealer Copy -- Not for Resale


turned 180 for a different alignment if necessary.

Hydraulic Breaker
51 of 260 20-10-5 Service Manual
TROUBLESHOOTING THE HYDRAULIC BREAKER

WARNING
Instructions are necessary before operating or
servicing machine. Read Operation & M aintenance
Manuals, Handbook and signs (decals) on ma chine.
Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing.
Check for correct function after adjustments, repairs
or service. Failure to follow instructions can cause
injury or death.
W-2003-1289

If the Hydraulic Breaker is not working correctly, check the hydraulic system of the Bobcat Loader or excavator thoroughly
before making any repairs on the breaker. Hydraulic Breaker performance can be affected by a hydraulic system that is
not 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 to
check 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 correct
problems with the Hydraulic Breaker which most often occur.

Dealer Copy -- Not for Resale


PROBLEM CAUSE CORRECTION
Breaker will not fire. Loader or excavator main relief valve set to Adjust main relief valve to correct setting.
low.
Loader or excavator fluid reservoir is low. Add hydraulic fluid to the fluid reservoir on
the loader or excavator.
No hydraulic flow to the breaker. Check the hydraulic flow to the breaker.
Loader or excavator hydraulic pump not Check flow of loader hydraulic pump.
working. Repair or replace as needed.
Nitrogen chamber not at correct pressure. Charge to required pressure.
Damaged electrical connection to breaker Check wiring harness and switch.
valve (backhoe mounted unit only).
Damaged quick couplers. Replace quick couplers.
Breaker runs very slowly or Loader or excavator main relief valve set to Adjust main relief valve to correct setting.
blow per minute reducing. low.
Not enough hydraulic flow. Test loader or excavator hydraulics for
correct flow and pressure.
Excessive heat build up. Check oil cooler for debris and air flow.
Check loader or excavator relief valve
pressure.
Damaged quick couplers. Replace quick couplers.
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 for
wear.
Excessive back pressure. Check for plugged or bent return lines

Hydraulic Breaker
52 of 260 20-10-6 Service Manual
TROUBLESHOOTING THE HYDRAULIC BREAKER (CONTD)

PROBLEM CAUSE CORRECTION


Breaker fires erratically. Loader or excavator main relief valve set to Adjust main relief valve to correct setting.
low.
Excessive back pressure. Check for plugged or kinked return lines.
Low fluid level. Add fluid to the reservoir as needed.
Damaged quick couplers. Replace quick couplers.
Tool binding. Add grease to the tool shank fitting.
Damaged electrical connection to breaker Check wiring harness and switch.
valve (backhoe mounted unit only).
Excessive heat build up. Blank firing. Refer to the hydraulic controls section for
correct operating procedure.

Dealer Copy -- Not for Resale

Hydraulic Breaker
53 of 260 20-10-7 Service Manual
PARTS IDENTIFICATION

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Hydraulic Breaker
54 of 260 20-10-8 Service Manual
DISASSEMBLY AND ASSEMBLY Figure 20-20-1

Breaker Frame Removal and Installation

WARNING
Wear safety glasses to prevent eye injury when any
of 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 hydraulic Have a second person remove the mounting pin clip and
breaker: pin [Figure 20-20-1].

6568037 - Charging Kit Have a second person remove the pivot pin bolts and the
pins (inset) [Figure 20-20-1].
Read and understand the complete Disassembly and
Assembly procedure before beginning the operation. Slowly move the machine away from the breaker.

Dealer Copy -- Not for Resale


NOTE: Always replace O-rings and seals when Figure 20-20-2
servicing the breaker.

NOTE: Before removing the breaker from the frame


do the following:

Disconnect the h ydraulic quick couplers from the loader


or excavator and remove them from the hose guide on
the boom arm.

Release the pressure from the nitrogen chamber. (See


Releasing Pressure From the Nitrogen Chamber on
Page 20-10-1.)

Loosen the 2 bolts in the upper section of the breaker. Do


not remove the bolts.

Put the breaker in a stand. Use a ch ain hoist [Figure 20-20-2] to c ontrol the fr ame
while removing or installing the mounting bolts.

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DISASSEMBLY AND ASSEMBLY (CONT'D) Shuttle Valve

Breaker Frame Removal and Installation (Contd) NOTE: Check the machined surfaces of the shuttle
valve for scratches or wear. The shuttle valve
Figure 20-20-3 parts can be replaced individually.

NOTE: Apply hydraulic oil to the O-rings and


machined surfaces during assembly.

Figure 20-20-5

Remove the retaining clips and washers (Item 1) [Figure


20-20-3] from the fr ame mounting bolts. Remove the
bolts from both sides of the breaker frame.

Dealer Copy -- Not for Resale


Installation: Use anti-seize on the bolt threads during
assembly. Tighten the bolts to 300 ft.-lb. (406 Nm) Remove the bolts from the shuttle valve cap (Item 1)
torque. [Figure 20-20-5].

Figure 20-20-4 Installation: Tighten the b olts to 20 ft.-lb. (27 Nm)


torque.

Figure 20-20-6

Lower the frame (Item 1) and use a hoist (Item 2) [Figure


20-20-4] to lift the breaker and remove the s tand.
Reinstall the breaker in the stand for repairs.
Install 2 of the mounting bolts (Item 1) [Figure 20-20-6]
into the threaded holes in the s huttle valve cap and
tighten evenly to remove the cap.

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 20-20-9

Shuttle Valve (Contd)

Figure 20-20-7

The sleeve (Item 1) [Figure 20-20-9] is a press fit. Do not


remove it.

If sleeve is damaged, replace the upper body of th e


Remove and replace the O-ring (Item 1) [Figure 20-20-7] breaker (replacement body will include a new sleeve).
from the cap.

Dealer Copy -- Not for Resale


Figure 20-20-8

Remove the shuttle valve (Item 1) [Figure 20-20-8] from


the shuttle valve sleeve.

A light scuffing or burnishing of the surfaces is normal.


Check for cracks and see that the spool moves freely in
the valve sleeve.

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

DO NOT break or buff the sharp edges of the valve


sleeve or valve spool. This will cause the valve to
malfunction.

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DISASSEMBLY AND ASSEMBLY (Cont'd) Figure 20-20-12

Charge Valve

Figure 20-20-10

Inspect the charge valve for cracks, scratches, or wear


[Figure 20-20-12].

Replace the O-rings (Items 1 & 2) [Figure 20-20-12] on


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

Dealer Copy -- Not for Resale


Figure 20-20-11

Use a slotted screwdriver to remove the charge valve


(Item 1) [Figure 20-20-11].

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 20-20-14

Upper Section Removal and Installation

Figure 20-20-13

Remove the 2 tie rods (Item 1) [Figure 20-20-13] and


washers (Item 2) [Figure 20-20-13] from the upper
section of the breaker.

Dealer Copy -- Not for Resale


The washers must be installed with the internal chamfer
UP.

Installation: Put anti-seize on the tie rod threads, tie rod


nuts, and washers. In an alternating pattern, tighten the
bolts to 150 ft.-lb. (203 Nm) torque, then to 500 ft.-lb.
(678 Nm) torque.
Use a ch ain hoist (Item 1) [Figure 20-20-14] to remove
Check the tie rods for wear or cracks. the upper section.

NOTE: If a tie rod is broken, both must be replaced. Install a lar ge punch (Item 2) [Figure 20-20-14] in the
lower section, lift the breaker slightly with the hoist and
strike the punch with a l arge rubber hammer to help
separate the sections

Continue to raise the hoist to remove the upper section.

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 20-20-17

Piston

Figure 20-20-15

Remove the O-rings from the seal carrier [Figure 20-20-


17].

Figure 20-20-18
Install a lifting eye in the piston and use the hoist (Item 1)
[Figure 20-20-15] to remove the piston from the sleeve.

Dealer Copy -- Not for Resale


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

Seal Carrier

Figure 20-20-16

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 the
seal with the lips DOWN.

Remove small burrs with 220 grit emery cloth.

Remove the seal carrier (Item 1) [Figure 20-20-16] from


the piston.

Check the seal carrier and piston for wear, galling, or


cracks [Figure 20-20-16].

A light scuffing or burnishing of surfaces is normal.

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 20-20-20

Sleeve Removal and Installation

Installing a shaft (screwdriver, etc.) through the sleeve


holes and pu ll while twisting should remove the s leeve
from the lower section.

Figure 20-20-19

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

Figure 20-20-21

Dealer Copy -- Not for Resale


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.


If the sleeve is tight, install a bolt (Item 1) through the Install the seal with the lips up.
holes in th e sleeve. Using a s lide hammer (Item 2)
[Figure 20-20-19] slowly remove the s leeve from the A light scuffing or burnishing of the surfaces is normal.
lower section. Check for cracks and see that the piston moves freely in
the sleeve.
Check the s leeve for scratches, damaged O-rings and
seals. If small burrs are found, remove them with 200 grit emery
cloth.

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DISASSEMBLY AND ASSEMBLY (CONT'D) Bushing Removal and Installation

Sleeve Removal and Installation (Contd) Check the bushings for cracks or excessive galling.

Figure 20-20-22 Install a new tool bit into the bushings and check the side
movement. There should be no m ore than 1/4 in. (6.4
mm) side movement at the tool point.

Replace the bushings if out of tolerance.

Lay the hydraulic breaker on it's side for bushing removal


and installation.

Clean the lower body before service.

Figure 20-20-23

Put oil on the outside and inside surface of th e sleeve


and install the sleeve in the lower section [Figure 20-20-
22].

Dealer Copy -- Not for Resale


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

Remove the tool retaining pin (Item 1) and the 2 rubber


holders (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 [Figure


20-20-24].

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 20-20-27

Bushing Removal and Installation (Cont'd)

Figure 20-20-25

Remove the bushings from the lower section [Figure 20-


20-27].

Remove the r oll pin (Item 1) and dowel pin (Item 2)


[Figure 20-20-25].

Dealer Copy -- Not for Resale


Figure 20-20-26

Drive the remaining roll pin flush with the o utside of th e


lower section to remove the bushing [Figure 20-20-26].

Repeat the procedure to remove the upper bushing roll


pin.

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Hydraulic Breaker
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SPECIFICATIONS

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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 @ 200F) (93.3C) 1250 @ 8 GPM (30 LPM)

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

Hydraulic Breaker
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2500/3500 HYDRAULIC BREAKER SERVICE

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

DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-20-1


Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-9
Breaker Frame Removal and Installation. . . . . . . . . . . . . . 30-20-1
Lower Body Bushings Removal . . . . . . . . . . . . . . . . . . . . . 30-20-7
Main Body Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-6
Manifold Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4
Nitrogen Chamber Disassembly and Assembly. . . . . . . . . 30-20-8
Nitrogen Chamber Removal and Installation . . . . . . . . . . . 30-20-3
Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4 2500/3500
Seals Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-11 HYDRAULIC
Start Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-12 BREAKER SERVICE
Valve Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-6
Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . 30-20-5

HYDRAULIC BREAKER LUBRICATION . . . . . . . . . . . . . . . . 30-10-9

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

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

Hydraulic Breaker
30-01 Service Manual
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30-02 Service Manual
68 of 260
NITROGEN CHAMBER Figure 30-10-3

Checking The High Pressure Accumulator Pressure

Use the nitrogen accumulator charge pressure gauge 1


MEL1523B to check pressure.

Figure 30-10-1
2

0.125
(3,2 mm)

P-42758

With the adapter (Item 1) ti ghtened on the g auge,


measure the pin (Item 2) [Figure 30-10-3] protrusion.

Manually extend or retract the pin until the pin measures


B-7047 0.125 in. (3,2 mm) from pin tip to adapter face.

Dealer Copy -- Not for Resale


Figure 30-10-4
Remove the charge valve plug [Figure 30-10-1].

Figure 30-10-2

P-42759

P18084 Loosen the adapter until the pin is flush with the end of
the adapter as shown [Figure 30-10-4].

Install the correct adapter (Item 1) [Figure 30-10-2] on Install the gauge/adatper on the breaker.
the gauge.

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NITROGEN CHAMBER (CONTD) Charging the High Pressure Accumulator

Checking The High Pressure Accumulator Pressure


(Contd)

Figure 30-10-5
WARNING
Wear safety glasses to prevent eye injury when any
of 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

1
Figure 30-10-7

B-23394

Tighten the adapter (Item 1) [Figure 30-10-5] on th e


breaker.

Dealer Copy -- Not for Resale


Figure 30-10-6

Remove the charge valve plug [Figure 30-10-7].

Figure 30-10-8
1

B-23394

Slowly turn the gauge valve body (Item 1) [Figure 30-10-


6] clockwise until the gauge shows a reading. If the
pressure is low, recharge the breaker using charging kit
number 6568037.

NOTE: The correct charge pressure is 850 P SI (58,6


bar).

Use charging kit (P/N 6568037) to charge the hydraulic Using a sm all shaft (Item 1) [Figure 30-10-8], push the
breaker. valve inward to release the gas pressure.

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NITROGEN CHAMBER (CONTD)

Checking The High Pressure Accumulator Pressure


(Contd)

Figure 30-10-9

B-7077

NOTE: Use the high pressure side of the charging tool


[Figure 30-10-9].

Dealer Copy -- Not for Resale


Figure 30-10-10

Connect This End


To High Pressure
Accumulator &
Nitrogen Chamber

Connect Hose From


Nitrogen Bottle Here
B-7196

Install the charging tool into the accumulator [Figure 30-


10-9].

Connect the n itrogen hose to the high pressure side of


the charging tool [Figure 30-10-10].

SLOWLY open the valve at the nitrogen tank and fill the
high pressure accumulator to 850 PSI (58,6 bar) [Figure
30-10-10]. DO NOT EXCEED THIS PRESSURE

Close the valve at the nitrogen tank when accumulator


pressure is reached.

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NITROGEN CHAMBER (CONTD) Figure 30-10-13

Checking The Low Pressure Accumulator Pressure

Use the nitrogen accumulator charge pressure gauge 1


MEL1523B to check pressure.

Figure 30-10-11
2

0.125
(3,2 mm)

P-42758

With the adapter (Item 1) ti ghtened on the g auge,


measure the pin (Item 2) [Figure 30-10-13] protrusion.

Manually extend or retract the pin until the pin measures


B-7078 0.125 in. (3,2 mm) from pin tip to adapter face.

Dealer Copy -- Not for Resale


Figure 30-10-14
Remove the charge valve plug [Figure 30-10-11].

Figure 30-10-12

P-42759

P18084 Loosen the adapter until the pin is flush with the end o f
the adapter as shown [Figure 30-10-14].

Install the correct adapter (Item 1) [Figure 30-10-12] on Install the gauge/adatper on the breaker.
the gauge.

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NITROGEN CHAMBER (CONTD) Charging the Low Pressure Accumulator

Checking The Low Pressure Accumulator Pressure The low pressure accumulator is located on the front side
(Contd) of the main body.

Figure 30-10-15 Remove the charge valve plug.

Figure 30-10-17

B-23393

Tighten the adapter (Item 1) [Figure 30-10-15] on th e


breaker.

Dealer Copy -- Not for Resale


Using a small shaft (Item 1) [Figure 30-10-17], push the
valve inward to release the gas pressure.
Figure 30-10-16
Figure 30-10-18

Connect This End


To Low Pressure
B-23393 Connect Hose From Accumulator
Nitrogen Bottle Here
B-7196

Slowly turn the gauge valve body (Item 1) [Figure 30-10-


16] clockwise until the gauge shows a r eading. If th e
NOTE: Use the low pressure side of the charging tool
pressure is low, recharge the breaker using charging kit
[Figure 30-10-18].
number 6568037.
Install the charging tool into the accumulator [Figure 30-
NOTE: The correct charge pressure is 100 PSI (6,9
10-18].
bar).

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NITROGEN CHAMBER (CONTD) Checking The Nitrogen Chamber Charge Pressure

Charging The Low Pressure Accumulator (Contd) Use the nitrogen accumulator charge pressure gauge
MEL1523B to check pressure.
Figure 30-10-19
Figure 30-10-20

B-7077

B-8887

Connect the nitrogen hose to the low pressure side of the


charging tool [Figure 30-10-19]. Remove the plug (Item 1) [Figure 30-10-20].

Dealer Copy -- Not for Resale


SLOWLY open the valve at the nitrogen tank until the gas Figure 30-10-21
escapes from the relief valve (Item 1) [Figure 30-10-19]
on the charging tool.

Close the valve at the tank. Disconnect the nitrogen hose


and charging tool.
1
Install and tighten the plug.

P18084

Install the correct adapter (Item 1) [Figure 30-10-21] on


the gauge.

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NITROGEN CHAMBER (CONTD) Figure 30-10-24

Checking The Nitrogen Chamber Charge Pressure


(Contd) 1

Figure 30-10-22

B-23395
0.125
(3,2 mm)
Tighten the a dapter (Item 1) [Figure 30-10-24] on th e
breaker.
P-42758
Figure 30-10-25

With the adapter (Item 1) tig htened on the ga uge,


measure the pin (Item 2) [Figure 30-10-22] protrusion.

Dealer Copy -- Not for Resale


1

Manually extend or retract the pin until the pin measures


0.125 in. (3,2 mm) from pin tip to adapter face.

Figure 30-10-23

B-
23395

Slowly turn the gauge valve body (Item 1) [Figure 30-10-


25] clockwise until the gauge shows a r eading. If th e
pressure is low, recharge the breaker using charging kit
number 6568037.

P-42759 NOTE: The correct charge pressure is:

2500 - 400 PSI (27,58 bar)


Loosen the adapter until the pin is flush with the end of 3500 - 500 PSI (31,71 bar)
the adapter as shown [Figure 30-10-23].

Install the gauge/adatper on the breaker.

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75 of 260 30-10-7 Service Manual
NITROGEN CHAMBER (CONTD) Figure 30-10-28

Charging the Nitrogen Chamber


Connect This End To
The nitrogen chamber charge valve is located on the Nitrogen Chamber
back side of the breaker above the hydraulic inlet and
outlet ports.

Figure 30-10-26

Connect Hose From


Nitrogen Bottle Here
B-7196

NOTE: Use the high pressure side of the charging tool


[Figure 30-10-28].

Connect the nitrogen hose to the hi gh pressure side of


the charging tool.

Dealer Copy -- Not for Resale


SLOWLY open the valve at the nitrogen tank and fill the
Remove the charge valve plug (Item 1) [Figure 30-10- nitrogen chamber.
26].
2500 - Fill the chamber to 400 PSI (27,58 bar)
Using a small shaft push the valve inward to release the 3500 - Fill the chamber to 500 PSI (31,71 bar)
gas pressure. Close the valve on the nitrogen tank.

Figure 30-10-27 Disconnect the hose and the charging tool.

Install and tighten the plug.

Install the charging tool in the charge valve [Figure 30-


10-27].

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76 of 260 30-10-8 Service Manual
HYDRAULIC BREAKER LUBRICATION

Put the breaker in the vertical position so the point is on


the ground and the point is pushed up inside the breaker
as far as possible.

Figure 30-10-29

B-11927

Stop the engine and have a second person add grease to

Dealer Copy -- Not for Resale


the fitting (Item 1) [Figure 30-10-29].

Apply grease (4 to 5 pumps) to the upper end of the tool


at the grease fitting (Item 1) [Figure 30-10-29] every 4 to
8 hours of operation, or when the tool bit looks dry.

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

IMPORTANT
Underwater use of the breaker will cause internal
damage. No por tion of t he breaker may be
submerged.
I-2053-0589

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77 of 260 30-10-9 Service Manual
CHECKING MOUNTING BOLT TORQUE

Figure 30-10-30

B-11927

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


daily.

Tighten the bolts to 900 ft.-lb. (1200 Nm) torque.

Dealer Copy -- Not for Resale

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78 of 260 30-10-10 Service Manual
TROUBLESHOOTING THE HYDRAULIC BREAKER

Manuals, Handbook and si gns (decals) on mac hine.


Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing.
Check for correct function after adjustments, repairs
or service. Failure to follow instructions can cause
Instructions are necessary before operating or injury or death.
servicing machine. Read Operation & M aintenance W-2003-1289

If the Hydraulic Breaker is not working correctly, check the hydraulic system of the Bobcat Loader or excavator thoroughly
before making any repairs on the breaker. Hydraulic Breaker performance can be affected by a hydraulic system that is
not 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 to
check 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 correct
problems with the Hydraulic Breaker which most often occur.

PROBLEM CAUSE CORRECTION


Breaker will not fire. Loader fluid reservoir is low. Add hydraulic fluid to the fluid reservoir
on the loader.
No hydraulic flow to the breaker. Check the hydraulic flow to the

Dealer Copy -- Not for Resale


breaker.
Loader main relief valve set too low. Adjust main relief valve to correct
setting.
Loader hydraulic pump not working. Check flow of loader hydraulic pump.
Repair or replace as needed.
Nitrogen chamber not at correct Charge to required pressure.
pressure.
Damaged quick couplers. Replace quick couplers.
Breaker runs very slowly. Not enough hydraulic flow. Test loader hydraulics for correct flow
and 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 correct
pressure (400 PSI maximum).
Internal leakage. Check seals and O-rings in the
breaker.
Refer to Service Letter 10 May 1996.
Breaker fires erratically. 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.
Damaged electrical connection to Check wiring harness and switch.
breaker valve (backhoe mounted unit
only).
Defective push pins. Replace push pins.

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79 of 260 30-10-11 Service Manual
PARTS IDENTIFICATION

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Hydraulic Breaker
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DISASSEMBLY AND ASSEMBLY Figure 30-20-1

Breaker Frame Removal and Installation

WARNING
Wear safety glasses to prevent eye injury when any
of 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 tools listed will be nee ded to do the fol lowing Loosen the 6 bolts which fasten the breaker to the frame
procedure: [Figure 30-20-1]. DO NOT REMOVE THE BOLTS.

6568037 - Charging Kit (purchased from Bobcat Sales) MEL1214 - Hex Bit Driver
OEM6106 - Torque Multiplier
MEL1214 - Hex Bit Driver Remove the 3/ 16 in. hex plug at the accumulator
MEL1308 - Lower Bearing Removal Plate chamber. Release the nitrogen gas from the chamber.

Dealer Copy -- Not for Resale


MEL1310 - Remover Handle
Read and understand the complete disassembly and Figure 30-20-2
assembly procedure before beginning the operation.

NOTE: Different colored seals have been used in the


breakers in the past. Do not identify the seals
by their colors, instead each seal is n ow
individually packaged with an identification
number. These identification numbers will be
refered 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 unused
seals 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 THE


BOLTS. Loosen the hex bolt (use a 2-1/16 inch socket) on the top
of the nitrogen gas chamber [Figure 30-20-2]. DO NOT
MEL1307 - Hex Bit Driver REMOVE THE BOLT.

Assembly: Tighten the bolts to 600 ft.-lb. (813 Nm)


torque.

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DISASSEMBLY AND ASSEMBLY (CONTD) Figure 30-20-5

Breaker Frame Removal and Installation (Contd)

Figure 30-20-3

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

Use MEL1214 - Hex Bit Driver

Install the eye bolt in the bo lt at th e top of th e breaker Assembly: Put anti-sieze lubricant on the threads and
[Figure 30-20-3]. Install a chain hoist at the eye bolt. tighten the bolts to 900 ft.-lb. (1220 Nm) torque.

Dealer Copy -- Not for Resale


Figure 30-20-4 Remove the frame from the breaker.

Figure 30-20-6

Have a second person remove the mounting pins (Item


1) [Figure 30-20-4] and the washers.
Remove the hydraulic hoses from the hydraulic breaker
Have a second person lift the breaker from the Bob-Tach [Figure 30-20-6].
frame. Put the breaker in th e vertical position in th e
stand. Remove the 3/1 6 inch hex plug at the accumulator
chamber. Release the nitrogen gas from the chamber.
Install a chain hoist on the frame of the breaker.

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DISASSEMBLY AND ASSEMBLY (CONTD) Nitrogen Chamber Removal and Installation

Breaker Frame Removal and Installation (Contd) Figure 30-20-8

Figure 30-20-7

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

Using a sm all shaft (Item 1) [Figure 30-20-7], push the Use MEL1214 - Hex Bit Driver
valve inward to r elease the nitrogen gas from the
chamber. NOTE: When the 4 main bolts are removed, the

Dealer Copy -- Not for Resale


nitrogen chamber, main body and lower body
are independent of each other. Be careful so
parts do not fall.

Assembly: Put anti-sieze lubricant on the threads of the


bolts and tighten to 600 ft.-lb. (814 Nm) torque.

Figure 30-20-9

Use a ch ain hoist and remove the nitrogen chamber


[Figure 30-20-9].

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83 of 260 30-20-3 Service Manual
DISASSEMBLY AND ASSEMBLY (CONTD) Piston Removal

Manifold Removal Figure 30-20-11

Figure 30-20-10

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


main body.
Lift the manifold assembly from the main body [Figure
30-20-10]. Check the piston for wear.

Dealer Copy -- Not for Resale


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

If there is no cross hatch pattern on the piston or if the


cross hatch is worn smooth on part of the piston, apply a
cross hatch pattern as follows:

Use an emery cloth and move the emery cloth up and


down in th e area (Item 2) [Figure 30-20-11] while
rotating the piston.

This will produce a very fine surface scratching in a cross


hatched pattern (Item 2) [Figure 30-20-11].

NOTE: The new style seals (See Seals Installation on


Page 30-20-11.) must be used with the cross
hatch pattern pistons. Both old and new style
seals are included in the breaker seal kit. We
recommend crosshatching the old style
(smooth) piston and using the latest design
seals.

Hydraulic Breaker
84 of 260 30-20-4 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 30-20-14

Valve Removal and Installation

Figure 30-20-12

NOTE: The manifold will not s eat correctly if the


timing marks (Item 1) [Figure 30-20-14] are not
aligned.

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

Assembly: Align the timing marks on the valve and valve

Dealer Copy -- Not for Resale


cylinder [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 not


plugged.

Hydraulic Breaker
85 of 260 30-20-5 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Main Body Removal

Valve Cylinder Removal Figure 30-20-17

Figure 30-20-15

Remove both disc springs from the main body [Figure


30-20-17].
Remove the v alve cylinder with the valve seat from the
main body [Figure 30-20-15]. NOTE: The disc springs help maintain tolerance
between components by keeping

Dealer Copy -- Not for Resale


Figure 30-20-16 components tightly against 1 another.

Figure 30-20-18

Remove the valve cylinder from the valve seat [Figure


30-20-16].
Assembly: Install the disc springs with the convex
NOTE: The valve cylinder and valve seat are indexed surface facing away from the lower bearing [Figure 30-
by a roll pin (Item 1) [Figure 30-20-16]. 20-18].

Install the socket head bolts into the body at both


accumulator sides.

Hydraulic Breaker
86 of 260 30-20-6 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Lower Body Bushings Removal

Main Body Removal (Contd) Figure 30-20-21

Figure 30-20-19

NOTE: A bead of weld may have to be put around the


I.D. of the tool stop (Item 1) [Figure 30-20-21]
Install a chain hoist and lift the main body from the lower bearing for easier removal.
body [Figure 30-20-19].
Disassembly of the lower body internal parts requires a

Dealer Copy -- Not for Resale


Figure 30-20-20 press for removal of the tool bearing (Item 2) and tool
stop (Item 1) [Figure 30-20-21]. Replace the parts as
needed.

MEL1308 - Lower Bearing Removal Plate


MEL1310 - Remover Handle
Clean in solvent and air dry them.

Inspect all parts for scratches, wear or damage. Replace


the parts as needed.

Turn 2 b olts, equally into the main body to r emove the


lower bearing [Figure 30-20-20].

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87 of 260 30-20-7 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 30-20-24

Nitrogen Chamber Disassembly and Assembly

Disassembly: Remove the large bolt and the top plate.

Figure 30-20-22

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

Figure 30-20-25

Remove the charge valve (Item 1) [Figure 30-20-22].

Dealer Copy -- Not for Resale


Clean and inspect the charge valve.

Turn the chamber over, install the large bolt. Use a soft
hammer and hit the bo lt to remove the diaphragm and
screen.

Remove the O-ring from the s creen and inspect the


diaphragm for wear.

DO NOT store the diaphragm in direct sunlight.

Figure 30-20-23 Install the O-ring on the screen [Figure 30-20-25]. (The
O-ring identification number is 350724.)

Assembly: Put approximately 1 teaspoon of clean


hydraulic oil on the o utside of the diaphragm. Lubricate
the sealing surface of th e nitrogen chamber. Install the
diaphragm [Figure 30-20-23].

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88 of 260 30-20-8 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Accumulator

Nitrogen Chamber Disassembly and Assembly Figure 30-20-28


(Cont'd)

Figure 30-20-26

Remove the hex socket bolt at the accumulator chamber


[Figure 30-20-28].

Install the O-ring (Item 1) on the top and bottom of th e Assembly: Put anti-sieze lubricant on the threads and
chamber.(The O-ring (Item 1) [Figure 30-20-26] tighten the bolts to 190 ft.-lb. (258 Nm) torque.

Dealer Copy -- Not for Resale


identification number is 350754.)
Disassembly: Put the accumulator body in a vise.
Install the top plate and bolt. The bolt must be tightened
after the chamber is installed on the main body. Figure 30-20-29

Tighten the bolt to 600 ft.-lb. (814 Nm) torque.

Figure 30-20-27

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

Remove the accumulator plug and diaphragm [Figure


30-20-29].
Install the O-ring (Item 1) [Figure 30-20-27] on th e
charge valve. (The O-ring identification number is Inspect the diaphragm for wear and replace as needed.
01605.)

Install the charge valve and tighten to 80 ft.-lb. (108 Nm)


torque[Figure 30-20-27].

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89 of 260 30-20-9 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 30-20-32

Accumulator (Contd)

Figure 30-20-30

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

Put approximately 1 teaspoon of clean oil in the cover.

Remove the charge valve [Figure 30-20-30]. Put the plug into the body and tighten to 600 ft.-lb. (814
Nm) torque.
Clean and inspect the charge valve.

Dealer Copy -- Not for Resale


Install the charge valve and tighten to 80 ft.-lb. (108 Nm)
Install the O-ring (Item 1) [Figure 30-20-30] on th e torque.
charge valve. (The O-ring identification number is
01605.)

Install the charge valve and tighten to 80 ft.-lb. (108 Nm)


torque[Figure 30-20-30].

Figure 30-20-31

Assembly: Install the diaphragm in the accumulator


[Figure 30-20-31].

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90 of 260 30-20-10 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 30-20-34

Seals Installation

NOTE: New and old style seals are include in each


seal kit. Not all of the seals will be used to
rebuild the breaker. The following procedure
will describe the usages of both the old and
the new seals. But, we recommend modifying
the piston and using the new style seals. (See
Piston Removal on Page 30-20-4.)

NOTE: Heating the seal to 150F (68C) in hot water


will ease the installation.

NOTE: Do not use a screwdriver or any sharp tool for


installation of the seals.
Install the seal (Item 1) [Figure 30-20-34] into the lower
The type of seal to be u sed is depended on the type of bearing. Make sure the s eal lip faces up ( toward the
piston in the breaker. (Early pistons are smooth, later nitrogen chamber). (The seal identification number is :
pistons are cross hatched.) We recommend using the
lastest style piston or modifing the early piston to use the For 2500 Breakers with smooth piston is 350832. For
lastest style seals. (See Piston Removal on Page 30-20- 2500 Breakers with cross hatch piston is 24893.
4.)

Dealer Copy -- Not for Resale


For 3500 Breakers with smooth piston is 12852. For 3500
Figure 30-20-33 Breakers with cross hatch piston is 24932.

Install the O-ring (Item 2) [Figure 30-20-34]. The seal


identification number for both 2500 and 3500 breakers is
350833.)

Figure 30-20-35

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

For 2500 Breakers with smooth piston is 500000. For


2500 Breakers with cross hatch piston is 24999.
When installing the se al (Item 1) [Figure 30-20-35] into
For 3500 Breakers with smooth piston is 12851. For 3500 the groove at the valve seat, make sure the seal lip faces
Breakers with cross hatch piston is 25000. down. (The seal identification number for 2500 or 3500
Breakers with either smooth or cross hatch piston is
27221.)

Install the O-ring (Item 1) [Figure 30-20-35]. The seal


identification number for both 2500 and 3500 breakers is
350835.)

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91 of 260 30-20-11 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D)

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)

Dealer Copy -- Not for Resale


[Figure 30-20-36] in the low er groove.(The seal
identification number is 27222.)

Install the larger seal (5-5/16 inch O.D.) (Item 2) [Figure


30-20-36] in th e upper groove.(The seal identification
number is 27223.)

The open side (O-ring side) of the seals must face toward
each 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 and


raise the tool off the work object.

Run the breaker above the object in the BLANK FIRE


position to he lp remove the air from the breaker. (See
Hydraulic/Hydrostatic Flow Chart Blank Firing
Operation.)

It may take several minutes for all the air to be removed


from the system.

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92 of 260 30-20-12 Service Manual
SPECIFICATIONS (2500)

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WEIGHT
Total Weight 390 lb. (177 kg)
ENERGY 250 ft.-lb. (339 J) CLASS
BLOWS PER MINUTE (Hyd. Oil @ 200F)(43.3C) 780 @ 12.5 GPM (47 L/min.)
RECOMMENDED HYDRAULIC OIL FLOW (For Optimum 10 to 15 GPM (23 to 57 L/min.)
Performance)
MINIMUM OPERATING PRESSURE 1800 PSI (12411 bar)

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93 of 260 30-30-1 Service Manual
SPECIFICATIONS (3500)

WEIGHT
Total Weight 390 lb. (177 kg)
ENERGY 350 ft.-lb. (475 J) CLASS
BLOWS PER MINUTE (Hyd. Oil @ 200F)(43.3C) 480 @ 12.9 GPM (47 L/min.)
RECOMMENDED HYDRAULIC OIL FLOW (For Optimum 13 to 18 GPM (49 to 68 L/min.)
Performance)
MINIMUM OPERATING PRESSURE 1800 PSI (12411 bar)

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

Dealer Copy -- Not for Resale

Hydraulic Breaker
94 of 260 30-30-2 Service Manual
2560/3560 HYDRAULIC BREAKER SERVICE

DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 40-20-1


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

PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-6

NITROGEN CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1 2560/3560


Charging the Nitrogen Chamber . . . . . . . . . . . . . . . . . . . . 40-10-3 HYDRAULIC
Checking The Nitrogen Chamber Charge Pressure . . . . . 40-10-1 BREAKER SERVICE
Releasing Pressure From The Nitrogen Chamber. . . . . . . 40-10-1

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

Dealer Copy -- Not for Resale


TROUBLESHOOTING THE HYDRAULIC BREAKER . . . . . . 40-10-4

Hydraulic Breaker
40-01 Service Manual
95 of 260
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Hydraulic Breaker
40-02 Service Manual
96 of 260
NITROGEN CHAMBER Checking The Nitrogen Chamber Charge Pressure

Releasing Pressure From The Nitrogen Chamber Use the nitrogen accumulator charge pressure gauge
MEL1523B to check pressure.

Figure 40-10-3
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
When fluids are under pressure.
Flying debris or loose material is present. 1
Engine is running.
Tools are being used.
W-2019-1285

Figure 40-10-1

P-1828

Remove the plug (Item 1) [Figure 40-10-3].

Dealer Copy -- Not for Resale


Figure 40-10-4

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


charge valve.

Figure 40-10-2

P18084

Install the correct adapter (Item 1) [Figure 40-10-4] on


the gauge.

Using a sm all shaft (Item 1) [Figure 40-10-2], push the


valve inward to release the gas pressure.

Install the plug in the charge valve hole.

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97 of 260 40-10-1 Service Manual
NITROGEN CHAMBER (CONTD) Figure 40-10-7

Checking The Nitrogen Chamber Charge Pressure


(Contd)

Figure 40-10-5

1
2

P-65363
0.125
(3,2 mm)
Tighten the adapter (Item 1) [Figure 40-10-7] on th e
breaker.
P-42758
Figure 40-10-8

With the adapter (Item 1) tig htened on the ga uge,


measure the pin (Item 2) [Figure 40-10-5] protrusion.

Dealer Copy -- Not for Resale


Manually extend or retract the pin until the pin measures
0.125 in. (3,2 mm) from pin tip to adapter face. 1

Figure 40-10-6

P-65363

Slowly turn the gauge valve body (Item 1) [Figure 40-10-


8] clockwise until the gauge shows a reading. If th e
pressure is low, recharge the breaker using charging kit
number 6568037.

P-42759 NOTE: The correct charge pressure is 350 PSI (24,13


bar)

Loosen the adapter until the pin is flush with the e nd of


the adapter as shown [Figure 40-10-6].

Install the gauge/adatper on the breaker.

Hydraulic Breaker
98 of 260 40-10-2 Service Manual
NITROGEN CHAMBER (CONTD) Figure 40-10-10

Charging the Nitrogen Chamber

Use charging kit (P/N 6568037) to charge the nitrogen Connect This End To
chamber. Nitrogen Chamber

The nitrogen chamber charge valve is located on the


front side of the nitrogen chamber housing.

WARNING Connect Hose From


Nitrogen Bottle Here

Wear safety glasses to prevent eye injury when any 350 PSI (24,14 BAR) B-7196
of the following conditions exist:
When fluids are under pressure.
Flying debris or loose material is present. NOTE: Be sure to use the adapter (P/N 6661802) (Item
Engine is running. 1) [Figure 40-10-10] and the correct side of the
Tools are being used. charging tool.
W-2019-1285

Connect the nitrogen hose to the charging tool.


Figure 40-10-9

Dealer Copy -- Not for Resale


SLOWLY open the charging valve on th e nitrogen tank
and fill the nitrogen chamber on the breaker to 35 0 PSI
(24,14 bar).

Close the valve on the nitrogen tank.

Disconnect the hose and charging tool.

Install and tighten the plug.

Install the charging tool in the charge valve [Figure 40-


10-9].

Hydraulic Breaker
99 of 260 40-10-3 Service Manual
TROUBLESHOOTING THE HYDRAULIC BREAKER

WARNING
Instructions are necessary before operating or
servicing machine. Read Operation & M aintenance
Manuals, Handbook and signs (decals) on ma chine.
Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing.
Check for correct function after adjustments, repairs
or service. Failure to follow instructions can cause
injury or death.
W-2003-1289

If the Hydraulic Breaker is not working correctly, check the hydraulic system of the Bobcat Loader or excavator thoroughly
before making any repairs on the breaker. Hydraulic Breaker performance can be affected by a hydraulic system that is
not 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 to
check 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 correct

Dealer Copy -- Not for Resale


problems with the Hydraulic Breaker which most often occur.

PROBLEM CAUSE CORRECTION


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 on
the loader.
No hydraulic flow to the breaker. Check the hydraulic flow to the breaker.
Loader hydraulic pump not working. Check flow of loader hydraulic pump.
Repair or replace as needed.
Nitrogen chamber not at correct pressure. Charge to required pressure.
Damaged quick couplers. Replace quick couplers.
Damaged electrical connection to breaker Check wiring harness and switch.
valve (backhoe mounted unit only).
Breaker runs very slowly or blow per Loader main relief valve set too low. Adjust main relief valve to correct setting.
minute reducing. Not enough hydraulic flow. Test loader hydraulics for correct flow and
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 correct pressure
(400 PSI maximum).
Internal leakage. Check seals and O-rings in the breaker.
Excessive back pressure. Check for plugged or kinked return lines.
Damaged quick couplers. Replace quick couplers.

Hydraulic Breaker
100 of 260 40-10-4 Service Manual
TROUBLESHOOTING THE HYDRAULIC BREAKER (CONT'D)

WARNING
Instructions are necessary before operating or
servicing machine. Read Operation & M aintenance
Manuals, Handbook and signs (decals) on ma chine.
Follow warnings and instructions in t he manuals
when making repairs, adjustments or servicing.
Check for correct function after adjustments, repairs
or service. Failure to follow instructions can cause
injury or death.
W-2003-1289

PROBLEM CAUSE CORRECTION


Breaker fires erratically. Loader main relief valve set too low. Adjust main relief valve to correct
setting.
Excessive back pressure. Check for plugged or bent return lines.
Low fluid level. Add fluid to the reservoir as needed.

Dealer Copy -- Not for Resale


Tool binding. Add grease to the tool shank fitting.
Damaged electrical connection to Check wiring harness and switch.
breaker valve (backhoe mounted unit
only).
Damaged quick couplers. Replace quick couplers.
Excessive pressure pulsations. Incorrect hoses. Refer to Serviceletter 13 May 1996.
Quick coupler failure. Refer to Serviceletter 13 May 1996.
Nitrogen chamber pressure Refer to Serviceletter 13 May 1996.
insufficient.
Breaker valve seal pressure. Refer to Serviceletter 13 May 1996.

Hydraulic Breaker
101 of 260 40-10-5 Service Manual
PARTS IDENTIFICATION

8
3

3 3

6
26
3
21 4
3
7 5
27
3 5
3
8 8
3
11 9

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3
12

13
25
3
1. Accumulator 10
2. Charge Valve Assembly 22
3 24 23
3. O-ring
4. Seal 3 18
5. Rod Seal 22 4
6. Seal Carrier 22 4 24
7. Manifold 24
3 4
8. O-ring Plug 23
22 8 4
9. Piston
10. Piston Sleeve 3 8 19
17
11. Valve Cap 3
23
12. Spool Sleeve 14 4 3
24
13. Valve Sleeve
23 20
14. Valve Spool
15. Main Body
16. Grease Fitting 3
17. Rod Wiper
18. Lower Body Assembly
19. Upper Bushing 3
20. Lower Bushing 3 16
8
21. Bolt
22. Backup Ring
23. Roll Pin
24. Pin
25. Dowel Pin
26. Bolt
27. Washer TS1153

Hydraulic Breaker
102 of 260 40-10-6 Service Manual
DISASSEMBLY AND ASSEMBLY Figure 40-20-2

WARNING
Wear safety glasses to prevent eye injury when any
of 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 tools listed will be needed to service the breaker:

MEL1430 - Hydraulic Breaker Sleeve Puller 6568037 - Put the breaker in a stand [Figure 40-20-2].
Charging Kit or MEL1523A
Figure 40-20-3
Read and understand the complete disassembly and
assembly procedure before beginning the operation.

NOTE: Always replace O-rings and seals when

Dealer Copy -- Not for Resale


servicing the breaker.

Before you remove the breaker from the frame do th e


following:

Release the pressure from the ac cumulator. (See


Releasing Pressure From The Nitrogen Chamber on
Page 40-10-1.)

NOTE: It is recommended that the hydraulic hoses be


loosened at the breaker fittings to release any
trapped hydraulic pressure.

Have a s econd person assist in the h ydraulic breaker


removal while the operator remains in the operator seat.

Figure 40-20-1

Loosen the top 4 bolts (Item 1) [Figure 40-20-3]. Do not


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

Hydraulic Breaker
103 of 260 40-20-1 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) NOTE: For clarity purposes, the breaker frame is
removed. However, most of the breaker
Have a second person disconnect the hydraulic quick servicing can be done with frame installed.
couplers from the loader and remove them from the hose
guide on the boom arm. NOTE: The frame can be left in the breaker stand
during repair if needed.
Remove the pivot pin bolts and the pins.
Nitrogen Chamber Removal and Installation
Slowly move the loader away from the breaker.
Figure 40-20-6
Use a chain hoist to control the frame while removing or
installing the mounting bolts (Item 1) [Figure 40-20-3 on
Page 40-10-1].

Figure 40-20-4

Dealer Copy -- Not for Resale


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 and


washer (Item 1) [Figure 40-20-6]. Tighten the bolts to
Remove the lock plates [Figure 40-20-4]. 200 ft.-lb. (271 Nm) torque in a cross pattern.

Figure 40-20-5 Repeat the tightening pattern to 5 00 ft.-lb. (678 Nm)


torque.

Figure 40-20-7

Remove the 4 mou nting bolts from the b reaker [Figure


40-20-5].

Installation: Put anti-sieze on the bolt threads and the Remove the nitrogen chamber [Figure 40-20-7].
shank of the bolt. Tighten the bolts to 300 ft.-lb. (407
Nm) torque. Replace the large O-ring (Item 1) [Figure 40-20-7] on the
nitrogen chamber.
Lower the frame to the floor and remove the chain.

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104 of 260 40-20-2 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 40-20-10

Nitrogen Chamber Removal and Installation (Cont'd)

Figure 40-20-8

Remove the seal carrier (Item 1) [Figure 40-20-10] from


the piston.

NOTE: Check the seal carrier for scratches, damaged


Replace the small O-ring (Item 1) [Figure 40-20-8] from seals, back-up washers or oil seals. Check the
the bottom surface of the nitrogen chamber. piston for wear areas.

Dealer Copy -- Not for Resale


Piston Removal Figure 40-20-11

Figure 40-20-9

Check the piston shaft and grooves for wear [Figure 40-
20-11].
Install an eye bolt in the end of the piston and remove the
piston [Figure 40-20-9].

Remove the piston slowly to prevent damage to the seal


carrier (Item 1) [Figure 40-20-9] and the piston.

NOTE: If the piston is clean or slightly discolored it is


an indication that the seal carrier is in good
condition.

Hydraulic Breaker
105 of 260 40-20-3 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 40-20-14

Piston Removal (Cont'd)

Figure 40-20-12

B-15066

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

Installation: Put oil on the se als and install with the lips
Remove the O-rings from the carrier [Figure 40-20-12]. down.

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

Dealer Copy -- Not for Resale


Figure 40-20-13 Use MEL1430 (Hydraulic Breaker Sleeve Puller) for the
following procedure:

Figure 40-20-15

Remove the back-up washer from the lower o-ring


groove [Figure 40-20-13].

NOTE: The back-up washer is located only in groove Install the puller hooks until the spring loaded pins (Item
(Item 1) [Figure 40-20-13]. 1) [Figure 40-20-15] are under the sleeve lip.

Installation: Put oil on the back-up washer and install on NOTE: Rotate the puller to be sure the puller pins are
the upper side of the O-ring. in the sleeve holes to prevent damage during
sleeve removal.

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106 of 260 40-20-4 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 40-20-18

Piston Sleeve Removal (Cont'd)

Figure 40-20-16

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

Valve Removal and Installation

Remove the O-rings from the carrier [Figure 40-20-16]. Figure 40-20-19

Tighten the nut un til the s leeve pulls free from the main

Dealer Copy -- Not for Resale


body [Figure 40-20-16].

Figure 40-20-17

Remove the bolts from the valve manifold [Figure 40-20-


19].

Installation: Put anti-sieze on th e bolt threads and


tighten to 70 to 75 ft.-lb. (95 to 102 Nm) torque.
Remove the sleeve [Figure 40-20-17].

Hydraulic Breaker
107 of 260 40-20-5 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 40-20-22

Valve Removal and Installation (Cont'd)

Figure 40-20-20

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

A pry bar used with a wooden block will also work to


remove the valve.
Replace the O -rings (Item 1) [Figure 40-20-20] on the
bottom of the manifold. NOTE: Be careful not to damage the face of the main
body.

Dealer Copy -- Not for Resale


Figure 40-20-21
NOTE: The spool should slide freely when the valve is
shaken.

Figure 40-20-23

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

Install a bolt in the hole of the valve cap.

Remove the O-rings and back-up washers from the valve


[Figure 40-20-23].

NOTE: The position of the O-rings and back-up


washers are VERY important during
assembly. Use insert for O-ring and back-up
washer location [Figure 40-20-23].

Hydraulic Breaker
108 of 260 40-20-6 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 40-20-26

Valve Removal and Installation (Cont'd)

Figure 40-20-24

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


cap.

Figure 40-20-27
Remove the cap from the valve [Figure 40-20-24].

Figure 40-20-25

Dealer Copy -- Not for Resale


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

NOTE: Rotating the spool while holding the valve will


Pry the sleeve from the cap [Figure 40-20-25]. aid during removal and installation.

NOTE: Rotate the sleeve to remove or install in the NOTE: Check the valve and spool for scratches.
cap.
Install the spool in the valve.

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


tighten.

Install the valve in the upper section.

Hydraulic Breaker
109 of 260 40-20-7 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 40-20-30

Valve Removal and Installation (Cont'd)

Figure 40-20-28

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

Installing Piston Sleeve


Use a s oft hammer to tap the valve until it s eats in
position [Figure 40-20-28]. Put the upper section in a press.

Dealer Copy -- Not for Resale


Main Body Removal and Installation Put oil on the O-rings, the outside of the sleeve and the
inside of the main body before installation.
Figure 40-20-29
Figure 40-20-31

Remove the main body from the lower body [Figure 40-
20-29]. Install the sleeve in the upper section [Figure 40-20-31].

NOTE: Lower sleeve slowly into upper section being


careful not to damage O-rings.

Hydraulic Breaker
110 of 260 40-20-8 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 40-20-34

Installing Piston Sleeve (Cont'd)

Figure 40-20-32

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

Figure 40-20-35
Press the sleeve slowly until it seats [Figure 40-20-32].

Lower Section Bushings Removal and Installation

Dealer Copy -- Not for Resale


NOTE: The lower bushings are not interchangeable.

Figure 40-20-33

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

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

Hydraulic Breaker
111 of 260 40-20-9 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 40-20-38

Lower Section Bushings Removal and Installation


(Cont'd)

Figure 40-20-36

The bushings are grooved in di fferent locations [Figure


40-20-38].

NOTE: The bushing pin holes and grooves will line up


in their original position and location only.
Remove the lower bushing [Figure 40-20-36].
Figure 40-20-39

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Figure 40-20-37

The pins (Item 1) [Figure 40-20-39] are rubber mounted


Repeat the same procedure to remove the upper bushing and hold the breaker tool retaining pin in position.
[Figure 40-20-37].
The pins usually do no t need replacing until they are
visibly worn out [Figure 40-20-39].

Hydraulic Breaker
112 of 260 40-20-10 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 40-20-42

Piston and Seal Carrier Installation

After the upper section and lower section have been


repaired do the following:

Set the lower section on the point in the stand.

Align the dowel and put the main body on the lower
section.

Figure 40-20-40

Use a soft hammer and a tool of the same diameter as


the seal carrier to tap the seal carrier into position
[Figure 40-20-42].

Start Up Procedure

Install the Hydraulic Breaker on the Bobcat Loader,

Dealer Copy -- Not for Resale


backhoe or excavator. Connect the quick couplers.

Start the engine. Raise the tool off the work surface and
engage the auxiliary hydraulics.

Slowly lower the piston in the sleeve, being careful not to Run the breaker for several minutes until the air is
damage the piston or the sleeve [Figure 40-20-40]. removed from the breaker.

Figure 40-20-41 Figure 40-20-43

Install the seal carrier in the upper section as s hown The extent of wear in the upper and lower bushings is
[Figure 40-20-41]. checked by installing a new bit ( Item 1) [Figure 40-20-
43] in the hydraulic breaker and checking the ga p
between the lower bushing and the tool bit shaft.

There can be no more than 0.25 in. (6,35 mm) gap


between the lower bushing and a new tool bit [Figure 40-
20-43].

Hydraulic Breaker
113 of 260 40-20-11 Service Manual
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Hydraulic Breaker
114 of 260 40-20-12 Service Manual
SPECIFICATIONS

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WEIGHT
Breaker With Cradle 470 lb. (210 kg)
Two Position Frame 360 lb. (160 kg)
ENERGY
2560 300 ft.-lb. Class
3560 500 ft.-lb. Class
BLOWS PER MINUTE (Hyd. Oil @ 200F) (93.3C)
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)

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

Hydraulic Breaker
115 of 260 40-30-1 Service Manual
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Hydraulic Breaker
116 of 260 40-30-2 Service Manual
2570/3570 HYDRAULIC BREAKER SERVICE

CHECKING MOUNTING BOLT TORQUE . . . . . . . . . . . . . . 50-10-10

DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 50-20-1


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

HYDRAULIC BREAKER LUBRICATION . . . . . . . . . . . . . . . . 50-10-9


2570/3570
PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-14 HYDRAULIC

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

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

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

TROUBLESHOOTING THE HYDRAULIC BREAKER . . . . . 50-10-12

Hydraulic Breaker
50-01 Service Manual
117 of 260
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Hydraulic Breaker
50-02 Service Manual
118 of 260
NITROGEN CHAMBER Figure 50-10-2

Releasing Pressure From The Nitrogen Chamber

The nitrogen chamber valve is located on the front side of


the hydraulic breaker.

WARNING
Wear safety glasses to prevent eye injury when any
of 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 Using a small shaft, push the valve (Item 1) [Figure 50-
10-2] inward to release the gas pressure.

NOTE: Release the charge pressure when storing the Install the plug in the charge valve.
hydraulic breaker for an extended period of
time. Checking The Nitrogen Chamber Charge Pressure

Dealer Copy -- Not for Resale


Figure 50-10-1 Use the nitrogen accumulator charge pressure gauge
MEL1523B to check pressure.

Remove the plug (Item 1) [Figure 50-10-1].

Figure 50-10-3

Remove the pl ug (Item 1) [Figure 50-10-1] from the


charge valve.

P18084

Install the correct adapter (Item 1) [Figure 50-10-3] on


the gauge.

Hydraulic Breaker
119 of 260 50-10-1 Service Manual
NITROGEN CHAMBER (CONTD) Figure 50-10-6

Checking The Nitrogen Chamber Charge Pressure


(Contd)

Figure 50-10-4

0.125
(3,2 mm) Tighten the adapter (Item 1) [Figure 50-10-6] on th e
breaker.

P-42758 Figure 50-10-7

With the adapter (Item 1) tig htened on the ga uge,


measure the pin (Item 2) [Figure 50-10-4].

Dealer Copy -- Not for Resale


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

Figure 50-10-5

Slowly turn the gauge valve body (Item 1) [Figure 50-10-


7] clockwise until the gauge shows a reading. If th e
pressure is low, recharge the breaker using charging kit
number 6568037.

NOTE: The correct charge pressure is 350 PSI (24,14


bar).
P-42759

Loosen the adapter until the pin is flush with the e nd of


the adapter as shown [Figure 50-10-5].

Install the gauge/adapter on the breaker.

Hydraulic Breaker
120 of 260 50-10-2 Service Manual
NITROGEN CHAMBER (CONTD) Figure 50-10-9

Charging The Nitrogen Chamber

WARNING
Wear safety glasses to prevent eye injury when any
of 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

NOTE: When in doubt of nitrogen charge pressure or Remove the plug (Item 1) [Figure 50-10-9].
when recharging a hot breaker, release the
nitrogen pressure completely and recharge Figure 50-10-10
the nitrogen chamber.

Figure 50-10-8

Dealer Copy -- Not for Resale


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

Block up the breaker so the tool bit (Item 1) [Figure 50-


10-8] is not under pressure and is not in contact with the
piston.

Hydraulic Breaker
121 of 260 50-10-3 Service Manual
NITROGEN CHAMBER (CONTD) Figure 50-10-13

Charging The Nitrogen Chamber (Cont'd)

Figure 50-10-11

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

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


breaker.

Dealer Copy -- Not for Resale


Remove the cap (Item 2) [Figure 50-10-11] from the
charging 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 the
nitrogen chamber to 350 PSI (24,14 bar). Close the valve
on the nitrogen tank.

Disconnect the hose and charging tool.

Hydraulic Breaker
122 of 260 50-10-4 Service Manual
NITROGEN CHAMBER (CONTD) Figure 50-10-15

Checking The Accumulator Charge Pressure

WARNING 1

Wear safety glasses to prevent eye injury when any


of 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
P-29454

Use the nitrogen accumulator charge pressure gauge


MEL1523B to check pressure. Install the correct adapter (Item 1) [Figure 50-10-15] on
the gauge.
Figure 50-10-14
Figure 50-10-16

Dealer Copy -- Not for Resale


1

0.125
(3,2 mm)

P-42758
Remove the plug (Item 1) [Figure 50-10-14].

With the adapter (Item 1) ti ghtened on the g auge,


measure the pin (Item 2) [Figure 50-10-16].

Manually extend or retract the pin until the pin measures


0.125 in. (3,2 mm) from pin tip to adapter face.

Hydraulic Breaker
123 of 260 50-10-5 Service Manual
NITROGEN CHAMBER (CONTD) Figure 50-10-19

Checking The Accumulator Charge Pressure (Contd)

Figure 50-10-17

Slowly turn the gauge valve body (Item 1) [Figure 50-10-


19] clockwise until the gauge shows a r eading. If th e
P-42759 pressure is low, recharge the breaker using charging kit
number 6568037.
Loosen the adapter until the pin is flush with the e nd of
NOTE: The correct charge pressure is 1000 PSI (68,97
the adapter as shown [Figure 50-10-17].
bar).

Dealer Copy -- Not for Resale


Figure 50-10-18

Install the gauge adapter on the breaker.

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


breaker.

Hydraulic Breaker
124 of 260 50-10-6 Service Manual
NITROGEN CHAMBER (CONTD)

Releasing Pressure From The Accumulator

Figure 50-10-20

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


charge valve.

Dealer Copy -- Not for Resale


Figure 50-10-21

Using a small shaft, push the valve (Item 1) [Figure 50-


10-21] inward to release the gas pressure.

Install the plug in the charge valve.

Hydraulic Breaker
125 of 260 50-10-7 Service Manual
NITROGEN CHAMBER (CONTD) Figure 50-10-23

Charging The Accumulator

Use kit 6568037 to charge the accumulator.

To gain access to the accumulator, put the hydraulic


breaker in the horizontal operating position.

Figure 50-10-22

Dealer Copy -- Not for Resale


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

Install the ch arge tool (Item 1) [Figure 50-10-23] in the


charge valve.

NOTE: Be sure to install the side of the charging tool


which reads "above 100 PSI".

Connect the hose (Item 2) to the charge tool fitting (Item


1) [Figure 50-10-23].

SLOWLY open the valve on the nitrogen tank until the


gauge reads 1000 PSI (68,97 bar). Close the valve on
the nitrogen tank.

Remove the hose, charge tool, and adaptor.

Install the plug in the charge valve.

Hydraulic Breaker
126 of 260 50-10-8 Service Manual
HYDRAULIC BREAKER LUBRICATION

Put the breaker in the vertical position so the point is on


the ground and the point is pushed up inside the breaker
as far as possible.

Figure 50-10-24

Stop the engine and have a second person add grease to

Dealer Copy -- Not for Resale


the fitting (Item 1) [Figure 50-10-24].

Apply grease (4 to 5 pumps) to the upper end of the tool


at the grease fitting (Item 1) [Figure 50-10-24] every 4 to
8 hours of operation or when the tool bit looks dry.

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

IMPORTANT
Underwater use of the breaker will cause internal
damage. No por tion of t he breaker may be
submerged.
I-2053-0589

Hydraulic Breaker
127 of 260 50-10-9 Service Manual
CHECKING MOUNTING BOLT TORQUE

Figure 50-10-25

Check the snap rings, lock plates and breaker mounting


bolts (Item 1) [Figure 50-10-25] every day.

If the snap rings and lock plates are missing, tighten the
bolts to 300 ft.-lb. (407 Nm) torque. Lock plates can be

Dealer Copy -- Not for Resale


turned 180 for a different alignment if necessary.

Hydraulic Breaker
128 of 260 50-10-10 Service Manual
TOOL BIT REMOVAL AND INSTALLATION Figure 50-10-27

Figure 50-10-26

Install the tool bit and align the notch (in the tool) with the
retaining pin hole [Figure 50-10-27].
Use a pun ch and a h ard rubber hammer to remove the
retaining pin from the tool [Figure 50-10-26]. Figure 50-10-28

NOTE: The retaining pin can be driven out or installed


from either side.

Dealer Copy -- Not for Resale


WARNING
AVOID BURN INJURY
Breaker bit can be hot after use. Let breaker bit cool
before removing bit or servicing breaker.
W-2204-0595

Put grease on th e top 8 i n. (203 mm) of t he tool before


installing the tool.
Use a har d rubber hammer to in stall the retaining pin
NOTE: During normal operation, the grease will heat [Figure 50-10-28].
up and run down the tool shaft.

NOTE: Grease the fitting every 4 to 8 hours of


operation or if the tool bit looks dry.

Hydraulic Breaker
129 of 260 50-10-11 Service Manual
TROUBLESHOOTING THE HYDRAULIC BREAKER

WARNING
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Handbook and
signs (decals) on machine. Follow warnings and
instructions in the manuals when making repairs,
adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained
operators and f ailure to follow instructions can
cause injury or death.
W-2003-0199

If the Hydraulic Breaker is not working correctly, check the hydraulic system of the Bobcat Loader or excavator thoroughly
before making any repairs on the breaker. Hydraulic Breaker problems can be affected by a hydraulic system that is not
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 to check flow
and pressure. (See the loader Service Manual for the correct procedure to connect the flow meter).

Dealer Copy -- Not for Resale


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

PROBLEM CAUSE CORRECTION


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 the
loader or excavator.
No hydraulic flow to the breaker. Check the hydraulic flow to the breaker.
Loader or excavator hydraulic pump not working. Check flow of lo ader hydraulic pump. Repair or
replace as needed.
Nitrogen chamber not at correct pressure. Charge to required pressure.
Damaged quick couplers. Replace quick couplers.
Breaker runs very slowly or Loader or excavator main relief valve set too low. Adjust main relief valve to correct setting
low blow energy. Not enough hydraulic flow. Test loader or excavator hydraulics for correct flow
and pressure.
Excessive heat build up. Check oil cooler for debris and air flow. Check
loader or excavator relief valve pressure.
Damaged quick couplers. Replace quick couplers.
Nitrogen chamber pressure incorrect Check and fill to correct pressure.
Internal leakage. Check seals and O-rings in the breaker. Check
piston, sleeve and seal carrier for wear.
Excessive back pressure. Check for plugged or bent return lines.
Breaker fires erratically. Loader or excavator main relief valve set too low. Adjust main relief valve to correct setting.
Excessive back pressure. Check for plugged or bent return lines.
Low fluid level. Add fluid to the reservoir as needed.
Damaged quick couplers. Replace quick couplers.
Tool binding. Add grease to the tool shank fitting.

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130 of 260 50-10-12 Service Manual
TROUBLESHOOTING THE HYDRAULIC BREAKER (CONTD)

PROBLEM CAUSE CORRECTION


Excessive heat build up. Blank firing. Refer to the hydraulic controls section of the
Operation And Maintenance Manual for
correct operating procedure.
Loader or excavator fluid reservoir is low. Add hydraulic fluid to the fluid reservoir on the
loader or excavator.
Excessive breaker inlet Accumulator charge pressure low or accu Check and fill to correct pressure or service
hose pulsations. mulator damaged. accumulator.

Dealer Copy -- Not for Resale

Hydraulic Breaker
131 of 260 50-10-13 Service Manual
PARTS IDENTIFICATION

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Hydraulic Breaker
132 of 260 50-10-14 Service Manual
PARTS IDENTIFICATION (CONTD)

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Hydraulic Breaker
133 of 260 50-10-15 Service Manual
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Hydraulic Breaker
134 of 260 50-10-16 Service Manual
DISASSEMBLY AND ASSEMBLY Figure 50-20-2

Breaker Frame Removal And Installation

WARNING
Wear safety glasses to prevent eye injury when any
of 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 tools listed will be needed to service the breaker. Install a hoist (Item 1) [Figure 50-20-2]. Raise the hoist
until the weight of the breaker is supported by the hoist.
MEL1430-Hydraulic Breaker Sleeve Puller
6568037-Charging Kit Figure 50-20-3
MEL1523B

Figure 50-20-1

Dealer Copy -- Not for Resale


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

Place the hydraulic breaker on blocks (Item 1) [Figure Figure 50-20-4


50-20-1].

Release the pressure from the nitrogen chamber and


accumulator. (See Releasing Pressure From The
Nitrogen Chamber on Page 40-10-1.)

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

Hydraulic Breaker
135 of 260 50-20-1 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-7

Breaker Frame Removal And Installation (Cont'd)

Mark the hoses for correct installation.

Figure 50-20-5

Install a puller (Item 1) in the pivot pins (Item 2) [Figure


50-20-7].

Remove the pivot pins (both sides).

Figure 50-20-8
Remove the hoses (Item 1) [Figure 50-20-5] from the

Dealer Copy -- Not for Resale


frame. Install caps and plugs.

Figure 50-20-6

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


frame.

Remove the bolts (Item 1) [Figure 50-20-6] and nuts


from the pivot pins.

Installation: Tighten the bolts to 25 to 28 ft.-lb. (34 to 38


Nm) torque.

Hydraulic Breaker
136 of 260 50-20-2 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-11

Breaker Frame Removal And Installation (Cont'd)

Figure 50-20-9

Mark the hoses for correct installation. Remove the


hoses (Item 1) [Figure 50-20-11]. Install caps and plugs.

Remove the tool bit (Item 2) [Figure 50-20-10]. (See


Raise the hoist (Item 1) [Figure 50-20-9] that is attached TOOL BIT REMOVAL AND INSTALLATION on Page 50-
to the breaker. 10-11.)

Dealer Copy -- Not for Resale


Remove the frame (Item 2) [Figure 50-20-9]. Figure 50-20-12

Figure 50-20-10

Install a lift eye (Item 1) and hoist (Item 2) [Figure 50-20-


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

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137 of 260 50-20-3 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-15

Breaker Frame Removal And Installation (Cont'd)

Figure 50-20-13

Remove the snap ring (Item 1) and retainer (Item 2) from


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

Raise the hoist and stand the breaker on end [Figure 50- Remove the 4 bolts (Item 1) [Figure 50-20-15].
20-13].
Installation: Apply anti-seize to the bolt threads. Tighten

Dealer Copy -- Not for Resale


Figure 50-20-14 the bolts to 300 ft.-lb. (407 Nm) 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.

Installation: Tighten the bolts to 65 to 70 ft.-lb. (88 to 95


Nm) torque.

Hydraulic Breaker
138 of 260 50-20-4 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Nitrogen Chamber Removal And Installation

Breaker Frame Removal And Installation (Cont'd) NOTE: Do not us e an impact wrench to loosen or
tighten the tie rods.
Figure 50-20-17
Figure 50-20-18

Raise the breaker and remove the frame [Figure 50-20-


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

Dealer Copy -- Not for Resale


Stand the breaker on the work surface.
Installation: Apply anti-seize to the threads of the tie
NOTE: Do not disassemble or assemble the breaker rods and both sides of the washers.
while it is laying on its side.
Tighten the tie rods to 150 ft.-lb. (203 Nm) pretorque.
Final tighten to 500 ft.-lb. (678 Nm) 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].

Hydraulic Breaker
139 of 260 50-20-5 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-22

Nitrogen Chamber Disassembly And Assembly

Figure 50-20-20

Remove the charge valve assembly (Item 1) [Figure 50-


20-22].

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

Figure 50-20-21

Dealer Copy -- Not for Resale


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

Remove the O-ring (Item 1) [Figure 50-20-21]. Figure 50-20-24

Remove the charge valve (Item 1) [Figure 50-20-24].

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-27

Nitrogen Chamber Disassembly And Assembly


(Cont'd)

Figure 50-20-25

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

Figure 50-20-28

Remove the spool (Item 1) and O-rings (Item 2) [Figure


50-20-25] from the charge valve and spool.

Dealer Copy -- Not for Resale


Piston Removal And Installation

Figure 50-20-26

Raise the hoist slowly to pr event damaging the seal


carrier (Item 1) [Figure 50-20-28].

Use a s oft faced hammer to di slodge the piston if


necessary.

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

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


piston.

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-31

Piston Removal And Installation (Cont'd)

Figure 50-20-29

Remove the 2 seals (Item 1) [Figure 50-20-31] from the


inside of the seal carrier.

Figure 50-20-32
Remove the seal carrier (Item 1) [Figure 50-20-29] from
the piston.

Dealer Copy -- Not for Resale


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

NOTE: If the piston is clean or slightly discolored it is


an indication that the seal carrier is in good
condition.

Figure 50-20-30

Remove the 3 O-rings (Item 1) and backup ring (Item 2)


[Figure 50-20-32] from the outside of the seal carrier.

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

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142 of 260 50-20-8 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-35

Piston Sleeve Removal

Use MEL1430 (Hydraulic Breaker Sleeve Puller) for the


following procedure:

Figure 50-20-33

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

Figure 50-20-36

Dealer Copy -- Not for Resale


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

NOTE: Rotate the puller to be sure the puller pins are


in the sleeve holes to prevent damage during
sleeve removal.

Figure 50-20-34

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

Tighten the nut un til the s leeve pulls free from the main
body [Figure 50-20-34].

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143 of 260 50-20-9 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Valve Removal And Installation

Piston Sleeve Installation Figure 50-20-39

Put the upper section in a press.

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

Figure 50-20-37

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

Figure 50-20-40

Dealer Copy -- Not for Resale


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

NOTE: Lower sleeve slowly into the upper section


being careful not to damage O-rings.

Figure 50-20-38

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


fittings.

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

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-43

Valve Removal And Installation (Cont'd)

Figure 50-20-41

Remove the 2 O -rings (Item 1) [Figure 50-20-43] from


the valve manifold.

Figure 50-20-44
Remove the 8 bolts (Item 1) [Figure 50-20-41] from the
valve manifold.

Dealer Copy -- Not for Resale


Installation: Apply anti-seize to the bolt threads and
tighten to 70 to 75 ft.-lb. (95 to 102 Nm) torque.

Figure 50-20-42

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

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

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145 of 260 50-20-11 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-47

Valve Removal And Installation (Cont'd)

Figure 50-20-45

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

Figure 50-20-48

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


plugs.

Dealer Copy -- Not for Resale


Figure 50-20-46

Use a block of wood (Item 1) and punch (Item 2) to pry


the valve (Item 3) [Figure 50-20-48] from the housing.

Remove the valve.

Remove the plug (Item 1) [Figure 50-20-46] from the Installation: Totally submerge the valve in c lean
valve. hydraulic fluid. Saturate the v alve bore with clean
hydraulic fluid and with 1 motion, as quickly as possible,
Remove the O -ring (Item 1) [Figure 50-20-45] from the install the valve from the container of hydraulic fluid into
plug. the valve bore. Apply additional hydraulic fluid, if
necessary, to the valve and valve bore during installation
to prevent damage to the O-rings.

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146 of 260 50-20-12 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-51

Valve Removal And Installation (Cont'd)

Figure 50-20-49

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

Figure 50-20-52

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


valve.

Dealer Copy -- Not for Resale


Installation: Hand tighten the cap.

NOTE: Do not overtighten the cap.

Prior to i nstalling the valve in the valve bore, place the


valve in a clean container and add clean hydraulic fluid
until the valve is completely submerged.

Figure 50-20-50

Remove the O-ring (Item 1) [Figure 50-20-52].

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


cap.

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147 of 260 50-20-13 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Upper Housing Removal And Installation

Valve Removal And Installation (Cont'd) Figure 50-20-55

Figure 50-20-53

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

Remove the s pool (Item 1) [Figure 50-20-53] from the Figure 50-20-56
valve.

Dealer Copy -- Not for Resale


Figure 50-20-54

Installation: Align the dowel (Item 1) with the hole (Item


2) [Figure 50-20-56].

Remove the O -rings (Item 1) and backup rings (Item 2)


[Figure 50-20-54].

Installation: Saturate the O-rings and seals during


assembly with clean hydraulic fluid.

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148 of 260 50-20-14 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-59

Upper Housing Removal And Installation (Cont'd)

Figure 50-20-57

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

Remove the O -ring (Item 1) [Figure 50-20-58] from the


plugs.
Remove the plugs (Item 1) [Figure 50-20-57].
Figure 50-20-60
Figure 50-20-58

Dealer Copy -- Not for Resale


Remove the seals (Item 1) [Figure 50-20-60].
Remove the O-rings (Item 1) [Figure 50-20-58] from the
plugs.

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149 of 260 50-20-15 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-63

Accumulator Removal And Installation

Figure 50-20-61

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

Figure 50-20-64

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

Figure 50-20-62

Dealer Copy -- Not for Resale


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

Installation: Tighten the ca p to 600 ft.-lb. (814 Nm)


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

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150 of 260 50-20-16 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-67

Accumulator Removal And Installation (Cont'd)

Figure 50-20-65

Remove the charge valve (Item 1) [Figure 50-20-67].

Figure 50-20-68

Remove the charge valve assembly (Item 1) [Figure 50-


20-65] from the cap.

Dealer Copy -- Not for Resale


Figure 50-20-66

Remove the spool (Item 1) and O-rings (Item 2) [Figure


50-20-69] from the charge valve.

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


charge valve assembly.

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151 of 260 50-20-17 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Bushing Removal And Installation

Accumulator Removal And Installation (Cont'd) Figure 50-20-71

Figure 50-20-69

Figure 50-20-72

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

Figure 50-20-70

Dealer Copy -- Not for Resale


Use a h ammer and punch to dr ive the r oll pins (Item 1)
[Figure 50-20-71] in until the roll pins (Item 1) [Figure
50-20-72] on th e other side of th e housing can be
removed.
Remove the screen (Item 1) [Figure 50-20-70].
Remove the roll pins (Item 1) [Figure 50-20-72].
NOTE: The screen cannot be removed without
damage.

Remove the O-ring (not shown), under the screen if the


screen has been removed.

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152 of 260 50-20-18 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-75

Bushing Removal And Installation (Cont'd)

Figure 50-20-73

Figure 50-20-76

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

Figure 50-20-74

Dealer Copy -- Not for Resale


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.

Drive the roll pins (Item 1) [Figure 50-20-74] back until


the end of the roll pins are flush with the housing.

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-79

Bushing Removal And Installation (Cont'd)

Figure 50-20-77

Installation: Align the slot (Item 2) [Figure 50-20-78] in


the upper bushing with the hole (Item 1) [Figure 50-20-
79] in the housing.

Use a brass or aluminum bushing driver (Item 1) [Figure


50-20-77] to remove the upper bushing.

Dealer Copy -- Not for Resale


Figure 50-20-78

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

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154 of 260 50-20-20 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D)

Tool Bit Retaining Pins Removal And Installation

Figure 50-20-80

The pins (Item 1) [Figure 50-20-80] are rubber mounted


and hold the breaker tool retaining pin in position.

Dealer Copy -- Not for Resale


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

Wash the breaker parts in clean solvent and dry with


compressed air.

Inspect the p arts for burrs, scratches, cracks or other


damage. Use fine emery cloth to r emove any burrs or
scratches. Replace any parts that are cracked.

Lubricate the parts with clean hydraulic fluid during


assembly. Always install new O -rings and seals during
assembly.

Start Up Procedure

Install the Hydraulic Breaker on th e Bobcat Loader,


backhoe or excavator. Connect the quick couplers.

Start the engine. Raise the tool off the work surface and
engage the auxiliary hydraulics.

Run the breaker for several minutes until the air is


removed from the breaker.

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155 of 260 50-20-21 Service Manual
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156 of 260 50-20-22 Service Manual
SPECIFICATIONS

Dimensions are given for loader equipped with standard tires. Dimensions may vary with other types. 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.

Dealer Copy -- Not for Resale


WEIGHT
Breaker With Cradle and Tool 470 lb. (210 kg)
Two Position Frame 360 lb. (160 kg)
ENERGY
2570 300 ft.-lb. Class
3570 500 ft.-lb. Class
BLOWS PER MINUTE (Hyd. Oil @ 200F) (93.3C) 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.)

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157 of 260 50-30-1 Service Manual
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158 of 260 50-30-2 Service Manual
5060 HYDRAULIC BREAKER SERVICE

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

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

DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 60-20-1


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

Dealer Copy -- Not for Resale


HYDRAULIC BREAKER LUBRICATION . . . . . . . . . . . . . . . . 60-10-7
5060
HYDRAULIC BREAKER MOUNT INSPECTION . . . . . . . . . . 60-10-6 HYDRAULIC
BREAKER SERVICE
LOADER MOUNT REMOVAL AND INSTALLATION . . . . . . 60-10-12

NITROGEN CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1


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

PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-15

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

Hydraulic Breaker
60-01 Service Manual
159 of 260
Dealer Copy -- Not for Resale

Hydraulic Breaker
60-02 Service Manual
160 of 260
NITROGEN CHAMBER Figure 60-10-2

Releasing Pressure From The Nitrogen Chamber

NOTE: Release the charge pressure when storing the


hydraulic breaker for an extended period of
time.

The nitrogen chamber charge valve is located on the


front side of the hydraulic breaker.

WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
When fluids are under pressure. Using a small shaft, push the charge valve (Item 1)
Flying debris or loose material is present. [Figure 60-10-2] in to release the gas pressure.
Engine is running.
Tools are being used. Install the plug (Item 1) [Figure 60-10-1] in the charge
W-2019-1285 valve after the pressure has been released.

Dealer Copy -- Not for Resale


Figure 60-10-1

Remove the pl ug (Item 1) [Figure 60-10-1] from the


charge valve.

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161 of 260 60-10-1 Service Manual
NITROGEN CHAMBER (CONTD) Figure 60-10-5

Checking The Nitrogen Chamber Charge Pressure

WARNING
Wear safety glasses to prevent eye injury when any 2
of the following conditions exist:
When fluids are under pressure.
Flying debris or loose material is present. 0.125
Engine is running. (3,2 mm)
Tools are being used.
W-2019-1285
P-42758

Use the nitrogen accumulator charge pressure gauge


MEL1523B to check pressure. With the adapter (Item 1) ti ghtened on the g auge,
measure the pin (Item 2) [Figure 60-10-5].
Figure 60-10-3
Manually extend or retract the pin until the pin measures
0.125 in. (3,2 mm) from pin tip to adapter face.

Dealer Copy -- Not for Resale


Figure 60-10-6

Remove the plug (Item 1) [Figure 60-10-3].

Figure 60-10-4 P-42759

Loosen the adapter until the pin is flush with the end o f
the adapter as shown [Figure 60-10-6].

1 Install the gauge/adatper on the breaker.

P-29454

Install the correct adapter (Item 1) [Figure 60-10-4] on


the gauge.

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162 of 260 60-10-2 Service Manual
NITROGEN CHAMBER (CONTD) Charging The Nitrogen Chamber

Checking The Nitrogen Chamber Charge Pressure


(Cont'd)

Figure 60-10-7
WARNING
Wear safety glasses to prevent eye injury when any
of 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

NOTE: When in doubt of nitrogen charge pressure or


when recharging a hot breaker, release the
nitrogen pressure completely and recharge
the piston.

Figure 60-10-9

Tighten the adapter (Item 1) [Figure 60-10-7] on th e


breaker.

Dealer Copy -- Not for Resale


Figure 60-10-8

Block up the breaker so the tool bit (Item 1) [Figure 60-


10-9] is not under pressure and is not in contact with the
piston.

Slowly turn the gauge valve body (Item 1) [Figure 60-10-


8] clockwise until the gauge shows a reading. If the
pressure is low, recharge the breaker using charging kit
number 6568037.

NOTE: The correct charge pressure is 230 PSI (15,86


bar).

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163 of 260 60-10-3 Service Manual
NITROGEN CHAMBER (CONTD) Install the charging tool (Item 1) [Figure 60-10-12] on the
breaker.
Charging The Nitrogen Chamber (Contd)
Remove the cap (Item 2) [Figure 60-10-12] from the
Figure 60-10-10 charging tool.

Figure 60-10-13

Remove the plug (Item 1) [Figure 60-10-10].

Figure 60-10-11
Connect the nitrogen hose (Item 1) to the charging tool

Dealer Copy -- Not for Resale


(Item 2) [Figure 60-10-13].

Slowly open the valve (Item 3) [Figure 60-10-13] on the


nitrogen tank and fill the n itrogen chamber to 230 PSI
(15,86 bar). Close the valve on the nitrogen tank.

Disconnect the hose and charging tool.

Figure 60-10-14

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

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164 of 260 60-10-4 Service Manual
BOB-TACH INSPECTION Figure 60-10-17

Figure 60-10-15

The spring loaded wedge (Item 1) [Figure 60-10-15]


must contact the lower edge of the hole in the attachment
Move the Bob-Tach levers to engage the wedges [Figure (Item 1) [Figure 60-10-16] and [Figure 60-10-17].
60-10-15]. The levers and wedges must move freely.
If the wedge does not contact the lower edge of the hole
The wedges must extend through the holes in th e [Figure 60-10-16] and [Figure 60-10-17], the
attachment mounting frame (Item 1) [Figure 60-10-15]. attachment will be loose and can come off the Bob-Tach.

Dealer Copy -- Not for Resale


Figure 60-10-18

WARNING
Bob-Tach wedges must extend through the holes in
attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0497

Figure 60-10-16

Inspect the mounting frame on th e attachment and the


Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 60-10-18]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.

Look for cracked welds.

Lubricate the wedges (See the correct loader Service


Manual for LUBRICATION OF THE BOBCAT LOADER).

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165 of 260 60-10-5 Service Manual
HYDRAULIC BREAKER MOUNT INSPECTION

Figure 60-10-19

Inspect the Bob-Tach wedge mounts (Item 1), mounting


flange (Item 2) [Figure 60-10-19] and all welds on th e
mount for wear and damage each time the hydraulic
breaker is removed from the loader.

Dealer Copy -- Not for Resale


Figure 60-10-20

Inspect the X-Change mount (Item 1) [Figure 60-10-


20] and all welds on the mount for wear and damage
each time the hydraulic breaker is removed from the
excavator.

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166 of 260 60-10-6 Service Manual
HYDRAULIC BREAKER LUBRICATION

Put the breaker in the vertical position so the tool bit is on


the ground and the tool bit is pushed up inside the
breaker as far as possible.

Figure 60-10-21

Dealer Copy -- Not for Resale


P-12836

Stop the engine and have a second person apply grease


(4 to 5 pumps) to the upper end of the tool at the grease
fitting (Item 1) [Figure 60-10-21] every 4 to 8 ho urs of
operation or when the tool bit looks dry.

IMPORTANT
Underwater use of the breaker will cause internal
damage. No por tion of t he breaker may be
submerged.
I-2053-0589

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167 of 260 60-10-7 Service Manual
DAILY INSPECTION Figure 60-10-23

Figure 60-10-22

1
The extent of wear in the upper and lower bushings is
checked by installing a new bit ( Item 1) [Figure 60-10-
23] in the hydraulic breaker and checking the ga p
between the lower bushing and the tool bit shaft.
1
There can be no more than 0.354 in. (9 mm) gap
between the lower bushing and a new tool bit [Figure 60-

Dealer Copy -- Not for Resale


10-23].

P-12836

Check the 4 wear plate retaining screws (Item 1) [Figure


60-10-22] everyday.

Tighten the screws to 250 ft.-lb. (339 Nm) torque.

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168 of 260 60-10-8 Service Manual
TOOL BIT REMOVAL AND INSTALLATION

WARNING
WARNING Before you leave the operator's seat:
Lower the lift arms, put the attachment flat on the
Wear safety glasses to prevent eye injury when any ground.
of the following conditions exist: Stop the engine.
When fluids are under pressure. Engage the parking brake.
Flying debris or loose material is present. Raise seat bar.
Engine is running. (Foot Pedal Controls) Move pedals until both
Tools are being used. lock.
W-2019-1285 (Mechanical Hand Controls) Move the hand
controls until both lock. The seat bar system
NOTE: Tool bit removal and installation is shown on a must lock the lift and tilt controls in neutral when
loader. The procedure is t he same for an the seat bar is u p. Service the system if hand
excavator mounted hydraulic breaker. controls do not lock correctly.
(Advanced Hand Controls) Move the hand
Figure 60-10-24 controls to the NEUTRAL POSITION to make sure
that both lift and tilt fu nctions are deactivated.
The seat bar system must deactivate the lift and
tilt control functions when the seat bar is up.
Service the system if hand controls do not
deactivate.

Dealer Copy -- Not for Resale


W-2323-0698

Place the hydraulic breaker in the position shown and


install blocks (Item 1) [Figure 60-10-24] under the
hydraulic breaker.

Fully lower the hydraulic breaker to the blocks.

Stop the engine.

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169 of 260 60-10-9 Service Manual
TOOL BIT REMOVAL AND INSTALLATION (CONTD) Figure 60-10-27

Figure 60-10-25

Measure the outside diameter of t he pin [Figure 60-10-


27].
Remove the roll pin (Item 2) [Figure 60-10-24 on Page
60-10-9] and (Item 1) [Figure 60-10-25]. Replace the pin if the measurement is 1.12 in. (28 mm) or
less at any location along the length of the pin.
Figure 60-10-26
Figure 60-10-28

Dealer Copy -- Not for Resale


Drive the tool retaining pin (Item 1) [Figure 60-10-26] out
the bottom of the hydraulic breaker. Remove the tool bit (Item 1) [Figure 60-10-28].

Hydraulic Breaker
170 of 260 60-10-10 Service Manual
TOOL BIT REMOVAL AND INSTALLATION (CONTD)

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.

Dealer Copy -- Not for Resale


Replace the bit if worn or damaged.

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171 of 260 60-10-11 Service Manual
LOADER MOUNT REMOVAL AND INSTALLATION Install a h oist (Item 1) [Figure 60-10-32] on the loader
mount.
Figure 60-10-30
Remove the 8 bolts (Item 2 [Figure 60-10-32].

Installation: Tighten the bolts to 475 to 525 ft.-lb. (645 to


710 Nm) torque.

Remove the loader mount (Item 3) [Figure 60-10-32]


from the hydraulic breaker.

Install blocks (Item 1) [Figure 60-10-30] under the body


of the hydraulic breaker.

Figure 60-10-31

Dealer Copy -- Not for Resale


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

Figure 60-10-32

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172 of 260 60-10-12 Service Manual
X-CHANGE MOUNT REMOVAL AND INSTALLATION

NOTE: The breaker shown is not the 5060 hydraulic


breaker. The procedure is the same.

Install blocks under the body of the hydraulic breaker.

Figure 60-10-33

Dealer Copy -- Not for Resale


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

Installation: Tighten the bolts to 475 to 525 ft.-lb. (645 to


710 Nm) torque.

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


from the hydraulic breaker.

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173 of 260 60-10-13 Service Manual
TROUBLESHOOTING

WARNING
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Handbook and
signs (decals) on machine. Follow warnings and
instructions in the manuals when making repairs,
adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained
operators and f ailure to follow instructions can
cause injury or death.
W-2003-0199

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

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

Dealer Copy -- Not for Resale


PROBLEM CAUSE CORRECTION
Breaker will not fire. No hydraulic flow to the breaker. Check the hydraulic flow to the breaker.
Damaged quick couplers. Replace quick couplers.
Loader or excavator fluid reservoir is low. Add hydraulic fluid to the reservoir on the loader
or 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 replace
as needed.
Breaker runs very slowly or lo w Excessive back pressure. Check for plugged or bent return lines.
blow energy. Damaged quick couplers. Replace quick couplers.
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 orrect
flow and pressure.
Loader or excavator main relief valve set too low. Adjust main relief valve to correct setting.
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 back pressure. Check for plugged or bent return lines.
Tool binding. Add grease to the tool shank fitting.
Damaged quick couplers. Replace quick couplers.
Loader or excavator main relief valve set too low. Adjust main relief valve to correct setting.
Excessive heat buildup. Blank firing. Refer to the hydraulic controls section of the
Operation and Maintenance Manual for correct
operating procedure.
Loader or excavator fluid reservoir is low. Add hydraulic fluid to the reservoir on the loader
or excavator.

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174 of 260 60-10-14 Service Manual
PARTS IDENTIFICATION

Dealer Copy -- Not for Resale

Hydraulic Breaker
175 of 260 60-10-15 Service Manual
PARTS IDENTIFICATION (CONT'D)

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Hydraulic Breaker
176 of 260 60-10-16 Service Manual
DISASSEMBLY AND ASSEMBLY Figure 60-20-2

Breaker Frame Removal And Installation

Remove the tool bit. (See TOOL BIT REMOVAL AND


INSTALLATION on Page 60-10-9.)

Remove the mount frame. (See TOOL BIT REMOVAL


AND INSTALLATION on Page 60-10-9.)

WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
When fluids are under pressure.
Flying debris or loose material is present. Remove the fittings (Item 1) [Figure 60-20-2].
Engine is running.
Tools are being used. Figure 60-20-3
W-2019-1285

Release the pressure from the nitrogen chamber. (See

Dealer Copy -- Not for Resale


Releasing Pressure From The Nitrogen Chamber on
Page 60-10-1.)

Figure 60-20-1

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

Figure 60-20-4

Mark the h oses for correct installation. Remove the


hoses (Item 1) [Figure 60-20-1].

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

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-7

Breaker Frame Removal And Installation (Cont'd)

Figure 60-20-5

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

Dealer Copy -- Not for Resale


Figure 60-20-6

Raise the hoist (Item 1) [Figure 60-20-7] & [Figure 60-


20-8] and remove the breaker from the housing [Figure
60-20-8].

Reinstall the hoist as shown in [Figure 60-20-6]. Lower the breaker and remove the hoist.

NOTE: Do not lay the breaker on it's side for


disassembly or assembly.

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-11

Wear Plate Removal And Installation

Figure 60-20-9

Remove the wear plate (Item 1) and shim (if installed)


(Item 2) [Figure 60-20-11] from both the front and rear of
the housing.

Figure 60-20-10 Figure 60-20-12

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Remove the 2 flange bolts (Item 1) [Figure 60-20-9] and Installation: Install the wear plate with the beveled side
nuts (Item 1) [Figure 60-20-10] from the wear plate (front (Item 1) [Figure 60-20-12] toward the inside of the frame.
and rear).
NOTE: The front wear plate and shim have a hole
Installation: Install the flange nuts into the wear plate, (Item 3) [Figure 60-20-11] that must be aligned
ensure the flange (Item 1) is flush with the wear plate with the hole in the frame (Item 2) [Figure 60-
(Item 2) [Figure 60-20-10]. 20-9] to provide access to a grease fitting in
the breaker.
Install the bolts finger tight.

Use a spanner wrench to hold the nut and tighten the


bolts to 250 ft.-lb. (339 Nm) torque.

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-15

Lower Bumper Removal And Installation

Figure 60-20-13

Remove the 4 washers (Item 1) [Figure 60-20-15].

Installation: Apply anti-sieze to both sides of the


washers.
Remove the l ower bumpers (Item 1) [Figure 60-20-13]
from the housing. Figure 60-20-16

Dealer Copy -- Not for Resale


Nitrogen Chamber Removal And Installation

Make sure the nitrogen chamber is discharged before


disassembly.

Figure 60-20-14

Remove the tie rods (Item 1) [Figure 60-20-16].

Installation: Clean and inspect the threads of the tie


rods for burrs or damaged threads. If any of the tie rods
were broken, replace all 4 tie rods.

Apply anti-sieze to the threads of the tie rods. Install the


Remove the nuts (Item 1) [Figure 60-20-14]. tie rods by hand until they are fully seated in the bottom
housing.
NOTE: Do not use an impact wrench to remove or
install the nuts. NOTE: Use care to prevent the breaker sections from
falling after removing the tie rods.
Installation: Apply anti-sieze to the threads of the nuts.
Tighten the nuts to 290 ft.-lb. (393 Nm) torque.

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DISASSEMBLY AND ASSEMBLY (CONT'D) Charge Valve Removal And Installation

Nitrogen Chamber Removal And Installation (Contd) Figure 60-20-19

Figure 60-20-17

Remove the charge valves (Item 1) [Figure 60-20-19]


from both front and rear of the nitrogen chamber.
Remove the nitrogen chamber (Item 1) [Figure 60-20-
17]. Installation: Clean the threads and apply thread lock
adhesive (LOCTITE 242).

Dealer Copy -- Not for Resale


Figure 60-20-18
Figure 60-20-20

Remove the O -ring (Item 1) [Figure 60-20-18] from the


nitrogen chamber. Remove the O-rings (Item 1) [Figure 60-20-20] from the
charge valves.

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-23

Piston Removal And Installation

Figure 60-20-21

Remove the O -ring (Item 1) [Figure 60-20-23] from the


seal carrier.

Install a lift eye (Item 1) in the top of the piston, attach a


hoist (Item 2) [Figure 60-20-21] to the lift eye.

Dealer Copy -- Not for Resale


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.

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-26

Piston Removal And Installation (Cont'd)

Figure 60-20-24

Remove the 2 se als (Item 1) and wiper (Item 2) [Figure


60-20-26] from the seal carrier.

Figure 60-20-27
Remove the seal carrier (Item 1) [Figure 60-20-24] from
the piston.

Dealer Copy -- Not for Resale


Figure 60-20-25

Remove the 2 O-rings (Item 1) [Figure 60-20-27].

Inspect the piston for burrs, scratches and other damage.


Measure the end of the piston. Replace the piston if the
dimension [Figure 60-20-25] is 7.40 in. (188 mm) or less.

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DISASSEMBLY AND ASSEMBLY (CONT'D) Valve Removal And Installation

Center Housing Removal And Installation Figure 60-20-30

Figure 60-20-28

Remove the O -ring (Item 1) [Figure 60-20-30] from the


valve plug.
Install a h oist (Item 1) [Figure 60-20-28] on the c enter
housing. Raise the hoist and remove the center housing. Figure 60-20-31

Dealer Copy -- Not for Resale


Figure 60-20-29

Install a l ift eye (Item 1) [Figure 60-20-31] in the valve


plug.
Remove the O-ring (Item 1) [Figure 60-20-29].

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184 of 260 60-20-8 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-34

Valve Removal And Installation (Cont'd)

Figure 60-20-32

Remove the valve (Item 1) [Figure 60-20-34].

Installation: Make sure the valve moves freely in the


port.
Use a punch (Item 1) and block of wood (Item 2) to pry
the valve plug (Item 3) [Figure 60-20-32] out of the Figure 60-20-35
center housing.

Dealer Copy -- Not for Resale


Remove the valve plug.

Figure 60-20-33

Do not remove the valve sleeve (Item 1) [Figure 60-20-


35].

Remove the O -ring (Item 1) [Figure 60-20-33] from the


valve plug.

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-38

Center Housing Disassembly And Assembly

Figure 60-20-36

Remove the seals (Item 1) [Figure 60-20-38].

Figure 60-20-39

Remove the 4 plugs (Item 1) [Figure 60-20-36].

Figure 60-20-37

Dealer Copy -- Not for Resale


Remove the vent (Item 1) [Figure 60-20-39].

Installation: Clean the threads of the vent and apply


thread lock adhesive (LOCTITE 242).
Remove the O -ring (Item 1) [Figure 60-20-37] from the
plugs.

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186 of 260 60-20-10 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-42

Center Housing Disassembly And Assembly (Cont'd)

Figure 60-20-40

Use a h ammer and punch to dr ive the r oll pins (Item 1)


[Figure 60-20-41] in until the roll pins (Item 1) [Figure
60-20-42] on th e other side of th e housing can be
removed.
Remove the O -ring (Item 1) [Figure 60-20-40] from the
vent. Remove the rollpins (Item 1) [Figure 60-20-42].

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Bushing Removal And Installation Figure 60-20-43

Figure 60-20-41

Remove the retaining pins (Item 1) [Figure 60-20-43].

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187 of 260 60-20-11 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-46

Bushing Removal And Installation (Cont'd)

Figure 60-20-44

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].
Measure the outside diameter of the pins [Figure 60-20-
44], replace the pins if the measurement at any location Figure 60-20-47
along the length of the pins is .56 inch (14 mm) or less.

Dealer Copy -- Not for Resale


Figure 60-20-45

Measure the inside diameter of the lower bushing .40 in.


(10 mm) in from the bottom of the bushing [Figure 60-20-
47].
Drive the rollpins (Item 1) [Figure 60-20-45] back until
the end of the rollpins are flush with the housing. Replace the bushing if the measurement is 3.56 inch (89
mm) or more.

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188 of 260 60-20-12 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-50

Bushing Removal And Installation (Cont'd)

Figure 60-20-48

Measure the inside diameter of the upper bushing, .40


inch (10 mm) in from the top of the bushing [Figure 60-
20-50]. Replace the bushing if the measurement is 2.84
inch (71 mm) or more.
Use a brass or aluminum bushing driver (Item 1) [Figure
60-20-48] and hammer to remove the upper bushing. Figure 60-20-51

Dealer Copy -- Not for Resale


Figure 60-20-49

On older models measure the thrust ring [Figure 60-20-


51] from the wear areas to the bottom of the ring.
Remove the upper bushing (Item 1) [Figure 60-20-49]. Replace the ring if the measurement is .30 inch (7,5 mm)
or less.
NOTE: Early models have a thrust ring located above
the upper bushing.

Installation: Install the up per bushing (Item 1) with the


slot (Item 2) aligned with the hole (Item 3) [Figure 60-20-
49].

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-54

Bushing Removal And Installation (Cont'd)

Figure 60-20-52

Remove the retainers (Item 1) [Figure 60-20-54].

Figure 60-20-55

Measure the inside diameter of the upper bushing


[Figure 60-20-52], on older models, midway between the
ends of th e bushing. Replace the bushing if th e

Dealer Copy -- Not for Resale


measurement is 2.84 inch (71 mm) or more.

NOTE: The thrust ring and upper bushing for older


models is no longer available. Use the newer
1 piece upper bushing for replacement.

Lower Housing Disassembly And Assembly

Figure 60-20-53

Remove the bolts (Item 1) [Figure 60-20-55] (both


sides).

Installation: Tighten the bolts to 600 ft.-lb. (813 Nm)


torque.

Remove the s nap rings (Item 1) from the bolts (Item 2)


[Figure 60-20-53] on both sides of the lower housing.

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190 of 260 60-20-14 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D)

Lower Housing Removal And Installation

Figure 60-20-56

Remove the stop blocks (Item 1) [Figure 60-20-56] (both


sides).

Dealer Copy -- Not for Resale


Wash the breaker parts in clean solvent and dry with
compressed air.

Inspect the p arts for burrs, scratches, cracks or other


damage. Use fine emery cloth to r emove any burrs or
scratches. replace any parts that are cracked.

Lubricate the parts with clean hydraulic fluid during


assembly. Always install new O -rings and seals during
assembly.

Start Up Procedure

Install the Hydraulic Breaker on th e Bobcat Loader,


backhoe or excavator. Connect the quick couplers.

Start the engine. Raise the tool off the work surface and
engage the auxiliary hydraulics.

Run the breaker for several minutes until the air is


removed from the breaker.

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191 of 260 60-20-15 Service Manual
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Hydraulic Breaker
192 of 260 60-20-16 Service Manual
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.

Dealer Copy -- Not for Resale


WEIGHT
Breaker With Tool; Loader 940 lb. (426 kg)
Breaker With Tool; Excavator 780 lb. (354 kg)
ENERGY 750 ft.-lb. (1017 Nm) Class
BLOWS PER MINUTE (Hyd. oil @ 200F [93.3C]) 800 to 900 @ 18.6 GPM (69.9 Lpm)
RECOMMENDED HYDRAULIC FLOW 15 to 22 GPM (57 to 83 L/min.)

Hydraulic Breaker
193 of 260 60-30-1 Service Manual
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Hydraulic Breaker
194 of 260 60-30-2 Service Manual
5500 HYDRAULIC BREAKER SERVICE

CHECKING MOUNTING BOLT TORQUE . . . . . . . . . . . . . . 70-10-10

DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 70-20-1


Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-8
Lower Body Bushings Removal . . . . . . . . . . . . . . . . . . . . . 70-20-6
Main Body Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-5
Manifold Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-3
Nitrogen Chamber Disassembly and Assembly. . . . . . . . . 70-20-6
Nitrogen Chamber Removal . . . . . . . . . . . . . . . . . . . . . . . 70-20-3
Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-4
Seals and Poly-Pak Installation . . . . . . . . . . . . . . . . . . . . . 70-20-9
Start Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-10
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-4

HYDRAULIC BREAKER LUBRICATION . . . . . . . . . . . . . . . . 70-10-9

PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-12

NITROGEN CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

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Charging the High Pressure Accumulator . . . . . . . . . . . . . 70-10-2
Charging the Low Pressure Accumulator . . . . . . . . . . . . . 70-10-5
Charging the Nitrogen Chamber . . . . . . . . . . . . . . . . . . . . 70-10-7
Checking The High Pressure Accumulator Pressure. . . . . 70-10-1
Checking The Low Pressure Accumulator Pressure . . . . . 70-10-3
Checking The Nitrogen Chamber Charge Pressure . . . . . 70-10-6 5500
HYDRAULIC
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1 BREAKER SERVICE

TROUBLESHOOTING THE HYDRAULIC BREAKER . . . . . 70-10-11

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70-01 Service Manual
195 of 260
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70-02 Service Manual
196 of 260
NITROGEN CHAMBER Figure 70-10-3

Checking The High Pressure Accumulator Pressure

Use the nitrogen accumulator charge pressure gauge 1


MEL1523B to check pressure.

Figure 70-10-1
2

0.125
(3,2 mm)

P-42758

With the adapter (Item 1) ti ghtened on the g auge,


measure the pin (Item 2) [Figure 70-10-3] protrusion.

Manually extend or retract the pin until the pin measures


B-7047 0.125 in. (3,2 mm) from pin tip to adapter face.

Dealer Copy -- Not for Resale


Figure 70-10-4
Remove the charge valve plug [Figure 70-10-1].

Figure 70-10-2

P-42759

P18084 Loosen the adapter until the pin is flush with the end of
the adapter as shown [Figure 70-10-4].

Install the correct adapter (Item 1) [Figure 70-10-2] on Install the gauge/adatper on the breaker.
the gauge.

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197 of 260 70-10-1 Service Manual
NITROGEN CHAMBER (CONTD) Charging the High Pressure Accumulator

Checking The High Pressure Accumulator Pressure Use charging kit (P/N 6568037) to charge the hydraulic
(Contd) breaker.

Figure 70-10-5

WARNING
Wear safety glasses to prevent eye injury when any
of 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
1

Figure 70-10-7

B-23394

Tighten the adapter (Item 1) [Figure 70-10-5] on th e


breaker.

Dealer Copy -- Not for Resale


Figure 70-10-6

1
Remove the charge valve plug [Figure 70-10-7].

Figure 70-10-8

B-23394

Slowly turn the gauge valve body (Item 1) [Figure 70-10-


6] clockwise until the gauge shows a reading. If the
pressure is low, recharge the breaker using charging kit
number 6568037.

NOTE: The correct charge pressure is 850 P SI (58,6


bar).

Using a sm all shaft (Item 1) [Figure 70-10-8], push the


valve inward to release the gas pressure.

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198 of 260 70-10-2 Service Manual
NITROGEN CHAMBER (CONTD) Checking The Low Pressure Accumulator Pressure

Charging The High Pressure Accumulator Pressure Use the nitrogen accumulator charge pressure gauge
(Contd) MEL1523B to check pressure.

Figure 70-10-9 Figure 70-10-11

B-7049 B-7078

NOTE: Use the high pressure side of the charging tool Remove the charge valve plug [Figure 70-10-11].
[Figure 70-10-9].

Dealer Copy -- Not for Resale


Figure 70-10-12
Figure 70-10-10

Connect This End


To High Pressure
Accumulator &
Nitrogen Chamber 1

Connect Hose From P18084


Nitrogen Bottle Here B-7196

Install the correct adapter (Item 1) [Figure 70-10-12] on


Install the charging tool into the accumulator [Figure 70- the gauge.
10-10].

Connect the n itrogen hose to the high pressure side of


the charging tool [Figure 70-10-9].

SLOWLY open the valve at the nitrogen tank and fill the
high pressure accumulator to 850 PSI (58,6 bar) [Figure
70-10-9]. DO NOT EXCEED THIS PRESSURE

Close the valve at the nitrogen tank when accumulator


pressure is reached.

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199 of 260 70-10-3 Service Manual
NITROGEN CHAMBER (CONTD) Figure 70-10-15

Checking The Low Pressure Accumulator Pressure


(Contd)

Figure 70-10-13 1

B-23393
0.125
(3,2 mm)
Tighten the a dapter (Item 1) [Figure 70-10-15] on th e
breaker.
P-42758
Figure 70-10-16

With the adapter (Item 1) tig htened on the ga uge,


measure the pin (Item 2) [Figure 70-10-13] protrusion.

Dealer Copy -- Not for Resale


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

Figure 70-10-14

B-23393

Slowly turn the gauge valve body (Item 1) [Figure 70-10-


6] clockwise until the gauge shows a reading. If th e
pressure is low, recharge the breaker using charging kit
number 6568037.

P-42759 NOTE: The correct charge pressure is 100 PSI (6,9


bar).

Loosen the adapter until the pin is flush with the e nd of


the adapter as shown [Figure 70-10-14].

Install the gauge/adatper on the breaker.

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NITROGEN CHAMBER (CONTD) Figure 70-10-19

Charging the Low Pressure Accumulator

The low pressure accumulator is located on the front side


of the main body.

Remove the charge valve plug.

Figure 70-10-17

B-7077

Connect the nitrogen hose to the low pressure side of the


charging tool [Figure 70-10-19].

SLOWLY open the valve at the nitrogen tank until the gas
escapes from the relief valve (Item 1) [Figure 70-10-19]
on the charging tool.

Dealer Copy -- Not for Resale


Close the valve at the tank. Disconnect the nitrogen hose
Using a small shaft (Item 1) [Figure 70-10-17], push the and charging tool.
valve inward to release the gas pressure.
Install and tighten the plug.
Figure 70-10-18

Connect Hose From Connect This End To Low


Nitrogen Bottle Here Pressure Accumulator
B-7196

NOTE: Use the low pressure side of the charging tool


[Figure 70-10-18].

Install the charging tool into the accumulator [Figure 70-


10-18].

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NITROGEN CHAMBER (CONTD) Figure 70-10-22

Checking The Nitrogen Chamber Charge Pressure

Use the nitrogen accumulator charge pressure gauge 1


MEL1523B to check pressure.

Figure 70-10-20
2

0.125
1 (3,2 mm)

P-42758

With the adapter (Item 1) ti ghtened on the g auge,


measure the pin (Item 2) [Figure 70-10-22] protrusion.

Manually extend or retract the pin until the pin measures


B-8887 0.125 in. (3,2 mm) from pin tip to adapter face.

Dealer Copy -- Not for Resale


Figure 70-10-23
Remove the plug (Item 1) [Figure 70-10-20].

Figure 70-10-21

P-42759

P18084 Loosen the adapter until the pin is flush with the end o f
the adapter as shown [Figure 70-10-23].

Install the correct adapter (Item 1) [Figure 70-10-21] on Install the gauge/adatper on the breaker.
the gauge.

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NITROGEN CHAMBER (CONTD) Charging the Nitrogen Chamber

Checking The Nitrogen Chamber Charge Pressure The nitrogen chamber charge valve is located on the
(Contd) back side of the breaker above the hydraulic inlet and
outlet ports.
Figure 70-10-24
Figure 70-10-26

B-23395

Tighten the adapter (Item 1) [Figure 70-10-24] on th e


Remove the charge valve plug (Item 1) [Figure 70-10-
breaker.

Dealer Copy -- Not for Resale


26].
Figure 70-10-25
Using a small shaft push the valve inward to release the
gas pressure.
1
Figure 70-10-27

B-23395

Slowly turn the gauge valve body (Item 1) [Figure 70-10-


25] clockwise until the gauge shows a r eading. If th e
pressure is low, recharge the breaker using charging kit
number 6568037. Install the charging tool in the charge valve [Figure 70-
10-27].
NOTE: The correct charge pressure is 500 PSI (34,48
bar)

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203 of 260 70-10-7 Service Manual
NITROGEN CHAMBER (CONTD)

Charging the Nitrogen Chamber (Cont'd)

Figure 70-10-28

Connect This End To


Nitrogen Chamber

Connect Hose From


Nitrogen Bottle Here
B-7196

NOTE: Use the high pressure side of the charging tool


[Figure 70-10-28].

Dealer Copy -- Not for Resale


Connect the n itrogen hose to the high pressure side of
the charging tool.

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

Fill the chamber to 500 PSI (34,48 bar)

Close the valve on the nitrogen tank.

Disconnect the hose and the charging tool.

Install and tighten the plug.

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204 of 260 70-10-8 Service Manual
HYDRAULIC BREAKER LUBRICATION

Put the breaker in the vertical position so the point is on


the ground and the point is pushed up inside the breaker
as far as possible.

Figure 70-10-29

Stop the engine and have a second person add grease to

Dealer Copy -- Not for Resale


the fitting (Item 1) [Figure 70-10-29].

Apply grease (4 to 5 pumps) to the upper end of the tool


at the grease fitting (Item 1) [Figure 70-10-30] every 4 to
8 hours of operation, or when the tool bit looks dry.

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

IMPORTANT
Underwater use of the breaker will cause internal
damage. No por tion of t he breaker may be
submerged.
I-2053-0589

Hydraulic Breaker
205 of 260 70-10-9 Service Manual
CHECKING MOUNTING BOLT TORQUE

Figure 70-10-30

Check the mounting bolts (Item 1) [Figure 70-10-30]


daily.

Tighten the bolts to 900 ft.-lb. (1200 Nm) torque.

Dealer Copy -- Not for Resale

Hydraulic Breaker
206 of 260 70-10-10 Service Manual
TROUBLESHOOTING THE HYDRAULIC BREAKER

WARNING
Instructions are necessary before operating or
servicing machine. Read Operation & M aintenance
Manuals, Handbook and signs (decals) on ma chine.
Follow warnings and instructions in t he manuals
when making repairs, adjustments or servicing.
Check for correct function after adjustments, repairs
or service. Failure to follow instructions can cause
injury or death.
W-2003-1289

If the Hydraulic Breaker is not working correctly, check the hydraulic system of the Bobcat Loader or excavator thoroughly
before making any repairs on the breaker. Hydraulic Breaker performance can be affected by a hydraulic system that is
not 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 to
check 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 correct
problems with the Hydraulic Breaker which most often occur.

Dealer Copy -- Not for Resale


PROBLEM CAUSE CORRECTION
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 the
loader.
No hydraulic flow to the breaker. Check the hydraulic flow to the breaker.
Nitrogen chamber not at correct pressure. Charge to required pressure of 500 PSI (3448
bar).
Damaged electrical connection to brea ker Check wiring harness and switch.
valve. (Backhoe mounted unit only.)
Damaged quick couplers. Replace quick couplers.
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 and
pressure.
Excessive heat build up. Check oil cooler for debris and air flow.
Check loader relief valve pressure.
Damaged quick couplers. Replace quick couplers.
Nitrogen chamber over-pressurized. Remove gas and refill to c orrect pressure of
500 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.
Excessive back pressure. Check for plugged or kinked return lines.
Low fluid level. Add fluid to the reservoir as needed.
Damaged quick couplers. Replace quick couplers.
Tool binding. Add grease to the tool shank fitting.
Damaged electrical connection to brea ker Check wiring harness and switch.
valve. (Backhoe mounted unit only.)

Hydraulic Breaker
207 of 260 70-10-11 Service Manual
PARTS IDENTIFICATION

Dealer Copy -- Not for Resale

Hydraulic Breaker
208 of 260 70-10-12 Service Manual
DISASSEMBLY AND ASSEMBLY Figure 70-20-2

WARNING
Wear safety glasses to prevent eye injury when any
of 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 tools listed will be nee ded to do the fol lowing


procedure:
Loosen the hex bolt (use a 2-1/16 inch socket) on the top
6568037 - Charging Kit of the nitrogen gas chamber [Figure 70-20-2]. DO NOT
OEM6106 - Torque Multiplier REMOVE THE BOLT.
MEL1306 - Hex Bit Driver
MEL1309 - Lower Bearing Removal Plate Figure 70-20-3
MEL1310 - Remove Handle
Read and understand the complete disassembly and

Dealer Copy -- Not for Resale


assembly procedure before beginning the operation.

Before you remove the Breaker from the Bob-Tach


frame, have a second person assist with the following:

Loosen the 4 main body bolts. DO NOT REMOVE THE


BOLTS.

MEL1306 - Hex Bit Driver

Remove the 3/ 16 in. hex plug at the accumulator


chamber. Release the nitrogen gas from the chamber.

Figure 70-20-1
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.

Loosen the eight bolts which fasten the b reaker to th e


frame [Figure 70-20-1]. DO NOT REMOVE THE BOLTS.

MEL1306 - Hex Bit Driver

Hydraulic Breaker
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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 70-20-6

Figure 70-20-4

Remove the hydraulic hoses from the hydraulic breaker


[Figure 70-20-6].
Remove the mounting pins [Figure 70-20-4].
Figure 70-20-7
Lift the breaker from the Bob-Tach frame. Put the breaker
in a vertical position in a stand.

Dealer Copy -- Not for Resale


Install a chain hoist on the frame of the breaker.

Figure 70-20-5

Remove the 3/1 6 inch hex plug at the accumulator


chamber. Put a p hillips screwdriver in the he x plug hole
and release the nitrogen gas from the chamber [Figure
70-20-7].

Remove the eight bolts [Figure 70-20-5].

MEL1306 - Hex Bit Driver

Assembly: Put anti-sieze lubricant on the threads and


tighten the bolts to 900 ft.-lb. (1220 Nm) torque.

Remove the frame from the breaker.

Hydraulic Breaker
210 of 260 70-20-2 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Manifold Removal

Nitrogen Chamber Removal Figure 70-20-10

Figure 70-20-8

Lift the manifold assembly from the main body [Figure


70-20-10].
Remove the 4 main socket head bolts [Figure 70-20-8].

MEL1306 - Hex Bit Driver

Dealer Copy -- Not for Resale


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

Assembly: Put anti-sieze lubricant on the bolt threads


and washers. Tighten to 600 ft.-lb. (814 Nm) torque.

Figure 70-20-9

Use a cha in hoist and remove the nitrogen chamber


[Figure 70-20-9].

Hydraulic Breaker
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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 70-20-13

Piston Removal

Figure 70-20-11

NOTE: The manifold will not s eat correctly if the


timing marks (Item 1) [Figure 70-20-13] are not
in alignment.

Remove the pi ston from the main body [Figure 70-20- Figure 70-20-14
11].

Dealer Copy -- Not for Resale


Valve Removal

Figure 70-20-12

Remove the v alve cylinder with the valve seat from the
main body [Figure 70-20-14].

Remove the valve with the push pins [Figure 70-20-12].

Assembly: Align the timing marks on the valve and valve


cylinder [Figure 70-20-12].

Remove the push pins and inspect for wear [Figure 70-
20-12].

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 70-20-17

Valve Removal (Cont'd)

Figure 70-20-15

Assembly: Install the disc springs with the convex


surface facing away from the lower bearing [Figure 70-
20-17].

Remove the valve cylinder from the valve seat [Figure Install the socket head bolts into the body at both
70-20-15]. accumulator sides.

Dealer Copy -- Not for Resale


NOTE: The valve cylinder and valve seat are indexed Figure 70-20-18
by a roll pin (Item 1) [Figure 70-20-15].

Main Body Removal

Figure 70-20-16

Install a chain hoist and lift the main body from the lower
body [Figure 70-20-18].

Remove both disc springs from the main body [Figure


70-20-16].

Hydraulic Breaker
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DISASSEMBLY AND ASSEMBLY (CONT'D) Inspect all the parts for scratches, wear or damage.
Replace the parts as needed.
Main Body Removal (Cont'd)
Nitrogen Chamber Disassembly and Assembly
Figure 70-20-19
Disassembly: Remove the large bolt and the top plate.

Figure 70-20-21

Turn 2 b olts, equally into the main body to r emove the


lower bearing [Figure 70-20-19].

Dealer Copy -- Not for Resale


Lower Body Bushings Removal Remove the charge valve (Item 1) [Figure 70-20-21].

Figure 70-20-20 Clean and inspect the charge valve.

Turn the chamber over, install the large bolt. Use a soft
hammer and hit the bolt to remove the diaphragm (Item
2) [Figure 70-20-21] and screen.

Remove the O-ring from the s creen and inspect the


diaphragm for wear.

Figure 70-20-22

NOTE: A bead of weld may have to be put around the


I.D. of the tool (Item 1) [Figure 70-20-20]
bearing for easier removal.

Disassembly of the lower body internal parts requires a


press for removal of the tool bearing (Item 1) and tool
stop (Item 2) [Figure 70-20-20]. Replace the parts as
needed.

MEL1309 - Lower Bearing Removal Plate Assembly: Lubricate the sealing surface of the nitrogen
MEL1310 - Remover Handle chamber. Install the diaphragm [Figure 70-20-22].
Remove all the O-rings, seals and Poly-Pak seals from
the breaker parts.

Clean in solvent and air dry them.

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 70-20-25

Nitrogen Chamber Disassembly and Assembly


(Cont'd)

Figure 70-20-23

Install the O-rings (Item 1) [Figure 70-20-25] on the top


and bottom of the chamber.

Install the top plate and bolt. The bolt must be tightened
after the chamber is installed on the main body.
Install the screen [Figure 70-20-23].
Tighten the bolt to 600 ft.-lb. (814 Nm) torque.

Dealer Copy -- Not for Resale


Figure 70-20-24
Figure 70-20-26

Install the O-ring on the screen [Figure 70-20-24].


Install the charge valve and tighten to 80 ft.-lb. (108 Nm)
torque [Figure 70-20-26].

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 70-20-29

Accumulator

Figure 70-20-27

Remove the charge valve [Figure 70-20-29].

Clean and inspect the charge valve.

Remove the hex socket bolts at the accumulator Figure 70-20-30


chamber [Figure 70-20-27].

Dealer Copy -- Not for Resale


Assembly: Put anti-sieze lubricant on the threads and
tighten the bolts to 280 ft.-lb. (380 Nm) torque.

Disassembly: Put the accumulator body in a vise.

Figure 70-20-28

Assembly: Install the diaphragm in the accumulator


[Figure 70-20-30].

Loosen the accumulator plug [Figure 70-20-28].

Remove the accumulator plug and diaphragm [Figure


70-20-28].

Inspect the diaphragm for wear and replace as needed.

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216 of 260 70-20-8 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 70-20-33

Accumulator (Cont'd)

Figure 70-20-31

Install the Poly-Pak into the lower bearing. Make sure the
seal lip faces up (toward the nitrogen chamber) [Figure
70-20-33].

Put the accumulator body in a vise [Figure 70-20-31]. NOTE: Do not use a screwdriver or any sharp tool for
installation of the Poly-Pak.
Put approximately 1 teaspoon of clean oil in the cover.

Dealer Copy -- Not for Resale


Figure 70-20-34
Put the plug into the body and tighten to 600 ft.-lb. (814
Nm) torque.

Install the charge valve and tighten to 80 ft.-lb. (108 Nm)


torque.

Seals and Poly-Pak Installation

NOTE: Heating the Poly-Pak to 1 50F (68C) in hot


water will ease the installation.

Figure 70-20-32

When installing the Poly-Pak into the groove at the valve


seat, make sure the lip faces down [Figure 70-20-34].

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].

Hydraulic Breaker
217 of 260 70-20-9 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D)

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 lower

Dealer Copy -- Not for Resale


groove [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, and


raise the tool off the work object.

Run the breaker above the object in the Blank Fire


position (See Hydraulic/Hydrostatic Flow Chart Blank
Firing Operation) to help remove the air from the breaker.

It may take several minutes for air to be removed from


the system.

Hydraulic Breaker
218 of 260 70-20-10 Service Manual
SPECIFICATIONS

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WEIGHT
Breaker W/Moil & Breaker Mount 627 lb. (285 kg)
Bob-Tach Adapter 441 lb. (200 kg)
Total Weight 1095 lb. (497 kg)
ENERGY 750 ft.-lb. (746 J) CLASS
BLOWS PER MINUTE 900 @ 25 GPM (95 L/min.)
HYDRAULIC FLOW REQUIRED 25 GPM (95 L/min.)
MINIMUM OPERATING PRESSURE 2000 PSI (13790 bar)
MOIL DIAMETER 2.75 in. (69,8 mm)
MOIl WORKING LENGTH 18.0 in. (457,2 mm)

Hydraulic Breaker
219 of 260 70-30-1 Service Manual
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Hydraulic Breaker
220 of 260 70-30-2 Service Manual
6560 HYDRAULIC BREAKER SERVICE

CHECKING MOUNTING BOLT TORQUE . . . . . . . . . . . . . . . 80-10-6

DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 80-20-1


Breaker Frame Removal and Installation. . . . . . . . . . . . . . 80-20-1
Bumper Pad Removal and Installation. . . . . . . . . . . . . . . 80-20-10
Bushing Removal and Installation . . . . . . . . . . . . . . . . . . 80-20-10
Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-4
Piston and Seal Carrier Installation . . . . . . . . . . . . . . . . . 80-20-13
Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-8
Seal Carrier Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-6
Seal Carrier Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-7
Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-12
Sleeve Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-9
Tie Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-14
Tool Retaining Pin Removal and Installation . . . . . . . . . . 80-20-12
Upper Body Removal and Installation . . . . . . . . . . . . . . . . 80-20-5

HYDRAULIC BREAKER LUBRICATION . . . . . . . . . . . . . . . . 80-10-5

Dealer Copy -- Not for Resale


PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-9

NITROGEN CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1


Checking The Nitrogen Chamber Charge Pressure . . . . . 80-10-3
Charging The Nitrogen Chamber. . . . . . . . . . . . . . . . . . . . 80-10-2
Releasing Pressure From The Nitrogen Chamber. . . . . . . 80-10-1

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1 6560


HYDRAULIC
TROUBLESHOOTING THE HYDRAULIC BREAKER . . . . . . 80-10-7 BREAKER SERVICE

Hydraulic Breaker
80-01 Service Manual
221 of 260
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Hydraulic Breaker
80-02 Service Manual
222 of 260
NITROGEN CHAMBER

Releasing Pressure From The Nitrogen Chamber

The nitrogen chamber charge valve is located on the


front side of the hydraulic breaker.

WARNING
Wear safety glasses to prevent eye injury when any
of 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

NOTE: Release the charge pressure when storing the


hydraulic breaker for an extended period of
time.

Dealer Copy -- Not for Resale


Remove the plug from the charge valve.

Figure 80-10-1

Using a s mall shaft push the charge valve inward to


release the gas pressure [Figure 80-10-1].

Install the plug in the charge valve hole.

Hydraulic Breaker
223 of 260 80-10-1 Service Manual
NITROGEN CHAMBER (CONTD) Figure 80-10-3

Charging The Nitrogen Chamber

NOTE: When in doubt of nitrogen charge pressure or


when recharging a hot breaker, release the
nitrogen pressure completely and recharge
the nitrogen chamber.

Position the breaker horizontal, charging valve will be


facing up. The tool must not touch the piston during
charging.

Use kit (P/N 6568037) to charge the hydraulic breaker.

Figure 80-10-2

Connect This End To


Nitrogen Chamber

Dealer Copy -- Not for Resale


1

Connect Hose From


Nitrogen Bottle Here
350 PSI (24,14 bar) B-7196

Using the adapter (Item 1) [Figure 80-10-2], install the


charging tool (Item 2) [Figure 80-10-3] in the charge
valve.

NOTE: Be sure to use the correct side of the charging


tool [Figure 80-10-3].

Connect the nitrogen hose (Item 1) to the charging tool


(Item 2) [Figure 80-10-3].

SLOWLY open the charging valve on th e nitrogen tank


and fill the 6560 breaker nitrogen chamber to 35 0 PSI
(24,14 bar).

Close the valve on the nitrogen tank.

Disconnect the hose and charging tool.

Install and tighten the plug.

Hydraulic Breaker
224 of 260 80-10-2 Service Manual
NITROGEN CHAMBER (CONT'D) Install the correct adapter (Item 1) [Figure 80-10-5] on
the gauge.
Checking The Nitrogen Chamber Charge Pressure
Figure 80-10-6

WARNING 1
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
When fluids are under pressure.
Flying debris or loose material is present. 2
Engine is running.
Tools are being used.
W-2019-1285 0.125
(3,2 mm)

Use the nitrogen accumulator charge pressure gauge


MEL1523B to check pressure. P-42758

NOTE: The hydraulic breaker shown is not the 6560.


The procedure is the same. With the adapter (Item 1) ti ghtened on the g auge,
measure the pin (Item 2) [Figure 80-10-6].
Figure 80-10-4

Dealer Copy -- Not for Resale


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

Figure 80-10-7

Remove the plug (Item 1) [Figure 80-10-4].

Figure 80-10-5 P-42759

Loosen the adapter until the pin is flush with the end of
the adapter as shown [Figure 80-10-7].

1 Install the gauge/adatper on the breaker.

P-29454

Hydraulic Breaker
225 of 260 80-10-3 Service Manual
NITROGEN CHAMBER (CONT'D)

Checking The Nitrogen Chamber Charge Pressure


(Cont'd)

Figure 80-10-8

Tighten the adapter (Item 1) [Figure 80-10-8] on th e


breaker.

Dealer Copy -- Not for Resale


Figure 80-10-9

Slowly turn the gauge valve body (Item 1) [Figure 80-10-


9] clockwise until the gauge shows a reading. If the
pressure is low, recharge the breaker using charging kit
number 6568037.

NOTE: The correct charge pressure is 500 PSI (34,48


bar).

Hydraulic Breaker
226 of 260 80-10-4 Service Manual
HYDRAULIC BREAKER LUBRICATION

Put the breaker in the vertical position so the tool bit is on


the ground and the tool bit is pushed up inside the
breaker as far as possible.

Figure 80-10-10

Dealer Copy -- Not for Resale


P-10520

Stop the engine and have a second person add grease to


the fitting (Item 1) [Figure 80-10-10].

Apply grease (4 to 5 pumps) to the upper end of the tool


at the grease fitting (Item 1) [Figure 80-10-10] every 4 to
8 hours on operation or when the tool bit looks dry.

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

IMPORTANT
Underwater use of the breaker will cause internal
damage. No por tion of t he breaker may be
submerged.
I-2053-0589

Hydraulic Breaker
227 of 260 80-10-5 Service Manual
CHECKING MOUNTING BOLT TORQUE

Figure 80-10-11

Dealer Copy -- Not for Resale


P-10520

Check the 4 wear plate retaining screws (Item 1) [Figure


80-10-11] everyday.

Tighten the screws to 250 ft.-lb. (339 Nm) torque.

Hydraulic Breaker
228 of 260 80-10-6 Service Manual
TROUBLESHOOTING THE HYDRAULIC BREAKER

WARNING
Instructions are necessary before operating or
servicing machine. Read Operation & M aintenance
Manuals, Handbook and signs (decals) on ma chine.
Follow warnings and instructions in t he manuals
when making repairs, adjustments or servicing.
Check for correct function after adjustments, repairs
or service. Failure to follow instructions can cause
injury or death.
W-2003-0797

If the Hydraulic Breaker is not working correctly, check the hydraulic system of the Bobcat Loader or excavator thoroughly
before making any repairs on the breaker. Hydraulic Breaker performance can be affected by a hydraulic system that is
not 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 to
check 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 correct

Dealer Copy -- Not for Resale


problems with the Hydraulic Breaker which most often occur.

PROBLEM CAUSE CORRECTION


Breaker will not fire. Loader or excavator main relief valve set too Adjust main relief valve to correct setting.
low.
Loader or excavator fluid reservoir is low. Add hydraulic fluid to the fluid reservoir on the
loader or excavator.
No hydraulic flow to the breaker. Check the hydraulic flow to the breaker.
Loader or excavator hydraulic pump not Check flow of loader hydraulic pump.
working. Repair or replace as needed.
Nitrogen chamber not at correct pressure. Charge to required pressure.
Damaged electrical connection to br eaker Check wiring harness and switch.
valve (backhoe mounted unit only).
Damaged quick couplers. Replace quick couplers.
Breaker runs very slowly Loader or excavator main relief valve set too Adjust main relief valve to correct setting.
or blow per minute low.
reducing. Not enough hydraulic flow. Test loader or excavator hydraulics for correct
flow and pressure.
Excessive heat build up. Check oil cooler for debris and air flow. Check
loader or excavator relief valve pressure.
Damaged quick couplers. Replace quick couplers.
Nitrogen chamber over-pressurized or loss of Remove gas and refill to correct pressure.
pressure.
Internal leakage. Check seals and O-rings in the breaker.
Check piston, sleeve and seal carrier for wear.
Excessive back pressure. Check for plugged or bent return lines.

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229 of 260 80-10-7 Service Manual
TROUBLESHOOTING THE HYDRAULIC BREAKER (CONTD)

PROBLEM CAUSE CORRECTION


Breaker fires erratically. Loader or excavator main relief valve set too Adjust main relief valve to correct setting.
low.
Excessive back pressure. Check for plugged or kinked return lines.
Low fluid level. Add fluid to the reservoir as needed.
Damaged quick couplers. Replace quick couplers.
Tool binding. Add grease to the tool shank fitting.
Damaged electrical connection to br eaker Check wiring harness and switch.
valve (backhoe mounted unit only).
Excessive heat build up. Blank firing. Refer to t he hydraulic controls section of the
OM for correct operating procedure.

Dealer Copy -- Not for Resale

Hydraulic Breaker
230 of 260 80-10-8 Service Manual
PARTS IDENTIFICATION

Dealer Copy -- Not for Resale

Hydraulic Breaker
231 of 260 80-10-9 Service Manual
PARTS IDENTIFICATION (CONTD)

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Hydraulic Breaker
232 of 260 80-10-10 Service Manual
DISASSEMBLY AND ASSEMBLY Figure 80-20-2

Breaker Frame Removal and Installation

WARNING
Wear safety glasses to prevent eye injury when any
of 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

NOTE: Before removing the breaker from the frame Use a hoist and chains to support the weight of the Bob-
release the nitrogen pressure from the Tach mounting frame [Figure 80-20-1] or the ex cavator
breaker. (See Releasing Pressure From The X-Change [Figure 80-20-2]. Remove the eight bolts
Nitrogen Chamber on Page 80-10-1.) (Item 1) [Figure 80-20-1] or [Figure 80-20-2] and
remove the mounting frame or X-Change.
Remove the hydraulic breaker from the loader or
excavator. (See the Operation & Maintenance Manual for Installation: Apply liquid adhesive (LOCTITE #242) to

Dealer Copy -- Not for Resale


the procedure.) the threads. Tighten the bolts and nuts to 474 to 525 ft.-
lb. (645 to 710 Nm) torque.
Lay the hydraulic breaker and frame on the floor.
Remove the hydraulic hoses from the breaker fittings.
Figure 80-20-1
Figure 80-20-3

Remove the upper bumper (Item 1) [Figure 80-20-3].

Hydraulic Breaker
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DISASSEMBLY AND ASSEMBLY (CONTD) Shuttle Valve

Breaker Frame Removal and Installation (Contd) NOTE: Check the machined surfaces of the shuttle
valve for scratches or wear. The shuttle valve
Figure 80-20-4 parts are not replaceable.

NOTE: Apply hydraulic oil to the O-rings and


machined surfaces during assembly.

Figure 80-20-5

Remove the fi ttings (Item 1) [Figure 80-20-4], install an


eyelet in the top of the breaker, and use a hoist to slide
the breaker from the frame.

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Put the breaker in a stand.
Remove the bolts from the shuttle valve cap (Item 1)
NOTE: Always replace O-rings and seals when [Figure 80-20-5].
servicing the breaker.
Installation: Tighten the bo lts to 85 ft.-lb. (115 Nm)
torque.

Figure 80-20-6

Rotate the cap until 1 edge (Item 1) [Figure 80-20-6]


clears the upper body.

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DISASSEMBLY AND ASSEMBLY (CONTD) Figure 80-20-9

Tap on the cap to remove it from the bore.

Shuttle Valve (Contd)

Figure 80-20-7

The sleeve (Item 1) [Figure 80-20-9] is a press fit. Do not


remove it unless it is damaged.

Use MEL1545 to remove it from the housing.

If the sleeve was removed, install the replacement sleeve


Remove and replace the O-ring (Item 1) [Figure 80-20-7] as follows:

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from the cap.
Freeze the s leeve for 2 hou rs in liquid CO2, then install
Check the cap machined surfaces for scratches or wear. the sleeve into the main body. The prongs of the sleeve
must contact the end face of the bore [Figure 80-20-9].
Figure 80-20-8
Allow the sleeve to warm before continuing.

Remove the shuttle valve (Item 1) [Figure 80-20-8] from


the shuttle valve sleeve.

A light scuffing or burnishing of the surfaces is normal.


Check for cracks and see that the spool moves freely in
the valve sleeve.

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

DO NOT break or buff the sharp edges of the valve


sleeve or valve spool. This will cause the valve to
malfunction.

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 80-20-12

Charge Valve

Figure 80-20-10

Inspect the charge valve for cracks, scratches, or wear


[Figure 80-20-12].

Replace the O-rings (Items 1 & 2) [Figure 80-20-12] on


Remove the p lug (Item 1) [Figure 80-20-10] to gain the charge valve assembly.
access to the charge valve.

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Figure 80-20-11

Use a slotted screwdriver to remove the charge valve


(Item 1) [Figure 80-20-11].

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 80-20-15

Upper Body Removal and Installation

Figure 80-20-13

Use MEL1544 to remove the tie rods (Item 1) [Figure 80-


20-15].

Lift the tie rods from the upper body.


Remove the protective vinyl caps (Item 1) from the tie rod
nuts (Item 2) [Figure 80-20-13]. Figure 80-20-16

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Figure 80-20-14

Remove the nuts from the slots in the lower body [Figure
80-20-16].
Remove the 4 tie rod nuts (Item 1) and lock plates (Item
2) [Figure 80-20-14].

NOTE: Do not use an impact wrench to remove the tie


rod nuts.

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DISASSEMBLY AND ASSEMBLY (CONT'D) Seal Carrier Removal

Upper Body Removal and Installation (Contd) If the seal carrier stays in the upper body, use MEL1542
and a slide hammer to remove the carrier.
Figure 80-20-17
Figure 80-20-18

Position the tool (Item 1) [Figure 80-20-18] to pass


through the seal carrier.

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Figure 80-20-19

Install a lifting eyelet (Item 1) [Figure 80-20-17] in the nut


of the upper body.

Use an overhead hoist to lift the upper body from the


lower body [Figure 80-20-17].

NOTE: Use a rubber hammer to strike the bumpers Seat the tool securely against the seal carrier flange and
(Item 2) [Figure 80-20-17] if sections stick use the slide hammer to remove the carrier [Figure 80-
together. 20-19].

Inspect the upper body for cracks or other damage (See


your dealer for repair or replacement.)

NOTE: The seal carrier and piston sleeve may b e


lifted out with the upper body. If this happens,
the parts may fall out. Use caution to protect
these parts when sections are separated.

Lay the upper body on its side.

If the piston sleeve lifts out with the upper body it can be
removed by pulling it from the body.

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 80-20-22

Seal Carrier Repair

Check the seal carrier and piston for wear, galling, or


cracks .

A light scuffing or burnishing or surfaces is normal.

Figure 80-20-20

Position the oil seal on the tool MEL1033 [Figure 80-20-


22]. Lips must face away from the tool.

Figure 80-20-23

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Remove the O-rings from the seal carrier [Figure 80-20-
20].

Figure 80-20-21

Install the seal with the lips DOWN [Figure 80-20-23].

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.

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DISASSEMBLY AND ASSEMBLY (CONTD) Figure 80-20-25

Piston Removal

Figure 80-20-24

Check the piston for wear, galling, or cracks [Figure 80-


20-25].

Figure 80-20-26

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Install a lifting eye (Item 1) [Figure 80-20-24] in the
piston and us e the hoist to r emove the piston from the Check the condition of the annual groves (Item 1)
sleeve. [Figure 80-20-26].

A light scuffing or burnishing of surfaces is normal.

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 80-20-28

Sleeve Removal

Figure 80-20-27

Remove the O-rings from the sleeve [Figure 80-20-28].

Installation: Apply grease to the O-rings before installing


them on the sleeve.

Figure 80-20-29

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If the sleeve stays in the lower body use MEL1541 to
remove the sleeve. Install the slide hammer (Item 1)
[Figure 80-20-27] on the tool.
Remove the wiper seal (Item 1) and the rod seal (Item 2)
Align the tool with the holes in the sleeve and install the [Figure 80-20-29] from the sleeve.
pin (Item 2) [Figure 80-20-27] through the sleeve and
tool. Installation: Put grease on the rod seal (Item 2) [Figure
80-20-29]. Install the seal with the lips up.
Use the slide hammer until the sleeve is free from the
lower body. Installation: Put grease on th e wiper seal (Item 1)
[Figure 80-20-29]. Install the seal with the beveled side
Check the s leeve for scratches, damaged O-rings and down.
seals.

A light scuffing or burnishing of the surfaces is normal.


Check for cracks and see that the piston moves freely in
the sleeve.

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

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 80-20-31

Bumper Pad Removal and Installation

NOTE: Do not remove the bumper pads unless they


are damaged.

Figure 80-20-30

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The pins (Item 1) [Figure 80-20-30] can be removed for
repair.

Install a bolt in the threaded hole of the bumper pad pins


(Item 1) [Figure 80-20-30]. Use the bolt to pull the pins
from the lower body.

Installation: Install the bumper pads (Item 2) [Figure 80-


20-30] so the angle is facing up. Install the pins so the Install chains through the tie rod holes. Use a bolt (Item
threaded hole is facing up. 1) [Figure 80-20-31] to connect the chains together.

Bushing Removal and Installation Use an overhead hoist to lift the lower body.

Before the lower body is lifted from the stand, the point Lay the lower body on it's side.
retaining pin can be removed and the point will remain in
the stand.

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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 80-20-34

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 side
movement. There should be no more than 1/4 inch (6.4
mm) 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

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 the


lower body.

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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 e


lower body.
Install a punch (Item 1) [Figure 80-20-32] through the roll
pin. Use a hammer to remove the roll pin and retaining
pin.

Repeat the procedure for both roll pins and retaining


pins.

Figure 80-20-33

The roll pins and retaining pins fit o nly 1 s et of holes


(Item 1) [Figure 80-20-33].

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243 of 260 80-20-11 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Sleeve Installation

Tool Retaining Pin Removal and Installation Lubricate the lower body bore and all sleeve surfaces
with hydraulic oil before installation.
Figure 80-20-35
Figure 80-20-37

Remove the pl ugs (Item 1) [Figure 80-20-35] from the


lower body.

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Installation: Apply LOCTITE #242 on th e plug threads
during assembly. Tighten the plugs to 150 ft.-lb. (203
Nm) torque.

Figure 80-20-36

Use MEL1543 and a hammer to install the sleeve in the


lower body bore [Figure 80-20-37].

Pry the retainer rubbers and retaining pins from the lower
body [Figure 80-20-36].

Clean the holes and threads of de bris before installing


rubbers and reataining pins.

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DISASSEMBLY AND ASSEMBLY (CONTD) Figure 80-20-39

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.

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Lubricate the piston (Item 1) [Figure 80-20-39] and
install 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 hammer


to install the seal carrier on the piston.

Install the upper body. (See Upper Body Removal and


Installation on Page 80-10-5.) Align the dowel pin (Item
4) [Figure 80-20-39] with the mating hole in the upper
body during assembly.

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DISASSEMBLY AND ASSEMBLY (CONTD) Figure 80-20-42

Tie Rod Installation

Apply anti-sieze to the following locations during


assembly:

Thread surfaces of tie rods


Top and bottom surfaces of the nuts
Tie rod nuts
Top and bottom surfaces of the lock plates

Figure 80-20-40

Install the 4 lock plates (Item 1) [Figure 80-20-42] on the


tie rods.

If necessary loosen the tie rods to align the lock plates.

Install the tie rod nuts (Item 2) [Figure 80-20-42].

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In a cr ossing pattern, tighten the tie rods to 200 f t.-lb.
(271 Nm) torque, then to 650 ft.-lb. (881 Nm) torque.

Figure 80-20-43

Install the nuts in the slots of the lower body [Figure 80-
20-40].

Figure 80-20-41

Install the vinyl caps (Item 1) [Figure 80-20-43] on the tie


rod nuts.

Charge the nitrogen chamber. (See Charging The


Nitrogen Chamber on Page 80-10-2.)
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 the
tie rods 1/4 turn.

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246 of 260 80-20-14 Service Manual
SPECIFICATIONS

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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)

Hydraulic Breaker
247 of 260 80-30-1 Service Manual
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Hydraulic Breaker
248 of 260 80-30-2 Service Manual
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PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: HB-1


Date: 5 September 1997
Product: Bobcat Attachment
Model: Hydraulic Breaker
Manual No: 6720280 (9-96)

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:

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TAKE OUT PUT IN
i, ii i (Revised Sept. 97), ii
iii, iv iii (Revised Sept. 97), iv
ix (Revised Sept. 97), x (Revised Sept. 97)
1-1, 1-2 1-1 (Revised Sept. 97), 1-2
1-5, 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), 3-8
3-9, 3-10 3-9 (Revised Sept. 97), 3-10
Hydraulic/Hydrostatic Flow Chart Hydraulic/Hydrostatic Flow Chart
2560 1560, 2560/3560, 6560
(Printed September 1993) (Printed September 1997)
5-5, 5-6 5-5, 5-6 (Revised Sept. 97
5-9, 5-10 5-9 (Revised Sept. 97), 5-10
5-11, 5-12 5-11 (Revised Sept. 97), 5-12
6-13, 6-14 6-13 (Revised Sept. 97), 6-14
Section 7 7-1 thru 7-8 (Revised Sept. 97)
7-9 thru 7-18 (Revised Sept. 97)
Section 8 (Revised Sept. 97)

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REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: HB-2


Date: 7 March 2001
Product: Bobcat Attachment
Model: 1250, 1560, 2500/3500, 2560/3560, 5500 & 6560
Manual No: 6720280 (9-96)

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:

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TAKE OUT PUT IN REVISION DESCRIPTION

4-1 - 4-14 4-1 - 4-14 Revised seal identification information. 2500/3500


seals are no longer identified by colors, seals are now
packaged in the seal kit with identification numbers.

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NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: HB-3


Date: 18 February 2002
Product: Bobcat Attachment
Model: 1250, 1560, 2500/3500, 2560/3560, 2570/3570, 5060 5500 & 6560
Manual No: 6720280 (9-96)

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:

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TAKE OUT PUT IN REVISION DESCRIPTION

ALPHABETICAL INDEX ALPHABETICAL INDEX Revised page


iii, iv iii, iv Revised contents page
ix thru xii ix thru xii Added models 2570/3570 and 5060
1-1, 1-2 1-1, 1-2 Revised contents page
1-9 thru 1-12 1-9 thru 1-30 Added models 2570/3570 and 5060
6-1 thru 6-14 6-1 thru 6-26 Added models 2570/3570
7-1 thru 7-18 7-1 thru 7-20 Added model 5060
8-1 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

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NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: Breaker - 4


Date: 19 October 2005
Product: Bobcat Attachment
Model: Hydraulic Breaker
Manual No: 6720280 (10-04)

Please remove the existing Hydraulic / Hydrostatic Flow Charts from Hydraulic Breaker Service Manual (P/N
6720280) Dated 9-96 and save these Flow Charts.

After the Hydraulic / Hydrostatic Flow Charts have been removed, discard your old Hydraulic Breaker Service
Manual (P/N 6720280) Dated 9-96 and replace it with the revised Hydraulic Breaker Service Manual (P/N 6720280)

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Date 10-05.

Insert the existing Hydraulic / Hy drostatic Flow Charts into t he new Hydraulic Breaker Service Manual (P/N
6720280) Date 10-05.

This Service Manual is in a new format with added updates.

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NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: Breaker-5


Date: 23 March 2006
Product: Attachment
Model: Hydraulic Breaker
Manual No: 6720280 (10-05)

Hydraulic Breaker Service Manual (P/N 6720280) Dated (2-06) contains updated service information which
replaces the previous Hydraulic Breaker Service Manual (P/N 6720280) Dated (10-05).

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NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: Breaker-6


Date: 15 June 2012
Product: Attachment
Model: Hydraulic Breaker
Manual No: 6720280 (2-06)

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The following Sections are a revision to the above Service Manual.

COVER

259 of 260
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