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Breaker 6720280 EnUS SM 06-12-1 PDF
Breaker 6720280 EnUS SM 06-12-1 PDF
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
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2 of 260
Dealer Copy -- Not for Resale
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Ma intenance Manual, Operator’s 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
MSW30-0805
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Dealer Copy -- Not for Resale
ALPHABETICAL INDEX
Hydraulic Breaker
10-01 Service Manual
5 of 260
ALPHABETICAL INDEX (CONT’D)
Hydraulic Breaker
10-02 Service Manual
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CONTENTS
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
7 of 260
Dealer Copy -- Not for Resale
Hydraulic Breaker
II Service Manual
8 of 260
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].
N-06610
Charge Fitting
Nitrogen Chamber
Breaker Body
Breaker Foot
Mounting Holes
Tool Point
B-12480
Breaker shown is mounted in excavator bracket
Hydraulic Breaker
III Service Manual
9 of 260
SERIAL NUMBER LOCATIONS & HYDRAULIC Always use the serial number of the machine when
BREAKER IDENTIFICATION (CONT’D) 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].
All 453 & 553 Bobcat Loaders and 320 & 325 excavators
P5589
Charge
Fitting
Main
Body
Hose
Fittings
Lower
Mounting Body
Bolts
Tool
Point
P-5745
Hydraulic Breaker
IV Service Manual
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SERIAL NUMBER LOCATIONS & HYDRAULIC Always use the serial number of the machine when
BREAKER IDENTIFICATION (CONT’D) 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].
All 453 & 553 Bobcat Loaders and 320 & 325 excavators
B-9608
Charge Fitting
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 (CONT’D) 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].
P1854
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 (CONT’D) 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
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 (CONT’D) 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
Tool Quick
Bit Couplers
Steps
Steps
P-12815
P-12814
Hydraulic Breaker
VIII Service Manual
14 of 260
SERIAL NUMBER LOCATIONS & HYDRAULIC Always use the serial number of the machine when
BREAKER IDENTIFICATION (CONT’D) 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
Grease
Fitting
Tool
Bit
P-12815
Hydraulic Breaker
IX Service Manual
15 of 260
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
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Hydraulic Breaker
10-01 Service Manual
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Dealer Copy -- Not for Resale
Hydraulic Breaker
10-02 Service Manual
18 of 260
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.
Figure 10-10-3
Nitrogen 600 PSI (41,38 bar)
Torque
400 ft.-lb.
(542,4 N•m)
Pressure
Return
Line
Always apply grease to the top 8 in. (203 mm) of the tool
point before reinstalling it in the breaker bore.
Hydraulic Breaker
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ACCUMULATOR (CONT’D)
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.
Hydraulic Breaker
21 of 260 10-10-3 Service Manual
PARTS IDENTIFICATION
Hydraulic Breaker
22 of 260 10-10-4 Service Manual
PARTS IDENTIFICATION (CONT'D)
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
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.
Figure 10-20-1
Hydraulic Breaker
25 of 260 10-20-1 Service Manual
DISASSEMBLY (CONT'D) Figure 10-20-6
Figure 10-20-4
Figure 10-20-7
Figure 10-20-5
IMPORTANT
Do not completely discharge the accumulator at this
time.
I-2037-0788
Hydraulic Breaker
26 of 260 10-20-2 Service Manual
DISASSEMBLY (CONT'D) Upper Body Removal and Installation
Figure 10-20-8
Hydraulic Breaker
27 of 260 10-20-3 Service Manual
DISASSEMBLY (CONT'D) Figure 10-20-14
Figure 10-20-12
Remove the rod wiper, washer and cup seal from the
piston [Figure 10-20-14].
Hydraulic Breaker
28 of 260 10-20-4 Service Manual
DISASSEMBLY (CONT'D) Flow Sleeve Removal and Installation
Figure 10-20-16
Figure 10-20-17
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
Figure 10-20-20
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].
Figure 10-20-21
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].
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
Hydraulic Breaker
31 of 260 10-20-7 Service Manual
DISASSEMBLY (CONT'D) Always replace both bushings as a set.
Figure 10-20-28
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].
Bushing Removal
Figure 10-20-29
Hydraulic Breaker
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.
Hydraulic Breaker
33 of 260 10-20-9 Service Manual
ASSEMBLY Figure 10-20-34
Figure 10-20-32
Figure 10-20-35
Figure 10-20-33
Hydraulic Breaker
34 of 260 10-20-10 Service Manual
ASSEMBLY (CONT'D) Figure 10-20-38
Figure 10-20-36
Figure 10-20-39
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].
Install the 2 long push pins into the automatic valve body
[Figure 10-20-37].
Hydraulic Breaker
35 of 260 10-20-11 Service Manual
ASSEMBLY (CONT'D) Figure 10-20-42
Figure 10-20-40
Figure 10-20-43
Figure 10-20-41
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.
Hydraulic Breaker
36 of 260 10-20-12 Service Manual
ASSEMBLY (CONT'D) Figure 10-20-46
Figure 10-20-44
Hydraulic Breaker
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
Figure 10-20-48
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
Hydraulic Breaker
38 of 260 10-20-14 Service Manual
ASSEMBLY (CONT'D) Figure 10-20-52
Figure 10-20-50
Figure 10-20-51
Insert the pilot spring (large end facing up) into the center
hole of the disc springs [Figure 10-20-51].
Hydraulic Breaker
39 of 260 10-20-15 Service Manual
ASSEMBLY (CONT'D) Figure 10-20-56
Figure 10-20-54
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
Figure 10-20-59
Hydraulic Breaker
41 of 260 10-20-17 Service Manual
Dealer Copy -- Not for Resale
Hydraulic Breaker
42 of 260 10-20-18 Service Manual
SPECIFICATIONS
* 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
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
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
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
Figure 20-10-3
P18084
Hydraulic Breaker
47 of 260 20-10-1 Service Manual
NITROGEN CHAMBER (CONT’D) Figure 20-10-6
Figure 20-10-4
0.125”
(3,2 mm) Tighten the adapter (Item 1) [Figure 20-10-6] on th e
breaker.
Figure 20-10-5
Hydraulic Breaker
48 of 260 20-10-2 Service Manual
NITROGEN CHAMBER (CONT’D) 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.
Figure 20-10-8
Figure 20-10-9
Hydraulic Breaker
49 of 260 20-10-3 Service Manual
HYDRAULIC BREAKER LUBRICATION
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
If the snap rings and lock plates are missing, tighten the
bolts to 300 ft.-lb. (407 N•m) torque. Lock plates can be
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.
Hydraulic Breaker
52 of 260 20-10-6 Service Manual
TROUBLESHOOTING THE HYDRAULIC BREAKER (CONT’D)
Hydraulic Breaker
53 of 260 20-10-7 Service Manual
PARTS IDENTIFICATION
Hydraulic Breaker
54 of 260 20-10-8 Service Manual
DISASSEMBLY AND ASSEMBLY Figure 20-20-1
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.
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.
Hydraulic Breaker
55 of 260 20-20-1 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Shuttle Valve
Breaker Frame Removal and Installation (Cont’d) 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.
Figure 20-20-5
Figure 20-20-6
Hydraulic Breaker
56 of 260 20-20-2 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 20-20-9
Figure 20-20-7
If small burrs are found, remove them with 200 grit emery
cloth.
Hydraulic Breaker
57 of 260 20-20-3 Service Manual
DISASSEMBLY AND ASSEMBLY (Cont'd) Figure 20-20-12
Charge Valve
Figure 20-20-10
Hydraulic Breaker
58 of 260 20-20-4 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 20-20-14
Figure 20-20-13
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
Hydraulic Breaker
59 of 260 20-20-5 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 20-20-17
Piston
Figure 20-20-15
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.
Seal Carrier
Figure 20-20-16
Installation: Put oil on the quad ring and seal. Install the
seal with the lips DOWN.
Hydraulic Breaker
60 of 260 20-20-6 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 20-20-20
Figure 20-20-19
Figure 20-20-21
Hydraulic Breaker
61 of 260 20-20-7 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Bushing Removal and Installation
Sleeve Removal and Installation (Cont’d) 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.
Figure 20-20-23
Figure 20-20-24
Hydraulic Breaker
62 of 260 20-20-8 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 20-20-27
Figure 20-20-25
Hydraulic Breaker
63 of 260 20-20-9 Service Manual
Dealer Copy -- Not for Resale
Hydraulic Breaker
64 of 260 20-20-10 Service Manual
SPECIFICATIONS
NOTE: The 1560 Hydraulic Breaker is unique in design and only 1560 tools will fit the breaker.
Hydraulic Breaker
65 of 260 20-30-1 Service Manual
Dealer Copy -- Not for Resale
Hydraulic Breaker
66 of 260 20-30-2 Service Manual
2500/3500 HYDRAULIC BREAKER SERVICE
Hydraulic Breaker
30-01 Service Manual
67 of 260
Dealer Copy -- Not for Resale
Hydraulic Breaker
30-02 Service Manual
68 of 260
NITROGEN CHAMBER Figure 30-10-3
Figure 30-10-1
2
0.125”
(3,2 mm)
P-42758
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.
Hydraulic Breaker
69 of 260 30-10-1 Service Manual
NITROGEN CHAMBER (CONT’D) Charging the High Pressure Accumulator
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
Figure 30-10-8
1
B-23394
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.
Hydraulic Breaker
70 of 260 30-10-2 Service Manual
NITROGEN CHAMBER (CONT’D)
Figure 30-10-9
B-7077
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
Hydraulic Breaker
71 of 260 30-10-3 Service Manual
NITROGEN CHAMBER (CONT’D) Figure 30-10-13
Figure 30-10-11
2
0.125”
(3,2 mm)
P-42758
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.
Hydraulic Breaker
72 of 260 30-10-4 Service Manual
NITROGEN CHAMBER (CONT’D) Charging the Low Pressure Accumulator
Checking The Low Pressure Accumulator Pressure The low pressure accumulator is located on the front side
(Cont’d) of the main body.
Figure 30-10-17
B-23393
Hydraulic Breaker
73 of 260 30-10-5 Service Manual
NITROGEN CHAMBER (CONT’D) Checking The Nitrogen Chamber Charge Pressure
Charging The Low Pressure Accumulator (Cont’d) Use the nitrogen accumulator charge pressure gauge
MEL1523B to check pressure.
Figure 30-10-19
Figure 30-10-20
B-7077
B-8887
P18084
Hydraulic Breaker
74 of 260 30-10-6 Service Manual
NITROGEN CHAMBER (CONT’D) Figure 30-10-24
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
Figure 30-10-23
B-
23395
Hydraulic Breaker
75 of 260 30-10-7 Service Manual
NITROGEN CHAMBER (CONT’D) Figure 30-10-28
Figure 30-10-26
Hydraulic Breaker
76 of 260 30-10-8 Service Manual
HYDRAULIC BREAKER LUBRICATION
Figure 30-10-29
B-11927
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
77 of 260 30-10-9 Service Manual
CHECKING MOUNTING BOLT TORQUE
Figure 30-10-30
B-11927
Hydraulic Breaker
78 of 260 30-10-10 Service Manual
TROUBLESHOOTING THE HYDRAULIC BREAKER
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.
Hydraulic Breaker
79 of 260 30-10-11 Service Manual
PARTS IDENTIFICATION
Hydraulic Breaker
80 of 260 30-10-12 Service Manual
DISASSEMBLY AND ASSEMBLY Figure 30-20-1
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.
Hydraulic Breaker
81 of 260 30-20-1 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT’D) Figure 30-20-5
Figure 30-20-3
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 N•m) torque.
Figure 30-20-6
Hydraulic Breaker
82 of 260 30-20-2 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT’D) Nitrogen Chamber Removal and Installation
Figure 30-20-7
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
Figure 30-20-9
Hydraulic Breaker
83 of 260 30-20-3 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT’D) Piston Removal
Figure 30-20-10
Hydraulic Breaker
84 of 260 30-20-4 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 30-20-14
Figure 30-20-12
Figure 30-20-13
Remove the push pins and inspect for wear [Figure 30-
20-13].
Hydraulic Breaker
85 of 260 30-20-5 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Main Body Removal
Figure 30-20-15
Figure 30-20-18
Hydraulic Breaker
86 of 260 30-20-6 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Lower Body Bushings Removal
Figure 30-20-19
Hydraulic Breaker
87 of 260 30-20-7 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 30-20-24
Figure 30-20-22
Figure 30-20-25
Turn the chamber over, install the large bolt. Use a soft
hammer and hit the bo lt to remove the diaphragm and
screen.
Figure 30-20-23 Install the O-ring on the screen [Figure 30-20-25]. (The
O-ring identification number is 350724.)
Hydraulic Breaker
88 of 260 30-20-8 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Accumulator
Figure 30-20-26
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 N•m) torque.
Figure 30-20-27
Hydraulic Breaker
89 of 260 30-20-9 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 30-20-32
Accumulator (Cont’d)
Figure 30-20-30
Remove the charge valve [Figure 30-20-30]. Put the plug into the body and tighten to 600 ft.-lb. (814
N•m) torque.
Clean and inspect the charge valve.
Figure 30-20-31
Hydraulic Breaker
90 of 260 30-20-10 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 30-20-34
Seals Installation
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 :
Hydraulic Breaker
91 of 260 30-20-11 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D)
Figure 30-20-36
The open side (O-ring side) of the seals must face toward
each other [Figure 30-20-36].
Start Up Procedure
Hydraulic Breaker
92 of 260 30-20-12 Service Manual
SPECIFICATIONS (2500)
Hydraulic Breaker
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 @ 200°F)(43.3°C) 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.
Hydraulic Breaker
94 of 260 30-30-2 Service Manual
2560/3560 HYDRAULIC BREAKER SERVICE
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Hydraulic Breaker
40-01 Service Manual
95 of 260
Dealer Copy -- Not for Resale
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
Figure 40-10-2
P18084
Hydraulic Breaker
97 of 260 40-10-1 Service Manual
NITROGEN CHAMBER (CONT’D) Figure 40-10-7
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
Figure 40-10-6
P-65363
Hydraulic Breaker
98 of 260 40-10-2 Service Manual
NITROGEN CHAMBER (CONT’D) Figure 40-10-10
Use charging kit (P/N 6568037) to charge the nitrogen Connect This End To
chamber. Nitrogen Chamber
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
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
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
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
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
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.
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
Figure 40-20-7
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
N•m) 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.
Hydraulic Breaker
104 of 260 40-20-2 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 40-20-10
Figure 40-20-8
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].
Hydraulic Breaker
105 of 260 40-20-3 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 40-20-14
Figure 40-20-12
B-15066
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
Figure 40-20-15
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.
Hydraulic Breaker
106 of 260 40-20-4 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 40-20-18
Figure 40-20-16
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
Figure 40-20-17
Hydraulic Breaker
107 of 260 40-20-5 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 40-20-22
Figure 40-20-20
Figure 40-20-23
Hydraulic Breaker
108 of 260 40-20-6 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 40-20-26
Figure 40-20-24
Figure 40-20-27
Remove the cap from the valve [Figure 40-20-24].
Figure 40-20-25
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.
Hydraulic Breaker
109 of 260 40-20-7 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 40-20-30
Figure 40-20-28
The upper section and the lower section are aligned with
a dowel (Item 1) [Figure 40-20-30].
Remove the main body from the lower body [Figure 40-
20-29]. Install the sleeve in the upper section [Figure 40-20-31].
Hydraulic Breaker
110 of 260 40-20-8 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 40-20-34
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].
Figure 40-20-33
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
Figure 40-20-36
Hydraulic Breaker
112 of 260 40-20-10 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 40-20-42
Align the dowel and put the main body on the lower
section.
Figure 40-20-40
Start Up Procedure
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.
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.
Hydraulic Breaker
113 of 260 40-20-11 Service Manual
Dealer Copy -- Not for Resale
Hydraulic Breaker
114 of 260 40-20-12 Service Manual
SPECIFICATIONS
NOTE: The same tools will fit both the 2560 and 3560 breakers.
Hydraulic Breaker
115 of 260 40-30-1 Service Manual
Dealer Copy -- Not for Resale
Hydraulic Breaker
116 of 260 40-30-2 Service Manual
2570/3570 HYDRAULIC BREAKER SERVICE
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Hydraulic Breaker
50-01 Service Manual
117 of 260
Dealer Copy -- Not for Resale
Hydraulic Breaker
50-02 Service Manual
118 of 260
NITROGEN CHAMBER Figure 50-10-2
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 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
Figure 50-10-3
P18084
Hydraulic Breaker
119 of 260 50-10-1 Service Manual
NITROGEN CHAMBER (CONT’D) Figure 50-10-6
Figure 50-10-4
0.125”
(3,2 mm) Tighten the adapter (Item 1) [Figure 50-10-6] on th e
breaker.
Figure 50-10-5
Hydraulic Breaker
120 of 260 50-10-2 Service Manual
NITROGEN CHAMBER (CONT’D) Figure 50-10-9
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.
• 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
Hydraulic Breaker
121 of 260 50-10-3 Service Manual
NITROGEN CHAMBER (CONT’D) Figure 50-10-13
Figure 50-10-11
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.
Hydraulic Breaker
122 of 260 50-10-4 Service Manual
NITROGEN CHAMBER (CONT’D) Figure 50-10-15
WARNING 1
0.125”
(3,2 mm)
P-42758
Remove the plug (Item 1) [Figure 50-10-14].
Hydraulic Breaker
123 of 260 50-10-5 Service Manual
NITROGEN CHAMBER (CONT’D) Figure 50-10-19
Figure 50-10-17
Hydraulic Breaker
124 of 260 50-10-6 Service Manual
NITROGEN CHAMBER (CONT’D)
Figure 50-10-20
Hydraulic Breaker
125 of 260 50-10-7 Service Manual
NITROGEN CHAMBER (CONT’D) Figure 50-10-23
Figure 50-10-22
Hydraulic Breaker
126 of 260 50-10-8 Service Manual
HYDRAULIC BREAKER LUBRICATION
Figure 50-10-24
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
If the snap rings and lock plates are missing, tighten the
bolts to 300 ft.-lb. (407 N•m) torque. Lock plates can be
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
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).
Hydraulic Breaker
130 of 260 50-10-12 Service Manual
TROUBLESHOOTING THE HYDRAULIC BREAKER (CONT’D)
Hydraulic Breaker
131 of 260 50-10-13 Service Manual
PARTS IDENTIFICATION
Hydraulic Breaker
132 of 260 50-10-14 Service Manual
PARTS IDENTIFICATION (CONT’D)
Hydraulic Breaker
133 of 260 50-10-15 Service Manual
Dealer Copy -- Not for Resale
Hydraulic Breaker
134 of 260 50-10-16 Service Manual
DISASSEMBLY AND ASSEMBLY Figure 50-20-2
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. 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
Hydraulic Breaker
135 of 260 50-20-1 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-7
Figure 50-20-5
Figure 50-20-8
Remove the hoses (Item 1) [Figure 50-20-5] from the
Figure 50-20-6
Hydraulic Breaker
136 of 260 50-20-2 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-11
Figure 50-20-9
Figure 50-20-10
Hydraulic Breaker
137 of 260 50-20-3 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-15
Figure 50-20-13
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
Figure 50-20-16
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
Figure 50-20-19
Hydraulic Breaker
139 of 260 50-20-5 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-22
Figure 50-20-20
Figure 50-20-23
Remove the O-ring (Item 1) [Figure 50-20-20].
Figure 50-20-21
Hydraulic Breaker
140 of 260 50-20-6 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-27
Figure 50-20-25
Figure 50-20-28
Figure 50-20-26
Hydraulic Breaker
141 of 260 50-20-7 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-31
Figure 50-20-29
Figure 50-20-32
Remove the seal carrier (Item 1) [Figure 50-20-29] from
the piston.
Figure 50-20-30
Check the piston shaft and grooves for wear [Figure 50-
20-30].
Hydraulic Breaker
142 of 260 50-20-8 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-35
Figure 50-20-33
Figure 50-20-36
Figure 50-20-34
Tighten the nut un til the s leeve pulls free from the main
body [Figure 50-20-34].
Hydraulic Breaker
143 of 260 50-20-9 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Valve Removal And Installation
Put oil on the O-rings, the outside of the sleeve and the
inside of the main body before installation.
Figure 50-20-37
Figure 50-20-40
Figure 50-20-38
Hydraulic Breaker
144 of 260 50-20-10 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-43
Figure 50-20-41
Figure 50-20-44
Remove the 8 bolts (Item 1) [Figure 50-20-41] from the
valve manifold.
Figure 50-20-42
Hydraulic Breaker
145 of 260 50-20-11 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-47
Figure 50-20-45
Figure 50-20-48
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.
Hydraulic Breaker
146 of 260 50-20-12 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-51
Figure 50-20-49
Figure 50-20-52
Figure 50-20-50
Hydraulic Breaker
147 of 260 50-20-13 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Upper Housing Removal And Installation
Figure 50-20-53
Remove the s pool (Item 1) [Figure 50-20-53] from the Figure 50-20-56
valve.
Hydraulic Breaker
148 of 260 50-20-14 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-59
Figure 50-20-57
Hydraulic Breaker
149 of 260 50-20-15 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-63
Figure 50-20-61
Figure 50-20-64
Figure 50-20-62
Hydraulic Breaker
150 of 260 50-20-16 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-67
Figure 50-20-65
Figure 50-20-68
Hydraulic Breaker
151 of 260 50-20-17 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Bushing Removal And Installation
Figure 50-20-69
Figure 50-20-72
Figure 50-20-70
Hydraulic Breaker
152 of 260 50-20-18 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-75
Figure 50-20-73
Figure 50-20-76
Figure 50-20-74
Hydraulic Breaker
153 of 260 50-20-19 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 50-20-79
Figure 50-20-77
Hydraulic Breaker
154 of 260 50-20-20 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D)
Figure 50-20-80
Start Up Procedure
Start the engine. Raise the tool off the work surface and
engage the auxiliary hydraulics.
Hydraulic Breaker
155 of 260 50-20-21 Service Manual
Dealer Copy -- Not for Resale
Hydraulic Breaker
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.
Hydraulic Breaker
157 of 260 50-30-1 Service Manual
Dealer Copy -- Not for Resale
Hydraulic Breaker
158 of 260 50-30-2 Service Manual
5060 HYDRAULIC BREAKER SERVICE
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-14
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
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.
Hydraulic Breaker
161 of 260 60-10-1 Service Manual
NITROGEN CHAMBER (CONT’D) Figure 60-10-5
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
Loosen the adapter until the pin is flush with the end o f
the adapter as shown [Figure 60-10-6].
P-29454
Hydraulic Breaker
162 of 260 60-10-2 Service Manual
NITROGEN CHAMBER (CONT’D) Charging The Nitrogen Chamber
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
Figure 60-10-9
Hydraulic Breaker
163 of 260 60-10-3 Service Manual
NITROGEN CHAMBER (CONT’D) Install the charging tool (Item 1) [Figure 60-10-12] on the
breaker.
Charging The Nitrogen Chamber (Cont’d)
Remove the cap (Item 2) [Figure 60-10-12] from the
Figure 60-10-10 charging tool.
Figure 60-10-13
Figure 60-10-11
Connect the nitrogen hose (Item 1) to the charging tool
Figure 60-10-14
Figure 60-10-12
Hydraulic Breaker
164 of 260 60-10-4 Service Manual
BOB-TACH INSPECTION Figure 60-10-17
Figure 60-10-15
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
Hydraulic Breaker
165 of 260 60-10-5 Service Manual
HYDRAULIC BREAKER MOUNT INSPECTION
Figure 60-10-19
Hydraulic Breaker
166 of 260 60-10-6 Service Manual
HYDRAULIC BREAKER LUBRICATION
Figure 60-10-21
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
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-
P-12836
Hydraulic Breaker
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.
Hydraulic Breaker
169 of 260 60-10-9 Service Manual
TOOL BIT REMOVAL AND INSTALLATION (CONT’D) Figure 60-10-27
Figure 60-10-25
Hydraulic Breaker
170 of 260 60-10-10 Service Manual
TOOL BIT REMOVAL AND INSTALLATION (CONT’D)
Figure 60-10-29
When installing the tool bit apply grease to the top 10 in.
(250 mm) of the tool bit shaft [Figure 60-10-29].
Hydraulic Breaker
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].
Figure 60-10-31
Figure 60-10-32
Hydraulic Breaker
172 of 260 60-10-12 Service Manual
X-CHANGE MOUNT REMOVAL AND INSTALLATION
Figure 60-10-33
Hydraulic Breaker
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.
Hydraulic Breaker
174 of 260 60-10-14 Service Manual
PARTS IDENTIFICATION
Hydraulic Breaker
175 of 260 60-10-15 Service Manual
PARTS IDENTIFICATION (CONT'D)
Hydraulic Breaker
176 of 260 60-10-16 Service Manual
DISASSEMBLY AND ASSEMBLY Figure 60-20-2
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. Remove the fittings (Item 1) [Figure 60-20-2].
• Engine is running.
• Tools are being used. Figure 60-20-3
W-2019-1285
Figure 60-20-1
Figure 60-20-4
Hydraulic Breaker
177 of 260 60-20-1 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-7
Figure 60-20-5
Figure 60-20-8
Raise the hoist and stand the hydraulic breaker on end
[Figure 60-20-5].
Reinstall the hoist as shown in [Figure 60-20-6]. Lower the breaker and remove the hoist.
Hydraulic Breaker
178 of 260 60-20-2 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-11
Figure 60-20-9
Hydraulic Breaker
179 of 260 60-20-3 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-15
Figure 60-20-13
Figure 60-20-14
Hydraulic Breaker
180 of 260 60-20-4 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Charge Valve Removal And Installation
Figure 60-20-17
Hydraulic Breaker
181 of 260 60-20-5 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-23
Figure 60-20-21
Hydraulic Breaker
182 of 260 60-20-6 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-26
Figure 60-20-24
Figure 60-20-27
Remove the seal carrier (Item 1) [Figure 60-20-24] from
the piston.
Hydraulic Breaker
183 of 260 60-20-7 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Valve Removal And Installation
Figure 60-20-28
Hydraulic Breaker
184 of 260 60-20-8 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-34
Figure 60-20-32
Figure 60-20-33
Hydraulic Breaker
185 of 260 60-20-9 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-38
Figure 60-20-36
Figure 60-20-39
Figure 60-20-37
Hydraulic Breaker
186 of 260 60-20-10 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-42
Figure 60-20-40
Figure 60-20-41
Hydraulic Breaker
187 of 260 60-20-11 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-46
Figure 60-20-44
Hydraulic Breaker
188 of 260 60-20-12 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-50
Figure 60-20-48
Hydraulic Breaker
189 of 260 60-20-13 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 60-20-54
Figure 60-20-52
Figure 60-20-55
Figure 60-20-53
Hydraulic Breaker
190 of 260 60-20-14 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D)
Figure 60-20-56
Start Up Procedure
Start the engine. Raise the tool off the work surface and
engage the auxiliary hydraulics.
Hydraulic Breaker
191 of 260 60-20-15 Service Manual
Dealer Copy -- Not for Resale
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.
Hydraulic Breaker
193 of 260 60-30-1 Service Manual
Dealer Copy -- Not for Resale
Hydraulic Breaker
194 of 260 60-30-2 Service Manual
5500 HYDRAULIC BREAKER SERVICE
Hydraulic Breaker
70-01 Service Manual
195 of 260
Dealer Copy -- Not for Resale
Hydraulic Breaker
70-02 Service Manual
196 of 260
NITROGEN CHAMBER Figure 70-10-3
Figure 70-10-1
2
0.125”
(3,2 mm)
P-42758
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.
Hydraulic Breaker
197 of 260 70-10-1 Service Manual
NITROGEN CHAMBER (CONT’D) Charging the High Pressure Accumulator
Checking The High Pressure Accumulator Pressure Use charging kit (P/N 6568037) to charge the hydraulic
(Cont’d) 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
1
Remove the charge valve plug [Figure 70-10-7].
Figure 70-10-8
B-23394
Hydraulic Breaker
198 of 260 70-10-2 Service Manual
NITROGEN CHAMBER (CONT’D) Checking The Low Pressure Accumulator Pressure
Charging The High Pressure Accumulator Pressure Use the nitrogen accumulator charge pressure gauge
(Cont’d) MEL1523B to check pressure.
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].
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
Hydraulic Breaker
199 of 260 70-10-3 Service Manual
NITROGEN CHAMBER (CONT’D) Figure 70-10-15
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
Figure 70-10-14
B-23393
Hydraulic Breaker
200 of 260 70-10-4 Service Manual
NITROGEN CHAMBER (CONT’D) Figure 70-10-19
Figure 70-10-17
B-7077
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.
Hydraulic Breaker
201 of 260 70-10-5 Service Manual
NITROGEN CHAMBER (CONT’D) Figure 70-10-22
Figure 70-10-20
2
0.125”
1 (3,2 mm)
P-42758
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.
Hydraulic Breaker
202 of 260 70-10-6 Service Manual
NITROGEN CHAMBER (CONT’D) Charging the Nitrogen Chamber
Checking The Nitrogen Chamber Charge Pressure The nitrogen chamber charge valve is located on the
(Cont’d) back side of the breaker above the hydraulic inlet and
outlet ports.
Figure 70-10-24
Figure 70-10-26
B-23395
B-23395
Hydraulic Breaker
203 of 260 70-10-7 Service Manual
NITROGEN CHAMBER (CONT’D)
Figure 70-10-28
SLOWLY open the valve at the nitrogen tank and fill the
nitrogen chamber.
Hydraulic Breaker
204 of 260 70-10-8 Service Manual
HYDRAULIC BREAKER LUBRICATION
Figure 70-10-29
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
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.
Hydraulic Breaker
207 of 260 70-10-11 Service Manual
PARTS IDENTIFICATION
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
Figure 70-20-1
Install the eye bolt in the bo lt at th e top of th e breaker
[Figure 70-20-3].
Hydraulic Breaker
209 of 260 70-20-1 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 70-20-6
Figure 70-20-4
Figure 70-20-5
Hydraulic Breaker
210 of 260 70-20-2 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Manifold Removal
Figure 70-20-8
Figure 70-20-9
Hydraulic Breaker
211 of 260 70-20-3 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 70-20-13
Piston Removal
Figure 70-20-11
Remove the pi ston from the main body [Figure 70-20- Figure 70-20-14
11].
Figure 70-20-12
Remove the v alve cylinder with the valve seat from the
main body [Figure 70-20-14].
Remove the push pins and inspect for wear [Figure 70-
20-12].
Hydraulic Breaker
212 of 260 70-20-4 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 70-20-17
Figure 70-20-15
Remove the valve cylinder from the valve seat [Figure Install the socket head bolts into the body at both
70-20-15]. accumulator sides.
Figure 70-20-16
Install a chain hoist and lift the main body from the lower
body [Figure 70-20-18].
Hydraulic Breaker
213 of 260 70-20-5 Service Manual
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 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.
Figure 70-20-22
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.
Hydraulic Breaker
214 of 260 70-20-6 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 70-20-25
Figure 70-20-23
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 N•m) torque.
Hydraulic Breaker
215 of 260 70-20-7 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 70-20-29
Accumulator
Figure 70-20-27
Figure 70-20-28
Hydraulic Breaker
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.
Figure 70-20-32
Hydraulic Breaker
217 of 260 70-20-9 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT'D)
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
Hydraulic Breaker
218 of 260 70-20-10 Service Manual
SPECIFICATIONS
Hydraulic Breaker
219 of 260 70-30-1 Service Manual
Dealer Copy -- Not for Resale
Hydraulic Breaker
220 of 260 70-30-2 Service Manual
6560 HYDRAULIC BREAKER SERVICE
Hydraulic Breaker
80-01 Service Manual
221 of 260
Dealer Copy -- Not for Resale
Hydraulic Breaker
80-02 Service Manual
222 of 260
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
Figure 80-10-1
Hydraulic Breaker
223 of 260 80-10-1 Service Manual
NITROGEN CHAMBER (CONT’D) Figure 80-10-3
Figure 80-10-2
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)
Figure 80-10-7
Loosen the adapter until the pin is flush with the end of
the adapter as shown [Figure 80-10-7].
P-29454
Hydraulic Breaker
225 of 260 80-10-3 Service Manual
NITROGEN CHAMBER (CONT'D)
Figure 80-10-8
Hydraulic Breaker
226 of 260 80-10-4 Service Manual
HYDRAULIC BREAKER LUBRICATION
Figure 80-10-10
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
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
Hydraulic Breaker
229 of 260 80-10-7 Service Manual
TROUBLESHOOTING THE HYDRAULIC BREAKER (CONT’D)
Hydraulic Breaker
230 of 260 80-10-8 Service Manual
PARTS IDENTIFICATION
Hydraulic Breaker
231 of 260 80-10-9 Service Manual
PARTS IDENTIFICATION (CONT’D)
Hydraulic Breaker
232 of 260 80-10-10 Service Manual
DISASSEMBLY AND ASSEMBLY Figure 80-20-2
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
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
Hydraulic Breaker
233 of 260 80-20-1 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT’D) Shuttle Valve
Breaker Frame Removal and Installation (Cont’d) NOTE: Check the machined surfaces of the shuttle
valve for scratches or wear. The shuttle valve
Figure 80-20-4 parts are not replaceable.
Figure 80-20-5
Figure 80-20-6
Hydraulic Breaker
234 of 260 80-20-2 Service Manual
DISASSEMBLY AND ASSEMBLY (CONT’D) Figure 80-20-9
Figure 80-20-7
If small burrs are found, remove them with 200 grit emery
cloth.
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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 80-20-12
Charge Valve
Figure 80-20-10
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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 80-20-15
Figure 80-20-13
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].
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DISASSEMBLY AND ASSEMBLY (CONT'D) Seal Carrier Removal
Upper Body Removal and Installation (Cont’d) 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
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].
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
Figure 80-20-20
Figure 80-20-23
Figure 80-20-21
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DISASSEMBLY AND ASSEMBLY (CONT’D) Figure 80-20-25
Piston Removal
Figure 80-20-24
Figure 80-20-26
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DISASSEMBLY AND ASSEMBLY (CONT'D) Figure 80-20-28
Sleeve Removal
Figure 80-20-27
Figure 80-20-29
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
Figure 80-20-30
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
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.
Figure 80-20-32
Figure 80-20-33
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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
Figure 80-20-36
Pry the retainer rubbers and retaining pins from the lower
body [Figure 80-20-36].
Hydraulic Breaker
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DISASSEMBLY AND ASSEMBLY (CONT’D) Figure 80-20-39
Figure 80-20-38
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DISASSEMBLY AND ASSEMBLY (CONT’D) Figure 80-20-42
Figure 80-20-40
Figure 80-20-43
Install the nuts in the slots of the lower body [Figure 80-
20-40].
Figure 80-20-41
Screw the 4 tie rods into the nuts finger tight. Loosen the
tie rods 1/4 turn.
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SPECIFICATIONS
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247 of 260 80-30-1 Service Manual
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NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
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)
Insert the existing Hydraulic / Hy drostatic Flow Charts into t he new Hydraulic Breaker Service Manual (P/N
6720280) Date 10-05.
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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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COVER
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