Breaker 6720280 enUS SM 06-12

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
S/N 705200101 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,
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,
Dealer Copy -- Not for Resale
Hydraulic
Breaker
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)
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Printed in U.S.A.
Bobcat Company 2006
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MAINTENANCE SAFETY
WARNING
WARNING
Instructions are necessary before operating or servicing machine. Read and

understand the Operation & Ma intenance Manual, Operators Handbook and
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
W-2003-0903
instructions can cause injury or death.
Safety Alert Symbol: This symbol with a warning statement, means: Warning, be alert! Your safety is
involved! Carefully read the message that follows.
CORRECT
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
lubricating or servicing.
round before
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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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
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
2500/3500 HYDRAULIC BREAKER SERVICE

DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-01
SPECIFICATIONS (2500) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
SPECIFICATIONS (3500) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
CONTINUED ON NEXT PAGE
10-01
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ALPHABETICAL INDEX (CONTD)

BOB-TACH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
HYDRAULIC BREAKER MOUNT INSPECTION . . . . . . . . . . 60-01
LOADER MOUNT REMOVAL AND INSTALLATION . . . . . . . 60-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
TOOL BIT REMOVAL AND INSTALLATION . . . . . . . . . . . . . 60-01
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01
10-02
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CONTENTS
SERIAL NUMBER LOCATIONS & HYDRAULIC BREAKER
IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III
1560 HYDRAULIC BREAKER SERVICE . . . . . . . . . . . . . . . . . . 20-01

2500/3500 HYDRAULIC BREAKER SERVICE. . . . . . . . . . . . . . 30-01
1250, 1250X
HYDRAULIC
BREAKER SERVICE
1560
HYDRAULIC
BREAKER SERVICE
2500/3500
HYDRAULIC
BREAKER SERVICE
2560/3560
HYDRAULIC
BREAKER SERVICE
2570/3570
HYDRAULIC
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.
I
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1250, 1250X HYDRAULIC BREAKER SERVICE . . . . . . . . . . . . 10-01

II
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SERIAL NUMBER LOCATIONS & HYDRAULIC

BREAKER IDENTIFICATION
Always use the serial number of the machine when

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to us a different procedure in doing a sp ecific service
operation [Figure 1].
Serial Number Locations (1250, 1250X)

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
Mounting Bracket
Charge Fitting
Nitrogen Chamber
Grease Fitting
Hose Fitting Port

Breaker Body
Breaker Foot
Mounting Holes
Tool Point
B-12480
Breaker shown is mounted in excavator bracket
III
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Hydraulic Breaker Identification (1250, 1250X)

BREAKER IDENTIFICATION (CONTD)

Serial Number Locations (1560)

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)
Mounting
Bracket
Charge
Fitting
Main
Body
Hose
Fittings
Lower
Body
Mounting
Bolts
Tool
Point
P-5745
IV
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Serial Number Locations (2500/3500 & 5500)

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)
Nitrogen Chamber
Charge Fitting
Hose Fitting Ports
Main Body
Accumulator
Grease Fitting
Mounting Bolts
Lower Body
Tool Point
B-09923
V
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to use a different procedure in doing a specific service
Serial Number Locations (2560/3560)

Figure 4
The breaker serial number plate is located on the front of

the nitrogen chamber [Figure 4].
P1854
Hydraulic Breaker Identification (2560/3560)

Mounting Bracket
Charge
Fitting
Nitrogen
Chamber
Hose
Fitting
Ports
Main
Body
Grease
Fitting
Mounting
Bolts
Lower
Body
Tool
Point
N-00221
N-00224
VI
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Serial Number Locations (2570/3570)

Figure 5
P1854
Hose
Fitting
Ports
Mounting
Bracket
Mounting
Bracket
Nitrogen
Chamber
Charge
Fitting
Main
Body
Accumulator
Grease
Fitting
Mounting
Bolts
Tool
Point
Two
Position
Frame
Accumulator
N-00221
P-10953
P-10958
VII
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Tool
Point
Hydraulic Breaker
Service Manual
Hydraulic Breaker Identification (2570/3570)



Figure 6
P1854
Wear
Plate
Bolts
Tool
Bit
Quick
Couplers
Steps
Steps
P-12815
P-12814
VIII
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Figure 7
P10516
Bob-Tach
Mounting
Frame
Auxiliary
Hydraulic
Couplers
Grease
Fitting
Tool
Bit
P-12815
IX
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X
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1250, 1250X HYDRAULIC BREAKER SERVICE

ACCUMULATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging The Accumulator . . . . . . . . . . . . . . . . . . . . . . . .
Checking Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . .
Hydraulic Breaker Lubrication . . . . . . . . . . . . . . . . . . . . . .
10-10-1
10-10-1
10-10-2
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
Upper Body Removal and Installation . . . . . . . . . . . . . . . . 10-20-3
PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-4
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
TROUBLESHOOTING THE HYDRAULIC BREAKER . . . . . . 10-10-3
10-01
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10-02
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ACCUMULATOR
Use charging
accumulator.
kit
(P/N
6568037)
to
charge
the
When the accumulator is fully charged close the valve on

the charging assembly hose.
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)
Pressure
Line
Remove the valve cap assembly (Item 1) [Figure 10-101] from the breaker.
Return
Line
2
Remove the protective cap from the charging valve and
loosen the hex locknut 2 to 3 turns.
Torque
400 ft.-lb.
(542,4 Nm)
Figure 10-10-2
Torque
28 ft.-lb.
(38,0 Nm)
Grease
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

the breaker [Figure 10-10-2].
Adjust the regulator to the charging pressure of 600 PSI
(4137 bar).
IMPORTANT
Underwater use of the breaker will cause internal
damage. No por tion of th e breaker may be
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.
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10-10-1
Hydraulic Breaker
Service Manual
Torque
400 ft.-lb.
(542,4 Nm)
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.
20 of 260
10-10-2
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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 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
Breaker will not fire.
Breaker does not hit effectively.
Breaker hits slowly.
CAUSE
CORRECTION
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.
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.
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.
21 of 260
Refer to operating instructions.
10-10-3
Hydraulic Breaker
Service Manual
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.)
PARTS IDENTIFICATION
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PARTS IDENTIFICATION (CONT'D)
23 of 260
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24 of 260
10-10-6
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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

breaker:
Have a se cond person remove the mounting pin clip

(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.
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.
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10-20-1
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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
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 O-rings and split back-up rings from the
swivel fitting [Figure 10-20-5].
Remove the RPC valve O-rings.
IMPORTANT
Do not completely discharge the accumulator at this
time.
I-2037-0788
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10-20-2
Hydraulic Breaker
Service Manual
Upper Body Removal and Installation
Return Pressure Compensating (RPC) Valve Removal

and Installation (Cont'd)
Figure 10-20-10
Place the RPC valve in a soft jaw vise.

Figure 10-20-8
Remove the valve cap [Figure 10-20-10].
Discharge the accumulator down to 20 PSI (137,9 bar).
Remove the O-ring boss plug [Figure 10-20-8].
Figure 10-20-11
Figure 10-20-9
Remove the valve assembly internal parts [Figure 10-209].

NOTE: Do not lose the parts in the RPC valve.
The RPC valve is blocked open and not used in the
loader mounted 1250 Breaker [Figure 10-20-9].
The RPC valve is used when 1250X Breaker is mounted
on the excavator [Figure 10-20-9].
27 of 260
Loosen the 4 breaker body bolts [Figure 10-20-11].

Loosen each bolt 1 turn and move to the next bolt. This
will insure no binding of the breaker body.
Remove the bolts.
Installation: Put anti-sieze compound on the bolt
threads and tighten the bolts equally working up to 400
ft.-lb. (542 Nm) torque.
10-20-3
Hydraulic Breaker
Service Manual
Loosen the locknut on the charging valve 1-1/2 turns.
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].
Tap around the to p flange with a r ubber hammer to
separate the breaker body [Figure 10-20-12].
Separate the body halves [Figure 10-20-13].
Figure 10-20-15
Figure 10-20-13
Use a r ubber hammer to tap around the lower body

flange [Figure 10-20-14].
Remove the lower body from the piston [Figure 10-2015].
Do not drop any internal parts.
28 of 260
10-20-4
Hydraulic Breaker
Service Manual
Flow Sleeve Removal and Installation
Lower Body Removal and Installation
Figure 10-20-18
Figure 10-20-16
Figure 10-20-19
Remove the piston from the flow sleeve [Figure 10-2016].
Put the assembly on the Flow Sleeve Removal Tube with

the automatic valve body facing down [Figure 10-20-18].
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].
IMPORTANT
Place the split ring (from the k it) between the automatic
valve body and flow sleeve assembly [Figure 10-20-17].
Put a rag in the bottom of the removal tube to protect

the automatic valve body when it drops out.
I-2038-0788
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10-20-5
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Service Manual
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].
Figure 10-20-23
The automatic valve, flow sleeve, 4 long push pins from

the flow sleeve and 2 long push pins from the automatic
valve body will drop out [Figure 10-20-20].
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).
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10-20-6
Hydraulic Breaker
Service Manual
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.
Put the accumulator chamber in a soft jaw vise and

loosen the lo cknut to completely discharge the
accumulator assembly [Figure 10-20-24].
Remove the accumulator chamber and diaphragm from
the accumulator cylinder by pressing on the charge valve
end [Figure 10-20-26].
IMPORTANT
The machined surfaces of the accumulator can
become damaged if a soft jaw vise is not used.
I-2039-0788
Figure 10-20-25
Squeeze the accumulator diaphragm and slide it off the

accumulator chamber at the charge valve end.
NOTE: Avoid damage to the inside wall of the
accumulator chamber.
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].
31 of 260
10-20-7
Hydraulic Breaker
Service Manual
Figure 10-20-26
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
Put the br eaker in a hor izontal position with the tool

against a solid object [Figure 10-20-28].
Move the breaker up, then down. If there is more than 1/2
in. movement of the tool in either direction the bushings
may be worn or damaged [Figure 10-20-28].
NOTE: Be sure the tool retainer pin ha s been

removed.
Put the breaker lower body in a press.
Figure 10-20-31
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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10-20-8
Hydraulic Breaker
Service Manual
Remove the r od wiper, washer and O-ring at the top of

the breaker foot [Figure 10-20-30].
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].
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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].
Install the r od wiper (lip first) in the counterbore of the

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].
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Figure 10-20-35
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
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 10-2039].
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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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
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 10-2043] 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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ASSEMBLY (CONT'D)
Figure 10-20-46
Figure 10-20-44
Put a th in coat of gr ease on th e inside surface of th e

accumulator diaphragm [Figure 10-20-44].
Push the accumulator chamber and diaphragm (charging

valve end first) halfway into the accumulator cylinder
[Figure 10-20-46].
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.
Slide the diaphragm onto the accumulator chamber from

the charging valve end [Figure 10-20-45].
NOTE: A ha nd powered press may be needed to

complete the accumulator assembly. Apply
short strokes during the last 12 inch (12 mm)
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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The parts are assembled from the end of the cylinder with
the chamfer on the outside diameter.
Figure 10-20-45
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
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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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].
ASSEMBLY (CONT'D)
Figure 10-20-52
Figure 10-20-50
Seat the outer keeper spring (Item 1) [Figure 10-20-50]

(beveled end facing up) on the accumulator cylinder.
Carefully place the breaker body over the accumulator

assembly [Figure 10-20-52].
Figure 10-20-53
Lubricate the 4 disc spring washers; then stack them

(Item 2) [Figure 10-20-50] (inside diameter up and
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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ASSEMBLY (CONT'D)
Figure 10-20-56
Figure 10-20-54
Tighten the bolts until they begin to compress the lo ck

washers.
Figure 10-20-55
Charge the accumulator. ( See

Accumulator on Page 10-10-1.)
Charging
The
Clean the flat surfaces of the RPC valve and the breaker
body.
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
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Install the bolts through the holes in the breaker body and
into the tapped holes in the breaker lower body [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)
torque [Figure 10-20-56].
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.

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].
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42 of 260
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SPECIFICATIONS
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.
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CHECKING MOUNTING BOLT TORQUE . . . . . . . . . . . . . . . 20-10-5
DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . .
Breaker Frame Removal and Installation. . . . . . . . . . . . . .
Bushing Removal and Installation . . . . . . . . . . . . . . . . . . .
Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sleeve Removal and Installation . . . . . . . . . . . . . . . . . . . .
Upper Section Removal and Installation . . . . . . . . . . . . . .
20-20-1
20-20-1
20-20-8
20-20-4
20-20-6
20-20-6
20-20-2
20-20-7
20-20-5
1560
HYDRAULIC
BREAKER SERVICE
HYDRAULIC BREAKER LUBRICATION . . . . . . . . . . . . . . . . 20-10-4

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

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
20-01
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20-02
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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
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

hydraulic breaker for an extended period of
time.
Install the plug in the charge valve hole.
Figure 20-10-1
Use the nitrogen accumulator charge pressure gauge

MEL1523B to check pressure.
Checking The Nitrogen Chamber Charge 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.
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Engine is running.
NITROGEN CHAMBER (CONTD)
Figure 20-10-6

(Contd)
Figure 20-10-4
2
0.125
(3,2 mm)
Tighten the adapter (Item 1) [Figure 20-10-6] on th e

breaker.
Figure 20-10-7
P-42758
With the adapter (Item 1) tig htened on the ga uge,

measure the pin (Item 2) [Figure 20-10-4] protrusion.
Manually extend or retract the pin until the pin 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 20-107] 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.
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Slowly open the valve on the nitrogen tank and fill the
1560 breaker nitrogen chamber to 250 PSI (17,24 bar).
Close the valve on the nitrogen tank.
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.
Disconnect the hose and charging tool.

Install and tighten the plug (Item 1) [Figure 20-10-1 on
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
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].
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HYDRAULIC BREAKER LUBRICATION

as far as possible.
Figure 20-10-10
IMPORTANT
damage. No por tion of th e breaker may be
submerged.
I-2053-0589

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

Figure 20-10-11
Check the snap rings and breaker mounting bolts (Item

1) [Figure 20-10-11] every day.
51 of 260
20-10-5
If the snap rings and lock plates are missing, tighten the
bolts to 300 ft.-lb. (407 Nm) torque. Lock plates can be
turned 180 for a different alignment if necessary.
Hydraulic Breaker
Service Manual
WARNING
Follow warnings and instructions in the manuals
injury or death.
W-2003-1289
PROBLEM
CAUSE
CORRECTION
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.
52 of 260
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.
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
20-10-6
Hydraulic Breaker
Service Manual
TROUBLESHOOTING THE HYDRAULIC BREAKER (CONTD)

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

Blank firing.
Refer to the hydraulic controls section for

correct operating procedure.
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DISASSEMBLY AND ASSEMBLY
Figure 20-20-1
WARNING
Engine is running.
The tool listed will be needed to s ervice the hydraulic

breaker:
Have a second person remove the mounting pin clip and

pin [Figure 20-20-1].
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.

Figure 20-20-2
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.
55 of 260
Use a ch ain hoist [Figure 20-20-2] to c ontrol the fr ame

while removing or installing the mounting bolts.
20-20-1
Hydraulic Breaker
Service Manual
W-2019-1285
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
parts can be replaced individually.
Figure 20-20-3
NOTE: Apply hydraulic oil to the O-rings and

machined surfaces during assembly.
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.
Installation: Use anti-seize on the bolt threads during
assembly. Tighten the bolts to 300 ft.-lb. (406 Nm)
torque.
Figure 20-20-4
Remove the bolts from the shuttle valve cap (Item 1)

[Figure 20-20-5].
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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Figure 20-20-5
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
breaker (replacement body will include a new sleeve).
Remove and replace the O-ring (Item 1) [Figure 20-20-7]

from the cap.
Figure 20-20-8
Remove the shuttle valve (Item 1) [Figure 20-20-8] 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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Service Manual
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
the charge valve assembly.
Remove the p lug (Item 1) [Figure 20-20-10] to gain

access to the charge valve.
Figure 20-20-11
Use a slotted screwdriver to remove the charge valve

(Item 1) [Figure 20-20-11].
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Service Manual
Figure 20-20-14
Upper Section Removal and Installation
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.
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.
Check the tie rods for wear or cracks.
NOTE: If a tie rod is broken, both must be replaced.
Use a ch ain hoist (Item 1) [Figure 20-20-14] to remove

the upper section.
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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Service Manual
Figure 20-20-13
Figure 20-20-17
Piston
Figure 20-20-15
Remove the O-rings from the seal carrier [Figure 20-2017].

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.
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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Service Manual
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].
Remove the quad ring (Item 1) and the inner seal (Item 2)
[Figure 20-20-21] from the sleeve.
If the sleeve is tight, install a bolt (Item 1) through the
holes in th e sleeve. Using a s lide hammer (Item 2)
[Figure 20-20-19] slowly remove the s leeve from the
lower section.
Check the s leeve for scratches, damaged O-rings and
seals.
61 of 260
Installation: Put hydraulic oil on the quad ring and seal.

Install the seal with the lips up.
Check for cracks and see that the piston moves freely in
the sleeve.
cloth.
20-20-7
Hydraulic Breaker
Service Manual
Figure 20-20-21
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.
Put oil on the outside and inside surface of th e sleeve

and install the sleeve in the lower section [Figure 20-2022].
Check the condition of the O-rings (Item 1) [Figure 2020-22] 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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Service Manual
Figure 20-20-23
Figure 20-20-27
Bushing Removal and Installation (Cont'd)

Figure 20-20-25
Remove the bushings from the lower section [Figure 2020-27].
Remove the r oll pin (Item 1) and dowel pin (Item 2)

[Figure 20-20-25].
Figure 20-20-26
Drive the remaining roll pin flush with the 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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SPECIFICATIONS
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.
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CHECKING MOUNTING BOLT TORQUE . . . . . . . . . . . . . . 30-10-10
DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-20-1
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-9
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
Seals Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-11
Start Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-12
Valve Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-6
Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . 30-20-5
2500/3500
HYDRAULIC
BREAKER SERVICE
Charging the High Pressure Accumulator . . . . . . . . . . . . .
Charging the Low Pressure Accumulator . . . . . . . . . . . . .
Charging the Nitrogen Chamber . . . . . . . . . . . . . . . . . . . .
Checking The High Pressure Accumulator Pressure. . . . .
Checking The Low Pressure Accumulator Pressure . . . . .
PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-12

30-10-1
30-10-2
30-10-5
30-10-8
30-10-1
30-10-4
30-10-6
SPECIFICATIONS (2500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

SPECIFICATIONS (3500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-2
TROUBLESHOOTING THE HYDRAULIC BREAKER . . . . . 30-10-11
30-01
67 of 260
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30-02
68 of 260
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Service Manual
NITROGEN CHAMBER
Figure 30-10-3
Checking The High Pressure Accumulator Pressure

1

Figure 30-10-1
2
0.125
(3,2 mm)
P-42758
With the adapter (Item 1) ti ghtened on the g auge,


B-7047
Figure 30-10-4
Remove the charge valve plug [Figure 30-10-1].

Figure 30-10-2
P-42759
Loosen the adapter until the pin is flush with the end of
P18084

the gauge.
69 of 260
30-10-1
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Service Manual
Charging the High Pressure Accumulator

(Contd)
WARNING
Figure 30-10-5

Engine is running.
W-2019-1285
1
Figure 30-10-7

breaker.
Figure 30-10-6

Figure 30-10-8
B-23394
Slowly turn the gauge valve body (Item 1) [Figure 30-106] clockwise until the gauge shows a reading. If the
number 6568037.
NOTE: The correct charge pressure is 850 P SI (58,6
bar).
Use charging kit (P/N 6568037) to charge the hydraulic
breaker.
70 of 260

30-10-2
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Service Manual
B-23394

(Contd)
Figure 30-10-9
B-7077
NOTE: Use the high pressure side of the charging tool

[Figure 30-10-9].
Figure 30-10-10
Connect This End
To High Pressure
Accumulator &
Nitrogen Chamber
Connect Hose From

B-7196
Install the charging tool into the accumulator [Figure 3010-9].

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.
71 of 260
30-10-3
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Service Manual
Figure 30-10-13
Checking The Low Pressure Accumulator Pressure

1

Figure 30-10-11
2
0.125
(3,2 mm)
P-42758


B-7078
Figure 30-10-14

Figure 30-10-12
P-42759
Loosen the adapter until the pin is flush with the end o f
P18084

the gauge.
72 of 260
30-10-4
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Service Manual
Charging the Low Pressure Accumulator

(Contd)
The low pressure accumulator is located on the front side

of the main body.
Figure 30-10-15
Remove the charge valve plug.

Figure 30-10-17

breaker.
Figure 30-10-16
Using a small shaft (Item 1) [Figure 30-10-17], push the

Figure 30-10-18
Connect Hose From

B-23393
Slowly turn the gauge valve body (Item 1) [Figure 30-1016] clockwise until the gauge shows a r eading. If th e
number 6568037.
bar).
73 of 260
Connect This End

To Low Pressure
Accumulator
B-7196
NOTE: Use the low pressure side of the charging tool

[Figure 30-10-18].
30-10-5
Hydraulic Breaker
Service Manual
B-23393
Charging The Low Pressure Accumulator (Contd)

Figure 30-10-19
Figure 30-10-20
B-7077
B-8887
SLOWLY open the valve at the nitrogen tank until the gas
escapes from the relief valve (Item 1) [Figure 30-10-19]
on the charging tool.
Connect the nitrogen hose to the low pressure side of the

charging tool [Figure 30-10-19].
Figure 30-10-21
Close the valve at the tank. Disconnect the nitrogen hose

and charging tool.
Install and tighten the plug.
P18084

the gauge.
74 of 260
30-10-6
Hydraulic Breaker
Service Manual
Figure 30-10-24

(Contd)
Figure 30-10-22
2
B-23395
0.125
(3,2 mm)
Tighten the a dapter (Item 1) [Figure 30-10-24] on th e

breaker.
P-42758


Figure 30-10-23
B23395
number 6568037.
NOTE: The correct charge pressure is:
P-42759
2500 - 400 PSI (27,58 bar)

3500 - 500 PSI (31,71 bar)
75 of 260
30-10-7
Hydraulic Breaker
Service Manual
Figure 30-10-25
Figure 30-10-28
Charging the Nitrogen Chamber

Connect This End To
Nitrogen Chamber
The nitrogen chamber charge valve is located on the

back side of the breaker above the hydraulic inlet and
outlet ports.
Figure 30-10-26
Connect Hose From

B-7196

[Figure 30-10-28].
Remove the charge valve plug (Item 1) [Figure 30-1026].
nitrogen chamber.
Using a small shaft push the valve inward to release the

gas pressure.
2500 - Fill the chamber to 400 PSI (27,58 bar)

3500 - Fill the chamber to 500 PSI (31,71 bar)
Figure 30-10-27
Disconnect the hose and the charging tool.

Install the charging tool in the charge valve [Figure 3010-27].
76 of 260
30-10-8
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Service Manual
Connect the nitrogen hose to the hi gh pressure side of

the charging tool.

as far as possible.
Figure 30-10-29
B-11927

8 hours of operation, or when the tool bit looks dry.
IMPORTANT
damage. No por tion of t he breaker may be
submerged.
I-2053-0589
77 of 260
30-10-9
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Service Manual

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.
78 of 260
30-10-10
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Service Manual
WARNING
Manuals, Handbook and si gns (decals) on mac hine.

injury or death.
W-2003-1289
CAUSE
Loader fluid reservoir is low.
Add hydraulic fluid to the fluid reservoir

on the loader.
Check the hydraulic flow

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.

Nitrogen chamber
pressure.
Breaker runs very slowly.
CORRECTION
not
at
to the
correct Charge to required pressure.
Test loader hydraulics for correct flow

and pressure.

Check loader relief valve pressure.
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.
Check for plugged or kinked return

lines.
Low fluid level.
Tool binding.
Damaged electrical connection to Check wiring harness and switch.

breaker valve (backhoe mounted unit
only).
Defective push pins.
79 of 260
30-10-11
Replace push pins.
Hydraulic Breaker
Service Manual
PROBLEM
80 of 260
30-10-12
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Service Manual
Figure 30-20-1
WARNING
Engine is running.
The tools listed will be nee ded to do the fol lowing

procedure:
Loosen the 6 bolts which fasten the breaker to the frame

[Figure 30-20-1]. DO NOT REMOVE THE BOLTS.
6568037 - Charging Kit (purchased from Bobcat Sales)

OEM6106 - Torque Multiplier
MEL1214 - Hex Bit Driver
MEL1308 - Lower Bearing Removal Plate
MEL1310 - Remover Handle

Remove the 3/ 16 in. hex plug at the accumulator
chamber. Release the nitrogen gas from the chamber.
Figure 30-20-2
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
REMOVE THE BOLT.
Assembly: Tighten the bolts to 600 ft.-lb. (813 Nm)
torque.
81 of 260
30-20-1
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Service Manual
W-2019-1285
DISASSEMBLY AND ASSEMBLY (CONTD)
Figure 30-20-5

Figure 30-20-3
Remove the 6 bolts [Figure 30-20-5].

Use MEL1214 - Hex Bit Driver
Assembly: Put anti-sieze lubricant on the threads and
tighten the bolts to 900 ft.-lb. (1220 Nm) torque.
Figure 30-20-4
Remove the frame from the breaker.
Install the eye bolt in the bo lt at th e top of th e breaker

[Figure 30-20-3]. Install a chain hoist at the eye bolt.
Figure 30-20-6
Have a second person remove the mounting pins (Item

1) [Figure 30-20-4] and the washers.
Have a second person lift the breaker from the Bob-Tach
frame. Put the breaker in th e vertical position in th e
stand.
Install a chain hoist on the frame of the breaker.
82 of 260
Remove the hydraulic hoses from the hydraulic breaker

[Figure 30-20-6].
Remove the 3/1 6 inch hex plug at the accumulator
30-20-2
Hydraulic Breaker
Service Manual
Nitrogen Chamber Removal and Installation
Figure 30-20-8
Figure 30-20-7
Remove the 4 main socket head bolts [Figure 30-20-8].

Use MEL1214 - Hex Bit Driver
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 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].
83 of 260
30-20-3
Hydraulic Breaker
Service Manual

valve inward to r elease the nitrogen gas from the
chamber.
Piston Removal
Manifold Removal
Figure 30-20-11
Figure 30-20-10
Check the piston for wear.

Later model breakers have a cross hatch pattern (Item 2)
[Figure 30-20-11] on the piston. Early model pistons 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.
84 of 260
30-20-4
Hydraulic Breaker
Service Manual
Lift the manifold assembly from the main body [Figure

30-20-10].
Remove the piston (Item 1) [Figure 30-20-11] from the

main body.
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

cylinder [Figure 30-20-12].
Figure 30-20-13
Remove the push pins and inspect for wear [Figure 3020-13].
Inspect oil holes in the valve. Be sure they are not
plugged.
85 of 260
30-20-5
Hydraulic Breaker
Service Manual
Main Body Removal
Valve Cylinder Removal
Figure 30-20-17
Figure 30-20-15
Figure 30-20-16
NOTE: The disc springs help maintain tolerance

between
components
by
keeping
components tightly against 1 another.
Figure 30-20-18
Remove the valve cylinder from the valve seat [Figure

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

surface facing away from the lower bearing [Figure 3020-18].
Install the socket head bolts into the body at both
accumulator sides.
86 of 260
30-20-6
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Service Manual
Remove the v alve cylinder with the valve seat from the
main body [Figure 30-20-15].
Remove both disc springs from the main body [Figure

30-20-17].
Lower Body Bushings Removal
Main Body Removal (Contd)
Figure 30-20-21
Figure 30-20-19
Disassembly of the lower body internal parts requires a

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

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].
87 of 260
30-20-7
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Service Manual
Install a chain hoist and lift the main body from the lower
body [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]
bearing for easier removal.
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].

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].
88 of 260
30-20-8
Hydraulic Breaker
Service Manual
Figure 30-20-25
Accumulator

(Cont'd)
Figure 30-20-28
Figure 30-20-26
Install the O-ring (Item 1) on the top and bottom of th e

chamber.(The O-ring (Item 1) [Figure 30-20-26]
identification number is 350754.)
Install the top plate and bolt. The bolt must be tightened
after the chamber is installed on the main body.

Disassembly: Put the accumulator body in a vise.
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].
Install the O-ring (Item 1) [Figure 30-20-27] on th e

charge valve. (The O-ring identification number is
01605.)
Remove the accumulator plug and diaphragm [Figure

30-20-29].
Inspect the diaphragm for wear and replace as needed.
Install the charge valve and tighten to 80 ft.-lb. (108 Nm)

torque[Figure 30-20-27].
89 of 260
30-20-9
Hydraulic Breaker
Service Manual
Remove the hex socket bolt at the accumulator chamber

[Figure 30-20-28].
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].
Install the O-ring (Item 1) [Figure 30-20-30] on th e
charge valve. (The O-ring identification number is
01605.)

torque.

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

[Figure 30-20-31].
90 of 260
30-20-10
Hydraulic Breaker
Service Manual
Put the plug into the body and tighten to 600 ft.-lb. (814
Nm) torque.
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
bearing. Make sure the s eal lip faces up ( toward the
nitrogen chamber). (The seal identification number is :
For 2500 Breakers with smooth piston is 350832. For
2500 Breakers with cross hatch piston is 24893.
For 3500 Breakers with smooth piston is 12852. For 3500
Breakers with cross hatch piston is 24932.
Figure 30-20-33
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.
For 3500 Breakers with smooth piston is 12851. For 3500
Breakers with cross hatch piston is 25000.
When installing the se al (Item 1) [Figure 30-20-35] into

the groove at the valve seat, make sure the seal lip faces
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.)
91 of 260
30-20-11
Hydraulic Breaker
Service Manual
The type of seal to be u sed is depended on the type of

piston in the breaker. (Early pistons are smooth, later
pistons are cross hatched.) We recommend using the
lastest style piston or modifing the early piston to use the
lastest style seals. (See Piston Removal on Page 30-204.)

Seal Installation (Cont'd)
Install the seal on the valve cylinder as follows:
Figure 30-20-36
Install the sm aller seal (5-3/16 inch O.D.) (Item 1)

[Figure 30-20-36] in the low er groove.(The 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.
92 of 260
30-20-12
Hydraulic Breaker
Service Manual
SPECIFICATIONS (2500)
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
93 of 260
1800 PSI (12411 bar)
30-30-1
Hydraulic Breaker
Service Manual
SPECIFICATIONS (3500)
WEIGHT
Total Weight
390 lb. (177 kg)
ENERGY
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)
1800 PSI (12411 bar)
NOTE: The same tools will fit the 2500 and 3500 breaker.
94 of 260
30-30-2
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Service Manual

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
Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . 40-20-5
Releasing Pressure From The Nitrogen Chamber. . . . . . .
40-10-1
40-10-3
40-10-1
40-10-1
2560/3560
HYDRAULIC
BREAKER SERVICE
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
40-01
95 of 260
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40-02
96 of 260
Hydraulic Breaker
Service Manual
NITROGEN CHAMBER
Releasing Pressure From The Nitrogen Chamber

Figure 40-10-3
WARNING
Engine is running.
W-2019-1285
Figure 40-10-1
P-1828

Figure 40-10-4

charge valve.
Figure 40-10-2
P18084

the gauge.

97 of 260
40-10-1
Hydraulic Breaker
Service Manual
Figure 40-10-7

(Contd)
Figure 40-10-5
P-65363
0.125
(3,2 mm)

breaker.
P-42758

Figure 40-10-6
P-65363
number 6568037.
bar)
P-42759

98 of 260
40-10-2
Hydraulic Breaker
Service Manual
Figure 40-10-8
Figure 40-10-10

Connect This End To

Nitrogen Chamber
Use charging kit (P/N 6568037) to charge the nitrogen

chamber.
front side of the nitrogen chamber housing.
1
WARNING
Connect Hose From


Engine is running.
W-2019-1285
350 PSI (24,14 BAR)
B-7196
NOTE: Be sure to use the adapter (P/N 6661802) (Item

1) [Figure 40-10-10] and the correct side of the
charging tool.
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).
99 of 260
40-10-3
Hydraulic Breaker
Service Manual
Connect the nitrogen hose to the charging tool.
Figure 40-10-9
WARNING
injury or death.
W-2003-1289
PROBLEM
CAUSE
CORRECTION
Adjust main relief valve to correct setting.
Add hydraulic fluid to the fluid reservoir on

the loader.


Breaker runs very slowly or blow per Loader main relief valve set too low.
minute reducing.

Test loader hydraulics for correct flow and
pressure.
100 of 260
Remove gas and refill to correct pressure

(400 PSI maximum).
Internal leakage.
40-10-4
Hydraulic Breaker
Service Manual
TROUBLESHOOTING THE HYDRAULIC BREAKER (CONT'D)
WARNING
injury or death.
W-2003-1289
CAUSE
CORRECTION
Adjust main relief valve to correct

setting.
Check for plugged or bent return lines.
Low fluid level.
Tool binding.
Damaged electrical connection to Check wiring harness and switch.

breaker valve (backhoe mounted unit
only).
Excessive pressure pulsations.
Incorrect hoses.
Refer to Serviceletter 13 May 1996.
Quick coupler failure.
Nitrogen
insufficient.
chamber
Breaker valve seal pressure.
101 of 260
40-10-5
pressure Refer to Serviceletter 13 May 1996.

Hydraulic Breaker
Service Manual
PROBLEM
8
3
1
3
26
3
4
21
3
7
3
8
27
3
8
11
3
12
13
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
25
Accumulator
22
Charge Valve Assembly
3
O-ring
3
Seal
22
Rod Seal
Seal Carrier
22
Manifold
3
O-ring Plug
8
22
Piston
3
Piston Sleeve
3
Valve Cap
14
Spool Sleeve
Valve Sleeve
Valve Spool
Main Body
Grease Fitting
Rod Wiper
Lower Body Assembly
Upper Bushing
3
Lower Bushing
8
Bolt
Backup Ring
Roll Pin
Pin
Dowel Pin
Bolt
Washer
102 of 260
10
24
23
18
4
4
4
24
24
23
4
17
19
23
24
23
20
16
TS1153
40-10-6
Hydraulic Breaker
Service Manual
Figure 40-20-2
WARNING
Engine is running.
W-2019-1285
The tools listed will be needed to service the breaker:

MEL1430 - Hydraulic Breaker Sleeve Puller 6568037 Charging Kit or MEL1523A
Put the breaker in a stand [Figure 40-20-2].

Figure 40-20-3

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 mounting pin clip and pin [Figure 40-20-1].
103 of 260
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.
40-20-1
Hydraulic Breaker
Service Manual

Have a second person disconnect the hydraulic quick
couplers from the loader and remove them from the hose
guide on the boom arm.
Remove the pivot pin bolts and the pins.
NOTE: For clarity purposes, the breaker frame is

removed. However, most of the breaker
servicing can be done with frame installed.
NOTE: The frame can be left in the breaker stand
during repair if needed.
Nitrogen Chamber Removal and Installation
Slowly move the loader away from the breaker.

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 40-20-6
Remove the to p 4 bol ts from the n itrogen chamber

[Figure 40-20-6].
Installation: Put anti-sieze on th e bolt threads and
washer (Item 1) [Figure 40-20-6]. Tighten the bolts to
200 ft.-lb. (271 Nm) torque in a cross pattern.
Remove the lock plates [Figure 40-20-4].

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
shank of the bolt. Tighten the bolts to 300 ft.-lb. (407
Nm) torque.
Lower the frame to the floor and remove the chain.
104 of 260
Remove the nitrogen chamber [Figure 40-20-7].

Replace the large O-ring (Item 1) [Figure 40-20-7] on the
nitrogen chamber.
40-20-2
Hydraulic Breaker
Service Manual
Figure 40-20-4
Figure 40-20-10
Nitrogen Chamber Removal and Installation (Cont'd)

Figure 40-20-8

the piston.
NOTE: Check the seal carrier for scratches, damaged
seals, back-up washers or oil seals. Check the
piston for wear areas.
Piston Removal
Figure 40-20-11
Replace the small O-ring (Item 1) [Figure 40-20-8] from

the bottom surface of the nitrogen chamber.
Figure 40-20-9
Install an eye bolt in the end of the piston and remove the
piston [Figure 40-20-9].
Check the piston shaft and grooves for wear [Figure 4020-11].
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.
105 of 260
40-20-3
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Service Manual
Figure 40-20-14
Piston Removal (Cont'd)

Figure 40-20-12
B-15066
Remove the O-rings from the carrier [Figure 40-20-12].
Installation: Put oil on the se als and install with the lips
down.
Installation: Put oil on the O-rings during assembly.
Piston Sleeve Removal
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
(Item 1) [Figure 40-20-13].
Install the puller hooks until the spring loaded pins (Item
1) [Figure 40-20-15] are under the sleeve lip.
Installation: Put oil on the back-up washer and install on

the upper side of the O-ring.
NOTE: Rotate the puller to be sure the puller pins are

in the sleeve holes to prevent damage during
sleeve removal.
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Service Manual
Remove the 2 inner seals [Figure 40-20-10].
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
Figure 40-20-17
Remove the bolts from the valve manifold [Figure 40-2019].
Remove the sleeve [Figure 40-20-17].
107 of 260
Installation: Put anti-sieze on th e bolt threads and

tighten to 70 to 75 ft.-lb. (95 to 102 Nm) torque.
40-20-5
Hydraulic Breaker
Service Manual
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].
Figure 40-20-21
NOTE: Be careful not to damage the face of the main

body.
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].
108 of 260
40-20-6
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Service Manual
Replace the O -rings (Item 1) [Figure 40-20-20] on the

bottom of the manifold.
A pry bar used with a wooden block will also work to

remove the valve.
Figure 40-20-26

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

Pry the sleeve from the cap [Figure 40-20-25].
NOTE: Rotating the spool while holding the valve will

aid during removal and installation.
NOTE: Rotate the sleeve to remove or install in the

cap.
NOTE: Check the valve and spool for scratches.

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.
109 of 260
40-20-7
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Service Manual
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].
Main Body Removal and Installation
Installing Piston Sleeve

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 40-20-29
Figure 40-20-31
Remove the main body from the lower body [Figure 4020-29].
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.
110 of 260
40-20-8
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Service Manual
Use a s oft hammer to tap the valve until it s eats in

position [Figure 40-20-28].
Figure 40-20-34
Installing Piston Sleeve (Cont'd)

Figure 40-20-32
Tip the lower section to remove the inner pin [Figure 4020-34].
Figure 40-20-35
Press the sleeve slowly until it seats [Figure 40-20-32].
Lower Section Bushings Removal and Installation

NOTE: The lower bushings are not interchangeable.
Figure 40-20-33
Drive the other roll pin back [Figure 40-20-35].
Drive out the roll pin (Item 1) [Figure 40-20-33] for the
lower bushing.
111 of 260
40-20-9
Hydraulic Breaker
Service Manual
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].
Repeat the same procedure to remove the upper bushing

[Figure 40-20-37].
Figure 40-20-39
Figure 40-20-37
The pins (Item 1) [Figure 40-20-39] are rubber mounted

and hold the breaker tool retaining pin in position.
The pins usually do no t need replacing until they are
visibly worn out [Figure 40-20-39].
112 of 260
40-20-10
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Service Manual
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].
Install the Hydraulic Breaker on the Bobcat Loader,

backhoe or excavator. Connect the quick couplers.
Start the engine. Raise the tool off the work surface and
engage the auxiliary hydraulics.
Slowly lower the piston in the sleeve, being careful not to
damage the piston or the sleeve [Figure 40-20-40].
Run the breaker for several minutes until the air is

removed from the breaker.
Figure 40-20-41
Figure 40-20-43
Install the seal carrier in the upper section as s hown

[Figure 40-20-41].
The extent of wear in the upper and lower bushings is

checked by installing a new bit ( Item 1) [Figure 40-2043] 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 4020-43].
113 of 260
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Service Manual
Start Up Procedure

114 of 260
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Service Manual
SPECIFICATIONS
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.
115 of 260
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116 of 260
40-30-2
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Service Manual


Charging The Accumulator . . . . . . . . . . . . . . . . . . . . . . . .
Checking The Accumulator Charge Pressure . . . . . . . . . .
Releasing Pressure From The Accumulator . . . . . . . . . . .
2570/3570
HYDRAULIC
BREAKER SERVICE
50-10-1
50-10-8
50-10-3
50-10-5
50-10-1
50-10-7
50-10-1
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
TOOL BIT REMOVAL AND INSTALLATION . . . . . . . . . . . . . 50-10-11
50-01
117 of 260
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Service Manual

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
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

50-02
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NITROGEN CHAMBER
Figure 50-10-2

The nitrogen chamber valve is located on the front side of
the hydraulic breaker.
WARNING
W-2019-1285
Using a small shaft, push the valve (Item 1) [Figure 5010-2] inward to release the gas pressure.

time.
Install the plug in the charge valve.
Figure 50-10-1


Figure 50-10-3

charge valve.
P18084

the gauge.
119 of 260
50-10-1
Hydraulic Breaker
Service Manual

Engine is running.
Figure 50-10-6

(Contd)
Figure 50-10-4
2
0.125
(3,2 mm)

breaker.
Figure 50-10-7
P-42758

measure the pin (Item 2) [Figure 50-10-4].
Figure 50-10-5
number 6568037.
bar).
P-42759

Install the gauge/adapter on the breaker.
120 of 260
50-10-2
Hydraulic Breaker
Service Manual
Figure 50-10-9
WARNING
Engine is running.
W-2019-1285


Figure 50-10-10
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 5010-8] is not under pressure and is not in contact with the
piston.
121 of 260
50-10-3
Hydraulic Breaker
Service Manual
Figure 50-10-8
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.
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.
122 of 260
50-10-4
Hydraulic Breaker
Service Manual
Figure 50-10-15

Checking The Accumulator Charge Pressure
WARNING

Engine is running.
W-2019-1285
P-29454

Figure 50-10-14

the gauge.
2
0.125
(3,2 mm)
P-42758

123 of 260
50-10-5
Hydraulic Breaker
Service Manual
Figure 50-10-16
Figure 50-10-19
Checking The Accumulator Charge Pressure (Contd)

Figure 50-10-17
P-42759


bar).
Figure 50-10-18
Install the gauge adapter on the breaker.

Tighten the adapter (Item 1) [Figure 50-10-18] on the
breaker.
124 of 260
50-10-6
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Service Manual
number 6568037.

Releasing Pressure From The Accumulator
Figure 50-10-20
Remove the plug (Item 1) [Figure 50-10-20] from the

charge valve.
Figure 50-10-21
Using a small shaft, push the valve (Item 1) [Figure 5010-21] inward to release the gas pressure.
125 of 260
50-10-7
Hydraulic Breaker
Service Manual
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.

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.
126 of 260
50-10-8
Hydraulic Breaker
Service Manual
Figure 50-10-22

as far as possible.
Figure 50-10-24

8 hours of operation or when the tool bit looks dry.
IMPORTANT
submerged.
I-2053-0589
127 of 260
50-10-9
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Service Manual

Figure 50-10-25
Check the snap rings, lock plates and breaker mounting

bolts (Item 1) [Figure 50-10-25] every day.
128 of 260
50-10-10
If the snap rings and lock plates are missing, tighten the
bolts to 300 ft.-lb. (407 Nm) torque. Lock plates can be
turned 180 for a different alignment if necessary.
Hydraulic Breaker
Service Manual
TOOL BIT REMOVAL AND INSTALLATION
Figure 50-10-27
Figure 50-10-26
Use a pun ch and a h ard rubber hammer to remove the

retaining pin from the tool [Figure 50-10-26].
Install the tool bit and align the notch (in the tool) with the
retaining pin hole [Figure 50-10-27].
Figure 50-10-28
NOTE: The retaining pin can be driven out or installed

from either side.
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.
NOTE: During normal operation, the grease will heat
up and run down the tool shaft.
Use a har d rubber hammer to in stall the retaining pin

[Figure 50-10-28].
NOTE: Grease the fitting every 4 to 8 hours of

operation or if the tool bit looks dry.
129 of 260
50-10-11
Hydraulic Breaker
Service Manual
WARNING
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
PROBLEM
CAUSE
CORRECTION
Loader or excavator main relief valve set too low.
Add hydraulic fluid to the fluid reservoir on the

loader or excavator.
Loader or excavator hydraulic pump not working.
Check flow of lo ader hydraulic pump. Repair or

replace as needed.
Breaker runs very slowly or Loader or excavator main relief valve set too low.
low blow energy.
130 of 260
Adjust main relief valve to correct setting

Test loader or excavator hydraulics for correct flow
and pressure.
Check oil cooler for debris and air flow. Check

loader or excavator relief valve pressure.
Nitrogen chamber pressure incorrect
Check and fill to correct pressure.
Internal leakage.
Check seals and O-rings in the breaker. Check

piston, sleeve and seal carrier for wear.
Loader or excavator main relief valve set too low.
Low fluid level.
Tool binding.
50-10-12
Hydraulic Breaker
Service Manual
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).

PROBLEM
CAUSE
CORRECTION
Blank firing.
Refer to the hydraulic controls section of the

Operation And Maintenance Manual for
correct operating procedure.

Excessive breaker inlet Accumulator charge pressure low or accu Check and fill to correct pressure or service
hose pulsations.
mulator damaged.
accumulator.
131 of 260
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Service Manual
132 of 260
50-10-14
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Service Manual
PARTS IDENTIFICATION (CONTD)
133 of 260
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134 of 260
50-10-16
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Service Manual
Figure 50-20-2
Breaker Frame Removal And Installation
WARNING
Engine is running.
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
MEL1523B
Figure 50-20-3
Figure 50-20-1
Remove the pin (Item 1) and washer (Item 2) [Figure 5020-3].

Place the hydraulic breaker on blocks (Item 1) [Figure
50-20-1].
Figure 50-20-4
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].
135 of 260
50-20-1
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Service Manual
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

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.
Nm) torque.
136 of 260
50-20-2
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Service Manual
Figure 50-20-11

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
TOOL BIT REMOVAL AND INSTALLATION on Page 5010-11.)
Remove the frame (Item 2) [Figure 50-20-9].
Figure 50-20-12
Raise the hoist (Item 1) [Figure 50-20-9] that is attached

to the breaker.
Figure 50-20-10
Set the breaker down on blocks (Item 1) [Figure 50-2010].
137 of 260
Install a lift eye (Item 1) and hoist (Item 2) [Figure 50-2012] on the end of the breaker.
50-20-3
Hydraulic Breaker
Service Manual
Figure 50-20-15

Figure 50-20-13
Raise the hoist and stand the breaker on end [Figure 5020-13].
Remove the 4 bolts (Item 1) [Figure 50-20-15].
Figure 50-20-14
Installation: Apply anti-seize to the bolt threads. Tighten

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.
Nm) torque.
138 of 260
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Service Manual
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).
Nitrogen Chamber Removal And Installation
NOTE: Do not us e an impact wrench to loosen or

tighten the tie rods.
Figure 50-20-17
Raise the breaker and remove the frame [Figure 50-2017].

Stand the breaker on the work surface.
NOTE: Do not disassemble or assemble the breaker
while it is laying on its side.
Remove the 4 t ie rods (Item 1) and washers (Item 2)

[Figure 50-20-18].
Installation: Apply anti-seize to the threads of the tie
rods and both sides of the washers.
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 50-2019].
139 of 260
50-20-5
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Service Manual
Figure 50-20-18
Figure 50-20-22
Nitrogen Chamber Disassembly And Assembly

Figure 50-20-20
Remove the charge valve assembly (Item 1) [Figure 5020-22].

Remove the O-ring (Item 1) [Figure 50-20-20].
Figure 50-20-23
Figure 50-20-21

charge valve assembly.
Figure 50-20-24
140 of 260
50-20-6
Hydraulic Breaker
Service Manual
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.
Remove the spool (Item 1) and O-rings (Item 2) [Figure

50-20-25] from the charge valve and spool.
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.
141 of 260
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Service Manual
Figure 50-20-28
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

the piston.
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 5020-30].
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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].
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
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Figure 50-20-36
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
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

fittings.
Press the sleeve slowly until it seats [Figure 50-20-38].
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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.
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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Figure 50-20-47

Figure 50-20-45
Install a lift eye (Item 1) [Figure 50-20-47] in the valve.

Figure 50-20-48
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.
valve.
plug.
146 of 260
Installation: Totally submerge the valve in c lean

hydraulic fluid. Saturate the v alve bore with clean
hydraulic fluid and with 1 motion, as quickly as possible,
install the valve from the container of hydraulic fluid into
the valve bore. Apply additional hydraulic fluid, if
necessary, to the valve and valve bore during installation
to prevent damage to the O-rings.
50-20-12
Hydraulic Breaker
Service Manual

plugs.
Figure 50-20-51

Figure 50-20-49
Remove the sleeve (Item 1) [Figure 50-20-51].

Figure 50-20-52
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

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

valve.
Upper Housing Removal And Installation
Figure 50-20-55
Figure 50-20-53
Remove the upper housing (Item 1) [Figure 50-20-55].

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

valve.
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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Figure 50-20-59
Upper Housing Removal And Installation (Cont'd)

Figure 50-20-57
Remove the plugs (Item 1) [Figure 50-20-59].

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

plugs.
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Remove the seals (Item 1) [Figure 50-20-60].
50-20-15
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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
Figure 50-20-62
Remove the cap (Item 1) [Figure 50-20-64].
Remove the retainer lock (Item 1) [Figure 50-20-62].
150 of 260
Installation: Tighten the ca p to 600 ft.-lb. (814 Nm)

torque.
50-20-16
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Service Manual
Remove the snap ring (Item 1) [Figure 50-20-61].
Figure 50-20-67
Accumulator Removal And Installation (Cont'd)

Figure 50-20-65

Figure 50-20-68
Figure 50-20-66
Remove the spool (Item 1) and O-rings (Item 2) [Figure

50-20-69] from the charge valve.

charge valve assembly.
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Remove the charge valve assembly (Item 1) [Figure 5020-65] from the cap.
Bushing Removal And Installation
Accumulator Removal And Installation (Cont'd)
Figure 50-20-71
Figure 50-20-69
Figure 50-20-72
Figure 50-20-70
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].

NOTE: The screen cannot be removed without
damage.
Remove the roll pins (Item 1) [Figure 50-20-72].
Remove the O-ring (not shown), under the screen if the

screen has been removed.
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Remove the diaphragm (Item 1) [Figure 50-20-69].
Figure 50-20-75
Bushing Removal And Installation (Cont'd)

Figure 50-20-73
Figure 50-20-76
Figure 50-20-74
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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Remove the retaining pins (Item 1) [Figure 50-20-73].
Figure 50-20-79

Figure 50-20-77
Installation: Align the slot (Item 2) [Figure 50-20-78] in

the upper bushing with the hole (Item 1) [Figure 50-2079] in the housing.
Use a brass or aluminum bushing driver (Item 1) [Figure

50-20-77] to remove the upper bushing.
Figure 50-20-78
Remove the upper bushing (Item 1) [Figure 50-20-78].
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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.
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,
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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.
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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BOB-TACH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8

HYDRAULIC BREAKER MOUNT INSPECTION . . . . . . . . . . 60-10-6
LOADER MOUNT REMOVAL AND INSTALLATION . . . . . . 60-10-12
5060
HYDRAULIC
BREAKER SERVICE
60-10-1
60-10-3
60-10-2
60-10-1

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
TOOL BIT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . 60-10-9
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-14
X-CHANGE MOUNT REMOVAL AND INSTALLATION . . . . 60-10-13
60-01
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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
Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-20-8
Wear Plate Removal And Installation . . . . . . . . . . . . . . . . 60-20-3

60-02
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Figure 60-10-2
NITROGEN CHAMBER
time.
front side of the hydraulic breaker.
WARNING
Engine is running.
Install the plug (Item 1) [Figure 60-10-1] in the charge

valve after the pressure has been released.
W-2019-1285
Using a small shaft, push the charge valve (Item 1)

[Figure 60-10-2] in to release the gas pressure.
Figure 60-10-1

charge valve.
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Figure 60-10-5

1
WARNING
2

Engine is running.
0.125
(3,2 mm)
W-2019-1285
P-42758

Figure 60-10-3


Figure 60-10-6

Figure 60-10-4
P-42759
1
P-29454

the gauge.
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(Cont'd)
WARNING
Figure 60-10-7

Engine is running.
W-2019-1285

the piston.
Figure 60-10-9

breaker.
Figure 60-10-8
Block up the breaker so the tool bit (Item 1) [Figure 6010-9] is not under pressure and is not in contact with the
piston.
number 6568037.
bar).
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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

charging tool.
Figure 60-10-10
Figure 60-10-13
Figure 60-10-11

(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.
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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Figure 60-10-17
BOB-TACH INSPECTION
Figure 60-10-15
The wedges must extend through the holes in th e

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

60-10-15]. The levers and wedges must move freely.
The spring loaded wedge (Item 1) [Figure 60-10-15]

must contact the lower edge of the hole in the attachment
(Item 1) [Figure 60-10-16] and [Figure 60-10-17].
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.
Figure 60-10-20
Inspect the X-Change mount (Item 1) [Figure 60-1020] and all welds on the mount for wear and damage
each time the hydraulic breaker is removed from the
excavator.
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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
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
submerged.
I-2053-0589
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DAILY INSPECTION
Figure 60-10-23
Figure 60-10-22
There can be no more than 0.354 in. (9 mm) gap

between the lower bushing and a new tool bit [Figure 6010-23].
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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The extent of wear in the upper and lower bushings is

checked by installing a new bit ( Item 1) [Figure 60-1023] in the hydraulic breaker and checking the ga p
between the lower bushing and the tool bit shaft.
TOOL BIT REMOVAL AND INSTALLATION
WARNING
Engine is running.
W-2019-1285
NOTE: Tool bit removal and installation is shown on a

loader. The procedure is t he same for an
excavator mounted hydraulic breaker.
Figure 60-10-24
Before you leave the operator's seat:

Lower the lift arms, put the attachment flat on the
ground.
Stop the engine.
Engage the parking brake.
Raise seat bar.
(Foot Pedal Controls) Move pedals until both
lock.
(Mechanical Hand Controls) Move the hand
controls until both lock. The seat bar system
must lock the lift and tilt controls in neutral when
the seat bar is u p. Service the system if hand
controls do not lock correctly.
(Advanced Hand Controls) Move the hand
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.
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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WARNING
Figure 60-10-27
TOOL BIT REMOVAL AND INSTALLATION (CONTD)

Figure 60-10-25
Remove the roll pin (Item 2) [Figure 60-10-24 on Page

60-10-9] and (Item 1) [Figure 60-10-25].
Figure 60-10-26
Measure the outside diameter of t he pin [Figure 60-1027].

Replace the pin if the measurement is 1.12 in. (28 mm) or
less at any location along the length of the pin.
Drive the tool retaining pin (Item 1) [Figure 60-10-26] out

the bottom of the hydraulic breaker.
170 of 260
Figure 60-10-28
Remove the tool bit (Item 1) [Figure 60-10-28].
60-10-10
Hydraulic Breaker
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.

Replace the bit if worn or damaged.
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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
Remove the hydraulic hoses (Item 1) from the hose guide

(Item 2) [Figure 60-10-31].
Figure 60-10-32
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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
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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TROUBLESHOOTING
WARNING
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.
PROBLEM
CAUSE
CORRECTION
Add hydraulic fluid to the reservoir on the loader

or excavator.
Nitrogen chamber pressure incorrect.
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.
blow energy.

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

Check loader or excavator relief valve pressure.
Test loader or ex cavator hydraulics for c orrect

flow and pressure.
Internal leakage.

Check piston sleeve and seal carrier for wear.
Low fluid level.
Tool binding.
Excessive heat buildup.
174 of 260
Blank firing.
Refer to the hydraulic controls section of the

Operation and Maintenance Manual for correct
operating procedure.
Add hydraulic fluid to the reservoir on the loader

or excavator.
60-10-14
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Service Manual
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PARTS IDENTIFICATION (CONT'D)
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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
Engine is running.
Remove the fittings (Item 1) [Figure 60-20-2].

Figure 60-20-3
Release the pressure from the nitrogen chamber. (See

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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Figure 60-20-7

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].
Figure 60-20-6
Raise the hoist (Item 1) [Figure 60-20-7] & [Figure 6020-8] 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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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 60-20-12
Remove the 2 flange bolts (Item 1) [Figure 60-20-9] and

nuts (Item 1) [Figure 60-20-10] from the wear plate (front
and rear).
Installation: Install the wear plate with the beveled side

(Item 1) [Figure 60-20-12] toward the inside of the frame.
Installation: Install the flange nuts into the wear plate,

ensure the flange (Item 1) is flush with the wear plate
(Item 2) [Figure 60-20-10].
NOTE: The front wear plate and shim have a hole

(Item 3) [Figure 60-20-11] that must be aligned
with the hole in the frame (Item 2) [Figure 6020-9] to provide access to a grease fitting in
the breaker.
Figure 60-20-10
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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Service Manual
Figure 60-20-15
Lower Bumper Removal And Installation

Figure 60-20-13
Remove the 4 washers (Item 1) [Figure 60-20-15].
Figure 60-20-16
Remove the l ower bumpers (Item 1) [Figure 60-20-13]

from the housing.
Installation: Apply anti-sieze to both sides of the

washers.
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.
Remove the nuts (Item 1) [Figure 60-20-14].
NOTE: Do not use an impact wrench to remove or
install the nuts.
Installation: Apply anti-sieze to the threads of the nuts.
Tighten the nuts to 290 ft.-lb. (393 Nm) torque.
180 of 260
Apply anti-sieze to the threads of the tie rods. Install the

tie rods by hand until they are fully seated in the bottom
housing.
NOTE: Use care to prevent the breaker sections from
falling after removing the tie rods.
60-20-4
Hydraulic Breaker
Service Manual
Charge Valve Removal And Installation
Nitrogen Chamber Removal And Installation (Contd)
Figure 60-20-19
Figure 60-20-17
Figure 60-20-18
Installation: Clean the threads and apply thread lock

adhesive (LOCTITE 242).
Figure 60-20-20

nitrogen chamber.
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Remove the O-rings (Item 1) [Figure 60-20-20] from the

charge valves.
60-20-5
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Service Manual
Remove the nitrogen chamber (Item 1) [Figure 60-2017].
Remove the charge valves (Item 1) [Figure 60-20-19]

from both front and rear of the nitrogen chamber.
Figure 60-20-23
Piston Removal And Installation

Figure 60-20-21

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.
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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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

the piston.
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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Valve Removal And Installation
Center Housing Removal And Installation
Figure 60-20-30
Figure 60-20-28
Figure 60-20-31
Install a h oist (Item 1) [Figure 60-20-28] on the c enter

housing. Raise the hoist and remove the center housing.

valve plug.
Figure 60-20-29
184 of 260
Install a l ift eye (Item 1) [Figure 60-20-31] in the valve

plug.
60-20-8
Hydraulic Breaker
Service Manual
Figure 60-20-34

Figure 60-20-32
Remove the valve (Item 1) [Figure 60-20-34].
Figure 60-20-35
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
center housing.
Installation: Make sure the valve moves freely in the

port.
Remove the valve plug.

Figure 60-20-33
Do not remove the valve sleeve (Item 1) [Figure 60-2035].

valve plug.
185 of 260
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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
Figure 60-20-37
Remove the vent (Item 1) [Figure 60-20-39].

plugs.
186 of 260
Installation: Clean the threads of the vent and apply

thread lock adhesive (LOCTITE 242).
60-20-10
Hydraulic Breaker
Service Manual
Remove the 4 plugs (Item 1) [Figure 60-20-36].
Figure 60-20-42
Center Housing Disassembly And Assembly (Cont'd)

Figure 60-20-40
Bushing Removal And Installation
Remove the rollpins (Item 1) [Figure 60-20-42].

vent.
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.
Figure 60-20-43
Figure 60-20-41
Remove the retaining pins (Item 1) [Figure 60-20-43].
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Figure 60-20-46

Figure 60-20-44
Remove the lower bushing (Item 1) [Figure 60-20-46].
Figure 60-20-47
Measure the outside diameter of the pins [Figure 60-2044], replace the pins if the measurement at any location
along the length of the pins is .56 inch (14 mm) or less.
Installation: Align the slot (Item 2) with the hole (Item 3)

[Figure 60-20-46].
Figure 60-20-45
Drive the rollpins (Item 1) [Figure 60-20-45] back until

the end of the rollpins are flush with the housing.
188 of 260
Measure the inside diameter of the lower bushing .40 in.

(10 mm) in from the bottom of the bushing [Figure 60-2047].
Replace the bushing if the measurement is 3.56 inch (89
mm) or more.
60-20-12
Hydraulic Breaker
Service Manual
Figure 60-20-50

Figure 60-20-48
Figure 60-20-51
Use a brass or aluminum bushing driver (Item 1) [Figure

60-20-48] and hammer to remove the upper bushing.
Measure the inside diameter of the upper bushing, .40

inch (10 mm) in from the top of the bushing [Figure 6020-50]. Replace the bushing if the measurement is 2.84
inch (71 mm) or more.
Figure 60-20-49
Remove the upper bushing (Item 1) [Figure 60-20-49].

NOTE: Early models have a thrust ring located above
the upper bushing.
On older models measure the thrust ring [Figure 60-2051] from the wear areas to the bottom of the ring.
Replace the ring if the measurement is .30 inch (7,5 mm)
or less.
Installation: Install the up per bushing (Item 1) with the

slot (Item 2) aligned with the hole (Item 3) [Figure 60-2049].
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Figure 60-20-54

Figure 60-20-52
Remove the retainers (Item 1) [Figure 60-20-54].
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
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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Figure 60-20-55

Lower Housing Removal And Installation
Figure 60-20-56
Remove the stop blocks (Item 1) [Figure 60-20-56] (both

sides).
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,
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SPECIFICATIONS
All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
Where applicable, specifications conform to SAE or ISO standards and are subject to change without notice.
WEIGHT
Breaker With Tool; Loader
940 lb. (426 kg)
Breaker With Tool; Excavator
780 lb. (354 kg)
ENERGY
750 ft.-lb. (1017 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.)
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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
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-4
Charging the High Pressure Accumulator . . . . . . . . . . . . .
Charging the Low Pressure Accumulator . . . . . . . . . . . . .
Checking The High Pressure Accumulator Pressure. . . . .
Checking The Low Pressure Accumulator Pressure . . . . .
70-10-1
70-10-2
70-10-5
70-10-7
70-10-1
70-10-3
70-10-6
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
5500
HYDRAULIC
BREAKER SERVICE
70-01
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70-02
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NITROGEN CHAMBER
Figure 70-10-3

1

Figure 70-10-1
2
0.125
(3,2 mm)
P-42758


B-7047
Figure 70-10-4

Figure 70-10-2
P-42759
P18084

the gauge.
197 of 260
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Charging the High Pressure Accumulator

(Contd)
Use charging kit (P/N 6568037) to charge the hydraulic

breaker.
Figure 70-10-5
WARNING
Engine is running.
W-2019-1285
1
Figure 70-10-7

breaker.
Figure 70-10-6

Figure 70-10-8
B-23394
number 6568037.
NOTE: The correct charge pressure is 850 P SI (58,6
bar).

198 of 260
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Service Manual
B-23394
Charging The High Pressure Accumulator Pressure

(Contd)

Figure 70-10-9
Figure 70-10-11
B-7049

[Figure 70-10-9].

Figure 70-10-12
Figure 70-10-10
Connect This End
To High Pressure
Accumulator &
Nitrogen Chamber
Connect Hose From

P18084
B-7196

the gauge.

the charging tool [Figure 70-10-9].
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.
199 of 260
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B-7078
Figure 70-10-15

(Contd)
Figure 70-10-13
2
B-23393
0.125
(3,2 mm)
Tighten the a dapter (Item 1) [Figure 70-10-15] on th e

breaker.
P-42758

Figure 70-10-14
1
B-23393
number 6568037.
bar).
P-42759

200 of 260
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Figure 70-10-16
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
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.
Using a small shaft (Item 1) [Figure 70-10-17], push the

Close the valve at the tank. Disconnect the nitrogen hose

and charging tool.
Figure 70-10-18
Connect Hose From

Connect This End To Low

Pressure Accumulator
B-7196
NOTE: Use the low pressure side of the charging tool

[Figure 70-10-18].
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Connect the nitrogen hose to the low pressure side of the

charging tool [Figure 70-10-19].
Figure 70-10-22

1

Figure 70-10-20
2
0.125
(3,2 mm)
P-42758


B-8887
Figure 70-10-23

Figure 70-10-21
P-42759
P18084

the gauge.
202 of 260
70-10-6
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(Contd)

back side of the breaker above the hydraulic inlet and
outlet ports.
Figure 70-10-24
Figure 70-10-26

breaker.
Figure 70-10-25
Remove the charge valve plug (Item 1) [Figure 70-1026].

Using a small shaft push the valve inward to release the
gas pressure.
Figure 70-10-27
B-23395
number 6568037.

bar)
203 of 260
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B-23395

Charging the Nitrogen Chamber (Cont'd)
Figure 70-10-28
Connect This End To

Nitrogen Chamber
Connect Hose From

B-7196

[Figure 70-10-28].
the charging tool.
nitrogen chamber.
Fill the chamber to 500 PSI (34,48 bar)
Disconnect the hose and the charging tool.
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as far as possible.
Figure 70-10-29

8 hours of operation, or when the tool bit looks dry.
IMPORTANT
submerged.
I-2053-0589
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Figure 70-10-30
Check the mounting bolts (Item 1) [Figure 70-10-30]

daily.
Tighten the bolts to 900 ft.-lb. (1200 Nm) torque.
206 of 260
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WARNING
injury or death.
W-2003-1289
PROBLEM
CAUSE
CORRECTION


loader.
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.)
Breaker runs very slowly.

Repair and replace as needed.
Test loader hydraulics for correct flow and

pressure.

Remove gas and refill to c orrect pressure of

500 PSI (3448 bar) maximum.
Internal leakage.

Low fluid level.
Tool binding.
Damaged electrical connection to brea ker Check wiring harness and switch.
valve. (Backhoe mounted unit only.)
207 of 260
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208 of 260
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Figure 70-20-2
WARNING
Engine is running.
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
of the nitrogen gas chamber [Figure 70-20-2]. DO NOT
REMOVE THE BOLT.
Figure 70-20-3

OEM6106 - Torque Multiplier
MEL1310 - Remove Handle
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.
Remove the 3/ 16 in. hex plug at the accumulator
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.
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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.
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].
Remove the frame from the breaker.
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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].

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].
211 of 260
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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.
Figure 70-20-14
Remove the pi ston from the main body [Figure 70-2011].

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 7020-12].
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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 7020-17].
Install the socket head bolts into the body at both
accumulator sides.
NOTE: The valve cylinder and valve seat are indexed

by a roll pin (Item 1) [Figure 70-20-15].
Figure 70-20-18
Remove the valve cylinder from the valve seat [Figure

70-20-15].
Main Body Removal

Figure 70-20-16
Install a chain hoist and lift the main body from the lower
Remove both disc springs from the main body [Figure

70-20-16].
213 of 260
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Inspect all the parts for scratches, wear or damage.

Replace the parts as needed.
Main Body Removal (Cont'd)
Figure 70-20-19
Disassembly: Remove the large bolt and the top plate.

Figure 70-20-21
Lower Body Bushings Removal
Figure 70-20-20

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.
Remove all the O-rings, seals and Poly-Pak seals from
the breaker parts.
Assembly: Lubricate the sealing surface of the nitrogen

chamber. Install the diaphragm [Figure 70-20-22].
Clean in solvent and air dry them.
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Service Manual
Turn 2 b olts, equally into the main body to r emove the

lower bearing [Figure 70-20-19].
Figure 70-20-25

(Cont'd)
Figure 70-20-23
Install the O-rings (Item 1) [Figure 70-20-25] on the top

and bottom of the chamber.
Figure 70-20-24
Tighten the bolt to 600 ft.-lb. (814 Nm) torque.

Figure 70-20-26
Install the O-ring on the screen [Figure 70-20-24].

torque [Figure 70-20-26].
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Install the screen [Figure 70-20-23].
Install the top plate and bolt. The bolt must be tightened
after the chamber is installed on the main body.
Figure 70-20-29
Accumulator
Figure 70-20-27
Remove the charge valve [Figure 70-20-29].

Figure 70-20-30
Remove the hex socket bolts at the accumulator

chamber [Figure 70-20-27].
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.
216 of 260
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Service Manual
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].
Put approximately 1 teaspoon of clean oil in the cover.
Put the plug into the body and tighten to 600 ft.-lb. (814
Nm) torque.
NOTE: Do not use a screwdriver or any sharp tool for

installation of the Poly-Pak.
Figure 70-20-34

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].
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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

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.
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SPECIFICATIONS
WEIGHT
Breaker W/Moil & Breaker Mount
627 lb. (285 kg)
Bob-Tach Adapter
441 lb. (200 kg)
Total Weight
1095 lb. (497 kg)
ENERGY
BLOWS PER MINUTE
900 @ 25 GPM (95 L/min.)
HYDRAULIC FLOW REQUIRED
25 GPM (95 L/min.)
2000 PSI (13790 bar)
MOIL DIAMETER
2.75 in. (69,8 mm)
MOIl WORKING LENGTH
18.0 in. (457,2 mm)
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220 of 260
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CHECKING MOUNTING BOLT TORQUE . . . . . . . . . . . . . . . 80-10-6

80-10-1
80-10-3
80-10-2
80-10-1
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
80-01
221 of 260
6560
HYDRAULIC
BREAKER SERVICE
Hydraulic Breaker
Service Manual

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

80-02
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NITROGEN CHAMBER
front side of the hydraulic breaker.
WARNING
Engine is running.
W-2019-1285

time.
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].
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Figure 80-10-3

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
1
Connect Hose From
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].
(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).
224 of 260
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Service Manual
Connect This End To

Nitrogen Chamber
NITROGEN CHAMBER (CONT'D)

the gauge.
Figure 80-10-6
WARNING

Engine is running.
2
0.125
(3,2 mm)
W-2019-1285

Figure 80-10-4

Figure 80-10-7

Figure 80-10-5
P-42759
1
P-29454
225 of 260
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NOTE: The hydraulic breaker shown is not the 6560.

The procedure is the same.
P-42758
NITROGEN CHAMBER (CONT'D)

(Cont'd)
Figure 80-10-8

breaker.
Figure 80-10-9
number 6568037.
bar).
226 of 260
80-10-4
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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
P-10520

8 hours on operation or when the tool bit looks dry.
IMPORTANT
submerged.
I-2053-0589
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Hydraulic Breaker
Service Manual

Figure 80-10-11
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.
228 of 260
80-10-6
Hydraulic Breaker
Service Manual
WARNING
injury or death.
W-2003-0797
PROBLEM
CAUSE
CORRECTION
Loader or excavator main relief valve set too Adjust main relief valve to correct setting.
low.

Loader or excavator hydraulic pump not Check flow of loader hydraulic pump.
working.
Damaged electrical connection to br eaker Check wiring harness and switch.

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.
Test loader or excavator hydraulics for correct
flow and pressure.
Check oil cooler for debris and air flow. Check

loader or excavator relief valve pressure.
Nitrogen chamber over-pressurized or loss of Remove gas and refill to correct pressure.
pressure.
229 of 260
Internal leakage.

Check piston, sleeve and seal carrier for wear.
80-10-7
Hydraulic Breaker
Service Manual

PROBLEM
CAUSE
CORRECTION
Loader or excavator main relief valve set too Adjust main relief valve to correct setting.
low.
Low fluid level.
Tool binding.
Damaged electrical connection to br eaker Check wiring harness and switch.

Blank firing.
Refer to t he hydraulic controls section of the

OM for correct operating procedure.
230 of 260
80-10-8
Hydraulic Breaker
Service Manual
231 of 260
80-10-9
Hydraulic Breaker
Service Manual
PARTS IDENTIFICATION (CONTD)
232 of 260
80-10-10
Hydraulic Breaker
Service Manual
Figure 80-20-2
WARNING
Engine is running.
W-2019-1285
Remove the hydraulic breaker from the loader or

excavator. (See the Operation & Maintenance Manual for
the procedure.)
Lay the hydraulic breaker and frame on the floor.
Figure 80-20-1
Use a hoist and chains to support the weight of the BobTach mounting frame [Figure 80-20-1] or the ex cavator
X-Change [Figure 80-20-2]. Remove the eight bolts
(Item 1) [Figure 80-20-1] or [Figure 80-20-2] and
remove the mounting frame or X-Change.
Installation: Apply liquid adhesive (LOCTITE #242) to
the threads. Tighten the bolts and nuts to 474 to 525 ft.lb. (645 to 710 Nm) torque.
Remove the hydraulic hoses from the breaker fittings.
Figure 80-20-3
Remove the upper bumper (Item 1) [Figure 80-20-3].
233 of 260
80-20-1
Hydraulic Breaker
Service Manual
NOTE: Before removing the breaker from the frame

release the nitrogen pressure from the
breaker. (See Releasing Pressure From The
Shuttle Valve
NOTE: Check the machined surfaces of the shuttle

valve for scratches or wear. The shuttle valve
parts are not replaceable.
Figure 80-20-4
NOTE: Apply hydraulic oil to the O-rings and

machined surfaces during assembly.
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.
Remove the bolts from the shuttle valve cap (Item 1)

[Figure 80-20-5].
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.
234 of 260
80-20-2
Hydraulic Breaker
Service Manual
Figure 80-20-5
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.
Remove and replace the O-ring (Item 1) [Figure 80-20-7]

from the cap.
If the sleeve was removed, install the replacement sleeve

as follows:
Freeze the s leeve for 2 hou rs in liquid CO2, then install
the sleeve into the main body. The prongs of the sleeve
must contact the end face of the bore [Figure 80-20-9].
Check the cap machined surfaces for scratches or wear.

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.
Check for cracks and see that the spool moves freely in
the valve sleeve.
cloth.
DO NOT break or buff the sharp edges of the valve
sleeve or valve spool. This will cause the valve to
malfunction.
235 of 260
80-20-3
Hydraulic Breaker
Service Manual
Use MEL1545 to remove it from the housing.
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
the charge valve assembly.
Remove the p lug (Item 1) [Figure 80-20-10] to gain

access to the charge valve.
Figure 80-20-11
Use a slotted screwdriver to remove the charge valve

(Item 1) [Figure 80-20-11].
236 of 260
80-20-4
Hydraulic Breaker
Service Manual
Figure 80-20-15
Upper Body Removal and Installation

Figure 80-20-13
Use MEL1544 to remove the tie rods (Item 1) [Figure 8020-15].

Lift the tie rods from the upper body.
Figure 80-20-16
Remove the protective vinyl caps (Item 1) from the tie rod
nuts (Item 2) [Figure 80-20-13].
Figure 80-20-14
Remove the 4 tie rod nuts (Item 1) and lock plates (Item
2) [Figure 80-20-14].
Remove the nuts from the slots in the lower body [Figure
80-20-16].
NOTE: Do not use an impact wrench to remove the tie

rod nuts.
237 of 260
80-20-5
Hydraulic Breaker
Service Manual
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
Position the tool (Item 1) [Figure 80-20-18] to pass

through the seal carrier.
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
(Item 2) [Figure 80-20-17] if sections stick
together.
Seat the tool securely against the seal carrier flange and
use the slide hammer to remove the carrier [Figure 8020-19].
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.
238 of 260
80-20-6
Hydraulic Breaker
Service Manual
Figure 80-20-18
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 80-2022]. Lips must face away from the tool.
Figure 80-20-23
Remove the O-rings from the seal carrier [Figure 80-2020].

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.
239 of 260
80-20-7
Hydraulic Breaker
Service Manual
Figure 80-20-25
Piston Removal
Figure 80-20-24
Check the piston for wear, galling, or cracks [Figure 8020-25].
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
sleeve.
Figure 80-20-26
Check the condition of the annual groves (Item 1)

[Figure 80-20-26].
A light scuffing or burnishing of surfaces is normal.
240 of 260
80-20-8
Hydraulic Breaker
Service Manual
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
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.
Align the tool with the holes in the sleeve and install the
pin (Item 2) [Figure 80-20-27] through the sleeve and
tool.
Use the slide hammer until the sleeve is free from the
lower body.
Check the s leeve for scratches, damaged O-rings and
seals.
Remove the wiper seal (Item 1) and the rod seal (Item 2)
[Figure 80-20-29] from the sleeve.
Installation: Put grease on the rod seal (Item 2) [Figure
80-20-29]. Install the seal with the lips up.
Installation: Put grease on th e wiper seal (Item 1)
[Figure 80-20-29]. Install the seal with the beveled side
down.

Check for cracks and see that the piston moves freely in
the sleeve.
cloth.
241 of 260
80-20-9
Hydraulic Breaker
Service Manual
Figure 80-20-31
Bumper Pad Removal and Installation

NOTE: Do not remove the bumper pads unless they
are damaged.
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 8020-30] so the angle is facing up. Install the pins so the
threaded hole is facing up.
Install chains through the tie rod holes. Use a bolt (Item
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
retaining pin can be removed and the point will remain in
the stand.
Lay the lower body on it's side.
242 of 260
80-20-10
Hydraulic Breaker
Service Manual
Figure 80-20-30
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 8020-34].
Check the condition of the bushings and the inside of the

lower body.
Align the retaining pin grooves (Item 1) [Figure 80-2034] in the bushings with the holes in the lower body.
Install the bushings, retaining pins, and roll pins.
Install a punch (Item 1) [Figure 80-20-32] through the roll

pin. Use a hammer to remove the roll pin and retaining
pin.
Drive the roll pins flush with the outside surface of th e

lower body.
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].
243 of 260
80-20-11
Hydraulic Breaker
Service Manual
Clean the bushings and inside of the lower body.
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.
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
Clean the holes and threads of de bris before installing
rubbers and reataining pins.
244 of 260
80-20-12
Hydraulic Breaker
Service Manual
Figure 80-20-39
Piston and Seal Carrier Installation

Figure 80-20-38
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.
245 of 260
80-20-13
Hydraulic Breaker
Service Manual
Be sure to install new O-rings (Item 1) [Figure 80-20-38]

in the lower body before installing the upper body.
Figure 80-20-42
Tie Rod Installation

Apply anti-sieze to the
assembly:
following locations during
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.
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 8020-40].
Figure 80-20-41
Install the vinyl caps (Item 1) [Figure 80-20-43] on the tie

rod nuts.
Use Mel1544 to install the tie rods (Item 1) [Figure 8020-41] in the upper body.
Charge the nitrogen chamber. (See Charging The

Screw the 4 tie rods into the nuts finger tight. Loosen the
tie rods 1/4 turn.
246 of 260
80-20-14
Hydraulic Breaker
Service Manual
Install the tie rod nuts (Item 2) [Figure 80-20-42].
SPECIFICATIONS
WEIGHT
Breaker With Tool
850 lb. (385 kg)
ENERGY
875 ft.-lb. (1186 J) Class
BLOWS PER MINUTE
600 to 1000
HYDRAULIC PRESSURE
1700 to 1900 PSI (117 to 131 bar)
RECOMMENDED HYDRAULIC FLOW
16 to 24 GPM (60 to 90 L/min.)
RECOMMENDED SYSTEM RELIEF
2500 PSI (172.4 bar)
247 of 260
80-30-1
Hydraulic Breaker
Service Manual

248 of 260
80-30-2
Hydraulic Breaker
Service Manual
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
Insert This Sheet With The Below Listed Manual For Future Reference.
HB-1
5 September 1997
Bobcat Attachment
Hydraulic Breaker
6720280 (9-96)
The following sections are a revision to the above Service Manual.
TAKE OUT
PUT IN
i, ii
iii, iv
i (Revised Sept. 97), ii

iii (Revised Sept. 97), iv
ix (Revised Sept. 97), x (Revised Sept. 97)
1-1 (Revised Sept. 97), 1-2
1-5, 1-6 (Revised Sept. 97)
1-9, 1-10 (Revised Sept. 97)
1-11 (Added Sept. 97), 1-12 (Revised Sept. 97)
3-7 (Revised Sept. 97), 3-8
3-9 (Revised Sept. 97), 3-10
Hydraulic/Hydrostatic Flow Chart
1560, 2560/3560, 6560
(Printed September 1997)
5-5, 5-6 (Revised Sept. 97
5-9 (Revised Sept. 97), 5-10
5-11 (Revised Sept. 97), 5-12
6-13 (Revised Sept. 97), 6-14
7-1 thru 7-8 (Revised Sept. 97)
7-9 thru 7-18 (Revised Sept. 97)
Section 8 (Revised Sept. 97)
1-1, 1-2
1-5, 1-6
1-7, 1-8
1-9, 1-10
3-5, 3-6
3-7, 3-8
3-9, 3-10
Hydraulic/Hydrostatic Flow Chart
2560
(Printed September 1993)
5-5, 5-6
5-9, 5-10
5-11, 5-12
6-13, 6-14
Section 7
Printed in U.S.A.
249 of 260
Take out the existing sections and put in the new sections as listed below:
250 of 260
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
HB-2
7 March 2001
Bobcat Attachment
1250, 1560, 2500/3500, 2560/3560, 5500 & 6560
6720280 (9-96)
TAKE OUT
4-1 - 4-14
PUT IN
4-1 - 4-14
REVISION DESCRIPTION
Revised seal identification information. 2500/3500
seals are no longer identified by colors, seals are now
packaged in the seal kit with identification numbers.
Printed in U.S.A.
251 of 260
252 of 260
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
HB-3
18 February 2002
Bobcat Attachment
1250, 1560, 2500/3500, 2560/3560, 2570/3570, 5060 5500 & 6560
6720280 (9-96)
TAKE OUT
PUT IN
REVISION DESCRIPTION
ALPHABETICAL INDEX
iii, iv
ix thru xii
1-1, 1-2
1-9 thru 1-12
6-1 thru 6-14
7-1 thru 7-18
8-1 thru 8-8
ALPHABETICAL INDEX
iii, iv
ix thru xii
1-1, 1-2
1-9 thru 1-30
6-1 thru 6-26
7-1 thru 7-20
8-1 thru 8-14
9-1 thru 9-18
Revised page
Revised contents page
Added models 2570/3570 and 5060
Revised contents page
Added models 2570/3570 and 5060
Added models 2570/3570
Added model 5060
Move model 5500 to section 8
Moved model 6560 to section 9
Printed in U.S.A.
253 of 260
254 of 260
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
Breaker - 4
19 October 2005
Bobcat Attachment
Hydraulic Breaker
6720280 (10-04)
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)
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.
Printed in U.S.A.
255 of 260
Please remove the existing Hydraulic / Hydrostatic Flow Charts from Hydraulic Breaker Service Manual (P/N
6720280) Dated 9-96 and save these Flow Charts.
256 of 260
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
Breaker-5
23 March 2006
Attachment
Hydraulic Breaker
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).
Printed in U.S.A.
257 of 260
258 of 260
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Breaker-6
15 June 2012
Attachment
Hydraulic Breaker
6720280 (2-06)
The following Sections are a revision to the above Service Manual.

COVER
259 of 260
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
260 of 260

Breaker 6720280 enUS SM 06-12

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Service

Dealer Copy -- Not for Resale

Doosan purchased Bobcat Company from Ingersoll-Rand Company in

Bobcat Company 2006

Dealer Copy -- Not for Resale

Instructions are necessary before operating or servicing machine. Read and

Dealer Copy -- Not for Resale

Never service attachments without instructions. See

Avoid contact with leaking hydraulic fluid or diesel fuel

Dealer Copy -- Not for Resale

Dealer Copy -- Not for Resale

2500/3500 HYDRAULIC BREAKER SERVICE

ALPHABETICAL INDEX (CONTD)

Dealer Copy -- Not for Resale

5500 HYDRAULIC BREAKER SERVICE

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

Dealer Copy -- Not for Resale

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

Dealer Copy -- Not for Resale

SERIAL NUMBER LOCATIONS & HYDRAULIC

Always use the serial number of the machine when

Serial Number Locations (1250, 1250X)

The breaker serial number plate is on the front of the

Hose Fitting Port

Breaker shown is mounted in excavator bracket

Dealer Copy -- Not for Resale

Hydraulic Breaker Identification (1250, 1250X)

SERIAL NUMBER LOCATIONS & HYDRAULIC

Always use the serial number of the machine when

Serial Number Locations (1560)

The 1560 Hydraulic Breaker is approved for the following

Dealer Copy -- Not for Resale

Hydraulic Breaker Identification (1560)

SERIAL NUMBER LOCATIONS & HYDRAULIC

Always use the serial number of the machine when

Serial Number Locations (2500/3500 & 5500)

The 1560 Hydraulic Breaker is approved for the following

Dealer Copy -- Not for Resale

Hydraulic Breaker Identification (2500/3500 & 5500)

SERIAL NUMBER LOCATIONS & HYDRAULIC

Always use the serial number of the machine when

Serial Number Locations (2560/3560)

The breaker serial number plate is located on the front of

Dealer Copy -- Not for Resale

Hydraulic Breaker Identification (2560/3560)

SERIAL NUMBER LOCATIONS & HYDRAULIC

Always use the serial number of the machine when

Serial Number Locations (2570/3570)

Dealer Copy -- Not for Resale

Hydraulic Breaker Identification (2570/3570)

SERIAL NUMBER LOCATIONS & HYDRAULIC

Always use the serial number of the machine when

Serial Number Locations (5060)

Dealer Copy -- Not for Resale

Hydraulic Breaker Identification (5060)

SERIAL NUMBER LOCATIONS & HYDRAULIC

Always use the serial number of the machine when

Serial Number Locations (6560)

Dealer Copy -- Not for Resale

Hydraulic Breaker Identification (6560)

Dealer Copy -- Not for Resale

1250, 1250X HYDRAULIC BREAKER SERVICE

Dealer Copy -- Not for Resale