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TA
CH M EN
CL
TA
TRUCTIO
NS
O
CL
TRUCTIO
NS
O
CH M EN
HYDRAULIC
BREAKER
CAL-225
CAL-450
CAL-550
CAL-750
CAL-1000
CAL-1200
CAL-2200
CAL-3200
CAL-4500
CAL-6000
CAL-8000
CAL-11000
OPERATORS MANUAL
Table of Contents
2. SPECIFICATIONS . 5
3. SAFETY
3.1
3.2
Safety Instructions
Machine Signs (Decals)
4. BREAKER NOMENCLATURE. 10
4.1
4.2
Main Structure
Principles of Operation
6. OPERATION
6.1
6.2
6.2
6.4
6.5
24
8. SERVICE ....
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.12
15
7. CHISEL
7.1
7.2
7.3
7.4
13
28
36
41
Dissembling
Assembling
Inspection
Repairing Parts
54
55
12.1
12.2
12.3
Malfunctions
Oil Leakage
Poor Operation of Breaker
13. TORQUE
13.1
13.2
13.3
13.4
59
Through Bolts
Bulk Cap Bolts
Accumulator Body Parts
Accumulator Cover Parts
66
69
____________________________
Address
Phone
This Operation Manual was written to give the owner/operator instructions on the safe operation and
maintenance of the Construction Attachments Hydraulic Breaker.
WARNING
READ AND UNDERSTAND THIS OPERATION & MAINTENANCE MANUAL BEFORE
OPERATING YOUR HYDRAULIC BREAKER.
If you have any questions, see your Construction Attachments Hydraulic Breaker Dealer.
2. SPECIFICATIONS
BREAKER MODELS
CAL-225
CAL-450
CAL-550
CAL-750
CAL-1000
CAL-1200
CAL-2200
Operating Weight
(lbs)
FEATURE
198
276
514
633
944
1,160
1,830
Overall Length
(in)
38.2
49.2
53.1
62.2
72.0
74.8
87.4
1.77 x 21.6
2.24 x 25.6
2.76 x 28.7
2.76 x 28.7
3.15 x 35.4
3.54 x 37.4
4.13 x 41.7
2,500
2,500
2,500
2,500
2,500
2,500
3,000
475
175
175
175
175
175
210
Working Pressure
(psi)
1,280 - 1,706
1,280 - 1,706
1,280 - 1,706
1,422 - 2,275
1,564 - 2,417
1,706 - 2,417
1,706 - 2,417
Working Pressure
(kg/cm2 )
90-120
90-120
90-120
100-160
110-170
120-170
120-170
3.7 - 6.6
5.3 - 10.6
7.9 - 15.8
10.6 - 18.5
13.2 - 23.8
15.8 - 26.4
23.8 - 34.3
650 - 1,500
500 - 1,200
500 - 1,200
400 - 1,100
400 - 900
400 - 900
400 - 800
Chisel Size
(Diameter x Length, in)
Blow Rate
(bpm)
BREAKER MODELS
FEATURE
CAL-3200
CAL-4500
CAL-6000
CAL-8000
CAL-11000
Operating Weight
(lbs)
2,514
3,660
4,631
5,689
8,379
Overall Length
(in)
91.7
112.0
120.0
127.2
143.7
4.92 x 47.2
5.31 x 51.2
5.51 x 55.1
5.91 x 57.1
6.89 x 66.9
3,000
3,000
3,000
3,000
3,000
210
210
210
210
210
Working Pressure
(psi)
1,849 - 2,560
1,849 - 2,560
1,849 - 2,560
1,849 - 2,560
2,133 - 2,560
Working Pressure
(kg/cm2 )
130-180
130-180
130-180
130-180
150-180
34.3 - 52.8
42.2 - 58.1
47.5 - 63.4
52.8 - 68.6
68.6 - 84.5
Blow Rate
(bpm)
400 - 700
400 - 700
350 - 650
300 - 600
270 - 500
Chisel Size
(Diameter x Length, in)
3. SAFETY
3.1
SAFETY INSTRUCTIONS
GENERAL SAFETY
Safety is the responsibility of the OPERATOR. Construction Attachments hydraulic breakers are
designed to give maximum safety, but no machine design can protect an operator from carelessness.
Read this manual carefully before attempting to operate the hydraulic breaker.
Untrained operators and failure to obey warnings can cause injury or death.
Check the rules and regulations regarding the use of this equipment at your worksite. The rules may
include an employers work safety requirements. Regulations may identify a hazard such as an
underground utility line.
For an operator to be qualified, he/she must not use drugs or alcohol that could change his/her alertness
or coordination while working. An operator who is taking prescription drugs must get medical advice to
determine if he/she can safely operate a machine.
Operational training must consist of demonstrations and verbal instruction. Your Construction
Attachments dealer can provide this training before the hydraulic breaker is placed into service.
The new operator must start in an area without bystanders and use all of the controls until he/she can
control the excavator with the hydraulic breaker safely under all conditions in the work area.
ALWAYS wear protective glasses, gloves, clothing, shoes, hearing protection and helmet when
operating breaker. This includes both the operator as well as workers in the immediate area.
ASSEMBLY/DISASSEMBLY SAFETY
When transporting the carrier unit with the breaker attached, refer to the host machines safety
regulations regarding the safe transport of this equipment.
When attaching the hydraulic breaker, use an assistant that has been instructed by the host machine
driver. All directions, signals etc. must be agreed to beforehand.
The breaker is heavy and difficult to move. Only the carrying lug provided should be used for
transporting.
The hydraulic breaker should only be attached to host machine with sufficient load capacity. If the host
machine is too light, it may become unstable under load and tip over.
OPERATIONAL SAFETY
When leaving the host machine, lower the breaker to the ground and turn the engine off.
DO NOT attach a cable or sling to the breaker to hoist a load. Doing so is extremely dangerous.
Keep all people and equipment away from the breaker during operation. Debris flying from the breaker
can cause serious injury.
DO NOT use the breaker for under water applications unless the breaker has been properly adapted for
that application.
DO NOT fire the breaker on the same spot continuously for more than (1) minute. Damage to the
internal components of the breaker can occur.
DO NOT operate the breaker with the hydraulic cylinders on the host machine fully extended.
DO NOT touch the breaker. During operation, the hydraulic oil becomes very hot.
Check the oil temperature regularly. Hydraulic oil temperature must never exceed 176 0F. If higher
temperatures are measured in the tank, an oil cooler must be installed.
At temperatures lower than -40 F, the hydraulic breaker should not be put into operation with cold
hydraulic oil as the seals in the hydraulic breaker may be damaged. Allow the engine and hydraulic
system to warm up before operating the hydraulic breaker.
Stop breaking immediately if anyone moves into the danger area, which is much larger for breaker
operation than for other operations due to the risk of flying debris.
DO NOT fire the breaker unless the breaker and host machine are in a stable working position.
Refer to the manufacturers safety regulations pertaining to the safe operation of the carrier.
Drive the tool slowly into the material being broken so it doesnt get stuck.
If equipped for underwater use, make sure the compressor is set to deliver air pressure that is
approximately 22 psi higher than the water pressure.
MAINTENANCE SAFETY
Check that there is sufficient hydraulic oil in the hydraulic reservoir and that it is not contaminated.
Check all hydraulic hose fittings and fasteners to ensure they are properly tightened.
Be careful when replacing the chisel. Internal pressure in the breaker may cause the chisel to move
suddenly.
DO NOT stand in front of the chisel when filling the accumulator or head cap with nitrogen.
BE SURE to release all of the nitrogen pressure from the system before attempting any repairs.
Removing the head cap under pressure is EXTREMELY DANGEROUS.
DO NOT charge the gas cushion chamber with anything other than nitrogen.
Only use approved hydraulic oils of the proper viscosity that are specified by the host machine
manufacturer.
Always wear protective glasses and a hard hat when replacing a chisel. Metal splinters may chip off
when the spring dowel sleeves are hammered out.
DO NOT use your fingers to check alignment of the recesses on the chisel to the slots for the retaining
bars.
STORAGE SAFETY
If not used for long periods, the breaker must be stored vertically, with the bore for the tool facing
upward. Storing the breaker on its side could deform the internal seals over time, making them
ineffective.
3.2
IMAGE CONTENT
Technical manual.
slash.
Grease gun.
Accumulator.
disassembly.
High Temperature.
SIGNS
4. BREAKER NOMENCLATURE
4.1
MAIN STRUCTURE
10
11
12
Downward stroke
1. When the piston and control valve are in the upward position, port D1 is closed off and the highpressure oil flow is re-routed though port D3. With the high-pressure oil flowing into the top side of the
hydraulic breaker, combined with the compressed nitrogen in the head, the piston is forced downward
against the chisel.
2. As the piston descends and strikes the chisel, the high-pressure in D6 becomes low-pressure while
passing through passage D7. The control valve goes down and returns to its original position with the
aid of high-pressure oil in D5. High-pressure oil is re-directed back through port D1 and the cycle
repeats itself.
When attaching the hydraulic breaker, use an assistant that has been instructed by the host machine
driver. All directions, signals etc. must be agreed to beforehand.
The hydraulic breaker should only be attached to a host machine with sufficient load capacity. If the host
machine is too light, it may become unstable under load and tip over.
Check all hydraulic hose fittings and fasteners to ensure they are properly tightened.
DO NOT touch the breaker. During operation, the hydraulic oil becomes very hot.
5.1
Disconnect the hydraulic hoses connected to the stop valve on the carrier boom.
2.
Cap off the hoses and the stop valve openings with the caps supplied in the toolbox.
3.
Place blocks underneath to support the breaker off of the ground while not in use.
4.
Remove the mounting pins that secure the breaker to the pivot linkages on the host machine.
5.
13
5.2
STORING
1. Be sure to cap off the ends of the hoses on the disconnected breaker.
2. Avoid subjecting the breaker to the weather elements while not in use. Store inside or store outside on
blocks with a suitable covering.
3. Grease the chisel thoroughly.
4. Follow these instructions to prevent the piston from rusting:
Remove the nitrogen gas from the head cap completely through the gas valve.
Using a round pole and hammer, drive the piston up into the cylinder chamber.
Apply grease to the lower bearing in the front cover. Apply grease to the chisel, then re-attach to the
front cover.
14
If the breaker is to be stored for long periods of time, it is recommended it be stored vertically. This will protect
the internal seal components from being damaged due to the weight of the piston. Secure the hydraulic breaker
during lengthy periods of non-use to ensure that it cannot fall over.
6. OPERATION
Precautionary measures should be taken to rule out the risk of accident.
6.1
Only operate the hydraulic breaker from the drivers seat in the host machine.
Close the front screen / splinter guard on the drivers cab to avoid injury from flying debris.
Wear ear protection to prevent hearing impairment. Anyone in the immediate vicinity of breaker
operations should also wear ear protection.
Switch off the hydraulic breaker immediately if any one moves into the danger zone, that is within a
radius of at least 25 feet around the hydraulic hammer. Depending on the application greater distances
may have to be observed.
PROPER OPERATION
Proper Downward Force
To break effectively, a proper download force has to be applied by the breaker. If the download force is
insufficient, the breaking energy of the piston will not be sufficient for breaking rocks. The breaking force
is then transferred to the breaker body, arm and boom of the base machine, resulting in possible damage
to those components.
15
Inversely, if the download force is excessive or the breaking is performed with the boom of the base
machine raised, the machine may suddenly tilt forward when rocks are broken. The breaker body may
violently hit against the rocks, resulting in machine damage.
Breaking under these conditions may also transmit shock loads to the carrier tracks, causing possible
damage. Take the necessary precautions to avoid these situations. Always take care when applying a
download force to the breaker. Do not break materials without the proper download force.
16
17
6.2
OPERATION PRECAUTIONS
The operator should pay attention to the following points during operation.
Stop the breaker operation immediately if the hydraulic hoses running to the breaker are observed
to be vibrating excessively.
Check to see if the high and low pressure hoses of the breaker vibrate excessively. If they do, the
accumulator may be defective. Contact your local Construction Attachments dealer in your
territory for service information.
Check for oil leakage at the hose fitting points. Retighten the fittings as necessary.
Visually inspect the breaker chisel to determine if it has sufficient chisel stroke during operation.
(See below). If the chisels movement is restricted, the tool must be seized in the front head.
Disassemble the front head, inspect the components and repair or replace any defective parts.
18
Chisel Stroke
CAL-225
1.28
CAL-450
1.61
BREAKER MODEL
CAL-550
CAL-750
1.89
1.50
CAL-1000
1.70
CAL-1200
1.77
CAL-2200
STROKE (in)
2.12
CAL-3200
2.32
BREAKER MODEL
CAL-4500 CAL-6000
2.48
2.80
CAL-8000
2.87
CAL-11000
2.95
STROKE (in)
STOPPING
As soon as material is broken, stop the oil flow to the breaker. If the breaker is allowed run while under
no load, it is considered to be dry firing. In this condition, the accumulator could be damaged, the bolts
loosened or broken and the host machine could be affected adversely.
19
20
21
22
DO NOT Operate the Host Machine with the Hydraulic Cylinders Fully Extended or Retracted
The host machine can be easily damaged when the breaker is operated with the cylinders positioned at
the end of their stroke.
If the breaker is operating in low ambient temperatures, the piston & seals could easily be damaged.
Required warm-up time for the carrier engine is from five to twenty minutes. Actuate various hydraulic
functions to ensure all hydraulic oil is circulated through system. Oil temperature must reach a
minimum of 86o F.
6.3
LUBRICATION
Hydraulic breakers require proper viscosity of hydraulic oil & grease. Refer to the chart below when
determining hydraulic oil requirements in extremely cold or hot weather conditions.
Lubricate the contact faces in the front head between the working tool and the wear bushings.
Hydraulic Oil
Grease
High Temperature
Low Temperature
ISO VG 68
(61.2-74.8 cst)
ISO VG 46
(41.4-51.6 cst)
NLGI No.2
(265-295)
No. of Pumps
5-6
7-8
10 - 11
CAL-11000
14 - 15
6.4
6.5
Note
The hydraulic breaker and host machine do not operate to full capacity until the oil temperature has reached at
least 140o F.
WARNING
Feeding hydraulic oil into an extremely cold hydraulic breaker will cause internal stresses in the unit resulting in
potential failure. If the breaker is used without preheating the hydraulic oil, the breaker seals may fracture and the
diaphragm in the high-pressure accumulator may tear. Observe the host machines manufacturers regulations
regarding operating conditions related to ambient temperature.
7. CHISEL (TOOL)
WARNING: For safety reasons, the host machine must be switched off before performing the following service.
7.1
DO NOT use your fingers to check whether the recesses on the working tool shaft are aligned to the slots
for the chisel pin.
Always wear protective glasses when fitting or removing the tool, since metal splinters may fly off when
hammering out the stopper pins.
Clean away any dirt adhering to the working tool in the insert zone.
Lubricate the contact faces in the front head between the working tool and the wear bushings.
The chisel can only be installed in one position, with the recessed area on the tool aligned with the
retaining pins in the front head.
25
CAL225 - CAL2200
CAL3200 CAL11000
7.2
Follow these guidelines to prevent damage to the chisel tool and lower bushing.
7.3
CHISEL SHAPES
26
Use only genuine Construction Attachments chisels for the hydraulic breaker. Substitute parts may not
meet the required design and safety specifications for this breaker and will void the warranty.
7.4
Continuous side pressure due to leverage, incorrect driving angle or using the breaker to pull heavy
objects.
Low temperatures that will cause the tool to be more susceptible to fatigue failure.
Overheating of the tool by friction caused by improper lubrication and excessive bending.
Excessive wear of the lower bushing allowing the piston to strike the top face of the chisel at an angle.
This will cause damage on the tool head as well as on the bottom of the piston.
27
28
8. SERVICE
8.1
WARNING
Use extreme care when disassembling the head cap: It could move suddenly due to the gas pressure in the head
cap.
Be sure to release the nitrogen gas out from the head cap completely before disassembly.
Be sure to completely tighten the through bolts with the specified torque before gas charging.
Use extreme care when disassembling the gas valve: It could be pressurized from the nitrogen gas in head
cap.
If the nitrogen gas pressure isnt released before the gas valve is disassembled, serious injury can result
from the gas valve being projected from the cylinder body due to the high gas pressure in the head cap.
Be sure to release the nitrogen gas completely out from the head cap before disassembling the gas valve.
Use caution when pressurizing the head cap. Gas pressure may cause the chisel to move suddenly.
To avoid injury, DO NOT stand in front of the chisel while servicing breaker.
29
8.2
Discharge the gas pressure using the L wrench (5mm) (from gas valve kit) after removing the gas
valve plug.
BOLTS
During long periods of use, the tie rod bolts may loosen. Check tie rod bolts regularly.
If the bolts require retightening, it is recommended they all be re-tightened together.
In case of frequent loosening, consult your dealer.
8.3
The hydraulic breaker operates with a combination of hydraulic oil & gas pressure.
WARNING
The head cap can only be filled with nitrogen. Filling with air or oxygen runs the RISK OF AN EXPLOSION!
If the gas pressure in the head cap becomes higher than the recommended gas pressure, the breaker will
get overloaded because the piston will have difficulty retracting into the head cap. If the gas pressure is
lower than the recommended gas pressure, the breakers performance will become sluggish due to the gas
pressure being unable to assist in the firing of the piston.
The gas pressure requirement could change depending on the working conditions. Maintain the proper
gas pressure while operating the breaker.
Check the head cap O-ring after charging the head cap to ensure it is maintaining the proper seal.
If the working oil from the cylinder leaks into the head cap, replace the gas seals and piston O-rings.
Check the cylinder bushings and piston for scratches.
The pressure in head cap should be set according to the chart as follows.
Gas Pressure
10 - 14
10 - 14
Accumulator (/)
55 -60
NOTE: Gas pressure should only be
checked with the chisel protruding fully from the front cover.
30
8.4
WEAR PARTS
The following items are considered wear parts that will require replacement as needed.
Chisel
Front Cover and Round Bushing
Chisel pins
Hydraulic Seals
Through Bolts
Hydraulic Hoses
SEALS: Replace hydraulic seals every (500) hours of actual operation or when kept over (6) months in storage.
CHISEL PINS: When each chisel pin is excessively deformed, it is difficult to replace the chisel. Therefore,
every (100) to (150) hours of operation, change the face of each pin that comes in contact with
the chisel. Both faces of each pin can be used.
Always use genuine Construction Attachments parts. Substitute parts may not meet the design criteria and
may cause the breaker to be dangerous. Substitute parts will also void the breaker warranty.
8.5
FRONT COVER
CAL225 CAL750
CAL1000 CAL3200
CAL4500 CAL8000
CAL11000
mm
10
12
Inch
0.230
0.315
0.394
0.472
Wear Limit
8.6
WORKING PRESSURE
The hydraulic breaker is designed to work in conjunction with the working hydraulic oil pressure supplied by the
auxiliary hydraulic pump of the host machine. An additional relief valve on the incoming high-pressure line to
the breaker is not required.
If the oil pressure supplied by the host machine is greater than the breakers recommended oil pressure range, the
breaker will produce a higher energy impact that may damage the breaker and host machine.
RELIEF VALVE
SETTING
Kg/cm 2
PSI
8.7
BREAKER MODELS
CAL-225 thru CAL-1200
175
210
2,500
3,000
OIL TEMPERATURE
The oil temperature is different according to working condition, but it is usually 122 - 176o F. If the breaker
operates with oil temperatures over 176o F for extended periods of time, internal damage to the seals and
accumulator (if equipped) will occur.
Use caution to avoid oil temperature increases due to the following:
8.8
Continuous breaking at the same point for over (1) minute intervals.
Increasing engine speed does not necessarily increase the breakers blow rate. However, an increase an
engine speed will cause additional hydraulic oil to be forced over the relief valve. This condition will
cause an oil temperature increase. Set engine throttle at the position that will deliver the recommended
amount of hydraulic oil to the breaker.
Keep all hydraulic oil cooling elements clean and in proper working condition.
32
Replace the accumulator if the high-pressure line vibrates erratically. When replacing the accumulator, replace
the O-ring and back up ring at the same time. Inspect the exhaust port under the accumulator for scratches. If
scratches are present, clean the inside of breaker. After replacement and inspection, torque the socket bolts that
secure the accumulator to the proper values.
8.9
OIL LEAKAGE
Check for oil leakage at all connections. A little oil leakage between the chisel and front cover is acceptable as it
helps lubricate the chisel. If excessive oil leakage is observed, check and replace the seals. When installing seals,
apply hydraulic oil to the seal kit and the seal grooves.
Inspect seals for any physical damage. Make sure seals are properly seated after installation.
If a seal gets damaged during installation, remove and replace it with a good seal. Do not place the
breaker back into service with a defective seal.
When seals get damaged, they become ineffective in their ability to prevent oil leakage. If seals are
replaced and the breaker still leaks oil, consult your local Construction Attachments dealer.
8.10
Contaminated hydraulic oil will cause damage to the control valve and reduce the performance of the breaker.
Contaminated oil will also damage the internal components to the host machines hydraulic pumps. Keep the
hydraulic oil clean. Replace the hydraulic filter on the host machine every (100) hours and the hydraulic oil every
(600) hours.
When installing the breaker on older host machines, it is highly recommended to replace the hydraulic oil and
filter prior to placing the breaker into service.
8.11
5. Be sure to tighten the release valve (7) of the gas-charging valve (4).
6. Slowly open the valve (9) of gas bottle (10). Note that a high volume of gas entering the head cap quickly
could damage the pressure gauge. Open gas bottle slowly.
7. When the pressure gauge (5) shows 10% above the desired pressure, close the valve (9) on the gas bottle
(10).
8. Allow the breaker to sit for (5) minutes. This will allow the nitrogen to stabilize in the head cap. Re-check
the pressure on the pressure gauge (5) while keeping the button (6) of gas charging- valve pushed down.
9. If the pressure is lower than desired, add more gas. If the pressure is higher than desired, open the release
(7) valve slowly and release the gas until the desired pressure is achieved. Be sure to keep the button (6) of
gas charging-valve pushed down.
10. Open the release valve (7) only to release any remaining gas in the gas charging-valve after pulling the
button (6) of gas-charging valve (4) up.
11. Disconnect gas-charging valve (4) from the gas valve (2) of the head cap.
12. Install the plug (3) to gas valve (2). Check for leakage around the gas valve (2).
After use, replace the cap on the gas bottle to avoid damage to the valve on the gas bottle. Check to ensure
the gas valve is properly attached to the gas bottle. Do not expose the gas bottle to direct sunlight for
extended periods of time.
8.12
After use, replace the cap on the gas bottle to avoid damage to the valve on the gas bottle. Check to ensure
the gas valve is properly attached to the gas bottle. Do not expose the gas bottle to direct sunlight for
extended periods of time.
32
35
8.13
Before checking head cap pressure, note if the breakers impact power is low or irregular. Also note whether
the breaker has been operated at a high oil temperature.
1. Remove the plug (3) out of the gas valve (2) on the head cap using the "L" wrench (5mm).
2. Connect gas-charging valve (4) to the gas valve (2).
3. Be sure to tighten the release valve (7) of the gas-charging valve (4).
4. Check the pressure on pressure gauge (5) while keeping the button (6) of gas-charging valve pushed down.
5. If the gas pressure is lower than desired, pull the button (6) up. Open the release valve (7) to release any
remaining gas in the gas charging-valve (4). Re-tighten release valve (7). Use procedure from Section
8.11 for proper filling instructions.
6. If the gas pressure is higher than desired, slowly open the release valve (7) with the button (6) of the gascharging valve depressed until the gas pressure is reduced to the desired pressure.
7. With the gas pressure adjusted, pull the button (6) of gas-charging valve (4) up. Slowly open the release
valve (7) to remove any gas from the gas-charging valve.
8. Disconnect the gas-charging valve (4) from the gas valve (2) in the head cap.
9. Install the plug (3) in to the gas valve (2). Check for gas leakage around the gas valve (2).
36
8.14
1. Check the high-pressure line attached to the breaker to determine if the line vibrates erratically.
2. Remove the plug (3) out of gas valve (2) on head cap using the "L" wrench (5mm).
3. Connect the gas-charging valve (4) to the valve of Accumulator cover (1).
4. Be sure to tighten the release valve (7) of the gas-charging valve (4).
5. Open the adjuster (2) on the accumulator cover (1).
6. Check the pressure on the pressure gauge (5) while keeping the button (6) pushed down.
7. If the gas pressure is lower than desired, pull the button (6) up. Open the release valve (7) to release any
remaining gas in the gas charging-valve (4). Re-tighten release valve (7). Use procedure from Section
8.12 for proper filling instructions.
8. If the gas pressure is higher than desired, slowly open the release valve (7) with the button (6) of the gascharging valve depressed until the gas pressure is reduced to the desired pressure.
9. With the gas pressure adjusted, pull the button (6) of gas-charging valve (4) up. Slowly open the release
valve (7) to remove any gas from the gas-charging valve
10. Lock the adjuster (2) to the accumulator cover (1).
11. Disconnect the gas-charging valve (4) from the gas valve (2) in the accumulator cover (1).
12. Install the plug (3) in to the gas valve (1). Check for gas leakage around the accumulator cover (1).
37
9.
9.1
33
38
The hydraulic breaker is not self-powered. It makes use of hydraulic power systems of the host machines it is
mounted on, such as excavators, mini-excavators, backhoe loaders, skid steers etc. To enable host machines to
operate with these attachments, the hydraulic power system has to be converted accordingly.
Hydraulic breakers require a proper oil flow and pump pressure. Breakers have a required pressure relief setting
needed to operate properly and ensure the host machines hydraulic components are not damaged. The chart
below shows the required pressure relief setting that is 10kg/cm2 less than the host machines main relief pressure.
9.2
CAL225 CAL1200:
CAL2200 CAL11000:
INSTALLATION PRECAUTIONS
When the bucket and breaker operation are performed alternately, the hydraulic breaker is connected to the host
machine with the two mounting pins, allowing the bucket and breaker to be easily interchanged with each other.
However, as the hydraulic circuit is easily apt to be damaged by contamination, remove and install the breaker in
the following procedures with care.
1. Select a level work site that is free from mud, dust and other contaminants.
2. Move the host machine into position. Stop the engine and turn off the key. The hydraulic tank on the host
machine may be pressurized. Bleed any pressurized air from the oil tank. With the host machine positioned
as shown in the picture; the breaker and bucket are positioned for easy replacement.
CAUTION
The stop valve must be closed before the breaker can be removed from the excavator.
39
9.3
HYDRAULIC SYSTEM
Pressure Pulse
The average operating pressure of the pump at
the breaker input line must be much less than
that of the compensating pressure. This prevents
abrasion of the regulator and swash plate
supporter of pump.
40
9.5
(CAL750 CAL3200)
(CAL4500 CAL11000)
41
The blow rate of the breaker can be adjusted by doing the following procedure.
1.
2.
3.
4.
CAUTION
The maximum adjustment to the blow rate is accomplished in (1) counter clockwise rotation. DO NOT adjust the
blow adjuster past (1) rotation. One eighth of a turn to the blow adjuster will change the blow rate by 10-15 bpm.
Use caution so that the blow rate matches the work being done.
9.6
1. The following hydraulic components of the host machine are used during the operation of the breaker.
2. The following hydraulic components have to be installed in order to complete the circuit to the breaker.
Hydraulic control valve (when a spare valve is not available in control valve bank of a host machine.)
Control pedal or lever (for breaker control)
High pressure pipe lines (for supply of high pressure oil to breaker)
Low pressure pipe lines (for return of low pressure oil to hydraulic oil tank)
Stop valve (For shutting off oil lines when the breaker is replaced with bucket etc.)
CAUTION
If excavator has a suitable hydraulic system, check the width of the hydraulic lines to determine flow
capacity.
Check the connections on the hydraulic breaker and the breaker hoses.
The connecting threads must be undamaged and free of sand or similar foreign bodies.
Check to be sure the pressure relief valve on the hydraulic system has been approved by the host machine
manufacturer.
Ensure that the pressure relief valve has been set correctly, i.e. to the maximum permissible operating
pressure of the hydraulic breaker. (Operating pressure + 435 psi (30.6 kg/cm2) min)
DO NOT touch the breaker. During operation, the hydraulic oil becomes very hot.
As the hydraulic circuit varies with the host machine, hydraulic pressure, oil capacity, pressure loss, etc.
of the host machine must be verified before the breaker is placed into service. Do not guess or assume
written specifications are accurate. Use as flow meter and hydraulic pressure gauge.
As the hydraulic pipe lines (hoses, pipes and fittings) are made of materials carefully selected in
consideration of durability, use only genuine replacement parts.
10.1
DISASSEMBLING
5. Disassemble the cylinder body from the front cover using the eyebolt provided along with a hoist or chain
block. Slide cylinder body in the direction indicated by the arrow in the picture below.
6. Position the cylinder body in a vertical position. Attach the eyebolt to the piston and remove the piston from
the cylinder body using a hoist or chain block as shown in the picture below.
7. Remove the through bolts from the front cover with a stander spanner.
44
(CAL-225 CAL2200)
(CAL3200 CAL11000)
8. Remove seals & o-rings
Using a screw driver, carefully remove the dust seal, u-packing, buffer ring, step seal, and gas seal from
the lower area of the cylinder and cylinder bushing.
WARNING
Excessive kinking of seals and o-rings will cause cracks and subsequent hydraulic failure.
CAUTION
Once seals and O-rings are removed, they should not be used again.
Make sure all seals are properly orientated before seating them into piston groove. Seals installed
improperly will leak.
MODEL
CYLINDER
CYLINDER BUSH
45
DESCRIPTION
CAL-225
CAL-450
Dust Seal
CAL-550
U-Packing
CAL-750
CAL-2200
CAL-3200
Step Seal
CAL-1000
CAL-1200
CAL-4500
CAL-6000
CAL-8000
CAL-11000
The part numbers & shape of seals & o-rings differ from each model. Refer to part lists for specific seal kit
information.
10.2
INSPECTION
1. Seals
While seals are still in there original position, check for scratches and deformation. Do not remove to check.
Even a small scratch will lead to oil leakage.
Damaged Seals
Replace the hydraulic seals every (500) hours of actual operation or when kept over (6) months in storage.
2. Control Valve
46
Inspect the valve for signs of seizure or scuffing. If marks left by the seizure are even small, polish them out
by using the fine oilstone or sand paper (#1000~1200). The corresponding marks on the valve bushing or
valve cap should be removed in the same manner.
If seizures or scratches are excessive, replace immediately with a new control valve assembly.
3. Piston
Periodically the lower end of piston must be checked for deformation.
Check piston for seizure marks and scuffing. If such marks appear on the surface, remove by polishing with an
oilstone or sand paper (#1000~1200). Corresponding marks on the mating parts should also be treated in the
same manner.
10.3
ASSEMBLING
2. Disassemble the worn front cover and lower bushing. There are several methods to effectively remove
lower bushing.
WARNING: Wear Safety Approved Eye Protection.
A. Remove the bushings using oxy-arc cutting. This requires a skilled worker. DO NOT allow the front
head from being overheated.
B. Press out the bushings with the appropriately sized pin as shown in the picture below.
This work can only be performed in a well-equipped workshop with a hydraulic press rated at 200 tons
or more capacity.
48
C. If no oxy-arc cutting & press are available to remove the bushings, the following procedure is possible.
Apply thick axial or radial welding beads inside the worn lower bushing using an electrode welder.
Upon cooling the lower bushing will contract and loosen in its seat.
3. Before fitting the round bushing into the front cover, heat the bore area in the front cover to make the bore
expand. Freeze the bushings in liquid nitrogen (N2) to make then shrink and be undersized for assembly.
CAUTION
Do not allow overheating of the front cover bore area. It can become weak.
4. Keep the contact surfaces clean during assembly. Press bushing evenly into front cover bore. Check to be
sure bushing is fully seated into bore.
49
6. General assembly
A. Attach the through-bolts to the front cover.
B. Replace the seals in the cylinder seal and lower bushing area.
C. Slide the piston into cylinder body after lubricating the piston and cylinder thoroughly.
D. Slide the cylinder bushing onto the piston as shown picture using a rubber hammer.
50
E. Apply approximately 150-250 cc of hydraulic oil to the inside of the head cap.
F. Connect the cylinder body, front cover and head cap together with through-bolts. Tighten the nuts on the
through-bolts to their specified torque.
G. Fill the cylinder body with hydraulic oil through the ports on the cylinder body.
H. Tighten the hose adapters to the inlet and exhaust ports on the cylinder body.
I. Install and tighten the gas valve to its specified torque.
J. Pressurize the head cap with nitrogen gas.
K. Install the bulkhead cap to complete assembly.
Push the spring pin back into the hole in the cylinder body. Using a punch, push out
the retaining pin to release the chisel.
CAL3200 CAL11000: Knock the stopper pins & rubber plugs out of the cylinder body. Using a hammer
and punch, drive the retaining pins out to release the chisel.
Replace the new chisel after removed.
NOTE: The chisel is heavy. Use caution when installing or removing chisel.
51
10.4
Model
Weight
(lbs)
Eye Bolt
CAL-225
121
M10
330
CAL-450
143
M10
330
CAL-550
257
M10
330
CAL-750
334
M12
484
CAL-1000
572
M16
990
CAL-1200
572
M16
990
CAL-2200
999
M20
1,386
CAL-3200
1,379
M24
2,090
CAL-4500
1,929
M24
2,090
CAL-6000
2,640
M30
3,300
CAL-8000
2,860
M30
3,300
CAL-11000
3,520
M36
5,060
REPAIRING PARTS
When correcting imperfections on sliding surfaces, finish surfaces as smooth as possible. Use an oilstone, emery
paper or flex hone. Keep in mind that overworking may cause parts to malfunction.
Operating Method
Rough Finish
Finish
52
Oilstone
Fine Grain
Emery Paper
#400, #600
1. Cylinder bushing
When using a buffing grindstone, move the grinder in the correct direction relative to the circumference. If the
grinder is led straight ahead, circularity of the bore will be ruined. Wash the parts thoroughly after grinding
operation.
2. Cylinder
Imperfections on the sliding surface may cause malfunction or oil leakage of the cylinder. Correct imperfections
to machined parts at an early stage, using an oilstone and emery paper.
Kind of Fault
Condition
Remedy
Vertical
Scratch
If burrs stick out above labyrinth grooves,
A striped fault running in the sliding remove burrs and correct vertical faults with
direction of the blow piston.
oil stone and/ or emery paper.
Galling
A localized fault that is wider than the Finish galling with an oil stone until no step
vertical scratch and is caused by sliding exists on the outer surface and then finish
motion.
with fine emery paper.
Chipping
Corner of sliding section is chipped.
Vermin
A vermin-like fault caused by cavitations A vermin causes galling if left uncorrected.
located at the corner of a sliding part.
Remove it with an air grinder and finish it
smoothly with an oilstone.
54
3. Piston
Correct faults at an early stage, using an oilstone and emery paper.
55
Kind of Fault
Condition
Remedy
Vertical
Scratch
Scratch in
labyrinth
grooves
Correct scratches at an early stage as Removes burrs sticking above labyrinth
scratches in this area may develop into a grooves and finish edges to remedy vertical
fatal failure of the cylinder.
scratches.
Reparation of
vertical
scratch
and/ or
rust pit
56
57
11.
DAILY MAINTENANCE
WEEKLY MAINTENANCE
MONTHLY MAINTENANCE
AS REQUIRED
MALFUNCTIONS
Prerequisites for the normal operation and long life of the Construction Attachment Hydraulic Breaker:
Supply of accurate rates (Pressure P and flow rate Q) to hydraulic breaker of this series.
Use of clean hydraulic oil.
Proper operation as described in the operators manual.
If the hydraulic breaker is not working correctly, check the hydraulic system of the host machine thoroughly
before making any repairs to the breaker. Hydraulic breaker problems can be affected by a hydraulic system that
is not operating to specifications or such problems as a plugged oil filter or hydraulic filter in the host machine.
Connect a flow meter to the host machine to check the hydraulic pump output, relief valve setting and tube lines
to check flow and pressure.
59
The following trouble shooting guide has been prepared to address common issues relating to the operation and
performance of the hydraulic breaker.
Conditions
Breaker does not work
Causes
Countermeasures
radiation
of
base Have
check.
Have
check.
excavator
manufacturer
excavator
manufacturer
Clogged piping.
Required flushing.
60
Conditions
Causes
Countermeasure
down
pressure
Check power.
on
Proper instructions.
Clogged piping.
Seizure of breaker.
Filling up of hydraulic oil in head Replace gas seal and check the
cap.
piston.
Lack of hydraulic oil.
Refill oil.
Check power.
Clogged piping.
Breakage of chisel
Lack of grease.
Proper instruction.
Check power.
Insufficient
chisel.
down
pressure
on
Proper instructions.
Insufficient
chisel.
down
pressure
on
Proper instructions.
Proper instructions.
12.2
OIL LEAKAGE
Even if oil leaks, there may not be cause for maintenance. Check the following points listed below.
The operator can check for possible remedies before contacting dealer.
Area of Oil Leakage
Conditions
Upper part
Oil leaking from hose adapter Loose breaker hoses and adapter.
portion.
Replace.
Oil leakage from reassembly of Check that O-ring is damaged.
Valve after overhaul.
Replace.
Oil leakage
Oil leakage
62
12.3
Major causes
Remedies
Lack of impact
excavator
manufacturer
13.
TORQUE
Before starting work, check all the bolts for proper tightness. Retighten loose bolts to the specified torque
referred to in the manual. The tightening torque of each bolt is as follows.
13.1
THROUGH BOLTS
BREAKER MODELS
FEATURE
CAL-225
CAL-450
CAL-550
CAL-750
CAL-1000
CAL-1200
TORQUE (ft-lbs)
326
326
326
362
724
724
TORQUE (kg-m)
45
45
45
50
100
100
BREAKER MODELS
FEATURE
CAL-2200
CAL-3200
CAL-4500
CAL-6000
CAL-8000
CAL-11000
TORQUE (ft-lbs)
941
1,085
1,809
2,315
2,605
2,605
TORQUE (kg-m)
130
150
250
320
360
360
64
13.2
CAL-225
CAL-450
CAL-550
CAL-750
CAL-1000
CAL-1200
TORQUE (ft-lbs)
31
31
80
80
152
152
TORQUE (kg-m)
4.3
4.3
11
11
21
21
BREAKER MODELS
FEATURE
CAL-2200
CAL-3200
CAL-4500
CAL-6000
CAL-8000
CAL-11000
TORQUE (ft-lbs)
210
391
528
926
926
1,201
TORQUE (kg-m)
29
54
73
128
128
166
CAL-6000
CAL-8000
CAL-11000
TORQUE (ft-lbs)
1,281
1,281
1,281
TORQUE (kg-m)
177
177
177
65
13.4
CAL-6000
CAL-8000
CAL-11000
TORQUE (ft-lbs)
333
333
333
TORQUE (kg-m)
46
46
46
13.5
MODELS
THROUGH
BOLTS
BULK CAPS
SIDE BOLTS
CAL-225
27
19
27
CAL-450
27
19
27
CAL-550
36
24
32
CAL-750
36
24
32
CAL-1000
46
30
41
CAL-1200
46
30
41
CAL-2200
50
32
46
CAL-3200
60
41
60
CAL-4500
65
46
65
CAL-6000
70
55
CAL-8000
80
CAL-11000
90
ACC BODIES
ACC COVERS
70
22(L)
17(L)
55
70
22(L)
17(L)
56
NON
22(L)
17(L)
Remark; L L Wrench
66
If the excavator is replaced during warranty time with another, the installation to the excavator must be
inspected and approved and corresponding information must be sent to Construction Attachments.
No warranty claims will be handled before the warranty registration card is received by Construction
Attachments.
Distribution
1st copy A Construction Attachments
2nd copy B Dealer
3rd copy C Customer
NOTE: You will receive prompter service after completing and returning your registration card.
67
SERIAL NUMBER
PRESSURE
KG/CM2
LOCATION OF DELIVERY
DATE OF DELIVERY
DATE OF INSPECTION
/
2. ACCESSORIES
NO
ACCESSORIES
NO
ACCESSORIES
BREAKER TOOL
YES, NO
MAINTENANCE TOOLS
YES, NO
YES, NO
TOOL BOX
YES, NO
GAS BOTTLE
YES, NO
OPERATION MANUAL
YES, NO
YES, NO
OIL COOLER
4. WARRANTY
DATE OF START
/
/
TON
MAX. OUTPUT OF
PUMPS
SUPPLYING
L/MIN
OPERATING PRESSURE
MAIN
RELIEF
PRESSURE
TOTAL WEIGHT
SET
L/MIN
NO
DATE OF EXPIRY
/
/
OIL FILTER
HOURS OF EXPIRY
KG/CM2
YES
REMARKS
SIGNATURE
NAME
DATE:
68
NO
CUSTOMER ADDRESS
DISTRIBUTOR NAME
DATE OF FAILURE
/
/ 200
LOCATION OF PRODUCT
/ 200
PERIOD OF WARRANTY
/ 200
/ 200
/ 200
MODEL
MFG. YEAR
/
L/MIN
OPERATING HOURS
OPERATING PRESSURE
KG/CM
CAL
(S/N;
OIL FLOW
)
ND
KG/CM2
ACC GAS PRESSURE
KG/CM2
L/MIN
KG/CM2
4. FAILURE INFORMATION
OUTLINE :
CAUSE :
ATTACHED
PHOTOS
ATTACHED
PART NO
QTY
PART NAME
69
PART NO
QTY
DATE OF CLAIM
SIGNATURE
Cylinder
Head Cap
Front Head
Piston
Control Valve Assembly
Cylinder Bushing
Bracket Body
Accumulator Body & Cover
WARRANTY EXCEPTIONS
The warranty shall not apply in the following circumstances, even if within the above warranty period.
1. The damages caused by excessive blank hammering
2. Any scratches on piston, cylinder & control valve that results in using contaminated hydraulic oil coming from
the host machine.
3. Damage resulting from the poor working performance of an old host machine.
4. Damage caused by improper storage of the breakers in wet conditions for an extended period of time. The
breaker has to be inspected before placing back into service after being stored for a period of longer than (2)
weeks.
5. Wear parts are excluded from warranty period.
6. A/S expenses such transportations, meals etc to be paid by dealer.
WEAR PARTS WARRANTY
The warranty period is (6) months for the following wear parts:
70
NOTE
Warranty is not applied to any damages or defects incurred through the misuse of this attachment as described in
this manual. Parts that are deemed as normal Wear Parts are not included into warranty
Seal Kits
Gas Bottles
Chisel Pin
Stop Pin
CHISEL WARRANTY
The chisel is guaranteed from defects in material and workmanship as described in the chisel warranty as
described in the operators manual.
All delivered products will be checked for defects, damages or missing parts to assure performance upon arrival.
The dealer has to inform Construction Attachments Inc. with a written claim on any missing or damaged parts
within (14) days after receipt of products.
Construction Attachments Inc. will not warrant any damage that is occurred by improper or careless handling,
excessive stress, normal wear and tear or similar cases not due to faults of Construction Attachments Inc.
(Please refer to the exception of warranty)
The dealer will keep the damaged products for a maximum period of (1) year for inspection and analysis by
Construction Attachments Inc.
Reimbursement will be carried out within (15) days after warranty has been granted.
71