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CONSTRUCTION ATTACHMENTS, INC.

TRUCTIO
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TRUCTIO
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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

(REV: 21 APR, 2003)

1. SERVICE WARRANTY REGISTRATION CARD.

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

5. REMOVAL & INSTALLATION of HYDRAULIC BREAKER


5.1
5.2

Removal of Hydraulic Breaker


Storing

6. OPERATION
6.1
6.2
6.2
6.4
6.5

24

Replacement of The Chisel


Essential Points in Use
Chisel Shapes
Cause of Tool Damage

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

Proper Way of Operation


Precaution for Operation
Lubrication
Working in High-Temperature Conditions
Working in Low-Temperature Conditions

7. CHISEL
7.1
7.2
7.3
7.4

13

Inspection & Maintenance


Bolts
Gas Pressure and Charging Nitrogen Gas
Wear Parts
Front Cover
Working Pressure
Oil Temperature
Accumulator
Oil Leakage
Oil Contamination
Charging The Gas in the Head Cap
Charging The Gas in the Accumulator
2

28

8.13 Checking The Gas Pressure in the Head Cap


8.13 Checking The Gas Pressure in the Accumulator
9. INSTALLATION of HYDRAULIC BREAKER
9.1
9.2
9.3
9.4
9.5
9.6

General View of Breaker Installed to Base Machine


Precautions During Installation
Hydraulic System
Proper Input Oil Flow
Adjusting Impact Blow Rate
Hydraulic Pipe Lines and Controls

10. DISASSEMBLY & REASSEMBLY


10.1
10.2
10.3
10.4

36

41

Dissembling
Assembling
Inspection
Repairing Parts

11. MAINTENANCE PERFORMED by The OPERATOR.

54

12. TROUBLE SHOOTING..

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

14. COMPLETING the SERVICE WARRANTY REGISTRATION & SUBMITTING


WARRANTY CLAIMS .

66

15. WARRANTY POLICY

69

1. SERVICE WARRANTY REGISTRATION CARD


The SERVICE WARRANTY REGISTRATION CARD must be completed by the dealer and signed by the
owner when the hydraulic breaker is delivered. A copy of the form must be given to the owner. Make sure it is
filled out completely.
Write the correct information for your Construction Attachments Hydraulic Breaker in spaces below:
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 use
a different procedure in doing a specific service operation.
Hydraulic Breaker:
Model
Serial Number

Hydraulic Breaker Dealer:


Name

____________________________

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

Pressure Relief Setting


(psi)

2,500

2,500

2,500

2,500

2,500

2,500

3,000

Pressure Relief Setting


(kg/cm2 )

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

Oil Flow Requirement


(gpm)

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)

140-200 psi (10-14 kg/cm2 )

Head Cap Nitrogen Pressure

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

Pressure Relief Setting


(psi)

3,000

3,000

3,000

3,000

3,000

Pressure Relief Setting


(kg/cm2 )

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

Oil Flow Requirement


(gpm)

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)

140-200 psi (10-14 kg/cm2 )

Head Cap Nitrogen Pressure


Accumulator Gas Pressure

780 - 850 psi (55-60 kg/cm2 )

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.

Safe operation requires a qualified operator.

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.

Do not touch any parts when the boom is moving.

Never use your fingers to check for hole alignment.

Collect any oil that leaks out and dispose of it properly.

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.

Remove the chisel before transporting the breaker.

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.

DO NOT use the breaker to lift or transport loads.

DO NOT use the breaker as a prying or chopping tool.


7

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.

Check the pressure relief valve on the hydraulic system.

Do not run any hydraulic lines through the drivers cab.

Grease the shank part of the chisel.

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

MACHINE SIGNS (DECALS)


REFERENCE

IMAGE CONTENT

Hearing protection must be worn.

Head wearing ear protection.

Consult manual for proper service


procedures.

Technical manual.

Keep away from breaking area

A working breaker with diagonal

while the breaker works.

slash.

Inject grease into the hole with


grease gun periodically.

Grease gun.

"HIGH PRESSURE" gas is present


that must be relieved prior to

Accumulator.

disassembly.

Keep away as the temperature of


the breaker is "HOT".

High Temperature.

SIGNS

Limit the time the breaker is


allowed to fire continuously.

Clock and Thermometer.

4. BREAKER NOMENCLATURE
4.1

MAIN STRUCTURE

CAL-225 thru CAL-3200

The hydraulic breaker consists of five main sections. This


includes the Cylinder, Piston, Control Valve, Front Head
and Head Cap.
1. The cylinder contains the piston and control valve.
2. Four through-bolts are assembled and hold the cylinder,
head cap and front head together.
3. The piston strikes the chisel with a combination of oil
and gas pressure.
4. The control valve is located inside of the cylinder and is
used to regulate the piston movement.
5. The chisel pin is located inside the front head and is
used to stop the chisel from coming out.
6. The head cap has pressurized nitrogen gas inside of it.

10

CAL-4500 thru CAL-11000

11

4-2. PRINCIPLES OF OPERATION

Elevating Strokes (Low Speed)


1. Operate the pedal and lever in the cab to supply the high-pressure oil into the hydraulic breaker.
2. The high-pressure oil enters the lower port D1 through passage D8 and forces the piston D2 to move up
and compress the nitrogen gas in chamber D4.
3. The high-pressure oil that flowed into passage D8 also makes to the control valve moves upward.

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.

5. REMOVAL & INSTALLATION OF THE HYDRAULIC BREAKER


WARNING

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.

Do not touch any parts when the boom is moving.

Collect any oil that leaks out and dispose of it properly.

Check the pressure relief valve on the hydraulic system.

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.

Never use your fingers to check for hole alignment.

5.1

REMOVAL OF THE HYDRAULIC BREAKER


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.

Slowly move host machine away from disconnected breaker.

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 chisel from the front cover.

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.

Release any residual gas pressure out of the head cap.

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

Direction of Downward Force


Apply a download force in a perpendicular plane to the work piece. If the work piece is odd-shaped, the
tool may slip during operation, causing the chisel and piston to break, or seize up. When breaking, select
the point on the work piece that will allow the breaker to perform in a stable manner.

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

DO NOT Use Breaker to Move Rocks.


As shown in the picture, do not use the breaker to move rocks. Damage to the breaker and the
components on the host machine could occur.

DO NOT Use the Breaker as a Lever


Never use the hydraulic breaker as a crowbar, as this will cause the working tool to break.

20

DO NOT Operate Breaker for Periods Longer than (1) Minute


In hard conditions, do not operate breaker for longer than (1) minute. Frequently move the chisel point
to different points on the material being broken. Continuous breaking in one location raises the
hydraulic oil temperature of the system to where internal components could be damaged. Also, the heat
generated to the tip of the chisel could cause premature and excessive wear.
On a Hard, Large Rock, Start Breaking at the End Point
Beginning to break at a crack or at the end will enable even a big rock to be broken comparatively easily.
Advancing in large steps will not improve working results. Advancing in small steps is more effective.

Operate the Breaker at a Proper Engine Speed


Break rocks at the specified engine speed. Raising the engine speed more than necessary does not
increase the hammering force but raises the hydraulic oil temperature that could result in damage to the
internal components of the breaker and host machine.

21

DO NOT use Breaker in Water or Mud Without Prior Conversion


If water were to penetrate the percussion chamber, each blow would create a pressure wave. These
pressure waves would cause irreparable damage to the stripper and seals on the hydraulic breaker. In
addition, the piston would rust. Water could also penetrate the carriers hydraulic system.
In order to avoid damage to the hydraulic breaker, a special kit is available for under water applications.

DO NOT Use the Breaker as a Sledgehammer


Before breaking material, always rest the breaker against the work piece. Never attempt to use the
breaker and excavator boom as a sledgehammer to break material. This will cause extensive damage to
the breaker and the host machine.

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.

DO NOT Use the Breaker for Transport or Lift Purposes


The hydraulic breaker is not designed to lift or transport loads. The breaker may be damaged and the
load being carried would be very unstable and dangerous.

Hydraulic Oil Warm-up Period Required


23

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)

Grease Gun Application


Model

No. of Pumps

CAL-225 thru CAL-1200

5-6

CAL-2200 thru CAL-4500

7-8

CAL-6000 thru CAL-8000

10 - 11

CAL-11000

14 - 15

6.4

WORKING IN HIGH-TEMPERATURE CONDITIONS


The temperature of the hydraulic oil must be monitored to ensure it does not exceed 176o F. If higher
temperatures are measured in the tank, an oil cooler must be fitted. Only use hydraulic oils of sufficient
viscosity. In summer and tropical climates, the minimum requirement is a hydraulic oil type HLP 68.

6.5

WORKING IN LOW-TEMPERATURE CONDITIONS


When ambient temperatures dont fall below -4o F, there are no special regulations, but the hydraulic oil
must be warmed up before operating. This is achieved by
Starting up the host machine motor.
Actuating the hydraulic circuits.
This raises the oil temperature. Once it has risen above 32o F, the hydraulic breaker can be operated.
Leave the motor and the pumps of the host machine running during breaker operation.
24

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.

REPLACEMENT OF THE CHISEL


1. CAL225 CAL2200: Push the spring pin back into the hole. Push retaining pin out with a punch to
release the tool.
2. CAL3200 CAL11000: Knock out the stopper pin & rubber plug from the front head. Drive out the
retaining pins with a punch to release the tool.
3. Replace with a new chisel. Use reverse procedure for re-installing retaining pins. The chisel is heavy, so
use extra caution when handling the tool.

25

CAL225 - CAL2200

CAL3200 CAL11000

7.2

ESSENTIAL POINTS IN USE

Follow these guidelines to prevent damage to the chisel tool and lower bushing.

7.3

Avoid improper lifting, twisting and hitting of the chisel tool.


Avoid allowing the breaker from getting wet due to outdoor storage.
Avoid injury from improper handling or installation of the tool chisel.
Avoid excessive heat to the chisel tool.

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

CAUSE OF TOOL DAMAGE

Continuous side pressure due to leverage, incorrect driving angle or using the breaker to pull heavy
objects.

Dry firing which leads to damage on the chisel pin.

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

INSPECTION & MAINTENANCE

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

GAS PRESSURE AND NITROGEN GAS CHARGING

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

CAL225 CAL4500 CAL6000 CAL11000

Head Cap (/)

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

Limit the amount of wear between the


chisel and front cover:
When the clearance between the chisel and
holder bushing becomes large, it is
strongly recommended to replace these
parts to prevent damage and reduced
breaker performance. Exceeding the
following wear allowances may damage
31

other component parts, such as the piston


and cylinder.
Model

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

CAL-2200 thru CAL-11000

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.

ACCUMULATOR (CAL4500 CAL11000)

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.

Check the Following When Replacing Seals.

Inspect seals for any physical damage. Make sure seals are properly seated after installation.

Only service the breaker in a clean working environment.

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

CONTAMINATION OF WORKING OIL

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

CHARGING THE GAS IN THE HEAD CAP

1. Remove the chisel from the front cover.


2. Connect hose (8) to the gas bottle (10).
3. Remove the plug (3) from the gas valve (2) on head cap using the "L" wrench (5mm).
4. Connect the gas-charging valve (4) to the gas valve (2).
33

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

CHARGING THE GAS IN THE ACCUMULATOR

1. Connect hose (8) to the gas bottle (10).


2. Remove the plug (3) from the gas valve (2) with "L" wrench (5mm).
34

3. Connect gas-charging valve (4) to the accumulator gas valve (1).


4. Open the adjuster (2) on the accumulator cover (1).
5. Be sure to tighten the release valve (7) of the gas-charging valve (4).
6. Open the valve (9) of gas bottle (10) slowly. Note that a high volume of gas entering the accumulator
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. Lock the adjuster (2) to the accumulator cover (1).
11. 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.
12. Disconnect the gas-charging valve (4) from the gas valve of the accumulator cover (1).
13. Install the plug (3) to the gas valve in the accumulator cover (1). 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.

32
35

8.13

CHECKING THE GAS PRESSURE IN THE HEAD CAP

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

CHECKING THE GAS PRESSURE IN THE ACCUMULATOR

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.

INSTALLATION OF THE HYDRAULIC BREAKER

9.1

GENERAL VIEW OF BREAKER INSTALLED TO BASE MACHINE

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:

2,500 psi (175 kg/cm2)


3,000 psi (210 kg/cm2)

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

9.4 PROPER INPUT OIL FLOW


To energize the breaker will require either a flow divider valve or a flow control valve in order to control the
output oil flow from the host machines hydraulic pump. High-pressure flow from the host machine determines
the blow rate of the breaker. The valve setup also reduces the peak pressure subjected to the breaker.

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

Outlet Pressure Pulse of Pump (Pmin. to Pmax.)


Pressure displacement must be within 1,160 psi
(82 kg/cm2) in 1 cycle of blow except for
instantaneous peak pressure within 10
milliseconds, in order to protect the pump.

Outlet Pressure Pulse of Pump (Pmin)


An instantaneous peak pressure drop in the
negative direction must be within 580 psi (41 kg/cm2),
when measured at the supply line. This is to
ensure long pump life.

Pressure Pulse (Pmin, Pump & Pmin, Breaker)


When operating the breaker, the minimum peak pressure of the pump outlet must be higher than that the
breaker inlet. (Pmin, Pump Pmin, Breaker). This is to check the load on the control valve and protect the
valves.

Inlet Pressure Pulse of Breaker (Pmin, Breaker)


When operating the breaker, the minimum value of peak pressure of the inlet must be kept higher than
the diaphragm recharge pressure of approximately 870 psi (61 kg/cm2). (Pmin, Breaker 870 psi (61
kg/cm2)). This is to protect hydraulic components and achieve diaphragm efficiency.

9.5

ADJUSTING IMPACT BLOW RATE


The blow rate of the breaker is adjusted by changing the oil flow rate from the host machine. This is
accomplished by reducing the pressure in the control valve at the breaker line. For more blows, set the
reducing pressure at a lower rate. For fewer blows, set the reducing pressure higher.

(CAL750 CAL3200)

(CAL4500 CAL11000)

41

The blow rate of the breaker can be adjusted by doing the following procedure.
1.
2.
3.
4.

Release the adjuster nut


High speed (Low power): turn adjuster to counter-clockwise.
Low speed (High power): turn adjuster to clockwise
Tighten the adjuster nut after setting.

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

HYDRAULIC PIPE LINES AND CONTROLS

1. The following hydraulic components of the host machine are used during the operation of the breaker.

Hydraulic oil tank.


Oil pump
Auxiliary Hydraulic Control Valve

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 run any hydraulic lines through the drivers cab.


42

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. DISASSEMBLY & REASSEMBLY


WARNING
If there is any nitrogen gas in the hydraulic breaker, it could be very dangerous. Be sure the gas pressure
in the head cap and accumulator has been released before doing any service work on the breaker.

10.1

DISASSEMBLING

1. Support the breaker on wooden supports of the appropriate size.


2. Relieve the nitrogen gas in head cap and accumulator (if equipped).

3. Remove nuts of main body through bolts.


43

4. Disassemble the head cap with a hoist or chain block.

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.

Use only new and genuine Construction Attachment replacement parts.

Make sure all seals are properly orientated before seating them into piston groove. Seals installed
improperly will leak.

Lightly coat seals and o-rings with oil before installation.

MODEL

CYLINDER

CYLINDER BUSH

45

DESCRIPTION

CAL-225
CAL-450

Dust Seal

CAL-550

U-Packing

CAL-750

CAL-2200

Buffer Ring Set


(Buffer Ring
+ Back Up Ring
or Step Seal)

CAL-3200

Step Seal

CAL-1000
CAL-1200

CAL-4500

Gas Ring Set


(Gas Ring
+Back Up Ring)

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

1. Assemble the Seals.


Once the cylinder bushing and cylinder bore
have been thoroughly cleaned, lightly coat
sealing elements with hydraulic oil before
assembling.
2. Assembly of the Lower Bushing and Front Cover.
1. Knock out the rubber plugs and
stopper pins using a hammer and
punch.
47

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

5. Install the stopper pins & rubber plugs.

6. General assembly
A. Attach the through-bolts to the front cover.
B. Replace the seals in the cylinder seal and lower bushing area.

CAL-225 thru CAL-2200

CAL-3200 thru CAL-11000

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.

8. Disassembling bracket (Box Type)


A. Remove the upper urethane from the cylinder body after the bulk cap has been removed.
B. Take the main body out from the bracket using a crane or hoist.
C. To re-assemble bracket, perform the above procedure in the reverse manner.
D. 9. Chisel Replacement
CAL225 CAL 2200:

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.

10. Breaker lifting point

51

11. Suitable Eyebolt Size for Breaker Main Body

10.4

Model

Weight
(lbs)

Eye Bolt

Allowed Weight (lbs)

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.

Tool for correction


Grain size or Type
Name of Tool

Operating Method
Rough Finish

Finish

52

Oilstone

Rough and medium


grain

Fine Grain

Emery Paper

#100, #160, #240

#400, #600

Polish perpendicular to a sliding direction.

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.

CAUTION ON USING A BUFFER GRINDER


53

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.

Finish an edge produced by chipping


smoothly with an oilstone.

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.

CAUTION ON USING A BUFFER GRINDER

55

Kind of Fault

Condition

Remedy

Vertical
Scratch

Striped scratches caused by sliding motion.

Remove burrs on the surface by polishing in


the circumferential direction.

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

Repair piston surface on a polishing


machine. Remove burrs on surface by
polishing in a circumferential direction for a
maximum 0.002 less than the nominal
diameter. If scratches and/or rust pitting still
remain, replace piston with a new one.

56

4. Damage on the impact surface


Damage to the impact surface on a piston will have an adverse effect on the chisel. Correct it at an early stage or
replace the piston with a new one.
1. Collapse:
If the impact surface has a collapsed area of .08 or over in depth, replace the piston with a new one.
If the impact surface has a step of less than .04 in depth, smooth the area.

2. Chipping and Peeling-off


If the impact surface shows a localized chipping or peeling-off area, correct the area to prevent the deformation
from progressing.

57

3. Chipping-off at edge of impact surface.


Replace piston with a new one.

11.

MAINTENANCE PERFORMED BY THE OPERATOR

DAILY MAINTENANCE

Tighten loose connections.


Grease chisel shank and chisel bushings.
Observe oil temperature, all lines and connections, as well as impact efficiency and smoothness of
operation.

WEEKLY MAINTENANCE

Remove retaining pin(s) and check condition.


Remove chisel and check chisel shank for wear.
Remove burrs from retaining pin groove of the chisel.
Check that the chisel has received sufficient greasing.

MONTHLY MAINTENANCE

Check chisel bushings for wear.


Check condition of vibration dampening mechanism.
Check condition of other wear parts and hoses.

WHEN CHANGING CHISEL OR APPROXIMATELY (4) TIMES PER YEAR

Check wear to working chisel.


Check wear to lower wear bushings.
Check adapter and breaker bracket for cracks.
Check impact face of piston for wear or damage.
Check impact face of working chisel for damage.
Check retainer bars for burring.
58

Check chisel for burring.

AS REQUIRED

Replace bent and squashed pipes.


Replace damaged hoses.
Check pressure in head cap and accumulator.
Check adapter bolts for wear.

12. TROUBLE SHOOTING


12.1

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

Low pressure relief valve setting.

Breaker easily damaged due to High pressure relief valve setting.


too strong impact power.
Gas pressure is too high.
Poor heat
machine.
Rapid increase in oil temperature

Hose pulsation on the return side

radiation

of

Premature wear of pump.

Check and adjust pressure on relief


valve setting.
Check and adjust pressure on relief
valve setting.
Check the gas pressure.

base Have
check.
Have
check.

excavator

manufacturer

excavator

manufacturer

Clogged piping.

Required flushing.

The amount of oil flow is too low.

Check oil flow.

Hose pulsation on the highGas pressure is too low or high


pressure line

Check the gas pressure.

Emulsification of hydraulic oil

Immediately replace hydraulic oil.

Entering of water into oil.


Insufficient output of engine.

Excessive decrease in engine


Drop of engine performance.
RPM
Excessively low temperature of oil.

60

Decrease the gas pressure and


increase RPM.
Have
excavator
manufacturer
check.
Required warming-up.

Conditions

Causes

Countermeasure

Insufficient power (PQ)


Insufficient
chisel.
Breaker will not work.

down

pressure

Check power.
on

Proper instructions.

Clogged piping.

Check and repair (Flushing).

Seizure of breaker.

Repair or replace worm parts.

Filling up of hydraulic oil in head Replace gas seal and check the
cap.
piston.
Lack of hydraulic oil.

Refill oil.

Insufficient power (PQ)

Check power.

Clogged piping.

Check and repair (Flushing).

Stop hammering or erratic action Gas pressure is too high.


in approx. 30~90min. operation
Damaged seals.

Breakage of chisel

Melting of chisel point


Cracking of chisel point

Check gas pressure.


Replace seals.

Filling up of hydraulic oil in head


cap.
Use of hammering chisel in bent
condition.
Use of chisel as lever, move rocks
with chisel.
Long time continuous hammering
in one place.
Full power operation from the
outset.

Difficulty in attach and removing


Deformation of chisel pin.
chisel point
Excessively worn urethane
Excessive play between bracket (Box type).
and breaker body
Loosened side bolts (Side type).
Premature wear of front cover

Low number of blows

Weak impact force

Replace gas seal and check the


piston.
Apply down force in tool direction.
Check if any excessive play on
arms, link & pins.
Relocate.
Low speed operation for first 30
minutes.
Regular check & grinding needed.
Replace.
Retighten bolts.

Lack of grease.

Proper instruction.

Insufficient power (PQ)

Check power.

Insufficient
chisel.

down

pressure

on

Proper instructions.

Gas pressure is too high.

Check gas pressure.

Gas pressure is too low.

Recharge the N2 gas.

Insufficient
chisel.

down

pressure

Insufficient power (PQ)


61

on

Proper instructions.
Proper instructions.

Breakage of chisel in front cover.

12.2

Replace tool and check the piston.

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

Causes & Remedies


Seals are damaged.
Replace.

Between the chisel and front cover

A large amount of oil is leaking.

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.

Between the cylinder & head cap

Between cylinder & front head

Oil leakage

Loosened through-bolts & nuts.


Retighten.

Oil leakage (also gas leakage)

Check that gas seal and O-ring are


damaged and oil & piston
condition.
Replace.

Oil leakage

Check that seals of cylinder are


damaged.
Replace.

62

12.3

POOR OPERATION OF BREAKER


Conditions

Does not impact

Major causes

Remedies

Required warming up the engine of


base machine from five to twenty
minutes and moving the boom.
Oil temperature is too low.
Oil temperature must reach to min.
86o F.
Main control valve (Excavator) Check conditions of main control
does not operate properly.
valve.
N2 gas pressure is too high in head
cap and setting pressure of relief Check gas pressure and relief valve.
valve is low.
Poor performance of hydraulic Contact excavator manufacturer
pump. (Excavator)
immediately.
Oil temperature increased due to
Supplement of hydraulic oil.
lack of hydraulic oil.
Gas pressure in head cap is too
Check gas pressure.
high.
Relief valve is set too low.

Not enough down pressure on


chisel.
The clearance between the chisel
Irregular blows it operates and front cover are too large.
normally at the beginning.
Wear on top of chisel.

Check pressure of relief valve.


Apply enough down pressure with
arm or boom of base machine.
Check the clearance between chisel
and front cover.
Disassemble chisel to check.

Poor performance of hydraulic


Have
pump and backpressure are too
check.
high.

Lack of impact

excavator

manufacturer

Foreign material inside main valve.

Disassemble and clean.

Seizure of piston & cylinder.

Overhaul and check.

Low gas pressure in back head.

Check gas pressure.

Gas pressure is too high.

Check gas pressure.

Not enough down pressure on Apply enough down pressure with


chisel.
arm and boom.
63

Setting pressure of relief valve is


Check pressure of relief valve.
too low.
Poor performance of hydraulic Have
excavator
manufacturer
pump.
check.
Check setting pressure or gas
Operating pressure is too high.
pressure.

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

BULK CAP BOLTS


BREAKER MODELS
FEATURE

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-4500 EXTERNAL VALVE CASE BOLT 125 Kg-m (904 ft-lbs)


13.3

ACCUMULATOR BODY BOLTS


BREAKER MODELS
FEATURE

CAL-6000

CAL-8000

CAL-11000

TORQUE (ft-lbs)

1,281

1,281

1,281

TORQUE (kg-m)

177

177

177

65

13.4

ACCUMULATOR COVER BOLTS


BREAKER MODELS
FEATURE

CAL-6000

CAL-8000

CAL-11000

TORQUE (ft-lbs)

333

333

333

TORQUE (kg-m)

46

46

46

13.5

SPANNER SIZE (mm) FOR BOLTS OF HYDRAULIC BREAKERS

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

14. SERVICE WARRANTY REGISTRATION & WARRANTY CLAIMS


FILING OF WARRANTY REGISTRATION CARD
Warranty registration card must be completed by dealer at the time of product delivery to the end user.
Copy A from warranty registration card must be returned to Construction Attachments within (15) days after
the installation inspection is carried out and the card is filled out with the corresponding information .

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

WARRANTY REGISTRATION CARD


MODEL

SERIAL NUMBER

GAS PRESSURE (HEAD GAS


CAP)
(ACCUMULATOR)
KG/CM2

PRESSURE
KG/CM2

1. CUSTOMER AND DATES RELATED


CUSTOMER NAME
CUSTOMER ADDRESS
DISTRIBUTOR NAME

LOCATION OF DELIVERY

DATE OF DELIVERY

DATE OF INSPECTION
/

2. ACCESSORIES
NO

ACCESSORIES

NO

ACCESSORIES

BREAKER TOOL

YES, NO

MAINTENANCE TOOLS

YES, NO

GAS CHARGING KIT

YES, NO

TOOL BOX

YES, NO

GAS BOTTLE

YES, NO

OPERATION MANUAL

YES, NO

SPRING GUARD HOSE

YES, NO

3. TYPE AND CONDITION OF BASE CARRIER


MAKER
MODEL
M.F.GYEAR
/

OIL COOLER
4. WARRANTY
DATE OF START
/
/

TON

MAX. OUTPUT OF
PUMPS
SUPPLYING
L/MIN

KG/CM2 OPERATING OIL FLOW

OPERATING PRESSURE
MAIN
RELIEF
PRESSURE

TOTAL WEIGHT

SET

L/MIN

KG/CM2 2ND RELIEF SET PRESSURE


YES

NO

DATE OF EXPIRY
/
/

OIL FILTER

HOURS OF EXPIRY

5. ACKNOWLEDGEMENT & COMMENT


INSPECTORS COMMENT / DISTRIBUTOR

KG/CM2
YES

REMARKS

SIGNATURE
NAME
DATE:
68

NO

INSPECTORS COMMENT / CUSTOMER


SIGNATURE
I hereby acknowledge that the product has been delivered in satisfactory condition and
operates satisfactorily, and that I received all items as checked above, and that all
aspect of the standard warranty and suggestions in use has been fully explained to me.
SERVICE REPORT

1. CUSTOMER AND DATES RELATED


CUSTOMER NAME

CUSTOMER ADDRESS

DISTRIBUTOR NAME

DELIVERY DATE TO DISRRIBUTOR


/

DATE OF FAILURE
/

DATE OF REPAIR (SERVICE)

/ 200

LOCATION OF PRODUCT

/ 200
PERIOD OF WARRANTY

/ 200

/ 200

/ 200

2. TYPE AND CONDITION OF BASE CARRIER


MAKER

MODEL

MFG. YEAR
/

MAX. OUTPUT OF PUMPS SUPPLYING


/

L/MIN

3. TYPE AND CONDITION OF PRODUCT


MODEL & SERIAL NO.

OPERATING HOURS

OPERATING PRESSURE
KG/CM

CAL
(S/N;

OIL FLOW
)

ND

B/H GAS PRESSURE


2

RELIEF SET PRESSURE

KG/CM2
ACC GAS PRESSURE

KG/CM2

L/MIN

KG/CM2

4. FAILURE INFORMATION
OUTLINE :

CAUSE :

STEP & RESULT


DETAILED REPORT

ATTACHED

PHOTOS

ATTACHED

5. WARRANTY CLAIM PARTS


PART NAME

PART NO

QTY

PART NAME

6. DECISION & COMMENT

69

PART NO

QTY

DISTRIBUTOR (OR SERVICE MAN) COMMENT

DATE OF CLAIM

SIGNATURE

15. WARRANTY POLICY


Construction Attachments Inc. provides the following warranty:
THE WARRANTY PERIOD
The warranty provided by Construction Attachments Inc. hereunder shall extend for a period of (12) months from
the date of sale by the dealer to the buyer, as determined by the date of dealer's invoice for the products to the
buyer either by facsimile or mail not later than (15) days after the date of sale.
Followings are the parts in the category of warranty applied.

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

Through Bolt Assembly


Gas Valve Set
Front Cover
Round Bushing
Hose Adaptor
Hose & Piping Kit Parts
Bracket Bolts, Pins & Bushings
Accumulator Bolts & Diaphragm

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

PARTS NOT INCLUDED IN WARRANTY


The followings parts are excluded from any warranty claims.

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.

THE CONTENTS OF WARRANTY

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

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