Hy-Ram

Hydraulic
Impact
Breaker
Model
HR270
HR290

Safety, Operation and Maintenance

Thoroughly read and understand the content of this manual before using the Allied Breaker. The safe and efficient
use of the Allied equipment depends upon proper installation, operation, maintenance and training.

Keep this manual in a convenient location so that it is easily accessible for future reference. Contact your Allied
Dealer or the Allied Customer Service Department for replacement manuals. Inquiries regarding the content of this
manual must include effective date shown on inside cover.

SOM577202
 Allied Construction Products, LLC www.alliedcp.com

Contact Information

3900 Kelley Ave

Cleveland, Ohio 44114

E-mail: sales@alliedcp.com

Tel: 216-431-2600 Fax: 216-431-2601

Revision History of Document 577202

Continuous improvement of our products is an Allied policy. The material in this publication, including figures, captions,
descriptions, remarks and specifications, describe the product at the time of its printing, and may not reflect the product in
the future. When changes become necessary, these will be noted in the table below. Specifications are based on published
information at the time of publication. Allied Construction Products, LLC, reserves the right to change, edit, delete or modify
the content of this document, including descriptions, illustrations and specifications without prior notification. For product or
document updates go to www.alliedcp.com .

Effective Date Page Summary of Change

Original Issue of SOM577202. Information for HR270,
2014 Mar
HR290 found previously in SOM575469.

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Safety Information

Safety Statements and Hazard Alerts Signal Words

Safety messages appear throughout this manual and “DANGER”, “WARNING” and “CAUTION” are signal
on labels affixed to the Allied equipment. Read and words used to express severity of consequences
understand the information communicated in safety should a hazard be encountered.
messages before any attempt to install, operate,
service or transport the Allied equipment. DANGER - Indicates an imminent hazard, which, if
not avoided, will result in death or serious injury.
Keep all safety labels clean. Words and illustrations
must be legible. Before operating this equipment, WARNING - Indicates an imminent hazard, which, if
replace damaged or missing labels. not avoided, can result in death or serious injury.

Purpose of Safety Messages CAUTION - Indicates hazards which, if not avoided,

could result in serious injury or damage to the
Safety messages provide information that is equipment.
important for your safety. These messages
communicate the extent, magnitude and likelihood of Safety messages are displayed in a uniform
injury associated with unsafe practices such as arrangement as shown in Fig S2.
misuse or improper handling of the Allied equipment.
Safety messages also explain how injury from
CAUTION
potential hazards can be avoided.
Burn injury from contact with hot
Safety messages presented throughout this manual surface. Some components become hot
communicate the following information: during operation. Allow parts and fluids
to cool before handling.
1. Alert personnel to potential hazards
Fig. S2 Safety Message – Typical Presentation
2. Identify the nature of the hazard
Signal Words Used for Non-Hazard Messages
3. Describe the severity of the hazard, if
encountered Other message types that appear in this manual
utilize signal words "IMPORTANT" and "NOTE".
4. Instruct how to avoid the hazard These are used only for the purpose of notifying
personnel to instructions and suggestions but do not
Safety Alert Symbol pose a safety hazard to workers.

IMPORTANT – Identify instructions that if not

followed, may diminish performance; interrupt
reliability and production or cause equipment
damage.

NOTE – Highlight suggestions, which will enhance

installation, reliability, or operation.

Fig. S1
ATTENTION, BECOME ALERT, YOUR SAFETY IS
INVOLVED – CAUTION REQUIRED.

Fig. S1. The exclamation point within an equilateral

triangle is the safety alert symbol. This symbol, either
used alone or with a signal word, is used to draw
attention to the presence of potential hazards.

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Safety Information – [cont’d]

Safety, Information and Identification Labels Keep all safety labels clean. Words and illustrations
must be readable. Before operating this equipment,
Information labels affixed to the Allied equipment replace damaged or missing labels. For replacement,
include safety warnings, identification and refer to the appropriate Parts Manual for
instructions important to operation and service. Refer identification.
to Figure “L14” for their location on the equipment.

Figure Label Description

READ INSTRUCTIONS - Decal directs personnel to the manual for

L1
further information / instructions.

STAY CLEAR – Decal alerts personnel and by-standers to maintain a

L2
safe distance from the Breaker while in operation.

FLYING DEBRIS – Alerts personnel to the hazard of debris becoming

projectiles and the need for a protective guard to shield the operator
L3 from injury. It directs personnel to the Operator’s Manual for safety
instructions. NOTE: Place the smaller size decal in a conspicuous
location inside the operator’s cab.

TOOL SHARPENING – Decal warns against welding, cutting, or hard-

L4 facing the tool. It directs personnel to the Operator’s Manual for
approved sharpening methods.

! WA R N I NG
PRESSURIZED PRESSURIZED NITROGEN ACCUMULATOR – Decal warns of
NITROGEN
L5* ACCUMULATOR pressurized gas and directs personnel to the Repair Manual for service
OP E RA TOR ' S M
TO
FE
R
R E OR E
BE
F
CH A R
G I NG O R S E A N U
RV
IC L
A
IN
G
instructions. *HR175 and HR230 are not equipped with accumulator.

GAS PRE-CHARGE – Decal outlines measuring / charging the back

head. Alerts personnel to the following –
 Maintenance interval – every 2 weeks
L6  Proper position when measured / charged
 Charge pressure when COLD vs. HOT
 Refers personnel to the Operation and Maintenance Manual
 Cautions personnel to use nitrogen gas only

L7 LIFT POINT – Decal identifies approved lift points.

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Safety Information – [cont’d]

Fig. Label Description

LUBRICATION – Decal emphasizes key re-lubrication instructions,

L8 including; frequency and precautions that must be observed to ensure
breaker is not damaged through unapproved methods.

LUBRICATION POINT – Decal identifies lubrication points. Refer to

L9 the manual(s) for grease type, re-lubrication schedules and
procedures. Risk of equipment damage if instructions are not followed.

PRESSURE I.D. TAG - The oil supply hose is tagged for ease of
L10
identification.

ALLIED LOGO – This decal is the Allied brand identifier and is a

L11
registered trademark of Allied Construction Products, LLC.

L12 HR230 MODEL – Decal identifies the specific model.

EQUIPMENT ID TAG - Contains identifying information about the

L13 equipment, including: Manufacturer’s name, address, product name,
model number, serial number, year of manufacture, and weight.

Fig. L14 Label Positions

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Safety Information – [cont’d]

Meaning of Pictograms

Pictograms are used to rapidly communicate Personnel maintain a safe

information. For the purposes of this manual and distance from breaker
labels affixed to the Allied equipment, pictograms are
defined as follows:
Fragments / debris
becoming airborne
 Read the manual projectiles
 Refer to the manual for further
details
 Procedures are explained in
the manual Protective guards required
on cab when operating this
work tool
Read the Service Manual For
Additional Information

Leaking fluid under

pressure

 Crush point Hot surfaces

Gas / Oil under pressure

Moving part (in direction indicated
by arrow)
Shut off carrier & remove
key before servicing
 Falling object
 Unsupported loads

Identifies lift point

Personal Protection Equipment
 Hearing protection

Figures marked with an X-

 Safety eyewear out or a circle with a
diagonal slash describes a
prohibited action.

Prohibited actions must be

 Gloves avoided to prevent injury
and/or equipment damage

 Safety shoes
The check mark symbol is
 Falling part
used to indicate actions
and methods that are
recommended, correct and
approved

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Safety Information – [cont’d]

General Construction Safety

Attention Read the Manual
Always follow procedures that promote safe
Improper installation, operation or maintenance of conditions for workers and bystanders. The standard
the Allied equipment could result in serious injury or safety precautions expected and required of those
death. Only qualified operators may operate the working in construction shall include, but not limited
Allied equipment. Personnel responsible for the to:
maintenance of the Allied equipment or its systems,
including inspection, installation or adjustments must
 Locating existing underground service and utility
also be qualified. Operators and personnel
lines
responsible for maintenance of this equipment
 Establishing pedestrian barriers
should read this manual. Other manuals, such as
those published by the machinery used in support of  Using personnel protection equipment
the Allied equipment, should also be read. appropriate to working conditions, etc.

Federal, State, Local and OSHA Construction

Qualified Person
Guidelines and Regulations
For the purposes of this manual, a qualified person
Use the Allied equipment in accordance with all
is an individual that has successfully demonstrated
federal, state and local regulations regarding
or completed the following:
construction practices and public safety.
Identification of, and compliance to, governing
 Has read, fully understands and adheres to all regulations are the responsibility of the owner and
safety statements in this manual. operator.

 Is competent to recognize predictable hazardous In the United States, comply with the
conditions and possess the authorization, skills recommendations of the Occupational Safety and
and knowledge necessary to take prompt Health Administration standards of the U.S.
corrective measures to safeguard against Department of Labor. For OSHA construction
personal injury and/or property damage. guidelines contact your local federal government
office or write:
 Has completed adequate training in safe and
proper installation, maintenance and operation U.S. Government Printing Office Superintendent of
of this Allied equipment. Documents P.O. Box 371954 Pittsburgh, Pa. 15250-
7954
 Is authorized to operate, service and transport Website: www.osha.gov
the Allied equipment identified in Table 1.1.
Ask for Construction Industry OSHA Standards
Safety Information Overview Stock #869-034-00107-6.

It’s important for all personnel working with the Allied Owner’s Responsibilities
equipment to read this manual in its entirety. It
includes important safety information intended to Ensure that only qualified personnel operate and
help personnel avoid unsafe practices that may lead service the Allied equipment.
to mishaps. Safety information described at the
beginning of this manual is generic in nature. As you Ensure personnel protection equipment is available
continue reading through later sections of this to personnel and enforce the use of PPE
manual, instructions and safety information become
tool-specific and operation-specific. Ensure equipment is kept in safe operating condition

Allied has made every effort to provide information Ensure safety-related materials such as instructions
as complete and accurate as possible for this and including this manual are kept in a convenient
document. Allied cannot anticipate every possible location so that they are easily accessible to
circumstance that might involve a potential hazard. operators and maintenance personnel.
The warnings in this manual and labels affixed to the
Allied attachment are therefore not all inclusive.

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Safety Information – [cont’d]

Operational Safety Program To prevent accidental start up, the control switch
shall be located in a protected area that is guarded
The safe and efficient use of the Allied equipment and makes it difficult to accidently operate the
depends upon proper installation, operation, equipment.
maintenance and repair. Operational safety programs
must encompass all of these elements. Unapproved Use or Modifications

Accident prevention through operational safety In order to provide and maintain efficient operation
programs are most effective when the equipment with reliable service, while ensuring operator safety,
owner further develops the program by taking into the Allied equipment may not be used for any other
account his own experience in using and maintaining purpose other than, for which it was intended. Use of
equipment. the Allied equipment, other than those cited in this
manual, may place personnel at risk of injury and/or
Developing such programs will help minimize may subject the equipment to damage.
equipment downtime, while maximizing service life
and performance. Most importantly, it will minimize When making repairs, use only the manufacturer's
the risk of personal injuries. genuine parts. Substitute parts may not meet the
required standards for fit and quality, or may impair
Personal Protective Equipment (PPE) function, safety and performance. The Allied
equipment shall not be modified or used in
Personnel operating or nearby the equipment that unapproved applications unless written consent is
may be exposed to the hazard of falling, flying and received from the Allied Engineering Department.
splashing objects, or exposed to harmful dusts,
fumes, mists, vapors, or gases shall use the
particular personal protection equipment (PPE)
necessary to protect them from the hazard. Such
PPE may include safety eyewear, face shield,
hearing protection, safety footwear, gloves, and dust
mask. Supervisors shall review proper PPE selection
and ensure PPE is made available to personnel.
Personnel are responsible for wearing PPE as
directed by the supervisor.

Protective Equipment - Guarding

Allied equipment designed with guards shall have

guards in place when equipment is in use. Guards
are fitted to the equipment to protect against unsafe
situations that could not be eliminated through design
measures. Where it was not possible to prevent an
unsafe situation by means of a guard, safety
messages appear on the equipment, warning
personnel of a hazardous condition.

Guards shall not be removed unless for the purpose

of inspection and service of components. All guards
must be reinstalled after service or adjustments are
completed. Do not operate the Allied equipment
without guards installed.

Additional guarding, not included with the Allied

equipment, is necessary at the operator’s station to
protect the operator and other nearby personnel
against flying debris from material being cut or
demolished. Do not handle, demolish or cut material
overhead without proper guards installed.

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Table of Contents

Section Pg.
Section Pg.
Record of Document Revisions……………….… i
4.0 Product Information…………………..…….….. 6
Safety Information.…………………………………. ii 4.1 Description and Use……………………..…….. 6
Safety Statements and Hazard Alerts……………… ii 4.2 Familiarization of Main Components………... 6
Purpose of Safety Messages……….……………… ii 4.3 Principle of Operation……………………..……. 6
Safety Alert Symbol...…………..…………………… ii
5.0 Sizing the Breaker…...………………………… 8
Signal Words………………………………………… ii
5.1 Breaker Selection - General……………………. 8
Non-Hazard Signal Words………….………………. ii
5.2 Auxiliary Circuits & Conversion Kits…………… 8
Safety, Information & Identification Labels……….. iii
Meaning of Pictograms ..…………………………… v 6.0 Operation….……………………………...……… 10
General Safety Precautions………........................ vi
6.1 Before the Breaker is Used……………….…….. 10
Qualified Person…………….…..………………….. vi
6.1.1 Pre-Operation Inspection…..…………………. 10
General Construction Safety……….…. vi
6.2 Proper Operation and Use………………….…... 10
Federal, State, Local and OSHA Construction
Guidelines and Regulations……………….……….. vi 6.2.1 Operating (Cycle) Time - Max.………………. 11
Owner’s Responsibilities……….….………………. vi 6.3 Operating Mistakes to Avoid…………………… 11
Operational Safety Program……………………….. vii 6.3.1 Recognize Changes in Pitch or Frequency.. 11
Protective Equipment – PPE and Guarding vii 6.3.2 Do Not Pry with Breaker……………………… 12
Unapproved Modifications………………………….. vi 6.3.3 Do Not Drop or Hack at the Material………… 12
6.3.4 Do Not Operate With Cylinders At Stroke End 12
Table of Contents……..……................................ viii
6.3.5 Other Operating Mistakes to Avoid………… 13

List of Figures…..…………………………………… x 6.4 Special Applications & Operating Conditions 13

6.4.1 Working Underwater…………………….…….. 13
1.0 Introduction & Scope.…………………………. 1
6.4.2 Working Underground……………………..…… 14
1.1 Purpose of This Manual………………………… 1
6.4.3 Working in Hot Temperatures……………….... 14
1.2 About This Manual……………..................... 1
6.4.4 Working in Cold Temperatures........................ 14
1.3 How to Order Replacement Publications…… 1
6.4.5 Flow Adjustment……………………..……….. 15
1.4 Related Publications….…………....................... 1

2.0 Equipment Identification…………….………... 3

7.0 Care and Maintenance………………………... 16
2.1 Serial Number Location.………..………………. 3
7.1 Inspection & Maintenance Schedule…………. 16
2.2 Equipment Identification Tag….………………. 3
7.2 Equipment Maintenance Log…………………... 17
2.3 Record Equipment Information.……………….. 3
7.3.1 Housing Box Inspection ……………………. 17
7.3.2 Vibration Dampening Parts Inspection….….... 17
3.0 Warranty Protection Summary…………..…… 4
7.4 Front Head – Description of Parts…..………..…. 18
3.1 Overview…….……………….…………………….. 4
7.4.1 Front Head Inspection…………………………. 18
3.2 Owner’s Responsibilities……..…........................ 4
7.4.2 Measure Gap Between Tool & Bushing …… 19
3.3 Allied Product Policies……………...................... 5

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Table of Contents - [cont’d]

SECTION Pg.
SECTION Pg.

10.3.2 Tools Needed to Install………….…………. 31

7.4.3 Front Head Inspection – Internal Parts……. 20
10.3 3 How to Install Tool………………….……... 31
7.4.4 Tool & Bushing - Measure Wear…………… 19
10.4 Tool Re-lubrication – Conventional Method 31
7.5 Piston Inspection…………………………….. 20
10.4.1 Avoid Costly Lubrication Mistakes……… 32
7.6 High-Pressure Accumulator…………….…….. 20
10.5 Tool Re-lubrication – Automatic Systems… 33
7.7 Inspect Mounting Pins…………………....…… 20
10.5.1 Tool Re-lubrication Carrier Mounted Type 33
7.8 Threaded Fastener Inspection………………. 20
10.5.2 Tool Re-lubrication Breaker Mounted Type 33
7.9 Inspect Hoses………………………………... 20
10.6 Benefits of Using Chisel Paste………..…… 33
7.10 Check Oil & Filter on Carrier…………….….. 22

7.11 Measuring Oil Pressure………………….….. 21 11.0 Tool Selection Guide………………………. 34

7.11.1 Safety Precautions – Read First………..… 21 11.1 Match the Application…………….………… 34
7.11.2 How To Measure Oil Pressure…………… 22 11.1.1 Methods Used to Break Up Material……… 34

11.2 Tool Working Length……………….………… 34

8.0 Safe Handling & Storage……………………. 23
11.3 Tool Sharpening………………….………….. 34
8.1 Transport Breaker Independently of Carrier… 23

8.2 Transport Breaker Installed on Carrier………. 23 12.0 Back Head & Accumulator Gas Charge… 35
8.3 Breaker Storage – Short Term (<14 days )… 23 12.1 Charge Tool - General Description……… 35
8.4 Breaker Storage – Long Term (> 14 days)… 23 12.2 Safety precautions for Charging Back Head 36

12.2.1 Tools Required for Charging Back Head 36

9.0 Breaker - Attach To /Remove From Carrier 25
12.2.2 Connecting the Charging Block…….….… 36
9.1 Carrier Requirements………………………… 25
12.2.3 How to Measure Gas Charge…………..…. 36
9.2 Mounting Kits………………………………….. 25
12.2.4 How to Pre-charge the Back Head.……… 37
9.3 Tools Required to Attach the Breaker………. 25
12.2.5 Removing the Charging Block…………….. 37
9.4 Attach Breaker to the Carrier………..……… 25
12.3 Safety precautions Charging Accumulator 37
9.5 Supply Hose IN and Return Hose OUT..…… 26
12.3.1 Tools Required for Charging Accumulator 38
9.6 Removal from Carrier………………..…..…... 27
12.3.2 Connecting the Charging Block……….… 38
9.6.1 Tools Required For Removal of Breaker.… 27
12.3.3 How to Measure Gas Charge…………….. 38
10.0 Tool Removal and Installation……………. 29 12.3.4 Charging the Accumulator.……………….. 38

10.1.1 Safety Precautions – Read First…………. 29 12.3.5 Removing the Charging Block………….... 38

10.1.2 Tools Needed For Removal…….…………. 29

13.0 Troubleshooting Guide……………………. 39
10.1.3 Overview of Tool Retainer System………. 29

10.1.4 Tool Removal…. ………………………...… 30 14.0 Technical Information……………………… 43

10.2 Tool Inspection & Prepare For Installation... 30 14.1 Definition of Terms………………………….. 43
10.3.1 Install Tool – General……….……………... 30 14.2 Testing the Hydraulic Circuit……………….. 44

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Table of Contents - [cont’d]

Section Pg.
Figure Pg.
Table 14.1 Specifications……………..………..…… 45
7-5 Measure Tool for Wear…………………..……. 19
Table 14.2 & 3 Tightening Torque – Side Rods..… 47 7-6 Measure Bushing for Wear…………...………. 19
Table 14.3 Tightening Torque – Mounting Bracket 47 7-7 Piston With Damage to Impact Face……….… 20
7-8 Measuring Oil Pressure……………......……… 22
8-1 Use Approved Lift Points…………..………….. 23
15.0 Service Record……………………………….. 48 8-2 Improper Park Position…………………………. 23
8-3 Push Piston to Its Highest Position………….. 24
8-4 Protect Piston Against Water Damage……….. 24
List of Figures
8-5 Protect Breaker With Tarp………………...…… 24
9-1 Top Mounting Bracket - Typical……..……...… 25
Figure Pg.
9-2 Attach Breaker to Carrier……..……..…………. 26
S1- Safety Alert Symbol……………………………… ii
9-3 Install Pins and Keepers……………………….. 26
S2- Safety Message Presentation – Typical………. Ii
9-4 Port Connection Markings [IN] and [OUT]…… 26
L1-14: Information Labels Found On Breaker……… iv
9-5 Connect Hoses to Carrier……………..………. 27
L15-Label Positions………………………………….. iv
9-6 Check Hose Movement……………….………. 27
Pictograms Used In This Manual………………….. v
9-7 Close Shut Off Valve to Breaker………….…. 27
2-1 Equipment Identification………………….…….. 3
10-1 Tool Retainer System – HR290……….…….. 29
2-2 Equipment Identification Tag……………….….. 3
10-2 Tool Retainer System – HR270……………… 29
4-1 Main Components of Hydraulic Breaker……… 6
10-3 thru 10-5 Tool Removal………….…………… 31
4-2 Cutaway View of the Breaker…………….…… 6
10-6 Pre-Lube the Tool Shank……………….…… 31
5-1 Auxiliary Conversion Circuit…………………….. 9
10-7 Tool Lubrication – Correct Position…………. 32
6-1 Install Window Guards………………………….. 10
10-8 Tool Seated Against Thrust Ring………….. 32
6-2 Operate at 90° to Work Surface……………….. 11
10-9 Lubricant Must Be Visible to Operator……… 32
6-3 Start at Outer Edge & Work Inward……………. 11
10-10 Tool Lubrication – Incorrect Position……… 32
6-4 Do Not Overheat Tool….………………………. 11
10-11 Carrier Mounted AutoLube.……………..…. 33
6-5 Do Not Blank Fire……………………………….. 11
10-12 Breaker Mounted AutoLube……………..…. 33
6-7 Do Not Pry with the Breaker……………….…… 12
11-1 Conical, Chisel, Blunt Tools……………….... 34
6-8 Do Not Drop Breaker or Hack at the Material… 12
11-2 Tool Working Length………………………... 35
6-9 Do Not Operate With Cylinders At Stroke End 12
12-1 N2 Gas Back Head..……………..….….…… 35
6-10 Do Not Lift or Carry Objects With Breaker……. 13
12-2 N2 Gas Accumulator...………………….…… 35
6-11 Travel With Breaker Low to Ground…………. 13
14-1 Flow-Pressure Diagram……………….……. 43
6-12 Correct and Incorrect Parking Positions…….. 13
14-2 General Dimensions – HR270….………….. 46
6-13 Working Underwater Requires Modifications 13
14-3 General Dimensions – HR290….………….. 46
14-4 Torque Locations……………………………. 47
14-5 Angle of Rotation & Tightening Sequence… 47
7-1 Vibration Dampening – Buffers & Wear Plates 17
14-6 Fastener Torque Mounting Bracket………… 47
7-2 Keep Dust Plugs Installed In Housing Box …… 17
7-3 Internal Parts of Front Head……………………. 18
7-4 Measure Gap Between Tool and Bushing…… 19

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1.0 Introduction and Scope

1.1 Purpose of this Manual 1.3 How to Order Replacement Publications

This manual has been prepared in support of the This manual is an integral part of this product. Keep it
Allied equipment named in Table 1.1 and is intended in a convenient location so that it is easily accessible
to assist the operator and maintenance personnel for future reference.
with the information necessary for the safe and
proper use of the Allied equipment. Replacement manuals can be ordered by contacting
your Allied dealer service center.
1.2 About This Manual
1.4 Related Publications
Table 1.1 About This Manual
Allied Construction Products, LLC offers the following
Document ID No. SOM577202 publications for the product identified in Table 1.1.

Safety, Operation and 1.4.1 Parts Manual

Type
Maintenance
Current Status See Inside Cover Parts Manuals identify each component of the Allied
work tool, including safety and information labels.
Product Name: Hydraulic Impact Breaker
1.4.2 Repair Manual
Series Hy-Ram
The Repair Manual has been prepared to assist the
Applicable Model[s]: HR270, HR290 Service Technician with the information necessary for
the disassembly & reassembly of the Breaker.
Years of Manufacture: 2011 & above Content includes:

Material presented in this manual, including figures,  Safety Information

captions, tables, descriptions, remarks and  Disassembly & Reassembly
specifications may not be suitable for use with  Bolt Torque Specifications
models other than those identified in Table 1.1. Prior  Wear Limits of Parts
to using this manual, confirm that all information  N2 Gas Charging Instructions
recorded on the equipment’s identification label
corresponds with Table 1.1. Figures and descriptions 1.4.3 AEM Safety Manual for Hydraulic Mounted
may show equipment that is optional. Breakers

This document is published solely for information The Association of Equipment Manufacturers offers a
purposes and should not be considered all-inclusive. safety manual designed for operators and
If further information is required, contact your local maintenance personnel of hydraulic mounted
Allied dealer or the Allied Customer Service breakers.
Department.
The manual is available in Spanish, French and
Material in this publication has been reviewed for English. It is published in an illustrated format of
accuracy. Allied Construction Products, LLC has sensible do's and don'ts, featuring typical daily
endeavored to deliver the highest degree of accuracy situations on the job site.
and every effort has been made to provide
information as complete as possible. However, Content includes safety tips concerning the
continuous improvement of our products is an Allied workplace and equipment, start up and shut down
policy. guidelines and special operating and maintenance
precautions.This publication is available by
Material in this publication, including figures, contacting:
captions, tables, descriptions, remarks and
specifications, describe the product at the time of its Association of Equipment Manufacturers
printing, and may not reflect the product in the future. Toll free 1-866-AEM-0442
When changes become necessary, these will be E-mail: aem@aem.org
noted on the inside cover. Website: www.aem.org

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1.0 Introduction and Scope – [cont'd]

Ask for FORM CMHB-1004, Hydraulic Mounted

Breakers.

This publication is also available through Allied under

part number 953076 (English). To order a copy,
contact the Allied Customer Service Department.

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2.0 Equipment Identification

2.1 Serial Number Location 2.3 Record Equipment ID Information for Future
Reference

Your local Allied dealer requires complete information

about the equipment to better assist you with
questions regarding parts, warranty, operation,
maintenance, or repair.

 Copy the Model and Serial Number from the

Equipment Identification Tag to the space
provided below.

 Indicate the date in which the Allied equipment

was placed into service.

 Fill out the Warranty Registration form and return

to Allied Construction Products, LLC.

Product Hydraulic Breaker

Fig 2-1 Equipment Identification

Refer to Figure 2-1. The Serial Number assigned to Series Hy-Ram

this equipment can be found in the following
locations:
Model
1. Stamped on the Equipment Identification Tag

2. Stamped on the back head near the charge plug. Part Number:

2.2 Equipment Identification Tag Serial Number:

In Service Date:

Registration Date
Fig 2-2 Equipment Identification Tag

The Equipment Identification Tag is affixed to the

housing. It provides the following information:

 Manufacturer’s name
 Address
 Product name
 Model number
 Serial number
 Year of manufacture
 Weight

Confirm that the information contained on the Tag

corresponds with the information provided in Section
1, Table 1.1.

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3.0 Warranty Protection Summary

3.1 Overview any faults that, if left uncorrected, could lead to

personal injury or further damage.
The Allied attachment is delivered assembled,
lubricated, and factory tested. Upon receipt of the  Use the Allied attachment only for the purpose for
equipment, inspect for possible shipping damage. which it is intended.

For every new Breaker, Allied requires that a

 Understand that particular applications, such as
Warranty Registration form be completed and
working underwater, will require modifications to
returned to Allied. The form includes a section to
the standard breaker and additional training for
record information about the carrier on which the
operation and service.
breaker is being installed.

To keep the Allied equipment operating within its  Appoint Who Does What. Ensure that all
performance limits, familiarize yourself with the personnel understand what their specific
technical specifications section of this manual. responsibilities include.
Adhere to these specifications when calibrating the
carrier. Improper installation, including failure to 1. Establish maintenance responsibilities to
calibrate the carrier correctly may result in loss of be performed by the OPERATOR.
performance or subject the equipment to conditions
beyond their design. 2. Establish maintenance responsibilities to
be performed by the SERVICE
Use of non-Allied parts, unapproved service TECHNICIAN.
methods, modifications to the attachment, or
installation, operation and maintenance, not in  Recognize problems and know how to take
accordance with the instructions outlined in this corrective action as detailed in Troubleshooting
manual may cause equipment failure or personal Section 13.
injury.
 Conduct regular checks and inspections as
For details regarding warranty terms and conditions, scheduled in the Care and Maintenance Section
refer to document 574490. 7.

3.2 Owner’s Responsibilities  Allow only qualified operators and Allied trained
service technicians to perform maintenance and
When properly installed, operated and maintained by repair as specified in the care and maintenance
qualified personnel, the Allied attachment will remain schedule.
productive with a minimum of service.

The following outlines general maintenance policies  Use only genuine Allied replacement parts and
required for all breaker models. The equipment recommended lubricants to protect total warranty
owner is strongly encouraged to adopt these general coverage.
guidelines and further develop them in order to
manage particular applications and operating  Maintain written records of equipment
environments. maintenance, service and repair. These records
are helpful if warranty coverage is ever in
Ensure that personnel entrusted with installation, question.
operation, maintenance and transporting of the Allied
equipment adhere to the following: Each record shall include at least:

 Read and thoroughly understand the information  Date of service, maintenance or repair.
and procedures detailed in this manual.  Description of the service, maintenance or repair
performed. Include part numbers if applicable.
 Understand proper operating techniques for all  Copies of purchase order(s) and invoice(s) for
recommended applications. repair parts and service.
 The name and signature of the person
 Use the Allied attachment only if it is in sound performing the service, maintenance or repair.
operating condition. Take prompt action to rectify

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3.0 Warranty Protection Summary – [cont'd]

3.3 Allied Product Policies

In this manual, Allied recommends breaker

applications, maintenance and service consistent
with industry practices.

Allied assumes no responsibility for the results of

actions not recommended in this manual and
specifically the results of:

 Improper Training

 Improper Installation

 Operation in unapproved applications

 Incorrect operation

 Improper maintenance

 Use of non-genuine Allied replacement parts

 Unapproved modifications

These exclusions apply to damage to the Allied

equipment, associated equipment and injury to
personnel.

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4.0 Product Information

4.1 Description and Use 4.3 Principle of Operation

The Allied Breaker is a hydraulic powered impact

breaker designed for mounting on mobile equipment
with hydraulic booms, such as rubber tired or track-
type construction vehicles.

The breaker is suited for many types of construction

and mining applications including -

 Clearance Work: Demolition of buildings, bridges,

reinforced foundations etc.

 Trenching: Breaking trenches out of rocky and

frozen ground.

 Mining and Quarrying Applications: Demolishing Fig 4-2 Cutaway View of Breaker Assembly
and leveling quarry rock, breaking oversized
minerals and other rock-like raw materials.  The Breaker is not self-powered. Performance
Excavation of rock from trenches, foundations relies on a capable host machine that's equipped
and tunneling. with a hydraulic circuit. Within the hydraulic
circuit, an ON/OFF valve is used to control flow in
 Underwater: Demolition and deepening of one direction to the Breaker. The valve will be
shipping channels. (Requires special modification managed with a momentary switch located inside
for underwater use!) the operator’s cab within easy reach of the
operator.
 Recycling: Breakup of "skulls" from the steel
industry.  With the valve ON, supply oil from the host
machine flows to the [IN] port on the breaker. Oil
4.2 Familiarization of Main Components is blocked from entering the breaker unless
sufficient contact pressure is applied on the tool
to push the piston up and out of the brake
position.

 Located on the breaker is the operating valve. Oil

is directed by this valve to the lower end of the
cylinder. The first half of the cycle begins when
oil, under pressure, raises the piston. As the
piston strokes upwards, oil in the upper cylinder
is expelled through the [OUT] port and returned
back to the machine.

 A gas-charged accumulator is equipped on larger

breakers. Inside this self-contained pressure
vessel is a pair of expansible chambers divided
Fig 4-1 Main Components of Hydraulic Breaker by an elastic membrane. The top chamber is pre-
charged with nitrogen gas (N2). The bottom
chamber will receive, store and discharge
pressurized oil.

 The chamber inside the Back Head is also filled

with nitrogen gas (N2). The pre-charged gas is
compressed to a higher pressure as the piston is
pushed into the back head.

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4.0 Product Information – [cont'd]

 As the piston nears the top of its stroke, signal

ports inside the cylinder become pressurized and
shift the operating valve closed. Blocked from
exiting the [OUT] port, the oil in the upper end of
the cylinder becomes pressurized.

 With the piston at the top of its stroke, the final

half of the cycle will begin. The force of the
pressurized oil combines with the charge
pressure inside the back head and drives the
piston down. The cycle is completed when the
piston impacts the tool.

 The cycle is continuous without interruption until

the machine operator releases the momentary
switch controlling the ON/OFF valve.

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5.0 Sizing The Breaker

5.1 Breaker Selection - General modifications and also take into account any add-ons
such as a quick attach coupler.
When selecting a breaker, key points to consider
include – Next, review the hydraulic specifications of the carrier
 Production rate (Material strength) and breaker. All hydraulic breakers are designed to
 Lifting capacity of machine provide optimum performance with reliable service
 Hydraulic power of machine life at a specific oil pressure and flow range. For a
combination to be successful, the circuit must be in
The size of the breaker is typically dictated by the job good working condition and able to deliver adequate
requirements, but the size must also be compatible flow and pressure with minimal heat generation and
with the carrier on which it will be mounted. power loss.

For optimum productivity, match the size of the Before the breaker is used, complete a performance
breaker to the job. Materials are fractured by two evaluation of the hydraulic circuit. These test results
methods – Penetrative and Impact. With penetrative will confirm if the hydraulic circuit is calibrated and set
breaking, blows from the piston drive the tool into the in accordance to the specifications of the breaker.
material and wedge it apart. With impact breaking,
blows from the piston generate a compressive force Tools required for testing the oil flow, operating
that squeezes the material. When the material's pressure and back pressure include a flow meter and
strength is exceeded, it fractures. pressure gages. An overview of the testing
procedure, along with a form to record the results of
Be careful not to undersize the breaker in hard the flow test, can be found in the Technical Data
material. It's important that the material absorb all of section in this manual. Compare test results with the
the energy (mechanical stress wave). Problems arise specifications of the breaker. Make all necessary
when these undesirable waves of energy are adjustments.
reflected back into the breaker.
5.2 Auxiliary Circuit and Conversion Kits
Ideally, it should take 3- 5 seconds to fracture the
material. When working in extremely hard materials,
undersized breakers will be subjected to longer CAUTION
running cycles. This negatively impacts production, Equipment damage from improper oil
component longevity and reliability. Continuous flow or pressure. Accurate calibration
running beyond 15 seconds will generate unwanted of the hydraulic circuit is important for
heat at the tip of the tool. Attention to wear parts, reliable operation.
such as bushings and tools, will need to be more
Hydraulic circuits differ between machines. Only
frequent. The machine’s service intervals will also
require extra attention. qualified personnel, having knowledge of the
machine’s systems, proper test equipment and tools
should perform conversion set-up and adjustments.
Reaching optimal production rates requires efficient
interaction between the operator and machine. A
machine that is undersized will force the operator to Work tools, such as Breakers, are not self-powered.
work at a slower pace to keep the machine stable. An Their performance is reliant upon the hydraulic power
undersized machine also reduces the size of the of the host machine. The hydraulic power it provides
material it can shuffle when repositioning materials. to the breaker must meet all of the requirements
specified in the technical data section of this manual.
Allied breakers are assigned a recommended carrier
weight range. On a general level, if the breaker falls Most machines will require some degree of
within this range, it's regarded as a good match. conversion to make use of their hydraulic power. A
hydraulic circuit, capable of producing flow and
To ensure the carrier can safely handle the weight of pressure in one direction is needed to operate a
the breaker, always consult the specifications in the breaker.
manual provided by the carrier manufacturer. Factors
such as boom and stick length, undercarriage and
tracks, counterweights, etc., all affect the lifting
capacity of the carrier. Check the machine for any

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5.0 Breaker Selection – [cont’d]

Conversions to machines equipped with a factory or

dealer installed auxiliary circuit may require little more
than minor adjustments to flow and pressure settings.
Follow the machine manufacturer’s instructions when
making any adjustments.

If the machine is not equipped with a hydraulic circuit,

a conversion kit, from Allied, can be installed. When
necessary, Allied conversion kits include the Allied
"AC" series valves. These are solenoid-operated
valves that control flow and pressure.

Fig 5-1 Allied Conversion Kit With AC-Series Valve

The process of selecting the right breaker must

consider the type of work to be done. This includes
any special needs such as required modifications
when working in underwater applications

Requests for further information or assistance with

breaker selection should be directed to your Allied
dealer or by contacting the Allied Sales or Product /
Technical Support Departments.

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6.0 Operation

6.1 Before the Breaker is Used 6.2 Proper Operation and Use

CAUTION
Before work can start, identify all site hazards,
including electrical and gas utilities. Set up barriers.

CAUTION
Only qualified personnel shall operate the breaker.
Never activate the breaker unless the operator is
seated in the operator’s seat and is in full control of
the machine.

Fig. 6-1 Install Protective Guards CAUTION

Injury from flying debris. Personal
CAUTION protection equipment is required when
Injury from flying debris. Protective operating this equipment. PPE must
guarding must be fitted to the include safety eyewear and hearing
operator’s cab when the breaker is protection.
used. Prolonged exposure to high noise levels
may cause hearing impairment or loss.
6.1.1 Pre-Operation Inspection Hearing protection must be worn when
breaker is in operation.
Prior to using the Breaker, check that it has been
properly serviced with all scheduled maintenance and
repairs completed. A qualified individual should CAUTION
conduct a visual inspection of the following:
Clear out all personnel before
maneuvering the carrier into the work
 Ensure Breaker is securely attached to the
area.
carrier.

 Ensure Breaker tool is locked securely in the Injury form flying debris. Do not
front head operate breaker with personnel in
vicinity of work zone.
 Ensure Breaker tool is well lubricated
IMPORTANT
 Check grease level and test operation of Serious equipment damage may result if proper
automatic lube system, if equipped procedures are not followed. Select proper engine
speed and set function mode to “BREAKER”.
 Ensure hoses are not rubbing and tubes are
secured tightly in clamps
IMPORTANT
Service life of parts is diminished if attention to correct
 Ensure fasteners are not loose, missing or
working methods is not applied. Prevent the tool from
damaged
binding against the bushings by always aligning the
Do not operate breaker until all faults are corrected. breaker tool 90 to the work surface.

An inspection record, which can be copied, is located  Use the boom and arm controls to extend the
in Section 7 of this manual. breaker away from the carrier.

 Position the breaker tool against the material to

be broken. Do not drop breaker on to material.

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6.0 Operation – [cont’d]

If the material does not break within 15 seconds of

hammering, stop and reposition the tool nearer the
edge.

OK 90°
OK 90°

NO!

NO!
90° OK

Fig 6-4 Begin at Outer Edge and Work Inward

6.3 Operating Mistakes to Avoid

Fig. 6-2 Align the Breaker 90 to the Work Surface
IMPORTANT
 With a “firm preload” applied on the breaker tool, Equipment damage may result if proper
the breaker is ready to operate. procedures are not followed. Carefully read
through this section as it describes actions to be
 Actuate the control that fires the breaker. avoided when using the breaker.

 Keep a constant feed force on the tool as it 6.3.1 Recognize Change in Pitch or Frequency
penetrates the material. Strong vibrations will
generate back to the carrier if sufficient force is Never operate the breaker when the tool suspended
not maintained. in the air (Blank Fire), or is not pressed firmly against
the material (Idle Strokes). Both conditions are
 Stop the breaker immediately when the tool damaging to the breaker.
breaks through.

6.2.1 Cycle Time

Breaking in extremely hard materials requires care to

prevent overheating the tool. Prolong hammering in
one spot must be avoided. NO!

Fig 6-5 Do Not Blank Fire

Fig. 6-3 Do Not Overheat Tool

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6.0 Operation – [cont’d]

The operator must remain attentive to the sound The leading cause of tool breakage is from bending.
emitted by the breaker. A metallic pinging sound is In the occurrence of tool failures from bending, the
emitted when the tool strikes against the retainer length of the tool, skill level of the operator and
pins. The tool must always remain firmly in contact lubrication management, all play a decisive role.
with the material. Prying will damage other parts as well, including the
bushings, front head and housing.
Always keep the tool in firm contact with the material
as it penetrates the material. Material that is weak NOTE: The force of the impact is dampened by soft
and easily fractured, requires quick reaction by the ground underneath the material and by rock dust
operator to stop the breaker so idle strokes are accumulated at the tool. Tilt the breaker to expel dust
prevented. away from the tool. Tilt no more than 5º to avoid
placing a strain on the front head and bending the
tool.

6.3.3 Do Not Drop or Hack at Material

Avoid reckless movements that may cause the carrier

to become unstable. Do not drop the breaker against
the material. Do not use the breaker to hack at the
material.

NO!

Fig 6-6 Misalignment – Side Load against Bushing

A hollow (thin) sound is emitted when the tool binds

in the bushing. This is usually accompanied by a drop
in blow frequency and reduced impact energy.

Binding results when the tool is misaligned or lacks

sufficient lubrication. Review operator technique.
Avoid binding by aligning the tool 90 to the material. Fig 6-8 Do Not Drop, Pound or Hack the Material.
Keep the tool and bushings well lubricated. Re-
lubricate the tool every two hours or if it appears dry. 6.3.4 Do Not Operate with Cylinders at Stroke End

6.3.2 Do Not Pry With the Breaker Operating the breaker with the cylinders fully
extended or retracted can damage cylinders.

NO!

NO!

Fig 6-7 Do Not Pry With the Breaker

Fig 6-9 Do not Operate with Cylinders at Stroke End

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6.0 Operation – [cont’d]

6.3.5 Other Prohibited Actions to Avoid with

Breaker

CAUTION
The Breaker is not designed to lift or transport loads.
This practice is unsafe and can damage the
Breaker.
OK

Fig 6-12 Park With Breaker Horizontally On Ground

NO!
NO!

Fig 6-10 Do Not Use the Breaker to Lift or Transport

Loads
6.4 Special Applications & Operating Conditions

6.4.1 Working Underwater

CAUTION
Serious equipment damage will result if Breaker is
submerged in water without proper modifications,
equipment and training.

NO!

Fig 6-11 Travel With Breaker Low to Ground NO!

CAUTION
The carrier may become unstable with risk of tipping
if work tool is too heavy or transported with loads too
high. Keep loads low to the ground when travelling. Fig 6-13 Breaker Is NOT Underwater Ready -
Modifications Are Required

Working underwater requires special preparation,

additional equipment and training. Further
instructions should be directed to the Allied Technical
Service Department.

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6.0 Operation – [cont’d]

6.4.2 Working Underground

 Use of fire-resistant hydraulic fluids. Hydraulic
When using the Breaker underground [tunneling or systems using fire-resistant fluids require special
mining applications] special safety regulations may engineering consideration when using the
apply. Additional considerations include: Breaker. With some fluids, decreased flow and/or
pressure to the Breaker may be necessary.
 Use of water sprays to suppress dust.

6.4.3 Working in Hot Temperatures

IMPORTANT  Check the oil level in reservoir

Serious equipment damage may result if proper Inspect the cooling system. Good air circulation is
procedures are not followed. Check the oil essential in dissipating heat from the hydraulic oil.
temperature often to ensure it does not exceed Make sure the cooler is clean.
176ºF [80ºC]. If higher temperatures are
measured in the tank, refer to the 6.4.4 Working in Cold Temperatures
Troubleshooting Section in this manual.
IMPORTANT
 Specify hydraulic oils with viscosity suitable for Serious equipment damage may result if proper
the climate conditions. In general, the hydraulic procedures are not followed. When working in
oil that was originally specified for the machine by temperature conditions below minus 4ºF [-20ºC],
the carrier manufacturer can be used with this operating the Breaker with cold hydraulic oil may
equipment. damage the seals.

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6.0 Operation – [cont’d]

 At temperatures below minus 4º F [-20º C], the

hydraulic oil must be warmed up before starting
the Breaker. Follow instructions provided by the
carrier manufacturer for on warming up the
carrier.

 Keep oil circulating in the carrier during pauses in

work to prevent it from falling below a
temperature that is too cold for normal operation.

 Specify hydraulic oils with viscosity suitable for

the climate conditions. In general, the hydraulic
oil that was originally specified for the machine by
the carrier manufacturer can be used with the
Allied equipment.

 Use oil viscosity based on the expected air

temperature range during the period between oil
changes.

 Optimum oil viscosity for the breaker @ operating

temperature is 60 – 30cSt. Allowable oil viscosity
range 1000 – 20cSt.

6.4.5 Flow Adjustment

Available on Hy-Ram models HR390 thru HR710.

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7.0 Care and Maintenance

7.1 Preventative Maintenance Checks & Services Every 100 Hours or 2 Weeks

All hydraulic breakers require regular inspection and Remove breaker tool from front head
maintenance. The aim of inspection and maintenance  Check retainer slot area for burring
programs is to preserve equipment reliability by  Inspect impact surface for uneven wear, cracks
replacing worn components before they reach the or chips
point of failure.  Inspect retainers for wear, cracks or chips
 Inspect impact surface of piston for uneven wear,
The following includes the minimum requirement for cracks or chips
maintaining the equipment in safe operating  Inspect thrust ring for evenness of wear, cracks
condition. Service intervals apply only to normal or chips
applications. In extreme operating conditions or
applications such as underwater, tunneling, scaling, Every 250 Hours or 3 Months (Or As Required)
foundry cleaning, etc., the breaker will require
inspections on more frequent intervals.  Measure hydraulic oil pressures and confirm all
are within required range
Daily Pre-operation Walk-around Inspection  Should repairs or changes be made to the
hydraulic system, the oil flow and pressure must
 Lubricate breaker tool be re-tested.
 Check breaker tool is properly engaged in front
head At Rebuild
 Check level and operation of automatic lube
system - If equipped  Replace all seals. Replace all worn components
 Check for loose or missing fasteners  Replace accumulator membrane and charge
 Check for fluid leaks at tubes, hoses, connections accumulator
and seals
 Ensure hoses are not rubbing and tubes are After Rebuild – Before Use
secured tightly in clamps
 Ensure breaker is properly engaged with carrier.  Test quality of hydraulic oil
Check mounting pins and ensure pin keepers are  Service hydraulic oil filters
secure  Test hydraulic circuit with flow meter and
 Check housing and mounting bracket for wear pressure gages.
and cracks
 Look for signs of contact between breaker and Service Notes Date
housing caused by excessive movement

Every 2 Hours (While in use – Service Hours)

 Lubricate breaker tool or sooner if the tool

appears dry
 Check breaker tool is properly engaged in front
head

During Shift (While breaker is in use)

 Actively monitor efficiency and evenness of

operation. Look and listen for any interruptions
from normal operation
 Monitor hydraulic oil temperature. Keep within the
required operating range
 Be alert to fluid leaks

Every 50 Hours or Weekly

 Measure gap between breaker tool and bushing

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7.0 Care And Maintenance – [cont’d]

7.2 Equipment Maintenance Log With guide plates in good condition, the breaker has
minimal movement inside the housing box. The
The importance of frequent inspections along with operator must actively monitor for excessive
regular maintenance and accurate record keeping movement. Never allow the breaker to contact the
cannot be overemphasized. Keep records of housing. Worn isolators must be replaced
equipment maintenance and services performed. immediately. Minimize wear of these abrasion
This is helpful if warranty coverage is ever in resistant plates by using proper operating techniques
question. Records should include: and keeping dust plugs and covers in place.

 Date of service and hour meter reading

 Details of the service, maintenance or repair
performed.
 Names of persons performing the service,
maintenance or repair
 Copy of the purchase order or invoice, including
part numbers used in the repair

7.3.1 Housing Box Inspection – Daily Start of Shift

Inspect the housing box for cracks and wear.

Frequent raking of material will lead to a higher rate
of wear. Build-up worn areas and promptly repair
cracks to prevent further spreading. Neglecting or
delaying repairs will lead to further damage and
increased repair costs.

7.3.2 Vibration Dampening Inspection

Fig. 7-2 Keep Dust Plugs and Covers In Place

Table 7.1 Buffer Wear Limits. Inch [mm]

HR270 HR290

A-Min

B-Min

C-Min

D-Min

7.4 Front Head Inspection – Description of Parts

The aim of regularly inspecting these parts is to spot

problems and correct them in their early stages.
Fig. 7-1 Buffers, Wear Plates Ignoring inspections or failure to complete
maintenance when repairs are minor can quickly
A system of buffers, dampers and guide plates help escalate into extensive damage and higher repair
minimize vibrations to the carrier and unwanted noise costs.
by isolating the breaker from the housing box.

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7.0 Care and Maintenance – [cont’d]

7.4.1 Front Head Inspection – Every 2 Hours

Each part of the front head plays a critical role.

The condition of these parts must be actively
monitored for wear and replaced when needed.

Visually inspect the front head area each time the tool
is re-lubricated.

 Check that the retainer system used to secure

the tool in the front head is fully engaged.

 Check that both the tool and bushings are

receiving sufficient lubrication.

 Be alert to any oil seepage on the ground, tool or

the front head, as this may indicate a serious
condition that will require further investigation

 Visually inspect the gap between the lower

bushing and tool. Further details in Section 7.4.2.

IMPORTANT
Many factors contribute to the wear of front head
components, but the most apparent of these include
the operator's technique and lubrication
Fig 7-3 Front Head Assembly - Description of Parts management.

Table 7.2 Inspection of Parts

Part - Condition Cause Remedy

Tool - Burs form in retainer slot Wedge shape tool prone

Use conical tool - less prone to twisting
to twisting from material

Maintain sufficient feed force. Stop hammering at

Tool retainer - Chipped, burs,
Blank fire / tool twist instant material breaks. Use conical tool - less
uneven wear.
prone to twisting

Lubricant must meet application requirements.

Tool, bushing or retainer - Rapid Ineffective lubricant,
Re-lubricate every 2 hours – sooner if tool shank
wear or galling Insufficient re-lubrication
is dry. Increase quantity dispensed.
Maintain sufficient feed force. Stop breaker as
Thrust Ring - Chipped, cracked or soon as material breaks. Align tool at 90° angle to
Idle blows
uneven wear work surface. Do not pound or hack material with
tool.

Piston - Impact face is cracked, Excessive gap between tool & bushing. Maintain
Tool misalignment
chipped, dished or sharp edges 90° angle to work surface.

Bushing - Cracked Side loading Do not pry with tool.

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7.0 Care and Maintenance – [cont’d]

7.4.2 Check Tool & Bushing Gap – Every 50 Hours

Inspect the condition of the tool and bushing. Check

the gap and replace worn parts when their wear limit
is reached.

Measure the gap between the lower bushing and tool.

If maximum gap, shown in Table 7.3, is reached,
follow the instructions in Section 7.4.3.

Fig 7-6 Measure Bushing & Tool for Wear

Table 7.3 Wear Limits – Inch [mm]

Fig 7-4 Gap (D4) Between Tool and Bushing Model HR270 HR290
D1
7.4.3 Front Head – Inspection of Internal Parts 2.67" 2.93"
Tool O.D.
[68] [74.5]
New
Internal components of the front head are viewable D2
only when the breaker tool is removed. 2.59" 2.85"
Tool O.D.
[66] [72.5]
Limit
Wipe grease from parts to be inspected. Check parts D3
for wear and damage. Review Table 7.2 for cause Bushing 2.75” 3.01”
and remedy. I.D. [70] [76.5]
Limit
7.4.4 Measure Tool and Bushing Wear
D4 3/16” 3/16”
The tool is guided by the bushings and is kept square Gap [4.5] [4.5]
to the piston. It's critical for the protection of the
piston and seal system to keep bushings in good IMPORTANT
condition. Replace parts that have reached their wear Wear cannot be prevented, but it can be minimized
limit. through proper operating techniques and timely re-
lubrication. Re-lubricate every two hours or sooner if
grease is not visible. Allied Chisel paste is
recommended.

7.4.5 Tool Retainer Inspection

Inspect tool retainers each time the breaker tool is

removed. The retainer should be rotated when the
Fig 7-5 Measure Tool Diameter for Wear surface becomes uneven or damaged from galling.
Replace when both sides are worn.

7.5 Piston Inspection

The piston can be viewed after the tool is removed.

The impact surface should be flat and smooth.

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7.0 Care And Maintenance – [cont’d]

Replace the piston if the impact face is cupped, accumulator daily for oil leaks and broken or loose
chipped, cracked or has sharp edges. This damage is bolts.
often the result of tool misalignment caused by
improper operating technique or from worn bushings. Generally, membrane failure is often sudden and
Damage can also be the result of metal fatigue. results in immediate and complete discharge of gas.
The breaker will continue to operate, but without
assistance from the accumulator, a noticeable
change in performance will be observed. Symptoms
include one or more of the following:

 Loss of blow energy

 Decrease in blow frequency
 Strong pulsations in hoses
 Oil leaking from around the accumulator
Fig 7-7 Piston Shown With Damage to Impact Face
After membrane replacement, the breaker cannot be
Complete disassembly of the breaker is required to used until the upper chamber is charged. Several
replace the piston. Contact your Allied service center. factors, including the pre-charge pressure, will affect
the function and reliability of the accumulator.
7.6 Inspection of the High-Pressure Accumulator Accurate charging to the proper pressure is important
if it is to deliver a long and reliable service life.

WARNING 7.7 Inspect the Mounting Pins

Prevent unexpected release of high Inspect the mounting pins for wear and damage
pressure gaseous energy. The when the breaker is removed from the carrier.
accumulator is pressurized with Replace worn or damaged pins.
nitrogen gas and remains pressurized
even at times when there is no 7.8 Threaded Fasteners
hydraulic pressure to the breaker.
Never attempt to dismantle the IMPORTANT
accumulator unless completely Keep threaded fasteners tight. Replace damaged
discharged of all pressure. If the or missing fasteners prior to operating equipment.
breaker is attached to a carrier do not Replacement must be the same type and grade.
service the accumulator until oil
pressure inside breaker and hydraulic Threaded fasteners are subjected to high stresses.
circuit is relieved. All threaded fasteners must be checked daily for the
first 50 operating hours and once a week thereafter.
Only qualified technicians with special tools and Tighten fasteners to the specified torque.
training should service the accumulator.
7.9 Inspect Hoses
CAUTION Replace hoses if any of the following conditions are
In the event of an accumulator failure, immediately present:
discontinue operation. Ignoring this notice can
damage the breaker and the carrier.  End fittings are damaged or leaking
 Outer coverings are chafed or cut.
The accumulator is a self-contained pressure vessel
with a flexible membrane dividing the inner chamber.
 Wires are exposed
The lower chamber is used to receive, store and  Outer coverings are ballooning
discharge pressurized oil. The upper chamber is filled  Flexible part of the hoses are kinked
with nitrogen gas.  Outer covers have embedded armoring
 End fittings are displaced
During normal operation, no service is required to the
accumulator between rebuilds. Visually inspect the

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7.0 Care and Maintenance – [cont’d]

7.10 Check Oil and Filter on Carrier

CAUTION

CAUTION Some procedures, such as measuring

the oil pressure, must be done while
Refer to the manuals provided by the the breaker is operating. This will
carrier manufacturer for required service require an assistant.
and maintenance intervals.
Both must be qualified in these procedures. Take all
Check oil level in reservoir. Check service record for necessary precautions. All directions and signals
last oil and filter change. Test oil quality. Review the must be agreed upon in advance. Never activate the
maintenance schedule from the manufacturer of the breaker unless the operator is seated in the
carrier. It may specify special maintenance conditions operator’s seat and is in full control of the machine.
when operating breakers.
CAUTION
7.11 Measuring Oil Pressure
Injury from flying debris. Personal
All hydraulic breakers are designed for optimum protection equipment is required when
performance with reliable service life when operated operating this equipment. PPE must
within specified parameters. Monitor the efficiency of include safety eyewear and hearing
the breaker through regular checks of the oil protection.
pressure. Prolonged exposure to high noise levels
may cause hearing impairment or loss.
It is required to measure the oil pressure – Hearing protection must be worn when
breaker is in operation.
 When the breaker is first installed to a new
carrier.
CAUTION
 Anytime the carrier's hydraulic circuit is repaired Injury from flying debris. Proper
or modified. guarding must be fitted to the
operator’s cab when the breaker is
 Anytime other work tools are used on the same used.
carrier and these operate at different flow and
pressure settings.
CAUTION
 Anytime the breaker is moved off one carrier and Crush injury from falling or shifting loads.
installed to a different carrier. All loads must be stable before service
begins.
It is recommended to measure the oil pressure – Engage interlock, shut off carrier and
remove key. Follow safety instructions in
 At every 250 hours of use. the manual provided by the carrier
manufacturer.
7.11.1 Safety Precautions – Read First

WARNING
CAUTION
Prevent injury from unexpected
Equipment damage from improper oil release of high pressure hydraulic
flow or pressure. Accurate calibration energy. Relieve all oil pressure inside
of the hydraulic circuit is important for breaker and attachment circuit before
reliable operation. service.
Hydraulic circuits differ between machines. Only Wear personal protection equipment,
qualified personnel, having knowledge of the including safety eyewear when
machine’s systems, proper test equipment and tools working with pressurized systems.
should perform conversion set-up and adjustments.

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7.0 Care And Maintenance – [cont’d]

WARNING
 Start the breaker and record the oil pressure. It's
Escaping fluid under pressure can cause normal for the needle of the gauge to pulsate.
injury from injection. Always relieve Compare the average reading with the values
pressure before disconnecting hydraulic listed in the Technical Data Section of this
lines or other pressurized lines. manual.
If any fluid appears to penetrate the skin, seek
immediate medical attention. Qualified technicians  Make all necessary adjustments. Remove the
with special tools and training should test the gauge when finished.
hydraulic system.

IMPORTANT
Contamination can shorten service life. Prevent dirt
and debris from contaminating the oil. Always clean
the area around the connections prior to removal of
plugs or caps. Have a suitable container and rags on
hand before disconnecting hose. Collect fluid and
dispose of it properly.

7.11.2 How to Measure Oil Pressure

Fig. 7-8 Measuring Oil Pressure

 Connect a pressure gauge [0-5000 PSI] into the

supply line near the breaker.

 Start the carrier and allow the oil temperature to

reach its normal operating temperature before
starting.

 Move the breaker into a suitable working position.

 Set the engine rpm at the normal operating

speed

 Set work mode to breaker.

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8.0 Safe Handling & Storage

WARNING
3. Inspect the mounting pins and hardware for
Falling or shifting loads may cause damage and integrity.
injury or equipment damage. Do not lift
the Breaker by the mounting pins or 4. Transport carrier in accordance with the carrier
hose. Approved lift points are identified manufacturer's recommendations
by the LIFT HOOK. The lifting eye
located on the housing is for handling 8.3 Breaker Storage – Short Term [ < 14 Days]
the breaker. Do not use it to lift other
loads. 1. The Breaker may be stored vertically (tool down)
Crush hazard. Falling or shifting loads or horizontally.
may cause injury. Lifting devices must
safely carry the loads to which they will
be subjected. Lift away from people. Do
not enter the danger zone while the
Breaker is being lifted.

NO!

Fig 8-2 Improper Park Position

IMPORTANT
Exposure to moisture can cause destructive rust
and pitting on the piston. Elevate the top of the
breaker slightly higher to prevent water ingress
through front head.

If the Breaker is stored off the carrier -

2. Seal all hydraulic connections.

3. If stored outside, cover the Breaker with a

Fig 8-1 Use Approved Lift Points waterproof tarp.
8.1 Transport Breaker Independently of Carrier: 8.4 Breaker Storage – Long Term [ > 14 Days]
1. Remove all loose debris from Breaker. 1. Remove the breaker tool from the Breaker.
[Refer to Section 10.]
2. Follow removal instructions in Section 9.6.
2. Seal all hydraulic connections.
3. Secure hoses to unit to avoid accidental damage.
3. Release back head charge. Push piston to its
4. Lift the Breaker at approved lift points only with highest position. (Crack open [OUT] cap).
appropriate lifting equipment.
IMPORTANT
5. Adequately stabilize and secure the Breaker for
Contamination can shorten service life. Prevent dirt
transport.
and debris from contaminating the oil. Always clean
the area around the connections prior to removal of
8.2 Transport Breaker Installed on Carrier:
plugs or caps. Have a suitable container and rags on
hand before disconnecting hose. Collect fluid and
1. Remove all loose debris from Breaker.
dispose of it properly.
2. Secure hoses to unit to avoid accidental damage.

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8.0 Safe Handling & Storage – [Cont’d]

Fig 8-5 Protect Breaker with Waterproof Tarp

Fig 8-3 Push Piston To Its Highest Position

4. Protect the lower end of the piston with grease

IMPORTANT
Exposure to moisture can cause destructive rust and
pitting on piston. Protect from damage by coating the
exposed surface (below the wiper) with grease.

Fig 8-4 Protect Piston From Water Damage

5. The Breaker must be stored in the vertical

position.

WARNING
Crush Hazard. Unsupported loads may
cause injury or equipment damage. Use
sufficient blocking and restraints to
stabilize loads.

6. If stored outside, cover the Breaker with a

waterproof tarp.

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9.0 Attach / Remove Breaker From Carrier

9.1 Carrier Requirements 9.3 Tools Required to Attach the Breaker

CAUTION No special tools are required, but the following tools

should be available:

Carrier may become unstable with risk of tipping if  PPE including Safety eyewear & gloves
work tool is too heavy or transported incorrectly.  Sledge Hammer
 The Breaker shall only be attached to carriers  Drift pin
that are capable of providing sufficient load  3/4 drive socket wrench
carrying capacity.  3/4 drive metric sockets
 Know the capacities and limitations of your  Grease gun
machine and do not exceed them.  Standard and Metric open end wrenches
 Consult the manual provided by the carrier  Pry bar
manufacturer for the lift capacity of the  Rags
machine.
9.4 Attach the Breaker to the Carrier
 Lift capacities decrease as the load moves
away from the machine.
 Factors such as stick length, undercarriage, CAUTION
counterweights, etc., all affect the lifting
Some procedures, such as attaching
capacity of the carrier.
the Breaker to and from the carrier, will
 Any modifications made to the Breaker or the require an assistant. Both the operator
carrier must be taken into consideration to and assistant must be qualified in
prevent machine instability these procedures.
Take all necessary precautions. Throughout the
procedure the machine operator shall be seated in
IMPORTANT the operator’s seat and maintain full control of the
Incorrect combination of Breaker and carrier will machine. All directions and signals must be agreed
result in poor performance or equipment damage. upon in advance. Take signals from only ONE
Review hydraulic specifications of each. person.
Crush hazard. Use sufficient blocking to
9.2 Mounting Kits
avoid accidental or sudden movement of
the Breaker. Keep hands and feet clear of
A mounting bracket is required to attach the Allied
crush points. Do not touch any moving
Breaker to a carrier. Allied offers an array of
parts.
mounting brackets to fit virtually any carrier, including
those equipped with quick mounting couplers. Use personal protective equipment when
handling the breaker. PPE should include
appropriate clothing, gloves, safety
eyewear and shoes.

The breaker is attached to the carrier in the same

manner as mounting a bucket. Use standard
mechanic’s techniques and tools to attach the
breaker to the carrier.

The installation described is for a typical pin on type.

Procedures may vary and you should follow the
instructions in the manual provided by the carrier
manufacturer.

For carriers equipped with a quick coupler, refer to

the owner’s manual provided by the coupler
Fig 9-1 Mounting Bracket – Pin-On Typical manufacturer for instructions.

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9.0 Attach / Remove Breaker From Carrier –
[cont’d]

The machine operator and an assistant shall perform 9.5 Supply Hose [IN] and Return Hose [OUT]
the following procedure:

1. Operator: Move carrier and Breaker to a firm

level surface. Position the Breaker horizontally
with the hose side up and the breaker tool
pointing toward the carrier.

Fig. 9-2 Attach Breaker to Carrier

2. Assistant: Check that the Breaker is stable and

all loads are supported.
Fig. 9-4 – Supply Hose [IN] and Return [OUT]. Port
3. Operator: Maneuver the stick in between lugging Connections On Cylinder Body
of the mounting bracket. Align the stick pin holes
and mounting bracket holes with each other. IMPORTANT
The Breaker will not operate if the supply and
4. Assistant: Pins must be free of rust and debris return hoses are reversed. Connect the hose
before they are installed. Clean pin and lightly tagged with “PRESSURE” to the pressure line of
coat with lubricant. Insert the stick pin through the the carrier. The location of the Supply Line can
holes. vary from one carrier to another. Determine
carefully if the supply line on the carrier is located
5. Assistant: Secure stick pin with keepers. on the right-hand or left-hand side. Do not guess.

6. Repeat procedure with link pin. IMPORTANT

Contamination can shorten service life. Prevent dirt
and debris from contaminating the oil. Always
clean the area around the connections prior to
removal of plugs or caps. Have a suitable container
and rags on hand before disconnecting hose.
Collect fluid and obey all local regulations for the
disposal of these fluids.

1. Remove the plugs from the ends of the hydraulic

hoses. Set plugs aside and store them for later
use when the Breaker is removed.

Fig. 9-3 Install Pins and Keepers

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9.0 Attach / Remove Breaker From Carrier –
[cont’d]

2. Connect hoses to the shut-off valves located on

the carrier. (Supply hose tagged "PRESSURE")
CAUTION

Some procedures, such as attaching

the Breaker to and from the carrier, will
require an assistant. Both the operator
and assistant must be qualified in
these procedures.
Take all necessary precautions. Throughout the
procedure the machine operator shall be seated in
the operator’s seat and maintain full control of the
machine. All directions and signals must be agreed
upon in advance. Take signals from only ONE
person.
Fig. 9-5 Connect Supply & Return Hoses to Carrier Crush hazard. Use sufficient blocking to
avoid accidental or sudden movement of
the Breaker. Keep hands and feet clear of
crush points. Do not touch any moving
parts.
Use personal protective equipment when
handling the breaker. PPE should include
appropriate clothing, gloves, safety
eyewear and shoes.

Fig. 9-6 Check hose routing and length

3. Raise the Breaker off the ground. Operate the

bucket cylinder thru its full range of motion to
assure hoses will not be pinched or restricted. Fig. 9-7 Close Shut Off Valve to Breaker

9.6 Removal from Carrier IMPORTANT

Contamination can shorten service life. Prevent dirt
and debris from contaminating the oil. Always
CAUTION
clean the area around the connections prior to
Burn injury from contact with hot removal of plugs or caps. Have a suitable container
surface. Some components become hot and rags on hand before disconnecting hose.
during operation. Allow parts and fluids Collect fluid and obey all local regulations for the
to cool before handling. disposal of these fluids.

The procedure described is for a typical pin on type. 9.6.1 Tools Required For Removal
Procedures can vary between different machines. Be
sure to follow the instructions found in the manual No special tools are required, but the following tools
provided by the carrier manufacturer. should be available:

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9.0 Attach / Remove Breaker From Carrier –

[cont’d]

 PPE including Safety eyewear & gloves

 Sledge Hammer
 Drift pin
 3/4 drive socket wrench
 3/4 drive metric sockets
 Grease gun
 Standard and Metric open end wrenches
 Pry bar
 Rags

1. Operator: Move carrier and Breaker to a firm

level surface. Position the Breaker horizontally
with the hose side up and the breaker tool
pointing toward the carrier.

2. Shut the carrier off and relieve the pressure in the

hydraulic tank and hydraulic lines.

3. Assistant: Check that the Breaker is stable and

all loads are supported. Close the shut off valves
on the carrier that's connected to the Breaker.

4. Clean dirt from connection areas. Disconnect the

hoses from the shut off valves. Seal all open
connections with the appropriate plugs and caps.

5. Remove the pin retainers from the stick and link

pins. Collect any spacers that may have been
used.

6. Refer to Section 8.0 for proper storage

instructions.

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10.0 Changing the Tool

10.1.1 Safety Precautions – Read First 10.1.2 Tools Required to Remove

CAUTION  PPE including safety eyewear and gloves

 Hammer - Hand sledge
Follow all safety and operating  Drift pin
instructions provided by the carrier  Snap Ring Pliers
manufacturer. Engage interlock, shut off  Sling and lifting device
engine and apply parking brake.
10.1.3 Overview of Tool Retainer System
CAUTION
The procedure for removing and installing the tool is
Crush injury. Unsupported loads may essentially the same for all models. The tool can be
cause injury or equipment damage. If changed with the breaker on or off the carrier.
attached to a carrier, lower the breaker
to a flat stable surface. Ensure all loads Housing box (G). The tool (F) is secured in the front
are stabilized. Use sufficient blocking head (A) by a pair of retainer pins. The large pin (B)
and restraints to stabilize loads. passes through the slot located on the shank end of
the tool (F). The smaller retainer (C) holds the larger
CAUTION pin captive. (D) Rubber Plug and (E) Snap Ring
secure the small retainer.
Crush injury. If breaker is attached to
carrier, relieve all hydraulic pressure
inside breaker and attachment circuit
before tool is removed.

CAUTION
Crush injury. Keep fingers, hands and
other body parts clear of falling or
moving parts. Do not insert fingers into
bores. Use a screwdriver or rod to push
pins out of bore.
Keep hands, feet and other body parts
out of path and clear of falling parts.

CAUTION
Fig. 10-1 HR290 Tool Retainer System
Burn injury from contact with hot
surface. Some components become hot
during operation. Allow parts and fluids
to cool before handling.

CAUTION
Injury from flying debris. PPE must be
worn when striking pins with hammer.
PPE includes appropriate clothing,
gloves, safety eyewear and shoes.

CAUTION
Tools and other components of the
breaker are heavy. Use suitable lifting Fig. 10-2 HR270 Tool Retainer System
equipment.

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10.0 Changing the Breaker Tool

10.1.4 How to Remove the Tool 2. Stop the engine and apply the parking brake.
Enable the hydraulic interlock. Close shut off
valves [Fig. 10-3].

3. Remove (E) Snap Ring and (D) Rubber Plug.

Drive small retainer (C) out of front head until it
clears large retainer (B). [Fig. 10-4].

4. Remove large retainer (B) and set aside. [Fig. 10-

4]

5. Tool is released from Front Head. Large Tools

are Heavy! Handle tools with a suitable hoist and
sling. [Fig. 10-5].

10.2 Tool Inspection / Prepare for Installation

1. Clean and inspect front head bushings, tool and

retainers. Check for uneven or excessive wear,
Fig. 10-3 Close Valves, Elevate, Support Tool cracks or other damage.

2. Measure bushing and tool. Parts must be

replaced if worn beyond wear limit.

3. Inspect impact face of piston and thrust ring for

uneven or excessive wear, cracks or other
damage.

4. Grind any burrs and sharp edges smooth if found

on tool shank.

IMPORTANT
Gradually remove burrs to prevent over-heating
the steel.
Fig. 10-4 Remove (E) Snap Ring and (D) Rubber
Plug. Next, remove smaller pin (C) and large pin (B). 10.3.1 How to Install Tool - General

WARNING
Read, understand and follow all safety precautions
described in section 10.1 of this manual before
installing the breaker tool. Incorrect installation
may allow the breaker tool to be driven out of the
front head, possibly causing bodily injury or
property damage.

The procedure for removing and installing the tool is

essentially the same for all models. The tool can be
changed with the breaker on or off the carrier.
Fig. 10-5 Support Weight of Tool & Remove
The tool is inserted into the open end of the front
1. If attached to the carrier, lower the breaker and head and secured by an arrangement of pins which
position horizontally on a stable and level pass through slots located on the tool shank.
surface. Allow access to the large retainer (B)
from below. Use adequate load bearing device to
support weight of breaker.

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10.0 Changing the Tool – [cont’d]

10.3.2 Tools Required to Install

CAUTION
 PPE including safety eyewear and gloves
 Snap Ring Pliers
 Hammer - Hand sledge If tool lubrication is provided by an automatic
 Drift pin dispenser, please read carefully. When delivery is
 Sling and lifting device continuous and the output is properly adjusted, the
 Grease gun amount dispensed from the pump will be sufficient
in volume to replenish the amount consumed
10.3.3 Tool Install during normal breaker operations. Any
interruptions from normal delivery will require
IMPORTANT special attention before the breaker is returned to
service. Interruptions from normal delivery include:
Rapid wear of bushings and tool will result if the  New replacement tool installed
following are not observed.  New replacement bushings installed or wiped
clean of grease for purpose of inspection
 Pre-lubricate the breaker tool before inserting  Any grease line is replaced or added
into front head. This applies to new tools and
 Operating the grease dispenser beyond the
tools that have been wiped clean for
minimum mark has depleted the reservoir
inspection.
Prior to insertion, pre-lubricate all new tools or if
 Prevent dirt and rocks from contaminating the used tool was cleaned for inspection. Spread a
grease. layer of clean grease over surface of tool shank
including the retainer slots. Further greasing is
required after it is installed. Read and follow
instructions for re-lubrication in Section 10.4. New
Chisel Paste
grease lines must be Pre-filled. Purge all pockets
Pre-Lube Coverage of air until delivery is continuous.

10.4 Tool Re-Lubrication – Conventional Method

Fig. 10-6 Pre-Lube the Tool Shank CAUTION

Crush injury from falling or shifting loads.

1. Position breaker horizontally on a stable and All loads must be stable before tool re-
level surface. Use adequate load bearing device lubrication.
to support weight of breaker.
Engage interlock, shut off carrier and
2. If attached to the carrier, close shut off valves remove key. Follow safety instructions in
[Fig. 10-3]. the manual provided by the carrier
manufacturer.
3. Large Tools are Heavy! [Fig. 10-5]. Handle tools
with a suitable hoist and sling. Insert tool in front Figure 10-7. The breaker must be stood upright with
head. the tool contacting the ground. Use the carrier to
push down until the tool is seated firmly against the
4. Insert the large retainer (B). [Fig. 10-4]. thrust ring.

5. Insert small pin (C) through slot in large retainer

(B) until fully engaged. [Fig. 10-4].

6. Install (D) Rubber Plug and (E) Snap Ring. [Fig.

10-4].

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10.0 Changing the Tool – [cont’d]

Generally, tool re-lubrication is recommended every

two hours. However, the operator must actively
monitor the tool and grease must always visible. If
not, shorten the time between re-lubrication. Excess
lubrication ends up as waste. Either extend period
between re-lubrication or decrease the number of
lever strokes.

Fig 10-7 Stand Upright. Push Tool Against Firm

Surface. OK To Grease

Fig 10-9 Grease Must Be Visible On Tool At All

Times

10.4.1 Avoid Costly Lubrication Mistakes

CAUTION
At no time is it permissible to re-lubricate
the tool with the breaker lying horizontally
as shown in Figure 10-9. Neglecting to
press the tool against thrust ring will allow
Fig 10-8 Tool Seated Against Thrust Ring Prevents grease to by-pass and fill the space above
Bypass Into Impact Chamber the tool (impact chamber).
If this occurs, the oil seals may be dislodged and lead
Conventional re-lubrication is accomplished with a to piston and cylinder damage.
grease dispenser such as a standard hand-operated
or power-assisted grease gun.

Apply lubricant as shown in Fig. 10-6. The top lube

fitting lubricates the upper bushing. The lower
bushing is lubricated through the bottom fitting.

1. On stable and level ground, stand the breaker

vertically and push the tool firmly against the
ground. Engage interlock and shut off carrier.

2. Wipe off grease nipple. Press grease gun over

top lubrication nipple. Pump lever 20-30* strokes.

3. Repeat step 2 on lower lube nipple.

*The amount a grease gun will deliver per lever

stroke will vary widely from one gun to the next. The
amount dispensed must equal the amount consumed
between last replenishment. If greasing intervals are
infrequent, additional strokes will be necessary to
refill grease reserves. Pump enough grease until
surfaces are sufficiently covered. Fig 10-10 Incorrect Re-Lubrication Position

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10.0 Changing the Tool – [cont’d]

10.5 Tool Re-Lubrication – AutoLube Options 10.5.2 Hammer Mounted Lubricator – HML Series

As an option, Allied offers automatic grease The AutoLube HML-series is a compact size pump
dispensing systems that provide continuous re- that mounts directly to the breaker. There are no
lubrication of the tool and bushings during operation. electric or hydraulic connections. Grease is
dispensed when the pump is pulsated by the breaker.
When installed correctly and properly maintained, The refillable reservoir is transparent and allows easy
automatic lubricators provide the following benefits- monitoring. Delivery is adjustable to match different
 Higher utilization rate of breaker size breakers and requires no special tools.
 Extend service life of tool and bushings
 Reduced grease waste

A choice of carrier and breaker mounted models is

available.

IMPORTANT
The AutoLube can be used with any breaker
having the necessary connection port. Available
on Hy-Ram models HR290-HR710.

10.5.1 Carrier Mounted Lubricator - CML Series

Fig 10-12 Hammer Mounted AutoLube System

Installation kits for both the CML-series and HML-

series are available from Allied. These kits do not
include Chisel paste. Order separately.

10.6 Benefits of Using Chisel Paste

Allied Chisel Paste is a specialty lubricant made for

use with all breakers. Developed exclusively for
bushing and tools, chisel paste (when applied
Fig 10-11 Carrier Mounted AutoLube System regularly) offers supreme protection against friction-
related wear from heavy-loading.
The CML series AutoLube is designed for mounting
on the carrier. It features a large refillable reservoir Chisel Paste is specially formulated from a unique
with a shut off switch that immobilizes the breaker blend of lubricants that also include solids of
and signals the operator when the reservoir reaches molybdenum disulfide [MoS2], graphite and copper.
the low level mark. The electric motor can drive up to These solids (typically not found in General Purpose”
three pumping elements. and “Multi-Purpose” grease) are key elements of
Chisel Paste that help extend the service life of
The CML series is highly configurable to suit virtually bushings and tools.
any size breaker. Allied offers kits to help facilitate
the installation. Components of each kit, such as the IMPORTANT
number of pumping elements and lube lines, are Pre-lubricate the tool before inserting into front
coordinated with the size of the breaker and carrier head. Keep dirt and rocks from contaminating
combination. Universal kits are also available for non- grease. If Allied Chisel Paste is not used, re-
Allied breakers. When ordering kits, it is necessary to lubrication frequency must be increased. Use high-
provide the make and model of the carrier and quality EP type grease that contains a high
breaker. percentage of molybdenum disulfide [MoS2] and
formulated for use in high-temperature applications.

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11.0 Tool Selection Guide

11.1 Match the Application

C. Blunt – Designed for impact breaking, the blunt
Hydraulic breakers are used in a variety of tool is effective in breaking concrete slabs,
applications including concrete demolition, rock boulder reduction and secondary breaking of
cutting and boulder reduction. Efficient operation, oversize rock. Blunt tools are best for igneous
production rates and service life of the Breaker is rock [e.g. granite] and tough metamorphic rock.
affected by many factors, including:
11.2 Working Length of Breaker Tool
 Variations in operator technique
Allied breaker tools are designed to provide
 Maintenance
exceptional quality and durability. Tools are made of
 Selection of breaker tool high-strength alloy steel and given specialized heat
treatment. Unless the application requires a longer
11.1.1 Methods Used to Break Material length tool, it is best to stay with the standard length
tool supplied with the breaker. Shorter tools are less
Materials are fractured by two methods – Penetrative prone to breaking when subjected to side loading
and Impact. With penetrative breaking, blows from forces. Review and adopt operating methods
the piston drive the tool into the material and wedge it described in Section 6.0.
apart. With impact breaking, blows from the piston
generate a compressive force that squeezes the
material. When the material's strength is exceeded, it
fractures.

The three most commonly used tools for concrete

demolition, rock cutting and boulder reduction are the
Conical, Chisel, and Blunt. Conical [Pointed] and
chisel [wedge] type tools work best in penetrative
applications. The blunt [Flat] tool is used for impact
breaking. Applications include bolder (oversize)
reduction, rip rap and any work with hard, brittle and
abrasive materials. Fig. 11-2 Tool Working Length

11.3 Sharpening the Tool

Breaker tools can be re-machined on suitable

equipment. Conical and blunt breaker tools can be
re-machined on a lathe with carbide tooling. Chisels
can be sharpened on a shaping or milling machine.

CAUTION
High temperatures will alter the original heat
treatment of the tool material and change the
Fig. 11-1 A-Conical, B-Chisel, C-Blunt
strength. Do not cut with torch, hard face or weld
breaker tools. When sharpening the breaker tool,
A. Conical [Point] – Designed for penetrative
prevent temperatures from exceeding 390º F.
breaking, the conical is suitable for most
applications, including trenching and benching in
sedimentary rock [e.g. sandstone], weak
metamorphic rock and general breaking of
concrete. The conical preforms well when
working in reinforced concrete because its round
shape resists twisting that can lead to retainer pin
and pin slot deformation.

B. Chisel [Wedge-Cross Cut transverse or In-line

parallel] – Same applications as the conical.
Useful when cutting action is required.

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12.0 Back Head and Accumulator Gas Charge

12.1 Back Head and Accumulator 1) Gas Charge

WARNING
The Back Head contains nitrogen gas (N2) under
pressure. The gas assists with the downward stroke Only qualified personnel, having
of the piston during the power stroke phase of the knowledge of the machine’s systems,
operating cycle. proper test equipment and tools
should attempt accumulator repairs.
The accumulator is a self-contained pressure vessel
with an elastic membrane that divides the inner Prevent injury from unexpected
housing into a pair of expansible chambers. The release of high pressure gaseous
lower chamber is used to receive, store and energy. The gas must be released
discharge pressurized oil. The upper chamber is filled before disassembly of accumulator
with nitrogen gas. and back head.

Protective eyewear must be worn

After membrane replacement, the accumulator must
when servicing the accumulator.
be pre-charged with nitrogen (N2) gas. This is
accomplished with the charging tool (Fig. 12-2) and a
commercially available nitrogen bottle.

Fig. 12-1 N2 Gas Charge in Back Head Fig. 12-2 N2 Gas Charge in Accumulator

Table 12.1 N2 Gas Charge Kit

Item Part No. Description Qty Remarks / Specifications
1 575427 N2 Gas Charge Kit 1 Kit Kit includes 2,3,4,5
2 --- Charge Tool and Gauge 1 (Fig 12-1 & 2 “Charging Block”)
3 --- Extension 1 (“Adaptor”)
4 --- Hose 1
5 --- Gas Bottle Adapter 1
6 N/A Nitrogen N2 Gas Bottle 1 Not Supplied (Source Locally)

Read, understand and follow all instructions for the safe and proper use of this tool.
1)
Not all models are equipped with accumulator.

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12.0 Back Head, Accumulator Charge – [cont’d]

12.2 Back Head N2 Charge – Safety Precautions  Hex wrench

Read, understand and follow all instructions for the  Torque Wrench
safe and proper use of this tool. These instructions
were prepared to assist the qualified technician with  Light weight oil
the information necessary for measuring/filling the
back head (figure 12-1). The following procedures  Rags
are accomplished with the use of the N2 charging
unit, part number 575427, and a commercially 12.2.2 Connecting the Charge Tool (Fig. 12-1)
available bottle of nitrogen. Refer to the list of “Tools
Required” for other tools needed. 1. Clean immediate area around the charge port.

WARNING 2. Use hex wrench to remove hex plug.

Risk of explosion if filled with 3. Inspect condition of O-ring on charge tool. Close
substitute gas or air. Use only dry bleed valve.
nitrogen gas to fill accumulator.
4. Thread the charge tool into the charge port.
WARNING
5. Attach hose to the charge valve and the nitrogen
Prevent injury from unexpected bottle.
release of high pressure hydraulic
energy. If attached to carrier, relieve 12.2.3 How to Measure Back Head Pressure
all oil pressure inside breaker and
attachment circuit before service.
WARNING

CAUTION For the purpose of these instructions, the nitrogen

bottle is equipped with a pressure regulator.
When working with pressurized
systems, personal protection Connect charge tool as described in Section 12.2.2.
equipment, including safety eyewear (Step 5 is not required to measure pressure).
must be worn.
IMPORTANT
WARNING Accurate charging to the specified pressure is
important for proper performance. Charge the back
Crush injury from falling or shifting head with the breaker positioned horizontally and
loads. All loads must be stable with no contact pressure on the tool. Charge
before service. If breaker is attached pressure shown in technical data section of this
to carrier, lower to a flat stable manual is at 70 ambient.
surface.
1. Depress valve handle on charge tool.
CAUTION
2. Read pressure gage *.
Stay clear of tool to prevent injury
from sudden release. Tool can
3. *Over-pressure of > 5% of specification will
extend from breaker when charging
require adjustment. Use bleed valve to vent
back head.
excess pressure.
12.2.1 Tools Required 4. *Under-pressure > 10% of specification will
require adjustment. Follow the instructions
 Charge Kit 575427 (Fig. 12-1) described in Section 12.2.4 for charging the back
head.
Source additional equipment locally:

 Nitrogen Bottle (equipped with a pressure

regulator is recommended)

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12.0 Back Head, Accumulator Charge – [cont’d]

12.2.4 How to Pre-charge the Back Head 8. Store charge tool in dry location

IMPORTANT 12.3 Accumulator N2 Gas Charge – Safety

Gas pressure is sensitive to temperature. Note that Precautions
the charge pressure shown in technical data section
of this manual is at 70 ambient. Fluctuations in WARNING
pressure will be seen as the temperature changes
between ambient and working temperatures. Only qualified technicians , having
knowledge of the machine’s systems,
IMPORTANT proper test equipment and tools
Accurate charging to the specified pressure is should attempt repairs to the
important for proper performance. Charge the back accumulator.
head with the breaker positioned horizontally and
with no contact pressure on the tool. Prevent injury from unexpected
release of high pressure gaseous
CAUTION energy.
Risk of injury if tool moves unexpectedly.
Stay clear of breaker tool when filling Protective eyewear must be worn
back head with gas. when servicing the accumulator.

1. Connect the charge tool following Section 12.2.2.

WARNING
2. Slowly open valve on nitrogen bottle. Risk of explosion if filled with
substitute gas or air. Use only dry
3. Adjust the regulator to the value specified in the nitrogen gas to fill accumulator.
Technical Data Section + 10 PSI above.

4. Depress and hold valve handle. Allow 1 to 3 WARNING

minutes. Prevent injury from unexpected
release of high pressure hydraulic
5. Release valve handle. Wait 5 to 15 minutes for energy. If attached to carrier, relieve all
temperature of gas inside back head to stabilize. oil pressure inside breaker and
attachment circuit before service.
6. Depress valve handle to recheck gas pressure.
Make final adjustments according to value
specified in Technical Data Section. CAUTION
When working with pressurized
12.2.5 Charge Tool Removal systems, personal protection
equipment, including safety eyewear
1. Close valve at nitrogen bottle. must be worn.
2. Open bleed valve.
WARNING
3. Remove charge tool. Crush injury from falling or shifting
loads. All loads must be stable before
4. Tighten hex plug with torque wrench to 15 lb-ft service. If breaker is attached to
[20 Nm]. carrier, lower to a flat stable surface.
5. Check for leaks by filling the area surrounding the Read, understand and follow all instructions for the
charge bolt with oil. safe and proper use of this tool. These instructions
were prepared to assist the qualified technician with
6. Wipe off oil the information necessary for measuring/filling the
Accumulator (figure 12-2).
7. Store nitrogen tank according to regulations

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12.0 Back Head, Accumulator Charge – [cont’d]

The following procedures are accomplished with the 3. *If +/- 5% of specification, no adjustment is
use of the N2 charging unit, part number 575427, and necessary. If so, remove charge tool from
a commercially available bottle of nitrogen. Refer to accumulator following instruction in Section
the list of “Tools Required” for other tools needed. 12.3.5.

12.3.1 Tools Required 4. *If > +/- 5% of specification adjustment is

required. Follow the instructions described in
 Charge Kit 575427 (Fig. 12-2) Section 12.3.4 of this manual for charging the
accumulator.
Source additional equipment locally:
 Nitrogen Bottle (equipped with a pressure 12.3.4 Charging the Accumulator
regulator is recommended)
 Wrench 1. Follow steps 1-5 for connecting the charge tool.
 Hex wrench
 Torque Wrench 2. Slowly open valve on nitrogen bottle.
 Light weight oil
 Rags 3. Adjust the regulator to value specified in the
Technical Data Section + 50 PSI above.
12.3.2 Connecting the Charge Tool (Fig. 12-2)
4. Depress and hold valve handle. Allow 1 – 3
1. Clean immediate area around the charge port. minutes for gas to transfer.

2. Use wrench to remove hex cap on accumulator 5. Release valve handle. Wait 5 to 15 minutes for
valve. temperature of gas inside accumulator to
stabilize.
3. Remove hex plug on top of accumulator.
6. Depress valve handle to recheck gas pressure.
4. Inspect condition of O-ring on charge tool. Close Make final adjustments according to value
bleed valve. specified in Technical Data Section.

5. Thread the charge tool into the charge port. 12.3.5 Charge Tool Removal

6. Attach hose to the charge tool and nitrogen 1. Close valve at accumulator.
bottle.
2. Close valve at nitrogen bottle.
12.3.3 How to Measure Accumulator Pressure
3. Open bleed valve.

WARNING 4. Remove charge tool.

For the purpose of these instructions, the nitrogen
bottle is equipped with a pressure regulator. 5. Check for gas leak. Use light weight oil around
charge port. Bubbles indicate leak.
Connect charge tool as described in Section 12.3.2.
(Step 6 is not required to measure pressure). 6. Clean oil from charge port

IMPORTANT 7. Install hex plug and tighten with torque wrench to

Gas pressure is sensitive to temperature. Note that 15 lb-ft [20 Nm].
the charge pressure shown in technical data section
of this manual is at 70 ambient. Fluctuations in 8. Install hex cap on accumulator valve.
pressure will be seen as the temperature changes
between ambient and working temperatures. 9. Store nitrogen tank according to regulations.

1. Depress valve handle on charge tool. 10. Store charge tool in dry location.

2. Read pressure gage *.

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13.0 Troubleshooting Guide

CAUTION This guide identifies several commonly encountered

conditions and the recommended corrective action.
Only qualified personnel, having knowledge of the
machine’s systems, proper test equipment and For conditions other than these, or if further
tools should attempt adjustments and repairs. assistance is required, contact the Allied Technical
Service Department.

Condition Possible Cause Corrective Action

Verify shut off valves are open, verify quick
Restriction in pressure or return
disconnects are in working condition. Check if hose
line
has collapsed
Pressure and return lines are Verify supply line is connected to port marked “IN” and
reversed return line to “OUT”
Piston must be pushed out of brake. Apply down
Piston in brake
pressure on the breaker tool

Incorrect breaker tool installed Verify breaker tool is correct

Breaker does not

operate Insufficient oil pressure Refer to section “Operating Pressure Too Low”

Return line pressure too high Refer to section “Return Line Pressure Too High”

Locate source of bypass – Adjust, repair or replace

Carrier hydraulic circuit leaks
faulty components
Control valve [Carrier] Incorrect working mode. Troubleshoot valve for
misadjusted or malfunction mechanical, pilot circuit, or electrical fault
AutoLube reservoir is empty -
Fill Auto-lube reservoir
power interrupted to valve
Maintain right angle to work surface. Refer to Section
6.0
Check breaker tool is receiving sufficient lubrication.
Breaker tool is binding
Check operation of AutoLube. Use Chisel Paste

Breaker tool / bushings are worn

Breaker starts but
operation is irregular Breaker tool loosing contact Use boom, arm and bucket cylinder to follow breaker
with material as tool penetrates material [Refer to Section 6.0]

Return line pressure too high Refer to section “Return Line Pressure Too High”

Operating flow or pressure is

Refer to section “Operating Pressure Too Low”
too low

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13.0 Troubleshooting Guide [cont’d]

Condition Possible Cause Corrective Action

Back head charge is low Fill back head to proper pressure

Operating pressure too low Refer to section “Operating Pressure Too Low”

Maintain right angle to work surface. Refer to Section

6.0
Improper Breaker operation Check breaker tool is receiving sufficient lubrication.
Breaker operates but Tool binding in bushing Check operation of AutoLube. Use Chisel Paste
at reduced impact
Breaker tool / bushings are worn

Return line pressure too high Refer to section “Return Line Pressure Too High”

Control valve [Carrier] Incorrect working mode. Check for mechanical or pilot
misadjusted or malfunction circuit failure

Hydraulic oil overheating Oil temperature should not exceed 176 F [80 C]

Hydraulic oil is overheated Refer to section “Operating Temperature Too High”

Return line pressure too high Refer to section “Return Line Pressure Too High”

Excessive charge pressure in

Readjust to correct pressure
back head
Measure oil Flow – Set to value listed in the
Flow too low
specifications section of this manual
Impact rate slows Leakage in hydraulic circuit
Test hydraulic components for malfunction
down [Carrier]
Consult carrier manufacturer for recommended oil
Oil viscosity too low
type
Maintain right angle to work surface. Refer to Section
6.0
Check breaker tool is receiving sufficient lubrication.
Breaker tool is binding
Check operation of AutoLube. Use Chisel Paste

Breaker tool / bushings are worn

Excessive pulsations
No gas charge in accumulator Stop breaker operation until accumulator is repaired
in pressure hose

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13.0 Troubleshooting Guide [cont’d]

Condition Possible Cause Corrective Action

Set to value listed in the specifications section of this
Relief valve set too low
manual
Leakage in carrier’s hydraulic Test hydraulic components for malfunction or improper
circuit adjustment
Operating pressure Insufficient pump delivery [low
Check pump flow [Measure with flow meter]
too low flow results in low pressure]

Flow adjuster misadjusted Reset flow adjuster

Set to value listed in the specifications section of this

Flow control set improperly
manual
Operating pressure too high or Refer to section “Operating Pressure Too High” or
too low “Operating Pressure Too Low”
Set to value listed in the specifications section of this
Relief valve set too low
manual
Auxiliary cooler may be required
Ambient temperature is high
Check with carrier manufacturer
Check breaker tool is receiving sufficient lubrication.
Tool binding in bushing
Use Chisel Paste

Return line pressure too high Refer to “Return Line Pressure Too High” section
Oil temperature too
high Limit hammering time to 15 seconds maximum
Excessive cycle time
[Refer to Section 6.0]
Set to value listed in the specifications section of this
Oil flow too high
manual
Review operating technique and application. Reduce
Breaking cycle too long
advance. Evaluate breaker size to material
Consult carrier manufacturer for recommended oil
Oil viscosity too low
type

Cooling system fault Clean cooler, repair

Flow restricted from blocked

Remove blockage, replace damaged hoses or fittings
hoses or fittings
Flow restricted from hoses or
Replace with proper size hose and fitting
Return line pressure fittings too small for installation
too high Flow restricted from small ports BREAKER return line must by-pass valve bank and be
in valve bank routed directly to the filter.
Flow restricted from cooler or Repair or replace cooler
return filters Change filter

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13.0 Troubleshooting Guide [cont’d]

Condition Cause Corrective Action

Damaged or worn seals Stop Breaker operation immediately and replace seals
Oil leakage from
Ruptured accumulator Stop Breaker operation immediately and service
body, accumulator or
membrane accumulator
front head
Broken Through Bolt Stop Breaker operation immediately and replace

Check breaker tool is receiving sufficient lubrication

Increase lubrication frequency. Use Allied Chisel
Excessive galling of tool shank Paste
or bushings
Maintain right angle to work surface. Refer to Section
Tool
6.0
Excessive / uneven
wear Reduce advance, Limit cycle time. Refer to Section
Excessive wear on tip
6.0
Maintain right angle to work surface. Refer to Section
Uneven wear on tip
6.0

Excessive tool length Use shorter length tool

Tool driven into material and

Limit tool penetration. Refer to Section 6.0
becomes stuck

Do not pry with tool. Refer to Section 6.0

Bending force exceeds material
strength Operator technique to adopt correct working angle.
Maintain right angle to work surface. Refer to Section
6.0
Tool breakage
Operator technique to adopt correct working angle.
Maintain right angle to work surface. Refer to Section
6.0. Check breaker tool is receiving sufficient
Material strength is weakened if
lubrication. Increase lubrication frequency. Only use
surface is damaged from
grease that is approved for this application such as a
galling, deep gouge or
premium high temperature and extreme pressure type
corrosion.
grease. Allied Chisel Paste is specifically formulated
for this application. Store indoors. Coat with grease to
protect from moisture.

The Breaker is not self-powered. Its performance output of the carrier’s hydraulic circuit. Measure oil
level is affected by a hydraulic system that is not pressures at the supply [IN] and return [OUT].
delivering to specification.
Use a flow meter to test oil delivery of the hydraulic
All hydraulic breakers are designed for optimum circuit. Be sure to include the breaker’s supply and
performance with reliable service life when operated return hoses when conducting a flow test, as they
within the specified parameters. If Breaker operation may be faulty, e.g. collapsed hose. The flow meter is
is abnormal, first check that the carrier's mode switch also used to verify normal operation of the relief valve
is set in the correct position for operating a breaker. and the correct setting of the cracking pressure.
Next, check that the shut off valves are fully open.

If no improvement is seen in the breaker’s

performance, conduct a series of tests to evaluate the

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14.0 Technical Information

14.1 Definition of Terms reached. A relief valve is safety device, used to

protect the circuit against hydraulic overload.
For the purposes of this manual, Hydraulic Flow, Relief valves vary in design. Pilot controlled
Operating Pressure, Dynamic Relief Pressure and pressure relief valves are designed so that the
Static Relief Pressure are defined as follows: relief pressure increases very little as the flow
through the valve increases. For Breaker
 Range – A range is represented by two values applications, they are recommended over direct
'V1 – V2' and generally means the lowest-to- acting type relief valves.
highest limit of a device that will allow it to
adequately respond. “Minimum flow” describes  Dynamic Relief Pressure – Also referred to as
the least amount required while permitting “Cracking Pressure”. The pressure measured at
continuous operation that is both satisfactory and the moment the oil pressure exceeds the preset
efficient. value of the relief valve and the spool “cracks”
open.
 Hydraulic Flow – A measure of the volume of oil
(values given in GPM / LPM) necessary for the  Static Relief Pressure – Also referred to as “Full
safe and efficient operation of the Allied Relief Pressure”. The pressure measured at the
attachment. Flow parameters for attachments moment the relief valve has opened fully and all
such as Breakers are represented by a minimum- oil is by-passed.
to-maximum range.
 Opening Curve – The opening curve is the rise
 Operating Pressure – A measure of the of pressure between dynamic (first open) and
hydraulic oil pressure (values given in PSI / BAR) static (all of the oil flow is bypassed). The
taken in the breaker’s supply line during dynamic pressure is always less than the static
operation. Pressure parameters for attachments pressure. A relief valve adjusted to a dynamic
such as Breakers, are represented by a pressure of 3000 psi (200 Bar) will crack open
minimum-to-maximum range. when the preset point is reached, but fully opens
at a higher pressure.
 Relief Valve – An adjustable, spring-loaded
valve that opens when a preset pressure value is

Dynamic Relief Pressure

Operating Pressure (Relief valve cracks open)

Hydraulic
Flow Range

Opening
FLOW Curve

Operating
Attachment Pressure
Operational Range
Range
Static Relief Pressure
(No flow to attachment)

PRESSURE

Fig. 14-1: Flow-Pressure Diagram

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14.0 Technical Information

14.2 Testing the Hydraulic Circuit The hydraulic breaker is designed to perform
efficiently and reliably at the prescribed
A performance evaluation of the carrier's hydraulic specifications. Performance is negatively impacted if
circuit is important before the breaker is first used. the hydraulic system is operating at a diminished
Accurate assessment entails thorough testing under capacity and/or set outside the permissible range.
varied conditions, including temperature, work mode,
engine speed and load. If the Breaker is not working or underperforming,
thoroughly check the hydraulic system of the carrier
Tools required to complete these tests include a flow before disassembly of the Breaker. Be sure to include
meter and pressure gages. Record the test the hoses attached to the breaker to eliminate any
measurements in the worksheet provided below. possible faults, e.g. collapsed hose.
Compare the test results with the Technical Data
section of this manual.

Load Relief Relief Return

Pressure Oil Temp Pressure Pressure Pressure
Mode Engine RPM Flow [GPM] [PSI] [ºF] [Crack] [Static] [PSI]
0

1000

1500

1800

2000

2200

2400

2600

2800

3000

3200

3400

Oil Temperature – Testing must be done while the

CAUTION
hydraulic oil temperature is at normal operating
Before starting, make sure the circuit to be tested temperature. Stop test if temperature exceeds 176 F
has a relief valve. Open restrictor valve on flow (80 C)
meter. Procedures can vary depending on specifics
of your equipment. Follow the instructions provided Relief Pressure [Crack] – Slowly close restrictor
by the manufacturer of the carrier and flow meter valve until pressure gage indicates relief valve has
when testing. cracked open.

Mode – Set to Breaker position (if equipped). Relief Pressure [Static] – After cracking pressure is
reached, further adjust restrictor valve until flow gage
Engine RPM – Set to normal operating speed indicates relief valve is fully open.

Flow [GPM] – Record measured flow at each load Return Pressure [PSI] – Record the pressure
pressure measured in the return line. Measuring point for gage
must be located near breaker’s outlet port.
Load Pressure [PSI] – Steadily increase load with
restrictor valve on the flow meter

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14.0 Technical Information – [cont’d]

Table 14.1 Technical Data HR270 HR290

Impact Rate a] Blows/min 500 - 1000 460 - 900

Oil Flow Range GPM [L/min] 10 – 18 [35 - 70] 12 – 23 [45 - 90]

Operating Pressure b] PSI [bar] 1380 – 2470 [95 - 170] 1380 – 2400 [95 - 165]

Pressure Relief – Min c] PSI [bar] 2600 [180] 2645 [170]

Pressure Relief – Max d] PSI [bar] 2900 [200] 2610 [180]

Back Pressure PSI [bar] 60 –145 [4 - 10]

Oil Viscosity @ Operating Temperature

cSt *30-60 [15 – 1000]
*Optimum [Permissible Range] h]

Oil Temperature F° [C°] -4 - 176° [-20 - 80°]

N2 Gas Charge – Back head 70 F° [21 C°] PSI [bar] 232 [16]

N2 Gas Charge – Accumulator @70 F° [21 C°] PSI [bar] Not Equipped

Port Connection – IN [OUT] Threaded BSPP 1/2-14 [same] BSPP 3/4-14 [same]

Line Size – Min. ID. IN [OUT] in. [mm] 1/ [12] [same] 3/4 [19] [same]
Standard Type Conical Conical
Breaker Tool: Diameter in. [mm] 2.68 [68] 2.93 [74.5]
Work Length in. [mm] 12 [305] 16 [406]
Working Weight e] lbs [kg] 650 [295] 950 [430]

Excavator f-E] 8 – 20 [3.5 - 9] 13 – 22 [6 – 10]

Carrier Weight Backhoe f-B] 1000 lbs [kg] N/A 12 – 25 [5.5 – 11]

Skid Steer f-SS] N/A 8 + [3.5 +]

Mounting Family BR BR

a] Actual frequency depends on oil flow. Factors that affect oil flow include oil viscosity and temperature.

b] Actual operating pressure depends on oil flow, back pressure, material to be broken. Models HR390 thru HR710 are equipped with
Pressure Adjuster.

c] Permissible setting of MINIMUM pressure relief – DYNAMIC. Measured operating pressure + Minimum 435 psi [30 Bar]

d] Permissible setting of MAXIMUM pressure relief – STATIC. Not to exceed carrier’s main relief setting.

e] Weight reflects standard equipped Breaker configured for E, B & S-type carriers with typical mounting bracket & standard tool

f-E], f-B], f-SS], Values shown are guidelines – Always consult carrier manufacturer’s lift capacity to assure stable carrier operation. The
carrier must have adequate lift and hydraulic capacities to properly and safely operate the Breaker.

h] Many factors can reduce the service life of hydraulic components. Incorrect fluid viscosity is just one of these factors. To
prevent low (or high) viscosity from cutting short component life, select an appropriate fluid for the operating temperature
and viscosity range and then keep it maintained on a continuous basis.

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14.0 Technical Information – [cont’d]

Fig. 14-2 General Dimensions HR270

Fig. 14-3 General Dimensions HR290

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14.0 Technical Information – [cont’d]

Fig. 14-5 Each Flat = 60 Rotation. Fastener

Fig 14-4 Fastener Location
Tightening Sequence

Table 14.2 A - Side Rod MPORTANT

Model A- Side Rod Torque  Apply Moly-Paste 676927 to threads at assembly.

 Follow sequence (Fig. 14-5) to ensure each tie rod is evenly
HR270, Refer to Table 14.3 loaded.
HR290  Follow progressive tightening* steps 1-4.
*Progressive tightening means the nut will be turned a little at a
time. Never exceed 1 full turn without turning the other 3 nuts.

Table 14.3 A - Side Rod Torque Ft-Lbs [N.m]

Final Torque
Model Step 1 Step 2 Step 3
Step 4
110 220 330 440
HR270
[150] [300] [450] [600]
165 330 500 660
HR290
[220] [450] [675] [900]

Table 14.4 D - Mounting Bracket

Fasteners Ft-Lbs [N.m]

Model D – M16

HR270, 130
HR290 [175]

Fig 14-6 Mounting Bracket

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15.0 Service Record

Service Performed By Date

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