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1. SERVICE MANUAL SSOOSAN NOTICE DO NOT ATTEMPT TO LIFT THE POWER CELL OUT OF THE HOUSING WITH FIT TINGS INSTALLED IN THE IN AND OUT PORTS THE FITTINGS WILL INTERFERE WITH THE HOUSING 8 Remove the excavator mounting bracket 9 Remove the upper cushion 1 10 Install a lifting eye into each of the threaded holes located in the top of the main accumulator 1 Using slings and a hoist lift the breaker out of the housing and set it on a flat surface in a vertical position Keep the slings attached NOTICE DO NOT DISASSEMBLE THE BREAKER WHILE IT IS LAYING ON ITS SIDE THIS MAY DAMAGE INTERNAL COMPONENTS Accumulators SERIOUS INJURY MAY RESULT FROM A PART OR OIL MOVING AT HIGH VELOCITY DUE TO SUDDEN UNEXPECTED RELEASE OF GAS UNDER PRESSURE DISCHARGE THE ACCUMULATOR BEFORE DISASSEM BLING THE BREAKER All breaker models contain an accumulator nitrogen gas chamber which assists in producing the impact energy This accumulator or chamber is located in the top of the breaker power cell and is typically charged with 230 psi 16 bar of nitrogen gas Some breaker models also contain an accumulator located at the mid section of the breaker power cell The purpose of this accumulator is to dampen the recoil shock produced during operation of the breaker This accumulator is typically charged with 785 1 54 bar of nitrogen gas Lae top accumulator i A side accumulator 201 2 can be serv
2. 18 Using a pry bar and scrap metal material to protect the cylinder face remove the valve plug 2 Lift out the valve 17 and valve sleeve 67 Thrust Bushing Disassembly 1 Use the following steps to remove the thrust bushing from the lower body If the lower bushing 37 has not been removed follow the instructions in step a below If the lower bushing has been removed skip step a Remove the hex socket plugs 35 and retaining 31 rings Using a punch and hammer Tap out the retaining pins 29 and the rubber plugs 30 Remove the lower bushing 37 b Remove the hex socket plug 28 Using a punch and hammer tap out the retainer pin 27 Slide the thrust bushing 36 out INSPECTION OF PARTS NOTE In addition to the instructions and guidelines below also see the pages titled WEAR TOLERANCES at the end of the SERVICE INSTRUCTIONS sec tion SEAL CARRIER PISTON AND CYLINDER Inspect the surfaces of the bore of the seal carrier and cylinder and the surface of the piston for wear galling and cracks A light scuffing or burnishing of surfaces is normal Check especially for freedom of movement of the parts and that the piston does not stick or bind as it is moved in the seal carrier and cylinder Coat the parts with hydraulic oil for this test If small burrs are found remove them with 220 grit emery cloth NOTICE The parts in the breaker are finely manufact
3. mm will cause damage to the piston Do not just replace the tool bit or the lower bushing individually as this will result in premature wear of the replaced component It is recom mended to replace all worn components a A N MOVE THE TOOL BIT BACK amp FORTH amp MEASURE THE GAP BETWEEN TOOL BIT amp LOWER BUSHING TIE RODS amp TIE ROD NUTS Inspect the tie rods and nuts for wear and cracks When clean and coated with anti sieze the tie rods should thread into the nuts without any effort If some resistance is encountered check all threads for dirt particles or damage NOTE If a tie rod is found to be broken all 4 tie rods must be replaced RETAINING PINS amp ROD PINS Inspect all retaining pins and tool retainers for excessive wear cracks and chipping Replace if cracks or chipping is noted Replace any rubber plug that was removed e HOUSING Inspect the housing for cracks on the outside and on the inside If cracks are present have a certified welder perform repairs After repairs the housing must be stress relieved Make sure all decals and stickers are legible Inspect the upper and down cushions for distress If the material is crushed cracked or has chunks missing replacement is necessary Inspect the all wear plates for excessive wear and looseness Replace parts as necessary ASSEMBLY Before assembly thoroughly clean all components with a degreasing solution and then bl
4. CUMULATOR ASSEMBLY 4 Apply Loctite 242 and install the capscrews 52 and tighten Final torque is accomplished later plug 28 Accumulator Charging Charge each accumulator as specified on the page titled NITROGEN CHARGING THE ACCUMULATOR found earlier in this manual Housing Installation NOTE If maintenance is performed on a breaker to the extent that the power cell is removed from the housing it is always recom mended to take advantage of this opportunity to replace the upper and down cushions and wear plates even if they appear only slightly used 1 Install a lifting eye into each of the threaded holes in the top of the main accumulator assembly Attach slings and a hoist 2 Lift the power cell and lower it into the housing Make sure the oil ports are positioned with the window opening in the housing Lower the power cell into the housing until it rests against the down cushion 16 Lowering The Power Cell Into The Housing 3 Install the wear plate guide 30 with a new wear plate 2 Secure in place with capscrews 28 and washers 29 4 Install the upper cushion 1 5 Install the mounting bracket Tool Bit Installation 1 Grease the top 250 mm 10 inches of the tool bit with high temperature grease and insert the tool bit into the lower body Align the notches of the bit with the rod pin holes in the lower body and then install the rod pins 2 Install the stop pin 43 followed by the
5. SERVICE INSTRUCTIONS DISASSEMBLY Refer to the parts illustration for correct orientation of parts Removing the Housing 1 Lay the breaker in a horizontal position to remove the tool bit Remove the sound plug 13 Remove the hex socket plug 28 Drive out the retainer pin 27 gS ill tool bit rod pins sound plug hex a socket plug and retainer pin sound plugs 2 Remove the sound plugs 12 Drive out the rod pins 43 and then remove the tool bit 3 Remove the sound plugs 13 hex socket plugs 35 and retaining rings 31 Using a punch and hammer Tap out the retaining pins 29 and the rubber plugs 30 Remove the lower bushing 37 sound plugs hex socket plugs and retainer pins lower bushing Stand the breaker up in a vertical position Remove the capscrews 25 and washers 26 securing the window covers 21 amp 24 to the housing Remove the sound plugs 10 from each side of the housing some models do not have these plugs Unscrew the hoses and fittings and remove them Install plugs in the open ports Install plugs or caps on the hoses sound plug capscrews amp washers Remove the capscrews 28 and washers 29 securing the wear plate guide 30 to the housing Remove the wear plate guide some wear plate guides are located near the mid section of the housing wear plate amp guide capscrews amp washers SOOSAN HYDRAULIC BREAKER
6. ces toward the tool bit end of the lower body 4 Obtain a piece of aluminum or brass round stock that has a diameter larger than the inside diameter of the thrust bushing Place the round stock on top of the upper bushing Using a rod or large punch against the piece of stock tap the thrust bushing into place Periodically check the position of the thrust bushing as the tapping progresses 5 Install the retainer pin Using a punch tap the retainer pin 27 until it seats Install the hex socket plug 26 6 Install the lower bushing 37 Align the grooves in the bushing with the retainer pin holes Install the retainer pins 29 new rubber plugs 30 and retaining rings 31 Install the hex socket plugs 35 using Loctite 608 Tighten to the torque specified in the torque chart in this manual 7 Position the lower body so that the lower bushing is resting on the floor or work surface Cylinder Assembly 1 Apply clean hydraulic fluid and install the seals 12 13 amp 14 to the underside of the cylinder 6 as shown in the illustration below CYLINDER PISTON LOWER BODY 14 Cylinder Seals 2 Position the cylinder on top of the lower body as shown in the parts illustration Valve and Valve Seals Installation Do not hammer the spool or sleeve into the bore in the main body Hammering the spool or sleeve into the bore will damage the spool stem 1 Lubricate the valve sleeve 67 with hydraulic f
7. hen turn the valve adjuster 2 1 2 turns counter clockwise 3 Using a felt pen place a mark on top of the valve adjuster and a corresponding mark on the face of the cylinder See the illustration below Location of o ring and back up rings if used Mark position after adjusting valve wee 7 Top view of valve adjuster and nut 4 Apply Loctite 680 to the threads of the nut 77 and then install the nut onto the valve adjuster DO NOT LET THE VALVE ADJUSTER TURN IT MUST REMAIN AT THE MARKS Use an allen wrench to prevent the valve adjuster from turning and then tighten the nut Final tighten the nut to 100 ft 1b 136 Nm Make sure the valve adjuster does not turn during the nut tightening process and that the mark on the adjuster valve and the cylinder face corre spond Side Accumulator not used on all models 1 Ifthe holders 61 62 amp 63 were disassembled reassemble them to the accumulator body 48 Make sure the center pin 64 is positioned correctly as shown in the illustration below 2 Tighten the nut 60 securely HOLDERS CENTER PIN _ HOLDER PIN CENTER PIN amp HOLDERS Install a new diaphragm 50 to the accumulator body 48 and then install the accumulator cover 51 as shown in the illustration below COVER DIAPHRAGM O RING BACKUP RING AC
8. hex socket 10
9. iced without removing power cell from housing Discharging The Accumulators Top Accumulator Remove the protective plug 79 from the charge valve 3 Release the nitrogen charge by depressing the charge valve poppet with a 2 Phillips screw driver or other blunt tool After discharging the accumulator the charge valve may be removed if necessary Removing the Protective Plug Side Accumulator Remove the 2 o ring plugs 56 amp 58 Then turn the charge valve 54 to 2 turns counter clockwise discharging the side accumulator Side Accumulator Disassembly NOTE The side accumulator can be serviced without removing the power cell from the housing If the accumulator does not require servicing than there is no need to disassemble it However if the breaker is being disassembled for servicing it is a good idea to also dissassemble and inspect the accumulator and replace the diaphragm and seals The weight of the assembled breaker will help provide leverage for loosening the capscrews 1 First loosen the capscrews 52 that secure the cover to the body of the accumulator Do not remove the capscrews at this time NOTE These capscrews may be loosened and removed after the accumulator has been removed from the breaker power cell Remove the side accumulator from the breaker power cell as an assembly by removing 4 capscrews 49 Remove all capscrews and lift off the cover 51 Lift out
10. luid and then install it into the cylinder 2 Lubricate the valve 17 with hydraulic fluid and then install the valve into the valve sleeve as shown in the parts illustration 3 Apply clean hydraulic fluid and install the o rings 19 amp 20 onto the valve plug 18 Install the valve plug Piston Installation 1 First make sure the interior of the cylinder is coated with hydraulic fluid 2 Coat the piston 38 with hydraulic fluid 3 Install a lifting eye into the top of the piston Using a hoist insert the piston into the cylinder Lower the piston slowly being carefull not to damage it or the interior of the cylinder Seal Carrier Assembly and Installation 1 Apply clean hydraulic fluid and install an o ring 4 into the top outside groove of the seal carrier 5 as shown in the illustration on this page 2 Apply clean hydraulic fluid and install the seals 9 10 amp 11 as shown in the illustration on this page MAIN ACCUMULATOR CYLINDER PISTON Seal Carrier Seals 3 Apply grease and install an o ring 4 into the groove located at the bottom outside of the seal carrier as shown in the illustration above 4 Place the seal carrier onto the piston Make sure the seal carrier is positioned as shown in the parts illustration Slide the seal carrier down the piston and into the cylinder Main Accumulator Assembly 1 Apply grease and install an o ring 4 into the groove on the main accum
11. ow dry with compressed air to thoroughly clean oil passage ways Exercise care when using compressed air and degreasing solutions Always use protective eye wear and breathing protection If flammable solvents are used make sure they are used in an area where there will be no presence of open flame static electricity or sparks from electrical equipment such as electric motors When assembling internal metal parts always coat them thoroughly with hydraulic fluid Seals and o rings should be lubricated with clean hydraulic oil Handle machined parts carefully to ensure they are not damaged during the assembly process Do not force parts together If difficulty is encountered in assembling parts inspect each part for burrs nicks or galling before proceeding any further Thrust Bushing and Lower Bushing Assembly Installing The Thrust Bushing NOTICE The thrust bushing is custom fitted to each individual breaker A new thrust busing must be machined prior to installation into the lower body 1 Measure the outside diameter of the thrust bushing 36 that was removed from the lower body 26 in at least two places Record the highest measurement Machine the outside diameter of the new thrust bushing to 001 inch under the recorded measure ment 2 Turn the lower body so that the tool bit end is facing up 3 Place the thrust bushing into the bore of the lower body so that the bevel on the inside diameter fa
12. the diaphragm 50 Discard the o ring and backup ring 46 amp 47 capscrew 8 8 8 backup ring Accumulator Piston amp Main Accumulator Disassembly 1 Unscrew and remove 4 nuts 39 Do not use an impact wrench Remove the 4 washers 41 washer 2 Unscrew and remove 4 tie rods 40 Do not use an impact wrench Keep the tie rods and tie rod nuts 42 together in matched sets Lift off the main accumulator using lifting eyes slings and a hoist accumulator assembly cylinder 3 Install a lifting eye into the top of the piston 16 Using a hoist lift the piston and seal retainer 5 out of the cylinder 6 Remove the seal retainer off of the piston by tapping it with a rubber hammer Remove and discard the o rings NOTE The thrust bushing should slide out through the bottom of the lower body without difficulty If the thrust bushing will not slide out it will be necessary to obtain a piece of aluminum or brass round stock that has a diameter larger than the inside diameter of the thrust ring and then place it on top of the thrust ring Using a rod or large punch against the piece of stock hammer the thrust bushing out MALLET gt ROD 5 Install a lifting eye into each side of the cylinder Using a hoist lift the cylinder off of the lower body 26 Valve Plug amp Valve Disassembly 1 Install a lifting eye into the top of the valve plug
13. ulator 1 as shown in the illustration below MAIN ACCUMULATOR CYLINDER Install O ring Into Grove on Main Accumulator 2 Install lifting eyes into the top of the main accumula tor Using a hoist set the main accumulator on top of the cylinder as shown in the exploded parts illustra tion Tie Rod Assembly 1 Apply Kopr Kote anti sieze to the threads of each tie rod 40 and nut 42 2 Install one tie rod at a time and check it and the nut for proper thread engagement If difficulty is encountered while turning the tie rod by hand inspect the threads of the tie rod and nut for burrs or dirt 4 With successful thread engagement screw the tie rods into the nuts 5 Apply Kopr Kote anti sieze to both sides of the washers 41 and the threads of the nuts 39 Install the washers and nuts onto the tie rods and tighten by hand 6 Tighten the nuts in a cross pattern in three torque increments to the torque specified in the torque chart in this manual DO NOT USE AN IMPACT WRENCH Valve Adjuster not used on all models 1 Apply grease and install a new o ring 73 and back up rings 68 onto the valve adjuster as shown in the illustration below NOTE Some models do not use the back up rings 2 Install the valve adjuster by hand until it bottoms out in the bore and stops turning If an allen wrench is used do not force the valve adjuster beyond the bottom out point as this will damage the valve T
14. ured with critical tolerances REFURBISHING OF PARTS SHOULD ONLY BE ACCOMPLISHED BY AN ADEQUATELY EQUIPPED MACHINE SHOP PARTS SHOULD NEVER BE POLISHED OR BUFFED WITHOUT THE USE OF A TURNING LATHE If galling is present consult the dealer to see if the part may be reworked If cracks are present the part must be replaced VALVE SLEEVE VALVE amp VALVE PLUG Inspect the surface of the bore of the valve sleeve and the surface of the valve and valve plug for wear galling and cracks A light scuffing or burnishing of surfaces is normal Check especially for freedom of movement of the valve in the valve sleeve If small burrs are found remove them with 220 grit emery cloth Do not break the sharp edges of the valve sleeve or valve spool as this will cause the valve to malfunction If galling is present the part should be replaced If cracks are present the part must be replaced THRUST BUSHING amp LOWER BUSHING Inspect the thrust bushing and lower bushing for excessive galling and metal pickup on the tool bit Also check for cracks If cracks are present the parts must be replaced The extent of wear of the upper and lower bushings and the tool bit can be checked by moving the tool bit back and forth and measuring the gap between the tool bit and the lower bushing If the gap is more than 0 354 in 9 mm the upper bushing lower bushing and the tool bit should be replaced A gap in excess of 0 354 in 9

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