"service manual"
Contents
1. VI Accumulator Removal and Rebuilding DAIS LVS POTIS eut restet miii 1 E TAZ AOS oreo mice eave ato T KU Mugen Uu eens ACHON a SE ACCUMUIALOF ING use ped stb prat bet EE KH ie Sao prd M d eae E Accumulator uii proni Aa ifelersig miserie nerien ori LOEO OLI ERR Vil Disassembly of the Breaker Removing Breaker Side Plates S Breaker Head Removal and Disassembly Cylinder Removal and Disassembly cesses Disassembly Of GhHckK HOUSING susc td exa uo e ep iR EX E Deb n e LU RC Sa c ac es PPM2000000 Version 102803 3 SG He Bust A INDECO NORTH AMERICA VIII Assembling the Breaker Chuck Housing Gylinder ASSembly ice scies a at DL ode itu edes Breaker Head Assembly Breaker Side Plate Assembly Assembly of Pressure and Return IX Trouble Shooting and Problem Diagnosis Checklist for Accurate Breaker Problem MT Low Worki2. se 53 APPENDIX NORTH AMERICA Breaker Parts Explosions Reference only MES 150 PPM2000000 Version 102803 54 APPENDIX 9 INDECO NORTH AMERICA This page was intentionally left blank PPM2000000 Version 102803 55
3. interference Figure 03 02 There should also be no obstruction between the hammer and the tool Figure 03 02 Operate Breaker Free and Clear of Obstructions PPM2000000 Version 102803 14 1 9 h INDECO NORTH AMERICA When breaking large blocks of rock any protrusions should be broken off first in order to reduce the overall size of the block For secondary demolition before starting the hammer adjust the material to be broken so that itis on a hard stable surface Figure 03 03 A small pocket of rock dust can sometimes occur in the well formed by the tool Figure 03 04 The hammer impact may be released on this therefore not breaking the rock The tool will then overheat and may deform The solutions to this are either to make another parallel hole nearby or to carry out small movements of the hammer to disburse the rock dust Do not continue in the same spot This will waste the hydraulic power and damage the tool When using the hammers in these positions the tool should be removed every 8 hours and the internal faces of the bush cleaned with a wire brush or lubricant cleaner Figure 03 05 If the hammer is very full of rock particles remove the appropriate plug from the side of the chuck housing and blow out the hammer with compressed air Figure 03 03 Maintain Hard Stable Working Surface Figure 03 04 Dust Pockets May Cause Tools To Become Deformed PPM2000000 Vers
4. is exclusive and na other warranty expressed or implied is given on this equipment NO WARRANTY REQUEST WILL BE ACCEPTED WITHOUT COMPLETION AND RETURN OF THIS FORM WITHIN THIRTY 30 DAYS FROM DELIVERY Customer Signature Dealer Dealer Authorized Signature WHITE INDECO YELLOW DEALER PINK OWNERS GOLDENROD UNIT FILE Figure 01 05 Sample Attachment Delivery Report ADR Soph the INDECO ll General Breaker Usage NORTH AMERICA GENERAL BREAKER USAGE This hydraulic demolition hammer as a general rule should be used with the same technique as a jackhammer Choose the appropriate tool in order to obtain maximum productivity The profile of the tool should be chosen according to the nature of the material depending on the type of job quarry earth moving trench work tunnels demolition etc a Position the carrier so that the reach to the work is adequate Ensure that the carrier is in a stable position and is not placed on a crumbling or slipping surface during operation Figure 02 01 This guarantees a constant load on the hammer Figure 02 01 Position Carrier Correctly b Place the hammer tool perpendicular to the surface to be broken Figure 02 02 Always act with the carrier arm keeping the hammer perpendicular to the work and describing a slight arc closing the arm towards the operator This method of operation will dramatically extend the life of the tool and bushing Figure 02 02 Ke
5. position of the side bolts Tighten if loose replace if broken Disassemble the variable valve Guiding Plug Position 418 and verify that it is working correctly PPM2000000 Version 102803 49 9 Sb He Best A INDECO NORTH AMERICA Disassemble the tool and looking into the upper bushing check that the piston is completely free Check the wear of the bushings in the chuck housing Check that the point end of the tool is in usable condition Check the wear of the upper bushing If the problem cannot be resolved call INDECO North America at 203 377 7791 for Breaker Lacks Power jn 2 Check to verify that the carrier s shut off valves are open Check the operation of the breaker control pedal Check the carrier pump for correct flow and pressure Push the hammer to the bottom to charge the piston and try again Verify that the pressure relief valve of the carrier circuit is not open If it is check its calibration level The minimum pressure to the carrier must be at least 3096 higher than that to the hammer Verify that there are no leaks in the carrier hydraulic circuit pump or other components Disassemble the variable valve Guiding Plug Position 418 and verify that it is working correctly Check if the pipes and hoses are vibrating or jumping excessively especially on the pressure side If necessary replace the diaphragm and recharge with nitrogen Check that the inlet operating pressur
6. the Accumulator onto the Breaker and fasten the Accumulator Nuts Position 507 cross tightening as per Torque Specifications Figure 06 06 Figure 06 06 Install and Torque Accumulator MES 150 ATTENTION The accumulator charging Specifications for all INDECO Breaker accumulators are 475 PSI to 550 PSI 32 to 38 BAR For all models up to and including the MES 1200 520 PSI to 620 PSI 36 to 43 BAR For all models MES 1500 HD and larger PPM2000000 Version 102803 3l the Best 2 INDECO NORTH AMERICA Nitrogen Recharge Note On Breaker Models MES 150 through MES 200 the accumulator must be assembled on the breaker prior to the nitrogen charge 1 Carefully install the Pressure Reducer Regulator assembly into the nitrogen tank following the safety instructions Figure 06 20 The nitrogen bottle must not have a level below 45 bars 652 5 psi 2 Attach the Rubber Hose to the Pressure Reducer Regulator and the nitrogen tank valve 3 Attach the Inflating Body so the hexagonal pin fits inside the Inflating Screw Position 504 8 mm HEX on Breakers up to 300 Series 14 mm HEX on Breakers 500 Series and up Check the O Ring on the sealing face Figure 06 21 Figure 06 20 Assemble and Install Figure 06 21 Attach and Install Inflation Pressure Regulator Onto Nitrogen Tank Body 4 Install the Inflating Body to the Accumulator Figures 06 22 Figure 06 22 Installation of Inf
7. the blows per minute For the same phenomena longer tools at equal energy and frequency bear more stress than shorter ones Breakers working at higher frequencies must be lubricated more often due to the above mentioned stress on the tool as well as the thermal damage created by the friction of the tool and lower bushing Matching a small breaker to a carrier larger than hammer specification creates high stress conditions on the tool Operators are not always skillful in using the breaker Visibility problems site conditions and the use of the point to move materials can set up surface fractures in the tool Breakage may not occur immediately but the conditions are now in place for a future failure Method to Reduce These Effects amp Increase Tool Life ge a To drastically reduce the undesirable stresses tool the breaker should be positioned perpendicular to the material to be worked Slight arching in of the hammer toward the operator while firing and billowing the progression of the tool into the material will deliver uniform pressure on the bushing in the contact areas This will also allow the lubricating grease to flow around and cool the tool thus avoiding seizures micro welding and the creation of localized hot spots detrimental to the heat treating of the tool All attempts must be made to eliminate prying with the tool or moving the carrier while the weight is on the tool Do not pivot the carrier on the
8. time an attachment is installed on a different carrier The customer should be advised of the correct operation and maintenance procedures The ADR should be used as a checklist for each delivery of an INDECO attachment A small investment of time to check these readings will save maintenance and repair costs and increase customer satisfaction by offering trouble free productive performance PPM2000000 Version 102803 8 the Best INDECO NORTH AMERICA lt 3 the Beat n INDECO ATTACHMENT DELIVERY REPORT Sa eria Stratford CT 06615 Date FAX 203 377 7796 Model S N Dealer Address City State Customer Address City State Zip Carrier Serial Number Oil Flow at Attachment Carrier Circuit or System Customer has received and reviewed Relief Pressure l all dacumentation including Operating Pressure at Attachment i CIMA Safety Return Circuit Pressure Operatior s Manual at Attachment i Oil Temperature c Carrier Circuit or System Relief Pressure should General Operation be a minimum of 500 PSI greater than the Warranty Attachment Operating Pressure Breaker Lubrication The distributor has instructed me and or my operator regarding correct operation maintenance and safety consideration of this equipment and delivered it to me in satisfactory condition Furthermore I have read the warranty and understood that such warranty
9. tool Overheating of the tool should be avoided on the point or chisel end This occurs when the tool works in an area longer than 30 seconds creating a dust pocket between the tool and hard material PPM2000000 Version 102803 21 9 INDECO NORTH AMERICA The tool should be constantly lubricated with INDECO Supreme 1000 grease You can never over grease the lower end of the breaker Attention to this fact will add longevity to your tool and bushing life PPM2000000 Version 102803 22 INDECO NORTH AMERICA Typical Tool Failures Misalignment or Pry Break Figure 05 02 The bending stress exceeds the materials strength and the tool snaps Caused by working at an incorrect angle or using the tool for mechanical leverage The failure usually occurs near the tool bushing s front face This failure can also be caused by the breaker slipping while hammering at angles not perpendicular to the surface of the material being broken he failure type is a brittle type and typically has a li formation d Figure 05 02 Misalignment Break Seizing in the Tool Bushing Figure 05 03 Strong side loading and striking the tool at the same time causes the tool and bushing surface to be damaged This failure is cause by incorrect or insufficient lubrication The failure generally occurs in the front tool bushing area The failure type is a fatigue fracture starting at the surface of the tool Figure 05 0
10. water If it has perform a general check and cleaning replacing any unusable parts If the problem cannot be resolved call INDECO North America at 203 377 7791 for assistance PPM2000000 Version 102803 51 opo the Best INDECO APPENDIX A NORTH AMERICA Breaker Technical and Torque Specifications MES 150 Technical Specifications Technical Specifications Value 11 Lbs Maximum Lower Bushing D Information required for Attachment Delivery Report ADR Torque specifications Item Positior Bolt Size Wrench Ft Lbs Side Bolt Nut 4 zm _ 40 o 6mmAlen 360 Link Screw 6 mm Allen Variable Plug Inflation Screw Accumulator Screw NA ___________ Shell Fixing Screw 506 1 0 0 0 ____________ Side Plate Screw 607 Self Locking Nut Top Cap Bolts I Initial torque is 80 ft lbs and final torque is 145 ft lbs Under Water Plug NA 607 PPM2000000 Version 102803 22 oye the Beet 9 INDECO NORTH AMERICA APPENDIX B Breaker Regulation Chip S REGULATION SYSTEM The has a new work pressure regulation system and therelera ako a impact energy regulation system Under the base ii has en adu Boss ara oboe dont let in or Ve the hock pressure the working power can be regulated by the chip in the required direction In graph the most working field amp
11. with Lithium grease Lower the Distributor Box Body Position 302 Assemble the Dowel Position 310 and the O Ring Position 311 and screw into the Distributor Box Body Place the Box Body Cover Position 305 onto the Distributor Box Figure 08 37 9 Insert the mushroom valve into the box body cover Figure 08 38 Figure 08 37 Install Box Body Cover Figure 08 38 Install Mushroom Valve PPM2000000 Version 102803 42 the Best INDECO NORTH AMERICA Breaker Head Assembly Insert the O ring Seal s Position 303 into the o ring groove located at the lower portion of 1 the Head Assembly Position 301 Figure 08 41 2 Lubricate all sliding areas between the Box Body Cover and the Head Figure 08 42 Figure 08 41 Install O ring Into Breaker Figure 08 42 Lubricate Sliding Areas Head Note On MES150 the Side Rods Position 312 must be torqued into the Chuck Housing Assembly Position 307 Figure 08 43 Figure 08 43 MES 150 Side Rods PPM2000000 Version 102803 43 Che Best 9 INDECO 3 Lower the Head Position 301 onto the Cylinder Position 201 4 Using a plastic dead blow sledgehammer drive the head down over the Distributor Box Body Cover Position 302 until it bottoms out on the Cylinder Position 201 Figure 08 44 Figure 08 44 Using a Dead Blow Hammer to Drive Head down 5 Cross tighten the Side Bolts to the specified Initial torque Tighten 1 3
12. 3 Tool Seized in Bushing Blank or Dry Firing Figure 05 04 Occurs when the working end of the tool is not in proper contact with the material being broken The failure can also occur when breaking through the material and the breaker strikes the tool a last time When struck without resistance at the working end the tool the tool stops abruptly when it is stopped by the retainers instead of the material This results in breaking and deformation in the retaining groove Firing Mechanical Damage on the Tool s Surface Figure 05 05 This is caused by heavy scratching on the tools surface The failure usually occurs outside the tool bushing The failure is generally a fatigue type fracture Figure 05 05 Mechanical Damage on Tools Surface PPM2000000 Version 102803 23 9 INDECO NORTH AMERICA Cold Fracture Figure 05 06 Cold temperatures can cause the tool to become brittle and break This failure can be avoided by warming the tool when working in cold temperatures Figure 05 06 Cool Fractured Tool Break at Retaining Groove Figure 05 07 This failure is a result of using a tool with worn or damaged retainers Any time a tool is replaced the tool retainers should be inspected for wear and replaced if worn or damaged Figure 05 07 Tool Retaining Groove Break Breaking of Chisel Tip Figure 05 08 This failure is caused by the improper contact between the tool and the material being brok
13. AMERICA Cylinder Assembly Figure 08 30 Exploded View 1 Assemble the Ujoint Seal Position 204 into the internal grooves of the Cylinder Position 201 After installation of seals in cylinder lubricate seals with oil Note Be certain that the seals are assembled back to back with the lips in the proper direction Figure 08 31 Figure 08 31 Install Cylinder Seals PPM2000000 Version 102803 40 Soph the Bert INDECO NORTH AMERICA 2 Lubricate piston surface with oil Lower the Piston onto the Cylinder Figure 08 32 3 Install the O ring Position 303 onto the Cylinder Position 201 Figure 08 33 Figure 08 32 Install Piston Into Cylinder Figure 08 33 Install Cylinder O ring 4 Insert the Check Valves Position 205 into the Cylinder Figure 08 34 5 Insert the Centering Pin Position 211 into the Guiding Plug Position 210 Insert this assembly into the Cylinder Figure 08 35 1 E T z MAS Figure 08 34 Insert Check Valves Into Figure 08 35 Insert Cylinder Centering the Cylinder Pin PPM2000000 Version 102803 41 77777 70 INDECO NORTH AMERICA 6 Install guide adapter over upper end of piston with smaller end pointing down Align it with the centering pin in the top of the cylinder Bottom guide adapter on top of cylinder 7 Place the Distributor Position 304 over the piston bottoming the Guiding Adapter Figure 08 36 8 Brush the Centering Pin
14. Dest PPM2000150 Grio x NORTH AMERICA 120 Dodge Avenue Stratford CT 06615 Phone 203 377 7791 FAX 203 377 7796 INDECO Hydraulic Breaker MES150 Service and Maintenance Manual 9 INDECO NORTH AMERICA IMPORTANT SAFETY NOTICE Most accidents involving service and maintenance are caused by failure to observe basic safety rules or precautions Accidents can often be avoided by recognizing potentially hazardous situations before an accident occurs It is necessary to read and understand all safety precautions before performing service and maintenance to any INDECO attachment Safety precautions are outline in this manual where they exist and failure to follow these precautions could cause serious bodily injury or death INDECO can not anticipate every possible situation that could involve a potential hazard Therefore the warnings in this guide are not to be considered all inclusive If a tool or repair procedure is not specifically recommended by INDECO you must satisfy yourself that it is safe for you and other people who could be involved You should not modify or change the configuration of INDECO attachments without the expressed written authorization of the manufacturer Improper maintenance of any attachment can be dangerous and could result in bodily injury or death Do not perform any maintenance on INDECO attachments until you have read and understand the procedures as described in the Service and Maintenance M
15. Disassembly of Chuck Housing 1 Slide out the Insert Chuck Housing Position 105 from the chuck housing pos 307 by hand Figure 07 10 If resistant gently tap with a small hammer 2 Slide out the Upper Position 107 and Lower Position 104 Flange by hand Figure 07 11 3 Drive out the Elastic Pins Position 109 from the insert chuck housing Position 105 4 Drive out Retaining Axle Position 110 from the insert chuck housing Position 105 Figure 07 11 Figure 07 10 Chuck Figure 07 11 Remove Elastic Pin and Housing Retaining Axle 5 Check the wear on the Lock Bolt O rings and pins 6 Remove the circlip Position 154 and then remove the insert bushing Position 153 Clean the insertchuck housing Position 105 Figure 07 11 PPM2000000 Version 102803 38 da Sin the Best INDECO Vill Assembling the Breaker NORTH AMERICA Chuck Housing Assembly 1 Clean the insert chuck housing Position 105 Figure 08 21 and then install the insert bushing Position 153 Install the circlip Position 154 to retain insert bushing 2 Slide the Insert Chuck Housing Position 105 into the chuck housing pos 307 by hand Figure 08 20 If resistant gently tap with a small hammer Position flat edge of insert chuck housing in alignment with pin in chuck housing Figure 08 20 Chuck Figure 08 21 Insert Chuck Housing Housing PPM2000000 Version 102803 39 the Best 3 INDECO NORTH
16. If this is not done the hammer impact will be wasted on the rock particles and in addition will create thermal energy in the particles and hammer causing overheating Prolonged overheating will cause the hammer materials to lose their original mechanical resistance In order to keep particles out of the hammer an air hose may be installed in the same way as would be done for underwater usage PPM2000000 Version 102803 12 INDECO NORTH AMERICA Figure 02 06 Lower Breaker Every Hour When Working Overhead k If the breaker is operating at temperatures below 15 Celsius increase the nitrogen charge pressure by 20 of the value recommended in normal conditions Disassemble the tool and store it in a place where the temperature is above 0 Celsius DO NOT heat up the tool with a torch or other device before operation Operate the tool slowly for the first 15 feet of excavation in order to gradually warm up the tool Never leave the tool exposed to inclement weather as this will oxidize the bushing contact area I The hydraulic oil feed viscosity must not be below 15 CST The maximum oil temperature during operation should not exceed 75 Celsius 160 Fahrenheit m When the hammer is not in use it must be kept in a vertical position Figure 02 07 This will allow any water or condensation to run off of the piston and prevent rusting which may cause seal failure and leakage SUMMARY OF INSTRUCTIONS Figure 02 07 St
17. age 53 for further instructions on setting chip Test port Oil inlet pressure Oil outlet return Figure 08 60 Link housing and regulation chip PPM2000000 Version 102803 46 INDECO IX Trouble Shooting and Problem Diagnosis NORTH AMERICA Checklist for Accurate Breaker Problem Diagnosis As in any repair it is very important to ask the customer the right questions In many cases the answers to a repair technicians questions will allow for a quicker and more cost effective resolve the customers problem Below are questions that will assist the technician in quick and accurate problem resolution of INDECO Breakers a Model and Serial Number of the breaker b Make Model and Serial Number of the carrier c Are both shut offs on the carrier if present both in the full on position d Are quick couplers being used Are the male and female ends of the same manufacturer and type Have you by passed the couplers using a direct hose connection e Whatare the results of the flow test of the carrier INITIAL READINGS Full Flow GPM Back Pressure Attachment Operating GPM PSI Back Pressure PSI Carrier Circuit Relief GPM PSI Back Pressure PSI Pressures at Test Ports Inlet PSI Outlet Back Pressure PSI FINAL READINGS Full Flow GPM Back Pressure Attachment Operating GPM PSI Back Pressure PSI Carrier Circuit Relief GPM PSI Back Pressure Pressures at Test Ports Inlet PSI Outlet Back Pres
18. anual If you have any questions or these procedures contact INDECO s Product Department at 203 377 7791 PPM2000000 Version 102803 2 hee Best INDECO NORTH AMERICA e Table of Contents Safety 22 E TT Breaker Installation eee eee eee s sue II General Breaker 2 euo Pu Epid dv Eae seruos Rue dE lll Common Causes of Breaker Damage IV Routine Maintenance Daily Weekly 500 Hours 1000 Breaker LUDNICA eo esses EE S dors uut E E odit Lower Bushing and Insert Vs Breaker TU Tool Breakage 8 Descplion or TyDICal SITOSS uoces dut aot i edema niae Methods to Reduce Stress Effects and Increase Tool Life EU T T Tm
19. atford CT 06615 Phone 203 377 7791 Fax 203 377 7697 PPM2000000 Version 102803 5 Best 8 INDECO NORTH AMERICA i Breaker Installation BREAKER INSTALLATION Figure 01 01 Testing Excavator Figure 01 02 Testing Tractor Loader Circuit Flow and Pressure Backhoe Circuit Flow and Pressure adi EU 5 r T mes Figure 01 03 Flow Meter and Pressure Figure 01 s Testing Skidsteer Loaders Gauge Connection Circuit Flow and Pressure Note During these test be certain that the carriers hydraulic fluid is at operating temperature usualy 130 F to 170 F This will insure that the attachment will operate at optimum performance Also if the carrier has any hydraulic problems they should appear during testing procedures BEFORE YOU HOOK UP THE HOSES TO THE ATTACHMENT 1 Install attachment hydraulic circuit on the carrier 2 Connect a flow meter Figure 01 03 to the circuits pressure line into the meter s inlet and the return side into the meter outlet Also install a 600 psi gauge into the return circuit at the flow meter This will allow for a starting point for the back pressure of the return circuit Refer to the Operators Manual for the specifications on the attachment you are installing PPM2000000 Version 102803 6 9 INDECO NORTH AMERICA 3 Before engaging the circuit be certain the pressure regulating valve on the flow meter Figure 01 03 is in the f
20. e The maximum number of shims allowed is 7 Remove shims to decrease pressure Add shims to increase pressure the spring in the guiding plug reassemble and tighten the pressure regulating valve Retest the breaker and if the readings are still not with in the correct specification repeat the above steps until the correct pressures are achieved If the pressure cannot be corrected call INDECO North America at 203 377 7791 for assistance Return Back Pressure on Test Gauges Is Above the Specification 1 Check the return filter and replace if necessary Note Some applications may require a larger return filter Check to verify that the return lines are not restricted and are large enough to allow for unrestricted return oil flow If the pressure is still excessive call the manufacturer of the hydraulic installation kit for assistance in lowering the pressure Breaker Does Not Hammer Check to verify that the carrier s shut off valves are open Check the operation of the breaker control pedal Check the carrier pump for correct flow and pressure Push the hammer to the bottom to charge the piston and try again Connect the pressure line to the return line and verify that the full load does not cause excessive back pressure Check the condition of the carriers hydraulic filter if necessary replace it Verify that the diameter of the return pipe is in line with the specifications Check the condition and
21. e is not too low See Appendix A Breaker Technical and Torque Specifications Page 96 Check that the oil flow meets the technical specs in the Owner s Manual Check that the oil temperature is not too high over 85 Celsius or 185 Fahrenheit Check that the oil viscosity is good if necessary change the oil 10 Check that there are no defects in the carrier cooling system Check that there are no internal leaks in the hammer evidenced by a rustling noise If the hammer leaks replace the seals If it is still leaking re machine the contact surfaces 11 Check if the inlet operating pressure gets lower as the tool penetrates The O Ring at the pressure valve may be damaged and should be replaced Also check that the spring is not broken and the slide is not worn or loose in the barrel 12 Check that the point end of the tool is in usable condition Check the wear of the upper bushing PPM2000000 Version 102803 50 m Spb the Beet A INDECO NORTH AMERICA 13 If the problem cannot be resolved call INDECO North America at 203 377 7791 for assistance Carrier Is Over Heating 1 Check the operation of the breaker control pedal Check the carrier pump for correct fow and pressure Push the hammer to the bottom to charge the piston and try again Verify that the pressure relief valve of the carrier circuit is not open If it is check its calibration level The minimum pressure to the carrier must be at l
22. east 30 higher than that to the hammer Verify that there are no leaks in the carrier hydraulic circuit or other components Check the condition and position of the side bolts Tighten if loose replace if broken Disassemble the variable valve Guiding Plug Position 418 and verify that it is working correctly Check that the inlet pressure is not too low see technical specs in Owner s Manual Check that the oil temperature is not too high over 85 Celsius or 185 Fahrenheit Check that the oil viscosity is good if necessary change the oil Check that there are no defects in the carrier cooling system Check that there are no internal leaks in the hammer evidenced by a rustling noise If the hammer leaks replace the seals If it is still leaking re machine the contact surfaces Check if the operating pressure gets lower as the tool penetrates The O Ring at the pressure valve may be damaged and should be replaced Also check that the spring is not broken and the slide is not worn or loose in the barrel 10 If the problem cannot be resolved call INDECO North America at 203 377 7791 for assistance Oil Leaks Occurring 1 Check that the oil temperature is not too high over 85 Celsius or 185 Fahrenheit Check that the oil viscosity is good if necessary change the oil Verify that the piston is not scratched If it is replace the piston and the seals Check that the breaker has not worked under
23. easure wear of lower and upper bushing Rotate retaining axles 180 degree or replace if worn Verify carrier hydraulic flow and pressure to initial specifications 1000 Hours a 2 2 ja i 2 2 Complete weekly and 500 hour inspection procedures Replace all rubber and polypack internal seals Inspect piston for scouring cracks or other related damage Inspect spacer while piston is out and replace if needed Inspect tie rods for stress in threaded area Die penatrant magnaflux is recommend Replace rods as a complete set Check the breaker s condition and replace all worn components Check all hydraulic tubes and hoses and replace if worn or damaged PPM2000000 Version 102803 17 Stopl the Best 9 INDECO NORTH AMERICA Breaker Lubrication It is essential to lubricate the tool using the grease chart Figure 04 01 below as a guideline Lubricate at grease fitting on chuck housing Figure 04 02 If working in dusty conditions the tool should be greased even more frequently The tool should also be removed weekly and the cavity cleaned and packed with new grease The tool must always have grease on the hammer contact area ATTENTION INDECO GREASING REQUIREMENTS WARNING A coating of grease must be maintained between the tool and the bushing of the breaker in order to avoid damage and eventual failure of the breaker The amount of grease necessary to maintain proper lubrication of the tool var
24. ee arapi D SYSTEME DE REGLAGE le d mclsssur 1 on systeme de rigore de pression de e CT dont d anergia da Eno En effect on trouve d so base um de s gle ge aver quare lorapes oliris une dhima de 0 l une de l autre veni le type de d bit amen ow de costrepression du reoh de retour on peut rige tinm e hinh mici inia M S 7 adi les cormcarisfiques de le mahine operate 1 salon In position dare lequel ele dera re vilat MEELUNGSSISTEN D 1 Der Abbrochhemmer besitzt ein naves Regeluegisytem des der Schlogenengie befindet sich unter der Basis in fe qthengschip vier zu 99 zwischenesmander prelen geeichten Lichen Je noch eir gelessenem oder dem Ruckstrompegendruck koan die Krott geregelt werden dr ip ad de eine ng verte vd s gra tel de opflecien je nach den Caorckterictien der UP 121 180 regolazione dal chip con P115 bar Tm PORTATA OLIO AL MARTELLO DEL FLOW BREAKER DEBIT D HURLE SUR LE ERISE ROCHE DOSIS DE ACHTE AL MARTILLO QELMENGE AM HAMMER CONTREPRESSION LA 1 ABFLUAGEGEMDRLCK PPM2000000 Version 102803 CONTROPRESSIONE ALLO SCARICO BACK PRESSURE AT DISCHARGE DECURGE COMTROPRESION A LA DESCARGA i Eu i q Eor DE eee ee eee Pete h Lifa issurim
25. en Figure 05 08 Broken Chisel Tip Mushrooming of Tip Figure 05 09 This failure is caused by hammering too long without penetration of the material This generates extreme heat and softens the tools materials which then mushrooms Once a tool has been overheated the properties of the tool s materials are permanently altered This change of properties can then lead to premature failure of the tool This damage can be prevented by proper lubrication and operation Figure 05 08 Broken Moil Tip PPM2000000 Version 102803 24 opo the Best INDECO NORTH AMERICA Tool Replacement Insert Chuck Housing pos 151 Retaining Axle Insert Bushing pos 153 Tool Figure 05 09 Check and Unlock Retaining Axles a The retaining axles are held in with a slotted pin and require a hammer and a roll pin punch to drive the slotted pin Position 103 out of the Insert chuck housing Figure 05 09 b Drive pin pos 103 in one direction to clear the end of the retaining axle below it Figure 05 10 Push Retaining Axle Out c With a blunt tool push the retaining axle out from the opposite side Figure 05 10 Repeat the operation for the second retaining axle d The tool is now free and can be removed from the breaker Caution the tool be hot if the breaker was just being used PPM2000000 Version 102803 25 the Best INDECO NORTH AMERICA D Figure 05 11 Grea
26. ep Tool Perpendicular to Working Surface PPM2000000 Version 102803 10 A INDECO NORTH AMERICA c Maintaining an even pressure from the carrier to the hammer start the hammer If the downward pressure from the boom is too weak you will hear metallic rather than sharp strokes because the hammer is not striking the tool correctly If the downward pressure is excessive it will produce strong vibrations in the carrier and the tool retaining axle bushings etc Figure 02 03 Figure 02 03 Maintain Even Working Pressure d If the hammer is the correct position and the hammer and case are vibrating Figure 02 04 the downward pressure from the carrier is insufficient If exerting further pressure from the carrier does not solve the problem it may be that internal hydraulic leaks from the rams or valves may not be allowing the carrier to exert the correct amount of pressure In this case replace the carrier cylinder seals and or check the control valve seals Figure 02 04 Insufficient Downward Pressure Results in Vibrations PPM2000000 Version 102803 11 1 9 h 9 INDECO NORTH AMERICA If vibrations start to occur after the hammer has been operative for some time this means that the carrier downward pressure has not followed the tool penetration You must maintain a constant pressure from the carrier on the hammer as the hammer is penetrating the work An INDECO hammer senses the st
27. ies with conditions It is the responsibility of the Operator to monitor the amount of grease on the tool When raising the breaker the portion of the tool CHECK FOR extending from the breaker GREASE HERE should always show grease Figure 04 01 grease chart 2 Lube Tool J Here Figure 04 02 MES 150 Lube Points PPM2000000 Version 102803 Best 8 INDECO NORTH AMERICA Lower Bushing and Insert Inspection 1 Remove the tool See Tool Replacement Section 5 30 and clean the inside of the Chuck Bushing Position 102 or the Insert Position 153 2 Inspect the insert bushing for condition and wear When the insert bushing has worn down flush with any part of the circlip pos 154 and or the tool is making contact with the circlip the insert bushing has meet its service limit and in need of replacement Note The greatest amount of wear normally occurs from front to back 3 If the Insert Holder Position 152 needs replacement it is recommended to remove the Breaker s Chuck Housing and remove the Chuck Bushing with a hydraulic press See Disassembly Figure 04 10 Measuring the Lower Chuck of the Chuck Housing Section 7 Page 51 Bushing or Insert for Wear 4 To replace the Insert Position 153 remove the circlip Position 154 and insert bushing Position 153 and clean the insert holder Position 152 Figure 04 11 and Figure 04 12 Note If the insert bushi
28. ion 102803 INDECO NORTH AMERICA Figure 03 05 Remove Tool and Clean Breaker Every Eight Hours h Do not use the tool of the hammer to rotate the carrier This causes superficial cuts on the contact areas which could cause breakage under stress Figure 03 06 Do Not Rotate Carrier on the Breaker s Tool PPM2000000 Version 102803 16 Sb He Bust i INDECO IV Routine Maintenance NORTH AMERICA ROUTINE MAINTENANCE Daily er 12 2 Grease breaker every 2 hours If working in very dusty conditions grease each hour Check cradle side shocks and side bolts for loose cracked or missing bolts Check tightness of tool retainers and locking bolts Examine hydraulic hoses for leaking or chaffing Visually inspect breaker for housing or side plate damage Weekly ae 2 ge ae aed Remove tool and wash out tool cavity with solvent Inspect upper and lower bushings retaining axles and face of piston for cracks uneven wear or mushrooming Before inserting tool re apply grease to upper lower bushings and retaining axles Re insert greased tool after rotating 180 degrees from original position and secure retaining axles Measure length of tool If too short replace to prevent damage to breaker bushing and housing Maximum Wear is 50 of exposed portion of tool when new 900 HOURS 2 Check accumulator charge Refer to INDECO specification for correct charge M
29. ition the breaker horizontally on a flat work surface with the pressure and return fittings pointing upward On MES 150 Breakers there are eight 8 bolts attaching the side plates Position 607 Figure 07 01 Figure 07 01 Remove Side Plates MES 150 2 Remove the eight bolts Position 608 from the side plates Position 609 and remove the side plates from the breaker PPM2000000 Version 102803 34 hee Best lt 3 INDECO NORTH AMERICA Breaker Head Removal and Disassembly MES 150 1 Loosen and remove Nuts Position 314 Figure 07 02 2 Lift the Head Oylinder and Piston Assembly Position 301 from the Chuck Housing Position 101 Figure 07 03 Figure 07 02 Loosen Nuts Figure 07 03 Lift Head Cylinder and Piston Assembly from Chuck Housing PPM2000000 Version 102803 35 opo the Best 3 INDECO NORTH AMERICA Cylinder pos 305 pos 306 Distributor Box Body pos 305 Guide Adapter Pos 210 Piston pos 209 Figure 07 04 Exploded View 3 Remove the Cylinder Position 305 with Piston and Guide Adapter from the Head Assembly Position 302 Remove and note the location of the Pin Position 211 Figure 07 04 Slide out Distributor pos 304 from bottom of the Distributor Box Body Position 302 Using suitable puller remove Distributor Box Body pos 302 from Head Remove Distributor Box Body Cover pos 305 and Valve pos 306 fr
30. lation Body MES 150 PPM2000000 Version 102803 32 amp 9 INDECO NORTH AMERICA 5 Loosen the Accumulator Charge Plug Position 34 by turning the Spanner Wrench in the Charging Fixture counter clockwise 6 Open the main valve on the nitrogen tank and purge the charge hose T Charge the accumulator to the correct pressure See Nitrogen Hecharge Section 6 Page 41 8 Tighten the Accumulator Charge Plug Position 34 by turning the Spanner Wrench in the Charging Fixture clockwise 9 Bleed the pressure from the charge hose and remove the Charging Fixture from the Accumulator 10 Tighten Accumulator Charge Plug Position 34 to specified torque 11 Using some oil verify that there are no nitrogen leaks from the Inflating ocrew or on the sides Figure 06 25 12 Turn the Accumulator upside down and fill the holes with oil to check the Diaphragm has no defects If no bubbles appear the Accumulator is correctly charged and ready to be installed on the breaker Figure 06 25 Check Accumulator for Leaks ATTENTION The accumulator charging Specifications for all INDECO Breaker accumulators are 475 PSI to 550 PSI 32 to 38 BAR For all models up to and including the MES 1200 520 PSI to 620 PSI 36 to 43 BAR For all models MES 1500 HD and larger PPM2000000 Version 102803 33 the Best INDECO VII Disassembly of the Breaker a Removing Breaker Side Plates 1 Pos
31. ng Pressure on Test Return Back Pressure on Test Gauges is Above the Specifications Breaker Does Not Breaker Lacks POWO EDDIE to Carlier ors Over uiis OW GS cutie TUTTI err APPENDIX Breaker Technical and Torque Specifications APPENDIX Breaker Regulation Chip APPENDIX C Breaker Parts Explosions APPENDIX D left intentionally blank PPM2000000 Version 102803 39 39 40 52 53 54 59 S INDECO NORTH AMERICA PREFACE The perfect match of hydraulic breaker to carrier is essential in order to guarantee the correct working conditions However in order to obtain maximum efficiency it is strongly recommended that regular and appropriate maintenance be performed Every attempt has been made to insure accuracy of the information provided However the manufacturer reserves the right to update this manual subject to the technological development of the product and service For the most current information a review of the Product Support Bulletins is recommended prior to any breaker repair For further information please contact INDECO North America Product Support Department 120 Dodge Avenue Str
32. ng does not slide out of the holder the bushing will need to be Note SUGGESTED PROCEDURE Protect the upper portion of housing Position 101 upper bushing Position 104 spacer Position 105 and piston Position 309 Relieve insert by cutting a slot lengthwise using a right angle 90 die grinder with cut off wheel Caution Be careful not to cut insert holder Remove insert Optional removal use a universal sleeve puller with slide hammer to remove insert See figure 04 13 Figure 04 11 Remove Insert Snap Ring Figure 04 13 Universal sleeve puller PPM2000000 Version 102803 19 S INDECO NORTH AMERICA Tool Selection V Breaker Tools Choose the most suitable tool for the operation required Figure 05 01 For the breaking of boulders use MOIL or OLGIVE points In restricted areas such as trenches use CHISEL points and proceed in line with the work face In particularly narrow places progress gradually through small sections of material making the most of the regularity of the striking frequency Keep the front of the hammer parallel to the operator with the machine arm drawn up This will avoid damage to the tool especially during cutting and squaring Point and Recommended Use 1 Figure 05 01 Breaker Tool Selection PPM2000000 Version 102803 Chisel All earth moving duties or excavations in narrow trenches or stratified soil or rock up to medium rock Demolition of rock
33. of the specified torque at a time Figures 08 45 Note On MES 121 through MES 553 tighten the Side Rod Nuts using a box style wrench Figure 08 45 Assemble and Tighten Side Bolts PPM2000000 Version 102803 44 the Best INDECO NORTH AMERICA m Breaker Side Plate Assembly 1 Position the Breaker and chuck housing on a level work surface 2 Position the Side Plate with the large holes pointing away from the accumulator 3 Fasten the Side Plates to the Breaker using eight 8 bolts Position 607 Figure 08 50 Figure 08 50 Install Side Plates MES 150 4 Tighten and torque the Side Plates to the proper specification See Appendix A Breaker Torque Specifications Page 52 PPM2000000 Version 102803 45 hee Best INDECO NORTH AMERICA a Breaker Regulation Chip 1 The link housing is secured to the head with six 6 socket head screws An O ring sets un a grove machined into the link housing and seals the mating surfaces Position 607 Figure 08 60 2 four 4 position chip fits in the link housing to regulate operating pressure of the breaker The four positions are 1 5mm 2 0mm 2 5mm and 3 0mm 3 The top right port on the link is a test port The threads are British Standard Parallel Pipe BSPP 04 1 4 inch A pressure gauge minimum of 3000 psi is inserted into the test port to take operating pressure readings Note See appendix B p
34. om Head Se m m Check that the Distributor face and inside are smooth and clean PPM2000000 Version 102803 36 L9 INDECO NORTH AMERICA Cylinder Removal and Disassembly 1 Remove the piston Position 209 Figure 07 05 The Guide Adapter Position 210 will come out of the Cylinder Position 210 with the piston Check that the two parts are not worn especially at the support surfaces Remove the Valves Position 205 206 off the Cylinder and check the seating surface This surface should be perfectly circular of equal thickness all around and without indentation Clean the valves and replace if necessary Check the sealing area of the Cylinder Check the guiding areas of the Cylinder by the head Figure 07 06 Figure 07 05 Remove A Figure 07 06 Remove Valves Piston from Cylinder Check the inside of the Cylinder for scoring and defects Hone out defects in the Cylinder walls with the appropriate lubricated tool Recommended BRM Flex Hone If this operation is performed the Cylinder should then be cleaned out with warm soapy water and then re oiled Replace the Cylinder if necessary Top of Piston Chuck Housing Figure 07 07 Remove Cylinder U joint Seals 4 Remove the O ring Position 303 and the Ujoint seals Position 204 and carefully clean u joint seal s internal grooves Figure 07 07 PPM2000000 Version 102803 37 the Best 3 INDECO NORTH AMERICA
35. or all INDECO Breaker accumulators are 475 PSI to 550 PSI 32 to 38 BAR For all models up to and including the MES 1200 520 PSI to 620 PSI 36 to 43 BAR For all models MES 1500 HD and larger 29 hee Best lt 3 INDECO NORTH AMERICA Accumulator Rebuilding MES 150 1 Carefully discharge the accumulator and remove the Inflating Screw Position 504 and O ring Position 505 Figure 06 02 2 Loosen and remove the Self Locking Nuts Position 314 and Shell Fixing Screws Position 506 Figure 06 03 Figure 06 02 Loosen Inflation Figure 06 03 Remove Accumulator Screw Carefully MES 150 Shell Bolts MES 150 3 Remove the Plate Position 313 and Upper Shell Half Position 502 4 Remove the Diaphragm Position 503 and replace Figure 06 04 5 Reassemble the Accumulator and torque to the required specification Figure 06 05 M ars oo JA m Figure 06 04 Remove Figure 06 05 Torque Accumulator Diaphragm MES 150 Shell Bolts MES 150 6 Install a new Oring Position 505 on the Inflating Screw and wrap Teflon tape around the threads of the Inflating Screw before installation Install Inflation Screw in the Upper Shell Half Position 502 Do not tighten at this time T The Accumulator is ready to be charged with nitrogen See Nitrogen Recharge Section 6 Page 32 and installation PPM2000000 Version 102803 30 Soph the Beet 9 INDECO NORTH AMERICA 1 Install
36. ore Maintain even pressure on the hammer Breaker in an Upright Follow the hammer during penetration of the material Position Always maintain a constant optimal pressure level Correct loading ensures hammer productivity and avoids damage to its component PPM2000000 Version 102803 13 INDECO Common Causes of Breaker Damage NORTH AMERICA COMMON CAUSES OF BREAKER DAMAGE a The hammer must not be used as a ripper nor should it be used as a lever Under no circumstances should the tool be used as a hook to lift weights Figure 03 01 This could cause serious damage to the tool the bushing and the housing Figure 03 01 Don t Use Breaker as a Ripper Lever or Crane b Ihe hammer must operate perpendicular to the work This ensures that the tools are not forcibly stressed bending stress does not occur and the specific pressures in the contact areas are maintained This will greatly extend the life of the tool and the bushings Check that the tool contact areas especially the chuck housing are well lubricated and smooth A properly lubricated tool will show streaks of grease below the lower bushing on the tool shank Remove any bumps or rough areas with a soft grinding wheel and wire brush The point of a chisel tool can be re sharpened in the same way Tools should be rotated 180 to evenly distribute the wear C hammer must be free to operate without any obstructions chafing or
37. ose at hand Situate flammable gas cylinders in a location so that if a fire does occur it may be easily extinguished In some cases it may be better to evacuate the area and let the cylinder burn especially if escaping gas could collect and explode Never attempt to adapt fittings from one device or cylinder to another Fittings or hoses may not be compatible with the gas products and may fail violently Gases should never be transferred from one cylinder to another The rate of flow of the gas itself may be sufficient to cause an explosion Check valves are an important safety feature but don t rely on them 100 to prevent a backflow condition Always open the cylinder slowly Purge the regulator and hoses by allowing a small amount of gas to pass through the system Potential Hazards PPM2000000 Version 102803 27 S INDECO NORTH AMERICA Fire or Explosion Nitrogen may burn but will not ignite readily The Cylinder may explode in the heat of a fire Health Hazards Vapors may cause dizziness or suffocation Contact with liquid may cause frostbite Fire may produce irritating or poisonous gases Emergency Action Keep unnecessary people away Isolate the hazard area and deny entry Stay up wind keep out of low areas Telephone local emergency professionals Positive pressure self contained breathing apparatus SCBA and structural firefighters protective clothing will provide limited protection Fires Small Fires Dr
38. rating the breaker verify that the tool and bushings have been properly lubricated Verify that the hose can move freely and are not rubbing against any other parts 12 Place the breaker on a hard compact surface and with shut off if so equipped turn on run the breaker at low Rpm s Gradually increase rpm s to the maximum Operating pressure and return back pressure must remain within specifications in order for the attachment to operate at maximum efficiency See Appendix A Breaker Technical and Torque opecifications Page 96 for the correct specification Run the breaker until the hydraulic oil is at operating temperature and again note the pressure readings Note The breaker should be fast during the initial stages As the tool penetrates the material the breaker should slow to a rhythm close to the minimum blows per minute 13 If readings are not within this range please refer to the trouble shooting and problem diagnosis section of this manual 14 Record the readings taken during the installation procedures on the Attachment Delivery Report ADR Figure 01 05 This report must be on file with INDECO before any warranty consideration can be given PPM2000000 Version 102803 7 A INDECO NORTH AMERICA The performance and reliability of any hydraulic attachment are directly related to the proper operation maintenance installation and adjustment For this reason it is imperative that pressures and flows are verified each
39. rength and density of the surface being broken and adjusts hammer impact power accordingly The operator will be able to hear the difference in the blows when a rock is broken or not broken The hammer rhythm will be fast and sharp if the material is frail and flaky slow and powerful if the rock is compact and uniform Impact speed will also be slower the deeper the hammer penetrates As soon as cracks start to appear in the material being worked on and the tool starts to appear from the bushing stop the hammer at once Do not raise the hammer from the material until it has stopped completely If cracks in the material do not appear in 30 seconds move to a new position along the grain of the material Figure 02 05 perhaps working on a smaller section or edge of the material Always look for advantageous weak points in the material e g cracks bumps veins at which to start This saves undue stress on the breaker L 1 1 uma M y Figure 02 05 Reposition Breaker Every 30 Seconds In a quarry or when breaking oversized rocks position the material to be broken on a hard base to minimize vibrations of the material In the case of horizontal or upside down operations e g tunnels once every hour the operator should lower the hammer to a vertical position Figure 02 06 so that any particles of rock which have collected in the hammer can fall out Operator can alternate hammering up and down
40. s materials not stratified rock up to medium hardness Olgive Demolition of hard to very hard rock Blank or Blunt Demolition of rocks up to medium hardness to be broken into smaller pieces Asphalt Cutter or Spade Cutting of concrete paving brick walls or turf Pole or Pipe Cutter Driving pipes poles or pre shaped metal objects IE shaped metal guardrail poles into Different materials 20 lt 3 INDECO NORTH AMERICA Tool Breakage Analysis Description of Typical Stress In order to understand the complexity of the stress phenomena that results in tool breakage some general information needs to be addressed The tool is considered an elastic element designed to transmit shock or kinetic energy from the hammer piston to the material to be demolished 2 r 2 The typical tool break starts as a small fracture in the surface of the tool that is the most stressed area Eventually a surface crack is created from micro welds from surface work hardening localized heating and cooling on the tool surface and tension and compression on opposite sides of the tool The surface crack then grows in a series of concentric rings until the section weakens and can no longer support the stresses imposed Complete failure occurs at this time stress per blow is not as critical as the frequency of blows The stress level in the tool becomes more critical with higher blows per minute and changes in
41. se New Tool And Align e Grease the new tool well Insure the cavity is clean and the bush is lubricated Slide it in so that the side notches are in line with the axle slots and push in snugly Figure 05 11 f Reverse the procedure to re install the retaining axles and slotted pin PPM2000000 Version 102803 26 amp 9 INDECO NORTH AMERICA VI Accumulator Removal and Rebuilding Safety Instructions Before working the Accumulator PLEASE read following safety procedures thoroughly you have any questions consult your INDECO dealer or INDECO N A Warnings Compressed gases by their nature are hazardous They are capable of creating environments that are oxygen deficient flammable or explosive Death has occurred during a routine repair on a carrier when nitrogen charged canister on the carrier exploded as it was being disassembled Nitrogen which is present in our atmosphere can still displace the oxygen in a room or enclosure and cause suffocation Never deliberately breathe or allow others to breathe any compressed gas of any type It 15 possible to deplete the oxygen in the bloodstream and cause rapid suffocation and DEATH Always wear proper clothing for the job Protective clothing safety shoes and leather gloves should be worn in addition to the required helmet or other protective gear Any time compressed gases are handled safety glasses should be worn Keep a fire extinguisher cl
42. sure PSI f Does breaker sound like it is cycling g Do the whip hoses appear to have fluid flowing through them PPM2000000 Version 102803 47 A INDECO h Does the breaker run and then stop If it does how long does it run and how do you get it to run again i With the carrier at an idle remove the tool and verify that the piston is moving 15 the piston hitting the tool k If the breaker is a model MES 1750 HD or larger does there seem to be air coming out around the valve assemble where the under water kit attaches to l Was the breaker recently rebuilt If yes what was done and what parts were installed In many cases service personnel when called for assistance will ask these questions Having the answers ready will save you time and allow the product support department at your dealer to assist you quicker and more efficiently PPM2000000 Version 102803 48 amp 9 INDECO NORTH AMERICA Troubleshooting Low Working Pressure on Breaker Test Gauges 1 2 Check to verify that you are hitting on a suitably hard surface Remove and adjust the pressure regulating valve as follows install the necessary number of shims underneath the spring Position 414 inside the guiding plug Position 418 to obtain the correct pressure reading See Appendix A Breaker Technical and Torque Specifications Page 96 Each 1 mm shim inserted increases the pressure approximately 73 PSI 5 Bars Not
43. sure slowly through the Inflating Screw while guarding yourself from bodily injury Figure 06 01 Please read the safety warnings at the beginning of this chapter Explanation The nitrogen is in at 500 lbs pressure The System pressure is 1500 2000 psi If the diaphragm ruptures at the edge it lets the oil in to make up the pressure thereby increasing the nitrogen chamber pressure In other words the fluid takes up the volume and increases the pressure on the gas Figure 06 01 Loosen Inflation Screw Carefully PPM2000000 Version 102803 28 9 INDECO NORTH AMERICA Accumulator Indicators In order to ensure smooth operation of the hammer it is necessary that the Accumulator be charged correctly If the Hammer is exhibiting strong vibrations of the oil supply pipe it is likely that Accumulator is discharged flat We recommend that the Accumulator be disassembled every 500 working hours At this time the Diaphragm Position 503 should be replaced even if it appears to be in good condition WHEN THE ACCUMULATOR GOES FLAT THE RUBBER DIAPHRAGM MUST BE REPLACED EVEN IF ITS CONDITION APPEARS SATISFACTORY When recharging the Accumulator also replace the Sealing Ring Position 505 and the O Ring Position 508 Before reassembling wrap Teflon tape around the Inflating Screws Position 504 in order to deter them from loosening PPM2000000 Version 102803 ATTENTION The accumulator charging Specifications f
44. ully open position 4 Start the carrier unit and check for hydraulic leaks Check and note the flow and back pressure readings at the meter 5 Increase engine RPM while a second person is monitoring he pressure and flow at the meter If the backpressure reading goes above specifications the cause must be determined before proceeding You may need to rework the return circuit to reduce the backpressure to INDECO specifications Contact the Product Support department at 203 377 7791 for assistance if required 6 the circuit s flow to the required specification NOTE It is better to be 5 1096 under the required GPM then to be over T Bring the pressure on the flow meter up to the high pressure reading for the attachment you are installing Check to assure that the correct GPM s are maintained and adjust if needed 8 Once the GPM s operating pressure and backpressure are within specification check the attachment circuit relief This setting must be at least 500 psi above the Attachments operating pressure Be certain the GPM reading remains the same as in the above steps 9 Next position the 4 position adjustment chip pos 420 located under the link pos 401 to the correct setting The oorrect setting is determined by reviewing the attached graph see Appendix B Breaker Regulation Chip 10 Install the breaker and connect a 0 3000 psi gauge inline with the hydraulic inlet port of the attachment 11 Before ope
45. y Chemical or C02 Large Fires Water spray fog or regular foam Move container from fire area if you can do so without risk Apply cool water to sides of container that is exposed to flames until well after the fire is out Withdraw immediately in case of rising sound from venting safety device or any discoloration of container If nitrogen is spilled it may evaporate leaving a flammable residue Leaks Stop leak if you can do it without risk First Aid Move victim to fresh air and call emergency medical care If the victim is not breathing give artificial respiration If breathing is difficult give oxygen If you suspect a problem with the Accumulator it should be bench tested for the pressure Before proceeding to any other operation connect a charging unit to the inflating screw If the pressure is within specs it may be assumed the Accumulator is okay If the pressure is low note that it is normal for an Accumulator to lose pressure over time with no defects If pressure has been lost in a short time there may be a problem with the diaphragm sealing ring or inflating screw If the pressure is checked and it is zero be suspect of a ruptured diaphragm WARNING If the pressure is checked and the gauge creeps up past the original specs exercise extreme care the diaphragm may be ruptured If so the hydraulic oil may have leaked into the nitrogen chamber and the pressure in the chamber may be greater than 2000 psi Bleed off the pres
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