HP Series Service Manual Rev6-4-2014
Contents
1. NOMINAL DIMENSION OA DA DB DB 9 843 8 465 7 677 7 677 7 087 7 087 6 299 5 906 5 709 5 512 5 118 4 724 4 528 4 331 BREAKER HP 25000 HP 16000 HP 13001 HP 12000 HP 12001 HP 10000 HP 8000 HP 7500 HP 5500 HP 5000 HP 4000 HP 3000 HP 2000 HP 1800 21 02 2012 IT GIOCO MAX DIAMETRALE B B 19mm 17mm 16 5 mm 16 5 mm 16mm 16mm 15 mm 13 mm 13 5 mm 12 mm 12 5 mm 11 mm 10 5 mm 9 mm 5 4 5 Bushings amp Tools SCZ MAX DIAMETER CLEARANCE A A 15 mm 13 mm 13 mm 13 mm 12 5 mm 12 5 mm 11 5 mm 10 mm 10 5 mm 9 mm 9 5 mm 8 5 mm 8 mm 7 mm NOMINAL DIMENSION OA DA DB DB 250 mm 215 mm 195 mm 195 mm 180 mm 180 mm 160 mm 150 mm 145 mm 140 mm 130 mm 120 mm 115 mm 110 mm BREAKER HP 25000 HP 16000 HP 13001 HP 12000 HP 12001 HP 10000 HP 8000 HP 7500 HP 5500 HP 5000 HP 4000 HP 3000 HP 2000 HP 1800 21 02 2012 6 Breaker troubleshooting 6 1 The breaker does not strike or strikes weakly If the breaker does not strike there are two possible types of reason e A probl2. 21 02 2012 7 Innovations 7 1 HP system The HP system is the result of a whole series of updates and innovations which have been brought in over the last few years The evolution from the original system to HP via the UP Upgrading series involved the following modifications e Looks a new color scheme and new stickers e Function hydraulic modifications e Reliability updates and improvements to the quality of various components e Structural and environmental the new closed soundproofed casings There have been design changes with a new color scheme and new labels The functional changes were brought in to optimise performance under various different operating conditions On top of the UP series modifications the hydraulic and power settings for some models have also been updated increasing the cylinder capacity and redesigning the regulation valves Reliability has been improved by optimising the following components with improvements to materials shape and design e Steel diaphragm and cover UP e Piston HP e Housing HP e Bushes HP e Side bolts UP e Casings HP e Lower shock absorber in casing HP e Greasing system UP e Anti dustkit optional UP e Side bolt locks UP e Fixing screws UP e Tools HP e Regulation valves HP 21 02 2012 The Piston and Cylinder have both been redesigned in order to increase the energy per blow the centralised greas
3. 29 72 51 36 232 145 181 289 HP 1500 Wrench 30 30 19 19 8 0 8 4 B17 B14 B12 30 580 psi 508 psi POS 307 418 403 615 409 504 507 506 107 618 Ft Ib 101 362 29 72 51 36 232 145 181 289 HP 1250 Wrench 30 30 19 19 B 0 B14 B17 B14 B12 30 580 psi 508 psi POS 307 418 403 615 409 504 507 506 107 618 A 2 Appendix Item Side bolt Guiding Plug Variable Valve Plug Pressure Testing Screw Vite Ammortiz Laterali Link Fixing Screw Inflating Screw Accumulator Fixing Screw Oil 140 F Oil 158 F Shell Screw Plug Bush Cradle Bolt Nitrogen Inflating Pressure Recharge as indicated by cross tightening the bolts in several phases Using the same technique tighten by 180 15 When this is complete loosen each side rod by 15 The torque setting shown must be reached gradually by cross tightening the bolts in several phases 21 02 2012 HP 4000 Wrench MKG 38 50 38 70 24 25 19 4 22 15 B14 18 B14 5 B 5 8 60 B 9 16 26 B12 25 30 40 40 Bars 35 Bars POS 307 418 438 403 615 409 504 506 123 618 HP 3000 Wrench MKG 38 42 38 70 19 4 22 15 B14 18 B14 5 B5 8 60 B9 16 26 B12 25 30 40 40 Bars 35 Bars POS 307 418 403 615 409 504 507 506 123 618 HP 2000
4. Soap water or hydraulic oil for leak testing The recharge must be carried out at 450 500 psi if the oil temperature is usually above 160 F otherwise if the cooling system is better and the temperature is around 140 F the recharge must be carried out around 500 575 psi Fig 22 21 02 2012 a WARNING Before recharging undo the screw pos 504 and release the nitrogen Wear gloves and use a protective screen to protect yourself against any oil that might be forced out b Open the accumulator by undoing the screws pos 506 with an Allen key c Replace the diaphragm pos 503 d Close the accumulator and cross tighten the screws pos 506 using a torque wrench to the torque settings indicated in the table below Appendix A e Use a new sealing ring pos 505 and check the resting surface Install the screw pos 504 finger tight after coating it with Teflon Tape Charge the accumulator to specified pressure Feed in the nitrogen through the reducer valve Finally tighten the screw on the accumulator to specified torque Fig 23 After removing the Indeco charging adaptor place some hydraulic oil or soapy water on the charge plug to check for gas leaks Leave the oil for a few hours fig 24 Fig 24 21 02 2012 4 3 Disassembling the breaker 4 3 1 Top Mount Cap Hose Swivel Links and Side Shocks a Place the breaker in a horizontal position pull out the tool retainers and remove the too
5. 181 289 HP 1100 Wrench 30 30 19 17 B10 B14 B17 B14 B12 30 508 psi 435 psi POS 307 418 403 615 409 507 506 107 618 HP 1000 POS Wrench Lb ft 308 32 347 418 30 362 403 19 29 409 B10 51 504 B14 36 507 B14 116 506 Bi2 80 618 30 289 607 30 311 608 30 217 508 psi 435 psi SCREW TORQUE SETTINGS AND NITROGEN INFLATING PRESSURE 1 MKG 7 233 Ft Lbs HP 750 Wrench Lb ft 30 101 B14 6 B14 6 B12 80 30 9 41 470 27 145 508 psi 435 psi POS 307 504 507 506 618 607 608 HP 500 Wrench Lb ft 27 3 24 217 B8 65 B12 80 810 1 22 145 27 217 27 145 508 psi 435 psi POS 308 413 504 506 505 618 607 608 HP 350 Wrench Lb ft 27 203 24 217 B8 65 INDECO 579 22 145 27 217 27 145 508 psi 435 psi POS 308 413 504 502 618 607 608 HP 200 POS Wrench Lb ft 314 27 145 413 19 181 403 6 36 409 6 22 504 8 65 506 27 232 618 2 145 607 22 87 508 psi 435 psi Appendix A 1 Item Side bolt Guiding Plug Pressure Testing Screw Side Shock Absorbers Screw Link Fixing Screw Inflating Screw Accumulator Fixing Screw or Shell Shell Screw Plug Cradle Bolt Casing Bolt Casing Spacer Nut Nitrogen Oil 140 F Inflating Pressure Oil 158 F Recharge as indicated by cross tightening the
6. B17 6 123 812 1 618 36 6 Oil 140 580 psi Oil 158 F 508 psi Item Side bolt Guiding Plug Variable Valve Plug Pressure Testing Screw Vite Ammortiz Laterali Link Fixing Screw Inflating Screw Accumulator Fixing Screw Shell Screw Bush Cradle Bolt Nitrogen Inflating Pressure Recharge as indicated by cross tightening the bolts in several phases Using the same technique tighten by 180 15 When this is complete loosen each side rod by 15 The torque setting shown must be reached gradually by cross tightening the bolts in several phases A 3 21 02 2012 HP 16000 Wrench MKG 55 125 41 100 24 25 19 4 30 32 B 14 18 B 14 5 41 150 B19 80 B12 25 55 190 40 Bars 35 Bars POS 307 418 438 403 615 409 504 507 506 123 618 HP 12000 POS Wrench MKG 307 55 100 418 41 100 438 24 5 403 19 4 615 30 32 409 B14 18 504 B14 5 507 B27 0 506 819 0 123 B12 5 618 55 190 40 Bars 35 Bars HP 10000 POS Wrench MKG 307 46 90 418 41 100 438 24 25 403 19 4 615 30 2 409 814 8 504 14 5 507 B27 150 506 819 50 123 B12 5 618 55 190 40 Bars 35 Bars HP 8000 POS Wrench MKG 307 46 75 418 41 100 438 24 5 403 19 4 615 24 0 409 514 8 504 514 5 507 B22 0 506 B17 45 123 B
7. CI 8900 45 80 rete 8 fig 11 21 02 2012 3 2 Checking Auxiliary Hydraulics on the carrier Before the breaker is mounted on the excavator the following points must be checked e The aux hydraulic flow on the excavator must match with the indications set out in the technical specifications for the breaker e In particular the return line must be directly connected to the tank e If however the return pipe goes to the control valve spool ensure that the backpressure is lower than the value shown in the breaker specifications or contact Indeco for help with the choice of breaker In most cases the backpressure will be too high e Also the size of the outlet and inlet pipes going to the breaker must conform to the indications set out in the technical specifications for the breaker In most cases the return is one size larger than the pressure e Check both whip hoses for restrictions such as 90degree turns quick couplers small shutoff valves or any other restrictions that could cause a loss of flow back to tank 3 3 Regulating the flow rate and the inlet pressure to the breaker Before installing the breaker on the excavator the flow rate and the inlet pressure have to be tested A flow meter shown here in figs 12 and 13 is adapted and connected to the excavator plumbing All of the calibration operations need to be carried out when the oil at working temperatures Fig 13 2
8. Remove the distributor and make sure that the external faces and the insides are uniform and clean j Remove any oil left inside the cylinder with a syringe so that it does not spill onto the ground k Make sure that the pin pos 211 stays in its place in the guide adapter figs 35 and 36 Remove the piston pos 209 using the corresponding screw pos 507 The guide adapter pos 210 will come out of the cylinder pos 201 at the same time Make sure that there is no anomalous wear on either component Particular attention must be paid to the two resting surfaces and if necessary they should be taken away and polished until smooth 21 02 2012 4 3 3 Cylinder disassembly Fig 37 removing the piston and the guide adapter a Remove the check valves pos 205 from the cylinder and check the blow area Clean and if necessary replace the check valves and check the cylinder seal area 21 02 2012 TOP OF PISTON CHUCK HOUSING Fig 38 removing the valves Fig 39 cylinder seals b Check the coupling areas of the cylinder in the head area c Remove the cylinder pos 201 from the chuck housing pos 101 using the screws pos 507 which should then be attached to the existing holes on the chuck housing Check the inside of the cylinder and if there are any seizures lap with an appropriate lapping tool cooled with petrol d Check the lower coupling and how it sits on the spacer replace the O ring
9. Wrench MKG 38 27 30 50 19 4 22 15 B10 7 B14 5 B19 55 B14 16 B12 25 30 40 40 Bars 35 Bars POS 307 418 403 615 409 504 507 506 107 618 HP 1800 Wrench MKG 38 22 30 50 19 4 22 15 B10 7 B14 5 B19 55 B14 16 B12 25 30 40 40 Bars 35 Bars POS 307 418 403 615 409 504 507 506 107 618 HP 1500 Wrench MKG 30 20 30 50 19 4 19 10 B10 7 B14 5 B17 32 B14 16 B12 25 30 40 40 Bars 35 Bars POS 307 418 403 615 409 504 507 506 107 618 HP 1250 Wrench MKG 30 14 30 50 19 4 19 10 B10 7 B14 5 B17 32 B14 20 B12 25 30 40 40 Bars 35 Bars POS 307 418 403 615 409 504 507 506 107 618 A 2 Appendix Item Side bolt Guiding Plug Variable Valve Plug Pressure Testing Screw Vite Ammortiz Laterali Link Fixing Screw Inflating Screw Accumulator Fixing Screw Oil 60 C Oil 70 C Shell Screw Plug Bush Cradle Bolt Nitrogen Inflating Pressure Recharge as indicated by cross tightening the bolts in several phases Using the same technique tighten by 180 15 When this is complete loosen each side rod by 15 The torque setting shown must be reached gradually by cross tightening the bolts in several phases SCREW TORQUE SETTINGS AND NITROGEN INFLATING PRESSURE A 3 Appendix 21 02 2012 HP 0 Wrench Ft Ib 55
10. is slightly worn you should grind the coupling surfaces After these controls carefully wash the steel diaphragm pos 306 and keep it carefully covered in a clean place Remove the four rubber stoppers pos 313 and the metal stops on the side bolts Loosen the four side bolts pos 307 fig 33 Slide the side bolts out one at a time to ensure that you remount the same polygonal nut pos 308 back onto each one fig 34 Clean and visually check the thread Check the resting surfaces for the side bolts nuts and head If necessary repair them Fig 33 loosening the side bolts Fig 34 lifting the head and side bolts Check the state of the O rings pos 303 on the head Check the state of the O Ring pos 410 on the central valve of the head then regulate the breaker pressure after first extracting the barrel pos 411 Carefully wash the head and the valves make sure they work replace the O Rings pos 303 amp 410 reassemble the valves and put them aside in a clean place If the distributor pos 304 did not come out at the same time as the barrel remove it now from the distributor box body Using the specific extractor tool for Indeco breakers extract the box body pos 302 from the head pos 301 and the shock absorber cover pos 305 making sure not to lose the pin pos 310 Check the state of the O Ring pos 311 and put it aside in aclean place 21 02 2012 Fig 35 Fig 36 i
11. DaS r 4 a 1 lypi Fig 5 YES reposition the breaker every 30 40 seconds Fig 7 NO allow an overheated cushion of air to form under the tool 21 02 2012 Fig 9 NO do not work if there are any obstacles contact the breaker Indeco recommends e Pushing the breaker firmly against the rock e Following through with the breaker as it penetrates correcting the inclination as it does so e Do not dry fire not enough down pressure on tool or blank firing e Keep an optimal thrust excavator position over work area gt Ensure that the breaker is in the right position tool at 90 degrees to material e Always ensure that there is a coating of grease on the tool amp inside the bushings at all times gt not pry and or overstress the working tool e Maintain or install a sharp working tool as needed e Inspect the tool Inspect upper part of tool spacer bushing amp axles 21 02 2012 2 3 Choosing the right tool Choosing the right tool can give the following advantages e Increases productivity e Reduction in tool breakage e Less bushing wear e Damage breaker wear items To make the right choice identify the most common type of work that the breaker has to perform We recommend that you follow the indications on the next page NOTES 21 02 2012 2 3 1 Tools and recommended use TOOLS Suitable for all earthworking or narrow section excavation jobs
12. Fixing Screw Inflating Screw Accumulator Fixing Screw or Shell Shell Screw Plug Cradle Bolt Casing Bolt Casing Spacer Nut Nitrogen Oil 60 C Inflating Pressure Oil 70 C Recharge as indicated by cross tightening the bolts in several phases Using the same technique tighten by 180 15 When this is complete loosen each side rod by 15 The torque setting shown must be reached gradually by cross tightening the bolts in several phases 21 02 2012 Ft lb 362 506 181 29 109 130 36 434 188 181 289 HP 4000 Wrench 38 38 24 19 22 B 4 B 14 B 5 8 B 9 16 B12 30 580 psi 508 psi POS 307 418 438 403 615 409 504 507 506 123 618 Ft lb 304 506 29 109 130 36 434 188 181 289 HP 3000 Wrench 38 38 19 22 B14 B14 B 5 8 B 9 16 B12 30 580 psi 508 psi POS 307 418 403 615 409 504 507 506 123 618 Ft lb 195 362 29 109 51 36 398 145 181 289 HP 2000 Wrench 38 30 19 22 B 10 B 14 B 19 B 14 B 12 30 580 psi 508 psi POS 307 418 403 615 409 504 507 506 107 618 Ft Ib 159 361 29 109 51 36 389 145 181 289 HP 1800 Wrench 38 30 19 22 B 10 B 14 B 19 B 14 B 12 30 580 psi 508 psi POS 307 418 403 615 409 504 507 506 107 618 Ft lb
13. a valve specifically designed for eliminating residual blows contact the Indeco technical department b Fit a two way electric valve on the line between the inlet and outlet on the breaker as shown in fig 64 This valve is usually open and closes only when the breaker requires oil OUTLET OUTLET BREAKER 2 WAY VALVE NORMALLY OPEN OIL INLET TANK EXCAVATOR MANIFOLD DISTRIBUTOR PUMP Fig 64 circuit diagram for valve eliminating blank firing 21 02 2012 6 7 Premature tool breakage Early tool breakage can be caused for different reasons each of which must be analysed separately First remember that the choice of tool for specific jobs is vital in order to ensure e High productivity e Less tool breakage See paragraph 2 3 for a guide to choosing the right tool The most common forms of breakage and their causes are as follows e Misalignment or leverage The section appears to have suffered fatigue failure due to flexure with a small section subject to shear breakage The breakage area is just outside the breaker below the lower bushing Caused by working the tool at an incorrect angle to the rock or by excessive tool leverage Fig 65 e Micro welding inside the bushing due to friction The section appears to have suffered fatigue failure due to flexure with clear signs of seizure on the outside In this case the cause is poor lubrication or a wrong insert in the lower bushing Seizure is responsible for
14. bolts in several phases Using the same technique tighten by 180 15 When this is complete loosen each side rod by 15 The torque setting shown must be reached gradually by cross tightening the bolts in several phases 21 02 2012 HP 1100 Wrench MKG 30 14 30 50 19 4 17 8 B10 7 B14 5 B17 32 B14 16 B12 25 30 40 35 Bars 30 Bars POS 418 403 615 409 504 507 506 107 618 SCREW TORQUE SETTINGS AND NITROGEN INFLATING PRESSURE 1 MKG 7 233 Ft Lbs HP 1000 POS Wrench MKG 308 32 48 418 30 50 403 19 4 409 0 7 504 4 5 507 4 16 506 2 11 618 30 40 607 30 43 608 30 30 35 Bars 30 Bars HP 750 Wrench MKG 30 14 B14 5 814 16 812 11 30 40 41 65 27 20 35 Bars 30 Bars POS 307 504 507 506 618 607 608 HP 500 Wrench MKG 27 28 24 30 B8 9 012 11 B10 7 22 20 27 30 27 20 35 Bars 30 Bars POS 308 413 504 506 505 618 607 608 HP 350 Wrench MKG 27 28 24 30 B8 9 INDECO 80 22 20 27 30 27 20 35 Bars 30 Bars POS 308 413 504 502 618 607 608 HP 200 Wrench MKG 27 20 19 25 B6 5 B6 3 B8 9 27 32 22 20 22 12 35 Bars 30 Bars POS 314 413 403 409 504 506 618 607 Appendix A 1 Item Side bolt Guiding Plug Pressure Testing Screw Side Shock Absorbers Screw Link
15. cost It involves planning service dates with the user so that machine downtime is kept down to a minimum All the servicing work the components and breakages are included in the price without further charges Each job is under warranty and very reliable Programmed maintenance also keeps second hand values high It is also possible to have a replacement breaker during repair periods 21 02 2012 5 4 Diagram showing service life of main components 5 4 1 spacer N Sie C F C F max HP 25000 2 205 1 319 0 709 4 252 HP 16000 2 205 1 555 0 748 4 528 HP 13001 1 575 1 378 0 630 3 583 21 02 2012 5 5 Diagram showing service life of main components 5 4 1 spacer i C F C F max HP25000 HP 16000 HP 13001 meo eee hero 10 8 ee esoo o o s o e o a T tra eee 6 8 a O Dto 7 1 8 65 5 8 10 21 02 2012 Emin inches 8 465 6 614 6 299 6 299 6 693 6 693 5 709 4 724 5 906 3 740 3 780 2 874 2 480 2 874 E inches 8 858 7 087 6 614 6 614 7 165 7 165 6 299 5 315 6 496 4 134 4 173 3 740 3 268 3 347 5 4 2 Tool Impact Area D inches 6 654 4 882 5 039 5 039 5 158 5 158 4 882 4 921 5 158 3 839 3 937 3 465 2 992 3 110 C inches 2 205 2 205 1 575 1 575 2 008 2 008 1 417 0 394 1 33
16. on medium to hard stratified rock Suitable for breaking up concrete or medium hard non stratified rock Secondary demolitions average hard or extremely hard blocks Suitable for breaking up concrete or medium hard non stratified rock Secondary demolitions average hard or extremely hard blocks Suitable for felling trees and cutting large tree stumps Suitable for pilework or press moulded supports for guardrails etc Suitable for cutting asphalt breaking up flooring as well as brick or sandstone walls where the working direction of the tool is perpendicular to the direction of the machine Suitable for demolishing hard reinforced concrete flooring as well as sedimentation material Suitable for all types of excavation work on medium hard to hard rock non stratified rock or rock which tends to pulverise when being broken up puddingstones Suitable for breaking up blocks of any hardness or to reduce the size of rubble Chisel tool Moil point tool Asphalt cutter Wood cutting chisel Pile driver Shovel shaped tool Pyramidal point Cobra chisel tool Blunt tool 21 02 2012 3 Breaker Installation 3 1 Machine amp Breaker Combination The breaker amp machine combination is very important In particular any comparison with competitors breakers should take into account tool diameter Making the right choice of breaker for a particular excavator eliminates any breaker reliability problem
17. upgrading Correct choice of insert will lengthen the service life of the tool Currently available are Bronze Steel and Composite e The lightweight of Indeco breakers which is due to their simple design reduces stress on the excavator arm Their slim lower end structure makes them ideal for specific uses like work in tunnels or in cuttings e Indeco breakers are available in the soundproofed HD model and in supersoundproofed Whisper model Both models ensure that noise levels are considerably reduced especially in the Whisper version which uses sound isolating material inside the casing 21 02 2012 2 Breaker Use 2 1 Foreword In order to use Indeco breakers correctly e Make sure to match the breaker amp carrier size with the right tool for the material to be broken e Review amp read operators manual e Check pre installation setup by experienced technician by checking the oil flow rate and pressure supplied to the breaker are within specifications e Check to see if the hydraulic plumbing is set to breaker mode and restriction free and the shut off valves are open e Make sure the breaker and the tool are pre greased e Adhere to all breaker safety precautions amp job site safety 2 2 Rules for correct use Fig 1 NO rotate or move the excavator using the tool as a lever 21 02 2012 Fig 4 NO press the breaker tool lightly against the rock 21 02 2012 4 a w mmm we n m a m a way
18. 1 02 2012 3 4 Flow testing amp adjusting the excavator relief valve After adjusting the flow rate on the carrier to the breaker the relief valve on the carrier must be adjusted Again a flow meter is used for this and is connected as shown above Choke the flow meter until the flow rate drops The pressure value corresponding to the reduction in the flow rate is the set up value for the valve This value has to correspond to that indicated in the breaker specifications about 25 higher than the operating pressure 3 5 Checking the breaker operating pressure amp backpressure Connect the breaker to the excavator and check that the oil is hot simply touch the pipes Then connect the pressure gauges to the breaker at the attachments This operation is carried out by adjusting the central valve on the breaker head using a large wrench see fig 15 and pressure gauges consisting of a glycerine filled pressure gauge see fig 14 range up to 5000 PSI with 1 4 or 1 8 test high pressure flexible hydraulic hose Indeco has a testing kits available for purchase if needed Fig 14 Check both oil pressures ports with the breaker working caution test ports are metric BSPP The pressure and return ports must show the values indicated in the specifications To regulate the pressure to the breaker adjust the central pressure valve in the breaker head by add or removing shims under spring wear disc 21 02 2012 Fig 15 The numbe
19. 12 5 618 41 0 40 Bars 35 Bars HP 7500 POS Wrench MKG 307 41 70 418 41 100 438 24 5 403 19 4 615 2 15 409 B14 18 504 514 5 507 B22 0 506 B17 5 123 812 5 618 36 0 40 Bars 35 Bars HP 5500 POS Wrench MKG 307 41 65 418 41 100 438 24 5 403 19 4 615 22 15 409 14 8 504 514 5 507 B22 0 506 17 5 123 812 5 618 36 0 40 Bars 35 Bars HP 5000 POS Wrenchi MKG 307 41 00 418 41 100 438 24 5 403 9 4 615 22 15 409 514 8 504 814 5 507 8 22 0 506 B17 5 123 B12 5 618 36 0 40 Bars 35 Bars Appendix Item Side bolt Guiding Plug Variable Valve Plug Pressure Testing Screw Vite Ammortiz Laterali Link Fixing Screw Inflating Screw Accumulator Fixing Screw Shell Screw Bush Cradle Bolt Nitrogen Oil 60 C Inflating Pressure Oil 70 C Recharge as indicated by cross tightening the bolts in several phases Using the same technique tighten by 180 15 When this is complete loosen each side rod by 15 The torque setting shown must be reached gradually by cross tightening the bolts in several phases 21 02 2012 21 02 2012
20. 2012 4 4 4 Accumulator assembly a Using the special Indeco tool check that the accumulator is charged Insert the O Ring seal into the lower shell pos 508 b Insert the accumulator into the breaker head tighten the eight screws pos 507 and cross tighten them to a final torque as set out in the specifications 21 02 2012 5 Breaker maintenance 5 1 General rules Breaker maintenance is essential for maintaining breaker efficiency and productivity over the course of time Indeed as it is used for breaking it is very important that components subject to wear which control how the breaker works should be kept under constant control maintaining the tolerances and the coupling parameters within acceptable values A distinction must be made between Large Medium and Small breakers For maintenance purposes it is important to understand that the stress on materials varies enormously from small to large breakers and therefore wear increases exponentially 5 2 Routine maintenance Routine maintenance involves replacing components subject to wear according to the Indeco specifications shown in the table below table 1 These values are the mean wear values during normal operations as reported in the manual supplied with the breaker This type of maintenance reduces the cost of replacing components subject to wear therefore preventing the problems arising from worse damage or long machine downtimes As Needed Min 1
21. 21 02 2012 SERVICE MANUAL HP SERIES 2 INDECO MOLITION TNERS IN DEI JR PAR YOL 1 Index 1 Description of Breaker Hydraulic Systems 1 1 Breaker Technologies 1 2 Indeco Hydraulic Breakers 2 Breaker Use 2 1 Foreword 2 2 Guidelines for correct use 2 3 Choosing the right Tool 3 Breaker Installation ADR 3 1 Machine amp Breaker combination 3 2 Checking the excavator auxiliary hydraulic system 3 3 Regulating the hydraulic flow and the pressure to the Indeco Breaker 3 4 Flow testing regulating amp setting the excavator OEM relief valve 3 5 Checking the Indeco Breaker operating pressure back pressure 3 6 Calibrating the Indeco Breaker speed and pressure valve regulation 4 Breaker Disassembly and Assembly 4 1 Removing the Tool 4 2 Disassembling the Accumulator and recharging it 4 3 Disassembling the Indeco Breaker 4 4 Assembling the Indeco Breaker 5 Breaker Maintenance 5 1 General rules 5 2 Routine maintenance end user 5 3 Rental maintenance to maximize ROI 5 3 Programmed maintenance 5 4 Service life data chart of main components 6 Description of the main problems found with breakers on site 6 1 The Indeco Breaker does not strike or strikes weak 6 2 The Indeco Breaker strikes slowly and powerfully without any variation 6 3 The Indeco Breaker is very irregular it stops and starts 6 4 The Hydraulic Oil overheats 6 5 Oil leaks 6 6 Residual blows Run On 6 7 Premature tool break
22. 9 0 295 0 236 0 276 0 276 0 256 BREAKER HP 25000 HP 16000 HP 13001 HP 12000 HP 12001 HP 10000 HP 8000 HP 7500 HP 5500 HP 5000 HP 4000 HP 3000 HP 2000 HP 1800 21 02 2012 Emin mm 215 168 160 160 170 170 145 120 150 95 96 73 63 73 mm 225 180 168 168 182 182 160 135 165 105 106 95 83 85 5 4 2 Tool Impact Area mm 169 124 128 128 131 131 124 125 131 97 5 100 88 76 79 5 4 3 wear plates on the casing mm 56 56 40 40 51 51 36 10 34 5 7 7 6 5 BREAKER HP 25000 HP 16000 HP 13001 HP 12000 HP 12001 HP 10000 HP 8000 HP 7500 HP 5500 HP 5000 HP 4000 HP 3000 HP 2000 HP 1800 Check the wear on the casing plates to ensure that there is a max clearance of 3 mm between the chuck housing and the casing 21 02 2012 a MAX DIAMETER CLEARANCE B B 0 748 0 669 0 650 0 650 0 630 0 630 0 591 0 512 0 532 0 472 0 492 0 433 0 413 0 354 J jg 5 4 5 Bushings amp Tools BN MAX DIAMETER CLEARANCE A A 0 591 0 512 0 512 0 512 0 492 0 492 0 453 0 394 0 413 0 354 0 374 0 335 0 315 0 276
23. 904 41 723 24 181 19 29 30 232 B14 130 B14 36 41 1085 B19 579 B12 181 55 1374 580 psi 508 psi POS 307 418 438 403 615 409 504 507 506 123 618 HP 12000 POS Wrench Ft lb 307 55 723 418 41 723 438 24 181 403 19 29 615 30 232 409 B14 130 504 B14 36 507 B27 1085 506 B19 362 123 B12 181 618 55 4 580 psi 508 psi HP 10000 POS Wrench Ft Ib 307 46 1 418 41 723 438 24 181 403 19 29 615 30 232 409 B 14 0 504 B14 6 507 B 27 1085 506 B 19 2 123 181 618 55 4 580 psi 508 psi SCREW TORQUE SETTINGS AND NITROGEN INFLATING PRESSURE HP 8000 POS Wrench Ft lb 307 46 3 418 41 723 438 24 181 403 19 29 615 24 5 409 814 0 504 814 36 507 B22 6 506 B17 6 123 12 181 618 41 723 580 psi 508 psi HP 7500 POS Wrench Ft Ib 307 41 6 418 41 723 438 24 181 403 19 29 615 22 109 409 814 130 504 814 6 507 B22 6 506 B17 6 123 B12 1 618 36 6 580 psi 508 psi HP 5500 POS Wrench Ft lb 307 41 0 418 41 723 438 24 181 403 19 29 615 22 109 409 B 14 0 504 814 6 507 B 22 6 506 B17 6 123 12 181 618 36 6 580 psi 508 psi HP 5000 POS Wrenchj Ft Ib 307 41 434 418 41 723 438 24 181 403 19 29 615 22 109 409 814 0 504 814 6 507 B 22 6 506
24. Hour e Greasing the tool if breaker does not have an power greasing system make sure that in the meantime the tool is always greased e In very dusty environments grease more often every hour and if necessary use a dust guard on the lower bushing Every 8 16 hours of work e Make a visual inspection to ensure the side bolts and all of the external screws are tightened side shock absorbers front side bolts screws on oil connections etc Especially during break in periods 21 02 2012 Every 80 100 hours of work e Remove the tool and turn 180 it so that it is in a new operating position e Remove amp check the condition of the tool retainers e Inspect the clearance between bushing and tool during tool see 3 4 5 e Check the wear on the inserts see 3 4 4 for alloy e Check the wear on the impact bushing see 3 4 1 e Grease the wear plates e Check the condition of the rubber shock absorbers on the sides and top of the breaker e Check underwater plug for tightness e Inspect for loose or missing bolts Every 600 800 hours of work e Check and flow the excavator in order to ensure the right flow rate and oil pressure to the breaker e Check the nitrogen charge and replace the seal if necessary e Check upper bushing amp upper spacer 5 3 Programmed Maintenance Programmed maintenance consists of a maintenance contract offered by Indeco that ensures low cost maintenance with short machine downtime at a fixed
25. age Technical innovations 7 1 HP system 7 2 Research and development projects Appendix Screw Torque Settings and Nitrogen Inflating Pressure N 21 02 2012 1 Description of Breaker Hydraulic systems 1 1 Breaker Technologies The breakers currently in the market can be classified into two main groups e Hydraulic thrust e Gas thrust The disadvantages of gas thrust breakers are as follows e Loss of nitrogen which gradually reduces the impact energy e High susceptibility to ageing and early wear e Efficiency greatly affected by temperature changes e Low second hand residual value e Excavator pumps wear out quickly e Hydraulically stiff they stress excavator arms and sleeves and they overstress the outlet and inlet pipes Therefore the advantages of oil thrust breakers such as INDECO over gas thrust old style breakers can be summarised as follows e The gas charge and energy per blow can remain constant e Reduced wear and tear and high resell value e Efficiency less affected by temperature changes Internally or Externally e Hydraulic shock absorption system leads to less stress is placed on carrier pins bushings and auxiliary plumbing components e Less needed maintenance results in lower costs and improved ROI e Leading manufacturers in breaker technology are adopting hydraulic thrust e Industry recognition for longer life between service intervals e Simple design and fewer seals in breake
26. d to follow specific indications such as for the HP 200 and HP 500 For further information please contact the Indeco technical department 21 02 2012 3 6 Calibrating the breaker speed and pressure valve regulation Breaker calibration involves regulating the blow frequency and thus the energy of each blow Make sure that the oil is hot This regulation can be carried out manually on medium and large breakers while it is automatic on small ones The calibration involves adjusting the variable valve which lies next to the central one in the head This is done after first calibrating the central valve In order to increase the working frequency either the number of spacers or the stiffness of the spring must be increased Similarly removing some spacers can reduce the frequency NOTES 21 02 2012 4 Breaker disassembly and assembly 4 1 Removing the tool In order to remove the tool the tool retainers pos 108 must be taken out of their housing in the sliding block Push the stop nut located beside the hammer pos 109 firmly into place with a screwdriver or similar tool turn 180 until it returns to its resting position Fig 17 21 02 2012 Then using the same screwdriver or rod push the tool retainer out from the opposite side Fig 18 Repeat the above for the second tool retainer During re assembly insert the WELL GREASED tool so that the hollows on the sides of the tool are aligned with the to
27. em with the excavator e A problem with the breaker To check the excavator make sure that the correct oil flow rate reaches the breaker then check all the possible reasons why the flow might be interrupted such as closed shut off valves defective or broken solenoid valves bad quick couplers circuit relief set too low leakages in the hydraulic flow system low outlet pressure high oil temperature After checking the excavator turn your attention to the breaker Check the following e The accumulator and in particular excessive pipe vibration e That the side bolts are tight e That the central valve is working and is not blocked e That the tool impact area and impact bushing are not excessively worn e Remove the tool and make sure that the piston moves freely there are no faults the breaker must be disassembled to check the state of the internal parts We recommend contacting an authorized dealer 6 2 The breaker strikes slowly and powerfully without any variation in speed If the breaker strikes slowly and without any variations you should check e The back pressure on the outlet e The central valve gt The oil flow rate to the breaker e The speed valve e The spring and O ring on the central valve In this case the operating pressure falls as the tool penetrates the rock 21 02 2012 6 3 The breaker is very irregular it stops and starts When the breaker strikes irregularly stopping and star
28. h the lips facing away from one another The lip seals pos 204 must be mounted on the internal seats of the cylinder fig 49 c Place the cylinder pos 203 complete with seals on the chuck housing pos 101 d Slide the piston into the cylinder using the anchoring screw pos 507 fig 50 Fig 50 Piston assembly Fig 51 Check valve assembly e Insert the check valves pos 205 fig 51 21 02 2012 f Mount the pin pos 211 in the circular guide pos 210 and insert them both into the cylinder pos 201 Fig 52 Fitting the guide adapter and pin Fig 53 Distributor assembly complete Insert the distributor inside the box body and check free movement pos 304 Set the distributor box body amp distributor together on guide adaptor pos 302 ensuring that the alignment hole lines up with the pin Then spread lubricant using a brush such as STP Oil Treatment or Vaseline Fig 54 Assembling the distributor box body Fig 55 STP oil treat the O rings 21 02 2012 4 4 3 Head assembly a Insert the O ring pos 410 onto the barrel pos 411 and mount on the central hole in the head Again spread lubricant liberally inside the head around the o ring for smooth assembly Fig 56 O ring in the head Fig 57 Assembling and lubricating the side bolts amp rubber b Use 2 accumulator screws pos 507 for lifting the head and then place the head perpendicularly on the cover and distribut
29. ing system has been redesigned in order to optimise the distribution of lubrication to the bushings all of the torque settings have been reviewed and corrected and locks have been added to the side bolts which thus can no longer work loose An optional anti dust kit has been designed for special applications Years of experience in various different markets have enabled us to develop new tools with improved penetration using innovative materials and manufacturing methods The housings and bushes have new materials and innovative manufacturing methods to increase their service life and reduce breakages to a minimum Casings have been redesigned in order to improve their durability toughness and soundproofing On the mini range the first closed casings have been introduced with polyurethane lining which reduces noise levels and increases reliability The HP series valves are far more versatile and provide better functionality and improved penetration the frequency can be regulated at will 7 2 Research and development projects Various research and development projects are under way The most important are as follows e Variable valve variability e Central valve introduction of a flow control system e Inserts for lower bushing new materials in bronze e Super soundproofed casing to reduce noise levels even further e Anti dustkit improved 21 02 2012 21 02 2012 Lb ft 101 362 29 58 51 36 232 116
30. l par 4 1 b Loosen the bolts and the corresponding nuts pos 618 and 619 that hold the Top Cap to the breaker casing fig 25 Fig 25 Fig 26 Using an Allen key remove the four bolts pos 409 that attach the H P connection pos 401 Fig 26 When dismantling check the state of the O rings pos 410 Repeat the same operation for the L P link right below it 21 02 2012 Fig 27 Then remove the side shock absorbers side shocks pos 602 by removing all the connection bolts with a spanner fig 27 Do not damage the threads Preheat bolts to soften red loc tight and if the breaker is horizontal support the breaker about 50 with a strap to unload the side shocks Clean thread with tap to remove remaining thread locker Fig 28 Unloading amp Removing Side Shocks Fig 29 Extraction Once the breaker has been removed from its casing see figs 28 and 29 for small breakers and fig 30 for large breakers place it in a pit or on a jig to keep it vertical during the subsequent disassembly and re assembly phases This becomes important when re torque the bolts fig 31 and 32 21 02 2012 Fig 30 Lifting Fig 31 Slinging the breaker Fig 32 Holding Note The Accumulator bolts are used as lifting aids for the Accumulator Head amp Cylinder 21 02 2012 Head disassembly 4 3 2 Remove the steel diaphragm pos 306 from the head pos 301 and check for damage If it
31. lows a Remove the snap rings pos 408 using a pair of special pliers b Remove the tab washer pos 407 and pull out the connection Check the state of the O Rings pos 406 and the keying areas If necessary replace the O Rings Clean carefully and put aside in a clean place 21 02 2012 404 405 Fig 44 supply unit Note Non swivel links are available for special applications were the swivels are not needed 4 4 Assembling the breaker 4 4 1 Assembling the chuck housing a Fix the lower insert holder pos 102 by aligning the pin seat with the outer face of the sliding block using the same pin lodged in the bushing gap and measuring the distances at the ends as shown in the picture After coupling activate the press and push Indeco recommends cooling insert holder overnight in freezer dry ice or liquid nitrogen for immediate installations 21 02 2012 Fig 45 positioning the bushing insert holder Fig 46 mounting the bushing holder b Mount the pin pos 103 using a hammer if necessary Fig 47 4 4 2 Cylinder and Piston assembly a Mount 2 screws accumulator bolts into the threaded holes pos 507 to enable the cylinder to move better and attach one O Ring to the cylinder 21 02 2012 Fig 48 lifting the cylinder Fig 49 Fitting the lip seals b Assemble two lip seals pos 204 into the internal seats of the cylinder pos 203 making sure that they are assembled wit
32. ol retainer compartments and push firmly into place Insert the tool retainer with the slots facing the front of the breaker and push firmly into place then push the stop nut down and twist 180 to block the tool retainers 21 02 2012 4 2 Disassembling the accumulator and recharging it The nitrogen charge in the accumulator is essential for the correct operation of the breaker both for blow energy and for hydraulic efficiency If the accumulator needs recharging then there will be strong vibrations on the breaker pipes especially on the inlet one Every 600 hours or every 12 months it is advisable to recharge the breaker with nitrogen The diaphragm should be replaced after each gun reseal or removal of accumulator gas The sealing ring under the charging plug must be replaced each use a Break free the eight accumulator screws pos 507 with an Allen Wrench See Appendix A Once the screws have been broke free speed up the operation with an impact driver b Remove the accumulator from the head using the same screws pos 507 assembled in the side holes and check the state of the O ring pos 508 21 02 2012 Fig 21 Some accessories are needed for the recharging operations a A high pressure nitrogen regulator gauge with a connection for a nitrogen bottle that is adjustable outlet up to 1000 PSI Clean hydraulic hose for connecting to charging valve no oily hoses Indeco Charging Kit Torque Wrench
33. or box body and mount it onto the cylinder Use 2 side bolts opposite the inlet ports to balance the head during installation Install remaining 2 after head installation is complete c Strike the head with a dead blow hammer until it fits tightly over the distributor box body and cylinder Larger breakers require larger dead blows Fig 59 21 02 2012 Fig 58 Setting head assembly Fig 59 Driving down the head d Spread Indeco HD grease generously all over the surface of the side bolts rubber on bolts nuts and threads Then assemble the four side bolts pos 307 and the corresponding nuts pos 308 to a light torque up to the value shown in the specifications e After preloading mark the heads of the side bolts with chalk and cross tighten them until the side bolt has performed 1 2 a turn 15 and then loosen it slightly anticlockwise so that it is tightened to exactly 1 2 turn the initial pre load torque NOTES BEREK ek SIDE BOLT Fig 60 tightening side bolts Fig 61 marking with chalk before the half turn f Insert 4 side bolt locks and 4 rubber stoppers pos 314 amp 313 onto the heads of the side bolts g Insert the steel shock absorbing diaphragm into the shock absorber cover fig 63 next page 21 02 2012 BREAKER HEAD SIDE BOLT LOCK SIDE BOLT FIT THE RUBBER STOPPER OVER THE LOCK Fig 62 side bolt lock Fig 63 steel shock absorbing diaphragm 21 02
34. pos 303 and the lip seals pos 204 Carefully clean the inner seal its lips turn inwards and the outer one which acts as a dust guard its lips turn outwards Keep in a clean place 4 3 4 Dismantling the chuck housing a Manually remove the spacer pos 105 If necessary put the tool back into its place to help remove the spacer b Manually remove the upper bushing pos 104 If necessary weld a disk inside it and extract it using a press c Using an M10 pin remove the nylon plugs pos 112 and remove the pin pos 103 if necessary using a pin remover 21 02 2012 mr a CX NN Note some units have one a piece spacer Fig 40 bushings Fig 41 elastic pin metric d Remove the elastic pin pos 110 by driving down using a metric pin remover into until it falls inside the housing fig 41 The tool retaining plug pos 109 will now be free check the wear on the retaining plug the replace O ring s pos 113 and the reaction spring pos 111 fig 42 Note a solid lock is available for hard rock conditions and under water applications to prevent premature axle unlocking q Fig 42 e Welda plug slice of an old tool inside the insert holder pos 102 21 02 2012 Fig 3 f With a plug welded onto the insert holder pos 102 remove it using a hydraulic press 4 3 5 Disassembling the hydraulic links If needed the HP and LP connection units can be checked as fol
35. r resulting in lower cost to renew e Simple design also aids in troubleshoot problems with ease 21 02 2012 1 2 Indeco Hydraulic Breakers The Indeco Hydraulic System is very simple to use and has several advantages over its rivals e First the Automatic Variable blows which recognise the type of material to be broken and adapt the power of the blow and the frequency to the type of rock This optimises the hydraulic power supplied by the excavator and cuts fuel costs e Indeco breakers also have a dual shock absorption system a hydraulic one and a mechanical one The first is a system made up of hydraulic cushions which dampen the outward vibrations Together with the external shock absorption system consisting of upper and side shock absorbers this system greatly reduces the vibrations and stress transmitted to the excavator e The simplicity of the hydraulic system and in particular the distribution require few O rings and seals with a large reduction of the cost of replacements e The automatic centralised greasing system considerably improves the greasing of all of the parts even those not in vertical positions e The quick change field replaceable lower bushing insert which enables maintenance to be carried out in the workplace without prolonged machine down times Does not require disassembly of breaker This insert bushing can be made either of steel or of a future alloy material and incorporated into older models for quick
36. r of shims can be changed to increase or decrease pressure To increase pressure add shims under wear spacing disc under the spring where as to decrease pressure remove the number of shims under spacing disc The medium size breakers will have two special shims that measure 2mm each instead of the 1mm If there are no more spacers to remove when decreasing pressure a reduction of GPM will be needed Contact Indeco service for guidance amp suggestions No more than eight spacers should be used Each 1 mm spacer increases the pressure by about 5 bars 75 to 100PSI depending on backpressure If the operating pressure is still too high this may be due to a High back pressure too small of a return line quick couplers too many 90 s or 45 s fittings return line not going straight to hydraulic tank b High oil flow rate GPM to high use a external flow control valve to reduce flow optional OEM or from Indeco c Central valve defects Trash in orifice bleed hole If the pressure is too high this will stress the breaker components reducing their service life the backpressure is too high the circuit needs to be rerouted by connecting the outlet directly to the tank or by asking the excavator manufacturer for advice For pressurized breakers closed circuits you must ensure that the backpressure is sufficient to provide adequate inlet pressure about 10 to 20 bars according to the type of breaker In some models you nee
37. s excessive or wasteful stress and poor work yield We recommend checking with your local dealer or Indeco s web site at www indeco breakers com Your dealer has sales brochures with detailed carrier and breaker combination listings NOTES 21 02 2012 It is also very important to choose the right breaker for the hydraulic characteristics of the excavator For small breakers make sure that the backpressure in the aux circuit is no higher than that shown on the breaker specifications For all circuits on medium and large breakers it is important to ensure that the backpressure is as low as possible 6 8 bars max 75 to 100 PSI To eliminate high backpressure you can modify the return line changing hose diameters and curves and altering any taps and or valves For further information please contact the Indeco technical department Below is a table with the technical specifications needed to install a breaker on a carrier It is not recommended to calibrate the carrier with the maximum oil delivery and maximum pressure Instead choose e Maximum delivery and minimum pressure for a high working frequency e Bvcontrast minimum delivery and maximum pressure for increased penetration Finally always make sure that the return line backpressure is lower than the maximum value shown in the specifications INLET PRESSURE BACK PRESSURE OPERATING EXCAVATOR MAX PSI MAX PSI WEIGHT lb WEIGHT OPTIMAL MIN MAX
38. ting again the following areas must be checked e The excavator solenoid valve e The breaker central valve e Oil leakages in the hydraulic flow system e That the side bolts are tight e The excavator relief valve e That the piston can move freely e That the temperature is not too high i e above 180 F e Wear on the bushings and tool impact area 6 4 The oil overheats In this case check e That the excavator cooling system is working properly e That the excavator solenoid valve is working properly e The excavator relief valve e Oil leakages in the hydraulic flow system e The breaker central valve e That the side bolts are tight e That the piston can move freely e That there are no leaks in the breaker head if necessary replace the o rings 6 5 Oil leaks If there are any oil leaks the problem may be caused by one of the following e Temperature too high i e above 180 F e Overheated seals on the piston due to lack of grease e Scored at seal area or damaged piston e Breaker use underwater e Worn out seals e Excessive back pressure e High operating pressure 21 02 2012 6 6 Residual blows The presence of residual blows on the breaker can create problems in particular situations and cause excessive stress to some breaker components such as tool retainers and stop nuts The following remedies can completely prevent residual blows a Replace the central valve on the breaker with
39. triggering the crack 21 02 2012 Fig 66 Blank firing This happens especially when breaking up blocks when the type of job causes the tool to bounce on the surface of the material These blows have a violent impact on the tool retainers on the breaker causing heading in the area indicated Note Excessive blank firing can destroy side shocks top shock and lower end parts eer ggn Fig 67 Mechanical damage to the tool surface A strong blow on the outside of the tool triggers this type of fatigue breakage 21 02 2012 BY e Cold break Using the tool in excessively low temperatures which make the tool more fragile causes this Fig 69 e Breakage in the tool retainer area Using worn and poorly greased tool retainers causes this type of breakage Micro cracks are produced in the sliding part of the tool retainer triggering the breakage 21 02 2012 Fig 70 e Breakage of the chisel tool tip This breakage is caused by contact between tool and rock at an incorrect angle Fig 71 21 02 2012 e Heading at the end of the tool This happens when the same point is hit for a long time without allowing the tool to cool In such cases there is a temperature change inside the material of the tool Fig 72 a material or manufacturing defect is found after analysing both the break and the tool material Indeco will replace the tool with a new one NOTES
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