International, Inc.101 Van Riper AvenueElmwood Park, NJ 07407(201) 797-46441-800-631-3816

SERVICE MANUALAND OPERATINGINSTRUCTIONSFOR HYDRAULICSPLITTERS ANDHYDRAULIC PUMP SYSTEM

September 2017

table of contents1 Operating Instructions2 How Tool Operates Cylinder & Pump3 Command Valve Operation3 Broken Plugs & Feathers3 Lubrication of Splitter4 Flow of Hydraulic Fluid4 Hose Specifications4 Hydraulic Fluid Specifications5 Pressurematic Valve5 Selection of Power Unit6 Drilling Holes

Notice...that there are two information notices that are attached to this hydraulic system. One is the red warning decal attached to the command valve on the cylinder – this relates to possible movement of the tool during operation. The second warning notice is a tag attached to the pump and cylinder unit describing the service checklist and hoses and fittings. These notices shall remain attached to the pump and cylinders at all times. If lost, ask for a replacement.

WARNINGWHEN TOOL IS WORKING KEEP ARMS LENGTH AWAY FROM CYLINDER DUE TO POSSIBLE SUDDEN MOVEMENT WHEN BREAK OCCURS.WHEN TOOL IS USED OFF THE GROUND OR OVERHEAD, THE CYLINDER SHOULD BE SUPPORTED SO IT DOES NOT FALL AFTER BREAK IS MADE.

6 Controlling Direction of Breaks6 Test Break7 Use of Two of More Splitters with Flow Bar8 Maintenance of Cylinder10 Service Tools10 Service Command Valve11 Gasoline Engine Service12 View of Basic Pump13 Air Motor for Basic Pump14 Trouble Shooting Chart17 Service Tips

WARNINGDO NOT REMOVE TAGOPERATE SYSTEM WITH THE FOLLOWING…High pressure hydraulic hose shall be rated at 10,000 PSI operating pressure, 40,000 PSI minimum burst.

Low pressure hydraulic hose shall be rated at 2,250 PSI operating pressure, 9,000 PSI minimum burst.

Quick connect couplers shall be rated at 10,000 PSI operating pressure, 40,000 PSI minimum burst.

High pressure hose fittings shall be rated at 10,000 PSI operating pressure, 40,000 PSI minimum burst.

Low pressure hose fittings shall be rated at 5,000 PSI operating pressure, 20,000 PSI minimum burst.

These hoses are not interchangeable and special care should be observed during re-assembly.

Hydraulic fluid for the operation of the power unit will be limited to the use of the following brands:

Exxon Mobil Univis HVI-13 - Code # 101556Shell Aeroshell Fluid 4

(Substitutions may cause damage to the power unit and/or render it inoperative.)

Plug lubricant, water resistant, coefficient friction factor 0.103 or less. Use Elco lube paste for maximum breaking force.

SERVICE CHECK LISTFOLLOWING MAINTENANCE IS RECOMMENDED AFTER EACH DAY’S OPERATION:

SPLITTER1. CHECK AND CLEAN ALL HOSE AND COUPLING CONNECTIONS2. CHECK FORWARD AND REVERSE PRESSURE3. CHECK WEAR PLATES AFTER EXTENDED USE —SEE MANUAL4. CHECK TENSION OF FEATHER LOCKS

POWER UNIT1. CHECK OPERATING PRESSURE2. CHECK SHAFT ADAPTER AND DRIVE COUPLER AFTER EXTENDED USE3. CHECK FELT DISC FOR CLOGGING4. CHECK OIL LEVEL

SEE SERVICE MANUAL FOR DETAILS

A. PLUG OUTB. NEUTRAL POSITIONC. PLUG IN

Pause at neutral when retracting plug.

©Copyright 2017 Elco International, Inc.

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UNPACKING AND SETTING UP TOOL FOR OPERATION

1. Unpack unit.

2. Attach hoses to pump unit at Valve. Tighten securely.

3. Unscrew dip stick and fill pump reservoir with recommended hydraulic fluid. (5 gal)

4. Unpack cylinder — check to see if hose whips are correctly installed, low pressure closest to handle on right side.

5. Connect cylinder whips to hoses with the quick connect couplers.

6. If a gas unit is used, be sure to put oil in the engine (SAE 30 summer/SAE 20 in winter) prior to starting.

7. Lube plug and feathers (see page 3). Assuming that you have read and understood the engine and operating manual, you are now ready to operate the DARDA Splitter.

RECOMMENDED HYDRAULIC FLUIDOIL SUITABLE FOR SUMMER AND WINTER USE WITH DARDA SPLITTING UNITS — Conforms with Mil-Spec.

EXXON MOBIL UNIVIS HVI13 Code #101556

SHELL AEROSHELL FLUID 4

Read the “New Method” book for suggested uses of the splitter in the demolition of rock and concrete. For detailed maintenance instructions on pump and cylinder, refer to the Service Manual.

OPERATING INSTRUCTIONS

PRIOR TO START1. Check all fluid levels, hose and power connections.

2. Electric power supply and extension cables should be adequate for 3000 watts.

3. Air hoses and piping should always be blown free from water, dirt and scale prior to connecting. If air motor is used continuously, add filter trap and line oiler 10 feet or closer to air motor.

4. On Gas engine check crankcase oil level each time gas tank is filled.

5. Start power unit always with lever on rock splitting cylinder in center (neutral) position.

START6. Check that Plug and Feathers are in good condition. End of retracted plug should be approximately 11/4” from tip of feathers. Don’t work with defective parts since additional damage might occur and splitting power is substantially impaired.

7. For efficiency, drill straight and proper size holes. SEE CHART FOR CORRECT SIZE AND DEPTH (PAGE NO. 2)

8. Lubricate plug and feathers with ELCO LUBE. Never use oil or grease.

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SPLITTER DO’S & DON’TS

DO… Lubricate every second or third split. Use only recommended lubricant for plug & feathers.DO… Keep connections clean.DO… Check fluid levels periodically (daily).DO… Follow standard safety procedures.DO… Drill holes the proper depth and diameter. See Chart page 2.DO… Consult ELCO if you’re not sure of hole pattern.DO… Rotate tool in correct position.DO… Keep arms length distance from the cylinder when it is operating, the cylinder may shift and move when the rock or concrete is broken.

DON’T… Use cylinder as a lever or pry bar.DON’T… Use standard lubricants such as grease or petroleum products on plugs and feathers.DON’T… Operate splitter with defective or damaged plug and feathers.DON’T… Let splitter deflect more than 1” from vertical when splitting.DON’T… Drill unnecessary holes.DON’T… Leave splitter with plug extended.

BEFORE OPERATING SPLITTER HAVE YOU…a) Read and understood “New Method” book, especially pages 3 to 7?

b) Drilled the correct size and depth holes?

c) Properly lubricated the plug and feathers?

d) Properly connected and serviced the cylinder and pump? (Hydraulic fluid, oil, all connected tight.)

READ BEFORE USING SPLITTER The DARDA Splitter is one of the finest tools made and has been engineered to give years of service. Years of field experience has proven that proper lubrication and operation will help reduce maintenance costs and prolong the life of the unit. Follow the recommended procedures outlined in this folder.

The Basic Pump (Model 521) is a two-stage pump: gear driven low pressure and axial piston driven high pressure. It has a built in safety valve that will not allow the pump to pump over 10,000 PSI. Normal operating pressures should never exceed 7100 lbs. We do not recommend that you try to service this unit as it requires facilities and testing equipment that most shops do not have. Return it to a dealer for repair.

PRESSURE-MATIC VALVE From the reservoir and the Basic Pump, the fluid flows directly to the Pressure-Matic Valve. This valve is the secret of the splitter’s one-man operation. It lets the basic pump build up pressure until the maximum of 7,100 PSI is reached, then it by-passes with an audible “pop” and routes the fluid directly into the reservoir at approximately 800-1,000 PSI. The release pressure of the valve can be adjusted if needed.

From the Pressure-Matic Valve, the fluid is pumped via high pressure hose (40,000 PSI minimum burst) to the Command Valve. This is the valve that controls the opera-tion of the splitter. The Command Valve has three positions.(See page no. 3 for details.)

CAUTION: In order for the splitter to operate, it is essential that the plug and feathers are lubricated before operation. Failure to apply the recommended lubricant before each break will reduce the breaking force and could bind the metal surfaces together and damage the tool. See the operating instructions for the recommended lubricant that is required to operate the splitter. Only well lubricated plug and feathers will operate the splitter at peak efficiency. (See photos on page no. 3)

HOW TOOL OPERATESThe hydraulic splitting cylinder contains one plug and two feathers.

The basic parts of the splitter consists of two cylinders. The upper cylinder houses the piston which moves the plug in the lower cylinder.

The command valve is operated by a single lever on top of the unit. The plug is extended or retracted by the command valve.

The cylinder operates to 7100 PSI hydraulic pressure. After the plug is extended, the pressure-matic valve automatically lowers the pressure to approximately 900 PSI; in a neutral position, the PSI drops under 50.

This assembly is inserted into a pre-drilled hole with the plug in a retracted position. When the control lever is turned to “(F)” forward position, the plug advances and the two feathers are forced sideways against the wall of the hole and with hundreds of tons of pressure tears rock or concrete apart. With the control lever on top of the cylinder, the plug can be advanced, retracted or held in any position. A break usually occurs within 10 seconds but with extremely hard material, it could happen in up to 60 seconds.

2

80007000600050004000300020001000

600 90200 70400 80100 60 50

PUMP PERFORMANCE CHARTFLOW — CU. IN. PER MIN.

PRES

SURE

— P

SI

SPLITTER MODEL

22W3*

3W*912

SPLITTING FORCE IN

TONS

220176250209220385

HOLEDIAMETER

1-3/16”1-3/16”1-5/16”1-5/16”1-3/4”1-3/4”

HOLEDEPTH

121218181826

METRIC: DIAMETER & DEPTH

31 x 30031 x 30024 x 45024 x 45045 x 45045 x 660

ExPANSION INCHES

.33

.45

.40

.51

.75.75-1.87**

ExPANSION MM

8.512101319

19-48**

* No longer in production** Using Enlarging Feathers

LUBRICATION OF PLUG AND FEATHERS USE ONLY ELCO LUBEExtend plug and lubricate both sides of plug with recommended lubricant. For hard work and best results, lubricate prior to each split. Small boulders of easy to split material require less frequent lubrication, e.g. each second to fifth split.

It is important that only recommended products be used, since other regular mineral oil types of greases do not perform at all and can damage the tool. Depending on the hardness of the rock and the size of the intended split, lubri-cation of plug & feathers has to be done more frequently. Under extreme con-ditions or with a new tool, lubricate prior to each split. Good lubrication means almost twice the power and production as compared to neglected lubrication.

Lubrication is simple. First extend plug fully. Apply lubricant with a flat piece of wood, steel or brush. Use lubricant sparingly, but frequently.

Do not continue to work with defective plug & feathers. It will lead to damage to the still intact working parts.

It is possible under certain conditions and lack of lubrication the plug cannot be retracted. In this case it will be necessary to drill another hole in the line with the intended split and break the frozen tool free using a second tool.

NOTE: Cracking of the hardened surface at the lower end of feathers is perfectly normal, it occurs during manufacturing and the first few uses of the tool. Moly-lubricant is retained in these cracks. However, lack of lubrication, crooked drill holes or a broken plug will cause one or both feathers to fail prematurely.

3

LEVER LEFT POS. 1 — PLUG FOWARD When the plug is at its exteme forward position, the Pres-sure-Matic valve will “pop” with a slight noise, switching the pump to low pressure by-pass.

LEVER TO RIGHT OF CENTER POS. 2 — PLUG STOPPED The plug will remain in any position desired and the oil will recirculate freely through hoses & both valves. This is the ideal idling position. Start pump with valve in this position.

LEVER RIGHT POS. 3 — RETRACT PLUG When the plug is at its upper end position, then the Pres-sure-Matic valve will auto-matically switch pump to low pressure by-pass. A “pop” noise is audible when this occurs.

Keep control valve in Pos. 2. This will relieve pressure in the en-tire system. Be sure quick con-nect couplings are well connect-ed, since these couplings are self-sealing. An incomplete con-nection can result in a blocked pressure line or a blocked return line. In this case it is possible that the low pressure whip will burst and have to be replaced. This is a safety feature to protect dam-age to the control valve. Don’t use high pressure hose as low pres-sure whip.

command valve operation

SHORT DRILLED HOLE1. If the drilled hole is too short to receive the fully extended plug, the plug will contact the bottom of the hole and break. This could also break one or both feathers. Be sure that the drilled hole is the proper depth. See chart on page no. 2.

IMPROPER LUBRICATION2. The plug and feathers generate up to 385 tons of pressure. If not lubricated, the plug and feathers can freeze together and the feather tops can be pulled out of the cylinder causing damage to both feather and cylinder. Use only recommended lubricant.

EXCESSIVE LEANING OF CYLINDER CAN CAUSE DAMAGE3. In some cases, where there are seams in rock or an unsupported rock, as illustrated, the rock shifts when a break is made and can break both plug and feathers. To prevent this, turn the tool to retract position when the cylinder shows any sign of leaning to one side.

COMMON REASONS FOR BROKEN PLUGS AND FEATHERS

IMPROPER LUBRICANT REDUCES THE SPLITTERS BREAKING POWER

4

simplified flow diagram

COMMAND VALVE LEVER IN CENTER POSITION — FLUID CIRCULATES FREELY AT LOW PRESSURE

PISTON REACHES FULL EXTENSION AND PRESSURE-MATIC VALVE BY-PASSES — FLUID IS RETURNED DIRECTLY TO RESERVOIR AT 800-1,000 PSI

COMMAND VALVE LEVER IN FORWARD POSITION — FLUID DIRECTED INTO CYLINDER FORCES PISTON FORWARD

COMMAND VALVE LEVER RETURNED TO CENTER POSITION. READY FOR RETURN CYCLE — SAME FLOW AS FIG. 4 Lever in retract position forces piston up, retracting the plug. When piston reaches full retraction, same conditions as Fig. 4 occur. When lever is returned to center position, cycle is complete. Fig. 4

THE HIGH AND LOW PRESSURE HOSES ARE NOT INTERCHANGEABLE! The standard hoses for the Darda splitter consists of one each, high pressure (40,000 psi minimum burst); one low pressure hose (9,000 psi minimum burst); and a pair of high and low pressure hose whips. The hoses are connected to the tool via quick disconnect, self-sealing couplings which carry identical pressure ratings.

WHIPS The hose manufacturer specifications for splitter whip hoses, 2 1/2 feet in length, are rated at 40,000 PSI and have two 1 foot hose guard shields; one at each end. Cylinder should not be operated without this type of 2 1/2 foot shielded whip. The low pressure whip is 2 1/2 feet in length and does not have shields.

HYDRAULIC FLUID We recommend that you use a high grade aircraft hydraulic fluid. This can be obtained at most airports and from the major oil companies.

RECOMMENDED HYDRAULIC FLUID Oil suitable for use with the hydraulic splitting units: EXXON - UNIVIS HVI-13 Code #101556 SHELL - Aeroshell Fluid 4Use of other hydraulic fluids may cause the pressurematic valve to malfunction.

During warm weather, use hydraulic fluid with viscosities of 300 SSU at 100° F. For best efficiency, especially during cold weather, use Hydraulic Fluid conforming to Elco recommendation.

Change hydraulic fluid every three months with average use. Inspect and clean suction filter of power unit by removing the 10 phillips head screws of the cover plate and lift unit from the tank. Check for sludge in tank. Avoid mixing hydraulic fluids since there is a possibility of jelling.

If a heavier weight standard hydraulic fluid is used, the speed at which the splitter operates (cycle time) will be greatly reduced, cutting production.

First check the operating pressure by using a test gauge. If the pressures are not consistent with the chart on page 2, check the following:

The pressure-matic valve:1. The relief valve is factory adjusted, set to 7100 PSI. Do not adjust to any higher setting than 7100 PSI. Call ELCO before any adjustments are made to the relief valve.It is essential that clean oil be used in these systems. Dirt can plug the orifice. Also, hot oil can effect the valve performance.

Pop-Off Relief Valve (06-300) Test and AdjustmentSet-Up — use oil in a pump that delivers approximately 20 cubic inches of oil at 7100 psi. A good pressure gauge is essential, pref-erably one which maintains peak pressure.

1. Remove reservoir cover plate screws and tip cover plate so you

have access to the valve.. 2. Loosen Housing Lock Nut (#2). Turn Valve Housing (#6)

clockwise to increase pressure and counterclockwise to decrease pressure.

3. Loosen Lock Nut (#8). Turn Set Screw (#7) until it touches the end of the Valve Stem (#4). Back off Set Screw (#7) 1 to 11/4

turns. 4. Tighten Lock Nuts (#2) and (#8). 5. Recheck pressure and install cover plate.

NOTE: the pop-off relief valve assembly must be used in conjunc- tion with the high pressure safety relief valve set at 10,000 psi.

SELECTION OF POWER UNIT Power unit and hydraulic splitter are connected with a pair of high and low pressure hydraulic hoses. Flow distribution bars are available which permit the use of up to five splitters from one power unit. Note that they can only operate simul- taneously, not intermittently or individually.

Hydraulic pressure applied (Maximum 7100 PSI) is used by all size splitters enabling the same hydraulic pump to be used for all models.

Power units are available in three types—Air, Gas and Elec- tric to suit all job conditions. When selecting a power unit, the following points should be considered: Job conditions usually determine type of power for the hydraulic pump.

AIR—Since most of the time air power is used to drill, power unit with air motor will always be useful. No exhaust gases, not affected by water. GAS—When all available air must be used for drilling, or when compressor is removed prior to splitting, or where power unit must be moved around frequently, a gas power unit is advantageous. ELECTRIC—It is quiet, no exhaust gases, useful inside buildings, faster cycling. Less maintenance required.

All models can be converted from one power unit to another.

POWER UNITS The hydraulic power units for the DARDA Rock Splitter are offered with three different power sources. See below.

*a - Air Pressure requirement is 50 to 80 CFM at 100 PSI. Air to be clean, dry and lubricated.*b - Universal type motor 50-60 cycles, 117V, 21-28 Amps varies with oil viscosity.*c - 60 Cycles 115/230 Volts, or 3 phase 208-220/440 Volts.*d - In summer, use non-foaming, high quality oil of viscosity (300-SSU at 100ºF). In winter, or all season, use Hydraulic Fluid conforming with Elco recommended. Oil capacity — 5 Gal.

The motors on these units can be interchanged easily so that you have complete versatility with one pump. Servicing of these motors and pumps is covered on pages 13 to 17.

CYCLE TIME (SECONDS)

This chart can be used as a guide to judge overall operating performance characteristics of your splitter and pump.

5

ITEM NO. PART NO. DESCRIPTION

1 0660 Valve Seat 2 0667 Housing Lock Nut 3 0661 Ball 4 0666 Valve Stem

ITEM NO. PART NO. DESCRIPTION

5 0662 Spring 6 0665 Valve Housing 7 0663 Set Screw 8 0664 Lock Nut

PRESSURE-MATIC VALVE TEST AND ADJUSTMENT — 06-300

**ITEM 38

POWER GASOLINE AIR ELECTRIC Code 01 02 03 Horsepower 3.5 3*a 1.0*b,*c RPM 32-3600 2-3500 3450 Weight— Exclusive Oil*d 79 lbs. 94 lbs. 85 lbs. Width 18” 18” 18” Depth 121/4” 121/4” 121/4” Height 22” 201/4” 231/2”

TOOL SIZE FORWARD RETRACT

#12 30.5 21 #9 10.5 8 #2 7 5.5

DRILLING HOLES FOR SPLITTERHole drilling is usually done with a conventional rock drill. To prevent dust, either a vacuum attachment or water flushing can be used. On work where all noise and dirt must be prevented such as in hospitals, computer centers, or control towers, a diamond core drill is usually used to pre-drill the holes required for the splitter.

It is very important that the holes should be of exact diameter, length and straight.

Integral drill steel is readily available which combines accurate diameter with short effective length to permit comfortable drilling. Notice the importance of having a close-hole diameter.

If for some reason the drilled holes are short, it is possible to hold the tool out of the hole the same distance as the differ-ence between the actual hole and the recommended depth.

Drill operator should keep drill steel firmly positioned in cen-ter of hole from beginning to end; otherwise, a crooked hole will result causing deformation of plug and feather assembly. Repeated deformation will lead to fatigue and breakage of the entire plug and feather assembly or part thereof. If deeper holes are drilled using two lengths of drill steel, make sure the lower part of the hole has almost the same diameter as on top. A step in the hole could cause “hang up” and possible break-age of wedge. Drill steel is available which is just long enough to permit drilling entire hole in one operation.

If many holes are drilled by different operators, the hydraulic splitter operator should check each hole with a ruler or broomstick to make sure that the hole is deep enough and free from hard obstructions. The plug will break if it is forced against solid rock.

TEST BREAKTo make a test, break a small section first (Fig A). If this works well, increase the size of the break until the maximum split is determined. Always keep in mind the size of rock or concrete that your removal equipment can handle.

CONTROLLING DIRECTION OF BREAKSThis is a simple operation, just line-up the handle in the same direction of the intended break—the plug and feathers will then be in the proper position for a con-trolled break.

As the piston pushes the plug between the two feath-ers, the splitting force extends from the sides of the two feathers. The break is in the same line as the plug. By rotating the tool, the plug can be aligned with the intended break. This allows control of the fractures direction. Notice the direction of the breaking force.

To speed up production, it is suggested that several test breaks be made to determine the hardness of the material to be removed. With test breaks, the pattern of holes can be determined. As drilling is a longer operation than splitting, the number of holes should be kept to a minimum.

6

EXAMPLE: For #12 cylinder if drilled holes are only 20” deep—then hold splitter 6” out of the hole. See illustra-tion. Do not hold tool more than 8” out of hole for best results.

SHORTDRILLEDHOLE

The dotted lines show the direction of the intended break in a boulder. For a maximum break, drill a hole in the center, (Fig B) of the rock. Now place the splitter in the hole and make sure that handle is in the same line as the intended break. Depending on the quality and structure of the rock, the crack can be placed with great accuracy. After the rock has been broken in half, use same procedure with each half. Do not drill unnecessary holes as this is wasted effort.

increase breaking power with two or more hydraulic splitters

HOW IT WORKSThe breaking force of Hydraulic Splitters can be increased by using two or more cylinders. The pumps 01, 02, 03 have been engineered and designed to operate up to five splitters simultaneously. To operate two or more cylinders off one pump a “Flow Bar” is required, both high and low pressure lines run from the pump to the flow bar. The flow bar has outlets for five cylinders.

When using this hook-up for two cylinders or more, the units work at the same time. That is the plugs are extended and retracted at the same time; the units will not operate

independently. To operate, one unit control lever is placed in the forward position (this is now a slave unit) the other unit is the “Master” cylinder and will now operate both cylinders, with its controlled lever.

This type of multiple splitting is recommended where breaks must be controlled. It is also recommended for very long breaks of both concrete and rock.

In field operations, five cylinders were able to break a granite rock 30 feet long by 12 feet deep in one operation.

7

HOOK UP The hydraulic pump (1) has two lines (2) that con-nect into the flow bar (3). Two hoses — for each splitter run from the flow bar to each cylinder, one cylinder becomes the master cylinder while the other becomes a slave unit.

The above photo shows a flow bar and connections to operate two cylinders. Note the extra outlet in the middle and there is an outlet on each end of the bar. This bar can operate up to five units at one time. Plugs are placed in the unused ports of the flow bar before unit is operational.

NO. OFMODEL 12 2 3 4 5SPLITTERS

CombinedSplitting Force 770 tons 1,156 tons 1,540 tons 1,925 tons

*Length ofbreak example 6 ft. 10 ft. 15 ft. 20 ft.(5 ft. thick concrete)Spacing of splitters 3 ft. 3 ft. 3 ft. 31/2 ft.

SPECIFICATIONS FOR MULTIPLE SPLITTERS

* Length of break depends on the thickness of the material(rock or concrete)

PUMP1

2

ELBOW 431

LAP ADAPTER

430

HP FITTING410

BLOCK 525

8

CHANGE or REMOVE PLUG(remove feathers first)

1. Extend plug fully and remove plastic plug (#23) and screw plug (#43).2. Using a small pin punch, knock out plug pin (#20). Pull plug straight out.3. Reinstall using reverse of the above.

9

CHANGE FEATHERS FOR MODELS 9 AND 12

1. Pull up both feather lock bars (#21) and push plug and one featherto one side as far as they will go.

2. Grasp other feather, twist 90º and pull out.3. Move plug to other side and remove other feather.4. Reinstall feathers using the reverse of the above.5. Do not attempt to operate the splitter with feathers unlatched.

CONTACT ELCO INTERNATIONAL, INC.FOR EXPLODED ASSEMBLIES

AND DETAILED SERVICE

PROCEDURESOFFICE: 201-797-0823

EMAIL: ELCOINTINC@AOL.COM

10

KEEP CONNECTIONS CLEAN Care should be taken not to allow any dirt to come in contact with the couplings. Failure to keep these clean will shorten their life. It is rec-ommended that when the cylinder is not connected to the hoses, use the rubber caps provided to place on couplings with disconnecter.

Field maintenance should be taken care of by the serviceman at the beginning of each day’s work, or the operator of the tool whenever he has the opportunity. These simple checks will help to combat costly downtime.

TEST GAUGEFig. 11

CONTACT ELCO INTERNATIONAL, INC.FOR EXPLODED ASSEMBLIES

AND DETAILED SERVICE

PROCEDURESOFFICE: 201-797-0823

EMAIL: ELCOINTINC@AOL.COM

SERVICE OF GASOLINE ENGINE

The Gasoline Engine is warranted by its manufacturer. Do not send to ELCO for warranty. Take to authorized repair station.

1. This engine is a standard gasoline engine and should be servicedaccordingly.

a. Clean air filter once a day under unusually dusty conditions.Otherwise, once a week.

b. Check oil once a day when unit is in daily use. Check it prior toeach use. Otherwise, change oil whenever it becomes dirty.

c. WARNING: Do not transport unit when gas tank is full and fill cap isblocked off. Due to the design of the carburetor, the gas could sloshinto the crankcase of the engine. If the oil is diluted and the engineis run, serious damage will occur.

d. This engine uses regular gasoline. Do not mix gas and oil together.e. Use SAE 30 oil in summer and 10W 20W in winter (straight 10W

below 20ºF.)f. In cold, damp conditions, it may be necessary to remove the air

cleaner and hand choke the engine.11

CONTACT ELCO INTERNATIONAL, INC.FOR EXPLODED ASSEMBLIES

AND DETAILED SERVICE

PROCEDURESOFFICE: 201-797-0823

EMAIL: ELCOINTINC@AOL.COM

The motors on these units can be interchanged easily so that you have complete versatility with one pump*. Servicing of these motors and pumps is covered on pages 13 to 17.

AIR MOTOR - 36 GAS ENGINE - 27 ELECTRICMOTOR - 29

12

13

41

42

43

45

46

47

48

49

50

47

51

52 56

59

37

60

68

53

54

55

41

5

65

25

24

30

44FIG. 24

FIG. 25

FIG. 26

FIG. 27

FIG. 23

SERVICE AIR MOTOR1. Remove air motor pump by removing the three nuts and lockwashers

from the studs.2. Remove shaft adapter (#25) from shaft; remove adapter plate (#5).3. Place motor in vise with soft jaws and clamp the shaft.4. Remove bearing cover (#42) and gasket (#43).5. Remove six hex bolts (#45); drive out small roll pins used for alignment.6. Remove motor from vise and turn over.7. Remove drive end bearing cover (#55) with o-ring (#54) and seal

(#53); replace seal and o-ring.8. Using a plastic or rubber mallet, drive the shaft up through the drive

end bearing until rotor assembly (#49) can be lifted out of the motorbody (#48) and drive casting (#51). Fig. 24

9. Using a small gear or bearing puller, remove dead end casting (#46)from rotor. Be very careful not to damage the gasket surfaces of thebody (#48) or dead end casting (#46). Fig. 25Note: On early models, it may be necessary to remove drive rotor nutand lockwasher before using puller.

10. Now tap out the dead end bearing (#44) from the casting and thedrive end bearing (#52) from lower casting.

11. Remove and discard old vanes (#50).Note: On early models, the vanes will be attached to small springsand push pins through the rotor. Fig. 27

12. Clean all parts thoroughly and inspect for damage and wear.13. If motor was leaking air between body (#48) and lower casting (#51),

remove six (6) socket screws (#56) and replace gasket (#47).14. Prior to reassembly, be sure all gasket surfaces are flat and free from

burrs or gouges. Surfaces can be trued up with a fine flat file.15. Begin reassembly by dropping rotor in body and lower casting (#48, #51).16. Replace vanes, making sure that the clipped corners face center of

rotor (#49).Note: When replacing vanes which require springs, be sure the smallslot in the vane is at the top of the rotor and the push pins are centeredin the rotor.

17. Squirt a liberal amount of oil on rotor, vanes, and inside body castingduring assembly.

18. Coat the gasket surface of body and dead end casting with a film ofoil. Place gasket (#47) on body making sure holes match up.

19. Replace dead end cover with six (6) hex bolts and make finger tight.Turn motor over.

20. Replace drive end bearing (#52), seal (#53), o-ring (#54), andcover (#55).

21. Turn motor upright, install dead end bearing (#44), and then tightensix (6) hex bolts (#45) and install roll pin for alignment.

22. At this point, you might discover that the rotor shaft will not turn.This is normal because now the rotor must be centered in the body.In some cases, the rotor will turn freely due to wear on the endcastings; if so, disregard next four steps.

23. Place motor in vise so that both ends of rotor shaft can be easilyreached. Attach muffler and air line (do not exceed 100 PSI).

24. Turn on air motor. If motor fails to spin, begin tapping on drive end ofshaft with light blows. (Brass or plastic hammer). Gradually increasethe strength of the blows until motor begins to rotate. If the motorstill fails to turn, repeat procedure on dead end of the rotor shaft.Never strike blows hard enough to cause mushrooming of the shaftends. Fig. 26

25. After motor begins to turn, take a center punch and press on drive endof the shaft. Note motor speed: If it increases when pressed, a few moretaps with the mallet are needed. If it slows down, take punch and pressdead end to see if motor speeds up. If motor speeds up when dead endis pressed, a few more blows are required.

26. Rotor is properly centered when pressing on both ends of shaft (one at atime) causes motor to slow down or causes little change in speed.

27. Replace dead end bearing cover and gasket; check for air leaks.

67

14

troubleshooting

leakage problemswhere

1 LEAKAGEBetween main and lower cylinder shell

2 LEAKAGEAround Command Valve

3 LEAKAGEAround Plugs & Feathers

4 LEAKAGEAround Reservoir

5 LEAKAGEAround Quick-Connects

why#0060 o-ring worn; seals worn; stuffing box

#0630 0-rings worn; #0613-0614 seals and screw covers too tight or not tight enough. #0617 or #0659 o-rings worn. Whip connectionsloose.

Same reasons as #1.

Cover plate gasket worn. Cover plate screws loose (#545). Reservoir cracked. Dip Stick o-ring (#525) worn. #526 Adapter gasket worn.

1. Fitting Loose.2. Couplings worn out.

fixReplace seals and o-ring.

Replace o-rings. Tighten or retighten seals and screw covers. Tighten hose connections or apply teflon tape.

Same fix as #1.

Tighten all screws. Replace gaskets. Weld or replace reservoir. Replace o-rings.

1. Tighten or reinstall with teflontape.

2. Replace.

plug & feathers problemssymptom

Plug broken or bent at bottom or lower half

Excessive wear and scoring

Plug broken at top

Plug “chatter”during splitting

Broken feather shoulders

Feathers Very Loose7, 8, 9, 12 Splitter

why1. Hole too shallow.2. Hole crooked.

1. Not enough lubrication2. Wrong lubricant.3. Lubricant contaminated with rock

chips, etc.

1. Lack of proper lubrication.

1. Not enough or improperlubrication

1. Insufficient lubrication.

1. Feather lock bars broken, bent.2. Wear bars broken or bent.3. Feather shoulders worn.

fix1. See chart for correct hole size.2. Drill straight holes.

1. Lubricate for every split.2. Use recommended lubricant

only.3. Keep container covered when

not in use.

1. Use recommended lube.

1. Lubricate every split in toughwork.

1. Lubricate every split in toughwork.

1. Replace.2. Replace.3. Replace.

15

troubleshooting

pressure problems (use gauge for checking)

symptomPressure rises slowly and holds without reaching maximum (7100 PSI). Both forward and retract.

Pressure too high—above 7100 PSI or Pressure too low.

Low pressure on forward cycle; retract ok (or reverse of above).

Plug extends but won’t retract (or reverse of above).

Pressure ok; tool won’t move in either forward or retract valve position.

Motor runs fine; no pressure

Low pressure whip breakage

why1. Faulty adjustment in

pressure-matic valve.2. Relief valve (#515) defective.3. Pump screen (#517B) blocked.4. Pump worn out.

1. Faulty adjustment ofpressure-matic valve.

1. Faulty springs (#0612), balls(#0611), valve seats (#0615), orvalve shafts (#0621). Any one of,or combination of, the above.

Same as #1 above.

1. Faulty quick-connect coupling onthe high pressure line.

2. Blocked high pressure whip.3. Broken camshaft (#0618) on

command valve.

1. Broken drive coupler (#551).2. Drive key missing.3. Pump screen blocked (#5173)4. Faulty check valve (#515)5. Faulty relief valve (#516).6. Pump worn out (#521).

1. Operator fails to pause in neutralvalve position.

2. Quick connect coupling worn out;check for severe ball grooves onmale half of couplings.

3. Hose blocked.4. Pressure too high.

fix1. Readjust pressure screw.2. Replace relief valve.3. Clean screen and replace fluid.4. Replace pump.

1. Adjust (see page #5).

1. Rebuild command valvestarting with springs (#0612),balls (#0611) and seats (#0615).

Same as #1 above.

1. Replace quick-connect2. Blow out or replace.3. Replace camshaft.

1. Replace; check for pumpstiffness.

2. Replace.3. Clean screen; change fluid.4. Replace.5. Replace.6. Replace or rebuild.

1. Refer to Command Valve.2. Replace.3. Check and release if needed.4. Recalibrate pressure-matic

valve.See Service Pressure-MaticValve.

16

troubleshooting

pressure matic valveErratic Pressure SettingsMany causes, look for:

Plugged orifice — may not be consistent.Bad poppet seat.Binding of the poppet — due to contamination, heat, etc.Spring ends shifting — on the orifice staking or an orifice that is above flush.

Continually Decreasing Pressure SettingsPlugged orifice — traps pressure between o-ring and poppet seat.Bad poppet seat — allows pressure to build behind seat and against o-ring.Spring changing.

Machine-gunningBad poppet seat — usually when spring is almost completely collapsed.Loose orifice.Bad O-ring.Leaky back pressure valve.

Occasional, Very High PressureBad poppet seat — may re-seat into a smaller area.Contaminated poppet & bore of pop-off — causing binding.Long term storage — O-ring adheres to bore somewhat, usually only requires 10% more pressure.Too smooth bore — unlikely, but possible cause.Off-center poppet — jams, due to side load at poppet tip.

The vast majority of problems can be attributed to a plugged or partially plugged orifice. It is essential that clean oil be used in these systems. An inlet screen will be made available for use with these valves which will limit par-ticle size to .006 x .006 right at the valve inlet. Unfortunately, most contamination is put directly into the orifice area when thread sealant and dirt are inserted.

Hot oil may also affect the performance of this valve. With low flows and low viscosity oil, the orifice may be passing all the pump output through it. Any other leaks at the threads, back pressure ball seat or O-ring, may allow the valve to re-seat or cycle repeatedly.

SERVICE TIPS

1. It is easy to purge the hydraulic system of fluid with air (see below).

2. In order to make removal of the wear plates easier, fasten the correct size Allen Wrench to a long extension. (See illustration)

NOTE: It is helpful to use a piece of thin plastic wrapped around the head of the piston to aid in sliding it back in the bore. The plastic will protect the seals and keep them from hanging up. Remove the plastic as you start to slide the piston in the bore.

Place steel bar (or large screwdriver) through plug pin hole for easy piston removal (C-8).

17

troubleshooting

ELCO offers free of charge, information on the Hydraulic Splitter and how it may apply to your work. This service is as close as your telephone. Contact our headquarters in New Jersey. No charge or obligation.