mes service manual

7/28/2019 MES Service Manual

http://slidepdf.com/reader/full/mes-service-manual 1/141

PPM2000000 Version 031003

INDECO Hydraulic Breaker

Service and Maintenance Manual

PPM2000000

$35.00

REV 11-17-2003



PPM2000000 Version: 102700 2

IMPORTANT SAFETY NOTICE

Most accidents involving service and maintenance are caused by failure toobserve basic safety rules or precautions. Accidents can often be avoided byrecognizing potentially hazardous situations before an accident occurs.

It is necessary to read and understand all safety precautions before performingservice and maintenance to any INDECO attachment. Safety precautions areoutline 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 potentialhazard. Therefore the warnings in this guide are not to be considered allinclusive. If a tool or repair procedure is not specifically recommended byINDECO, you must satisfy yourself that it is safe for you and other people whocould be involved. You should not modify or change the configuration of INDECOattachments without the expressed written authorization of the manufacturer.

Improper maintenance of any attachment can be dangerous and could result inbodily injury or death.

Do not perform any maintenance on INDECO attachments until you have readand understand the procedures as described in the Service and MaintenanceManual.

If you have any questions or these procedures contact INDECO’s ProductSupport Department at (203) 377-7791.



PPM2000000 Version: 102700 3

Table of Contents

Safety Information…………………………………………...………………….….

2

Preface………………………………………………………………………………..

7

I. Breaker Installation…………………………………..………….……….……

8

II. General Breaker Usage……………………………………...………………..

12

III. Common Causes of Breaker Damage …………...………………..…..…..

16

IV. Routine Maintenance ………………………………………...…………….… 19Daily, Weekly, 500 Hours, 1000 Hours……………………………………………..… 19

Breaker Lubrication……………………………………………………………………... 20Checking and Adjusting HD Casing to Breaker Clearance………………………… 22Lower Bushing and Insert Inspection……………………………………………….… 24

V. Breaker Tools…………………………………………………………..…….... 25

Tool Selection…………………………………………………………………………… 25Tool Breakage Analysis………………………………………………………………… 26

Description of Typical Stress………………………………………………………….. 26Methods to Reduce Stress Effects and Increase Tool Life………………………… 26

Typical Tool Failures………………………………………………………………….… 28Tool Replacement…………………………………………………………………….… 30

VI. Accumulator Removal and Rebuilding ..........……………………………. 32Safety Instructions .................................................................................……….… 32

Warnings………………………………………………………………………………… 32Potential Hazards………………………………………………………………………. 32Emergency Action…………………………………………………………………….… 33

Accumulator Indicators……………………………………………………………….… 34 Accumulator Rebuilding MES 121 and MES 150……………………………………. 35 Accumulator Rebuilding MES 181 and MES 200……………………………………. 36 Accumulator Rebuilding MES 300 and up……………………………………………. 38Nitrogen Recharge……………………………………………………………………… 41

VII. Disassembly of the Breaker ....................................................………………….. 43Removing Breaker Side Plates ................................................………………….… 43Removing the Mounting Bracket and Breaker Case…………….…………….……. 44Breaker Head Removal and Disassembly................................................…….….. 46

MES 121 and MES 150............................................................… …………..……... 46MES 181 and MES 200 .............................................................…………….…….. 46MES 300 Through MES 553 ..................................................……………..………. 47MES 601 and up .....................................................…………………………….….. 47

Cylinder Removal and Disassembly………………………………………………….. 50Disassembly of Chuck Housing...…………………………………………….……….. 51



PPM2000000 Version: 102700 4

Disassembly of High and Low Pressure Links…...…..………………….…………... 53Disassembly of The (Power) Pressure-Regulating Valve .....…..........…....….…… 54Disassembly of The Frequency Regulating (Speed) Valve .................…..……….. 55

VIII. Assembling the Breaker .........……..................................................……..…….... 56Chuck Housing Assembly ..................................................................……..……... 56Cylinder Assembly .............................................................................………..…… 58Pressure Regulating Valve Assembly........................…...............……………..….. 60Frequency Valve Assembly .....................…..............................................……..... 61Breaker Head Assembly ...........................................…........................……….….. 62Breaker Side Plate Assembly ...................................….....................………….…. 67

Assembly of Breaker Case and Mounting Bracket ....…..........................……..….. 68 Assembly of Pressure and Return Links ...................….............................……..... 70

IX. Trouble Shooting and Problem Diagnosis …………………………....… 71

Checklist for Accurate Breaker Problem Diagnosis……………..…………………... 71Troubleshooting………………………………………………………..………………... 73

Low Working Pressure on Test Gauges…………………………..……………... 73Return (Back) Pressure on Test Gauges is Above the Specifications……..……... 73Breaker Does Not Hammer……………………………………………………...…….. 73Breaker Lacks Power ……………………..…………………………………..….. 74Carrier Oil is Over Heating ……………………………………………………..... 75Oil Leaks……………………………………………………………………….… 75

X. Information Request Forms for Hydraulic Kits ...…....................…..…. 76 XI. Power Lubrication Systems .............….................……......………….….. 78

Excavator 411I Pump................................…......................................…………….. 78Theory of Operation…........................……………................................…………... 78Testing and Adjustments ........………....................................................…..……… 78

711-ITH Pump 24Volt – 2 Speed Electric Grease Pump….......................….....…. 81Grease Pump with Electric Control .................................…........................…....... 82Flow Master ™ Rotary Driven Hydraulic Pump……………..…………………..…… 84

Safety …………………………………………………….………………..…..… 84Description ……….................................................….............….……...…… 85Installing the Pump ...……………..............................................…......……… 86Maintenance and Repair ………………………………….……………..………. 88Troubleshooting ……………………………………………….……………….………. 91

XII. Under Water Kits...................................................................………..…... 92Pressure Switch Operational Test………………………………..…..……………….. 92Pressure Switch Continuity Test .............................................…..…...…………… 93

Adjusting Under Water Operating Pressure ..................……………..…................. 93

XIII. Compactors…………………………………………………………….……… 94

Installing of Flow Regulating Valve for INDECO IHC65 and IHC 130Compactors………………………………………………………………..…………….. 94Compactor Eccentric Assembly Procedure…………………………….……………. 95



PPM2000000 Version: 102700 5

APPENDIX A - Breaker Technical and Torque Specifications ............…. 96

APPENDIX B - Compactor Technical Specifications .……………………... 118 APPENDIX C - Chuck Housing Specifications..............................…............ 120 APPENDIX D - (left intentionally blank)………………...............……..…........ 121 APPENDIX E - (left intentionally blank)………………………............…......... 122 APPENDIX F - Breaker Mounting Bracket Specifications ....….......….…… 123 APPENDIX G - HARDOX and WELDOX Welding........................…….……… 126 APPENDIX H - Breaker Parts Explosions ............................................….…. 134

MES 121 and MES 150 .................................................………..............…….…... 134MES 181 and MES 200 ..................................................................…………..…... 135MES 300 Through MES 553............................................…...................………..… 136MES 601 Through MES 3000................................................…....………………… 137MES 3500 Through MES 12000......................................………...………………… 138



PPM2000000 Version: 102700 6



PPM2000000 Version: 102700 7

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 recommendedthat regular and appropriate maintenance be performed.

Every attempt has been made to insure accuracy of the information provided. However, themanufacturer reserves the right to update this manual subject to the technological developmentof the product and service. For the most current information, a review of the Product SupportBulletins is recommended prior to any breaker repair.

For further information, please contact:

INDECO North America Product Support Department120 Dodge Avenue

Stratford, CT 06615Phone: (203) 377-7791Fax: (203) 377-7697



PPM2000000 Version: 102700 8

BREAKER INSTALLATION

Figure 01-01: Testing Excavator Circuit Flow and Pressure

Figure 01-02: Testing Tractor Loader Backhoe Circuit Flow and Pressure

Figure 01-03: Flow Meter and PressureGauge Connection

Figure 01-04: Testing Skidsteer LoadersCircuit Flow and Pressure

Note: During these test, be certain that the carrier’s hydraulic fluid is at operating temperature,usually 130 F to 170 F. This will insure that the attachment will operate at optimumperformance. Also, if the carrier has any hydraulic problems, they should appear during testingprocedures.

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 circuit’s pressure line into the meter’s inlet andthe return side into the meter outlet. Also, install a 600 psi gauge into the return circuit at theflow 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.)

I. Breaker Installation



PPM2000000 Version: 102700 9

3. Before engaging the circuit, be certain the pressure regulating valve on the flow meter (Figure 01-03) is in the fully open position.

4. Start the carrier unit and check for hydraulic leaks. Check and note the flow and backpressure readings at the meter.

5. Increase engine RPM while a second person is monitoring the pressure and flow at themeter. If the back pressure reading goes above specifications the cause must bedetermined 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. Adjust the circuit’s flow to the required specification. (NOTE: It is better to be 5-10% under the required GPM then to be over.)

7. Bring the pressure on the flow meter up to the high pressure reading for the attachment youare installing. Check to assure that the correct GPM’s are maintained and adjust if needed.

8. Once the GPM’s, operating pressure and back pressure are within specification check theattachment circuit relief. This setting must be at least 500 psi above the Attachmentsoperating pressure. (Be certain the GPM reading remains the same as in the above steps.)

9. Install the breaker and connect a 0-3000 psi gauge into the inlet port of the attachment.(There is a 19 mm plug in the upper link which is the pressure circuit.) Connect a 0-600 psigauge into the attachment’s return line. (There is a 19 mm plug in the lower link which is theattachments return line.) You can use a BSPP – 04 Fitting (British Standard Parallel Pipe)

10.Before operating the breaker, verify that the tool and bushings have been properlylubricated. Verify that the hose can move freely and are not rubbing against any other parts.

11.Place the breaker on a hard, compact surface and, with shut off (if so equipped) turn on, runthe breaker at low Rpm’s. Gradually increase rpm’s to the maximum. Operating pressureand return (back) pressure must remain within specifications in order for the attachment tooperate at maximum efficiency (See Appendix A, Breaker Technical and TorqueSpecifications - 6 for the correct specification). Run the breaker until the hydraulic oilis at operating temperature and again note the pressure readings.

Note: The breaker should be fast during the initial stages. As the tool penetrates the materialthe breaker should slow to a rhythm close to the minimum blows per minute.

12. If readings are not within this range please refer to the trouble shooting and problemdiagnosis section of this manual.

13.Record the readings taken during the installation procedures on the Attachment DeliveryReport (ADR) (Figure 01-05). This report must be on file with INDECO before anywarranty consideration can be given.



PPM2000000 Version: 102700 10

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 time an attachment is installed on a different carrier. Thecustomer should be advised of the correct operation and maintenance procedures. The ADRshould be used as a checklist for each delivery of an INDECO attachment. A small investmentof time to check these readings will save maintenance and repair costs and increase customer satisfaction by offering trouble free, productive performance.

Note: The fittings needed to test the operating and return pressures, on all INDECO BreakersModel MES 621 HD and larger, are – 4 Male BSPP x –4 JIC (See Position #403 on the partsbreak down). These fittings are available through the parts department by ordering part number HF9002-0404.



PPM2000000 Version 031003

Figure 01-05: Sample Attachment Delivery Report (ADR)



PPM2000000 Version: 102700 14

e) If vibrations start to occur after the hammer has been operative for some time, this meansthat the carrier downward pressure has not followed the tool penetration. You must maintaina constant pressure from the carrier on the hammer, as the hammer is penetrating the work.

f) An INDECO hammer senses the strength and density of the surface being broken, andadjusts hammer impact power accordingly. The operator will be able to hear the differencein the blows when a rock is broken or not broken. The hammer rhythm will be fast and sharpif the material is frail and flaky; slow and powerful if the rock is compact and uniform. Impactspeed will also be slower the deeper the hammer penetrates.

g) As soon as cracks start to appear in the material being worked on, and the tool starts toappear from the bushing, stop the hammer at once. Do not raise the hammer from thematerial until it has stopped completely.

h) If cracks in the material do not appear in 30 seconds, move to a new position along thegrain 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.

i) In a quarry, or when breaking oversized rocks, position the material to be broken on a hard

base to minimize vibrations of the material.

j) In the case of horizontal or upside-down operations (e.g. tunnels), once every hour theoperator should lower the hammer to a vertical position (Figure 02-06), so that any particlesof rock which have collected in the hammer can fall out. (Operator can alternate hammeringup and down.) 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 mechanicalresistance. In order to keep particles out of the hammer, an air hose may be installed in thesame way as would be done for underwater usage.

Figure 02-05: Reposition Breaker Every 30 Seconds



PPM2000000 Version: 102700 16

COMMON CAUSES OF BREAKER DAMAGE

a) The hammer must not be used as a ripper, nor should it be used as a lever. Under nocircumstances should the tool be used as a hook to lift weights. (Figure 03-01) This couldcause serious damage to the tool, the bushing and the housing.

b) The hammer must operate perpendicular to the work. This ensures that: the tools are notforcibly stressed; bending stress does not occur; and the specific pressures in the contactareas are maintained. This will greatly extend the life of the tool and the bushings.

c) Check that the tool contact areas(especially the chuck housing) arewell lubricated and smooth. Aproperly lubricated tool will showstreaks of grease below the lower bushing on the tool shank. Remove anybumps or rough areas with a softgrinding wheel and wire brush. Thepoint of a chisel tool can be re-sharpened in the same way. Toolsshould be rotated 180° to evenlydistribute the wear.

d) The hammer must be free to operatewithout any obstructions, chafing or interference. (Figure 03-02) Thereshould also be no obstruction betweenthe hammer and the tool.

III. Common Causes of Breaker Damage

Figure 03-01: Don’t Use Breaker as a Ripper, Lever or Crane

Figure 03-02: Operate Breaker Free andClear of Obstructions



PPM2000000 Version: 102700 17

e) When breaking large blocks of rock, anyprotrusions should be broken off first, in order toreduce the overall size of the block.

f) For secondary demolition, before starting thehammer, adjust the material to be broken so thatit is on a hard, stable surface. (Figure 03-03)

g) 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 thenoverheat and may deform. The solutions to thisare 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.

h) When using the hammers in these positions, thetool should be removed every 8 hours, and theinternal faces of the bush cleaned with a wirebrush or lubricant cleaner. (Figure 03-05) If thehammer is very full of rock particles, remove theappropriate plug from the side of the chuckhousing, and blow out the hammer withcompressed air.

Figure 03-03: Maintain HardStable Working Surface

Figure 03-04: Dust Pockets May Cause Tools To Become Deformed



PPM2000000 Version: 102700 19

ROUTINE MAINTENANCE

Daily

• 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, locking bolts and under water plug (POS 107)

• Examine hydraulic hoses for leaking or chaffing.

• Visually inspect breaker for housing or side plate damage.

Weekly

• 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 retainingaxles.

• Measure length of tool. If too short, replace to prevent damage to breaker bushing andhousing (Maximum Wear is 50% of exposed portion of tool when new) .

500 HOURS

• Check accumulator charge. Refer to INDECO specification for correct charge.

• Measure 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

• 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 thread are. 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.

• Check the upper and side shock absorbers (Positions 601 and 602). Replace if necessary

IV. Routine Maintenance



PPM2000000 Version: 102700 21

Figure 04-01: MES 121 andMES 150 Lube Points

Figure 04-02: MES 181 throughMES 553 Lube Points

Figure 04-03: MES 181 throughMES 553 HD and Whisper Lube

Points


Figure 04-05: MES 621HD andMES 650 HD and Whisper Lube

Points


Figure 04-07: MES 1050HDand MES 1200HD and Whisper

Lube Points

Figure 04-08: MES 1500 andMES 8500 HD and Whisper

Lube Points

Figure 04-09: MES 12000 HDand Whisper Lube Points

Lube Points



PPM2000000 Version: 102700 23

Note: To center the Breaker in the Case, an equal amount of shims should be installed under each Wear Block.

9. Remove the Grease Fitting (Position 621) and install a 3/8” - 16 bolt through the passageinto the Wear Blocks. (Figure 04-13) This will hold the Wear Blocks and Shim pack inposition during the Breaker installation.

10. Install the Breaker into the Case and remeasure the clearance as previously described.(See Assembly of Breaker Case - Section 8 Page 68 )

Figure 04-11: Breaker Spacing Toolfrom Bottom Case

Figure 04-12: Breaker Spacing Tool fromInside Case



PPM2000000 Version: 102700 24

Lower Bushing and Insert Inspection

1. Remove the tool (See Tool Replacement - Section 5 Page 30) and clean the inside of theChuck Bushing (Position 102) or the Insert (Position 153).

2. Measure the inside diameter of the Lower Bushingor Insert, using an inside measuring device (I.E.caliper, telescoping gauge or inside micrometer)with a .001” graduation. (Compare thesemeasurements to Chart in Appendix D on Page121).

Note: The greatest amount of wear normally occursfrom front to back.

3. If the Chuck Bushing (Position 102) or the InsertHolder (Position 152) needs replacement it isrecommended to remove the Breaker’s ChuckHousing and remove the Chuck Bushing with ahydraulic press. (See Disassembly of the Chuck Housing - Section 7 Page 51).

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 04-15 and Figure 04-16)

Note: If the insert bushing is steel and it does not slide out of the holder, the bushing will needto be cut.

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 cuttinga slot lengthwise, using a right angle (90°) die grinder with cut-off wheel. Caution: Be carefulnot to cut insert holder. Remove insert. Optional removal - use a universal sleeve puller withslide hammer to remove insert (See figure 04-17).

Figure 04-14: Measuring the Lower Chuck Bushing or Insert for Wear

Figure 04-15: RemoveInsert Snap Ring

Figure 04-16: Remove Insert Figure 04-17: Universalsleeve puller



PPM2000000 Version: 102700 27

• The tool should be constantly lubricated with INDECO Supreme 1000 grease. You cannever over-grease the lower end of the breaker!! Attention to this fact will add longevity toyour tool and bushing life.



PPM2000000 Version: 102700 28

Typical Tool Failures

Misalignment or Pry Break(Figure 05-02) The bending stress exceeds the materials strength and thetool snaps. Caused by working at an incorrect angle or usingthe tool for mechanical leverage. The failure usually occursnear the tool bushing’s front face. This failure can also becaused by the breaker slipping while hammering at anglesnot perpendicular to the surface of the material being broken.The failure type is a brittle type and typically has a lipformation. Figure 05-02: Misalignment

Break

Seizing in the Tool Bushing(Figure 05-03) Strong side loading and striking the tool at the same timecauses the tool and bushing surface to be damaged. Thisfailure is cause by incorrect or insufficient lubrication. Thefailure generally occurs in the front tool bushing area. Thefailure type is a fatigue fracture starting at the surface of thetool.

Figure 05-03: Tool Seized inBushing

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 alsooccur when breaking through the material and the breaker strikes the tool a last time. When struck without resistance atthe working end the tool , the tool stops abruptly when it isstopped by the retainers instead of the material. This resultsin breaking and deformation in the retaining groove.

Figure 05-04: Blank or DryFiring

Mechanical Damage on the Tool’s Surface(Figure 05-05)

This is caused by heavy scratching on the tools surface. Thefailure usually occurs outside the tool bushing. The failure isgenerally a fatigue type fracture.

Figure 05-05: MechanicalDamage on Tools Surface



PPM2000000 Version: 102700 30

Figure 05-10: Use Screw Drive to Push Down Lock Bolt

Tool Replacement

Note: Models MES 181-553 have round retaining axles

a) In order to install the tool, insure that the retaining axles (Position 108) are not in their locked position. (Figure 05-09)

b) With the aid of a screw driver or similar instrument, push down the lock bolt located on theside of the hammer (Position 109). Turn it 180° to its resting position. (Figure 05-10). Unlockcounter clock wise and lock clock wise.

Note: Newer lock bolts only turn in one direction.

Note: On 181 and 200 Series Breakers above Serial Number 14028, 300 Series Breakersabove Serial Number 21344 and 500 Series Breakers above serial number 21723 lock bolts areno longer used. The retaining axles are held in with slotted pins and require a hammer and apunch to drive the pin (Position 103) out of the chuck housing.

Figure 05-09: Check and Unlock Retaining Axles



PPM2000000 Version: 102700 32

Safety Instructions

Before working on the Accumulator, PLEASE read the followingsafety procedures thoroughly. If you have any questions, consultyour INDECO dealer or INDECO N.A.

Warnings

Compressed gases, by their nature, are hazardous. They are capable of creating environmentsthat are oxygen deficient, flammable or explosive. Death has occurred during a routine repair on a carrier when a nitrogen-charged canister on the carrier exploded as it was beingdisassembled.

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 is

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 glovesshould be worn, in addition to the required helmet or other protective gear. Any timecompressed gases are handled, safety glasses should be worn.

Keep a fire extinguisher close at hand. Situate flammable gas cylinders in a location so that if afire does occur, it may be easily extinguished. In some cases, it may be better to evacuate thearea 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 notbe 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 anexplosion.

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 byallowing a small amount of gas to pass through the system.

Potential Hazards

Fire or ExplosionNitrogen may burn, but will not ignite readily. The Cylinder may explode in the heat of a fire.

VI. Accumulator Removal and Rebuilding



PPM2000000 Version: 102700 33

Health HazardsVapors may cause dizziness or suffocation. Contact with liquid may cause frostbite. Fire mayproduce irritating or poisonous gases.

Emergency Act ion

Keep unnecessary people away. Isolate the hazard area and deny entry. Stay up-wind; keepout of low areas. Telephone local emergency professionals. Positive-pressure, self-containedbreathing apparatus (SCBA) and structural firefighters’ protective clothing will provide limitedprotection.

FiresSmall Fires: Dry Chemical or C02Large Fires: Water spray, fog or regular foamMove 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.

LeaksStop leak if you can do it without risk.

First AidMove victim to fresh air and call emergency medical care. If the victim is not breathing, giveartificial 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 pressurehas 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 uppast the original specs, exercise extreme care - the diaphragmmay be ruptured. If so, the hydraulic oil may have leaked into thenitrogen chamber and the pressure in the chamber may be greater than 2000 psi. Bleed off the pressure slowly through the InflatingScrew, 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 Systempressure is 1500 -2000 psi. If the diaphragm ruptures at the edge, itlets the oil in to make up the pressure, thereby increasing thenitrogen chamber pressure. In other words, the fluid takes up thevolume and increases the pressure on the gas.)

Figure 06-01: LoosenInflation Screw Carefully



PPM2000000 Version: 102700 34

Accumulator Indicators

In order to ensure smooth operation of the hammer, it is necessary that the Accumulator becharged correctly. If the Hammer is exhibiting strong vibrations of the oil supply pipe, it is likelythat 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 BEREPLACED, 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 (Position504) in order to deter them from loosening.

ATTENTION:

The accumulator chargingSpecifications for all

INDECOBreaker accumulators are:

475 PSI to 550 PSI(32 to 38 BAR)

For allmodels up to and including

the MES 1200.


For allmodels MES 1500 HD

and larger.



PPM2000000 Version: 102700 35

Accumulator Rebuilding MES 121 and 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 (Position506). (Figure 06-03)

3. Remove the Plate (Position 313) and Upper Shell Half (Position 502).

4. Remove the Diaphram (Position 503) and replace. (Figure 06-04)

5. Reassemble the Accumulator and torque to the required specification. (Figure 06-05)

6. Install a new O-ring (Position 505) on the Inflating Screw and wrap Teflon tape around thethreads of the Inflating Screw before installation. Install Inflation Screw in the Upper ShellHalf (Position 502). Do not tighten at this time.

7. The Accumulator is ready for installation or can be charged with nitrogen. (See NitrogenRecharge Section 6 Page 41).

Figure 06-02: Loosen InflationScrew Carefully MES 121and MES 150

Figure 06-04: Remove DiaphramMES 121 and MES 150

Figure 06-03: Remove Accumulator Shell Bolts MES 121 and MES 150

Figure 06-05: Torque Accumulator Shell Bolts MES 121 and MES 150



PPM2000000 Version: 102700 36

Accumulator Rebuilding MES 181 and 200

1. Carefully discharge the accumulator and remove the Inflating Screw (Position 504) and O-ring (Position 505).

2. Using four (4) 12 mm -1.75 x 30 mm bolts, install fabricated tool onto the Upper Shell Half (Position 502) and remove the Upper Shell Half from the Head (Position301). (Figure 06-06)

Note: The tool is fabricated using an old socket and a flat piece of steel plate. Mark and drill theplate to match the bolt pattern on the Upper Shell Half (Position 502). Weld the socket to thecenter of the plate with the drive slot away from the plate.

3. Remove the Diaphram (Position 503), Lower Shell Half (Position 501) and O-ring (Position309). Clean, inspect and replace as required, all components. (Figure 06-07)

4. Lubricate O-ring (Position 309) with hydraulic oil and install in the Head (Position 301).(Figure 06-08)

5. Install the Lower Shell Half (Position 501) and Diaphram (Position 503). (Figure 06-09)

Note: The raised center of the Diaphram points down. Be certain that the flange of the diaphramis seated in the groove located in the Lower Shell Half.

6. Install and tighten the Upper Shell Half (Position 502) and torque to specs.

7. Install O-ring (Position 505) on the Inflating Screw (Position 504) and wrap the threads withTeflon tape before installation. Install Inflation Screw in the Upper Shell Half (Position 502).Do not tighten at this time.

Figure 06-06: Unscrew Upper Accumulator Half MES 181and MES 200

Figure 06-07: Remove DiaphramMES 181 and MES 200.



PPM2000000 Version: 102700 37

8. The Accumulator is ready to be charged with nitrogen. (See Nitrogen Recharge Section 6Page 41).

ATTENTION:





the MES 1200.



and larger.

Figure 06-08: Lubricate Accumulator O-ring MES 181 andMES 200

Figure 06-09: Install Lower Accumulator Lower Shell Half

MES 181 and MES 200



PPM2000000 Version: 102700 40

13. Assemble the Accumulator onto the Breaker and fasten the Accumulator Screws (Position507), cross-tightening as per Torque Specifications. (Figure 06-17, Figure 06-18, Figure 06-19)

Note: Check the accumulator bolts by holding them by the thread end and tapping the headwith a hammer. If the bolt is good is should ring. Accumulator bolts should be re-placed as a setand not individually.

Note: On Breaker Models MES 300 and Up, the accumulator may be charged on the benchprior to installation on the breaker.

ATTENTION:





the MES 1200.



and larger.

Figure 06-17: Install andTorque Accumulator MES121

Figure 06-18: Install andTorque Accumulator MES181 and MES 200

Figure 06-18: Install andTorque Accumulator MES300 and U



PPM2000000 Version: 102700 41

Nitrogen Recharge

Note: On Breaker Models MES 150 through MES 200, the accumulator must be assembled onthe breaker prior to the nitrogen charge.

1. Carefully install the Pressure Reducer/Regulator assembly into the nitrogen tank, followingthe safety instructions. (Figure 06-20) The nitrogen bottle must not have a level below 45bars (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)

4. Install the Inflating Body to the Accumulator. (Figures 06-22, 06-23 and 06-24)

Figure 06-20: Assemble and InstallPressure Regulator Onto Nitrogen Tank

Figure 06-21: Attach and Install InflationBody

Figure 06-22: Installationof Inflation Body MES 121and MES 150

Figure 06-24: Installation of Inflation Body Assembly withNewer Style Holder MES 300and Up (with two 8 mm - 1.25Tapped holes in the top)

Figure 06-24: Installationof Inflation Body Assemblywith Older Style Holder MES 300 and Up



PPM2000000 Version: 102700 42

5. Loosen the Accumulator Charge Plug (Position 34) by turning the Spanner Wrench in theCharging Fixture counter-clockwise.

6. Open the main valve on the nitrogen tank and purge the charge hose.

7. Charge the accumulator to the correct pressure. (See Nitrogen Recharge - Section 6 Page41).

8. Tighten the Accumulator Charge Plug (Position 34) by turning the Spanner Wrench in theCharging Fixture clockwise.

9. Bleed the pressure from the chargehose and remove the ChargingFixture from the Accumulator.

10.Tighten Accumulator Charge Plug(Position 34) to specified torque.

11.Using some oil, verify that there areno nitrogen leaks from the InflatingScrew or on the sides. (Figure 06-25)

12.Turn the Accumulator upside downand fill the holes with oil to check theDiaphragm has no defects. If nobubbles appear, the Accumulator iscorrectly charged and ready to beinstalled on the breaker.

ATTENTION:





the MES 1200.



and larger.

Figure 06-25: Check Accumulator for Leaks

Page REV 01-23-01



PPM2000000 Version: 102700 44

Removing the Mounting Bracket and Breaker Case

1. Lay the hammer in a horizontal position, remove the retaining axles (Position 106) and takeout the tool. (See Tool Replacement - Section 5 Page 30).

2. With two wrenches (see specifications), unscrew the nuts and bolts (Positions 618 and 619).(Figure 07-04)

3. With an Allen wrench (see specifications), remove the Screws (Position 409) which areholding the High Pressure Link group (Position 401). At this point, check the condition of theO-Ring (Position 410).

4. Repeat the same operation as above for the Low Pressure Link group (Position 405),located directly below the HP group. (Figure 07-05)

5. If the breaker is equipped with a Power Lubrication System, remove the fitting and plateassembly. (Figure 07-06)

6. Remove the grease fittings and install 3/8”-16 bolts to hold the wear pads and shims inplace. (Figure 07-07)

Figure 07-04: Remove MountingBracket and Top Shock Holder

Figure 07-05: Remove High and LowPressure Links

Figure 07-06: Remove Power LubeFitting

Figure 07-07: Remove Grease FittingsFrom Case



PPM2000000 Version: 102700 46

Breaker Head Removal and Disassembly

MES 121 and MES 150

1. Loosen and remove Nuts (Position 314). (Figure 07-12)

2. Lift the Head Assembly (Position 301) from the Chuck Housing (Position 101). (Figure 07-13)

3. Go to Page 48 Step 04 to continue the disassembly.

MES 181 and MES 200

1. See Accumulator Removal and Rebuilding - Section6 Page 32 and remove the accumulator beforeproceeding.

2. Remove the four nuts (Position 308) from the sidebolts (Position 307) and lift the head assembly

(Position 301) from the cylinder (Position 201). Toprovide clearance, remove the nuts (Position 308)while lifting the head.

3. Remove the side bolts (Position 307) from the head(Position 301). (Figure 07-14)

4. Proceed to Page 48 Step 04.

Figure 07-12: Loosen Nuts Figure 07-13: Lift Head

Assembly from Chuck Housing

Figure 07-14: Loosen SideBolts MES 181 and MES 200



PPM2000000 Version: 102700 48

3. Using the proper lifting tools, remove the Head Assembly (Position 301) and Side Rods(Position 307) from the breaker and set aside. (Figure 07-18)

4. Remove the Distributor Box Cover (Position 305) from the Distributor Box Body (Position302). Remove and note the location of the Pin (Position 310). (Figure 07-19)

5. Lift the Distributor Box Body (Position 302) off the Cylinder Assembly as shown. Removeand note the location of the Centering Pin (Position 211). (Figure 07-20)

Caution: The Distributor (Position 304) may stick and fall out during this process.

Figure 07-18: Lift Off Head and SideRods

Figure 07-19: Remove Distributor Box Body Cover



PPM2000000 Version: 102700 50

Cylinder Removal and Disassembly

1. Remove the piston (Position 209) using the Accumulator Screw (Position 507). (Figure 07-23) The Guide Adapter (Position 210) will come out of the Cylinder (Position 210) with thepiston. Check that the two parts are not worn, especially at the support surfaces.

2. Remove the Valves (Position 205/206) off the Cylinder and check the seating surface. Thissurface 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. Checkthe guiding areas of the Cylinder, by the head. (Figure 07-24)

3. Place the Accumulator Screws (Position 507) in the holes on the sides of the Housing.Extract the Cylinder (Position 201) from the Chuck Housing (Position 101). (Figure 07-25)

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 thisoperation is performed, the Cylinder should then be cleaned out with warm, soapy water andthen re-oiled). Replace the Cylinder if necessary.

4. Remove the O-ring (Position 303) and the U-joint seals (Position 204) and carefully clean u- joint seals internal grooves. (Figure 07-26)

Figure 07-23: RemovePiston

Figure 07-24: Remove Valvesfrom Cylinder

Figure 07-26: Remove Cylinder U-joint Seals

Figure 07-25: RemoveCylinder from ChuckHousing



PPM2000000 Version: 102700 51

Disassembly of Chuck Housing

1. Slide out the Spacer (Position 105) by hand. (Figure 07-27) If resistant, gently tap with asmall hammer.

2. Slide out the Upper Bush (Position 104) by hand. (Figure 07-27) If necessary, weld a smalldisc on the inside and press to extract it.

3. Remove the Nylon Plugs (Position 112) with a pin and slide out the bushing pin (Position103).

4. Drive in the Elastic Pin (Position 110) until it falls into the chuck housing. This will cause theLock Bolt (Position 109) to be released. (Figure 07-28)

5. Check the wear on the Lock Bolt, O-Ring (Position 113) and Spring (Position 111). (Figure07-29)

Note: Newer model MES 181 through MES 553 DO NOT have lock bolts. The retaining axlesare held in by roll pins only.

6. Remove the Grease Nipple (Position 106)

with a 14mm socket wrench.

7. On breakers with insert holders remove thecirclip (Position 154) and insert bushing(Position 153) and clean the insert holder (Position 152) (Figure 07-30)

Note: If the insert bushing is steel and it does notslide out of the holder, the bushing will need to becut.

Figure 07-27: RemoveSpacer and Upper BushingFrom Chuck Housing

Figure 07-28: Remove Nylon Plugsand Elastic Pin From Chuck Housing

Figure 07-29: Inspect Lock Bolts



PPM2000000 Version: 102700 52

Note: SUGGESTED PROCEDURE - Protect the upper portion of housing (Position 101), upper bushing (Position 104), spacer (Position 105) and piston (Position 309) with a fire proof material.Using a 180° cutting torch, equipped with a gouging nozzle and exercise caution when cutting toprevent damaging the insert holder (Position 152).

8. To remove the lower bushing, weld a steel disc inside the chuck bushing. (Figure 07-31)

Note: If the lower bushing is an insert holder, and does not need to be replaced, skip the nexttwo steps.

9. With the aid of a press, extract the Chuck Bush by pressing on the welded disc. (Figure 07-32)

Figure 07-30: Remove Insert Bushing

Figure 07-31: Weld Plate on Lower ChuckBushing or Insert Holder

Figure 07-32: Press OutLower Chuck Bushing or Insert Holder



PPM2000000 Version: 102700 53

Disassembly of High and Low Pressure Links

1. Disassemble the Seeger/Snap Ring (Position 408) with pliers. (Figure 07-34)

2. Remove the Washer (Position 407) and slide the Link out. (Figure 07-34) Check thecondition of the O-Ring (Position 406) and of the mortising areas. Clean the O-rings or replace as needed.

Figure 07-34: Disassemble High and LowPressure Links



PPM2000000 Version: 102700 54

Disassembly of the (Power) Pressure-Regulating Valve

1. Unscrew the Guiding Plug (Position 418) and remove it along with the Adjustment Shims(Position 415). (Figure 07-35)

2. Extract the Spring (Position 414). (Figure 07-36)

3. Extract the Slide Piston (Position 413). (Figure 07-37)

4. Extract the Barrel (Position 411) using a hook-shaped tool to pull the barrel from thebreakers head. (Figure 07-38)

5. Check the sliding areas of the above parts and examine for wear. Clean the parts carefully,replace the o-ring and reassemble. The valve is now ready for re-assembly of the head. Donot alter the number of Adjustment Shims at this time.

Figure 07-35: Remove Pressure regulatingValve Guide Plug

Figure 07-36: Extract Pressure regulatingValve Spring

Figure 07-37: Remove Pressure regulatingValve Piston

Figure 07-38: Remove Pressure regulatingValve Barrel



PPM2000000 Version: 102700 55

Disassembly of the Frequency Regulating (Speed) Valve

1. Unscrew the Plug (Position 438) and remove it along with the Adjustment Shims. Do notalter the number of adjustment shims at this time. (Figure 07-39)

2. Extract the Spring (Position 434). (Figure 07-40)

3. Take out the Needle (Positions 432). and check for wear.

4. Extract the Valve body with needle-nosed pliers.

5. Clean the Valve body, replace the O-Ring (Position 436) and set aside the assembly.

Figure 07-39: Remove Frequency ValveGuide Plug

Figure 07-40: Remove Frequency ValveSpring

Figure 07-41: Remove Frequency ValveBody

Figure 07-42: Remove Frequency ValveBody



PPM2000000 Version: 102700 57

5. Insert the Spacer and Spacer Ring (Position 105 and 106). (Figure08-05)

Note: On older breakers these two pieces were one unit.

6. Insert the Grease Nipples (Position 106) and the Plug (Position 107) and tighten accordingto the Torque Specifications. (Figure 08-06)

7. Insert the Spring (Position 111) in the appropriate slot in the housing. (Figure 08-07)

8. Assemble the O-Ring on the Lock Bolt (Position 114) and screw the assembly into theChuck housing with a screwdriver, making sure that the groove is in line with the pin hole.

While holding the Lock Bolt in position, hammer in the Elastic Pin. (Figure 08-08)

Figure 08-05: Install Upper Spacer Figure 08-06: Install Chuck Housing GreaseFittings

Figure 08-07: Install Lock Assembly

Figure 08-08: Install Lock BoltElastic Pin



PPM2000000 Version: 102700 58

Cylinder Assembly

1. Insert two Accumulator Screws (Position 507) in the sides of the Cylinder (Position 201), asshown, (Figure 08-09) and suspend it for freedom of movement. Insert the O-Ring seals.

2. Assemble the U-joint Seal (Position 204) into the internal grooves of the Cylinder (Position201).

Note: Be certain that the seals are assembled back-to-back, with the lips on the outer sides.

3. Insert the locator pin into the lower chuck housing.

4. Insert an Accumulator Screw (Position 507) into the Piston (Position 209) and lower thePiston onto the Cylinder. (Figure 08-11)

5. Install the O-ring (Position 303) onto the Cylinder (Position 201). (Figure 08-12)

Figure 08-9: Install Cylinder Seals Figure 08-10: Insert Chuck Housing/Cylinder Locator Pin

Figure 08-11: Install Piston Into Cylinder Figure 08-12: Install Cylinder O-ring



PPM2000000 Version: 102700 61

Frequency Valve Assembly

1. Assemble the following in the hole to the right of the central Head hole: the Valve Body(Position 431), the Needle (Position 432), the Bush (Position 433) and the Spring (Position434). Assemble the completed Plug: the Plug (Position 438), the O-Ring (Position 436), theSpacer Barrel (Position 435) and the Adjustment Shims (Position 437). Install and tightenPlug as per the Torque Specifications. (Figure 08-20)

Figure 08-20: Assemble Frequency Valve



PPM2000000 Version: 102700 62

Figure 08-23: LubricateSide Rod Heads

Figure 08-24: LubricateSide Rod Threads

Breaker Head Assembly

1. Insert the O-ring Seal(s) (Position 303) into the o-ring groove located at the lower portion of the Head Assembly (Position 301). (Figure 08-21)

2. Lubricate all sliding areas between the Box Body Cover and the Head. (Figure 08-22)

3. Install the Side Rods (Position 307) into the Breaker Head (Position 301). Lubricate both theupper heads and lower thread portions of the Side Rods (Position 307) using INDECO PartNumber 490100, Dry Spray Moly Lubricant. (Figures 08-23 and 08-24)

Note: On MES 121 and MES 150 the Side Rods (Position 312) must be torqued into the ChuckHousing Assembly (Position 307). (Figure 08-23)

Note: On MES 181 through MES 553 the Side Rods (Position 307) must be torqued into theHead Assembly (Position 301). (Figure 08-24)

Figure 08-21: Install O-ring Into Breaker Head

Figure 08-22: Lubricate Sliding Areas



PPM2000000 Version: 102700 63

Figure 08-25: MES 121and MES 150 Side Rods

Figure 08-26: MES181 through MES 553

Figure 08-27: Insert Bolts IntoHead

4. Insert two Accumulator Screws (Position 507) in either side of the head, in the appropriateholes. Lift the Head (Position 301)and position it perpendicularly to the Box Body Cover (Position 305) and the Distributor Box Body (Position 302). Install the four side rods into the

head. (Figure 08-27)

5. Lower the Head (Position 301) onto the Cylinder (Position 201).

Note: On MES 181 through MES 553 as the Side Rods (Position 307) protrude through theChuck Housing (Position 101), install the Side Rod Nuts (Position 308).

6. Using the side shock, hammer the Head (Position 301) with a plastic/dead-blow sledgehammer until it meets the Distributor Box Body Cover (Position 302) and Cylinder (Position

201). (Figure 08-28)

7. Insert the Mushroom Valve/ Steel Diaphragm (Position 306). (Figure 08-29)

Figure 08-28: Use Side Shock and DeadBlow to Drive Head

Figure 08-29: Install Check MushroomValve/ Steel Diaphragm

Page REV 01-23-01



PPM2000000 Version: 102700 65

The Side Bolt Locks will retrofit all Breakers currently in the Field and can be easily installedby simply removing the Accumulator.

11. Install Rubber Stops (Position 313) on the top of each Side Bolt (Position 307) on Breaker

Models MES 601 and larger. (Figure 08-34)

12. Install the Accumulator. (See Accumulator Removal and Rebuilding - Section 6 Page 32).

Figure 08-33: Using Torque Turn Procedureto Tighten Side Rods

Figure 08-34: Install Rubber Stops on Side Bolts



PPM2000000 Version: 102700 68

7. Assemble the Shock Absorber Holder (Position 614) and the Upper Shock Absorber (Position 601).

8. Install the Top Shock (Position 601), Holder (Position 614) and the Mounting Bracket onto

the Casing with the Screws (Position 618) and the Self Locking Nuts (Position 619). Tightenaccording to the Torque Specifications. (Figure 08-42)

Figure 08-42: Install Top Shock andMounting Bracket



PPM2000000 Version: 102700 73

Troubleshooting

Low Working Pressure on Breaker Test Gauges

1. Check to verify that you are hitting on a suitably hard surface.

2. 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 obtainthe correct pressure reading (See Appendix A - Breaker Technical and TorqueSpecifications Page 96). Each 1 mm shim inserted increases the pressure approximately 73PSI. (5 Bars). Note: The maximum number of shims allowed is 7. Remove shims todecrease pressure. Add shims to increase pressure.

3. Replace the spring in the guiding plug, reassemble and tighten the pressure regulating

valve.

4. Retest the breaker and, if the readings are still not with in the correct specification, repeatthe above steps until the correct pressures are achieved.

5. 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 Specif ication

1. Check the return filter and replace if necessary. Note: Some applications may require alarger return filter.

2. Check to verify that the return lines are not restricted and are large enough to allow for unrestricted return oil flow.

3. If the pressure is still excessive, call the manufacturer of the hydraulic installation kit for assistance in lowering the pressure.

Breaker Does Not Hammer

1. Check to verify that the carrier’s shut-off valves are open.

2. Check the operation of the breaker control pedal. Check the carrier pump for correct flowand pressure. Push the hammer to the bottom to charge the piston and try again.

3. Connect the pressure line to the return line and verify that the full load does not causeexcessive 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.

4. Check the condition and position of the side bolts. Tighten if loose; replace if broken.

5. Disassemble the variable valve (Guiding Plug - Position 418) and verify that it is workingcorrectly.



PPM2000000 Version: 102700 74

6. Disassemble the tool and, looking into the upper bushing, check that the piston iscompletely free.

7. Check the wear of the bushings in the chuck housing.

8. Check that the point end of the tool is in usable condition. Check the wear of the upper bushing.

9. If the problem cannot be resolved, call INDECO North America at (203)377-7791 for

Breaker Lacks Power

1. Check to verify that the carrier’s shut-off valves are open.

2.Check the operation of the breaker control pedal. Check the carrier pump for correct flowand pressure. Push the hammer to the bottom to charge the piston and try again.

3. Verify that the pressure relief valve of the carrier circuit is not open. If it is, check itscalibration level. (The minimum pressure to the carrier must be at least 30% higher than thatto the hammer.)

4. Verify that there are no leaks in the carrier hydraulic circuit (pump or other components).


6. Check if the pipes and hoses are vibrating or jumping excessively, especially on thepressure side. If necessary, replace the diaphragm and recharge with nitrogen.

7. Check that the inlet operating pressure is not too low (See Appendix A - Breaker Technical and Torque Specifications Page 96).

8. Check that the oil flow meets the technical specs in the Owner’s Manual.

9. Check that the oil temperature is not too high (over 85° Celsius, or 185° Fahrenheit). Checkthat 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, replacethe 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 thepressure valve may be damaged and should be replaced. Also check that the spring is notbroken, 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: 102700 75

13. If the problem cannot be resolved, call INDECO North America at (203) 377-7791 for assistance.

Carrier Oil Is Over Heating

1. Check the operation of the breaker control pedal. Check the carrier pump for correct flowand pressure. Push the hammer to the bottom to charge the piston and try again.

2. Verify that the pressure relief valve of the carrier circuit is not open. If it is, check itscalibration level. (The minimum pressure to the carrier must be at least 30% higher than thatto the hammer.)

3. Verify that there are no leaks in the carrier hydraulic circuit (pump or other components).

4. Check the condition and position of the side bolts. Tighten if loose; replace if broken.


6. Check that the inlet pressure is not too low (see technical specs in Owner’s Manual).


8. Check that there are no defects in the carrier cooling system. Check that there are nointernal leaks in the hammer (evidenced by a rustling noise). If the hammer leaks, replacethe seals. If it is still leaking, re-machine the contact surfaces.

9. Check if the operating pressure gets lower as the tool penetrates. The O-Ring at thepressure valve may be damaged and should be replaced. Also check that the spring is notbroken, and the slide is not worn or loose in the barrel.


Oil Leaks Occurring


2. Verify that the piston is not scratched. If it is, replace the piston and the seals.

3. Check that the breaker has not worked under water. If it has, perform a general check andcleaning, replacing any unusable parts.




PPM2000000 Version: 102700 76

The following Kit Information Request Forms have been designed to ensure that our dealersand their customers receive a kit which best fits their respective carrier. These forms areforwarded to the dealer’s service department upon receipt of any kit order. Hydraulic kits willnot be built without the return of this form. Although helpful, the carrier make, model and

serial number do not help us identify any carrier modifications that have been made after original shipment from the factory.

Request for InformationTractor Loader Backhoe Hydraulic Ki ts

a. Manufacturer:______________________________________________________________

b. Model, Serial Number: _______________________________________________________

c. Dimension A (Center of Pin to Center of Pin) (Figure 10-01): _________________________

d. Dimension B (Center of Pin to Center of Pin) (Figure 10-01): _________________________

e. Does the TLB have an auxiliary control valve? Yes No

f. Does the TLB have four wheel drive?Yes No

g. Does the TLB have an extendible dipperstick? Yes No

X. Information Request Forms for H draulic Kits

Figure 10-01: Pin to Pin Dimensions for Tractor Loader Backhoes (TLB)



PPM2000000 Version: 102700 77

Request for InformationExcavator Hydraulic Kits

a. Manufacturer:______________________________________________________________

b. Model, Serial Number: _______________________________________________________

c. Dimension A (Center of Pin to Center of Pin) (Figure 10-02): _________________________

d. Dimension B (Center of Pin to Center of Pin) (Figure 10-02): _________________________

e. Dimension C (Center of Pin to Center of Pin) (Figure 10-02):_________________________

f. Does the Excavator have an auxiliary control valve? Yes No

Figure 10-02: Pin to Pin Dimensions for Excavators



PPM2000000 Version: 102700 79

4. TOGGLE SWITCH TEST: Across posts (7)and (13)...if not HOT, replace toggle switch.Make sure switch is ON.

5. ACTUATOR SWITCH TEST: Across posts (9) and (13)...if not HOT, replace actuator switch.Make sure armature is fully UP.

6. RELAY TEST: Across posts (11) and (12)...If HOT, replace relay and capacitor. Also, acrossposts (13) and (1 4)...if HOT, replace relay and capacitor.

7. NORMAL ADJUSTMENTS: INDECO grease pumps will only require minor adjustment of theactuator switch, periodically, to compensate for normal wear. There should be no other

routine adjustments required.

Actuator Switch AdjustmentRemove the top cover and locate the actuator switch adjusting screws, accessible from the“front” of the pump, inside the panel box (See Figure 11-02). Slightly loosen the two adjustingscrews so the switch and backing plate can be moved with some resistance, much like theignition contact points on a car or truck.

Figure 11-01: 411I Lube Pump Electrical Circuit



PPM2000000 Version: 102700 80

A screwdriver can be used to positionthe switch by inserting the tip betweenthe switch mounting screw head and theedge of the large hole, and twisting the

screwdriver to pivot the switch andbacking plate. If the mounting screw ismoved too far up, the pump stroke willbecome shorter and finally, the armaturewill “lock” down. CAUTION! Do notleave the switch in this position verylong, as the pump coil is continuouslyenergized and WIN overheat. If themounting screw is mooed too far down,the pump will not stroke down fully,causing the pump to “flutter”, and finallyto not run at all.

The ideal position is that which allows the pump to stroke fully, with the armature bottomingsolidly and then returning to the top of its travel. Re-tighten the adjusting screws, and check thepump operation at system pressure. Readjust if necessary.

Special AdjustmentsThe only other adjustment on the pump is the totalstroke length, set by turning the armature on the upper drive-shaft. This adjustment should not be requiredunless the pump has been disassembled or the locknuts on top of the armature have loosened. Remove thetop cover and locate the lock nuts, accessible from the

top of the pump, inside the switch box (See Figure 11-03). Loosen the nuts enough so the armature can beturned on the drive-shaft tube (the top-most nut can beremoved until adjustment is completed). Remove thebrass plug on the bottom of the pump stem, and removethe check valve spring. Hold the check valve ball firmlyagainst its seat with a finger or suitably-sized woodendowel and turn on the toggle switch momentarily (longenough for at least one full stroke). The piston should

just touch the ball without displacing it, which will be feltas a “stinging” sensation on the end of the finger. If thepiston does not touch the ball, the armature should be

turned out (counter-clockwise, from top) to lengthen thestroke. Do not move the armature more than one fullturn at a time, or damage to the ball could result. If thepiston actually pushes the ball off its seat, the armatureshould be turned in (clockwise, from top) to shorten thestroke.

The optimum setting is where the piston just touches the ball. Reassemble the check valvespring and brass plug, and tighten the armature lock nuts securely against the armature (Vise-Grip C-Clamp works well to hold the armature while tightening the nuts).

Figure 11-02: Actuator Switch Ajustment

Figure 11-03: Special Adjustments



PPM2000000 Version: 102700 82

PG

Port for Pressure

Gauge

(Optional)

T

Hydraulic Grease Pump with Electrical Control

24V-DC

SolenoidMounting Bolts

To Excavator -4 Male JICChassis/Frame Fittings

Ground

From a fused (24V DC)Power source withON/OFF Switch

Diagram of Grease Pump Manifold

Tee into PilotGrease Flow PressureAdjustment Source

Screw To TankReturn

Installation of INDECO Hydraulic Grease Pump with Electrical Control

Hydraulic Connections

1. Tee into the Pressure side of the Pilot Hydraulic System and connect hose between Teeand Port ‘P’ on the Grease Pump Manifold.

2. From the ‘T’ Port on the Grease Pump Manifold run a hose directly back to tank or Tee intothe Return side of the Pilot Hydraulic System.

Figure 11-04: Hydraulic Grease Pump with Electrical Control



PPM2000000 Version: 102700 83

Electrical Connections

3. Connect one wire from the Solenoid mounted on the Grease Pump Manifold to a goodelectrical Ground on the Excavator chassis or frame.

4. Connect the other wire from the Solenoid mounted on the Grease pump Manifold to a fused(10 amp minimum) 24V power source, controlled by an ON/OFF Switch. The switch shouldbe easily assessable to the operator.

Adjustments

5. Turn adjustment Screw on Relief Valve in the Grease Pump Manifold to adjust volume of grease. Turn Clockwise to increase and Counter clockwise to decrease.



PPM2000000 Version: 102700 84

FIowMaster™ Rotary Driven Hydraulic Pump

For 5 Gallon Pail/ container Model: 85486 Series “A”

Lincoln Industrial

Foreign and U.S. Patent Pending

This pump conforms to the European Directive for ProductSafety

Safety

Read and carefully observe these operating instructions beforeunpacking and operating the pump! The pump must be

operated, maintained and repaired exclusively by personsfamiliar with the operating instructions. Local safety regulationsregarding installation, operation and maintenance must befollowed.

Operate this pump only after safety instructions and this servicemanual are fully understood.

Indicates a potentially hazardous situation which,if not avoided, could result in death or seriousinjury.

Indicates a potentially hazardous situationwhich, if not avoided, may result in minor or moderate injury.

Safety Instructions

This equipment generates very high grease pressure. Extreme caution should be used whenoperating this equipment as material leaks from loose or ruptured components can inject fluidthrough the skin and into the body causing serious bodily injury. Adequate protection isrecommended to prevent splashing of material onto the skin or into the eyes.

If any fluid appears to penetrate the skin, get emergency medical care

immediately. Do not treat as a simple cut. Tell attending physical exactly whatfluid was injected.

InspectionIf overpressurizing of the equipment is believed to have occurred, contact the factory authorizedwarranty and service center nearest you for inspection of the pump.

Specialized equipment and knowledge is required for repair of this pump. Contact the factoryauthorized warranty and service center nearest you for repair or adjustments other thanmaintenance specified in this manual.

Figure 11-08: FIowMaster™Rotary Driven Hydraulic Pump(Model: 85486 Series “A”)



PPM2000000 Version: 102700 85

Annual inspection by the factory authorized warranty and service center nearest you isrecommended. A list of factory authorized warranty and service centers is available uponrequest.

Damaged Pumps Any pump that appears to be damaged in any way, is badly worn or operatesabnormally, shall be removed from use until repairs are made. Contact the factoryauthorized warranty and service center nearest to you for repairs.

Description

General Description

The Lincoln Industrial FIowMaster Pump Model 85486 is a fully hydraulically operated greasepump. Grease output is propor6onal to the hydraulic input flow. The pump is primarily designedfor use in a 5 gallon pail or small container.

The pump is driven by the rotary motion of the hydraulic motor. Rotary motion is converted toreciprocating motion through an eccentric crank mechanism. The reciprocating action causesthe pump cylinder to move up and down. The pump is a positive displacement single actingpump. Grease output occurs during the up stroke of the pump.

During the down stroke, the pump cylinder is extended into the grease. Through thecombination of shovel action and vacuum generated in the pump cylinder chamber, the greaseis forced into the pump cylinder. During the upstroke, the inlet check closes, and the greasetaken in during the previous stroke is transferred through the outlet check and discharged to theoutlet port. Typical output of the pump is shown on page 4.

Appropriate Use• The pump is exclusively designed to pump and dispense lubricants using hydraulic power.

• The maximum specification ratings should not be exceeded.

• Any other use not in accordance with instructions will result in loss of claims for warranty andliability.

Do not exceed 450 PSIG (32 bar) maximum supply inlet hydraulic pressure.Exceeding the rated pressure may result in damage to system components andpersonal injury.



PPM2000000 Version: 102700 86

Installing the Pump

1. Pump Model 854862. Plug, unused outlet3. Hose Reel4. Follower, Model 252725

5. Control Valve6. Shut-off Valve7. Hydraulic Power Supply and Return8. Swivel

Pump Performance and Specification

Maximum Output Pressure: 4,5000 Psig Maximum Pump Output: 22 in3

/min. *

320 Bar 244 grams/ min)

Supply inlet hydraulic 450 Psig Weight: 36 Lbs

pressure (maximum): 32 Bar 16 Kg

Hydraulic Inlet Flow: Up to 7 GPM Crankcase oil: 10 oz of API 10W30

Up to 28 l/ min motor oiISF-SC

Operating Temperature: -20 – +150 °F Hydraulic Inlet Port: 318 NPTF In

-10 – +65 °C

Tank Return Port: 318 NPTF In

Pump Ratio with manifold: 10:1

Pump Outlets: 1/4 NPTF In

* Tested with NLGI #2 grease and 1,000 PSI (68 bar) backpressure at 5 gpm (19 I/pm)

6

Figure 11-09: Typical Installation of the Hydraulic Pump



PPM2000000 Version: 102700 87

Typical installation is shown only as a guide for selecting and installing system components.Contact your Lincoln Industrial representative for assistance in designing a system to suit your specific needs.

The pump was tested in light weight oil which was left in to protect the pump from corrosion.Flush the pump before connecting it to the system to prevent contamination of the grease withresidual oil.

Use follower plate 252725 for a 35 Ib (5 gallon) pail.

1. Mount the pump securely on the drum cover so that is cannot move or vibrate duringoperation.

2. Attach hydraulic supply line and return line to the motor ports. The pump will work in either direction.

3. Connect hose reel inlet line to the pump outlet. Plug the unused outlet on the opposite sideof the pump.

Mount the pump securely on the drum cover. Failure to do so could result inpersonal injury and equipment damage.

Do not exceed 450 PSIG (32 bar) working hydraulic pressure. Use high pressurecomponents to reduce risk of serious injury including fluid injection and splashingin the eyes or on the skin. All accessories connected to the pump outlet musthave at least 5,000 PSIG (345 bar) minimum hydraulic pressure.

OperationConnect one port of the pump to a hydraulic power supply and the other to the tank line. Thepump motor will run in either direction, so it makes no difference which port connects to thepower supply

1. Slowly turn on the hydraulic flow until the pump begins to run.

2. Prime the pump by slowly operating the pump until lubricant begins to flow. Make sure thatall air has been expelled from the pump and even lubricant flow is achieved.

3. Adjust the pump pressure to the desired application requirements. Do not exceed pumpoperating pressure of 450 PSIG (32 bar).

4. Always use the lowest pump output pressure to obtain the desired results. This will reducethe pump wear.

Do not exceed maximum operating temperature of the hydraulic fluid (200° F (93° C)).Recommended minimum hydraulic fluid viscosity is 50 SUS. Never allow the pump to run dry of lubricant. A dry pump quickly speeds up, creating friction heat, which can damage the seals.Monitor the supply lubricant level and refill when necessary



PPM2000000 Version: 102700 88

Maintenance and Repair

Relieve pressure from the pump and supply lines before servicing or repairing the pump, toreduce the risk of an injury from injection, splashing fluid or moving parts.

Disassembly Procedure (See Parts Manual for reference)

TOOLS REQUIRED:- Hex Bit Socket Wrenches (3/8" square drive) with 3/8" hex, 5/32" hex, 1/4" hex.- 3/8" O.D. Steel Rod- 12" Crescent Wrench- Spanner Wrench (for 3/8" diameter tube, 1/8" pin) - 1/2" to 3/8" square drive adapter

- Torque wrench (1/2" square drive, 0 - 50 ft-Ib capacity)- Torque wrench (3/8" square drive, 0 - 120 in-Ib capacity) - 1/4" nut driver - Screwdriver (flat blade, 1/8" blade width)

1. Remove the four Socket Head Screws (32) and separate Connection Manifold (33) from theHydraulic Motor (36).

2. Remove Pipe Plug (39) and drain the crankcase oil from the Pump Housing (40).

3. Remove six self-threading Screws (29) and remove the Housing Cover (30) and theCover Gasket (31).

4. Remove Retaining Ring (51) and pull the Shovel Plug (50) from the Housing Tube (49).

5. Remove two Socket Head Screws (38) and separate the Hydraulic Motor (36) from thePump Housing (40).

6. Remove two Outlet Pin Nuts (44) from the Pump Housing (40).

7. Remove the Pump Subassembly (1 through 28) from the Pump Housing (40). Pushing thesubassembly up with a wooden or plastic rod 3/4 O.D. against the Check Seat Housing (28)is helpful.

8. Remove the Housing Tube (49) from the Pump Housing (40) by inserting a 3/4 rod through

the inlet holes at the bottom of the Housing Tube (49) and unscrewing it.

9. Remove the Bronze Bearing (45), the O-Ring (46), and the Backup Washer (47) from theHousing Tube (49).

10. Remove the Crankrod Assembly (1 through 8) from the pump by unscrewing the ButtonHead Screws (12) and then pulling out the Wrist Pin Bushings (13).

11. Remove the Check Seat Housing (28) from the Reciprocating Tube (21). There is a 3/8 Allen Head socket in the throat of the Check Seat Housing (28) to facilitate removal.

Always use Lincoln Industrial parts for service and repair.



PPM2000000 Version: 102700 89

12. Unscrew the Wrist Pin Anchor (14) from the Reciprocating Tube (21) and pull the Plunger Assembly (9 through 20) from the tube.

13. Using a 1/2" dia. wooden or plastic rod, push the Cup Seal(22) and the Pump Cylinder (24)

from the Reciprocating Tube (21).

14. Remove the Pump Plunger (20) from the Plunger Link Rod (17). A spanner wrench, whichuses the holes in the Pump Plunger, is required.

15. Unscrew the Plunger Link Rod (17) from the Plunger Tube (11) and slide off the Cup Seal(16), the Backup Washer (15) and the Wrist Pin Anchor (14).

16. Unscrew the Plunger Tube (11) from the Outlet Pin (9).

17. To dismantle the Crankrod Assembly (1 through 8), remove Flat Head Screws (1) and theInner and Outer Weights (2 & 3).

18. Remove the large Retaining Rings (6) and press the Ball Bearing Assembly (6, 7, 8) out of the Crank Rod (5). Be sure to press the Ball Bearing (8) on the outer race.

19. Remove the small Retaining Rings (6) and press the Crank Eccentric (7) out of the BallBearing (8). Be sure to support the Ball Bearing (8) on the inner race.

Pump Assembly Procedure 1. When the pump is dissembled, it is recommended to replace all seals and gaskets, which

are included in the repair kit.

2. In the process of disassembly, examine the following components and replace if excessive

wear is indicated: Ball Bearing (8), Crank Eccentric (7), Crankrod (5), Wrist Pin Bushings(13), Plunger Tube (11), Pump Plunger and Upper Check Parts (20, 19 and 18), PumpCylinder (24), Check Seat Housing and Lower Check Balland seat (28 and 26), upper Bronze Bushing (45), Housing Tube (49), Shovel Plug (50), and Reciprocating Tube (21).

3. Assembly Procedure is the reverse of the Disassembly Procedure except for the following

4. Install parts (22) through (28) into the Reciprocating Tube (21) after the plunger assembly (9through 20) is installed.

5. Install the Pump Subassembly (1 through 28) into the pump Housing (40) before tighteningthe Housing Tube (49) to the Pump Housing (40). Be sure the Reciprocating Tube (21) is

inserted through both bushings before tightening the Housing Tube (49).

6. Use loctite 242 (or similar product) medium strength thread lock on all torqued threadedconnections. Extreme care must be exercised to prevent excess compound from flowing intocritical areas such as clearance fits and ball check. Allow a minimum of 30 minutes curetime before operating the pump.

7. Fill cranckcase with 10W30 motor oil up to the bottom off the pipe plug (39).



PPM2000000 Version: 102700 90

TORQUE SPECIFICATIONS:a)Plunger Tube (11) to Outlet Pin (9) - 100 to 110 In.-Lbs.

b)Button Head Screws (12) to Wrist Pin Anchor (14) 100 to 110 In.-Lbs.

c) Plunger Tube (11) to Plunger Link Rod (17) - 100 to 110 In.-Lbs.

d)Plunger Link Rod (17) to Pump Plunger (20) - 100 to 110 In.-Lbs.

e)Flat Head Screws (1) to Outer Weight (2) - 100 - 110 In.-Lbs.

f) Wrist Pin Anchor (14) to Reciprocating Tube (21) - 20 to 25 Ft.-Lbs.

g)Check Seat Housing (28) to Reciprocating Tube (21) 20 to 25 Ft.-Lbs.

h)Outlet Pin Nut (44) to Pump Housing (40) - 30 to 35 Ft.Lbs.

i) Housing Tube (49) to Pump housing (40) - 20 to 25 Ft.Lbs.



PPM2000000 Version: 102700 91

Troubleshooting

Condition Possible Cause Corrective Action

Closed supply line shut off

valve Open shut-off valve.Insufficient Hydraulic Fluidsupply.

Check hydraulic supply for proper pressure and flow.

Closed fluid outlet line.Check outlet line and clear obstructions.

Pump is stalled due togrease backpressure.

Relieve grease backpressure.

Pump does not run

Pump is seized or damaged

Dismantle the pump and repair defective or seized component. Seedisassembly and assemblyprocedure.

Low level of grease or reservoir is empty. Refill reservoir.

Follower plate is stuck andseparated from grease.

Check follower plate and container for damage.

Pump speeds up or runs erratically.

Pump piston or checks areworn.

Disassemble the pump and repair.

Insufficient hydraulic fluidsupply.

Check hydraulic supply and adjustflow.

Pump runs, but outputis low.

Inlet pressure too low. Increase pressure using valve 38.

Weepage fromhousing cover 30.

Cup seal (16) or O-Ring (48)failure.

Check the seals and replace if necessary.

No crank case oil.

Add crank case oil. Remove Pipe

Plug (39) from Pump Housing (40).Oil level should be at the bottom of the Pipe Plug opening. Add 10W30motor oil until the crankcase is full.

Pump becomes noisy.

Worn wrist pin bushing 13.Check the bushings and replace if necessary.

Americas: Europe/ Africa: Asia/ Pacific:One Lincoln Way Heinrich-Hertz-Str 2-8 25 Int'I Business Park

St. Louis, MO 63120-1578 D-69183 Walldort #01-65 German Centre © Copyright 1999

USA Germany Singapore 609916 Printed in USA

Phone +1.314.679.4200 Phone +49.6227.33.0 Phone +65.562.7960 Web site:

Fax +1.800.424.5359 Fax +49.6227.33.259 Fax +65.562.9967 www.lincolnindustrial.com



PPM2000000 Version: 102700 92

DepthShut-off Pressure on

Pressure Switch Dynamic Pressurein Breaker Housing

Meters Feet Bar PSI Bar PSI

0.0 - 5.0 0.0 - 16.4 1.5 21.8 2.5 36.3

5.0 - 10.0 16.4 - 32.8 2.0 29.0 3.0 43.5

10.0 - 15.0 32.8 – 49.2 2.5 36.0 3.5 50.8

Pressure Switch Operational Test1. Determine operating depth of hammer and note the value in the “Depth” Column (Table 12-

01).

2. Follow the row across the table to the column marked “Shut-off Pressure on PressureSwitch” and note and record the pressure value. (Table 12-01)

3. Continue across the table to the column marked “Dynamic Pressure in Breaker Housing”and note and record that pressure value. (Table 12-01)

XII. Under Water Kits

Figure 12-01: Under Water Circuit

Table 12-01: Under Water Kit Depth and Air Requirements



PPM2000000 Version: 102700 93

4. Start the compressor and adjust the regulator to pressure slightly above the value re-cordedpreviously in step 2.

5. Start the breaker and then shut-off the compressor. If the breaker does not stop check the

pressure switch for continuity.

Pressure Switch Continuity Test

1. Connect a continuity tester (i.e. Ohmmeter) across the contacts of the pressure switch. Thiscircuit is normally open and should read zero or no continuity on the tester.

2. Determine operating depth of hammer and note the value in the “Depth” Column (Figure 12-02).

3. Start the compressor and charge the breaker with air to the appropriate value in the “Shut-off Pressure on Pressure Switch” column (Table 12-01). At this point the tester should

indicate continuity or a reading greater than zero. If there is no reading the switch may bebad and should be replaced.

Adjusting Under Water Operating Pressure

1. Check the and adjust the “Shut-off Pressure on Pressure Switch” as previously described.(Table 12-01)

2. Adjust the air pressure to the correct “Dynamic Pressure in Breaker Housing” for the depthat which the unit will be working. (Table 12-01)

Note: The breaker must be charged with the correct air pressure before it is placed in the water.

Note: Due to the compressibility of air, it may be necessary to increase the compressor volumeas the working depth is increased. At water depths below 16 feet (5 meters), a delivery volumeof 35 cubic feet (1 cubic meter) is no longer sufficient. A compressor with a deliver of at least125 - 175 cubic feet (3.5 to 5 cubic meters) must be provided.

Note: Ventilation of the lower chuck housing increases the need for a lubrication supply to thebreaker tool. To properly lubricate the breaker’s tool, a power lubrication system isrecommended in under water applications.



PPM2000000 Version: 102700 94

Installation of Flow Regulating Valve for INDECO IHC65 &IHC 130 Compactors

XIII. Compactors

Pressure

Inlet

Port 1

Port 2

1. Install (SAE O-ring x JIC) Bulkhead fitting into the #1 Port of the Flow control Valve.

2. Install (SAE O-ring x JIC) 90°Elbow into Port #2 On Flow Control Valve.3. Install Flow Control Valve into Mounting Bracket on Compactor using the Bulkhead Fitting installed

in Port #1.

4. Connect Hose from 90° Elbow to Motor.5. Connect Pressure Hose from Auxiliary circuit to the Inlet Bulkhead fitting on Flow Control Valve.6. No adjustment to the Valve is necessary.

SAE O-ring

x JIC 90°

Hose to

motor

INDECO Flow Control Valve

SAE O-ringx JIC Bulkheadfitting

Compactor Mounting Bracket

Hose

from

motor Return

Outlet

JIC Bulkheadfitting

NOTE: Flow ControlValve may be mounted ineither the upper or thelower hole of theCompactor MountingBracket.



PPM2000000 Version: 102700 95

Compactor Eccentric Assembly Procedure

1. Install Snap-ring side of Eccentric (A) into motor-side Bearing (D).

2. Install Snap-ring (F) onto Eccentric shaft (A).

3. Install motor-side Bearing (D) into motor-side Bearing retainer (B).

4. Install Eccentric (A), Bearing (D) and Retainer (B) into motor-side of Housing (J).

5. Install Adjustment-side Bearing (E) onto Eccentric shaft (A).

6. Install Adjustment-side Bearing retainer (C) onto Adjustment-side Bearing (E) and intoHousing (J).

7. Install two adjustment bolts (G) without washers into Adjustment-side Bearing retainer (C)

and tighten until bolts stop turning and there is no longer a gap at point (I). Do not use air gun!

8. At this point measure the distance (K) between the head of the Adjustment bolts (G) andthe Adjustment-side Bearing retainer (C).

9. Remove Adjustment bolts (G) and install Washers (H) onto bolts so that the thickness of theWashers is slightly greater than the measured gap in step 8.

10. Install motor.

Compactor Eccentric Cross Section



PPM2000000 Version: 102700 96

Breaker Technical and Torque SpecificationsMES 121

Technical Specifi cations

Technical Specifications Values

Energy Class 180

Blows Per Minute 950 - 1,350

Carrier Weight 1,200 - 5,000 Lbs

Total Height 37.8 In

Working Weight 176 Lbs

Length Of Tool 17.3 In

Diameter Of Tool 1.8 In

Tool Weight 11 Lbs

H.P. Fitting Size 0.5 In. BSPP

L.P. Fitting Size 0.5 In. BSPP

Accumulator Charge 475 - 550 Psi

Maximum Lower Bushing ID 2.04 In

* Required Flow @ Operating Pressure 3 - 9 Gpm

* Operating Pressure 1,650 ±100 Psi

* Circuit Relief 2,100 Psi

* Preferred Backpressure 130 Psi or less

Allowable Maximum Backpressure 160 Psi

* Oil Temperature For Setting Flows & Pressures 150 ° F* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt Nut 314 27 mm ***

Test Plug 403 6 mm Allen 36

Guide Plug 413 19 mm 109

Variable Plug

Inflation Screw 504 8 mm Allen 65

Accumulator Screw

Shell Fixing Screw 506 27 mm Allen 238

Under Water Plug

Side Plate Screw 607 22 mm 87

Self Locking Nut 608

Top Cap Bolts*** Initial torque is 80 ft/lbs and final torque is 145 ft/lbs.

APPENDIX A

Page REV PTU 03-10-2003



PPM2000000 Version: 102700 97

MES 150


Technical Specifications Value

Energy Class 180



Total Height 38 In




Tool Weight 11 Lbs


L.P. Fitting Size 0.5 In. BSPP


Maximum Lower Bushing ID

* Required Flow @ Operating Pressure 4 –10.5 Gpm

* Operating Pressure 1650 ±100 Psi







Side Bolt Nut 314 27 mm ***

Test Plug 403 6 mm Allen 36

Link Screw 409 6 mm Allen 22

Variable Plug NA


Accumulator Screw NA

Shell Fixing Screw 506 27 mm 238

Under Water Plug NA

Side Plate Screw 607 22 mm 145

Self Locking Nut 608 22 mm 87





PPM2000000 Version: 102700 98

MES 181



Energy Class 250







Tool Weight 15.4 Lbs


L.P. Fitting Size 0.75 In. BSPPAccumulator Charge 475 - 550 Psi


* Required Flow @ Operating Pressure 6.5-10.5 Gpm

* Operating Pressure 1,650 ± 100 Psi







Side Bolt 308 27 mm ***

Test Plug


Variable Plug


Accumulator Screw Pin Spanner 579

Shell Fixing Screw

Under Water Plug

Side Plate Screw 607 27 mm 217Self Locking Nut 608 27 mm 145

Top Cap Bolts 618 22 mm 108*** Initial torque is 100 ft/lbs and final torque is 203 ft/lbs.




PPM2000000 Version: 102700 99

MES 200



Energy Class 250











* Required Flow @ Operating Pressure 6 – 11 Gpm

* Operating Pressure 1,650 ±100 Psi








Test Plug

Link Screws


Variable Plug


Accumulator Screw Pin Spanner 578

Shell Fixing Screw

Under Water PlugSide Plate Screw 607 27 mm 217

Self Locking Nut 608 27 mm 145





PPM2000000 Version: 102700 100

MES 350



Energy Class 500

Blows Per Minute 550 - 950 Standard

690 - 1,235 High Speed






Tool Weight 22 Lbs

H.P. Fitting Size 0.5 In. BSPPL.P. Fitting Size 0.75 In. BSPP












Test Plug

Link Screws


Variable Plug


Accumulator Screw 506 14mm x 1.5 x 80mm 12 mm Allen 80

Shell Fixing Screw 505 12mm x 1.5 x 30mm 10 mm Allen 50Under Water Plug

Side Plate Screw 607 18mm x 1.5 x 180mm 27 mm 217

Self Locking Nut 608 18mm x 1.5 27 mm 145

Top Cap Bolts 618 ¾ in. x 3 ½ in*** Initial torque is 100 ft/lbs and final torque is 203 ft/lbs.

Page REV 03-10-2003



PPM2000000 Version: 102700 102

MES 550



Energy Class 750

Blows Per Minute 500 - 900






Tool Weight 33 Lbs













Test Plug 403 19 mm 29

Link Screws 409 10 mm Allen 51


Variable Plug


Accumulator Screw 507 14 mm Allen 116

Shell Fixing Screw 506 14mm x 1.5 x 35mm 12 mm Allen 80

Under Water PlugSide Plate Screw 607 20mm x 1.5 x 205mm 30 mm 311

Self Locking Nut 608 20mm x 1.5 30 mm 217

Top Cap Bolts 618 ¾ in. x 3 ½ in*** Initial torque is 175 ft/lbs and final torque is 347 ft/lbs.

Pa e REV 03-10-2003



PPM2000000 Version: 102700 104

MES 621 (HD) Heavy Duty and (W) Whisper



Energy Class 1,000












* Required Flow @ Operating Pressure 13 – 22.5 Gpm












Variable Plug


Accumulator Screw 507 20mm x 1.5mm x 100mm 17 mm Allen 231

Shell Fixing Screw 506 16mm x 1.5mm x 50 mm 14 mm Allen 116Under Water Plug

Shock Absorber Screw 615 10mm x 1.25 x 30mm 17mm 58

Top Cap Bolts 618 ¾ in. x 3 ½ in

*** Initial torque is 101 ft/lbs, then cross tighten bolts an additional 180 ° in 60 increments. Bolts should

then be tightened another 15 ° and then backed off 15 ° to take the twist out of the bolts. This is your final torque.

Page REV 03-10-2003



PPM2000000 Version: 102700 105




Energy Class 1,000












* Required Flow @ Operating Pressure 18.5 - 25 Gpm










Link Screws 409 17 mm 51


Variable Plug



Shell Fixing Screw 506 16mm x 1.5mm x 50 mm 14 mm Allen 116Under Water Plug

Side Plate Screw

Self Locking Nut

Shock absorber Screw 615 10mm x 1.25 x 30mm 17 mm 58


*** Initial torque is 101 ft/lbs, then cross tighten bolts an additional 180 ° in 60 increments. Bolts should


Page REV 03-10-20033



PPM2000000 Version: 102700 109




Energy Class 1,500





Working Weight 1,045 Lbs










* Preferred Backpressure 220 Psi







Link Screws 409 17 mm 51


Variable Plug



Shell Fixing Screw 506 16mm x 1.5 x 50 mm 14 mm Allen 116Under Water Plug 107 12 mm Allen 145

Side Plate Screw

Self Locking Nut

Shock Absorber Bolts 615 12mm x 1.5 x 30mm 19 mm 72


*** Initial torque is 145 ft/lbs, then cross tighten bolts an additional 180 ° in 60° increment. Bolts should


Page REV DS 11-17-03



PPM2000000 Version: 102700 110

MES 1500 (HD) Heavy Duty, (W) Whisper, and (SP) Side Plate



Energy Class 1,750

Blows Per Minute 600 - 1,000 Standard







Tool Weight 125 Lbs
















Variable Plug



Shell Fixing Screw 506 16mm x 1.5 x 50 mm 14 mm Allen 145Under Water Plug 107 12 mm Allen 180

Side Plate Screw

Self Locking Nut

Side Shock Bolts 615 14mm x 1.5 x 35mm 22 mm 108







PPM2000000 Version: 102700 114




Energy Class 4,500


500 - 910 High Speed






Tool Weight 275 Lbs
















Variable Plug 438 24 mm 180



Shell Fixing Screw 506 22mm x 1.5 x 80mm 17 mm Allen 325Under Water Plug 107 12 mm Allen 180

Side Plate Screw

Self Locking Nut








PPM2000000 Version: 102700 115




Energy Class 5,500

Blows Per Minute 350 – 600








L.P. Fitting Size 1.25 In. BSPPAccumulator Charge 520 – 620 Psi


















Under Water Plug 107 12 mm Allen 180Side Plate Screw

Self Locking Nut








PPM2000000 Version: 102700 117




Energy Class 7,500





Length Of Tool 52 In


Tool Weight 440 Lbs







* Preferred Maximum Backpressure 75 Psi or less














Self Locking Nut


Top Cap Bolts 618 1 in. x 5 in

*** Initial torque is 542 ft/lbs, then cross tighten bolts an additional 180 ° . Bolts should then be tightened

another 15 ° and then backed off 15 ° to take the twist out of the bolts. This is your final torque.




PPM2000000 Version: 102700 118




Energy Class 10,000



Total Height 126 In




Tool Weight 616 Lbs







* Preferred Maximum Backpressure 75 Psi or less





Side Bolt 307 46 Mm ***

Test Plug 403 19 Mm 29


Guide Plug 418 41 Mm 723

Variable Plug 438 24 Mm 180





Self Locking Nut

Shock Absorber Bolts 615 20mm x 1.5 x 50mm 30 Mm 231

Top Cap Bolts 618 1 ½ in. x 6 ½ in






PPM2000000 Version: 102700 120




Energy Class 16,000







Tool Weight 902 Lbs




* Required Flow @ Operating Pressure 86 - 111 Gpm














Accumulator Screw 507 27 mm Allen 1085



Self Locking Nut


Top Cap Bolts 618 1 ½ in. x 6 ½ in

*** Initial torque is 905 ft/lbs, then cross tighten bolts an additional180 ° . Bolts should then be tightened

another 15 ° and then backed off 15 ° to take the twist out of the bolts. This is your final torque.




PPM2000000 Version: 102700 122

IHC 130


Technical Specifications Optional

Shipping Weight 1,500 Lbs

Height 34 In

Width 23 ½ In

Base Plate Size 23 ½ X 32 X 2 In

Low Flow 30Gpm @2000 Psi

Centrifugal Force Low 18,900 Lbs

Frequency Low 2,100 Vpm

High Flow 34Gpm @2000 Psi

Centrifugal Force High 24,000 Lbs

Frequency High 2,350 VpmCarrier Weight 16,000 – 43,000 Lbs

Oil Reservoir Capacity 1.27 Gal

Oil Type HD80-90

Motor Gear Size 1.25 In

NOTE: External drain line must be connected to ¼ in NPT case drain plug if the back pressureexceeds 100 PSI.

IHC 200


Technical Specifications Optional

Shipping Weight 2,500 Lbs

Height 34 In

Width 35 In

Base Plate Size 35 X 37 X 2 In

Low Flow 45Gpm @2000 Psi

Centrifugal Force Low 12,480 Lbs

Frequency Low 1,500 Vpm

High Flow 55Gpm @2000 Psi

Centrifugal Force High 18,650 Lbs

Frequency High 1,900 Vpm

Carrier Weight 43,000 – 100,000 Lbs

Oil Reservoir Capacity 2.46 Gal

Oil Type HD80-90

Motor Gear Size 2.25 In

NOTE: External drain line must be connected to ¼ in NPT case drain plug if the back pressureexceeds 100 PSI.

REV 01-30-01



PPM2000000 Version: 102700 124

APPENDIX D

This page was intentionallyleft blank



PPM2000000 Version: 102700 126

Breaker Mounting Bracket Specifications

Figure F-01: Mounting Bracket Specifications MES 181 through MES 1200


APPENDIX F



PPM2000000 Version: 102700 127


Figure F-04: Mounting Bracket Specifications MES 5000 through 8500



PPM2000000 Version: 102700 128

Figure F-05: Mounting Bracket Specifications MES 12000



PPM2000000 Version: 102700 129

Figure G-01: Factors that affect the mechanicalproperties of the welded joint

Table G-01: Typical CE values for a particular platethickness

Steel Grade Thicknessrange

Carbonequivalent CE

(IIW)

A 572-50 3/16 – 4 in. 0.39 - 0.43

WELDOX 100 5/32 – 5 in. 0.39 - 0.64

WELDOX 130 5/32 – 3 ¼ in. 0.56

WELDOX 160 3/16 – 1 ½ in. 0.68 - 0.72

WELDOX 400 5/32 – 5 in. 0.36 - 0.70

WELDOX 500 3/16 – 3 ¼ in. 0.58 - 0.68

HARDOX and WELDOX Welding

SSAB Oxelösund steel grades in HARDOX wear plate and WELDOX high strength structuralplate have low contents of alloying elements and thus have low carbon equivalents. As a result,they can be easily welded to all ordinary structural plate using any conventional arc weldingmethods.

When HARDOX plate is welded, theobjectives are: 1. To maintain the hardness in the

heat affected zone (HAZ).2. To achieve good toughness of the

HAZ.

When WELDOX plate is welded, theobjectives are:

1. To obtain proper strength in thewelded joint.

2. To achieve good toughness of thewelded joint.

HARDOX and WELDOX have lowcarbon equivalents for their strengthclass. A steel with a low carbonequivalent (CF) has better weldabilitythan a steel with a high value. TypicalCE values for a particular platethickness are given in our data sheets.

The carbon equivalent (according tothe IIW) can be calculated from thefollowing equation:

1556

NiCuV MoCr MnC CE

++

++++=

Workpiece Temperature During Welding

Whenever structural and wear-resistant steels are welded, it is important to minimize the risk of cold cracking (also known as hydrogen cracking or delayed cracking). The occurrence of hydrogen with the presence of stresses in the welded joint is the main reason for such cracking.

The risk of cracking can be minimized by:1. preheating the parent material before welding.2. ensuring that the joint surfaces are perfectly clean and dry.



PPM2000000 Version: 102700 131

Post-treatment

Post weld heat treatment (PWHT)PWHT is carried out to reduce the residual stresses after welding. WELDOX should be postweld heat treated only if this is specified in the design rules. HARDOX and WELDOX I60 mustnot be subjected to PWHT

Measures to increase the fatigue st rengthThe fatigue strength of a welded joint can be increased by various types of post-treatment. Suchtreatments give a smoother transition between the weld and plate and lower the stressconcentrations. For further information, please consult the Handbook on Welding of Oxelösundsteels.

Selection of Head Input

The folowing heat input limitations are recommended for welded joints in HARDOX or WELDOX. A heat input below this level produces a satisfactory combination of toughness of theheat affected zone (HAZ).

Figure G-02: HARDOXMeasure Temperature

Figure G-03: HARDOX WeldPreparation

Figure G-04: HARDOXPlate Thickness



PPM2000000 Version: 102700 132

Q=

Increasing

heat input

Decreasing

heat input

Welding method Arc efficiency factor η

Manual metal arc (MMA) 0.8

Gas metal arc (MIG / MAG) 0.8-0.9

Flux cored arc ( FCAW) 0.9

Submerged arc (SAW) 1.0

TIG (GTAW) 0.7

Increased strength of welded joint

Better toughness of the HAZ

Narrower soft zone

Higher productivity

To Calculate the Heat Input η * U * I * 60

v * 1000

Q = Heat input [kJ/inch]U = Voltage [V]I = Current [A]v = Welding speed [inch/min] η = Arc efficiency factor

Figure G-05: Recommended max. heatinput when welding HARDOX 400 andHARDOX 500

Figure G-06: Hardness profile HARDOX 400

Figure G-07: Recommended max. heatinput when welding WELDOX

Table G-04: Arc efficiency factor η



PPM2000000 Version: 102700 134

HARDOX can very successfully be welded with austenitic stainless steel filler material in thefollowing cases:

1. if the workpiece is rigidly restrained

2. if the workpiece cannot be preheated3. if the plate is thicker than 2 ½ inch

In order to prevent moisture absorption, the filler material should be stored in accordance withthe manufacturer’s recommendations. If there is a risk of moisture having been absorbed, thefiller material must be scrapped or re-dried in accordance with the manufacturer’s instructions.

Welding of Primer Coated Plate

Welding of plate coated with anti-corrosion primer may give rise to varying amounts of prorosity.

However, porosity can be minimized by selecting the right type and coat thickness of primer andby employing suitable welding parameters. Welding can then be carried out within the limitsspecified by the relevant standards, without the need for removing the primer.

HARDOX and WELDOX plate can be delivered with a corrosion protecting low zinc silicateprimer. This paint has been specially developed to minimize the pore volumes during welding.

As a result, welding may be carried out directly onto the primer coat, which contributes towardsimproved productivity in the workshop.

If the plate is anti-corrosion coated with PVB (polyvinyl butyral) or an epoxy primer, the paintshould be removed before welding in order to ensure satisfactory weld quality.

Work hygiene

When welding or grinding plate coated with primer, make sure that the work area is wellventilated.

Ar (inert gas) (active gas) CO2Ar / CO2

Figure G-09: Effect of the shielding gas on the porosity of the weld metal in FCAW, MIG / MAGwelding of plate painted with low zinc silicate primer.

High porosity of the weld metal.Stable arc.

Low porosity.Weld spatter / clogging of welding nozzle.



PPM2000000 Version: 102700 135

Stud Welding

HARDOX arid WELDOX are very well suited for stud weldingand need not be preheated for welding at room temperature.

Stud welding can be carried out directly on the followingsurfaces, provided that they dry and thoroughly cleaned:- bright- painted with low zinc silicate primer - painted with PVB primer

Stud welding is a fast, simple and economical method of securing bolts, screws; studs, etc. to a metal surface. The

method can often replace costly machining operations such asdrilling, countersinking and tapping. The procedure is simpler than traditional welding and can be carried out even bypersonnel who are not trained welders.

Stud welding provides a more protectedinstallation than the use of countersunk headscrews or bolts screwed into tapped holes.

This reduces the necessary wear allowanceand increases the useful life.

Figure G-10: Recommendations for ensuring good weld quality when welding HARDOXand WELDOX painted with low zinc silicate primer.

Figure G-12: Installation provided by studwelding method

Figure G-13: Stud weldingmethod



PPM2000000 Version: 102700 138

MES 181 AND MES 200

Figure H-02: Exploded Parts for MES 181 and MES 200



PPM2000000 Version: 102700 140

MES 601 THROUGH MES 3000

Figure H-04: Exploded Parts for MES 601 and MES 3000



MES 3500 THROUGH MES 12000

mes service manual

Documents