MES Service Manual

PPM2000000 $35.
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INDECO Hydraulic Breaker
Service and Maintenance Manual
REV 11-17-2003
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Version 031003
IMPORTANT SAFETY NOTICE

Most accidents involving service and maintenance are caused by failure to observe basic safety rules or precautions. Accidents can often be avoided by recognizing potentially hazardous situations before an accident occurs. It is necessary to read and understand all safety precautions before performing service and maintenance to any INDECO attachment. Safety precautions are outline in this manual where they exist and failure to follow these precautions could cause serious bodily injury or death. INDECO can not anticipate every possible situation that could involve a potential hazard. Therefore the warnings in this guide are not to be considered all inclusive. If a tool or repair procedure is not specifically recommended by INDECO, you must satisfy yourself that it is safe for you and other people who could be involved. You should not modify or change the configuration of INDECO attachments without the expressed written authorization of the manufacturer. Improper maintenance of any attachment can be dangerous and could result in bodily injury or death. Do not perform any maintenance on INDECO attachments until you have read and understand the procedures as described in the Service and Maintenance Manual. If you have any questions or these procedures contact INDECOs Product Support Department at (203) 377-7791.
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Table of Contents
Safety Information..... Preface.. I. Breaker Installation.... 2 7 8
II. General Breaker Usage..... 12 III. Common Causes of Breaker Damage .........
Daily, Weekly, 500 Hours, 1000 Hours.. Breaker Lubrication... Checking and Adjusting HD Casing to Breaker Clearance Lower Bushing and Insert Inspection.
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19 20 22 24
IV. Routine Maintenance .... 19
V. Breaker Tools...... 25
Tool Selection 25 Tool Breakage Analysis 26 Description of Typical Stress.. 26 Methods to Reduce Stress Effects and Increase Tool Life 26 Typical Tool Failures. 28 Tool Replacement. 30
VI. Accumulator Removal and Rebuilding ........... 32

Safety Instructions .................................................................................. 32 Warnings 32 Potential Hazards. 32 Emergency 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. 38 Nitrogen Recharge 41
VII. Disassembly of the Breaker ...................................................... 43

Removing Breaker Side Plates ................................................. 43 Removing the Mounting Bracket and Breaker Case... 44 Breaker Head Removal and Disassembly................................................... 46 MES 121 and MES 150................................................................. 46 MES 181 and MES 200 ................................................................ 46 MES 300 Through MES 553 ..................................................... 47 MES 601 and up ........................................................ 47 Cylinder Removal and Disassembly.. 50 Disassembly of Chuck Housing...... 51
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Disassembly of High and Low Pressure Links......... 53 Disassembly of The (Power) Pressure-Regulating Valve .................... 54 Disassembly of The Frequency Regulating (Speed) Valve ..................... 55
VIII. Assembling the Breaker ................................................................. 56

Chuck Housing Assembly ....................................................................... Cylinder Assembly ............................................................................... Pressure Regulating Valve Assembly........................................... Frequency Valve Assembly ........................................................................ Breaker Head Assembly ...................................................................... Breaker Side Plate Assembly .......................................................... Assembly of Breaker Case and Mounting Bracket .................................. Assembly of Pressure and Return Links ..................................................... 56 58 60 61 62 67 68 70
IX. Trouble Shooting and Problem Diagnosis .... 71

Checklist for Accurate Breaker Problem Diagnosis..... 71 Troubleshooting..... 73 Low Working Pressure on Test Gauges..... 73 Return (Back) Pressure on Test Gauges is Above the Specifications..... 73 Breaker Does Not Hammer..... 73 Breaker Lacks Power...... 74 Carrier Oil is Over Heating..... 75 Oil Leaks. 75
X.
Information Request Forms for Hydraulic Kits .......................... 76

Excavator 411I Pump........................................................................ 78 Theory of Operation........................................................... 78 Testing and Adjustments .............................................................. 78 711-ITH Pump 24Volt 2 Speed Electric Grease Pump............................. 81 Grease Pump with Electric Control ................................................................ 82 Flow Master Rotary Driven Hydraulic Pump.... 84 Safety ..... 84 Description .................................................................. 85 Installing the Pump ....................................................... 86 Maintenance and Repair .... 88 Troubleshooting ... 91
XI. Power Lubrication Systems ....................................... 78
XII. Under Water Kits........................................................................ 92

Pressure Switch Operational Test...... 92 Pressure Switch Continuity Test .................................................. 93 Adjusting Under Water Operating Pressure ..................................... 93
XIII. Compactors. 94
Installing of Flow Regulating Valve for INDECO IHC65 and IHC 130 Compactors.... 94 Compactor Eccentric Assembly Procedure.. 95
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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 ................................................................... MES 181 and MES 200 ....................................................................... MES 300 Through MES 553................................................................. MES 601 Through MES 3000.................................................... MES 3500 Through MES 12000......................................... 134 135 136 137 138
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PREFACE
The perfect match of hydraulic breaker to carrier is essential in order to guarantee the correct working conditions. However, in order to obtain maximum efficiency, it is strongly recommended that regular and appropriate maintenance be performed. Every attempt has been made to insure accuracy of the information provided. However, the manufacturer reserves the right to update this manual subject to the technological development of the product and service. For the most current information, a review of the Product Support Bulletins is recommended prior to any breaker repair. For further information, please contact: INDECO North America Product Support Department 120 Dodge Avenue Stratford, CT 06615 Phone: (203) 377-7791 Fax: (203) 377-7697
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I. BREAKER INSTALLATION
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 Pressure Gauge Connection
Figure 01-04: Testing Skidsteer Loaders Circuit Flow and Pressure
Note: During these test, be certain that the carriers hydraulic fluid is at operating temperature, usually 130 F to 170 F. This will insure that the attachment will operate at optimum performance. Also, if the carrier has any hydraulic problems, they should appear during testing procedures. BEFORE YOU HOOK UP THE HOSES TO THE ATTACHMENT:
1. Install attachment hydraulic circuit on the carrier. 2. Connect a flow meter (Figure 01-03) to the circuits pressure line into the meters inlet and
the return side into the meter outlet. Also, install a 600 psi gauge into the return circuit at the flow meter. (This will allow for a starting point for the back pressure of the return circuit. Refer to the Operators Manual for the specifications on the attachment you are installing.)
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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 back
pressure readings at the meter.
5. Increase engine RPM while a second person is monitoring the pressure and flow at the
meter. If the back pressure reading goes above specifications the cause must be determined before proceeding. You may need to rework the return circuit to reduce the back pressure to INDECO specifications. (Contact the Product Support department at (203)3777791 for assistance if required.) the required GPM then to be over.)
6. Adjust the circuits flow to the required specification. (NOTE: It is better to be 5-10% under 7. Bring the pressure on the flow meter up to the high pressure reading for the attachment you
are installing. Check to assure that the correct GPMs are maintained and adjust if needed.
8. Once the GPMs, operating pressure and back pressure are within specification check the
attachment circuit relief. This setting must be at least 500 psi above the Attachments operating pressure. (Be certain the GPM reading remains the same as in the above steps.) (There is a 19 mm plug in the upper link which is the pressure circuit.) Connect a 0-600 psi gauge into the attachments return line. (There is a 19 mm plug in the lower link which is the attachments return line.) You can use a BSPP 04 Fitting (British Standard Parallel Pipe)
9. Install the breaker and connect a 0-3000 psi gauge into the inlet port of the attachment.
10. Before operating the breaker, verify that the tool and bushings have been properly
lubricated. Verify that the hose can move freely and are not rubbing against any other parts.
11. Place the breaker on a hard, compact surface and, with shut off (if so equipped) turn on, run
the breaker at low Rpms. Gradually increase rpms to the maximum. Operating pressure and return (back) pressure must remain within specifications in order for the attachment to operate at maximum efficiency (See Appendix A, Breaker Technical and Torque Specifications - Page 96 for the correct specification). Run the breaker until the hydraulic oil is at operating temperature and again note the pressure readings. Note: The breaker should be fast during the initial stages. As the tool penetrates the material the breaker should slow to a rhythm close to the minimum blows per minute.
12. If readings are not within this range please refer to the trouble shooting and problem
diagnosis section of this manual.
13. Record the readings taken during the installation procedures on the Attachment Delivery
Report (ADR) (Figure 01-05). This report must be on file with INDECO before any warranty consideration can be given.
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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. The customer should be advised of the correct operation and maintenance procedures. The ADR should be used as a checklist for each delivery of an INDECO attachment. A small investment of time to check these readings will save maintenance and repair costs and increase customer satisfaction by offering trouble free, productive performance. Note: The fittings needed to test the operating and return pressures, on all INDECO Breakers Model MES 621 HD and larger, are 4 Male BSPP x 4 JIC (See Position #403 on the parts break down). These fittings are available through the parts department by ordering part number HF9002-0404.
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Figure 01-05: Sample Attachment Delivery Report (ADR)
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II. GENERAL BREAKER USAGE
General Breaker Usage
This hydraulic demolition hammer, as a general rule, should be used with the same technique as a jackhammer. Choose the appropriate tool in order to obtain maximum productivity. The profile of the tool should be chosen according to the nature of the material, depending on the type of job: quarry, earth moving, trench work, tunnels, demolition, etc. a) Position the carrier so that the reach to the work is adequate. Ensure that the carrier is in a stable position and is not placed on a crumbling or slipping surface during operation. (Figure 02-01) This guarantees a constant load on the hammer.
Figure 02-01: Position Carrier Correctly b) Place the hammer tool perpendicular to the surface to be broken. (Figure 02-02) Always act with the carrier arm, keeping the hammer perpendicular to the work and describing a slight arc, closing the arm towards the operator. This method of operation will dramatically extend the life of the tool and bushing.
Figure 02-02: Keep Tool Perpendicular to Working Surface
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c) Maintaining an even pressure from the carrier to the hammer, start the hammer. If the downward pressure from the boom is too weak, you will hear metallic (rather than sharp) strokes, because the hammer is not striking the tool correctly. If the downward pressure is excessive, it will produce strong vibrations in the carrier and the tool, retaining axle, bushings, etc. (Figure 02-03)
Figure 02-03: Maintain Even Working Pressure d) If the hammer is in the correct position, and the hammer and case are vibrating (Figure 0204), the downward pressure from the carrier is insufficient. If exerting further pressure from the carrier does not solve the problem, it may be that internal hydraulic leaks from the rams or valves may not be allowing the carrier to exert the correct amount of pressure. In this case, replace the carrier cylinder seals and/or check the control valve seals.
Figure 02-04: Insufficient Downward Pressure Results in Vibrations
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e) If vibrations start to occur after the hammer has been operative for some time, this means that the carrier downward pressure has not followed the tool penetration. You must maintain a constant pressure from the carrier on the hammer, as the hammer is penetrating the work. f) An INDECO hammer senses the strength and density of the surface being broken, and adjusts hammer impact power accordingly. The operator will be able to hear the difference in the blows when a rock is broken or not broken. The hammer rhythm will be fast and sharp if the material is frail and flaky; slow and powerful if the rock is compact and uniform. Impact speed will also be slower the deeper the hammer penetrates. g) As soon as cracks start to appear in the material being worked on, and the tool starts to appear from the bushing, stop the hammer at once. Do not raise the hammer from the material until it has stopped completely. h) If cracks in the material do not appear in 30 seconds, move to a new position along the grain of the material (Figure 02-05), perhaps working on a smaller section or edge of the material. Always look for advantageous weak points in the material (e.g. cracks, bumps, veins) at which to start. This saves undue stress on the breaker.
Figure 02-05: Reposition Breaker Every 30 Seconds

i) j) In a quarry, or when breaking oversized rocks, position the material to be broken on a hard base to minimize vibrations of the material. In the case of horizontal or upside-down operations (e.g. tunnels), once every hour the operator should lower the hammer to a vertical position (Figure 02-06), so that any particles of rock which have collected in the hammer can fall out. (Operator can alternate hammering up and down.) If this is not done, the hammer impact will be wasted on the rock particles, and in addition will create thermal energy in the particles and hammer, causing overheating. Prolonged overheating will cause the hammer materials to lose their original mechanical resistance. In order to keep particles out of the hammer, an air hose may be installed in the same way as would be done for underwater usage.
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Figure 02-06: Lower Breaker Every Hour When Working Overhead

k) If the breaker is operating at temperatures below -15 Celsius, increase the nitrogen charge pressure by 20% of the value recommended in normal conditions. Disassemble the tool and store it in a place where the temperature is above 0 Celsius. DO NOT heat up the tool with a torch or other device before operation. Operate the tool slowly for the first 15 feet of excavation in order to gradually warm up the tool. Never leave the tool exposed to inclement weather, as this will oxidate the bushing contact area. l) The hydraulic oil feed viscosity must not be below 15 CST. The maximum oil temperature during operation should not exceed 75 Celsius (160 Fahrenheit).
m) When the hammer is not in use, it must be kept in a vertical position. (Figure 02-07) This will allow any water or condensation to run off of the piston and prevent rusting which may cause seal failure and leakage.
SUMMARY OF INSTRUCTIONS a) b) c) d) Maintain even pressure on the hammer. Follow the hammer during penetration of the material. Always maintain a constant optimal pressure level. Correct loading ensures hammer productivity and avoids damage to its component. Figure 02-07: Store Breaker in an Upright Position
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III.
Common Causes of Breaker Damage
COMMON CAUSES OF BREAKER DAMAGE

a) The hammer must not be used as a ripper, nor should it be used as a lever. Under no circumstances should the tool be used as a hook to lift weights. (Figure 03-01) This could cause serious damage to the tool, the bushing and the housing.
Figure 03-01: Dont Use Breaker as a Ripper, Lever or Crane

b) The hammer must operate perpendicular to the work. This ensures that: the tools are not forcibly stressed; bending stress does not occur; and the specific pressures in the contact areas are maintained. This will greatly extend the life of the tool and the bushings. c) Check that the tool contact areas (especially the chuck housing) are well lubricated and smooth. A properly lubricated tool will show streaks of grease below the lower bushing on the tool shank. Remove any bumps or rough areas with a soft grinding wheel and wire brush. The point of a chisel tool can be resharpened in the same way. Tools should be rotated 180 to evenly distribute the wear. d) The hammer must be free to operate without any obstructions, chafing or interference. (Figure 03-02) There should also be no obstruction between the hammer and the tool.
Figure 03-02: Operate Breaker Free and Clear of Obstructions
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e) When breaking large blocks of rock, any protrusions should be broken off first, in order to reduce the overall size of the block. f) For secondary demolition, before starting the hammer, adjust the material to be broken so that it 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 then overheat and may deform. The solutions to this are either to make another parallel hole nearby, or to carry out small movements of the hammer to disburse the rock dust. Do not continue in the same spot. This will waste the hydraulic power and damage the tool. h) When using the hammers in these positions, the tool should be removed every 8 hours, and the internal faces of the bush cleaned with a wire brush or lubricant cleaner. (Figure 03-05) If the hammer is very full of rock particles, remove the appropriate plug from the side of the chuck housing, and blow out the hammer with compressed air.
Figure 03-03: Maintain Hard Stable Working Surface
Figure 03-04: Dust Pockets May Cause Tools To Become Deformed
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Figure 03-05: Remove Tool and Clean Breaker Every Eight Hours h) Do not use the tool of the hammer to rotate the carrier. This causes superficial cuts on the contact areas which could cause breakage under stress.
Figure 03-06: Do Not Rotate Carrier on the Breakers Tool
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IV. ROUTINE MAINTENANCE

Daily
Routine Maintenance
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 retaining axles. Measure length of tool. If too short, replace to prevent damage to breaker bushing and housing (Maximum Wear is 50% of exposed portion of tool when new) .
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 breakers 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
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Breaker Lubrication
It is essential to lubricate the tool using the grease chart below as a guideline. If working in dusty conditions, the tool should be greased even more frequently (See the individual operators manuals for proper greasing points). The tool should also be removed weekly and the cavity cleaned and packed with new grease. The tool must always have grease on the hammer contact area. YOU CAN SAVE TIME AND ENERGY BY USING AN INDECO POWER LUBE SYSTEM TO AUTOMATICALLY CARRY OUT THIS FUNCTION.
INDECO GREASING REQUIREMENTS

WARNING !!! A coating of grease must be maintained between the tool and the bushing of the breaker in order to avoid damage and eventual failure of the breaker. The amount of grease necessary to maintain proper lubrication of the tool varies with conditions. It is the responsibility of the Operator to monitor the amount of grease on the tool. When raising the breaker, the portion of the tool CHECK FOR extending from the breaker GREASE HERE should always show grease!
* ATTENTION *
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Lube Points
Figure 04-01: MES 121 and MES 150 Lube Points
Figure 04-02: MES 181 through MES 553 Lube Points
Figure 04-03: MES 181 through MES 553 HD and Whisper Lube Points
Figure 04-05: MES 621HD and MES 650 HD and Whisper Lube Points
Figure 04-07: MES 1050HD and MES 1200HD and Whisper Lube Points PPM2000000 Version: 102700
Figure 04-08: MES 1500 and MES 8500 HD and Whisper Lube Points
Figure 04-09: MES 12000 HD and Whisper Lube Points
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Checking and Adjusting HD Casing to Breaker Clearance

1. Position the Breaker horizontally on a level working surface. 2. Install a dial indicator on top of the case above the cut-out for the retaining axles. 3. Advance the contact point of the dial indicator through the cut-out until it contacts the
Retaining Axles (Position 108). Note: The dial indicator should be in the middle of its range.
4. Using a suitable pry bar, pry the Chuck

Housing down towards the bottom of the Breaker Case and zero the dial indicator.
5. Pry the Chuck Housing up towards the top of

the Breaker Case and record the reading. (Figure 04-11) If the reading is 1.5 mm (0.0600 or less, the Breaker to Case clearance is within specification.
6. If the reading is greater than 1.5 mm (0.060)

the Breaker will need to be removed from the Case and re-shimmed. (See Removing the Mounting Bracket and Breaker Case Section 7 Page 44).
7. Fabricate a Spacing tool using electrical

conduit. (See Table 04-02 for the correct tool dimensions)
Figure 04-10: Measuring Breaker to Case Clearance
Breaker Model(s)
600 Series Breakers MES 1050 & MES 1200 MES 1500 MES 1750 MES 1800 MES 2000 MES 2500
Tool Length In. mm 6.69 170 7.09 180 8.07 205 8.27 210 8.66 220 8.66 220 9.45 240
Breaker Model(s)
MES 3000 MES 3500 MES 4000 MES 5000 MES 7000 MES 8500 MES 12000
Tool Length In. mm 10.63 270 10.63 270 11.42 290 11.81 300 12.99 330 14.17 360 16.54 420
Table 04-02: Breaker Spacing Tool Dimensions
8. Add or install Shims as required to achieve the proper clearance between the Breaker and
the Case. Install the Wear Blocks into the Breaker Case and insert the Spacing Tool between the Wear Blocks and Shims. (Figure 04-11 and Figure 04-12)
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Note: To center the Breaker in the Case, an equal amount of shims should be installed under each Wear Block.
Figure 04-11: Breaker Spacing Tool from Bottom Case
Figure 04-12: Breaker Spacing Tool from Inside Case
9. Remove the Grease Fitting (Position 621) and install a 3/8 - 16 bolt through the passage
into the Wear Blocks. (Figure 04-13) This will hold the Wear Blocks and Shim pack in position 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 )
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Lower Bushing and Insert Inspection

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

or Insert, using an inside measuring device (I.E. caliper, telescoping gauge or inside micrometer) with a .001 graduation. (Compare these measurements to Chart in Appendix D on Page 121). Note: The greatest amount of wear normally occurs from front to back.
3. If the Chuck Bushing (Position 102) or the Insert

Holder (Position 152) needs replacement it is recommended to remove the Breakers Chuck Housing and remove the Chuck Bushing with a hydraulic press. (See Disassembly of the Chuck Housing - Section 7 Page 51). Figure 04-14: Measuring the Lower Chuck Bushing or Insert for Wear
4. To replace the Insert (Position 153), remove the circlip (Position 154) and insert bushing
(Position 153) and clean the insert holder (Position 152) (Figure 04-15 and Figure 04-16) Note: If the insert bushing is steel and it does not slide out of the holder, the bushing will need to 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 cutting a slot lengthwise, using a right angle (90) die grinder with cut-off wheel. Caution: Be careful not to cut insert holder. Remove insert. Optional removal - use a universal sleeve puller with slide hammer to remove insert (See figure 04-17).
Figure 04-15: Remove Insert Snap Ring
Figure 04-16: Remove Insert
Figure 04-17: Universal sleeve puller
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V. Tool Selection
Breaker Tools
Choose the most suitable tool for the operation required. (Figure 05-01) For the breaking of boulders, use MOIL or OLGIVE points. In restricted areas, such as ENCHES, use CHISEL points and proceed in-line with the work face. In particularly narrow places, progress gradually, through small sections of material, making the most of the regularity of the striking frequency. Keep the front of the hammer parallel to the operator, with the machine arm drawn up. This will avoid damage to the tool, especially during cutting and squaring.
Point and Recommended Use 1) Chisel All earth-moving duties or excavations in narrow trenches or stratified soil or rock up to medium rock. 2) Moil Demolition of rocks and materials, not stratified rock, up to medium hardness. 3) Olgive Demolition of hard to very hard rock. 4) Blank or Blunt Demolition of rocks up to medium hardness to be broken into smaller pieces. 5) Asphalt Cutter or Spade Cutting of concrete paving, brick walls or turf. 6) Pole or Pipe Cutter Driving pipes, poles or preshaped metal objects (IE. shaped metal gaurdrail poles) into Different materials.
1 2 3 4 1 2 3 4 5 5 6
Figure 05-01: Breaker Tool Selection
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Tool Breakage Analysis

Description of Typical Stress In order to understand the complexity of the stress phenomena that results in tool breakage, some general information needs to be addressed. The tool is considered an elastic element designed to transmit shock or kinetic energy from the hammer piston to the material to be demolished. The typical tool break starts as a small fracture in the surface of the tool that is the most stressed area. Eventually a surface crack is created from: micro-welds from surface work hardening; localized heating and cooling on the tool surface; and tension and compression on opposite sides of the tool. The surface crack then grows in a series of concentric rings until the section weakens and can no longer support the stresses imposed. Complete failure occurs at this time. Stress per blow is not as critical as the frequency of blows. The stress level in the tool becomes more critical with higher blows per minute and changes in the blows per minute. For the same phenomena, longer tools at equal energy and frequency bear more stress than shorter ones. Breakers working at higher frequencies must be lubricated more often due to the abovementioned stress on the tool as well as the thermal damage created by the friction of the tool and lower bushing. Matching a small breaker to a carrier larger than hammer specification creates high stress conditions on the tool. Operators are not always skillful in using the breaker. Visibility problems, site conditions and the use of the point to move materials can set up surface fractures in the tool. Breakage may not occur immediately but the conditions are now in place for a future failure.
Method to Reduce These Effects & Increase Tool Life To drastically reduce the undesirable stresses on the tool, the breaker should be positioned perpendicular to the material to be worked. Slight arching-in of the hammer toward the operator while firing and following the progression of the tool into the material will deliver uniform pressure on the bushing in the contact areas. This will also allow the lubricating grease to flow around and cool the tool, thus avoiding seizures, micro-welding, and the creation of localized hot spots detrimental to the heat-treating of the tool. All attempts must be made to eliminate prying with the tool or moving the carrier while the weight is on the tool. Do not pivot the carrier on the tool! Overheating of the tool should be avoided on the point or chisel end. This occurs when the tool works in an area longer than 30 seconds, creating a dust pocket between the tool and hard material.
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The tool should be constantly lubricated with INDECO Supreme 1000 grease. You can never over-grease the lower end of the breaker!! Attention to this fact will add longevity to your tool and bushing life.
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Typical Tool Failures

Misalignment or Pry Break
(Figure 05-02) The bending stress exceeds the materials strength and the tool snaps. Caused by working at an incorrect angle or using the tool for mechanical leverage. The failure usually occurs near the tool bushings front face. This failure can also be caused by the breaker slipping while hammering at angles not perpendicular to the surface of the material being broken. The failure type is a brittle type and typically has a lip Figure 05-02: Misalignment formation. Break
Seizing in the Tool Bushing

(Figure 05-03) Strong side loading and striking the tool at the same time causes the tool and bushing surface to be damaged. This failure is cause by incorrect or insufficient lubrication. The failure generally occurs in the front tool bushing area. The failure type is a fatigue fracture starting at the surface of the tool. Figure 05-03: Tool Seized in Bushing
Blank or Dry Firing

(Figure 05-04) Occurs when the working end of the tool is not in proper contact with the material being broken. The failure can also occur when breaking through the material and the breaker strikes the tool a last time. When struck without resistance at the working end the tool , the tool stops abruptly when it is stopped by the retainers instead of the material. This results in breaking and deformation in the retaining groove.
Figure 05-04: Firing
Blank or Dry
Mechanical Damage on the Tools Surface

(Figure 05-05) This is caused by heavy scratching on the tools surface. The failure usually occurs outside the tool bushing. The failure is generally a fatigue type fracture.
Figure 05-05: Mechanical Damage on Tools Surface

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Cold Fracture
(Figure 05-06) Cold temperatures can cause the tool to become brittle and break. This failure can be avoided by warming the tool when working in cold temperatures.
Figure 05-06: Cool Fractured Tool
Break at Retaining Groove

(Figure 05-07) This failure is a result of using a tool with worn or damaged retainers. Any time a tool is replaced the tool retainers should be inspected for wear and replaced if worn or damaged.
Figure 05-07: Tool Retaining Groove Break
Breaking of Chisel Tip

(Figure 05-08) This failure is caused by the improper contact between the tool and the material being broken.
Figure 05-08: Broken Chisel Tip
Mushrooming of Tip
(Figure 05-09) This failure is caused by hammering too long without penetration of the material. This generates extreme heat and softens the tools materials which then mushrooms. Once a tool has been overheated, the properties of the tools materials are permanently altered. This change of properties can then lead to premature failure of the tool. This damage can be prevented by proper lubrication and operation.
Figure 05-08: Broken Moil Tip
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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)
Figure 05-09: Check and Unlock Retaining Axles b) With the aid of a screw driver or similar instrument, push down the lock bolt located on the side of the hammer (Position 109). Turn it 180 to its resting position. (Figure 05-10). Unlock counter 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 Breakers above Serial Number 21344 and 500 Series Breakers above serial number 21723 lock bolts are no longer used. The retaining axles are held in with slotted pins and require a hammer and a punch to drive the pin (Position 103) out of the chuck housing.
Figure 05-10: Use Screw Drive to Push Down Lock Bolt

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c) With a screwdriver or tool, push the retaining axle out from the opposite side. (Figure 05-11) Repeat the operation on the second retaining axle. Remove the tool. Caution the tool may be hot if the breaker was just being used.
Figure 05-11: Push Retaining Axle Out c) Grease the new tool well. Insure the cavity is clean and the bush is lubricated. Slide it in so that the side notches are in line with the axle slots and push in snugly. (Figure 05-12)
Figure 05-12: Grease New Tool And Align d) Slide in the retaining axles with the indents facing the front of the hammer. Push in snugly and turn the lock bolt 180 to secure the retaining axle. Note: For MES 121 and MES 151 follow the above instructions using just one screw driver to push the retaining axle out. Note: Breaker Models MES 601 and larger use a spring-loaded locking pin to lock the retaining axles into place. Two screw drivers are required for these models. Take the first screw driver and push the pin from the housing side into the recess. Use the second screw driver to push the retaining axle out from the opposite side of the breaker.
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VI. Safety Instructions
Accumulator Removal and Rebuilding
Before working on the Accumulator, PLEASE read the following safety procedures thoroughly. If you have any questions, consult your INDECO dealer or INDECO N.A. Warnings
Compressed gases, by their nature, are hazardous. They are capable of creating environments that are oxygen deficient, flammable or explosive. Death has occurred during a routine repair on a carrier when a nitrogen-charged canister on the carrier exploded as it was being disassembled. Nitrogen, which is present in our atmosphere, can still displace the oxygen in a room or enclosure and cause suffocation. Never deliberately breathe, or allow others to breathe, any compressed gas of any type. It 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 gloves should be worn, in addition to the required helmet or other protective gear. Any time compressed gases are handled, safety glasses should be worn. Keep a fire extinguisher close at hand. Situate flammable gas cylinders in a location so that if a fire does occur, it may be easily extinguished. In some cases, it may be better to evacuate the area and let the cylinder burn, especially if escaping gas could collect and explode. Never attempt to adapt fittings from one device or cylinder to another. Fittings or hoses may not be compatible with the gas products and may fail violently. Gases should never be transferred from one cylinder to another. The rate of flow of the gas itself may be sufficient to cause an explosion. Check valves are an important safety feature, but dont rely on them 100% to prevent a backflow condition. Always open the cylinder slowly Purge the regulator and hoses by allowing a small amount of gas to pass through the system.
Potential Hazards
Fire or Explosion Nitrogen may burn, but will not ignite readily. The Cylinder may explode in the heat of a fire.
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Health Hazards Vapors may cause dizziness or suffocation. Contact with liquid may cause frostbite. Fire may produce irritating or poisonous gases.
Emergency Action
Keep unnecessary people away. Isolate the hazard area and deny entry. Stay up-wind; keep out of low areas. Telephone local emergency professionals. Positive-pressure, self-contained breathing apparatus (SCBA) and structural firefighters protective clothing will provide limited protection. Fires Small Fires: Dry Chemical or C02 Large Fires: Water spray, fog or regular foam Move container from fire area if you can do so without risk. Apply cool water to sides of container that is exposed to flames until well after the fire is out. Withdraw immediately in case of rising sound from venting safety device or any discoloration of container. If nitrogen is spilled, it may evaporate leaving a flammable residue. Leaks Stop leak if you can do it without risk. First Aid Move victim to fresh air and call emergency medical care. If the victim is not breathing, give artificial respiration. If breathing is difficult, give oxygen. If you suspect a problem with the Accumulator, it should be bench-tested for the pressure. Before proceeding to any other operation, connect a charging unit to the inflating screw. If the pressure is within specs, it may be assumed the Accumulator is okay. If the pressure is low, note that it is normal for an Accumulator to lose pressure over time with no defects. If pressure has been lost in a short time, there may be a problem with the diaphragm, sealing ring or inflating screw. If the pressure is checked and it is zero, be suspect of a ruptured diaphragm. WARNING: If the pressure is checked and the gauge creeps up past the original specs, exercise extreme care - the diaphragm may be ruptured. If so, the hydraulic oil may have leaked into the nitrogen chamber and the pressure in the chamber may be greater than 2000 psi. Bleed off the pressure slowly through the Inflating Screw, while guarding yourself from bodily injury. (Figure 06-01) (Please read the safety warnings at the beginning of this chapter.) (Explanation: The nitrogen is in at 500 lbs. pressure. The System pressure is 1500 -2000 psi. If the diaphragm ruptures at the edge, it lets the oil in to make up the pressure, thereby increasing the nitrogen chamber pressure. In other words, the fluid takes up the volume and increases the pressure on the gas.) Figure 06-01: Loosen Inflation Screw Carefully
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Accumulator Indicators
In order to ensure smooth operation of the hammer, it is necessary that the Accumulator be charged correctly. If the Hammer is exhibiting strong vibrations of the oil supply pipe, it is likely that Accumulator is discharged (flat). We recommend that the Accumulator be disassembled every 500 working hours. At this time, the Diaphragm (Position 503) should be replaced, even if it appears to be in good condition. WHEN THE ACCUMULATOR GOES FLAT, THE RUBBER DIAPHRAGM MUST BE REPLACED, EVEN IF ITS CONDITION APPEARS SATISFACTORY. When recharging the Accumulator, also replace the Sealing Ring (Position 505) and the O-Ring (Position 508). Before reassembling, wrap Teflon tape around the Inflating Screws (Position 504) in order to deter them from loosening.
ATTENTION:
The accumulator charging Specifications for all
INDECO
Breaker accumulators are: 475 PSI to 550 PSI (32 to 38 BAR) For all models up to and including the MES 1200. 520 PSI to 620 PSI (36 to 43 BAR) For all models MES 1500 HD and larger.
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Accumulator Rebuilding MES 121 and MES 150

1. Carefully discharge the accumulator and remove the Inflating Screw (Position 504) and Oring (Position 505). (Figure 06-02)
2. Loosen and remove the Self Locking Nuts (Position 314) and Shell Fixing Screws (Position
506). (Figure 06-03)
Figure 06-02: Loosen Inflation Screw Carefully MES 121 and MES 150
Figure 06-03: Remove Accumulator Shell Bolts MES 121 and MES 150
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)
Figure 06-04: Remove Diaphram Figure 06-05: Torque Accumulator Shell Bolts MES 121 and MES 150 MES 121 and MES 150
6. Install a new O-ring (Position 505) on the Inflating Screw and wrap Teflon tape around the
threads of the Inflating Screw before installation. Install Inflation Screw in the Upper Shell Half (Position 502). Do not tighten at this time. 7. The Accumulator is ready for installation or can be charged with nitrogen. (See Nitrogen Recharge Section 6 Page 41).
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Accumulator Rebuilding MES 181 and 200

1. Carefully discharge the accumulator and remove the Inflating Screw (Position 504) and Oring (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 the plate to match the bolt pattern on the Upper Shell Half (Position 502). Weld the socket to the center 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 (Position
309). Clean, inspect and replace as required, all components. (Figure 06-07)
Figure 06-06: Unscrew Upper Accumulator Half MES 181 and MES 200
Figure 06-07: Remove Diaphram MES 181 and MES 200.
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 diaphram is 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 with
Teflon tape before installation. Install Inflation Screw in the Upper Shell Half (Position 502). Do not tighten at this time.
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Figure 06-08: Lubricate Accumulator O-ring MES 181 and MES 200
Figure 06-09: Install Lower Accumulator Lower Shell Half MES 181 and MES 200
8. The Accumulator is ready to be charged with nitrogen. (See Nitrogen Recharge Section 6
Page 41).
ATTENTION:
INDECO
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Accumulator Rebuilding MES 300 and up

1. Remove the breaker from the side plates or case. (See Removing Breaker Side Plates Section 7 Page 43).
2. Carefully loosen the accumulator inflation screw and bleed off any internal pressure. 3. For breaker models MES 300 and up. Unscrew the eight Accumulator Screws (Position 507)
with an Allen wrench (see specifications). Once the screws have been loosened, they may be removed with a pneumatic wrench, if desired. (Figure 06-10)
4. Install two bolts into the side of the accumulator and lift the assemble from the breaker.
(Figure 06-11)
Figure 06-10: Loosen Accumulator Bolts MES 300 and Up
Figure 06-11: Lift Off Accumulator MES 300 and UP
5. Remove the Check (Mushroom) Valve/ Steel Diaphragm (Position 306) from the Head
(Position 301). Inspect the valve and accumulator contact surfaces. Clean the check valve and cover it and set it aside in a clean area. (Figure 06-12) Note: If the seat of the Mushroom Valve/ Steel Diaphragm shows signs of wear, use valve lapping compound to smooth the mating surface between the valve and Box Body Cover (Position 305).
Figure 06-12: Remove and Inspect Check Mushroom Valve/ Steel Diaphragm MES 300
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6. Unscrew the Shell Fixing Screws (Position 506) to open the Accumulator. (Figure 06-13)
Use an Allen wrench, as per the Torque Specifications.
7. Replace the Diaphragm (Position 503). (Figure 06-14)
Figure 06-13: Loosen and Remove Accumulator Shell Fixing Bolts MES 300 and Up
Figure 06-14: Replace Diaphragm MES 300 and Up
8. Close the Accumulator and re-fasten the Shell Fixing Screws (Position 506). Cross-tighten
with an Allen wrench, as per the Torque Specifications. (Figure 06-15)
9. Replace the Sealing Ring (Position 505) and check the sealing zone. Apply Teflon tape to
the Inflating Screw (Position 504) to deter loosening of the screw. Screw the Inflating Screw into the appropriate seat in the Accumulator, making sure that the seal does not move while doing so. Tighten finger-tight. Proceed to the Nitrogen Charging phase in the next section.
10. Re-install the Mushroom Valve/ Steel Diaphragm (Position 306). 11. Insert the O-Ring (Position 508) on the lower side in the appropriate seat. 12. Lubricate the Accumulator Bolts with INDECO Supreme 1000 grease. (Figure 06-16)
Figure 06-15: Torque Shell Fixing Bolts MES 300 and Up

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Figure 06-16: Lubricate Accumulator Bolts
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13. Assemble the Accumulator onto the Breaker and fasten the Accumulator Screws (Position
507), cross-tightening as per Torque Specifications. (Figure 06-17, Figure 06-18, Figure 0619) Note: Check the accumulator bolts by holding them by the thread end and tapping the head with a hammer. If the bolt is good is should ring. Accumulator bolts should be re-placed as a set and not individually. Note: On Breaker Models MES 300 and Up, the accumulator may be charged on the bench prior to installation on the breaker.
Figure 06-17: Install and Torque Accumulator MES 121
Figure 06-18: Install and Torque Accumulator MES 181 and MES 200
Figure 06-18: Install and Torque Accumulator MES 300 and Up
ATTENTION:
INDECO
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Nitrogen Recharge
Note: On Breaker Models MES 150 through MES 200, the accumulator must be assembled on the breaker prior to the nitrogen charge.
1. Carefully install the Pressure Reducer/Regulator assembly into the nitrogen tank, following
the safety instructions. (Figure 06-20) The nitrogen bottle must not have a level below 45 bars (652.5 psi).
2. Attach the Rubber Hose to the Pressure Reducer/Regulator and the nitrogen tank valve. 3. Attach the Inflating Body so the hexagonal pin fits inside the Inflating Screw (Position 504).
(8 mm HEX on Breakers up to 300 Series; 14 mm HEX on Breakers 500 Series and up). Check the O-Ring on the sealing face. (Figure 06-21)
Figure 06-20: Assemble and Install Pressure Regulator Onto Nitrogen Tank
Figure 06-21: Attach and Install Inflation Body
4. Install the Inflating Body to the Accumulator. (Figures 06-22, 06-23 and 06-24)
Figure 06-22: Installation of Inflation Body MES 121 and MES 150
Figure 06-24: Installation of Inflation Body Assembly with Newer Style Holder MES 300 and Up (with two 8 mm - 1.25
Tapped holes in the top)
Figure 06-24: Installation of Inflation Body Assembly with Older Style Holder MES 300 and Up
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5. Loosen the Accumulator Charge Plug (Position 34) by turning the Spanner Wrench in the
Charging Fixture counter-clockwise.
6. Open the main valve on the nitrogen tank and purge the charge hose. 7. Charge the accumulator to the correct pressure. (See Nitrogen Recharge - Section 6 Page
41).
8. Tighten the Accumulator Charge Plug (Position 34) by turning the Spanner Wrench in the
Charging Fixture clockwise.
9. Bleed the pressure from the charge

hose and remove the Charging Fixture from the Accumulator.
10.Tighten Accumulator Charge Plug

(Position 34) to specified torque.
11.Using some oil, verify that there are

no nitrogen leaks from the Inflating Screw or on the sides. (Figure 0625)
12.Turn the Accumulator upside down

and fill the holes with oil to check the Diaphragm has no defects. If no bubbles appear, the Accumulator is correctly charged and ready to be installed on the breaker.
Figure 06-25: Check Accumulator for Leaks
ATTENTION:
INDECO
Page REV 01-23-01 PPM2000000 Version: 102700 42
VII. Disassembly of the Breaker Removing Breaker Side Plates

1. Position the breaker horizontally on a flat work surface with the pressure and return fittings
pointing upward. Remove the four nuts (Position 608) from the side plate bolts (Position 607). (Figure 07-01 and 07-02) Note: On MES 121 and MES 150 Breakers there are only eight (8) bolts attaching the side plates.
Figure 07-01: Remove Side Plates MES 121 and MES 150
Figure 07-02: Loosen Side Plates MES 181 and Up
2. Reposition the breaker with the bolt head towards the work surface. 3. Remove the two nuts (Position 608) from the casing spacer (Position 609). Remove the
upper side plate from the breaker
4. Support the breaker and remove it from the lower side plate. (Figure 07-03) Place the
breaker in a appropriate holder to allow for safe disassembly.
Figure 07-03: Lift Breaker From Side Plates MES 181 and Up
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Removing the Mounting Bracket and Breaker Case

1. Lay the hammer in a horizontal position, remove the retaining axles (Position 106) and take
out 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 are
holding the High Pressure Link group (Position 401). At this point, check the condition of the O-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)
Figure 07-04: Remove Mounting Bracket and Top Shock Holder
Figure 07-05: Remove High and Low Pressure Links
5. If the breaker is equipped with a Power Lubrication System, remove the fitting and plate
assembly. (Figure 07-06)
6. Remove the grease fittings and install 3/8-16 bolts to hold the wear pads and shims in
place. (Figure 07-07)
Figure 07-06: Remove Power Lube Fitting

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Figure 07-07: Remove Grease Fittings From Case

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7. Support the breaker in the case and remove the Shock Absorber bolts and Side Shock
Absorbers (Position 602). (Figure 07-08)
8. Slide the hammer out of the case, as shown in the picture. (Figure 07-09)
Figure 07-08: Slide Breaker From Case
Figure 07-09: Remove Breaker From Case
9. Once the breaker is out of the case, install two bolts into the head assembly. If necessary,
these bolts can be removed from the accumulator. (Figure 07-10) Note: Be certain to check the condition of the accumulator bolts by holding the bolt by the thread end and tapping the head with a hammer. The bolt should ring.
10. Lift the breaker and place it in a suitable holding bracket to keep it in an upright position
during disassembly and re-assembly. (Figure 07-11)
Figure 07-10: Install Bolts and Stand Breaker Up
Figure 07-11: Place Breaker in Suitable Tear Down Stand
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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 0713)
3. Go to Page 48 Step 04 to continue the disassembly.
Figure 07-12: Loosen Nuts
Figure 07-13: Lift Head Assembly from Chuck Housing
MES 181 and MES 200

1. See Accumulator Removal and Rebuilding - Section
6 Page 32 and remove the accumulator before proceeding.
2. Remove the four nuts (Position 308) from the side

bolts (Position 307) and lift the head assembly (Position 301) from the cylinder (Position 201). To provide 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 07-14: Loosen Side Bolts MES 181 and MES 200
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MES 300 through MES 553

1. Remove the four nuts (Pos 308) from the side bolts (Pos 307) and lift the head assembly
(Pos 301) from the cylinder (Pos 201). To provide clearance, remove the nuts (Pos 308) while lifting the head.
2. Remove the side bolts (Pos 307) from the head (Pos 301). (Figure 07-15) 3. Proceed to Page 48 step 4.
Figure 07-15: Loosen Side Bolts MES 300 through MES 553
MES 601 and up

1. Loosen and unscrew the four Rubber Side Bolts (Position 307). (Figure 07-01) 2. Install accumulator bolts into the Head Assemble (Position 301) and using a puller as
shown, remove the Head Assembly. (Figure 07-02)
Figure 07-01: Loosen Side Bolts MES 601 and Up

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Figure 07-02: Remove Head Assembly MES 601 and Up

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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)
Figure 07-18: Lift Off Head and Side Rods
4. Remove the Distributor Box Cover (Position 305) from the Distributor Box Body (Position
302). Remove and note the location of the Pin (Position 310). (Figure 07-19)
Figure 07-19: Remove Distributor Box Body Cover
5. Lift the Distributor Box Body (Position 302) off the Cylinder Assembly as shown. Remove
and 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.
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Figure 07-20: Lift Distributor Box Body Off the Cylinder Assembly
6. Check that the Distributor face and inside are smooth and clean. (Figure 07-21) 7. Lift the Piston (Position 209) and Cylinder Assembly (Position 201) off the Chuck Housing
(Position 101) using Accumulator Bolts (Position 507) as shown. (Figure 07-22) Set the assembly into a drain pan to separate the Guide Adapter (Position 210) from the Cylinder (Position 211). Caution: The Cylinder Assembly (Position 211) may be top heavy. Cover the assembly with a rag to prevent oil from spraying out of the Guide Adapter (Position 210).
Figure 07-21: Remove and Inspect Distributor
Figure 07-22: Remove Cylinder Assembly
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Cylinder Removal and Disassembly

1. Remove the piston (Position 209) using the Accumulator Screw (Position 507). (Figure 0723) The Guide Adapter (Position 210) will come out of the Cylinder (Position 210) with the piston. Check that the two parts are not worn, especially at the support surfaces.
2. Remove the Valves (Position 205/206) off the Cylinder and check the seating surface. This
surface should be perfectly circular, of equal thickness all around and without indentation. Clean the valves and replace if necessary. Check the sealing area of the Cylinder. Check the guiding areas of the Cylinder, by the head. (Figure 07-24)
Figure 07-23: Remove Piston
Figure 07-24: Remove Valves from Cylinder
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 this operation is performed, the Cylinder should then be cleaned out with warm, soapy water and then re-oiled). Replace the Cylinder if necessary.
Figure 07-25: Remove Cylinder from Chuck Housing joint seals internal grooves. (Figure 07-26)
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Figure 07-26: Remove Cylinder U-joint Seals
4. Remove the O-ring (Position 303) and the U-joint seals (Position 204) and carefully clean u50
Disassembly of Chuck Housing

1. Slide out the Spacer (Position 105) by hand. (Figure 07-27) If resistant, gently tap with a
small hammer.
2. Slide out the Upper Bush (Position 104) by hand. (Figure 07-27) If necessary, weld a small
disc on the inside and press to extract it.
3. Remove the Nylon Plugs (Position 112) with a pin and slide out the bushing pin (Position
103).
4. Drive in the Elastic Pin (Position 110) until it falls into the chuck housing. This will cause the
Lock Bolt (Position 109) to be released. (Figure 07-28)
Figure 07-27: Remove Spacer and Upper Bushing From Chuck Housing
Figure 07-28: Remove Nylon Plugs and Elastic Pin From Chuck Housing
5. Check the wear on the Lock Bolt, O-Ring (Position 113) and Spring (Position 111). (Figure
07-29) Note: Newer model MES 181 through MES 553 DO NOT have lock bolts. The retaining axles are 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 the

circlip (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 not slide out of the holder, the bushing will need to be cut.
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Figure 07-29: Inspect Lock Bolts

51
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 to prevent damaging the insert holder (Position 152).
Figure 07-30: Remove Insert Bushing
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 next two steps.
9. With the aid of a press, extract the Chuck Bush by pressing on the welded disc. (Figure 0732)
Figure 07-31: Weld Plate on Lower Chuck Bushing or Insert Holder
Figure 07-32: Press Out Lower Chuck Bushing or Insert Holder
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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 the
condition 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 Low Pressure Links
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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)
Figure 07-35: Remove Pressure regulating Valve Guide Plug
Figure 07-36: Extract Pressure regulating Valve Spring
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 the
breakers 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. Do not alter the number of Adjustment Shims at this time.
Figure 07-37: Remove Pressure regulating Valve Piston
Figure 07-38: Remove Pressure regulating Valve Barrel
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Disassembly of the Frequency Regulating (Speed) Valve

1. Unscrew the Plug (Position 438) and remove it along with the Adjustment Shims. Do not
alter the number of adjustment shims at this time. (Figure 07-39)
2. Extract the Spring (Position 434). (Figure 07-40)
Figure 07-39: Remove Frequency Valve Guide Plug
Figure 07-40: Remove Frequency Valve Spring
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 07-41: Remove Frequency Valve Body
Figure 07-42: Remove Frequency Valve Body
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VIII. Assembling the Breaker Chuck Housing Assembly

1. Assemble the Chuck Bushing (Position 102), lining up the bushing pin slot with the bushing
pin hole through the Chuck Housing. Place the Bushing Pin in the bushing pin slot and measure the distances at each end to ensure the pin is lined up straight. Place the Bushing and Housing under a press and push the Bushing down until the slot and the bushing pin hole line up. (Figure 08-01) Note: Dry ice should be used to shrink the lower bushing prior to installation.
2. Insert the Bushing Pin (Position 103), using a hammer if necessary. (Figure 08-02)
Figure 08-01: Install Lower Figure 08-02: Install Lower Bushing or Bushing or Insert Holder Insert Holder Pin
3. Insert the Nylon Plugs (Position 112), using a hammer. 4. If equipped with a insert bushing, install the insert bushing (Position 153) into the insert
holder (Position 152) Note: Beveled end of the insert (Position 153) goes in first. Grease grooves on the insert (Position 153) and the holder (Position 152 must line up when the bushing bottoms in the holder. Turn the housing over and insert the Upper Bushing (Position 104).
Figure 08-03: Install Lower Bushing or Insert Holder Nylon Plug

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Figure 08-04: Install Upper Bushing

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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 according
to the Torque Specifications. (Figure 08-06)
Figure 08-05: Install Upper Spacer
Figure 08-06: Install Chuck Housing Grease Fittings
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 the
Chuck 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 08-07: Install Lock Assembly
Figure 08-08: Install Lock Bolt Elastic Pin
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Cylinder Assembly
1. Insert two Accumulator Screws (Position 507) in the sides of the Cylinder (Position 201), as
shown, (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 (Position
201). 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.
Figure 08-9: Install Cylinder Seals
Figure 08-10: Insert Chuck Housing/ Cylinder Locator Pin
4. Insert an Accumulator Screw (Position 507) into the Piston (Position 209) and lower the
Piston onto the Cylinder. (Figure 08-11)
5. Install the O-ring (Position 303) onto the Cylinder (Position 201). (Figure 08-12)
Figure 08-11: Install Piston Into Cylinder
Figure 08-12: Install Cylinder O-ring
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6. Insert the Check Valves (Position 205) into the Cylinder.(Figure 08-13) 7. Insert the Centering Pin (Position 211) into the Guiding Plug (Position 210). Insert this
assembly into the Cylinder. (Figure 08-14)
Figure 08-13: Insert Check Valves Into the Cylinder
Figure 08-14: Insert Cylinder Centering Pin
8. Place the Distributor (Position 304) onto the Guiding Plug. (Figure 08-15) 9. Brush the Centering Pin with Lithium grease. Lower the Distributor Box Body (Position 302)
by the Shell Fixing Screws onto the Distributor, guiding with the Centering Pin.
10. Assemble the Dowel (Position 310) and the O-Ring (Position 311), and screw into the
Distributor Box Body. Place the Box Body Cover (Position 305) onto the Distributor Box. (Figure 08-16)
Figure 08-15: Install Distributor
Figure 08-16: Install Box Body Cover
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Pressure Regulating Valve Assembly

1. Place the O-Ring (Position 410) on the Barrel (Position 411), and insert into the Head
central hole, as illustrated. (Figure 08-17)
2. Insert the Slide (Position 413) into the same central hole. (Figure 08-18)
Figure 08-17: Install Pressure Regulating Valve Barrel.
Figure 08-18: Install Pressure Regulating Valve Slide
3. Assemble the O-Ring (Position 416), the Guiding Plug (Position 418), the Adjustment Shims
(Position 415), and the Spring (Position 414). DO NOT alter the number of Adjustment Shims at this time. Insert the Assembly into the central hole of the Head, and tighten as per the Torque Specifications. (Figure 08-19)
Figure 08-19: Install Pressure regulating Valve Spring, Shims and Guide Plug
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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 (Position 434). Assemble the completed Plug: the Plug (Position 438), the O-Ring (Position 436), the Spacer Barrel (Position 435) and the Adjustment Shims (Position 437). Install and tighten Plug as per the Torque Specifications. (Figure 08-20)
Figure 08-20: Assemble Frequency Valve
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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)
Figure 08-21: Install O-ring Into Breaker Head
Figure 08-22: Lubricate Sliding Areas
3. Install the Side Rods (Position 307) into the Breaker Head (Position 301). Lubricate both the
upper heads and lower thread portions of the Side Rods (Position 307) using INDECO Part Number 490100, Dry Spray Moly Lubricant. (Figures 08-23 and 08-24)
Figure 08-23: Lubricate Side Rod Heads
Figure 08-24: Lubricate Side Rod Threads
Note: On MES 121 and MES 150 the Side Rods (Position 312) must be torqued into the Chuck Housing Assembly (Position 307). (Figure 08-23) Note: On MES 181 through MES 553 the Side Rods (Position 307) must be torqued into the Head Assembly (Position 301). (Figure 08-24)
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4. Insert two Accumulator Screws (Position 507) in either side of the head, in the appropriate
holes. 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 the Chuck Housing (Position 101), install the Side Rod Nuts (Position 308).
Figure 08-25: MES 121 and MES 150 Side Rods
Figure 08-26: MES Figure 08-27: Insert Bolts Into 181 through MES 553 Head
6. Using the side shock, hammer the Head (Position 301) with a plastic/dead-blow sledge
hammer 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 Dead Blow to Drive Head
Figure 08-29: Install Check Mushroom Valve/ Steel Diaphragm
8. Cross-tighten the Side Bolts to the specified Initial torque. Tighten 1/3 of the specified torque
at a time. (Figures 08-30 and 08-31) Note: On MES 121 through MES 553, tighten the Side Rod Nuts using a box style wrench.
Figure 08-30: Assemble and Tighten Side Bolts
Figure 08-31: Tighten Side Bolts with a Hydraulic Wrench
9. On Breaker Models MES 601 and larger, mark the Side Bolt heads with chalk and then
tighten an additional 180 degrees in 60 increment, plus 15 degrees. Then turn Bolts back (counter-clockwise) 15 degrees. This will reduce the twisting of the bolt. Therefore, the final torque is the torque in the chart plus 180 degrees. (Figure 08-32)
10. Installation of Side Bolt Locks on Mes 621 to Mes 12000 Hydraulic Breakers. In order to
insure that the Side Bolts maintain proper torque after installation, INDECO N.A. is now requiring the installation of Side Bolt Locks on all Breakers MES 621 and up. These are to be ordered and installed when any Breaker is reassembled. A quantity of 4 will be required. Part numbers MES 621 to MES 1200 MES 1750 to MES 2500 MES 3000 to MES 3500 MES 5000 to MES 7000 MES 8500 to MES 12000 0603140 2701271 3003140 5003140 8503140
Below is a diagram showing proper installation.
Figure 08-32: Installation of Side Bolt Locks

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The Side Bolt Locks will retrofit all Breakers currently in the Field and can be easily installed by 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)
Figure 08-33: Using Torque Turn Procedure to Tighten Side Rods
Figure 08-34: Install Rubber Stops on Side Bolts
12. Install the Accumulator. (See Accumulator Removal and Rebuilding - Section 6 Page 32).
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Breaker Side Plate Assembly

1. Install two (2) Casing Spacers (Position 609) into on of the Breakers Side Plates (Position
600).
2. Position the Side Plate on a level work surface with the Casing Spacers (Position 609)
pointing upward away from the surface.
3. Support the Breaker and lower it onto the Side Plate. (Figure 08-35)
Note: Be careful to orient the Breaker with the Chuck Housing towards the bottom of the Side Plate.
Figure 08-35: Lower Breaker Into Side Plates MES 181 and Up
4. Tighten and torque the Side Plates to the proper specification. (See Appendix A - Breaker
Torque Specifications Page 96). (Figures 08-36 and 08-37) Note: On MES 121 and MES 150 Breakers there are only eight (8) bolts attaching the side plates.
Figure 08-36: Install Side Plates MES 121 and MES 150
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Figure 08-37: Install Side Plates MES 181 and Up

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Assembly of Breaker Case and Mounting Bracket

1. Install the Wear Pads (Position 620) and Shims (Position 622). (See Checking and Adjusting
the HD Casing to Breaker Clearance - Section 4 Page 22).
2. Slide the hammer in the Breaker Case as shown. (Figure 08-38) 3. Push the hammer deep inside the Casing. Check the breaker for proper clearance per the
specifications and shim as required.
4. Assemble the Side Shock Absorbers (Position 602) and tighten as per the Torque
Specifications. (Figure 08-39)
Figure 08-38: Slide Breaker Into the Case
Figure 08-39: Install and Tighten Side Shocks
5. Measure the clearance between the breaker and the case. (See Checking and Adjusting the
HD Casing to Breaker Clearance - Section 4 Page 22).
6. Install the Grease Fitting(s) (Position 621) into the Case (Position 603). (Figures 08-40 and
08-41)
Figure 08-40: Assemble MES 621 through MES 1800 Top Shock
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Figure 08-41: Assemble MES 2000 and Up Side Shock

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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). Tighten according to the Torque Specifications. (Figure 08-42)
Figure 08-42: Install Top Shock and Mounting Bracket
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Assembly of Pressure and Return Links

1. There are two (2) Links (Position 401). The sizes of the Connections are different, but the
assembly of each is the same. Assemble the Sealing Washer (Position 402) and the Plug 1/4" Gas (Position 403) on the Link (feed base). Insert the two O-Ring seals (Position 406) inside the Connections (Position 404 H.P. and 405 L.P.). Then install the Connections on the neck of the Links. Assemble the Washer (Position 407) and the Seeger/ Snap Ring (Position 408) onto the Connections. (Figure 08-43)
2. On the back side of the Link, insert the two O-Ring seals (Position 410) in their sockets.
(Figure 08-44)
Figure 08-43: Assemble High and Low Pressure Links
Figure 08-44: Install High and Low Pressure Link O-rings
3. Install the H.P. Connection (High Pressure/Supply) onto the UPPER part of the hammer,
and the L.P. Connection (Low Pressure/Return) onto the LOWER part of the hammer. Using an Allen wrench, tighten as per the Torque Specifications. (Figure 08-45)
Figure 08-45: Install High and Low Pressure Links

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IX.
Trouble Shooting and Problem Diagnosis
Checklist for Accurate Breaker Problem Diagnosis

As in any repair it is very important to ask the customer the right questions. In many cases the answers to a repair technicians questions will allow for a quicker and more cost effective resolve the customers problem. Below are questions that will assist the technician in quick and accurate problem resolution of INDECO Breakers: a. Model and Serial Number of the breaker. __________________________________ b. Make, Model and Serial Number of the carrier. ______________________________ c. Are both shut-offs on the carrier, if present, both in the full on position? __________ d. Are quick couplers being used? _________________________________________ Are the male and female ends of the same manufacturer and type? _____________ Have you by-passed the couplers using a direct hose connection? ______________ e. What are the results of the flow test of the carrier? INITIAL READINGS Full Flow: GPM ___________Back Pressure _________ Attachment Operating ______GPM @ _________PSI Back Pressure ______PSI Carrier Circuit Relief________GPM @ _________PSI Back Pressure ______PSI *Pressures at Test Ports: Inlet _______ PSI Outlet (Back Pressure) ________PSI FINAL READINGS Full Flow: GPM ___________Back Pressure _________ Attachment Operating ______GPM @ _________PSI Back Pressure ______PSI Carrier Circuit Relief________GPM @ _________PSI Back Pressure ______PSI *Pressures at Test Ports: Inlet _______ PSI Outlet (Back Pressure) ________PSI f. Does the breaker sound like it is cycling? __________________________________ g. Do the whip hoses appear to have fluid flowing through them? _________________
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h. Does the breaker run and then stop? If it does, how long does it run and how do you get it to run again? ____________________________________________________ i. With the carrier at an idle, remove the tool and verify that the piston is moving._____ j. Is the piston hitting the tool? ____________________________________________ k. If the breaker is a model MES 1750 HD or larger, does there seem to be air coming out around the valve assemble where the under water kit attaches to? ___________ l. Was the breaker recently rebuilt? If yes, what was done and what parts were installed? ___________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________
In many cases these questions will be asked by service personnel, when called for assistance. Having the answers ready will save you time and allow the product support department at your dealer to assist you quicker and more efficiently.
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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 obtain the correct pressure reading (See Appendix A - Breaker Technical and Torque Specifications Page 96). Each 1 mm shim inserted increases the pressure approximately 73 PSI. (5 Bars). Note: The maximum number of shims allowed is 7. Remove shims to decrease 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, repeat
the 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 Specification

1. Check the return filter and replace if necessary. Note: Some applications may require a
larger 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 carriers shut-off valves are open. 2. Check the operation of the breaker control pedal. Check the carrier pump for correct flow
and pressure. Push the hammer to the bottom to charge the piston and try again.
3. Connect the pressure line to the return line and verify that the full load does not cause
excessive back-pressure. Check the condition of the carriers hydraulic filter; if necessary, replace it. Verify that the diameter of the return pipe is in line with the specifications.
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 working
correctly.
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6. Disassemble the tool and, looking into the upper bushing, check that the piston is
completely 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 carriers shut-off valves are open. 2. Check the operation of the breaker control pedal. Check the carrier pump for correct flow
3. Verify that the pressure relief valve of the carrier circuit is not open. If it is, check its
calibration level. (The minimum pressure to the carrier must be at least 30% higher than that to the hammer.)
4. Verify that there are no leaks in the carrier hydraulic circuit (pump or other components). 5. Disassemble the variable valve (Guiding Plug - Position 418) and verify that it is working
correctly.
6. Check if the pipes and hoses are vibrating or jumping excessively, especially on the
pressure side. If necessary, replace the diaphragm and recharge with nitrogen.
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 Owners Manual. 9. Check that the oil temperature is not too high (over 85 Celsius, or 185 Fahrenheit). Check
that the oil viscosity is good; if necessary, change the oil.
10. Check that there are no defects in the carrier cooling system. Check that there are no
internal leaks in the hammer (evidenced by a rustling noise). If the hammer leaks, replace the seals. If it is still leaking, re-machine the contact surfaces.
11. Check if the inlet operating pressure gets lower as the tool penetrates. The O-Ring at the
pressure valve may be damaged and should be replaced. Also check that the spring is not broken, and the slide is not worn or loose in the barrel.
12. Check that the point end of the tool is in usable condition. Check the wear of the upper
bushing.
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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 flow
2. Verify that the pressure relief valve of the carrier circuit is not open. If it is, check its
calibration level. (The minimum pressure to the carrier must be at least 30% higher than that to 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. 5. Disassemble the variable valve (Guiding Plug - Position 418) and verify that it is working
correctly.
6. Check that the inlet pressure is not too low (see technical specs in Owners Manual). 7. Check that the oil temperature is not too high (over 85 Celsius, or 185 Fahrenheit). Check
8. Check that there are no defects in the carrier cooling system. Check that there are no
internal leaks in the hammer (evidenced by a rustling noise). If the hammer leaks, replace the seals. If it is still leaking, re-machine the contact surfaces.
9. Check if the operating pressure gets lower as the tool penetrates. The O-Ring at the
pressure valve may be damaged and should be replaced. Also check that the spring is not broken, and the slide is not worn or loose in the barrel.
assistance.
Oil Leaks Occurring

1. Check that the oil temperature is not too high (over 85 Celsius, or 185 Fahrenheit). Check
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 and
cleaning, replacing any unusable parts.
assistance.
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X.
Information Request Forms for Hydraulic Kits
The following Kit Information Request Forms have been designed to ensure that our dealers and their customers receive a kit which best fits their respective carrier. These forms are forwarded to the dealers service department upon receipt of any kit order. Hydraulic kits will not 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 Information Tractor Loader Backhoe Hydraulic Kits
Figure 10-01: Pin to Pin Dimensions for Tractor Loader Backhoes (TLB) 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? f. Does the TLB have four wheel drive? Yes No Yes No Yes No
g. Does the TLB have an extendible dipperstick?
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Request for Information Excavator Hydraulic Kits
Figure 10-02: Pin to Pin Dimensions for Excavators 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
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XI. Excavator 411I Pump

Theory of Operation
Power Lubrication Systems
The pump end (bottom) consists of a hardened steel bushing, through which the piston runs. As the piston strokes down grease is pushed past the check valve ball and out through the extruded discharge holes in the pump system. As the piston strokes up, the check valve prevents drawback, and a vacuum is created inside the bushing. When the piston uncovers the suction holes in the bushing, another charge of grease is drawn in through the suction ports on the bottom of the stem and into the bushing. The cycle then repeats. The reciprocating motion of the piston is generated by the power pack, and is transmitted through the drive shafts, with the return (up) motion caused by the return spring. The heart of the power pack is a giant solenoid, which, when energized by the relay, pulls its armature down, operating the upper drive shaft. The lower drive shaft, including the piston, is forced down against the return spring, and against the discharge pressure. At the bottom of the armatures stroke, the actuator switch turns off the signal to the relay, de-energizing the pump solenoid coil, allowing the return spring to push everything back up. At the top of the stroke, the actuator switch turns on, and the cycle repeats. In addition to the actuator switch, the control circuit also includes a toggle (on-off) switch, and a pressure switch, which will stop the pump when the set point is reached. The adjusting cap on the pressure switch assembly can be turned clock-wise (tightened) to increase the shutoff set point, or counter-clockwise (loosened) to de-crease the set point. System pressure operates a spring-loaded piston, which actuates the micro-switch on the front of the assembly. When the system (hose) pressure drops about 400 psi, the switch closes to allow the pump to run. The factory set point is about 2500-3000 psi (for standard pump), which should be adequate for most requirements. Unnecessarily high pressure operation will put undue stress on all pump components, and shorten its life. The power circuit includes the aforementioned pump coil and relay, and also a 40 amp thermal type circuit breaker. The breaker will automatically reset, if tripped, after a short cooling-off period. A permanent installation can be accomplished by mounting the junction box near the pump location, and connecting it to the source. Standard color coding should be observed in making all connection red connectors are positive (+) and black connectors are negative (-). Reversing polarity will damage the suppression capacitor across the pump relay contacts, causing shortened relay life and possible fire/smoke damage. Testing and Adjustments: 1. POWER TEST: Across posts (1) and (13 )...if not HOT, check source & power leads. 2. BREAKER TEST: Across posts (2) and (13 )...lf not HOT, replace the breaker. If the pump has been running intermittently, breaker may have tripped, and will reset If allowed to cool. Check for shorts in power circuit as a possible cause. Power must be supplied to the pump for the following tests. 3. PRESSURE SWITCH TEST: Across posts (5) and (13 )...if not HOT, replace the microswitch. Make sure that all pressure is RELEASED.
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Figure 11-01: 411I Lube Pump Electrical Circuit 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, across posts (13) and (1 4)...if HOT, replace relay and capacitor. 7. NORMAL ADJUSTMENTS: INDECO grease pumps will only require minor adjustment of the actuator switch, periodically, to compensate for normal wear. There should be no other routine adjustments required. Actuator Switch Adjustment Remove 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 adjusting screws so the switch and backing plate can be moved with some resistance, much like the ignition contact points on a car or truck.
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A screwdriver can be used to position the switch by inserting the tip between the switch mounting screw head and the edge of the large hole, and twisting the screwdriver to pivot the switch and backing plate. If the mounting screw is moved too far up, the pump stroke will become shorter and finally, the armature will lock down. CAUTION! Do not leave the switch in this position very long, as the pump coil is continuously energized and WIN overheat. If the mounting screw is mooed too far down, the pump will not stroke down fully, causing the pump to flutter, and finally to not run at all.
Figure 11-02: Actuator Switch Ajustment
The ideal position is that which allows the pump to stroke fully, with the armature bottoming solidly and then returning to the top of its travel. Re-tighten the adjusting screws, and check the pump operation at system pressure. Readjust if necessary. Special Adjustments The only other adjustment on the pump is the total stroke length, set by turning the armature on the upper drive-shaft. This adjustment should not be required unless the pump has been disassembled or the lock nuts on top of the armature have loosened. Remove the top cover and locate the lock nuts, accessible from the top of the pump, inside the switch box (See Figure 1103). Loosen the nuts enough so the armature can be turned on the drive-shaft tube (the top-most nut can be removed until adjustment is completed). Remove the brass plug on the bottom of the pump stem, and remove the check valve spring. Hold the check valve ball firmly against its seat with a finger or suitably-sized wooden dowel and turn on the toggle switch momentarily (long enough for at least one full stroke). The piston should just touch the ball without displacing it, which will be felt as a stinging sensation on the end of the finger. If the piston does not touch the ball, the armature should be turned out (counter-clockwise, from top) to lengthen the stroke. Do not move the armature more than one full turn at a time, or damage to the ball could result. If the piston actually pushes the ball off its seat, the armature should be turned in (clockwise, from top) to shorten the stroke.
Figure 11-03: Special Adjustments
The optimum setting is where the piston just touches the ball. Reassemble the check valve spring and brass plug, and tighten the armature lock nuts securely against the armature (ViseGrip C-Clamp works well to hold the armature while tightening the nuts).
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711-ITHPump 24Volt - 2 Speed Electric Grease Pump

Green Screw Ground 24V (+) (G) (X) G w 12V (+) (Y) (W)
x Trip Wire Y
Figure 11-05: Looking at female connector, plug side.
Figure 11-06: Looking from rear of female connector.
Wiring instructions for the INDECO 24Volt - 2 Speed Electric Grease Pump 1. Wire from (G) terminal connects to a good chassis or frame ground. 2. Wire from the (W) terminal should be wired to a fused (10 Amp minimum) 24V power source, controlled by an ON/OFF Switch. The Switch should be easily assessable to the operator. 3. Wire from the (Y) terminal connects to the 12V(+) positive terminal of the first of the two Batteries. (See Figure 11-07.) 4. Wire from the (X) terminal connects to the 24V(+) positive terminal of the second of the two Batteries. (See Figure 11-07.)
12V Battery #1 Batteries wired In Series (-) (-)
12V Battery #2 To machine
(+) Ground Wire from terminal (Y) connects here for 12V
(+) Wire from terminal (X) connects here for 24V
Figure 11-07: Wiring of 24 Volt 2 Speed Electric Grease Pump
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Hydraulic Grease Pump with Electrical Control
24V-DC Solenoid Mounting Bolts
P G
To Excavator Chassis/Frame Ground From a fused (24V DC) Power source with ON/OFF Switch Port for Pressure Gauge (Optional) -4 Male JIC Fittings
Diagram of Grease Pump Manifold Tee into Pilot Pressure Source To Tank Return
Grease Flow Adjustment Screw Figure 11-04: Hydraulic Grease Pump with Electrical Control
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 Tee and 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 into
the Return side of the Pilot Hydraulic System.
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Electrical Connections 3. Connect one wire from the Solenoid mounted on the Grease Pump Manifold to a good electrical 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 should be 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.
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FIowMaster Rotary Driven Hydraulic Pump

For 5 Gallon Pail/ container Model: 85486 Series A Lincoln Industrial This pump conforms to the European Directive for Product Safety
Foreign and U.S. Patent Pending
Safety
Read and carefully observe these operating instructions before unpacking and operating the pump! The pump must be operated, maintained and repaired exclusively by persons familiar with the operating instructions. Local safety regulations regarding installation, operation and maintenance must be followed. Operate this pump only after safety instructions and this service manual are fully understood. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Safety Instructions This equipment generates very high grease pressure. Extreme caution should be used when operating this equipment as material leaks from loose or ruptured components can inject fluid through the skin and into the body causing serious bodily injury. Adequate protection is recommended 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 what fluid was injected. Inspection If overpressurizing of the equipment is believed to have occurred, contact the factory authorized warranty and service center nearest you for inspection of the pump. Specialized equipment and knowledge is required for repair of this pump. Contact the factory authorized warranty and service center nearest you for repair or adjustments other than maintenance specified in this manual.
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Figure 11-08: FIowMaster Rotary Driven Hydraulic Pump (Model: 85486 Series A)
Annual inspection by the factory authorized warranty and service center nearest you is recommended. A list of factory authorized warranty and service centers is available upon request. Damaged Pumps
Any pump that appears to be damaged in any way, is badly worn or operates abnormally, shall be removed from use until repairs are made. Contact the factory authorized warranty and service center nearest to you for repairs.
Description
General Description The Lincoln Industrial FIowMaster Pump Model 85486 is a fully hydraulically operated grease pump. Grease output is propor6onal to the hydraulic input flow. The pump is primarily designed for 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 to reciprocating motion through an eccentric crank mechanism. The reciprocating action causes the pump cylinder to move up and down. The pump is a positive displacement single acting pump. Grease output occurs during the up stroke of the pump. During the down stroke, the pump cylinder is extended into the grease. Through the combination of shovel action and vacuum generated in the pump cylinder chamber, the grease is forced into the pump cylinder. During the upstroke, the inlet check closes, and the grease taken in during the previous stroke is transferred through the outlet check and discharged to the outlet 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 and liability. Do not exceed 450 PSIG (32 bar) maximum supply inlet hydraulic pressure. Exceeding the rated pressure may result in damage to system components and personal injury.
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Installing the Pump
Figure 11-09: Typical Installation of the Hydraulic Pump 1. 2. 3. 4. Pump Model 85486 Plug, unused outlet Hose Reel Follower, Model 252725 5. 6. 7. 8. Control Valve Shut-off Valve Hydraulic Power Supply and Return Swivel
Pump Performance and Specification

Maximum Output Pressure: 4,5000 320 450 32 Up to 7 Up to 28 -20 +150 -10 +65 10:1 Pump Outlets: * Tested with NLGI #2 grease and 1,000 PSI (68 bar) backpressure at 5 gpm (19 I/pm) 1/4 NPTF In Psig Bar Psig Bar GPM l/ min F C Maximum Pump Output: 22 244 36 16 in /min. * grams/ min) Lbs Kg
3
Supply inlet hydraulic pressure (maximum): Hydraulic Inlet Flow:
Weight:
Crankcase oil:
10 oz of API 10W30 motor oiISF-SC 318 NPTF 318 NPTF In In
Operating Temperature:
Hydraulic Inlet Port: Tank Return Port:
Pump Ratio with manifold:
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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 with residual 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 during operation. 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 side of the pump. Mount the pump securely on the drum cover. Failure to do so could result in personal injury and equipment damage. Do not exceed 450 PSIG (32 bar) working hydraulic pressure. Use high pressure components to reduce risk of serious injury including fluid injection and splashing in the eyes or on the skin. All accessories connected to the pump outlet must have at least 5,000 PSIG (345 bar) minimum hydraulic pressure. Operation Connect one port of the pump to a hydraulic power supply and the other to the tank line. The pump motor will run in either direction, so it makes no difference which port connects to the power 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 that all 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 pump operating pressure of 450 PSIG (32 bar). 4. Always use the lowest pump output pressure to obtain the desired results. This will reduce the 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
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Maintenance and Repair

Relieve pressure from the pump and supply lines before servicing or repairing the pump, to reduce the risk of an injury from injection, splashing fluid or moving parts. Always use Lincoln Industrial parts for service and repair.
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 the Hydraulic 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 the Cover 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 the Pump 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 the subassembly 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 the Housing Tube (49). 10. Remove the Crankrod Assembly (1 through 8) from the pump by unscrewing the Button Head 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.
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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, which uses 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 the Inner 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 Ball Bearing (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), Pump Cylinder (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 (9 through 20) is installed. 5. Install the Pump Subassembly (1 through 28) into the pump Housing (40) before tightening the 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 threaded connections. Extreme care must be exercised to prevent excess compound from flowing into critical areas such as clearance fits and ball check. Allow a minimum of 30 minutes cure time before operating the pump. 7. Fill cranckcase with 10W30 motor oil up to the bottom off the pipe plug (39).
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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.
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Troubleshooting
Condition Possible Cause Closed supply line shut off valve Insufficient Hydraulic Fluid supply. Closed fluid outlet line.
Pump does not run
Corrective Action Open shut-off valve. Check hydraulic supply for proper pressure and flow. Check outlet line and clear obstructions. Relieve grease backpressure. Dismantle the pump and repair defective or seized component. See disassembly and assembly procedure. Refill reservoir. Check follower plate and container for damage. Disassemble the pump and repair. Check hydraulic supply and adjust flow. Increase pressure using valve 38. Check the seals and replace if necessary. 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 10W30 motor oil until the crankcase is full. Check the bushings and replace if necessary.
Pump is stalled due to grease backpressure. Pump is seized or damaged Low level of grease or reservoir is empty. Follower plate is stuck and separated from grease. Pump piston or checks are worn. Insufficient hydraulic fluid supply. Inlet pressure too low. Cup seal (16) or O-Ring (48) failure. No crank case oil.
Pump speeds up or runs erratically.
Pump runs, but output is low. Weepage from housing cover 30.
Pump becomes noisy. Worn wrist pin bushing 13.
Americas:
One Lincoln Way St. Louis, MO 63120-1578 USA Phone +1.314.679.4200 Fax +1.800.424.5359 PPM2000000 Version: 102700
Europe/ Africa:
Heinrich-Hertz-Str 2-8 D-69183 Walldort Germany Phone +49.6227.33.0 Fax +49.6227.33.259
Asia/ Pacific:
25 Int'I Business Park #01-65 German Centre Singapore 609916 Phone +65.562.7960 Fax +65.562.9967
Copyright 1999 Printed in USA Web site: www.lincolnindustrial.com
91
XII. Under Water Kits
Figure 12-01: Under Water Circuit Depth Meters

0.0 - 5.0 5.0 - 10.0 10.0 - 15.0
Feet
0.0 - 16.4 16.4 - 32.8 32.8 49.2
Shut-off Pressure on Pressure Switch Bar PSI

1.5 2.0 2.5 21.8 29.0 36.0
Dynamic Pressure in Breaker Housing Bar PSI

2.5 3.0 3.5 36.3 43.5 50.8
Table 12-01: Under Water Kit Depth and Air Requirements
Pressure Switch Operational Test

1. Determine operating depth of hammer and note the value in the Depth Column (Table 1201). 2. Follow the row across the table to the column marked Shut-off Pressure on Pressure Switch 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)
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4. Start the compressor and adjust the regulator to pressure slightly above the value re-corded previously 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. This circuit 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 1202). 3. Start the compressor and charge the breaker with air to the appropriate value in the Shutoff 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 be bad 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 depth at 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 volume as the working depth is increased. At water depths below 16 feet (5 meters), a delivery volume of 35 cubic feet (1 cubic meter) is no longer sufficient. A compressor with a deliver of at least 125 - 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 the breaker tool. To properly lubricate the breakers tool, a power lubrication system is recommended in under water applications.
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XIII. Compactors Installation of Flow Regulating Valve for INDECO IHC65 & IHC 130 Compactors
Hose to motor
SAE O-ring x JIC 90
Compactor Mounting Bracket
Port 2
SAE O-ring x JIC Bulkhead fitting
INDECO Flow Control Valve
Port 1
Pressure
Inlet
JIC Bulkhead fitting
NOTE: Flow Control Valve may be mounted in either the upper or the lower hole of the Compactor Mounting Bracket.
Hose from motor
Return Outlet
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) 90Elbow 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.
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Compactor Eccentric Assembly Procedure

1. 2. 3. 4. 5. 6. 7. Install Snap-ring side of Eccentric (A) into motor-side Bearing (D). Install Snap-ring (F) onto Eccentric shaft (A). Install motor-side Bearing (D) into motor-side Bearing retainer (B). Install Eccentric (A), Bearing (D) and Retainer (B) into motor-side of Housing (J). Install Adjustment-side Bearing (E) onto Eccentric shaft (A). Install Adjustment-side Bearing retainer (C) onto Adjustment-side Bearing (E) and into Housing (J). 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! At this point measure the distance (K) between the head of the Adjustment bolts (G) and the Adjustment-side Bearing retainer (C). Remove Adjustment bolts (G) and install Washers (H) onto bolts so that the thickness of the Washers is slightly greater than the measured gap in step 8.
8. 9.
10. Install motor.
Compactor Eccentric Cross Section
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APPENDIX A Breaker Technical and Torque Specifications MES 121

Technical Specifications Technical Specifications Energy Class Blows Per Minute Carrier Weight Total Height Working Weight Length Of Tool Diameter Of Tool Tool Weight H.P. Fitting Size L.P. Fitting Size Accumulator Charge Maximum Lower Bushing ID * Required Flow @ Operating Pressure * Operating Pressure * Circuit Relief * Preferred Backpressure Allowable Maximum Backpressure * Oil Temperature For Setting Flows & Pressures
* Information required for Attachment Delivery Report (ADR)
Values 180 950 - 1,350 1,200 - 5,000 Lbs 37.8 In 176 Lbs 17.3 In 1.8 In 11 Lbs 0.5 In. BSPP 0.5 In. BSPP 475 - 550 Psi 2.04 In 3 - 9 Gpm 1,650 100 Psi 2,100 Psi 130 Psi or less 160 Psi 150 F
Torque specifications Item Side Bolt Nut Test Plug Guide Plug Variable Plug Inflation Screw Accumulator Screw Shell Fixing Screw Under Water Plug Side Plate Screw Self Locking Nut Top Cap Bolts Position 314 403 413 504 506 607 608 Bolt Size Wrench 27 mm 6 mm Allen 19 mm 8 mm Allen 27 mm Allen 22 mm Ft/Lbs. *** 36 109 65 238 87
*** Initial torque is 80 ft/lbs and final torque is 145 ft/lbs.
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MES 150
Value 180 850 - 1,250 1,200 - 5,000 Lbs 38 In 176 Lbs 17.3 In 1.75 In 11 Lbs 0.5 In. BSPP 0.5 In. BSPP 475 - 550 Psi 4 10.5 1650 100 2,100 188 260 150 Gpm Psi Psi Psi or less Psi F
Torque specifications Item Side Bolt Nut Test Plug Link Screw Variable Plug Inflation Screw Accumulator Screw Shell Fixing Screw Under Water Plug Side Plate Screw Self Locking Nut Top Cap Bolts Position 314 403 409 NA 504 NA 506 NA 607 608 Bolt Size Wrench 27 mm 6 mm Allen 6 mm Allen 8 mm Allen 27 mm 22 mm 22 mm Ft/Lbs. *** 36 22 65 238 145 87
MES 181
Values 250 800 - 1,200 4,000 - 8,000 47.2 264 20.9 1.9 15.4 0.5 0.75 475 - 550 2.04 6.5-10.5 1,650 100 2,100 130 160 150
Lbs In Lbs In In Lbs In. BSPP In. BSPP Psi In Gpm Psi Psi Psi or less Psi F
Torque specifications Item Side Bolt Test Plug Guide Plug Variable Plug Inflation Screw Accumulator Screw Shell Fixing Screw Under Water Plug Side Plate Screw Self Locking Nut Top Cap Bolts Position 308 413 504 Bolt Size Wrench 27 mm 24 mm 8 mm Allen Pin Spanner Ft/Lbs. *** 217 65 579
607 608 618
27 mm 27 mm 22 mm
217 145 108
MES 200
Values 250 600 - 1,000 4,000 - 8,000 47.2 264 20.9 1.9 15.4 0.5 0.75 475 - 550 2.04 6 11 1,650 100 2,100 200 275 150
Torque specifications Item Side Bolt Test Plug Link Screws Guide Plug Variable Plug Inflation Screw Accumulator Screw Shell Fixing Screw Under Water Plug Side Plate Screw Self Locking Nut Top Cap Bolts Position 307 Bolt Size Wrench 27 mm Ft/Lbs. ***
413 504
24 mm 8 mm Allen Pin Spanner
217 65 578
607 608
27 mm 27 mm
217 145
MES 350
Values 500 550 - 950 690 - 1,235 5,000 - 10,000 55.1 396 22.8 2.2 22 0.5 0.75 475 - 550 2.38 8 16 1,650 100 2,100 200 247 150 Standard High Speed Lbs In Lbs In In Lbs In. BSPP In. BSPP Psi In Gpm Psi Psi Psi or less Psi F
413 504 506 505 607 608 618
24 mm 8 mm Allen 12 mm Allen 10 mm Allen 27 mm 27 mm
217 65 80 50 217 145
14mm x 1.5 x 80mm 12mm x 1.5 x 30mm 18mm x 1.5 x 180mm 18mm x 1.5 in. x 3 in
MES 351
Technical Specifications Technical Specifications Energy Class Blows Per Minute Carrier Weight Total Height Working Weight Length Of Tool Diameter Of Tool Tool Weight H.P. Fitting Size L.P. Fitting Size Accumulator Charge Maximum Lower Bushing ID * Required Flow @ Operating Pressure * Operating Pressure * Circuit Relief * Preferred Backpressure AllowableMaximum Backpressure * Oil Temperature For Setting Flows & Pressures
Values 500 550 - 950 690 - 1,225 5,000 - 10,000 55.1 396 22.8 2.2 22 0.5 0.75 475 - 550 2.38 11 - 17 1,650 100 2,100 362 450 150 Standard High Speed Lbs In Lbs In In Lbs In. BSPP In. BSPP Psi In Gpm Psi Psi Psi or less Psi F
413 504 506 505 607 608 618
24 mm 8 mm Allen 12 mm Allen 10 mm Allen 27 mm 27 mm
217 65 80 50 217 145
14mm x 1.5 x 80mm 12mm x 1.5 x 30mm 18mm x 1.5 x 180mm 18mm x 1.5 in. x 3 in
MES 550
Values 750 500 - 900 6,000 - 14,000 59.1 572 23.6 2.6 33 0.75 0.75 475 - 550 2.75 13 21 1,650 100 2,200 220 275 150
Torque specifications Item Side Bolt Test Plug Link Screws Guide Plug Variable Plug Inflation Screw Accumulator Screw Shell Fixing Screw Under Water Plug Side Plate Screw Self Locking Nut Top Cap Bolts Position 307 403 409 413 504 507 506 607 608 618 Bolt Size Wrench 32 mm 19 mm 10 mm Allen 30 mm 14 mm Allen 14 mm Allen 12 mm Allen 30 mm 30 mm Ft/Lbs. *** 29 51 362 36 116 80 311 217
14mm x 1.5 x 35mm 20mm x 1.5 x 205mm 20mm x 1.5 in. x 3 in
MES 553
Values 750 500 - 900 625 - 1,170 8,000 - 14,000 61 583 25.6 2.9 39.6 0.75 0.75 475 - 550 13 21 1,675 100 2,200 220 275 150 Standard High Speed Lbs In Lbs In In Lbs In. BSPP In. BSPP Psi Gpm Psi Psi Psi or less Psi F
Torque specifications Item Side Bolt Test Plug Link Screws Guide Plug Variable Plug Inflation Screw Accumulator Screw Shell Fixing Screw Under Water Plug Side Plate Screw Self Locking Nut Top Cap Bolts Position 307 403 409 418 504 507 506 607 608 618 Bolt Size Wrench 32 mm 19 mm 10 mm Allen 30 mm 14 mm Allen 14 mm Allen 12 mm Allen 30 mm 30 mm Ft/Lbs. *** 29 51 362 36 116 80 311 217
14mm x 1.5 x 35mm 20mm x 1.5 x 205mm 20mm x 1.5 in. x 3 in
MES 621 (HD) Heavy Duty and (W) Whisper

Values 1,000 500 - 950 560 - 1,170 8,000 - 18,000 54.3 880 25.6 3.2 48.4 0.75 0.75 475 - 550 3.39 13 22.5 1,650 100 2,200 130 175 150 Standard High Speed Lbs In Lbs In In Lbs In. BSPP In. BSPP Psi In Gpm Psi Psi Psi or less Psi F
Torque specifications Item Side Bolt Test Plug Link Screws Guide Plug Variable Plug Inflation Screw Accumulator Screw Shell Fixing Screw Under Water Plug Shock Absorber Screw Top Cap Bolts Position 307 403 409 418 504 507 506 615 618 Bolt Size Wrench 30 mm 19 mm 10 mm Allen 30 mm 14 mm Allen 17 mm Allen 14 mm Allen 17mm Ft/Lbs. *** 29 51 362 36 231 116 58
20mm x 1.5mm x 100mm 16mm x 1.5mm x 50 mm 10mm x 1.25 x 30mm in. x 3 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 104

Values 1,000 450 - 900 560 - 1,170 10,000 - 18,000 54.3 880 25.6 3.2 48.4 0.75 0.75 475 - 550 3.39 18.5 - 25 1,650 100 2,200 220 290 150 Standard High Speed Lbs In Lbs In In Lbs In. BSPP In. BSPP Psi In Gpm Psi Psi Psi or less Psi F
Torque specifications Item Side Bolt Test Plug Link Screws Guide Plug Variable Plug Inflation Screw Accumulator Screw Shell Fixing Screw Under Water Plug Side Plate Screw Self Locking Nut Shock absorber Screw Top Cap Bolts Position 307 403 409 418 504 507 506 Bolt Size Wrench 30 mm 19 mm 17 mm 30 mm 14 mm Allen 17 mm Allen 14 mm Allen Ft/Lbs. *** 29 51 362 36 231 116
20mm x 1.5mm x 100mm 16mm x 1.5mm x 50 mm
615 618
10mm x 1.25 x 30mm in. x 3 in
17 mm
58
*** 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 03-10-20033 PPM2000000 Version: 102700 105

Values 1,000 500 - 800 Standard 11,200 24,400 60.2 1,056 27.6 3.5 63.5 0.75 1.00 475 550 3.81 18.5 26.5 1,650 100 2,200 160 203 150 Lbs In Lbs In In Lbs In. BSPP In. BSPP Psi In Gpm Psi Psi Psi or less Psi F
Torque specifications Item Side Bolt Test Plug Link Screws Guide Plug Variable Plug Inflation Screw Accumulator Screw Shell Fixing Screw Under Water Plug Side Plate Screw Self Locking Nut Shock Absorber Bolts Top Cap Bolts Position 307 403 409 418 504 507 506 107 Bolt Size Wrench 30 mm 19 mm 17 mm 30 mm 14 mm Allen 17 mm Allen 14 mm Allen 12 mm Allen Ft/Lbs. *** 29 51 362 36 231 145 180
20mm x 1.5 x 120mm 16mm x 1.5 x 50 mm
615 618
12mm x 1.5 x 30mm in. x 3 in
19 mm
72
*** Initial torque is 101 ft/lbs, then cross tighten bolts an additional 180 in 60 increment. 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 106

Values 1,500 450 900 560 - 1,170 10,000 - 18,000 54.3 1,045 25.6 3.2 48.4 0.75 0.75 475 550 3.81 20-28 1,650 100 2200 220 290 150 Standard High Speed Lbs In Lbs In In Lbs In. BSPP In. BSPP Psi In Gpm Psi Psi Psi or less Psi F
20mm x 1.5 x 120mm 16mm x 1.5 x 50 mm
615 618
12mm x 1.5 x 30mm in. x 3 in
19 mm
72
*** Initial torque is 145 ft/lbs, then cross tighten bolts an additional 180 in 60 increment. 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. Rev PTU 03-10-2003 PPM2000000 Version: 102700 107

Values 1,500 500 - 950 625 - 1,235 12,000 - 28,000 68.9 1,375 29.9 3.5 81.4 0.75 1.00 475 550 3.81 18.5- 28 1,650 100 2,200 75 145 150 Standard High Speed Lbs In Lbs In In Lbs In. BSPP In. BSPP Psi In Gpm Psi Psi Psi or less Psi F
Torque specifications Item Side Bolt Test Plug Link Screws Guide Plug Variable Plug Inflation Screw Accumulator Screw Shell Fixing Screw Under Water Plug Side Plate Screw Self Locking Nut Shock Absorber Bolt Top Cap Bolts Position 307 403 409 418 504 507 506 107 Bolt Size Wrench 30 mm 19 mm 17 mm 30 mm 14 mm Allen 17 mm Allen 14 mm Allen 12 mm Allen Ft/Lbs. *** 29 51 361 36 231 116 145
20mm x 1.5 x 120mm 16mm x 1.5 x 50 mm
615 618
12mm x 1.5 x 30mm in. x 3 in
19 mm
72
*** Initial torque is 145 ft/lbs, then cross tighten bolts an additional 180 in 60 increment. 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 03-10-03 PPM2000000 Version: 102700 108

Values 1,500 450 - 900 560 - 1,170 10,000 - 18,000 54.3 1,045 25.6 3.2 48.4 0.75 0.75 475 - 550 3.81 20 28 1,650 100 2,200 220 290 150 Standard High Speed Lbs In Lbs In In Lbs In. BSPP In. BSPP Psi In Gpm Psi Psi Psi Psi F
20mm x 1.5 x 120mm 16mm x 1.5 x 50 mm
615 618
12mm x 1.5 x 30mm in. x 3 in
19 mm
72
*** Initial torque is 145 ft/lbs, then cross tighten bolts an additional 180 in 60 increment. 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 DS 11-17-03 PPM2000000 Version: 102700 109
MES 1500 (HD) Heavy Duty, (W) Whisper, and (SP) Side Plate
Values 1,750 600 - 1,000 750 - 1,300 22,000 - 42,000 68.9 1,735 29.9 4.3 125 0.75 0.75 475 - 550 21 33 1,850 75 2,350 120 275 150 Standard High Speed Lbs In Lbs In In Lbs In. BSPP In. BSPP Psi Gpm Psi Psi Psi or less Psi F
Torque specifications Item Side Bolt Test Plug Link Screws Guide Plug Variable Plug Inflation Screw Accumulator Screw Shell Fixing Screw Under Water Plug Side Plate Screw Self Locking Nut Side Shock Bolts Top Cap Bolts Position 307 403 409 418 504 507 506 107 Bolt Size Wrench 38 mm 19 mm 10 mm Allen 30 mm 14 mm Allen 17 mm Allen 14 mm Allen 12 mm Allen Ft/Lbs. *** 29 51 361 36 400 145 180
20mm x 1.5 x 120mm 16mm x 1.5 x 50 mm
615 618
14mm x 1.5 x 35mm in. x 3 in
22 mm
108

Values 2,000 600 - 950 750 - 1,235 24,000 - 42,000 80 1,980 37.4 4.5 162.8 0.75 1.00 520 - 620 4.93 22 30 1,900 75 2,400 75 150 150 Standard High Speed Lbs In Lbs In In Lbs In. BSPP In. BSPP Psi In Gpm Psi Psi Psi or less Psi F
Torque specifications Item Side Bolt Test Plug Link Screws Guide Plug Variable Plug Inflation Screw Accumulator Screw Shell Fixing Screw Under Water Plug Side Plate Screw Self Locking Nut Side Shock Bolts Top Cap Bolts Position 307 403 409 418 504 507 506 107 Bolt Size Wrench 38 mm 19 mm 10 mm Allen 30 mm 14 mm Allen 17 mm Allen 14 mm Allen 12 mm Allen Ft/Lbs. *** 29 51 361 36 400 145 180
20mm x 1.5mm x 125mm 16mm x 1.5mm x 50 mm
615 618
14mm x 1.5 x 35mm in. x 4 in
22 mm
108
*** Initial torque is 195 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. Page REV DS 11-17-03 PPM2000000 Version: 102700 111

Values 3,000 500 - 900 625 - 1,125 32,000 - 48,000 83.9 2,640 39.4 4.72 189.2 1.00 1.25 520 - 620 5.17 29 38 1,900 75 2,400 75 150 150 Standard High Speed Lbs In Lbs In In Lbs In. BSPP In. BSPP Psi In Gpm Psi Psi Psi or less Psi F
Torque specifications Item Side Bolt Test Plug Link Screws Guide Plug Variable Plug Inflation Screw Accumulator Screw Shell Fixing Screw Under Water Plug Side Plate Screw Self Locking Nut Shock Absorber Bolts Top Cap Bolts Position 307 403 409 418 504 507 506 107 Bolt Size Wrench 38 mm 19 mm 14 mm Allen 38 mm 14 mm Allen 5/8 Allen 9/16 Allen 12 mm Allen Ft/Lbs. *** 29 130 506 36 434 220 180
x 16 x 2
615 618
14mm x 1.5 x 35mm in. x 4 in
22 mm
108

Values 4,000 400 850 500 - 1,105 32,000 - 54,000 89.8 2,970 41.3 5.1 231 1.00 1.25 520 620 5.62 33 41 1,900 75 2,400 75 150 150 Standard High Speed Lbs In Lbs In In Lbs In. BSPP In. BSPP Psi In Gpm Psi Psi Psi or less Psi F
Torque specifications Item Side Bolt Test Plug Link Screws Guide Plug Variable Plug Inflation Screw Accumulator Screw Shell Fixing Screw Under Water Plug Side Plate Screw Self Locking Nut Shock Absorber Bolts Top Cap Bolts Position 307 403 409 418 438 504 507 506 107 Bolt Size Wrench 38 mm 19 mm 14 mm Allen 38 mm 24 mm 14 mm Allen 5/8 Allen 9/16 Allen 12 mm Allen Ft/Lbs. *** 29 130 506 180 36 434 217 180
x 16 x 2
615 618
14mm x 1.5 x 35mm in. x 4 in
22 mm
108
*** Initial torque is 362 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 DS 11-17-03 PPM2000000 Version: 102700 113

Values 4,500 400 - 700 500 - 910 38,000 - 60,000 96.5 3,850 43.3 5.5 275 1.00 1.25 520 - 620 6.07 38 46 1,900 75 2,400 75 150 150 Standard High Speed Lbs In Lbs In In Lbs In. BSPP In. BSPP Psi In Gpm Psi Psi Psi or less Psi F
Torque specifications Item Side Bolt Test Plug Link Screws Guide Plug Variable Plug Inflation Screw Accumulator Screw Shell Fixing Screw Under Water Plug Side Plate Screw Self Locking Nut Shock Absorber Bolts Top Cap Bolts Position 307 403 409 418 438 504 507 506 107 Bolt Size Wrench 41 mm 19 mm 14 mm Allen 41 mm 24 mm 14 mm Allen 22 mm Allen 17 mm Allen 12 mm Allen Ft/Lbs. *** 29 130 723 180 36 795 325 180
30mm x 2.0mm x 155mm 22mm x 1.5 x 80mm
615 618
14mm x 1.5 x 40mm in. x 4 in
22 mm
108

Values 5,500 350 600 42,000 - 72,000 103.94 4,840 46.06 5.71 347.6 1.00 1.25 520 620 6.22 42 51 2,175 75 2,800 75 125 150
30mm x 2.0mm x 155mm 22mm x 1.5 x 80mm
615 618
14mm x 1.5 x 40mm in. x 4 in
22 mm
108

Values 6,500 400 600 42,000 - 72,000 Lbs 102.4 In 5513 Lbs In 5.9 In Lbs 1.00 In. BSPP 1.25 In. BSPP 520 620 Psi 6.22 In 47.5 61 Gpm 2,175 75 Psi 2,800 Psi 75 Psi or less 125 Psi 150 F
30mm x 2.0mm x 155mm 22mm x 1.5 x 80mm
615 618
14mm x 1.5 x 40mm in. x 4 in
22 mm
108

Technical Specifications Technical Specifications Energy Class Blows Per Minute Carrier Weight Total Height Working Weight Length Of Tool Diameter Of Tool Tool Weight H.P. Fitting Size L.P. Fitting Size Accumulator Charge Maximum Lower Bushing ID * Required Flow @ Operating Pressure * Operating Pressure * Circuit Relief * Preferred Maximum Backpressure Allowable Maximum Backpressure * Oil Temperature For Setting Flows & Pressures
Values 7,500 350 - 500 56,000 - 100,000 111.4 5,940 52 6.3 440 1.25 1.50 520 - 620 6.89 50 67 2,175 75 2,800 75 125 150
30mm x 2.0mm x 155mm 22mm x 1.5 x 80mm
615 618
16mm x 1.5 x 40mm 1 in. x 5 in
22 mm
231
*** 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.
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Technical Specifications Technical Specifications Energy Class Blows Per Minute Carrier Weight Total Height Working Weight Length Of Tool Diameter Of Tool Tool Weight H.P. Fitting Size L.P. Fitting Size Accumulator Charge Maximum Lower Bushing ID * Required Flow @ Operating Pressure * Operating Pressure * Circuit Relief * Preferred Maximum Backpressure Allowable Maximum Backpressure * Oil Temperature For Setting Flows & Pressures
Values 10,000 350 - 500 70,000 - 130,000 126 7,700 57.1 7.1 616 1.25 1.50 520 - 620 63 80 2,210 75 2,900 75 125 150
Lbs In Lbs In In Lbs In. BSPP In. BSPP Psi Gpm Psi Psi Psi or less Psi F
Torque specifications Item Side Bolt Test Plug Link Screws Guide Plug Variable Plug Inflation Screw Accumulator Screw Shell Fixing Screw Under Water Plug Side Plate Screw Self Locking Nut Shock Absorber Bolts Top Cap Bolts Position 307 403 409 418 438 504 507 506 107 Bolt Size Wrench 46 Mm 19 Mm 14 mm Allen 41 Mm 24 Mm 14 mm Allen 27 mm Allen 19 mm Allen 12 mm Allen Ft/Lbs. *** 29 130 723 180 36 1085 362 180
36mm x 2.0mm x 180mm 24mm x 2.0 x 90mm
615 618
20mm x 1.5 x 50mm 1 in. x 6 in
30 Mm
231
*** Initial torque is 651 ft/lbs, then cross tighten bolts an additional 180 in 60 increment. 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.
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Values 12,000 350 450 80,000 - 160,000 132.3 9,900 60.2 7.7 770 1.25 1.50 520 620 8.44 77 94 2,325 75 2,900 75 125 150
36mm x 2.0mm x 180mm 24mm x 2.0 x 90mm
615 618
20mm x 1.5 x 50mm 1 in. x 6 in
30 mm
231
*** Initial torque is 723 ft/lbs, then cross tighten bolts an additional 180 in 60 increment. 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.
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Values 16,000 325 - 400 120,000 - 240,000 137.8 15,730 62.1 8.5 902 1.25 1.50 520 - 620 86 - 111 2,325 75 2,900 75 125 150
Lbs In Lbs In In Lbs In. BSPP In. BSPP Psi Gpm Psi Psi Psi or less Psi F
27mm x 2.0 x 110mm
615 618
20mm x 1.5 x 50mm 1 in. x 6 in
30 mm
231
*** 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.
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APPENDIX B Compactor Technical Specifications IHC 30

Technical Specifications Technical Specifications Optional Shipping Weight 270 Lbs Height 25 In Width 11 In Base Plate Size 11 X 23 X In Low Flow 7 Gpm @2000 Psi Centrifugal Force Low 2,500 Lbs Frequency Low 2,000 Vpm High Flow 11Gpm @2000 Psi Centrifugal Force High 6,700 Lbs Frequency High 3,000 Vpm Carrier Weight 2,100 12,000 Lbs Oil Reservoir Capacity 0.34 Gal Oil Type HD80-90 Standard 270 Lbs 25 In 11 In 11 X 23 X In 11Gpm @2000 Psi 2,700 Lbs 2,100 Vpm 17Gpm @2000 Psi 6,700 Lbs 3,000 Vpm 2,100 12,000 Lbs 0.34 Gal HD80-90 Optional 270 25 11 11 X 23 X 17Gpm@2000 3,300 2,200 24Gpm@2000 6,700 3,000 2,100 12,000 0.34 HD80-90 Lbs In In In Psi Lbs Vpm Psi Lbs Vpm Lbs Gal
NOTE: External drain line must be connected to in NPT case drain plug if the back pressure exceeds 100 PSI.
IHC 65
Technical Specifications Technical Specifications Shipping Weight Height Width Base Plate Size Low Flow Centrifugal Force Low Frequency Low High Flow Centrifugal Force High Frequency High Carrier Weight Oil Reservoir Capacity Oil Type Motor Gear Size Optional 790 Lbs 26 In 23 In 23 X 26 X 1 In 18Gpm @2000 Psi 3,375 Lbs 1,250 Vpm 30Gpm @2000 Psi 9,375 Lbs 2,100 Vpm 9,000 16,000 Lbs 1.23 Gal HD80-90 1.25 In
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IHC 130
Technical Specifications Technical Specifications Shipping Weight Height Width Base Plate Size Low Flow Centrifugal Force Low Frequency Low High Flow Centrifugal Force High Frequency High Carrier Weight Oil Reservoir Capacity Oil Type Motor Gear Size Optional 1,500 Lbs 34 In 23 In 23 X 32 X 2 In 30Gpm @2000 Psi 18,900 Lbs 2,100 Vpm 34Gpm @2000 Psi 24,000 Lbs 2,350 Vpm 16,000 43,000 Lbs 1.27 Gal HD80-90 1.25 In
IHC 200
Technical Specifications Technical Specifications Shipping Weight Height Width Base Plate Size Low Flow Centrifugal Force Low Frequency Low High Flow Centrifugal Force High Frequency High Carrier Weight Oil Reservoir Capacity Oil Type Motor Gear Size Optional 2,500 Lbs 34 In 35 In 35 X 37 X 2 In 45Gpm @2000 Psi 12,480 Lbs 1,500 Vpm 55Gpm @2000 Psi 18,650 Lbs 1,900 Vpm 43,000 100,000 Lbs 2.46 Gal HD80-90 2.25 In
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APPENDIX C Chuck Housing Specifications
Figure C-01: Chuck Housing Specifications Breaker Model(S)

MES 181& MES 200 300 Series Breakers 500 Series Breakers 600 Series Breakers MES 1050 & MES 1200 MES 1500 MES 1750 MES 1800 MES 2000 MES 2500 MES 3000 MES 3500 MES 4000 MES 5000 MES 7000 MES 8500 MES 12000
Dimension A Dimension B Dimension C Dimension A Dimension D

In 4.53 5.31 5.91 6.69 7.09 8.07 8.27 8.66 8.66 9.45 10.63 10.63 11.42 11.81 12.99 14.17 16.54 mm 115 135 150 170 180 205 210 220 220 240 270 270 290 300 330 360 420 In 7.28 8.27 8.94 9.06 11.61 11.69 15.91 17.52 17.32 19.80 20.20 23.03 22.05 25.79 27.36 27.95 26.77 mm 185 210 227 230 295 297 404 445 440 503 513 585 560 655 695 710 680 In 11.61 11.38 14.57 13.58 17.32 17.72 22.05 23.62 23.62 25.91 25.98 28.35 27.76 33.46 35.43 37.01 37.01 mm 295 289 370 345 440 450 560 600 600 658 660 720 705 850 900 940 940 In 3.54 4.33 5.91 4.72 5.91 5.75 7.64 8.66 8.66 9.65 9.25 10.63 10.24 11.02 11.81 12.60 12.60 mm 90 110 150 120 150 146 194 220 220 245 235 270 260 280 300 320 320 In 3.07 3.70 4.33 5.04 5.31 6.61 7.01 7.28 7.48 7.72 8.86 8.86 8.86 9.37 10.83 11.81 14.02 mm 78 94 110 128 135 168 178 185 190 196 225 225 225 238 275 300 356
Table C-01: Chuck Housing Specifications
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APPENDIX D
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APPENDIX E
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APPENDIX F Breaker Mounting Bracket Specifications
Figure F-01: Mounting Bracket Specifications MES 181 through MES 1200
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Figure F-04: Mounting Bracket Specifications MES 5000 through 8500

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Figure F-05: Mounting Bracket Specifications MES 12000
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APPENDIX G HARDOX and WELDOX Welding

SSAB Oxelsund steel grades in HARDOX wear plate and WELDOX high strength structural plate 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 welding methods. When HARDOX plate is welded, the objectives 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, the objectives are: 1. To obtain proper strength in the welded joint. 2. To achieve good toughness of the welded joint.
Figure G-01: Factors that affect the mechanical properties of the welded joint Steel Grade A 572-50 WELDOX 100 WELDOX 130 WELDOX 160 WELDOX 400 WELDOX 500 Thickness range 3/16 4 in. 5/32 5 in. 5/32 3 in. 3/16 1 in. 5/32 5 in. 3/16 3 in. Carbon equivalent CE (IIW) 0.39 - 0.43 0.39 - 0.64 0.56 0.68 - 0.72 0.36 - 0.70 0.58 - 0.68
HARDOX and WELDOX have low carbon equivalents for their strength class. A steel with a low carbon equivalent (CF) has better weldability than a steel with a high value. Typical CE values for a particular plate thickness are given in our data sheets. The carbon equivalent (according to the IIW) can be calculated from the following equation:
CE = C +
Mn Cr + Mo + V Cu + Ni + + 6 5 15
Table G-01: Typical CE values for a particular plate thickness
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.
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3. minimizing the shrinkage stresses. This can be achieved by good fit between the workpieces and a well planned sequence of weld runs (balanced welding). 4. selecting a filler material with low hydrogen content. Preheating Preheating is most important in tack welding and in welding of the root pass. The higher the temperature during and after welding, the easier it will be for the hydrogen to escape from the steel. The need for preheating increases with the plate thickness, (see the table on the next page) in order to compensate for the faster cooling of thick plate, and because thick plate has a higher CE value than thinner plate. If the ambient humidity is high and/or the temperature is below 40 F, the tabulated value should be increased by 80 F. Correspondingly, the temperature should be increased if the workpiece being welded is rigidly restrained. If different steel grades are welded together or if the consumables used for welding have a higher CE than the parent material, the necessary preheating is determined by the steel (or consumable) with the highest carbon equivalent. Post-heating Poat-heating of the welded joint immediately after welding also makes it casier for hydrogen to escape from the steel. The post-heating temperature should not be the same as the preheating temperature. The soaking time should not be at least 30 minutes per inch of plate thickness, although not less than one hour.
Table G-02: Recommended preheating temperatures* for different combined plate thicknesses [inch]
Table G-03: Recommended interpass temperature
*) The recommended workpiece temperatures are based on the assumption that: - the hydrogen content does not exceed 3/4 floz per pound of weld metal - the heat input is approximately 43 kJ/inch **) The filler material determines the preheating temperature if its carbon equivalent is higher than that of the plate.
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Figure G-02: HARDOX Measure Temperature
Figure G-03: HARDOX Weld Preparation
Figure G-04: HARDOX Plate Thickness
Post-treatment
Post weld heat treatment (PWHT) PWHT is carried out to reduce the residual stresses after welding. WELDOX should be post weld heat treated only if this is specified in the design rules. HARDOX and WELDOX I60 must not be subjected to PWHT Measures to increase the fatigue strength The fatigue strength of a welded joint can be increased by various types of post-treatment. Such treatments give a smoother transition between the weld and plate and lower the stress concentrations. For further information, please consult the Handbook on Welding of Oxelsund steels.
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 the heat affected zone (HAZ).
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Increased strength of welded joint Better toughness of the HAZ Narrower soft zone Higher productivity
Decreasing heat input
Increasing heat input
Figure G-05: Recommended max. heat input when welding HARDOX 400 and HARDOX 500
Figure G-06: Hardness profile HARDOX 400
Figure G-07: Recommended max. heat input when welding WELDOX
To Calculate the Heat Input

Q= * U * I * 60 v * 1000 Welding method Manual metal arc (MMA) Gas metal arc (MIG / MAG) Flux cored arc ( FCAW) Submerged arc (SAW) TIG (GTAW) Arc efficiency factor 0.8 0.8-0.9 0.9 1.0 0.7
Q = Heat input [kJ/inch] U = Voltage [V] I = Current [A] v = Welding speed [inch/min] = Arc efficiency factor
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Table G-04: Arc efficiency factor

132
Selection of Filler Material *

All conventional arc welding methods intended for welding ordinary and high strength plate can be used for welding HARDOX and WELDOX. The choice of filler material is determined by the demands made on the mechanical properties of the welded joinr in each individual case. Basic consumables should be used for welding HARDOX and WELDOX. Choose a filler material which gives a hydrogen content of floz per pound in the weld metal. The following alternatives are available when selecting the yield strength of the filler material: 1. Undermatching weld metal (the weld metal has a lower yield strength ** than the parent material). 2. Matching weld metal (the weld metal and parent material have the same yield strength **. 3. Overmatching weld metal-(the weld metal has a higher yield strength than the parent material). When steel grades in the range from WELDEX IOO to WELDEX I60 are welded, it is advisable to consumables with different degrees of matching, e.g. soft consumables in the root run and consumables of higher strength in the filler beads. *) See figure G-13 for a list of AWS classes for filler material. **)This refers to the nominal minimum value of the yield strength. The major benefits of selecting lowstrength filler material rather than highstrength filler material (yield stregth in excess of 70 ksi) are: 1. higher toughness of the weld metal, 2. improved ductility of the welded joint, 3. reduced sensitivity to cracking For fillet welds, it is always advisable to select undermatching filler materials. HARDOX should be welded with soft basic consumables. A soft consumable is filler material with a yield strength of 70 ksi or below. Such consumables reduce the residual stress level in the joint and thus its sensitivity to cold cracking. If the weld is Iocated so that it is subjected to heavy wear, hard facing consumables can be used for the cap beads.
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WELDOX 100 WELDOX130 WELDOX160 HARDOX 400 / 500
Matching / Undermatching Undermatching Undermatching Undermatching
Table G-05: Recommended degree of matching when HARDOX and WELDOX steels are welded
Figure G-08: Recommendations on storage of the filler material

133
HARDOX can very successfully be welded with austenitic stainless steel filler material in the following cases: 1. if the workpiece is rigidly restrained 2. if the workpiece cannot be preheated 3. if the plate is thicker than 2 inch In order to prevent moisture absorption, the filler material should be stored in accordance with the manufacturers recommendations. If there is a risk of moisture having been absorbed, the filler material must be scrapped or re-dried in accordance with the manufacturers 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 and by employing suitable welding parameters. Welding can then be carried out within the limits specified by the relevant standards, without the need for removing the primer. HARDOX and WELDOX plate can be delivered with a corrosion protecting low zinc silicate primer. 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 towards improved productivity in the workshop. If the plate is anti-corrosion coated with PVB (polyvinyl butyral) or an epoxy primer, the paint should 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 well ventilated.
Ar (inert gas)
Ar / CO2
(active gas) CO2
High porosity of the weld metal. Stable arc.
Low porosity. Weld spatter / clogging of welding nozzle.
Figure G-09: Effect of the shielding gas on the porosity of the weld metal in FCAW, MIG / MAG welding of plate painted with low zinc silicate primer.
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Figure G-10: Recommendations for ensuring good weld quality when welding HARDOX and WELDOX painted with low zinc silicate primer.
Stud Welding
HARDOX arid WELDOX are very well suited for stud welding and need not be preheated for welding at room temperature. Stud welding can be carried out directly on the following surfaces, 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 as drilling, countersinking and tapping. The procedure is simpler than traditional welding and can be carried out even by personnel who are not trained welders. Figure G-13: Stud welding method Stud welding provides a more protected installation than the use of countersunk head screws or bolts screwed into tapped holes. This reduces the necessary wear allowance and increases the useful life. Figure G-12: Installation provided by stud welding method
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Figure G-13: General recommendations for selection of filler material for welding HARDOX and WELDOX steels 1. Basic flux should always be employed in FCAW, SAW and MMA welding 2. The impact toughness of the weld metal should be at least the same as that of the plate 3. Always use a filler material with low hydrogen content (HD floz per pound). For more detailed information, please refer to the Handbook on Welding of Oxelsund steels which can be obtained from us free of charge. You are also welcome to get in touch with one of our application engineers who will be pleased to provide advice and recommendations concerning welding, selection of materials, machining and other working, and surface treatment.
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APPENDIX H Breaker Parts Explosions

MES 121 and MES 150
Figure H-01: Exploded Parts for MES 121 and MES 150
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MES 181 AND MES 200
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MES 300 THROUGH MES 553
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MES Service Manual

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PPM2000000 $35.

INDECO Hydraulic Breaker

Service and Maintenance Manual

IMPORTANT SAFETY NOTICE

IV. Routine Maintenance .... 19

VI. Accumulator Removal and Rebuilding ........... 32

VII. Disassembly of the Breaker ...................................................... 43

VIII. Assembling the Breaker ................................................................. 56

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

Information Request Forms for Hydraulic Kits .......................... 76

XI. Power Lubrication Systems ....................................... 78

XII. Under Water Kits........................................................................ 92

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

Figure 01-01: Testing Excavator Circuit Flow and Pressure

Figure 01-03: Flow Meter and Pressure Gauge Connection

Figure 01-04: Testing Skidsteer Loaders Circuit Flow and Pressure

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

II. GENERAL BREAKER USAGE

General Breaker Usage

Figure 02-02: Keep Tool Perpendicular to Working Surface

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Figure 02-04: Insufficient Downward Pressure Results in Vibrations

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Figure 02-05: Reposition Breaker Every 30 Seconds

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Figure 02-06: Lower Breaker Every Hour When Working Overhead

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Common Causes of Breaker Damage

COMMON CAUSES OF BREAKER DAMAGE

Figure 03-01: Dont Use Breaker as a Ripper, Lever or Crane

Figure 03-02: Operate Breaker Free and Clear of Obstructions

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Figure 03-03: Maintain Hard Stable Working Surface

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

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Figure 03-06: Do Not Rotate Carrier on the Breakers Tool

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IV. ROUTINE MAINTENANCE

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INDECO GREASING REQUIREMENTS

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Figure 04-01: MES 121 and MES 150 Lube Points

Figure 04-02: MES 181 through MES 553 Lube Points

Figure 04-04: MES 601 and MES 651 Lube Points

Figure 04-06: MES 1050 and MES 1201 Lube Points

Figure 04-09: MES 12000 HD and Whisper Lube Points

Checking and Adjusting HD Casing to Breaker Clearance

4. Using a suitable pry bar, pry the Chuck

5. Pry the Chuck Housing up towards the top of

6. If the reading is greater than 1.5 mm (0.060)

7. Fabricate a Spacing tool using electrical

Figure 04-10: Measuring Breaker to Case Clearance

Table 04-02: Breaker Spacing Tool Dimensions

Figure 04-11: Breaker Spacing Tool from Bottom Case

Figure 04-12: Breaker Spacing Tool from Inside Case

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Lower Bushing and Insert Inspection

2. Measure the inside diameter of the Lower Bushing

3. If the Chuck Bushing (Position 102) or the Insert

Figure 04-15: Remove Insert Snap Ring

Figure 04-16: Remove Insert

Figure 04-17: Universal sleeve puller

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