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MES Service Manual PDF
MES Service Manual PDF
$35.00
REV 11-17-2003
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.
Do not perform any maintenance on INDECO attachments until you have read
and understand the procedures as described in the Service and Maintenance
Manual.
Preface.. 7
I. Breaker Installation.... 8
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
XIII. Compactors. 94
Installing of Flow Regulating Valve for INDECO IHC65 and IHC 130
Compactors.... 94
Compactor Eccentric Assembly Procedure.. 95
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.
BREAKER INSTALLATION
Figure 01-03: Flow Meter and Pressure Figure 01-04: Testing Skidsteer Loaders
Gauge Connection 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.
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.)
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)377-
7791 for assistance if required.)
6. Adjust the circuits flow to the required specification. (NOTE: It is better to be 5-10% under
the required GPM then to be over.)
7. Bring the pressure on the flow meter up to the high pressure reading for the attachment 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.)
9. Install the breaker and connect a 0-3000 psi gauge into the inlet port of the attachment.
(There is a 19 mm plug in the upper link which is the pressure circuit.) Connect a 0-600 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)
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.
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.
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.
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.
d) If the hammer is in the correct position, and the hammer and case are vibrating (Figure 02-
04), the downward pressure from the carrier is insufficient. If exerting further pressure from
the carrier does not solve the problem, it may be that internal hydraulic leaks from the rams
or valves may not be allowing the carrier to exert the correct amount of pressure. In this
case, replace the carrier cylinder seals and/or check the control valve seals.
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.
i) In a quarry, or when breaking oversized rocks, position the material to be broken on a hard
base to minimize vibrations of the material.
j) In the case of horizontal or upside-down operations (e.g. tunnels), once every hour 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.
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).
SUMMARY OF INSTRUCTIONS
Figure 02-07: Store
a) Maintain even pressure on the hammer. Breaker in an Upright
b) Follow the hammer during penetration of the material. Position
c) Always maintain a constant optimal pressure level.
d) Correct loading ensures hammer productivity and avoids damage to
its component.
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.
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.
ROUTINE MAINTENANCE
Daily
Grease breaker every 2 hours. If working in very dusty conditions, grease each hour.
Check cradle, side shocks and side bolts for loose, cracked or missing bolts.
Check tightness of tool retainers, locking bolts and under water plug (POS 107)
Examine hydraulic hoses for leaking or chaffing.
Visually inspect breaker for housing or side plate damage.
Weekly
500 HOURS
1000 Hours
* ATTENTION *
INDECO GREASING REQUIREMENTS
WARNING !!! A coating of grease must be maintained
between the tool and the bushing of the breaker in order to
avoid damage and eventual failure of the breaker.
The amount of grease necessary to maintain
proper lubrication of the tool 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!
Figure 04-01: MES 121 and Figure 04-02: MES 181 through Figure 04-03: MES 181 through
MES 150 Lube Points MES 553 Lube Points MES 553 HD and Whisper Lube
Points
Figure 04-04: MES 601 and Figure 04-05: MES 621HD and Figure 04-06: MES 1050 and
MES 651 Lube Points MES 650 HD and Whisper Lube MES 1201 Lube Points
Points
Figure 04-07: MES 1050HD Figure 04-08: MES 1500 and Figure 04-09: MES 12000 HD
and MES 1200HD and Whisper MES 8500 HD and Whisper and Whisper Lube Points
Lube Points Lube Points
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).
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)
Figure 04-11: Breaker Spacing Tool Figure 04-12: Breaker Spacing Tool from
from Bottom Case 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 )
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 Figure 04-16: Remove Insert Figure 04-17: Universal
Insert Snap Ring sleeve puller
Tool Selection
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.
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 above-
mentioned stress on the tool as well as the thermal damage created by the friction of the
tool and lower bushing.
Matching a small breaker to a carrier larger than hammer specification creates high stress
conditions on the tool.
Operators are not always skillful in using the breaker. Visibility problems, site conditions and
the use of the point to move materials can set up surface fractures in the tool. Breakage
may not occur immediately but the conditions are now in place for a future failure.
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.
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
a) In order to install the tool, insure that the retaining axles (Position 108) are not in their
locked position. (Figure 05-09)
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.
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)
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.
PPM2000000 Version: 102700 31
VI. Accumulator Removal and Rebuilding
Safety Instructions
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.
PPM2000000 Version: 102700 32
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.
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:
2. Loosen and remove the Self Locking Nuts (Position 314) and Shell Fixing Screws (Position
506). (Figure 06-03)
5. Reassemble the Accumulator and torque to the required specification. (Figure 06-05)
6. Install a new O-ring (Position 505) on the Inflating Screw and wrap Teflon tape around 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).
PPM2000000 Version: 102700 35
Accumulator Rebuilding MES 181 and 200
1. Carefully discharge the accumulator and remove the Inflating Screw (Position 504) and O-
ring (Position 505).
2. Using four (4) 12 mm -1.75 x 30 mm bolts, install fabricated tool onto the Upper Shell Half
(Position 502) and remove the Upper Shell Half from the Head (Position301). (Figure 06-06)
Note: The tool is fabricated using an old socket and a flat piece of steel plate. Mark and drill 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)
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.
8. The Accumulator is ready to be charged with nitrogen. (See Nitrogen Recharge Section 6
Page 41).
ATTENTION:
The accumulator charging
Specifications for all
INDECO
Breaker accumulators are:
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 Figure 06-11: Lift Off Accumulator MES
MES 300 and Up 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
PPM2000000 Version: 102700 38
6. Unscrew the Shell Fixing Screws (Position 506) to open the Accumulator. (Figure 06-13)
Use an Allen wrench, as per the Torque Specifications.
Figure 06-13: Loosen and Remove Accu- Figure 06-14: Replace Diaphragm MES
mulator Shell Fixing Bolts MES 300 and Up 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.
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 Figure 06-16: Lubricate Accumulator Bolts
MES 300 and Up
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 Figure 06-18: Install and Figure 06-18: Install and
Torque Accumulator MES Torque Accumulator MES Torque Accumulator MES
121 181 and MES 200 300 and Up
ATTENTION:
The accumulator charging
Specifications for all
INDECO
Breaker accumulators are:
1. Carefully install the Pressure Reducer/Regulator assembly into the nitrogen tank, following
the safety instructions. (Figure 06-20) The nitrogen bottle must not have a level below 45
bars (652.5 psi).
2. Attach the Rubber Hose to the Pressure Reducer/Regulator and the nitrogen tank valve.
3. Attach the Inflating Body so the hexagonal pin fits inside the Inflating Screw (Position 504).
(8 mm HEX on Breakers up to 300 Series; 14 mm HEX on Breakers 500 Series and up).
Check the O-Ring on the sealing face. (Figure 06-21)
Figure 06-20: Assemble and Install Figure 06-21: Attach and Install Inflation
Pressure Regulator Onto Nitrogen Tank Body
4. Install the Inflating Body to the Accumulator. (Figures 06-22, 06-23 and 06-24)
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.
ATTENTION:
The accumulator charging
Specifications for all
INDECO
Breaker accumulators are:
Note: On MES 121 and MES 150 Breakers there are only eight (8) bolts attaching the side
plates.
Figure 07-01: Remove Side Plates Figure 07-02: Loosen Side Plates
MES 121 and MES 150 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.
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 Figure 07-05: Remove High and Low
Bracket and Top Shock Holder 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 Figure 07-07: Remove Grease Fittings
Fitting From Case
PPM2000000 Version: 102700 44
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 Figure 07-09: Remove Breaker From
Case 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 Figure 07-11: Place Breaker in Suitable
Breaker Up Tear Down Stand
2. Lift the Head Assembly (Position 301) from the Chuck Housing (Position 101). (Figure 07-
13)
2. Remove the side bolts (Pos 307) from the head (Pos 301). (Figure 07-15)
2. Install accumulator bolts into the Head Assemble (Position 301) and using a puller as
shown, remove the Head Assembly. (Figure 07-02)
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)
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.
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).
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)
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)
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.
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 07-
32)
Figure 07-31: Weld Plate on Lower Chuck Figure 07-32: Press Out
Bushing or Insert Holder Lower Chuck Bushing or
Insert Holder
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 07-35: Remove Pressure regulating Figure 07-36: Extract Pressure regulating
Valve Guide Plug Valve Spring
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 Figure 07-38: Remove Pressure regulating
Valve Piston Valve Barrel
Figure 07-39: Remove Frequency Valve Figure 07-40: Remove Frequency Valve
Guide Plug Spring
3. Take out the Needle (Positions 432). and check for wear.
5. Clean the Valve body, replace the O-Ring (Position 436) and set aside the assembly.
Figure 07-41: Remove Frequency Valve Figure 07-42: Remove Frequency Valve
Body Body
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)
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 Figure 08-04: Install Upper Bushing
Insert Holder Nylon Plug
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
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.
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
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 Figure 08-14: Insert Cylinder Centering
the Cylinder 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)
2. Insert the Slide (Position 413) into the same central hole. (Figure 08-18)
Figure 08-17: Install Pressure Regulating Figure 08-18: Install Pressure Regulating
Valve Barrel. 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)
2. Lubricate all sliding areas between the Box Body Cover and the Head. (Figure 08-22)
Figure 08-21: Install O-ring Into Breaker Figure 08-22: Lubricate Sliding Areas
Head
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)
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)
PPM2000000 Version: 102700 62
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 Figure 08-26: MES Figure 08-27: Insert Bolts Into
and MES 150 Side Rods 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 Figure 08-29: Install Check Mushroom
Blow to Drive Head Valve/ Steel Diaphragm
Figure 08-30: Assemble and Tighten Figure 08-31: Tighten Side Bolts with a
Side Bolts 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.
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 Figure 08-34: Install Rubber
to Tighten Side Rods Stops on Side Bolts
12. Install the Accumulator. (See Accumulator Removal and Rebuilding - Section 6 Page 32).
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.
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 Figure 08-37: Install Side Plates
MES 121 and MES 150 MES 181 and Up
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)
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)
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 Figure 08-44: Install High and Low
Pressure Links 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)
c. Are both shut-offs on the carrier, if present, both in the full on position? __________
Are the male and female ends of the same manufacturer and type? _____________
Have you by-passed the couplers using a direct hose connection? ______________
INITIAL READINGS
FINAL READINGS
g. Do the whip hoses appear to have fluid flowing through them? _________________
i. With the carrier at an idle, remove the tool and verify that the piston is moving._____
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.
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.
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.
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.
PPM2000000 Version: 102700 73
6. Disassemble the tool and, looking into the upper bushing, check that the piston is
completely free.
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
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. 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.
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
that the oil viscosity is good; if necessary, change the oil.
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.
10. If the problem cannot be resolved, call INDECO North America at (203) 377-7791 for
assistance.
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.
4. If the problem cannot be resolved, call INDECO North America at (203) 377-7791 for
assistance.
Figure 10-01: Pin to Pin Dimensions for Tractor Loader Backhoes (TLB)
a. Manufacturer:______________________________________________________________
a. Manufacturer:______________________________________________________________
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.
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 micro-
switch. Make sure that all pressure is RELEASED.
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.
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 11-
03). 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 Figure 11-03: Special
piston actually pushes the ball off its seat, the armature Adjustments
should be turned in (clockwise, from top) to shorten the
stroke.
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 (Vise-
Grip C-Clamp works well to hold the armature while tightening the nuts).
Green Screw
Ground 24V (+)
(G) (X) x
G
w
12V (+) Trip Wire Y
(Y) (W)
Figure 11-05: Looking at female connector, Figure 11-06: Looking from rear of
plug side. female connector.
Wiring instructions for the INDECO 24Volt - 2 Speed Electric Grease Pump
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.)
(+) (+)
Ground
24V-DC
Solenoid
Mounting Bolts
P
G
To Excavator -4 Male JIC
Port for Pressure
Chassis/Frame Fittings
Gauge
Ground
(Optional)
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.
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.
Lincoln Industrial
Foreign and U.S. Patent Pending
This pump conforms to the European Directive for Product
Safety
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.
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.
PPM2000000 Version: 102700 84
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.
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.
* Tested with NLGI #2 grease and 1,000 PSI (68 bar) backpressure at 5 gpm (19 I/pm)
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.
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
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.
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.
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).
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.
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)
5. Start the breaker and then shut-off the compressor. If the breaker does not stop check the
pressure switch for continuity.
2. Determine operating depth of hammer and note the value in the Depth Column (Figure 12-
02).
3. Start the compressor and charge the breaker with air to the appropriate value in the Shut-
off Pressure on Pressure Switch column (Table 12-01). At this point the tester should
indicate continuity or a reading greater than zero. If there is no reading the switch may be
bad and should be replaced.
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.
Port 2
SAE O-ring
x JIC Bulkhead
fitting
INDECO Flow Control Valve
Port 1
Pressure
Inlet
JIC Bulkhead
fitting
Hose
NOTE: Flow Control from
Valve may be mounted in Return
either the upper or the
motor
Outlet
lower hole of the
Compactor Mounting
Bracket.
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.
4. Install Eccentric (A), Bearing (D) and Retainer (B) into motor-side of Housing (J).
6. Install Adjustment-side Bearing retainer (C) onto Adjustment-side Bearing (E) and into
Housing (J).
7. Install two adjustment bolts (G) without washers into Adjustment-side Bearing retainer (C)
and tighten until bolts stop turning and there is no longer a gap at point (I). Do not use air
gun!
8. At this point measure the distance (K) between the head of the Adjustment bolts (G) and
the Adjustment-side Bearing retainer (C).
9. 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.
Torque specifications
Technical Specifications
Torque specifications
Technical Specifications
Torque specifications
Technical Specifications
Torque specifications
Technical Specifications
Torque specifications
Technical Specifications
Torque specifications
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Torque specifications
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Torque specifications
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Torque specifications
Technical Specifications
Torque specifications
Technical Specifications
Torque specifications
Technical Specifications
Torque specifications
Technical Specifications
Torque specifications
Technical Specifications
Torque specifications
Technical Specifications
Torque specifications
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Torque specifications
Technical Specifications
Torque specifications
Technical Specifications
Torque specifications
Technical Specifications
Torque specifications
Technical Specifications
Torque specifications
Technical Specifications
Torque specifications
Technical Specifications
Torque specifications
Technical Specifications
Torque specifications
Technical Specifications
Torque specifications
Technical Specifications
Torque specifications
Technical Specifications
NOTE: External drain line must be connected to in NPT case drain plug if the back pressure
exceeds 100 PSI.
IHC 65
Technical Specifications
NOTE: External drain line must be connected to in NPT case drain plug if the back pressure
exceeds 100 PSI.
REV 01-30-01
Technical Specifications
NOTE: External drain line must be connected to in NPT case drain plug if the back pressure
exceeds 100 PSI.
IHC 200
Technical Specifications
NOTE: External drain line must be connected to in NPT case drain plug if the back pressure
exceeds 100 PSI.
REV 01-30-01
Figure F-01: Mounting Bracket Specifications MES 181 through MES 1200
Figure F-02: Mounting Bracket Specifications MES 621 through MES 2000
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.
**) The filler material determines the preheating temperature if its carbon equivalent is higher
than that of the plate.
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
Figure G-05: Recommended max. heat Figure G-06: Hardness profile HARDOX 400
input when welding HARDOX 400 and
HARDOX 500
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).
If the weld is Iocated so that it is subjected Figure G-08: Recommendations on storage of the
to heavy wear, hard facing consumables filler material
can be used for the cap beads.
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.
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.
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.
Stud Welding
HARDOX arid WELDOX are very well suited for stud welding
and need not be preheated for welding at room temperature.
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.
Figure H-01: Exploded Parts for MES 121 and MES 150
Figure H-02: Exploded Parts for MES 181 and MES 200
Figure H-03: Exploded Parts for MES 300 and MES 553
Figure H-04: Exploded Parts for MES 601 and MES 3000
Figure H-05: Exploded Parts for MES 3500 and MES 12000