PPM2000000

$35.00

INDECO Hydraulic Breaker

Service and Maintenance Manual

REV 11-17-2003

PPM2000000 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..... 2

Preface.. 7

I. Breaker Installation.... 8

II. General Breaker Usage..... 12

III. Common Causes of Breaker Damage ......... 16

IV. Routine Maintenance .... 19

Daily, Weekly, 500 Hours, 1000 Hours.. 19
Breaker Lubrication... 20
Checking and Adjusting HD Casing to Breaker Clearance 22
Lower Bushing and Insert Inspection. 24

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 ....................................................................... 56
Cylinder Assembly ............................................................................... 58
Pressure Regulating Valve Assembly........................................... 60
Frequency Valve Assembly ........................................................................ 61
Breaker Head Assembly ...................................................................... 62
Breaker Side Plate Assembly .......................................................... 67
Assembly of Breaker Case and Mounting Bracket .................................. 68
Assembly of Pressure and Return Links ..................................................... 70

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

Checklist for Accurate Breaker Problem Diagnosis..... 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

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

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

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

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PPM2000000 Version: 102700 6
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 Figure 01-02: Testing Tractor Loader

Circuit Flow and Pressure Backhoe Circuit Flow and Pressure

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.

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)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.

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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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PPM2000000 Version 031003
Figure 01-05: Sample Attachment Delivery Report (ADR)
 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 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.

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) 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.

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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
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.

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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 re-
sharpened 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 Figure 03-03: Maintain Hard
housing, and blow out the hammer with
Stable Working Surface
compressed air.

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

ROUTINE MAINTENANCE
Daily

Grease breaker every 2 hours. If working in very dusty conditions, grease each hour.
Check cradle, side shocks and side bolts for loose, cracked or missing bolts.
Check tightness of tool retainers, locking bolts and under water plug (POS 107)
Examine hydraulic hoses for leaking or chaffing.
Visually inspect breaker for housing or side plate damage.

Weekly

Remove tool and wash out tool cavity with solvent.

Inspect upper and lower bushings, retaining axles and face of piston for cracks, uneven
wear or mushrooming.
Before inserting tool, re-apply grease to upper, lower bushings, and retaining axles.
Re-insert greased tool after rotating 180 degrees from original position and secure 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.

* 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!

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 Lube Points

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

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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 Figure 04-10: Measuring Breaker to Case
dimensions) Clearance

Breaker Model(s) Tool Breaker Model(s) Tool

Length Length
In. mm In. mm
600 Series Breakers 6.69 170 MES 3000 10.63 270
MES 1050 & MES 1200 7.09 180 MES 3500 10.63 270
MES 1500 8.07 205 MES 4000 11.42 290
MES 1750 8.27 210 MES 5000 11.81 300
MES 1800 8.66 220 MES 7000 12.99 330
MES 2000 8.66 220 MES 8500 14.17 360
MES 2500 9.45 240 MES 12000 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 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 )

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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 Figure 04-14: Measuring the Lower
hydraulic press. (See Disassembly of the Chuck Chuck Bushing or Insert for Wear
Housing - Section 7 Page 51).

4. To replace the Insert (Position 153), remove the circlip (Position 154) and insert bushing
(Position 153) and clean the insert holder (Position 152) (Figure 04-15 and Figure 04-16)

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

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 V. Breaker Tools

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.

Point and Recommended Use

1) Chisel All earth-moving duties or

1 excavations in narrow trenches or
stratified soil or rock up to medium
rock.
2
2) Moil Demolition of rocks and
materials, not stratified rock, up to
3 medium hardness.

3) Olgive Demolition of hard to very

4
1 hard rock.
2
3 4) Blank or Blunt Demolition of rocks
4
5 up to medium hardness to be broken
5 into smaller pieces.
6
5) Asphalt Cutter or Spade Cutting of
concrete paving, brick walls or turf.

6 6) Pole or Pipe Cutter Driving pipes,

poles or preshaped metal objects (IE.
shaped metal gaurdrail poles) into
Different materials.

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 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.

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.

PPM2000000 Version: 102700 27

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
formation. Figure 05-02: Misalignment
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: Blank or Dry
Firing

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

PPM2000000 Version: 102700 28

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

PPM2000000 Version: 102700 29

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

PPM2000000 Version: 102700 30

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.
PPM2000000 Version: 102700 31
 VI. Accumulator Removal and Rebuilding

Safety Instructions

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.
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.

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

PPM2000000 Version: 102700 33

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.

PPM2000000 Version: 102700 34

Accumulator Rebuilding MES 121 and MES 150
1. Carefully discharge the accumulator and remove the Inflating Screw (Position 504) and O-
ring (Position 505). (Figure 06-02)

2. Loosen and remove the Self Locking Nuts (Position 314) and Shell Fixing Screws (Position
506). (Figure 06-03)

Figure 06-02: Loosen Inflation Figure 06-03: Remove Accumulator

Screw Carefully MES 121 Shell Bolts MES 121 and MES 150
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

MES 121 and MES 150 Shell Bolts 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).
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)

Figure 06-06: Unscrew Upper Figure 06-07: Remove Diaphram

Accumulator Half MES 181 MES 181 and MES 200.
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.

PPM2000000 Version: 102700 36

 Figure 06-08: Lubricate Figure 06-09: Install Lower
Accumulator O-ring MES 181 and Accumulator Lower Shell Half
MES 200 MES 181 and MES 200

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:

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.

PPM2000000 Version: 102700 37

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 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.

7. Replace the Diaphragm (Position 503). (Figure 06-14)

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.

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 Figure 06-16: Lubricate Accumulator Bolts
MES 300 and Up

PPM2000000 Version: 102700 39

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 06-
19)

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:

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.

PPM2000000 Version: 102700 40

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 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)

Figure 06-22: Installation Figure 06-24: Installation of Figure 06-24: Installation

of Inflation Body MES 121 Inflation Body Assembly with of Inflation Body Assembly
and MES 150 Newer Style Holder MES 300 with Older Style Holder
and Up (with two 8 mm - 1.25 MES 300 and Up
Tapped holes in the top)

PPM2000000 Version: 102700 41

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 06-
25)

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:
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.
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 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.

Figure 07-03: Lift Breaker From Side

Plates MES 181 and Up

PPM2000000 Version: 102700 43

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 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

PPM2000000 Version: 102700 45

Breaker Head Removal and Disassembly
MES 121 and MES 150
1. Loosen and remove Nuts (Position 314). (Figure 07-12)

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

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

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

PPM2000000 Version: 102700 46

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 Figure 07-02: Remove Head

MES 601 and Up Assembly MES 601 and Up

PPM2000000 Version: 102700 47

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.

PPM2000000 Version: 102700 48

 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 Figure 07-22: Remove

Distributor Cylinder Assembly

PPM2000000 Version: 102700 49

Cylinder Removal and Disassembly
1. Remove the piston (Position 209) using the Accumulator Screw (Position 507). (Figure 07-
23) The Guide Adapter (Position 210) will come out of the Cylinder (Position 210) with 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 Figure 07-24: Remove Valves

Piston 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 Figure 07-26: Remove Cylinder

Cylinder from Chuck U-joint Seals
Housing
4. Remove the O-ring (Position 303) and the U-joint seals (Position 204) and carefully clean u-
joint seals internal grooves. (Figure 07-26)
PPM2000000 Version: 102700 50
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 Figure 07-28: Remove Nylon Plugs

Spacer and Upper Bushing and Elastic Pin From Chuck Housing
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. Figure 07-29: Inspect Lock Bolts

PPM2000000 Version: 102700 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 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

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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 Figure 07-36: Extract Pressure regulating
Valve Guide Plug 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 Figure 07-38: Remove Pressure regulating
Valve Piston 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 Figure 07-40: Remove Frequency Valve
Guide Plug 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 Figure 07-42: Remove Frequency Valve
Body 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 Figure 08-04: Install Upper Bushing
Insert Holder Nylon Plug

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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 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)

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 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)

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 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)

Figure 08-23: Lubricate Figure 08-24: Lubricate

Side Rod Heads 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 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

Page REV 01-23-01

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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 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.

Part numbers MES 621 to MES 1200 0603140

MES 1750 to MES 2500 2701271
MES 3000 to MES 3500 3003140
MES 5000 to MES 7000 5003140
MES 8500 to MES 12000 8503140

Below is a diagram showing proper installation.

Figure 08-32: Installation of Side Bolt Locks Page REV 01-23-01

PPM2000000 Version: 102700 64

 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 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).

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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 Figure 08-37: Install Side Plates
MES 121 and MES 150 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 Figure 08-41: Assemble MES

through MES 1800 Top Shock 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 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)

Figure 08-45: Install High and Low

Pressure Links

PPM2000000 Version: 102700 69

PPM2000000 Version: 102700 70
 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.

PPM2000000 Version: 102700 72

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.
PPM2000000 Version: 102700 73
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
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.

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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
and pressure. Push the hammer to the bottom to charge the piston and try again.

2. Verify that the pressure relief valve of the carrier circuit is not open. If it is, check 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.

Oil Leaks Occurring

1. 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.

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.

PPM2000000 Version: 102700 75

 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?
Yes
No

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

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

PPM2000000 Version: 102700 76

 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

PPM2000000 Version: 102700 77

 XI. Power Lubrication Systems

Excavator 411I Pump

Theory of Operation

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 micro-
switch. Make sure that all pressure is RELEASED.

PPM2000000 Version: 102700 78

 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.

PPM2000000 Version: 102700 79

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
Figure 11-02: Actuator Switch Ajustment
to not run at all.

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).

PPM2000000 Version: 102700 80

711-ITHPump 24Volt - 2 Speed Electric Grease Pump

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

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 12V Battery #2

Batteries wired
In Series (-) (-)
To machine

(+) (+)
Ground

Wire from terminal (Y) Wire from terminal (X)

connects here for 12V connects here for 24V

Figure 11-07: Wiring of 24 Volt 2 Speed Electric Grease Pump

PPM2000000 Version: 102700 81

Hydraulic Grease Pump with Electrical Control

24V-DC

Solenoid
Mounting Bolts

P
G
To Excavator -4 Male JIC
Port for Pressure
Chassis/Frame Fittings
Gauge
Ground
(Optional)

From a fused (24V DC) T

Power source with
ON/OFF Switch

Diagram of Grease Pump Manifold

Tee into Pilot

Grease Flow Pressure
Adjustment Source
Screw To Tank
Return

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.

PPM2000000 Version: 102700 82

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.

PPM2000000 Version: 102700 83

FIowMaster Rotary Driven Hydraulic Pump
For 5 Gallon Pail/ container
Model: 85486 Series A

Lincoln Industrial
Foreign and U.S. Patent Pending
This pump conforms to the European Directive for 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.

Indicates a potentially hazardous situation which,

if not avoided, could result in death or serious Figure 11-08: FIowMaster
injury. Rotary Driven Hydraulic Pump
(Model: 85486 Series A)
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.
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.

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.

PPM2000000 Version: 102700 85

Installing the Pump

Figure 11-09: Typical Installation of the Hydraulic Pump

1. Pump Model 85486 5. Control Valve

2. Plug, unused outlet 6. Shut-off Valve
3. Hose Reel 7. Hydraulic Power Supply and Return
4. Follower, Model 252725 8. Swivel

Pump Performance and Specification

3
Maximum Output Pressure: 4,5000 Psig Maximum Pump Output: 22 in /min. *
320 Bar 244 grams/ min)

Supply inlet hydraulic 450 Psig Weight: 36 Lbs

pressure (maximum): 32 Bar 16 Kg

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

Up to 28 l/ min motor oiISF-SC

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

-10 +65 C
Tank Return Port: 318 NPTF In
Pump Ratio with manifold: 10:1
Pump Outlets: 1/4 NPTF In

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

PPM2000000 Version: 102700 86

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

PPM2000000 Version: 102700 87

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.

PPM2000000 Version: 102700 88

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).

PPM2000000 Version: 102700 89

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

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

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

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

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

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

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

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

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

PPM2000000 Version: 102700 90

Troubleshooting
Condition Possible Cause
Closed supply line shut off
valve
Insufficient Hydraulic Fluid
supply.
Closed fluid outlet line.
Pump does not run
Pump is stalled due to
grease backpressure.
Pump is seized or damaged
Low level of grease or
reservoir is empty.
Pump speeds up or Follower plate is stuck and
runs erratically. separated from grease.
Pump piston or checks are
worn.
Insufficient hydraulic fluid
Pump runs, but output
supply.
is low.
Inlet pressure too low.
Weepage from Cup seal (16) or O-Ring (48)
housing cover 30. failure.
No crank case oil.
Pump becomes noisy.
Worn wrist pin bushing 13.
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.

Americas: Europe/ Africa: Asia/ Pacific:

One Lincoln Way Heinrich-Hertz-Str 2-8 25 Int'I Business Park
St. Louis, MO 63120-1578 D-69183 Walldort #01-65 German Centre Copyright 1999
USA Germany Singapore 609916 Printed in USA
Phone +1.314.679.4200 Phone +49.6227.33.0 Phone +65.562.7960 Web site:
Fax +1.800.424.5359 Fax +49.6227.33.259 Fax +65.562.9967 www.lincolnindustrial.com

PPM2000000 Version: 102700 91

 XII. Under Water Kits

Figure 12-01: Under Water Circuit

Shut-off Pressure on Dynamic Pressure

Depth
Pressure Switch in Breaker Housing
Meters Feet Bar PSI Bar PSI
0.0 - 5.0 0.0 - 16.4 1.5 21.8 2.5 36.3
5.0 - 10.0 16.4 - 32.8 2.0 29.0 3.0 43.5
10.0 - 15.0 32.8 49.2 2.5 36.0 3.5 50.8

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 12-
01).

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)

PPM2000000 Version: 102700 92

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 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.

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.

PPM2000000 Version: 102700 93

 XIII. Compactors

Installation of Flow Regulating Valve for INDECO IHC65 &

IHC 130 Compactors

Hose to SAE O-ring Compactor Mounting Bracket

motor x JIC 90

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.

PPM2000000 Version: 102700 94

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

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

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

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

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

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

10. Install motor.

Compactor Eccentric Cross Section

PPM2000000 Version: 102700 95

 APPENDIX A

Breaker Technical and Torque Specifications

MES 121
Technical Specifications

Technical Specifications Values

Energy Class 180
Blows Per Minute 950 - 1,350
Carrier Weight 1,200 - 5,000 Lbs
Total Height 37.8 In
Working Weight 176 Lbs
Length Of Tool 17.3 In
Diameter Of Tool 1.8 In
Tool Weight 11 Lbs
H.P. Fitting Size 0.5 In. BSPP
L.P. Fitting Size 0.5 In. BSPP
Accumulator Charge 475 - 550 Psi
Maximum Lower Bushing ID 2.04 In
* Required Flow @ Operating Pressure 3 - 9 Gpm
* Operating Pressure 1,650 100 Psi
* Circuit Relief 2,100 Psi
* Preferred Backpressure 130 Psi or less
Allowable Maximum Backpressure 160 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt Nut 314 27 mm ***
Test Plug 403 6 mm Allen 36
Guide Plug 413 19 mm 109
Variable Plug
Inflation Screw 504 8 mm Allen 65
Accumulator Screw
Shell Fixing Screw 506 27 mm Allen 238
Under Water Plug
Side Plate Screw 607 22 mm 87
Self Locking Nut 608
Top Cap Bolts
*** Initial torque is 80 ft/lbs and final torque is 145 ft/lbs.

Page REV PTU 03-10-2003

PPM2000000 Version: 102700 96

MES 150

Technical Specifications

Technical Specifications Value

Energy Class 180
Blows Per Minute 850 - 1,250
Carrier Weight 1,200 - 5,000 Lbs
Total Height 38 In
Working Weight 176 Lbs
Length Of Tool 17.3 In
Diameter Of Tool 1.75 In
Tool Weight 11 Lbs
H.P. Fitting Size 0.5 In. BSPP
L.P. Fitting Size 0.5 In. BSPP
Accumulator Charge 475 - 550 Psi
Maximum Lower Bushing ID
* Required Flow @ Operating Pressure 4 10.5 Gpm
* Operating Pressure 1650 100 Psi
* Circuit Relief 2,100 Psi
* Preferred Backpressure 188 Psi or less
Allowable Maximum Backpressure 260 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt Nut 314 27 mm ***
Test Plug 403 6 mm Allen 36
Link Screw 409 6 mm Allen 22
Variable Plug NA
Inflation Screw 504 8 mm Allen 65
Accumulator Screw NA
Shell Fixing Screw 506 27 mm 238
Under Water Plug NA
Side Plate Screw 607 22 mm 145
Self Locking Nut 608 22 mm 87
Top Cap Bolts
*** Initial torque is 80 ft/lbs and final torque is 145 ft/lbs.

Page REV PTU 03-07-2003

PPM2000000 Version: 102700 97

 MES 181

Technical Specifications

Technical Specifications Values

Energy Class 250
Blows Per Minute 800 - 1,200
Carrier Weight 4,000 - 8,000 Lbs
Total Height 47.2 In
Working Weight 264 Lbs
Length Of Tool 20.9 In
Diameter Of Tool 1.9 In
Tool Weight 15.4 Lbs
H.P. Fitting Size 0.5 In. BSPP
L.P. Fitting Size 0.75 In. BSPP
Accumulator Charge 475 - 550 Psi
Maximum Lower Bushing ID 2.04 In
* Required Flow @ Operating Pressure 6.5-10.5 Gpm
* Operating Pressure 1,650 100 Psi
* Circuit Relief 2,100 Psi
* Preferred Backpressure 130 Psi or less
Allowable Maximum Backpressure 160 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 308 27 mm ***
Test Plug
Guide Plug 413 24 mm 217
Variable Plug
Inflation Screw 504 8 mm Allen 65
Accumulator Screw Pin Spanner 579
Shell Fixing Screw
Under Water Plug
Side Plate Screw 607 27 mm 217
Self Locking Nut 608 27 mm 145
Top Cap Bolts 618 22 mm 108
*** Initial torque is 100 ft/lbs and final torque is 203 ft/lbs.

Page REV PTU 3-10-2003

PPM2000000 Version: 102700 98

MES 200

Technical Specifications

Technical Specifications Values

Energy Class 250
Blows Per Minute 600 - 1,000
Carrier Weight 4,000 - 8,000 Lbs
Total Height 47.2 In
Working Weight 264 Lbs
Length Of Tool 20.9 In
Diameter Of Tool 1.9 In
Tool Weight 15.4 Lbs
H.P. Fitting Size 0.5 In. BSPP
L.P. Fitting Size 0.75 In. BSPP
Accumulator Charge 475 - 550 Psi
Maximum Lower Bushing ID 2.04 In
* Required Flow @ Operating Pressure 6 11 Gpm
* Operating Pressure 1,650 100 Psi
* Circuit Relief 2,100 Psi
* Preferred Backpressure 200 Psi or less
Allowable Maximum Backpressure 275 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 27 mm ***
Test Plug
Link Screws
Guide Plug 413 24 mm 217
Variable Plug
Inflation Screw 504 8 mm Allen 65
Accumulator Screw Pin Spanner 578
Shell Fixing Screw
Under Water Plug
Side Plate Screw 607 27 mm 217
Self Locking Nut 608 27 mm 145
Top Cap Bolts
*** Initial torque is 100 ft/lbs and final torque is 203 ft/lbs.

Page REV PTU 03-10-2003

PPM2000000 Version: 102700 99

MES 350

Technical Specifications

Technical Specifications Values

Energy Class 500
Blows Per Minute 550 - 950 Standard
690 - 1,235 High Speed
Carrier Weight 5,000 - 10,000 Lbs
Total Height 55.1 In
Working Weight 396 Lbs
Length Of Tool 22.8 In
Diameter Of Tool 2.2 In
Tool Weight 22 Lbs
H.P. Fitting Size 0.5 In. BSPP
L.P. Fitting Size 0.75 In. BSPP
Accumulator Charge 475 - 550 Psi
Maximum Lower Bushing ID 2.38 In
* Required Flow @ Operating Pressure 8 16 Gpm
* Operating Pressure 1,650 100 Psi
* Circuit Relief 2,100 Psi
* Preferred Backpressure 200 Psi or less
Allowable Maximum Backpressure 247 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 27 mm ***
Test Plug
Link Screws
Guide Plug 413 24 mm 217
Variable Plug
Inflation Screw 504 8 mm Allen 65
Accumulator Screw 506 14mm x 1.5 x 80mm 12 mm Allen 80
Shell Fixing Screw 505 12mm x 1.5 x 30mm 10 mm Allen 50
Under Water Plug
Side Plate Screw 607 18mm x 1.5 x 180mm 27 mm 217
Self Locking Nut 608 18mm x 1.5 27 mm 145
Top Cap Bolts 618 in. x 3 in
*** Initial torque is 100 ft/lbs and final torque is 203 ft/lbs.

Page REV 03-10-2003

PPM2000000 Version: 102700 100

MES 351

Technical Specifications

Technical Specifications Values

Energy Class 500
Blows Per Minute 550 - 950 Standard
690 - 1,225 High Speed
Carrier Weight 5,000 - 10,000 Lbs
Total Height 55.1 In
Working Weight 396 Lbs
Length Of Tool 22.8 In
Diameter Of Tool 2.2 In
Tool Weight 22 Lbs
H.P. Fitting Size 0.5 In. BSPP
L.P. Fitting Size 0.75 In. BSPP
Accumulator Charge 475 - 550 Psi
Maximum Lower Bushing ID 2.38 In
* Required Flow @ Operating Pressure 11 - 17 Gpm
* Operating Pressure 1,650 100 Psi
* Circuit Relief 2,100 Psi
* Preferred Backpressure 362 Psi or less
AllowableMaximum Backpressure 450 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 27 mm ***
Test Plug
Link Screws
Guide Plug 413 24 mm 217
Variable Plug
Inflation Screw 504 8 mm Allen 65
Accumulator Screw 506 14mm x 1.5 x 80mm 12 mm Allen 80
Shell Fixing Screw 505 12mm x 1.5 x 30mm 10 mm Allen 50
Under Water Plug
Side Plate Screw 607 18mm x 1.5 x 180mm 27 mm 217
Self Locking Nut 608 18mm x 1.5 27 mm 145
Top Cap Bolts 618 in. x 3 in
*** Initial torque is 100 ft/lbs and final torque is 203 ft/lbs.

Page REV 03-10-2003

PPM2000000 Version: 102700 101

MES 550

Technical Specifications

Technical Specifications Values

Energy Class 750
Blows Per Minute 500 - 900
Carrier Weight 6,000 - 14,000 Lbs
Total Height 59.1 In
Working Weight 572 Lbs
Length Of Tool 23.6 In
Diameter Of Tool 2.6 In
Tool Weight 33 Lbs
H.P. Fitting Size 0.75 In. BSPP
L.P. Fitting Size 0.75 In. BSPP
Accumulator Charge 475 - 550 Psi
Maximum Lower Bushing ID 2.75 In
* Required Flow @ Operating Pressure 13 21 Gpm
* Operating Pressure 1,650 100 Psi
* Circuit Relief 2,200 Psi
* Preferred Backpressure 220 Psi or less
Allowable Maximum Backpressure 275 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 32 mm ***
Test Plug 403 19 mm 29
Link Screws 409 10 mm Allen 51
Guide Plug 413 30 mm 362
Variable Plug
Inflation Screw 504 14 mm Allen 36
Accumulator Screw 507 14 mm Allen 116
Shell Fixing Screw 506 14mm x 1.5 x 35mm 12 mm Allen 80
Under Water Plug
Side Plate Screw 607 20mm x 1.5 x 205mm 30 mm 311
Self Locking Nut 608 20mm x 1.5 30 mm 217
Top Cap Bolts 618 in. x 3 in
*** Initial torque is 175 ft/lbs and final torque is 347 ft/lbs.

Page REV 03-10-2003

PPM2000000 Version: 102700 102

MES 553

Technical Specifications

Technical Specifications Values

Energy Class 750
Blows Per Minute 500 - 900 Standard
625 - 1,170 High Speed
Carrier Weight 8,000 - 14,000 Lbs
Total Height 61 In
Working Weight 583 Lbs
Length Of Tool 25.6 In
Diameter Of Tool 2.9 In
Tool Weight 39.6 Lbs
H.P. Fitting Size 0.75 In. BSPP
L.P. Fitting Size 0.75 In. BSPP
Accumulator Charge 475 - 550 Psi
Maximum Lower Bushing ID
* Required Flow @ Operating Pressure 13 21 Gpm
* Operating Pressure 1,675 100 Psi
* Circuit Relief 2,200 Psi
* Preferred Backpressure 220 Psi or less
Allowable Maximum Backpressure 275 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 32 mm ***
Test Plug 403 19 mm 29
Link Screws 409 10 mm Allen 51
Guide Plug 418 30 mm 362
Variable Plug
Inflation Screw 504 14 mm Allen 36
Accumulator Screw 507 14 mm Allen 116
Shell Fixing Screw 506 14mm x 1.5 x 35mm 12 mm Allen 80
Under Water Plug
Side Plate Screw 607 20mm x 1.5 x 205mm 30 mm 311
Self Locking Nut 608 20mm x 1.5 30 mm 217
Top Cap Bolts 618 in. x 3 in
*** Initial torque is 175 ft/lbs and final torque is 347 ft/lbs.

Page REV 03-10-2003

PPM2000000 Version: 102700 103

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

Technical Specifications

Technical Specifications Values

Energy Class 1,000
Blows Per Minute 500 - 950 Standard
560 - 1,170 High Speed
Carrier Weight 8,000 - 18,000 Lbs
Total Height 54.3 In
Working Weight 880 Lbs
Length Of Tool 25.6 In
Diameter Of Tool 3.2 In
Tool Weight 48.4 Lbs
H.P. Fitting Size 0.75 In. BSPP
L.P. Fitting Size 0.75 In. BSPP
Accumulator Charge 475 - 550 Psi
Maximum Lower Bushing ID 3.39 In
* Required Flow @ Operating Pressure 13 22.5 Gpm
* Operating Pressure 1,650 100 Psi
* Circuit Relief 2,200 Psi
* Preferred Backpressure 130 Psi or less
Allowable Maximum Backpressure 175 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 30 mm ***
Test Plug 403 19 mm 29
Link Screws 409 10 mm Allen 51
Guide Plug 418 30 mm 362
Variable Plug
Inflation Screw 504 14 mm Allen 36
Accumulator Screw 507 20mm x 1.5mm x 100mm 17 mm Allen 231
Shell Fixing Screw 506 16mm x 1.5mm x 50 mm 14 mm Allen 116
Under Water Plug
Shock Absorber Screw 615 10mm x 1.25 x 30mm 17mm 58

Top Cap Bolts 618 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

MES 650 (HD) Heavy Duty and (W) Whisper

Technical Specifications

Technical Specifications Values

Energy Class 1,000
Blows Per Minute 450 - 900 Standard
560 - 1,170 High Speed
Carrier Weight 10,000 - 18,000 Lbs
Total Height 54.3 In
Working Weight 880 Lbs
Length Of Tool 25.6 In
Diameter Of Tool 3.2 In
Tool Weight 48.4 Lbs
H.P. Fitting Size 0.75 In. BSPP
L.P. Fitting Size 0.75 In. BSPP
Accumulator Charge 475 - 550 Psi
Maximum Lower Bushing ID 3.39 In
* Required Flow @ Operating Pressure 18.5 - 25 Gpm
* Operating Pressure 1,650 100 Psi
* Circuit Relief 2,200 Psi
* Preferred Backpressure 220 Psi or less
Allowable Maximum Backpressure 290 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 30 mm ***
Test Plug 403 19 mm 29
Link Screws 409 17 mm 51
Guide Plug 418 30 mm 362
Variable Plug
Inflation Screw 504 14 mm Allen 36
Accumulator Screw 507 20mm x 1.5mm x 100mm 17 mm Allen 231
Shell Fixing Screw 506 16mm x 1.5mm x 50 mm 14 mm Allen 116
Under Water Plug
Side Plate Screw
Self Locking Nut
Shock absorber Screw 615 10mm x 1.25 x 30mm 17 mm 58
Top Cap Bolts 618 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 03-10-20033

PPM2000000 Version: 102700 105

MES 1000 (HD) Heavy Duty and (W) Whisper

Technical Specifications

Technical Specifications Values

Energy Class 1,000
Blows Per Minute 500 - 800 Standard

Carrier Weight 11,200 24,400 Lbs

Total Height 60.2 In
Working Weight 1,056 Lbs
Length Of Tool 27.6 In
Diameter Of Tool 3.5 In
Tool Weight 63.5 Lbs
H.P. Fitting Size 0.75 In. BSPP
L.P. Fitting Size 1.00 In. BSPP
Accumulator Charge 475 550 Psi
Maximum Lower Bushing ID 3.81 In
* Required Flow @ Operating Pressure 18.5 26.5 Gpm
* Operating Pressure 1,650 100 Psi
* Circuit Relief 2,200 Psi
* Preferred Backpressure 160 Psi or less
Allowable Maximum Backpressure 203 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 30 mm ***
Test Plug 403 19 mm 29
Link Screws 409 17 mm 51
Guide Plug 418 30 mm 362
Variable Plug
Inflation Screw 504 14 mm Allen 36
Accumulator Screw 507 20mm x 1.5 x 120mm 17 mm Allen 231
Shell Fixing Screw 506 16mm x 1.5 x 50 mm 14 mm Allen 145
Under Water Plug 107 12 mm Allen 180
Side Plate Screw
Self Locking Nut
Shock Absorber Bolts 615 12mm x 1.5 x 30mm 19 mm 72
Top Cap Bolts 618 in. x 3 in
*** 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

MES 1050 (HD) Heavy Duty and (W) Whisper

Technical Specifications

Technical Specifications Values

Energy Class 1,500
Blows Per Minute 450 900 Standard
560 - 1,170 High Speed
Carrier Weight 10,000 - 18,000 Lbs
Total Height 54.3 In
Working Weight 1,045 Lbs
Length Of Tool 25.6 In
Diameter Of Tool 3.2 In
Tool Weight 48.4 Lbs
H.P. Fitting Size 0.75 In. BSPP
L.P. Fitting Size 0.75 In. BSPP
Accumulator Charge 475 550 Psi
Maximum Lower Bushing ID 3.81 In
* Required Flow @ Operating Pressure 20-28 Gpm
* Operating Pressure 1,650 100 Psi
* Circuit Relief 2200 Psi
* Preferred Backpressure 220 Psi or less
Allowable Maximum Backpressure 290 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 30 mm ***
Test Plug 403 19 mm 29
Link Screws 409 17 mm 51
Guide Plug 418 30 mm 362
Variable Plug
Inflation Screw 504 14 mm Allen 36
Accumulator Screw 507 20mm x 1.5 x 120mm 17 mm Allen 231
Shell Fixing Screw 506 16mm x 1.5 x 50 mm 14 mm Allen 145
Under Water Plug 107 12 mm Allen 180
Side Plate Screw
Self Locking Nut
Shock Absorber Bolts 615 12mm x 1.5 x 30mm 19 mm 72
Top Cap Bolts 618 in. x 3 in
*** 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

MES 1200 (HD) Heavy Duty and (W) Whisper

Technical Specifications

Technical Specifications Values

Energy Class 1,500
Blows Per Minute 500 - 950 Standard
625 - 1,235 High Speed
Carrier Weight 12,000 - 28,000 Lbs
Total Height 68.9 In
Working Weight 1,375 Lbs
Length Of Tool 29.9 In
Diameter Of Tool 3.5 In
Tool Weight 81.4 Lbs
H.P. Fitting Size 0.75 In. BSPP
L.P. Fitting Size 1.00 In. BSPP
Accumulator Charge 475 550 Psi
Maximum Lower Bushing ID 3.81 In
* Required Flow @ Operating Pressure 18.5- 28 Gpm
* Operating Pressure 1,650 100 Psi
* Circuit Relief 2,200 Psi
* Preferred Backpressure 75 Psi or less
Allowable Maximum Backpressure 145 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 30 mm ***
Test Plug 403 19 mm 29
Link Screws 409 17 mm 51
Guide Plug 418 30 mm 361
Variable Plug
Inflation Screw 504 14 mm Allen 36
Accumulator Screw 507 20mm x 1.5 x 120mm 17 mm Allen 231
Shell Fixing Screw 506 16mm x 1.5 x 50 mm 14 mm Allen 116
Under Water Plug 107 12 mm Allen 145
Side Plate Screw
Self Locking Nut
Shock Absorber Bolt 615 12mm x 1.5 x 30mm 19 mm 72
Top Cap Bolts 618 in. x 3 in
*** 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
MES 1250 (HD) Heavy Duty and (W) Whisper

Technical Specifications

Technical Specifications Values

Energy Class 1,500
Blows Per Minute 450 - 900 Standard
560 - 1,170 High Speed
Carrier Weight 10,000 - 18,000 Lbs
Total Height 54.3 In
Working Weight 1,045 Lbs
Length Of Tool 25.6 In
Diameter Of Tool 3.2 In
Tool Weight 48.4 Lbs
H.P. Fitting Size 0.75 In. BSPP
L.P. Fitting Size 0.75 In. BSPP
Accumulator Charge 475 - 550 Psi
Maximum Lower Bushing ID 3.81 In
* Required Flow @ Operating Pressure 20 28 Gpm
* Operating Pressure 1,650 100 Psi
* Circuit Relief 2,200 Psi
* Preferred Backpressure 220 Psi
Allowable Maximum Backpressure 290 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 30 mm ***
Test Plug 403 19 mm 29
Link Screws 409 17 mm 51
Guide Plug 418 30 mm 361
Variable Plug
Inflation Screw 504 14 mm Allen 36
Accumulator Screw 507 20mm x 1.5 x 120mm 17 mm Allen 231
Shell Fixing Screw 506 16mm x 1.5 x 50 mm 14 mm Allen 116
Under Water Plug 107 12 mm Allen 145
Side Plate Screw
Self Locking Nut
Shock Absorber Bolts 615 12mm x 1.5 x 30mm 19 mm 72
Top Cap Bolts 618 in. x 3 in
*** 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

Technical Specifications

Technical Specifications Values

Energy Class 1,750
Blows Per Minute 600 - 1,000 Standard
750 - 1,300 High Speed
Carrier Weight 22,000 - 42,000 Lbs
Total Height 68.9 In
Working Weight 1,735 Lbs
Length Of Tool 29.9 In
Diameter Of Tool 4.3 In
Tool Weight 125 Lbs
H.P. Fitting Size 0.75 In. BSPP
L.P. Fitting Size 0.75 In. BSPP
Accumulator Charge 475 - 550 Psi
Maximum Lower Bushing ID
* Required Flow @ Operating Pressure 21 33 Gpm
* Operating Pressure 1,850 75 Psi
* Circuit Relief 2,350 Psi
* Preferred Backpressure 120 Psi or less
Allowable Maximum Backpressure 275 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 38 mm ***
Test Plug 403 19 mm 29
Link Screws 409 10 mm Allen 51
Guide Plug 418 30 mm 361
Variable Plug
Inflation Screw 504 14 mm Allen 36
Accumulator Screw 507 20mm x 1.5 x 120mm 17 mm Allen 400
Shell Fixing Screw 506 16mm x 1.5 x 50 mm 14 mm Allen 145
Under Water Plug 107 12 mm Allen 180
Side Plate Screw
Self Locking Nut
Side Shock Bolts 615 14mm x 1.5 x 35mm 22 mm 108
Top Cap Bolts 618 in. x 3 in
*** Initial torque is 160 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 110

MES 1750 (HD) Heavy Duty and (W) Whisper

Technical Specifications

Technical Specifications Values

Energy Class 2,000
Blows Per Minute 600 - 950 Standard
750 - 1,235 High Speed
Carrier Weight 24,000 - 42,000 Lbs
Total Height 80 In
Working Weight 1,980 Lbs
Length Of Tool 37.4 In
Diameter Of Tool 4.5 In
Tool Weight 162.8 Lbs
H.P. Fitting Size 0.75 In. BSPP
L.P. Fitting Size 1.00 In. BSPP
Accumulator Charge 520 - 620 Psi
Maximum Lower Bushing ID 4.93 In
* Required Flow @ Operating Pressure 22 30 Gpm
* Operating Pressure 1,900 75 Psi
* Circuit Relief 2,400 Psi
* Preferred Backpressure 75 Psi or less
Allowable Maximum Backpressure 150 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 38 mm ***
Test Plug 403 19 mm 29
Link Screws 409 10 mm Allen 51
Guide Plug 418 30 mm 361
Variable Plug
Inflation Screw 504 14 mm Allen 36
Accumulator Screw 507 20mm x 1.5mm x 125mm 17 mm Allen 400
Shell Fixing Screw 506 16mm x 1.5mm x 50 mm 14 mm Allen 145
Under Water Plug 107 12 mm Allen 180
Side Plate Screw
Self Locking Nut
Side Shock Bolts 615 14mm x 1.5 x 35mm 22 mm 108
Top Cap Bolts 618 in. x 4 in
*** 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

MES 2000 (HD) Heavy Duty and (W) Whisper

Technical Specifications

Technical Specifications Values

Energy Class 3,000
Blows Per Minute 500 - 900 Standard
625 - 1,125 High Speed
Carrier Weight 32,000 - 48,000 Lbs
Total Height 83.9 In
Working Weight 2,640 Lbs
Length Of Tool 39.4 In
Diameter Of Tool 4.72 In
Tool Weight 189.2 Lbs
H.P. Fitting Size 1.00 In. BSPP
L.P. Fitting Size 1.25 In. BSPP
Accumulator Charge 520 - 620 Psi
Maximum Lower Bushing ID 5.17 In
* Required Flow @ Operating Pressure 29 38 Gpm
* Operating Pressure 1,900 75 Psi
* Circuit Relief 2,400 Psi
* Preferred Backpressure 75 Psi or less
Allowable Maximum Backpressure 150 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 38 mm ***
Test Plug 403 19 mm 29
Link Screws 409 14 mm Allen 130
Guide Plug 418 38 mm 506
Variable Plug
Inflation Screw 504 14 mm Allen 36
Accumulator Screw 507 5/8 Allen 434
Shell Fixing Screw 506 x 16 x 2 9/16 Allen 220
Under Water Plug 107 12 mm Allen 180
Side Plate Screw
Self Locking Nut
Shock Absorber Bolts 615 14mm x 1.5 x 35mm 22 mm 108
Top Cap Bolts 618 in. x 4 in
*** Initial torque is 304 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 112

MES 2500 (HD) Heavy Duty and (W) Whisper

Technical Specifications

Technical Specifications Values

Energy Class 4,000
Blows Per Minute 400 850 Standard
500 - 1,105 High Speed
Carrier Weight 32,000 - 54,000 Lbs
Total Height 89.8 In
Working Weight 2,970 Lbs
Length Of Tool 41.3 In
Diameter Of Tool 5.1 In
Tool Weight 231 Lbs
H.P. Fitting Size 1.00 In. BSPP
L.P. Fitting Size 1.25 In. BSPP
Accumulator Charge 520 620 Psi
Maximum Lower Bushing ID 5.62 In
* Required Flow @ Operating Pressure 33 41 Gpm
* Operating Pressure 1,900 75 Psi
* Circuit Relief 2,400 Psi
* Preferred Backpressure 75 Psi or less
Allowable Maximum Backpressure 150 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 38 mm ***
Test Plug 403 19 mm 29
Link Screws 409 14 mm Allen 130
Guide Plug 418 38 mm 506
Variable Plug 438 24 mm 180
Inflation Screw 504 14 mm Allen 36
Accumulator Screw 507 5/8 Allen 434
Shell Fixing Screw 506 x 16 x 2 9/16 Allen 217
Under Water Plug 107 12 mm Allen 180
Side Plate Screw
Self Locking Nut
Shock Absorber Bolts 615 14mm x 1.5 x 35mm 22 mm 108
Top Cap Bolts 618 in. x 4 in
*** 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

MES 3000 (HD) Heavy Duty and (W) Whisper

Technical Specifications

Technical Specifications Values

Energy Class 4,500
Blows Per Minute 400 - 700 Standard
500 - 910 High Speed
Carrier Weight 38,000 - 60,000 Lbs
Total Height 96.5 In
Working Weight 3,850 Lbs
Length Of Tool 43.3 In
Diameter Of Tool 5.5 In
Tool Weight 275 Lbs
H.P. Fitting Size 1.00 In. BSPP
L.P. Fitting Size 1.25 In. BSPP
Accumulator Charge 520 - 620 Psi
Maximum Lower Bushing ID 6.07 In
* Required Flow @ Operating Pressure 38 46 Gpm
* Operating Pressure 1,900 75 Psi
* Circuit Relief 2,400 Psi
* Preferred Backpressure 75 Psi or less
Allowable Maximum Backpressure 150 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 41 mm ***
Test Plug 403 19 mm 29
Link Screws 409 14 mm Allen 130
Guide Plug 418 41 mm 723
Variable Plug 438 24 mm 180
Inflation Screw 504 14 mm Allen 36
Accumulator Screw 507 30mm x 2.0mm x 155mm 22 mm Allen 795
Shell Fixing Screw 506 22mm x 1.5 x 80mm 17 mm Allen 325
Under Water Plug 107 12 mm Allen 180
Side Plate Screw
Self Locking Nut
Shock Absorber Bolts 615 14mm x 1.5 x 40mm 22 mm 108
Top Cap Bolts 618 in. x 4 in
*** Initial torque is 434 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 114

MES 3500 (HD) Heavy Duty and (W) Whisper

Technical Specifications

Technical Specifications Values

Energy Class 5,500
Blows Per Minute 350 600
Carrier Weight 42,000 - 72,000 Lbs
Total Height 103.94 In
Working Weight 4,840 Lbs
Length Of Tool 46.06 In
Diameter Of Tool 5.71 In
Tool Weight 347.6 Lbs
H.P. Fitting Size 1.00 In. BSPP
L.P. Fitting Size 1.25 In. BSPP
Accumulator Charge 520 620 Psi
Maximum Lower Bushing ID 6.22 In
* Required Flow @ Operating Pressure 42 51 Gpm
* Operating Pressure 2,175 75 Psi
* Circuit Relief 2,800 Psi
* Preferred Backpressure 75 Psi or less
Allowable Maximum Backpressure 125 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 41 mm ***
Test Plug 403 19 mm 29
Link Screws 409 14 mm Allen 130
Guide Plug 418 41 mm 723
Variable Plug 438 24 mm 180
Inflation Screw 504 14 mm Allen 36
Accumulator Screw 507 30mm x 2.0mm x 155mm 22 mm Allen 795
Shell Fixing Screw 506 22mm x 1.5 x 80mm 17 mm Allen 325
Under Water Plug 107 12 mm Allen 180
Side Plate Screw
Self Locking Nut
Shock Absorber Bolts 615 14mm x 1.5 x 40mm 22 mm 108
Top Cap Bolts 618 in. x 4 in
*** Initial torque is 470 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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MES 4001 (HD) Heavy Duty and (W) Whisper

Technical Specifications

Technical Specifications Values

Energy Class 6,500
Blows Per Minute 400 600
Carrier Weight 42,000 - 72,000 Lbs
Total Height 102.4 In
Working Weight 5513 Lbs
Length Of Tool In
Diameter Of Tool 5.9 In
Tool Weight Lbs
H.P. Fitting Size 1.00 In. BSPP
L.P. Fitting Size 1.25 In. BSPP
Accumulator Charge 520 620 Psi
Maximum Lower Bushing ID 6.22 In
* Required Flow @ Operating Pressure 47.5 61 Gpm
* Operating Pressure 2,175 75 Psi
* Circuit Relief 2,800 Psi
* Preferred Backpressure 75 Psi or less
Allowable Maximum Backpressure 125 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 41 mm ***
Test Plug 403 19 mm 29
Link Screws 409 14 mm Allen 130
Guide Plug 418 41 mm 723
Variable Plug 438 24 mm 180
Inflation Screw 504 14 mm Allen 36
Accumulator Screw 507 30mm x 2.0mm x 155mm 22 mm Allen 795
Shell Fixing Screw 506 22mm x 1.5 x 80mm 17 mm Allen 325
Under Water Plug 107 12 mm Allen 180
Side Plate Screw
Self Locking Nut
Shock Absorber Bolts 615 14mm x 1.5 x 40mm 22 mm 108
Top Cap Bolts 618 in. x 4 in
*** Initial torque is 506 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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MES 5000 (HD) Heavy Duty and (W) Whisper

Technical Specifications

Technical Specifications Values

Energy Class 7,500
Blows Per Minute 350 - 500
Carrier Weight 56,000 - 100,000 Lbs
Total Height 111.4 In
Working Weight 5,940 Lbs
Length Of Tool 52 In
Diameter Of Tool 6.3 In
Tool Weight 440 Lbs
H.P. Fitting Size 1.25 In. BSPP
L.P. Fitting Size 1.50 In. BSPP
Accumulator Charge 520 - 620 Psi
Maximum Lower Bushing ID 6.89 In
* Required Flow @ Operating Pressure 50 67 Gpm
* Operating Pressure 2,175 75 Psi
* Circuit Relief 2,800 Psi
* Preferred Maximum Backpressure 75 Psi or less
Allowable Maximum Backpressure 125 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 46 mm ***
Test Plug 403 19 mm 29
Link Screws 409 14 mm Allen 130
Guide Plug 418 41 mm 723
Variable Plug 438 24 mm 180
Inflation Screw 504 14 mm Allen 36
Accumulator Screw 507 30mm x 2.0mm x 155mm 22 mm Allen 795
Shell Fixing Screw 506 22mm x 1.5 x 80mm 17 mm Allen 325
Under Water Plug 107 12 mm Allen 180
Side Plate Screw
Self Locking Nut
Shock Absorber Bolts 615 16mm x 1.5 x 40mm 22 mm 231
Top Cap Bolts 618 1 in. x 5 in
*** Initial torque is 542 ft/lbs, then cross tighten bolts an additional 180. Bolts should then be tightened
another 15 and then backed off 15 to take the twist out of the bolts. This is your final torque.

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MES 7000 (HD) Heavy Duty and (W) Whisper

Technical Specifications

Technical Specifications Values

Energy Class 10,000
Blows Per Minute 350 - 500
Carrier Weight 70,000 - 130,000 Lbs
Total Height 126 In
Working Weight 7,700 Lbs
Length Of Tool 57.1 In
Diameter Of Tool 7.1 In
Tool Weight 616 Lbs
H.P. Fitting Size 1.25 In. BSPP
L.P. Fitting Size 1.50 In. BSPP
Accumulator Charge 520 - 620 Psi
Maximum Lower Bushing ID
* Required Flow @ Operating Pressure 63 80 Gpm
* Operating Pressure 2,210 75 Psi
* Circuit Relief 2,900 Psi
* Preferred Maximum Backpressure 75 Psi or less
Allowable Maximum Backpressure 125 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 46 Mm ***
Test Plug 403 19 Mm 29
Link Screws 409 14 mm Allen 130
Guide Plug 418 41 Mm 723
Variable Plug 438 24 Mm 180
Inflation Screw 504 14 mm Allen 36
Accumulator Screw 507 36mm x 2.0mm x 180mm 27 mm Allen 1085
Shell Fixing Screw 506 24mm x 2.0 x 90mm 19 mm Allen 362
Under Water Plug 107 12 mm Allen 180
Side Plate Screw
Self Locking Nut
Shock Absorber Bolts 615 20mm x 1.5 x 50mm 30 Mm 231
Top Cap Bolts 618 1 in. x 6 in
*** 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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MES 8500 (HD) Heavy Duty and (W) Whisper

Technical Specifications

Technical Specifications Values

Energy Class 12,000
Blows Per Minute 350 450
Carrier Weight 80,000 - 160,000 Lbs
Total Height 132.3 In
Working Weight 9,900 Lbs
Length Of Tool 60.2 In
Diameter Of Tool 7.7 In
Tool Weight 770 Lbs
H.P. Fitting Size 1.25 In. BSPP
L.P. Fitting Size 1.50 In. BSPP
Accumulator Charge 520 620 Psi
Maximum Lower Bushing ID 8.44 In
* Required Flow @ Operating Pressure 77 94 Gpm
* Operating Pressure 2,325 75 Psi
* Circuit Relief 2,900 Psi
* Preferred Backpressure 75 Psi or less
Allowable Maximum Backpressure 125 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 55 mm ***
Test Plug 403 19 mm 29
Link Screws 409 14 mm Allen 130
Guide Plug 418 41 mm 723
Variable Plug 438 24 mm 180
Inflation Screw 504 14 mm Allen 36
Accumulator Screw 507 36mm x 2.0mm x 180mm 27 mm Allen 1085
Shell Fixing Screw 506 24mm x 2.0 x 90mm 19 mm Allen 362
Under Water Plug 107 12 mm Allen 180
Side Plate Screw
Self Locking Nut
Shock Absorber Bolts 615 20mm x 1.5 x 50mm 30 mm 231
Top Cap Bolts 618 1 in. x 6 in
*** 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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MES 12000 (HD) Heavy Duty and (W) Whisper

Technical Specifications

Technical Specifications Values

Energy Class 16,000
Blows Per Minute 325 - 400
Carrier Weight 120,000 - 240,000 Lbs
Total Height 137.8 In
Working Weight 15,730 Lbs
Length Of Tool 62.1 In
Diameter Of Tool 8.5 In
Tool Weight 902 Lbs
H.P. Fitting Size 1.25 In. BSPP
L.P. Fitting Size 1.50 In. BSPP
Accumulator Charge 520 - 620 Psi
Maximum Lower Bushing ID
* Required Flow @ Operating Pressure 86 - 111 Gpm
* Operating Pressure 2,325 75 Psi
* Circuit Relief 2,900 Psi
* Preferred Backpressure 75 Psi or less
Allowable Maximum Backpressure 125 Psi
* Oil Temperature For Setting Flows & Pressures 150 F
* Information required for Attachment Delivery Report (ADR)

Torque specifications

Item Position Bolt Size Wrench Ft/Lbs.

Side Bolt 307 55 mm ***
Test Plug 403 19 mm 29
Link Screws 409 14 mm Allen 130
Guide Plug 418 41 mm 723
Variable Plug 438 24 mm 180
Inflation Screw 504 14 mm Allen 36
Accumulator Screw 507 27 mm Allen 1085
Shell Fixing Screw 506 27mm x 2.0 x 110mm 19 mm Allen 579
Under Water Plug 107 12 mm Allen 180
Side Plate Screw
Self Locking Nut
Shock Absorber Bolts 615 20mm x 1.5 x 50mm 30 mm 231
Top Cap Bolts 618 1 in. x 6 in
*** Initial torque is 905 ft/lbs, then cross tighten bolts an additional180. Bolts should then be tightened
another 15 and then backed off 15 to take the twist out of the bolts. This is your final torque.

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 APPENDIX B

Compactor Technical Specifications

IHC 30

Technical Specifications

Technical Specifications Optional Standard Optional

Shipping Weight 270 Lbs 270 Lbs 270 Lbs
Height 25 In 25 In 25 In
Width 11 In 11 In 11 In
Base Plate Size 11 X 23 X In 11 X 23 X In 11 X 23 X In
Low Flow 7 Gpm @2000 Psi 11Gpm @2000 Psi 17Gpm@2000 Psi
Centrifugal Force Low 2,500 Lbs 2,700 Lbs 3,300 Lbs
Frequency Low 2,000 Vpm 2,100 Vpm 2,200 Vpm
High Flow 11Gpm @2000 Psi 17Gpm @2000 Psi 24Gpm@2000 Psi
Centrifugal Force High 6,700 Lbs 6,700 Lbs 6,700 Lbs
Frequency High 3,000 Vpm 3,000 Vpm 3,000 Vpm
Carrier Weight 2,100 12,000 Lbs 2,100 12,000 Lbs 2,100 12,000 Lbs
Oil Reservoir Capacity 0.34 Gal 0.34 Gal 0.34 Gal
Oil Type HD80-90 HD80-90 HD80-90

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 Optional

Shipping Weight 790 Lbs
Height 26 In
Width 23 In
Base Plate Size 23 X 26 X 1 In
Low Flow 18Gpm @2000 Psi
Centrifugal Force Low 3,375 Lbs
Frequency Low 1,250 Vpm
High Flow 30Gpm @2000 Psi
Centrifugal Force High 9,375 Lbs
Frequency High 2,100 Vpm
Carrier Weight 9,000 16,000 Lbs
Oil Reservoir Capacity 1.23 Gal
Oil Type HD80-90
Motor Gear Size 1.25 In

NOTE: External drain line must be connected to in NPT case drain plug if the back pressure
exceeds 100 PSI.
REV 01-30-01

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IHC 130

Technical Specifications

Technical Specifications Optional

Shipping Weight 1,500 Lbs
Height 34 In
Width 23 In
Base Plate Size 23 X 32 X 2 In
Low Flow 30Gpm @2000 Psi
Centrifugal Force Low 18,900 Lbs
Frequency Low 2,100 Vpm
High Flow 34Gpm @2000 Psi
Centrifugal Force High 24,000 Lbs
Frequency High 2,350 Vpm
Carrier Weight 16,000 43,000 Lbs
Oil Reservoir Capacity 1.27 Gal
Oil Type HD80-90
Motor Gear Size 1.25 In

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

IHC 200

Technical Specifications

Technical Specifications Optional

Shipping Weight 2,500 Lbs
Height 34 In
Width 35 In
Base Plate Size 35 X 37 X 2 In
Low Flow 45Gpm @2000 Psi
Centrifugal Force Low 12,480 Lbs
Frequency Low 1,500 Vpm
High Flow 55Gpm @2000 Psi
Centrifugal Force High 18,650 Lbs
Frequency High 1,900 Vpm
Carrier Weight 43,000 100,000 Lbs
Oil Reservoir Capacity 2.46 Gal
Oil Type HD80-90
Motor Gear Size 2.25 In

NOTE: External drain line must be connected to in NPT case drain plug if the back pressure
exceeds 100 PSI.
REV 01-30-01

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 APPENDIX C

Chuck Housing Specifications

Figure C-01: Chuck Housing Specifications

Dimension A Dimension B Dimension C Dimension A Dimension D

Breaker Model(S)
In mm In mm In mm In mm In mm
MES 181& MES 200 4.53 115 7.28 185 11.61 295 3.54 90 3.07 78
300 Series Breakers 5.31 135 8.27 210 11.38 289 4.33 110 3.70 94
500 Series Breakers 5.91 150 8.94 227 14.57 370 5.91 150 4.33 110
600 Series Breakers 6.69 170 9.06 230 13.58 345 4.72 120 5.04 128
MES 1050 & MES 1200 7.09 180 11.61 295 17.32 440 5.91 150 5.31 135
MES 1500 8.07 205 11.69 297 17.72 450 5.75 146 6.61 168
MES 1750 8.27 210 15.91 404 22.05 560 7.64 194 7.01 178
MES 1800 8.66 220 17.52 445 23.62 600 8.66 220 7.28 185
MES 2000 8.66 220 17.32 440 23.62 600 8.66 220 7.48 190
MES 2500 9.45 240 19.80 503 25.91 658 9.65 245 7.72 196
MES 3000 10.63 270 20.20 513 25.98 660 9.25 235 8.86 225
MES 3500 10.63 270 23.03 585 28.35 720 10.63 270 8.86 225
MES 4000 11.42 290 22.05 560 27.76 705 10.24 260 8.86 225
MES 5000 11.81 300 25.79 655 33.46 850 11.02 280 9.37 238
MES 7000 12.99 330 27.36 695 35.43 900 11.81 300 10.83 275
MES 8500 14.17 360 27.95 710 37.01 940 12.60 320 11.81 300
MES 12000 16.54 420 26.77 680 37.01 940 12.60 320 14.02 356

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

Figure F-02: Mounting Bracket Specifications MES 621 through MES 2000

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 Figure F-03: Mounting Bracket Specifications MES 2500 through MES 4000

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

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 Figure F-05: Mounting Bracket Specifications MES 12000

PPM2000000 Version: 102700 128

 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

HARDOX and WELDOX have low Steel Grade Thickness Carbon

carbon equivalents for their strength range equivalent CE
class. A steel with a low carbon (IIW)
equivalent (CF) has better weldability A 572-50 3/16 4 in. 0.39 - 0.43
than a steel with a high value. Typical WELDOX 100 5/32 5 in. 0.39 - 0.64
CE values for a particular plate WELDOX 130 5/32 3 in. 0.56
thickness are given in our data sheets. WELDOX 160 3/16 1 in. 0.68 - 0.72
WELDOX 400 5/32 5 in. 0.36 - 0.70
The carbon equivalent (according to WELDOX 500 3/16 3 in. 0.58 - 0.68
the IIW) can be calculated from the
following equation: Table G-01: Typical CE values for a particular plate
thickness
Mn Cr + Mo + V Cu + Ni
CE = C + + +
6 5 15

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* Table G-03: Recommended

for different combined plate thicknesses [inch] 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 Figure G-03: HARDOX Weld Figure G-04: HARDOX
Measure Temperature Preparation 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
Decreasing Higher productivity Increasing
heat input heat input

Figure G-05: Recommended max. heat Figure G-06: Hardness profile HARDOX 400
input when welding HARDOX 400 and
HARDOX 500

Figure G-07: Recommended max. heat

input when welding WELDOX

To Calculate the Heat Input

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

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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

WELDOX 100 Matching / Undermatching
WELDEX IOO to WELDEX I60 are
WELDOX130 Undermatching
welded, it is advisable to consumables
WELDOX160 Undermatching
with different degrees of matching, e.g.
HARDOX 400 / 500 Undermatching
soft consumables in the root run and
consumables of higher strength in the Table G-05: Recommended degree of matching
filler beads. when HARDOX and WELDOX steels are welded

*) 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 low-

strength filler material rather than high-
strength 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 Figure G-08: Recommendations on storage of the
to heavy wear, hard facing consumables filler material
can be used for the cap beads.

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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. Low porosity.

Stable arc. 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.

PPM2000000 Version: 102700 136

 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

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

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MES 300 THROUGH MES 553

Figure H-03: Exploded Parts for MES 300 and MES 553

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MES 601 THROUGH MES 3000

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

PPM2000000 Version: 102700 140

MES 3500 THROUGH MES 12000

Figure H-05: Exploded Parts for MES 3500 and MES 12000

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