Operating instructions

Indeco hydraulic breaker: operating instructions

As a general rule, the hydraulic breaker should be used in the same way as a hand-held breaker. To achieve top productivity, the breaker should be fitted with the right tool for the material to be demolished.

The world's first intelligent hydraulic breaker

Our breaker is intelligent in the sense that it automatically evaluates the hardness of the rock and adapts the striking frequency and energy per blow. From the variations in the energy per blow, the operator can understand how consistent the rock is.

The operator therefore gets several benefits from a truly collaborative working relationship with this breaker. In fact, when the rock is fragile or fractured, the breaker rhythm will be rapid and sharp; whereas if the rock is compact and uniform, the rhythm will be regular and powerful. The breaker rhythm also varies as the tool penetrates into the rock.

How to use the breaker

1. Before starting up the breaker, check that the hoses are free from any obstacles and that there are no bottlenecks in the excavator boom.
2. Make sure the tool is properly greased. If there is an automatic lubrication system, make sure that the grease injection line is primed and that the grease can flow to the breaker.
3. Start up the engine of the excavator, keeping to 2/3 of its maximum potential.
4. Place the breaker tool perpendicular (Fig. 1-2) to the surface that is to be demolished, applying the right down pressure using the excavator boom. Begin work. Warning: if the down pressure from the boom is too low, the body of the breaker will rattle against the casing, making metallic noises; by contrast, if the pressure is too high, the breaker will transmit extremely hard vibrations to the excavator (Fig. 3-4).
   To prevent damage both to the boom and to the breaker, constant and correct boom pressure must be applied, and this will work on the breaker as the tool penetrates.
5. Correct use of the breaker prolongs the life of the tool and bushings. So the operator has to follow the breaker as it penetrates, moving the boom in a semi-circular motion.
6. As soon as cracks form in the material being demolished, the tool will tend to slip out of the bushing stop the breaker immediately to prevent blank firing, which can be damaging.
   Warning: do not raise the breaker until it has completely stopped.

fig. 1	fig. 2	fig. 3	fig. 4

How to prevent damage to the breaker

1. The breaker must not be used as a ripper (Fig. 5).
2. Do not use the breaker tool to pry up material (Fig. 6)
3. The breaker must always work perpendicular to the area being demolished.
4. Start up the breaker only if resting firmly on the tool.
5. Check that the breaker meets no obstacles when following the tool (Fig. 7).
6. In order to demolish unstable rocks, you may find it convenient to use the breaker body to move them. Do not use the breaker tool to pry up material.
7. Do not persevere on any given spot if penetration has not been achieved alter 45 seconds. Reposition the breaker slightly to one side, or look for a weak point in the rock (Fig. 8-9) such as layers, cracks, etc.
8. Keep the breaker in a vertical position at all times when resting, or for any prolonged period of inactivity (Fig. 10). If the breaker were to be put down in a horizontal position, this would cause permanent damage to the cylinder's lip seal rings which would bear the whole weight of the piston.
9. The ring on the front of the casing through which the tubes pass must never be used as a lifting ring.
10. Do not use the tool as a lever to rotate the excavator. That will break the tool (Fig. 11).
11. During horizontal or head-down operations (e.g. tunnelling) after every hour of work, place the breaker in a vertical position for one minute (Fig. 12).
    This will help to remove any rock debris trapped in the bushing that will reduce the impact energy and overheat the tool. If this is not sufficient, inject compressed air into the hole provided on the chuck housing. The pressure will be sufficient to prevent any debris from entering.
12. The excavator should be kept in a stable position, never on steep or loose ground (Fig. 13-14) This would damage the tool or the bushing.
13. At the end of the shift, leave the breaker in an upright resting position. Do not leave the tool stuck inside the ground, since it could break - especially during the cold season - as the boom gradually settles, exerting greater down force on the tool.

fig. 5	fig. 6	fig. 7	fig. 8	fig. 9
fig. 10	fig. 11	fig. 12	fig. 13	fig. 14

Troubleshooting: checklist

Find the problem in the checklist below. Each letter corresponds to a type of remedy, to carry out in alphabetical order (eg if the breaker does not strike, first try out action A, then B, then E, then F and so on).

Troubleshooting: possible causes and solutions

1. Check the efficiency of the excavator's solenoid valve or distributor. Push the tool down to load the piston and try again.
2. Connect the high-pressure pipe to the return pipe and check that the full flow does not cause too much -back-pressure (see enclosed technical specifications). Check the efficiency of the filter and replace it if necessary with a filter with a wider mesh. Check that the diameter of the return line is as indicated in the technical data and that the return line is connected directly to the hydraulic tank.
3. Check that the pressure-relief valve on the excavator circuit does not open. If it does, check the calibration.
   As a general rule, the minimum pressure at the excavator must be at least 30% higher than at the breaker.
4. Check that the excavator hydraulic circuit is not leaking (pump or other components).
5. Dismantle the accumulator and check the mushroom valve in the head, and the non-return valves located between the cylinder and the circular guide.
6. Check the efficiency of the side bolts (tie-rods) and repair if any are loose or broken.
7. Dismantle the pressure-regulating valve (Item 418 in the attached exploded view) and check that it is working correctly.
8. Dismantle the tool and check that the piston inside the breaker is free.
9. Check whether the pipes are vibrating a lot, especially the inlet pipe. If necessary, replace the accumulator diaphragm and recharge it.
12. Make sure that the inlet pressure at the breaker is not too low. It must fall within the range shown in the enclosed technical specifications.
13. Check that the oil flow is consistent with the indications set out in the enclosed technical specifications.
14. Check the calibration and condition of the variable speed valve and the preloading spring, and make sure the needle is not seized, etc.
15. Check that the oil temperature does not rise above 85°C. If so, wait for the oil to cool down. Check the viscosity of the oil and if necessary change it.
16. Check that there are no defects in the excavator cooling system or oil leaks inside the breaker, which cause a characteristic loud hissing sound in the head; if so, replace the O-ring mounted inside it and check the seals on the steel diaphragm and the shock absorber cover.
17. Check whether the working pressure when breaking the same type of material tends to reduce as the tool tip penetrates. If so, check that the spring of the pressure valve is working properly, that the O-ring of the barrel is not worn and that the slide (Item 413) moves freely inside the barrel.
18. Check the wear on the bushings in the chuck housing.
19. Check that the piston is not scored, and if so repair it or replace the lip seals.
20. Check that the breaker has not been operating underwater. If so, carry out a generai check-up.
21. Check that the tool is in perfect condition on the holding cone and check the wear on the spacer.
22. Contact your nearest Indeco dealer or the head office.