NEXGEN IMPULSE 100L, Operations Manual & Parts List

Page 1: ...OPERATION MANUAL PARTS LIST HYDRAULIC BREAKER IMPULSE 100L S ...

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Page 4: ...an be operated in any position ranging from horizontal to vertical and in ambient temperatures of 40 C to 40 C Before operating the breaker the instruction and safety manual should be read and understood Adhering to all the requirements of the instructions in this manual the manufacturer guarantees high productivity reliability and safe operation WARNING Breaker s operator must read and understand...

Page 5: ...ecautions in this manual as well as safety stickers and plates on the breaker itself Warning messages are classified below so that the operator can read and learn them either in this manual or on the breaker itself DANGER Points at hazards This shows the most dangerous situation CAUTION Points at a potentially hazardous situation WARNING Points at a potentially hazardous situation which may cause ...

Page 6: ...ns after operation is completed Before the operator leaves the equipment make sure the breaker is moved down to the ground level and the equipment s engine is turned off Clean your attachment and equipment regularly keep your work area organized Be careful with the hydraulic oil pressure Before disconnection or connection of hydraulic hoses stop the equipment engine release oil pressure in the hos...

Page 7: ...10 psi Oil flow l min 30 50 The purity class of the hydr oil by Russian ISO 4406 1999 no less than 19 16 Working tool s diameter mm in 68mm 2 67in Working tool s useful length mm in 345mm 13 58in DN hoses mm fitting 13 1 2 BSP Nitrogen chamber charging pressure bar psi 16 17 bar 232 246 psi Breaker s length without tool and mounitng plate mm in 970mm 38 18in Breaker s length without tool and with ...

Page 8: ...8 04 DESIGN AND COMPONENTS OF BREAKER 4 1 Components of Impulse 100S breaker 1 3 5 10 11 8 2 6 7 8 4 1 3 5 10 11 8 2 6 7 8 4 ...

Page 9: ...07 005 Pressure plate 1 4 Mounting plate for excavator 1 4 1 Mounting plate for loader 1 5 Working tool 1 6 ТК 296 07 004 Bottom buffer 1 7 ТК 297 22 003 Upper buffer 1 8 ТК 297 22 002 Upper buffer ring 1 9 Seal S01 P 99 66 18 1 10 Screw М16х55 10 9 12 11 Locking washer 16Т DIN 127 12 12 Nut М16 10 0 DIN 985 12 ...

Page 10: ...breaker 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 19 33 33 13 40 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 19 33 33 13 40 ...

Page 11: ... 5 1 16 ТК 080 00 188 Buffer ring ST08 94 40х100 00 2 1 17 Screw М14х100 8 8 DIN 912 8 18 Screw М20х40 10 9 DIN 912 2 19 Adapter 1 2 х1 2 2 20 Locking washer 14 DIN 127 8 21 Locking washer20 DIN 127 2 22 Spring pin 12х60 1 23 Oiler М10 1 24 Plug М10 1 25 Plug VHR 90 3 8 ED 4 26 O ring 1 2 2 27 Plug blind nut AB08 1 2 2 28 DF05D 0040 Seal ISI 70х80х6 1 29 DF05D 0050 Seal DSI 70х80х6х8 1 30 DF05D 00...

Page 12: ...reaker Return line Pressure line Relief valve Relief valve Pump Hydraulic distribution valve Operating сontrol block NOTE If the hydraulic circuit of your machine differs from scheme 5 1 contact your dealer or the equipment manufacturer 5 2 General view NOTE Check all oil supply lines for compliance with the hydraulic pressure of the breaker A pressure release valve should be mounted if there is n...

Page 13: ... Operating control block Directional valve Intput pipeline pressure line Output pipeline drain line 5 3 Installation of the breaker on an excavator WARNING Never put your hands or fingers into the pin holes WARNING During arm hole adjustment ensure there is no one under the arm of the equipment or excavator bucket Moving the equipment while installing the breaker is dangerous Wear safety boots to ...

Page 14: ...p the equipment s engine turn off directional control valves and release air pressure from the hydraulic tank 6 Take plugs off of the hydraulic hoses at the end of the excavator s arm connect the breaker to the hydraulic circuit using high pressure hoses NOTE Be careful to avoid oil leakage onto the ground Keep the plugs from the hydraulic circuit in the toolbox when they are not in use Every time...

Page 15: ...ety boots to protect your feet 1 Set the breaker on a clean horizontal surface Block the brake pedal of the equipment 2 Stop engine 3 Set stop valves in the closed position 4 Disconnect high pressure hoses and shut off valves and make sure there is no oil leakage 5 Connect plugs to high pressure hoses 6 Take off excavator s arm and linkage pins 7 Take equipment s arm out of the breaker s mounting ...

Page 16: ...arts 6 2 Informational stickers plates Tag Charge pressure Tag High pressure hose connections Greasing points tag Tag Check pressure before operation Warning tag High noise level ear protection is required Warning tag Read and understand manual before operation Tag Discharge pressure before dismounting Machine marks and numbers Warning tag Projectile rock chips Model Serial Number Manufacuring Dat...

Page 17: ...ry 50 hours or weekly Check the gap between the working tool and tool bushing Check the working tool s condition Check the nitrogen pressure in the breaker s gas chamber Every 200 hours or every month Check the working tool s pins condition Every 1000 hours or every 6 months An inspection of the breaker in authorized service station is recommended Every 1500 hours or once every two years Change al...

Page 18: ...hever comes first Oil temperature The oil temperature depends on environmental conditions the efficiency of the cooling system the connection scheme and the operating mode of the hydraulic breaker The normal operating oil temperature range is 20 C 80 C If the temperature falls lower than 20 C the oil should be preheated before starting the breaker To heat the oil you should start the equipment and...

Page 19: ... danger of cavitation in pumps and hydraulic breaker sticky valves if the filter is too dirty the hydraulics of the equipment may be damaged If the oil is too thin efficiency losses internal leakages damage of gaskets seals or O rings accelerated parts wear due to lack of lubrication Oil purity Oil filters as per the filtration specifications should comply with the excavator or any other equipment...

Page 20: ... Retinax AM Grease S 5826 Kuggfett Albida HLS 2 Mobile Special Grease Mobile ASPO Molycent MP Grease TEBOIL Tebo Gear Grease MDS UNION Texaco Molytex Grease Delta Marathon DM 3000 RAMMER TOOL GREASE part no 902045 FUCHS Meisselpaste KENDALL Tough TAC KLUBER Crafloscon C SG 0 Ultra LE 3751 3752 Almagard varipurpose lubricant WYNNS GS80 Russian ГОСТ 3333 55 УСсА ГОСТ 3333 80 23258 78 СКа 2 6 23 6 6 ...

Page 21: ... Relief valve Charging valve Needle Pressure gauge Charge valve Pneumatic hose T handle Nitrogen cylinder N 1 Carefully open the plug of the nitrogen charging valve 2 Put charge valve into the charging valve 3 Close relief valve 4 Screw on charging valve cap 5 Screw on pressure gauge 6 Push needle once and hold it for 5 seconds you ll see the charging pressure of the gas chamber on the pressure ga...

Page 22: ... required pressure is achieved release the needle 12 If the pressure in the chamber is too high adjust it by holding the relief valve needle 13 Repeat step 6 to check the pressure 14 Repeat step 7 and disconnect the charging system from the breaker 15 Close the charging valve Model Charging pressure Impulse 100S 16 17 bar 232 246 psi 6 7 Adjustment of relief valve The breaker s pressure relief val...

Page 23: ...urs find and eliminate the cause Be careful not to damage seals with excessive strain 6 9 Inspection of gap between tool and tool bushing A A Too large of a gap between the tool and the sleeve due to wear can cause damage or breakage of the tool bushing and piston It may also cause the formation of burrs on its surface and consequently leakage of hydraulic oil Maximum wear limit between the tool a...

Page 24: ... Tool exchange Dismounting WARNING Falling parts during replacement may result in injury Wear safety shoes to protect your feet 1 Remove the linch pin from the tool pin using a hammer and knockout pos 21 2 Remove the tool pin from the breaker s housing pos 11 3 Remove the working tool Mounting new tool NOTE Tool shank and impact area must be thoroughly greased before installing 1 Install the worki...

Page 25: ...g m 294 n m Torque recommended for assembling main body Impulse 100S pos Part Q ty Torque value kg m n m Thread fixing fluid Preliminary Final 17 Screw М14х100 8 8 DIN912 8 5 1 50 11 110 Loctite 243 18 Screw М20х40 10 9 DIN 912 2 15 150 30 1 300 Loctite 243 19 Adapter1 2 х1 2 2 10 2 100 no 25 Plug VHR 90 3 8 ED 4 4 1 40 Loctite 270 WARNING Never use an impact wrench for screwing or unscrewing the ...

Page 26: ... as it may be overheated and can cause a burn injury Inspect the breaker for exterior oil leakages and check the tool condition If you operate your breaker underwater a special underwater kit is required dry the water from the tool and grease the pin holes in the adaptor plate Close the pressure and return couplings with pressure plugs When not planning to use the breaker for an extended period st...

Page 27: ...27 WARNING Neglecting the following procedures will cause housing rust which will result in serious damage ...

Page 28: ...breaker and equipment for safety before operation to avoid accidents Warming up equipment In cold temperatures and especially in the wintertime warm up the equipment before you start operating the breaker Safety maintenance Work sites can be hazardous Inspect the site before working on it check for potholes weak ground hidden rocks and old buildings 7 2 2 Warning for operating equipment Movement M...

Page 29: ...aterial is broken It will overheat the hydraulic system cause undue wear and result in damage to the breaker s parts Don t use your breaker as a lever to move stones by tool point or the breaker s body It may cause damage to the bolts working tool or other components Don t use your breaker tool as a pry bar Don t operate the breaker underwater Underwater operation without special underwater kit ma...

Page 30: ...e dust layer which slows the breaking effect Move your breaker to another object if there is no breaking for more than 15 seconds Constant breaker operation for more than 30 seconds may cause the working surfaces to overheat in the pair of piston sleeves and it will increase the chances of galling as well as seal damage Stop time should be longer than the time of operation Keep the incline of the ...

Page 31: ...e gas chamber In and Out ports are closed Open in and out ports Oil level is too low Add some oil Output of the tool is not in striking position for piston Push the tool deeper into the breaker body by pushing the tool with your equipment Impact energy is too low Nitrogen gas leakage from the gas chamber Charge nitrogen into the gas chamber Uneven impact rate Filter blocked Wash or replace filter ...

Page 32: ...ing tool Tool bushing and working tool seize and as a result block the tool motion Clean up tool and bushing surface Deformed working tool or strike surface Change working tool Gas leakage from the gas chamber Seize of charging valve Clean up charging valve O ring or and gas gasket damage Change gaskets ...

Page 33: ...itrogen cylinder T handle Pneumatic hose Charge valve Pressure gauge Needle O Ring Cap Part description Part number Q ty 1 Pressure gauge 1 2 Charge valve 1 3 Cap 1 4 Pneumatic hose 1 5 Nitrogen gas cylinder 5 liters 1 6 O Ring FB513212 011 015 25 1 ...

Page 34: ...oft medium sized stones C Flat End Is suitable for breaking large hard stone blocks D Moil Point The most universal and effective tool for breaking concrete asphalt and frozen ground CAUTION Never weld on the working tool as it loses its wear resistant properties when heated CAUTION Correct working tool choice is very important not only to increase the breaker s performance but also extends its se...

Page 35: ...e subject to constant wear These warranties do not cover failures resulting from If you use your breaker for other than its intended purpose or if your equipment s specifications don t meet breaker s requirements If you mount the breaker on faulty equipment Improper service or operation Poor maintenance Use of low quality oil and lubricants Disregarding oil purity and viscosity requirements Modify...

Page 36: ... PAGE Please fill in the form and keep it togehter with the manual You should use the data in the form when you contact the dealer PRODUCT MODEL SERIAL NUMBER DATE OF MANUFACTURE YOUR DEALER DATE OF SALE EQUIPMENT MODEL ...

Page 37: ...point Chisel 5 Grease gun 300 ml 1 6 Working tool grease 300 ml 1 7 Charging valve 1 8 Pressure gauge glycerine filled 1 9 Cylinder 5 L with T handle 1 10 Adapter to the gas cylinder 1 11 O ring 16 6 2 1 12 O ring to gas cylinder 1 13 Nut G3 4 1 14 Pneumatic hose 3 8 1000 1 15 Knockout 1 16 Wrench 27x32 1 17 Service Tool case 1 18 Hydraulic breaker manual 1 ...

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Page 40: ...NEXGEN Attachments Inc 1 866 921 0333 info nexgenattachments ca www nexgenattachments ca ...