IHC-70-Compactor Manual

COMPACTOR MANUAL
IHC70
YOUR PARTNERS IN DEMOLITION
Note: This manual is written in English. It is for use only by people that can read, speak and understand
English. In addition, the operators of the attachment (compactor) must also read, speak and understand
English.
TABLE OF CONTENTS
3
4
5
6
12
WARRANTY
PREFACE
DECLARATION OF CONFORMITY
I SAFETY INFORMATION
Precautions
6-9
Safety Decals
10
Airbore Noise
11
II TECHNICAL SPECIFICATIONS
IHC75
14
12-13
III EXPLODED VIEW AND PARTS LIST
IHC75
18
14-15
IV VALVE & HOSE PARTS AND INSTALLATION
HVFK050F000 Manifold Assembly with Fittings
16
20
21
22
V COMPACTOR INSTALLATION
Preping the Carrier
18
Setting Up Compactor
19
Trouble Shooting
20
Compactor Installation Record
21
VI COMPACTOR OPERATION Initial & Normal Operation
VII COMPACTOR MAINTENANCE (Daily, Weekly, 500 Hours)
VIII COMPACTOR ECCENTRIC
Assembly Procedure
Cross Section
2
16-17
Compactor Manual
24
25
WARRANTY
INDECO NA 135 Research Drive Milford, CT 06460
Standard New Compactor Limited Warranty
INDECO N.A. warrants New Indeco Compactors to be free of defects in materials or workmanship subject to
the following terms and conditions.
1)
Warranty period shall be 12 months from date of first installation.
2)
This Warranty covers Labor as listed in the INDECO Flat Rate Schedule at 75% of the Distributors shop labor rate.
3)
This Warranty covers Compactors used in accordance with published INDECO maintenance and operation procedures.
4)
This warranty does not cover failures determined by INDECO to be due to lack of
lubrication, improper installation, poor maintenance or improper operation.
5)
This warranty does not cover the replacement of Wear Items.
The following parts are considered to be Wear Items:
Shock Absorbers
6)
This Warranty does not cover the replacement of service items during the course of normal maintenance.
The following parts are considered Service Items:
O-ringsSeals
7)
This warranty does not cover loss of operating time, loss of use or other consequential damages while the Compactor is out of service.
8)
The repair or replacement of parts during the warranty period does not prolong this warranty.
9)
This Warranty does not cover, or include, items sold with, or attached to, the Compactor.
Examples: Grease Pumps, Hydraulic Kits and Hoses.
10)
Use of Non INDECO OEM Spare parts will terminate this warranty.
11)
Altering or modifying of the Compactor without the written approval by INDECO will terminate this warranty and any obligations under this warranty.
12)
Warranty Registration: INDECO assumes no liability for warranty request submitted for products for which a New Product Warranty Registration form has not been completed and submitted to INDECO within 60 days from the time of first installation of the Compactor. Any warranty request submitted for a product for which INDECO does not have a New Product Warranty
Registration form on file will be denied.
INDECO does not authorize any other person or company to assume its liability in connection
with the sale or use of its products.
WAR-0010-CREV 01-01-10
4/29/2015
3
DECLARATION OF CONFONFORMITY
Manufacture and address:
Indeco North America
135 Research Drive
Milford Connecticut, 06460
U.S.A.
We declare under our sole responsibility that the product described as:
Machine description: Hydraulic compactor
Make: Indeco
Type: IHC70
Serial number: /
Complies with the requirements of the following directive:
Machinery Directives 98/37
Standards considered:
EN 21200-1, EN 12100-2
Date January 1, 2010
Chief Executive Officer,
Signature
4
Compactor Manual
PREFACE
Congratulations on your purchase of this fine INDECO product. To best utilize the advanced
technology engineered into our attachments, we recommend you take the time to familiarize yourself with this manual and the attachment. The information in this manual will
ensure long life, high productivity and minimum downtime from this attachment. Because
we want you to be pleased with your decision to purchase our products, compactor owners
should strictly adhere to the information and technical specifications contained within this
manual.
The INDECO Hydraulic Compactor is simply a machine, and like any other machine, is designed to perform within specified guidelines. The compactor takes the hydraulic energy
created by the carrier pumps (excavator, tractor loader backhoe, etc.) and converts this
energy into mechanical or kinetic energy. Therefore, the perfect match of hydraulic compactor to carrier is essential in order to produce maximum performance of the compactor. If the
hydraulic energy (oil pressure, oil flow and return oil pressure between carrier and the compactor) is outside the INDECO specifications contained herein, then the compactor’s mechanical energy will also be incorrect. Statistics show that 90% of all compactor problems
can be traced back to incorrect mechanical or hydraulic installation to the carrier.
While every attempt has been made by INDECO to manufacture a superior product, we
cannot install the compactor. It is up to the dealer to ensure that compactors are installed
within the enclosed correct parameters for their particular carrier.
To further ensure maximum productivity and longevity of INDECO compactors,
we recommend:
•
•
•
•
Adherence to INDECO’s daily, weekly and annual compactor maintenance
programs (enclosed)
Regular replacement of carrier hydraulic filters (especially in dusty conditions)
Always check compactor circuit flows and pressures when the carrier is changed
Annual checks of compactor circuit flows and pressures
If problems with the compactor do occur, we have made every attempt to include any eventuality in this Owner’s Manual. Most problems can be easily remedied due to the causeand-effect nature of these machines. We have also done our best to ensure correctness of
the information within. However, the manufacturer reserves the right to update this manual
subject to the technological development of the product and service.
4/29/2015
5
I SAFETY INFORMATION
Safety Precautions
Before operating this INDECO Hydraulic Compactor, please read carefully the
enclosed information. If you have any questions consult your INDECO dealer
for more information.
•
The dealer must instruct user on proper and safe operation
before delivery of this compactor.
•
Wear safety glasses, hard hat and noise protection while
operating compactor.
•
Operate compactor only while inside of cab of machine.
•
Keep all personnel well clear of machine and compactor while in operation.
•
Install a safety protection device between operator and
compactor.
•
6
Use common sense when using this compactor. Flying stone
chips can injure or even kill.
Compactor Manual
I SAFETY INFORMATION
Carefully read the following safety precautions. Make sure you fully understand them. Failure to follow a safety warning or recognize and rectify a
safety hazard could result in injury of death to you or others around you. In
general, always use common sense in your work habits and keep your tools
and equipment in good operating condition.
Use trained personnel
Allow only trained personnel to operate or service this equipment. Read
and understand all safety precautions listed in the Indeco manual and in
the Carrier manual.
Flying objects or high-pressure fluid hazards
Do not operate Indeco equipment with personnel in the immediate proximity of the equipment because of possible flying objects of high-pressure
fluid hazards. The operator’s compartment should have the necessary
protective guards to prevent entry of flying or falling objects.
Wear correct safety protection
Verify that all personal wear protective headgear, eye protection and steel toe boots.
In dusty conditions, wear a respirator to protect against dust.
Do not wear loose fitting clothing or jewelry while working on the machine.
Pay attention to your hands when mounting the compactor
Keep your fingers clear when inserting mounting pins. Do not use your fingers to
“feel” pin alignment. Unexpected boom or equipment movement could result in injury
and possible loss of your fingers. Instruct the operator to touch the controls only when
instructed.
4/29/2015
7
I SAFETY INFORMATION
Precautions
Relieve system pressure prior to working on equipment
Escaping fluid under pressure can penetrate the skin causing serious
injury.
To avoid any risk, be sure to relieve the pressure before disconnecting
hydraulic lines. Consult the operator’s manual of the carrier for the proper
procedure for relieving pressure.
Important checkpoints before operation
√ Tighten all hydraulic fittings before applying pressure.
√
Keep hands and body away from pinholes and nozzles that eject fluid under high pressure.
√
Do not use your hands to search for leaks. Use a piece of paper.
Operation and maintenance precautions
Never activate the compactor unless the operator is in full control of the carrier and is
seated in the operator’s seat.
Do not operate the compactor above 180°F (82 C) hydraulic oil temperature.
Do not make any alterations to the compactor without authorization from Indeco
Product Support Department.
Make frequent visual inspections of fasteners, attaching pins, hoses and rubber
isolators.
Use caution when torquing fasteners, do not over torque. Adhere to SAE torque
specifications only. A previously overstress part may fail later.
8
Compactor Manual
I SAFETY INFORMATION
Precautions
Major compactor components are heavy. Always use an adequate lifting device.
Never mount the compactor on a carrier that cannot adequately handle the compactor weight.
For nighttime operation, the carrier should offer adequate lighting for safe operation during compacting, repositioning of transporting (European harmonized standard EN-500-0 paragraph 5.1).
Never use the compactor as part of a lifting device, additional weight could cause the carrier to tip over or cause damage to the compactor components
Be cautious of flying metal particles when striking any hardened parts with a hand held tool.
Operate the compactor aware of the effects the vibrations may have on trench walls and never operate the compactor in a trench with personal working nearby in the trench at the same time.
Never service or work on the compactor in an open trench of other unsafe area.
Always clean up oil spills.
Do not over compact near buried utilities or foundations; serious damage to utilities or foundations could result.
Keep personnel clear of the full range of swing, reach, height, depth of carrier boom while operating or positioning the compactor. During standby periods, always lower carrier boom so the compactor rests firmly on the ground and turn off the carrier engine.
Make sure that a window of protective screen is in place on the carrier to fully protect the operator against flying objects.
4/29/2015
9
I SAFETY INFORMATION
Safety Decals
Maintain safety decals
Always replace any safety or warning decals that become damaged of illegible. Replace
all safety of warning decals when repainting the equiment. These decals are available
from your Indeco dealer or from Indeco.
10
Compactor Manual
I SAFETY INFORMATION
Airbore Noise
Statement of conformity with Directive 98/37/EC
Indeco North America, 135 Research Drive, Milford Connecticut, USA, as manufacturer
and keeper of technical documentation, declares under its own responsibility that the
Indeco Compactor, model IHC50 conforms with the essential health and safety requirements of framework directives 98/37/EC and successive modifications, has the following measured sound levels;
SOUND POWER LEVEL (MEASURED)
Continuous A-weighted sound pressure level at workstations
Exceeds 70 dB (A) at 38.1 meters (125 feet)
Sound power level emitted by machinery where the equivalent continuous A-weighted
sound pressure level at workstations. Exceeds 85 dB (A) at 13.7 meters (45 feet)
1-18-2010 PTU, IHC150 compactor
4/29/2015
11
II TECHNICAL SPECIFICATIONS
IHC70
Carrier weight:
Operating weight
Height
Width
Base Plate
Base Plate Thickness
Oil Supply
Maximum Operating Pressure
Maximum Back Pressure
Force @ Maximum Frequency
Frequency
Reservoir Capacity
(85/90W Gear Oil)
NOTE: Dimensions are nominal and are for reference only
12
Compactor Manual
3,636 - 12,701 kg
8,000 – 28,000 lbs
360 kg
790 lbs
600 mm
23.5 in
635 mm.
25.0 in
460 mm x 865 mm
18.0 in x 33.0 in
32 mm
1.25 in
76 l/min
20 GPM
200 bar
3000 psi
21 bar
300 psi
3,275 kg
7,220 lbs
33 Hz
2,000 vpm
4.7 l.
1.23gal.
PAGE LEFT
INTENTIONALLY BLANK
4/29/2015
13
III EXPLODED VIEW AND PARTS LIST
IHC70
1
3b
8
2
4a
10
12
6
7
2
4b
5
11
3b
9
13
14
6
3a
Ref #
Qty
1
1
Motor
VC9081504-WS
2
32
Bolt - ¾” - 10 x 2-¼”
HW8292
3a
2
Bolt - ½” - 13 x 7/8”
HW8215
3b
14
Bolt - ½” - 13 x 1-½”
HW30114
4a
20
Washer - ½”
HW-39754
4b
64
Washer - ¾”
HW-FW207
5
32
Lock Nut - ¾”-10
HW-NS107
6
2
Eccentric Bearing
VC9201500
7
1
Eccentric
CM-70-ECCA-C
8
1
Snap Ring
VC9100065
9
1
Base Assembly
CM-70-B-C
10
4
Isolator
VC9082500
11
1
Bearing Carrier (opposite motor)
CM-75-BSRC-C
12
1
Bearing Carrier (motor side)
CM-75-MSRP-C
13
2
Reservoir Plug - ½”- 20
HW14196
Compactor Manual
Description
Part #
3b
4a
III EXPLODED VIEW AND PARTS LIST
IHC70
16
22
17
21
15
19
20
15
23
24
25
14
Ref #
Qty
Description
Part #
14
1
Manifold/Assembly
See Page 22
15
2
Clamp Kit
HW-FF593-16
16
1
Upper Mounting Frame
CM-75-TB-ASM
17
2
Bulkhead Fitting
HF2041-1212
18
4
Fitting (valve)
HF202702-1212
19
1
Hose - Manifold “OUT” Port to Bulkhead
HH-75-19US
20
1
Hose - Manifold “IN” Port to Bulkhead
HH-75-23US
21
1
Hose - Manifold “B” Port to Front Motor Port
HH-75-24US
22
1
Hose - Manifold “A” Port to Rear Motor Port
HH-75-18US
23
2
Bolt
HW8175
24
4
Washer
HW-FW202
25
2
Lock Nut
HW-NS102
4/29/2015
15
IV VALVE & HOSE PARTS LIST & INSTALLATION
HVFK032F000 Manifold Assembly with Fittings
Fitting and port identification (IHC70)
Including Serial Numbers:
G IN
A
A1
D1
B
D3
G OUT
B1
G IN
3
B
4
27
A
26
B
A
30
NOTE: Single character
callouts identify ports
and/or cavities
IN
1
D2
2
OUT
29
28
16
Compactor Manual
IV VALVE & HOSE PARTS LIST & INSTALLATION
HVFK032F000 Manifold Assembly with Fittings
Fitting and port identification (IHC70)
Including Serial Numbers:
The IHC70 is factory equipped with a flow control valve with an integral relief bypass circuit. The flow control
valve limits the maximum flow that can be delivered to the motor on the compactor. It is 20 GPM. The relief
valve limits the maximum operating pressure of the system. The check valve allows hydraulic oil to bypass
from the return side of the motor to the supply side of the motor. This is a safety feature to prevent premature
failure of the motor if the compactor is shut-off abruptly at high speed (full flow).
The case drain only needs to be connected when the circuit-return pressure exceeds the maximum allowable
pressure. Install a hose from the case drain port on the valve to the hydraulic tank on the carrier. Ports D1
and D2 are isolated spare ports to be used as a through connection passage for a case drain if needed.
Ref #
Qty
Description
Part #
26
1
Flow Valve Manifold
HVFK032F32
27
1
Relief Valve - Port “3”
HVRV1226A0
28
1
Flow Valve Cartridge- Port “2”
HVFR1630F0-N-20
29
5
Plug
HF-FF2138-06
30
1
Check Valve - Port #1
HVCV16200N5
4/29/2015
17
V COMPACTOR INSTALLATION
Installation Procedures for INDECO Hydraulic Compactors
Prepping the Carrier.
Step one: Installing the Flow meter
Install a Hydraulic Flow-meter into the Auxiliary Circuit that will be used to run the Compator. The Flow meter should be installed in place of the Compactor and not in line with the Compactor. Also tee a pressure gauge into the return line if your Flow meter does not have a gauge port on its Outlet.
Step two:
With the Restrictor-valve on the Flow-meter turned to the fully open position, (fully closed on machines with closed center Hydraulics.) Start the machine and run at ½ to ¾ throttle.
Step three: Heating the Hydraulic oil.
Engage the auxiliary circuit and turn the Flow-meter Restrictor-valve until the Flow-meter pressure gauge reaches approximately 1500 psi. Continue to run the machine until the hydraulic oil reaches an operating temperature of at least 150 degrees Farenhiet or 66 degrees Celsius.
* Write this temperature on line F1 of the Compactor Installation Record on page 4.
The following steps should be done with engine rpm’s set at full throttle.
Step four: Setting the Circuit relief.
When the Hydraulic oil has reached operating temperature, turn the Flow-meter Restrictor-valve in until the pressure no longer rises on the Flow-meter pressure gauge. This is the current setting of the relief valve for this auxiliary circuit. Using the pressure gauge on the Flow meter reset the circuit relief valve to between 500 and 800 psi above the operating pressure of the Compactor you are installing.
* Write this pressure on line F2 of the Compactor Installation Record on page 4.
Compactor Circuit Relief Settings
IHC70 2500 psi
Step five: Setting the operating pressure.
Using the Flow-meter Restrictor-valve reset the pressure on the Flow meter gauge to the operating pressure of the Compactor to be installed.
* Write this on line F3 of the Compactor Installation Record on page 4.
Compactor Operating Pressures
IHC70 3,000 psi
18
Compactor Manual
V COMPACTOR INSTALLATION
Installation Procedures for INDECO Hydraulic Compactors
Step six: Checking the Flow
With the Flow meter pressure gauge set at the operating pressure of the Compactor, read the Oil flow on the Flow-meter flow gauge. This must be with in the range of the Compactor you are installing.
Compactor Flow Specifications
IHC70
20 gpm
Step seven: Setting the flow.
If the Flow is not within the specified range for the Compactor being installed, it must be ad
justed to within spec. Depending on the Auxiliary circuit being used, flow may be adjusted several different ways. Consult the carrier manufacturer or auxiliary kit manufacturer for the proper procedure for adjusting the flow.
* After setting the flow, write it on line F4 of the Compactor Installation Record on page 4.
Step eight: Checking the Backpressure.
With the flow properly adjusted and the Flow-meter pressure gauge still set to the operating pressure of the Compactor being installed, read the gauge, which is teed into the return line. This is the Backpressure reading for the circuit.
* Write this pressure on line F5 of the Compactor Installation Record on page 4.
Compactor *Maximum* Back pressures
IHC70 300 psi
If the Backpressure reading is too high, there is too much restriction in the return circuit.
A case drain must be installed to prevent damage to the motor.
Doing the following can decrease Return circuit pressure.
1)
Increase the size of the Return hoses and tubes.
2)
Make sure the return line runs directly back to tank and not back
through the valve.
3)
Make sure any return filters are clean.
4)
Remove elbows and/or tight bends from the return circuit.
5)
Make sure there are no kinks in the return tubes or hoses.
Setting up the Compactor
Step nine: Check oil level in reservoir
To check oil level, remove 3/8” NPT plug from the side of the oil reservoir on the base plate assembly. The operating oil level should be flush with the bottom of the plughole.
4/29/2015
19
V COMPACTOR INSTALLATION
Installation Procedures for INDECO Hydraulic Compactors
.
Step ten: Hooking up the hydraulic whip hoses.
On all INDECO Compactors the Inlet on the Compactor is the Supply (pressure) and the Out
let Port is the Return (tank). Make sure when hooking the hoses to the machine that they are installed in this fashion.
Step eleven: Running and checking the Compactor.
Start the compactor slowly and check for operation. Check compactor and hydraulic connections for leaks.
Trouble shooting
Operating pressure too low.
Recheck the flow and back pressure.
Possibly insufficient oil flow
Operating pressure too high.
Recheck the flow and back pressure.
Possibly excess oil flow to compactor and/or excessive restriction in return line.
Compactor does not cycle.
Check to make sure Compactor whip hoses are connected correctly.
(Left –Return, Right - Pressure)
Compactor runs too fast/slow.
Recheck inlet flow with Flow meter.
Use this information when filling out the Warranty Registration form (WAR-0001) you received with
the Compactor.
Dealer Name & Address:______________________________________
20
Compactor Manual
V COMPACTOR INSTALLATION
Compactor Installation Record
______________________________________
______________________________________
Compactor Model: ____________________
Serial #: __________________
Mounted on:
Machine Make: _______________ Model: __________ Serial # ___________
Flow meter readings:
F1) Temperature of Hydraulic Oil (150°F min.) ____________________
F2) Circuit Relief Valve setting:
____________________
F3) Flow meter set to operating pressure of:
F4) Flow of auxiliary circuit set to:
____________________
F5) Backpressure of return circuit:
____________________
____________________
Technician completing Installation: ______________________
Date: _____________
The installation of the Compactor is now complete. These procedures should be followed whenever
this Compactor is installed onto a machine to guaranty the best performance. Make a copy of
this page for your records and then,
Mail, Fax or E-mail this page to:
INDECO N.A.
ATTN: Product Support Department
135 Research Drive
Milford, CT 06460
Fax (203) 713-1040 E-mail [email protected]
Questions about this installation can be directed to the INDECO Service Department at:
1-800-5HAMMER (1-800-542-6637)
4/29/2015
21
VI COMPACTOR OPERATION
INITIAL OPERATION
1)
Start Machine and run at low idle.
2)
All bystanders must be clear of machine and compactor.
3)
Raise the compactor off the ground with the carrier. Rotate the compactor with the bucket control to assure that the hydraulic hoses will not be pinched or restricted. Swing the backhoe, stretch and curl the boom and stick to check for hose problems.
4)
Return compactor to horizontal position and place compactor firmly on the ground.
5)
Activate control valve on machine for compactor circuit.
6)
Test run compactor at low RPM to purge air from the hydraulic system, gradually increase the machine RPM until compactor is fully powered
Observe Compactor performance and inspect for any oil leaks.
7)
8)
When temperature is below freezing (32°F), the compactor should be operated at an idle until the hydraulic oil comes up to temperature.
NOTE: THE COMPACTOR ROTATES IN TWO DIRECTIONS. THE COMPACTOR MUST BE BROUGHT
TO A FULL STOP BEFORE REVERSING DIRECTION. IF THE DIRECTION IS REVERSED BEFORE IT
COMES TO A FULL STOP, DAMAGE CAN BE CAUSED TO THE INTERNAL COMPONENTS.
NORMAL OPERATION
1)
Normal compaction technique is to turn the compactor on and place it on the material to be compacted. Apply boom down pressure deflecting the rubber isolators about half way. The compactor is then slowly passed over the material to be compacted while continuing to apply down pressure.
2) The compactor is very effective in compacting granular materials It will produce excellent results depending on the makeup of the material being compacted and the moisture content of the material. Lifts will vary dependent on these factors.
It is necessary to turn the compactor off when it is sitting idle and being transported.
3)
22
Compactor Manual
VI COMPACTOR MAINTENANCE
DAILY
Check mounting bracket for loose, cracked or missing bolts.
Examine hydraulic hoses for leaking of chaffing.
Visually inspect compactor for housing damage.
Check hydraulic hose quick couplers for full engagement.
Check return line connection. If it becomes restricted, (pinched), motor failure could result.
Weekly
Check fasteners for tightness. Replacement fasteners should be the same type and grade as originals.
Inspect rubber isolators for condition.
Check oil level within compactor reservoir.
To check oil level, remove 3/8” NPT plug from the side of the oil reservoir on the base plate assembly. Operating oil level should be flush with the bottom of the plug hole.
500 Hours of operation
Verify carrier hydraulic flow and pressure.
4/29/2015
23
VII 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 an 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.
Install motor.
24
10)
Compactor Manual
VIII COMPACTOR ECCENTRIC
CROSS SECTION
4/29/2015
25