COMPACTOR MANUAL IHC250 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 WARRANTY 4 PREFACE 5 DECLARATION OF CONFORMITY 6 I SAFETY INFORMATION Precautions 6-9 Safety Decals 10 Airbore Noise 11 12 II TECHNICAL SPECIFICATIONS IHC250 12-13 14 III EXPLODED VIEW AND PARTS LIST IHC250 14-15 18 IV HYDRAULIC MOTOR Relief and Check Valve Operation 16-17 16 V COMPACTOR INSTALLATION Preping the Carrier 18 Setting Up Compactor 19 Trouble Shooting 20 Compactor Installation Record 21 20 VI COMPACTOR OPERATION Initial & Normal Operation 21 VII COMPACTOR MAINTENANCE (Daily, Weekly, 500 Hours) 22 VIII COMPACTOR ECCENTRIC Assembly Procedure 24 Cross Section 25 2 Compactor Manual
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-rings Seals 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 REV 8/26/2014 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: IHC250 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. REV 8/26/2014 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. Use common sense when using this compactor. Flying stone chips can injure or even kill. 6 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. REV 8/26/2014 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. 8 Use caution when torquing fasteners, do not over torque. Adhere to SAE torque specifications only. A previously overstress part may fail later. 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. REV 8/26/2014 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 IHC250 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 REV 8/26/2014 11
II TECHNICAL SPECIFICATIONS IHC250 Carrier weight: 20,412-45,360 kg. 45,000 100,000lbs Operating weight 996 kg 2,196 lbs Height 785 mm 31.0 in Width 889 mm. 35.0 in Base Plate 889 mm x 1207 mm 35.0 in x 47.5 in Base Plate Thickness 38 mm 1.50 in Oil Supply Range 189-265 l/min 50-70 GPM Maximum Operating Pressure 170 bar 2,500 psi Maximum Back Pressure 7 bar 100 psi Force @ Maximum Frequency 16,090 kg 35,473 lbs Frequency 30-37 Hz 1,800-2,200 vpm Reservoir Capacity (85/90W Gear Oil) NOTE: Dimensions are nominal and are for reference only 9 l. 2.46 gal. 12 Compactor Manual
PAGE LEFT INTENTIONALLY BLANK REV 8/26/2014 13
III EXPLODED VIEW AND PARTS LIST IHC250 11 12 7 10 9 6 14 4 5 3 13 10 9 1 5 2 8 9 Ref # Qty Description Part # 1 1 Base Plate Assembly CM-250-B-C 2 1 Bearing Carrier (opposite motor) CM-250-BSBR-C 3 1 Eccentric CM-250-ECCA-C 4 1 Bearing Carrier (motor side) CM-250-BSBR-C 5 2 Eccentric Bearing VC9337000 6 1 Snap Ring VC9100200 7 1 Motor VC306930 8 2 Bolt ½ - 13 x 1.25 HW-HC8217 9 36 Washer ½ HW-39754 10 18 Bolt ½ - 13 x 1.50 HW-30114 11 2 Bolt 5/8-11 x 1.50 HW-8264 12 2 Washer 5/8 SAE G8 HW-FWA206 13 2 Reservoir Plug HW-14196 14 Compactor Manual
III EXPLODED VIEW AND PARTS LIST IHC250 16 17 19 15 18 19 21 20 22 23 24 Ref # Qty Description Part # 15 1 Bracket Top CM-250-TB-ASM 1 Hose Kit IHC-250 Hose Kit Long-R 16 2 Bulkhead Fitting HF2041-1616 17 1 Hose Lower Motor Port to Left Front Bulkhead Fitting HH-250-38US 18 1 Hose Front Motor Port to Right Front Bulkhead Fitting HH-250-27US 19 2 Clamp Kit HW-FF593-16 20 4 Isolator VC9338000 1 Bolt Kit, Isolator HWIHC-250-ISO 21 16 Shock Absorber Bolt - ¾ - 10 x 2.5 HW-8293 22 76 Washer - ¾ FLAT SAE G8 HW-FW-207 23 32 Lock Nut - ¾ - 10 SAE G8 HW-NS-107 24 16 Shock Absorber Bolt ¾ - 10 x 2.25d HW8292 REV 8/26/2014 15
IV HYDRAULIC MOTOR Relief and Check Valve Operation Release/Check Valve Optional Case Drain Port 16 Compactor Manual
IV HYDRAULIC MOTOR Relief and Check Valve Operation The IHC250 hydraulic motor is equipped with a relief valve that 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 shutoff 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 motor to the hydraulic tank on the carrier. NOTE: The Motor Relief Valve is preset at the factory. For any service issues with the valve, contact the Indeco North America Service Department. REV 8/26/2014 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 port into the return line if your Flow meter does not have a separate gauge 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. If the pressure setting of the relief valve is not in spec, procede as follows. 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 IHC250: 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 IHC250: 2500 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 IHC250 50-70 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 IHC250 100 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. REV 8/26/2014 19
V COMPACTOR INSTALLATION Installation Procedures for INDECO Hydraulic Compactors. Step ten: Connecting up the hydraulic whip hoses. On all INDECO Compactors the Inlet on the Compactor is the Supply (pressure) and the Outlet Port is the Return (tank). Make sure when connecting 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 service@indeco-breakers.com Questions about this installation can be directed to the INDECO Service Department at: 1-800-5HAMMER (1-800-542-6637) REV 8/26/2014 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 7) Observe Compactor performance and inspect for any oil leaks. 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. 3) It is necessary to turn the compactor off when it is sitting idle and being transported. 22 Compactor Manual
VI COMPACTOR MAINTENANCE DAILY Weekly 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. 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. REV 8/26/2014 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. 10) Install motor. 24 Compactor Manual
VIII COMPACTOR ECCENTRIC CROSS SECTION REV 8/26/2014 25