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NEXGEN IMPULSE 100L Operations Manual & Parts List

Hydraulic breaker
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OPERATION MANUAL & PARTS LIST
HYDRAULIC BREAKER
IMPULSE 100L/S

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Summary of Contents for NEXGEN IMPULSE 100L

  • Page 1 OPERATION MANUAL & PARTS LIST HYDRAULIC BREAKER IMPULSE 100L/S...

  • Page 3: Table Of Contents

    С ONTENTS 01 GENERAL INFORMATION ON THE PRODUCT 02 SAFETY INSTRUCTIONS 03 TECHNICAL SPECIFICATIONS 04 DESIGN AND COMPONENTS OF BREAKER 05 CONNECTION AND DISMOUNTING 06 MAINTENANCE 07 OPERATION 08 TROUBLESHOOTING 09 SERVICE TOOLS 10 WORKING TOOL SELECTION 11 WARRANTY 12 REGISTRATION PAGE...

  • Page 4: General Information On The Product

    GENERAL INFORMATION ON THE PRODUCT Hydraulically operated breakers can be used as attachments to different models of hydraulic excavators of both domestic & foreign origin, as well as with other hydraulic machines (such as loaders, manipulators etc.) with relevant weights & load capacities, subject to compliance with the requirements of hydraulic circuit of excavator and breaker.

  • Page 5: Safety Instructions

    SAFETY INSTRUCTIONS Before operation Most accidents involving machine operation and maintenance are caused by failure to observe basic safety rules of connection, operation or neglecting visual inspection of the hydraulic breaker. Before operation or service of the breaker, make sure that you read and understand the safety precautions in this manual as well as safety stickers and plates on the breaker itself.
  • Page 6 CAUTION! This hydraulic breaker is not to be used for any other activity other than the work mentioned in the product designation section. CAUTION! Observe all safety precautions. Observing safety precautions • Adhere to all the rules, precautions and safety procedures while operating or servicing the breaker •...

  • Page 7: Technical Specifications

    TECHNICAL SPECIFICATIONS Specifications Impulse 100S Breaker’s weight, with mounting plate and working tool, kg / lb 275kg / 606lb Excavator’s weight, t / lb 1–6,5t / 2204-14330lb Impact energy, J / ft-lbs 630j / 464 ft-lbs Impact rate, bpm 800–1600 Operating pressure, bar / psi 90–130 bar / 1305-1885 psi Max pressure, bar / psi...

  • Page 8: Design And Components Of Breaker

    DESIGN AND COMPONENTS OF BREAKER 4.1. Components of Impulse 100S breaker...
  • Page 9 № Part number Part description Qty, pcs ТК 296.07.200 Breaker housing ТК 296.07.100 Main body ТК 296.07.005 Pressure plate Mounting plate for excavator Mounting plate for loader Working tool ТК 296.07.004 Bottom buffer ТК 297.22.003 Upper buffer ТК 297.22.002 Upper buffer ring Seal S01-P 99--66-/18 Screw М16х55 10.9 Locking washer 16Т...
  • Page 10 4.2. Main body components of 100S breaker...
  • Page 11 № Part number Part description Qty, pcs ТК 296.07.110 Breaker housing ТК 296.01.102-01 Control block housing ТК 296.03.102 Piston ТК 296.03.101 Sleeve ТК 296.01.103 Bushing ТК 296.01.104 Spacer ТК 296.01.105 Screw cap ТК 296.01.106-01 Cap (M20) ТК 296.01.113 Thrust washer ТК...

  • Page 12: Connection And Dismounting

    ASSEMBLING & DISASSEMBLING 5.1. Breaker’s connection to excavator’s hydraulic circuit This schematic shows one of the simplest hydraulic circuits when the breaker is connected to the backup distributor of the equipment Shut-o˜ valves (or quick coupler) Return line Pressure line Hydraulic breaker Relief valve Operating ontrol block...
  • Page 13 Standard breaker installation is shown in the diagram below. Oil output pipeline Stop valves (or Quick Release Valves) Oil supply Oil output line pressure line Hydraulic tank Oil input line Operating Air heater control block Directional valve Intput pipeline (pressure line) Hydraulic pump Output pipeline (drain line)
  • Page 14 CAUTION! Be careful not to allow any dust, mud or sand into the breaker and its hydraulic circuit. Perform connection and disconnection of the breakers on a clean, horizontal surface. Wooden bars 1. Set breaker on the wooden bars in a horizontal position 2.
  • Page 15 NOTE! Run excavator boom and arm for 5 minutes after the engine starts to raise oil temperature in the hydraulic circuit. WARNING! Stay away from the hydraulic breaker. 5.4. Dismounting breaker from excavator CAUTION! Be careful not to be injured by falling pins or tool during dismantling. WARNING! Wear safety boots to protect your feet.

  • Page 16: Maintenance

    Warning tag «Projectile rock chips» Model Serial Number Manufacuring Date (kg) Working Weight Nexgen Attachments Inc. +1-866-921-0333 «Greasing points tag» Machine marks and numbers Tag «Check pressure before operation» Tag «Discharge pressure before dismounting» Warning tag «High noise level, ear protection is required»...
  • Page 17 6.3. Maintenance NOTE! Before using the hydraulic breaker, make sure you have checked the following points: Every 3 hours • Add grease into the front head of the hammer (working tool greasing) • Check oil temperature, pipelines and high-pressure connections, working conditions. •...
  • Page 18 Shell Tellus V46 Tellus V32 Mobile DTE Excel 46 DTE Excel 32 Gulf Harmony 46 Harmony 32 Oil МГЕ-46В Oil ВМГЗ Russian (МГ46-В) (МГ-15В) ТУ 38-001347-83 ТУ 38-101479 Changing oil and oil filters The hydraulic breaker is advanced and high precision equipment. Internal components move at high speeds and operate within the smallest gaps, so oil purity and viscosity should be carefully measured and controlled.
  • Page 19 NOTE! Equipment’s parameters should always be monitored. Oil temperature in the hydraulic circuit should not exceed 80°C. If the temperature exceeds the maximum allowed, stop the breaker and don’t start it until the oil temperature drops to normal. Oil viscosity Viscosity is an especially important parameter of hydraulic oil.
  • Page 20 Apply tool grease with a grease gun to the greasing points marked with stickers every 3 hours of operation. Grease stickers NOTE! Grease the tool shank properly before installation. The breaker must stand upright resting on the tool to ensure that the grease will penetrate downwards between the tool and the bushing to avoid implosion and gasket damage.
  • Page 21 WARNING! Use nitrogen gas only. When charging or checking the nitrogen level, make sure the breaker’s housing temperature is ambient temperature. WARNING! Only hand tighten the charging valve! Never use a wrench to tighten it. Tightening should not exceed 20 Nm (2 kg). Pressure gauge T-handle Needle...
  • Page 22 NOTE! Nitrogen leakage for the period of 1 second is allowed. If the valve doesn’t close, twist it fully out of the housing, disassemble it and clean it so that it is free from dust and debris. NOTE! If the gas chamber is full in accordance with steps 1–7, disconnect the charge valve and the charging valve.
  • Page 23 6.8. Seals inspection CAUTION! Change all seals and gaskets every 1500 hours. 1. If any leakage is detected, damaged seals and gaskets should be replaced. Examples of damaged seals and gaskets are shown below: 2. If any seal or gasket failure occurs, find and eliminate the cause. Be careful not to damage seals with excessive strain.
  • Page 24 Model Maximum wear 6mm / 0.23in Impulse 100S 6.10. Tool pin inspection NOTE! Every 200 hours or once a month, check the condition of the tool pin, and if necessary, remove the influx of metal, clean the surface of the finger with a file or angle grinder.
  • Page 25 6.12. Bolts torque chart NOTE! Operating the breaker with loose bolts and nuts may cause oil leakage, bolt and nut thread damages and bolt failure. 1. Check the torque of the bolts and nuts before starting operation. 2. Tighten bolts and nuts according to the torque values mentioned in the chart below. 3.
  • Page 26 The screws of the valve block (pos. 17) are tightened sequentially in two steps: first as preliminary tighten (hand tighten), then final tighten in the same sequence. 6.13. Storage When the breaker has stopped operation or after the job is finished When you stop working, clean the breaker.
  • Page 27 WARNING! Neglecting the following procedures will cause housing rust which will result in serious damage.

  • Page 28: Operation

    OPERATION Before operation make sure the equipment is in good working condition to avoid injury. 7.1. Starting operation To engage the breaker, put the working tool on the material to be crushed, and using the excavator arm’s force push the working tool inside the breaker so that it is fully inside the breaker and start operation.
  • Page 29 7.2.3. Safe operation Stop the breaker if you feel over vibration of the hydraulic high-pressure hoses. Check nitrogen pressure in the accumulator and in the gas chamber. As soon as the material is broken, release the control lever or pedal to prevent unnecessary blank firing. Blank firing is continued breaker operation after the material is broken.
  • Page 30 Avoid operating the breaker with the excavator’s boom and arm cylinders in the fully extended position; keep at least 100 mm(4in) gap for recoil from cylinders strike. Operate your breaker only in front of or at the back of the equipment. Working from the sides may cause rollover of the equipment.

  • Page 31: Troubleshooting

    TROUBLESHOOTING This troubleshooting manual was created to help to investigate failures. If failures happen, see the chart below to find the parts and service required to eliminate them, and contact your dealer or distributor. WARNING! See the troubleshooting chart and contact your service team to eliminate any failure you can’t handle.
  • Page 32 Symptom Reason Troubleshooting Wrong tool diameter Change working tool Hampered Tool bushing and working tool seize movement of Clean up tool and bushing surface and as a result block the tool motion the working Deformed working tool or strike tool Change working tool surface Gas leakage...

  • Page 33: Service Tools

    SERVICE TOOLS 9.1. Nitrogen charging kit Pressure gauge Needle T-handle Charge valve Pneumatic hose Nitrogen cylinder O-Ring № Part description Part number Q-ty Pressure gauge Charge valve Pneumatic hose Nitrogen gas cylinder 5 liters O-Ring FB513212 (011-015-25)

  • Page 34: Working Tool Selection

    WORKING TOOL SELECTION 10.1. Tool selection А: Chisel • Is suitable for ripping and narrow trenching on soft/medium rock. B: Conical Point • Is suitable for breaking soft rock. • Boulder fragmentation of soft, medium sized stones C: Flat End •...

  • Page 35: Warranty

    WARRANTY The manufacturer guarantees performance of the hydraulic breaker for 36 months from sale date, but no longer than 1500 operating hours if all operating rules are adhered to. Warranty for the breakers housing, fasteners (screw bolts, bolts, nuts and washers), seals, including rings is 6 months.
  • Page 36 REGISTRATION 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 12.1. Packing list of Impulse hydraulic breaker № Part description Qty, pcs Hydraulic breaker Adapter plate / Hitch Hydraulic hoses Working tool Moil point Chisel Grease gun 300 ml Working tool grease 300 ml Charging valve Pressure gauge (glycerine filled) Cylinder 5 L with T-handle 10 Adapter to the gas cylinder 11 O-ring 16 –...
  • Page 38 NOTES...
  • Page 40 NEXGEN Attachments Inc. 1-866-921-0333 info@nexgenattachments.ca www.nexgenattachments.ca...

This manual is also suitable for:

Impulse 100s

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