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INSTRUCTION MANUAL PART No. 571608

Rev 2011jun

AR-SERIES BREAKERS

UNDERWATER APPLICATION

This Manual provides instructions for modifying the standard version AR-Series Breaker for use underwater. It was prepared as a supplement to the Operation & Maintenance Manual (102706). Read, understand and follow all safety instructions and procedures described in the Operation & Maintenance Manual before any operation or service procedures are performed.

Allied Construction Products, LLC AR-Series Breaker Underwater Kit 571458

i

Change Notice for Document 571608 Please note that material presented in this publication, including descriptions, illustrations and specifications, is subject to change without prior notice. Go to www.alliedcp.com for product or

document updates.

Date Page Description of Change

Sept 12, 2005 Original

June 14, 2007 4, 5, 10 and 11 Add 2 air lines to breaker.

June 21, 2011 Throughout Revise drawings

http://www.alliedcp.com/


ii

SAFETY INFORMATION

Be Alert to Safety Messages Safety messages appear throughout this guide and on labels affixed to the Allied equipment. Read and understand the information contained in the safety message before attempting to install, operate, service or transport the Allied equipment. Keep all safety labels clean. Words and illustrations must be readable. Before operating this equipment, replace damaged or missing labels. Purpose of Safety Messages The information provided in the safety message is important for your safety. These messages provide instructions on how to avoid injury from potential hazards associated with improper use, operation or handling of the Allied equipment. Read and follow the instructions of each safety message and be aware the consequence if these instructions are not followed. Safety messages are arranged to provide the following information:

Alert personnel to potential hazards

Describe the severity of the hazard, if encountered

Identify the nature of the hazard

Instruct how to avoid the hazard Safety Alert Symbol

ATTENTION, BECOME ALERT, YOUR SAFETY IS INVOLVED.

The exclamation point within an equilateral triangle is the safety alert symbol. The symbol is used to draw attention to the presence of potential hazards. Signal Words “DANGER”, “WARNING” and “CAUTION” are signal words used to express the different degrees of hazard seriousness. Learn to recognize and understand the severity and consequence associated with each of these signal words should a potentially hazardous condition be encountered. “DANGER” identifies the highest degree of hazard seriousness. Its use is limited to the most extreme situations. DANGER - Indicates an imminent hazard, which, if not avoided, will result in death or serious injury. WARNING - Indicates an imminent hazard, which, if not avoided, can result in death or serious injury. CAUTION - Indicates hazards which, if not avoided, could result in serious injury or damage to the equipment. Additional Precautionary Messages and Instructions Additional precautionary messages and instructions found in this guide are preceded with – “IMPORTANT” and “NOTE”. IMPORTANT - indicates instructions that if not followed, may cause damage to the equipment. NOTE – Indicates instructions that highlight suggestions, which will result in enhanced installation, reliability, or operation.


iii

SAFETY INFORMATION (cont’d) Overview of Pictograms For the purposes of this publication, pictograms displayed in safety messages are defined as follows.

Read the manual

Refer to the manual for more information

Procedure is explained in the manual

See the Service Manual For Additional Information

Moving part

Crush point

Pinch point

Moving part (in direction indicated by arrow)

Falling object

Unsupported loads

Personal protection equipment

Hearing protection

Safety eyewear

Gloves

Safety shoes

Falling part

Safety Alert Symbol

Stay clear

Maintain safe distance

Flying projectiles

Fluid injection

Hot surface

Pressurized gas

Shut off carrier & remove key before servicing

Identifies lift point

Electric Shock

Explosion

Falls into open excavations

Trench collapse


iv

SAFETY INFORMATION (cont’d) Before Operating Any Equipment

Qualified Person For the purposes of this guide and product labels, a qualified person is one who:

Has read, understands and adheres to the safety messages in this guide.

Is competent in recognizing potential hazards and possess the knowledge and skills necessary to make prompt decisions resulting in appropriate actions to safeguard against personal injury and property damage.

Has received adequate training in safe and proper installation, maintenance and operation for this Allied equipment.

Is authorized to operate, service and transport the Allied equipment.

Allied cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this guide and labels affixed to the Allied attachment are therefore not all inclusive.

Owner’s Responsibilities The equipment owner is responsible to ensure that only qualified personnel operate and service the Allied attachment. Qualified personnel must adhere to the procedures explained in this guide, especially regarding personnel safety. If necessary, the owner or safety/training personnel must expand upon these general instructions and adapt them to particular applications.

General Construction Safety Always follow procedures that promote safe conditions for workers and bystanders. The standard safety precautions expected and required of those working in construction shall include, but not limited to: locating existing underground service and utility lines, establishing pedestrian barriers and using personnel protection equipment, etc.

Federal, State, Local and OSHA Construction Guidelines and Regulations Use the Allied equipment in accordance with all federal, state and local regulations regarding construction practices and public safety. Identification of, and compliance to, governing regulations are the responsibility of the owner and operator. In the United States, comply with the recommendations of the Occupational Safety and Health Administration standards of the U.S. Department of Labor. For OSHA construction guidelines contact your local federal government office or write: U.S. Government Printing Office Superintendent of Documents P.O. Box 371954 Pittsburgh, Pa. 15250-7954 www.osha.gov

Read the Manual

The Operators Manual contains important information for the safe and proper use of the Allied attachment. Read, understand and follow all safety instructions described in the Operators Manual and this guide before installing, operating or servicing the Allied equipment. Read and understand all safety precautions and operating instructions found in the manuals provided by the carrier manufacturer. Do not operate the carrier, or perform any inspection, maintenance or service to its systems unless you are qualified.


v

SAFETY INFORMATION (cont’d)

Ask for Construction Industry OSHA Standards Stock #869-034-00107-6.

Operational Safety Program The safe and effective use of the Allied attachment depends upon proper installation, operation, maintenance and repair. Operational safety must encompass all of these factors.

Accident prevention through operational safety programs are most effective when the equipment owner further develops the program by taking into account his own experience in using and maintaining equipment. Developing such programs will result in improved equipment life, performance and reduced downtime. Most importantly, it will minimize the risk of personal injuries and equipment damage.


vi

TABLE OF CONTENTS

SECTION Pg.

Document Change Notice…….…. i

Safety Information……...………… ii

Be Alert to Safety Messages……….… ii

Purpose of Safety Messages……….… ii

Safety Alert Symbol ..…………..……… ii

Signal Words – “DANGER”, “WARNING” and “CAUTION”………… ii

Additional Precautionary Messages…. ii

Overview of Pictographs…………… iii

Before Operating Any Equipment…...... vi

Qualified Person…………….…..……… vi

Owner’s Responsibilities……….….…… vi

General Construction Safety……….…. vi Federal, State, Local & OSHA Construction Guidelines & Regulations vi

Operational Safety Program………….. vii

Table of Contents…….……..…….. viii

1.0 Introduction……..……..……… 1

1.1 About This Publication.…….……… 1

1.2 Additional Information…..……….... 1

2.0 Product Identification……….. 2

2.1 Serial Number Location.………..…. 2

2.2 Identification Tag..….……….……... 2

2.3 Record the Serial Number……..….. 2

3.0 Warranty Protection Summary……………………….. 3

3.1 Overview…………….…….. 3

3.2 Owner’s Responsibilities……..…... 3

3.3 Allied Product Policies……………... 4

4.0 Before the Breaker Can Be Used Underwater………...………. 5

4.1 Overview…………………………….. 5

SECTION Pg.

4.2 Preparing the Breaker………..……. 5

4.2.1 Pressurized Air System…..……… 5 4.2.3 Seal Joints with Silicone

Compound………………………... 6

4.2.4 Lubrication………………………… 5

5.0 Underwater Kit……………..…. 6

5.1 Contents of Underwater Kit……….. 7

5.2 Underwater Chisel Paste..….…….. 7

6.0 Installation Instructions..…… 8

6.1 Items Not Furnished in Kit………… 8

6.2 Before Starting……………………… 8

6.3 Lubricating Filter…………..……….. 8

6.4 Pressure Gauge……………..…….. 8

6.5 Cut-off Circuit (Pressure Switch)…. 8

6.5.1 Set Point Adjustment…………….. 9

6.6 Compressor / Air Line……………… 9

6.7 Air Supply Specifications………….. 9

6.8 Overview of Breaker Modifications 9

6.9 Air Line Connections………………. 10

6.10 Seal Joints - Silicone Compound 11

7.0 Operation..…………..………… 12

7.1 Pre-operation Inspection………..… 12

7.2 Operation…………………………... 12

7.3 Productivity Underwater…………… 13

8.0 Maintenance (Modified)….…. 14

8.1 General………………..……….…… 14

8.2 Maintenance – Every 1/2 Hour.…… 14

8.3 Maintenance – Daily (10 Hours)….. 14

8.4 Maintenance – Completion of Work 15

9.0 Troubleshooting……..…….…. 16


1

SECTION 1.0 INTRODUCTION

1.1 About this Publication This Manual provides instructions for modifying the standard version AR-Series Breaker for use underwater. It was prepared as a supplement to the Operation & Maintenance Manual (102706). Information includes:

Safety Messages

Overview of Breaker Modifications

Contents of underwater kit 571458

Installation Instructions

Compressor & air line specifications

Pre-operation Inspection & Operation

Maintenance – Modified for application

Troubleshooting

Table 1.1 Installation Guide 571608

Publication 571608 is applicable to the following Allied product(s):

Product Name: AR-Series Breaker

Model(s): 130B, 140B, 160C, 180C

Serial Numbers:

Years of Manufacture: 2005 and beyond

Keep this guide in a convenient location so that it is easily accessible for future reference. Material presented in this guide, including illustrations and descriptions, is intended solely for use with the equipment identified in this table and may not be suitable for other models. Confirm that the information recorded on the Equipment Identification Plate corresponds with the above. For the location of the ID Plate, refer to Section 2.0.

Material presented in this publication, including descriptions, illustrations and specifications, is subject to change without prior notice. Revisions are described at the

beginning of this guide under “Change Notice”.

1.2 Additional Information / Publications Include: Parts Manual – Includes spare parts list. Operation & Maintenance Manual - Includes product specifications, operating instructions, tool replacement, maintenance, troubleshooting, attachment to & removal from carrier, storage, lifting and transporting. Repair Manual – Includes accumulator service, seal and bushing replacement. Mounted Hydraulic Breakers Safety Manual for Operating and Maintenance Personnel - Publication issued by AEM FORM MB-140.

Table 1.2 Publications

Type Model Part No.

Parts

AR 110B 571827

AR 120B 572403

AR 130 101633

AR 130B 571021

AR 140B 570978

AR 160B 572694

AR 160C

AR 170C 573056

AR 180C 572964

Operators AR 110B thru AR 180C

102706

Repair 572591

Safety 953076

Underwater Table 1.1 571608


2

SECTION 2.0 EQUIPMENT IDENTIFICATION

2.1 Location of the Serial Number The Breaker is delivered assembled, lubricated and factory tested for proper operation. Upon receipt of this equipment, inspect for possible shipping damage. The Model and Serial Number are stamped on the Equipment Identification Plate. Verify that the information found on the ID Plate corresponds with the information provided in Section 1 of this guide. A secondary location for the serial number appears near the IN port.

2.2 Equipment Identification Tag The Equipment Identification Tag is affixed to the housing plates and contains the following information:

Manufacturer’s name

Address

Product name

Model number

Serial number

Year of manufacture

Weight

Fig. 2-1 Equipment Identification Tag

Fig. 2-2

Equipment Identification 1) Equipment ID Tag, 2) Secondary location of serial number is

scribed near the (IN) Port

2.3 Record Equipment Identification for Future Reference Copy the information from the warranty registration, such as the Model and Serial Number, to the space provided below. Indicate the date in which the Allied equipment was placed into service.

Model:

Serial Number:

In service date:

Provide the above information when contacting the local Allied dealer about this equipment. The dealer requires this information to better assist you with questions regarding parts, warranty, operation, maintenance, or repair service.


3

SECTION 3.0 WARRANTY PROTECTION SUMMARY

3.1 Overview Keep the Allied equipment operating within its performance limits by familiarizing yourself with the technical specifications provided in the Operation & Maintenance Manual. Follow the specifications when calibrating the carrier. Improper installation, including failure to calibrate the carrier correctly may result in loss of performance or subject the equipment to conditions beyond their design. Use of non-Allied parts, unapproved service methods, modifications to the attachment, or installation, operation and maintenance, not in accordance with the instructions outlined in this guide may cause equipment failure or personal injury. For details regarding warranty terms and conditions, refer to document A100668.

3.2 Owner’s Responsibilities When properly installed, operated and maintained by qualified personnel, the Allied attachment will remain productive with a minimum of service. The following outlines general maintenance policies required for all Breakers models. The equipment owner is strongly encouraged to further develop these general guidelines and adapt them in order to manage particular applications and operating environments. Ensure that personnel entrusted with the installation, operation, maintenance and transport of the Allied equipment adhere to the following:

Read and thoroughly understand the information and procedures detailed in this guide.

Understand and follow proper operating techniques.

Use the Allied attachment only if it is in sound operating condition. Immediately rectify any faults that, if left uncorrected, could lead to personal injury or further damage.

Use the Allied attachment only for the purpose for which it is intended. Special applications, such as underwater use, require modifications to protect the equipment from damage. Consult other publications for specific details.

Adhere to the technical specifications listed in the Operation & Maintenance Manual. Do not operate the Allied equipment beyond its performance limits.

Appoint Who Does What. Ensure that all personnel understand what their specific responsibilities include.

1. Establish maintenance

responsibilities to be performed by the OPERATOR.

2. Establish maintenance

responsibilities to be performed by the SERVICE TECHNICIAN.

Recognize problems and know how to take corrective action as detailed in the Troubleshooting Section of this guide.

Conduct regular checks and inspections as scheduled in the Care and Maintenance Section of this guide.

Allow only qualified operators and Allied trained service technicians to perform maintenance and repair as specified in the care and maintenance schedule.


4

Use only genuine Allied replacement parts and recommended lubricants to protect total warranty coverage.

Maintain written records of Breaker maintenance, service and repair. These records are helpful if warranty coverage is ever in question.

Maintenance, service and repair records shall include at least:

Date of the service, maintenance or repair.

Description of the service, maintenance or repair performed. Include part numbers if applicable.

Copies of purchase order and invoices for repair parts and service.

The name and signature of the person performing the service, maintenance or repair.

3.3 Allied Product Policies In this publication, Allied recommends Breaker applications, maintenance and service consistent with industry practices. Allied assumes no responsibility for the results of actions not recommended in this guide and specifically the results of:

Improper Training

Improper Installation (Failure to properly calibrate the Host Machine)

Operation in unapproved applications

Incorrect operation

Improper maintenance

Use of non-genuine Allied replacement parts

Unapproved modifications These exclusions apply to damage to the Allied equipment, associated equipment and injury to personnel.


5

SECTION 4.0 BEFORE THE BREAKER CAN BE USED UNDERWATER

4.1 Overview The standard version AR-Series breaker is not prepared for underwater use. Make no attempt to operate the breaker underwater until it has been properly modified. Serious damage to the breaker may result if water fills the area above and below the piston. Failure to make all necessary modifications may result in water penetrating the carrier’s hydraulic system. Damage incurred as a result of water penetration is excluded from the terms of the Allied warranty policy A100661.

4.2 Preparing the Breaker After the breaker has been properly modified and the underwater kit has been installed, it can be used for short periods of underwater use.

4.2.1 Pressurized Air System With the use of an air compressor, pressurized air is conducted into the area above and below the piston.

Fig. 4-1

Pressurized Air is Fed Into the Areas Above & Below Piston

4.2.3 Seal Joints with Silicone Compound Use a premium grade of silicone compound to seal off joints and mating surfaces. Neglecting to seal off areas where sediment can accumulate will make disassembly of the breaker difficult and time consuming.

Fig. 4-2

Seal Off Joints with Silicone Compound

4.2.4 Lubrication Use biodegradable lubricants when working underwater. Allied offers an UNDERWATER lubricant for this application.

123

5

6

4

8

7

-MAX-

-MIN-

Fig. 4-3

Automatic Lubricator –BreakerLube CML

An automatic lubricator will pump a semi-continuous supply of lubricant to the tool.


6

SECTION 5.0 UNDERWATER KIT

CAUTION

Earlier versions of the AR130 & AR140 cannot be modified for underwater use. The front head is not equipped with the required service port for connecting an air supply. Later versions of these models (AR130B & AR140B) may be modified for underwater use. “B” versions are equipped with an air service port located on the front head.

Fig 5-1

Parts Information


7

SECTION 5.0 PARTS INFORMATION

Table 5.1 Underwater Kit

Item Part No. Qty Description Remarks/Specifications

1-30 571458 1 UNDERWATER KIT KIT INCLUDES 1-30

1 571548 1 BREATHER INLET PORT

2 815235 2 O-RING 2-213

3 573041 1 BLIND FLANGE

4 719167 1 ELBOW 90*

5 573042 2 HOSE 3/8 x 84"

6 053149 1 TEE

7 653349 1 ADAPTER JIC x NPT

8 053314 2 QD CPLR SOCKET

9 053317 1 TEE 12NPT

10 708569 1 ADAPTER 04FNPT x 12MNPT

11 903258 1 TEE 04NPT

12 054539 1 GAUGE

13 659682 2 ADAPTER 04MJIC x 04MNPT

14 051003 1 HOSE ¼ x 48"

15 054241 1 PRESSURE SWITCH

16 056118 2 HEX HD CAP SCR #10-24

17 798220 2 LOCKWASHER #10

18 656743 2 HEX NUT #10-24

19 054242 1 LUBRICATING FILTER

20 798057 3 ADAPTER 12MNPT

21 798056 2 ADAPTER 12FNPT

22 054244 2 BRACKET

23 056254 2 U-BOLT 3/8 X 1-3/4

24 798190 4 LOCKWASHER 3/8

25 798189 4 NUT 3/8

26 719730 2 HEX HD CAP SCR 0.50 x 1.75

27 719238 2 LOCKWASHER 0.50

28 719239 2 HEX NUT 0.50-13

29 R903074 4 SHCS M10 x 50MM

30 056012 1 GROUND WIRE 36”, NOT SHOWN

Table 5.2 Underwater Chisel Paste (Not included - Order separately)

Part No. Package Description – Container Size / Container Type

103011 14 oz / standard cartridge, box of 12

102880 35 lb / Pail

A101925 120 lb / Drum


8

SECTION 6.0 INSTALLATION INSTRUCTIONS

6.1 Items Not Furnished in Kit Items not furnished in Kit 571458 include the compressor, air lines and couplers. Source these and other items locally. 6.2 Before Starting Before starting, confirm all parts listed in Table 5.1 are included in packaging.

6.3 Lubricating Filter

Fig. 6-1 Lubricating Filter

Locate a suitable area on the carrier to mount the lubricating filter.

6.4 Pressure Gauge

Fig. 6-2 Gauge and Pressure Switch

Mount the air pressure gauge in an area that is within view of the operator.

6.5 Cut-off Circuit (Pressure Switch)

Fig. 6-3

Air System with Cut-off Switch To safeguard the Breaker against damage, the pressure switch interrupts power to the breaker operating valve if the air pressure falls below the actuation point of the switch.

Table 6.1 Pressure Switch Specifications

054241 Circuit 1 Circuit 2

Set point 70 psi 110 psi

N/C Blue Orange

C Purple Brown

N/O Red Yellow

Lead @18” #16AWG

Wire Code Connection

Purple From foot switch

Red & Brown Tie together

Orange To Breaker valve

Yellow & Blue Not used


9

6.5.1 Set point Adjustment The pressure switch is a dual circuit type. Both circuits are adjustable. Neither circuit is pre-set. To adjust the set points, first remove the cover. The circuits are marked 1 and 2. The actuation point is raised / lowered by turning the adjustment screw. (Turn Counterclockwise to raise). Set point adjustment requires a test light 1. Disconnect wire lead at the breaker

operating valve. 2. Press tool firmly against hard surface

(above water). 3. Turn on air supply. Depress breaker

switch. Adjust set point for circuit #1 and #2.

6.6 Air Compressor / Air Line

Minimize pressure drop in the air line by locating the air compressor on, or as near to the carrier as possible. See Table 6.2. 6.7 Air Supply Specifications Refer to Table 6.2 for air supply specifications.

IMPORTANT

Do not set the air pressure higher than necessary. Excessive air pressure can damage the breaker and may have a detrimental effect on performance.

IMPORTANT

As the tool shank and lower bushing become increasingly worn, the gap, through which pressurized air can escape, becomes larger. To compensate for this, reset the air pressure as necessary.

6.8 Overview of Breaker Modifications (Fig. 6-4) Install the air lines that supply pressurized air to the area above and below the piston.

(Fig. 6-5) Seal off joints and mating surfaces to prevent sediment accumulation that can make disassembly of breaker difficult.

Fig. 6-4 Fig. 6-5

Table 6.2 Compressor / Air Line Specifications

Model AR130B AR140B AR160C AR180C

Air flow (cfm) 110 125 135 140

*Pressure (psi) Circuit #1 / #2 70 / 110 70 / 110 70 / 110 70 / 110

Air hose Min Dia / Max length 3/4” / 50’ 3/4” / 50’ 3/4” / 50’ 3/4” / 50’

*Air pressure measured near the connection port on the breaker.


10

6.9 Air Line Connections 1. Remove breaker from housing.

Fig. 6-6 Remove Breaker From Housing – Follow

Instructions in Repair Manual

NOTE: Some figures may be shown as individual components separated from the breaker. To connect the air line, remove the breaker from the housing. No further disassembly of the breaker is necessary. 1. Remove breather covers from seal

carrier.

Fig. 6-7

A) Seal Carrier, B) Breather Covers, C) Bolts

2. Install breather inlet port and seal (Items

1 & 2) into one of the breather ports

Fig. 6-8 Air Line Connection At Seal Carrier

3. Install air line (Item 5), to breather inlet

port. 4. Install blind flange, seal and bolts (Items

2, 3, 29), on the other breather port.

Fig. 6-9

5. The air service port is located on the

Front head. Remove threaded plug.

Fig. 6-10 F) Front Head /

G) Threaded Plug

Fig. 6-11 AR180 only

D) Front Head E) Vent Plug


11

6. Install the second air line (Item 5), to the threaded port on the front head.

Fig. 6-12 Air Line Connection on Front Head

7. Assemble items 4, 6, 7, 8, 9 & 10 as shown. Attach assembly to air lines (5).

Fig. 6-13 Air Line Connection

6.10 Seal Off Joints with Silicone Compound All joints between body sections, covers, through holes and other mating components must be sealed with silicone compound.

IMPORTANT

Neglecting to seal these areas against sediment accumulating in joints can lead to parts seizing or becoming cemented. This will make disassembly of the breaker very difficult and time consuming.

Fig. 6-14 Areas to Seal Using Silicone Compound

Seal the following areas using a high-quality silicone compound (1) Accumulator bolts (2) Between accumulator the valve housing (3) Check & pressure valve covers (4) Main spool covers (5) Gap at tie rod valve housing (6) Between valve housing and cylinder (7) Between cylinder and front head (8) Lift eye holes (9) Between tie rod and front head (10) Gap at tie rod nut and front head (11) Gap at lower tool bushing and front

head 8. Install breaker into housing. Route air

line as not to interfere with breaker and housing.


12

SECTION 7.0 OPERATION

7.1 Pre-operation Inspection

CAUTION Prior to operating the equipment, inspect all critical parts. Replace parts if wear or damage is evident. Repair all system faults. Do not operate the equipment until all faults are corrected.

For safe and proper operation, perform a daily inspection of the equipment before it is used.

Ensure Breaker is securely attached to the carrier. Check mounting pins and hardware for wear or damage.

Check for excessive movement inside the housing. Check that breaker does not contact housing. For correct procedure, refer to Operation & Maintenance Manual.

Check Hoses and fittings for oil leaks

Check Threaded fasteners for tightness

Check operation of AutoLube (if equipped). Fill reservoir with Underwater Chisel Paste.

NOTE: The items listed above are not all inclusive. Refer to the Operation & Maintenance Manual for a complete list of maintenance requirements and procedures.

NOTE: To obtain a copy of the “Operation & Maintenance Manual”, contact your local dealer or Allied’s Customer Service. Ask for part number 102706.

7.2 Operation NOTE: To increase the equipment’s service life, pay particular attention to correct working methods.

IMPORTANT

Do not operate Breaker with hydraulic oil temperature above 176

oF (80

oC)

Do not allow Breaker to contact housing. Replace worn guides and buffers.

Do not use the Breaker to lift, sweep or push materials.

Do not operate the Breaker underwater unless pressurized air system is installed and functioning properly.

IMPORTANT

Do not operate Breaker beyond its performance limits. Adhere to the specifications listed in Operation & Maintenance Manual.

CAUTION

Risk of eye injury from flying debris. Wear eye protection when operating or servicing this equipment.

CAUTION

Noise hazard. Exposure to high noise levels may cause hearing loss. Wear hearing protection when operating this equipment.

CAUTION Never activate the Breaker unless the operator is seated in the operator’s seat and in full control of the machine. Refer to carrier’s instructions.


13

CAUTION

Keep personnel away from the Breaker while in operation. Never operate the Breaker with workers in close proximity to the Breaker.

1. Clear all personnel from the work area. 2. Position carrier in-line with direction of

work. 3. Turn on air supply before breaker enters

water. 4. Use the boom, stick and bucket controls

to align the tip of the Breaker’s tool perpendicular to the work surface.

5. For maximum effectiveness, the tool

must be in full contact with the work surface. Use the boom control to press the tool firmly against the work surface.

6. Activate the Breaker with the switch

located in the operator’s cab. 7. Follow the breaker as it progresses

through the material. Maintain a constant feed force with the carrier.

8. Continue to operate the Breaker until

the material is fractured. Short bursts (5-10 seconds) allow for better control. If material does not break in less than 15 seconds, reposition the tool closer to the material’s edge.

9. After the material fractures, reposition

the Breaker and/or carrier to continue working.

IMPORTANT

Stop the Breaker before re-positioning. Do not allow the Breaker to blank fire.

7.3 Productivity in Underwater Applications. In underwater applications, the productivity of the hydraulic breaker is considerably lower than normal work. One reason for this is that the object to be demolished is not visible to the operator. This may take the operator more time to adjust the position of breaker with the object.

Another reason for lower productivity is due to the extra time necessary to inspect the breaker. Follow the modified maintenance intervals in Section 8. Many factors, including variations in operator technique can produce different results. Other factors include -

It may be necessary to try different tool types, i.e. wedge or conical to determine the most effective level of production.

NOTE: Further information is available in the “Operation & Maintenance Manual”. To obtain a copy, contact your local dealer or Allied’s Customer Service. Ask for part number 102706.

Fig. 7-1 A) Wedge, B) Conical


14

SECTON 8.0 MAINTENANCE – MODIFIED SCHEDULE FOR UNDERWATER

APPLICATIONS 8.1 General Inspection and maintenance must be adapted to meet the type of work in which the breaker is operating. When used in underwater applications, the breaker will be subjected to an additional risk from corrosion. Also, sediment suspended in the water, such as clay, sand, lime, etc, is abrasive. As a result, the wear resistance of breaker parts is lower in underwater use than in normal use.

8.2 Maintenance - Every 1/2 Hour

Check that the tool is receiving sufficient lubrication. Lubricate the tool shank and tool bushing through the lubrication nipple. For correct procedure, refer to Operation & Maintenance Manual.

Fig. 8-1

Lubricate the Tool Only When Pressed Firmly Against a Hard Surface

Check that the breaker moves normally

inside the housing and that the buffers are in good conditions.

Check all hoses and connections.

Check the operation of the air pressure switch.

Top Buffers

Wear Plates

Side Buffers

Fig. 8-2 Housing, Buffers & Wear Plates

8.3 Maintenance – Daily (Every 10 Hours) Remove retaining pin and the tool for

inspection. For correct procedure, refer to Operation & Maintenance Manual.

Fig. 8-3 Tool & Retainers

Check that the tool is receiving sufficient lubrication.


15

Measure the tool shank and bushing for wear. For correct procedure and wear limits, refer to Operation & Maintenance Manual.

D

Fig. 8-4 Measure Diameter of Tool Shank

IMPORTANT

During periods of non-use, stand the Breaker upright to allow water to drain away from the piston. With contact pressure on the tool, run the air supply for a few minutes to dry out the front head. If water is not promptly removed, it can cause irreversible damage to the piston’s surface, i.e. pitting.

Fig. 8-5 Piston

8.4 Maintenance – Completion of Underwater Work The Breaker must be completely dismantled and serviced after the underwater work is completed. Neglecting to perform breaker service promptly after working underwater can cause severe damage to the breaker and the carrier. After only a few days, the piston can rust making it unusable.

All parts need to be cleaned to prevent water damage.

Inspect all parts. Replace if wear or damage is evident.

Assemble breaker with new seals. For correct procedure, refer to Repair Manual.

NOTE: To obtain a copy of the “Repair Manual” contact your local dealer or Allied’s Customer Service. Ask for part number 572591.


16

SECTION 9.0 TROUBLESHOOTING

The Troubleshooting guide identifies several commonly encountered conditions and the recommended course of action. For conditions other than these, contact the Allied Technical Service Department. NOTE: Further information is available in the “Operation & Maintenance Manual”. To obtain a copy, contact your local dealer or Allied’s Customer Service. Ask for part number 102706. NOTE: The performance of the Allied attachment is affected by a hydraulic system that is not operating to specifications. If the attachment is not working correctly, make a thorough check the carrier’s hydraulic system.

Using a flow meter, measure the oil flow and determine the cracking pressure of the relief valve. Include the hoses from the attachment as part of the test. This will eliminate the possibility of a collapsed hose. Compare the results of your test with the specifications listed in the Operation & Maintenance Manual.

CAUTION Only qualified personnel, having knowledge of the machine’s systems, proper test equipment and tools should attempt adjustments and repairs.

Fault Possible Cause Remedy

Breaker does not start

Low air pressure Check air supply system; make corrections as required.

Mis-adjusted or faulty pressure switch

Adjust actuation set point. Test switch; replace if necessary

Breaker runs erratically

Erratic air flow Check air supply system; make corrections as required.

Tool misaligned Operator must maintain feed force and proper alignment

Oil discharge from front head

Damaged seals Stop breaker. Install new seals.


17

Notes: