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6. Maintenance

6.4 Nitrogen gas in the backhead

Dehaco or an approved Dehaco dealer will ensure that

the hydraulic breaker will be ready to use at delivery.

The backhead therefore will be charged with nitrogen.

For inspection or maintenance purposes it is required

to monitor and refill the nitrogen.

The breaker will be supplied with a gas charging kit

as standard. This includes a charging block, extension,

25 bar pressure gauge (IBEX 70GS – IBEX 4000GS) and

100 bar pressure gauge (IBEX 1200GS – IBEX 4000GS).

By following the steps below it is possible to safely

and accurately inspect and fill the backhead with

nitrogen.

Procedure for filling backhead

1) Unscrew the gas plug on the backhead using a 5

mm Allen key.

2) Attach the charging kit to the charging valve on

the backhead (it is possible that an extension is

required to mount the kit).

3) Ensure that the pusher is in the up position.

4) Close the screw valve.

5) Attach the gas cylinder.

6) Charge the backhead to the pressure indicated in

column A. This is 4 bar higher than the required

pressure.

7) Open the cylinder and wait for the pressure to

equalise between the regulator and the backhead,

once equalised close the cylinder.

8) Open the screw valve whilst the pusher is in the

up position to release the pressure within the

charging kit and hose, then remove the hose from

the charging kit.

9) Screw the stop back onto the charging kit.

10) Press the pusher in to measure the nitrogen in the

backhead.

11) Whilst holding the pusher in the down position

adjust the pressure to the value indicated in

column B using the screw valve.

12) Release the pusher and the backhead should be

charged to the desired pressure.

13) If the pressure is lower than desired then repeat

procedure from step 6.

14) Open the screw valve whilst the pusher is in the

up position to release the pressure within the

gauge and dismount the charging kit.

15) Tighten the gas plug.

6.4.2 Technical data nitrogen gas backhead

PULL

OPEN

BACK HEAD

PUSH

OPEN-CLOSE

OPEN

PULL

REMOVE

CHARGING KIT:

HANDLE

SWITCH

SCREW
GAUGE

CHARGING BLOCK

PLUG

CHARGING VALVE

GAS CHARGING ASSEMBLY:

INSTRUCTIONS FILLING BACKHEAD:

Model

IBEX 130

16 bar (232 psi)

12 bar (174 psi)

IBEX

135

12 bar (174 psi)

8 bar (116 psi)

IBEX 170

20 bar (290 psi)

16 bar (232 psi)

IBEX 200

12 bar (174 psi)

8 bar (116 psi)

IBEX 320

20 bar (290 psi)

16 bar (232 psi)

IBEX 400

20 bar (290 psi)

16 bar (232 psi)

IBEX 600

20 bar (290 psi)

16 bar (232 psi)

IBEX 900

20 bar (290 psi)

16 bar (232 psi)

IBEX 1200

10 bar (145 psi)

6 bar (87 psi)

IBEX 1800

10 bar (145 psi)

6 bar (87 psi)

IBEX 2200

10 bar (145 psi)

6 bar (87 psi)

IBEX 2800

13 bar (188 psi)

9 bar (130 psi)

IBEX 3200

20 bar (290 psi)

16 bar (232 psi)

IBEX 4000

20 bar (290 psi)

16 bar (232 psi)

Содержание IBEX 1200GS

Страница 1: ...IBEX Hydraulic breakers G type Operation and maintenance manual English IBEX Versie 17 08 2018 ...

Страница 2: ......

Страница 3: ...c breaker By opting for the IBEX breaker you have chosen for years of experience in development sales aftersales and servicing of hydraulic breakers The IBEX breakers are suitable for breaking large boulders in quarries tunnels creating trenches for pipe construction demolition of concrete structures removing slag from blast furnaces and breaking asphalt As standard the IBEX breakers are available...

Страница 4: ...0GS IBEX 2800GS IBEX 3200GS Manufacturer Dehaco B V Kruisbaak 25 2165 AJ Lisserbroek The Netherlands General manager Jeroen Korporaal Standard s EN ISO 12100 2 2003 EN 982 1996 A1 2008 Place and date Lisserbroek 04 07 2013 EG Declaration of Conformity IBEX 400GS 1800GS 4000GS EC Machinery Directive 2006 42 EC We Dehaco B V herewith declare that the following products comply to the essential requir...

Страница 5: ... 2 6 Accessories standard and as ordered 12 3 Transport 13 3 1 Transport using an excavator or crane 13 3 2 Transport using a forklift 13 3 3 Transport using a van or truck 13 4 Installation 14 4 1 Tool 14 4 2 Mounting the breaker on the excavator 14 4 3 Setting the breaker 15 5 Working Methods 16 5 1 Correct working Methods 16 5 2 Operating Temperature 17 5 3 Other important points 17 6 Maintenan...

Страница 6: ...ows in this operation and maintenance manual DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTE The signal word NOTICE is used to address practi...

Страница 7: ...ir first use the safety facilities on the hydraulic installation must be checked by a professional authorised monitoring body for their quality CE mark etc suitability and proper functioning Ø Ø If any significant changes are made to the hydraulic installation a new acceptance inspection is to be carried out in accordance with the relevant national safety provisions WARNING The hydraulic system is...

Страница 8: ...ng diagrams 1 10 Falling stones precautions WARNING Fragments of material which come loose while operating the IBEX breaker may become airborne and can cause serious injury if people are hit by them Small objects falling from a great height or at a high velocity can also cause serious damage During IBEX breaker operation the danger zone is considerably greater than during the excavation operation ...

Страница 9: ... and should be returned immediately complete and unmodified A guarantee claim will only be considered when a written claim has been registered with Dehaco BV or an approved dealer The damage or malfunction should be registered within 24 hours of the first occurrence All claims must contain the following information The serial number The type of carrier that the machine has been mounted on A descri...

Страница 10: ...Tool B Front head C Piston D Cylinder E Back head F Valve IBEX 1200GS IBEX 1800GS IBEX 2200GS IBEX 2800GS IBEX 3200GS IBEX 4000GS A Tool B Front head C Piston D Cylinder E Valve F Back head G Valve block H Accumulator A B C D F Dehaco B V Kruisbaak 25 2165 AJ Lisserbroek NL 31 0 252 41 79 50 info dehaco nl www dehaco nl E G H A B C D E F ...

Страница 11: ...ways be clearly legible Ø Ø Immediately replace a defective name plate Ø Ø Use the spare parts list to order a new name plate Dehaco B V Kruisbaak 25 2165 AJ Lisserbroek NL www dehaco nl TYPE MODEL MODÈLE MODELL YEAR KG BAR L MIN SERIENUMMER SERIAL NUMBER NUMÉRO DE SÉRIE SERIENNUMMER BOUWJAAR MANUFACTURE DATE ANNÉE DE FABRICATION HERSTELLUNGSDATUM GEWICHT WEIGHT POIDS GEWICHT MAX WERKDRUK MAX OPER...

Страница 12: ...breaker Operation and maintenance manual Spare parts list EC Declaration of Conformity Accessories 2 6 2 6 Accessories standard and as ordered Every IBEX breaker has a standard set of accessories These are supplied alongside the breaker at delivery These accessories ensure that the breaker can be prepared for use directly after delivery The standard accessories consist of Hydraulic hoses specific ...

Страница 13: ...before attempting to lift the breaker Place the forks under the housing of the breaker so that the weight is evenly distributed Carefully lift the breaker and once stable transport the breaker It is possible that the breaker is much wider than the forklift Take care to assess the surrounding area for obstacles before attempting to transport the breaker Extra attention should be given when driving ...

Страница 14: ...nd Ensure that the excavator is turned off and pressure from the hydraulic system released 2 For IBEX types 130GS to 400GS remove the spring pin and tool pin using the tool included 3 For IBEX types 600GS to 4000GS loosen cover plate bolts and remove the cover plate tool pin buffers and tool pins 4 The tool should now be loose in the front head and can be removed Great care should be take whilst d...

Страница 15: ... the pressure rises in the hydraulic circuit 2 The operating pressure of the breaker determines the setting of the relief valve in the pressure line 3 The relief valve setting should be acceptable as per the specifications of each model We advise that this work is to be undertaken by a qualified technician from a Dehaco approved dealership Stop valve Hydraulic breaker Working pressure Return line ...

Страница 16: ...regularities in the material that will break easily causing idle strokes or an incorrect working angle 4 Use the excavators boom to press the breaker firmly against the object Ensuring that the tool remains perpendicular to the material Never start the breaker until the correct force has been applied to the tool 5 Start the breaker Stop the breaker immediately if someone enters the working area Wh...

Страница 17: ...1 Working in high ambient temperatures The temperature of the hydraulic oil must be continuously monitored If the excavator cannot maintain the temperature of the oil below 80 C then an oil cooler should be installed or the excavator should be inspected for the cause of the higher temperatures Using the correct oil is also essential Dependant on the climate and season the correct oil and viscosity...

Страница 18: ... of lubricant for IBEX 1200 IBEX 4000 Inspect maximum temperature of hydraulic oil after continuous operation Measure back head and accumulator pressure Check the tension of the through bolts If automatic lubricating pump is fitted cartridge should be checked and replaced where necessary Check for damage on the hoses either from rubbing or contact with another object Inspect adapter plate and bolt...

Страница 19: ...ng through the breaker 2 The purpose of the oil filter is to remove impurities from the hydraulic oil air and water are also impurities in oil 3 Impurities also cause the oil to overheat and deteriorate Oil filter The excavator oil filter must fulfill the following specifications The oil filter must be rated at a maximum of 25 micron The oil filter must be a standard return line filter rated to ma...

Страница 20: ...20 Dehaco B V Kruisbaak 25 2165 AJ Lisserbroek NL 31 0 252 41 79 50 info dehaco nl www dehaco nl 6 Maintenance Recommended oil temperature viscosity ...

Страница 21: ...er is in the up position to release the pressure within the charging kit and hose then remove the hose from the charging kit 9 Screw the stop back onto the charging kit 10 Press the pusher in to measure the nitrogen in the backhead 11 Whilst holding the pusher in the down position adjust the pressure to the value indicated in column B using the screw valve 12 Release the pusher and the backhead sh...

Страница 22: ...essure with the gauge by opening the screw valve 5 Remove the charging kit and replace the plug and cap Take care to ensure that the o rings are still in position 6 5 2 Filling the accumulator with nitrogen 1 Remove both the gas plug and adjuster cap from the accumulator 2 Attach the charging kit to the accumulator and ensure that the screw valve is tight 3 Attach the gas cylinder to the charging ...

Страница 23: ...y Do not turn the valve adjuster more than 4 times counter clockwise Nut Adjust bolt Back up ring O Ring 6 7 Wear parts 1 When damaged or worn it is highly recommended to replace the following items These should be inspected regularly and replaced as soon as possible Tool Tool bushing Tool pins Retainer pin bushing pin Accumulator and steering valve bolts Hydraulic seals Through bolts Hydraulic ho...

Страница 24: ...1 Tool 2 Tool bushing 3 New Reject New Reject New Reject IBEX 130GS 4 mm 44 5 mm 42 5 mm 44 5 mm 46 5 mm IBEX 135GS 4 mm 40 mm 38 mm 40 mm 42 mm IBEX 170GS 4 mm 53 mm 51 mm 53 mm 55 mm IBEX 200GS 4 mm 59 5 mm 57 5 mm 59 5 mm 61 5 mm IBEX 320GS 4 mm 68 mm 70 mm 68 mm 66 mm 70 mm 68 mm IBEX 400GS 4 mm 75 mm 77 mm 74 5 mm 72 5 mm 74 5 mm 76 5 mm IBEX 600GS 4 mm 85 mm 88 mm 85 mm 82 mm 85 mm 88 mm IBE...

Страница 25: ...6 mm 250 mm IBEX 600GS 542 mm 350 mm IBEX 900GS 557 mm 350 mm IBEX 1200GS 707 mm 400 mm IBEX 1800GS 750 mm 400 mm IBEX 2200GS 800 mm 450 mm IBEX 2800GS 735 mm 450 mm IBEX 3200GS 785 mm 500 mm X X Y Detail A E E C A B D A B C D E IBEX 600GS 54 30 51 37 1 5 IBEX 900GS 60 32 57 29 1 5 IBEX 1200GS 72 40 69 37 1 5 IBEX 1800GS 80 40 77 37 1 5 IBEX 2200GS 90 45 87 42 1 5 IBEX 2800GS 100 50 97 47 1 5 IBEX...

Страница 26: ... Wear limit wearing plate New wearing plate A Wear limit B IBEX 70GS 10 8 IBEX 130GS 10 8 IBEX 135GS 10 8 IBEX 170GS 10 8 IBEX 200GS 10 8 IBEX 320GS 12 10 IBEX 400GS 12 10 IBEX 600GS 16 14 IBEX 900GS 16 14 IBEX 1200GS 20 18 IBEX 1800GS 20 18 IBEX 2200GS 20 18 IBEX 2800GS 20 18 IBEX 3200GS 20 18 IBEX 4000GS 20 18 A B ...

Страница 27: ... used to mount the adapter plate must be rated to a quality of 8 8 or higher A Through bolt nut N m lb f ft B Top cover bolt N m lb f ft IBEX 70 90 67 90 67 IBEX 130 350 258 350 258 IBEX 135 300 258 300 221 IBEX 170 350 258 350 258 IBEX 200 350 258 350 258 IBEX 320 600 443 600 443 IBEX 400 900 664 900 664 IBEX 600 1500 1106 1500 1106 IBEX 900 1700 1254 1700 1254 ...

Страница 28: ...N m kg f m lb f ft G Top cover bolt N m kg f m lb f ft IBEX 1200GS 1700 1254 1700 1254 950 96 700 4 500 50 368 6 200 20 147 4 200 20 147 8 650 66 479 12 IBEX 1800GS 3000 2213 3000 2213 950 96 700 4 500 50 368 8 200 20 147 4 200 20 147 8 650 66 479 12 IBEX 2200GS 3500 2481 3500 2581 950 96 700 4 500 50 368 8 500 50 368 8 200 20 147 8 2300 235 1696 12 IBEX 2800GS 4250 3135 4250 3135 950 66 479 4 500...

Страница 29: ...utomatically closes hammer lines 3 Disconnect hoses plug the hoses and the breaker inlet and outlet ports 4 Remove bucket pins and other parts or release quick hitch if fitted 5 The carrier can be moved aside For quick coupler or other systems adhere to the operataion guidelines of the manufacturer 7 1 2 Short term storage Lay the breaker flat on the floor and follow the instructions above 7 1 7 1...

Страница 30: ...ator Pressure in backhead and setting pressure of relief valve is low Check pressure of nitrogen gas and relief valve Poor performance of hydraulic pump Contact excavator manufacturer Cause Required action Oil temperature increased due to lack of hydraulic oil Replace hydraulic oil Pressure in back head too high Check gas pressure Relief valve is set too low Check pressure of relief valve Not enou...

Страница 31: ...BEX 600GS Silenced housing Automatic lubrication Elevated underwater connection Low underwater connection N2 accumulator Anti blank firing system Double speed system Single tool bush IBEX 900GS IBEX 1200GS IBEX 1800GS IBEX 2200GS IBEX 2800GS IBEX 3200GS IBEX 4000GS Silenced housing Automatic lubrication Elevated underwater connection Low underwater connection N2 accumulator Anti blank firing syste...

Страница 32: ...Spanner 46 1 1 1 1 1 Spanner 50 1 1 1 Spanner 55 2 2 2 Spanner 60 1 1 1 Double open ended spanner 17 19 1 Double open ended spanner 24 27 1 Double open ended spanner 27 30 1 1 Double open ended spanner 32 36 1 Allen key 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Allen key 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Allen key 10 1 1 1 1 1 1 1 1 1 1 1 1 Allen key 12 1 1 1 1 1 1 1 Allen key 14 1 1 1 1 1 1 1 1 T Spanner handle ...

Страница 33: ...9 mm 3 4 in 19 mm 3 4 in 19 mm 3 4 in Backhead pressure bar psi 12 bar 174 psi 15 bar 217 psi 16 bar 232 psi 8 bar 116 psi 16 bar 232 psi 16 bar 232 psi 16 bar 232 psi 16 bar 232 psi IBEX 1200 IBEX 1800 IBEX 2200 IBEX 2800 IBEX 3200 IBEX 4000 Excavator weight ton 13 18 18 25 25 32 32 40 36 45 40 55 Weight incl tool kg 1150 1650 2100 2660 3100 3780 Impact frequency bpm 450 800 400 800 350 700 250 5...

Страница 34: ...dard pressure required for all models is between 3 5 bar 32 72 psi Setting the supplied air pressure is also dependent on the working depth of the breaker 2 Bar should be added per 10 meter depth I e 10 meter 3 5 bar 2 bar 5 7 bar Flow is dependant on model Procedure for supplied air pressure setting 1 After installation of the underwater kit operate the compressor to supply the air to the breaker...

Страница 35: ... 1 5 Maintenance Intervals The IBEX breakers are designed for underwater operations of only a short duration The wear resistance of breaker parts is considerably lower in underwater conditions than in normal use This is due to the corrosive nature of the underwater conditions During underwater breaking routine inspections must be performed more often For example every half hour of operation Adapt ...

Страница 36: ...ker operates under high pressure which can cause serious injury and death The remaining pressure within the hydraulic system must be removed before attempting to adjust the ABF Do not attempt to operate this function if you do not fully understand its operation Factory standard ABF is on When switched on the ABF adjuster should protrude 5mm from the hex nut A 2 1 1 To turn ABF on 1 Place the break...

Страница 37: ...37 2018 Dehaco B V Operation and maintenance manual IBEX Hydraulic breakers G type Version 17 08 2018 Notities Notes NOTITIES NOTES ...

Страница 38: ...38 Dehaco B V Kruisbaak 25 2165 AJ Lisserbroek NL 31 0 252 41 79 50 info dehaco nl www dehaco nl Notities Notes NOTITIES NOTES ...

Страница 39: ...39 2018 Dehaco B V Operation and maintenance manual IBEX Hydraulic breakers G type Version 17 08 2018 Notities Notes NOTITIES NOTES ...

Страница 40: ...Dehaco B V Kruisbaak 25 2165 AJ Lisserbroek NL 31 0 252 41 79 50 info dehaco nl www dehaco nl Dehaco B V Headquarters address Kruisbaak 25 2165 AJ Lisserbroek Nederland T E www dehaco nl 31 0 252 41 79 50 info dehaco nl ...

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