This document is an owner's manual for TB Series hydraulic breakers. It provides information on properly sizing a breaker based on the type of work being done and the carrier equipment. The manual describes typical hydraulic circuits for operating breakers and gives guidance on setting the correct oil flow and pressure. It also covers breaker maintenance, service, and troubleshooting tool failures.
This document is an owner's manual for TB Series hydraulic breakers. It provides information on properly sizing a breaker based on the type of work being done and the carrier equipment. The manual describes typical hydraulic circuits for operating breakers and gives guidance on setting the correct oil flow and pressure. It also covers breaker maintenance, service, and troubleshooting tool failures.
This document is an owner's manual for TB Series hydraulic breakers. It provides information on properly sizing a breaker based on the type of work being done and the carrier equipment. The manual describes typical hydraulic circuits for operating breakers and gives guidance on setting the correct oil flow and pressure. It also covers breaker maintenance, service, and troubleshooting tool failures.
30625 Solon Industrial Drive, 3464 DURAHART ST. 35 ELGIN ST., SOLON OHIO, RIVERSIDE,CALIF. THORNBURY,ONT. 44139 U.S.A. 92507 U.S.A. N0H 2P0 CANADA PH. 440-542-3720 PH. 909-369-0878 PH. 519-599-2015 FAX. 440-542-3721 FAX. 909-369-8281 FAX. 519-599-6803 B R E A K E R T E C H N O L O G Y TB SERIES HYDRAULIC BREAKERS General Installation Breaker Operation Breaker Service Revision : 11/2001 Manual # : 150-2079 CONTENTS 3 Breaker Owners Manual Sizing The Breaker ....................... Typical Hydraulic Circuits .............. Breaker Tool Troubleshooting ....... General Information ...................... Safety ............................................ Operation ...................................... Maintenance ................................. Service .......................................... Breaker Disassembly .................... Breaker Reassembly ..................... Breaker Removal & Storage ......... Underwater Applications ............... Troubleshooting Guide .................. Small Breaker Torques ................. Medium Breaker Torques .............. Large Breaker Torques ................. Serial Number Location ................ General Specifications .................. Warranty ........................................ 4 7 10 12 15 16 20 22 23 34 42 43 44 47 48 49 50 51 54 4 Breaker Owners Manual This is the most critical factor in choosing the breaker size. Up to 1200-ft.lbs. (1627 Joules), are typically used in concrete and other light duty work. 1200 - 4000-ft.lbs. (1627 - 5423 Joules) are used in both concrete and rock applications with limitations on the size and amount of material to be broken. Over 4000 ft. lbs. (5423 Joules), are typically used in rock and large scale concrete dem- olition projects. When breaking oversize material the breaker is expected to break the material down the middle into two pieces. This is optimum production. If the operator has to re-position the breaker towards the edge of the rock and gradually downsize the material, produc- tion rate slows down. To assess what size of breaker will effectively handle this applica- tion, the size and hardness of the material must be known. If a 4 cu. yard piece of hard rock (20,000 psi or greater) needs to be broken in half you will require a 7,500-ft. lb. or larger breaker. If a 2 cu.yd. piece of limestone (20,000 psi or less) needs to be broken in half you will require a 3,000 - 5,000-ft. lb. breaker. When trenching, the breaker is expected to fracture a solid mass of rock into manage- able pieces. The size of the material could be 100's of cu.yds, and the energy will be quickly absorbed. This is why it is recommended to work from a bench so the rock has somewhere to break out. We recommend that when trenching in limestone or medium hard rock, to use a 3,000 - 5,000-ft. lb. breaker. When working in hard material we rec- ommend a 7,500 - 10,000-ft.lb. breaker, and if high production is critical, a 13,500-ft.lb. breaker would be beneficial. When breaking Concrete, the breaker is expected to penetrate the material, allowing it to crack and shake loose from the reinforcing steel. High frequency breakers tend to pro- vide better performance in this application as it is not the energy per blow, but the fast blow rate that destroys the concrete's structural integrity. We recommend on concrete walls, footings, and floors to use a 750 - 1,500-ft. lb. breaker. With larger projects, con- sisting of large footings greater then 4 cu. yards, use a 2,000 - 5,000-ft. lb. breaker. The high production demand of bridge and building demolition requires a 7,500 - 10,000-ft. lbs. breaker. SIZING THE BREAKER SIZING BREAKER BASED ON TYPE OF WORK: SMALL BREAKERS: MEDIUM BREAKERS: LARGE BREAKERS: BREAKING OVERSIZE MATERIAL: TRENCHING: BREAKING CONCRETE: SIZING THE BREAKER The breaker must be sized properly for both the work it will do and the carrier on which it will be mounted. After considering the application work, determine the carrier on which the breaker will be installed. BTI has assigned a Recommended Carrier Weight (see chart on page 6) range for each breaker. If the operating weight of the carrier falls within this range, the carrier will safely handle this model of breaker. If the desired breaker falls outside of this recommended carrier weight range, the carriers lifting capacity and oil flow will need to be verified to ensure a proper fit. Provided the weight of the breaker does not exceed the maximum lifting capacity at any position, the carrier is assumed to be stable. On most loader backhoes and excavators, the maximum lifting capacity is lowest when the boom is at full reach. This is the value that must be compared to the operating weight of the breaker. A required oil flow range is specified for each breaker (see chart on pages 51-31). Oil flow to the breaker within this range is adequate for operation. However, for maximum productivity the carrier should be capable of providing the maximum required flow. Compare the maximum oil flow requirement of the breaker with the oil flow capacity of the carrier. Remember the breaker operates at 1400-2600-psi. therefore, oil flow should be evaluated at operating pressure. SIZING BREAKER BASED ON CARRIER SIZE: LIFTING CAPACITY: OIL FLOW & OPERATING PRESSURE: 5 Breaker Owners Manual SIZING THE BREAKER 6 Breaker Owners Manual Carrier Weight in Metric Tonnes How to Use This Chart Find your carrier weight along the top of this chart. Draw a line straight down from that weight. Any black breaker bars this line intersects will give you a breaker suitable for your carrier. TB125 / TB135 TB225 / TB235 TB275 / TB285 TB325 / TB335 TB425ME TB425QA / X TB625QA TB625X TB725QA TB725X TB830 TB980 TB1430 TB1680 TB2080 TB2580 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 Skidsteer Mini Excavator Backhoe Excavator Wheel Loader Figure 1 7 Breaker Owners Manual FOR HYDRAULIC BREAKERS: To operate a Hydraulic Breaker you only need hydraulic flow and pressure in one direc- tion. The supply line should be directed out the left side of the boom and the return line on the right. These attachments will operate within a range of flow. The operating pressure will depend on the amount of oil flow, the return line pressure, and internal efficiency of the individual attachment. The relief valve in the supply line should be set at least 350 psi (24.1 bar). greater than the maximum stated operating pressure. The carrier will quite often be equipped with an aux. control valve. (see Fig.2) In this case the auxiliary control can be used to control the supply of oil. It can usually be adjusted to provide the correct amount of flow and a relief cartridge can be installed to protect the hydraulic circuit. Notice when using the auxiliary control valve that oil is not routed back through the return port on the valve. It is recommended to send the oil directly back to the cooler, filter, and tank. If the circuit is plumbed using both ports on the auxiliary valve, the return line should have a bleed line connected to tank. This will prevent a pressure spike in the return- ing oil, which is damaging to the hydraulic breakers. TYPICAL HYDRAULIC CIRCUITS CARRIER WITH AUXILIARY CIRCUIT: Figure 2 8 Breaker Owners Manual TYPICAL HYDRAULIC CIRCUITS SETTING FLOW & PRESSURE: When setting the flow, connect a flow meter in place of the attachment. Measure the "No-Load" flow when activating the control valve. Then put a load on the circuit to sim- ulate the attachment working (refer to the operating pressure) and measure the flow at this point. This is the flow that needs to be adjusted to the specified oil flow for the attachment. Continue to load the circuit until the flow drops to zero. Measure the pressure at which this happens and adjust the relief valve setting to ensure this pressure is at least 350 psi (24.1 bar) greater than the maximum operating pressure of the attachment. If more than one attachment will be used on this circuit with different flow require- ments, you will need to measure the flow and note the adjustment in two locations. Be sure to record this information on the BTI Warranty Card provided with each new attachment. 9 Breaker Owners Manual SIZING BREAKER BASED ON TYPE OF WORK If the carrier is not equipped with an auxiliary control valve, you will need to install a priority flow control valve to direct the correct flow away from the normal circuit and operate the attachment (see Fig.3). The priority flow control is usually equipped with a flow adjustment and pressure relief. These valves often need a check valve on the regulated port to completely close the flow. If dividing too much flow, this circuit will generate heat and will need cooling capacity. TYPICAL HYDRAULIC CIRCUITS Figure 3 10 Breaker Owners Manual TYPICAL TOOL FAILURES: TOOL TROUBLESHOOTING Tool breakage due to improper contact between the tools tip and the rock or concrete. Typical failure caused by misalign- ment between down pressure, breaker and tool (from prying, lever- ing, etc.) Mushrooming or fast wearing caused by operating too long on the same spot. Fatigue breakage with typical fatigue wrinkles due to steel defect. Failure due to operation with worn-out retaining pins, blank-firing, or twisting the tool. NO WARRANTY Failure due to blank-firing or exces- sive wear of bushings and/or front head. NO WARRANTY NO WARRANTY 100% WARRANTY NO WARRANTY NO WARRANTY Mushrooming due to operating with worn bushings. NO WARRANTY Figure 4 11 Breaker Owners Manual EXTERNAL FORCES: The main cause of increased fatigue stress in a tool is any form of side force during operation which creates bending. Therefore using the tool to pry, using the incorrect working angle, or attempting to break ground using the pull of the machine, are all detrimental to the life of a tool and must be avoided. The hydraulic power available in a carrier far exceeds the strength of a tool, and if being used incorrectly, can snap a tool like a twig. This is any situation where the breaker piston strikes the top of the tool, but the working end of the tool is not in contact with the work. This happens when the tool slides off the work, and also on a break-through of thin concrete slabs or boulders. Low temperatures cause the tool to be more susceptible to fatigue failure. Tools should be warmed before extensive use by moderate or light breaking. Any form of damage to the surface of a tool renders it more liable to suffer fatigue fail- ure. Care must be taken to prevent scratches, gouges, weld marks on the tool, or pick up between the tool and tool bushing due to lack of lubrication or excessive bending. Avoid scratches or gouges to the surface of the tool. Metal to metal contact causing pick up could cause deep damage marks which, in turn, lead to the formation of fatigue cracks and eventual failure of the tool. Ensure that the tool shank is well lubricated before inserting it into the tool holder. Molybdenum disul- fide grease is recommended for the application at 2 hour intervals, with the tool pushed fully up inside the breaker. (Refer to Fig. 14). Keep tools well greased and sheltered from the weather when not in use. A rusty tool is more likely to suffer fatigue failure. For greasing instructions refer to Fig 14. CAUSES OF TOOL FAILURE BLANK-FIRING: COLD TEMPERATURES: MECHANICAL & THERMAL DAMAGE: POOR LUBRICATION: CORROSION: 12 Breaker Owners Manual GENERAL INFORMATION BREAKER STRUCTURE & DESIGN: A BTI hydraulic breaker represents the state of the art in rock and aggregate breaking. Our hydraulic breaker is a self-actuated hammer that delivers rock-breaking power with the minimum of parts. The main sections of a BTI breaker are the front head, cylinder, rear head, and control valve. The FRONT HEAD contains the breaker tool, bushings, and retainer pins. By removing the retainer pins, the tool can be quickly changed. The CYLINDER contains the moving piston, which strikes the tool. The seals for both ends of the piston are also located in the cylinder. The REAR HEAD houses the cushion chamber, which is charged with nitrogen gas. The gas in the cushion chamber absorbs the piston's upward recoil and stores this energy for the next blow. The CONTROL VALVE is mounted on the cylinder and directs the flow of hydraulic oil and therefore the movement of the piston. Located directly above the control valve are the hydraulic oil inlet and outlet ports. Two side plates hold the breaker and protect it during operation. The breaker is attached to the carrier by a bracket fastened to these plates. Rear Head Cylinder Tie Rod Air Valve Front Head Figure 5 13 Breaker Owners Manual GENERAL INFORMATION PRINCIPLE OF OPERATION: Pressure Pressure Pressure Pressure Return Return Return Return Nitrogen Return Pressure 1 2 2 3 7 7 7 7 4 6 6 5 A B C D 5 (A) UPWARD MOVEMENT Oil flows into cylinder chamber (1) and control valve chamber (7). The piston is pushed up towards the cushion chamber (5), and the control valve spool is forced down. (B) REVERSING DIRECTION When the lower flange fills with oil, it will reach cylinder chamber (2). At this time both control valve chambers (6) and (7) have the same pressure, but the spool moves up due to the flange surface area differences. (C) DOWNWARD MOVEMENT When the control valve spool rises and reaches chamber (7), the flow moves through the control valve to chamber (4). Due to the area difference between the piston flange and the extra force from the cushion chamber pressure (5), the piston accelerates down. (D) IMPACT The piston hits the tool. The mid section of the piston will hit chamber (2). As a result, chamber (6) will remove pres- sures through chambers (2) and (3). Since chamber (6) is exhausted, chamber (7) is constantly pressurized and the control valve will moves down. Control Valve Spool Breaker Body Piston Cushion Chamber Tool Tool Retainer Pin Breaker Parts Hose Adaptors Figure 6 Figure 7 GENERAL INFORMATION 14 Breaker Owners Manual OPERATING VISCOSITY RANGE: For optimum efficiency and service life we recommend that the operating viscosity (at operating temperature) be selected in the range. V opt = opt. Operating viscosity 1645 mm 2 /s referred to tank temperature (open loop circuit) The following values are valid for extreme operating conditions: V min = 10mm 2 /s for short periods at max. leakage oil temperature of 90 0 C V max = 800 mm 2 /s for short periods upon cold start. Temperature range (see figure 8) t min = -20 0 C t max = +75 0 C For correct selection of the fluid it is assumed that the operating temperature in the tank is known, in relation to the ambient temperature. The fluid should be selected so that, within the optimum range (V opt ), (see shaded section of selection diagram). We recommend that the higher Viscosity grade is selec- tion in each case. Example: At an ambient temperature of X 0 C. The operating temperature in the tank will be 60 0 C. In the optimum operating viscosity range (V opt ; shaded section) this corre- sponds to viscosity grade VG 46 or VG 68; VG 68 should be selected. Important: The leakage oil temperature is influenced by pressure and speed and always higher than the tank temperature. At no point in the system, however may the tempera- ture be higher than 90 0 C. If it is not possible to comply with the above conditions because of extreme operating with the operating parameters or higher ambient temperature, please contact us. LIMITS OF VISCOSITY RANGE: NOTES ON FLUID SELECTION: Figure 8 HYDRAULIC FLUID: 15 Breaker Owners Manual SAFETY SAFETY PRECAUTIONS: Danger, Warning, and Caution are harzard alerts used in this manual and on the breaker safety signs to identify hazards on or near the rockbreaker system. Danger - Immediate hazards, which WILL result in severe personal injury or death if the proper precautions are not taken. Warning - Hazards or unsafe practices, which COULD result in personal injury or death if the proper precautions are not taken. Caution - Hazards or unsafe practices, which COULD result in product or property damage if the proper precautions are not taken. BTI cannot anticipate every possible circumstance that might involve a hazard. The haz- ard alerts in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating technique not specifically recommended by BTI is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the breaker and carrier will not be damaged or made unsafe by the operation, main- tenance or repair procedures you choose. To avoid injury from flying chips of stone or concrete, be sure you and others stay well away from the breaker when it is operating. BTI Hydraulic Breakers and their components are heavy! Plan carefully how you will handle them when removing, disassembling, or installing the breaker. Stand clear when slinging the breaker off the ground. Only trained mechanics should disassembly the breaker. However if you should disas- semble the breaker be sure to all Nitrogen gas pressure from the cushion chamber. Refer to the breaker disassembly (page 24) of this manual for instructions. Stay clear of the tool when charging the cushion chamber with nitrogen gas. It may jump against the retainer pins as the gas pressure forces the piston down. 16 Breaker Owners Manual OPERATION INITIAL STARTUP & COLD WEATHER STARTING: Before operating the breaker you may need to warm the carrier's hydraulic system. This cold starting technique is useful if the breaker has been in extended storage, or the ambient temperature is below 20 0 F. Warming up the sys- tem to its operating temperature will prevent the breaker misfiring. First, cycle each boom function by extending and retracting each cylinder through its full stroke. Hold the valve open for 3 to 5 seconds at each end of the cylinder's travel. This will push oil over the relief and generate heat. Repeat this procedure until all booms operate smoothly. Next, raise the breaker so the tool is not pressing onto any material and fire the hammer. This is called 'idle firing'. In this position the breaker does not normally run, but circu- lates warm system oil through the control valve to the tank. Hold the hammer fire on for 5 seconds, then release for 5 seconds. Repeat this procedure for 3 to 5 minutes depend- ing on the ambient temperature. While idle-firing the piston may move up and down, but should not hit the tool. And finally, start breaking rock by operating the breaker in short 3-second bursts. Continue operating with short bursts until the carrier and breaker are at the operating tempera- ture. New breakers require a break-in period before full opera- tion. For the first 30 minutes, operate in soft material or compacted ground and do not fire the breaker continuously for more than 20 seconds at a time. For large rocks start at the edge and work toward the cen- ter, breaking off small chunks each time. Breaking along the rock's natural faults and seams also make for easier breaking. (Fig. 9) When breaking on a wall or steep incline use a combina- tion of the carrier's stick cylinder and tilt cylinder to pro- vide the necessary force to hold the breaker against the material. Always work the tool 90 degrees to the material being broken. (Fig. 10 & 11) As you apply down-force to the breaker, the carrier will lift slightly giving you a clue that the breaker is properly pressed onto the material. Excessive down-force will not make breaking easier, in fact the carrier will be lifted too far off the ground, and this can damage your equipment. Not enough down-force and the tool will bounce on the material, blank-firing Figure 9 Figure 10 Figure 11 17 Breaker Owners Manual OPERATION SUGGESTIONS FOR EFFICIENT OPERATION: Do not operate the breaker continuously for more than 20 seconds. Excessive heat will be generated and you may mushroom the end of the tool. If the rock or stone shows no sign of breaking within 20 seconds, change its position or that of the breaker. The breaker should not be fired when the carrier's boom cylinders are fully extended or fully retracted. The cylinders may be damaged from the breaker's shock pulses. If your carrier throttle has been set to run at a specific setting, do not deviate. This pro- vides the proper flow to the breaker. But be careful, excess flow does not increase breaking power. Your carrier's operating temperature may run too high, and actually decrease breaking power. If the hydraulic oil temperature exceeds. 175oF (79oC), stop breaking! If you plan to operate the breaker underwater, ensure that it has been equipped with an underwater kit. Refer to page 43. Blank firing emits a distinct metallic ringing. Blank firing most often occurs in hard rock, just as the rock shatters under the tool. With no material under the tool, the piston smashes the tool and retainers too far into the front head, transfering the breaking force back through the breaker and excavator. To prevent blank-firing learn to anticipate when the material will break. Predicting this moment is probably best done by listening to the sound of the hammer hitting the rock. You will soon notice a change in the hammering sound as the stone is breaking, you are now on your way to anticipating when a rock will break. BLANK FIRING: 18 Breaker Owners Manual OPERATION Do not use the breaker to pry, pick, pound, or lift. This can cause serious damage to the breaker as the tool side loads or binds in the bushing. The tool must always move freely straight up and down in the bushing. But remember, your breaker sideplates are designed to push and rake material for better positioning. SUGGESTIONS FOR EFFICIENT OPERATION: BENDING IMPROPER BREAKER OPERATION POUNDING PRYING PUSHING LIFTING PROPER BREAKER OPERATION RAKING PUSHING Figure 12 Figure 13 19 Breaker Owners Manual TRENCHING & EXCAVATION WORK: OPERATION Before trenching, you will first need to remove all overburden material, exposing the surface of the rock to be broken. To begin, penetrate the breaker tool deep into the mate- rial, splitting and loosening the rock. Repeat this penetration several times within a small area, excavating a hole. When excavating a deep trench it is more effective to use steps or benches allowing a place for the rock to break out to. Keep maintaining the benches as the trench advances. The sides of the trench must be sloped to accommodate the width of the breaker. In other words, the larger the breaker and the deeper the trench, the wider the opening at the top will need to be. For most situations the excavator will sit off to the side of the trench allowing you to keep steeper slopes. However the carrier swing function will not have the strength to push broken rock away from the work area. In some cases the excavator will sit on top of the trench and the broken material can be back filled under the excavator. For best performance, apply the down force in line with the tool, repositioning every 10 to 15 seconds or when no penetration is evident. Keep the breaker well greased at all times. With practice and experience you will learn to determine the best place to begin break- ing just by looking at the rock. You will want to position the tool on flat areas of the rock, or look for a seam or crack, which may allow easier splitting. To fully absorb all the breakers energy, the rock must be resting on a solid base. Begin by penetrating the concrete several times in one area with the breaker tool. This should loosen the concrete and separate the reinforcing steel. The reinforcing steel may need to be cut, keeping the concrete pieces manageable for hauling away. When breaking concrete floors, use the down force from the carrier's boom cylinder to follow the tool through the concrete. Breaking vertical walls is more difficult, force must be maintained using a combination of boom, stick, and tilt cylinders. A fast blow rate gives the best performance in breaking concrete, so ensure your carrier is providing the breaker with the maximum recommended oil flow. Generally when breaking concrete, a chisel point gives the best splitting action. However if you are breaking hard concrete with lots of reinforcing steel, a moil point may be better. The moil tip allows the tool to deflect off the steel as it breaks through the concrete. If the grizzly is covered with rock, use the breaker sideplates to rake the material. This will get most of the finer material through the bars and lets the larger pieces rest directly on the grizzly. Large pieces will break easier if they rest directly against the grizzly bars. This way all the energy from the breaker is applied to the rock. Breaking energy will be absorbed if there is too much material under the rock you are breaking. If rocks are just hanging on the edge of the bars, use the breaker to hammer them through with short bursts. Do not push them through with the force of the boom, this can damage your breaker as the front head hits the grizzly bars. BREAKING OVERSIZE MATERIAL: BREAKING CONCRETE: BREAKING ROCK ON A GRIZZLY: MAINTENANCE 20 Breaker Owners Manual To keep your breaker working in top operating condition, the following maintenance must be performed. Keep in mind that lubrication is the single most important procedure for sustaining the life of a breaker. To make this chore easier, we offer an auto lubrication unit, call BTI for details Lubricate the tool with BTI chisel paste or a moly-based grease every two hours of con- tinuous operation and any time you have serviced the tool. Failure to lubricate regularly reduces the life of the tool, tool bushings and front head. Never use ordinary grease, because it melts and runs down the tool providing very poor lubrication. For proper tool lubrication the breaker must be vertical with enough down-force applied to push the tool into the breaker. This will prevent grease from entering the area above the tool. Check that the tool moves freely in the bushings. Visually check the tool retainer pins. The round retainer pins rotate during normal oper- ation. To confirm they are rotating, look at the ends of the pins for fresh radial marks in the grease on the cross pin. Every 100 hours the carrier's hydraulic filter must be checked. Inspect your filter or fil- ter indicator and change as necessary. Clean oil is crucial for proper breaker perform- ance and life. Check all nuts and bolts for the correct torque. Improperly torqued bolts can damage the breaker. Remove and inspect the tool. See page 23. Every 1,000 hours, check the breaker's hydraulic circuit pressure relief and flow settings and adjust to the recommended levels. Change the carrier hydraulic oil and the oil filter. Replace all breaker seals and inspect all wear parts. DAILY MAINTENANCE: AFTER EVERY 100 HOURS: AFTER EVERY 1000 HOURS: MAINTENANCE 21 Breaker Owners Manual GREASING THE BREAKER: Failure to lubricate regularly will reduce the life of the tool, tool bushings, and the front head. To properly lubricate the tool, the breaker must be in a vertical position, with enough down pressure applied to force the tool up into the breaker housing. This will prevent excessive grease entering the impact chamber which could cause the breaker to lose power due to cushioning, or to stop operating altogether due to a hydraulic lock in the impact chamber. The breaker should be greased every two hours of use or when the tool appears shiny where it rides inside the front head. The chart (page 51-53) shows the minimum amount recommended for each breaker,and can be used as a guideline. Preform a visual check when greasing to ensure the retainer pins rotate during normal operation. By looking at the side of the front head, check the ends of the pins confirm- ing they are rotating by the fresh grease marks. Before greasing, down pressure must be applied to push the tool up into the breaker. Grease until the grease oozes out around the tool. Grease the breaker every two hours. Use only BTI Chisel Paste or a molybde- num disulphide based grease. RETAINER PINS: Tool Retainer Retainer Pin Grease traces leave radial marks Figure 14 Figure 15 SERVICE 22 Breaker Owners Manual BTI breakers are built using the highest quality materials and workmanship to ensure long life and maximum efficiency. To keep a breaker in top operating condition, lubrica- tion, inspection, and servicing all need to be conducted at regular intervals. This overhauling should be scheduled to occur every year or after every 1,000 hours of operation, whichever comes first. For units being operated on a continuous basis in very hard rock, overhaul is advisable after every 500 hours. Breakers operate in very dirty conditions. Their efficient operation relies on keeping that dirt out of the close tolerance mechanism. It is important to maintain the breaker and especially the seals in good condition by following proper operating and maintenance procedures. Some breakers are used for overhead scaling which have special concerns, consult your BTI dealer for more information. Rockbreaker servicing must be carried out in a clean, dry area. Even a small amount of dirt in the cylinder or control valve can cause premature failure. To do a complete service you will require the following items; a suitable hoist, replace- ment parts, lubricants, a torque multiplier, a nitrogen charging kit, and a pressure gauge. The gauge is provided in the rockbreaker tool kit. Always take proper safety precautions. You must wear safety glasses, work gloves, and safety shoes. Use of a safety stand is recommended. Before servicing the breaker review this technical manual and read all decals. Before lifting the breaker, refer to page 51 for the approximate working weight of the breaker. SAFETY PRECAUTIONS: BREAKER DISASSEMBLY 23 Breaker Owners Manual REMOVING THE TOOL: Once the breaker is removed from the boom, lay it down so that the control valve side of the breaker is facing up. Check the wear width between the tool and the tool bushing. Refer to the Bushing Wear Width charts on pages 51-53 for the accepted clearance values. To remove the tool, drive out the retainer pin and stopper plug using the drift supplied in the tool kit. Carefully roll the breaker onto its side with the locked sideplate bolts facing the ground and drive out the two tool retainers from the side opposite the control valve. Inspect the tool retainers for cracks or deformities. BTI's new 'O' series oval tool retain- ers should be examined for wear along the edge of the retainer that rests against the tool. The 'E' series breakers have round retainer pins that will show radial grease marks con- firming they have been rotating properly. Also look for wear at the top of the tool retain- er, where the tool hits it. Stopper Plug Retainer Pin Drift Hammer Tool Retainer Drift Applicable on Breaker E Series Models: TB125, TB135, TB225, TB235, TB275, TB285, TB325, TB335, TB425, TB625, TB725, TB825, TB925, TB975, TB1025, TB1425, TB1675, TB1825, TB2075, TB2225, TB2575. Applicable on Breaker O Series Models: TB830, TB980, TB1280, TB1430, TB1680, TB2080, TB2580. Wear Width Tool Retainer Stopper Plug Retainer Pin Drift Figure 16 Figure 17 Figure 18 E Series O Series BREAKER DISASSEMBLY 24 Breaker Owners Manual Remove the tool and inspect the top for pitting and mushrooming. Also, check for chip- ping of the impact face, which may indicate excessive tool bushing wear. Any of these conditions may suggest a need for more frequent servicing, because of extreme operating conditions or because the tool is being incorrectly operated. Refer to page 10. Inspect the retainer pin contact area on the tool for deformation and scoring. In normal use, this wear will be minimal. If tool wear seems extreme, it may indicate frequent blank firing. If the retainer pin contact areas on the tool cannot be repaired, the tool must be replaced to avoid premature failure of the retainers. Also, inspect the tool bushing area for wear. Excessive wear here may also indicate that more frequent greasing is needed, and if this area cannot be repaired, the tool must be replaced to avoid damaging the new bushings. Make any necessary repairs to the tool before putting it back into the refurbished front head. If your breaker has a top or side mount bracket, remove it now. With the breaker on its side, use a torque multiplier to remove the sideplate nuts. Now lift the sideplate off the breaker with the lifting eyes provided in your tool kit. Remove the breaker from the lower sideplate and lie it down in a clean work area. Inspect the sideplates for cracks, worn bolt holes, and damaged threads in nuts and on bolts. Any defects should be corrected before the sideplates are reinstalled. Pay particu- lar attention to the shear blocks and make sure they are not worn so they will fit closely with the key groove in the breaker body. Thoroughly clean the outside of the breaker before disassembly. During this cleaning, look for signs of physical damage, especially around the key groove area. Any damage should be repaired while the breaker is disassembled. The cushion chamber in the rear head contains nitrogen gas under pressure. Do not remove the tie rod nuts or gas valve until this pressure is relieved. To relieve this pressure, remove the gas valve plug and press firmly on the disc in the gas valve with a blunt object. Be sure to protect yourself adequately from the escaping jet of gas. BLEEDING THE NITROGEN GAS: REMOVING THE MOUNTING BRACKET & SIDEPLATES: 25 Breaker Owners Manual BREAKER DISASSEMBLY REMOVING THE CONTROL VALVE (E and O SERIES ONLY): While the breaker is securely held, remove the control valve. Use only hand tools to loosen the tie rod nuts and control valve bolts, since they thread into special hardened- steel inserts that can be damaged by impact tools. The recommended methods for loosen- ing the nuts and bolts are the sledge wrench method and the torque multiplier method. Remove the control valve bolts and lock washers and lift the control valve from the cylin- der. Place the control valve on clean protective material. Figure 19 Insert lifting eyes into the rear head and stand the breaker onto the safety stand. Back off the tie rod nuts a couple of turns, this can be done using a torque multiplier if the breaker is standing up. If the breaker is lying down, use the sledge-wrench method. Then using the hoist, jerk the assembly upwards, which should loosen the rear head from the cylinder. If the rear head is stuck, it may be necessary to tap the cylinder cover on alternate sides, with a soft-faced mallet. Remove the nuts from the four tie rods. Remove the plastic tie rod washers and remove the rear head from the cylinder, using the lifting eyes. In some cases, the nuts may be seized onto the tie rods and the nut and tie rod may come out as a unit. Place the rear head on a clean protective surface. REMOVING THE REAR HEAD FROM THE CYLINDER: Tie Rod Nut Tie Rod Washer Cylinder Cover Figure 20 Install a lifting eye into the top of the piston, and lift the piston straight up and out of the cylinder to avoid scratching its polished surface. Tapping the cylinder with a soft-faced mallet may ease the removal of the piston. The seal bushing will come out with the piston. Place the piston on a clean protective surface. 26 Breaker Owners Manual BREAKER DISASSEMBLY REMOVING THE PISTON: Piston Upper Seal Bushing Figure 21 27 Breaker Owners Manual BREAKER DISASSEMBLY REMOVING THE CYLINDER & TIE RODS: Use hand tools to loosen the tie rods; impact tools will damage the thread inserts in the front head. To loosen the tie rods it may be necessary to secure the front head to prevent it from rotating. Loosen the tie rods by rotating them counter-clockwise. Use an adjustable wrench and a soft-faced mallet or a sledge wrench on the tie rod flats to loosen the tie rods. Removing the cylinder involves installing two lifting eyes into the threaded holes in the top of the cylinder and lifting the cylinder straight up off the tie rods. The cylinder should slip easily out of the front head. If not, tap the front head with a soft-faced, until the cylinder and front head come apart. Place the cylinder on clean protective material. Remove the four tie rods. Place the tie rods on clean protective material. While the front head is still on the safety stand, remove the air valve assembly and grease fitting to avoid accidental damage during bushing replacement. Put them in a safe place for reuse later. REMOVING FRONT HEAD GREASE FITTING & AIR VALVE: Cylinder Figure 22 Figure 23 BREAKER DISASSEMBLY 28 Breaker Owners Manual Do not gouge out the bushings with a torch. The tool bushings are held in position by four retainer pins. Remove these pins by driv- ing them out with a drift, from the side opposite the stopper plugs. The tool bushings need to be shrunk to remove them from the front head. The recommended method of shrinking the bushings is to use an arc welder, using a very hot weld, laying crescent-shaped beads completely covering the inside of the bush- ing. Depending on the breaker bushing size this could take from one-half to three hours. Allow the bushing to cool, without quenching, for about one-half hour to allow the weld to contract and shrink the bushing. This time will be less for smaller breakers. Knock the bushing out with a bar from the top end of the front head. Remove the lower bushing first, and then repeat the procedure for the upper bushing. If you plan to install the new bushings immediately after removing the old ones, place the new bushings in dry ice before you start the removal procedure. Dry ice can take up to 4 hours to achieve the desired results. Then the bushings will be fully chilled and the front head will still be hot enough from welding, to receive them. If you are using liquid nitrogen to shrink the bushings, it can take as little as 15 minutes to properly chill them. REMOVING THE TOOL BUSHINGS: Front Head Upper Tool Bushing Lower Tool Bushing Tool Bushing Alignment Slot and Retainer Pin Figure 24 29 Breaker Owners Manual BREAKER DISASSEMBLY INSTALLING THE TOOL BUSHING: Check the inside of the front head for damage, and repair or replace as required. Extreme care must be taken when installing the tool bushings in the front head. Because the bushings are a shrink fit, the front head must be heated, so that it will expand, and the bushings placed in liquid nitrogen, so they contract. As the pieces return to room temperature, they become tightly fitted together. If the bushings are not installed proper- ly before this point is reached, they must be taken out and replaced with new ones. With liquid nitrogen you have about one minute to align the retainers. Clean the inside of the front head thoroughly, and use a wire rotary brush to clean and smooth the surfaces in the areas where the bushings seat. If the front head has cooled, it must be heated with a torch to 300 o F, (150 o C). This will expand the housing a small amount. Then line up the slots in the bushing with the retainer holes. When fully inserted, the upper tool bushing will seat against a step in the bore of the front head. Care must be taken to ensure that the grooves in the tool bushings line up with the retainer-pin holes in the front head. Do not install the stopper plugs until the front head has cooled to room temperature. Apply a coat of Never-seize to the two retaining pins, and fully insert them into the retaining pin holes. Repeat the procedure for the lower bushing. The upper and lower tool bushings are installed from the tool side of the front head on most models of BTI breakers. 30 Breaker Owners Manual BREAKER DISASSEMBLY INSPECTING THE SEAL BUSHING: Start by cleaning, and inspecting the cylinder seal bushing. The seal bushing carries several specially designed seals. Careful attention should be paid to the condition and orientation of the old seals as they are removed. This may help to identify any operating problems that the breaker had before it was disassembled. All parts should be thoroughly washed in clean solvent and dried with compressed air. Once the seal bushing is clean and dry, protect it from dirt and set it aside. Upper Seal Bushing Gas Seal* Oil Seal* P i s t o n C y l i n d e r Oil Seal* Dust Seal* Slide Ring with Square Ring (Models TB725X and up) Slide Ring with O-ring (Model TB925X and up have 2 as shown) * When inserting seals, make sure direction is as shown. Figure 25 31 Breaker Owners Manual BREAKER DISASSEMBLY INSPECTING THE PISTON: The piston should be carefully cleaned and inspected for corrosion, cavitation, pitting, and scoring. Check the grooves in the piston for metal that has been pulled in due to galling. If this has occurred clean the grooves. Small marks can be removed with an oilstone or fine emery cloth and oil. Look for pitting and deformation of the impact face. They may indicate that the tool has been operated with too much wear in the tool bushings. If the face is dished, carefully measure the amount and refer to the service manual to see that this amount is allowable for the model you are servicing. Refer to Maximum Allowable Piston Deformation on the charts on pages 51-53 of this manual. Thoroughly dry the piston, protect it from dirt, and set it aside. If the piston is not going to be installed immediately, coat it with oil and store it protect- ed, in a clean dry place. Piston Impact Face Deformation Scoring Figure 26 Figure 27 32 Breaker Owners Manual BREAKER DISASSEMBLY INSPECTING THE CYLINDER: Thoroughly clean the cylinder bore, and remove the dust seal, oil seal, and slide ring. The TB625 and smaller breakers do not have a slide ring in the cylinder. Check the seals for signs of excessive wear conditions. Thoroughly inspect the inside walls of the cylinder for corrosion, cavitation, or scoring. Check grooves above seal area for small pieces of metal, due to galling. If these are not cleaned out they will chip off and go between the piston and cylinder, and galling will occur again. Also inspect the main inlet and outlet adapter threads for damage. Always replace the seals and ensure that the adapters are not interchanged if they are removed. The cylinder is marked with a "P" beside the pressure adapter and a "T" beside the tank adapter. The Pressure adapter has a smaller hole than the tank adapter. Check for any damage to the threaded inserts that hold the control valve, and repair or replace as necessary to ensure secure control valve mounting. Thoroughly dry the cylinder and protect it from dirt. 33 Breaker Owners Manual BREAKER DISASSEMBLY DISASSEMBLING THE CONTROL VALVE (E & O SERIES ONLY): The control valve controls the flow of oil through the breaker, which causes the piston to move in the cylinder. Prepare the control valve for disassembly by washing it thoroughly and clamp it in a vise. Remove the hex bolts holding the valve cap, then remove the cap by threading the puller bolts provided in the toolbox into the two threaded holes in the cap. Gradually tighten the bolts, alternating from one to the other, until the cap is pulled from the con- trol valve. The control valve spool should move smoothly in the bore, and can usually be easily removed. A sliding hammer puller can assist in removing a seized spool. REMOVING THE CONTROL VALVE SPOOL (M SERIES ONLY): Insert lifting eyes into the rear head and stand the breaker onto the safety stand. Back off the tie rod nuts a couple of turns, this can be done using a torque multiplier if the breaker is standing up. If the breaker is lying down, use the sledge-wrench method. Then using the hoist, jerk the assembly upwards, which should loosen the rear head from the cylinder. If the rear head is stuck, it may be necessary to tap the cylinder cover on alternating sides, with a soft-faced mallet. Remove the nuts from the four tie rods. Remove the plastic tie rod washers and remove the rear head from the cylinder, using the lifting eyes. In some cases, the nuts may be seized onto the tie rods and the nut and tie rod may come out as a unit. Place the rear head on a clean protective surface. Using the lifting eye remove the control spool guide plug (Fig. 33B) and place it on a clean protective surface. Next, slide the control spool out of the cylinder (Fig. 33C). The spool should slide easily out of the cylinder, without the use of tools. If the spool is stuck or seized a mechanical puller may have to be used. Tie Rod Nut Tie Rod Washer Cylinder Cover Figure 33 Figure 33B Figure 33C 34 Breaker Owners Manual BREAKER REASSEMBLY Inspect the control valve spool for any signs of scoring, binding and cavitation. Pay par- ticular attention to the spool holes. Small scratches and marks may be removed with a fine oilstone or fine emery cloth and oil. Also check the control valve cap and valve body for marks or scratches, and remove them if they are not too severe. If the score marks are too deep or large, the complete control valve assembly must be replaced. Examine the control valve ports for cavitation and erosion. Check all the oil passage holes in the control valve and be sure they are not plugged. Clean them with a fine wire if necessary to remove any dirt particles. Clean all parts of the control valve in clean solvent and dry them with compressed air. Holding the control valve body in the vice, oil the valve spool and the valve body and then install the spool. Before placing the o-ring and backup ring on the valve cap, lubricate the o-ring grooves with oil to prevent damage to the o-ring. Install the valve cap into the valve body, and snug the four-valve cover bolts diagonally and uniformly to prevent binding. Use only hand tools when tightening the bolts; impact tools will damage the helisert inserts. Tighten the cap bolts to the torque specified in the service manual for the model of breaker you are servicing. Protect the control valve assembly from dirt and set it aside INSPECTING THE CONTROL VALVE: REASSEMBLING THE CONTROL VALVE (E & O SERIES ONLY): Valve Body Spool Valve Cap Figure 28 35 Breaker Owners Manual BREAKER REASSEMBLY Remove the gas valve plug and the gas valve from the rear head. Thoroughly clean the cover and valve and inspect them for damage. Cover the gas valve threads with a good quality thread sealer. Reinstall the gas valve and seal, and tighten the valve to 61 foot- pounds. Insert the gas valve plug and just hand tighten it for now. When the front head has cooled sufficiently, clean and inspect the previously removed grease fitting and air valve for damage and reinstall or replace as necessary. The air valve maintains a positive pressure in the strike chamber to help exclude dirt, oil, and other contaminants. Remember to reapply loctite or thread tape to the air valve whenever it is removed and insert the spring before the check ball, for proper operation. INSPECTING THE GAS VALVE: INSTALLING THE FRONT HEAD GREASE FITTING & AIR VALVE: Figure 29 36 Breaker Owners Manual BREAKER REASSEMBLY INSTALLING THE TIE RODS: Inspect the tie rod threads. If they are damaged beyond repair, the tie rods must be replaced. Lubricate the tie rods thoroughly using a moly-based grease or Never Seize. The tie rods should turn smoothly and easily until they bottom out in the holes. If they do not bottom out, or there is excessive resistance, the threads on the tie rods or the helisert inserts may be damaged. Remove damaged heliserts and restore the front head threads with conventional thread chasers and taps. Insert new heliserts with the appropriate tool. Torque tie rods to the specifications on page 47-49. Liberally oil the inside surface of the cylinder and the new seals, and install the seals and rings into the grooves at the lower end of the cylinder. Pay close attention to the correct placement and orientation of the seals. Improper seal installation will cause pre- mature leakage and premature wear. Apply some grease to the rubber pieces on the tie rods so the cylinder will slide on easi- ly. Lower the cylinder carefully onto the tie rods. The control valve mounting holes on the cylinder should face the same direction as the grease fitting on the front head. Oil the seal bushing and seals, and install the seals and rings in the correct positions and orientations. INSTALLING THE CYLINDER: RE-SEALING THE SEAL BUSHING: Upper Seal Bushing Gas Seal* Oil Seal* P i s t o n C y l i n d e r Dust Seal* Slide Ring with Square Ring (Models TB725X and up) Slide Ring with O-ring (Model TB925X and up have 2 as shown) * When insert- ing seals, make sure direction is as shown. Oil Seal* Figure 30 Figure 31 37 Breaker Owners Manual BREAKER REASSEMBLY INSTALLING THE PISTON: Replace the o-ring in the top of the cylinder. Lubricate the top end of the piston, and slide the seal bushing into place, with the chamfer or step towards the center of the piston. Lift the piston with the lifting eye, lubricate it thoroughly, and lower it carefully into the cylinder. It may need a tap to push it through the lower seals. When the piston is all the way into the cylinder bore, use a soft mallet to tap the seal bushing into position in the cylinder. The bushing will stop when it reaches the support flange inside the cylinder bore. Replace the o-rings and backup rings on the top of the cylinder where the rear head makes contact. The cushion chamber in the rear head needs a small amount of oil for proper operation. Just before you install the rear head, make a circular grease dam on the top of the pis- ton, just high enough to contain the required amount of oil. The amount of oil needed can be obtained from the chart on page 51-53. Lower the rear head over the tie rods. The gas valve should face the same direction as the control valve bolt holes on the cylinder. Install new tie rod washers. Lubricate the tie rod nuts with Never Seize, and tighten them in a crossing pattern to draw the breaker components together evenly. Finish tight- ening the nuts to the correct torque in four stages, using the same crossing pattern. INSTALLING THE REAR HEAD: Piston Upper Seal Bushing Figure 32 1 4 2 3 Tie Rod Nut Tie Rod Washer Cylinder Cover Figure 33 Figure 34 38 Breaker Owners Manual BREAKER REASSEMBLY INSTALLING THE CONTROL VALVE (E AND O SERIES ONLY): Lightly grease the control valve o-rings and backup ring and install them in the under- side of the control valve. Carefully fasten the control valve to the side of the cylinder using the bolts and washers removed earlier. The control valve cap must face toward the tool. Tighten the bolts evenly in a crossing pattern until they contact the valve. See torque specifications on pages 47-49. Ensure the control valve spool is clean and insert it back into the cylinder body. (Fig. 34B) Lubricate the seals on the control spool guide, ensuring that the guide is clean and insert it into the cylinder body. The guide should slide easily but if tools are required make sure the guide is squarely in the cylinder body and tap it into position using a soft-faced mallet. (Fig. 34C) Figure 34 INSTALLING THE CONTROL VALVE SPOOL (M SERIES ONLY): Figure 34B Figure 34C 39 Breaker Owners Manual BREAKER REASSEMBLY RECHARGING THE CUSHION CHAMBER: This gas is stored under high pressure. Caution is advised when handling. Remove the gas valve plug from the gas valve. Attach one end of the charging hose to the gas regulator and attach the charging adapter to the other end of the hose. With the charging adapter inserted into the gas valve and the nitrogen tank valve open, adjust the regulator handle slowly to build the pressure to the value specified in the service manual. If the piston is not at the bottom of its stroke the pressure will move it down to rest on the inside of the front head. Be aware that if the tool is installed at this stage, it may accelerate dangerously out of the cylinder when the cushion chamber is being pressurized. To check the cushion chamber pressure, remove the charging adapter from the end of the hose and put it on the pressure gauge. Insert the adapter into the gas valve and observe the pressure reading. If the reading is too high, bleed off a small amount of gas to make the final adjustment, and test again. If the pressure is too low, reinsert the charging adapter, and build pressure to the required value. When the pressure is at the correct value, (refer to the Cushion Chamber Pressure on the General Specification Chart on page 55), install the gas valve plug, using a new o- ring, and tighten to 8.7 foot-pounds torque. Take care not to cut the o-ring. C B A Pressure Gauge N 2 GAS TANK Regulator Figure 35 40 Breaker Owners Manual BREAKER REASSEMBLY SIDEPLATES & MOUNTING BRACKET INSTALLATION: Mounted to the sideplates on larger breakers (TB725 and up) are anti-vibration rubbers. Inspect these for damage and replace as necessary. Insert the sideplate bolts and washers into the hex retainers on the sideplate and lay the sideplate on a flat surface, with the retainers facing down and the bolts sticking up. Some of BTI's breakers only require one washer under the bolt head. Now slip the spac- er tubes onto the appropriate bolts. Carefully lower the breaker body onto the sideplate. Be sure to align the shear block on the sideplate with the key groove in the breaker body. You must also make sure that the hydraulic ports on the breaker align with the access cutouts in the sideplates. Next lower the other sideplate into place over the bolts, again taking care to align the shear block with the key groove. To prevent galling the threads on the side plate bolts, apply Never Seize or equivalent to the threads before installing the nuts, and then put a washer and nut on each bolt. Make sure the bolt heads are seated into the locking collars on the lower side plate. With a hand wrench, tighten all the sideplate nuts until the plates are seated against the breaker. This will prevent movement between the sideplates and the breaker during final tightening. Now using the torque multiplier tighten the bolts to 60 percent of the torque specified on pages 47-49. Follow the pattern shown here to distribute the load evenly. When all bolts have been tightened to 60 percent of their full torque value, tighten to 80 percent, then 90 percent and finally to 100 percent of the torque value for your breaker. Install the mounting bracket in the correct position, which depends on the intended application. 1 6 5 3 4 2 8 7 9 10 Figure 36 41 Breaker Owners Manual BREAKER REASSEMBLY INSTALLING THE TOOL: First grease the inside of the lower bushing, then when the tool is inserted it will take the grease with it. Cover the sides of the tool's top section with grease, and insert the tool into the front head. Grease and insert the tool retainers and then grease and insert the retainer pins and stop- per plug. The stopper plug should be flush with the front head. If storing your breaker for an extended period of time, refer to Removal & Storage on page 42 for storage instructions. Apply Grease Tool Retainers Retainer Pin Stopper Plug Apply Grease Tool Retainer O Series Breakers E Series Breakers Figure 38 Figure 37 Stopper Plug Retainer Pin 42 Breaker Owners Manual BREAKER REMOVAL & STORAGE BREAKER REMOVAL & STORAGE: At the end of the day if the breaker is not to be removed from the carrier, it should be left resting in a vertical position. When it's time to remove and store your breaker, fol- low one of these steps. Storing your breaker for up to a week, is considered short term storage. This is how to store the breaker. Using your excavator lay the breaker on wooden blocks, the breaker mounting end should lie higher than the tool end. Now remove the pins to disconnect the breaker from the boom. Remove the tool and ensure the retaining pins, bushings and piston bottom are all well greased. Then reinstall the tool and cover the breaker with a tarp. If you plan to store the breaker longer than a week, use one of the following two proce- dures depending on whether you are standing the breaker up or laying it down. For long term storage in which you are laying down the breaker, first release the cush- ion chamber gas pressure. Then remove the tool. Liberally grease the piston bottom, retaining pins and inside the front head. Next, push the piston up inside the breaker and reinstall the tool. Finally, with the breakers mounting end elevated, cover the breaker with a tarp. For long term storage where you are standing the breaker up, the breaker must be stored in a safety stand. Allow the breaker's weight to push the tool up into the breaker. You do not need to release the cushion chamber gas pressure. The piston will not slide into the cylinder with a pressure of 114 psi. SHORT TERM STORAGE: LONG TERM STORAGE - STANDING UP: LONG TERM STORAGE - LYING DOWN: 43 Breaker Owners Manual UNDERWATER APPLICATIONS SETUP: To adapt the BTI Breaker for underwater use, compressed air must be fed into the breaker front head area, creating a positive air pressure that will keep the water out. If water does enter the front head and the breaker is fired, it could force water and debris up inside, resulting in seal damage. An 18 cfm compressor is recommended at 21 psi. For depths exceeding 15 ft, increase to 26 psi. For TB125 to TB425, remove the grease fitting and tie the line in here. For TB725 and up, remove the check valve to plumb the line in. Start supplying air to the breaker before placing it underwater, and continue supplying air until the breaker is removed from the water. Continue to operate the breaker out of the water for approximately 10 minutes, then grease the tool and front head with the tool pressed in. UNDERWATER OPERATION: Figure 39 44 Breaker Owners Manual TROUBLESHOOTING GUIDE OIL LEAKAGE: If oil leakage develops, it may not be necessary to replace parts. Check the fol- lowing points in the chart below before calling your BTI representative. A slight amount of oil seepage around the breaker connecting parts is normal during the first 200 hours of operation. Area of Leakage Condition Corrections A. The space between Large amounts of Damaged seals. the tool and bushing oil coming out. Re-seal as necessary. B. Oil over the surface Possible loose hoses Check condition of the breaker. or adapter fittings. of hoses and fittings, tighten as necessary. C. Control valve cap Oil ooze after Normal oozing of bolts. overhaul of unit. assembly lubricants. D. Between control Oil ooze after Normal oozing of valve and surface of breaker overhaul assembly cylinder. lubricants. E. Joining surface of Oil oozing Loose tie rod cylinder and rear New oil leaking nut, re-tighten head. Damaged O-ring, replace. F. Joining surface of New oil leaking Loose plugs on cylinder and front face of cylinder, head. retighten. Damaged seals in the cylinder, replace as necessary. B D C A F E Figure 40 45 Breaker Owners Manual TROUBLESHOOTING GUIDE POOR BREAKER PERFORMANCE: CONDITION CAUSE CORRECTION Does not hammer Base carrier selector valve does not Check connection from cab operate properly. controls to the selector valve. Poor performance of the hydraulic pump. Check pump output. Repair or replace. Pressure relief valve set too low. Check relief settings and adjust. Clogged or restricted hoses. Clean or replace. Cushion chamber fills with oil. Replace seals. Seizure of breaker. Overhaul and replace worn parts. Erratic Hammering Hyd. oil temperature too high. Oil temperature must not exceed 170 deg.F (77 deg. C). Insufficient oil flow and/or pressure. Check base carrier hydraulic system. Clogged or restricted hoses, or pipes. Clean or replace. Not enough down force on the tool. Increase the down pressure acting on the tool. Pressure too high in cushion chamber. Adjust pressure. Too much grease in the impact chamber. Remove tool from front head and clean out excess grease. Follow proper greasing instructions. Excessive clearance between tool and Check clearance and replace tool bushing. worn parts. Excess wear at top of tool. Remove and inspect the tool. Replace if necessary. Foreign matter in the breaker control valve. Disassemble and clean. Seizure of piston and cylinder. Overhaul the breaker. 46 Breaker Owners Manual TROUBLESHOOTING GUIDE POOR BREAKER PERFORMANCE CONTINUED: CONDITION CAUSE CORRECTION Lack of Power Insufficient oil flow or oil pressure. Check hydraulics of the base carrier. Broken tool Replace tool, check piston for damage. Cushion chamber gas pressure is too low. Check and adjust. Breaking of Tool Abuse of tool and prying with tool. Apply down force in the direction of tool only. Check for excess play in arms, links, and pins. Mushrooming of Tool Continuous hammering in one place. Use short bursts. Re-position breaker every 30 seconds. Rapid increase in Oil Insufficient oil cooling. Check oil cooler. Temperature Insufficient oil flow. Check pump output. Incorrect oil pressure. Check relief valve setting. Emulsification of Oil Oil contaminated with water. Locate source of water and repair. Replace oil TORQUE SPECIFICATIONS 47 Breaker Owners Manual Small Breaker Torque Chart (TB125-TB425) kg-m 18 18 18 28 28 45 45 ft-lbs 130 130 130 202 202 325 325 kg-m 18 18 18 28 28 45 45 ft-lbs 130 130 130 202 202 325 325 kg-m 12 12 12 12 15 15 20 20 20 25 25 ft-lbs 87 87 87 87 108 108 145 145 145 181 181 kg-m 45 45 45 45 55 55 65 65 65 100 100 ft-lbs 325 325 325 325 398 398 470 470 470 723 723 kg-m 40 40 40 40 50 50 70 70 70 120 120 ft-lbs 290 290 290 290 362 362 506 506 506 868 868 kg-m 22 45 ft-lbs 159 325 kg-m 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 ft-lbs 61 61 61 61 61 61 61 61 61 61 61 kg-m 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 ft-lbs 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 kg-m 45 45 45 45 45 45 45 45 45 55 55 ft-lbs 325 325 325 325 325 325 325 325 325 398 398 kg-m 5 5 5 5 10 10 20 20 20 20 20 ft-lbs 36 36 36 36 72 72 145 145 145 145 145 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A T B 2 8 5 M E / Q A T B 3 2 5 C M / M E / Q A T B 3 2 5 X T B 3 3 5 M E / Q A T B 4 2 5 C M / M E / Q A T B 4 2 5 X T B 2 3 5 M E T B 2 7 5 C M / M E T B 1 3 5 M E T B 2 2 5 C M / M E Hose Adaptor Choke Plug N/A Control Valve Cover Bolt Side Plate Bracket Nut Top Mount Bracket Bolt Gas Valve Body Gas Valve Plug Control Valve Body Bolt T B 1 2 5 C M / M E Tie Rod Bolt Tie Rod Nut TORQUE SPECIFICATIONS 48 Breaker Owners Manual Medium Breaker Torque Chart (TB625-TB830) kg-m 45 45 45 45 75 75 ft-lbs 325 325 325 325 542 542 kg-m 45 45 45 45 75 75 ft-lbs 325 325 325 325 542 542 kg-m 30 30 50 50 50 50 ft-lbs 217 217 362 362 362 362 kg-m 130 130 200 200 200 200 ft-lbs 940 940 1447 1447 1447 1447 kg-m 120 120 150 150 150 150 ft-lbs 868 868 1085 1085 1085 1085 kg-m 22 22 22 22 ft-lbs 159 159 159 159 kg-m 8.5 8.5 8.5 8.5 8.5 8.5 ft-lbs 61 61 61 61 61 61 kg-m 1.2 1.2 1.2 1.2 1.2 1.2 ft-lbs 8.5 8.5 8.5 8.5 8.5 8.5 kg-m 55 55 55 55 55 55 ft-lbs 398 398 398 398 398 398 kg-m 20 20 20 20 30 30 ft-lbs 145 145 145 145 217 217 N/A N/A T B 6 2 5 C M / Q A T B 6 2 5 X T B 7 2 5 C M / Q A T B 7 2 5 X / X S T B 8 3 0 X / X S T B 8 2 5 X / X S Control Valve Body Bolt Tie Rod Bolt Control Valve Cover Bolt Hose Adaptor Choke Plug Gas Valve Body Gas Valve Plug Tie Rod Nut Side Plate Bracket Nut Top Mount Bracket Bolt TORQUE SPECIFICATIONS 49 Breaker Owners Manual Large Breaker Torque Chart (TB925 - TB2580) kg-m 75 75 75 90 90 90 90 90 90 130 130 130 130 130 130 ft-lbs 542 542 542 651 651 651 651 651 651 940 940 940 940 940 940 kg-m 75 75 75 90 90 90 90 90 90 130 130 130 130 130 130 ft-lbs 542 542 542 651 651 651 651 651 651 940 940 940 940 940 940 kg-m 60 60 60 60 80 90 90 90 90 90 90 90 120 120 120 ft-lbs 434 434 434 434 579 651 651 651 651 651 651 651 868 868 868 kg-m 230 230 230 230 290 360 360 360 360 360 360 360 580 580 580 ft-lbs 1664 1664 1664 1664 2098 2604 2604 2604 2604 2604 2604 2604 4195 4195 4195 kg-m 180 180 180 180 165 300 300 300 300 300 300 300 500 500 500 ft-lbs 1302 1302 1302 1302 1193 2170 2170 2170 2170 2170 2170 2170 3617 3617 3617 kg-m 70 70 70 120 120 120 120 120 120 180 180 180 180 180 180 ft-lbs 506 506 506 868 868 868 868 868 868 1302 1302 1302 1302 1302 1302 kg-m 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 ft-lbs 61 61 61 61 61 61 61 61 61 61 61 61 61 61 61 kg-m 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 ft-lbs 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 kg-m 60 60 60 60 60 60 60 60 60 65 65 65 65 65 65 ft-lbs 434 434 434 434 434 434 434 434 434 470 470 470 470 470 470 kg-m 30 30 30 30 30 30 30 30 30 40 40 40 40 40 40 ft-lbs 217 217 217 217 217 217 217 217 217 290 290 290 290 290 290 T B 2 5 7 5 X / X S T B 2 5 8 0 X / X S T B 1 0 2 5 X T B 2 0 8 0 X / X S T B 2 2 2 5 X / X S T B 2 0 7 5 X / X S T B 1 6 8 0 X / X S T B 1 8 2 5 X / X S T B 1 4 3 0 X / X S T B 1 6 7 5 X / X S T B 1 2 8 0 X T B 1 4 2 5 X / X S T B 9 2 5 X / X S T B 9 8 0 X / X S T B 9 7 5 X / X S Gas Valve Body Control Valve Cover Bolt Control Valve Body Bolt Gas Valve Plug Hose Adaptor Choke Plug Tie Rod Bolt Tie Rod Nut Side Plate Bracket Nut Top Mount Bracket Bolt SERIAL NUMBER LOCATION 50 Breaker Owners Manual SERIAL NUMBERS / MODEL NUMBERS: It is important to know the correct breaker model number when researching spec- ifications or data from this manual. The actual breaker model number can be con- firmed by checking the serial number of your breaker and cross referencing it to the chart below. The breaker serial number is located on the pressure and return port side of the breaker on the cylinder body as shown. (EXAMPLE: A typical serial number for a TB725X would be 7E-2277) Serial Number GENERAL SPECIFICATIONS 51 Breaker Owners Manual 52 Breaker Owners Manual GENERAL SPECIFICATIONS 53 Breaker Owners Manual GENERAL SPECIFICATIONS WARRANTY 54 Breaker Owners Manual 1. BREAKER TECHNOLOGY INC. Company (hereinafter referred to as "BTI") warrants this product against defects in materials and workmanship for a period of twelve (12) months or 2000 hours from the date of installation, or 18 months from the date of shipment, whichever comes first. This warranty will become void if, (a) replacement parts not manufactured by BTI are used, and (b) non- standard length tools are used. This warranty does not cover o-rings, seals, fit- tings, hoses, breaker tools or other items considered normal wear items. These are covered by the LimitedWarranty period of thirty (30) days. Warranty for pro- priety items such as valves, filters, installation kits, and componentry that are not manufactured by BTI, will be governed by the warranty terms of their manu- facturer. This warranty is void if BTI's standard installation specifications and procedures are not adhered to. 2. BTI will authorize return of any defective components or sufficient evidence of such defect to a BTI warehouse. Such components or such evidence must clearly show that the defect was caused by faulty material or poor workman- ship.Warranty claim will be accepted only if it is submitted on a proper claims form with proof of purchase and received within sixty (60) days from the date of discovery of the defect.Warranty claims will be considered only if the "Installation Notice" has been duly filled in and returned to BTI's within thirty (30) days from the date of installation. 3. BTI will at it's option, repair or refurbish the defective part(s) without charge to the initial user or may elect to issue full or partial credit toward the purchase of a new part(s). The extent of credit issued, which will be in the form of a "Credit Memo", will be determined by pro-rating against the normal life of the part(s) in question . 4. BTI is not responsible for mileage, travel time, travel expenses, overtime labor, and any freight expenses required to facilitate the repair. 5. This warranty does not apply if the product has been damaged by accident, abuse, misuse, misapplication or neglect, or as a result of service, disassembly or modification, without BTI's express authorization. 6. BTI assumes no liability beyond the replacement of defective parts or materi- als and/or the correction of such defective parts or materials. 7. BTI neither assumes nor authorizes any other person to assume for it any lia- bility in connection with the sale of its products other than that specifically stated herein. 8. THISWARRANTY IS EXPRESSLY IN LIEU OF ANYAND ALL OTHERWAR- RANTIES. EXCEPT AS EXPRESSLY SET FORTH HEREIN, BTI MAKES NO REPRESENTATION ORWARRANTY, STATUTORY, EXPRESS OR IMPLIED, WITH RESPECT TO THE PRODUCTS MANUFACTURED AND/OR SUPPLIED BY BTI, WHETHER AS TO MERCHANTABILITY, FITNESS FOR A PARTICU- LAR PURPOSE OR ANY OTHER MATTER. IN NO EVENT, INCLUDING IN THE CASE OF A CLAIM OF NEGLIGENCE, SHALL BTI BE LIABLE FOR INCI- DENTAL OR CONSEQUENTIAL DAMAGES. NOTES 55 Breaker Owners Manual SOLON FACILITY RIVERSIDE FACILITY THORNBURY FACILITY 30625 Solon Industrial Drive, 3464 DURAHART ST. 35 ELGIN ST., SOLON OHIO, RIVERSIDE,CALIF. THORNBURY,ONT. 44139 U.S.A. 92507 U.S.A. N0H 2P0 CANADA PH. 440-542-3720 PH. 909-369-0878 PH. 519-599-2015 FAX. 440-542-3721 FAX. 909-369-8281 FAX. 519-599-6803