Manual Del Usuario Serie TB

OWNER’S MANUAL

SOLON FACILITY RIVERSIDE FACILITY THORNBURY FACILITY30625 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 CANADAPH. 440-542-3720 PH. 909-369-0878 PH. 519-599-2015FAX. 440-542-3721 FAX. 909-369-8281 FAX. 519-599-6803

BR

EAK

ERTEC

HN

OLO

GY

TB SERIES HYDRAULIC BREAKERS

General InstallationBreaker Operation

Breaker Service

Revision : 04/2001Manual # : 150-2079

CONTENTS

3Breaker Owner’s 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 ........................................

471012151620222328404142454647484950

4 Breaker Owner’s 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 dutywork.

1200 - 4000-ft.lbs. (1627 - 5423 Joules) are used in both concrete and rock applicationswith 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 themiddle into two pieces. This is optimum production. If the operator has to re-positionthe 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 hardrock (20,000 psi or greater) needs to be broken in half you will require a 7,500-ft. lb. orlarger breaker. If a 2 cu.yd. piece of limestone (20,000 psi or less) needs to be broken inhalf 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 bequickly absorbed. This is why it is recommended to work from a bench so the rock hassomewhere to break out. We recommend when trenching in limestone or medium hardrock, to use a 3,000 - 5,000-ft. lbs. breaker. When working in hard material we recom-mend a 7,500 - 10,000-ft.lbs. breaker, and if high production is critical, a 13,500-ft.lbs.breaker would be beneficial.

When breaking Concrete, the breaker is expected to penetrate the material, allowing it tocrack 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 fastblow rate that destroys the concrete's structural integrity. We recommend on concretewalls, footings, and floors to use a 750 - 1,500-ft. lbs. breaker. With larger projects, con-sisting of large footings greater then 4 cu. yards, use a 2,000 - 5,000-ft. lbs. breaker. Thehigh 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 in which itwill be mounted. See chart on following page.

After considering the application work, determine the carrier on which the breaker willbe 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, thecarrier will safely handle this model of breaker. If the desired breaker falls outside ofthis recommended carrier weight range, the carriers lifting capacity and oil flow willneed to be verified to ensure a proper fit.

Provided the weight of the breaker does not exceed the maximum lifting capacity at anyposition, 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 valuethat must be compared to the operating weight of the breaker.

A required oil flow range is specified for each breaker. Oil flow to the breaker withinthis range is adequate for operation. However, for maximum productivity the carriershould be capable of providing the maximum required flow. Compare the maximum oilflow requirement of the breaker with the oil flow capacity of the carrier. Remember thebreaker operates at 1400-2600-psi. therefore, oil flow should be evaluated at operatingpressure.

SIZING BREAKER BASED ON CARRIER SIZE:

LIFTING CAPACITY:

OIL FLOW & OPERATING PRESSURE:


SIZING THE BREAKER


Carrier Weight in Metric Tonnes

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80

TB125CM

TB225CM

TB275CM

TB325CM

TB425CM

TB425X

TB625CM

TB625X

TB725CM

TB725X

TB830X

TB980X

TB1280X

TB1430X

TB1680X

TB2080X

TB2580X

SM

AL

LB

RE

AK

ER

SM

ED

IUM

BR

EA

KE

RS

LA

RG

EB

RE

AK

ER

S

HOW TO USE THIS CHART

Find your carrier weight along the top of thischart. Draw a line straight down from that weight.Any shaded bars intersected gives you abreaker suitable for your carrier.

Skidsteer

Mini Excavator

Backhoe

Excavator

Wheel Loader

Figure 1


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 lineon the right.

These attachments will operate within a range of flow. The operating pressure willdepend on the amount of oil flow, the return line pressure, and internal efficiency of theindividual 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 casethe auxiliary control can be used to control the supply of oil. It can usually be adjusted toprovide the correct amount of flow and a relief cartridge can be installed to protect thehydraulic circuit.

Notice when using the auxiliary control valve that oil is not routed back through the returnport on the valve. It is recommended to send the oil directly back to the cooler, filter, andtank. If the circuit is plumbed using both ports on the auxiliary valve, the return lineshould 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



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 atthis point. This is the flow that needs to be adjusted to the specified oil flow for theattachment.

Continue to load the circuit until the flow drops to zero. Measure the pressure at whichthis 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 then 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 newattachment.


SIZING BREAKER BASED ON TYPE OF WORKIf the carrier is not equipped with an auxiliary control valve, you will need to install apriority flow control valve to direct the correct flow away from the normal circuit andoperate 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 theflow. If dividing too much flow, this circuit will generate heat and will need coolingcapacity.


Figure 3


TYPICAL TOOL FAILURES:

TOOL TROUBLESHOOTING

Tool breakage due to improper contactbetween the tool’s tip and the rock orconcrete.

Typical failure caused by misalign-ment between down pressure, ham-mer and tool (from prying, levering,etc.)

Mushrooming or fast wearing causedby operating too long on the samespot.

Fatigue breakage with typical fatiguewrinkles due to steel defect.

Failure due to operation with worn-outretaining pins, blank-firing, or twistingthe tool.

NOWARRANTY

Failure due to blank-firing or exces-sive wear of bushings and/or fronthead.

NOWARRANTY

NOWARRANTY

100%WARRANTY

NOWARRANTY

NOWARRANTY

Mushrooming due to blank firingand / or firing more than 20 sec. ata time. (Excessive Heat).

NOWARRANTY

Figure 4


EXTERNAL FORCES:The main cause of increased fatigue stress in a tool is any form of side force duringoperation which creates bending. Therefore using the tool to pry, using the incorrectworking angle, or attempting to break ground using the pull of the machine, are alldetrimental to the life of a tool and must be avoided. The hydraulic power available in acarrier far exceeds the strength of a tool, and if being used incorrectly, can “snap a toollike a twig”. Incorrect working angle or using the machine to pull is detrimental to toollife.

This is any situation where the hammer piston strikes the top of the tool, but the work-ing end of the tool is not in contact with the work. This includes when the tool slides offthe 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 shouldbe 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 upbetween the tool and tool bushing due to lack of lubrication or excessive bending. Avoidscratches 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 thetool 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 pushedfully up inside the hammer. (Refer page 21).

Keep tools well greased and sheltered from the weather when not in use. A rusty tool ismore likely to suffer fatigue failure. For greasing instructions refer to page 21.

CAUSES OF TOOL FAILURE

BLANK-FIRING:

COLD TEMPERATURES:

MECHANICAL & THERMAL DAMAGE:

POOR LUBRICATION:

CORROSION:


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 withthe 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 removingthe retainer pins, the tool can be quickly changed.

The CYLINDER contains the moving piston, which strikes the tool. The seals for bothends of the piston are also located in the cylinder.

The REAR HEAD houses the cushion chamber, which is charged with nitrogen gas. Thegas in the cushion chamber absorbs the piston's upward recoil and stores this energy forthe next blow.

The CONTROL VALVE is mounted on the cylinder and directs the flow of hydraulic oiland therefore the movement of the piston. Located directly above the control valve arethe hydraulic in and out ports.

Two side plates hold the breaker and protect it during operation. The breaker is attachedto the carrier by a bracket fastened to these plates.

Rear Head

CylinderTie Rod

Air Valve

Front Head

Figure 5


GENERAL INFORMATION

PRINCIPLE OF OPERATION:

Pressure Pressure Pressure PressureReturn Return Return Return

Nitrogen ReturnPressure

1

2 23

7 7 77

4

6

6

5

A B C D

5

(A) UPWARD MOVEMENTOil flows into cylinder chamber (1) and control valvechamber (7). The piston is pushed up towards the cushionchamber (5), and the control valve spool is forced down.

(B) REVERSING DIRECTIONWhen the lower flange fills with oil, it will reach cylinderchamber (2). At this time both control valve chambers (6)and (7) have the same pressure, but the spool moves up dueto the flange surface area differences.

(C) DOWNWARD MOVEMENTWhen 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 flangeand the extra force from the cushion chamber pressure (5),the piston accelerates down.

(D) IMPACTThe piston hits the tool. The mid section of the piston willhit chamber (2). As a result, chamber (6) will remove pres-sures through chambers (2) and (3). Since chamber (6) isexhausted, chamber (7) is constantly pressurized and thecontrol valve will moves down.

ControlValve

Spool

Breaker Body

Piston

CushionChamber

Tool

Tool Retainer Pin

Breaker Parts

Hose Adaptors

Figure 6

Figure 7

GENERAL INFORMATION


OPERATING VISCOSITY RANGE:

For optimum efficiency and service life we recommend that the operating viscosity (atoperating temperature) be selected in the range. V opt = opt. Operating viscosity 16…45 mm2 /s referred to tank temperature (open loop circuit)

The following values are valid for extreme operating conditions: V min = 10mm2 /s for short periods at max. leakage oil temperature Of 90 o C V max = 800 mm2 /s for short periods upon cold start. Temperature range (see selection diagram) t min = -20 o C t max = +75 o C

For correct selection of the fluid it is assumed that the operating temperature in the tankis known, in relation to the ambient temperature.

The fluid should be selected so that, within the optimum range (V opt ), (see shadedsection of selection diagram). We recommend that the higher Viscosity grade is selec-tion in each case.

Example: At an ambient temperature of X o C. The operating temperature in the tankwill be 60 o C. In the optimum operating viscosity range (V opt ; shaded section) thiscorresponds 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 alwayshigher then the tank temperature. At no point in the system, however may the tempera-ture be higher than 90 o C.

If it is not possible to comply with the above conditions because of extreme operatingwith the operating parameters or higher ambient temperature, please contact us.

LIMITS OF VISCOSITY RANGE:

NOTES ON FLUID SELECTION:

Figure 8


SAFETY

SAFETY PRECAUTIONS:Danger, Warning, and Caution are harzard alerts used in this manual and on the com-pactor safety signs to identify hazards on or near the rockbreaker system.

Danger - Immediate hazards, which WILL result in severe personal injury or death ifthe proper precautions are not taken.

Warning - Hazards or unsafe practices, which COULD result in personal injury ordeath if the proper precautions are not taken.

Caution - Hazards or unsafe practices, which COULD result in product or propertydamage 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 isused, you must satisfy yourself that it is safe for you and others. You should also ensurethat the compactor and carrier will not be damaged or made unsafe by the operation,maintenance or repair procedures you choose.

To avoid injury from flying chips of stone or concrete, be sure you and others stay wellaway from the breaker when it is operating.

BTI Hydraulic Breakers and their components are heavy! Plan carefully how you willhandle them when removing, disassembling, or installaling the breaker. Stand clearwhen 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. Referto the service section of this manual for instructions.

Stay clear of the tool when charging the cushion chamber with nitrogen gas. It mayjump against the retainer pins as the gas pressure forces the piston down.

For additional safety precautions please refer to your CIMA Safety Manual thatwas included in your shipment.


OPERATION

INITIAL STARTUP & COLD WEATHER STARTING:

Before operating the breaker you may need to warm thecarrier's hydraulic system. This cold starting technique isuseful if the breaker has been in extended storage, or theambient temperature is below 20 F. Warming up the systemto its operating temperature will prevent the breaker misfir-ing.

First, cycle each boom function by extending and retractingeach cylinder through its full stroke. Hold the valve openfor 3 to 5 seconds at each end of the cylinder's travel. Thiswill push oil over the relief and generate heat. Repeat thisprocedure until all booms operate smoothly.

Next, raise the breaker so the tool is not pressing onto anymaterial and fire the hammer. This is called 'idle firing'. Inthis 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 5seconds. Repeat this procedure for 3 to 5 minutes depend-ing on the ambient temperature. While idle-firing the pistonmay move up and down, but should not hit the tool.

And finally, start breaking rock by operating the breaker inshort 3-second bursts. Continue operating with short burstsuntil 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 orcompacted ground and do not fire the hammer continuous-ly 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 alongthe rock's natural faults and seams also make for easierbreaking. (Fig. 1)

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 tothe material being broken. (Fig. 2 & 3)

As you apply down-force to the breaker, the carrier will liftslightly giving you a clue that the breaker is properlypressed onto the material. Excessive down-force will notmake breaking easier, in fact the carrier will be lifted toofar off the ground, and this can damage your equipment.Not enough down-force and the tool will bounce on thematerial, blank-firing

Figure 9

Figure 10

Figure 11


OPERATION

SUGGESTIONS FOR EFFICIENT OPERATION:Do not operate the hammer continuously for more than 20 seconds. Excessive heat willbe generated and you may mushroom the end of the tool. If the rock or stone shows nosign 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 orfully 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 increasebreaking power. Your carrier's operating temperature may run too high, and actuallydecrease breaking power. If the hydraulic oil temperature exceeds. 175 F (79 C), stop breaking!

If you plan to operate the breaker underwater, ensure that it has been equipped with anunderwater kit. Refer to page 41.

Blank firing emits a distinct metallic ringing. Blank firing most often occurs in hardrock, just as the rock shatters under the tool. With no material under the tool, the pistonsmashes the tool and retainers too far into the front head, bouncing the breaking forceback through the breaker and excavator.

To prevent blank-firing learn to anticipate when the material will break. Predicting thismoment 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 arenow on your way to anticipating when a rock will break.

BLANK FIRING:


OPERATION

Do not use the breaker to pry, pick, pound, or lift. This can cause serious damage to thebreaker as the tool side loads or binds in the bushing. The tool must always move freelystraight up and down in the bushing. But remember, your breaker sideplates aredesigned 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


TRENCHING & EXCAVATION WORK:

OPERATION

Before trenching, you will first need to remove all overburden material, exposing thesurface 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 asmall area, excavating a hole. When excavating a deep trench it is more effective to usesteps or benches allowing a place for the rock to break out to. Keep maintaining thebenches as the trench advances. The sides of the trench must be sloped to accommodatethe 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 tokeep steeper slopes. However the carrier swing function will not have the strength topush broken rock away from the work area. In some cases the excavator will sit on topof 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 10to 15 seconds or when no penetration is evident. Keep the breaker well greased at alltimes.

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 therock, or look for a seam or crack, which may allow easier splitting. To fully absorb allthe 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. Thisshould loosen the concrete and separate the reinforcing steel. The reinforcing steel mayneed 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 tofollow the tool through the concrete. Breaking vertical walls is more difficult, forcemust 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 carrieris 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 pointmay be better. The moil tip allows the tool to deflect off the steel as it breaks throughthe concrete.

If the grizzly is covered with rock, use the breaker sideplates to rake the material. Thiswill get most of the finer material through the bars and lets the larger pieces rest directlyon the grizzly.

Large pieces will break easier if they rest directly against the grizzly bars. This way allthe energy from the breaker is applied to the rock. Breaking energy will be absorbed ifthere 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 themthrough with short bursts. Do not push them through with the force of the boom, thiscan damage your breaker as the front head hits the grizzly bars.

BREAKING OVERSIZE MATERIAL:

BREAKING CONCRETE:

BREAKING ROCK ON A GRIZZLY:

MAINTENANCE


To keep your breaker working in top operating condition, the following maintenancemust be performed. Keep in mind that lubrication is the single most important procedurefor 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 regularlyreduces 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 appliedto push the tool into the breaker. This will prevent grease from entering the area abovethe 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 inthe 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 thebreaker.

Remove and inspect the tool. See page 23.

Every 1,000 hours, check the breaker's hydraulic circuit pressure relief and flow settingsand 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


GREASING THE BREAKER:Failure to lubricate regularly will reduce the life of the tool, tool bushings, and the toolholder. To properly lubricate the tool, the breaker must be in a vertical position, withenough down pressure applied to force the tool up into the breaker housing. This willprevent excessive grease entering the impact chamber which could cause the breaker tolose power due to cushioning, or to stop operating altogether due to a hydraulic lock inthe impact chamber.

The breaker should be greased every two hours of use or when the tool appears shinywhere it rides inside the front head. The chart to follow shows the minimum amountrecommended for each breaker,and can be used as a guideline.

Preform a visual check when greasing to ensure the retainer pins rotate during normaloperation. 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 beapplied to push the tool up into thebreaker.

Grease until the grease oozes out aroundthe tool.

Grease the breaker every two hours.

Use only BTI Chisel Paste or a molybde-num disulphide based grease.

RETAINER PINS:

Tool RetainerRetainer Pin

Grease tracesleave radial marks

Figure 14

Figure 15

SERVICE


BTI breakers are built using the highest quality materials and workmanship to ensurelong 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 ofoperation, whichever comes first. For units being operated on a continuous basis in veryhard rock, overhaul is advisable after every 500 hours.

Breakers operate in very dirty conditions. Their efficient operation relies on keeping thatdirt out of the close tolerance mechanism. It is important to maintain the breaker andespecially the seals in good condition by following proper operating and maintenanceprocedures. 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 ofdirt 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 toolkit.

Always take proper safety precautions. You must wear safety glasses, work gloves, andsafety shoes. Use of a safety stand is recommended. Before servicing the breaker reviewthis technical manual and read all decals. Before lifting the breaker, refer to page 49 forthe approximate working weight of the breaker.

SAFETY PRECAUTIONS:

BREAKER DISASSEMBLY


REMOVING THE TOOL:Once the breaker is removed from the boom, lay it down so that the control valve side ofthe breaker is facing up.

Check the wear width between the tool and the tool bushing. Refer to the “Bushing WearWidth” charts on pages 49-51 for the accepted clearance values.

To remove the tool, drive out the retainer pin and stopper plug using the drift supplied inthe tool kit.

Carefully roll the breaker onto its side with the locked sideplate bolts facing the groundand 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 retainer,where the tool hits it.

Stopper PlugRetainer Pin

DriftHammer Retainer Pin

Drift

Applicable onBreaker “E” SeriesModels:

TB125, TB135, TB225,TB235, TB275, TB285,TB325, TB335, TB425,TB625, TB725, TB825,TB925, B975,TB1025,TB1425, TB1675,TB1825, TB2075,TB2225, TB2575.

Applicable onBreaker “O” SeriesModels:

TB830, TB980,TB1280, TB1430,TB1680, TB2080,TB2580.

WearWidth

Tool Retainer

Stopper Plug

Retainer Pin

Drift

Figure 16

Figure 17

Figure 18

BREAKER DISASSEMBLY


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 theseconditions may suggest a need for more frequent servicing, because of extreme operatingconditions 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 normaluse, this wear will be minimal. If tool wear seems extreme, it may indicate frequent blankfiring. If the retainer pin contact areas on the tool cannot be repaired, the tool must bereplaced to avoid premature failure of the retainers.

Also, inspect the tool bushing area for wear. Excessive wear here may also indicate thatmore frequent greasing is needed, and if this area cannot be repaired, the tool must bereplaced 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. Nowlift the sideplate off the breaker with the lifting eyes provided in your toolkit.

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 onbolts. 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 closelywith 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 damageshould be repaired while the breaker is disassembled.

The cushion chamber in the rear head contains nitrogen gas under pressure. Donot 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 thegas valve with a blunt object. Be sure to protect yourself adequately from the escapingjet of gas.

BLEEDING THE NITROGEN GAS:

REMOVING THE MOUNTING BRACKET & SIDEPLATES:


BREAKER DISASSEMBLY

REMOVING THE CONTROL VALVE:While the breaker is securely held, remove the control valve use only hand tools to loosenthe tie rod nuts and control valve bolts, since they thread into special hardened-steelinserts that can be damaged by impact tools. The recommended methods for loosening thenuts 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.

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 thebreaker is standing up. If the breaker is lying down, use the sledge-wrench method. Thenusing the hoist, jerk the assembly upwards, which should loosen the rear head from thecylinder.

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 tierod washers and remove the rear head from the cylinder, using the lifting eyes. In somecases, the nuts may be seized onto the tie rods and the nut and tie rod may come out as aunit.

Place the rear head on a clean protective surface.

Install a lifting eye into the top of the piston, and lift the piston straight up and out of thecylinder to avoid scratching its polished surface. Tapping the cylinder with a soft-facedmallet may ease the removal of the piston. The seal bushing will come out with the piston.

Place the piston on a clean protective surface.

REMOVING THE REAR HEAD FROM THE CYLINDER:

REMOVING THE PISTON:

Tie Rod Nut

Tie Rod WasherCylinder Cover

PistonUpper SealBushing

Figure 19

Figure 20

Figure 21

BREAKER DISASSEMBLY


REMOVING THE CYLINDER & TIE RODS:

Use hand tools to loosen the tie rods; impact tools will damage the thread inserts inthe front head.

To loosen the tie rods it may be necessary to secure the front head to prevent it fromrotating.

Loosen the tie rods by rotating them counter-clockwise. Use an adjustable wrench and asoft-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 thetop 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 asoft mallet, 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 andgrease fitting to avoid accidental damage during bushing replacement. Put them in asafe place for reuse later.

REMOVING FRONT HEAD GREASE FITTING & AIR VALVE:

Rear Head

CylinderTie Rod

Air Valve

Front Head

CylinderFigure 22

Figure 23


BREAKER DISASSEMBLY

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 avery 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 weldto contract and shrink the bushing. This time will be less for smaller breakers. Knockthe 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. Ifyou plan to install the new bushings immediately after removing the old ones, place thenew bushings in dry ice before you start the removal procedure. Dry ice can take up to 4hours to achieve the desired results. Then the bushings will be fully chilled and the fronthead will still be hot enough from welding, to receive them. If you are using liquidnitrogen to shrink the bushings, it can take as little as 15 minutes to properly chill them.

REMOVING THE TOOL BUSHINGS:

Tool Holder

Upper ToolBushing

Lower ToolBushing

Tool BushingAlignment Slotand Retainer Pin

Figure 24


BREAKER REASSEMBLY

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. Becausethe bushings are a shrink fit, the front head must be heated, so that it will expand, andthe bushings placed in liquid nitrogen, so they contract. As the pieces return to roomtemperature, 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. Withliquid 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 andsmooth the surfaces in the areas where the bushings seat. If the front head has cooled, itmust be heated with a torch to 300 F, (150 C). This will expand the housing a smallamount. 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 thefront head. Care must be taken to ensure that the grooves in the tool bushings line upwith the retainer-pin holes in the front head. Do not install the stopper plugs until thefront head has cooled to room temperature.

Apply a coat of Never-seize to the two retaining pins, and fully insert them into theretaining 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 onmost models of BTI breakers.


BREAKER REASSEMBLY

INSPECTING THE SEAL BUSHING:

Start by cleaning, and inspecting the cylinder seal bushing.

The seal bushing carries several specially designed seals. Careful attention should bepaid to the condition and orientation of the old seals as they are removed. This may helpto 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 SealBushing

Gas Seal*

Oil Seal*

Pist

on

Cyl

inde

r

Oil Seal*

Dust Seal*

Slide Ring withSquare Ring(Models TB725X and up)

Slide Ringwith O-ring(Model TB925Xand up have 2as shown)

* When insertingseals, make suredirection is asshown.

Figure 25


BREAKER REASSEMBLY

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 thishas occurred clean the grooves. Small marks can be removed with an oilstone or fineemery cloth and oil.

Look for pitting and deformation of the impact face. They may indicate that the tool hasbeen operated with too much wear in the tool bushings. If the face is dished, carefullymeasure the amount and refer to the service manual to see that this amount is allowablefor the model you are servicing. Refer to “Maximum Allowable Piston Deformation” onthe charts on pages 49-51 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.

PistonImpactFace

Deformation

Scoring

Figure 26

Figure 27


BREAKER REASSEMBLY

INSPECTING THE CYLINDER:Thoroughly clean the cylinder bore, and remove the dust seal, oil seal, and slide ring.The TB625 and smaller hammers do not have a slide ring in the cylinder. Check theseals for clues about 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 notcleaned out they will chip off and go between the piston and cylinder, and galling willoccur again.

Also inspect the main inlet and outlet adapter threads for damage. Always replace theseals and ensure that the adapters are not interchanged if they are removed. The cylinderis marked with a "P" beside the pressure adapter and a "T" beside the tank adapter. ThePressure adapter has a smaller hole than the tank adapter.

Check for any damage to the threaded inserts that hold the control valve, and repair orreplace as necessary to ensure secure control valve mounting.

Thoroughly dry the cylinder and protect it from dirt.


BREAKER REASSEMBLY

DISASSEMBLING THE CONTROL VALVE:

The control valve controls the flow of oil through the breaker, which causes the pistonto move in the cylinder.

Prepare the control valve for disassembly by washing it thoroughly and clamp it in avise.

Remove the hex bolts holding the valve cap, then remove the cap by threading thepuller bolts provided in the toolbox into the two threaded holes in the cap. Graduallytighten 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 easilyremoved. A sliding hammer puller can assist in removing a seized spool.

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 afine oilstone or fine emery cloth and oil. Also check the control valve cap and valvebody for marks or scratches, and remove them if they are not too severe. If the scoremarks 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 passageholes in the control valve and be sure they are not plugged. Clean them with a fine wireif 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 andthen install the spool.

Before placing the o-ring and backup ring on the valve cap, lubricate the o-ring grooveswith oil to prevent damage to the o-ring.

Install the valve cap into the valve body, and snug the four-valve cover bolts diagonallyand uniformly to prevent binding.

Use only hand tools when tightening the bolts; impact tools will damage the helisertinserts.

Tighten the cap bolts to the torque speci-fied in the service manual for the modelof breaker you are servicing.

Protect the control valve assemblyfrom dirt and set it aside

INSPECTING THE CONTROL VALVE:

REASSEMBLING THE CONTROL VALVE:

Valve Body

Spool

Valve Cap

Figure 28


BREAKER REASSEMBLY

Remove the gas valve plug and the gas valve from the rear head. Thoroughly clean thecover and valve and inspect them for damage. Cover the gas valve threads with a goodquality thread sealer. Reinstall the gas valve and seal, and tighten the valve to 61½ 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 removedgrease 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 valvewhenever 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:

Rear Head

CylinderTie Rod

Air Valve

Front Head

Figure 29


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 theydo not bottom out, or there is excessive resistance, the threads on the tie rods or thehelisert inserts may be damaged.

Remove damaged heliserts and restore the front head threads with conventional threadchasers and taps. Insert new heliserts with the appropriate tool.

Torque tie rods to the specifications on page 49.

Liberally oil the inside surface of the cylinder and the new seals, and install the sealsand rings into the grooves at the lower end of the cylinder. Pay close attention to thecorrect 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 onthe 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 andorientations.

INSTALLING THE CYLINDER:

RE-SEALING THE SEAL BUSHING:

UpperSeal

BushingGas Seal*Oil Seal*

Pist

on

Cyl

inde

r

Dust Seal*

Slide Ring withSquare Ring(Models TB725X and up)

Slide Ring withO-ring(Model TB925X andup have 2 as shown)* When insert-

ing seals,make suredirection isas shown.

Oil Seal*

Figure 30

Figure 31


BREAKER REASSEMBLY

INSTALLING THE PISTON:Replace the o-ring in the top of the cylinder. Lubricate the top end of the piston, andslide 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 thecylinder. 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 sealbushing into position in the cylinder. The bushing will stop when it reaches the supportflange inside the cylinder bore.

Replace the o-rings and backup rings on the top of the cylinder where the rear headmakes 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 neededcan be obtained from the chart on page 49.

Lower the rear head over the tie rods. The gas valve should face the same direction asthe control valve bolt holes on the cylinder.

Install new tie rod washers. Lubricate the tie rod nuts with Never Seize, and tightenthem 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:

PistonUpper Seal

Bushing

Figure 32

1 4

23

Tie Rod Nut

Tie RodWasherCylinder

Cover

Figure 33 Figure 34


BREAKER REASSEMBLY

INSTALLING THE CONTROL VALVE: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 washersremoved earlier. The control valve cap must face toward the tool. Tighten the boltsevenly in a crossing pattern until they contact the valve.

Figure 34


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 tothe 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 theservice manual. If the piston is not at the bottom of its stroke the pressure will move itdown to rest on the inside of the front head. Be aware that if the tool is installed at thisstage, it may accelerate dangerously out of the cylinder when the cushion chamber isbeing pressurized.

To check the cushion chamber pressure, remove the charging adapter from the end ofthe hose and put it on the pressure gauge. Insert the adapter into the gas valve andobserve the pressure reading. If the reading is too high, bleed off a small amount of gasto make the final adjustment, and test again. If the pressure is too low, reinsert thecharging adapter, and build pressure to the required value.

When the pressure is at the correct value, (refer to the “Cushion Chamber” Pressure onthe General Specification Chart on page 46), 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

BA

PressureGauge

N2 GASTANK

Regulator

Figure 35


BREAKER REASSEMBLY

SIDEPLATES & MOUNTING BRACKET INSTALLATION:

Mounted to the sideplates are anti-vibration rubbers. Inspect these for damage andreplace as necessary.

Insert the sideplate bolts and washers into the hex retainers on the sideplate and lay thesideplate 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 onthe sideplate with the key groove in the breaker body. You must also make sure that thehydraulic 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 theshear block with the key groove.

To prevent galling the threads on the side plate bolts, apply Never Seize or equivalent tothe 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 thebreaker. This will prevent movement between the sideplates and the breaker during finaltightening.

Now using the torque multiplier tighten the bolts to 60 percent of the torque specifiedon page X. Follow the pattern shown here to distribute the load evenly. When all boltshave been tightened to 60 percent of their full torque value, tighten to 80 percent, then90 percent and finally to 100 percent of the torque value for your hammer.

Install the mounting bracket in the correct position, which depends on the intendedapplication.

1

6

5 3

428

7 9

10

Figure 36


BREAKER REASSEMBLY

INSTALLING THE TOOL:

First grease the inside of the lower bushing, then when the tool is inserted it will takethe 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” onpage 39 for storage instructions.

Apply Grease

ToolRetainers

Retainer Pin

Stopper Plug

ApplyGrease

Tool Retainer

Retainer Pin

Stopper Plug

“O” Series Breakers“E” Series Breakers

Figure 38

Figure 37


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 beleft 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 tostore the breaker.

Using your excavator lay the breaker on wooden blocks, the breaker mounting endshould lie higher than the tool end. Now remove the pins to disconnect the breaker fromthe boom. Remove the tool and ensure the retaining pins, bushings and piston bottomare 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 andreinstall the tool. Finally, with the breakers mounting end elevated, cover the breakerwith a tarp.

For long term storage where you are standing the breaker up, the breaker must be storedin a safety stand. Allow the breaker's weight to push the tool up into the breaker. You donot need to release the cushion chamber gas pressure.

The piston will not slide into the cylinder with a pressure of 8 bar.

SHORT TERM STORAGE:

LONG TERM STORAGE - STANDING UP:

LONG TERM STORAGE - LYING DOWN:


UNDERWATER APPLICATIONS

SETUP:

To adapt the BTI Breaker for underwater use, compressed air must be fed into thebreaker front head area, creating a positive air pressure that will keep the water out. Ifwater does enter the front head and the breaker is fired, it could force water and debrisup inside, resulting in seal damage. An 18 cfm compressor is recommended at 21 psi. For depths exceeding 15 ft, increaseto 26 psi. For TB125 to TB425, remove the grease fitting and tie the line in here. ForTB725 and up, remove the check valve to plumb the line in.

Start supplying air to the breaker before placing it underwater, and continue supplyingair until the breaker is removed from the water. Continue to operate the breaker out ofthe water for approximately 10 minutes, then grease the tool and front head with thetool pressed in.

UNDERWATER OPERATION:

Air supplyto breaker

TB125 to TB625XRemove grease fitting

TB725 to TB2580XRemove check valve

Figure 39


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 slightamount of oil seepage around the breaker connecting parts is normal during thefirst 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 conditionof the breaker. or adapter fittings. of hoses and

fittings, tightenas necessary.

C. Control valve cap Oil ooze after Normal oozing ofbolts. overhaul of unit. assembly

lubricants.

D. Between control Oil ooze after Normal oozing of valve and surface of breaker overhaul assemblybreaker. lubricants.

E. Joining surface of Oil oozing Loose tie rodcylinder and cylinder New oil leaking nut, re-tightencover. Damaged O-ring,

replace.

F. Joining surface of New oil leaking Loose plugs oncylinder and tool face of cylinder,

holder. retighten.Damaged seals inthe cylinder, replace as necessary.

B

D

C

A

F

E

Figure 40



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.

Plugged or restricted hoses. Clean or replace.

Cushion chamber fills with oil. Replace seals.

Seizure of breaker. Overhaul and replaceworn 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 pipe. Clean or replace.

Not enough down force on the tool. Increase the down pressureacting 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 greasinginstructions.

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.



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 valvesetting.

Emulsification of Oil Oil contaminated with water. Locate source of water and repair. Replace oil

TORQUE SPECIFICATIONS


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/AN/A N/A N/A N/A

TB

285M

E/Q

A

TB

325C

M/M

E/Q

A

TB

32

5X

TB

335M

E/Q

A

TB

425C

M/M

E/Q

A

TB

42

5X

TB

235M

E

TB

275C

M/M

E

TB

135M

E

TB

225C

M/M

E

Hose Adaptor

Choke Plug

N/AControl Valve

Cover Bolt

Side Plate

Bracket Nut

Top Mount

Bracket Bolt

Gas Valve Body

Gas Valve Plug

Control Valve

Body BoltT

B125C

M/M

E

Tie Rod Bolt

Tie Rod Nut



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

TB

625C

M/Q

A

TB

62

5X

TB

725C

M/Q

A

TB

725X

/X

S

TB

830X

/X

S

TB

825X

/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



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

TB

2575X

/X

S

TB

2580X

/X

S

TB

10

25

X

TB

2080X

/X

S

TB

2225X

/X

S

TB

2075X

/X

S

TB

1680X

/X

S

TB

1825X

/X

S

TB

1430X

/X

S

TB

1675X

/X

S

TB

12

80

X

TB

1425X

/X

S

TB

925X

/X

S

TB

980X

/X

S

TB

975X

/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


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 tothe chart below. The breaker serial number is located on the pressure and returnport side of the breaker on the cylinder body as shown.

(EXAMPLE: A typical serial number for a TB725X would be 7E-2277)

SerialNumber

GENERAL SPECIFICATIONS


Breaker Model TB12

5TB13

5TB22

5TB

235

TB27

5TB28

5TB32

5TB33

5TB42

5

E=roundO=oval

kg 110 110 185 185 210 210 272 272 372lbs 240 240 405 405 460 460 605 605 820

joules 475 475 745 745 1017 1017 1152 1152 1491ft/lbs 350 350 550 550 750 750 850 850 1100

CIMA Impact Energy joules 220 230 235 237 298 335 358 365 509ft/lbs 162 170 318 321 404 455 485 495 690

min 600 600 550 550 600 580 550 550 550max 1070 1150 1000 1000 1200 1060 1000 1000 1000

CIMA Frequency bpm 1214 1040 1116 1099 1084 983 1069 1063 1043

bar 78-137 78-147 98-147 98-147 98-151 98-156 98-151 98-156 98-157psi 1150-2000 1138-2133 1400-2150 1400-2150 1400-2300 1400-2275 1400-2300 1400-2275 1400-2300

CIMA Preasure bar 150 148 155 155 158 150 158 160 156psi 2175 2146 2248 2248 2291 2175 2291 2320 2262

l/min 20-35 20-35 25-45 25-45 46-70 30-55 35-60 35-60 45-80gpm (U.S.) 5-9 5-9 7-12 7-12 12-18 8-14 9-16 9-16 12-21

CIMA Flow l/min 34 35 45 45 54 53 57 58 80gpm (U.S.) 9 9 12 12 14 14 15 15 21

kg 6 6 10 10 15 15 20 20 36lbs 13 13 22 22 32 32 44 44 79

mm 50 50 56 58 66 64 75 75 95inches 2 2 2.3 2.3 2.6 2.5 3 3 3.75

ml 35 35 35 35 35 35 70 70 100ounces 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 2-1/4 2-1/4 3-1/2

bar 8 8 8 8 8 8 8 8 8psi 114 114 114 114 114 114 114 114 114

bar 200 200 200 200 200 200 200 200 200psi 2844 2844 2844 2844 2844 2844 2844 2844 2844

mm 3 3 3 3 3 3 4 4 4inches 1/8 1/8 1/8 1/8 1/8 1/8 3/16 3/16 3/16

mm 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0inches .04 .04 .04 .04 .04 .04 .04 .04 .04

5M 6E

Energy Class

3M 3E 4M 4E1E 2M 2E

1/2 1/2

Blows / Minute

Working Pressure

Oil Flow Required

Min. Tube I.D. 3/4 3/4

Tool Weight

Tool Diameter

1/2 3/4 3/4 3/4inches 1/2

Cushion Chamber Oil Volume

Cushion Chamber Presure

Relief Valve Setting

Shut Off Valve Size inches 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4

Breaker Ports inches 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4

Bushing Wear Width Limit

Max. Piston Deformation

Grease Every 2 Hours shots 4-6 8-11 12-144-6 8-11 8-11 8-11 8-11 8-11

Model / Serial X-Ref

Working Weight



Breaker Model TB625

TB725

TB825

TB830

TB925

TB975

TB980

TB1280

TB1425

E=roundO=oval

kg 590 840 1136 1130 1636 1950 1865 2160 2540lbs 1300 1850 2500 2490 3600 4300 4100 4750 5600

joules 2035 2712 4068 4068 5152 6102 6102 7458 7458ft/lbs 1500 2000 3000 3000 3800 4500 4500 5500 5500

CIMA Impact Energy joules 817 1108 1635 2640 3459ft/lbs 1108 1502 2217 3579 4691

min 600 450 430 430 460 450 450 370 410max 900 700 600 600 600 600 600 490 500

CIMA Frequency bpm 899 744 682 677 565

bar 108-167 118-167 118-167 118-167 125-167 127-167 127-167 137-177 127-167psi 1600-2400 1700-2400 1700-2400 1700-2400 1825-2400 2000-2550 2000-2550 2000-2600 1850-2400

CIMA Preasure bar 162 184 174 192 191psi 2349 2668 2523 2784 2769

l/min 70-110 70-110 100-140 100-140 130-170 150-200 150-200 160-210 180-220gpm (U.S.) 18-29 18-29 26-37 26-37 34-45 40-53 40-53 42-55 48-58

CIMA Flow l/min 99 111 141 203 228gpm (U.S.) 26 29 37 54 60

kg 36 70 70 70 115 115 115 130 140lbs 79 154 154 154 253 253 253 286 308

mm 95 115 115 115 135 135 135 140 146inches 3.75 4.5 4.5 4.5 5.3 5.3 5.3 5.5 5.75

ml 100 180 240 240 300 300 300 380ounces 3-1/2 6 8 8 10 10 10 12-3/4

bar 8 8 8 8 8 11 8 8 8psi 114 114 114 114 114 156 114 114 114

bar 200 200 200 200 200 250 250 250 200psi 2844 2844 2844 2844 2844 3555 3555 3555 2844

mm 4 6 6 6 8 8 8 10 10inches 3/16 1/4 1/4 1/4 5/16 5/16 5/16 3/8 3/8

mm 1.0 2.0 2.0 2.0 2.0 2.0 2.0 3.0 3.0inches .04 .08 .08 .08 .08 .08 .08 .12 .12

7E 10E 19O 22E

Working Weight

Energy Class

10O 14E 15E 15OModel / Serial X-Ref 6.5E

3/4 3/4

Blows / Minute

Working Pressure

Oil Flow Required

Min. Tube I.D. 1 1

Tool Weight

Tool Diameter

3/4 1 1 1inches 3/4




Shut Off Valve Size inches 3/4 3/4 3/4 3/4 1 1 1 1 1

Breaker Ports inches 3/4 3/4 3/4 3/4 1 1 1 1 1



Grease Every 2 Hours shots 12-14 16-18 16-1812-14 14-16 14-16 14-16 14-16 14-16



Breaker Model TB1430

TB1675

TB1680

TB1825

TB2075

TB2080

TB2225

TB2575

TB2580

E=roundO=oval

kg 2540 2860 2560 3600 3990 3660 4260 4763 4940lbs 5600 6300 5635 7920 8800 8050 9400 10500 10870

joules 7458 10170 10170 10846 13560 13560 14914 18306 18306ft/lbs 5500 7500 7500 8000 10000 10000 11000 13500 13500

CIMA Impact Energy joules 4217 5388 Pendingft/lbs 5719 7306 Pending

min 410 380 380 390 370 370 390 370 370max 500 450 450 500 470 470 500 470 470

CIMA Frequency bpm 532 505 Pending

bar 127-167 127-177 127-177 140-180 137-177 137-177 137-177 137-177 137-177psi 1850-2400 1850-2550 1850-2550 2000-2600 2000-2600 2000-2600 2000-2600 2000-2600 2000-2600

CIMA Preasure bar 187 183 Pendingpsi 2710 2650 Pending

l/min 180-220 180-230 180-230 220-280 240-300 240-300 270-380 280-390 280-390gpm (U.S.) 48-58 48-61 48-61 58-74 63-79 63-79 71-100 74-103 74-103

CIMA Flow l/min 238 316 Pendinggpm (U.S.) 63 83 Pending

1-1/4

kg 140 140 140 203 203 203 261 278 278lbs 308 308 308 447 447 447 575 613 613

mm 146 146 146 160 160 160 170 175 175inches 5.75 5.75 5.75 6.3 6.3 6.3 6.7 7 7

ml 380 380 380 440 440 440 600 600 600ounces 12-3/4 12-3/4 12-3/4 15 15 15 20 20 20

bar 8 8 8 8 8 8 8 8 8psi 114 114 114 114 114 114 114 114 114

bar 200 250 250 200 250 250 200 250 250psi 2844 3555 3555 2844 3555 3555 2844 3555 3555

mm 10 10 10 10 10 10 10 10 10inches 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8

mm 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0inches .12 .12 .12 .12 .12 .12 .12 .12 .12

23E 23O 40E 40O

Working Weight

Energy Class

30E 31E 31O 38EModel / Serial X-Ref 22O

1 1

Blows / Minute

Working Pressure

Oil Flow Required

Min. Tube I.D. 1-1/4

Tool Weight

Tool Diameter


1-1/4 1-1/4 1-1/4 1-1/4inches 1



Shut Off Valve Size inches 1 1 1 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4

1-1/4



1-1/4

Breaker Ports inches 1 1 1 1-1/4

shots 16-18 16-18

1-1/41-1/4 1-1/4 1-1/4

22-24 22-24 22-2416-18 20-22 20-22 20-22Grease Every 2 Hours

WARRANTY


1. BREAKER TECHNOLOGY INC. Company (hereinafter referred to as "BTI")warrants this product against defects in materials and workmanship for a periodof twelve (12) months from the date of Installation. This warranty will becomevoid 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. Theseare covered by the Limited Warranty period of thirty (30) days. Warranty for pro-priety items such as valves, filters, installation kits, and componentry that arenot manufactured by BTI, will be governed by the warranty terms of their manu-facturer. This warranty is void if BTI's standard installation specifications andprocedures are not adhered to.

2. BTI's Customer Service Department will authorize return of any defectivecomponents or sufficient evidence of such defect to a BTI warehouse. Suchcomponents or such evidence must clearly show that the defect was caused byfaulty material or poor workmanship. Warranty claim will be accepted only if it issubmitted on a proper claims form with proof of purchase and received withinsixty (60) days from the date of discovery of the defect. Warranty claims will beconsidered only if the "Installation Notice" has been duly filled in and returned toBTI's Customer Service Department within thirty (30) days from the date ofinstallation.

3. BTI will at it's option, repair or refurbish the defective part(s) without chargeto the initial user or may elect to issue full or partial credit toward the purchaseof 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 thepart(s) in question.

4. BTI is not responsible for mileage, travel time, travel expenses, overtimelabor, 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, disassemblyor 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 anyliability in connection with the sale of it's products other than that specificallystated herein.

8. THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHERWARRANTIES. EXCEPT AS EXPRESSLY SET FORTH HEREIN, BTI MAKESNO REPRESENTATION OR WARRANTY, STATUTORY, EXPRESS ORIMPLIED, WITH RESPECT TO THE PRODUCTS MANUFACTURED AND/ORSUPPLIED BY BTI, WHETHER AS TO MERCHANTABILITY, FITNESS FOR APARTICULAR PURPOSE OR ANY OTHER MATTER. IN NO EVENT, INCLUD-ING IN THE CASE OF A CLAIM OF NEGLIGENCE, SHALL BTI BE LIABLEFOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

NOTES


SOLON FACILITY RIVERSIDE FACILITY THORNBURY FACILITY30625 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 CANADAPH. 440-542-3720 PH. 909-369-0878 PH. 519-599-2015FAX. 440-542-3721 FAX. 909-369-8281 FAX. 519-599-6803

Documents

Manual Del Usuario Serie TB