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150-4059 - Rockbreaker Installation Manual PDF
150-4059 - Rockbreaker Installation Manual PDF
150-4059 - Rockbreaker Installation Manual PDF
Manual # : 150-4059
- General Information
- Installation
- Initial Startup
- Maintenance
- Warranty
BREAKER TECHNOLOGY
CONTENTS
Introduction ................................... 4
Hazard Alerts ................................ 5
Safety ............................................ 6
Installation ..................................... 8
Initial Startup ................................. 15
Breaker Installation ....................... 16
Lubrication & Maintenance ........... 18
Daily Checks ................................. 20
Conversion Factors ....................... 21
General Torque Values ................. 22
Warranty ........................................ 23
Notes ............................................. 24
INTRODUCTION
HAZARD ALERTS
Danger, Warning, and Caution are hazard alerts used in this manual and on the boom &
breaker decals 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.
SAFETY
Head
Protection
Foot
Protection
Eye
Protection
Hearing
Protection
Do not operate or service the Rockbreaker System unless you are qualified.
Avoid loose fitting clothing, loose or uncovered long hair, jewelry and loose personal
articles. These can get caught in moving parts. Jewelry may also ground a live circuit.
Know and use the protective equipment that is to be worn when operating or servicing
the boom. Hard hats, protective glasses, protective shoes, gloves, reflector type vests
and ear protection are types of equipment that may be required.
Never operate any machinery while you are under the influence of alcohol or drugs.
Consult your supervisor if you do not understand this Manual.
SAFETY
Do not operate the boom with personnel in the immediate area of the crusher or rockbreaker.
Do not operate this machine unless you have read and understood the instructions and
warnings in the Owner's Manual. Failure to follow the instructions or heed the warnings
could result in injury or death. Proper care is your responsibility. Contact your distributor or BTI for replacement manuals or decals.
Hydraulic fluids are under high pressure. Fluid escaping under pressure can penetrate
the skin causing serious injury. Relieve all pressure before disconnecting hoses. Do not
use your hand to check for hydraulic leaks.
If any fluid is injected into the skin, a doctor must surgically remove it within a few
hours or gangrene may set in.
Do not attempt to repair or modify the rockbreaker unless you are a qualified service
technician. Read and understand your owner's manuals. Failure to follow the instructions or heed the warnings could result in severe personal injury or death. Proper care is
your responsibility. Contact your distributor or BTI for replacement parts.
Rockbreaker components are heavy or awkward, plan carefully how you will handle
them when installing, removing, or disassembling.
The cylinders are full of air and may need bleeding at startup. Failure to do so will
result in the boom running away and may cause serious injury or property damage.
INSTALLATION
INSTALLATION
INSTALLATION
10
INSTALLATION
11
INSTALLATION
Unpack the hose plumbing kit. And refer to the Boom Hose and Tube Layout drawing in
section 3 of your Owner's Manual.
The routing of your hoses and tubes is shown on this drawing.
Install the stacking clamps, their locations are also on the boom hose and tube layout.
Install the 90 degree bulkhead fittings.
Install the tube assembly bulkhead on the outer boom section.
Next install the cylinder hose adapters.
When installing the hoses, be aware of any grease points and rout the hoses for easy
access to your grease fittings.
Continue plumbing your boom as shown on the boom hose and tube layout drawing.
12
INSTALLATION
13
INSTALLATION
SETTING PRESSURES:
Next set the pump and control valve main relief pressure. You must refer to the
hydraulic schematic for these pressure values.
First, adjust your Pump's Load Sense or Standby pressure to 450 psi.
Next, set the pump's cut-off pressure 300 psi above the control valve relief setting,
shown on the hydraulic schematic.
Adjust the control valve main relief setting to 200 psi above the pump's cut-off pressure.
And re-adjust the pump's main cut-off to the specification shown on the hydraulic
schematic.
Now, using a flow meter, check and adjust the pump's flow. Adjustment is made at the
pump's mechanical flow limiter. Refer to the drawing below.
The pump's Mechanical stop is always factory set. Do Not Adjust it.
14
STARTUP
15
BREAKER INSTALLATION
The cylinders are full of air and may need bleeding at startup. Failure to do so will result
in the boom running away and may cause serious injury or property damage.
Extend the dipperstick cylinder.
Pin the rod end of the cylinder to the outer boom and secure the pin with the retaining
bolt.
ATTACHING THE BREAKER TO THE BOOM:
To attach the Hydraulic Breaker to the end of the boom, first clean the outer boom nose
bushings and the breaker link bushings.
Remove the hammer mounting pins from the hammer mount.
Ensure that the hydraulic system is capped-off and use the boom to align the hammer
links with the breaker links and the outer boom.
Finish the hammer installation by inserting the pins and retaining bolts.
Install the hammer whip hoses.
16
BREAKER INSTALLATION
E Series Breakers
Apply
Grease
Apply Grease
Tool
Retainers
Tool Retainer
Retainer Pin
Stopper Plug
Retainer Pin
Stopper Plug
17
18
Remember to properly grease the hammer tool every 2 hours of operation, with a Molybased grease. To do this the breaker must be in a vertical position with enough down
pressure applied to force the tool into the breaker housing. For more detailed instructions refer to the section Greasing the Breaker, in the Hydraulic Breaker Owners
Manual.
Adjust the control valve and pump pressures. The pressure settings are shown on the
hydraulic schematic in your Owner's manual. Your system comes with a pressure gauge
that you attach to either the Load Sense or Main pressure ports of the control valve
After all the pressures have been set, test the operation of your Rockbreaker system
with the control levers.
Next adjust the control valve speed settings. These settings affect how quickly your
boom moves. BTI recommends a slower boom movement until the operator is comfortable with the Rockbreaker's operation.
Now test the operation of the rockbreaker system and hammer movement with the joysticks.
Adjust the boom direction controls to suit the operator's position, pulling the joystick to
the left should move the boom left.
Attach your joystick decals.
The pedestal floor plate can now be reinstalled.
19
DAILY CHECKS
20
CONVERSION FACTORS
QUANTITY
SI UNIT OF MEASURE
CONVERSION
US UNIT OF MEASURE
Length
Millimeter (mm)
Inch (in)
1 in. = 25.4 mm
Pressure
(note 1)
Pressure
(see note 2)
Inches of mercury
(in Hg)
1 in Hg (@ 600 F)
= 0.034 bar
Flow
(note 3)
Flow
(note 3)
Flow
(note 4)
Force
Newton (N)
Pound (f)
1 lb(f) = 4.44 N
Mass
Kilogram (kg)
Time
Second (s)
Second (s)
Volume
(note 3)
Liter (l)
Temperature
Torque
Power
Kilowatt (kW)
Horsepower (HP)
1 kW = 1.34 HP
Shaft speed
Frequency
Hertz (Hz)
1 Hz = 1 cps
Kinematic
viscosity
Centistokes (cSt)
Saybolt (SUS)
Velocity
Material
stress
lb(f)
1 kg = 2.20 lb(m)
C= 5/9 ( 0 F -32)
21
THREAD
SIZE
1/4 -20
1/4 -28
5/16 -18
5/16 -24
3/8 -16
3/8 -24
7/16 -14
7/16 -20
1/2 -13
1/2 -20
9/16 -12
9/16 -18
5/8 -11
5/8 -18
3/4 -10
3/4 -16
7/8 -9
7/8 -14
1 -8
1 -14
1 1/8 -7
1 1/8 -12
1 1/4 - 7
1 1/4 -12
1 3/8 -6
1 3/8 -12
1 1/2 -6
1 1/2 -12
HEX
SIZE
7/16
7/16
1/2
1/2
9/16
9/16
5/8
5/8
3/4
3/4
13/16
13/16
15/16
15/16
1 1/8
1 1/8
1 5/16
1 5/16
1 1/2
1 1/2
1 11/16
1 11/16
1 7/8
1 7/8
2 1/16
2 1/16
2 1/4
2 1/4
SAE GRADE 5
DRY
LUBRICATED
SAE GRADE 8
LUBRICATED
DRY
Ft-lb
kgm
Ft-lb
kgm
Ft-lb
kgm
Ft-lb
kgm
8
10
17
19
30
35
50
55
75
90
110
120
150
180
260
300
430
470
640
730
800
880
1120
1240
1460
1680
1940
2200
1.1
1.4
2.4
2.6
4.1
4.8
6.9
7.6
10.4
12.4
15.2
16.6
20.7
24.9
40.0
41.5
59.5
65.0
88.5
101
111
122
155
171
202
232
268
304
*75
*86
13
14
23
25
35
40
55
65
80
90
110
130
200
220
320
360
480
540
600
660
840
920
1100
1260
1460
1640
0.86
0.99
1.8
1.9
3.2
3.5
4.8
5.5
7.6
9.0
11.1
12.4
15.2
18.0
27.7
30.4
44.3
49.8
66.4
74.7
83.0
91.3
116
127
152
174
202
227
12
14
25
25
45
50
70
80
110
120
150
170
280
240
380
420
600
660
900
1020
1280
1440
1820
2000
2380
2720
1360
3560
1.7
1.9
3.5
3.5
6.2
6.9
9.7
11.1
15.2
16.6
20.7
23.5
38.7
33.2
52.6
58.1
83.0
91.3
124
141
177
199
232
277
329
376
437
492
9
10
18
20
35
35
55
60
80
90
110
130
170
180
280
320
460
500
680
760
960
1080
1360
1500
1780
2040
2360
2660
1.2
1.4
2.5
2.8
4.8
4.8
7.6
8.3
11.1
12.4
15.2
18.0
23.5
24.9
38.7
44.3
63.6
69.2
94.0
105
133
149
188
207
246
282
326
368
* in-lb.
NOTES:
1. Always use the torque value listed above when specific torque are not available.
2. Do not use above values in place of those specified in other sections of this manual or other manuals pertaining to this equipment.
3. The torque values listed in the "dry" columns are based on use of clean, dry threads.
4. The torque values listed in the "lubricated" columns are based on the use of cleans threads lubricated with
oil, grease, molybdenum disulphide based grease, and usage of hardened washers.
5. Bolts threaded into aluminum may require reduction in torque values of up to 30 %, unless inserts are used.
Grade 5 and grade 8 bolts can be distinguished by their head markings.
22
PRODUCT WARRANTY
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 from the date of Installation. This warranty does not cover o-rings, seals,
fittings, hoses, breaker tools or other items considered normal wear items. These are
covered by the Limited Warranty period of thirty (30) days. Warranty for propriety
items such as valves, pumps, filters, electric motors, panels and componentry that are
not manufactured by BTI, will be governed by the warranty terms of their manufacturer.
This warranty is void if BTI's standard installation specifications and procedures are not
adhered to.
2. BTI's Customer Service Department 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
workmanship. 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 Customer Service Department
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 materials
and/or the correction of such defective parts or materials.
7. BTI neither assumes nor authorizes any other person to assume for it any liability in
connection with the sale of it's products other than that specifically stated herein.
8. THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER WARRANTIES.
EXCEPT AS EXPRESSLY SET FORTH HEREIN, BTI MAKES NO REPRESENTATION OR
WARRANTY, STATUTORY, EXPRESS OR IMPLIED, WITH RESPECT TO THE
PRODUCTS MANUFACTURED AND/OR SUPPLIED BY BTI, WHETHER AS TO
MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR ANY
OTHER MATTER. IN NO EVENT, INCLUDING IN THE CASE OF A CLAIM OF
NEGLIGENCE, SHALL BTI BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
23
NOTES
24
NOTES
25
SOLON FACILITY
30625 Solon Industrial Drive,
SOLON OHIO,
44139 U.S.A.
PH. 440-542-3720
FAX. 440-542-3721
RIVERSIDE FACILITY
3464 DURAHART ST.
RIVERSIDE,CALIF.
92507 U.S.A.
PH. 909-369-0878
FAX. 909-369-8281
THORNBURY FACILITY
35 ELGIN ST.,
THORNBURY,ONT.
N0H 2P0 CANADA
PH. 519-599-2015
FAX. 519-599-6803