Professional Documents
Culture Documents
MRH
MRH
150-4062
General Installation
© ASTEC INDUSTRIES, INC. APRIL 2022
Contents
Introduction............................................................................................. 3
To our customer......................................................................................... 3
Rockbreaker System Components...................................................... 4
Safety.......................................................................................................... 5
Hazard Alerts............................................................................................... 5
Site Location & Sizing........................................................................... 7
Determining Correct Boom Size........................................................... 7
Base Installation...................................................................................13
Reinforced Concrete Base Installation.............................................13
Bolt Centers and Mounting..................................................................13
Typical Concrete Base Configuration................................................13
Site Preparation for Pedestal ..............................................................14
Structural Steel Base...............................................................................14
Typical Steel Foundation ......................................................................15
Pedestal Mounting Arrangements................................................17
RC11/TB275/TB325SC/TB425SC.........................................................17
PB Series Rockbreaker Assembly.......................................................18
NT Series Rockbreaker Assembly.......................................................19
TM16,20 & 25 Series Rockbreaker Assembly.................................20
TM30, 30-35XH Series Rockbreaker Assembly..............................21
SX Series Boom Systems.......................................................................22
TT45/TB1680X Rockbreaker Assembly............................................23
Controls...................................................................................................24
Remote Electro/Hydraulic Controls...................................................24
Remotely Located Control Stand.......................................................24
Portable Controls.....................................................................................25
Ergonomic Seat........................................................................................26
Power Pack.............................................................................................27
Installation Requirements....................................................................27
Power Pack Arrangement.....................................................................28
Power Pack Options................................................................................29
Power Pack Arrangement.....................................................................30
Immersion Heater Installation............................................................36
Suction Filter Pressure Differential Switch......................................38
Thermostat Installation.........................................................................39
Schematics.............................................................................................40
Typical Electrical Schematic.................................................................40
Typical Hydraulic Schematic................................................................41
Installation..............................................................................................42
Installing the Pedestal/Turntable.......................................................42
Typical Concrete Foundation Installation.......................................43
Installing the Inner Boom.....................................................................44
Installing the Dipperstick Cylinder....................................................45
Plumbing the Boom & Pedestal..........................................................46
Connecting the Control Valve.............................................................47
Starting the Boom...................................................................................48
Setting Pressures......................................................................................49
Breaker Installation..............................................................................50
Attaching the Breaker to the Boom..................................................50
Installing the Breaker Tool....................................................................51
Reference Information.......................................................................52
Conversion Factors..................................................................................52
General Torque Values............................................................................53
Reference Charts......................................................................................54
Weights of Various Materials................................................................55
Reference Charts......................................................................................57
Introduction
ROCKBREAKER SYSTEMS To our customer
Introduction
To our customer
Thank you for purchasing an Astec Industries (Astec) product for your application. At Astec, we
pride ourselves in the equipment we manufacture and distribute.
Astec has led the way providing equipment and services for construction, aggregate and mining
industries for over 50 years. Technology plays a critical role in the company’s continued success.
Astec enjoys a reputation for engineering products with the most advanced technologies, yet the
resulting systems are remarkably easy to use.
At Astec we believe our product is the industry standard, without exception. Meticulous care has
been taken to ensure that this product will meet rigorous product requirements. Using up-to-
date CAD modelling software,complemented with finite element analysis, you can be satisfied
that our product will meet and exceed your prerequisites. Astec has successfully registered our
Thornbury facilities as ISO 9001 compliant and to ISO 14001, which is an internationally recognized
environmental management system. As always, Astec is committed to continuous improvements
translated into positive action.
We feel fortunate to say that our team consists of seasoned, long-term, dedicated employees.
They are able to respond quickly from our strategically located sales and service locations to any
questions you may have.
Astec Industries, Inc. may use their catalog and literature, field photographs of their products that may have been modified by
the owners, products furnished by Astec Industries, Inc., may not necessarily be as illustrated therein. Also continuous design
process makes it necessary that specifications by subject to change without notice. All sales of the products of Astec Industries,
Inc. are subject to the provisions of their standard warranty. Astec industries, Inc. does not warrant or represent that their
products meet any federal, state, or local statutes, codes, ordinances, rules, standards or other regulations, including OSHA and
MSHA, covering safety, pollution, electrical wiring, etc. Compliance with these statutes and regulations is the responsibility of
the user and will be dependent upon the area and the use to which the products is put to use. In some photographs, guards
may have been removed for illustrative purposes only. This equipment should not be operated without all guards attached in
their normal position. Placement of guards and other safety equipment is often depending upon the area and how the product
is used. A safety study should be made by the user of the application, and, if required, additional guards, warning signs, and
other safety devices should be installed by the user, wherever appropriate before operating the products.
NOTE: SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
1) The Pedestal and Swing post. The equipment's serial number is located on the cor-
ner of your Pedestal.
3) The Hydraulic Breaker. If you are not going to install your hammer now, store it
indoors standing up.
Also included will be a box or boxes containing the boom hoses, and tubes. The crate
may also contain the Joysticks, and any spare parts and options that may have been
ordered.
Figure 1
Safety
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.
Astec cannot anticipate every possible circumstance that might involve a hazard. The
hazard 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 Astec is used, you must satisfy yourself that it is safe for you and others. You should
also ensure that the compactor and carrier will not be damaged or made unsafe by
the operation, maintenance or repair procedures you choose.
Head Foot
Eye Hearing
Protection Protection Protection 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 servic-
ing 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.
The following sections outline how to determine the correct boom and breaker
size. Compiling the answers to the following questions will form the parameters for
achieving the best installation:
Parameters
Installation: Stationary jaw crusher
Problem Areas: Bridging over jaw
Require some raking on grizzly
Figure 2
Section Through Crusher
To Show Coverage
In any situation it would be ideal to cover all problem areas plus the complete box
or feeder. This is not always feasible as some situations would require increasing the
boom size to do this. Emphasis should be placed on covering the pertinent problem
area(s) first.
Our example crusher has a substantial difference in elevations from the top of the
jaw to the feeder floor. Typically the Vertical Breaker Coverage should extend at least
half way into the jaw. The Rockbreaker should be mounted in line with material flow
so that it can rake towards itself. Area "A" on the above illustration is of the greatest
concern although the customer would like to rake on the grizzly and reach as far as
possible in area "B". Area "C" is critical also as it is desirable not to have the coverage
too low. This allows extra clearance above the rock if required to break in this area.
Note how the fattest part of the envelope is stretched over where the Rockbreaker
will be working.
In Figures 3,4,5 on the following pages, the Rockbreaker is located over the problem
area and is installed so that it can work in-line with the material flow.
Figure 3
Figure 3 above is typical of the type of coverage drawing furnished by Astec illustrat-
ing the two areas of concern: The first is VERTICAL BREAKER COVERAGE, and the sec-
ond is MAXIMUM REACH.
Vertical Breaker Coverage simply means that, within the envelope represented by
cross hatched lines, the breaker has superior maneuverability for breaking rocks and
turning them to break them. This envelope must be located over the problem area.
This situation required a boom large enough to cover the gyratory crusher and main-
tain a pedestal location outside the rock box.
Maximum Reach of the Rockbreaker is represented with a line showing where the tip
of the tool is capable of reaching from the pedestal. Please note how this dimension
will change with the elevation changes. It can easily be determined on site after a
pedestal location has been decided.
Figure 4 shows a typical installation over an underground grizzly. The unit is located
opposite the dump point. The coverage enables it to rake and break oversize in line
with material flow on the flat section of the grizzly (where the problem area is). Finer
material is eliminated on the inclined section of the grizzly. The Vertical Breaker
Coverage remains high enough above oversize on the grizzly to allow sufficient clear-
ance for turning and breaking.
In this situation a side mounted hammer permits working under low back heights by
allowing a lower elevation for the pedestal. The concrete base under the pedestal is
anchored to the rock.
Figure 4
NOTE: The breaker can reach and operate within all the arcs as shown and does NOT
have to be vertical to fire. The tool, however, must remain at a 90 degree angle to the
rock.
Figure 5 below illustrates a typical installation on a portable crusher. The vertical cov-
erage is located over the area where the material is bridging, but also at an elevation
where good reach is still maintained in the feeder.
Figure 5
Figure 6 shows an installation on a mobile crusher. The total weight of the unit and
ease of disassembly are key factors here, so a PB boom is used. A beam straddles the
feeder, and the pedestal is located off to one side allowing good coverage over the
feeder and jaw. Raking the material becomes less important in this situation, so this
allows the pedestal to be located off to the side. In this way, the vertical members on
the feeder can be used in the substructure for the pedestal.
Figure 6
Base Installation
Reinforced Concrete Base Installation
This type of installation is used where a concrete pad can be poured on the quarry
floor or anywhere it is feasible to pour a pad in contrast to using structural steel. See
Figure 7 showing a typical installation. Note the concrete pad in Fig. 7 is not tied to
the quarry floor, but has sufficient mass to act as a counter weight and remain effec-
tive rather than be anchored down. A base plate must be submerged in the concrete
to anchor the bolts, otherwise they will pull through. A rubber pad or grouting is used
under the pedestal to eliminate irregularities and increase the contact between the
surface of the concrete and the base to better distribute the load.
Bolt Centers and Mounting
See drawings on the following pages for bolt centers and structural mounting infor-
mation. The next page shows a typical concrete installation. Dimensions for the con-
crete base are found on the following page. A re-bar grid in this case is placed above
the base plate embedded in the concrete. The whole system is then anchored to the
quarry floor.
Backfill
Rock Box
Base Plate Bolts
Base could be tied to
box wall or other
Figure 7
NOTE: Astec is not responsible for the supply of or design of supporting structures.
Structural Steel Base
This set up is used when it is necessary to build a tower up to the required elevation
beside or on the crusher, or incorporate a structure into the existing crusher frame-
work. Please note here that a separate structure from the crusher is preferred but
not required. See Figure 9 for a typical installation. Superior strength is achieved in a
tower with the use of box sections 'X' braced on all sides. Taller towers can locate the
power pack on the next level below the pedestal. In some cases the framework of the
crusher becomes a more suitable mounting location. This will have to be verified on
site. In either case it is recommended to provide a platform for adequate service and
operator accessibility around the pedestal (approximately 3 ft).
TYPICAL TOWER
CONFIGURATION
Handrail all around
“X” Braced
“H” Beams
Figure 9
PEDESTAL
BEARING 1” PLATE
WASHER WELDED TO
“H” BEAMS
RUBBER
BUSHING
3/4” - 1” *BOLTS
CONVEYOR 1 1/2” - 12”NF
BELTING THD. BOTH ENDS
*SELF LOCKING
NUT
NOTES:
THE PURPOSE OF THE CONVEYOR BELTING UNDER THE PEDESTAL IS
TO:
Figure 11
RC11/TB275/TB325SC/TB425SC
Rockbreaker Assembly
(Drawing SD-3948)
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Controls
Remote Electro/Hydraulic Controls
This system consists of two dual axis joystick controls with thumb switch on right
hand controller for breaker fire. An indicator "on" light and an emergency stop but-
ton are also located with the controllers. The main control valve is located on the
Rockbreaker pedestal and permits a manual override on all functions. The signal from
the joystick controller is fed through a multi-conductor cable to an electrical activa-
tion module on each spool of the boom control valve. These modules provide sensi-
tive control for the movement of spools through an internal pilot circuit for smooth
and positive control of all cylinder functions.
Figure 23
EMERGENCY STOP
110V POWER AND CABLE
SUPPLIED BY CUSTOMER
TO POWER SUPPLY IN
CONTROL STAND
ELECTRIC CABLE
CONNECTED TO
JUNCTION BOX IN
PEDESTAL Figure 24
Portable Controls
This portable controller option includes all the features as previously noted, except
the power supply is located remotely from both the pedestal and the controller in a
dust and moisture resistant box. In this case the customer is required to supply the
110V cabling to the power supply box, and the 12V cabling to the pedestal from the
power supply. With this option, the power supply is remotely located and has only
12V supply coming to the controllers.
The 24V cable from the portable controller to the pedestal is supplied by Astec, but
the required length must be determined when ordering.
24V CABLE
CONNECTED TO
PEDESTAL
Figure 25
SWING
BREAKER TILT
(MANUAL) DIPPERSTICK
24V FROM
REMOTE HOIST
CONTROLLER MAIN CONTROL VALVE
PEDESTAL
ELECTRIC CABLE
TO REMOTE
CONTROLLER
CONTROL VALVE
LOAD SENSE LINE
PRESSURE AND
RETURN LINES
TO POWER
PACK
Figure 26
Ergonomic Seat
This option combines the same smooth operation of the Rockbreaker system in the
previous options, with an ergonomic seat designed for operator comfort. This seat
can be located in an existing control room or enclosure. With this option, the power
supply is remotely located and has only 24V supply coming to the controllers. The
24V cable from the seat to the pedestal are supplied by Astec, but the required
length must be determined when ordering.
Power Pack
Installation Requirements
Once the pedestal site has been determined, a power pack location can be chosen
convenient for repair and operator accessibility. The unit can be placed against a wall
leaving one side and end open for plumbing connections and service. See below for
bolt centers and orientation. If possible, locate the power pack at the same elevation
as the pedestal in an area not subject to direct exposure to dust and dirt.
Astec will provide hydraulic hoses to connect the power pack to the pedestal.
Standard power pack hoses are 10 ft long. Optional hoses are available in lengths of
15 feet, 20 feet, and 30 feet. The distance required must be specified at the time the
order is placed. If the power pack has to be located at a distance greater than 30 feet,
please consult the factory.
The following pages outline the power pack components, specifications, features,
plus standard and optional equipment.
Figure 28
Figure 29
Figure 30
2 kw IMMERSION HEATER
INTEGRAL THERMOSTAT
00 TO 1000 F
(-180 TO 380C)
Figure 31
THERMOSTAT
SWITCHES ARE TO BE WIRED ON SITE BY
CUSTOMER. REFER TO DRAWING 216-0176D
FOR TEMPERATURE SETTINGS TO SUIT
APPLICATION.
7/8” (22mm)
SWITCH 1 FOR 1/2” (13mm) CONDUIT
TRANSFERS ON INCREASING TEMPERATURE FITTING
N.O. OR N.C. CONTACTS NEMA 4 WATERTIGHT
SWITCH 2
TRANSFERS ON DECREASING TEMPERATURE
N.O. OR N.C. CONTACTS
Figure 32
For RC boom series only. Cooler note available for this option.
Figure 33
Figure 35
Figure 37
Figure 38
Figure 39
Thermostat Installation
Thermostat Installation
(PN 1002439)
(Drawing SD-3177)
Figure 40
Schematics
Typical Note:
This is a typical Electrical
Electrical Schematic and may not reflect
your system.
Schematic
Figure 41
Installation
Installing the Pedestal/Turntable
Ensure foundation is prepared to the type that is applicable and cured (if concrete)
before the Rockbreaker arrives on site.
Use a crane to lift the pedestal onto the base. Your crane must have sufficient capacity
to lift the Rockbreaker components.
Lift the pedestal / turntable with care, keeping it level the whole time.
Carefully lower the pedestal / turntable and align the Pedestal mounting holes with
the Base mounting holes.
Lift the Power Pack into its location beside the Pedestal.
With your crane, install the Base end of Hoist Cylinder(s) into the Swing post.
Install the shims, insert the pin and secure it with the pin retaining bolt.
Using a second crane or suitable lifting method, pin the rod ends of the Hoist
Cylinders to the inner boom. You may have to extend or retract the cylinder rod to
align it with the inner boom lug and install the pin retaining bolt.
Figure 47
Strap the rod end of the dipperstick cylinder to the inner boom for now.
Figure 48
Before connecting the hoses and tubes, remove the pedestal floor plate to verify
which line is pressure and which is return. The pressure outlet is marked on the con-
trol valve with a 'P', and the return to tank is marked 'T'. Label the hoses where they
exit the pedestal bulkhead.
Figure 49
Unpack the hose plumbing kit. And refer to the Boom Hose and Tube Layout drawing
in section 3 of your Owner's Manual.
Install the stacking clamps, their locations are also on the boom hose and tube layout.
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.
Now install the control valve hoses. This information is shown on the Hydraulic
Schematic in section 4 of your Owner's Manual. Some of these hoses are already
attached. Connect the remaining hoses next to these, to allow easier access with your
tools.
Next attach the hoses from the power pack to the pedestal.
Connect the power pack return line to the pedestal return line.
Connect the power pack pressure line to the pedestal pressure line.
Install the load sense line from the power pack to the pedestal.
Double-check that the pressure line is connected to the pump pressure, and the
return line is connected to the pump return.
Cap the outer boom and breaker hoses at the control valve. This will facilitate the
assembly of the outer boom and breaker.
Install the control valve handles, to prepare the valve for operation.
If you purchased the fan optional thermostatic control for the Oil Cooler, install
it now. The oil cooler is standard on systems with a TB825 or larger hammer, and
optional on Rockbreakers with smaller hammers.
Set the temperature switches on the thermostatic control. Refer to the Electrical
Requirements section of the General Installation manual for these temperature set-
tings.
If your system was sold with a joystick control, it can now be wired. The wiring sche-
matic is located inside the joystick control stand.
Add hydraulic oil to the hydraulic tank. Detailed information about your systems oil is
found in the Hydraulic Oil section of the General Installation manual.
Your electrician should have electrical power available and connected to the Power
Pack. It's also important to make sure the pump and cooler fan are rotating in the
correct direction. With electrical power to your Rockbreaker, bump the motor driving
the hydraulic pump. If you encounter any problems, refer to the Troubleshooting sec-
tion of your manual.
Eliminate the remaining air from the hydraulic system by moving each control lever
up and down while the system is running. By extending and retracting the cylinder it
will release the air.
Once the air has been bled from the system and finish filling the hydraulic tank with
oil.
Walk around your boom and power pack, checking for and repairing any oil leaks.
Setting Pressures
First, adjust your Pump's Load Sense or Standby pressure to 450 psi.
Next set the pump and control valve main relief pressure. You must refer to the
hydraulic schematic for these pressure values.
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 pres-
sure.
And re-adjust the pump's main cut-off to the specification shown on the hydraulic
schematic.
Breaker Installation
Sling the outer boom and prepare it for installation.
Carefully raise the inner boom to a safe working height and attach the outer boom
using the appropriate shims, pin and retainer bolts.
Pin the rod end of the cylinder to the outer boom and secure the pin with the retain-
ATTACHING THE BREAKER TO THE BOOM:
ing bolt.
To attach the Hydraulic Breaker to the end of the boom, first clean the outer boom
nose bushings and the breaker link bushings.
Ensure that the hydraulic system is capped-off and use the boom to align the ham-
mer links with the breaker links and the outer boom.
Finish the hammer installation by inserting the pins and retaining bolts.
For easier installation thoroughly grease the top of the hammer tool with a moly-
based grease.
Apply
Grease
Apply Grease
Tool Retainers
Tool Retainer
Retainer Pin
Retainer Pin
Stopper Plug
Stopper Plug
Figure 50
Reference Information
Conversion Factors
QUANTITY SI UNIT OF MEASURE US UNIT OF MEASURE CONVERSION
Pressure Bar (assumed to be "gauge" unless otherwise Pounds per square inch 1 Bar = 14.5 psi
(note 1) stated) (psi or psig)
Pressure Bar ( a value less than 1.0 is shown as a deci- Inches of mercury 1 in Hg (@ 600 F)
(see note 2) mal, i.e. 0.95 bar) (in Hg) = 0.034 bar
Kilowatt (kW)
Power Horsepower (HP) 1 kW = 1.34 HP
Revolutions per minute
Shaft speed (rev/min) Revolutions per minute -
(RPM)
Hertz (Hz)
Frequency Cycles per second (cps) 1 Hz = 1 cps
Milliliters per revolution
Displacement (ml/rev) Cubic inches per revolution 1 ml / rev = 0.061 cipr
(note 3) (cip)
Centistokes (cSt)
Kinematic Saybolt (SUS) cSt = (4.635) (SUS)
viscosity (note 5)
Meter per second (m/s)
Velocity Feet per second (fps) 1 m/s = 3.28 fps
Deka newtons per sq. millimeter
Material (da N /mm2) Pounds per sq. inch (psi) 1 da N / mm2 = 1450 psi
stress
NOTE 1 : PRESSURE ABOVE ATMOSPHERIC
NOTE 2 : PRESSURE BELOW ATMOSPHERIC NOTE 4 : GAS -UNDER STANDARD TEMPERATURE, HUMIDITY, AND PRESSURE CONDITIONS
NOTE 3 : LIQUID NOTE 5 : @ 38 0 C; FACTOR IS 4.667 @ 99 0 C
GRADE 5 BOLT, CARBON STEEL, HEAT GRADE 8 BOLT, ALLOY STEEL, HEAT
TREATED TREATED
Reference Charts
Clay Gypsum
Reference Charts
Table 7 Table 8
Hardness of Rocks Typical Toughness of Various Kinds of Rock
From Drop Hammer Tests
Soft Medium Hard Very Hard
Toughness
Asbestos rock Limestone Granite Iron ore (Taconite) Variety of Rock Limestone = 1
Gypsum rock Dolomite Quartzite Granite Fresh Diabase (Trap) ........................... 3.0
Slate Sandstone Iron ore Grantic gravel Pyroxene Quartzite ...............................
Talc Trap rock Trap rock 2.7
Soft Limestone Gravel Sandstone.............................................. 2.6
Altered Diabase.....................................2.4
Fresh Basalt........................................... 2.3
Hornblende Schist.................................. 2.1
Diorite..................................................... 2.1
Hornblende Granite................................ 2.1
Mohs Scale of Hardness Rhyolite.................................................. 2.0
Quartzite................................................. 1.9
1. Talc 6. Orthoclase Biotite Gneiss......................................... 1.9
Augite Diorite.......................................... 1.9
2. Gypsum 7. Quartz Altered Basalt......................................... 1.7
3. Clacite 8. Topaz Feldspathic Sandstone...... .................... 1.7
4. Fluorite 9. Corundum Gabbro................................................... 1.6
Chert...................................................... 1.5
5. Apatite 10. Diamond
Calcareous Sandstone.......................... 1.5
Granite................................................... 1.5
Testing (you can do in the field): Slate....................................................... 1.2
Peridotite................................................ 1.2
Scratched with: Hardness Granite Gneiss....................................... 1.2
Andesite................................................. 1.1
Fingernail...................................................................................................................................Little over 2 Limestone.............................................. 1.0
Copper coin................................................................................................................................About 3 Mica Schist............................................ 1.0
Pocket knife................................................................................................................................Little over 5 Amphibolite............................................ 1.0
Dolomite................................................. 1.0
Window glass.............................................................................................................................5.5 Biotite Granite........................................
1.0
Steel file.....................................................................................................................................6.5
Augite Syenite........................................ 1.0
Hornblende Gneiss................................. 1.0
Table 9
Rock Compressive Strength (ASTM C170)
5,000 - 10,000 PSI - Soft 30,000 - 45,000 PSI - Very Hard
10,000 - 20,000 PSI - Medium over 45,000 PSI - Extremely Hard
20,000 - 30,000 PSI - Hard
Table 10
Physical Properties of Common Rocks