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Owner'S Manual: TB Series Hydraulic Breakers
Owner'S Manual: TB Series Hydraulic Breakers
Owner'S Manual: TB Series Hydraulic Breakers
Manual # : 150-2079
BREAKER TECHNOLOGY
OWNER’S MANUAL
TB SERIES HYDRAULIC BREAKERS
General Installation
Breaker Operation
Breaker Service
SMALL BREAKERS:
Up to 1200-ft.lbs. (1627 Joules), are typically used in concrete and other light duty
work.
MEDIUM BREAKERS:
1200 - 4000-ft.lbs. (1627 - 5423 Joules) are used in both concrete and rock applications
with limitations on the size and amount of material to be broken.
LARGE BREAKERS:
Over 4000 ft. lbs. (5423 Joules), are typically used in rock and large scale concrete dem-
olition projects.
TRENCHING:
When trenching, the breaker is expected to fracture a solid mass of rock into manage-
able pieces. The size of the material could be 100's of cu.yds, and the energy will be
quickly absorbed. This is why it is recommended to work from a bench so the rock has
somewhere to break out. We recommend that when trenching in limestone or medium
hard rock, to use a 3,000 - 5,000-ft. lb. breaker. When working in hard material we rec-
ommend a 7,500 - 10,000-ft.lb. breaker, and if high production is critical, a 13,500-ft.lb.
breaker would be beneficial.
BREAKING CONCRETE:
When breaking Concrete, the breaker is expected to penetrate the material, allowing it to
crack and shake loose from the reinforcing steel. High frequency breakers tend to pro-
vide better performance in this application as it is not the energy per blow, but the fast
blow rate that destroys the concrete's structural integrity. We recommend on concrete
walls, footings, and floors to use a 750 - 1,500-ft. lb. breaker. With larger projects, con-
sisting of large footings greater then 4 cu. yards, use a 2,000 - 5,000-ft. lb. breaker. The
high production demand of bridge and building demolition requires a 7,500 - 10,000-ft.
lbs. breaker.
After considering the application work, determine the carrier on which the breaker will
be installed. BTI has assigned a ‘Recommended Carrier Weight’ (see chart on page 6)
range for each breaker. If the operating weight of the carrier falls within this range, the
carrier will safely handle this model of breaker. If the desired breaker falls outside of
this recommended carrier weight range, the carriers lifting capacity and oil flow will
need to be verified to ensure a proper fit.
LIFTING CAPACITY:
Provided the weight of the breaker does not exceed the maximum lifting capacity at any
position, the carrier is assumed to be stable. On most loader backhoes and excavators,
the maximum lifting capacity is lowest when the boom is at full reach. This is the value
that must be compared to the operating weight of the breaker.
TB125 / TB135
TB225 / TB235
TB275 / TB285
TB325 / TB335
TB425ME
TB425QA / X
TB625QA
TB625X
TB725QA
TB725X
TB830
TB980
TB1430
TB1680
TB2080
TB2580
Figure 2
The priority flow control is usually equipped with a flow adjustment and pressure relief.
These valves often need a check valve on the regulated port to completely close the
flow. If dividing too much flow, this circuit will generate heat and will need cooling
capacity.
Figure 3
Figure 4
EXTERNAL FORCES:
The main cause of increased fatigue stress in a tool is any form of side force during
operation which creates bending. Therefore using the tool to pry, using the incorrect
working angle, or attempting to break ground using the pull of the machine, are all
detrimental to the life of a tool and must be avoided. The hydraulic power available in a
carrier far exceeds the strength of a tool, and if being used incorrectly, can “snap a tool
like a twig”.
BLANK-FIRING:
This is any situation where the breaker piston strikes the top of the tool, but the working
end of the tool is not in contact with the work. This happens when the tool slides off the
work, and also on a break-through of thin concrete slabs or boulders.
COLD TEMPERATURES:
Low temperatures cause the tool to be more susceptible to fatigue failure. Tools should
be warmed before extensive use by moderate or light breaking.
POOR LUBRICATION:
Metal to metal contact causing pick up could cause deep damage marks which, in turn,
lead to the formation of fatigue cracks and eventual failure of the tool. Ensure that the
tool shank is well lubricated before inserting it into the tool holder. Molybdenum disul-
fide grease is recommended for the application at 2 hour intervals, with the tool pushed
fully up inside the breaker. (Refer to Fig. 14).
CORROSION:
Keep tools well greased and sheltered from the weather when not in use. A rusty tool is
more likely to suffer fatigue failure. For greasing instructions refer to Fig 14.
The FRONT HEAD contains the breaker tool, bushings, and retainer pins. By removing
the retainer pins, the tool can be quickly changed.
The CYLINDER contains the moving piston, which strikes the tool. The seals for both
ends of the piston are also located in the cylinder.
The REAR HEAD houses the cushion chamber, which is charged with nitrogen gas. The
gas in the cushion chamber absorbs the piston's upward recoil and stores this energy for
the next blow.
The CONTROL VALVE is mounted on the cylinder and directs the flow of hydraulic oil
and therefore the movement of the piston. Located directly above the control valve are
the hydraulic oil inlet and outlet ports.
Two side plates hold the breaker and protect it during operation. The breaker is attached
to the carrier by a bracket fastened to these plates.
Rear Head
Cylinder
Tie Rod
Air Valve
Front Head
Figure 5
PRINCIPLE OF OPERATION:
A B C D
Return Return Return Return
5 Pressure Pressure Pressure Pressure
5
4
7 7 7 7
6
3
2 2 6
Figure 6
Nitrogen Pressure Return
(A) UPWARD MOVEMENT
Oil flows into cylinder chamber (1) and control valve
Breaker Parts chamber (7). The piston is pushed up towards the cushion
chamber (5), and the control valve spool is forced down.
Hose Adaptors
HYDRAULIC FLUID:
The fluid should be selected so that, within the optimum range (V opt ), (see shaded
section of selection diagram). We recommend that the higher Viscosity grade is selec-
tion in each case.
Example: At an ambient temperature of X0C. The operating temperature in the tank will
be 600C. In the optimum operating viscosity range (V opt ; shaded section) this corre-
sponds to viscosity grade VG 46 or VG 68; VG 68 should be selected.
Important: The leakage oil temperature is influenced by pressure and speed and always
higher than the tank temperature. At no point in the system, however may the tempera-
ture be higher than 900C.
If it is not possible to comply with the above conditions because of extreme operating
with the operating parameters or higher ambient temperature, please contact us.
Figure 8
SAFETY PRECAUTIONS:
Danger, Warning, and Caution are harzard alerts used in this manual and on the breaker
safety signs to identify hazards on or near the rockbreaker system.
Danger - Immediate hazards, which WILL result in severe personal injury or death if
the proper precautions are not taken.
BTI cannot anticipate every possible circumstance that might involve a hazard. The haz-
ard alerts in this publication and on the product are therefore not all inclusive. If a tool,
procedure, work method or operating technique not specifically recommended by BTI is
used, you must satisfy yourself that it is safe for you and others. You should also ensure
that the breaker and carrier will not be damaged or made unsafe by the operation, main-
tenance or repair procedures you choose.
To avoid injury from flying chips of stone or concrete, be sure you and others stay well
away from the breaker when it is operating.
BTI Hydraulic Breakers and their components are heavy! Plan carefully how you will
handle them when removing, disassembling, or installing the breaker. Stand clear when
slinging the breaker off the ground.
Only trained mechanics should disassembly the breaker. However if you should disas-
semble the breaker be sure to all Nitrogen gas pressure from the cushion chamber. Refer
to the breaker disassembly (page 24) of this manual for instructions.
Stay clear of the tool when charging the cushion chamber with nitrogen gas. It may
jump against the retainer pins as the gas pressure forces the piston down.
Next, raise the breaker so the tool is not pressing onto any
material and fire the hammer. This is called 'idle firing'. In Figure 9
this position the breaker does not normally run, but circu-
lates warm system oil through the control valve to the tank.
Hold the hammer fire on for 5 seconds, then release for 5
seconds. Repeat this procedure for 3 to 5 minutes depend-
ing on the ambient temperature. While idle-firing the piston
may move up and down, but should not hit the tool.
For large rocks start at the edge and work toward the cen-
ter, breaking off small chunks each time. Breaking along
the rock's natural faults and seams also make for easier
breaking. (Fig. 9)
The breaker should not be fired when the carrier's boom cylinders are fully extended or
fully retracted. The cylinders may be damaged from the breaker's shock pulses.
If your carrier throttle has been set to run at a specific setting, do not deviate. This pro-
vides the proper flow to the breaker. But be careful, excess flow does not increase
breaking power. Your carrier's operating temperature may run too high, and actually
decrease breaking power. If the hydraulic oil temperature exceeds. 175oF (79oC),
stop breaking!
If you plan to operate the breaker underwater, ensure that it has been equipped with an
underwater kit. Refer to page 43.
BLANK FIRING:
Blank firing emits a distinct metallic ringing. Blank firing most often occurs in hard
rock, just as the rock shatters under the tool. With no material under the tool, the piston
smashes the tool and retainers too far into the front head, transfering the breaking force
back through the breaker and excavator.
To prevent blank-firing learn to anticipate when the material will break. Predicting this
moment is probably best done by listening to the sound of the hammer hitting the rock.
You will soon notice a change in the hammering sound as the stone is breaking, you are
now on your way to anticipating when a rock will break.
Figure 12
RAKING PUSHING
PUSHING LIFTING
Figure 13
For most situations the excavator will sit off to the side of the trench allowing you to
keep steeper slopes. However the carrier swing function will not have the strength to
push broken rock away from the work area. In some cases the excavator will sit on top
of the trench and the broken material can be back filled under the excavator.
For best performance, apply the down force in line with the tool, repositioning every 10
to 15 seconds or when no penetration is evident. Keep the breaker well greased at all
times.
BREAKING CONCRETE:
Begin by penetrating the concrete several times in one area with the breaker tool. This
should loosen the concrete and separate the reinforcing steel. The reinforcing steel may
need to be cut, keeping the concrete pieces manageable for hauling away.
When breaking concrete floors, use the down force from the carrier's boom cylinder to
follow the tool through the concrete. Breaking vertical walls is more difficult, force
must be maintained using a combination of boom, stick, and tilt cylinders.
A fast blow rate gives the best performance in breaking concrete, so ensure your carrier
is providing the breaker with the maximum recommended oil flow.
Generally when breaking concrete, a chisel point gives the best splitting action.
However if you are breaking hard concrete with lots of reinforcing steel, a moil point
may be better. The moil tip allows the tool to deflect off the steel as it breaks through
the concrete.
Large pieces will break easier if they rest directly against the grizzly bars. This way all
the energy from the breaker is applied to the rock. Breaking energy will be absorbed if
there is too much material under the rock you are breaking.
If rocks are just hanging on the edge of the bars, use the breaker to hammer them
through with short bursts. Do not push them through with the force of the boom, this
can damage your breaker as the front head hits the grizzly bars.
To keep your breaker working in top operating condition, the following maintenance
must be performed. Keep in mind that lubrication is the single most important procedure
for sustaining the life of a breaker. To make this chore easier, we offer an auto
lubrication unit, call BTI for details
DAILY MAINTENANCE:
Lubricate the tool with BTI chisel paste or a moly-based grease every two hours of con-
tinuous operation and any time you have serviced the tool. Failure to lubricate regularly
reduces the life of the tool, tool bushings and front head. Never use ordinary grease,
because it melts and runs down the tool providing very poor lubrication.
For proper tool lubrication the breaker must be vertical with enough down-force applied
to push the tool into the breaker. This will prevent grease from entering the area above
the tool.
Visually check the tool retainer pins. The round retainer pins rotate during normal oper-
ation. To confirm they are rotating, look at the ends of the pins for fresh radial marks in
the grease on the cross pin.
Check all nuts and bolts for the correct torque. Improperly torqued bolts can damage the
breaker.
The breaker should be greased every two hours of use or when the tool appears shiny
where it rides inside the front head. The chart (page 51-53) shows the minimum amount
recommended for each breaker,and can be used as a guideline.
RETAINER PINS:
Preform a visual check when greasing to ensure the retainer pins rotate during normal
operation. By looking at the side of the front head, check the ends of the pins confirm-
ing they are rotating by the fresh grease marks.
Tool Retainer
Retainer Pin
Grease traces
leave radial marks
Figure 15
BTI breakers are built using the highest quality materials and workmanship to ensure
long life and maximum efficiency. To keep a breaker in top operating condition, lubrica-
tion, inspection, and servicing all need to be conducted at regular intervals.
This overhauling should be scheduled to occur every year or after every 1,000 hours of
operation, whichever comes first. For units being operated on a continuous basis in very
hard rock, overhaul is advisable after every 500 hours.
Breakers operate in very dirty conditions. Their efficient operation relies on keeping that
dirt out of the close tolerance mechanism. It is important to maintain the breaker and
especially the seals in good condition by following proper operating and maintenance
procedures. Some breakers are used for overhead scaling which have special concerns,
consult your BTI dealer for more information.
Rockbreaker servicing must be carried out in a clean, dry area. Even a small amount of
dirt in the cylinder or control valve can cause premature failure.
To do a complete service you will require the following items; a suitable hoist, replace-
ment parts, lubricants, a torque multiplier, a nitrogen charging kit, and a pressure gauge.
The gauge is provided in the rockbreaker tool kit.
SAFETY PRECAUTIONS:
Always take proper safety precautions. You must wear safety glasses, work gloves, and
safety shoes. Use of a safety stand is recommended. Before servicing the breaker review
this technical manual and read all decals. Before lifting the breaker, refer to page 51 for
the approximate working weight of the breaker.
Check the wear width between the tool and the tool bushing. Refer to the “Bushing Wear
Width” charts on pages 51-53 for the accepted clearance values.
Wear
Width
Figure 16
To remove the tool, drive out the retainer pin and stopper plug using the drift supplied in
the tool kit.
“E” Series
Hammer Tool Retainer
Drift
Applicable on
Breaker “E” Series
Models: Retainer Pin Figure 17
Remove the tool and inspect the top for pitting and mushrooming. Also, check for chip-
ping of the impact face, which may indicate excessive tool bushing wear. Any of these
conditions may suggest a need for more frequent servicing, because of extreme operating
conditions or because the tool is being incorrectly operated. Refer to page 10.
Inspect the retainer pin contact area on the tool for deformation and scoring. In normal
use, this wear will be minimal. If tool wear seems extreme, it may indicate frequent blank
firing. If the retainer pin contact areas on the tool cannot be repaired, the tool must be
replaced to avoid premature failure of the retainers.
Also, inspect the tool bushing area for wear. Excessive wear here may also indicate that
more frequent greasing is needed, and if this area cannot be repaired, the tool must be
replaced to avoid damaging the new bushings.
Make any necessary repairs to the tool before putting it back into the refurbished
front head.
Remove the breaker from the lower sideplate and lie it down in a clean work area.
Inspect the sideplates for cracks, worn bolt holes, and damaged threads in nuts and on
bolts. Any defects should be corrected before the sideplates are reinstalled. Pay particu-
lar attention to the shear blocks and make sure they are not worn so they will fit closely
with the key groove in the breaker body.
Thoroughly clean the outside of the breaker before disassembly. During this cleaning,
look for signs of physical damage, especially around the key groove area. Any damage
should be repaired while the breaker is disassembled.
The cushion chamber in the rear head contains nitrogen gas under pressure. Do
not remove the tie rod nuts or gas valve until this pressure is relieved.
To relieve this pressure, remove the gas valve plug and press firmly on the disc in the
gas valve with a blunt object. Be sure to protect yourself adequately from the escaping
jet of gas.
Figure 19
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.
REMOVING THE REAR HEAD FROM THE CYLINDER:
Insert lifting eyes into the rear head and stand the breaker onto the safety stand.
Back off the tie rod nuts a couple of turns, this can be done using a torque multiplier if the
breaker is standing up. If the breaker is lying down, use the sledge-wrench method. Then
using the hoist, jerk the assembly upwards, which should loosen the rear head from the
cylinder.
If the rear head is stuck, it may be necessary to tap the cylinder cover on alternate sides,
with a soft-faced mallet. Remove the nuts from the four tie rods. Remove the plastic tie
rod washers and remove the rear head from the cylinder, using the lifting eyes. In some
cases, the nuts may be seized onto the tie rods and the nut and tie rod may come out as a
unit.
Place the rear head on a clean protective surface.
Figure 20
Figure 21
Use hand tools to loosen the tie rods; impact tools will damage the thread inserts in
the front head.
To loosen the tie rods it may be necessary to secure the front head to prevent it from
rotating.
Loosen the tie rods by rotating them counter-clockwise. Use an adjustable wrench and a
soft-faced mallet or a sledge wrench on the tie rod flats to loosen the tie rods.
Removing the cylinder involves installing two lifting eyes into the threaded holes in the
top of the cylinder and lifting the cylinder straight up off the tie rods.
The cylinder should slip easily out of the front head. If not, tap the front head with a
soft-faced, until the cylinder and front head come apart.
Remove the four tie rods. Place the tie rods on clean protective material.
Cylinder
Figure 22
Figure 23
The tool bushings are held in position by four retainer pins. Remove these pins by driv-
ing them out with a drift, from the side opposite the stopper plugs.
The tool bushings need to be shrunk to remove them from the front head.
The recommended method of shrinking the bushings is to use an arc welder, using a
very hot weld, laying crescent-shaped beads completely covering the inside of the bush-
ing. Depending on the breaker bushing size this could take from one-half to three hours.
Allow the bushing to cool, without quenching, for about one-half hour to allow the weld
to contract and shrink the bushing. This time will be less for smaller breakers. Knock
the bushing out with a bar from the top end of the front head.
Remove the lower bushing first, and then repeat the procedure for the upper bushing. If
you plan to install the new bushings immediately after removing the old ones, place the
new bushings in dry ice before you start the removal procedure. Dry ice can take up to 4
hours to achieve the desired results. Then the bushings will be fully chilled and the front
head will still be hot enough from welding, to receive them. If you are using liquid
nitrogen to shrink the bushings, it can take as little as 15 minutes to properly chill them.
Front Head
Upper Tool
Bushing Tool Bushing
Alignment Slot
and Retainer Pin
Lower Tool
Bushing
Figure 24
Extreme care must be taken when installing the tool bushings in the front head. Because
the bushings are a shrink fit, the front head must be heated, so that it will expand, and
the bushings placed in liquid nitrogen, so they contract. As the pieces return to room
temperature, they become tightly fitted together. If the bushings are not installed proper-
ly before this point is reached, they must be taken out and replaced with new ones. With
liquid nitrogen you have about one minute to align the retainers.
Clean the inside of the front head thoroughly, and use a wire rotary brush to clean and
smooth the surfaces in the areas where the bushings seat. If the front head has cooled, it
must be heated with a torch to 300oF, (150oC). This will expand the housing a small
amount. Then line up the slots in the bushing with the retainer holes.
When fully inserted, the upper tool bushing will seat against a step in the bore of the
front head. Care must be taken to ensure that the grooves in the tool bushings line up
with the retainer-pin holes in the front head. Do not install the stopper plugs until the
front head has cooled to room temperature.
Apply a coat of Never-seize to the two retaining pins, and fully insert them into the
retaining pin holes. Repeat the procedure for the lower bushing.
The upper and lower tool bushings are installed from the tool side of the front head on
most models of BTI breakers.
The seal bushing carries several specially designed seals. Careful attention should be
paid to the condition and orientation of the old seals as they are removed. This may help
to identify any operating problems that the breaker had before it was disassembled.
All parts should be thoroughly washed in clean solvent and dried with compressed air.
Once the seal bushing is clean and dry, protect it from dirt and set it aside.
Gas Seal*
Upper Seal
Bushing
Oil Seal*
Slide Ring
with O-ring
(Model TB925X
and up have 2
as shown)
Cylinder
* When inserting
seals, make sure Slide Ring with
direction is as Square Ring
shown. (Models TB725X
and up)
Oil Seal*
Dust Seal*
Piston
Figure 25
Check the grooves in the piston for metal that has been pulled in due to galling. If this
has occurred clean the grooves. Small marks can be removed with an oilstone or fine
emery cloth and oil.
Look for pitting and deformation of the impact face. They may indicate that the tool has
been operated with too much wear in the tool bushings. If the face is dished, carefully
measure the amount and refer to the service manual to see that this amount is allowable
for the model you are servicing. Refer to “Maximum Allowable Piston Deformation” on
the charts on pages 51-53 of this manual.
Thoroughly dry the piston, protect it from dirt, and set it aside.
If the piston is not going to be installed immediately, coat it with oil and store it protect-
ed, in a clean dry place.
Impact
Piston
Face Figure 26
Deformation
Scoring
Figure 27
Thoroughly inspect the inside walls of the cylinder for corrosion, cavitation, or scoring.
Check grooves above seal area for small pieces of metal, due to galling. If these are not
cleaned out they will chip off and go between the piston and cylinder, and galling will
occur again.
Also inspect the main inlet and outlet adapter threads for damage. Always replace the
seals and ensure that the adapters are not interchanged if they are removed. The cylinder
is marked with a "P" beside the pressure adapter and a "T" beside the tank adapter. The
Pressure adapter has a smaller hole than the tank adapter.
Check for any damage to the threaded inserts that hold the control valve, and repair or
replace as necessary to ensure secure control valve mounting.
Prepare the control valve for disassembly by washing it thoroughly and clamp it in a
vise.
Remove the hex bolts holding the valve cap, then remove the cap by threading the
puller bolts provided in the toolbox into the two threaded holes in the cap. Gradually
tighten the bolts, alternating from one to the other, until the cap is pulled from the con-
trol valve.
The control valve spool should move smoothly in the bore, and can usually be easily
removed. A sliding hammer puller can assist in removing a seized spool.
Next, slide the control spool out of the cylinder (Fig. 33C). The spool should slide easily
out of the cylinder, without the use of tools. If the spool is stuck or seized a mechanical
puller may have to be used.
Examine the control valve ports for cavitation and erosion. Check all the oil passage
holes in the control valve and be sure they are not plugged. Clean them with a fine wire
if necessary to remove any dirt particles.
Clean all parts of the control valve in clean solvent and dry them with compressed air.
Before placing the o-ring and backup ring on the valve cap, lubricate the o-ring grooves
with oil to prevent damage to the o-ring.
Install the valve cap into the valve body, and snug the four-valve cover bolts diagonally
and uniformly to prevent binding.
Use only hand tools when tightening the bolts; impact tools will damage the helisert
inserts.
Tighten the cap bolts to the torque specified in the service manual for the model of
breaker you are servicing.
Protect the control valve assembly from dirt and set it aside
Valve Body
Spool
Valve Cap
Figure 28
The air valve maintains a positive pressure in the strike chamber to help exclude dirt,
oil, and other contaminants. Remember to reapply loctite or thread tape to the air valve
whenever it is removed and insert the spring before the check ball, for proper operation.
Figure 29
Lubricate the tie rods thoroughly using a moly-based grease or Never Seize.
The tie rods should turn smoothly and easily until they bottom out in the holes. If they
do not bottom out, or there is excessive resistance, the threads on the tie rods or the
helisert inserts may be damaged.
Remove damaged heliserts and restore the front head threads with conventional thread
chasers and taps. Insert new heliserts with the appropriate tool.
Figure 30
Torque tie rods to the specifications on page 47-49.
Apply some grease to the rubber pieces on the tie rods so the cylinder will slide on easi-
ly. Lower the cylinder carefully onto the tie rods. The control valve mounting holes on
the cylinder should face the same direction as the grease fitting on the front head.
Upper
Seal Gas Seal*
Bushing
Oil Seal*
Slide Ring with
O-ring
(Model TB925X and
* When insert- up have 2 as shown)
ing seals,
Cylinder
Dust Seal*
Piston
Figure 31
Lift the piston with the lifting eye, lubricate it thoroughly, and lower it carefully into the
cylinder. It may need a tap to push it through the lower seals.
When the piston is all the way into the cylinder bore, use a soft mallet to tap the seal
bushing into position in the cylinder. The bushing will stop when it reaches the support
flange inside the cylinder bore.
Replace the o-rings and backup rings on the top of the cylinder where the rear head
makes contact.
Upper Seal
Bushing Piston
Figure 32
Lower the rear head over the tie rods. The gas valve should face the same direction as
the control valve bolt holes on the cylinder.
Install new tie rod washers. Lubricate the tie rod nuts with Never Seize, and tighten
them in a crossing pattern to draw the breaker components together evenly. Finish tight-
ening the nuts to the correct torque in four stages, using the same crossing pattern.
3 2
Figure 33 Figure 34
Carefully fasten the control valve to the side of the cylinder using the bolts and washers
removed earlier. The control valve cap must face toward the tool. Tighten the bolts
evenly in a crossing pattern until they contact the valve. See torque specifications on
pages 47-49.
Figure 34
Lubricate the seals on the control spool guide, ensuring that the guide is clean and insert
it into the cylinder body. The guide should slide easily but if tools are required make
sure the guide is squarely in the cylinder body and tap it into position using a soft-faced
mallet. (Fig. 34C)
This gas is stored under high pressure. Caution is advised when handling.
Remove the gas valve plug from the gas valve. Attach one end of the charging hose to
the gas regulator and attach the charging adapter to the other end of the hose.
With the charging adapter inserted into the gas valve and the nitrogen tank valve open,
adjust the regulator handle slowly to build the pressure to the value specified in the
service manual. If the piston is not at the bottom of its stroke the pressure will move it
down to rest on the inside of the front head. Be aware that if the tool is installed at this
stage, it may accelerate dangerously out of the cylinder when the cushion chamber is
being pressurized.
To check the cushion chamber pressure, remove the charging adapter from the end of
the hose and put it on the pressure gauge. Insert the adapter into the gas valve and
observe the pressure reading. If the reading is too high, bleed off a small amount of gas
to make the final adjustment, and test again. If the pressure is too low, reinsert the
charging adapter, and build pressure to the required value.
When the pressure is at the correct value, (refer to the “Cushion Chamber” Pressure on
the General Specification Chart on page 55), install the gas valve plug, using a new o-
ring, and tighten to 8.7 foot-pounds torque. Take care not to cut the o-ring.
B
A
C Regulator
N2 GAS
Pressure TANK
Gauge
Figure 35
Insert the sideplate bolts and washers into the hex retainers on the sideplate and lay the
sideplate on a flat surface, with the retainers facing down and the bolts sticking up.
Some of BTI's breakers only require one washer under the bolt head. Now slip the spac-
er tubes onto the appropriate bolts.
Carefully lower the breaker body onto the sideplate. Be sure to align the shear block on
the sideplate with the key groove in the breaker body. You must also make sure that the
hydraulic ports on the breaker align with the access cutouts in the sideplates.
Next lower the other sideplate into place over the bolts, again taking care to align the
shear block with the key groove.
To prevent galling the threads on the side plate bolts, apply Never Seize or equivalent to
the threads before installing the nuts, and then put a washer and nut on each bolt.
Make sure the bolt heads are seated into the locking collars on the lower side plate.
With a hand wrench, tighten all the sideplate nuts until the plates are seated against the
breaker. This will prevent movement between the sideplates and the breaker during final
tightening.
Now using the torque multiplier tighten the bolts to 60 percent of the torque specified
on pages 47-49. Follow the pattern shown here to distribute the load evenly. When all
bolts have been tightened to 60 percent of their full torque value, tighten to 80 percent,
then 90 percent and finally to 100 percent of the torque value for your breaker.
Install the mounting bracket in the correct position, which depends on the intended
application.
6
4 8 2
10
5 7 3 9 1
Figure 36
Cover the sides of the tool's top section with grease, and insert the tool into the
front head.
Grease and insert the tool retainers and then grease and insert the retainer pins and stop-
per plug. The stopper plug should be flush with the front head.
If storing your breaker for an extended period of time, refer to “Removal & Storage” on
page 42 for storage instructions.
“E” Series Breakers “O” Series Breakers
Apply
Grease
Apply Grease
Tool
Retainers
Tool Retainer
Figure 38
Figure 37
Retainer Pin
Stopper Plug
Retainer Pin
Stopper Plug
Using your excavator lay the breaker on wooden blocks, the breaker mounting end
should lie higher than the tool end. Now remove the pins to disconnect the breaker from
the boom. Remove the tool and ensure the retaining pins, bushings and piston bottom
are all well greased. Then reinstall the tool and cover the breaker with a tarp.
The piston will not slide into the cylinder with a pressure of 114 psi.
SETUP:
To adapt the BTI Breaker for underwater use, compressed air must be fed into the
breaker front head area, creating a positive air pressure that will keep the water out. If
water does enter the front head and the breaker is fired, it could force water and debris
up inside, resulting in seal damage.
An 18 cfm compressor is recommended at 21 psi. For depths exceeding 15 ft, increase
to 26 psi. For TB125 to TB425, remove the grease fitting and tie the line in here. For
TB725 and up, remove the check valve to plumb the line in.
UNDERWATER OPERATION:
Start supplying air to the breaker before placing it underwater, and continue supplying
air until the breaker is removed from the water. Continue to operate the breaker out of
the water for approximately 10 minutes, then grease the tool and front head with the
tool pressed in.
Figure 39
OIL LEAKAGE:
If oil leakage develops, it may not be necessary to replace parts. Check the fol-
lowing points in the chart below before calling your BTI representative. A slight
amount of oil seepage around the breaker connecting parts is normal during the
first 200 hours of operation.
Figure 40
Does not hammer Base carrier selector valve does not Check connection from cab
operate properly. controls to the selector valve.
Pressure relief valve set too low. Check relief settings and adjust.
Erratic Hammering Hyd. oil temperature too high. Oil temperature must not exceed
170 deg.F (77 deg. C).
Not enough down force on the tool. Increase the down pressure
acting on the tool.
Too much grease in the impact chamber. Remove tool from front head
and clean out excess grease.
Follow proper greasing
instructions.
Lack of Power Insufficient oil flow or oil pressure. Check hydraulics of the
base carrier.
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.
TB325CM / ME / QA
TB425CM / ME / QA
TB125CM / ME
TB225CM / ME
TB275CM / ME
TB285ME / QA
TB335ME / QA
TB135ME
TB235ME
TB325X
TB425X
Control Valve kg-m 18 18 18 28 28 45 45
N/A N/A N/A N/A
Cover Bolt ft-lbs 130 130 130 202 202 325 325
kg-m 12 12 12 12 15 15 20 20 20 25 25
Tie Rod Bolt
ft-lbs 87 87 87 87 108 108 145 145 145 181 181
kg-m 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5
Gas Valve Body
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
Gas Valve Plug
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
Hose Adaptor
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
Choke Plug
ft-lbs 36 36 36 36 72 72 145 145 145 145 145
TB725CM / QA
TB625CM /QA
TB725X / XS
TB825X / XS
TB830X / XS
TB625X
Control Valve kg-m 45 45 45 45 75 75
Cover Bolt ft-lbs 325 325 325 325 542 542
kg-m 30 30 50 50 50 50
Tie Rod Bolt
ft-lbs 217 217 362 362 362 362
kg-m 55 55 55 55 55 55
Hose Adaptor
ft-lbs 398 398 398 398 398 398
kg-m 20 20 20 20 30 30
Choke Plug
ft-lbs 145 145 145 145 217 217
TB1425X / XS
TB1430X / XS
TB1675X / XS
TB1680X / XS
TB1825X / XS
TB2075X / XS
TB2080X / XS
TB2225X / XS
TB2575X / XS
TB2580X / XS
TB925X / XS
TB975X / XS
TB980X / XS
TB1025X
TB1280X
Control Valve kg-m 75 75 75 90 90 90 90 90 90 130 130 130 130 130 130
Cover Bolt ft-lbs 542 542 542 651 651 651 651 651 651 940 940 940 940 940 940
kg-m 230 230 230 230 290 360 360 360 360 360 360 360 580 580 580
Tie Rod Nut
ft-lbs 1664 1664 1664 1664 2098 2604 2604 2604 2604 2604 2604 2604 4195 4195 4195
Side Plate kg-m 180 180 180 180 165 300 300 300 300 300 300 300 500 500 500
Bracket Nut ft-lbs 1302 1302 1302 1302 1193 2170 2170 2170 2170 2170 2170 2170 3617 3617 3617
Top Mount kg-m 70 70 70 120 120 120 120 120 120 180 180 180 180 180 180
Bracket Bolt 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
Gas Valve Body
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
Gas Valve Plug
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
Hose Adaptor
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
Choke Plug
ft-lbs 217 217 217 217 217 217 217 217 217 290 290 290 290 290 290
Serial
Number
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.
7. BTI neither assumes nor authorizes any other person to assume for it any lia-
bility in connection with the sale of its products other than that specifically stated
herein.