VZ Owners Manual - 2008

an Astec company

VZ

HYD

RA

ULIC

BR

EA

KER

SOWNER’S MANUALOPERATION, SERVICE & PARTS

FOR MODELS VZ50 & VZ85

www.rockbreaker.com 3

SafetyBreaker Structure & Design

Principle of OperationVZ50 FeaturesVZ85 Features

Sizing the BreakerTypical Hydraulic Circuits

Hydraulic Breaker OperationTool Operation

Tool TroubleshootingMaintenance Schedules

LubricationRemoval & Storage

Hydraulic OilBreaker DisassemblyBreaker Reassembly

TroubleshootingSpecfi cations

Parts

CONTENTS

461014151619222627323536384759707580

VZ Series Hydraulic Breaker Owner’s Manual4

Danger, Warning, and Caution are harzard alerts used in this manual and on the breaker safety signs to identify hazards on or near the rockbreaker system.

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

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

Caution - Hazards or unsafe practices, which COULD result in product or property dam-age 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 specifi cally 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, mainte-nance or repair procedures you choose.

Avoid loose fi tting 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 carrier. Hard hats, protective glasses, protective shoes, gloves, refl ector type vests and ear protection are types of equipment that may be required.

Hazard Alerts:

SAFETY

HeadProtection

FootProtection

EyeProtection

HearingProtection


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Safety Precautions:

SAFETY

To avoid injury from fl ying 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 in 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.

Observe overhead obstructions and power lines etc, when slinging the breaker.

As the breaker is used the lower portion of the housing becomes worn. Used breaker housings are far more unstable than new housings and may not remain standing without being restrained.

Consult the “AEM Safety Manual” for additional operation safety tips and proce-dures for maintenance personnel.

Additional procedure specifi c warnings are located throughout this manual. Read this manual carefully to ensure that you can both operate and service your breaker safely.


Breaker Assembly:

BREAKER STRUCTURE & DESIGN

Nitrogen Cushion Chamber:Designed to absorb piston recoil and pro-vide energy to the impact blow.

Tie Rods:Four tie rods hold the front & rear head together; utilize protected threads which yield long life and high reliability.Control Valve:Simplicity of the valve’s design minimizes interruption of oil fl ow, reducing hydraulic pulsations.

Air Check Valve:Contamination is reduced by drawing clean air into the front head and expelling it to the lower tool bushing.

Piston:Large piston mass and supporting area provides for positive alignment, transfer-ring maximum energy and effi ciency to the tool.

Retainer Pins:Dual retainer pins ensure positive tool alignment and easy tool replacement.

Front Head / Mounting Plates:Deep sectioned front head and reinforced mounting plates work together to with-stand side loading, reduce tie rod prob-lems, and protect cylinder body and rear head.

Tool:Hardened, special alloy tool designed to balance the need for hardness and dura-bility, accommodating a wide range of applications.


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BTI hydraulic breakers represent state-of-the-art rock and aggregate breaking technology. The hydraulic breakers deliver rock-breaking power with minimal parts.

The main sections of a BTI breaker are; the front head, cylinder, rear head, and control valve.

Front Head:The Front Head contains the breaker tool, bush-ings, and retainer pins. By removing the retainer pins, the tool can be quickly changed.

Cylinder:The Cylinder contains the moving piston, which strikes the tool. The seals for both ends of the piston are located in the cylinder.

Rear Head: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 provides energy for the impact blow.

Control Valve:The Control Valve mounts to the cylinder and directs the fl ow of hydraulic oil and therefore the movement of the piston. The hydraulic oil inlet and outlet ports are located above the control valve.

Bare Breaker:



BTI hydraulic breakers represent state-of-the-art in rock and aggregate breaking. Our hydraulic breaker is a self-actuated hammer that delivers rock-breaking power with the minimum of parts.

The main sections of a BTI breaker are; the front head, cylinder, rear head, and control valve.

Bare Breaker:



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Bare Breaker - Exploded View:


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1) Piston Upward Movement:Pressurized oil enters cylinder chamber (1), pilot chamber (13), and control valve chamber (16), the high/low speed selector valve is pushed to the right (low speed condition) by low-pressure. The pressurized oil in pilot chamber (13) pushes the pilot valve to the right side.

The pressurized oil in control valve chamber (16) pushes the control valve spool down. The pressurized oil in cylinder chamber (1) lifts the piston up compressing gas in nitrogen chamber (6).

At this time the oil on the opposite side of the piston in cylinder chamber (5) fl ows out through the control valve chamber (15).

2) Pilot Valve ON:When the oil from the lower piston fl ange reaches cylinder chamber (3), pres-surized oil fl ows through the high/low speed selector valve chamber (7) working against pilot valve chamber (10). Once the pressurized oil activates pilot chamber (10), pilot chambers (10 & 13) equalize pressure and due to the surface area differ-ence, the pilot control valve spool is pushed to the left.

3) Pilot Valve ON:When the pilot valve spool is pushed to the left (due to the groove in the pilot valve) the pressurized oil working on pilot chamber (13) allows oil to pass through pilot chamber (12), activating the lower section of control valve chamber (14). When pressurized oil activates control valve chamber (14), chamber (14 & 16) equalize pressure (due to surface area difference) and the control valve spool moves up.

4) Piston Downward Movement:When the control valve spool moves up, the pressurized oil in control valve cham-ber (16) moves through the control valve into cylinder chamber (5) pushing the piston down. The piston’s push downward is assisted by the compressed gas in the nitrogen chamber (6).

PRINCIPLE OF OPERATION


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1) Piston Upward Movement:Pressurized oil enters cylinder chamber (1), pilot chamber (13), and control valve chamber (16), the high/low speed selector valve is pushed to the right (low speed condition) by low-pressure. The pressurized oil in pilot chamber (13) pushes the pilot valve to the right side.

The pressurized oil in control valve chamber (16) pushes the control valve spool down. The pressurized oil in cylinder chamber (1) lifts the piston up compressing gas in nitrogen chamber (6).

At this time the oil on the opposite side of the piston in cylinder chamber (5) fl ows out through the control valve chamber (15).

2) Pilot Valve ON:When the oil from the lower piston fl ange reaches cylinder chamber (3), pres-surized oil fl ows through the high/low speed selector valve chamber (7) working against pilot valve chamber (10). Once the pressurized oil activates pilot chamber (10), pilot chambers (10 & 13) equalize pressure and due to the surface area differ-ence, the pilot control valve spool is pushed to the left.

3) Pilot Valve ON:When the pilot valve spool is pushed to the left (due to the groove in the pilot valve) the pressurized oil working on pilot chamber (13) allows oil to pass through pilot chamber (12), activating the lower section of control valve chamber (14). When pressurized oil activates control valve chamber (14), chamber (14 & 16) equalize pressure (due to surface area difference) and the control valve spool moves up.

4) Piston Downward Movement:When the control valve spool moves up, the pressurized oil in control valve cham-ber (16) moves through the control valve into cylinder chamber (5) pushing the piston down. The piston’s push downward is assisted by the compressed gas in the nitrogen chamber (6).


The VZ series can be confi gured for anti-blank fi ring mode. During normal operation the blank-fi re port (1) stops high pressure oil moving to the upper diameter of the piston. As a result the piston moves up and down normally.

When a blank-fi re situation occurs (tool is too low for the piston to hit) the groove located in the large diameter of the piston connects to the blank-fi re blow port (1).

At this point, the high/low speed pilot lines (2) are activated and move the control valve spool up, and as a result allow high-pressure oil to the upper diameter of the piston. This keeps the piston down and it stops hitting the tool.

Anti-Blank Firing:



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The VZ series hydraulic breakers have a 2-speed (long stroke / short stroke) control port for connecting a high-pressure hose. However, on boom applications only the long stroke mode is used. Consult BTI for two-speed applications.

Long stroke / low speed: Using vertical or tank pressure from the remote operation hose (tank return line) the 2-speed valve moves to the right due to the back-pressure within the breaker. As a result the high-speed pilot line (2) will be blocked triggering the low-speed pilot line (1) allow-ing the piston to operate in long-stroke mode.

Short stroke / high speed:Using pressure from the remote operation hose (over 600 psi / 40 bar is needed) the speed valve is pushed left. This connects high-speed pilot line (2) and low-speed pilot line (1), triggering the high-speed pilot line (2). This allows the piston to work in the short-stroke mode (high-blow frequency).

High / Low Speed Selector Valve:


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VZ50 FEATURES


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VZ85 FEATURES

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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 demo-lition 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, productionrate slows down. To assess what size of breaker will effectively handle this application,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 manageablepieces. 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 that when trenching in limestone or mediumhard 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 benefi cial.

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 providebetter 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 fl oors 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. Thehigh production demand of bridge and building demolition requires a 7,500 - 10,000-ft.lbs. breaker.

Sizing the Breaker Based on Type of Work:

SIZING THE BREAKER

Small Breakers:

Medium Breakers:

Large Breakers:

Breaking Oversize Material:

Trenching:

Breaking Concrete:


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SIZING THE BREAKER

The breaker must be sized properly for both the work it will do and the carrier on whichit will be mounted.

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 fl ow willneed to be verifi ed to ensure a proper fi t.

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 fl ow range is specifi ed for each breaker (see chart on pages 59). Oil fl owto the breaker within this range is adequate for operation. However, for maximum pro-ductivity the carrier should be capable of providing the maximum required fl ow.Compare the maximum oil fl ow requirement of the breaker with the oil fl ow capacity ofthe carrier. Remember the breaker operates at 1400-2600-psi. therefore, oil fl ow shouldbe evaluated at operating pressure.

Sizing the Breaker Based on Carrier Size:

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Oil fl ow & Operating Pressure:


SIZING THE BREAKER


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To operate a Hydraulic Breaker you only need hydraulic fl ow 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 fl ow. The operating pressure willdepend on the amount of oil fl ow, the return line pressure, and internal effi ciency 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. In this case the auxil-iary control can be used to control the supply of oil. It can usually be adjusted to provide the correct amount of fl ow and a relief cartridge can be installed to protect the hydraulic circuit.

Notice when using the auxiliary control valve that oil is not routed back through the re-turn port on the valve. It is recommended to send the oil directly back to the cooler, fi lter, and tank. 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 re-turning oil, which is damaging to the hydraulic breakers.

For Hydraulic Breakers:

TYPICAL HYDRAULIC CIRCUITS

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Carrier With Auxiliary Circuit:


Note:Adjust the relief valve setting to ensure this pressure is at least 400 psi (28 bar) greater than the operating pressure of the attachment.

When setting the fl ow, connect a fl ow meter in place of the attachment. Measure the“No-Load” fl ow when activating the control valve. Then put a load on the circuit to simu-late the attachment working (refer to the operating pressure) and measure the fl ow atthis point. This is the fl ow that needs to be adjusted to the specifi ed oil fl ow for theattachment.

Continue to load the circuit until the fl ow 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 than one attachment will be used on this circuit with different fl ow requirements,you will need to measure the fl ow and note the adjustment in two locations.

Be sure to record this information on the BTI Warranty Card provided with each newattachment.

Boxed breaker housing require specifi c modifi cations for underwater applications. Please contact BTI for more information.

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 fi red, 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. Remove the check valve to plumb the line in. Start supplying air to the breakerbefore placing it underwater, and continue supplying air until the breaker is removedfrom the water. Continue to operate the breaker out of the water for approximately 10minutes, then grease the tool and front head with the tool pressed in.

Setting Flow & Pressure:


Setup for Underwater Applications:


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If the carrier is not equipped with an auxiliary control valve, you will need to install apriority fl ow control valve to direct the correct fl ow away from the normal circuit andoperate the attachment.

The priority fl ow control is usually equipped with a fl ow adjustment and pressure relief.These valves often need a check valve on the regulated port to completely close thefl ow. If dividing too much fl ow, this circuit will generate heat and will need coolingcapacity.

Carrier Without Auxiliary Circuit:


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Before operating the breaker you may need to warm the carrier’s hydraulic system.This cold starting technique is useful if the breaker has been in extended storage, or the am-bient temperature is below 20°F. Warming up the system to its operating temperature prevents breaker misfi ring.

First, cycle each boom function by extending and retracting each cylinder through its full stroke. Hold the valve open for 3 to 5 seconds at each end of the cylinder’s travel. Repeat this procedure until all boom functions operate smoothly.

Next, raise the breaker so the tool is not pressing onto any material and fi re the hammer - 5 seconds on, then 5 seconds off. Repeat for 3 to 5 minutes, depending on the ambient temperature.This is called ‘idle-fi ring’ and in this position the breaker does not normally run, but circulates warm system oil through the control valve to the tank. The piston may move up and down while idle-fi ring but should not hit the tool.

Finally, start breaking rock by operating the breaker in short 3-second bursts. Continue operating with short bursts until the carrier and breaker are at operating temperature.

Blank-fi ring emits a distinct metallic ringing and 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 into the front head, transferring the breaking force back through the breaker and excavator. This can cause premature failure of the breaker lower end.

To prevent blank-fi ring 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.

Note:Stationary Rockbreaker Systems should be equipped with immersion heaters.

Initial Startup & Cold Weather Starting:

HYDRAULIC BREAKER OPERATION

Danger of Blank-Firing:

Prevent Blank-Firing:


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Do not operate the breaker continuously for more than 20 seconds. Excessive heat will be generated and you may mushroom the end of the tool. If the rock or stone shows no sign of breaking within 20 seconds, change its position or that of the breaker.

The breaker should not be fi red when the carrier’s boom cylinders are fully extended or fully retracted. The cylinders may be damaged from the breaker’s shock pulses.

The BTI power pack provides the proper fl ow to the breaker. But be careful, excess fl ow 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. 70°C, stop breaking!

For large rocks start at the edge and work toward the center, breaking off small chunks each time. Breaking along the rock’s natural faults and seams also make for easier break-ing.

When breaking on a wall or steep incline use a combination of the carrier’s stick cylinder and tilt cylinder to provide the necessary force to hold the breaker against the material. Always work the tool 90°to the material being broken.

As you apply down-force to the breaker, the carrier will lift slightly giving you a clue that the breaker is properly pressed onto the material. Excessive down-force will not make breaking easier, in fact the carrier will be lifted too far off the ground and this can damage your equipment. Not enough down-force and the tool will bounce on the material, blank-fi ring.

Do not use the breaker to pry, pick, pound, or lift. This can cause serious damage to the breaker as the tool side loads or binds in the bushing. The tool must always move freely straight up and down in the bushing.

Breaker sideplates are designed to push and rake material for better positioning.

Suggestions for Effi cient Operation:


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Before trenching, you fi rst need to remove all overburden material, exposing the rock sur-face to be broken. To begin, penetrate the breaker tool deep into the material, splitting and loosening the rock. Repeat this penetration several times within a small area, excavating a hole. When excavating a deep trench it is more effective to use steps or benches al-lowing a place for the rock to break out to. Maintain the benches as the trench advances. The sides of the trench must be sloped to accommodate the width of the breaker. In other words, the larger the breaker and the deeper the trench, the wider the opening at the top will need to be.

For most situations the excavator will sit to the side of the trench allowing you to keep steeper slopes. However the carrier swing function may not have the strength to push bro-ken rock away from the work area. In some cases the excavator sits on top of the trench and the broken material can be back fi lled under the excavator.

For best performance, apply the down force in line with the tool, repositioning every 10 to 15 seconds or when no penetration is evident. Keep the breaker well greased at all times.

With practice you will learn to determine the best place to begin breaking by just looking at the rock. Position the tool on fl at areas of the rock, or look for a seam or crack, which may allow easier splitting. To fully absorb all the breakers energy, the rock must be rest-ing on a solid base.

Begin by penetrating the concrete several times in one area with the breaker tool. This should loosen the concrete and separate the reinforcing steel. This rebar may need to be cut, keeping the concrete pieces manageable for hauling away. When breaking concrete fl oors, use the down force from the carrier’s boom cylinder to follow the tool through the concrete. Breaking vertical walls is more diffi cult, 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 fl ow.

Generally when breaking concrete, a chisel point gives the best splitting action. However if you are breaking hard concrete with lots of rebar, a moil point may be better. The moil tip helps defl ect the tool off the steel as it breaks the concrete.

Trenching & Excavation:


Breaking Oversize Material:

Breaking Concrete:


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If the grizzly is covered with rock, use the breaker sideplates in the case of a TB “X” series or the reinforced rock claws and wear resistant wear plate of the box housing on a TB “XC”, the BT and VZ series to rake the material. This will get most of the fi ner mate-rial through the bars and let the larger pieces rest directly on the grizzly. Large pieces are easier to break if they rest directly against the grizzly bars. Then all the energy from the breaker is applied to the rock. Breaking is less effective with too much material under the rock, absorbing the energy.

If rocks are hanging on the edge of the bars, use short bursts of the breaker to hammer them through. Do not use boom force to push rock through, this can cause the front head to hit the grizzly bars damaging the breaker.

Breaking on a Grizzly:

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When the piston strikes the top of the tool, it sends a compressive stress wave down to the working end of the tool. If the tool is touching a rock, this energy/force (compressive stress wave) travels out the tool directly into the rock, fracturing it.

Immediately following the compressive stress wave, a tensile stress wave is formed, which travels back up the tool, ‘bouncing’ the piston up from the top of the tool. This cycle of compressive and tensile stresses following down the tool is repeated with each hammer blow.

Anything interfering with the strength of the fl ow of the compressive stress waves during operation such as blank-fi ring (“free-running”) or prying with the tool, can lower breaker effi ciency 80% and cause tool fatigue.

Blank-fi ring — fi ring the hammer without the tool pressing on a rock, ses the energy that normally travels out the tool into the rock, to mash the tool out the breaker body, stopped only by the retainer pins, which must absorb this force. This damages the retainer pins.

Principle of Operation - Breaker Tool

TOOL OPERATION


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Anything interfering with the fl ow of compressive and tensile stresses increase the level of fatigue stress applied to the tool and increases the risk to the tool of early fatigue fail-ure.

The main cause of increased tool fatigue stress is any side force during operation which creates bending. Using the tool to pry, using the incorrect working angle or attempting to break ground using the pull of the machine, are all detrimental and must be avoided.

The hydraulic power of a rockbreaker far exceeds the strength of a tool and used incor-rectly can “snap the tool like a twig.”

Blank-fi ring (“free running”): any situation where the hammer piston strikes the top of the tool, but the tool is not in proper contact with the material. This can happen when the tool slides off the work and also when breaking through thin concrete slabs or boulders.

Cold: low temperature makes the tool more susceptible to fatigue failure. Warm the tool fi rst with moderate or light breaking.

Mechanical and Thermal Damage: any type of damage to the tool surface makes it more likely to suffer fatigue failure. Care must be taken to: • Prevent scratches, gouges, weld marks. • Keep tool well lubricated to prevent dirt between the tool and tool bushings. • Operate properly and avoid excessive bending of the tool.

Poor Lubrication: metal to metal contact causes material pick up, which can scrape deep damage marks, developing into fatigue cracks, causing tool failure. Ensure the tool shank is well lubricated before inserting into the tool holder. Molybedenum disulphide (Chisel Paste) grease is recommended at 2 hour intervals (make sure tool is pushed up fully in-side the hammer).

Corrosion: keep tools well greased and sheltered from the weather when not in use. A rusty tool is more likely to suffer fatigue failure.

The polished semi-circular area is the fatigue area, spreading inwards from a damage mark or other stress event on the outside of the tool. The fatigue area spreads until the stresses applied will cause sudden tool failure.

Generally, the size of the fatigue area indicates the level of stress applied to the tool, i.e. the smaller the fatigue area, the higher the stress level, although, once a fatigue crack begins, it will grow with even less stress.

Cause & Effect of Fatigue:

TOOL TROUBLESHOOTING

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Other Causes of Increased Tool Fatigue Stress:



Typical Failures (guide to Warranty Claims): BTI tools are manufactured from top quality materials and heat treated to produce a fatigue and wear resistant tool.

When a tool fails to give satisfactory service life, a brief visual inspection usually reveals the cause.

A phenomenon which results in the sudden fracture of a component after a period of cy-clic loading in the elastic regime. Failure is the end result of a process involving the ini-tiation and growth of a crack, usually at the site of a stress concentration on the surface.

A tool metal “fatigue” failure generally occurs within 4” (100mm) above and below the face of the front head, or at the retainer pin fl at.

A less common failure area is about 8” (200mm) from the face of the front end, depend-ing on the nature of the breaking be done.

The fracture face itself normally appears as a semi-circular polished area with the remain-der looking uneven and rough.

The polished semi-circle is the fatigue area, originating from a damage mark or other stress event outside of the tool.

The fatigue area spreads slowly into the tool, until the stress causes sudden failure to the section. Generally, the size of the fatigue area indicates the level of stress applied to the tool, i.e. the smaller the fatigue area, the higher the stress level. Once a fatigue crack begins, it takes less stress to make it grow.

Metal Fatigue:


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Metal Fatigue:


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Tool Fatigue Failures:



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Warranty Policy:


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To keep your breaker in top operating condition, the following maintenance must be done. Keep in mind that lubrication is the single most important procedure for sustaining the life of a breaker. To make this chore easier, BTI offers lubrication systems, call for details.

Use proper grease! Always use BTI chisel paste or a moly-based grease. Never use GP (General Purpose) grease, it melts and runs down the tool providing very poor lubrication.

Grease Often! Failure to lubricate regularly reduces the life of the tool, tool bush-ings and front head.

MAINTENANCE SCHEDULE


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LUBRICATION

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Greasing The Breaker:

• Grease the breaker after every two hours of continuous use, or when the tool ap-pears shiny where it rides inside the front head.

• The breaker must be in a vertical position for greasing, with enough down-pres-sure to push the tool up into the breaker housing. This prevents excessive grease entering the impact chamber causing “cushioning” - with a loss of breaker power, or a hydraulic “lock” in the impact chamber - which stops the breaker.

• Grease until clean grease oozes out around the tool or retainer pins. Use only BTI Chisel Paste or a molybdenum disulphide (MoS2) based grease.

• Visually check the tool retainer pins when breaking.

The round retainer pins rotate during normal operation. To confi rm they are rotat-ing, look at the end of the pin for fresh radial marks on the cross pin’s grease.

The oval retainer pins should be removed and checked for wear. Swap pins from side to side and fl ip to ensure even wear every 100 hrs, or as Breaker’s Owner’s manual suggests.

Use proper grease! Always use BTI chisel paste or a moly-based grease. Never use GP (General Purpose) grease, it melts and runs down the tool providing very poor lubrication.

Grease Often! Failure to lubricate regularly reduces the life of the tool, tool bush-ings and front head.


At the end of the day if the breaker is not removed from the carrier, it should be left standing vertical. When removing and storing your breaker, follow one of these steps.

Storing your breaker up to a week is short term storage. This is how to store the breaker. If shut-off valves are used with the breaker, turn them to the OFF position. Disconnect the pressure and return lines. Plug the lines and the breaker ports to prevent contamination. Use your excavator to lay the breaker on wooden blocks with the breaker mounting end lying higher than the tool end. Support the breaker before proceeding. Remove the pins to disconnect the breaker from the boom. Remove the tool and ensure the retaining pins, bushings and piston bottom (inside break-er) are well greased. Reinstall the tool and cover the breaker with a tarp (waterproof if outdoors).

Storing the breaker over a week is long term storage. Use one of the following two proce-dures depending on whether you are standing the breaker up or laying it down.

Release the cushion chamber gas pressure. Remove the tool and liberally grease the piston bottom, retaining pins and inside the front head. Push the piston up inside the breaker and reinstall the tool.

Lay the breaker on wooden blocks (using your excavator). Breaker mounting end should lie higher than the tool end. Cover the breaker with a tarp (waterproof if outdoors).

Using Breaker The Next Day:

REMOVAL & STORAGE

Short Term Storage:

Long Term Storage:

Long Term Storage - Lying Down:


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REMOVAL & STORAGE

Breaker must be stored in a safety stand.

Allow the breaker’s weight to push the tool up into the breaker.

Push the piston up inside the breaker and reinstall the tool.

Release the cushion chamber gas pressure, the piston will not slide into the cylinder with a pressure over 114 psi (8 bar).

Long term storage may introduce air into the hydraulic circuit, if during operation this air suddenly compresses it may cause a malfunction. This air must be removed from the circuit. Circulating the oil will also remove other foreign substances from the system.

If the breaker was stored lying down, seals can deform. Follow these steps to circulate the hydraulic oil, and correct these problems.

With the breaker mounted and oil warmed to operating temperatures:

Lift the unit off the ground.

Press the Start button or pedal to fi re the breaker, momentarily.

Continue to turn the breaker ON and OFF in this manner for ten minutes.

Clean all fi ttings and hose ends before reconnecting the breaker to prevent contami-nating the breaker with dust or dirt.

Long Term Storage - Standing Up:

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Initial Start-Up After Long Term Storage:


Generally speaking, hydraulic oil intended for a stationary rockbreaker can be used in the hydraulic breaker. However, working with the hydraulic breaker will heat the oil much more than in excavation work, the viscosity of the oil must be checked regularly. (Vis-cosity is commonly perceived as “thickness”, or resistance to fl ow. Viscosity describes a fl uid’s internal resistance to fl ow and may be thought of as a measure of fl uid friction).

In continuous breaker operation, the temperature of the hydraulic oil stabilizes. This is dependent on ambient temperature, working conditions, and the rockbreaker. In this situa-tion the viscosity of the hydraulic oil must be 20 - 40 cSt (2.90-5.35°E).

The breaker must NOT be started if the oil viscosity is above 860 cSt (114° E), or operated when the oil viscosity is below 15 cSt (2.35°E).

To ensure correct oil viscosity, it is recommended different hydraulic oils be used in summer and winter if there is an average temperature difference of more than 35°C (95°F).

HYDRAULIC OIL


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Petro Canada HVI 36 Hydraulic Oil or equivalent.

This is a multigrade hydraulic oil which gives very good low temperature performance, while also improving lubrication of hydraulic components at high operating temperatures.

Refer to the following page for the hydraulic oil table and other oil brands.

Recommended Hydraulic Oil for BTI Booms & Breakers

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The following hydraulic oils are recommended for BTI Breakers. A mineral based hy-draulic or motor oil meeting the SE quality requirements in API classifi cation should be used. Hydraulic oil intended for an excavator or front-end loader can be used in the Breaker.

The most suitable oil is selected such that the temperature of the oil (after continuous use) is in the Ideal Operating Temperature Range shown on the chart on the following page. This is when the hydraulic system is used to best advantage. In continuous opera-tion, the oil temperature will stabilize - at this temperature the viscosity of the hydraulic oil must be 17 - 40 cSt (2.90 - 5.35°E).

See the chart: Recommended Hydraulic Oils, for suitable breaker oil. Select an oil such that the temperature of the oil - in continuous use - falls within the chart’s shaded area.

HYDRAULIC OIL


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For optimum effi ciency and service life we recommend the operating viscosity (oil at operating temperature) be selected in the range V opt = opt. Operating viscosity 16 . . . 45 mm2/s refers to tank temperature (open loop circuit).

The following values are valid for extreme operating conditions:• Vmin = 15mm2/s for short periods at max. leakage oil temp. of 90°C• Vmax = 800 mm2/s for short periods upon cold start.• Temperature range: t min = +20°C t max = +70°C (see chart)

For correct selection of the fl uid it is assumed the operating temperature in the tank is known in relation to the ambient temperature.

The fl uid should be selected within the optimum range Vopt (shaded area of chart) - we recommend you choose the higher viscosity grade in each case.

Example: at an ambient temperature of X°C the operating temperature in the tank will be 60°C. In the optimum operating viscosity range (Vopt; shaded section) this corresponds to viscosity grade VG 46 or VG 68. You should select VG 68.

Important: the leakage oil temperature is infl uenced by pressure and speed and is al-ways higher than the tank temperature. The Breaker can stop working at temperatures over70°C.

Note: in cold climates an Immersion Heater is recommended.Contact BTI if you cannot comply with the above recommendations because of extreme operating conditions or high ambient temperatures.

HYDRAULIC OIL

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It is benefi cial for the tank return line to pass through a fi lter. This ensures dirt introduced into the system by connecting and disconnecting the hammer is caught before entering the rockbreaker’s pump. Dirt destroys a hydraulic system, so ensure the hammer connec-tions are protected when the breaker is not in use.

Due to fl ow restrictions quick disconnects are not recommended - if the couplings fail, metal particles can cause internal damage in the breaker.

Oil fi lters remove impurities from the hydraulic, dirt causes accelerated component wear, blockages and seizing. Impurities also heat and age the hydraulic oil.

Air and water are also impurities in oil (not all impurities can be seen with the naked eye).

• during hydraulic oil changes and refi lling• when the breaker is being installed on the stationary rockbreaker• when components are repaired or serviced

1) Working life of pumps is signifi cantly shortened. • there is rapid wear of parts • cavitation

2) Valves do not function properly. • spools bind • accelerated wear of parts • blocking of small holes

3) Rapidly accelerated wear on cylinders and gaskets.

4) Reduced breaker effi ciency • accelerated wear of moving parts and seals • piston seizing up • oil leakage

5) Shortened working life & reduced effi ciency of hydraulic oil • oil overheats • oil ages • electro-chemical changes in hydraulic oil

Component damage is only a symptom. The trouble itself cannot be cured by remov-ing the symptom. After any component damage, the entire hydraulic system must be cleaned.

Hydraulic Oil Purity:

HYDRAULIC OIL

Impurities Can Enter the Hydraulic System:

Results of Damage by Hdraulic Oil Impurity:


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The maximum permitted hydraulic oil temperature in continuous breaker use is 120°-175°F (50°-80°C), depending on the viscosity of the oil in the system. It is essential the rockbreaker has a reliable hydraulic oil thermometer installed. The temperature of the hydraulic oil will depend upon ambient conditions, effi ciency of the rockbreaker’s cool-ing system, and the amount of breaker use.

In continuous breaking it is necessary to have a cooling system with a rated cooling ca-pacity of 5-8 kW more than is needed in rockbreaker work.

If the breaker’s return line is fed through the rockbreaker’s cooler, back pressure must not exceed 300 psi (20 bar) at full volume fl ow. The cooler must withstand a dynamic pres-sure of at least 300 psi (20 bar).

The hydraulic breaker must NEVER be used when the hydraulic oil viscosity is lower than 15° cSt.

Prior to project design, please review our catalogue sheets RE90220 (mineral oils) and RE 90221 (environmentally compatible fl uids) for detailed information on the selection of hydraulic fl uids and application conditions. When using environmentally compatible fl uids certain limitations may apply. Please consult BTI.

The following values are valid for extreme operating conditions; Vmin = 10mm2/s (for short periods at max. leakage oil temperature of 90C. Vmax = 1000 mm2/s (for short periods upon cold start).

tmin= -25°C tmax = +90°C

For correct selection of the fl uid it is assumed that the operating temperature in the tank is known (open circuits), in relation to the ambient temperature.

The hydraulic fl uid should be selected so that, within the operating temperature range, the operating viscosity lies within the optimum range Vopt (see shaded section of selection diagram). We recommend that the higher viscosity grade is selected in each case.

Hydraulic Oil Cooling:

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Hydraulic Fluid:

Limits of Viscosity Range:

Temperature Range:

Selecting Hydraulic Fluid:


Viscosity Conversion Chart:

HYDRAULIC OIL


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BTI breakers are built using the highest quality materials and workmanship to ensurelong life and maximum effi ciency. 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 fi rst. 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 effi cient 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 tool kit.

Always take proper safety precautions. You must wear safety glasses, work gloves, and safety shoes. Use of a safety stand is recommended. Before servicing the breaker review this technical manual and read all decals. Before lifting the breaker, refer to specifi cations section of this manual for the approximate working weight of the breaker.

SERVICE


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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” in the specifi cation section of this manuals 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. Oval tool retainers should be exam-ined for wear along the edge of the retainer that rests against the tool.

Removing the Tool:

BREAKER DISASSEMBLY

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WearWidth

Drift

Retainer Pin

Stopper Plug

Tool Retainer


Install lifting eyes to the top of the bare breaker on the nitrogen chamber. Lifting eyesizes and specifi cations are listed in the chart above.

BTI Hydraulic Breakers and their components are heavy! Plan carefully how youwill handle them when removing, disassembling, or installing the breaker. Standclear when slinging the breaker off the ground.

Using a crane of suitable lift capacity with safety locks on the lifting hooks lift thebreaker up until the bottom of the breaker is well above the housing fl ange. Refer to thechart above for breaker and component weights.

Position the bare breaker in a safe area outside of the immediate working area of thebox housing and restrain the breaker to a suitable structure to prevent possible tippingof the breaker and possible injury.

Lay the breaker on its back (control valve face up) for safety.Lay the box housing on its back on top of suitable stands about 3 feet high with theaccess ports for the control valve facing upwards. This makes for easy access to the bot-tom shims and wear pads.

Removing the Breaker:

BREAKER DISASSEMBLY


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Remove blue nylon wear pads and brass shims from the inside of the breaker housing besure to mark the location of the pads and shims as the same shims could go back in thesame spot at reassembly if in good condition.

Inspect the nylon wear pads for heat damage, wear, warping, cracking etc. If the padsare in poor condition they must be replaced.

Check the thickness of the wear pads:Wear pads with an original thickness of 1.000” should be no less than 0.925” thick.Wear pads with an original thickness of 0.750” should be no less than 0.675” thick.

If the pads are below the minimum thickness they either must be replaced or reshimmed. Refer to the chart below for wear pad minimum thicknesses.

Front and back pads wear more quickly than the side pads. Not all pads may have tobe replaced at the same time. Seven of the eight pads can be re-positioned into differentholes. This can be done at reassembly to prolong wear pad usage.

NOTE:Nylon wear pads should last 1000 to 2000 hours during normal operation. Pads are considered a wear item and are NOT covered under the Breaker Warranty for ex-cessive wear. It is recommended that the pads be replaced after every 1500 hours of operation or as required.

BREAKER DISASSEMBLY

Removing & Inspecting the Wear Pads:

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Remove the lower isolator from the box housing.

Inspect the lower isolator for heat damage, wear, cracking, compression etc. If the isola-tor is in poor condition it must be replaced.

Check the lower isolator height. If the isolator is below it’s minimum height it hasbecome permanently deformed and must be replaced. Refer to the chart below for isolatorminimum height specifi cations.

NOTE:The upper and lower isolators are considered a wear parts and are not covered un-der the Breaker Warranty for life. It is recommended that the isolators be replaced after every 800 hours of operation or as required.

Clean inside of the housing and the bare breaker. Inspect for weld cracks, damage etc. both inside and outside. Repair as required.

Inspect fronthead area of the bare breaker. If there is excessive wear at the location of the side wear pads reshiming of the breaker may be required.

Clean and inspect shims.

NOTE:Remember to mark the location of each shim set for each pocket as they arematched at the factory.

Removing & Inspecting the Lower Isolator:

BREAKER DISASSEMBLY

Inspecting the Housing & Bare Breaker:


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While the breaker is securely held, remove the control valve. Use only hand tools toloosen the tie rod nuts and control valve bolts, since they thread into special hardened-steel inserts that can be damaged by impact tools. The recommended methods for loosen-ing the nuts and bolts are the sledge wrench method and the torque multiplier method.

Remove the control valve bolts and lock washers and lift the control valve from the cylin-der. Place the control valve on clean protective material.

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 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.

Removing the Control Valve:

BREAKER DISASSEMBLY

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Removing the Rear Head from the Cylinder:

Cylinder Cover

Tie Rod NutTie Rod Washer


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 pis-ton.

Place the piston on a clean protective surface.

Removing the Piston:

BREAKER DISASSEMBLY

PistonUpper Seal Bushing


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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 fromrotating.

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 fl ats 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 cyl-inder 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 to avoidaccidental damage during bushing replacement. Put it in a safe place for reuse later.

Removing the Cylinder & Tie Rods:

BREAKER DISASSEMBLY

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Cylinder

Removing Front Head Grease Fitting & Air Valve:


Do not gouge out the bushings with a torch.

The tool bushings are held in position by four retainer pins. Remove these pins by drivingthem 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 fi rst, 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 Bushing:

BREAKER DISASSEMBLY


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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 fi t, 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 fi tted together. If the bushings are not installed properlybefore 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 300oF, (150oC). 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.

Installing the Tool Bushing

BREAKER DISASSEMBLY

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Cylinder Cover



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.

Inspecting the Seal Bushing:

BREAKER DISASSEMBLY


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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 fi neemery 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 at the end 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.

Inspecting the Piston:

BREAKER DISASSEMBLY

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Thoroughly clean the cylinder bore, and remove the dust seal, oil seal, and slide ring.Check the seals for signs of excessive wear conditions.

Thoroughly inspect the inside walls of the cylinder for corrosion, cavitation, or scoring.Check grooves above seal area for small pieces of metal, due to galling. If these are notcleaned out they will chip off and go between the piston and cylinder, and galling willoccur again.

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.

The control valve controls the fl ow 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 controlvalve.

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.

Inspecting the Cylinder:

BREAKER DISASSEMBLY

Disassembling the Control Valve:


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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 afi ne oilstone or fi ne 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 fi ne 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 specifi ed in the service manual for the model ofbreaker you are servicing.

Protect the control valve assembly from dirt and set it aside

Inspecting the Control Valve:

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Reassembling the Control Valve:


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 suffi ciently, clean and inspect the previously removedgrease fi tting 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.

Inspect the tie rod threads. If they are damaged beyond repair, the tie rodsmust 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 specifi cations shown in the chart in the Specifi cations section of this manual.

Inspecting the Gas Valve:

BREAKER REASSEMBLY

Installing the Front Head Grease Fitting & Air Valve:

Installing the Tie Rods:


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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 easily.Lower the cylinder carefully onto the tie rods. The control valve mounting holes onthe cylinder should face the same direction as the grease fi tting on the front head.

Oil the seal bushing and seals, and install the seals and rings in the correct positions andorientations.

Installing the Cylinder:

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Re-Sealing the Seal Bushing:


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 centerof 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 supportfl ange inside the cylinder bore.

Replace the o-rings and backup rings on the top of the cylinder where the rear headmakes contact.

Installing the Piston:

BREAKER REASSEMBLY

PistonUpper Seal Bushing


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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 piston,just high enough to contain the required amount of oil. The amount of oil neededcan be obtained from the chart in the Specifi cations section of this manual.

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 tie rod washers. Lubricate the tie rod nuts with Never Seize, and tighten them ina crossing pattern to draw the breaker components together evenly. Finish tightening thenuts to the correct torque in four stages, using the same crossing pattern.

Installing the Rear Head:

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1 4

3 2

Cylinder Cover



Lightly grease the control valve o-rings and backup ring and install them in the undersideof 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. See torque specifi cations on thecharts at the end of this manual.

Installing the Control Valve:

BREAKER REASSEMBLY


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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 specifi ed 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 fi nal 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 chart below), 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.

Recharging the Cushion Chamber:

BREAKER REASSEMBLY

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Use core solder .025” thick and about 1.5” long ,make it a horseshoe shape fi rst thentwisting it lightly three turns so it looks like this --> XO (See image on left).

Then tape four of these to each pad about 2” in from each corner with selotape this willbe your measurement point after they have been compressed.

Do this behind only two top and the two at the bottom on the same sides. Record ondata sheet the wear pad width for easy reference later for the correct shims.

Using small pieces of lead solder place 6 small pieces of solder on the corner and longsides of the wear pads.

Place the wear pads into the housing. Use wood screws to secure the wear pads.

Lower the breaker into the housing.

Remove the breaker.

Remove the wear pads using a micrometer accurate to .001” measure the compressedthickness of the lead pieces. The average thickness of these pieces (per pocket) will bethe thickness of the shim required for that pocket.

Peel off the shim stock to the desired thickness and place into the corresponding pockets.Place the nylon wear pads over the shim stock and secure using wood screws.

NOTE:The wear pads and shim stock can be held in place using small screws. The screwscan be put through the existing holes in the box housing.

Shimming the Breaker:

BREAKER REASSEMBLY


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Place the nylon wear pads over the shim stock.

NOTE:The wear pads and shim stock can be held in place using small screws. The screwscan be put through the existing holes in the box housing.

Place the lower isolator into the bottom of the box housing.

Using the lifting eyes supplied in the breaker tool box fastened into the threaded connec-tions in the top breaker.

Lift the breaker above the box housing, center it for entry into the housings.

Do NOT grease the wear pads and / or bare breaker for easy insertion.NOTE:If the hammer is new, all protruding parts must be ground fl ush with the hammersurface to allow passage past the wear pads to enter the box housing.

Slowly lower the breaker into the housing. The breaker should slide on the wear padsunder its own weight. If the breaker binds or seizes in the housing remove the breakerand check the cross sectional dimensions again. Ensure the lower isolator remains cen-tered. Repeat the procedure for a close slide fi t.

Installing the Bare Breaker:

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Ensure that the breaker has fully bottomed out in the housing. This is done by looking at the position of the retaining pins -vs- the clearance holes in the bottom of the breaker.The retaining pins should be just above the centerline of the clearance holes in the housing.

Using a leverage bar check for play between the breaker and housing. The breaker should have no vis-ible movement. If movement in excess of .080” in any direction (measured by changes in the gap between the nitrogen chamber of the bare breaker and inside of thehousing) remove the breaker and add additional shims to obtain the correct play.

Install remote grease hose inside breaker (if required). Ensure the hose is slack to accommodate the vertical breaker movement during the recoil. Position upper isolator interface plate on to nitrogen chamber.

Check for correct orientation of the clearance slot for the gas valve.

Position the upper isolator inside the bowl of the up-per isolator plate.

Check the distance that the upper isolator is above the fi nished face of the fl ange.

For new isolators the distance is .200” to .300”.

BREAKER REASSEMBLY


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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 thefront head.

Grease and insert the tool retainers and then grease and insert the retainer pins and stop-per plug. The stopper plug should be fl ush with the front head.

If storing your breaker for an extended period of time, refer to “Removal & Storage”.

Installing the Tool:

BREAKER REASSEMBLY

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Oil Leakage:

TROUBLESHOOTING GUIDE


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Gas Leakage:



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TROUBLESHOOTING


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VZ50 Torque Specifi cations:

SPECIFICATIONS


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VZ85 Torque Specifi cations:

SPECIFICATIONS


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VZ50 PARTS


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VZ50 PARTS


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VZ50 PARTS


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VZ85 PARTS


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VZ85 PARTS


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VZ85 PARTS


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VZ85 PARTS


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VZ85 PARTS

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an Astec company

RIVERSIDE FACILITY

3453 Durahart StreetRIVERSIDE, CALIFORNIA

92507 U.S.A.Phone: (951) 369-0878

Fax: (915) 369-8281

SOLON FACILITY

30625 Solon Industrial DriveSOLON, OHIO44139 U.S.A.

Phone: (440) 542-3720Fax: (440) 542-3721

THORNBURY FACILITY

35 Elgin StreetTHORNBURY, ONTARIO

N0H 2P0 CanadaPhone: (519) 599-2015

Fax: (519) 599-6803

Documents

VZ Owners Manual - 2008