Hydraulic Breaker Owner's Manual - Louvil
Hydraulic Breaker Owner’s Manual BXR SERIES Operation and Parts BXR50, BXR65, BXR85, BXR100, BXR120, BXR160 150-2086
BXR SERIES Introduction To our customer 1 Introduction To our customer Thank you for purchasing a Breaker Technology (BTI) product for your application. At BTI, we pride ourselves in the equipment we manufacture and distribute. BTI has led the way providing equipment and services for construction, aggregate and mining industries for over 50 years. Technology plays a critical role in the company’s continued success. BTI enjoys a reputation for engineering products with the most advanced technologies, yet the resulting systems are remarkably easy to use. At BTI we believe our product is the industry standard, without exception. Meticulous care has been taken to ensure that this product will meet rigorous product requirements. Using up-to-date CAD modelling software, complemented with finite element analysis, you can be satisfied that our product will meet and exceed your prerequisites. BTI has successfully registered our Thornbury facilities as ISO 9001:2008 compliant and to ISO 14001:2004, which is an internationally recognized environmental management system. As always, BTI is committed to continuous improvements translated into positive action. We feel fortunate to say that our team consists of seasoned, long-term, dedicated employees. They are able to respond quickly from our strategically located sales and service locations to any questions you may have. Canada & International Phone (519) 599-2015 (866) BTI-PART [284-7278] Fax: (519) 599-6803 35 Elgin Street P.O. Box 130 Thornbury, Ontario, Canada N0H 2P0 Western USA & Mexico www.rockbreaker.com Phone (951) 369-0878 Fax: (951) 369-8281 3453 Durahart Street Riverside, CA 92507 Eastern USA Phone (440) 248-7168 Fax: (440) 248-8645 30625 Solon Industrial Parkway Solon, OH 44139 HYDRAULIC BREAKER OWNER’S MANUAL P/N 150-2086 Document P/N 150-2086 BREAKER TECHNOLOGY Rev 3 01/2013
2 BXR SERIES Introduction Foreword Foreword This book is intended as a guide to the use and maintenance of the BTI BXR Series Hydraulic Breakers. Keep it with the operator at all times. Replace it immediately if it becomes lost. The design of the BXR Series of Hydraulic Breakers produces stable highspeed percussion, and exceptional value and durability for all construction, demolition, and rock breaking requirements. BTI BXR Series Hydraulic Breakers use sophisticated technology to produce a simple design. Field-proven and customer-sanctioned BTI breakers are enthusiastically accepted as the standard for the industries they serve. Some typical applications are: Construction Demolition Recycling Mining Quarrying Trenching Tunneling 10595 BREAKER TECHNOLOGY P/N 150-2086 HYDRAULIC BREAKER OWNER’S MANUAL
BXR SERIES Introduction Contents 3 Contents Introduction . 1 To our customer. 1 Foreword . 2 General Information . 7 Product Serial Number. 7 Structure and Design . 8 Bare Breaker Exploded View . 9 Features and Benefits .10 Simplified Principle of Operation .12 (A) Piston Upward Movement .12 (B) Activating Pilot Valve On .12 (C) Pilot Valve ON .12 (D) Piston Downward Movement – Impact .13 (E) Piston Upward Movement.13 (F) Pilot Valve OFF .13 Main Control Valve OFF .14 Oil Regeneration System .14 How the Tool Breaks Rock .14 Contact–Initial Compression Stress Wave.14 Recoil–Reflected Stress Wave .14 Blank-firing .15 Anti-blank Firing .15 High/low Speed Selector Valve .16 Start-up .39 Typical hydraulic Circuits.39 Carrier with Auxiliary Hydraulic Circuit .39 Carrier without Auxiliary Hydraulic Circuit .40 Operation . 41 Suggestions for Efficient Operation .41 End of Shift .42 Improper Use of Breaker.42 Blank Firing.43 Breaking Oversize Material .44 Trenching and Excavation.44 Breaking Concrete .44 Breaking on a Grizzly .45 Guide to Tool Choice .45 Underwater Operation.46 Preparations for Underwater Operation.46 Air Pressure for Underwater Operation .47 Operating the Breaker Underwater.47 Cold Weather Operation .48 Cold Weather Starting .48 Hydraulic System Warm-up Procedure .48 Breaker Warm-up Procedure.48 Grease for Cold Weather Operation .49 Long stroke / Slow speed (factory setting) .16 Short stroke / High speed (requires oil supply) .16 High/Low Speed Selector Valve .49 Sizing the Hydraulic Breaker .17 Maintenance . 51 Based on Carrier Weight .17 Based on Material Type and Hardness .18 Based on the Type of Work .18 Breaker Production Rates.19 Recommended Hydraulic Oils.20 Other Hydraulic Oils.21 Arctic Grade Oils .23 Oil is Too Thick or Too Thin.24 Hydraulic Oil Purity .24 Hydraulic Oil Cooling.25 Locking the Valve in High or Low Speed Mode .49 Greasing the Breaker .51 Automatic Greasing Systems .51 General .51 Comparison of Automatic Lubrication Systems to Manual Lubrication .52 Changing the Breaker Tool .52 Safety Rules. 27 Tool and Front Tool Bushing Clearance.52 Permissible Nominal Minimum and Maximum Diameters for Wear Bushings and Breaker Tool .53 Tool Removal .53 Tool Installation .54 Signal Words .27 Cushion Chamber Gas Pressure – Checking .54 Cushion Chamber Gas Pressure – Adjusting .56 Safety Alert Symbol .27 General Safety Precautions .28 Practice Safe Maintenance .28 Precautions for Working on Hydraulic Systems .29 Precautions for Handling Hydraulic Oil.30 Work Site Precautions .30 Fire Prevention .31 Welding and Grinding Work .31 Work on Painted Surfaces .32 Rubber and Plastics .32 Hazard Alerts .32 Transporting Safety Precautions .36 Installation . 37 General.37 Mounting the Breaker .38 Setting Flow and Pressure .38 Setting the Flow .38 Setting the Relief pressure .38 HYDRAULIC BREAKER OWNER’S MANUAL P/N 150-2086 Increasing the Pressure.56 Decreasing the Pressure .56 Removing the Gauge and Hose.56 Accumulator Gas Pressure – Checking.57 Accumulator Gas Pressure – Adjusting .58 Increasing the Pressure.58 Decreasing the Pressure .58 Removing the Gauge and Hose.58 Nitrogen Charging Pressure versus Ambient Temperature .59 Maintenance Schedule .60 Pre Shift .60 Every 2 Hours.60 Every 8 Hours – Daily .60 Every 50 Hours – Weekly .60 Every 100 Hours.61 Every 500 Hours.61 Every 1000 Hours or Yearly .61 BREAKER TECHNOLOGY
4 BXR SERIES Introduction Contents Service . 63 Model BXR65 . 106 BXR65 Mounting Plate . 107 Safety Warnings .63 Breaker Disassembly .64 Model BXR85 . 108 Breaker Body Disassembly.67 Model BXR100 . 110 Removing Breaker Body from Housing .65 Rear head Removal .67 Accumulator Removal .68 Diaphragm Replacement .68 Accumulator Assembly .69 Control Valve Removal and Disassembly .69 Control Valve Inspection .70 Control Valve Assembly .71 Piston Removal .72 Cylinder Removal .73 Cylinder Inspection .73 Cylinder Clean-up .74 Maximum Clearances Between Cylinder and Piston .75 Seal Bushing Inspection .76 Tool Bushing Removal.76 Breaker Body Assembly .77 Tool Bushing Installation .77 Tie Rod Installation .78 Cylinder Installation .79 Seal Bushing – Re-sealing .79 Piston Installation .80 Inspect Gas and Air Valve .80 Control Valve Installation .81 Accumulator Installation .81 Charging the Accumulator .82 Installing the Rear head.83 Charging the Cushion Chamber.84 Breaker Assembly.84 Nylon Support Pads .85 Determining Shims Required .85 Upper and lower Isolator Limits .87 Installing the Breaker Body Into the Housing.88 Start-up.90 Troubleshooting Guide . 91 Oil Leakage .91 Hydraulic Breaker .92 Breaker Tool .97 Normal Breaker Tool Wear.97 Breaker Tool Fatigue Failures .97 Cause and Effect of Fatigue .98 Other Causes of Increased Tool fatigue Stress .98 Area of Typical Tool Failures .99 Guide to Warranty Claims .99 Mushrooming. 100 Steel Defect Failure . 100 Removal and Storage . 101 Short-term Storage . 101 Long-term Storage . 101 Breaker Stored Lying Down. 101 Initial Start-up after Storage . 102 BXR85 Mounting Plate . 109 BXR100 Mounting Plate. 111 Model BXR120 . 112 BXR120 Mounting Plate. 113 Model BXR160 . 114 BXR160 Mounting Plate. 115 Torque Specifications . 116 BXR50 . 116 BXR65 . 118 BXR85 . 120 BXR100 . 122 BXR120 . 124 BXR160 . 126 Breaker Parts. 129 BXR50 . 129 Main Breaker Assembly . 129 Bare Breaker . 130 Control Valve. 132 Accumulator Assembly . 133 Master Seal Kit. 134 Control Valve Seal Kit . 135 Internal Seal Kit . 136 Accumulator Seal Kit. 137 BXR65 . 139 Main Breaker Assembly . 139 Bare Breaker . 140 Control Valve. 142 Accumulator Assembly . 143 Master Seal Kit. 144 Control Valve Seal Kit . 145 Internal Seal Kit . 146 Accumulator Seal Kit. 147 BXR85 . 149 Main Breaker Assembly . 149 Bare Breaker . 150 Control Valve. 152 Accumulator Assembly . 153 Master Seal Kit. 154 Control Valve Seal Kit . 156 Internal Seal Kit . 157 Accumulator Seal Kit. 159 BXR100 . 161 Main Breaker Assembly . 161 Bare Breaker . 162 Control Valve. 164 Accumulator Assembly . 165 Master Seal Kit. 166 Control Valve Seal Kit . 168 Internal Seal Kit . 169 Accumulator Seal Kit. 171 Breaker Stored Standing Up . 102 Specifications . 104 Model BXR50 . 104 BXR50 Mounting Plate . 105 BREAKER TECHNOLOGY P/N 150-2086 HYDRAULIC BREAKER OWNER’S MANUAL
BXR SERIES Introduction Contents 5 BXR120 . 173 Main Breaker Assembly . 173 Bare Breaker . 174 Control Valve. 176 Accumulator Assembly . 177 Master Seal Kit. 178 Control Valve Seal Kit . 179 Internal Seal Kit . 180 Accumulator Seal Kit. 181 BXR160 . 183 Main Breaker Assembly . 183 Bare Breaker . 184 Control Valve. 186 Accumulator Assembly . 187 Master Seal Kit. 188 Control Valve Seal Kit . 189 Internal Seal Kit . 190 Accumulator Seal Kit. 191 Stroke Adjuster Assembly . 192 Air Valve Assembly. 193 Regeneration Valve . 194 BXR Auto-Lube System . 196 BXR50 Auto Grease System . 198 BXR65 Auto Grease System . 199 BXR85 Auto Grease System . 200 BXR100 Auto Grease System. 201 BXR120 Auto Grease System. 202 BXR160 Auto Grease System. 203 Warranty . 205 Hydraulic Breaker Warranty Policy . 205 Reference Information . 206 Hardness of Rock . 206 Viscosity Conversion Table. 207 Fluid Grade Systems. 208 Box Housing Measurement Data Sheet . 209 Service Report . 210 Receiving Inspection Report. 211 Delivery Report . 212 Conversion factors . 213 HYDRAULIC BREAKER OWNER’S MANUAL P/N 150-2086 BREAKER TECHNOLOGY
6 BXR SERIES NOTES BREAKER TECHNOLOGY P/N 150-2086 HYDRAULIC BREAKER OWNER’S MANUAL
BXR SERIES General Information Product Serial Number 7 General Information Product Serial Number Always state the product serial number (S.N.) in any correspondence with BTI or any authorized customer service center. The Master Serial Number for the breaker and the body are stamped at the top of the cylinder body. There are other serial numbers for major parts stamped on different parts of the breaker. This may not be the same as the master serial number for the cylinder and breaker. 1) Master Breaker / Cylinder Serial Number 2) Rear Head Serial Number 3) Breaker Model Number 4) Valve Chest Serial Number 5) Front Head Serial Number HYDRAULIC BREAKER OWNER’S MANUAL P/N 150-2086 BREAKER TECHNOLOGY
8 BXR SERIES General Information Structure and Design Structure and Design The BXR hydraulic breaker represents the state of the art in rock breaking technology. The BTI hydraulic breaker delivers rock-breaking power with the minimum of parts. Four tie rods are assembled to hold the cylinder and rear head together with the front head. A control valve is assembled to the cylinder and regulates piston movement. The cylinder contains a moving piston that strikes the tool. Retainer pins inside the front head prevent the tool from coming out. BREAKER TECHNOLOGY P/N 150-2086 HYDRAULIC BREAKER OWNER’S MANUAL
BXR SERIES General Information Structure and Design 9 Bare Breaker Exploded View NOTE: Drawing is intended as a reference only. Consult Parts Section of this manual for information on a specific model. HYDRAULIC BREAKER OWNER’S MANUAL P/N 150-2086 BREAKER TECHNOLOGY
10 BXR SERIES General Information Features and
BREAKER TECHNOLOGY P/N 150-2086 HYDRAULIC BREAKER OWNER'S MANUAL BXR SERIES 10595 Foreword This book is intended as a guide to the use and maintenance of the BTI BXR Series Hydraulic Breakers. Keep it with the operator at all times. Replace it immediately if it becomes lost. The design of the BXR Series of Hydraulic Breakers produces stable high-
HYDRAULIC BOTTLE JACKS 1 HYDRAULIC BOTTLE JACKS K12150 - 1850kg Hydraulic Bottle Jack K12151 - 4000kg Hydraulic Bottle Jack K12152 - 6000kg Hydraulic Bottle Jack K12153 - 10000kg Hydraulic Bottle Jack K12157 - 20000kg Hydraulic Bottle Jack K12158 - 10000kg Hydraulic Bottle Jack K12159 - 20000kg Hydraulic Bottle Jack ED1 / JUNE 19 Distributed by Kincrome Tools and Equipment www.kincrome.com.au
F9 Qt Hydraulic Breaker assembled in low noise case w/ bolt-on cap l Fx125 TLB Hydraulic breaker with full length protective side plates ll Fx125 Qtv Hydraulic breaker assembled in low noise case w/ bolt-on cap Notes: 1) All Hydraulic Breakers are shipped with choice of standard working steel (Moil / Chisel / Blunt), two hose whips, standard
15 amp time-delay fuse or breaker 20 amp time-delay fuse or breaker 25 amp time-delay fuse or breaker 15 amp time-delay fuse or breaker 20 amp time-delay fuse or breaker 25 amp time-delay fuse or breaker Units connected through sub-base do not require an LCDI or AFCI device since they are not considered to be line-cord-connected.
Circuit-breaker with RHE RHD Circuit-breaker with HTC Circuit-breaker with LTC Circuit-breaker with FLD A IP 40 IP 20 IP 40 IP 40 IP 40 IP 40 B IP 20 IP 20 IP 20 IP 40 IP 30 IP 20 (1) During installation of the electrical accessories Weights A1 [Kg] A2 [Kg] A3 [Kg] Circuit-breaker 1 pole 0.245 0.37 - Circuit-breaker 2 poles 0.47 0.73 - Circuit .
electronic trip circuit breaker A circuit breaker which uses current sensors and electronic circuitry to sense, measure and respond to current levels. fixed-mounted circuit breaker A circuit breaker so mounted that it cannot be removed without removing primary and sometimes secondary connections and/or mounting supports.
Student Manual Circuit Breaker Cubicle USNRC 4-1 Rev 0 4.0 CIRCUIT BREAKER CUBICLE Learning Objectives The circuit breaker cubicle is the component of the switchgear that holds the circuit breaker,
S0932.9 Hydraulic Reservoirs . S0932.10 Hydraulic Oil Filters . S0932.11 Hydraulic Cylinders . S0932.12 Hydraulic Pumps . S0932.13 Hydraulic Valves and Controls . S0932.14 Hydraulic Piping Supports . S0932.14 Hydraulic System Drawings . S0932.16 Hydraulic System Commissioning
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