Revision : 11/2000

Manual # : 150-4059

BTI ROCKBREAKER SYSTEMS

SX, ESX, MRH & TT

BOOM MODELS

- General Information
- Installation
- Initial Startup
- Maintenance
- Warranty

BREAKER TECHNOLOGY

INSTALLATION & STARTUP

CONTENTS

Introduction ................................... 4
Hazard Alerts ................................ 5
Safety ............................................ 6
Installation ..................................... 8
Initial Startup ................................. 15
Breaker Installation ....................... 16
Lubrication & Maintenance ........... 18
Daily Checks ................................. 20
Conversion Factors ....................... 21
General Torque Values ................. 22
Warranty ........................................ 23
Notes ............................................. 24

Rockbreaker Installation & Startup Manual

INTRODUCTION

ROCKBREAKER SYSTEM COMPONENTS:

Most of BTI Booms are shipped unassembled, included with the shipment are:
1) The Pedestal and Swing post. The equipment's serial number is located on the corner
of your Pedestal.
2) The electric hydraulic Power Pack.
3) The Hydraulic Breaker. If you are not going to install your hammer now, store it
indoors standing up.
4) An Outer or Stick Boom with the Tilt Cylinder installed.
5) An Inner Boom, with the Dipperstick Cylinder installed.
6) The hoist Cylinder.
Also included will be a box or boxes containing the boom hoses, and tubes. The crate
may also contain the Joysticks, and any spare parts and options that may have been
ordered.

Rockbreaker Installation & Startup Manual

HAZARD ALERTS

Danger, Warning, and Caution are hazard alerts used in this manual and on the boom &
breaker decals to identify hazards on or near the Rockbreaker System.

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

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

Caution - Hazards or unsafe practices, which COULD result in product or property

damage if the proper precautions are not taken.
BTI cannot anticipate every possible circumstance that might involve a hazard. The hazard alerts in this publication and on the product are therefore not all inclusive. If a tool,
procedure, work method or operating technique not specifically recommended by BTI is
used, you must satisfy yourself that it is safe for you and others. You should also ensure
that the compactor and carrier will not be damaged or made unsafe by the operation,
maintenance or repair procedures you choose.

Rockbreaker Installation & Startup Manual

SAFETY

Head
Protection

Foot
Protection

Eye
Protection

Hearing
Protection

Do not operate or service the Rockbreaker System unless you are qualified.
Avoid loose fitting clothing, loose or uncovered long hair, jewelry and loose personal
articles. These can get caught in moving parts. Jewelry may also ground a live circuit.
Know and use the protective equipment that is to be worn when operating or servicing
the boom. Hard hats, protective glasses, protective shoes, gloves, reflector type vests
and ear protection are types of equipment that may be required.
Never operate any machinery while you are under the influence of alcohol or drugs.
Consult your supervisor if you do not understand this Manual.

Rockbreaker Installation & Startup Manual

SAFETY

Do not operate the boom with personnel in the immediate area of the crusher or rockbreaker.

Do not operate this machine unless you have read and understood the instructions and
warnings in the Owner's Manual. Failure to follow the instructions or heed the warnings
could result in injury or death. Proper care is your responsibility. Contact your distributor or BTI for replacement manuals or decals.

Hydraulic fluids are under high pressure. Fluid escaping under pressure can penetrate
the skin causing serious injury. Relieve all pressure before disconnecting hoses. Do not
use your hand to check for hydraulic leaks.
If any fluid is injected into the skin, a doctor must surgically remove it within a few
hours or gangrene may set in.

Do not attempt to repair or modify the rockbreaker unless you are a qualified service
technician. Read and understand your owner's manuals. Failure to follow the instructions or heed the warnings could result in severe personal injury or death. Proper care is
your responsibility. Contact your distributor or BTI for replacement parts.

Rockbreaker components are heavy or awkward, plan carefully how you will handle
them when installing, removing, or disassembling.

The cylinders are full of air and may need bleeding at startup. Failure to do so will
result in the boom running away and may cause serious injury or property damage.

Rockbreaker Installation & Startup Manual

INSTALLATION

INSTALLING THE PEDESTAL:

Before your Rockbreaker arrives on site conveyor belting should be mounted to the
Pedestal base. This will more evenly distribute the Rockbreaker's weight.
Use a crane to lift the pedestal onto the base. Your crane must have sufficient capacity to
lift the Rockbreaker components.
Lift the pedestal with care, keeping it level the whole time.
Carefully lower the pedestal and align the Pedestal mounting holes with the Base
mounting holes.
Install rubber grommets, washers and mounting bolts into the mounting holes. (NT
Boom systems do not require rubber grommets).
Torque each bolt, in a dry condition, to 450 foot pounds, or until the washer is flush
with the top of the mounting lug. Torque all bolts evenly.
When mounting the pedestal to the base, BTI recommends the use of long bolts, capable
of bolting through both flanges of the beam.

Rockbreaker Installation & Startup Manual

INSTALLATION

TYPICAL CONCRETE FOUNDATION INSTALLATION:

Rockbreaker pedestals can be mounted to structural steel or concrete. If your installation
requires it you can now crane lift the pedestal and base to its final location on the tower.
For concrete installations refer to your General Installation Manual included in section 2
of your owners manual.
Lift the Power Pack into its location beside the Pedestal.
With your crane, install the Base end of both Hoist Cylinders into the Swing post.
Grease each pin before continuing with assembly.
Insert the pins and retaining bolts.
Let the cylinders lie unsupported for now.

Rockbreaker Installation & Startup Manual

INSTALLATION

INSTALLING THE INNER BOOM:

Using a crane, lift the Inner Boom assembly and align it with the Pedestal swing post.
Grease each pin before continuing with assembly.
Install the shims, insert the pin and secure it with the pin retaining bolt.
Using a second crane or suitable lifting method, pin the rod ends of the Hoist Cylinders
to the inner boom. You may have to extend or retract the cylinder rod to align it with the
inner boom lug and install the pin retaining bolt.
Connect the Hoist Cylinder hoses to the control valve.
Lower the boom and disconnect the crane.

10

Rockbreaker Installation & Startup Manual

INSTALLATION

INSTALLING THE DIPPERSTICK CYLINDER:

Pin the base end of the dipperstick cylinder to the inner boom.
Strap the rod end of the dipperstick cylinder to the inner boom for now.

Rockbreaker Installation & Startup Manual

11

INSTALLATION

PLUMBING THE BOOM & PEDESTAL:

Before connecting the hoses and tubes, remove the pedestal floor plate to verify which
line is pressure and which is return. The pressure outlet is marked on the control valve
with a 'P', and the return to tank is marked 'T'. Label the hoses where they exit the
pedestal bulkhead.

Typical Control Valve Section

Unpack the hose plumbing kit. And refer to the Boom Hose and Tube Layout drawing in
section 3 of your Owner's Manual.
The routing of your hoses and tubes is shown on this drawing.
Install the stacking clamps, their locations are also on the boom hose and tube layout.
Install the 90 degree bulkhead fittings.
Install the tube assembly bulkhead on the outer boom section.
Next install the cylinder hose adapters.
When installing the hoses, be aware of any grease points and rout the hoses for easy
access to your grease fittings.
Continue plumbing your boom as shown on the boom hose and tube layout drawing.

12

Rockbreaker Installation & Startup Manual

INSTALLATION

CONNECTING THE CONTROL VALVE:

Now install the control valve hoses. This information is shown on the Hydraulic
Schematic in section 4 of your Owner's Manual. Some of these hoses are already
attached. Connect the remaining hoses next to these, to allow easier access with your
tools.
Next attach the hoses from the power pack to the pedestal.
Connect the power pack return line to the pedestal return line.
Connect the power pack pressure line to the pedestal pressure line.
Install the load sense line from the power pack to the pedestal.
Double-check that the pressure line is connected to the pump pressure, and the return
line is connected to the pump return.
Cap the outer boom and breaker hoses at the control valve. This will facilitate the
assembly of the outer boom and breaker.
Install the control valve handles, to prepare the valve for operation.

Rockbreaker Installation & Startup Manual

13

INSTALLATION

SETTING PRESSURES:
Next set the pump and control valve main relief pressure. You must refer to the
hydraulic schematic for these pressure values.
First, adjust your Pump's Load Sense or Standby pressure to 450 psi.
Next, set the pump's cut-off pressure 300 psi above the control valve relief setting,
shown on the hydraulic schematic.
Adjust the control valve main relief setting to 200 psi above the pump's cut-off pressure.
And re-adjust the pump's main cut-off to the specification shown on the hydraulic
schematic.
Now, using a flow meter, check and adjust the pump's flow. Adjustment is made at the
pump's mechanical flow limiter. Refer to the drawing below.
The pump's Mechanical stop is always factory set. Do Not Adjust it.

14

Rockbreaker Installation & Startup Manual

STARTUP

STARTING THE BOOM:

Before initial start up, the following items need to be checked.
If you purchased the fan optional thermostatic control for the Oil Cooler, install it now.
The oil cooler is standard on systems with a TB825 or larger hammer, and optional on
Rockbreakers with smaller hammers.
Set the temperature switches on the thermostatic control. Refer to the Electrical
Requirements section of the General Installation manual for these temperature settings.
If your system was sold with a joystick control, it can now be wired. The wiring
schematic is located inside the joystick control stand.
Add hydraulic oil to the hydraulic tank. Detailed information about your systems oil is
found in the Hydraulic Oil section of the General Installation manual.
Release any air from the hydraulic pump case drain.
Your electrician should have electrical power available and connected to the Power
Pack. It's also important to make sure the pump is rotating in the correct direction. With
electrical power to your Rockbreaker, bump the motor driving the hydraulic pump. If
you encounter any problems, refer to the Troubleshooting section of your manual.
Eliminate the remaining air from the hydraulic system by moving each control lever up
and down while the system is running. This releases the air from each cylinder.
Once the air has been bled from the system and finish filling the hydraulic tank with oil.
Walk around your boom and power pack, checking for and repairing any oil leaks.

Rockbreaker Installation & Startup Manual

15

BREAKER INSTALLATION

Sling the outer boom and prepare it for installation.

Carefully raise the inner boom to a safe working height and attach the outer boom using
the appropriate shims, pin and retainer bolts.

The cylinders are full of air and may need bleeding at startup. Failure to do so will result
in the boom running away and may cause serious injury or property damage.
Extend the dipperstick cylinder.
Pin the rod end of the cylinder to the outer boom and secure the pin with the retaining
bolt.
ATTACHING THE BREAKER TO THE BOOM:
To attach the Hydraulic Breaker to the end of the boom, first clean the outer boom nose
bushings and the breaker link bushings.
Remove the hammer mounting pins from the hammer mount.
Ensure that the hydraulic system is capped-off and use the boom to align the hammer
links with the breaker links and the outer boom.
Finish the hammer installation by inserting the pins and retaining bolts.
Install the hammer whip hoses.

16

Rockbreaker Installation & Startup Manual

BREAKER INSTALLATION

INSTALLING THE BREAKER TOOL:

First, knock out the stopper plug and retainer pin.
Then remove the tool retainer.
Lift the tool into position.
For easier installation thoroughly grease the top of the hammer tool with a moly-based
grease.
Install the tool by lowering the hammer onto the tool.
Replace the tool retainer, retainer pin, and stopper plug.
O Series Breakers

E Series Breakers

Apply
Grease

Apply Grease

Tool
Retainers

Tool Retainer

Retainer Pin
Stopper Plug

Retainer Pin
Stopper Plug

Rockbreaker Installation & Startup Manual

17

LUBRICATION & MAINTENANCE

BOOM LUBRICATION POINTS:

You must lubricate all grease points on the boom. Refer to the drawing below for the
grease points. There are also decals on both the boom and pedestal showing the grease
points specifically on your system.
You must lubricate all grease points before and after the initial start-up. Pump grease
into the fittings until it oozes from around the pins and bushings.
Lubrication points are:
The left and right Swing cylinders, base end and rod end
The Boom Swing, top pin and bottom pin
The Boom Pivot Pin
The Hoist Cylinder, base end and rod end
The Dipperstick Cylinder, base end and rod end
The Boom Joint Pin
The Tilt Cylinder, base end and rod end
The Breaker Link, which has 3 grease fittings
The Boom Link
The Outer Boom Nose Pin
The Breaker.

18

Rockbreaker Installation & Startup Manual

LUBRICATION & MAINTENANCE

Remember to properly grease the hammer tool every 2 hours of operation, with a Molybased grease. To do this the breaker must be in a vertical position with enough down
pressure applied to force the tool into the breaker housing. For more detailed instructions refer to the section Greasing the Breaker, in the Hydraulic Breaker Owners
Manual.

Adjust the control valve and pump pressures. The pressure settings are shown on the
hydraulic schematic in your Owner's manual. Your system comes with a pressure gauge
that you attach to either the Load Sense or Main pressure ports of the control valve
After all the pressures have been set, test the operation of your Rockbreaker system
with the control levers.
Next adjust the control valve speed settings. These settings affect how quickly your
boom moves. BTI recommends a slower boom movement until the operator is comfortable with the Rockbreaker's operation.
Now test the operation of the rockbreaker system and hammer movement with the joysticks.
Adjust the boom direction controls to suit the operator's position, pulling the joystick to
the left should move the boom left.
Attach your joystick decals.
The pedestal floor plate can now be reinstalled.

Rockbreaker Installation & Startup Manual

19

DAILY CHECKS

These checks must be made on your Rockbreaker System every shift.

As a reminder there is a Daily Checks decal on the Power Pack.
Check oil level in reservoir. You do this by looking at the Oil level indicator on the
hydraulic oil tank.
Grease entire machine. During operation, look for clues like excessive noise, or rusty
water, which can indicate a lack of grease.
Visually check for any loose bolts or oil leaks.
Listen for excessive noise from motor or pump.
Check return and pressure filter by-pass under load. Check the filter indicators while
your Rockbreaker is in operation.
Always change the oil and filters in your system every 1,000 hours of operation. And
check and clean the Suction Strainer when you change your filters.
Visually check for:
- Indication of structural fatigue.
- Excess play in the pins.
- Wear in the hinge points.
- Worn hoses and tubes, and check that all hoses and tubing is properly secured.
For detailed maintenance instructions refer to the Owner's manual.
If you need specific information on mounting Rockbreakers to suit your application, our
Service department will be happy to assist you. BTI's Service department can be reached
by calling 1-800-567-8267.

20

Rockbreaker Installation & Startup Manual

CONVERSION FACTORS

QUANTITY

SI UNIT OF MEASURE

CONVERSION

US UNIT OF MEASURE

Length

Millimeter (mm)

Inch (in)

1 in. = 25.4 mm

Pressure
(note 1)

Bar (assumed to be "gauge"

unless otherwise stated)

Pounds per square inch

(psi or psig)

1 Bar = 14.5 psi

Pressure
(see note 2)

Bar ( a value less than 1.0 is

shown as a decimal, i.e. 0.95
bar)

Inches of mercury
(in Hg)

1 in Hg (@ 600 F)
= 0.034 bar

Flow
(note 3)

Liters per minute

(l/min)

Gallons per minute

(gpm)-U.S.

1 gpm = 3.79 l/min

Flow
(note 3)

Liters per second

(l/sec)

Gallons per minute

(gpm)- U.S.

1 gpm = 0.063 l/sec

Flow
(note 4)

Cubic decimeters per second

(dm3/s)

Cubic feet per minute

(cfm)

1 dm3/s = 2.12 scfm

Force

Newton (N)

Pound (f)

1 lb(f) = 4.44 N

Mass

Kilogram (kg)

Pound (m) lb(m)

Time

Second (s)

Second (s)

Volume
(note 3)

Liter (l)

Gallon (gal) U.S.

Temperature

Degrees Celsius (0C)

Degrees Fahrenheit (0F)

Torque

kilogram - meters (kg-m)

Foot -pounds (ft-lbs)

1 kg.m = 7.23 ft-lbs

Power

Kilowatt (kW)

Horsepower (HP)

1 kW = 1.34 HP

Shaft speed

Revolutions per minute

(rev/min)

Revolutions per minute

(RPM)

Frequency

Hertz (Hz)

Cycles per second (cps)

1 Hz = 1 cps

Displacement Milliliters per revolution

(note 3)
(ml/rev)

Cubic inches per revolution

(cip)

1 ml / rev = 0.061 cipr

Kinematic
viscosity

Centistokes (cSt)

Saybolt (SUS)

cSt = (4.635) (SUS)

(note 5)

Velocity

Meter per second (m/s)

Feet per second (fps)

1 m/s = 3.28 fps

Material
stress

Deka newtons per sq. millimeter

(da N /mm2)

Pounds per sq. inch (psi)

1 da N / mm2 = 1450 psi

NOTE 1 : PRESSURE ABOVE ATMOSPHERIC

NOTE 2 : PRESSURE BELOW ATMOSPHERIC
NOTE 3 : LIQUID

lb(f)

1 kg = 2.20 lb(m)

1 U.S. gal = 3.79 l

C= 5/9 ( 0 F -32)

NOTE 4 : GAS -UNDER STANDARD TEMPERATURE, HUMIDITY, AND

PRESSURE CONDITIONS
NOTE 5 : @ 38 0 C; FACTOR IS 4.667 @ 99 0 C

Rockbreaker Installation & Startup Manual

21

GENERAL TORQUE VALUES

THREAD
SIZE
1/4 -20
1/4 -28
5/16 -18
5/16 -24
3/8 -16
3/8 -24
7/16 -14
7/16 -20
1/2 -13
1/2 -20
9/16 -12
9/16 -18
5/8 -11
5/8 -18
3/4 -10
3/4 -16
7/8 -9
7/8 -14
1 -8
1 -14
1 1/8 -7
1 1/8 -12
1 1/4 - 7
1 1/4 -12
1 3/8 -6
1 3/8 -12
1 1/2 -6
1 1/2 -12

HEX
SIZE
7/16
7/16
1/2
1/2
9/16
9/16
5/8
5/8
3/4
3/4
13/16
13/16
15/16
15/16
1 1/8
1 1/8
1 5/16
1 5/16
1 1/2
1 1/2
1 11/16
1 11/16
1 7/8
1 7/8
2 1/16
2 1/16
2 1/4
2 1/4

SAE GRADE 5
DRY

LUBRICATED

SAE GRADE 8
LUBRICATED
DRY

Ft-lb

kgm

Ft-lb

kgm

Ft-lb

kgm

Ft-lb

kgm

8
10
17
19
30
35
50
55
75
90
110
120
150
180
260
300
430
470
640
730
800
880
1120
1240
1460
1680
1940
2200

1.1
1.4
2.4
2.6
4.1
4.8
6.9
7.6
10.4
12.4
15.2
16.6
20.7
24.9
40.0
41.5
59.5
65.0
88.5
101
111
122
155
171
202
232
268
304

*75
*86
13
14
23
25
35
40
55
65
80
90
110
130
200
220
320
360
480
540
600
660
840
920
1100
1260
1460
1640

0.86
0.99
1.8
1.9
3.2
3.5
4.8
5.5
7.6
9.0
11.1
12.4
15.2
18.0
27.7
30.4
44.3
49.8
66.4
74.7
83.0
91.3
116
127
152
174
202
227

12
14
25
25
45
50
70
80
110
120
150
170
280
240
380
420
600
660
900
1020
1280
1440
1820
2000
2380
2720
1360
3560

1.7
1.9
3.5
3.5
6.2
6.9
9.7
11.1
15.2
16.6
20.7
23.5
38.7
33.2
52.6
58.1
83.0
91.3
124
141
177
199
232
277
329
376
437
492

9
10
18
20
35
35
55
60
80
90
110
130
170
180
280
320
460
500
680
760
960
1080
1360
1500
1780
2040
2360
2660

1.2
1.4
2.5
2.8
4.8
4.8
7.6
8.3
11.1
12.4
15.2
18.0
23.5
24.9
38.7
44.3
63.6
69.2
94.0
105
133
149
188
207
246
282
326
368
* in-lb.

NOTES:
1. Always use the torque value listed above when specific torque are not available.
2. Do not use above values in place of those specified in other sections of this manual or other manuals pertaining to this equipment.
3. The torque values listed in the "dry" columns are based on use of clean, dry threads.
4. The torque values listed in the "lubricated" columns are based on the use of cleans threads lubricated with
oil, grease, molybdenum disulphide based grease, and usage of hardened washers.
5. Bolts threaded into aluminum may require reduction in torque values of up to 30 %, unless inserts are used.
Grade 5 and grade 8 bolts can be distinguished by their head markings.

GRADE 5 BOLT, CARBON

STEEL, HEAT TREATED

22

GRADE 8 BOLT, ALLOY

STEEL, HEAT TREATED

Rockbreaker Installation & Startup Manual

PRODUCT WARRANTY

1. BREAKER TECHNOLOGY INC. Company (hereinafter referred to as "BTI") warrants this product against defects in materials and workmanship for a period of twelve
(12) months from the date of Installation. This warranty does not cover o-rings, seals,
fittings, hoses, breaker tools or other items considered normal wear items. These are
covered by the Limited Warranty period of thirty (30) days. Warranty for propriety
items such as valves, pumps, filters, electric motors, panels and componentry that are
not manufactured by BTI, will be governed by the warranty terms of their manufacturer.
This warranty is void if BTI's standard installation specifications and procedures are not
adhered to.
2. BTI's Customer Service Department will authorize return of any defective components or sufficient evidence of such defect to a BTI warehouse. Such components or
such evidence must clearly show that the defect was caused by faulty material or poor
workmanship. Warranty claim will be accepted only if it is submitted on a proper claims
form with proof of purchase and received within sixty (60) days from the date of discovery of the defect. Warranty claims will be considered only if the "Installation
Notice" has been duly filled in and returned to BTI's Customer Service Department
within thirty (30) days from the date of installation.
3. BTI will at it's option, repair or refurbish the defective part(s) without charge to the
initial user or may elect to issue full or partial credit toward the purchase of a new
part(s). The extent of credit issued, which will be in the form of a "Credit Memo", will
be determined by pro-rating against the normal life of the part(s) in question.
4. BTI is not responsible for mileage, travel time, travel expenses, overtime labor, and
any freight expenses required to facilitate the repair.
5. This warranty does not apply if the product has been damaged by accident, abuse,
misuse, misapplication or neglect, or as a result of service, disassembly or modification,
without BTI's express authorization.
6. BTI assumes no liability beyond the replacement of defective parts or materials
and/or the correction of such defective parts or materials.
7. BTI neither assumes nor authorizes any other person to assume for it any liability in
connection with the sale of it's products other than that specifically stated herein.
8. THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER WARRANTIES.
EXCEPT AS EXPRESSLY SET FORTH HEREIN, BTI MAKES NO REPRESENTATION OR
WARRANTY, STATUTORY, EXPRESS OR IMPLIED, WITH RESPECT TO THE
PRODUCTS MANUFACTURED AND/OR SUPPLIED BY BTI, WHETHER AS TO
MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR ANY
OTHER MATTER. IN NO EVENT, INCLUDING IN THE CASE OF A CLAIM OF
NEGLIGENCE, SHALL BTI BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Rockbreaker Installation & Startup Manual

23

NOTES

24

Rockbreaker Installation & Startup Manual

NOTES

Rockbreaker Installation & Startup Manual

25

SOLON FACILITY
30625 Solon Industrial Drive,
SOLON OHIO,
44139 U.S.A.
PH. 440-542-3720
FAX. 440-542-3721

RIVERSIDE FACILITY
3464 DURAHART ST.
RIVERSIDE,CALIF.
92507 U.S.A.
PH. 909-369-0878
FAX. 909-369-8281

THORNBURY FACILITY
35 ELGIN ST.,
THORNBURY,ONT.
N0H 2P0 CANADA
PH. 519-599-2015
FAX. 519-599-6803