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RBI Complete Manual - Rock Breakers Inc.

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1. 22 RBI HYDRAULIC BREAKER USER MANUAL Q Pad alignment BENDS the tool Always break at 90 to surface of rock A CAUTION 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 resulting in blank firing e Do not POUND or PRY with the breaker Blank Firing A CAUTION Avoid blank firing Premature failure of parts in the breaker lower end can result Stop the movement of the breaker s piston when full contact to the target material is lost This reduces the strain on the tool retainers and front head during normal operation Blank firing emits a distinct metallic ringing sound 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 parts in the lower end of the breaker To prevent blank firing learn to anticipate when the material will break Predicting this moment is probably best done by listening to the sound of the tool hitting the rock A change in the hammering sound is noticed as the tool breaks through This is the point to stop firing the breaker 23 RBI HYDRAULIC BREAKER USER MANUAL Breaking Oversize Material
2. For example if a 4 cubic yard piece of hard rock 20 000 psi or greater needs to be broken in half a 7 500 ft lb or larger breaker is required If a 2 cubic yard piece of limestone 20 000 psi or less needs to be broken in half a 3 000 5 000 ft lb breaker is required Trenching When trenching the breaker is expected to fracture a solid mass of rock into manageable pieces The size of the material could be hundreds of cubic yards and the energy will be quickly absorbed This is why it is recommended to work from a bench so the rock has somewhere to break out When trenching in limestone or medium hard rock use a 3 000 5 000 ft lb breaker When working in hard material use a 7 500 10 000 ft lb breaker RBI HYDRAULIC BREAKER USER MANUAL Breaking Concrete When breaking Concrete the breaker is expected to penetrate the material allowing it to crack and shake loose from the reinforcing steel High frequency breakers tend to provide better performance in this application It is not the energy per blow but the fast blow rate that destroys the concrete s structural integrity On concrete walls footings and floors use a 750 1 500 ft lb breaker With larger projects consisting of large footings greater than 4 cubic yards use a 2 000 5 000 ft lb breaker The high production demand of bridge and building demolition requires a 7 500 10 000 ft lb breaker Recommended Hydraulic Oils Oil is Too Thick or Too Thin Thick oil may cause Di
3. RB105 Wear Tolerance Unit mm e RB105 8 a VENE D d 7 BEEN 4 Tool Rod 4 RB2000 51 5 0 4 8 6 2 5 3 1 Wear Limit New Part New Part 32 RBI HYDRAULIC BREAKER USER MANUAL Changing the Breaker Tool Check the wear width between the tool and tool bushing See table on the previous pages for maximum and minimum permissible wear limit Tool and Front Tool Bushing Clearance Check the clearance between the tool and the front tool bushing every 100 hours Worm parts may cause misalignment between the tool and the piston If the value exceeds those shown in the following table both front and rear tool bushings must be replaced to prevent damage A CAUTION Exceeding the following values may damage other component parts such as the piston and cylinder Tool Removal 1 To remove the tool drive out the retainer pin and stopper plug using the drift supplied in the tool kit 2 Use the drift to drive out the tool retainers Inspect them for cracks or deformities and wear on the edge that rests against the tool NOTE Models RB105 RB155 RB305 RB505 RB755 have spring tool retainer pins other larger models have round tool retainer pins Ensure tool retainer pins RB1005 and larger model are rotated properly Check for hash mark where pin contacts KT Lo front head pin 2 S 3 Remove any burrs on the retainer pins and the tool with a grinder Che
4. RBI HYDRAULIC BREAKER USER MANUAL Area of Typical Tool Failures Guide to Warranty Claims RBI 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 tool metal fatigue failure generally occurs within 4 in 100 mm above and below the face of the front head or at the retainer pin flat A less common failure area is about 8 in 200 mm from the face of the front end depending on the work the breaker is doing Front Head Retainer Pin Flat High Risk Fatigue Area gt e qw oq Low Risk Fatigue Area Typical fractures caused by excessive bending of the tool Fractures like this are not covered by warranty Typical fracture caused by prying with the tool while it was buried in the work piece Fractures like this are not covered by warranty 65 4 in 100 mm 100 mm 4 in 10283 10287 10282 RBI HYDRAULIC BREAKER USER MANUAL Mushrooming Hammering the tool too long in hard dense material without penetrating through causes mushrooming This generates intense heat that softens and mushrooms the point This is not a fault of the tool If the rock or stone shows no sign of breaking within 20 seconds reposition the breaker Warranty claims made for mushrooming on the ends of the tool will be rejected Steel Defect Failure
5. 17 5 249 Back Head Cushion Chamber Gas Pressure Adjusting Increasing the Pressure 1 2 Connect the charging hose 4 to N2 gas cylinder 1 after screwing the bombe adapter 3 onto adapter nut 2 and installing them to the N2 gas cylinder Connect the 3 way valve assembly 5 to the charging hose 4 after unscrewing the cap on the 3 way valve Install the 3 way valve assembly 5 to the charging valve of the Back Head At this time the handle of the 3 way valve assembly must be up position to prevent the gas from coming out Push the handle of the 3 way valve assembly fully and turn the handle of the N2 gas cylinder counterclockwise gradually to charge gas When the gas pressure exceeds 10 higher than the specified pressure close the N2 gas cylinder by turning the handle clockwise Leave the handle of 3 way valve assembly up Generated pressure makes it return back to original position naturally In order to discharge N2 gas in the charging hose 4 and the 3 way valve assembly turn the relief valve counterclockwise Remove the charging hose 4 from the N2 gas cylinder 1 and the 3 way valve assembly 5 and screw the cap into the 3 way valve assembly Push the handle of the 3 way valve assembly fully and the gas pressure inside the Back Head is indicated on the pressure gauge When the pressure is higher discharge a small amount of gas from the Back Head by repeatedly opening and closing the valve until gas press
6. Have the hydraulic excavator manufacturer the excavator check the pump performance If the performance is poor repair or replace Back pressure too high in circuit Find source causing increased back pressure in return circuit and remove Lack of Power Insufficient oil flow or oil pressure Check hydraulics of the base carrier Broken tool Replace tool check piston for damage Cushion chamber gas pressure is too low Check and adjust Back pressure too high in circuit Find source causing increased back pressure in return circuit and remove 59 RBI HYDRAULIC BREAKER USER MANUAL Erratic hammering Not enough down force on the tool Increase the down pressure acting on the tool Pressure too high in cushion chamber Too much grease in the impact chamber Remove tool and clean out excess grease Follow proper greasing instructions Excessive clearance between tool and tool Check clearance and replace worn parts bushing Excess wear at top of tool Remove and inspect the tool Replace if necessary Foreign matter in the breaker control valve Disassemble and clean Seizure of piston and cylinder Overhaul the breaker Back pressure to high in circuit Find source causing increased back pressure in return circuit and remove Control valve bolts loose Tighten bolts to correct torque in a staggered pattern Tool Mushrooming Continuous hammering in one place Use short bursts Re position breaker ev
7. This failure has fatigue lines originating from an internal point and not from the outer surface This is a very rare failure caused by a defect in the steel This type of defect is covered under the normal warranty period No Warranty No Warranty No Warranty No Warranty No Warranty Lm Lm ares TT TT No Warranty 66 10289 10290 Mushrooming from operating with worn bushings or firing the breaker too long at one time Failure from blank firing or excessive wear to bushings and or fronthead Failure from operating with worn out retainer pins blank firing or twisting the tool Failure caused by misalignment of down pressure breaker and the tool prying levering etc Tool Breakage improper contact with tool tip and material to be broken Mushrooming fast wear caused by breaking too long on the same spot RBI HYDRAULIC BREAKER USER MANUAL Removal and Storage A CAUTION Use extreme care to prevent dirt from entering the hydraulic circuit when disconnecting or reconnecting hydraulic lines Cap or plug lines when disconnecting clean thoroughly before reconnecting Even the smallest dirt particles will cause damage to the internal workings of the breaker Short term Storage Storing your breaker up to a week is considered Short term Storage Follow this procedure 1 If shut off valves are used with the breaker turn them to the OFF position 2 Disconnect the pressure and return li
8. abnormal leakage replace with new ones To prevent fatal defect periodical replacement is carried out every 3months without external leakage of breaker Although the breaker is not operated in a long time replace seals periodically to prevent rust corrosion of oil and transformation of seals 30 RBI HYDRAULIC BREAKER USER MANUAL Wear Tolerance Using the breaker with the parts exceeding wear tolerances can cause fatal damage Prevent damage through regular inspection and repair using factory replacement parts Use the tables below for NEW vs Reject wear tolerances Minimum and Maximum Diameters for Wear bushings Tools and Pistons Wear Tolerance Unit mm NEW REJECT Inside Dia Inside Dia RBl05 40 42 L 21 n J RB305 60 62 RBs05 68 71 RBi005 85 89 Ring Bush 140 150 155 Wear Tolerance Unit mm Mose finite pia side Dia N Inside Dia Inside Dia a FPO RB305 60 RBS05 68 Front Cover 85 RB4000 i140 175 4 W Lower Bush Q 0 0 4 5 7 8 1 12 1 1 1 1 1 5 5 5 5 Ooo 89 LAA hhh La Wear area Lh Ahh hehe ded THRUST BUSH Measure at center RB105 RB1005 Measure at 30mm FRONT COVER Measure at 10mm RB1500 RB9500 31 RBI HYDRAULIC BREAKER USER MANUAL Minimum and Maximum Diameters for Wear bushings Tools and Pistons Wear Tolerance Unit mm me
9. becomes worn Worn housings can be unstable 6 Ensure breaker is supported and restrained to prevent tipping over 7 The breaker housing must also be restrained against upward movement produced by the lift crane 8 Remove crane rigging from the breaker housing only AFTER the breaker housing has been fully restrained 43 RBI HYDRAULIC BREAKER USER MANUAL A CAUTION Upper and lower isolators inside the breaker housing are compressed to provide a preload on the breaker body to support it within the housing Loosen bolts gradually and equally to remove pre load and prevent injury 9 Loosen top mount bracket bolts gradually and equally to reduce spring pre load from isolators Once all bolts have been loosened the spring pre load will be gone and it is safe to remove the bolts 10 Remove top mount bracket bolts and bracket Store in a safe place away from the work area If the upper or lower isolators are not thick enough it should be replaced 11 Remove the upper isolator from the breaker and check for cracking heat damage wear etc If the isolator is in poor condition it must be replaced NOTE Upper and lower isolators must be replaced after 1000 hours of operation Removing Breaker Body from Housing NOTE All lifting eyes required for breaker disassembly are found in the breaker tool kit Wear Pads Besides the upper and lower isolators the breaker body has wear pads between it and the inside of the housing to keep it
10. from the gas valve Replace worn or damaged seals Check gas valve for damage repair or replace Leakage from gas valve body Worn or damaged o ring Replace Gas leakage from between the cylinder and Worn or damaged o ring Replace the cylinder cover Tie rods loose Tighten to correct torque value in a cross pattern 61 RBI HYDRAULIC BREAKER USER MANUAL Erratic blows after breaker has been operating normally Probable Cause Correction Seizure of control valve Repair or replace control valve Seizure of piston and cylinder Remove and inspect piston and inside of cylinder body Relief valve for the excavator is set too low Set the relief valve to correct pressure setting Poor performance of the hydraulic pump on the excavator Lack of down pressure on the tool Nitrogen gas pressure in the rear head is too low Back pressure too high in circuit Control valve bolts loose Blows min decreased Have the hydraulic excavator manufacturer check the pump performance If the performance is poor repair or replace Operate the arm and bucket so that pressure is applied to the tool Adjust the nitrogen gas to the correct pressure Find source causing increased back pressure in return circuit and remove Tighten bolts to correct torque in a staggered pattern Nitrogen gas pressure in the rear head is too high Lack of down pressure on the tool Pressure setting for the relief val
11. into place with the chamfer or step towards the center of the piston 2 Lift the piston with the lifting eye lubricate it thoroughly and lower it carefully into the cylinder It may need a tap to push it through the lower seals 3 When the piston is all the way into the cylinder bore use a soft mallet to tap the seal bushing into position in the cylinder The bushing will stop when it reaches the support flange on the front head Replace the o rings and back up rings on the top of the cylinder where the rear head makes contact 53 RBI HYDRAULIC BREAKER USER MANUAL Control Valve Installation Control valve is housed within the cylinder body It is installed from the upper end of the cylinder body 59 Lightly oil the control valve spool valve sleeve plug and o rings with clean hydraulic oil Qy 1 Insert the valve sleeve first and then insert the spool Insert the small end of the spool first 2 Insert the plug and ensure the o rings are placed correctly before installing the rear head 10544 Installing the Rear Head The cushion chamber in the rear head needs a small amount of oil to function properly Just before installing the rear head make a circular dam of grease on the top of the piston just high enough to contain the required amount of oil see table below l Lower the rear head over the tie rods The gas valve must face the same direction as the control valve on the cylinder 2 Install the tie rod
12. supported Wear pads can be reused also if in good condition 1 Upper Isolator Crosse Damper 2 Lower Isolator Lower Damper 3 Wear Plate 4 Wear Plate 5 Wear Plate 6 Back Head Holding Block 44 RBI HYDRAULIC BREAKER USER MANUAL Weight of Main body e lama Rn Kg Ibs Kg Ibs A CAUTION Ensure breaker is restrained to prevent tipping over 1 Insert the appropriate lifting eyes into the rear head 2 Using an overhead crane pull the breaker body straight up out of the housing 3 Carefully lower the bare breaker onto a smooth clean level surface 4 Clean inside of the housing Inspect for weld cracks damage etc inside and outside of the housing Repair as required 5 Clean and inspect the front head area of the bare breaker Clean and inspect the wear pads NOTE The upper lower isolators and wear pads are considered wear parts and are not covered under the breaker warranty It is recommended that they be replaced after every 1000 hours of operation or as required Breaker Body Disassembly The breaker body can be disassembled standing up or laying down The following instructions describe the standing method A WARNING Release cushion chamber gas pressure before disassembly The cushion chamber in the back head contains nitrogen gas under pressure Do not remove the tie rod nuts or gas valve until this pressure is released A WARNING DO NOT use impact tools to disassemble or reas
13. tie rod threads If they are damaged beyond repair the tie rod must be replaced 1 Lubricate the tie rods and threads thoroughly using grease 2 Install the tie rods and tighten until they bottom out in the front head 3 The tie rods should turn in smoothly and easily until they seat themselves If they do not bottom out or there is excessive resistance the threads on the tie rods may be damaged NOTE As a reference tie rod torque can be found in Torque Specifications Cylinder Installation 1 Check the cylinder for burrs 2 Liberally oil the inside surface of the cylinder and the new seals and then install the seals and rings into the grooves at the lower end of the cylinder 3 Lower the cylinder carefully onto the tie rods The control valve mounting holes on the cylinder must face the same direction as the grease fitting on the front head 1 Lower Cylinder Pay close attention to the correct placement and orientation 2 Buffer Seal of the seals Improper seal installation will cause leakage and 3 U Packing premature wear 4 Dust Seal 52 RBI HYDRAULIC BREAKER USER MANUAL Seal Bushing Re sealing Ensure the bushing is clean and there are no burrs Oil the seal bushing and seals Install the seals and o rings in the correct positions and orientations 6 Gas Seal 7 Step Seal 8 O ring 9 Back up ring Piston Installation 1 Lubricate the top end of the piston and slide the seal bushing
14. to impact the retainer pins 9 and front head causing excess stress to these components RBI HYDRAULIC BREAKER USER MANUAL Sizing the Hydraulic Breaker When sizing the breaker to the machine two key points should be given careful consideration e Machine operating weight e Hydraulic system capabilities With the correct carrier weight RBI offers hydraulic breakers that are designed to break any material that the machine can handle Sizing the breaker by carrier hydraulics gives the operator a carrier breaker combination designed to optimize the system efficiency thereby reducing heat generation and eliminating power loss The following steps will result in a well matched installation This manual will not cover all types of applications so for assistance in any unusual situations please contact your RBI representative Based on Carrier Weight By using the Carrier Sizing Chart below you can narrow your hammer choice Normally breaker production rate is the most crucial factor when trying to choose a breaker size It is of great benefit to do some research and understand your hydraulic system capabilities and the material size and hardness before determining an expected production rate This rate will also be affected by breaking conditions and the operator RBI HYDRAULIC BREAKER USER MANUAL dicis EL EL RB1005 RB1500 RB2000 RB3600 RB4000 BREAKER Carrier Weight in Metric Ton MODEL 25 30 35 40 45 RB4500 25 30 RB58
15. until this pressure is released 46 1 Accumulator body bolt 2 Accumulator cover 3 Accumulator Hex Plug 4 O Ring 5 Accumulator cover bolt RBI HYDRAULIC BREAKER USER MANUAL AWARNING DO NOT use impact tools to remove the accumulator from the breaker body The accumulator mounting bolts use heli serts steel threaded inserts that can be damaged by the use of impact tools 1 Take an initial reading of the nitrogen gas pressure in the accumulator A higher than normal reading may indicate a problem AWARNING A gas pressure reading in the accumulator higher than the last time it was charged indicates the diaphragm may have ruptured Pressurized oil may exist in the accumulator Proceed with caution 2 Bleed off the nitrogen gas with the charging kit hose Fully vent the accumulator Confirm with the gauge in the charging kit 3 Loosen the 4 bolts in a staggered pattern Use multiple steps 4 Remove the accumulator from the breaker body Diaphragm Replacement A CAUTION Nitrogen gas must be fully vented before disassembly 1 Confirm the gas pressure has been fully vented using the charging kit with gauge 2 Loosen the bolts holding the accumulator halves together in a staggered pattern 3 Loosen the bolts off in 1 8 in 3mm increments watch for movement Movement of the halves may mean residual pressure remains 4 Continue loosening the bolts in a staggered pattern 5 Remove the cover to replace the diaphra
16. washers 3 Lubricate the tie rod nuts with grease and tighten them in a crossing pattern to draw the breaker components together evenly 4 Finish tightening the nuts to the correct torque in four stages 40 60 80 and 100 using the same crossing pattern Tie Rod Through Bolt Nut Torque Model Torque Value bs F9 ne RB1005 54 RBI HYDRAULIC BREAKER USER MANUAL 5 Pour the required amount of oil for the cushion chamber through the gas valve port Use medium viscosity hydraulic oil Cushion Chamber Oil Volume RB105 755 RB1005 1500 RB2000 3600 RB4000 RB4500 9500 zs 3s 60 s 9 Charging the Cushion Chamber Before the breaker is put into service the cushion chamber must be recharged with N2 nitrogen gas Breaker Assembly Installing body into boxed frame A WARNING 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 The RBI breaker uses upper and lower isolators to support the breaker body within the housing IMPORTANT After the top mount bracket is installed the upper and lower isolators must compress to form a spring pre load on the breaker body within the housing If the breaker body has been disassembled to be rebuilt replace the isolators 55 Tn Pm JP rd CaF 1 Cross Damp
17. where it rides inside the front head A CAUTION Grease often Failure to lubricate regularly reduces the life of the tool bushings and front head If the tool becomes dry and shiny during the shift apply additional grease Automatic Greasing Systems A provision hole for automatic greasing systems is provided RB1500 and larger models When greasing with an automatic greasing system the grease should only be injected into the breaker when it s firing This will allow the breaker to consume the grease correctly Set the flow rate so there is a continuous new grease shine near the top of the tool coming from the breaker If the tool appears shiny the greasing flow rate may need to be increased This rate may change due to specific operating conditions 29 RBI HYDRAULIC BREAKER USER MANUAL Comparison of Automatic Lubrication Systems to Manual Lubrication e Constant lubrication e Inconsistent lubrication Lube while machine runs e Cannot lubricate while operating e Closed system no contamination e Constant contamination e Extended bearing life Premature bearing failure less downtime Labor expense Quick payback on investment Seal amp O Ring Since hydraulic breaker operates at high pressure and high temperature leakage or scratch could be occurred by friction wear and breakage of seals Considering pressure temperature viscosity of oil a little leakage is accepted to be normal But in case of
18. 00 TE alf RB8000 30 40 ome o HA Skidsteer de Backhoe Mini excavator alfa Excavator RBI HYDRAULIC BREAKER USER MANUAL Based on the Type of Work The Production Rate is the next important factor to consider in sizing the breaker Most situations call for the largest breaker that your carrier could handle The largest breaker is therefore the one to choose The lifting capacity of your machine is then the limiting factor The carrier must be able to safely handle the breaker at any distance out from the machine where you might be working Small Breakers Smaller sized breakers up to 1 000 ft lb class 1350 joule are typically used in concrete and other light duty work Medium Breakers Medium sized breakers 1 500 4 000 ftlb class 2000 5400 joule are used in both concrete and rock applications with limitations on the size and amount of material to be broken Large Breakers Larger breakers greater than the 4 000 ft lb class 5400 joule are typically used in hard rock high production applications Breaking Oversize When breaking oversize material the breaker is expected to break the material down quickly into multiple pieces This is optimum production If the operator has to re position the breaker towards the edge of the rock and gradually downsize the material the production rate slows down To assess which breaker will effectively handle this application the size and hardness of the material must be known
19. Avoid sudden movements 14 RBI HYDRAULIC BREAKER USER MANUAL AWARNING Ensure that the structure supporting your machine is strong enough to support it s weight Danger of falling A WARNING Stay a minimum of 30ft 9 1m away from overhead wires with any part of the machine AWARNING To keep dust at a minimum during operation spray the work area with water AWARNING No adaptations or modifications to the breaker are allowed unless agreed upon by RBI engineering Written approval must be received beforehand Check the carrier owner s manual Further precautions may be required 15 RBI HYDRAULIC BREAKER USER MANUAL A WARNING All operations of adjustment maintenance repair or cleaning must be made with the engine OFF and the attachment resting firmly on the ground Fasten a DO NOT OPERATE or similar tag in the cab l fr lt gt A WARNING When carrying out maintenance or transporting procedures take care to place the breaker in a stable position The relative movement of various parts should be prevented using ties supports blocks etc 10392 DO NOT OPERATE A CAUTION Use only original RBI spare parts Transporting Safety Precautions Use a pressure washer to remove any loose gravel mud or debris from the breaker and or carrier Load and unload the machine on a level surface Ensure that the combined height of the trailer bed and the top of the m
20. RBI HYDRAULIC BREAKER USER MANUAL Hydraulic Breaker Owner s Manual Rock Breakers Inc www rbibreakers com RBI HYDRAULIC BREAKER USER MANUAL Introduction To our customer Thank you for choosing a RBI product for your application At RBI we pride ourselves in the equipment we manufacture and distribute At RBI we believe our product is without exception the industry standard Meticulous care has been taken to ensure that this product will meet rigorous product requirements Using up to date CAD modeling software complemented with finite element analysis you can be satisfied that our product will meet and exceed your prerequisites We are proud 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 Foreword This book is intended as a guide to the use and maintenance of the RBI Hydraulic Breakers Keep it with the operator at all times Replace it immediately if it becomes lost The design of the RBI Hydraulic Breakers produces stable high speed percussion and exceptional value and durability for all construction demolition and rock breaking requirements RBI Hydraulic Breakers use sophisticated technology to produce a simple design With only two internal moving parts this line of breakers makes the operation of hydraulic equipment easy flexible and reliable Field proven
21. With practice the best place to begin breaking will be learned by just looking at the rock Position the tool on flat areas of the rock or look for a seam or crack which may allow easier splitting e To fully absorb the entire breaker s energy make sure the rock is resting on a solid base Trenching and Excavation Before trenching remove all overburden material exposing the rock surface 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 allowing a place for the rock to break out to Maintain the benches as the trench advances Slope the sides of the trench to accommodate the width of the breaker The larger the breaker 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 broken rock away from the work area In some cases the excavator can sit on top of the trench and the broken material can be back filled under the excavator For best performance apply the down force in line with the tool repositioning every 10 to 15 seconds or when no penetration is evident Keep the breaker well grea
22. achine cab is lower than local height restrictions or any bridges overpasses or overhead obstructions expected to be encountered during transport Ensure that the transporting equipment is adequate to hold the weight and size of the machine Place chocks against the truck and trailer wheels Use a ramp or loading dock Ensure that the ramp is strong enough and has a low angle of rise to the height of the trailer bed Do not place tie down cables or chains over or against hydraulic tubes hoses cylinders or valves etc Fasten chains or cables to machine frame Obey all local laws concerning loading unloading or transporting the machine Keep the trailer bed clean Always keep bystanders clear of the area 16 RBI HYDRAULIC BREAKER USER MANUAL Installation General To obtain the best performance from an RBI hydraulic breaker it must be installed correctly and the carrier machine supplying the hydraulic power must be operating properly The following checklist will assist in the installation 1 Make sure the hydraulic circuit targeted for the breaker matches the requirements for hydraulic flow and pressure relief settings 2 The hydraulic tubing and hose size must match the requirements of the breaker 3 The hydraulic oil and filter must be clean Be sure the hydraulic reservoir is full at all times 4 Make sure any hoses or tubes that are used are routed to prevent rubbing or chafing during operation It is beneficial for the t
23. and customer sanctioned RBI breakers are enthusiastically accepted as the standard for the industries they serve Some typical applications are e Construction Demolition Recycling Mining Quarrying Trenching Tunneling RBI HYDRAULIC BREAKER USER MANUAL How the Tool Breaks Rock The following paragraphs describe what happens to break rock when the piston strikes the tool A Contact Initial Compression Stress Wave When the piston 1 strikes the top of the tool 2 it sends a compressive stress wave 3 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 4 fracturing it B Recoil Reflected Stress Wave Immediately following the initial compressive stress wave a reflected stress wave is formed 5 which travels back up the tool bouncing the piston up off the top of the tool This cycle of compressive and tensile stresses flowing up and down the tool is repeated with each piston blow E amp F C Bending Anything interfering with the strength of the compressive stress waves 7 during operation such as blank firing free running or prying with the tool can lower breaker performance and cause tool fatigue The breaker must be at a 90 angle to the face of the rock D Blank firing Blank firing the breaker without the tool pressing on a rock causes the energy that normally travels out the tool into the rock 8
24. ank return line to pass through a filter This ensures dirt introduced into the system by connecting and disconnecting the breaker is caught before entering the carrier s pump Quick disconnects on the pressure and return lines are not recommended If they fail metal particles can cause internal damage in the breaker such as accelerated component wear blockages and seizing They will also cause a pressure drop and flow restrictions A CAUTION Make sure the hose fittings are clean and dust free ACAUTION Be sure the operating pressure values do not exceed those instructed in this manual AWARNING It is advisable to provide clearly marked shut off valves in the breaker pressure and return line circuits Shut off valves will enable them to be isolated when removing or installing the breaker This will overcome the risk of releasing high pressure oil and limit the discharge of oil from the hydraulic lines 17 RBI HYDRAULIC BREAKER USER MANUAL Mounting the Breaker 1 Clean the inner surfaces of the breaker attachment bracket with a cloth 2 Draw the carrier machine near inserting the STICK boom into the breaker attachment bracket 3 Carefully clean any dirt from the pins and bushing Insert the bucket pin checking its alignment and securing it with the collars and locking bolts ACAUTION Do not force the pin re check its alignment instead 4 Move the LINK cylinder to line up the hole of the connecting rod
25. any loose bolts or oil leakage The breaker is now ready to operate High Speed and Low Speed Valve Adjusting Valve Adjuster The manual High Low Speed Selecting Valve Adjuster is on upper right side on Cylinder 2 Valve Adjuster Nut High Speed Stroke Setting 1 Turn the valve adjuster screw 1 3 complete turns anti clockwise from normal factory setting 1 Valve Adjuster Low Speed Stroke Setting 1 Turn the valve adjuster screw 1 to bottom out tight If it is hard to turn valve adjuster because of the valve nut 2 tight please loosen the valve adjuster nut 2 a little bit to make valve adjuster turn easily 57 RBI HYDRAULIC BREAKER USER MANUAL Troubleshooting Guide Oil Leakage If oil leakage develops it may not be necessary to replace parts Check the following points in the table below before calling your RBI representative A slight amount of oil seepage around the breaker connecting parts is normal during the first 200 hours of operation Area of Leakage Probable Cause The space between the tool Damaged seals Re seal as necessary and the bushing Large amounts of oil coming out Oil over the surface of the Loose hydraulic hoses or Check condition of hydraulic breaker adapters hoses and adapters Tighten as necessary Joining surface of cylinder and Loose tie rod nut Damaged o Tighten tie rod Replace rear head Oil oozing New oil ring damaged o ring leaking Joining surface
26. at can result in failure and potential accidents Always remove paint from areas to be welded Work on Painted Surfaces Heated paint gives of poisonous gases Therefore paint must be removed from an area with a radius of at least 4 10 cm before carrying out welding grinding or gas cutting In addition to the health hazard the weld will be of inferior quality and strength if the paint is not removed Methods and precautionary measures when removing paint Blasting use respiratory protective equipment and protective goggles Paint remover or other chemicals use a portable air extractor respiratory protective equipment and protective gloves Grinding use a portable air extractor respiratory protective equipment and protective gloves and goggles 12 RBI HYDRAULIC BREAKER USER MANUAL Rubber and Plastics A WARNING When heated rubber and plastics can give off substances that are hazardous to personal health and the environment The following safety instructions must be followed Do not weld or cut with a torch near polymer materials plastics urethane and rubber without first protecting them from the heat Never burn polymer materials when scrapping them Be careful when handling machines that have been exposed to fire or other intense heat Always use gloves protective safety glasses and breathing protection Hazard Alerts AWARNING The breaker should only be mounted to excavators whose lifting capacit
27. atigue failure Other Causes of Increased Tool fatigue Stress Prying with Breaker Blank Firing Blank firing is any situation where the breaker 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 first 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 10280 Prevent scratches gouges weld marks Keep tool well lubricated Operate properly and avoid excessive bending of the tool ts Pulling with Carrier Poor Lubrication Metal to metal contact causes material pick up that can scrape deep damage marks These will develop into fatigue cracks causing tool failure Ensure the tool shank is well lubricated before inserting into the tool holder Molybdenum disulfide grease or eb A RBIs own brand of Chisel Paste containing copper graphite and silica is recommended at 2 hour intervals e Make sure tool is pushed up fully inside the breaker Grease until clean grease runs freely from cavities Corrosion Keep spare tools well greased and sheltered from the weather when not in use A rusty tool is more prone to fatigue failure 64
28. bly to discharge the N2 gas in the 3 way valve assembly 5 Remove the 3 way valve assembly 5 and tighten the plug 9 and cap 11 IMPORTANT To determine the correct pressure in relation to ambient temperatures refer to the below table m Conversion Table for charging nitrogen gas pressure to Accumulator Surface Temperature F Gas Pressure kg cm psi PEDHITIUISTUY 0 32 10 50 20 68 30 86 40 104 Accumulator 53 755 55 780 57 815 59 830 i i i i mk ke m n fe i H 51 730 Accumulator Gas Pressure Adjusting Increasing the Pressure 1 2 3 4 2 6 7 8 9 10 11 Connect the charging hose 4 to N2 gas cylinder 1 after screwing the bombe adapter 3 onto adapter nut 2 and installing to the N2 gas cylinder Connect the 3 way valve assembly 5 to the charging hose 4 after unscrewing the cap on the 3 way valve assembly Remove the cap 11 form the accumulator and tighten the charging valve 12 fully Check if O rings 6 amp 8 are installed to the bushing 7 Remove the plug 9 and screw the bushing Loosen the accumulator charging valve 12 after checking if bushing 7 is installed to the 3 way valve assembly Turn the handle of the N2 gas cylinder counter clockwise slowly to charge gas Charge gas in accordance with the conversion table for charging N2 gas pressure to accumulator Turn the handle of the N2 gas cylin
29. c Circuit If the carrier is not equipped with an auxiliary control valve install a priority flow control valve to direct the correct flow away from the normal circuit and operate the attachment The priority flow control valve is usually equipped with a flow adjustment and pressure relief These valves often need a check valve on the regulated port to completely close the flow If dividing too much flow this circuit can generate heat and may require additional cooling capacity Priority Flow Hydraulic Electric Control Valve Breaker Foot Switch 6E Check Ei o Valve Case Drain Example of a carrier hydraulic circuit without an auxiliary hydraulic circuit 20 RBI HYDRAULIC BREAKER USER MANUAL Operation Suggestions for Efficient Operation A CAUTION Do not operate the breaker continuously in one spot for more than 20 seconds Doing so will cause excessive heat that could mushroom the end of the tool For large rocks start at the edge and work toward the center breaking off small chunks each time Always keep the tool 90 to the surface of the rock to reduce side loading on the tool bushings e If the rock or stone shows no sign of breaking within 20 seconds reposition the breaker Breaking along a rocks natural faults and seams makes breaking easier When breaking on a wall or steep incline use a combination of the carrier s stick cylinder and tilt cylinder to provide t
30. ce the breaker in the vertical stand This will allow the breaker s weight to push the tool and piston up inside the breaker 5 Cover the breaker with a tarp waterproof if outdoors 67 RBI HYDRAULIC BREAKER USER MANUAL Initial Start up after Storage A CAUTION Use extreme care to prevent dirt from entering the hydraulic circuit when disconnecting or reconnecting hydraulic lines Cap or plug lines when disconnecting clean thoroughly before reconnecting Even the smallest dirt particles will cause damage to the internal workings of the breaker Storage can introduce air into the hydraulic circuit If air is present in the hydraulic circuit during operation it may cause a malfunction Circulating the oil will remove air and 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 1 First recharge cushion chamber with nitrogen gas With the breaker mounted and oil warmed to operating temperatures 2 Lift the unit of the ground 3 Press the Start button or pedal to fire the breaker momentarily 4 Continue to turn the breaker ON and OFF in this manner for ten minutes The breaker is now ready to be put into service 68
31. ck for mushrooming on the top of tool 4 If rotating the retainer pins make sure the marked surface is towards the tool as shown 1 Drift 2 Retainer Pin 4 Tool Retainer 5 Drift 6 Tool 33 RBI HYDRAULIC BREAKER USER MANUAL Tool Installation To install the tool reverse the above procedure 1 First grease the inside of the lower bushings When the tool is inserted it will take the grease with it 2 Cover the sides of the tool s top section with grease and insert the tool into the front head 3 Grease and insert the tool retainers then grease and insert the retainer pins TA de n Ex c 25 A n M i 1 T A s ec f e Soy l fF gt ae kc em T 2 CX Pd non 1 Tool 2 Tool Retainer 3 Retainer Pin 34 RBI HYDRAULIC BREAKER USER MANUAL Cushion Chamber Gas Pressure Checking IMPORTANT Incorrect nitrogen gas pressure in the cushion chamber can damage the breaker and cause poor or erratic breaker behavior ACAUTION Stay clear of the tool when charging the breaker cushion chamber Gas pressure may cause unexpected piston movement and force the tool to jump against the retainer pins A CAUTION The cushion chamber is charged with nitrogen N2 a non explosive inert gas Use only N2 when refilling it Charging it with any other gas could trigger an explosion and lead to serious or possibly fatal injuries Handle cy 1 IMPORTANT Before charging th
32. correct nitrogen gas pressure in the accumulator can damage the breaker and cause poor or erratic breaker behavior IMPORTANT Hydraulic oil pressure MUST be fully vented inside the breaker before charging the accumulator Residual pressure will result in an incorrect N2 charge pressure rem ranam aw fa N2 Gas Cylinder ee 777 Adapter Nut EUM 07 b al O 3 Way Valve Assembly Rr eR I Weis J 7 O Ring Hex Bushing f b Y 7 P S N ls 8 O Ri n g P u g a de a TST 2 d Je Lo e 10 O Ring d3 fm 7 Ff g D y ee e fi O Ring Cap Fd ay t n AC a D u 12 Accumulator Charging Valve 1 O Ring 37 RBI HYDRAULIC BREAKER USER MANUAL Accumulator Gas Pressure Checking 1 2 3 4 2 6 7 8 Make sure if the cap and valve of the 3 way valve assembly 5 are fully tightened Remove the cap 11 from the accumulator and tighten the charging valve 12 fully Check if O rings 6 amp 8 are installed to the bushing 7 Remove the plug 9 and screw the bushing Install the bushing 7 to the 3 way valve assembly 5 Loosen the charging valve 12 gradually The charging pressure is indicated on the pressure gauge Close the valve clockwise when the gas pressure is normal If the gas pressure is higher repeat loosening and tightening the relief valve of 3 way valve assembly The pressure is lowered gradually Loosen the relief valve of the 3 way valve assem
33. d seals Reduced breaker efficiency accelerated wear of moving parts and seals piston seizing up oil leakage e Shortened working life and reduced efficiency of hydraulic oil overheats ages electrochemical changes Excessive large particle contamination can cause severe damage to the piston and piston cavity A CAUTION After a major component failure the hydraulic system must be flushed Component damage is only a symptom The trouble itself cannot be cured by removing the symptom Hydraulic Oil Cooling A CAUTION The maximum permitted hydraulic oil temperature in continuous breaker use is 120 158 F 50 70 C depending on the viscosity of the oil in the system It is essential the carrier has a reliable hydraulic oil temperature sensor installed The temperature of the hydraulic oil will depend upon ambient conditions efficiency of the cooling system and the amount of breaker use Additional cooling may be required RBI HYDRAULIC BREAKER USER MANUAL Safety Rules RBI s policy is to produce products that are safe and reliable However even when using well engineered equipment there will always be an element of risk To minimize the risks and promote safety at all times this section of the operator s manual details a number of safety rules that must always be followed and obeyed IMPORTANT When it comes to safety nothing will ever replace a careful operator This Owner s Manual is the p
34. der clockwise to close the cock Close the accumulator charging valve 12 Loosen the relief valve of the 3 way valve assembly to discharge the N2 gas remaining in the charging hose Remove the charging hose 3 way valve assembly and bushing and tighten the plug 9 and cap 11 38 RBI HYDRAULIC BREAKER USER MANUAL Nitrogen Charging Pressure vs Ambient Temperature Conversion table for charging The following table is a guide to accumulator pressure values N gas pressure to accumulator adjusted to ambient temperature differences e Allow the hydraulic breaker and the nitrogen bottle temperatures to normalize to room temperature in a shop environment e Adjust the accumulator and cushion chamber pressure as indicated in the tables below for the ambient temperature expected N gas sealing pressure kg cm Accumulator Surface Temperature C 39 RBI HYDRAULIC BREAKER USER MANUAL Maintenance Schedule Pre Shift Verify correct operation of all machine functions Check for leaks damaged hoses or clamps Check that all electrical components are in operational condition Grease the breaker tool retainer pins and plugs with Chisel Paste If equipped with auto lube system ensure there is adequate grease in the reservoir Verify correct operation of all machine functions Grease breaker tool bushing Pump grease in until it is visible around tool and retainer Check general condition of machine and surrou
35. e J A e If the valve body has flaws in area D smooth the A MISI TA HI surface with 800 1200 grit emery cloth Do not use ZZ LLLA a buffing grinder on this area Control Valve Body Incase of scuffing on the inner diameter G finish by buffing with a flap wheel Clean all parts of the control valve in clean solvent and dry them with compressed air 48 RBI HYDRAULIC BREAKER USER MANUAL Piston Removal A CAUTION Handle these components with care Damaging them will cause breaker malfunction 1 2 NOTE Avoid scratching the piston s polished surface Tapping the cylinder with a soft faced mallet may ease the removal of the piston The seal bushing will come out with the piston 3 4 2 6 7 8 9 Install a lifting eye into the top of the piston Lift the piston straight up and out of the cylinder Place the piston and seal bushing on a clean protective surface 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 this has occurred clean the EN ve grooves Small marks can be removed with an oilstone or fine emery cloth and oil Check the corresponding mating 3 part as well and treat in the same manner 1 Normal Impact Face Look for pitting and deformation of the impact face This 2 Impact Face with Deformation indica
36. e cushion chamber 3 aca make sure the tool is NOT pushed up inside the l DP SUE breaker Lay the breaker down in a horizontal position up i SEE 4 JL Hose connection ed part Synflex Hose 3 Way Valve Assembly Cushion Chamber Back Head Gas Pressure Checking 1 Make sure if the cap and valve of the 3 way valve assembly 5 are fully tightened Screw the 3 way valve assembly 5 into the charging valve of the back head after removing the plug 2 At this time the handle must stand up to prevent the gas from coming out 3 Push the handle into the charging valve fully so the gas pressure inside the back head is indicated on the pressure gauge 4 When the gas pressure is normal unscrew the 3 way valve assembly after discharging gas inside the 3 way valve assembly 5 When the gas pressure is higher or lower charge it as described below NOTE Be careful to connect the hose as quickly as possible Once the hose end is starting to thread on 35 RBI HYDRAULIC BREAKER USER MANUAL the valve will unseat and gas pressure can be lost Refer to Specifications below table for back head gas pressure values m Conversion Table for charging nitrogen gas pressure to Back Head Depends on the temperature of Back Head surface Surface Temperature F Back Head 0 32 10 50 20 68 30 86 40 104 Back Head Gas Pressure kg cm psi 15 5 220 16 228 16 5 235 17 242
37. enance Only trained mechanics should repair or disassemble the hydraulic breaker Be sure you understand a service procedure before beginning any work if you are uncertain contact your RBI representative Avoid unauthorized machine modifications never substitute alternate parts not intended for the application This could create hazardous situations or machine failure RBI Engineering must approve all machine modifications they can affect product reliability and machine stability Before performing any work on the machine attach a DO NOT OPERATE or similar tag in the operator s tag in the operator s cab to alert others of service work being performed Remove engine key and master key switch Unexpected machine movement can cause serious injury The cushion chamber back head is charged with nitrogen N2 a non explosive inert gas Only use N2 when refilling it Charging it with any other gas could trigger an explosion and lead to serious or possibly fatal injuries Relieve all gas pressure in the cushion chamber before beginning disassembly procedures to avoid the potential for accidents or injury It remains under pressure even after the hydraulic system is depressurized Refer to the Maintenance section of the manual Stay clear of the tool when charging the breaker cushion chamber Gas pressure may cause unexpected piston movement and force the tool to jump against the tool retainer pins RBI HYDRAULIC BREAKER USER MANUAL Use on
38. er speed turn valve adjuster counter clockwise 2 1 2 turn To set higher speed than the normal factory setting turn clockwise 2 turn or more A Valve adjuster 1 found on the upper side of the breaker cylinder body is used to switch between high speed and low speed 28 RBI HYDRAULIC BREAKER USER MANUAL Maintenance Lubrication is the single most important procedure for sustaining the life of a hydraulic breaker To keep your breaker in top operating condition perform the maintenance procedures outlined in this section Greasing the Breaker A CAUTION Use proper grease Always use RBI chisel Paste or a molybdenum disulfide based MoS2 grease to lubricate the tool The use of GP general purpose grease is not recommended It will melt and run down the tool providing very poor lubrication Use only as a last resort MT Pressing the tool up inside the breaker prevents excessive grease entering the impact chamber The excessive grease will cause a E X cushioning affect and a lack of breaker power when the breaker is o fired EN nl Excessive grease could contaminate the oil and cause seal failure SY A 1 The breaker must be in a vertical position to grease with m ut LA enough down pressure to push the tool up inside the P si housing d 2 Grease until clean grease oozes out around the tool and retainer pins 3 Grease the breaker after every two hours of continuous use or when the tool appears shiny
39. er Upper Isolator 2 Lower Damper Lower Isolator RBI HYDRAULIC BREAKER USER MANUAL NOTE The upper lower isolators and wear pads are considered wear parts and are not covered under the breaker warranty It is recommended that they be replaced after every 1000 hours of operation or as required A CAUTION Check to make sure the housing is upright secure and fully restrained 1 Install the wear pads and lower isolator into the breaker housing NOTE Do not lubricate the wear pads to ease installation of the breaker body NOTE If the breaker body is new check to make sure nothing is protruding to hinder insertion into the housing 2 3 4 2 6 7 8 9 Lift the breaker body up and center it for entry into the housing Check the orientation of the body the pressure and return ports must face the control valve side Slowly lower the breaker into the housing The breaker may have to be slightly tapped in using a dead blow If the breaker binds or seizes in the housing remove it and determine the cause Keep the lower isolator centered nylon side up Lower the breaker until it fully bottoms out in the housing Check by comparing the position of the retaining pins and the clearance holes in the bottom of the housing The retaining pins should be just above the centerline of the clearance holes Position the upper isolator on the rear head Verify it protrudes above the finished face of the breake
40. ery 20 seconds Rapid Increase in Oil Temperature Emulsification of Cil Oil contaminated with water Locate source of water and repair Replace oil 60 RBI HYDRAULIC BREAKER USER MANUAL Leakage The space between the tool and bushing has Damaged seals Re seal as necessary large amounts of oil coming out Possible loose hoses or adapter fittings cause Check condition of hoses and fittings tighten oil over the surface of the breaker as necessary Oil oozing after overhaul of breaker between Normal oozing of assembly lubricants the control valve and surface of the cylinder Oil ooze after overhaul of breaker between Loosen tie rod nuts and retighten Damaged the joining surfaces of cylinder and rear head o ring replace New oil leaking from surface between cylinder Loosen plugs on face of the cylinder and and front head then re tighten Damaged seals in the cylinder replace as necessary Between the cylinder and hose adapter Replace worn or damaged o ring Check and re tighten the hose adapter to the specified torque Leakage at stroke adjuster cap Replace worn or damaged o ring Loosen the stroke adjuster cap and then re tighten to specified torque Leakage at pilot valve cap Replace worn or damaged o ring Loosen the pilot valve cap and then re tighten to specified torque Control valve bolts loose Tighten bolts to correct torque in a staggered pattern Gas Leakage Gas leakage
41. f damage is too great call your RBI representative Check the slide areas A B and C for flaws If there are scuffing flaws finish the surface smooth with a cylinder hone e If there are flaws in area D use 800 1200 grit emery cloth Never use a buffing grinder in this area Area E can be finished by buffing with a grinder Wash the parts after finishing them JULI ZZ B o MILL 51 RBI HYDRAULIC BREAKER USER MANUAL IMPORTANT When using a buffing grinder apply flap around the inside diameter of the part only If applied along the axis roundness will be affected Seal Bushing Inspection Clean and inspect the cylinder seal bushing The seal bushing carries several specially designed seals Pay attention to the condition and orientation of the old seals as they are removed This may help to identify any operating problems that the breaker had before it was dismantled If burrs are found on the seal bushing use a buffing grindstone to remove them IMPORTANT When using a buffing grinder apply the flap wheel around the inside diameter of the part only If applied along the axis roundness will be affected A CAUTION Handle this component with care Damage will cause breaker malfunction 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 Tie Rod Installation Inspect the
42. fficient ventilation when working in buildings or confined areas AWARNING Never operate the breaker in the vicinity of explosives Make sure there are no explosives hidden in the rock or stones being broken The impact of the tool could cause them to explode AWARNING Avoid all overhead cables and electrical wiring when operating the breaker to prevent the risk of electrical shock Any contact with sources of electricity can lead to an electric shock resulting in serious injury or death Check the worksite for hidden electrical circuits Fire Prevention IMPORTANT Maintain a charged fire extinguisher on the machine at all times and KNOW HOW TO USE IT Prevent combustible debris from collecting in tight corners of the machine This debris by itself may not cause a fire however when mixed with fuel oil or grease in a hot or confined space the danger of fire increases dramatically 11 RBI HYDRAULIC BREAKER USER MANUAL To reduce the chance of a fire starting follow these instructions Clean dust and debris from the machine daily Inspect the machine daily for potential fire hazards and make any necessary repairs immediately Inspect electrical wiring and connections and hydraulic hoses to ensure they are secure and not rubbing against other components Clean up any excess grease and oil accumulation and spillage immediately Use only non flammable solutions for cleaning the machine or components St
43. fficult start up Stiff operation Danger of cavitation in the pumps Accelerated wear of pumps and breaker Sticky valves Filter bypasses oil impurities not removed contamination in hydraulic tank Thin oil may cause Efficiency losses internal leakage Breaker strikes slowly and irregularly Damage to gaskets and seals leaks Accelerated wear of parts from decreased lubrication Hydraulic Oil Purity It is beneficial for the tank return line to pass through a filter This ensures dirt introduced into the system by connecting and disconnecting the breaker is caught before entering the carrier s pump Dirt destroys a hydraulic system so ensure the breaker hose connections are protected when the breaker is not in use Impurities also heat and age the hydraulic oil Air and water are also considered impurities in oil not all impurities can be seen with the naked eye Impurities can enter the hydraulic system e When components are repaired or serviced e During hydraulic oil changes and refilling When the breaker is operated with worn cylinder and seals e When hoses are disconnected during breaker removal installation RBI HYDRAULIC BREAKER USER MANUAL Results of damage by hydraulic oil impurity e Working life of pump s significantly shortened rapid wear of parts corrosion Valves do not function properly spools bind accelerated wear of parts blocking of small holes Rapidly accelerated wear on cylinders an
44. fully how you will handle them when removing disassembling or installing the breaker Stand clear when slinging the breaker off the ground ACAUTION Use extreme care to prevent dirt from entering the hydraulic circuit when disconnecting or reconnecting hydraulic lines Cap or plug lines when disconnecting clean thoroughly before reconnecting Even the smallest dirt particles will cause damage to the internal workings of the breaker AWARNING Risk of personal injury Wear safety glasses boots and protective gloves Relieve all trapped pressure in the breaker hydraulic circuit Pressure can be maintained in hydraulic circuits long after the power source and pump have been shut down 1 Relieve all pressure before disconnecting hoses or tubes 2 Use a lifting crane of suitable capacity to remove the breaker from the carrier NOTE Breaker disassembly must be carried out in a clean shop environment 3 Remove the tool from the breaker Measure and record the clearance value between the tool and the tool bushing 4 Position the breaker upright on a clean level shop floor surface 5 Restrain the breaker upright in this position while keeping the crane in place Restrain the breaker with chains straps or other suitable method to prevent it from tipping over if knocked or hit from an external load forklift cranes loads on cranes etc A CAUTION Be aware of worn housings As the breaker is used the lower portion of the housing
45. gm Accumulator Assembly 1 Install the accumulator diaphragm into the accumulator base Make sure the groove is clean and free of any debris 2 Lubricate the cover bolt threads 3 Install the cover bolts and washers and tighten in stages in a staggered pattern For information on accumulator bolt torque see Torque amp Gas pressure table 47 RBI HYDRAULIC BREAKER USER MANUAL Charging the Accumulator Before the breaker is put into service the accumulator must be recharged with N2 gas Refer to Accumulator Gas Pressure Adjusting Control Valve Removal and Disassembly A CAUTION 3 Handle these components with care Damaging them will cause breaker malfunction The control valve is responsible for directing oil within the breaker to move the piston within the cylinder The RBI Model has an internal control valve contained within the cylinder body The control valve is housed within the cylinder body Once the back head is removed it can be accessed from the upper end of the cylinder body 1 Remove the o rings then the valve plug 2 The valve spool and valve sleeve can then be slid out If spool is not seized it can be easily removed 1 Valve Sleeve A puller can assist in removing a seized spool 2 Valve Spool 3 Valve Cap Control Valve Inspection D e Ifthe valve spool surface is scuffed remove it with 800 1200 grit emery cloth If the area is extremely ZR TT damaged replace the valv
46. he left side of the carrier and the return line on the right as viewed by the operator RBI breakers operate within a specified flow range The operating pressure will depend on the amount of oil flow the return line pressure and internal efficiency of the individual attachment Carrier with Auxiliary Hydraulic Circuit The carrier will often be equipped with an auxiliary control valve In this case the auxiliary control can be used to control the supply of oil It can usually be adjusted to provide the correct amount of flow and a relief cartridge can be installed to protect the hydraulic circuit A CAUTION When using the carrier s existing auxiliary control valve for the hydraulic breaker circuit do not route the return line back through its return port High back pressures may result It is recommended to send the oil directly back through the cooler return filter to the tank If it is necessary to plumb the circuit using both ports on the auxiliary valve the return line should have a drain line connected to the tank This will reduce back pressure in the hydraulic circuit and protect the control valve from return line pressure spikes 19 RBI HYDRAULIC BREAKER USER MANUAL Typical hydraulic Circuits From E Electric Pilot Circuit Foot Switch Hydraulic Oil Supply On Off Breaker Valve oo Example of a carrier hydraulic circuit with an auxiliary hydraulic circuit Carrier without Auxiliary Hydrauli
47. he necessary force to hold the breaker against the material Always work the tool at 90 to the material being broken As down force is applied on the breaker the carrier will lift slightly indicating breaker tool is properly pressed onto the material ACAUTION On large rocks take a smaller bite Do not start in the middle Keep tool 90 to surface of rock The breaker should not be fired when the carrier s boom hydraulic cylinders are fully extended or fully retracted The cylinders may be damaged from the breaker s shock pulses 21 RBI HYDRAULIC BREAKER USER MANUAL A CAUTION When hydraulic oil temperature exceeds 158 F 70 C stop breaking If the carrier s operating temperature runs too high it will actually decrease the breaking power Rake ONLY with breaker wear plate and reinforced rock claws Do not use the tool to rake materials Qe Push ONLY with breaker wear plate and reinforced rock claws End of Shift If the breaker is not removed from the carrier at the end of the day it should be left standing vertical with the tool pushed up into the breaker Improper Use of Breaker A CAUTION Do not use the breaker to pry pick pound or lift This can cause serious damage to the breaker as the tool is side loaded or binds in the bushing The tool must always move freely straight up and down in the bushing Qe Do not PUSH incorrectly Use breaker wear plate and reinforced rock claws
48. ly lifting devices with sufficient capacity to safely support the expected weight you are lifting e All lifting devices straps slings chains ratchet blocks etc must comply with applicable local regulations and certifications RBI cannot accept responsibility for the use of sub standard equipment and work practices When lifting or supporting the breaker or its parts use equipment with a sufficient lifting capacity Use the lifting eyes or lifting points that are located on certain breaker components Do not work under a hanging or suspended load If a jack is used the floor or ground must be flat and of sufficient strength to support the expected load Precautions for Working on Hydraulic Systems A WARNING Risk of personal injury Wear safety glasses and use protective gloves Relieve all trapped pressure before performing any service to the hydraulic system Pressure can be maintained in the hydraulic circuits long after the power source and pump have been shut down Relieve all pressure before disconnecting hoses or tubes e Tighten all connections before applying pressure It is important that each person who comes in contact with the machine be alert to any faults Follow these basic precautions Never adjust a pressure relief valve or other pressure limiting device to a higher pressure than specified Check to make sure hydraulic hoses are not worn or damaged and are routed to avoid chafing Replace any hydra
49. nding work area Check all screw connections for tightness during first 50 hours of operation Refer to Torque Specifications Check torque on all fasteners Check mounting pins for wear Check impact surface of tool for deformation Remove the breaker tool and inspect the wearing surface Remove any burrs before reinstalling Inspect the tool retainer pins Remove the pins rotate 180 degrees and reinstall After initial 100 hours of operation change hydraulic pressure and return line filter elements Check tool bushing clearance Check that the pressure return filter indicators on the carrier hydraulic system are functioning correctly and not in by pass 40 RBI HYDRAULIC BREAKER USER MANUAL Every 500 Hours Take a sample of the hydraulic oil Review the results and determine if an increase in filter change interval and or oil change is required File the results Check cushion chamber nitrogen gas pressure Refer to Cushion Chamber Gas Pressure Checking Perform all breaker checks above as required Check that the retainer pins cross pins and stopper plugs are not damaged and are in Check that the upper isolator and tie rod nuts are in place and tight Check for wear Replace the retainer pins Perform all breaker checks listed above as required Disassemble the breaker to replace all seals Replace upper and lower breaker isolators inside the housing Measure the wear limit on the Front and Rear Bu
50. nes Plug the lines and the breaker ports to prevent contamination 3 Use your excavator to lay the breaker on wooden blocks with the mounting bracket end lying higher than the tool end Support the breaker before proceeding 4 Remove the pins to disconnect the breaker from the carrier 5 Remove the tool and ensure the retaining pins bushings and piston bottom inside breaker are well greased 6 Reinstall the tool and cover the breaker with a tarp Use a waterproof cover if storing outdoors Long term Storage Storing the breaker over a week is considered Long term Storage Breaker Stored Lying Down Use the following procedure 1 Release the cushion chamber gas pressure 2 Remove the tool and liberally grease the piston bottom retaining pins and inside the front head 3 Ensure inlet ports are open to allow piston to move up to the top 4 Push the piston up inside the breaker and reinstall the tool 5 Lay the breaker on wooden blocks using your excavator Mounting bracket end should lie higher than the tool end 6 Cover the breaker with a tarp waterproof if outdoors Breaker Stored Standing Up If the breaker is to be stored standing up place in a safety stand Use the following procedure 1 Release the cushion chamber gas pressure 2 Remove the tool and liberally grease the piston bottom retaining pins and inside the front head 3 Ensure inlet ports are open to allow piston to move up to top 4 Reinstall the tool and pla
51. of cylinder and Loose plugs on face of Tighten loose plugs Replace front head cylinder Damaged seals damaged seals as necessary New oil leaking High low speed selector Loose locknut Tighten loose locknut Oil running down breaker Damaged O ring Replace damaged O ring RBI HYDRAULIC BREAKER USER MANUAL Hydraulic Breaker Does not hammer Anti blank fire has activated Push breaker down on tool to disengage blank fire mode Base carrier selector valve does not operate Check connection from cab controls to correctly selector valve Poor performance of the hydraulic pump Check pump outlet Repair or replace Pressure relief valve set too low Check relief settings and adjust Clogged or restricted hoses Clean or replace Cushion chamber filled with oil Replace seals Seizure of breaker Overhaul and replace worn parts Back pressure too high in circuit Find source causing increased back pressure in return circuit and remove Control valve bolts loose Tighten bolts to correct torque in a staggered pattern Check all ball valves Open ball valve Does Not Impact Temperature of the hydraulic oil is too low Warm up the hydraulic excavator The nitrogen gas pressure in the cushion Adjust the nitrogen gas to the correct chamber is too high pressure Pressure setting for the relief valve is too low Set the relief valve to the correct pressure setting Poor performance of the hydraulic pump on
52. ore rags and other combustible materials in a safe fireproof location Before starting repair work such as welding clean the surrounding area and place a fire extinguisher close by e Store flammable fluids away from fire hazards Do not incinerate or puncture pressurized containers Welding and Grinding Work IMPORTANT A fire extinguisher should be easily accessible during all welding work Welding repairs are to be performed by a trained welder with proper service instructions Know the material to be welded and select the correct welding procedure and materials electrodes rods wire that will provide a weld metal strength equivalent to the parent material e Move the machine to a clean safe area before welding grinding or using an oxy acetylene torch on it This type of work should only be done in a clean area and not in places that contain combustible liquids such as fuel tanks hydraulic pipes or similar Consult the carrier operator s manual before starting welding procedures Sensitive equipment may require disconnecting machine electronics If welding the breaker side plates or box housing remove them from the breaker assembly This prevents the possibility of internal damage to the breaker resulting from internal arcing between the cylinder and piston Work with extra care when welding grinding or torch cutting near flammable objects Welding on painted surfaces releases dangerous fumes and results in a poor weld joint th
53. r housing See previous page Position the mounting bracket on the top of the breaker Ensure bracket is not put on backwards and install bolts Lubricate the bolts with MoS2 grease Tighten bolts in a cross pattern to provide even loading to the upper isolator Top Mount Bracket Bolt Torque Torque Value Torque Value Ibs ft Ibs ft RB105 155 260 RB2000 3600 1320 260 RB305 755 RB4000 2600 RB1005 1500 RB4500 9500 2600 56 1 Top mount bracket Bolts RBI HYDRAULIC BREAKER USER MANUAL Reinstall the tool Refer to Tool Installation A CAUTION Use extreme care to prevent dirt from entering the hydraulic circuit when disconnecting or reconnecting hydraulic lines Cap or plug lines when disconnecting clean thoroughly before reconnecting Even the smallest dirt particles will cause damage to the internal workings of the breaker e Install the breaker onto the carrier and reconnect the pressure and return lines Start up Air may have been introduced to the hydraulic circuit and may cause a malfunction Warm the carrier hydraulic system up to operating temperature then cycle the oil to remove the air 1 Lift the unit off the ground 2 Press the start button or pedal to fire the breaker momentarily eu 3 Continue to turn the breaker ON and OFF in this manner Dn rie irt rt ort for 10 minutes 4 Work the breaker in soft material in short bursts for 10 minutes 5 Check for
54. rimary source in maintaining optimum performance from the hydraulic breaker It is imperative that the operator reads and understands all the safety information in this manual before proceeding Failure to follow the instructions or heed the warnings could result in injury or death Proper care is your responsibility RBI 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 RBI is used you must satisfy yourself that it is safe for you and others You should also ensure the hydraulic breaker will not be damaged or made unsafe by the operation maintenance or repair procedures you choose It is the obligation of the operator to make sure that all warning decals are in place on the machine and that they are readable Accidents may otherwise occur Contact your distributor or RBI for replacement manuals or decals e Should there be any information or instructions in this manual that are not in compliance with local laws and regulations in force in the country or region where this equipment is operated the local laws and regulations must take precedence RBI HYDRAULIC BREAKER USER MANUAL General Safety Precautions AWARNING The operator of this machine must have sufficient knowledge and instructions before he she operates the machine Un
55. s then applied directly to the rock Breaking oversize is less effective when there is material under the rock that can absorb energy If rocks are hanging on the edge of the bars use short bursts of the breaker to hammer them through Guide to Tool Choice 1 Moil used for penetration in low abrasive materials of similar make up 2 Chisel X used for splitting material made up of substances that have a different make up 3 Chisel Y Use for asphalt cutting 4 Blunt Used for impact in hard crumbly rock ACAUTION Use of after market tools not approved by RBI may void warranty 25 RBI HYDRAULIC BREAKER USER MANUAL Underwater Operation Optional A CAUTION Do not operate the breaker underwater or in mud Permanent damage to the breaker may result RBI breakers require specific modifications for underwater applications Underwater operation of the breaker is possible to pour air into the striking area between the piston and the rod For the sake of underwater operation the adapter is supplied as a standard part For the sake of underwater operation breaker is installed the air supply kit separately Underwater usage of the breaker without the underwater kit and air compressor will cause serious damage to the hydraulic breaker Installing the Air Supply Kit Clean the air check valve hole on the left side of the cylinder Except RB505 the air check valve hole is located on the right side Remove
56. seal and slide ring Check the seals for signs of extension and excessive wear both before and after removal e Thoroughly inspect inside walls of the cylinder for corrosion cavitation or scoring Check grooves above seal area for small pieces of metal due to galling If these are not cleaned out they will chip off and go between the piston and cylinder and galling will occur again Check for any damage to the heli serts that secure the control valve Repair or replace as necessary to ensure the valve can be installed properly Inspect the main inlet and outlet adapter threads for damage Always replace the seals it they are removed A CAUTION Do not install the hydraulic adapters in the wrong port The pressure adapter has a smaller through hole than the tank adapter The cylinder is marked IN beside the pressure adapter and OUT beside the tank adapter 50 RBI HYDRAULIC BREAKER USER MANUAL Cylinder clean up Any slight galling and other irregularities on the cylinder wall must be removed before reassembly Use a cylinder hone to ensure the cylindricity of the bore is maintained After using a hone de burr the edges of all the lands The preferred method to remove irregularities is to use a blade fixed type hone A second method is to use a flexible hone The amount of de burring required will be reduced with the flexible hone A die grinder should only be used for de burring edges and severe local points of galling I
57. sed at all times Breaking Concrete Begin by penetrating the concrete several times in one area with the breaker tool This should loosen the concrete and separate the reinforcing steel This rebar may need to be cut to keep the concrete pieces manageable for removal e When breaking concrete floors use the down force from the carrier s boom cylinder to follow the tool through the concrete For vertical walls force must be maintained using a combination of boom stick and tilt cylinders A fast blow rate gives the best performance in breaking concrete so ensure your carrier is providing the breaker with the maximum recommended oil flow Generally a chisel point gives the best splitting action when breaking concrete However if breaking hard concrete with lots of rebar a moil point may be better The moil tip helps deflect the tool off the steel as it breaks the concrete 24 RBI HYDRAULIC BREAKER USER MANUAL Breaking on a Grizzly NOTE Breaking on a grizzly can cause excessive blank firing It is recommended the breaker be configured for anti blank firing mode If the grizzly is covered with rock use the breaker s reinforced rock claws and the wear plate of the box housing to rake the material This will get most of the finer material 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 All the energy from the breaker i
58. semble the breaker body The tie 1 Back Head Charging Valve rods and control valve bolts use heli serts steel threaded inserts that can be damaged by the use of impact tools 45 RBI HYDRAULIC BREAKER USER MANUAL Rear Head Removal 1 2 3 4 2 6 7 8 Use the charging hose in tool kit to fully vent the N2 gas from the cushion chamber Insert lifting eyes into the rear head and stand the breaker on a safety stand Remove the back head charging valve to avoid accidental damage during bushing replacement Put it in a safe place for reuse later 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 Using a hoist jerk the assembly upwards slightly which should loosen the rear head from the cylinder Place the rear head on a clean protective surface 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 and washers from the four tie rods Remove the rear head from the cylinder using lifting eyes l Lifting Eye 2 Back head charging valve In some cases the nuts may be seized onto the tie rod and may come out as a unit Accumulator Removal AWARNING Release accumulator gas pressure before disassembly The accumulator contains nitrogen gas under pressure Do not remove the bolts
59. shings Replace each bushing if the allowable tolerances are exceeded Check Hydraulic flow to breaker and operating pressure Adjust as necessary 41 RBI HYDRAULIC BREAKER USER MANUAL Torque and Gas Pressure Table 068 068 068 068 068 068 OSC SEZC 029 029 914 9190 91 0 FUA FIO 08S 08S SLT SLT SLT OTT OTT osot osot Ea a d JE 3 0 90 0 W LEN 078 ZND O9TT O9TT O9TT 0 8 jvZIWN 08S 08S 008T 008T 008T OSVT O I SII O I SII OET STT O T STT O T STIT OET SIT O T STT O T STT O T STT OET STT OET SIT O T STT OCT STI 8 OCC O8T 00p 09 SSc 0cc 0cc 081 S8I SZT O T STI O T STT OET STT OET STT O T STT OEL STL ttm oo rt oo Le amp ST SVC STA SVC 91 0 SZI LA T N LA qT N GCE yew ZrO ZND 08S 0S5 08S 08S 08S 0CVO Oz SCE GCE SCL jqe isd aunssaig ses X 3 Ssqj anbioy OLTC OLTC OS6T 008T SELT oos 6ay 000894 009 8H oossayY O0SPtHH O00t8H 000c8H Scrad solgay Sag dis 5 BS LA 9JnssoJd Ser Jojemumooy emsselg Ser peop Peg yog de yunoyy yog PIS 31ex eg GA eA Surgeu sez APBA 3290 Jry MN INPE AWA Jeydepy LNO NI yog 19409 10jemumooy yog Apog 1oje umooy og 19409 2 BujsnoH A yog ynon onbJo onbJo 42 RBI HYDRAULIC BREAKER USER MANUAL Breaker Disassembly AWARNING Hydraulic breakers and their components are heavy Plan care
60. tes that the tool has been operated with too much wear on the tool bushings If the face is dished carefully measure the amount of deformation Thoroughly clean and dry the piston to protect it from dirt then set it aside If the piston is not going to be installed immediately coat it with oil and store it protected in a clean dry place If the piston face is scuffed finish it with a buffing grinder then 800 1200 grit emery cloth IMPORTANT When using a buffing grinder apply the flap wheel around the circumference of the part only If applied along the axis roundness of the part will be affected Wash the parts after finishing them AN uci 49 RBI HYDRAULIC BREAKER USER MANUAL Cylinder Removal A CAUTION Handle this component with care Damage will cause breaker malfunction 1 Install lifting eyes into the top of the cylinder 2 Lift the cylinder straight up off the tie rods LKO C CO 3 Loosen and remove the tie rods It may be necessary to secure the front head to prevent it from rotating 4 Loosen the tie rods by rotating them counter clockwise Use an adjustable wrench and a soft faced mallet or a sledge wrench on the tie rod flats to loosen them 10330 The cylinder should slip out of the front head If not tap the front head with a soft faced mallet until the cylinder and front head come apart Cylinder Inspection e Thoroughly clean the cylinder bore and remove the dust seal oil
61. the air check valve with the standard tool Apply the O ring to the cylinder s air check valve hole and install it Connect the hose to the air check valve hole and install it Air must be flowing before entering the water Before underwater operation Air flow rate for underwater operation The air capacity levels are in the following chart Supply appropriate air flow rate in accordance with the breaker model and operating depth Depth Pressure j y Y m bar l t RB105 1 RB755 ITI T j L M99 RB1500 RB2000 RB3600 7 RB305 7 15 3bar j LT E 13 12 1 Lat cT i l ale UP RB9500 RB4000 L RB4500 RB5800 _ t gt am it pe lt 1 RB8000 26 RBI HYDRAULIC BREAKER USER MANUAL Illustration for Installing the Underwater Breaker RB105 RB9500 O Ring W Adapter Hose Air Check Valve Qty AIR COMPRESSOR 27 RBI HYDRAULIC BREAKER USER MANUAL High Low Speed Selector valve Breaker models RB1500 and larger can operate at two speeds The higher speed setting is obtained by shortening the piston stroke At the higher speed the breaking power is somewhat lower but higher production rates can be achieved in softer materials such as concrete It is not available on models smaller than RB1500 To set low
62. trained operators may cause severe injuries or even fatalities Therefore it is important that you read and follow the instructions of this Owner s Manual Never use a machine that has no Owner s Manual available Learn and understand the safety signs and symbols on the machine and the operator instructions before you begin to use the machine Wear protective clothing know and use the protective equipment that is to be worn when operating or servicing the hydraulic breaker Hard hats protective glasses protective shoes gloves reflector type vests respirators and ear protection are types of equipment that may be required Prolonged exposure to loud noise can cause hearing damage Operate the machine only when physically fit and not under the influence of alcohol or drugs Avoid loose fitting clothing loose or uncovered long hair jewelry and loose personal articles These can get caught in moving parts Keep all personnel well away from the hydraulic breaker when it is operating Small pieces of stone or concrete can fly off causing serious injury to bystanders Keep a first aid kit and a multi purpose fire extinguisher on or near the machine and know how to use them Know where to get help Before starting up the hydraulic breaker perform a daily inspection and include it in the daily machine walk around Pay special attention to hoses and electrical connections Make repairs before operating the breaker Practice Safe Maint
63. ulic hose immediately that shows signs of swelling wear leaks or damage before it bursts e Hydraulic fluid escaping under pressure can penetrate the skin causing serious injury Do not use your hand to check for hydraulic oil leaks Use a piece of cardboard If skin penetration occurs seek medical attention immediately Relieve all pressure before disconnecting hoses Do not bend or strike high pressure lines tubes or hoses or reinstall them in a bent or damaged condition 10 RBI HYDRAULIC BREAKER USER MANUAL Precautions for Handling Hydraulic Oil AWARNING Risk of burns Use protective work gloves Hot oil can cause painful burns Use caution when changing the hydraulic oil Oils can irritate and damage the eyes throat and other sensitive skin Avoid contact e Petroleum based oils are hazardous to the environment Take special care not to spill or discharge these fluids Use approved containers and methods to handle and dispose of them Use an authorized disposal and recycling company Work Site Precautions A WARNING Know the location of any flammable gas lines in the construction area Damaged gas lines could lead to a fire or explosion Operation the breaker may create sparks that could ignite highly flammable gases Never operate the breaker in an environment where highly explosive gases could be present e Make sure there are no sources of flammable gases in the work area Always provide su
64. ure falls to the specified pressure 10 When the gas pressure reaches to the specified pressure close the valve and release the handle 11 Open the valve completely and discharge gas inside the 3 way valve assembly Remove the 3 way valve assembly from the charging valve of Back Head and install the plug to the charging valve At this time prevent contamination from entering the breaker 36 RBI HYDRAULIC BREAKER USER MANUAL Nitrogen Charging Pressure vs Ambient Conversion table for charging Tem peratu re N gas pressure to back head The following table is a guide to back head cushion chamber m g 21 rT pressure values adjusted to ambient temperature differences 5 Rai C 20 t e Allow the hydraulic breaker and the nitrogen bottle Pa xo vw n temperatures to normalize to room temperature in a o yg JL es an did shop environment G7 L Qe we e Adjust the cushion chamber pressure as indicated in the 16 tet table below for the ambient temperature expected 15 je o 14 3 2 12 11 0 20 40 60 80 Back Head Surface Accumulator Gas Pressure Checking Temperature C Check accumulator gas pressure every 500 hours of operation A CAUTION The accumulator is charged with nitrogen N2 a non explosive inert gas Use only N2 when refilling it Charging it with any other gas could trigger an explosion and lead to serious or possibly fatal injuries IMPORTANT In
65. ve is too low Poor performance of the hydraulic pump on the excavator Clogged or restricted hoses pipes Back pressure too high in circuit Tool Breaking Adjust the nitrogen gas to the correct pressure Operate the boom and bucket cylinders so that pressure is applied to the tool Set the relief valve to the correct pressure setting Have the excavator manufacturer check the pump performance Investigate the blocked area and repair or replace Find source causing increased back pressure in return circuit and remove Abuse of tool and prying with tool Apply down force in the direction of tool only Check for excess play in arms links and pins 62 RBI HYDRAULIC BREAKER USER MANUAL Breaker Tool Cia Normal Breaker Tool Wear Wear depends on rock conditions Hard abrasive rock wears A Dia the tool down faster Working in softer materials will keep the point shape longer Blunt tools A will wear back 1 3 of the diameter to be shaped 2 in as shown 5 mm Moil and Chisel tools B amp C will wear back 2 inches b1mm or more to be shaped as shown As a general guide this is considered normal wear and reasonable tool life Warranty claims are not accepted for normal wear 2 in 10288 Breaker Tool Fatigue Failures Metal Fatigue Metal fatigue is the sudden fracture of a component This effect occurs on metal after a period of repeated c
66. with the second mounting bracket attachment hole Insert the pin and secure it with the collars and locking bolts Setting Flow and Pressure See Specifications below for operating pressure and oil flow requirements for all RBI models Description Unt Rer Reiss Resos Rsos Re7ss Re1oos _RB1600 kom 30 120 90 120 100 130 110 140 120 150 130 160 150 170 operating P 2280 1707 __ 4280 1707 1422 149 1565 199 1767 2194 1849 2276 2134 2418 mmm RB8000 RBSSU0 160 180 2276 2560 2276 2560 Em uc mew o p mess RE1509 U min 15 25 25 50 30 60 40 70 50 90 60 100 80 110 Oil flow S3 min 4 8 6 5 13 8 16 10 5 18 5 13 24 16 16 5 21 29 RB2000 RB3600 RB4000 RB4500 RB5800 RB8000 RB9500 requirements t min 90 120 100 150 120 180 150 210 180 240 200 260 210 290 gal min 24 32 27 40 32 48 40 56 48 63 51 69 55 77 A CAUTION DO NOT operate the breaker below its minimum flow rate Internal damage to the breaker may result DO NOT operate the breaker at a pressure near to or above the relief valve setting Internal damage to the relief valve may result Ensure the relief valve is set 400 600 psi 27 41 bar above the actual operating pressure of the breaker Setting the Flow 1 Install an in line flow meter in place of the breaker 2 Adjust the flow on the flow control valve to the maximum permitted for the breaker The highest flow will permit the most blows per minute 3 Ensure the flow is
67. within the permitted range Setting the Relief pressure 1 Connect a flow and pressure meter in place of the breaker Bypass the hydraulic breaker and route the return line directly to the tank 2 Measure the flow under no load and verify it is in the range for the breaker 3 Slowly increase the pressure and at the same time verify the flow remains constant right up to the predetermined relief setting 4 Adjust accordingly Double check both relief pressure and flow settings 5 When the breaker is installed and the oil is warmed to operating temperature use a pressure gauge in the pressure line to verify the average operating pressure is within the specification 18 RBI HYDRAULIC BREAKER USER MANUAL Start up Before putting the breaker to work in hard material it is necessary to remove air from the hydraulic system and allow the new seals to work in properly 1 Lift the unit off the ground 2 Press the start button or pedal to fire the breaker momentarily 3 Continue to turn the breaker ON and OFF in this manner for 10 minutes 4 Work the breaker in soft material in short bursts for 10 minutes 5 Check for any loose bolts or oil leakage The breaker is now ready to operate On new units be sure the Installation Notice is properly completed and submitted Typical hydraulic Circuits For a hydraulic breaker to function it needs hydraulic flow and pressure in one direction only The supply line should be directed out t
68. y is greater than the minimum value a WARNING When working overhead always be aware of the possibility of falling blocks or material fragments Ensure that the machine is equipped with the necessary protection and that the cab is of the 10010 F O P S Falling Object Protective Structure type A WARNING Keeps a minimum distance of 100 ft 30 5 m from the excavator operating area Protect bystanders from the working area to prevent injuries Proceed carefully when moving the excavator 10394 100 ft 30 5 m N OK 13 RBI HYDRAULIC BREAKER USER MANUAL AWARNING The breaker must only be used by a skilled operator who has read and understood the Owner s Manual AWARNING Do not allow any unauthorized person to operate or carry out any type of maintenance AWARNING The breaker must be used only on the condition that it has been installed correctly using the attachment bracket and pins AWARNING Do not use the breaker for lifting hammering or transporting materials AWARNING If the breaker becomes entangled in the reinforcement bars of the structure being demolished free it before proceeding 10276 AWARNING Do not begin demolition work from lower parts of a structure The upper part could collapse A WARNING Do not use the breaker to hammer against the structure being demolish AWARNING The excavator boom must be moved safely with slow accurate movements
69. ycles of 1 stress Normally there will be no obvious warning A crack 9 forms without any visual change making it difficult to detect the presence of growing cracks Fractures usually start from small nicks or scratches or fillets that cause a localized 10284 concentration of stress The fracture face itself normally appears as a semi circular polished area with the remainder 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 63 RBI HYDRAULIC BREAKER USER MANUAL Cause and Effect of Fatigue In normal operation a cycle of compressive and tensile stresses Incorrect flow up and down the tool with each piston blow as the breaker S Breaking Angle fires The main cause of increased tool fatigue stress is any side force applied during operation that bends the tool Prying with the tool using the incorrect working angle or attempting to break ground using the pull of the carrier machine will shorten tool life and must be avoided Anything that interferes with these normal stresses increases the risk of early tool f

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