® artungshandbuch

BEILITE HYDRAULIC für den AND

HAMMER OPERATING Beilite Hydraulikhammer
MAINTENANCE MANUAL

40

BEILITE BLTB 40 - 210

© 2020 Taizhou Beilite Machinery Co. ltd. 1

Version M.GB.03.2020
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© 2020 Taizhou Beilite Machinery Co. ltd. 202

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FOREWORD

• First of all, thank you for choosing Beilite Hydraulic Hammer. Manufactured by Beilite Company with strong research and
development teams and exquisite process technologies, this product is more powerful and durable. Proper operation and
timely maintenance will improve the working efficiency and service life of the product.

• In order to use the hydraulic hammer of the Company safely and correctly, please carefully read the safety indicators and
operation specifications in this Manual. Please do not operate this product until you have fully grasped the contents.

• Keep this Manual in the place where you can read and use it at any time.
• The structure of the product may not be changed without the permission of the Company. It is not allowed to operate the
product outside the specified range of purpose; otherwise, you will not enjoy the warranty of the Company.

• The Company will not be responsible for any damage caused by improper operation and use of other parts except the
original parts of the Company.
• The operator must take personal safety protection measures and confirm the safety of the surrounding environment, people
and objects to avoid accidents when using the product for operation.
• For the contents or the descriptions that are not detailed enough in this Manual, please consult the agent or the After-sales
Service Department of the Company.

—Beilite Machinery Co., Ltd.

Permanent quality, fast service Unswerving efforts, constant innovation

© 2020 Taizhou Beilite Machinery Co. ltd. 03

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© 2020 Taizhou Beilite Machinery Co. ltd. 404

 ® CONTENTS

CONTENTS

I. Safety Specification-------------------------------------------------------------------------- 06
1.1 Basic Safety Rules---------------------------------------------------------------------------- 06
1.2 Basic Safety Operations --------------------------------------------------------------------- 07
II. echnical Parameters------------------------------------------------------------------------- 08
III. Structure and Main parts of Hydraulic Hammer------------------------------------------ 10
IV. Product Identification and Position-------------------------------------------------------- 11
V. Installation and Disassembly--------------------------------------------------------------- 12
5.1 Diagram of Hydraulic Hammer------------------------------------------------------------ 13
5.2 Hydraulic Pipeline of Hydraulic Hammer ------------------------------------------------ 14
5.3 Preparation before Installation------------------------------------------------------------- 15
5.3.1 Requirements for Main Engine ------------------------------------------------------------ 15
5.3.2 Hydraulic Oil Discharge and Pipeline Cleaning ----------------------------------------- 17
5.4 Installation and Disassembly Steps--------------------------------------------------------- 18
5.4.1 Installation of Connecting Base ------------------------------------------------------------ 18
5.4.2 Connection between Hydraulic Hammer and Main Engine ----------------------------- 19
5.4.3 Disassembly of Hydraulic Hammer ------------------------------------------------------- 22
5.4.4 Installation and Disassembly of Chisel ---------------------------------------------------- 22
5.5 Setting of Overflow Valve Pressure--------------------------------------------------------- 24
5.6 Adjusting Method of Valve Adjuster------------------------------------------------------- 24
5.7 Anti-idle Adjustment Method-------------------------------------------------------------- 25
5.8 Adjustment Method of Hitting Frequency------------------------------------------------- 26
5.9 Inspection after Installation---------------------------------------------------------------- 27
VI. Method of Application---------------------------------------------------------------------- 28
6.1 Operation Precautions---------------------------------------------------------------------- 28
6.2 Correct Operation Essentials--------------------------------------------------------------- 34
6.3 Appropriate Storage Method--------------------------------------------------------------- 36
VII. Maintenance--------------------------------------------------------------------------------- 39
7.1 Maintenance Cycle-------------------------------------------------------------------------- 39
7.2 Daily Inspection----------------------------------------------------------------------------- 41
7.3 Inspection Emphasis------------------------------------------------------------------------ 42
7.4 Replacement of Chisel---------------------------------------------------------------------- 44
7.5 Replacement of Chisel Pin------------------------------------------------------------------ 46
7.6 Replacement of Chisel Bush---------------------------------------------------------------- 47
7.7 Replacement of Thrust Bush---------------------------------------------------------------- 48
7.8 Nitrogen Gas Supplement------------------------------------------------------------------ 49
7.9 Hydraulic Oil-------------------------------------------------------------------------------- 51
VIII. Fault and Solution-------------------------------------------------------------------------- 53
IX. Automatic lubrication Device ------------------------------------------------------------- 55
X. Important Notes----------------------------------------------------------------------------- 57
XI. BLTB40-155 Warranty Guarantee--------------------------------------------------------- 58
11.1 BLTB165-210 Warranty Guarantee-------------------------------------------------------- 59
XII. Commissioning card for warranty--------------------------------------------------------- 60
XIII. Judgment and Treatment of Oil Leakage in Hammer Cylinder-------------------------- 61
XIV. Hydraulic Hammer Daily Inspection------------------------------------------------------ 62

© 2020 Taizhou Beilite Machinery Co. ltd. 505

 ® SAFETY SPECIFICATION

I. Safety specification

• This Manual describes the correct use and basic safety knowledge of the hydraulic hammer. When you see the important
content indication symbol , you must be alert to possible personal injury or death and confirm the safety matters.

• The safety content in this Manual does not cover all the situations that may cause personal injury, death or product damage
and it mainly provides basic safety operation and maintenance knowledge.

Danger W
Warning Attention
This symbol indicates that wrong This symbol indicates that wrong This symbol indicates that wrong
operations may cause death or serious operations may cause injury to the operations may shorten the service
injury to the operator. operator or damage to objects life of the equipment

1.1 Basic safety rules

Danger
1. The accumulator and rear cylinder are filled with high-pressure nitrogen gas and wrong operations will cause major personal
injury or death. Please pay attention to the use matters and never carry out violation operations.

2. If the other gases except nitrogen gas are used for the accumulator or rear cylinder, an explosion may occur, thus causing
major personal injury or death. Therefore, it is not allowed to use the other gases except nitrogen gas.

3. Do not weld or drill the accumulator and rear cylinder and keep them away from fire to prevent cracking or explosion.

4. When disassembling the accumulator and front, middle and rear cylinders, please discharge the high-pressure nitrogen
gas in the accumulator and rear cylinder. Please entrust the discharge operation to the Company or our agent.

5. Please entrust the repair operations of the accumulator and front, middle and rear cylinders to the Company or our agent.

© 2020 Taizhou Beilite Machinery Co. ltd. 06

 ® SAFETY SPECIFICATION

Warning
1. When the hydraulic hammer is just used, do not touch the chisel, because the temperature is high at this time and there is a
risk of injury.
2. In the period after the hydraulic hammer is used and just stopped, the internal pressure of the hydraulic oil pipe may be still
high, and if the oil pipe is released at this time, the high-pressure oil in the pipe may be ejected, so please turn off the main
engine and carry out this operation after the oil pressure in the oil pipe is completely released.
3. Do not use the standard hydraulic hammer for underwater operations. If underwater operations are needed, please consult
the Beilite Company or the designated agent.

Attention
1. When connecting the oil pipe of the hydraulic hammer of the Company, take care to prevent foreign matter from entering
to hydraulic oil pipe.
2. Make sure that the high and low pressure oil pipes are properly connected to the hydraulic hammer of the Company.
The length of the oil pipe at the front end of the pipeline stop valve should be appropriate.
3. Intermittently turn on the hydraulic hammer starter to remove the gas in the oil pipe and hydraulic pipeline.

1.2 Basic safety operations

1. When operating, repairing and maintaining the hydraulic hammer of the Company, you must strictly observe all the safety
rules, precautions and operation methods.
2. Only the personnel who have been trained in safety technology and own operation qualifications can operate, repair or
maintain the hydraulic hammer.
3. When using the hydraulic hammer of the Company, the operators should properly wear safety helmets, safety glasses, safety
shoes, masks, gloves and other safety protection articles.
4. Please connect the hydraulic hammer with supporting machines in a flat and spacious place. When more than two people
carry out operations together, they must strictly abide by the prior agreement and various safety rules, such as sign language,
slogan and other communication modes.
5. Before the use of the hydraulic hammer of the Company, confirm whether the other relevant personnel around are in a safe
place and whether the broken matters may fall or fly into the operation room. In order to protect the safety of the operator,
please install protectors around the operation room to prevent the broken matters from hurting the operator or other people
around.

© 2020 Taizhou Beilite Machinery Co. ltd. 07

 ® TECHNICAL PARAMETER

II. TECHNICAL PARAMETERS

Beilite product parameters (BLTB40-BLTB140)

© 2020 Taizhou Beilite Machinery Co. ltd. 08

 ® TECHNICAL PARAMETER

Beilite product parameters (BLTB150-BLTB255)

© 2020 Taizhou Beilite Machinery Co. ltd. 09

 ® STRUCTURE AND MAIN PARTS OF HYDRAULIC HAMMER

III. Structure and main parts of hydraulic hammer

Structure and Main parts of Hydraulic Hammer

Built-in control valve External control valve • Through bolt
It refers to the four main bolts used to closely
Through bolt connect the rear cylinder, middle cylinder and
front cylinder.
Charging valve
• Charging valve
Rear cylinder
It is used to fill gas into the rear cylinder.
Middle cylinder
• Rear cylinder
Reversing valve It is mainly used to store nitrogen gas.

Accumulator
• Middle cylinder
As the heart of the hydraulic hammer, it includes
thereciprocating actions of the hydraulic circulation
system and control piston.
Piston
• Reversing valve
It is used to control the piston to move up and down.
Front cylinder
• Accumulator
It is used to provide adequate oil reserve and improve
the stability of the hydraulic system.
Chisel pin
• Piston
It is used to convert hydraulic energy into kinetic
energy and impact the chisel to play a breaking role.

Chisel
• Front cylinder
It is used to support the main body of the hydraulic
breaker.

• Chisel pin
It is used to fix the chisel and make orientation.

• Chisel
IIt is used to break up objects.
The type of this part is optional:
① blunt type 2 slot type 3 sharp-pointed type

© 2020 Taizhou Beilite Machinery Co. ltd. 10

 ® PRODUCT IDENTIFICATION AND POSITION

IV. PRODUCT IDENTIFICATION AND POSITION

4 5
7

1
6

2 8

Note: This diagram is a structure diagram and it may differ from the actual situation if the models are different.

In order to help the operator better use and maintain the hydraulic hammer, the related signs are attached to the surface
of the hydraulic hammer when it leaves the factory.
11

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 ® INSTALLATION AND DISASSEMBLY

V. Product identification and position

1. Beilite sign 5. Rear cylinder warning 7. Beilite sign
sign It includes the relevant parameters of the
product which must be confirmed when
you purchase the product.
® Beilite Machinery Co., Ltd.

2. Grease nipple
Modelno.:
Serialno.:
hours
Weight kg
6. Accumulator warning Length mm
Required Oil Flow l/min
sign
It refers to the oil injection Working Pressure kg/cm2
port. It is recommended to Impate Rate b.p.m
Hose Diameter
add grease every two hours
Chisel Diameter mm
and grease can be added at Chisel Length m2
any time when it is found that Applicable Excavator mm
the chisel is dry. Ton

3. Valve adjuster

8. Operation precautions
(Note: Be sure to adjust the pressure
when the hydraulic hammer stops) The operator should pay attention to the following
items when using the hydraulic hammer
To regulating the return pressure, you
can adjust the hitting power and Check before start up:
frequency. If the adjustment is improper, • •Check whether the main engine • When disassembling the hydraulic
the hydraulic hammer will stop, so it is is equipped with sufficient hydraulic breaker, protect the in/out adapter
prohibited to make adjustment randomly. oil and whether the hydraulic oil is port and prevent external impurities
clean. Otherwise, please add or from polluting hydraulic oil.
replace hydraulic oil timely.
Nitrogen gas charging pressure • Before starting work, please warm • Carry out maintenance and replace
up the main engine for 10 minutes the hydraulic oil and filter element
N2 GAS CHARGE to ensure 12
that the temperature of timely.
1.7 ~ 2.0 MPA hydraulic oil is suitable. • When loading the hydraulic hammer,
• Check whether there is oil leakage please remove the chisel.
It indicates the charging pressure of the at the in/out adapters and whether • Main inspection points:
rear cylinder and accumulator. Gas should the bolts are loose. Otherwise, • Check whether the stop valve is
be charged in strict accordance with the tighten the joints or bolts to the fully open;
indicated scope of pressure. specified torque. • Check whether the oil pipe shakes
• Add grease to the hydraulic hammer abnormally;
timely. • Check whether the hydraulic oil is
• Attention: sufficient and clean;
• Do not use this hydraulic hammer • Check whether the system pressure
for underwater operations. (If is normal;
underwater operations are needed, • Check whether the oil temperature
please consult the Beilite Company , is normal;
or the designated agent.) • Check whether the filter element is
clean;

—Beilite Machinery Co., Ltd.

© 2020 Taizhou Beilite Machinery Co. ltd. 12

 ® INSTALLATION AND DISASSEMBLY

5.1 Diagram of hydraulic hammer

In order to enable the hydraulic hammer to work normally, the connecting pipes between the hydraulic hammer and the main
engine must be connected in accordance with the method shown in the figure below. Please confirm whether these pipes are
installed on the main engine. If not, please contact the Company or the designated agent.

Installation diagram of hydraulic hammer:

Hydraulic Hammer body

Hydraulic Hammer housing
04 Side plate bolt
Stop valve
02 Steel tube of hydraulic hammer
Multi-way valve
03
01 07

05
08
Overflow valve (if the main engine
is not equipped with any overflow valve, 09
an overflow valve should be installed)
Hydraulic oil tank
10
Return oil filter element
Oil cooler
12
Hydraulic pump 13
Foot valve or joystick

13 06

11

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 ® INSTALLATION AND DISASSEMBLY

5.2 Hydraulic pipeline of hydraulic hammer

Beilite Hydraulic Hammer can be installed on a variety of different construction machines. In order to enable the machine to
run normally with the maximum work efficiency, Beilite advises you to let the company’s staff to perform installation if you
adopt the products of the Company; if there is no any service personnel of the Company in the region where you are located,
it is recommended to entrust the dealer or agent of the Company with the installation work to ensure the safety of the products
and operators.

Oil pipeline used alone

For the operation of the hydraulic hammer, a separate hydraulic circuit should be used and it is not allowed to share the pipeline
with other hydraulic circuits. Since the hydraulic systems in different types of machines are different, the pressure and flow S of
the hydraulic circuit and the wear of hydraulic parts should be checked before installation. It is also recommended to select the
original parts when it is necessary to replace parts.

Overflow valve

Main control valve

Stop valve

In
Hydraulic Hammer
Pilot valve 14
Out

Foot switch

Pilot pumpt Main pump

© 2020 Taizhou Beilite Machinery Co. ltd. 14

 ® INSTALLATION AND DISASSEMBLY

5.3 Preparation
I before installation

This section describes the safety operation and the correct installation method that can extend the service life of the product.
Be sure to strictly observe the contents in this section to prevent accidents.

5.3.1 Requirements for main engine

Requirements for main engin Weight of main engine

Beilite Hydraulic Hammer is specially manufactured for There will be a risk of overturn if the hydraulic hammer is used
excavator and loader models. Please pay attention to for the main engine with the lighter weight than the load or
the following requirements when you select to connect that has a longer big or small arm than the specified arm.
the hydraulic hammer equipment.
Installation confirmation Performance of main engine
The size of the main engine arm and connecting part should The flow and pressure of the main engine set should be
be matched to that of the hydraulic hammer. Check the size matched to that of the hydraulic hammer, otherwise, the
of the connecting part, pin hole and distance between pins performan ce of the hydraulic hammer will be affected.
before connection.

Hydraulic contents
• The hydraulic unit of the main engine should be matched to that of the hydraulic hammer. When the hydraulic hammer is installed
on the main engine with a smaller value than the specified value or when the highest pressure of the pipeline is lower than the set
pressure of the hydraulic hammer, the hitting frequency of the hydraulic hammer may become smaller or the hydraulic hammer fails
to start.
• 15 increases. For the serious aging hydraulic pump, the hydraulic
The hydraulic oil flow will decrease as the hydraulic oil temperature
oil flow will decrease sharply as the oil temperature increases, and the hitting frequency will become smaller or the hydraulic
breaker fails to start. Repair or replace the hydraulic pump at this time.
• When the working flow of the main engine is higher than the required flow of the hydraulic hammer, the hitting frequency will
become larger, excessive pressure will be applied and the oil temperature will rise sharply, thus damaging the hydraulic hammer.
Please contact the main engine manufacturer or the Company for the details of installation requirements.

• The hydraulic pipeline of the hydraulic hammer should be consistent with the data indicated in “2. Table of technical parameters”.
If the pipeline with the smaller valve than the specified value is used, the hydraulic pressure will increase, and irregular movement
will occur as the oil temperature of the pipeline rises.
• In order to prevent heat and irregular work caused by increased back pressure, the size of the oil return pipe should be larger than
that of the oil inlet pipe.
• The hydraulic hammer can only be installed on the main engine with sufficient loading capacity. If a quick connector is used, the
total weight including that of the quick connector should be confirmed.
• For the installation dimension, please consult the agent or the Company.
• The pipeline connecting the hydraulic hammer should meet the working pressure and flow of the hydraulic hammer.

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 ® INSTALLATION AND DISASSEMBLY

• When the special hydraulic oil is used instead of normal hydraulic oil, the service life of the seal assemblies of the hydraulic
breaker will be reduced. Please be sure to consult the Company in advance.
• The use of the hydraulic hammer will result in higher heat to the hydraulic oil than general main engines, so the oil temperature
nd viscosity should be checked before use. Too high or low viscosity of the hydraulic oil will not only enable the hydraulic
accessories of the hydraulic hammer and main engine to fail to function normally, but also damage the hydraulic accessories or
reduce the service life. Select the hydraulic oil with appropriate viscosity based on the external temperature and the state of main
engine before the hydraulic hammer is used.

• During re-installation after the installation or maintenance of the hydraulic hammer, some hydraulic oil will be consumed. Check
the hydraulic oil gauge before installation. If the oil is insufficient, add some hydraulic oil before use.

• The main engine with the hydraulic hammer should be equipped with a cooler that is big enough to cool the hydraulic oil. When
the cooler is too small or polluted and the cooling power is insufficient, the hydraulic oil temperature will increase, and it may
become higher especially in high temperature. When the hydraulic hammer is working, the maximum oil temperature is limited
to 80℃.
• The range of oil temperature can guarantee the adequate breaking performance of the hydraulic hammer. When the oil
temperature rises above 90T in the using process, damage will be caused to all hydraulic accessories, including seal assemblies;
therefore, check or upgrade the cooler to ensure that the oil temperature will not exceed the maximum. For details, please consult
the main engine manufacturer or the Company.

© 2020 Taizhou Beilite Machinery Co. ltd. 16

 ® INSTALLATION AND DISASSEMBLY

5.3.2 Hydraulic
H oil discharge and pipeline cleaning

Purpose
The damage between the hydraulic hammer cylinder and the piston is mainly
caused by the foreign matter in the hydraulic oil. It is essential for the long-term
trouble-free use of the hydraulic hammer to keep the hydraulic oil clean.
In particular, in order to remove the pollutants from the hydraulic oil when Oil inlet
installing the pipeline, the hydraulic oil must be discharged and circulated.

Hydraulic oil discharge method

Prepare a clean oil drum with a volume of more than 20 liters.
Oil return port
Enable the small arm of the main engine to contact the ground.

Turn on the work switch of the hydraulic hammer 3-5 times when the stop valves
of the oil inlet pipe and oil return pipe are in the closed state.

Open the stop valves of the oil inlet pipe and oil return pipe and drain the
hydraulic oil in the pipeline into the prepared empty drum. (Note! Do not turn on
the work switch when the hydraulic oil is discharged).

Repeat Steps ③-④ more than 3 times.

Pipeline cleaning
After the hydraulic oil is drained, connect the oil inlet (2) and
oil return port (1) of the stop valve directly by using an oil pipe
Oil inlet without passing through the hydraulic hammer.

Adjust the engine speed to the maximum, keep a stop of 5

seconds in 10 seconds after the work switch of the hydraulic
breaker is turned on, and repeat this operation for more than 5
Oil return port minutes. (Hydraulic oil circulation)
In order to clean the pipeline more effectively, beat the hydraulic
breaker pipelines on the large and small arms evenly with a rubber
hammer during the circulation of hydraulic oil, so that the foreign
matter in the pipelines falls.

After the hydraulic oil circulation is completed, replace the hydraulic

oil and hydraulic oil filter element of the main engine.

© 2020 Taizhou Beilite Machinery Co. ltd. 17

 ® INSTALLATION AND DISASSEMBLY

5.4 Installation and disassembly steps

Attention
When various fixing pins are disassembled by using a hammer, metal chips may fly out due to the knocking, and major
injury accidents may be caused especially when metal chips enter into eyes. Therefore, be sure to wear safety protection
articles, such as safety helmets, safety glasses, safety boots, masks and gloves during disassembly.
Please disassemble the hydraulic hammer in a flat, spacious and clean place. When more than two people carry out
operations together, they should agree on and strictly observe contact modes, such as sign language.
Do not put your hands into the shaft holes when installing the connecting shaft, because the small arm and hydraulic
breaker may move, and thus causing injury.
Before disassembling the oil pipe, first confirm the temperature of the equipment and oil circuit, and then release the
pressure of the hydraulic system to avoid injury.
Installation and disassembly should be carried out on clean, smooth and hard ground to prevent foreign matter from
flowing into the hydraulic system; otherwise, fatal damage may be caused to the hydraulic hammer and main engine.

5.4.1 Installation of connecting base

For top type and box type hydraulic hammers, the connecting base should be connected with the hydraulic
breaker housing first before connecting to the main engine.
1. Place the hydraulic hammer on a wooden block or base plate with the pipe joint of the hydraulic hammer up.
2. Fasten the connecting base and hydraulic hammer housing with bolts, spring washers and nuts. For the box type hydraulic
breaker, put a damping block in the hydraulic hammer housing before the connecting base is fastened.

Connecting base

Outer shex.ocket bolt

Nord lock ring

Damping block

Nord lock ring

Lock nut

© 2020 Taizhou Beilite Machinery Co. ltd. 18

 ® INSTALLATION AND DISASSEMBLY

5.4.2 Connection between hydraulic hammer and main engine

Connection of small arm of main engine

1. Place the hydraulic hammer on a smooth and hard ground with the chisel of the hydraulic hammer facing
the main engine.
2. Place the two shaft sleeves inside the pin shaft holes respectively.
3. Operate the main engine and align the pin shaft holes on the small arm of the main engine to the pin shaft holes on
the hydraulic hammer housing.
4. After it is confirmed that the pin shaft holes are aligned, insert the connecting shaft, install the check ring on the
connecting shaft and then lock it with bolts and nuts.

Small arm of main engine

Cylinder

Outer shex.ocket bolt

Connecting shaft Ring

Lock nut

Hydraulic hammer housing

Shaft sleeve

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 ® INSTALLATION AND DISASSEMBLY

Connection of connecting rod of main engine

5. Raise the hydraulic hammer to an appropriate height.
6. Place the two shaft sleeves inside the pin shaft holes respectively.
7. Make them pass through the bucket cylinder until the pin shaft holes of the connecting rod are aligned with the pin
shaft holes of the hydraulic hammer housing.
8. After it is confirmed that the pin shaft holes are aligned, insert the connecting shaft, install the check ring on the
connecting shaft, and lock it with bolts and nuts.
9. Check whether there is clamping stagnation, looseness or mechanical defects during operation.

Bucket cylinder

Cylinder

Shaft sleeve

Hydraulic hammer housing

Outer shex.ocket bolt

Connecting shaft Ring

Lock nut
Connecting rod

© 2020 Taizhou Beilite Machinery Co. ltd. 20

 ® INSTALLATION AND DISASSEMBLY

Connection of hydraulic oil pipe

Before the hydraulic pipeline is connected, make inspection according to the following items:
To avoid the damage to the hydraulic hammer, keep the hydraulic system of the main engine clean. Check the oil pollution,
replace the hydraulic oil or further filter the hydraulic oil if necessary, and replace the filter element according to the maintenance
rules of main engine.
When the hydraulic hammer pipeline is used for the first time, remove the pollution in the hydraulic circuit through circulating
filtration (do not connect it to the hydraulic hammer). See Section 5.3.2 Hydraulic oil discharge and pipeline cleaning.
Check the set pressure of the hydraulic hammer overflow valve. The pressure should be at least 30-40 bars higher than the
measured working pressure of the hydraulic hammer. See Section 5.5 Setting of overflow valve pressure.
Completely release the pressure in the hydraulic system before installation or maintenance.
The sealing surface, oil pipes and joint connecting threads should not be damaged or polluted by sand or other similar impurities.

10. Confirm that the stop valve is closed.

11. Remove the in/out adapter cover on the hydraulic hammer body and connect the oil inlet and outlet pipes. The oil inlet is
IN and the oil outlet is OUT.
12. Connect the oil pipe to the oil inlet and outlet of the stop valve, be careful not to connect the oil inlet and outlet reversely,
ensure that the pipeline is smooth and do not distort the pipeline.
13. After the oil pipe is connected properly, open the stop valve. When the stop valve is opened, the hydraulic hammer will
suddenly move. Please keep a safe distance from the chisel.
14. Operate the hydraulic hammer slowly and check the oil pipe for oil leakage and deformation.

Stop valve

Oil return pipe

Oil inlet pipe

Oil pipe joint cover

Oil pipe joint

© 2020 Taizhou Beilite Machinery Co. ltd. 21

 ® INSTALLATION AND DISASSEMBLY

5.4.3 DISASSEMBLY OF HYDRAULIC HAMMER

Place the hydraulic hammer on a clean and smooth surface, stop the main engine and release the hydraulic system pressure.

1. Completely close the stop valve.

2. Remove the hydraulic oil pipe (IN, OUT) from the stop valve.
3. In order to prevent dirt from entering the stop valve and oil pipe, plug the stop valve interface and the both ends -
of oil pipe with plugs.
4. Confirm that there is no oil leakage in the stop valve and oil pipe.
5. Remove the connecting shaft from the small arm and connecting rod.
6. Remove the small arm from the hydraulic hammer so as to move the hydraulic hammer or install other accessories on
the main engine.

5.4.4 INSTALLATION AND DISASSEMBLY OF CHISEL

• Please use the real Beilite chisel. If other brands are used, serious damage may be caused to the hydraulic hammer, and
in this case, our company will refuse the warranty.
• Please select the appropriate lifting equipment according to the weight of chisel to prevent it from falling off.
• The chisel should be installed according to the method described. Otherwise, the chisel may fall off, which may cause
safety accidents.
• After the hydraulic hammer works for a period of time, the chisel, especially the rod tip will be overheated for a long time.
Never touch it. Otherwise, severe scald may be caused.

INSTALLATION OF CHISEL
1. Observe the both ends of the lock pin, and knock the lock pin out from the side with small diameter to the side with large
diameter by using a punch pin.
2. Take the chisel pin out of the front cylinder.
3. Remove all the dirt adsorbed on the surface of the inserted part of the chisel and apply grease to the chisel and hydraulic
breaker chisel bush.
4. Insert the tail of the chisel into the front cylinder, and align the pin hole plane on the chisel with the pin hole plane on the
front cylinder by rotation.
5. Insert the chisel pin.
6. Insert the lock pin into the pin hole of the front cylinder and confirm that the lock pin is fully inserted.
7. Check whether the rubber ring (or rubber plug) inserted in the pin hole is damaged; if it is damaged, replace it timely.
8. Operate the main engine so that the hydraulic hammer is erected vertically. The hydraulic hammer chisel can move up and
down freely after a certain pressure is applied.

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 ® INSTALLATION AND DISASSEMBLY

Chisel pin

PU Ring

Rubber ring Lock pin

Note: This diagram is a structure diagram and it may differ from the actual situation if the models are different.

DISASSEMBLY OF CHISEL
1. Observe the both ends of the lock pin, and knock the lock pin out from the side with small diameter to the side with large
diameter by using a mandril.
2. Take the two chisel pin out of the front cylinder.
3. Take out the chisels.
4. Check the wear degree of the contact surface between the chisel pin and chisel and the thrust bush of the front cylinder.
If the wear limit is exceeded, replace them with new products.

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 ® INSTALLATION AND DISASSEMBLY

5.5 SETTING OF OVERFLOW VALVE PRESSURE

• When a new product is to be delivered, re-install the pipeline or replace the overflow valve product and readjust the
overflow pressure, including the overflow pressure of pipeline (it is not the overflow pressure of the main engine).
• The overflow valve is usually located on the hydraulic hammer pipeline of the big arm. If you cannot find the overflow
valve, please consult the main engine manufacturer or our local agent.
• When the overflow setting pressure is too low, the hitting frequency of the hydraulic hammer will become small or the
hydraulic hammer may be unable to start; on the contrary, if the overflow setting pressure is too high, the oil pipe, steel
pipe, pump, valve and other surrounding parts will be damaged.

Please set the overflow pressure according to the following method;

1. Close the stop valves of the oil inlet and return pipelines of the hydraulic hammer pipeline.
2. Connect the oil inlet and return pipes with the oil inlet and oil return port of the pressure measuring equipment respectively.
3. Open the stop valve, start the main engine hydraulic hammer mode and adjust the overflow valve knob until the specified
pressure of each model is reached (the setting overflow static pressure is the maximum working pressure of the hydraulic
breaker plus 30-40bar).
4. If the main engine instrument panel has the hydraulic system pressure display function, it is unnecessary to carry out test by
using the pressure measuring equipment.

5.6 ADJUSTING METHOD OF VALVE ADJUSTER

O ring
O ring

Nut
Nut

O ring
O ring

Regulating valve
element Regulating valve
element

• The BLTB125 and above hydraulic hammers are equipped with valve
• The valve adjuster can control the oil return pressure of the hydraulic hammer to enable the working pressure of the
hydraulic hammer to increase or decrease. When the oil supply of the hydraulic hammer is too small or too large, it can
be adjusted by using the valve adjuster.

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 ® INSTALLATION AND DISASSEMBLY

Close the valve adjuster (rotate clockwise):

• The working pressure increases;
• The hitting power increases;
• The hitting frequency decreases.

Open the valve adjuster (rotate anticlockwise):

• The working pressure decreases;
• The hitting power decreases;
• The hitting frequency increases.

When the valve adjuster is closed and the working pressure is increased to the setting overflow pressure, the hitting frequency
will be significantly reduced. Sometimes the hydraulic hammer will stop automatically and it is prohibited to adjust the valve at
will. Before the delivery, the valve adjuster has been initially adjusted by the manufacturer. Please make re-adjustment according
to the actual working conditions. The method is shown below: (The hydraulic hammer should be stopped)

1. Place the hydraulic hammer on a clean and smooth ground and stop the main engine.
2. Loosen the nut until the regulating valve is able to rotate.
3. Rotate the regulating valve element clockwise or anticlockwise as needed.
4. When tightening the nut, to prevent the regulating valve element from rotating together, fix it with an L-shaped wrench.
5. The adjusting method of the valve adjuster when leaving the factory is as follows: close it completely and then release it for
2.5-3 turns.

5.7 ANTI-BLANK-FIRE ADJUSTMENT METHOD

• When the hydraulic hammer is idle, the piston transmits the impact force to
the chisel, the chisel transfers the impact force to the chisel pin, and the c
hisel pin will be easily broken due to strong impact force. In addition, when
the chisel is subjected to impact, the impact force will also be dispersed to
the cross pin, so that the edge of the inner hole of the cross pin is cracked Plug
and the lower cylinder is broken finally. If the hydraulic hammer is always
idle, the front cylinder block, chisel, chisel pin, bolt and other parts may O Ring
be broken, oil leakage in soft and hard pipes and other faults will occur, Anti-blank-fire Valve
and the service life of the hydraulic hammer will be greatly reduced.

• The BLTB140F/175L hydraulic hammer is equipped with the anti-idle function.

When the hydraulic hammer is idle, this function can automatically enable the
hydraulic hammer to stop work. When the chisel touches the object to be broken,
the piston will be lifted by the chisel and the hydraulic hammer will restore its
normal hitting operation. The anti-idle function can also be turned off according
to the working conditions to simplify the controllability.

• In case of hard rock breaking, heavy concrete structure breaking and other
operations, you can turn on the anti-idle function.

• In case of soft rock and soil breaking, house demolition, secondary breaking of
ore and other operations, you can turn off the anti-idle function.

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The operation method to turn on/off the anti-blank-fire function is shown below:
1. Place the hydraulic hammer on a smooth and hard ground.
2. Release the pressure in the hydraulic system.
3. Close the stop valve.
4. Remove the anti-blank-fire valve element plug.
5. Take out the anti-blank-fire valve element.
6. Check the anti-blank-fire valve element; if the threaded end is placed outward, it indicated that the anti-blank-fire function is on;
if the threaded end is placed inward, it indicated that the anti-blank-fire function is off.
7. Insert the anti-blank-fire valve element again.
8. Install the plug and tighten it. Check whether the O ring of the plug is damaged; if it is damaged, replace it with a new product.
9. Turn on the anti-blank-fire function when the equipment leaves the factory.

5.8 ADJUSTMENT METHOD OF HITTING FREQUENCY

Check ring
Nut

O ring Regulating valve element

• The BLTB135G/150G hydraulic hammer is equipped with the function of controlling the number of hitting times per
minute by rotating the regulating valve element. The hitting frequency can be adjusted according to the working condition,
that is, the type of the object to be broken, to improve the work efficiency.

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 ® INSTALLATION AND DISASSEMBLY

Close the regulating valve element (rotate clockwise)

• The piston has a long-stroke impact.
• The hitting power increases.
• The hitting frequency decreases.
• It is applicable to the breaking of large and hard rock, breaking of high-hardness cement with many reinforced
constructions and other work conditions.

Open the regulating valve element (rotate anticlockwise):

• The piston has a short-stroke impact.
• The hitting power decreases.
• The hitting frequency increases.
• It is applicable to the breaking of small-hardness rock, cement and brick walls with less rebars and other
breakable objects.

The adjustment method is shown below:

1. Loosen the nut until the regulating valve is able to rotate.
2. When low-frequency hitting is required, rotate the regulating valve element clockwise to the bottom; when high-frequency
hitting is required, rotate the regulating valve element for 1-1.5 turns anticlockwise.
3. Tighten the nut. To prevent the regulating valve element from rotating together, fix it with an L-shaped wrench.

5.9 INSPECTION AFTER INSTALLATION

After the hydraulic hammer is installed, installation inspection must be carried out;
• Working pressure of hydraulic hammer:
When the hydraulic hammer works, check the pressure at the oil inlet pipe with a pressure gauge; if the main engine instrument
panel has the pressure display function, you can check the pressure directly on the instrument panel.
• The pressure of the pre-installed gas in the rear cylinder and accumulator must be measured under static conditions and
the hydraulic hammer should not work at this time.
• Check whether the hitting frequency of the hydraulic hammer meets the requirements.
• Check whether the connecting oil pipe of the hydraulic hammer shakes abnormally and whether there is oil leakage at the
joint part.

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VI. Method of Application

Warning
Before using the hydraulic hammer, please confirm that the special pipe for hydraulic hammer has been installed on the
main engine.
If the main engine is equipped with the “hydraulic hammer mode”, please use this mode.
If the main engine is equipped with the special pipe for hydraulic shear, it must be replaced with the special pipe for
hydraulic hammer to prevent excessive flow.
The hydraulic hammer is used with the supporting main engine. Before using the hydraulic hammer, please set the main
engine speed correctly in accordance with the operation and maintenance manual of main engine.

6.1 OPERATION PRECAUTIONS

Check the replacement cycles of thrust bush and chisel bush. (See P.41 P.42)

The piston side

will lean toward
the side after being hit

Long time deflection of piston and abrasion of chisel bush &thrust bush will caused the piston scratched
and hit part broken.

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 ® METHOD OF APPLICATION

The wear of inner diameter of chisel and thrust bushes may cause the breakage of the chisel.

Minimize the number of idling times as far as possible.

• Idling will accelerate the breakage and wear of the hydraulic hammer and main engine connecting fittings.
-
• Frequent idling will cause the following problems.

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 ® METHOD OF APPLICATION

The wear of the chisel pin will cause the cracks of the front cylinder. (See P.40)

When grease is added, place the hydraulic hammer vertically and press the chisel at the top of the thrust bush.

If the grease oil flows into the hydraulic hammer

cylinder, the entire hydraulic system will be
damaged and the hydraulic oil will become black.

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Do not carry out continuous hitting operation for more than 1 minute
When the hydraulic hammer hits the same fixed point continuously for more than 1 minute and fails to break the
object, change the hitting point and try again. If the hydraulic hammer hits the same fixed point continuously for
more than 1 minute, the excessive loss of the chisel may be caused.
When the target object is a large or hard stone, start the breaking operation from the edge.

Do not shake the chisel when in use

If the chisel is shaken during the breaking operation, the chisel, front cylinder, thrust bush, chisel bush, main body and
other parts may be damaged.

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 ® INSTALLATION AND DISASSEMBLY

Do not push the object to be broken by using the hydraulic breaker

Do not use the hydraulic breaker as a tool to push materials during operation; otherwise, the side plate bolt, housing
and chisel may be damaged, and even the main engine failure may be caused.

Do not use the hydraulic breaker as a tool to lift materials

Lifting heavy objects with the hydraulic breaker or chisel is a kind of dangerous operation and it may cause
damage to the hydraulic breaker and main engine.

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Do not operate the hydraulic breaker when the cylinder of the main engine is fully extended or fully retracted.
If the hitting operation is carried out when the cylinder of the main engine is fully extended or fully retracted, the shock will
be returned to the oil cylinder and other parts, thus damaging the main engine seriously.

Please stop operation immediately when it is found that the oil pipe is loose
When the high-pressure or low-pressure oil pipe of the hydraulic breaker is loose, stop operation immediately, perform
inspection and repair timely, and check whether there is any oil leakage in other places.

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6.2 CORRECT OPERATION ESSENTIALS

Please warm up the main engine before operation Please select an appropriate engine speed when you operate
the hydraulic breaker
Before the hydraulic breaker operates, please warm up
the main engine for 10 minutes in advance. The proper Carry out the breaking operation at an appropriate engine speed.
warming will help the smooth operation of the breaking When the engine speed is improperly increased above the speed
operation especially in winter. required for operation, the strength of hitting power cannot be
increased; on the contrary, the temperature of hydraulic oil will
rise rapidly, the lubrication and work ability will be reduced and
the piston and reversing valve may be damaged.

The engine speed should be medium

when the hydraulic hammer operates

Correct load
When the load is insufficient, the hitting power cannot be fully exerted, and the hitting power of the hydraulic breaker
will make the hydraulic breaker body and housing as well as the operation arm of the main engine shake, thus resulting
in damage to the above parts.

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 ® INSTALLATION AND DISASSEMBLY

When the load is too large, the front of the main engine will be lifted up, and the main engine may lean forward
suddenly due to the stone breaking, so that the hydraulic breaker body or housing will hit the stone, thus causing damage.

The above situation should be avoided as much as possible, because improper shock will be returned to the main engine.
Therefore, it should be confirmed that each operation is correct load during breaking operation, which can effectively reduce
the failure rate and prolong the service life.

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 ® INSTALLATION AND DISASSEMBLY

Select an appropriate origin of force

When the hydraulic breaker operates, make sure that the direction of the origin of force of the chisel is perpendicular to
the surface of the object to be broken and maintain this status as much as possible. If it is inclined to the surface of the object
to be broken, the chisel may slide off from the surface, thus damaging the chisel and affecting the piston and other parts.

During the breaking operation, please select the appropriate hitting point and confirm that the chisel is stable before hitting.

6.3 APPROPRIATE STORAGE METHOD

To ensure the proper use of the hydraulic breaker, please observe the following contents. Improper storage may reduce the -
service life of the hydraulic breaker or cause serious faults!

TEMPORARY STORAGE
Place the main engine smoothly and close the stop valve.
Place the hydraulic breaker vertically, fix the chisel against the ground and keep the piston inside the cylinder to avoid pollution.

LONG-TERM STORAGE (MORE THAN 1 MONTH)

There are two main reasons for the damage to the hydraulic breaker caused by long-term storage:
1. Rust damage
The lower part of the piston is often exposed to air, and the moisture, oxygen and dust in the air may damage the piston.
Corrosion is the main cause for the oil leakage and serious fault of the hydraulic breaker.damage
2. Deformation of seal assembly
If the hydraulic breaker is stored for a long time, the weight of piston will squeeze the seal assembly, thus deforming the seal
assembly. If the seal assembly is deformed or damaged, the cylinder will directly contact the piston (direct metal contact fault)
and the piston and cylinder will be damaged simultaneously.

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 ® INSTALLATION AND DISASSEMBLY

Weight of piston

Humidity+oxygen+salt

Rust damage

The weight of piston results in the deformation

of the seal assembly

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 ® INSTALLATION AND DISASSEMBLY

Close the stop valve of the hydraulic breaker pipeline.

Remove the hydraulic breaker connecting hose and block the interface with a plug to prevent the entry of foreign matter.

Take out the chisel from the hydraulic breaker.

Place the hydraulic breaker on a clean and flat ground horizontally, put sleepers at the front and rear ends to enable the rear
end of the hydraulic breaker to be slightly higher than the front end, and ensure that the surrounding environment is dry and
ventilated.
Completely release the nitrogen gas in the rear cylinder.
Insert a round stick from the front cylinder hole of the hydraulic breaker and enable the stick to contact with the piston. Gently
knock the stick with a hammer to push the piston into the cylinder (when knocking the stick, open the gas charging valve of t
he rear cylinder with a tool).
The bottoms of the piston, chisel and bushing must be protected with grease and anti-rust oil.
Cover the entire hammer with a waterproof cloth.

Block the oil pipe

with a plug

Release the
Knock the round stick nitrogen gas
with a hammer lightly

Open the gas charging valve

element with a tool during
knocking

Push the piston to the top Big block

of the return stroke by using
Small block the stick
Protect the bottom of the piston
and the bushing with grease and
anti-rust oil

INSPECTION AFTER LONG-TERM STORAGE

The hydraulic breaker must be checked before it is reused after long-term storage. The internal parts of the hydraulic
breaker, such as seal assembly, piston and cylinder may be damaged; if they are damaged, replace them in a timely
manner. If you use the hydraulic breaker that has been stored for a long time without any inspection, the faults
incurred will not be covered by the warranty of the Company.

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VII. Maintenance

Warning

The hydraulic components must be kept absolutely clean, and dirt is the biggest cause for hydraulic system failure.
The hydraulic breaker components should be kept in a clean place. Clean the components with diesel before use and do
not use water or acid to clean them.
The sealing components, such as O ring and sealing gasket should be cleaned with diesel before installation. For the
hydraulic components that are tightly installed, grease should be applied to their sliding surfaces.
The gas in the rear cylinder and accumulator should be completely released before maintenance or repair.
Use correct maintenance tools.
The hydraulic breaker should not be changed or refitted without authorization. The resulting fault or the decrease in
the service life of the hydraulic breaker will not be covered by the warranty of the Company.

7.1 MAINTENANCE CYCLE

In order to keep the hydraulic breaker in the best condition, periodic maintenance must be carried out as follows:

Cycle Inspection items

1. When the grease is insufficient, add grease timely
1. Check the grease in the chisel,thrust bush and chisel bush. and correctly.
(BLTB40-85:20ml/2h,BLTB100-155:40ml/2h, BLTB165-200:60ml/2h,BLTB210-255:100ml/2h) 2. When the hydraulic oil pipe is loose or damaged,
Every 2 hours
2. Check the hydraulic oil pipe for oil leakage. tighten or replace it.
3. Check the hitting effect. 3. If the hitting is abnormal, contact the agent for
maintenance and repair.
1. Remove the chisel pin and chisel and check the burrs
1. Remove burrs if any.
caused by wear.
2. When the grease is insufficient, add grease; when
2. Check whether the gap between the chisel, thrust bush
the gap is too large, replace the thrust bush and
Every 10 and chisel bush is too large and whether there is sufficient
chisel bush.
hours or 1 day grease.
3. Replace the chisel when there is too much loss.
3. Check the loss of the chisel.
4. If these parts are loose, tighten them diagonally; if
4. Check whether the side plate bolts, through bolts,
they are damaged, please replace them timely.
accumulator bolts and in/out adapters are loose or damaged.
1. When the nitrogen pressure is abnormal, please
release or add nitrogen gas.
1. Check the nitrogen chamber pressure.
2. In case of excessive wear, please contact the agent
2. Check the wear of the tail of chisel, the thrust bush, the
Every 50 for repair and replacement.
chisel bush and the head of piston.
hours or 1 3. If there is oil leakage or excessive wear, please
week 3. Check the hydraulic pipeline for oil leakage.
tighten or replace it timely.
4. Check whether the side plate bolts and through bolts need
4. If they are loose, please tighten them timely; if
to be tightened or replaced.
there is any crack or damage, please replace them
timely.

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 ® MAINTENANCE

Every 100 1. Carry out major inspections by the agent. 1. In case of oil leakage or excessive wear, please
hours or 1
2. Check the connection of the hydraulic oil pipeline. tighten or replace it timely.
month
1. Please handle the fault risks timely if any.
1. Carry out major inspections by the agent. 2. In case of oil leakage or excessive wear, please
2. Check the connection of the hydraulic pipeline used and tighten or replace them timely.
Every 540 the oil return filter element. 3. In case of looseness or crack, please tighten or
hours or 3
3. Check the side plate bolts and through bolts for cracks. replace them timely.
months
4. Replace all seals. 4. Replace them by the agent.
5. Check the hydraulic system. 5. If there is a fault, maintain the hydraulic system
by the main engine service provider.

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7.2 Daily inspection

Before operation, please make sure to check the key points listed in the table below:

Inspection parts Inspection results Maintenance methods

1. Through bolt Looseness, fall-off and loss of bolts and nuts Re-tighten the bolts symmetrically
2. Side plate bolt
3. Accumulator
connecting bolt
4. Reversing valve seat bolt

1. Hydraulic oil pipe Looseness and oil leakage of hydraulic Tighten the loose parts and replace the
2. Hydraulic pipeline of oil pipe and hydraulic pipeline seriously damaged parts
hydraulic breaker

1. Rear cylinder Abnormal oil leakage Please contact the local dealer or
2. Front cylinder and chisel maintenance unit

Chisel Abnormal wear and breakage Replace the excessively worn chisels
timely and update or repair the damaged
or broken chisels immediately

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7.3 Inspection emphasis

The fastening bolts on the hydraulic hammer are subjected to particularly high loads and vibrations. Within the first 50 hours,
the fastening bolts on the must be checked every day, and then they can be checked every week thereafter.
When tightening the bolts, be careful not to exceed the specified torque.

Model Position Unit BLTB- BLTB- BLTB- BLTB- BLTB- BLTB- BLTB- BLTB- BLTB- BLTB-
Items 40 45 53 70 75 85 100 125 135 135G
Pre-tightening torque A N •m 400 500 600 800 800 1300 1840 2700 3000 2700
of through bolt

Pre-tightening torque B N •m / / / 100 100 100 500 500 940 940

of accumulator seat
bolt
Pre-tightening torque C N •m I / / 100 100 100 200 200 480 540
of accumulator cover
bolt
Pre-tightening torque D N •m 200 270 450 800 1150 1150 1800 3000 4600 4600
of side plate bolt

Modell Position Einheit BLTB- BLTB- BLTB- BLTB- BLTB- BLTB- BLTB- BLTB- BLTB- BLTB-
Items 140 150 150G 155 165 175L 185G 190G 195 210L
Pre-tightening torque A N •m 4000 4800 3500 4800 4800 5200 6000 7500 7500 14000
of through bolt

Pre-tightening torque B N •m 940 940 1500 940 940 1500 940 940 940 4500
of accumulator seat
bolt
Pre-tightening torque C N •m 480 350 540 350 350 540 540 540 540 1285
of accumulator cover
bolt
Pre-tightening torque D N •m 4600 5600 5600 5600 5600 6700 6700 8000 8000 10000
of side plate bolt

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Pre-tightening torque
of side plate bolt: D

Pre-tightening torque of
through bolt: A

Pre-tightening torque
of accumulator seat
bolt: B
Grease nipple:
Add grease before
work and add grease
every 2 hours during
Pre-tightening torque work
of accumulator cover
bolt: C

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7.4 Replacement of chisel

The service life of the chisel depends on the method of use. The chisel can withstand the vertical working load sufficiently,
but its ability to withstand the horizontal load is weak. In particular, some ways that may damage the chisel or enable the
chisel to lose work ability, such as lifting operation and inclined and unfocused hitting, will shorten the service life of the
chisel.

The hitting power focuses on a certain point (origin)

of the chisel by 90 degrees.
Sharp and clear side

Unebener grauer Bereich

For the above typical breakage caused by For the fracture caused by the use of the chisel as a crowbar in the
overbending, the Company rejects the warranty above picture, the Company rejects the warranty claim.
claim

When the gap between the chisel and chisel bush is too large, the piston will not be able to hit the chisel accurately,
thus causing damage to the cylinder and piston. Please replace the chisel timely and replace the thrust bush and chisel
bush simultaneously.

If you do not use the real chisel of the Company, the working efficiency of the hydraulic hammer will not be guaranteed.

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 ® MAINTENANCE

The chisel needs to be replaced when it wears to a certain extent.

The specific size is as follows: Unit: mm

The replacement size B indicated

above is the size remaining when
the chisel is pressed into the
innermost end of the main engine.

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7.5 Replacement of chisel pin

If the chisel pin wears with a length of more than 1.5mm on one side, reverse the chisel pin and use the other side. After
the chisel pin wears to a certain extent, it should be replaced immediately, as shown in the table below:

Unit: mm
No. Model Initial size A Replacement size B Pin shape
1 BLTB-40 φ22 φ19
2 BLTB-45 φ24 φ21
3 BLTB-53 φ24 φ21 Rund
4 BLTB-70 φ35 φ32
5 BLTB-75 φ35 φ32
6 BLTB-85 54 50
7 BLTB-100 60 56
8 BLTB-125 76 71
9 BLTB-135 81 76
10 BLTB-135G 80 75 Round chisel pin
11 BLTB-140 89 83
12 BLTB-150 94 88
13 BLTB-150G 90 84 Flach
14 BLTB-155 97 91
15 BLTB-165 97 91
16 BLTB-175L 120 114
17 BLTB-185G 110 104
18 BLTB-190G 120 114
19 BLTB-195 120 114
20 BLTB-210L 140 134

Flat chisel pin

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7.6 Replacement of chisel bush

If the chisel bush wears seriously, the service life of the piston and chisel will be shortened, and even the piston
and chisel may be broken. Therefore, when the chisel bush wears to a certain extent, please replace it timely, as
hown in the table below:

Unit: mm

Chisel busht

Box type chisel bush

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7.7 REPLACEMENT OF THRUST BUSH

WIf the thrust bush wears seriously, the service life of the piston and chisel will be also shortened, and in case of serious
wear, the piston and chisel may be broken.

For the replacement of worn round bushing, refer to the data in the small table. If any of the
sizes A and C in the table exceeds the allowable range, the thrust bush needs to be replaced.

Unit: mm

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7.8 NITROGEN GAS SUPPLEMENT

Attention

Do not approach the front of the chisel when adding nitrogen gas. (The chisel may bounce off due to the high pressure
of nitrogen gas)
Do not use other gases instead of nitrogen gas.
When adding nitrogen gas, place the hydraulic hammer horizontally.
Because the nitrogen gas cylinder is a high pressure vessel, special attention should be paid to its storage and use.
When replacing the through bolt or disassembling the main body, make sure that the nitrogen gas has been completely
released before operation.

Table of gas filling pressure

NITROGEN GAS Valve
of rear cylinder
FILLING TOOLS
Hose

g
Gas filling pressure (bar) fi llin
Nut Handle d gas
nd e
me ange
ecom r
R
Exhaust Gas filling
valve device Nitrogen
gas
bottle

Surface temperature of rear cylinder ( )

Rear Table of gas filling pressure of
Gas charging valve cylinder accumulator
plug and O ring
Gas charging valve
plug and O ring
lin g
s fil
Gas filling pressure (bar)

d ed ga
en
omm range
Rec

Accumulator
Gas charging
adjuster, O ring
and nut Surface temperature of accumulator
( )

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Nitrogen gas inspection and gas filling methods for rear cylinder:

1) Remove the rear cylinder gas charging valve plug.

2) After it is confirmed that the nut and exhaust valve of the gas filling device are tightened and the handle is to
bounce off upward, screw the gas filling device on the gas charging valve.

3) Press the handle of the gas filling device, measure the nitrogen gas pressure and make adjustment.

If the nitrogen gas pressure is within the standard range, enable the handle of the gas filling device to
bounce off upward, open the exhaust valve to release the residual gas, then remove the gas filling device
from the gas charging valve and tighten the gas charging valve plug.

If the nitrogen gas pressure is higher than the standard range, slowly open the exhaust valve of the gas
filling device, release the pressure to the standard range, tighten the exhaust valve, enable the handle of
the gas filling device to bounce off upward, open the exhaust valve to release the residual gas, then
remove the gas filling device from the gas charging valve and tighten the gas charging valve plug.

If the nitrogen gas pressure is lower than the standard range, enable the handle of the gas filling device
to bounce off upward, open the exhaust valve to release the residual gas and remove the nut of the gas
filling device. Connect the gas filling hose with the gas filling device and nitrogen gas bottle and press
the handle of the gas filling device; slowly open the valve of the nitrogen gas bottle, fill the bottle with
nitrogen gas and then close the valve after a while; open the valve to charge gas and then close it again;
repeat the steps and check the pressure of the nitrogen gas gauge at any time until the pressure reaches
the standard range. Close the valve of the nitrogen bottle, enable the handle of the gas filling device to
bounce off upward, open the exhaust valve to release the residual gas, then remove the gas filling device
from the gas charging valve and tighten the gas charging valve plug.

Nitrogen gas inspection and gas filling methods for accumulator:

1) Remove the gas charging adjuster nut on the accumulator, tighten the gas charging adjuster, and remove the gas
charging valve nut on the accumulator.

2) After it is confirmed that the nut and exhaust valve of the gas filling device are tightened and the handle is to
bounce off upward, screw the gas filling device on the accumulator.

3) Slowly loosen the gas charging adjuster, measure the nitrogen gas pressure and make adjustment.

a. If the nitrogen gas pressure is within the standard range, tighten the gas charging adjuster, open the
exhaust valve to release the residual gas, then remove the gas filling device from the accumulator and
tighten the gas charging valve plug and gas charging adjuster nut.

b. If the nitrogen gas pressure is higher than the standard range, slowly open the exhaust valve of the gas
filling device, release the pressure to the standard range, tighten the exhaust valve, tighten the gas
charging adjuster, open the exhaust valve to release the residual gas, then remove the gas filling device
from the accumulator and tighten the gas charging valve plug and gas charging adjuster nut.

c. If the nitrogen gas pressure is lower than the standard range, tighten the gas charging adjuster, open
the exhaust valve to release the residual gas and remove the nut of the gas filling device. Connect the
gas filling pipe with the gas filling device and nitrogen gas bottle and loosen the gas charging adjuster;
slowly open the valve of the nitrogen gas bottle, fill the bottle with nitrogen gas and then close the valve
after a while; open the valve to charge gas and then close it again; repeat the steps and check the
pressure of the nitrogen gas gauge at any time until the pressure reaches the standard range. Close the
valve of the nitrogen bottle, tighten the gas charging adjuster, open the exhaust valve to release the
residual gas, then remove the gas filling device from the accumulator and tighten the gas charging valve
plug and gas charging adjuster nut.

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7.9 Hydraulic oil

Attention
Operating temperature and viscosity of hydraulic oil
Please operate the hydraulic hammer when the operating temperature of hydraulic oil is 20 to 80℃.
Do not use the mixture of hydraulic oil and other oils
Please do not add other oils or hydraulic oils with different components in the hydraulic oil or use the mixture.
Periodic replacement of hydraulic oil
The hydraulic oil needs to be checked periodically. When the hydraulic oil needs to be replaced, all the hydraulic
oil in the oil tank and hydraulic circuit should be replaced.
When the temperature of hydraulic oil exceeds the range of operating temperature, the abnormal operation or fatal
fault of the hydraulic hammer may be caused.
When replacing the hydraulic oil, the hydraulic oil filter should be washed or replaced simultaneously.

Selection of hydraulic oil/The selection of hydraulic oil determines the efficiency and service life of the hydraulic hammer.
Please contact the agent in the following cases.
1. When the hydraulic hammer must be used under special weather conditions (for example, in extremely cold or hot
regions).
2. When the recommended hydraulic oil is not available and needs to be replaced by other hydraulic oils.
3. When the oil recommended by the main engine manufacturer is different from the oil recommended by the hydraulic
breaker manufacturer.

Hydraulic oil and grease (recommended by Beilite)

Manufacturer Summer oil Winter oil Grease
Your Choice of Energy Beilite 68 # Beilite 46 # Beilite 2# Beilite 3#
Shell Shell TellusT68 Shell Tellus T46 Alvania Grease2
Esso Nuto H68 Nuto H46 Beacon 02
Mobil Mobil DTE 16 Mobil DTE 15 Mobil Grease Special
Gulf Harmony 68 Harmony 46 Golf Grown EP2
Caltex Lando CZ68 Lando GZ46 --------------
Fuchs -------------- -------------- Hammerpasta

© 2020 Taizhou Beilite Machinery Co. ltd. 51

 ® MAINTENANCE

Operating temperature of hydraulic oil:

1. The hydraulic oil recommended by the Company is used at a temperature of 20 to 80℃. Please use the hydraulic oil
within this range. If the temperature of hydraulic oil rises above 80℃, fatal damage may be caused to the hydraulic
breaker. Therefore, please check the hydraulic oil cooler to keep the hydraulic oil within a reasonable temperature range
in the operation process.
2. After the hydraulic hammer works for a long time, the temperature of hydraulic oil will rise above the operating
temperature range. Therefore, stop work for a while, and then continue the operation after the temperature
decreases.
3. The temperature is low in winter, so the hydraulic hammer should be sufficiently preheated first and then the operation
can be started after the temperature of the main engine rises. If sufficient hydraulic oil cannot be supplied to the
hydraulic hammer at a low temperature, fatal damage may be caused to the hydraulic hammer.

Oil pollution:
If the polluted hydraulic oil is used, the hydraulic hammer and main engine will fail, so special attention should be paid to
the hydraulic oil quality. When the hydraulic oil is polluted or deteriorated, please replace it immediately without delay.
When replacing the hydraulic oil, please clean the pipeline, oil tank and other parts thoroughly, and replace them if necessary.

1. Replacement of filter element: The filter element should be replaced 250 hours after first use, and then it can be replaced every 600 hours.

2. Replacement of hydraulic oil: The hydraulic oil should be replaced 600 hours after first use, and then it can be replaced every 1500 hours.

© 2020 Taizhou Beilite Machinery Co. ltd. 52

 ® FAULT AND SOLUTION

VIII. FAULT AND SOLUTION

Fault Cause Solution

The hydraulic hammer fails to hit The high and low pressure connecting Exchange the connecting pipes
pipes are installed reversely

The stop valve is closed or it is not fully Open the stop valve
opened
The nitrogen gas pressure of the rear Adjust the nitrogen gas pressure of the
cylinder is too high rear cylinder to the specified value

The hydraulic oil level is too low Add hydraulic oil

The overflow valve pressure is too low Adjust the overflow valve pressure to the
specified value
The piston or control valve gets stuck Consult the agent

The circuit of the main engine fails Maintain the circuit of the main engine

The oil return quantity of the main Check the oil return quantity and engine
engine is too low speed
The hitting frequency is too small The middle cylinder or piston wears Consult the agent (replace the cylinder
or piston)
The oil supply of the main engine is Check the main engine (engine,
too low hydraulic pump and hydraulic system)
The back pressure of the oil return Check the filter element and cooler and
pipeline of the hydraulic hammer is clean or replace the oil return pipeline
too high (the oil return pipeline shakes with larger caliber
seriously)
The hydraulic oil temperature is too high Clean or replace the cooler and replace
the hydraulic oil with high viscosity

The overflow valve pressure is too low Adjust the overflow valve pressure to the
specified value
The hydraulic oil level is too low Add hydraulic oil
The frequency regulating valve or Consult the agent
regulating valve of the hydraulic
breaker is adjusted improperly
The piston or control valve is damaged Consult the agent

© 2020 Taizhou Beilite Machinery Co. ltd. 53

 ® FAULT AND SOLUTION

The hitting frequency is too large The hydraulic system of the main Consult the agent (maintain or replace
engine is unstable the accumulator)

The thrust bush wears (the installation Consult the agent (replace the thrust
position of the chisel is too high) bush)

The piston or control valve is damaged Consult the agent

The hitting frequency is unstable The hydraulic system of the main Consult the main engine agent
engine is unstable
The control valve of the hydraulic hammer Consult the agent
is damaged
Oil leakage The middle cylinder seal is aged or has Consult the agent (replace the seal)
a quality problem

© 2020 Taizhou Beilite Machinery Co. ltd. 54

 ®
AUTOMATIC LUBRICATION DEVICE

IX. Automatic lubrication device

Warning
When automatic lubrication is adopted, an automatic lubrication device should be installed on the hydraulic
breaker.
Do not use liquid grease, and please select the grease recommended by the Company.
The accessories required for automatic lubrication are optional and need to be purchased separately.

Installation method of automatic lubrication device:

When it is necessary to install an automatic lubrication device, please consult Beilite Company or the agent designated by Beilite.

1. Clean the mounting hole of the automatic lubrication device ① of the shell and clear the foreign matter at the grease hole
of the middle cylinder.

2. Align the four mounting holes of the automatic lubrication device ① with the holes on the shell respectively, place the bolt
pads ⑥ into the mounting holes of the automatic lubrication device, then put the shield ⑤ and tighten it with the nord
lock ring. ④, spring washer ⑤ and bolt ③.

3. Remove the grease nipple on the middle cylinder with a tool.

4. Install the joint ⑦(thread specification: G1/4’’) at the grease hole on the middle cylinder.

5. Connect the G1/4’’ grease pipe ② to the joints of the lubrication device and the grease hole of the middle cylinder respectively.

6. The grease in the automatic lubrication pipeline inside the hydraulic hammer will be hardened and blocked due to foreign
matter or temperature changes. If the grease cannot be added smoothly, disassemble the hydraulic hammer, remove the foreign
matter and grease deposited in the internal pipeline and then clean the pipeline.

① Automatic lubrication device

② Grease pipe
③ Bolt
④ Nord lock ring
⑤ Shield
⑥ Bolt pad
⑦ Joint

© 2020 Taizhou Beilite Machinery Co. ltd. 55

 ® AUTOMATIC LUBRICATION DEVICE

Composition of automatic lubrication device (BLTB85 and above)

Automatic
Inner shex.
Part name lubrication Grease pipe Nord lock ring Shield Bolt pad Joint
ocket bolt
device
Quantity

Corresp
on ding
model

If the contents or illustrations in this manual are not detailed enough,

please contact the company's representative or customer service terms.

—Taizhou Beilite Machinery Co., Ltd.

© 2020 Taizhou Beilite Machinery Co. ltd. 56

 ® BLTB IMPORTANT NOTES

BLTB

© 2020 Taizhou Beilite Machinery Co. ltd. 57

 ® BLTB WARRENTY GUARANTEE

BLTB

breaker 40 155

breaker

© 2020 Taizhou Beilite Machinery Co. ltd. 58

 ® BLTB WARRENTY GUARANTEE

breaker

breaker

© 2020 Taizhou Beilite Machinery Co. ltd. 59

 ® COMMISSIONING CARD FOR WARRANTY

Hammer model:
Serial number:
END USER
Name:

Adresse:

Contact person:

Telephone:

DEALER: SUPPLIER:
Company: Company:
Postal code/city: Postal code/city:
Delivery date: / 200 Delivery date: / 200
Country: Country:

HYDRAULIC INSTALLATION
Installed by: Company:
Excavator make: Model:
Build: Total weight:
Serial number: Working hours on clock:

Measured max. oil displacement to attachment l/min

Measured max. excavator system pressure to attachment bar
Measured setting of reliefvalve pressure for attachment bar
Measured working pressure of hammer at max. engine rpm bar
Measured max. oil displacemnet to attachment at working pressure l/min
Measured back pressure in return line from hammer bar
Measured max. oil temperature at continues operation °C
Hydraulic oil make, type, quality:

Hammer valve for hammer: ja / no Setting: l/min

Oilcooler installed: ja / no
Returnline over filter: ja / no
Quick release coupling at stick: ja / no
Rotation function: ja / no Setting: l/min bar

Installation approved no: / 200 By:

Warranty starts: / 200 Finished: / 200
Next scheduled service: / 200 at: Working hours
Customer excepts installation on: / 200

A signed copy of this commissioning card has to be send or e mailed Whenever the hammer or attachment is switched to a different excavator,
directly after the commissioning of the hammer to Beilite Europe. you will have to commission this new excavator and provide Beilite Europe
Claim can only be handled when the commissioning card is available. with  a new commission card after measuring and administrating the required
information.

BEILITE EUROPE Mobile +31 653 150 283

Phone +31 316 267291
© 2020 Taizhou Beilite Machinery Co. ltd. 60
Website www.beilite-europe.com E-mail info@beilite-europe.com
ADVANCED HYDRAULIC HAMMER TECHNOLOGY
®
 JUDGMENT AND TREATMENT OF OIL
®
LEAKAGE IN HAMMER CYLINDER

© 2020 Taizhou Beilite Machinery Co. ltd. 61

 ® ® HAMMER DAILY INSPECTON

© 2020 Taizhou Beilite Machinery Co. ltd. 62

 ®

®
www.beilite.com
www.beilite-europe.com
If the contents or illustrations in this manual are not detailed enough,
please contact the company's representative or customer service terms.
—Tai Zhou Beilite Machinery Co., Ltd.

© 2020 Taizhou Beilite Machinery Co. ltd.