Allied Hy-Ram HR270 Safety, Operation And Maintenance Instructions Download Page 1

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Thoroughly read and understand the content of this manual before using the Allied Breaker. The safe and efficient

use of the Allied equipment depends upon proper installation, operation, maintenance and training.

Keep this manual in a convenient location so that it is easily accessible for future reference. Contact your Allied

Dealer or the Allied Customer Service Department for replacement manuals. Inquiries regarding the content of this

manual must include effective date shown on inside cover.

SOM57

202

Hy-Ram

Hydraulic

Impact

Breaker

Model

Safety, Operation and Maintenance

Summary of Contents for Hy-Ram HR270

Page 1: ...and training Keep this manual in a convenient location so that it is easily accessible for future reference Contact your Allied Dealer or the Allied Customer Service Department for replacement manuals Inquiries regarding the content of this manual must include effective date shown on inside cover SOM577202 Hy Ram Hy Ram Hydraulic Impact Breaker Model HR270 HR290 Safety Operation and Maintenance ...

Page 2: ...at the time of its printing and may not reflect the product in the future When changes become necessary these will be noted in the table below Specifications are based on published information at the time of publication Allied Construction Products LLC reserves the right to change edit delete or modify the content of this document including descriptions illustrations and specifications without pri...

Page 3: ...IRED Fig S1 The exclamation point within an equilateral triangle is the safety alert symbol This symbol either used alone or with a signal word is used to draw attention to the presence of potential hazards Signal Words DANGER WARNING and CAUTION are signal words used to express severity of consequences should a hazard be encountered DANGER Indicates an imminent hazard which if not avoided will re...

Page 4: ... and the need for a protective guard to shield the operator from injury It directs personnel to the Operator s Manual for safety instructions NOTE Place the smaller size decal in a conspicuous location inside the operator s cab L4 TOOL SHARPENING Decal warns against welding cutting or hard facing the tool It directs personnel to the Operator s Manual for approved sharpening methods L5 PRESSURIZED ...

Page 5: ... s for grease type re lubrication schedules and procedures Risk of equipment damage if instructions are not followed L10 PRESSURE I D TAG The oil supply hose is tagged for ease of identification L11 ALLIED LOGO This decal is the Allied brand identifier and is a registered trademark of Allied Construction Products LLC L12 HR230 MODEL Decal identifies the specific model L13 EQUIPMENT ID TAG Contains...

Page 6: ...ng object Unsupported loads Personal Protection Equipment Hearing protection Safety eyewear Gloves Safety shoes Falling part Personnel maintain a safe distance from breaker Fragments debris becoming airborne projectiles Protective guards required on cab when operating this work tool Leaking fluid under pressure Hot surfaces Gas Oil under pressure Shut off carrier remove key before servicing Identi...

Page 7: ...all include but not limited to Locating existing underground service and utility lines Establishing pedestrian barriers Using personnel protection equipment appropriate to working conditions etc Federal State Local and OSHA Construction Guidelines and Regulations Use the Allied equipment in accordance with all federal state and local regulations regarding construction practices and public safety I...

Page 8: ...against unsafe situations that could not be eliminated through design measures Where it was not possible to prevent an unsafe situation by means of a guard safety messages appear on the equipment warning personnel of a hazardous condition Guards shall not be removed unless for the purpose of inspection and service of components All guards must be reinstalled after service or adjustments are comple...

Page 9: ...view 4 3 2 Owner s Responsibilities 4 3 3 Allied Product Policies 5 Section Pg 4 0 Product Information 6 4 1 Description and Use 6 4 2 Familiarization of Main Components 6 4 3 Principle of Operation 6 5 0 Sizing the Breaker 8 5 1 Breaker Selection General 8 5 2 Auxiliary Circuits Conversion Kits 8 6 0 Operation 10 6 1 Before the Breaker is Used 10 6 1 1 Pre Operation Inspection 10 6 2 Proper Opera...

Page 10: ...tem 29 10 1 4 Tool Removal 30 10 2 Tool Inspection Prepare For Installation 30 10 3 1 Install Tool General 30 SECTION Pg 10 3 2 Tools Needed to Install 31 10 3 3 How to Install Tool 31 10 4 Tool Re lubrication Conventional Method 31 10 4 1 Avoid Costly Lubrication Mistakes 32 10 5 Tool Re lubrication Automatic Systems 33 10 5 1 Tool Re lubrication Carrier Mounted Type 33 10 5 2 Tool Re lubrication...

Page 11: ...ugs Installed In Housing Box 17 7 3 Internal Parts of Front Head 18 7 4 Measure Gap Between Tool and Bushing 19 Figure Pg 7 5 Measure Tool for Wear 19 7 6 Measure Bushing for Wear 19 7 7 Piston With Damage to Impact Face 20 7 8 Measuring Oil Pressure 22 8 1 Use Approved Lift Points 23 8 2 Improper Park Position 23 8 3 Push Piston to Its Highest Position 24 8 4 Protect Piston Against Water Damage 2...

Page 12: ...tion including figures captions tables descriptions remarks and specifications describe the product at the time of its printing and may not reflect the product in the future When changes become necessary these will be noted on the inside cover 1 3 How to Order Replacement Publications This manual is an integral part of this product Keep it in a convenient location so that it is easily accessible f...

Page 13: ...m SOMM577202_14mar 2 1 0 Introduction and Scope cont d Ask for FORM CMHB 1004 Hydraulic Mounted Breakers This publication is also available through Allied under part number 953076 English To order a copy contact the Allied Customer Service Department ...

Page 14: ...name Model number Serial number Year of manufacture Weight Confirm that the information contained on the Tag corresponds with the information provided in Section 1 Table 1 1 2 3 Record Equipment ID Information for Future Reference Your local Allied dealer requires complete information about the equipment to better assist you with questions regarding parts warranty operation maintenance or repair C...

Page 15: ...ion operation maintenance and transporting of the Allied equipment adhere to the following Read and thoroughly understand the information and procedures detailed in this manual Understand proper operating techniques for all recommended applications Use the Allied attachment only if it is in sound operating condition Take prompt action to rectify any faults that if left uncorrected could lead to pe...

Page 16: ... industry practices Allied assumes no responsibility for the results of actions not recommended in this manual and specifically the results of Improper Training Improper Installation Operation in unapproved applications Incorrect operation Improper maintenance Use of non genuine Allied replacement parts Unapproved modifications These exclusions apply to damage to the Allied equipment associated eq...

Page 17: ...pable host machine that s equipped with a hydraulic circuit Within the hydraulic circuit an ON OFF valve is used to control flow in one direction to the Breaker The valve will be managed with a momentary switch located inside the operator s cab within easy reach of the operator With the valve ON supply oil from the host machine flows to the IN port on the breaker Oil is blocked from entering the b...

Page 18: ...he OUT port the oil in the upper end of the cylinder becomes pressurized With the piston at the top of its stroke the final half of the cycle will begin The force of the pressurized oil combines with the charge pressure inside the back head and drives the piston down The cycle is completed when the piston impacts the tool The cycle is continuous without interruption until the machine operator rele...

Page 19: ...re the carrier can safely handle the weight of the breaker always consult the specifications in the manual provided by the carrier manufacturer Factors such as boom and stick length undercarriage and tracks counterweights etc all affect the lifting capacity of the carrier Check the machine for any modifications and also take into account any add ons such as a quick attach coupler Next review the h...

Page 20: ...sion kit from Allied can be installed When necessary Allied conversion kits include the Allied AC series valves These are solenoid operated valves that control flow and pressure Fig 5 1 Allied Conversion Kit With AC Series Valve The process of selecting the right breaker must consider the type of work to be done This includes any special needs such as required modifications when working in underwa...

Page 21: ... site hazards including electrical and gas utilities Set up barriers CAUTION Only qualified personnel shall operate the breaker Never activate the breaker unless the operator is seated in the operator s seat and is in full control of the machine CAUTION Injury from flying debris Personal protection equipment is required when operating this equipment PPE must include safety eyewear and hearing prot...

Page 22: ...s care to prevent overheating the tool Prolong hammering in one spot must be avoided Fig 6 3 Do Not Overheat Tool If the material does not break within 15 seconds of hammering stop and reposition the tool nearer the edge Fig 6 4 Begin at Outer Edge and Work Inward 6 3 Operating Mistakes to Avoid IMPORTANT Equipment damage may result if proper procedures are not followed Carefully read through this...

Page 23: ... Re lubricate the tool every two hours or if it appears dry 6 3 2 Do Not Pry With the Breaker Fig 6 7 Do Not Pry With the Breaker The leading cause of tool breakage is from bending In the occurrence of tool failures from bending the length of the tool skill level of the operator and lubrication management all play a decisive role Prying will damage other parts as well including the bushings front ...

Page 24: ... tipping if work tool is too heavy or transported with loads too high Keep loads low to the ground when travelling Fig 6 12 Park With Breaker Horizontally On Ground 6 4 Special Applications Operating Conditions 6 4 1 Working Underwater CAUTION Serious equipment damage will result if Breaker is submerged in water without proper modifications equipment and training Fig 6 13 Breaker Is NOT Underwater...

Page 25: ...cedures are not followed Check the oil temperature often to ensure it does not exceed 176ºF 80ºC If higher temperatures are measured in the tank refer to the Troubleshooting Section in this manual Specify hydraulic oils with viscosity suitable for the climate conditions In general the hydraulic oil that was originally specified for the machine by the carrier manufacturer can be used with this equi...

Page 26: ...falling below a temperature that is too cold for normal operation Specify hydraulic oils with viscosity suitable for the climate conditions In general the hydraulic oil that was originally specified for the machine by the carrier manufacturer can be used with the Allied equipment Use oil viscosity based on the expected air temperature range during the period between oil changes Optimum oil viscosi...

Page 27: ...ar and cracks Look for signs of contact between breaker and housing caused by excessive movement Every 2 Hours While in use Service Hours Lubricate breaker tool or sooner if the tool appears dry Check breaker tool is properly engaged in front head During Shift While breaker is in use Actively monitor efficiency and evenness of operation Look and listen for any interruptions from normal operation M...

Page 28: ...ng or delaying repairs will lead to further damage and increased repair costs 7 3 2 Vibration Dampening Inspection Fig 7 1 Buffers Wear Plates A system of buffers dampers and guide plates help minimize vibrations to the carrier and unwanted noise by isolating the breaker from the housing box With guide plates in good condition the breaker has minimal movement inside the housing box The operator mu...

Page 29: ...onents but the most apparent of these include the operator s technique and lubrication management Table 7 2 Inspection of Parts Part Condition Cause Remedy Tool Burs form in retainer slot Wedge shape tool prone to twisting from material Use conical tool less prone to twisting Tool retainer Chipped burs uneven wear Blank fire tool twist Maintain sufficient feed force Stop hammering at instant mater...

Page 30: ...re to the piston It s critical for the protection of the piston and seal system to keep bushings in good condition Replace parts that have reached their wear limit Fig 7 5 Measure Tool Diameter for Wear Fig 7 6 Measure Bushing Tool for Wear Table 7 3 Wear Limits Inch mm Model HR270 HR290 D1 Tool O D New 2 67 68 2 93 74 5 D2 Tool O D Limit 2 59 66 2 85 72 5 D3 Bushing I D Limit 2 75 70 3 01 76 5 D4...

Page 31: ...on no service is required to the accumulator between rebuilds Visually inspect the accumulator daily for oil leaks and broken or loose bolts Generally membrane failure is often sudden and results in immediate and complete discharge of gas The breaker will continue to operate but without assistance from the accumulator a noticeable change in performance will be observed Symptoms include one or more...

Page 32: ...important for reliable operation Hydraulic circuits differ between machines Only qualified personnel having knowledge of the machine s systems proper test equipment and tools should perform conversion set up and adjustments CAUTION Some procedures such as measuring the oil pressure must be done while the breaker is operating This will require an assistant Both must be qualified in these procedures...

Page 33: ... prior to removal of plugs or caps Have a suitable container and rags on hand before disconnecting hose Collect fluid and dispose of it properly 7 11 2 How to Measure Oil Pressure Fig 7 8 Measuring Oil Pressure Connect a pressure gauge 0 5000 PSI into the supply line near the breaker Start the carrier and allow the oil temperature to reach its normal operating temperature before starting Move the ...

Page 34: ...r 1 Remove all loose debris from Breaker 2 Secure hoses to unit to avoid accidental damage 3 Inspect the mounting pins and hardware for damage and integrity 4 Transport carrier in accordance with the carrier manufacturer s recommendations 8 3 Breaker Storage Short Term 14 Days 1 The Breaker may be stored vertically tool down or horizontally Fig 8 2 Improper Park Position IMPORTANT Exposure to mois...

Page 35: ...ctive rust and pitting on piston Protect from damage by coating the exposed surface below the wiper with grease Fig 8 4 Protect Piston From Water Damage 5 The Breaker must be stored in the vertical position WARNING Crush Hazard Unsupported loads may cause injury or equipment damage Use sufficient blocking and restraints to stabilize loads 6 If stored outside cover the Breaker with a waterproof tar...

Page 36: ...aker No special tools are required but the following tools should be available PPE including Safety eyewear gloves Sledge Hammer Drift pin 3 4 drive socket wrench 3 4 drive metric sockets Grease gun Standard and Metric open end wrenches Pry bar Rags 9 4 Attach the Breaker to the Carrier CAUTION Some procedures such as attaching the Breaker to and from the carrier will require an assistant Both the...

Page 37: ...pin with keepers 6 Repeat procedure with link pin Fig 9 3 Install Pins and Keepers 9 5 Supply Hose IN and Return Hose OUT Fig 9 4 Supply Hose IN and Return OUT Port Connections On Cylinder Body IMPORTANT The Breaker will not operate if the supply and return hoses are reversed Connect the hose tagged with PRESSURE to the pressure line of the carrier The location of the Supply Line can vary from one...

Page 38: ...stant Both the operator and assistant must be qualified in these procedures Take all necessary precautions Throughout the procedure the machine operator shall be seated in the operator s seat and maintain full control of the machine All directions and signals must be agreed upon in advance Take signals from only ONE person Crush hazard Use sufficient blocking to avoid accidental or sudden movement...

Page 39: ...se side up and the breaker tool pointing toward the carrier 2 Shut the carrier off and relieve the pressure in the hydraulic tank and hydraulic lines 3 Assistant Check that the Breaker is stable and all loads are supported Close the shut off valves on the carrier that s connected to the Breaker 4 Clean dirt from connection areas Disconnect the hoses from the shut off valves Seal all open connectio...

Page 40: ... and clear of falling parts CAUTION Burn injury from contact with hot surface Some components become hot during operation Allow parts and fluids to cool before handling CAUTION Injury from flying debris PPE must be worn when striking pins with hammer PPE includes appropriate clothing gloves safety eyewear and shoes CAUTION Tools and other components of the breaker are heavy Use suitable lifting eq...

Page 41: ...d sling Fig 10 5 10 2 Tool Inspection Prepare for Installation 1 Clean and inspect front head bushings tool and retainers Check for uneven or excessive wear cracks or other damage 2 Measure bushing and tool Parts must be replaced if worn beyond wear limit 3 Inspect impact face of piston and thrust ring for uneven or excessive wear cracks or other damage 4 Grind any burrs and sharp edges smooth if ...

Page 42: ...erly adjusted the amount dispensed from the pump will be sufficient in volume to replenish the amount consumed during normal breaker operations Any interruptions from normal delivery will require special attention before the breaker is returned to service Interruptions from normal delivery include New replacement tool installed New replacement bushings installed or wiped clean of grease for purpos...

Page 43: ...ry widely from one gun to the next The amount dispensed must equal the amount consumed between last replenishment If greasing intervals are infrequent additional strokes will be necessary to refill grease reserves Pump enough grease until surfaces are sufficiently covered Generally tool re lubrication is recommended every two hours However the operator must actively monitor the tool and grease mus...

Page 44: ...s When ordering kits it is necessary to provide the make and model of the carrier and breaker 10 5 2 Hammer Mounted Lubricator HML Series The AutoLube HML series is a compact size pump that mounts directly to the breaker There are no electric or hydraulic connections Grease is dispensed when the pump is pulsated by the breaker The refillable reservoir is transparent and allows easy monitoring Deli...

Page 45: ... sandstone weak metamorphic rock and general breaking of concrete The conical preforms well when working in reinforced concrete because its round shape resists twisting that can lead to retainer pin and pin slot deformation B Chisel Wedge Cross Cut transverse or In line parallel Same applications as the conical Useful when cutting action is required C Blunt Designed for impact breaking the blunt t...

Page 46: ... Fig 12 2 and a commercially available nitrogen bottle Fig 12 1 N2 Gas Charge in Back Head WARNING Only qualified personnel having knowledge of the machine s systems proper test equipment and tools should attempt accumulator repairs Prevent injury from unexpected release of high pressure gaseous energy The gas must be released before disassembly of accumulator and back head Protective eyewear must...

Page 47: ...event injury from sudden release Tool can extend from breaker when charging back head 12 2 1 Tools Required Charge Kit 575427 Fig 12 1 Source additional equipment locally Nitrogen Bottle equipped with a pressure regulator is recommended Hex wrench Torque Wrench Light weight oil Rags 12 2 2 Connecting the Charge Tool Fig 12 1 1 Clean immediate area around the charge port 2 Use hex wrench to remove ...

Page 48: ...en bottle 2 Open bleed valve 3 Remove charge tool 4 Tighten hex plug with torque wrench to 15 lb ft 20 Nm 5 Check for leaks by filling the area surrounding the charge bolt with oil 6 Wipe off oil 7 Store nitrogen tank according to regulations 8 Store charge tool in dry location 12 3 Accumulator N2 Gas Charge Safety Precautions WARNING Only qualified technicians having knowledge of the machine s sy...

Page 49: ...section of this manual is at 70 ambient Fluctuations in pressure will be seen as the temperature changes between ambient and working temperatures 1 Depress valve handle on charge tool 2 Read pressure gage 3 If 5 of specification no adjustment is necessary If so remove charge tool from accumulator following instruction in Section 12 3 5 4 If 5 of specification adjustment is required Follow the inst...

Page 50: ...correct breaker tool installed Verify breaker tool is correct Insufficient oil pressure Refer to section Operating Pressure Too Low Return line pressure too high Refer to section Return Line Pressure Too High Carrier hydraulic circuit leaks Locate source of bypass Adjust repair or replace faulty components Control valve Carrier misadjusted or malfunction Incorrect working mode Troubleshoot valve f...

Page 51: ...l or pilot circuit failure Hydraulic oil overheating Oil temperature should not exceed 176 F 80 C Impact rate slows down Hydraulic oil is overheated Refer to section Operating Temperature Too High Return line pressure too high Refer to section Return Line Pressure Too High Excessive charge pressure in back head Readjust to correct pressure Flow too low Measure oil Flow Set to value listed in the s...

Page 52: ...cooler may be required Check with carrier manufacturer Tool binding in bushing Check breaker tool is receiving sufficient lubrication Use Chisel Paste Return line pressure too high Refer to Return Line Pressure Too High section Excessive cycle time Limit hammering time to 15 seconds maximum Refer to Section 6 0 Oil flow too high Set to value listed in the specifications section of this manual Brea...

Page 53: ...deep gouge or corrosion Operator technique to adopt correct working angle Maintain right angle to work surface Refer to Section 6 0 Check breaker tool is receiving sufficient lubrication Increase lubrication frequency Only use grease that is approved for this application such as a premium high temperature and extreme pressure type grease Allied Chisel Paste is specifically formulated for this appl...

Page 54: ... value is reached A relief valve is safety device used to protect the circuit against hydraulic overload Relief valves vary in design Pilot controlled pressure relief valves are designed so that the relief pressure increases very little as the flow through the valve increases For Breaker applications they are recommended over direct acting type relief valves Dynamic Relief Pressure Also referred t...

Page 55: ...faults e g collapsed hose Mode Engine RPM Flow GPM Load Pressure PSI Oil Temp ºF Relief Pressure Crack Relief Pressure Static Return Pressure PSI 0 1000 1500 1800 2000 2200 2400 2600 2800 3000 3200 3400 CAUTION Before starting make sure the circuit to be tested has a relief valve Open restrictor valve on flow meter Procedures can vary depending on specifics of your equipment Follow the instruction...

Page 56: ... 12 25 5 5 11 Skid Steer f SS N A 8 3 5 Mounting Family BR BR a Actual frequency depends on oil flow Factors that affect oil flow include oil viscosity and temperature b Actual operating pressure depends on oil flow back pressure material to be broken Models HR390 thru HR710 are equipped with Pressure Adjuster c Permissible setting of MINIMUM pressure relief DYNAMIC Measured operating pressure Min...

Page 57: ...Allied Construction Products LLC www alliedcp com SOMM577202_14mar 46 14 0 Technical Information cont d Fig 14 2 General Dimensions HR270 Fig 14 3 General Dimensions HR290 ...

Page 58: ...4 5 to ensure each tie rod is evenly loaded Follow progressive tightening steps 1 4 Progressive tightening means the nut will be turned a little at a time Never exceed 1 full turn without turning the other 3 nuts HR270 HR290 Refer to Table 14 3 Table 14 3 A Side Rod Torque Ft Lbs N m Model Step 1 Step 2 Step 3 Final Torque Step 4 HR270 110 150 220 300 330 450 440 600 HR290 165 220 330 450 500 675 ...

Page 59: ...Allied Construction Products LLC www alliedcp com SOMM577202_14mar 48 15 0 Service Record Service Performed By Date ...

Page 60: ...SOMM57720214mar R ...

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