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Maintenance - Page 59

COPYRIGHT © 2020 SANDVIK MINING AND CONSTRUCTION OY

Lower tool bushing

1533E STD

3. LOWER TOOL BUSHING

WEAR LIMITS AND LUBRICANTS FOR LOWER TOOL BUSHING

REMOVAL OF LOWER TOOL BUSHING

The lower tool bushing cannot be removed without removing the hammer from the
housing. Contact your local dealer for more information.

Item

Wear limit

Tool bushing (worn out)

Grease groove is worn out. Bushing
must be replaced.

Item

Lubricant

Contact surfaces of front head

Thread grease

R0

3

0109

Groove

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Summary of Contents for 1533E

Page 1: ...Original instructions 4 20 OPERATOR S MANUAL OM1533ESENG 420 HYDRAULIC HAMMER RAMMER 1533E STD ...

Page 2: ...e 54 Overview 54 Inspection and maintenance by the operator 54 Inspection and maintenance by the dealer 55 Maintenance intervals in special applications 55 Other maintenance procedures 55 2 Changing the tool 56 Wear limits and lubricants for tool removal 56 Removal of tool 57 Installation of tool 58 3 Lower tool bushing 59 Wear limits and lubricants for lower tool bushing 59 Removal of lower tool ...

Page 3: ...Operation Page 3 COPYRIGHT 2020 SANDVIK MINING AND CONSTRUCTION OY 1533E STD OPERATION ...

Page 4: ... Pyydä suomenkielinen ohjekirja Rammer jälleenmyyjältäsi FR Adressez vous à votre revendeur Rammer pour obtenir la version française de ce manuel HR Hrvatsku verziju ovog priručnika zatražite od zastupnika tvrtke Rammer HU Ez a kézikönyv magyar nyelven is elérhető kérje Rammer forgalmazójától IS Biðjið Rammer dreifingaraðila ykkar um íslenska útgáfu af þessari handbók IT È possibile richiedere la ...

Page 5: ...could result in injury to you or others and could also cause damage to equipment See illustration 1 This symbol identifies a prohibited action or a hazardous location Failure to understand and obey this safety warning could result in injury to you or others and could also cause damage to equipment See illustration 2 This symbol identifies correct and recommended action See illustration 3 This symb...

Page 6: ...dealer Improper operation lubrication or maintenance of this machine can be dangerous and could result in injury Do not operate this machine until you have read and understood the instructions in this manual Do not perform any lubrication and maintenance on this machine until you have read and understood the instructions in this manual 1 3 WARRANTY Check that a separate warranty sheet explaining t...

Page 7: ...ng maintenance to your machinery please contact your local dealer Quick deliveries are ensured by exact orders Required information 1 Name of customer contact person 2 Order number when available 3 Delivery address 4 Mode of delivery 5 Required delivery date 6 Invoicing address 7 Model and serial number of product 8 Name number and required amount of spare parts ...

Page 8: ...er of this manual It is important to make correct reference to the serial number of the attachment when making repairs or ordering spare parts Identification of the serial number is the only proper means of maintaining and identifying parts for a specific product CONTENT OF THE PRODUCTIDENTIFICATION PLATE 1 Hydraulic Hammer 2 Model 3 Version 4 Serial Number 5 Hammer weight kg 6 Min working weight ...

Page 9: ...draulic system 3 2 REMOVAL FROM PACKAGE Remove all the steel belts from the package Open the package and remove all plastics covering the product Recycle all package materials steel plastic wood properly Check that the product is in good condition and that there is no visible damage Check that all ordered parts and accessories have been enclosed with the product Some options may be provided by you...

Page 10: ...inder outer surfaces For handling the parts see product workshop documentation for suitable lifting methods and lifting adapters LIFTING EYE SCREWS Tighten the lifting eye screws completely Put a burden on the lifting eye only if the screw is properly tightened to the housing Failure to properly tighten the screw before allowing load pressure on the lifting eye may cause lifting eye to break and f...

Page 11: ...E STD Lifting devices must safely carry the working weight of the product See Hammer specifications on page 66 Place chains or slings as shown by the illustration to lift the product Note Before starting to operate the hammer always replace the lifting eye with a blanking screw R010266 R010274 ...

Page 12: ...one shall be under the hoisted load Do not lift people and never ride the hoisted load Keep people clear from lift area Avoid side pull of the load Make sure you take up the slack slowly Start and stop carefully Lift the load a few centimeters and verify it before proceeding Make sure the load is well balanced Check for any loose items Never leave the suspended load unattended Maintain load contro...

Page 13: ...n dampening elements D Hose connections pressure line marked IN and return line marked OUT E Pressure accumulator F Tool retaining mechanism G Greasing device H Lifting eye I Grease nipple 3 5 RAMLUBE II The hammer can be equipped with an automatic greasing device Ramlube II The tool grease is supplied from the greasing device into the hammer by the grease lines See Ramlube II on page 43 R010276 ...

Page 14: ...RD3 and data privacy on page 72 Warning RD3 contains a SIM card to enable remote connections and an encased lithium metal battery Both items are regulated for air transport Consult your forwarder about any restrictions for air freight Warning Lithium is a highly flammable substance Store damaged lithium batteries in a fire proof container Never transport a damaged or unprotected lithium battery Fo...

Page 15: ...ment should be serviced immediately Follow the product s greasing instructions and avoid excessive greasing Be careful when handling storing and transporting oils Dispose of empty oil or grease containers appropriately Consult local authorities for detailed instructions All metal parts of the product can be recycled by delivering them to an authorized scrap metal collection facility Comply with lo...

Page 16: ...self that it is safe for you and others You should also ensure that the product will not be damaged or made unsafe by the method of operation or maintenance procedures you choose Safety is not just a matter of responding to the warnings All the time you are working with your attachment you must pay attention to what hazards there might be and how to avoid them Do not work with the product until yo...

Page 17: ...an get caught in the machinery Wear protective clothing to suit the job Examples are a safety helmet safety shoes safety glasses well fitting overalls ear protectors and industrial gloves Keep cuffs fastened Do not wear a necktie or scarf Keep long hair restrained PRACTICE You and others can be killed or injured if you perform unfamiliar operations without practising them first Practice away from ...

Page 18: ... Mark the positions of underground cables and pipes if you will be breaking the ground Poor visibility can cause accidents and damage Make sure that visibility and lighting of the working area are adequate BANKS AND TRENCHES Banked material and trenches can collapse Do not work too close to banks and trenches where there is a danger of collapse SAFETY BARRIERS Unguarded equipment in public places ...

Page 19: ... in the area of airborne pollutants and make sure they have proper respirators Respirators are as important for bystanders as hard hats Respirators for both operator and bystanders must be approved by the respirator manufacturer for the application in question It is essential that the respirators protect from the tiny dust particles which cause silicosis and which may cause other serious lung dise...

Page 20: ...rotect the windows from flying chips of rock HIGH NOISE LEVEL A hammer in operation creates a high noise level Always wear ear protection to prevent personal injury The safety label on the hammer is shown below NOISE HAZARD Continuous exposure to noise above 80 dB A will cause hearing impairment Wear approved hearing protectors R010355 FLYING OBJECTS HAZARD Fragments fly up to 40 m 130 ft and coul...

Page 21: ... withstand maximum pressure and mechanical stresses caused by operation of the attachment Consult your local dealer for instructions FIRE HAZARD Most hydraulic fluids are flammable and might ignite when contacting hot surface Avoid spilling hydraulic fluid to hot surfaces Working with the product on certain materials can cause sparks and hot splinters to get loose These can ignite flammable materi...

Page 22: ...aler first LIFTING EQUIPMENT You can be injured if you use faulty lifting equipment Make sure that lifting equipment is in good condition Make sure that the lifting equipment complies with all local regulations and is suitable for the job Make sure that the lifting equipment is strong enough for the job and that you know how to use it Do not use this product or any of its parts for lifting See Lif...

Page 23: ... hammer or drifts to remove and fit metal pins such as bucket pins Always wear safety glasses LABELS ON THE PRODUCT Safety labels communicate the following four things The severity level of the risk that is signal word DANGER or WARNING The nature of the hazard such as high pressure or dust The consequence of interaction with the hazard How to avoid the hazard You must ALWAYS follow the instructio...

Page 24: ...g of pressurized accumulator will cause death or severe injury Read workshop manual before disassembly Release pressure before disassembly Recharge with nitrogen N2 only 169410_ENG 5 IGNORING INSTRUCTIONS HAZARD Faulty handling practice could cause death or severe injury Read and follow the instructions in the operator s manual WARNING 169400_ENG 3 FLYING OBJECTS HAZARD Fragments fly up to 40 m 13...

Page 25: ...hydraulic circuit the installation requires only suitable hoses and fittings If the carrier does not have suitable kit to run the attachment one must be built This may require installation including new piping and additional valves such as directional valve and pressure relief valve Suitable kits can be ordered from the local dealers from carrier manufacturers and their dealers or from third party...

Page 26: ... the correct tool for the job There are essentially two ways of breaking with a hydraulic hammer Penetrative breaking or cutting In this form of breaking a moil point or chisel tool is forced inside the material This method is most effective in soft layered or plastic low abrasive material The high impact rate of the small hammers makes them ideal for penetrative breaking Impact breaking With impa...

Page 27: ...e testing please consult with your local dealer See Tool specifications on page 70 Chisel moil point and pyramid For sedimentary e g sandstone and weak metamorphic rock into which the tool penetrates Concrete Trenching and benching Blunt tool For igneous e g granite and tough metamorphic rock e g gneiss into which the tool doesn t penetrate Concrete Breaking boulders It is important to choose a to...

Page 28: ...es If the object moves or its surface breaks correct the angle immediately Keep the feed force and tool aligned Keep the tool shank well greased during operation Regular visual inspections during operation are recommended An unlubricated tool shank requires more frequent greasing intervals A tool shank covered with excessive grease requires less frequent greasing intervals To use the hammer most e...

Page 29: ...dampens the impact effect and produces heat Do not let the tool move outwards from the hammer when it penetrates Keep the down pressure on the hammer while breaking Listen to the hammer s sound when you are using it If the sound becomes weaker and the impact less efficient the tool is misaligned with the material and or there is not enough down force on the tool Realign the tool and press the tool...

Page 30: ...ay break Bending may be caused by stones inside hard or frozen ground Be careful and stop striking if you find sudden resistance under the tool When breaking hard or frozen ground use the benching method Start with clearing a small area from the edge Then continue by breaking material towards the open area Do not use the hammer tools to move rocks The stone claws are designed for this purposes ...

Page 31: ...RUCTION OY Operation 1533E STD Do not use the hammer to sweep the ground of debris This may damage the hammer and the housing will wear out more quickly When operating the hammer make sure that it does not make contact with the carrier boom or hydraulic lines ...

Page 32: ...t operate the hammer with the carrier s boom stick or bucket cylinders at the end of their stroke either fully extended or fully retracted Damage to the carrier may result Do not use the hammer or hammer tools for lifting Lifting eyes on the hammer are for storage and maintenance purposes only ...

Page 33: ...hat may damage the hammer Warning To avoid falling objects do not use the product to lift other products The lifting eyes located on the product housing are to be used solely to lift or handle the product itself See Lifting instructions on page 9 1 Prepare the carrier for normal excavation work Move the carrier to the required position Set the drive to neutral 2 Set the engine speed to the recomme...

Page 34: ...ject Do not pry the hammer with the boom Do not press too hard or too gently with the boom The correct force is applied when the tracks start to lift slightly from the ground 5 Place the tool against the object at a 90 degree angle Avoid small irregularities on the object which will break easily and cause either idle strokes or an incorrect working angle ...

Page 35: ...peration 1533E STD 6 Start the hammer 7 Stop the hammer quickly Do not allow the hammer to fall down and make idle strokes when an object breaks Frequent idle strokes have a deteriorating effect on the hammer If the hammer falls through the housing wears out more quickly ...

Page 36: ...can cause severe injuries 1 Position hammer horizontally on the floor If the hammer is going to service remove the tool 2 Stop the carrier engine Operate boom and hammer controls to release pressure trapped inside hoses Wait ten minutes for oil pressure to drop 3 Close hammer inlet and outlet lines If quick couplers are used disconnection automatically closes hammer lines If hammer line includes b...

Page 37: ... mounting a bucket Install bucket pins 2 Connect hoses Hammer inlet port is marked on the valve body with IN and outlet port with OUT An installation inspection must be carried out after the product has been mounted on the carrier In the installation inspection certain specifications such as operating pressure oil flow are checked so that they are within given limits See Hammer specifications on p...

Page 38: ... for some work other than normal breaking or demolition such as Tunneling Scaling Foundry cleaning Underwater operations Operations in extremely low or high temperatures Use of special hydraulic fluids Hammer operations with a special carrier e g an extra long boom Other special conditions Special conditions of use may require modifications to the attachment special operating techniques increased ...

Page 39: ... and the machine is ready to be used whenever necessary 1 The storage area must be dry 2 The tool must be removed in hydraulic hammers 3 The lower end of the piston tool and tool bushings must be well protected with grease in all hydraulic hammers 4 Connections must be sealed with clean plugs to prevent oil leakage and dirt from getting into couplings 5 The product must be stored in the vertical p...

Page 40: ...COPYRIGHT 2020 SANDVIK MINING AND CONSTRUCTION OY Page 40 Operation Operation 1533E STD ...

Page 41: ...Lubrication Page 41 COPYRIGHT 2020 SANDVIK MINING AND CONSTRUCTION OY 1533E STD LUBRICATION ...

Page 42: ... No dropping point or very high over 250 C 480 F Maximum service temperature at least 150 C 300 F Minimum working temperature below lowest ambient temperature Additives molybdenum disulfide MoS2 graphite or equivalent Penetration 0 2 NLGI No reaction with hydraulic oils Water resistant Good adhesion with steel AUTOMATIC GREASING RAMLUBE II RAMMER GREASE CARTRIDGE part no 951370 Wear gloves when ha...

Page 43: ...or manual greasing and do not include an automatic greasing device REPLACING THE GREASE CARTRIDGE Measure the distance from the top of the grease cartridge Replace the grease cartridge if the distance is more than 200 mm 7 87 in The grease cartridge is empty and has to be replaced when the distance is 210 mm 8 27 in 1 Unscrew and remove the grease cartridge 2 Dispose the used cartridge appropriate...

Page 44: ...f grease comes out 7 Insert the cartridge and tighten it 1 3 ADJUSTING THE DOSE Note Some hammer models are equipped with an adapter kit for manual greasing and do not include an automatic greasing device A Grease hose B Pressure hose C Grease nipple for manual greasing D Adjusting screw for grease dosage E Locking nut for the adjusting screw R020111 R020128 A B E D C ...

Page 45: ...me In practice this means that in an application where the working cycles are short but the quantity is high a smaller dose can be used wear rate of the tool shank and bushing condition of the tool seal operators working techniques grease quality 1 Turn the locking plate and plug aside 2 Open the locking nut 3 Turn the adjusting screw for grease dosage clockwise to close it completely 4 Next open ...

Page 46: ...reasing is in the right end of the greasing device GREASING INTERVAL 1 Tool shank must be well lubricated before installing tool 2 10 20 strokes from grease gun to tool bushings and tool at regular intervals 3 Adapt interval and amount of grease to wear rate of tool and working conditions This can be anything between two hours and daily depending on material rock concrete to be broken See Recommen...

Page 47: ... 10 minutes for oil pressure to drop inside hammer 3 Apply tool grease from grease gun to greasing points marked with the following sticker Note The hammer must stand upright resting on the tool to ensure that the grease will penetrate downwards between the tool and the bushing Do not fill the space between the piston and the tool with grease A lower piston seal failure can result and the hammer w...

Page 48: ...If the temperature of the hydraulic oil exceeds 80 C 176 F an auxiliary oil cooler is needed The oil viscosity must be between 20 1000 cSt while the attachment is being used When the product is used continuously the temperature of the hydraulic oil normalizes at a certain level depending on conditions and on the carrier The temperature in the tank must not exceed the maximum allowed The hammer mus...

Page 49: ...ost suitable oil is selected in such a way that the temperature of the hydraulic oil in continuous use is in the ideal area on the chart and the hydraulic system is used to best advantage Oil too thick Difficult start up Stiff operation Hammer strikes slowly Danger of cavitation in pumps and in the hydraulic hammer Sticky valves Filter bypass opens impurities in the oil are not removed ...

Page 50: ...e lubrication properties must be sufficient The corrosion resistance properties must be good enough Note Although a special oil could be used in the carrier always check its suitability with the hammer due to high piston speed of the hammer Contact the oil manufacturer or your local dealer for more information about special oils 2 2 OIL COOLER The correct place to connect the hammer return line is...

Page 51: ...e oil filter is to remove impurities from the hydraulic oil Air and water are also impurities in oil Not all impurities can be seen with the naked eye Impurities enter the hydraulic system During hydraulic oil changes and refilling When components are repaired or serviced When the hammer is being installed on the carrier Because of component wear Normally the existing main oil filters of the carri...

Page 52: ...moving parts and seals Danger of piston seizing up Oil leakages 4 Shortened working life and reduced lubricating capability of oil Oil overheats Oil quality deteriorates Electro chemical changes in hydraulic oil 5 Valves do not function properly Spools bind Rapid wear of parts Blocking of small holes Note Component damage is only a symptom The trouble itself will not be cured by removing the sympt...

Page 53: ...Maintenance Page 53 COPYRIGHT 2020 SANDVIK MINING AND CONSTRUCTION OY 1533E STD MAINTENANCE ...

Page 54: ...iven refer to the carrier hours while the attachment is installed EVERY TWO HOURS Check that the grease cartridge is not empty Replace if necessary Check the indicator for the need of refilling the grease container Refill the grease container if necessary Check that the tool has received sufficient grease Grease manually if the automatic greasing device is not in use See Manual greasing on page 46...

Page 55: ...ation about annual servicing During this maintenance you should do the following tasks Check all hydraulic connections Check that the hydraulic hoses do not rub against anything in any boom position Inspect the hydraulic oil filters of the carrier and replace if needed 1 4 MAINTENANCE INTERVALS IN SPECIAL APPLICATIONS The service interval is considerably shorter in special applications See Special...

Page 56: ... the tool 1533E STD 2 CHANGING THE TOOL WEAR LIMITS AND LUBRICANTS FOR TOOL REMOVAL Item Wear limit Tool diameter worn out 103 mm 4 06 in Item Wear limit Tool retaining pin diameter Z worn out 47 mm 1 85 in Item Lubricant Tool and tool retaining pins Tool grease R030065 R030149 Z ...

Page 57: ...use severe injuries 1 Set the hammer on level ground 2 Make sure the carrier s transmission is in neutral and the parking brake is engaged 3 Stop the carrier engine 4 Remove plugs 5 Remove rubber rings 6 Remove tool retaining pins by using t puller 7 Remove tool Use lifting device if necessary If the tool cannot be removed contact your local dealer Note If hammer is still on carrier it may be easi...

Page 58: ... Replace tool if necessary See Changing the tool on page 56 3 Measure the tool retaining pin diameter Z Replace tool if necessary See Changing the tool on page 56 4 Check tool seal Replace if necessary 5 Clean the tool and retaining pins and lubricate them with tool grease 6 Install tool and align the grooves of the tool with the pin bores 7 Install tool retaining pins 8 Install rubber rings 9 Ins...

Page 59: ...FOR LOWER TOOL BUSHING REMOVAL OF LOWER TOOL BUSHING The lower tool bushing cannot be removed without removing the hammer from the housing Contact your local dealer for more information Item Wear limit Tool bushing worn out Grease groove is worn out Bushing must be replaced Item Lubricant Contact surfaces of front head Thread grease R030109 Groove ...

Page 60: ...rrect working methods See Daily operation on page 28 RELIEF VALVE IN HYDRAULIC CIRCUIT OPENS AT A LOW PRESSURE HAMMER OPERATING PRESSURE IS NOT REACHED Check the installation Check the relief valve operation Adjust the relief valve in hydraulic circuit Measure the high pressure in the hammer inlet line Contact your local dealer for more information PRESSURE CONTROL VALVE SETTING IS INCORRECT The h...

Page 61: ...erviced in an authorized Rammer service shop FAILURE IN HAMMER VALVE OPERATION The hammer must be serviced in an authorized Rammer service shop 4 4 THE HAMMER DOES NOT STOP OR HAS RUN ON INTERNAL OIL LEAK IN THE HAMMER The hammer must be serviced in an authorized Rammer service shop FAILURE IN HAMMER CONTROL VALVE OPERATION Check the hammer control valve in the carrier 4 5 OIL OVERHEATS APPLICATIO...

Page 62: ...o correct working methods TOO LONG TOOL Use shortest tool possible Refer to recommended use and to correct working methods RAPID WEAR OF TOOL Refer to recommended use and to correct working methods See Daily operation on page 28 There is a wider selection of tools available for different applications Consult with your local dealer for more information 4 7 AUTOMATIC GREASING DEVICE RAMLUBE II PROBL...

Page 63: ...rease hose LUBRICATION DEVICE IS WORKING WHILE THE GREASE HOSE IS DISCONNECTED Leak in hammer lubrication channel The hammer must be serviced in an authorized Rammer service shop Hammer lubrication channel is blocked The hammer must be serviced in an authorized Rammer service shop LUBRICATION DEVICE DOES NOT WORK WHILE THE GREASE HOSE IS DISCONNECTED Remove the lubrication device from the hammer a...

Page 64: ...COPYRIGHT 2020 SANDVIK MINING AND CONSTRUCTION OY Page 64 Maintenance Troubleshooting 1533E STD ...

Page 65: ...Specifications Page 65 COPYRIGHT 2020 SANDVIK MINING AND CONSTRUCTION OY 1533E STD SPECIFICATIONS ...

Page 66: ... psi Input power 37 kW 50 hp Tool diameter 105 mm 4 13 in Pressure line connection IN ORFS 1 7 16 12 UN Return line connection OUT ORFS 1 7 16 12 UN Grease connection G 5 5 Located on the left side of the valve body behind cover Tema 2520 Pressure line size minimum inner diameter 19 mm 0 75 in Return line size minimum inner diameter 19 mm 0 75 in Optimum oil temperature 40 60 C 104 140 F Allowed o...

Page 67: ...Specifications Page 67 COPYRIGHT 2020 SANDVIK MINING AND CONSTRUCTION OY Hammer specifications 1533E STD 1 2 MAIN DIMENSIONS Ø105 R040270 2004 274 1639 274 510 570 ...

Page 68: ...port position of the hammer Most common hammering position in which the bucket cylinder is in the middle position Mechanical stops to protect the bucket cylinder when the hammer is fully in or out Placement of the pin holes on the mounting bracket hinges Normally they are placed almost symmetrically from the hammer center line Height of the stick s mounting bracket pin from the mounting bracket bo...

Page 69: ...D 1 4 RD3 TECHNICAL SPECIFICATIONS Item Specification Battery type Primary lithium built in encapsulated Temperature operating 20 85 C 4 185 F Temperature storage 40 85 C 40 185 F Antenna GPS Internal Antenna 3G GSM Internal IP rating IP69k ADR UN3091 Lithium content 2 0 grams R040252 M8 100 118 84 84 39 ...

Page 70: ... Chisel 1 331 1000 mm 39 37 in 62 4 kg 138 lb 105 mm 4 13 in Moil point 2 333 1000 mm 39 37 in 61 8 kg 136 lb 105 mm 4 13 in Blunt 3 334 800 mm 31 50 in 53 2 kg 117 lb 105 mm 4 13 in Pyramid 4 333K3 1000 mm 39 37 in 62 4 kg 138 lb 105 mm 4 13 in Long blunt 5 334C1 1000 mm 39 37 in 66 5 kg 147 lb 105 mm 4 13 in Spade transverse to boom 6 336 1000 mm 39 37 in 61 9 kg 136 lb 230 mm 9 06 in Spade para...

Page 71: ...Radio Equipment Directive 2014 53 EU Electromagnetic Compatibility Directive 2014 30 EC And the following parts clauses of standards have been applied EN ISO 12100 Safety of machinery General principles for design Risk Assessment and risk reduction DNV GL certified quality management system according to ISO 9001 Design and manufacture of product Technical file and manufacturing conformity N N Dire...

Page 72: ... the Product you consent and agree that Sandvik may generate collect record upload store analyse and process standard industry information and data relating to the activity and condition of the Product including but not limited to location engine percussion and or transmission hours You agree and acknowledge that Sandvik may use as well as disclose such data to its affiliates or other members with...

Page 73: ...Page 73 COPYRIGHT 2020 SANDVIK MINING AND CONSTRUCTION OY ...

Page 74: ...dvik Mining and Construction Oy Breakers Lahti Taivalkatu 8 P O Box 165 FI 15101 Lahti Finland Phone Int 358 205 44 151 Telefax Int 358 205 44 150 www rammer com 51 16 14140 21 224 14 51 16 14140 27 68 273 ...

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