RAMMER 1655 Operator'S Manual Download

Page: 72 / 72

Sandvik 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

87-20-14105-27-184-56

87-20-14105-33-192-329

Summary of Contents for 1655

Page 1: ...Original instructions ...

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Page 4: ...rating or maintaining the attachment for the first time In this manual the units of measurement are metric For example weights are given in kilograms kg In some cases the other unit follows in parenthesis For example 28 litres 7 4 US gal The specifications and designs presented in this manual are subject to change without prior notice This symbol identifies important safety messages within this ma...

Page 5: ...ide instructions and to identify specific hazards which if not observed could cause bodily injury or death to you or other persons These warnings in the guide and on the machine labels are identified by the warning symbol To use the attachment correctly you must also be a competent operator of the carrier machine Do not use or install it if you can not use the carrier machine properly The attachme...

Page 6: ...sure that you get a copy of it after the installation inspection and that it is correctly filled out An installation inspection must be carried out after the product has been installed on the carrier In the installation inspection certain specifications such as operating pressure and oil flow are checked so that they are within given limits See Hammer specifications on page 66 When you need spare ...

Page 7: ...heck that the model corresponds to the one given on the cover 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 ...

Page 8: ...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 your local dealer like installation kits including hoses and mounting ...

Page 9: ...ct workshop documentation for suitable lifting methods and lifting adapters 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 free fall of the product If you use mechanical tools for tightening make ...

Page 10: ...he 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 ...

Page 11: ...r 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 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 control at all times Never lift the load over the rated capacity see prod...

Page 12: ...w A Housing B Mounting flange C Vibration dampening elements D Hose connections pressure and return lines automatic lubrication and pressurized air E Pressure accumulator F Tool retaining mechanism G Lifting eye H Greasing device Grease nipples ...

Page 13: ... to decrease the carrier s oil flow The hammer can be equipped with an automatic greasing device The tool grease is supplied from the greasing device into the hammer by the grease lines See Automatic greasing on page 41 Advantages of the automatic lubrication system are Longer service life for wear parts Higher utilization rate of the hammer Possibility to grease manually Reduced grease waste Note...

Page 14: ...ducts contribute to the recycling of materials to help customers achieve their environmental objectives During the manufacturing all the necessary precautions are taken to make sure that no harm is done to the environment Every effort is made to foresee and minimize the risks that might be associated with the operation and maintenance of Rammer products and which could pose danger to humans or the...

Page 15: ...e 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 local waste classification rules when disposing of used rubber or plastic parts buffers wear plates seals When scrapping the whole product or pressure accumulator consult ...

Page 16: ...e 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 you are sure that you control it Do not start any job until you are sure that you and those around you will be safe Warning Read the following warning messag...

Page 17: ...an be killed or injured if you perform unfamiliar operations without practising them first Practice away from the job site in a clear area Keep other people away Do not perform new operations until you are sure you can do them safely Obey all laws work site and local regulations which affect you and your equipment Bad communications can cause accidents Keep people around you informed of what you w...

Page 18: ...guarded equipment in public places can be dangerous Place barriers around the machine to keep people away The related safety label on the hammer and the text on the label are shown below DUST HAZARD Breathing dust will cause death or severe injury Always wear approved respirator Airborne pollutants are microscopic particles which will damage your health when inhaled Airborne pollutants on construc...

Page 19: ...irator 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 diseases You should not use the equipment until you are sure the respirators are working properly This means the respirators must be checked to make sure that it is clean that its filter has been changed and to ot...

Page 20: ...ying chips of rock 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 FLYING OBJECTS HAZARD Fragments fly up to 40 m 130 ft and could cause death or severe injury Stop operation when ...

Page 21: ... 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 materials around working area Ensure that adequate extinguisher is available Hydraulic fluid at system pressure can injure you Before disconnecting or conn...

Page 22: ...able 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 Lifting instructions on page 8 Contact your carrier dealer to find out how to lift with your carrier Use only genuine spare parts Use only genuine tools with hydraulic hammers The use of other spare part or hammer tool brands...

Page 23: ...d symbols of the product safety labels and the instructions set forth in the manuals to avoid death or severe injury Keep the safety labels clean and visible at all times Check the condition of safety labels daily Safety labels and instructions which have disappeared been damaged painted over come loose or do not meet the legibility requirements for safe viewing distance must be replaced before op...

Page 24: ...ollow the instructions in the operator s manual WARNING 169400_ENG 3 FLYING OBJECTS HAZARD Fragments fly up to 40 m 130 ft and could cause death or severe injury Stop operation when a person enters hazard zone Wear approved personal protective equipment WARNING 169400_ENG 2 NOISE HAZARD Continuous exposure to noise above 80 dB A could cause hearing impairment Wear approved hearing protectors WARNI...

Page 25: ... 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 suppliers Hydraulic oil In general the hydraulic oil originally intended for the carrier can be used with this product See Requirements for hydraulic oil on page 46 Operating temperature The operating temperature is 20 C 4 F to 80 C 17...

Page 26: ... strong mechanical stress waves from the tool into the material Impact breaking is most effective in hard brittle and very abrasive materials The high impact energy of the big hammers makes them ideal for impact breaking The best possible energy transfer between the tool and the object is achieved with a blunt tool The use of a chisel tool in hard material will cause the sharp edge to wear very qu...

Page 27: ...five seconds before trying again The sensor repeats the signal about every 20 seconds for the next four minutes The status of the service interval should be checked weekly It is also recommended that you keep a log of the status of the LED display One 1 flash Indicates that the hammer is operating at 0 25 of the service interval Two 2 flashes Indicates that the hammer is operating at 25 50 of the ...

Page 28: ...e 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 efficiently when breaking large objec...

Page 29: ...t dampens the impact effect and produces heat 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 firmly against the material Do not let the tool move outwards from the hammer when it penetrates Keep the down pressur...

Page 30: ...aused 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: ... hammer make sure that it does not make contact with the carrier boom or hydraulic lines Do not 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 ...

Page 32: ...ikes the tool this generates a strong pressure wave that 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 8 1 Prepare the carrier for normal excavation work Move the carrier to the required position Set the d...

Page 33: ... and careless boom movements can result in damage to the hammer 4 Use the excavator boom to press the hammer firmly against the object 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 ...

Page 34: ...asily and cause either idle strokes or an incorrect working angle 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 35: ...let lines If quick couplers are used disconnection automatically closes hammer lines If hammer line includes ball valves please make sure that they are closed 4 Disconnect hoses Protect environment from oil spills Plug the hoses and the hammer inlet and outlet ports 5 Remove bucket pins and other parts 6 The carrier can be moved aside 1 Install hammer in the same manner as mounting a bucket Instal...

Page 36: ...emolition such as Hammer tunneling 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 maintenance or special wear items If you are pl...

Page 37: ...d below the piston The air pressure prevents water entering the hammer The hammer as a standard assembly must not be used under water If water fills the space where the piston strikes the tool a strong pressure wave is generated and the hammer may be damaged The wear resistance of the hammer parts is considerably lower under water than in normal use This is caused by corrosion and by the abrasive ...

Page 38: ...he 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 position 6 Make sure the product cannot fall ...

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Page 40: ...aximum 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 RAMMER GREASE CARTRIDGE part no 951370 Wear gloves when handling the grease containers If you get grease onto your skin wash it away with ...

Page 41: ...ude an automatic greasing device 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 appropriately Note The grease cartridge is disposable it can not be refilled...

Page 42: ...t the cartridge and tighten it 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 ...

Page 43: ... 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 the adjusting screw for grease dosage by turning...

Page 44: ...fore installing tool 2 5 10 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 Recommended greases on page 40 Insufficient greasing or improper grease may cause Abnormal wear of tool bushing and t...

Page 45: ...er 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 will subsequently leak oil ...

Page 46: ...d 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 must not be started if the ambient temperature is below freezing and the oil is very thick The...

Page 47: ...nuous use is in the ideal area on the chart and the hydraulic system is used to best advantage Problems due to incorrect hydraulic oil viscosity in the hammer 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 48: ...rrosion 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 The correct place to connect the hammer return line is between the oil cooler and the main filters The hammer return li...

Page 49: ...e 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 carrier are used as hammer circuit return line filters Consult the carrier manufacturer or your local dealer concerning instructions for the filter change intervals In hydraul...

Page 50: ...orates 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 symptom After any component damage due to impurities in the oil the entire hydraulic system has to be cleaned Dismantle clean and reassemble the hammer and change the h...

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Page 52: ...d with clean hydraulic oil before assembly Note The time intervals given refer to the carrier hours while the attachment is installed Check that the grease cartridge is not empty Replace 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 44 Observe hydraulic oil temperature all lines and connect...

Page 53: ...t is recommended to have the first inspection done by your local dealer after 50 to 100 operating hours Contact your local dealer for more information about the initial 50 hour inspection This service is recommended to be done by your local dealer after 1000 operating hours or at least once a year Neglecting the annual service can cause severe damage to the hammer Your local dealer will reseal the...

Page 54: ... grease Service the hammer after underwater jobs The hammer must be totally dismantled and serviced after working underwater Neglecting a hammer service after underwater work can cause severe damage to the hammer The hammer as a standard assembly must not be used under water If water fills the space where the piston strikes the tool a strong pressure wave is generated and the hammer may be damaged...

Page 55: ...Tool diameter X worn out 113 mm 4 45 in Tool diameter Y worn out 104 mm 4 09 in Tool retaining pin diameter worn out 52 mm 2 05 in Tool and tool retaining pins Tool grease ...

Page 56: ...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 plug 5 Remove rubber ring 6 Remove tool retaining pin by using t puller 7 Remove tool Use lifting device if necessary See Tool specifications on page 69 Note If hammer is still on carrier it may be easier to stick the tool in the ground and lift the hammer off th...

Page 57: ...ol on page 55 3 Measure the tool retaining pin diameter Z Replace tool if necessary See Changing the tool on page 55 4 Check tool seal Replace if necessary 5 Clean the tool and retaining pin and lubricate them with grease 6 Install tool and align the groove of the tool with the pin bores 7 Install tool retaining pin 8 Install rubber ring 9 Install plug ...

Page 58: ...n not be removed without removing the hammer from the housing Contact your local dealer for more information Tool bushing worn out Grease groove is worn out Bushing must be replaced Contact surfaces of front head Thread grease ...

Page 59: ...his indicates the hammer control valve is opening If the valve does not operate check the operating means mechanical connections pilot pressure or electrical control Check the installation Check the relief valve operation Adjust the relief valve in hydraulic circuit Measure the high pressure in the hammer inlet line Check the installation Check the size of the return line Check the installation Ch...

Page 60: ...ced in an authorized Rammer service shop The hammer must be serviced in an authorized Rammer service shop The hammer must be serviced in an authorized Rammer service shop Check for a fault in the oil cooling system or an internal leak in the hammer Check the hydraulic circuit of the carrier Check the relief valve operation in the carrier Check the line size Assemble an extra oil cooler Check hydra...

Page 61: ... serviced in an authorized Rammer service shop Check the hammer control valve in the carrier Refer to recommended use and to correct working methods See Daily operation on page 28 Assemble an extra oil cooler 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 info...

Page 62: ...on page 42 Blockage in greasing device Contact your local dealer for more information Doser adjusting is wrong for the application The doser must be readjusted See Adjusting the dose on page 42 Leak in the doser The doser must be replaced Contact your local dealer for more information Grease cartridge is empty or damaged Replace the grease cartridge See Automatic greasing on page 41 Doser defectiv...

Page 63: ...n device from the hammer and deliver it for service in an authorized Rammer service shop If further assistance is required please prepare to answer the following questions before calling your dealer Model and serial number Working hours and service history Ramdata report if available Carrier model Installation Oil flow operating pressure and return line pressure if known Application Has the produc...

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Page 66: ... psi 1 Return line connection OUT SAE 6000 psi 1 Grease connection G 5 5 Located on the same side of the valve body as the return line OUT connection BSPP internal 3 8 Air connection A 6 6 Located on the same side of the valve body as the pressure line IN connection BSPP internal 3 8 Pressure line size minimum inner diameter 26 mm 1 02 in Return line size minimum inner diameter 26 mm 1 02 in Optim...

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Page 68: ...latness of the plate and mill surface as needed Maximum acceptable deviation from flatness is 1 mm 0 04 in Bottom plate recommended minimum thickness X 25 mm 0 98 in Side plate recommended minimum thickness Y 25 mm 0 98 in ...

Page 69: ...h your local dealer for more information Chisel A BB491 1000 mm 39 37 in 67 kg 150 lb 115 mm 4 53 in Moil point B BB493 1000 mm 39 37 in 67 kg 150 lb 115 mm 4 53 in Blunt C BB494 800 mm 31 50 in 58 kg 130 lb 115 mm 4 53 in Pyramid D BB493K3 1000 mm 39 37 in 66 kg 150 lb 115 mm 4 53 in ...

Page 70: ...pment Noise Directive 2000 14 EC The procedure applied for conformity assessment is Internal control of production Annex V Technical file N N Director R D E is authorized to compile the technical file and confirms the product design to conform with the essential health and safety requirements Manufacturing conformity M M Director Supply confirms compliance of the manufactured machinery with the te...

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Page 72: ...vik 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 87 20 14105 27 184 56 87 20 14105 33 192 329 ...

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RAMMER 1655, Operator'S Manual

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