RAMMER 455 Original Instructions Manual Download Page 51

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Maintenance - Page 51

Troubleshooting

455

LEAKAGE FROM PRESSURE TO RETURN IN EXCAVATOR HYDRAULIC CIRCUIT

Check the installation. Check the pump and the other hydraulic components.

PRESSURE LOSS IN PRESSURE ACCUMULATOR

The hammer must be serviced in an authorized Rammer service shop.

FAILURE IN HAMMER VALVE OPERATION

The hammer must be serviced in an authorized Rammer service shop.

4.5 THE HAMMER DOES NOT STOP OR HAS RUN-ON

FAILURE IN HAMMER CONTROL VALVE OPERATION

Check the hammer control valve in the carrier.

4.6 OIL OVERHEATS

APPLICATION NOT CORRECT FOR HAMMER

Refer to recommended use and to correct working methods. See “Daily operation”
on page 23.

COOLING CAPACITY OF THE FACTORY OIL COOLER IS TOO SMALL

Assemble an extra oil cooler.

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.

HYDRAULIC OIL VISCOSITY TOO LOW

Check hydraulic oil. See “Requirements for hydraulic oil” on page 36.

LEAKAGE FROM PRESSURE TO RETURN IN EXCAVATOR HYDRAULIC CIRCUIT

Check the installation. Check the pump and the other hydraulic components.

INTERNAL OIL LEAK IN THE HAMMER

The hammer must be serviced in an authorized Rammer service shop.

EXCESSIVE BACK PRESSURE IN RETURN LINE

Check the installation. Check the size of the return line.

4.7 RECURRENT TOOL FAILURE

APPLICATION NOT CORRECT FOR HAMMER

Refer to recommended use and to correct working methods. See “Operating
instructions” on page 21.

Summary of Contents for 455

Page 1: ...Original instructions 1 13 OPERATOR S MANUAL OM455ENG 113 HYDRAULIC HAMMER RAMMER 455 ...

Page 2: ...maintenance 42 Overview 42 Inspection and maintenance by the operator 42 Inspection and maintenance by the dealer 43 Maintenance intervals in special applications 43 Other maintenance procedures 43 2 Removal of tool 44 Wear limits and lubricants for tool removal 44 Removal of tool 44 Installation of tool 45 3 Tool bushing 47 Wear limits and lubricants for lower tool bushing 47 Removal of tool bush...

Page 4: ...nual from front to back before installing operating 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 SYMBOLS USED IN TH...

Page 5: ...so been put on the machine to provide 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 car...

Page 6: ...ortant because no warranty claims are handled without it Make sure that you get a copy of it after the installation inspection and that it is correctly filled out INSTALLATION INSPECTION An installation inspection must be carried out after the product has been installed on the carrier In the installation inspection certain specifications operating pressure oil flow etc are checked so that they are...

Page 7: ...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 R010414 Hydraulic Hammer Model Serial Number Hammer weight Min working weight Operating pressure Oil flow Manufactured Version...

Page 8: ...stem 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 your local de...

Page 9: ...he procedure you choose is safe for you and others Do not lift load over people No 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 load a few centimeters and verify it before proceeding Make sure the load is well balanced Check for...

Page 10: ...r products 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 o...

Page 11: ... 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 local waste classification rules when disposing of used rubber or plastic parts buffers wear plates seals When scrapping the ...

Page 12: ... 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 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 War...

Page 13: ...ety 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 the job site in a clear area Keep other people away Do not perform new operations until you are sure you can do them ...

Page 14: ...ectric cables gas and water pipes etc 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 ...

Page 15: ... respirators must be utilized Stop working when bystanders are 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 whi...

Page 16: ...hat adequate operator s protection such as bullet proof glass mesh guard or an equivalent protection is used Keep the cabin windows and doors closed during operation Window bars are recommended to protect 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 sho...

Page 17: ...If hydraulic fluid penetrates your skin seek medical help immediately Hot hydraulic fluid can cause severe injuries HYDRAULIC HOSES AND FITTINGS Ensure all hydraulic components will 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 s...

Page 18: ...al before disassembly Release pressure before disassembly Recharge with nitrogen N2 only The hammer incorporates one or two pressure accumulators depending on the model The accumulators are pressurized even when there is no hydraulic pressure to the hammer Attempting to dismantle the accumulators without first releasing the pressure can cause injury or death Do not try to dismantle pressure accumu...

Page 19: ...fications can cause injury and damage Contact your local dealer for advice before modifying the product Before welding on the product while it is installed on the carrier disconnect the carrier alternator and battery Note that welding of the hammer tools will render them useless and make the warranty void METAL SPLINTERS You can be injured by flying splinters when driving metal pins in and out Use...

Page 20: ...sive that secures the safety labels Loose adhesive will allow the safety label to fall R010413 IGNORING INSTRUCTIONS HAZARD Faulty handling practice could cause death or severe injury Read and follow the instructions in the operator s manual WARNING 169410_ENG 3 DUST HAZARD Breathing dust will cause death or severe injury Always wear approved respirator DANGER 169410_ENG 1 FLYING OBJECTS HAZARD Fr...

Page 21: ...is already equipped with an installation kit 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 more complex installation including new piping and additional valves such as directional valve and pressure relief valve Suitable kits can be ordered from the manufacturer or local dealers from car...

Page 22: ... 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 impact breaking the material is broken by transferring very strong mechanical stress waves from the tool into the material Impact breaking is most effective in hard brittle and very abr...

Page 23: ...depend on hammer model See Tool specifications on page 56 5 2 DAILY OPERATION Warning Protect yourself and your neighbourhood against flying chips of rock Do not operate the hammer or carrier if someone is too close 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 hamm...

Page 24: ... the carrier controls to place the hammer and boom into the breaking position Quick and careless boom movements could 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 25: ...ties on the object which will break easily and cause either idle strokes or an incorrect working angle 6 When demolishing vertical structures e g brick walls place the tool against the wall at a 90 degree angle 7 Start the hammer 8 A safety screen is recommended to protect the operator from flying debris Keep the cabin windows and doors closed during operation ...

Page 26: ...ect does not break or if the tool does not penetrate stop the hammer and change the position of the tool Working too long in one spot will create stone dust under the tool Dust dampens the impact effect and produces heat 11 Do not let the tool move outwards from the hammer when it penetrates Keep the down pressure on the hammer while breaking 12 To use the hammer most efficiently when breaking con...

Page 27: ...mer falls through the housing wears out more quickly 15 When breaking concrete hard or frozen ground never strike and pry with the tool at the same time The tool may 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 16 Keep the tool at a 90 degree angle at all times If the object moves or its surface breaks ...

Page 28: ...y damage the hammer and the housing will wear out more quickly 18 When operating the hammer make sure that it does not make contact with the carrier boom or hydraulic lines 19 Do not operate the hammer with the carrier s boom stick or bucket cylinders at the end of their stroke either fully extended or retracted Damage to the carrier may result ...

Page 29: ... greasing intervals A tool shank covered with excessive grease requires less frequent greasing intervals 5 3 MOUNTING AND DISMOUNTING THE HAMMER REMOVAL FROM CARRIER Warning The hammer must be secured from rolling over when disconnecting from the carrier Only use a skilled operator to position the carrier for hammer removal Warning Hydraulic pressure inside the hammer must always be released befor...

Page 30: ...ake 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 INSTALLATION 1 Install hammer in the same manner as mounting a bucket Install bucket pins 2 Connect hoses Hammer inlet port is marked with IN and outlet port with OUT In the installation inspe...

Page 31: ...or some work other than normal breaking or demolition 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 mai...

Page 32: ...d 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 posi...

Page 34: ...purpose lubricant SHELL Kuggfett SHELL Albida HLS 2 WYNNS GS80 Wear gloves when handling the grease containers If you get grease onto your skin wash it away with water 1 2 MANUAL GREASING Follow the product s greasing instructions and avoid excessive greasing Dispose of empty grease containers appropriately GREASING INTERVAL 1 Tool shank must be well lubricated before installing tool 2 3 5 strokes...

Page 35: ...ol bushing and tool Tool breakage CORRECT GREASING 1 Position the hammer standing upright resting on the tool on firm surface 2 Stop carrier engine and wait 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 downward...

Page 36: ...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 must n...

Page 37: ...h 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 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 oi...

Page 38: ...rication 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 betw...

Page 39: ...ties 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 carrier are used as hammer circuit return line filters Consult the carrier manufacturer or your local dealer concerning ...

Page 40: ...pability 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 symptom After any component damage due to impurities in the oil the entire hydraulic system has to be cleaned Dismantle ...

Page 42: ...sembly 1 2 INSPECTION AND MAINTENANCE BY THE OPERATOR Note The time intervals given refer to the carrier hours while the attachment is installed EVERY TWO HOURS Grease the tool shank and the tool bushings See Manual greasing on page 34 Observe hydraulic oil temperature all lines and connections as well as impact efficiency and evenness of operation Tighten loose connections EVERY 10 HOURS OR AT LE...

Page 43: ...r more information 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 Replace and inspect the hydraulic oil filters of the carrier 1 4 MAINTENANCE INTERVALS IN SPECIAL APPLICATIONS The service interval is considerably shorter in special applications See Spec...

Page 44: ...tes for oil pressure to drop inside hammer Warning Hot tool can cause severe injuries Do not throw used hammer tool away at job site Used tools can be recycled by delivering them to an authorized scrap metal collection facility 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 plug and O ring It...

Page 45: ...n removing the tool Note If hammer is still on carrier it may be easier to stick the tool in the ground and lift the hammer off the tool Make sure that the tool can not fall INSTALLATION OF TOOL 1 Clean all parts carefully 2 Measure the tool diameter X from the area marked on the illustration Replace tool if necessary See Removal of tool on page 44 3 Check tool bushing for wear See Tool bushing on...

Page 46: ...3 SANDVIK MINING AND CONSTRUCTION OY Page 46 Maintenance Removal of tool 455 6 Install tool and align the groove of the tool with the pin bore 7 Install retaining pin and O ring 8 Grease plug and install it R030130 ...

Page 47: ...ER TOOL BUSHING REMOVAL OF TOOL BUSHING 1 Remove tool Notice that tool bushing and tool are locked with same tool retaining pin Prevent tool bushing from dropping on ground when removing the tool Item Wear limit Tool bushing inner diameter worn out 59 mm 2 32 in Item Lubricant Contact surfaces of front head Thread grease R030101 R030122 ...

Page 48: ...ATION OF TOOL BUSHING 1 Clean all parts carefully 2 Measure the bushing inner diameter marked Y Replace bushing if necessary See Tool bushing on page 47 3 Install seal 4 Lubricate the contact surfaces of the front head 5 Install the tool bushing Align the holes in the tool bushing with the holes in the front head 6 Install the tool R030123 R030124 ...

Page 49: ...cates the hammer control valve is opening If the valve does not operate check the operating means mechanical connections pilot pressure or electrical control 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 in...

Page 50: ...NG VALVE SETTING IS INCORRECT The hammer must be serviced in an authorized Rammer service shop PRESSURE LOSS IN PRESSURE ACCUMULATOR The hammer must be serviced in an authorized Rammer service shop FAILURE IN HAMMER VALVE OPERATION The hammer must be serviced in an authorized Rammer service shop 4 4 IMPACT RATE SLOWS DOWN OIL HAS OVERHEATED OVER 80 C 176 F Check for a fault in the oil cooling syst...

Page 51: ...OIL COOLER IS TOO SMALL Assemble an extra oil cooler 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 HYDRAULIC OIL VISCOSITY TOO LOW Check hydraulic o...

Page 52: ...hods RAPID WEAR OF TOOL Refer to recommended use and to correct working methods See Daily operation on page 23 There is a wider selection of tools available for different applications Consult with your local dealer for more information 4 8 FURTHER ASSISTANCE FURTHER ASSISTANCE If further assistance is required please prepare to answer the following questions before calling your dealer Model and se...

Page 54: ... Input power 19 8 kW 27 hp Tool diameter 56 mm 2 20 in Pressure line connection IN BSPP internal 3 4 Return line connection OUT BSPP internal 3 4 Pressure line size minimum inner diameter 16 mm 0 63 in Return line size minimum inner diameter 16 mm 0 63 in Optimum oil temperature 40 60 C 104 140 F Allowed oil temperature range 20 80 C 4 176 F Optimum oil viscosity at operating temperature 30 60 cSt...

Page 55: ...N OY Hammer specifications 455 1 2 MAIN DIMENSIONS h Check carrier s lifting capacity from carrier manufacturer i According to European Union DIRECTIVE 2000 14 EC j According to European Union DIRECTIVE 2000 14 EC R040196 827 1126 286 440 390 440 230 286 Ø23 Ø56 210 240 ...

Page 56: ...eter Width Chisel A BG551 520 mm 20 47 in 9 3 kg 20 lb 56 mm 2 20 in Moil point B BG553 520 mm 20 47 in 9 1 kg 20 lb 56 mm 2 20 in Spade parallel to boom C BG555 560 mm in 9 7 kg 20 lb 115 mm 4 53 in Spade transverse to boom D BG556 560 mm 22 05 in 9 7 kg 20 lb 115 mm 4 53 in Compacting plate E BG557 430 mm 16 93 in 23 kg 50 lb 250 mm 9 84 in R040155 ...

Page 57: ...the product Is in conformity with all the relevant provisions of the Outdoor Equipment 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 ...

Page 60: ...ndvik 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 24 12 14091 33 8 28 24 12 14091 33 96 371 ...

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