RAMMER S 83 STD Operation And Maintenance Manual Download Page 51

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MAINTENANCE - Page 51

Troubleshooting

S 83 STD

EXCESSIVE BACK PRESSURE IN RETURN LINE

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

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.

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

INTERNAL LEAKAGE 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.

Summary of Contents for S 83 STD

Page 1: ...3 05 OPERATION AND MAINTENANCE OMS83SENG 305 HYDRAULIC HAMMER RAMMER S 83 STD ...

Page 2: ...il filter 37 MAINTENANCE 39 1 Routine maintenance 40 Overview 40 Inspection and maintenance by the operator 40 Inspection and maintenance by the dealer 41 Maintenance intervals in special applications 42 Other maintenance procedures 42 2 Removal of tool 43 Wear limits and lubricants for tool removal 43 Removal of tool 43 Installation of tool 45 3 Lower tool bushing 46 Wear limits and lubricants fo...

Page 3: ...OPERATION Page 3 2005 SANDVIK TAMROCK CORP S 83 STD OPERATION ...

Page 4: ...front to back before installing operating or maintain ing 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 exam ple 28 litres 7 4 US gal The specifications and designs presented in this manual are subject to change with out prior notice SYMBOLS USED IN THIS MANU...

Page 5: ...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 attachment is a powerful tool If used without proper care it can cause damage Do not rush when you are learning to use the pr...

Page 6: ...r 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 within given limits 1 5 SPARE PART ORDERS When you need spare parts or some information concerni...

Page 7: ...el and serial number are also located on the CE marking Check 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: ... remove all plas tics covering the product Recycle all package materials steel plastic wood prop erly 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 bracket 3 3 LIFTING INSTRUCTIONS Us...

Page 9: ...OPERATION Page 9 2005 SANDVIK TAMROCK CORP Product introduction S 83 STD Note The lifting eye must always be removed from the hammer and replaced with a blanking screw before starting to operate hammer ...

Page 10: ... 4 MAIN PARTS The main parts of the hammer are shown below A Housing B Mounting flange C Vibration dampening elements D Hose connections pressure and return lines E Pressure accumulator F Tool retaining mechanism G Tool bushing retaining mechanism H Lifting eye I Grease nipples ...

Page 11: ... can be burned or re cycled Deliver the steel belts to metal recycling center Protect environment from oil spills In case of hydraulic oil leaks the equipment 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 f...

Page 12: ...hoose Safety is not just a matter of responding to the warnings All the time you are work ing 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 messages carefully They...

Page 13: ...and your equipment COMMUNICATIONS Bad communications can cause accidents Keep people around you informed of what you will be doing If you will be working with other people make sure they understand any hand signals you will be using Work sites can be noisy Do not rely only on spoken commands WORK SITE Work sites can be hazardous Inspect the site before working on it Check for potholes weak ground ...

Page 14: ...IMITS Operating the product beyond its design limits can cause damage It can also be dan gerous See Hammer specifications on page 54 Do not try to enhance the product s performance by unapproved modifications HYDRAULIC FLUID Fine jets of hydraulic fluid at high pressure can penetrate the skin Do not use your fingers to check for hydraulic fluid leaks Do not put your face close to suspected leaks H...

Page 15: ...ure can injure you Before disconnecting or connect ing hydraulic hoses stop the carrier engine operate the controls to release pressure trapped in the hoses and wait ten 10 minutes During the operation keep people away from the hydraulic hoses There might be pressurized oil trapped inside the product even if it is disconnected from the carrier Be aware of possible blank firing while greasing or re...

Page 16: ...mage the product EQUIPMENT CONDITION Defective equipment can injure you or others Do not operate equipment which is defective or has missing parts Make sure the maintenance procedures in this manual are completed before using the product REPAIRS AND MAINTENANCE Do not try to do repairs or any other maintenance work you do not understand MODIFICATIONS AND WELDING Non approved modifications can caus...

Page 17: ...y 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 includ ing 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 carrier man...

Page 18: ...nside 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 The best possible energy transfer be tween the tool and the object is achi...

Page 19: ... which the tool doesn t penetrate Concrete Breaking boulders Super blunt When tool wear is extensive in igneous e g granite and tough metamorphic rock e g gneiss into which the tool doesn t penetrate Breaking boulders very abrasive rock Do not use for penetrative work or in non abrasive rock It is important to choose a tool which is suitable for your hammer and for the ap plication you are working...

Page 20: ...er If water fills the space where the piston strikes the tool a strong pressure wave is gen erated and the hammer may be damaged 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 recommended engine RPM for correct amount of oil supply 3 Carefully operate the carrier controls to place the hammer and boom...

Page 21: ...ry 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 incor rect working angle ...

Page 22: ...afety screen is recommended to protect the operator from flying debris Keep the cabin windows and doors closed during operation 9 Note 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 ...

Page 23: ...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 big boulders concentrate on small steps from the outer edge towards the middle 13 When breaking hard or frozen ground use the benching method Start with cl...

Page 24: ...through the housing wears out more quick ly 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 re sistance under the tool 16 Keep the tool at a 90 degree angle at all times If the object moves or its surface breaks correct ...

Page 25: ...to move rocks The stone claws are designed for this purposes 18 Do not use the hammer to sweep the ground of debris This may damage the hammer and the housing will wear out more quickly 19 When operating the hammer make sure that it does not make contact with the carrier boom or hydraulic lines ...

Page 26: ...o the carrier may result 21 Do not use the hammer or hammer tools for lifting Lifting eyes on the hammer are for storage and maintenance purposes only 22 The tool shank must be well greased during operation Regular visual inspec tions during operation are recommended An unlubricated tool shank requires more frequent greasing intervals A tool shank covered with excessive grease requires less freque...

Page 27: ...er 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 ball valves please make sure that they are closed 4 Disconnect hoses Protect environment from oil spills Plug the hoses and the hammer in...

Page 28: ...dry cleaning Underwater operations Operations in extremely low or high temperatures Use of special hydraulic fluids Hammer operations with special carrier extra long boom etc Other special conditions That may require modifications to attachment special operating techniques in creased maintenance or special wear items In case of special conditions of use please consult your local dealer for instruc...

Page 29: ...ine is ready to be used when ever 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 position 6 Ma...

Page 30: ... 2005 SANDVIK TAMROCK CORP Page 30 OPERATION Operation S 83 STD ...

Page 31: ...LUBRICATION Page 31 2005 SANDVIK TAMROCK CORP S 83 STD LUBRICATION ...

Page 32: ...instructions and avoid excessive greasing Dis pose of empty grease containers appropriately GREASING INTERVAL 1 Tool shank must be well lubricated before 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 condi tions This can be anything between two hours and daily depending on materia...

Page 33: ...or 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 will subsequen...

Page 34: ...rature of the hydraulic oil exceeds 80 C 176 F an auxiliary oil cooler is needed The oil viscosity must be between 1000 20 cSt while the attachment is being used When the product is used continuously the temperature of the hydraulic oil normal izes 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 st...

Page 35: ...at 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 advan tage 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...

Page 36: ...operties 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 manufac turer or your local dealer for more information about special oils 2 2 OIL COOLER The correct place to connect the hammer return line is between the oi...

Page 37: ...r 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 carrier are used...

Page 38: ... 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 symptom After any...

Page 39: ...MAINTENANCE Page 39 2005 SANDVIK TAMROCK CORP S 83 STD MAINTENANCE ...

Page 40: ...trachloride Components gaskets and seals in the hydraulic system should be oiled with clean hydraulic oil before assembly 1 2 INSPECTION AND MAINTENANCE BY THE OPERATOR Note The times 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 32 Observe hydraulic oil temperature all lines and connection...

Page 41: ... refer to the carrier hours while the attachment is installed INITIAL 50 H INSPECTION It 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 EVERY 600 HOURS OR ONCE A YEAR This service is recommended to be done by your local dealer after 600 operating hours Neglecti...

Page 42: ...r the correct service intervals 1 5 OTHER MAINTENANCE PROCEDURES WASHING THE ATTACHMENT When working with attachment and removing it from the carrier dirt mud rock powder etc can become attached to it Wash the outside of the product with a steam washer before sending it to the workshop Dirt can cause difficulties in disassembly and assembly otherwise CAUTION Plug the pressure and return line befor...

Page 43: ...ere 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 en gaged 3 Stop the carrier engine 4 Push the rubber plate upwards so that the pin holes are accessible 5 Remove rubber plugs 6 Push l...

Page 44: ...ve retaining pin 8 Remove tool retaining pins 9 Remove tool Use lifting device if necessary See Tool specifications on page 56 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 ...

Page 45: ...ushing for wear See Lower tool bushing on page 46 4 Check tool seal Replace if necessary 5 Clean and coat tool and retaining pins with grease 6 Install tool and align the grooves of the tool with the pin bores 7 Install retaining pins 8 Push locking pin so far that pin can be installed 9 Install pin 10 Check that pin is secured by locking pin 11 Install rubber plugs into their places 12 Slide the ...

Page 46: ... groove is visible Bushing can be re installed Rotate bushing 90 so that the unused bushing surface will be utilized bushing has two grooves for retaining pins Tool bushing worn out Both first and second grease grooves are worn out Bushing must be replaced Item Specification Distance from upper end of bushing H 140 mm 5 51 in Width of silicone compound L 40 mm 1 57 in Item Lubricant Contact surfac...

Page 47: ...STD REMOVAL OF LOWER TOOL BUSHING Do not throw used hammer tool bushing away at job site Used tool bushings can be recycled by delivering them to an authorized scrap metal collection fa cility 1 Remove tool 2 Remove split pin and retaining pin 3 Remove lower tool bushing ...

Page 48: ...silicone compound to the lower tool bushing as specified 5 Check the condition of the seal in housing Replace if necessary 6 Lubricate the contact surfaces of the front head Leave 50 mm 1 97 in area from the opening of the hole clean from lubricant Do not allow the silicone compound and the thread grease get mixed 7 Install the lower tool bushing Align the groove in the lower tool bushing with the...

Page 49: ...ng the hammer control valve check that the pressure line pulsates this indicates 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 r...

Page 50: ...YDRAULIC 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 hammer must be serviced in an authorized Rammer service shop PRESSURE L...

Page 51: ...ine Contact your local dealer for more information 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 HAM...

Page 52: ...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 34 LEAKAGE FROM PRESSURE TO RETURN IN EXCAVATOR HYDRAULIC CIRCUIT Check ...

Page 53: ...SPECIFICATIONS Page 53 2005 SANDVIK TAMROCK CORP S 83 STD SPECIFICATIONS ...

Page 54: ...g actual operating pressure 50 bar 730 psi 185 bar 2680 psi Pressure relief max 220 bar 3190 psi Oil flow range 160 230 l min 42 3 60 8 gal min Back pressure max 5 bar 70 psi Input power 54 kW 72 hp Tool diameter 140 mm 5 51 in Pressure line connection IN SAE 6000 psi 1 Return line connection OUT SAE 6000 psi 1 1 4 Pressure line size minimum inner diameter 26 mm 1 02 in Return line size minimum in...

Page 55: ...SPECIFICATIONS Page 55 2005 SANDVIK TAMROCK CORP Hammer specifications S 83 STD 1 2 MAIN DIMENSIONS ...

Page 56: ...fferent applications Consult with your local dealer for more information Tool Part no Length Weight Diameter Chisel A 831 1200 mm 47 24 in 137 kg 302 lb 140 mm 5 51 in Moil point B 833 1200 mm 47 24 in 137 kg 302 lb 140 mm 5 51 in Blunt C 834 1050 mm 41 34 in 122 kg 269 lb 140 mm 5 51 in Super blunt D 834T2 1100 mm 43 31 in 134 kg 295 lb 150 mm 5 91 in ...

Page 57: ...Page 57 2005 SANDVIK TAMROCK CORP ...

Page 58: ...Sandvik Tamrock Corp Breakers Lahti Taivalkatu 8 P O Box 165 FIN 15101 Lahti Finland Phone Int 358 205 44 161 Telefax Int 358 205 44 160 www rammer com 69 12 14035 51 76 413 87 12 14035 39 200 175 ...

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