RAMMER 2155E Operator'S Manual Download

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Original instructions

9/19

OPERATOR'S MANUAL

OM2155ESENG.919

HYDRAULIC HAMMER

RAMMER 2155E

STD

Summary of Contents for 2155E

Page 1: ...Original instructions 9 19 OPERATOR S MANUAL OM2155ESENG 919 HYDRAULIC HAMMER RAMMER 2155E STD ...

Page 2: ...nspection and maintenance by the operator 58 Inspection and maintenance by the dealer 59 Maintenance intervals in special applications 60 Other maintenance procedures 60 2 Changing the tool 61 Wear limits and lubricants for tool removal 61 Removal of tool 61 Installation of tool 62 3 Lower tool bushing 64 Wear limits and lubricants for lower tool bushing 64 Removal of lower tool bushing 64 4 Troub...

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 ...

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: ...e 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 CONTENT OF THE PRODUCT IDENTIFICATION PLATE 1 Hydraulic Hammer 2 Model 3 Version 4 Serial Number 5 Hammer weight kg 6 Min working w...

Page 9: ...ure accumulator absorbs hydraulic pressure peaks The impact energy of the hammer is almost constant and independent of the carrier s hydraulic 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 3 3 LIFTING INSTRUCTIONS Use a hoist when lifting components ...

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 70 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: ...TD 3 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 line marked IN and return line marked OUT E Pressure accumulator F Tool retaining mechanism G Greasing device H Lifting eye I Grease nipple R010276 ...

Page 14: ...is a hammer mounted device that enables remote monitoring of a hammer units During hammer operation RD3 collects and transmits operating and location information This information will be made available through an online service and can be used for example to view hammer work history manage service schedules optimize hammer performance plan operator training and conduct fleet management For more in...

Page 15: ...a highly flammable substance Store damaged lithium batteries in a fire proof container Never transport a damaged or unprotected lithium battery Follow local laws and regulations on proper disposal of damaged lithium batteries Warning Inhalation skin contact and eye contact can occur when the battery is opened Upon exposure to internal contents the corrosive fumes will be very irritating to the ski...

Page 16: ...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 17: ... 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 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 ...

Page 18: ...ir 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 safely REGULATIONS AND LAWS Obey all laws work site and local regulations which affect you and your equipment COMMUNICATIONS Bad commu...

Page 19: ...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 construction sites can be for example silica dust oil fumes or diesel exhaust particles visible or invisible Especially in demolition sites there may be other dangerous substances such as asbestos or lead pa...

Page 20: ...s the respirators must be checked to make sure that it is clean that its filter has been changed and to otherwise make sure the respirator will protect in the way it is meant to Always make sure dust has been cleaned off your boots and clothes when you leave your shift The smallest particles of dust are the most harmful They may be so fine that you can not see them Remember you MUST protect yourse...

Page 21: ...e hearing impairment Wear approved hearing protectors EQUIPMENT LIMITS Operating the product beyond its design limits can cause damage It can also be dangerous See Hammer specifications on page 70 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 hydra...

Page 22: ...dling of pressurized accumulator will cause death or severe injury Read workshop manual 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 rel...

Page 23: ...l brands may damage 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 modific...

Page 24: ...ctions which have disappeared been damaged painted over come loose or do not meet the legibility requirements for safe viewing distance must be replaced before operating the product If a safety label is attached to a part that is replaced install a new safety label on the replacement part If this manual is available in your language then the safety labels should be available in the same language T...

Page 25: ...actice 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 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 heari...

Page 26: ...oes 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 suppliers Hydraulic oil In general the hydraulic oil originally intended for the carrier can...

Page 27: ...or 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 quickly CHOOSING TOOLS A selection of standard and special tools to suit each application are available The correct type of tool must be selected to get the best possible working results and longest life ...

Page 28: ...CTION OY Page 28 Operation Operation 2155E STD It is important to choose a tool which is suitable for your hammer and for the application you are working on The tool selection available depend on hammer model See Tool specifications on page 74 ...

Page 29: ...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 30: ...nder the tool Dust 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...

Page 31: ...ame 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 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 fo...

Page 32: ...ay 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 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 ...

Page 33: ...ation Page 33 COPYRIGHT 2019 SANDVIK MINING AND CONSTRUCTION OY Operation 2155E STD Do not use the hammer or hammer tools for lifting Lifting eyes on the hammer are for storage and maintenance purposes only ...

Page 34: ...s 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 recommended engine RPM for correct amount of oil supply 3 Carefully operate the carrier controls to place the hammer and boom i...

Page 35: ...egularities on the object which will break easily 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 36: ...t hydraulic fluid 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 hamm...

Page 37: ...aside INSTALLATION 1 Install hammer in the same manner as 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 th...

Page 38: ...on Operation 2155E STD 5 4 MOVEMENT The transportation and parking positions are shown below When moving with the hammer ensure that it isn t too close and doesn t point at the cabin window Item Torque Mounting screws for flange couplings H 110 Nm 81 lbf ft R010484 H ...

Page 39: ...hniques increased maintenance or special wear items If you are planning to use the hammer under a special condition of use please consult your local dealer for instructions 5 6 STORAGE LONG TERM STORAGE Observe the following points when the hammer is stored In this way the vital parts of the attachment are protected from rust and the machine is ready to be used whenever necessary 1 The storage are...

Page 42: ...teria 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 wh...

Page 43: ... when the grease container is full The status of the indicator can be checked through the window in the cover plate The check must be done every two hours The grease container must be refilled when spool of indicator has come out of its base PARTS FOR OPERATING THE GREASING DEVICE A Indicator for the need of refilling B Quick coupler connection for grease filling device C Pressure releasing plug D...

Page 44: ...ng device equipped with pressure release valve and grease filter delivered by hammer manufacturer 1 On the housing turn the cover plate of the greasing device aside 2 Clean carefully excessive grease from nipple in the greasing device B 3 Connect the grease filling device to the quick coupler B of the greasing device 4 The spool of the indicator A will draw back when the grease container starts to...

Page 45: ...osswise and press it in and simultaneously press air releasing plug H 6 Detach the quick coupler and install the cover plate ADJUSTING DOSER CARTRIDGE 1 Turn the cover plate of the greasing device aside 2 Open adjusting screw locking nut 3 Turn adjusting screw clockwise to close completely 4 Open adjusting screw counter clockwise half turn 5 Torque adjusting screw locking nut Item Specification Ad...

Page 46: ...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 appropriately Note The grease cartridge i...

Page 47: ...5 Check the grease cartridge seal 6 Push the cartridge piston with fingers until approximately 15 mm of grease comes out 7 Insert the cartridge and tighten it 1 4 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 R020110 R020111 R020128 A B E D C ...

Page 48: ... grease needed for proper lubrication varies according to hammer size application the amount of grease depends on the number of working cycles within a given time 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 q...

Page 49: ...SING Follow the product s greasing instructions and avoid excessive greasing Dispose of empty grease containers appropriately Manual greasing is always possible even if the hammer is equipped with the automatic greasing device Manual greasing is necessary if the greasing device has a malfunction The grease nipple for manual greasing is in the right end of the greasing device Item Specification Tor...

Page 50: ... on page 42 Insufficient greasing or improper grease may cause Abnormal wear of tool 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 s...

Page 51: ...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 52: ...n 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 Oil too thin Efficiency losses internal leaks Damage to gaskets and seals leaks Accelerated wearing of parts because of decreased lubric...

Page 53: ...mmer return line is between the oil cooler and the main filters The hammer return line should not be connected before the oil cooler Routing the hammer return flow through the cooler might damage either the cooler due to pulsating flow or the hammer due to increased back pressure The carrier hydraulic system must be able to maintain the temperature within an acceptable level during the hammer oper...

Page 54: ...rrier oil filter must fulfil the following specifications The oil filter must allow maximum particle size of 25 microns 0 025 mm The oil filter material must be artificial fibre cloth or very fine gauge metallic mesh to withstand pressure fluctuations The oil filter must have a nominal flow capacity of at least twice the hammer s maximum flow In general oil companies guarantee new oils to have a p...

Page 55: ...rly 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 hydraulic oil ...

Page 58: ...mbly 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 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 ...

Page 59: ...Contact your local dealer for more information about the initial 50 hour inspection EVERY 1000 HOURS OR ONCE A YEAR 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 hammer replace the accumulator membranes and replace safety decals as n...

Page 60: ...or 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 and ...

Page 61: ...e the hammer must always be released before removing the tool After operating the hammer wait 10 minutes for oil pressure to drop inside hammer Warning Hot tool can cause severe injuries 1 Set the hammer on level ground Item Wear limit Tool diameter worn out 116 mm 4 57 in Item Wear limit Tool retaining pin diameter Z worn out 52 mm 2 05 in Item Lubricant Tool and tool retaining pins Tool grease R...

Page 62: ...vice if necessary If the tool cannot be removed contact your local dealer 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 cannot 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 Changing the tool on pa...

Page 63: ...nging the tool 2155E STD 4 Check tool seal Replace if necessary 5 Clean the tool and retaining pins and lubricate them with 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 Install plugs R030110 ...

Page 64: ...OR LOWER TOOL BUSHING REMOVAL OF LOWER TOOL BUSHING The lower tool bushing can not 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 65: ...rrect working methods See Daily operation on page 29 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 66: ...ced 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 APPLICATION NO...

Page 67: ...to 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 29 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 PROB...

Page 68: ...ase 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 and...

Page 70: ... power 48 kW 64 hp Tool diameter 118 mm 4 65 in Pressure line connection IN ORFS ISO 8434 3 1 11 16 12 UN Return line connection OUT ORFS ISO 8434 3 1 11 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 26 mm 1 02 in Return line size minimum inner diameter 26 mm 1 02 in Optimum oil temperature 40 60 C 104 1...

Page 72: ...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 73: ...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 74: ...or different applications Consult with your local dealer for more information Tool Part no Length Weight Diameter Chisel A 551 1050 mm 41 34 in 82 7 kg 182 lb 118 mm 4 65 in Moil point B 553 1050 mm 41 34 in 82 7 kg 182 lb 118 mm 4 65 in Blunt C 554 850 mm 33 46 in 71 1 kg 157 lb 118 mm 4 65 in Pyramid D 553K3 1050 mm 41 34 in 82 7 kg 182 lb 118 mm 4 65 in R040269 D C B A ...

Page 75: ...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 76: ...to a new set of data By using 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 aff...

Page 80: ...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 27 40 14133 45 20 49 30 40 14133 24 120 49 ...

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