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RAMMER 1655 Operator's Manual

Hydraulic hammer, heavy duty
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Summary of Contents for RAMMER 1655

  • Page 1 Original instructions...
  • Page 4 Congratulations on having purchased this product. A properly installed attachment should prove to be a productive machine requiring maintenance only at regular intervals. This manual is arranged to give you a good understanding of the equipment and its safe operation. It also contains maintenance information and technical specifications.
  • Page 5 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 symbol identifies environmental and recycling matter.
  • Page 6 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. Check that a separate warranty sheet explaining the export warranty terms is delivered with the attachment.
  • Page 7 The equipment serial number is stamped on the valve body. The model 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.
  • Page 8 The product is a hydraulically operated breaker. It can be used on any carrier which meets the necessary hydraulic and mechanical installation requirements. The unit functions by repeatedly raising a steel piston and driving it down onto the head of a removable breaking tool.
  • Page 9 Use the lifting eyes located on the product housing only to lift or handle the product itself. The lifting capacity calculation is based on the product's working weight including a normal working tool and an average sized mounting bracket. Warning! To avoid falling objects, do not use the product to lift other products. Use the lifting eyes located on the product housing only to lift or handle the product itself.
  • Page 10 Lifting devices must safely carry the working weight of the product. See “Hammer specifications” on page 66. Place chains or slings, as shown by the illustration, to lift the product. Note: Before starting to operate the hammer, always replace the lifting eye with a blanking screw.
  • Page 11 Below are some common safety instructions concerning lifting operations. In addition to this, the local, national standards for machines and lifting-equipments must always be strictly observed. Please note that the list below is not all inclusive, you must always ensure the procedure you choose is safe for you and others. Do not lift load over people.
  • Page 12 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, automatic lubrication and pressurized air) E. Pressure accumulator F. Tool retaining mechanism G. Lifting eye H.
  • Page 13 The hammer is equipped with a built-in Ramvalve (check the part number (X) from the parts manual). The Ramvalve is designed to decrease oil flow remarkably to the hammer when oil flow from the carrier is too high. If the impact rate of the hammer decreases suddenly when operating the hammer, contact your local carrier dealer to decrease the carrier's oil flow.
  • Page 14 27. Checking the service interval status Rammer 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.
  • Page 15 When working with a Rammer product please follow these guidelines: Dispose of packaging materials properly. Wood and plastic can be burned or recycled. 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.
  • Page 16 All mechanical equipment can be hazardous if operated without due care or correct maintenance. Most accidents involving machine operation and maintenance are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.
  • Page 17 WARNING IGNORING INSTRUCTIONS HAZARD Faulty handling practice could cause death or severe injury. Read and follow the instructions in the operator’s manual. 169400_ENG-3 All the time you are working with the product, take care and stay alert. Always be alert for hazards. The possibility of a serious or even fatal accident is increased when you are intoxicated.
  • Page 18 Work sites can be hazardous. Inspect the site before working on it. Check for potholes, weak ground, hidden rocks and other possible hazards on the ground. Check for utilities (such as electric cables, gas and water pipes). Mark the positions of underground cables and pipes if you will be breaking the ground. Poor visibility can cause accidents and damage.
  • Page 19 The effect of airborne pollutants may be immediate if the substance is poisonous. The main danger with airborne pollutants comes from long term exposure, where particles are inhaled but not removed from the lungs. The disease is called silicosis, asbestosis or other, and will result in death or serious injury. To protect yourself from airborne pollutants, always keep excavator doors and windows closed during operation.

  • Page 20: Noise Hazard

    WARNING 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. 169400_ENG-2 Protect yourself and your neighbourhood against flying chips of rock. Do not operate the product or carrier if someone is too close.
  • Page 21 Operating the product beyond its design limits can cause damage. It can also be dangerous. See “Hammer specifications” on page 66. Do not try to enhance the product's performance by unapproved modifications. Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks.
  • Page 22 Read workshop manual before disassembly. Release pressure before disassembly. Recharge with nitrogen (N ) only." DANGER HIGH PRESSURE HAZARD Improper handling of pressurized accumulator will cause death or severe injury. Read workshop manual before disassembly. Release pressure before disassembly. Recharge with nitrogen (N ) only.
  • Page 23 Do not try to do repairs or any other maintenance work you do not understand. Non-approved modifications 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.
  • Page 24 WARNING IGNORING INSTRUCTIONS HAZARD Faulty handling practice could cause death or severe injury. Read and follow the instructions in the operator's manual. 169 400_ ENG-3 DANGER DUST HAZARD Breathing dust will cause death or severe injury. Always wear approved respirator. 169 400_ ENG-1 WARNING FLYING OBJECTS...
  • Page 25 The hammer is designed to be used in breaking concrete, road surface or asphalt, hard or frozen ground. It can be also used in breaking moderate sized boulders as well as in demolishing reinforced structures and for major excavation and clearing work.
  • Page 26 2. Replace or fix all parts that are worn out, damaged or loosened. This not only saves your hammer but it also decreases the noise level. To increase the hammer's working life, pay particular attention to correct working methods and how to choose the correct tool for the job. There are essentially two ways of breaking with a hydraulic hammer.
  • Page 27 Blunt tool For igneous (e.g. granite) and tough metamorphic rock (e.g. gneiss) into which the tool doesn't penetrate. Concrete. Breaking boulders. It is important to choose a tool, which is suitable for your hammer and for the application you are working on. The tool selection available depend on hammer model.
  • Page 28 A safety screen is recommended to protect the operator from flying debris. Keep the cabin windows and doors closed during operation. Keep the tool at a 90 degree angle at all times. 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.
  • Page 29 on small steps from the outer edge towards the middle. Do not strike in one spot for more than 15 seconds at a time. If the object does not break, or if the tool does not penetrate, stop the hammer and change the position of the tool.
  • Page 30 against the wall at a 90 degree angle. 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.
  • Page 31 Do not use the hammer to sweep the ground of debris. This may damage the hammer and the housing will wear out more quickly. When operating the hammer, make sure that it does not make contact with the carrier boom or hydraulic lines. 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).
  • Page 32 are for storage and maintenance purposes only. 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. Do not use the hammer, as a standard assembly, under water. If water fills the space where the piston strikes the tool, this generates a strong pressure wave that may damage the hammer.
  • Page 33 3. Carefully operate the carrier controls to place the hammer and boom into the breaking position. Quick 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.
  • Page 34 5. Place the tool against the object at a 90 degree angle. Avoid small irregularities on the object which will break easily and cause either idle strokes or an incorrect working angle. 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.
  • Page 35 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 before opening hose connections! Warning! Hot hydraulic fluid can cause severe injuries! 1.
  • Page 36 3. Open hammer inlet and outlet lines. 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. Special conditions of use are conditions in which the hammer is used for some work other than normal breaking or demolition, such as: Hammer tunneling Foundry cleaning...
  • Page 37 Use environmental friendly oil and tool grease when you are using the hammer under water. Warning! If you are using the hammer under water, protect yourself and your surroundings against compressed water/air spray and possible broken compressed air hoses. Warning! If you are using the hammer under water, check the stability of the carrier and the hammer.
  • Page 38 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 area must be dry. 2. The tool must be removed in hydraulic hammers. 3.
  • Page 40 For tool lubrication use only RAMMER TOOL GREASE, part no. 902045 (400 g cartridge), part no. 902046 (18 kg drum), or any grease that meets the following criteria: No dropping point or very high, over 250 °C (480 °F). Maximum service temperature at least 150 °C (300 °F).
  • Page 41 Dispose of empty grease containers appropriately. The hammer can be equipped with an automatic greasing device. See “Greasing device” on page 13. Do not remove the grease cartridge unnecessarily. Always keep the grease cartridge in the greasing device to prevent dirt from entering the greasing device. Note: Some hammer models are equipped with an adapter kit for manual greasing and do not include an automatic greasing device.
  • Page 42 6. Push the cartridge piston with fingers until approximately 15 mm of grease comes out. 7. Insert 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.
  • Page 43 Please note that the actual amount of 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.
  • Page 44 5. Tighten the locking nut to the specified torque setting. See table below. 6. Turn the locking plate and plug to the correct positions. Shield screws 175 Nm (129 lbf ft) Adjusting screw locking nut 50 Nm (37 lbf ft) Adjusting range Linear 0 ...
  • Page 45 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 subsequently leak oil.
  • Page 46 In general the hydraulic oil originally intended for the carrier can be used with this product. However, since working with the product heats the oil more than the usual excavation work, the temperature of the oil must be monitored. If the temperature of the hydraulic oil exceeds 80 °C (176 °F), an auxiliary oil cooler is needed.
  • Page 47 Table below shows hydraulic oils recommended for hammer use. The most suitable oil is selected in such a way that the temperature of the hydraulic oil in continuous use is in the ideal area on the chart and the hydraulic system is used to best advantage.
  • Page 48 Oil too thin Efficiency losses (internal leaks) Damage to gaskets and seals, leaks Accelerated wearing of parts, because of decreased lubrication efficiency Hammer strikes irregularly and slowly Danger of cavitation in pumps and in the hydraulic hammer Note: We strongly recommend the use of different hydraulic oils in the summer and in the winter if there is an average temperature difference of more than 35 °C (63 °F).
  • Page 49 A standard carrier, with a proper hammer circuit, meets the requirements of the necessary cooling capacity. If the oil temperature tends to be too high during the hammer operation, the following things must be checked: The hammer circuit pressure relief valve is not open when the hammer is operated.
  • Page 50 3. Reduced hammer efficiency. Accelerated wear of moving parts and seals. Danger of piston seizing up. Oil leakages. 4. Shortened working life and reduced lubricating capability of oil. Oil overheats. Oil quality deteriorates. Electro-chemical changes in hydraulic oil. 5. Valves do not function properly. Spools bind.
  • Page 52 This product is a precision made hydraulic machine. Therefore great care and cleanliness should be taken when handling any of the hydraulic components. Dirt is the worst enemy in hydraulic systems. Handle the parts carefully and remember to cover any cleaned and dried parts with clean lint-free cloth.
  • Page 53 Check the tool shank and tool bushings for wear. See “Changing the tool” on page 55. See “Lower tool bushing” on page 58. Check the hydraulic hoses. Replace if necessary. Do not let dirt get into the hammer or hoses. Check that the hammer moves normally inside the housing and that vibration dampening elements (pads and buffers) are in good condition.
  • Page 54 The service interval is considerably shorter in special applications. See “Special conditions of use” on page 36. In special applications, please consult your local dealer for the correct service intervals. After every half hour operation Grease the tool shank and the tool bushings through the grease nipples. Check that the hammer moves normally inside the housing and that the buffers are in good condition.
  • 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 Warning! The hydraulic pressure inside 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. 2.
  • Page 57 1. Clean all parts carefully. 2. Measure the tool diameters (X and Y) from the areas marked on the illustration. Replace tool if necessary. See “Changing the tool” on page 55. 3. Measure the tool retaining pin diameter (Z). Replace tool if necessary. See “Changing the tool”...
  • Page 58 Tool bushing (worn out) Grease groove is worn out. Bushing must be replaced. Contact surfaces of front head Thread grease The lower tool bushing can not be removed without removing the hammer from the housing. Contact your local dealer for more information.
  • Page 59 Check the installation. Check the size of the return line. Check the installation. Check the pump and the other hydraulic components. The hammer must be serviced in an authorized Rammer service shop. The hammer must be serviced in an authorized Rammer service shop.
  • Page 60 Check the installation. Check the relief valve operation. Adjust the relief valve in hydraulic circuit. Measure the high pressure in the hammer inlet line. The hammer must be serviced in an authorized Rammer service shop. Refer to the correct working methods. See “Daily operation” on page 28.
  • Page 61 If impact rate is too slow check the oil flow. Contact your local carrier dealer for more information. The hammer must be serviced in an authorized Rammer service shop. The hammer must be serviced in an authorized Rammer service shop.
  • Page 62 Refer to recommended use and to correct working methods. See “Operating instructions” on page 25. Refer to recommended use and to correct working methods. See “Daily operation” on page 28. Refer to recommended use and to correct working methods. Refer to recommended use and to correct working methods. See “Daily operation” on page 28.
  • Page 63 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. Remove the lubrication device from the hammer and deliver it for service in an authorized Rammer service shop.
  • Page 66 1080 kg (2380 lb) Minimum working weight Hammer weight 870 kg (1920 lb) 540...920 bpm Impact rate 135...145 bar (1960...2105 psi) Operating pressure 190 bar (2755 psi) Pressure relief, min Pressure relief, max 220 bar (3190 psi) Oil flow range 90...130 l/min (23.8...34.3 gal/min) Back pressure, max 10 bar (145 psi)
  • Page 68 After welding check flatness of the plate and mill surface as needed. Maximum acceptable deviation from flatness is 1 mm (0.04 in) Bottom plate recommended minimum 25 mm (0.98 in) thickness (X) Side plate recommended minimum 25 mm (0.98 in) thickness (Y)
  • Page 69 Chisel (A) BB491 1000 mm 67 kg (150 115 mm (39.37 in) (4.53 in) Moil point (B) BB493 1000 mm 67 kg (150 115 mm (39.37 in) (4.53 in) Blunt (C) BB494 800 mm 58 kg (130 115 mm (31.50 in) (4.53 in) Pyramid (D) BB493K3...
  • Page 70 (Directive 2006/42/EC, Annex II. 1. A; Directive 2000/14/EC) Manufacturer: Sandvik Mining and Construction Oy, Breakers Lahti Address: Taivalkatu 8, FI-15170 Lahti, Finland Herewith declares that the Rammer hydraulic hammer Model: 1655 Is in conformity with all the relevant provisions of the Machinery Directive 2006/42/EC.
  • Page 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...