RAMMER 255E Operator's Manual

Hydraulic hammer

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8/20

OPERATOR'S MANUAL

OM255EENG.820

HYDRAULIC HAMMER

RAMMER 255E

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Page 1 Original instructions 8/20 OPERATOR'S MANUAL OM255EENG.820 HYDRAULIC HAMMER RAMMER 255E...
Page 2: Table Of Contents
Wear limits and lubricants for lower tool bushing ... . . 53 OPERATION......3 Removal of tool bushing.
Page 4: Foreword
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 versione in lingua italiana di questo manuale presso il rivenditore Rammer. LT: Paprašykite savo Rammer platintojo lietuviškos instrukcijos versijos.
Page 5 255E Foreword SYMBOLS USED IN THIS MANUAL This symbol identifies important safety messages within this manual. Carefully read the message that follows. 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 1.
Page 6: Important Safety Information
Foreword 255E 1.2 IMPORTANT SAFETY INFORMATION Basic safety precautions are outlined in the "Safety" section of this manual and in the description of operations where hazards exist. Warning labels have also 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.
Page 7: Spare Part Orders
255E Foreword 1.4 SPARE PART ORDERS When you need spare parts or some information concerning 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.
Page 8: Product Numbers
Product numbers 255E 2. PRODUCT NUMBERS 2.1 MODEL AND SERIAL NUMBER The product serial number is stamped on the valve body. Both the model and serial number are located on the product identification plate. Check that the model corresponds to the one given on the cover of this manual.
Page 9: Product Introduction
255E Product introduction 3. PRODUCT INTRODUCTION 3.1 OVERVIEW The product is a hydraulically operated hammer. 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 10 Product introduction 255E Lifting devices must safely carry the working weight of the product. See “Hammer specifications” on page 60. Place chains or slings, as shown by the illustration, to lift the product. R010415 SAFETY INSTRUCTIONS FOR LIFTING Below are some common safety instructions concerning lifting operations. In addition to this, the local, national standards for machines and lifting-equipment must always be strictly observed.
Page 11: Main Parts
255E Product introduction 3.4 MAIN PARTS The main parts of the hammer are shown below. R010416 A. Side plates B. Mounting flange C. Hammer mechanism D. Hose connections E. Grease nipple F. Tool and tool bushing retaining mechanism COPYRIGHT © 2020 SANDVIK MINING AND CONSTRUCTION OY...
Page 12: Rd3 Remote Monitoring Device
For more information, contact your local Rammer dealer. Note: See “RD3 and data privacy” on page 66. R010515 Warning! RD3 contains a SIM card to enable remote connections and an encased lithium metal battery.
Page 13: Environmental Protection And Recycling Policy
Product introduction 3.6 ENVIRONMENTAL PROTECTION AND RECYCLING POLICY 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 14: Safety
Safety 255E 4. SAFETY 4.1 GENERAL SAFETY 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 15: Safety Instructions
255E Safety 4.2 SAFETY INSTRUCTIONS MANUALS Study this manual before installing, operating or maintaining the product. If there is anything you don't understand, ask your employer or your local dealer to explain it. Keep this manual clean and in good condition.
Page 16 Safety 255E 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.
Page 17 255E Safety AIRBORNE POLLUTANTS The related safety label on the hammer and the text on the label are shown below. "DUST HAZARD Breathing dust will cause death or severe injury. Always wear approved respirator." DANGER DUST HAZARD Breathing dust will cause death or severe injury.
Page 18 Safety 255E 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 which cause silicosis and which may cause other serious lung diseases.
Page 19 255E Safety The European standard EN 474-1 on safety of earth-moving machinery requires that 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.
Page 20 Safety 255E 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. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid.
Page 21 255E Safety PRESSURE ACCUMULATORS The safety label on or near the accumulator is shown below. "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 22 Safety 255E 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.
Page 23 255E Safety There are several specific safety labels on this hammer. Please become familiarized with all safety labels. The location of the safety labels is shown in the illustration below. When you clean the safety labels, use a cloth, water and soap. Do not use solvent, gasoline or other harsh chemicals to clean the safety labels.
Page 24: Operation
Operation 255E 5. OPERATION 5.1 OPERATING INSTRUCTIONS RECOMMENDED USE The hammer is designed to be used in breaking concrete, road surface or asphalt, hard or frozen ground. It is also suitable for light trenching and benching applications or in ground compacting. It can be also used in breaking small and soft boulders.
Page 25 255E Operation Noise dampening Operating the hammer near residential areas or other noise sensitive areas can cause noise pollution. In order to avoid unnecessary noise, please follow these basic rules: 1. When operating the hammer, keep the tool at a 90 degree angle to the material and the feed force in-line with the tool.
Page 26 Operation 255E Chisel and moil point ■ For sedimentary (e.g. sandstone) and weak metamorphic rock into which the tool penetrates. ■ Concrete. ■ Trenching and benching. ■ Scaling. Spade tool ■ Frozen or compact ground. ■ Asphalt. Compacting plate ■ Ground compacting.
Page 27: Daily Operation
255E Operation 5.2 DAILY OPERATION GENERAL GUIDELINES 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.
Page 28 Operation 255E 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. Working too long in one spot will create stone dust under the tool.
Page 29 255E Operation 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 30 Operation 255E Do not use the hammer to sweep the ground of debris. This may damage the hammer and the housing will wear out more quickly. Do not use the hammer or hammer tools for lifting. Lifting eyes on the hammer are for storage and maintenance purposes only.
Page 31 255E Operation WORKING PROCEDURE 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 32 Operation 255E 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 force is correct when the tracks start to lift slightly from the ground.
Page 33 255E Operation 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 34: Mounting And Dismounting The Hammer
Operation 255E 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...
Page 35: Movement
255E Operation 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. 5.5 SPECIAL CONDITIONS OF USE Special conditions of use are conditions in which the hammer is used for some work other than normal breaking or demolition, such as: ■...
Page 36: Storage
Operation 255E 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 area must be dry.
Page 38: Hammer Tool Greasing
255E 1. HAMMER TOOL GREASING 1.1 RECOMMENDED GREASES 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).
Page 39: Manual Greasing
255E Hammer tool greasing 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 from grease gun to tool bushings and tool at regular intervals.
Page 40 Hammer tool greasing 255E 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 40 - Lubrication COPYRIGHT © 2020 SANDVIK MINING AND CONSTRUCTION OY...
Page 41: Carrier Hydraulic Oil
255E Carrier hydraulic oil 2. CARRIER HYDRAULIC OIL 2.1 REQUIREMENTS FOR HYDRAULIC OIL GENERAL REQUIREMENTS 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.
Page 42 Carrier hydraulic oil 255E OIL SPECIFICATIONS 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 43: Oil Cooler
255E Carrier hydraulic oil 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...
Page 44: Oil Filter
Carrier hydraulic oil 255E 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 45 255E Carrier hydraulic oil 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.
Page 48: Routine Maintenance
Routine maintenance 255E 1. ROUTINE MAINTENANCE 1.1 OVERVIEW 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 49: By The Dealer
255E Routine maintenance 1.3 INSPECTION AND MAINTENANCE BY THE DEALER Note: The times given refer to the carrier hours while the attachment is installed. INITIAL 50-HOUR INSPECTION It is recommended to have the first inspection done by your local dealer after 50 to 100 operating hours.
Page 50: Changing The Tool
Changing the tool 255E 2. CHANGING THE TOOL WEAR LIMITS AND LUBRICANTS FOR TOOL REMOVAL Item Wear limit Tool diameter (worn out) 38 mm (1.50 in) R030149 Item Wear limit Tool retaining pin diameter Z (worn 20 mm (0.79 in)
Page 51: Removal Of Tool
255E Changing the tool REMOVAL OF TOOL 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.
Page 52: Installation Of Tool
Changing the tool 255E 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 page 50. 3. Measure the tool retaining pin diameter (Z). Replace it if necessary. See “Changing the tool”...
Page 53: Tool Bushing
255E Tool bushing 3. TOOL BUSHING WEAR LIMITS AND LUBRICANTS FOR LOWER TOOL BUSHING R030101 Item Wear limit Tool bushing inner diameter (worn out) 43 mm (1.69 in) Item Lubricant Contact surfaces of front head Thread grease REMOVAL OF TOOL BUSHING 1.
Page 54: Installation Of Tool Bushing
Tool bushing 255E INSTALLATION 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 53. 3. Install seal. R030124 4. Lubricate the contact surfaces of the front head.
Page 55: Troubleshooting
Check the installation. Check the pump and the other hydraulic components. FAILURE IN HAMMER VALVE OPERATION The hammer must be serviced in an authorized Rammer service shop. PISTON FAILURE The hammer must be serviced in an authorized Rammer service shop.
Page 56: The Hammer Operates Irregularly But The Blow Has Full Power
Measure the high pressure in the hammer inlet line. FAILURE IN HAMMER VALVE OPERATION The hammer must be serviced in an authorized Rammer service shop. 4.3 THE HAMMER OPERATES IRREGULARLY AND BLOW HAS NO POWER THE WORKING METHOD IS NOT CORRECT Refer to the correct working methods.
Page 57: The Hammer Does Not Stop Or Has Run-On
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.
Page 58: Further Assistance
Troubleshooting 255E 4.7 FURTHER ASSISTANCE FURTHER ASSISTANCE If further assistance is required, please prepare to answer the following questions before calling your dealer. ■ Model and serial number ■ Working hours and service history ■ RD3 report if available ■ Carrier model ■...
Page 60: Hammer Specifications
Hammer specifications 255E 1. HAMMER SPECIFICATIONS 1.1 TECHNICAL SPECIFICATIONS Item Specification 110 kg (243 lb) Minimum working weight Hammer weight 88 kg (194 lb) 600...3200 bpm Impact rate 95...150 bar (1380...2175 psi) Operating pressure 150...200 bar (2175...2900 psi) Pressure relief, min...
Page 62: Mounting Bracket Specifications
Hammer specifications 255E 1.3 MOUNTING BRACKET SPECIFICATIONS R040238 Item Specification Bottom plate, recommended minimum 20 mm (0.79 in) thickness (X) Side plate, recommended minimum 20 mm (0.79 in) thickness (Y) Side plate, recommended minimum 20 mm (0.79 in) thickness (Y) Note: After welding, check the flatness of the plate and mill surface as needed.
Page 63: Rd3 Technical Specifications
255E Hammer specifications 1.4 RD3 TECHNICAL SPECIFICATIONS R040253 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 UN3091 Lithium content 2.0 grams...
Page 64: Tool Specifications
Tool specifications 255E 2. TOOL SPECIFICATIONS R040229 Diameter/ Tool Part no. Length Weight Width Chisel (A) BG351 380 mm 3.4 kg ( 7 lb) 40 mm (1.57 (14.96 in) Moil point (B) BG353 380 mm 3.5 kg ( 8 lb) 40 mm (1.57 (14.96 in)
Page 65: Ce Mark And Ec Declaration Of Conformity
(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: 255E Is in conformity with all the relevant provisions of the Machinery Directive 2006/42/EC.
Page 66: Rd3 And Data Privacy
255E 3.1 RD3 AND DATA PRIVACY Important notice: This 255E Hereinafter referred to as the "Product", is equipped with a remote monitoring service device which collects location data and data of usage of the Product (including remote monitoring hardware and software installed, connected, and activated by Sandvik at the factory or otherwise) in order for Sandvik to (i) provide you and Sandvik's distributor/sub-distributor(s) involved in the sale of the Product ("Distributors") with the availability...
Page 68 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 18-32-14140-33-184-182 21-32-14140-27-168-7...

RAMMER 255E Operator's Manual

Operation

Lubrication

Maintenance

Specifications

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