RAMMER 1655E Operator's Manual

Hydraulic hammer

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5/25

OPERATOR'S MANUAL

OM1655ESENG.525

HYDRAULIC HAMMER

RAMMER 1655E

STD

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Page 1 Original instructions 5/25 OPERATOR'S MANUAL OM1655ESENG.525 HYDRAULIC HAMMER RAMMER 1655E...
Page 2: Table Of Contents
Removal of tool ....62 Installation of tool ....63 OPERATION.
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: Symbols Used In This Manual
1655E STD 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 1655E STD 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
1655E STD 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: ■ Name of customer and contact person ■...
Page 8: Product Numbers
Product numbers 1655E STD 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
1655E STD 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 1655E STD PROVIDED LIFTING POINTS 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.
Page 11 1655E STD Product introduction When two lifting eye screws are used, the lifting capacity depends on the angle of the lifting chains. The angle should not be less than 45°, as shown in the illustration. When the lifting eye screws are tightened, both rings should be aligned.
Page 12 Product introduction 1655E STD Lifting devices must safely carry the working weight of the product. See “Hammer specifications” on page 78. Place chains or slings, as shown by the illustration, to lift the product. R010495 Note: Before starting to operate the hammer, always replace the lifting eye with a blanking screw.
Page 13: Main Parts
1655E STD Product introduction 3.4 MAIN PARTS The main parts of the hammer are shown below. R010496 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.
Page 14: Ramvalve
See the "Remote monitoring device" guide for technical specifications and installation instructions. For more information, contact your local Rammer dealer. Note: The equipment data can be viewed in the online service, SAM. To access SAM, go to https://sam.rockprocessing.sandvik/ or install the SAM mobile app to your mobile device.
Page 15 1655E STD Product introduction R010509 Warning! RD3/RD3X contains a SIM card to enable remote connections and an encased lithium metal battery. Both items are regulated for air transport. Consult your forwarder about any restrictions for air freight. Warning! Lithium is a highly flammable substance. Store damaged lithium batteries in a fire proof container.
Page 16: Environmental Protection And Recycling Policy
1655E STD 3.8 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 17: Safety
1655E STD Safety 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 18: Safety Instructions
Safety 1655E STD 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 19 1655E STD Safety 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 communications can cause accidents. Keep people around you informed of what you will be doing.
Page 20 Safety 1655E STD 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 21 1655E STD Safety 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 cannot see them. Remember, you MUST protect yourself and bystanders from the danger of breathing or inhaling dust.
Page 22: Noise Hazard
Safety 1655E STD 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 shown below: "NOISE HAZARD Continuous exposure to noise above 80 dB(A) will cause hearing impairment.
Page 23 1655E STD Safety FIRE HAZARD Most hydraulic fluids are flammable and might ignite when contacting hot surface. Avoid spilling hydraulic fluid to hot surfaces. Working with the product on certain materials can cause sparks and hot splinters to get loose. These can ignite flammable materials around working area.
Page 24 Safety 1655E STD LIFTING EQUIPMENT You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that the lifting equipment complies with all local regulations and is suitable for the job. Make sure that the lifting equipment is strong enough for the job and that you know how to use it.
Page 25 1655E STD Safety LABELS ON THE PRODUCT Safety labels communicate the following four things: ■ The severity level of the risk (that is, signal word "DANGER" or "WARNING"). ■ The nature of the hazard (such as high pressure, or dust).
Page 26 Safety 1655E STD Hydraulic Hammer XXXX Model: XXXXXXXX Version: XXXXXXXXX Serial number: XXXX Hammer weight: WARNING Min. working weight: XXXX IGNORING Operating pressure: INSTRUCTIONS HAZARD Faulty handling practice could l/min cause death or severe injur y. Oil flow: Read and follow the...
Page 27: Operation
1655E STD Operation 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 can be also used in breaking moderate sized boulders as well as in demolishing reinforced structures and for major excavation and clearing work.
Page 28 Operation 1655E STD 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 29 1655E STD Operation 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 time for the tool. Choosing the best tool type for an application may require some testing, please consult with your local dealer.
Page 30 Operation 1655E STD Idle Blow Protection ON (factory setting) It is recommended that you keep Idle Blow Protection on during normal hammer work. In the ON position, Idle Blow Protection is activated to prevent idle strokes. See illustration 1. Note: When Idle Blow Protection is on, the hammer can be started only after pressing the tool against an object.
Page 31 1655E STD Operation TURNING IDLE BLOW PROTECTION ON AND OFF 1. Remove the shield plate. R010510 2. To turn Idle Blow Protection on, turn the valve clockwise with a hexagon wrench so that the arrow points to ON. To turn it off, turn to valve counterclockwise so that the arrow points to OFF.
Page 32: Daily Operation
Operation 1655E STD 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 33 1655E STD Operation 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 34 Operation 1655E STD 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 35 1655E STD Operation 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.
Page 36 Operation 1655E STD 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. Do not use the hammer or hammer tools for lifting. Lifting eyes on the hammer are for storage and maintenance purposes only.
Page 37: Working Procedure
1655E STD 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 38 Operation 1655E STD 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 39 1655E STD Operation 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 40: Mounting And Dismounting The Hammer
Operation 1655E STD 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 41: Movement
1655E STD 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 42: Underwater Operation
Operation 1655E STD UNDERWATER OPERATION Use environmentally 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.
Page 43: Storage
1655E STD Operation 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.
Page 46: Hammer Tool Greasing
1655E STD 1. HAMMER TOOL GREASING 1.1 RECOMMENDED GREASES For tool lubrication use only RAMMER SPECIAL 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 47: Automatic Greasing
1655E STD Hammer tool greasing 1.2 AUTOMATIC GREASING Dispose of empty grease containers appropriately. The hammer can be equipped with an automatic greasing device. See “Greasing device” on page 14. Do not remove the grease cartridge unnecessarily. Always keep the grease cartridge in the greasing device to prevent dirt from entering the greasing device.
Page 48: Adjusting The Dose
Hammer tool greasing 1655E STD 6. Push the cartridge piston with fingers until approximately 15 mm of grease comes out. 7. Insert the cartridge and tighten it. R020111 1.3 ADJUSTING THE DOSE Note: Some hammer models are equipped with an adapter kit for manual greasing and do not include an automatic greasing device.
Page 49 1655E STD Hammer tool greasing ADJUSTING THE DOSE 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 50: Manual Greasing
Hammer tool greasing 1655E STD 5. Tighten the locking nut to the specified torque setting. See table below. 6. Turn the locking plate and plug to the correct positions. Item Specification/Torque Shield screws 175 Nm (129 lbf ft) Adjusting screw locking nut...
Page 51 1655E STD Hammer tool greasing 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.
Page 52: Carrier Hydraulic Oil
Carrier hydraulic oil 1655E STD 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 53: Oil Specifications
1655E STD Carrier hydraulic oil 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 54: Oil Cooler
Carrier hydraulic oil 1655E STD SPECIAL OILS In some cases special oils (for example biological oils and non-inflammable oils) can be used with hydraulic hammers. Observe the following aspects when considering the use of special oils: ■ The viscosity range in the special oil must be in the given range (20-1000 cSt) ■...
Page 55: Oil Filter
1655E STD Carrier hydraulic oil 2.3 OIL FILTER The purpose of the oil filter 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.
Page 56 Carrier hydraulic oil 1655E STD 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.
Page 58: Routine Maintenance
Routine maintenance 1655E STD 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 59: By The Dealer
1655E STD Routine maintenance EVERY 50 CARRIER HOURS OR AT LEAST ONCE A MONTH ■ Check the tool shank and tool bushings for wear. See “Changing the tool” on page 61. See “Changing the lower tool bushing” on page 64.
Page 60: Maintenance Intervals In Special Applications
Routine maintenance 1655E STD 1.4 MAINTENANCE INTERVALS IN SPECIAL APPLICATIONS The service interval is considerably shorter in special applications. See “Special conditions of use” on page 41. In special applications, consult your local dealer for the recommended service intervals. MAINTENANCE INTERVALS IN UNDERWATER USE After every half hour of carrier operation ■...
Page 61: Changing The Tool
1655E STD Changing the tool 2. CHANGING THE TOOL WEAR LIMITS AND LUBRICANTS FOR TOOL REMOVAL Item Wear limit Tool diameter X (worn out) 113 mm (4.45 in) Tool diameter Y (worn out) 104 mm (4.09 in) R030149 Item Wear limit Tool retaining pin diameter Z (worn 46 mm (1.81 in)
Page 62: Removal Of Tool
Changing the tool 1655E STD 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 63: Installation Of Tool
1655E STD Changing the tool INSTALLATION OF TOOL 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 61. 3. Measure the tool retaining pin diameter (Z). Replace tool if necessary. See “Changing the tool”...
Page 64: Changing The Lower Tool Bushing
Changing the lower tool bushing 1655E STD 3. CHANGING THE LOWER TOOL BUSHING WEAR LIMITS AND LUBRICANTS FOR LOWER TOOL BUSHING Groove R030183 Item Wear limit Tool bushing (worn out) First three grease grooves are worn out. Bushing must be replaced.
Page 65 1655E STD Changing the lower tool bushing R030239 A. Puller frame B. Puller plate C. Screw D. Plate E. Plate F. Nut G. Hydraulic hole cylinder H. Locking plate I. Wedge Note: Contact your local dealer for more information on these parts.
Page 66: Removal Of Lower Tool Bushing
Changing the lower tool bushing 1655E 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 facility. 1. Remove tool.
Page 67 1655E STD Changing the lower tool bushing 9. Install screw to puller plate. R030215 10. Install plate, hole cylinder and nut. R030216 11. Pull lower tool bushing out by using hydraulic hole cylinder. If tool bushing is stick, loose screw and hit wedges with a sledge hammer to loose lower tool bushing and then pull lower tool bushing out.
Page 68: Installation Of Lower Tool Bushing
Changing the lower tool bushing 1655E STD INSTALLATION OF LOWER TOOL BUSHING 1. Clean and dry all parts carefully. Check all parts for cracks and excessive wear. See wear limits for thrust ring and upper tool bushing in specifications section. See “Changing the lower tool bushing”...
Page 69 1655E STD Changing the lower tool bushing 8. Install plate, hole cylinder and nut. R030218 9. Push lower tool bushing in with hole cylinder. 10. Install retaining pins. 11. Install rubber rings. 12. Install rubber plugs. R030189 13. Remove tool retaining pins and tool bushing's assembly tool.
Page 70: 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 71: The Hammer Operates Irregularly But The Blow Has Full Power
The hammer must be serviced in an authorized Rammer service shop. FAILURE IN GREASING DEVICE HYDRAULIC CIRCUIT Oil leakage. 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 72: Impact Rate Slows Down
Contact your local carrier dealer for more information. 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 73: Oil Overheats
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.
Page 74: Automatic Greasing Device Problems
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.
Page 75: Further Assistance
1655E STD Troubleshooting 4.9 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 ■ Remote monitoring device report if available ■...
Page 78: Hammer Specifications
Hammer specifications 1655E STD 1. HAMMER SPECIFICATIONS 1.1 TECHNICAL SPECIFICATIONS Item Specification 1100 kg (2430 lb) Minimum working weight Hammer weight 890 kg (1960 lb) 540...920 bpm Impact rate 135...145 bar (1960...2105 psi) Operating pressure 190 bar (2755 psi) Pressure relief, min...
Page 80: Mounting Bracket Specifications
Hammer specifications 1655E STD 1.3 MOUNTING BRACKET SPECIFICATIONS R040239 Item Specification Bottom plate, recommended minimum 25 mm (0.98 in) thickness (X) Side plate, recommended minimum 25 mm (0.98 in) thickness (Y) Width of the opening for pressure hose (Z) 200 mm (7.87 in) Depth of the opening for pressure hose (V) 60 mm (2.36 in)
Page 81: Tool Specifications
1655E STD Tool specifications 2. TOOL SPECIFICATIONS R040285 Tool Part no. Length Weight Diameter Chisel (A) BB49E1 1000 mm 67 kg (150 115 mm (39.37 in) (4.53 in) Moil point (B) BB49E3 1000 mm 68 kg (150 115 mm (39.37 in) (4.53 in)
Page 82: Compliance
(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: 1655E Is in conformity with all the relevant provisions of the Machinery Directive 2006/42/EC.
Page 83: Declaration Of Conformity
Original Manufacturer: Sandvik Mining and Construction Oy, Breakers Lahti Address: Taivalkatu 8, FI-15170 Lahti, Finland Herewith declares that the Rammer hydraulic hammer Model: 1655E Is in conformity with the relevant provisions of the Supply of Machinery (Safety) Regulations 2008 No. 1597, as amended.
Page 86 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 48-20-14175-36-212-49 36-24-14175-39-24-273...

RAMMER 1655E Operator's Manual

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