RAMMER 455E Operator's Manual

Hydraulic hammer

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OPERATOR'S MANUAL

OM455EENG.525

HYDRAULIC HAMMER

RAMMER 455E

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Page 1 Original instructions 5/25 OPERATOR'S MANUAL OM455EENG.525 HYDRAULIC HAMMER RAMMER 455E...
Page 2: Table Of Contents
Wear limits and lubricants for lower tool bushing......54 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 455E 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 455E 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
455E 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: n Name of customer and contact person...
Page 8: Product Numbers
Product numbers 455E 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 455E Product numbers CONTENT OF THE PRODUCT IDENTIFICATION PLATE Hydraulic Hammer Model Version Serial Number Hammer weight (kg) Min working weight (kg) Operating pressure (bar) Oil flow (l/min) Manufactured or Manufacturing date Manufacturer Address COPYRIGHT © 2025 SANDVIK MINING AND CONSTRUCTION OY...
Page 10: Product Introduction
Product introduction 455E 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 11: Lifting Instructions
455E Product introduction 3.3 LIFTING INSTRUCTIONS Use a hoist when lifting components which weight 23 kg (50 lb) or more, to avoid back injury. Make sure all lifting equipment is in good condition and are in the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.
Page 12 Product introduction 455E 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. Please note that the list below is not all inclusive, you must always ensure the procedure you choose is safe for you and others.
Page 13: Main Parts
See the "Remote monitoring device" guide for technical specifications and installation instructions. For more information, contact your local Rammer dealer. COPYRIGHT © 2025 SANDVIK MINING AND CONSTRUCTION OY Operation - Page 13...
Page 14 Product introduction 455E 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. For more information, see the mobile app guide for the SAM digital service.
Page 15: 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 16: Safety
Safety 455E 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 17: Safety Instructions
455E 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 18 Safety 455E 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 19 455E 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 20 Safety 455E 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 21 455E 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 22: Hydraulic Fluid
Safety 455E 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 23: Lifting Equipment
455E 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 24 Safety 455E 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 25 455E 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 26: Operation
Operation 455E 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 27 455E 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 28 Operation 455E 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 29: Daily Operation
455E 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 30 Operation 455E 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 31 455E 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 32 Operation 455E Do not operate the hammer with the carrier's boom stick or bucket cylinders at the end of their stroke (either fully extended or retracted). Damage to the carrier may result. Do not use the hammer to sweep the ground of debris. This may damage the hammer and the housing will wear out more quickly.
Page 33: Working Procedure
455E 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 34 Operation 455E 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 35: Mounting And Dismounting The Hammer
455E 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 36: Installation
Operation 455E 5. Remove bucket pins and other parts. 6. The carrier can be moved aside. INSTALLATION 1. Install hammer in the same manner as mounting a bucket. Install bucket pins. 2. Connect hoses. Hammer inlet port is marked with "IN" and outlet port with "OUT".
Page 37: Special Conditions Of Use
455E Operation 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: n Tunneling n Scaling n Foundry cleaning n Underwater operations...
Page 40: Hammer Tool Greasing
455E 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: n No dropping point or very high, over 250 °C (480 °F).
Page 41: Manual Greasing
455E 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 42 Hammer tool greasing 455E 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 42 - Lubrication COPYRIGHT © 2025 SANDVIK MINING AND CONSTRUCTION OY...
Page 43: Carrier Hydraulic Oil
455E 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 44 Carrier hydraulic oil 455E Oil too thick n Difficult start up n Stiff operation n Hammer strikes slowly n Danger of cavitation in pumps and in the hydraulic hammer n Sticky valves n Filter bypass opens, impurities in the oil are not removed...
Page 45: Oil Cooler
455E Carrier hydraulic oil 2.2 OIL COOLER The correct place to connect the hammer 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.
Page 46 Carrier hydraulic oil 455E In hydraulic hammer work the carrier oil filter must fulfil the following specifications: n The oil filter must allow maximum particle size of 25 microns (0.025 mm). n The oil filter material must be artificial fibre cloth or very fine gauge metallic mesh to withstand pressure fluctuations.
Page 48: Routine Maintenance
Routine maintenance 455E 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: Inspection And Maintenance By The Dealer
455E 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: Other Maintenance Procedures
Routine maintenance 455E 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.
Page 51: Changing The Tool
455E Changing the tool 2. CHANGING THE TOOL WEAR LIMITS AND LUBRICANTS FOR TOOL REMOVAL Item Wear limit Tool diameter (worn out) 54 mm (2.13 in) R030149 Item Wear limit Tool retaining pin diameter Z 30 mm (1.18 in) (worn out)
Page 52: Removal Of Tool
Changing the tool 455E 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 53: Installation Of Tool
455E Changing the tool 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 51. 3. Measure the tool retaining pin diameter (Z). Replace it if necessary. See “Changing the tool”...
Page 54: Tool Bushing
Tool bushing 455E 3. TOOL BUSHING WEAR LIMITS AND LUBRICANTS FOR LOWER TOOL BUSHING R030101 Item Wear limit Tool bushing inner diameter (worn out) 59 mm (2.32 in) Item Lubricant Contact surfaces of front head Thread grease REMOVAL OF TOOL BUSHING 1.
Page 55: Installation Of Tool Bushing
455E Tool bushing 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 54. 3. Install seal. R030124 4. Lubricate the contact surfaces of the front head.
Page 56: 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 57: 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 58: 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 59: Further Assistance
455E Troubleshooting 4.7 FURTHER ASSISTANCE FURTHER ASSISTANCE If further assistance is required, please prepare to answer the following questions before calling your dealer. n Model and serial number n Working hours and service history n Remote monitoring device report if available...
Page 62: Hammer Specifications
Hammer specifications 455E 1. HAMMER SPECIFICATIONS 1.1 TECHNICAL SPECIFICATIONS Item Specification 230 kg (510 lb) Minimum working weight Hammer weight 190 kg (420 lb) 700...2600 bpm Impact rate 100...170 bar (1450...2465 psi) Operating pressure 150...220 bar (2175...3190 psi) Pressure relief, min...
Page 64: Mounting Bracket Specifications
Hammer specifications 455E 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) Bottom plate, recommended minimum 20 mm (0.79 in) thickness (X) Side plate, recommended minimum 20 mm (0.79 in)
Page 65: Tool Specifications
455E Tool specifications 2. TOOL SPECIFICATIONS R040231 Tool Part no. Length Weight Diameter/Width Chisel (A) BG551 520 mm 9.3 kg (20 lb) 56 mm (2.20 in) (20.47 in) Moil point (B) BG553 520 mm 9.1 kg (20 lb) 56 mm (2.20 in) (20.47 in)
Page 66: 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: 455E Is in conformity with all the relevant provisions of the Machinery Directive 2006/42/EC.
Page 67: 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: 455E Is in conformity with the relevant provisions of the Supply of Machinery (Safety) Regulations 2008 No. 1597, as amended.
Page 70 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 9-24-14175-42-184-98...

RAMMER 455E Operator's Manual

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