1/01

SERVICE MANUAL
SME65ENG.101

HYDRAULIC HAMMER
RAMMER E 65
RAMMER E 65 CITY
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hammer does not start . . . . . . . . . . . . . 48
1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . 4 The hammer operates irregularly
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . 4 but the blow has full power . . . . . . . . . 49
This manual . . . . . . . . . . . . . . . . . . . . . . 4 Hammer operates poorly and blow
Important safety information . . . . . . . . . 5 has no power . . . . . . . . . . . . . . . . . . . . 49
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . 6 Impact rate slows down . . . . . . . . . . . . 50
Spare part orders. . . . . . . . . . . . . . . . . . . 6 Oil overheats . . . . . . . . . . . . . . . . . . . . 50
2. Machine numbers . . . . . . . . . . . . . . . . . . 7
Model and serial number . . . . . . . . . . . . 7 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . 53
3. Product introduction. . . . . . . . . . . . . . . . 8 1. Hammer specifications . . . . . . . . . . . . . 54
Overview. . . . . . . . . . . . . . . . . . . . . . . . . 8 Technical specifications . . . . . . . . . . . . 54
Removal from packaging . . . . . . . . . . . . 8 Main dimensions E 65, E 65 CITY . . . . 55
Lifting instructions . . . . . . . . . . . . . . . . . 8 2. Tool Specifications . . . . . . . . . . . . . . . . 56
Main parts . . . . . . . . . . . . . . . . . . . . . . 10 Tool specifications E 65 . . . . . . . . . . . . 56
4. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . 11 WORKSHOP. . . . . . . . . . . . . . . . . . . . . . . . . 57
General safety . . . . . . . . . . . . . . . . . . . . 11 1. Disassembly and assembly . . . . . . . . . . 58
Safety instructions . . . . . . . . . . . . . . . . . 11 Main components. . . . . . . . . . . . . . . . . 58
5. Optional equipment . . . . . . . . . . . . . . . 15 Releasing hydraulic pressure
Ramlube . . . . . . . . . . . . . . . . . . . . . . . . 15 from hammer . . . . . . . . . . . . . . . . . . . . 59
6. Operation . . . . . . . . . . . . . . . . . . . . . . . 16 Housing and vibration dampening . . . . 60
Operating instructions. . . . . . . . . . . . . . 16 Pressure accumulator . . . . . . . . . . . . . . 64
Daily operation . . . . . . . . . . . . . . . . . . . 18 Charging accumulator . . . . . . . . . . . . . 68
Mounting and dismounting the hammer 26 Main valve . . . . . . . . . . . . . . . . . . . . . . 71
Movement. . . . . . . . . . . . . . . . . . . . . . . 27 Check valve . . . . . . . . . . . . . . . . . . . . . 74
Special conditions of use . . . . . . . . . . . . 27 Pressure control valve . . . . . . . . . . . . . . 76
Storage . . . . . . . . . . . . . . . . . . . . . . . . . 29 Tie rods . . . . . . . . . . . . . . . . . . . . . . . . 79
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . 31 Body parts . . . . . . . . . . . . . . . . . . . . . . 82
1. Hammer tool greasing. . . . . . . . . . . . . . 32 Front head . . . . . . . . . . . . . . . . . . . . . . 87
Recommended greases. . . . . . . . . . . . . . 32 2. Testing . . . . . . . . . . . . . . . . . . . . . . . . . 90
Manual lubrication . . . . . . . . . . . . . . . . 32 Measuring hammer circuit . . . . . . . . . . 90
Automatic lubrication . . . . . . . . . . . . . . 33 Measuring hammer operating pressure . 92
2. Carrier hydraulic oil . . . . . . . . . . . . . . . 34 3. Service tools . . . . . . . . . . . . . . . . . . . . . 95
Requirements for hydraulic oil . . . . . . . 34 Special service tools . . . . . . . . . . . . . . . 95
Oil cooler . . . . . . . . . . . . . . . . . . . . . . . 36 Standard service tools . . . . . . . . . . . . . . 97
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . 37
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 39
1. Routine maintenance . . . . . . . . . . . . . . 40
Overview. . . . . . . . . . . . . . . . . . . . . . . . 40
Maintenance intervals . . . . . . . . . . . . . . 40
Maintenance intervals in special
applications. . . . . . . . . . . . . . . . . . . . . . 41
Other maintenance procedures . . . . . . . 42
2. Removal of tool . . . . . . . . . . . . . . . . . . 43
Wear limits and lubricants for
tool removal . . . . . . . . . . . . . . . . . . . . . 43
Removal of tool . . . . . . . . . . . . . . . . . . 43
Installation of tool. . . . . . . . . . . . . . . . . 44
3. Lower tool bushing . . . . . . . . . . . . . . . . 45
Wear limits and lubricants for
lower tool bushing . . . . . . . . . . . . . . . . 45
Removal of lower tool bushing . . . . . . . 45
Installation of lower tool bushing . . . . . 46
4. Troubleshooting . . . . . . . . . . . . . . . . . . 48
 OPERATION

© 2001 SANDVIK TAMROCK CORP. OPERATION - Page 3

FOREWORD

1. FOREWORD

1.1 PREFACE
Congratulations on having purchased this product. A properly installed attachment
should prove to be a productive machine requiring maintenance at only regular in-
tervals.

1.2 THIS MANUAL

This manual is arranged to give you a good understanding of the equipment and its
safe operation. It also contains maintenance information and technical specifica-
tions. Read this manual from front to back before installing, operating or maintain-
ing the attachment for the first time.
In this manual, the units of measurement are metric. For example, weights are given
in kilograms (kg). In some cases the other unit follows in parenthesis (). For exam-
ple 28 litres (7.4 US gal).
The specifications and designs presented in this manual are subject to change with-
out prior notice.

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 il-
lustration 1.

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 FOREWORD

This symbol identifies prohibited action or hazardous location. Failure to under-

stand 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.

1.3 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. These warnings
in the guide and on the machine labels are identified by the warning symbol.
To use the attachment correctly, you must also be a competent operator of the carrier
machine. Do not use or install it if you can not use the carrier machine. The attach-
ment is a powerful tool. Used without proper care, it can cause damage.
Do not rush when you are learning to use the product. Take your time and most im-
portantly, take it safely. Do not guess. If there is anything you do not understand,
ask your local dealer. He will be pleased to advise you.
Improper operation, lubrication or maintenance of this machine can be dangerous
and could result in injury.
Do not operate this machine until you read and understand the instructions in this
manual.
Do not perform any lubrication and maintenance on this machine until you read and
understand the instructions in this manual.

© 2001 SANDVIK TAMROCK CORP. OPERATION - Page 5

FOREWORD

1.4 WARRANTY
The customer is provided with a separate warranty sheet, where the export warranty
terms are explained. Check always that this warranty sheet is provided with the at-
tachment. If not, contact your local dealer immediately.

WARRANTY REGISTRATION CARD

A warranty registration card is filled out after the installation inspection by the deal-
er and a copy of it is sent to the manufacturer. This card is very important because
no warranty claims are handled without it. Make sure that you get a copy of it after
the installation inspection and that it is correctly filled out.

INSTALLATION INSPECTION
An installation inspection must be carried out after the product has been installed on
the carrier. In the installation inspection certain specifications (operating pressure,
oil flow etc.) are checked so that they are within given limits.

1.5 SPARE PART ORDERS

When you need spare parts or some information concerning maintenance to your
machinery, please contact your local dealer. Quick deliveries are secured by exact
orders.
Required information:
1. Name of customer, contact person
2. Order number (when available)
3. Delivery address
4. Mode of delivery (air mail etc.)
5. Required delivery date
6. Invoicing address
7. Model and serial number of product
8. Name, number and required amount of spare parts

Page 6 - OPERATION © 2001 SANDVIK TAMROCK CORP.

 MACHINE NUMBERS

2. MACHINE NUMBERS

2.1 MODEL AND SERIAL NUMBER

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 and serial number
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. Identification of the serial number is the only
proper means of maintaining and identifying parts for a specific product.

© 2001 SANDVIK TAMROCK CORP. OPERATION - Page 7

PRODUCT INTRODUCTION

3. PRODUCT INTRODUCTION

3.1 OVERVIEW
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.
No extra pressure accumulators are necessary since the internal pressure accumula-
tor absorbs hydraulic pressure peaks. The impact energy of the hammer is constant
and independent of the carrier's hydraulic system.

3.2 REMOVAL FROM PACKAGING

Remove all the steel belts from the packaging. Open the packaging and remove all
plastics covering the product. Scrap the steel belts and plastics. The wooden frames
and boxes can be recycled.
Check that the product is in good condition and that there is no visible damage.
Check that all ordered parts and accessories have been enclosed with the product.
Some options may be provided by your local dealer like installation kits; including
hoses and mounting bracket.

3.3 LIFTING INSTRUCTIONS

Use a hoist when lifting components which weigh 23 kg (50 Ib) or more, to avoid
back injury. Make sure all chains, hooks, slings etc., are 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. Do not use the hammer's tools for lifting.
Lifting devices must safely carry the working weight of the product. See “Hammer
specifications” on page 54. Place chains or slings, as shown by the illustration, to
lift the product.

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 PRODUCT INTRODUCTION

Note: The lifting eye must always be removed from the hammer and replaced with
a blanking screw before starting to operate hammer.

© 2001 SANDVIK TAMROCK CORP. OPERATION - Page 9

PRODUCT INTRODUCTION

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 and return lines, automatic lubrication and pressu-
rized air)
E. Pressure accumulator
F. Tool retaining mechanism
G. Tool bushing retaining mechanism
H. Lifting eye
I. Grease nipples

Page 10 - OPERATION © 2001 SANDVIK TAMROCK CORP.

 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 oc-
curs.
Because it is impossible to anticipate every possible circumstance that might in-
volve a potential hazard, the warnings in this guide and on the machine are not all
inclusive. If a procedure, tool, working method or operating technique not specifi-
cally recommended by manufacturer is used, you must satisfy yourself that it is safe
for you and others. You should also ensure that the product will not be damaged or
made unsafe 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 work-
ing with your attachment you must be thinking 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.

Warning! Read the following warning messages carefully. They tell you of dif-
ferent hazards and how to avoid them. If proper precautions are not taken you
or others could be seriously injured.

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.
Study also the operating and maintenance manual of your carrier before operating
the attachment.

CARE AND ALERTNESS

All the time you are working with the product, take care and stay alert. Always be
careful. Always be alert for hazards. The possibility of a serious or even fatal acci-
dent is increased when you are intoxicated.

© 2001 SANDVIK TAMROCK CORP. OPERATION - Page 11

SAFETY

CLOTHING
You can be injured if you do not wear proper clothing. Loose clothing can get
caught in the machinery. Wear protective clothing to suit the job.
Examples are: a safety helmet, safety shoes, safety glasses, well-fitting overalls,
ear-protectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or
scarf. Keep long hair restrained.

PRACTICE
You and others can be killed or injured if you do unfamiliar operations without prac-
tising 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 communications can cause accidents. Keep people around you informed of
what you will be doing. If you will be working with other people make sure they
understand any hand signals you will be using.
Work sites can be noisy. Do not rely on spoken commands.

WORK SITE
Work sites can be hazardous. Inspect the site before working on it.
Check for potholes, weak ground, hidden rocks etc. Check for utilities (electric ca-
bles, gas and water pipes etc.). Mark the positions of underground cables and pipes
if you will be breaking the ground.

BANKS AND TRENCHES

Banked material and trenches can collapse. Do not work too close to banks and
trenches where there is a danger of collapse.

SAFETY BARRIERS
Unguarded equipment in public places can be dangerous. Place barriers around the
machine to keep people away.

Page 12 - OPERATION © 2001 SANDVIK TAMROCK CORP.

 SAFETY

FLYING CHIPS OF ROCK

Protect yourself and your neighbourhood against flying chips of rock. Do not oper-
ate the product or carrier if someone is too close.
Keep the cabin windows and doors closed during operation. Window bars are rec-
ommended to protect the windows from flying chips of rock.

EQUIPMENT LIMITS
Operating the product beyond its design limits can cause damage. It can also be dan-
gerous. See “Hammer specifications” on page 54.
Do not try to upgrade 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 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 card-
board for signs of hydraulic fluid. If hydraulic fluid penetrates your skin seek med-
ical help immediately.

HYDRAULIC PRESSURE
Hydraulic fluid at system pressure can injure you. Before disconnecting or connect-
ing hydraulic hoses, stop the carrier engine, operate the controls to release pressure
trapped in the hoses and wait ten (10) minutes. During the operation, keep people
away from the hydraulic hoses.
There might be pressurized oil trapped inside the product even if it is disconnected
from the carrier. Be aware of possible blank firing while greasing or removing and
installing hammer tools. See “Removal of tool” on page 43.

PRESSURE ACCUMULATORS
The hammer incorporates one or two pressure accumulators, depending on the mod-
el. The accumulators are pressurized even when there is no hydraulic pressure to the
hammer. Attempting to dismantle the accumulators without first releasing the pres-
sure can cause injury or death. Do not try to dismantle pressure accumulators, con-
tact your local dealer first. See “Releasing hydraulic pressure from hammer” on
page 59. See “Pressure accumulator” on page 64.

LIFTING EQUIPMENT
You can be injured if you use faulty lifting equipment. Make sure that lifting equip-
ment is in good condition. Make sure that the lifting tackle complies with all local
regulations and is suitable for the job. Make sure that the lifting equipment is strong
enough for the job and you know how to use it.

© 2001 SANDVIK TAMROCK CORP. OPERATION - Page 13

SAFETY

Do not use this product or any of its parts for lifting. See “Lifting instructions” on
page 8. Contact your carrier dealer to find out how to lift with your carrier.

SPARE PARTS
Use only genuine spare parts. Use only genuine tools with hydraulic hammers. The
use of other spare part or hammer tool 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 modifications can cause injury and damage. Contact your local deal-
er 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.

METAL SPLINTERS
You can be injured by flying splinters when driving metal pins in and out. Use soft-
faced hammer or drifts to remove and fit metal pins, such as pivot pins. Always wear
safety glasses.

Page 14 - OPERATION © 2001 SANDVIK TAMROCK CORP.

 OPTIONAL EQUIPMENT

5. OPTIONAL EQUIPMENT

5.1 RAMLUBE
Lubrication of the tool and the tool bushings of the hammer can be made automati-
cally by equipping the carrier with a lubrication pump. The tool grease is supplied
from the pump into the hammer by hose.
The advantages of the automatic lubrication system are: longer service life for wear
parts and a higher utilization rate for the hammer.
The latest hammer models are equipped with a built-in automatic lubrication system
connection point, from where the tool grease is fed along an internal channel to the
tool bushing and the tool shank. See “Operation of Ramlube” on page 26.

© 2001 SANDVIK TAMROCK CORP. OPERATION - Page 15

OPERATION

6. OPERATION

6.1 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. Your local dealer will gladly give you more information.

OPERATING CONDITIONS
Principle of installation
Almost all carriers meeting mechanical and hydraulic requirements can be used to
operate attachments. See “Hammer specifications” on page 54. The product is in-
stalled on the carrier much in the same manner as installing a bucket or other attach-
ments. A top mounted attachment requires also a separate mounting bracket. For
more information, see "Mounting brackets" in Dealer manual.
The attachment is connected to a carrier's hydraulic circuit with an installation kit.
If the carrier is already fitted with an installation kit, the installation requires only
suitable hoses and fittings. If the carrier does not have suitable kit to run attach-
ments, one must be built. This may require more complex installation including new
piping and additional valves such as flow control valve or pressure relief valve. For
more information, see "Making an installation" in Dealer manual.
Suitable kits can be ordered from the manufacturer or 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 be used with this
product. See “Requirements for hydraulic oil” on page 34.
Operating temperature
The operating temperature is -20°C to +80°C (-4°F to +176°F). If the temperature
is lower than -20°C (-4°F), the hammer and tool have to be preheated before any
operations can begin, in order to avoid breaking the accumulator's membrane and
the tool. During operation they will remain warm.
Note: The temperature of the hydraulic oil must be monitored. Ensure that oil grade
and monitored oil temperature together guarantee correct oil viscosity. See “Oil
specifications” on page 35.
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:

Page 16 - OPERATION © 2001 SANDVIK TAMROCK CORP.

 OPERATION

1. When operating with the hammer, keep the tool at 90 degree angle to the mate-
rial and the feed force in-line with the tool.
2. Replace or fix all parts that are worn out, damaged or loosened. This not only
saves your hammer but it decreases the noise level.

Silenced CITY models are ideally suited for breaking in urban areas.

PRINCIPLES OF BREAKING
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.
Penetrative breaking (or cutting)
In this form of breaking a moil point or chisel tool is forced inside the material. This
method is most effective in soft, layered or plastic, low abrasive material. The high
impact rate of the small hammers makes them ideal for penetrative breaking.
Impact breaking
With impact breaking, the material is broken by transferring very strong mechanical
stress waves from the tool into the material. The best possible energy transfer be-
tween the tool and the object is achieved with a blunt tool. Impact breaking is most
effective in hard, brittle and very abrasive materials. The use of a chisel tool in hard
material will cause the sharp edge to wear very quickly. The high impact energy of
the big hammers makes them ideal for impact breaking.

© 2001 SANDVIK TAMROCK CORP. OPERATION - Page 17

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 re-
quire some testing, please consult with your local dealer. See “Tool Specifications”
on page 56.
Chisel and moil
■ For sedimentary (e.g. sandstone) and weak metamorphic rock into which the
tool penetrates.
■ Concrete.
■ Trenching and benching.
Blunt tool
■ For igneous (e.g. granite) and tough metamorphic rock (e.g. gneiss) into which
the tool doesn't penetrate.
■ Concrete.
■ Breaking boulders.
Super blunt
■ When tool wear is extensive in igneous (e.g. granite) and tough metamorphic
rock (e.g. gneiss) into which the tool doesn't penetrate.
■ Breaking boulders (very abrasive rock).
■ Do not use for penetrative work or in non-abrasive rock!
Spade tool
■ Frozen or compact ground.Asphalt.
Compacting plate
■ Ground compacting.
It is important to choose a tool, which is suitable for your hammer and for the ap-
plication you are working on. The tool selection available depend on hammer mod-
el. See “Tool Specifications” on page 56.

6.2 DAILY OPERATION

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 ham-
mer.

Page 18 - OPERATION © 2001 SANDVIK TAMROCK CORP.

 OPERATION

The hammer as a standard assembly, must not be used under water. If water
fills the space where the piston strikes the tool, a strong pressure wave is gen-
erated and the hammer may be damaged.
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.
3. Carefully operate the carrier controls to place the hammer and boom into the
breaking position. Quick and careless boom movements could result in damage
to the hammer.

© 2001 SANDVIK TAMROCK CORP. OPERATION - Page 19

OPERATION

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.

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 incor-
rect working angle.

Page 20 - OPERATION © 2001 SANDVIK TAMROCK CORP.



,

OPERATION

,






6. When demolishing vertical structures (e.g. brick walls), place the tool against
the wall at a 90 degree angle.

 
 7. Start the hammer.
8. A safety screen is recommended to protect the operator from flying debris.
Keep the cabin windows and doors closed during operation.

9. Note: Listen to the hammer's sound when you are using it. If the sound becomes
thinner 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 and press the
tool firmly against the material.

© 2001 SANDVIK TAMROCK CORP. OPERATION - Page 21

OPERATION

10. 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 po-
sition of the tool. Working too long in one spot will create stone dust under the
tool. Dust dampens the impact effect and produces heat.

11. Do not let the tool move outwards from the hammer when it penetrates. Keep
the down-pressure on the hammer while breaking.
12. To use the hammer most efficiently when breaking big boulders, concentrate on
small steps from the outer edge towards the middle.

13. When breaking hard or frozen ground, use the benching method. Start with
clearing a small area from the edge. Then continue by breaking material to-
wards the open area.

Page 22 - OPERATION © 2001 SANDVIK TAMROCK CORP.

 OPERATION

14. 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 quick-
ly.

15. When breaking concrete, hard or frozen ground, never strike and pry with the
tool at the same time. The tool may snap off. Bending may be caused by stones
inside hard or frozen ground. Be careful and stop striking if you find sudden re-
sistance under the tool.

16. 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.

© 2001 SANDVIK TAMROCK CORP. OPERATION - Page 23

OPERATION

17. Do not use the hammer tools to move rocks. The stone claws are designed for
this purposes.

18. Do not use the hammer to sweep the ground of debris. This may damage the
hammer and the housing will wear out more quickly.

19. When operating the hammer, make sure that it does not make contact with the
carrier boom or hydraulic lines.

Page 24 - OPERATION © 2001 SANDVIK TAMROCK CORP.

 OPERATION

20. 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.

21. Do not use the hammer or hammer tools for lifting. Lifting eyes on the hammer
are for storage and maintenance purposes only.

22. The tool shank must be well greased during operation. Regular visual inspec-
tions 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.

© 2001 SANDVIK TAMROCK CORP. OPERATION - Page 25

OPERATION

OPERATION OF RAMLUBE
Lubrication of the tool and the tool bushings of the hammer can be made automati-
cally by equipping the carrier with a lubrication pump. The tool grease is supplied
from the pump into the hammer by hose. During operation, grease holder must be
filled with suitable tool grease. Adjust pump output to working conditions.
Advantages of the automatic lubrication system are:
■ Longer service life for wear parts
■ Higher utilization rate of the hammer
The latest hammer models are equipped with a built-in automatic lubrication system
connection point, from where the tool grease is fed along an internal channel to the
tool bushing and the tool shank.

6.3 MOUNTING AND DISMOUNTING THE HAMMER

REMOVAL FROM CARRIER

Warning! The hammer must be secured from rolling over when disconnecting
from the carrier. Only use skilled operator to position carrier for hammer re-
moval!
Warning! Hydraulic pressure inside hammer must always be released before
opening hose connections!
1. Position hammer horizontally on the floor and 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 hammer line includes ball valves, please
make sure that they are closed.
4. Disconnect hoses. Plug the hoses and the hammer inlet and outlet ports.
5. Remove bucket pins and other parts.

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 OPERATION

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 on the valve body with "IN" and
outlet port with "OUT".
3. Open hammer inlet and outlet lines.

6.4 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.

6.5 SPECIAL CONDITIONS OF USE

If hammer is to be used in conditions that differ from normal breaking or demolition
work conditions, such as:
■ Hammer tunnelling
■ Foundry cleaning

© 2001 SANDVIK TAMROCK CORP. OPERATION - Page 27

OPERATION

■ Underwater operations
■ Operations in extremely low or high temperatures
■ Use of special hydraulic fluids
■ Hammer operations with special carrier (extra long boom etc.)
■ Other special conditions
That may require modifications to attachment, special operating techniques, in-
creased maintenance or special wear items.
In case of special conditions of use, please consult your local dealer for instructions.

UNDERWATER OPERATION
The latest hammer models can be modified for underwater operations for only short
periods. The operating principle in underwater hammering is to conduct pressurized
air through a built-in channel to the spaces above and below the piston. The air pres-
sure prevents water entering the hammer. The hammer as a standard assembly, must
not be used under water. If water fills the space where the piston strikes the tool, a
strong pressure wave is generated and the hammer may be damaged.
The wear resistance of the hammer parts is considerably lower under water than in
normal use. This is caused by corrosion and by the abrasive effect of mud in water.
After starting underwater hammering, the hammer must be inspected regularly, for
example after every half hour operation. Adapt the inspection intervals to the work-
ing conditions. See “Maintenance intervals in underwater use” on page 41.
In underwater applications, the productivity of a hydraulic hammer is considerably
lower than in normal work. This is caused by:
1. The breaking object is not visible to the operator. This causes misalignment be-
tween the tool and the object and unnecessary idle strokes.
2. The hammer must be inspected and greased more often than in normal situa-
tions.
3. The hammer must always be completely serviced after working on underwater
job sites.

The hammer as a standard assembly, must not be used under water. If water
fills the space where the piston strikes the tool, a strong pressure wave is gen-
erated and the hammer may be damaged.

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 OPERATION

6.6 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 when-
ever necessary.
1. The storage area must be dry.
2. The tool must be removed in hydraulic hammers.
3. The lower end of the piston, tool and tool bushings must be well protected with
grease in all hydraulic hammers.
4. Connections must be sealed with clean plugs to prevent oil leakage and dirt
from getting into couplings.
5. The product must be stored in the vertical position.
6. Make sure the product can not fall.

© 2001 SANDVIK TAMROCK CORP. OPERATION - Page 29

OPERATION

Page 30 - OPERATION © 2001 SANDVIK TAMROCK CORP.

 LUBRICATION

© 2001 SANDVIK TAMROCK CORP. LUBRICATION - Page 31

HAMMER TOOL GREASING

1. HAMMER TOOL GREASING

1.1 RECOMMENDED GREASES

■ RAMMER TOOL GREASE, Part no. 902045
■ ESSO EOL 232, Part no. 90203
■ WYNNS GS80
■ SHELL Kuggfett
■ SHELL Extrema MDS
■ KLÜBER Crafloscon C-SG 0 Ultra
■ LE 3751/3752

1.2 MANUAL LUBRICATION

GREASING INTERVAL
1. Tool shank must be well lubricated before installing tool.
2. 5-10 strokes from grease gun to tool bushings and tool at regular intervals.
3. Adapt interval and amount of grease to wear rate of tool and working condi-
tions. This can be anything between two hours and daily, depending on material
(rock/concrete) to be broken. See “Recommended greases” on page 32. For
more information, see "Grease guide" in Dealer manual.
Insufficient greasing or improper grease may cause:
■ Abnormal wear of tool bushing and tool
■ Tool breakage

CORRECT GREASING
While greasing, the hammer must be standing upright resting on the tool to ensure
that the grease will penetrate downwards between the tool and the bushing.

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 HAMMER TOOL GREASING

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.

GREASING POINT(S)
The greasing point(s) on the hammer have been marked with the following sticker.

1.3 AUTOMATIC LUBRICATION

The hammer can be equipped with an automatic lubrication device. For more infor-
mation consult your local dealer. See “Ramlube” on page 15.

© 2001 SANDVIK TAMROCK CORP. LUBRICATION - Page 33

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.
If the temperature of the hydraulic oil exceeds +80°C (+176°F), an auxiliary oil
cooler is needed. The oil viscosity must be between 1000-20 cSt while the attach-
ment is being used.
When the product is used continuously, the temperature of the hydraulic oil normal-
izes at a certain level depending on conditions and on the carrier. The temperature
in the tank must not exceed the maximum allowed.
The hammer must not be started if the ambient temperature is below freezing and
the oil is very thick. The machine must be moved to bring the oil temperature above
0°C (32°F) before hammering can start (viscosity 1000 cSt or 131 °E).

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 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 advan-
tage.

Problems due to incorrect hydraulic oil viscosity in the hammer:

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 lubrication efficiency
■ Hammer strikes irregularly and slowly

© 2001 SANDVIK TAMROCK CORP. LUBRICATION - Page 35

CARRIER HYDRAULIC OIL

■ 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).
The correct hydraulic oil viscosity is thus ensured.

SPECIAL OILS
In some cases special oils (e.g. biological oils and non-inflammable oils) can be
used with the 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)
■ The lubrication properties must be sufficient
■ The corrosion resistance properties must be good enough
Note: Although a special oil could be used in the carrier, always check it's suitability
with the hammer due to the hammers high piston speed. Contact the oil manufac-
turer or your local dealer for more information about special oils.

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 cool-
er. 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 ac-
ceptable level during the hammer operation. This is for two reasons.
1. Seals, wipers, membranes and other parts manufactured from the corresponding
materials can normally stand temperatures up to 80°C.
2. The higher the temperature is, the less viscous the oil gets thus losing its capabil-
ity to lubricate.
A standard carrier, with a proper hammer circuit, meets the requirements of the nec-
essary cooling capacity. If the oil temperature tends to be too high during the ham-
mer operation, the following things must be checked:
■ The hammer circuit pressure relief valve is not open when the hammer is oper-
ated.
■ The hammer circuit pressure drops are reasonable. Less than 10 bar in the pres-
sure line and less than 5 bar in the return line.
■ Hydraulic pumps, valves, cylinders, motors etc. and hammer do not have inter-
nal leakages.
If all of the above mentioned things are in order, and the temperature of the hydrau-
lic oil still tends to be too high, extra cooling capacity is needed. Consult the carrier
manufacturer or dealer for details.

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 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.
Impurities enter the hydraulic system:
■ During hydraulic oil changes and refilling.
■ When components are repaired or serviced.
■ When the hammer is being installed on the carrier.
■ Because of component wear.
Normally the existing main oil filters of the carrier are used as hammer circuit return
line filters. Consult the carrier manufacturer or your local dealer concerning instruc-
tions for the filter change intervals.
In hydraulic hammer work the carrier oil filter must fulfil the following specifica-
tions:
■ The oil filter must allow maximum particle size of 25 microns (0.025 mm).
■ The oil filter material must be man-made 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 particle count of 40 microns
maximum. Filter the oil when filling the tank.
The damage caused by hydraulic oil impurities in the carrier and hammer circuits:
1. The working life of the pumps and other components is significantly shortened.
■ Rapid wear of parts.
■ Cavitation.
2. Wear of cylinder and gaskets.
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.

© 2001 SANDVIK TAMROCK CORP. LUBRICATION - Page 37

CARRIER HYDRAULIC OIL

■ 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 38 - LUBRICATION © 2001 SANDVIK TAMROCK CORP.

 MAINTENANCE

© 2001 SANDVIK TAMROCK CORP. MAINTENANCE - Page 39

ROUTINE MAINTENANCE

1. ROUTINE MAINTENANCE

1.1 OVERVIEW
This product is a precision made hydraulic machine. Therefore great care and clean-
liness 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. Do not use anything other than purpose designed materials for
cleaning hydraulic parts. Never use water, paint thinners or carbon tetrachloride.
Components, gaskets and seals in the hydraulic system should be oiled with clean
hydraulic oil before assembly.

1.2 MAINTENANCE INTERVALS

Note: The times given refer to the machine hours while the attachment is installed.

INITIAL 50-H INSPECTION

It is recommended to have the first inspection done by your local dealer after 50 to
100 operating hours. Contact your local dealer for more information about the initial
50-hour inspection.

EVERY TWO HOURS

1. Grease the tool shank and the tool bushings.
2. Observe hydraulic oil temperature, all lines and connections as well as impact
efficiency and evenness of operation.
3. Tighten loose connections.

EVERY 10 HOURS OR AT LEAST ONCE A WEEK

1. Remove the retaining pin and the tool and check their condition. Grind the burrs
away if necessary. See “Removal of tool” on page 43.
2. Check that the tool has received sufficient grease. Grease more frequently, if
necessary.

EVERY 50 HOURS OR AT LEAST ONCE A MONTH

1. Check the tool shank and tool bushings for wear. See “Removal of tool” on page
43. See “Lower tool bushing” on page 45.

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 ROUTINE MAINTENANCE

2. Check the hydraulic hoses. Replace if necessary. Do not let dirt get into the
hammer or hoses.
3. Check that the hammer moves normally inside the housing and that vibration
dampening elements (pads and buffers) are in good condition.
4. Check the condition of wear plates by moving hammer with a pry bar from side
to side inside housing. The maximum allowed clearance is approximately ±10
mm.

EVERY 600 HOURS OR ONCE A YEAR

This service is recommended to be done by your local dealer after 600 operating
hours. Neglecting the yearly service can cause severe damage to the hammer.
Your local dealer will reseal the hammer, replace the accumulator membranes and
replace safety decals as needed. Contact your local dealer for more information
about yearly servicing.
1. Check all hydraulic connections.
2. Check that the hydraulic hoses do not rub against anything in any boom/stick
position.
3. Replace and inspect the hydraulic oil filters of the carrier.

1.3 MAINTENANCE INTERVALS IN SPECIAL APPLICATIONS

The service interval is considerably shorter with special applications such as: ham-
mer tunnelling, scaling, foundry cleaning, underwater use, etc. In special applica-
tions, please consult your local dealer for the correct service intervals.

MAINTENANCE INTERVALS IN UNDERWATER USE

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.
■ Check all hoses and connections.
■ Check the operation of the air pressure switch.
Daily maintenance
■ Remove the retaining pin and the tool for inspection. Grind the burrs away if
necessary.
■ Check that the tool has received sufficient grease.
■ Service the hammer after underwater jobs.
The hammer must be totally dismantled and serviced after working underwater.

© 2001 SANDVIK TAMROCK CORP. MAINTENANCE - Page 41

ROUTINE MAINTENANCE

Neglecting a hammer service after underwater work can cause severe damage to the
hammer.

The hammer as a standard assembly, must not be used under water. If water
fills the space where the piston strikes the tool, a strong pressure wave is gen-
erated and the hammer may be damaged.

1.4 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 before washing the product or else dirt
can enter into it and this may cause damage to the components.

Page 42 - MAINTENANCE © 2001 SANDVIK TAMROCK CORP.

 REMOVAL OF TOOL

2. REMOVAL OF TOOL

WEAR LIMITS AND LUBRICANTS FOR TOOL REMOVAL

Item Wear limit

Tool diameter X (worn out) 123 mm (4.84 in)
Tool diameter Y (worn out) 113 mm (4.45 in)

Item Lubricant
Tool and tool retaining pins Tool grease

REMOVAL OF TOOL
1. Set the hammer on level ground.
2. Make sure the carrier's transmission is in neutral and the parking brake is en-
gaged.
3. Stop the carrier engine.
4. Push the rubber plate upwards so that the pin holes are accessible.
5. Remove rubber plugs.
6. Knock split pin so far that retaining pin can be removed.
7. Remove retaining pin.

8. Remove tool retaining pins.

© 2001 SANDVIK TAMROCK CORP. MAINTENANCE - Page 43

REMOVAL OF TOOL

9. Remove tool. Use lifting device if necessary. See “Tool Specifications” on page
56.

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 can not fall.

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.
3. Check lower tool bushing for wear. See “Lower tool bushing” on page 45.
4. Check tool seal. Replace if necessary.

5. Clean and coat tool and retaining pins with grease.

6. Install tool and align the grooves of the tool with the pin bores.
7. Install retaining pins.
8. Install pin.
9. Knock split pin backwards.
10. Check that pin is secured by split pin.
11. Install rubber plugs into their places.
12. Slide the rubber plate back to original position.

Page 44 - MAINTENANCE © 2001 SANDVIK TAMROCK CORP.

 LOWER TOOL BUSHING

3. LOWER TOOL BUSHING

WEAR LIMITS AND LUBRICANTS FOR LOWER TOOL BUSHING

Item Wear limit

Tool bushing: Inspect the size of the First groove is worn out but the sec-
area from where the grease grooves ond groove is visible. Bushing can be
are worn out. re-installed. Rotate bushing 90° so
that the unused bushing surface will
be utilized (bushing has two grooves
for retaining pins).
Tool bushing (worn out) Both first and second grease grooves
are worn out. Bushing must be
replaced.

Item Specification
Distance from upper end of bushing 150 mm (5.91 in)
(H)
Width of silicon compound (L) 30 mm (1.18 in)

Item Lubricant
Contact surfaces of front head Thread grease
Contact surfaces of lower tool bush- Silicon compound
ing

REMOVAL OF LOWER TOOL BUSHING

1. Remove tool.
2. Remove split pin and retaining pin.

© 2001 SANDVIK TAMROCK CORP. MAINTENANCE - Page 45

LOWER TOOL BUSHING

3. Remove lower tool bushing.

INSTALLATION OF LOWER TOOL BUSHING

1. Clean all parts carefully.
2. Measure the length of the area (marked Y) from where the grease grooves are
worn out. Rotate or replace bushing if necessary.
3. Install seal.
4. Spread silicon compound to the lower tool bushing as specified.

5. Check the condition of the seal in housing. Replace if necessary.

6. Lubricate the contact surfaces of the front head. Leave 50 mm area from the
opening of the hole clean from lubricant. Do not allow the silicon compound
and the thread grease get mixed.
7. Install the lower tool bushing. Align the groove in the lower tool bushing with
the hole in the front head.

Page 46 - MAINTENANCE © 2001 SANDVIK TAMROCK CORP.

 LOWER TOOL BUSHING

8. Install retaining pin.

9. Install split pin.
10. Install the tool.

© 2001 SANDVIK TAMROCK CORP. MAINTENANCE - Page 47

TROUBLESHOOTING

4. TROUBLESHOOTING

4.1 HAMMER DOES NOT START

PRESSURE OR RETURN LINES CLOSED
Check the operation of quick couplings in hammer line. Open hammer line ball
valves if closed. For more information, see "Shut-off valves" in Dealer manual.
PRESSURE AND RETURN HOSES INSTALLED BACKWARDS
Swap the pressure and return hoses.
PISTON IS IN ITS LOWER HYDRAULIC BRAKE
Keep the hammer control valve open and force the tool against an object. The tool
head will push the piston out of its brake area. See “Daily operation” on page 18.
GREASE BETWEEN PISTON AND TOOL CONTACT AREA
Remove the tool and wipe excessive grease off. See “Manual lubrication” on page
32.
HAMMER CONTROL VALVE DOES NOT OPEN
When operating the hammer control valve, check that the pressure line pulsates (this
indicates the hammer control valve is opening). If the valve does not operate, check
the operating means: mechanical connections, pilot pressure or electrical control.
For more information, see "Hammer control valve" in Dealer manual.
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. See “Measur-
ing hammer operating pressure” on page 92. See “Measuring hammer circuit” on
page 90. For more information, see "Pressure relief valves" in Dealer manual.
EXCESSIVE BACK PRESSURE IN RETURN LINE
Check the installation. See “Measuring hammer circuit” on page 90. For more in-
formation, see "Some hammer features" in Dealer manual. Check the size of the
return line. For more information, see "Correct line size" in Dealer manual.
LEAKAGE FROM PRESSURE TO RETURN IN EXCAVATOR HYDRAULIC CIRCUIT
Check the installation. For more information, see "Hammer circuits" in Dealer man-
ual. Check the pump and the other hydraulic components. For more information,
see "Pump operating principle" in Dealer manual.
FAILURE IN HAMMER VALVE OPERATION
The hammer must be serviced in an authorized Rammer service shop. See “Main
valve” on page 71.

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 TROUBLESHOOTING

PISTON FAILURE
The hammer must be serviced in an authorized Rammer service shop. See “Body
parts” on page 82.

4.2 THE HAMMER OPERATES IRREGULARLY BUT THE BLOW HAS

FULL POWER
NOT ENOUGH FEED FORCE FROM EXCAVATOR
Refer to the correct working methods. See “Daily operation” on page 18.
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. See “Measur-
ing hammer operating pressure” on page 92. See “Measuring hammer circuit” on
page 90. For more information, see "Pressure relief valves" in Dealer manual.
FAILURE IN HAMMER VALVE OPERATION
The hammer must be serviced in an authorized Rammer service shop. See “Main
valve” on page 71.

4.3 HAMMER OPERATES POORLY AND BLOW HAS NO POWER

THE WORKING METHOD IS NOT CORRECT
Refer to the correct working methods. See “Daily operation” on page 18.
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. See “Measur-
ing hammer operating pressure” on page 92. See “Measuring hammer circuit” on
page 90. For more information, see "Pressure relief valves" in Dealer manual.
PRESSURE CONTROL VALVE SETTING IS INCORRECT
The hammer must be serviced in an authorized Rammer service shop. See “Meas-
uring hammer circuit” on page 90. For more information, see "Pressure relief
valves" in Dealer manual.
PRESSURE LOSS IN PRESSURE ACCUMULATOR
The hammer must be serviced in an authorized Rammer service shop. See “Pressure
accumulator” on page 64. See “Charging accumulator” on page 68.
FAILURE IN HAMMER VALVE OPERATION
The hammer must be serviced in an authorized Rammer service shop. See “Main
valve” on page 71.

© 2001 SANDVIK TAMROCK CORP. MAINTENANCE - Page 49

TROUBLESHOOTING

4.4 IMPACT RATE SLOWS DOWN

OIL HAS OVERHEATED (OVER +80°C/+176°F)
Check for a fault in the oil cooling system or an internal leak in the hammer. Check
the hydraulic circuit of the carrier. See “Measuring hammer circuit” on page 90.
Check the relief valve operation in the carrier. For more information, see "Pressure
relief valves" in Dealer manual. Check the line size. For more information, see
"Correct line size" in Dealer manual. Assemble an extra oil cooler.
HYDRAULIC OIL VISCOSITY TOO LOW
Check hydraulic oil. See “Requirements for hydraulic oil” on page 34.
EXCESSIVE BACK PRESSURE IN RETURN LINE
Check the installation. See “Measuring hammer circuit” on page 90. For more in-
formation, see "Some hammer features" in Dealer manual. Check the size of the
return line. For more information, see "Correct line size" in Dealer manual.
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. See “Measur-
ing hammer operating pressure” on page 92. See “Measuring hammer circuit” on
page 90. For more information, see "Pressure relief valves" in Dealer manual.
LEAKAGE FROM PRESSURE TO RETURN IN EXCAVATOR HYDRAULIC CIRCUIT
Check the installation. For more information, see "Hammer circuits" in Dealer man-
ual. Check the pump and the other hydraulic components. For more information,
see "Pump operating principle" in Dealer manual.
PRESSURE LOSS IN PRESSURE ACCUMULATOR
The hammer must be serviced in an authorized Rammer service shop. See “Pressure
accumulator” on page 64. See “Charging accumulator” on page 68.
FAILURE IN HAMMER VALVE OPERATION
The hammer must be serviced in an authorized Rammer service shop. See “Main
valve” on page 71.

4.5 OIL OVERHEATS

APPLICATION NOT CORRECT FOR HAMMER
Refer to recommended use and to correct working methods. See “Daily operation”
on page 18.
COOLING CAPACITY OF THE FACTORY OIL COOLER IS TOO SMALL
Assemble an extra oil cooler.

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 TROUBLESHOOTING

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. See “Measur-
ing hammer operating pressure” on page 92. See “Measuring hammer circuit” on
page 90. For more information, see "Pressure relief valves" in Dealer manual.
HYDRAULIC OIL VISCOSITY TOO LOW
Check hydraulic oil. See “Requirements for hydraulic oil” on page 34.
LEAKAGE FROM PRESSURE TO RETURN IN EXCAVATOR HYDRAULIC CIRCUIT
Check the installation. For more information, see "Hammer circuits" in Dealer man-
ual. Check the pump and the other hydraulic components. For more information,
see "Pump operating principle" in Dealer manual.
INTERNAL OIL LEAK IN THE HAMMER
The hammer must be serviced in an authorized Rammer service shop. See “Body
parts” on page 82.

© 2001 SANDVIK TAMROCK CORP. MAINTENANCE - Page 51

TROUBLESHOOTING

Page 52 - MAINTENANCE © 2001 SANDVIK TAMROCK CORP.

 SPECIFICATIONS

© 2001 SANDVIK TAMROCK CORP. SPECIFICATIONS - Page 53

HAMMER SPECIFICATIONS

1. HAMMER SPECIFICATIONS

1.1 TECHNICAL SPECIFICATIONS

Item Specification
Working weighta 1330 kg (2900 lb)
Impact energyb 2160 J
Impact ratec 450-800 bpm
Operating pressured 135-145 bar (1960-2100 psi)
Pressure relief, mine 200 bar (2900 psi)
Pressure relief, max 220 bar (3190 psi)
Oil flow range 120-170 l/min (32-45 gal/min)
Back pressure, max 10 bar (145 psi)
Input power 40 kW (54 HP)
Tool diameter 125/115 mm (4.92/4.53 in)
Pressure line connection (IN) SAE 6000 psi 1 1/4"
Return line connection (OUT) SAE 6000 psi 1 1/4"
Grease connection (G) BSP-internal 3/8"
Air connection (A) BSP-internal 3/8"
Pressure line size (minimum inner diam- 26 mm (1 in)
eter)
Return line size (minimum inner diame- 26 mm (1 in)
ter)
Optimum oil temperature +40 - +60°C (+104 - +140°F)
Allowed oil temperature range -20 - +80°C (-4 - +176°F)
Optimum oil viscosity at operating tem- 30-60 cSt
perature
Allowed oil viscosity range 20-1000 cSt
Carrier weight f 18-26 ton (40000-57000 lb)
Noise level 85 dB(A)/26-38 m (85-125 ft)
Noise level CITY 85 dB(A)/16-22 m (53-70 ft)
a. Includes average mounting bracket and standard tool
b. CIMA impact energy rating method used
c. Actual impact frequency depends on oil flow, oil viscosity, temperature, and material to be broken
d. Actual pressure depends on oil flow, oil viscosity, temperature, material to be broken and back pressure
e. Minimum setting = actual operating pressure + 50 bar (730 psi)
f. Check carrier's lifting capacity from carrier manufacturer

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 HAMMER SPECIFICATIONS

1.2 MAIN DIMENSIONS E 65, E 65 CITY

© 2001 SANDVIK TAMROCK CORP. SPECIFICATIONS - Page 55

TOOL SPECIFICATIONS

2. TOOL SPECIFICATIONS

2.1 TOOL SPECIFICATIONS E 65

Part
Tool Length Weight Diameter
no.
Chisel tool (A) 651 1050 mm (41.3 83 kg (183 lb) 125/115 mm
in) (4.92/4.53 in)
Moil point (B) 653 1050 mm (41.3 82 kg (181 lb) 125/115 mm
in) (4.92/4.53 in)
Blunt tool (C) 654 850 mm (33.5 in) 72 kg (159 lb) 125/115 mm
(4.92/4.53 in)

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 WORKSHOP

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DISASSEMBLY AND ASSEMBLY

1. DISASSEMBLY AND ASSEMBLY

1.1 MAIN COMPONENTS

LOCATION OF E 65 MAIN COMPONENTS (HAMMER MECHANISM)

A. Pressure measuring plug

B. Main valve
C. Check valve
D. Pressure control valve
E. Tie rods
F. Valve body
G. Piston and cylinder
H. Front head
I. Accumulator

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 DISASSEMBLY AND ASSEMBLY

1.2 RELEASING HYDRAULIC PRESSURE FROM HAMMER

RELEASING PRESSURE

Warning! The hydraulic pressure inside the hammer must always be released
before making any adjustments or repairs when the hammer is connected to
the carrier. There may also be pressurized oil trapped inside the hammer even
if the hammer is disconnected from the carrier. Release the hydraulic pressure
according to the following instructions before opening any plugs or valve cov-
ers.
1. Stop the carrier engine.
2. Operate boom and hammer controls to release any pressure trapped inside hos-
es.
3. Wait 10 minutes for oil pressure to drop inside hammer.

Warning! This procedure does not release the pressure from the pressure ac-
cumulator! Read the instructions dealing with the accumulator before disas-
sembling the accumulator.

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DISASSEMBLY AND ASSEMBLY

1.3 HOUSING AND VIBRATION DAMPENING

SPECIFICATIONS FOR HOUSING AND VIBRATION DAMPENING

Item Specification
Mounting bracket screws (A) 1050 Nm (775 lbf ft)
Buffer minimum thickness (D1) 70 mm (2.76 in)
Pad minimum thickness (D2) 112 mm (4.41 in)
Max. clearance between hammer -10...+10 mm (-0.39...+0.39 in)
and housing (D3)
Max. distance between wear plates 264 mm (10.39 in)
(D4)
Max. distance between wear plates 263 mm (10.35 in)
(D5)
Mounting bracket screw threads and Thread grease
bearing surfaces

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 DISASSEMBLY AND ASSEMBLY

DISASSEMBLING HOUSING AND VIBRATION DAMPENING

Warning! The hammer must be secured from falling down in either direction
when handling it. Check that the lifting capacity of the hoist you are using is
sufficient for the job. See “Lifting instructions” on page 8. See “Hammer spec-
ifications” on page 54.
1. Remove the tool and disconnect the hammer from the carrier.
2. Remove fastening screws and lift cover out of way.
3. Disconnect hose couplings from hammer.

4. Open mounting bracket screws.

5. Lift mounting bracket off.
6. Remove buffer.

7. Install lifting adapter. Lift hammer so there is a 10 mm gap between the valve
body shoulders and pads.

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DISASSEMBLY AND ASSEMBLY

8. Move hammer from side-to-side inside housing. Measure clearance at level of

valve body shoulders. If maximum clearance is exceeded, wear plates inside
housing must be replaced.

9. Lift hammer out of housing.

10. Remove pads.

11. Set hammer housing horizontally on floor or on assemly stand.

12. If necessary, remove wear plates by prying them out with a screwdriver.
13. Remove seal.

ASSEMBLING HOUSING AND VIBRATION DAMPENING

1. Check all parts for cracks and excessive wear.
2. Measure thickness of pads and buffer. If measured thicknesses are smaller than
specified, or any cracks are noticed, parts must be replaced. Note: Pads must be
replaced as a pair.

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 DISASSEMBLY AND ASSEMBLY

3. Install wear plates.

4. Set housing to vertical position.
5. Install seal.
6. Install pads.
7. Lower hammer into housing. Check clearance by moving hammer from side-
to-side.

8. Install buffer.
9. Install mounting bracket.
10. Install mounting bracket screws. Torque them to specified setting.
11. Install hose couplings.
12. Install covers.
13. Install hammer to carrier.

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DISASSEMBLY AND ASSEMBLY

1.4 PRESSURE ACCUMULATOR

TORQUES, ADJUSTMENTS AND LUBRICANTS FOR PRESSURE ACCUMULATOR

Item Tightening torque

Accumulator mounting screws (A) 500 Nm (370 lbf ft)
Accumulator cover screws (B) 450 Nm (330 lbf ft)

Item Lubricant
Screw threads and bearing surfaces Thread grease
Accumulator cover (gas side) Silicone grease
All seals and O-rings O-ring grease
Contact surfaces of valve body and Anticorrosive agent (e.g. CRC 3-36)
accumulator

RELEASING PRESSURE FROM ACCUMULATOR

Warning! Do not disassemble hammer before releasing pressure from accu-

mulator.
1. Remove shield plug.
2. Carefully loosen filling plug and let nitrogen gas escape.

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 DISASSEMBLY AND ASSEMBLY

3. When gas is completely released, remove filling plug and Usit-ring.

REMOVAL OF ACCUMULATOR
1. Remove accumulator mounting screws (8 pcs).
2. Using lifting device, lift accumulator out.

DISASSEMBLING ACCUMULATOR

Warning! Make sure that accumulator is depressurized!

1. Set accumulator upside down on the assembly stand.
2. Remove seal.
3. Remove accumulator cover screws.

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DISASSEMBLY AND ASSEMBLY

4. Remove accumulator bottom, membrane and parallel pins.

ASSEMBLING ACCUMULATOR
1. Clean and dry parts carefully.
2. Set accumulator bottom on work bench.
3. Install a new membrane. See that it fits properly in its groove.
4. Insert parallel pins.
5. Apply thin layer of silicone grease inside accumulator cover.
6. Lower accumulator cover onto accumulator bottom.
7. Grease threads and bearing surfaces of accumulator cover screws.
8. Insert accumulator cover screws.

9. Set accumulator upside down on the assembly stand.

10. Torque accumulator cover screws to specified setting.

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 DISASSEMBLY AND ASSEMBLY

11. Insert seal. Use some grease to prevent seal from falling during accumulator in-
stallation.

INSTALLING ACCUMULATOR
1. Apply anticorrosive agent on contact surfaces of valve body and accumulator.
2. Lower accumulator into its correct position using lifting device.
3. Grease threads and bearing surfaces of accumulator mounting screws.
4. Install accumulator mounting screws. Torque screws to specified setting.

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DISASSEMBLY AND ASSEMBLY

1.5 CHARGING ACCUMULATOR

TORQUES, ADJUSTMENTS AND LUBRICANTS FOR ACCUMULATOR CHARGING

Item Tightening torque

Accumulator filling plug (A) 20 Nm (15 lbf ft)
Shield plug (B) 150 Nm (111 lbf ft)

Item Charging pressure

Nitrogen (N2) 40 bar (580 psi)

CHARGING ACCUMULATOR

Warning! Use only nitrogen (N2) for charging accumulator. Use of other gases
may cause accumulator to explode.
1. Install new usit ring.
2. Install filling plug.
3. Install adapter with O-ring.

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 DISASSEMBLY AND ASSEMBLY

4. Insert pin.

5. Install charging device.

6. Connect charging system to nitrogen bottle.
7. Tighten filling plug carefully through charging device until you feel it stop, then
open it three (3) turns.
8. Open discharge valve on charging device fully.
9. Carefully open nitrogen gas bottle valve and adjust gas flow to minimum.

10. CAUTION! Charging device does not have any pressure relief valve. Shut gas
bottle valve when gauge shows correct charging pressure.
11. Close discharge valve on charging device and charge accumulator 2-3 bar
above specified charging pressure. Observe pressure gauge reading.
12. Shut nitrogen bottle valve.
13. Wait 10 minutes for nitrogen gas pressure to stabilize inside accumulator.
14. Adjust pressure in accumulator to correct setting by carefully opening discharge
valve.

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DISASSEMBLY AND ASSEMBLY

15. Torque filling plug through charging device to specified setting.

16. Release pressure from charging hose by opening discharge valve.

17. Remove charging system from accumulator.
18. Check accumulator for nitrogen leak by filling Usit-ring area with thin oil. If
gas bubbles appear, discharge accumulator and replace Usit-ring.
19. Install shield plug.

20. Torque shield plug to specified setting.

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 DISASSEMBLY AND ASSEMBLY

1.6 MAIN VALVE

TORQUES, ADJUSTMENTS AND LUBRICANTS FOR MAIN VALVE

Item Tightening torque

Main valve cover screws (A) 120 Nm (89 lbf ft)

Item Lubricant
Screw threads and bearing surfaces, Thread grease
lock washers
All seals and O-rings O-ring grease
All spools and guides Hydraulic oil

DISASSEMBLING MAIN VALVE

Warning! The hydraulic pressure inside the hammer must always be released
before removing any of the plugs or valves. Read the instructions on releasing
the hydraulic pressure from the hammer. See “Releasing hydraulic pressure
from hammer” on page 59.
1. Remove main valve cover screws and lock washers.

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DISASSEMBLY AND ASSEMBLY

2. Use two removed screws as forcing screws in covers to pull covers out.

3. Remove main spool and small spools.

4. Attach puller using cover screw holes.
5. Insert puller's flange between puller screw and main valve bushing.
6. Drive main valve bushing out from valve body.

7. Remove old seals and O-rings from main valve bushing and covers.

ASSEMBLING MAIN VALVE

1. Check all parts for wear and damage. If necessary, use fine emery cloth or
grinding agent. Clean and oil all parts.
2. Install new seals on main valve bushing.
3. Attach puller to the valve body side marked with "X".
4. Install main valve bushing with "X" facing same side as valve body "X". If
available, note text "UP" stamped on bushing and rotate bushing accordingly.

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 DISASSEMBLY AND ASSEMBLY

5. Put flange against main valve bushing.

6. Drive main valve bushing in carefully.

7. Install main spool with "X" on spool facing "X" of valve body and main valve
bushing.
8. Install small spools. Check that all spools move freely.
9. Install new O-rings on main valve covers. Note: Before installing covers, en-
sure that all "X"'s on all assembled parts appear on same side as valve body "X".

10. Install covers. Ensure that cover marked with "X" faces same side as valve body
marked with "X".
11. Grease threads and bearing surfaces of screws and lock washers. Install them.
12. Torque screws to specified setting.

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DISASSEMBLY AND ASSEMBLY

1.7 CHECK VALVE

TORQUES, ADJUSTMENTS AND LUBRICANTS FOR CHECK VALVE

Item Tightening torque

Check valve screws (A) 200 Nm (148 lbf ft)

Item Lubricant
Screw threads and bearing surfaces, Thread grease
lock washers
All seals and O-rings O-ring grease
All spools and guides Hydraulic oil

DISASSEMBLING CHECK VALVE

Warning! The hydraulic pressure inside the hammer must always be released
before removing any of the plugs or valves. Read the instructions on releasing
the hydraulic pressure from the hammer. See “Releasing hydraulic pressure
from hammer” on page 59.
Note: The check valve is located in the valve body on the pressure (oil inlet) side.
It can also be removed without removing the hammer mechanism from the housing.
1. Remove check valve screws and lock washers.

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 DISASSEMBLY AND ASSEMBLY

2. Use two removed screws as forcing screws in check valve housing to pull check
valve out.

3. Clamp check valve in vice.

4. Remove O-rings.
5. Remove circlip.
6. Remove spring guide, spring and spool.

ASSEMBLING CHECK VALVE

1. Check all parts for wear and damage. If necessary, use fine emery cloth or
grinding agent. Clean and oil all parts.
2. Install spool, spring and spring guide.
3. Install circlip. Check that spool moves freely against spring force.
4. Install new O-rings.
5. Install check valve into valve body.
6. Grease threads and bearing surfaces of screws and lock washers. Install them.
7. Torque screws to specified setting.

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DISASSEMBLY AND ASSEMBLY

1.8 PRESSURE CONTROL VALVE

TORQUES, ADJUSTMENTS AND LUBRICANTS FOR PRESSURE CONTROL VALVE

Item Tightening torque

Pressure control valve screws (A) 200 Nm (148 lbf ft)
Valve housing (B) approx. 300 Nm (220 lbf ft)
Guide (C) approx. 300 Nm (220 lbf ft)
Free lenght (D1) 80.0 mm (3.15 in)

Item Lubricant
Thread grease Screw threads and bearing surfaces,
lock washers
All seals and O-ring O-ring grease
All spools and guides Hydraulic oil

DISASSEMBLING PRESSURE CONTROL VALVE

Warning! The hydraulic pressure inside the hammer must always be released
before removing any of the plugs or valves. Read the instructions on releasing
the hydraulic pressure from the hammer.
Note: The pressure control valve is located in the valve body on the return (oil out-
let) side. It can also be removed without removing the hammer mechanism from the
housing.
1. Remove pressure control valve screws and lock washers.

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 DISASSEMBLY AND ASSEMBLY

2. Use two removed screws as forcing screws in valve cover to pull pressure con-
trol valve out.

3. Clamp pressure control valve in vice.

4. Remove seals and O-ring.
5. Release spring pressure by loosening both guide and valve housing simultane-
ously. Remove guide and its spool. Remove valve housing.

6. Remove spool, spring, spring guide and shim plates.

ASSEMBLING PRESSURE CONTROL VALVE

1. Check all parts for wear and damage. If necessary, use fine emery cloth or
grinding agent. Clean and oil all parts.
2. Clamp pressure control valve cover in a vice.

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DISASSEMBLY AND ASSEMBLY

3. Install shim plates, spring guide, spring and spool. Measure free lenght for cor-
rect pre-loading of spring. The correct operating pressure, which is preset at fac-
tory is on the average achieved when measured height is as specified. Adjust
pre-load to specifications by adding or removing shim plates. Always measure
hammer operating pressure with a pressure gauge after pressure control valve
adjustment.

4. Install valve housing and guide. Torque parts to specified setting.

5. Install new seals. Note details in illustration for proper seal installation.
6. Insert spool.
7. Install pressure control valve into valve body.
8. Grease threads and bearing surfaces of screws and lock washers. Install them.
9. Torque screws to specified setting.

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 DISASSEMBLY AND ASSEMBLY

1.9 TIE RODS

TORQUES, ADJUSTMENTS AND LUBRICANTS FOR TIE RODS

Item Tightening torque

Tie rod (A) pre-tightening torque 1) 100 Nm, 2) 300 Nm, 3) 500Nm
steps (370 lbf ft)
Additional tightening angle after 120°
heating

Item Lubricant
Tie rod threads and bearing surfaces, Thread grease
tie rod nuts
Centre part of tie rod Heat resistant paint

LOOSENING TIE RODS

1. Remove rubber rings and lock plates.
2. Mark each tie rod and its nut as pairs. Mark also each tie rod's location in ham-
mer.
3. Heat tie rods with propane flame until tie rods can be loosened using wrench.
Avoid heating one spot only. Do not exceed 300°C. Ensure flame heats only tie
rods, not hammer body.

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DISASSEMBLY AND ASSEMBLY

4. Lift tie rods out with lifting device. Be careful with hot parts.
5. Remove nuts.

TIGHTENING TIE RODS

1. Clean all parts thoroughly.
2. Use crack detecting equipment to check if there are cracks in rod threads or un-
der head. If cracks are detected, change tie rod and its nut. Also change diagonal
tie rod and nut.
3. Apply heat resistant paint to part of tie rods located inside front head.
4. Grease threads and bearing surfaces of tie rods, valve body and tie rod nuts.
5. Install tie rod nuts and tie rods. Note arrow and text "UP" stamped on nut.
Check each tie rod has correct nut as it's pair. Also check location of each tie
rod in hammer is same as before disassembly.
6. Use torque wrench to tighten tie rods in small steps crosswise to pretightening
torque.
7. Mark additional tightening angle to valve body and tie rods.

8. Heat all tie rods with propane flame so they can be tightened according to re-
quired tightening angle with a socket and handle. Do not exceed 300°C.

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 DISASSEMBLY AND ASSEMBLY

9. Fill grooves between tie rods and front head with silicone compound, when suf-
ficiently cool.

10. Install lock plates.

11. Install rubber rings.

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DISASSEMBLY AND ASSEMBLY

1.10 BODY PARTS

TORQUES, ADJUSTMENTS AND LUBRICANTS FOR BODY PARTS

Item (located in valve body or in cylinder) Tightening torque

Taper plug 1/4", 1 pcs 33 Nm (24 lbf ft)
Breather BSP 3/8", 1 pcs 70 Nm (52 lbf ft)
Breather BSP 1/2", 1 pcs 120 Nm (89 lbf ft)
Flange plug BSP 1/4", 7 pcs 33 Nm (24 lbf ft)
Flange plug BSP 3/8", 1 pcs 70 Nm (52 lbf ft)
Flange plug BSP 3/4", 1 pcs 150 Nm (111 lbf ft)

Item Lubricant
Plugs and breathers Locking fluid (e.g. Loctite 275)
All seals and O-rings O-ring grease
Contact surfaces between valve body, Anticorrosive agent (e.g. CRC 3-36)
cylinder and seal carrier
Contact surfaces between seal carrier Thread grease
and front head
All parts, especially piston Hydraulic oil

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 DISASSEMBLY AND ASSEMBLY

DISASSEMBLING BODY PARTS

1. Screw lifting eyes in valve body and lift valve body off.
2. Remove seals.
3. Remove O-rings.
4. Remove parallel pin.

5. Lift the piston, cylinder and seal carrier carefully out from front head. Take care
that seal carrier does not fall down.
6. Place plywood plate on the top of front head.
7. Place piston, cylinder and seal carrier on the plywood plate.

8. Screw lifting eyes into cylinder and lift it so that there is about 50 mm distance
between plywood plate and seal carrier.
9. Remove seal carrier from cylinder by knocking piston with nailon drift and
plastic hammer. Be careful with oil leaking out.

10. Lift cylinder carefully out.

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DISASSEMBLY AND ASSEMBLY

11. Lift piston carefully out.

12. Remove guide pin and O-rings from seal carrier.

13. Remove seals and wiper from seal carrier.

14. Remove O-ring, seals and wiper from cylinder.

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 DISASSEMBLY AND ASSEMBLY

ASSEMBLING BODY PARTS

1. Check all parts for wear and damage. If necessary, use fine emery cloth or
grinding agent. Clean and oil all parts.
2. Lubricate and install seals, wiper, guide pin and O-rings of seal carrier.
3. Place seal carrier on plywood plate located on the front head.
4. Oil piston and lift it into seal carrier. Hit piston carefully in its place with plastic
hammer.

5. Install seals, O-rings and wiper into cylinder.

6. Apply anticorrosive agent to contact surfaces of cylinder and seal carrier and lift
cylinder on the piston. Hit cylinder carefully in its place with plastic hammer.

7. Srew lifting eye into piston and lift the package out of way. Remove plywood
plate.
8. Apply a thin layer of thread grease to the top of thrust ring.

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DISASSEMBLY AND ASSEMBLY

9. Note: It is possible to make the hammer either left- or right-handed, i.e. the pres-
sure (oil inlet) connection in the valve body is either on the left hand side or on
the right hand side. Standard hammers are manufactured with the oil inlet on the
right and oil outlet on the left. The lower seal carrier includes two positioning
grooves for this purpose. To make the hammer right-handed (standard assem-
bly), install the cylinder/seal carrier package so that the front head's wedge goes
to the positioning groove marked with a small dot in the cylinder (see detail).
When assembling a left-handed hammer, use the groove on the opposite side.

10. Lower piston, cylinder and seal carrier together into its correct position inside
front head. Take care that seal carrier does not fall down. Remove lifting eye
from piston.

11. Install seals, O-rings and parallel pin between valve body and cylinder.
12. Apply anticorrosive agent on contact surfaces of cylinder and valve body. In-
stall valve body.

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 DISASSEMBLY AND ASSEMBLY

1.11 FRONT HEAD

TORQUES, ADJUSTMENTS AND LUBRICANTS FOR FRONT HEAD

Item Wear limit

Thrust ring, max. length (D1). 8.5 mm (0.33 in)
Upper tool bushing, max. diameter 118.2 mm (4.65 in)
(D2).
Lower tool bushing See “Lower tool bushing” on page
45.

Item Lubricant
All seals and O-rings O-ring grease
Contact surfaces between all parts Thread grease
Inside tool bushings Tool grease

DISASSEMBLING FRONT HEAD

1. Remove wedge and O-ring with drift pin.

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DISASSEMBLY AND ASSEMBLY

2. Lift thrust ring out.

3. Attach tool bushing's extractor tool. Install puller's flange by tilting it as shown
in detail.
4. Pull bushing out by using hydraulic jack.
5. Lift bushing out from front head.

6. Set front head upside down on floor.

7. Remove split pin and retaining pin.
8. Using bushing's extractor tool, pull lower tool bushing out.

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 DISASSEMBLY AND ASSEMBLY

9. If necessary, remove grease nipples.

ASSEMBLING FRONT HEAD

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 “Lower tool bushing” on page 45.
2. Install grease nipples.
3. Install tool seal and O-ring to lower tool bushing.
4. Apply thread grease on contact surfaces of lower tool bushing and front head.
Install the lower tool bushing.
5. Install retaining pin and split pin.
6. Lubricate inner surface of lower tool bushing with tool grease.
7. Set front head standing on lower tool bushing on floor.
8. Apply thread grease on outer surfaces of upper tool bushing and thrust ring. Lu-
bricate inner surface of upper tool bushing with tool grease.
9. Install upper tool bushing.
10. Install thrust ring.
11. Install wedge with O-ring.

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TESTING

2. TESTING

2.1 MEASURING HAMMER CIRCUIT

MEASURING POINTS

p0 tank (with closed circuit from suction pipe of the pump)

p2 straight before the restriction of the flow meter (e.g. Webster flow meter includes
pressure gauge for p2)
Q2, T2 at flow meter, which connects pressure and return line of the hammer circuit
p3 straight after flow meter

HOW TO MEASURE
Procedure for measuring and adjusting the hammer circuit:
Note: Check and calibrate all the gauges you are going to use. Faulty pressure gaug-
es should be changed.

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 TESTING

Note: If the flow to the hammer is adjusted by changing the engine revolutions, al-
ways check the flow also at full engine revolutions. Note: It is absolutely forbidden
to use hammer above specified oil flow range.

Warning! Don't exceed the carrier's main relief valve setting.

1. Check the lines, couplings, clamps etc. to ensure their condition. Replace worn
or damaged components and tighten loose joints.
2. Check that there is a pressure relief valve in the hammer line.
3. Make sure that carrier's hydraulic oil temperature is at normal operating level.
4. Connect the flowmeter in place of the hammer. It is preferable to use same hos-
es and couplings that are used with the hammer, especially in cases when hoses
are equipped with quick couplings.
5. Check that the adjustable restriction is open.
6. Press the hammer operating switch.
7. Close the hammer line to the full relief and adjust the pressure relief valve 50
bar (gauge p2) above the hammer max. operating pressure shown in the techni-
cal data.
8. Open the restriction so that the hammer's operating pressure at gauge p2 is
reached.
9. Check that the hammer's oil flow is within the limits.
10. Check that the return line back pressure p3 doesn't exceed the values allowed at
the hammer oil flow.
11. Check that the hammer's oil flow doesn't increase when the carrier's operating
pressure exceeds the pressure in the hammer line (pressure compensated flow
control). To do that, drive the boom, stick and bucket cylinders to the tilt posi-
tion while pressing the hammer operating switch and checking the flow.
12. Open the restriction.
13. Stop the carrier engine.
14. Connect the hammer in place of the flow meter.
15. Measure hammer operating pressure. See “Measuring hammer operating pres-
sure” on page 92.
16. When installing a new hammer check all the values after working about 50
hours with the hammer.

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TESTING

2.2 MEASURING HAMMER OPERATING PRESSURE

SPECIFICATIONS FOR MEASURING OPERATING PRESSURE

Item Description
Plug (A) Pressure measuring port

Item Torque
Plug (A) 33 Nm (24 lbf ft)

MEASURING HAMMER OPERATING PRESSURE

Warning! When measuring hammer operating pressure, you are working in

hammer's danger area. Protect yourself against flying debris.
1. Hammer operating pressure must be measured with carrier hydraulic circuit in
its normal operating temperature. Before starting hammer operating pressure
measuring procedure, operate carrier until hydraulic oil has warmed sufficient-
ly.
2. Stop the carrier engine.
3. Remove pressure measuring plug (A) and connect a 250 bar pressure gauge
with a minimum 10 meter hose to high pressure measuring port, BSP 1/4" on
check valve cover.
4. Start carrier and adjust engine revolutions. Set engine revolutions to hammer
operating revs. If carrier has power/work modes, please select mode intended
for hammer work.

Page 92 - WORKSHOP © 2001 SANDVIK TAMROCK CORP.

 TESTING

5. Position tool e.g. on a thick steel plate and start to operate hammer.
6. Read average operating pressure reading on pressure gauge.

7. Average operating pressure reading should range between given specifications.

Note: When measuring operating pressure by hammering on a steel plate or
equivalent hard material, the pressure reading should be in the lower end of the
specified pressure range. Hammer's operating pressure tends to raise when
working with soft material. See “Hammer specifications” on page 54.
8. If pressure reading is not within specifications, re-adjust pressure control valve
spring pre-load and measure operating pressure again. See “Pressure control
valve” on page 76.
9. Stop carrier and remove gauge. Torque plug (A) to specified setting.

MEASURING HAMMER OPERATING PRESSURE IN CITY AND CITY-JET MODELS

Warning! When measuring hammer operating pressure, you are working in

hammer's danger area. Protect yourself against flying debris.
1. Hammer operating pressure must be measured with carrier hydraulic circuit in
its normal operating temperature. Before starting hammer operating pressure
measuring procedure, operate carrier until hydraulic oil has warmed sufficient-
ly.
2. Stop the carrier engine.
3. Remove pressure measuring plug (A) and connect a 250 bar pressure gauge
with a minimum 10 meter hose to high pressure measuring port, BSP 1/4" on
check valve cover.
4. Start carrier and adjust engine revolutions. Set engine revolutions to hammer
operating revs. If carrier has power/work modes, please select mode intended
for hammer work.
5. Position tool e.g. on a thick steel plate and start to operate hammer.

© 2001 SANDVIK TAMROCK CORP. WORKSHOP - Page 93

TESTING

6. Read average operating pressure reading on pressure gauge.

7. Average operating pressure reading should range between given specifications.

Note: When measuring operating pressure by hammering on a steel plate or
equivalent hard material, the pressure reading should be in the lower end of the
specified pressure range. Hammer's operating pressure tends to raise when
working with soft material. See “Hammer specifications” on page 54.
8. If pressure reading is not within specifications, replace hammer's pilot valve
and measure operating pressure again. If reading still is not within specifica-
tions, re-adjust pressure sequence valve spring pre-load and measure operating
pressure again.
9. Stop carrier and remove gauge. Torque plug (A) to specified setting.

Page 94 - WORKSHOP © 2001 SANDVIK TAMROCK CORP.

 SERVICE TOOLS

3. SERVICE TOOLS

3.1 SPECIAL SERVICE TOOLS

Item Name Part no. Qty Picture

1 Accumulator 40633 1
charging kit (incl.
parts 1.1-1.4)
1.1 Charging device 101688 1
1.2 Socket 40601 1
1.3 Adapter 101635 1
1.4 O-ring 901135 1

Item Name Part no. Qty Picture

1 Bushing extrac- 101101 1
tion tool, (incl.
parts 1.1-1.6)
1.1 Puller frame 101118 1
1.2 Threaded rod 101104 1
1.3 Puller plate (E 64 101153 1
lower tool bush-
ing)
1.3 Puller plate (E 65 110722 1
lower tool bush-
ing)
1.3 Puller plate (E 66 101074 1
lower tool bush-
ing)
1.3 Puller plate (E 68 101059 1
lower tool bush-
ing)
1.4 Washer 101124 2
1.5 Nut 902001 2
1.6 Puller plate set 101125 1
(60-series upper
tool bushings)

© 2001 SANDVIK TAMROCK CORP. WORKSHOP - Page 95

SERVICE TOOLS

Name Part no. Qty Picture

Pressure gauge 250 bar 41738 1

Hammer lifting adapter 102767 1

Hammer assembly 102548 1

stand

Accumulator assembly 101099 1

stand

Puller 101100 1

Assembly stand for seal 101144 1

carrier, cylinder and
piston

Adapter for French 901311 1

nitrogen bottle

Page 96 - WORKSHOP © 2001 SANDVIK TAMROCK CORP.

 SERVICE TOOLS

Name Part no. Qty Picture

Torque converter 90634 1

Slogging ring wrench 90643 1

36 mm

Hook spanner 90621 1

Name Part no. Qty Picture

Drift pins
Drift pin D9 101048 1
Drift pin D11 400368 1
Drift pin D12 400366 1
Drift pin D25 400367 1

Name Part no. Qty Picture

Lifting eyes
Lifting eye M10 901067 2
Lifting eye M12 90607 2
Lifting eye M16 90690 2
Lifting eye M24 90605 2
Lifting eye M24x2 40212 2

3.2 STANDARD SERVICE TOOLS

Name Specification
Torque wrench 150-700 Nm (3/4")
Torque wrench 20-200 Nm (1/2")
Ratchet handle 1/2"
Extension L=125 mm (1/2")
Sliding T-handle 3/4"

© 2001 SANDVIK TAMROCK CORP. WORKSHOP - Page 97

SERVICE TOOLS

Name Specification
Adapter 3/4"->1/2"
Adapter 1/2"->3/4"
Combination spanner 24 mm
Combination spanner 30 mm
Combination spanner 36 mm
Combination spanner 46 mm
Hex. socket 14 mm (1/2")
Hex. socket 19 mm (1/2")
Hex. socket 24 mm (1/2")
Hex. socket 30 mm (3/4")
Hex. socket 36 mm (3/4")
Hex. socket 41 mm (3/4")
Allen type screw socket 6 mm (1/2")
Allen type screw socket 8 mm (1/2")
Allen type screw socket 12 mm (1/2")
Allen type screw socket 17 mm (3/4")
Allen type screw socket 19 mm (3/4")
Pry bars 400 mm
Lifting chain
Hammer Plastic, 1000 g
Hammer Ball headed, 680 g
Hammer 2000 g
Screwdriver 6x150 mm
Screwdriver 8x250 mm
Oil can 0.5 l
Grease gun

Page 98 - WORKSHOP © 2001 SANDVIK TAMROCK CORP.

© 2001 SANDVIK TAMROCK CORP. Page 99
 SANDVIK TAMROCK CORP.
Breakers Lahti
Taivalkatu 8, P.O. Box 165, FIN-15101 Lahti, Finland
Phone Int. +358 205 44 161, Telefax Int. +358 205 44 160,
Internet http://www.rammer.com

9-4-14007-39-56-294
12-4-14007-24-228-182