RAMMER 2155E Operator's Manual

Hydraulic

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Original instructions

9/19

OPERATOR'S MANUAL

OM2155ESENG.919

HYDRAULIC HAMMER

RAMMER 2155E

STD

Table of Contents

Summary of Contents for RAMMER 2155E

Page 1 Original instructions 9/19 OPERATOR'S MANUAL OM2155ESENG.919 HYDRAULIC HAMMER RAMMER 2155E...
Page 2: Table Of Contents
OPERATION......3 3. Lower tool bushing ....64 Wear limits and lubricants for lower tool 1.
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 2155E STD Foreword SYMBOLS USED IN THIS MANUAL This symbol identifies important safety messages within this manual. Carefully read the message that follows. Failure to understand and obey this safety warning could result in injury to you or others, and could also cause damage to equipment. See illustration 1.
Page 6: Important Safety Information
Foreword 2155E STD 1.2 IMPORTANT SAFETY INFORMATION Basic safety precautions are outlined in the "Safety" section of this manual and in the description of operations where hazards exist. Warning labels have also been put on the machine to provide instructions and to identify specific hazards which if not observed could cause bodily injury or death to you or other persons.
Page 7: Spare Part Orders
2155E STD Foreword 1.4 SPARE PART ORDERS When you need spare parts or some information concerning maintenance to your machinery, please contact your local dealer. Quick deliveries are ensured by exact orders. Required information: 1. Name of customer, contact person 2.
Page 8: Product Numbers
Product numbers 2155E STD 2. PRODUCT NUMBERS 2.1 MODEL AND SERIAL NUMBER The product serial number is stamped on the valve body. Both the model and serial number are located on the product identification plate. Check that the model corresponds to the one given on the cover of this manual.
Page 9: Product Introduction
2155E STD Product introduction 3. PRODUCT INTRODUCTION 3.1 OVERVIEW The product is a hydraulically operated hammer. It can be used on any carrier which meets the necessary hydraulic and mechanical installation requirements. The unit functions by repeatedly raising a steel piston and driving it down onto the head of a removable breaking tool.
Page 10 Product introduction 2155E STD PROVIDED LIFTING POINTS Use the lifting eyes located on the product housing only to lift or handle the product itself. The lifting capacity calculation is based on the product's working weight including a normal working tool and an average sized mounting bracket.
Page 11 2155E STD Product introduction R010266 Lifting devices must safely carry the working weight of the product. See “Hammer specifications” on page 70. Place chains or slings, as shown by the illustration, to lift the product. R010274 Note: Before starting to operate the hammer, always replace the lifting eye with a blanking screw.
Page 12 Product introduction 2155E STD 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-equipments must always be strictly observed. Please note that the list below is not all inclusive, you must always ensure the procedure you choose is safe for you and others.
Page 13: Main Parts
2155E STD Product introduction 3.4 MAIN PARTS The main parts of the hammer are shown below. R010276 A. Housing B. Mounting flange C. Vibration dampening elements D. Hose connections (pressure line marked "IN" and return line marked "OUT") E. Pressure accumulator F.
Page 14: Ramlube Ii
For more information, contact your local Rammer dealer and See “Important information concerning the remote monitoring device and data privacy” on page 76. Page 14 - Operation...
Page 15 2155E STD Product introduction R010541 Warning! RD3 contains a SIM card to enable remote connections and an encased lithium metal battery. Both items are regulated for air transport. Consult your forwarder about any restrictions for air freight. Warning! Lithium is a highly flammable substance. Store damaged lithium batteries in a fire proof container.
Page 16: Environmental Protection And Recycling
2155E STD 3.7 ENVIRONMENTAL PROTECTION AND RECYCLING POLICY Rammer products contribute to the recycling of materials to help customers achieve their environmental objectives. During the manufacturing, all the necessary precautions are taken to make sure that no harm is done to the environment.
Page 17: Safety
2155E STD Safety 4. SAFETY 4.1 GENERAL SAFETY All mechanical equipment can be hazardous if operated without due care or correct maintenance. Most accidents involving machine operation and maintenance are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.
Page 18 Safety 2155E STD WARNING IGNORING INSTRUCTIONS HAZARD Faulty handling practice could cause death or severe injury. Read and follow the instructions in the operator’s manual. 169400_ENG-3 R010354 CARE AND ALERTNESS All the time you are working with the product, take care and stay alert. Always be alert for hazards.
Page 19 2155E STD Safety WORK SITE Work sites can be hazardous. Inspect the site before working on it. Poor visibility can cause accidents and damage. Make sure that visibility and lighting of the working area are adequate. 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.
Page 20 Safety 2155E STD To protect yourself from airborne pollutants, always keep excavator doors and windows closed during operation. Excavators with pressurized cabins should be utilized in hammer operation. Proper maintenance of fresh air filters of the excavator is essential. Where pressurized cabins are not available, proper respirators must be utilized.
Page 21 2155E STD 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 Safety 2155E STD HYDRAULIC HOSES AND FITTINGS Ensure all hydraulic components will withstand maximum pressure and mechanical stresses caused by operation of the attachment. Consult your local dealer for instructions. FIRE HAZARD Most hydraulic fluids are flammable and might ignite when contacting hot surface.
Page 23 2155E STD Safety LIFTING EQUIPMENT You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that the lifting equipment complies with all local regulations and is suitable for the job. Make sure that the lifting equipment is strong enough for the job and that you know how to use it.
Page 24 Safety 2155E STD LABELS ON THE PRODUCT Safety labels communicate the following four things: ■ The severity level of the risk (that is, signal word "DANGER" or "WARNING"). ■ The nature of the hazard (such as high pressure, or dust).
Page 25 2155E STD Safety WARNING DANGER IGNORING DUST HAZARD INSTRUCTIONS HAZARD Breathing dust will cause death or severe injury. Faulty handling practice could cause death or severe injury. Always wear approved respirator. Read and follow the instructions in the operator's manual.
Page 26: Operation
Operation 2155E STD 5. OPERATION 5.1 OPERATING INSTRUCTIONS RECOMMENDED USE The hammer is designed to be used in breaking concrete, road surface or asphalt, hard or frozen ground. It can be also used in breaking moderate sized boulders as well as in demolishing reinforced structures and for major excavation and clearing work.
Page 27 2155E STD Operation 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.
Page 28 Operation 2155E STD It is important to choose a tool, which is suitable for your hammer and for the application you are working on. The tool selection available depend on hammer model. See “Tool specifications” on page 74. Page 28 - Operation...
Page 29: Daily Operation
2155E STD 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 2155E STD 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 2155E STD Operation against the wall at a 90 degree angle. When breaking concrete, hard or frozen ground, never strike and pry with the tool at the same time. The tool may break. Bending may be caused by stones inside hard or frozen ground. Be careful and stop striking if you find sudden resistance under the tool.
Page 32 Operation 2155E STD Do not use the hammer to sweep the ground of debris. This may damage the hammer and the housing will wear out more quickly. When operating the hammer, make sure that it does not make contact with the carrier boom or hydraulic lines.
Page 33 2155E STD Operation Do not use the hammer or hammer tools for lifting. Lifting eyes on the hammer are for storage and maintenance purposes only. COPYRIGHT © 2019 SANDVIK MINING AND CONSTRUCTION OY Operation - Page 33...
Page 34 Operation 2155E STD 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 35 2155E STD Operation 5. Place the tool against the object at a 90 degree angle. Avoid small irregularities on the object which will break easily and cause either idle strokes or an incorrect working angle. 6. Start the hammer. 7. Stop the hammer quickly. Do not allow the hammer to fall down and make idle strokes when an object breaks.
Page 36: Mounting And Dismounting The Hammer
Operation 2155E STD 5.3 MOUNTING AND DISMOUNTING THE HAMMER REMOVAL FROM CARRIER Warning! The hammer must be secured from rolling over when disconnecting from the carrier. Only use a skilled operator to position the carrier for hammer removal! Warning! Hydraulic pressure inside the hammer must always be released...
Page 37 2155E STD Operation 5. Remove bucket pins and other parts. 6. If you have to check or remove hose connections in the hammer, remove shield plate by pulling it out of the housing. Then you can reach to the connections.
Page 38: Movement
Operation 2155E STD R010484 Item Torque Mounting screws for flange couplings 110 Nm (81 lbf ft) 5.4 MOVEMENT The transportation and parking positions are shown below. When moving with the hammer, ensure that it isn't too close and doesn't point at the cabin window.
Page 39: Special Conditions Of Use
2155E STD 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: ■ Tunneling ■ Scaling ■ Foundry cleaning ■ Underwater operations ■...
Page 42: Hammer Tool Greasing
2155E STD 1. HAMMER TOOL GREASING 1.1 RECOMMENDED GREASES For tool lubrication use only RAMMER TOOL GREASE, part no. 902045 (400 g cartridge), part no. 902046 (18 kg drum), or any grease that meets the following criteria: ■ No dropping point or very high, over 250 °C (480 °F).
Page 43: Automatic Greasing
2155E STD Hammer tool greasing 1.2 AUTOMATIC GREASING The hammer is equipped with an automatic greasing device. The greasing device has an indicator for showing the need of refilling the grease container. When refilling grease, the same indicator shows when the grease container is full.
Page 44 Hammer tool greasing 2155E STD REFILLING OF GREASE CONTAINER Warning! Hydraulic pressure inside hammer must always be released before refilling of grease container! After operating the hammer, wait 10 minutes for oil pressure to drop inside hammer. Hammer return line must be clear to the hydraulic oil tank when refilling the grease container.
Page 45 2155E STD Hammer tool greasing 5. If grease does not come from grease pump while pumping, check that grease cartridge is not empty. If it is not empty there might be air inside grease pump. To remove air from pump pull piston rod out and turn piston rod 90 degrees crosswise and press it in and simultaneously press air releasing plug (H).
Page 46: Ramlube Ii
Hammer tool greasing 2155E STD Item Specification 0.5-turn adjustment 0.05 g grease/impact period min adjustment 0.07 g grease/impact period max adjustment 0.33 g grease/impact period 1.3 RAMLUBE II Dispose of empty grease containers appropriately. The hammer can be equipped with an automatic greasing device Ramlube II. See “Ramlube II”...
Page 47: Adjusting The Dose
2155E STD Hammer tool greasing 4. Remove the protective cap from the new cartridge. R020110 5. Check the grease cartridge seal. 6. Push the cartridge piston with fingers until approximately 15 mm of grease comes out. 7. Insert the cartridge and tighten it.
Page 48 Hammer tool greasing 2155E STD B. Pressure hose C. Grease nipple for manual greasing D. Adjusting screw for grease dosage E. Locking nut for the adjusting screw ADJUSTING THE DOSE Please note that the actual amount of grease needed for proper lubrication varies according to: ■...
Page 49: Manual Greasing
2155E STD Hammer tool greasing 3. Turn the adjusting screw for grease dosage clockwise to close it completely. R020124 4. Next open the adjusting screw for grease dosage by turning it counter- clockwise as needed. See table below. 5. Tighten the locking nut to the specified torque setting. See table below.
Page 50 Hammer tool greasing 2155E STD GREASING INTERVAL 1. Tool shank must be well lubricated before installing tool. 2. 10-20 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 conditions.
Page 51: Carrier Hydraulic Oil
2155E STD 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 52 Carrier hydraulic oil 2155E STD OIL SPECIFICATIONS Table below shows hydraulic oils recommended for hammer use. The most suitable oil is selected in such a way that the temperature of the hydraulic oil in continuous use is in the ideal area on the chart and the hydraulic system is used to best advantage.
Page 53: Oil Cooler
2155E STD Carrier hydraulic oil 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.
Page 54: Oil Filter
Carrier hydraulic oil 2155E STD 2.3 OIL FILTER The purpose of the oil filter is to remove impurities from the hydraulic oil. Air and water are also impurities in oil. Not all impurities can be seen with the naked eye.
Page 55 2155E STD Carrier hydraulic oil 4. Valves do not function properly. ■ Spools bind. ■ Rapid wear of parts. ■ Blocking of small holes. Note: Component damage is only a symptom. The trouble itself will not be cured by removing the symptom. After any component damage due to impurities in the oil, the entire hydraulic system has to be cleaned.
Page 58: Routine Maintenance
Routine maintenance 2155E STD 1. ROUTINE MAINTENANCE 1.1 OVERVIEW This product is a precision made hydraulic machine. Therefore great care and cleanliness should be taken when handling any of the hydraulic components. Dirt is the worst enemy in hydraulic systems.
Page 59: Dealer
2155E STD Routine maintenance EVERY 50 HOURS OR AT LEAST ONCE A MONTH ■ Check the tool shank and tool bushings for wear. See “Changing the tool” on page 61. See “Lower tool bushing” on page 64. 1.3 INSPECTION AND MAINTENANCE BY THE DEALER Note: The times given refer to the carrier hours while the attachment is installed.
Page 60: Maintenance Intervals In Special
Routine maintenance 2155E STD 1.4 MAINTENANCE INTERVALS IN SPECIAL APPLICATIONS The service interval is considerably shorter in special applications. See “Special conditions of use” on page 39. In special applications, please consult your local dealer for the correct service intervals.
Page 61: Changing The Tool
2155E STD Changing the tool 2. CHANGING THE TOOL WEAR LIMITS AND LUBRICANTS FOR TOOL REMOVAL R030065 Item Wear limit Tool diameter (worn out) 116 mm (4.57 in) R030149 Item Wear limit Tool retaining pin diameter Z (worn 52 mm (2.05 in)
Page 62: Installation Of Tool
Changing the tool 2155E STD 2. Make sure the carrier's transmission is in neutral and the parking brake is engaged. 3. Stop the carrier engine. 4. Remove plugs. 5. Remove rubber rings. 6. Remove tool retaining pins by using t-puller.
Page 63 2155E STD Changing the tool 4. Check tool seal. Replace if necessary. R030110 5. Clean the tool and retaining pins and lubricate them with grease. 6. Install tool and align the grooves of the tool with the pin bores. 7. Install tool retaining pins.
Page 64: Lower Tool Bushing
Lower tool bushing 2155E STD 3. LOWER TOOL BUSHING WEAR LIMITS AND LUBRICANTS FOR LOWER TOOL BUSHING Groove R030109 Item Wear limit Tool bushing (worn out) Grease groove is worn out. Bushing must be replaced. Item Lubricant Contact surfaces of front head...
Page 65: Troubleshooting
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. 4.2 THE HAMMER OPERATES IRREGULARLY AND BLOW HAS NO POWER THE WORKING METHOD IS NOT CORRECT Refer to the correct working methods.
Page 66: 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 67: Recurrent Tool Failure
Check the installation. Check the pump and the other hydraulic components. INTERNAL OIL LEAK IN THE HAMMER The hammer must be serviced in an authorized Rammer service shop. EXCESSIVE BACK PRESSURE IN RETURN LINE Check the installation. Check the size of the return line.
Page 68: Further Assistance
LUBRICATION DEVICE IS WORKING (WHILE THE GREASE HOSE IS DISCONNECTED) ■ Leak in hammer lubrication channel. The hammer must be serviced in an authorized Rammer service shop. ■ Hammer lubrication channel is blocked. The hammer must be serviced in an authorized Rammer service shop.
Page 70: Hammer Specifications
Hammer specifications 2155E STD 1. HAMMER SPECIFICATIONS 1.1 TECHNICAL SPECIFICATIONS Item Specification 1240 kg (2734 lb) Minimum working weight Hammer weight 1040 kg (2293 lb) 490...780 bpm Impact rate 140...160 bar (2030...2320 psi) Operating pressure 220 bar (3190 psi) Pressure relief, min...
Page 72: Mounting Bracket Specifications
Hammer specifications 2155E STD 1.3 MOUNTING BRACKET SPECIFICATIONS R040238 Item Specification Bottom plate, recommended minimum 25 mm (0.98 in) thickness (X) Side plate, recommended minimum 25 mm (0.98 in) thickness (Y) Note: After welding, check the flatness of the plate and mill surface as needed.
Page 73: Rd3 Technical Specifications
2155E STD Hammer specifications 1.4 RD3 TECHNICAL SPECIFICATIONS R040252 Item Specification Battery type Primary lithium, built-in, encapsulated Temperature, operating -20...85 °C (-4...185 °F) Temperature, storage -40...85 °C (-40...185 °F) Antenna, GPS Internal Antenna, 3G/GSM Internal IP rating IP69k UN3091 Lithium content 2.0 grams...
Page 74: Tool Specifications
Tool specifications 2155E STD 2. TOOL SPECIFICATIONS R040269 Tool Part no. Length Weight Diameter Chisel (A) 1050 mm 82.7 kg (182 118 mm (41.34 in) (4.65 in) Moil point (B) 1050 mm 82.7 kg (182 118 mm (41.34 in) (4.65 in)
Page 75: Ce Mark And Ec Declaration Of Conformity
(Directive 2006/42/EC, Annex II. 1. A; Directive 2000/14/EC) Manufacturer: Sandvik Mining and Construction Oy, Breakers Lahti Address: Taivalkatu 8, FI-15170 Lahti, Finland Herewith declares that the Rammer hydraulic hammer Model: 2155E Is in conformity with all the relevant provisions of the Machinery Directive 2006/42/EC.
Page 76: Important Information Concerning The Remote Monitoring Device And Data
3.1 IMPORTANT INFORMATION CONCERNING THE REMOTE MONITORING DEVICE AND DATA PRIVACY Important notice: This 2155E Hereinafter referred to as the "Product", is equipped with a remote monitoring service device which collects location data and data of usage of the Product (including remote monitoring hardware and software installed, connected, and activated by Sandvik at the factory or otherwise) in order for Sandvik to (i) provide you and Sandvik's distributor/sub-distributor(s) involved in the sale of the Product ("Distributors") with the availability...
Page 80 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 27-40-14133-45-20-49 30-40-14133-24-120-49...

RAMMER 2155E Operator's Manual

Operation

Lubrication

Maintenance

Specifications

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