BRH 625 Manual

Transcription

BRH 625 Manual

BRH 625 Manual
Parts, Safety, Operation
& Maintenance
Form No. M1078-POMS
Revision 0
April 2002
Page 1
BRH 625
TABLE OF CONTENTS
INTRODUCTION
TABLE OF CONTENTS
1
2
I MAIN DATA
I-1 Overall dimensions
I-2 Technical specifications
3
3
4
II MAINTENANCE INSTRUCTIONS
II-1 Mounting tool and pin
II-2 Lubrication
II-3 Tool retainers
II-4 Tool bushing and front guide wear parameters
II-5 Side-rods
II-6 Screw Tightening
II-7 Accumulator
II-8 Storage
II-9 Underwater working
II-10 Roof scaling
II-11 Sound proof cradle
5
5
6
7
8
9
9
10
10
11
12
12
III OPERATING INSTRUCTIONS
III-1 Cold weather starting
III-2 How to obtain maximum productivity and long life
III-3 How a demolition tool cracks rock and concrete
III-4 Cause and effect of fatigue
III-5 Demolition tool fatigue failure
III-6 Typical failures
III-7 TRAMAC demolition tool guide
14
14
14
15
15
17
18
18
IV HAMMER TEST
20
V SAFETY PRECAUTIONS
21
PARTS LIST
ACCUMULATOR
GREASING FLANGE ASSEMBLY
SOUND PROOF CRADLE
P3
P6
P7
P8
TROUBLE SHOOTING
DISASSEMBLY
INSPECTION OF BACKHEAD AND DISTRIBUTION PARTS
INSPECTION OF FRONT GUIDE AND CRADLE
INSPECTION AND SERVICE OF THE ACCUMULATOR
CHARGING OF THE ACCUMULATOR
ASSEMBLY
M1
M4
M13
M24
M30
M35
M40
Page 2
BRH 625
MAIN DATA
I MAIN DATA
I - 1 Overall dimensions
Original measurements are in
Inch figures are rounded
mm.
values
Page 3
BRH 625
MAIN DATA
I - 2 Technical specifications
Impact class
Blows per minute
Oil supply *
Operating pressure
Max. Back pressure
Working weight
Height
Shock dampener in hydraulic circuit
Shock absorber bracket
Automatic cut-off
Tool diameter
2500 ft - lbs
860
34 gpm
1700 psi
45 psi
2200 lbs
79 in
Yes
Yes
Yes
4.65 in
The 34 gpm oil supply is the maximum oil flow setting allowed on this hammer. The BRH 625 hammer can be used with carriers providing lower oil
flows (in the 21 to 34 gpm range), but will produce lower blow rates.
However, the back-head low-pressure valve has been specially designed to
maintain the same working pressure whatever the oil flow supply [see II-5].
Tool references
Standard moil point
Long moil point
Chisel
Blunt
Maximum temperature
Dimension
39 in
50 in
39 in
39 in
hammer
175 ºF
P/N
78509
78510
78511
78515
excavator tank
160 ºF
Oil temperature plays an important role as excessively hot oil increases
internal leakage [which lowers efficiency] and deteriorates the piston seals
and the accumulator diaphragm.
Page 4
BRH 625 MAINTENANCE INSTRUCTIONS
II MAINTENANCE INSTRUCTIONS
The life of a tool is determinated by its operating time. The hour-meter of your excavator will not
produce an accurate measurement of the hammer operating time. Travelling and boom positioning
are excavator functions that consume a lot of time but do not involve actual hammer operating time.
II-1 Mounting tool and pin
When taking delivery of your new hammer, spend just a few minutes to familiarize yourself with the
tool changing procedure.
III-1.1 To insert a tool
a> Insert the tool [rep. 72] into the front guide. Make sure that the two flat edges are well positioned
in order to insert the retaining pins.
b> Insert the two retaining pins [rep. 53] and put the shutters [55] back.
c> insert the two pins [rep. 54] in order to lock the shutters.
d> Always check the o'rings [rep. 53] inside the shutters. The pins [rep. 54] must not be moving
freely. If the case, replace the o'rings.
Before inserting a new tool inside the hammer, make sure the shank of the
tool, the bushing, and the two retaining pins are hand-greased [as a grease,
we recommend the use of TRAMAC BRH7].
55
56
53
54
72
Page 5
II-1.2 To remove a tool
a> Use a screw-driver to drive out the pin [rep. 54 - see previous page] from hole A.
b> Using a long screw-driver in hole B, push out the retaining pin [rep. 53 - see previous page] and
the shutter [rep. 55 - see previous page].
When removing the tool, take care not to drop the tool on sharp objects, or polished surfaces may be damaged permanently.
II-2 Lubrication
Proper lubrication is essential for the efficiency of the BRH 625 hammer. It will lengthen of the life of the hammer since it considerably reduces the frictions between the bushings and the tool. The use of the automatic
lube station promotes a complete distribution of the lubricant through out the bushings.
However, this should not prevent the operator from hand-lubricating the tool before
inserting it and performing frequent visual inspections to insure that the point is
wet.
Before inserting the tool [rep. 72] inside the hammer, hand-lubricate
the shank of the tool, the bushing, and the two tool-retainers. As lubricant, we recommend the use of TRAMAC P11 oil lubricant.
A properly lubricated hammer will show some grease running down the point :
Keep the tool wet all the time.
Page 6
II-3 Tool retainers
Examine the retaining pins [rep. 53] 2 or 3 times a week. Change them
when they show signs of heavy wear (like becoming oval shaped or
showing big cracks) or when any portion of the grooves have disappeared (if not, lubrication can be impaired, leading to high frictions
between the tool and the pins and, possibly, to the tool failure [see IV7.6]).
When removing retaining pins, wear should be checked to decide if they should be turned over or not prior
inserting in the front guide. In normal working conditions, the pins will show marks which correspond to the
impact of the upper round shoulder of the tool flat section. When controlling pins, two cases may arise :
]
Hollow shape
a> Hollow shaped deformation without any bump
around the mark. Pin can be turned over by 180º to
lengthen life time.
View F
F
Page 7
Bump
b> Hollow shaped deformation shows peripheral
bump more particularly located on round part of pin.
View G
G
It is imperative to eliminate the bump by grinding prior turning the pin over 180
degrees.
Deep and irreversible damages may result from ignoring the above mentioned recommendations and lead to forfeiture of warranty.
II-4 Tool bushing and front guide wear parameters
TRAMAC BRH 625 features replaceable chuck-bushings [rep. 50 & 52]. The bushings and front guide must
be regularly checked for wear. Excess wear will cause
misalignment between the tool and the striking piston.
Thus, the impact will generate stress contractions
detrimental to the striking faces.
The chuck-bushings are grooved in such a way as to provide perfect lubrication of
the tool : When any portion of these grooves has disappeared, consult your TRAMAC dealer for part replacement.
Page 8
II-5 Side-rods
Daily, inspect the side rods [rep. 58] for possible breakage or loosening
by tapping on each rod with a metal object. You will notice if a rod is broken by its particular sound.
Daily, check for loose tie rods. Consult your TRAMAC dealer for the tie rod tightening procedure. It is a very sensitive undertaking and incorrect methods can result
in serious consequences. Your TRAMAC dealer knows the torque specifications
and will assist you in tightening the tie rods.
II-6 Screws tightness
II-6.1 Bracket cap bolts [upper suspension bolts [rep. 405]
Check these 12 screws [rep. 69] and nuts [rep. 71]
for tightness :
o 30 minutes after having put the hammer into
operation for the first time,o then weekly.
The proper torque is 380 ft-lbs.
II-6.2 Suspension screws
Every 500 hours, check the two lower suspensions screws [65] for tightness. The
proper torque is 290 ft-lbs.
Page 9
II-6.3 Accumulator fixing screws
Every 500 hours, check the 18 accumulator fixing screws [rep. 6] for tightness. The
proper torque is 470 ft-lbs.
II-6.4 Greasing flange screws [rep. 128]
Every 500 hours, check these screws [rep. 40]. The proper torque is 288 ft-lbs.
II-7 Accumulator
TRAMAC accumulators [rep. 3] should stay charged for at least one operating year. In normal operation, the
two hammer hoses vibrate lightly; but when the accumulator is discharged, the hoses will jump violently. You
will also note a power loss as the hammer will continue to fire, but will have no force.
Report this immediately to your TRAMAC dealer.
Check nitrogen pressure with test gauge P/N 21006 and, if necessary, recharge with charging fixture P/N
51347.
Accumulator pressure
Accumulator tightening screw [rep 4] torque
530 psi
145 ft.lbs
TRAMAC accumulators do not loose their charge through leakage. A TRAMAC
accumulator consists of two flanges between which is held a diaphragm (reassembling a pie plate). The only time a TRAMAC accumulator will loose its charge will be
when this diaphragm becomes perforated.
Never try to open the accumulator without discharging previously the pressure
through the inflating screw.
II-8 Storage
Put the appropriate plugs on the hammer and excavator couplings, to avoid any oil leakage and dust penetration. Put the breaker away under cover in a clean place. Lubricate with grease the visible part of the piston
and the entire tool to avoid damage from rust.
Page 10
Remember, a corroded piston destroys its seals in a few minutes.This operation
can't be overlooked in case of underwater work, and in particular, in the case of sea
water,
II-9 Underwater working
The TRAMAC BRH 625 model in the standard version must
not be used for underwater work, even for very short periods
of time. If the chamber between the piston and the tool fills
with water when the piston strikes, the water will not be
evacuated fast enough and a considerable pressure rise will
then occur which will destroy the piston seal (with a risk of
seizure).
Page 11
For underwater operation, the ball [rep. 4] and the spring [rep. 5] included in the lubrication flange must be
eliminated and the flange connected to an air compressor. Pressure from the compressor must be at least 22
psi above the water pressure at the working depth.
II-10 Roof scaling
When working upwards, it is imperative to pressurize the front guide of the BRH 625 in order to avoid the
penetration of abrasive dust [see III-9 for the removing of parts 4 & 5]. In addition, the standard upper bushing [rep. 50] must be replaced by a specially designed upper-bushing [rep. 51] which provides enlarged air
passages.
II-11 Sound proof cradle
The BRH 625 model in the standard version can easily be converted in the sound proofed version for work
being completed in an urban environment requiring the lowest possible level of noise.
Page 12
Please, contact your TRAMAC dealer for more information about this option. When
the hammer is equipped with the soundproof arrangement, care must be taken to
observe warnings and recommendations, particularly in the maintenance of parts
involving sound proofing materials, some of which are flammable.
Page 13
BRH 625
TIONS
OPERATING INSTRUC-
III OPERATING INSTRUCTIONS
III-1 Cold weather starting
Start up the excavator and circulate the hydraulic oil to warm
it up before starting the hammer. When oil is warm, raise the
hammer from ground, idle the the engine and energize the
hammer control valve. The oil will pass through the hammer
but the hammer will not fire. Run this way for 5 to 10 minutes;
this will warm up the hammer parts. In below zero temperatures, we suggest the tool be stored in a warm shed at night.
Extreme cold can crack the point when you start the breaking
operation.
III-2 How to obtain maximum productivity and long life
TRAMAC working tools are made from a special steel far superior to any tool steel commercially
available. Unlike other tools on the market, our steel is hardened all the way through - no thin shell
of hard steel which wears quickly. When the tools lose their edge, either at the tip or on the sides, it
is possible to sharpen them without repeating heat treatment, using one of the following methods :
A> With a milling or planning machine for chisels and cutters, or with a lathe for the
moils and chisels. These operations must be completed using the adequate type of hard metal tool.
B> By sharpening : this operation must be performed using a coolant, in order not to
overheat the tool to be maintained.
As a general rule, never let the tool cool quickly or suddenly, even when it is
used with the breaker.
The fact of dipping a tool into water when it has been heated in the course of work, or leaving it in
the snow in winter, results in a quenching effect on the tip or cutting bit, and this increases the risk
of breakage.
Page 14
BRH 625
TIONS
OPERATING INSTRUC-
Tools are covered by TRAMAC against metal defects (very uncommon). It is not
unusual that some operations (working at angles, blank firing, ...) lead to tool breakage, including inside the chuck housing.The use of after market tools will void your
warranty for any claim related to parts in contact with the tool (which includes the
main piston).
Learning to run a hammer properly is not difficult. It takes a little time and just plain common sense. To preserve the life of the tool and obtain maximum hammer productivity, we urge you to read the following.
III-3 How a demolition tool cracks rock and concrete
When the hammer piston strikes the top of a demolition tool, it sends a compressive stress wave down to the
working end of the tool. Provided the demolition tool is in contact with the rock or concrete which requires
breaking, it is this compressive stress wave which fractures the rock. Then, immediately following the compressive wave, a tensile stress wave is formed due to the hammer piston lifting from the top of the demolition
tool.
The cycle of compressive and tensile stresses flowing down the tool is repeated for each hammer blow.
Obviously, anything that interferes with the strength of the compressive stress wave during service, for example "Blank Firing" or bending of the demolition tool due to leverage, will result in loss of breaker efficiency of
up to 80 % and possible failure of the tool itself.
III-4 Cause and effect of fatigue
III-4.1 Correct operating conditions
The continuous cycle of compressive and tensile stresses in the demolition tool, even under correct operating conditions, creates fatigue stress in the tool which can lead to the fatigue failure of the tool before it is
worn out. Anything which interferes with the cycle of compressive and tensile stresses will also increase the
level of fatigue stress being applied to the demolition tool and, thus, increases the risk of early fatigue failure
of the tool.
Page 15
BRH 625
TIONS
OPERATING INSTRUC-
The main cause of increased fatigue stress in a demolition tool is
any form of side pressure during service which creates bending.
Thus, utilizing the tool as a lever, using an incorrect driving angle
or attempting to break ground using the pull of the excavator are
all detrimental to the life of a demolition tool and should be avoided [see figure].
The hydraulic power available in the machine far exceeds the strength of a demolition tool if it is used incorrectly and can "snap the tool like a carrot".
III-4.2 Other causes of increased fatigue stress in a demolition tool include :
A> Free running ( or Blank firing)
Free running occurs when the hammer piston strikes the top of the demolition tool when the working end is
not in proper contact with the rock or concrete to be broken. This includes jobs where the tool slides off the
work and also when break-through of thin concrete slabs or boulders occurs.
B> Cold :
Low temperatures cause a demolition tool to be more susceptible to fatigue failure. Tools should be warmed
before use.
C> Mechanical and thermal damage :
Any form of damage to the surface of a demolition tool renders it more liable to suffer fatigue failure. Thus, all
care must be exercised to prevent scratches, gouges or weld marks occurring due to accidental damage,
galling caused by contact between the tool and chuck bushing trough the lack of lubrication or excessive
bending.
D> Lubrication :
Care must be taken to avoid metal to metal contact that, as a result of galling, could cause deep damage
marks which, in turn, may lead to the formation of fatigue cracks and eventually failure of the demolition tool.
Make sure that the shank of the demolition tool is well lubricated before linserting it into the hammer.
Page 16
BRH 625
TIONS
OPERATING INSTRUC-
E> Corrosion :
A rusty demolition tool is more likely to suffer fatigue failure. Keep tools well greased and sheltered from the
weather when not in use.
III-5 Demolition tool fatigue failure
Demolition tool fatigue failure will occur approximately 4 inches either side of the chuck front face [see figure]
or through the retainer pin flat. Another slightly less common failure area can fall approximately 8 inches
from the working end, subject to the nature of use. The fracture face itself will normally exhibit semi-circular
polished area with the remainder being of rougher appearance (see figure). The polished semi-circular area
is the fatigue area and generally started from a damage mark or other stress initiated on the outside of the
demolition tool and spread inwards.
The fatigue area slowly widens until the stresses being applied to the demolition tool cause sudden failure of
the remaining section. Generally, the size of the fatigue area indicates the level of stress applied to the tool,
i.e. the smaller the fatigue area, the higher the stress level, although it must be borne in mind that once initiation of a fatigue crack has taken place, it requires a lower stress level to cause it to grow.
Page 17
BRH 625
TIONS
OPERATING INSTRUC-
III-6 Typical failures
TRAMAC demolition tools are manufactured from fist class materials and then heat treated to produce a fatigue and wear resistant tool. Thus when a tool has apparently failed to give a satisfactory
service life, a brief visual inspection can often give a quick indication about the cause.
Wear is dictated by the conditions of the material being broken, but, in general, the following guidelines apply:
Blank tools worn more than 1/3 of their diameter, or moils and chisels worn back more than 2
inches from the working end, are classed as reasonable life.
III-7 TRAMAC demolition tool guide
A
B
C
D
E
Ref
Tool type
Application
A
B
C
D
E
F
Moil point
Chisel
In-line chisel
Blunt
In-line asphalt cutter
Spade Frost
Low abrasive, homogenous material
Plastic or heterogeneous material
Plastic or heterogeneous material
Crumbly rock
Asphalt cutter and trenching
Asphalt and trenching
Page 18
F
BRH 625
TIONS
BREAKAGE CHART
OPERATING INSTRUC-
Failure due to blank firing or
excessive wear of bushings
and/or chuck housing.
NO WARRANTY
Failure due to
- operation with worn out
retaining pins,
- blank firing,
- twisting tool.
NO WARRANTY
Fatigue breakage with typical
fatigue wrinkles due to steel
defect.
100% WARRANTY
Typical failure caused by
misalignment between down
pressure, hammer and tool
(prying, levering).
NO WARRANTY
Breakage due to improper
contact between the tool's
tip and rock or concrete.
NO WARRANTY
Mushrooming or fast wearing
caused by operating too long
on the same spot.
NO WARRANTY
Page 19
BRH 625 HAMMER TEST
IV HAMMER TEST
3/8" x 12' Hose
Gauge 0-3000 psi
Steel plate 1"min
or hard rock
Measurement of the high pressure setting
For normal day to day work, TRAMAC's BRH 625 hammer has been preadjusted in manufacturing to obtain 1700 psi at 34 gpm for an oil temperature
of 110 ºF on a moderately hard ground.
MAX FLOW RATE
MAX WORKING PRESSURE
MAX BACK PRESSURE
34 GPM
1700 PSI
45 PSI
Page 20
BRH 625 SAFETY PRECAUTIONS
V SAFETY PRECAUTIONS
1
2
3
4
Never use the hammer as a lifting device
Stay clear of hammer while in operation, flying objects can
cause severe injures, even death.
Be sure decals are clearly visible. Clean or replace as
necessary.
Activate the hammer only when the operator is seated in the
cabin with full-control of the machine.
5
Do not make any alterations to the hammer without
authorization from Tramac Product Support department.
6 Use only Tramac replacement parts.
7 The major hammer components are heavy. Take safety
precautions when handling.
8 When installing or removing hammer, keep hands and fingers
clear of mounting pin holes and linkage. Instruct operator to
touch controls only when signaled.
9 Be cautious of possible flying metal particles when striking
any hardened surfaces with a hand tool. Wear safety glasses
when performing such activities.
10 Wear ear protection if conditions warrant. Consult OSHA
regulations.
11 Use hammer for its intended purpose only.
Page 21
BRH 625
This Page Left Blank Intentionally
Cette Page est Laissée Blanche Intentionnellement
Page 22
BRH 625
PARTS MANUAL
Form No. M1078-P
Revision 0
April 2002
Page P1
BRH 625
Page P2
PARTS LIST
BRH 625
Rep
Qty
1
3
4
5
6
1
1
1
1
8
Back Head ass'y, composed of :
- Accumulator ass'y
- Ring
- O'ring
- Disk
- Screw
23947
18652
33616
77227
78508
7
1
8
1
1
2
Bach Head ass'y, composed of :
- Back head including
Insert thread
Sleeve
Rush
- O'ring
78499
21910
80664
10380
23992
1
1
6
1
1
1
Rotating connections
Low pressure
- Valve
- Spring
- Washer
- Pin
- O'ring
- Plug
80665
74258
67293
74240
71817
71828
8
9
10
11
12
13
14
15
16
Designation
PARTS LIST
High pressure
17
18
19
20
21
1
1
1
1
1
Oil supply
22
23
2
4
24
25
26
27
28
29
30
31
32
33
34
35
1
1
1
11
1
4
1
1
1
1
1
1
36
37
38
39
40
1
2
2
1
1
-
Spring
Valve
Seal
O'ring
Plug
- Knee piece
- O'ring
Distribution ass'y, composed of :
- Lower piston
- Upper piston
- Distribution
- O'ring
- O'ring
- O'ring
- Pin
Part number
79730
71830
80250
71817
71828
56047
5346
- Plunger
- Distributor
- O'ring
- Distributor cover
- Valve
62287
62288
54273
9649
23131
10050
51806
62289
54275
13006
54277
51808
Cylinder ass'y, composed of :
- Cylinder
- Pin
- Valve
- Valve spring ass'y
- Oiler flange ass'y
62286
42221
51803
51991
74716
Page P3
BRH 625
Page P4
PARTS LIST
BRH 625
PARTS LIST
Rep
Qty
Designation
Part number
42
43
44
45
46
47
48
1
1
1
2
1
1
1
Spacer ass'y, composed of :
- Spacer
- Tight ring
- O'ring
- Tight seal
- Bearing washer
- Diaphragm
- Accumulator body
62290
51933
52204
54279
54280
54281
54282
49
50
51
52
53
54
55
56
57
1
1
or
1
2
2
2
4
1
Front guide ass'y, composed of :
- Front-guide
- Upper chuck bushing (standard)
- Upper chuck bushing (for roof scaling)
- Lower chuck bushing
- Retaining pin
- Lock pin
- Pin shutter including :
O'ring
- Plastic plug
78244
78226
78790
78333
73571
57842
57844
5353
75555
58
59
60
4
4
1
Assembling parts :
- Side-rods
- Nuts
- Pin
64506
52027
71848
64
65
66
67
2
4
8
1
Cradle suspension
- Lower suspension
- Screw
- Disk lock washer
- Shock-absorber
78361
73505
51742
78365
68
69
70
71
1
12
48
12
Standard cradle
- Standard cradle
- Screw
- Disk lock washer
- Nut
78358
60180
51742
54968
Page P5
BRH 625
BRH 625
ACCUMULATOR
Accumulator HP
Tighten Bolts to 140 ft-lbs
Item
1
2
3
4
5
6
7
Page P6
Part Number
23947
23948
17639
26599
65385
26428
14826
36306
Qty.
1
1
1
16
1
1
16
DESCRIPTION
Accumulator ass'y, composed of :
(Lower flange
(Diaphragm
(Upper flange
(Screw CHc
(Inflating screw
(Tight ring
(Plug
BRH 625 GREASING FLANGE
ASSEMBLY
Item
1
2
3
4*
5*
6
7
8*
Part Number
74716
74718
74719
74725
3521
9213
73505
51742
5330
Qty.
1
1
1
1
1
2
4
1
DESCRIPTION
CHUCK HOUSING:
Greasing flange assembly :
(Support plate
(Pin
(Locking plate
(Ball
(Spring
(Screws
(Washers
(O-ring
(* - these items are included in the seal kit PN 75464)
59735
73571
57842
5353
75464
78509
1
2
2
8
1
1
Seal kit
Tool retainers
Lock pins
O'rings
Grease flange spare kit
Spare tool
Page P7
BRH 625 SOUND PROOF CRADLE
Item
1
2
3
4
5
6
7
8
9
10
11
Page P8
Part Number
78781
26241
78784
78786
60165
51742
60180
78791
51742
54986
78789
78788
Qty.
1
12
1
1
12
24
8
4
24
12
1
1
DESCRIPTION
Sound proof cradle including:
(Helicoils - 3/4” UNF
LP cover
HPcover
Screw
Washer
Screw
Screw
Washer
Nut
Locking plate
Lube cover
BRH 625
TROUBLE SHOOTING
TROUBLES SHOOTING … REMEDIES
A - Oil leakage on hammer.
PANNES POSSIBLES … REMÉDES
A - Fulte d'hulle au niveau du marteau.
Damaged or worn seals.
Call your TRAMAC distributor.
Joints d'étanchéité endommagés ou usés.
Consultez votre distributeur TRAMAC le plus
proche.
B - The breaker loses power; high vibrations in
breaker hoses.
B - Le marteau manque de puissance, les flexibles
de raccordement battent.
The accumulator is deflated or diaphragm
punctured. Check the oil temperature.
If oil is too hot, ask a technician to check the
breaker circuit relief valve setting.
Call your TRAMAC distributor.
L'accumulateur est dégonflé, la membrane de
I'accumulateur est percée. Vérifier la température
de I'huile. En cas d'échauffement important, faire
vérifier par un technicien, le réglage des clapets de
décharge du circuit de pelle. Consultez votre
distributeur TRAMAC le plus proche.
C - The hammer operates normally, then slows
down and stops. A few minutes later the hammer
will start again then stop again.
C - Le marteau fonctionne normalement puis la
cadence ralentit et le marteau s'arrêite. Quelque
temps après le marteau redémarre puis s'arrête.
Hydraulic oil is too hot.
Excavator circuit must be checked for heat source.
If necessary reduce the breaker operating pressure.
L'huile hydraulique est trop chaude.
Le porteur doit être vérifié pour trouver l'origine de
l'échauffement. Si nécessaire réduire la pression de
frappe du marteau.
D - One side rod bolt has broken.
D - Un tirant d'assemblage est cassé.
Stop working immediately and call your TRAMAC
distributor.
Arrdter le travail immédiatement.
Consultez votre distributeur TRAMAC le plus
proche.
E - After connection to carrier, the breaker operates
for few blows then stops.
E - Après adaptation au porteur, le marteau tape
quelques coups puis s'arrête.
The return hose is plugged, check the quick coupling seat (if installed).
Le flexible retour est bouché, vérifier le coupleur (si
montée).
Recommendation: Check oil temperature and
settings of carrier relief valves. If relief valve is not
adjusted properly, oil may heat up quicker due to
the high total power of rock breaker. This will cause
the rock breaker to perform poorly.
Recommandation: Le brise roche ayant une puissance globale élevée, veiller au bon refroidissement
de I'huile. Un mauvals réglage du clapet de surpression du porteur peut être la cause d'un échauffement important de I'huile entrainant un mauvais
fonctionnement du brise roche.
Page M1
BRH 625
TROUBLE SHOOTING
TECHNICAL PROBLEMS
Before looking for a hammer problem, look for a problem in the installation, like bad quick couplers or a
plugged filter [see page M3 for how to check the installation].
Make sure that the hammer has not been hooked up backwards.
Make sure that the hammer has the proper tool.
Make sure that the down pressure has been applied.
Make sure that no valve(s) are closed.
For any other problem, refer to the Trouble Shooting page M1. If you cannot identify the problem, BEFORE
calling your TRAMAC dealer, collect the following information. A complete diagnosis cannot be done without
it.
A.
B.
C.
D.
Flow rate in high pressure line running to the hammer at operating temperature and operating pressure.
Value of high pressure at hammer inlet when hammer is operating (use a 0-3000 psi gauge).
Value of back pressure in return line (use a 0-160 psi gauge).
Setting of relief valve in the system. For more details, please refer to page M3.
Low Pressure Gauge 0-160 Psi
Return and Supply Lines (Same Size as Breaker)
Flow Meter
Flow Scale
Oil Temperature Gauge
Pressure Gauge
Page M2
Needle Valve
BRH 625
TROUBLE SHOOTING
How to check hydraulic circuit and installation
Mount a flow meter in place of the hammer. Also, mount a low pressure (0-160 psi) gauge on the outlet of
the flow meter in order to test the back pressure in the return circuit
With the flow meter in place, activate the circuit and bring the machine up to operating temperature; do not
test the machine cold.
If the control valve is equipped with solenoid, switch on the solenoid before starting the engine to avoid
damage to the flow meter. Do not switch on or off the solenoid when the engine is running. Adjust the flow
output to match the requirements of the BRH 625 - see table on page 20.
After the flow has been adjusted, load the flow meter to the hammer operating pressure value (see table on
page 20) plus 400 psi, and readjust the flow if necessary to keep the hammer flow value constant for pressure varying between 1000 psi and hammer operating pressure value (see table on page 20) plus 400 psi.
Relief valve problems
If you cannot reach the proper oil flow at the hammer operating pressure value plus 400 psi, you may have a
bad system relief setting or a bad hammer control valve.
To check system relief valve see excavator manual for proper relief setting. Build pressure with flow meter to
determine relief cracking pressure (usually 50 to 100 psi below relief setting). Reset relief if needed.
There should be 400 to 500 psi between hammer regulated pressure value and system cracking pressure or
heat may develop.
Pump problems
If you cannot produce proper oil flow against pressure varying from 500 psi to hammer operating pressure
plus 400 psi, the pump could be bad or there is excessive leakage in the circuit.
Hammer control valve problems
If relief valve and pump are good, open and close valve three or four times: The valve spool may be sticking
or back pressure is developing on return line.
With the flow adjusted and the flow meter loaded to hammer operating pressure value plus 400 psi, take
note of the low pressure gauge reading.
The return pressure should be less than 45 psi. If the back pressure is more than 45 psi, the restriction causing this higher pressure must be found and eliminated.
After the flow meter test is completed, disconnect the flow meter and connect the hoses to the hammer.
Mount a high pressure gauge (0-3000 psi) on the hammer HP line and take the machine outside. Run the
hammer on a heavy 3 inch by 40 inch by 40 inch steel plate on hard ground and take note of the pressure
reading. Call your TRAMAC dealer if pressure adjustments are needed.
Page M3
BRH 625
DISASSEMBLY
First, remove the point from the hammer by :
o Pushing out the 2 stop pins (o 54) with a screwdriver or a
steel rod (hole A).
o Pushing out the 2 pin shutters (o 55) and the tool retainers (o 53 with a screw driver or a steel rod (hole B).
o Pulling out the tool (o 72).
Remove the greasing flange (o 40) by unscrewing the 2 bolts
(o 41-6).
Unscrew the attaching bolts (o 69) between the bracket cap
and the cradle. Remove the bracket cap.
Page M4
BRH 625
DISASSEMBLY
Remove the suspension plate (o 67).
Pull out the hammer from its cradle ( 68).
Make sure that the hammer is safely
secured when proceeding.
Drive both tool retainers (o 53) half-way inside the frontguide (o 49).
Install the hammer in the service box. Make sure that both
tool retainers (o 53) rest on the floor.
Page M5
BRH 625
DISASSEMBLY
Use a 3/4 " hexagonal socket to unscrew the 8 bolts (o 6).
Remove these bolts (o 6), the accumulator disk (o 5), the
accumulator (o 1), the o'ring (o 4) and the back-up ring (o 3).
To make it easier to handle the accumulator (o
1), screw in 2 bolts (o 6) by hand.
Unscrew and remove the HP plug (o 21) with a 1 1/2 "
wrench. Then, remove the slide (o 18), the spring (o 17) and
the seals (o 19 & 20).
Remove the HP swivel (o 22) and the 2 o'rings (o 23).
Never use a steel hammer to drive out the
swivel. You may permanently damage its
seat on the back-head.
Page M6
BRH 625
DISASSEMBLY
Unscrew and remove the LP plug (o 16) using a 1 1/2 "
wrench. Then, remove the pressure adjustment shims (o 13),
the stop pin (o 14), the spring (o 12), the pressure regulator
slide (o 11) and the o'ring (o 15).
Remove the LP swivel (o 22) and the 2 o'rings (o 23).
Never use a steel hammer to drive out the swivel. You may damage permanently its
seat on the back-head.
Unscrew the 4 side-rods (o 58) using a special wrench (P/N
22775), available from Tramac.
Before unscrewing, mark each side-rod to
reassemble them in the same location. To
unscrew, proceed in X.
Never use an impact wrench.
Page M7
BRH 625
DISASSEMBLY
To drive out the back-head (o 7), use a nylon strip installed between
the 2 swivel seats to lift it while levering between the back-head and the
distribution cover.
Make sure that the back-head stays perfectly
aligned with the hammer when lifting it.
Remove the 2 o'rings (o 10) and lay down the back-head.
Remove the valve (o 35) on top of the distribution parts.
Remove the distribution cover (o 34) and the centering pin (o 30).
Remove the 4 o'rings (o 29).
Page M8
BRH 625
DISASSEMBLY
Pull up the plunger (o 31).
Remove the distributor (o 32). Also, remove the o'ring (o 33)
inside the distributor.
Screw 4 metric bolts [M8 x 50] in the threaded holes on top of
the distribution box (o 26). Progressively tighten these bolts in
order to pull out the distribution box (o 26).
Make sure to keep the distribution cover
perfectly aligned with he cylinder.
Remove the distribution box (o 26) and the o'rings (11 x o 27 and o 28).
Page M9
BRH 625
DISASSEMBLY
Pull up the thrust piston (o 25).
Remove the centering pin (o 37) and the complete valves (o
38 & o 39).
Screw a hook into the lower piston (o 24) (use 3/4" -16
threads).
Pull out the lower piston (o 24).
Always remove the lower piston (o 24) from the cylinder (o
36) before disassembling the cylinder (o 36). If not, you
may permanently damage the lower piston (o 24) seat on
the the bearing washer (o 46).
Page M10
BRH 625
DISASSEMBLY
Screw 2 bolts (o 6) on the side of the cylinder (o 36) to pull off
the cylinder from the spacer (o 42). Remove the o'ring (o 44).
Screw 2 bolts (o 6) onto the side of the spacer (o 42) to pull
off the spacer (o 42) from the front-guide (o 49).
Remove the centering pin (o 37) from the spacer (o 42).
Remove the tight ring (o 43) from the spacer (o 42).
Page M11
BRH 625
DISASSEMBLY
Remove the accumulator body (o 47) and the diaphragm (o
48) from the spacer (o 42).
Remove the bearing washer (o 46) from the spacer (o 42).
Remove the 2 lip seals (o 45) from the spacer (o 42).
Remove the centering pin (o 60) from the front-guide (o 49).
Page M12
BRH 625 INSPECTION OF BACKHEAD AND DISTRIBUTION PARTS
Some parts like the cylinder (# 16), the distributor (# 20) or the plunger (# 21), are protected with an
"Antiseize" black coat. These parts must be cleaned with gasoline only. If not, the protective coat
may be damaged and seizure may occur later.
In case of lapping, always clean and wipe the lapping compound after the operation. Always use fine
grain products. During lapping or grinding, make sure to always turn in the same direction around
the part. Never lap or grind vertically to avoid making longitudinal marks which may induce greater
internal leakage or o'ring failures.
In case a black area ("Antiseize" protection coat) should be polished, always keep the area as small
as possible around the damaged surface. If not, the protection coat will no longer be efficient and
seizure may occur later.
To wipe parts, always use new service rags. If textile fibers remain inside the hammer, they may disturb the operation of the hammer.
Always use TRAMAC genuine seals and o'rings. They are made with high quality elastomers in order
to increase their resistance and to lengthen their life expectancy. Grease the seals and o'rings in
order to facilitate their installation.
Page M13
Before installing any part, always coat it with an oil film. Never hit a part with a
steel tool. Use always either a rubber sledge hammer or a piece of wood
between the part and the hammer.
Plunger (o 31):
Check all surfaces of the plunger (o 31). When
there is only minor damage, just lightly polish the
area. Make sure to always turn in the same direction around the part.
Make sure that the plunger (o 31) slides smoothly into its housing
in the thrust piston (o 25).
Make sure that the plunger (o 31) slides smoothly into its
housing in the distributor (o 32).
Make sure that the plunger (o 31) slides smoothly into its housing in the distribution cover (o 34).
Page M14
When there is minor damage to the plunger housings in the the
thrust piston (o 25), the distributor (o 32) or the distribution
cover (o 34), use a fine grain hone for removing high spots without modifying the inside diameters.
When there is major damage, please contact Tramac Product
Support Department for proper instructions.
Check the seat area between the distribution cover (o 34) and
the valve (o 35).
In case of minor damage, lap with extra-fine compound.
Check the seat area between the distribution cover (o 34) and the backhead (o 7).
When there is damage on the back-head (o 7), remachine this surface.
Make sure to remove less than 0.020 inches.
Over 0.020 inches the back-head is not reusable.
Make sure to keep the surfaces parallel when machining.
When there is damage on the distribution cover, remove the high spots by
grinding slightly with an emery stone.
Page M15
Check the seat of the o'rings (o 29) on the distribution cover (o
34). Use a fine grain emery paper to remove any rubber debris
or smooth any damage.
Check the seat area between the distribution cover (o 34) and
the distributor (o 32).
When there is minor damage, lap with an extra fine compound. To process assemble the 2 parts with the plunger (o
31) to keep the parts properly aligned.
Check the outside surfaces of the distributor (o 32).
Never remove or smooth the V-shape notch on
the distributor (o 32). This is an orifice piloting
the cycling of the hammer.
Page M16
Check the seat area between the thrust piston (o 25) and
the distributor (o 32). If necessary, lap the damaged area
with extra fine compound. To process, assemble the 2
parts with the plunger (o 31) to keep the parts properly
aligned.
Check the outside surface of the thrust piston (o 25).
Check inside and outside surfaces of the distribution box (o 26).
Make sure that there is no high spot on the
area facing the cylinder.
Check the o'ring (o 10) seats on the distribution box (o 26).
Page M17
Make sure that the upper piston slides smoothly into the distribution box (o 26) and that the surfaces of both parts are in
good shape.
Back-head (o 7) :
Check the seats of the side-rods (o 58). In case of damage, lap
with fine compound.
Check and replace if necessary the helicoils.
Check the seats of the HP swivel (o 22) and LP swivel (o
22).
Make sure that the snap-ring holding the sleeve around the
pressure regulator slide (o 11) is properly seated.
Check the threads (where the LP plug (o 16) and the HP
plug (o 21) are screwed in).
Page M18
Check the seat of the accumulator (o 1). If necessary,
remove the high spots.
When there is damage, check with
Tramac Product Support Department for
the proper procedure.
Look for any crack, notch or sharp edge near by the o'ring
grooves and the surfaces facing the distributor box (o 26).
Make sure that the pressure regulator slide (o 11) moves
smoothly into its housing.
Check the threads on the side-rod nuts (o 59). Also, their
seats should be perfectly flat. If not, use the other face, if
never used.
Page M19
Check the threads on the side-rods (o 58). They should be
perfectly smooth.
If not, the complete set of side-rods
should be changed.
Check the seats on the side-rod (o 58)heads. In case of minor damage, lap the high spots.
It is highly recommended to change the complete set of side-rods and nuts after either 1200
hours or 2 years of operation, whichever comes
first.
Make sure that the side-rod nuts (o 59) can be smoothly handscrewed to the side-rods (o 58). If not, the damaged part must
be changed.
Check the surface of the cylinder (o 36) in contact with the distribution box (o 26). If necessary, remove high spots with an extra-fine
emery paper.
Page M20
Check the inside of the cylinder (o 36).
Never grind or lap the black "Anti-seize"
coat inside the cylinder (o 36). When there
is damage, contact Tramac Product
Support Department.
Check the lower face of the cylinder (o 36), in contact with
the spacer (o 42). The surface should be perfectly smooth.
If necessary, remove high spots.
Check all faces of the lower piston (o 24). When there is damage, contact
Tramac Product Support Department.
Check the striking face at the base of the lower iston (o 24).
The overall length of the piston should not be less than
23.444 " [595.5 mm]. If less, the piston must be
changed.
Page M21
When there is damage, on both lower piston (o 24) and cylinder (o 36), these parts
can be exchanged for factory remanufactured parts. Consult Tramac Parts
Department for availability.
Check the top suspension (o 67). If necessary, use a
grinder to smooth the accumulator disk (o 5) seat.
Check the side of the shock-absorber on the top suspension (o 67). Make sure that the shock-absorber grips properly to its support steel plate.
Check the accumulator disk (o 5). Make sure that the bolt
seats are smooth. If necessary, polish but never remove
more than 0.020 ".
Page M22
Make sure that the contact area between the accumulator disk
(o 5) and the accumulator (o 1) is perfecty smooth and flat.
Check the accumulator body (o 47) for any damage or cracks.
Make sure that the groove where the diaphragm (o 48) seats
does not show evidence of damage.
Check the bearing washer (o 46).
Page M23
BRH 625 INSPECTION OF FRONT
GUIDE AND CRADLE
Check the wear on the upper bushing (o 50).
The bushing must be replaced whenever
the gap between the bushing and a new
tool exceeds 3/16 '' [5 mm].
Check the seat of the tool in the upper bushing (o 50). To measure, install a new tool and push it as far as possible into the
front-guide. Then, measure the dimension X as shown on the
drawing. This dimension should not exceed 1.024 in. [26 mm]. If
it does, the upper bushing (o 50) should be replaced.
Page M24
GUIDE AND CRADLE
Check the wear on the lower bushing (o 52);
The bushing must be replaced whenever
the gap between the bushing and a new
tool exceeds 3/16 '' [5 mm].
Check the side-rod nuts (o 59) seats on the front-guide (o 49).
The nut must be in full contact with its seat.
If a seat is damaged, it must be remachined.
Never remove more than 0.020 " (or 0.5 mm)
in thickness.
Check the tool retainers (o 53) seats in the front-guide (o 49).
Check the seat of the spacer (o 42) on the front-guide (o 49),
When there is damage or wear, no matter
how minor, the surfaces must be remachined.
Page M25
GUIDE AND CRADLE
Check the seat of the front-guide (o 49) and the upper bushing (o 50)
on the spacer (o 42).
When there is damage or wear, no matter how
minor, the surfaces must be remachined.
Check the seat of the cylinder (o 36) on the spacer (o 42).
In case of damage or wear, even minor, the surfaces must be remachined.
It is essential to keep a perfect alignement between the
cylinder (o 36), the spacer (o 42) and the front-guide (o
49).
Make sure to carefully examined each of the faces in
contact.
When there is a damage, no matter how minor, the surfaces must be remachined.
Refer to the Service Bulletin 9006-02 for the proper
dimensions.
Page M26
GUIDE AND CRADLE
Check the seat of the spacer (o 42) on the front-guide (o 49).
When there is damage or wear, no matter
how minor, the surfaces must be remachined.
Check the seat of the side-rod nuts (o 59) on the front-guide (o 49).
In case of damage or wear, even minor, the surfaces must be remachined.
Cradle: Check the cradle (o 68) for cracks.
Make sure that the upper face of the cradle (o 68) is perfectly flat.
Page M27
GUIDE AND CRADLE
Check the 2 lower suspensions (o 64).
Check the 4 lower suspension bolts (o 65).
Check the tool lock assembly including :
o the 2 stop pins (o 54),
o the 8 o'rings (o 56),
o the 2 pin shutters (o 55),
o the 2 tool retainers (o 53).
Check also the housing of the stop pins (o 54) in the cradle.
Check the wear of the holes in the pin shutters (o 55). Measure by mounting the 2 o'rings (o 56) in the pin shutters (o 55) and checking that the stop
pins (o 54) are properly handled by the o'rings. If not, change the defective
pin shutters (o 55).
Page M28
GUIDE AND CRADLE
Check the tool retainers (o 53) for wear.
It is imperative to eliminate the wear marks before
turning the pin over 180 degrees.
Page M29
BRH 625 INSPECTION AND SERVICE OF THE ACCUMULATOR
Never try to open the accumulator without first discharging the pressure through the inflating screw
(#1-5).
Clean the special syringe tool and suck in clean diesel
fuel until the syringe is completely full without air bubble. Push the syringe into the central hole in the accumulator grid and press in normal manner (around 45 lbs
thrust). When the oil pressure in the syringe reaches
the nitrogen pressure, the diaphragm will move away
from the grid, the oil will run out from the syringe and
will flush out of the other holes of the grid. The pressure
in the accumulator is then indicated by the pressure
gauge.
Page M30
Note : If the checking is performed on a stocked accumulator, or if the hydraulic hammer has not been working for a certain time, the value read off the gauge may be higher than that advised. In such case, the
diaphragm may have remained glued to the grid or may have hardened, which results in supplementary
resistance. The accumulator can, however, be used as such.
If the value is lower than advertised, it is time to repair the accumulator.
Check the area of the accumulator lower flange (o 1-1) in
contact with the back-head (o 7).
Check the area of the accumulator lower flange (o 1-1) in
contact with the o'ring (o 4) and its back-up ring (o 3).
When there is damage, no matter how
minor, both surfaces must be remachined
while keeping the same distance between
them.
Disassembling of the accumulator:
Unscrew the inflating screw (o 1-5) by 3 complete
turns, then make sure that the nitrogen pressure is
fully release before pursuing.
Page M31
Install 2 bolts 3/4 x 7" into 2 opposite holes where the bolts (o 6)
go. Grip these bolts with a bench-vice to fix the accumulator.
Unscrew the inflating screw (o 1-5) to release the pressure inside
the accumulator. Remove the inflating screw (o 1-5) and the tight
ring (o 1-6).
Unscrew and remove the 16 bolts (o 1-4) using a 5/8 " hexagonal
socket.
Remove the accumulator upper flange (o 1-3).
Remove the accumulator diaphragm (o 1-2).
Page M32
Remove the tight ring (o 1-6). Check the seat of the ring. If necessary, polish it. This area should be perfectly smooth.
Check the contact area between the accumulator upper flange (o
1-3) and the accumulator lower flange (o 1-1). If necessary, polish
them.
Assembling procedures :
Special tools required to service a TRAMAC accumulator :
o
o
o
o
o
(1) Nitrogen gas bottle,
(1) Regulating gauge installed on top of the nitrogen bottle.
(1) Charging fixture (P/N 80348)
(1) Socket 3/8 ' (or 10 mm)
(2) 1 1/8 " wrenches.
Page M33
Clean and completely dry the accumulator upper flange (o 1-3) and
the accumulator diaphragm (o 1-2) before inserting the diaphragm
in the lower flange.
Cover with the accumulator upper flange (o 1-3). Make sure
this flange is clean and dry.
Grease the bolts (o 1-4) threads with "NeverSeize" product like
Molykote 1000, available from Tramac. Use a 5/8" hexagonal socket
to tighten the bolts. The proper torque is 220 ft-lbs (30 kg-m).
Always cross-tighten bolts in steps : 50 ft-lbs (7
kg-m) each time.
Install the tight ring (o 1-6) and hand-screw the inflating
screw (o 1-5).
Page M34
BRH 625 CHARGING OF THE
ACCUMULATOR
Make sure that the inflating screw (o 1-5) is in close-contact with
the tight ring (o 1-6). If not, you may damage the internal threads
when installing the charging fixture tool .
Install the charging fixture (P/N 80348) on top of the accumulator
with the long bolts going through 2 accumulator holes.
Make sure that the special socket (P/N 21563) is properly seated inside the inflating screw (o 1-5) head. While tightening the
two nuts, make sure that the seat of the charging fixture stays in
contact with the accumulator over the entire circumference. Use
two 1 1/8" wrenches.
Grip the complete assembly on a bench vice.
Close the charging fixture tap (P/N 80348).
Page M35
ACCUMULATOR
Completely unscrew the regulator.
Make sure that the tap located down-stream of the 0-1000 psi gauge is off.
Open the tap on top of the nitrogen bottle. You should read at least an 800
psi (55 bars) pressure on the 0-3000 psi gauge. If not, recharge the nitrogen
bottle.
Carefully screw on the regulating gauge so as to adjust the pressure to 465
psi (32 bars) on the 0-1000 psi gauge.
Page M36
ACCUMULATOR
Open the tap downstream from the 0-1000 psi gauge.
Make sure that no nitrogen gas leak occurs between the bottle
and the charging fixture. If it does, fix the problem before going
any further.
Unscrew the screw P/N 26428 using the socket P/N 21563 of the
charging fixture (P/N 80348).
o Make sure that the nitrogen gas is entering the accumulator. You
should hear the rushing sound.
o Wait until the pressure is stabilized at 465 psi (32 bars) (at least 5
minutes).
o Make sure to have the same pressure reading on both 0-1000 psi
gauges (gauge on the charging fixture and on the bottle). If not,
check the gauges.
Page M37
ACCUMULATOR
If the nitrogen gas does not enter the accumulator, it may be due to an
insufficient loosening of the screw P/N 26428. Try again by inserting a
nylon washer between the inflating device (P/N 80348) and the accumulator [see diagram at right for proper dimensions].
Tighten the screw P/N 26428 using a 3/8 " socket. The proper torque
is 20 ft.lbs [2.75 m.kg].
Turn off the nitrogen bottle tap.
Make sure that the circuit is not pressurized by
the nitrogen bottle. Then, open the drain tap
on the inflating device (P/N 80348) in order to
release the gas pressure in the circuit.
Before removing the charging fixture (P/N 80348) from the top of
the accumulator, make sure that the pressure has dropped to
atmospheric pressure.
Page M38
ACCUMULATOR
Check the actual accumulator pressure using the syringe P/N
21006.
If you are using the syringe on a new or rebuilt accumulator, the pressure reading
may be above 465 psi [32 bars]. If so, the accumulator can be used as is. If not, (pressure reading below 465 psi), the accumulator must be recharged.
To check that seal P/N 14826 is leak-proof, fill the cavity above
the screw P/N 26428 with hydraulic oil. If bubbles appear, the
accumulator must be recharged again using the same procedure.
Page M39
BRH 625
ASSEMBLY
The following procedures must be followed :
o Assembling a hydraulic breaker must be done in a clean area.
o All parts must be carefully cleaned and wiped before their installation.
o Make sure that the following parts have been washed with cleaning solvent (mineral spirits).
Distribution cover (o 34),
Distribution box (o 26),
Distributor (o 32),
Plunger (o 31),
Pressure regulator slide (o 11),
Cylinder (o 36),
o
o
o
o
o
All dust particles (metal and other) must be removed.
Blow dry to clean parts.
Before installing any seal or o'ring, grease them. Their installation will be easier and their life lengthened.
Make sure to lubricate all parts with hydraulic oil before inserting them.
Never hit a part with a steel tool in order to drive it in; always use a rubber mallet.
If necessary, drive the lower bushing (o 52) and the upper bushing (o 50)
into the front-guide (o 49) by using the Tramac bushing extractor or an
hydraulic press.
Page M40
BRH 625
ASSEMBLY
Drive both tool retainers (o 53) half-way inside the front-guide (o 49). Then,
install the hammer in the service stand .
Install the centering pin (o 60) in its housing on top of the front-guide
(o 49). If necessary, remove any high spot on the top surface of the
front-guide (o 49).
Check the spacer (o 42) for high spots. If necessary, remove them.
Also, make sure that no contamination or debris are trapped between
the spacer (o 42) and the front-guide (o 49) before installing the spacer
(o 42) on top of the front-guide (o 49).
Install the centering pin (o 37) in its housing on top of the spacer (o
42).
Page M41
BRH 625
ASSEMBLY
Install the tight ring (o 43) in its housing on top of the spacer (o 42).
Grease the two lip seals (o 45) before installing them in the proper grooves
inside the spacer.
Make sure that the lip seals are properly oriented :o
Lower seal has the lips downward (dust proof),o Upper
seal has the lips upward (leak proof).
Install the bearing washer (o 46). Make sure that the chamfer side is
oriented downward.
Page M42
BRH 625
ASSEMBLY
Install the diaphragm (o 48) onto the accumulator body (o 47). Make sure
that both parts are perfectly dry before assembling.
Install the complete assembly (o 47 & 48) into its housing in the spacer (o
42).
Roll the o'ring (o 44) properly greased at the base of the cylinder (o
36).
Install the cylinder (o 36) on top of the spacer (o 42) after checking for high
spots or any contamination.
Page M43
BRH 625
ASSEMBLY
Use hydraulic oil to lubricate the inside of the cylinder (o 36).
Properly lubricate the lower piston (o 24) with hydraulic oil before sliding it
into the cylinder (o 36).
Install the centering pin (o 37) into its housing on top of the cylinder (o 36).
Install the 2 complete valve assemblies (o 38) in their housings. Make
sure that they are leak-proof once installed.
Page M44
BRH 625
ASSEMBLY
Install the o'rings (o 27) and the o'rings (o 28) on the distribution box (o
26).
The o'rings should be greased to facilitate their
installation. However, any extra-grease should be
removed before installing the distribution box in
order to avoid any grease cushion while tightening
the side-rods (o 58).
Align the distribution box (o 26) with the centering pin (o 37) when
installing it on top of the cylinder
Make sure that the o'rings (o 27 & 28) are still in
their grooves at the end of the operation.
Install the o'rings (o 29) on top of the distribution box (o 26).
Install the centering pin (o 30) in its housing in the distribution box (o
26).
Page M45
BRH 625
ASSEMBLY
Lubricate the thrust piston (o 25) with hydraulic oil before sliding it
inside the distribution box (o 26).
Make sure that the thrust piston (o 25) slides
smoothly.
Install the o'ring (o 33) in the distributor (o 32) after lubrication.
Lubricate the distributor (o 32) with hydraulic oil before sliding it
inside the distribution box (o 26).
Make sure that the distributor (o 32) is properly
oriented with the notch at its bottom.
Use hydraulic oil to lubricate the plunger (o 31) before inserting it
inside the distributor (o 32).
Page M46
BRH 625
ASSEMBLY
Mount the distribution cover (o 34) on top of the distribution box (o
26). Make sure that the distribution cover (o 34) is properly oriented
with the centering pin (o 30).
Use hydraulic oil to lubricate the valve (o 35) before mounting it on top
of the distribution cover (o 34).
Make sure that the valve (o 35) slides smoothly.
Properly grease the side-rod holes in the spacer (o 42) and the frontguide (o 49). That will make future disassembling of the hydraulic
breaker easier.
Install the o'rings (o 10) into the back-head (o 7) after greasing them.
Make sure to remove any extra grease.
Page M47
BRH 625
ASSEMBLY
Also, grease the seat of these o'rings (o 10) on the distribution box (o 26).
Drive in the back-head (o 7) on top of the cylinder assembly (using a
rubber mallet).
Make sure that the back-head (o 7) stays aligned
with the other parts. If not, you may jam and permanently damaged the parts.
Check the threads on the side-rods (o 58) and the side-rod nuts (o 59). Make
sure that hand-turning is easy.
Make sure that the face of the side-rod nuts (o 59) in contact with the
front-guiide is perfectly flat and smooth.
Page M48
BRH 625
ASSEMBLY
Use a "Never-Seize" grease like Molikote 1000 available from Tramac to:
Grease the threads of the side-rod nuts (o 59).
Grease the threads of the side-rods (o 58).
Grease the back of the side-rods (o 58) heads.
Grease the seat of the side-rods (o 58) on the back-head (o 7).
Always remove the extra grease. If not, grease may act as a cushion during the tightening of the side-rods.
Page M49
BRH 625
ASSEMBLY
Install the 4 side-rods (o 58) across the back-head (o 7), the spacer
(o 42), and the front-guide (o 49). Then, hand-tighten the 4 side-rod
nuts (o 59).
Pre-tightening procedure:
Tighten the 4 side-rods (o 58) up to 300 ft-lbs (40 kg-m) in order to
close any gap between the distribution box (o 26) and the cylinder (o
36).
Always cross-tighten the bolts in steps : 50 ft-lbs
(7 kg-m) each time.
Fully release the torque on the side-rods (o 58) before tightening
them again. Tighten to 150 ft-lbs (or 20 kg-m).
Always cross-tighten the bolts in steps : 50 ftlbs (7 kg-m) each time.
Page M50
BRH 625
At the end of the operation, check the marks located near each side-rod head on the back-head (o 7).
They should be close to a flat notch on the siderod head.
o If the flat notch is within an angle of ± 15º, turn
the side-rod (by tightening or loosening it) up to
get a perfect alignment between the 2 marks.
o If not, the side-rod(s) must be completely lossened and the nut should be either turned or
changed and the full procedure repeated.
Once the head notches of the 4 side-rods are properly
aligned with the 4 marks on the back-head, identified
the fourth notch on each one.
Use the special Tramac wrench P/N 22775 or a 1 1/2" hexagonal socket to screw each side-rod by 4/6 th of a turn [4 flats]
plus 3/16" [or 5 mm].
Always cross-tighten in steps, 2 flats per bolt
per time.
Never use a pneumatic wrench to tighten or
loosen the side-rods as you can damage the
threads with micro-seizures on the side-rods
(o 58) or the side-rod nuts (o 59).
Page M51
BRH 625
ASSEMBLY
Install the lip seal (o 19) in the inlet port. Make sure that the lips are
facing the inside of the back-head (o 7).
Grease the seats of the LP swivel (o 22) and the HP swivel (o 22) on
the back-head (o 7).
Install the o'rings (o 23) in the LP swivel (o 22). Also install the
o'ring (o 15) on the LP plug (o 16).
Install the o'rings (o 23) in the HP swivel (o 22). Also, install the
o'ring (o 20) on the HP plug (o 21).
Page M52
BRH 625
ASSEMBLY
Grease the inside of both swivels (o 22) and drive them onto the
back-head (o 7).
Never directly hammer on the swivels. You may
permanently damage their seats.
Install the pressure regulator slide (o 11) in the outlet port. Make sure
that the pressure regulator slide (o 11) moves smoothly inside its
housing. Also, install the spring (o 12), the stop pin (o 14) and the
pressure adjustment shims (o 13).
Mount the spring (o 17) and the check valve (o 18) on the oil inlet.
Install and tighten the LP plug (o 16) and HP plug (o 21).
Page M53
BRH 625
ASSEMBLY
Install the o'ring (o 4) and its back-up ring (o 3). Also, lightly grease
the inside of the back-head (o 7). Make sure that the back-up ring
(o 3) stays dry.
Make sure that the opposite seats on the accumulator (o 1) and
the back-head (o 7) do not show evidence of any damage.
Mount the accumulator (o 1) and the accumulator disk (o 5) on
top of the back-head (o 7).
Use a "Never-Seize" grease, like the Molycote 1000 available from
Tramac, to grease the threads of the bolts (o 6).
Remove any extra-grease on the bolts to avoid
a cushion effect when tightening them.
Page M54
BRH 625
ASSEMBLY
Tighten the bolts (o 6) up to 470 ft.lbs 65 m.kg].
Always cross-tighten bolts in steps : 50 ft-lbs
[7 kg-m] per step.
Use a crane or a fork-lift to remove the hydraulic breaker from the
work stand. Remove the tool retainers (o 53).
Use a 15/16" socket to check the torque on the lower suspension
bolts (o 65). The proper torque is 300 ft-lbs [40 kg-m].
Install the hydraulic breaker in its cradle (o 68). Make sure that the
inlet and outlet ports are properly oriented :
The HP inlet should be on the right, and the LP
outlet on the left, when facing the hydraulic
hammer from the operator seat.
Page M55
BRH 625
ASSEMBLY
Install the suspension plate (o 67) on top of the cradle (o 68).
Install the bracket cap on top of the suspension plate (o 67). Bolt
them to the cradle (o 68) using the bolts (o 69) and the nuts (o 70).
The proper toque is 475 ft.lbs [65 m.kg].
Install the lube flange (o 40) on the right side of the cylinder (HP
side). The proper torque for the bolts is 300 ft.lbs [40 m.kg].
Install the o'rings (o 56) in the pin shutters (o 55). Make sure that
they are properly greased.
Page M56
BRH 625
ASSEMBLY
Before inserting the tool (o 72), properly grease its shank.
Then, grease and mount the tool retainers (o 53) and the
lock pins (o 54).
Page M57

BRH 625 Manual

Transcription

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