BRH 501 Manual Parts, Safety, Operation & Maintenance Form No. M1075-POMS Revision 0
March 2002 Page 1
BRH 501
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 Screws II-7 Accumulator II-8 Storage II-9 Underwater working
5 5 6 7 8 9 10 10 11 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
GREASE SCHEDULE, TORQUE AND OTHER SPECIFICATIONS
22
PARTS LIST C R A D LE ACCUMULATOR
P3 P4 P5
TROUBLE SHOOTING PART NAMES PARTS INSPECTION AND REASSEMBLING OVER SIZE BUSHING OPTION FOR UNDERWATER OPERATION
M1 M4 M5 M13 M16
Page 2
BRH 501
MAIN DAT DATA
I MAIN DATA I - 1 Overall dimensions
Page 3
BRH 501
MAIN DAT DATA
I - 2 Technical specifications
501B Impact class Oil supply Blows / minute Operating pressure Max Back Pressure Height Working weight (lbs) Shock absorber bracket Shock dampener in hydraulic circuit Tool diameter
501SB
1700 ft.lbs 32 gpm 500 1600 psi 45 psi 84 in 1500 2400 No Yes Yes 4.5 in
501C
501SC
2000 ft.lbs 37 gpm 500 1200 psi 45 psi 84 in 1500 2400 No Yes Yes 4.5 in
The oil supply ( respectively 30 gpm and 37 gpm for the BRH 501B(SB) and BRH 501C(SC) models) is the maximum oil flow setting allowed on these hammers. The BRH 501B(SB) and BRH 501C(SC) hammers can be used with carriers providing lower oil flows, but will produce lower blow rates. To maintain an efficient hammer power, pressure adjustment shims have been designed [see paragraph II-2].
Tool references
Dimension
P/N
Standard moil point Long moil point Chisel Spade Blunt
39 in 50 in 39 in 8 in wide 39 in
26132 26133 26136 26138 26141
Maximum temperature
hammer 175 ºF
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 501 MAINTENANCE INSTR. II MAINTENANCE INSTRUCTIONS The life of a tool is determined 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. II-1.1 To insert a tool a> Insert the tool [rep. 350] into the front guide. Make sure that the two flat edges are well positioned in order to insert the retaining pins. b> Using a screw driver, position lock [rep. 252] as to fully insert the retaining pin [rep. 251]. The lock will release itself. Proceed the same way with the second pin.
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].
251 252
251 252
Page 5
BRH 501 MAINTENANCE INSTR. II-1.2 To remove a tool a> Use a screw-driver to push in the lock [rep. 252] . b> Using another screw-driver, push retaining pin [rep. 251] out of hole B. c> Repeat on the other side for the second pin. d> remove the tool.
When removing the tool, take care not to drop the tool on sharp objects, or polished surfaces may be damaged permanently.
II-2 Lubrication The only routine maintenance for the TRAMAC models BRH 501B(SB) and BRH 501C(SC) is point lubrication. It is essential and cannot be overlooked; it reduces considerably the frictions between the bushing and the tool and lengthens the life of your hammer.
a> Before inserting the tool [rep. 350] inside the hammer, hand-grease the shank of the tool, the bushing, and the two tool-retainers.
b> During normal daily operation, every two hours 20 shots with a hand operated grease pump in the grease fitting [rep. 258]. Use TRAMAC BRH7 grease which may be obtained from your TRAMAC dealer.
A properly lubricated hammer will show some grease running down the point : Keep the tool wet all the time.
Page 6
BRH 501 MAINTENANCE INSTR. II-3 Tool retainers
Examine the retaining pins [rep. 251] 2 or 3 times a week. Change them when they show signs of heavy wear (like becoming oval shaped or showing big cracks).
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
View F
a> Hollow shaped deformation without any bump around the mark. Pin can be turned over by 180º to lengthen life time.
F
Bump
b> Hollow shaped deformation shows peripheric bump more particularly located on round part of pin.
View G G
Page 7
BRH 501 MAINTENANCE INSTR. 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
X A
B
Page 8
BRH 501 MAINTENANCE INSTR. TRAMAC BRH 501B(SB) & BRH 501C(SC) features a replaceable chuck-bushing [rep. 255]. The bushing 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.
Rep. A B X
Designation Front guide diameter Chock bushing diameter Striking chamber length
Length (in) ? 4.605 ? 4.645 ? 4.290
Check wear regularly to be sure not to exceed 3/16 " between tool and bushing. When wear exceeds above indicated tolerances, consult your TRAMAC dealer for part replacement.
II-5 Side-rods
Daily, inspect the side rods [rep. 300] 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.
Page 9
BRH 501 MAINTENANCE INSTR. II-6 Screws II-6.1 BRH 501SB & BRH 501SC : Bracket cap bolts [rep. 310]
Check these 12 screws [rep. 310] and nuts [rep. 311] 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 BRH 501SB & BRH 501SC : Wearing plates bolts [rep. 308]
Every 500 hours, check these 16 wearing plates bolts [rep. 308] for tightness. The proper torque is 368 ft.lbs. II-6.3 Accumulator fixing bolts [rep. 6]
Every 500 hours, check the 8 screws [rep. 6] for tightness. The proper torque is 470 ft.lbs. II-7 Accumulator TRAMAC accumulators [rep. 2] 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.
Page 10
BRH 501 MAINTENANCE INSTR. 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.
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.
Page 11
BRH 501 MAINTENANCE INSTR. II-9 Underwater working
The TRAMAC BRH 501B(SB) & BRH 501C(SC) models 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).
II-9.1 Underwater kit Position of the protecting plate
Page 12
BRH 501 MAINTENANCE INSTR. For underwater operation, two different procedures have to be following depending on the front guide your hammer is equipped with : case A : If equipped with new standard spacer (P/N 23830) and drilled front guide (P/N29209, install air-pressurization kit 79102 case B : If equipped with the old standard front guide (not drilled before 1978) and the old spacer (P/N21649 before summer 1989), install the new front guide (P/N 29209) and the new spacer (P/N23830) and air pressurization kit 79102.
Rep
Qty
1 2 3 4 5
1 1 2 1 1
Designation
Part number
- Fitting - Knee piece - Lip seal - Screw Protecting plate (not provided w/kit but to be welded on the cradle by the customer)
23832 7295 12817 19716
Kit for air blowing II-9.2 Compressor pressure Pressure from the compressor must be at least 22 psi above the water pressure at the working depth. Consult the following chart to determine minimum pressure required at the corresponding depths.
Water Depth (ft) 1 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30
Air pressure required (psi) 22 23 24 25 26 27 28 29 31 32 33 34 35
Page 13
BRH 501
OPERATING INSTR.
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 501
OPERATING INSTR.
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 501
OPERATING INSTR.
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 inserting it into the hammer.
Page 16
BRH 501
OPERATING INSTR.
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 501
OPERATING INSTR.
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 SpadeFrost
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 501 BREAKAGE CHART
OPERATING INSTR.
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 501 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 501 hammer has been pread justed in manufacturing to obtain 1120 psi at 26 gpm for an oil temperature of 110 ºF on a moderately hard ground.
Page 20
MAX FLOW
MAX WORKING
MAX BACK
RATE
PRESSURE
PRESSURE
BRH 501B & 501SB
32 gpm
1600 psi
45 psi
BRH 501C & 501SC
37 gpm
1200 psi
45 psi
BRH 501 SAFETY PRECAUTIONS V SAFETY PRECAUTIONS
1 2
Never use the hammer as a lifting device Stay clear of hammer while in operation, flying objects can cause severe injures, even death. 3 Be sure decals are clearly visible. Clean or replace as necessary. 4 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 501 GREASE SCHEDULE, TORQUE AND OTHER SPECS ROUTINE MAINTENANCE AND LUBRICATION RECOMMENDATIONS: The only routine maintenance for BRH is point lubrication. Incorrect lubrication can lead to scouring of point and chuck housing as well as loss of production. RECOMMENDED LUBRICANT - TRAMAC BRH-7 grease which may be obtained from your TRAMAC dealer. GREASING SCHEDULE - New points and tool retainers should be greased before inserting. Every 2 hours 20 shots with hand grease gun. TOOL RETAINERS - Change when they show signs of heavy wear to avoid their breaking in chuck. RECOMMENDED SPARE PARTS: 1) Seal seat 2) Two tool retainers 3) Grease fitting 4) Spare tool ACCUMULATOR NITROGEN CHARGES: Check with test gauge 21006-L Pressure = 530 psi TORQUE SPECIFICATIONS: Reference Number 6 = 500 ft-lbs Reference Number 300 = 730 ft-lbs Reference Number 308 = 365 ft-lbs 1 x 13 1/2 Bolts = 150 ft-lbs - Notch on bolt head must line-up with mark in back head (Ref. 1). Remove tie rod and nut in matched sets and replace in same location. Place arrow on nut so that it is not reversed. SPECIAL TOOLS REQUIRED: For Nitrogen charge: - Pressure test gauge 21006-L - Charging fixture 30932-J
Page 22
BRH 501 PARTS MANUAL Form No. M1075-P Revision 0
March 2002 Page P1
BRH 501
Page P2
PARTS LIST
BRH 501 Rep
Qty
1 3 4 2 5 5 6 8 9
1 1 1 1 2 2 8 8 8
10 11 12 13
1 1 1 2
10 11 12 13 14 or 17 15 16 18
1 1 1 2 1 1 12 - 20 1 1 1
104 107 106 105 102
1 1 3 1 2
100 108 103
1 2 1
150 101 150 101
1 1 1 1
250 250 259 255 256 257 254 252 251
1 1 1 1 1 2 4 2 2
Designation
PARTS LIST Part number
Back Head ass'y, composed of : - Back head - Nylon washer - O'ring - Accumulator - O'ring - O'ring - Screw 5 1/2" - Spring guide - Washer
to s/n 20214 from s/n 20236
53221 18652 33616 22848 19856 36579 24658 22894 22573
HP rotating connection ass'y, composed of : - Knee part (1 "1/4 NPTF) - Threaded plug - O'ring - O'ring
56047 21292 6711 5346
LP rotating connection ass'y, composed of : - Knee piece (1"1/4 NPTF) - Threaded plug - O'ring - O'ring - Slide BRH 501B & 501SB - Slide BRH 501C & 501SC - Pressure adjustment shims - Spring slide - Barrel - Spring
56047 21292 6711 5346 22974 22975 21291 21289 21290 18083
Distribution ass'y, composed of : - Distribution box - Distributor - Piston - Distribution cover - Centering pin
19708 17678 23062 23061 19867
Cylinder ass'y, composed of : - Cylinder - Lip seal - O'ring
28362 19698 19856
Striker ass'y, composed of : - Piston BRH 501B & 501SB - Plunger - Piston - Plunger
BRH 501C & 501SC
19703 19171 19704 19170
Front guide ass'y, composed of : Front-Guide (square retaining pins) Front Guide (round retaining pins) O'ring Chuck bushing Pin Split pin Plug Bolt Retaining pin(square)
29209 38939 19856 20944 20948 7046 7076 22680 26130
Page P3
BRH 501
Page P4
PARTS LIST
BRH 501 Rep 251 253 262 258 260 261 261 300 301
Qty 2 2 1 1 1 1 1 4 4
Designation Retaining pin (round) Bolt spring Plug Oiler Spacer ass'y including : Wear bushing 2 3/8" Wear bushing 4" (ref. spacer 21649) - Side rods - Nuts
PARTS LIST Part number 22679 22681 38894 6178 23830 22448 21768 57891 57369
Page P5
BRH 501
Rep
Qty
304 305 306 307 308 7 302 303 310 311
1 2 8 8 16 8 1 1 12 12
Designation
CRADLE
Part number
Heavy Duty Shock Absorbing Cradle :
Page P6
- Cradle Stop Wearing plate Locking plate Screw Spring Top plate Shock absorber - Screw - Nut
26756 21032 21028 21078 21159 21033 21029 21031 31121 5159
BRH 501 BRH 501
ACCUMULATOR
Accumulator HP
Tighten Bolts to 140 ft-lbs
Accumulator parts table Rep
Qty
1 2 3 4 5 6 7
1 1 1 16 1 1 16
Designation
Part number
Lower flange Diaphragm Upper flange Screw Inflating screw Ring Plug
22847 17639 26600 18645 26248 14826 36306
Maintenance accessories list Recommended spare parts kit
Part name Seal kit Tools retainers Grease fitting Spare tool
Qty
P/N
1 2 1 1
53247 26130 6178 26132
Page P7
BRH 501
ACCUMULATOR
This Page Left Blank Intentionally Cette Page est Laissée Blanche Intentionnellement
Page P8
BRH 501
TROUBLE SHOOTING
TROUBLES SHOOTING … REMEDIES
PANNES POSSIBLES … REMÉDES
A - Oil leakage on hammer.
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 501
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 501
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 501B(SB) and BRH 501C(SC) - 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 501
PART NAMES
What to look for when assembling the BRH. NOTE: For general assembly procedure, refer to parts description.
Page M4
BRH 501 PARTS INSPECTION AND REASSEMBLING PARTS INSPECTION AND REASSEMBLING PROCESS:
Accumulator 1. Check o-ring seat “A” on lower flange. If damaged, polish with fine hand stone or remove 0.005” maximum. If the damage is too deep or more 0.005”, remove both sides according to “J” dimension. 2. Clean diaphragm groove “D.” 3. Check ring seat “E” on upper flange. Perfect seat only is acceptable. 4. Clean and check all bolts’ threads “K” in upper flange. 5. Clean and check all bolts “B.” 6. Mount new “BS” ring with hydraulic oil. IMPORTANT - DO NOT USE GREASE. 7. Make sure bores “L” are not plugged with rubber. Clean if necessary. 8. Reassembling, tightening and inflating, refer to specifications.
Page M5
BRH 501 PARTS INSPECTION AND REASSEMBLING Device for quick nitrogen pressure checking 21006: - Made for service men or maintenance workshop. - Direct reading of the existing pressure in accumulator on pressure gauge ref. 21013 fitted to the syringe. - One only type of end part (ref. 21317) for breakers type BRH.
Instructions: - Clean out syringe. - Suck up clean oil until syringe is full without air bubble. - Put syringe end into accumulator grid hole and press without excess (about 45 lbs.). When oil pressure into syringe equals nitrogen pressure, diaphragm is pushed down from grid, oil can flow out of syringe and appears on grid. Then nitrogen pressure in accumulator can be read on pressure gauge.
N.B. If control is affected on an accumulator taken from stock, or already mounted on a BRH having not operated for quite some time, the value read on pressure gauge may be higher then the recommended one. In this case diaphragm may be stuck on grid or may have hardened, which causes further resistance. Accumulator may however be used as such. If value is lower it is necessary to change or repair the accumulator.
Inflating device for accumulator 41543: - Make for service truck or maintenance workshop. - Must be used together with a nitrogen tank.
Instructions: - Put accumulator inside fitting 41543, (1). - Unscrew slightly five flat screws with spanner 21653, (2). - Once connection to nitrogen taknk is made, open tank cock and adjust pressure to the required value by acting on expander . - When pressure is reached, tighten five flat screw, close nitrogen tank, open drain cock 11653, (3) and disconnect hose.
Nitrogen pressure in 400 and 450 accumulators is 525 to 555 psi.
Page M6
BRH 501 PARTS INSPECTION AND REASSEMBLING Back head PARTS INSPECTION: 9. Check all helicoils “B.” 10. Check o-ring seat “A.” Polish if necessary. 11. Check snap ring on slide sleeve inside to the outlet port “E.” 12. Make sure that slide sleeve is tight in the back head and not damaged. 13. Make sure that side rod seat “D” is not damaged. If damaged, remove high spots only with hand fine stone or sand paper.
Side rod and nut 14. Make sure that the side rod seat “I” is not damaged. Remove high spots only. 15. Check threads in side rod “H.” 16 Check thread in nuts. 17 Screw nut in side rod by hand. Make sure the nut screws in freely.
Note: When replacing broken side rod, it is recommended that all four (4) rods are replaced.
Page M7
BRH 501 PARTS INSPECTION AND REASSEMBLING Back head - distributor cover 18. Make sure that the seat “A” on the cover of the distributor is not damaged. Polish with hand fine stone or surfacing plate, if necessary.
Note: remove high sopt only, (maximum surfacing 0.003”). 19. Check seat “B” in the back head. Same procedure as no. 18.
Distributor cover - distributor box 20. Check seat “C.” If damaged, polish the high spot only with hand fine stone and repolish with fine compound, if necessary.
Distributor box - cylinder 21. Check seats “E” and “H.” If damaged, polish the high spot only with hand fine stone and repolish with fine compound, if necessary.
Note: Remove all compound before reassembling.
Page M8
BRH 501 PARTS INSPECTION AND REASSEMBLING 22. Check plunger seat “A” on distributor cover. Polish if necessary.
Note: Remove 0.004” max. only once. If you remove material, indicate how many times on the cover of the distributor. 23. Make sure that the piston “B” is not damaged.
Plunger 24. Make sure that area “C” on the plunger is not damaged. If the damage is all around, mount new plunger.
Distributor 25. Check the distributor seats, “B,” “H,” and “D.” Seat “B” - remove only once, a maximum of 0.004.” Seats “H” and “D” - just polish by hand. If the damage is severe or too deep, replace the distributor.
Distributor box 26. Check the internal distributor seat in the distributor box. Polish by hand. If the damage is severe or too deep, replace the distributor box.
Note: If damaged by aeration or cavitation, check excavator hydraulic circuit or hydraulic fluid type.
Page M9
BRH 501 PARTS INSPECTION AND REASSEMBLING 27. Make sure that there is no obstruction between the distributor and the distributor box. Insert the distributor into the distributor box and turn by hand. Make sure it turns freely. If not,
use fine compound and polish. Note: Remove all compound before reassembling. 28. Do not remove the small orifice “A.” 29. Check seat “D” on distributor. If damaged, remove only once, a maximum of 0.004.”
Piston 30. Check seat “B,” perfect seat only is acceptable. 31. Check plunger seat “C.” Remove high spots only. If damage is too deep, replace piston. 32. Check area “E.” If damaged, remove high spots only. If too much damage, replace piston. 33. Check chrome area “H.” If damaged, use service exchange if possible. 34. Check striking area “I.” If cracked or clenched, replace piston and check operating pressure, flow and tool alignment in chuck housing.
Page M10
BRH 501 PARTS INSPECTION AND REASSEMBLING Cylinder
35. Check internal surface in cylinder. If damaged, remove high spots only with hand fine stone. Polish the surface.
IMPORTANT: Clean internal lube and alignment piston groove “A.” 36. Check seal groove edges “B.” If too sharp, smoothen by using a soft hand stone.
Note: Edge rodurs 0.008” +/- 0.004.” If the edges are too sharp, peeling of chrome of the piston will occur. 37. Check o-ring seals “C” and “D.” 38. Wash and clean cylinder.
Page M11
BRH 501 PARTS INSPECTION AND REASSEMBLING Chuck housing 39. Make sure that the chuck housing is not cracked or damaged. 40. Check the wear on spacer bushing, on limit tool stroke area and inside the chuck housing.
Note: Maximum wear depth is 0.125.” If more, install a new one. Refer to “48C.” 41. Make sure that the brass bushing in spacer bushing “B,” is not damaged.
Important: If you install a new brass bushing, make sure that the piston strokes freely through that bushing. If not, polish with sand paper. 42. Clean the side rod boring “A” in chuck housing with wire brush. Be sure that the side rod strokes freely on nylon area. 43. Check lock plate retainer “C.” Refer to “55.” 44. Check the wear in bushing “D” (area “E”).
Note: Maximum, allowed wear is 0.125.” If more, remove and mount a new bushing (refer to 45, 46, 51, 52 and 53. 45. Make sure that the bushing “D” sits tightly in the chuck housing. If not, remve the existing bushing and mount a new one in place of the existing bushing.
Note: Refer to over size bushing procedure drawing (page M13). 46. Check wear tolerance “H” between tool and bushign. Maximum allowed wear is 0.125.”
Page M12
BRH 501 OVER SIZE BUSHING Over size bushing
Page M13
BRH 501 PARTS INSPECTION AND REASSEMBLING 47. Before you press the spacer bushing into the chuck housing, freeze the spacer bushing in dry ice for one hour. 48. Maximum allowed wear of area “C” is 0.125.” 49. Clean the wall inside the chuck housing before you press the spacer bushing.
Note: Make sure that there is no obstruction between the spacer and the chuck housing wall. 50. If there is crack and shell on spacer area “C,” mount a new spacer and check the wear on bushing area. Refer to step “44,” area “E.” 51. Before you press the bushing “E” into the chuck housing, freeze the bushing in dry ice for no less than 1 hour. 52. The pin “H” locks the bushing in chuck housing. 53. The bushing press fit is 0.0023” +/- 0.0001 dia.
Important: Check alignment of lock pin before you press the bushing into the chuck housing. 54. Check the wear “K” on lock plate “N.” If too worn out, replace the lock plate with a new one. 55. Check lock pin assembly “P,” “O” and “T.”
Page M14
BRH 501 PARTS INSPECTION AND REASSEMBLING Chuck housing 56. This model has no spacer bushing. The tolerance from tool stroke limit “A” is 0.190.”
Note: Same check as “48.” 57. Clean the side rod boring “E” with a wire brush.
Note: Be sure that the side rod strokes freely on nylon area. 58. Make sure that the chuck housing “H” is not cracked or damaged. 59. Check “D” if the bushing is press fit into the chuck housing “H.” 60. Over size bushing is available. Refer to over size bushing procedure drawing page M13. 61. Before you press the bushing “B” into the chuck housing, freeze the bushing in dry ice for minimum of one hour. 62. Before you press the bushing “B” make sure that the lock pin allignment is perfect. Refer to “53 - H.” 63. The tolerance between the chuck housing and wearing plate 306 is 0.060” (maximum). Add lock plate 307 in between cradle and wearing plate, if necessary.
Page M15
