This manual is arranged to give you a good understanding of the product and its safe
operation. It also contains maintenance information and technical specifications.
Read this manual from front to back before installing, operating or maintaining the
product for the first time.
In this manual, the units of measurement are metric. For example, weights are given
in kilograms (kg). In some cases, an other unit follows in parenthesis (). For
example 28 litres (7.4 US gal).
The specifications and designs presented in this manual are subject to change
without prior notice.
SYMBOLS USED IN THIS MANUAL
This symbol identifies important safety messages within this manual. Carefully read
the message that follows. Failure to understand and obey this safety warning could
result in injury to you or others, and could also cause damage to product. See
illustration 1.
This symbol identifies prohibited action or hazardous location. Failure to
understand and obey this safety warning could result in injury to you or others, and
could also cause damage to product. See illustration 2.
This symbol identifies correct and recommended action. See illustration 3.
This symbol identifies environmental and recycling matter. See illustration 4.
1.2 IMPORTANT SAFETY INFORMATION
Basic safety precautions are outlined in the "Safety" section of this manual and in
the instructions where hazards exist. These warnings are identified by a warning
symbol.
To use the product correctly, you must also be a competent operator of the carrier.
Do not use or install it if you cannot use the carrier. The product is a powerful tool.
Used without proper care, it can cause damage.
Do not rush when you are learning to use the product. Take your time and most
importantly, take it safely. Do not guess. If there is anything you do not understand,
ask your local dealer.
Improper operation, lubrication or maintenance of this product can be dangerous
and could result in injury.
Do not operate this product until you read and understand the instructions in this
manual.
Do not perform any lubrication and maintenance on this product until you read and
understand the instructions in this manual.
The customer is provided with a separate warranty sheet, where the export warranty
terms are explained. Check always that this warranty sheet is provided with the
product. If not, contact your local dealer immediately.
WARRANTY REGISTRATION CARD
A warranty registration card is filled out after the installation inspection by the
dealer and a copy of it is sent to the manufacturer. This card is very important
because no warranty claims are handled without it. Make sure that you get a copy
of it after the installation inspection and that it is correctly filled out.
INSTALLATION INSPECTION
An installation inspection must be carried out after the product has been installed on
the carrier. During the installation inspection, certain specifications (operating
pressure, oil flow, etc.) are checked so that they are within given limits. See
“Product specifications” on page 64.
1.4 SPARE PART ORDERS
When you need spare parts or some information concerning maintenance to your
product, please contact your local dealer. Quick deliveries are ensured by exact
orders.
The product serial number is stamped on the product body. The model and serial
number are also located on the product identification plate.
It is important to make correct reference to the serial number of the product when
making repairs or ordering spare parts. Identification of the serial number is the only
proper means of maintaining and identifying parts for a specific product.
See the following figure for the location of the serial number on your product
model.
1
2
Serial number
3
Sandvik Mining and Construction Oy, Taivalkatu 8, 15170 LAHTI, FINLAND
The product is a hydraulically operated pulverizer. It can be used on any carrier
which meets the necessary hydraulic and mechanical installation requirements.
3.2 REMOVAL FROM PACKAGE
Remove all the steel belts from the package. Open the package and remove all
plastics covering the product. Recycle all package materials (steel, plastic, wood)
properly.
Check that the product is in good condition and that there is no visible damage.
Check that all ordered parts and accessories have been enclosed with the product.
Some options may be provided by your local dealer, such as installation kits,
including hoses and mounting bracket.
3.3 LIFTING INSTRUCTIONS
Use a hoist when lifting components which weigh 23 kg (51 lb) or more, to avoid
back injury. Make sure all chains, hooks, slings, etc., are in good condition and are
in the correct capacity. Make sure hooks are positioned correctly. Do not side load
the lifting eye during a lifting operation.
PROVIDED LIFTING POINTS
The lifting points located on the product frame are to be used solely to lift or handle
the product itself. The lifting capacity calculation is based on the product's working
weight, including an average sized mounting bracket.
Warning! To avoid falling objects, do not use the product to lift other products.
The lifting points located on the product frame are to be used solely to lift or
handle the product itself.
The maximum allowed total weight is shown on the product's identification plate
and specification page. See “Product specifications” on page 64. If the weight
exceeds the maximum allowed total weight shown on the identification plate and
specification page, you will have to use other lifting points/methods than originally
provided on the product.
The other threaded holes on the product are intended for handling single parts only.
You must not lift the entire assembly by using these threaded holes. For handling
the parts, see product workshop documentation for suitable lifting methods and
lifting adapters.
LIFTING EYE SCREWS
If lifting eye screws are used, lifting eye screws must be completely tightened. The
lifting eye can be loaded only if the screw is properly tightened to the frame.
Failure to properly tighten the screw before allowing load pressure on the
lifting eye may cause lifting eye to break and free fall of the product.
If you use mechanical tools for tightening, make sure not to overstrain the shank.
Before lifting, make sure that the rope and/or hook is stretched.
When two lifting points are used, the lifting capacity depends on the angle of the
lifting chains. The angle should not be less than 45°, as shown in the illustration.
When the lifting eye screws are tightened, both rings should be aligned.
The loading capacity calculation applies to temperatures between -10 °C (14 °F)
and 40 °C (104 °F).
Before reuse of lifting eye screws, make sure there are no surface flaws (for example
pits, voids, folds and seams, deformation of the ring, missing or broken threads,
rust, etc.).
The local, national safety standards for machines and lifting-tackles must always be
strictly observed.
Note: The lifting eye must always be removed from the product and replaced with
a screw before operation.
Lifting devices must safely carry the working weight of the product. See “Product
specifications” on page 64.
Place a chain or sling as shown in the illustration to lift the product.
MB010011
Note: The lifting eye screws must always be removed from the product and replaced
with a screw before operation.
SAFETY INSTRUCTIONS FOR LIFTING
Below are some common safety instructions concerning lifting operations. In
addition to this, the local, national standards for machines and lifting-tackles must
always be strictly observed. Please note that the list below is not all inclusive, you
must always ensure the procedure you choose is safe for you and others.
■Do not lift the load over people. No one must be under the hoisted load.
■Do not lift people and never ride the hoisted load.
■Keep people clear from the lift area.
■Avoid side pull of the load. Make sure you take up the slack slowly. Start and
stop carefully.
■Lift the load a few centimeters and verify it before proceeding. Make sure the
load is well balanced. Check for any loose items.
■Never leave the suspended load unattended. Maintain load control at all times.
■Never lift the load over the rated capacity (see the product's operating weight
from the specification page).
■Inspect all lifting product before use. Do not use twisted or damaged lifting
product. Protect lifting product from sharp corners.
Rammer products support the recycling of materials to help customers achieve their
environmental objectives. During manufacturing all necessary precautions are
taken to make sure that no harm is done to the environment.
Every effort is made to foresee and minimize the risks that might be associated with
the operation and maintenance of Rammer products, and which could pose danger
to humans or the environment. We support customers in their efforts to consider the
environmental protection in their everyday work.
When working with a Rammer product please follow these guidelines:
■Dispose of packaging materials properly. Wood and plastic can be burned or
recycled. Deliver the steel belts to metal recycling center.
■Protect the environment from oil spills.
In case of hydraulic oil leaks, the product should be serviced immediately.
Follow the product's greasing instructions and avoid excessive greasing.
Be careful when handling, storing and transporting oils.
Dispose of empty oil or grease containers appropriately.
Consult local authorities for detailed instructions.
■All metal parts of the product can be recycled by delivering them to an
authorized scrap metal collection facility.
■Comply with local waste classification rules when disposing of used rubber or
plastic parts (wear plates, seals).
Consult with your local dealer for more information.
All mechanical product can be hazardous if operated without due care or correct
maintenance. Most accidents involving machine operation and maintenance are
caused by failure to observe basic safety rules or precautions. An accident can often
be avoided by recognizing potentially hazardous situations before an accident
occurs.
Because it is impossible to anticipate every possible circumstance that might
involve a potential hazard, the warnings in this guide and on the product are not all
inclusive. If a procedure, tool, working method or operating technique not
specifically recommended by manufacturer is used, you must satisfy yourself that
it is safe for you and others. You should also ensure that the product will not be
damaged or made unsafe by the method of operation or maintenance procedures you
choose.
Safety is not just a matter of responding to the warnings. All the time you are
working with your product you must pay attention to what hazards there might be
and how to avoid them. Do not work with the product until you are sure that you can
control it. Do not start any job until you are sure that you and those around you will
be safe.
Warning! Read the following warning messages carefully. They tell you of
different hazards and how to avoid them. If proper precautions are not taken,
you or others could be seriously injured.
4.2 SAFETY INSTRUCTIONS
MANUALS
Study this manual before installing, operating or maintaining the product. If there is
anything you do not understand, ask your employer or your local dealer to explain
it. Keep this manual clean and in good condition.
The related safety label on the product and the text on the label are shown below.
"IGNORING INSTRUCTIONS HAZARD
Faulty handling practice could cause death or serious injury.
Read and follow the instructions in the operator's manual."
Faulty handling practice could
cause death or severe injury.
Read and follow the instructions
in the operator’s manual.
WARNING
169410_ENG-3
CARE AND ALERTNESS
All the time you are working with the product, take care and stay alert. Always be
alert for hazards. The possibility of a serious or even fatal accident is increased
when you are intoxicated.
CLOTHING
You can be injured if you do not wear proper clothing. Loose clothing can get
caught in the machinery. Wear protective clothing to suit the job.
Examples are: a safety helmet, safety shoes, safety glasses, well-fitting overalls,
ear-protectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or
scarf. Keep long hair restrained.
PRACTICE
You and others can be killed or injured if you perform unfamiliar operations without
practicing them first. Practice away from the job site, in a clear area.
Keep other people away. Do not perform new operations until you are sure you can
do them safely.
REGULATIONS AND LAWS
Obey all laws, work site and local regulations which affect you and your product.
Bad communications can cause accidents. Keep people around you informed of
what you will be doing. If you will be working with other people, make sure they
understand any hand signals you will be using.
Worksites can be noisy. Do not rely on spoken commands.
WORKSITE
Worksites can be hazardous. Inspect the site before working on it.
Check for potholes, weak ground, hidden rocks, etc. Check for utilities (electric
cables, gas and water pipes, etc.). Mark the positions of cables and pipes.
Poor visibility can cause accidents and damage. Make sure that visibility and
lighting in the working area are adequate.
Worksites can be noisy. Wear ear protection to prevent personal injury.
BANKS AND TRENCHES
Banked material and trenches can collapse. Do not work too close to banks and
trenches where there is a danger of collapse.
SAFETY BARRIERS
Unguarded product in public places can be dangerous. Place barriers around
machinery to keep people away.
AIRBORNE POLLUTANTS
The related safety label on the product and the text on the label are shown below.
Airborne pollutants are microscopic particles, which will damage your health when
inhaled. Aiborne pollutants on construction sites can be for example silica dust, oil
fumes or diesel exhaust particles, visible or invisible. Especially in demolition sites,
there may be other dangerous substances, such as asbestos, lead paints or other
chemical substances.
The effect of airborne pollutants may be immediate if the substance is poisonous.
The main danger with airborne pollutants comes from long term exposure, where
particles are inhaled but not removed from the lungs. The disease is called silicosis,
asbestosis or other, and will result in death or serious injury.
To protect yourself from airborne pollutants, always keep excavator doors and
windows closed during operation. Excavators with pressurized cabins should be
utilized in product operation. Proper maintenance of fresh air filters of the excavator
is essential. Where pressurized cabins are not available, proper respirators must be
utilized.
Stop working when bystanders are in the area of airborne pollutants and make sure
they have proper respirators. Respirators are as important for bystanders as hard
hats.Respirators for both operator and bystanders must be approved by the
respirator manufacturer for the application in question. It is essential that the
respirators protect from the tiny dust particles which cause silicosis and which may
cause other serious lung diseases. Do not use the product until you are sure the
respirators are working properly. This means each respirator must be checked to
make sure that it is clean, that its filter has been changed, and to otherwise make sure
the respirator will protect in the way it is meant to.
Always make sure dust has been cleaned off your boots and clothes when you leave
your shift. The smallest particles of dust are the most harmful. They may be so fine
that you cannot see them. Remember, you MUST protect yourself and bystanders
from the danger of breathing or inhaling dust.
Always follow local laws and regulations for airborne pollutants in the working
environment.
Protect yourself and your surroundings from flying debris. Do not operate the
product or carrier with people around it.
The European standard EN 474-1 on safety of earth-moving machinery requires that
adequate operator's protection, such as bullet proof glass, mesh guard or an
equivalent protection is used.
Keep the cabin windows and doors closed during operation. Window bars are
recommended to protect the windows from flying debris.
CRUSHING HAZARD
The safety label on the product is shown below:
"CRUSHING HAZARD
Contact with moving parts or material could cause death or severe injury.
Protect yourself and your surroundings from collapsing concrete frames. Do not
operate the product or carrier with people around it.
PRODUCT LIMITS
Operating the product beyond its design limits can cause damage. It can also be
dangerous. See “Product specifications” on page 64.
Do not try to upgrade the product's performance by unapproved modifications.
HYDRAULIC FLUID
Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your
fingers to check for hydraulic fluid leaks. Do not put your face close to suspected
leaks. Hold a piece of cardboard close to suspected leaks and then inspect the
cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates your skin, seek
medical help immediately.
Hot hydraulic fluid can cause severe injuries.
HYDRAULIC HOSES AND FITTINGS
Ensure all hydraulic components will withstand maximum pressure and mechanical
stresses caused by operation of the product. Consult your local dealer for
instructions.
Most hydraulic fluids are flammable and might ignite when contacting hot surface.
Avoid spilling hydraulic fluid to hot surfaces.
Working with the product on certain materials can cause sparks and hot splinters to
get loose. These can ignite flammable materials around working area.
Ensure that adequate extinguisher is available.
HYDRAULIC PRESSURE
Hydraulic fluid at system pressure can injure you. Before disconnecting or
connecting hydraulic hoses, stop the carrier engine and operate the controls to
release pressure trapped in the hoses. During operation, keep people away from the
hydraulic hoses.
There might be pressurized oil trapped inside the product even if it is disconnected
from the carrier. Be aware of possible unexpected jaw movements while
maintaining product.
LIFTING EQUIPMENT
You can be injured if you use faulty lifting equipment. Make sure that lifting
equipment is in good condition. Make sure that the lifting tackle complies with all
local regulations and is suitable for the job. Make sure that the lifting equipment is
strong enough for the job and you know how to use it.
Do not use this product or any of its parts for lifting. Contact your carrier dealer to
find out how to lift with your carrier.
SPARE PARTS
Use only genuine spare parts. Use only genuine cutting blades with pulverizers. The
use of other spare part or cutting blade brands may damage the product.
PRODUCT CONDITION
Defective product can injure you or others. Do not operate product which is
defective or has missing parts.
Make sure the maintenance procedures in this manual are completed before using
the product.
REPAIRS AND MAINTENANCE
Do not try to do repairs or any other maintenance work you do not understand.
Non-approved modifications can cause injury and damage. Contact your local
dealer for advice before modifying the product. Before welding on the product
while it is installed on the carrier, consult your carrier dealer for precautions in
welding.
METAL SPLINTERS
You can be injured by flying splinters when driving metal pins in and out. Use softfaced hammer or drifts to remove and fit metal pins, such as pivot pins. Always wear
safety glasses.
LABELS ON THE PRODUCT
Safety labels communicate the following four things:
■The severity level of the risk (that is signal word "DANGER" or
"WARNING").
■The nature of the hazard (such as high pressure, dust, etc.).
■The consequence of interaction with the hazard.
■How to avoid the hazard.
You must ALWAYS follow the instructions in the safety messages, the messages
in the product safety labels and the instructions set forth in the manuals to avoid
death or severe injury!
Keep the safety labels clean and visible at all times. Check the condition of safety
labels daily. Safety labels and instructions which have disappeared, been damaged,
painted over, come loose, or do not meet the legibility requirements for safe viewing
distance must be replaced before operating the product.
If a safety label is attached to a part that is replaced, install a new safety label on the
replacement part. If this manual is available in your language, then the safety labels
should be available in the same language.
There are several specific safety labels on this product. Please become familiarized
with all safety labels. The location of the safety labels is shown in the illustration
below.
When you clean the safety labels, use a cloth, water and soap. Do not use solvent,
gasoline or other harsh chemicals to clean the safety labels.
Solvents, gasoline or harsh chemicals could loosen the adhesive that secures the
safety labels. Loose adhesive will allow the safety label to fall.
The pulverizer is designed for use in demolishing work to pulverize demolition
material. It can be used in recycling plants for separating the concrete from the
reinforcement bars or for removing and regrinding road surfaces. For more
information, contact your local dealer.
Almost all carriers meeting mechanical and hydraulic requirements can be used to
operate products. See “Product specifications” on page 64. The product is installed
on the carrier much in the same manner as installing a bucket or other attachment.
A flange-mounted products requires also a separate mounting bracket.
The products is connected to a carrier's hydraulic circuit with an installation kit. If
the carrier is already fitted with an installation kit, the installation requires only
suitable hoses and fittings. For product installation, secondary relief valves in the
bucket cylinder circuit and the carrier auxiliary circuit are needed. If the carrier does
not have a suitable kit to run attachments, one must be built. This may require a
more complex installation, including new piping and additional valves such as a
flow control valve or pressure relief valve.
Suitable kits can be ordered from the manufacturer or their local dealers, carrier
manufacturers and their dealers, or third party suppliers.
Note: In models equipped with a system to prevent rotation of the product,
remember to unlock the system before starting operation. See “Mounting and
dismounting the product” on page 32.
Hydraulic oil
In general, the hydraulic oil originally intended for the carrier can be used with this
product.
Operating temperature
The operating temperature is -20 °C (-4 °F) to 80 °C (176 °F). If you must work in
a temperature lower than -20 °C (-4 °F), the product must be preheated before any
operation can begin. Start the operation with low hydraulic flow.
Note: The temperature of the hydraulic oil must be monitored. Ensure that oil grade
and monitored oil temperature together guarantee correct oil viscosity.
The operation of the product is based on a static force produced by the hydraulic
cylinder of the product. To increase the product's working life, pay particular
attention to correct working methods.
Crushing is performed at the front of the jaws. NOTICE! Avoid using cuttingblades for crushing. Doing so may damage the blades.
Cutting is performed with cutting blades at the rear of the jaws. The cutting blades
can be reversed.
JAWS, TEETH AND CUTTING BLADES
Jaws
The jaws are operated by the hydraulic cylinder. One jaw is fixed and the other,
equipped with breaking teeth, is moving. Crushing is performed using the crushing
teeth of the jaws.
Crushing teeth
Crushing is performed using the crushing teeth of the jaws. The long-lasting,
convex teeth are made of special steel. They are fastened with screws and can be
replaced.
Crushing plate
The teeth of the crushing plate are made of special steel. The teeth are welded
directly onto the plate. The crushing plate is removable, so that the teeth can be
serviced separately.
Cutting blades
The cutting blades are fastened with screws. You can turn them to use unused
cutting edges or replace them with new cutting blades. See “Turning and changing
cutting blades” on page 49.
Warning! Protect yourself and your surroundings from flying debris and
collapsing concrete frames. Do not operate the product or carrier with people
around it.
The product, as a standard assembly, must not be used under water. It must be
adapted for underwater applications. Contact your local dealer for more
information on underwater use.
After operating the product under water or in environments close to the sea,
carefully wash the product. Subsequently disassemble the hinges and carefully
clean the pins and bushings to remove all traces of oxidation. Lastly, grease the
disassembled parts.
■Open the jaws, position the object on the fixed jaw side by operating excavator
cylinders and close the jaws to crush. The best crushing result is obtained by
using the whole tooth area of the jaws. NOTICE! Avoid using cutting bladesfor crushing. Doing so may damage the blades.
MB010054
■When crushing very large concrete blocks, start crushing from the outer edges
of the concrete.
■Use a safety screen to protect the operator from flying debris. Keep the cabin
windows and doors closed during operation.
■To cut rebars or similar objects with the product, open the jaws. Operate the
excavator cylinder to position the object on the cutting blade of the fixed jaw
side and close the jaws to cut. For the best possible cutting performance and to
avoid damaging the product, only use cutting blades for cutting.
■The product is intended for pulverizing. Do not use the product as a lever or to
strike, hit or ram objects. Do not use the side of the product to move concrete
or objects.
■Do not use the product for lifting. Lifting eyes on product are for storage and
maintenance purposes only.
■When operating the product, make sure that it does not make contact with the
carrier boom or hydraulic lines.
MB010061
■Do not operate the jaws with the carrier's boom stick or bucket cylinders at the
end of their stroke (either fully extended or retracted). This may damages the
carrier.
■When the jaws are closed, the cylinder rod is exposed. NOTICE! Avoid hitting
the rod or shield plate with concrete or iron bars. Damage to the cylinder rod or
shield plate may cause rod seal breakage and oil leaks.
MB010063
■Always remove demolition debris from the product. Getting steel frame or rebar
between the jaws and cylinder rod clevis can damage the cylinder rod or jaws.
Getting steel bars in the clearance between the cylinder and the base of the fixed
jaw can damage the main shaft.
■To avoid a dangerous fall, ensure that the structure your carrier is on is strong
enough to support it
■To prevent the spread of dust during operation, constantly keep the working
area damp with water jets.
■Stay more than 10 meters (33 feet) away from live, overhead electric cables
with any part of the machine.
■The bearings must be well greased during operation. Make regular inspections
during operation. If no grease is visible, the bearings require more frequent
greasing. If bearings are covered with excessive grease, they require less
frequent greasing.
Warning! The product must be secured from falling over when disconnecting
it from the carrier. Only use a skilled operator to position the carrier for the
removal!
Warning! Hydraulic pressure inside the product must always be released
before opening hose connections!
Warning! Hot hydraulic fluid can cause severe injuries!
Warning! The thrust bearing must be locked to prevent the product from
rotating during maintenance or transportation.
1.Position the product horizontally on the floor.
MB010089
2.Stop the carrier engine. Operate the boom and product controls to release
pressure trapped inside hoses.
3.Close the product shut-off valve. If quick couplers are used, disconnection
automatically closes product lines. If the line includes ball valves, make sure
that they are closed.
3.Connect the hoses. An installation inspection must be carried out after the
product has been mounted on the carrier. During installation inspection, certain
specifications (operating pressure, oil flow, etc.) are checked so that they are
within given limits. See “Product specifications” on page 64.
4.Open the ball valves.
5.Remove the air from the hoses by carefully operating the crusher cylinder.
Open and close the empty jaws several times.
Note:
■If the lines going to the opening and closing connection have two different
pressure values, connect the line with the highest pressure (which should not
exceed the max. value) to the connection fitting jaw closing and the lower
pressure line to the connection fitting jaw opening, in order to have the
maximum clamping force.
■Remove the cap from the fitting of the hydraulic hoses connecting the excavator
and the crusher.
■Make sure that the hose fittings are perfectly clean and dust-free, and attach
them to the machine by tightening the screws or the fittings.
Note:
■The hydraulic rotation motor can operate with the drainage outlet plugged if,
during activation, the back-pressure on the drainage branch during operation is
not greater than 15 bar (218 psi).
■At first installation, check the backpressure value on the return branch of the
rotation system, activating the hydraulic rotation in both directions.
■If the measured back pressure is greater than 15 bar (218 psi), connect a
drainage line that connects the drainage attachment of the motor to the tank.
■The drainage attachment of the motor, normally plugged, is located on the
bottom of the motor (see illustration).
The transportation and parking positions are shown below. When moving the
carrier, ensure that the product is not too close to the carrier.
5.5 SPECIAL CONDITIONS OF USE
The product may require modifications, special operating techniques, increased
maintenance or special wear items if it is used in conditions that differ from normal
breaking or demolition work. Special conditions of use are:
In case of special conditions of use, contact your local dealer for instructions.
The product as a standard assembly, must not be used under water. Contact
your local dealer for more information on underwater use.
5.6 STORAGE
LONG TERM STORAGE
Observe the following points when the product is stored. This way, the vital parts
of the product are protected from rust and the product is ready to be used whenever
necessary.
1.Make sure your storage area is dry.
2.To avoid damaging the cylinder rod, operate the cylinder to the shortest position
by leaving the jaws open.
3.Insert blocks under the product to keep it off the ground. If the product is stored
outside, cover it to prevent rusting.
4.Apply grease to all product parts. Protect the mounting bracket, pin holes,
cutting blades and pivot ends with an anticorrosive agent.
5.Seal connections with clean plugs to prevent oil leakage and dirt from getting
into the couplings.
In general, the hydraulic oil originally intended for the carrier can be used with this
product. However, since working with the product heats the oil more than with the
usual excavation work, the temperature of the oil must be monitored.
If the temperature of the hydraulic oil exceeds 80 °C (176 °F), an auxiliary oil cooler
is needed. The oil viscosity must be between 1000-20 cSt while the product is being
used.
When the product is used continuously, the temperature of the hydraulic oil
normalizes at a certain level depending on conditions and on the carrier. The
temperature in the tank must not exceed the maximum allowed.
The product must not be started if the ambient temperature is below freezing and
the oil is very thick. The machine must be moved to bring the oil temperature above
0 °C (32 °F) before working can start (viscosity 1000 cSt or 131 °E).
The table below shows hydraulic oils recommended for product use. The most
suitable oil is selected in such a way that the temperature of the hydraulic oil in
continuous use is in the ideal area on the chart and the hydraulic system is used to
best advantage.
Problems due to incorrect hydraulic oil viscosity in the product:
Oil too thick
■Difficult start up
■Stiff operation
■Danger of cavitation
■Sticky valves
■Filter bypass opens, impurities in the oil are not removed
Oil too thin
■Efficiency losses (internal leaks)
■Damage to gaskets and seals, leaks
■Accelerated wearing of parts, because of decreased lubrication efficiency
Note: We strongly recommend the use of different hydraulic oils in the summer and
in the winter if there is an average temperature difference of more than 35 °C (95
°F). The correct hydraulic oil viscosity is thus ensured.
SPECIAL OILS
In some cases, special oils (for example biological oils and nonflammable oils) can
be used with the product Observe the following aspects when considering the use
of special oils:
■The viscosity range in the special oil must be in the given range (1000-20 cSt).
■The lubrication properties must be sufficient.
■The corrosion resistance properties must be good enough.
Note: Although a special oil could be used in the carrier, always check its suitability
with the product Contact the oil manufacturer or your local dealer for more
information about special oils.
2.2 OIL COOLER
The carrier hydraulic system must be able to maintain a temperature within an
acceptable level during the product operation. This is because:
1. Seals, wipers, membranes and other parts manufactured from the corresponding
materials can normally stand temperatures up to 80 °C (176 °F).
2. The higher the temperature is, the less viscous the oil gets, thus losing its
capability to lubricate.
A standard carrier, with a proper product circuit, meets the requirements of the
necessary cooling capacity. If the oil temperature tends to be too high during
product operation, the following must be checked:
■The product circuit pressure relief valve should not be opened unnecessarily.
■The product circuit pressure drops must be reasonable; that is, less than 20 bar
(290 psi) in the hydraulic line.
■There should be no internal leakages in product or carrier hydraulic pumps,
valves, cylinders, motors, etc.
If all of the above-mentioned items are in order, and the temperature of the hydraulic
oil still tends to be too high, extra cooling capacity is needed. Contact the carrier
manufacturer or your local dealer for details.
The purpose of the oil filter is to remove impurities from the hydraulic oil. Air and
water are also impurities in oil. Not all impurities can be seen with the naked eye.
Impurities enter the hydraulic system:
■During hydraulic oil changes and refilling.
■When components are repaired or serviced.
■When the product is being installed on the carrier.
■Because of component wear.
Normally the existing, main oil filters of the carrier are used as attachment circuit
return line filters. Contact the carrier manufacturer or your local dealer concerning
instructions for the filter change intervals.
In product work, the carrier oil filter must fulfill the following specifications:
■The oil filter must allow maximum particle size of 25 microns (0.025 mm).
■The oil filter material must be man-made fibre cloth or very fine gauge metallic
mesh to withstand pressure fluctuations.
■The oil filter must have a nominal flow capacity of at least twice the product's
maximum flow.
In general, oil companies guarantee new oils to have a maximum particle size of 40
microns. Therefore, filter the oil when filling the tank.
The damage caused by hydraulic oil impurities in the carrier and attachment circuits
include:
Shortened working life of pumps and other components
■Rapid wear of parts.
■Cavitation.
■Wear of cylinder and gaskets.
Reduced attachment efficiency
■Accelerated wear of moving parts and seals.
■Oil leakages.
Shortened working life and reduced lubricating capability of oil
Note: Component damage is only a symptom. The trouble itself will not be cured
by removing the symptom. After any component damage due to impurities in the
oil, the entire hydraulic system must be cleaned. Dismantle, clean and reassemble
the product and change the hydraulic oil.
This product is a precision-made hydraulic machine. Therefore, great care and
cleanliness should be taken when handling any of the hydraulic components. Dirt is
the worst enemy in hydraulic systems.
Handle the parts carefully and remember to cover any cleaned and dried parts with
a clean, lint-free cloth. Do not use anything other than purpose-designed materials
for cleaning hydraulic parts. Never use water, paint thinners or carbon tetrachloride.
Components, gaskets and seals in the hydraulic system should be oiled with clean
hydraulic oil before assembly.
Remember to grease the product parts regularly, according to the instructions in this
manual.
Prior to maintenance or inspection, operate all the control levers to their fully
extended stroke. This will release pressure within the hydraulic piping and prevent
unexpected movement of the jaw and loss of oil through the hydraulic lines.
Close the jaws during maintenance or inspection. If you must leave the jaws
open, remember to block the jaws to prevent them from closing.
1.2 INSPECTION AND MAINTENANCE BY THE OPERATOR
Note: The times given refer to the carrier hours with the product installed.
EVERY EIGHT HOURS
Grease shafts and pins.
DAILY MAINTENANCE
1.Check the hydraulic hoses and hose connections. Tighten if necessary.
2.Check the cutting blades and their clearance. Tighten bolts or replace the
cutting blades, if necessary. See “Turning and changing cutting blades” on page
3.Check the jaws and teeth for wear. Replace if necessary. Any type of hardfacing
welding on the teeth of the jaws is not recommended as they are made of diecast, wear-resistant material. Hardfacing welding on the teeth would alter their
special shape, reducing the ability to penetrate concrete as well as productivity.
See “Replacing teeth” on page 52.
4.Check the grease nipples.
WEEKLY MAINTENANCE
1.Check the main body for wear.
2.Check the pins and bushings for wear.
3.Check the cylinder rod, seals and connection points for wear. Tighten if
necessary.
4.Observe hydraulic oil temperature for all lines and connections.
5.Check that the product works smoothly by operating the jaws.
6.Tighten connections, if necessary.
EVERY 40...80 HOURS
Grease the thrust bearing. Adapt the greasing interval and amount of grease to
working conditions.
1.3 INSPECTION AND MAINTENANCE BY THE DEALER
Note: The times given refer to carrier hours with the product installed.
INITIAL 50 HOUR INSPECTION
It is recommended that your local dealer perform the first inspection after 50 to 100
operating hours. Contact your local dealer for more information about the initial 50hour inspection.
The 600-hour/yearly service is performed by your local dealer. It is recommended
every 600 operating hours or once a year, whichever comes first. Neglecting the
600-hour/yearly service can cause severe damage to the product.
Your local dealer will reseal the product and replace safety decals as needed.
Contact your local dealer for more information about 600-hour/yearly servicing.
During this service, you should also perform the following tasks:
■Check all hydraulic connections.
■Check that the hydraulic hoses do not rub against anything in any boom/stick
position.
1.4 MAINTENANCE INTERVALS IN SPECIAL APPLICATIONS
The service interval is considerably shorter with special applications such as
underwater use. In special applications, consult your local dealer for the correct
service intervals.
The product, as a standard assembly, must not be used under water. It must be
adapted for underwater applications. Contact your local dealer for more
information on underwater use.
1.5 OTHER MAINTENANCE PROCEDURES
WASHING THE PRODUCT
When working with product and removing it from the carrier, dirt (mud, rock
powder, etc.) can become attached to it. Wash the outside of the product with a
steam washer before sending it to the workshop. Otherwise dirt can cause
difficulties in disassembly and assembly.
CAUTION! Plug the pressure and return line before washing the product or else dirt
could get into it and cause damage to the components.
Turning and changing cutting bladesRPV14R, RPV22R, RPV29R, RPV39R, RPV53R, RPV75R
MB030008
TURNING AND CHANGING CUTTING BLADES
Warning! Prior to maintenance or inspection, operate all the control levers to
their fully extended stroke. This will release pressure within the hydraulic
piping and prevent unexpected movement of the jaw and loss of oil through the
hydraulic lines.
Warning! Support the jaw to prevent it from closing unexpectedly during
maintenance.
Used cutting blades can be recycled. Contact your dealer for more information
about local regulations of recycling.
1.Position the product on level ground.
2.Support the jaw.
3.Make sure the carrier's transmission is in neutral and the parking brake is
engaged.
Turning and changing cutting bladesRPV14R, RPV22R, RPV29R, RPV39R, RPV53R, RPV75R
6.Remove the screws, cutting blades and shim plates. Turn the blades to use one
of the 4 sharp sides (the blades may be rotated up to 4 times). Replace the blades
if necessary.
MB030007
7.Grind the surfaces to flush all burrs from the cutting blade and cutter base. If
burrs remain on the surface, the cutting blade will not have proper contact with
the cutting blade base. This will cause the cutting blade to break.
8.With a feeler gauge check, that the clearance between the two cutting blades is
the required 0.2...1.2 mm (0.008...0.05 in). If necessary, restore the correct
clearance by inserting the appropriate shims below the cutting blade.
9.Install the screws and tighten them to the specified torque.
Welding must occur in a workshop with proper welding tools. If you must weld
the product when it is on the carrier, consult your carrier dealer for
precautions during welding.
Warning! Support the jaw to prevent it from closing unexpectedly during
maintenance.
A used tooth can be recycled. Contact your dealer for more information about
local regulations of recycling.
Periodically check the wear and tear of the teeth and the interchangeable plates.
For the product to perform and operate well and to reduce maintenance costs, it is
necessary to replace the interchangeable parts before wear and tear can undermine
their housings.
If, due to lack of maintenance, teeth are lost during product operation, stop
operation immediately or you will damage the housings on the product body.
During complete shutdown, make sure that the jaw rest on the central tooth of the
product framework. If you do not, it will be necessary to replace the interchangeable
part where the central tooth is located.
WARNING! When replacing the interchangeable plate, close the mobile jaw on the
fixed part to prevent the plate from falling when the screws are removed and
creating a danger to the operator.
NOTICE! Any type of hardfacing welding on the interchangeable parts is not
recommended, since they are made of wear proof material and hard to weld.
Furthermore, the hardfacing welding would alter the flatness of the manufactured
parts, making the coupling in their housings difficult.
1.Place the product on the ground at a 30° incline so that the side with the tooth
to be replaced faces upward. Remove the fastening pin (2), together with the
hardened resin (5) with of the supplied pin extractor, striking the end with a
hammer (see illustration).
2.Extract the tooth (1) from its housing. Carefully clean the space (6), which
contained the resin, and eliminate any residue.
6
1
MB030014
3.Place the product on the ground at a 30° incline so that, due to gravity, the tooth
will naturally come into contact with the adapter.
4.Once the tooth (1), is positioned on the adapter, insert the fastening pin (2) from
the back.
5.By gently hammering, make sure that the key is in full contact with the tooth.
Make sure that contact between the tooth and the adapter is maintained.
6.Prepare the STIMIX kit. The kit includes a pistol (3), one cartridge containing
resin, and two mixing tubes.
7.Remove the plug by unscrewing the screw and insert the mixing tube by
fastening it with the nut. Place everything on the pistol. NOTICE! To prevent
the product leaking hold the pistol vertically.
8.Press the pistol handgrip and, keeping the pistol vertical, push the resin into the
mixing tube.
9.Press three times to release all of the resin. Insert the STIMIX resin into the
relevant hole between the pin and the tooth.
10. Operate slowly, but constantly, and without interruption (on all teeth).
Changing oil in the rotation unitRPV14R, RPV22R, RPV29R, RPV39R, RPV53R, RPV75R
Avoid mixing oils of different viscosity or of different brands. Do not mix mineral
oils with synthetic oils.
After start-up, check the lubricant level periodically and top it up whenever
necessary.
During continuous operation, the temperature of the lubricant must not exceed 80
°C (176 °F). Whenever this value is in danger of being exceeded, forcibly cool the
oil.
NOTICE! Change the oil while the rotation unit is hot.
1.Position the product on level ground. The rotation unit and product must be in
an upright position.
2.Support the jaws.
3.Unscrew the filler cap (B) and the drain plug (A).
4.Completely empty oil in the rotation unit.
5.Replace the drain plug (A).
6.Remove the level plug (C).
7.Fill the rotation unit with new oil using the filler cap until the oil begins to
overflow from the level plug (C).
8.Replace the filler cap (B) and the level plug (C).