BRH 625 SANDVİK BREAKER

BRH 625 ManualParts, Safety, Operation

& Maintenance

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Form No. M1078-POMS

Revision 0

April 2002

BRH 625 TABLE OF CONTENTS

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INTRODUCTION 1TABLE OF CONTENTS 2

I MAIN DATA 3I-1 Overall dimensions 3I-2 Technical specifications 4

II MAINTENANCE INSTRUCTIONS 5II-1 Mounting tool and pin 5II-2 Lubrication 6II-3 Tool retainers 7II-4 Tool bushing and front guide wear parameters 8II-5 Side-rods 9II-6 Screw Tightening 9II-7 Accumulator 10II-8 Storage 10II-9 Underwater working 11II-10 Roof scaling 12II-11 Sound proof cradle 12

III OPERATING INSTRUCTIONS 14III-1 Cold weather starting 14III-2 How to obtain maximum productivity and long life 14III-3 How a demolition tool cracks rock and concrete 15III-4 Cause and effect of fatigue 15III-5 Demolition tool fatigue failure 17III-6 Typical failures 18III-7 TRAMAC demolition tool guide 18

IV HAMMER TEST 20

V SAFETY PRECAUTIONS 21

PARTS LIST P3ACCUMULATOR P6GREASING FLANGE ASSEMBLY P7SOUND PROOF CRADLE P8

TROUBLE SHOOTING M1DISASSEMBLY M4INSPECTION OF BACKHEAD AND DISTRIBUTION PARTS M13INSPECTION OF FRONT GUIDE AND CRADLE M24INSPECTION AND SERVICE OF THE ACCUMULATOR M30CHARGING OF THE ACCUMULATOR M35ASSEMBLY M40

BRH 625 MAIN DATA

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Original measurements are in mm. Inch figures are rounded

values

I MAIN DATA

I - 1 Overall dimensions

BRH 625 MAIN DATA

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I - 2 Technical specifications

The 34 gpm oil supply is the maximum oil flow setting allowed on this ham-mer. The BRH 625 hammer can be used with carriers providing lower oilflows (in the 21 to 34 gpm range), but will produce lower blow rates.However, the back-head low-pressure valve has been specially designed tomaintain the same working pressure whatever the oil flow supply [see II-5].

Oil temperature plays an important role as excessively hot oil increasesinternal leakage [which lowers efficiency] and deteriorates the piston sealsand the accumulator diaphragm.

Impact class 2500 ft - lbs Blows per minute 860 Oil supply * 34 gpm Operating pressure 1700 psi Max. Back pressure 45 psi Working weight 2200 lbs Height 79 in Shock dampener in hydraulic circuit Yes Shock absorber bracket Yes Automatic cut-off Yes Tool diameter 4.65 in

Tool references Dimension P/N Standard moil point 39 in 78509 Long moil point 50 in 78510 Chisel 39 in 78511 Blunt 39 in 78515

hammer excavator tank Maximum temperature 175 ºF 160 ºF

BRH 625 MAINTENANCE INSTRUC-TIONS

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II MAINTENANCE INSTRUCTIONS

The life of a tool is determinated by its operating time. The hour-meter of your excavator will notproduce an accurate measurement of the hammer operating time. Travelling and boom positioningare 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 thetool 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 positionedin 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 movingfreely. If the case, replace the o'rings.

Before inserting a new tool inside the hammer, make sure the shank of thetool, the bushing, and the two retaining pins are hand-greased [as a grease,we recommend the use of TRAMAC BRH7].

5555

53535656

5454

7272


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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] andthe shutter [rep. 55 - see previous page].

When removing the tool, take care not to drop the tool on sharp objects, or pol-ished 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 ham-mer since it considerably reduces the frictions between the bushings and the tool. The use of the automaticlube station promotes a complete distribution of the lubricant through out the bushings.

However, this should not prevent the operator from hand-lubricating the tool beforeinserting it and performing frequent visual inspections to insure that the point iswet.

Before inserting the tool [rep. 72] inside the hammer, hand-lubricatethe shank of the tool, the bushing, and the two tool-retainers. As lubri-cant, 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.


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II-3 Tool retainers

Examine the retaining pins [rep. 53] 2 or 3 times a week. Change themwhen they show signs of heavy wear (like becoming oval shaped orshowing big cracks) or when any portion of the grooves have disap-peared (if not, lubrication can be impaired, leading to high frictionsbetween the tool and the pins and, possibly, to the tool failure [see IV-7.6]).

When removing retaining pins, wear should be checked to decide if they should be turned over or not priorinserting in the front guide. In normal working conditions, the pins will show marks which correspond to theimpact of the upper round shoulder of the tool flat section. When controlling pins, two cases may arise :

]

a> Hollow shaped deformation without any bumparound the mark. Pin can be turned over by 180º tolengthen life time.

Hollow shape

View F

F


b> Hollow shaped deformation shows peripheralbump more particularly located on round part of pin.

It is imperative to eliminate the bump by grinding prior turning the pin over 180degrees.Deep and irreversible damages may result from ignoring the above mentioned rec-ommendations and lead to forfeiture of warranty.

II-4 Tool bushing and front guide wear parameters

TRAMAC BRH 625 features replaceable chuck-bush-ings [rep. 50 & 52]. The bushings and front guide mustbe regularly checked for wear. Excess wear will causemisalignment between the tool and the striking piston.Thus, the impact will generate stress contractionsdetrimental to the striking faces.

The chuck-bushings are grooved in such a way as to provide perfect lubrication ofthe tool : When any portion of these grooves has disappeared, consult your TRA-MAC dealer for part replacement.

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View G

Bump

G


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II-5 Side-rods

Daily, inspect the side rods [rep. 58] for possible breakage or looseningby tapping on each rod with a metal object. You will notice if a rod is bro-ken by its particular sound.

Daily, check for loose tie rods. Consult your TRAMAC dealer for the tie rod tighten-ing procedure. It is a very sensitive undertaking and incorrect methods can resultin serious consequences. Your TRAMAC dealer knows the torque specificationsand 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 intooperation 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. Theproper torque is 290 ft-lbs.


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II-6.3 Accumulator fixing screws

Every 500 hours, check the 18 accumulator fixing screws [rep. 6] for tightness. Theproper 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, thetwo hammer hoses vibrate lightly; but when the accumulator is discharged, the hoses will jump violently. Youwill 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/N51347.

TRAMAC accumulators do not loose their charge through leakage. A TRAMACaccumulator consists of two flanges between which is held a diaphragm (reassem-bling a pie plate). The only time a TRAMAC accumulator will loose its charge will bewhen this diaphragm becomes perforated.

Never try to open the accumulator without discharging previously the pressurethrough the inflating screw.

II-8 Storage

Put the appropriate plugs on the hammer and excavator couplings, to avoid any oil leakage and dust pene-tration. Put the breaker away under cover in a clean place. Lubricate with grease the visible part of the pistonand the entire tool to avoid damage from rust.

Accumulator pressure 530 psi Accumulator tightening screw [rep 4] torque 145 ft.lbs


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Remember, a corroded piston destroys its seals in a few minutes.This operationcan't be overlooked in case of underwater work, and in particular, in the case of seawater,

II-9 Underwater working

The TRAMAC BRH 625 model in the standard version mustnot be used for underwater work, even for very short periodsof time. If the chamber between the piston and the tool fillswith water when the piston strikes, the water will not beevacuated fast enough and a considerable pressure rise willthen occur which will destroy the piston seal (with a risk ofseizure).


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For underwater operation, the ball [rep. 4] and the spring [rep. 5] included in the lubrication flange must beeliminated and the flange connected to an air compressor. Pressure from the compressor must be at least 22psi 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 thepenetration of abrasive dust [see III-9 for the removing of parts 4 & 5]. In addition, the standard upper bush-ing [rep. 50] must be replaced by a specially designed upper-bushing [rep. 51] which provides enlarged airpassages.

II-11 Sound proof cradle

The BRH 625 model in the standard version can easily be converted in the sound proofed version for workbeing completed in an urban environment requiring the lowest possible level of noise.

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Please, contact your TRAMAC dealer for more information about this option. Whenthe hammer is equipped with the soundproof arrangement, care must be taken toobserve warnings and recommendations, particularly in the maintenance of partsinvolving sound proofing materials, some of which are flammable.

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BRH 625 OPERATING INSTRUC-TIONS

III OPERATING INSTRUCTIONS

III-1 Cold weather starting

Start up the excavator and circulate the hydraulic oil to warmit up before starting the hammer. When oil is warm, raise thehammer from ground, idle the the engine and energize thehammer control valve. The oil will pass through the hammerbut the hammer will not fire. Run this way for 5 to 10 minutes;this will warm up the hammer parts. In below zero tempera-tures, we suggest the tool be stored in a warm shed at night.Extreme cold can crack the point when you start the breakingoperation.

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 commerciallyavailable. Unlike other tools on the market, our steel is hardened all the way through - no thin shellof hard steel which wears quickly. When the tools lose their edge, either at the tip or on the sides, itis 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 themoils 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 tooverheat the tool to be maintained.

As a general rule, never let the tool cool quickly or suddenly, even when it isused with the breaker.

The fact of dipping a tool into water when it has been heated in the course of work, or leaving it inthe snow in winter, results in a quenching effect on the tip or cutting bit, and this increases the riskof breakage.

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Tools are covered by TRAMAC against metal defects (very uncommon). It is notunusual that some operations (working at angles, blank firing, ...) lead to tool break-age, including inside the chuck housing.The use of after market tools will void yourwarranty for any claim related to parts in contact with the tool (which includes themain piston).

Learning to run a hammer properly is not difficult. It takes a little time and just plain common sense. To pre-serve 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 theworking end of the tool. Provided the demolition tool is in contact with the rock or concrete which requiresbreaking, it is this compressive stress wave which fractures the rock. Then, immediately following the com-pressive wave, a tensile stress wave is formed due to the hammer piston lifting from the top of the demolitiontool.

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 exam-ple "Blank Firing" or bending of the demolition tool due to leverage, will result in loss of breaker efficiency ofup 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 operat-ing conditions, creates fatigue stress in the tool which can lead to the fatigue failure of the tool before it isworn out. Anything which interferes with the cycle of compressive and tensile stresses will also increase thelevel of fatigue stress being applied to the demolition tool and, thus, increases the risk of early fatigue failureof the tool.


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The main cause of increased fatigue stress in a demolition tool isany form of side pressure during service which creates bending.Thus, utilizing the tool as a lever, using an incorrect driving angleor attempting to break ground using the pull of the excavator areall detrimental to the life of a demolition tool and should be avoid-ed [see figure].

The hydraulic power available in the machine far exceeds the strength of a demoli-tion 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 isnot in proper contact with the rock or concrete to be broken. This includes jobs where the tool slides off thework 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 warmedbefore 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, allcare 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 excessivebending.

D> Lubrication :Care must be taken to avoid metal to metal contact that, as a result of galling, could cause deep damagemarks 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.


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E> Corrosion :A rusty demolition tool is more likely to suffer fatigue failure. Keep tools well greased and sheltered from theweather 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 inchesfrom the working end, subject to the nature of use. The fracture face itself will normally exhibit semi-circularpolished area with the remainder being of rougher appearance (see figure). The polished semi-circular areais the fatigue area and generally started from a damage mark or other stress initiated on the outside of thedemolition tool and spread inwards.

The fatigue area slowly widens until the stresses being applied to the demolition tool cause sudden failure ofthe 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 initia-tion of a fatigue crack has taken place, it requires a lower stress level to cause it to grow.


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A B C D E F

Ref Tool type Application

A Moil point Low abrasive, homogenous materialB Chisel Plastic or heterogeneous materialC In-line chisel Plastic or heterogeneous materialD Blunt Crumbly rockE In-line asphalt cutter Asphalt cutter and trenchingF SpadeFrost Asphalt and trenching

III-6 Typical failures

TRAMAC demolition tools are manufactured from fist class materials and then heat treated to pro-duce a fatigue and wear resistant tool. Thus when a tool has apparently failed to give a satisfactoryservice 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 guide-lines apply:

Blank tools worn more than 1/3 of their diameter, or moils and chisels worn back more than 2inches from the working end, are classed as reasonable life.

III-7 TRAMAC demolition tool guide


Fatigue breakage with typicalfatigue wrinkles due to steeldefect.100% WARRANTY

Failure due to blank firing orexcessive wear of bushingsand/or chuck housing.

NO WARRANTY

Failure due to- operation with worn out retaining pins,- blank firing,- twisting tool.

NO WARRANTY

Typical failure caused bymisalignment between downpressure, hammer and tool(prying, levering).

NO WARRANTY

Breakage due to impropercontact between the tool'stip and rock or concrete.

NO WARRANTY

Mushrooming or fast wearingcaused by operating too longon the same spot.

NO WARRANTY

BREAKAGE CHART

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BRH 625 HAMMER TEST

IV HAMMER TEST

Measurement of the high pressure setting

For normal day to day work, TRAMAC's BRH 625 hammer has been pread-justed in manufacturing to obtain 1700 psi at 34 gpm for an oil temperatureof 110 ºF on a moderately hard ground.

Steel plate 1"min or hard rock

3/8" x 12' Hose

Gauge 0-3000 psi

MAX FLOW RATE MAX WORKING PRESSURE MAX BACK PRESSURE

34 GPM 1700 PSI 45 PSI

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BRH 625 SAFETY PRECAUTIONS

V SAFETY PRECAUTIONS

1 Never use the hammer as a lifting device

2 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.

BRH 625

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This Page Left Blank Intentionally

Cette Page est Laissée Blanche Intentionnellement

Page P1

BRH 625PARTS MANUAL

Form No. M1078-P

Revision 0

April 2002

BRH 625 PARTS LIST

Page P2

Page P3

BRH 625 PARTS LIST

Rep Qty Designation Part number Back Head ass'y, composed of :

1 1 - Accumulator ass'y 23947 3 1 - Ring 18652 4 1 - O'ring 33616 5 1 - Disk 77227 6 8 - Screw 78508 Bach Head ass'y, composed of :

7 1 - Back head including 78499 8 Insert thread 21910

8 1 Sleeve 80664 9 1 Rush 10380

10 2 - O'ring 23992 Rotating connections Low pressure

11 1 - Valve 80665 12 1 - Spring 74258 13 6 - Washer 67293 14 1 - Pin 74240

15 1 - O'ring 71817 16 1 - Plug 71828

High pressure

17 1 - Spring 79730 18 1 - Valve 71830

19 1 - Seal 80250 20 1 - O'ring 71817 21 1 - Plug 71828

Oil supply

22 2 - Knee piece 56047 23 4 - O'ring 5346

Distribution ass'y, composed of :Distribution ass'y, composed of :

24 1 - Lower piston 62287 25 1 - Upper piston 62288

26 1 - Distribution 54273 27 11 - O'ring 9649 28 1 - O'ring 23131 29 4 - O'ring 10050 30 1 - Pin 51806 31 1 - Plunger 62289 32 1 - Distributor 54275 33 1 - O'ring 13006 34 1 - Distributor cover 54277 35 1 - Valve 51808

Cylinder ass'y, composed of :

36 1 - Cylinder 62286 37 2 - Pin 42221 38 2 - Valve 51803 39 1 - Valve spring ass'y 51991 40 1 - Oiler flange ass'y 74716

BRH 625 PARTS LIST

Page P4

Page P5

BRH 625 PARTS LIST

Rep Qty Designation Part number Spacer ass'y, composed of :

42 1 - Spacer 62290 43 1 - Tight ring 51933 44 1 - O'ring 52204 45 2 - Tight seal 54279 46 1 - Bearing washer 54280 47 1 - Diaphragm 54281 48 1 - Accumulator body 54282

Front guide ass'y, composed of :

49 1 - Front-guide 78244 50 1 - Upper chuck bushing (standard) 78226 51 or - Upper chuck bushing (for roof scaling) 78790 52 1 - Lower chuck bushing 78333 53 2 - Retaining pin 73571 54 2 - Lock pin 57842 55 2 - Pin shutter including : 57844 56 4 O'ring 5353 57 1 - Plastic plug 75555

Assembling parts :

58 4 - Side-rods 64506 59 4 - Nuts 52027 60 1 - Pin 71848

Cradle suspension

64 2 - Lower suspension 78361 65 4 - Screw 73505 66 8 - Disk lock washer 51742 67 1 - Shock-absorber 78365

Standard cradle

68 1 - Standard cradle 78358 69 12 - Screw 60180 70 48 - Disk lock washer 51742 71 12 - Nut 54968

Page P6

BRH 625 ACCUMULATOR

BRH 625 Accumulator HP

Item Part Number DESCRIPTION

23947 Accumulator ass'y, composed of :1 23948 1 (Lower flange2 17639 1 (Diaphragm3 26599 1 (Upper flange4 65385 16 (Screw CHc5 26428 1 (Inflating screw6 14826 1 (Tight ring7 36306 16 (Plug

Qty.

Tighten Bolts to 140 ft-lbs

BRH 625 GREASING FLANGEASSEMBLY

Page P7


CHUCK HOUSING:74716 Greasing flange assembly :

1 74718 1 (Support plate2 74719 1 (Pin3 74725 1 (Locking plate4* 3521 1 (Ball5* 9213 1 (Spring6 73505 2 (Screws7 51742 4 (Washers8* 5330 1 (O-ring

(* - these items are included in the seal kit PN 75464)

59735 1 Seal kit73571 2 Tool retainers57842 2 Lock pins5353 8 O'rings75464 1 Grease flange spare kit78509 1 Spare tool

Qty.

BRH 625 SOUND PROOF CRADLE

Page P8


1 78781 1 Sound proof cradle including:26241 12 (Helicoils - 3/4” UNF

2 78784 1 LP cover3 78786 1 HPcover4 60165 12 Screw5 51742 24 Washer6 60180 8 Screw7 78791 4 Screw8 51742 24 Washer9 54986 12 Nut10 78789 1 Locking plate11 78788 1 Lube cover

Qty.

BRH 625 TROUBLE SHOOTING

Page M1

PANNES POSSIBLES … REMÉDESA - Fulte d'hulle au niveau du marteau.

Joints d'étanchéité endommagés ou usés.Consultez votre distributeur TRAMAC le plusproche.

B - Le marteau manque de puissance, les flexiblesde raccordement battent.

L'accumulateur est dégonflé, la membrane deI'accumulateur est percée. Vérifier la températurede I'huile. En cas d'échauffement important, fairevérifier par un technicien, le réglage des clapets dedécharge du circuit de pelle. Consultez votre distributeur TRAMAC le plus proche.

C - Le marteau fonctionne normalement puis lacadence ralentit et le marteau s'arrêite. Quelquetemps après le marteau redémarre puis s'arrête.

L'huile hydraulique est trop chaude.Le porteur doit être vérifié pour trouver l'origine del'échauffement. Si nécessaire réduire la pression defrappe du marteau.

D - Un tirant d'assemblage est cassé.

Arrdter le travail immédiatement.Consultez votre distributeur TRAMAC le plusproche.

E - Après adaptation au porteur, le marteau tapequelques coups puis s'arrête.

Le flexible retour est bouché, vérifier le coupleur (simontée).

Recommandation: Le brise roche ayant une puis-sance globale élevée, veiller au bon refroidissementde I'huile. Un mauvals réglage du clapet de sur-pression du porteur peut être la cause d'un échauf-fement important de I'huile entrainant un mauvaisfonctionnement du brise roche.

TROUBLES SHOOTING … REMEDIES A - Oil leakage on hammer.

Damaged or worn seals.Call your TRAMAC distributor.

B - The breaker loses power; high vibrations inbreaker hoses.

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.

C - The hammer operates normally, then slowsdown and stops. A few minutes later the hammerwill start again then stop again.

Hydraulic oil is too hot.Excavator circuit must be checked for heat source.If necessary reduce the breaker operating pressure.

D - One side rod bolt has broken.

Stop working immediately and call your TRAMACdistributor.

E - After connection to carrier, the breaker operatesfor few blows then stops.

The return hose is plugged, check the quick cou-pling seat (if installed).

Recommendation: Check oil temperature and settings of carrier relief valves. If relief valve is notadjusted properly, oil may heat up quicker due tothe high total power of rock breaker. This will causethe rock breaker to perform poorly.


TECHNICAL PROBLEMS

Before looking for a hammer problem, look for a problem in the installation, like bad quick couplers or aplugged 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, BEFOREcalling your TRAMAC dealer, collect the following information. A complete diagnosis cannot be done withoutit.

Low Pressure Gauge 0-160 Psi

Return and Supply Lines (Same Size as Breaker)

Flow Meter

Flow Scale

Oil Temperature Gauge

Pressure Gauge

Needle ValvePage M2

A. Flow rate in high pressure line running to the hammer at operating temperature and operating pressure.B. Value of high pressure at hammer inlet when hammer is operating (use a 0-3000 psi gauge).C. Value of back pressure in return line (use a 0-160 psi gauge).D. Setting of relief valve in the system. For more details, please refer to page M3.


Page M3

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 ofthe 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 nottest 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 flowoutput 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 onpage 20) plus 400 psi, and readjust the flow if necessary to keep the hammer flow value constant for pres-sure 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 abad 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 todetermine 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 orheat may develop.

Pump problems

If you cannot produce proper oil flow against pressure varying from 500 psi to hammer operating pressureplus 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 stickingor back pressure is developing on return line.

With the flow adjusted and the flow meter loaded to hammer operating pressure value plus 400 psi, takenote 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 caus-ing 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 thehammer on a heavy 3 inch by 40 inch by 40 inch steel plate on hard ground and take note of the pressurereading. Call your TRAMAC dealer if pressure adjustments are needed.

BRH 625 DISASSEMBLY

Page M4

First, remove the point from the hammer by :

o Pushing out the 2 stop pins (o 54) with a screwdriver or asteel rod (hole A).

o Pushing out the 2 pin shutters (o 55) and the tool retain-ers (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 capand the cradle. Remove the bracket cap.

BRH 625 DISASSEMBLY

Page M5

Remove the suspension plate (o 67).

Pull out the hammer from its cradle ( 68).

Make sure that the hammer is safelysecured when proceeding.

Drive both tool retainers (o 53) half-way inside the front-guide (o 49).

Install the hammer in the service box. Make sure that bothtool retainers (o 53) rest on the floor.

BRH 625 DISASSEMBLY

Page M6

Use a 3/4 " hexagonal socket to unscrew the 8 bolts (o 6).Remove these bolts (o 6), the accumulator disk (o 5), theaccumulator (o 1), the o'ring (o 4) and the back-up ring (o 3).

To make it easier to handle the accumulator (o1), 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) andthe 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 theswivel. You may permanently damage itsseat on the back-head.

BRH 625 DISASSEMBLY

Page M7

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 regulatorslide (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 itsseat on the back-head.

Unscrew the 4 side-rods (o 58) using a special wrench (P/N22775), available from Tramac.

Before unscrewing, mark each side-rod toreassemble them in the same location. Tounscrew, proceed in X.

Never use an impact wrench.

To drive out the back-head (o 7), use a nylon strip installed betweenthe 2 swivel seats to lift it while levering between the back-head and thedistribution cover.

Make sure that the back-head stays perfectlyaligned 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

BRH 625 DISASSEMBLY

Page M9

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 ofthe distribution box (o 26). Progressively tighten these bolts inorder to pull out the distribution box (o 26).

Make sure to keep the distribution coverperfectly aligned with he cylinder.

Remove the distribution box (o 26) and the o'rings (11 x o 27 and o 28).

BRH 625 DISASSEMBLY

Page M10

Pull up the thrust piston (o 25).

Remove the centering pin (o 37) and the complete valves (o38 & o 39).

Screw a hook into the lower piston (o 24) (use 3/4" -16threads).

Pull out the lower piston (o 24).

Always remove the lower piston (o 24) from the cylinder (o36) before disassembling the cylinder (o 36). If not, youmay permanently damage the lower piston (o 24) seat onthe the bearing washer (o 46).

BRH 625 DISASSEMBLY

Page M11

Screw 2 bolts (o 6) on the side of the cylinder (o 36) to pull offthe 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 pulloff 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).

BRH 625 DISASSEMBLY

Page M12

Remove the accumulator body (o 47) and the diaphragm (o48) 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).

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 coatmay be damaged and seizure may occur later.

In case of lapping, always clean and wipe the lapping compound after the operation. Always use finegrain products. During lapping or grinding, make sure to always turn in the same direction aroundthe part. Never lap or grind vertically to avoid making longitudinal marks which may induce greaterinternal leakage or o'ring failures.

In case a black area ("Antiseize" protection coat) should be polished, always keep the area as smallas possible around the damaged surface. If not, the protection coat will no longer be efficient andseizure may occur later.

To wipe parts, always use new service rags. If textile fibers remain inside the hammer, they may dis-turb the operation of the hammer.

Always use TRAMAC genuine seals and o'rings. They are made with high quality elastomers in orderto increase their resistance and to lengthen their life expectancy. Grease the seals and o'rings inorder to facilitate their installation.

BRH 625 INSPECTION OF BACK-HEAD AND DISTRIBUTION PARTS

Page M13

Page M14

Before installing any part, always coat it with an oil film. Never hit a part with asteel tool. Use always either a rubber sledge hammer or a piece of woodbetween the part and the hammer.

Plunger (o 31):Check all surfaces of the plunger (o 31). Whenthere is only minor damage, just lightly polish thearea. Make sure to always turn in the same direc-tion around the part.

Make sure that the plunger (o 31) slides smoothly into its housingin the thrust piston (o 25).

Make sure that the plunger (o 31) slides smoothly into itshousing in the distributor (o 32).

Make sure that the plunger (o 31) slides smoothly into its hous-ing in the distribution cover (o 34).


Page M15

When there is minor damage to the plunger housings in the thethrust piston (o 25), the distributor (o 32) or the distributioncover (o 34), use a fine grain hone for removing high spots with-out modifying the inside diameters.

When there is major damage, please contact Tramac ProductSupport Department for proper instructions.

Check the seat area between the distribution cover (o 34) andthe 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 back-head (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 bygrinding slightly with an emery stone.


Page M16

Check the seat of the o'rings (o 29) on the distribution cover (o34). Use a fine grain emery paper to remove any rubber debrisor smooth any damage.

Check the seat area between the distribution cover (o 34) andthe distributor (o 32).

When there is minor damage, lap with an extra fine com-pound. To process assemble the 2 parts with the plunger (o31) to keep the parts properly aligned.

Check the outside surfaces of the distributor (o 32).

Never remove or smooth the V-shape notch onthe distributor (o 32). This is an orifice pilotingthe cycling of the hammer.


Check the seat area between the thrust piston (o 25) andthe distributor (o 32). If necessary, lap the damaged areawith extra fine compound. To process, assemble the 2parts with the plunger (o 31) to keep the parts properlyaligned.

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 thearea 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 distri-bution box (o 26) and that the surfaces of both parts are ingood shape.

Back-head (o 7) :

Check the seats of the side-rods (o 58). In case of damage, lapwith fine compound.

Check and replace if necessary the helicoils.

Check the seats of the HP swivel (o 22) and LP swivel (o22).

Make sure that the snap-ring holding the sleeve around thepressure regulator slide (o 11) is properly seated.

Check the threads (where the LP plug (o 16) and the HPplug (o 21) are screwed in).

Page M18


Page M19

Check the seat of the accumulator (o 1). If necessary,remove the high spots.

When there is damage, check withTramac Product Support Department forthe proper procedure.

Look for any crack, notch or sharp edge near by the o'ringgrooves and the surfaces facing the distributor box (o 26).

Make sure that the pressure regulator slide (o 11) movessmoothly into its housing.

Check the threads on the side-rod nuts (o 59). Also, theirseats should be perfectly flat. If not, use the other face, ifnever used.



Check the threads on the side-rods (o 58). They should beperfectly smooth.

If not, the complete set of side-rodsshould be changed.

Check the seats on the side-rod (o 58)heads. In case of minor dam-age, lap the high spots.

It is highly recommended to change the com-plete set of side-rods and nuts after either 1200hours or 2 years of operation, whichever comesfirst.

Make sure that the side-rod nuts (o 59) can be smoothly hand-screwed to the side-rods (o 58). If not, the damaged part mustbe changed.

Check the surface of the cylinder (o 36) in contact with the distribu-tion box (o 26). If necessary, remove high spots with an extra-fineemery paper.

Page M20

Page M21

Check the inside of the cylinder (o 36).

Never grind or lap the black "Anti-seize"coat inside the cylinder (o 36). When thereis damage, contact Tramac ProductSupport Department.

Check the lower face of the cylinder (o 36), in contact withthe 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, contactTramac 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 than23.444 " [595.5 mm]. If less, the piston must bechanged.


Page M22

When there is damage, on both lower piston (o 24) and cylinder (o 36), these partscan be exchanged for factory remanufactured parts. Consult Tramac PartsDepartment for availability.

Check the top suspension (o 67). If necessary, use agrinder to smooth the accumulator disk (o 5) seat.

Check the side of the shock-absorber on the top suspen-sion (o 67). Make sure that the shock-absorber grips prop-erly to its support steel plate.

Check the accumulator disk (o 5). Make sure that the boltseats are smooth. If necessary, polish but never removemore than 0.020 ".


Page M23

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) seatsdoes not show evidence of damage.

Check the bearing washer (o 46).


BRH 625 INSPECTION OF FRONTGUIDE AND CRADLE

Page M24

Check the wear on the upper bushing (o 50).

The bushing must be replaced wheneverthe gap between the bushing and a newtool exceeds 3/16 '' [5 mm].

Check the seat of the tool in the upper bushing (o 50). To mea-sure, install a new tool and push it as far as possible into thefront-guide. Then, measure the dimension X as shown on thedrawing. This dimension should not exceed 1.024 in. [26 mm]. Ifit does, the upper bushing (o 50) should be replaced.


Page M25

Check the wear on the lower bushing (o 52);

The bushing must be replaced wheneverthe gap between the bushing and a newtool 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 matterhow minor, the surfaces must be remachined.


Page M26

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 howminor, 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 sur-faces must be remachined.

It is essential to keep a perfect alignement between thecylinder (o 36), the spacer (o 42) and the front-guide (o49).

Make sure to carefully examined each of the faces incontact.

When there is a damage, no matter how minor, the sur-faces must be remachined.

Refer to the Service Bulletin 9006-02 for the properdimensions.


Page M27

Check the seat of the spacer (o 42) on the front-guide (o 49).

When there is damage or wear, no matterhow minor, the surfaces must be rema-chined.

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 sur-faces 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 M28

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 mount-ing the 2 o'rings (o 56) in the pin shutters (o 55) and checking that the stoppins (o 54) are properly handled by the o'rings. If not, change the defectivepin shutters (o 55).


Page M29

Check the tool retainers (o 53) for wear.

It is imperative to eliminate the wear marks beforeturning the pin over 180 degrees.

Page M30

BRH 625 INSPECTION AND SER-VICE 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 dieselfuel until the syringe is completely full without air bub-ble. Push the syringe into the central hole in the accu-mulator grid and press in normal manner (around 45 lbsthrust). When the oil pressure in the syringe reachesthe nitrogen pressure, the diaphragm will move awayfrom the grid, the oil will run out from the syringe andwill flush out of the other holes of the grid. The pressurein the accumulator is then indicated by the pressuregauge.

Page M31

Note : If the checking is performed on a stocked accumulator, or if the hydraulic hammer has not been work-ing for a certain time, the value read off the gauge may be higher than that advised. In such case, thediaphragm may have remained glued to the grid or may have hardened, which results in supplementaryresistance. 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) incontact with the back-head (o 7).

Check the area of the accumulator lower flange (o 1-1) incontact with the o'ring (o 4) and its back-up ring (o 3).

When there is damage, no matter howminor, both surfaces must be remachinedwhile keeping the same distance betweenthem.

Disassembling of the accumulator:

Unscrew the inflating screw (o 1-5) by 3 completeturns, then make sure that the nitrogen pressure isfully release before pursuing.


Page M32

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 insidethe accumulator. Remove the inflating screw (o 1-5) and the tightring (o 1-6).

Unscrew and remove the 16 bolts (o 1-4) using a 5/8 " hexagonalsocket.

Remove the accumulator upper flange (o 1-3).

Remove the accumulator diaphragm (o 1-2).


Page M33


Remove the tight ring (o 1-6). Check the seat of the ring. If nec-essary, polish it. This area should be perfectly smooth.

Check the contact area between the accumulator upper flange (o1-3) and the accumulator lower flange (o 1-1). If necessary, polishthem.

Assembling procedures :

Special tools required to service a TRAMAC accumulator :

o (1) Nitrogen gas bottle,o (1) Regulating gauge installed on top of the nitrogen bottle.o (1) Charging fixture (P/N 80348)o (1) Socket 3/8 ' (or 10 mm)o (2) 1 1/8 " wrenches.

Page M34

Clean and completely dry the accumulator upper flange (o 1-3) andthe accumulator diaphragm (o 1-2) before inserting the diaphragmin the lower flange.

Cover with the accumulator upper flange (o 1-3). Make surethis flange is clean and dry.

Grease the bolts (o 1-4) threads with "NeverSeize" product likeMolykote 1000, available from Tramac. Use a 5/8" hexagonal socketto tighten the bolts. The proper torque is 220 ft-lbs (30 kg-m).

Always cross-tighten bolts in steps : 50 ft-lbs (7kg-m) each time.

Install the tight ring (o 1-6) and hand-screw the inflatingscrew (o 1-5).


Page M35

Make sure that the inflating screw (o 1-5) is in close-contact withthe tight ring (o 1-6). If not, you may damage the internal threadswhen installing the charging fixture tool .

Install the charging fixture (P/N 80348) on top of the accumulatorwith the long bolts going through 2 accumulator holes.

Make sure that the special socket (P/N 21563) is properly seat-ed inside the inflating screw (o 1-5) head. While tightening thetwo nuts, make sure that the seat of the charging fixture stays incontact with the accumulator over the entire circumference. Usetwo 1 1/8" wrenches.Grip the complete assembly on a bench vice.

Close the charging fixture tap (P/N 80348).

BRH 625 CHARGING OF THEACCUMULATOR

Page M36

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 800psi (55 bars) pressure on the 0-3000 psi gauge. If not, recharge the nitrogenbottle.

Carefully screw on the regulating gauge so as to adjust the pressure to 465psi (32 bars) on the 0-1000 psi gauge.


Page M37

Open the tap downstream from the 0-1000 psi gauge.

Make sure that no nitrogen gas leak occurs between the bottleand the charging fixture. If it does, fix the problem before goingany further.

Unscrew the screw P/N 26428 using the socket P/N 21563 of thecharging fixture (P/N 80348).

o Make sure that the nitrogen gas is entering the accumulator. Youshould hear the rushing sound.

o Wait until the pressure is stabilized at 465 psi (32 bars) (at least 5minutes).

o Make sure to have the same pressure reading on both 0-1000 psigauges (gauge on the charging fixture and on the bottle). If not,check the gauges.


Page M38

If the nitrogen gas does not enter the accumulator, it may be due to aninsufficient loosening of the screw P/N 26428. Try again by inserting anylon washer between the inflating device (P/N 80348) and the accumula-tor [see diagram at right for proper dimensions].

Tighten the screw P/N 26428 using a 3/8 " socket. The proper torqueis 20 ft.lbs [2.75 m.kg].

Turn off the nitrogen bottle tap.

Make sure that the circuit is not pressurized bythe nitrogen bottle. Then, open the drain tapon the inflating device (P/N 80348) in order torelease the gas pressure in the circuit.

Before removing the charging fixture (P/N 80348) from the top ofthe accumulator, make sure that the pressure has dropped toatmospheric pressure.


Page M39

Check the actual accumulator pressure using the syringe P/N21006.

If you are using the syringe on a new or rebuilt accumulator, the pressure readingmay be above 465 psi [32 bars]. If so, the accumulator can be used as is. If not, (pres-sure reading below 465 psi), the accumulator must be recharged.

To check that seal P/N 14826 is leak-proof, fill the cavity abovethe screw P/N 26428 with hydraulic oil. If bubbles appear, theaccumulator must be recharged again using the same procedure.


BRH 625 ASSEMBLY

Page M40

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 All dust particles (metal and other) must be removed. o Blow dry to clean parts. o Before installing any seal or o'ring, grease them. Their installation will be easier and their life lengthened. o Make sure to lubricate all parts with hydraulic oil before inserting them.o 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 anhydraulic press.

BRH 625 ASSEMBLY

Page M41

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 thefront-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 betweenthe 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 (o42).

BRH 625 ASSEMBLY

Page M42

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 groovesinside the spacer.

Make sure that the lip seals are properly oriented :oLower seal has the lips downward (dust proof),o Upperseal has the lips upward (leak proof).

Install the bearing washer (o 46). Make sure that the chamfer side isoriented downward.

Page M43

BRH 625 ASSEMBLY

Install the diaphragm (o 48) onto the accumulator body (o 47). Make surethat both parts are perfectly dry before assembling.

Install the complete assembly (o 47 & 48) into its housing in the spacer (o42).

Roll the o'ring (o 44) properly greased at the base of the cylinder (o36).

Install the cylinder (o 36) on top of the spacer (o 42) after checking for highspots or any contamination.

Page M44

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 itinto the cylinder (o 36).

Install the centering pin (o 37) into its housing on top of the cylin-der (o 36).

Install the 2 complete valve assemblies (o 38) in their housings. Makesure that they are leak-proof once installed.

Page M45

BRH 625 ASSEMBLY

Install the o'rings (o 27) and the o'rings (o 28) on the distribution box (o26).

The o'rings should be greased to facilitate theirinstallation. However, any extra-grease should beremoved before installing the distribution box inorder to avoid any grease cushion while tighteningthe side-rods (o 58).

Align the distribution box (o 26) with the centering pin (o 37) wheninstalling it on top of the cylinder

Make sure that the o'rings (o 27 & 28) are still intheir 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 (o26).

Page M46

BRH 625 ASSEMBLY

Lubricate the thrust piston (o 25) with hydraulic oil before sliding itinside the distribution box (o 26).

Make sure that the thrust piston (o 25) slidessmoothly.

Install the o'ring (o 33) in the distributor (o 32) after lubrication.

Lubricate the distributor (o 32) with hydraulic oil before sliding itinside the distribution box (o 26).

Make sure that the distributor (o 32) is properlyoriented with the notch at its bottom.

Use hydraulic oil to lubricate the plunger (o 31) before inserting itinside the distributor (o 32).

Page M47

BRH 625 ASSEMBLY

Mount the distribution cover (o 34) on top of the distribution box (o26). Make sure that the distribution cover (o 34) is properly orientedwith the centering pin (o 30).

Use hydraulic oil to lubricate the valve (o 35) before mounting it on topof 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 front-guide (o 49). That will make future disassembling of the hydraulicbreaker easier.

Install the o'rings (o 10) into the back-head (o 7) after greasing them.Make sure to remove any extra grease.

Page M48

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 arubber mallet).

Make sure that the back-head (o 7) stays alignedwith the other parts. If not, you may jam and per-manently damaged the parts.

Check the threads on the side-rods (o 58) and the side-rod nuts (o 59). Makesure that hand-turning is easy.

Make sure that the face of the side-rod nuts (o 59) in contact with thefront-guiide is perfectly flat and smooth.

BRH 625 ASSEMBLY

Page M49

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 tight-ening of the side-rods.

BRH 625 ASSEMBLY

Page M50

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-rodnuts (o 59).

Pre-tightening procedure:

Tighten the 4 side-rods (o 58) up to 300 ft-lbs (40 kg-m) in order toclose any gap between the distribution box (o 26) and the cylinder (o36).

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 tighteningthem again. Tighten to 150 ft-lbs (or 20 kg-m).

Always cross-tighten the bolts in steps : 50 ft-lbs (7 kg-m) each time.

BRH 625

Page M51

At the end of the operation, check the marks locat-ed near each side-rod head on the back-head (o 7).They should be close to a flat notch on the side-rod head.

o If the flat notch is within an angle of ± 15º, turnthe side-rod (by tightening or loosening it) up toget a perfect alignment between the 2 marks.

o If not, the side-rod(s) must be completely loss-ened and the nut should be either turned orchanged and the full procedure repeated.

Once the head notches of the 4 side-rods are properlyaligned with the 4 marks on the back-head, identifiedthe fourth notch on each one.

Use the special Tramac wrench P/N 22775 or a 1 1/2" hexago-nal 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 boltper time.Never use a pneumatic wrench to tighten orloosen the side-rods as you can damage thethreads with micro-seizures on the side-rods(o 58) or the side-rod nuts (o 59).

BRH 625 ASSEMBLY

Page M52

Install the lip seal (o 19) in the inlet port. Make sure that the lips arefacing the inside of the back-head (o 7).

Grease the seats of the LP swivel (o 22) and the HP swivel (o 22) onthe back-head (o 7).

Install the o'rings (o 23) in the LP swivel (o 22). Also install theo'ring (o 15) on the LP plug (o 16).

Install the o'rings (o 23) in the HP swivel (o 22). Also, install theo'ring (o 20) on the HP plug (o 21).

BRH 625 ASSEMBLY

Page M53

Grease the inside of both swivels (o 22) and drive them onto theback-head (o 7).

Never directly hammer on the swivels. You maypermanently damage their seats.

Install the pressure regulator slide (o 11) in the outlet port. Make surethat the pressure regulator slide (o 11) moves smoothly inside itshousing. Also, install the spring (o 12), the stop pin (o 14) and thepressure 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).

BRH 625 ASSEMBLY

Page M54

Install the o'ring (o 4) and its back-up ring (o 3). Also, lightly greasethe 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) andthe back-head (o 7) do not show evidence of any damage.

Mount the accumulator (o 1) and the accumulator disk (o 5) ontop of the back-head (o 7).

Use a "Never-Seize" grease, like the Molycote 1000 available fromTramac, to grease the threads of the bolts (o 6).

Remove any extra-grease on the bolts to avoida cushion effect when tightening them.

BRH 625 ASSEMBLY

Page M55

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 thework stand. Remove the tool retainers (o 53).

Use a 15/16" socket to check the torque on the lower suspensionbolts (o 65). The proper torque is 300 ft-lbs [40 kg-m].

Install the hydraulic breaker in its cradle (o 68). Make sure that theinlet and outlet ports are properly oriented :

The HP inlet should be on the right, and the LPoutlet on the left, when facing the hydraulichammer from the operator seat.

BRH 625 ASSEMBLY

Page M56

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). Boltthem 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 (HPside). 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 thatthey are properly greased.

BRH 625 ASSEMBLY

Page M57

Before inserting the tool (o 72), properly grease its shank.Then, grease and mount the tool retainers (o 53) and thelock pins (o 54).

Documents

BRH 625 SANDVİK BREAKER