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BRH 501 Manual

Parts, Safety, Operation &


Maintenance

Form No. M1075-POMS

Revision 0

March 2002
Page 1
BRH 501 TABLE OF CONTENTS
INTRODUCTION 1
TABLE OF CONTENTS 2

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

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

III OPERATING INSTRUCTIONS 14


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

IV HAMMER TEST 20

V SAFETY PRECAUTIONS 21

GREASE SCHEDULE, TORQUE AND OTHER SPECIFICATIONS 22

PARTS LIST P3
CRADLE P4
ACCUMULATOR P5

TROUBLE SHOOTING M1
PART NAMES M4
PARTS INSPECTION AND REASSEMBLING M5
OVER SIZE BUSHING M13
OPTION FOR UNDERWATER OPERATION M16

Page 2
BRH 501 MAIN DATA
I MAIN DATA

I - 1 Overall dimensions

Page 3
BRH 501 MAIN DATA
I - 2 Technical specifications

501B 501SB 501C 501SC


Impact class 1700 ft.lbs 2000 ft.lbs
Oil supply 32 gpm 37 gpm
Blows / minute 500 500
Operating pressure 1600 psi 1200 psi
Max Back Pressure 45 psi 45 psi
Height 84 in 84 in
Working weight (lbs) 1500 2400 1500 2400
Shock absorber bracket No Yes No Yes
Shock dampener in hydraulic circuit Yes Yes
Tool diameter 4.5 in 4.5 in

The oil supply ( respectively 30 gpm and 37 gpm for the BRH 501B(SB) and
BRH 501C(SC) models) is the maximum oil flow setting allowed on these
hammers. The BRH 501B(SB) and BRH 501C(SC) hammers can be used with
carriers providing lower oil flows, but will produce lower blow rates. To main-
tain an efficient hammer power, pressure adjustment shims have been
designed [see paragraph II-2].

Tool references Dimension P/N


Standard moil point 39 in 26132
Long moil point 50 in 26133
Chisel 39 in 26136
Spade 8 in wide 26138
Blunt 39 in 26141

hammer excavator tank


Maximum temperature 175 F 160 F

Oil temperature plays an important role as excessively hot oil increases


internal leakage [which lowers efficiency] and deteriorates the piston seals
and the accumulator diaphragm.

Page 4
BRH 501 MAINTENANCE INSTR.
II MAINTENANCE INSTRUCTIONS

The life of a tool is determined by its operating time. The hour-meter of your excavator will not pro-
duce an accurate measurement of the hammer operating time. Travelling and boom positioning are
excavator functions that consume a lot of time but do not involve actual hammer operating time.

II-1 Mounting tool and pin

When taking delivery of your new hammer, spend just a few minutes to familiarize yourself with the
tool changing procedure.

II-1.1 To insert a tool

a> Insert the tool [rep. 350] into the front guide. Make sure that the two flat edges are well posi-
tioned in order to insert the retaining pins.
b> Using a screw driver, position lock [rep. 252] as to fully insert the retaining pin [rep. 251]. The
lock will release itself. Proceed the same way with the second pin.

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

251
251
252 252

Page 5
BRH 501 MAINTENANCE INSTR.
II-1.2 To remove a tool

a> Use a screw-driver to push in the lock [rep. 252] .


b> Using another screw-driver, push retaining pin [rep. 251] out of hole B.
c> Repeat on the other side for the second pin.
d> remove the tool.

When removing the tool, take care not to drop the tool on sharp objects, or pol-
ished surfaces may be damaged permanently.

II-2 Lubrication

The only routine maintenance for the TRAMAC models BRH 501B(SB) and BRH 501C(SC) is point lubrica-
tion. It is essential and cannot be overlooked; it reduces considerably the frictions between the bushing and
the tool and lengthens the life of your hammer.

a> Before inserting the tool [rep. 350] inside the hammer, hand-grease
the shank of the tool, the bushing, and the two tool-retainers.

b> During normal daily operation, every two hours 20 shots with a
hand operated grease pump in the grease fitting [rep. 258]. Use TRA-
MAC BRH7 grease which may be obtained from your TRAMAC deal-
er.

A properly lubricated hammer will show some grease running down the point :
Keep the tool wet all the time.

Page 6
BRH 501 MAINTENANCE INSTR.
II-3 Tool retainers

Examine the retaining pins [rep. 251] 2 or 3 times a week. Change them
when they show signs of heavy wear (like becoming oval shaped or
showing big cracks).

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

Hollow shape

a> Hollow shaped deformation without any bump


around the mark. Pin can be turned over by 180 to
View F
lengthen life time.

Bump

b> Hollow shaped deformation shows peripheric bump


more particularly located on round part of pin.

View G

Page 7
BRH 501 MAINTENANCE INSTR.

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

II-4 Tool bushing and front guide wear parameters

Page 8
BRH 501 MAINTENANCE INSTR.

TRAMAC BRH 501B(SB) & BRH 501C(SC) fea-


tures a replaceable chuck-bushing [rep. 255]. The
bushing and front guide must be regularly checked
for wear. Excess wear will cause misalignment
between the tool and the striking piston. Thus, the
impact will generate stress contractions detrimental
to the striking faces.

Rep. Designation Length (in)


A Front guide diameter ? 4.605
B Chock bushing diameter ? 4.645
X Striking chamber length ? 4.290

Check wear regularly to be sure not to exceed 3/16 " between tool and bushing.
When wear exceeds above indicated tolerances, consult your TRAMAC dealer for
part replacement.

II-5 Side-rods

Daily, inspect the side rods [rep. 300] for possible breakage or loosening
by tapping on each rod with a metal object. You will notice if a rod is 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 result
in serious consequences. Your TRAMAC dealer knows the torque specifications
and will assist you in tightening the tie rods.

Page 9
BRH 501 MAINTENANCE INSTR.
II-6 Screws

II-6.1 BRH 501SB & BRH 501SC : Bracket cap bolts [rep. 310]

Check these 12 screws [rep. 310] and nuts [rep. 311] for tightness :
o 30 minutes after having put the hammer into operation for the first time,
o then weekly
The proper torque is 380 ft.lbs.

II-6.2 BRH 501SB & BRH 501SC : Wearing plates bolts [rep. 308]

Every 500 hours, check these 16 wearing plates bolts [rep. 308] for tightness. The
proper torque is 368 ft.lbs.

II-6.3 Accumulator fixing bolts [rep. 6]

Every 500 hours, check the 8 screws [rep. 6] for tightness. The proper torque is 470
ft.lbs.

II-7 Accumulator

TRAMAC accumulators [rep. 2] should stay charged for at least one operating year. In normal operation, the
two hammer hoses vibrate lightly; but when the accumulator is discharged, the hoses will jump violently. You
will also note a power loss as the hammer will continue to fire, but will have no force.

Report this immediately to your TRAMAC dealer.

Page 10
BRH 501 MAINTENANCE INSTR.
Check nitrogen pressure with test gauge P/N 21006 and, if necessary, recharge with charging fixture
P/N 51347.

Accumulator pressure 530 psi


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

TRAMAC accumulators do not loose their charge through leakage. A TRA-


MAC accumulator consists of two flanges between which is held a
diaphragm (reassembling a pie plate). The only time a TRAMAC accumulator
will loose its charge will be when this diaphragm becomes perforated.

Never try to open the accumulator without discharging previously the pres-
sure through the inflating screw.

II-8 Storage

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

Remember, a corroded piston destroys its seals in a few minutes.

This operation can't be overlooked in case of underwater work, and in partic-


ular, in the case of sea water.

Page 11
BRH 501 MAINTENANCE INSTR.
II-9 Underwater working

The TRAMAC BRH 501B(SB) & BRH 501C(SC) models


in the standard version must not be used for underwa-
ter work, even for very short periods of time. If the
chamber between the piston and the tool fills with
water when the piston strikes, the water will not be
evacuated fast enough and a considerable pressure
rise will then occur which will destroy the piston seal
(with a risk of seizure).

II-9.1 Underwater kit


Position of the protecting plate

Page 12
BRH 501 MAINTENANCE INSTR.
For underwater operation, two different procedures have to be following depending on the front guide your
hammer is equipped with :

case A : If equipped with new standard spacer (P/N 23830) and drilled front guide (P/N29209, install
air-pressurization kit 79102

case B : If equipped with the old standard front guide (not drilled before 1978) and the old spacer
(P/N21649 before summer 1989), install the new front guide (P/N 29209) and the new spacer (P/N23830)
and air pressurization kit 79102.

Rep Qty Designation Part number

1 1 - Fitting 23832
2 1 - Knee piece 7295
3 2 - Lip seal 12817
4 1 - Screw 19716
5 1 Protecting plate (not provided w/kit
but to be welded on the cradle by the
customer)

Kit for air blowing

II-9.2 Compressor pressure

Pressure from the compressor must be at least 22 psi above the water pressure at the working depth.
Consult the following chart to determine minimum pressure required at the corresponding depths.

Water Depth Air pressure required


(ft) (psi)
1 22
2.5 23
5 24
7.5 25
10 26
12.5 27
15 28
17.5 29
20 31
22.5 32
25 33
27.5 34
30 35

Page 13
BRH 501 OPERATING INSTR.
III OPERATING INSTRUCTIONS

III-1 Cold weather starting

Start up the excavator and circulate the hydraulic oil to warm it up


before starting the hammer. When oil is warm, raise the hammer
from ground, idle the the engine and energize the hammer control
valve. The oil will pass through the hammer but the hammer will
not fire. Run this way for 5 to 10 minutes; this will warm up the
hammer parts. In below zero temperatures, we suggest the tool be
stored in a warm shed at night. Extreme cold can crack the point
when you start the breaking operation.

III-2 How to obtain maximum productivity and long life

TRAMAC working tools are made from a special steel far superior to any tool steel commercially available.
Unlike other tools on the market, our steel is hardened all the way through - no thin shell of hard steel which
wears quickly. When the tools lose their edge, either at the tip or on the sides, it is possible to sharpen them
without repeating heat treatment, using one of the following methods :

A> With a milling or planning machine for chisels and cutters, or with a lathe for the moils and chisels.
These operations must be completed using the adequate type of hard metal tool.

B> By sharpening : this operation must be performed using a coolant, in order not to overheat the tool
to be maintained.

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

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

Page 14
BRH 501 OPERATING INSTR.

Tools are covered by TRAMAC against metal defects (very uncommon). It is not
unusual that some operations (working at angles, blank firing, ...) lead to tool
breakage, including inside the chuck housing.

The use of after market tools will void your warranty for any claim related to parts
in contact with the tool (which includes the main piston).

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

The cycle of compressive and tensile stresses flowing down the tool is repeated for each hammer blow.
Obviously, anything that interferes with the strength of the compressive stress wave during service, for exam-
ple "Blank Firing" or bending of the demolition tool due to leverage, will result in loss of breaker efficiency of
up to 80 % and possible failure of the tool itself.

III-4 Cause and effect of fatigue

III-4.1 Correct operating conditions

The continuous cycle of compressive and tensile stresses in the demolition tool, even under correct operat-
ing conditions, creates fatigue stress in the tool which can lead to the fatigue failure of the tool before it is
worn out. Anything which interferes with the cycle of compressive and tensile stresses will also increase the
level of fatigue stress being applied to the demolition tool and, thus, increases the risk of early fatigue failure
of the tool.

Page 15
BRH 501 OPERATING INSTR.

The main cause of increased fatigue stress in a demolition tool


is any form of side pressure during service which creates bend-
ing. Thus, utilizing the tool as a lever, using an incorrect driving
angle or attempting to break ground using the pull of the exca-
vator are all detrimental to the life of a demolition tool and
should be avoided [see figure].

The hydraulic power available in the machine far exceeds the strength of a
demolition tool if it is used incorrectly and can "snap the tool like a carrot".

III-4.2 Other causes of increased fatigue stress in a demolition tool include :

A> Free running ( or Blank firing)


Free running occurs when the hammer piston strikes the top of the demolition tool when the working
end is not in proper contact with the rock or concrete to be broken. This includes jobs where the tool
slides off the work and also when break-through of thin concrete slabs or boulders occurs.

B> Cold :
Low temperatures cause a demolition tool to be more susceptible to fatigue failure. Tools should be
warmed before use.

C> Mechanical and thermal damage :


Any form of damage to the surface of a demolition tool renders it more liable to suffer fatigue failure.
Thus, all care must be exercised to prevent scratches, gouges or weld marks occurring due to acci-
dental damage, galling caused by contact between the tool and chuck bushing trough the lack of
lubrication or excessive bending.

D> Lubrication :
Care must be taken to avoid metal to metal contact that, as a result of galling, could cause deep
damage marks which, in turn, may lead to the formation of fatigue cracks and eventually failure of
the demolition tool. Make sure that the shank of the demolition tool is well lubricated before inserting
it into the hammer.

Page 16
BRH 501 OPERATING INSTR.
E> Corrosion :
A rusty demolition tool is more likely to suffer fatigue failure. Keep tools well greased and sheltered
from the weather when not in use.

III-5 Demolition tool fatigue failure

Demolition tool fatigue failure will occur approximately 4 inches either side of the chuck front face
[see figure] or through the retainer pin flat. Another slightly less common failure area can fall
approximately 8 inches from the working end, subject to the nature of use. The fracture face itself
will normally exhibit semi-circular polished area with the remainder being of rougher appearance
(see figure). The polished semi-circular area is the fatigue area and generally started from a dam-
age mark or other stress initiated on the outside of the demolition tool and spread inwards.

The fatigue area slowly widens until the stresses being applied to the demolition tool cause sudden
failure of the remaining section. Generally, the size of the fatigue area indicates the level of stress
applied to the tool, i.e. the smaller the fatigue area, the higher the stress level, although it must be
borne in mind that once initiation of a fatigue crack has taken place, it requires a lower stress level
to cause it to grow.

Page 17
BRH 501 OPERATING INSTR.
III-6 Typical failures

TRAMAC demolition tools are manufactured from fist class materials and then heat treated to pro-
duce a fatigue and wear resistant tool. Thus when a tool has apparently failed to give a satisfactory
service life, a brief visual inspection can often give a quick indication about the cause.

Wear is dictated by the conditions of the material being broken, but, in general, the following guide-
lines apply:
Blank tools worn more than 1/3 of their diameter, or moils and chisels worn back more than 2
inches from the working end, are classed as reasonable life.

III-7 TRAMAC demolition tool guide

A B C D E F

Ref Tool type Application

A Moil point Low abrasive, homogenous material


B Chisel Plastic or heterogeneous material
C In-line chisel Plastic or heterogeneous material
D Blunt Crumbly rock
E In-line asphalt cutter Asphalt cutter and trenching
F Spade Frost Asphalt and trenching

Page 18
BRH 501 OPERATING INSTR.

BREAKAGE CHART Failure due to blank firing or


excessive wear of bushings
and/or chuck housing.

NO WARRANTY

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

NO WARRANTY

Fatigue breakage with typical


fatigue wrinkles due to steel
defect.
100% WARRANTY
Typical failure caused by
misalignment between down
pressure, hammer and tool
(prying, levering).

NO WARRANTY

Breakage due to improper


contact between the tool's
tip and rock or concrete.

NO WARRANTY

Mushrooming or fast wearing


caused by operating too long
on the same spot.

NO WARRANTY

Page 19
BRH 501 HAMMER TEST
IV HAMMER TEST

3/8" x 12' Hose


Gauge 0-3000 psi

Steel plate 1"min


or hard rock
Measurement of the high pressure setting

For normal day to day work, TRAMAC's BRH 501 hammer has been pread-
justed in manufacturing to obtain 1120 psi at 26 gpm for an oil temperature
of 110 F on a moderately hard ground.

MAX FLOW MAX WORKING MAX BACK

RATE PRESSURE PRESSURE

BRH 501B & 501SB 32 gpm 1600 psi 45 psi

BRH 501C & 501SC 37 gpm 1200 psi 45 psi


Page 20
BRH 501 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.

Page 21
BRH 501 GREASE SCHEDULE,
TORQUE AND OTHER SPECS

ROUTINE MAINTENANCE AND LUBRICATION RECOMMENDATIONS:

The only routine maintenance for BRH is point lubrication. Incorrect lubrication can lead to scouring of point
and chuck housing as well as loss of production.

RECOMMENDED LUBRICANT - TRAMAC BRH-7 grease which may be obtained from your TRAMAC dealer.
GREASING SCHEDULE - New points and tool retainers should be greased before inserting. Every 2 hours -
20 shots with hand grease gun.

TOOL RETAINERS - Change when they show signs of heavy wear to avoid their breaking in chuck.

RECOMMENDED SPARE PARTS:

1) Seal seat
2) Two tool retainers
3) Grease fitting
4) Spare tool

ACCUMULATOR NITROGEN CHARGES:

Check with test gauge 21006-L


Pressure = 530 psi

TORQUE SPECIFICATIONS:

Reference Number 6 = 500 ft-lbs


Reference Number 300 = 730 ft-lbs
Reference Number 308 = 365 ft-lbs
1 x 13 1/2 Bolts = 150 ft-lbs - Notch on bolt head must line-up with mark in back head (Ref. 1). Remove tie
rod and nut in matched sets and replace in same location. Place arrow on nut so that it is not reversed.

SPECIAL TOOLS REQUIRED:

For Nitrogen charge:

- Pressure test gauge 21006-L


- Charging fixture 30932-J

Page 22
BRH 501
PARTS MANUAL
Form No. M1075-P

Revision 0

March 2002
Page P1
BRH 501 PARTS LIST

Page P2
BRH 501 PARTS LIST
Rep Qty Designation Part number
Back Head ass'y, composed of :
1 1 - Back head 53221
3 1 - Nylon washer 18652
4 1 - O'ring 33616
2 1 - Accumulator 22848
5 2 - O'ring to s/n 20214 19856
5 2 - O'ring from s/n 20236 36579
6 8 - Screw 5 1/2" 24658
8 8 - Spring guide 22894
9 8 - Washer 22573

HP rotating connection ass'y, composed of :


10 1 - Knee part (1 "1/4 NPTF) 56047
11 1 - Threaded plug 21292
12 1 - O'ring 6711
13 2 - O'ring 5346

LP rotating connection ass'y, composed of :


10 1 - Knee piece (1"1/4 NPTF) 56047
11 1 - Threaded plug 21292
12 1 - O'ring 6711
13 2 - O'ring 5346
14 1 - Slide BRH 501B & 501SB 22974
or 1 - Slide BRH 501C & 501SC 22975
17 12 - 20 - Pressure adjustment shims 21291
15 1 - Spring slide 21289
16 1 - Barrel 21290
18 1 - Spring 18083

Distribution ass'y, composed of :


104 1 - Distribution box 19708
107 1 - Distributor 17678
106 3 - Piston 23062
105 1 - Distribution cover 23061
102 2 - Centering pin 19867

Cylinder ass'y, composed of :


100 1 - Cylinder 28362
108 2 - Lip seal 19698
103 1 - O'ring 19856

Striker ass'y, composed of :


150 1 - Piston BRH 501B & 501SB 19703
101 1 - Plunger 19171
150 1 - Piston BRH 501C & 501SC 19704
101 1 - Plunger 19170

Front guide ass'y, composed of :


250 1 Front-Guide (square retaining pins) 29209
250 1 Front Guide (round retaining pins) 38939
259 1 O'ring 19856
255 1 Chuck bushing 20944
256 1 Pin 20948
257 2 Split pin 7046
254 4 Plug 7076
252 2 Bolt 22680
251 2 Retaining pin(square) 26130

Page P3
BRH 501 PARTS LIST

Page P4
BRH 501 PARTS LIST

Rep Qty Designation Part number


251 2 Retaining pin (round) 22679
253 2 Bolt spring 22681
262 1 Plug 38894
258 1 Oiler 6178
260 1 Spacer ass'y including : 23830
261 1 Wear bushing 2 3/8" 22448
261 1 Wear bushing 4" (ref. spacer 21649) 21768
300 4 - Side rods 57891
301 4 - Nuts 57369

Page P5
BRH 501 CRADLE

Rep Qty Designation Part number

Heavy Duty Shock Absorbing Cradle :


304 1 - Cradle 26756
305 2 Stop 21032
306 8 Wearing plate 21028
307 8 Locking plate 21078
308 16 Screw 21159
7 8 Spring 21033
302 1 Top plate 21029
303 1 Shock absorber 21031
310 12 - Screw 31121
311 12 - Nut 5159

Page P6
BRH 501 ACCUMULATOR

BRH 501 Accumulator HP

Tighten Bolts to 140 ft-lbs

Accumulator parts table

Rep Qty Designation Part number

1 1 Lower flange 22847


2 1 Diaphragm 17639
3 1 Upper flange 26600
4 16 Screw 18645
5 1 Inflating screw 26248
6 1 Ring 14826
7 16 Plug 36306

Maintenance accessories list

Recommended spare parts kit

Part name Qty P/N


Seal kit 1 53247
Tools retainers 2 26130
Grease fitting 1 6178
Spare tool 1 26132

Page P7
BRH 501 ACCUMULATOR

This Page Left Blank Intentionally

Cette Page est Laisse Blanche Intentionnellement

Page P8
BRH 501 TROUBLE SHOOTING

TROUBLES SHOOTING REMEDIES PANNES POSSIBLES REMDES


A - Oil leakage on hammer. A - Fulte d'hulle au niveau du marteau.

Damaged or worn seals. Joints d'tanchit endommags ou uss.


Call your TRAMAC distributor. Consultez votre distributeur TRAMAC le plus
proche.

B - The breaker loses power; high vibrations in B - Le marteau manque de puissance, les flexibles
breaker hoses. de raccordement battent.

The accumulator is deflated or diaphragm L'accumulateur est dgonfl, la membrane de


punctured. Check the oil temperature. I'accumulateur est perce. Vrifier la temprature
If oil is too hot, ask a technician to check the de I'huile. En cas d'chauffement important, faire
breaker circuit relief valve setting. vrifier par un technicien, le rglage des clapets de
Call your TRAMAC distributor. dcharge du circuit de pelle. Consultez votre
distributeur TRAMAC le plus proche.

C - The hammer operates normally, then slows C - Le marteau fonctionne normalement puis la
down and stops. A few minutes later the hammer cadence ralentit et le marteau s'arrite. Quelque
will start again then stop again. temps aprs le marteau redmarre puis s'arrte.

Hydraulic oil is too hot. L'huile hydraulique est trop chaude.


Excavator circuit must be checked for heat source. Le porteur doit tre vrifi pour trouver l'origine de
If necessary reduce the breaker operating pressure. l'chauffement. Si ncessaire rduire la pression de
frappe du marteau.

D - One side rod bolt has broken. D - Un tirant d'assemblage est cass.

Stop working immediately and call your TRAMAC Arrdter le travail immdiatement.
distributor. Consultez votre distributeur TRAMAC le plus
proche.

E - After connection to carrier, the breaker operates E - Aprs adaptation au porteur, le marteau tape
for few blows then stops. quelques coups puis s'arrte.

The return hose is plugged, check the quick cou- Le flexible retour est bouch, vrifier le coupleur (si
pling seat (if installed). monte).

Recommendation: Check oil temperature and Recommandation: Le brise roche ayant une puis-
settings of carrier relief valves. If relief valve is not sance globale leve, veiller au bon refroidissement
adjusted properly, oil may heat up quicker due to de I'huile. Un mauvals rglage du clapet de sur-
the high total power of rock breaker. This will cause pression du porteur peut tre la cause d'un chauf-
the rock breaker to perform poorly. fement important de I'huile entrainant un mauvais
fonctionnement du brise roche.

Page M1
BRH 501 TROUBLE SHOOTING

TECHNICAL PROBLEMS

Before looking for a hammer problem, look for a problem in the installation, like bad quick couplers or a
plugged filter [see page M3 for how to check the installation].
Make sure that the hammer has not been hooked up backwards.
Make sure that the hammer has the proper tool.
Make sure that the down pressure has been applied.
Make sure that no valve(s) are closed.
For any other problem, refer to the Trouble Shooting page M1. If you cannot identify the problem, BEFORE
calling your TRAMAC dealer, collect the following information. A complete diagnosis cannot be done without
it.

A. 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.

Low Pressure Gauge 0-160 Psi

Return and Supply Lines (Same Size as Breaker)


Flow Meter
Flow Scale
Oil Temperature Gauge

Pressure Gauge

Needle Valve
Page M2
BRH 501 TROUBLE SHOOTING

How to check hydraulic circuit and installation

Mount a flow meter in place of the hammer. Also, mount a low pressure (0-160 psi) gauge on the outlet of
the flow meter in order to test the back pressure in the return circuit
With the flow meter in place, activate the circuit and bring the machine up to operating temperature; do not
test the machine cold.
If the control valve is equipped with solenoid, switch on the solenoid before starting the engine to avoid
damage to the flow meter. Do not switch on or off the solenoid when the engine is running. Adjust the flow
output to match the requirements of the BRH 501B(SB) and BRH 501C(SC) - see table on page 20.
After the flow has been adjusted, load the flow meter to the hammer operating pressure value (see table on
page 20) plus 400 psi, and readjust the flow if necessary to keep the hammer flow value constant for 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 a
bad system relief setting or a bad hammer control valve.
To check system relief valve see excavator manual for proper relief setting. Build pressure with flow meter to
determine relief cracking pressure (usually 50 to 100 psi below relief setting). Reset relief if needed.
There should be 400 to 500 psi between hammer regulated pressure value and system cracking pressure or
heat may develop.

Pump problems

If you cannot produce proper oil flow against pressure varying from 500 psi to hammer operating pressure
plus 400 psi, the pump could be bad or there is excessive leakage in the circuit.

Hammer control valve problems


If relief valve and pump are good, open and close valve three or four times: The valve spool may be sticking
or back pressure is developing on return line.
With the flow adjusted and the flow meter loaded to hammer operating pressure value plus 400 psi, take
note of the low pressure gauge reading.
The return pressure should be less than 45 psi. If the back pressure is more than 45 psi, the restriction 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 the
hammer on a heavy 3 inch by 40 inch by 40 inch steel plate on hard ground and take note of the pressure
reading. Call your TRAMAC dealer if pressure adjustments are needed.

Page M3
BRH 501 PART NAMES

What to look for when assembling the BRH.


NOTE: For general assembly procedure, refer to parts description.

Page M4
BRH 501 PARTS INSPECTION AND
REASSEMBLING
PARTS INSPECTION AND REASSEMBLING PROCESS:

Accumulator

1. Check o-ring seat A on lower flange. If damaged, polish with fine hand stone or remove 0.005 maximum.
If the damage is too deep or more 0.005, remove both sides according to J dimension.

2. Clean diaphragm groove D.

3. Check ring seat E on upper flange. Perfect seat only is acceptable.

4. Clean and check all bolts threads K in upper flange.

5. Clean and check all bolts B.

6. Mount new BS ring with hydraulic oil. IMPORTANT - DO NOT USE GREASE.

7. Make sure bores L are not plugged with rubber. Clean if necessary.

8. Reassembling, tightening and inflating, refer to specifications.

Page M5
BRH 501 PARTS INSPECTION AND
REASSEMBLING
Device for quick nitrogen pressure checking 21006:

- Made for service men or maintenance workshop.

- Direct reading of the existing pressure in accumulator on pressure


gauge ref. 21013 fitted to the syringe.

- One only type of end part (ref. 21317) for breakers type BRH.

Instructions:
- Clean out syringe.

- Suck up clean oil until syringe is full without air bubble.

- Put syringe end into accumulator grid hole and press without
excess (about 45 lbs.).
When oil pressure into syringe equals nitrogen pressure,
diaphragm is pushed down from grid, oil can flow out of syringe
and appears on grid.
Then nitrogen pressure in accumulator can be read on pressure
gauge.

N.B. If control is affected on an accumulator taken from stock, or


already mounted on a BRH having not operated for quite some
time, the value read on pressure gauge may be higher then the
recommended one. In this case diaphragm may be stuck on grid or
may have hardened, which causes further resistance. Accumulator
may however be used as such. If value is lower it is necessary to
change or repair the accumulator.

Inflating device for accumulator 41543:

- Make for service truck or maintenance workshop.

- Must be used together with a nitrogen tank.

Instructions:
- Put accumulator inside fitting 41543, (1).

- Unscrew slightly five flat screws with spanner 21653, (2).

- Once connection to nitrogen taknk is made, open tank cock and


adjust pressure to the required value by acting on expander .

- When pressure is reached, tighten five flat screw, close nitrogen


tank, open drain cock 11653, (3) and disconnect hose.

Nitrogen pressure in 400 and 450 accumulators is 525 to 555


psi.
Page M6
BRH 501 PARTS INSPECTION AND
REASSEMBLING
Back head

PARTS INSPECTION:

9. Check all helicoils B.

10. Check o-ring seat A. Polish if necessary.

11. Check snap ring on slide sleeve inside to


the outlet port E.

12. Make sure that slide sleeve is tight in the


back head and not damaged.

13. Make sure that side rod seat D is not


damaged. If damaged, remove high spots only
with hand fine stone or sand paper.

Side rod and nut

14. Make sure that the side rod seat I is


not damaged. Remove high spots only.

15. Check threads in side rod H.

16 Check thread in nuts.

17 Screw nut in side rod by hand. Make sure


the nut screws in freely.

Note: When replacing broken side rod,


it is recommended that all four (4) rods
are replaced.

Page M7
BRH 501 PARTS INSPECTION AND
REASSEMBLING
Back head - distributor cover

18. Make sure that the seat A on the cover of the


distributor is not damaged. Polish with hand fine
stone or surfacing plate, if necessary.
Note: remove high sopt only, (maximum
surfacing 0.003).

19. Check seat B in the back head. Same


procedure as no. 18.

Distributor cover - distributor box

20. Check seat C. If damaged, polish the high


spot only with hand fine stone and repolish with
fine compound, if necessary.

Distributor box - cylinder

21. Check seats E and H. If damaged, polish


the high spot only with hand fine stone and
repolish with fine compound, if necessary.
Note: Remove all compound before
reassembling.

Page M8
BRH 501 PARTS INSPECTION AND
REASSEMBLING

22. Check plunger seat A on distributor cover.


Polish if necessary.
Note: Remove 0.004 max. only once. If you
remove material, indicate how many times on
the cover of the distributor.

23. Make sure that the piston B is not damaged.

Plunger

24. Make sure that area C on the plunger is not


damaged. If the damage is all around, mount
new plunger.

Distributor

25. Check the distributor seats, B, H, and D.


Seat B - remove only once, a maximum of 0.004.
Seats H and D - just polish by hand. If the
damage is severe or too deep, replace the
distributor.

Distributor box

26. Check the internal distributor seat in the


distributor box. Polish by hand. If the
damage is severe or too deep, replace the
distributor box.
Note: If damaged by aeration or cavitation,
check excavator hydraulic circuit or hydraulic
fluid type.

Page M9
BRH 501 PARTS INSPECTION AND
REASSEMBLING

27. Make sure that there is no obstruction between


the distributor and the distributor box.
Insert the distributor into the distributor box and
turn by hand. Make sure it turns freely. If not,
use fine compound and polish.
Note: Remove all compound before
reassembling.

28. Do not remove the small orifice A.

29. Check seat D on distributor. If damaged,


remove only once, a maximum of 0.004.

Piston

30. Check seat B, perfect seat only is acceptable.

31. Check plunger seat C. Remove high spots


only. If damage is too deep, replace piston.

32. Check area E. If damaged, remove high spots


only. If too much damage, replace piston.

33. Check chrome area H. If damaged, use


service exchange if possible.

34. Check striking area I. If cracked or clenched,


replace piston and check operating pressure, flow
and tool alignment in chuck housing.

Page M10
BRH 501 PARTS INSPECTION AND
REASSEMBLING
Cylinder

35. Check internal surface in cylinder. If damaged,


remove high spots only with hand fine stone. Polish
the surface.

IMPORTANT:
Clean internal lube and alignment piston
groove A.

36. Check seal groove edges B. If too sharp,


smoothen by using a soft hand stone.

Note: Edge rodurs 0.008 +/- 0.004. If the edges


are too sharp, peeling of chrome of the piston
will occur.

37. Check o-ring seals C and D.

38. Wash and clean cylinder.

Page M11
BRH 501 PARTS INSPECTION AND
REASSEMBLING
Chuck housing

39. Make sure that the chuck housing is not cracked


or damaged.

40. Check the wear on spacer bushing, on limit tool


stroke area and inside the chuck housing.
Note: Maximum wear depth is 0.125. If more,
install a new one. Refer to 48C.

41. Make sure that the brass bushing in spacer bush-


ing B, is not damaged.
Important: If you install a new brass bushing,
make sure that the piston strokes freely through
that bushing. If not, polish with sand paper.

42. Clean the side rod boring A in chuck housing


with wire brush. Be sure that the side rod strokes
freely on nylon area.

43. Check lock plate retainer C. Refer to 55.

44. Check the wear in bushing D (area E).


Note: Maximum, allowed wear is 0.125. If more,
remove and mount a new bushing (refer to 45, 46,
51, 52 and 53.

45. Make sure that the bushing D sits tightly in the


chuck housing. If not, remve the existing bushing and
mount a new one in place of the existing bushing.
Note: Refer to over size bushing procedure draw-
ing (page M13).

46. Check wear tolerance H between tool and


bushign. Maximum allowed wear is 0.125.

Page M12
BRH 501 OVER SIZE BUSHING

Over size bushing

Page M13
BRH 501 PARTS INSPECTION AND
REASSEMBLING

47. Before you press the spacer bushing into the chuck
housing, freeze the spacer bushing in dry ice for one
hour.

48. Maximum allowed wear of area C is 0.125.

49. Clean the wall inside the chuck housing before you
press the spacer bushing.
Note: Make sure that there is no obstruction
between the spacer and the chuck housing wall.

50. If there is crack and shell on spacer area C, mount


a new spacer and check the wear on bushing area.
Refer to step 44, area E.

51. Before you press the bushing E into the chuck


housing, freeze the bushing in dry ice for no less than 1
hour.

52. The pin H locks the bushing in chuck housing.

53. The bushing press fit is 0.0023 +/- 0.0001 dia.


Important: Check alignment of lock pin before you
press the bushing into the chuck housing.

54. Check the wear K on lock plate N. If too worn


out, replace the lock plate with a new one.

55. Check lock pin assembly P, O and T.

Page M14
BRH 501 PARTS INSPECTION AND
REASSEMBLING
Chuck housing

56. This model has no spacer bushing. The


tolerance from tool stroke limit A is 0.190.
Note: Same check as 48.

57. Clean the side rod boring E with a wire


brush.
Note: Be sure that the side rod strokes
freely on nylon area.

58. Make sure that the chuck housing H


is not cracked or damaged.

59. Check D if the bushing is press fit into


the chuck housing H.

60. Over size bushing is available. Refer to


over size bushing procedure drawing
page M13.

61. Before you press the bushing B into the


chuck housing, freeze the bushing in dry ice
for minimum of one hour.

62. Before you press the bushing B make


sure that the lock pin allignment is perfect.
Refer to 53 - H.

63. The tolerance between the chuck housing


and wearing plate 306 is 0.060 (maximum).
Add lock plate 307 in between cradle and
wearing plate, if necessary.

Page M15
BRH 501 OPTION FOR UNDERWA-
TER OPERATION

64. Make sure that the nylon stopper 305 is not


cracked or damaged.

65. Make sure that the nylon shock absorber 303 is


not cracked or damaged.

66. Make sure that the cradle is not cracked or


damaged. Reweld if necessary.

67. Check spring 7 for fatigue and cracks.

68. Make sure that the shock absorber retaining pin


A is not cracked or damaged.

69. Chuck housing internal dimension area A.


(97 +3 mm). Refer to page M13, area B.

Page M16