Model 900 Manual Parts, Safety, Operation & Maintenance Form No.
Model 900 Quick Reference Quick Reference Parts Item Part Number Ref # 360 370 420 500 530 510 520 540 680 690 86419314 86419348 86419330 86415163 86415171 86415213 86504198 86419462 86318490 86415361 Qty.
Model 900 Quick Reference Quick Reference Torques Part Number Ref # DESCRIPTION Assembly Side Rods 86419355 92686 86308145 52027 Side rod bolt Nut Bracket Cap Bolts 86576345 97056 Fixing cap bolts 220 ft-lbs. Wear plate Bolts 86576386 97060 Wear plate bolts 650 ft-lbs. 89496 26428 78508 H.P. accumulator Accumulator bolts Inflation screw Accumulator fixing bolts 465 psi charge pressure 220 ft-lbs. 16 ft-lbs. 480 ft-lbs. Pull the nuts to 150 ft-lbs in a crisscross pattern. Align the notches.
Model 900 Table of Contents Forward Avant Propos 5 Safety Securite S1 Ten Commandments Dix Commandements O1 Overall Dimensions Encombrement O2 Technical Specifications Caracteristiques Techniques O3 Mounting Montage O6 Tool Mounting Montage de Outil O8 Operation & Adjustment Utilisation & Reglage O10 Maintenance Entretien O13 Underwater Operations Sous - Marine les Fonctionnements O15 Tool Guide Guide Outil O16 Parts List Pieces Detachees P3 Accessories Accessoires P8
Model 900 Foreword FOREWORD AVANT PROPOS The contents of this manual are considered to be proprietary and confidential to TRAMAC and should not be reproduced without prior written permission from TRAMAC.
Model 900 Safety WARNING! ATTENTION! WARNING! - Pressurized component or system. ATTENTION! - Composant ou systéme sous pression WARNING! - Pressurized vessel (accumulator). WARNING! - Consult the operation and maintenance manual before beginning any maintenance. ATTENTION! - Consulter le manuel d'utilisation et d'entretien avant d'entreprendre toute interventions. ATTENTION! - Récipient sous pression (accumulateur) Lifting point. Point de levage.
Model 900 Safety SAFETY SECURITE WARNINGS ATTENTION "Warnings" call attention to instructions which must be followed precisely to avoid injury or death. L'indication "ATTENTION" précise que les instructions doivent être suivies absolument pour éviter tout accident grave. CAUTION PRECAUTIONS "Caution" calls attention to instructions which must be followed precisely to avoid damaging the product, process or its surroundings.
Model 900 Safety GENERAL INFORMATION INFORMATIONS GENERALES A rock breaker is an accessory for mini-excavators, backhoes or other excavators according to the model. Un brise roche est un accessoire adaptable aux mini-pelles, tracto-pelles ou pelles hydrauliques selon le modéle. The operator must have the necessary knowledge and must be allowed to operate such carriers.
Model 900 Safety When someone helps to install the breaker, make sure any hand signals will be well understood. Lorsque un aide participe au montage du brise roche, s'assurer que les instructions données par gestes soient blen comprises. Unexpected boom movements when installing the breaker could result in hand injury: - Be sure the carrier is immobile and stable. - Keep your hands clear when moving the boom end between fixing plates. - Do not use your fingers to "feel" pin alignment.
Model 900 Safety Should hydraulic oil come into contact with skin, wsh it off immediately. Nettoyer immédiatement la peau si de I'huile entre en contact avec celle-ci. Fine jets of hydraulic fluids at high pressure can penetrate the skin causing serious injury. - Be sure the circuit is not under pressure prior to any intervention. - Do not use your hand to check for hydraulic fluid leakages. - If hydraulic fluid penetrates the skin, get medical help immediately.
Model 900 Safety Stand clear from a breaker in operation. Ne pas rester à proximité du brise roche en fonctionnoment. It is highly recommended to have a protection grid in front of the excavator and in all places where special care and safety are necessary. Il est vivement recommandé de prévoir une grille de protection devant le poste de conduite de l'engin porteur et tous les endrolts indispensables à la sécurité de l'environnement immédiat du chantier.
Model 900 Safety MAINTENANCE AND REPAIRING MAINTENANCE ET REPARATION All components, accessories, pipes and connectors added to the rock breaker should be: Tous les composants, accessoires, tuyauteries et connecteurs ajoutés au brise roche doivent être : - Of good quality, procured from a reputable manufacturer and, wherever possible, be of a type approved by TRAMAC.
Model 900 Ten Commandments 1 Don’t ever modify the hydraulic installation set by the dealer. 6 Ne jamais pousser I'accélérateur jusqu'à dépasser la limite indiquée au moment des essais de mise en route. 2 Avoid any violent movement when the breaker is operating. 7 Eviter toute manoeuvre brutale du bras, alors que le brise roche est en phase de frappe. 3 8 Applied pressure is perpendicular to the material to be broken and always follows the tool.
Model 900 Dimensions BP HP 1645 2105 Ø 118 52 Operating Weight Poids Total 2400 Lbs 1100 kg Dimensions in Millimeters Les Cotes Sont Données en Millimétres Page O2
Model 900 Technical TECHNICAL SPECIFICATIONS CARACTERISTIQUES TECHNIQUES TRAMAC Carrier recommended weight Adaptation sur pelles de poids conseiIIé: 12 to 28 Tons Recommended oil flow Dèbit d'huile recommandé 26 to 40gpm 100 / 150 lpm Minimum pressure at excavator pressure relief valve Pression minimale de déclenchement du clapet de sécurité de la pelle 2610 psi 180 bar Admissible counter pressure Contre pression admissible 150 psi 10 bar Ø of the HP hose (inside) Ø de la tuyauterie haute
Model 900 Technical IMPORTANT IMPORTANT Prior to any mounting, the operator must check that the carrier characteristics correspond to the required specifications, mainly: - Weight, flow and setting of relief valve(s) mounted on breaker line (refer to technical specifications sheet).
Model 900 Technical Normal working Marche normale Fig. 1 Mechanically impossible (stop) Rendu mécanicanique impossible (butée) Normal working Marche normale Fig. 2 Possible Possible Precautions to be taken when connecting the breaker Précautions à prendre lors du raccordement Feeding the rock breaker by the "breaker" LP line, (which is theoretically possible when the carrier is fitted with an extra spool with 3 positions) is forbidden; otherwise the rock breaker may be damaged.
Model 900 3 LP HP 1 2 Page O6 Mounting
Model 900 Mounting MOUNTING ON EXCAVATOR MONTAGE SUR PELLE PREEOUIPEE Review the general safety instructions. Revoir les Instructions generales de socurite, entre autres, chapitre: Montage sur porteur. - Move the dipper stick end between the corresponding sides of the fixing cap. - Descendre le balancier entre les flancs. - Insert the pin (mark 1) and secure it. - Engager l'axe (rep. 1) et l'immobiliser. - Move the linkage between the corresponding sides of the fixing cap.
Model 900 Tool Mounting Fig.B Fig.A 2 3 A 1 B Fig.C Fig.D 1 Fig.F Fig.
Model 900 Tool Mounting TOOL MOUNTING MONTAGE DE L'OUTIL On a brand new breaker, remove the plastic protection cover at the bottom of the front guide. Dans le cas d'un brise roche neuf, enlever le bouchon de protection. Lift the breaker and position it horizontally. Lever le brise roche et I'amener à l'horizontal. Using a pin driver drive out the pin (mark 1), through holes A. A l'aide d'un chasse-goupille, éjecter les axes (rep. 1), par les orifices A.
Model 900 Operation Review the general safety instructions. Revolr les Instructions générales de sécurité principalement chapitre "utilisation". Before operating the breaker, train yourself to check: Avant d'utiliser le brise roche pour la premiére fois, habituez vous à contrôler - The position The rock breaker must be perpendicular to the material face at all times. - La position Le brise roche doit toujours être perpendiculaire à la surface du matériau à casser.
Model 900 Operation When in use, keep the breaker perpendicular Pendant le travail maintenir le brise roche perpendiculaire If the breaker is not perpendicular, the tool may slip off and get stuck between guiding bushings. Severe friction created between tool and bushings leads to seizing which will result in tool breakages, bushing breakages or the lower bushing sliding off. Energy dissipated into the side plates or into the cradle of the breaker leads to welding breakage.
Model 900 Operation Do not use the breaker under water Ne pas utiliser le marteau sous l'eau For underwater operation (even for a short time), it is essential to pressurize the breaker front part to prevent water from entering inside the breaker. Dans le cas d'un travail sous l'eau (même pour une courte durée), il est nécessaire de pressuriser la partie avant du marteau, pour éviter que l'eau ne pénètre à l'intérieur. See page O13. Consulter page O13.
Model 900 Maintenance Every 2 Hours Toutes les 2 heures Daily Toutes les jours Weekly Toutes les semaines Page O13
Model 900 Maintenance EVERY 2 HOURS TOUTES LES 2 HEURES D'UTILISATION Grease the tool shank. Graisser l'emmanchement de l'outil. DAILY TOUSLES JOURS Check the breaker attachment at the boom end. Vérifier la fixation du marteau en bout de bras. Make sure that the side rod is not broken. Vérifier qu'un tirant d'assemblage ne soit pas cassé. WEEKLY CHAQUE SEMAINE Check tightening of fixing cap bolts. Contrôler le serrage des boulons de fixation des plaques latérales.
Model 900 Operation The TRAMAC Model 900 in the standard version must not be used for underwater work, even for very short periods of time. If the chamber between the piston and the tool fills with water when the piston strikes, the water will not be evacuated fast enough and a considerable pressure rise will then occur which and destroy the piston seal (with a risk of piston seizure). Compressor Pressure: Pressure from the compressor must be at least 22 psi above the water pressure at the working depth.
Model 900 Tool Guide 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 that the demolition tool is in contact with the rock or concrete which requires breaking, it is this compressive stress wave which fractures the rock.
Model 900 Tool Guide Causes of increased fatigue stress in a demolition tool 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 working area and also when breakthrough of thin concrete slabs or boulders occurs. B. Cold: Low temperatures cause a demolition tool to be more susceptible to fatigue failure.
Model 900 Tool Guide TRAMAC demolition tool guide A B C D E Ref Tool type Application A B C D E F Moil point Chisel In-line chisel Blunt In-line asphalt cutter Spade Frost Low abrasive, homogenous material Plastic or heterogeneous material Plastic or heterogeneous material Crumbly rock Asphalt cutter and trenching Asphalt and trenching Page O18 F
Model 900 Tool Guide 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 defe ct. 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.
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MODEL 900 PARTS MANUAL Form No.
Model 900 Page P3 Parts List
Model 900 Item • • • • • • • • • 10 20 30 40 50 60 70 80 90 100 110 120 86249810 86275559 86368313 86419280 86349883 86223542 86419298 86419272 86404308 86314952 86228970 86419603 18652 33616 78508 92704 71817 67293 92705 92703 87786 56047 5346 18406 DESCRIPTION DESCRIPTION 1 1 8 ACCUMULATOR Nylon ring O-ring Screw CHc UNF 1” ACCUMULATEUR Bague nylon Joint torique Vis CHc UNF 1” 1 1 11 1 1 1 1 2 1 ROTATINGCONNECTIONS LP Threaded plug O-ring Shim Thrust spring Spring Slide Knee piece 1 1/4”
Model 900 Page P5 Parts List
Model 900 Parts List Item Part Number Ref # Qty.
Model 900 Parts List Excavator Side Côté Pelle 930 920 910 900 * Remove Plug * Enlever le Bouchon Page P7 *
Model 900 Parts List Item Part Number Ref # Qty.
Model 900 Sound Proof Option Sound Proof Kit/Kit d’insonorisation Item Part Number Ref # Qty.
Model 900 Accumulator 900 Accumulator HP/ HP Accumulateur Item Part Number Ref # Qty.
Model 900 * Remove plug *Enlever le bouchon Page P11
Model 900 Item Part Number Ref # 10 20 30 40 50 60 70 80 86417243 91235 86383759 86417201 86398153 86352481 86231644 86238466 86355500 86450798 82720 91228 86055 73008 7294 12817 74256 94236 Qty.
Model 900 This Page Left Blank Intentionally Cette Page est Laissée Blanche Intentionnellement Page P13
Model 900 Trouble Shooting TROUBLE SHOOTING … REMEDIES A - Oil leakage on hammer. PANNES POSSIBLES … REMÉDES A - Fulte d'hulle au niveau du marteau. Damaged or worn seals. Call your TRAMAC distributor. Joints d'étanchéité endommagés ou usés. Consultez votre distributeur TRAMAC le plus proche. B - The breaker loses power, high vibrations in breaker hoses. The accumulator is deflated or diaphragm punctured. Check the oil temperature.
Model 900 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.
Model 900 Trouble Shooting How to check hydraulic circuit and installation Mount a flow meter in place of the hammer. Also, mount a low pressure (0-300 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.
Model 900 Disassembly DISMANTLING DÉMONTAGE - Prior to removing the breaker from its cradle, remove the oiler holder plug. - Avant de retirer le marteau de son caisson, démontez le bouchon porte graisseur. - Loosen and remove the fixing cap bolts. - Desserrez les vis de fixation du chapeau. - Remove the fixing cap and the upper suspension. - Démontez le chapeau de fixation et I'amortisseur supérieur. - Remove the breaker from its cradle, place it on the mounting support.
Model 900 Disassembly - Using a syringe, drain oil contained in the breaker. Fig. F F - A I'aide d’une seringue, videz I'huile contenue dans le marteau. Fig. F - Remove the o-ring and the nylon ring. Fig. G G - Retirez le joint torique et la bague nylon. Fig. G - Remove the distributor. Fig. H H Retirez le distributeur. Fig. H - Plug the back head to prevent particles from entering in. Fig. I I - Bouchez la tête arrière pour éviter l'introduction de particules étrangères. Fig.
Model 900 Disassembly - When removing the back head, be sure the 2 valves mounted in the back head stay in place. If necessary, hold them. Fig. L L - Lors du démontage de la tête arrière, assurez-vous que les 2 clapets montés dans la tête arrière restent en position. Les tenir si nécessaire. Fig. L - Turn the back head over and remove the valves. Fig. M M - Retournez le tête arriêre et retirez les clapets. Fig. M - Use a plastic sledge hammer to extract the distribution box. Fig.
Model 900 R - Use an M8 metric screw to remove the thrust piston guide positioning pin. Fig. R - Remove the o-ring located on the upper part of the spacer. Fig. S S - Use the extractor to extract the thrust piston guide. Fig. T T - Position and fix the flange (1) onto the thrust piston guide by means of screws (2). U Place the tripod (3) and the ring (4). - Remove the thrust piston guide and the extractor. - Utilisez l'extracteur 74784 (CPN 86356763) pour extraire la culasse. Fig.
Model 900 - Mount the piston lifting tool. Remove the piston from the cylinder. Fig. X X - Screw the lifting tool into the assembling support. Lift the complete assembly from the pit and place it on the floor. Remove the lifting tool. Disassembly - Montez l'outil de levage du piston. Retirez le piston du cylindre. Fig. X - Vissez l’outil de levage dans le support de montage. Sortez le support de la fosse et posez le au sol. Démontez l’outil de levage. - Remove the pin (A). Fig.
Model 900 Accumulator 2 REPAIRING 2 RÉPARATION 2.1 2 Part Accumulators 2.1 Accumulateur en 2 parties A B C F D E - Loosen the inflation screw (A) to relieve nitrogen pressure. - Dévissez la vis de gonflage (A) pour décharger la pression d’azote. - Drill the safety nylon plugs (B) to loosen and remove the assembling screws (C). - Percez les bouchons plastiques de sécurité (B) et dévissez les vis d’assemblage (C).
Model 900 Accumulator - Tighten the fixing bolts to the specified torque (refer to the accumulator parts list). - Serrez le vis d’assemblage au couiple indiqué. (Voir la nomenclature de l’accumulateur). - Use the tightening sequences described below. - Respectez l’ordre de serrage des vis comme indiqué ci-dessous). - Remount new safety plugs (B). - Remontez des bouchons plastiques de sécurité neufs (B). - Mount new “BS” ring (F). - Montez une bague “BS” neuve (F). - Mount a new inflation screw.
Model 900 Accumulator Page M11
Model 900 Accumulator For BRP M.P. Accumulators and All others WARNING: Only use nitrogen to reinflate accumulators. ATTENTION: N'utlisez que de l’azote pour gonfler les accumulateurs. - Use the inflating tool 84539K. - Utilisez I'appareil de gonflage 84539K. - Make sure that the inflating screw is not tight. - Assurez vous que la vis de gonflage de I'accumulateur n’est pas bloquée. - Mount the inflating tool on the accumulator. Make sure the key is well engaged on the inflating screw head.
Model 900 PARTS INSPECTION Parts Inspection EXAMEN DES PIECES Back head Tête arrière A E C F D B G - Check all Helicoils (A). - Vérifiez tous les filets hélicoïl (A). - Check o-ring seat (B). Polish if necessary. - Vérifiez les portées de joints (B). Les polir si nécessaire. - Check snap ring (C) on spool sleeve. - Vérifiez que le jonc de retenue de la chemise est en place dans sa gorge (C) . - Make sure that the spool sleeve (D) is resting against the snap ring (C) and is not damaged.
Model 900 - Check the distribution box inner diameters (I). Replace if scratched. Parts Inspection - Vérifiez l'intérieur de la boîte de distribution (l). La remplacer si elle présente des rayures importantes. - Check the overpressure valve seat (J) and the corresponding seat on the thrust piston guide (K). Polish if necessary. - Vérifiez le siège du clapet (J) et la portée sur la culasse (K). Roder si nécessaire. - Make sure that the slide (L) is not damaged. Replace if the slide shows erosion marks.
Model 900 - Carefully clean all parts after polishing. Parts Inspection - Nettoyez soigneusement les pièces après polissage. - Check the cradle wearing plate area (R). Replace the cylinder if wear limit is reached. - Vérifiez la zone d'appui des patins d'usure du berceau (R). Remplacez le cylindre lorsque la limite d'usure est atteinte. Front guide Guide avant W mini = 30 mm (new 32.7 ± 1 mm) S min.
Model 900 Parts Inspection - Check ovalization of the upper bushing (X). Replace the bushing if wear limit is reached. - Vérifiez l'ovalisation de la douille supérieure (X). Remplacez la douille lorsque la limite d'usure est atteinte. - Check ovalization of front end bushing (Y). Replace the bushing if wear limit is reached. - Vérifiez l'ovalisation de la douille inférieure (Y). Remplacez la douille lorsque la limite d'usure est atteinte.
Model 900 Parts Inspection - Check wear on rubber parts. Replace the suspension when wear limit is reached. - Contrôlez l'usure des éléments caoutchouc. Remplacez la suspension lorsque la limite d'usure est atteinte. - Check the disk for cracks. Replace if necessary. - Vérifiez que le disque d'appui nest pas fissuré. Remplacez si nécessaire. Cradle Berceau - Make sure that the cradle is not cracked or damaged. - Vérifiez que le berceau nest pas fissuré ou endommagé.
Model 900 Parts inspection - Make sure that steel bars (AA) are not damaged. Replace both if wear limit is reached. - Vérifiez que les barrettes (AA) ne sont pas endommagées. Remplacez les 2 barrettes si la limite d'usure est atteinte. - Make sure that wearing plates (AB) are not damaged. Replace if wear limit is reached. - Vérifiez que les plaques d'usures (AB) ne sont pas endommagées. Les remplacer si la limite d'usure est atteinte. - Check the cradle lower protections (AC) for wear.
Model 900 Assembly ASSEMBLING MONTAGE - All parts must be cleaned and oiled with hydraulic oil at the time they are mounted. - Toutes les pièces doivent être propres et huilées avec de I'huile hydraulique lors du montage. - Mount the upper and front bushings in the front guide. - Montez les douilles supérieure et inférieure dans le guide avant. - Place the front guide on the assembling support that is placed on the floor. - Placez le guide avant sur le support de montage pose au sol.
Model 900 - If the breaker is not pressureized, mount the plug (460). Fig. E E 460 Assembly - Si le marteau ne doit pas etre pressurise, montez le bouchon (460). Fig. E - Mount the cylinder. Fig. F F - Montez le cylindre. Fig. F - Mount the locating pin on the cylinder. Fig. G G - Montez la goupille de positionnement sur le cylindre. Fig. G - Using the piston lifting tool, mount the piston in the cylinder. Remove the lifting tool. Fig. H Use a plastic sledge hammer to drive the piston to the end.
Model 900 - Prior to assembling, carefully clean the thrust piston guide seat (A) and corresponding surface of the spacer. Fig. L - Mount the thrust piston guide. Mind the orientation: The groove of the thrust piston guide must face the inclined hole of the cylinder. Fig. M Use a plastic sledge hammer to drive the guide to the end. L M - Avant montage, nettoyez soigneusement la surface d'appui (A) de la culasse et la face correspondante du cylindre. Fig. L - Montez la culasse.
Model 900 - Mount the complete valves and the o-rings in the back head (90). Use grease to hold the valves and o-rings in their housing. Fig. S S Assembly - Montez dans la tête arrière - Les ensembles clapets - Les joints toriques (90). Utilisez de la graisse pour tenir les clapets et les joints dans leurs logements. Fig. S 90 - Mount the back head. Fig. T - When mounting the back head, be sure the 2 valves are in place. If necessary, hold them. Fig. U T U - Montez la tête arrière. Fig.
Model 900 - Mount the 4 side rods on their original position. Avoid any shock against nuts. Fig. Y Z AA - Using a torque wrench, pretighten in a crisscross pattern the 4 side rods to 150 ft-Ibs. Correct the rod head position by aligning the closest notch with the one on the back head: - By loosening the rod if the closest notch is further than the back head notch (A). - By tightening the rod a little more if the closest notch has not reach the back head notch (B). Fig.
Model 900 Assembly AD - Mount the distribution box. Align 2 lower openings with the swivel axis. Fig. AD - Montez la boîte de distribution. Alignez 2 des passages inférieurs avec I'axe des manetons. Fig. AD AE - Use a plastic sledge hammer to drive the distribution box to the end. Fig. AE - Mount the distributor. Fig. AF AF AG - Mount the nylon ring and the o-ring. Fig. AG - Grease all the parts covered by the accumulator. Fig.
Model 900 Grease and mount o-rings (280) in the HP swivel. Mount the swivel. Mount the o-ring (240) and the seal (260) on the plug. Mind the orientation. Mount the slide in the plug. Mount the complete assy. Tighten the plug to 480 ft-lbs. Fig. AK - Mount the LP slide. Grease and mount o-rings (210) in the HP swivel. Mount the swivel. Mount the o-ring (150) on the plug. Mount the adjusting shims, the spring thrust and the spring in the plug. Mount the complete assy. Tighten the plug to 480 ft-lbs. Fig.
Grease Station GREASE STATION MANUAL Form No.
Grease Station Installation Page G2
Grease Station Parts List Page G3
Grease Station Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 25 27 28 29 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Part Number Ref # Qty.
Grease Station Service Parts/Kits Part Number Qty.
Grease Station Electric Page G6
