Sandvik Operators Manual

Original instructions
OMBR999CENG.311
Operator's manual
BR999
Contents
1. OPERATION .................................................................................................................. 5
1.1. Foreword .................................................................................................................... 6
1.1.1 Preface............................................................................................................................................... 6
1.1.2 This manual ....................................................................................................................................... 6
1.1.3 Important safety information .............................................................................................................. 7
1.1.4 Warranty ............................................................................................................................................ 8
1.1.5 Spare part orders ............................................................................................................................... 8
1.2. Machine numbers ...................................................................................................... 9
1.2.1 Model and serial number ................................................................................................................... 9
1.3. Product introduction ............................................................................................... 10
1.3.1 Overview .......................................................................................................................................... 10
1.3.2 Removal from package .................................................................................................................... 10
1.3.3 Lifting instructions ............................................................................................................................ 11
1.3.4 Main parts ........................................................................................................................................ 12
1.3.5 Environmental protection and recycling policy ................................................................................. 13
1.4. Safety........................................................................................................................ 14
1.4.1 General safety.................................................................................................................................. 14
1.4.2 Safety instructions............................................................................................................................ 14
1.5. Operation.................................................................................................................. 22
1.5.1 Operating instructions ...................................................................................................................... 22
1.5.2 Daily operation ................................................................................................................................. 24
1.5.3 Mounting and dismounting the hammer........................................................................................... 29
1.5.4 Turning hammer left- or right-handed .............................................................................................. 31
1.5.5 Movement ........................................................................................................................................ 33
1.5.6 Special conditions of use ................................................................................................................. 33
1.5.7 Storage ............................................................................................................................................ 33
2. LUBRICATION............................................................................................................. 35
2.1. Hammer tool greasing............................................................................................. 36
2.1.1 Recommended greases................................................................................................................... 36
2.1.2 Manual greasing .............................................................................................................................. 36
2.2. Carrier hydraulic oil................................................................................................. 38
2.2.1 Requirements for hydraulic oil ......................................................................................................... 38
2.2.2 Oil cooler.......................................................................................................................................... 40
2.2.3 Oil filter............................................................................................................................................. 40
3. MAINTENANCE ........................................................................................................... 43
3.1. Routine maintenance .............................................................................................. 44
3.1.1 Overview .......................................................................................................................................... 44
3.1.2 Inspection and maintenance by the operator................................................................................... 44
3.1.3 Inspection and maintenance by the dealer ...................................................................................... 44
3.1.4 Maintenance intervals in special applications .................................................................................. 45
2 Copyright © 2011 Sandvik Mining and Construction Oy

3.1.5 Other maintenance procedures ....................................................................................................... 45
3.2. Removal of tool........................................................................................................ 46
3.2.1 Wear limits and lubricants for tool removal ...................................................................................... 46
3.2.2 Removal of tool ................................................................................................................................ 46
3.2.3 Installation of tool ............................................................................................................................. 48
3.3. Tool bushing ............................................................................................................ 49
3.3.1 Wear limits and lubricants for tool bushing ...................................................................................... 49
3.3.2 Removal of tool bushing .................................................................................................................. 49
3.3.3 Installation of tool bushing ............................................................................................................... 50
3.4. Troubleshooting ...................................................................................................... 51
3.4.1 The hammer does not start.............................................................................................................. 51
3.4.2 The hammer operates irregularly but the blow has full power ......................................................... 51
3.4.3 The hammer operates irregularly and blow has no power ............................................................... 52
3.4.4 Impact rate slows down ................................................................................................................... 52
3.4.5 The hammer does not stop or has run-on........................................................................................ 53
3.4.6 Oil overheats.................................................................................................................................... 53
3.4.7 Recurrent tool failure........................................................................................................................ 53
3.4.8 Further assistance ........................................................................................................................... 54
4. SPECIFICATIONS ....................................................................................................... 55
4.1. Hammer specifications ........................................................................................... 56
4.1.1 Technical specifications ................................................................................................................... 56
4.1.2 Main dimensions .............................................................................................................................. 57
4.2. Tool specifications .................................................................................................. 58
4.3. CE mark and EC Declaration of Conformity ......................................................... 59
4.3.1 Text Contents of the EC declaration of conformity: ......................................................................... 59
Copyright © 2011 Sandvik Mining and Construction Oy 3

OPERATION BR999
1. Operation
Copyright © 2011 Sandvik Mining and Construction Oy

5
BR999 OPERATION
1.1. FOREWORD
1.1.1 Preface
Congratulations on having purchased this product. A properly installed attachment should prove to be a
productive machine requiring maintenance only at regular intervals.
1.1.2 This manual

This manual is arranged to give you a good understanding of the equipment and its safe operation. It also
contains maintenance information and technical specifications. Read this manual from front to back before
installing, operating or maintaining the attachment for the first time.
In this manual, the units of measurement are metric. For example, weights are given in kilograms (kg). In some
cases the other unit follows in parenthesis (). For example 28 litres (7.4 US gal).
The specifications and designs presented in this manual are subject to change without prior notice.
1.1.2.1 Symbols used in this manual
This symbol identifies important safety messages within this manual. Carefully read the message that follows.
Failure to understand and obey this safety warning could result in injury to you or others, and could also cause
damage to equipment. See illustration 1.
This symbol identifies prohibited action or hazardous location. Failure to understand and obey this safety
warning could result in injury to you or others, and could also cause damage to equipment. See illustration 2.

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OPERATION BR999
This symbol identifies correct and recommended action. See illustration 3.
This symbol identifies environmental and recycling matter. See illustration 4.
R010265
1.1.3 Important safety information

Basic safety precautions are outlined in the "Safety" section of this manual and in the description of operations
where hazards exist. Warning labels have also been put on the machine to provide instructions and to identify
specific hazards which if not observed could cause bodily injury or death to you or other persons. These
warnings in the guide and on the machine labels are identified by the warning symbol.
To use the attachment correctly, you must also be a competent operator of the carrier machine. Do not use or
install it if you can not use the carrier machine properly. The attachment is a powerful tool. If used without
proper care, it can cause damage.
Do not rush when you are learning to use the product. Take your time and most importantly, take it safely. Do
not guess. If there is anything you do not understand, ask your local dealer. He will be pleased to advise you.
Improper operation, lubrication or maintenance of this machine can be dangerous and could result in injury.
Do not operate this machine until you read and understand the instructions in this manual.
Do not perform any lubrication and maintenance on this machine until you read and understand the instructions
in this manual.

7
BR999 OPERATION
1.1.4 Warranty
The customer is provided with a separate warranty sheet, where the export warranty terms are explained.
Check always that this warranty sheet is provided with the attachment. If not, contact your local dealer
immediately.
1.1.4.1 Warranty registration card
A warranty registration card is filled out after the installation inspection by the dealer and a copy of it is sent to
the manufacturer. This card is very important because no warranty claims are handled without it. Make sure
that you get a copy of it after the installation inspection and that it is correctly filled out.
1.1.4.2 Installation inspection
An installation inspection must be carried out after the product has been installed on the carrier. In the
installation inspection certain specifications (operating pressure, oil flow, etc.) are checked so that they are
within given limits. See “Hammer specifications” on page 56.
1.1.5 Spare part orders

When you need spare parts or some information concerning maintenance to your machinery, please contact
your local dealer. Quick deliveries are ensured by exact orders.
Required information:
1. Name of customer, contact person
2. Order number (when available)
3. Delivery address
4. Mode of delivery (air mail, etc.)
5. Required delivery date
6. Invoicing address
7. Model and serial number of product
8. Name, number and required amount of spare parts

8
OPERATION BR999
1.2. MACHINE NUMBERS
1.2.1 Model and serial number

The equipment serial number is stamped on the valve body. The model and serial number are also located on
the CE marking. Check that the model corresponds to the one given on the cover of this manual.
It is important to make correct reference to the serial number of the attachment when making repairs or ordering
spare parts. Identification of the serial number is the only proper means of maintaining and identifying parts for
a specific product.
R010312

9
BR999 OPERATION
1.3. PRODUCT INTRODUCTION
1.3.1 Overview
The product is a hydraulically operated breaker. It can be used on any carrier which meets the necessary
hydraulic and mechanical installation requirements. The unit functions by repeatedly raising a steel piston and
driving it down onto the head of a removable breaking tool.
No additional pressure accumulators are necessary since the integrated pressure accumulator absorbs
hydraulic pressure peaks. The impact energy of the hammer is almost constant and independent of the carrier's
hydraulic system.
1.3.2 Removal from package
Remove all the steel belts from the package. Open the package and remove all plastics covering the product.
Recycle all package materials (steel, plastic, wood) properly.
Check that the product is in good condition and that there is no visible damage. Check that all ordered parts
and accessories have been enclosed with the product. Some options may be provided by your local dealer like
installation kits; including hoses and mounting bracket.

10
OPERATION BR999
1.3.3 Lifting instructions
Use a hoist when lifting components which weigh 23 kg (50 lb) or more, to avoid back injury. Make sure all
chains, hooks, slings etc., are in good condition and are in the correct capacity. Be sure hooks are positioned
correctly. Lifting eyes are not to be side loaded during a lifting operation. Do not use the hammer's tools for
lifting.
Lifting devices must safely carry the working weight of the product. See “Hammer specifications” on page 56.
Place chains or slings, as shown by the illustration, to lift the product.
R010313
1.3.3.1 Safety instructions for lifting
Below are some common safety instructions concerning lifting operations. In addition to this, the local, national
standards for machines and lifting-tackles must always be strictly observed. Please note that the list below is
not all inclusive, you must always ensure the procedure you choose is safe for you and others.
■ Do not lift load over people. No one shall be under the hoisted load.
■ Do not lift people and never ride the hoisted load.
■ Keep people clear from lift area.
■ Avoid side pull of the load. Make sure you take up the slack slowly. Start and stop carefully.
■ Lift load a few centimeters and verify it before proceeding. Make sure the load is well balanced. Check for
any loose items.
■ Never leave the suspended load unattended. Maintain load control at all times.
■ Never lift the load over the rated capacity (see product's operating weight from specification page).
■ Inspect all lifting equipment before use. Do not use twisted or damaged lifting equipment. Protect lifting
equipment from sharp corners.
■ Obey all local safety instructions.

11
BR999 OPERATION
1.3.4 Main parts

The main parts of the hammer are shown below.
C
B
D
R010314
A. Side plates
B. Mounting flange
C. Hammer mechanism
D. Hose connections
E. Grease nipple
F. Tool and tool bushing retaining mechanism

12
OPERATION BR999
1.3.5 Environmental protection and recycling policy
Sandvik manufactures products which contribute to the recycling of materials to help customers achieve their
environmental objectives. During the manufacturing all the necessary precautions are taken to make sure that
no harm is done to the environment.
Sandvik strives to foresee and minimize the risks that might be caused by operation or maintenance of
products, which could expose humans or the environment to danger. Sandvik support customers in their efforts
to consider the environmental protection in their everyday work.
When working with Sandvik product please follow these guidelines:
■ Dispose of packaging materials properly. Wood and plastic can be burned or recycled. Deliver the steel
belts to metal recycling center.
■ Protect environment from oil spills.
In case of hydraulic oil leaks, the equipment should be serviced immediately.
Follow the product's greasing instructions and avoid excessive greasing.
Be careful when handling, storing and transporting oils.
Dispose of empty oil or grease containers appropriately.
Consult local authorities for detailed instructions.
■ All metal parts of the product can be recycled by delivering them to an authorized scrap metal collection
facility.
■ Comply with local waste classification rules when disposing of used rubber or plastic parts (buffers, wear
plates, seals).
■ When scrapping the whole product or pressure accumulator, consult your local Sandvik dealer for
instructions on depressurizing the accumulator.
■ Do not bring the product or accumulator to a scrap metal collection center before depressurizing the
accumulator first.
Consult with your local dealer for more information.

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BR999 OPERATION
1.4. SAFETY
1.4.1 General safety

All mechanical equipment can be hazardous if operated without due care or correct maintenance. Most
accidents involving machine operation and maintenance are caused by failure to observe basic safety rules or
precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs.
Because it is impossible to anticipate every possible circumstance that might involve a potential hazard, the
warnings in this guide and on the machine are not all inclusive. If a procedure, tool, working method or
operating technique not specifically recommended by manufacturer is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the
method of operation or maintenance procedures you choose.
Safety is not just a matter of responding to the warnings. All the time you are working with your attachment you
must pay attention to what hazards there might be and how to avoid them. Do not work with the product until
you are sure that you control it. Do not start any job until you are sure that you and those around you will be
safe.
Warning! Read the following warning messages carefully. They tell you of different hazards and how
to avoid them. If proper precautions are not taken you or others could be seriously injured.
1.4.2 Safety instructions
1.4.2.1 Manuals
Study this manual before installing, operating or maintaining the product. If there is anything you don't
understand, ask your employer or your local dealer to explain it. Keep this manual clean and in good condition.
The related safety label on the hammer and the text on the label are shown below.
"IGNORING INSTRUCTIONS HAZARD
Faulty handling practice could cause death or serious injury.
Read and follow the instructions in the operator's manual."

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OPERATION BR999
WARNING
IGNORING
INSTRUCTIONS HAZARD
Faulty handling practice could
cause death or severe injury.
Read and follow the instructions
in the operator’s manual.
169410_ENG-3
R010348
1.4.2.2 Care and alertness
All the time you are working with the product, take care and stay alert. Always be alert for hazards. The
possibility of a serious or even fatal accident is increased when you are intoxicated.
1.4.2.3 Clothing
You can be injured if you do not wear proper clothing. Loose clothing can get caught in the machinery. Wear
protective clothing to suit the job.
Examples are: a safety helmet, safety shoes, safety glasses, well-fitting overalls, ear-protectors and industrial
gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained.
1.4.2.4 Practice
You and others can be killed or injured if you perform unfamiliar operations without practising them first.
Practice away from the job site, in a clear area.
Keep other people away. Do not perform new operations until you are sure you can do them safely.
1.4.2.5 Regulations and laws
Obey all laws, work site and local regulations which affect you and your equipment.
1.4.2.6 Communications
Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you
will be working with other people make sure they understand any hand signals you will be using.
Work sites can be noisy. Do not rely only on spoken commands.

15
BR999 OPERATION
1.4.2.7 Work site
Work sites can be hazardous. Inspect the site before working on it.
Check for potholes, weak ground, hidden rocks etc. Check for utilities (electric cables, gas and water pipes
etc.). Mark the positions of underground cables and pipes if you will be breaking the ground.
Poor visibility can cause accidents and damage. Make sure that visibility and lightning of the working area are
adequate.
1.4.2.8 Banks and trenches
Banked material and trenches can collapse. Do not work too close to banks and trenches where there is a
danger of collapse.
1.4.2.9 Safety barriers
Unguarded equipment in public places can be dangerous. Place barriers around the machine to keep people
away.
1.4.2.10 Airborne pollutants
The related safety label on the hammer and the text on the label are shown below.
"DUST HAZARD
Breathing dust will cause death or severe injury.
Always wear approved respirator."
DANGER
DUST HAZARD
Breathing dust will cause death
or severe injury.
Always wear approved
respirator.
169410_ENG-1
R010349
Airborne pollutants are microscopic particles, which will damage your health, when inhaled. Aiborne pollutants
on construction sites can be e.g. silica dust, oil fumes or diesel exhaust particles, visible or invisible. Especially
in demolition sites, there may be other dangerous substances, such as e.g. asbestos or lead paints or other
chemical substances.

16
OPERATION BR999
The effect of airborne pollutants may be immediate if the substance is poisonous. The main danger with
airborne pollutants comes from long term exposure, where particles are inhaled but not removed from the
lungs. The disease is called e.g. silicosis, asbestosis or other and will result in death or serious injury.
To protect yourself from airborne pollutants, always keep excavator doors and windows closed during
operation. Excavators with pressurized cabins should be utilized in hammer operation. Proper maintenance of
fresh air filters of the excavator is essential. Where pressurized cabins are not available, proper respirators
must be utilized.
Stop working, when bystanders are in the area of airborne pollutants and make sure they have proper
respirators. Respirators are as important for bystanders as hard hats.Respirators for both operator and
bystanders must be approved by the respirator manufacturer for the application in question. It is essential that
the respirators protect from the tiny dust particles which cause silicosis and which may cause other serious lung
diseases. You should not use the equipment until you are sure the respirators are working properly. This
means the respirators must be checked to make sure that it is clean, that its filter has been changed, and to
otherwise make sure the respirator will protect in the way it is meant to.
Always make sure dust has been cleaned off your boots and clothes when you leave your shift. The smallest
particles of dust are the most harmful. They may be so fine that you can not see them. Remember, you MUST
protect yourself and bystanders from the danger of breathing or inhaling dust.
Always follow local laws and regulations for airborne pollutants in the working environment.
1.4.2.11 Flying chips of rock
The safety label on the hammer is shown below:
"FLYING OBJECTS HAZARD
Fragments fly up to 40 m (130 ft) and could cause death or serious injury.
Stop operation when a person enters hazard zone.
Wear approved personal protective equipment."
WARNING
FLYING OBJECTS HAZARD
Fragments fly up to 40 m (130 ft)
and could cause death or severe
injury.
Stop operation when a
person enters hazard zone.
Wear approved personal
protective equipment.
169410_ENG-2
R010350

17
BR999 OPERATION
Protect yourself and your neighbourhood against flying chips of rock. Do not operate the product or carrier if
someone is too close.
The European standard EN 474-1 on safety of earth-moving machinery requires that adequate operator's
protection, such as bullet proof glass, mesh guard or an equivalent protection is used.
Keep the cabin windows and doors closed during operation. Window bars are recommended to protect the
windows from flying chips of rock.
1.4.2.12 High noise level
A hammer in operation creates a high noise level. Always wear ear protection to prevent personal injury.
The safety label on the hammer is shown below:
"NOISE HAZARD
Continuous exposure to noise above 80 dB(A) will cause hearing impairment.
Wear approved hearing protectors."
WARNING
NOISE HAZARD
Continuous exposure to noise
above 80 dB(A) could cause
hearing impairment.
Wear approved hearing
protectors.
169410_ENG-4
R010351
1.4.2.13 Equipment limits
Operating the product beyond its design limits can cause damage. It can also be dangerous. See “Hammer
specifications” on page 56.
Do not try to enhance the product's performance by unapproved modifications.
1.4.2.14 Hydraulic fluid
Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic
fluid leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks
and then inspect the cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates your skin seek medical
help immediately.
Hot hydraulic fluid can cause severe injuries.

18
OPERATION BR999
1.4.2.15 Hydraulic hoses and fittings
Ensure all hydraulic components will withstand maximum pressure and mechanical stresses caused by
operation of the attachment. Consult your local dealer for instructions.
1.4.2.16 Fire hazard
Most hydraulic fluids are flammable and might ignite when contacting hot surface. Avoid spilling hydraulic fluid
to hot surfaces.
Working with the product on certain materials can cause sparks and hot splinters to get loose. These can ignite
flammable materials around working area.
Ensure that adequate extinguisher is available.
1.4.2.17 Hydraulic pressure
Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the
carrier engine, operate the controls to release pressure trapped in the hoses and wait ten (10) minutes. During
the operation, keep people away from the hydraulic hoses.
There might be pressurized oil trapped inside the product even if it is disconnected from the carrier. Be aware
of possible blank firing while greasing or removing and installing hammer tools. See “Removal of tool” on page
46.
1.4.2.18 Pressure accumulators
The safety label on or near the accumulator is shown below.
"HIGH PRESSURE HAZARD
Improper handling of pressurized accumulator will cause death or severe injury.
Read workshop manual before disassembly.
Release pressure before disassembly.
Recharge with nitrogen (N2) only."
DANGER
HIGH PRESSURE HAZARD
Improper handling of pressurized
accumulator will cause death or
severe injury.
Read workshop manual before
disassembly.
Release pressure before
disassembly.
Recharge with nitrogen (N2) only.
169410_ENG-5
R010352
The hammer incorporates one or two pressure accumulators, depending on the model. The accumulators are
pressurized even when there is no hydraulic pressure to the hammer. Attempting to dismantle the
accumulators without first releasing the pressure can cause injury or death. Do not try to dismantle pressure
accumulators, contact your local dealer first.
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BR999 OPERATION
1.4.2.19 Lifting equipment
You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition.
Make sure that the lifting tackle complies with all local regulations and is suitable for the job. Make sure that
the lifting equipment is strong enough for the job and you know how to use it.
Do not use this product or any of its parts for lifting. See “Lifting instructions” on page 11. Contact your carrier
dealer to find out how to lift with your carrier.
1.4.2.20 Spare parts
Use only genuine spare parts. Use only genuine tools with hydraulic hammers. The use of other spare part or
hammer tool brands may damage the product.
1.4.2.21 Equipment condition
Defective equipment can injure you or others. Do not operate equipment which is defective or has missing
parts.
Make sure the maintenance procedures in this manual are completed before using the product.
1.4.2.22 Repairs and maintenance
Do not try to do repairs or any other maintenance work you do not understand.
1.4.2.23 Modifications and welding
Non-approved modifications can cause injury and damage. Contact your local dealer for advice before
modifying the product. Before welding on the product while it is installed on the carrier, disconnect the carrier
alternator and battery. Note that welding of the hammer tools will render them useless and make the warranty
void.
1.4.2.24 Metal splinters
You can be injured by flying splinters when driving metal pins in and out. Use soft-faced hammer or drifts to
remove and fit metal pins, such as pivot pins. Always wear safety glasses.
1.4.2.25 Labels on the Product
Safety labels communicate the following four things:
- The severity level of the risk (i.e. signal word "DANGER" or "WARNING").
- The nature of the hazard (i.e. the type of hazard: high pressure, dust, etc.).
- The consequence of interaction with the hazard.
- How to avoid the hazard.
You must ALWAYS follow the instructions of the safety messages and symbols of the product safety labels and
the instructions set forth in the manuals to avoid death or severe injury!

20
OPERATION BR999
Keep the safety labels clean and visible at all times. Check the condition of safety labels daily. Safety labels
and instructions which have disappeared, been damaged, painted over, come loose or do not meet the legibility
requirements for safe viewing distance, must be replaced before operating the product.
If a safety label is attached to a part that is replaced, install a new safety label on the replacement part. If this
manual is available in your language, then the safety labels should be available in the same language.
There are several specific safety labels on this hammer. Please become familiarized with all safety labels. The
location of the safety labels is shown in the illustration below.
When you clean the safety labels, use a cloth, water and soap. Do not use solvent, gasoline or other harsh
chemicals to clean the safety labels.
Solvents, gasoline or harsh chemicals could loosen the adhesive that secures the safety labels. Loose
adhesive will allow the safety label to fall.
DANGER WARNING
DUST HAZARD NOISE HAZARD
Breathing dust will cause death Continuous exposure to noise
or severe injury.
above 80 dB(A) could cause
DANGER Always wear approved
respirator.
hearing impairment.
HIGH PRESSURE HAZARD Wear approved hearing

Improper handling of pressurized protectors.
severe injury.
disassembly.
disassembly.
169410_ENG-5 169410_ENG-1 169410_ENG-4
WARNING
FLYING OBJECTS HAZARD
Fragments fly up to 40 m (130 ft)
and could cause death or severe
injury.
Stop operation when a
person enters hazard zone.
Wear approved personal
protective equipment.
169410_ENG-2
WARNING
IGNORING
INSTRUCTIONS HAZARD
Faulty handling practice could
cause death or severe injury.
Read and follow the instructions
in the operator’s manual.
169410_ENG-3
San San
d v i k 168 9 0 7 d v i k 168 9 0 7
DANGER
HIGH PRESSURE HAZARD
Improper handling of pressurized
severe injury.
disassembly.
disassembly.
169410_ENG-5
R010345

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BR999 OPERATION
1.5. OPERATION
1.5.1 Operating instructions
1.5.1.1 Recommended use
The hammer is designed to be used in breaking concrete, road surface or asphalt, hard or frozen ground. It is
also suitable for light trenching and benching applications or in ground compacting. It can be also used in
breaking small and soft boulders. Your local dealer will gladly give you more information.
1.5.1.2 Operating conditions
Principle of installation
Almost all carriers meeting mechanical and hydraulic requirements can be used to operate the attachment. See
“Hammer specifications” on page 56. The product is installed on the carrier much in the same manner as
installing a bucket or other attachments. A flange mounted attachment requires a separate mounting bracket.
The attachment is connected to a carrier's hydraulic circuit with an installation kit. If the carrier is already
equipped with an installation kit, the installation requires only suitable hoses and fittings. If the carrier does not
have suitable kit to run the attachment, one must be built. This may require more complex installation including
new piping and additional valves such as directional valve and pressure relief valve.
Suitable kits can be ordered from the manufacturer or local dealers, from carrier manufacturers and their
dealers or from third party suppliers.
Hydraulic oil
In general the hydraulic oil originally intended for the carrier can be used with this product. See “Requirements
for hydraulic oil” on page 38.
Operating temperature
The operating temperature is -20 °C (-4 °F) to 80 °C (176 °F). If the temperature is lower than -20 °C (-4 °F),
the hammer and tool have to be preheated before any operations can begin, in order to avoid breaking the
accumulator's membrane and the tool. During operation they will remain warm.
Note: The temperature of the hydraulic oil must be monitored. Ensure that oil grade and monitored oil
temperature together guarantee correct oil viscosity. See “Oil specifications” on page 38.
Noise dampening
Operating the hammer near residential areas or other noise sensitive areas can cause noise pollution. In order
to avoid unnecessary noise, please follow these basic rules:
1. When operating with the hammer, keep the tool at 90 degree angle to the material and the feed force in-
line with the tool.
2. Replace or fix all parts that are worn out, damaged or loosened. This not only saves your hammer but it
also decreases the noise level.
1.5.1.3 Principles of breaking
To increase the hammer's working life, pay particular attention to correct working methods and how to choose
the correct tool for the job. There are essentially two ways of breaking with a hydraulic hammer.

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OPERATION BR999
Penetrative breaking (or cutting)
In this form of breaking a moil point or chisel tool is forced inside the material. This method is most effective in
soft, layered or plastic, low abrasive material. The high impact rate of the small hammers makes them ideal for
penetrative breaking.
Impact breaking
With impact breaking, the material is broken by transferring very strong mechanical stress waves from the tool
into the material. Impact breaking is most effective in hard, brittle and very abrasive materials. The high impact
energy of the big hammers makes them ideal for impact breaking. The best possible energy transfer between
the tool and the object is achieved with a blunt tool. The use of a chisel tool in hard material will cause the sharp
edge to wear very quickly.
1.5.1.4 Choosing tools
A selection of standard and special tools to suit each application are available. The correct type of tool must
be selected to get the best possible working results and longest life time for the tool. Choosing the best tool
type for an application may require some testing, please consult with your local dealer. See “Tool
specifications” on page 58.
Chisel and moil point
■ For sedimentary (e.g. sandstone) and weak metamorphic rock into which the tool penetrates.
■ Concrete.
■ Trenching and benching.
Spade tool
■ Frozen or compact ground.
■ Asphalt.
Compacting plate
■ Ground compacting.
It is important to choose a tool, which is suitable for your hammer and for the application you are working on.
The tool selection available depend on hammer model. See “Tool specifications” on page 58.

23
BR999 OPERATION
1.5.2 Daily operation
Warning! Protect yourself and your neighbourhood against flying chips of rock. Do not operate the
hammer or carrier if someone is too close to the hammer.
The hammer as a standard assembly, must not be used under water. If water fills the space where the
piston strikes the tool, a strong pressure wave is generated and the hammer may be damaged.
Warning! To avoid falling objects, do not use Product to lift other products. See “Lifting instructions”
on page 11.
1. Prepare the carrier for normal excavation work. Move the carrier to the required position. Set the drive to
neutral.
2. Set the engine speed to the recommended engine RPM for correct amount of oil supply.
3. Carefully operate the carrier controls to place the hammer and boom into the breaking position. Quick and
careless boom movements could result in damage to the hammer.

24
OPERATION BR999
4. Use the excavator boom to press the hammer firmly against the object. Do not pry the hammer with the
boom. Do not press too hard or too gently with the boom. The correct force is applied, when the tracks
start to lift slightly from the ground.
5. Place the tool against the object at a 90 degree angle. Avoid small irregularities on the object which will
break easily and cause either idle strokes or an incorrect working angle.
6.
;; ;;
When demolishing vertical structures (e.g. brick walls), place the tool against the wall at a 90 degree angle.

25
BR999 OPERATION
7. Start the hammer.
8. A safety screen is recommended to protect the operator from flying debris. Keep the cabin windows and
doors closed during operation.
9. Note: Listen to the hammer's sound when you are using it. If the sound becomes weaker and the impact
less efficient, the tool is misaligned with the material and/or there is not enough down force on the tool.
Realign the tool and press the tool firmly against the material.
10. Do not strike in one spot for more than 15 seconds at a time. If the object does not break, or if the tool does
not penetrate, stop the hammer and change the position of the tool. Working too long in one spot will create
stone dust under the tool. Dust dampens the impact effect and produces heat.
11. Do not let the tool move outwards from the hammer when it penetrates. Keep the down-pressure on the
hammer while breaking.

26
OPERATION BR999
12. To use the hammer most efficiently when breaking, concentrate on small steps from the outer edge
towards the middle.
13. When breaking hard or frozen ground, use the benching method. Start with clearing a small area from the
edge. Then continue by breaking material towards the open area.
14. Stop the hammer quickly. Do not allow the hammer to fall down and make idle strokes when an object
breaks. Frequent idle strokes have a deteriorating effect on the hammer. If the hammer falls through, the
housing wears out more quickly.
15. When breaking concrete, hard or frozen ground, never strike and pry with the tool at the same time. The
tool may break. Bending may be caused by stones inside hard or frozen ground. Be careful and stop
striking if you find sudden resistance under the tool.

27
BR999 OPERATION
16. Keep the tool at a 90 degree angle at all times. If the object moves or its surface breaks, correct the angle
immediately. Keep the feed force and tool aligned.
17. Do not use the hammer to sweep the ground of debris. This may damage the hammer and the housing
will wear out more quickly.
18. When operating the hammer, make sure that it does not make contact with the carrier boom or hydraulic
lines.
19. Do not operate the hammer with the carrier's boom stick or bucket cylinders at the end of their stroke
(either fully extended or retracted). Damage to the carrier may result.

28
OPERATION BR999
20. Do not use the hammer or hammer tools for lifting. Lifting eyes on the hammer are for storage and
maintenance purposes only.
21. The tool shank must be well greased during operation. Regular visual inspections during operation are
recommended. An unlubricated tool shank requires more frequent greasing intervals. A tool shank covered
with excessive grease requires less frequent greasing intervals.
1.5.3 Mounting and dismounting the hammer
1.5.3.1 Removal from carrier
Warning! The hammer must be secured from rolling over when disconnecting from the carrier. Only
use skilled operator to position carrier for hammer removal!
Warning! Hydraulic pressure inside hammer must always be released before opening hose
connections!
Warning! Hot hydraulic fluid can cause severe injuries!
1. Position hammer horizontally on the floor and remove the tool.
2. Stop the carrier engine. Operate boom and hammer controls to release pressure trapped inside hoses.
Wait ten minutes for oil pressure to drop.
3. Close hammer inlet and outlet lines. If quick couplers are used, disconnection automatically closes
hammer lines. If hammer line includes ball valves, please make sure that they are closed.

29
BR999 OPERATION
4. Disconnect hoses. Protect environment from oil spills. Plug the hoses and the hammer inlet and outlet
ports.
5. Remove bucket pins and other parts.
6. The carrier can be moved aside.
1.5.3.2 Installation
1. Install hammer in the same manner as mounting a bucket. Install bucket pins.
2. Connect hoses. Hammer inlet port is marked on the valve body with "IN" and outlet port with "OUT". An
installation inspection must be carried out after the product has been mounted on the carrier. In the
installation inspection certain specifications (operating pressure, oil flow, etc.) are checked so that they are
within given limits. See “Hammer specifications” on page 56.
3. Open hammer inlet and outlet lines.

30
OPERATION BR999
1.5.4 Turning hammer left- or right-handed
1.5.4.1 Torques and lubricants
OUT IN
IN OUT
R010315
Item Tightening torque

Manifold fastenings screws (A) 175 Nm (129 lbf ft)
Plug (B) 80 Nm (59 lbf ft)
Item Lubricant
O-rings O-ring grease
Plug (B) Locking fluid (e.g. Loctite 275)
1.5.4.2 Turning hammer left- or right-handed
It is possible to make the hammer either left- or right-handed by turning manifold 180 degree.
Warning! The hydraulic pressure inside the hammer must always be released before removing any of
the plugs or valves. Read the instructions on releasing the hydraulic pressure from the hammer.
Warning! Hot hydraulic fluid can cause severe injuries!
1. Stop the carrier engine. Operate boom and hammer controls to release pressure trapped inside hoses.
Wait ten minutes for oil pressure to drop.

31
BR999 OPERATION
2. Close hammer inlet and outlet lines. If quick couplers are used, disconnection automatically closes
hammer lines. If hammer line includes ball valves, please make sure that they are closed.
3. Remove hoses from swivels. Protect environment from oil spills. Plug hose ends and swivels.
4. Remove flange plugs from manifold. Plug connections.
5. Remove manifold screws and manifold.
6. Remove O-rings from manifold.
R010316
7. Turn manifold 180 degree.
R010317
8. Clean contact surface carefully. Paint manifold outside surface against corrosion.
9. Install O-rings to manifold.
10. Install manifold. Torque manifold screws to specified setting.
11. Install flange plugs for input/output channels and torque them to specified setting.
R010318
12. Install hoses to swivels and carrier.

32
OPERATION BR999
1.5.5 Movement
The transportation and parking positions are shown below. When moving with the hammer, ensure that it isn't
too close and doesn't point at the cabin window.
1.5.6 Special conditions of use

If hammer is to be used in conditions that differ from normal breaking or demolition work conditions, such as:
■ Hammer tunnelling
■ Foundry cleaning
■ Underwater operations
■ Operations in extremely low or high temperatures
■ Use of special hydraulic fluids
■ Hammer operations with special carrier (extra long boom etc.)
■ Other special conditions
That may require modifications to attachment, special operating techniques, increased maintenance or special
wear items.
In case of special conditions of use, please consult your local dealer for instructions.
The hammer as a standard assembly, must not be used under water. If water fills the space where the
piston strikes the tool, a strong pressure wave is generated and the hammer may be damaged.
1.5.7 Storage
1.5.7.1 Long term storage
Observe the following points when the hammer is stored. In this way the vital parts of the attachment are
protected from rust and the machine is ready to be used whenever necessary.

33
BR999 OPERATION
1. The storage area must be dry.
2. The tool must be removed in hydraulic hammers.
3. The lower end of the piston, tool and tool bushings must be well protected with grease in all hydraulic
hammers.
4. Connections must be sealed with clean plugs to prevent oil leakage and dirt from getting into couplings.
5. The product must be stored in the vertical position.
6. Make sure the product can not fall.

34
LUBRICATION BR999
2. Lubrication

35
BR999 LUBRICATION
2.1. HAMMER TOOL GREASING
2.1.1 Recommended greases

■ RAMMER TOOL GREASE, part no. 902045
■ FUCHS Meisselpaste
■ KENDALL Tough TAC
■ KLÜBER Crafloscon C-SG 0 Ultra
■ LE 3751/3752 Almagard varipurpose lubricant
■ SHELL Kuggfett
■ SHELL Albida HLS 2
■ WYNNS GS80
Wear gloves when handling the grease containers. If you get grease onto your skin, wash it away with
water.
R020112
2.1.2 Manual greasing
Follow the product's greasing instructions and avoid excessive greasing. Dispose of empty grease
containers appropriately.
2.1.2.1 Greasing interval
1. Tool shank must be well lubricated before installing tool.
2. 3-5 strokes from grease gun to tool bushings and tool at regular intervals.
3. Adapt interval and amount of grease to wear rate of tool and working conditions. This can be anything
between two hours and daily, depending on material (rock/concrete) to be broken. See “Recommended
greases” on page 36.

36
LUBRICATION BR999
Insufficient greasing or improper grease may cause:
■ Abnormal wear of tool bushing and tool
■ Tool breakage
2.1.2.2 Correct greasing
1. Position the hammer standing upright resting on the tool on firm surface.
2. Stop carrier engine and wait 10 minutes for oil pressure to drop inside hammer.
3. Apply tool grease from grease gun to greasing points marked with the following sticker.
Note: The hammer must stand upright resting on the tool to ensure that the grease will penetrate downwards
between the tool and the bushing.
Do not fill the space between the piston and the tool with grease. A lower piston seal failure can result and the
hammer will subsequently leak oil.

37
BR999 LUBRICATION
2.2. CARRIER HYDRAULIC OIL
2.2.1 Requirements for hydraulic oil
2.2.1.1 General requirements
In general the hydraulic oil originally intended for the carrier can be used with this product. However, since
working with the product heats the oil more than the usual excavation work, the temperature of the oil must be
monitored.
If the temperature of the hydraulic oil exceeds 80 °C (176 °F), an auxiliary oil cooler is needed. The oil viscosity
must be between 20-1000 cSt while the attachment is being used.
When the product is used continuously, the temperature of the hydraulic oil normalizes at a certain level
depending on conditions and on the carrier. The temperature in the tank must not exceed the maximum
allowed.
The hammer must not be started if the ambient temperature is below freezing and the oil is very thick. The
machine must be moved to bring the oil temperature above 0 °C (32 °F) before hammering can start (viscosity
1000 cSt or 131 °E).
2.2.1.2 Oil specifications
Table below shows hydraulic oils recommended for hammer use. The most suitable oil is selected in such a
way that the temperature of the hydraulic oil in continuous use is in the ideal area on the chart and the hydraulic
system is used to best advantage.

38
LUBRICATION BR999
Problems due to incorrect hydraulic oil viscosity in the hammer:
Oil too thick
■ Difficult start up
■ Stiff operation
■ Hammer strikes slowly
■ Danger of cavitation in pumps and in the hydraulic hammer
■ Sticky valves
■ Filter bypass opens, impurities in the oil are not removed
Oil too thin
■ Efficiency losses (internal leaks)
■ Damage to gaskets and seals, leaks
■ Accelerated wearing of parts, because of decreased lubrication efficiency
■ Hammer strikes irregularly and slowly
■ Danger of cavitation in pumps and in the hydraulic hammer
Note: We strongly recommend the use of different hydraulic oils in the summer and in the winter if there is an
average temperature difference of more than 35 °C (35 °C). The correct hydraulic oil viscosity is thus ensured.
2.2.1.3 Special oils
In some cases special oils (e.g. biological oils and non-inflammable oils) can be used with the hydraulic
hammers. Observe the following aspects when considering the use of special oils:
■ The viscosity range in the special oil must be in the given range (20-1000 cSt)
■ The lubrication properties must be sufficient
■ The corrosion resistance properties must be good enough
Note: Although a special oil could be used in the carrier, always check its suitability with the hammer due to
high piston speed of the hammer. Contact the oil manufacturer or your local dealer for more information about
special oils.

39
BR999 LUBRICATION
2.2.2 Oil cooler

The correct place to connect the hammer return line is between the oil cooler and the main filters. The hammer
return line should not be connected before the oil cooler. Routing the hammer return flow through the cooler,
might damage either the cooler, due to pulsating flow, or the hammer, due to increased back pressure.
The carrier hydraulic system must be able to maintain the temperature within an acceptable level during the
hammer operation. This is for two reasons.
1. Seals, wipers, membranes and other parts manufactured from the corresponding materials can normally
stand temperatures up to 80 °C (176 °F).
2. The higher the temperature is, the less viscous the oil gets thus losing its capability to lubricate.
A standard carrier, with a proper hammer circuit, meets the requirements of the necessary cooling capacity. If
the oil temperature tends to be too high during the hammer operation, the following things must be checked:
■ The hammer circuit pressure relief valve is not open when the hammer is operated.
■ The hammer circuit pressure drops are reasonable. Less than 10 bar (150 psi) in the pressure line and
less than 5 bar (50 psi) in the return line.
■ Hydraulic pumps, valves, cylinders, motors etc. and hammer do not have internal leakages.
If all of the above mentioned things are in order, and the temperature of the hydraulic oil still tends to be too
high, extra cooling capacity is needed. Consult the carrier manufacturer or dealer for details.
2.2.3 Oil filter

The purpose of the oil filter is to remove impurities from the hydraulic oil. Air and water are also impurities in
oil. Not all impurities can be seen with the naked eye.
Impurities enter the hydraulic system:
■ During hydraulic oil changes and refilling.
■ When components are repaired or serviced.
■ When the hammer is being installed on the carrier.
■ Because of component wear.
Normally the existing main oil filters of the carrier are used as hammer circuit return line filters. Consult the
carrier manufacturer or your local dealer concerning instructions for the filter change intervals.
In hydraulic hammer work the carrier oil filter must fulfil the following specifications:
■ The oil filter must allow maximum particle size of 25 microns (0.025 mm).
■ The oil filter material must be artificial fibre cloth or very fine gauge metallic mesh to withstand pressure
fluctuations.
■ The oil filter must have a nominal flow capacity of at least twice the hammer's maximum flow.
In general, oil companies guarantee new oils to have a particle count of 40 microns maximum. Filter the oil
when filling the tank.
The damage caused by hydraulic oil impurities in the carrier and hammer circuits:

40
LUBRICATION BR999
1. The working life of the pumps and other components is significantly shortened.
■ Rapid wear of parts.
■ Cavitation.
2. Wear of cylinder and gaskets.
3. Reduced hammer efficiency.
■ Accelerated wear of moving parts and seals.
■ Danger of piston seizing up.
■ Oil leakages.
4. Shortened working life and reduced lubricating capability of oil.
■ Oil overheats.
■ Oil quality deteriorates.
■ Electro-chemical changes in hydraulic oil.
5. Valves do not function properly.
■ Spools bind.
■ Rapid wear of parts.
■ Blocking of small holes.
Note: Component damage is only a symptom. The trouble itself will not be cured by removing the symptom.
After any component damage due to impurities in the oil, the entire hydraulic system has to be cleaned.
Dismantle, clean and reassemble the hammer and change the hydraulic oil.

41
BR999 LUBRICATION

42
MAINTENANCE BR999
3. Maintenance

43
BR999 MAINTENANCE
3.1. ROUTINE MAINTENANCE
3.1.1 Overview
This product is a precision made hydraulic machine. Therefore great care and cleanliness should be taken
when handling any of the hydraulic components. Dirt is the worst enemy in hydraulic systems.
Handle the parts carefully and remember to cover any cleaned and dried parts with clean lint-free cloth. Do not
use anything other than purpose designed materials for cleaning hydraulic parts. Never use water, paint
thinners or carbon tetrachloride.
Components, gaskets and seals in the hydraulic system should be oiled with clean hydraulic oil before
assembly.
3.1.2 Inspection and maintenance by the operator

Note: The time intervals given refer to the carrier hours while the attachment is installed.
3.1.2.1 Every two hours
■ Grease the tool shank and the tool bushings. See “Manual greasing” on page 36.
■ Observe hydraulic oil temperature, all lines and connections as well as impact efficiency and evenness of
operation.
■ Tighten loose connections.
3.1.2.2 Every 10 hours or at least once a week
■ Remove the tool retaining pin and the tool and check their condition. Grind the burrs away if necessary.
See “Removal of tool” on page 46.
■ Check that the tool has received sufficient grease. Grease more frequently, if necessary.
3.1.2.3 Every 50 hours or at least once a month
■ Check the tool shank and tool bushings for wear. See “Removal of tool” on page 46. See “Tool bushing”
on page 49.
■ Check the hydraulic hoses. Replace if necessary. Do not let dirt get into the hammer or hoses.
3.1.3 Inspection and maintenance by the dealer

Note: The times given refer to the carrier hours while the attachment is installed.
3.1.3.1 Initial 50-h inspection
It is recommended to have the first inspection done by your local dealer after 50 to 100 operating hours. Contact
your local dealer for more information about the initial 50-hour inspection.

44
MAINTENANCE BR999
3.1.3.2 Every 600 hours or once a year
This service is recommended to be done by your local dealer after 600 operating hours. Neglecting the annual
service can cause severe damage to the hammer.
Your local dealer will reseal the hammer, replace the accumulator membranes and replace safety decals as
needed. Contact your local dealer for more information about annual servicing.
During this maintenance you should do the following tasks.
■ Check all hydraulic connections.
■ Check that the hydraulic hoses do not rub against anything in any boom position.
■ Replace and inspect the hydraulic oil filters of the carrier.
3.1.4 Maintenance intervals in special applications

The service interval is considerably shorter in special applications. See “Special conditions of use” on page
33. In special applications, please consult your local dealer for the correct service intervals.
3.1.5 Other maintenance procedures
3.1.5.1 Washing the attachment
When working with attachment and removing it from the carrier, dirt (mud, rock powder etc.) can become
attached to it. Wash the outside of the product with a steam washer before sending it to the workshop. Dirt can
cause difficulties in disassembly and assembly otherwise.
CAUTION! Plug the pressure and return line before washing the product or else dirt can enter into it and this
may cause damage to the components.

45
BR999 MAINTENANCE
3.2. REMOVAL OF TOOL
3.2.1 Wear limits and lubricants for tool removal
R030118
Item Wear limit

Tool diameter (worn out) 88 mm (3.46 in)
Item Lubricant
Tool and tool retaining pins Tool grease
3.2.2 Removal of tool
Warning! The hydraulic pressure inside the hammer must always be released before removing the tool.
After operating the hammer, wait 10 minutes for oil pressure to drop inside hammer.
Warning! Hot tool can cause severe injuries.
Do not throw used hammer tool away at job site. Used tools can be recycled by delivering them to an
authorized scrap metal collection facility.
1. Set the hammer on level ground.
2. Make sure the carrier's transmission is in neutral and the parking brake is engaged.
3. Stop the carrier engine.
4. Remove plug and O-ring.

46
MAINTENANCE BR999
5. Remove tool retaining pin.
R030120
6. Remove tool. Use lifting device if necessary. See “Tool specifications” on page 58. Notice that tool bushing
and tool are locked with same tool retaining pin. Prevent tool bushing from dropping on ground when
removing the tool.
R030119
Note: If hammer is still on carrier, it may be easier to stick the tool in the ground and lift the hammer off the tool.
Make sure that the tool can not fall.

47
BR999 MAINTENANCE
3.2.3 Installation of tool

1. Clean all parts carefully.
2. Measure the tool diameter (X) from the area marked on the illustration. Replace tool if necessary.
3. Check tool bushing for wear. See “Tool bushing” on page 49.
4. Check tool seal. Replace if necessary.
R030121
5. Clean and coat tool and retaining pin with grease.
6. Install tool and align the groove of the tool with the pin bore.
7. Install retaining pin and O-ring.
8. Grease plug and install it.
R030128

48
MAINTENANCE BR999
3.3. TOOL BUSHING
3.3.1 Wear limits and lubricants for tool bushing
R030101
Item Wear limit

Tool bushing inner diameter (worn out) 92 mm (3.62 in)
Item Lubricant
Contact surfaces of front head Thread grease
3.3.2 Removal of tool bushing

1. Remove tool. Notice that tool bushing and tool are locked with same tool retaining pin. Prevent tool
bushing from dropping on ground when removing the tool.
R030122
2. Remove tool bushing.
R030123
3. Remove seal from tool bushing.

49
BR999 MAINTENANCE
3.3.3 Installation of tool bushing

1. Clean all parts carefully.
2. Measure the bushing inner diameter (marked Y). Replace bushing if necessary.
3. Install seal.
R030124
4. Lubricate the contact surfaces of the front head.
5. Install the tool bushing. Align the holes in the tool bushing with the holes in the front head.
6. Install the tool.

50
MAINTENANCE BR999
3.4. TROUBLESHOOTING
3.4.1 The hammer does not start
PRESSURE OR RETURN LINES CLOSED

Check the operation of quick couplings in hammer line. Open hammer line ball valves if closed.
PRESSURE AND RETURN HOSES INSTALLED BACKWARDS

Swap the pressure and return hoses.
PISTON IS IN ITS LOWER HYDRAULIC BRAKE

Keep the hammer control valve open and force the tool against an object. The tool head will push the piston
out of its brake area. See “Daily operation” on page 24.
GREASE BETWEEN PISTON AND TOOL CONTACT AREA

Remove the tool and wipe excessive grease off. See “Manual greasing” on page 36.
HAMMER CONTROL VALVE DOES NOT OPEN

When operating the hammer control valve, check that the pressure line pulsates (this indicates the hammer
control valve is opening). If the valve does not operate, check the operating means: mechanical connections,
pilot pressure or electrical control.
RELIEF VALVE IN HYDRAULIC CIRCUIT OPENS AT A LOW PRESSURE. HAMMER OPERATING

PRESSURE IS NOT REACHED
Check the installation. Check the relief valve operation. Adjust the relief valve in hydraulic circuit. Measure the
high pressure in the hammer inlet line.
EXCESSIVE BACK PRESSURE IN RETURN LINE

Check the installation. Check the size of the return line.
LEAKAGE FROM PRESSURE TO RETURN IN EXCAVATOR HYDRAULIC CIRCUIT

Check the installation. Check the pump and the other hydraulic components.
FAILURE IN HAMMER VALVE OPERATION

The hammer must be serviced in an authorized Sandvik service shop.
PISTON FAILURE
3.4.2 The hammer operates irregularly but the blow has full power
NOT ENOUGH FEED FORCE FROM EXCAVATOR

Refer to the correct working methods. See “Daily operation” on page 24.


51
BR999 MAINTENANCE

3.4.3 The hammer operates irregularly and blow has no power
THE WORKING METHOD IS NOT CORRECT

Refer to the correct working methods. See “Daily operation” on page 24.

PRESSURE ADJUSTING VALVE SETTING IS INCORRECT

PRESSURE LOSS IN PRESSURE ACCUMULATOR


3.4.4 Impact rate slows down
OIL HAS OVERHEATED (OVER +80 °C/+176 °F)

Check for a fault in the oil cooling system or an internal leak in the hammer. Check the hydraulic circuit of the
carrier. Check the relief valve operation in the carrier. Check the line size. Assemble an extra oil cooler.
HYDRAULIC OIL VISCOSITY TOO LOW

Check hydraulic oil. See “Requirements for hydraulic oil” on page 38.


high pressure in the hammer inlet line. Contact your local dealer for more information.

PRESSURE LOSS IN PRESSURE ACCUMULATOR



52
MAINTENANCE BR999
3.4.5 The hammer does not stop or has run-on
FAILURE IN HAMMER CONTROL VALVE OPERATION

Check the hammer control valve in the carrier.
3.4.6 Oil overheats
APPLICATION NOT CORRECT FOR HAMMER

Refer to recommended use and to correct working methods. See “Daily operation” on page 24.
COOLING CAPACITY OF THE FACTORY OIL COOLER IS TOO SMALL

Assemble an extra oil cooler.

high pressure in the hammer inlet line. Contact your local dealer for more information.
HYDRAULIC OIL VISCOSITY TOO LOW

Check hydraulic oil. See “Requirements for hydraulic oil” on page 38.

INTERNAL OIL LEAK IN THE HAMMER


3.4.7 Recurrent tool failure
APPLICATION NOT CORRECT FOR HAMMER

Refer to recommended use and to correct working methods. See “Operating instructions” on page 22.
ROUGH OPERATING PRACTICES

Refer to recommended use and to correct working methods. See “Daily operation” on page 24.
TOOL DOES NOT GET ENOUGH LUBRICANT

Refer to recommended use and to correct working methods.
TOO LONG TOOL

Use shortest tool possible. Refer to recommended use and to correct working methods.
RAPID WEAR OF TOOL

Refer to recommended use and to correct working methods. See “Daily operation” on page 24. There is a wider
selection of tools available for different applications. Consult with your local dealer for more information.

53
BR999 MAINTENANCE
3.4.8 Further assistance
FURTHER ASSISTANCE
If further assistance is required, please prepare to answer the following questions before calling your dealer.
■ Model and serial number
■ Working hours and service history
■ Carrier model
■ Installation: Oil flow, operating pressure and return line pressure if known
■ Application
■ Has the product operated normally before

54
SPECIFICATIONS BR999
4. Specifications

55
BR999 SPECIFICATIONS
4.1. HAMMER SPECIFICATIONS
4.1.1 Technical specifications
Item Specification
Working weighta 505 kg (1110 lb)
Impact rateb 500...1700 bpm
Operating pressurec 100...140 bar (1450...2050 psi)
Pressure relief, mind 150...190 bar (2200...2750 psi)

Pressure relief, max 220 bar (3200 psi)
Pressure in LP-circuit 36...38 bar (500...38 psi)
Oil flow range 50...150 l/min (13...40 gal/min)
Back pressure, max 20 bar (300 psi)
Input power 35 kW (47 hp)
Tool diameter 90 mm (3.54 in)
Pressure line connection (IN) BSPP-internal 1"
Return line connection (OUT) BSPP-internal 1"
Pressure line size (minimum inner 26 mm (1.02 in)
diameter)
Return line size (minimum inner diameter) 26 mm (1.02 in)
Optimum oil temperature 40...60 °C (104...140 °F)
Allowed oil temperature range -20...80 °C (-4...176 °F)
Optimum oil viscosity at operating 30...60 cSt
temperature
Allowed oil viscosity range 20...1000 cSt
Miniexcavator, tractor backhoe weighte 7.0...12.5 t (15400...27600 lb)
Skid steer, robot weightf 4.0...7.0 t (8800...15400 lb)

Noise level, guaranteed sound power level, 127 dB (127 dB)
LWAg
a. Includes average mounting bracket and standard tool
b. Actual impact frequency depends on oil flow, oil viscosity, temperature, and material to be broken
c. Actual pressure depends on oil flow, oil viscosity, temperature, material to be broken and back pressure
d. Minimum setting = actual operating pressure + 50 bar (730 psi)
e. Check carrier's lifting capacity from carrier manufacturer
f. Check carrier's lifting capacity from carrier manufacturer
g. According to European Union DIRECTIVE 2000/14/EC

56
4.1.2 Main dimensions
400
526
15˚
1217
1089
1669
400
100 160 100
120
480
Ø22
Ø90
120
278 325 R040161

57
BR999 SPECIFICATIONS
4.2. TOOL SPECIFICATIONS
R040155
Diameter/
Tool Part no. Length Weight
Width
Chisel (A) BJ801 830 mm 38.5 kg (80 90 mm (3.54
(32.68 in) lb) in)
Moil point (B) BJ803 830 mm 38.4 kg (80 90 mm (3.54
(32.68 in) lb) in)
Spade, parallel to boom BJ805 840 mm 37.7 kg (80 210 mm (8.27
(C) (33.07 in) lb) in)
Spade, transverse to BJ806 840 mm 37.7 kg (80 210 mm (8.27
boom (D) (33.07 in) lb) in)
Compacting plate (E) BJ807 800 mm 76.6 kg (170 330 mm
(31.50 in) lb) (12.99 in)

58
4.3. CE MARK AND EC DECLARATION OF CONFORMITY
4.3.1 Text Contents of the EC declaration of conformity:

Original
EC DECLARATION OF CONFORMITY
(2006/42/EC, Annex II.1, sub A, Directive 2000/14/EC)
Manufacturer: Sandvik Mining and Construction Oy, Breakers Lahti
Address: Taivalkatu 8, FI-15170 Lahti, Finland
Herewith declares that the Sandvik hydraulic breaker
type: BR999
- is in conformity with the provisions of the Machinery Directive (2006/42/EC)
The procedure applied for the Machinery Directive Conformity Assessment is "Internal checks on the
manufacture" (Annex VIII). The risk assessment is made according to ISO 14121. The DNV certified
Quality Management System according to ISO 9001 is applied to design and manufacture of the product.
- Is in conformity with the provisions of the Noise Directive (Directive 2000/14/EC)
The procedure applied for the Noise Directive Conformity Assessment is "Internal control of production
(Annex V)"
TYPE S/N Measured Guaranteed

sound power sound power
level: LWA level: LWA
[dB] [dB]
BR999 999A 123 127
This declaration remains valid, as long as no modification is carried out without the manufacturer's written
agreement.
N.N., PDC Impact Products Manager, is authorized to compile the technical file and confirms the product
design to conform with the essential health and safety requirements.
M.M., Plant Manager Breakers, confirms compliance of the manufactured machinery with the technical file.
N.N. and M.M. are empowered to draw up this declaration of conformity.
Date of issue: dd.mm.yyyy
Place of issue: Taivalkatu 8, FI-15170 Lahti, Finland
for Sandvik Mining and Construction Oy, Breakers Lahti

59
Copyright © 2011 Sandvik Mining and Construction Oy 61
36-16-14077-33-144-21
36-16-14077-33-236-357
SANDVIK MINING AND CONSTRUCTION OY, BREAKERS LAHTI P.O. BOX 165, (TAIVALKATU 8), FI-15101 LAHTI, FINLAND 62
TEL. +358 205 44 151 FAX +358 205 44 150 www.sandvik.com

Sandvik Operators Manual

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2 Copyright © 2011 Sandvik Mining and Construction Oy

Copyright © 2011 Sandvik Mining and Construction Oy 3

Copyright © 2011 Sandvik Mining and Construction Oy

1.1.2 This manual

1.1.2.1 Symbols used in this manual

Copyright © 2011 Sandvik Mining and Construction Oy

This symbol identifies environmental and recycling matter. See illustration 4.

1.1.3 Important safety information

Copyright © 2011 Sandvik Mining and Construction Oy

1.1.4.1 Warranty registration card

1.1.4.2 Installation inspection

1.1.5 Spare part orders

1. Name of customer, contact person

2. Order number (when available)

4. Mode of delivery (air mail, etc.)

5. Required delivery date

7. Model and serial number of product

8. Name, number and required amount of spare parts

Copyright © 2011 Sandvik Mining and Construction Oy

1.2.1 Model and serial number

Copyright © 2011 Sandvik Mining and Construction Oy

1.3. PRODUCT INTRODUCTION

1.3.2 Removal from package

Copyright © 2011 Sandvik Mining and Construction Oy

1.3.3.1 Safety instructions for lifting

■ Do not lift people and never ride the hoisted load.

■ Keep people clear from lift area.

■ Obey all local safety instructions.

Copyright © 2011 Sandvik Mining and Construction Oy

1.3.4 Main parts

F. Tool and tool bushing retaining mechanism

Copyright © 2011 Sandvik Mining and Construction Oy

When working with Sandvik product please follow these guidelines:

■ Protect environment from oil spills.

In case of hydraulic oil leaks, the equipment should be serviced immediately.

Follow the product's greasing instructions and avoid excessive greasing.

Be careful when handling, storing and transporting oils.

Dispose of empty oil or grease containers appropriately.

Consult local authorities for detailed instructions.

Consult with your local dealer for more information.

Copyright © 2011 Sandvik Mining and Construction Oy

1.4.1 General safety

1.4.2 Safety instructions

"IGNORING INSTRUCTIONS HAZARD

Faulty handling practice could cause death or serious injury.

Read and follow the instructions in the operator's manual."

Copyright © 2011 Sandvik Mining and Construction Oy

1.4.2.2 Care and alertness

1.4.2.5 Regulations and laws

Work sites can be noisy. Do not rely only on spoken commands.

Copyright © 2011 Sandvik Mining and Construction Oy

1.4.2.7 Work site

1.4.2.8 Banks and trenches

1.4.2.9 Safety barriers

1.4.2.10 Airborne pollutants

Breathing dust will cause death or severe injury.

Always wear approved respirator."

Copyright © 2011 Sandvik Mining and Construction Oy