How to Rebuild a Tramac Hydraulic Hammer: Step-by-Step Guide, Terminology, and Practical Tips

[MikePhua]

Rebuilding a Tramac hydraulic hammer is a meticulous process that restores the hammer’s performance, reliability, and extends its working life. This guide breaks down the entire rebuild procedure, explaining key components, maintenance advice, and solutions to common issues. It offers a thorough, uniquely written overview designed to assist operators and technicians in understanding and efficiently performing a Tramac hammer rebuild with best practices and cautionary notes.
Understanding the Tramac Hydraulic Hammer
The Tramac hydraulic hammer is a powerful attachment used on excavators and other heavy machinery for demolition, rock breaking, and concrete operations. Its core function is to convert hydraulic energy into mechanical impacts delivered by a chisel or tool. Key parts include the piston, cylinder body, bushings, seals, accumulator, and valve assembly, all of which contribute to smooth, effective hammer operation.

• Piston: The moving part that transfers hydraulic energy into impact force.
  
• Cylinder Body: Houses the piston and acts as the hydraulic chamber.
  
• Bushings: Support moving parts and reduce metal-on-metal wear.
  
• Seals and O-rings: Maintain hydraulic pressure by preventing fluid leaks.
  
• Accumulator: Absorbs pressure spikes, protecting hydraulic circuits.
  
• Valve Assembly: Controls hydraulic fluid flow within the hammer.
  

When to Rebuild Your Tramac Hammer
Indicators for rebuild include:

• Decreased impact force or irregular hammer operation.
  
• Visible hydraulic oil leaks around the tool or body.
  
• Excessive play or movement in the bushings or tool pins.
  
• Unusual noises like knocking due to worn components.
  
• Regular maintenance schedules recommending rebuild after specific working hours.
  

Typically, smaller hammers can operate from 1,200 to 1,500 hours between rebuilds, while larger units may need rebuilding every 500 to 800 hours, depending on usage and maintenance.
Step-by-Step Rebuild Process

1. Preparation and Safety
   • Park the machine on level ground and relieve hydraulic pressure.
     
   • Clean the hammer exterior to reduce dirt contamination during teardown.
     
   • Prepare a clean and organized workspace with all necessary tools and replacement parts.
     
2. Disassembly
   • Remove the tool (chisel) by extracting retaining pins and rings carefully.
     
   • Detach hoses and valve components, labeling connections if necessary.
     
   • Remove tie rods or bolts securing the hammer body parts.
     
   • Separate the front head, middle cylinder, and back head carefully.
     
   • Extract the piston, bushings, seals, and wear parts.
     
3. Inspection and Cleaning
   • Thoroughly clean all parts with a suitable solvent or degreaser.
     
   • Inspect the piston for scoring, cracks, or excessive wear.
     
   • Check the cylinder bore for scratches, ovality, or corrosion.
     
   • Examine bushings, especially lower and upper bushings, for wear and replace if beyond limits.
     
   • Inspect all seals, O-rings, and buffer seals; replace all 'soft' parts even if they appear intact.
     
   • Inspect the valve spool and cartridge for wear or sticking; clean or replace as needed.
     
   • Check the accumulator diaphragm and charging pressure; maintain or replace if compromised.
     
4. Replacement of Components
   • Use genuine or high-quality aftermarket kits for seals, bushings, and pins.
     
   • Replace tie rods if bent or damaged.
     
   • For bushings, ensure they fit correctly using specified press-fit procedures.
     
   • Use proper grease on moving parts during assembly to prevent metal wear.
     
   • Replace the tool or chisel if excessively worn or mushroomed.
     
5. Reassembly
   • Assemble hydraulic seals in the correct orientation; improper seal installation will cause leaks or pressure loss.
     
   • Press bushings in with appropriate tools—avoid forceful hammering which can damage components.
     
   • Reassemble the body sections, torquing bolts and tie rods according to manufacturer specifications.
     
   • Reinstall the valve assembly and reconnect hydraulic hoses.
     
   • Insert retaining pins and rings on the tool; grease pins for smooth operation.
     
6. Testing and Fine-Tuning
   • Attach the hammer to the excavator and connect hydraulics.
     
   • Prime the hydraulic system, checking for leaks and ensuring hoses are secure.
     
   • Test the hammer at low pressure first, gradually increasing to working pressure.
     
   • Monitor for proper impact rate, smooth operation, and absence of leaks.
     
   • Address any abnormal noises or behavior immediately to prevent damage.
     

Common Challenges and Solutions

• Difficult Seal Installation: Create seal drivers using hardwood or plastic forms to ensure even seal placement without damage.
  
• Bushings Falling Out or Improper Fit: Always align roll pins correctly and ensure bushings match specifications.
  
• Corrosion and Surface Damage: Light polishing with fine grit sandpaper may remove minor corrosion, but replace parts with deep pitting.
  
• Welding Pins: In some repairs, retaining pins might require welding if loosened; use proper welding methods to avoid heat damage.
  
• Preventing Contamination: Maintain cleanliness throughout rebuild to avoid introducing dirt into hydraulic passages.
  

Maintenance Tips to Extend Hammer Life

• Regularly grease the tool and pins using recommended lubricants.
  
• Monitor hydraulic oil quality and replace filters frequently to prevent contamination.
  
• Avoid excessive hammering without forward pressure to prevent premature bushing wear.
  
• Store the hammer properly to avoid weather or moisture damage.
  
• Schedule mid-life inspections to detect wear before failure.
  

Real-World Example
One operator noted a dramatic improvement after rebuilding a Tramac hammer that had lost impact force and began leaking hydraulic oil. Careful replacement of piston seals, bushings, and valve cleaning restored original performance. The operator emphasized that using factory spec grease and replacing all soft parts minimized future downtime.
Parameter Reminders and Recommendations

• Typical rebuild times vary from 4 to 10 hours depending on hammer size and shop expertise.
  
• Hydraulic operating pressures often reach up to 3,000 psi; seals and components must withstand these pressures.
  
• Bushings are often slip-fitted in smaller hammers, speeding rebuild times.
  
• Accumulator pre-charge pressures must match specifications, typically set with nitrogen gas.
  

By following this structured rebuild process, understanding hydraulic hammer components, and adhering to maintenance best practices, technicians and operators can confidently restore and maintain their Tramac hydraulic hammers for efficient and reliable jobsite performance. This comprehensive overview combines essential technical knowledge, hands-on tips, and practical advice to ensure successful rebuilds with minimal risk of failure.