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Huskie Tools HH1500 Service Manual

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HUSKIE
HYDRAULIC
HAMMERS
SERVICE
MANUAL
HH1500
HH2000
HH3600
HH4500
HH5800
HH8000
1

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Table of Contents
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Summary of Contents for Huskie Tools HH1500

  • Page 1 HUSKIE HYDRAULIC HAMMERS SERVICE MANUAL HH1500 HH2000 HH3600 HH4500 HH5800 HH8000...

  • Page 2: Table Of Contents

    CONTENTS Safety Information Page 3 Safety Decals Safety Symbols Operating Instructions Page 6 How the Hammer Operates Mounting the Hammer to Carrier Connecting Hoses Daily Inspection before Operation Initial Startup, Hammer Break-in General Operation Instructions Cold Weather Startup and Operation Underwater Operation Storage Tool Replacement...

  • Page 3: Safety Information

    1. SAFETY INFORMATION • Always read the information in this manual before operating the hammer. Failure to do so can result in personal injury or damage to the equipment. • Check that all safety decals attached to the hammer and carrier are legible. Replace worn or illegible decals.

  • Page 4: Safety Decals

    SAFETY DECALS The decals shown below are attached to the hammer when shipped from the factory. Read and understand them before operating the hammer. Replace any decal that has become worn, damaged or illegible. Decals can be ordered through the parts department. CAUTION DANGER This symbol may appear on...
  • Page 5 The notice below is included in the shipping carton. It contains information relating to operator safety. Read and understand this notice before unpacking or operating the hammer. We suggest you retain this notice and include it in your local safety program. CAUTION Never operate the hammer unless the following Safety Instructions have been read and understood.

  • Page 6: Operating Instructions

    2. OPERATING INSTRUCTIONS HOW THE HAMMER OPERATES On larger hammers the main valve is contained in the valve box, which is bolted to the cylinder (Figure 1). During the upward stroke, the pressure in the upper chamber is released via the main valve and through the outlet. High pressure in the lower chamber then forces the piston upward.

  • Page 7: Mounting The Hammer To Carrier

    MOUNTING THE HAMMER TO THE CARRIER 1. Skid Steer Loader All hammers are mounted to hammer brackets, which are then mounted to an adapter plate using two pins. The adapter plate is mounted to the quick mount of the carrier. To remove the hammer, first disconnect the hydraulic couplers from the inlet and outlet ports and detach the quick mount.

  • Page 8: Initial Startup, Hammer Break-In

    INITIAL STARTUP, HAMMER BREAK-IN New or rebuilt hammers require 20-40 minutes of operation at half the rated speed as a break-in period. This allows for proper lubrication of all moving parts and for all sliding surfaces to mate properly. GENERAL OPERATING INSTRUCTIONS 1.

  • Page 9: Underwater Operation

    3. Set pressure regulator to 50 – 90 psi. 4. Maintain air supply to hammer at all times when operating under water 5. For HH1500 through HH8000, 20 to 50 CFM is required. PRESSURE REGULATOR Figure 3. Air Compressor Supply...

  • Page 10: Storage

    If corrosion is found do not use the hammer until the defective piston has been repaired or replaced. TOOL REPLACEMENT Table 1. Standard Tool Weights TOOL WEIGHTS lbs. HH1500 HH2000 HH3600 HH4500 HH5800 HH8000...
  • Page 11 Carefully drive out the tool spring pin. Push the tool set pin up and out of the front cap using a screwdriver or round bar. Note: Check Table 1, Page 10, before handling tools. For models HH100 through HH750-2, manual removal is possible. ...

  • Page 12: Maintenance

    3. MAINTENANCE HYDRAULIC OIL Note: It is not recommended to mix types of hydraulic oils. Check carriers hydraulic oil recommendations before adding hydraulic oil. 1. Check the oil level, oil filter condition and oil cooler in the carrier periodically. 2. Replace the hydraulic oil every 600 hours and the filter every 100 hours, or according to carrier recommendations.

  • Page 13: Fasteners

    FASTENERS Inspect all bolts and nuts for tightness. Tighten as required. (Refer to Table 4.) Replace all missing or damaged fasteners before operating the hammer. Fastener bolt and nut sizes are listed in Table 3. These are wrench sizes (distance across flats.) Table 3.

  • Page 14: Greasing Requirements

    400 ±35 840 ±35 1320 ±35 2600 ±35 2600 ±35 2600 ±35 Side Rod Valve Box Set Bolt Valve Box Set Bolt Valve Cap Bolt Back Nut. (HH1500, HH2000, (HH4500, HH5800, (HH2000 and up) & HH3600) HH8000) Mode Valve Set Bolt Figure 5.

  • Page 15: Nitrogen (N 2 ) Gas Pressure Adjustment

    NITROGEN (N ) GAS PRESSURE ADJUSTMENT The hammer will not operate properly and may not start due to an incorrect gas charge. Follow the procedure described below to adjust nitrogen (N ) gas pressure. WARNING! DO NOT STAND NEAR THE HAMMER WHEN ADDING NITRIGEN. THE TOOL MAY EJECT SUDDENLY AND CAUSE SEVERE INJURY.

  • Page 16: Oil Leakage Inspection

    Figure 9. Gas Charger Valve d. Open the main gas valve on the N gas container and regulate the N gas pressure (see Figure 8.) e. Turn the gas charger “T” handle clockwise and adjust N gas pressure in the gas chamber to the correct gas pressure shown on Table 10, Page 26.

  • Page 17: Gas Leakage Inspection

    Figure 10. GAS LEAKAGE INSPECTION Gas leakage can be easily detected using soapy water (refer to Table 6 and Figure 11.) Table 6. Diagnosis of Gas Leakage LEAK LOCATION POSSIBLE CAUSE REMEDY Gas valve assembly (A) or Defective O-ring, Replace gas valve Between gas valve assembly damaged assembly...

  • Page 18: Disassembly And Assembly

    4. DISASSEMBLY AND ASSEMBLY DISASSEMBLY 1. Tool Refer to tool replacement procedures on Figure 4, page 11. 2. Back cap Support the cylinder (Figure 12). Loosen and remove four side rods and washers, then remove the back cap. 3. Front cap (See Table 3 page 13 for eyebolt sizes) Install an eyebolt and suspend the front cap as shown in Figure 12.
  • Page 19 4. Main Valve Box Assembly Service of the Valve Box includes the Mode Valve Assembly and the Main Valve with Box Sleeve. a. Remove six or eight (depending on hammer model) Valve Box (4) Set Bolts and place Valve Box on a clean flat service. Note: Inspect o-rings located at ports on cylinder and replace o-rings as necessary.
  • Page 20 Figure 15. Do not force the cylinder sleeve. Tap uniformly on all sides of the sleeve. Figure 15. Removing Cylinder Sleeve Table. 7. Piston Weights WEIGHTS HAMMER MODEL lbs. HH1500 HH2000 HH3600 HH4500 HH5800 HH8000...

  • Page 21: Inspection Of Parts

    INSPECTION OF PARTS 1. Seals Seals that are deformed, scratched, worn or aged should be replaced (see Figure 16). It is recommended that all seals be replaced when disassembling the hammer. Figure 16. Seal Conditions 2. Moving parts Check for any scratches or damage on the surface of the piston, cylinder sleeves, main valve and bottom part of the piston where it strikes the tool.
  • Page 22 5. Replacing the shank bushing Note: Replacement of the front cap bushing is required when replacing the shank bushing, as the front cap bushing must be removed to replace the shank bushing. a. Measure the shank and front cap bushing; refer to Table 8 page 23 and Table 9 page 24.

  • Page 23: Component Wear Limits

    COMPONENT WEAR LIMITS Parts are to be replaced if not within the wear parameters. See Table 8 and Figure 17 below, for new dimensions see Table 9 page 24. Table 8. Component Wear Limits COMPONENT WEAR LIMITS When the clearance between the tool and the front cap bushing Front cap exceeds .300 in.

  • Page 24: Assembly

    Table 9. New Component Dimensions PART HH1500 HH2000 HH3600 HH4500 HH5800 HH8000 101. mm. 116. mm. 136. mm. 146. mm 156. mm 166. mm Front Cap Bushing I.D. 3.967 in. 4.567 in. 5.354 in. 5.748 in. 6.142 in. 6.535 in.
  • Page 25 8. Insert and tighten the four side rods together with the washer to the specified torque (see Table 4 and Figure 5 on page 14.) 9. Refill the hammer with Nitrogen (N ) gas. Refer to pages 15 and 16. Make sure that the piston is positioned at the lower end of its stroke before charging.

  • Page 26: Specifications

    SPECIFICATIONS Table 10. Specifications ITEM UNIT HH1500 HH2000 HH3600 HH4500 HH5800 HH8000 ft-lbs. 5800 8000 Impact energy 1500 2000 3600 4500 kg-m 450-560 340-450 Blows per 400-650 480-630 480-625 480-550 minute 300-500 380-500 350-450 345-430 280-370 50-63 62-73 Required 21.3-28.7 21.3-36.7...

  • Page 27: Refinishing Of Pistons And Cylinders

    6. REFINISHING OF PISTONS & CYLINDERS If the pistons and cylinders should be scored or scratched due to dirty oil, or improper hydraulic oil specifications, the piston and cylinder can in many cases be polished and salvaged, instead of being replaced. This is possible because the components in this hammer are made of high quality alloy steel and do not use chromium surface finishes which cannot be polished.

  • Page 28: Troubleshooting Diagnosis

    7. TROUBLESHOOTING DIAGNOSIS Table 11. Troubleshooting SYMPTOM POSSIBLE CAUSE REMEDY Hammer Couplers are not engaged Connect couplers securely does not run Adjust main and secondary relief Relief valve set incorrectly valve Malfunction of the hydraulic pump Repair pump Nitrogen gas pressure is too high Adjust gas pressure Main valve is damaged Replace main valve...

  • Page 29: Warranty Guide Lines

    Shank bushing (Includes complete disassembly, removal of both bushing and re- assembly) HH150 - HH1000 = 3 hours HH1500 - HH2000 = 4 hours HH3600 – HH8000 = 5 hours Side rod replacement only (Includes complete disassembly, removal of broken side rod...

  • Page 30: Limited Warranty

    IPC Industries, Inc. 194 N. Brandon Dr. Glendale Heights, IL 60139 LIMITED WARRANTY FOR HYDRAULIC HAMMERS LIMITED WARRANTY The manufacturer warrants its Products against defects in material and workmanship. Such LIMITED warranty shall apply to the initial Purchaser only. The BACK-CAP, MAIN BODY and FRONT CAP carry a LIFETIME, UNLIMITED HOURS warranty.
  • Page 31 Warranty Policy Statement This document explains IPC Industries, Inc. specific policies concerning submission and reconciliation of warranty claims. This document is in addition to and a part of the IPC Industries, Inc. Limited Lifetime Warranty For Hydraulic Hammers that accompanies all new hydraulic hammer products.
  • Page 32 6. Requesting a Returned Goods Authorization (RGA) Before returning a suspected warranty part, call IPC at (800) 487-5431 and our customer service representatives will provide you with a RGA number. Please have the description of the part(s) at hand and the method by which you will be returning the part prepaid to IPC.

  • Page 33: Parts List And Illustrations

    9. PARTS LIST AND ILLUSTRATIONS HH1500 HH2000 HH3600 HH4500 HH5800 HH8000...
  • Page 34 HH1500 HAMMER ITEM NAME NUMBER QTY. Cylinder 3J01-212001 Cylinder O-Ring* Seal Kit Cylinder O-Ring* Seal Kit Cylinder O-Ring* Seal Kit Cylinder Sleeve 3J01-212002 Cylinder Sleeve O-Ring* Seal Kit Quad Ring* Seal Kit Back Up Ring* Seal Kit Step Seal* Seal Kit...
  • Page 35 HH1500 HAMMER Effective 07/05...
  • Page 36 HH1500 HAMMER BRACKET ASSEMBLY PARTS LIST PART NO. ITEM DESCRIPTION MODEL HH1500 3J01-212501 Hammer Bracket (R)* ----------------- Hammer Bracket (L)* 3H01-215502 Bracket Bolt Assembly of Item 3 Washer Assembly of Item 3 3J01-212504 Support Pipe 3H01-TC2000B Top Cap Bolt Assembly of item 7...
  • Page 38 HH2000 HAMMER UP TO S/N 2K031 SOLD BEFORE 9/96 ITEM NAME NUMBER QTY. Cylinder 3H01-2150001 Cylinder O-Ring* 3H01-09098B Cylinder O-Ring* 3H01-09072B Cylinder Sleeve 3H01-2150002 Cylinder Sleeve O-Ring* 3H01-09288W Gas U-Packing* 3H01-U15000G U-Packing* 3H01-U15000I U-Packing with Back Up Ring* 3H01-15000H Dust Seal* 3H01-15000D Drain Plug 3Z01-DP0014...
  • Page 39 HH2000 HAMMER UP TO S/N 2K031 SOLD BEFORE 9/96 Effective 07/05...
  • Page 40 HH2000 HAMMER S/N 3K001 & UP SOLD AFTER 10/96 ITEM NAME NUMBER QTY. Cylinder 3H01-2150001 Cylinder O-Ring* 3H01-09098B Cylinder O-Ring* 3H01-09072B Plug 3J01-2210081 Cylinder O-Ring* 3J01-09056W Buffer Ring* 3H01-08056P Cylinder Sleeve 3H01-2150002 Cylinder Sleeve O-Ring* 3H01-09288W Quad Ring* 3H01-QD215000 Back Up Ring* 3H01-BU215000 Step Seal* 3H01-ST215000...
  • Page 41 HH2000 HAMMER S/N 3K001 & UP SOLD AFTER 10/96 Effective 07/05...
  • Page 42 HH2000 HAMMER BRACKET ASSEMBLY PARTS LIST PART NO. ITEM DESCRIPTION MODEL HH2000 3H01-215501 Hammer Bracket (R)* ----------------- Hammer Bracket (L)* 3H01-215502 Bracket Bolt Assembly of Item 3 Washer Assembly of Item 3 3H01-215504-198 Support Pipe (Top) 3H01-215505-262 Support Pipe (Middle) 3H01-215506-162 Support Pipe (Bottom) 3H01-TC2000B...
  • Page 44 HH3600-2 HAMMER S/N 5M1000 & UP ITEM NAME NUMBER QTY. Cylinder 3J01-B2210001-2 Cylinder O-Ring* 3J01-09108B Cylinder O-Ring* 3H01-09072B Cylinder Sleeve 3J01-2210002-2 Cylinder Sleeve O-Ring* 3J01-07328W Step Seal with O-Ring* 3J01-170561 Quad Ring* 3J01-QD221000 Back Up Ring* 3J01-170563 U-Packing* 3J01-U21000I Dust Seal* 3J01-D21000D Piston 3J01-2210011-2...
  • Page 45 HH 3600-2 HAMMER S/N: 5M1000 & UP Effective 07/05...
  • Page 46 HH3600-2 HAMMER S/N 5M1000 & UP BRACKET ASSEMBLY PARTS LIST PART NO. ITEM DESCRIPTION MODEL HH3600-2 3J01-221501 Hammer Bracket (R)* ----------------- Hammer Bracket (L)* 3J01-221502 Bracket Bolt Assembly of Item 3 Washer Assembly of Item 3 3J01-221504-226 Support Pipe (Top) 3J01-221507-298 Support Pipe (Middle) 3J01-221506-234...
  • Page 48 HH4500 HAMMER ITEM NAME NUMBER QTY. Cylinder 3K01-2270001 Cylinder O-Ring* 3K01-09128B Cylinder O-Ring* 3H01-09072B Cylinder Sleeve 3K01-2270002 Cylinder Sleeve O-Ring* 3K01-07348W Quad Ring* 3K01-170570 Back Up Ring* 3K01-170573 U-Packing* 3K01-U27000I U-Packing with Back Up Ring* 3K01-U27000H Dust Seal* 3K01-D27000D Step Seal with O-Ring* 3K01-170571 Piston 3K01-2270011...
  • Page 49 HH4500 HAMMER Effective 07/05...
  • Page 50 HH4500 HAMMER BRACKET ASSEMBLY PARTS LIST PART NO. ITEM DESCRIPTION MODEL HH4500 3K01-227501 Hammer Bracket (R)* ----------------- Hammer Bracket (L)* 3K01-227502 Bracket Bolt Assembly of Item 3 Washer Assembly of Item 3 3K01-227504-262 Support Pipe (Top) 3K01-227507-334 Support Pipe (Middle) 3K01-227504-262 Support Pipe (Bottom) 3J01-TC3600B...
  • Page 52 HH5800 HAMMER ITEM NAME NUMBER QTY. Cylinder 3L01-2330001 Cylinder O-Ring* 3J01-09108B Cylinder O-Ring* 3J01-09138B Cylinder O-Ring* 3H01-09072B Cylinder Sleeve 3L01-2330002 Cylinder Sleeve O-Ring* 3L01-07378W Quad Ring* 3L01-170580 Back Up Ring* 3L01-170583 Step Seal with O-Ring* 3L01-170581 U-Packing* 3L01-U33000I U-Packing with Back Up Ring* 3L01-U33000H Dust Seal* 3L01-D33000D...
  • Page 53 HH5800 HAMMER Effective 07/05...
  • Page 54 HH5800 HAMMER BRACKET ASSEMBLY PARTS LIST PART NO. ITEM DESCRIPTION MODEL HH5800 3L01-233501 Hammer Bracket (R)* ----------------- Hammer Bracket (L)* 3L01-233502 Bracket Bolt Assembly of Item 3 Washer Assembly of Item 3 3L01-233504-284 Support Pipe (Top) 3L01-233507-364 Support Pipe (Middle) 3L01-233504-284 Support Pipe (Bottom) 3J01-TC3600B...
  • Page 56 HH8000 HAMMER ITEM NAME NUMBER QTY. Cylinder 3M01-2400001 Cylinder O-Ring* 3L01-09138B Cylinder O-Ring* 3M01-09098B Cylinder O-Ring* 3H01-09072B Cylinder Sleeve 3M01-2400002 Cylinder Sleeve O-Ring* 3M01-07398W Quad Ring* 3M01-170590 Back Up Ring* 3M01-170593 Step Seal with O-Ring* 3M01-170591 U-Packing* 3M01-U40000I U-Packing with Back Up Ring* 3M01-U40000H Dust Seal* 3M01-D40000D...
  • Page 57 HH8000 HAMMER Effective 07/05...
  • Page 58 HH8000 HAMMER BRACKET ASSEMBLY PARTS LIST PART NO. ITEM DESCRIPTION MODEL HH8000 3M01-240501 Hammer Bracket (R)* ----------------- Hammer Bracket (L)* 3M01-240502 Bracket Bolt Assembly of Item 3 Washer Assembly of Item 3 3M01-240504-304 Support Pipe (Top) 3M01-240507-384 Support Pipe (Middle) 3M01-240504-304 Support Pipe (Bottom) 3M01-TC8000B...
  • Page 59 NOTES...
  • Page 60 HYDRAULIC HAMMERS IPC INDUSTRIES, INC. 194 N. Brandon Dr. Glendale Heights, IL 60139 TOLL FREE (800) 487-5431 Phone: (630) 893-5558 Fax: (630) 790-3751 rev: 7/05...

This manual is also suitable for:

Hh2000Hh4500Hh5800Hh8000Hh3600

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