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Huskie Tools HH100 Service Manual

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HUSKIE
HYDRAULIC
HAMMERS
SERVICE
MANUAL
HH100
HH150-2
HH300-2
HH500-2
HH750-2
HH1000-2

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Summary of Contents for Huskie Tools HH100

  • Page 1 HUSKIE HYDRAULIC HAMMERS SERVICE MANUAL HH100 HH150-2 HH300-2 HH500-2 HH750-2 HH1000-2...

  • Page 3: Table Of Contents

    CONTENTS Safety Information Page 4 Safety Decals Safety Symbols Operating Instructions Page 7 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 4: 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 5: 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 parts department. DANGER CAUTION This symbol may appear on...
  • Page 6 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 7: Operating Instructions

    2. OPERATING INSTRUCTIONS HOW THE HAMMER OPERATES The main valve (Figure 1) for the hammer is built into the cylinder. Hydraulic oil is supplied into the hammer through this valve. 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 8: 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 9: 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 10: Underwater Operation

    1. To prepare the hammer for underwater operation you will need an external compressed air supply. a. For HH100 through HH500-2, 5 –10 CFM at 50 to 90 psi is adequate. b. For HH750-2 and HH1000-2, 20 to 50 CFM is required.

  • Page 11: 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 WEIGHTS HAMMER MODEL lbs. HH100 HH150-2 HH300-2 HH500-2 HH750-2 HH1000-2...
  • Page 12 Note: Check Table 1, Page 11, before handling tools. • For models HH100 through HH750-2, manual removal is possible. • For the hammer models HH1000-2 and larger use hoist and sling as shown. Check for sling load rating and compare to Table 1, Page 11.

  • Page 13: 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 14: Fasteners

    LIFTING NIPPLES ALLEN BODY HAMMER BOLTS BACK NUT EYES (mm.) HEAD (inches) (mm.) (mm.) (mm.) (inches) (mm.) 1” Crow HH100 ½”-13pt Foot 1” Crow HH150-2 ½”-13pt Foot 1” Crow HH300-2 ½”-13pt Foot 1” Crow HH500-2 ¾”-10pt Foot 1” Crow HH750-2 ¾”-10pt...

  • Page 15: Greasing Requirements

    Table 4. Tightening Torque Requirements (Ft. lbs.) HH100 HH150-2 HH300-2 HH500-2 HH750-2 HH1000-2 Side Rod 400 ±35 550 ±35 Side Rod Back Nut 730 ±35 730 ±35 770 ±35 Front Cap Set Bolt 175 ±35 Back Cap Set Bolt 175 ±35 Bracket Bolt 150 ±35...
  • Page 16 NITROGEN (N ) GAS PRESSURE ADJUSTMENT The hammer will not operate properly and may not start due to an incorrect gas charge. It is normal for the nitrogen pressure to rise as the hammer warms up. For that reason, a range of pressures is stamped on a plate near the charge valve.
  • Page 17 3. Refilling Nitrogen (N ) Gas a. Perform paragraph 2 procedure. b. Remove the cap on the gas charger, nitrogen hose connection port. See Fig 9. c. Attach the N gas pressure regulator to the gas container. Connect the nitrogen ) Supply tank to the gas charger with the charging kit hose.

  • Page 18: Oil Leakage Inspection

    OIL LEAKAGE INSPECTION Check for oil leakage at the points shown in Table 5. It is not unusual to have a small amount of oil leakage along the tool or cylinder, (refer to Figure 10, Page 18) Table 5. Diagnosis of Oil Leakage LEAK LOCATION POSSIBLE CAUSE REMEDY...

  • Page 19: Gas Leakage Inspection

    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 20: Disassembly

    DISASSEMBLY 1. Tool Refer to tool replacement procedures (Figure 4, Page 12). 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 14 for eyebolt sizes) Install an eyebolt and suspend the front cap as shown in Figure 12.

  • Page 21: Inspection Of Parts

    Figure 15. Do not force the cylinder sleeve. Tap uniformly on all sides of the sleeve. Figure 15. Removing Cylinder Sleeve Note: Support piston on wood blocks. Table. 7. Piston Weights WEIGHTS HAMMER MODEL lbs. HH100 12.7 HH150-2 13.2 HH300-2 21.3 HH500-2 10.0 22.0...
  • Page 22 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. Significantly damaged or scratched parts must be replaced. 3. Front cap a.

  • Page 23: Component Wear Limits

    d. Any scratches on the front cap during the cutting operation must be smoothed out using a hand grinder. e. Install a new shank bushing after greasing. As bushings are a press, or interference fit, heating of the front cap or cooling of the bushing will ease installation of the bushing.

  • Page 24: Assembly

    2.559 in. 2.953 in. 3.543 in. * HH100 does not have replaceable bushings. Measurements refer to the front cap itself. ASSEMBLY Note: Clean every part before assembly. Keep parts clean and do not scratch during assembly. Assembly can basically be done in the reverse order of disassembly. Make...
  • Page 25 5. Insert the main valve and the outer sleeve. 6. Apply hydraulic oil into the back cap for gas seal lubrication. See Figure 18. 7. Attach the back cap to the cylinder. HH100 – HH1000-2 1.7 oz. or 50 cc Figure 18. Adding oil to the Back Cap.

  • Page 26: Specifications

    SPECIFICATIONS Table 10. Specifications by Model ITEM UNIT HH100 HH150-2 HH300-2 HH500-2 HH750-2 HH1000-2 Impact ft-lbs. 1200 Energy Class kg-m Adjustable Blows Per 700-1300 520-1170 590-1200 510-1,180 600-1080 500-860 Minute Required Oil 5-12 8-16 9-18 13-24 16-35 Flow l/min 20-45...

  • 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 12. 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 Guidelines

    8. WARRANTY GUIDE LINES Time based on total man-hours. Seal kit installation (Includes testing, complete disassembly, cleaning and re-assembly) HH100 - HH1000 = 4 hours Front cap bushing (Includes removal and re-installation, hammer disassembly not required) HH150 - HH1000 = ½ hour...
  • Page 30 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 HH100 HH150-2 HH300-2 HH500-2 HH750-2 HH1000-2...

  • Page 34: Gas Valve

    HH100 HAMMER ITEM NAME NUMBER QTY. Cylinder 3A01-2010001 Cylinder Sleeve 3A01-2010002 O-Ring* 3A01-07148A O-Ring* 3A01-07148A Gas U-Packing* 3A01-U01000G U-Packing* 3A01-U01000I Dust Seal* 3A01-D01000D Piston 3A01-2010011 Main Valve 3A01-2010122 Main Valve Inner Sleeve 3A01-2010123 Main Valve Outer Sleeve 3A01-2010124 O-Ring* 3A01-09068B...
  • Page 35 HH100 HAMMER Effective 07/09...
  • Page 36 HH100 MINI-EXCAVATOR BRACKET ASSEMBLY PARTS LIST PART NO. ITEM DESCRIPTION MODEL HH100 3A01-311020ME Hammer Bracket(R)* ----------------- Hammer Bracket(L)* 3A01-311050ME Bracket Bolt 3A01-311060ME Bracket Bolt Assembly of Item 3 and 4 3A01-311091ME Support Pipe By Carrier Model Bushing By Carrier Model...
  • Page 38 HH150-2 HAMMER S/N 001 – 099 & 2B2-1000 & UP ITEM NAME NUMBER Cylinder 3C02-H040001 Cylinder Sleeve 3C01-2020002 Cylinder Sleeve O-Ring* 3C01-07148B Quad Ring* 3C02-QD202000 Back Up Ring* 3C02-BU202000 U-Packing* 3C02-ISI 50 Dust Seal* 3C02-DSI 50 Drain Plugs (For reference only) Call IPC for details ***** Step Seal w/ o-ring*...
  • Page 39 HH150-2 HAMMER S/N 001 – 099 & 2B2-1000 & UP Effective 07/09...
  • Page 40 HH150-2 – SKID STEER MULTI-FIT BRACKET ASSEMBLY PARTS LIST PART NO. ITEM DESCRIPTION MODEL HH150-2 3C02-311021MF Hammer Bracket (R)* ----------------- Hammer Bracket (L)* 3C01-311050SS Bracket Bolt 3E01-206602SM Bracket Bolt Assembly of Item 3-4 By Carrier Model Bushing By Carrier Model *Sold as matched set w/ hardware Effective 07/09...
  • Page 42 HH300-2 HAMMER S/N 001 – 099 & 2E2-1000 & UP ITEM NAME NUMBER QTY. Cylinder 3D02-H050001 Cylinder Sleeve 3D02-H050002 Cylinder Sleeve O-Ring* 3D01-07178B Quad Ring* 3D02-QD005000 Back Up Ring* 3D02-BU005000 U-Packing* 3D02-ISI 60 Dust Seal* 3D02-DSI 60 Drain Plugs (For reference only) Call IPC for details ***** Step Seal w/ o-ring*...
  • Page 43 HH300-2 HAMMER S/N 001 – 099 & 2E2-1000 & UP Effective 07/09...
  • Page 44 HH300-2 – SKID STEER MULTI-FIT BRACKET ASSEMBLY PARTS LIST PART NO. ITEM DESCRIPTION MODEL HH300-2 3D02-312021MF Hammer Bracket (R)* ----------------- Hammer Bracket (L)* 3D01-312051MF Bracket Bolt Assembly of Item 3 By Carrier Model Bushing By Carrier Model *Sold as matched set w/ hardware Effective 07/09...
  • Page 45 HH300-2 MULTI-FIT VARIABLE BRACKET ASSEMBLY PARTS LIST ITEM PART NO. DESCRIPTION MODEL HH300-2 3D02-312021MFV Hammer Bracket (R)* Hammer Bracket (L)* 3D01-312051MF Bracket Bolt w/ nut Assembly of Item 3 By Carrier Model Variable Plate By Carrier Model Bushing By Carrier Model 3Z01-5161834 Set Screw *Sold as matched set w/ hardware...
  • Page 46 HH300-2 FLANGE MOUNT BRACKET ASSEMBLY PARTS LIST ITEM PART NO. DESCRIPTION MODEL HH300-2 3D02-312021FM Flange Mount Bracket 3D01-312051MF Bracket Bolt w/ nut Assembly of Item 3 3D01-TC300B Top Cap Bolt w/ nut & washer 3D01-TC300W Top Cap Washer 3D01-TC300N Top Cap Nut 3Z01-5161834 Set Screw Per Carrier Model...
  • Page 48 HH500-2 HAMMER S/N 001 – 099 & 2R2-1000 &UP ITEM NAME NUMBER QTY. Cylinder 3G02-H060001 Cylinder Sleeve 3G02-H060002 Cylinder Sleeve O-Ring* 3D01-07178B Back Up Ring* 3G02-BU006000 Quad Ring* 3G02-QD006000 Step Seal w/ o-ring * 3G02-ST06000 Port Plug w/ o-ring 3G02-GPF1 Drain Plugs Call IPC for details *****...
  • Page 49 HH500-2 HAMMER S/N 001 – 099 & 2R2-1000 & UP Effective 07/09...
  • Page 50 HH500-2 – SKID STEER MULTI-FIT BRACKET ASSEMBLY PARTS LIST PART NO. ITEM DESCRIPTION MODEL HH500-2 3D02-312021MF Hammer Bracket (R)* ----------------- Hammer Bracket (L)* 3D01-312051MF Bracket Bolt Assembly of Item 3 By Carrier Model Bushing By Carrier Model *Sold as matched set w/ hardware Effective 07/09...
  • Page 51 HH500-2 VARIABLE MULTI-FIT BRACKET ASSEMBLY PARTS LIST ITEM PART NO. DESCRIPTION MODEL HH500-2 3D02-312021MFV Hammer Bracket (R)* Hammer Bracket (L)* 3D01-312051MF Bracket Bolt w/ nut Assembly of Item 3 By Carrier Model Variable Plate By Carrier Model Bushing By Carrier Model 3Z01-5161834 Set Screw *Sold as matched set w/ hardware...
  • Page 52 HH500-2 FLANGE MOUNT BRACKET ASSEMBLY PARTS LIST ITEM PART NO. DESCRIPTION MODEL HH500-2 3D02-312021FM Flange Mount Bracket 3D01-312051MF Bracket Bolt w/ nut Assembly of Item 3 3D01-TC300B Top Cap Bolt w/ nut & washer 3D01-TC300W Top Cap Washer 3D01-TC300N Top Cap Nut 3Z01-5161834 Set Screw Per Carrier Model...
  • Page 53 HH500-2 SLIP-FIT TLB/WLB BRACKET ASSEMBLY PARTS LIST PART NO. ITEM DESCRIPTION MODEL HH500-2 3D02-31203TLB Hammer Bracket (R)* ----------------- Hammer Bracket (L)* 3D01-312051MF Bracket Bolt 3E01-31208TLB Bracket Bolt Assembly of Item 3 and 4 3E01-31209TLB Support Pipe By Carrier Model Bushing By Carrier Model *Sold as matched set w/ hardware.
  • Page 54 HH750-2 HAMMER S/N 001 – 099 & 2F2-1000 & UP ITEM NAME NUMBER QTY. Cylinder 3E02-H070001 Cylinder Sleeve 3E02-H070002 Cylinder Sleeve O-Ring* 3E01-07218B Quad Ring* 3E02-QD007000 Back Up Ring* 3E02-BU007000 Step Seal * 3E02-ST07000 Port Plug w/ o-ring 3G01-GPF1 Drain Plugs Call IPC for details ***** U-Packing*...
  • Page 55 HH750-2 HAMMER S/N 001 – 099 & 2F2-1000 & UP Effective 07/09...
  • Page 56 HH750-2 SKID STEER MULTI-FIT BRACKET ASSEMBLY PARTS LIST PART NO. ITEM DESCRIPTION MODEL HH750-2 3E02-31206SSL Hammer Bracket (R)* ----------------- Hammer Bracket (L)* 3E01-31206SSL Bracket Bolt Assembly of Item 3 By Carrier Model Bushing By Carrier Model *Sold as matched set w/ hardware Effective 07/09...
  • Page 57 HH750-2 SLIP-FIT TLB/WLB BRACKET ASSEMBLY PARTS LIST ITEM PART NO. DESCRIPTION MODEL HH750-2 3E02-31206TLB Hammer Bracket (R)* Hammer Bracket (L)* 3E01-31206SSL Bracket Bolt w/ nut 3E01-31208TLB Bracket Bolt w/ nut Assembly of Item 3 and 4 3D01-31209TLB Support Pipe By Carrier Model Variable Plate 3Z01-5161834 Set Screw...
  • Page 58 HH750-2 FLANGE MOUNT BRACKET ASSEMBLY PARTS LIST ITEM PART NO. DESCRIPTION MODEL HH750-2 3E02-31226FM Flange Mount Bracket 3E01-31206SSL Bracket Bolt w/ nut Assembly of Item 3 3H01-TC2000B Top Cap Bolt w/ nut & washer 3H01-TC2000W Top Cap Washer 3H01-TC2000N Top Cap Nut 3Z01-5161834 Set Screw By Carrier Model...
  • Page 60 HH1000-2 HAMMER S/N 001 – 099 & 2H2-1000 &UP ITEM NAME NUMBER QTY. Cylinder 3F02-H080001 Cylinder Sleeve 3F02-H080002 Cylinder Sleeve O-Ring* 3F01-07248B Quad Ring* 3F02-QD008000 Back Up Ring* 3F02-BU008000 Step Seal * 3F02-ST08000 Port Plug w/ o-ring 3G01-GPF1 Drain Plugs Call IPC for details ***** U-Packing*...
  • Page 61 HH1000-2 HAMMER S/N 001 – 099 & 2H2-1000 & UP Effective 07/09...
  • Page 62 HH1000-2 SLIP-FIT TLB/WLB BRACKET ASSEMBLY PARTS LIST ITEM PART NO. DESCRIPTION MODEL HH1000-2 3F02-210601TLB Hammer Bracket (R)* Hammer Bracket (L)* 3F01-210602TLB Bracket Bolt w/ nut 3F01-210604TLB Bracket Bolt w/ nut Assembly of Item 3 and 4 3F01-21010SM Support Pipe By Carrier Model Variable Plate 3Z01-5161834 Set Screw...
  • Page 63 HH1000~HH1000-2 FLANGE MOUNT BRACKET ASSEMBLY PARTS LIST ITEM PART NO. DESCRIPTION MODEL HH1000~HH1000-2 3F02-210601FM Flange Mount Bracket 3F01-210602TLB Bracket Bolt w/ nut Assembly of Item 2 3H01-TC2000B Top Cap Bolt w/ nut & washer 3H01-TC2000W Top Cap Washer 3H01-TC2000N Top Cap Nut 3Z01-5161834 Set Screw By Carrier Model...
  • Page 64 HYDRAULIC HAMMERS IPC INDUSTRIES, INC. 194 N. Brandon Dr. Glendale Heights, IL 60139 www.huskiehammer.com Toll Free (800) 487-5431 Phone: (630) 893-5558 Fax: (630) 790-3751 rev: 7/09...

This manual is also suitable for:

Hh750-2Hh1000-2Hh150-2Hh300-2Hh500-2Hh750 ... Show all

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