HUSKIE HYDRAULIC HAMMERS
Contents
1. Bushing Spring Pin 3C01 S34058 Nipple PF 1 2in 3 4in UN 3C03 N00001 O Ring Not sold separately included w 24 3C03 07058B Side Rod Assembly 3C01 010051 Side Rod Washer Included w 26 3C01 010054 Grease Nipple 3Z01 GN0018 Tool Set Pin 3C01 010061 Tool Spring Pin 3C01 S34148 Tool Moil Chisel Blunt 3C01 202P Fx E Seal Kit 3C02 202SK Gas Charger 3Z01 202GC Gas Valve Assembly includes item 33 3Z01 G00001 Gas Valve Cap with O Ring 3Z01 G00004 N BRIN e m b ile NIe Included in seal kit NI denotes not illustrated 38 Effective 01 07 HH150 2 HAMMER S N 001 099 amp 2B2 1000 amp UP 31 Effective 07 05 39 HH150 2 SKID STEER MULTI FIT BRACKET ASSEMBLY PARTS LIST PART NO MODEL HH150 2 QTY DESCRIPTION 3C02 311021MF Hammer Bracket R Hammer Bracket L 3C01 311050SS Bracket Bolt 3E01 206602SM Bracket Bolt Assembly of Item 3 4 Nut By Carrier Model Bushing By Carrier Model Sold as matched set w hardware 40 Pin Effective 01 07 41 HH300 2 HAMMER Cylinder NUMBER 3D02 H050001 S N 001 099 amp 2E2 1000 amp UP QTY 1 Cylinder Sleeve 3D02 H050002 Cylinder Sleeve O Ring 3D01 07178B Quad Ring2. Shown above is a copy of a decal that must be installed on a surface of the hammer that faces the operator and on the carrier operator s control area Never operate the hammer if these decals are missing Decals must be inspected periodically to ensure that all wording is legible Decals should be replaced if illegible Decals can be obtained at no charge from your IPC Distributor or by contacting IPC s Customer Service Department 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 As soon as the piston reaches the upper end of the stroke the main valve directs flow to the upper chamber causing it to become high pressure Since surface A is greater than surface B the piston is driven downward with the help of the accumulated energy from the gas chamber creating the impact stroke of the hammer At the point of impact the main valve shifts releasing the high pressure from the upper chamber enabling the upward stroke to occur again GAS CHAMBER UPPER CHAMBER VARIABLE PRESSURE PRESSURE RECIEVING SURFACE A BUILT IN MAIN VALVE MIDDLE CHAMBER PRESSURE RECIEVING LOW PRESSURE SURFACE B LOWER CHAMBER HIGH P
3. mm 1 575 1 768 in 2 362 in 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 sure parts are installed in the correct direction 24 1 Lubricate the U packing O ring piston cylinder and main valve with hydraulic before assembly Place cylinder sleeve on the piston 3 Insert the piston fully into the cylinder to its bottom position gt a Make sure that all seals are positioned correctly and facing the right direction b Handle seals very carefully in order not to cause scratches c To avoid scratching the piston the cylinder sleeve can be installed with a plastic hammer or nylon bar Install the front cap on the cylinder Insert the main valve and the outer sleeve Apply hydraulic oil into the back cap for gas seal lubrication See Figure 18 Attach the back cap to the cylinder pi cow Ps HH100 HH1000 2 1 7 oz or 50 cc Figure 18 Adding oil to the Back Cap 8 Insert and tighten the four side rods together with the washer to the specified torque see Table 4 and Figure 5 on page 15 9 Refill the hammer with Nitrogen N2 gas Refer to pages 16 and 17 A DANGER DO NOT STAND IN AREA OF TOOL WHE
4. 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 3D02 ST05000 Piston 3D02 H050011 Main Valve 3C01 2020122 Main Valve Inner Sleeve 3C01 2020123 Main Valve Outer Sleeve 3C01 2020124 Main Valve O Ring 3C01 09060B Main Valve O Ring 3C01 09076B Back Cap 3D01 2030031 Back Cap O Ring 3D01 07178A Front Cap Front Cap Plug 3D01 2030041 3Z01 FP0038 Shank Bushing Front Cap Bushing 3D01 030042 3D01 030043 Bushing Set Pin 3D01 060344 Bushing Spring Pin 3C01 S34058 Nipple PF 1 2in 3 4in UN 3C03 N00001 O Ring Not sold separately included w 24 3C03 07058B Side Rod Assembly 3D01 030051 Side Rod Washer Included w 26 3D01 030054 Grease Nipple 3Z01 GN0018 Tool Set Pin 3D01 030061 Tool Spring Pin 3C01 534148 Tool Moil Chisel Blunt 3D01 203P Fx E Seal Kit 3D02 203SK Gas Charger 3Z01 202GC 32 Gas Valve Assembly includes item 33 3Z01 G00001 1 2 1 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 2 4 2 2 4 4 1 1 1 1 1 1 1 33 Gas Valve Cap with O Ring 3Z01 G00004 1 Included in seal kit NI denotes not illustrated 42 Effective 01 07 HH300
5. of Item 3and 4 Nut ITEM 3 4 5 3F01 21009SM Support Pipe 7 Support Pipe By Carrier Model Bushing By Carrier Model Pin Sold as matched set w hardware Effective 07 05 3F01 210108M N BIRT RE 1 2 6 amp 9 S 59 NOTES 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 12 06
6. of use When the clearance between the tool and the shank bushing exceeds Shank bushing 160 in 4mm a new shank bushing is required Approximately 700 hours of use Tool If 120 in 3mm of wear in the diameter is observed a new tool is required Approximately 500 hours of use Keep tool sharp 23 COMPONENT WEAR LIMITS Continued Tool set pin If 080 in 2mm of wear in the diameter is observed a new tool set pin is required If the corner of the front cap is worn to the edge of the front cap bushing a new front cap is required When indentation or serious damage on the piston surface is Piston observed a new piston is required Approximately 2 000 hours of use n CLEARANCE Z Y PISTON IMPACT BETWEEN TOOL 8 SY NH SURFACE SHANK BUSHING FAN 2 BUSHING A 2 N R UN Y TOOL SET PIN SIS WEAR AT FRONT CAP CLEARANCE BETWEEN FRONT CAP BUSHING TOOL amp FRONT CAP BUSHING TOOL Figure 17 Wear Limit Points Table 9 New Component Dimensions PART HH100 HH150 2 HH300 2 HH500 2 HH750 2 HH1000 2 Front Cap 41 51 mm 61 mm 66 mm 76 mm 91 mm Bushing LD 1 614 in 2 008 in 2 402 in 2 598 in 3 0 in 3 583 in Shank 41 mm 51 mm 61 66 mm 76 mm 91 mm Bushing I D 1 614 in 2 008 in 2 402 in 2 598 in 3 0 in 3 583 in Tool O D 40 mm 50 mm 60 mm 65 mm 75 mm 90
7. oil Low impact power Nitrogen gas pressure is low Adjust gas pressure Relief valve set incorrectly Adjust main and secondary relief valve Malfunction of the hydraulic pump Repair pump 28 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 HH1500 HH2000 6hours HH3600 HH4500 7hours HH5800 HH8000 8hours Front cap bushing Includes removal and re installation hammer disassembly not required HH150 HH1000 hour HH1500 HH8000 1 hour 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 and re assembly HH150 HH1000 2 hours HH1500 HH2000 3 hours HH3600 HH8000 4 hours Bracket bolt replacement HH100 HH1000 hour HH1500 HH8000 hour 29 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 All other components exce
8. or cause abnormal wear to the tool bushings 4 Avoid continuous impact on the same area for more than one minute Continuous impact may cause a rapid increase in oil temperature and improper hammer operation 5 Break large objects from the outside edges and work inward 6 Do not submerge the hammer in water The hammer is not watertight and damage can occur if used in this manner Consult your dealer for underwater applications Ref Figure 3 7 Do not use the hammer to move very large or heavy broken objects This can cause damage to the hammer and carrier Do not use the hammer as a lifting device 9 Do not operate the hammer when boom cylinders are at their extreme ends This may cause damage to the cylinders 10 Stop operation immediately if hoses vibrate abnormally or impact energy is dramatically reduced Consult Section 7 Troubleshooting Diagnosis for additional information 9o COLD WEATHER STARTUP AND OPERATION Note Internal parts of the hammer will be damaged if proper warm up procedures are not applied in cold weather 1 Warm the hydraulic system of the carrier before starting the hammer Circulate the oil in carrier system until it is warm to the touch or approximately 60 15 2 With engine at half throttle activate the hammer for 5 seconds and stop for 15 seconds Repeat cycle for 2 to 3 minutes UNDERWATER OPERATION Operation of hydraulic hammers under water requires proper preparation to p
9. 2 H070061 Tool Spring Pin 3E01 S34188 Tool Moil Chisel Blunt 3E01 206P FX E Seal Kit 3E02 206SK P I INN AIN e Rel Rl Rl Rl me me Rl Rl Rte NI ee Dil Included in seal kit Gas Charger NI denotes not illustrated 3Z01 202GC Effective 01 07 HH750 2 HAMMER S N 001 099 amp 2F2 1000 amp UP 34 Effective 07 05 51 HH750 2 SKID STEER MULTI FIT BRACKET ASSEMBLY PARTS LIST PART NO MODEL HH750 2 QTY DESCRIPTION 3E02 31206SSL Hammer Bracket R Hammer Bracket L 3E01 31206SSL Bracket Bolt Assembly of Item 3 Nut By Carrier Model By Carrier Model Bushing Pin Sold as matched set w hardware 52 Effective 07 05 HH750 2 SLIP FIT TLB WLB BRACKET ASSEMBLY PARTS LIST PART NO QTY DESCRIPTION MODEL HH750 2 Hammer Bracket R 3E02 31206TLB Hammer Bracket L Bracket Bolt Bracket Bolt 3E01 31206SSL 3E01 31208TLB Nut 3E01 31209TLB Support Pipe By Carrier Model Bushing ne RR e 1 2 3 4 3 Assembly of Item 3 and 4 6 7 8 Pin By Carrier Model Sold as matched set w hardware Effective 07 05 53 HH750 2 SIDE MOUNT TLB WLB BRACKET ASSEMBLY PARTS LIST PART NO MODEL HH750 2 QTY DESCRIPTION 3E02 206601SM Hamme
10. 2 HAMMER S N 001 099 amp 2E2 1000 amp UP 31 Effective 07 05 43 HH300 2 SKID STEER MULTI FIT BRACKET ASSEMBLY PARTS LIST PART NO MODEL HH300 2 QTY DESCRIPTION 3D02 312021MF Hammer Bracket R Hammer Bracket L 3D01 312051MF Assembly of Item 3 Bracket Bolt Nut By Carrier Model By Carrier Model Bushing Pin Sold as matched set w hardware Effective 07 05 45 HH500 2 HAMMER Cylinder NUMBER 3G02 H060001 S N 001 099 amp 2R2 1000 amp UP 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 U Packing 3G02 ISI 67 Dust Seal 3G02 DSI 67 Piston 3G02 H060011 Main Valve 3E01 2060622 Main Valve Inner Sleeve 3G02 H060623 Main Valve Outer Sleeve 3E01 2060624 Main Valve O Ring 3E01 09092B Back Cap 3G02 H060031 Back Cap O Ring 3D01 07178A Gas Valve Assembly includes item 19 Gas Valve Cap with O Ring 3Z01 G00001 3Z01 G00004 Front Cap Front Cap Plug 3G02 H060041 3Z01 FP0038 Shank Bushing 3G02 H060042 Front Cap Bushing 3G01 050043 Bushing Set Pin 3D01 060344 Bushing Spring Pin 3C01 S34058 Ni
11. 3F03 N00002 3F03 07068B Side Rod Assembly 3F02 H080051 Side Rod Back Nut Included w 28 3F02 H080053 Side Rod Washer Included w 28 3F02 H080054 Grease Nipple 3Z01 GN0018 Tool Set Pin 3E02 H080061 Tool Spring Pin 3E01 S34188 Tool Moil Chisel Blunt 3F01 210P FX E Cylinder Plug 3J01 240081 Cylinder Plug O Ring 3J01 09056B Cylinder Plug Back Up Ring 3H01 08056P Seal Kit 3F02 210SK Gas Charger 3Z01 202GC m m m AI AIAININI AND DVD Del Included in seal kit NI denotes not illustrated 56 Effective 01 07 HH1000 2 HAMMER S N 001 099 amp 2H2 1000 amp UP Effective 07 05 57 HH1000 2 SLIP FIT TLB WLB BRACKET ASSEMBLY PARTS LIST PART NO TY DESCRIPTI MODEL HH1000 2 Q PE PN 3F02 210601TLB Hammer Bracket R Hammer Bracket L Bracket Bolt Bracket Bolt Nut Support Pipe By Carrier Model Bushing 8 By Carrier Model Pin Sold as matched set w hardware Effective 07 05 3F01 210602TLB 3F01 210604TLB Assembly of Item 3 and 4 3F01 21010SM N Ble ne 58 HH1000 2 SIDE MOUNT TLB WLB BRACKET ASSEMBLY PARTS LIST PART NO MODEL HH10002 QTY DESCRIPTION 3F02 210601SM Hammer Bracket R Hammer Bracket L 3F01 210605TLB Bracket Bolt 3F01 210606TLB Bracket Bolt Assembly
12. 4 NI denotes not illustrated Effective 07 05 HH100 HAMMER Effective 07 05 35 HH100 MINI EXCAVATOR BRACKET ASSEMBLY PARTS LIST PART NO MODEL HH100 QTY DESCRIPTION 3A01 311020ME Hammer Bracket R Hammer Bracket L 3A01 311050ME Bracket Bolt 3A01 311060ME Bracket Bolt Assembly of Item 3 and 4 Nut 3A01 311091ME Support Pipe By Carrier Model 8 By Carrier Model N b 4 Bushing Pin Sold as matched set w hardware 36 Effective 07 05 37 HH150 2 HAMMER Cylinder NUMBER 3C02 H040001 S N 001 099 amp 2B2 1000 amp UP 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 3C02 ST04000 Piston 3C02 H040011 Main Valve 3C01 2020122 Main Valve Inner Sleeve Main Valve Outer Sleeve 3C01 2020123 3C01 2020124 Main Valve O Ring Main Valve O Ring 3C01 09060B 3C01 09076B Back Cap 3C01 2020031 Back Cap O Ring 3C01 07148A Front Cap 3C01 2020041 Front Cap Plug 3Z01 FP0038 Shank Bushing 3C01 010042 Front Cap Bushing 3C01 010043 Bushing Set Pin 3C01 010044
13. HUSKIE HYDRAULIC HAMMERS SERVICE MANUAL HH100 HH150 2 HH300 2 HH500 2 HH750 2 HH1000 2 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 Maintenance Page 13 Hydraulic Oil Checking Condition of Hydraulic Oil Fasteners Greasing Requirements Nitrogen N2 Gas Pressure Adjustment Oil Leakage Inspection Gas Leakage Inspection Disassembly and Assembly Page 19 Disassembly Inspection of Parts Component Wear Limits Assembly Specifications Page 26 Refinishing of Pistons and Cylinders Page 27 Troubleshooting Diagnosis Page 28 Warranty Guidelines Page 29 Parts List and Illustrations Page 33 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 Do not use drugs or alcoholic beverages that impair alertness or coordination while operating the carrier or hammer An operator taking prescription drugs must obtain professional medical advice to determine if he she can safely operate th
14. N ADDING NITROGEN TO HAMMER THE TOOL MAY EJECT SUDDENLY AND CAUSE SEVERE INJURY Make sure that the piston is positioned at the lower end of its stroke before charging The piston and the cylinder may be damaged during gas charging by sudden movement due to a pressure increase if the piston is not at the bottom of its stroke in the cylinder 25 5 SPECIFICATIONS Table 10 Specifications by Model ITEM UNIT HH100 HH150 2 HH300 2 HH500 2 HH750 2 HH1000 2 Impact ft lbs 100 200 350 575 825 1200 Energy Class kg m 14 28 49 81 116 168 Adjustable Blows Per bpm 700 1300 520 1170 590 1200 510 1 180 600 1080 500 860 Minute Required Oil gpm 4 7 5 12 8 16 9 18 13 24 16 35 Flow l min 20 45 20 45 30 60 35 70 50 90 60 130 1 000 1 014 1 294 1 441 1 441 2 275 1 867 1 867 1 867 2 161 a E 69 160 70 129 89 129 99 129 99 149 Nitrogen Gas psi 140 160 190 210 190 210 160 185 190 210 190 210 Pressure bar 10 11 13 14 13 14 11 13 13 14 13 14 Total Weight lbs 165 340 520 550 800 1 100 with Tool kg 154 154 236 250 363 500 inch 35 50 52 54 64 73 889 1 270 1 321 1372 1 626 1 854 Tool Diamet inch 1 6 2 0 24 2 6 3 0 3 5 ST n m 40 50 60 65 75 90 AUR Tons 75 225 1 25 3 25 225 6 275 7 335 8 35 12 Carrier Remarks The hammer is to be used within the specified oil pressure oil flow and gas pressure parameters The carrier hydraul
15. RESSURE Figure 1 Principles of Operation A CAUTION MATCH CARRIER HYDRAULIC FLOW TO CORRECT FLOW RANGE FOR HAMMER TO PREVENT INTERNAL DAMAGE TO HAMMER CONTACT YOUR DEALER FOR CARRIER SPECIFICATIONS Refer to Table 10 page 26 MOUNTING THE 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 Seal off all plugs and hoses to prevent dust dirt and foreign particles from entering the system 2 Rubber Tired Backhoes and Excavators All hammers are mounted to hammer brackets The hammer brackets are mounted to the stick of the carrier using two pins and four bushings To remove the hammer first disconnect the hydraulic couplers from the inlet and outlet ports Seal the couplers and hoses to prevent dust dirt and foreign particles from entering the system Remove the mounting pins to detach hammer and bracket from the carrier stick CONNECTING HOSES Connect the two hydraulic hoses to the inlet and outlet ports of the carrier using hose couplers When connecting make sure that the couplers are clean and engaged securely DAILY INSPECTION BEFORE OPERATION 1 Check the carrier hydraulic oil level before operation The hydraulic oil level mus
16. TLB By Carrier Model 8 By Carrier Model Sold as matched set w hardware Effective 07 05 N i 49 HH750 2 HAMMER Cylinder NUMBER 3E02 H070001 S N 001 099 amp 2F2 1000 amp UP 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 3E02 ISI 80 Dust Seal 3E02 DSI 80 Piston 3E02 H070011 Main Valve Main Valve Inner Sleeve 3E01 2060622 3E01 2060623 Main Valve Outer Sleeve Main Valve O Ring 3E01 2060624 3E01 09092B Back Cap 3E02 H070031 Back Cap O Ring 3E01 07218A Gas Valve Assembly includes item 19 3Z01 G00001 Gas Valve Cap with O Ring 3Z01 G00004 Front Cap 3E02 H070041 Front Cap Plug 3Z01 FP0038 Shank Bushing 3E01 060042 Front Cap Bushing 3E01 060043 Bushing Set Pin 3E01 060344 Bushing Spring Pin 3 02 534068 Nipple PF 1 2in 3 4in UN 3C03 N00001 O Ring Not sold separately included w 26 3C03 07058B Side Rod Assembly 3E02 H070051 Side Rod Back Nut Included w 28 3F01 100053 Side Rod Washer Included w 28 3F01 100054 Grease Nipple 3Z01 GNO0018 Tool Set Pin 3E0
17. a press mandrel to remove the bushing 22 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 a press or interference fit heating of the front cap or cooling of the bushing will ease installation of the bushing f Install the bushing set pin and the bushing spring pin 6 Refinishing surface scratches see Section 6 Page 27 a Cylinder and Cylinder Sleeve Scratches on the inside surface of the cylinder should be smoothed using a flap wheel with 240 grit and finish with 360 grit b Piston Grind off any scratches on the outside surface using a flap wheel with 240 grit and finish with 360 grit When polishing the piston or the cylinder bore it is not necessary to completely remove scratches only the sharp edges as this may remove excess material Figures 19 20 and 21 Page 27 c Main Valve and Sleeves Main valve and sleeves cannot be polished Replace if these parts do not slide freely by finger pressure COMPONENT WEAR LIMITS Parts are to be replaced if they are not within the wear parameters See Table 8 and Figure 17 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 CR bushing exceeds 200 in 5mm a new front cap bushing is required Approximately 500 hours
18. d Transparent but with black spots Foreign particles mixed Bubbly Grease mixed 13 FASTENERS Inspect all bolts and nuts for tightness Tighten as required Refer to Table 4 Page 15 Replace all missing or damaged fasteners before operating the hammer A WARNING USE ONLY ORINIGAL PARTS WHEN REPLACING BOLTS NUTS AND WASHERS SUBSTITUTE PARTS MAY APPEAR SIMILAR BUT MAY FAIL IN USE AND CAUSE SERIOUS INJURY OR DEATH Fastener bolt and nut sizes are listed in Table 3 These are wrench sizes distance across flats Table 3 Bolt Sizes GAS VALVE BRACKET SIDE ROD SIDE ROD LIFTING HAMMER pis pet Peay HEAD ake ale s HHI00 19 28 NA ja aa Foot HH150 2 30 36 32 NA sapi 156 Foot HH300 2 30 36 41 NA spe S 36 Foot HH500 2 30 36 4l a ro STO 36 Foot HH750 2 30 36 46 4 do l COW Foot HH1000 2 36 50 46 D ao C Sw e Foot Allen wrench size for the front and back cap bolts 14 Table 4 Tightening Torque Requirements Ft Ibs HH100 HH150 2 HH300 2 HH500 2 HH750 2 HH1000 2 Side Rod NA 400 35 550 35 NA NA NA Side Rod Back Nut NA NA NA 730 35 730 35 770 35 Front Cap Set Bolt 175 35 NA NA NA NA NA Back Cap Set Bolt 175 35 NA NA NA NA NA Bracket Bolt 150 35 260 35 260 35 260 35 260 35 400 35 Figure 5 Tightening Sequence GREASING REQUIREMENTS The hammer should be greas
19. day may run erratically until the hammer warms up thoroughly Please contact IPC Industries Inc if you have any questions 26 6 REFINISHING OF PISTONS amp 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 Follow the procedures in Figures 19 20 amp 21 and finish by thorough flushing and cleaning These parts can usually be salvaged Caution Wear safety glasses for eye protection Use hand held air grinder with flap type wheels Two grit wheels were used 240 for Heavy Polish 360 for Finishing Rotate piston and polish with brushing motion of grinder Polish total area before changing to fine grit for finishing After completion of fine polishing clean labyrinth grooves carefully with fine needle file to remove all burrs and rough edges Figure 21 After polishing all rough surfaces and edges clean all parts by flushing thoroughly Lubricate with hydraulic oil before reassembling Note It is not necessary to completely remove all scoring or scratching to full depth of the scratches Instead polish the surfaces until any raised edges are flush and smooth with the original su
20. e carrier and hammer Work at a slow pace when learning to operate the hammer Operator training must consist of a demonstration and verbal instruction New operators must start in an area free of bystanders He she must become familiar with all carrier controls before operating the hammer Be aware of any prohibited uses in work areas Excessive slopes poor or dangerous terrain conditions and utility hazards Operate the carrier or hammer from the operator s seat ONLY Make sure the seat is fastened securely before activating controls Keep hands and feet on the controls at all times while the hammer is operating Always operate the carrier with the outriggers firmly positioned on the surface Make sure all controls levers and pedals are in NEUTRAL before starting the carrier NEVER leave the carrier with the engine running ALWAYS ENGAGE THE PARKING BRAKE Make certain there are no persons within the arc determined by the movement of stabilizers front bucket or backhoe boom with the hammer at full extension Never operate with any person near the hammer or between the hammer and the operator Replace all faulty or leaking hydraulic hoses or fittings before operation Travel with the hammer in the full tuck transport position only Never operate the hammer with the tool retaining pin removed Wear safety goggles hearing protection and hardhat while operating the hammer Before leaving the operators seat always lower the carrie
21. e we can t warranty the part 31 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 At that time it may be determined that you need not return the part and IPC may at its sole discretion warrant the part without examination Do not scrap any parts under watranty consideration unless authorized by IPC or credit is received 7 Returning a Warranted Part All returned parts must be shipped prepaid not collect and include the RGA number prominently displayed on the shipping label Ifa part is particularly heavy please contact us for further information 8 Warranty Part Freight Costs IPC Industries Inc will cover inbound when requested by IPC and outbound freight for warranted parts under the following circumstances only e IPC will cover surface freight costs for parts judged to be defective in materials or workmanship e The cost of shipping warranted parts via an expedited surface or air shipment will be paid as follows IPC will pay the difference between standard surface freight and air or expedited surface freight whichever is less 9 IPC Claims Processing IPC will respond to the dealer submitting the claim within 30 days as follows e A credit for an a
22. ed each startup and after every 2 3 hours of operation The grease nipple is located at the front cap as shown in Figure 6 Approximately 10 shots in the front cap are recommended when the tool is at the upper limit of travel Grease Fitting Inside Figure 6 15 NITROGEN N2 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 When ambient temperatures of over 100 F are a routine occurrence the nitrogen charge can raise enough to stop the hammer See Table 11 Page 26 for charge settings at high ambient temperatures Follow the procedure described below to adjust nitrogen N2 gas pressure WARNING DO NOT STAND NEAR THE HAMMER WHEN ADDING NITROGEN THE TOOL MAY EJECT SUDDENLY AND CAUSE SEVERE INJURY 1 Gas Pressure Testing a With the gas charger disconnected from the hammer plug the inlet the nitrogen hose connection port of the gas charger with the cap provided then turn the handle fully to the left counter clockwise b Remove the gas valve cap located on the hammer back cap and attach gas charger see Figure 7 T HANDLE PRESSURE REGULATOR NITROGEN HOSE VALVE GAS CHARGER VALVE BODY NITROGEN TANK HAMMER BACK CAP Figure 7 Connecting Gas Charger to Figure 8 Connecti
23. everse steps 1 through 4 above Note that tool spring pin must be inserted with the slot or open side away from the tool set pin SLING ANGLES NOT SMALLER THAN 60 CORRECT INCORRECT Figure 4 Tool Replacement 12 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 3 Always be aware of any abnormalities in the operation of the hammer such as changes to hammer blow speed impact force or oil temperature The oil temperature should not exceed 180 F 80 C 4 Check the condition of the hydraulic oil as specified in Table 2 CHECKING CONDITION OF HYDRAULIC OIL Note Refer to carrier service manual for proper class and type of hydraulic oil Hydraulic oil must be changed more frequently than the carrier instruction manual recommends This is because hammer operation requires more oil circulation than normal operation Oil condition can be visually checked as specified in Table 2 Table 2 Hydraulic Oil Conditions COLOR CONDITION Transparent and no color change Good Transparent but too bright Oil Mixed Milky white Air and or water mixed Dark and dirty with odor Deteriorate
24. hat cause bodily injury to the can result in damage to the operator or other personnel hammer or other equipment 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 e Projectiles from the hammer tool rock or other broken material may enter the operator s area and cause serious or fatal injury Use personal protection equipment Projectiles from the hammer tool rock or other broken material may cause serious or fatal injury to bystanders Do not operate the hammer when bystanders are in the area In some cases the hammer may enter the operator s area if a bracket or cylinder breaks Make sure appropriate shields are used when operating the hammer with this type of equipment A DANGER 1 A PROJECTILE FROM THE HAMMER HAMMER TOOL OR WORK AND OR A SWINGING OR FALLING HAMMER CAN BE FATAL TO THE OPERATOR OR BYSTANDERS 2 DO NOT OPERATE HAMMER WHEN BYSTANDERS ARE IN WORK AREA 3 THE OPERATOR MUST BE PROTECTED FROM FLYING DEBRIS USE PERSONAL PROTECTION EQUIPMENT 4 DO NOT WELD CUT WITH ACETYLENE TORCH OR HARDFACE THE HAMMER TOOL IMPORTANT SEE OPERATORS MANUAL FOR SAFETY INSTRUCTION DETAILS PART NO DD 101
25. ic system relief pressure is to be set at 600 to 800 psi above the hammer Operating Pressure measured at the hose end of the carrier pressure hose when disconnected from the hammer The nitrogen charge in a hammer is directly related to the operating pressure of the circuit powering it An increase of 10 in gas charge will cause a 10 rise in hammer operating pressure This is prevalent in hammers if gas pressure has been set or checked on a cool morning 60 F and then run in increasingly higher ambient temperatures up to and over 100 F This increase in ambient temperature can cause the carrier operating pressure to rise past its relief setting stalling the hammer Table 11 Recommended Gas Pressure Based Upon Ambient Temperature Hammer Model Standard Pressure 80 F 90 F 100 F 110 120 HH100 140 160 psi 160 psi 150 psi 140 psi 130 psi 120 psi HH150 2 190 210 psi 210 psi 200 psi 190 psi 180 psi 170 psi HH300 2 190 210 psi 210 psi 200 psi 190 psi 180 psi 170 psi HH500 2 160 185 psi 185 psi 175 psi 160 psi 150 psi 140 psi HH750 2 190 210 psi 210 psi 200 psi 190 psi 180 psi 170 psi HH1000 2 190 210 psi 210 psi 200 psi 190 psi 180 psi 170 psi Gas pressure should be set bearing in mind the possible high ambient temperature potential for that day s work While unlikely a setting that will run well on a hot
26. nd Using the Warranty Claim Form Fill out all items as completely as possible Take note of 5 below In the section titled DESCRIPTION OF FAILURE describe the failure as clearly as possible along with operating conditions of the hammer and carrier as best you can In order for IPC to consider DEALER LABOR and DEALER MILEAGE in your claim your published labor and mileage rates must be on file with IPC or must accompany the claim form Please see 8 below for an explanation of FREIGHT PAID no event shall IPC Industries Inc warrant more than one 1 hour travel time each way or eight 8 hours of labor for a hammer repair Please refer to the service manual for easy to follow disassembly and assembly procedures IPC Industries Inc would be pleased to provide you with no charge on site service training covering all aspects of hammer service Warranty Submission Time Limit No more than thirty 30 days can elapse between the DATE OF FAILURE and DATE OF CLAIM Claims submitted beyond thirty 30 days from the DATE OF FAILURE will be denied IPC s purpose is to provide the best possible product reliability and customer service Our best sources for product reliability information and failure analysis are used failed parts from the field A part that has been exposed to weeks of weather tells us little or nothing If we can t tell why or where a part failed because of rust or damag
27. ng Gas Charger to Hammer Nitrogen N2 Supply c Turn the T handle on the gas charger valve clockwise and then measure the N2 gas pressure 2 Releasing Gas Pressure if over charged or prior to disassembly a Testthe gas pressure as described in paragraph 1 b For disassembly loosen the bleeder screw on the gas charger very slowly and release the N2 gas Watch the pressure gauge until the nitrogen pressure is fully released see Figure 7 and 8 c Ifovercharged close the Bleeder Screw when the gas pressure reaches the correct gas pressure shown on Table 10 Page 26 then turn the T handle to the left counter clockwise d Finally remove the gas charger Install and tighten the gas valve cap 16 3 Refilling Nitrogen N2 Gas a Perform paragraph 2 procedure b Remove the cap on the gas charger nitrogen hose connection port See Fig 9 Attach the N2 gas pressure regulator to the gas container Connect the nitrogen N2 Supply tank to the gas charger with the charging kit hose GUAGE T HANDLE ER NITROGEN HOSE CONNECTION PORT GAS CHARGER BLEEDER SCREW VALVE BODY Figure 9 Gas Charger Valve Open the main gas valve on the N2 gas container and regulate the N2 gas pressure see Figure 8 Turn the gas charger T handle clockwise and adjust N2 gas pressure in the gas chamber to the correct gas pressure shown on Table 10 Page 26 Turn the gas charger T handle fully counter clockwise and rem
28. ng set pin and bushing spring pin using a hammer and drive pin c The front cap bushing must be torch cut at three locations at three 120 grooves if it is the only bushing to be replaced Avoid cutting into the front cap itself press out the front cap bushing only if both bushings need replacement Any scratches in the front cap must be smoothed after bushing removal e Install the new front cap bushing in the correct direction with part numbers on the bushing facing the installer away from the hammer Because the bushings are a press or interference fit heating of the front cap and cooling of the bushing will help installation f Insert the bushing set pin and the bushing spring pin A WARNING BE CAREFUL OF HOT SURFACE USE GLOVES TO PROTECT AGAINST BURNS AND POSSIBLE SHARP EDGES 5 Replacing the shank bushing Note Replacement of the front cap bushing is highly recommended 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 b Remove bushing spring pin and bushing set pin for shank bushing on the front cap using a punch and hammer c Press out shank bushing from the cylinder side together with front cap bushing using a round bar If the shank bushing is too tight cutting it with a torch may be required A worn moil or chisel can be machined flat at the working end to serve as
29. ogether with cylinder sleeve toward the top b It may be useful to use a pry bar as a lever as shown in Figure 14 Be careful to not damage the piston 6 Cylinder sleeve Remove the cylinder sleeve from the piston A plastic hammer or nylon bar can be used for removal as shown in Figure 15 Do not force the cylinder sleeve Tap uniformly on all sides of the sleeve Figure 14 Removing the piston Table 7 Piston Weights Figure 15 Removing Cylinder Sleeve Note Support piston on wood blocks HAMMER MODEL WEIGHTS kg Ibs HH100 5 8 12 7 HH150 2 6 0 13 2 HH300 2 9 7 21 3 HH500 2 10 0 22 0 HH750 2 17 1 37 6 HH1000 2 25 4 55 9 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 Significantly damaged or scratched parts must be replaced 3 Front cap a Deformed or worn shank bushings or front cap bushings must be replaced see Table 8 page 23 b A severely worn or damaged tool set pin must be replaced 4 Replacing the front cap bushing a Measure shank and front cap bushings and refer to Table 8 page 23 and Table 9 page 24 Remove bushi
30. ove the hose Attach the cap to the gas inlet of the charger Remove the gas charger and attach the gas valve cap and O ring firmly to the gas valve nut on the hammer back cap 17 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 LEAK LOCATION POSSIBLE CAUSE Table 5 Diagnosis of Oil Leakage REMEDY Between front cap and tool E Damaged or worn U packing Replace seal kit Between cylinder and nipple F Loose nipple or damaged O ring or nipple Tighten or replace nipple and or O ring Between cylinder and back cap G Damaged U packing or main Valve outer sleeve O ring or Back cap O ring Replace seal kit Plug ports H Plugs loosen Remove plugs and reinstall with sealant Figure 10 18 GAS LEAKAGE INSPECTION Gas leakage can be easily detected using soapy water refer to Table 6 and Figure 11 A CAUTION ALWAYS MAINTAIN SPECIFIED NITROGEN GAS PRESSURE IF GAS PRESSURE IS TOO LOW HAMMER IMPACT FORCE MAY BE LOW IF GAS PRESSURE IS TOO HIGH AN INCREASE IN HYDRAULIC OIL TEMPERATURE MAY RESULT CAUSING MALFUNCTION AND SHORT SEAL LIFE Table 6 Diagnosis of Gas Leakage and back cap B Spring or gas valve LEAK LOCATION POSSIBLE CAUSE REMEDY Gas valve assembly A or Defective O ring a
31. pple PF 1 2in 3 4in UN 3C03 N00001 O Ring Not sold separately included w 26 3C03 07058B Side Rod Assembly 3G02 H060051 Side Rod Back Nut Included w 28 3E01 060053 Side Rod Washer Included w 28 3E01 060054 Grease Nipple 37201 GN0018 Tool Set Pin 3G02 H060061 Tool Spring Pin 3C01 534148 Tool Moil Chisel Blunt 3G02 205P Fx E Seal Kit 3G02 205SK Gas Charger 3Z01 202GC I DTN AINI Rl m me me m ae XR NI eje N Included in seal kit NI denotes not illustrated 46 Effective 01 07 HH500 2 HAMMER S N 001 099 amp 2R2 1000 amp UP Effective 07 05 47 HH500 2 SKID STEER MULTI FIT BRACKET ASSEMBLY PARTS LIST PART NO MODEL 500 2 3D02 312021 MF QTY DESCRIPTION Hammer Bracket R Hammer Bracket L 3D01 31205 1 MF Bracket Bolt Assembly of Item 3 Nut By Carrier Model By Carrier Model Bushing Pin Sold as matched set w hardware 48 Effective 07 05 HH500 2 SLIP FIT TLB WLB BRACKET ASSEMBLY PARTS LIST PARTNO MODEL HH500 2 QTY DESCRIPTION Hammer Bracket R 3D02 31203TLB Hammer Bracket L Bracket Bolt Bracket Bolt Nut Support Pipe Bushing Pin 3D01 312051 MF 3E01 31208TLB Assembly of Item 3 and 4 3E01 31209
32. pproved claim which contains the required information or e request for further information for return of the parts for analysis refer to 6 and 7 above or e Notification of a denied claim with an explanation of why the claim was denied 32 9 PARTS LIST AND ILLUSTRATIONS HH100 HH150 2 HH300 2 HH500 2 HH750 2 HH1000 2 HH100 HAMMER Cylinder NUMBER 3A01 2010001 Cylinder Sleeve 3A01 2010002 O Ring 3A01 07148A O Ring 3A01 07148A Gas U Packing 3A01 U01000G U Packing Dust Seal 3A01 U010001 3A01 D01000D Piston Main Valve 3A01 2010011 3A01 2010122 Main Valve Inner Sleeve 3A01 2010123 Main Valve Outer Sleeve 3A01 2010124 O Ring 3A01 09068B Plug 3A01 2010081 Plug O Ring 3A01 09040W Back Cap 3A01 2010031 O Ring 3A01 07148A Gas Valve Assembly 3Z01 G00001 Gas Valve Cap with O Ring Front Cap 3Z01 G00004 3A01 2010041 Grease Nipple Tool Set Pin 3A01 AMT6075 3A01 2010061 Tool Spring Pin 3A01 S24080 Back Cap Set Bolt A 3A01 B40258 Back Cap Set Bolt B 3A01 B40148 Front Cap Set Bolt 3A01 B40148 Nipple 3Z03 N00201 Tool Moil Chisel Blunt 3A01 201P Fx E Seal Kit 3A01 201SK Gas Charger NI AININ ll le Helm 3Z01 202GC Included in seal kit 3
33. pt seals and exclusions listed below are warranted as follows THREE 3 YEARS UNLIMITED HOURS Seals are warranted for a period of TWO 2 YEARS UNLIMITED HOURS All Warrantees begin from the date of sale to the original retail end user or the initial rental service of the hammer ITEMS EXCLUDED FROM THIS WARRANTY Normal wear items such as tools moil chisel blunt tamper frost wedge and asphalt cutter shank bushings tool bushings set pins hoses hose adapters and accessories are specifically excluded from any and all warrantees WARRANTY LIMITATIONS This warranty will be in effect only if 1 The Purchaser or his agent has the Product installed and operating in accordance with the published Manufacturers specifications and guidelines 2 The Purchaser or his agent does not exceed the Products published design operating range for hydraulic flow pressure or recommended carrier size 3 The Purchaser or his agent complies with the maintenance schedule in the Operating and Service Manual supplied with each Product 4 The Purchaser or his agent uses replacement parts products received from or approved by IPC Industries Inc This Warranty will not cover defects failures caused by abuse neglect misuse lack of maintenance accident or use of the Product beyond its published design capacity specifications or recommended applications The Manufacturer will authorize the return of defective components to the Manufacturers wareho
34. r Bracket R Hammer Bracket L 3E01 206602SM Bracket Bolt 3E01 31208TLB Bracket Bolt Assembly of Item 3and 4 Nut 3E02 206604SM 3E01 31209TLB Support Pipe Support Pipe AMADA AE pS By Carrier Model Bushing 9 By Carrier Model N u e m Pin Sold as matched set w hardware 54 Effective 07 05 55 HH1000 2 HAMMER Cylinder NUMBER 3F02 H080001 S N 001 099 amp 2H2 1000 amp UP Cylinder Sleeve 3F02 H080002 Cylinder Sleeve O Ring 3F01 07248B Quad 3F02 QD008000 Back Up Ring 3F02 BU008000 Step Seal 3F02 ST08000 Port Plug w o ring Drain Plugs 3G01 GPF1 Call IPC for details U Packing 3F02 ISI 98 Dust Seal 3F02 D08000 Piston 3F02 H080011 Main Valve Main Valve Inner Sleeve 3F02 H080622 3F02 H080623 Main Valve Outer Sleeve 3F02 H080624 Main Valve O Ring 3E01 07118B Back Cap 3E02 H080031 Back Cap O Ring 3E01 07218A Gas Valve Assembly includes item 19 3Z01 G00001 Gas Valve Cap with O Ring 3Z01 G00004 Front Cap 3F02 H080041 Front Cap Plug 3Z01 FP0038 Shank Bushing 3F01 100042 Front Cap Bushing 3F01 100043 Bushing Set Pin 3F01 100044 Bushing Spring Pin 3E01 S34068 Nipple PF 1 2in 3 4in UN O Ring Not sold separately included w 26
35. r boom or bucket arms Stop the engine before attempting to make any repairs or adjustments to either the carrier or the hammer ALWAYS OBSERVE ALL SAFETY INSTRUCTIONS APPLICABLE TO YOUR CARRIER 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 A DANGER 1 A PROJECTILE FROM THE HAMMER HAMMER TOOL OR WORK AND OR A SWINGING OR FALLING HAMMER CAN BE FATAL TO THE OPERATOR OR BYSTANDERS DO NOT OPERATE HAMMER WHEN BYSTANDERS ARE IN WORK AREA THE OPERATOR MUST BE PROTECTED FROM FLYING DEBRIS USE PERSONAL PROTECTION EQUIPMENT DO NOT WELD CUT WITH ACETYLENE TORCH OR HARDFACE THE HAMMER TOOL IMPORTANT SEE OPERATORS MANUAL FOR SAFETY INSTRUCTION DETAILS PART NO DD 101 WEAR EAR FLYING WEAR FACE READ PROTECTION DEBRIS SHIELD OR MANUAL WHEN CAN CAUSE GOGGLES BEFORE OPERATING INJURY WHEN OPERATING OPERATING PART NO DD 102 AWARNING ACAUTION This symbol may appear on the hammer or in the text of this manual It is used to alert the operator of an action that can place him her or others in a life threatening situation This symbol may appear in This symbol appears in the the text of this manual to text of this manual to identify identify an action that can an action or condition t
36. revent internal damage to hammer parts and carrier hydraulic system A CAUTION DO NOT OPERATE MOUNTED HYDRAULIC HAMMER UNDERWATER WITHOUT AIR SUPPLY TO THE HAMMER SERIOUS DAMAGE WILL RESULT TO THE PISTON SEALS AND OTHER INTERNAL PARTS AS WATER AND ABRASIVE SOLIDS ARE DRAWN INTO THE FRONT CAP CAVITY AND FORCED INTO THE HYDRAULIC CIRCUIT DURING OPERATION A CAUTION DO NOT SUBMERGE HOT HAMMER BODY IN WATER HAMMER BODY WILL CONTRACT AND CAUSE PISTON SCORING AND SEIZURE 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 2 ye AA 1 N UE 2 Connect air supply line to front cap threaded port remove plug A P N 3Z01 FP0038 as shown Thread is 3 8 inch pipe tapered ALL 3 Set pressure regulator to 50 90 psi A A 4 Maintain air supply to hammer at all times when operating 2 under water A W2 SIN S 2 AL KK LLL ES am AA PRESSURE REGULATOR Figure 3 Air Compressor Supply 10 STORAGE Ah WARNING INCORRECT STORAGE OF HAMMER CAN CAUSE CORROSION AND FAILURE OF INTERNAL PARTS 1 Short Term If the hammer will not be used for periods of one week or more the tool should be removed from the hammer and grease must be applied to the piston bottom The hammer should be stored indoors
37. rface If this procedure is followed excess material will not be removed and normal tolerances can be maintained inside the hammer 27 7 TROUBLESHOOTING DIAGNOSIS Table 12 Troubleshooting SYMPTOM POSSIBLE CAUSE REMEDY Hammer does not run Couplers are not engaged Connect couplers securely Relief valve set incorrectly Adjust main and secondary relief valve Malfunction of the hydraulic pump Repair pump Nitrogen gas pressure is too high Adjust gas pressure Main valve is damaged Replace main valve Piston is damaged Repair or replace piston Hesitation or erratic operation Couplers are not fully engaged Connect couplers securely Relief valve set incorrectly Adjust main and secondary relief valve Malfunction of the hydraulic pump Repair pump Oil temperature is too high exceeds 180 F or 80 C Check oil cooler Main valve is damaged Replace damaged main valve Decreased oil flow Avoid simultaneous axis movement Auto shut off in operation tool is suspended Apply proper down force Excessive bushing wear Replace worn bushings Piston is damaged Repair or replace piston Slow impact speed Nitrogen pressure is too high Hydraulic oil leakage into the gas chamber Adjust gas pressure Replace seal kit Malfunction of the hydraulic pump Repair pump Deteriorated or contaminated oil Change
38. sla 7 Between gas valve assembly damaged P assembly Between back cap and cylinder C Defective back cap O ring Replace back cap O ring Figure 11 4 DISASSEMBLY AND ASSEMBLY A DANGER NITROGEN 2 GAS MUST BE RELEASED BEFORE DISASSEMBLY OF HAMMER SEE NITROGEN 2 GAS PRESSURE ADJUSTMENT PROCEDURE 19 A CAUTION ASSEMBLY AND DISASSEMBLY MUST BE PERFORMED UNDER CLEAN CONDITIONS FREE FROM DIRT AND FOREIGN PARTICLES DISASSEMBLY 1 Tool Refer to tool replacement procedures Figure 4 Page 12 Back cap Support the cylinder Figure 12 Loosen and remove four side rods and washers then remove the back cap Front cap See Table 3 page 14 for eyebolt sizes Install an eyebolt and suspend the front cap as shown in Figure 12 Pull out the front cap being careful not to damage the piston Figure 12 Connecting Hoist to Front Cap Main valve Attach an eyebolt to outer sleeve and remove it by pulling the eyebolt Figure 13 Remove the main valve The inner sleeve cannot be removed it is press fitted and requires a special tool Contact the factory for further details SH Figure 13 Removing the Main Valve m 20 5 Piston See Table 7 for Piston weights Note For large hammers you may wish to stand the hammer upright with proper support and pull the piston upward using a lifting device a Attach an eyebolt to the top of the piston and pull out t
39. standing vertically in the working position 2 Long Term For storage of more than 2 3 weeks or where condensation or corrosion is prevalent salt water areas note the following instructions Remove and clean the tool Flush the front cap with clean solvent or hydraulic oil Coat the exposed portion of the piston with grease apply grease to the tool and re install Store the hammer vertically and away from standing moisture To start the hammer after long term storage remove the tool and inspect the exposed portion of the piston for corrosion If corrosion is found do not use the hammer until the defective piston has been repaired or replaced TOOL REPLACEMENT A WARNING TOOL MAY BE HOT FROM OPERATION USE GLOVES TO PROTECT AGAINST BURNS AND POSSIBLE SHARP EDGES A DANGER TOOLS ARE HEAVY REFER TO TABLE 1 BEFORE PROCEEDING Table 1 Standard Tool Weights HAMMER MODEL WEICH kg Ibs HH100 5 12 HH150 2 7 15 HH300 2 14 30 HH500 2 15 32 HH750 2 23 51 HH1000 2 37 82 11 e Carefully drive out the tool spring pin e Push the tool set pin up and out of the front cap using a screwdriver or round bar 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 When installing the tool in the hammer r
40. t be correct for proper operation 2 Check the hydraulic oil for any signs of contamination or discoloration If any signs of contamination appear change the oil Refer to Table 2 Page 13 NOTE Do not mix different types of hydraulic oil 3 Inspect all hoses and fittings for leaks or damage Check all fasteners and tighten as required Replace any broken fasteners 4 The hammer must be greased daily before use Ten shots of grease with a grease gun is adequate The hammer should be greased every 2 3 hours during operation See Figure 2 5 Check the temperature of the hydraulic oil Optimum operating temperature is 120 200 F 49 93 C The unit may not function properly and seal damage may result if the hydraulic oil temperature goes beyond the recommended range Grease Fitting Inside Figure 2 Hammer Lubrication Point 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 Never apply the tool with a side load The tool must always be pressed firmly against and be perpendicular to the material to be broken Failure to do so can cause tool or seal failure 2 Impact action must be stopped immediately when the object has been broken 3 Do not pry with the tool This may cause the tool to break
41. th respect to products sold or services rendered by the Manufacturer or any undertakings acts or omissions relating thereto The Manufacturer reserves the right to change these policies as conditions dictate July 1 2005 30 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 1 Warranty Registration Card Each hydraulic hammer is shipped with a Warranty Registration Card In order to properly process your claim this card must be on file at IPC This card not only registers the product for warranty purposes it keeps IPC informed so we can contact you concerning product updates parts specials and service bulletins Ordering Warranty Replacement Parts All parts ordered from IPC will without exception be invoiced and shipped freight collect or prepaid with freight on the invoice Warranted costs for freight will be resolved on the Warranty Claim form you will be returning with the defective part Filing a Claim Every IPC product shipped includes two service manuals and a package containing a Warranty Claim form and a Delivery Report form for pre delivery The Warranty Claim form is located in the envelope labeled Distributor Information Labor Reimbursement a
42. use or location specified by the Manufacturer The Manufacturer will determine if said components show clear and evident proof of defective material and or workmanship A warranty claim will only be accepted if accompanied by proof of purchase and received within thirty 30 days of the warranted defect or failure The Manufacturer will at its option determine what if any defective faulty components will be accepted for warranty coverage The Manufacturer will at its option determine whether to repair or replace components deemed faulty because of defective materials or workmanship The manufacturer will not be accountable for mileage travel time travel costs and or any freight costs incurred to facilitate the needed replacement or repairs beyond those stated within the document attached titled Warranty Policy Statement The Manufacturer shall not be liable for lost rental income machine availability or failure of components not supplied or installed by Manufacturer WARRANTY DISCLAIMER This Warranty is exclusive and in lieu of all other representations and warranties expressed or implied The Manufacturer expressly disclaims and excludes any implied warranty of merchantability or fitness for a particular purpose In no event shall the Purchaser or his agent be entitled to any consequential damages of any kind whether arising out of breach of contract warranty including negligence and strict liability or other theories of law wi
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