HYDRAULIC HAMMERS - Rock Breakers Inc.
Contents
1. Table 4 Tightening Torque Requirements HH100 HH150 HH300 HH500 750 HH1000 Side Rod NA 400435 550435 550435 NA NA Side a Back wA NA NA NA 730435 770235 po Set 175435 NA NA NA NA NA NA NA NA NA NA Bracket Bolt 175 35 260 35 260 35 260 35 260 35 400 35 HH1500 HH2000 HH3600 HH4500 HH5800 HH8000 Side Rod 880 35 880 35 1100 35 1850 75 2560 75 3300 75 Se ns Back 280 20 280420 330420 330420 590435 590435 Dus Set 175420 280420 330420 330420 480435 480435 Back NA 7023 7023 7043 7043 7023 Bracket Bolt 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 Side Rod Back Nut HH1500 HH2000 HH4500 HH5800 HH2000 and up Mode Valve Set HH3600 HH8000 Bolt Valve Cap Bolt HH100 Front Cap Set Bolt HH100 Figure 5 Tightening Sequence 16 GREASING REQUIREMENTS The hammer should be greased 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 Grease Fitting NITROGEN N2 GAS PRESSURE ADJUSTMENT The hammer will not operate properly and may not start due to an incorre2. 29 Tool Spring Pin 3E01 S34188 1 30 Tool Moil Chisel Blunt 3E01 206P Fx E 1 NI Seal Kit 3E01 206SK 1 NI Gas Charger 3Z01 202GC 1 31 Gas Valve Assembly 3Z01 G00001 1 32 Gas Valve Cap with O Ring 3Z01 G00004 1 Included in seal kit 34 NI denotes not illustrated Effective 9 98 UP TO S N 6F349 HH750 HAMMER Effective 9 98 35 HH750 HAMMER S N 6F350 amp UP NUMBER 1 Cylinder 3E01 2060001 1 2 Cylinder Sleeve 3E01 2060002X 1 3 Cylinder Sleeve O Ring 3E01 07208B 3 4 Quad Ring 3E01 QD206000 1 5 Back Up Ring 3E01 BU206000 1 6 Step Seal 3E01 ST206000 2 7 Buffer O Ring 3E01 OR206000 2 8 Drain Plug 3201 DP0014 1 9 U Packing 3E01 U060001 2 10 Dust Seal 3E01 D06000D 1 11 Piston 3E01 2060011 1 12 Main Valve 3E01 2060622 1 13 Main Valve Inner Sleeve 3E01 2060623 1 14 Main Valve Outer Sleeve 3E01 2060624 1 15 Main Valve O Ring 3E01 09092B 1 16 Back Cap 3E01 2060031 1 17 Back Cap O Ring 3E01 07208A 1 18 Gas Valve Assembly 3Z01 G00001 1 19 Gas Valve Cap with O Ring 3Z01 G00004 1 20 Front Cap 3E01 2060041 1 21 Front Cap Plug 3Z01 FP0038 1 22 Shank Bushing 3E01 060042 1 23 Front Cap Bushing 3E01 060043 1 24 Bushing Set Pin 3E01 060344 2 25 Bushing Spring Pin 01 534068 4 26 Nipple PF 1 2in 3 4in UN 3C03 N00001 2 27 O Ring 1BG 30 3C03 07058B 2 28 Side Rod Assembly 3E01
3. 060051 4 29 Side Rod Front Nut 3C01 060052 4 30 Side Rod Back Nut 3C01 060053 4 31 Side Rod Washer 3E01 060054 4 32 Grease Nipple 3Z01 GN0018 1 33 Tool Set Pin 3E01 060061 1 34 Tool Spring Pin 3E01 S34188 1 35 Tool Moil Chisel Blunt 3E01 206P Fx E 1 NI Seal Kit 3E01 206SKX 1 NI Gas Charger 3Z01 202GC 1 Included in seal kit NI denotes not illustrated 36 Effective 9 98 HH750 HAMMER S N 6F350 amp UP en 15 Effective 9 98 37 HH1000 PARTS LIST UP TO S N 6H399 ITEM NAME NUMBER QTY 1 Cylinder 3F01 2100001 1 2 Cylinder Sleeve 3F01 2100002 1 3 Cylinder Sleeve O Ring 3F01 07228B 3 4 Gas U Packing 3F01 U10000G 1 5 U Packing 3F01 U10000I 1 6 U Packing 3F01 U10000H 1 7 Dust Seal 3F01 D10000D 1 8 Drain Plug 3Z01 DP0014 1 9 Piston 3F01 2100011 1 10 Main Valve 3F01 2100622 1 11 Main Valve Inner Sleeve 3E01 2060623 1 12 Main Valve Outer Sleeve 3E01 2060624 1 13 Main Valve O Ring 3E01 09092B 1 14 Back Cap 3F01 2100031 1 15 Back Cap O Ring 3F01 07228A 1 16 Front Cap 3F01 2100041 1 17 Front Cap Plug 3Z01 FP0038 1 18 Shank Bushing 3F01 100042 1 19 Front Cap Bushing 3F01 100043 1 20 Bushing Set Pin 3F01 100044 3 21 Bushing Spring Pin 3E01 S34088 6 22 Nipple PF 3 4in 1 1 16in UN 3F03 N00002 2 23 O Ring 1BG 30 3F03 07068B 2 24 Side Rod Assembly 3F01 100051 4 25 Side Rod
4. Cap Bushing 3F01 100043 1 24 Bushing Set Pin 3F01 100044 2 25 Bushing Spring Pin 01 534068 4 26 Nipple PF 3 4in 1 1 16in UN 3Z03 N00002 2 27 O Ring 1BG 30 3F03 07068B 2 28 Side Rod Assembly 3F01 100051 4 29 Side Rod Front Nut 3F01 100052 4 30 Side Rod Back Nut 3F01 100053 4 31 Side Rod Washer 3F01 100054 4 32 Grease Nipple 3Z01 GN0018 1 33 Tool Set Pin 3F01 100061 1 34 Tool Spring Pin 3E01 S34188 1 35 Tool Moil Chisel Blunt 3F01 201P Fx E 1 NI Seal Kit 3F01 210SKX 1 NI Gas Charger 3Z01 202GC 1 Included in seal kit NI denotes not illustrated 40 Effective 9 98 HH1000 HAMMER S N 6H400 amp UP 30 Effective 9 98 42 HYDRAULIC HAMMERS IPC INDUSTRIES INC 194 N BRANDON DRIVE GLENDALE HEIGHTS IL 60139 TOLL FREE 1 800 487 5431 PHONE 630 893 5558 FAX 630 790 3751
5. Front Nut 3F01 100052 4 26 Side Rod Back Nut 3F01 100053 4 27 Side Rod Washer 3F01 100054 4 28 Grease Nipple 3Z01 GN0018 1 29 Tool Set Pin 3F01 100061 1 30 Tool Spring Pin 3E01 S34188 1 31 Tool Moil Chisel Blunt 3F01 201P Fx E 1 NI Seal Kit 3F01 210SK 1 NI Gas Charger 3Z01 202GC 1 32 Gas Valve Assembly 3Z01 G00001 1 33 Gas Valve Cap with O Ring 3Z01 G00004 1 Included in seal kit NI denotes not illustrated 38 Effective 9 98 6H399 un E e gt gt T lt Effective 9 98 HH1000 PARTS LIST S N 6H400 amp UP ITEM NAME NUMBER QTY 1 Cylinder 3F01 2100001 1 2 Cylinder Sleeve 3F01 2100002X 1 3 Cylinder Sleeve O Ring 3F01 07228B 3 4 Quad Ring 3F01 QD210000 1 5 Back Up Ring 3F01 BU210000 1 6 Step Seal 3F01 ST210000 2 F Buffer O Ring 3F01 OR210000 2 8 U Packing 3F01 U10000I 1 9 U Packing 3F01 U10000H 1 10 Dust Seal 3F01 D10000D 1 11 Piston 3F01 2100011 1 12 Main Valve 3F01 2100622 1 13 Main Valve Inner Sleeve 3E01 2060623 1 14 Main Valve Outer Sleeve 3E01 2060624 1 15 Main Valve O Ring 3E01 09092B 1 16 Back Cap 3F01 2100031 1 17 Back Cap O Ring 3F01 07228A 1 18 Gas Valve Assembly 3Z01 G00001 1 19 Gas Valve Cap with O Ring 3Z01 G00004 1 20 Front Cap 3F01 2100041 1 21 Front Cap Plug 3Z01 FP0038 1 22 Shank Bushing 3F01 100042 1 23 Front
6. Tighten or replace nipple nipple F O ring or nipple and O ring Damaged U packing or main yunder and Valve outer sleeve O ring Replace seal kit back cap G er Back cap O ring Remove plugs and reinstall Plug ports H Plugs loosen e 19 Figure 11 GAS LEAKAGE INSPECTION Gas leakage can be easily detected using soapy water refer to Table 6 and Figure 12 A CAUTION ALWAYS MAINTAIN SPECIFIED NITROGEN GAS PRESSURE IF GAS PRESSURE IS TOO LOW HAMMER IMPACT FORCE MAY 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 LEAK LOCATION POSSIBLE CAUSE REMEDY Gas valve assembly A or Defective O ring Between gas valve assembly damaged and back cap B Spring or gas valve Between back cap and cylinder Replace gas valve assembly Defective back cap O ring Replace back cap O ring Figure 12 20 4 DISASSEMBLY AND ASSEMBL Y A DANGER NITROGEN N2 GAS MUST BE RELEASED BEFORE DISASSEMBLY OF HAMMER SEE NITROGEN N2 GAS PRESSURE ADJUSTMENT PROCEDURE CAUTION ASSEMBLY AND DISASSEMBLY MUST BE PERFORMED UNDER CLEAN CONDITIONS FREE FROM DIRT AND FOREIGN PARTICLES DISASSEMBLY 1 Tool Refer to tool replacement procedures on page 10 and Figure 4 2 Back cap Support the cylinder Figure 13 Loosen and
7. for more than one minute Continuous impact may cause a rapid increase in oil temperature and improper hammer operation Break large objects from the outside edges and work inward 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 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 Do not operate the hammer when boom cylinders are at their extreme ends This may cause damage to the cylinders Stop operation immediately if hoses vibrate abnormally or impact energy is dramatically reduced Consult Section 7 Troubleshooting Diagnosis for additional information 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 2 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 F 15 C 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 prevent internal damage to hammer parts and carrier hydraulic system A CAUTION DO NOT OPERATE MOUNTED HYDR
8. lt CLEARANCE 4 BETWEEN TOOL amp ANZ SURFACE oT SHANK BUSHING AS SHANK BUSHING A NW N N TOOL SET PIN A NA WEAR AT FRONT CAP CLEARANCE BETWEEN FRONT CAP BUSHING TOOL amp FRONT CAP BUSHING TOOL Figure 18 Wear Limit Points Table 9 New Component Dimensions PART HH100 HH150 76 91 mm Front Cap Bushing I D 3 0 in 3 583 in 76 mm 91 mm Shank Bushing LD 3 0 in 3 583 in 75 mm 90 mm Tool DD 2 953 in 3 543 in 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 1 2 3 NR Lubricate the U packing O ring piston cylinder and main valve with hydraulic oil before assembly Place cylinder sleeve on the piston Insert the piston fully into the cylinder to its bottom position a Make sure that all seals are positioned correctly 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 about 1 7 ounces 50cc of hydraulic oil into the back cap for lubrication of the seals as shown in Figure 19 Attach the back cap to the cylinder Figure 19 Lubricating Seal
9. paragraph 2 procedure b Remove the cap on the gas charger nitrogen hose connection port See Figure 10 c Attach the N2 gas pressure regulator to the gas container Connect the nitrogen Supply tank to the gas charger with the charging kit hose DANGER DO NOT STAND IN AREA OF TOOL WHEN ADDING NITROGEN TO HAMMER THE TOOL MAY EJECT SUDDENLY AND CAUSE SEVERE INJURY WARNING N Figure 9 18 GUAGE T HANDLE A NITROGEN HOSE CONNECTION PORT GAS CHARGER VALVE BODY BLEEDER SCREW Figure 10 Gas Charger Valve d Open the main gas valve on the N2 gas container and regulate the N2 gas pressure see Figure 8 e Turn the gas charger T handle clockwise and adjust N2 gas pressure in the gas chamber to 140 160 psi 10 11 bar 160 175 psi 11 12 bar on HH500 model f Turn the gas charger T handle fully counter clockwise and remove the hose Attach the cap to the gas inlet of the charger g Remove the gas charger and attach the gas valve cap and O ring firmly to the gas valve nut on the hammer back cap 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 11 Table 5 Diagnosis of Oil Leakage LEAK LOCATION POSSIBLE CAUSE REMEDY Between front cap Damaged or worn and tool E U packing Basen Between cylinder and Loose nipple or damaged
10. 0 CORRECT Figure 4 Tool Replacement 12 Table 1 Standard Tool Weights HAMMER MODEL WEIGHTS HH100 3 6 8 HH150 7 15 HH300 14 30 HHS00 15 32 HH750 23 51 1000 37 82 1500 45 99 HH2000 74 162 HH3600 118 260 HH4500 152 334 HH5800 174 381 HH8000 214 470 3 MAINTENANCE HYDRAULIC 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 colo
11. 00 to 800 psi above the hammer Operating Pressure e Hydraulic pressure is to be measured at the hose end of the carrier output or pressure hose when disconnected from the hammer 29 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 IPC Huskie components are high quality alloy steel and do not use chromium surface finishes which cannot be polished Follow the procedures in Figures 20 21 amp 22 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 22 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 raise
12. 7 21 3 HH500 10 0 22 0 HH750 17 1 37 6 HH 1000 25 4 55 9 HH1500 41 0 90 1 HH2000 64 3 141 5 HH3600 101 0 222 HH4500 122 6 269 7 HH5800 153 4 337 5 HH8000 198 1 435 8 23 INSPECTION OF PARTS 1 Seals Seals that are deformed scratched worn or aged should be replaced see Figure 17 It is recommended that all seals be replaced when disassembling the hammer Figure 17 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 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 and 9 Remove bushing set pin and bushing spring pin using a hammer and drive pin The front cap bushing must be torch cut at three locations at three 120 grooves if it is the only bushing to be replaced Press out the front cap bushing only if both bushings need replacement Any scratches in the front cap must be smoothed after bushing removal 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 o
13. AULIC 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 m a For HH100 through HH500 5 10 CFM at 50 to 90 psi is adequate b For HH750 and larger 20 to 50 is required 2 Connect air supply line to front cap threaded port remove plug P N 3Z01 FP0038 as shown Thread is 3 8 inch pipe tapered 3 Set pressure regulator to 50 90 psi Maintain air supply to hammer at all times when operating under water c 7 ante SS LEE TR ARI BA NN SN IN Na LEE SS N m i SEAN NN gt p KK 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 hydraulic oil must be applied to the piston bottom The ha
14. HYDRAULIC HAMMERS ES HYDRAULIC 1 MN HAMMERS CONTENTS Safety Information Page 2 Safety Decals Safety Symbols Operating Instructions Page 5 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 12 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 27 Refinishing of Pistons and Cylinders Page 28 Troubleshooting Diagnosis Page 29 Parts List and Illustrations Page 31 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 1f he she can safely operate the carrier and hammer Work at a slow pace when learning to operate the hammer Ope
15. TION 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 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 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 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 must be correct for proper operation 2 Check the hydraulic oil for any signs of conta
16. ct gas charge Follow the procedure described below to adjust nitrogen N2 gas pressure 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 PRESSURE REGULATOR VALVE T HANDLE NITROGEN HOSE m a CONNECTION PORT 4 QU GAS CHARGER Q VALVE BODY KO HAMMER Figure 7 Connecting Gas Charger to Figure 8 Connecting 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 17 2 Releasing Gas Pressure if over charged or prior to disassembly a Test 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 10 c If overcharged close the Bleeder Screw when the gas pressure reaches 140 160 psi 10 11 bar 160 175 psi 11 12 bar on HH500 model then turn the T handle to the left counter clockwise d Finally remove the gas charger Install and tighten the gas valve cap 3 Refilling Nitrogen N2 Gas a Perform
17. d edges are flush and smooth with the original surface If this procedure is followed excess material will not be removed and normal tolerances can be maintained inside the hammer 30 7 TROUBLESHOOTING DIAGNOSIS Table 11 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 Repair or 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 Decreased oil flow Repair or replace damaged main valve 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 Adjust gas pressure Hydraulic oil leakage into the gas chamber Replace seal kit Malfunction of the hydraul
18. f the front cap and cooling of the bushing will help installation Insert the bushing set pin and the bushing spring pin 24 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 and 9 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 to a square end at the working end to serve as a press mandrel to remove the bushing 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 inference 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 28 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 flapwheel with 240 g
19. formation 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 4h WARNING FLYING DEBRIS AND HIGH NOISE A DANGER LEVEL WEAR SAFETY GLASSES AND EAR PROTECTION TO AVOID SERIOUS INJURY 1 A PROJECTILE FROM THE HAMMER HAMMER TOOL OR WORK AND OR A SWINGING OR FALLING HAMMER CAN BE FATAL TO PART NO WD 101 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 e Shown above is a copy of a decal that must be installed on a su
20. ic pump Repair pump Deteriorated or contaminated oil Change 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 31 32 8 PARTS LIST AND ILLUSTRATIONS HH750 HH1000 HH7S0 PARTS LIST UP S N 6F349 ITEM NAME NUMBER QTY 1 Cylinder 3E01 2060001 1 2 Cylinder Sleeve 3E01 2060002 1 3 Cylinder Sleeve O Ring 3E01 07208B 3 4 Gas U Packing 3E01 U06000G 1 5 U Packing 3E01 U06000I 4 6 Dust Seal 3E01 D06000D 1 7 Drain Plug 3Z01 DP0014 1 8 Piston 3E01 2060011 1 9 Main Valve 3E01 2060622 1 10 Main Valve Inner Sleeve 3E01 2060623 1 11 Main Valve Outer Sleeve 3E01 2060624 1 12 Main Valve O Ring 3E01 09092B 1 13 Back Cap 3E01 2060031 1 14 Back Cap O Ring 3E01 07208A 1 15 Front Cap 3E01 2060041 1 16 Front Cap Plug 3Z01 FP0038 1 17 Shank Bushing 3E01 060042 1 18 Front Cap Bushing 3E01 060043 1 19 Bushing Set Pin 3D01 060344 3 20 Bushing Spring Pin 01 534088 6 21 Nipple PF 1 2in 3 4in UN 3C03 N00001 2 22 O Ring 1BG 30 3C03 07058B 2 23 Side Rod Assembly 3E03 060051 4 24 Side Rod Front Nut 3E01 060052 4 25 Side Rod Back Nut 3E01 060053 4 26 Side Rod Washer 3E01 060054 4 27 Grease Nipple 3Z01 GN0018 1 28 Tool Set Pin 3E01 060061 1
21. in Back Cap 27 8 Insert and tighten the four side rods together with the washer to the specified torque see Table 4 Follow the tightening order shown in Table 5 9 Refill the hammer with Nitrogen N2 gas Ref Figure 9 DANGER DO NOT STAND IN AREA OF TOOL WHEN ADDING NITROGEN TO HAMMER THETOOL 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 1f the piston 1s not at the bottom of its stroke in the cylinder 28 5 SPECIFICATIONS Table 10 Specifications ITEM Remarks e The hammer is to be used within the specified oil pressure oil flow and gas pressure parameters MODEL HH750 MODEL HH750 Impact energy ft lbs 750 1000 kg m 102 136 Blows per 530 1 070 580 850 bpm minute Required oil gpm 6 7 13 3 14 7 21 3 flow l min 25 50 55 80 Operating psi 1 700 2 000 1 860 2 140 pressure bar 120 140 130 150 Nitrogen gas psi 140 160 140 160 pressure bar 10 11 10 11 Total weight lbs 675 1 070 with tool kg 307 487 inch 57 64 Total length Mr 1435 1 620 inch 3 0 3 5 Tool diameter a 75 90 Applicable lbs 7 500 15 000 11 000 26 000 carrier kg 3 400 6 800 4 990 11 790 e The carrier hydraulic system relief pressure is to be set at 2 400 2 600 psi 170 185 bar This is 6
22. mination or discoloration If any signs of contamination appear change the oil Refer to Table 2 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 100 180 F 40 80 C The unit may not function properly and seal damage may result if the hydraulic oil temperature goes Sa 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 9o 10 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 Impact action must be stopped immediately when the object has been broken Do not pry with the tool This may cause the tool to break or cause abnormal wear to the tool bushings Avoid continuous impact on the same area
23. mmer should be stored indoors 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 Ah WARNING TOOL MAY BE HOT FROM OPERATION USE GLOVES TO PROTECT AGAINST BURNS AND POSSIBLE SHARP EDGES A DANGER TOOLS ARE HEAVY REFERTO TABLE 1 BEFORE PROCEEDING 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 Check Table 1 Page 11 before handling tools For models HH100 through HH750 manual removal is possible For hammer models HH1000 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 reverse 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 6
24. r change Good Transparent but too bright Oil Mixed Milky white Air and or water mixed Dark and dirty with odor Deteriorated Transparent but with black spots Foreign particles mixed Bubbly Grease mixed 14 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 A WARNING USE ONLY ORIGINAL MANUFACTURER PARTS WHEN REPLACING BOLTS NUTS AND WASHERS SUBSTITUTE PARTS MAY APPEAR SIMILAR BUT MAY FAIL 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 VALVEBOX GAS VALVE HAMME NIPPLES BEACKET SIDE LIFTING CAP SET CAP BODY R mm inne er a BOLTS inches mm 100 19 28 14 13pt NA NA 36 150 30 36 32 Y 13pt NA NA 36 300 30 36 41 y 13pt NA NA Eo 36 500 30 36 41 10p NA NA o 36 750 30 36 46 7 10 NA NA E 36 1000 36 50 46 10pt NA NA E 36 1500 36 50 54 9 l0pt 14 30 TRY 36 2000 36 50 54 NE 17 30 9unc Foot 3600 46 60 63 ME do er 9unc Foot 4500 46 75 71 1 8unc 17 32 os 36 1 5800 46 15 85 A 19 41 ME 8unc Foot 1 2 8000 50 75 90 LA 19 At 96 6unc Foot Allen Wrench Sizes 15
25. rator 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 1s 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 hard hat while operating the hammer Before leaving the operator s seat always lower the carrier boom or bucket arms Stop the engine before attempting to make any repairs or adju
26. remove four side rods and washers then remove the back cap 3 Front cap See Table 3 for eyebolt sizes Install an eyebolt and suspend the front cap as shown in Figure 13 Pull out the front cap being careful not to damage the piston Figure 13 Connecting Hoist to Front Cap 21 4 Main valve Attach an eye bolt to outer sleeve and remove it by pulling the eyebolt Figure 14 Remove the main valve The inner sleeve cannot be removed as it is press fitted and requires a special tool Contact the factory for further details Figure 14 Removing the Main Valve 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 eye bolt to the top of the piston and pull out together with cylinder sleeve toward the top b It may be useful to use a pry bar as a lever as shown in Figure 15 Be careful to not damage the piston Figure 15 Removing the piston 6 Cylinder sleeve Note Support piston on wood blocks Remove the cylinder sleeve from the piston A plastic hammer or nylon bar can be used for removal as shown in Figure 16 Do not force the cylinder sleeve uniformly on all sides of the sleeve Figure 16 Removing Cylinder Sleeve Table 7 Piston Weights 22 HAMMER MODEL WEIGHTS a kgoo hs HH100 5 8 12 7 HH150 6 0 13 2 HH300 9
27. rface 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 lt lt MIDDLE CHAMBER PRESSURE RECIEVING LOW PRESSURE SURFACE B LOWER CHAMBER HIGH PRESSURE Figure 1 Principles of Operation A CAU
28. rit and finish with 360 grit When polishing the piston or the cylinder bore it is not necessary to completely remove scratches as this may remove excess material See Figures 20 21 and 22 c Main Valve and Sleeves Main valve and sleeves cannot be polished Replace if these parts do not slide freely by finger pressure 25 COMPONENT WEAR LIMITS Parts are to be replaced if they are not within the wear parameters See Table 8 and Figure 18 for new dimensions see Table 9 Table 8 Component Wear Limits COMPONENT WEAR LIMITS When the clearance between the tool and the front cap bushing Front cap es exceeds 200 in 5mm a new front cap bushing is required ene Approximately 500 hours 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 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 Front ca P 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 SN lt
29. stments 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 Repair Parts Department 4A WARNING ee A DANGER AND EAR PROTECTION TO AVOID SERIOUS INJURY PART NO WD 101 1 APROJECTILE 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 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 that 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 in
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