Huskie Tools HH1500 User manual

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HUSKIE
HYDRAULIC
HAMMERS
SERVICE
MANUAL
HH1500
HH2000
HH3600
HH4500
HH5800
HH8000

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CONTENTS
1. Safety Information Page 3
Safety Decals
Safety Symbols
2. Operating Instructions Page 6
How the Hammer Operates
Mounting the Hammer to Carrier
Connecting Hoses
Daily Inspection before Operation
Initial Startup, Hammer Break-in
General Operation Instructions
Cold Weather Startup and Operation
Underwater Operation
Storage
Tool Replacement
3. Maintenance Page 12
Hydraulic Oil
Checking Condition of Hydraulic Oil
Fasteners
Greasing Requirements
Nitrogen (N2) Gas Pressure Adjustment
Oil Leakage Inspection
Gas Leakage Inspection
4. Disassembly and Assembly Page 18
Disassembly
Inspection of Parts
Component Wear Limits
Assembly
5. Specifications Page 26
6. Refinishing of Pistons and Cylinders Page 27
7. Troubleshooting Diagnosis Page 28
8. Warranty Guide Lines Page 29
9. Parts List and Illustrations Page 33

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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 the 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 operator’s seat, always lower the carrier 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.

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SAFETY DECALS
The decals shown below are attached to the hammer when shipped from the factory.
Read and understand them before operating the hammer. Replace any decal that has
become worn, damaged or illegible. Decals can be ordered through the parts department.
DANGER
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.
CAUTION
This symbol appears in the
text of this manual to identify
an action or condition that
can result in damage to the
hammer or other equipment.

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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.
• 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.
• 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.

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2. OPERATING INSTRUCTIONS
HOW THE HAMMER OPERATES
On larger hammers the main valve is contained in the valve box, which is bolted to the
cylinder (Figure 1). During the upward stroke, the pressure in the upper chamber is
released via the main valve and through the outlet. High pressure in the lower chamber
then forces the piston upward.
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 Ais 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.
Figure 1. Principle of Operation
(Refer to Table 10.)
Gas
Chamber
Pressure
receiving
surface A
Piston
Pressure
receiving
surface B Lower Chamber
High pressure
Middle Chamber
Low pressure
Main Valve
Valve Box

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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 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 shut off
valves. When connecting, make sure that the ends 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 contamination 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 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.
Figure 2. Hammer Lubrication Point

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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 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.
8. 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.
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°F (15°C)
2. With engine at half throttle, activate the hammer for 5 seconds and stop for 15
seconds. Repeat cycle for 2 to 3 minutes.

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UNDERWATER OPERATION
Operation of hydraulic hammers under water requires proper preparation to prevent
internal damage to hammer parts and carrier hydraulic system.
1. To prepare the hammer for underwater operation you will need
an external compressed air supply.
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.
4. Maintain air supply to hammer at all times when operating
under water
5. For HH1500 through HH8000, 20 to 50 CFM is required.
PRESSURE REGULATOR
Figure 3. Air Compressor Supply

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STORAGE
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 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
Table 1. Standard Tool Weights
TOOL WEIGHTS Kg lbs.
HH1500 45 99
HH2000 74 162
HH3600 118 260
HH4500 152 334
HH5800 174 381
HH8000 214 470

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Carefully drive out the tool spring pin.
Push the tool set pin up and out of the front
cap using a screwdriver or round bar.
Note: Check Table 1, Page 10, before handling
tools.
For models HH100 through HH750-2,
manual removal is possible.
For hammer models HH1000-2 and larger
use hoist and sling as shown. Check for
sling load rating and compare to
Table 1, Page 10.
• 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.
Figure 4. Tool Replacement
4
60
o
1/3 1/3 1/3
SLING ANGLES
NOT SMALLER THAN:

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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 Deteriorated
Transparent but with black spots Foreign particles mixed
Bubbly Grease mixed

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FASTENERS
Inspect all bolts and nuts for tightness. Tighten as required. (Refer to Table 4.) Replace
all missing or damaged fasteners before operating the hammer.
Fastener bolt and nut sizes are listed in Table 3. These are wrench sizes (distance across
flats.)
Table 3. Bolt Sizes
VALVE BOX GAS VALVE
HAMMER NIPPLES
(mm.)
BRACKET
BOLTS
(mm.)
SIDE
RODS
(mm.)
LIFTING
EYES
(inches)
*CAP
BOLTS
SET
BOLTS
(mm.)
CAP
(inches)
BODY
(mm.)
1500 36 50 54 ¾”-10pt *14 30
1”
Crow
Foot
36
2000 36 50 54 7/8”-
9unc *17 30
1”
Crow
Foot
36
3600 46 60 63 7/8”-
9unc *17 32
1”
Crow
Foot
36
4500 46 75 71 1”-8unc *17 32
1”
Crow
Foot
36
5800 46 75 85 1 ¼”-
8unc *19 41
1”
Crow
Foot
36
8000 50 75 90 1 ½”-
6unc *19 41
1”
Crow
Foot
36
* Allen wrench size for the front and back cap bolts.

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Table 4. Tightening Torque Requirements (Ft. lbs.)
HH1500 HH2000 HH3600 HH4500 HH5800 HH8000
Side Rod 880 ±35 880 ±35 1100 ±35 1850 ±75 2560 ±75 3300 ±75
Valve Box
Set Bolt 280 ±20 280 ±20 330 ±20 330 ±20 590 ±35 590 ±35
Valve Cap Bolt 175 ±20 280 ±20 330 ±20 330 ±20 480 ±35 480 ±35
Mode Valve
Set Bolt N/A 70 ±3 70 ±3 70 ±3 70 ±3 70 ±3
Bracket Bolt 400 ±35 840 ±35 1320 ±35 2600 ±35 2600 ±35 2600 ±35
Side Rod
Back Nut.
&
Mode Valve
Set Bolt
Valve Box Set Bolt
(HH1500, HH2000,
HH3600)
Valve Box Set Bolt
(HH4500, HH5800,
HH8000)
Valve Cap Bolt
(HH2000 and up)
Figure 5. Tightening Sequence
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.
Figure 6. Grease Fitting
Figure 6.
1 3
42
513
62
4
713 5
26 48
4
1
3
25

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NITROGEN (N2) GAS PRESSURE ADJUSTMENT
The hammer will not operate properly and may not start due to an incorrect gas charge.
Follow the procedure described below to adjust nitrogen (N2) gas pressure.
WARNING!
DO NOT STAND NEAR THE HAMMER WHEN ADDING NITRIGEN. 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
“T” 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.
Figure 7. Connecting Gas Charger to
Hammer
Figure 8. Connecting Gas Charger to
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. Test the gas pressure as described in paragraph 1.
b. For disassembly loosen the bleeder screw on the gas charger very slowly and
release the N2gas. Watch the pressure gauge until the nitrogen pressure is fully
released. (see Figure 7 and 8.)
c. If overcharged 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.
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.
c. Attach the N2gas pressure regulator to the gas container. Connect the nitrogen
(N2) Supply tank to the gas charger with the charging kit hose.

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Figure 9. Gas Charger Valve
d. Open the main gas valve on the N2gas container and regulate the N2gas pressure
(see Figure 8.)
e. Turn the gas charger “T” handle clockwise and adjust N2gas pressure in the gas
chamber to the correct gas pressure shown on Table 10, Page 26.
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 10.)
Table 5. Diagnosis of Oil Leakage
LEAK LOCATION POSSIBLE CAUSE 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

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

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4. DISASSEMBLY AND ASSEMBLY
DISASSEMBLY
1. Tool
Refer to tool replacement procedures on Figure 4, page 11.
2. Back cap
Support the cylinder (Figure 12). Loosen and remove four side rods and washers,
then remove the back cap.
3. Front cap (See Table 3 page 13 for eyebolt sizes)
Install an eyebolt and suspend the front cap as shown in Figure 12. Pull out the front
cap, being careful not to damage the piston.
Figure 12. Connecting Hoist to Front Cap.

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4. Main Valve Box Assembly
Service of the Valve Box includes the Mode Valve Assembly and the Main Valve
with Box Sleeve.
a. Remove six or eight (depending on hammer model) Valve Box (4) Set Bolts and
place Valve Box on a clean flat service.
Note: Inspect o-rings located at ports on cylinder and replace o-rings as
necessary. When re-installing Valve Box check that all o-rings are
in correct position.
b. Remove four Mode Valve (1) Set Bolts and replace o-ring seals as necessary.
c. Remove ten socket head cap screws and the Upper Valve Cap (3) and Lower
Valve Cap (7).
d. Remove the Box Sleeve (6) and the Main Valve (5) from the Lower Valve bore
and inspect for scoring or wear.
Note: Minor scratches can be polished by hand using the same procedure
as the piston and cylinders. Ref. Para. 6 page 27. Main Valve (5)
and Box Sleeve (6) must be capable of free movement by hand
without sticking or dragging. If not satisfactory replace with new
parts.
e. Reassemble by reversing above procedure.
Note: Keep work area clean and lubricate all parts with clean hydraulic
oil during assembly.
f. Torque bolts to proper specifications and sequence shown on Table 4 and figure 5
on page 14.
Figure 13. Main Valve Box Assembly

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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 14. Be careful to
not damage the piston.
Figure 14. Removing the piston.
5. 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 15. Do not force the cylinder sleeve. Tap uniformly on
all sides of the sleeve.
Figure 15. Removing Cylinder Sleeve
Table. 7. Piston Weights
WEIGHTS
HAMMER MODEL kg lbs.
HH1500 41 90
HH2000 64 142
HH3600 101 222
HH4500 122 270
HH5800 153 338
HH8000 198 436