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