Ironton 61587 User manual

READ & SAVE THESE INSTRUCTIONS
Breaker Hammer Kit with Cart
Owner’s Manual
WARNING: Read carefully and understand all ASSEMBLY AND OPERATION
INSTRUCTIONS before operating. Failure to follow the safety rules and other basic safety
precautions may result in serious personal injury.
Item #61587

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Thank you very much for choosing an Ironton™product!
For future reference, please complete the owner’s record below:
Serial Number/Lot Date Code: ________________________________
Purchase Date: ____________________________________________
Save the receipt, warranty, and this manual. It is important that you read
the entire manual to become familiar with this product before you begin
using it.
This breaker hammer kit with cart is designed for certain applications
only. Northern Tool and Equipment is not responsible for issues arising
from modification or improper use of this product such as an application
for which it was not designed. We strongly recommend that this product
not be modified and/or used for any application other than that for which
it was designed.
For technical questions, please call 1-800-222-5381.

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Table of Contents
Intended Use..........................................................................................................................................4
Packaging Contents..............................................................................................................................4
Technical Specifications......................................................................................................................4
Important Safety Information...............................................................................................................4
Specific Operation Warnings...............................................................................................................6
Grounding..............................................................................................................................................6
Extension Cords....................................................................................................................................8
Main Parts of Breaker Hammer Kit with Cart .....................................................................................9
Assembly Instructions........................................................................................................................10
Before Each Use..................................................................................................................................12
Operating Instructions........................................................................................................................12
After Each Use.....................................................................................................................................16
Maintenance ........................................................................................................................................16
Troubleshooting..................................................................................................................................17
Hammer Parts Diagram ......................................................................................................................18
Hammer Parts List ..............................................................................................................................19
Cart Parts Diagram..............................................................................................................................21
Cart Parts List......................................................................................................................................22
Replacement Parts..............................................................................................................................22
Limited Warranty.................................................................................................................................23

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Intended Use
The Ironton Breaker Hammer Kit with Cart contains all of the accessories needed for rapid breaking
and chipping of concrete and masonry blocks.
Packaging Contents
Hammer Kit
Mobile Cart
Grease
2 Chisels
Owner’s Manual
Technical Specifications
Property
Specification
Rate
110V / 60Hz
Amperage
15A
Impact rate
950 BPM
Impact Energy
75 J
Important Safety Information
⚠WARNING
Read and understand all instructions. Failure to follow all instructions may result in serious injury
or property damage.
The warnings, cautions, and instructions in this manual cannot cover all possible conditions or
situations that could occur. Exercise common sense and caution when using this tool. Always be
aware of the environment and ensure that the tool is used in a safe and responsible manner.
Do not allow persons to operate or assemble the product until they have read this manual and
have developed a thorough understanding of how it works.
Do not modify this product in any way. Unauthorized modification may impair the function and/or
safety and could affect the life of the product. There are specific applications for which the product
was designed.
Use the right tool for the job. DO NOT attempt to force small equipment to do the work of larger
industrial equipment. There are certain applications for which this equipment was designed. This
product will be safer and do a better job at the capacity for which it was intended. DO NOT use
this equipment for a purpose for which it was not intended.
Industrial or commercial applications must follow OSHA requirements.
⚠WARNING
WORK AREA SAFETY
Inspect the work area before each use. Keep work area clean, dry, free of clutter, and well-lit.

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Cluttered, wet, or dark work areas can result in injury. Using the product in confined work areas
may put you dangerously close to cutting tools and rotating parts.
Do not use the product where there is a risk of causing a fire or an explosion; e.g., in the presence
of flammable liquids, gases, or dust. The product can create sparks, which may ignite the
flammable liquids, gases, or dust.
Do not allow the product to come into contact with an electrical source. The tool is not insulated
and contact will cause electrical shock.
Keep children and bystanders away from the work area while operating the tool. Do not allow
children to handle the product.
Be aware of all power lines, electrical circuits, water pipes, and other mechanical hazards in your
work area. Some of these hazards may be hidden from your view and may cause personal injury
and/or property damage if contacted.
⚠WARNING
PERSONAL SAFETY
Stay alert, watch what you are doing, and use common sense when operating the tool. Do not use
the tool while you are tired or under the influence of drugs, alcohol, or medication. A moment of
inattention while operating the tool may result in serious personal injury.
Dress properly. Do not wear loose clothing, dangling objects, or jewelry. Keep your hair, clothing
and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving
parts. Air vents on the tool often cover moving parts and should be avoided.
Wear the proper personal protective equipment when necessary. Use ANSI Z87.1 compliant safety
goggles (not safety glasses) with side shields, or when needed, a face shield. Use a dust mask in
dusty work conditions. Also use non-skid safety shoes, hardhat, gloves, dust collection systems,
and hearing protection when appropriate. This applies to all persons in the work area.
Do not overreach. Keep proper footing and balance at all times.
Remove keys or wrenches before connecting the tool to an air supply, power supply, or turning on
the tool. A wrench or key that is left attached to a rotating part of the tool may cause personal
injury.
Secure the work with clamps or a vise instead of your hand when practical. This safety precaution
allows for proper tool operation using both hands.
⚠CAUTION
BREAKER HAMMER KIT WITH CART USE AND CARE
Do not force the demolition hammer. Products are safer and do a better job when used in the
manner for which they are designed. Plan your work, and use the correct product for the job.
Check for damaged parts before each use. Carefully check that the product will operate properly
and perform its intended function. Replace damaged or worn parts immediately. Never operate the
product with a damaged part.
Do not use a product with a malfunctioning switch. Any power tool that cannot be controlled with

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the power switch is dangerous and must be repaired by an authorized service representative
before using.
Disconnect the power/air supply from the product and place the switch in the locked or off position
before making any adjustments, changing accessories, or storing the tool. Such preventive safety
measures reduce the risk of starting the tool accidentally.
Store the demolition hammer when it is not in use. Store it in a dry, secure place out of the reach
of children. Inspect the tool for good working condition prior to storage and before re-use.
Use only accessories that are recommended by the manufacturer for use with your product.
Accessories that may be suitable for one product may create a risk of injury when used with
another tool. Never use an accessory that has a lower operating speed or operating pressure than
the tool itself.
Keep guards in place and in working order. Never operate the product without the guards in place.
Do not leave the tool running unattended.
Specific Operation Warnings
⚠WARNING
To reduce the risk of injury, always wear eye protection
Wear ear protection when using the hammer. Exposure to noise can cause hearing loss.
Wear heavy duty anti-vibration gloves.
Be sure the bit is secured in place before operation.
Hold power tools by insulated gripping surfaces, when performing an operation where the cutting
tool may contact hidden wiring or its own cord.
When drilling or screwing into walls, ceilings, etc., make sure beforehand that you will not damage
any hidden electric cables. During this work you should not touch any metal parts of the machine;
only touch the machine by the plastic housing.
Always be sure you have a firm footing.
Hold the hammer firmly with both hands.
Be sure no one is below you when using the tool in high locations.
Do not point the tool at anyone in the area when operating. The bit could fly out and seriously
injure someone.
Burn hazard. Do not touch the bit or parts close to the bit immediately after operation; they will be
extremely hot.
Grounding
⚠WARNING
This machine must be grounded while in use to protect the operator from electrical shock. This
unit is equipped with an electrical cord that has an equipment grounding conductor and a

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grounding plug. The plug MUST be plugged into a matching receptacle that is properly installed
and grounded in accordance with ALL local codes and ordinances.
DO NOT MODIFY THE PROVIDED PLUG. If it will not fit the receptacle, have the proper
receptacle installed by a qualified electrician.
CHECK with a qualified electrician or service person if you do not completely understand the
grounding instructions, or if you are not sure the tool is properly grounded.
Grounded Tools: Tools with 3-Prong Plugs
Tools marked with Grounding Required have a 3-wire cord and 3-prong grounding plug. The plug
must be connected to a properly grounded outlet. If the tool should electrically malfunction or break
down, grounding provides a low resistance path to carry electricity away from the user, reducing the
risk of electric shock. (See Figure A.)
The grounding prong in the plug is connected through the green wire inside the cord to the grounding
system in the tool. The green wire in the cord must be the only wire connected to the tool’s grounding
system and must never be attached to an electrically live terminal.
Your tool must be plugged into an appropriate outlet, properly installed and grounded in accordance
with all codes and ordinances. The plug and outlet should look like those in the following illustration.
Double Insulated Tools: Tools with Two-Prong Plugs
Tools marked Double Insulated do not require grounding. They have a special double insulation
system which satisfies OSHA requirements and complies with the applicable standards of
Underwriters Laboratories, Inc., the Canadian Standard Association, and the National Electrical Code.
(See Figure B.)
Double insulated tools may be used in either of the 120 volt outlets shown in the following illustration.

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Extension Cords
⚠WARNING
USE A PROPER EXTENSION CORD. Make sure your extension cord is in good condition. When
using an extension cord, be sure to use one heavy enough to carry the current your product will
draw. An undersized cord will cause a drop in line voltage, resulting in loss of power and cause
overheating.
Be sure your extension cord is properly wired and in good condition. Always replace a damaged
extension cord or have it repaired by a qualified person before using it. Protect your extension
cords from sharp objects, excessive heat and damp or wet areas.
Grounded tools require a 3-wire extension cord. Double Insulated tools can use either a 2- or 3-
wire extension cord.
As the distance from the supply outlet increases, you must use a heavier gauge extension cord.
Using extension cords with inadequately sized wire causes a serious drop in voltage, resulting in
loss of power and possible tool damage.
The smaller the wire’s gauge number, the greater the capacity of the cord. For example, a 14-
gauge cord can carry a higher current than a 16-gauge cord. Minimum extension cord wire size is
shown in the following table:
Minimum Wire Size Of Extension Cords
Nameplate AMPS
Cord Length
25'
50'
100'
150'
0-6
18 AWG
16 AWG
16 AWG
14 AWG
6-10
18 AWG
16 AWG
14 AWG
12 AWG
10-12
16 AWG
16 AWG
14 AWG
12 AWG
12-16
14 AWG
12 AWG
NOT RECOMMENDED
When using more than one extension cord to make up the total length, make sure each cord
contains at least the minimum wire size required.
If you are using one extension cord for more than one tool, add the nameplate amperes and use
the sum to determine the required minimum cord size.
If you are using an extension cord outdoors, make sure it is marked with the suffix W-A (Win
Canada) to indicate it is acceptable for outdoor use.
Make sure your extension cord is properly wired and in good electrical condition. Always replace
a damaged extension cord or have it repaired by a qualified electrician before using it.
Protect your extension cords from sharp objects, excessive heat, and damp or wet areas.

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Main Parts of Breaker Hammer Kit with Cart
Subassembly
Gear Box
Aluminum Head
Handle
Switch
Chisel
Mobile Cart

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Assembly Instructions
⚠WARNING
Unplug the demolition hammer.
Always wear gloves when changing accessories. Skin may become exposed to extreme heat
during operation.
If the chisel doesn’t slide in easily, apply grease to the loading end of it.
Assembling the Bit without a Shoulder (with groove)
1. Extend lock part 2 to a 150° position and insert bit 1 into holder 3.
2. Extend lock part 2 by it pulling back. Pull bit 1 to be sure it is locked.

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Assembling a Bit with a Shoulder
1. Extend lock part 2 to a 210° position. Insert bit 1 into holder 3.
2. Extend lock part 2 to a 180° position and lock the bit.
Note: The shoulder position should be between lock part 2 and holder 3.
3. Extend lock part 2 and pull bit 1 to ensure that it was locked.
Assembling the Cart
1. Slide the wheel (11) on to the bottom support (4).
2. Insert the main poles (2) into the connecting bar (5) and add the plastic feet (6).

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3. Slide the hand holder (1) to the main poles (2) and attach the side poles (3) to the clamp piece
(16).
Before Each Use
⚠WARNING
Be sure the bit is secured in place before operation.
When drilling or screwing into walls, ceilings, etc., make sure beforehand that you will not damage
any hidden electric cables. During this work you should not touch any metal parts of the machine;
only touch the machine by the plastic housing.
Be sure no one is below you when using the hammer in high locations.
Always remove the plug from the power source before installing or removing a bit or accessory
from the chuck.
Operating Instructions
⚠WARNING
To reduce the risk of injury, always wear eye protection
Wear ear protection when using the hammer. Exposure to noise can cause hearing loss.
Wear heavy duty anti-vibration gloves.
Be sure the bit is secured in place before operation.
Hold power tools by insulated gripping surfaces, when performing an operation where the cutting
tool may contact hidden wiring or its own cord.
Always be sure you have a firm footing.
Hold the hammer firmly with both hands.

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Do not point the hammer at anyone in the area when operating. The bit could fly out and seriously
injure someone.
Burn hazard. Do not touch the bit or parts close to the bit immediately after operation; they will be
extremely hot.
Use only well-sharpened bits that are in good condition and appropriate to task.
To prevent the bit from jamming, keep the motor running when pulling the bit out of a completed
hole.
Switch Operation
To turn the switch ON, press the 1 button.
To turn the switch OFF, release the 2 button.
Note: Sometimes the demolition hammer does not begin striking even when the motor is running
because the oil inside has becomes too thick. If the demolition hammer is used at a low temperature,
or it is used after a long idle time, it needs to run for a little over 5 minutes to warm up.
Grease and Oil Filling
1. Using a 12mm Hex head wrench (NOT included), loosen the 4 screws between the aluminum
head and the gear box.

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2. Disassemble the aluminum head, cylinder, and piston.
3. Clean the inside of aluminum head. It must be free of metal chips and granular dust. Also, clean
the piston and the cylinder.
Note on Cleaning: Clean both the inside and outside of the cylinder, especially the inside. It must
be free of metal chips and granular dust. If necessary, use gasoline to clean. Clean the surface of
the piston. If necessary, disassemble the O-ring and clean the piston with gasoline. At the same
time, check the condition of the O-ring. If the outside diameter is less than the piston, replace the
O-ring (#56) to ensure proper performance.

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4. Using the oil bottle (#108), fill the aluminum head with grease. Make sure the aluminum head
inside is clean before filling.
Note: There are 4 grooves in the aluminum head. Fill all 4 grooves with .53 oz. of grease, for a
total of 2.12 oz. of grease.
5. Fill the cylinder with 0.42 oz. of grease. Be sure they cylinder is clean before filling.
6. Reassembly
a) Assemble the piston into the cylinder. Make sure the O-ring has been included.
b) Assemble the cylinder into the aluminum head.

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c) Tighten the 4 inner Hex head screws being careful not to forget the spring washer. If
tightening the screws with an electric or pneumatic driver, check the torque of the screw with
a 12mm wrench (not included) to make sure it’s tightened properly.
d) If necessary, put glue on the screw and screw it in.
After Each Use
⚠WARNING
Do not remove the chisel until it has cooled.
Store the tool in dry and clean place.
Keep away from children.
Maintenance
⚠WARNING
Do not use solvents to clean the hammer.
Carbon brushes are consumable parts. When they become worn they can cause problems with
the motor. Use an auto-stop carbon brush which will stop automatically when the carbon brush is
worn, then replace the brushes.
If the supply cord of this power tool is damaged, it must be replaced and only by a qualified
service technician.

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Maintain the demolition hammer by adopting a program of conscientious repair and maintenance in
accordance with the following recommended procedures. It is recommended that the general
condition of any tool be examined before it is used. Keep your tool in good repair Keep handles dry,
clean, and free from oil and grease. The following chart is based on a normal operation schedule.
Maintenance Interval
Maintenance Point
Daily before operating
Keep the vents clear of dust and debris.
Inspect the cord and have it replaced by an authorized
technician.
After the 60 hours of use
Check the brushes and replace as needed.
If you replace the brushes, run the hammer without load for 15
minutes to seat the brushes properly.
Troubleshooting
Use the table below to troubleshoot problems before contacting service personnel or your local
dealer. If the problem continues after troubleshooting, call your local dealer for assistance.
Failure
Possible Cause
Corrective Action
Hammer will not
start.
There has been a power supply
interruption.
Check the power supply or use
another.
Cable or plug is out of order.
Have an electrician check the cable or
replace it if necessary.
Carbon brush is worn out.
Take the hammer to the service
department to change the carbon
brush.
Not enough
impact.
The hammer needs to warm up.
Allow the hammer to warm up.
The grease is worn out.
Add the grease.
Not enough
power.
The hammer does not function
correctly.
Adjust the speed control to correct
position.

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Hammer Parts Diagram

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Hammer Parts List
Reference
Part Description
Quantity
1
Housing Assembly
1
2
Side Cover
1
3
Hex Socket Bolt M10×35
4
4
Ø10 Flat Washer
14
5
Brush Cap
2
6
Carbon Brush
2
7
Brush Holder
2
8
Insulation Washer
2
9
Cap Rubber
2
10
Fan Cover
1
11
Ø6×Ø10.5 Flat Washer
6
12
Hex Socket Bolt M6×20
8
13
Ø32 Urethane Washer
1
14
Ball Bearing
1
14A
Ball Bearing 6201 2Rs C3
1
15
Stator Assembly
1
17
Coil
1
18
Stator 110-120V
1
19
Ø5 Flat Washer
2
20
Tapping Screw St4.8×85
2
21
Armature 110-120V
1
22
Inner Cover
1
22A
O-Ring Ø143×Ø2
1
23
Hex Socket Bolt M10×30
2
24
Ball Bearing 6203 2Rs C3
1
25
Bearing Bracket
1
26
Hex Socket Bolt M5×12
6
27
Needle Bearing Bk1312
1
28
Counter Gear
1
29
6201 2Rs C3 Bearing Cover
1
30
Gear Cover
1
31
Secondary Handle
1
31A
Secondary Handle Steel Bushing
4
34
Hex Socket Bolt M8×30
4
35
Hex Socket Bolt M10×55
4
36
Ball Bearing 6204 2Rz/Zzc2
1
37
Big Gear Partition Washer
1
38
Final Gear
1
39
Distance Ring
1
40
Pin Ø8×14
2
41
Ball Bearing 6305 RS
1
42
Oil Seal Ring Ø34×Ø48×5
1
43
Bearing Cover
1
44
Key 4×18
2
45
Crank Shaft
1
46
Crank Shaft Ring
1
47
O Ring Ø37×Ø2
1
48
Oil Tank Cover
1
49
Hex Socket Bolt M10×1.25×35
1
50
Crank Washer
1
51
Needle Bearing Nk2220
1

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Reference
Part Description
Quantity
52
Connecting Rod Assembly
1
53
Piston Pin
1
54
Y-Type Sealing Ring Ø45.7×Ø55.2×7
1
55
Piston
1
56
O-Ring Ø46×Ø5.3
1
57
Ram
1
58
O-Ring Ø82×Ø2
1
59
Hex Socket Bolt M10×45 (12.9)
4
60
Aluminum Housing
1
61
Washer
1
61A
Protective Support for Urethane Ring
1
62
Big Urethane Ring
1
63
Mouth
1
65
Locking Ring
1
66
Small Urethane Ring
1
67
Shank Sleeve
1
68
Y-Type Sealing Ring Ø46.2xØ33x6
1
69
O-Ring Ø78×Ø3
1
70
Impact Hammer
1
71
O-Ring Ø55×Ø5.3
1
72
O-Ring Ø90×Ø2
1
73
Hex Socket Bolt M14×40 (12.9)
4
74
Chisel Chuck
1
75
Lock Lever Spring Cap
2
76
Needle Roller
2
77
Lock Lever Spring
2
78
Lock Lever Ring
2
79
Lock Lever Axle
1
80
Main Handle Cover
1
81
Trigger Spring
1
82
Trigger
1
86
Main Handle
1
88
Wire Cover
1
89
Screw St4.2×18
6
90
Hex Socket Bolt M6×15
4
91
Ø6×Ø18 Flat Washer
2
92
Handle Support
1
93
Ø6 Spring Washer
2
94
Capacitor 0.33μf
1
95
Rivet
2
96
Switch
1
97
Cord Clip
1
98
Spring Pole
4
99
Cord Armor
1
100
Cord
1
101
5Mm Hex Key
1
102
6Mm Hex Key
1
103
8Mm Hex Key
1
104
12Mm Hex Key
1
105
Wrench for Tank Cover
1
108
Oil Bottle
1
109
Fan Guide
1
110
Spring Column Pin Ø8×40
2