Huskie Tools HH1500 Service Manual Download Page 2 | Manualshive

Page: 2 / 60

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2

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 (N

2

) 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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Summary of Contents for HH1500

Page 1: ...1 HUSKIE HYDRAULIC HAMMERS SERVICE MANUAL HH1500 HH2000 HH3600 HH4500 HH5800 HH8000...

Page 2: ...derwater 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 Insp...

Page 3: ...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 outrig...

Page 4: ...r 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 hi...

Page 5: ...ool 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...

Page 6: ...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...

Page 7: ...ECTING 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...

Page 8: ...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 hamm...

Page 9: ...water 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...

Page 10: ...ove 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 an...

Page 11: ...750 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 re...

Page 12: ...hould 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 hyd...

Page 13: ...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 10pt 14 30 1 Crow Foot 36 2000 36 50...

Page 14: ...600 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 G...

Page 15: ...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 pa...

Page 16: ...y 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 cyli...

Page 17: ...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 g...

Page 18: ...upport 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 sh...

Page 19: ...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 pol...

Page 20: ...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 pla...

Page 21: ...cap bushing a Measure shank and front cap bushings and refer to Table 8 page 23 and Table 9 page 24 b Remove bushing set pin and bushing spring pin using a hammer and drive pin c The front cap bushing...

Page 22: ...l a new shank bushing after greasing As bushings are a press or interference fit heating of the front cap or cooling of the bushing will ease installation of the bushing f Install the bushing set pin...

Page 23: ...en the tool and the shank bushing exceeds 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 Approx...

Page 24: ...on 1 Lubricate the U packing O ring piston cylinder and main valve with hydraulic oil before assembly 2 Place cylinder sleeve on the piston 3 Insert the piston fully into the cylinder to its bottom po...

Page 25: ...9 Refill the hammer with Nitrogen N2 gas Refer to pages 15 and 16 Make sure that the piston is positioned at the lower end of its stroke before charging The piston and the cylinder may be damaged dur...

Page 26: ...s kg 1400 636 2100 955 3200 1455 4200 1909 5400 2455 6800 3091 Total length inch mm 70 176 78 199 90 228 98 250 105 266 116 294 Tool diameter inch mm 4 0 100 4 5 115 5 3 135 5 7 140 6 1 155 6 5 165 Ap...

Page 27: ...type wheels Two grit wheels were used 240 for Heavy Polish 360 for Finishing Figure 19 Rotate piston and polish with brushing motion of grinder Polish total area before changing to fine grit for fini...

Page 28: ...Repair pump Oil temperature is too high exceeds 180 F or 80 C Check oil cooler Main valve is damaged Replace damaged main valve Decreased oil flow Avoid simultaneous axis movement Auto shut off in op...

Page 29: ...re installation hammer disassembly not required HH150 HH1000 hour HH1500 HH8000 1 hour Shank bushing Includes complete disassembly removal of both bushing and re assembly HH150 HH1000 3 hours HH1500...

Page 30: ...its published design capacity specifications or recommended applications The Manufacturer will authorize the return of defective components to the Manufacturers warehouse or location specified by the...

Page 31: ...and Using the Warranty Claim Form Fill out all items as completely as possible Take note of 5 below In the section titled DESCRIPTION OF FAILURE describe the failure as clearly as possible along with...

Page 32: ...f a part is particularly heavy please contact us for further information 8 Warranty Part Freight Costs IPC Industries Inc will cover inbound when requested by IPC and outbound freight for warranted pa...

Page 33: ...33 9 PARTS LIST AND ILLUSTRATIONS HH1500 HH2000 HH3600 HH4500 HH5800 HH8000...

Page 34: ...092B 1 26 Valve Cap 3J01 2120023 1 27 Valve Cap Bolt 3J01 C4009B 4 28 Valve Box Set Bolt 3H01 B48138 6 29 Back Cap 3J01 2120031 1 30 Back Cap O Ring Seal Kit 1 31 Front Cap 3J01 2120041 1 32 Front Cap...

Page 35: ...35 Effective 07 05 HH1500 HAMMER...

Page 36: ...4 Bracket Bolt 4 Assembly of Item 3 4 Washer 5 Assembly of Item 3 8 Nut 6 3J01 212504 2 Support Pipe 7 3H01 TC2000B 10 Top Cap Bolt 8 Assembly of item 7 10 Top Cap Washer 9 Assembly of item 7 10 Top...

Page 37: ...37...

Page 38: ...1 30 Shank Bushing 3H01 150042 1 31 Front Cap Bushing 3H01 150043 1 32 Bushing Set Pin 3H01 150044 3 33 Bushing Spring Pin 3H01 S40108 6 34 Nipple PF 3 4in 1 1 16in UN 3Z03 N00002 2 35 O Ring 1BG 30...

Page 39: ...39 HH2000 HAMMER UP TO S N 2K031 SOLD BEFORE 9 96 Effective 07 05...

Page 40: ...O Ring 3H01 09044W 1 33 Mode Valve O Ring 3H01 09036W 1 34 Mode Valve Set Bolt 3H01 B32068 4 35 Mode Valve Lock Bolt 3H01 B24040 1 36 Spring Washer 3H01 SW0008 1 37 Locater Pin 3Z01 PN0510 3 38 Stop...

Page 41: ...41 Effective 07 05 HH2000 HAMMER S N 3K001 UP SOLD AFTER 10 96...

Page 42: ...98 2 Support Pipe Top 6 3H01 215505 262 2 Support Pipe Middle NI 3H01 215506 162 2 Support Pipe Bottom 7 3H01 TC2000B 10 Top Cap Bolt 8 Assembly of Item 8 10 Top Cap Washer 9 Assembly of Item 8 10 Top...

Page 43: ...43...

Page 44: ...O Ring 3J01 09056W 1 33 Front Cap 3J01 2210041 2 1 34 Front Cap Plug 3Z01 FP0038 1 35 Shank Bushing 3J01 2210042 1 36 Front Cap Bushing 3J01 210043 1 37 Bushing Set Pin 3J01 210044 3 38 Bushing Sprin...

Page 45: ...45 HH 3600 2 HAMMER S N 5M1000 UP Effective 07 05...

Page 46: ...pport Pipe Top 6 3J01 221507 298 2 Support Pipe Middle NI 3J01 221506 234 4 Support Pipe Bottom 7 3J01 TC3600B 12 Top Cap Bolt 8 Assembly of Item 7 12 Top Cap Washer 9 Assembly of Item 7 12 Top Cap Nu...

Page 47: ...47...

Page 48: ...er Ring 3K01 8066P 4 32 Front Cap 3K01 2210041 1 33 Front Cap Plug 3Z01 FP0038 1 34 Shank Bushing 3K01 2270042 1 35 Front Cap Bushing 3K01 270043 1 36 Bushing Set Pin 3K01 270044 3 37 Bushing Spring P...

Page 49: ...49 HH4500 HAMMER Effective 07 05...

Page 50: ...62 2 Support Pipe Top 6 3K01 227507 334 2 Support Pipe Middle NI 3K01 227504 262 4 Support Pipe Bottom 7 3J01 TC3600B 12 Top Cap Bolt 8 Assembly of Item 7 12 Top Cap Washer 9 Assembly of Item 7 12 Top...

Page 51: ...51...

Page 52: ...der O Ring 3K01 09066W 12 32 Buffer Ring 3K01 08066P 6 33 Front Cap 3L01 2330041 1 34 Front Cap Plug 3Z01 FP0038 1 35 Shank Bushing 3L01 2330042 1 36 Front Cap Bushing 3L01 330043 1 37 Bushing Set Pin...

Page 53: ...53 HH5800 HAMMER Effective 07 05...

Page 54: ...84 2 Support Pipe Top 6 3L01 233507 364 2 Support Pipe Middle NI 3L01 233504 284 4 Support Pipe Bottom 7 3J01 TC3600B 12 Top Cap Bolt 8 Assembly of Item 7 12 Top Cap Washer 9 Assembly of Item 7 12 Top...

Page 55: ...55...

Page 56: ...r O Ring 3J01 09076W 10 32 Buffer Ring 3J01 08076P 5 33 Front Cap 3M01 2400041 1 34 Front Cap Plug 3Z01 FP0038 1 35 Shank Bushing 3M01 2400042 1 36 Front Cap Bushing 3M01 2400043 1 37 Bushing Set Pin...

Page 57: ...57 HH8000 HAMMER Effective 07 05...

Page 58: ...04 2 Support Pipe Top 6 3M01 240507 384 2 Support Pipe Middle NI 3M01 240504 304 4 Support Pipe Bottom 7 3M01 TC8000B 12 Top Cap Bolt 8 Assembly of Item 7 12 Top Cap Washer 9 Assembly of Item 7 12 Top...

Page 59: ...59 NOTES...

Page 60: ...60 HYDRAULIC HAMMERS IPC INDUSTRIES INC 194 N Brandon Dr Glendale Heights IL 60139 TOLL FREE 800 487 5431 Phone 630 893 5558 Fax 630 790 3751 rev 7 05...

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