HUSKIE
HYDRAULIC
HAMMERS
SERVICE
MANUAL
HH1500
HH2000
HH3600
HH4500
HH5800
HH8000
1
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 Inspect ion 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
2
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.
3
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 sym bol may appear on
the hammer or in the text of
this manual. It is used to alert
the operator of an ac ti on that
can place him/her or others in
a life threatening sit uation.
CAUTION
This symbol appears in the
text of this manual to identify
an act ion or condition that
can result in damage to the
hammer or other equipment.
4
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.
5
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 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
Pressure
receiving
surface A
Piston
Pressure
receiving
surface B
Valve Box
Lower Chamber
High pressure
Figure 1. Principle of Operation
(Refer to Table 10.)
Main Valve
Middle Chamber
Low pressure
6
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
7
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.
8
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
9
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
10
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.
4
SLING ANGLES
NOT SMALLER THAN:
o
60
1/3
1/3 1/3
11
Figure 4. Tool Replacement
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
12
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.)
1500 36 50 54 ¾”-10pt *14 30
2000 36 50 54
3600 46 60 63
4500 46 75 71 1”-8unc *17 32
5800 46 75 85
8000 50 75 90
* Allen wrench size for the front and back cap bolts.
SIDE
RODS
(mm.)
LIFTING
EYES
(inches)
7/8”-
9unc
7/8”-
9unc
1 ¼”-
8unc
1 ½”-
6unc
*CAP
BOLTS
SET
BOLTS
(mm.)
*17 30
*17 32
*19 41
*19 41
CAP
(inches)
1”
Crow
Foot
1”
Crow
Foot
1”
Crow
Foot
1”
Crow
Foot
1”
Crow
Foot
1”
Crow
Foot
BODY
(mm.)
36
36
36
36
36
36
13
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
1 3
1
5
3
13 5
7
1
4
3
4
2
4
62
26
4
8
25
Side Rod
Back Nut.
&
Valve Box Set Bolt
(HH1500, HH2000,
HH3600)
Valve Box Set Bolt
(HH4500, HH5800,
HH8000)
Valve Cap Bolt
(HH2000 and up)
Mode Valve
Set Bolt
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.
14
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
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 N2 gas. 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 N
(N
2) Supply tank to the gas charger with the charging kit hose.
2 gas pressure regulator to the gas container. Connect the nitrogen
Figure 8. Connecting Gas Charger to
Nitrogen (N2) Supply
15
Figure 9. 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 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)
Between cylinder and
nipple (F)
Damaged or worn
U-packing
Loose nipple or damaged
O-ring or nipple
Replace seal kit
Tighten or replace nipple,
and / or O-ring
Damaged U-packing or
Between cylinder and
back cap (G)
Valve outer sleeve O-ring,
main
Replace seal kit
or
Back cap O-ring
Plug ports (H) Plugs loosen
Remove plugs and reinstall
with sealant
16
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)
Between back cap and
cylinder (C)
Defective O-ring,
damaged
Spring or gas valve
Replace gas valve
assembly
Defective back cap O-ring Replace back cap O-ring
Figure 11
17
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.
18
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.
19
Figure 13. Main Valve Box Assembly
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
HAMMER MODEL
kg lbs.
WEIGHTS
HH1500 41 90
HH2000 64 142
HH3600 101 222
HH4500 122 270
HH5800 153 338
HH8000 198 436
20
INSPECTION OF PARTS
1. Seals
Seals that are deformed, scratched, worn or aged should be replaced (see Figure 16).
It is recommended that all seals be replaced when disassembling the hammer.
Figure 16. 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 page 23.
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 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 must be torch cut at three locations (at three 120° grooves)
if it is the only bushing to be replaced. Avoid cutting into the front cap itself.
d. Any scratches in the front cap must be smoothed after bushing removal.
e. 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 of the front cap and cooling of the bushing will
help installation.
f. Insert the bushing set pin and the bushing spring pin.
BE CAREFUL OF HOT SURFACE. USE GLOVES TO PROTECT
AGAINST BURNS AND POSSIBLE SHARP EDGES.
21
5. Replacing the shank bushing
Note: Replacement of the front cap bushing is required 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 page 23 and Table 9
page 24.
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.
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
interference 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 27)
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 flap wheel with 240 grit and
finish with 360 grit. When polishing the piston or the cylinder bore, it is not necessary
to completely remove scratches (only the sharp edges) as this may remove excess
material. (See Figures 19, 20 and 21 on page 27.)
c. Main Valve and Sleeves
Main valve and sleeves cannot be polished. Replace if these parts do not slide freely
by finger pressure.
22
COMPONENT WEAR LIMITS
Parts are to be replaced if not within the wear parameters. See Table 8 and Figure 17
below, for new dimensions see Table 9 page 24.
Table 8. Component Wear Limits
COMPONENT WEAR LIMITS
Front cap
bushing
Shank bushing
Tool
Tool set pin
Front cap
Piston
When the clearance between the tool and the front cap bushing
exceeds .300 in. (8mm), a new front cap bushing is required.
(Approximately 500 hours of use).
When the clearance between the tool and the shank bushing
exceeds .160 in. (4mm), a new shank bushing is required.
(Approximately 700 hours of use).
If .120 in. (3mm) of wear in the diameter is observed, a new tool is
required. (Approximately 500 hours of use). Keep tool sharp.
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
bushing, a new front cap is required.
When indentation or serious damage on the piston surface is
observed, a new piston is required. (Approximately 2,000 hours of
use).
Figure 17. Wear Limit Points
23
Table 9. New Component Dimensions
PART HH1500 HH2000 HH3600 HH4500 HH5800 HH8000
Front Cap Bushing I.D.
Shank Bushing I.D.
Tool O.D.
101. mm.
3.967 in.
101. mm.
3.967 in.
100. mm.
3.937 in.
116. mm.
4.567 in.
116. mm.
4.567 in.
115. mm.
4.528 in.
136. mm.
5.354 in.
136. mm.
5.354 in.
135. mm.
5.315 in.
146. mm
5.748 in.
146. mm.
5.748 in.
145. mm.
5.709 in.
156. mm
6.142 in.
156. mm
6.142 in.
155. mm
6.102 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. 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 position.
a. Make sure that all seals are positioned correctly and facing the right direction.
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.
4. Install the front cap on the cylinder.
5. Insert the main valve and the outer sleeve.
6. Apply hydraulic oil into the back cap for gas seal lubrication. See Figure 18.
7. Attach the back cap to the cylinder.
Figure 18. Adding oil to the Back Cap.
HH1500 1.0 oz. or 30 cc.
HH2000 3.5 oz. or 100 cc.
HH3600 5.0 oz. or 150. cc.
HH4500 5.0 oz. or 150. cc.
HH5800 5.0 oz. or 150. cc.
HH8000 6.0 oz. or 180. cc.
166. mm
6.535 in.
166. mm
6.535 in.
165. mm
6.496 in.
24
8. Insert and tighten the four side rods together with the washer to the specified torque
(see Table 4 and Figure 5 on page 14.)
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 during gas charging by sudden movement (due
to a pressure increase) if the piston is not at the bottom of its stroke in the cylinder.
25
5. SPECIFICATIONS
Table 10. Specifications
ITEM UNIT HH1500 HH2000 HH3600 HH4500 HH5800 HH8000
Impact energy
ft-lbs.
kg-m
1500 2000 3600 4500
5800 8000
Blows per
minute
Required
oil flow
Operating
pressure
Nitrogen
gas pressure
Total weight
with tool
Total length
Tool diameter
Applicable
carrier
Carrier Relief
Valve Setting
bpm 480-550
gpm
l/min
psi
bar
psi
bar
lbs.
kg
inch
mm
inch
mm
lbs.
kg
Psi
Bar
21.3-28.7
80-108
2000-2290
140-160
140-160
10-11
1400
636
70
176
4.0
100
18000-
30000
8200-13700
2600-2900
180-200
400-650
300-500
21.3-36.7
80-138
2000-2290
140-160
140-175
10-12
2100
955
78
199
4.5
115
20000-
40000
9070-18140
2600-2900
180-200
480-630
380-500
36-55
136-207
2290-2570
160-180
160-185
11-13
3200
1455
90
228
5.3
135
36000-
58000
16330-
26310
2900-3300
200-230
480-625
350-450
40-56
151-211
2430-2710
170-190
160-185
11-13
4200
1909
98
250
5.7
140
41000-
70000
18600-
31750
2980-3550
210-250
450-560
345-430
50-63
189-238
2430-2710
170-190
160-185
11-13
5400
2455
105
266
155
55000-
90000
24950-
40820
2980-3550
210-250
Remarks:
• The hammer is to be used within the specified oil pressure, oil flow and gas pressure
parameters.
• The carrier hydraulic system relief pressure is to be set at 600 to 800 psi above the
hammer “Operating Pressure.”
• Hydraulic pressure is to be measured at the hose end of the carrier (output or pressure
hose) when disconnected from the hammer.
6.1
340-450
280-370
62-73
234-276
2430-2710
170-190
160-185
11-13
6800
3091
116
294
6.5
165
70000-
130000
31750-
58970
2980-3550
210-250
26
6. REFINISHING OF PISTONS & 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 components in this hammer are made of high quality alloy
steel and do not use chromium surface finishes which cannot be polished.
Follow the procedures in Figures 19, 20 & 21 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.
Figure 19.
Rotate piston and polish with brushing motion of
grinder.
Polish total area before changing to fine grit for
finishing.
Figure 20.
After completion of fine polishing, clean labyrinth
grooves carefully with fine needle file to remove all
burrs and rough edges.
Figure 21.
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 raised 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.
27
7. TROUBLESHOOTING DIAGNOSIS
Table 11. Troubleshooting
SYMPTOM POSSIBLE CAUSE REMEDY
Hammer
does not run
Hesitation or
erratic
operation
Slow impact
speed
Low impact
power
Couplers are not engaged Connect couplers securely
Relief valve set incorrectly
Malfunction of the hydraulic pump Repair pump
Nitrogen gas pressure is too high Adjust gas pressure
Main valve is damaged Replace main valve
Piston is damaged Repair or replace piston
Couplers are not fully engaged Connect couplers securely
Relief valve set incorrectly
Malfunction of the hydraulic pump Repair pump
Oil temperature is too high
(exceeds 180°F or 80°C)
Main valve is damaged Replace damaged main valve
Decreased oil flow Avoid simultaneous axis movement
Auto shut-off in operation, tool is
suspended
Excessive bushing wear Replace worn bushings
Piston is damaged Repair or replace piston
Nitrogen pressure is too high Adjust gas pressure
Hydraulic oil leakage into the gas
chamber
Malfunction of the hydraulic pump Repair pump
Deteriorated or contaminated oil Change oil
Nitrogen gas pressure is low Adjust gas pressure
Relief valve set incorrectly
Malfunction of the hydraulic pump Repair pump
Adjust main and secondary relief
valve
Adjust main and secondary relief
valve
Check oil cooler
Apply proper down force
Replace seal kit
Adjust main and secondary relief
valve
28
8. WARRANTY GUIDE LINES
Time based on total man-hours.
Seal kit installation (Includes testing, complete disassembly, cleaning and re-assembly)
HH100 - HH1000 = 4 hours
HH1500 - HH2000 = 6hours
HH3600 - HH4500 = 7hours
HH5800 – HH8000 = 8hours
Front cap bushing (Includes removal and re-installation, hammer disassembly not
required)
HH150 - HH1000 ½ hour
HH1500 - HH8000 1 hour
Shank bushing (Includes complete disassembly, removal of both bushing and reassembly)
HH150 - HH1000 = 3 hours
HH1500 - HH2000 = 4 hours
HH3600 – HH8000 = 5 hours
Side rod replacement only (Includes complete disassembly, removal of broken side rod
and re-assembly)
HH150 - HH1000 = 2 hours
HH1500 - HH2000 = 3 hours
HH3600 - HH8000 = 4 hours
Bracket bolt replacement
HH100 - HH1000 = ¼ hour
HH1500 - HH8000 = ½ hour
29
IPC Industries, Inc.
194 N. Brandon Dr.
Glendale Heights, IL 60139
The manufacturer warrants its Products against defects in material and workmanship. Such LIMITED
warranty shall apply to the initial Purchaser only. The BACK-CAP, MAIN BODY and FRONT CAP carry
a LIFETIME, UNLIMITED HOURS warranty. All other components (except seals and exclusions listed
below) are warranted as follows: THREE (3) YEARS, UNLIMITED HOURS. Seals are warranted for a
period of TWO (2) YEARS, UNLIMITED HOURS. All Warrantees begin from the date of sale to the
original retail end-user or the initial rental service of the hammer.
Normal wear items such as tools (moil, chisel, blunt, tamper, frost wedge and asphalt cutter), shank
bushings, tool bushings, set pins, hoses, hose adapters and accessories are specifically excluded from
any and all warrantees.
This warranty will be in effect only if:
1. The Purchaser or his agent has the Product installed and operating in accordance with the published
2. The Purchaser or his agent does not exceed the Products published design operating range for
3. The Purchaser or his agent complies with the maintenance schedule in the Operating and Service
4. The Purchaser or his agent uses replacement parts/products received from or approved by IPC
This Warranty will not cover defects/failures caused by abuse, neglect, misuse, lack of maintenance,
accident or use of the Product beyond 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 Manufacturer. The Manufacturer will determine if said components show clear
and evident proof of defective material and/or workmanship. A warranty claim will only be accepted
if accompanied by proof of purchase and received within thirty-(30)-days of the warranted defect
or failure.
The Manufacturer will, at its option, determine what, if any, defective/faulty components will be accepted
for warranty coverage. The Manufacturer will, at its option, determine whether to repair or replace
components deemed faulty because of defective materials or workmanship. The manufacturer will not
be accountable for mileage, travel time, travel costs, and/or any freight costs incurred to facilitate the
needed replacement or repairs beyond those stated within the document (attached) titled “Warranty
Policy Statement”. The Manufacturer shall not be liable for lost rental income, machine availability or
failure of components not supplied or installed by Manufacturer.
Manufacturers specifications and guidelines.
hydraulic flow, pressure or recommended carrier size.
Manual supplied with each Product.
Industries, Inc.
This Warranty is exclusive and in lieu of all other representations and warranties, expressed or implied. The Manufacturer
expressly disclaims and excludes any implied warranty of merchantability or fitness for a particular purpose. In no event shall
the Purchaser or his agent be entitled to any consequential damages of any kind, whether arising out of breach of contract,
warranty (including negligence and strict liability) or other theories of law, with respect to products sold or services rendered
by the Manufacturer, or any undertakings, acts or omissions relating thereto. The Manufacturer reserves the right to change
these policies as conditions dictate. July 1, 2005
LIMITED WARRANTY FOR HYDRAULIC HAMMERS
LIMITED WARRANTY
ITEMS EXCLUDED FROM THIS WARRANTY
WARRANTY LIMITATIONS
WARRANTY DISCLAIMER
30
Warranty Policy Statement
This document explains IPC Industries, Inc. specific policies concerning submission and
reconciliation of warranty claims. This document is in addition to and a part of the IPC
Industries, Inc. Limited Lifetime Warranty For Hydraulic Hammers that accompanies all
new hydraulic hammer products.
1. Warranty Registration Card
Each hydraulic hammer is shipped with a Warranty Registration Card. In order to
properly process your claim this card must be on file at IPC. This card not only
registers the product for warranty purposes it keeps IPC informed so we can contact
you concerning product updates, parts specials and service bulletins.
2. Ordering Warranty Replacement Parts
parts ordered from IPC will, without exception, be invoiced and shipped freight
All
collect or prepaid with freight on the invoice. Warranted costs for freight will be
resolved on the Warranty Claim form you will be returning with the defective part.
3. Filing a Claim
Every IPC product shipped includes two service manuals and a package containing a
Warranty Claim form and a Delivery Report form for pre-delivery. The Warranty
Claim form is located in the envelope labeled ”Distributor Information”.
4. Labor Reimbursement 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
operating conditions of the hammer and carrier as best you can.
In order for IPC to consider “DEALER LABOR” and “DEALER MILEAGE” in your claim,
your published labor and mileage rates must be on file with IPC or must accompany
the claim form. Please see (8.) below for an explanation of “FREIGHT (PAID)”.
In no event shall IPC Industries, Inc. warrant more than one (1) hour travel time
(each way) or eight (8) hours of labor for a hammer repair.
Please refer to the service manual for easy to follow disassembly and assembly
procedures. IPC Industries, Inc. would be pleased to provide you with no-charge
“on-site” service training covering all aspects of hammer service.
5. Warranty Submission Time Limit
No more than thirty- (30)-days can elapse between the “DATE OF FAILURE” and
“
DATE OF CLAIM”. Claims submitted beyond thirty- (30)-days from the “DATE OF
FAILURE” will be denied.
IPC’s purpose is to provide the best possible product reliability and customer service.
Our best sources for product reliability information and failure analysis are used/failed
parts from the field. A part that has been exposed to weeks of weather tells us little or
nothing. If we can’t tell why or where a part failed because of rust or damage we can’t
warranty the part.
31
6. Requesting a Returned Goods Authorization (RGA)
Before returning a suspected warranty part, call IPC at (800) 487-5431 and our customer
service representatives will provide you with a RGA number. Please have the description
of the part(s) at hand and the method by which you will be returning the part prepaid to
IPC. At that time it may be determined that you need not return the part and IPC may, at
its sole discretion, warrant the part without examination. Do not scrap any parts under
warranty consideration unless authorized by IPC or credit is received.
7. Returning a Warranted Part
All returned parts must be shipped prepaid (not collect) and include the RGA number
prominently displayed on the shipping label. If 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 parts under the following circumstances only:
• IPC will cover surface freight costs for parts judged to be defective in materials
or workmanship.
• The cost of shipping warranted parts via an expedited surface or air shipment will
be paid as follows: IPC will pay the difference between standard surface freight
and air or expedited surface freight, whichever is less.
9. IPC Claims Processing
IPC will respond to the dealer submitting the claim within 30 days as follows:
• A credit for an approved claim which contains the required information or,
• A request for further information, for return of the parts for analysis (refer to 6.
and 7. above)
or,
• Notification of a denied claim with an explanation of why the claim was denied.
32
9. PARTS LIST AND ILLUSTRATIONS
HH1500
HH2000
HH3600
HH4500
HH5800
HH8000
33
HH1500 HAMMER
ITEM NAME NUMBER QTY.
1 Cylinder 3J01-212001 1
2 Cylinder O-Ring* Seal Kit 2
3 Cylinder O-Ring* Seal Kit 2
4 Cylinder O-Ring* Seal Kit 1
5 Cylinder Sleeve 3J01-212002 1
6 Cylinder Sleeve O-Ring* Seal Kit 2
7 Quad Ring* Seal Kit 1
8 Back Up Ring* Seal Kit 1
9 Step Seal* Seal Kit 1
10 Step Seal O-Ring* Seal Kit 1
11 U-Packing* Seal Kit 2
12 Dust Seal* Seal Kit 1
13 Drain Plug 3Z01-DP0014 1
14 Choke Plug #1 3J01-2120095 1
15 Choke O-Ring* 3Z01-21209040B 1
16 Plug 3J01-2120081 1
17 Plug O-Ring* 3Z01-21209056W 1
18 Choke Plug #2 3J01-2120082 1
19 Plug O-Ring* 3Z01-21209040B 1
20 Piston 3J01-2120011 1
21 Valve Box 3J01-2120021 1
22 Main Valve 3F01-2100622 1
23 Main Valve Inner Sleeve 3E01-2060623 1
24 Main Valve Outer Sleeve 3E01-2060624 1
25 Main Valve O-Ring* 3E01-09092B 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 Plug 3Z01-FP0038 1
33 Shank Bushing 3J01-2120042 1
34 Front Cap Bushing 3J01-2120043 1
35 Bushing Set Pin 3J01-2120044 3
36 Bushing Spring Pin 3H01-S40108 6
37 Nipple PF—3/4in.—1.1/16in. UN 3F03-N00002 2
38 O-Ring 1BG-30 Ass’y of item 37 2
39 Side Rod Assembly 3J01-2120051 4
40 Side Rod Front Nut Ass’y of item 39 4
41 Side Rod Back Nut Ass’y of item 39 4
42 Side Rod Washer Ass’y of item 39 4
43 Grease Nipple 3Z01-GN0018 1
44 Tool Set Pin 3J01-2120061 1
45 Tool Spring Pin 3H01-S40248 2
46 Tool Moil (Chisel, Blunt) 3J01-212P(Fx, E) 1
NI Seal Kit 3J01-212SK 1
NI Gas Charger 3Z01-202GC 1
47 Gas Valve Assembly (Includes item # 48) 3Z01-G00001 1
48 Gas Valve Cap with O-Ring 3Z01-G00004 1
*Included in seal kit. NI denotes not illustrated. Effective 07/05
34
HH1500 HAMMER
Effective 07/05
35
HH1500 HAMMER
BRACKET ASSEMBLY PARTS LIST
ITEM
1. 3J01-212501 1 Hammer Bracket (R)*
2. ----------------- 1 Hammer Bracket (L)*
3. 3H01-215502 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 Cap Nut
10. Per Carrier Model 1 Top Cap
*Sold as matched set w/ hardware Effective 07/05
Prices subject to change without notice.
36
PART NO.
MODEL HH1500
QTY DESCRIPTION
37
HH2000 HAMMER UP TO S/N 2K031 SOLD BEFORE 9/96
ITEM NAME NUMBER QTY.
1 Cylinder 3H01-2150001 1
2 Cylinder O-Ring* 3H01-09098B 2
3 Cylinder O-Ring* 3H01-09072B 3
4 Cylinder Sleeve 3H01-2150002 1
5 Cylinder Sleeve O-Ring* 3H01-09288W 3
6 Gas U-Packing* 3H01-U15000G 1
7 U-Packing* 3H01-U15000I 2
8 U-Packing with Back Up Ring* 3H01-15000H 2
9 Dust Seal* 3H01-15000D 1
10 Drain Plug 3Z01-DP0014 1
11 Piston 3H01-2150011 1
12 Valve Box 3H01-2150021 1
13 Main Valve 3H01-2150022 1
14 Upper Valve Cap 3H01-2150023 1
15 Valve Cap O-Ring* 3H01-07108B 1
16 Back Up Ring* 3H01-08108G 1
17 Valve Cap O-Ring* 3H01-051180 1
18 Lower Valve Cap 3H01-2150025 1
19 Locater Pin 3Z01-PN0510 1
20 Box Sleeve 3H01-2150026 1
21 O-Ring* 3H01-07118B 1
22 Back Up Ring* 3H01-08118G 1
23 Valve Box Set Bolt 3H01-B48138 6
24 Valve Cap Bolt 3H01-B44098 10
25 Valve Box O-Ring* 3H01-09040B 2
26 Back Cap 3H01-21580031 1
27 Back Cap O-Ring* 3H01-07358A 1
28 Front Cap 3H01-2150041 1
29 Front Cap Plug 3Z01-FP0038 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 3Z03-07068B 2
36 Side Rod Assembly 3H01-150051 4
37 Side Rod Front Nut 3H01-150052 4
38 Side Rod Back Nut 3H01-150053 4
39 Side Rod Washer 3H01-150054 4
40 Grease Nipple 3Z01-GN0018 1
41 Tool Set Pin 3H01-150061 1
42 Tool Spring Pin 3H01-S40248 2
43 Tool Moil (Chisel, Blunt) 3H01-215P(Fx, E) 1
44 Mode Valve Body 3H01-2210027 1
45 Mode Valve 3H01-2210028 1
46 Mode Valve O-Ring* 3H01-09044W 1
47 Mode Valve O-Ring* 3H01-09036W 1
48 Mode Valve Set Bolt 3H01-B32068 4
49 Mode Valve Lock Bolt 3H01-B24040 1
50 Spring Washer 3H01-SW0008 1
51 Locater Pin 3H01-PN0308 3
52 Stop Ring 3H01-SL10018 1
NI Seal Kit 3H01-215SK 1
NI Gas Charger 3Z01-202GC 1
NI Mode Valve Assembly 3H01-221MVA 1
NI Valve Box Assembly 3H01-215VBA 1
53 Gas Valve Assembly (Includes item # 54) 3Z01-G00001 1
54 Gas Valve Cap with O-Ring 3Z01-G00004 1
*Included in seal kit only. NI denotes not illustrated. Effective 07/05
38
HH2000 HAMMER UP TO S/N 2K031 SOLD BEFORE 9/96
39
Effective 07/05
HH2000 HAMMER S/N 3K001 & UP SOLD AFTER 10/96
ITEM NAME NUMBER QTY.
1 Cylinder 3H01-2150001 1
2 Cylinder O-Ring* 3H01-09098B 2
3 Cylinder O-Ring* 3H01-09072B 3
4 Plug 3J01-2210081 5
5 Cylinder O-Ring* 3J01-09056W 10
6 Buffer Ring* 3H01-08056P 5
7 Cylinder Sleeve 3H01-2150002 1
8 Cylinder Sleeve O-Ring* 3H01-09288W 2
9 Quad Ring* 3H01-QD215000 1
10 Back Up Ring* 3H01-BU215000 1
11 Step Seal* 3H01-ST215000 2
12 Step Seal O-Ring* 3H01-OR215000 2
13 U-Packing* 3H01-U15000I 1
14 U-Packing* 3H01-15000H 1
15 Dust Seal* 3H01-15000D 1
16 Piston 3H01-2150011 1
17 Valve Box 3H01-2150021 1
18 Main Valve 3H01-2150022 1
19 Upper Valve Cap 3H01-2150023 1
20 Valve Cap O-Ring* 3H01-07108B 1
21 Back Up Ring* 3H01-08108G 1
22 Valve Cap O-Ring* 3H01-051180 1
23 Lower Valve Cap 3H01-2150025 1
24 Locater Pin 3Z01-PN0510 1
25 Box Sleeve 3H01-2150026 1
26 Box Sleeve O-Ring* 3H01-07118B 2
27 Back Up Ring* 3H01-08118G 1
28 Valve Cap Bolt 3H01-B44098 10
29 Valve Box Set Bolt 3H01-B48138 6
30 Mode Valve Body 3H01-2210027 1
31 Mode Valve 3H01-2210028 1
32 Mode Valve 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 Ring 3H01-SL0018 1
39 Valve Box O-Ring* 3H01-09040B 2
40 Back Cap 3H01-21580031 1
41 Back Cap O-Ring* 3H01-07358A 1
42 Gas Valve Assembly (Includes item # 43) 3Z01-G00001 1
43 Gas Valve Cap with O-Ring 3Z01-G00004 1
44 Front Cap 3H01-2150041 1
45 Front Cap Plug 3Z01-FP0038 1
46 Shank Bushing 3H01-150042 1
47 Front Bushing 3H01-150043 1
48 Bushing Set Pin 3H01-150044 3
49 Bushing Spring Pin 3H01-S40108 6
50 Nipple PF—3/4in.—1.1/16in. UN 3Z03-N00002 2
51 O-Ring 1BG-30 3Z03-07068B 2
52 Side Rod Assembly 3H01-150051 4
53 Side Rod Front Nut 3H01-150052 4
54 Side Rod Back Nut 3H01-150053 4
55 Side Rod Washer 3H01-150054 4
56 Grease Nipple 3Z01-GN0018 1
57 Tool Set Pin 3H01-150061 1
58 Tool Spring Pin 3H01-S40248 1
59 Tool Moil (Chisel, Blunt) 3H01-215P(Fx, E) 1
NI Seal Kit 3H01-215SKX 1
NI Gas Charger 3Z01-202GC 1
NI Mode Valve Assembly 3H01-221MVA 1
NI Valve Box Assembly 3H01-215VBA 1
*Included in seal kit only. NI denotes not illustrated. Effective 07/05
40
HH2000 HAMMER S/N 3K001 & UP SOLD AFTER 10/96
41
Effective 07/05
HH2000 HAMMER
BRACKET ASSEMBLY PARTS LIST
ITEM
PART NO.
QTY DESCRIPTION
MODEL HH2000
1. 3H01-215501 1 Hammer Bracket (R)*
2. ----------------- 1 Hammer Bracket (L)*
3. 3H01-215502 6 Bracket Bolt
4. Assembly of Item 3 6 Washer
5. Assembly of Item 3 12 Nut
NI 3H01-215504-198 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 Cap Nut
10. 3H01-215505 4 Cushion Rubber
11. Assembly of Item 10 4 Screw
12. Per Carrier Model 1 Top Cap
*Sold as matched set w/ hardware. NI denotes not illustrated. Effective 07/05
Prices subject to change without notice.
42
43
HH3600-2 HAMMER S/N 5M1000 & UP
ITEM NAME NUMBER QTY.
1 Cylinder 3J01-B2210001-2 1
2 Cylinder O-Ring* 3J01-09108B 3
3 Cylinder O-Ring* 3H01-09072B 4
4 Cylinder Sleeve 3J01-2210002-2 1
5 Cylinder Sleeve O-Ring* 3J01-07328W 2
6 Step Seal with O-Ring* 3J01-170561 2
7 Quad Ring* 3J01-QD221000 1
8 Back Up Ring* 3J01-170563 2
9 U-Packing* 3J01-U21000I 2
10 Dust Seal* 3J01-D21000D 1
11 Piston 3J01-2210011-2 1
12 Valve Box 3J01-2210021-2 1
13 Main Valve 3J01-2210022-2 1
14 Upper Valve Cap 3J01-2210023 1
15 Valve Cap O-Ring* 3H01-07118B 1
16 Back Up Ring* 3H01-08118G 1
17 Valve Cap O-Ring* 3J01-051280 1
18 Lower Valve Cap 3J01-2210025-2 1
19 Locater Pin 3Z01-PN0510 1
20 Box Sleeve 3J01-2210026-2 1
21 Box Sleeve O-Ring* 3J01-07128B 2
22 Back Up Ring* 3J01-08128G 1
23 Valve Box Set Bolt 3J01-B52146 6
24 Valve Cap Bolt 3J01-B52128 10
25 Valve Box O-Ring* 3H01-09040B 2
26 Back Cap 3J01-2210031 1
27 Back Cap O-Ring* 3J01-07398A 1
28 Plug 3J01-240081 2
29 Cylinder O-Ring* 3J01-09076W 4
30 Buffer Ring* 3J01-08076P 2
31 Valve Box Plug 3J01-2212095 1
32 Valve Box 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 Spring Pin 3J01-S46128 6
39 Nipple PF—3/4in.—1.1/16in. UN 3J01-N00003 2
40 O Ring 3J01-07078B 2
41 Side Rod Assembly 3J01-210051 4
42 Side Rod Front Nut 3J01-210052 4
43 Side Rod Back Nut 3J01-210053 4
44 Side Rod Washer 3J01-210054 4
45 Grease Nipple 3Z01-GN0018 1
46 Tool Stopper Pin 3J01-221091 2
47 Tool Spring Pin 3J01-S46128 2
48 Tool Set Pin 3J01-210061 1
49 Tool Moil (Chisel, Blunt) 3J01-221P(Fx, E) 1
50 Mode Valve Body 3H01-2210027 1
51 Mode Valve 3H01-2210028 1
52 Mode Valve O-Ring* 3H01-09044W 1
53 Mode Valve O-Ring* 3H01-09036W 1
54 Mode Valve Set Bolt 3H01-B32068 4
55 Mode Valve Lock Bolt 3H01-B24040 1
56 Spring Washer 3H01-SW0008 1
57 Locater Pin 3H01-PN0308 3
58 Stop Ring 3H01-SL0018 1
NI Mode Valve Assembly 3H01-221MVA 1
NI Valve Box Assembly 3J01-221VBA 1
NI Seal Kit 3J01-221SK 1
NI Gas Charger 3Z01-202GC 1
59 Gas Valve Assembly (Includes item # 60) 3Z01-G00001 1
60 Gas Valve Cap with O-Ring 3Z01-G00004 1
*Included in seal kit only. NI denotes not illustrated. Effective 07/05
44
HH 3600-2 HAMMER S/N: 5M1000 & UP
45
Effective 07/05
HH3600-2 HAMMER S/N 5M1000 & UP
BRACKET ASSEMBLY PARTS LIST
ITEM
1. 3J01-221501 1 Hammer Bracket (R)*
2. ----------------- 1 Hammer Bracket (L)*
3. 3J01-221502 8 Bracket Bolt
4. Assembly of Item 3 8 Washer
5. Assembly of Item 3 16 Nut
NI 3J01-221504-226 2 Support 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 Nut
10. 3J01-221505 4 Cushion Rubber
11. Assembly of Item 10 4 Screw
12. Per Carrier Model 1 Top Cap
*Sold as matched set w/ hardware. NI denotes not illustrated. Effective 07/05
Prices subject to change without notice
PART NO.
MODEL HH3600-2
QTY DESCRIPTION
46
47
HH4500 HAMMER
ITEM NAME NUMBER QTY.
1 Cylinder 3K01-2270001 1
2 Cylinder O-Ring* 3K01-09128B 2
3 Cylinder O-Ring* 3H01-09072B 3
4 Cylinder Sleeve 3K01-2270002 1
5 Cylinder Sleeve O-Ring* 3K01-07348W 2
6 Quad Ring* 3K01-170570 1
7 Back Up Ring* 3K01-170573 2
8 U-Packing* 3K01-U27000I 1
9 U-Packing with Back Up Ring* 3K01-U27000H 1
10 Dust Seal* 3K01-D27000D 1
11 Step Seal with O-Ring* 3K01-170571 2
12 Piston 3K01-2270011 1
13 Valve Box 3K01-2270021 1
14 Main Valve 3K01-2270022 1
15 Upper Valve Cap 3K01-2270023 1
16 Valve Cap O-Ring* 3H01-07118B 1
17 Back Up Ring* 3H01-08118G 1
18 Valve Cap O-Ring* 3J01-051280 1
19 Lower Valve Cap 3K01-2270025 1
20 Locater Pin 3Z01-PN0510 1
21 Box Sleeve 3K01-2270026 1
22 Box Sleeve O-Ring* 3K01-07138B 2
23 Back Up Ring* 3K01-08138G 1
24 Valve Box Set Bolt 3J01-B52146 8
25 Valve Cap Bolt 3J01-B52128 10
26 Valve Box O-Ring* 3H01-09040B 2
27 Back Cap 3K01-2270031 1
28 Back Cap O-Ring* 3K01-09418A 1
29 Plug 3K01-22182 4
30 Cylinder O-Ring* 3K01-9066W 8
31 Buffer 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 Pin 3J01-S46128 6
38 Nipple 3J03-N00003 2
39 O-Ring 3J03-07078B 2
40 Side Rod Assembly 3K01-270051 4
41 Side Rod Front Nut 3K01-270052 4
42 Side Rod Back Nut 3K01-270053 4
43 Side Rod Washer 3K01-270054 4
44 Grease Nipple 3Z01-GN0018 1
45 Tool Set Pin 3K01-270061 1
46 Tool Spring Pin 3J01-S46128 2
47 Tool Stopper Pin 3K01-227091 2
48 Tool Moil (Chisel, Blunt) 3K01-227P(Fx, E) 1
49 Mode Valve Body 3H01-2210027 1
50 Mode Valve 3H01-2210028 1
51 Mode Valve O-Ring* 3H01-09044W 1
52 Mode Valve O-Ring* 3H01-09036W 1
53 Mode Valve Set Bolt 3H01-B32068 4
54 Mode Valve Lock Bolt 3H01-B24040 1
55 Spring Washer 3H01-SW0008 1
56 Locater Pin 3H01-PN0308 3
57 Stop Ring 3H01-SL0018 1
NI Mode Valve Assembly 3H01-221MVA 1
NI Valve Box Assembly 3K01-227VBA 1
NI Seal Kit 3K01-227SK 1
NI Gas Charger 3Z01-202GC 1
58 Gas Valve Assembly (Includes item # 59) 3Z01-G00001 1
59 Gas Valve Cap with O-Ring 3Z01-G00004 1
*Included in seal kit only. NI denotes not illustrated. Effective 07/05
48
HH4500 HAMMER
49
Effective 07/05
HH4500 HAMMER
BRACKET ASSEMBLY PARTS LIST
ITEM
1. 3K01-227501 1 Hammer Bracket (R)*
2. ----------------- 1 Hammer Bracket (L)*
3. 3K01-227502 8 Bracket Bolt
4. Assembly of Item 3 8 Washer
5. Assembly of Item 3 16 Nut
NI 3K01-227504-262 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 Cap Nut
10. 3K01-227505 4 Cushion Rubber
11. Assembly of Item 10 4 Screw
12. Per Carrier Model 1 Top Cap
*Sold as matched set w/ hardware. NI denotes not illustrated. Effective 07/05
Prices subject to change without notice.
PART NO.
MODEL HH4500
QTY DESCRIPTION
50
51
HH5800 HAMMER
ITEM NAME NUMBER QTY.
1 Cylinder 3L01-2330001 1
2 Cylinder O-Ring* 3J01-09108B 1
3 Cylinder O-Ring* 3J01-09138B 2
4 Cylinder O-Ring* 3H01-09072B 2
5 Cylinder Sleeve 3L01-2330002 1
6 Cylinder Sleeve O-Ring* 3L01-07378W 2
7 Quad Ring* 3L01-170580 1
8 Back Up Ring* 3L01-170583 2
9 Step Seal with O-Ring* 3L01-170581 2
10 U-Packing* 3L01-U33000I 1
11 U-Packing with Back Up Ring* 3L01-U33000H 1
12 Dust Seal* 3L01-D33000D 1
13 Piston 3L01-2330011 1
14 Valve Box 3L01-2330021 1
15 Main Valve 3L01-2330022 1
16 Upper Valve Cap 3L01-2330023 1
17 Valve Cap O-Ring* 3K01-07138B 1
18 Back Up Ring* 3K01-08138G 1
19 Valve Cap O-Ring* 3L01-051480 1
20 Lower Valve Cap 3L01-2330025 1
21 Locater Pin 3Z01-PN0510 1
22 Box Sleeve 3L01-2330026 1
23 Box Sleeve O-Ring* 3L01-07148B 2
24 Back Up Ring* 3L01-08148G 1
25 Valve Box Set Bolt 3L01-B62154 8
26 Valve Cap Bolt 3L01-B56144 10
27 Valve Box O-Ring* 3H01-09040B 2
28 Back Cap 3L01-2330031 1
29 Back Cap O-Ring* 3L01-09468A 1
30 Plug 3K01-2210082 6
31 Cylinder 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 3L01-330044 4
38 Bushing Spring Pin 3L01-S52168 8
39 Nipple 3J03-N00003 2
40 O-Ring 3J03-07078B 2
41 Side Rod Assembly 3L01-230051 4
42 Side Rod Front Nut 3L01-2330052 4
43 Side Rod Back Nut 3L01-2330053 4
44 Side Rod Washer. 3L01-2330054 4
45 Grease Nipple 3Z01-GN0018 1
46 Tool Set Pin 3L01-330061 1
47 Tool Spring Pin 3L01-S52368 2
48 Tool Moil (Chisel, Blunt) 3L01-233P(Fx, E) 1
49 Mode Valve Body 3H01-2210027 1
50 Mode Valve 3H01-2210028 1
51 Mode Valve O-Ring* 3H01-09044W 1
52 Mode Valve O-Ring* 3H01-09036W 1
53 Mode Valve Set Bolt 3H01-B32068 4
54 Mode Valve Lock Bolt 3H01-B24040 1
55 Spring Washer 3H01-SW0008 1
56 Locater Pin 3H01-PN0308 3
57 Stop Ring 3H01-SL0018 1
NI Mode Valve Assembly 3H01-221MVA 1
NI Valve Box Assembly 3L01-233VBA 1
NI Seal Kit 3L01-233SK 1
NI Gas Charger 3Z01-202GC 1
58 Gas Valve Assembly (Includes item # 59) 3Z01-G00001 1
59 Gas Valve Cap with O-Ring 3Z01-G00004 1
*Included in seal kit only. NI denotes not illustrated. Effective 07/05
52
HH5800 HAMMER
53
Effective 07/05
HH5800 HAMMER
BRACKET ASSEMBLY PARTS LIST
ITEM
1. 3L01-233501 1 Hammer Bracket (R)*
2. ----------------- 1 Hammer Bracket (L)*
3. 3L01-233502 8 Bracket Bolt
4. Assembly of Item 3 8 Washer
5. Assembly of Item 3 16 Nut
NI 3L01-233504-284 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 Cap Nut
10. 3L01-233505 4 Cushion Rubber
11. Assembly of Item 10 4 Screw
12. Per Carrier Model 1 Top Cap
*Sold as matched set w/ hardware. NI denotes not illustrated. Effective 07/05
Prices subject to change without notice.
PART NO.
MODEL HH5800
QTY DESCRIPTION
54
55
HH8000 HAMMER
ITEM NAME NUMBER QTY.
1 Cylinder 3M01-2400001 1
2 Cylinder O-Ring* 3L01-09138B 2
3 Cylinder O-Ring* 3M01-09098B 1
4 Cylinder O-Ring* 3H01-09072B 2
5 Cylinder Sleeve 3M01-2400002 1
6 Cylinder Sleeve O-Ring* 3M01-07398W 2
7 Quad Ring* 3M01-170590 1
8 Back Up Ring* 3M01-170593 2
9 Step Seal with O-Ring* 3M01-170591 2
10 U-Packing* 3M01-U40000I 1
11 U-Packing with Back Up Ring* 3M01-U40000H 1
12 Dust Seal* 3M01-D40000D 1
13 Piston 3M01-2400011 1
14 Valve Box 3M01-2400021 1
15 Main Valve 3M01-2400022 1
16 Upper Valve Cap 3M01-2400023 1
17 Valve Cap O-Ring* 3K01-07138B 1
18 Back Up Ring* 3K01-08138G 1
19 Valve Cap O-Ring* 3M01-051480 1
20 Lower Valve Cap 3M01-2400025 1
21 Locater Pin 3Z01-PN0510 1
22 Box Sleeve 3M01-2400026 1
23 Box Sleeve O-Ring* 3M01-07158B 2
24 Back Up Ring* 3M01-08158G 1
25 Valve Box Set Bolt 3L01-B62154 2
26 Valve Cap Bolt 3L01-B56144 10
27 Valve Box O-Ring* 3H01-09040B 2
28 Back Cap 3M01-2400031 1
29 Back Cap O-Ring* 3M01-09488A 1
30 Plug 3J01-240081 5
31 Cylinder 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 3M01-2400044 4
38 Bushing Spring Pin 3L01-S52168 8
39 Nipple 3M03-N00004 2
40 O-Ring 3M03-07098B 2
41 Side Rod Assembly 3M01-2400051 4
42 Side Rod Front Nut 3M01-2400052 4
43 Side Rod Back Nut 3M01-2400053 4
44 Side Rod Washer. 3M01-2400054 4
45 Grease Nipple 3Z01-GN0018 1
46 Tool Set Pin 3M01-400061 1
47 Tool Spring Pin 3L01-S52368 2
48 Tool Moil (Chisel, Blunt) 3M01-240P(Fx, E) 1
49 Mode Valve Body 3H01-2210027 1
50 Mode Valve 3H01-2210028 1
51 Mode Valve O-Ring* 3H01-09044W 1
52 Mode Valve O-Ring* 3H01-09036W 1
53 Mode Valve Set Bolt 3H01-B32068 4
54 Mode Valve Lock Bolt 3H01-B24040 1
55 Spring Washer 3H01-SW0008 1
56 Locater Pin 3H01-PN0308 3
57 Stop Ring 3H01-SL0018 1
NI Mode Valve Assembly 3H01-221MVA 1
NI Valve Box Assembly 3M01-240VBA 1
NI Seal Kit 3M01-240SK 1
NI Gas Charger 3Z01-202GC 1
58 Gas Valve Assembly (Includes item # 59) 3Z01-G00001 1
59 Gas Valve Cap with O-Ring 3Z01-G00004 1
*Included in seal kit only. NI denotes not illustrated. Effective 07/05
56
HH8000 HAMMER
57
Effective 07/05
HH8000 HAMMER
BRACKET ASSEMBLY PARTS LIST
ITEM
1. 3M01-240501 1 Hammer Bracket (R)*
2. ----------------- 1 Hammer Bracket (L)*
3. 3M01-240502 8 Bracket Bolt
4. Assembly of Item 3 8 Washer
5. Assembly of Item 3 16 Nut
NI 3M01-240504-304 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 Cap Nut
10. 3M01-240505 4 Cushion Rubber
11. Assembly of Item 10 4 Screw
12. Per Carrier Model 1 Top Cap
*Sold as matched set w/ hardware. NI denotes not illustrated. Effective 07/05
Prices subject to change without notice.
PART NO.
MODEL HH8000
QTY DESCRIPTION
58
NOTES
59
HYDRAULIC HAMMERS
194 N. Brandon Dr.
Glendale Heights, IL 60139
TOLL FREE (800) 487-5431
Phone: (630) 893-5558 Fax: (630) 790-3751
rev: 7/05
60
IPC INDUSTRIES, INC.
Loading...