MOUNTED HYDRAULIC
DROP HAMMER
DH1500
DH3500
DH9000
Safety, OperatiOn and Maintenance
USer’S ManUaL
© 2012 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
67737 5/2013 Ver. 8
TABLE OF CONTENTS
IMPORTANT
DECLARATION OF CONFORMITY ................................................................................................................................... 4
SAFETY SYMBOLS ........................................................................................................................................................... 5
SAFETY PRECAUTIONS ................................................................................................................................................... 6
TOOL STICKERS & TAGS ................................................................................................................................................. 9
OPERATION ..................................................................................................................................................................... 10
PRE-INSTALLATION INSTRUCTIONS ......................................................................................................................... 10
SKIDSTEER, BACKHOE OR EXCAVATOR SIZE ......................................................................................................... 10
TEST THE HYDRAULIC SYSTEM ............................................................................................................................... 10
HYDRAULICS .............................................................................................................................................................. 10
TOOL INSTALLATION ................................................................................................................................................... 10
MOUNTING TO THE CARRIER.....................................................................................................................................11
OPERATION ..................................................................................................................................................................11
ADJUSTING IMPACT .................................................................................................................................................... 12
MAINTENANCE ............................................................................................................................................................... 12
DAILY INSPECTION ....................................................................................................................................................... 12
MONTHLY CHECK ........................................................................................................................................................... 13
TRAVEL AND STORAGE ................................................................................................................................................. 13
TROUBLESHOOTING ..................................................................................................................................................... 14
SPECIFICATIONS ............................................................................................................................................................ 15
DH1500 PARTS ILLUSTRATION ..................................................................................................................................... 16
DH1500 PARTS LIST ....................................................................................................................................................... 17
DH3500 PARTS ILLUSTRATION ..................................................................................................................................... 18
DH3500 PARTS LIST ....................................................................................................................................................... 19
DH9000 PARTS ILLUSTRATION ..................................................................................................................................... 20
DH9000 PARTS LIST ....................................................................................................................................................... 21
To ll out a Product Warranty Recording form, and for information on your warranty,
visit Stanleyhydraulic.com and select the Warranty tab.
(NOTE: The warranty recording form must be submitted to validate the warranty).
SERVICING THE STANLEY HYDRAULIC DROP HAMMER. This manual contains safety, operation, and routine
maintenance instructions. Servicing of hydraulic tools, other than routine maintenance, must be
performed by an authorized and certied dealer. Please read the following warning.
SERIOUS INJURY OR DEATH COULD RESULT FROM THE
IMPROPER REPAIR OR SERVICE OF THIS TOOL.
REPAIRS AND / OR SERVICE TO THIS TOOL MUST ONLY BE
DONE BY AN AUTHORIZED AND CERTIFIED DEALER.
3
DECLARATION OF CONFORMITY
Weisbeck, Andy
Directive/Standards
No.
Approved body
EN ISO
12100-1, 12100-2:2009
Self
ÜBEREINSTIMMUNGS-ERKLARUNG
DECLARATION DE CONFORMITE CEE
DECLARACION DE CONFORMIDAD
Hydraulic Tools
DICHIARAZIONE DI CONFORMITA
________________ ______________________________________________________
I, the undersigned:
Ich, der Unterzeichnende:
Je soussigné:
El abajo firmante:
lo sottoscritto:
hereby declare that the equipment specified hereunder:
bestätige hiermit, daß erklaren Produkt genannten Werk oder Gerät:
déclare que l’équipement visé ci-dessous:
Por la presente declaro que el equipo se especifica a continuación:
Dichiaro che le apparecchiature specificate di seguito:
Surname and First names/Familiennname und Vornamen/Nom et pr énom/Nombre y apellido/Cognome e nom e
1. Category:
Kategorie:
Catégorie:
Categoria:
Categoria:
2. Make/Marke/Marque/Marca/Marca
3. Type/Typ/Type/Tipo/Tipo: DH1500, DH1501, DH1502, DH3500, DH9000, DH9001
4. Serial number of equipment:
Seriennummer des Geräts:
Numéro de série de l’équipement:
Numero de serie del equipo:
Matricola dell´attrezzatura:
Has been manufactured in conformity with
Wurde hergestellt in Übereinstimmung mit
Est fabriqué conformément
Ha sido fabricado de acuerdo con
E’ stata costruita in conformitá con
Richtlinie/Standards
Directives/Normes
Directriz/Los Normas
Direttiva/Norme
EN ISO
Machinery Directive
5. Special Provisions: None
Spezielle Bestimmungen:
Dispositions particulières:
Provisiones especiales:
Disposizioni speciali:
Nr
Numéro
No
n.
982:2008
2006/42/EC:2006
Drop Hammer, Breaker
Stanley
All
Prüfung durch
Organisme agréé
Aprobado
Collaudato
Self
Self
6. Representative in the Union: Patrick Vervier, Stanley Dubuis 17-19, rue Jules Berthonneau-BP 3406 41034 Blois Cedex, France.
Vertreter in der Union/Représentant dans l’union/Representante en la Union/Rappresentante presso l’Unione
Done at/Ort/Fait à/Dado en/Fatto a Stanley Hydraulic Tools, Milwaukie, Oregon USA
Signature/Unterschrift/Signature/Firma/Firma
Position/Position/Fonction/Cargo/Posizione Engineering Manager
1/10/2011
Date/Datum/le/Fecha/Data 1-10-11
4
NOTICE
CAUTION
SAFETY SYMBOLS
IMPORTANT
Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair
actions which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to equipment.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
This safety alert and signal word indicate an imminently hazardous situation which, if not avoided, will result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury.
This signal word indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
This signal word indicates a situation which, if not avoided, will result in
damage to the equipment.
This signal word indicates a situation which, if not avoided, may result in
damage to the equipment.
Always observe safety symbols. They are included for your safety and for the protection of the tool.
LOCAL SAFETY REGULATIONS
Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and maintenance personnel.
5
SAFETY PRECAUTIONS
WARNING
Do not operate the tool unless the
following safety instructions have been
thoroughly read and understood! Read this
manual before installing, operating or
maintaining this equipment.
A flying projectile from the tool,
Rock or other material may enter the
operator's compartment and cause serious
or fatal injury to the operator. Personal
protection equipment must be used.
A flying projectile from the tool
Rock or other material may cause
serious or fatal injury to bystanders. Never
operate the tool when bystanders are in
the work area.
On some machines/carriers, the tool
can enter the operator's compartment if it
breaks loose and swings toward the
operator. Make sure that suitable impact
shields are used when operating the
Tool with this type of equipment.
Do not operate the tool unless all safety
decals described in this manual are in
place. The decals must be inspected
periodically to ensure that all wording is
legible. The decals must be replaced if
illegible. Replacement decals can be
obtained from your authorized Stanley
Distributor.
When operating the tool you must use
ear protection, eye protection, and
breath
ing protection.
Read the Manual
Wear Breathing
Protection
Wear Hearing
Protection
Wear Eye
Protection
Exposure to silica dust during construction
activities can cause serious or fatal respiratory
disease. Use adequate respiratory protection.
6
SAFETY PRECAUTIONS
Tool operators and maintenance personnel must always comply with the safety
precautions given in this manual and on the stickers and tags attached to the tool and
hose.
These safety precautions are given for your safety. Review them carefully before operating
the tool and before performing general maintenance or repairs.
Supervising personnel should develop additional precautions relating to the specic work
area and local safety regulations. If so, place the added precautions in the space provided
on page 5 in this manual.
The mounted hydraulic drop hammers will provide safe and dependable service if
operated in accordance with the instructions given in this manual. Read and understand this
manual and any stickers and tags attached to the tool and hoses before operation. Failure
to do so could result in personal injury or equipment damage.
Check the rules and regulations at your location. The rules might include an employer's
work safety program. Regulations may identify hazards such as working around utility supply lines or hazardous slopes.
BE THOROUGHLY TRAINED BEFORE OPERATING THE UNIT ALONE
• Operator training must start in an area without bystanders and use all the controls until he/she can control the machine
fully under the conditions of the work area.
• When learning to operate a machine, do so at a slow pace.
KNOW THE WORK CONDITIONS
• The operator must know any prohibited uses or work areas for the machine. For example, excessive slopes and poor or
dangerous terrain conditions must be avoided.
OBEY SAFETY RULES
• Operate the tool in accordance with all laws and regulations which affect you, your equipment and the work-site.
• Do not operate the tool until you have read this manual and thoroughly understand all safety, operation and
maintenance instructions.
• The operator must be familiar with all prohibited work areas such as excessive slopes and dangerous terrain
conditions.
• Do not operate the tool until you have read the carrier equipment manual and thoroughly understand all safety,
operation and maintenance instructions. The word “carrier”, as used in this manual, means a skidsteer loader, backhoe or
excavator used to operate the tool.
• Ensure that all maintenance procedures recommended in this manual are completed before using the equipment.
• Warning: Use of this tool on certain materials during demolition could generate dust potentially containing a variety of
hazardous substances such as asbestos, silica or lead. Inhalation of dust containing these or other hazardous substances
could result in serious injury, cancer or death. Protect yourself and those around you. Research and understand the ma
terials you are cutting. Follow correct safety procedures and comply with all applicable national, state or provisional health
and safety regulations relating to them, including, if appropriate arranging for the safe disposal of the materials by a quali
ed person.
7
SAFETY PRECAUTIONS
• The operator must not operate the tool or carrier if any people are within the area where they may be injured by ying
debris or movement of the equipment.
• Know the limits of your equipment.
• Establish a training program for all operators to ensure safe operation.
• Do not operate the tool unless thoroughly trained or under the supervision of an instructor.
• Become familiar with the carrier controls before operating the carrier and the tool.
• When operating the tool you must use ear protection, eye protection, and breathing protection.
• While learning to operate the tool and carrier, do so at a slow pace. If necessary, set the carrier mode selector to the
slow position.
• Make sure all controls (levers and pedals) are in the NEUTRAL position before starting the carrier.
• While operating the tool and carrier, keep hands and feet on the controls at all times.
• Before leaving the carrier, always lower the boom and insure the carrier is stable. Never leave the machine with the
engine running. ALWAYS ENGAGE THE PARKING BRAKE.
• Stop the engine before attempting to make any repairs, adjustments or servicing to either the carrier or the tool.
• Do not operate the tool at oil temperatures above 190°F/88°C. Operation at higher temperatures can damage the internal
components of the equipment and will result in reduced performance.
• Do not operate a damaged, leaking, improperly adjusted, or incompletely assembled tool.
• Do not modify the tool in any manner.
• To avoid personal injury or equipment damage, all tool repair, maintenance and service must only be performed by
authorized and properly trained personnel.
• If you do not understand how to safely operate your tool, contact an authorized Stanley Dealer for assistance.
• Keep this manual with the tool.
• Do not operate this equipment if you are taking medication which may affect your mental judgement or physical
performance.
• Do not operate this equipment if you are under the inuence of drugs or alcohol.
• Replace all faulty or leaking hydraulic hoses before further operation.
• After operation, hydraulic components may be hot enough to burn skin.
8
TOOL STICKERS & TAGS
Nacco MTLS Handling Group (91040)
PN: 1581055 Hoist Tilt
Material: AD-1487
Cut: Steel Rule Die Cut
Die Location:
R/C:
Score:
Lamination:
Printer / Press:
Fonts Used:
Adhesive:
Application Tape:
Blue Print Created On: 04-May-07
Blue Print Created By: ME
DateApproved by
Proof OK as is. Make indicated changes and proceed. Make changes and send another proof.
Job #54077 5-17-07 Stanley (15820) P.O. 751392
Fax: 503•682•2542
PMS 144 Orange
Black
Clear
6”
4”
Cut Line
6”
4”
Ensure travel lock is correctly installed.
Sliding / crushing hazard from weight.
The sliding weight can cause serious
injury or death.
67859
Nacco MTLS Handling Group (91040)
PN: 1581055 Hoist Tilt
Material: AD-1487
Cut: Steel Rule Die Cut
Die Location:
R/C:
Score:
Lamination:
Printer / Press:
Fonts Used:
Adhesive:
Application Tape:
Blue Print Created On: 04-May-07
Blue Print Created By: ME
DateApproved by
Job #54077 5-16-07 Stanley (15820) P.O. 751392
Fax: 503•682•2542
PMS 144 Orange
Black
Clear
6”
4”
Nacco MTLS Handling Group (91040)
PN: 1581055 Hoist Tilt
Material: AD-1487
Cut: Steel Rule Die Cut
Die Location:
R/C:
Score:
Lamination:
Printer / Press:
Fonts Used:
Adhesive:
Application Tape:
Blue Print Created On: 04-May-07
Blue Print Created By: ME
DateApproved by
Job #54077 5-16-07 Stanley (15820) P.O. 751392
Fax: 503•682•2542
RED
Black
Clear
6”
4”
DANGER
Nacco MTLS Handling Group (91040)
PN: 1581055 Hoist Tilt
Material: AD-1487
Cut: Steel Rule Die Cut
Die Location:
R/C:
Score:
Lamination:
Printer / Press:
Fonts Used:
Adhesive:
Application Tape:
Blue Print Created On: 04-May-07
Blue Print Created By: ME
DateApproved by
Job #54077 5-17-07 Stanley (15820) P.O. 751392
Fax: 503•682•2542
PMS 123 Yellow
Black
Clear
6”
4”
Cut Line
6”
4”
Ensure travel lock is correctly installed.
Sliding / crushing hazard from weight.
The sliding weight can cause serious
injury or death.
67859
Nacco MTLS Handling Group (91040)
PN: 1581055 Hoist Tilt
Material: AD-1487
Cut: Steel Rule Die Cut
Die Location:
R/C:
Score:
Lamination:
Printer / Press:
Fonts Used:
Adhesive:
Application Tape:
Blue Print Created On: 04-May-07
Blue Print Created By: ME
DateApproved by
Job #54077 5-17-07 Stanley (15820) P.O. 751392
Fax: 503•682•2542
PMS 123 Yellow
Black
Clear
6”
4”
Cut Line
6”
4”
Ensure travel lock is correctly installed.
Sliding / crushing hazard from weight.
The sliding weight can cause serious
injury or death.
67859
Material: 3M VS5124
Cut: Steel Rule Die Cut
Die Location:
R/C:
Score:
Lamination:
Printer / Press:
Fonts Used:
Adhesive:
Application Tape:
DateApproved by
Fax: 503•682•2542
123 Yellow
Black
6.5”
29”
Refer to the Parts Illustration page in this manual for proper placement of stickers.
®
DH 3500
67768
DH1500 Model Number Sticker
67735
DH3500 Model Number Sticker
67780
DH9000 Model Number Sticker
KEEP CLEAR OF TOP OF
DROP HAMMER
Impact Hazard
Contact with moving weight could
result in serious injury or death.
67791
Drop Hammer Sticker
Ensure travel lock is correctly installed.
Sliding / crushing hazard from weight.
The sliding weight can cause serious
injury or death.
67859
Travel Lock Sticker
TOPPLING & CRUSH
HAZARD!
Lay down on hard, flat level
ground only.
Do not store standing upright.
Death or serious injury
will result.
67860
Toppling & Crush Sticker
67859
67860
67791
47351
Composite Warning
Sticker
CAUTION
EQUIPMENT DAMAGE AND
STABILITY HAZARD!
Skids must be firmly on material being
broken while machine is in operation.
Failure to comply may result in
equipment damage.
67861
67861
Stability Sticker
CAUTION
EQUIPMENT DAMAGE HAZARD!
Repeated blows in material 6 inches
or less can result in Dry-firing.
Failure to comply may result in
machine damage.
Keep breaker moving.
67862
Equipment Damage Sticker
67862
Specication Plate
68641
DH1500 CE Spec Plate
68581
DH3500 CE Spec Plate
70982
DH9000 CE Spec Plate
52539 (DH1500)
Sound Power Level Sticker
60917 (DH3500)
Sound Power Level Sticker
52539 (DH9000)
Sound Power Level Sticker
9
OPERATION
PRE-INSTALLATION INSTRUCTIONS
SKIDSTEER, BACKHOE OR EXCAVATOR SIZE
Check the Specifications section of this manual to
determine correct carrier size, hydraulic ow and pressure
requirements.
Before connecting the drop hammer to the carrier hydraulic
system; it is important to determine which are the pressure and
tank lines of the carrier and connect the hoses appropriately.
The pressure and tank lines are marked where they enter the
valve block. If the hydraulics are connected incorrectly, the
motor will rotate in the wrong direction. This will not damage
the machine but it will not lift.
If hydraulic pressure, hydraulic back-pressure,
hydraulic ow or excavator weight class are exceeded, the
drop hammer warranty is void.
Do not use bare hands to check or search for hydraulic
leaks around hoses and ttings. Pinhole leaks can
penetrate the skin. To inspect for leaks, depressurize
the system, clean around suspected area, repressurize
the system and visually check for leaks.
TEST THE HYDRAULIC SYSTEM
1. Have your Stanley dealer test the carrier hydraulic
system to make sure the system is op e r at i n g at th e
manufacturers specied capacity and pressure ratings.
2. Be sure the uid in the hydraulic system is clean.
3. Check the hydraulic lter. Replace the lter if dirty or
deteriorated.
TOOL INSTALLATION
WARNING
Do not lift or transport the drop hammer without the
travel lock installed.
The hammer can move freely in the housing if the
travel lock is not installed which can result in serious
injury or death.
Ensure travel lock is installed.
The drop hammer may be lifted with a forklift through the
mounting bracket or by feeding chains through the points
shown in Figure 1 below. Always lift the drop hammer with
machinery and lifting equipment that is rated to carry the
weight of the machine.
4 Have your Stanley dealer test the circuit to which the
breaker will be connected to make sure that the circuit is
supplying the specied ow and pressure rating for the
breaker. See the Specications section of this manual.
HYDRAULICS
Some carriers may have ows above or below ow and
pressure ranges required. Refer to Flow and Pressure
Specications on page 17 of this manual. If the ow is lower
the drop hammer will simply cycle at a slower rate. If the ow
rate is higher the control valve on the drop hammer will limit
the ow to prevent the chain over-speeding and catching the
weight as it drops.
10
Traveling
Lock
Center of
Gravity
Figure 1. Lift Points
Mounting Bracket
OPERATION
MOUNTING TO THE CARRIER
1. With the drop hammer laying on a at level surface bolt the
mounting plate to the mounting bracket. Ensure these bolts
are torqued to the recommended value.
2. Bring the carrier up to the drop hammer from the bottom or
impact end. If you have a quick attachment systems maneuver
the mount plate on the carrier until it engages with the adaption
plate. Then actuate the slides or levers to lock the plates
together. With a pin mount system; maneuver the carrier until
the pinholes are aligned and slide in the connection pins.
Ensure the pins are bolted in place. Grease these pivots as per
the carrier manufactures recommendations. Never operate
the drop hammer with a loose or ill-tting attachment.
Connect the hoses to supply oil to the port marked "PRESS"
on the valve block.
3. Carefully raise the drop hammer to the vertical position
keeping the base of the machine close to the ground
throughout the lifting movement. Slowly move the Cyclone
through the full extent of rotation and lift to ensure no part of
the machine or any hydraulic hosing foul the carrier arms or
cylinders. Ensure hoses are long enough so they do not pull
tight in any part of the rotation and short enough to stay clear
of the ground or operating area.
OPERATION
NOTICE
Failure to remove the travel lock may result in damage
to the equipment during operation.
Exposure to silica dust during construction activities
can cause serious or fatal respiratory disease. Use
adequate respiratory protection.
4. Once the drop hammer is securely mounted to the carrier
the Traveling Lock may be removed. Be sure to store this
plate safely for future use.
During use, the traveling lock may be bolted outside the
housing using the same hole as shown in Figure 2 below.
Traveling Lock
OPERATION
Ensure that the drop hammer is operated at a safe distance
from other personnel and equipment. Be sure all guards are
in place.
The drop hammer's weight is normally rested on the skids
during use. However when moving about the drop hammer
may represent a heavy load for the carrier. Therefore care
must be taken when moving about a job-site or when loading
or unloading from a transporter. The drop hammer should be
carried as low as possible and special care taken when negotiating uneven surfaces. Know the limits of your carrier.
NOTICE
The drop hammer is intended for use only on level or near
level surfaces. Do not operate the drop hammer on uneven
or unlevel surfaces.
Figure 2. Traveling Lock
11
OPERATION
GENERAL TECHNIQUE FOR BREAKING SLAB
Rest the drop hammer in a vertical position on the concrete
to be broken. The skids should be just resting on the concrete
with some of the weight taken by the carrier. If a crack appears
in the top surface of the concrete you can be sure it is broken
all the way through.
Actuate the hydraulics and the drop hammer will start to cycle.
As the concrete cracks or breaks move the carrier. It is best
to move while the hammer is raised and pause momentarily
as the hammer strikes.
Generally all that is required is to hit the concrete until it cracks
and then move 6-12 inches /150-300 mm. Sitting in one place
will pulverize the concrete and eventually the hammer will hit
the column buffers. This is felt as a hard jarring action through
the machine.
With skid steers movement can be in any direction but generally moving in a reverse direction provides the best control.
On excavators setting the machine down and moving in arc
with the slew drive is usually the quickest method.
It is important to keep the drop hammer as vertical as possible
during operation as this provides the greatest impact.
1. Tip the drop hammer to a horizontal position.
2. Gradually move the drop hammer past horizontal until the
weight slides forward. This can be done in a controlled manner
by shaking the weight out using the curl lever.
3. Allow the Hammer to slide out until it hits against the Safety
Pin.
4. Return the drop hammer to horizontal and rest it on the
ground and Shut the carrier off.
5. On the under-side of the Hammer remove the Bolt and Peg
Locking Plate that hold the Hammer Peg.
6. Remove the Hammer Peg and replace it in the next hole.
Tighten to 180 ft/lbs/240 Nm for the DH3500 and DH9000,
for the DH1500 tighten to 140 ft lbs/190 Nm with the Bolt and
Peg Locking Plate. See Figure 3 below.
Hammer Peg
Hex Head Setscrew
Peg Locking Plate
Hammer Safety Pin
When breaking thinner concrete, the drop hammer may hit
too hard and punch completely through. In this instance the
hammer sticking into the concrete and stopping the carrier
traveling can slow production. If this occurs adjust the impact
of the drop hammer as described below.
ADJUSTING IMPACT
Hammer
Figure 3. Hammer Adjustment
7. Restart the carrier and SLOWLY raise the drop hammer
until the Hammer slides down the column.
MAINTENANCE
It is recommended that only genuine Stanley parts are used.
Genuine Stanley drop hammer parts are all checked for
allowable tolerances.
Although the drop hammer is a simple machine, it is subject
to severe stresses and shocks during normal operation. A
ve-minute daily check will ensure that your drop hammer
remains in good condition and will prevent unscheduled
down time.
DAILY INSPECTION
Check that all the mount plate bolts that connect the drop
hammer to the carrier are tight and torqued to the recommended value.
Check that the motor ange bolts are tight and secure.
12
OPERATION
Check the chain adjustment bolts and secure the nuts if
required.
Check the Housing Cover plate bolts and tighten if needed.
Check the hydraulic hoses, ttings and valves for any leaks
and repair as required.
With the machine turned off, oil the chain over the top sprocket
with a heavy duty gear oil such as Mobil Gear 600 Series.
Refer to the table below for recommended chain oil.
Ambient Temperature Lubricant Rating (SAE)
23° - 41°F / -5° - +5°C 20 46 - 68
41° - 104°F / 5° - 40°C 30 100
104° - 122°F / 40° - 50°C 40 150 - 220
122° - 140°F / 50° - 60°C 50 320
Viscosity Grade
(Hydraulic Fluid)
MONTHLY CHECK
With the drop hammer in a vertical position and the carrier
turned off remove the Housing Cover plate. Check the chain
tension. The chain should move about 1/2 inch/10-15 mm at
its center point. To adjust the chain, loosen the Tensioning
Bolt lock nuts (Item 32 DH1500 or Item 30 DH3500) and the
Clamp Nut (Items 41-42 DH1500 or Items 34-35 DH3500).
Adjust the Tension Bolts evenly (so that the lower shaft/
sprocket are kept parallel). See Figure 4 below.
Note: In the rst month of operation this should be
done weekly until the chain beds in.
Lower
Sprocket
Shaft
Sprocket
Spacer
Adjuster
Bracket
Nut
Standing clear of the machine, start the drop hammer and
SLOWLY rotate the chain until the chain Connecting Plate
Assembly is accessible. Turn the carrier off and disconnect
hydraulic hoses.
Check this assembly for signs of excessive wear, and replace
as required.
Lubricate this assembly and the chain. Refer to the table on
the previous page.
Replace the Housing Cover.
Tip the drop hammer forward and slide the weight out as
described Adjusting Impact section of this manual.
Inspect the Hammer Connecting Pin and replace if excessively
worn.
Liberally grease the Hammer Connecting Pin USE A LITHIUM
BASED GREASE WITH NGLI 1 or 2 RATING (Mobilgrease
HP or Shell Alvania EP) and replace the hammer as described
in Adjusting Impact section of this manual.
It is worthwhile at this stage to dress the hammer tip and
remove any excessive burring.
TRAVEL AND STORAGE
1. Ensure the travel lock is installed before transporting the
drop hammer.
Half Nut
Bearing
Nut
Washer
Hex Head Setscrew
(Long)
Hex Head Setscrew
(Short)
Washer
Bearing
Nut
Washer
Figure 4. Lower Sprocket Assembly
Remove the rubber inspection cover at the top of the drop
hammer and check the motor nut is tight. Replace the
inspection cover.
13
TROUBLESHOOTING
This section describes how to nd and resolve problems users may experience. If a situation occurs that is not covered, call
your Stanley Customer Service representative for assistance.
WARNING
Inspecting the tool or installing parts with the hydraulic hoses connected can result in severe personal injury or equipment
damage. To prevent accidental startup, disconnect the hydraulic power before beginning any inspection or installation
task.
If symptoms of poor performance develop, the following chart can be used as a guide to correct the problem.
When diagnosing faults in operation of the tool, always check that the hydraulic power source is supplying the correct hydraulic
ow and pressure to the tool as listed in the table below. Use a owmeter known to be accurate. Check the ow with the
hydraulic oil temperature at least 80° F/27° C.
PROBLEM CAUSE SOLUTION
Hydraulic ow is in wrong direction. Reverse the ow.
Low hydraulic oil level. Fill reservoir.
No ow to breaker. Have hydraulic circuit tested by
Hammer will not re.
Hammer runs slowly.
Hammer runs erratically.
Hydraulic system overheats.
Main relief set low.
Internal damage.
Damaged quick couplers. Replace.
Low hydraulic ow
Internal leakage.
Damaged switch or connection.
Relief set too low.
Internal damage.
Hammer binding. Clean hammer in housing.
Chain tension too tight Have unit serviced.
Main relief set low.
Insufcient cooling capability in hydraulic
circuit.
Line/hose size too small.
Excessive back-pressure.
authorized dealer/distributor per
approved procedure.
Have unit serviced by an authorized
dealer/distributor.
Have hydraulic circuit tested by an
authorized dealer/distributor per
approved procedure.
Have unit serviced by an authorized
dealer/distributor.
Have carrier serviced by an authorized
dealer/distributor.
Have unit serviced by an authorized
dealer/distributor.
14
SPECIFICATIONS
DIMENSIONS AND WEIGHTS
Weight w/o Mounting Bracket
DH1500 ....................................................................................................................................................700 lbs / 317.5 kg
DH3500 .....................................................................................................................................................1570 lbs / 712 kg
DH9000 ...................................................................................................................................................3100 lbs / 1406 kg
Height
DH1500 ................................................................................................................................................... 63.75 in. / 162 cm
DH3500 ..................................................................................................................................................... 65.5 in. / 166 cm
DH9000 ................................................................................................................................................. 74.375 in. / 189 cm
Hydraulic Pressure Range
DH1500 ...................................................................................................................................2300-3000 psi / 159-207 bar
DH3500 ...................................................................................................................................2350-3000 psi / 162-207 bar
DH9000 ...................................................................................................................................2400-3000 psi / 166-207 bar
Minimum Flow Range
DH1500 ........................................................................................................................................8.7-20.6 gpm / 33-78 lpm
DH3500 ......................................................................................................................................10.6-20.6 gpm / 40-78 lpm
DH9000 ....................................................................................................................................... 20.6-31 gpm / 78-117 lpm
Recommended Hose .............................................................................................................................. 5/8" Parker 451TC
NOTE: Weights, dimensions and operating specications listed on this sheet are subject to change without notice. Where specications are critical to your application, please consult the dealer.
15
DH1500 PARTS ILLUSTRATION
MODEL & SERIAL
NUMBER LOCATION
16
DH1500 PARTS LIST
Item SHT No. Qty Description
1 04353 8 NYLOCK NUT
2 04585 16 WASHER
3 06638 4 HSHCS
4 07860 8 HSHCS
7 20871 2 HHCS
8 20908 1 HHCS
9 44956 4 NYLOCK NUT
10 47351 1
11 52539 1 SOUND POWER LEVEL
12 67709 1 INSPECTION COVER
15 69803 1 BRACKET WELDMENT
16 67740 1 HOUSING
17 67747 1 HAMMER MACHINING
18 67748 1 HAMMER PEG
19 67749 1 PEG LOCKING PLATE
20 67750 1 HAMMER SAFETY PIN
21 67751 1 RIGHT SIDE LIFT LUG
22 67752 1 CENTER LIFT LUG
23 67753 1 MOTOR SPROCKET
24 67754 1 CHAIN
25 67755 1 SHAFT CYCLONE
26 67756 1 SPROCKET SPACER
27 67757 1 ADJUSTER BRACKET
29 67767 2 POLY-BUSH
30 67768 3 DECAL, DH1500
31 69788 1 VALVE ASSEMBLY
32 67788 2 HEX NUT END
33 67789 6 WASHER
34 67790 2 HHCS
35 67791 2
36 67792 1 HHCS
37 67796 2 LIFT LUG SPACER
38 67797 1 HHCS
39 67798 1 FLEX LOCK NUT
40 67799 2 HSHCS
DECAL, COMPOSITE
WARNING
DECAL, KEEP CLEAR OF
HAMMER
Item SHT No. Qty Description
41 67801 1 HEX NUT
42 67802 1 HEX JAM NUT
43 67803 1 WASHER
44 67804 1 HHCS
45 67820 1 HHCS
46 67852 1 LEFT SIDE LIFT LUG
47 67859 1 DECAL, TRAVEL LOCK
48 67860 2 DECAL, TOPPLING HAZARD
49 67861 1 DECAL, STABILITY HAZARD
50 67869 2 HOSE
51 NO ITEM
52 68023 1 LOWER SPROCKET ASSY
53 68340 2 FLEX LOCK NUT
54 68542 1 HYDRAULIC MOTOR
55 68578 4 HHCS
56 68641 1 CE SPECIFICATION PLATE
59 371050 3 WASHER
60 371500 1 NYLOCK NUT
61 371507 2 NYLOCK NUT
62 67746 1 HAMMER STOP
63 67742 1 TRAVELING LOCK
64 67741 1 HOUSING COVER
65 70788 1 NYLOCK NUT
66 00354 2 O-RING
17
DH3500 PARTS ILLUSTRATION
MODEL & SERIAL
NUMBER LOCATION
18
DH3500 PARTS LIST
Item SHT No. Qty Description
1 06638 4 HSHCS
4 20871 8 HHCS
5 23630 2 HHCS
6 44956 4 NYLOCK NUT
7 47351 1
8 60917 1 SOUND POWER LEVEL
9 67703 1 HOUSING
10 67709 1 INSPECTION COVER
11 67710 1 HAMMER MACHINING
12 67711 1 HAMMER PEG
13 67712 1 PEG LOCKING PLATE
14 67713 1 HAMMER SAFETY PIN
15 67714 1 RIGHT SIDE LIFT LUG
16 67716 1 CENTER LIFT LUG
17 67717 1 MOTOR SPROCKET
18 67718 1 CHAIN
19 67719 1 SHAFT, CYCLONE
20 67720 1 SPROCKET SPACER
21 67721 1 ADJUSTER BRACKET
25 67734 2 POLY-BUSH
26 67735 3 DECAL, DH3500
27 67736 1 BRACKET WELDMENT
28 69789 1 VALVE ASSEMBLY
29 67787 1 HHCS
30 67788 2 HEX NUT
31 67789 5 WASHER
32 67791 2
33 67795 1
34 67801 1 HEX NUT
35 67802 1 HEX JAM NUT
36 67803 1 WASHER
37 67808 1
38 67809 2 LIFT LUG SPACER
39 67810 1 SCREW FOR SPACER
40 67811 1 NUT FOR SPACER
DECAL, COMPOSITE
WARNING
DECAL, KEEP CLEAR OF
HAMMER
NYLOCK NUT, HOLDS
SPROCKET TO MOTOR
HHCS
Item SHT No. Qty Description
41 67812 2 SCREW FOR CHAIN
42 67813 2 CRIMP LOCK NUT
43 67820 1 HHCS
44 67853 1 LEFT SIDE LIFT LUG
45 67859 1 DECAL, TRAVEL LOCK
46 67860 2 DECAL, TOPPLING HAZARD
47 67861 1 DECAL, STABILITY HAZARD
48 67869 2 HOSE
49 NO ITEM
50 68024 1 LOWER SPROCKET ASSY
51 68543 1 HYDRAULIC MOTOR
52 68578 4 HHCS
53 68581 1 CE SPECIFICATION PLATE
56 370352 1 HHCS
57 371050 10 WASHER
58 371052 4 WASHER
59 371500 8 NYLOCK NUT
60 371501 2 NYLOCK NUT
61 371507 1 NYLOCK NUT
62 67708 1 HAMMER STOP
63 67705 1 TRAVELING LOCK
64 67704 1 HOUSING COVER
65 02504 2 CAPSCREW
66 00354 2 O-RING
19
DH9000 PARTS ILLUSTRATION
MODEL & SERIAL
NUMBER LOCATION
20
DH9000 PARTS LIST
Item SHT No. Qty Description
1 00719 2 NYLOCK NUT
2 04539 2 WASHER
3 04786 1 WASHER
4 06638 4 HSHCS
6 18600 10 NYLOCK NUT
8 20871 12 HHCS
9 47351 1
10 67712 1 PEG LOCKING PLATE
11 67713 1 HAMMER SAFETY PIN
12 67714 1 RIGHT SIDE LIFT LUG
13 67716 3 CENTER LIFT LUG
16 67738 1 CHAIN WEAR SHEET
17 67764 1 HAMMER MACHINING
18 67771 1 HOUSING
19 67775 1 LOWER SHAFT
20 69790 1 MANIFOLD BLOCK
22 67779 2 POLY-BUSH
23 67780 3 DECAL, DH9000
24 67781 1 BRACKET WELDMENT
25 67790 4 HHCS
26 67791 2
27 67805 4 HHCS
28 67808 1 HHCS
29 67809 4 LIFT LUG SPACER
30 67853 1 LEFT SIDE LIFT LUG
31 67859 1 DECAL, TRAVEL LOCK
32 67860 2 DECAL, TOPPLING HAZARD
33 67861 1 DECAL, STABILITY HAZARD
34 67862 1 DECAL, EQUIP DAMAGE
35 67869 1 HOSE
36 67869 1 HOSE
37 67896 1 CHAIN
38 68213 1 DRIVE SHAFT
39 68277 2 SPROCKET
40 68280 1 HYDRAULIC MOTOR
DECAL, COMPOSITE
WARNING
DECAL, KEEP CLEAR OF
HAMMER
Item SHT No. Qty Description
41 68331 2 FLANGE BEARING PILOTED
42 68332 2 KEY
43 68366 1 HAMMER PEG
44 68503 2 FLANGE BEARING
45 68504 2 SHAFT ADJUSTER BRACKET
46 68506 2 HHCS
47 68519 4 SETSCREW
48 68520 1 HHCS
49 68521 2 SHOULDER SCREW
50 68578 6 HHCS
51 69654 5 HHCS
52 70982 1 CE SPEC PLATE
54 370252 2 HHCS
55 370253 4 HHCS
56 371050 16 WASHER
57 371500 16 NYLOCK NUT
58 371506 4 HEX NUT
59 67628 6 NYLOCK NUT
60 372037 1 SERIAL NUMBER PLATE
61 372155 2 DRIVE PIN
62 67773 1 TRAVELING LOCK
63 68206 1 HOUSING COVER
64 00354 2 O-RING
21
Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie, Oregon 97267
503-659-5660 / Fax 503-652-1780
www.stanleyhydraulic.com
To ll out a Product Warranty Recording form, and for information on your warranty,
visit Stanleyhydraulic.com and select the Warranty tab.
(NOTE: The warranty recording form must be submitted to validate the warranty).
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