maverick hsp owners manual v2 0.pdf

8/10/2019 Maverick HSP Owners Manual V2 0.pdf

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MAVERICKHYDRAULIC HAMMERSOWNERS AND OPERATORS MANUAL

HSP SERIESHYDRAULIC HAMMERS

Models

9250HSP 8250HSP 6250HSP 5250HSP4750HSP 3250HSP 2250HSP 1500HSP1000HSP 750HSP 500HSP 400HSP

Inside U.S. Toll-Free: (800)-618-7628Outside U.S.A: (401)-738-6800

www MaverickHammers com
http://www.maverickhammers.com/http://www.maverickhammers.com/http://www.maverickhammers.com/


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Welcome!

Thank you for purchasing a MaverickHydraulic Hammer. We want you to know thatour entire company appreciates your business and we are here to support youwhenever you need us. You may contact us with any questions, comments, orconcerns at www.MaverickHammers.comor toll free at 800-618-7268 (001-401-738-6800).

MaverickHydraulic Hammers have been designed and manufactured by a highlyskilled and experienced team and quality is built in to all of our products. Ourhammers are built using a minimum number of moving parts to ensure years of trouble-free operation.

Proper care, maintenance, and inspections are critical to ensure high performance formany years.

Please read this Manual carefully BEFORE INSTALLING OR OPERATING THEHAMMER.

When replacing parts, be sure to use only MAVERICKGENUINE PARTS. Failure todo so may seriously impair the operation of the hammer and may also void anywarranty.


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TABLE OF CONTENTS

Section Description Page

1 Safety Precautions 4

2 Standard Specifications 9

3 Principle of Operation 10

4 Installation and Removal 13

5 Operation of the Hammer 19

6 Maintenance 26

7 Inspection and Repair 31

8 Hammer Tool Replacement 32

9 Inspection and Charging of the Hammer 36

10 Trouble Shooting Guide 42

Careless operation of this machine can result in death or serious injuries.Keep this Manual near the hammer and machine as a reference. All personnelinvolved in the maintence or operation of the hydraulic hammer and/or hostequipment are advised to read it at periodical intervals.

If the Manual should be lost or damaged immediately contact Maverick.


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Section 1 - SAFETY

It is important to understand that circumstances, hazards, andpotential dangers may exist relating to conditions beyond the scopeof this manual. Please use common sense, and if in doubt, DONT DOIT!

Introduction to safety

A hydraulic hammer, like all moving heavy equipment, can be dangerous if notoperated and taken care of properly. Most accidents occur as result of mishandling orimproperly operating the equipment.

Before unpacking, installing, operating, servicing, or storing the hammer, carefully readand understand this manual. WE CANNOT EMPHASIZE THIS ENOUGH.

This hammer is to be mounted on a host piece of equipment. It is imperativeand necessary for the hammer and host equipments user to read and understand theOperation Manualsfor both the hammer and host equipment.

Operators of the hydraulic hammer that this manual covers MUST BE:

Licensed:As required by law. Please check with your local authorities for the proper training andlicensing

Trained:Have read and thoroughly understand all aspects of this manual, the manual for thehost equipment, have practiced and tested the operation of the hammer and hostequipment, and have a thorough understanding of generally accepted principles ofoperation of heavy equipment.

Experienced:In the operation, care and proper maintence of heavy equipment and hydraulichammers.

Physically Competent:Excellent HearingExcellent VisionExcellent CoordinationPhysically capable and willing to perform all of the required functions in the safeoperation of the hammer and host equipment.


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WARNING!

GENERAL Safety DOs and Donts:

NEVERoperate the hammer or host equipment with any person near the work area.Broken rocks, concrete pieces, and metal splinters may become projectiles, possiblycausing death or serious injury.

ALWAYSwear hearing protection, eye protection (approved impact resistant safetygoggles), and approved head protection (hardhat) while operating the hammer.

ALWAYSmake sure appropriate shields are installed and used on the hammer andoperators area of the host equipment. Broken and flying debris or pressurized oil may

enter the operators area and could cause death or serious injury.

NEVERleave the operators cab while the hammer or machine is running.

ALWAYSstop the engine of the host equipment and lower the hammer, boom andany other parts of the equipment to the ground before attempting to make any repairsor adjustments to either the host equipment or the hammer.

ALWAYScheck that all safety decals attached to the hammer are legible prior tooperating. If decals are worn or illegible, immediately visit

www.MaverickHammers.comor call us toll free at 800-417-3259 (401-738-6800) forreplacement decals before operating.

ALWAYSbe aware of any dangerous conditions or prohibited work areas. Theseinclude (but are not limited to): Excessive slopes which could cause equipmentrollover, overhead or underground power lines, gas lines, utilities, tanks, very softground including poor or dangerous terrain, or other hazardous conditions and/or utilityhazards.

NEVERuse any kind of drugs or alcohol that may impair your alertness, physicalabilities, or coordination while operating the hammer or host equipment. Anyone taking

prescription drugs MUST obtain written permission from their doctor or medicalprofessional before operating the hammer or host equipment.

ALWAYSwork at a slow and careful pace when operating the hammer or hostequipment.
http://www.maverickhammers.com/http://www.maverickhammers.com/http://www.maverickhammers.com/


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ALWAYSoperate the hammer and host equipment from the operators seat ONLY.Make sure the seatbelt is securely fastened before starting the hammer or hostequipment.

ALWAYSkeep hands and feet on the controls while the hammer is operating.

ALWAYSmake sure all controls (levers and pedals) are in NEUTRAL beforestarting the carrier.

ALWAYScheck hydraulic hoses and fittings for leaks and damage prior tooperating the hammer and host equipment.

NEVER leave the host equipment with the engine running.

NEVERwear baggy clothes, loose jewelry, or anything else that may be caught bythe controls of the host equipment or hammer.

NEVERoperate the hammer or host equipment with any person near the work area.

Broken rocks, concrete pieces, and metal splinters may become projectiles, possiblycausing death or serious injury.

Safety Precautions

This manual contains safety, operation, and routine maintenance instructions. It doesnot contain service disassembly instructions. If needed, complete service disassemblyand assembly instructions are contained in the Service Manual Part Number HSPSM-1015(A), which can be ordered from Maverickor any factory authorized MaverickDealer or MaverickCertified Service Center.

Hammer operators and all maintenance personnel must comply with all safetyprecautions presented in this manual and on all markings on the hammer. Failure todo so may result in death or serious injury.

These instructions, precautions, and guidelines are provided for your safety and for thesafety of those around you. It is critical that they are reviewed carefully BEFOREunpacking, installing, operating, and/or servicing the hammer.

Operators and supervisory personnel should be familiar with local regulationsgoverning job safety and the operation of heavy equipment and hydraulic hammers.


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a DANGER

SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER

HANDLING, INSTALLATION, OPERATION, MAINTENANCE, OR

REPAIR/SERVICE OF THIS HAMMER. REPAIRS AND/OR SERVICE TO THIS

HAMMER SHOULD ONLY BE PERFORMED BY TRAINED PERSONS OR A

MAVERICKAUTHORIZED DEALER AND/OR SEVICE CENTER.

Operating Safety Precautions

MaverickHSP Series Hammers will provide safe and reliable performance andoperation in accordance with the instructions given in this manual. Please read and

understand this manual and any decals and tags attached to the hammer beforeoperation. Failure to do so could result in death or serious injury and equipmentdamage. Please strictly adhere to the following safety precautions:

Operate the hammer at all times in accordance with all laws and regulations.

Do not operate the hammer unless you have read the host/carrier equipmentmanual.

Ensure that all maintenance procedures recommended in this manual arecompleted before installing, operating, maintaining and/or servicing the hammer andhost equipment.

The operator must not operate the hammer or the carrier with anyone within thearea where they may be injured by flying debris or movement of the equipment.

Know the limits of the equipment.

Establish a training program for all operators to ensure safe operation.

Do not operate the hammer unless thoroughly trained or under the supervision of a

qualified instructor.

Become familiar with the carrier controls before operating the carrier and/or thehammer.

While learning to operate the hammer and carrier, do so at a slow and cautiouspace. If necessary, set the carrier mode selector and throttle to the slow position.


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Before leaving the carrier, always lower the boom and ensure the carrier is stable.Never leave the operators area of the machine with the engine running. Always engagethe parking brake.

Stop the engine before attempting to make any repairs, adjustments to, or servicingof either the carrier or the hammer.

Do not operate the hammer at oil temperatures above 175 F/ 80 C. Hammer andcarrier operation at higher temperatures can cause damage to the internal componentsof the hammer and carrier and will result in reduced hammer performance.

Do not operate a damaged, leaking, improperly adjusted, or incompletelyassembled hammer or carrier equipment.

Never modify the hammer in any manner, whatsoever.

Use only genuine MAVERICK Hammer Tools. Use of hammer tools produced bysome manufacturers may damage the equipment and may void the warranty.

To avoid personal injury and/or equipment damage, all hammer repair,maintenance, and/or service should only be performed by properly trained personnel.For assistance, please contact MAVERICKor an authorized MAVERICKDealer/Service Center.

f you do not understand how to safely operate your hammer, contact MAVERICKor an authorized MAVERICKDealer for assistance.

Keep this manual with the hammer.

Do not operate this equipment if you are taking medication which may affect yourmental judgment or physical performance.

Remove the hammer from the carrier during transport

Read and completely understand this Manual before using the equipment


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SECTION 2 - Standard Specifications

Model HSP 400 500 750 1000

Energy Class ft. lbs. 250 350 500 750

Operating WeightKg 135 175 210 330

Lbs 298 386 463 728

Operating Pressurebar 90 - 120 90 - 120 90 - 130 95 - 130

psi 1305 - 1740 1305 - 1740 1305 - 1885 1377 - 1885

Oil Flowl/min 20 - 40 25 - 40 30 - 50 30 - 60

g/min 5.25 - 10 6.6 - 10 8 - 13 8 - 16

Back Head Pressurebar 13 - 15 13 - 15 13 - 15 13 - 15

psi 189 - 218 189 - 218 189 - 218 189 - 218

Accumulator Pressurebar - - - -

psi - - - -

Impact Rate bpm 650 - 1,200 550 - 1,100 500 - 1,000 450 - 1,000

Tool Diametermm 45 53 60 68

inch 1.8 2.1 2.4 2.7

Carrier Weight lbs. 3,000 - 7,000 6,000 - 10,000 7,000 - 12,000 10,000-17,000

Model HSP 1500 2250 3250 4750

Energy Class ft. lbs. 1,000 1,500 2,500 3,500

Operating Weight Kg 400 500 795 1280Lbs 882 1275 1755 2821

Operating Pressurebar 100 -130 130 - 150 150 - 170 140 - 170

psi 1450 - 1885 1885 - 2175 2175 - 2465 2030 - 2465

Oil Flowl/min 40 - 90 45 - 80 80 - 110 90 - 120

g/min 10 - 24 12 - 21 21 - 29 23 - 32

Back Head Pressurebar 13-15 15 -17 15 -17 5 -7

psi 189-218 218 -247 218 -247 73 -101

Accumulator Pressurebar - - - 55

psi - - - 798

Impact Rate bpm 450 - 900 450 - 700 400 - 700 350 - 750

Tool Diameter mm 75 85 100 120inch 3.0 3.4 3.9 4.7

Carrier Weight lbs. 14,000-19,000 16,000 - 24,000 22,000 - 38,000 35,000 - 48,000

Model HSP 5250 6250 8250 9250

Energy Class ft. lbs. 4,500 5,500 6,000 8,500

Operating WeightKg 1690 1754 2336 2650

Lbs 3726 3867 5150 5842

Operating Pressurebar 160 - 180 160 - 180 160 - 180 160 - 190

psi 2320 - 2610 2320 - 2610 2320 - 2610 2,320 - 2,702

Oil Flowl/min 125 - 150 120 - 180 160 - 190 190 - 250

g/min 33 - 40 38 - 48 42 - 50 50 - 66

Back Head Pressurebar 5 -7 5 -7 5 -7 15 -17

psi 73 -101 73 -101 73 -101 218 -247

Accumulator Pressurebar 55 55 55 60

psi 798 798 798 870

Impact Rate bpm 300 - 600 350 - 500 450 - 750 260 - 400

Tool Diametermm 135 140 150 160

inch 5.3 5.5 5.9 6.3

Carrier Weight lbs. 38,000 - 54,000 42,000 - 65,000 55,000 - 89,000 72,000105,000


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SECTION 3 - How the Hammer Operates

Through Bolt: The Front Head, Cylinderand the Back-Head of the main body aresecured with four through bolts.

Back-Head: The Gas Charging Valve is

integral and charged with N2-gas.

Valve Assembly: The Cylindrical controlvalve is built in to the valve housing andcontrols piston reciprocation.

Piston: Kinetic energy of the piston isconverted into hammering energy afterstriking the Tool. The Hammer energy istransmitted to the Tool.

Front Head: The Front Head supports theforce of the hammer. The Thrust Ring andthe Thrust Bushing attenuate recoil fromthe Tool.

Tool: The MaverickTool is heat-treatedand is directly applied to subject material.

Accumulator Assembly: Theaccumulator compensates for pressurechanges in the hydraulic circuit. Chargewith N2-gas only


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Principle of Operation

The relationship between the pressure affectedarea A1 of the piston rear chamber and thepressure affected area A2 of the piston frontchamber is A1>A2. High-pressure oil is appliedto A2. When oil pressure applied to A1 ischanged from high to low pressure and viceversa. Piston C2 then reciprocates. Similarly therelationship between the pressure affected area

A3 of the valve high-pressure chamber and thepressure affected area A4 and A3. High-pressure oil is applied to A3, A4, nd A3


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Valve Charging

When the piston moves backward and the piston rearchamber B1 is connected to the valve change portB3, the high-pressure oil acts upon the valve changechamber V4 and the valve changes.

At this time, the piston rear chamber B1 isdisconnected from the valve low-pressure chamberV3 and connected to the valve high-pressurechamber V1 and pressure in the piston rear chamberB1 increase.

Piston Hammering Stroke

When piston C2 reaches top dead center, high-

pressure oil from the valve high-pressure chamberV1 acts upon the piston rear chamber B1 and in thehammering stroke is converted into the compressedgas energy in the Back-Head. The valve is heldopen because of the high-pressure chamber V1 andvalve change chamber V4.


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SECTION 4 - Installation

DO NOT INSTALL THE HAMMER WITHOUT FIRST PRESSURE AND FLOWTESTING THE HOST EQUIPMENT! IMPROPER HYDRAULIC FLOW AND/ORPRESSURES WILL DAMAGE THE HAMMER AND VOID ANY WARRANTY!

a WARNING

CHECK THE "SPECIFICATIONS" SECTION OF THIS MANUAL TO DETERMINECORRECT CARRIER EQUIPMENT HYDRAULIC PRESSURES AND FLOW

REQUIREMENTS.

IF HYDRAULIC PRESSURE OR FLOW ARE EXCEEDED, THE HAMMER WILL BEDAMAGED AND MAY VOID ANY WARRANTY

a WARNING

HYDRAULIC FLUID IN THE HYDRAULIC SYSTEM MUST BE CLEAN

CHECK THE HYDRAULIC FILTER. REPLACE THE FILTER EACH 100 HOURS OFUSE

HOSE AND PIPING MUST BE FLUSHED WHEN CHANGING FILTERS


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Hammer Installation - Steps

STEP 1. Flow and pressure test carrier/host equipment BEFORE mounting orconnecting the hammer. Flows and pressures must be set according toRecommended Circuit Relief Pressure Settings and Back Pressures (seechart) or internal damage will result.

STEP 2. Carefully unpack and remove the hammer and any components fromany shipping materials.

STEP 3. On safe and level ground, install hammer tool retainers and keepers.

STEP 4. Connect hoses to hammer and carrier host equipment. (Caution:Make sure that pressure line from the carrier is connected to the portmarked IN on the hammer and that the return line to the carrier isconnected to the hammer port marked OUT If these lines are

reversed and the hammer is operated, internal damage to the hammerWILL result.

STEP 5. During Break-in period (first 5 hours of operation) operate the hammerat 1/3 speed (throttle).


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Recommended Circuit Relief Pressure Settings and Back Pressures

Model HSP 400 500 750 1000

Relief Setting Pressurebar 110 - 140 110 - 140 110 - 140 120 - 150

psi 1564 - 1991 1564 - 1991 1564 - 1991 1706 - 2133

Back Pressure (Max)bar 5 5 5 5

psi 72 72 72 72

Model HSP 1500 2250 3250 4750


psi 1849 - 2275 1991 - 2275 2133 - 2417 2275 - 2560

Back Pressure (Max) bar 5 5 5 8psi 72 72 72 116

Model HSP 5250 6250 8250 9250


psi 2560 - 2844 2560 - 2844 2560 - 2844 2560 - 2986

Back Pressure (Max)bar 8 8 8 8

psi 116 116 116 116


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Hydraulic pipe lines for exclusive use:

Operation of the hydraulic hammer requires installation of hydraulic pipes. Thesepipes should be for the exclusive use of the MAVERICK Hydraulic Hammer.Hydraulic pipes may vary depending on host machines and hydraulic pressures, oilcapacity, pressure loss and other conditions of the carrier.


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Removal of the Hydraulic Hammer

STEP 1. Move the carrier equipment and hammer to stable ground free from mud,dust and dirt. Lower the boom and attachments (including hammer) tostable ground and place hammer on solid and level wooden blocks.

WARNING: NEVER PLACE ANY PART OF BODY BETWEEN HAMMERAND GROUND OR MACHINE AS IT COULD MOVE AND CRUSH!.Stop the engine. Turn off the main switch and release air from the oil tankif it is pressurized

Step 2. Turn the shut off valve (installed to the end of the boom/arm) to the "off"position to prevent the hydraulic oil from flowing out


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STEP 3. Loosen the hoses on the hammer. Collect any oil overflow andplace into a container for proper disposal. Be careful to prevent mud ordust from touching or entering the oil hoses and the pipe lines. Plug theoil hoses with the hose plugs, and the pipe lines with the union caps. Bindthe high-and low pressure hoses with a wire to prevent them from falling.Wrap the ends of the hoses with plastic to prevent contamination. Anydirt or particles may contaminate the hydraulic system of the carrier anddamage to hammer.

STEP 4. Remove hammer from machine. To remove the hammer, make sure anypressure is removed between the carrier machine and the hammer pins.Remove the pins in the bucket link first, then remove the stick (dipper)pin. CAUTION: When storing the hammer for more than one (1) weekcover with weatherproof protective cover.

Oil Hose Plug

The Oil hose plug is a stopper

aimed at preventing mud or dust

from entering the oil hose

attached to the hydraulic

hammer during the bucket

operation.

Union Cap

Union caps prevents mud or

dust from entering the pipe lines

attached to the machine body.

When storing the hammer for long periods (more than three months), clean the exteriorof the hammer. Remove the Tool from the hammer and spray with rust preventive oil. .Have a trained technician or a Maverick Dealer or Authorized Service Center relievethe N2-gas from the Back-Head and push the piston into the cylinder. Grease shouldbe applied to each part of the hammer cylinder wall and then the tool should be re-installed NOTICE: For Storing the hammer over extended periods (more thanthree (3) weeks) the hammer should be stored vertically in a stable position.Please contact Maverick or your nearest Maverick Dealer for a Storage Stand(not included)


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SECTION 5 - Operation (Hammering)

Proper position of the tool

The hammer must be applied in the proper position for effective use its force and toprevent damage to the hammer or carrier equipment. When the position is incorrect,the hammer energy of the piston is not transferred properly and the hammers forceshocks the hammer and the stick and boom of the carrier machine.

When the position of the front of the base machine is raised (including tracks), the

machine may suddenly tilt forward when the subject material is broken. The hammerbody may hit the ground and/or subject material and result in damage to hammerand/or carrier equipment.


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Alignment of the Tool

Apply the direction of force in line with the Tool and place the Tool on the hammeringsurface vertically (perpendicular to the surface of the subject material). DO NOTPLACE THE TOOL AT AN ANGLE TO THE MATERIAL OR PRY WITH THE HAMMERTOOL. This may cause the Tool to seize or break and will cause piston damage.

Operation Precautions

aIMPORTANT

DO NOT BREAK CONTINUOUSLY IN ONE PLACE - CONTINUOUSPENETRATION IN THE SAME AREA FOR LENGTHILY PERIODS WILLCREATE EXCESSIVE TEMPERATURES AT THE END OF THE TOOLRESULTING IN LOSS OF TEMPER(HARDNESS) OF THE TOOL ANDCAUSE DAMAGE TO THE TIP OF THE TOOL, AND MAY LEAD TOFAILURE OF THE BIT

aIMPORTANT

NEVER USE THE TOOL OR HAMMER AS A PRYING OR LIFTINGDEVICE


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a CAUTION

BEFORE LEAVING THE CARRIER, ALWAYS LOWER THE BOOMSO THAT THE CARRIER IS STABLE. NEVER LEAVE THE MACHINEWITH THE ENGINE RUNNING

ALWAYS ENGAGE THE PARKING BRAKE BEFORE LEAVING THECONTROLS

Stop operation if Hammer hoses jump or vibrate excessively.

Excessive vibration of both hoses of the hammer calls for instant disassembly andrepair of the Hammer. If this occurs, immediately contact Maverickor a MaverickDealer or Authorized Service Center

Avoid all blank firing of the hammer

The moment the subject material is broken, stop hammering. Continuous blank firingthe Hammer will damage front head, piston, and loosen and break internal bolts. Blankfiring occurs when the Tool is not properly applied with pressure to the subject material(rocks) or the hammer or the Tool is used as a prying device. A sign of this is whenhammer recoil sound becomes extremely rapid during hammer operation.


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Avoid moving rocks with the side of the Hammer

Do not use the Tool as a lever.

Do not pry with the hammer or the tool! Never use the tool as a lever. Damage to thetool or hammer will result.


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Continuous Hammering

Extended hammering at the same place causes the excessive tool wear (due tooverheating) and could result in tool failure.

Always begin breaking material at an edge

This will result in the most efficient operation of the hammer

DO NOT operate the hammer at fifty percent (50%) engine speed

Raising engine speed more than necessary does not strengthen the hammer force andincreases hydraulic oil temperature which will result in damage the hammers internal

components.


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Do not operate the hammer in water and mud

Do not operate the hammer when components (except Tool) are immersed in waterand/or mud. The piston and similar components may gather rust and becomedamaged.

aIMPORTANT

DO NOT USE UNDERWATER WITHOUT AIR APPLICATION(UNDERWATER) KIT

o NO PART OF THE MAVERICK HSP SERIES HAMMER MAYBE SUBMERGED IN WATER WITH IT FIRST ADAPTING THEHAMMER FOR UNDERWATER USE.

o USE OF THE HAMMER UNDERWATER REQUIRES AN

UNDERWATER APPLICATION KIT AND AN AIRCOMPRESSOR CAPABLE OF PRODUCING 6000LPM /150PSI. (PLEASE CONTACT MAVERICK)

o UNDERWATER USAGE OF THE HAMMER WITHOUT THEUNDERWATER KIT AND AIR COMPRESSOR WILL CAUSEINTERNAL DAMAGE TO THE HAMMER. -SEE UNDERWATEROPERATION OF THE HAMMER


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Do not allow the hammer to fall to break a rock

Dropping the hammer onto a rock will apply excessive force to the hammer or thecarrier machine, causing damage to the hammer and the carrier machine.

Do not hammer with the carrier equipment cylinders at the end of their stroke ineither direction.

Hammering with carrier cylinders fully extended or retracted will damage to the

cylinders of the carrier equipment


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Never use the hammer as a lifting device

Warm up carrier equipment prior to operation

Especially in winter, the base machine engine should be warmed up to oil temperatureof at least (80f -105f / 30C - 40C) before hammer operation.

All personnel must stay well clear of the hammer during and immediatelyfollowing its operationFlying debris, heated hydraulic oil and hammer parts (including tool), and unstablesubject material can pose serious risk of Death or personal injury. During hammeroperation, the hammer parts can reach high temperatures.

When operating the hammer you must use the ear, eye and breathingprotection

Accumulator Pressure DangerDANGER! The Accumulator is under extremely high pressure. DO NOT OPEN!

Please consult with Maverickor your nearest Authorized MaverickDealer orService Center.

Eye ProtectionAlways wear the impact resistant eye protection when operating, maintaining, servicingthe hammer (including while removing the stop pin or changing tools)


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Section 6 - Hydraulic Hammer Maintenance

MAVERICKHydraulic Hammers are built to last and will deliver years of trouble freeoperation, provided that they are properly maintained.

Regular Hammer Inspection and Maintenance Regular inspection is essential forkeeping the hydraulic hammer operating in the best condition. It is highlyrecommended that customers contact an authorized and trained hammer technician forinspection within six months of original hammer purchase.

Daily Hammer InspectionBefore starting operation, be sure to inspect the hammer referring to the followingtable:

Inspection Item Inspection Point

.

Loose, missing or damaged to thebolts, nuts, and fasteners

...

Through bolts Bracket mounting boltsAccumulator bolts

.

Loose hose fittings,. Hydraulic pipes for the hammer

Visible damage to the hoses . Oil hoses

Leaking hoses

.

Hammer oil leaks

..

Connections of the Back-Head and thecylinder. Clearance between the fronthead & the Tool

.

Abnormal wear and cracks on theTool

.

Tool

.

Greasing/Lubrication

..

Grease each day hammer startup and10 pumps every 3 hours using thehead grease pump

.

Hydraulic oil: level andcontamination

.

Hydraulic Reservoir (Carrier Machine)

.

Missing rubber plugs and snaprings

..

Rubber plugs Snap rings HammerBody


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Greasing and Lubricating

To grease hammer: With the hammer mounted on the carrier, apply down pressure onthe Tool and pump grease into grease fitting as indicated on hammer to fill cavity withthe recommended grease.

Greasing/Lubricating the Hammer

STEPS:

1. With the hammer mounted on carrier, applypressure to the Tool, in the vertical position.

2. Fill the cavity with recommended grease

3. Grease AT LEAST EVERY THREE HOURS OF

USE

4. When installing a new Tool, liberally coat theupper 1/3 of the Tool with grease before inserting

5. Avoid getting rock or cement chips into the toolcavity when replacing hammer tools. Particleswhich may have adhered to the grease cancause scratches and scaring inside the hammer.

6. Failure to comply with these instructions WILLresult in damage to the hammer and may void

any warranty

Grease

MaverickHydraulic Hammers are equipped with grease fittings. Lack of lubricationcan cause failure of the working tool, piston, and or shorten the life of the seals. AnNLGI NO.2 grease is recommended. The following is a list of the recommendedgreases: SHELL ALVANIA EP2, ESSO LITHTAN EP2, MOBIL MOBILPLEX 48


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Hydraulic Oil

Selection of Oil

The Selection of the hydraulic oil determines the efficiency of thehydraulic hammersperformance. MAVERICK recommends ShellTellus56/Mobile DTE26 and Shell Tellus Oil 46/Mobile DTE25 for coldweather operations.

Please consult with MAVERICK or an Authorized Maverick Dealer orService Center under following conditions:

a) When used in special regions where the climate is extremely cold or hot.Oil viscosity may be changed at different constant ambient airtemperatures.

b) When recommended brand of hydraulic oil is not available.

c) When hydraulic oils supplied for the base machine differ from therecommended one.

Oil Contamination

Contaminated oil will result in malfunctions of the hammer as well as thebase machine and cause damage. Pay special attention to oilcontamination. Contaminated oil should be changed without delay.When changing oil, thoroughly wash the oil tank, the carriers cylindersand pipes. When cleaning or replacing the oil filter always check for oil

contamination.

Replacement of the filter: After first 50 hours and every 100 hours ofhammer use.

Replacement of the hydraulic oil: Every 300 hours of Carrier orHammer use.

a WARNING

HYDRAULIC OIL TEMPERATURE AND VISCOSITYDo not operate the hydraulic hammer at oil temperatures from 20/68to 80

/176. Operation at higher temperatures can damage the internal components of

the hammer and the excavator, which will result in reduced hammer performance.


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Criteria of Oil Contamination and Malfunction (General Analysis)

Analysis Item Criteria Causes and Effects when exceeds the criteria

Adhesiveness Within 10%

(104f/40cst) Adhesiveness rarely decreases due solely to of oil use. Entryof different kinds of oil may reduce the adhesiveness which

contributes to rising oil temperatures, wear and stretch ofbearings and gears, and malfunction of hammer.

Oxidizing Less than 0.3

Level (mg KOH/g) Use of lubricating oil for long periods under hightemperatures will oxidize it. Oxidizing level rises asoxidization proceeds. Sludge will be produced during theprocess, leading to unsatisfactory operation of the hammer,erosion of metals or obsolescence of seal materials.

Moisture Less than0.1(%) Moisture causes rust, wear and stretch. Moisture of >0.1%

gathers a considerable amount of rust inside of the hammer.moisture of >0.3% more will cause severe damage to thehammer.

Criteria of Hydraulic Oil Failure by Oil Color (Discrimination by ASTM color)

Hydraulic oil becomes darker when it is contaminated or worn. Hydraulic oil is

contaminated when there is a visual difference between the operating oil and new oilcolor, and functions begin to deteriorate when hydraulic oil becomes darker than thenew oil color by more than (ASTM number) two (2).


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SECTION 7 - Hammer Inspection and RepairInspection Points

Model HSP 500 1000 1500 2250 3250 4750 5250 6250 8250 9250

Through Bolt

Kg.m 40 40 40 100 150 175 225 240 250 360

ft. lbs. 289 289 289 723 1,085 1,266 1,627 1,736 1,808 2,604

Charge ValveKg.m 35 35 35 35 35 35 35 35 35 35

ft. lbs. 253 253 253 253 253 253 253 253 253 253

Side BoltKg.m 100 100 100 145 170 200 250 250 305 360

ft. lbs. 723 723 723 1,049 1,230 1,447 1,808 1,808 2,206 2,604

Mounting CapKg.m 40 40 40 80 100 130 150 150 160 220

ft. lbs. 289 289 289 579 723 940 1,085 1,085 1,157 1,591

Flange Adapter BoltKg.m 20 20 - 20 20

ft. lbs. 145 145 - 145 145

Valve Cover BoltKg.m 60 60 - 45 45

ft. lbs. 434 434 - 326 326

Valve Body Bolt Kg.m 45 45 - 45 45ft. lbs. 326 326 - 326 326

Acc' Body BoltKg.m 60 60 60 60 60

ft. lbs. 434 434 434 434 434

Acc' Cover BoltKg.m 45 45 45 45 45

ft. lbs. 326 326 326 326 326


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Check Torque and Tighten Through Bolts Every 150 Hours of Operation. All Others:

Every 300 Hours of Operation

**All bolt torques should be tightened in sets. To properly set, all bolts in that group should first beloosened, and then re-tightened in stages, so all bolts in the torque group share the load equally.

SECTION 8- Hammer Tool Replacement

Replacement of the Tool: When a Tool tip is worn out, it can be sharpened. Grindingthe Tool tip more than twice to sharpen the edge will remove the heat-treatedhardening. After two (2) sharpenings, the tool should be replaced.

STEP 1. Pull out rubber cap using screwdriver or end-pointed instruments.

Disassemble Rubber caps.

.


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STEP 2. Insert the MAVERICK pin removal tool (part# T10587) into the stop pin

hole and strike the pin using pin removal tool. Remove the stop pin.


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STEP 3. Insert the MAVERICK pin removal tool (part# T10587) into the tool tool

retainer holes and push out the retainers. Remove the tool retainers.

Step 4. Set a nylon lifting sling in the center of the tool and lift it just enough to takethe bottom pressure off of the tool. Remove the tool slowly using extremecaution.


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STEP 5. Before installing a new Tool, check each part for wear, breakage, andscores. Remove any debris or burrs on each Tool Retainer asnecessary. Apply lubricating grease to the Tool Retainers.

STEP 6. Install Tool reversing the process in steps 1-4.

CAUTION- Excessively deformed Tool Retainers will make replacement of the Tool

difficult and will damage the tool and hammer. Replace the Tool Retainers with ONLYGenuine MAVERICK Parts, as they are machined to specific tolerances designed forthe hammer. Not using Genuine MAVERICK Tool Retainers and Hammer Toolsmay damage your hammer and may void any warranty.


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Bushing Wear

When the gap between the tool and the tool bushing becomes in excess of thetolerances listed in the chart below, the tool bushing MUST be replaced. Excessbushing wear can cause the piston to fail to precisely strike the upper part of the tool,resulting in hammer damage. Bushings and tools should be replaced together. Pleaserefer to the chart below for proper tolerances.

Tool/Bushing Wear Limits

Model

Dimension Width of Wear

(mm/inch)ToolBush (mm/inch) ToolDia. (mm/inch)

400HSP 45/1.77 45/1.77 3/.11

500HSP 53/2.08 53/2.08 3/.11

750HSP 60/2.36 60/2.36 4/.15

1000HSP 68/2.67 68/2.67 4/.151500HSP 75/2.95 75/2.95 4/.15

2250HSP 85/3.34 85/3.34 5/.19

3250HSP 100/3.93 100/3.93 6/.23

4750HSP 120/4.72 120/4.72 7/.27

5250HSP 135/5.31 135/5.31 8/.31

6250HSP 140/5.51 140/5.51 8/.31

8250HSP 150/5.90 150/5.90 9/.35

9250HSP 160/6.29 160/6.29 11/.43


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SECTION 9 - Charging the Hammer

Inspection and Charging N2-Gas at the Back-Head

a

WARNING CHARGING GAS PRESSURE CHANGES ACCORDING TO THE TOOL CONDITION.

LAY DOWN THE HAMMER AND EXTEND THE TOOL FULLY.

STAY CLEAR OF THE TOOL WHILE CHARGING THE HAMMER WITH GAS. THETOOL AND/OR PISTON MAY MOVE ABRUPTLY

WHEN THE THROUGH BOLTS ARE CHANGED, THE N2 GAS MUST BEDISCHARGED FROM THE BACK HEAD. PLEASE CONSULT MAVERICKOR ATRAINED HAMMER TECHNICTION. DANGER : THE BACKHEAD IS HIGHLYPRESSURIZED

USE NITROGEN GAS ONLY

SEE "CONVERSION TABLE FOR CHARGING N2 GAS PRESSURE TO THE BACKHEAD"

Inspection of N2-Gas at the Back-Head

1. Make sure that the cap and the valve of the gas charging kitare fullytightened. Screw the gas charging kitinto the charging valve of the Back-Head

after removing the plug

2. At this time the valve handle must be in to prevent the gas from leaking out

3. Push the handle into the charging valve fully, so the gas pressure inside theBack-Head is indicated on the pressure gauge

4. If gas pressure is normal (see chart), unscrew the gas charging kit. Reinsert theplug to the hammer

5. If the N2-gas pressure is too high or low, charge it as described below


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Charging of N2-Gas into the Back-Head

1. Connect the charging hoseto N2-gas cylinder after screwing the bombadapter onto adapter nut and installing than to the N2-gas cylinder

2. Connect the gas charging kit to the charging hoseafter unscrewing the capon the gas charging kit

3. Install the gas charging kit

to the charging valve of the Back-Head. At thistime the handle of the gas charging kit must be up position to prevent the gasfrom coming out

4. Push the handle of the gas charging kit fully and turn the handle of the N2-gascylinder counter clockwise gradually to charge the Back-Head

5. When the gas pressure exceeds 10% higher then the specified pressure, closethe N2-gas cylinder by turning the handle clockwise

6. Leave the handle of gas charging kit up. generated pressure makes, it return

back to original position naturally

7. Remove the charging hose from the N2-gas cylinder and the gas chargingkit and screw the cap onto the gas charging kit.

8. Push the handle of the gas charging kit fully, and the gas pressure inside theBack-Head is indicated on the pressure gauge. When the pressure is higher,discharge a small amount of gas from the Back-Head repeatedly opening andclosing the valve and then gas pressure falls to the specified pressure

9. When the gas pressure reaches to the specified pressure, close the valve andrelease the handle

10. Open the valve completely and discharge gas inside the gas charging kit.Remove the gas charging kit from the charging valve of the Back-Head andinstall the plug to the charging valve


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Inspection of N2-Gas in the Accumulator

Be sure to use only the MAVERICK Charging Kit for charging the hammer with N2-gas.

If charging gas leaks directly from the cylinder, the diaphragm may have failed.

If charging for handling N2-gas to only the accumulator, make sure that theaccumulator body and the cover are tightened fully

1. Make sure the cap and the valve of the gas charging kitare fully tightened

2. Remove the capfrom the accumulator and tighten the charging valvefully

3. Check if the O-ringsare installed to the bushing. Remove the plug

and the screw in the bushing.

4. Install the bushingto the gas charging kit

5. Loosen the charging valvegradually. The charging pressure is indicated on

the pressure gauge.

6. Close the valve clockwise when the gas pressure is normal. When the gaspressure is higher, repeat loosening and tightening the valve of gas charging kit.The pressure is lowered gradually.

7. Loosen the valve of the gas charging kit to discharge the N2-gas in the gas

charging kit

8. Remove the gas charging kitand tighten the plugand the cap

Charging on N2-Gas into the Accumulator

1. Connect the charging hoseto the N2-Gas cylinderafter screwing the

adapteron to the adapter nutand installing to the N2-Gas cylinder.

2. Connect the gas charging kitto the charging hoseafter unscrewing the

cap of the gas charging kit

3. Remove the accumulator capfrom the accumulator and tighten the charging

valvefully

4. Check to make sure the o-rings are installed on the bushing. Remove

the plugand screw in the bushing.


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5. Loosen the accumulator charging valveafter checking if the bushingis

installed to the gas charging kit.

6. Turn the N2-Gas cylinder handle clockwise slowly to charge gas

7. Add charge gas in accordance with the conversion table for charging N2-Gaspressure to the accumulator.

8. Turn the N2-Gas cylinder handle clockwise to close.

9. Close the accumulator charging valve.

10. Loosen the valve of the gas charging kit to discharge the N2-Gas remaining inthe charging hose

11.Remove the charging hose, the gas charging kit and the bushing, and tighten

the plugand cap.

WARNING!USE SPECIAL CARE TO HANDLE AND STORE THE N2-GAS CYLINDER AS IT IS A HIGHLYPRESSURIZED CONTAINER.

USE NITROGEN GAS ONLY.

STANDARD ACCUMULATOR GAS PRESSURE is 55kg/cm2/780PSI AT 20 /68 AMBIENT

TEMPERATURE. DO NOT OVER PRESSURIZE THE ACCUMULATOR.

SEE "CONVERSION TABLE FOR CHARGING N2-GAS PRESSURE TO THE ACCUMULATOR".


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SECTION 10 -Trouble-Shooting Guide

The trouble-shooting chart is to help operators identify and locate causes and remedieswhen operating trouble occurs

TROUBLE CAUSE REMEDY

1. Hammer fails to operate:(1) Sufficient high pressure oildoes not flow to hammerinlet. (2) Sufficient highpressure oil flows to hammerinlet.

(a) Defective hose or pipes.Closed valves on Carrier machine.Clogged or damaged piping (b)Defective control valve and relatedparts. Missing or damaged tie Toolor control cable (c) Insufficienthydraulic oil (d) Internal hammerdefects

(a) Check, clean and repairpiping or replace with new ones.(b) Check and repair Valve andits related parts or replace withnew ones. (c) Refill the oil tank.(d) Consult with our servicestation.

2. Hammer operates withreduced force. (1) Sufficienthigh pressure oil does not

flow to hammer inlet. (2)Sufficient high pressure oilflows to hammer inlet.

(a) Defective hose or pipes .Closed (or partially) valves onCarrier machine. Clogged or

damaged piping (b) Defectivecontrol valve and related parts.Defective pedal/control. Defectivecontrol valve. Stuck control valve.Insufficient control valve stroke. (c)Clogged filter in return line ofcarrier machine (d) Insufficienthydraulic oil (e) Contaminated ordeteriorated hydraulic oil (f)Defective carrier machine pump(g) Internal hammer failure . Entryof contaminated articles inhydraulic system(h) Drop in N2-

gas pressure of Back-Head

(a) Check, clean and repairpiping or replace. (b) Checkcontrol Valve and related parts

or replace. (c) Clean or replace.(d) refill. (e) After flushing tank,change oil entirely (f) ServiceCarrier Machine pumps(s) (g)Consult with AuthorizedMAVERICKDEALER orAuthorized Service Center (h)Adjust the gas pressure refer toChart.

3. Hammering force suddenlydrops and high pressure hosevibrates excessively duringoperation.

(a) Failure of Back-Head or Gasleakage

(a) Ask our service station forrepairs

4. Excessive oil leaks from

front head or Tool.

(a) Worn cylinder seals (a) Ask our service station for

repairs

5. Piston works but does nothammer.

(a) Tool Jammed (with subjectmaterial)

(a) Remove front parts and pullout Tool, check, clean andreplace.


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