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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual Safety Precautions Standard Specifications Principle of Operation Installation and Removal Operation of the Hammer Maintenance Inspection and Repair Hammer Tool Replacement Inspection and Charging of the Hammer Trouble Shooting Guide Parts Manual

MAVERICK™ HYDRAULIC HAMMERS OWNERS & OPERATORS MANUAL

(401)738-6800 www.maverickhammers.com


MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual Welcome! Thank you for purchasing a MAVERICK™ Hydraulic Hammer. We want you to know that our entire company appreciates your business and we are here to support you whenever you need us. You may contact us with any questions, comments, or concerns at www.MaverickHammers.com or call us at (401)738-6800. MAVERICK™ Hydraulic Hammers have been designed and manufactured by a highly skilled and experienced team and quality is built in to all of our products. Our hammers 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 for many years. Please read this Manual carefully BEFORE INSTALLING OR OPERATING THE HAMMER. When replacing parts, be sure to use only MAVERICK™ GENUINE PARTS. Failure to do so may seriously impair the operation of the hammer and may also void any warranty.

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual

TABLE OF CONTENTS Section 1 2 3 4 5 6 7 8 9 10

Description Safety Precautions Standard Specifications Principle of Operation Installation and Removal Operation of the Hammer Maintenance Inspection and Repair Hammer Tool Replacement Inspection of Charging of the Hammer Trouble Shooting Guide

Page 3 8 10 12 18 2 30 32 37 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 personnel involved in the maintence or operation of the hydraulic hammer and/or host equipment are advised to read it at periodical intervals. If the Manual should be lost or damaged immediately contact MAVERICK™.

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual Section 1 - SAFETY It is important to understand that circumstances, hazards, and potential dangers may exist relating to conditions beyond the scope of this manual. Please use common sense, and if in doubt, DONT DO IT! Introduction to safety A hydraulic hammer, like all moving heavy equipment, can be dangerous if not operated and taken care of properly. Most accidents occur as result of mishandling or improperly operating the equipment. Before unpacking, installing, operating, servicing, or storing the hammer, carefully read and understand this manual. WE CANNOT EMPHASIZE THIS ENOUGH. This hammer is to be mounted on a host piece of equipment. It is imperative and necessary for the hammer and host equipment’s user to read and understand the Operation Manual’s for 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 and licensing. Trained: Have read and thoroughly understand all aspects of this manual, the manual for the host equipment, have practiced and tested the operation of the hammer and host equipment, and have a thorough understanding of generally accepted principles of operation of heavy equipment. Experienced: In the operation, care and proper maintence of heavy equipment and hydraulic hammers. Physically Competent: - Excellent Hearing - Excellent Vision - Excellent Coordination - Physically capable and willing to perform all of the required functions in the safe operation of the hammer and host equipment.

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual

WARNING! GENERAL Safety DO’s and Don’ts: NEVER operate the hammer or host equipment with any person near the work area. Broken rocks, concrete pieces, and metal splinters may become projectiles, possibly causing death or serious injury. ALWAYS wear hearing protection, eye protection (approved impact resistant safety goggles), and approved head protection (hardhat) while operating the hammer. ALWAYS make sure appropriate shields are installed and used on the hammer and operators area of the host equipment. Broken and flying debris or pressurized oil may enter the operator’s area and could cause death or serious injury. NEVER leave the operators cab while the hammer or machine is running. ALWAYS stop the engine of the host equipment and lower the hammer, boom and any other parts of the equipment to the ground before attempting to make any repairs or adjustments to either the host equipment or the hammer. ALWAYS check that all safety decals attached to the hammer are legible prior to operating. If decals are worn or illegible, immediately visit www.MaverickHammers.com or call us at (401)738-6800 for replacement decals before operating. ALWAYS be aware of any dangerous conditions or prohibited work areas. These include (but are not limited to): Excessive slopes which could cause equipment rollover, overhead or underground power lines, gas lines, utilities, tanks, very soft ground including poor or dangerous terrain, or other hazardous conditions and/or utility hazards. NEVER use any kind of drugs or alcohol that may impair your alertness, physical abilities, or coordination while operating the hammer or host equipment. Anyone taking prescription drugs MUST obtain written permission from their doctor or medical professional before operating the hammer or host equipment. ALWAYS work at a slow and careful pace when operating the hammer or host equipment. ALWAYS operate the hammer and host equipment from the operator’s seat ONLY. Make sure the seatbelt is securely fastened before starting the hammer or host equipment. ALWAYS keep hands and feet on the controls while the hammer is operating.

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual ALWAYS make sure all controls (levers and pedals) are in NEUTRAL before starting the carrier. ALWAYS check hydraulic hoses and fittings for leaks and damage prior to operating the hammer and host equipment. NEVER leave the host equipment with the engine running. NEVER wear baggy clothes, loose jewelry, or anything else that may be caught by the controls of the host equipment or hammer. NEVER operate the hammer or host equipment with any person near the work area. Broken rocks, concrete pieces, and metal splinters may become projectiles, possibly causing death or serious injury.

Safety Precautions This manual contains safety, operation, and routine maintenance instructions. It does not contain service disassembly instructions. If needed, complete service disassembly and assembly instructions are contained in the Service Manual Part Number HSPSM-1015(A), which can be ordered from MAVERICK™ or any factory authorized MAVERICK™ Dealer or MAVERICK™ Certified Service Center. Hammer operators and all maintenance personnel must comply with all safety precautions presented in this manual and on all markings on the hammer. Failure to do so may result in death or serious injury. These instructions, precautions, and guidelines are provided for your safety and for the safety of those around you. It is critical that they are reviewed carefully BEFORE unpacking, installing, operating, and/or servicing the hammer. Operators and supervisory personnel should be familiar with local regulations governing job safety and the operation of heavy equipment and hydraulic hammers.

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual

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 MAVERICK™ AUTHORIZED DEALER AND/OR SEVICE CENTER. Operating Safety Precautions MAVERICK™ HSP Series Hammers will provide safe and reliable performance and operation in accordance with the instructions given in this manual. Please read and understand this manual and any decals and tags attached to the hammer before operation. Failure to do so could result in death or serious injury and equipment damage. 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 equipment manual. Ensure that all maintenance procedures recommended in this manual are completed before installing, operating, maintaining and/or servicing the hammer and host equipment. The operator must not operate the hammer or the carrier with anyone within the area 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 the hammer. While learning to operate the hammer and carrier, do so at a slow and cautious pace. If necessary, set the carrier mode selector and throttle to the slow position. 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 engage the parking brake. Page 6


MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual Stop the engine before attempting to make any repairs, adjustments to, or servicing of either the carrier or the hammer. Do not operate the hammer at oil temperatures above 175˚ F/ 80˚ C. Hammer and carrier operation at higher temperatures can cause damage to the internal components of the hammer and carrier and will result in reduced hammer performance. Do not operate a damaged, leaking, improperly adjusted, or incompletely assembled hammer or carrier equipment. Never modify the hammer in any manner, whatsoever. Use only genuine MAVERICK™ Hammer Tools. Use of hammer tools produced by some 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 MAVERICK™ or an authorized MAVERICK™ Dealer/Service Center. If you do not understand how to safely operate your hammer, contact MAVERICK™ or an authorized MAVERICK™ Dealer for assistance. Keep this manual with the hammer. Do not operate this equipment if you are taking medication which may affect your mental 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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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual SECTION2 - Standard Specifications Description Energy Class Operating Weight Operating Pressure Oil Flow Back Head Pressure Accumulator Pressure Overall Length Impact Rate Tool Diameter Hose Diameter Carrier Weight Description Energy Class Operating Weight Operating Pressure Oil Flow Back Head Pressure Accumulator Pressure Overall Length Impact Rate Tool Diameter Hose Diameter Carrier Weight

HSP

400

500

750

1000

1500

2250

Ft. Lbs

250

350

500

750

1,000

1,500

Joules

339

475

678

1,017

1,356

2,034

Lbs.

298

386

463

728

882

1,275

Kg.

135

175

210

330

400

500

PSI

1,305-1,740

1,305-1,740

1,305-1,885

1,377-1,885

1,450-1,885

1,885-2,175

BAR

90-120

90-120

90-130

95-130

100-130

130-150

G/Min.

5.25-10

6.6-10

8-13

8-16

10-24

12-21

L/Min.

20-40

25-40

30-50

30-60

40-90

45-80

PSI

189-218

189-218

189-218

189-218

189-218

218-247

BAR

13-15

13-15

13-15

13-15

13-15

15-17

PSI

NA

NA

NA

NA

NA

NA

BAR

NA

NA

NA

NA

NA

NA

In.

42

44.6

45

57

57.6

70

MM

1,073

1,133

1,142

1,452

1,464

1,781

SPM

650-1,200

550-1,100

500-1,000

450-1,000

450-900

450-700

In.

1.8

2.1

2.4

2.7

3.0

3.4

MM

45

53

60

68

75

85

In.

3/8

1/2

1/2

1/2

1/2

3/4

Lbs.

3,000-7,000

6,000-10,000

7,000-12,000

10,000-17,000

14,000-19,000

16,000-24,000

Tons

1.5-3.5

3-5

3.5-6

5-8.5

7-9.5

8-12

HSP

3250

4750

5250

6250

8250

9250

Ft. Lbs

2,500

3,500

4,500

5,500

6,000

8,500

Joules

3,390

4,745

6,101

7,457

8,135

11,524

Lbs.

1,755

2,821

3,726

3,867

5,150

5,842

Kg.

795

1,280

1,690

1,754

2,336

2,650

PSI

2,175-2,465

2,030-2,465

2,320-2,610

2,320-2,610

2,320-2,610

2,275-2,702

BAR

150-170

140-170

160-180

160-180

160-180

160-190

G/Min.

21-29

23-32

33-40

38-48

42-50

50-66

L/Min.

80-110

90-120

125-150

120-180

160-190

190-250

PSI

218-247

73-102

73-102

73-102

73-102

220-247

BAR

15-17

5-7

5-7

5-7

5-7

15-17

PSI

NA

798

798

798

798

870

BAR

NA

55

55

55

55

60

In.

80

84

94

97

103

118

MM

2,024

2,141

2,397

2,466

2,621

2,990

SPM

400-700

350-750

300-600

350-500

450-750

260-400

In.

3.9

4.7

5.3

5.5

5.9

6.3

MM

100

120

135

140

150

160

In.

3/4

3/4

1

1

1

1 1/4

Lbs.

22,000-36,000

35,000-48,000

38,000-54,000

42,000-65,000

55,000-89,000

70,000105,000

Tons

11-18

17.5-24

19-27

21-32.5

27.5-44.5

35-52.5 Page 8


MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual SECTION 3 - How the Hammer Operates Through Bolt: The Front Head, Cylinder and the Back-Head of the main body are secured with four through bolts. Back-Head: The Gas Charging Valve is integral and charged with N2-gas. Valve Assembly: The Cylindrical control valve is built in to the valve housing and controls piston reciprocation. Piston: Kinetic energy of the piston is converted into hammering energy after striking the Tool. The Hammer energy is transmitted to the Tool. Front Head: The Front Head supports the force of the hammer. The Thrust Ring and the Thrust Bushing attenuate recoil from the Tool. Tool: The MAVERICK™ Tool is heat-treated and is directly applied to subject material. Accumulator Assembly: The accumulator compensates for pressure changes in the hydraulic circuit. Charge with N2-gas only.

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MAVERICKâ&#x201E;˘ Hammers MAVERICKâ&#x201E;˘ Owners & Operators Manual Principle of Operation The relationship between the pressure affected area A1 of the piston rear chamber and the pressure affected area A2 of the piston front chamber is A1>A2. High-pressure oil is applied to A2. When oil pressure applied to A1 is changed from high to low pressure and vice versa. Piston C2 then reciprocates. Similarly the relationship between the pressure affected area A3 of the valve high-pressure chamber and the pressure affected area A4 and A3. Highpressure oil is applied to A3, A4, nd A3<A4. Therefore, the Valve is move the A4 side and vice versa, valve C4 changes to alter the port to the piston rear chamber B1 from the high-pressure side to the low-pressure side and vice versa and, in accordance with the reciprocation of valve C4, piston C2 reciprocates. Further, the Back-Head is charged with N2-gas. When the piston moves backward, the N2-gas is compressed to store the gas energy and, when the piston hammers, the gas energy is converted into piston hammering energy.

Piston Startup When high-pressure oil is applied to the IN port of the hydraulic hammer, the high-pressure oil acts upon the piston front chamber A2 and valve high-pressure chamberV1 to hold down the valve. As the piston rear chamber B1 is connected to the OUT port through the valve and changed to the low-pressure side, piston C2 starts moving backward under the high-pressure oil applied to the pressure affected area A2 of the piston front chamber. At this time, N2-gas in the Back-Head is compressed.

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MAVERICKâ&#x201E;˘ Hammers MAVERICKâ&#x201E;˘ Owners & Operators Manual Valve Charging When the piston moves backward and the piston rear chamber B1 is connected to the valve change port B3, the highpressure oil acts upon the valve change chamber V4 and the valve changes. At this time, the piston rear chamber B1 is disconnected from the valve low-pressure chamber V3 and connected to the valve high-pressure chamber V1 and pressure in the piston rear chamber B1 increase.

Piston Hammering Stroke When piston C2 reaches top dead center, high-pressure oil from the valve high-pressure chamber V1 acts upon the piston rear chamber B1 and in the hammering stroke is converted into the compressed gas energy in the Back-Head. The valve is held open because of the high-pressure chamber V1 and valve change chamber V4.


MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual SECTION 4 - Installation DO NOT INSTALL THE HAMMER WITHOUT FIRST PRESSURE AND FLOW TESTING THE HOST EQUIPMENT! IMPROPER HYDRAULIC FLOW AND/OR PRESSURES WILL DAMAGE THE HAMMER AND VOID ANY WARRANTY!

WARNING • CHECK THE “SPECIFICATIONS” SECTION OF THIS MANUAL TO DETERMINE CORRECT CARRIER EQUIPMENT HYDRAULIC PRESSURES AND FLOW REQUIREMENTS. • IF HYDRAULIC PRESSURE OR FLOW ARE EXCEEDED, THE HAMMER WILL BE DAMAGED AND MAY VOID ANY WARRANTY

WARNING • HYDRAULIC FLUID IN THE HYDRAULIC SYSTEM MUST BE CLEAN • CHECK THE HYDRAULIC FILTER. REPLACE THE FILER EACH 100 HOURS OF USE • HOSE AND PIPING MUST BE FLUSHED WHEN CHANGING FILTERS

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual Hammer Installation - Steps STEP 1.

Flow and pressure test carrier/host equipment BEFORE mounting or connecting the hammer. Flows and pressures must be set according to Recommended Circuit Relief Pressure Settings and Back Pressures (see chart) or internal damage will result.

STEP 2.

Carefully unpack and remove the hammer and any components from any shipping mate-

STEP 3.

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

rials.

STEP 4.

Connect hoses to hammer and carrier host equipment. (Caution: Make sure that pressure line from the carrier is connected to the port marked “IN” on the hammer and that the return line to the carrier is connected to the hammer port marked “OUT” – If these lines are reversed and the hammer is operated, internal damage to the hammer WILL result.

STEP 5.

(throttle).

During Break-in period (first 5 hours of operation) operate the hammer at 1/3 speed

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual Recommended Circuit Relief Pressure Settings and Back Pressures Model Relief Setting Pressure Back Pressure (Max) Model Relief Setting Pressure Back Pressure (Max) Model Relief Setting Pressure Back Pressure (Max)

HSP kg/cm ² psi kg/cm ² psi

400 110-140 1564-1991 5 72

500 110-140 1564-1991 5 72

750 110-140 1564-1991 5 72

1000 120-150 1706-2133 5 72

HSP kg/cm ² psi kg/cm ² psi

1500 130-160 1849-2275 5 72

2250 140-160 1991-2275 5 72

3250 150-170 2133-2417 5 72

4750 160-180 2275-2560 5 72

HSP kg/cm ² psi kg/cm ² psi

5250 180-200 2560-2844 5 72

6250 180-200 2560-2844 5 72

8250 180-200 2560-2844 5 72

9250 180-210 2560-2986 5 72

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual Hydraulic pipe lines for exclusive use: Operation of the hydraulic hammer requires installation of hydraulic pipes. These pipes should be for the exclusive use of the MAVERICK™ Hydraulic Hammer. Hydraulic pipes may vary depending on host machines and hydraulic pressures, oil capacity, pressure loss and other conditions of the carrier.

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual 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) to stable ground and place hammer on solid and level wooden blocks. WARNING: NEVER PLACE ANY PART OF BODY BETWEEN HAMMER AND GROUND OR MACHINE AS IT COULD MOVE AND CRUSH!. Stop the engine. Turn off the main switch and release air from the oil tank if 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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MAVERICKâ&#x201E;˘ Hammers MAVERICKâ&#x201E;˘ Owners & Operators Manual

STEP 3. Loosen the hoses on the hammer. Collect any oil overflow and

place into a container for proper disposal. Be careful to prevent mud or dust from touching or entering the oil hoses and the pipe lines. Plug the oil hoses with the hose plugs, and the pipe lines with the union caps. Bind the high-and low pressure hoses with a wire to prevent them from falling. Wrap the ends of the hoses with plastic to prevent contamination. Any dirt or particles may contaminate the hydraulic system of the carrier and damage to hammer.

STEP 4. Remove hammer from machine. To remove the hammer, make sure any pressure is re-

moved 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) week cover with weatherproof protective cover.

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual

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 exterior of 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 relieve the N2-gas from the Back-Head and push the piston into the cylinder. Grease should be 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 than three (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)

SECTION 5 - Operation (Hammering) Proper position of the tool The hammer must be applied in the proper position for effective use its force and to prevent damage to the hammer or carrier equipment. When the position is incorrect, the hammer energy of the piston is not transferred properly and the hammer’s force shocks the hammer and the stick and boom of the carrier machine.

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual

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 hammer body may hit the ground and/or subject material and result in damage to hammer and/or carrier equipment.

Alignment of the Tool Apply the direction of force in line with the Tool and place the Tool on the hammering surface vertically (perpendicular to the surface of the subject material). DO NOT PLACE THE TOOL AT AN ANGLE TO THE MATERIAL OR PRY WITH THE HAMMER TOOL. This may cause the Tool to seize or break and will cause piston damage.

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual

Operation Precautions

IMPORTANT • DO NOT BREAK CONTINUOUSLY IN ONE PLACE - CONTINUOUS PENETRATION IN THE SAME AREA FOR LENGTHILY PERIODS WILL CREATE EXCESSIVE TEMPERATURES AT THE END OF THE TOOL RESULTING IN LOSS OF TEMPER(HARDNESS) OF THE TOOL AND CAUSE DAMAGE TO THE TIP OF THE TOOL, AND MAY LEAD TO FAILURE OF THE BIT

IMPORTANT • NEVER USE THE TOOL OR HAMMER AS A PRYING OR LIFTING DEVICE

CAUTION • BEFORE LEAVING THE CARRIER, ALWAYS LOWER THE BOOM SO THAT THE CARRIER IS STABLE. NEVER LEAVE THE MACHINE WITH THE ENGINE RUNNING • ALWAYS ENGAGE THE PARKING BRAKE BEFORE LEAVING THE CONTROLS

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual Stop operation if Hammer hoses jump or vibrate excessively. Excessive vibration of both hoses of the hammer calls for instant disassembly and repair of the Hammer. If this occurs, immediately contact MAVERICK™ or a MAVERICK™ Dealer or Authorized Service Center

Avoid all blank firing of the hammer The moment the subject material is broken, stop hammering. Continuous blank firing the Hammer will damage front head, piston, and loosen and break internal bolts. Blank firing 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 when hammer recoil sound becomes extremely rapid during hammer operation.

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MAVERICKâ&#x201E;˘ Hammers MAVERICKâ&#x201E;˘ Owners & Operators Manual 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 the tool or hammer will result.

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MAVERICKâ&#x201E;˘ Hammers MAVERICKâ&#x201E;˘ Owners & Operators Manual Continuous Hammering Extended hammering at the same place causes the excessive tool wear (due to overheating) 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 and increases hydraulic oil temperature which will result in damage the hammers internal components.

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual Do not operate the hammer in water and mud Do not operate the hammer when components (except Tool) are immersed in water and/or mud. The piston and similar components may gather rust and become damaged.

IMPORTANT • DO NOT USE UNDERWATER WITHOUT AIR APPLICATION (UNDERWATER) KIT •NO PART OF THE MAVERICK™ HSP SERIES HAMMER MAY BE SUBMERGED IN WATER WITH IT FIRST ADAPTING THE HAMMER FOR UNDERWATER USE. •USE OF THE HAMMER UNDERWATER REQUIRES AN UNDERWATER APPLICATION KIT AND AN AIR COMPRESSOR CAPABLE OF PRODUCING 6000LPM / 150PSI. (PLEASE CONTACT MAVERICK™) •UNDERWATER USAGE OF THE HAMMER WITHOUT THE UNDERWATER KIT AND AIR COMPRESSOR WILL CAUSE INTERNAL DAMAGE TO THE HAMMER. -SEE “UNDERWATER OPERATION OF THE HAMMER”

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MAVERICKâ&#x201E;˘ Hammers MAVERICKâ&#x201E;˘ Owners & Operators Manual 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 the carrier machine, causing damage to the hammer and the carrier machine.

Do not hammer with the carrier equipment cylinders at the end of their stroke in either direction. Hammering with carrier cylinders fully extended or retracted will damage to the cylinders of the carrier equipment.

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual 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 temperature of at least (80°f -105°f / 30°C - 40°C) before hammer operation. All personnel must stay well clear of the hammer during and immediately following its operation Flying debris, heated hydraulic oil and hammer parts (including tool), and unstable subject material can pose serious risk of Death or personal injury. During hammer operation, the hammer parts can reach high temperatures. When operating the hammer you must use the ear, eye and breathing protection Accumulator Pressure Danger DANGER! The Accumulator is under extremely high pressure. DO NOT OPEN! Please consult with MAVERICK™ or your nearest Authorized MAVERICK™ Dealer or Service Center. Eye Protection Always wear the impact resistant eye protection when operating, maintaining, servicing the hammer (including while removing the stop pin or changing tools)

Page 26


MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual Section 6 - Hydraulic Hammer Maintenance MAVERICK™ Hydraulic Hammers are built to last and will deliver years of trouble free operation, provided that they are properly maintained. Regular Hammer Inspection and Maintenance Regular inspection is essential for keeping the hydraulic hammer operating in the best condition. It is highly recommended that customers contact an authorized and trained hammer technician for inspection within six months of original hammer purchase.

Daily Hammer Inspection

Before starting operation, be sure to inspect the hammer referring to the following table: Inspection Item . Loose, missing or damaged to the bolts, nuts, and fasteners

Inspection Point Through bolts Bracket mounting bolts Accumulator bolts

Loose hose fittings, Visible damage to the hoses Leaking hoses

Hydraulic pipes for the hammer Oil hoses

Hammer oil leaks

Connections of the Back-Head and the cylinder. Clearance between the front head & the Tool

Abnormal wear and cracks on the Tool

Tool

Greasing/Lubrication

Grease each day hammer startup and 10 pumps every 3 hours using the head grease pump

Hydraulic oil: level and contamination

Hydraulic Reservoir (Carrier Machine)

Missing rubber plugs and snap rings

Rubber plugs Snap rings Hammer Body

Page 27


MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual Greasing and Lubricating To grease hammer: With the hammer mounted on the carrier, apply down pressure on the Tool and pump grease into grease fitting as indicated on hammer to fill cavity with the recommended grease.

Greasing/Lubricating the Hammer STEPS 1.With the hammer mounted on carrier, apply pressure 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 the upper 1/3 of the Tool with grease before inserting 5.Avoid getting rock or cement chips into the tool cavity when replacing hammer tools. Particles which may have adhered to the grease can cause scratches and scaring inside the hammer. 6.Failure to comply with these instructions WILL result in damage to the hammer and may void any warranty

Grease MAVERICK™ Hydraulic Hammers are equipped with grease fittings. Lack of lubrication can cause failure of the working tool, piston, and or shorten the life of the seals. An NLGI NO.2 grease is recommended. The following is a list of the recommended greases: SHELL ALVANIA EP2, ESSO LITHTAN EP2, MOBIL MOBILPLEX 48

Hydraulic Oil

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual Selection of Oil The Selection of the hydraulic oil determines the efficiency of the hydraulic hammer’s performance. MAVERICK™ recommends Shell Tellus56/Mobile DTE26 and Shell Tellus Oil 46/Mobile DTE25 for cold weather operations. Please consult with MAVERICK™ or an Authorized MAVERICK™ Dealer or Service 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 air temperatures. b) When recommended brand of hydraulic oil is not available. c) When hydraulic oils supplied for the base machine differ from the recommended one.

Oil Contamination Contaminated oil will result in malfunctions of the hammer as well as the base machine and cause damage. Pay special attention to oil contamination. Contaminated oil should be changed without delay. When changing oil, thoroughly wash the oil tank, the carriers cylinders and 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 of hammer use. • Replacement of the hydraulic oil: Every 300 hours of Carrier or Hammer use.

WARNING • HYDRAULIC OIL TEMPERATURE AND VISCOSITY Do not operate the hydraulic hammer at oil temperatures from 20°C /68°C to 80°C /176°C. 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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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual Criteria of Oil Contamination and Malfunction (General Analysis) Analysis Item

Criteria

Adhesiveness

Within ±10% (104f/40°C cst)

Oxidizing Level

Less than 0.3 (mg KOH/g)

Moisture

Less than 0.1(%)

Causes and Effects when exceeds the criteria Adhesiveness rarely decreases due solely to of oil use. Entry of different kinds of oil may reduce the adhesiveness which contributes to rising oil temperatures, wear and stretch of bearings and gears, and malfunction of hammer. Use of lubricating oil for long periods under high temperatures will oxidize it. Oxidizing level rises as oxidization proceeds. Sludge will be produced during the process, leading to unsatisfactory operation of the hammer, erosion of metals or obsolescence of seal materials. 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 the hammer.

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 oil color, and functions begin to deteriorate when hydraulic oil becomes darker than the new oil color by more than (ASTM number) two (2).

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual SECTION 7 - Hammer Inspection and Repair Inspection Report

Model

HSP

Through Bolt Charge Valve Side Bolt Mounting Cap Flange Adapter Bolt Valve Cover Bolt Valve Body Bolt Acc’ Body Bolt Acc’ Cover Bolt

500

1000

1500

2250

3250

4750

5250

6250

8250

9250

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

Kg.m

35

35

35

35

35

35

35

35

35

35

ft. lbs.

253

253

253

253

253

253

253

253

253

253

Kg.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

Kg.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

Kg.m

20

20

-

20

20

ft. lbs.

145

145

-

145

145

Kg.m

60

60

-

45

45

ft. lbs.

434

434

-

326

326

Kg.m

45

45

-

45

45

ft. lbs.

326

326

-

326

326

Kg.m

60

60

60

60

60

ft. lbs.

434

434

434

434

434

Kg.m

45

45

45

45

45

ft. lbs.

326

326

326

326

326

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 be loosened, and then re-tightened in stages, so all bolts in the torque group share the load equally.


MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual SECTION 8 - Hammer Tool Replacement Replacement of the Tool: When a Tool tip is worn out, it can be sharpened. Grinding the Tool tip more than twice to sharpen the edge will remove the heat-treated hardening. After two (2) sharpening’s, the tool should be replaced. STEP 1.

Pull out rubber cap using screwdriver or end-pointed instruments. Disassemble Rubber caps.

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual 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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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual STEP 3.

STEP 4.

Insert the MAVERICK™ pin removal tool (part# T10587) into the tool retainer holes and push out the retainers. Remove the tool retainers.

Set a nylon lifting sling in the center of the tool and lift it just enough to take the bottom pressure off of the tool. Remove the tool slowly using extreme caution.

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual STEP 5.

Before installing a new Tool, check each part for wear, breakage, and scores. Remove any debris or burrs on each Tool Retainer as necessary. 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 ONLY Genuine MAVERICK™ Parts, as they are machined to specific tolerances designed for the hammer. Not using Genuine MAVERICK™ Tool Retainers and Hammer Tools may damage your hammer and may void any warranty.

Bushing Wear When the gap between the tool and the tool bushing becomes in excess of the tolerances listed in the chart below, the tool bushing MUST be replaced. Excess bushing 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. Please refer to the chart below for proper tolerances.

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual Tool/Bushing Wear Limits Model

Tool Bush (mm/inch)

Tool Dia.(mm/inch)

400HSP 500HSP 750HSP 1000HSP 1500HSP 2250HSP 3250HSP 4750HSP 5250HSP 6250HSP 8250HSP 9250HSP

45/1.77 53/2.08 60.2.36 68/2.67 75/2.95 85/3.34 100/3.93 120/4.72 135/5.31 140/5.51 150/5.90 160/6.29

45/1.77 53/2.08 60/2.36 68/2.67 75/2.95 85/3.34 100/3.93 120/4.72 135/5.31 140/5.51 150/5.90 160/6.29

Width of Wear (mm/ inch) 3/.11 3/.11 4/.15 4/.15 4/.15 5/.19 6/.23 7/.27 8/.31 8/.31 9/.35 11/.43

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual SECTION 9 -

Charging the Hammer

Inspection and Charging N2-Gas at the Back-Head

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. THE TOOL AND/OR PISTON MAY MOVE ABRUPTLY • WHEN THE THROUGH BOLTS ARE CHANGED, THE N2 GAS MUST BE DISCHARGED FROM THE BACK HEAD. PLEASE CONSULT MAVERICK™ OR A TRAINED HAMMER TECHNICTION. DANGER : THE BACKHEAD IS HIGHLY PRESSURIZED • USE NITROGEN GAS ONLY • SEE “CONVERSION TABLE FOR CHARGING N2 GAS PRESSURE TO THE BACK HEAD”

Inspection of N2-Gas at the Back-Head 1. Make sure that the cap and the valve of the gas charging kit  are fully tightened. Screw the gas charging kitinto 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 the Back-Head is indicated on the pressure gauge 4. If gas pressure is normal (see chart), unscrew the gas charging kit. Reinsert the plug to the hammer 5. If the N2 -gas pressure is too high or low, charge it as described below

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual Charging of N2 -Gas into the Back-Head 1. Connect the charging hose to N2-gas cylinder  after screwing the bomb adapter  onto adapter nut  and installing than to the N2-gas cylinder 2. Connect the gas charging kit  to the charging hose  after unscrewing the cap on the gas charging kit 3. Install the gas charging kit  to the charging valve of the Back-Head. At this time the handle of the gas charging kit must be up position to prevent the gas from coming out 4. Push the handle of the gas charging kit fully and turn the handle of the N2-gas cylinder counter clockwise gradually to charge the Back-Head 5. When the gas pressure exceeds 10% higher then the specified pressure, close the 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 charging kit  and screw the cap onto the gas charging kit. 8. Push the handle of the gas charging kit fully, and the gas pressure inside the Back-Head is indicated on the pressure gauge. When the pressure is higher, discharge a small amount of gas from the Back-Head repeatedly opening and closing the valve and then gas pressure falls to the specified pressure 9. When the gas pressure reaches to the specified pressure, close the valve and release 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 and install the plug to the charging valve.

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual N2-Gas Charging tools to the Back-Head

Inspection and Charging N2-Gas at the Accumulator

WARNING

• USE SPECIAL CARE TO HANDLE AND STORE THE N2-GAS CYLINDER AS IT IS A HIGHLY PRESSURIZED CONTAINER. • USE NITROGEN GAS ONLY • STANDARD ACCUMULATOR GAS PRESSURE 55kg/cm2/780PSI AT 20℃ /68℉ AMBIENT TEMPERATURE. DO NOT OVER PRESSURIZE THE ACCUMULATOR • USE NITROGEN GAS ONLY • SEE “CONVERSION TABLE FOR CHARGING N2-GAS PRESSURE TO THE ACCUMULATOR”.


MAVERICKâ&#x201E;˘ Hammers MAVERICKâ&#x201E;˘ Owners & Operators Manual Inspection of N2-Gas in the Accumulator Be sure to use only the MAVERICKâ&#x201E;˘ 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 the accumulator body and the cover are tightened fully 1. Make sure the cap and the valve of the gas charging kit (5) are fully tightened. 2. Remove the cap (11) from the accumulator and tighten the charging valve (12) fully. 3. Check if the O-rings (6)(8) are installed to the bushing (7). Remove the plug (9)and the screw in the bushing. 4. Install the bushing (7) to the gas charging kit.(5) 5. Loosen the charging valve (12) gradually. The charging pressure is indicated on the pressure gauge. 6. Close the valve clockwise when the gas pressure is normal. When the gas pressure 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.(5) 8. Remove the gas charging kit (5) and tighten the plug (9) and the cap.(11)

Charging on N2-Gas into the Accumulator 1. Connect the charging hose (4) to the N2-Gas cylinder (1) after screwing the adapter (3) on to the adapter nut (2) and installing to the N2-Gas cylinder. 2. Connect the gas charging kit (5) to the charging hose (4) after unscrewing the cap of the gas charging kit. 3. Remove the accumulator cap (11) from the accumulator and tighten the charging valve (12) fully. 4. Check to make sure the o-rings(6)(8) are installed on the bushing(7). Remove the plug(9) and screw in the bushing.

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MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual 5. Loosen the accumulator charging valve(12) after checking if the bushing (7) is 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-Gas pressure 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 in the charging hose 11. Remove the charging hose, the gas charging kit and the bushing, and tighten the plug(9) and cap.(11)

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. THE TOOL AND/OR PISTON MAY MOVE ABRUPTLY • WHEN THE THROUGH BOLTS ARE CHANGED, THE N2 GAS MUST BE DISCHARGED FROM THE BACK HEAD. PLEASE CONSULT MAVERICK™ OR A TRAINED HAMMER TECHNICTION. DANGER : THE BACKHEAD IS HIGHLY PRESSURIZED • USE NITROGEN GAS ONLY • SEE “CONVERSION TABLE FOR CHARGING N2 GAS PRESSURE TO THE BACK HEAD”


MAVERICK™ Hammers MAVERICK™ Owners & Operators Manual SECTION 10 -Trouble-Shooting Guide The trouble-shooting chart is to help operators identify and locate causes and remedies when operating trouble occurs TROUBLE 1. Hammer fails to operate: (1) Sufficient high pressure oil does not flow to hammer inlet. (2) Sufficient high pressure oil flows to hammer inlet.

CAUSE (a) Defective hose or pipes. Closed valves on Carrier machine. Clogged or damaged piping (b) Defective control valve and related parts. Missing or damaged tie Tool or control cable (c) Insufficient hydraulic oil (d) Internal hammer defects (a) Defective hose or pipes 2. Hammer operates with reduced force. (1) Sufficient high . Closed (or partially) valves on Carrier machine. Clogged pressure oil does not flow to hammer inlet. (2) Sufficient high or damaged piping (b) Defective control valve and related pressure oil flows to hammer parts. Defective pedal/control. inlet. Defective control valve. Stuck control valve. Insufficient control valve stroke. (c) Clogged filter in return line of carrier machine (d) Insufficient hydraulic oil (e) Contaminated or deteriorated hydraulic oil (f) Defective carrier machine pump (g) Internal hammer failure . Entry of contaminated articles in hydraulic system(h) Drop in N2-gas pressure of Back-Head 3. Hammering force suddenly (a) Failure of Back-Head or drops and high pressure hose Gas leakage vibrates excessively during operation. 4. Excessive oil leaks from front (a) Worn cylinder seals head or Tool. 5. Piston works but does not (a) Tool Jammed (with subject hammer. material)

REMEDY (a) Check, clean and repair piping or replace with new ones. (b) Check and repair Valve and its related parts or replace with new ones. (c) Refill the oil tank. (d) Consult with our service station. (a) Check, clean and repair piping or replace. (b) Check control Valve and related parts or replace. (c) Clean or replace. (d) refill. (e) After flushing tank, change oil entirely (f) Service Carrier Machine pumps(s) (g) Consult with Authorized MAVERICK™ DEALER or Authorized Service Center (h) Adjust the gas pressure refer to Chart.

(a) Ask our service station for repairs (a) Ask our service station for repairs (a) Remove front parts and pull out Tool, check, clean and replace. Page 42


English Owner's Manual