MAVERICK HYDRAULIC HAMMERS

OWNERS AND OPERATORS MANUAL

HSP SERIES HYDRAULIC HAMMERS
Models
9250HSP 8250HSP 6250HSP 5250HSP
4750HSP 3250HSP 2250HSP 1500HSP
1000HSP 750HSP 500HSP 400HSP

Inside U.S. Toll-Free:

(800)-618-7628
Outside U.S.A:
(401)-738-6800
www.MaverickHammers.com

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 toll free at 800-618-7268 (001-401-7386800).
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 troublefree 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.

Page 2 of 43 V2.1 3/08

TABLE OF CONTENTS

Section

Description

Page

Safety Precautions

Standard Specifications

Principle of Operation

10

Installation and Removal

13

Operation of the Hammer

19

Maintenance

26

Inspection and Repair

31

Hammer Tool Replacement

32

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 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.

Page 3 of 43 V2.1 3/08

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 equipments user to read and understand the
Operation Manuals 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.

Page 4 of 43 V2.1 3/08

WARNING!
GENERAL Safety DOs and Donts:
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 operators 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 toll free at 800-417-3259 (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.

Page 5 of 43 V2.1 3/08

ALWAYS operate the hammer and host equipment from the operators 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.
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 HSPSM1015(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.

Page 6 of 43 V2.1 3/08

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.

Page 7 of 43 V2.1 3/08

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.
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.
f 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

Page 8 of 43 V2.1 3/08

SECTION 2 - Standard Specifications

Model
Energy Class
Operating Weight
Operating Pressure
Oil Flow
Back Head Pressure
Accumulator Pressure
Impact Rate
Tool Diameter
Carrier Weight
Model
Energy Class
Operating Weight
Operating Pressure
Oil Flow
Back Head Pressure
Accumulator Pressure
Impact Rate
Tool Diameter
Carrier Weight
Model
Energy Class
Operating Weight
Operating Pressure
Oil Flow
Back Head Pressure
Accumulator Pressure
Impact Rate
Tool Diameter
Carrier Weight

HSP
ft. lbs.
Kg
Lbs
bar
psi
l/min
g/min
bar
psi
bar
psi
bpm
mm
inch
lbs.
HSP
ft. lbs.
Kg
Lbs
bar
psi
l/min
g/min
bar
psi
bar
psi
bpm
mm
inch
lbs.
HSP
ft. lbs.
Kg
Lbs
bar
psi
l/min
g/min
bar
psi
bar
psi
bpm
mm
inch
lbs.

400
250
135
298
90 - 120
1305 - 1740
20 - 40
5.25 - 10
13 - 15
189 - 218
650 - 1,200
45
1.8
3,000 - 7,000
1500
1,000
400
882
100 -130
1450 - 1885
40 - 90
10 - 24
13-15
189-218
450 - 900
75
3.0
14,000-19,000
5250
4,500
1690
3726
160 - 180
2320 - 2610
125 - 150
33 - 40
5 -7
73 -101
55
798
300 - 600
135
5.3
38,000 - 54,000

500
350
175
386
90 - 120
1305 - 1740
25 - 40
6.6 - 10
13 - 15
189 - 218
550 - 1,100
53
2.1
6,000 - 10,000
2250
1,500
500
1275
130 - 150
1885 - 2175
45 - 80
12 - 21
15 -17
218 -247
450 - 700
85
3.4
16,000 - 24,000
6250
5,500
1754
3867
160 - 180
2320 - 2610
120 - 180
38 - 48
5 -7
73 -101
55
798
350 - 500
140
5.5
42,000 - 65,000

750
500
210
463
90 - 130
1305 - 1885
30 - 50
8 - 13
13 - 15
189 - 218
500 - 1,000
60
2.4
7,000 - 12,000
3250
2,500
795
1755
150 - 170
2175 - 2465
80 - 110
21 - 29
15 -17
218 -247
400 - 700
100
3.9
22,000 - 38,000
8250
6,000
2336
5150
160 - 180
2320 - 2610
160 - 190
42 - 50
5 -7
73 -101
55
798
450 - 750
150
5.9
55,000 - 89,000

1000
750
330
728
95 - 130
1377 - 1885
30 - 60
8 - 16
13 - 15
189 - 218
450 - 1,000
68
2.7
10,000-17,000
4750
3,500
1280
2821
140 - 170
2030 - 2465
90 - 120
23 - 32
5 -7
73 -101
55
798
350 - 750
120
4.7
35,000 - 48,000
9250
8,500
2650
5842
160 - 190
2,320 - 2,702
190 - 250
50 - 66
15 -17
218 -247
60
870
260 - 400
160
6.3
72,000 105,000

Page 9 of 43 V2.1 3/08

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

Page 10 of 43 V2.1 3/08

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 highpressure 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 highpressure 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 lowpressure 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.

Page 11 of 43 V2.1 3/08

Valve Charging
When the piston moves backward and the piston rear
chamber B1 is connected to the valve change port
B3, the high-pressure 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, highpressure 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.

Page 12 of 43 V2.1 3/08

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 FILTER EACH 100 HOURS OF
USE

HOSE AND PIPING MUST BE FLUSHED WHEN CHANGING FILTERS

Page 13 of 43 V2.1 3/08

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 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 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.

During Break-in period (first 5 hours of operation) operate the hammer

at 1/3 speed (throttle).

Page 14 of 43 V2.1 3/08

Recommended Circuit Relief Pressure Settings and Back Pressures

Model

HSP

400

500

750

1000

Relief Setting Pressure

bar
psi

110 - 140
1564 - 1991

110 - 140
1564 - 1991

110 - 140
1564 - 1991

120 - 150
1706 - 2133

Back Pressure (Max)

bar
psi

5
72

5
72

5
72

5
72

Model

HSP

1500

2250

3250

4750

Relief Setting Pressure

bar
psi

130 - 160
1849 - 2275

140 - 160
1991 - 2275

150 - 170
2133 - 2417

160 - 180
2275 - 2560

Back Pressure (Max)

bar
psi

5
72

5
72

5
72

8
116

Model

HSP

5250

6250

8250

9250

Relief Setting Pressure

bar
psi

180 - 200
2560 - 2844

180 - 200
2560 - 2844

180 - 200
2560 - 2844

180 - 210
2560 - 2986

Back Pressure (Max)

bar
psi

8
116

8
116

8
116

8
116

Page 15 of 43 V2.1 3/08

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.

Page 16 of 43 V2.1 3/08

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

Page 17 of 43 V2.1 3/08

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 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) week
cover 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 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 reinstalled 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)

Page 18 of 43 V2.1 3/08

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

Page 19 of 43 V2.1 3/08

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.

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

Page 20 of 43 V2.1 3/08

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

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.

Page 21 of 43 V2.1 3/08

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.

Page 22 of 43 V2.1 3/08

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.

Page 23 of 43 V2.1 3/08

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
o NO PART OF THE MAVERICK HSP SERIES HAMMER MAY
BE SUBMERGED IN WATER WITH IT FIRST ADAPTING THE
HAMMER FOR UNDERWATER USE.
o USE OF THE HAMMER UNDERWATER REQUIRES AN
UNDERWATER APPLICATION KIT AND AN AIR
COMPRESSOR CAPABLE OF PRODUCING 6000LPM /
150PSI. (PLEASE CONTACT MAVERICK)
o 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

Page 24 of 43 V2.1 3/08

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

Page 25 of 43 V2.1 3/08

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 (80f -105f / 30C - 40C) 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 of 43 V2.1 3/08

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

Inspection Point
.

Loose, missing or damaged to the

bolts, nuts, and fasteners

Loose hose fittings,

Visible damage to the hoses

. Through bolts Bracket mounting bolts

Accumulator bolts
.
.
Hydraulic pipes for the hammer
.
Oil hoses

Leaking hoses
.
.

Hammer oil leaks

Abnormal wear and cracks on the
Tool

Connections of the Back-Head and the

cylinder. Clearance between the front
.
head & the Tool
.

Tool

.
.

Greasing/Lubrication
Hydraulic oil: level and
contamination

Grease each day hammer startup and

10 pumps every 3 hours using the
.
head grease pump
.

Hydraulic Reservoir (Carrier Machine)

.
.

Missing rubber plugs and snap

rings

Rubber plugs Snap rings Hammer

. Body

Page 27 of 43 V2.1 3/08

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

Page 28 of 43 V2.1 3/08

Hydraulic Oil
Selection of Oil
The Selection of the hydraulic oil determines the efficiency of the
hydraulic hammers 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 /68 to 80
/176. Operation at higher temperatures can damage the internal components of
the hammer and the excavator, which will result in reduced hammer performance.

Page 29 of 43 V2.1 3/08

Criteria of Oil Contamination and Malfunction (General Analysis)

Analysis Item

Criteria

Adhesiveness

Within 10%
(104f/40 cst)

Oxidizing

Less than 0.3

Level

(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).

Page 30 of 43 V2.1 3/08

SECTION 7 Hammer Inspection and Repair

Inspection Points

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

HSP
Kg.m
ft. lbs.
Kg.m
ft. lbs.
Kg.m
ft. lbs.
Kg.m
ft. lbs.
Kg.m
ft. lbs.
Kg.m
ft. lbs.
Kg.m
ft. lbs.
Kg.m
ft. lbs.
Kg.m
ft. lbs.

500
40
289
35
253
100
723
40
289

1000
40
289
35
253
100
723
40
289

1500
40
289
35
253
100
723
40
289

2250
100
723
35
253
145
1,049
80
579

3250
150
1,085
35
253
170
1,230
100
723

4750
175
1,266
35
253
200
1,447
130
940
20
145
60
434
45
326
60
434
45
326

5250
225
1,627
35
253
250
1,808
150
1,085
20
145
60
434
45
326
60
434
45
326

6250
240
1,736
35
253
250
1,808
150
1,085
60
434
45
326

8250
250
1,808
35
253
305
2,206
160
1,157
20
145
45
326
45
326
60
434
45
326

Page 31 of 43 V2.1 3/08

9250
360
2,604
35
253
360
2,604
220
1,591
20
145
45
326
45
326
60
434
45
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.

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) sharpenings, the tool should be replaced.
STEP 1.

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

Disassemble Rubber caps.

Page 32 of 43 V2.1 3/08

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.

Page 33 of 43 V2.1 3/08

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 take
the bottom pressure off of the tool. Remove the tool slowly using extreme
caution.

Page 34 of 43 V2.1 3/08

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.

Page 35 of 43 V2.1 3/08

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.

Tool/Bushing Wear Limits

Dimension
Model

Tool Bush (mm/inch) Tool Dia. (mm/inch)

Width of Wear
( mm/inch )

400HSP
500HSP

45/1.77
53/2.08

45/1.77
53/2.08

3/.11
3/.11

750HSP

60/2.36

60/2.36

4/.15

1000HSP
1500HSP
2250HSP

68/2.67
75/2.95
85/3.34

68/2.67
75/2.95
85/3.34

4/.15
4/.15
5/.19

3250HSP
4750HSP
5250HSP

100/3.93
120/4.72
135/5.31

100/3.93
120/4.72
135/5.31

6/.23
7/.27
8/.31

6250HSP
8250HSP

140/5.51
150/5.90

140/5.51
150/5.90

8/.31
9/.35

9250HSP

160/6.29

160/6.29

11/.43

Page 36 of 43 V2.1 3/08

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 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 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

Page 37 of 43 V2.1 3/08

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

Page 38 of 43 V2.1 3/08

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/cm /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".

Page 39 of 43 V2.1 3/08

Inspection of N2-Gas in the Accumulator

Be sure to use only the MAVERICK Charging Kit for charging the hammer with N2gas.
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 are fully tightened
2. Remove the cap from the accumulator and tighten the charging valve fully
3. Check if the O-rings are installed to the bushing . Remove the plug
and the screw in the bushing.
4. Install the bushing to the gas charging kit
5. Loosen the charging valve 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
8. Remove the gas charging kit and tighten the plug and the cap

Charging on N2-Gas into the Accumulator

1. Connect the charging hose to the N2-Gas cylinder after screwing the
adapter on to the adapter nut and installing to the N2-Gas cylinder.
2. Connect the gas charging kit to the charging hose after unscrewing the
cap of the gas charging kit
3. Remove the accumulator cap from the accumulator and tighten the charging
valve fully
4. Check to make sure the o-rings are installed on the bushing . Remove
the plug and screw in the bushing.

Page 40 of 43 V2.1 3/08

5. Loosen the accumulator charging valve after checking if the bushing 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 and cap .

WARNING!
USE SPECIAL CARE TO HANDLE AND STORE THE N2-GAS CYLINDER AS IT IS A HIGHLY
PRESSURIZED CONTAINER.
USE NITROGEN GAS ONLY.
2
STANDARD ACCUMULATOR GAS PRESSURE is 55kg/cm /780PSI AT 20 /68 AMBIENT
TEMPERATURE. DO NOT OVER PRESSURIZE THE ACCUMULATOR.
SEE "CONVERSION TABLE FOR CHARGING N2-GAS PRESSURE TO THE ACCUMULATOR".

Page 41 of 43 V2.1 3/08

SECTION 10 -Trouble-Shooting Guide

The trouble-shooting chart is to help operators identify and locate causes and remedies
when operating trouble occurs
TROUBLE

CAUSE

REMEDY

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.

(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) 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.

2. Hammer operates with

reduced force. (1) Sufficient
high pressure oil does not
flow to hammer inlet. (2)
Sufficient high pressure oil
flows to hammer inlet.

(a) Defective hose or pipes .

Closed (or partially) valves on
Carrier machine. Clogged or
damaged piping (b) Defective
control valve and related parts.
Defective pedal/control. 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 N2gas pressure of Back-Head

(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.

3. Hammering force suddenly

drops and high pressure hose
vibrates excessively during
operation.

(a) Failure of Back-Head or Gas

leakage

(a) Ask our service station for

repairs

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 not

hammer.

(a) Tool Jammed (with subject

material)

(a) Remove front parts and pull

out Tool, check, clean and
replace.

Page 42 of 43 V2.1 3/08

NOTES
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Page 43 of 43 V2.1 3/08