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MAINTENANCE INTERVALS - Safety

1. Compacting Plate 8 5 kg 18 7 Ib 9 9 kg 21 8 Ib Table 14 Weights of Small Hammer Tools Sales Model H55D S H65D S Moil Tool 9 10 kg 20 Ib io Chisel Tool 9 32 kg 20 5 Ib Se SE Parallel Spade Tool 9 69 kg 21 4 Ib Ce G Transverse Spade 12 9 kg Tool 9 74 kg 21 5 Ib 28 4 Ib Compacting Plate 23 kg 50 7 Ib ee fs g01401123 g01162252 10 After you have removed the tool inspect the hammer tool for wear Refer to the Operation and Maintenance Manual Tool Inspect for information on inspecting the hammer tool 11 After you have removed the tool inspect the seal in the lower tool bushing for wear You must replace the seal if the seal is worn or if the seal is damaged SEBU7921 03 Installation of Tool Ee Illustration 83 g01162252 typical example 1 Clean tool 3 2 Apply lubricant 130 6951 Grease Hammer Paste to tool 3 3 Install tool 3 Illustration 84 g01162251 typical example 4 Apply lubricant 130 6951 Grease Hammer Paste to pin 2 Illustration 85 g01401123 53 Maintenance Section Tool Retaining Pins Inspect Replace 5 Install retaining ring 4 6 Install pin 2 to tool 3 Illustration 86 g01162248 typical example 7 Install plug 1 i02552060 Tool Retaining Pins Inspect Replace SMCS Code 6826 040 6826 510 Illustration 87 g01162425 typical example 1 Remove pin 1 f
2. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpil All Rights ee CATERPI LLAR CATERPILLAR RK UI Operation and Maintenance Manual H35D S H45D S H55D S and H65D S Hydraulic Hammers BXH1 Up H35D S flat top BXJ1 Up H45D S flat top FTF1 Up H55D S flat top FTS1 Up H65D S flat top BWM1 Up H55D S pin on BYT1 Up H65D S pin on 46 Maintenance Section Maintenance Interval Schedule 02794753 Maintenance Interval Schedule SMCS Code 6700 041 7519 Every 2 Service Hours or 4 Times Daily Work Tool Lubricate A 47 Daily Mounting Bracket Inspect 49 Initial 50 Service Hours Mounting Bracket Bolts Tighten nnaannanneannnan 49 Side Plate Bolts Tighten cecccceeeeeeeeeeeeeeees 49 Every 50 Service Hours or Weekly Hydraulic Fittings Inspect eeeeeeee eens 47 Velo EH Ee GE 50 Tool Remove and Install cc ceecceeeeeeeee ees 51 Tool Retaining Pins Inspect Replace 53 Tool Bushing Inspect Replace cccceeeeeeees 54 Every 1000 Service Hours or 1 Year Work Tool Inspect Recondition cccceceeees 47 SEBU7921 03 SEBU7921 03 102808879 Work Tool Inspect Recondition SMCS Code 6333 020 6333 040 6700 020 6700 040 All of the seals in the hammer must be replaced on a yearly schedule or every 1000 machine service hours which ever comes first At this time
3. Inspect the bolts 1 for the mounting bracket If necessary tighten the bolts 1 for the mounting bracket to the proper torque Refer to table 8 for the proper torque value Table 8 Sales Model Bolt Bolt Torque H35D S flat top 530 70 Nm H45D S flat top 8T 4141 H55D S flat top 391 52 Ib ft H55D S flat top 8T 4187 H65D S flat top 7X 2564 391 52 Ib ft 1 Some models use these bolts 49 Maintenance Section Mounting Bracket Bolts Tighten 02326114 Mounting Bracket Inspect SMCS Code 7079 S N BWM1 Up S N BYT1 Up SSL MTL Arrangement Illustration 73 g01162046 Inspect upper angled plate 1 and ensure that the plate is not bent or otherwise damaged Inspect holes 2 for wear and for damage Inspect lower angled plate 3 and ensure that the plate is not bent or otherwise damaged Consult your Caterpillar dealer if any wear is suspected or any damage is suspected 102797037 Side Plate Bolts Tighten SMCS Code 6333 079 BC Inspect the socket head bolts for the side plates for the proper torque If necessary tighten the socket head bolts to the proper torque Refer to illustrations 74 and 76 and tables 9 10 and 11for the proper torque value Note Tighten the socket head bolts in a cross pattern in order to ensure correct alignment of the housing and the dampening elements Coat the threads on the socket head bolts at the time of assembly
4. 55 Maintenance Section Tool Bushing Inspect Replace SEBU7921 03 4 Inspect seal 3 Replace seal 3 if the seal is worn or if the seal is damaged 5 Install tool 1 Refer to Operation and Maintenance Manual Tool Remove and Install for information on the installation procedure b
5. Couplings 1 Check the hydraulic fittings 1 and 3 for damage or leaks 2 Check the supply hoses 2 for damage or wear 3 Check all of the clamps on the host machine 4 Repair any damaged parts or worn parts before you operate the hammer Replace any damaged parts or worn parts before you operate the hammer Repair any leaks before you operate the hammer Note The hydraulic ports are located on the operator s side of the hammer for the MHE arrangement The supply port is located on the top on the H35D S flat top and H45D S flat top hammer The supply port is located on the right on the H55D S flat top and H65D S flat top hammer The supply port is marked as the IN port The return port is located on the bottom on the H35D S flat top and H45D S flat top hammer The return port is located on the left on the H55D S flat top and H65D S flat top hammer The return port is marked as the OUT port Note The hydraulic ports are located on the top of the hammer for the SSL MTL arrangements The supply port is located on the right The supply port is marked as the IN port The return port is located on the left The return port is marked as the OUT port SEBU7921 03 i02796812 Mounting Bracket Bolts Tighten SMCS Code 7079 527 BK 7079 527 BC S N FTF1 Up S N BXH1 Up S N BXJ1 Up S N FTS1 Up Illustration 72 g01400999 H35D S flat top H45D S flat top H55D S flat top and H65D S flat top
6. SMCS Code 6826 010 Note Use caution when you remove the hammer tool The tool can be very hot after the tool has been in operation When you remove the hammer tool wear protective gloves 1 Position the hammer on level ground 2 Put the host machine s transmission in neutral The parking brake should be engaged 3 Stop the engine 4 Exit the host machine Illustration 78 g01162248 typical example 5 Remove plug 1 from the side of the hammer Illustration 79 g01162250 typical example 52 Maintenance Section Tool Remove and Install Illustration 80 g01162251 typical example 6 Insert a punch in hole Y and strike the punch with a mallet in order to remove retaining pin 2 and Tool 3 Note Do not hesitate in striking the punch with significant force in order to remove the retaining pin Illustration 81 7 Remove retaining ring 4 Ee Illustration 82 typical example SEBU7921 03 8 Remove tool 3 When you remove the hammer tool wear protective gloves 9 If necessary use a suitable lifting device to remove the tool Refer to table 14 for the weight of the tool Table 13 Weights of Small Hammer Tools Sales Model H35D S H45D S Moil Tool 3 4 kg 7 5 lb 5 8 kg 12 8 Ib Chisel Tool 3 5 kg 7 7 Ib 5 9 kg 13 Ib Parallel Spade ki 3 5 kg 7 7 Ib 5 9 kg 13 Ib Transverse Spade Ki 3 5 kg 7 7 Ib 5 9 kg 13 Ib
7. the membranes for the accumulators must also be replaced Inspect all of the wear parts You must replace all of the damaged parts or the parts that are worn You must make sure that the accumulators are charged to the correct pressure Refer to the Service Manual Specifications Disassembly and Assembly and the Systems Operation Testing and Adjusting Sections for information on the hammer 102798571 Work Tool Lubricate SMCS Code 6700 086 NOTICE Failure to apply down pressure on the hammer tool during lubrication could result in piston seal failure This seal failure will allow oil to leak from the ham mer tool To avoid seal damage always apply down pressure on the hammer tool during lubrication Note Before you install the hammer tool the tool shank must be well lubricated Illustration 67 g01355826 typical example 1 Lubricate the hammer There is one fitting on the H35D S H45D S H55D S and the H65D S hammer 47 Maintenance Section Work Tool Inspect Recondition Illustration 68 g01161963 Note The fitting has been marked with the film that is shown in Illustration 68 2 Apply 10 to 15 strokes from the grease gun to the tool bushings and the hammer tool Caterpillar strongly recommends the use of 130 6951 Grease for all applications on the hydraulic hammers Refer to the Operation and Maintenance Manual Lubricating Grease for more information Adjust the intervals and the amount
8. 50 Maintenance Section Tool Inspect Illustration 74 g01275843 Example of the silenced housing on the H35D S flat top and H45D S flat top hammer Table 9 Torque Values for Silenced Hammer Sales Model H35D S flat top H45D S flat top Bolt 216 8310 223 8990 Nominal Torque EEN on 129 Ib ft 129 Ib ft Maximum 205 N m 205 N m Torque 151 Ib ft 151 Ib ft Minimum 145 N m 145 N m Torque 107 Ib ft 107 lb ft g01397237 Illustration 75 Example of the silenced housing on the H55D S flat top and H65D S flat top hammer Table 10 SEBU7921 03 Torque Values for Silenced Hammer Illustration 76 Sales Model H55D S flat top H65D S flat top Bolt 263 6016 174 6393 Nominal Torque on E 129 lb ft 251 Ib ft Maximum 205 N m 380 N m Torque 151 Ib ft 280 Ib ft Minimum 145 N m 300 N m Torque 107 Ib ft 221 Ib ft g01162082 Example of the silenced housing on the H55D S pin on and H65D S pin on hammers Table 11 Torque Values for Silenced Hammer Sales Model H55D S pin on H65D S pin on Bolt 263 6016 174 6393 Nominal Torque o a SC GE Maximum 205 N m 380 N m Torque 151 Ib ft 280 Ib ft Minimum 145 N m 300 N m Torque 107 lb ft 221 Ib ft i02798624 Tool Inspect SMCS Code 6826 040 Note Use caution when you remove the hammer tool The tool can be very hot after the tool has been in op
9. eration When you remove the hammer tool wear protective gloves 1 Remove the tool from the hammer Refer to the Operation and Maintenance Manual Tool Remove and Install SEBU7921 03 2 If necessary grind the burrs off the hammer tool Make sure that you remove the burrs from the notch for the retaining pin Remove the burrs from the retaining pin Illustration 77 g00678194 3 Check the hammer tool for wear When you measure the wear of the tool you must measure the part of the tool A that is in the tool bushings 4 Measure the dimension B 5 Refer to Table 12 for the dimension of a new tool Refer to Table 12 for the minimum diameter of a tool Table 12 Wear Limits for Hammer Tools Diameter of Minimum Sales Model New Tool Diameter of Tool 40 mm 38 mm Rigen 1 57 inch 1 50 inch 48 mm 46 mm GE 1 89 inch 1 81 inch 56 mm 54 mm Ee 2 20 inch 2 13 inch 65 mm 63 mm EES 2 56 inch 2 48 inch 6 You must replace the tool if dimension B is smaller than the minimum diameter of the tool for your hammer Note Do not weld on a hammer tool Welding on the hammer tool causes cracks in the hammer tool The cracks will cause the hammer tool to fail 7 Inspect the hammer tool for cracks If there are cracks in the hammer tool you must replace the hammer tool 51 Maintenance Section Tool Remove and Install 102797434 Tool Remove and Install
10. of grease to the wear rate of hammer tool and to the working conditions Lack of grease or improper grease will cause the following problems e Abnormal wear of the tool bushing and the hammer tool e Broken hammer tool Hydraulic Fittings Inspect SMCS Code 5057 040 X6 Personal injury or death can result from improp erly checking for a leak Always use a board or cardboard when checking for a leak Escaping air or fluid under pressure even a pin hole size leak can penetrate body tis sue Causing serious injury and possible death If fluid is injected into your skin it must be treated immediately by a doctor familiar with this type of injury 48 Maintenance Section Hydraulic Fittings Inspect Illustration 69 g01396898 Typical example of hydraulic fittings on an MHE arrangement for the H35D S flat top H45D S flat top H55D S flat top and H65D S flat top hammers Illustration 70 g01161971 Typical example of hydraulic fittings on an MHE arrangement or BHL arrangement for the H55D S pin on H55D S flat top H65D S pin on or H65D S flat top hammers Illustration 71 g01161972 Typical example of hydraulic fittings on an SSL or MTL for the H55D S pin on or H65D S pin on hammers SEBU7921 03 NOTICE For maximum durability in demanding applications al ways use Caterpillar High Vibration Hose Couplings Refer to Parts Manual SEBP4160 for additional infor mation on Caterpillar High Vibration Hose
11. rom the hammer Refer to Operation and Maintenance Manual Tool Remove and Install for additional information on removing the pin 54 Maintenance Section Tool Bushing Inspect Replace Si typical example Illustration 88 g01162427 2 Inspect the pin for wear or for cracks 3 If the pin is cracked you must replace the pin Illustration 89 g01162431 typical example 4 Inspect the retaining ring 2 for wear or for damage The retaining ring is located inside the hammer housing Replace the retaining ring if the retaining ring is worn or if the retaining ring is damaged Refer to Service Manual RENR4478 for additional information on replacing the retaining ring SEBU7921 03 102797436 Tool Bushing Inspect Replace SMCS Code 6826 040 GY 6826 528 Illustration 90 g01162452 typical example 1 Remove tool 1 Refer to Operation and Maintenance Manual Tool Remove and Install for information on the removal procedure 2 Clean the inside of tool bushing 2 Inspect the inside bore of the tool bushing for wear Illustration 91 g01277588 typical example 3 You must replace the tool bushing if the tool bushing has too much wear Refer to Table 15 for the dimensions Table 15 Tool Bushing Wear Limits Sales Model Maximum Dimension A H35D S 43 mm 1 7 inch H45D S 51 mm 2 inch H55D S 59 mm 2 3 inch H65D S 68 mm 2 7 inch

MAINTENANCE INTERVALS - Safety

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