MAINTENANCE INTERVALS - Safety
Contents
1. 11 Ib 7 kg 15 Ib 13 kg 29 Ib 19kg 421b 34 kg 75 Ib 39 kg 85 Ib Tool Transverse 5 kg 11 Ib 7 kg 15 Ib 13 kg 29 Ib 19kg 421b 34 kg 75 Ib 39 kg 85 Ib Spade Tool Compacting 21 kg 46 Ib 23 kg 51 Ib 30 kg 66 Ib 54 kg Plate 119 Ib 8 After you remove the tool inspect the lower tool bushing for wear Refer to the Operation and Maintenance Manual Tool Bushing Lower Inspect Replace for information on inspecting the bushing 9 After you remove the tool inspect the upper tool bushing for wear Refer to the Operation and Maintenance Manual Tool Bushing Upper Inspect Replace for information on inspecting the bushing for the following hydraulic hammers 90 H90C and H90Cs 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 Installation of Tool 1 Clean the hammer tool 2 and lubricate the hammer tool 2 with grease Coat the sides of the tool with grease Do not place any grease on the top of the tool 2 Clean the pins 3 Clean the buffers 4 Lubricate the pins 3 with grease 3 Install the hammer tool 2 and align the grooves of the tool with the pin bores2. 4 Install the retaining pin or retaining pins 3 5 Install the buffer or buffers 4 6 Install the split pin or the split pins 1 i01570377 Tool Retaining Pins Inspect Replace SMCS Code 6826 040 6826 510 D2 L Illustration 49 900815523 1 Remove the pin from the hammer 2 Inspect the pin for wear or for cracks 3 Measure the amount of wear Compare Dimension D1 to Dimension D2 The difference between Dimension D1 and Dimension D2 must be less than 1 0 mm 0 04 inch If the difference is greater than 1 0 mm 0 04 inch you must replace the pin 48 Maintenance Section Tool Bushing Upper Inspect Replace 4 If the pin is cracked you must replace the pin i01570752 Tool Bushing Upper Inspect Replace H90C H90Cs and H100 H100s Only SMCS Code 6826 040 GY 6826 528 1 Remove the hammer tool Inspect the hammer tool Refer to Operation and Maintenance Manual Tool Hammer Inspect 2 Remove the lower tool bushing Inspect the lower tool bushing Refer to Operation and Maintenance Manual Tool Bushing Lower Inspect Replace 3 Remove the upper tool bushing 4 Inspect the upper tool bushing for excessive wear Inspect the upper tool bushing for damage Illustration 50 5 Measure Dimension A Dimension A is from the top of the tool to the top of the tool bushing You must use a Caterpillar hammer tool for the measurement Measure Dimension
3. B Refer to Table 22 for the acceptable dimensions 900815770 Table 22 Specifications for Upper Tool Bushing for H90C H90Cs 100 100s H100 and H100s Minimum Maximum Sales Model Distance A Diameter B 28 mm H90C H90Cs 1 10 inch 86 mm 3 4 inch 100 100s H100 38 mm 3 H100s 1 50 inch 97 mm 3 8 inch 6 If the upper tool bushing has any damage you must replace the bushing If the upper tool bushing has any cracks you must replace the bushing If the upper tool bushing does not meet the dimensions in Table 22 you must replace the bushing 7 Coat all of the outer surfaces of the upper tool bushing with 5P 3931 Anti Seize Compound Install the upper tool bushing into the head 8 Coat all of the outer surfaces of the lower tool bushing with 5P 3931 Anti Seize Compound Install the lower tool bushing into the head 9 Coat the sides of the hammer tool that contact the tool bushings with grease Install the hammer tool into the tool bushings i01670115 Tool Bushing Lower Inspect Replace SMCS Code 6826 040 GY 6826 528 1 Remove the tool Refer to Operation and Maintenance Manual Tool Remove and Install for information on the procedure to remove the tool from your hammer 2 Clean the inside of the bushing Inspect the inside bore of the bushing for wear Se OX eee 1202625982228289 SS a KO KOS VS IIIS OOO P Zl AA
4. 020 6333 040 6700 020 6700 040 All of the seals in the hammer must be replaced on a yearly schedule At this time the membrane for the accumulator 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 accumulator is 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 101866472 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 hammer tool To avoid seal damage always apply down pres sure on the hammer tool during lubrication Note Before you install the hammer tool the tool shank must be well lubricated P ud T Illustration 36 900676898 1 Lubricate the hammer There is one fitting on the H45 H45s H50and the H50s There are two fittings on the 63 H63 H63s 70 70s H70 H70s H90C H90Cs 100 100s H100 and the H100s Illustration 37 900673000 Note The fittings have been marked with the decal that is shown in Illustration 37 2 Apply 10 to 15 strokes from the grease gun to the tool bushings and the hammer tool Caterpillar Impact Products Limited strongly recommends the use of 130 6951 Grease for all applic
5. 5561 Silicone Lubricant 6 on the outer surface of lower tool bushing 3 Refer to Illustration 53 for applying the silicone sealant Illustration 54 900862983 c Apply grease 8 to the bore of front head 7 Grease will prevent corrosion and seizures The removal of the lower tool bushing will be made easier by applying grease Refer to Illustration 54 d Install the lower tool bushing before the sealant hardens Install the split pins
6. A NIIS REELS RK RELL YORK fesso cS ESS SRLS RRS ASK NN Illustration 51 900678377 49 Maintenance Section Tool Bushing Lower Inspect Replace 3 You must replace the bushing if the bushing has too much wear Refer to Table 23 for the dimensions Table 23 Tool Bushing Lower Wear Limits Sales Model Maximum Dimension A H45 H45s 47 mm 1 8 inch H50 H50s 52 mm 2 0 inch 63 H63 H63s 65 mm 2 5 inch 70 70s H70 H70s 72 mm 2 8 inch H90C H90Cs 86 mm 3 4 inch 100 100s H100 H100s 97 mm 3 8 inch Illustration 52 900678426 In order to remove the bushing you must perform the following steps 1 Remove the split pins 1 There are two split pins There is one pin on each side of the bushing 2 Slide the bushing 3 from the head 3 Inspect the seal 4 and inspect the O ring 2 Replace the seal if the seal is damaged Replace the O ring if the O ring is damaged 4 If the lower tool bushing has been removed from the front head you must perform the following steps before you install the lower tool bushing Illustration 53 g00862982 Note Do not apply 5N 5561 Silicone Lubricant to the bore of the front head a Refer to Illustration 53 If you have previous lower tool 3 remove O ring seal 2 from groove 5 Do not replace the O ring seal Silicone sealant will replace O ring seal 2 b Apply a thin layer of 5N
7. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved A e SEBU7345 02 CATERPILLAR Janay 200 Operation and Maintenance manual H45 H45s H50 H50s 63 H63 H63s 70 70s H70 H 70s H90C H90Cs and 100 H100 H100s Hydraulic Hammers 6CZ1 Up H45 H45s Suzi Up H50 H50s 4 rigs o ie 4KL1 1029 70 70s 4KL1030 Up H70 H70s 6TZ1 Up H90C H90Cs 158 158 100 4ML159 Up H100 H100s 39 Maintenance Section Maintenance Interval Schedule i01866383 Maintenance Interval Schedule SMCS Code 6700 041 7519 Every 2 Service Hours or 4 Times Daily Work Tool Lubricate seeeeeeese 40 Initial 50 Service Hours Mounting Bracket Bolts Tighten 41 Side Plate Bolts Tighten sssssse 42 Every 50 Service Hours or Weekly Hydraulic Fittings Inspect 41 Tool InSpeGt ine oontra ces 45 Tool Remove and Install sssse 46 Tool Retaining Pins Inspect Replace 47 Tool Bushing Upper Inspect Replace 48 Tool Bushing Lower Inspect Replace 48 Every 1000 Service Hours or 1 Year Work Tool Inspect Recondition 40 40 Maintenance Section Work Tool Inspect Recondition 101858219 Work Tool Inspect Recondition SMCS Code 6333
8. ations on the hydraulic hammers Refer to the Operation and Maintenance Manual Lubricating Grease for more information 3 If the hammer is equipped with an automatic lubrication system check the hammer tool for a collar of grease The collar of grease must be completely around the hammer tool If the collar of grease is too large or the collar of grease is too small refer to the Service Manual Testing and Adjusting for information about setting the timer Refer to the Operation and Maintenance Manual Automatic Lubrication for more information on the automatic lubrication system Adjust the intervals and the amount 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 41 Maintenance Section Hydraulic Fittings Inspect i01273608 Hydraulic Fittings Inspect SMCS Code 5057 040 X6 A WARNING Personal injury or death can result from improper ly 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 Illustration 38 900677053 Typical exampl
9. e of hydraulic fittings 1 Check the hydraulic fittings 1 and 3 for damage or leaks 2 Check the connector lines 2 for damage or for wear 3 Check the supply hoses for damage or wear 4 Check all of the clamps on the boom and all of the clamps on the stick of the host machine 5 You must repair any damaged parts or worn parts before you operate the hammer You must replace any damaged parts or worn parts before you operate the hammer You must repair any leaks before you operate the hammer 101866452 Mounting Bracket Bolts Tighten SMCS Code 7079 527 BK 7079 527 BC Check the bolts for the mounting bracket If necessary tighten the bolts to the proper torque value Refer to the following tables for the proper torque value 900678912 Illustration 39 The typical example that is shown is for the following machines e Excavator e Backhoe loader 42 Maintenance Section Side Plate Bolts Tighten Table 12 Sales Model Bolt 1 Bolt Torque H45 H45s H50 H50s 70s H70s 81 4141 or 530 70N m H90Cs 100 8T 4187 391 52 Ib ft 100s 63 H63 H63s 270 40 Nm 70 H70 H90C INEST 199 30 Ib ft 900 100 N m H100 H100s 7X 2454 DT KY Ss Illustration 40 g00630645 Mounting bracket for skid steer loaders 2 Bolts to mount H45 H45s H50 and H50s 3 Bolts to mount H63 and H63s Table 13 Sales Bolt Model Bol
10. ol i01866444 Tool Remove and Install SMCS Code 6826 010 900678536 Illustration 48 Note Use caution when you remove the hammer tool The tool can be very hot after the tool has been in operation 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 Remove the split pin or cotter pins 1 There can be one split pin or cotter pin on each side of the hammer The following hydraulic hammers use one pin H45 H45s 63 H63 and H63s All of the other hydraulic hammers use two pins 5 Remove the buffer or the buffers 4 6 Remove the retaining pin or retaining pins for the tool 3 7 If necessary use a Suitable lifting device to remove the tool Refer to the Table 21 for the weight of the tool Remove the hammer tool 2 47 Maintenance Section Tool Retaining Pins Inspect Replace Table 21 Weights of Small Hammer Tools H45 H50 63 70 H90C 100 H45s H50s H63 70s H90Cs H100 H63s H70 H100s H70s Blunt Tool 43 kg 95 Ib Chisel Tool 5 kg 11 Ib 8 kg 18 Ib 15 kg 33 Ib 20 kg 441b 324 kg 75 Ib 46 kg 101 Ib Long Chisel 18 kg 40 Ib 23kg 511b 37 kg 81 Ib 55 kg 121 Ib Moil Tool 5 kg 11 Ib 7 kg 15 Ib 15 kg 331b 20 kg 441b 33 kg 73 Ib 44 kg 97 Ib Long Moil Tool 18 kg 40 Ib 23kg 511b 37 kg 81 Ib 53 kg 117 Ib Parallel Spade 5 kg
11. r Refer to the Operation and Maintenance Manual Tool Remove and Install 2 f 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 47 900678194 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 the Table 20 for the dimension of a new tool Refer to the Table 20 for the minimum diameter of a tool Table 20 Wear Limits for Hammer Tools Sales Model Diameter of Minimum New Tool Diameter of Tool H45 H45s 45 0 mm 43 0 mm 1 77 inch 1 69 inch H50 H50s 50 0 mm 48 0 mm 1 99 inch 1 89 inch H63 H63s 63 0 mm 61 0 mm 2 48 inch 2 40 inch H70 H70s 70 0 mm 68 0 mm 2 76 inch 2 68 inch H90C H90Cs 84 0 mm 82 0 mm 8 31 inch 3 23 inch H100 H100s 95 0 mm 93 0 mm 8 74 inch 3 66 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 46 Maintenance Section Tool Remove and Install 7 Inspect the hammer tool for cracks If there are cracks in the hammer tool you must replace the hammer to
12. s 7Y 5215 428 74 lb ft Illustration 43 900677987 Example of a H70 Pin On hammer Table 16 Torque Values for Pin On Side Plates Sales Model Bolt 1 Bolt 2 Torque 580 100 70 H70 7X 2576 N m 428 74 Ib ft 580 100 70 H70 7X 2575 N m 428 74 Ib ft 44 Maintenance Section Side Plate Bolts Tighten Illustration 44 900678005 Illustration 45 g00678006 Example of H70s Pin On hammer Example of a H90C Pin On hammer Table 17 Table 18 Torque Values for Pin On Side Plates Torque Values for Pin On Side Plates Sales Model Bolt 3 Torque ante Bolt 4 Bolt 5 Torque 340 60 N m 70S 0s 9X 2494 251 44 Ib ft 1150 200 H90C 7X 2580 N m 848 148 Ib ft 580 100 H90C 7X 2575 N m 428 74 Ib ft 45 Maintenance Section Tool Inspect Illustration 46 900678007 Example of a H100 Pin On hammer Table 19 Torque Values for Pin On Side Plates Sales Model Bolt 6 Bolt 7 Torque 1150 200 H100 7X 2583 N m 848 x 148 Ib ft 580 100 H100 7X 2576 N m 428 74 Ib ft 101866450 Tool Inspect SMCS Code 6826 040 Note You must use caution when you touch the hammer tool The hammer tool can be extremely hot after the hammer tool has been in operation 1 Remove the tool from the hamme
13. t 2 Bolt 3 Torque 530 70 ed DE 8T 4141 N m 391 i 52 Ib ft 270 40 p es 7X 2554 Num 199 30 Ib ft i01585135 Side Plate Bolts Tighten SMCS Code 6333 079 BC Inspect the bolts for the side plates for the proper torque If necessary tighten the bolts to the proper torque Refer to the following illustrations and the following tables for the proper torque value Illustration 41 900617830 Example of a non silenced hammer Table 14 Torque Values for the bolts on Non Silenced Hammers Sales Model Bolt 1 Torque 240 40 N m H4S ota 177 30 Ib ft 340 60 N m H50 STAHA 251 44 Ib ft 580 x 100 N m 63 H63 7X 2575 428 74 Ib ft 580 100 N m 70 H70 7X 2577 428 74 Ib ft 1150 200 N m ae ix PSB 848 148 Ib ft 1150 200 N m 100 H100 7X 2583 848 148 lb ft 2 Tighten the nuts for the threaded rod to a torque value of 100 20 N m 74 15 lb ft Use this torque value for all side plates that are equipped with a threaded rod Use the threaded rod to help with the alignment of the side plates and the mounting bracket 43 Maintenance Section Side Plate Bolts Tighten Illustration 42 990077934 Example of a silenced housing Table 15 Torque Values for Silenced Hammers Sales Model Bolt 1 Torque 175 30 Nm H45s H50s 8T 1447 129 22 Ib ft 340 60 N m H63s 70s H70s 9X 2404 251 44 Ib ft 580 100 N m H90Cs H100
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