MAINTENANCE INTERVALS - Safety
Contents
1. 08 39 Every 50 Service Hours or Weekly Hydraulic Fittings Inspect cc eeeeeeeeeeeees 39 TOOl INSDCGCE ccestetertunaate i o 39 OOP INS OC Gb muan a EA 40 TOON SNS DOC ane tew tonsa getnenaean ts 41 Tool Remove and Install cee eeeceeeeeeeee es 41 Tool Retaining Pins Inspect Replace 45 Tool Bushing Lower Inspect Replace 45 Tool Bushing Lower Inspect Replace 46 Every 1000 Service Hours or 1 Year Work Tool Inspect Recondition cceceeeee 37 SEBU7 662 04 SEBU7662 04 01862214 Work Tool Inspect Recondition SMCS Code 6333 020 6333 040 6700 020 6700 040 The hammer must be resealed and the membrane for the hydraulic accumulator must be replaced on an annual schedule Inspect all of the wear parts You must replace all of the damaged parts or the parts that are worn Refer to the Service Manual Specifications Disassembly and Assembly and the Systems Operation Testing and Adjusting Sections for information on the hammer You must make sure that the accumulator for the hammer is charged properly Refer to the Service Manual Hydraulic Accumulator Test and Charge for procedures on servicing the accumulator Refer to Guideline For Reusable Parts and Salvage Operations SEBF8474 Hydraulic Hammer Reuse and Salvage Guide in order to determine the reusability of the components 102. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpil All Rights alana CATERPI LLAR CATERPILLAR May 2007 Operation and Maintenance Manual H140D S H160D S and H180D S Hydraulic Hammers BXB1 Up H140D S BXF1 Up H160D S P1 Up H180D S 36 Maintenance Section Maintenance Interval Schedule 102767095 Maintenance Interval Schedule SMCS Code 6700 041 7519 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Note Before each consecutive interval is performed all maintenance from the previous interval must be performed Every 2 Service Hours or 4 Times Daily Work Tool Lubricate cccccceccseeeeeceeeseeeaees 37 Initial 50 Service Hours Mounting Bracket Bolts Tighten
3. 6 Ib 206 kg 454 2 Ib 230 kg 507 1 Ib Soft Rock Chisel Tool 140 kg 308 6 Ib 197 kg 434 3 Ib 240 kg 529 1 Ib Hard Rock Chisel Tool 132 kg 291 0 Ib 197 kg 434 3 Ib 225 kg 496 Ib Long Chisel Tool 156 kg 343 9 Ib 222 kg 489 4 Ib Not Available Moil Tool 127 kg 280 0 Ib 197 kg 434 3 Ib 225 kg 496 Ib Long Moil Tool 152 kg 335 1 Ib 221 kg 487 2 Ib Not Available Pyramid Point Tool 132 kg 291 0 Ib 197 kg 434 3 Ib 215 kg 474 Ib 7 After you remove the hammer 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 8 After you have removed the hammer tool inspect the hammer tool for wear Refer to the Operation and Maintenance Manual Tool Inspect for information on inspecting the hammer tool 9 After you have removed the hammer tool inspect the seal for the bushings for wear You must replace the seal if the seal is worn or if the seal is damaged Alternate Removal Procedure For Tool Retaining Pins on H180D S Note The H180D S tool retaining pins can also be removed with a threaded rod Note Use caution when you touch the hammer tool The hammer tool is very hot after the hammer has been used Illustration 51 TaN g01384091 Illustration 52 Illustration 53 Lay the hammer on the ground in order to remove hammer tool 1 Positi
4. 2396713 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 lubricate the hammer refer to Special Instruction REHS1368 Procedure to Properly Grease Hydraulic Hammers Note Before you install the hammer tool the tool shank must be well lubricated 37 Maintenance Section Work Tool Inspect Recondition Illustration 36 g01197156 There are two locations 1 on the hammer for lubrication g01197159 Illustration 37 Fittings 2 are located near the bottom of the hammer In order to access the grease fittings remove the protective plugs Illustration 38 g01161963 The grease points have been marked with a grease decal Apply 10 strokes to 15 strokes from the grease gun to the tool bushings and the hammer tool Note The letter G is stamped into the valve body near the port for the autolube system The port for the autolube system is near the inlet port or the outlet port 38 Maintenance Section Work Tool Lubricate Adjust the intervals and the amount of grease to the wear rate of hammer tool 4 and the working conditions Lack of grease or improper grease will cause the following problems e Abnormal wear of the too
5. cond groove for grease 3 Wear pattern 4 Inspect the wear pattern 3 in the tool bushing If first groove 1 is worn away and second groove 2 is visible you can reuse the bushing Illustration 60 g00701610 a In order to reuse the tool bushing you can rotate the tool bushing by 90 degrees 5 If grooves 1 and 2 are worn away you must replace the tool bushing 46 Maintenance Section Tool Bushing Lower Inspect Replace SEBU7 662 04 Illustration 61 g01200105 4 Lower tool bushing 5 Area on the lower tool bushing for applying grease 6 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 a Apply grease to the entire surface 5 on the lower tool bushing 4 Grease will prevent corrosion and seizures The removal of the lower tool bushing will be made easier by applying grease b Install the lower tool bushing Install the retaining pins 102776017 Tool Bushing Lower Inspect Replace SMCS Code 6826 040 GY 6826 528 S N BXP1 Up 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 If you need to remove the lower tool bushing refer to the Service Manual Tool Bushing Lower Remove and Install for more information Refer to Table 10 for the weight of the lower tool bushi
6. e of the tool Welding can cause failure due to metal fatigue 102776014 Tool Remove and Install SMCS Code 6826 010 Removal of Tool Note Use caution when you touch the hammer tool The hammer tool is very hot after the hammer has been used 42 Maintenance Section Tool Remove and Install Illustration 48 g01197485 1 Lay the hammer on blocks in order to remove hammer tool 1 Position the hammer in order to remove the retaining pins from the top of the housing The blocks should be high enough to allow the retaining pins to be removed 2 Put the host machine s transmission in neutral The parking brake should be engaged 3 Stop the engine Illustration 49 g01197488 4 The locking pin 2 is spring loaded Fully depress locking pin 2 with a screwdriver in order to remove pin 3 SEBU7 662 04 ae Illustration 50 g01197489 5 Remove retaining pin 4 and retaining pin 5 in order to remove hammer tool 1 6 Use a suitable lifting device in order to remove hammer tool 1 Refer to the Table 8 for the weight of the hammer tools Remove hammer tool 1 SEBU7 662 04 43 Maintenance Section Tool Remove and Install Table 8 Approximate Weights of Large Hammer Tools H140D S H160D S H180D S Blunt Tool 123 kg 271 2 Ib 187 kg 412 3 Ib 225 kg 496 Ib Super Blunt Tool 134 kg 295 4 Ib 214 kg 471 8 Ib 248 kg 546 7 Ib Chisel Tool 130 kg 286
7. h A the output of the pump is not correct Refer to Special Instruction REHS1286 Installation Procedure for the 24 Volt Automatic Lubrication System for the Hydraulic Hammers or Special Instruction GESRO531 Hydraulic Autolube Kit for instructions on resetting the pump Note The volume of grease is not adjustable on the pump for the 148 8098 Automatic Lubrication Group This group is only available in Europe SEBU7 662 04 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 Illustration 41 g00675272 1 In order to perform the following inspection remove the covers at the top of the hammer housing 2 Check supply lines and return lines 1 for damage or wear 3 Check hydraulic fittings 2 and 4 for damage or leaks 4 Check connector hoses 3 for damage or for wear 39 Maintenance Section Hydraulic Fittings Inspect 5 Check all of the clamps on the boom and all of the clamps on the stick of the host machine Repair any damaged parts or worn parts before you operate the hammer Replace any damaged par
8. l bushing and hammer tool 4 e Broken hammer tool 4 Hammers with Automatic Lubrication Illustration 39 g01197169 3 Hammer 4 Tool A 50 100 mm 2 4 inch Check the Reservoir Note To ensure that the autolube system will work properly make sure that the grease reservoir for the autolube system is full of grease SEBU7 662 04 Illustration 40 g0086808 1 Typical example of reservoir and nipple for refilling the reservoir Fill the reservoir 5 of the automatic lubrication system Refill the reservoir when the grease reaches MIN mark on the reservoir Fill the reservoir up to the MAX mark on the reservoir Check the Operation of the Pump Visually verify the amount of grease around tool 4 below the lower tool bushing An adequate amount of grease is indicated if there is a collar of grease around the tool for a distance of 50 100 mm 2 4 inch A This should be checked with no down pressure on the tool The tool must be off the ground and pointing downward Note When hammer 3 is removed from the stick the grease line should be disconnected at the same location as the hydraulic pressure and return lines will be disconnected The grease lines and the return lines must be capped or plugged The electrical circuit should be deactivated by removing the fuse from the fuse holder in the red wire Adjust the Operation of the Pump If the collar of grease is not 50 100 mm 2 4 inch in lengt
9. l the tool Refer to Operation and Maintenance Manual Tool Remove and Install for information on the installation procedure 47 Maintenance Section Tool Bushing Lower Inspect Replace
10. ng Table 10 Approximate Weight of Lower Tool Bushing H180D S 71 kg 157 Ib 3 Completely clean the inside of the bushing Illustration 62 g01197387 1 Wear pattern 2 Seal 4 Inspect the inside bore of the bushing for wear 5 You can reuse the bushing if the wear 1 is only located on two sides of the bushing and if the bushing has never been rotated due to wear Illustration 63 g01197406 a In order to reuse the tool bushing you can rotate the tool bushing by 90 degrees Illustration 64 g01384101 SEBU7 662 04 6 You must replace the tool bushing if the tool bushing has too much wear Refer to Illustration 64 and Table 11 for the dimensions Table 11 Wear Limit For Tool Bushing Sales Model Maximum Dimension A H180D S 178 mm 7 0 inch 7 Inspect the seal 2 in the tool bushing Replace the seal in the tool bushing if the seal is worn or if the seal is damaged Illustration 65 g01200105 4 Lower tool bushing 5 Area on the lower tool bushing for applying grease 8 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 a Apply grease to the entire surface 5 on the lower tool bushing 4 Grease will prevent corrosion and seizures The removal of the lower tool bushing will be made easier by applying grease b Install the lower tool bushing 9 Instal
11. ol A that is in the tool bushings 5 Measure dimension B of the tool 6 Replace the tool if dimension B is less than 138 mm 5 43 inch 7 Inspect the tool for cracks If the tool is cracked replace the tool Note Do not weld a tool to repair Welding causes cracks on the surface of the tool Welding can cause failure due to metal fatigue SEBU7 662 04 102402705 Tool Inspect SMCS Code 6826 040 S N BXF1 Up Note Use caution when you touch the hammer tool The hammer tool can be very hot after the tool has been in operation Illustration 44 g00675483 1 Remove the tool from the hammer Refer to the Operation and Maintenance Manual Tool Remove and Install 2 Inspect the retaining pins for the hammer tool Remove any burrs from the retaining pins Replace the pins if the pins have excessive wear Illustration 45 g01200031 3 Check the hammer tool for wear If necessary grind the burrs off the hammer tool Inspect the notch for the retaining pins Remove any burrs 4 When you measure the wear of the tool you must measure the part of the tool A that is in the upper tool bushing and the part of the tool C that is in the lower tool bushing 5 Measure dimension B of the tool SEBU7 662 04 6 Replace the tool if dimension B is less than 156 mm 6 14 inch 7 Measure dimension D of the tool 8 Replace the tool if dimension D is less than 158 mm 6 22 inch 9 In
12. on the hammer in order to remove the retaining pins from the top of the housing Put the host machine s transmission in neutral The parking brake should be engaged Stop the engine g01197488 4 The locking pin 2 is spring loaded Fully depress locking pin 2 with a screwdriver in order to remove pin 3 g01197688 5 A 16 mm 0 6299 inch threaded hole is located in the end of the pin 44 Maintenance Section Tool Remove and Install 6 Insert a 16 mm 0 6299 inch threaded rod into the tool retaining pin Illustration 54 g01197752 7 Pull the threaded rod outward in order to remove the retaining pin 4 and retaining pin 5 8 Use a suitable lifting device in order to remove hammer tool 1 Refer to the Table 8 for the weight of the hammer tools Remove hammer tool 1 Installation of Tool Illustration 55 g01197485 1 Position the hammer in order to install the retaining pins from the top of the housing 2 Clean hammer tool 1 and lubricate hammer tool 1 with grease 3 Clean pins 3 4 and 5 Lubricate pins 3 4 and 5 with grease 4 Install hammer tool 1 and align the grooves of the tool with the pin bores SEBU7 662 04 Illustration 56 g01197489 5 Install retaining pin 4 and install retaining pin 5 Illustration 57 g01197488 6 The locking pin is spring loaded Fully depress locking pin 2 Install pin 3 that locks
13. spect the tool for cracks If the tool is cracked replace the tool Note Do not weld a tool to repair Welding causes cracks on the surface of the tool Welding can cause failure due to metal fatigue 102397357 Tool Inspect SMCS Code 6826 040 S N BXP1 Up Note Use caution when you touch the hammer tool The hammer tool can be very hot after the tool has been in operation g00675483 Illustration 46 1 Remove the tool from the hammer Refer to the Operation and Maintenance Manual Tool Remove and Install 2 Inspect the retaining pins for the hammer tool Remove any burrs from the retaining pins Replace the pins if the pins have excessive wear 41 Maintenance Section Tool Inspect Illustration 47 g01200031 3 Check the hammer tool for wear If necessary grind the burrs off the hammer tool Inspect the notch for the retaining pins Remove any burrs 4 When you measure the wear of the tool you must measure the part of the tool A that is in the upper tool bushing and the part of the tool C that is in the lower tool bushing 5 Measure dimension B of the tool 6 Replace the tool if dimension B is less than 167 mm 6 58 inch 7 Measure dimension D of the tool 8 Replace the tool if dimension D is less than 172 mm 6 77 inch 9 Inspect the tool for cracks If the tool is cracked replace the tool Note Do not weld a tool to repair Welding causes cracks on the surfac
14. the retaining pins 7 Check that retaining pin 4 and retaining pin 5 are secured by locking pin 3 SEBU7 662 04 101570377 Tool Retaining Pins Inspect Replace SMCS Code 6826 040 6826 510 D1 D2 g00815523 Illustration 58 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 4 lf the pin is cracked you must replace the pin 102776016 Tool Bushing Lower Inspect Replace SMCS Code 6826 040 GY 6826 528 S N BXB1 Up S N BXF1 Up 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 If you need to remove the lower tool bushing refer to the Service Manual Tool Bushing Lower Remove and Install for more information Refer to Table 9 for the weight of the lower tool bushing 45 Maintenance Section Tool Retaining Pins Inspect Replace Table 9 Approximate Weight of Lower Tool Bushing H140D S 34 kg 75 b H160D S 36 kg 79 lb 3 Completely clean the inside of the bushing Inspect the inside bore of the bushing for wear Illustration 59 g01200224 1 First groove for grease 2 Se
15. ts or worn parts before you operate the hammer Repair any leaks before you operate the hammer Replace any covers that were removed before you operate the hydraulic hammer 102775997 Mounting Bracket Bolts Tighten SMCS Code 7079 527 BC 7079 527 BK Tighten the bolts for the mounting bracket to the following torque value Table 7 Torque Values for the Bolts for the Mounting Bracket Part Sales Number Quantit Torque Model and Part y Value Name 900 100 Hi4o0s ries 10 N m 664 74 Ib ft 3100 350 HigoDS 98 10 N m 2286 258 Ib ft 3100 350 HigoDS Yoro 10 N m 2286 258 Ib ft i01958469 Tool Inspect SMCS Code 6826 040 S N BXB1 Up Note Use caution when you touch the hammer tool The hammer tool can be very hot after the tool has been in operation 40 Maintenance Section Tool Inspect Illustration 42 g00675483 1 Remove the tool from the hammer Refer to the Operation and Maintenance Manual Tool Remove and Install 2 Check the hammer tool for wear If necessary grind the burrs off the hammer tool Inspect the notch for the retaining pins Remove any burrs 3 Inspect the retaining pins for the hammer tool Remove any burrs from the retaining pins Replace the pins if the pins have excessive wear Illustration 43 g01018196 4 Check the hammer tool for wear When you measure the wear of the tool you must measure the part of the to
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