Caterpillar Impact Products Ltd.
Caterpillar Hammers
Maintenance
“KEY to SUCCESS”
YES
Read the manuals
---
It’s important!
Hammer Components are machined with close
tolerances.
-- Oil components before assembly
-- Use solvent tank and Krokus cloth to clean
-- Do not use steam cleaner on internal parts.
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Caterpillar Impact Products Ltd.
Caterpillar Hammers
M
aintenance
Operator Requirements
• Properly grease hammer
• Tighten loose connections in hydraulic system
• Inspect tool retaining pins
• Remove burrs from retaining pin groove on tool
• Check lower tool bushing for wear
• Check top and side buffers for cracks and wear
• Check condition of wear parts, hydraulic connections etc.
Daily
Weekly
Monthly
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Caterpillar Impact Products Ltd.

Caterpillar Hammers
GREASING INTERVAL
■
Every two hours; hourly in extreme conditions
■
10-15 strokes from the grease gun
Adapt interval and amount according to grease
quality, wear rate and working conditions.
GREASE TYPE
■
Molybdenum disulfide or graphite grease.
■
Dropping point at over 250° C or 480° F
■
Maximum working temperature >150°C/302°F
■
Minimum working temperature under lowest
ambient temperature
■
Grade NGLI number 0-2
■
Water resistant
GREASING OF TOOL
■
Hammer must be standing upright against
the tool
■
Check that grease goes between tool
and bushings
■

Do not over grease
Lubrication Guide
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Caterpillar Impact Products Ltd.
Caterpillar Hammers
RESULTS of IMPROPER GREASING
Without proper down force grease WILL cause premature seal failure.
Improper Greasing
Tool
Piston
Grease blows up pass seals
ANY and ALL hydraulic hammers.
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Caterpillar Impact Products Ltd.
Caterpillar Hammers
Automatic Lubrication System - Autolube
Grease Pump activated by electrical signal
from hammer foot switch or pressure switch,
supplies grease to hammer tool bushings.
Grease amount is adjusted by dials inside
pump/motor housing. Greasing cycle is
adjusted by both the ON and OFF dials .
• BLUE dial controls OFF time in cycle
• RED dial controls ON time in cycle
Cycle active only when hammer is operating.
Pump/motor housing
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Caterpillar Impact Products Ltd.
Caterpillar Hammers
Autolube -

Small Hammers (H45-H100)
Port located on front
Auto-Lube
Connection
Air channel for
underwater
applications
SMALL HAMMERS (H45-H100C)
Manual Grease Points Autolube Connection Air Connection
Model # points location port size location port size location port size
H45/H45s 1 LH 1/8" BSPP
H50/H50s 2 LH 1/8" BSPP Front 3/8" BSPP Back 1/2" BSPP
H63/H63s 2 LH 1/8" BSPP Front 3/8" BSPP Back 1/2" BSPP
H70/H70s 2 LH 1/8" BSPP
H90C/H90Cs 2 LH 1/8" BSPP Front 3/8" BSPP Back 1/2" BSPP
H100/H100s 2 LH 1/8" BSPP Front 1/4" BSPP Back 1/2" BSPP
side of lower body
.
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Caterpillar Impact Products Ltd.
Caterpillar Hammers
Manual Grease Points Autolube Connection Air Connection
Model # points location port size location port size location port size
H115s 2 LH 1/4" BSPP Return-RH 1/4" BSPP Supply-LH 1/4" BSPP
H120Cs 2 LH 1/4" BSPP Supply-LH 3/8" BSPP Supply-LH 3/8" BSPP
H130s 2 LH 1/4" BSPP Supply-LH 3/8" BSPP Return-RH 3/8" BSPP
H140s 1 RH 1/4" BSPP
H160s 1 RH 1/4" BSPP
H180s 2 LH 1/4" BSPP Supply-LH 3/8" BSPP Return-RH 1/2" BSPP
Autolube -

Large Hammers (H115s-H180s)
Port is located on upper valve housing
next to the supply or return port - see
chart below .
Port identifications:
• ‘G’ indentifies autolube port.
• ‘A’ indentifies ‘Air’ channel port.
Note: For H140s & H160s, Autolube adapts
externally at the manual grease port. External
guarding is required to protect line and fittings.
See Note
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Caterpillar Impact Products Ltd.
Caterpillar Hammers
Installation:
1)Fasten grease line securely along supply/return line.
2)Install pump in convenient location.
3)Protect electrical circuit with fuses provided.
4)Provide convenient means of deactivation.
5)Prime lines with quality grease suitable for hammers.
6)Adjust grease amount to recommended dial settings.
7)ALWAYS confirm proper operation following installation.
8)Consult service manual for more detailed information.
Daily Checks:
1)Confirm adequate grease amount, adjust accordingly.
2)Check for damaged hoses, fittings, etc…
3)Assure grease canister is full.
Autolube - Important Reminders
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Caterpillar Impact Products Ltd.

Caterpillar Hammers
Maintenance
Operator Requirements
Grind burrs off edges
Check For Burrs in tool retaining pin groove
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Caterpillar Impact Products Ltd.
Caterpillar Hammers
Maintenance
• Once a year or between 600-1000 machine hours
• Replace all seals and accumulator membranes.
• Inspect internal components for wear.
• Replace warning and safety labels.
• Inspect tie rods.
Inspect and replace according to specifications:
• Tool bushings
• Tool retaining pins
• Tool
• Thrust Ring
• Buffers H115s - H180s
• Wear Plates H115s - H180s
• Machine hydraulic specifications are set properly
• engine rpm, relief settings, flow
• Hammer hydraulic circuit specifications are set properly
•Flow at Pressure, Return line pressure (Back Pressure)
• All hoses and fittings on machine are in good condition
• No leakage, No damaged or pinched hoses
Annual Service
Replace Wear Items
Check Systems

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Caterpillar Impact Products Ltd.
Caterpillar Hammers
Why Reseal? Wear on seals
Seal in a hydraulic Hammer experience
between 13 million to 87 million duty cycles
depending on oil flow.
Model H70
Impact Frequency: = 600 - 1800 bpm
1800bpm x 60 min/hr. = 108,000 cycles per hour
108,000cycles/hr x 8hrs = 864,000 cycles per day
864,000 cycles/day x5days = 4,320,000 cycles per week
4,320,000 cycles/wk x52wks =
224,640,000 cycles per year
Estimated 35% usage factor =
78,624,000 cycles
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Caterpillar Impact Products Ltd.
Caterpillar Hammers
Expected Life per Hour Usage Estimates
Wear Components
Low
Normal
Extended
DESCRIPTION 10 50 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300
TOOL
Expected Maximum Life
TOOL RETAINER PIN(S)
Expected Maximum Life
LOWER TOOL BUSHING

Expected Maximum Life
THRUST BUSHING
UPPER TOOL BUSHING
Expected Max
SEAL KIT
Recommended Change Every 600 Hrs
MEMBRANE(S)
Recommended Change Every 600 Hrs
TIE RODS
HOUSING WEAR PLATES
SIDE PLATES MODELS H63-H100
HOUSING MODELS H115s-H195
BUFFER ASSEMBLY H115s-H195
BUFFER PADS H115s-H195
Expected Max
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Caterpillar Impact Products Ltd.
Caterpillar Hammers

Long Term Storage - 6 months or longer
Incorrect Storage Position
1) Remove tool
2) Protect with grease (anti-rust)
Front end of piston
Bushing
Tool
3) Plug hydraulic connections
4) Store in a dry area
5) Store hammer in vertical position ONLY
Piston

Weight
Seal Damage
Correct Storage
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Caterpillar Impact Products Ltd.
Caterpillar Hammers
Membranes
and
Seals
Analysis
of
Wear Component
Failure
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Caterpillar Impact Products Ltd.
Caterpillar Hammers
Membranes and Seals
Inspection of components can assist in
analyzing cause of failure and /or operating
conditions.
Seals
Membrane
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