M0080743 - Ball Stud Breaker (524-9370 Hammer Group) PDF

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Producto: NO SE HA ESCOGIDO NINGUN EQUIPO

Modelo: NO SE HA ESCOGIDO NINGUN EQUIPO
Configuración: NO SE HA ESCOGIDO NINGUN EQUIPO
Manual de Operación de Herramientas

Ball Stud Breaker (524-9370 Hammer Group) {0374, 0599, 0700, 0732, 0738}
Número de medio -M0080743-05 Fecha de publicación -13/12/2018 Fecha de actualización -13/12/2018
i07452257
Ball Stud Breaker (524-9370 Hammer Group) {0374, 0599, 0700, 0732,
0738}
SMCS - 0374; 0599; 0700; 0732; 0738
Off-Highway Truck/Tractor
789D (S/N: SPD1-UP; SHH1-UP)
793D (S/N: FDB1-UP)
793F (S/N: SND1-UP; SSP1-UP; SXP1-UP; D3T1-UP; RBT1-UP)
795F AC (S/N: ERM1-UP)
795FAC XQ (S/N: SNT1-UP)
797F (S/N: LAJ1-UP)
Introduction
European Union Compliant, CE Marked
Important Safety Information
Illustration 1 g02139237
Think Safety
Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
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before an accident occurs. A person must be alert to potential hazards. This person should also have the
necessary training, skills, and tools to perform these functions properly.
Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could
result in injury or death.
Do not operate, perform lubrication, maintenance, or repair on this product until you have read and
understood the operation, lubrication, maintenance, and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not
heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as “DANGER”,
“WARNING”, or “CAUTION”. The Safety Alert “WARNING” label is shown below.
A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the
product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are therefore, not all inclusive. If a tool, procedure, work
method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure
that the procedures are safe. The operator must also be sure that the product will not be damaged or
made unsafe by any unspecified procedures.
The information, specifications, and illustrations in this publication are based on information that was available
at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments,
illustrations, and other items can change at any time. These changes can affect the service that is given to the
product. Obtain the complete and most current information before you start any job.
When replacement parts are required for this product, Caterpillar recommends using Cat replacement
parts or parts with equivalent specifications including, but not limited to physical dimensions, type,
strength, and material.
Literature Information
This manual contains safety information, operation instructions, and maintenance information and should be
stored with the tool group.
Some photographs or illustrations in this publication may show details that can be different from your service
tool. Guards and covers might have been removed for illustrative purposes.
Continuing improvement and advancement of product design might have caused changes to your service tool,
which are not included in this publication.
Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST)
for the latest available information.
Safety Section
The Safety Section lists basic safety precautions.
Read and understand the basic precautions listed in the Safety Section before operating or performing
maintenance and repair on this service tool.
General Information Section
The General Information Section describes tooling functions and features. This section provides useful
information on individual parts, extra tooling, and resources.
Operation Section
The Operation Section is a reference for the new operator and a refresher for the experienced operator.
Photographs and illustrations guide the operator through correct procedures for using the tool group.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains
knowledge of the service tool and tool capabilities.
Maintenance Section
The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal.
Parts Section
The Parts Section is a reference for parts identification and available part numbers.
Safety Section
Personal Protection/Important Information
Always wear a hard hat, protective glasses, and other protective equipment, as required. Do not wear loose
clothing or jewelry that can snag on controls or on other parts of the equipment. Make sure that all protective
guards and all covers are secured in place on the equipment.
Know the appropriate work site hand signals and the personnel that are authorized to give the hand signals.
Accept hand signals from one person only.
Obey all local regulations for the disposal of liquids. Do not allow unauthorized personnel on the equipment.
Unless you are instructed otherwise, perform maintenance with the equipment in the servicing position.
Crushing Prevention and Cutting Prevention

Support the equipment properly before you perform any work or maintenance beneath that equipment. Do not
depend on the hydraulic cylinders to hold up the equipment. Equipment can fall if a control is moved, or if a
hydraulic line breaks.
Stay clear of all rotating and moving parts.
Safety Icon Nomenclature
Do not operate or work on this machine unless you have read and
understand the instructions and warnings in the Operation and
Maintenance Manuals. Failure to follow the instructions or heed the
warnings could result in injury or death. Contact your Cat dealer for
replacement manuals. Proper care is your responsibility.
Symbols for Mandatory Actions
Personal Protective Equipment (PPE) Symbols
Hazard Avoidance
Contact Information
For product support questions concerning this tool, contact the Dealer Service Tools Hotline at:
USA: 800-542-8665, Option 1
International: 1-309-578-7372
Note: Continuing improvement and advancement of product design can mean some photographs or illustrations
in this publication will show details that are different from your service tool.
General Information Section
Personal injury or death can result from improper lifting or blocking.
When a hoist or jack is used to lift any part or component, stand clear of
the area. Be sure the hoist or jack has the correct capacity to lift a
component. Install blocks or stands before performance of any work
under a heavy component.
Approximate weights of the components are shown. Clean all surfaces

where parts are to be installed.
To avoid injury do not stand on or between implement and machine

while operating lift control.
Introduction
NOTICE
The following image reflects the latest version of 524-9370. Within this
document, some pictures of the tool are for reference only, and differ
slightly from the updated version.
The hammer group separates the tapered interface between the ball stud/pin-cylinders and the steering
components located on Cat 789, 793, 795 and 797 Large Mining Trucks. It has been configured to operate with
the optional pump group, allowing for optimum hydraulic flow and pressure.
The hammer group consists of an engineered base, inverted hydraulic breaker and multiple extensions, adapters
and work tools designed to accommodate the various under chassis heights. It is designed to work on flat and
rigid shop floor surfaces with up to 5 degree slopes. (Refer to image below.)
To increase operator safety, a custom designed pump group is available for usage with the hammer group. The
pump is operated remotely, thereby allowing the technician to maintain a safe working distance.
During operation, the pressure and flow developed from the pump enables the hammer to deliver reciprocal
motion and impact energy required to separate the ball stud/pin cylinder and steering component tapered
interface within seconds.
Note: Refer to the appropriate Disassembly and Assembly Service Manual for mounting and lifting hardware
and for the correct location of the lifting point.
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Hammer Group with optional Pump Group
Nomenclature-Hammer Group Components
Table 1
No. Name
1 Hammer Group
2 Hydraulic Hammer
3 Work Tool (Softer steel wears out before Extensions or Adapters over time.)
4 Extension
5 Adapter
6 Inspection Hole
7 Relief Valve
8 Hand Pump
9 Bottom Plate
10 Caster Wheel
11 Forklift Pocket
12 Load Lock
13 Handle
14 Upper Plate
15 Lift Cylinder
NOTICE
The Hammer must not be used underwater. If water fills the space
where the piston strikes the tool, a strong pressure wave is generated
and the hammer may be damaged.
Accessories
Adapters
524-5368 (2 1/4 - 12 Thread)
524-5369 (3 1/4 - 12 Thread)
524-5374 (2/1/4 - 12 Thread - Direct Coupler)
Note: When Ball Stud threads are damaged during removal of Ball Stud nut, and a threadless adapter is needed,
contact DST Engineering. (524-9377 will not be included with the purchase of the Hammer Group.)
Note: When Ball Studs are a close fit to the tire, contact DST Engineering for offset adapter plate. (524-9376
will not be included in the purchase of the Hammer Group.)
Extensions
524-5376 (110mm)
524-5370 (170mm)
524-5371 (260mm)
524-5372 (350mm)
Work Tools
524-5364 (303mm)
524-5373 (254mm)
524-9363 (288mm)
524-9365 (337mm)
Service Parts
Hydraulics
524-9369 Quick Disconnect Kit - 1/2" & 3/4"
360-6957 Lift Cylinder
524-9378 Lift Cylinder Hose
524-5331 Hand Pump
524-9168 Hand Pump Service Kit
524-9361 Hammer Assembly - Includes 524-9366, 524-9367, and 524-9369
Misc
524-9368 Locking Ring with Handle Assembly
524-5366 Hammer Group Swivel Caster
524-5367 Hammer Group Rigid Caster
524-5375 Guard (For Outer or Inner/Y-Link Ball Studs
524-9364 Guard (For Outer Ball Studs only)
524-9366 60Hz Orifice - Includes Restrictor plus (2) O-Rings
524-9367 50Hz Orifice - Includes Restrictor plus (2) O-Rings
524-9371 Tool Chest
524-5383 Tool Chest Swivel Caster
524-5384 Tool Chest Rigid Caster
524-5377 Push/Pull Tool Handle
524-9349 Nitrogen Charging Kit for 524-9361 Hammer Assembly (524-9379 is included for regulator
connection. 524-9372 is not included for connection to hammer)
524-9372 Nitrogen Charging Adapter for 524-9361 Hammer Assembly
524-9374 Service Kit includes parts for refurbishing 524-9361 Hammer Assembly
Note: 524-9374 Service Kit. For detailed hammer rebuild instructions, refer to the document below.
General Hammer Group Commissioning

The hammer group is factory equipped with an orifice tuned for operation with Cat pump groups having a 60Hz
electrical supply. If the hammer group is to be used with the 50Hz Cat pump group, the orifice in the outlet port
of the hydraulic breaker must be interchanged with orifice 524-9367 (included with hammer). Refer to
Commissioning Hammer Group for Use with 50Hz Cat Pump Group for instruction on interchanging the orifice.
NOTICE
Never install attachments or change orifices in the hammer unless
pump group or auxiliary power source is off and hydraulic system is
de-energized.
The hammer group has been optimized to operate along with the engineered Cat pump group. When using an
auxiliary power source a flow of 8.5 gpm (32.2 lpm) and 2,350 psi (162 bar) is required.
NOTICE
Exceeding pressure and/or flow requirements may cause personal
injury and internal damage to the hammer components. Operating
below recommended settings will significantly decrease hammer
performance, reducing effectivity of the tool.
Table 2
Caterpillar recommends the use of the following Cat fluids:
Oil Type and Classification Oil Viscosity Ambient Temperature Range

°C °F
Min Max Min Max

Cat HYDO Advanced 10 SAE 10W -20 40 -4 104
Cat oils are the preferred oils. An ISO 46 hydraulic oil may be substituted when needed.
Note: Different brands of oils may use different additive packages to meet the recommended classifications and
specifications of performance of the various machine compartments. For the best results, do not mix oil brands.
Hammer Group (1) Pre-Operation

1. Inspect the hammer group work tools, extensions, and adapters for signs of wear, chipping or cracking
prior to use. Replace any non-conforming or damaged components prior to operating the tool.
2. Inspect the ground conditions within the work area. The hammer group may operate on a slope up to 5
degrees. To ensure optimum performance, the tool must be used on a clean, debris free rigid concrete or
steel plate surface.
Note: Under certain floor slope conditions, the hammer attachment height may not accommodate full
engagement and compression of the hammer group platform. In this event, it may be necessary to place a
steel spacer below the hammer group. The spacer must be of adequate size to support the full footprint of
the hammer group
3. Hydraulic hoses are not supplied with the 524-9370 Hammer Group. If utilizing local power source,
ensure that hoses are properly connected. If utilizing Cat pump group, connect hoses to the corresponding
fittings on the Hammer Group.
Always inspect hoses for signs of wear prior to using.
Note: When replacing hose fittings on the hammer group, torque fittings to 82 Nm.
Note: Cap lines/fittings to minimize contamination of hydraulic system when disconnected for storage or
service.
Hydraulic Hammer (2) Operation and Maintenance

The hammer group contains (1) an inverted hydraulic hammer (2) mounted to a custom designed base. The
following recommendations and warnings should be adhered to when operating the hammer group.
Pressurized Gas in Hydraulic Hammer Accumulator
Before any workshop service of Work Tool, the accumulator must be depressurized.
Use only nitrogen (N2) for recharging accumulators. The use of other gas may cause accumulators to explode.
Failure to comply could result in serious injury or death.
The accumulator charging device does not have any pressure relief valve. Shut gas bottle valve when the gauge
shows correct charging pressure.
Do not disassemble hydraulic hammer before releasing gas pressure from accumulators and oil pressure from
hydraulic hammer. Failure to comply could result in serious injury or death.
Airborne Pollution
During operation, dust particles or contaminants may become airborne. Breathing or inhaling dust particles may
cause death or severe injury.
Always work with an approved respirator rated for the intended airborne contaminants while operating the
hammer group.
Flying Fragments During Operation
Prior to operating the hammer group, ensure that the tool has been properly set up and all guarding has been
installed.
The safe distance for unprotected people is approx. 40 m (130 ft). The hydraulic hammer must be stopped
immediately, when the operator observes people without proper PPE to come any closer than this.
Safety barriers must also be erected, where unprotected bystanders may be crossing through the hazard zone
(reasonably foreseeable misuse).
Noise
A hydraulic hammer in operation creates a high noise level. Always wear ear protection to prevent personal
injury.
Continuous exposure to noise above 80 dB(A) will cause hearing impairment!
Always wear approved ear protection!
Blank Firing
Operating the Work Tool piston, even though there is no material under the tool is called blank firing.
Stop the hydraulic flow to the hammer group the moment the ball stud or pin-cylinder has been separated from
the corresponding steering component.
Do not operate the hammer group unless properly assembled to the serviced joint.
Blank firing will destroy major components of the hydraulic hammer, starting from the work tool, and tool
retaining pin. Continuous blank firing will destroy front end, piston, and tie rods.
Charging the Accumulator

Accumulator
NOTICE
The accumulator is pressurized even when the hydraulic system is shut
off. Disassembling the accumulator before letting the gas out can cause
injury.
1. Let the gas out slowly by opening the charging valve.
2. Make sure that there is no gas pressure in the accumulator before

disassembling the accumulator housing.
Charge the Accumulator
NOTICE
The accumulator must only be charged with Nitrogen (N²). Other gases
can cause explosions.
Cleaning and Service
Replace all safety labels, which are damaged, lost or not legible.
Wait for hydraulic oil inside Work Tool to cool down before disassembly or service. Oil inside hydraulic
hammer may be extremely hot. Do not handle hydraulic hoses (connect or disconnect) while oil is hot. Use
approved Personal Protective Equipment (PPE).
Plug pressure and return line before washing the Work Tool, to prevent water and dirt from entering into the
Work Tool.
When pressurized air and/or pressure water is used for cleaning, wear protective clothing, protective shoes, and
eye protection. Eye protection includes safety glasses or a protective face shield.
The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). The maximum water pressure
for cleaning purposes must be below 275 kPa (40 psi).
Hot Substances
Hot oil and hot components can cause personal injury. Do not allow hot oil to contact the skin. Also, do not
allow hot components to contact the skin.
Metal parts, such as valves or body parts may have the same temperature as the hydraulic oil.
The working end of the tool may get extremely hot during operation. Make sure that the tool has had time to
cool down before starting to handle it.
Hydraulic Oil Requirements

The hydraulic oil originally intended for the carrier can be used with this product. Since working with the
product heats the oil more than the usual excavation work, the temperature of the oil must be monitored.
If the temperature of the hydraulic oil exceeds 80 degrees C (175 degrees F) an auxiliary oil cooler is needed.
The oil viscosity must be between 20 - 1000 cSt while the attachment is being used.
When the product is used continuously, the temperature of the hydraulic oil normalized at a certain level,
depending on the current conditions.
Workshop Service
Workshop service must be performed at a trained and Caterpillar approved workshop. Non-professional service
will be a severe risk for the staff performing the service. Non-professional service may be a risk for the operator
as well, while most certainly causing damage to equipment, which may become expensive.
Flammable Liquids
All fuels, most lubricants, and some coolant mixtures are flammable.
Flammable fluids that, are leaking or spilled onto hot surfaces or onto electrical components can cause a fire.
Fire may cause personal injury and property damage
Remove all flammable materials such as fuel, oil, and debris from the hydraulic hammer. Do not allow any
flammable materials to accumulate on the hydraulic hammer.
Do not operate the hydraulic hammer near any flame.
Fire Hazard
Most hydraulic fluids are flammable and may ignite when contacting a hot surface. Avoid spilling any hydraulic
fluid onto hot surfaces.
Working with the product on certain materials can cause sparks and hot splinters to get loose. These can ignite
flammable materials around the working area.
Ensure that an appropriate fire extinguisher is easily available.
Proper Operating Practice
Only operate the hydraulic hammer when properly assembled to the hammer group.
Protective glasses, hearing protection, gloves, and safety shoes must be worn while you operate the hammer
group.
Observe any additional local safety requirements and protocols.
For maximum service life of the hammer group and for safety, perform a thorough walk-around inspection
before you operate the hammer group. Complete necessary repairs prior to operation.
Confirm your understanding of the signs with the other person before starting. Accept hand signals from one
person only.
Do not allow unauthorized personnel to operate the equipment.

Accumulator Cleaning and Service
Replace all safety labels, which are damaged, lost or not legible.
Wait for hydraulic oil inside Work Tool to cool down before disassembly or service. Oil inside hydraulic
hammer may be extremely hot. Do not handle hydraulic hoses (connect or disconnect) while oil is hot. Use
approved Personal Protective Equipment (PPE).
Plug pressure and return line before washing the Work Tool, to prevent water and dirt from entering into the
Work Tool.
When pressurized air and/or pressure water is used for cleaning, wear protective clothing, protective shoes, and
eye protection. Eye protection includes safety glasses or a protective face shield.
The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). The maximum water pressure
for cleaning purposes must be below 275 kPa (40 psi).
Hot Substances
Hot oil and hot components can cause personal injury. Do not allow hot oil to contact the skin. Also, do not
allow hot components to contact the skin.
Metal parts, such as valves or body parts may have the same temperature as the hydraulic oil.
The working end of the tool may get extremely hot during operation. Make sure that the tool has had time to
cool down before starting to handle it.
Workshop Service
Workshop service must be performed at a trained and Caterpillar approved workshop. Non-professional service
will be a severe risk for the staff performing the service. Non-professional service may be a risk for the operator
as well, while most certainly causing damage to equipment, which may become expensive.
Flammable Liquids
All fuels, most lubricants, and some coolant mixtures are flammable.
Flammable fluids that, are leaking or spilled onto hot surfaces or onto electrical components can cause a
fire. Fire may cause personal injury and property damage.
Remove all flammable materials such as fuel, oil, and debris from the hydraulic hammer. Do not allow any
flammable materials to accumulate on the hydraulic hammer.
Do not operate the hydraulic hammer near any flame
Proper Operating Practice

Only operate the hydraulic hammer when properly assembled to the hammer group.
Protective glasses, hearing protection, gloves, and safety shoes must be worn while you operate the hammer
group.
Observe any additional local safety requirements and protocols.
For maximum service life of the hammer group and for safety, perform a thorough walk-around inspection
before you operate the hammer group. Complete necessary repairs prior to operation.
Confirm your understanding of the signs with the other person before starting. Accept hand signals from one
person only.
Do not allow unauthorized personnel to operate the equipment.
Blank Firing
Operating the Work Tool piston, even though there is no material under the tool is called blank firing.
Stop the hydraulic flow to the hammer group the moment the ball stud or pin-cylinder has been separated from
the corresponding steering component.
Do not operate the hammer group unless properly assembled to the serviced joint.
Blank firing will destroy major components of the hydraulic hammer, starting from the work tool, and tool
retaining pin. Continuous blank firing will destroy front end, piston, and tie rods.
Hammer Group Operation
1. Remove the retaining nut from the component to be serviced. Refer to the appropriate Disassembly and
Assembly Instruction manual.
2. Measure the distance from the ground surface to the bottom of the serviced component and identify thread
size.
3. Utilizing Table 1, select the corresponding work tool (3) and adapter (5). The measured dimension must
fall between the Minimum Roll-In Height and the Maximum Operational Height. An extension (4) may be
required for certain under chassis heights as identified in the table.
Table 3
Work Tool Combination
Part
Description Tool Combination
No.
Extension 524-
X
110 5376
Extension 524-
X
170 5370
Extension 524-
X
260 5371
Extension 524-
X
350 5372
Work Tool 524-

X
254 5373
Work Tool 524-

X
288 9363
Work Tool 524-

X X X X X
303 5364
Work Tool 524- X X X X X

337 9365
Adapter 2- 524-
X X
1/4 DC 5374
Adapter 2- 524-
X X X X
1/4 5368
Adapter 3- 524-
X X X X
1/4 5369
**Offset
524-
Adapter
9376
Plate
**Threadless 524-
X X X X
Adapter 9377
Min. Roll-In
1046(41.2) 1171(46.1) 1193(46.9) 1253(49.3) 1343(52.8) 1433(56.4)
Heightmm (inch)
Max Operational
1202(47.3) 1268(49.9) 1290(50.8) 1350(53.1) 1440(56.7) 1530(60.2)
Heightmm (inch)
Note: ** Contact DST Engineering to order
NOTICE
Hydraulic systems may contain stored hydraulic energy. Prior to
servicing the hydraulic hammer, isolate and de-energize the hydraulic
power source from the hammer group. Depressurize hydraulic
accumulators.
Note: Install the work tool in accordance with Tool Remove and Install instructions.
4. Maneuver the hammer group (1) under the machine and align with component to be serviced.
5. Place the extension (4) over the work tool (3), if required.
NOTICE
The hydraulic pressure inside the hammer must always be released
before removing the tool. After operating the hammer, wait 10 minutes
for oil pressure to drop inside hammer.
NOTICE
Hot tool can cause severe injuries.
6. Place the adapter (5) over the extension (4) or directly onto work tool (3).
7. Ensure that the pressure relief valve (7) on the hand pump (8) is closed by rotating the knob clockwise.
Pump the hand pump (8), raising the hammer (2), until the adapter (5) is within 25mm of the ball stud.
8. Lift the adapter by hand (5) and thread on to the protruding threads.
9. Using the inspection hole in the side of the adapter (see illustration below), ensure that the adapter is
bottomed against the protruding threads.
Above illustration showing inspection hole.
10. Pump the hand pump (8) until the caster wheels (10) fully compress and the lower plate (9) of the hammer
group fully contacts the ground surface.
steel spacer below the hammer group. The spacer must be of adequate size to fully support the full
footprint of the hammer group.
11. Using the handle (13), rotate the load lock mechanism (12) counter clockwise until it bottoms against the
upper support plate (14).
12. Rotate the relief valve (7) located on the hand pump (8) counter-clockwise to release the internal lift
cylinder (15).
NOTICE
Failure to engage the load lock mechanism and release the hand pump
pressure relief valve prior to using the hammer group, may cause the
internal lift cylinder to fail prematurely.
13. Install the guard 524-5375. The guard clamps around the ball stud/pin-cylinder between the adapter and
the steering component.
14. Connect the hammer group to the hydraulic power source. If using a Cat pump group, refer to Tool
Operating Manual, M0083627.
15. Enable hydraulic flow to the hammer group for up to 30 seconds. The work tool (3) attached to the
hydraulic hammer (2) will reciprocate providing impact energy to the joint.
When the joint is separated from the steering component, a distinct clanging sound will be heard.
Note: If joint does not separate within 30 seconds, refer to Troubleshooting Section.
16. Discontinue hydraulic flow to the hammer group (1) after joint separates.
17. Isolate and de-energize the hydraulic power source.
Note: If servicing additional components, hydraulic hoses may remain installed. If service is complete,
remove hoses from input/output connection on the hydraulic hammer and store as required.
Note: Cap lines/fittings to minimize contamination of hydraulic system when disconnected for storage or
service.
18. Remove the guard.
19. Rotate the relief valve (7) on the hand pump (8) clockwise, ensuring the valve is closed.
steel spacer below the hammer group. The spacer must be of adequate size to fully support the full
footprint of the hammer group.
20. Pump the hand pump (8) until the upper plate (14) disengages from the load lock (12) mechanism.
21. Using the handle (13), rotate the load lock mechanism (12) clockwise until fully retracted.
22. Rotate the relief valve (7) on the hand pump (8) counter-clockwise allowing the hydraulic hammer (2) to
partially lower.
23. Unthread the adapter (5) and place on the extension (4) or work tool (3).
24. Release the pressure relief valve (7) on the hand pump allowing the hydraulic hammer (2) to fully lower.
25. If servicing additional components, relocate the hammer group and repeat steps 1 - 24.
If storing hammer group, remove extension and adapter from work tool and place in tool chest. Store in
accordance with Storage Guidelines.
Maintenance Section
The Ball Stud Breaker Hammer is a precision made hydraulic machine. Great care and cleanliness should be
taken when handling the hydraulic components. Handle the parts carefully and use a lint free cloth to cover
cleaned and dried parts.
Use appropriate materials to clean hydraulic parts. Never use paint thinners or carbon tetrachloride.
Components gaskets and seals in the hydraulic system should be oiled with clean hydraulic oil before assembly
Inspection
Inspect all components prior to each use for nicks, burrs, dents, cracks, bends, or worn parts. If damage is found,
discontinue use until inspected by an approved dealership inspector.
Inspect all welds, and check for damaged, cracked, or bent components.
Do not use unless load identification markings are legible.
Every two hours Grease the tool shank and the tool bushings. Observe the hydraulic oil temperature, all lines,
and connections, as well as the impact efficiency and evenness of operation. Tighten any loose connections.
Wear Limits and Lubricants for Tool Removal
Table 4
Item Wear Limit Lubricant
Tool diameter (worn out) 34 mm (1.34 in)

Tool and Tool Retaining Pins Tool Grease
Cleaning
Clean the tooling after each use, using a non-solvent cleaner.
Washing the Attachment
Dirt and debris can become attached to the attachment. Wash the outside of the product with a steam washer
before sending product to the workshop. Dirt and particles can cause difficulties in the disassembly and
assembly process.
NOTICE
Plug the pressure and return line before washing the product to
prevent dirt and debris from entering into lines. This can cause
damage to the components.
Tool Disposal
At the end of the operational life of the tool, destroy the tool and dispose of as scrap.
Loading and Unloading

Practice safe work procedures when loading or unloading the service tool. Shown forklift pockets may be used
with fork truck or with (2) lifting straps for overhead crane removal. Alternative option is to use a single sling.
Choke the hammer as shown below for lifting the hammer group for overhead crane removal.
Storage Guidelines
Store the tooling in a clean dry location to prevent corrosion. Tooling may become damaged due to moisture or
high humidity.
All adapters, extensions, and work tools should be cleaned and inspected. Components having chipped, cracked,
deformed, damaged, or worn surfaces must be replaced immediately. Components in acceptable condition
should be placed in the tool chest after use.
Inspect the guard for signs of damage. Replace if necessary.
Long-Term Storage
Following are some points to follow when storing the hammer. This will allow for vital parts to be protected
from rust and allow the machine to be ready to use.
1. Keep in a dry storage area.
2. Remove tool in hydraulic hammers.
3. The lower end of the piston, tool, and bushings should be protected by applying an appropriate grease in
all hammers.
4. Connections must be sealed with clean plugs to prevent oil leakage and to prevent oil from entering
couplings.
5. Store product in a vertical position.
6. Make sure that the product is in a stable position to prevent the product from falling.
Hydraulic Hammer Service

Tool - Remove and Install
NOTICE
Hydraulic systems may contain stored hydraulic energy. Prior to
servicing hammer, isolate and de-energize the hydraulic power source
from the hammer group. Depressurize hydraulic accumulators.
Note: Use caution when removing the work tool. The tool can be very hot after the tool has been in operation.
When you remove the tool, wear protective gloves.
Note: The images shown in this section depict a chisel end work tool. These images are for illustration purposes
only. Only use the specific work tools developed for the hammer group on this equipment.
FROM THIS POINT, SEE COMMENTS ABOUT WHAT TO DELETE, ETC.
1. Using a drift, drive the retaining pin from the hammer housing. Remove the lock buffer.
2. Lubricate the OD of the custom chisel and the internal bushing, utilizing Atlas Copco Chisel Paste
(Alternate: Cat Desert Gold NLGI 2).
3. Install the custom work tool into the bushing.
4. Rotate the work tool to spread the grease.
5. Mount the tool retainers one at a time.
6. Drive in the lock pin until the lock buffer attaches in the lock pin groove.
Troubleshooting
Table 5
Troubleshooting Chart
Issue Possible Cause Possible Solution
Relief valve on had

Close valve
pump is open
Hand pump oil reservoir

Verify oil level
Hydraulic is low
hammer does
not raise or Hydraulic leak Check hoses/fittings for leads. Repair as needed.
raises slowly Malfunctioning hand
when pumping Repair or replace hand pump.
pump
hand pump.
Hydraulic fittings loose Tighten hydraulic fittings between hand pump and lift cylinder
Malfunctioning lift
Repair or replace lift cylinder
cylinder
Ball stud was incorrectly
Verify hammer setup, then strike ball stud/pin cylinder with
installed (over torqued,
hammer group for an extra 30 seconds. Repeat process up to 3
absence of moly paste,
times. If components do not separate, submit issue through
assembled while frozen,
DSN.
etc.)
Reference Ball Stud Heating procedure document.Refer to

Parts need heat added
document M0095512.
Hammer
Group does Verify setup of the hammer group. Ensure that the
not separate extension/adapter/work tool is properly engaged, caster wheels
Hammer group was
Ball Stud/Pin are bottomed, lower plate rests flat against floor, load lock
improperly set up
Cylinder mechanism is engaged, and internal hydraulic cylinder is
retracted.
Low oil level in
Verify oil level
hydraulic power source
Verify that the flow rate and pressure from the hydraulic power
Insufficient hydraulic
source meet the following specifications:8.5 gpm (32.2 lpm)
flow or pressure
2,359 psi (162 bar)
Hammer group Improper combination of

Verify that under chassis height and select components are in
does not work
accordance with Table 1.
bottom to floor tools/extensions/adapters
(caster wheels
do not Locking Ring becomes Verify cylinder pressure has been removed and tighten locking
compress) Loose ring with breaker bar, if required
Under chassis height Measure the distance required. Place a spacer (steel plate) on the
exceeds allowable work floor below the tool. The spacer must accommodate the entire
tool/extension/adapter footprint of the hammer group. The spacer must be of sufficient
working range. thickness to allow the hammer group to properly engage the
extension/adapter/work tool combination and the lower plate to
fully bottom.
Hydraulic
Hammer does
Non-operational
not sound right Verify flow/operation at hydraulic power source.
hydraulic power source
or seems
underpowered
Guard does not Wrong guard is being

Use appropriate guard (See Illustration 38 or 54)
fit used
Hammer
Some older sales model
Group and Flip Hammer Group 180 degrees or install offset hammer plate
trucks have interference
Tire (See Illustration 53)
with Hammer Group
Interference
Lubrication
NOTICE
Insufficient greasing or improper grease may cause abnormal wear of
tool bushing and tool, or tool breakage.
Correct Greasing
1. Position the hammer in an upright position, resting the tool on a firm surface.
2. Stop the carrier engine, and wait 10 minutes for the oil pressure to drop inside the hammer.
3. Apply tool grease from grease gun, to greasing points marked with the following sticker.
NOTICE
The hammer must be positioned upright, resting on the tool to ensure
that the grease will penetrate downwards between the tool and the
bushing.
NOTICE
Do not fill the space between the piston and the tool with grease. A
lower piston seal failure can result and the hammer will later leak oil.
Copyright 1993 - 2019 Caterpillar Inc.

Todos los derechos reservados.

M0080743 - Ball Stud Breaker (524-9370 Hammer Group) PDF

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Producto: NO SE HA ESCOGIDO NINGUN EQUIPO

Manual de Operación de Herramientas

Important Safety Information

Crushing Prevention and Cutting Prevention

Stay clear of all rotating and moving parts.

Safety Icon Nomenclature

Symbols for Mandatory Actions

Personal Protective Equipment (PPE) Symbols

USA: 800-542-8665, Option 1

Personal injury or death can result from improper lifting or blocking.

Approximate weights of the components are shown. Clean all surfaces

To avoid injury do not stand on or between implement and machine

Nomenclature-Hammer Group Components

524-5368 (2 1/4 - 12 Thread)

524-5369 (3 1/4 - 12 Thread)

524-5374 (2/1/4 - 12 Thread - Direct Coupler)

524-9369 Quick Disconnect Kit - 1/2" & 3/4"

360-6957 Lift Cylinder

524-9378 Lift Cylinder Hose

524-5331 Hand Pump

524-9168 Hand Pump Service Kit

524-9361 Hammer Assembly - Includes 524-9366, 524-9367, and 524-9369

524-9368 Locking Ring with Handle Assembly

524-5366 Hammer Group Swivel Caster

524-5367 Hammer Group Rigid Caster

524-5375 Guard (For Outer or Inner/Y-Link Ball Studs

524-9364 Guard (For Outer Ball Studs only)

524-9366 60Hz Orifice - Includes Restrictor plus (2) O-Rings

524-9367 50Hz Orifice - Includes Restrictor plus (2) O-Rings

524-9371 Tool Chest

524-5383 Tool Chest Swivel Caster

524-5384 Tool Chest Rigid Caster

524-5377 Push/Pull Tool Handle

524-9372 Nitrogen Charging Adapter for 524-9361 Hammer Assembly

General Hammer Group Commissioning

Oil Type and Classification Oil Viscosity Ambient Temperature Range

Min Max Min Max

Hammer Group (1) Pre-Operation

Always inspect hoses for signs of wear prior to using.

Hydraulic Hammer (2) Operation and Maintenance

Pressurized Gas in Hydraulic Hammer Accumulator

Flying Fragments During Operation

Continuous exposure to noise above 80 dB(A) will cause hearing impairment!

Always wear approved ear protection!

Charging the Accumulator

2. Make sure that there is no gas pressure in the accumulator before

Charge the Accumulator

Cleaning and Service

Hydraulic Oil Requirements

Do not operate the hydraulic hammer near any flame.

Ensure that an appropriate fire extinguisher is easily available.

Proper Operating Practice

Observe any additional local safety requirements and protocols.

Do not allow unauthorized personnel to operate the equipment.

fire. Fire may cause personal injury and property damage.

Do not operate the hydraulic hammer near any flame

Proper Operating Practice

Do not allow unauthorized personnel to operate the equipment.

Hammer Group Operation

Work Tool 524-

Work Tool 524-

Work Tool 524-