Caterpillar Hammer Failure Analysis Guide

Service Information System Page 1 of 69
Reuse And Salvage Guidelines

Caterpillar Hammer Failure Analysis Guide
Media Number -SEBF8892-00 Publication Date -20/07/2004 Date Updated -20/07/2004
SEBF88920001
Caterpillar Hammer Failure Analysis Guide

SMCS - 5050; 5102
CATERPILLAR®
GUIDELINE FOR
REUSABLE PARTS
AND SALVAGE OPERATIONS
Caterpillar Hammer Failure Analysis
Guide
Small Series Hammers

6CZ1-Up (H45/H45s)
5MZ1-Up (H50/H50s)
4GL1-121 (63)
4GL122-Up (H63/H63s)
4KL1-1029 (70/70s)
4KL1030-Up (H70/H70s)
6TZ1-Up (H90C/H90Cs)
4ML1-158 (100)
4ML159-Up (H100/H100s)
Large Series Hammers

4PL1-213 (H115)
4PL214-Up (H115s)
9MM1-229 (120)
9MM230-399 (H120s)
9MM400-Up (H120Cs)
7CM1-379 (130)
7CM380-Up (H130s)
4SL1-281 (140)
https://sis.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/sisweb/sisweb/medias... 09/05/2008
4SL282-Up (H140s)
BXB1-Up (H140Ds)
BED1-Up (H140Cs)
4TL1-211 (160)
4TL212-Up (H160s)
BFB1-Up (H160Cs)
BXF1-Up (H160Ds)
9PM1-211 (180)
9PM212-Up (H180s)
Introduction
This Guideline enables dealers and their customers to benefit from cost reductions made possible through an
established parts reusability and salvage program. Every effort has been made to provide the most current and
relevant information known to Caterpillar Inc. Since the Company makes ongoing changes and improvements to
its products, this Guideline must be used with the latest technical information available from Caterpillar to ensure
such changes and improvements are incorporated where applicable.
For questions or additional information concerning this Guideline, contact the CIPL (Cat Impact Products Limited
hotline at (800) 382-2842, or Caterpillar Dealer Service Operations at (309) 675-8263.
Summary
This guideline is structured to point out areas of concern when a given failure type is found. There are five areas
used:
Application Causes
Failure possibly caused by incorrect application of the hammer
Customer Maintenance Causes
Failure possibly caused by maintenance outlined in the OMM
Dealer Service Causes
Failure possibly caused by annual rebuild or pre-delivery of hammer
Manufacturing Causes
Failure possibly caused by machining, material quality, heat treatment, etc.
Operational Causes
Failure possibly caused by incorrect operation as explained in the OMM
Parts listed in this document are:
Accumulator
Buffer Side
Buffer Top
Bushing Lower
Bushing Thrust Ring
Bushing Upper
Cylinder
Front Head
Housing
Piston
Seals Lower Piston
Seals Upper Piston
Side Plate
Tie Rod Nuts
Tie Rods
Tool
Tool Retaining pin
Wear Plate
Important Safety Information
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
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 or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.
Safety precautions and warning 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 "WARNING" as
shown below.
View Image
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be wither written or pictorially
presented.
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 specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for
you and for others. You should also ensure that the product will not be damaged or be made unsafe by the
operation, lubrication, maintenance or repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torque, pressures, measurement,
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 star any job. Caterpillar
dealers have the most current information available.
Safety
View Image
Do not operate or work on this product until you have

read and understood the operation, lubrication,
maintenance, and repair information. Failure to follow
the instructions for operation, lubrication, maintenance,
or repair of this product could result in injury or death.
Hot oil and components can cause personal injury. Do

not allow hot oil or components to contact skin.
Always use a board or cardboard when checking for a

leak. Escaping fluid under pressure, even a pinhole
size leak, can penetrate body tissue, causing serious
injury and possibly death. If fluid is injected into the
skin, a doctor familiar with this type of injury must
surgically remove it within a few hours.
NOTICE
Notice labels in this publication identify operations that

may cause product damage.
Using this Guideline

Information is listed in the following form:
Section heading
Photos of example failures
Potential causes
Potential causes are listed below the illustrations. They are grouped by areas of responsibility. Underlined items
are most likely to be the cause, however it should be noted that this cannot be said with certainty.
Accumulator
Loss of Nitrogen Charge - U-Sit Seal Damaged
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Illustration 1
View Image
Illustration 2
o Nitrogen charge checked without replacing U-sit seal

o Fill valve over torqued during charge
o Seal reused
Loss of Nitrogen Charge - Diaphragm Center Perforations
View Image
Illustration 3
View Image
Illustration 4
Hydraulic oil contamination
Lines or ports open during storage
o Failure to charge accumulator prior to operation
Operational Causes
Excessive oil flow
Excessive blank firing of hammer
Loss of Nitrogen Charge - Diaphragm Deformed and Hardened
View Image
Illustration 5
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Illustration 6
o High hydraulic oil temperature from incorrect auxiliary settings
o High hydraulic oil temperature from poor machine cooler maintenance
o Prolonged operation beyond specified service interval
Operational Causes
o High oil temperatures due to operation in single spot longer than 15 seconds
Loss of Nitrogen Charge - Diaphragm Extruded Through Screen
View Image
Illustration 7
View Image
Illustration 8
o Excessive nitrogen charge
o Excessive nitrogen charge
Loss of Nitrogen Charge - Diaphragm Rim Tear
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Illustration 9
View Image
Illustration 10
o U-Sit seal not replaced when nitrogen charge is checked
o Failure to charge accumulator prior to operation
o Incorrect charge method
o Lack of silicone lubricant used during accumulator assembly
o U-Sit seal over torqued or reused
Loss of Nitrogen Charge - Torn or Damaged O-Ring
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Illustration 11
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Illustration 12
o No lubrication used on o-ring during installation
o Excessive torque applied to fill valve
o No lubrication used on o-ring during installation
o Excessive torque applied to fill valve
Buffer - Side
Cracked / Split
View Image
Illustration 13
View Image
Illustration 14
Operational Causes
o Excessive oil flow
o Excessive blank firing of hammer
Buffer - Top
Cracked / Split
View Image
Illustration 15
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Illustration 16
Operational Causes
o Excessive oil flow
o Extreme impact loading during material breakthrough
o Extreme impact loading during setup on material
o Operation in single spot longer than 15 seconds
o Excessive down force applied during hammer operation
Bushing - Lower
Cracked / Broken
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Illustration 17
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Illustration 18
o Improper greasing interval
o Inadequate greasing
o Non-approved grease used
o Wear plates worn beyond specifications
o Material defect
o Material heat treatment
Operational Causes
o Improper working angle
Premature Wear
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Illustration 19
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Illustration 20
Application Causes
o Scaling or other horizontal applications
o Underwater operation without proper grease
o Auto lube system not functioning
o Improper greasing of the tool
o Inadequate greasing of the tool
o Use of non-approved grease
Operational Causes
Bushing Thrust Ring
Erosion
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Illustration 21
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Illustration 22
Application Causes
o High piston rebound velocity
o Non CAT tools used
o Non standard tools used (tools which have been customized or modified)
Premature Wear
View Image
Illustration 23
View Image
Illustration 24
Operational Causes
o Extreme impact during material breakthrough
o Extreme impact during setup on material
o Excessive down force applied during operation
Bushing - Upper
Cracked / Broken
View Image
Illustration 25
View Image
Illustration 26
o Non-approved grease used
o Prolonged use beyond specified service interval
o Material defect
Operational Causes
Premature Wear
View Image
Illustration 27
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Illustration 28
Application Causes
o Scaling or other horizontal applications
o Underwater operation without proper grease
Operational Causes
Cylinder
Abrasive Wear
View Image
Illustration 29
View Image
Illustration 30
o Lines or ports open during storage
o Hydraulic oil contamination
o Contamination during rebuild process
o Hose contamination
Adhesive Wear
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Illustration 31
View Image
Illustration 32
o Carrier oil viscosity too low
o Worn tool and/or bushings
o Incorrect seal installation
o Incorrect seal used
o Incorrect tie rod installation - Uneven tie rod loading
o Hammer operated with broken tie rod
Front Head
Cracked / Broken
View Image
Illustration 33
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Illustration 34
o Worn or disintegrated side and/or top buffers
o Wear plates worn beyond specifications
o Worn or disintegrated side and/or top buffers
Operational Causes
o Extreme impact during material breakthrough
o Extreme impact from dropping hammer on material
Housing
Base Metal Cracked / Broken
View Image
Illustration 35
View Image
Illustration 36
o Operation with worn top and/or side buffers
o Material defect
Operational Causes
o Excessive side loading during operation
o Moving material with the housing above the rock claw
Cracked / Broken Welds
View Image
Illustration 37
View Image
Illustration 38
o Improper weld technique
o Inadequate weld penetration
o Material defect
Operational Causes
o Excessive impacting upon breakthrough of material
o Moving material with housing above the rock claw
Piston
Abrasive Wear
View Image
Illustration 39
View Image
Illustration 40
o Contamination from open ports during storage
o Lines or ports not capped during storage
Adhesive Wear
View Image
Illustration 41
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Illustration 42
o Horizontal hammer storage
o Housing wear plates cracked or broken
o Housing wear plates worn beyond specified limits
o Improper greasing of the tool causing seal damage
o Worn tool and or bushings
o Incorrect tie rod installation – Uneven tie rod loading
o Over speeding hammer
Bearing Area – Cracked / Broken
View Image
Illustration 43
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Illustration 44
o Housing wear plates cracked or broken
o Housing wear plates worn beyond specified limits
o Improper greasing of the tool causing seal damage
o Incorrect tie rod installation – Uneven tie rod loading
o Over speeding hammer
o Material defect
Operational Causes
Corrosive Wear
View Image
Illustration 45
View Image
Illustration 46
o Lines or ports not capped during storage
o Hammer stored in a horizontal position
o Improper part cleaning technique
Impact Face - Cracked / Broken
View Image
Illustration 47
View Image
Illustration 48
o Debris between tool and piston
o Excessive hydraulic flow to hammer
o Excessive operating pressure
o Material defect
Lower Seal Area Cracked / Broken
View Image
Illustration 49
View Image
Illustration 50
Application Causes
o Underwater operation without proper setup
o Broken tie rods
o Improper greasing of the tool causes seal damage
o Material defect
Vertically Cracked / Broken
View Image
Illustration 51
View Image
Illustration 52
o Material defect
Seals Lower Piston
Erosion Due to Cavitation
View Image
Illustration 53
View Image
Illustration 54
Application Causes
o High piston rebound velocity due to incorrect hammer selection
Extrusion
View Image
Illustration 55
View Image
Illustration 56
Application Causes
Premature Hardening
View Image
Illustration 57
View Image
Illustration 58
Operational Causes
Seals Upper Piston
Erosion Due to Cavitation
View Image
Illustration 59
View Image
Illustration 60
Premature Hardening
View Image
Illustration 61
View Image
Illustration 62
Operational Causes
Side Plate
Base Metal Cracked / Broken
View Image
Illustration 63
View Image
Illustration 64
Operational Causes
o Blank firing of the hammer
o Material impacting side plates
o Moving material with hammer
o High prying loads
Cracked or Broken Welds
View Image
Illustration 65
View Image
Illustration 66
o Improper weld technique
o Inadequate weld penetration
o Material defect
Operational Causes
o Material impacting side plates
o Moving material with hammer
o High prying loads
o Blank firing of the hammer
Tie Rod Nuts
Cracked / Broken
View Image
Illustration 67
View Image
Illustration 68
o Nut installed upside down
o Tie rod nut, rod and front head numbers not matched up
o Tie rod removal without use of proper heat torque method
o Material defect
Operational Causes
o Excessive blank firing
Tie Rods
Cracked / Broken Above Nut, Inside Front Head
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Illustration 69
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Illustration 70
o Rust caused by lack of silicone applied during assembly
o Proper torque procedure not followed during assembly
Operational Causes
Erosion / Pitting Under Rod Head

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Illustration 71
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Illustration 72
o Material defect
Operational Causes
Material Transfer in Threads
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Illustration 73
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Illustration 74
Application Causes
o Installation without utilizing the heat torque method
o Lack of anti-seize used in assembly
o Removal without utilizing the heat torque method
Rod Head Cracked / Broken
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Illustration 75
View Image
Illustration 76
o Lack of anti-seize compound under head
Operational Causes
Threads Cracked / Broken
View Image
Illustration 77
View Image
Illustration 78
Operational Causes
Tool
Bending
View Image
Illustration 79
View Image
Illustration 80
o Material defect
Operational Causes
o Moving machine with tool
o Prying with tool
Break Due to Inclusion in Tool
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Illustration 81
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Illustration 82
o Material defect
Break in Lower Bushing Area

View Image
Illustration 83
View Image
Illustration 84
o Auto lube system non functioning
Operational Causes
o Operation at an incorrect angle to the material
Break in Upper Bushing Area
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Illustration 85
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Illustration 86
Operational Causes
o Operation at an incorrect angle to the material
Chipped Tip
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Illustration 87
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Illustration 88
Operational Causes
o Prying with tool
o Surface damage
o Corner loading of the tool tip
Excessive Galling
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Illustration 89
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Illustration 90
Operational Causes
o Operation at incorrect angle to material to be broken
Mushrooming Tip
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Illustration 91
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Illustration 92
Application Causes
o Too small of a hammer used
Operational Causes
Prying Break
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Illustration 93
View Image
Illustration 94
Operational Causes
o Prying with tool
Tool Retaining Pin
Cracked / Broken
View Image
Illustration 95
View Image
Illustration 96
o Prolonged operation beyond specifications
o Material defect
Operational Causes
Premature Wear
View Image
Illustration 97
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Illustration 98
o Use of non Cat tool
Operational Causes
o Ratcheting of tool during operation - Usually a chisel (chisel point tool may twist to follow cracks, causing
excessive force against retaining pins)
Wear Plate
Cracked / Broken
View Image
Illustration 99
View Image
Illustration 100
o Incorrect installation
Operational Causes
o Excessive prying loads
© 2004 Caterpillar
Printed in the U.S.A
All Rights Reserved
Copyright 1993 - 2008 Caterpillar Inc. Fri Sep 5 08:51:19 CDT 2008
All Rights Reserved.
Private Network For SIS Licensees.

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Service Information System Page 1 of 69

Reuse And Salvage Guidelines

Caterpillar Hammer Failure Analysis Guide

Small Series Hammers

Large Series Hammers

Failure possibly caused by incorrect application of the hammer

Customer Maintenance Causes

Failure possibly caused by maintenance outlined in the OMM

Dealer Service Causes

Failure possibly caused by annual rebuild or pre-delivery of hammer

Failure possibly caused by machining, material quality, heat treatment, etc.

Failure possibly caused by incorrect operation as explained in the OMM

Parts listed in this document are:

Bushing Thrust Ring

Seals Lower Piston

Seals Upper Piston

Tie Rod Nuts

Tool Retaining pin

Important Safety Information

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

Do not operate or work on this product until you have

Hot oil and components can cause personal injury. Do

Always use a board or cardboard when checking for a

Notice labels in this publication identify operations that

Using this Guideline

Loss of Nitrogen Charge - U-Sit Seal Damaged

o Nitrogen charge checked without replacing U-sit seal

o Fill valve over torqued during charge

Loss of Nitrogen Charge - Diaphragm Center Perforations

Dealer Service Causes

o Failure to charge accumulator prior to operation

Loss of Nitrogen Charge - Diaphragm Deformed and Hardened

o High hydraulic oil temperature from incorrect auxiliary settings

o High hydraulic oil temperature from poor machine cooler maintenance

Dealer Service Causes

o High hydraulic oil temperature from incorrect auxiliary settings

o Prolonged operation beyond specified service interval

Loss of Nitrogen Charge - Diaphragm Extruded Through Screen

Customer Maintenance Causes

o Excessive nitrogen charge

Dealer Service Causes

o Excessive nitrogen charge

Loss of Nitrogen Charge - Diaphragm Rim Tear

Customer Maintenance Causes

o U-Sit seal not replaced when nitrogen charge is checked

Dealer Service Causes

o Failure to charge accumulator prior to operation

o Incorrect charge method

o Prolonged operation beyond specified service interval

o Lack of silicone lubricant used during accumulator assembly

o U-Sit seal over torqued or reused

Loss of Nitrogen Charge - Torn or Damaged O-Ring

Customer Maintenance Causes

o No lubrication used on o-ring during installation

o Excessive torque applied to fill valve

Dealer Service Causes

o No lubrication used on o-ring during installation

o Excessive torque applied to fill valve

Dealer Service Causes

o Prolonged operation beyond specified service interval

o Excessive oil flow

o Excessive blank firing of hammer

Dealer Service Causes