Installation Procedure for the 12 Volt Automatic Lubrication System for the Hydraulic Hammers {6333, 7540} Caterpillar

Backhoe Loader

416D (S/N: BKG1-UP; BFP1-UP)

Work Tool

COUPLER (S/N: 7SW1-UP)

H90 (S/N: 4LL1-UP)

Introduction

Note: Before the installation of this kit, compare the voltage of this kit with the voltage of the host machine. The voltage of the kit must match the voltage of the host machine.

The Special Instruction, REHS1285 is for the installation of the 152-5342 Automatic Lubrication System. The 152-5342 Automatic Lubrication System is designed for installation on machines that have a 12 volt electrical system only. If you need more information about the installation of the automatic lubrication system on your machine, consult your Caterpillar dealer.

The automatic lubrication system consists of the following items: lubrication pump, lubrication lines and toggle switch in the operator compartment. In order to activate the automatic lubrication system, the operator moves the toggle switch to the ON position. A timer in the lubrication pump controls the operation of the pump.

Do not perform any procedure that is outlined in this publication and do not order any parts until you understand the information that is contained in this document.

Parts Information

Required Parts List

Table 1

Required Parts
Item Number	Quantity	Part Number	Description
1	1	153-7532	Lubrication Pump Gp
2	1	124-1890	Permanent Coupling
3	1	231-0899	Hose(1)
4	2	8T-6869	Bolt
5	4	8T-4224	Hard Washer
6	2	6V-9189	Locknut
7	1	2L-8079	Terminal
8	3	2L-8077	Terminal
9	2	3K-8781	Fuse
10	2	5P-4571	Blade Terminal
11	1	4K-5122	Fuse Holder As
12	100	6K-0806	Cable Strap(1)
13	2	8S-4626	Wire Splice
14	1	9D-0904	Holder and Wire
15	1	7X-0873	Tee(2)
16	2	6V-9746	O-Ring Seal(2)
17	2	3J-1907	O-Ring Seal
18	1	101-3082	Pressure Switch(2)
19	5	124-2113	Permanent Coupling
20	5	6V-8397	O-Ring Seal
21	2	6V-8730	Union
22	1	7K-0613	Coupling Assembly
23	2	3K-0360	O-Ring Seal
24	1	6V-8634	Connector
25	200 cm	5P-0653	Wire
26	1	061-8844	Grommet
27	1	147-1719	Permanent Coupling
28	1	8D-2676	Toggle Switch
29	1	185-3149	Plate
30	1	8T-7910	Adapter(3)
31	1	6V-0405	Bonded Seal(3)
32	1	8T-7911	Adapter(4)
33	1	6V-0406	Bonded Seal(4)
34	1	152-6942	Connector
35	1	6V-8398	O-Ring Seal
36	1	154-0095	Permanent Coupling
37	1	216-6884	Mounting Plate
38	1	6V-9169	Bulkhead Nut
39	1	222-3482	Film
40	1	8H-8648	Instruction Plate

(1)	As required
(2)	Use this part on 416, 416B, 416C, and 416D machines.
(3)	Use this part on the following models: H100/H100s (S/N: 4ML1-280) and H115s (S/N: 4PL1-2999)
(4)	Use this part on the following models: H90/H90Cs (S/N: 6TZ1-2999), H120Cs (S/N: 9MM1-2999), H130 (S/N: 7CM1-2999), H140Cs (S/N: BED1-UP), H160Cs (S/N: BFB1-UP), H100/H100s (S/N: 4ML281-2999) and H180s (S/N: 9PM174-2999)

Installation Section

1. Before you perform any work on the machine, you must complete the following steps.

   1. Park the host machine on ground that is level and solid. Lower the hydraulic hammer to the ground.

   2. Turn off the engine of the host machine.

   3. Turn the engine start key to the ON position. Do not start the engine. Cycle all of the controls of the host machine in order to relieve the pressure in the hydraulic system.

   4. Turn the engine start key to the OFF. Remove the engine start key.
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      Illustration 1	g00104545

   5. Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before you start to install the automatic lubrication system. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer.

   6. Turn the battery disconnect switch key to the OFF position. Remove the battery disconnect switch key.

      Note: If you are connecting the power wire to the batteries, you must disconnect the batteries.

Installation of the Autolube Pump

Note: Before you install the lubrication pump, set the lubrication pump for the recommended operation for your hammer. Refer to "Initial Setup of the Lubrication Pump".

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Illustration 2	g01076966
Recommended mounting location for the lubrication pump (A)

Note: Mount the lubrication pump on a vertical surface. In some applications, it may be necessary to build an additional bracket in order to mount the autolube pump.

1. Locate a position on the host machine in order to mount the lubrication pump. The location of the lubrication pump is important in the prevention of damage to the lubrication pump. In order to check the level of the grease, the reservoir should be easily seen. The location should allow easy access in order to refill the reservoir.
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   Illustration 3	g01069053
   (1) 153-7532 Lubrication Pump Gp (4) 8T-6869 Bolt (5) 8T-4224 Hard Washer (6) 6V-9189 Locknut

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   Illustration 4	g01076087
   (37) 216-6884 Mounting Plate

2. Install 216-6884 Mounting Plate (37) onto the host machine. Use the following components to install the lubrication pump onto the mounting plate: two 8T-6869 Bolts (4), four 8T-4224 Hard Washers (5) and two 6V-9189 Locknuts (6). Fasten the lubrication pump to the mounting plate.

Welding Requirements

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Welding quality is critical to the success of the installation procedures. Welds must be smooth and continuous. Do not undercut the welds. No overlap is allowed. Grind the ends of the welds to a smooth radius.

Prepare the metal for welding according to "Preparing the Metal for Welding".

Use LB-26 Electrodes (AWS E7016 or AWS E7018) or equivalent electrodes to weld the boss assemblies to the stick assemblies. Basic welding wire ESAB OK tubrod 15.00 with a 1.2 mm (0.05 inch) diameter can also be used. The basic welding wire must be the equivalent to AWS A5.20 E71T-5 with positive polarity. The welding wire must be protected with CO2 gas.

All electrodes must be completely dried. The electrodes can be dried by heating the electrodes to 300°C (572°F). The electrodes must be dried for at least 30 minutes.

Do not weld in windy conditions. Do not weld when temperatures are below 16°C (60°F).

Penetration characteristics may vary greatly depending on the following conditions:

• electrode diameter

• shielding gas

• welding current

• plate thickness

The following items also affect the welds:

• geometry of welded joints

• surface conditions

• composition of the base metal and of the electrode

A root pass should be applied before each weld is finished.

Maintain a 3 mm (0.12 inch) minimum root opening on all cross welds and circle welds.

All welds to the stick must be welded in the direction from the rear of the stick toward the front of the stick.

For more welding information, consult the Caterpillar Service Welding Guide, SEBD0512.

Preparing the Metal for Welding

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

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NOTICE
Before carrying out arc welding on the machine or on any equipment attached to the machine, disconnect all power and ground leads from the batteries in order to avoid possible damage to electronic components.

All grease, water, paint, rust, dirt, and scale must be removed before welding. Any of these materials will discharge gas which will cause porosity in the weld deposit. Water and rust will cause hydrogen embrittlement. Hydrogen embrittlement causes cracks in the weld deposit.

Remove paint, rust, dirt, and scale with a wire brush or by buffing or grinding. Shot blasting all work areas will also remove foreign material.

Remove any oil or grease with a Caterpillar approved solvent.

Installation of the Plate

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Illustration 5	g01076999
Location for bracket (B)

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Illustration 6	g01077047
( 29) 185-3149 Plate (34) 152-6942 Connector (38) 6V-9169 Bulkhead Nut

1. Weld the 185-3149 Plate (29) to the stick of the host machine. The mounting plate should be located near the diverter valve (B) for the hydraulic system.

2. Install 152-6942 Connector (34) into 185-3149 Bulkhead Plate (29).

   Note: The long end of the connector must be toward the boom. The short side of the connector must be toward the hammer.

3. Secure the connector to the mounting plate with 6V-9169 Bulkhead Nut (38).

Assemble the Grease Line

1. Measure the necessary length of 231-0899 Hydraulic Hose (3) from the lubrication pump to 185-3149 Bulkhead Plate (29).

   Note: The length of the hose should not restrict the movement of the stick or the boom while the host machine is operating.

   1. Cut the hose to the correct length.

2. Measure the necessary length of 231-0899 Hydraulic Hose (3) from 185-3149 Bulkhead Plate (29) to the grease fitting on the hammer.

   Note: The length of the hose should not restrict the movement of the stick or the hammer while the host machine is operating.

   1. Cut the hose to the correct length.

3. Perform the following steps in order to assemble the hose from the lubrication pump to the mounting plate:

   1. Install 124-1890 Permanent Coupling (2) to one end of 231-0899 Hydraulic Hose (3).

   2. Install 154-0095 Permanent Coupling (36) to the other end of 231-0899 Hydraulic Hose (3).

4. Perform the following steps in order to assemble the hose from the mounting plate to the hammer:

   1. Install 124-2113 Permanent Coupling (19) to one end of 231-0899 Hydraulic Hose (3).

   2. Install 147-1719 Permanent Coupling (27) to the other end of 231-0899 Hydraulic Hose (3).

Installation of the Grease Line

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Illustration 7	g01069154
(1) 153-7532 Lubrication Pump Gp (2) 124-1890 Permanent Coupling (3) 231-0899 Hose (20) 6V-8397 O-Ring Seal (C) Connector

1. The following steps describe the process of connecting the hose from the lubrication pump to the mounting plate on the stick of the host machine.

   1. Install 124-1890 Permanent Coupling (2) into 153-7532 Lubrication Pump (1).

   2. If the lubrication pump is located in any compartments, drill a 25.4 mm (1 inch) hole in the host machine in order to route the hose to the hammer. After you drill the hole, install 061-8844 Grommet into the hole. Route the hose through the grommet.

   3. Route the hose for the grease along the existing hydraulic lines on the boom and the stick. Fasten the hose to the hydraulic lines by using 6K-0806 Cable Straps (12).
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      Illustration 8	g01076178
      (3) 231-0899 Hose (35) 6V-8398 O-Ring Seal (36) 154-0095 Permanent Coupling (19) 124-2113 Permanent Coupling (20) 6V-8397 O-Ring Seal (22) 7K-0613 Coupling Assembly (23) 3K-0360 O-Ring Seal (24) 6V-8634 Connector (29) 185-3149 Plate (34) 152-6942 Connector (38) 6V-9169 Bulkhead Nut

   4. Install 6V-8398 O-Ring Seal (35) into 154-0095 Permanent Coupling (36).

   5. Connect 154-0095 Permanent Coupling (36) to 152-6942 Connector (34) on the mounting plate.

2. The following steps describe the process of connecting the hose between the mounting plate on the stick of the host machine to the grease port on the hammer.

   1. Install 6V-8397 O-Ring Seal (20) into 124-2113 Permanent Coupling (19).

   2. Install 6V-8634 Connector (24) and 3K-0360 O-Ring Seal (23) onto 124-2113 Permanent Coupling (19).

   3. Install 7K-0613 Coupling (22) and 3K-0360 O-Ring Seal (23) onto 6V-8634 Connector (24).

   4. Connect 7K-0613 Coupling (22) to 152-6942 Connector (34).

Connecting the Grease Line to the Hammer

Locate the grease port on the hammer. The port is identified with the letter "G". The letter is stamped into the metal or cast into the metal.

Note: Use the tables that are shown below to identify your hammer by the serial number. Refer to the illustration above the table in order to locate your hammer's grease port. The correct fittings are also called out in the illustration.

Note: Before you connect the hose to the hammer, you must fill the grease line with grease.

Note: Before you operate the hammer, you must ensure that the hammer tool and the tool bushing are greased and that all of the air in the hose for the grease has been purged. Position the hammer in an upright position. Place downward force on the tip of the tool. The top of the tool must be in contact with the bottom of the piston before you add grease to the hammer.

Illustration 9	g01069888
(G) Grease Port (3) 231-0899 Hose (17) 3J-1907 O-Ring Seal (27) 147-1719 Permanent Coupling (32) 8T-7911 Adapter (33) 6V-0406 Bonded Seal

Table 2

Model	Serial Number
H50/H50s	(S/N: 5MZ1-2999)
H63/H63s	(S/N: 4GL1-2999)
H90C/H90Cs	(S/N: 6TZ1-2999)
H100/H100s	(S/N: 4ML281-2999)
Refer to illustration 9.

Illustration 10	g01069890
(G) Grease Port (3) 231-0854 Hose (17) 3J-1907 O-Ring Seal (27) 147-1719 Permanent Coupling

Table 3

Model	Serial Number
H50/H50s	(S/N: 5MZ3000-UP)
H63/H63s	(S/N: 4GL3000-UP)
H90C/H90Cs	(S/N: 6TZ3000-UP)
H100/H100s	(S/N: 4ML3000-UP)
Refer to illustration 10.

Illustration 11	g01070438
(G) Grease Port (3) 231-0854 Hose (17) 3J-1907 O-Ring Seal (27) 147-1719 Permanent Coupling (30) 8T-7910 Adapter (31) 6V-0405 Bulkhead Nut

Table 4

Model	Serial Number
H100/H100s	(S/N: 4ML1-280)
Refer to illustration 11.

Illustration 12	g01069892
(G) Grease Port (3) 231-0854 Hose (17) 3J-1907 O-Ring Seal (27) 147-1719 Permanent Coupling (30) 8T-7910 Adapter (31) 6V-0405 Bulkhead Nut

Table 5

Model	Serial Number
H115s	(S/N: 4PL1-2999)
Refer to illustration 12.

Illustration 13	g01070698
(G) Grease Port (3) 231-0854 Hose (17) 3J-1907 O-Ring Seal (27) 147-1719 Permanent Coupling

Table 6

Model	Serial Number
H115s	(S/N: 4PL3000-UP)
Refer to illustration 13.

Illustration 14	g01069896
(G) Grease Port (3) 231-0854 Hose (17) 3J-1907 O-Ring Seal (27) 147-1719 Permanent Coupling (32) 8T-7911 Adapter (33) 6V-0406 Bonded Seal

Table 7

Model	Serial Number
H120C/H120Cs	(S/N: 9MM1-2999)
Refer to illustration 14.

Illustration 15	g01069898
(G) Grease Port (3) 231-0854 Hose (17) 3J-1907 O-Ring Seal (27) 147-1719 Permanent Coupling

Table 8

Model	Serial Number
H120C/H120Cs	(S/N: 9MM3000-UP)
Refer to illustration 15.

Illustration 16	g01069901
(G) Grease Port (3) 231-0854 Hose (17) 3J-1907 O-Ring Seal (27) 147-1719 Permanent Coupling (32) 8T-7911 Adapter (33) 6V-0406 Bonded Seal

Table 9

Model	Serial Number
H130/H130s	(S/N: 7CM1-2999)
Refer to illustration 16.

Illustration 17	g01070719
(G) Grease Port (3) 231-0854 Hose (17) 3J-1907 O-Ring Seal (27) 147-1719 Permanent Coupling

Table 10

Model	Serial Number
H130/H130s	(S/N: 7CM3000-UP)
Refer to illustration 17.

Illustration 18	g01069902
(G) Grease Port (3) 231-0854 Hose (17) 3J-1907 O-Ring Seal (27) 147-1719 Permanent Coupling (32) 8T-7911 Adapter (33) 6V-0406 Bonded Seal

Table 11

Model	Serial Number
H140C/H140Cs	(S/N: BED1-2999)
Refer to illustration 18.

Illustration 19	g01070748
(G) Grease Port (3) 231-0854 Hose (17) 3J-1907 O-Ring Seal (27) 147-1719 Permanent Coupling

Table 12

Model	Serial Number
H140C/H140Cs	(S/N: BED3000-UP)
H140Ds	(S/N: BXB1-UP)
Refer to illustration 19.

Illustration 20	g01069904
(G) Grease Port (3) 231-0854 Hose (17) 3J-1907 O-Ring Seal (27) 147-1719 Permanent Coupling (32) 8T-7911 Adapter (33) 6V-0406 Bonded Seal

Table 13

Model	Serial Number
H160C/H160Cs	(S/N: BFB1-2999)
Refer to illustration 20.

Illustration 21	g01070811
(G) Grease Port (3) 231-0854 Hose (17) 3J-1907 O-Ring Seal (27) 147-1719 Permanent Coupling

Table 14

Model	Serial Number
H160C/H160Cs	(S/N: BFB3000-UP)
H160Ds	(S/N: BXF1-UP)
Refer to illustration 21.

Illustration 22	g01069905
(G) Grease Port (3) 231-0854 Hose (17) 3J-1907 O-Ring Seal (27) 147-1719 Permanent Coupling (32) 8T-7911 Adapter (33) 6V-0406 Bonded Seal

Table 15

Model	Serial Number
H180/H180s	(S/N: 9PM1-2999)
Refer to illustration 22.

Illustration 23	g01070834
(G) Grease Port (3) 231-0854 Hose (17) 3J-1907 O-Ring Seal (27) 147-1719 Permanent Coupling

Table 16

Model	Serial Number
H180/H180s	(S/N: 9PM3000-UP)
Refer to illustration 23.

Installation of the Electrical Components

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Illustration 24	g01071463
(7) 2L-8079 Terminal (8) 2L-8077 Terminal (9) 3K-8781 Fuse (10) 5P-4571 Blade Terminal (11) 4K-5122 Fuse Holder As (12) 6K-0806 Cable Strap (25) 5P-0653 Wire

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Illustration 25	g01071499
(8) 2L-8077 Terminal (9) 3K-8781 Fuse (13) 8S-4626 Wire Splice (14) 9D-0904 Holder and Wire (28) 8D-2676 Toggle Switch

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Illustration 26	g01731613
(28) Toggle switch (29) 8 amp fuses (30) Power cord and socket (31) Plug on pump housing (32) Pump housing (33) Printed circuit board (34) Pressure switch (35) Red wire (36) White wire (37) Blue wire

Note: Red wire connects to the following components: 8 amp fuse, toggle switch (28) and battery (+) terminal.

Note: White wire connects to the battery (-) terminal.

Note: Blue wire connects to the following components: 8 amp fuse, pressure switch (34), and battery (+) terminal.

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Illustration 27	g01730933
Electrical connector at the pump

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Illustration 28	g00879278
Location of the toggle switch

1. Install 8D-2676 Toggle Switch (28) for the automatic lubrication system in the cab of the host machine. Install the fuse holder in a location that is close to the switch.

2. Install the power cable to the connector on the autolube pump.

3. Connect the white wire on the harness to a ground.

4. Route the red wire from the lubrication pump to 4K-5122 Fuse Holder (11). Install 5P-4571 Terminal (10) to the red wire. Connect the terminal to the fuse holder.

5. Measure the length of 5P-0653 Wire (25) that is needed to connect 4K-5122 Fuse Holder (11) to 8D-2676 Toggle Switch (28).

   1. Cut the wire to the correct length. Install one 5P-4571 Terminal (10) to one end of the wire. Install one 2L-8077 Terminal (8) to the other end of the wire.

   2. Connect 5P-4571 Terminal (10) to the fuse holder.

   3. Connect 2L-8077 Terminal (8) to terminal "3" on the switch.

6. Install one 2L-8077 Terminal (8) to one end of the remaining 5P-0653 Wire (25). Connect the 2L-8077 Terminal (8) to terminal "2" on the switch.

7. Route the remaining wire to the power source for the lubrication pump.

8. If the hammer is controlled by an electrical switch, route the blue wire in the wiring harness to the switch. The hammer can be controlled by either the joystick or by a foot switch.

   Note: If the hammer is not controlled by an electrical switch, consult Caterpillar Work Tools for more information .

9. Connect 9D-0904 Holder and Wire (14) to the blue wire of the harness. Use 8S-4626 Wire Splice (13) in order to connect the holder to the blue wire.

10. Connect the other end of the holder to the side of the switch that controls the operation of the hammer.

11. Install 3K-8781 Fuse (9) into 9D-0904 Holder and Wire (14).

Option 1

This process provides an optional method in order to hydraulically connect the circuit. This will allow the auxiliary hydraulic circuit to activate the lubrication system on a Caterpillar machine. The use of a pressure switch depends on the machine's configuration. Consult the machine's service manual for details.

Note: The parts that are used in this section are not included with the 152-5342 Automatic Lubrication Gp. These parts can be ordered through your Caterpillar dealer.

Table 17

Required Parts
Part Number	Description	Quantity
8T-8902	Tee	1
4I-8812	Adapter	1
106-0179	Pressure Switch	1
106-0180	Pressure Switch	1

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Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, perform the procedure that follows before testing and adjusting the hydraulic system.

1. All hydraulic pressure must be released before any hydraulic components are worked on.

   1. Park the host machine on ground that is level and solid. Lower the hydraulic hammer to the ground.

   2. Turn off the engine of the host machine.

   3. Turn the engine start key to the ON position. Do not start the engine. Cycle all of the controls of the host machine in order to relieve the pressure in the hydraulic system.

   4. To relieve all of the pressure in the hydraulic oil tank, slowly loosen the filler cap.

   5. Install the filler cap.

   6. Turn the engine start key to the OFF. Remove the engine start key.

2. Connect the 8T-8902 Tee to the auxiliary spool of the machine's pilot valve.

3. Connect the 4I-8812 Adapter to the number 6 port on the 8T-8902 Tee.

4. Connect the 106-0179 Pressure Switch or 106-0180 Pressure Switch to the 4I-8812 Adapter. The actuation pressure and the deactuation pressure for the switch is shown in table 18.
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   Table 18

   Part Number	Actuation Pressure	Deactuation Pressure
   106-0179	1520 ± 98 kPa (220 ± 14 psi)	1127 kPa (163 psi)
   106-0180	2646 ± 196 kPa (384 ± 28 psi)	2156 kPa (312 psi)

Option 2

This process provides an optional method in order to hydraulically connect the circuit. This will allow the auxiliary hydraulic circuit to activate the lubrication system on a Caterpillar machine. The use of a pressure switch depends on the machine's configuration. Consult the machine's service manual for details.

Note: The parts that are used in this section are not included with the 152-5342 Automatic Lubrication Gp. These parts can be ordered through your Caterpillar dealer.

Table 19

Required Parts
Part Number	Description	Quantity
5I-4015	Fitting	1
106-0179	Pressure Switch	1
106-0180	Pressure Switch	1

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Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, perform the procedure that follows before testing and adjusting the hydraulic system.

1. All hydraulic pressure must be released before any hydraulic components are worked on.

   1. Park the host machine on ground that is level and solid. Lower the hydraulic hammer to the ground.

   2. Turn off the engine of the host machine.

   3. Turn the engine start key to the ON position. Do not start the engine. Cycle all of the controls of the host machine in order to relieve the pressure in the hydraulic system.

   4. To relieve all of the pressure in the hydraulic oil tank, slowly loosen the filler cap.

   5. Install the filler cap.

   6. Turn the engine start key to the OFF. Remove the engine start key.
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   Illustration 29	g01072708
   (D) 5I-4015 Fitting (E) 106-0179 Pressure Switch

2. Connect the 5I-4015 Fitting to the auxiliary spool of the machine's pilot valve.
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   Illustration 30	g01072712
   (D) 5I-4015 Fitting (E) 106-0179 Pressure Switch

3. Connect the 106-0179 Pressure Switch or 106-0180 Pressure Switch to the 5I-4015 Fitting. The actuation pressure and the deactuation pressure for the switch is shown in table 20.
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   Table 20

   Part Number	Actuation Pressure	Deactuation Pressure
   106-0179	1520 ± 98 kPa (220 ± 14 psi)	1127 kPa (163 psi)
   106-0180	2646 ± 196 kPa (384 ± 28 psi)	2156 kPa (312 psi)

Operation Section

Operation of the Timer

The "OFF" timer begins accumulating time when the ignition switch closes. When the "OFF" timer reaches the preset value, the pump will turn on. The pump remains activated for the period of time that is preset on the "ON" timer.

When the ignition switch opens, the "OFF" timer will retain the accumulated time for a period of five days. When the ignition switch closes during the five days, the "OFF" timer will resume timing. If the ignition switch is not closed before the end of the five days, the timer will begin with an "ON" period.

Illustration 31	g01731834
Plug connections of the printed circuit board

Table 21

Terminals on the Printed Circuit Board
31	Ground
15	Ignition switch
M	Motor
V	Low level
N	Level control
Z	Extra lube
X	Lamp

Illustration 32	g01732001
Printed circuit board

1. The printed circuit board is supplied with voltage by the ignition switch (terminal 15) and the ground (terminal 31).

2. The printed circuit board is supplied with voltage from a capacitor. This capacitor ensures that the pause or operating times are safely stored for about five days. After this time has expired, all stored data will be canceled.

3. When the ignition switch is turned "ON", a new lubrication cycle begins.

The operating time of the vehicles and the pause time of the centralized lubrication system are started or stopped via the ignition switch.

Operating Schedule

Illustration 33	g01732053
Location of the timing pins

Selection of the time ranges for both "OFF" and "ON" times are set by installation of timing pin cover over the specific pin to be used for control of time. Illustration 33 shows the correct timing pin locations on pins "1a" and "2b".

Table 22

"OFF" Timing Pin Location
Range	Settings
1a. Minutes	3.75 to 56.25 minutes
1b. Hours	1 to 15 hours

Table 23

"ON" Timing Pin Location
Range	Settings
2a. Seconds	7.5 to 112.25 seconds
2b. Minutes	2b. Minutes

Note: "OFF" timing pin on "1a"

Note: "ON" timing pin on "2b"

Illustration 34	g01072340

(M) The blue rotary switch controls the time when the lubrication pump is not operating. The switch can be adjusted to 15 values. Refer to "Recommended Settings for the Lubrication Pump" and "Setting for the Lubrication System".

(N) The red rotary switch controls the time when the lubrication pump operates. The switch can be adjusted to 15 values. Refer to "Recommended Settings for the Lubrication Pump" and "Setting for the Lubrication System".

(O) This LED that is marked "battery" lights when power is applied to the printed circuit board.

(P) This LED that is marked "motor" lights when the pump is running.

(Q) Press the push button for two seconds in order to manually activate the lubrication pump.

Initial Setup of the Lubrication Pump

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Illustration 35	g00878533

1. Remove the bottom cover plate that is located on the base of the autolube pump. Remove ten screws from the bottom of the autolube pump. To separate the cover from the housing of the lubrication pump , firmly pry on the flange that is located on the bottom cover.

2. Remove the connectors that are connected to the bottom of the circuit board.
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   Illustration 36	g01071600

3. Remove seal plug (F) from the lubrication pump.
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   Illustration 37	g01071604

4. From the bottom of the lubrication pump, gently pull board (H) in order to remove the board from the pump.
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   Illustration 38	g01071619
   (M) Blue rotary switch (N) Red rotary switch

5. Rotate the blue rotary switch (M) until the recommended setting appears in the slot. Refer to "Recommended Settings for the Lubrication Pump".

6. Rotate the red rotary switch (N) until the recommended setting appears in the slot.

7. Install the board into the lubrication pump. Plug the connectors into the board.

8. Install the bottom cover of the lubrication pump.

9. Install seal plug (F).

10. Fill the reservoir through the grease fitting that is located at the base of the reservoir. Use a hand operated grease pump. Refill the reservoir when the grease reaches the "MIN" mark that is located on the reservoir. Fill the reservoir up to the "MAX" mark.

Recommended Settings for the Lubrication Pump

Table 24

Recommended Settings
Model of Hammer	Blue rotary switch (M)		Red rotary switch (N)
	Setting	Minutes	Setting	Minutes
H50/H50s	B	41.25	5	10.00
63/H63/H63s	B	41.25	6	12.00
70/70s/H70/H70s	A	37.50	6	12.00
H90C/H90Cs	A	37.50	8	16.00
100/H100/H100s	9	33.75	8	16.00
H115s	8	30.00	9	18.00
120/H120/H120s/H120Cs	7	26.25	9	18.00
130/H130/H130s	6	22.50	A	20.00
H140s/H140Cs/H140Ds	6	22.50	B	22.00
H160s/H160Cs/H160Ds	4	15.00	B	22.00
H180s	4	15.00	D	26.00
195/H195	3	11.25	E	28.00

Note: The maximum flow setting for this unit is with the blue dial that is set at 1 and the red dial that is set at position F. If the hammer does not receive enough grease, start with the maximum setting. Reduce the flow until the desired setting is found. Refer to the Specification Section "Setting for the Lubrication System" for the entire range of settings that are available.

Operating Principles

The automatic lubrication system operates when the hammer is active. When the hammer is started, the timer for the lubrication system will start. The lubrication system will cycle according to the settings of the jumpers and the red dial and the blue dial. The cycles are divided into an “ON” time cycle and an “OFF” time cycle. The “ON” time cycle is the length of time of operation for the lubrication system. The “OFF” time cycle is the time between the operation cycles of the lubrication system.

Illustration 39	g01072348

After several hours of use, you must check the hammer tool for proper lubrication. In order to check the lubrication of the hammer, raise the hammer away from the ground. The hammer tool should extend fully from the lower tool bushing. Visually verify the amount of grease around tool 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) (R).

If the collar of grease is less than 50 mm (2 inch), increase the output of grease to the hammer. You must increase the amount of grease to the hammer. If there is an excess amount of grease on the tool, the amount of grease must be reduced. Refer to the Operation Section "Increase the Output of Grease" or "Decrease the Output of Grease".

Increase the Output of Grease

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Illustration 40	g01072523

Note: If the collar of grease is less than 50 - 100 mm (2 - 4 inch) dimension (R), follow the instruction below.

1. Refer to Table 26 for the settings of the blue rotary switch. In order to increase the output of grease, you should decrease the time on the blue rotary switch. When you reduce the time on the blue rotary switch, the autolube system will cycle more frequently.

2. Refer to Table 27 for the settings of the red rotary switch. In order to increase the output of grease, you should increase the time on the red rotary switch. When you increase the time on the red rotary switch, the autolube system will operate for a longer period of time.

   Note: If the previous steps do not increase the output of grease to the desired specification, you must check the position of the jumpers on the circuit board. In order to check the jumpers on the circuit board, perform the following steps.

3. If the lubrication system is connected to the power supply, remove the power cord from the side of the lubrication pump.
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   Illustration 41	g00878533

4. Remove the bottom cover plate that is located on the base of the lubrication pump. To separate the cover from the housing of the lubrication pump, remove the ten screws from the base of the lubrication pump. Pull the bottom cover from the lubrication pump.

5. Remove the connectors from the circuit board.

6. To access the top of the circuit board, remove the seal plug. Gently pry the circuit board down with a screwdriver until the board protrudes from the bottom of the lubrication pump.

7. Verify that both of the jumpers are positioned for minutes.

8. If the pins are not in the position for minutes, refer to "Initial Setup of the Lubrication Pump".

9. Reinstall the circuit board by inserting the board into the slot. Reconnect the power cord and connectors to the bottom of the circuit board.

10. Replace the bottom panel on the base of the lubrication pump.

11. Replace the seal plug.

Decrease the Output of Grease

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Illustration 42	g01072523

Note: If the collar of grease exceeds 50 - 100 mm (2 - 4 inch) dimension (R), follow the instruction below.

1. Remove the bottom cover plate that is located on the base of the lubrication pump. To separate the cover from the housing of the lubrication pump, firmly pry on the flange that is located on the bottom cover.

2. To access the top of the circuit board, remove the seal plug. Gently pry the circuit board down with a screwdriver until the board protrudes from the bottom of the lubrication pump.

3. If the lubrication system is hooked up, remove the power cord and the wire connectors from the terminals on the circuit board. The jumper terminal is located on the lower left-hand side of the circuit board. The two pins are accessible through the circuit board.

   Note: To decrease the output of grease of the lubrication system, follow the instructions below.

4. Gently pull the pin which is located at the "HOUR" position and move the pin to the left one position. Move the pin to the "MINUTES" position. Make sure that the pin is firmly in place.

5. Rotate the red rotary switch until the letter "A" appears in the slot. This will increase the pause time to 3 times an hour from 2 times an hour.

6. Reinstall the circuit board by inserting the board into the slot and push the board halfway down the slot. Reconnect the power cord and jumper wire connections to the bottom of the circuit board. Push the board to the bottom of the slot until the board is completely seated.

7. Replace the bottom panel on the base of the lubrication pump.

8. Replace the seal plug.

Specification Section

Lubrication Pump

Power requirement ... 24 Volts

Current draw ... 2 Amperes

Maximum operating pressure ... 24800 kPa (3600 psi)

Pump output per minute with a 7 mm (0.28 inch) element ... 4.0 cc (0.24 in³)

Capacity of the reservoir ... 4000 cc (244 in³)

Operating temperature range ... −26 °C to 70 °C (−15 °F to 158 °F)

Recommended Grease

Table 25

Recommended Lubricants
Grease	Size of Container
130-6951 Grease	400 g (14 oz) Cartridge
133-8807 Grease	5 kg (11 lb) Container
129-1938 Grease Cartridge	454 g (16 oz) Container

Refer to Special Instruction, REHS1368, "Procedure to Properly Grease Hydraulic Hammers"

Setting for the Lubrication System

Table 26

Settings for the Blue Rotary Switch (M)
Rotary Switch Setting	Lube Cycle in Minutes(1)	Lube Cycle in Hours(2)
0	0(3)	0(3)
1	3.75 minutes	1 hour
2	7.5 minutes	2 hours
3	11.25 minutes	3 hours
4	15 minutes	4 hours
5	18.75 minutes	5 hours
6	22.5 minutes	6 hours
7	26.25 minutes	7 hours
8	30 minutes	8 hours
9	33.75 minutes	9 hours
A	37.5 minutes	10 hours
B	41.25 minutes	11 hours
C	45 minutes	12 hours
D	48.75 minutes	13 hours
E	52.5 minutes	14 hours
F	56.25 minutes	15 hours

(1)	Jumpers in the minute positions
(2)	Jumpers in the hour position
(3)	The lubrication pump will not operate.

Table 27

Settings for the Red Rotary Switch (N)
Rotary Switch Setting	Lube Cycle in Seconds(1)	Lube Cycle in Minutes(2)
0	0(3)	0(3)
1	7.5 seconds	2 minutes
2	15 seconds	4 minutes
3	22.5 seconds	6 minutes
4	30 seconds	8 minutes
5	37.5 seconds	10 minutes
6	45 seconds	12 minutes
7	52.5 seconds	14 minutes
8	60 seconds	16 minutes
9	67.5 seconds	18 minutes
A	75 seconds	20 minutes
B	82.5 seconds	22 minutes
C	90 seconds	24 minutes
D	97.5 seconds	26 minutes
E	105 seconds	28 minutes
F	112.5 seconds	30 minutes

(1)	Jumpers in the seconds position
(2)	Jumpers in the minutes position
(3)	The lubrication pump will not operate.

Troubleshooting Section

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.

Verify that all of the electrical connections have been made. Operate the hammer and observe operation of lubrication system.

Manual Operation of the Lubrication Pump

Illustration 43	g01072340

1. Set the ignition switch to the ON. This will illuminate LED (O).

2. Press button (Q) for 2 seconds with power to the circuit. Press the foot switch or the thumb switch that activates the hammer. A pause will occur. A normal lubrication cycle will follow. The LED (P) will become illuminated.

Troubleshooting Problem List

Table 28

Troubleshooting Problem List
The lubrication system does not operate.
Probable Cause	Possible Solution
Insufficient power is delivered to the circuit board.	Make sure that the red power wire is securely connected. Test the voltage at the connection.
Insufficient power is delivered to the blue wire.	Make sure that the blue wire is securely connected. Test the voltage at the connection.
The jumpers are set incorrectly.	Verify that the jumpers are set correctly. Refer to section"Initial Setup of the Lubrication Pump".
The in-line fuse has failed.	Replace the fuse.
The lubrication system does not provide sufficient grease.
Probable Cause	Possible Solution
The timer's setting is incorrect.	Verify that the timer's settings are correct. Refer to section"Recommended Settings for the Lubrication Pump".
The grease line has been damaged or the grease line has an obstruction.	Verify that there is no damage to the grease line.
The grease line is not connected to the correct port on the hammer.	Verify the correct port location for the hammer. Refer to section "Connecting the Grease Line to the Hammer".
The lubrication system has not been primed prior to hammer operation.	Prime the lubrication pump.
The jumper is set incorrectly.	Verify that the jumper is set correctly. Refer to "Initial Setup of the Lubrication Pump".