Removal Procedure
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 4C-6486 | Stand | 1 |
| 8S-7621 | Tube | 1 | |
| 8S-7615 | Pin | 1 | |
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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. |
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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. |
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Cylinders equipped with lock valves can remain pressurized for very long periods of time, even with the hoses removed. Failure to relieve pressure before removing a lock valve or disassembling a cylinder can result in personal injury or death. Ensure all pressure is relieved before removing a lock valve or disassembling a cylinder. |
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| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
- Put identification marks on all hoses and on all tubes for installation purposes. Plug all hoses and all tubes. This helps to prevent fluid loss and this helps to prevent contaminants from entering the system.
- Install Tooling (A) on the underside of boom (1) in order to support the boom.
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| Illustration 1 | g00928270 |
- Remove bolt (2) and the washer which secures pin (3) to quick coupler (4) . Remove the pin out of the quick coupler and cylinder (5) .
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| Illustration 2 | g00928271 |
- Remove cover (6) from boom head (7) .
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| Illustration 3 | g00928272 |
- Disconnect hoses (8) from elbows (9) and remove the elbows from cylinder (5) .
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| Illustration 4 | g00928273 |
- Feed a suitable nylon lifting sling down through boom head (7) . Attach the sling around cylinder (5) and to a suitable hoist. Take up the tension in order to support the cylinder. The weight of the cylinder is approximately 60 kg (132 lb).
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| Illustration 5 | g00928286 |
- Remove bolt (10) and the washer which secures pin (11) to boom head (7) . Remove the pin out of the boom head and cylinder (5) .
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| Illustration 6 | g00928287 |
- Use the hoist to carefully lower cylinder (5) out of boom head (7) . Remove the cylinder from the machine.
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| Illustration 7 | g00928316 |
Disassembly and Assembly Information
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | NEDG6005 (1) | Hydraulic Cylinder Repair Stand | 1 |
| B | 7M-7456 | Bearing Mount Compound | 1 |
| C | 1P-0808 | Multipurpose Grease | 1 |
| D | 4C-8092 | Universal Wrench | 1 |
| E | 9U-7868 | Spanner Wrench | 1 |
| 127-8064 | Adapter Plate | 1 | |
| F | FT-2802 | Plate | 1 |
| 2J-3507 | Full Nut | 1 | |
| 3K-5234 | Hard Washer | 1 | |
| 123-3804 | Plate | 1 | |
| 4C-9634 | Puller Stud | 1 | |
| 6V-4035 | Sleeve | 1 | |
| 9U-5337 (2) | Bearing Puller Adapter | 1 | |
| 6V-3175 | Double Acting Cylinder | 1 | |
| 9U-6832 | Nut | 1 | |
| 3S-6224 or 8S-8033 |
Electric Hydraulic Pump Gp | 1 | |
| 6D-7726 | Hose As | 2 | |
| G | 233-7211 | Seal Guide | 1 |
| 233-7210 (2) | Seal Guide | 1 | |
| H | 1P-0510 or 1P-0520 |
Driver Gp | 1 |
| ( 1 ) | Refer to NEDG6005, "Hydraulic Cylinder Servicers" for information on the hydraulic cylinder repair stands that are available from Caterpillar. |
| ( 2 ) | TH460 Only |
Note: SERVICE DATA: THE TOOLING IN TABLE 2 MAY NOT BE IDENTIFIED IN THE FOLLOWING PHOTOGRAPHS. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.
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| Illustration 8 | g00943486 |
(A) Install bearing (1) . The bearing must not extend beyond either face of the cylinder eye.
(B) Install bearing (12) . Install the bearing to depth (X) from the bottom face before installing lip seals (13) .
Dimension (X) ... 7 ± 0.5 mm (0.276 ± 0.020 inch)
(C) Apply Tooling (B) to the seal groove prior to the installation of the wiper seal (8) . Lubricate the lip of wiper seal (8) , seal (6) , backup ring (7) and wear ring (5) with the lubricant that is being sealed.
(D) Lubricate the threads of self-locking nut (2) with Tooling (C) . Use a 90 mm socket for the removal and for the installation of the self-locking nut. The torque setting for the self-locking nut TH350B/TH360B SLD-1Up/SLE1-Up ... 6500 ± 100 N·m (4795 ± 75 lb ft)
(-) Lubricate the threads of self-locking nut (2) with Tooling (C) . Use a 65 mm socket for the removal and for the installation of the self-locking nut. The torque setting for the self-locking nut TH450B (SLF1-Up) ... 3000 ± 100 N·m (2210 ± 75 lb ft)
(E) Lubricate piston seals (3) and wear ring (4) with the lubricant that is being sealed.
(F) Lubricate O-ring seal (9) , the backup ring and O-ring seal (10) with the lubricant that is being sealed.
(G) Lubricate the threads of head (11) with Tooling (C) . The torque setting for head (110) ... 600 ± 130 N·m (440 ± 95 lb ft)
Installation Procedure
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 4C-6486 | Stand | 1 |
| 8S-7621 | Tube | 1 | |
| 8S-7615 | Pin | 1 | |
- Clean all parts and inspect all parts. If any parts are worn or damaged, use new Caterpillar parts for replacement.
- Attach a suitable nylon lifting sling around cylinder (5) . Feed the opposite end of the sling through boom head (7) to a suitable hoist. Use the hoist to carefully lift the cylinder and at the same time guide the cylinder into the boom head. The weight of the cylinder is approximately 60 kg (132 lb).
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| Illustration 9 | g00935776 |
- Align the bore in cylinder (5) with the bores in boom head (7) and install pin (11) , bolt (10) and the washer. Remove the nylon lifting sling.
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| Illustration 10 | g00928287 |
- Install elbows (9) into cylinder (5) before connecting hoses (8) .
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| Illustration 11 | g00928273 |
- Install cover (6) onto boom head (7) .
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| Illustration 12 | g00928272 |
- Align the bore in cylinder (5) with the bores in quick coupler (4) and install pin (3) , bolt (2) and the washer.
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| Illustration 13 | g00928271 |
- Remove Tooling (A) from the underside of boom (1) .
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| Illustration 14 | g00928270 |