Usage:
1. Start the machine, and fully extend the stick and bucket. Lower the stick and bucket to the ground.
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At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. To prevent possible personal injury, release the pressure in the implement hydraulic circuits (boom, stick and bucket) before any hydraulic lines or components are disconnected or removed. |
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- a. Shut off the engine, and put the hydraulic activation control lever in the "Lock" position.
- b. Move the control levers for the boom, bucket, stick and swing through their full travel strokes. This will relieve any pressure that may be present in the pilot system.
- c. Slowly loosen the air breather cap on the hydraulic oil tank to release the pressure.
- d. Tighten the air breather cap on the hydraulic oil tank.
- e. The pressure in the hydraulic system has now been released. Lines and components can now be removed.
- b. Move the control levers for the boom, bucket, stick and swing through their full travel strokes. This will relieve any pressure that may be present in the pilot system.
2. Release the pressure in the hydraulic system as follows:
3. Fasten a hoist to the rod end of the bucket cylinder as shown. Put a wood block (3) under the link assemblies as a support.
4. Remove the two nuts and retaining bolt (1). Using tooling (A), remove pin (2). The weight of the pin is 23 kg (50 lb).
5. Raise bucket cylinder (4) until it is level; then fasten a lifting strap and a hoist to the head end of the bucket cylinder as shown. Disconnect two hoses (5) from the bucket cylinder. Put plugs in the ends of the hoses to keep dirt and debris out of the hydraulic system.
6. Remove pin assembly retaining bolt (6) and under the washer. Using tooling (A) remove pin assembly (7). Remove the bucket cylinder. The weight of the bucket cylinder is 191 kg (420 lb).
NOTE: Some machines may be equipped with shims between the stick and bucket cylinder at the stick-to-bucket cylinder pin joint. For assembly purposes, put identification marks on the shims as to their location.
7. Remove the shims (if so equipped) at the stick-to-bucket cylinder pin joint.
NOTE: The following steps are the for the installation of the bucket cylinder.
8. Be sure the pin bores in the stick, link assemblies and bucket cylinder are clean and free of dirt prior to installation of the bucket cylinder.
9. Fasten a hoist to bucket cylinder (4), and put it in position in the stick. Be sure the pin bores in the stick and bucket cylinder are in alignment. Also, be sure the grease fitting in the head end and rod end of the bucket cylinder are facing away from the stick.
10. Put a thin coat of 5P0960 Multipurpose Grease on pin assembly (7). Temporarily install the pin assembly. Do not remove the hoist from the bucket cylinder at this time.
Top View Of Stick And Bucket Cylinder
11 Slide the bucket cylinder to one side until it makes contact with the stick. Measure the total clearance between the bucket cylinder and stick at the pin bore. The total clearance of (a) and (b) must not be more than 1.6 mm (0.06 in). If the total clearance is less than 1.6 mm (0.06 in), the addition of shims between the bucket cylinder and stick will not be required. If the total clearance is more than 1.6 mm (0.06 in), add the correct thickness of shims to obtain the necessary clearance.
12. If it has been determined that shims need to be installed between the stick and bucket cylinder, remove pin assembly (7). Install the shims between the stick and bucket cylinder on the same side as the pin assembly retaining bolt; then, using tool (B), reinstall pin assembly (7). Install pin assembly retaining bolt (6) and the washer that holds the pin assembly in position. Tighten pin assembly retaining bolt (6) to a torque of 325 ± 40 N·m (240 ± 30 lb ft).
13. Lower the bucket cylinder between the link assemblies. Put a thin coat of 5P0960 Multipurpose Grease on pin (2). Be sure the bore in the bucket cylinder rod is in alignment with the bores in the link assemblies. Using tool (B), install pin (2). Install retaining bolt (1) and the two nuts.
14. Rotate pin (2) until it is in the position shown. Tighten the nuts on retaining bolt (1) as shown in the illustration. Tighten the outside nut until it is even or 0.5 mm (0.02 in) above the end of the retaining bolt. Tighten the inside nut against the outside nut.
15. Check the condition of the O-ring seals in the ends of hoses (5) prior to installation. If the seals are worn or damaged, use new parts for replacement. Connect two hoses to the bucket cylinder.
16. Fill the hydraulic oil tank with oil to the correct level. Lubricate the bucket cylinder support pins. See the Operation & Maintenance Manual for the correct procedures.
Disassemble & Assemble Bucket Cylinder
*If the Wolff Hydraulic Cylinder Repair Stand is not available to disassemble the bucket cylinder, contact the Caterpillar Service Technology Group.
Start By:
a. remove bucket cylinder
1. Put the bucket cylinder on tooling (A).
2. Remove bolts (7) that hold head (9) to cylinder assembly (1).
3. Use tooling (A) to slide rod assembly (8) out of cylinder assembly (1).
4. Remove ring (3), seal assembly (4) and ring (5) from piston (8).
5. Using tool (B), remove locknut (2) that holds piston (6) to rod assembly (8). Remove the piston from the rod assembly.
6. Slide cylinder assembly (1) back onto the rod assembly. Install bolts (7) that hold head (9) to the cylinder assembly. Put the cylinder assembly and head (9) as a unit away from the rod assembly. Remove the head from the cylinder assembly.
7. Remove O-ring seal (13), ring (12), ring (11), bearing (10), seal (17), seal (16), ring (15) and lip-type seal (14) from head (9).
8. Remove the lip-type seal from both sides of the cylinder assembly and the rod assembly.
9. Remove the bearing from the cylinder assembly and the rod assembly.
NOTE: The following steps are for the assembly of the bucket cylinder. Refer to illustration C49436P1 for assembly of the bucket cylinder.
10. Install the bearing in the cylinder assembly and the rod assembly. Be sure the bearings are centered in the bore.
11. Using tool (C), install the lip-type seals in the rod assembly and the cylinder assembly. Install the seals with the lip facing out.
12. Install ring (11), bearing (10), seal (17), seal (16) and ring (15) in head (9) as shown. Using tool (C), install lip-type seal (14) in head (9) with the lip facing away from the inside of the cylinder. Install O-ring seal (13) and ring (12) in head (9) as shown.
13. Put clean hydraulic oil on the lip of the lip-type seal (14), ring (13), seal (16) and seal (17).
14. Put head (9) in position on cylinder assembly (1). Install bolts (7) that hold it. Install rod assembly (8) in head (9) and the cylinder assembly. Remove bolts (7). Remove cylinder assembly (1) from the rod assembly and head.
15. Install piston (6) on the rod assembly. Lubricate the threads on the end of the rod assembly with 2P2506 Threads Lubricant. Install locknut (2), and tighten it with tool (B) to a torque of 6200 ± 320 N·m (4720 ± 240 lb ft).
16. Install ring (3), seal assembly (4) and ring (5) on piston (6). Lubricate the outside of the piston with 1P0808 General Purpose Lubricant.
17. Using tooling (A), install cylinder assembly (1) on the rod assembly. Install bolts (7) that hold head (9) to the cylinder assembly. Tighten bolts (7) with the rod assembly fully extended.
End By:
a. install bucket cylinder