Assembly Procedure
Required Tools     | |||
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Tool     | Part Number     | Part Description     | Qty     |
A     |     | (1)Hydraulic Cylinder Repair Stand     | 1     |
3S-6224 | Electric Hydraulic Pump     | 1     | |
8T-0820 | Pressure Gauge     | 1     | |
3B-7722 | Bushing     | 2     | |
1P-2376 | Coupler Assembly     | 2     | |
1P-2377 | Plug     | 2     | |
8F-0024 | Hose Assembly     | 2     | |
B     | 123-3806     | 95 mm Socket     | 1     |
1P-0851 | Spline Adapter     | 1     | |
C     | 1P-0520     | Driver Group     | 1     |
( 1 ) | If the Wolff Hydraulic Cylinder Repair Stand is not available to assemble the boom cylinder, contact the Caterpillar Service Technology Group. |
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 machine. 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 Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of all fluids according to local regulations and mandates. |
Illustration 1 | g00478096 |
- Check the condition of all of the parts of the boom cylinder for wear or damage. If any of the parts are worn or damaged, use new parts for replacement.
- Install ring (16), bearing (17), seal (18), seal (22), and ring (23) in head (8) .
Note: Make sure that the grooves for the seals in head (8) are thoroughly clean prior to assembly.
- Apply 4C-4032 Bearing Mount Compound to the groove for the wiper seal prior to assembly. Use Tooling (C) to install lip type seal (19) in head (8). Install the seal with the sealing lip toward the outside of the cylinder assembly.
- Install seal (20) and ring (21) in head (8) .
- Put clean hydraulic oil on the lip of lip type seal (19), ring (23), seal (22), and seal (18) .
- Place head (8) in position on cylinder assembly (1). Install the eight bolts that hold head (8) to cylinder assembly (1). Install rod assembly (9) in head (8) and cylinder assembly (1) .
- Remove the eight bolts that hold head (8) to cylinder assembly (1). Remove cylinder assembly (1) from the rod assembly and the head.
- Install ring (11) on the rod assembly. The slit in ring (11) must face piston (7). Install stop (10) on rod assembly (9) .
Note: The slit of ring (11) must be positioned in the direction of the piston.
- Install piston (7) on the rod assembly. Lubricate the threads on the end of the rod assembly with 4C-5593 Anti-Seize Compound. Install locknut (2). Use Tooling (B) to tighten locknut (2) to a torque of 5900 ± 300 N·m (4350 ± 220 lb ft).
- Install ring (6), ring (5), seal assembly (4) and ring (3) on piston (7). Lubricate the outside of the piston with 1P-0808 Multipurpose Grease .
- Use Tooling (A) to install cylinder assembly (1) on rod assembly (9). Install the eight bolts that hold head (8) to cylinder assembly (1). Fully extend the rod assembly. Tighten the eight bolts that hold head (8) to cylinder assembly (1) .
- Lower the temperature of sleeve bearing (13). Use Tooling (C) to install the bearing in the pin bore of rod assembly (9). Install the bearing until the bearing is centered in the bore. Use Tooling (C) to install lip type seals (15) in the pin bore on both sides of rod assembly (9). Install the lip type seals with the sealing lips toward the outside of the bore. Install the lip type seals until the lip type seals are 1.00 ± 0.50 mm (.039 ± .020 inch) below the outside surface of rod assembly (9) .
- Lower the temperature of sleeve bearing (12). Use Tooling (C) to install the bearing in the pin bore of cylinder assembly (1). Install the bearing until the bearing is centered in the bore. Use Tooling (C) to install lip type seals (14) in the pin bore on both sides of cylinder assembly (1). Install the lip type seals with the sealing lips toward the outside of the bore. Install the lip type seals until the lip type seals are 1.00 ± 0.50 mm (.039 ± .020 inch) below the outside surface of cylinder assembly (1) .
- Install the grease fitting in cylinder assembly (1) .
End By: Install the boom cylinder. Refer to Disassembly and Assembly, "Boom Cylinder - Install" in this manual.