| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | 3S-6224 | Electric Hydraulic Pump | 1 |
| 8T-0820 | Hydraulic Pressure Gauge | 1 | |
| 3B-7722 | Pipe Bushing | 2 | |
| 1P-2376 | Connecting Coupler | 2 | |
| 1P-2377 | Dust Plug | 2 | |
| 6D-7726 | Hose Assembly | 2 | |
| 1U-5197 | Hydraulic Cylinder | 1 | |
| 8T-4133 | Nut | 4 | |
| 8T-4121 | Washer | 4 | |
| 9U-6809 | Nut | 1 | |
| 8T-5463 | Washer | 1 | |
| 9R-3979 | Rod | 4 | |
| 9U-6753 | Retaining Plate | 1 | |
| 9U-6811 | Puller Stud | 1 | |
| 9U-6754 | Adapter Plate | 1 | |
| 9U-6752 | Sleeve | 1 | |
| 6V-5192 | Bolt | 3 | |
| B | 8S-7630 | Stand | 2 |
| 8S-7615 | Pin | 2 | |
| 8S-7621 | Tube | 2 | |
| 8S-8048 | Saddle | 2 | |
| C | 9U-6225 | Pin Driver Cap | 1 |
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
| NOTICE |
|---|
|
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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.
- Start the machine. Fully extend the stick and fully extend the attachment. Lower the stick and the attachment to the ground.
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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 attachments have been lowered, 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.
- Release the hydraulic system pressure. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release".
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Illustration 1 g00489825 Typical Example - Disconnect lubrication hose assembly (3) from the rod end of each boom cylinder.
- Remove bolts (1), retainer plate (2) and the spacer from each side of the support pin.
- Support the right boom cylinder with a nylon lifting strap and a hoist.
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Illustration 2 g00612782 Typical Example - Make sure that the threaded puller hole in the left end of the support pin is clean.
- Fasten a nylon lifting strap and a hoist to Tooling (A). Fasten Tooling (A) to the left end of the support pin.
- Use Tooling (A) to remove the support pin from the pin joint. Remove the pin until the right boom cylinder is free from the support pin.
- Lower the right boom cylinder on Tooling (B).
- Remove Tooling (A) from the support pin.
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Illustration 3 g00504929 Typical Example - Support the left boom cylinder with a nylon lifting strap and a hoist.
- Fasten Tooling (C) to the threaded hole in the left end of the support pin.
- Use a hammer and a punch to drive the support pin in the boom until the left boom cylinder is free from the support pin.
- Remove Tooling (C) from the end of the support pin.
- Lower the boom cylinder on Tooling (B).
- If the support pin must be removed from the boom, fasten nylon lifting straps and a hoist to Tooling (A) for support. The weight of the support pin is
57 kg (126 lb) . - Fasten Tooling (A) to the threaded hole in the end of the support pin.
- Use Tooling (A) to remove the support pin from the boom.
- Lower the support pin to the ground.
- Remove Tooling (A) from the support pin.
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Illustration 4 g00504933 Typical Example - Remove hoses (4) from boom lowering control valve (10).
- Remove bolts (5) and (8) in order to disconnect tube assemblies (6) and (7).
- Remove socket head screws (11) and the boom lowering control valve (10) from the boom cylinder.
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Illustration 5 g00504936 Typical Example - Adjust the height of Tooling (B) so that the boom cylinders are level.
- Readjust the nylon lifting straps and the hoist in order to hold the boom cylinder level.
Note: Oil will drain from the hose assemblies when the assemblies are disconnected from the boom cylinder. Drain the oil in a suitable container for disposal.
- Disconnect hose assemblies (13), (14) and (15) from the right hand boom cylinder. Put plugs in the ends of the hose assemblies. Plugs prevent oil loss. Plugs prevent contamination of the hydraulic system.
- Remove bolts and clamps (17), and remove the tube assemblies.
- Remove bolts (12) and bracket (16).
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Illustration 6 g00612783 Typical Example - Put slight lifting tension on right hand boom cylinder. The weight of the boom cylinder is
318 kg (701 lb) . - Remove the retaining bolt for pin assembly (18) and the washer.
- Remove pin assembly (19) and the spacer.
- Remove the right hand boom cylinder.
Note: Machines may be equipped with shims that are between the boom cylinder and the frame. The shims are located between the joints. For assembly purposes, put identification marks on the shims.
- If the joint is equipped with shims, remove the shims from the joint.
- Remove the left hand boom cylinder from the machine. Repeat 25 through 33.
