Removal Procedure
Start By:
- Release the hydraulic system pressure. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release".
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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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At operating temperature, the hydraulic oil is hot and under pressure. Hot oils can cause burns. To prevent possible personal injury, release the pressure in the work tool hydraulic circuit (boom, stick, bucket, and swing), travel circuits, and the hydraulic oil tank at the filler cap before any hydraulic lines or components are disconnected or removed. Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch. |
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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. |
| NOTICE |
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Keep all parts clean from contaminants. Contamination of the hydraulic system with foreign material will reduce the service life of the hydraulic system components. To prevent contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. Cover any disassembled components and clean them properly before assembly. Clean the hydraulic system properly after any major component exchange or especially after a component failure, to remove any contamination. |
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, all hoses and all tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.
- Loosen nut (2) and turn screw (1) inward. This will relieve the pressure in lock valve (3) .
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| Illustration 1 | g01181842 |
- Disconnect grease hose assembly (5) .
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| Illustration 2 | g01181844 |
- Remove bolts (4) and reposition lock valve (3) .
- Disconnect grease hose assembly (7). Disconnect hose assembly (6) .
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| Illustration 3 | g01181845 |
- Attach a suitable lifting device to stick cylinder (10). The weight of stick cylinder (10) is approximately 215 kg (475 lb).
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| Illustration 4 | g01181846 |
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| Illustration 5 | g01181847 |
- Remove bolts (8) and plates (9) from both ends of stick cylinder (10) .
- Remove spacer (11) and shims (12) from both sides of stick cylinder (10). Reposition pins (13) on both ends of stick cylinder (10) .
- Use the suitable lifting device to remove stick cylinder (10) .
Disassembly and Assembly Information
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 125-0079 | Hydraulic Cylinder Repair Stand | 1 |
| B | 195-4609 | Seal Pick | 1 |
| C | 7M-7456 | Bearing Mount Compound | - |
| D | 1P-0808 | Multipurpose Grease | - |
| E | 1P-0510 | Driver Gp | 1 |
| F | 9U-5338 | Adapter | 1 |
| 9U-6832 | Nut 1 1/4 - 12 |
1 | |
| 4C-9634 | Puller Stud 1 1/4 - 12 |
1 | |
| 3S-6224 | Electric Hydraulic Pump Gp | 1 | |
| 6V-3175 | Double Acting Cylinder | 1 | |
| 6V-2098 | Press Sleeve | 1 | |
| G | 9U-5338 | Adapter | 1 |
| 9U-6832 | Nut 1 1/4 - 12 |
1 | |
| 4C-9634 | Puller Stud 1 1/4 - 12 |
1 | |
| 3S-6224 | Electric Hydraulic Pump Gp | 1 | |
| 6V-3175 | Double Acting Cylinder | 1 | |
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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. |
|
| 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, "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. |
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| Illustration 6 | g01181848 |
(1) (2) Use Tooling (F) to remove the bearings. Use Tooling (G) to install bearings to a depth of 9.5 ± 0.3 mm (0.37 ± 0.01 inch).
(3) Lubricate the threads with Tooling (D). Tighten the locknut to a torque of 5900 ± 300 N·m (4352 ± 221 lb ft).
(4) Lubricate the inner diameter and outer diameter with Tooling (D).
(5) Lubricate the seals slightly with the lubricant that is being sealed.
(6) Apply Tooling (C) to the wiper seal groove prior to assembly.
Installation Procedure
- Attach a suitable lifting device to stick cylinder (10). The weight of stick cylinder (10) is approximately 215 kg (475 lb). Use the suitable lifting device to position stick cylinder (10) .
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| Illustration 7 | g01181846 |
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| Illustration 8 | g01181847 |
- Position pins (13) on both ends of stick cylinder (10). Install spacer (11) and shims (12) to both sides of stick cylinder (10). Adjust shims (12) in order to provide no more than 0.8 mm (0.03 inch) of lateral clearance between plates (9) and stick cylinder (10) .
- Install bolts (8) and plates (9) to both ends of stick cylinder (10). Tighten bolts (8) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
- Connect grease hose assembly (7). Connect hose assembly (6) .
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| Illustration 9 | g01181845 |
- Connect grease hose assembly (5) .
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| Illustration 10 | g01181844 |
- Position lock valve (3) and install bolts (4) .
- Adjust screw (1) to the original location on lock valve (3). Tighten nut (2) .
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| Illustration 11 | g01181842 |