Removal Procedure
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 9U-5344 | Puller Stud M30 x 3.5 |
1 |
| 9U-5346 | Nut M30 x 3.5 |
1 | |
| 6V-4035 | Sleeve | 1 | |
| 6V-3175 | Hydraulic Cylinder Gp | 1 | |
| 3S-6224 | Electric Hydraulic Pump Gp | 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. |
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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.
- Position boom (1) on suitable cribbing.
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| Illustration 1 | g01185348 |
- Release the hydraulic system pressure. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release".
- Loosen nut (4) and turn screw (3) clockwise in order to release the pressure in valve assembly (5) .
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| Illustration 2 | g01185349 |
- Remove bolts (2) and (6). Reposition valve assembly (5) .
- Disconnect grease hose assemblies (7) and (8). Disconnect hose assembly (9) .
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| Illustration 3 | g01185350 |
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| Illustration 4 | g01185351 |
- Attach a suitable lifting device to boom cylinder (10). The weight of boom cylinder (10) is approximately 213 kg (470 lb).
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| Illustration 5 | g01185352 |
- Remove bolts (11) and plate (12) .
- Remove shims (13) and reposition pin assembly (14) .
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| Illustration 6 | g01185353 |
- Remove bolt (16). Attach Tooling (A) to pin assembly (15) .
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| Illustration 7 | g01185354 |
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| Illustration 8 | g01185355 |
- Use two people and Tooling (A) to remove pin assembly (15). The combined weight of Tooling (A) and pin assembly (15) is approximately 32 kg (70 lb). Remove shims (17) .
- Remove boom cylinder (10) .
- Repeat Steps 3 through 11 for the remaining boom cylinder.
Disassembly and Assembly Information
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| B | 127-4904 | Hydraulic Cylinder Repair Stand | 1 |
| C | 1P-1838 | Adapter | 1 |
| 9U-6832 | Nut 1 1/4 - 12 NC |
1 | |
| 4C-9634 | Puller Stud 1 1/4 - 12 NC |
1 | |
| 3S-6224 | Electric Hydraulic Pump Gp | 1 | |
| 6V-2108 | Sleeve | 1 | |
| D | 9U-6227 | Adapter | 1 |
| 9U-6832 | Nut 1 1/4 - 12 NC |
1 | |
| 4C-9634 | Puller Stud 1 1/4 - 12 NC |
1 | |
| 3S-6224 | Electric Hydraulic Pump Gp | 1 | |
| 6V-3175 | Double Acting Cylinder | 1 | |
| 1M-6756 | Sleeve | 1 | |
| E | 7M-7456 | Bearing Mount Compound | - |
| F | 1P-0808 | Multipurpose Grease | - |
| G | 195-4609 | Seal Pick | 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 9 | g01185583 |
(1) Use Tooling (C) to remove the sleeve bearing. Install the sleeve bearing to a depth of 7.5 ± 0.3 mm (0.30 ± 0.01 inch).
(2) Use Tooling (D) to remove the sleeve bearing. Install sleeve bearing to a depth of 9.5 ± 0.3 mm (0.37 ± 0.01 inch).
(3) Lubricate the seals slightly with the lubricant that is being sealed.
(4) Apply Tooling (E) to the wiper seal groove prior to assembly.
(5) Lubricate the threads and the face of the locknut with Tooling (F). Tighten the locknut to a torque of 7900 ± 300 N·m (5827 ± 221 lb ft).
(6) Lubricate the inner diameters and outer diameters with Tooling (F).
(7) The slit of the ring must turn in the direction of the piston.
Installation Procedure
- Attach a suitable lifting device to boom cylinder (10). The weight of boom cylinder (10) is approximately 213 kg (470 lb). Use the suitable lifting device to position boom cylinder (10) .
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| Illustration 10 | g01185354 |
- Install shims (17) in order to maintain a maximum lateral clearance of 0.8 mm (0.03 inch). Install pin assembly (15) and bolt (16) .
- Install shims (13) in order to maintain a maximum lateral clearance of 0.8 mm (0.03 inch). Reposition pin assembly (14) .
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| Illustration 11 | g01185353 |
- Install plate (12) and bolts (11). Tighten bolts (11) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
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| Illustration 12 | g01185352 |
- Remove the suitable lifting device from boom cylinder (10) .
- Connect grease hose assemblies (7) and (8). Connect hose assembly (9) .
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| Illustration 13 | g01185350 |
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| Illustration 14 | g01185351 |
- Position valve assembly (5) and install bolts (2) and (6). Return nut (4) and screw (3) to the original position.
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| Illustration 15 | g01185349 |
- Repeat Steps 1 through 7 for the remaining boom cylinder.
- Remove the suitable cribbing from boom (1) .
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| Illustration 16 | g01185348 |