The Replacement Procedure for the Hydraulic Cylinder Assembly on Certain Shears{5553} Caterpillar

Work Tool:

S365B (S/N: C1A123-192)

S385B (S/N: C1B123-150)

VHS-60/3 (S/N: B1X123-137)

VHS-70/3 (S/N: B1Y123-125)

Introduction

ReferenceDisassembly and Assembly, RENR4474.

ReferenceDisassembly and Assembly, RENR4476.

This special instruction provides the procedure for the hydraulic cylinder assembly on certain shears. The Cat S365B and the S385B Shears and Verachtert VHS-60/3 and VHS-70/3 Shears have experienced cracking failures near the shear cylinder mount and gussets. Replacing the cylinder assembly (barrel) to one with trunnions removes the stress levels that occur within the housing. This publication describes the replacement of the cylinder assembly and the trunnion bearing mounting for the shear assembly.

Instructions

Remove the hydraulic cylinder from the shear housing.

ReferenceDisassembly and Assembly, RENR4474 or RENR4476, "Hydraulic Cylinder -Remove" for detailed instructions.

ReferenceDisassembly and Assembly, RENR4474 or RENR4476, "Hydraulic Cylinder-Disassemble" for detailed instructions.

Conversion Procedure

ReferenceDisassembly and Assembly, RENR4474 or RENR4476, "Hydraulic Cylinder -Assemble" for detailed instructions.

Required Parts

The following list of parts is required for each hydraulic cylinder assembly that is replaced.

Assembly Procedure

Note: Cleanliness is an important factor. Before assembly, clean all parts thoroughly cleaned with cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new Caterpillar parts for replacement.

Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.

Note: Use Tooling (T2) for Steps 1 through 8.

Note: Lubricate the (5) O-ring seal through (12) Rod Seal with the lubricant that is being sealed.

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Illustration 1	g02212333

1. Install the following items into the cylinder head assembly:
   • (7) wiper seal

   • (10) seal assembly

   • (11) rod seal

   • (12) rod seal

   • (9) wear rings

   • (8) wear ring

   1. Install backup seal (6) and O-ring seal (5) to the outside seal lip.

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Illustration 2	g02212801
(A) Cylinder Head Assembly (B) Cylinder Rod

2. Attach a suitable lifting device to the cylinder head assembly (A). Attach a suitable lifting device to rod (B). Slide cylinder head assembly (A) onto rod (B). The weight of the cylinder head assembly (A) for the S365B or the VHS-60/3 is approximately 113 kg (250 lb). The weight of the cylinder head assembly (A) for the S385B or VHS-70/3 is approximately 136 kg (300 lb). The weight of the rod (B) for the S365B or the VHS-60/3 is approximately 358 kg (790 lb). The weight of the rod (B) for the S385B or VHS-70/3 is approximately 431 kg (950 lb).

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Illustration 3	g02213074
(C) Piston (13) O-ring Seal

3. Install O-ring seal (13) to piston (C) .

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Illustration 4	g02213163
(C) Piston (T3) Bolt ( 6V-8336 Bolt ) quantity of 2

Note: Be sure to utilize a suitable work surface that is flat and level in order to support piston (C) .

4. Apply Tooling (T6) to the threads of rod (B) and piston (C). Install Tooling (T3) to piston (C). Use a suitable pry bar in order to rotate piston (C). The weight of piston (C) for the S365B or the VHS-60/3 is approximately 73 kg (160 lb). The weight of piston (C) for the S385B or the VHS-70/3 is approximately 113 kg (250 lb). Install piston (C). Be sure that piston (C) is fully seated onto rod (B). Remove Tooling (T3) .

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Illustration 5	g02213256
(C) Piston (14) Bolts quantity of 2 (15) Lock (16) Ring half quantity of 2

5. Apply Tooling (T4) to bolts (14). Install ring halves (16), lock bar (15), and bolts (14). Tighten bolts (14) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).

Note: Make sure that lock bar (15) does not extend beyond the end surface of the rod. The end surface of the rod acts as the end stop. Make sure that lock bar (15) does not contact the face of piston (C).

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Illustration 6	g02213293
(2) Seal Assembly (3) Wear Ring quantity of 3 (4) Wear Ring quantity of 2

6. Install wear rings (3 and 4) and seal assembly (2) .

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Illustration 7	g02213314
(A) Cylinder Head Assembly (B) Rod Assembly (C) Piston Assembly () Cylinder Assembly

7. Attach a suitable lifting device to rod assembly (B) in order to install the following items into the hydraulic cylinder assembly (17) : rod assembly (B), cylinder head assembly (A) and piston assembly (C). The combined weight of the rod assembly (B), cylinder head assembly (A), and piston assembly (C ) for the S365B or VHS-60/3 is approximately 544 kg (1200 lb). The combined weight of rod assembly (B), cylinder head assembly, (A) and piston assembly (C) for the S385B or VHS-70/3 is approximately 680 kg (1500 lb).

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Illustration 8	g02217673
(D) Existing bolts: S365B or VHS-60/3 part number 175-6608 Bolt quantity of 27S385B or VHS-70/3 part number 172-7682 Bolt quantity of 29

8. Apply Tooling T5 to bolts (D) and install bolts (D). Tighten bolts (D) to a torque of 700 N·m (520 lb ft) for the S365B or VHS-60/3. Tighten bolts (D) to a torque of 850 N·m (620 lb ft) for the S385B or VHS-70/3.

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Illustration 9	g02217733
(17) Cylinder Assembly (18) Bearing Sleeve quantity of 2

Note: Orientation of bearing sleeves (18) is critical for installation of cylinder into shear housing. The flat surfaces of the bearing sleeves (18) must be held parallel to the cylinder assembly (17) .

9. Install bearing sleeves (18) to cylinder assembly (17) .

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Illustration 10	g02217814
(E) Existing hose (F) Existing hose (G) Existing hardware (20) Rectangular seal quantity of 2 (21) O-ring seal

10. Install existing fitting assembly with new seal (21) and existing hose (F). Install existing hose (E) with new seals (20) and existing hardware (G) .

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Illustration 11	g02218195
(G) Existing hardware (H) Existing Speed Control Valve (22) O-ring seal quantity of 3

11. Install the new seals (22). Use two people in order to install the existing speed control valve (H). Install existing bolts (G). The weight of the speed valve (H) is approximately 29 kg (65 lb).

12. Install the hydraulic cylinder into the shear housing. Refer to Disassembly and Assembly,, RENR4474 or RENR4476, "Hydraulic Cylinder-Install" for detailed instructions. Apply Tooling (T6) to inside of new trunnion bearings (24) with new grease fittings (23) to complete installation.

13. Lubricate the pivot pin for the cylinder and lubricate the one fitting on the end of the cylinder. Refer to Operation and Maintenance Manual, SEBU7915, "Bushings-Lubricate".

Housing-Repair Weld Procedure

Welding Requirements

Welding quality is critical to the success of the installation process. Welds must be smooth and continuous. Do not undercut the welds. No overlap is allowed. Grind the ends of the welds smooth.

Prepare the metal for welding. Refer to ""Prepare the Metal for Welding" ". Refer to the illustrations in this special instruction for welding symbols.

For more welding information, consult Caterpillar Service Welding Guide, SEBD0512.

Preparing the Metal for Welding

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

All grease, paint, and foreign objects must be removed before welding. Any of these materials will discharge gas which will cause porosity in the weld deposit. Water and rust will cause hydrogen embrittlement. Hydrogen embrittlement causes cracks in the weld deposit.

Remove foreign objects with a wire brush, a buffer, or a grinder. Shot blasting the appropriate areas will also remove foreign material.

Remove any oil or grease with an approved solvent.

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

1. Use welding material according to AWS 5.18 RE70S-6/DIN8559 SG-3 to add fillet weld to housing

   Do not weld in windy conditions. Do not weld when temperatures are below 16°C (60°F).

   Penetration characteristics may vary greatly depending on the following conditions:

   • Electrode diameter

   • Shielding gas

   • Welding current

   • Plate thickness

   The following items also affect the welds:

   • Geometry of welded joints

   • Surface conditions

   • Composition of the base metal and of the electrode

   A root pass should be applied before each weld is finished.

   Maintain a 3 mm (0.12 inch) minimum root opening on all cross welds and circle welds.

   All welds to the stick must be welded in the direction from the rear of the stick toward the front of the stick.

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Illustration 12	g02218453

2. Utilize two weld passes to increase the existing fillet weld. Weld sequence should follow path from (A) to (B) and (B) to (C). Repeat. The result should be a 12 mm (0.5 inch) fillet on the inside of the eye.

3. Remove any weld splatter or debris from the weld and from the welded area.

4. Complete steps 2 to 4 on the opposite side of housing.

5. Allow the weld to cool to ambient temperature. Do not use forced air to speed cooling process.