TH62, TH63, TH82, TH83 and TH103 Telehandlers Machine Systems Caterpillar

Removal Procedure

Start By:

1. Release the pressure that is locked in the telescoping cylinder. Refer to Disassembly and Assembly, "Load Control Valve (Telescoping Cylinder) - Remove".

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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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 work tools have been lowered to the ground, and the 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.

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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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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 Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Note: Put identification marks on all hoses, on all tubes and on all cylinders for installation purposes. Plug all hoses, all tubes and all cylinders in order to prevent fluid loss and help keep contaminants from entering the system.

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Illustration 1	g00710898

1. Partially extend the boom and support the boom with Tooling (A) in order to position the boom in the horizontal position.

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Illustration 2	g00710899

2. Use Tooling (B) to remove two snap rings (1). Use a copper hammer and a suitable punch to remove pin (2) .

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Illustration 3	g00748539

3. Remove two bolts (3), the washers and rear cover (4) from the boom.

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Illustration 4	g00711090

4. Remove six bolts (5), the washers, the plates and six half clamps (6). Disconnect four tubes (7) and move aside.

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Illustration 5	g00746765

5. Remove the left side half clamp (8), the plate, the washer and the bolt. Disconnect two tubes (9) and move aside. Remove two bolts (10), the washers and the nuts that are used to secure the lower flange of bracket (11) onto the boom. Remove six bolts (12), the washers and the nuts that are used to secure the upper flange of bracket (11). Remove four bolts (13), the washers and plate (14) .

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Illustration 6	g00746687

6. Use a suitable pry bar to raise the rear of telescoping cylinder (15). At the same time use a second person to remove bracket (11) and shims (17). Lower the telescoping cylinder and remove two tubes (16) .

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Illustration 7	g00746689

7. Install plate (14), four bolts (13), and the four washers onto telescoping cylinder (15). Attach a suitable sling to telescoping cylinder (15) and to a suitable lifting device in order to support the telescoping cylinder. Use the lifting device to raise the rear of telescoping cylinder (15) and partially withdraw the telescoping cylinder from the boom.

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Illustration 8	g00746763

8. Withdraw telescoping cylinder (15) approximately halfway out of the boom and use Tooling (C) to support the rod end of the telescoping cylinder. Move the sling to the center of telescoping cylinder (15) and rotate the telescoping until the eye at the rod end is in the vertical position. Continue to withdraw the telescoping cylinder from the boom. The weight of telescoping cylinder is approximately 285 kg (628 lb).

Disassembly and Assembly Procedure

Remove the External Cylinder Components

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Illustration 9	g00757170

1. Remove four bolts (3), the washers and the nuts in order to remove two supports (2) from telescoping cylinder (1) .

2. Use Tooling (A) to remove two bushings (4) from the rod eye of telescoping cylinder (1) .

Install the External Cylinder Components

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Illustration 10	g00757170

1. Install four bolts (3), the washers and the nuts in order to attach two supports (2) onto telescoping cylinder (1) .

2. Use Tooling (B) and a hammer to install two bushings (4) into the rod eye of telescoping cylinder (1) .

Disassembly and Assembly of the Cylinder

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Illustration 11	g00757436

1. Firmly secure the cylinder onto a bench. Use tooling (C) and a suitable 1in square drive wrench in order to remove the end cover and install the end cover.

2. Firmly secure the rod onto Tooling (D). Remove the locking screw for the piston. Use Tooling (D) to remove the piston and install the piston.

3. Refer to Specifications, " Telescoping Cylinder" for the required torque value.

Installation Procedure

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Illustration 12	g00746763

1. Attach a suitable sling onto telescoping cylinder (15) and to a suitable lifting device in order to support the telescoping cylinder. The weight of telescoping cylinder is approximately 285 kg (628 lb). Install telescoping cylinder (15) approximately halfway into the boom and use Tooling (C) to support the rear of the telescoping cylinder.

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Illustration 13	g00746689

2. Move the sling to the rear of telescoping cylinder (15) and rotate the telescoping until the eye at the rod end is in the horizontal position. Use the lifting device to install the telescoping cylinder into position inside the boom.

3. Remove plate (14), four bolts (13), and the four washers from telescoping cylinder (15). Remove the sling.

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Illustration 14	g00710899

4. Use a copper hammer to install pin (2). Use Tooling (B) to install two snap rings (1).

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Illustration 15	g00746687

5. Install two tubes (16). Use a suitable pry bar to raise the rear of telescoping cylinder (15). At the same time use a second person to install bracket (11) and shims (17). Lower the telescoping cylinder and remove the pry bar.

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Illustration 16	g00746765

6. Connect two tubes (9). Apply a small amount of Tooling (D) onto two bolts (10). Install two bolts (10), the washers and the nuts that are used to secure the lower flange of bracket (11) onto the boom. Apply a small amount of Tooling (D) onto six bolts (12). Install six bolts (12), the washers and the nuts that are used to secure the upper flange of bracket (11). Apply a small amount of Tooling (D) onto four bolts (13). Install four bolts (13), the washers and plate (14). Install the left side half clamp (8), the plate, the washer and the bolt.

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Illustration 17	g00711090

7. Install six half clamps (6), the plates, the washers and six bolts (5). Reconnect four tubes (7) .

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Illustration 18	g00748539

8. Install rear cover (4), two bolts (3), and the washers onto the boom.

9. Remove Tooling (A) .

End By: Reset the pressure for the load control valve. Refer to Disassembly and Assembly, "Load Control Valve (Telescoping Cylinder) - Install".