Using 6V4947 Hydraulic Cylinder Repair Stand And 6V4948 Kit{0600} Caterpillar

Hydraulic Cylinder Repair Stand Features:

* Designed to handle all current production Caterpillar Hydraulic Cylinders.

* Rigid frame construction is designed to resist 10,000 lbs. ft. of torque.

* Heavy duty end post fixture holds the "eye" of the cylinder rod stationary.

* Cylinders are mounted on a heavy duty carriage assembly.

* The power cylinder on the travel cylinder carriage has an 18-inch stroke.

* The repair stand is 20 feet long and can handle a full cylinder extension of up to 13 feet in length.

* Designed for a convenient working height with adjustable legs for precise vertical alignment and an oil trough for holding excess hydraulic oil.

* Supplied with positioning fixture for the torque multiplier.

* The recommended Torque Multiplier for the repair stand is the 1P850 unit with accessories.

* The recommended power supply is the 3S6224 (115V) or 8S8053 (230V) Electric Hydraulic Pump.

Introduction

The 6V4947 HYDRAULIC CYLINDER REPAIR STAND is a shop service item used to disassemble hydraulic cylinders for repair purposes such as resealing or repacking.

The main function of the unit is to restrain the cylinder barrel during disassembly. The rod eye is locked on the end post and the cylinder cap fasteners are removed. The travel carriage is then used to pull the piston shaft free of the barrel. Support stands are used to keep the shaft in alignment with the cylinder barrel.

Additionally, this unit is designed to withstand the high torsion necessary for replacing the piston nut on hydraulic cylinders as well as the threaded crowns on certain types of cylinders.

The unit is designed to withstand 10,000 lb. ft. of torsion for replacing the nut on a piston and 2,000 lb.ft. for removing the threaded crown from the cylinder.

Cylinders from 3 1/2" O.D. to 13 1/2" O.D. can be repaired. Rod extensions range from 12" to 13" in length.

Specifications

THE HYDRAULIC PUMP UNIT AND THE TORQUE MULTIPLIER ARE NOT OFFERED AS STANDARD WITH THE HYDRAULIC CYLINDER REPAIR STAND.

The recommended power supply is the Caterpillar 3S6224 (115V) or 8S8033 (230V) Hydraulic Pump Unit.

The recommended Torque Multiplier is the Caterpillar 1P850 unit with accessories.

For the best application, these accessories should be included.

The parts listed above are available through the Caterpillar parts system.

Specifications are subject to change without notice.

Installation

Operation And Storage Areas

The cylinder repair stand should be located so that it fits into your shop's work flow system. Additional consideration for its placement should include:

1. The proper electrical supply for the equipment's power supply.

2. Adequate working and storage space that permits the free handling of all types of cylinders.

3. Adequate support components for the physical movement of the cylinders.

4. Adequate lighting and ventilation for the operator.

Parts Check

Before the installation begins, an inventory check of the equipment should be made to see if any items have been damaged or lost while in transit.

Machine Accessories

For information concerning standard machine parts, reference the various assembly illustrations in the replacement parts section or consult the Parts Order Desk as indicated on page 20.

Setting Up The Equipment

1. After the equipment components have been uncrated, locate them near the location chosen for operating the equipment.

2. The main frame should be suspended (VERY CAREFULLY) so that the five (5) leg assemblies (P.N. 70 052 000) can be connected with the appropriate fasteners.

(REF. MAIN ASSEMBLY ILLUSTRATION ON PAGE 21.)

NOTE: THE LEGS ARE CROSS-MARKED TO THE MOUNTING POSITIONS ON THE FRAME.

3. With the legs attached, set the frame in position on the floor and level it. It is critical to proper equipment operation that the frame be level along its entire length. Use the adjustment bolts on the legs for this and secure them with the locking nuts.

IMPORTANT ONCE THE FRAME HAS BEEN LEVELED (BUBBLE GAUGE), THEN THE OPERATOR HAS AN ACCURATE WORK BENCH ON WHICH HE MAY LOCATE AND LEVEL THE CYLINDER TO THE END POST. WITHOUT PROPER LEVELING, THE CYLINDER AND ROD COULD TWIST AND BIND DURING EITHER DISASSEMBLY OR REASSEMBLY.

The first major component that is added to the repair stand must be the cylinder carriage assembly (P.N. 70 020 000). Set the carriage in the center of the bed with the clevis pin end away from the end post weldment. Roll the carriage forward until the front lower bearings drop into the pre-cut slots in the bed channel. Next, roll the carriage to the far end of the bed and let the bearings on the clevis end of the carriage drop into the slots pre-cut into that end of the bed.

NOTE: THE CLEVIS PIN (ITEM 10 ON PAGE 26 MUST BE IN PLACE ON THE CARRIAGE BEFORE THE BACK END OF THE CARRIAGE IS FITTED INTO THE SLOTS.

Move the cylinder carriage forward towards the front end (end post end) of the repair stand.

5. The cylinder mounting assembly (P.N. 70 010 000) should be located next. Reference the illustration on page 24 for component identification.

a. Unbolt the fasteners (items 8&9) so that the cylinder (item 1) may be freed from the two (2) cylinder mount weldments.

b. Unscrew the rod adapter (item 4) from the cylinder shaft.

c. Remove both cylinder mount weldments (items 2 & 3) from the cylinder.

d. Slip the rod end cylinder mount weldment (item 2) into the frame slots on the back end (furthest from the end post weldment) of the main frame and move it about six (6) feet down the center channel.

e. Slip the reaction end cylinder mount weldment (WITH THE HYDRAULIC PACKAGE MOUNT LOOSELY ATTACHED) into the same slot and move it forward a short distance.

f. Place the hydraulic cylinder (item 1) between the two mount weldments and use the fasteners that were removed earlier to reconnect the cylinder assembly.

g. Screw the rod adapter (item 4) back onto the end of the cylinder shaft.

h. Slide the entire cylinder assembly forward until the rod adapter (item 4) slips between the clevis plates of the carriage assembly. Then, slide the 1" dia. pin (item 10 on page 26 through the slotted hole of the rod adapter. Center the pin and then tighten the two set screws on the clevis plates.

6. The hydraulic package mount (P.N. 70 070 000) can now be attached to the cylinder mounting assembly (P.N. 70 010 000) as shown on page 24.

a. The entire hydraulic package mount will slip over the lip of the main frame on the operator's side as shown in the illustration on page 34.

b. Use the 1/2" fasteners (items 2 and 3) to attach the roller mounting angle (item 5) to the hydraulic package mount (item 10).

c. There is room for adjustment of the hydraulic package mount to the cylinder mounting assembly. The entire hydraulic package (power supply) mount must ride smoothly along the lip of the main bed frame.

7. Use the illustration on page 38 to complete the hydraulic hookup for the relief valve assembly. Connect the hydraulic hoses from your power supply to the couplers (item 17) located under the mounting angle.

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THE RELIEF VALVE (ITEM 9 ON PAGE 38) IS PRESET AT THE FACTORY FOR 3000 PSI. ANY TAMPERING (BROKEN SEAL) WITH THE VALVE COULD RESULT IN PERSONAL INJURY.

8. The interior components of the end post assembly (P.N. 70 060 000) should now be added to the end post weldment. (REFERENCE PAGES 31 AND 32)

a. Place one (1) of the bronze thrustwashers (item 13) inside the end post tube (item 2) and set it over the hole in the bottom.

b. Slip the lifting tube (item 7) and shaft (item 8) assembly into the larger tube so that the threaded end of the shaft extends through the hole in the base.

c. Slip the second bronze thrustwasher (item 13) over the shaft and follow this with the handwheel (item 12). Insert a 1/4" dia. roll pin through the predrilled holes in both the handwheel and the shaft.

d. Slip a 3/4" I.D. flat washer (item 18) over the remaining portion of the shaft and secure it with a 3/4"-10 NC hex nut.

Operational Instructions

The 6V4947 HYDRAULIC CYLINDER REPAIR STAND has been designed to handle the full range of current Caterpillar production cylinders. The instructions that follow have been prepared to acquaint the operator with the general operational principles of the repair stand so that he may adapt them as necessary to fit the requirements of any given cylinder.

V-Block Assemblies

There are two (2) V-Block Assemblies used on the repair stand. During each application they should be located on the carriage assembly in positions that will give the greatest spread (cylinder support) while still holding the cylinder level to the bed and frame.

1. Secure the V-Blocks to the carriage assembly (P.N. 70 020 000) with 1/2"-13 NC socket head cap screws X 1" lg. (P.N. 70 790 045)

2. For certain offset cylinders, a set of shims is supplied to raise either V-Block Assembly from 1/8" to 2 1/4". See the listing on page 21 for the correct part numbers and descriptions.

NOTE: IF OFFSET TYPE CYLINDERS REQUIRE THE USE OF SHIMS UNDER THE V-BLOCKS, BE CERTAIN THAT A PROPERLY SIZED BOLT IS USED TO HOLD THE ASSEMBLY SECURE. THE BOLTS RANGE IN LENGTHS OF 1", 1 1/2", 2", 2 1/2", 3" & 3 1/2".

3. Each V-Block Assembly has its own chain tightener assembly. Reference the illustrations on pages 36 & 40 during the following explanation for their proper use.

a) The illustration on page 40 shows the chain assembly in its "LOCKED" position. This is the final position which holds the cylinder secure against the teeth of the V-Block Assembly.

b) In order to get to this position, start with the chain completely free of the V-Block Assembly.

NOTE: USE STEP b FOR THE INITIAL SETUP ONLY.

1. Position the cylinder in the V-blocks with the ports in a downward position (if possible). Remove all covers or plugs from the parts; failure to do so will make it impossible to remove the cylinder and rod.

a) The bar knob (item 8 on page 36) should be backed off as far as possible.

2. Slip the open end of the chain (item 16 on page 40) through the guide block (item 2 on page 36) and pull it parallel to the locking handle until it hangs down out of the end of the block. Until the cylinder is positioned, the other end of the chain (with chain end, P.N. 70 000 005) should be laid back over the knob end of the V-block.

NOTE: IN ORDER TO PREVENT THE CHAIN FROM ACCIDENTALLY SLIPPING THROUGH THE GUIDE BLOCK, A BOLT & NUT SHOULD BE ATTACHED TO THE OPEN END OF EACH LENGTH OF CHAIN.

3) After the cylinder has been positioned on the V-Blocks, the top section of chain should be laid over the top of the cylinder and the chain end slipped into the locking groove as shown in the illustration below. Pull the other end of the chain to take up the slack.

4. When all the slack has been removed, depress the locking handle (item 15 on page 36) while pulling the chain tight.

5. With continued pressure on both the chain and locking handle, tighten down the bar knob (item 8 on page 36) until the chain is securely locked in place.

6. The cylinder is now secured to the V-Block Assembly. Repeat the procedure with the second chain assembly.

c) In order to release the chain, back the knob off while pulling out on the locking handle. As soon as it loosens, push the pin removal plate (item 11 on page 40) towards the center of the V-Block and the chain end will slip loose thereby freeing the cylinder.

End Post Assembly: Locking The Cylinder Rod Eye In Position.

The end post assembly is used to lock the cylinder rod eye in place so that the cylinder barrel may be separated from the cylinder head and rod assembly.

1. The eight inch chuck is attached to the end plate of the end post adjustment shaft with three 1/2"-13 socket head cap screws X 1 3/8" lg.

2. Depending upon the rod eye's I.D. on the cylinder being worked, either the large P.N. 70 110 002) or the small (P.N. 70 110 001) chuck jaws should be bolted to the chuck

3. Pull the carriage stop pin (item 24 on page 22) and the entire cylinder can be rolled down the frame until the rod eye is located over the chuck assembly.

NOTE: BEFORE THE CHUCK ASSEMBLY IS RAISED TO LOCK INTO THE ROD EYE, BE CERTAIN THAT THE CHUCK JAWS HAVE BEEN CLOSED DOWN FAR ENOUGH TO CLEAR THE I.D. OF THE EYE.

4. Use the handwheel (item 12 on page 32) to raise the chuck assembly until it rests against the bottom of the rod eye with the chuck jaws inside the eye.

5. Use the chuck adjustment tool to lock the chuck jaws against the inside area of the rod eye.

6. Again, depending upon the size of the rod eye and the clearance space between the chuck jaws in their tightened-down position, insert the appropriate cam lock shaft (P.N. 70 000 001-small)(P.N. 70 000 002-large) into the top plate of the end post assembly.

NOTE: ALWAYS USE THE LARGER SHAFT (P.N. 70 000 002) WHENEVER POSSIBLE.

Slip the shaft through the rod eye and chuck jaws until it drops between the roll pins in the top plate of the end post vertical adjustment shaft. Turn the shaft clockwise until it locks itself in place.

7. Secure the rod eye with the button plate and the appropriate fasteners. Reference the main assembly illustration on page 22.

a. A rod eye "WITHOUT" the spherical bearing uses the button plate (P.N. 70 000 010) turned so that the adjustment screws are UP and therefore clear of the rod eye facing surface.

1) With the two inch (2") cam lock shaft, use a 2" hex nut (P.N. 70 790 192) with a 2" washer (P.N. 70 790 190).

2) With the one inch (1") cam lock shaft, a spacer (P.N. 70 000 009) is placed through the center hole of the button plate and then all components are secured with a 1" hex nut (P.N. 70 790 193) and a 1" washer (P.N. 70 790 191).

b. A rod eye "WITH" a spherical bearing uses the button plate (P.N. 70 000 010) turned so that the adjustment screws may be positioned to bear against the face side of the rod eye at a point that is furthest from the center hole.

NOTE: THE HEADS OF THE CONTACT BOLTS MUST ALL CONTACT THE FACE SURFACE TO ENSURE THAT TORQUING PRESSURE IS DISTRIBUTED EVENLY ALONG THE ROD EYE.

8. On certain types of cylinders (NO ROD EYE), a special adapter (FT 649) must be used to secure the end of the shaft to the end post assembly.

Operation Of The Cylinder Repair Stand For Cylinder Disassembly

1. The cylinder head retaining bolts should now be loosened and removed from the cylinder and the repair stand.

2. Replace the carriage stop pin (item 24 on page 22) in its guide tube.

3. Extend the ram on the cylinder mounting assembly (P.N. 70 010 000) until the carriage stop pin drops into one of the pre-drilled holes in the base of the bed frame.

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THE RELIEF VALVE (ITEM 9 ON PAGE 38) FOR THE POWER SUPPLY SYSTEM IS PRESET AT THE FACTORY FOR 3000 PSI. ANY TAMPERING (BROKEN SEAL) WITH THE VALVE COULD RESULT IN PERSONAL INJURY.

4. Reverse the direction on the power supply pump and retract the ram on the cylinder mounting assembly. This will pull the cylinder shell away from the end post, thereby extending the work cylinder's ram shaft.

5. When the cylinder mounting assembly's ram has bottomed out, again remove the carriage stop pin, reverse the direction of the ram and extend it until the carriage stop pin (which is replaced in its slot after the ram extension is started) drops into the next hole along the main frame's bed.

6. Continue the pushing/pulling process until the cylinder shaft starts to bottom out against the cylinder head. When the head (cap) starts to separate from the cylinder, install either one or two Rod Support Assemblies (P.N. 70 040 000) under the rod and adjust them to hold it parallel to the cylinder center line.

7. With the rod support assemblies in position (see below), continue pulling until the cylinder and rod are fully separated.

Rod Support Assemblies

Reference page 29 for descriptions of all components for the rod support assemblies. With the assembly in its collapsed or closed position, place the unit over the slot in the base of the frame. Use the adjustment nut (item 6) to raise the shaft (item 5) until the "V" rest is touching the cylinder rod. After checking to be certain that the unit is centered, spread the guide bars (item 4) until they contact the channel edges in the bed. Tighten down the 3/8"-16 NC hex head cap screws X 3/4" lg. (item 10).

Torque Multiplier Mounting Assembly

Reference page 27 for the descriptions of all the components of the torque multiplier mounting assembly.

1. Place the Torque Multiplier Mounting Stand (P.N. 70 030 000) into the main frame bed between the cylinder and the extracted rod.

NOTE: USE AN OVERHEAD JIB ASSEMBLY TO LIFT THE TORQUE MULTIPLIER MOUNTING STAND ASSEMBLY BY THE LIFTING EYE ON THE TOP FRAME.

2. Once located on the bed frame, raise the mounting plate weldment (item 2 on page 27) until the torque multiplier (not shown) is of the proper height to slip over the piston retaining nut.

3. Select the proper socket for the particular piston retaining nut; then, push the entire mounting assembly toward the nut until the two pieces are securely joined.

4. Lock the mounting stand to the bed frame with the two (2) locking wedge assemblies (R.H. 70 034 000 & L.H. 70 035 000). Start with the wedges spread as far apart as possible and then close them until the top piece contacts the base of the mounting stand. A sharp tap on the wide end of the top bar will lock the wedge in place. Use a nylon tipped or rubber hammer on the wedge assemblies.

5. Use the torque multiplier to remove the retaining nut. Once the nut is freed, a light tap on the small ends of the locking wedges will free the mounting stand and the entire assembly can be pushed free of the cylinder rod.

6. After all repair work has been completed on the packings of the cylinder rod and the new or rebuilt components have been properly located, the torque multiplier mounting stand should be repositioned to the retaining nut so that it may be properly retorqued.

7. Clear the mounting stand assembly from the rod nut and remove the entire assembly from the bed.

Operation Of The Cylinder Repair Stand For Cylinder Reassembly

The procedures used in reassembling the cylinder shaft to the cylinder barrel are simply the reverse of the disassembly process. However, certain cautions must be stressed; these include:

1. The cylinder barrel and rod must be level to the bed and they must be on the same centerline. Otherwise, when they are pressed together, they may wedge and damage the cylinder components and possibly freeze up the entire assembly.

2. Before the piston can be inserted into the cylinder barrel, move them until they almost touch and then visually inspect the items to be certain that the alignment is correct.

Maintenance

Power Unit

Be sure to follow the manufacturers recommendations for fluid type and replacement procedures.

Working Cylinder: P.N. 70 750 001

The cylinder has a shock rating of 5000 PSI, BUT, its maximum operating pressure is pre-set at 3000 PSI.

Carriage Rollers

Use a chassis lubricant on the nut ends of the carriage rollers once a month.

End Post Assembly

Raise the end post to its highest position once a month and lubricate the shaft with SAE 30 oil.

Troubleshooting

The 6V4947 HYDRAULIC CYLINDER REPAIR STAND has been designed for simplicity of operation and maintenance. With its power unit's relief valve pre-set at a safe operating pressure (3000 PSI), the problems that could develop with the unit will probably be mechanical.

Items to be checked on the cylinder repair stand on at least a weekly basis are:

Cylinder Mounting Assembly: P.N. 70 010 000

Fasteners should be checked and tightened if they have worked loose. Special care should be taken for the fasteners that hold the hydraulic package mounting arm (item 12 on page 24) in place. If the fasteners continue to work loose, use liquid locktite to seal them in place.

Torque Multiplier Mounting Assembly: P.N. 70 030 000

Fasteners (especially set screws) should be checked and tightened if they have worked loose. If the lifting mechanism is working improperly, check for a loose or broken chain or possibly a sheared roll pin.

End Post Assembly: P.N. 70 060 000

If the end post raises too slowly or not at all, coat the shaft (item 7 on page 32) with SAE 30 oil and check the roll pin (item 16) to see if it has been sheared.

Hydraulic Package Mount: P.N. 70 070 000

Fasteners should be checked and tightened if they have worked themselves loose.

Chain Tightener Assembly: P.N. 70 080 000

This assembly is very critical to the operation of the V-Block assemblies. The fasteners should be checked each time the equipment is used. Clean all dirt and paint chips away from critical sliding areas and specifically from the shaft (item 4 on page 36) and threaded block (item 3).

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Model HCRS Relief Valve Assembly: P.N. 70 112 000 Inspect for leaking fittings. Remember, the relief valve (item 9) is pre-set at the factory for 3000 PSI. Any tampering (broken seal) with the valve could result in personal injury.

Fixed V-Block Assembly: P.N. 70 100 000

The problems with the chain locking mechanism are covered under Chain Tightener Assembly (described above). Other than the positioning of the chain in the locking mechanism (see illustration on page 40) and the placement of the height adjustment shims, the only problem with this assembly should be loosened fasteners.

Special Problems: Easily Overlooked Handling Mistakes

1. Rod eye will not lock securely in place.

a. Incorrect shaft being used.

b. Correct shaft incorrectly positioned in end post.

c. Button plate incorrectly used.

1) The flat surface of the button plate (no bolts) faces down on the bearing-less rod eyes.

2) The buttons (bolts) must be properly located against the flat surface of the rod eye when it is fitted with a spherical bearing.

d. Button plate spacer not in place when using the small shaft.

e. Wrong size jaw bits being used.

f. Chuck is not fully closed.

2. The Torque Multiplier Mounting Stand will not lock in place; locking wedges being improperly used.

3. The Chain Assembly will not lock down; locking handle not being properly positioned.

4. The Cylinder Mounting Assembly will not move freely in the track of the bed.

a. The locking pin is still in the locking slot.

b. Foreign material in the bed is blocking the travel path of the assembly.

5. The Hydraulic (working) cylinder is not functioning properly.

a. Power unit is not plugged in.

b. Directional lever on the Power Unit is in the wrong position.

c. The Relief Valve has been tampered with.

Replacement Parts

How To Order Parts

Write or phone:

Phone: (415) 692-5010

Telex: 349-414 Cable: SALENCO Burlingame

1) Part Number(s) listed on the component or assembly illustration. (Never order by Item Number or Code Number.)

2) Complete Part Description.

3) Serial Number found on the metal label of each machine.

4) State quantity desired.

5) State when delivery is required.

6) List the manual identification number 79 01 11 70.

Selling prices will be furnished on request, or parts will be shipped at prevailing prices and you will be billed accordingly.

Model H C R S Main Assembly Parts Listing (P.N. 70 000 000)

Main Assembly: P.N. 70 000 000

Cylinder Mounting Assembly (P.N. 70 010 000) Parts Listing

Cylinder Mounting Assembly (P.N. 70 010 000)

Carriage Assembly (P.N. 70 020 000)

Carriage Assembly (Parts Listing P.N. 70 020 000)

Torque Multiplier Mounting Assembly (P.N. 70 030 000)

Vertical Chain Adjustment Assembly (P.N. 70 036 000)

Rod Support Assembly (P.N. 70 040 000)

Factory Suggested Spare Parts One Year Supply

End Post Assembly Parts List (P.N. 70 060 000)

End Post Assembly P.N. 70 060 000

Hydraulic Package Mount (P.N. 70 070 000)

Hydraulic Package Mount (P.N. 70 070 000)

Chain Tightener Assembly (P.N. 70 080 000)

Chain Tightener Assembly (P.N. 70 080 000)

H C R S Relief Valve Assembly (P.N. 70 112 000)

H C R S Relief Valve Assembly (P.N. 70 112 000)

Show/hide table

THE RELIEF VALVE (ITEM 9) IS PRE-SET AT THE FACTORY FOR 3000 PSI. TAMPERING (BROKEN SEAL) WITH THE VALVE COULD RESULT IN PERSONAL INJURY.

Stationary V-Block: Cylinder Restrainer (P.N. 70 100 000)

Stationary V-Block: Cylinder Restrainer (P.N. 70 100 000)

Frame Main Assembly (P.N. 70 050 000)

Bed Weldment (P.N. 70 051 000)

Bed Weldment Sequence (P.N. 70 051 000)

Leg Assembly (P.N. 70 052 000)