- Caterpillar Products: All
Introduction
Important Safety Information
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| Illustration 1 | g02139237 |
Think Safety | |
European Union Compliant, CE marked
Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.
Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.
A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.
The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.
Literature Information
This manual should be stored with the 265-4177 Service Group and/or the 265-4209 Service Group .
This manual contains safety information, operation instructions, and maintenance information.
Some photographs or illustrations in this publication show details that can be different from your service tool.
Continuing improvement and advancement of product design may have caused changes to your service tool which is not included in this publication. Read, study, and keep this manual with the tooling.
Whenever a question arises regarding your service tool or this publication, consult your Cat dealer for the latest available information.
Safety Section
The Safety Section lists basic safety precautions. Read and understand the basic precautions listed in the Safety Section before using this service tool.
Assembly
The Assembly Section provides the instructions to assemble the tooling.
Operation
The Operation Section is a reference for the new operator and a refresher for the experienced operator.
Photographs and illustrations guide the operator through correct procedures for using the 265-4177 Service Group and/or 265-4209 Service Group to install sensors in position-sensing hydraulic cylinders.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and its capabilities.
Maintenance
The Maintenance Section is a guide to equipment care.
Safety Section
Safety Icon Nomenclature
Personal Protection/Important Information
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| Illustration 2 | g02166423 |
Personal Protection/Important Information | |
Prohibited Action
| No Smoking |
Hazard Avoidance
| Crushing Hazard (foot) |
| Crushing Hazard (hand) |
| Pinch Point |
| Fire Hazard |
| Electrical Shock - Hazard |
|
| Fire Hazard |
Safety Section
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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure. |
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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. |
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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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. |
| NOTICE |
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To prevent dirt and contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. This action also lessens the chance of oil spills. |
Introduction
265-4177 Service Group
The 265-4177 Service Group is used to install sensors in clevis-mounted, position-sensing hydraulic cylinders (PCS). Use of the service group ensures accurate alignment of the sensor. It also reduces the possibility of damage to the seal on the sensor and reduces the chances of damaging the cylinder bore during installation.
The 265-4177 Service Group contains all the components necessary to service the current clevis-mounted, PCS cylinders. The components included in the 265-4177 Service Group are listed in this manual. The components are also available for purchase separately in order to acquire the tooling, as needed.
Refer to the Disassembly and Assembly manual for each specific hydraulic cylinder for complete instructions on sensor installation.
265-4209 Service Group
The 265-4209 Service Group is used to install sensors in trunnion-mounted, position-sensing hydraulic cylinders (PCS). Use of the service group ensures accurate alignment of the sensor and reduces the possibility of damage to the seal on the sensor.
The 265-4209 Service Group contains all the components necessary to service the current trunnion-mounted PCS cylinders. The components included in the 265-4209 Service Group are in this manual. The components are also available for purchase separately.
Refer to the correct Disassembly and Assembly manual for complete instructions on sensor installation of each hydraulic cylinder.
Additional Contact Information
For further assistance with ordering tools, or for information on other specialized tooling, contact:
USA: 800-542-8665
International: 1-309-578-7372
E-mail: dealerservicetool_hotline@cat.com
265-4177 Service Group for Clevis-Mounted Hydraulic Cylinders
Nomenclature
| Item | Part No | Description | Qty |
| 1 | 265-4178 (1) | Case Group (Includes 4C-9664 Tool Case As and 265-4179 Foam Insert ) | 1 |
| 2 | 265-4180 | Installer Group | 1 |
| 3 | 265-4181 | Sleeve | 1 |
| 4 | 265-4182 | Sleeve Removal Tool | 1 |
| 5 | 265-4183 | Driver Group (includes driver cap and bolt) | 1 |
| 6 | 265-4184 | Extension Tube 50 cm (19.7 inch) | 2 |
| 7 | 265-4185 | Extension Tube 75 cm (30 inch) |
3 |
| 8 | 265-4186 | Coupler Group | 2 |
| 9 | 8T-0269 | M6 x 1 Bolt | 6 |
| 10 | 265-4187 | Support Disc Group | 1 |
| 11 | 265-4188 | Support Disc 266.50 mm (10.49 inch) |
1 |
| 12 | 265-4189 | Support Disc 253.80 mm (9.99 inch) |
1 |
| 13 | 265-4190 | Support Disc 234.75 mm (9.24 inch) |
1 |
| 14 | 265-4191 | Support Disc 219.80 mm (8.65 inch) |
1 |
| 15 | 265-4192 | Support Disc 196.65 mm (7.74 inch) |
1 |
| 16 | 265-4193 | Support Disc 179.80 mm (7.07 inch) |
1 |
| 17 | 265-4194 | Support Disc 158.55 mm (6.24 inch) |
1 |
| 18 | 265-4195 | Support Disc 149.80 mm (5.89 inch) |
1 |
| 19 | 265-4196 | Support Disc 139.80 mm (5.50 inch) |
1 |
| 20 | 265-4197 | Support Disc 133.05 mm (5.24 inch) |
1 |
| 21 | 265-4198 | Support Disc 129.80 mm (5.11 inch) |
1 |
| 22 | 265-4199 | Support Disc 126.80 mm (4.99 inch) |
1 |
| 23 | 265-4200 | Support Disc 120.45 mm (4.74 inch) |
1 |
| 24 | 265-4201 | Support Disc 119.80 mm (4.72 inch) |
1 |
| 25 | 265-4202 | Support Disc 114.10 mm (4.49 inch) |
1 |
| 26 | 265-4203 | Support Disc 107.75 mm (4.24 inch) |
1 |
| 27 | 265-4204 | Support Disc 95.05 mm (3.74 inch) |
1 |
| 28 | 265-4205 | Support Disc 88.70 mm (3.49 inch) |
1 |
| 29 | 265-4206 | Support Disc 84.80 mm (3.34 inch) |
1 |
| 30 | 265-4207 | Support Disc 76 mm (2.99 inch) |
1 |
| 31 | 265-4208 | Wire Guide Group | 1 |
| ( 1 ) | Not Shown. |
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| Illustration 3 | g02688217 |
Assembly
- Begin by measuring bore (B) and stroke (S) dimensions in millimeters of the hydraulic cylinder to be serviced. The bore dimension will be used to select the correct support disc or discs. The stroke dimension will be used to select the proper combination of extension tubes.
- Based on stroke (S) dimension, select the proper combination of extension tubes (6), (7) to extend beyond the length of the sensor probe.
Note: Use a combination of extension tubes that only extend a minimal amount beyond the sensor probe. Excessive length will make the installation process more difficult.
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| Illustration 4 | g02688276 |
Clevis-Mounted Cylinder. (B) Bore. (S) Stroke. | |
- If necessary, join selected extension tubes (6), (7) by inserting one end of each tube into coupler (8). One end of the coupler will accept the large end of the extension tube, and the opposite side of the coupler will accept the small end of the extension tube. Make sure grooves (A) in the extension tubes align with the bolt holes in the coupler. Insert M6 x 1 bolts (9) and tighten snugly.
- Select a support disc (11 through 30), that is two sizes smaller than the cylinder bore diameter. Slide the support disc over the small end of extension tube (6), (7). Secure the support disc to coupler (8) with three M6 x 1 bolts (9) provided in the service group.
Example: A 127 mm (5.0 inch) diameter hydraulic cylinder bore would use 265-4200 Support Disc (23) with 120.45 mm (4.74 inch<).
| NOTICE |
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Do not over-tighten the shoulder bolts in aluminum coupler (8). The threads can be damaged or stripped. |
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| Illustration 5 | g02688327 |
(6) Extension Tube (Large End Shown). (7) Extension Tube (Small End Shown). (8) Coupler. | |
- Install the driver cap and bolt, part of driver group (5), onto the large end of extension tube (6), (7). Align the cross-hole in the cap with the cross-hole in the extension tube. Install and tighten the M8 x 1.25 bolt to secure the cap to the extension tube assembly.
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| Illustration 6 | g02689777 |
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| Illustration 7 | g02689778 |
(6) Extension Tube. (7) Extension Tube. (8) Coupler. (9) M6 x 1 Bolts. (11 - 30) Support Disc. | |
- Slide support collar (10) onto the small end of extension tube (6), (7), approximately 102 mm (4.0 inch) from the end of the extension tube, with the lip facing the end of the tube.
| NOTICE |
|---|
Do not over-tighten the bolt. The threads in the driver are easily damaged or stripped. |
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| Illustration 8 | g02689779 |
(5) Driver Cap and Bolt. (6) (7) Extension Tube. | |
Note: The painted alignment mark on the cap must line up with the small hole at the far end of the extension tube assembly, as shown.
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| Illustration 9 | g02689780 |
- Tighten the M6 x 1 bolt (9) in the support collar.
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| Illustration 10 | g02689797 |
(6) (7) Extension Tube. (10) Support Collar. | |
- Select a support disc (11 through 30) that is one size smaller than the cylinder bore diameter. Slide the support disc over the extension tube to the support collar. Secure the support disc to the support collar with three M6 x 1 bolts (9) provided in the service group.
Example: A 127 mm (5.0 inch) diameter hydraulic cylinder bore would use 265-4199 Support Disc (22) with a 126.80 mm (4.99 inch) diameter.
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| Illustration 11 | g02689836 |
Lip On Collar Faces End of Extension Tube. | |
- Slide installer (2) onto the small diameter of the extension tube. Make sure that the threaded hole in the installer is aligned with the cross-hole in the extension tube. Secure the installer with special M10 x 1.5 bolt (2) provided with the installer.
Note: The position of the alignment mark on the installer must have the same orientation as the alignment mark on the driver cap at the other end of the tooling.
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| Illustration 12 | g02689838 |
(6) (7) Extension Tube. (9) M6 x 1 Bolt. (11-30) Support Disc. | |
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| Illustration 13 | g02689910 |
(2) Installer with Special Bolt. | |
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| Illustration 14 | g02689912 |
Mark On Driver Aligns With Short Mark on Installer. | |
Operation
- Slide the probe of the sensor into the hole that runs through the center of the installer and extension tubes. Slide the sensor into the tooling until the sensor base contacts the installer.
- Align the groove in the sensor with the alignment marks on the installer and driver. This allows the groove in the sensor to be aligned with the locator pin protruding from the sensor bore at the bottom of the hydraulic cylinder in Step 9.
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| Illustration 15 | g02689917 |
Sensor Probe Slides Inside Extension Tube. | |
- Lubricate the sensor and seal with hydraulic oil. Slide sleeve (3) over the wires and onto the sensor and end of installer (2). The sleeve should be positioned so the dimple in the sensor is visible, but the sleeve still covers the seal.
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| Illustration 16 | g02689920 |
Alignment Groove In Sensor Body. | |
- Disconnect the bullet from the swivel of wire guide group (31) .
| NOTICE |
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If the sleeve slides past the seal, do not attempt to pull it back over the seal. The seal can be damaged and cause leaks. Push the sleeve further onto the installer and remove the sensor. Remove the sleeve and repeat Step 3. |
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| Illustration 17 | g02689925 |
(2) Installer. (3) Sleeve. | |
- Slide the pin connectors from the sensor wiring into the bullet tool. Gently tighten the screw in the bullet tool to secure the pins.
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| Illustration 18 | g02689927 |
(31) Swivel Disconnect. | |
- Feed the swivel end of wire guide group (31) through the passage for the sensor wiring at the base of the cylinder. Continue to feed the cable through until the swivel comes out the open end of the cylinder.
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| Illustration 19 | g02689936 |
- Connect the swivel on the wire group to the bullet tool.
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| Illustration 20 | g02689937 |
Note: Position the locator pin in the sensor bore, at the bottom of the hydraulic cylinder, to a 12 o'clock position.
- Pull the wire guide group through the cylinder while inserting the sensor. The bullet will help guide the sensor wiring through the passage at the bottom of the cylinder.
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| Illustration 21 | g02690076 |
- Use the alignment mark on the driver to position the groove in the sensor to the 12 o'clock position to align with the locator pin.
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| Illustration 22 | g02690077 |
- When the sensor is aligned, carefully tap the driver until the sensor is installed. As the sensor is tapped into the bore, the sleeve (3) will compress the sensor seal, allowing it to slide into the sensor bore.
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| Illustration 23 | g02690080 |
- Loosen the bullet clamp screw and disconnect the bullet from the wiring pin connections.
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| Illustration 24 | g02690081 |
| NOTICE |
|---|
The sensor is very fragile. Failure to hammer gently could cause the sensor to break. |
- Carefully pull the installation tooling away from the sensor probe, and remove the sensor probe from the hydraulic cylinder.
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| Illustration 25 | g02690083 |
- Remove the bolt securing installer (2) and slide the installer and sleeve off the end of the extension tube.
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| Illustration 26 | g02690087 |
- During the installation of the sensor, the sleeve (3) will be driven onto the installer (2). It may be necessary to use the sleeve removal tool (4) to separate the sleeve from the installer.
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| Illustration 27 | g02690095 |
(2) Installer. | |
- To remove the installer, insert it into the sleeve removal tool with the flange of the sleeve resting on the top edge of the sleeve removal tool. Use a rubber mallet and an appropriate punch to drive the installer out of the sleeve and into the sleeve removal tool.
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| Illustration 28 | g02690098 |
(2) Installer. (3) Sleeve. (4) Sleeve Removal Tool. | |
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| Illustration 29 | g02690101 |
265-4209 Service Group for Trunnion-Mounted Hydraulic Cylinders
Nomenclature
| Item | Part No | Description | Qty |
| 1 | 265-4210 (1) | Case Group (includes 4C-9662 Carrying Case Gp and 265-4211 Foam Insert ) | 1 |
| 2 | 265-4212 | Slide Hammer Group | 1 |
| 3 | 265-4180 | Installer Group | 1 |
| 4 | 264-4181 | Top Panel | 1 |
| 5 | 265-4182 | Sleeve Removal Tool | 1 |
| ( 1 ) | Not Shown. |
 | |
| Illustration 30 | g02690277 |
Assembly
- Assemble the 265-4212 Slide Hammer Group . Install the metal slide and thread both end caps onto the rod.
- Slide installer (3) onto the adapter end of slide hammer assembly (2). Make sure that the threaded hole in the installer is aligned with the cross-hole in the adapter. Secure the installer with the special M10 x 1.5 bolt provided with the installer.
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| Illustration 31 | g02690456 |
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| Illustration 32 | g02690476 |
(2) Slide Hammer Assembly. (3) Installer and Bolt. | |
Operation
- Slide the probe of the sensor through the hole that runs through the installer and slide the hammer assembly until the sensor base contacts the installer.
- Note the location of the groove in the sensor, relative to the locator pin in the sensor bore, located in the base of the cylinder end cap.
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| Illustration 33 | g02690516 |
- Lubricate the sensor and seal with hydraulic oil. Slide the sleeve (4) over the wires and onto the sensor and the end of the installer (3). The sleeve should be positioned so the dimple in the sensor is visible, but the sleeve still covers the seal.
| | |
| Illustration 34 | g02689920 |
Alignment Groove in Sensor. | |
- Feed the wiring from the sensor through the passage at the bottom of the sensor bore.
| NOTICE |
|---|
If the sleeve slides past the seal, do not attempt to pull it back over the seal. The seal can be damaged and cause leaks. Push the sleeve further onto the installer and remove the sensor. Remove the sleeve and repeat Step 2. |
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| Illustration 35 | g02690558 |
(2) Slide Hammer Assembly. (3) Installer. (4) Sleeve. | |
- Line up the groove in the sensor with the locator pin in the sensor bore.
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| Illustration 36 | g02690576 |
- Use the slide hammer assembly to drive the sensor into the sensor bore.
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| Illustration 37 | g02690596 |
- Carefully remove the installation tooling from the sensor.
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| Illustration 38 | g02690616 |
| NOTICE |
|---|
The sensor is very fragile. Failure to hammer gently could cause the sensor to break. |
- Remove the installer (3) and sleeve (4) from the end of the slide hammer assembly (2) .
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| Illustration 39 | g02690623 |
- During installation of the sensor, the sleeve (4) will be driven onto the installer (3). It may be necessary to use the sleeve removal tool (5) to separate the sleeve from the installer.
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| Illustration 40 | g02690631 |
(2) Slide Hammer Assembly. (3) Installer. (4) Sleeve. | |
- Insert the installer into the sleeve removal tool with the flange of the sleeve resting on the top edge of the sleeve removal tool. Use a rubber mallet and an appropriate punch to drive the installer out of the sleeve and into the sleeve removal tool.
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| Illustration 41 | g02690637 |
(3) Installer. (4) Sleeve. (5) Sleeve Removal Tool. | |
| | |
| Illustration 42 | g02690101 |
Maintenance
Wipe off the individual components before and after each use. It is important to keep dirt and contaminants out of the hydraulic cylinder during sensor installation.
Warranty Information
For 6 months from the date of purchase, Dealer Service Tools will replace for the original purchasers free of charge, any part or parts of equipment manufactured by Dealer Service Tools found upon examination by the factory to be defective in material, workmanship, or both. This is the exclusive remedy. All transportation charges on parts submitted for replacement under this warranty must be born by the purchaser. THERE IS NO OTHER EXPRESS WARRANTY. IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO ONE YEAR FROM PURCHASE AND TO THE EXTENT PERMITTED BY LAW AND ALL IMPLIED WARRANTIES ARE EXCLUDED. LIABILITY FOR CONSEQUENTIAL DAMAGES UNDER ANY AND ALL WARRANTIES ARE EXCLUDED TO THE EXTENT EXCLUSION IS PERMITTED BY LAW.