Removal Procedure
Note: Put identification marks on all hoses, on all hose assemblies, on all harness assemblies, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.
Note: Cleanliness is an important factor. Before you begin the removal procedure, the exterior of the components should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.
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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. |
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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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- Start the machine. Fully extend the stick. Fully extend the bucket. Lower the stick and the bucket to the ground.
- Release the hydraulic system pressure. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release".
- Attach a suitable lifting device to stick cylinder (3) , as shown. The weight of the stick cylinder is approximately 185 kg (410 lb).
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| Illustration 1 | g00358752 |
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| Illustration 2 | g00358772 |
- Disconnect hose assemblies (4) . Put plugs in the ends of the hose assemblies. Plugs prevent oil loss. Plugs prevent contaminating the hydraulic system. Disconnect tube assembly (7) .
- Remove bolt (1) and pin assembly (2) . Remove bolt (6) and pin assembly (5) . Remove stick cylinder (3) .
Note: Note the locations of all shims for assembly purposes.
Disassembly and Assembly Information
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | 127-4904 | Hydraulic Cylinder Repair Stand | 1 |
| B | 195-4609 | Seal Pick | 1 |
| C | 7M-7456 | Bearing Mount Compound | 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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| Illustration 3 | g01813097 |
(1) Lubricate the face of the locknut and threads of the locknut prior to assembly. Tighten the locknut to a torque of 6300 ± 320 N·m (4646 ± 236 lb ft).
(2) Lubricate the inside diameter and the outside diameter with clean grease.
(3) Install the tapered side of the bearing into the bearing bore. ... 7.35 ± 0.50 mm (0.289 ± 0.020 inch)
(4) Lubricate the sealing lip slightly with the lubricant that is being sealed.
(4) Install the seal in the bearing bore. ... 1.00 ± 0.50 mm (0.039 ± 0.020 inch)
(5) Install the tapered side of the bearing into the bearing bore. ... 7.50 ± 0.50 mm (0.295 ± 0.020 inch)
(6) Free movement for stop after assembly ... 0.50 ± 0.26 mm (0.020 ± 0.010 inch)
(7) Maximum diameter of outer ring after assembly ... 53.3 mm (2.10 inch)
(8) The slit in the ring must turn in the direction of the piston.
(9) Lubricate the sealing lip slightly with the lubricant that is being sealed.
(10) Apply Tooling (C) to the groove before the cylinder is assembled.
Installation Procedure
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| D | 5P-0960 | Molybdenum Grease | 1 |
- Make sure that the pin bores in the stick cylinder, the boom and the stick are clean and free of dirt prior to the installation of the stick cylinder.
- Attach a suitable lifting device to stick cylinder (3) , as shown. The weight of the stick cylinder is approximately 185 kg (410 lb). Position stick cylinder (3) .
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| Illustration 4 | g00358752 |
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| Illustration 5 | g00358772 |
- Apply Tooling (D) to pin assemblies (2) and (5) . Install pin assemblies (2) and (5) . Install bolts (1) and (6) .
- Tighten bolts (1) and (6) to a torque of 325 ± 40 N·m (240 ± 30 lb ft).
- Connect hose assemblies (4) and tube assembly (7) .
- Start the machine, and run the machine at low idle speed. Move the control lever for the stick cylinder so that the cylinder rod extends to the halfway position. Retract the cylinder rod. The stick cylinder should be cycled in this manner for approximately ten cycles in order to remove the air from the hydraulic system. Recheck the oil level in the hydraulic oil tank.