315C Excavator Machine Systems Caterpillar

Removal Procedure

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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.

Note: The procedure which follows can be used to remove either boom cylinder or both of the boom cylinders.

1. Fully extend the stick. Fully extend the bucket. Lower the bucket to the ground.

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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 implement 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.

2. Release the hydraulic system pressure. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release".

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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 machine. 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 in Caterpillar machines. Dispose of all fluids according to local regulations and mandates.

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Illustration 1	g01012637

3. Disconnect lubrication hose assembly (1) at the rod end of each boom cylinder.

4. Fasten a suitable lifting device at the rod end of the right hand boom cylinder, as shown. Remove bolts (2), retainer plate (3), and the spacer from the end of the support pin. Push the support pin out of the rod end of the right hand boom cylinder and into the boom only. Lower the right boom cylinder completely.

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Illustration 2	g00362416

5. Refasten the suitable lifting device to right hand boom cylinder (4), as shown. Raise the boom cylinder until the boom cylinder is horizontal. Adjust the lifting straps so that the boom cylinder is held horizontally.

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Illustration 3	g01012646

6. Disconnect hose assemblies (5) from the boom cylinder. Put plugs in the ends of the hose assemblies. Plugs prevent oil loss. Plugs prevent contaminating the hydraulic system.

7. Remove retaining bolt (7) and the washer. Remove pin assembly (6) and the spacer. Remove boom cylinder (4). The weight of boom cylinder (4) is approximately 147 kg (325 lb).

Note: Shims may be used between the boom cylinders and the frame. These shims are used to adjust the lateral clearance between the components at the pin joint. Put identification marks on all shims for assembly purposes.

8. Remove the shims at the pin joint for the boom cylinder on the frame.

9. Fasten a suitable lifting device to the left hand boom cylinder. Remove the three bolts, the retainer plate and the spacer from the left side of the boom cylinder support pin. Push the support pin into the boom only. Lower the left hand boom cylinder completely. Fasten a suitable lifting device to the support pin, and remove the pin from the boom. The weight of the support pin is approximately 23 kg (50 lb).

10. Complete the removal of the left hand boom cylinder by repeating steps 5 through 8.

Disassembly and Assembly Information

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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.

Illustration 4	g01012663

(1) Lubricate the face of the locknut and threads of the locknut prior to assembly.

Torque for locknut ... 4500 ± 230 N·m (3319 ± 170 lb ft)

(2) Lubricate the inside diameter and the outside diameter with clean grease.

(3) Install the bearing in 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.

Install the seal in the bearing bore. ... 1.00 ± 0.50 mm (0.039 ± 0.020 inch)

(5) Install the bearing in the bearing bore. ... 10.00 ± 0.50 mm (0.394 ± 0.020 inch)

(6) The slit of the ring must turn in the direction of the piston.

(7) Lubricate the sealing lip slightly with the lubricant that is being sealed.

(8) Apply Tooling (F) to the groove before the cylinder is assembled.

Installation Procedure

1. Be sure that the pin bores in the boom cylinders, the boom and the frame are clean and free of dirt prior to installation of the boom cylinders.

2. Attach a suitable lifting device to right hand boom cylinder (4). Place boom cylinder (4) in position in the frame. Be sure that the pin bores in the boom cylinder and the pin bores in the frame are aligned with each other.

3. Apply Tooling (G) on pin assembly (6) that holds the boom cylinder to the frame. Temporarily install the pin assembly. Do not remove the suitable lifting device from the boom cylinder at this time.

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Illustration 5	g00363112
Top view of boom cylinder and frame

4. Slide the boom cylinder to one side until the boom cylinder makes contact with the frame. Measure the total clearance between the boom cylinder and the frame at the pin bore. The total clearance of measurement (a) plus measurement (b) must not be more than 1.0 mm (0.04 inch). If the total clearance is less than 1.0 mm (0.04 inch), the addition of shims between the boom cylinder and frame will not be required. If the total clearance is more than 1.0 mm (0.04 inch), the addition of shims between the boom cylinder and frame will be required.

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Illustration 6	g01012646

5. Remove pin assembly (6), if shims are required. Refer to Disassembly and Assembly, "Boom Cylinder - Remove". Install the shims between the boom cylinder and the frame on the side opposite retaining bolt (7). Install the spacer and pin assembly (6). Install the washer and retaining bolt (7). Tighten retaining bolt (7) to a torque of 325 ± 40 N·m (240 ± 30 lb ft).

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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 machine. 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 in Caterpillar machines. Dispose of all fluids according to local regulations and mandates.

6. Check the condition of the O-ring seals in hose assemblies (5). If the seals are damaged, use new parts for replacement. Connect hose assemblies (5) to the boom cylinder.

7. Install the left hand boom cylinder by repeating Steps 1 through 6.

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Illustration 7	g01012637

8. Raise the rod end of the boom cylinders until the pin bores in the boom cylinders are aligned with the bore in the boom. Extend or retract the cylinder rods until the pin bores in the boom cylinders are aligned with the bore in the boom.

9. Apply Tooling (G) on the support pin for the rod end of the boom cylinders. Install the support pin, two spacers, retainer plates (3), bolts (2) and the washers on the end of the support pin.

10. Connect lubrication hose assembly (1) at the rod end of each boom cylinder.

11. Fill the hydraulic oil tank with oil to the correct level. Refer to Operation and Maintenance Manual, "Capacities (Refill)". Lubricate the boom mounting pins and the boom cylinder mounting pins. Refer to Operation and Maintenance Manual for the correct procedure.

12. Start the machine and run the machine at low idle speed. Move the control lever for the boom cylinders so that the cylinder rods extend to the halfway position. Retract the cylinder rods. The boom cylinders should be cycled in this manner for approximately ten cycles in order to remove the air from the hydraulic system.

13. Check the oil level in the hydraulic oil tank. If necessary, refill the hydraulic oil tank to the correct level. Refer to Operation and Maintenance Manual, "Capacities (Refill)".