Using the 9U-7868 and 9U-7869 Spanner Wrench to Remove and install Threaded Gland Cylinder Heads{0374, 0599, 0602, 0738} Caterpillar

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Introduction

Important Safety Information

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 contains safety information, operation instructions and maintenance information and should be stored with the tool group

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) 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 operating or performing maintenance and repair on this service tool.

General Information Section

The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.

Operation Section

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 tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.

Maintenance Section

The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal

Service Parts Section

The Service Parts section is a reference for parts identification and available part numbers.

Safety Icon Nomenclature

Personal Protection/Important Information

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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

General Information

Introduction

The 9U-7868 and 9U-7869 Spanner Wrenches are designed to remove and install threaded gland cylinder heads. The unique advantage of the spanner wrenches is in the design. A Spanner Wrench provides nonslip, positive engagement of the spanner pins, because the wrench is attached to the cylinder being serviced.

Spanner Wrenches make removing the glands simpler and easier by eliminating the need for

• chain wrenches

• destructive-type removal methods such as cutting away the barrel or cutting the gland

• welding of removal tooling onto gland

• a hammer and punch

A Spanner Wrench should remove even the most difficult glands. Many times, dirt, and water cause the threads of the gland to become corroded. Corrosion will lock the gland into the barrel, making removal using current methods difficult.

The wrenches and adapters are packaged separately. Dealers can order just what is required. Also, as new adapters are developed, dealers can add the new adapters to current tooling.

The new wrench design has many features to help wrench stay in place and provide the maximum removal torque directly to the gland. The wrenches wrap around the cylinder rod. The design keeps the wrench centered on the gland and helps to prevent slipping off the gland. Two sizes of wrenches are available, depending on the diameter of the cylinder rod.

Illustration 3	g02803198
Typical Gland Removal Wrench And Universal Adapter Plate (1) Locking Plate (2) Adapter Plate (3) Cylinder (4) Swivel Screws (5) Spanner Wrench (6) Cylinder Rod

Other features of the spanner wrench include a nylon pad on the inside diameter of the wrench to protect the cylinder rod from damage. Each centering screw is also fitted with nylon swivel pads, which helps prevent damage to rod. The handle is heat-treated to Rc 32-38 for maximum strength. All the parts are zinc plated to resist rust/corrosion and provide a long lasting tool.

Illustration 4	g02803199
Nomenclature Refer to Table 1 For Item Identification.

References

Major Equipment Guide, NEHC2004, "Hydraulic Cylinder Repair Stands"

Special Instruction, NEHG4067, "Tool Announcement"

Tool Operating Manual, NEHS0627, "1U-9001 and 1U-9002 Automatic Honing Tool"

Special Instruction, NEVN3229, "The Adjustable Spanner Wrench"

Special Instruction, SEHS7150, "Torque Computer (sliding scale)"

Tool Operating Manual, SEHS9538, "Using the 9U-6463 Hone Group and Attachments "

Additional Tooling

Additional Contact Information

For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:

USA: 800-542-8665, Option 1

International: 1-309-578-7372

Adapter Plates

There are now two types of adapters used to remove threaded gland cylinder heads. One type is a universal position, shown in Figure 5. The other type is a fixed-position adapter, as shown in Figure 6.

Regardless of which type of adapter is used, the result is a tool that provides the best possible nonslip spanner engagement. Both designs allow the mechanic to use the maximum amount of force required to remove or install the cylinder gland.

Universal-Position Adapters

Illustration 5	g02803216
Universal Adapter Plates

In order to meet the continually changing threaded gland head designs of hydraulics cylinders, four universal-position adapters have been designed. Adapters work on heads with slots in the face, pin holes in the face, and/or milled flats on the outside diameter of the threaded gland. The design of the adapter heads allow the pins or flats to be infinitely adjustable within the size range of the adapter.

Using the universal-position adapters will eliminate the need for individual fixed-position adapters when servicing threaded gland cylinders. The new adapters will also help to minimize the storage space for the many fixed-position adapters required to service each Caterpillar cylinder. New adapters will minimize storage space for other machines, as well.

Refer to the ""Universal-Position Adapters" " Section for additional information and part numbers for this type of adapter.

Fixed-Position Adapters

Eleven fixed-position adapters are available depending on the design and size of the gland. The adapters are designed with pins that fit into the slots of the gland providing maximum pin engagement. Refer to Tables 3 and 7 for the part number and application of each fixed-position adapters.

Illustration 6	g02803217
Adapter Plates Must Be Ordered Separately

Selecting Either Universal-Position Adapters or Fixed-Position Adapters

Table 3 will help determine which adapter plate matches a specific gland. The Table includes a list of each available adapter, the part number of the threaded gland, and the model of the machine. Use Table 3 to select the adapter plate required for disassembly of the cylinder.

Universal-Position Adapters

Specifications

These universal-position adapters work on cylinders with slots or pin holes in the face, and/or milled flats on the outside diameter of the threaded gland. The design of the adapter heads allow the pins or flats to be infinitely adjustable within the size range of the adapter. The universal-position adapters will eliminate the need for individual fixed-position adapters except where noted in Table 3.

Illustration 7	g02803220
127-8064 Adjustable Adapter Plate Group

The adapter plate is used on glands with slots machined in the face.

Illustration 8	g02803221
130-1810 Pin/Key Group

The pin/key group is used with the 127-8064 Adjustable Adapter Plate Group to remove glands with holes machined in the face. Refer to Table 5 for item identification.

Illustration 9	g02803222
127-8069 Adapter Plate Group

This adapter plate is used on glands with flats machined on the outside diameter of the gland. Refer to Table 6 for item identification.

Illustration 10	g02803224
162-7189 Plate Adapter Group

Refer to Table 7 for item identification.

Universal-Position Procedure

This procedure explains, the installation, and use of the spanner wrench with universal-position adapter plates. The setup and use of the spanner wrench can be done quickly and easily. Read and follow all instructions and warnings before using the spanner wrench.

1. Remove the cylinder from the machine. Put the cylinder on a cylinder repair stand or equivalent fixture to hold cylinder in place during disassembly.

2. Extend the cylinder rod far enough to install the wrench assembly onto the rod [at least 200 mm (7.9 inch).

3. Clean the surface of the nylon pads on the wrench and remove any debris which could damage cylinder rod.

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Illustration 11	g02803225
Nylon Pad Designed To Protect Cylinder Rod Always make sure that this pad is in place and free of debris or dirt

4. Select the correct universal-position adapter plate and keys/pins.

5. Put the keys/pins into the adapter plate and loosely tighten the setscrews that hold keys/pins in position.

6. Position the adapter plate and keys/pins close to the gland. Adjust the pins to fit into the holes, slots, or flats depending on the style of gland.

   Note: Always make sure the keys/pins are evenly positioned from side to side, as shown in Figure 12.

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Illustration 12	g02803226
Make Sure Keys/Pins Are Equally Positioned

7. Assemble the adapter plate onto the wrench using four bolts.

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NOTICE
Do not use swivel screws without nylon pads. Using screws in this manner will result in damage to the rod.

8. Turn the swivel screws outward (open) as far as possible and place wrench assembly over the rod. Be careful not to nick or scratch the rod. The wrench has a protective nylon pad which should eliminate possible damage, but the adapter plate can contact the rod during this initial assembly. Refer to Figures 11, 12, and 13

Note: For easier installation, the bottom locking plate can remain attached to the spanner wrench by using one screw to hold plate onto the wrench. The plate can then be swiveled out of the way. Using this method allows one hand to hold the wrench in place, while using the other hand to install the second bolt.

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Illustration 13	g02803227
Adapter Plate Must Not Touch Rod Be careful during initial assembly not to damage the rod

9. Hold wrench assembly firmly against the face of the gland. Finger tighten the back two swivel screws until the rod is contacted.

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Illustration 14	g02803230
Finger Tighten Back Two Swivel Screws Tighten the screws until the rod is contacted and the wrench is centered and vertically aligned

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NOTICE
The wrench assembly must be centered with the gland (equal radial space between adapter and gland). Vertically align the wrench with the gland face. Misalignment could cause the wrench to slip during disassembly and possibly damage the gland or the adapter. Refer to Figure 15 and 16.

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Illustration 15	g02803231
When Correctly Installed The Wrench Assembly Must be Vertically Aligned

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Illustration 16	g02803232
Misalignment Misalignment could cause the wrench to slip and damage the adapter plate or gland Adjust the back two swivel screws until the spanner wrench is radial and vertically aligned

10. Finger tighten the two front swivel screws until the rod is touched.

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Illustration 17	g02803235
Attach Bottom Locking Plate to Wrench

11. Holding the wrench assembly in place, install the bottom locking plate with two socket head cap screws and tighten.

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Illustration 18	g02803236
Tighten Bottom Swivel Screws Until The Rod Is Contacted

12. Finger tighten the bottom two swivel screws until the rod is touched.

13. Finger tighten all the swivel screws evenly until wrench is held firmly against cylinder rod.

    When the wrench is correctly installed and the swivel screws properly adjusted:

    • Keys/pins should easily engage into holes or slots.

    • Wrench should freely rotate around cylinder rod.

    • Wrench should easily slide along the axial length of the rod.

14. Attach a breaker bar to the wrench assembly and remove the gland. A torque wrench should only be used during assembly, ensuring that the specified torque is applied.

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Illustration 19	g02803238
Remove Gland From Cylinder

15. Remove the wrench assembly from the rod.

    Note: Before assembling a new gland into the cylinder, the barrel should be honed to obtain the correct surface finish and cross hatch pattern. Refer to the ""References" " Section for equipment and procedures to hone cylinder barrels.

Fixed Position Adapter Plate

Specifications

Illustration 20	g02803239
Style "A" Adapter Plate

Refer to Table 8 for specifications.

• Pins engage radially.

• Counterbore surrounds outside diameter of gland.

Illustration 21	g02803356
Style "B" Adapter Plate

Refer to Table 8 for specifications.

• Pins engage axially.

• Counterbore surrounds outside diameter of gland.

Illustration 22	g02803376
Style "C" Adapter Plate.

Refer to Table 8 for specifications.

• Pins engage axially.

• No counterbore.

• Plate and gland faces contact each other.

Table 8 can be used to identify adapter plates, or to determine if an adapter plate can be used on a gland not listed in Table 3. There are three styles of adapter plates, as shown in Figures 20, 21 and 22.

Fixed Position Procedure

The procedure for the installation and use of the spanner wrench with fixed-position adapter plates is explained below. The setup and use of the spanner wrench can be done quickly and easily. Read and follow all instructions and warnings before using the spanner wrench.

1. Remove the cylinder from the machine. Put the cylinder on a cylinder repair stand or equivalent fixture to hold cylinder in place during disassembly.

2. Select and assemble the correct fixed position adapter plate onto the rod [at least 200 mm (7.9 in)].

3. Extend the cylinder rod far enough to install the wrench assembly onto the rod [at least 200 mm (7.9 in).

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Illustration 23	g02803396
Nylon Pad Nylon Pad is designed to protect the cylinder rod. Always make sure that pad is in place and free of dirt and debris

4. Clean the surface of the nylon pads on the wrench and remove any debris which could damage cylinder rod.

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NOTICE
Do not use swivel screws without nylon pads. Using the screws in this manner will result in damage to the rod.

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Illustration 24	g02803439
Adapter Plate Must Not Touch Rod Be careful during initial assembly not to damage the rod

5. Turn the swivel screws outward (open) as far as possible and place wrench assembly over the rod. Be careful not to nick or scratch the rod. The wrench has a protective nylon pad which eliminates possible damage, but the adapter plate can contact the rod during initial assembly. Refer to Figures 23 and 24.

   Note: For easier installation, the bottom locking plate can remain attached to the spanner wrench by using one screw to hold onto the wrench. This step allows the plate to be swiveled out of the way. Using this method allows one hand to hold the wrench in place, while using the other hand to install the second bolt.

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Illustration 25	g02803436
Finger Tighten Back Two Swivel Screws Tighten the screws until the rod is contacted and the wrench is centered and vertically aligned

6. Hold wrench assembly firmly against the face of the gland. Finger tighten the back two swivel screws until rod is contacted.

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NOTICE
The wrench assembly must be centered with the gland, equal radial space between adapter and gland. The vertically align the wrench with the gland face. Misalignment could cause the wrench to slip during disassembly and possibly damage the gland or the adapter. Refer to Figures 26 and 27.

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Illustration 26	g02803442
When Correctly Installed, The Wrench Assembly Must Be Vertically Aligned

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Illustration 27	g02803444
Misalignment Misalignment could cause the wrench to slip and damage the adapter plate or gland Adjust the back two swivel screws until the spanner wrench is radial and vertically aligned

7. Finger tighten the front two swivel screws until the rod is touch.

8. Holding the wrench assembly in place, install the bottom locking plate with two socket head capscrews and tighten.

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Illustration 28	g02803456
Attach Bottom Locking Plate To Wrench

9. Finger tighten the bottom two swivel screws until the rod is touched.

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Illustration 29	g02803458
Tighten Bottom Swivel Screws Until The Rod Is Contacted

10. Finger tighten all the swivel screws evenly until wrench is held firmly against cylinder rod.

11. Attach a breaker bar to the wrench assembly and remove the gland. A torque wrench should only be used during assembly, ensuring that the specified torque is applied.

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Illustration 30	g02803459
Remove Gland From Cylinder

12. Remove the wrench assembly from the rod.

    Note: Before assembling a new gland into the cylinder, the barrel should be honed to obtain the correct surface finish and cross hatch pattern. Refer to the ""References" " Section for equipment and procedures to hone cylinder barrels.