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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: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
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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. |
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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. |
- Start the engine and fully retract the bucket cylinder and the stick cylinder. Lower the boom until the bucket is lowered onto the ground. Shut off the engine.
- Relieve hydraulic system pressure. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release".
Show/hide table
Illustration 1 g01215300 Show/hide table
Illustration 2 g01215303 - Attach a suitable lifting device to both ends of stick cylinder (1). The weight of stick cylinder (1) is approximately
325 kg (715 lb) . - Disconnect hose assemblies (4). Remove bolt (3) and pin assembly (2). Remove bolt (5) and pin assembly (6).
- Remove stick cylinder (1).
Disassembly and Assembly Information
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | 127-4904 | Hydraulic Cylinder Repair Stand Gp | 1 |
| 1P-0520 | Driver Gp | 1 | |
| 9U-7868 | Spanner Wrench | 1 | |
| 127-8064 | Adapter Plate Gp | 1 | |
| 195-4609 | Seal Pick | 1 | |
| B | 4C-4032 | Bearing Mount Compound | 1 |
| C | 5P-0960 | Grease Cartridge | 1 |
| D | 1P-1837 | Bearing Puller Adapter | 1 |
| 4C-9633 | Puller Stud | 1 | |
| 1A-1935 | Full Nut | 1 | |
| 3S-6224 | Electric Hydraulic Pump Gp | 1 | |
| 6V-3175 | Double Acting Cylinder | 1 | |
| 6V-2098 | Press Sleeve | 1 | |
Note: Tooling (D) is used for the removal of the bearings that are located at the head end and the rod end of the cylinder.
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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. |
- Apply Tooling (B) to seal (1) prior to assembly.
- Apply clean hydraulic oil on the lip of seal (1), seal (2), and seal (3).
- Apply Tooling (C) to the threads of head (5).
- Lubricate the threads of rod assembly (7) with Tooling (C).
- Tighten locknut (8) to a torque of
8890 ± 440 N·m (6557 ± 325 lb ft) . - Install ball (10) and setscrew (9) in locknut (8). Tighten setscrew (9) to a torque of
57 ± 10 N·m (42 ± 7 lb ft) . - Lubricate the outside of piston (6) with Tooling (C).
- Tighten bolts (4) to a torque of
367 ± 55 N·m (271 ± 41 lb ft) .
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| Illustration 3 | g01174095 |
Note: Apply a light film of hydraulic oil to all components before assembly.
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| E | 5P-0960 | Grease Cartridge | 1 |
- Attach a suitable lifting device to both ends of stick cylinder (1). The weight of stick cylinder (1) is approximately
325 kg (715 lb) . Position stick cylinder (1) onto the machine. - Apply Tooling (E) to pin assembly (2). Install pin assembly (2) and bolt (3). Apply Tooling (E) to pin assembly (6). Install pin assembly (6) and bolt (5).
- Connect hose assemblies (4).
- Fill the hydraulic oil tank. Refer to Operation and Maintenance Manual, "Hydraulic Oil Level - Check".
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| Illustration 4 | g01215300 |
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| Illustration 5 | g01215303 |