GSH420, GSH425, GSH440, GSH520, GSH525, GSH455 and GSH555 Orange Peel Grapples Hydraulic Cylinder - Remove and Install Caterpillar

Removal Procedure

Start By:

1. Release the hydraulic system pressure.

2. Remove the grapple assembly from the host machine.

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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.

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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 1	g06029708

1. Attach a suitable lifting device and crane to grapple assembly (1). The weight of grapple assembly (1) is approximately 2230 kg (4916 lb). Lower grapple assembly (1) with closed shells to the ground. Secure grapple assembly (1) against moving. Refer to Illustration 1.
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   Illustration 2	g06030243

2. Remove bolts (2), bushings (3), washers (4), and cover (5).
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   Illustration 3	g06038832

3. Attach suitable lifting device to cylinder (6). The weight of cylinder (6) is approximately 32 kg (71 lb).

4. Remove bolt (8), washer (9), and pin (7) from rod end of the cylinder.
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   Illustration 4	g06030184

5. Remove bolts (10) and cover plate (11).
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   Illustration 5	g06030190

6. Retract the hydraulic cylinder rod.

7. Place an identification mark on hose assemblies (12) for installation purpose. Disconnect hose assemblies (12). Install the cap to the hose couplings to prevent hydraulic oil leakage from the cylinder.
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   Illustration 6	g06030252

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   Illustration 7	g06030255

8. Remove bolt (13), washer (14), and pin (15) from base end of the cylinder.

9. Remove the cylinder.

Installation Procedure

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Illustration 8	g06038828

1. Attach suitable lifting device to cylinder (6). The weight of cylinder (6) is approximately 32 kg (71 lb). Install cylinder (6).

   Note: Hydraulic hoses are to be installed onto the hydraulic cylinder ports before hydraulic cylinder installation.

   Note: Do not install pin (15).

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   Illustration 9	g06030190

2. Connect hose assemblies (12) to the distributor.
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   Illustration 10	g06030255

3. Apply Tooling (B) to the bore of pin (15). Install pin (15).

   Note: Assemble pin (15) with lubricant bore pointing towards the housing.

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   Illustration 11	g06030252

4. Apply Tooling (A) to the threads of bolt (13). Install washer (14) and bolt (13). Tighten bolts (13) to a torque of 270 ± 40 N·m (199 ± 30b ft).
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   Illustration 12	g06030247

5. Apply Tooling (B) to the bore of pin (7). Install pin (7).

   Note: Assemble pin (15) with lubricant bore pointing towards the housing.

6. Apply Tooling (A) to the threads of bolt (8). Install washer (9) and bolt (8). Tighten bolts (8) to a torque of 270 ± 40 N·m (199 ± 30b ft).
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   Illustration 13	g06030184

7. Install cover (11) and bolts (10). Tighten bolts (10) to a torque of 105 ± 20 N·m (78 ± 15 lb ft).
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   Illustration 14	g06030243

8. Install cover (5), washers (4), bushings (3) and bolts (2).

Disassembly Procedure

1. Place the hydraulic cylinder on a suitable table. Remove the cap from the hydraulic cylinder ports and drain the hydraulic oil.
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   Illustration 15	g06030259

2. Use Tooling (A) to remove retaining ring (17). Remove retaining ring (17) and bearing (16) from rod end of the cylinder.
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   Illustration 16	g06030262

3. Use Tooling (A) to remove retaining ring (19). Remove retaining ring (19) bearing (18) from base end of the cylinder.
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   Illustration 17	g06035071

4. Remove ring (20) out of the notch present on the head and the cylinder housing.
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   Illustration 18	g06030263

5. Use Tooling (B) to remove head (22). Remove rod assembly (23) with head (22) and piston (21).
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   Illustration 19	g06030267

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   Illustration 20	g06253744

6. Remove wear ring (26), seal (25), and wear ring (27).

7. Preheat piston (21) and setscrew (24) to soften the sealant. Raise the temperature of head (21) and setscrew (24) to 260° to 300°C (468° to 540°F). Remove setscrew (24) .

8. Attach Tooling (B) to the piston (21). Attach Tooling (C) to Tooling (B) and remove piston (21).
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   Illustration 21	g06030269

9. Remove O-ring seal (28).
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   Illustration 22	g06035104

10. Remove seal (30), O-ring seal (29), and ring (20) from head (22).
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    Illustration 23	g06030274

11. Remove wiper seal (34), wear ring (33), seal (32), and wear ring (31) from head (22).
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    Illustration 24	g06030277

12. Remove seal (37), wear rings (36), seal (35) from head (22).

Assembly Procedure

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Illustration 25	g06030277

Note: Lubricate all seals with a thin covering of the lubricant that is being used.

1. Install seal (35), wear rings (36), seal (37) into head (22).
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   Illustration 26	g06030274

   Note: Lubricate all seals with a thin covering of the lubricant that is being used.

2. Install wear ring (31), seal (32), wear ring (33), and wiper seal (34) into head (22).
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   Illustration 27	g06035104

   Note: Lubricate all seals with a thin covering of the lubricant that is being used.

3. Install ring (20), O-ring seal (29), and seal (30) onto head (22).
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   Illustration 28	g06030269

   Note: Lubricate all seals with a thin covering of the lubricant that is being used.

4. Install O-ring seal (28).
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   Illustration 29	g06030360

5. Install head (22). Apply Tooling (E) to the threads of piston (21). Install piston (21) onto rod (23). Tighten piston (21) to a torque of 300 to 330 N·m (221 to 243 lb ft).

   Note: Do not loosen the piston to align. The locking setscrew must be relocated to a new hole.

6. Drill a 7.0 mm (0.28 inch) diameter hole, 34.0 ± 1.0 mm (1.33 ± 0.04 inch) deep. Tap the hole using M8 X 1.25-6H tap to a depth of 30.0 ± 1.0 mm (1.18 ± 0.4 inch).

7. Apply Tooling (E) to the threads of set screw (24). Install set screw (24). Tighten set screw (24) to a torque of 24 to 26 N·m (212 to 230 lb in).
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   Illustration 30	g06030361

   Note: Lubricate all seals with a thin covering of the lubricant that is being used.

8. Install wear rings (27) and (26). Install seal (25).
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   Illustration 31	g06030263

9. Install piston (21), head (22), and rod (23) into the cylinder. Tighten head (22) to a torque of 300 to 330 N·m (221 to 243 lb ft).
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   Illustration 32	g06035071

10. Deform ring (20) into notch of the head and the cylinder assembly after the head tightening has been completed.
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    Illustration 33	g06030262

11. Install bearing (18) and retaining ring (19) to the base end of the cylinder.
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    Illustration 34	g06030259

12. Install bearing (16) and retaining ring (17) to the rod end of the cylinder.