M325B Material Handler Machine Systems Boom Cylinder - Assemble Caterpillar


Boom Cylinder - Assemble
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1.1. Assembly Procedure

Assembly Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
  Hydraulic Cylinder Repair Stand (1) 
3S-6224 Electric Hydraulic Pump 
8T-0820 Hydraulic Pressure Gauge 
3B-7722 Bushing 
1P-2376 Connecting Coupler 
1P-2377 Dust Plug 
6D-7726 Hose Assembly 
4C-4470  Socket (80 mm) 
3S-6224  Electric Hydraulic Pump 
8T-0820 Hydraulic Pressure Gauge 
3B-7722 Bushing 
1P-2376 Connecting Coupler 
1P-2377 Dust Plug 
6D-7726 Hose Assembly 
6V-0113 Cylinder Group (Double Acting) 
9U-6832 Nut 
4C-9634 Puller Stud 
9U-5339 Adapter (Bearing Puller) 
1P-0520  Driver Group 
(1) Refer to Tool Guide, NEHC2004, "Hydraulic Cylinder Repair Stands".

Note: Cleanliness is an important factor. Before the assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.


NOTICE

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.


Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.



    Illustration 1g00614594
    Typical Example

  1. Check the condition of all parts of the boom cylinder for wear or damage. If any of the parts are worn or damaged, use new parts for replacement.

    Note: Make sure that the grooves for the seals in head (19) are thoroughly clean prior to assembly.

  2. Install ring (11), bearing (14), seal (15), seal (16), and ring (17) in head (19).

  3. Apply 4C-4032 Bearing Mount Compound to the wiper seal groove prior to assembly.

  4. Ensure that the lip is facing away from the inside of the cylinder. Use Tooling (D) in order to install seal (18) in head (19).

  5. Install seal (9) and ring (10) in head (19).

  6. Put clean hydraulic oil on the lip of seal (18), ring (17), seal (16), and seal (15).

  7. Put head (19) in position on cylinder assembly (1).

  8. Install eight bolts (13) that hold head (19) to cylinder assembly (1).

  9. Install rod assembly (12) in head (19) and cylinder assembly (1).

  10. Remove eight bolts (13).

  11. Remove cylinder assembly (1) from the rod assembly and the head.

    Note: The cut out of ring (7) must be positioned in the direction of piston.

  12. Install ring (7) on the rod assembly. The cut out of ring (7) must face the piston (6).

  13. Install stop (8) on rod assembly (12).

  14. Install piston (6) on the rod assembly.

  15. Lubricate the threads on the end of the rod assembly with 4C-5593 Anti-Seize Compound.

  16. Install locknut (2).

  17. Use Tooling (B) to tighten locknut (2) to a torque of 7900 ± 400 N·m (5826 ± 295 lb ft).

  18. Install rings (27), stop (29), ring (26), and ring (28) on rod assembly (16).

  19. Install ring (5), seal assembly (4) and ring (3) on piston (6).

  20. Lubricate the outside of the piston with 1P-0808 Multipurpose Grease.

  21. Use Tooling (A) to install cylinder assembly (1) on rod assembly (12).

  22. Install eight bolts (13) that hold head (19) to cylinder assembly (1).

  23. When the rod assembly is fully extended, tighten the bolts (13).

  24. Lower the temperature of sleeve bearing (25).

  25. Use Tooling (D) to install the bearing in the pin bore of the rod assembly (12). Install the bearing until the bearing is centered in the bore.

  26. Ensure that the sealing lips are facing out. Install the seals. Use Tooling (D) to install lip seals (24) in the pin bore on both sides of rod assembly (12). Install the seals until the face makes contact with the bearing.

  27. Lower the temperature of sleeve bearing (23).

  28. Use Tooling (D) to install the bearing in the pin bore of the cylinder assembly (1). Install the bearing until the bearing is centered in the bore.

  29. Ensure that the sealing lips are facing out. Install the seals. Use Tooling (D) to install lip seals (22) in the pin bore on both sides of cylinder assembly (1). Install the seals until the face makes contact with the bearing.

  30. Install grease fitting (20) in cylinder assembly (1). Tighten the grease fitting.

End By:

  1. Install the boom cylinder. Refer to Disassembly and Assembly, "Boom Cylinder - Install".

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