VHC-30, VHC-40, VHC-50 and VHC-60 Hydraulic Crushers Hydraulic Cylinder - Remove and Install Caterpillar


Hydraulic Cylinder - Remove and Install
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1.1. Removal Procedure
2.1. Installation Procedure
3.1. Disassembly Procedure
4.1. Assembly Procedure

Removal Procedure

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     170-5738     Wrench     1    
B     -     Locktite 242     -    

------ WARNING! ------

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.

----------------------

  1. Position the work tool on suitable cribbing that is on a hard, level surface.



    Illustration 1g02043837

  1. Remove bolts (1) . Remove plate (2) .



    Illustration 2g02043838

  1. Disconnect hose assemblies (3) .



    Illustration 3g02104273

  1. Disconnect hose assemblies (4) .



    Illustration 4g02103296

  1. Remove bolts (5) in order to remove Tooling (A) from the work tool.



    Illustration 5g02103958

  1. Remove the two bolts that secure nut (6) . Use Tooling (A) to remove nut (6) .



    Illustration 6g02029428

  1. Install a suitable block between the cylinder rod and the jaw. Ensure that the suitable block is a tight fit. Remove pin (7) from the work tool. The weight of pin (7) is approximately 35 kg (77 lb).



    Illustration 7g02141358

  1. Attach a suitable lifting device to hydraulic cylinder (8) . Raise hydraulic cylinder (8) to a vertical position and remove the suitable block. Remove cylinder cover (9) .



    Illustration 8g02141388

  1. Use bolts (5) as pusher bolts. Remove bolts (10) . Remove cover (11) . Repeat for the other side.



    Illustration 9g02104113

  1. Remove hydraulic cylinder (8) . The weight of hydraulic cylinder (8) is approximately 680 kg (1500 lb).

Installation Procedure

  1. Install the hydraulic cylinder (8) in the reverse order as the removal.

    1. Torque bolts (10) to a torque of 520 ± 70 N·m (384 ± 52 lb ft). Repeat for the other side.

    1. Use Tooling (A) to tighten nut (6) to a torque of 300 ± 50 N·m (221 ± 37 lb ft). After you torque nut (6) , back off nut (6) until the nearest set of holes are aligned.

    1. Apply Tooling (B) to bolts (2) .

Disassembly Procedure

Table 2
Required Tools    
Tool     Part Number     Part Description     Qty    
A     9U-6260     Adapter     1    
4C-9634 Puller Stud     1    
7H-7539 Full Nut     1    
8M-4839 Adapter Assembly     1    
6V-3175 Double Acting Cylinder     1    
3S-6224 Electric Hydraulic Pump Gp     1    
B     152-4250     Hydraulic Cylinder Repair Stand     1    
C     6V-5684     Bolt     2    
1F-7960 Washer     8    
D     8C-8407     Bolt     2    

Start By:

  1. Remove the hydraulic cylinder.

------ WARNING! ------

When you are using hydraulic cylinders and puller studs, always ensure that the rated capacity of the puller stud meets or exceeds the rated capacity of the hydraulic cylinder. If the puller stud does not meet or exceed the rated capacity of the hydraulic cylinder, a sudden failure of the puller stud could occur. The sudden failure of the puller stud could result in personal injury or death.

----------------------

------ WARNING! ------

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 10g01320903

  1. Remove bushings (1) .



    Illustration 11g01320906

  1. Remove retaining rings (2) that are located between bushings (3) .



    Illustration 12g01320916

  1. Use Tooling (A) in order to remove bushings (3) .



    Illustration 13g01320920



    Illustration 14g01320922

  1. Remove hose assembly (4) and hose assembly (5) .

  1. Remove fitting (6) .

  1. Remove relief valve (7) .



    Illustration 15g01320925

  1. Attach a suitable lifting device to hydraulic cylinder (8) . The weight of hydraulic cylinder (8) is approximately 905 kg (2000 lb). Position hydraulic cylinder (8) on Tooling (B) . Use suitable cribbing between hydraulic cylinder (8) and Tooling (B) .

    Note: Ensure that all fluids are drained from the hydraulic cylinder.

  1. Use Tooling (B) in order to extend the rod assembly.



    Illustration 16g01320937

    Note: Mark the head assembly and the hydraulic cylinder for assembly purposes.

  1. Remove bolts (9) . Separate the hydraulic cylinder and rod assembly (10) .



    Illustration 17g01320940

  1. Remove wear rings (11) and seal assembly (12) . Remove bolts (13) and lock plate (14) .



    Illustration 18g01320946

  1. Install Tooling (C) in piston (15) . Use Tooling (C) and a suitable pry bar in order to loosen piston (15) .



    Illustration 19g01320949



    Illustration 20g01320951

  1. Install suitable cribbing under piston (15) . The weight of piston (15) is approximately 45 kg (100 lb). Install Tooling (D) in order to prevent piston (15) from falling.

  1. Use a suitable lifting device in order to remove piston (15) . Remove Tooling (C) and Tooling (D) .



    Illustration 21g01320954

  1. Remove O-ring seal (16) from piston (15) .



    Illustration 22g02243015

  1. Grind away the tack welds and remove half rings (17) from piston (15) .



    Illustration 23g02243077

  1. Attach a suitable lifting device to head assembly (18) . The weight of head assembly (18) is approximately 85 kg (185 lb). Remove head assembly (18) .



    Illustration 24g02243078

  1. Remove the following items from head assembly (18) : backup ring (19) , O-ring seal (20) , wiper seal (21) , seal assembly (22) , seal assembly (23) , seal assembly (24) and wear rings (25) .

Assembly Procedure

Table 3
Required Tools    
Tool     Part Number     Part Description     Qty    
A     9U-6260     Adapter     1    
4C-9634 Puller Stud     1    
7H-7539 Full Nut     1    
8M-4839 Adapter Assembly     1    
6V-3175 Double Acting Cylinder     1    
3S-6224 Electric Hydraulic Pump Gp     1    
B     152-4250     Hydraulic Cylinder Repair Stand     1    
C     6V-5684     Bolt     2    
1F-7960 Washer     8    
D     8C-8407     Bolt     2    
E     129-1967     Multipurpose Grease     1    
F     4C-9507     Retaining Compound     1    
G     -     Locktite 242     -    

Note: Cleanliness is an important factor. Thoroughly clean all parts in cleaning fluid before assembly. 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.

Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.


NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.


------ WARNING! ------

When you are using hydraulic cylinders and puller studs, always ensure that the rated capacity of the puller stud meets or exceeds the rated capacity of the hydraulic cylinder. If the puller stud does not meet or exceed the rated capacity of the hydraulic cylinder, a sudden failure of the puller stud could occur. The sudden failure of the puller stud could result in personal injury or death.

----------------------



    Illustration 25g02243078

    Note: Lubricate backup ring (19) through wear rings (25) with the lubricant that is being sealed.

  1. Install the following items into head assembly (18) : wear rings (25) , seal assembly (24) , seal assembly (23) , seal assembly (22) , wiper seal (21) , O-ring seal (20) and backup ring (19) .



    Illustration 26g01320964

  1. Attach a suitable lifting device to head assembly (17) . The weight of head assembly (17) is approximately 85 kg (185 lb). Position head assembly (17) on Tooling (B) . Slide head assembly (17) on the rod assembly.



    Illustration 27g01320954

  1. Install O-ring seal (16) on piston (15) .



    Illustration 28g01320951



    Illustration 29g01320949

  1. Install Tooling (C) on piston (15) . Install Tooling (D) in the rod assembly.

    Note: Be sure to utilize a suitable work surface that is flat and level in order to support piston (15) .

  1. Attach a suitable lifting device to piston (15) . The weight of piston (15) is approximately 45 kg (100 lb). Place piston (15) on Tooling (B) and suitable cribbing. Apply Tooling (E) to the threads of the rod assembly and piston (15) . Use Tooling (C) and a suitable pry bar in order to rotate piston (15) . Install piston (15) . Be sure that piston (15) is fully seated onto the rod assembly. Tighten piston (15) to a torque of 800 ± 200 N·m (590 ± 148 lb ft). Remove Tooling (C) and Tooling (D) .



    Illustration 30g01321387



    Illustration 31g02243914



    Illustration 32g01320940

    Note: During installation, ensure that Surface (X) is lower than Surface (Y) .

  1. Apply Tooling (F) to bolts (13) . Install lock plate (14) and bolts (13) .

    Note: Make sure that lock plate (14) does not extend beyond the end surface of the rod. The end surface of the rod acts as the end stop. Make sure that lock plate (14) does not contact the face of the piston.

  1. Use 3.0 mm (0.125 inch) low hydrogen welding rods "7018" and tack weld the two half rings to the piston. Refer to 31 for weld placement and dimensions.

  1. Install wear rings (11) and seal assembly (12) .

    Note: Lubricate wear rings (11) and seal assembly (12) with the lubricant that is being sealed.




    Illustration 33g01320925



    Illustration 34g01320937

  1. Slide hydraulic cylinder (8) over rod assembly (10) . Align the Mark on the head assembly with the Mark on hydraulic cylinder (8) .

  1. Apply Tooling (G) to bolts (9) and install bolts (9) . Tighten bolts (9) to a torque of 690 ± 35 N·m (510 ± 26 lb ft).



    Illustration 35g01320922



    Illustration 36g01320920

  1. Install relief valve (7) .

  1. Install fitting (6) .

  1. Install hose assembly (5) and hose assembly (4) .



    Illustration 37g01320916

  1. Use Tooling (A) in order to install bushings (3) .



    Illustration 38g01320906

  1. Install retaining rings (2) that are located between bushings (3) .



    Illustration 39g01320903

  1. Install bushings (1) .

End By: Install the hydraulic cylinder.

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