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 4g02108680

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



    Illustration 5g02029420

  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 19 kg (42 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 8g02141372

  1. Use bolts (5) as pusher bolts. Remove bolts (10) . Remove cover (9) . Repeat for the other side.



    Illustration 9g02104113

  1. Remove hydraulic cylinder (8) . The weight of hydraulic cylinder (8) is approximately 452 kg (996 lb).

Installation Procedure

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

    1. Torque bolts (10) to a torque of 270 ± 40 N·m (199 ± 30 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     6V-4035     Sleeve     1    
4C-9634 Puller Stud     1    
7H-7539 Full Nut     1    
9U-5338 Adapter     1    
6V-3175 Double Acting Cylinder     1    
3S-6224 Electric Hydraulic Pump Gp     1    
B     152-4250     Hydraulic Cylinder Repair Stand     1    
C     4C-8155     Spanner Wrench As     1    

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 10g01321496

  1. Remove bushings (1) .



    Illustration 11g01321492

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



    Illustration 12g01321490

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

  1. Attach a suitable lifting device to hydraulic cylinder (4) . The weight of hydraulic cylinder (4) is approximately 403 kg (888 lb). Position hydraulic cylinder (4) on Tooling (B) .



    Illustration 13g01321493

  1. Remove hose assembly (6) and hose assembly (7) .

  1. Remove fitting (8) .

  1. Remove relief valve (5) .



    Illustration 14g01321491

    Note: Ensure that all fluids are drained from hydraulic cylinder (4) .

  1. Use Tooling (B) in order to extend rod assembly (11) .

    Note: Mark head assembly (9) and hydraulic cylinder (4) for assembly purposes.

  1. Remove bolts (10) . Separate hydraulic cylinder (4) and rod assembly (11) .



    Illustration 15g01321494

  1. Remove wear rings (12) and seal assembly (13) . Remove lock pin (14) .



    Illustration 16g01321505

  1. Use Tooling (C) in order to loosen piston (15) . Remove piston (15) .



    Illustration 17g01321497

  1. Remove O-ring seals (16) and backup ring (17) .



    Illustration 18g01321503

  1. Use a suitable lifting device in order to remove head assembly (9) . The weight of head assembly (9) is approximately 38 kg (84 lb).



    Illustration 19g01321500

  1. Remove the following items from head assembly (9) : wiper seal (19) , seal assembly (20) , seal assembly (21) and wear rings (18) .

Assembly Procedure

Table 3
Required Tools    
Tool     Part Number     Part Description     Qty    
A     6V-4035     Sleeve     1    
4C-9634 Puller Stud     1    
7H-7539 Full Nut     1    
9U-5338 Adapter     1    
6V-3175 Double Acting Cylinder     1    
3S-6224 Electric Hydraulic Pump Gp     1    
B     152-4250     Hydraulic Cylinder Repair Stand     1    
C     4C-8155     Spanner Wrench As     1    
D     129-1967     Multipurpose Grease     1    
E     -     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 20g01321500

    Note: Lubricate wear rings (18) through seal assembly (21) with the lubricant that is being sealed.

  1. Install the following items into head assembly (9) : wear rings (18) , seal assembly (21) , seal assembly (20) and wiper seal (19) .



    Illustration 21g01321503

  1. Attach a suitable lifting device to head assembly (9) . The weight of head assembly (9) is approximately 38 kg (84 lb). Position head assembly (9) on Tooling (B) . Slide head assembly (9) on the rod assembly.



    Illustration 22g01321497

  1. Install backup ring (17) and O-ring seals (16) .



    Illustration 23g01321505

  1. Apply Tooling (D) to the threads of the rod assembly and piston (15) prior to assembly. Install piston (15) on the rod assembly. Use Tooling (C) to tighten piston (15) to a torque of 800 ± 200 N·m (590 ± 148 lb ft).



    Illustration 24g02237895

  1. Drill an 8 mm hole through the piston rod. Use the hole in piston (15) as a guide. Remove the burrs from the hole and clean the hole.



    Illustration 25g01321494

  1. Install lock pin (14) . Install seal assembly (13) and wear rings (12) .

    Note: Lubricate wear rings (12) and seal assembly (13) with the lubricant that is being sealed.




    Illustration 26g01321491

  1. Slide hydraulic cylinder (4) over rod assembly (11) . Align the Mark on head assembly (9) with the Mark on hydraulic cylinder (4) .

  1. Apply Tooling (E) to bolts (10) and install bolts (10) . Tighten bolts (10) to a torque of 300 ± 25 N·m (220 ± 18 lb ft).



    Illustration 27g01321493

  1. Install relief valve (5) .

  1. Install fitting (8) .

  1. Install hose assembly (7) and hose assembly (6) .



    Illustration 28g01321492

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



    Illustration 29g01321490

  1. Use Tooling (A) in order to install bushings (3) in hydraulic cylinder (4) .



    Illustration 30g01321496

  1. Install bushings (1) .

End By: Install the hydraulic cylinder.

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