ORIFICE 2838325 - Caterpillar

Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-9900 Hydraulic Cylinder Repair Stand 1
B(1) 6V-6080 Torque Multiplier 1
5S-6079 65 mm Socket 1
C 9U-7868 Spanner Wrench 1
123-3803 Adapter Plate 1
D 1P-0510 Seal Driver 1
E 9U-6600 Hydraulic Pump 1
5P-4749 Puller Plate 1
5P-4776 Threaded Rod 1
7S-9484 Sleeve 1
5P-8713 Plate 1
9U-6833 Nut 1
6V-7047 Hydraulic Cylinder 1
F - Loctite 609 -
G - Loctite Graphite-50 Anti-Seize -
H 1P-0808 Multipurpose Grease -
J - Loctite Gasket Sealant No. 2 -
(1) Use Tooling (B) if Tooling (A) is unavailable.
Illustration 1 g00546843
Check the condition of all the 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 (17) are thoroughly clean prior to assembly.
Install ring (19), bearing (20), seal (21), seal (22), and ring (23) in head (17), as shown. Apply Tooling (F) in the bore of the head of lip seal (24). Use Tooling (D) to install lip seal (24) in head (17). Make sure that the sealing lip is toward the outside of the cylinder.
Install O-ring seal (13) and ring (14) in head (17).
Put clean hydraulic oil on the lip of lip seal (24), ring (23), seal (22), and seal (21).
Position head (17) on cylinder assembly (10). Tighten the head by hand. Carefully install rod assembly (9) in head (17) and the cylinder assembly. Loosen the head. Remove the head and rod assembly as a unit from the cylinder assembly.Note: The slit of ring (11) must be positioned in the direction of the piston.
Install ring (11) on the rod assembly. The slit in ring (11) must face piston (6). Install stop (12) on rod assembly (9).
Install piston (6) on the rod assembly. Lubricate the threads on the end of the rod assembly with Tooling (G). Install locknut (2). Use Tooling (B) to tighten locknut (2) to a torque of 3600 190 N m (2660 140 lb ft).
Install ring (5), O-ring seal (4), and ring (3) on piston (6). Lubricate the outside of the piston with Tooling (H).
Install O-ring seal (7), ring (8), and O-ring seal (16) on head (17).
Use Tooling (A) to install cylinder assembly (10) on rod assembly (9). Extend the rod fully. Use Tooling (C) to tighten head (17) to a torque of 850 90 N m (625 65 lb ft).Note: If the hole in the cylinder assembly does not align with the hole in the head, a new hole must be drilled. If a new head (17) is used, a new hole must be drilled. Use a 4.5 mm (0.18 inch) drill bit. Drill in the original hole in the cylinder assembly. Drill the new hole to the required depth in the head. The combined depth of the hole is 23.0 0.50 mm (0.91 0.019 inch) from the outside surface of the cylinder assembly to the