PIN AS 3641374 - Caterpillar

Start By:a. remove belt tensioner cylinder
Dry nitrogen is the only gas approved for use in the belt tensioner cylinders. The charging of oxygen gas in these components, by accident, will cause an explosion. This danger can be eliminated by the use of nitrogen cylinders with standard CGA (Compressed Gas Association, Inc.) No. 580 Connections. When nitrogen gas is ordered, make sure to order the cylinders with CGA No. 580 Connections. Do not attempt to identify by color codes or other methods of identification to tell the difference between nitrogen and oxygen cylinders. Never use an adapter to connect the nitrogen charging group to a valve outlet used on both nitrogen, oxygen or other gas cylinders. Be sure to use dry nitrogen.
1. Position belt tensioner cylinder (2) as shown.2. Bleed off the nitrogen gas from belt tensioner cylinder (2) by loosening nitrogen valve cap (1). 3. Remove four bolts and washers (3) and remove plate assembly (4). 4. Remove two bolts (5) and remove manifold (6). a. Remove the O-ring seal from manifold (6). 5. Remove two bolts (7) and relief valve (8). a. Remove the O-ring seal from relief valve (8). 6. Install belt tensioner cylinder (2) in Tooling (A). Align rod assembly (9) with the notch on the side and at the bottom of fixture (A). 7. Install a strap and hoist to cap (11).a. Remove four bolts and washers (10).b. Remove cap (11) from tensioner cylinder (2).c. The weight of cap (11) is 27 kg (60 lb). 8. Remove O-ring seal (12) and head seal (13) from cap (11). 9. Remove bolt and washer (14) from piston (15) in tensioner cylinder (2) with Tooling (D) and (E). 10. Install Tool (B) to piston (15).a. Remove piston (15) from tensioner cylinder (2). 11. Remove seal assembly (16) and wear ring (17) from piston (15). 12. Install two straps and a hoist 180 degrees apart around the top coils of spring (18).a. Install four pieces of cardboard (X) 90 degrees apart, cut to 711 mm (28 in) X 51 mm (2 in).b. Insert cardboard (X) between tensioner cylinder (2) wall and spring (18).c. Remove spring (18), stopping periodically to move cardboard (X) down in bore of tensioner cylinder (2) until spring (18) is completely removed. The weight of spring (18) is 78 kg (170 lb). 13. Install Tool (C) to tensioner cylinder (2).a. Lift tensioner cylinder (2) off rod assembly (9). The weight of tensioner cylinder (2) is 106 kg (235 lb). 14. If necessary, remove lip seal (19), two "U" cup seal assemblies (20), and wear ring (21) from tensioner cylinder (2). 15. Install bolt (14) and a strap to rod assembly (9).a. Remove rod assembly (9) from Tool (A).b. The weight of rod assembly (9) is 33 kg (73 lb). 16. If necessary, remove two rings (22) and aligning bearing (23) from rod assembly (9). The following steps are for assembly of the belt tensioner cylinder.17. Apply 7M-7456 Bearing Mount to the bore of rod assembly