PLUG-EXPANSION 2074929 - Caterpillar

Start By:
Release hydraulic system pressure.
Remove the hydraulic hammer.
Remove the tool bushing.
Illustration 1 g03479390
Illustration 2 g03479400
Discharge the high-pressure accumulator. Remove plug (1) and the O-ring seal. Slowly loosen plug (2) until the dry nitrogen gas begins to escape, stop turning plug (2). When the discharge of the gas can no longer be heard, remove plug (2) and the O-ring seal.
Illustration 3 g03479456
Illustration 4 g03479461
Discharge the low-pressure valve body. Remove plug (3) and the O-ring seal. Slowly loosen plug (4) until the dry nitrogen gas begins to escape, stop turning plug (4). When the discharge of the nitrogen gas can no longer be heard, remove plug (4) and the O-ring seal .
Illustration 5 g03472296
Personal injury can result from air pressure against the valve body. The valve body can come off the head with force when applying air pressure.To prevent possible personal injury, the valve body must be retained to the head by bolts when applying air pressure.
Use Tooling (B) and a suitable lifting device to remove valve body (6). The weight of valve body (6) is approximately 29 kg (65 lb)
With bolts (5) backed out to approximately 25 mm (1.0 inch), use a suitable air gun and apply shop air to Port (X). Valve body (6) will separate from the head. Remove bolts (5) and valve body (6) .Note: Make sure that all port holes are plugged to avoid oil spray from compressed air.
Illustration 6 g03468298
Illustration 7 g03468301
Using Tooling (C) to remove seal carrier (7) from valve body (6). Remove seals (8) from seal carrier (7).
Illustration 8 g03442676
Using Tooling (A) and a suitable lifting device to remove piston (9).
Illustration 9 g03446164
Use a suitable lifting device to reposition the head assembly as shown. Refer to Table 2 for the approximate weight of the head assembly. Use Tooling (D) to remove sleeve assembly (10).
Table 2
Sales Model     Head Assembly
Approximate Weight    
H55E    
45 kg (99 lb)    
H65E    
62 kg (137 lb)    
Illustration 10 g03468397
Illustration 11 g03442682
Remove membrane (11) from sleeve assembly (10). Remove seal assemblies (12) from sleeve assembly (10). Note: Do NOT remove tube (13) from sleeve assembly (10), the components are not individually serviced.