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 1 g03420954Note: Bucket has been removed for photo purposes. Position Tooling (A) under lift arms (1). Illustration 2 g03421324 Disconnect hose assemblies (2). Illustration 3 g03421363 Attach a suitable lifting device to lift cylinder (3). The weight of cylinder (3) is approximately 726 kg (1600 lb). Illustration 4 g03421378 Remove bolt (4). Illustration 5 g03421381 Illustration 6 g03421430 Attach a suitable lifting device to Tooling (B). The weight of Tooling (B) is approximately 136 kg (300 lb). Install Tooling (B) onto pin assembly (5). The weights of Tooling (B) and pin assembly (5) are approximately 181 kg (400 lb). Remove Tooling (B) and pin assembly (5). Lower lift cylinder (3) on to suitable cribbing. Reposition suitable lifting device on lift cylinder (3). The weight of lift cylinder (3) is approximately 726 kg (1600 lb). Illustration 7 g03421517 Attach a suitable lifting device to Tooling (C). The weight of Tooling (C) is approximately 136 kg (300 lb). Install Tooling (C) onto pin assembly (6). The weights of Tooling (C) and pin assembly (6) are approximately 181 kg (400 lb). Remove Tooling (C) and pin assembly (6). Remove the lift cylinder.Disassembly and Assembly Table 2 Required Tools Tooling Part Number Part Description Qty F 127-4904 Hydraulic Cylinder Repair Stand Gp 1 G 195-4609 Seal Pick 1 H - Loctite® 638 1 J 485-0088 Seal Guide 1 Illustration 8 g03828388Lubricate seals (4), (5), and (6) with a minimal amount of the fluid that is being sealed. (2) Torque for the nut ... 13500 1350 N m (9960 995 lb ft)Note: Lubricate the threads of the cylinder rod before nut (2) is installed. (3) Torque for the bolts ... 900 100 N m (664 74 lb ft)Apply Tooling (H) to the seal groove prior to assembling the wiper seal.Tooling (J) is used when you are installing seals (4), (5), and (6).Assemble the piston seal with the step cut oriented 180° from the head ports.Installation Procedure Illustration 9 g03485498Note: Use Illustration (8) as a guide for the pins and the pin joints that are being referenced in the procedure. Install lift cylinder (3) in the reverse order of removal. Check and replace lip seals if necessary. If replacing the lip seal, apply Tooling (D) to the bore. Lubricate the diameter of Y-pin (6) with Tooling (D). Use Tooling (C) to install pin (6). Add Tooling (E) through grease hardware until lubricant extrudes from the seal. Lubricate the diameter of K-pin (5) with Tooling (D). Use Tooling (B) to install pin (5). Add Tooling (E) through grease hardware until lubricant extrudes from the seal.
