WIRE-BULK 5424432 - Caterpillar

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g00696722
Illustration 2 g00697052
Coat the outside surface of the upper tool bushing with 4C-5598 High Temperature Anti-Seize. Install upper tool bushing (12) into head (11). Coat the inside surface of the upper tool bushing with clean grease.
Use a suitable lifting device in order to lift the head. The weight of the head is 1200 kg (2646 lb). Place the head (11) on 185-3208 Hammer Stand. Refer to FT-2639 for the prints for the pins that are required to hold the hammer on the stand.
Coat the outside surface of the thrust ring with 4C-5598 High Temperature Anti-Seize. Use a suitable lifting device in order to lift the thrust ring. The weight of the thrust ring is 72 kg (159 lb). Install thrust ring (13) into head (11). Coat the inside surface of the thrust ring with clean grease.
Illustration 3 g00697068Note: The standard location of the inlet port is to the left side of the hammer. When you install the wedge, you must install the wedge in the hole in the head that does not have the dot that is punched into the head. The dot is above the hole. If you are installing the inlet port on the right side, you must install the wedge in the hole that has the dot above the hole.
Align the notch in the thrust ring with the hole for the wedge. Install wedge (9) and O-ring (10) into the bore of the head. Install the wedge with the chamfers in the upward direction.
Illustration 4 g00697036
Install new seals (14) into the bore of lower seal carrier (15). Install new O-rings (8) and (17) onto the top of lower seal carrier (15).
Illustration 5 g00697046
Coat piston (18) with clean oil . Install cylinder (7) onto piston (18). Use a suitable lifting device in order to lift the piston and the cylinder. The weight of the piston is 260 kg (573 lb). The weight of the cylinder is 255 kg (562 lb).
Illustration 6 g00696906
Install lower seal carrier (15) onto piston (18). Use a suitable lifting device in order to lift the lower seal carrier. The weight of the lower seal carrier is 111 kg (245 lb).
Illustration 7 g00696922
Install three threaded rods (16) through lower seal carrier (15) and into cylinder (7).
Use a suitable lifting device in order to lift cylinder (7), lower seal carrier (15), and piston (18). The combined weight of the cylinder, piston, and lower seal carrier is 626 kg (1380 lb). Coat the outer surfaces of the lower seal carrier and the cylinder that contact the head and the thrust ring with 4C-5598 High Temperature Anti-Seize.