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Product: EXCAVATOR
Model: 320B EXCAVATOR 5BR
Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-UP
(MACHINE) POWERED BY 3066 ENGINE

Disassembly and Assembly

320B, 320B L,320B LN, 320B N, & 320B S EXCAVATORS MACHINE SY
Media Number -SENR9257-06 Publication Date -01/04/2004 Date Updated -02/12/2004

SENR92570004

Bucket Cylinder
SMCS - 5457-010; 5457-017

Remove & Install Bucket Cylinder

Fluid Spillage Containment

Care must be taken to ensure that the fluids are contained during performance of the inspection, the
maintenance, the testing, the adjusting and the repair of the machine. Be prepared to collect the fluid with
suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to the "Tools And Shop Products Guide, NENG2500" the tools and the supplies suitable to collect and
contain any of the fluids in Caterpillar machines. Dispose of the fluids according to local regulations and
mandates.

Cylinders equipped with lock valves can remain pressurized for long
periods of time, even with the hoses removed.

Failure to relieve pressure before removing a lock valve or

disassembling a cylinder can result in personal injury or death.

Ensure all pressure is relieved before removing a lock valve or

disassembling a cylinder.

1. Start the machine, and fully extend the stick and the bucket. Lower the stick and the bucket to the ground.

At operating temperature, the hydraulic oil tank is hot and under

pressure. Hot oil can cause burns. To prevent possible personal injury,
release the pressure in all of the implement hydraulic circuits (the
 boom, the stick and the bucket) before any of the hydraulic lines or any
of the components are disconnected or removed.

2. Release the pressure in all of the implement hydraulic circuits (the boom, the stick and the bucket) before
any of the hydraulic lines or any of the components are disconnected or removed. Release the pressure as
follows:

a. Shut off the engine and place key in the "ON" position. Put the hydraulic activation control lever in
the "UNLOCK" position.

b. Move the control levers for the boom, the stick and the swing to all full stroke positions. This will
release any pressure that might be present in the pilot system.

c. Return the key to "OFF" position.

d. Slowly loosen the fill plug on the hydraulic tank and release the pressure.

e. Tighten the fill plug on the hydraulic tank. Tighten the fill plug to a torque of 68 ± 7 1*m (50 ± 5 lb
ft).

f. The pressure in the hydraulic system has been released and the hydraulic lines and the components
can be removed.

3. Fasten a hoist to the rod end of the bucket cylinder as shown. Put a wood block (3) under the link
assemblies as a support.

4. Remove the two nuts and retaining bolt (1). Remove pin (2).

5. Raise bucket cylinder (4) until it is level; then fasten a lifting sling and a host to the head end of the bucket
cylinder as shown.

6. A small amount of oil will drain from hoses (5) when they are disconnected from the bucket cylinder.
Drain the oil from hoses (5) in a suitable container for disposal. Disconnect two hoses (5) from the bucket
cylinder. Put plugs in the ends of the hoses to prevent oil loss and to keep contaminants out of the hydraulic
system.

7. Remove pin assembly retaining bolt (6), the washer, pin assembly (7) and the spacer. Remove the bucket
cylinder. The weight of the bucket cylinder is 147 kg (325 lb).

1OTE: Machines may be equipped with shim(s) between the stick and the bucket cylinder at the stick-to-
bucket cylinder pin joint. For assembly purposes, put identification marks on the shim(s) as to their location.

8. Remove the shim(s) (if so equipped) at the stick-to-bucket cylinder pin joint.

1OTE: The following steps are for the installation of the bucket cylinder.

9. Make sure the pin bores in the stick, the link assemblies, and the bucket cylinder are clean and free of dirt
prior to the installation of the bucket cylinder.

10. Fasten a hoist to bucket cylinder (4), and put it in position in the stick. Make sure the pin bores in the
stick and the bucket cylinder are in alignment. Also, make sure the grease fitting in the head end and rod end
of the bucket cylinder are facing away from the stick.

11. Put a thin coat of 5P-0960 Multipurpose Grease on pin assembly (7). Temporarily install the spacer and
pin assembly (7). Do 1ot remove the hoist from the bucket cylinder at this time.
Top View Of Stick And Bucket Cylinder

12. Slide the bucket cylinder to one side until it makes contact with the stick. Measure the total clearance
between the bucket cylinder and the stick at the pin bore. The total clearance of (a) and (b) must not be more
than 1.0 mm (.04 in). If the total clearance is less than 1.0 mm (.04 in), the addition of shim(s) between the
bucket cylinder and the stick will not be required. If the total clearance is more than 1.0 mm (.04 in), add the
correct thickness of shim(s) to obtain the necessary clearance.

13. If it has been determined that shim(s) need to be installed between the stick and the bucket cylinder,
remove pin assembly (7) and the spacer. Install the shim(s) between the stick and the bucket cylinder on the
side opposite pin assembly retaining bolt; then reinstall the spacer and pin assembly (7). Install pin assembly
retaining bolt (6) and the washer that holds the pin assembly in position. Tighten pin assembly retaining bolt
(6) to a torque of 325 ± 40 1*m (240 ± 30 lb ft).
14. Lower the bucket cylinder between the link assemblies. Put a thin coat of 5P-0960 Multipurpose
Grease on pin (2). Make sure the bore in the bucket cylinder rod is in alignment with the bores in the link
assemblies. Install pin (2). Install retaining bolt (1) and the two nuts.

15. Rotate pin (2) until it is in the position shown. Tighten the nuts on retaining bolt (1) as shown in the
illustration. Tighten the outside nut until it is even or 0.5 mm (.02 in) above the end of the retaining bolt.
Tighten the inside nut against the outside nut to a torque of 200 ± 40 1*m (150 ± 30 lb ft).

16. Check the condition of the O-ring seals in the ends of hoses (5) prior to the installation. If the O-ring
seals are damaged, use new parts for replacement. Connect the two hoses to the bucket cylinder.

1OTE: Refer to the topic "Lubricant Viscosities and Refill Capacities" in the "Operation & Maintenance
Manual" for the proper filling procedure and the proper levels for the hydraulic system.

17. Fill the hydraulic oil tank with oil to the correct level. Lubricate the bucket cylinder support pins.

18. Start the machine, and run it at low idle speed. Move the control lever for the bucket cylinder so the
cylinder rod extends to its halfway position; then retract the cylinder rod. The cylinder should be cycled this
way approximately ten times to remove the air from the hydraulic system. Recheck the oil level in the
hydraulic oil tank.

Disassemble & Assemble Bucket Cylinder

Start By:

a. remove bucket cylinder

Cylinders equipped with lock valves can remain pressurized for long
periods of time, even with the hoses removed.

Failure to relieve pressure before removing a lock valve or

disassembling a cylinder can result in personal injury or death.

Ensure all pressure is relieved before removing a lock valve or

disassembling a cylinder.
1. Put the bucket cylinder on Tooling (A).

2. Remove bolts (6) that hold head (23) to cylinder assembly (22).

3. Use Tooling (A) to slide rod assembly (24) out of cylinder assembly (22).

4. Remove seal assembly (20), ring (19), ring (18) and ring (17) from the piston.

5. Remove setscrew (13) and ball (14) from locknut (15). Using Tool (B), remove locknut (15) that holds
piston (21) to rod assembly (24). Remove spacer (16). Remove the piston from the rod assembly.

6. Slide cylinder assembly (22) back on the rod assembly. Install bolts (6) that hold head (23) to the cylinder
assembly. Pull the cylinder assembly and head (23) as a unit away from the rod assembly. Remove the head
from the cylinder assembly.

7. Remove ring (9), O-ring seal (8), ring (7), bearing (5), seal (1), ring (2), ring (3) and ring (4) from head
(23).

8. Remove lip seals (12) and (26) from both sides of the cylinder assembly and the rod assembly.

9. Remove bearings (11) and (25) from the cylinder assembly and the rod assembly.

1OTE: The following steps are for the assembly of the bucket cylinder. Refer to illustration C49586P1 for
the assembly of the bucket cylinder.

10. Install bearings (25) and (11) in the cylinder assembly and the rod assembly. Be sure the bearings are
centered in the bore.

11. Using Tooling (C), install lip seals (26) and (12) in the rod assembly and the cylinder assembly. Install
the lip seals with the lip facing out.

12. Install ring (4), ring (3) and ring (2) in head (23), as shown. Using Tooling (C), install seal (1) in head
(23) with the lip of the seal facing away from the inside of the cylinder. Install bearing (5) and ring (7) in
head (23), as shown. Install O-ring seal (8) and ring (9) in head (23), as shown.

13. Put clean hydraulic oil on the lip of seal (1), ring (2), ring (3) and ring (4).

14. Put head (23) in position on cylinder assembly (22). Install bolts (6) that hold it. Install rod assembly (24)
in head (23) and the cylinder assembly. Remove bolts (6). Remove cylinder assembly (22) from the rod
assembly and the head.

15. Install piston (21) on the rod assembly. Lubricate the threads on the end of the rod assembly with 2P-
2506 Threads Lubricant. Install spacer (16).

16. Install locknut (15), and tighten it with Tool (B) to a torque of 6540 ± 325 1*m (4820 ± 240 lb ft).
Install ball (14) and setscrew (13) in the locknut. Tighten the setscrew to a torque of 57 ± 10 1*m (42 ± 7 lb
ft).

17. Clean the remaining threads in the setscrew hole of the locknut. Make sure the remaining threads are
clean and dry. To prevent setscrew (13) from loosening, apply 5P-3321 Fast Cure Epoxy in the threaded
setscrew hole. Make sure the epoxy is even with the outside surface of the locknut after application.

18. Install ring (17), ring (18), ring (19) and seal assembly (20) on piston (21). Lubricate the outside of the
piston with 1P-0808 General Purpose Lubricant.

19. Using Tooling (A), install cylinder assembly (22) on the rod assembly. Install bolts (6) that hold head
(23) to the cylinder assembly. Tighten bolts (6) with the rod assembly fully extended. Tighten the bolts to a
torque of 265 ± 40 1*m (195 ± 30 lb ft).

End By:

a. install bucket cylinder.

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