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Product: HYDRAULIC SHOVEL

Model: 6050 FS HYDRAULIC SHOVEL DH2
Configuration: USE PARTS IDENTIFICATION EXPANDED MINING DH200001-UP (MACHINE)

Disassembly and Assembly

6050 Hydraulic Mining Shovel Machine Systems
Media Number -M0070070-09 Publication Date -01/10/2017 Date Updated -31/10/2017

i06683482

Cylinder - Disassemble and Assemble - Boom Cylinder

SMCS - 7562-017

S/N - DH21-UP

Disassembly Procedure
Table 1
Required Tools
Tool Part Number Description Qty
A 152-4249 Hydraulic Cylinder Repair Stand Gp 1

Table 2
Cylinder Specifications
Part Number Cylinder Assembly Cylinder Rod
486-9962 6494 kg (14317 lb) 2889 kg (6369 lb) 2448 kg (5397 lb)
471-2158 6495 kg (14319 lb) 2890 kg (6371 lb) 2448 kg (5397 lb)
465-8707 4908 kg (10820 lb) 2234 kg (4925 lb) 1731 kg (3816 lb)
471-2152 996 kg (2196 lb) 388 kg (855 lb) 408 kg (899 lb)
467-1674 1931 kg (4257 lb) 894 kg (1971 lb) 705 kg (1554 lb)
471-2159 4012 kg (8845 lb) 1796 kg (3959 lb) 1301 kg (2868 lb)
465-6234 2116 kg (4665 lb) 948 kg (2090 lb) 744 kg (1640 lb)

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471-2134 3485 kg (7683 lb) 1582 kg (3488 lb) 1190 kg (2623 lb)
471-2135 549 kg (1210 lb) 223 kg (492 lb) 208 kg (459 lb)
471-2137 9325 kg (20558 lb) 4550 kg (10031 lb) 2715 kg (5986 lb)
471-2138 2750 kg (6063 lb) 1330 kg (2932 lb) 918 kg (2024 lb)

Start By:

a. Remove the boom cylinder.

Cylinders equipped with lock valves can remain pressurized for very
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.

NOTICE

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.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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Refer to the procedures that are listed below to disassemble and assemble the following hydraulic
cylinders:

• 486-9962 Boom Cylinder Gp

• 471-2158 Boom Cylinder Gp

• 465-8707 Boom Cylinder Gp

• 471-2152 Boom Cylinder Gp

• 467-1674 Boom Cylinder Gp

• 471-2159 Boom Cylinder Gp

• 465-6234 Hydraulic Cylinder Gp

• 471-2134 Boom Cylinder Gp

• 471-2135 Boom Cylinder Gp

• 471-2137 Boom Cylinder Gp

• 471-2138 Boom Cylinder Gp

Note: Some rod and piston assemblies may be one piece machined design.

1. Ensure that all the oil is removed from the cylinder.

2. Use a suitable lifting device to place the cylinder onto Tooling (A). Refer to Table 2 for the
approximate weight of the appropriate cylinder.

Illustration 1 g06219801

3. Use a suitable lifting device to support the weight of rod assembly (2). Refer to Table 2 for
the approximate weight of rod assembly (2).

4. Remove bolts (1) and rod assembly (2).

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Illustration 2 g06219803

5. Remove bolts (3) and eye (4).

Illustration 3 g06219805

6. Remove retaining ring (5) and bearing (6).

Illustration 4 g06219811

7. Remove O-ring seal (9) from flange (8).

8. Remove flange (8) from rod assembly (2).

9. Remove dowel (7) from rod assembly (2).

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Illustration 5 g06219822

10. Remove head assembly (10) from rod assembly (2).

Illustration 6 g06219986

11. Remove wiper seal (11), U-cup seal (12), buffer seal (13), and wear ring (14).

12. Remove O-ring seal and back up ring (15).

Illustration 7 g06220005

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13. Remove seal (16), wear ring (20), wear ring (17), piston seal (21), wear ring (18), wear ring
(23), and seal (19) from the rod assembly.

Assembly Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Prior to assembly, ensure that all the components are clean and free of defects.

1. Lubricate all the cylinder components with the lubricant that is being used prior to
installation.

Illustration 8 g06220005

2. Install seal (19), wear ring (23), wear ring (18), piston seal (21), wear ring (17), wear ring
(20), and seal (16).

Illustration 9 g06219986

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3. Install O-ring seal and back-up ring (15).

4. Install wear ring (14), buffer seal (13), U-cup seal (12), and wiper seal (11).

Illustration 10 g06220037

5. Install head assembly (10) onto rod assembly (2).

Illustration 11 g06219811

6. Install dowel (7) onto rod assembly (2).

7. Install flange (8) onto rod assembly (2).

8. Install seal (9) onto flange (8).

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Illustration 12 g06219805

9. Install bearing (6) and retaining ring (5).

Illustration 13 g06219803

10. Install eye (4) and bolts (3).

Illustration 14 g06219801

11. Use a suitable lifting device to install rod assembly (2). Refer to Table 2 for the approximate
weight of rod assembly (2).

12. Install bolts (1). Tighten bolts (1) to a torque of 1350 N·m (996 lb ft).

End By:

a. Install the boom cylinder.

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