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1. Tilt Cylinder Components on farmboy 440 443 Rod Case Nut Piston O Ring Piston Seal O Ring Back Up Washer End Cap Head Wiper Seal 9 NO 0 B w D mb d See Page 17 for torque C 2808 Hydraulic Cylinder 4 Component Repair Manual CYLINDER IDENTIFICATION Cont d Tilt Cylinder Components on 540 640 740 Series amp 843 Not Equipped With Cushion Sleeve h P PHN H bM gt Rod Case Nut Piston O Ring Piston Seal O Ring Back Up Washer End Cap Head Wiper Seal See Page 17 for torque 5 C 2808 Hydraulic Cylinder Component Repair Manual CYLINDER IDENTIFICATION Cont d Tilt Cylinder Components on 640 amp 740 Series Equipped With Cushion Sleeve d D 5 ESA N Rod Case Nut Piston O Ring Piston Seal Cushion Sleeve O Ring Back Up Washer End Cap Rod Seal Wiper Seal See Page 17 for torque 6 C 2742 Hydraulic Cylinder Component Repair Manual CYLINDER IDENTIFICATION Cont d Tilt Cylinder Components on 753 amp 853 Case Tube Plug O ring Bolt Clamp Nut Piston Seal SEP LA o O O ring O ring Washer O ring Head Seal Seal Rod Bushing MC 1688 MC 1688 Tighten To 400 425 ft Ibs 543 577 Nm Torque TS 1012 Hydraulic Cylinder 7 Component Repair ani CYLINDER IDENTIFICATION Cont d Tilt Cylinder Components on 753 amp 853 1 Case 10 O ring 2 Tu2. 2h BETO BIDEN HYDRAULIC COMPONENT REPAIR MANUAL BERN N Melrose Company 1992 Seer IN LT O RAN HS ER RE SANT QUE 7 A BUSINESS UNIT OF CLARK EQUIPMENT COMPANY Na DOREEN BEN SRA Printed i MAINTENANCE SAFETY Instructions are necessary before operating or servicing machine Read Operation amp Maintenance Manual Handbook and signs decals on machine FoHow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Failure to follow instructions can cause injury or death WARNING W 2003 1089 Safety Alert Symbol This symbol is used for important safety messages When you see this symbol follow the safety message to avoid personal injury or death CORRECT Ad Never service the Bobcat loader without instructions B 11799 Have good ventilation when welding or grinding painted parts Wear dust mask when grinding painted parts Toxic dust and gas can be produced Stop cool and clean engine of flammable materials before checking fluids A Never service or adjust loader with the engine running unless instructed to do so in the manual Avoid contact with leaking hydraulic fluids or diesel fuel which is under pressure It can penetrate the skin or eyes Never fill fuel tank with engine running while smoking or when near open flame CORRECT B 12365 Don t lift or lower operato
3. Cont d Install the rod assembly in the cylinder case A Put oil on the seals on the head B Put oil on the threads of the head Use the adjustable gland nut wrench to tighten the head C Replace the seal on the rod end if so equipped if it shows signs of wear or damage D 16 Hydraulic Cylinder Component Repair Manual TORQUE SPECIFICATIONS All torques shown are for lubricated threads Aluminum Piston Boom Cylinder Trencher 3 4 Thread 7 8 Thread 1 eu 8 6 een LSO 01H 0170 6 ee SB BES we se BH ENE UGS aaa RR Oe eRe BEE eine SS Se Si Oey ee A EEES E ESA St PSS 9 Cewek See 0 0 3752 ve Gray Iron Piston 7 8 Thread 1 1 2 Thread 2 Thread EESUPIIDIE 40 75 Be 5 E RI dA RA RT a d RA Ft Lbs 100 111 150 160 170 210 330 360 330 360 250 300 470 550 700 800 800 900 1800 2200 17 Nm 135 150 205 217 230 285 447 488 447 488 340 407 637 746 949 1085 1085 1220 2440 2983 Hydraulic Cylinder Component Repair Manual NOTES NOTES
4. air Manual AD HYDRAULIC CYLINDER Cont d Install the wiper seal with the lip toward the outside of the head pa Al Install the back up washer on the head B C Install the O ring next to the back up ring D Hydraulic Cylinder 43 Component Repair Manual HYDRAULIC CYLINDER Cont d If aseal was removed from the head use the following procedure to install a new one 1 Install the guide with a pilot and an adapter if they are required See Special Tools Page 1 on the head 2 Install the seal on the head using the guide A NOTE Do not turn roll the seal as you install it Damage to the seal may result 3 Use a ring compressor to compress the seal to the correct size B Leave the tool over the Teflon seal for five minutes Install the head on the rod C Cylinders With Cushioned Piston Install the piston on the rod with the tapered end first toward the head D Hydraulic Cylinder 14 Component Repair Manual HYDRAULIC CYLINDER Cont d Cylinders Without Cushioned Piston Install the cushion sleeve and the piston on the rod A Lubricate the threads and install the nut B See Page 15 for the correct torque specifications Remove the rod from the vise Install the cylinder case in the vise rn Put oil on the seal surface of the cylinder case C Put oil on the Teflon seal on the piston D Hydraulic Cylinder 15 Component Repair Manual HYDRAULIC CYLINDER
5. be 11 O ring 3 Plug 12 Washer 4 O ring 13 O ring 5 Nut 14 Head 6 Clamp 15 Seal 7 Nut 16 Seal 8 Piston 17 Rod 9 Seal 18 Bushing MC 1688 Tighten To 425 525 ft Ibs 576 712 Nm Torque TS 1063 Hydraulic Cylinder 8 Component Repair Manual HYDRAULIC CYLINDER Disassembly NOTE The drawings may not show the cylinder exactly as it appears but the procedure is correct for all cylinders See the Service Manual for your model loader to find the correct information for removing and installing the cylinder NT SS O rt C T Put the base end of the hydraulic cylinder in a drain pan Move the rod in and out to remove the fluid from the cylinder Move the rod slowly so the fluid will go directly into the drain pan Put the base end of the cylinder in a vise Use the adjustable gland nut wrench to loosen the head A Remove the rod assembly from the cylinder case B Remove the cylinder case from the vise Put the rod end in the vise Remove the nut from the piston end of the rod C Pull the piston off the rod Item 1 D If the cylinder has a cushion sleeve Item 2 pull it off the rod D Pull the head Item 3 off the rod D Hydraulic Cylinder e Component Repair Manual HYDRAULIC CYLINDER Cont d If the head has a seal remove the seal from the head A Remove the O ring and back up washer from the head B Remove the wiper seal C Remove the oil seal f
6. ervice Manager or Melroe Service Office Gwinner N D 701 678 6465 for schedule This Component Repair Manual provides the Service Technician with information for servicing Melroe Hydraulic Cylinders Refer to the SERVICE MANUAL for your MODEL Loader to troubleshoot test remove and install the hydraulic cylinders SAFETY INSTRUCTIONS We Care About your Safety BEFORE YOU WORK ON THE HYDRAULIC CYLINDER Read the complete sequence so you know the complete disassembly or assembly procedure before the work is actually started IMPORTANT This notice identifies procedures which must be followed to avoid damage to the loader 1 2019 0284 Hydraulic Cylinder Component Repair Manual HYDRAULIC CYLINDER CYLINDER IDENTIFICATION Tilt Cylinder Components on 753 amp 853 Tilt Cylinder Components on 753 amp 853 Tilt Cylinder Components 640 amp 740 Series Equipped with Cushion Sleeve Tilt Cylinder Components on 540 640 740 Series amp 843 Not Equipped with Cushion Sleeve Tilt Cylinder Components on farmboy 440 443 Lift Cylinder Components on All 40 Series HYDRAULIC CYLINDER Assembly Cylinders With Cushioned Piston Cylinders Without Cushioned Piston Disassembly HYDRAULIC CYLINDER SERVICE TOOLS MEL 1032 or MEL 1033 Rod Seal Tool MEL 1075 Adjustable Gland Nut Wrench MEL 1178 Seal Tool MEL 1076 Cylinder Wrench MEL 1074 O ring Seal Hook MEL 1396 Seal Tool TORQUE SPECIFICATIONS Al
7. r cab without instruction Ad vent exhaust to outside when engine must be run for service Exhaust system must be tightly sealed Exhaust fumes can kill without warning EN CA DEA EN Keep body jewelry and clothing away from moving parts electrical contacts hot parts and exhaust Wear eye protection to guard from battery acid compressed springs fluids under pressure and flying debris when engines are running or tools are used Use eye protection approved for type of welding CORRECT Cleaning and maintenance are required daily Ah Keep rear doo closed except for service Close and latch door before operating the loader A Never work on loader with lift arms up unless lift arms are held by a lift arm support device A Never modify equipment or add attachments not approved by Melroe Company Ad Lead acid batteries produce flammable and explosive gases Ad Keep arcs sparks flames and lighted tobacco away from batteries Batteries contain acid which burns eyes or skin on contact Wear protective clothing If acid contacts body flush well with water For eye contact flush well and get immediate medical attention 10 91 INTRODUCTION Melroe recommends that all service technicians attend either field or factory Bobcat Service Workshops for necessary information and education Workshops are held many times a year at various locations throughout the U S and Canada Contact your District S
8. rom the head D Hydraulic Cylinder 10 Component Repair Manual HYDRAULIC CYLINDER Cont d Remove the piston seal from the piston A Remove the O ring from the piston B Wash the cylinder parts in solvent and air dry them While servicing the cylinder do not damage the parts Inspect for nicks scratches or otherwise damaged or bent parts before assembling the cylinder Replace parts that appear damaged in any way The cylinder may not function correctly if there is damage to any of the parts Destroy all the O rings and seals and replace them with NEW O rings and seals Assembly Install the O ring on the piston C NOTE Do not overstretch the seal Install the seal on the tool and stretch it until it fits the piston D Allow the O ring to stretch for 30 seconds before removing it from the tool TER en AID N NENNE 11 RAN B 12812 B 12809 Hydraulic Cylinder Component Repair Manual HYDRAULIC CYLINDER Cont d Install the seal on the piston A ns B 12813 Use the ring compressor to compress the seal to the correct size B Leave the piston in the ring compressor for three minutes B 12811 Install the oil seal on the rod seal tool C NOTE The O ring side of the oil seal goes toward the inside of the cylinder Install the oil seal in the head D o A PR RES EEE LO FRERE RES Di RER c Hydraulic Cylinder Component Rep
9. uminum Piston Gray Iron Piston Bi 0 p E y DD OC Ore Bowe ae BR Hydraulic Cylinder Component Repair HYDRAULIC CYLINDER SERVICE TOOLS MEL 1074 O Ring Seal Hook Use this tool to remove the seals from the piston and the cylinder head A MEL 1396 Seal Installation Tool Use this tool to stretch the Teflon seals before installing seals on cylinder pistons B Use ring compressor to compress the Teflon seal into the groove after installing it on the piston B 12810 MEL 1032 or MEL 1033 Rod Seal Installation Tool Use one of these tools to install internal seals in the cylinder head Use Tool MEL 1033 when servicing cylinders with rods 1 1 4 in diameter through 2 diameter C MEL 1075 Adjustable Gland Nut Wrench Use this tool with correct pins Tool MEL 1075 1 or MEL 1075 2 for the cylinder head removal and installation D Hydraulic Cylinder 1 Component Repair Manual HYDRAULIC CYLINDER SERVICE TOOLS Cont d MEL 1076 Cylinder Wrench Use this tool to remove the end cap from the hydraulic cylinder Al Hydraulic Cylinder 2 Component Repair Manual CYLINDER IDENTIFICATION Lift Cylinder Components on All 40 Series Rod Case Nut Piston Piston Seal O Ring Spacer O Ring Back Up Washer Head Rod Seal Wiper Seal w muu PU N dh e See Page 17 for torque B 6942 Hydraulic Cylinder 3 Component Repair Manual CYLINDER IDENTIFICATION Cont d
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