CYLINDER GP-STICK 2898138 - Caterpillar

2. Release the pressure in the hydraulic system as follows: a. Fully retract the rod in the stick cylinder.b. Adjust the position of the bucket so it will be flat on the ground when the boom is lowered.c. Lower the boom until the bucket is flat on the ground.d. Shut off the engine, and put the hydraulic activation control lever in the "Lock" position.e. Move the control levers for the boom, bucket, stick and swing through their full travel strokes. This will relieve any pressure that may be present in the pilot system.f. Slowly loosen the air breather cap on the hydraulic oil tank to release the pressure.g. Tighten the air breather cap on the hydraulic oil tank.h. The pressure in the hydraulic system has now been released. Lines and components can now be removed. 3. Fasten a lifting strap and a hoist to lift chain assembly (1) as shown. Raise the lift chain assembly a small amount to support it. 4. Remove the two nuts, washers and pins (2) that hold lift chain assembly (1) to the mounting bracket on the frame of the machine. Remove the lift chain assembly. The weight of the lift chain assembly is 54 kg (120 lb). 5. Fasten a lifting strap and a hoist to counterweight lift cylinder (3) as shown. Put slight lifting tension on the cylinder. 6. Disconnect tube assembly (4) from the counterweight lift cylinder.7. Remove tube assembly (4) from bracket (5). 8. Remove four bolts (6), the washers and mounting band (7). 9. Remove the retaining bolt, washer, pin assembly (8) and the shims from the head end of the counterweight lift cylinder. Remove counterweight lift cylinder (3). The weight of the counterweight lift cylinder is 136 kg (300 lb). 10. Remove the cotter pin, nut (9), the spacer and pin (10) from the rod end of the counterweight lift cylinder. Remove two sprocket assemblies (11).11. Remove the other counterweight lift cylinder as in Steps 2 through 10. The following steps are for the installation of the counterweight lift cylinders 12. Lubricate the bushings in both sprocket assemblies (11) and in the rod end of the counterweight lift cylinder with 5P-0960 Multipurpose Grease. Put the sprocket assemblies in position on the counterweight lift cylinder, and install pin (10), the spacer, nut (9) and the cotter pin. Make sure the sprocket assemblies rotate freely. 13. Fasten a hoist to counterweight lift cylinder (3), and put it in position on the rear of the machine. Do not remove the hoist from the counterweight lift cylinder at this time. Temporarily install pin assembly (8) to hold the head end of the counterweight lift cylinder to the frame mounting bracket. Slide the counterweight lift cylinder to one side until it makes contact with the frame mounting bracket. Measure the lateral clearance between the frame mounting bracket and the counterweight lift cylinder. The lateral clearance must not be more