KIT-JOYSTICK CONVERSION 2185966 - Caterpillar

Start By:
Remove the stick. Refer to Disassembly and Assembly, "Stick - Remove".
When you are using hydraulic cylinders and puller studs, always ensure that the rated capacity of the puller stud meets or exceeds the rated capacity of the hydraulic cylinder. If the puller stud does not meet or exceed the rated capacity of the hydraulic cylinder, a sudden failure of the puller stud could occur. The sudden failure of the puller stud could result in personal injury or death.
Do not use threaded rods that have not been hardened as tooling with hydraulic cylinders. The maximum rated tonnage should be stamped on one end of the puller studs. Do not use threaded rods that have not been stamped with the rated tonnage.
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, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Start the machine. Lower the boom to the ground.
Retract the stick cylinder. Secure the rod of the stick cylinder so that the rod is unable to extend. Stop the engine.
Install the pin assembly that holds the stick to the boom.
Illustration 1 g00558404
Disconnect lubrication hose assembly (1) at the rod end of each boom cylinder.Note: The mounting pin for the boom cylinders does not need to be completely removed from the boom in order to remove the boom cylinders from the boom.
Fasten a suitable lifting device to the left hand boom cylinder, as shown. Remove bolts (2) and retainer plate (3) from the end of the mounting pin. Pull the mounting pin out of the rod end of the right hand boom cylinder and into the boom. Lower the right hand boom cylinder onto Tooling (A) .
Fasten a lifting strap and a hoist to the right hand boom cylinder. Remove bolts (2) and retainer plate (3) from the mounting pin. Pull the mounting pin out of the cylinder rod and into the boom. Lower the right hand boom cylinder onto Tooling (A) .
Illustration 2 g00558526
Fasten a suitable lifting device to boom (4) , as shown. Put slight lifting tension on boom (4) .
At operating temperature, the hydraulic oil is hot and under pressure. Hot oils can cause burns.To prevent possible personal injury, release the pressure in the work tool hydraulic circuit (boom, stick, bucket, and swing), travel circuits, and the hydraulic oil tank at the filler cap before any hydraulic lines or components are disconnected or removed.Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch.
Release the hydraulic system pressure. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release".
Illustration 3 g00558534
Disconnect four hose assemblies (5) . Put plugs in the ends of the hose assemblies. Plugs prevent oil loss. Plugs prevent