KIT, EGR COOLER CLEANING (Kit) 3015980C92 - Caterpillar

1. Start the machine. Move the rod out of the stick cylinder until it is completely extended. Put the bottom of the bucket flat on the ground or floor.2. Fasten a strap and hoist to the right boom cylinder. 3. Remove lock bolt (1) and nut from the cylinder pin. 4. Use tooling (A) to remove the pin from the head end of the cylinder.5. Fasten the boom cylinder to the boom with a chain. 6. Fasten a strap and hoist to master cylinder (3) then remove lock bolt (2) and nut. 7. Use tooling (B) to remove the pin from the rod end of the master cylinder.8. Lower the rod end of the cylinder. 9. Disconnect grease line (4) and remove all lines (5) from master cylinder. 10. Lower the cylinder all the way down then remove four bolts (6) and plate (7) from either side of the head end of the cylinder. 11. Fasten the master cylinder to a lift truck with tooling (C) as shown.12. Remove the pin through the head end of the cylinder with a brass rod. Remove the cylinder. Weight of the master cylinder is 640 lb. (288 kg).Install Master Cylinder
1. Fasten the master cylinder (1) to a lift truck with tooling (A) as shown.2. Put the hole in the head end of the cylinder in alignment with the hole in the boom. 3. Install the pin (2) through the boom and cylinder. 4. Install plates (3) on each side of the pin with four bolts.5. Fasten a hoist to cylinder and lift the rod end of the cylinder. 6. Connect lines (5) to the cylinder.7. Connect grease line (4) to cylinder.8. Move the rod out of the master cylinder until the hole in the rod is in alignment with the hole in the frame. 9. Use tooling (B) to install the pin through the frame and the rod. When the pin is installed make sure the hole in the pin is in alignment with the hole in the frame so the lock bolt can be installed. 10. Install the lock bolt (6) and nut.11. Fasten a hoist to the boom cylinder and remove the chain (7) from the cylinder. 12. Start the machine and operate the boom cylinder until the pin hole in the head end of the cylinder is in alignment with the pin hole in the frame.13. Install pin (8) and make sure the hole in the pin is in alignment with the hole in the frame so the lock bolt can be installed. 14. Install tool (C) in the pin and push the pin (8) into place.15. Install lock bolt and the nut.