DOOR 3844259 - Caterpillar

2. Put on identification and remove two hoses (1) from the counterweight cylinder (2). 3. Install hoist on the cylinder as shown. Remove two pins (3) which fasten the cylinder to the counterweight frame. Remove the cylinder. The weight of the cylinder is 130 lb. (59 kg).Install Counterweight Cylinder
1. Fasten a hoist to counterweight cylinder (1) as shown. Put the cylinder in position in the counterweight frame and install pins (2) which fasten the cylinder to the frame. 2. Inspect and make a replacement if necessary, of the O-ring seals on hoses (3). Install the hoses on the cylinder.Disassemble Counterweight Cylinders
start by:a) remove counterweight cylinders1. Put the cylinder in position on tooling (A). 2. Use tooling (B) as shown to remove the bearings from the cylinder and rod end. 3. Fasten the rod end of the cylinder to tooling (A) as shown and extend the rod with tooling (A). 4. Install support (2) and hold down strap (1) [part of tooling (A)] as shown. 5. Remove locking screw (4) from crown (3). 6. Remove the crown from the cylinder with tooling (C). 7. Remove the cylinder from the piston and head with tooling (A). 8. Remove the bolt from the end of the rod with torque multiplier (5) [part of tooling (A)] as shown. 9. Remove the piston (7) and head (6) from the rod. 10. Remove the wear ring (8) and seal assembly (9) from the piston. 11. Remove the O-ring seal (10) and back-up ring (11) from the head. 12. Remove three seals (12) from the head.Assemble Counterweight Cylinders
For correct installation of seals see the cylinder illustration. 1. Install three seals in head (1). Use tooling (A) to install the top seal. Put a layer of 1P808 General Purpose Lubricant on the inside and outside surfaces of the head. 2. Install back-up ring (2) and O-ring seal (3) on the head. The O-ring seal goes toward the inside of the cylinder. 3. Use tooling (B) as shown to expand the seal for installation on the piston. 4. Install seal assembly (5) and wear ring (4) on piston. Put a light layer of the lubricant to be sealed on the ring and seal assembly. 5. Put the rod and cylinder in position on tooling (C). Install the crown (6), head (1) and piston (7) on rod. 6. Install the washer and bolt which fasten the piston on the rod with torque multiplier (8) and torque wrench (9) [part of tooling (C)]. Tighten the bolt