320D2 GC Excavator Machine Systems Boom - Remove and Install Caterpillar


Boom - Remove and Install
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1.1. Removal Procedure
2.1. Installation Procedure

Removal Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
4C-9485  Pin Driver Cap 
1U-9202  Lever Puller Hoist 
3S-6224  Electric Hydraulic Pump Gp 
141-1785 Receiving Sleeve 
9U-6811 Puller Stud 
9U-6809 Nut 
6V-0113 Double Acting Cylinder 

Start By:

  1. Release the hydraulic system pressure. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release".

  2. Remove the stick.


    Illustration 1g01212856

  1. Disconnect grease hose assembly (1) from boom cylinder (3). Remove bolts (2). Remove the retainer plate and spacer (4).


    Illustration 2g01212871


    Illustration 3g01212838

  2. Attach a suitable lifting device to boom cylinder (3). The weight of boom cylinder (3) is approximately 287 kg (633 lb). Install Tooling (A) into pin (5). Use a hammer to drive pin (5) out of boom cylinder (3). Lower boom cylinder (3).

    Note: Remove any shims that may be present. Mark the shims for installation purposes.

  3. Repeat Steps 1 through 2 for the other boom cylinder.


    Illustration 4g01212891

  4. Remove bolts (6). Remove cover (7).


    Illustration 5g01212899

  5. Remove three bolts (8). Remove step (9).


    Illustration 6g01212931


    Illustration 7g01212925

  6. Open cover (10) of the storage box. Remove bolts (13). Remove bolts (12) and remove handhold (11).


    Illustration 8g01228933

  7. Position retainer plate (4) and bolts (2) onto each side of pin (5). Attach a suitable lifting device to each side of pin (5).


    Illustration 9g01217554


    Illustration 10g01212951

  8. Attach a suitable lifting device to pin assembly (15). The weight of pin assembly (15) is approximately 48 kg (105 lb). Install pin assembly (15) and install bolt (16).

  9. Attach Tooling (B) and a suitable lifting device to boom (14) and pin assembly (15). The combined weight of boom (14) and the stick cylinder is between 1500 kg (3300 lb) and 3016 kg (6650 lb). Apply slight lifting tension to boom (14).


    Illustration 11g01212965

  10. Disconnect hose assemblies (17).


    Illustration 12g01212967

  11. Disconnect harness assembly (19). Disconnect hose assemblies (18), (20), (21), and (22).


    Illustration 13g01212979


    Illustration 14g01212983

  12. Remove bolt (24). Attach a suitable lifting device to Tooling (C). The weight of Tooling (C) is approximately 136 kg (300 lb). Attach Tooling (C) to pin assembly (23). Use Tooling (C) in order to remove pin assembly (23). The combined weight of Tooling (C) and pin assembly (23) is approximately 215 kg (475 lb).

  13. Remove the boom. Remove any shims that may be present.

    Note: Note the locations of any shims for assembly purposes.

Installation Procedure

Table 2
Required Tools 
Tool  Part Number  Part Description  Qty 
5P-0960  Grease Cartridge 

Note: Make sure that the pin bores in the boom and the pin bores in the upper frame are clean and free of dirt and debris prior to installing the boom in the upper frame.

  1. Apply Tooling (D) to the bores in the upper frame and in the bore of the boom.


    Illustration 15g01228933


    Illustration 16g01217554


    Illustration 17g01212951

  2. Position retainer plate (4) and install bolts (2) onto each side of pin (5).

  3. Attach a suitable lifting device to pin assembly (15). The weight of pin assembly (15) is approximately 48 kg (105 lb). Install pin assembly (15) and install bolt (16).

  4. Attach Tooling (B) and a suitable lifting device to boom (14). The combined weight of boom (14) and the stick cylinder is between 1500 kg (3300 lb) and 3016 kg (6650 lb). Position boom (14) onto the machine.


    Illustration 18g01217774

  5. Apply Tooling (D) to pin assembly (23). Attach a suitable lifting device to pin assembly (23). The weight of pin assembly (23) is approximately 80 kg (175 lb). Use Tooling (A) and the suitable lifting device in order to install pin assembly (23).


    Illustration 19g01213028

  6. Measure the total clearance between the boom and the upper frame at the bore for the boom foot pin assembly. The total clearance of Dimension (a) plus Dimension (b) must not be more than 1.0 mm (0.04 inch). If the total clearance is less than 1.0 mm (0.04 inch), the addition of shims between the boom and the upper frame will not be required. If the total clearance is more than 1.0 mm (0.04 inch), add the correct thickness of shims in order to obtain the required clearance.

  7. Use the following table to determine the correct shims (25).

    Table 3
    Table for Shims (30) 
    Shim  Thickness (mm) 
    212-2840  2.0(2) 
    113-2127  0.5 
    093-0084  1.0 
    093-0116  2.0 
    (2) This shim is requiredto be used. This shim must be next to the boom.


    Illustration 20g01212983

  8. If shims (25) need to be installed, attach a suitable lifting device to Tooling (C). The weight of Tooling (C) is approximately 136 kg (300 lb). Attach Tooling (C) to pin assembly (23). Use Tooling (C) in order to remove pin assembly (23). The combined weight of Tooling (C) and pin assembly (23) is approximately 215 kg (475 lb).

  9. Install the correct amount of shims. Repeat Step 6.


    Illustration 21g01212979

  10. Remove Tooling (C) and the suitable lifting device. Install bolt (24) that retains pin assembly (23).


    Illustration 22g01212967

  11. Connect harness assembly (19). Connect hose assemblies (18), (20), (21), and (22). Tighten hose assemblies (18) and (20) to a torque of 76 ± 4 N·m (56 ± 3 lb ft).


    Illustration 23g01212965

  12. Connect hose assemblies (17).


    Illustration 24g01212931


    Illustration 25g01212925

  13. Position handhold (11) and bolts (12). Install bolts (13). Close cover (10) of the storage box.


    Illustration 26g01212899

  14. Install step (9). Install three bolts (8).


    Illustration 27g01212891

  15. Install cover (7). Install bolts (6).


    Illustration 28g01212871

  16. Use Tooling (A) in order to drive pin (5) so that the pin is flush with the boom. Remove Tooling (A) and install Tooling (A) onto the other side of pin (5).

    Attach a suitable lifting device to boom cylinder (3). The weight of boom cylinder (3) is approximately 290 kg (633 lb).

    Raise boom cylinder (3) into position. Install any shims that were present. Install Tooling (A) into pin (5). Use a hammer to drive pin (5) into boom cylinder (3). Remove Tooling (A). Repeat for the other boom cylinder (3).



    Illustration 29g01212856

  17. Install the retainer plate and spacer (4). Install bolts (2). Connect grease hose assembly (1).

End By:

  1. Install the stick.

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