336D 2L and 340D 2L Excavators Machine Systems Boom - Remove and Install Caterpillar

Removal Procedure

Start By:

a. Release the hydraulic system pressure.

b. Remove the stick.

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Illustration 1	g01225073

1. Disconnect grease hose assembly (1) from boom cylinder (3). Remove bolts (2), plate (4), and the spacer.
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   Illustration 2	g01225067

2. Attach a suitable lifting device to boom cylinder (3). The weight of boom cylinder (3) is approximately 380 kg (838 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.
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   Illustration 3	g01212891

4. Remove bolts (6). Remove cover (7).
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   Illustration 4	g01212899

5. Remove bolts (8). Remove step (9).
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   Illustration 5	g01212931

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   Illustration 6	g01212925

6. Open cover (10) of the storage box. Remove bolts (13). Remove bolts (12) and remove handhold (11).
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   Illustration 7	g01227852

7. Position plate (4) and bolts (2) onto each side of pin (5). Attach a suitable lifting device to each side of pin (5).
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   Illustration 8	g01217554

8. Attach a suitable lifting device to pin assembly (15). The weight of pin assembly (15) is approximately 61 kg (135 lb). Install pin assembly (15) and install bolt (16).
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   Illustration 9	g01212951

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 2835 kg (6250 lb) and 2914 kg (6425 lb). Apply slight lifting tension to boom (14).
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   Illustration 10	g01225070

10. Disconnect hose assemblies (17).
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    Illustration 11	g01225071

11. Disconnect harness assembly (19). Disconnect hose assemblies (18), (20), (21), and (22).
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    Illustration 12	g01225068

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    Illustration 13	g01226791

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) to remove pin assembly (23). The combined weight of Tooling (C) and pin assembly (23) is approximately 245 kg (540 lb).

13. Remove the boom. Remove shims if present.

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

Installation Procedure

Note: Make sure that the pin bores in the boom and 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.
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   Illustration 14	g01227852

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   Illustration 15	g01217554

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   Illustration 16	g01212951

2. Position 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 61 kg (135 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 2835 kg (6250 lb) and 2914 kg (6425 lb). Position boom (14) onto the machine.
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   Illustration 17	g01217774

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 109 kg (240 lb). Use Tooling (A) and the suitable lifting device to install pin assembly (23).
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   Illustration 18	g01213028

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 to obtain the required clearance.

7. Use the following table to determine the correct shims (25).
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   Table 2

   Table for Shims (25)
   Shim	Thickness (mm)
   166-1487	2.0(1)
   113-2127	0.5
   093-0084	1.0
   093-0116	2.0

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   (1)	This shim is required to be used. This shim must be next to the boom.

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   Illustration 19	g01226791

8. If shims (25) should 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) to remove pin assembly (23). The combined weight of Tooling (C) and pin assembly (23) is approximately 245 kg (540 lb).

9. Install the correct number of shims. Repeat Step 6.
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   Illustration 20	g01225068

10. Remove Tooling (C) and the suitable lifting device. Install bolt (24) that retains pin assembly (23).
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    Illustration 21	g01225071

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).
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    Illustration 22	g01225070

12. Connect hose assemblies (17).
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    Illustration 23	g01212931

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    Illustration 24	g01212925

13. Position handhold (11) and bolts (12). Install bolts (13). Close cover (10) of the storage box.
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    Illustration 25	g01212899

14. Install step (9). Install bolts (8).
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    Illustration 26	g01212891

15. Install cover (7) and bolts (6).
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    Illustration 27	g01225067

16. Use Tooling (A) 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).

17. Attach a suitable lifting device to boom cylinder (3). The weight of boom cylinder (3) is approximately 380 kg (838 lb).

18. Raise boom cylinder (3) into position. Install all 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).
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    Illustration 28	g01225073

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

    End By:

    a. Install the stick.