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


Boom Cylinder - Remove and Install
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1.1. Removal Procedure
2.1. Disassembly and Assembly Information
3.1. Installation Procedure

Removal Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
4C-9485  Pin Driver Cap 

------ WARNING! ------

Cylinders equipped with lock valves can remain pressurized for very long periods of time, even with the hoses removed.

Failure to relieve pressure before removing a lock valve or disassembling a cylinder can result in personal injury or death.

Ensure all pressure is relieved before removing a lock valve or disassembling a cylinder.



NOTICE

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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.

Dispose of all fluids according to local regulations and mandates.


  1. Fully extend the bucket cylinder. Fully extend the stick cylinder. Lower the boom until the stick assembly is in contact with the ground.

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


    Illustration 1g01217839


    Illustration 2g01217840

  3. Loosen nut (1). Turn bolt (2) counterclockwise in order to release the pressure in the cylinder.


    Illustration 3g01217850

  4. Remove bolts (3).


    Illustration 4g01217906

  5. Remove clamps (4).


    Illustration 5g01217908

  6. Remove bolts (6) and support assemblies (5).


    Illustration 6g01217912

  7. Remove bolts (7) and reposition tube assembly (8) out of the way.


    Illustration 7g01217915

  8. Remove bolts (9) and reposition valve assembly (10) out of the way.


    Illustration 8g01217921

  9. Attach a suitable lifting device to boom cylinder (11). The weight of boom cylinder (11) is approximately 287 kg (632 lb).


    Illustration 9g01217928

  10. Remove bolts (12) and plate (13). Remove spacer (14) (not shown).


    Illustration 10g01218003


    Illustration 11g01218010

  11. Attach Tooling (A) to pin (15). Use a suitable driver in order to reposition pin (15). Remove shim (16).


    Illustration 12g01218011

  12. Lower boom cylinder (11) onto suitable cribbing and attach a suitable lifting device to boom cylinder (11), as shown. The weight of boom cylinder (11) is approximately 287 kg (632 lb).


    Illustration 13g01218013

  13. Remove bolt (18). Remove pin assembly (19) and shims (17). Remove boom cylinder (11).

Disassembly and Assembly Information

Table 2
Required Tools 
Tool  Part Number  Part Description  Qty 
127-4904  Hydraulic Cylinder Repair Stand Gp 
7M-7456  Bearing Mount Compound 
1P-0808  Multipurpose Grease 
195-4609  Seal Pick 
3S-6224  Electric Hydraulic Pump Gp 
6V-3175 Double Acting Cylinder 
9S-5564 Pin Puller Sleeve As 
9U-6832 Nut 
4C-9634 Puller Stud 
9U-5338 Bearing Puller Adapter 
3S-6224  Electric Hydraulic Pump Gp 
6V-3175 Double Acting Cylinder 
9S-5564 Pin Puller Sleeve As 
9U-6832 Nut 
4C-9634 Puller Stud 
9U-5339 Bearing Puller Adapter 

------ WARNING! ------

Cylinders equipped with lock valves can remain pressurized for very long periods of time, even with the hoses removed.

Failure to relieve pressure before removing a lock valve or disassembling a cylinder can result in personal injury or death.

Ensure all pressure is relieved before removing a lock valve or disassembling a cylinder.




Illustration 14g01218033

Note: Tooling (F) is used for the removal and installation of bearing (8). Tooling (G) is used for the removal and installation of bearing (2).

(3) Torque for the nut ... 7400 ± 370 N·m (5460 ± 270 lb ft)

(1) Torque for the bolts ... 367 ± 55 N·m (270 ± 40 lb ft)

Tighten the setscrew that retains nut (3) to a torque of 57 ± 11 N·m (42 ± 8 lb ft).

The slit of ring (5) must be in the direction of the piston.

Apply Tooling (D) to seals (4) prior to assembly.

Lubricate seals (6) with the lubricant that is being sealed.

Apply Tooling (C) to the wiper seal (7) prior to assembly.

Installation Procedure

Table 3
Required Tools 
Tool  Part Number  Part Description  Qty 
4C-9485  Pin Driver Cap 


    Illustration 15g01218011

  1. Attach a suitable lifting device to boom cylinder (11), as shown. The weight of boom cylinder (11) is approximately 287 kg (632 lb). Position boom cylinder (11) onto the machine.


    Illustration 16g01218013

  2. Install shims (17) and pin assembly (19) on the head end of boom cylinder (11). Install bolt (18).


    Illustration 17g01217921

  3. Use the suitable lifting device in order to position boom cylinder (11) onto suitable cribbing. Reposition the suitable lifting device near the rod end of boom cylinder (11). The weight of boom cylinder (11) is approximately 287 kg (632 lb). Use the suitable lifting device to raise the rod end of boom cylinder (11) into position.


    Illustration 18g01218505


    Illustration 19g01217928

  4. Install shim (16). Position pin (15) through the rod end of the boom cylinder.

  5. Install spacer (14) (not shown). Install plate (13) and bolts (12).


    Illustration 20g01217915

  6. Position valve assembly (10) and install bolts (9).


    Illustration 21g01217912

  7. Position tube assembly (8) and install bolts (7).


    Illustration 22g01217908

  8. Install support assemblies (5) and bolts (6).


    Illustration 23g01217906

  9. Install clamps (4).


    Illustration 24g01217850

  10. Install bolts (3).


    Illustration 25g01217839


    Illustration 26g01217840

  11. Turn bolt (2) clockwise into the original position. Tighten nut (1).

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