Removal and Installation of Boom

Caution ・ Stop the machine on a level location with good footing. ・ Be sure to stop the engine before beginning work. ・ When working together with others, always be sure to exchange signals and pay adequate attention to safety. ・ Always wear protective devices (protective eyewear and safety shoes, etc.) when working with a hammer. ・ Be sure to inspect the nylon sling and other lifting equipment before beginning work. ・ Do not stand or pass under the suspended load.

Items to prepare •Wrenches (10 mm, 19 mm, 22 mm, 30 mm, 36 mm, 41 mm) •Slide hammer (24 mm) •Nylon sling (with the required lifting capacity) •Crane (with the required lifting capacity) •Marking pen •Caps •Plugs •Rag •Cleaning fluid •Batten •Square wooden pieces •Wire 1.Removal of Boom [1] Remove the bucket. (For details, see "Removal and Installation of Bucket".) [2] Remove the bucket cylinder. (For details, see "Removal and Installation of Bucket Cylinder".) [3] Remove the arm cylinder. (For details, see "Removal and Installation of Arm Cylinder".) [4] Remove the arm. (For details, see "Removal and Installation of Arm".) [5] When removing the boom cylinder too, see "Removal and Installation of Boom". [6] This section explains the procedure for when not removing the boom cylinder. Bring the boom (1) top in contact with the ground.

1 Boom

[7] Use a wrench (19 mm) to remove the grease hose (2). •Use caps and plugs to prevent any entry of water, dust or dirt.

[8] Use a wrench (30 mm) to remove the double nuts (3) and bolt (4), and then remove the fastening ring (5).

[9] Use a hammer (6) and striking rod (7) to push the pin (8) out.

Use a crane and nylon sling (9) to hold the boom cylinder so that it does not fall.

2 Grease hose 3 Nut 4 Bolt 5 Ring 6 Hammer 7 Striking rod 8 Pin 9 Nylon sling

[10]Tie the cylinder rod with wire (10) so that it cannot come out.

[11]Use a wrench (10 mm) to remove the grease nipple (11), and then secure the base of the boom cylinder with the batten (12).

[12]Lower the boom cylinder and let it rest on the batten (12).

[13]Remove the cab side boom cylinder from the boom in the same way.

10 Wire 11 Grease nipple 12 Batten

[14]Install the pin (8) removed in Step [9].

Use a wrench (30 mm) to install the bolt (4) with the 2 double nuts (3), and then install the fastening ring (5).

[15]Wrap the nylon sling (9) around the pin installed in Step [13] and secure with the crane.

3 Nut 4 Bolt 5 Ring 8 Pin 9 Nylon sling

[16]Use wrenches (22 mm, 36 mm, 41 mm) to remove the hoses (13), (14), (15), (16), (17) and (18). •Mark the hoses and lines so that the connectors match at the time of assembly. •Use caps and plugs to cover the hoses and lines to prevent any entry of water, dust or dirt. •Clean the hoses and lines by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

[17]Use a wrench (19 mm) to remove the bolt (19) and washer (20).

[18]Use a slide hammer (21) (24 mm) to remove the pin (22).

13 Bucket hose (use 36 mm wrench) 14 Bucket hose (use 36 mm wrench) 15 Arm hose (use 36 mm wrench) 16 Arm hose (use 41 mm wrench) 17 2nd option hose (use 22mm wrench) 18 2nd option hose (use 22mm wrench) 19 Bolt 20 Washer 21 Slide hammer 22 Pin

[19]Back up the machine and remove the boom (1).

2.Installation of Boom Cylinder

To install, perform the reverse of the removal procedure. •Clean each pin and pin hole. •When inserting pins, be careful not to damage the dust seals. •As the final step, always grease up.

1 Boom