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 (M24) •Nylon sling (with the required lifting capacity) •Liftcrane (with the required lifting capacity) •Marking pen •Cap •Plug •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.

[7] Use a wrench (22 mm) to remove the grease hose (2). •Use caps or plugs to prevent any entry of water, dust or dirt.

[8] Use a wrench (36 mm) to remove the 2 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 liftcrane and nylon sling (9) to hold the boom cylinder so that it does not fall.

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

[11]Secure the base of the boom cylinder with the batten (11).

[12]Lower the boom cylinder and let it rest on the batten (11). [13]Remove the cab side boom cylinder from the boom in the same way.

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

Use a wrench (36 mm) to install the fastening ring (5) with the 2 nuts (3) and bolt (4).

[15]Wrap the nylon sling (9) around the pin installed in Step [14] and secure with the liftcrane.

[16]Use hexagon wrenches (12 mm, 14 mm) to remove each group of 4 bolts, and then remove the hoses (12), (13), (14), (15) and (16). •Mark the hoses and lines so that the connectors match at the time of assembly. •Use caps or 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 (30 mm) to remove the bolt (17) and spacer (18).

[18]Use a slide hammer (19) (M24) to remove the pin (20).

[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.