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Product: EXCAVATOR
Model: 320B EXCAVATOR 5BR
Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-UP
(MACHINE) POWERED BY 3066 ENGINE

Disassembly and Assembly

320B, 320B L,320B LN, 320B N, & 320B S EXCAVATORS MACHINE SY
Media Number -SENR9257-06 Publication Date -01/04/2004 Date Updated -02/12/2004

SENR92570009

Boom Cylinders
SMCS - 5456-010; 5456-017

Remove & Install Boom Cylinders

Fluid Spillage Containment

Care must be taken to ensure that the fluids are contained during performance of the inspection, the
maintenance, the testing, the adjusting and the repair of the machine. Be prepared to collect the fluid with
suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to the "Tools And Shop Products Guide, NENG2500" the tools and the supplies suitable to collect and
contain any of the fluids in Caterpillar machines. Dispose of the fluids according to local regulations and
mandates.

Cylinders equipped with lock valves can remain pressurized for 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.

OTE: The procedure which follows can be used to remove either or both the boom cylinders.

1. Lower the bucket to the ground with the stick fully extended and the bucket fully open.

At operating temperature, the hydraulic oil tank is hot and under

pressure. Hot oil can cause burns. To prevent possible personal injury,
release the pressure in the hydraulic system before any of the hydraulic
lines or any of the components are disconnected or removed.

2. Release the pressure in all of the implement hydraulic circuits (the boom, the stick and the bucket) before
any of the hydraulic lines or any of the components are disconnected or removed, as follows:

a. Shut off the engine and place key in the "ON" position. Put the hydraulic activation control lever in
the "UNLOCK" position.

b. Move the control levers for the boom, the stick and the swing to all full stroke positions. This will
release any pressure that might be present in the pilot system.

c. Return the key to "OFF" position.

d. Slowly loosen the fill plug on the hydraulic tank and release the pressure.

e. Tighten the fill plug on the hydraulic tank. Tighten the fill plug to a torque of 68 ± 7 *m (50 ± 5 lb
ft).

f. The pressure in the hydraulic system has been released and the hydraulic lines and the components
can be removed.
3. Disconnect lubrication hose assembly (3) at the rod end of each boom cylinder.

4. Remove three bolts (1), retainer plate (2) and the spacer from each side of the support pin.

5. Make sure the threaded puller hole in the end of support pin (4) is clean. Fasten Tooling (A) to support pin
(4) as shown. Fasten a lifting sling and a hoist to Tooling (A) to support it.

6. Fasten a lifting slings and a hoist to the rod end of right hand boom cylinder (5) and left hand boom
cylinder (6). Using Tooling (A), pull support pin (4) out of the rod end of both of the boom cylinders and the
boom. The weight of support pin (4) is 34 kg (75 lb).
7. Lower the rod ends of both of the boom cylinders onto Tooling (B). Adjust the height of Tooling (B) so
the boom cylinders are level. Readjust the lifting slings and hoist to hold the boom cylinder level.

8. Put sling lifting tension on right hand boom cylinder (5).

9. Disconnect two hose assemblies (9) from the right hand boom cylinder. Oil will drain from hose
assemblies (9). Drain the oil into a suitable container for disposal. Put plugs in the ends of the hose
assemblies to prevent oil loss and to keep contaminants out of the hydraulic system.

10. Remove pin assembly retaining bolt (7) and the washer. Remove pin assembly (8) and the spacer.
Remove right hand boom cylinder (5). The weight of the boom cylinders is 170 kg (375 lb).

OTE: Machines may be equipped with shim(s) between the boom cylinders and the frame at the boom
cylinder-to-frame pin joint. For assembly purposes, put identification marks on the shim(s) as to their
location.

11. Remove the shim(s) (if so equipped) at the boom cylinder-to-frame pin joint.

12. Remove left hand boom cylinder (6) from the machine as in Steps 8 through 11.

OTE: The following steps are for the installation of the boom cylinders.

13. Make sure the pin bores in the boom cylinders, the boom and the frame are clean and free of dirt prior to
installation of the boom cylinders.

14. Fasten lifting slings and a hoist to right hand boom cylinder (5), and put it in position in the frame. Make
sure the pin bores in the boom cylinder and the frame are in alignment with each other.

15. Apply 5P-0960 Multipurpose Grease on pin assembly (8) that holds the right hand boom cylinder to the
frame. Temporarily install the spacer and pin assembly (8). Do ot remove the hoist from the right hand
boom cylinder at this time.
(Typical Example) Top View Of Boom Cylinder And Frame

16. Slide the right hand boom cylinder to one side until it makes contact with the frame. Measure the total
clearance between the right hand boom cylinder and the frame at the pin bore. The total clearance of (a) and
(b) must not be more than 1.6 mm (.06 in). If the total clearance is less than 1.6 mm (.06 in), the addition of
shim(s) between the right hand boom cylinder and the frame will not be required. If the total clearance is
more than 1.6 mm (.06 in), add the correct thickness of shim(s) to obtain the necessary clearance.

17. If it has been determined that shim(s) need to be installed between the right hand boom cylinder and the
frame, remove pin assembly (8). Install the shim(s) between the right hand boom cylinder and the frame on
the same side as pin assembly retaining bolt (7); then reinstall the spacer and pin assembly (8). Install the
washer and retaining bolt (7). Tighten the retaining bolt to a torque of 325 ± 40 *m (240 ± 30 lb ft).

18. Check the condition of the O-ring seals in hose assemblies (9). If the O-ring seals are damaged, use new
parts for replacement. Connect two hose assemblies (9) to the right hand boom cylinder.

19. Fasten left hand boom cylinder (6) to the frame as in Steps 14 through 18.
20. Fasten tool (D) and a hoist to support pin (4). Apply 5P-0960 Multipurpose Grease on the support pin.
Partially install support pin (4) in the boom. Remove the hoist from the support pin. Install Tool (C) in the
end of the support pin. Using a hammer, drive the support pin into the boom. Position the left side of the
support pin so it is even with the outside surface of the boom.

21. Fasten a lifting sling and a hoist to the rod end of left hand boom cylinder (6). Raise the left hand boom
cylinder until the pin bore in the rod is in alignment with the pin bore in the boom. It may be necessary to
retract or extend the rod to align the pin bores. Drive the support pin into the rod end of the left hand boom
cylinder. Position the right side of the support pin so it is even with the outside surface of the boom. Remove
Tool (C).

22. Fasten a lifting sling and a hoist to the rod end of the right hand boom cylinder (5). Raise the right hand
boom cylinder until the pin bore in the rod is in alignment with the pin bore in the boom. It may be necessary
to retract or extend the rod to align the pin bores. Use a hammer and a brass punch to drive the support pin
into the rod end of the right hand boom cylinder.

23. Install the spacer, retainer plate (2) and three bolts (1) on each end of the support pin. Connect
lubrication hose assembly (3) to the rod end of each boom cylinder.

OTE: Refer to the topic "Lubricant Viscosities and Refill Capacities" in the "Operation & Maintenance
Manual" for the proper filling procedure and the proper levels for the hydraulic system.

24. Fill the hydraulic oil tank with oil to the correct level.

25. Lubricate the boom mounting pins and the boom cylinder mounting pins. Refer to the "Operation &
Maintenance Manual" for the correct lubricating procedure.

26. Start the machine, and run it at low idle speed. Move the control lever for the boom so the boom cylinder
rods extend to their halfway position; then retract the cylinder rods. The cylinders should be cycled this way
approximately ten times to remove the air from the hydraulic system. Recheck the oil level in the hydraulic
oil tank.

Disassemble & Assemble Boom Cylinders

Start By:

a. remove boom cylinders

OTE: Several different boom cylinders are available. The disassembly and the assembly procedures which
follows can be used for all of the boom cylinders. However, reference must be made to the appropriate
"320B, 320B L and 230B N Hydraulic Excavator, Attachments Specifications Manual," for the correct
specifications for a specific boom cylinder.

Fluid Spillage Containment

Care must be taken to ensure that the fluids are contained during performance of the inspection, the
maintenance, the testing, the adjusting and the repair of the machine. Be prepared to collect the fluid with
suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to the "Tools And Shop Products Guide, NENG2500" the tools and the supplies suitable to collect and
contain any of the fluids in Caterpillar machines. Dispose of the fluids according to local regulations and
mandates.

Cylinders equipped with lock valves can remain pressurized for 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.

1. Put the boom cylinder on Tooling (A). The weight of the boom cylinder is 240 kg (530 lb).

2. Remove grease fitting (26) from cylinder assembly (12).

3. Remove 12 bolts (9) that hold head (6) to cylinder assembly (12).

4. Use Tooling (A) to slide rod assembly (1) out of cylinder assembly (12).

5. Remove two rings (19), two rings (18), two rings (17) and seal assembly (16) from piston (15).

6. Remove setscrew (22) and ball (23) from locknut (21). Using Tooling (B), remove locknut (21) that holds
piston (15) to rod assembly (1). Remove shim (20) and the piston from the rod assembly. Remove stop (13)
from the rod assembly. Remove ring (14) from the rod assembly.

7. Slide cylinder assembly (12) back on the rod assembly. Install 12 bolts (9) that hold head (6) to the
cylinder assembly. Pull the cylinder assembly and head (6) as a unit away from the rod assembly. Remove
the head from the cylinder assembly.

8. Remove ring (10), O-ring seal (11), ring (8) and bearing (7) from the head. Remove seal (2), ring (3), seal
(4) and seal (5) from head (6).

9. Remove lip seals (24) from both sides of the cylinder assembly at the pin bore.

10. Remove lip seals (27) from both sides of the rod assembly at the pin bore.
11. Remove bearings (25) from the cylinder assembly and the rod assembly at the pin bores.

OTE: The following steps are for the assembly of the bucket cylinder. Refer to Illustration C49588P1 for
the assembly of the boom cylinders.

12. Check the condition of all parts of the boom cylinder for wear or damage. If any of the parts are worn or
damaged, use new parts for replacement.

13. Install bearing (7) and ring (8) in head (6). Install seal (5), seal (4) and ring (3) in the head as shown.
Using Tooling (C), install seal (2) in head (6) with the lip facing away from the inside of the cylinder. Install
O-ring seal (11) and ring (10) in head (6) as shown.

14. Put clean hydraulic oil on the lip of seal (2), ring (3), seal (4) and seal (5).

15. Put head (6) in position on cylinder assembly (12). Install 12 bolts (9) that hold it. Install rod assembly
(1) in head (6) and the cylinder assembly. Remove bolts (9). Remove cylinder assembly (12) from the rod
assembly and head.

16. Install ring (14) on the rod assembly. Install ring (14) so the recess in the ring is facing in the direction of
the piston as shown. Install stop (13) on rod assembly (1).

17. Install piston (15) on the rod assembly. Lubricate the threads on the end of the rod assembly with 4C-
5593 Thread Compound. Install shim (20). Install locknut (21), and tighten it with Tooling (B) to a torque
of 4375 ± 215 *m (3220 ± 160 lb ft). Install ball (23) and setscrew (22) in the locknut. Tighten the
setscrew to a torque of 57 ± 10 *m (42 ± 7 lb ft).

18. Install seal assembly (16), two rings (17), two rings (18) and two rings (19) on piston (6). Lubricate the
outside of the piston with 1P-0808 General Purpose Lubricant.

19. Clean the remaining threads in the setscrew hole of the locknut. Make sure the remaining threads are
clean and dry. To prevent setscrew (22) from loosening, apply 5P-3321 Fast Cure Epoxy in the threaded
setscrew hole. Make sure the epoxy is even with the outside surface of the locknut after application.

20. Using Tooling (A), install cylinder assembly (12) on the rod assembly. Install bolts (9) that hold head (6)
to the cylinder assembly. Tighten bolts (9) with the rod assembly fully extended. Tighten the bolts to a
torque of 265 ± 39 *m (195 ± 29 lb ft).

21. Lower the temperature of bearing (25). Using Tooling (C), install the bearing the pin bore of the rod
assembly. Install the bearing until it is centered in the bore. Using Tooling (C), install two lip seals (27) in
the pin bore of the rod assembly. Install the seals with the sealing lips facing out and until they make contact
with the bearing.

22. Lower the temperature of bearing (25). Using Tooling (C), install the bearing the pin bore of the cylinder
assembly. Install the bearing until it is centered in the bore. Using Tooling (C), install two lip seals (24) in
the pin bore of the cylinder assembly. Install the seals with the sealing lips facing out and until they make
contact with the bearing.

23. Install grease fitting (26) in the cylinder assembly. Tighten the grease fittings to the specified torque
valve.

End By:
a. install boom cylinders

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