GROUP 9 BOOM, ARM AND BUCKET CYLINDER

1. REMOVAL AND INSTALL

1) BUCKET CYLINDER
(1) Removal
Expand the arm and bucket fully, lower
the work equipment to the ground and
stop the engine.
Operate the control levers and pedals
several times to release the remaining
13031GE18
pressure in the hydraulic piping.
Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can Bucket Cylinder
penetrate the skin causing serious
injury.
Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or dust
from entering.
Arm
Set block between bucket cylinder and
arm. Wooden block
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Remove bolt (2), nut (3) and pull out pin

2
(1).
Tie the rod with wire to prevent it from
3
coming out.

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Disconnect bucket cylinder hoses (4)

and put plugs (5) on cylinder pipe. 5

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 Sling bucket cylinder assembly (8) and
8
remove bolt (6) then pull out pin (5).
Remove bucket cylinder assembly (8).
Weight : 175 kg (390 lb)

6 21078DA17

(2) Install
Carry out installation in the reverse order
to removal.
When aligning the mounting position of
the pin, do not insert your fingers in the
pin hole.
Bleed the air from the bucket cylinder.
Confirm the hydraulic oil level and check
the hydraulic oil leak or not.

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2) ARM CYLINDER
(1) Removal
Expand the arm and bucket fully, lower
the work equipment to the ground and
stop the engine.
Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
Loosen the breather slowly to release the 13031GE18

pressure inside the hydraulic tank.

Escaping fluid under pressure can
penetrate the skin causing serious
injury. Arm cylinder
Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or
dust from entering. Block
Set block between arm cylinder and
boom.

21098CY18

Remove bolt (2) and pull out pin (1).

Tie the rod with wire to prevent it from
coming out.

21098CY19

Disconnect arm cylinder hoses (4) and

5
put plugs on cylinder pipe.
Disconnect greasing pipings (5). 4
Plug

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 Sling arm cylinder assembly(8) and
remove bolt (7) then pull out pin (6).
Remove arm cylinder assembly (8). 8
Weight : 290 kg (640 lb)

6
7

21098CY21

(2) Install
Carry out installation in the reverse order
to removal.
When aligning the mounting position
of the pin, do not insert your fingers in
the pin hole.
Bleed the air from the arm cylinder.
Confirm the hydraulic oil level and check
the hydraulic oil leak or not.

8-130
3) BOOM CYLINDER
(1) Removal
Expand the arm and bucket fully, lower
the work equipment to the ground and
stop the engine.
Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
Loosen the breather slowly to release the 13031GE18

pressure inside the hydraulic tank.

Escaping fluid under pressure can
penetrate the skin causing serious
injury.
Fit blind plugs in the hoses after 1
disconnecting them, to prevent dirt or dust
from entering.
Disconnect greasing hoses (1).
Sling boom cylinder assembly.

21078DA22

Remove bolt (4), stopper (5) and pull out 4

pin (2). 2
5
Tie the rod with wire to prevent it from
coming out.

2107A8DA23

Lower the boom cylinder assembly (6)

on a stand.

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 Disconnect boom cylinder hoses (7) and
put plugs on cylinder pipe.

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Remove bolt (9) and pull out pin (8).

Remove boom cylinder assembly (6).
Weight : 180 kg (400 lb)
6

8
9
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(2) Install
Carry out installation in the reverse order
to removal.
When aligning the mounting position
of the pin, do not insert your fingers in
the pin hole.
Bleed the air from the boom cylinder.
Conformed the hydraulic oil level and
check the hydraulic oil leak or not.

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2. DISASSEMBLY AND ASSEMBLY
1) STRUCTURE
(1) Bucket cylinder

9,10 6,7 8 4,5 23 31 30 22 11,12 3 1 2 13 14 17 16 15 18,19 20 21

Internal detail

24,26 28 27 29 25,26

21098CY01

1 Tube assembly 12 Back up ring 23 Hexagon socket head bolt

2 Rod assembly 13 Cushion ring 24 Pin bushing
3 Gland 14 Piston 25 Pin bushing
4 DD2 bushing 15 Piston seal 26 Dust seal
5 Snap ring 16 Wear ring 27 Band assembly
6 Rod seal 17 Dust ring 28 Pipe assembly-R
7 Back up ring 18 O-ring 29 Pipe assembly-B
8 Buffer ring 19 Back up ring 30 O-ring
9 Dust wiper 20 Lock nut 31 Hexagon socket head bolt
10 Snap ring 21 Hexagon socket set screw
11 O-ring 22 O-ring

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(2) Arm cylinder

9,10 6,7 8 4,5 23 34 33 22 11,12 3 1 2 13 14 17 16 15 18,19 20 21

Internal detail

24,25 30 32 31 24,25

26,27,28,29
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1 Tube assembly 13 Cushion ring 25 Dust seal

2 Rod assembly 14 Piston 26 Check valve
3 Gland 15 Piston seal 27 Coil spring
4 DD2 bushing 16 Wear ring 28 O-ring
5 Snap ring 17 Dust ring 29 Plug
6 Rod seal 18 O-ring 30 Band assembly-R
7 Back up ring 19 Back up ring 31 Band assembly-B
8 Buffer ring 20 Lock nut 32 Pipe assembly-R
9 Dust wiper 21 Hexagon socket set screw 33 O-ring
10 Snap ring 22 O-ring 34 Hexagon socket head bolt
11 O-ring 23 Hexagon socket head bolt
12 Back up ring 24 Pin bushing

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(3) Boom cylinder

9,10 6,7 8 4,5 23 31 30 22 11,12 3 1 2 13 14 17 16 15 18,19 20 21

Internal detail

24,26 28 27 29 25,26
21098CY03

1 Tube assembly 12 Back up ring 23 Hexagon socket head bolt

2 Rod assembly 13 Cushion ring 24 Pin bushing
3 Gland 14 Piston 25 Pin bushing
4 DD2 bushing 15 Piston seal 26 Dust seal
5 Snap ring 16 Wear ring 27 Band assembly
6 Rod seal 17 Dust ring 28 Pipe assembly-R
7 Back up ring 18 O-ring 29 Pipe assembly-B
8 Buffer ring 19 Back up ring 30 O-ring
9 Dust wiper 20 Lock nut 31 Hexagon socket head bolt
10 Snap ring 21 Hexagon socket set screw
11 O-ring 22 O-ring

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2) TOOLS AND TIGHTENING TORQUE
(1) Tools
Tools Remark

6
8 B
Allen wrench
14
17
7
Spanner
8
(-) Driver Small and large sizes
Torque wrench Capable of tightening with the specified torques

(2) Tightening torque

Torque
Part name Item Size
kgfm lbfft
23 M16 232.0 16614.5
Bucket cylinder
31 M10 5.40.5 39.13.6
23 M16 232.0 16614.5
Socket head bolt Boom cylinder
31 M10 5.40.5 39.13.6
23 M18 323.0 23221.7
Arm cylinder
34 M12 9.41.0 687.2
Bucket cylinder 20 - 10010 72372.3
Lock nut Boom cylinder 20 - 10010 72372.3
Arm cylinder 20 - 15015 1085108
Bucket cylinder 14 - 15015 1085108
Piston Boom cylinder 14 - 15015 1085108
Arm cylinder 14 - 20020 1447145

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3) DISASSEMBLY
(1) Remove cylinder head and piston rod
Procedures are based on the bucket
cylinder.
Hold the clevis section of the tube in a
vise.
Use mouth pieces so as not to damage
the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.

Pull out rod assembly (2) about

200mm (7.1in). Because the rod
assembly is rather heavy, finish
extending it with air pressure after the oil

m
0m
20
draining operation.

21078DA30

Loosen and remove socket bolts (23) of

Hexagon
the gland in sequence. socket wrench
Cover the extracted rod assembly (2) 23
with rag to prevent it from being
accidentally damaged during operation. Turn counter
clockwise

Cover here
with rag
2
21098DA31

Draw out cylinder head and rod assembly

together from tube assembly (1). Lift
Since the rod assembly is heavy in this
case, lift the tip of the rod assembly (2)
with a crane or some means and draw it Full straight
sideways
out. However, when rod assembly (2)
has been drawn out to approximately
two thirds of its length, lift it in its center
Oil pan
to draw it completely.
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 Note that the plated surface of rod
assembly (2) is to be lifted. For this
reason, do not use a wire sling and
others that may damage it, but use a
strong cloth belt or a rope.

Place the removed rod assembly on a

wooden V-block that is set level.
Piston assy
Cover a V-block with soft rag.

Wooden block

21078DA33

(2) Remove piston and cylinder head 13 14 18 19 20 21

Remove set screw (21).
Since set screw (21) and lock nut (20) is
tightened to a high torque, use a
hydraulic and power wrench that utilizers
a hydraulic cylinder, to remove the lock
set screw (21) and lock nut (20).
Remove piston assembly (14), back up
ring (19), and O-ring (18).
2907A8CY02

Remove the cylinder head assembly

Plastic
from rod assembly (2). hammer
If it is too heavy to move, move it by
Lift with a crane
striking the flanged part of cylinder head
with a plastic hammer.
Pull straight
Pull it straight with cylinder head
assembly lifted with a crane.
Exercise care so as not to damage the
lip of rod bushing (4) and packing
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(5,6,7,8,9,10) by the threads of rod
assembly (2).

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(3) Disassemble the piston assembly 17 16 15 16 17
Remove wear ring (16).
Remove dust ring (17) and piston seal
(15).
Exercise care in this operation not to
damage the grooves.

2907A8CY03

(4) Disassemble cylinder head assembly

Remove back up ring (12) and O-ring 10 9 6 7 8 4 5 12 11
(11).
Remove snap ring (10), dust wiper (9).
Remove back up ring (7), rod seal (6)
and buffer ring (8).
Exercise care in this operation not to
damage the grooves.
Do not remove seal and ring, if does not
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damaged.
Do not remove bushing (4).

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3) ASSEMBLY
(1) Assemble cylinder head assembly
Check for scratches or rough surfaces if
found smooth with an oil stone.
Coat the inner face of gland (3) with
hydraulic oil.

21078DA37

Coat dust wiper (9) with grease and fit Press here
dust wiper (9) to the bottom of the hole of (Straight down)
dust seal.
Metal
At this time, press a pad metal to the 9
metal ring of dust seal.
Fit snap ring (10) to the stop face.

8-157(2)

Fit back up ring (7), rod seal (6) and

buffer ring (8) to corresponding grooves,
in that order.
Coat each packing with hydraulic oil Wrong Right
before fitting it.
Insert the backup ring until one side of it
is inserted into groove.

8-157(3)

Rod seal (6) has its own fitting direction.

Push bar
Therefore, confirm it before fitting them.
Fitting rod seal (6) upside down may
damage its lip. Therefore check the
correct direction that is shown in fig.

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 Fit back up ring (12) to gland (3).
Put the backup ring in the warm water of
11
30~50C .
Fit O-ring (11) to gland (3). 12

21078DA39

(2) Assemble piston assembly

Check for scratches or rough surfaces.
If found smooth with an oil stone.
Coat the outer face of piston (14) with
hydraulic oil.

8-158(2)

Fit piston seal (15) to piston.

Put the piston seal in the warm water of 15
60~100C for more than 5 minutes.
After assembling the piston seal, press
its outer diameter to fit in.

2907A8CY04

Fit wear ring (16) and dust ring (17) to

17 16 15 16 17
piston (14).
14

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(3) Install piston and cylinder head
Fix the rod assembly to the work bench. Cylinder head assembly
Apply hydraulic oil to the outer surface of Rod assembly
rod assembly (2), the inner surface of
piston and cylinder head.
Insert cylinder head assembly to rod
assembly.

21078DA40

Insert cushion ring (13) to rod assembly.

Note that cushion ring (13) has a 13
direction in which it should be fitted.
Insert

8-159(2)

Fit piston assembly to rod assembly. Piston assembly

Tightening torque : 15015 kgfm
(1085108 lbfft)

50078CY09

Fit lock nut (20) and tighten the screw

20 21
(21).
Tightening torque :
Item kgfm lbfft
Bucket 10010 72372.3
20 Boom 10010 72372.3
Arm 15015 1085108
21 2.70.3 19.62.2

50078CY10

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(3) Overall assemble Fix with a bar
Place a V-block on a rigid work bench.
Mount the tube assembly (1) on it and Lift
fix the assembly by passing a bar
through the clevis pin hole to lock the
assembly. Straight
Insert the rod assembly in to the tube
assembly, while lifting and moving the
rod assembly with a crane. Appply liquid packing
21078DA41
Be careful not to damage piston seal by
thread of tube assembly.
Match the bolt holes in the cylinder head
flange to the tapped holes in the tube Turn clockwise
assembly and tighten socket bolts to a Apply loctite
specified torque.
Refer to the table of tightening torque.

Place rag
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