DISASSEMBLY

assembly.

1. Piston rod assembly

Common screw size for boom,

1) Remove piping from cylinder

arm, and bucket cylinder:

assembly.

M12 x Pitch 1.75.

2) Remove mounting bolts and

disconnect
head assembly (1).
3) Pull out piston rod assembly (2).
Place a container under the
cylinder to
catch the oil.
If the caulking of screw (3) is too
strong and it cannot be removed,
tighten the screw fully, then fit a tap
to
the thread and remove the screw.
4) Disassemble piston rod assembly
as follows.
i) Set piston rod assembly (2) in tool
N1.

iii) Using tool N2, remove piston

assembly
(4).
When not using tool N2, use the
drill holes (DH) (10, 4 places)
and loosen the piston assembly.
ii) Remove stopper screw (3) of
piston

iv) Remove plunger (5).

2. Disassembly of piston assembly

Boom and arm cylinder only

1) Remove rings (11).

v) Remove collar (6).

2) Remove wear rings (12).

Boom and arm cylinder only

3) Remove piston ring (13).

vi) Remove head assembly (7).

4) Remove O-ring and backup ring

(14)

vii) Remove cap (8), and pull 12

balls (9),

3. Disassembly of cylinder head

then remove plunger (10).

assembly

Arm cylinder only

1) Remove O-ring and backup ring

Since cap (8) is made of nylon,

(15).

tighten a screw into it and pull it

2) Remove snap ring (16), then

out with pliers.

remove dust
seal (17).
3) Remove rod packing (18).
4) Remove buffer ring (19).
5) Remove bushing (20).

ASSEMBLY
Be careful not to damage the
packing, dust
seals, and O-rings.
Clean each part, then cover the
piping ports
and pin-inserting hole to prevent dust

2. Assembly of piston assembly

from

1) Using tool N3, expand piston ring

entering them.

(13).

Do not try to force the backup

Set the piston ring on tool N3, and

ring into position.

turn the handle 8 10 times to

Warm it in warm water (50 60C)

expand

before

the ring.

installing it.

2) Set tool N4 in position, and

1. Assembly of head assembly

compress piston

1) Using tool N5, press fit bushing

ring (13).

(20).
2) Assemble buffer ring (19).
3) Assemble rod packing (18).
4) Using tool N6, install dust seal
(17), and
secure with snap ring (16).
5) Install backup ring and O-ring
(15).

3) Install backup ring and O-ring

Boom and arm cylinder only

(14).
4) Assemble wear ring (12).
5) Assemble ring (11).
Be careful not to open the end gap
of
the ring too wide. 2 Ring grove:
Grease (G2-LI)

5) Set cushion plunger (10) to piston

rod,
then assemble 12 balls (9) and secure
with cap (8).
Check that there is a small amount
of
play at the tip of the plunger.
Arm cylinder only

3. Piston rod assembly

1) Set piston rod assembly (2) to tool
N1.

6) Assemble piston assembly (4) as

follows.
When using piston rod assembly
2) Assemble head assembly (7).

(2)

3) Fit O-ring and backup ring to

and piston assembly (4) again:

collar (6),

Wash thoroughly and remove all

then assemble.

metal particles and dirt.

Boom and arm cylinder only

i) Screw in piston assembly (4), then

4) Assemble plunger (5).

use tool Q2 to tighten piston

assembly (4) so the position of the

cap (8) position on the end of the

screw thread H hole matches.

rod.

Remove all burrs and flashes with

(See step 5).)

a file.

Arm cylinder only

i) Screw in until piston assembly (4)
contacts
end face of rod, then use tool to
tighten. 3 Piston assembly:
294 29.4 Nm {30 3.0 kgm}
After tightening the piston, check

ii) Tighten screw (3). 2 Screw thread:

Loctite No. 262 3 Screw:
58.9 73.6 Nm {6 7.5 kgm}

that
there is play in plunger (5).
Boom, arm cylinder only

iii) Punch threads [1] at 4 points for

caulking.

ii) Machine one of the holes used to

install
When using a new part for either or
both of
piston rod assembly (2) and piston
assembly
(4).
For the rod with bottom cushion,
mark the

screw (3).
Align a drill horizontal with the
Vgroove
of the thread of piston rod
assembly (2) and piston assembly
(4),
then carry out machining.
For the cylinder with bottom
cushion

(arm cylinder), avoid cap (8)

Set the end gap of the ring

machining

horizontally (at

holes position when machining.

the side position), align axial center

(See step 5).)

of cylinder

Screw machining dimension (mm)

tube, then insert.

After inserting, check that the ring
is not

iii) After machining, wash

broken and has not come out, then

thoroughly to

push

remove all metal particles and dust.

in fully.

8) Tighten head assembly (1) with

iv) Tighten screw (3). 3 Screw:

mounting

58.9 73.6 Nm {6 7 kgm}

bolts.

v) Caulk thread at 4 places with

Mounting bolt:

punch.

7) Assemble piston rod assembly (2).

9) Install piping.