32.

ATTACHMENTS
TABLE OF CONTENTS

32.1 REMOVING AND INSTALLING .......................................................................................... 32-3

32.1.1 ATTACHMENT ASSEMBLY AND NAME .................................................................. 32-3
32.1.2 BUCKET .................................................................................................................... 32-4
32.1.3 ARM .......................................................................................................................... 32-6
32.1.4 BOOM ....................................................................................................................... 32-9
32.1.5 SWING ...................................................................................................................... 32-12
32.1.6 DOZER ...................................................................................................................... 32-14
32.2 DISASSEMBLING AND ASSEMBLING ............................................................................. 32-15
32.2.1 CYLINDER ................................................................................................................ 32-15

Book Code No. S5PJ3211E01

32-1
32. ATTACHMENTS

Issue Date of Issue Applicable Machines Remarks

S5PJ3211E01
First edition December, 2004 CX55B : PJ04–03001~ KE
(CASE Shanghai)

32-2
 32. ATTACHMENTS

32.1 REMOVING AND INSTALLING

32.1.1 ATTACHMENT ASSEMBLY AND NAME

(N) SWING CYLINDER HEAD PIN

(M) SWING CYLNDER ROD PIN

(L1) (UPPER)
(L2) (LOWER)
SWING CENTER PIN

(A) BOOM FOOT PIN

(C) BOOM CYLINDER ROD PIN
(D) ARM CYLINDER HEAD PIN (B)
BOOM CYLINDER
HEAD PIN

(F) BOOM TOP PIN

(E)
ARM CYLINDER
ROD PIN

(Q)
(I) (K) DOZER CYLINDER
IDLER LINK PIN BUCKET HEAD PIN (P)DOZER PIN
ATTACHING PIN
(H)
(G) BUCKET CYLINDER (J) (R)
BUCKET CYLINDER ROD PIN BUCKET DOZER CYLINDER
HEAD PIN DRIVE PIN ROD PIN

Fig. 32-1 Attachment name and position

32-3
32. ATTACHMENTS

32.1.2 BUCKET

32.1.2.1 REMOVAL OF BUCKET

(1) Operate the operating lever and place the bucket
on the ground, so the bucket and arm connecting
pins are not loaded.
(2) Move the O-rings (3) toward the bucket bosses us-
ing a spatula.
(3) In order to remove pin (K) which links arm and
bucket, remove the ring (2) and the pin (3) by
means of straight driver, and draw out pin (K).
• If the pin does not come off easily, the pin is
loaded. Take off the load by manipulating the
operating lever. Fig. 32-2 To place Bucket on ground
• Take care so the dust seal between the arm and
3
the bucket bosses is not damaged.
(4) Adjust the bucket by manipulating the operating le-
J B
ver so the pin (J) between the bucket link and the
bucket is not loaded.
2
(5) Remove the ring (2) and pin (1) then pull out the
pin (J). B

(6) Remove bucket assembly. PIN FOR BUCKET

LINK
Weight :
DUST SEAL DAST SEAL
131kg (289 lbs) — CX55B
1 SECTION BB 3

K
B
PIN FOR ARM

Fig. 32-3 Assembly of pin (SECTION A-A)

32-4
 32. ATTACHMENTS

32.1.2.2 INSTALLATION OF BUCKET

Installation is performed in the reverse order of re-
moval, including the following workings :

When aligning the pin position, do not put your fin-

ger in the pin holes in any circumstances, but align
them visually.

(1) Clean the welded part of the structures and

check that there is no crack on the part.
(2) Check that the dust seal is not damaged, and re-
place a faulty one if necessary.
(3) Replace the worn pins and bushings according
to the Section "ATTACHMENT DIMENSIONS"
of "SPECIFICATIONS".
(4) When inserting the pin, coat the shaft with
grease.
• The bucket can be mounted easily if the buck-
et link is installed in the beginning.
Fig. 32-4 Installation of bucket

32-5
32. ATTACHMENTS

32.1.3 ARM

32.1.3.1 REMOVAL OF ARM

(1) Making the arm cylinder and bucket cylinder to the
most retracting conditions, get touch the arm tip
with the ground.
(2) Shut off the engine and operate the arm control le-
ver several times at the same moment, and the
pressure in circuit is released.
Then put the safety lock lever in the "Locked" posi-
tion, and depress the air breather on the hydraulic
oil tank, release the pressure in the tank. Fig. 32-5 Arm removing posture
(3) Disconnect the 2 hoses connected to the bucket
cylinder. Then apply plugs to the openings.
E
: 27mm
(4) Lift up the arm cylinder body with a nylon sling in
order not to exert any load to the pin (E).
(5) Remove the capscrew and nuts that are preventing
the pin (E) from coming out. Then remove the pin F
(E) and shims.

: 19mm
(6) Placing a square timber under the arm cylinder, get
down the cylinder.
(7) Install the pin (E) to the original position, and install
the capscrew and nuts that prevents the pin (E) PIN (F) PORTION PIN (E) PORTION
from coming out. Applying a rope to the pin (E) and
the arm tip, slightly lift it up in order not to exert any Fig. 32-6 Sectional view of Installing Pin
load to the pin (F).
(8) Remove the capscrew that is preventing the pin (F)
connecting the arm and boom, from coming out.
Then pull off the pin (F). BUCKET CYLINDER

: 36mm
G
(9) Remove the arm assembly paying attention to the H
E
stability of arm.
Weight of arm assembly : approx.
180kg (397 lbs) — CX55B

Fig. 32-7 Removal of Arm assembly

32-6
 32. ATTACHMENTS

(10)Removal of Bucket Cylinder SHIM SHIM

1) Remove the capscrew that is preventing the rod
pin (H) from coming out, then pull off the pin (H).

: 24mm
2) Remove the capscrew and nuts that are pre-
PIN (H) PORTION PIN (G) PORTION
venting the head pin (G) from coming out, then
Fig. 32-8 Sectional view of Installing Pin
pull off the pin (G).

: 17mm
3) Apply a nylon sling to the tube of bucket cylin-
der, and remove the cylinder.
Weight ; approx. 27kg (60 lbs)

32.1.3.2 INSTALLATION OF ARM

Installation is performed in the reverse order of re-
moval, including the following workings.

• At the alignment of pin positions, never insert

your finger into the pin holes.
• Make sure to align them with visual confirma-
tion.

(1) Make the welded area clean to inspect any

cracks there. BOSS
(2) Check the dust seal for damages, and replace
the faulty dust seal to new one (referring to Fig.
32-9 for the installing procedures).
(3) Referring to the Section "ATTACHMENT DI- DUST SEAL
MENSIONS" of Specifications, replace the
worn-out pin and bushing to new ones.
(4) Before installing the pin, apply grease to the
shaft area. BUSHING

(5) Referring to Fig. 32-10, install the capscrew and

nuts to prevent the pin from coming out. Fig. 32-9 Dust seal installation

: 19mm, 24mm, 36mm

(6) Make sure to provide an appropriate clearance
for thrust direction at the installation of pin refer-
ring to Fig. 32-10.
(7) For the adjustment for clearance, insert resin
(plastic) shim first, then adjust the clearance
with steel shims.

32-7
32. ATTACHMENTS

G
H
E

The sum of both clearances:
To be from 0.6mm(0.024in)to
1.0mm(0.039in)
after shim adjustment
SHIM
The sum of both clearances:
To be from 0.5mm(0.020in)to
0.9mm(0.035in)
after shim adjustment
SHIM
The sum of both clearances :
less than0.5mm(0.020in)
after shim adjustment
SHIM
The sum of both clearances:
To be from 0.5mm(0.020in)to
0.9mm(0.035in)
after shim adjustment
SHIM

1.0 1.5 1.0 1.5

3.5
(0.14")

SHIM Apply Loctite #242

The clearance to be from 0.1mm(0.004in) Apply Loctite #242 equivalent
to 0.5mm(0.02in) equivalent
PIN (H) PORTION PIN (G) PORTION PIN (F) PORTION PIN (E) PORTION

Fig. 32-10 Sectional view of Installing Pin

32-8
 32. ATTACHMENTS

32.1.4 BOOM

32.1.4.1 REMOVAL OF BOOM

(1) Get down the boom from which the arm was re-
D
moved, and support the boom end with a stable
stand.
(2) Disconnect all hoses from the bucket cylinder,
arm cylinder and boom cylinder, and apply plugs
A
to all the openings.
C
: 27mm
B
(3) Disconnect the wiring for working light at the
connector.
(4) Removal of Boom Cylinder
1) Temporarily lift up the boom cylinder with a
nylon sling to prevent the boom cylinder from Fig. 32-11 Removal of Boom Cylinder
falling down.
2) Removing the capscrew and nuts that are
preventing the rod pin (C) from coming out,
remove the pin (C).

: 19mm
3) Retract the rod, then put the cylinder on a sta- PIN (C) PORTION PIN (B) PORTION

ble stand. Fig. 32-12 Sectional view of Installing Pin

4) Removing the capscrew that is preventing the
head pin (B) from coming out, remove the pin
(B). D
5) Remove the boom cylinder.
Weight :
57 kg (126 lbs) — CX55B
A
(5) Removal of Boom assembly
1) Temporarily lift up the boom assembly in or-
der not to exert any load to the boom foot pin
(A).
Weight of boom assembly : approx.
240 kg (529 lbs) — CX55B
Fig. 32-13 Removal of Boom assembly
2) Removing the capscrew that is preventing the
boom foot pin (A) from coming out, pull off the
pin (A).

: 19mm
3) Applying a sling to the boom assembly, re-
move the boom assembly.

32-9
32. ATTACHMENTS

(6) Removal of Arm Cylinder

1) Removing the capscrew and nuts that are
preventing the head pin (D) from coming out,
remove the pin (D).

: 19mm
PIN (D) PORTION PIN (A) PORTION
2) Applying a nylon sling to the tube of arm cyl-
Fig. 32-14 Sectional view of Installing Pin
inder, remove the arm cylinder.
Weight :
49 kg (108 lbs) — CX55B

32.1.4.2 INSTALLATION OF BOOM

Installation is performed in the reverse order of re-
moval, including the following.

• At the alignment of pin positions, never insert

your finger into the bores.
• Make sure to align them with visual confirma-
tion.

(1) Make clean the welded area on each of struc-

ture to inspect any cracks there. BOSS
(2) Check the dust seal for damages, and replace
the faulty dust seal to new one (referring to Fig.
32-15 for the installing procedures).
(3) Referring to the Section "ATTACHMENT DI- DUST SEAL
MENSIONS" of Specifications, replace the
worn-out pin and bush to new ones.
(4) Before inserting the pin, apply grease to the
shaft area. BUSHING
(5) Referring to Fig. 32-16, install the capscrew and
nuts to prevent the pin from coming out. Fig. 32-15 Dust seal installation

: 19mm
(6) Make sure to provide an appropriate clearance
for thrust direction at the installation of pin refer-
ring to Fig. 32-16.
(7) For the adjustment for clearance, insert resin
(plastic) shim first, then adjust the clearance
with steel shims.

32-10
 32. ATTACHMENTS

C
Apply grease when install A

The sum of both clearances to be

from 0.1mm(0.004in) to 0.5 (0.02in)
after shim adjustment

Apply Loctite
#242 equivalent
The sum of both clearances:
To be from 0.5mm (0.020in)
to 0.9mm (0.035in)
after shim adjustment
SHIM
PIN (A) PORTION
The sum of both clearances to be
from 0.1mm(0.004in) to 0.5 (0.02in)
after shim adjustment
SHIM
B
The sum of both clearances to be
from 0.1mm(0.004in) to 0.5 (0.02in)
after shim adjustment
SHIM

1.0~1.5 1.0~1.5
(0.04"~0.06") (0.04"~0.06")
2.5
(0.1") Apply Loctite 3.5 (0.14")
PIN (C) PORTION #242 equivalent PIN (B) PORTION PIN (D) PORTION

Fig. 32-16 Sectional view of Installing Pin

32-11
32. ATTACHMENTS

32.1.5 SWING

32.1.5.1 PREPARATION FOR REMOVAL

(1) To make the removing work easy, swing by
around 30 for leftward.
(2) Disconnect the hoses of bucket cylinder, arm
cylinder and boom cylinder, and apply plugs to

all the openings. : 27mm

32.1.5.2 Removal of Swing Bracket and Cylinder

(1) Removal of swing bracket (A9) C5
C11
1) Removing the capscrew (C4) that is prevent- N
ing the rod side pin (M) of swing cylinder
(C11) from coming out, remove the pin (M).

: 19mm M
2) Install the boom foot pin (A) to the original po-
sition on swing bracket (A9), then temporarily C4
lift it up.
3) Removing two capscrews (B8) (B9) those are
preventing the pins (L1) (L2) from coming out,
remove the pins (L1) (L2).

: 19mm B8
Apply loctite #242 equivalent
4) Remove the swing bracket (A9).
Weight of Swing Bracket : 112kg (247 lbs).
(2) Removal of Swing Cylinder (C11)
A
1) Disconnect 2 connecting hoses for the swing
cylinder.
A9
: 22mm
B9
2) Removing the capscrew (C5) that is prevent-
ing the head side pin (N) of swing cylinder
from coming out, remove the pin (N).

: 19mm
3) Take out the swing cylinder (C11) from the A
front side.
Weight of Swing Cylinder : 39kg (86 lbs)
A9

L1

L2

B9
VIEW I

Fig. 32-17 Swing portion

32-12
 32. ATTACHMENTS

32.1.5.3 INSTALLATION OF SWING BRACKET AND CYLINDER

Installation is performed in the reverse order of re-
moval, including the following workings.
(1) Check the dust seal for damages, and replace
the faulty dust seal to new one.
(2) Referring to the Section "ATTACHMENT DI-
MENSIONS" of Specifications, replace the
worn-out pin and bushing to new ones.
(3) Before inserting the pin, apply grease to the
shaft area.
(4) Refer to Fig. 32-18 for the shim adjustment at
pin installing portion.

Set this washer with the oil groove side

positioned downward (Thickness 2.3)

SECTION C-C SHIM

The sum of both clearances:
To be from 0.5mm(0.020in)to
0.9mm(0.035in)
after shim adjustment
SHIM
The sum of both clearances: The sum of both clearances :
To be from 0.5mm(0.020in)to less than0.5mm(0.020in)
Apply Loctite 0.9mm(0.035in)
after shim adjustment
#262 equivalent after shim adjustment
SHIM 4

1.0~1.5
(0.04~0.06in)
Apply Loctite
Apply Loctite #242 equivalent
#242 equivalent
SECTION A-A SECTION B-B VIEW I
Fig. 32-18 Sectional view of Pin Installing

32-13
32. ATTACHMENTS

32.1.6 DOZER

32.1.6.1 REMOVAL
(1) Put a support of appropriate height under the
mounting side of dozer body, and make the doz-
er at a stable condition not to exert any load to
the pin (P).
(2) Disconnect the hydraulic hoses and apply a plug
to the connecting portions.

: 22mm
(3) Apply a nylon sling to the dozer cylinder (C1),
and lift it up slightly not to exert any load to the B2, B3 Q
pin (Q) of rod side. C3, C4
C1
(4) Remove the capscrew (C3) and nuts (C4) that R
are preventing the pin (Q) from coming out, of
rod side. Remove the pin (Q), and support the
cylinder (C1) with a wood block, etc.

: 19mm
(5) Remove the capscrew (B2) and nuts (B3) that
are preventing the dozer body fixing pin (P) from P SUPPORT
coming out, and remove the two pins (P).
Fig. 32-19 Removing/Installing Dozer
(6) Gradually move the machine to backward to re-
move the dozer.
Weight of dozer assembly :
175 kg (386 lbs) — CX55B
(7) If necessary, remove the dozer cylinder by
means of removing the pin (R) of head side.
Weight of dozer cylinder :
27 kg (60 lbs)

32.1.6.2 INSTALLATION
The installation is carried out with the reverse order
of the removal paying attention for the following.
(1) Referring to the Section "ATTACHMENT DI-
MENSIONS" of Specifications, replace the
worn-out bushings and dust seals to new ones.
(2) Before installing pin (P), (Q) and (R), apply
grease to their shaft area.
(3) Referring to Fig. 32-20, install the nuts for cap-
screw to prevent the pin from coming out.

: 19mm

Fig. 32-20 Tightening Procedures for Nuts

32-14
 32. ATTACHMENTS

32.2 DISASSEMBLING AND ASSEMBLING

32.2.1 CYLINDER

32.2.1.1 NECESSARY TOOLS

Though the required tools and jigs differ in types of cylinder, as a guide line, tools and jigs to be prepared are shown
in Table 32-1.
Table 32-1 List of Tools and Jigs
Tool/Jig Remarks Tool/Jig Remarks
1. Steel hammer A sharp-point tool may be used in
Hammer Gimlet
2. Wooden or plastic hammer place of gimlet
Several kinds of minus driver of small 1. For press-fitting rod bushing (A)
Screwdriver
and large sizes
2. For press-fitting bushing (B)
Chisel Flat chisel Jig
3. For press-fitting dust seal (C)
Capable to hold outer dia. of cylinder
Vise 4. For reforming seal ring (D)
head and tube installing pin portion.
1. Slide calipers
1. Spanner, Plier, Torque wrench Measuring De- 2. Micrometer
Wrench
2. Extension pipe for wrench vice 3. Cylinder gauge
4. V-block

• For the details of special jigs, refer to the end of this section.

32.2.1.2 GENERAL PRECAUTIONS

• Carry out the disassembly and assembly works in a clean work shop, and always keep disassembled parts at
clean conditions.
• Prior to disassembly, thoroughly clean the cylinder externally.
• Use caution not to give any damages to the parts while carrying out the disassembly / assembly works.
• Thinly apply grease or hydraulic oil to seals prior to installation.
• After the installation of O-ring, confirm there is no twist on it.
• Apply clean hydraulic oil to each sliding portion before the installation.
• Ensure each sliding portion for no burr and defect, and its smooth sliding operation.
• This manual describes mainly for the boom cylinder as an typical example.
Refer to 24.1.8 of COMPONENT SYSTEM for the construction of hydraulic cylinders when disassembling and
reassembling the cylinders.

32-15
32. ATTACHMENTS

32.2.1.3 CYLINDER CONSTRUCTION (EXAMPLE OF BOOM CYLINDER)

• See 24.1.8 CYLINDER for the others.

7
21

8 22
4 20 19 18 2 1 5 6 11 10 9

17 16 15 14 13 12

Fig. 32-21 Construction of boom cylinder

No. NAME Q’TY No. NAME Q’TY

1 Tube assembly 1 12 Seal ring 1
2 Rod assembly 2 13 Ring 1
3 Bushing 1 14 Rod bushing 1
4 Cylinder Head 1 15 Seal ring 1
5 Cushion bearing 1 16 Back-up ring 1
6 Piston 1 17 Dust seal 1
7 Pipe 1 18 O-ring 2
8 Pipe 2 19 Back-up ring 3
9 Lock nut 1 20 O-ring 1
10 Wear ring 1 21 Dust seal 4
11 Seal ring 1 22 Bolt 2

32.2.1.4 DISASSEMBLY
• The numbers in ( ) following to each part name are the Items corresponding to those in Fig. 32-21 unless other-
wise noted.
(1) Disassembly of cylinder assembly
1) Fix the clevis portion of tube with a vice, and
hold the other end with a wooden stand to
hold the cylinder in level.
2) Drain hydraulic oil remained in the cylinder.
• Slowly move the piston rod so that the hy-
draulic oil does not spout out.

Fig. 32-22 Disassembling cylinder assembly

32-16
 32. ATTACHMENTS

3) Make straight the locking fin for the cylinder

head (4).
• Use cautions bending / straightening of lock-
ing fin, because locking fin and cylinder tube
are made with one-piece.
4) Loosen the cylinder head (4).
• Prior to loosening the cylinder head, pull out
the piston rod (2) by 100 ~ 200 mm (4 ~ 8 in).

• Cover the rod with an appropriate material to

prevent it from unexpected dents. Fig. 32-23 Disassembling cylinder assembly

5) Pull off the piston rod assembly from the tube.

• Pull the piston rod in straight not to give any
damages on the sliding surface.

Fig. 32-24 Disassembling cylinder head

(2) Disassembly of piston rod assembly
1) Fix the piston rod assembly in level.

Fig. 32-25 Disassembling piston rod

32-17
32. ATTACHMENTS

2) Remove ring (25) using snap ring pliers, and

remove plate ring (24) and cushion ring (23).
(Only for arm cylinder)
• If cushion bearing (23) is left, the lock nut can-
not remove.
Remove cushion bearing before loosening
lock nut (9).

25

23

24

3) Loosen lock nut (9) by means of torque

wrench, and remove lock nut (9).

4) Remove piston (6).

32-18
 32. ATTACHMENTS

5) Remove cushion bearing (5). (Only for boom

cylinder and arm cylinder)

6) Remove seal ring (12). (Only for boom cylin-

der and arm cylinder)
• Expand the split on the seal ring as minimum
as required to remove.

12

7) Remove the cylinder head (4)

• Pull out the piston rod straightly not to give
any damages on the rod surface.

(3) Disassembly of piston assembly : 10

1) Remove the wear ring (10) from the piston
(6).
• Expand the split on the wear ring (10) as min-
imum as required to pull it off for axial direc-
tion. (2 Points)
2) Remove the seal ring assembly (11).
• Cut off the seal ring (11) or remove it using a 11
minus screw driver.
Fig. 32-26 Disassembling piston assembly

32-19
32. ATTACHMENTS

(4) Disassembly of cylinder head assembly :

1) Remove the O-rings (18), (20) and back-up
ring (19) from the outer periphery of cylinder
head (4).

Fig. 32-27 Disassembling cylinder head assem-

bly
2) Removal of seal ring
Remove the seal ring (15) and back-up ring
(16).

Fig. 32-28 Disassembling cylinder head

3) Remove the dust seal (17).
• Alternately tap inside of the metal ring of dust
seal at several positions, as shown in the fig-
ure, to push it out step by step from the
groove.

Fig. 32-29 Removing wiper ring

4) Remove the ring (13) using a gimlet and re-
move the rod bushing (14) using a screw driv-
er.
• Take care to damage the head portion.

Fig. 32-30 Removing bushing

32-20
 32. ATTACHMENTS

(5) Disassembly of clevis portion :

1) Remove the dust seal (21) from the clevis 2
portion of tube (1) and piston rod (2).

21

Fig. 32-31 Removing dust seal

2) Remove the pin bushing (3).
• Using a metal block, push it out with a press
machine.

Fig. 32-32 Removing pin bushing

32.2.1.5 ASSEMBLY
(1) Assembling Clevis Portion
1) With the installing jig (B), press-fit the bush-
ings (3) into the piston rod (2) and tube (1).
• Prior to the work, apply hydraulic oil on the B
surface of parts. 3

Fig. 32-33 Installing pin bushing (3)

2) With the setting tool, install the dust seal (21).

Fig. 32-34 Installing dust seal

32-21
32. ATTACHMENTS

(2) Assembling Cylinder Head

1) With installing jig (A), press-fit the bushing
(14) and install ring (13).
• Prior to the work, apply hydraulic oil on inner
periphery of the cylinder head (4).
• At press-fitting the bushing (14) into the cylin-
der head (4), make the top surfaces of them
in level without step.

Fig. 32-35 Assembling cylinder head

2) Install the back-up ring (19) and O-rings (18)
and (20).

Fig. 32-36 Installing back-up ring and O-ring

3) Installing seal ring
Install the back-up ring (16) and seal ring
(15).
• Refer to article 32.2.1.3 CYLINDER CON-
STRUCTION (EXAMPLE OF BOOM CYLIN-
DER) and install the seal ring correctly.

Fig. 32-37 Installing seal ring

4) Using the setting tool (C), install the dust seal
(17).

Fig. 32-38 Installing dust seal

32-22
 32. ATTACHMENTS

(3) Assembly of piston portion :

1) Install the O-ring for the seal ring assembly
6
(11).
In this case, stretch the O ring as minimum as
required to install.

11

2) Install wear ring (10) for piston from rod side.

(2 places)
• Expand the split of wear ring as minimum as
required.

3) The O-ring of seal ring was extremely

stretched at the installation, insert the piston
PISTON SUB-ASSEMBLY
subassembly from the taper side of reforming
jig (D) to reform the ring.
D

(4) Assembly of piston rod

1) Keep clevis of piston rod (2) horizontal, and
install the head sub-assembly.
2
• Apply hydraulic oil to seal slightly.
• Take care not to hit the seal against the
thread of piston rod.

HEAD SUB-ASSEMBLY

32-23
32. ATTACHMENTS

2) Face the slit of seal ring (12) to the thread,

and install the seal ring into groove of piston
rod.
SLIT OF SEAL RING
Install the cushion bearing (5) on the rod from
taper side as shown in the photo.
• Take care of the direction of seal ring and
cushion bearing.
If the direction is mistaken, the cushion effect
is not obtained.

TAPER

CUSHION
BEARING

3) Install the piston sub-assembly and lock nut

(9). PISTON SUB-ASSY STEP IN PISTON
• Insert the piston from the flat side of piston
bore.

4) Tighten the lock nut (9) with torque wrench.

Refer to the table of torque in the mainte-
nance standard about the tightening torque
for lock nut.
TORQUE WRENCH

32-24
 32. ATTACHMENTS

5) Install the cushion bearing (23) of rod retract-

ing side, plate ring (24) and ring (25).
24
(Arm cylinder only) FLAT PORTION (2 PLACES)

• Place the flat portion (2 places) of cushion

bearing (23) toward the direction as shown in
the right photo.
• Confirm that the cushion bearing is movable
after ring fixing.
25

23

(5) Assembly of cylinder :

1) Fix the tube in level, and install the piston rod
assembly into it.
• At the installation, align the center of piston
rod to the center of tube and install the piston
rod in straight, paying attention not to damage
seals.

Fig. 32-39 Inserting piston rod assembly

2) Install the cylinder head (4).
• Apply hydraulic oil on the packings (seals) pri-
or to install.
• Tightening torque for cylinder head :
See 32.2.1.6 (4) in MAINTENANCE STAN-
DARDS .

Fig. 32-40 Installing cylinder head

3) Bend the locking fin on the tube to lock the
cylinder head.

Fig. 32-41 Assembling cylinder assembly

32-25
32. ATTACHMENTS

32.2.1.6 MAINTENANCE STANDARDS

(1) Inspection after disassembly
1) Inspection item
Table 32-2
Parts Name Inspecting Portion Inspection Item Remedy
1. Neck of rod Presence of crack Replace
2. Stepped part to which
Presence of crack Replace
piston is attached
3. Threads Presence of seizure, etc. Recondition or replace
4. Bend Measure amount of bend Refer to Rod Bend
Piston rod 1. Wearing off of plating 1. Replace
5. Plated surface 2. Rust on plating 2. Replace
3. Presence of defect 3. Recondition or replace
6. Rod Wear of outside Recondition or replace
7. Bushing at mounting
Wear of inside Replace
part
1. Welded part of bottom Presence of crack Replace
2. Tube at mounting part Presence of crack Replace
Cylinder tube 3. Tube inside Presence of defect Replace if oil leak is seen
4. Bushing at mounting
Scratch and wear of inside Replace
part
1. Wear of inside
Cylinder head 1.Bushing Replace
2. Defect of inside

(2) Repair procedure

Replace sliding parts and seal parts according to the followings.

1 Bushing Where 1/4 of circumference is worn in copper color.

2 Seals and slide rings Replace them when cylinder is disassembled.
3 Pin bushing Where severe scuffing is appeared.
4 Piston rod Where the bend 0.5 mm/m (0.02 in/3.3 ft) or more is appeared.

32-26
 32. ATTACHMENTS

(3) Service limits

Service limits represent the limits of wear on the sliding surfaces of the cylinder tube and the piston rod that have
no such faults as may degrade the sealing effect.
1) Clearance between piston rod and rod bushing :
Replace the bushing if the clearance between the piston rod and the rod bushing exceeds 0.25 mm (0.01 in).
2) Bend of piston rod :
The allowable bend of the rod is maximum 0.5 mm / 1 m (0.02 in / 3.3ft). For measurement, support both
ends of the parallel section of the piston rod with V-blocks, set a dial indicator in the center between the two
V-blocks turn the piston rod, and read the difference between the maximum and minimum values on the dial
indicator.
• Even if the bend is within the allowable limit, the cylinder may not operate smoothly because of localized
bend. Beware of it during function test after installation.
Replace the rod if the cylinder makes a squeaking noise or dose not operate smoothly.

Distance between Deflectional value

V-blocks of the dial gauge Remedy
m (ft) mm (in)

1 (3.3) 1 (0.04) Replace

2 (6.6) 2 (0.08) Replace
V-BLOCK 0 1/2 0

Fig. 32-42 Measuring method

(4) Tightening torque

A B

A : CYLINDER HEAD
B : PISTON ASSY

Unit : N•m (lbf•ft)

Model Cylinder Cylinder head A Piston B
Boom 650 (480) 1860 (1370)
Arm 550 (406) 1500 (1110)
CX55B Bucket 390 (288) 830 (612)
Swing 550 (406) 1520 (1120)
Dozer 600 (443) 1520 (1120)

32-27
32. ATTACHMENTS

(5) Inspection after installation

1) Unloaded performance test
a. Put the cylinder horizontally at unloaded condition.
b. Apply pressure slowly and alternately through the ports at both ends to operate the piston rod 5 or 6
times.
c. Check that the cylinder operates normally.


   



 
   
Fig. 32-43 Unloaded test
2) Leakage test
• External leakage
a. Apply test pressure for 3 minutes each to the rod retraction side and to the rod extension side of the cyl-
inder.
b. Confirm that rod seals, cylinder head tightening part, and each weld are free from abnormalities, such
as external leakage and permanent deformation.
• Internal leakage
a. Disconnect the hose from the rod extension side of the cylinder.
b. Apply test pressure to the rod retraction side of the cylinder for 3 minutes.
c. Measure the leakage from the rod extension side.
• Leakage should be below 1 cc (0.06 cu•in) / 3 min.

PUMP

CONTROL VALVE

Internal Leakage
TANK

HYDRAULIC CYLINDER
Fig. 32-44 Leakage test
(6) Bleeding air from hydraulic cylinder
Bleed air from the cylinder after removing or installing it, or after disconnecting a hydraulic pipe.
1) Start the engine, and let it idling for about 5 minutes.
2) Repeat the step of extending and retracting the cylinder 4 or 5 times at slow speed of engine.
• Move the piston rod 100 mm (4 in) short of its stroke end.
Do not extend or retract the rod until the end to prevent the relief condition.
3) Perform the above 2) procedures at high idling speed, then move the piston rod to its stroke end at low idling
speed to reach the relief condition.

32-28
 32. ATTACHMENTS

32.2.1.7 JIG LIST

32.2.1.7.1 Installing Jig (A) for Press Fitting of Rod Bushing

C D 20 (0.787) Unit mm (in)

Applicable Cylinder
Dimension :

A+20 (0.787)
CX55B
(Rod dia : 50 (1.97)) A 54.5 (2.15)
B 49.5 (1.95)
A

B
Swing C 30 (1.18)
D 6 (0.24)

Applicable Cylinder Applicable Cylinder

Dimension : Dimension :
CX55B CX55B
(Rod dia : 45 (1.77)) A 49.5 (1.95) (Rod dia : 55 (2.17)) A 59.5 (2.34)
B 44.5 (1.75) B 54.5 (2.15)
Bucket C 30 (1.18) Boom C 25 (0.98)
D 7 (0.28) D 52 (2.17)

Applicable Cylinder Applicable Cylinder

Dimension : Dimension :
CX55B CX55B
(Rod dia : 50 (1.97)) A 54.5 (2.15) (Rod dia : 55 (2.17)) A 59.5 (2.34)
B 49.5 (1.95) B 54.5 (2.15)
C 25 (0.98) Dozer C 30 (1.18)
Arm
D 52 (2.17) D 7 (0.28)
32.2.1.7.2 Installing Jig (B) for Press Fitting of Pin Bushing

C D E
A

Unit mm (in)
Applicable Cylinder Applicable Cylinder
Dimension Dimension
CX55B CX55B
(Pin dia : 45 (1.77)) A 54.7 (2.15) (Pin dia : 55 (2.17)) A 64.7 (2.55)
Arm B 44.8 (1.76) B 54.8 (2.16)
C 40 (1.57) C 40 (1.57)
D 5 (0.20) Dozer D 5 (0.20)
Bucket
E 15 (0.59) E 15 (0.59)
F 65 (2.56) F 75 (2.95)
(Pin dia : 50 (1.97)) A 59.7 (2.35)
B 49.8 (1.96)
Boom
C 40 (1.57)
D 5 (0.20)
Swing E 15 (0.59)
F 70 (2.76)

32-29
32. ATTACHMENTS

32.2.1.7.3 Installing Jig (C) for press fitting of dust seal

30 (1.18) 70 (2.76)

(1.57)
40
A

5 (0.20)

Unit mm (in)
Applicable Cylinder
Dimension :
CX55B
(Rod dia : 45 (1.77)) A 56 (2.20)
Bucket B 46 (1.81)
(Rod dia : 50 (1.97)) A 63 (2.48)
B 53 (2.09)
Arm
Swing
(Rod dia : 55 (2.17)) A 68 (2.68)
Boom B 58 (2.28)
Dozer

32.2.1.7.4 Reforming Jig (D) for seal ring

Unit mm (in)
Applicable Cylinder
Dimension :
CX55B
16 (0.63)

R3
(Rod dia : 75 (2.95)) A 75 (2.95)
Bucket B 90 (3.54)
(Rod dia : 90 (3.54)) A 90 (3.54)
50 (1.97)

B 108 (4.25)
15 Arm
Swing
(Rod dia : 95 (3.74)) A 95 (3.74)
A Dozer B 114 (4.49)
(Rod dia : 100 (3.94)) A 100 (3.94)
B Boom B 120 (4.72)

32-30
 32. ATTACHMENTS

32.2.1.8 POSSIBLE CAUSES FOR TROUBLE AND REMEDY

Trouble Conditions Major Possible Causes Remedy

• Foreign matter is caught by U-ring or wip-
• Remove foreign matter.
er ring at its inside periphery.
• Scuffing or fault on U-ring or wiper ring at
• Replace each part with new one.
its inside periphery.
Oil leakage from sliding face
• Grind sliding face with a fine oil
of piston rod.
stone. (less than 1.6S)
(A ring shape oil is formed
• If leakage is not stopped by grind-
on piston rod and enlarged
• Scuffing on sliding face of piston rod. ing, replace seals such as U-ring,
resulting dripping down of
etc. with new ones.
oil)
• If leakage is not stopped by replac-
ing seals, replace piston rod.
• Re-plating of hard chrome on piston
• Peeling off of hard chrome plating.
rod.
Oil leakage from outer pe- • Damages on O-ring. • Replace.
riphery of cylinder head. • Damages on back-up ring. • Replace.
Oil leakage from welded
• Damages on welded portion on tube. • Replace.
portion.
• Foreign matter is caught by sliding face of
Piston movement due to
slide ring. • Remove foreign matter.
leakage.
(For the case when static
• Scuffing or faulty condition on sliding face
load that is equivalent to
of slide ring. • Replace.
product of multiplication of
max. working pressure and
• Scuffing on sliding face of seal ring as-
cylinder area, is applied to
sembly. • Replace.
rod, max. movement of pis-
ton is larger than 0.5mm
• Damages on O-ring.
(0.02 in)) per 10 minutes. • Replace.

32-31
32. ATTACHMENTS

[MEMO]

32-32