BOOM/ARM/BUCKET

CYLINDER
OVERHAUL MANUAL

Applicable
Subject part No. Subject model
serial No.
329-16400001 HD2045 From first
329-16500001 HD2045 From first
329-19600001 HD2045 5125
329-19600011 HD2045 5126
329-26100001 HD2045 From first

805681E
 Introduction (C102-0001-2E)

This book is the procedure manual concerning disassembly and assembly and inspection of pneumatic and hydraulic parts
(units) and main equipment (assembly parts).
When disassembling applicable parts, observe the precautions below and work according to this manual.

1. When disassembling hydraulic equipment etc., aim for cleanliness, order and good management.
Particularly when detaching and handling heavy objects from the main body, use a suitable crane or hoist winch.
When disassembling and assembling, use the specified jigs and tools and the regulation torque control.

2. Refer to the "Service Manual" for the procedure when removing and reattaching applicable parts from the main
body of the machine.

3. Always refer to the applicable parts list when replacing parts.

4. When the reassembly of applicable parts is finished, test them as separate units before reattaching to the main body
of the machine.

5. For the test after reattachment, first carry out preoperational checks then operate unloaded.

(5151-002-0E)

Structure ........................................................................................................... 1

Explanation of functions ................................................................................... 5

Principles of the action of cylinders .................................................................. 7

Precautions on handling .................................................................................. 9

Inspection and servicing ................................................................................ 11

Diagnosis of problems ................................................................................... 12

Storage standards .......................................................................................... 17

Disassembly and assembly procedure .......................................................... 19

Test running ................................................................................................... 30

1
A C E 00C-R00-006
329-16400001
329-16500001
B 329-19600001 D 2001.10 TG F
329-19600011
329-26100001
(5681-0042-0J)

2
1. Structure (5681-0002-0E)

1-1 Boom cylinder (5681-0003-0E)

(R): 329-16400001
(L): 329-16500001

Ref. No. Name Q'ty Ref. No. Name Q'ty

1 Cylinder tube kit 1 2-2 Pin bush 1
1-1 Cylinder tube 1 2-3 Wiper ring 2
1-2 Pin bush 1 3 Cylinder head 1
1-3 Wiper ring 2 4 Bush 1
1-4 Pipe 1 5 Snap ring 1
1-5 Pipe 1 6 Buffer ring 1
1-6 O-ring 1 7 U-ring 1
1-7 Hexagon socket bolt 4 8 Backup ring 1
1-8 O-ring 1 9 Slide ring 1
1-9 Hexagon socket bolt 4 10 Wiper ring 1
1-10 Band 1 11 O-ring 1
1-11 Band 1 12 Backup ring 1
1-12 Band 2 13 Hexagon socket bolt 8
1-13 Bolt 4 14 Cushion bearing 1
1-14 Washer 4 15 Cushion seal 1
1-15 Pipe holder 2 16 Piston 1
1-16 Bolt 1 17 Seal ring 1
1-17 Spring washer 1 18 Slide ring 2
1-18 Pipe holder 1 19 Slide ring 2
1-19 Bolt 1 20 Shim 1
1-20 Spring washer 1 21 Nut 1
1-21 Grease nipple 1 22 Setscrew 1
2 Piston rod kit 1 23 Steel ball 1
2-1 Piston rod 1
-1- (777S-0204-0E)
1-2 Arm cylinder (5681-0004-0E)

(1) 329-19600001 ( Serial No. 5125)

Ref. No. Name Q'ty Ref. No. Name Q'ty

1 Cylinder tube kit 1 4 Bush 1
1-1 Cylinder tube 1 5 Snap ring 1
1-2 Pin bush 1 6 Buffer ring 1
1-3 Wiper ring 2 7 U-ring 1
1-4 Pipe 1 8 Backup ring 1
1-5 Pipe 1 9 Slide ring 1
1-6 O-ring 2 10 Wiper ring 1
1-7 Hexagon socket bolt 8 11 O-ring 1
1-8 Band 2 12 Backup ring 1
1-9 Band 2 13 Hexagon socket bolt 8
1-10 Bolt 4 14 Cushion bearing 1
1-11 Washer 4 15 Cushion seal 1
1-12 Pipe holder 2 16 Piston 1
1-13 Bolt 2 17 Seal ring 1
1-14 Spring washer 2 18 Slide ring 2
2 Piston rod kit 1 19 Slide ring 2
2-1 Piston rod 1 20 Nut 1
2-2 Pin bush 1 21 Shim 1
2-3 Wiper ring 2 22 Steel ball 1
3 Cylinder head 1 23 Setscrew 1
(777S-0202-0E)

-2-
(2) 329-19600011 (Serial No. 5126 )

Ref. No. Name Q'ty Ref. No. Name Q'ty

1 Cylinder tube kit 1 4 Bush 1
1-1 Cylinder tube 1 5 Snap ring 1
1-2 Pin bush 1 6 Buffer ring 1
1-3 Wiper ring 2 7 U-ring 1
1-4 Pipe 1 8 Backup ring 1
1-5 Pipe 1 9 Slide ring 1
1-6 O-ring 2 10 Wiper ring 1
1-7 Hexagon socket bolt 8 11 O-ring 1
1-8 Band 2 12 Backup ring 1
1-9 Band 2 13 Hexagon socket bolt 8
1-10 Bolt 4 14 Cushion bearing 1
1-11 Washer 4 16 Piston 1
1-12 Pipe holder 2 17 Seal ring 1
1-13 Bolt 2 18 Slide ring 2
1-14 Spring washer 2 19 Slide ring 2
2 Piston rod kit 1 20 Nut 1
2-1 Piston rod 1 21 Shim 1
2-2 Pin bush 1 22 Steel ball 1
2-3 Wiper ring 2 23 Setscrew 1
3 Cylinder head 1
(777S-0203-0E)

-3-
1-3 Bucket cylinder (5681-0005-0E)

329-26100001

Ref. No. Name Q'ty Ref. No. Name Q'ty

1 Cylinder tube kit 1 3 Cylinder head 1
1-1 Cylinder tube 1 4 Bush 1
1-2 Pin bush 1 5 Snap ring 1
1-3 Wiper ring 2 6 Buffer ring 1
1-4 Pipe 1 7 U-ring 1
1-5 Joint 1 8 Backup ring 1
1-6 O-ring 2 9 Slide ring 1
1-7 Hexagon socket bolt 8 10 Wiper ring 1
1-8 Band 2 11 O-ring 1
1-9 Band 2 12 Backup ring 1
1-10 Bolt 4 13 Hexagon socket bolt 8
1-11 Washer 4 14 Cushion bearing 1
1-12 Pipe holder 2 15 Piston 1
1-13 Bolt 2 16 Seal ring 1
1-14 Spring washer 2 17 Slide ring 2
2 Piston rod kit 1 18 Slide ring 2
2-1 Piston rod 1 19 Nut 1
2-2 Pin bush 1 20 Steel ball 1
2-3 Wiper ring 2 21 Setscrew 1
2-4 Grease nipple 1
(777S-0201-0E)

-4-
2. Explanation of functions (5151-007-0E)

2-1 Basic functions (5151-008-1E)

As a type of hydraulic actuator, the cylinder transmits the energy of pressurised oil, supplied from the hydraulic pump,
through the piston to convert it into strong linear force. The direction of movement can be switched between extension
and retraction by the lever movement for the control valve.
Forceful linear movement and switching action of the direction are the basic functions of the cylinder.

2-2 Functions of each part (5681-0008-0E)

(1) Cylinder head assembly

This serves as a bearing for piston rod [2] which is supported on bush [4] pressed and slide ring [9] inserted into the
inside of cylinder head [3]. Buffer ring [6], U-ring [7] and backup ring [8] inserted into the inside of the cylinder
head prevent oil leakage to the outside. Wiper ring [10] pressed into the inside of the cylinder head prevents the
entry of dust from outside. Cushion bearing [14] is inset so that pressure rises highly in its cushion chamber as the
cylinder nears full extension to cushion the shock when the cylinder reaches full stroke.
This also functions to convey high-pressure oil in both directions between the port and the cylinder tube.

1) Bush [4]
This is pressed into the inside of the cylinder head and is in contact with the piston rod. It bears lateral loads
applied to the cylinder, guides the linear movement of the high contact pressure on the piston rod and supports one
end of the piston rod to reduce eccentricity which impairs sealing performance.
2) Buffer ring [6]
This comprises the slide ring, square ring and backup ring and is located between the U-ring and the bush. The
function of the buffer ring as an auxiliary seal which is in direct contact with high-pressure oil in the cylinder is
to buffer the pressure to reduce the pressure acting on the U-ring, thus increasing the lifespan of the U-ring which
is the main seal.
3) U-ring [7]
This is located between the wiper ring and the buffer ring. It seals the annular clearance between the piston rod
and the cylinder head against pressurised oil between the U-ring and the backup ring. It also functions as an anti-
corrosion device by forming a suitable oil film over the piston rod.
4) Slide ring [9]
This is located between the wiper ring and the U-ring. With the bush, it bears lateral loads applied to the cylinder,
guides the linear movement of the high contact pressure on the piston rod and supports one end of the piston rod
to reduce eccentricity which impairs sealing performance.

-5-
 5) Wiper ring [10]
This is located in the opening where the piston rod moves in and out of the cylinder. It prevents the entry of dust
or water into the rod seal section which comprises the U-ring, buffer ring etc. in the cylinder and clears mud etc.
from the piston rod with the rod moving.
(2) Piston assembly
This comprises seal ring [17] inserted into the center of piston [16] to prevent the passage of oil between chambers
on either side of the piston, slide rings [18] inserted into either end of the seal ring to function as a bearing for
lateral loads on the cylinder and slide rings [19] inserted from outside to act as a bearing and capture contaminants.

1) Seal ring [17]

This is located at the center of the piston and uses the tension of the O-ring to seal the annular clearance between
the piston and the cylinder tube, thus forming high-pressure and low-pressure chambers separated by the piston.
2) Slide rings [18] and [19]
These are located on either side of the seal ring and are in contact with the inner surface of the cylinder tube.
They combine with the bush in the cylinder head to bear lateral loads on the cylinder, guide the linear movement
of the high contact pressure relative to the inner surface of the tube and support one end of the piston rod to reduce
eccentricity which impairs sealing performance. Slide rings [19] work to cover and trap contaminants which are
caught between the cylinder tube and the slide rings.
3) Cushion bearing [14]
This is located between the piston and the step section of the piston rod. At the cylinder head near full extension,
it forms an annular clearance which constricts the oil and reduces the thrust speed of the cylinder to cushion the
shock at stroke end.

-6-
3. Principles of the action of cylinders (5151-010-1E)

Cylinders are hydraulic devices which obey Pascal's principles and are
F1: Large force
made to act by pressurised oil supplied from outside.
F2

Action of
the pump

A1 A2

P: Pressure
0311-008E-1

The force generated by a cylinder equals the product of the pressure-bearing area A1 of the part which moves under
pressure and the pressure P which acts on it.

F2 F2
FI = A1 P P = A2 FI = A1 A2

In general the pressure-bearing areas on the extension and retraction sides differ only by the cross-sectional area of the
piston rod.

A2
P A1
Fe
Fr

Thrust: Extension side Fe = P A1 P Q P Q

Retraction side Fr = P (A1 – A2)
0311-009J-2

Q
Velocity: Extension side Ve = A1 Q is the flow volume of pressurised oil supplied
to the cylinder.
Q
Retraction side Vr = A1 – A2

When the cylinder is pushed or pulled by external forces, oil is forced out of the cylinder. If this outflow of oil is constricted
through a choke, the movement of the cylinder is regulated.

Choke
0311-010E-1

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The cylinder cushion automatically constricts the outflow of pressurised oil at stroke end to reduce the speed of the
cylinder in order to alleviate the shock at stroke end.

JIS symbol
Constriction

0311-011E-1

The pressure-bearing area differs between the extension and retraction sides, so when the outflow from the rod side is
blocked and pressure is added from the bottom end, a large pressure is generated on the rod side.
A2

A1 A1
P2 = P1 A1 – A2
P2 P1

0311-012E-1

When the cushion acts, two forces act on the cylinder; external force (inertia) and the pressure of oil from the pump.
Pressurised oil from the pump is increased in pressure as shown in the above diagram with the result that other factors
(external force, choke constriction) being equal, the cushioning effect is inferior on the extension side to the retraction
side.

If air has entered the cylinder, it will not act smoothly. Furthermore when
pressure is increased rapidly, the air generates high temperatures due to Air bubbles
adiabatic compression, potentially setting fire to the gaskets.
If air has dissolved into the oil, it will emerge to form bubbles and foam
if the oil pressure drops suddenly. Choke

Before starting work, move the cylinder gently through its full stroke 0311-013E-1

several times to expel any air inside the cylinder in order to prevent the
above problems.

-8-
4. Precautions on handling (5151-011-1E)

(1) Precautions when mounting the cylinder onto the machine

1) When mounting or dismounting the cylinder, check for safety and stability before you lift the cylinder.
Lifting the cylinder by its pipes is dangerous and can cause severe damage to the cylinder. Fully retract the rod
and use a band etc. to hold it in place to avert the danger of it shifting position unexpectedly during lifting. This
will also safeguard the rod from damage.
2) Welding while the cylinder is mounted on the machine can cause severe damage.
Welding of parts which are in place on the cylinder can cause damage requiring replacement of the entire
cylinder. In the case of electrical welding away from the cylinder itself, sparks inside the cylinder can still cause
this degree of damage.
3) Mask the cylinder when the machine is being painted.
If the cylinder moves while there is paint on the rod surface or the wiper ring, the wiper ring will not function
adequately and dirt and paint flakes will be able to enter the cylinder easily, damaging seals and drastically
reducing the lifespan of the cylinder itself.
4) Clean the cylinder thoroughly before you mount it.
(2) Precautions on use
1) Use the cylinder under the stipulated conditions.
If you use hydraulic oil of other than the designated type, the seals may deteriorate and fail rapidly as a result. In
an atmosphere of extremely high or low temperature (about 100°C or higher, –20°C or lower), ordinary seals will
fail immediately. The leading cause of cylinder breakdown is oil leakage due to damage to the rod. Use cylinders
with care to avoid damaging their rods.
2) Warm up the cylinders adequately before you start work.
When the cylinder has not been used for a long period, the seals inside the cylinder can be hardened or stuck to
the metal on the sliding surface, so avoid a sudden rapid movement or application of high pressure. The new
cylinder or one which has gone unused for a long period can contain large amounts of air which will cause the
cylinder to move jerkily. Furthermore, sudden application of pressure without air extraction can cause high
temperatures due to adiabatic compression of the air, possibly carbonizing the seals which leads to the
remarkable decrease in the function. Before you start work, always move each cylinder through its full stroke
several times without load to expel air from the inside of the cylinder.
3) Leave the machine in a safe and stable fixed position for brief stops as well as for longer storage.
Cylinders when mounted cannot remain in a fixed position for long periods. Oil can leak and changing oil
temperature causes volume variations within the cylinder. The resulting extension and retraction of the cylinders
causes unforeseen movements of the machine which can be dangerous. Always adopt a safe and stable fixed
position for the machine for brief stops and long storage.
(3) Precautions on maintenance and inspection
1) Always observe daily maintenance and inspection schedules.
Daily maintenance and inspection is the key to a long service life for cylinders. Follow the section "5. Inspection
and servicing" to ensure full performance at all times. Wipe away dirt, water, dust and grease from the rods
frequently and make a point of keeping them in a proper condition at all times. Use a dry rag to clean the wiper
rings and seals and never use water. Apply corrosion-inhibiting oil to the surface of the rod if it is to be left unused
for a week or more.

-9-
2) Always use genuine replacement parts.
If you use unauthorised spare parts, they may not perform adequately. Always use genuine replacement parts.
We also manufacture the specific jigs and tools for the fast and safe disassembly and assembly of certain parts.
3) Disassemble and assemble with care.
If you attempt to disassemble the cylinder head while it remains mounted on the machine, dangerous and
unexpected movements of the machine could result. Always dismount the cylinder from the machine before you
disassemble it. If your hands are dirty when you assemble the cylinder, dirt could get inside and damage other
hydraulic devices as well as shortening the lifespan of the cylinder itself. Always work with clean hands. Always
tighten screws and bolts to the tightening torque stated in the text or on the diagram. If tightening torque is either
too low or too high, the screw could break.
4) Observe the cylinder storage standards strictly.

- 10 -
5. Inspection and servicing (5681-0011-0E)

You should regularly inspect and service the hydraulic cylinders according to the "Independent inspection table" to keep
them at full performance for a long period. Defects should be repaired promptly according to the section "6. Diagnosis
of problems".
(5681-0012-0E)

When you are working on the inspection and servicing of the machine, your prime concern should
be to preserve your own safety through a sensible attitude and preventive precautions.

Inspection and
service point Inspection and service task Daily Monthly Annually Notes
Is the cylinder (particularly the sliding
surface of the rod) clean ?
External Is there any oil leakage from the pipe
appearance couplings or other fastenings ?
Is the paint flaking or peeling ? Is there
corrosion ?
Is the action smooth and without abnormal
noise or other phenomena ?
Is responsivity good ?
Is there any oil leakage from the sliding
Action surfaces ?
Is there any internal oil leakage ?
Is the operating pressure normal ?
Is the set pressure of the overload relief
valve normal ?
Is the hydraulic oil dirty or deteriorated ?
Hydraulic oil Has the hydraulic oil been replaced regularly ?
Have the filters been inspected regularly ?
Are the pins adequately greased ?
Is there any abnormal noise or seizure from
the pins ?
Mounting to Are the pins slack or worn ?
the body Are the pin seals functioning normally ?
Have any of the attachment bolts loosened
or fallen out ?
Tighten the mounting bolts.
Are the sliding surfaces worn ? Apply corrosion-
Are the sliding surfaces scratched or dented ? inhibiting oil to the rod
Piston rods Are the sliding surfaces losing their plating ? if its sliding surfaces
Are the sliding parts bent ? are to be exposed for a
Are any welded joints cracked or broken ? long period.
Are any nuts, bolts or screws loose ?
Cylinder tubes
Tighten all attachment nuts, bolts etc.
(including
Are any welded joints cracked or broken ?
pipes)
Is the tube seriously dented or squashed ?
(5681-0013-0E)

- 11 -
6. Diagnosis of problems (5681-0014-0E)

Hydraulic cylinder problems and countermeasures

It is not easy to locate a malfunction. The table below indicates common problems with their likely causes and suggested
countermeasures. Refer to the "Countermeasures" in the table below to repair the cylinder.
However problems in the machine may not be due simply to the malfunction of one part. In many cases the problem is
related to several components and you should be aware that repairs beyond those listed in the table may well be
necessary. At this time contact your authorised KATO dealer to investigate further to find the problem and its solution.

Section Problem
1 Oil leakage from the sliding section of the piston rod
2 Oil leakage from the joints of the cylinder head
3 Oil leakage from the welded joints of the pipe or the cylinder tube
4 Malfunction
(5681-0015-0E)

Section Problem Related parts Symptom Countermeasures

Damage or Use an oilstone to remove the surface
corrosion irregularity and leave the sliding surface
sufficient to catch smooth. (1.5S maximum)
a fingernail on the If oil leakage continues even when the rod
sliding surface surface is smooth, the U- ring and other
seals may have been damaged by the
surface irregularity. Disassemble the
cylinder and inspect the seals.
If there is extensive damage or corrosion
Piston rod which cannot be repaired with an oilstone,
the piston rod must be replaced along with
Oil leakage from the U-ring, wiper ring and other seals and
1 the sliding section bearing parts which contact the piston rod.
of the piston rod Peeling plating Replate or replace the piston rod.
At the same time inspect the seals and
bearing parts which come into contact with
the piston rod and replace them if they
have been damaged.
Foreign body Remove the foreign body.
lodged in the Replace the gasket if it is damaged.
Rod gaskets internal or external
(Buffer ring, periphery
U-ring) Damage in the Replace.
internal or external
periphery
(5681-0016-0E)

- 12 -
Section Problem Related parts Symptom Countermeasures
The lip and The gasket has probably been burned by
channel parts are heat generated by adiabatic compression
locally carbonized of residual air inside the cylinder.
(scorched). Replace the gasket, and the next time the
cylinder is used, run it at low speed and
low pressure to eliminate air.
The gasket is worn Replace.
out and lack of The gasket life span has ended or the
elasticity, or the lip hydraulic oil has probably been
is missing all contaminated or heated.
Rod gaskets
round edge. 1. Replace the hydraulic oil.
(Buffer ring,
2. Check the temperature of the hydraulic oil
U-ring)
in use. (Should be below 80°C)
3. Check for localised overheating.
An excessive Replace.
amount of the The gasket is probably being affected by
gasket heel has abnormally high pressure.
been forced out 1. Check the operation pressure and pressure
from between the when the cushion bearing acts.
gasket faces. 2. In cylinders fitted with a buffer ring, a
malfunction of the buffer ring is likely.
Oil leakage from Inspect the buffer ring.
1 the sliding section Backup ring Deformation is As a rule, the rod gaskets should be replaced
of the piston rod large. at the same time. (In cylinders fitted with a
buffer ring, it should also be replaced.)
The backup ring is probably being affected
by abnormally high pressure. Check as for
the item above "An excessive amount of
the gasket heel has been forced out from
between the gasket faces".
Wiper ring Foreign body Remove the foreign body.
lodged in the lip
Damage to the lip Replace.
or other abnormal
damage
Bearing parts Clearance between Replace.
(Bush) the bush and the Refer to the section "Service standards"
piston rod exceeds for maximum allowable clearance.
the allowable limit
due to excessive
wear.
The sliding surface Replace.
is severely Inspect the piston rod at the same time.
damaged.
(5681-0017-0E)
- 13 -
Section Problem Related parts Symptom Countermeasures
The seal fitting Use an oilstone etc. to remove damage or
Oil leakage from
surfaces are corrosion.
1 the sliding section Cylinder head
damaged or If a repair by this method is impossible,
of the piston rod
corroded. replace the cylinder head.
Foreign body is Remove the foreign body.
lodged in the Replace the O-ring if it is damaged.
internal or external Inspect the inside of the tube: If there are
periphery. any scratches or corrosion, smooth them
O-ring The O-ring is using an oilstore.
damaged. Inspect the O-ring groove of the cylinder
head: As above
Inspect the backup ring: Replace it if it is
deformed or extruded.
Check the above and replace the O-ring when
required.
Backup ring Deformation or Replace together with the O-ring.
extrusion
Oil leakage from
Looseness Disassemble the cylinder head and inspect
2 the joints of the
the O-ring and backup ring. Replace any
cylinder head
that are damaged.
Cylinder Check the threads of the tube and cylinder
head head for damage. Replace if there is any
damage.
After inspection, tighten to the regulation
torque.
Bolt Looseness, Replace all bolts and tighten the new bolts
stretching, fracture to their regulation torque.
Abnormal swelling Replace.
Oil leakage from the joints may be caused by
Cylinder tube abnormally high pressure, including cushion
pressure. Look for bulging or deformation of
the tube and check circuit pressure.
Cracks in welds Replace.
(5681-0052-0E)

Cracks will propagate, leading to

Oil leakage from Cylinder tube eventual total breakage.
the welded joints pipe Breakage is extremely dangerous, so
3
of the pipe or the (Hollow if you notice any cracks, stop work
cylinder tube piston rod) immediately and replace the
affected parts.
Welding over cracks has no effect.

(5681-0018-0E)

- 14 -
Section Problem Related parts Symptom Countermeasures
Bending greatly Replace.
Piston rod exceeds regulation The seals and sliding parts may also be
Cylinder tube bending limit. damaged and should be inspected. Replace
them if there is any abnormality.
Cylinder tube Denting Replace.
Inspect the seals and sliding parts as in the
Malfunction countermeasures above.
4-1 Action is not Abnormal wear or Replace.
smooth. damage to the Inspect the seals and sliding parts as in the
Sliding parts sliding section countermeasures above.
of the piston Foreign body Remove the foreign body.
rod and lodged in the Inspect the seals and sliding parts as in the
cylinder tube sliding section of countermeasures above.
the piston or
cylinder head
4-2 Internal oil Scratches, wear or Replace.
leakage Piston seals otherwise damage Inspect the inner surface of the cylinder
4 tube.
The piston rod The inner surface Remove scratches and corrosion with an
extends or retracts is scratched or oilstone or by honing to smooth the tube
spontaneously when Cylinder tube corroded. surface. If there are deep scratches which
it stops operation or cannot be repaired, replace the cylinder tube.
is lowered Replace the piston seals.
excessively during Insufficiently Tighten to the regulation torque.
Piston nut
operation. tightened
Speed does not Leakage from the Check the volume of leakage from the
Valves
reach the specified valves valves and service them.
value.
(5681-0043-0E)

Hydraulic oil expands and contracts with changes in temperature and pressure.
Theses volumetric changes cause the cylinders to extend and retract and these
effects can easily be mistaken for symptoms of internal oil leakage. Check for
internal oil leakage under conditions of constant temperature and pressure.

(5681-0019-0E)

- 15 -
Section Problem Related parts Symptom Countermeasures
Air Air accumulation Expel the air.
inside the cylinder For cylinders without an air bleed port,
expel air by moving the cylinder through
full stroke several times at low speed and
pressure.
For cylinders with an air bleed port,
4-3 Action is remove load from the cylinder so that its
"spongy" and internal pressure is not excessively high
imprecise. and then open the air bleeder to let air out.
Note
When the motion of the cylinder is stopped
4 suddenly, it extends and retracts a small
amount. This is due to the compressibility of
the hydraulic oil and is most pronounced in
cylinders with a long stroke length.
4-4 Excessive Clearance between Measure the dimensions of the pin and pin
shocks on the mounting bush and replace them if they exceed the
changeover Pin bush, pin section and the pin limit of use.
between extension bush has become
and retraction excessive.
4-5 Noise when the Oil supply Insufficient oiling Add oil.
cylinder is sliding Pin bush, pin Chafing where Replace the affected parts and add oil.
parts fit together

(5681-0044-0E)

Hydraulic oil expands and contracts with changes in temperature and pressure.
Theses volumetric changes cause the cylinders to extend and retract and these
effects can easily be mistaken for symptoms of internal oil leakage. Check for
internal oil leakage under conditions of constant temperature and pressure.

(5681-0020-0E)

- 16 -
7. Storage standards (5681-0021-0E)

Complete packaging and preparation measures are taken before hydraulic cylinders are shipped, but if a cylinder is to be
stored, we ask that you observe the precautions below to prevent problems during storage and to increase the lifespan of
the product.
(1) Separate storage (As a rule, store indoors)
Avoid locations which are hot or humid or exposed to corrosive fumes or liquids. Place the cylinder on some
support to keep it off the ground. To avoid condensation due to variations in temperature, the cylinder is tested with
testing oil containing a measured addition of volatile anti-corrosion compound then the piston rod is unscrewed in
super-dried air (dew point –35°C or below) and the cap is screwed on before shipping. Avoid leaving off the cap
unnecessarily or spilling residual oil from inside the cylinder.

Storage for 2 months or more Storage for 6 months or more
(3 months for the single-acting cylinder)
Wipe away dust etc. from the Reciprocate the cylinder a few
cylinder and apply corrosion- times using clean hydraulic oil
inhibiting oil to the flange, then fill it with corrosion-
piston rod and other corrosion- inhibiting oil. Follow the
prone areas. procedure "Storage for 2
months or more" in this table.
If it is not possible to work the
cylinder, just fill it with
corrosion-inhibiting oil and seal
it.
Take care not to drop or hit the cylinder when you place it in storage.
Storage for one year or more
There is the risk of gasket
deterioration, so ideally you
should disassemble the cylinder,
inspect the gaskets and replace
them. Also check for corrosion
of the inside of the cylinder.
If you use a cylinder which has
been in long-term storage
without further treatment, there
is the risk that seals may
become temporarily unsettled
causing oil leakage.
(5681-0045-0E)

(2) When mounted on the machine

1. Work the cylinders at least every 6 months.

2. Retract the piston rods as far as possible to avoid their contact with the air and apply corrosion-
inhibiting oil or grease to exposed surfaces at least once per month.
3. Handle the piston rods with extreme care to avoid damaging them.
4. If the machine is to be exposed to salt spray or other corrosive atmosphere during shipping etc., the
piston rods must be coated with corrosion-inhibiting oil and covered with polyethylene sheet or V.C.I.
paper.
5. Solvents found in corrosion-inhibiting oil can have an adverse effects on rubber seals, so select them
with care (from the following list of recommended oils) and handle so that they do not adhere to the
dust seals etc.

(5681-0022-0E)

- 17 -
(3) Recommended corrosion-inhibiting oils
For use inside Volatile Corrosion Inhibitor (V.C.I.)
cylinders a Ferroguard #1009 (U.S.C. Corp.)
b Knuckle oil #105S (Parker Kohsan)
Amount of either a or b to be added to hydraulic oil is in
the range 3 5%.
Proportion of volume
Ferroguard: 5/100
Knuckle oil: 2/100
For piston rods P-1300 (NIPPON MITSUBISHI OIL) Solvent-diluted type
For finished Select any from the following.
mechanical surfaces NP-1, 2, 3-1, and 3-2 (Solvent-diluted type anticorrosive oil
other than oiltight JIS K2246-1994)
parts NP-6 (Anticorrosive petrolatum JIS K2246-1994)
(5681-0023-0E)

- 18 -
8. Disassembly and assembly procedure (5151-015-0E)

8-1 Preparation (5151-016-1E)

Make the following preparations before you begin disassembly.

(1) Work bench preparation
The work bench should be large enough to lay out all components and steady enough to avoid dropping or moving
pieces placed on it.
(2) Preparation of tools and materials
Prepare the tools and materials listed in the section "8-5 Tools".

8-2 General working precautions (5151-017-1E)

(1) Clean the outside of the cylinder of all dirt and dust before you start to disassemble it.
(2) All parts are finished to a high degree of precision, so handle them with appropriate care and do not allow them to
hit each other or fall.
(3) If you hit or wrench parts excessively because they are stiff or difficult to remove, you will mutilate them, possibly
causing burr or breakage, failure to reassemble, oil leakage or reduced performance. Cautious and patient work is
required.
(4) If you leave the cylinder disassembled or partially disassembled, moisture and debris can cause corrosion in the
components. If it is unavoidable, take precautions against corrosion and the entry of dust.

8-3 Service standards (5181-0027-1E)

Replace sliding parts and seals according to the criteria below.

(1) Bush Replace when one quarter of the circumference is worn down to copper color for its
full length.
(2) Seal and slide ring Replace when you disassemble the cylinder.
(3) Pin bush Replace when severely chafed.

- 19 -
8-4 Inspection after assembly (5681-0028-0E)

Unladen operation Move the cylinder through full stroke at least five times unladen to check that action is
test smooth and all parts behave normally.
Inspection of Check the fully-retracted length and stroke as stated in the plan of the cylinder.
dimensions
Pressure resistance Subject the cylinder at each stroke end to the test pressure stated in the plan of the
test cylinder for three minutes or more. There should be no loosening, permanent deformation
or external oil leakage.
External oil Check the volume of oil leakage on the rod.
leakage inspection (Refer to "Oil leakage evaluating value from the rod" shown below.)
Units: ml/10min.
Inner diameter Oil leakage Inner diameter Oil leakage Inner diameter Oil leakage
mm volume mm volume mm volume
Internal oil 32 0.4 100 4.0 160 10.0
leakage inspection 40 0.6 125 5.6 180 12.6
50 1.0 140 6.0 200 15.6
63 1.6 220 20.0
80 2.3 250 22.0
(5681-0029-0E)

(1) Oil leakage evaluating value from the rod

Move the cylinder through 20 full strokes in each direction at an oil temperature 20 40°C, then examine the oil
ring on the rod to estimate the state of oil leakage at the rod. If the oil ring is uneven as in "A", a malfunction is
indicated, so refer to the section "6. Diagnosis of problems" and take the necessary action.

Oil ring

2mm 1mm

Fail Pass
5151-004E-0

- 20 -
8-5 Tools (5681-0046-0E)

(1) General tools

0311-014J-0

Location Tool name Q'ty

Screwdriver

1 1
0311-015J-0

Hexagon key spanner

2 1 set
0311-016J-0

Vise

3 1
0311-017J-0

Spanner
(for piston nuts)
4 1 set
0311-018J-0

Punch

5 1
0311-019J-0

Torque wrench

6 1 set
0311-020J-0

Hammer

7 1
0311-021J-0

Monkey wrench

8 1
0311-022J-0

Spatulas

9 1 pair
0311-023J-0

(5681-0030-0E)

- 21 -
(2) Special jigs
The following special jigs are necessary for cylinder assembly.

Jig name Appearance

Bush extraction and

insertion jig

Wiper ring insertion jig

0311-047J-0

Seal ring correction jig

Insertion jig External form

correction jig 0311-048E-0

Cylinder head insertion jig

0311-049J-0

Piston insertion jig

0311-050J-0

(5681-0031-0E)

- 22 -
8-5-1 Disassembly procedure (5681-0032-0E)
(1) Drain oil.
(2) Disconnect pipes.
(3) Clamp the cylinder in a horizontal or vertical position.
The vertical position allows easier disassembly and assembly.
Use the bottom pin hole to clamp the cylinder against both rotation
and axial movement.
(4) Use a hexagon key spanner to unscrew and remove the eight bolts
which attach the cylinder head.
If you place a pipe to extend the spanner as shown below, the task
will be easier.

(5) Pull out the piston rod.

1) Check that the piping ports are open.
2) Place a container under the port on the retraction side (cylinder head side) to catch oil.
3) When the piston rod is pulled out fully, take the cylinder head out gently.
4) Take the piston rod out with the cylinder head and rest it on wooden blocks.
(5681-0033-0E)

When clamping the cylinder in a vertical position

for disassembly and assembly, pay particular
attention to the following.
In the operation to pull out the piston rod with
Danger of falling

the cylinder head completely unscrewed, the

cylinder head is pulled out of the tube so that
there is clear space between the cylinder head
and the piston. From this position the cylinder
head can slide down suddenly, possibly injuring
anyone who is working below. To prevent this,
always move the cylinder head down until it When working with
the cylinder vertical
rests on the piston before you go on working. 0311-025E-1

- 23 -
 (0000-0000-0E)

If you take the piston rod out horizontally, it can When working with the
cylinder horizontal
fall down as soon as it is completely clear of the
tube, possibly causing damage. Place wooden
blocks underneath and hold the piston rod
horizontal as you pull it out. Wooden
block
Take care that the rod does not
fall when you pull it out.
0311-026E-2

(6) Clamp the piston rod. A

Use the flat faces or the pin hole on the rod head to prevent it from
turning.

View from A
5151-05E-0

(7) Remove the piston nut.

Drill
Remove the setscrew.
The setscrew is punch caulked in two places after being
screwed into place. Use a hand drill to cut away the punched
areas then unscrew the setscrew.
Remove the steel ball from behind the setscrew. Steel ball
Remove the piston nut, which is tightened to the torque 0311-027E-1
indicated in the assembly diagram. 1.5 times of the tightening Piston nut
torque will be required to undo it. If the large torque is
required, use a powered wrench with a hydraulic jack or
cylinder.

Hydraulic jack
Hydraulic
cylinder
0311-028E-1

(8) Remove the piston, cushion bearing and cylinder head in sequence.

Cushion bearing Piston

Cylinder head

Cushion seal

0311-029E-1

- 24 -
 (9) Remove the piston seals.
1) The slide rings can be removed easily by hand.
2) Cut the seal ring by standing a screwdriver against it, tapping
down with a hammer etc. to take the ring off as shown in the
diagram on the right.
3) Take the O-ring out with a spatula.
4) The seals cannot be reused once removed.

(10) Disassemble the buffer ring.

1) The buffer ring (a Teflon seal) is fitted into the groove inside the cylinder head. Remove it by piercing with a
pointed tool to lift it up then lever it out with a spatula.
2) The buffer ring cannot be reused once removed.

(11) Disassemble the U-ring, backup ring, slide ring and wiper ring.
1) Use a screwdriver etc. to lift out the U-ring, backup ring and slide ring.
2) The wiper ring is pressed into place. Use a screwdriver or similar tool like a chisel to extract it.
3) The seals cannot be reused once removed.

(12) Disassemble the bush.

1) Use a screwdriver to lift the snap ring then remove it from the Push with a press.
Jig
cylinder head.
2) Use a jig and press to remove the bush.
Bush

(13) Washing and storage

1) Wash all disassembled parts in kerosene then apply hydraulic oil
and cover them for storage.
2) If you leave them untreated without covering after disassembly,
corrosion and dust contamination will impair the performance of
the machine after reassembly. 0311-032E-1

- 25 -
8-5-2 Assembly procedure (5681-0035-0E)

(5681-0036-0E)

If paint or plating is peeling from any part, take care that the flakes do not enter the cylinder during
assembly.

(1) Replacement of seals

1) Replace all seals every time you disassemble the cylinder. Backup ring
2) O-ring
Clean the O-ring groove carefully then fit the O-ring with its O-ring
backup ring. Any foreign bodies in the groove will cause oil
Pressurised side
leakage. Take care to position the backup ring correctly. Coat the
O-ring and backup ring with grease or hydraulic oil so that they
Cylinder head
slide easily into place. If they do not slide easily, the O-ring will
become twisted during fitting to cause oil leakage. 0311-034E-1

(2) Cylinder head

1) Use a jig and press to push the bush into place. Hydraulic press
2) Fit the slide ring.
Cylinder head
Jig

Bush
Press support

0311-035E-1

3) Use a jig and press to push the wiper ring into place.
4) Fit the backup ring and then the U-ring into the U-ring groove.
After fitting, check that there are no wrinkles or other permanent
deformation.

- 26 -
(3) Buffer ring assembly
1) Fit the square ring into the groove. Then take the backup ring and slide ring, in that order, bend into a U-shape
with your fingertips and insert them into the groove. Install them by pushing the rings back to their original shape
into the groove. If the bending radius is too small, it will leave a kink in them after assembly, so bend a radius that
is 6mm or more. After assembly, make sure that they have not kinked.
(5681-0047-0E)

Take care to fit the seals correctly. If you fit them backwards, extremely high pressure will result
in the space between them and the U-ring which could distort the cylinder head.

2) Fit the retainer snap ring for the bush.

(4) Piston
1) Place the piston on a press table and use jigs as shown below to fit the seal ring. (Fit the O-ring in advance.)
2) Immediately after you have fitted the seal ring, use the correction jig to prevent the seal ring remaining in the
expanded state.

(5681-0048-0E)

If you don't correct the seal ring, it could catch on the tube when inserting it into the tube. If you
insert it forcedly, oil leakage could occur.

- 27 -
 3) Fit the slide rings.
(5681-0050-0E)

Take care to fit them correctly.

(5) Assemble the piston rod.

Assembly jig
1) Clamp the piston rod.
2) Fit the cylinder head onto the piston rod.
Take care to avoid catching the lips of the wiper ring and the U-
ring on the stepped parts of the piston rod.

0311-039E-1

3) Fit the cushion seal, cushion bearing and piston. Then insert the
Piston
shim and tighten the piston nut. (The slit on the cushion seal must Cushion bearing Shim
Nut
be on the piston side.) Cushion seal

4) Tighten the piston nut to the torque indicated in the assembly

diagram. Undertightening can lead to internal leakage, further
loosening of the nut and destruction of the screw threads.
The slit must be on
the piston side.

0311-040E-1

5) After tightening the piston nut, insert the steel ball and tighten
Caulk Caulk
the setscrew to the torque indicated in the assembly diagram.
Punch caulk on the periphery in two points.
Punch

Setscrew

Steel ball
0311-041E-1

- 28 -
(6) Push the piston rod into the tube.
1) Clamp the tube in a vertical or horizontal position and insert the Jig
Two halves of a nylon pipe
piston rod into the tube.
2) When you insert the rod into the tube, take care that the slide
rings do not drop out.
Slide rings
(Slide the
position of the
opening by 180°
at a time.)

0311-043E-1

(7) Fit the cylinder head.

Position the cylinder head in the position shown in the assembly
diagram and secure it by initially tightening the attachiment bolts
in sequence. After that, tighten the bolts to the regulation torque,
following the sequence pattern shown in the diagram.

Tightening torque setting sequence

(8) Connect the pipes. Tighten the bolt.

1) Check that the O-rings are fitted correctly into their grooves.
2) Tighten the bolt of the port section first.
3) Tighten to the tightening torque specified in the assembly
diagram.
4) Tighten the pipe band evenly to the torque specified in the
assembly diagram so that there are no clearances at the joints.

Note the O-ring.

0311-045E-1

Joint Joint
clearance clearance
Pipe band
0311-046E-1

- 29 -
9. Test running (5681-0037-0E)

(1) After mounting the cylinder on the body of the machine, work the switching valve to move the cylinder slowly
through full stroke at least eight times.
Fill the cylinder completely with oil.
Rapid movement of the cylinder from the start of operation will cause aeration of the hydraulic oil.
(2) If there is an air bleed plug, pressurise the cylinder so that the plug is on the low pressure side (return oil side) and
bleed air off.
(3) Grease the pins on both ends.

Limits of use

Limit of wear on the outer diameter of the piston rod

Nominal diameter (mm) Minimum outer diameter Action
50 80 –0.023 Replace or replate
85 120 –0.027 Replace or replate

(5681-0038-0E)

Limit of wear on the inner diameter of the rod bush

Nominal diameter (mm) Standard inner diameter (mm) Maximum inner diameter (mm) Action
55 75 0.06 0.19 0.30 Replace the bush
80 120 0.06 0.195 0.30 Replace the bush

(5681-0039-0E)

Limit of wear on the thickness of the piston slide ring

Nominal diameter (mm) Standard thickness (mm) Limit of wear (mm) Action
95 160 2.42 2.48 2.37 Replace the slide ring
165 250 2.92 2.98 2.87 Replace the slide ring

(5681-0040-0E)

- 30 -