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
pressure in the hydraulic piping. 13031GE18

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.
① Set block between bucket cylinder and Arm
arm.
Wooden block
29078CY001

② Remove bolt(2), nut(3) and pull out pin

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

29078CY002

③ Disconnect bucket cylinder hoses(4) and

put plugs(5) on cylinder pipe. 5

29078CY003

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 ④ Sling bucket cylinder assembly(8) and
8
remove bolt(6) then pull out pin (5).
⑤ Remove bucket cylinder assembly(8).
·Weight : 300kg(660lb, R450LC-7A )
381kg(840lb, R500LC-7A )
5

6 29078CY004

(2) Install
① 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 disco-
nnecting them, to prevent dirt or dust
from entering.
① Set block between arm cylinder and
boom. Block

29078CY01

② Remove bolt(2) and pull out pin(1).

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

29078CY02

③ Disconnect arm cylinder hoses(4) and 5

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

29078CY03

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 ⑤ Sling arm assembly(8) and remove bolt
(7) then pull out pin(6).
⑥ Remove arm cylinder assembly(8). 8
·Weight : 540kg(1190lb, R450LC-7A )
630kg(1390lb, R500LC-7A )

6
7

29078CY04

(2) Install
① 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.

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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
disconnecting them, to prevent dirt or dust 1
from entering.
① Disconnect greasing hoses(1).
② Sling boom cylinder assembly.

29078CY05

③ Remove bolt(4), pin stopper(5) and pull 4

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

4
5

50078CY11

④ Lower the boom cylinder assembly(6) on

a stand.

29078CY07

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 ⑤ Disconnect boom cylinder hoses(7) and
put plugs on cylinder pipe.

29078CY08

⑥ Remove bolt(9) and pull out pin(8).

⑦ Remove boom cylinder assembly(6).
·Weight : 335kg(740lb, R450LC-7A )
6
415kg(915lb, R500LC-7A )

8
9
29078CY09

(2) Install
① 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(R450LC-7A)

9,10 6,7 8 4 22 5 29 28 3 11,12 1 2 13 14 15,16 17 18 19 20 21

Internal detail

30 23,24 26 25 27 29 23,24 30

470078BK01

1 Tube assembly 11 O-ring 21 Lock nut

2 Rod assembly 12 Back up ring 22 Hexagon socket head bolt
3 Gland 13 Cushion ring 23 Pin bushing
4 DD2 bushing 14 Piston 24 Dust seal
5 Snap ring 15 O-ring 25 Band assembly
6 Rod seal 16 Back up ring 26 Pipe assembly
7 Back up ring 17 Piston seal 27 Pipe assembly
8 Buffer ring 18 Wear ring 28 O-ring
9 Dust wiper 19 Dust ring 29 Hexagon socket head bolt
10 Snap ring 20 Lock washer 30 Grease nipple

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 (2) Bucket cylinder(R500LC-7A)

9,10 6,7 8 4 22 5 30 29 3 11,12 1 2 13 14 19 18 17 15,16 20 21

Internal detail

25 23,24 27 26 28 30 23,24 25
50078BK02

1 Tube assembly 11 O-ring 21 Hexagon socket set screw

2 Rod assembly 12 Back up ring 22 Hexagon socket head bolt
3 Gland 13 Cushion ring 23 Pin bushing
4 DD2 bushing 14 Piston 24 Dust seal
5 Snap ring 15 O-ring 25 Grease nipple
6 Rod seal 16 Back up ring 26 Band assembly
7 Back up ring 17 Piston seal 27 Pipe assembly
8 Buffer ring 18 Wear ring 28 Pipe assembly
9 Dust wiper 19 Dust ring 29 O-ring
10 Snap ring 20 Lock nut 30 Hexagon socket head bolt

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(3) Arm cylinder(R450LC-7A)

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

Internal detail

24,25 28 26 27 29 31 30 24,25

470078AM01

1 Tube assembly 12 O-ring 22 Lock nut

2 Rod assembly 13 Back up ring 23 Hexagon socket head bolt
3 Gland 14 Cushion ring 24 Pin bushing
4 DD2 bushing 15 Piston 25 Dust seal
5 Snap ring 16 O-ring 26 Band assembly
6 Rod seal 17 Back up ring 27 Band assembly
7 Back up ring 18 Piston seal 28 Pipe assembly
8 Buffer ring 19 Wear ring 29 Pipe assembly
9 Dust wiper 20 Dust ring 30 O-ring
10 Snap ring 21 Lock washer 31 Hexagon socket head bolt
11 Wear ring

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(4) Arm cylinder(R500LC-7A)

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

Internal detail

25,26,27,28

23,24 31 29 30 32 34 33 23,24

50078AM12

1 Tube assembly 12 Back up ring 23 Pin bushing

2 Rod assembly 13 Cushion ring 24 Dust seal
3 Gland 14 Piston 25 Check valve
4 DD2 bushing 15 O-ring 26 Coil spring
5 Snap ring 16 Back up ring 27 O-ring
6 Rod seal 17 Piston seal 28 Plug
7 Back up ring 18 Wear ring 29 Band assembly
8 Buffer ring 19 Dust ring 30 Band assembly
9 Dust wiper 20 Lock nut 31 Pipe assembly
10 Snap ring 21 Hexagon socket set screw 32 Pipe assembly
11 O-ring 22 Hexagon socket head bolt 33 O-ring
34 Hexagon socket head bolt

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(5) Boom cylinder(R450LC-7A)

9,10 11 6,7 8 4,5 23 28 27 3 12,13 1 2 14 15 16,17 18 19 20 21 22

Internal detail

29,31 25 24 26 28 33 30,32

470078BO01

1 Tube assembly 13 Back up ring 24 Band assembly

2 Rod assembly 14 Cushion ring 25 Pipe assembly
3 Gland 15 Piston 26 Pipe assembly
4 DD2 bushing 16 O-ring 27 O-ring
5 Snap ring 17 Back up ring 28 Hexagon socket head bolt
6 Rod seal 18 Piston seal 29 Pin bushing
7 Back up ring 19 Wear ring 30 Pin bushing
8 Buffer ring 20 Dust ring 31 Dust seal
9 Dust wiper 21 Lock washer 32 Dust seal
10 Snap ring 22 Lock nut 33 Grease nipple
11 Wear ring 23 Hexagon socket head bolt
12 O-ring

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(6) Boom cylinder(R500LC-7A)

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

Internal detail

23,25 28 27 29 31 26 24,25

50078BO01

1 Tube assembly 11 O-ring 21 Hexagon socket set screw

2 Rod assembly 12 Back up ring 22 Hexagon socket head bolt
3 Gland 13 Cushion ring 23 Pin bushing
4 DD2 bushing 14 Piston 24 Pin bushing
5 Snap ring 15 O-ring 25 Dust seal
6 Rod seal 16 Back up ring 26 Grease nipple
7 Back up ring 17 Piston seal 27 Band assembly
8 Buffer ring 18 Wear ring 28 Pipe assembly
9 Dust wiper 19 Dust ring 29 Pipe assembly
10 Snap ring 20 Lock nut 30 O-ring
31 Hexagon socket head bolt

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2) TOOLS AND TIGHTENING TORQUE
(1) Tools

10
B
14
Allen wrench 18
24
30
(-) Driver Small and large sizes
Torque wrench Capable of tightening with the specified torques

(2) Tightening torque(R450LC-7A)

Torque
Part name Item Size
kgf·m lbf·ft
Bucket cylinder 14 - 150±15 1085±108
Piston Boom cylinder 15 - 150±15 1085±108
Arm cylinder 15 - 150±15 1085±108
Bucket cylinder 21 - 100±10 723±72
Piston lock nut Boom cylinder 22 - 100±10 723±72
Arm cylinder 22 - 100±10 723±72
22 M20 46±5.0 332±36
Bucket cylinder
29 M12 9.4±1.0 67.9±7.2
23 M27 116±12 839±86.7
Socket head bolt Boom cylinder
31 M12 9.4±1.0 67.9±7.2
23 M30 157±16 1135±116
Arm cylinder
31 M12 9.4±1.0 67.9±7.2

(3) Tightening torque(R500LC-7A)

Torque
Part name Item Size
kgf·m lbf·ft
Bucket cylinder 14 - 100±10 723±72
Piston Boom cylinder 14 - 100±10 723±72
Arm cylinder 14 - 100±10 723±72
22 M22 63.0±6.0 456±43
Bucket cylinder
30 M12 9.4±1.0 68.0±7.2
22 M22 63.0±6.0 456±43
Socket head bolt Boom cylinder
31 M12 9.4±1.0 68.0±7.2
22 M24 79.0±8.0 571±58
Arm cylinder
34 M12 9.4±1.0 68.0±7.2
Bucket cylinder 20 - 200±10 1447±145
Piston lock nut Boom cylinder 20 - 200±10 1447±145
Arm cylinder 20 - 200±10 1447±145

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3) DISASSEMBLY
(1) Remove cylinder head and piston rod
※ Procedures are based on the bucket
cylinder.
① 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.

② 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 draining operation.

m
0m
20

36078CY21A

③ Loosen and remove socket bolts(22) of

the gland in sequence.
※ Cover the extracted rod assembly(2) with
rag to prevent it from being accidentally
damaged during operation.

4507A8CY01

④ 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
out. However, when rod assembly(2) sideways
has been drawn out to approximately
two thirds of its length, lift it in its center to
draw it completely. Oil pan
36078CY21C

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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.

⑤ Place the removed rod assembly on a

wooden V-block that is set level.
※ Cover a V-block with soft rag. Rod assembly

Wooden block

36078CY22A

(2) Remove piston and cylinder head

(R450LC-7A) 13 15 16 14 20 21
① Remove lock nut(21).
※ Since lock nut(21) and lock washer(20)
is tightened to a high torque, use a
hydraulic and power wrench that utilizers
a hydraulic cylinder, to remove the lock
nut(21) and lock washer(20).
② Remove piston assembly(14), back up
470078CY01
ring(16), and O-ring(15).

(3) Remove piston and cylinder head

13 14 15 16 20 21
(R500LC-7A)
① Remove screw(21) and lock nut(20).
※ Since lock nut(20) is tightened to a high
torque use a hydraulic and power
wrench that utilizers a hydraulic cylinder,
to remove the lock nut(20).
② Remove piston assembly(14), back up
ring(16), and O-ring(15).

50078CY02

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③ Remove the cylinder head assembly
from rod assembly(2). Plastic
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 it straight with cylinder head Pull straight
assembly lifted with a crane.
Exercise care so as not to damage the lip
of rod bushing(4) and packing (6, 7, 8, 9,
36078CY22C
10) by the threads of rod assembly(2).

(3) Disassemble the piston assembly

19 18 17 18 19
① Remove wear ring(18).
② Remove dust ring(19) and piston seal
(17).
※ Exercise care in this operation not to
damage the grooves.

50078CY03

(4) Disassemble cylinder head assembly

① Remove back up ring(12) and O-ring
(11).
② Remove snap ring(10), dust wiper(9).
③ 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
50078CY04
damaged.

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

21078DA37

② Coat dust wiper(9) with grease and fit

Press here
dust wiper(9) to the bottom of the hole of (Straight down)
dust seal.
At this time, press a pad metal to the 9 Metal
metal ring of dust seal.
③ Fit snap ring(10) to the stop face.

36078CY24A

④ 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.

45078CY11

※ Rod seal(6) has its own fitting direction.

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.

45078CY24

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⑤ Fit back up ring(12) to gland(3).
※ Put the backup ring in the warm water of 12
30~50。 C.
11
⑥ Fit O-ring(11) to gland(3).

50078CY05

(2) Assemble piston assembly

※ Check for scratches or rough surfaces.
If found smooth with an oil stone.
① Coat the outer face of piston(14) with
hydraulic oil.

45078CY12

② Fit piston seal(17) to piston.

※ Put the piston seal in the warm water of 17
60~100。 C for more than 5 minutes.
※ After assembling the piston seal, press
its outer diameter to fit in.

50078CY06

③ Fit wear ring(18) and piston ring(19) to

19 18 17 18 19
piston(14).
14

50078CY07

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(3) Install piston and cylinder head
① Fix the rod assembly to the work bench.
Gland assembly
② Apply hydraulic oil to the outer surface of
rod assembly(2), the inner surface of Rod assembly
piston and cylinder head.
③ Insert cylinder head assembly to rod
assembly.

36078CY26A

④ Insert cushion ring(13) to rod assembly.

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

Insert

50078CY08

⑤ Fit piston assembly to rod assembly.

(R450LC-7A) Piston assembly
·Tightening torque : 150±15.0kgf·m
(1085±108lbf·ft)

36078CY26C

⑥ Fit piston assembly to rod assembly.

Piston assembly
(R500LC-7A)
·Tightening torque : 100±10kgf·m
(723±72.3lbf·ft)

50078CY09

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⑦ Fit lock washer(20) and lock nut(21) to
piston(R450LC-7A) 21
·Tightening torque :

Item kgf·m lbf·ft

Bucket 21 100±10 723±72.3

Boom 22 100±10 723±72.3
Arm 22 100±10 723±72.3

4507A8CY26

⑧ Fit lock nut(20) and tighten the screw 20 21

(21). (R500LC-7A)
·Tightening torque :

Item kgf·m lbf·ft

20 200±20 1447±147
Bucket
21 5.4±0.5 39.1±3.6
20 200±20 1447±147
Boom
21 5.4±0.5 39.1±3.6 50078CY10

20 200±20 1447±147
Arm
21 5.4±0.5 39.1±3.6

(3) Overall assemble Fix with a bar

① Place a V-block on a rigid work bench.
Mount the tube assembly(1) on it and fix
the assembly by passing a bar through Lift
the clevis pin hole to lock the assembly.
② Insert the rod assembly in to the tube Straight
assembly, while lifting and moving the
rod assembly with a crane.
※ Be careful not to damage piston seal by Appply liquid packing
36078CY27A
thread of tube assembly.
③ Match the bolt holes in the cylinder head
flange to the tapped holes in the tube
assembly and tighten socket bolts to a Apply loctite
specified torque. Turn clockwise
※ Refer to the table of tightening torque.

Place rag

36078CY27B

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