Disassembly and Assembly

375 EXCAVATOR MACHINE SYSTEMS

Media Number -SENR6027-02

Publication Date -01/06/2004

Date Updated -10/08/2009

SENR60270004

Bucket Cylinder
SMCS - 5457-010; 5457-017

Remove & Install Bucket Cylinder

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1. Start the machine, and fully extend the stick and bucket. Lower the stick and bucket to
the ground.

At operating temperature, the hydraulic oil tank is hot and under

pressure. Hot oil can cause burns. To prevent possible personal injury,
release the pressure in the implement hydraulic circuits (boom, stick and
bucket) before any hydraulic lines or components are disconnected or
removed.

2. Release the pressure in the hydraulic system as follows:

a. Fully retract the rod in the stick cylinder.
b. Adjust the position of the bucket so it will be flat on the ground when the boom is
lowered.
c. Lower the boom until the bucket is flat on the ground.
d. Shut off the engine, and put the hydraulic activation control lever in the "Lock"
position.

e. Move the control levers for the boom, bucket, stick and swing through their full travel
strokes. This will relieve any pressure that may be present in the pilot system.
f. Slowly loosen the air breather cap on the hydraulic oil tank to release the pressure.
g. Tighten the air breather cap on the hydraulic oil tank.
h. The pressure in the hydraulic system has now been released. Lines and components
can now be removed.
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Typical Example
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Typical Example

3. Fasten a hoist to the rod end of the bucket cylinder as shown. Put a wood block (3)
under the link assemblies as a support.
4. Remove the two nuts and retaining bolt (1).
5. Make sure the threaded puller hole in the pin (2) is clean prior to installation of Tooling
(A). Fasten Tooling (A) to pin (2) as shown. Fasten a lifting strap and a hoist to Tooling
(A) to support it.
6. Using Tooling (A), remove pin (2). The weight of the pin is 109 kg (240 lb).
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Typical Example

7. Raise bucket cylinder (4) until it is level; then fasten a lifting strap and a hoist to the
head end of the bucket cylinder as shown. Disconnect two hose assemblies (5) from the
bucket cylinder. Put plugs in the ends of the hose assemblies to keep dirt and debris out of
the hydraulic system. Disconnect the lubrication hose assembly from the bucket cylinder.
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Typical Example
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8. Remove pin assembly retaining bolt (6) and the washer.

9. Make sure the threaded puller hole in the pin assembly (7) is clean prior to installation
of Tooling (B). Fasten Tooling (B) to pin assembly (7) as shown. Fasten a lifting strap
and a hoist to Tooling (B) to support it. Using Tooling (B), remove pin assembly (7). The
weight of the pin assembly is 39 kg (85 lb).
10. Remove bucket cylinder (4). The weight of the bucket cylinder is 465 kg (1025 lb).
NOTE: Some machines may be equipped with shims between the stick and bucket
cylinder and the stick-to-bucket cylinder pin joint. For assembly purposes, put
identification marks on the shims as to their location.
11. Remove the shims (if so equipped) at the stick-to-bucket cylinder pin joint.
NOTE: The following steps are for the installation of the bucket cylinder.
12. Make sure the pin bores in the stick, link assemblies and bucket cylinder are clean
and free of dirt prior to installation of the bucket cylinder.
13. Fasten a hoist to bucket cylinder (4), and put it in position in the stick. Make sure the
pin bores in the stick and bucket cylinder are in alignment. Also, make sure the grease
fitting in the head end and rod end of the bucket cylinder are facing away from the stick.
14. Make sure the threaded puller hole in the end of pin assembly (7) is clean. Put a thin
coat of 5P-0960 Multipurpose Grease on pin assembly (7). Install Tool (C) in the end of
the pin assembly. Temporarily install pin assembly (7) with a hammer. Remove Tool (C)
from the pin assembly. Do not remove the hoist from the bucket cylinder at this time.
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15. Slide the bucket cylinder to one side until it makes contact with the stick. Measure the
total clearance between the bucket cylinder and stick at the pin bore. The total clearance
of (a) and (b) must not be more than 1.6 mm (.06 in). If the total clearance is less than 1.6

mm (.06 in), the addition of shims between the bucket cylinder and stick will not be
required. If the total clearance is more than 1.6 mm (.06 in), add the correct thickness of
shims to obtain the necessary clearance.
16. If it has been determined that shims need to be installed between the stick and bucket
cylinder, remove pin assembly (7). Install the shims between the stick and bucket
cylinder on the same side as the pin assembly retaining bolt. Install Tool (C) in the end of
the pin assembly. Reinstall the pin assembly using a hammer. Remove Tool (C) from the
pin assembly.
17. Install pin assembly retaining bolt (6) and the washer. Tighten pin assembly retaining
bolt (6) to a torque of 530 70 Nm (395 50 lb ft).
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Typical Example
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18. Lower the bucket cylinder between the link assemblies. Make sure the threaded puller
hole in the end of pin (2) is clean. Put a thin coat of 5P-0960 Multipurpose Grease on
pin (2). Install Tool (C) in the end of the pin. Install pin (2) with a hammer. Remove Tool
(C) from the pin. Install retaining bolt (1) and the two nut in the end of pin (2).
19. Rotate pin (2) until it is in the position shown. Tighten the nuts on retaining bolt (1) as
shown in the illustration. Tighten the outside nut until it is 0.5 mm (.02 in) above the end
of the bolt. Tighten the inside nut against the outside nut.
20. Check the condition of the O-ring seals used in the ends of hose assemblies (5). If the
seals are worn or damaged, use new parts for replacement. Connect two hose assemblies
(5) to the bucket cylinder. Connect the lubrication hose assembly to the bucket cylinder.
21. Fill the hydraulic oil tank with oil to the correct level. Lubricate the bucket cylinder
support pins. See the Operation & Maintenance Manual for the correct procedure.
22. Start the machine, and run it at low idle speed. Move the control lever for the bucket
cylinder so the cylinder rod extends to its halfway position; then retract the cylinder rod.
The cylinder should be cycled this way approximately 10 times to remove the air from
the hydraulic system. Recheck the oil level in the hydraulic oil tank.

Disassemble & Assemble Bucket Cylinder

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Start By:
a. remove bucket cylinder
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1. Put the bucket cylinder on Tooling (A). The weight of the bucket cylinder is 465 kg
(1025 lb).
2. Remove bolts (16) and the washers that hold head (7) to cylinder assembly (1).
3. Use Tooling (A) to slide rod assembly (11) out of cylinder assembly (1).
4. Remove ring (3), seal assembly (4) and ring (5) from piston (6).
5. Using Tool (B), remove nut (2) that holds piston (6) to rod assembly (11). Remove the
piston from the rod assembly.
6. Slide cylinder assembly (1) back onto the rod assembly. Install bolts (16) and the
washers that hold head (7) to the cylinder assembly. Pull the cylinder assembly and head
(7), as a unit, away from the rod assembly. Remove the head from the cylinder assembly.
7. Remove seal (8), ring (9), ring (10), seal (12), seal (13), ring (14) and wiper seal (15)
from head (7).
8. Remove the lip-type seal from both sides of the cylinder assembly and the rod
assembly at the mounting pin locations.
9. Remove the bearing from the cylinder assembly and the rod assembly at the mounting
pin locations.
NOTE: The following steps are for the assembly of the bucket cylinder. Refer to
Illustration C52043P1 for assembly of the bucket cylinder.
10. Install the bearing in the cylinder assembly and the rod assembly at the mounting pin
locations. Make sure the bearing is centered in each bore.
11. Using Tool (C), install the lip-type seals in the rod assembly and the cylinder
assembly at the mounting pin locations. Install the seals with the lip facing out.

12. Install ring (10), seal (12), seal (13) and ring (14) in head (7) as shown. Put 7M-7456
Bearing Mount in the wiper seal groove in head (7). Using Tool (C), install wiper seal
(15) in head (7) with the sealing lip facing away from the inside of the cylinder as shown.
Install ring (9) and seal (8) on head (7).
13. Put clean hydraulic oil on the lip of wiper seal (15), ring (14), seal (13), seal (12) and
ring (10).
14. Put head (7) in position on cylinder assembly (1). Install bolts (16) and the washers
that hold it. Install rod assembly (11) in head (7) and the cylinder assembly. Remove bolts
(16) and the washers. Remove cylinder assembly (1) from the rod assembly and head.
15. Install piston (6) on the rod assembly. Lubricate the threads on the end of the rod
assembly with 4C-5593 Thread Lubricant. Install nut (2), and tighten it with Tool (B) to
a torque of 12700 600 Nm (9400 445 lb ft).
16. Install ring (5), seal assembly (4) and ring (3) on piston (6). Lubricate the outside of
the piston with 1P-0808 General Purpose Lubricant.
17. Using Tool (A), install cylinder assembly (1) on the rod assembly. Install bolts (16)
and the washers that hold head (7) to the cylinder assembly. Tighten bolts (16) with the
rod assembly fully extended.
End By:
a. install bucket cylinder