Operation and maintenance manual

Body System - Body Cylinder
Section 230-0130
2
SM 1409 Rev 1 9-05
(1) and piston rod (2) end. Press out spherical
bearings (21).
3. Remove lock ring (10) from end cap (3).
4. Using special tool which can be fabricated as shown
in Fig. 2, unscrew end cap (3) until thread is
disengaged from cylinder body (1).
Note: Approximate weight of piston rod (2) is 318 kg
(700 lb), therefore, correct slinging is important along
the length of the rod to prevent subsequent damage.
5. Support piston rod (2) at the rod eye and withdraw
piston rod (2) from cylinder body (1). Ensure centre
lines of piston rod (2) and cylinder body (1) remain
coincidental during removal of piston rod (2).
6. Place piston rod (2) on supports which will not
damage the piston rod diameter.
7. Remove and discard piston seals (13) and bearing
rings (14) from piston (12).
8. Remove grub screws (15 & 16) from bearing ring
(14) groove in piston (12).
9. Provide an anti-torsion device through piston rod (2)
eye to allow unscrewing of piston (12). Using special
tool which can be fabricated as shown in Fig. 3,
unscrew piston (12) from piston rod (2).
10. Remove cushion spear (11) and 'O' rings (17) from
piston rod (2). Discard 'O' rings (17).
11. Remove cylinder end cap (3) from piston rod (2).
Remove and discard cushion sleeve (4), circlip (5),
rod seal (6), nylon ring (29), wiper (7), backup ring (18)
and 'O' rings (8 & 9).
INSPECTION
Numbers in parentheses refer to Fig. 1.
1. Clean all parts of the cylinder with a suitable solvent
and dry with clean, lint-free cloths. Clean all grooves
carefully to remove any foreign material.
2. Check cylinder body (1) and outer diameter of
piston (12) for scratches, cracks or other defects.
Remove ridges, nicks and scratches with a fine stone
and re-clean. Replace any components which cannot
be repaired.
3. Inspect piston rod (2) for distortion, cracks or other
defects. Replace piston rod (2) if defective area is
irreparable.
switch off the engine. Turn steering wheel in both
directions several times to relieve any pressure in the
steering circuit.
2. Block all road wheels and place battery master
switch in the 'Off' position.
3. Position a suitable oil container at line ends of the
cylinder. Ensure hydraulic lines connected to the body
cylinder assembly are identified for ease of installation
and disconnect hydraulic lines. Fit blanking caps to all
open lines and fittings to prevent entry of dirt.
4. Install a suitable strap around one body cylinder
assembly and attach to a suitable lifting device.
Remove bolt (28), washer (27) and upper pin (25)
connecting piston rod (2) eye end to the body. If due to
lack of maintenance the upper pin can not be removed
from the front, there is plate on the inside of the body
that can be removed to allow access to the rear of the
pin to ease removal. This plate is tack welded in place
so a grinder is required to remove it.
WARNING
Exercise extreme caution when lowering the
cylinder from the body, as the cylinder will
swing out sharply as it leaves its mounting.
5. Lower cylinder slowly and remove spacers (26).
6. Remove bolt (28), washer (27) and lower pin (24)
connecting base end of body cylinder to the frame.
7. Remove spacers (26) and remove cylinder to a
clean area for disassembly.
8. Repeat steps 2 through 7 for opposite cylinder.
DISASSEMBLY
Numbers in parentheses refer to Fig. 1.
WARNING
To prevent personal injury and property
damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job
safely.
1. Ensure clean working conditions, remove any port
plugs thus allowing easy entry of air into cylinder body
(1), preventing a vacuum when parts are withdrawn
from cylinder body (1).
2. Remove circlips (22) from base end of cylinder body