Operation and maintenance manual

Section 230-0130
SM 1409 Rev 1 9-05
3
4. Check spherical bearing (21) for wear and replace if
necessary.
ASSEMBLY
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. Press spherical bearing (21) in base end of cylinder
body (1) and piston rod (2) end. Secure spherical
bearings (21) with circlips (22).
Note: Install circlip (22) to base end of cylinder
ensuring that it is facing down when the cylinder is
mounted to the unit.
2. Install new cushion ring (4), circlip (5), rod seal (6),
nylon ring (29), 'O' rings (8 & 9) and backup ring (18)
in end cap (3).
3. Apply Loctite 242 to the first two threads on end cap
(3). Load end cap (3) over piston rod (2) thread taking
care not to damage rod seal (6) on the thread.
4. Install new 'O' rings (17) on piston rod (2) and
replace cushion spear (11).
5. Using special tool which can be fabricated as shown
in Fig. 3, screw on piston (12) and tighten to a torque
of 1 356 Nm (1 000 lbf ft).
6. Insert piston grub screw (16) through bearing ring
(14) groove in piston (12) and into groove machined in
piston rod (2). Tighten grub screw (16) to a torque of
49 Nm (36 lbf ft).
7. Lock grub screw (16) in place with grub screw (15)
and tighten grub screw (15) to a torque of 49 Nm
(36 lbf ft). Ensure the extreme of grub screw (15) is
below the level of bearing ring (14) groove.
8. Ensure cushion ring (19) and circlip (20) are secure
in piston (12).
9. Insert new piston seal (13) and new bearing rings
(14) in piston (12).
10. Fully grease piston (12) OD and 'O' rings (8 & 9) in
end cap (3).
Body System - Body Cylinder
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.
11. Sling assembled piston rod (2) in a manner to allow
careful leading of the assembled piston rod into
cylinder body (1). Take care not to damage piston seal
(13) on cylinder body threads.
12. After piston (12) is inserted in cylinder body (1),
push the piston rod assembly into cylinder body (1)
maintaining coincidental centre lines of piston rod and
cylinder body.
13. Before piston rod (2) is fully home and, with slings
still taking some of piston rod (2) weight, engage end
cap (3) thread and screw home.
14. Push piston rod (2) to the fully retracted position
and torque tighten end cap (3) to 237 Nm (175 lbf ft).
15. Re-drill end cap (3) for lock ring (10) (3 x 12 mm
(0.125 x 0.50 in) deep) if necessary. Insert lock ring
(10) in end cap (3).
INSTALLATION
Numbers in parentheses refer to Fig. 1.
Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 230-0000, BODY
SYSTEM SCHEMATIC. Renew all 'O' rings where
used.
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. Install a suitable strap around the cylinder and
position cylinder on unit with base end of cylinder
(circlip (22) facing down) ready for mounting.
2. Install spacers (26) in base end of cylinder, align
spherical bearing (21) with bores in frame mounting
and install lower pin (24) through mounting bores,
spacers (26) and spherical bearing (21). Secure lower
pin (24) to the frame with washer (27) and bolt (28).
Tighten bolt (28) to a torque of 66 Nm (49 lbf ft).
3. Install spacers (26) in piston rod (2) eye end of
cylinder, align spherical bearing (21) with bores in
body and install upper pin (25) through mounting
bores, spacers (26) and spherical bearing (21). Secure