HYDRAULIC SYSTEM TMS700E SERVICE MANUAL
2-78 Published 01-29-2015, Control # 512-01
9. Place the rod on a clean table.
10. Install the head followed by the spacer, then the piston
onto the rod. Note proper orientation of each
component.
11. Torque the piston 406 to 474.5 Nm (300 to 350 lb-ft).
12. Install the piston setscrews.
13. Apply anti-seize lubricant to the head outer threads.
14. Brush piston seals and head seals with hydraulic oil and
install rod assembly into barrel. Alignment is critical.
Make sure the seals are not damaged during rod
installation. If necessary use a sleeve to cover the seals.
15. Slide the head into the barrel and engage the threads.
Turn the head counter clockwise until the first thread just
passes the engagement point, then turn the head
clockwise until it is hand-tight or fully seated. When the
head becomes tight, use a mallet or dead blow hammer
to knock the spanner wrench an extra 1/8 of a turn.
16. Brush the check valve with hydraulic oil and thread into
cavity. Torque to 135.5 to 149.1 Nm (100 to 110 lb-ft).
17. Install the plugs.
Test
1. Set test stand pressure to 241.32 bar (3500 psi).
2. Attach hose fittings to cylinder.
3. Connect a ball valve to the “test extend” port (marked
“PC” on rod mount) so that the pressure can be released
after testing and is not trapped in the valve. Test cylinder
through working ports with ball valve closed.
4. The cylinder shall be stroked its full length in both
directions to fill it with oil and remove trapped air.
5. Pressurize to recommended test pressure at each end,
beginning with the rod end for a minimum of 10 seconds
per end. While under pressure, cylinder shall be
checked for leaks at weld, SAE fittings, valve, and all
external static and dynamic seals (refer to Outrigger
Jack Cylinder, page 8-71 for outrigger jack cylinder
Internal Leak Testing). Cycle cylinder completely (retract
and extend) three times under pressure.
6. When testing is complete, relieve pressure on working
ports. Slowly open ball valve on PC port to relieve
trapped oil pressure. Plug the extend port (marked
“EXT”) and retract the cylinder with air using a regulator
at the RET port and a return line connected to the PC
port. Reclaim all oil. Carefully bleed off air pressure once
cylinder is fully retracted.
7. Seal ports with port plugs to prevent contamination from
entering cylinder.
COUNTERWEIGHT REMOVAL CYLINDER
Description
The counterweight cylinder (Figure 2-61) has a 8.9 cm (3.5
in) diameter bore. The retracted length of the cylinder from
the end of the barrel to the center of the rod lug is 99.5 ±0.22
cm (39.19 ± 0.09 in). The extended length of the cylinder
from the end of the barrel to the center of the rod lug is
170.66 ±0.22 cm (67.19 ± 0.09 in). Its stroke is 71.12 cm
(28.0 in). A wiper ring prevents foreign material from entering
the cylinder. O-rings and other seals prevent internal and
external leakage.
The cylinder weighs approximately 42 kg (92 lb).
Maintenance
Disassembly
NOTE: Any maintenance requiring disassembly of the
cylinder should include replacement of all seals
and rings. A seal kit will supply the required items.
1. Remove the holding valve from the port block.
2. Remove the bolts, washers, and nuts securing the rod
end lug to the cylinder rod and remove the lug.
3. Clean away all dirt from the head. Place protective
padding around the rod near the head to prevent
damaging the chrome during head removal. Using a
spanner wrench, unscrew the head from the barrel.
4. Remove the rod and attached parts from the barrel.
NOTE: Cover the barrel opening to avoid contamination.
NOTE: Arranging discarded seals and rings in the order of
disassembly will aid in installation of new seals and
DANGER
Do not use air pressure to remove the cylinder rod. Use
only a source of controlled hydraulic oil pressure if the rod
is hard to move.
CAUTION
Exercise extreme care when handling or setting down the
rod. Damage to the rod surface may cause unnecessary
maintenance and expense.
CAUTION
When removing seals and rings, avoid scratching the
grooved and gland surfaces.
Reference Only
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