Hydraulic Section
8-52
31211015 6036, 6042, 8042, 10042, 10054
10. Remove the piston head from the rod and carefully slide
the head gland off the end of the rod.
11. Remove all seals, back-up rings and o-rings from piston
head and all seals, back-up rings and o-rings from the
head gland.
Note: The head gland bearing will need to be inspected to
determine if replacement is necessary.
DO NOT attempt to salvage cylinder seals, sealing rings or
o-rings. ALWAYS use a new, complete seal kit when
rebuilding hydraulic components. Consult the parts catalog
for ordering information.
c. Cylinder Cleaning Instructions
1. Discard all seals, back-up rings and o-rings. Replace with
new items from seal kit to ensure proper cylinder
function.
2. Clean all metal parts with an approved cleaning solvent
such as trichlorethylene. Carefully clean cavities,
grooves, threads, etc.
Note: If a white powdery residue is present on threads or parts,
it can be removed by using a soft brass wire brush. Wipe clean
with Loctite Cleaner prior to reassembly.
d. Cylinder Inspection
1. Inspect internal surfaces and all parts for wear, damage,
etc. If the inner surface of the cylinder barrel does not
display a smooth finish, or is scored or damaged in any
way, replace the barrel.
2. Remove light scratches on the piston, head gland, rod
with a 400 - 600 grit emery cloth. Use the emery cloth in
a rotary motion to polish out and blend the scratch(es)
into the surrounding surface.
3. Proper honing is required to smooth the inner surface
of the cylinder barrel.
4. Check the piston rod assembly for run-out. If the rod is
bent, it must be replaced.
5. Inspect rod eye bushing and replace if worn or
damaged.
e. Cylinder Assembly Instructions
1. Use the proper tools for specific installation tasks. Clean
tools are required for installation.
2. Install new seals, back-up rings and o-rings on the
piston and new seals, back-up rings, o-rings and
bearing on the head gland.
Note: The extend/retract cylinder has a spacer that MUST be
installed over the rod
AFTER the head gland and BEFORE the
piston head.
3. Fasten the rod eye in a soft-jawed vise, and place a
padded support under and near the threaded end of
the rod to prevent any damage to the rod.
Note: Protect the finish on the cylinder rod at all times.
Damage to the surface of the rod can cause seal failure.
4. Lubricate and slide the head gland over the cylinder
rod. Install the piston head on to the end of the cylinder
rod. Loctite
®
243
TM
and install the set screw in the piston
head. Refer to Section 8.9.4, “Cylinder Torque
Specifications”, for torque specifications for the piston
head and the set screw.
Note: Avoid using excess force when clamping the cylinder
barrel in a vise. Apply only enough force to hold the cylinder
barrel securely. Excessive force can damage the cylinder barrel.
5. Place the cylinder barrel in a soft-jawed vise or other
acceptable holding devise.
Note: When sliding the rod and piston assembly into the
cylinder barrel, prevent the threaded end of the cylinder barrel
from damaging the piston head. Keep the cylinder rod centered
within the barrel to prevent binding.
6. Carefully insert the cylinder rod assembly into the
cylinder barrel.
7. Screw the head gland into the cylinder barrel and
tighten with a spanner wrench. Refer to Section 8.9.4,
“Cylinder Torque Specifications”, for torque
specifications for the head gland.
8. If applicable, install new counter balance valve into
block on the cylinder barrel.
f. Cylinder Installation
1. Grease the bushings at the ends of the hydraulic
cylinder. Using an appropriate sling, lift the cylinder into
it’s mounting position.
2. Align cylinder bushing and install pin, lock bolt or
retaining clip.
3. Connect the hydraulic hoses in relation to the labels or
markings made during removal.
4. Before starting the machine, check fluid level of the
hydraulic fluid reservoir and if necessary fill to full mark.
5. Start the machine and run at low idle for about one
minute. Slowly activate hydraulic cylinder function in
both directions allowing the cylinder to fill with
hydraulic oil.
6. Inspect for leaks and check level of hydraulic fluid in
reservoir. Add hydraulic fluid if needed. Shut the engine
OFF.
7. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
8. Close and secure the engine cover.
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