BOOM ZR 30

C 44150--3 en 0507/LH 1 (15)

BOOM ZR 30

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. BOOM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. HYDRAULIC FLOWCHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. ADJUSTING BOOM CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.1. Adjusting clearance between inner and outer tube
and replacing slide pieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6. ADJUSTING ROTATION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7. FLUSHING AND BLEEDING BOOM HYDRAULIC CIRCUIT . . . . . . . . . . . . . . 8
7.1. Flushing boom swing circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.2. Flushing zoom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.3. Flushing boom tilt cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.4. Flushing DM rotation mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.5. Flushing DM transfer cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8. BOOM GREASING POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
9. MAINTENANCE OF ROTATION MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10. CHECKING AND REPLACING BEARING BUSHINGS . . . . . . . . . . . . . . . . . . . 12
10.1. Checking bearing bushings and pins . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
10.2. Replacing bearing bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
10.3. Checking cylinder pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
12. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2 (15) C 44150--3 en 0507/LH

 BOOM ZR 30

1. GENERAL
These instructions contain information on maintenance and repair work on the ZR 30
booms. By observing these instructions you can lengthen the operating life and increase
the reliability of the boom.

2. SAFETY
Before starting any maintenance work, make sure that the rig cannot be started, not even
by accident!
Do not attempt any maintenance work unless you have received
maintenance training. Read the maintenance instructions before
starting any maintenance work.
WARNING

Do not disconnect any hydraulic hoses or valves unless you are quite
sure that there is no static load in the system. Remove all static loads
before maintenance work by resting the boom against a suitable support
WARNING or by running it to the extreme position where the static load is carried by
the mechanical parts.

When cylinders have been removed, the hydraulic circuit must be blend
and flushed according to chapter “Flushing and bleeding boom
hydraulic circuit“. This prevents disturbances of operation caused by
WARNING impurities or air trapped in the cylinders.

Do not go under the booms unnecessarily.

WARNING

Make sure that no functions can be started during maintenance work,

not even by accident.

WARNING

When lifting parts during maintenance work, always use a sufficiently

powerful crane and good lifting equipment.

WARNING

C 44150--3 en 0507/LH 3 (15)

BOOM ZR 30

3. BOOM COMPONENTS

3000

3
6
4

7
5

Front frame type A_ B_

Type F 53 22
Type C 30 45

1. Rotation mechanism, 2 units . . . . . . . . rotation 360_

2. Cradle , 1unit
3. Zoom cylinder, 1unit . . . . . . . . . . . . . . . φ 100/50 stroke 620 mm
4. Tilt cylinder, 2 units . . . . . . . . . . . . . . . . φ 140/70
5. Swing cylinder, 2 units . . . . . . . . . . . . . φ 140/70
6. Feed extension cylinder, 1 units . . . . . φ 100/50 stroke 1500 mm
7. Rear stinger cylinder, 2 units . . . . . . . . φ 80/50 stroke 1500/1700 mm

4 (15) C 44150--3 en 0507/LH

 4.
Boom swing
Cradle zoom Boom swing forward/backward Zoom Drilling module rotation

C 44150--3 en 0507/LH
HYDRAULIC FLOWCHART

Carrier block 3
BOOM ZR 30

5 (15)
BOOM ZR 30

5. ADJUSTING BOOM CLEARANCES

5.1. Adjusting clearance between inner and outer tube, and replacing
slide pieces
Positions Z and Y

30 inner tube
21
Z 60
outer tube
22

M 80x2
Y Hex. socketkey,
19 mm

30
21

x) Replace the wear pieces (21) if distance x is about 5 mm

Replacing and adjusting slide pieces at position Z:
-- The number of wear pieces is eight.
-- Turn the boom into vertical position.
-- Remove the locking nut (30).
-- Install a new slide piece (21).
-- Screw the nut (22) in until the slide piece presses against the inner tube, and the
back up the nut (22) 1/4 turn.
-- Install the locking nut (30) and tighten it.
Adjusting slide pieces at position Y (4 pcs):
-- Turn the boom into vertical position.
-- Run DM transfer movement against the ground so that the clearances between the
inner and outer tube are in the middle position.
-- Adjust the clearances as described above.

6 (15) C 44150--3 en 0507/LH

 BOOM ZR 30

6. ADJUSTING ROTATION SENSOR

The purpose of the sensor (S11) is to send a signal when the rotation movement is
approaching the end position. Up to the stopper, the movement is then retarded (reduced
speed), governed by the sensor (S11).

4 mm
S11

Adjust the clearance between the sensor (S11) and the surface of the identifier piece to
4 mm and lock the sensor with the locking nuts.

C 44150--3 en 0507/LH 7 (15)

BOOM ZR 30

7. FLUSHING AND BLEEDING BOOM HYDRAULIC CIRCUIT

The boom hydraulic circuit must always be flushed and bled whenever a cylinder or a hose
has been disconnected. This must be done to ensure disturbance--free boom
movements.

7.1. Flushing boom swing circuit

1. Switch the boom swing movement on by pushing the boom joystick to the right (3
o’clock), and hold the boom in the extreme position for approx. 10 seconds. The
pressure in the piston rod side of the left swing cylinder and in the piston head side
of the right swing cylinder is released through the overcenter valve into the tank.
2. Switch the boom swing movement on by pushing the boom joystick to the left (9
o’clock), and hold the boom in the extreme position for approx. 10 seconds. The
pressure in the piston rod side of the right swing cylinder and in the piston head
side of the left swing cylinder is released through the overcenter valve into the tank.
3. Repeat the movement twice from one extreme position to the other until the
movement is steady.

7.2. Flushing zoom cylinder

1. Switch on the boom zoom movement up by pressing down the push button and
pushing the boom joystick forwards (12 o’clock), and hold the movement in the
extreme position for approx. 10 seconds. The pressure in the piston rod side of the
zoom cylinder is released through the overcenter valve into the tank.
2. Switch on the boom zoom movement down by pressing down the push button and
pulling the boom joystick back (6 o’clock), and hold the movement in the extreme
position for approx. 10 seconds. The pressure in the piston head side of the zoom
cylinder is released through the overcenter valve into the tank.
3. Repeat the movement twice from one extreme position to the other until the
movement is steady.

7.3. Flushing boom tilt cylinders

1. Switch on the boom tilt movement forwards by pulling the boom joystick back (6
o’clock), and hold the movement in the extreme position for approx. 10 seconds.
The pressure in the piston head side of the tilt cylinders is released through the
overcenter valves into the tank.
2. Switch on the boom tilt movement backwards by pushing the boom joystick
forwards (12 o’clock), and hold the movement in the extreme position for approx.
10 seconds. The pressure in the piston rod side of the tilt cylinders is released
through the overcenter valves into the tank.
3. Repeat the movement twice from one extreme position to the other until the
movement is steady.

8 (15) C 44150--3 en 0507/LH

 BOOM ZR 30

7.4. Flushing DM rotation mechanism

1. Run the rotation mechanism against the extreme position and hold it in that
position for approx. 10 seconds. Then open the bleed screw carefully to release
the air possibly trapped inside. Close the bleeding screw and run the rotation
mechanism into the other extreme position and hold it there for approx. 10
seconds. Repeat the bleeding as above.
2. Repeat the movement twice from one extreme position to the other until the
movement is steady.

7.5. Flushing DM transfer cylinders

1. Turn the long--hole unit into horizontal position.
2. Run the long--hole unit transfer movement to the forward extreme position by
pushing the boom joystick forwards to the right (half past one) and hold the
movement in the extreme position for approx. 10 seconds. The pressure in the
piston head side of the cylinders is released through the overcenter valves and into
the tank. Run the long--hole unit transfer movement to the backward extreme
position by pulling the boom joystick backwards to the left (half past seven) and
hold the movement in the extreme position for approx. 10 seconds.
3. Repeat the movement twice from one extreme position to the other until the
movement is steady.

The return filter must be replaced after flushing the cylinders!

CAUTION

C 44150--3 en 0507/LH 9 (15)

BOOM ZR 30

8. BOOM GREASING POINTS

Central lubricator (option)
The rig can be equipped with a central lubricator that takes care of the grease lubrication
of the boom. Refer to separate instructions.
10

Manual greasing
4, 7, 8

3
9

5
1

4
6

Grease the following points every day:

1. Boom swing cylinders . . . . . . . . . . . . . . 4 nipples
2. Boom tilt cylinders . . . . . . . . . . . . . . . . . 4 nipples
3. Feed extension cylinder . . . . . . . . . . . . 2 nipples
4. Zoom cylinder . . . . . . . . . . . . . . . . . . . . . 2 nipples
5. Zoom slide pieces . . . . . . . . . . . . . . . . . 16 nipples
6. Boom joint . . . . . . . . . . . . . . . . . . . . . . . . 2 nipples
7. Feed rotation . . . . . . . . . . . . . . . . . . . . . . 2 nipples
8. Feed rotation stopper . . . . . . . . . . . . . . 1 nipple
9. Cradle zoom cylinder (option) . . . . . . . 2 nipples
10. Stinger cylinder . . . . . . . . . . . . . . . . . . . . 2 nipples
The number of greasing points is 37.

10 (15) C 44150--3 en 0507/LH

 BOOM ZR 30

9. MAINTENANCE OF ROTATION MECHANISM

The most important maintenance on the rotation mechanism is the regular checking of the
oil level, and oil change using the recommended oil types.
Oil filling plug Oil filling plug

Brake Gear

Oil level plug

B1 A1
Oil drain plug Oil drain plug

Oil type Capacities

Brake RF 5/65 SHELL DONAX TD 0,6 litres
Gear RR 500/70 SHELL SPIRAX HD 80W/90 1,4 litres

For the best possible operation and long life, the oils must be changed regularly.
Use only the recommended oil type. Wrong type of oil can cause glazing
on the brake’s disc surfaces weakening the braking effect.

CAUTION

Oil changing interval:

-- After the first 50--60 operating hours.
-- Later, every 1000 operating hours or once a year.
Check the gearwheel mounting. Tighten the mounting screws.
Bleeding:
After maintenance or repair (e.g. replacement of sealings) the brake and the gear must
be bled.
Bleeding is done through the hydraulic connection when the rotation mechanism is
stopped.
Wear eye protection during bleeding and beware of possibly hot oil
sprays.

WARNING

Run and stop the rotation mechanism back and forth. Open the hydraulic connection
cautiously to let out the air. Repeat the procedure until no more air comes out.

C 44150--3 en 0507/LH 11 (15)

BOOM ZR 30

10. CHECKING AND REPLACING BEARING BUSHINGS

Bearing bushings and pins are used at the boom joints and in the eyes of the hydraulic
cylinders. Each of these are grease lubricated and provided with grease nipples so that
new grease can be pressed in.

10.1. Checking bearing bushings and pins

To check the condition of the bearing bushings and pins at the boom joints and hydraulic
cylinder eyes, the boom (or its part) is moved into a position where the bearing bushings
and pins of the cylinder to be checked are not carrying the weight of the boom or any of
its parts. Then the boom (or its part) is rocked by hand in the working direction of the
cylinder. Any clearance between the bearing bushings and pins can be easily detected
by observing the movement between the cylinder and the boom (or its part).

10.2. Replacing bearing bushings

The bearing bushings in the hydraulic cylinder eyes and in the body can be driven out of
their holes.
When new bearing bushings are installed, the temperature difference between the
bearing bushing and the hydraulic cylinder eye or the metal around the hole in the body
must be 40...50_C.
When a bearing bushing is installed into a hole in the body, the metal around the hole can
be warmed up with a blowtorch so that it is 40...50_C warmer than the bearing bushing.
When a bearing bushing is installed in a hydraulic cylinder eye, the required temperature
difference should be achieved by cooling down the bearing bushing sufficiently. This is to
avoid the risk of damaging the hydraulic cylinder seals with the blowtorch flame.

12 (15) C 44150--3 en 0507/LH

 BOOM ZR 30

10.3. Checking cylinder pins

The cylinder pins are adjustable conical pins that are tightened clearance--free to the
cylinder ears.

D
-- Check the tightening torque. The correct values are shown in table below.
-- Check the position of the cut in the pins. The cut must be at right angle to the
cylinder’s direction of movement and downwards if possible.

D [mm] Tightening using torque wrench Tightening using pneumatic tool

[Nm] [Nm]
45 150 130
55 150 130
75 290 270

Cut

C 44150--3 en 0507/LH 13 (15)

BOOM ZR 30

11. TROUBLESHOOTING
All hydraulic functions are either very slow or do not work at all.
1. Oil level too low or oil viscosity too high.
D Check oil level. Refer to oil recommendations for correct oil viscosity.
2. Leaks in hydraulic circuit or blocked hose.
D Check hoses and connections.
3. Insufficient pump output or lack of pressure.
D Incorrectly adjusted pressure relief valve or leaking internally. Check and
repair.
D Power transmission between motor and pump damaged. Check and
repair.
4. Foreign object blocking pump intake.
D Drain and clean tank.
D Check hoses.
5. Leaks between carrier block and boom hydraulics.
D Check carrier block and repair if necessary.
Boom rotation not working properly.
1. External leaks.
D Check hoses and connections.
2. Internal leaks.
D Check condition of rotation motor and replace seals if necessary.
3. Faulty overcenter valves.
D Impurities or damaged O--rings and seals in overcenter valves. Check
and repair.
4. Faulty shuttle valve.
D Impurities or damaged O--rings and seals in shuttle valves. Check and
repair.
5. Fault in control of directional valve of rotation.
D Check controls of coils Y18 and Y19.
6. Rotation mechanism brake dragging.
D Check shuttle valve, hoses, and connections.
Boom not holding position.
1. Faulty overcenter valves of boom swing, tilt, or zoom cylinders.
D Impurities or damaged O--rings and seals in overcenter valves. Check
and repair.
D Worn seating surfaces of overcenter valves. Check and repair.

14 (15) C 44150--3 en 0507/LH

 BOOM ZR 30

12. PERIODIC MAINTENANCE

Daily maintenance:
D Tighten all loosened screws and nuts.
D Repair possible oil leaks.
D Lubricate the greasing points of boom.
D Observe the operation and condition of the boom. Report on observation to the
responsible person.
Every week or every 50 percussion hours:
D Go through the daily maintenance list.
D Wash the whole rig.
D Check the condition of the cylinder pins bearing bushings.
D Check the operation and mounting of the rotation sensor (S11).
D Lubricate the rotation gear rim.
D Check the condition of the hydraulic hoses. Replace damaged hoses.
D Check all adjustable cylinder pins and their correct tightness.
Once a month or every 200 percussion hours
D Go through the daily and weekly maintenance lists.
D Check the oil level of the rotation mechanism brakes and gears.
D Check the operation of the rotation mechanism brakes.
D Check the mechanical structure of the boom. Pay special attention to possible
buckles, breaks, and the condition of welding. Repair any damage at once.
D Check the sliding clearance at the boom’s slide pieces. Adjust if necessary.
D Check the sliding clearance at the cradle’s slide pieces. Adjust if necessary.
Once every 6 months or every 500 percussion hours
D Go through the daily, weekly and monthly maintenance lists.
D Check the condition and fastening of the rotation mechanisms’ gearwheels.
D Check the condition of the rotation gear rim.
Once a year or every 1000 percussion hours
D Change oil in rotation mechanism brake.
D Change oil in rotation mechanism gear.
D Change the cradle’s slide pieces.

C 44150--3 en 0507/LH 15 (15)

 HYDRAULIC CYLINDERS

REPAIR AND ADJUSTMENT

CONTENTS

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1. Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. OVERCENTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.1. Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2. Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.3. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.4. Replacing of bearings bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6. ASSEMBLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.1. Assembling of cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7. TESTING OF CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.1. Line A, inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.2. Line B, inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

C 47150--5 en 1207 / AR 1 (8)

HYDRAULIC CYLINDERS

1. GENERAL
1.1. Structure
The main structural differences between hydraulic cylinders are:
D single and double acting
D cylinder bore
D stroke
D overcenter valve equipment
Stroke can be limited with a spacer mounted either to the piston side or the piston rod side.
Correct type of spacer is given in the spare parts list.

2. SAFETY
Acquaint yourself with the service and user instructions before starting
to work on a cylinder. Learn to know all the components that you will be
working on.
CAUTION

Follow the installation instructions issued by Sandvik

CAUTION

Installation, adjustment and repair work can only be carried out by a

person who has the necessary qualifications and knows the equipment.

CAUTION

Proper use and service guarantee longer life of the hydraulic cylinder.

CAUTION

Use all necessary safety devices and check their condition.

CAUTION

Before starting the rig, make sure that nobody is working close to, or
under the rig

WARNING

Never disconnect any hydraulic hoses or valves before making sure that
there is no static load in the system.

WARNING

2 (8) C 47150--5 en 1207 / AR

 HYDRAULIC CYLINDERS

3. OVERCENTER VALVE
3.1. Operation
Most hydraulic cylinders are equipped with an overcenter valve. They are either built--in
or connected to the hydraulic circuit via hydraulic hoses.

Overcenter valves are one--piece components and they cannot be readjusted. Sets of
seal rings (1) are provided. The four tasks of an overcenter valve are:
-- If a hose connected to the hydraulic cylinder breaks, the overcenter valve acts as
a safety valve.
-- During drilling, the overcenter valve prevents oil flow from the cylinder to the oil
tank. The boom maintains accurately the position to which it was moved to by using
the boom control valves.
-- When the boom is moved, the overcenter valve does not allow oil to flow from the
return side until the pressure on the pressured side rises high enough. Boom
movements are smoother and more accurate, and the boom’s own weight cannot
accelerate the speed movement.
-- If an external force raises the pressure in the cylinder higher than the set value of
the overcenter valve, the valve opens and lets oil out of the cylinder. This enables
the boom to yield under external force, and mechanical damage to the boom can
be avoided.
The set value of the overcenter valves for different purposes are
different. Therefore, you must not replace an overcenter valve with one
from a other cylinder. The set value of the valve is punched on the top of
CAUTION the valve.

C 47150--5 en 1207 / AR 3 (8)

HYDRAULIC CYLINDERS

4. COMPONENTS
10
1
2
9
8
5
3
6
7
4

10

Components of a typical cylinder

1. Socket screw 6. Locking plate

2. Cylinder cover 7. Rod nut
3. Piston 8. Piston rod
4. Overcenter valves 9. Spacer
5. Cylinder tubes 10. Bearing bushing

10
2
9
8
5
3
6
7
4

10

Components of a typical cylinder (threaded cylinder cover)

4 (8) C 47150--5 en 1207 / AR

 HYDRAULIC CYLINDERS

5. DISMANTLING
Before starting to remove the cylinder, make sure that the boom is properly supported, and
all static loads of the cylinder are removed. Disconnect the hydraulic hoses to the cylinder
and plug the open hose ends and cylinder adapters.
Remove the locking rings of the cylinder pins, support and secure the cylinder so that it
cannot fall down. Tap the pins out.
Wash the cylinder externally and mount securely before starting to dismantle it.

5.1. Cylinder
If you can use hydraulic pressure, connect the hoses to the cylinder and run the piston
rod (8) out, remove the overcenter valves (4). Unscrew the socket screws off of the cover
(2) or, if the cover is thread mounted, open the cover with a suitable tool. Screw the
overcenter valves (4) back, and run the piston rod (8) and the cylinder cover (2) out. When
pressing out, support the piston rod (8) properly to get it out smoothly.
Be aware of oil spilling

WARNING

5.2. Piston
Mount the piston rod firmly from the eye end, and tap out the locking washer lug from the
groove of the nut, and remove the nut (7). Remove the piston (3) together with the seals.
Pull the cylinder cover (2) off the piston rod and remove the cylinder cover seals and the
wiper and replace them. Unscrew the overcenter valves (4) from the cylinder tube and
visually check their condition. Wash all components.

5.3. Inspection
Replace all seals and wipers. Check all sliding surfaces. If scratches, big enough to feel
with a fingernail are found, the components should be replaced because the sealing ability
of the surfaces is no longer good. Also check the piston rod for straightness. If the rod is
distorted, check that it is not caused by a incorrect spacer. Check the condition of the
bearing bushings (10), and replace them if there are any marks of wear.

5.4. Replacing of bearings bushing

If the cylinder already has been removed from the rig, support the cylinder well and tap
the old bearing bushings out using a suitable drift and a copper hammer.
The new bearing bushings are easier to install if they are cooled in a freezer, and the
cylinder eye is warmed up with a torch.

C 47150--5 en 1207 / AR 5 (8)

HYDRAULIC CYLINDERS

6. ASSEMBLING
If the stroke of the cylinder is limited with a spacer and it is left out, the
cylinder can be damaged in use. Check that you install the correct type
spacer.
CAUTION

6.1. Assembling of cylinder

2
Grease the seal grooves and install the
9 O--rings, the lip seal and the guide rings on
the cylinder cover (2). Install the cover of
the piston rod (8). If a spacer (9) is used to
limit the maximum stroke of the cylinder,
install the bushing on the piston rod before
8 installing the piston.

Grease the seal grooves and install the

11 piston seal (10). When installing the
6
piston’s O--ring (11), be careful not to
7 damage it in the piston rod thread. Install
the locking plate (6) and the locking nut (7).
Tighten the nut and lock it in a place by
turning a tang of the locking plate into its
10 groove.

The piston rod and the cover assembly

6 (8) C 47150--5 en 1207 / AR

 HYDRAULIC CYLINDERS

Check if the minimum stroke of the cylinder is limited. If it is, the spacer must be inserted
into the cylinder first. Push the piston assembly into the cylinder. Remember to lubricate
the seals before assembling!

Push the cylinder cover (2) in and insert the socket screws (1) through the cover and
tighten them. If the cylinder cover is thread--mounted, use a special tool for tightening.
Install the overcenter valves (4) and the adapters, and test the cylinder.

2 1

Assembled cylinder

C 47150--5 en 1207 / AR 7 (8)

HYDRAULIC CYLINDERS

7. TESTING OF CYLINDER

11
12
10

13
14

Testing of cylinder

7.1. Line A, inspection

Run the piston rod completely out. Disconnect line A, and pressurize line B. Check line
A for leaking oil. If oil leaks out, one of the seals (10, 11 or 12) or overcenter valve is faulty.

7.2. Line B, inspection

Run the piston rod completely in. Disconnect line B, and pressurize line A. Check line B
for leaking. If oil leaks out, one of the seals (10, 11 or 12) or the overcenter valve is faulty.
If oil comes out from between the cylinder cover and the cylinder tube, the cylinder cover
O--ring (13) is faulty. If oil comes out from between the cylinder cover and the piston rod,
the cylinder cover O--ring (14) is faulty.

8 (8) C 47150--5 en 1207 / AR