Service Manual 1212 SM17---002---022.

00

Approximate Position of Cylinder Piston

1. Straps 3. Gland 5. Rod End

2. Case 4. Rod

Figure 1
Typical Cylinder & Cylinder Support

Boom Telescope Cylinder, Recondition

This procedure covers recondition of boom telescope cylinders with the piston threaded onto the rod. For recondi-
tion procedures, for other types of telescope cylinders, refer to SM Keysheet Area 17---002. For removal and installa-
tion procedures, refer to Boom, Recondition in SM Keysheet Area 17---001.
Disassembly
Refer to Figure 1.
1. Firmly support the cylinder at the rod end (5) and 4. Plug open ports of the cylinder. Thoroughly clean
three places equally spaced along case (2). Refer exterior surface of cylinder with an approved clean-
to Table A to determine the weight of the cylinder. er to prevent contamination during disassembly.
2. Adjust the height of the support at the rod end (5) to 5. Place a container, of adequate size, below the
be sure rod (4) is centered in gland (3). open ports. Remove the plugs which were
3. Secure case (2) to supports with straps (1), to pre- installed in the cylinder during the cleaning pro-
vent it from rolling or sliding during disassembly. cess. Refer to Table A to determine how much oil
may be contained in the cylinder.
6. Fully extend, then fully retract, the rod (4) to com-
WARNING pletely drain the oil. Properly store or dispose of
used oil.
Solvents and cleaning solutions can be 7. Extend the rod (4) approximately half way. The
hazardous. Serious personal injury may result
length of the exposed portion of the rod (4) should be
from misuse of these products. Read and
equal to half the length of the cylinder case (2). Ad-
follow all the manufacturer’s recommendations just the support under the rod (4), as required, to en-
concerning solvents and cleaning solutions. sure the rod (4) is centered within the gland (3).

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SM17---002---022.00 1212 Service Manual

1 2 3 A 4 B 5 6 7

C D 8 9 10 1 2

11

12 13 4 A 14 B C D
18

4 15 16 17 9 19 9 20 21

1. Case 7. Counterbalance Valve 12. O-ring 17. Wiper

2. Rod 8. Wear Ring 13. Back Up Ring 18. O-ring
3. Wear Ring 9. Piston 14. O-ring 19. Back Up Rings
4. Gland 10. Stop Tube 15. Step Seal 20. Piston Seal
5. O-ring 11. Setscrew 16. Rod Seal 21. O-ring
6. O-rings & Back Up Rings
Figure 2
Boom Telescope Cylinder

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Service Manual 1212 SM17---002---022.00
Case Wet Retracted Wet Extended Oil Capacity Oil Capacity Test
Diameter Weight Weight Retracted Extended Pressure
in cm lb kg lb kg gal L gal L psi kPa
5.03 12.78 935 425 1,016 462 12.30 46.56 23.50 88.95 4,200 28 959
5.38 13.67 1,134 515 1,220 554 12.80 48.45 24.70 93.49 4,500 31 027
6.20 15.75 1,499 681 1,643 746 22.60 85.55 42.50 160.87 4,500 31 027
6.25 15.88 1,716 780 1,864 847 21.70 82.14 42.30 160.11 5,000 34 475
6.50 16.51 1,863 846 2,035 924 24.70 93.49 48.40 183.20 5,000 34 475
6.75* 17.15 2,154 978 2,366 1 075 30.32 114.77 59.65 225.78 4,000 27 580
6.75† 17.15 1,933 878 2,123 964 26.70 101.06 52.90 200.23 5,000 34 475
7.00 17.78 2,300 1 043 2,532 1 148 34.00 128.70 66.00 250.00 5,000 34 475
7.19 18.26 1,936 879 2,182 991 15.2 57.53 49.2 186.22 5,000 34 475
* Cylinder from diamond embossed boom
† Cylinder from formed boom

Table A
Cylinder Specifications

Refer to Figure 2.
8. Remove the counterbalance valve (7) from the rod
(2), and remove the o-rings and back up rings (6)
from the counterbalance valve (7).
CAUTION
The cylinder must be adequately supported
and the rod centered within the gland before
attempting to disassemble the cylinder. An
improperly supported cylinder will sag at the
gland, causing irreparable damage to the
threads, as the gland is removed.
9. Use a spanner wrench to rotate gland (4) until its
threads disengage case (1).
10. Using an auxiliary lifting device, carefully slide the
rod (2), gland (4), stop tube (10), and piston (9) out
of case (1), and place in an area where it can be
disassembled without damaging the chrome on
the rod (2) or individual parts.
11. Remove wear rings (8), piston seal (20), and o-ring
(21) from piston (9).
12. Remove the setscrew (11) from the piston (9).
CAUTION
Use care not to damage the chrome finish on
the piston rod. Any nicks or scratches could
result in cylinder leakage. Weld splatter may
also do damage. When using a vise, clamp to
portions of the rod which are not chrome
plated, or protect the chrome surface with a
soft material before clamping.
13. Rotate piston (9) until its threads disengage from
the rod (2).
14. Remove the back up rings (19) and o-ring (18) from
the piston (9).
15. Remove stop tube (10) from the rod (2).
16. Slide the gland (4) off the rod (2).
17. Remove the wear ring (3), o---ring (12), back up
ring (13), o-ring (14), step seal (15), rod seal (16),
wiper (17), and o-ring (5) from the gland (4).

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SM17---002---022.00 1212 Service Manual
Cleaning And Inspection 4. The rod should be thoroughly inspected for dam-
age such as dents, deep scratches, and/or dam-
aged chrome plating. All sharp edges on both
ends of the rod should be carefully removed with a
WARNING fine file or hone to prevent damage to seals during
assembly.
Solvents and cleaning solutions can be
5. Carefully inspect all components for damage,
hazardous. Serious personal injury may result
wear, fatigue or stress fractures, corrosion, deep
from misuse of these products. Read and
scratches, cracks, and scuffed metal. Remove any
follow all the manufacturer’s recommendations
burrs or sharp edges with a fine file, hone, emery
concerning solvents and cleaning solutions.
cloth, or crocus cloth. Replace any damaged or
1. Thoroughly clean all metal parts with an approved worn components, as required.
cleaning solvent. Place parts on a clean, lint free 6. All “soft parts”, such as seals, gaskets, back up
surface and allow to air dry. Exercise every rings, and o-rings, should be replaced.
precaution possible to keep all parts free of dust, 7. In the event of severe defects, contact factory
dirt, or any other foreign material during assembly. personnel for directions whether to repair or
2. All Loctite, Permatex, or other sealant residue replace any major component.
should be removed from threads of hardware and
the mounting surfaces of parts that are going to be
reused. Prior to applying new thread locking
compounds or sealants, clean threads and
surfaces with Loctite 7070 Cleaner to ensure best
performance of products.
3. The cylinder case bore should be thoroughly in-
spected for signs of “scoring” or deep scratches.

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Service Manual 1212 SM17---002---022.00
Assembly
Crane Serial Number
ft lb Nm
WARNING Prefix
Follow all manufacturer’s recommendations D3 150---160 203 ---216
concerning lubricants, sealants, joint and
thread locking compounds, etc. Serious D7 150---160 203 ---216
personal injury may result from misuse of F2 150---160 203 ---216
these products.
F7 150---160 203 ---216
J6 150---160 203 ---216
Lubricate o-rings, back up rings, wear rings, and cylin-
der case bore with CosmolubeR No. 2 or equivalent J7 330---375 448 ---508
prior to assembly. Use care to avoid getting the lubri-
cant on the threaded portions of the cylinder case, rod, J9 150---160 203 ---216
piston, and gland. R2 150---160 203 ---216
Refer to Figure 2. R8 150---160 203 ---216
Soak new piston seal (20), wiper (17), rod seal (16), S1 330---375 448 ---508
and step seal (15) in clean hydraulic oil, which has
been heated to a temperature of 100---120 _F S4 150---160 203 ---216
(38 ---48_C). Allow adequate time for the parts to reach Table B
the temperature of the hydraulic oil which will greatly Counterbalance Valve Installation Torques
ease their assembly.
1. Install the wear ring (3), o-ring (12), back up ring 8. Apply a light coat of Loctite 242 to the threads set-
(13), o-ring (14), step seal (15), rod seal (16), wiper screw (11). Install setscrew (11) in the piston (9).
(17), and o-ring (5) on the gland (4). 9. Install the wear rings (8), o-ring (21), and piston
seal (20) on the piston (9).

CAUTION Refer to Figure 1.

Threaded surfaces are sharp. Use care to
prevent damage to seals or o-rings during
installation of components onto rod or during
installation of rod and piston assembly into
case.
2. Install a thin layer of masking tape over the threads
of the rod (2).
3. Carefully slide the gland (4) onto rod (2) taking care
not to damage the seals. A slight oscillating motion
should be used to enable the lips of seals to slip
onto and past the rod shoulder. Slide the gland (4)
at least half way up rod (2).
4. Slide stop tube (10) onto the rod (2).
5. Install o-ring (18) and back up rings (19) into the
piston (9).
6. Apply a light coat of Loctite 242 to the threads of
the piston (9).
7. Carefully slide the piston (9) on rod (2). Use care to
avoid damaging the o-ring (18) and back up rings
(19). Start threads by rotating piston (9) by hand.
After piston (9) is started, use a spanner wrench to
torque to 750---800 ft lb (1 017 ---1 084Nm).
CAUTION
The cylinder must be adequately supported
and the rod centered within the gland before
attempting to assemble the cylinder. An
improperly supported cylinder will sag at the
gland, causing irreparable damage to the
threads, as the gland is installed.
10. Place three equally spaced supports along case (2).
11. Secure case (2) to the supports with straps (1), to
prevent it from rolling or sliding during assembly.
Refer to Figure 2.
12. Using an auxiliary lifting device, carefully slide the
rod (2), gland (4), stop tube (10), and piston (9) into
the case (1). Use care to avoid damaging the seals
and o-rings on the gland (4) and piston (9) assem-
bly as they are installed in the case (1).
13. Slowly rotate gland (4) into case (1) making sure
the threads are not being damaged as the gland
(4) is installed. Using a spanner wrench, torque to
400---450 ft lb (542 ---610Nm).

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SM17---002---022.00 1212 Service Manual
14. Carefully retract the rod (2) into the case (1). High Pressure Leakage Test
15. Install the counterbalance valve (7) in the rod (2) 1. Extend cylinder full stroke and pressurize extend
using new o-rings and back up rings (6). Torque to port to the “Test Pressure” specified in Table A.
correct specification found in Table “B”. Hold this pressure for a minimum of one minute. If
16. Test the reconditioned cylinder for leaks and prop- leakage across the piston exceeds 0.33 cc/min,
er operation. See Cylinder Test Procedure found disassemble the cylinder, replace the defective
on Page 6. parts, and repeat the entire test procedure.
2. Relieve pressure and examine the cylinder for
Cylinder Test Procedures structural failure. No leakage is acceptable. If leak-
age is found, disassemble the cylinder, replace the
Low Pressure Leakage & Static Friction Test
defective parts, and repeat the entire test proce-
1. Fill the fully retracted cylinder with clean hydraulic
dure.
oil. Refer to Table A and the Operator’s Manual for
3. Fully retract the cylinder.
the correct amount and grade of oil to use.
4. Pressurize retract port to the “Test Pressure” speci-
2. Cycle the cylinder, full stroke each direction, a mini-
fied in Table A. Hold this pressure for a minimum of
mum of five times to remove entrapped air, using
one minute. If leakage across the piston exceeds
only the pressure level which is required to move
0.33 cc/min, disassemble the cylinder, replace any
the cylinder rod at a steady rate. If the cylinder
defective parts; repeat the entire test procedure.
squeaks or sticks, disassemble the cylinder and
5. Once again relieve pressure and examine the cyl-
replace the defective part and repeat the entire test
inder for any external leakage. No leakage is ac-
procedure.
ceptable. If leakage is found, disassemble the cyl-
3. Stop the rod at mid stroke and examine the cylin-
inder, replace any defective parts; repeat the entire
der for any external leakage. No leakage is accept-
test procedure.
able. If leakage is found, disassemble the cylinder
6. If the cylinder is not to be installed on crane im-
and replace any defective parts, as required; re-
mediately, plug all ports to prevent contamination
peat the entire test procedure.
and properly store.
4. Fully retract the cylinder.
5. Gradually pressurize the extend port, at a pressure
increase of one to ten percent of the cylinder work-
ing pressure per minute, until rod movement is initi-
ated. Pressure to initiate rod movement or “break-
away” pressure, shall not exceed 120 psi (827kPa).
6. Once the breakaway pressure is determined, the
pressure needed to maintain movement of the cyl-
inder rod, is termed “running pressure”. Running
pressure should not exceed 80% of the breakaway
pressure or diminish to no less than 20% of the
breakaway pressure as the cylinder is extended. If
running pressure exceeds these guidelines, disas-
semble the cylinder and replace any defective
parts; repeat the entire test procedure.

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