Simulator Activities Student Workbook MF400-HCTS Hydraulic Cylinder Training System REVISION 4.1 MF400-HCTS Hydraulic Cylinder Training System Simulator Activities Student Workbook Published by: FLUID POWER TRAINING INSTITUTE™ 2170 South 3140 West West Valley City, UT 84119 www.fpti.org HC-R025-TA (REV. 4.1) Unless permission is granted, this format or material con- tained herein shall not be copied, reproduced, or quoted for reproduction, by electrical, mechanical, or chemical process, or accomodation thereof, now or later developed. Violations will be pursued vigorously by all legal means available against the companies and individuals involved. The information contained in this book is designed for educational purposes only. The FLUID POWER TRAINING INSTITUTE™ has carefully compiled and thoroughly checked this information for accuracy. However, since any segment of information can apply to one application and not to a similar application due to: differences in environmental conditions; operating personnel; operating conditions; materials; components; and since errors can occur in system circuits, tables, and text, we assume no liability for the safe and/or satisfactory operation of any machine or installation designed from the information contained in this book. Any design which could cause injury to personnel or dam- age to a machine or installation should be independently checked by a certified engineer. COPYRIGHT © 2021 FLUID POWER TRAINING INSTITUTE™ Rev 4.1 - October 14, 2021 Printed in the UNITED STATES of AMERICA INTRODUCTION ................................................................................. i GENERAL INSTRUCTIONS ................................................................... ii OBJECTIVES ........................................................................................ ii PROCEDURES ...................................................................................... ii SIMULATOR FAMILIARIZATION .......................................................... 1 SAFETY INSTRUCTIONS ...................................................................... 6 LAB ACTIVITY 1.0 - WELDED-TYPE CYLINDER with MICROLEAK 1.1 Leakage Test with MicroLeak System ......................................... 1-3 1.2 Disassemble, Inspect, Reseal, Assemble & Test .......................... 1-9 1.3 Leakage Re-Test with MicroLeak System .................................... 1-21 LAB ACTIVITY 2.0 - TIE-ROD CYLINDER with MICROLEAK 2.1 Leakage Test with MicroLeak System ......................................... 2-3 2.2 Disassemble, Inspect, Reseal, Assemble & Test ......................... 2-9 2.3 Leakage Re-Test with MicroLeak System .................................... 2-24 Contents The hands-on MF400-HCTS Hydraulic Cylinder Training System is an integral and essential part of the fluid power training process. There is no substitute for students to be able to disassemble, inspect, assemble, and test, welded type and tie-rod type hydraulic cylinders in the safety of the classroom. By observing the following safety procedures, you will insure a safe, effective and pleasant experience with our fluid power simulators. - Whenever the power is on and the simulator is energized: ALWAYS WEAR YOUR SAFETY GLASSES! If you are in doubt about what you are doing, stop and ask your instructor for assistance. The instructor, the equipment, and the training materials are for you to utilize to the fullest possible extent to enhance your understanding of this exciting subject. Please ask questions, make suggestions, or comment on any aspect of your training. Feel free to share your experience in fluid power with the class. Remember, there are no dumb questions! In addition to yourself, your fellow students and the instructor will benefit from your full participation in the learning process. If you see any way in which the program, the materials, or the simulators might be made more effective; please make a note of it, and include it in your course evaluation. Introduction Do not work on or around hydraulic systems with- out wearing safety glasses which conform to ANSI Z87.1-1989 standard. i General Instructions Before undertaking any of the activities, please consider the following in- structions which will apply throughout. Only by following instructions exactly, will you derive the maximum benefit from your hands-on experience. Objectives Be certain at the outset that you understand clearly the OBJECTIVE of the activity. By considering what you are supposed to be learning before you begin, you will be more likely to make the correct observations and analysis of the experiment. Look for and identify all the components that are referred to in the objective statement at the beginning of each activity. Be sure that you understand all the terminology that is used. If there is any- thing that you don’t fully understand, do not hesitate to ask. THERE ARE NO DUMB QUESTIONS! Procedures Study the entire activity thoroughly, and understand all the terminology used, before proceeding to implement any procedure. Locate, on the simulator, all the components that are to be used in the activity. Follow the instructions to the letter. Do not deviate in any way from the prescribed sequence. Complete each step, and answer any questions before going on to the next one. After you have completed the activity, and are comfortable with the results, shut off the power to de-energize the simulator. ii 1 MF400-HCTS Hydraulic Cylinder Training System Simulator Familiarization 2 MF400-HCTS Hydraulic Cylinder Training System Description - The model MF400-HCTS is a training system that is designed to teach students how to safely disassemble, inspect, assemble, and test welded type and tie-rod type hydraulic cylinders. NOTE: Welded-type cylinders and tie-rod type cylinders are available for purchase for use with the MF400-HCTS trainers. If additional cylinders are needed, the part number for the cylinders are as follows: Welded cylinders - MF400-RWC Tie-rod cylinders - MF400-TRC The model MF400-HCTS Hydraulic Cylinder Training System has a number of key features: • Four (4) individual cylinder test stations, which operate inde- pendently from one another. One to four students are able to test cylinders at the same time. • Integrated storage racks that store up to eighteen (18) cylinders. • Each test station has a transparent safety cover which is harnessed to the trainer with a cable. The covers store conveniently on pins above each station. • Each test station has a mechanical ratcheting system, which allows the student to push the cylinder rod back to evacuate the oil before placing it in the storage rack. • Residual oil is never wasted. The filler cap on the top tray of the trainer is designed to permit the student to pour excess oil back into the reservoir. The filler is equipped with a atrainer that is de- signed to clean the recycled oil before it is returned to the reservoir. • Special tools are needed to disassemble the cylinders. The tools include a 2” (50mm) wrench to remove and install the gland, and a tool for installing the gland seals. • Four (4) heavy-duty casters with brakes. Seal kits can be purchased from FPTI™. Both the welded type cylinder and the tie-rod type cylinder utilize the same seals. The part number for the seal kit is – MF400-SK For cylinder and seal kit prices, please send an email to: matt@fpti.org 3 SPECIFICATIONS - MF400-HCTS Power: 120VAC Pump: Variable volume pressure-compensated vane pump Flow: 1.0 GPM (3.78 Lpm) Pressure compensator setting: 750 PSI (52 bar) Oil reservoir: 12 gallons (46 Liters) Type of oil: AW32 Hydraulic oil or equivalent Cylinders: Welded-type Tie rod-type 29.0” (74cm) 45.0” (114cm) 69.0” (175cm) MF400-HCTS Dimensions Figure 1 4 SIMULATOR FAMILIARIZATION - MF400-HCTS Figure 2 Take a moment to familiarize yourself with the components on your model MF400-HCTS Hydraulic Cylinder Training Simulator. NOTE: Some components may vary from those shown in the photographs. 1 2 3 4 5 6 7 8 1. Cylinder Test stations (4) 2. Joystick – controls cylinder travel direction 3. Pressure gauge – 0-1000 PSI (0-69 bar) 4. Cylinder safety shield in stored position 5. Oil filler/recycle pod 6. Cylinder test fixture with locking pin 7. Power switch 8. Filter with by-pass indicator 9. Hydraulic reservoir 10. Hydraulic pump 11. Electrical plug 12. Electric motor 13. Casters with brakes (4) 14. Cylinder storage rack (double-sided) (cylinders not included) 9 10 1213 14 11 5 SAFETY INSTRUCTIONS - MF400-HCTS 1. The MF400 must be used under the supervision of a trained and authorized instructor(s). Students must not be allowed to be left alone during lab activities. 2. The MF400 is designed to be used in conjunction with the specially- designed training cylinders. It is unsafe to use the MF400 in conjunc- tion with any other type of hydraulic or pneumatic cylinders. WARNING: Using any other type of cylinder in conjunction with the MF400 can lead to an incident that can result in severe injury. 3. The training cylinders are heavy. It is recommended that students wear steel-toe boots when using the MF400. Especially when carrying the cylinders to and from the workbenches. 4. Students MUST wear safety glasses while performing ALL learning activities related to the MF400. 5. DO NOT attempt to increase the pressure setting of the MF400. 6. When testing a cylinder on the MF400 the security pin must be installed and the transparent safety cover MUST be in place. CAUTION: There is a possibility the oil will spray from the cylinder if a seal has been incorrectly installed or damaged during the installation. The safety covers are designed to protect students from oil spray. If the covers are not installed and there is an oil leak, there is a chance the student will get sprayed with oil. Failure to wear safety glasses, and/or install the safety covers over the cylinders while the power unit is operating, can lead to eye injury. 7. Do not modify the MF400 in any way shape or form. All modifications must be approved in writing by the Fluid Power Training Institute™. 8. NEVER attempt to disassemble a hydraulic cylinder with air pressure. 6 WARNING: Using compressed air to disassemble a hydraulic cylinder is extremely dangerous. Compressed air can cause parts of a cylinder to explode. It can also cause an inferno if there is residual oil in the cylinder and the atomized oil comes into contact with an ignition source. Workers that have used compressed air to aid in disassembling cylinders have, in some instances, been severely injured or killed. 9. There is a possibility that a small amount of oil will be spilled when a hydraulic cylinder is disassembled. The Fluid Power Training Institute™ recommends that the disassembly table should be designed to prevent the oil from spilling onto the floor. Any oil that is spilled onto the floor must be cleaned up imme- diately. CAUTION: Oil spills must be cleaned up immediately. Oil spills create dangerous slip hazards. If slip hazards are ignored they can lead to falls. Falls have, in some instances, caused workers to suffer severe injury or death. 7 HYDRAULIC CYLINDERS - INTRODUCTION________________________________________________ Hydraulic cylinders are used to convert hydraulic power into mechanical pow- er. They are energy conversion devices that convert fluid power expressed as flow and pressure into linear mechanical power expressed as speed and force. Hydraulic cylinders are sized according to their bore diameter (inside diam- eter), stroke (rod travel), rod diameter, and maximum rated pressure. TYPES OF CYLINDERS: WHAT A SINGLE-ACTING, SINGLE ROD CYLINDER CONSISTS OF: 8 HOW A SINGLE-ACTING, SINGLE ROD CYLINDER WORKS: TYPICAL APPLICATION OF A SINGLE-ACTING, SINGLE ROD CYLINDER: 9 WHAT A DOUBLE-ACTING, SINGLE ROD CYLINDER CONSISTS OF: HOW A DOUBLE-ACTING, SINGLE ROD CYLINDER WORKS: HYDRAULIC CYLINDERS - INTRODUCTION________________________________________________ 10 MF400-HCTS Hydraulic Cylinder Training System________________________________________________ TYPICAL APPLICATION OF A DOUBLE-ACTING, SINGLE ROD CYLINDER: 11 WHAT A DOUBLE-ACTING, DOUBLE ROD CYLINDER CONSISTS OF: HOW A DOUBLE-ACTING, DOUBLE ROD CYLINDER WORKS: HYDRAULIC CYLINDERS - INTRODUCTION________________________________________________ 12 TYPICAL APPLICATION OF A DOUBLE-ACTING, DOUBLE ROD CYLINDER: MF400-HCTS Hydraulic Cylinder Training System________________________________________________ 13 HYDRAULIC CYLINDERS - INTRODUCTION________________________________________________ WHAT A TELESCOPING CYLINDER CONSISTS OF: HOW A TELESCOPING CYLINDER WORKS: 14 MF400-HCTS Hydraulic Cylinder Training System________________________________________________ TYPICAL APPLICATION OF A TELESCOPING CYLINDER: 15 HYDRAULIC CYLINDERS - INTRODUCTION________________________________________________ HYDRAULIC CYLINDERS IN HIGH-RISK APPLICATIONS: A hydraulic system functions on the basis of transmitting power by pushing on a confined liquid. A hydraulic system can only work if the liq- uid is confined. Also, the movement of an actuator can only be controlled if the liquid is confined. What will happen if the oil transmission line that transports oil to and from the control valve to the cylinder breaks and leaves the liquid free to leave the system? If the cylinder is supporting a load, the force of gravity will convert the cylinder into a pump. As the load drops it will pump the oil out of the cylinder leaving the operator with no way to control the speed of the cylinder or distance of travel. This is a concern when using hydraulic cyl- inders to lift workers, position booms on cranes, lift and whirl children on amuse- ment park rides and set ladders for fire- fighters. 16 MF400-HCTS Hydraulic Cylinder Training System________________________________________________ Cylinders used in these types of applications must be equipped with some type of valve that will contain the oil in the cylinder if the oil transmission line fails. These valves are typically called counterbalance valves, pilot-operated check valves, and velocity fuses. Also, as an added safety measure, these types of valves are oftentimes “hidden” inside the cylinder housing. These valves add another dimension of hazard when rebuilding hydraulic cylinders. Those people that rebuild hydraulic cylinders MUST be aware of these valves and their knowledge must extend to how these valves function, their settings, and how to test them. Here are some photos that will help to identify where the valves are typically located in cylinders. CAUTION: These photos do not show all configurations. 17 HYDRAULIC CYLINDERS - INTRODUCTION________________________________________________ Here are the steps that must be taken when receiving hydraulic cylinders for repair: 1. You MUST know if the cylinder was removed from a system/ machine that works with hazardous waste and/or materials. 2. You must ask the company to provide the MSDS report for the liquid within the cylinder or system. 3. You MUST know from what type of machine the cylinder was removed. Record the information on the work order that will be given to the rebuild technician. 4. You MUST also record the reason why the cylinder was removed from the machine. 5. If the cylinder was removed from an aerial platform, scissor lift, utility (bucket) truck, crane, amusement park ride, firetruck, or any high-risk application, DO NOT receive it unless you are authorized to repair the cylinder by the original equipment manufacturer. The following are a company’s conditions of acceptance for repairing hydraulic cylinders: 1. The company must have the means to safely transport the cylinder within the facility. 2. The company must have the tools and fixtures needed to safely disassemble and assemble the cylinder. 3. If it is necessary to weld the cylinder, all welding must meet the original cylinder manufacturer’s specifications. 4. If it is necessary to replace parts, all parts, including seals, must be purchased from the original cylinder manufac- turer. 18 MF400-HCTS Hydraulic Cylinder Training System________________________________________________ 5. If it is necessary to remanufacture parts the parts must be manufactured with the same material and to the same specifications as set forth by the original cylinder manu- facturer. 6. The company must have the torque wrenches needed to torque all bolts and nuts to the respective cylinder manu- facturer’s recommended torque specifications. 7. The company must have a test bench that can test the cylinder to the maximum pressure recommended by the original cylinder manufacturer. 8. If the cylinder is equipped with a load-holding valve the repair facility must be able to test the pressure setting and performance of the valve. 9. If you cannot test the cylinder to the maximum pressure recommended by the original cylinder manufacturer it is your duty of care to advise your client. 10. If you cannot test a cylinder that is equipped with an integrated load-holding valve it is your duty of care to advise your client. 11. The company must have the fixtures and equipment needed to remove residual oil from the cylinder and dis- pose of it according to local laws. 12. The company must have the fixtures and equipment needed to thoroughly clean the exterior surfaces of the cylinder. DO NOT use solvents that can damage or deface warning labels. 19 1-1 Lab Activity 1 WELDED-TYPE CYLINDER LEAKAGE TEST with MICROLEAK TEST SYSTEM 1-3 1. Remove a welded-type cylinder (blue) from the storage rack and slide the cylin- der welded plate into the test fixture and install the locking pin (Figure 1.3-1). 2. Install the transparent safety shield (Figure 1.3-2). CAUTION: If you do not install the transpar- ent safety shield and the cylinder leaks, you could be sprayed with hydraulic oil. NOTE: After repairing a hydraulic cylinder, or when placing a cylinder in a test station from the storage rack, it will be neces- sary to first refill it with oil and purge the air from that cylinder. 3. Connect the hose from port “A,” on the control cabinet, to the closed-end of the cylinder. Connect the hose from port “B,” on the control cabinet, to the live-end of the cylinder (Figure 1.3-3). Figure 1.1-2 Figure 1.1-3 Figure 1.1-1 LAB ACTIVITY 1.1 - WELDED-TYPE CYLINDER Leakage Test with MicroLeak Test System_____________________________________________________ 4. Connect the MicroLeak air-bleed hose assembly to the red-capped, Safe-T-Bleed valves on the cylinder (Figure 1.1-4). Rotate the knobs until they are fully engaged on the valves. Tighten them by hand only. 5. Start the power unit (Figure 1.1-5). NOTE: It is safe to connect the oil trans- mission lines to the cylinder ports while the power unit is running. 6. Activate the joy-stick to position “A” (Figure 1.1-6) and hold position until the cylinder rod is fully extended. Continue to hold the joystick in position “A” for approximately 1-minute. This will purge air from the cylinder. 7. Activate the joystick to position “B” (Figure 1.1-7) and hold position of the joy- stick until the cylinder rod is fully retracted. Continue to hold the joystick in position “B” for approximately 1-minute. This will purge air from the cylinder. LAB ACTIVITY 1.1 - WELDED-TYPE CYLINDER Leakage Test with MicroLeak Test System_____________________________________________________ Figure 1.1-7 Figure 1.1-6 Figure 1.1-5 1-4 Figure 1.1-4 8. Remove the MicroLeak air-bleed hose assembly and replace the red caps on the Safe-T-Bleed valves (Figure 1.1-8). 9. While the button is depressed, fully extend then fully retract the cylinder rod by operating the joystick to position “A” and then to position “B” (Figure 1.1-9). 10. Perform a cylinder seal, bypass test. 11. Remove the quick-disconnect hose from the port at the live-end of the cylinder. Connect the MicroLeak test pump hose to the quick-connect fitting on the port at the live-end of the cylinder (Figure 1.1-10). 12. Operate the MicroLeak test pump (Figure 1.1-11). If the cylinder piston seals are in good condition, the pressure will begin to increase. Stop when the pressure reaches 1000 PSI (69 bar). LAB ACTIVITY 1.1 - WELDED-TYPE CYLINDER Leakage Test with MicroLeak Test System_____________________________________________________ Figure 1.1-10 Figure 1.1-8 Figure 1.1-9 1-5 Figure 1.1-11 If the pressure fails to increase, there is leakage across the cylinder piston seals. NOTE: Before removing the cylinder from the test station, to conduct Lab Activity 1.2, drain the oil from the cylinder using the following procedure: 13. Disconnect the MicroLeak test pump hose from the the live-end cylinder port. Connect the quick-disconnect hose from port “B,” on the control cabinet, to the live-end cylinder port (Figure 1.1-12). 14. Activate the joy-stick to position “A” to extend the cylinder rod (Figure 1.1-13). Release the joystick when the cylinder rod is fully extended. 15. Lockout the power supply at the test station at which you are working. 16. Remove the quick-disconnect hose from the port at the live-end of the cylinder. Remove the quick-disconnect hose from the port at the closed-end of the cylinder. (Figure 1.1-14). LAB ACTIVITY 1.1 - WELDED-TYPE CYLINDER Leakage Test with MicroLeak Test System_____________________________________________________ Figure 1.1-13 1-6 Figure 1.1-12 Figure 1.1-14 17. Connect a drain-line hose from one of the drain ports to the live-end of the cylinder. Connect a drain-line hose from the other drain port to the closed-end of the cylin- der (Figure 1.1-15). 18. Remove the pry-bar from the tool rack and slide it into the plate welded to the cylinder rod and into the plate mounted below the cylinder rod (Figure 1.1-16). 19. Apply force to the pry-bar and push the cylinder rod back into the cylinder. Realign the pry-bar and repeat the proce- dure until the cylinder rod stops at the fully retracted position (Figure 1.1-17). 20. Disconnect the hoses from the cylinder. 21. Remove the safety cover and store it on the pegs (Figure 1.1-18). 22. Proceed to LAB ACTIVITY 1.2 where you will learn how to disassemble, inspect, reseal, assemble and then re-test your cylinder. LAB ACTIVITY 1.1 - WELDED-TYPE CYLINDER Leakage Test with MicroLeak Test System_____________________________________________________ 1-7 Figure 1.1-16 Figure 1.1-17 Figure 1.1-18 Figure 1.1-15 1-9 1.2-1 CAUTIONS 1. These instructions and procedures apply only to cylinders with the following part numbers - MF400-RWC and MF400-TRC. Performing these activities with any other cylinder(s) can cause an incident that can lead to severe injury. 2. The cylinders are specifically designed for training. They are equipped with safety handles and mounting plates. Always carry them using the integrated handles. Lock them firmly in a vice with the locking plates (Figure 1.2-1). Figure 1.2-1 PPE required for this activity: • Safety glasses with side shields • Steel-toe boots or approved protective shoe covers • Gloves Seal kit part number: MF400-SK LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ 1-10 1.2-2 TOOLS AND FIXTURES REQUIRED FOR THIS ACTIVITY • Workbench with vice. Jaws of vice must be a least 6” (152mm). Vice must be firmly attached to the workbench with four mounting bolts. • Small oil-drip tray to catch the residual oil in the cylinder. Tool kit required for use with Lab Activity 1.2: Welded-type Cylinder (Figure 1.2-2): • Safety glasses (not supplied) • Medium size mallet (not supplied) • Snap-ring pliers - external (not supplied) • Wrench to remove piston (not supplied) • Picks to remove seals (not supplied) • Small flashlight (not supplied) • Oil catch pan (not supplied) • Oil can (not supplied) • 2” (50mm) open-end wrench (supplied) • Internal seal installation tool (supplied) • Seal kit (supplied) Figure 1.2-2 LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ 1-11 1.2-3 DISASSEMBLY INSTRUCTIONS 1. Remove the cylinder retaining pin in the test fixture of the welded- type cylinder (blue) that you tested and found to be leaking in Activity 1.1. Carry the cylinder to the vice on your workbench. CAUTION: ALWAYS carry the cylinders using the integrated carry handle. The vice used in this activity must be securely attached to a workbench. If it is not secure, and it falls off the table, it could cause severe injury to you and or a colleague. 2. Lower the integrated steel mounting plate into the vice and tighten it securely. Leave approximately 1” (25.4mm) of space between the vice and the cylinder (Figure 1.2-3). 3. Remove the male quick-connect valves from both ends of the hydraulic cylinder. 4. Use the 2” (50mm) open-end wrench and loosen the cylinder gland (Figure 1.2-4). Put the oil catch pan under the cylinder gland and slowly screw it out. 5. Hold the cylinder rod firmly and pull it out of the cylinder tube (Figure 1.2-5). It may be necessary to tap the edge of the cylin- der rod retaining plate to extract the cyl- inder rod from the cylinder. Hold the oil- drip tray below the cylinder gland to catch residual oil from the cylinder. Place the cylinder rod and gland assembly on the workbench. 6. Use a lint-free cloth and wipe the residual oil out of the cylinder tube. Figure 1.2-5 Figure 1.2-3 Figure 1.2-4 LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ 1-12 7. Remove the cylinder tube from the vice and place it on the workbench. 8. The cylinder rod is equipped with an integrated plate to hold it securely in the vice (Figure 1.2-6). Place the plate in the vice and tighten it securely. 9. Remove all of the seals from the cylinder piston (Figure 1.2-7). 10. Use the snap-ring pliers and remove the snap-ring from the end of the cylinder rod (Figure 1.2-8). 11. The piston is attached to the cylinder rod with threads. Use the spanner wrench and loosen the cylinder piston. Remove the cylinder piston from the cylinder rod and place it on the workbench (Figure 1.2-9). Figure 1.2-9 LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ Figure 1.2-7 Figure 1.2-8 Figure 1.2-6 12. Use a pick and remove the small O-ring from the cylinder rod (Figure 1.2-10). 13. Slide the cylinder gland off the cylinder rod and place it on the workbench. 14. Hold onto the cylinder rod and loosen the vice. Place the cylinder rod on the work- bench. 15. Place the cylinder gland in the vice and secure it. Do not overtighten the vice (Figure 1.2-11). 16. Use a pick and remove the wiper seal and fiber wear band. 17. Loosen the vice and turn the cylinder gland around 180º and secure it. Do not overtighten the vice (Figure 1.2-12). 18. Use the pick and remove the fiber wear band, cylinder rod seal, and external O-ring. 19. Hold onto the cylinder gland and loosen the vice. Place the cylinder gland on the workbench. 1-13 Figure 1.2-10 Figure 1.2-11 Figure 1.2-12 LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ 1.2-4 CLEANING AND INSPECTING THE COMPONENTS • Cylinder Tube: 1. Clean inside the cylinder tube with a biodegradable agent. 2. Inspect the outside surfaces of the cylinder tube for damage. You are looking for cracks, dents, and corrosion. 3. Inspect the inside surfaces of the cylinder tube for wear and or damage. You are looking for damage caused by contamination, misalignment, corrosion, and “ballooning” due to excessive pressure. Write your assessment of the cylinder tube’s condition here: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ • Cylinder Rod: 1. Clean the cylinder rod. 2. Inspect the cylinder rod. You are looking for surface damage caused by surface strikes due to the application, surface damage due to misalign- ment, gouging, and rod alignment. If the cylinder rod is equipped with a mounting clevis or eye, inspect it for wear. If it is equipped with bushings inspect the bushings for wear. Write your assessment of the cylinder rod’s condition here: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ 1-14 LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ 1-15 • Cylinder Rod Piston: 1. Clean the cylinder rod piston. 2. Inspect the piston. On the outside surfaces of the cylinder rod piston you are looking for wear caused by contamination, corrosion, and misalignment. Inspect the seal grooves, and threads. Write your assessment of the cylinder rod piston’s condition here: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ • Cylinder Gland: 1. Clean the cylinder gland. 2. Inspect the cylinder gland. Inspect the inside surfaces for wear due to contamination, misalignment and corrosion. Inspect the threads. Write your assessment of the cylinder gland’s condition here: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ 1-16 1.2-5 ASSEMBLE SUB-ASSEMBLIES • Assemble the Cylinder Gland 1. Secure the cylinder gland in the vice. 2. Use the oil can and squirt oil into the cylinder gland grooves. 3. Remove the cylinder rod seal from the kit. Lubricate the seal. Make sure the cylinder rod seal is facing the correct direction. Use the seal installation tool and install the cylinder rod seal in its groove (Figure 1.2-13). 4. Install the wear band. The wear band is fabricated out of a fiber. Consequently, it breaks very easily. Squeeze it just enough to slide it into its groove (Figure 1.2-14). 5. Install the O-ring (Figure 1.2-15). LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ Figure 1.2-13 Figure 1.2-14 Figure 1.2-15 1-17 7. Remove the cylinder gland from the vice, rotate it 180º and again, secure it in the vice and install the second wear band (Figure 1.2-16). 8. Use the seal installation tool and install the wiper seal (Figure 1.2-17). 9. Remove the cylinder gland and place it on the workbench. • Assemble the Cylinder Rod: 1. Fasten the cylinder rod in the vice and install the small O-ring into the O-ring groove on the cylinder rod. 2. Lubricate the cylinder rod and the inside of the cylinder gland with oil (Figure 1.2-18). Slide the cylinder gland onto the cylinder rod, make sure it is correctly aligned. If necessary, tap the cylinder gland gently with the mallet. LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ Figure 1.2-18 Figure 1.2-17 Figure 1.2-16 1-18 3. Screw the cylinder piston onto the cylin- der rod and use the spanner wrench to tighten it (Figure 1.2-19). 4. Use the snap-ring pliers and install the snap-ring on the end of the cylinder rod. 5. Slide the thin nylon seals (white) into the seal groove. Be careful not to stretch them (Figure 1.2-20). 6. Install the rubber seal (black) in the groove. 7. Carefully slide the white nylon seals onto the grooves on either side of the rubber seal. Be careful not to stretch them (Figure 1.2-21). LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ Figure 1.2-21 Figure 1.2-20 Figure 1.2-19 1-19 LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ 8. Install the first of the two nylon (blue) wear bands. The wear bands are very flexible (Figure 1.2-22). 9. Pull the wear band apart and slide it over the cylinder rod. Now slide it into position on the piston. 10. Install the second wear band (Figure 1.2-23). 11. Lubricate the seals. 12. Remove the cylinder rod from the vice. Figure 1.2-23 Figure 1.2-22 1-20 1.2-6 Assemble the Cylinder 1. Fasten the cylinder barrel in the vice. Tighten it securely (Figure 1.2-24). 2. Lubricate the inside surfaces of the cylin- der barrel. 3. Slide the cylinder piston into the cylin- der tube (Figure 1.2-25). Make sure it’s correctly aligned. Push it, while at the same time moving it side to side, and up and down. If necessary, tap the end of the cylinder rod with a mallet. 4. Slide the cylinder rod into the cylinder barrel and thread the cylinder gland into the cylinder barrel (Figure 1.2-26). Tighten it with the 2” (50mm) wrench. 5. Install the two male quick-connect valves and tighten them securely. 6. Proceed to LAB ACTIVITY 1.3 to re-test your rebuilt cylinder. Figure 1.2-25 Figure 1.2-26 LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ Figure 1.2-24 1-21 1. Remove from the vice, the welded-type cylinder (blue) which you have just finished rebuilding. Slide the cylinder welded plate into the test fixture on your test station. Install the locking pin (Figure 1.3-1). 2. Install the transparent safety shield (Figure 1.3-2). CAUTION: If you do not install the transpar- ent safety shield and the cylinder leaks, you could be sprayed with hydraulic oil. NOTE: After repairing a hydraulic cylinder, or when placing a cylinder in a test station from the storage rack, it will be neces- sary to first refill it with oil and purge the air from that cylinder. 3. Connect the hose from port “A,” on the control cabinet, to the closed-end of the cylinder. Connect the hose from port “B,” on the control cabinet, to the live-end of the cylinder (Figure 1.3-3). Figure 1.3-2 Figure 1.3-3 Figure 1.3-1 LAB ACTIVITY 1.3 - WELDED-TYPE CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ 4. Connect the MicroLeak air-bleed hose assembly to the red-capped, Safe-T-Bleed valves on the cylinder (Figure 1.3-4). Rotate the knobs until they are fully engaged on the valves. Tighten them by hand only. 5. Start the power unit (Figure 1.3-5). 6. Activate the joy-stick to position “A” (Figure 1.3-6) and hold position until the cylinder rod is fully extended. Continue to hold the joystick in position “A” for approximately 1-minute. This will purge air from the cylinder. 7. Activate the joystick to position “B” (Figure 1.3-7) and hold position of the joy- stick until the cylinder rod is fully retracted. Continue to hold the joystick in position “B” for approximately 1-minute. This will purge air from the cylinder. LAB ACTIVITY 1.3 - WELDED-TYPE CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ Figure 1.3-7 Figure 1.3-6 Figure 1.3-5 1-22 Figure 1.3-4 8. Remove the MicroLeak air-bleed hose assembly and replace the red caps on the Safe-T-Bleed valves (Figure 1.3-8). 9. Operate the joystick valve to position “A” and fully extend the cylinder rod (Figure 1.3-9). 10. Now, operate the joystick to position “B” and fully retract the cylinder rod. Hold position of the joystick and inspect for leakage at the cylinder rod seal and cylin- der gland (Figure 1.3-10). If there are no signs of oil leakage, pro- ceed to Step 11. If there are signs of oil leakage, stop and report the problem to your instructor for further instructions. 11. Turn off the power unit (Figure 1.3-11). LAB ACTIVITY 1.3 - WELDED-TYPE CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ Figure 1.3-10 1-23 Figure 1.3-8 Figure 1.3-9 Figure 1.3-11 Figure 1.3-12 12. Remove the quick-disconnect hose from the port at the live-end of the cylinder. Connect the MicroLeak test pump hose to the quick-connect fitting on the port at the live-end of the cylinder (Figure 1.3-12). 13. Operate the MicroLeak test pump (Figure 1.3-13). If the cylinder seals are in good condition, the pressure will begin to increase. Stop when the pressure reaches 1000 PSI (69 bar). If the pressure fails to increase, the seal is leaking. If there are no signs of oil leakage, pro- ceed to Step 14. If there are signs of oil leakage, stop and report the problem to your instructor for further instructions. 14. Disconnect the MicroLeak test pump hose from the the live-end of the cylinder. Connect the quick-disconnect hose from port “B,” on the control cabinet, to the live-end of the cylinder (Figure 1.3-14). LAB ACTIVITY 1.3 - WELDED-TYPE CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ 1-24 Figure 1.3-13 Figure 1.3-14 15. Start the power unit and activate the joy-stick to position “A” to extend the cylinder rod (Figure 1.3-15). Release the joystick when the cylinder rod is fully extended. 16. Lockout the power supply at the test station at which you are working. 17. Remove the quick-disconnect hose from the port at the closed-end of the cylinder. Connect the MicroLeak test pump hose to the quick-connect fitting on the closed- end of the cylinder (Figure 1.3-16). 18. Operate the MicroLeak test pump (Figure 1.3-17). If the cylinder seals are in good condition, the pressure will begin to increase. Stop when the pressure reaches 1000 PSI (69 bar). If the pressure fails to increase, the seal is leaking. If there are no signs of oil leakage, pro- ceed to Step 18. If there are signs of oil leakage, stop and report the problem to your instructor for further instructions. LAB ACTIVITY 1.3 - WELDED-TYPE CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ 1-25 Figure 1.3-16 Figure 1.3-15 Figure 1.3-17 Figure 1.3-19 1-26 18. Disconnect the MicroLeak test pump hose from the port at the closed-end of the cylinder. Disconnect the hose from the live-end of the cylinder (Figure 1.3-18). 19. The following steps should be followed to remove the majority of the oil from a cylinder prior to storing it in the rack. 20. Connect a drain-line hose from one of the drain ports to the live-end of the cylinder. Connect a drain-line hose from the other drain port to the closed-end of the cylin- der (Figure 1.3-19). 21. Remove the pry-bar from the tool rack and slide it into the plate welded to the cylinder rod and into the plate mounted below the cylinder rod (Figure 1.3-20). 22. Apply force to the pry-bar and push the cylinder rod back into the cylinder. Realign the pry-bar and repeat the proce- dure until the cylinder rod stops at the fully retracted position (Figure 1.3-21). LAB ACTIVITY 1.3 - WELDED-TYPE CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ Figure 1.3-18 Figure 1.3-21 Figure 1.3-22 1-27 LAB ACTIVITY 1.3 - WELDED-TYPE CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ Figure 1.3-23 Figure 1.3-22 23. Disconnect the hoses from the cylinder. 24. Remove the safety cover and store it on the pegs (Figure 1.3-22). 25. Remove the cylinder retaining pin. 26. Remove the cylinder from the test fixture and place it in the storage rack (Figure 1.3-23). 2-1 Lab Activity 2 TIE-ROD CYLINDER LEAKAGE TEST with MICROLEAK TEST SYSTEM 1. Remove a tie-rod cylinder (red) from the storage rack and slide the cylinder welded plate into the test fixture and install the locking pin (Figure 2.1-1). 2. Install the transparent safety shield (Figure 2.1-2). CAUTION: If you do not install the transpar- ent safety shield and the cylinder leaks, you could be sprayed with hydraulic oil. NOTE: After repairing a hydraulic cylinder, or when placing a cylinder in a test station from the storage rack, it will be neces- sary to first refill it with oil and purge the air from that cylinder. 3. Connect the hose from port “A,” on the control cabinet, to the closed- end of the cylinder. Connect the hose from port “B,” on the control cabinet, to the live-end of the cylinder (Figure 2.1-3). Figure 2.1-1 Figure 2.1-2 Figure 2.1-3 2-3 LAB ACTIVITY 2.1 - TIE-ROD CYLINDER Leakage Test with MicroLeak Test System_____________________________________________________ 4. Connect the MicroLeak air-bleed hose assembly to the red-capped, Safe-T-Bleed valves on the cylinder (Figure 2.1-4). Rotate the knobs until they are fully engaged on the valves. Tighten them by hand only. 5. Start the power unit (Figure 2.1-5). NOTE: It is safe to connect the oil transmis- sion lines to the cylinder ports while the power unit is running. 6. Activate the joy-stick to position “A” (Figure 2.1-6) and hold position until the cylinder rod is fully extended. Continue to hold the joystick in position “A” for approximately 1-minute. This will purge air from the cylinder. 7. Activate the joystick to position “B” (Figure 2.1-7) and hold position of the joystick until the cylinder rod is fully retracted. Continue to hold the joystick in position “B” for approximately 1-minute. This will purge air from the cylinder. LAB ACTIVITY 2.1 - TIE-ROD CYLINDER Leakage Test with MicroLeak Test System_____________________________________________________ 2-4 Figure 2.1-5 Figure 2.1-7 Figure 2.1-6 Figure 2.1-4 8. Remove the MicroLeak air-bleed hose assembly and replace the red caps on the Safe-T-Bleed valves (Figure 2.1-8). 9. While the button is depressed, fully extend then fully retract the cylinder rod by operating the joystick to position “A” and then to position “B” (Figure 2.1-9). 10. Perform a cylinder seal, bypass test. 11. Remove the quick-disconnect hose from the port at the live-end of the cylinder. Connect the MicroLeak test pump hose to the quick-connect fitting on the port at the live-end of the cylinder (Figure 2.1-10). 12. Operate the MicroLeak test pump (Figure 2.1-11). If the cylinder piston seals are in good condition, the pressure will begin to increase. Stop when the pressure reaches 1000 PSI (69 bar). If the pressure fails to increase, there is leakage across the cylinder piston seals. Figure 2.1-8 LAB ACTIVITY 2.1 - TIE-ROD CYLINDER Leakage Test with MicroLeak Test System_____________________________________________________ 2-5 Figure 2.1-9 Figure 2.1-10 Figure 2.1-11 NOTE: Before removing the cylinder from the test station, to conduct Lab Activity 2.2, drain the oil from the cylinder using the following procedure: 13. Disconnect the MicroLeak test pump hose from the live-end cylinder port. Connect the quick-disconnect hose from port “B,” on the control cabinet, to the live-end cylinder port (Figure 2.1-13). 14. Activate the joy-stick to position “A” to extend the cylinder rod (Figure 2.1-13). Release the joystick when the cylinder rod is fully extended. 15. Lockout the power supply at the test station at which you are working. 16. Remove the quick-disconnect hose from the port at the live-end of the cylinder. Remove the quick-disconnect hose from the port at the closed-end of the cylinder. (Figure 2.1-14). 17. Connect a drain-line hose from one of the drain ports to the live-end of the cylinder. LAB ACTIVITY 2.1 - TIE-ROD CYLINDER Leakage Test with MicroLeak Test System_____________________________________________________ 2-6 Figure 2.1-13 Figure 2.1-12 Figure 2.1-14 Connect a drain-line hose from the other drain port to the closed-end of the cylin- der (Figure 2.1-16). 18. Remove the pry-bar from the tool rack and slide it into the plate welded to the cylinder rod and into the plate mounted below the cylinder rod (Figure 2.1-17). 19. Apply force to the pry-bar and push the cylinder rod back into the cylinder. Realign the pry-bar and repeat the proce- dure until the cylinder rod stops at the fully retracted position (Figure 2.1-18). 20. Disconnect the hoses from the cylinder. 21. Remove the safety cover and store it on the pegs (Figure 2.1-19). 22. Proceed to LAB ACTIVITY 2.2 where you will learn how to disassemble, inspect, reseal, assemble and then re-test your cylinder. LAB ACTIVITY 2.1 - TIE-ROD CYLINDER Leakage Test with MicroLeak Test System_____________________________________________________ 2-7 Figure 2.1-16 Figure 2.1-18 Figure 2.1-17 Figure 2.1-19 2-9 2.2-1 CAUTIONS 1. These instructions and procedures apply only to cylinders with the following part numbers - MF400-RWC and MF400-TRC. Performing these activities with any other cylinder(s) can cause an incident that can lead to severe injury. 2. The cylinders are specifically designed for training. They are equipped with safety handles and mounting plates. Always carry them using the integrated handles. Lock them firmly in a vice with the mounting plates (Figure 2.2-1). Figure 2.2-1 PPE required for this activity: • Safety glasses with side shields • Steel-toe boots or approved protective shoe covers • Gloves Seal kit part number: MF400-SK LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ 2-10 2.2-2 TOOLS AND FIXTURES REQUIRED FOR THIS ACTIVITY • Workbench with vice. Jaws of vice must be a least 6” (152mm). Vice must be firmly attached to the workbench with four mounting bolts. • Small oil-drip tray to catch the residual oil in the cylinder. Tool kit required for use with Activity 2.2: Tie-Rod Cylinder (Figure 2.2-2): • Safety glasses (not supplied) • Large adjustable wrench (not supplied) • Two (2) 9/16” wrenches (not supplied) • Wrench to remove piston (not supplied) • Snap-ring pliers - external (not supplied) • Small flashlight (not supplied) • Picks to remove seals (not supplied) • Medium size mallet (not supplied) • Torque wrench (not supplied) • Oil catch pan (not supplied) • Oil can (not supplied) • Internal seal installation tool (supplied) • Female quick-connect air-release valve (supplied) • Seal kit (supplied) Figure 2.2-2 LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ 2.2-3 INSTRUCTIONS 1. Remove the cylinder retaining pin in the test fixture of the tie-rod cylinder (red) that you tested and found to be leaking in Activity 2.1. Carry the cylinder to the vice on your workbench. CAUTION: ALWAYS carry the cylinders using the integrated carry handle. The vice used in this activity must be securely attached to a workbench. If it is not secure, and it falls off the table, it could cause severe injury to you and or a colleague. 2. Lower the integrated steel mounting plate into the vice and tighten it securely. Leave approximately 1” (25.4mm) of space be- tween the vice and the cylinder (Figure 2.2-3). 3. To release trapped air, place the female quick-connect air-release valve on the male quick-connect valve on the closed- end of the hydraulic cylinder (Figure 2.2-4). 4. Use two (2) 9/16” wrenches and remove the four (4) tie-rod retaining bolts (Figure 2.2-5). NOTE: Use a diagonal pattern to loosen the tie-rod bolts (See Figure 2.2-6). 2-11 Figure 2.2-5 LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ Figure 2.2-3 Figure 2.2-4 Figure 2.2-7 Figure 2.2-8 Figure 2.2-6 5. Place an oil-drip tray below the closed- end of the cylinder. Hold the end-cap with one hand. Use a mallet and gently strike the end-cap. Place it on the workbench (Figure 2.2-7). 6. Place the oil-drip tray underneath the cap at the rod-end of the cylinder. Use a mal- let and gently strike the end-cap. Hold firmly on to the cylinder rod and pull it out of the cylinder tube. Place the cylin- der rod and gland assembly on the work- bench (Figure 2.2-8). 7. Use a lint-free cloth and wipe the residual oil out of the cylinder tube. 8. Remove the cylinder tube from the vice and place it on the workbench. 2-12 LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ Figure 2.2-9 9. The cylinder rod is equipped with an integrated plate to hold it securely in the vice. Place the plate in the vice and tight- en it securely (Figure 2.2-9). 10. Use the snap-ring pliers and remove the snap-ring from the end of the cylinder rod (Figure 2.2-10). 11. The cylinder piston is attached to the cylin- der rod with threads. Use the spanner wrench and loosen the cylinder piston (Figure 2.2-11). 12. Remove the seals from the cylinder piston and remove it from the cylinder rod and place the cylinder piston on the work- bench. 13. Use a pick and remove the small O-ring from the threaded end of the cylinder rod (Figure 2.2-12). 2-13 LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ Figure 2.2-10 Figure 2.2-11 Figure 2.2-12 Figure 2.2-14 Figure 2.2-13 14. Slide the cylinder gland off the cylinder rod and place it on the workbench (Figure 2.2-13). 15. Hold onto the cylinder rod and loosen the vice. Place the cylinder rod on the work- bench. 16. Place the cylinder gland in the vice and secure it. Do not overtighten it. 17. Use a pick and remove the external O-ring, fiber wear band, rod seal, and wiper seal (Figure 2.2-14). 18. Hold onto the cylinder gland and loosen the vice. Place the cylinder gland on the workbench. 2-14 LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ 2.2-4 CLEANING AND INSPECTING THE COMPONENTS • Cylinder Tube: 1. Clean the cylinder tube with a biodegradable agent. 2. Inspect the outside surfaces of the cylinder tube for damage. You are looking for cracks, dents, and corrosion. 3. Inspect the inside surfaces of the cylinder tube for wear and or dam- age. You are looking for damage caused by contamination, misalign- ment, corrosion, and “ballooning” due to excessive pressure. Write your assessment of the cylinder tube’s condition here: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ • Cylinder Rod: 1. Clean the cylinder rod. 2. Inspect the cylinder rod. You are looking for surface damage caused by surface strikes due to the application, surface damage due to misalign- ment, gouging, and cylinder rod alignment. If the cylinder rod is equipped with a mounting clevis or eye inspect it for wear. If it is equipped with bushings inspect the bushings for wear. Write your assessment of the cylinder rod’s condition here: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ 2-15 LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ • Cylinder Piston 1. Clean the cylinder piston. 2. Inspect the cylinder piston. On the outside surfaces of the cylinder piston you are looking for wear caused by contamination, corrosion, and misalignment. Inspect the seal grooves, and threads. Write your assessment of the cylinder piston’s condition here: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ • Cylinder Gland 1. Clean the cylinder gland. 2. Inspect the cylinder gland. Inspect the inside surfaces for wear due to contamination, misalignment and corrosion. Inspect the threads. Write your assessment of the cylinder gland’s condition here: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ 2-16 LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ 2-17 2.2-5 ASSEMBLE SUB-ASSEMBLIES • Assemble the Cylinder Gland 1. Secure the cylinder gland in the vice. 2. Use the oil can and squirt oil into the cyl- inder gland grooves. 3. Remove the wear band from the seal kit. The wear band is fabricated out of a fiber. Consequently, it breaks very easily. Lubricate it first then squeeze it just enough to slide it into its groove (Figure 2.2-15). 4. Remove the cylinder rod seal from the kit. Lubricate the seal. Make sure the cyl- inder rod seal is facing the correct direc- tion. Use the seal installation tool and install the cylinder rod seal in its groove (Figure 2.2-16). 5. Remove the second wear band from the seal kit. Remember, the wear band is fab- ricated out of a fiber and can break very easily. Lubricate it first then squeeze it just enough to slide it into its groove (Figure 2.2-17). LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ Figure 2.2-15 Figure 2.2-16 Figure 2.2-17 2-18 6. Install the O-ring (Figure 2.2-18). 7. Remove the cylinder gland, rotate it 180º and secure it in the vice. 8. Use the seal installation tool and install the wiper seal (Figure 2.2-19). 9. Remove the cylinder gland and place it on the workbench. • Assemble the Cylinder Rod 1. Fasten the cylinder rod in the vice 2. Lubricate the cylinder rod. 3. Install the small O-ring into the O-ring groove on the threaded end of the cylin- der rod (Figure 2.2-20). 4. Slide the cylinder gland cap-end onto the cylinder rod (Figure 2.2-21). Make sure it is correctly aligned. 5. Now, slide the cylinder gland onto the cylinder rod (Figure 2.2-21). If necessary, tap it gently with the mallet. LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ Figure 2.2-19 Figure 2.2-20 Figure 2.2-21 Figure 2.2-18 2-19 6. Screw the cylinder piston onto the cylin- der rod and use the spanner wrench to tighten it (Figure 2.2-22). 7. Use the snap-ring pliers and install the snap-ring to the end of the cylinder rod (Figure 2.2-23). 8. Slide the thin nylon seals (white) into the seal groove on the cylinder piston. Be careful not to stretch them (Figure 2.2-24). 9. Install the rubber seal (black) into the center groove on the cylinder piston (Figure 2.2-25). LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ Figure 2.2-22 Figure 2.2-23 Figure 2.2-24 Figure 2.2-25 2-20 10. Carefully slide the white nylon seals onto the grooves on either side of the black rubber seal. Be careful not to stretch them. (Figure 2.2-26). 11. Install the first of the two nylon (blue) wear bands. The wear bands are very flex- ible. 12. Pull the wear band apart and slide it over the cylinder rod. Now slide it into position on the cylinder piston (Figure 2.2-27). 13. Install the second blue nylon wear band (Figure 2.2-28). 14. Lubricate the seals. 15. Remove the cylinder rod from the vice. LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ Figure 2.2-26 Figure 2.2-28 Figure 2.2-27 2-21 2.2-6 Assemble the Cylinder 1. Fasten the cylinder tube in the vice. Tight- en it securely (Figure 2.2-29). 2. Lubricate the inside surfaces of the cylin- der tube. 3. Before installing the cylinder rod and piston assembly into the cylinder tube, (Figure 2.2-30) read the instructions below. Slide the cylinder rod and piston assembly into the cylinder tube. Make sure it’s cor- rectly aligned (see NOTE: below). Push it in while at the same time moving it side to side and up and down. If necessary, tap the end of the cylinder rod with a mallet. NOTE: Although the end-caps can be installed in either end of the cylinder tube the cylinder mounting plate has a hole in it that must be correctly aligned in closer proximity to the live-end than the closed- end of the cylinder (Figure 2.2-31). Figure 2.2-31 LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ Figure 2.2-30 Figure 2.2-29 2-22 4. Install the O-ring on the cap-end cover (Figure 2.2-32). 5. Install the closed-end end-cap (Figure 2.2-33). 6. Install the four (4) tie-rod bolts. Install the flat washers and screw the nuts onto the threads. Use two (2) 9/16” wrenches and tighten the bolts until they are snug (Figure 2.2-34). NOTE: The end-caps must be aligned before the bolts are tightened to the specified torque. To align the end-caps, remove the cylinder from the vice and place it on a flat surface (Figure 2.2-35). Apply a downward force to both end- caps. The end-caps are aligned when they do NOT rock when a force is applied to the opposing corners. LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ Figure 2.2-32 Figure 2.2-33 Figure 2.2-34 Figure 2.2-35 2-23 LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ 7. Put the cylinder back into the vice and tighten securely. 8. The specified torque for the four (4) nuts is 35-feet pounds/40 Newton meters). The nuts must be torqued in stages until the correct torque is achieved. See STEP 9. for directions. 9. Using a torque wrench (Figure 2.2-36), tighten the bolts using the diagonal pat- tern and torque specifications shown below. NOTE: Use a diagonal pattern to tighten the tie-rod bolts (See Figure 2.2-37). Figure 2.2-37 Here are the torques for each tightening stage: Stage 1 - 10-feet pounds/13.5 Newton meters. Stage 2 - 20-feet pounds/27 Newton meters. Stage 3 - 35-feet pounds/47 Newton meters. 10. Proceed to LAB ACTIVITY 2.3 to re-test your rebuilt cylinder. Figure 2.2-36 1. Remove from the vice, the tie-rod cylinder (red) which you have just finished rebuild- ing. Slide the cylinder welded plate into the test fixture on your test station. Install the locking pin (Figure 2.3-1). 2. Install the transparent safety shield (Figure 2.3-2). CAUTION: If you do not install the transpar- ent safety shield and the cylinder leaks, you could be sprayed with hydraulic oil. NOTE: After repairing a hydraulic cylinder, or when placing a cylinder in a test station from the storage rack, it will be neces- sary to first refill it with oil and purge the air from that cylinder. 3. Connect the hose from port “A,” on the control cabinet, to the closed- end of the cylinder. Connect the hose from port “B,” on the control cabinet, to the live-end of the cylinder (Figure 2.3-3). Figure 2.3-1 Figure 2.3-2 Figure 2.3-3 2-24 LAB ACTIVITY 2.3 - TIE-ROD CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ 4. Connect the MicroLeak air-bleed hose assembly to the red-capped, Safe-T-Bleed valves on the cylinder (Figure 2.3-4). Rotate the knobs until they are fully engaged on the valves. Tighten them by hand only. 5. Start the power unit (Figure 2.3-5). 6. Activate the joy-stick to position “A” (Figure 2.3-6) and hold position until the cylinder rod is fully extended. Continue to hold the joystick in position “A” for approximately 1-minute. This will purge air from the cylinder. 7. Activate the joystick to position “B” (Figure 2.3-7) and hold position of the joystick until the cylinder rod is fully retracted. Continue to hold the joystick in position “B” for approximately 1-minute. This will purge air from the cylinder. Figure 2.3-4 LAB ACTIVITY 2.3 - TIE-ROD CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ 2-25 Figure 2.3-5 Figure 2.3-7 Figure 2.3-6 8. Remove the MicroLeak air-bleed hose assembly and replace the red caps on the Safe-T-Bleed valves (Figure 2.3-8). 9. Operate the joystick valve to position “A” and fully extend the cylinder rod. Hold position of the joystick and inspect for leakage at the closed-end cylinder gland (Figure 2.3-9). 10. Now, operate the joystick to position “B” and fully retract the cylinder rod. Hold position of the joystick and inspect for leakage at the cylinder rod seal and live- end cylinder gland (Figure 2.3-10). 11. Turn off the power unit (Figure 2.3-11). LAB ACTIVITY 2.3 - TIE-ROD CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ 2-26 Figure 2.3-10 Figure 2.3-9 Figure 2.3-11 Figure 2.3-8 Figure 2.3-12 12. Remove the quick-disconnect hose from the port at the live-end of the cylinder. Connect the MicroLeak test pump hose to the quick-connect fitting on the port at the live-end of the cylinder (Figure 2.3-12). 13. Operate the MicroLeak test pump (Figure 2.3-13). If the cylinder seals are in good condition, the pressure will begin to increase. Stop when the pressure reaches 1000 PSI (69 bar). If the pressure fails to increase, the seal is leaking. If there are no signs of oil leakage, pro- ceed to Step 14. If there are signs of oil leakage, stop and report the problem to your instructor for further instructions. 14. Disconnect the MicroLeak test pump hose from the live-end port of the cylinder. Connect the quick-disconnect hose from port “B, “ on the control cabinet, to the live-end port of the cylinder (Figure 2.3-14). LAB ACTIVITY 2.3 - TIE-ROD CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ 2-27 Figure 2.3-13 Figure 2.3-14 15. Start the power unit and activate the joy- stick to position “A” to extend the cylinder rod (Figure 2.3-15). Release the joystick when the cylinder rod is fully extended. 16. Remove the quick-disconnect hose from the port at the closed-end of the cylinder. Connect the MicroLeak test pump hose to the quick-connect fitting on the port at the closed-end of the cylinder (Figure 2.3-16). 17. Operate the MicroLeak test pump (Figure 2.3-17). If the cylinder seals are in good condition, the pressure will begin to increase. Stop when the pressure reaches 1000 PSI (69 bar). If the pressure fails to increase, the seal is leaking. If there are no signs of oil leakage, pro- ceed to Step 18. If there are signs of oil leakage, stop and report the problem to your instructor for further instructions. NOTE: Before removing the cylinder from the test station, drain the oil from the cylinder using the following procedure: LAB ACTIVITY 2.3 - TIE-ROD CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ 2-28 Figure 2.3-17 Figure 2.3-16 Figure 2.3-15 18. Lockout the power supply at the test station at which you are working. 20. Connect a drain-line hose from one of the drain ports to the live-end of the cylinder. Connect a drain-line hose from the other drain port to the closed-end of the cylin- der (Figure 2.3-20). 21. Remove the pry-bar from the tool rack and slide it into the plate welded to the cylinder rod and into the plate mounted below the cylinder rod (Figure 2.3-21). 22. Apply force to the pry-bar and push the cylinder rod back into the cylinder. Realign the pry-bar and repeat the pro- cedure until the cylinder rod is fully retracted (Figure 2.3-22). 23. Disconnect the hoses from the cylinder. 25. Remove the safety cover and store it on the pegs (Figure 2.3-23). 26. Remove the cylinder retaining pin. 2-29 LAB ACTIVITY 2.3 - TIE-ROD CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ Figure 2.3-20 Figure 2.3-21 Figure 2.3-22 Figure 2.3-23 2-30 LAB ACTIVITY 2.3 - TIE-ROD CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ 27. Remove the cylinder and place it in the storage rack (Figure 2.3-24). Figure 2.3-24
