C 47150 - 3 en 0205 / JKn

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HYDRAULIC CYLINDERS

REPAIR AND ADJUSTMENT

CONTENTS
1.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1. Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2
2

2.

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.

OVERCENTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3
3

4.

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.

DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1. Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2. Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4. Replacing of bearings bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5
5
5
5
5

6.

ASSEMBLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1. Assembling of cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6
6

7.

TESTING OF CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1. Line A, inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2. Line B, inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8
8
8

E 2005 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120

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C 47150 - 3 en 0205 / JKn

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 Tamrock

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

E 2005 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120

C 47150 - 3 en 0205 / JKn

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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 booms 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.

CAUTION

The set value of the overcenter valves for different purposes are
different. Therefore, you must replace an overcenter valve with one from
a other cylinder. the set value of the valve is punched on the top of the
valve.

E 2005 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120

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C 47150 - 3 en 0205 / JKn

HYDRAULIC CYLINDERS

4.

COMPONENTS
2

10

10

Components of a 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

10

Components of a cylinder (threaded cylinder cover)

E 2005 SANDVIK TAMROCK CORP., Tampere Plant,
P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120

C 47150 - 3 en 0205 / JKn

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HYDRAULIC CYLINDERS

5.

DISMANTLING

Before starting to remove the cylinder, make sure that the boom is properly supported, and
any 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 before starting to dismantle it. Mount the cylinder firmly at the
lug in the cylinder tube end.

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.

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, should the components 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.

E 2005 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120

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C 47150 - 3 en 0205 / JKn

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

Grease the seal grooves and install the

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
installing the piston.

11

10

Grease the seal grooves and install the

piston seal (10). When installing the
pistons O--ring (11), be careful not to
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
groove.

The piston rod and the cover assembly

E 2005 SANDVIK TAMROCK CORP., Tampere Plant,
P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120

C 47150 - 3 en 0205 / JKn

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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

A assembled cylinder

E 2005 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120

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C 47150 - 3 en 0205 / JKn

HYDRAULIC CYLINDERS

7.

TESTING OF CYLINDER
11
10

12

14

13

B
A

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.

E 2005 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120