Original instructions

371 3 en 2010-12-14

HYDRAULIC CYLINDERS
Repair and adjustment
Table of Contents

1. GENERAL ...................................................................................................................................... 5

2. SAFETY ......................................................................................................................................... 6

3. OVERCENTER VALVE .................................................................................................................. 7

4. COMPONENTS .............................................................................................................................. 8

5. DISMANTLING ............................................................................................................................... 9
5.1. Cylinder ............................................................................................................................................................... 9
5.2. Piston ................................................................................................................................................................... 9
5.3. Inspection ........................................................................................................................................................... 9
5.4. Replacing of bearing bushings ..................................................................................................................... 9

6. ASSEMBLING ................................................................................................................................ 10

7. TESTING OF CYLINDER ............................................................................................................... 14

7.1. Line A, inspection ............................................................................................................................................. 14
7.2. Line B, inspection ............................................................................................................................................. 14

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ID: 371 3 en 2010-12-14
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ID: 371 3 en 2010-12-14
 HYDRAULIC CYLINDERS
Repair and adjustment

1. GENERAL

The main structural differences between hydraulic cylinders are:

• single and double acting
• cylinder bore
• stroke
• 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.

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ID: 371 3 en 2010-12-14
HYDRAULIC CYLINDERS
Repair and adjustment

2. SAFETY

Installation, adjustment and repair work can only be carried out

by a person who has the necessary qualifications and knows
the equipment.

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

Never disconnect any hydraulic hoses or valves beforemaking

sure that there is no static load in the system.

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.

Follow the installation instructions issued by Sandvik.

Use all necessary safety devices and check their condition.

Proper use and service guarantee longer life of the hydraulic

cylinder.

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 HYDRAULIC CYLINDERS
Repair and adjustment

3. OVERCENTER VALVE

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. 1

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 the valve.

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ID: 371 3 en 2010-12-14
HYDRAULIC CYLINDERS
Repair and adjustment

4. COMPONENTS

10
1
2
9
8
5
3
4 6
7

10

Figure: Components of a typical cylinder

10

2
9
8
5
3
4 6
7

10

Figure: Components of a typical cylinder (threaded cylinder cover)

1 Socket screw 2 Cylinder cover

3 Piston 4 Overcenter valves
5 Cylinder tubes 6 Locking plate
7 Rod nut 8 Piston rod
9 Spacer 10 Bearing bushing

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 HYDRAULIC CYLINDERS
Repair and adjustment

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.

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 bearing bushings

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.

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ID: 371 3 en 2010-12-14
HYDRAULIC CYLINDERS
Repair and adjustment

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.

Grease the seal grooves and install the O-rings,

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

Figure: Cylinder parts

2 Piston rod
4 Piston
5 Locking nut
6 Locking ring
According to drawing "Cylinder parts", loctite 243 (SMC LT1) should be use in threads between piston
rod - piston. Use Loctite 243 by adding it few drops on the beginning of the several threads.

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 HYDRAULIC CYLINDERS
Repair and adjustment

Threads [mm] Torques [Nm]

16-17 140
18-29 250
30-> 500

Table: Tightening torques for piston and cylinder cover

Grease the seal grooves and install the piston

seal (10). When installing the piston’s O-ring (11), 6
be careful not to damage it in the piston rod
thread. When installing the piston, remember to 7 11
add Loctite 243 glue to the threads between pis-
ton rod - piston. 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.

10

Threads [mm] Max torques [Nm]

20 30
30 40
40 50
45 60
50 70
60 100
65 120
75 150
80 180
85 200

Table: Maximum tightening torques for piston's locking nuts

Figure: The piston rod and the cover assembly

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HYDRAULIC CYLINDERS
Repair and adjustment

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!

Figure: Cylinder with thread-mounted cover

If the cylinder cover is thread-mounted, add Loctite 572 on the threads of the cylinder cover and use
a special tool for tightening. Use the same tightening torques than with piston rod.

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 HYDRAULIC CYLINDERS
Repair and adjustment

Figure: Assembled cylinder

Push the cylinder cover (2) in and insert the socket screws (1) through the cover and tighten them.
Install the overcenter valves (4) and the adapters, and test the cylinder.

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ID: 371 3 en 2010-12-14
HYDRAULIC CYLINDERS
Repair and adjustment

7. TESTING OF CYLINDER

10 12 11

13
14

Figure: 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.

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 HYDRAULIC CYLINDERS
Repair and adjustment

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ID: 371 3 en 2010-12-14
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Repair and adjustment

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