Revision 1, 5/99

AIR CYLINDERS: F- 2
OPERATION: F- 3
LUBRICATION: F- 3
ADJUSTMENTS: F- 3
CUSHION: F- 3
MAINTENANCE: F- 3
REPLACING WORN PACKINGS OR SEALS: F- 3
HYDRAULIC CYLINDERS: F- 7
OPERATION: F- 8
ADJUSTMENTS: F- 8
CUSHION: F- 8
MAINTENANCE: F- 8
CUSHION NEEDLE ASSEMBLY REPLACEMENT: F- 8
OTHER CYLINDER REPAIRS: F- 9
HYDRAULIC CYLINDER REBUILDING PROCEDURE: F- 9
REPLACING PISTON RING AND BACKUP O-RING: F - 10
REASSEMBLY PROCEDURE: F - 11

F-1
 CYLINDERS

- REPAIR PARTS -
FOR

HUNTER PNEUMATIC CYLINDERS

PARTS ORDERING
INFORMATION

See the Bill of Material for normal

parts and part numbers.

Air cylinder repair kits contain: rod

wipers, rod seal, u-cups, o-rings,

This cylinder is shown for reference

only and does not represent any par-
ticular cylinder on the machine.

F-2
 AIR CYLINDERS:
OPERATION:
Air cylinders operate by applying pressure to one side of a piston, while exhausting air
from the other side. The pressure differential causes the piston to move, which moves
whatever load is attached to the piston rod.

Warning
The words "Safe", "Safety", and "Safely",
when used in this book are never intended to
be construed as absolute or perfect protec-
tion from harm injury or risk. When used,
they assume and are dependent on prudent
behavior, use of personal protective equip-
ment associated with the action or area, and
that only trained people will do the work.

The speed of a cylinder is normally controlled by a flow control on the exhaust side of
the cylinder. A flow control limits the amount of air that is exhausted from the cylinder.

Cushions slow the final portion of the cylinder stroke by decreasing the size of the ex-
haust port. An adjustable cushion uses a needle valve to regulate the degree of
cushioning.

LUBRICATION:

All air cylinders require clean, dry, lubricated air to assure proper function and long life.
Therefore, an airline filter/lubricator is provided on the machine. A 10 wt., non-detergent
oil is recommended for proper cylinder function. See section "R".

ADJUSTMENTS:

CUSHION:

The cushion adjusters are located in the heads of the cylinder. Using an Allen wrench,
rotate the adjuster to achieve the desired cushion effect. Turn the adjuster:
Clockwise to increase the cushion effect.
Counterclockwise to decrease the cushion effect.

Note:
Do not unscrew the adjuster far enough to allow leakage around the stem.

F-3
 CYLINDERS
MAINTENANCE:
REPLACING WORN PACKINGS OR SEALS:
Since repair parts for air cylinders are sold only as kits, and since organic compounds
tend to deteriorate at the same rate, it is recommended that all packings and seals be
replaced at the same time.

Note:
Kits containing all necessary parts are available from Hunter Automated. Please see
the HMP Parts Manual.

1. Remove the cylinder from the machine.

2. Take the cylinder to a clean area and disassemble.
A. Use an Allen wrench to remove the four (4) Allen head cap screws from the
gland.

B. Remove the rod bearing with seals.

C. Unscrew the head from the cylinder barrel.

Note:
Never clamp the cylinder barrel in a vise, or turn it with a pipe wrench as deformation
of the barrel may result.

D. Remove the plastic shims in the head recess. Note the color(s) for
reassembly.

E. Withdraw the piston rod assembly and set it aside.

F. Unscrew the blank end cap from the barrel.

F-4
AIR CYLINDERS (CONT'D):

A. Remove the plastic shims in the head recess. Note the color(s) for
reassembly.

1. REPLACING WORN PACKINGS OR SEALS (CONT'D):Clean and dry all the parts.
2. Remove the existing u-cups and reinstall a new one on the rod side of the piston,
as illustrated.

NOTE:
Should it be necessary to remove the piston from the rod, be sure to remove the set
screw before unscrewing. Line up the threads and reinstall the set screw when
reassembling.

3. Lightly coat the new u-cup with oil and insert it into the cylinder barrel.
4. Push the piston through the barrel, until the groove for the blank end u-cup pro-
trudes. Install the blank end u-cup, oil lightly, and pull the piston back into the barrel

5. Apply a light film of grease and replace the shims in the blank end cap.
.003 Green
.004 Tan
.005 Blue
.006 Clear

Note:
Make sure the shims are flat and properly seated.

6. Replace the o-ring static seal in the cap.

7. Reassemble the cap onto the barrel and tighten to align the timing marks on the
barrel and end caps.

F-5
 CYLINDERS

AIR CYLINDERS (CONT'D):

REPLACING WORN PACKINGS OR SEALS (CONT'D):

1. Replace the o-ring and shims in the head and reassemble onto the barrel.
2. Replace the o-rings onto the rod bearing and install into the head end of the
cylinder.

Note:
Be sure the "lip" of the rod bearing is up, (away from the barrel).

Rod Bearing -

Lip must be up

3. Install a new rod seal and rod wiper to the gland.

4. Install the gland over the rod and rod bearing. Tighten the four (4) hex head bolts.
5. Back off on the cushion adjustment(s).
6. With a modified screw driver, (see figure below) remove the cushion assembly

Notch Out Here

gland.
7. Replace the "O" rings and reinstall the cushion gland, seating it firmly.
8. Readjust the cushion.

Note:
To prevent damage to the cushion needle and/or seat, always back off the cushion
adjustment before replacing the gland.

F-6
- REPAIR PARTS -
FOR

HUNTER HYDRAULIC CYLINDERS

PARTS ORDERING INFORMATION

See the Bill of Material for normal re-

pair parts and numbers.

Hydraulic cylinder repair kits contain:

rod wipers, rod seal, square piston
ring, seal kit and a shim set.

Hydraulic cylinder seal kits contain:

o-rings.

This cylinder is shown for reference

only and does not represent any par-
ticular cylinder on the machine..
F-7
 CYLINDERS
HYDRAULIC CYLINDERS
OPERATION:
Hydraulic cylinders operate by applying pressure to one side of the piston while ex-
hausting fluid from the other side. The pressure differential causes the piston to move,
moving whatever load is attached to the piston rod.

The speed of a cylinder is usually controlled by a flow control on the exhaust side of the
cylinder. A flow control limits the amount of fluid that is exhausted from the cylinder.

Cushions slow the final portion of the cylinder stroke by decreasing the size of the ex-
haust port. An adjustable cushion uses a stem to regulate the degree of cushioning.

ADJUSTMENTS:

CUSHION:

On cylinders that have adjustable cushions, the cushion adjusters are located in the rod
end head and/or blank end cap.

Using the proper size Allen wrench, turn the cushion needle adjustment.
Clockwise to increase the cushioning action.
Counterclockwise to decrease the cushioning action.

Note:
It is not necessary to loosen the cushion locking gland to make adjustments.

MAINTENANCE:

CUSHION NEEDLE ASSEMBLY REPLACEMENT:

F-8
HYDRAULIC CYLINDERS (CONT'D):
CUSHION NEEDLE ASSEMBLY REPLACEMENT (CONT'D):

Note:
When reinstalling, the cushion assembly and/or seat may be damaged if the cushion
needle is in too far.

1. Using the proper size Allen wrench, back off on the cushion needle adjustment.
2. Using a modified screw driver, remove the gland and cushion needle assembly.
3. Remove the o-ring and install a new one.
4. Reinstall the cushion assembly by reversing the procedure.

OTHER CYLINDER REPAIRS:

Rod seals and cushions are the only items replaceable from the outside of the cylinders.
When other repairs are necessary, it is recommended that the cylinder be completely
rebuilt, replacing all parts supplied in the cylinder repair kit.

Generally, repairs other than the replacement of the items above is not feasible, due to
the time and money involved. Replacing the entire cylinder is usually more economical
than replacing barrels, heads, etc.

HYDRAULIC CYLINDER REBUILDING PROCEDURE:

1. Remove the cylinder from the machine.

2. Clean the outside of the cylinder.

F-9
 CYLINDERS
HYDRAULIC CYLINDERS (CONT'D):
HYDRAULIC CYLINDER REBUILDING PROCEDURE (CONT'D):
3. In a clean area, disassemble the cylinder
A. Using the proper Allen wrench, remove the four (4) Allen head cap screws
from the gland.

B. Remove the gland and rod bearing.

C. Unscrew the rod end head from the barrel. (Note the order of the shims for
later replacement.)

Note:
The cylinder barrel should not be clamped in a vise or turned with a pipe wrench as
the barrel shape may be distorted. A nylon strap wrench is recommended.

D. Withdraw the rod and piston assembly and set it aside.

E. Unscrew the blank end cap. (Note the order of the shims for later
replacement.)

4. Clean and dry all the parts.

5. Inspect all the parts for wear or damage.

REPLACING PISTON RING AND BACKUP O-RING:

Note:
The piston ring will not stretch enough to slide over the piston.

1. Remove the sleeve retaining screw holding the cushion sleeve onto the cylinder
rod.
2. Remove the cushion sleeve.
3. Remove the set screw locking the piston to the cylinder rod.
4. Unscrew the piston from the cylinder rod.
5. Slide the piston plate and rod side cushion sleeve from the rod.
6. Clean all surfaces.
7. Install a new o-ring onto the rod side cushion sleeve and install the assembly onto
the rod.

F - 10
HYDRAULIC CYLINDERS (CONT'D):
REPLACING PISTON RING AND BACKUP O-RING (CONT'D):
8. Replace the o-ring and square piston ring onto the piston.
9. While holding the piston plate against the piston, screw the piston back on the cyl-
inder rod.

Note:
Be sure the "O" ring and square piston ring remain in proper position.

10. Tighten the piston until the set screw threads are lined up.
11. Reinstall the set screw.
12. Reinstall the cushion sleeve and retaining screw.

REASSEMBLY PROCEDURE:

1. Replace the o-ring in the blank end cap of the cylinder.

2. Replace the shims.
A. Determine what thickness shim(s) are required.

B. Apply a light coating of grease and seat them in the cap, the thickest one clos-
est to the barrel.

3. Screw the end cap onto the barrel to a point where the timing marks on the end cap
and barrel are aligned.
4. Apply a light coating of oil to the piston ring and the inside of the barrel.
5. Carefully insert the piston rod assembly into the barrel to prevent damage to the
piston ring.
6. Install the o-ring seals into the cylinder head.
7. Using the same procedure as in Step 2 A & B, install the necessary shims in the
head end of the cylinder.
8. Screw the head firmly onto the barrel to align the timing marks.

Note:
Do Not tighten down excessively. This can damage the shims.

9. Replace the o-rings on the rod bearing.

10. Install the rod bearing over the rod and seat it firmly in the cap.

F - 11
 CYLINDERS
Note:
Be sure the "lip" of the rod bearing is up, (away from the barrel).
11. Replace the rod seal and rod wiper into the gland.
12. Seat the gland firmly over the rod bearing.
13. Install the four (4) Allen head cap screws and tighten them firmly.

Rod Bearing -

Lip must be up

F - 12