Hydraulic Cylinder Overhaul Instructions Rev. 2.0 - Low

Hydraulic Cylinder
Overhaul Instructions
Table of contents
Hydraulic Cylinder Overhaul Instructions
Table of contents
1. Description ................................................................................................... 1
1.1. Safety precautions ............................................................................. 1
1.2. Symbols ............................................................................................. 2
1.3. Threadlockers and hydraulic sealants ............................................... 3
2. Identifying hydraulic cylinders .................................................................... 5
3. Detaching the hydraulic cylinder from the jet ............................................. 7
4. Overhaul instructions A ............................................................................... 9
4.1. Exploded view of the hydraulic cylinder ........................................... 9
4.2. Disassembling the hydraulic cylinder .............................................. 10
4.3. Removing the hydraulic cylinder’s seals ......................................... 13
4.4. Installing the hydraulic cylinder’s new seal kit and assembling
the hydraulic cylinder ............................................................................. 14
4.5. Commissioning the hydraulic cylinder ............................................ 19
5. Overhaul instructions B ............................................................................. 21
5.1. Exploded view of the hydraulic cylinder ......................................... 21
5.2. Replacing the hydraulic cylinder’s seals ......................................... 24
6. Modification instructions B ........................................................................ 35
6.1. Modifying a hydraulic cylinder for use with an automatic
lubrication unit ....................................................................................... 35
7. Overhaul instructions C ............................................................................. 39
7.1. Exploded view of the hydraulic cylinder ......................................... 39
7.2. Disassembling the hydraulic cylinder .............................................. 40
7.3. Removing the hydraulic cylinder’s seals ......................................... 43
7.4. Installing the hydraulic cylinder’s new seal kit and assembling
the hydraulic cylinder ............................................................................. 45
HM/HS/EN/2.0.0 iii
Description
1. Description
Use the instructions provided in this manual to overhaul your jet’s hydraulic
cylinder. The instructions are applicable to the hydraulic cylinders listed
in section 2. Identifying hydraulic cylinders, page 5. Please note that the
instructions used must be selected based on the type of hydraulic cylinder.
The manual also includes instructions for modifying certain types of hydraulic
cylinders for the purpose of retrofitting an automatic lubrication unit to the
system.
1.1. Safety precautions
Read these instructions carefully before carrying out any procedures. Always
follow these instructions and the safety precautions shown below.
• Only a person with adequate training is permitted to carry out the

demanding maintenance procedures described in this manual.
• The person carrying out the procedures must always wear the appropriate
protective equipment.
• The work premises must be sufficiently large, safe and well lit.
• The tools that are to be used must be clean and appropriate for the intended
purpose.
WARRANTY!
Replacements may only be carried out by a person with

appropriate training. The guarantee shall not be valid if the
task is performed by a person not meeting this requirement.
NOTE!
Special tools are needed in the replacement work.
CAUTION!
When a cylinder is attached to a vice, padding (e.g. pieces of

aluminium sheet) needs to be used in the fixing clamp.
A hard clamp will cause scratches to the surface and may lead
to leaking seals.
A used cylinder contains oil that will leak out when the
cylinder is disassembled. Please make sure that the waste oil
is appropriately disposed of.
HM/HS/EN/2.0.0 1
Description
WARNING!
Successful hydraulic cylinder overhaul is ensured with a

pressure test performed at the end of the overhaul. The
success of the overhaul cannot be ascertained without the
pressure test. Using an inadequately overhauled hydraulic
cylinder may lead to sudden loss of control of the boat.
1.2. Symbols
Please refer to table 1 for a description of the symbols used in this manual.
Table 1. The symbols used in the manual
Icon Description
DANGER
Negligence in the performance of the procedure can endanger

your life.
WARNING
Negligence in the performance of the procedures can lead to

personal injury, breakdown of equipment, or serious malfunction
of the equipment.
CAUTION
The procedure involves minor danger or a possibility of minor

damage to equipment.
WARRANTY
The warranty is voided if the procedure is carried out incorrectly.
NOTE
Important notice or fact.
TIP
Additional information that facilitates the performance of work or

a procedure.
INDICATOR ARROW
ARROW DESCRIBING MOTION
CHECK THE CONDITION/FUNCTIONING OF THE INDICATED

COMPONENT
OIL LEAK
Please note that these instructions use the terms ‘jet’ and ‘jet propulsion unit’.
They mainly refer to the same thing.
2 HM/HS/EN/2.0.0
Description
1.3. Threadlockers and hydraulic sealants

Recommended threadlockers and hydraulic sealants are listed below.
Medium strength threadlocker Loctite 242

Hydraulic sealant Loctite 542
HM/HS/EN/2.0.0 3
Description
4 HM/HS/EN/2.0.0
Identifying hydraulic cylinders
2. Identifying hydraulic cylinders

Check your hydraulic cylinder’s product code and then use the table below
to select the corresponding seal kit and overhaul instructions. To order the
seal kits needed for a hydraulic cylinder overhaul, please contact your local
Alamarin-Jet distributor.
Table 2. Hydraulic cylinders, corresponding seal kits and replacement

instructions
Hydraulic cylinder code Seal kit code Overhaul/modification

instructions
10798 P9908 A
11106 P9908 A
10295 P9913 B
10475 P9904 B
10559 P9904 B
10830 P9913 B
10946 P9913 B
11096 P9913 B
11151 P9920 C
11152 P9920 C
11249 P9920 C
11250 P9920 C
11260 P9920 C
10576 P9919 C
11238 P9921 C
HM/HS/EN/2.0.0 5
Identifying hydraulic cylinders
6 HM/HS/EN/2.0.0
Detaching the hydraulic cylinder from the jet
3. Detaching the hydraulic cylinder from the jet

The hydraulic cylinder must be detached from the jet before it can be
overhauled. For instructions on how to detach the hydraulic cylinder from the
jet and disconnect hydraulic hoses, please refer to the jet’s repair manual.
HM/HS/EN/2.0.0 7
Detaching the hydraulic cylinder from the jet
8 HM/HS/EN/2.0.0
Overhaul instructions A
4. Overhaul instructions A
These instructions are applicable to the hydraulic cylinders listed in section 2.
Identifying hydraulic cylinders, page 5.
4.1. Exploded view of the hydraulic cylinder

The parts to be replaced in the overhaul are presented in the exploded view
below with the numbers 2, 3, 5 and 7. Seal number 7 consists of a piston seal
and o-ring. The o-ring listed as number 10 is located under the piston and does
not need to be replaced.
HM/HS/EN/2.0.0 9
Pos. Description Code Pcs

1 Lock ring 10809 2
2 Wiper 5773 2
3 Pressure seal 5774 2
4 Cylinder tube end 10802 1
5 O-ring 5775 2
6 Piston rod 10811 1
7 Piston seal 5776 1
8 Piston 10799 1
9 Set screw M6 R05060060 1
10 O-ring T0000013 1
12 Set screw M5 R05050082 2
13 Cylinder tube 10801 1
15 Bleeder fitting (deliver P0376 2
with the seal kit)
4.2. Disassembling the hydraulic cylinder

1. Remove the set screws from the cylinder tube and detach the fittings.
Figure 1. Removing the set screws and fittings
A Fittings
B Set screws
10 HM/HS/EN/2.0.0
2. Rotate the front end of the cylinder tube by 180° so that the ear of the lock
ring becomes visible in the lock ring’s eyelet on the cylinder tube (figure
3).
To help rotate the cylinder tube, you can insert a 6 mm round rod in the
hole on the front end of the cylinder tube (figure 2). Rotate the end of the
cylinder tube in the direction that it is easiest to move it in.
Figure 2. Rotating the front end of the cylinder tube
Figure 3. The ear of the lock ring visible in the eyelet on the front
end of the cylinder tube
3. Use a sharp tool to lift the lock ring from its groove and rotate the front
end of the cylinder tube in the same direction to push the lock ring off
from the groove.
HM/HS/EN/2.0.0 11
4. Remove the lock ring and pull off the end of the cylinder tube.
Watch out for the oil flowing out of the cylinder tube.
Figure 4. Removing the cylinder tube lock ring
Figure 5. Pulling off the front end of the cylinder tube
5. The rear end of the cylinder tube is removed in the same way as the front
end. Repeat steps 2–4 for the rear end of the cylinder tube and remove the
rear end.
6. Pull the piston rod out of the cylinder tube.
12 HM/HS/EN/2.0.0
Figure 6. Pulling out the piston rod
4.3. Removing the hydraulic cylinder’s seals

1. Remove the piston seal by splitting it with a knife, but be careful not to
scratch the seal groove.
2. Remove the o-ring located under the piston seal.
Figure 7. Removing the piston seal
A The o-ring under the piston seal

B The cut piston seal
The seals on the old ends of the cylinder tube do not need to removed as
the ends of the cylinder tube are replaced with new ones in connection
with the overhaul.
HM/HS/EN/2.0.0 13
4.4. Installing the hydraulic cylinder’s new seal kit and

assembling the hydraulic cylinder
1. Make sure that you have the following parts on hand:
• New seal kit
• Piston rod
• Cylinder tube
Please note that some of the parts to be replaced are already installed on
the ends of the cylinder tube included in the new seal kit.
Clean all parts of any dirt and shavings. Clean the piston rod and remove
any impurities. It is easiest to do this by using a lathe and emery cloth.
2. Check that the seals are installed on the new ends of the cylinder tube (3
pcs/end) and clean the parts.
Figure 8. Checking the seals on the ends of the cylinder tube
3. Place a new o-ring into the groove on the piston by carefully stretching it.
4. Install a new piston seal on top of the o-ring by stretching it carefully and
helping it into the groove with a round-edged tool.
14 HM/HS/EN/2.0.0
Figure 9. Installing the piston seal
CAUTION!
Do not stretch the piston seal too much, as it breaks easily.
5. Lubricate the o-rings on the ends of the cylinder tube thoroughly.
Figure 10. O-ring on the rear end of the Figure 11. O-ring on the

cylinder tube front end of the cylinder
tube
6. Lubricate the lock ring groove on the cylinder tube with corrosion
prevention compound (wax-based, solvent cutback, such as Tectyl
Multipurpose 506).
HM/HS/EN/2.0.0 15
Figure 12. Protecting the lock ring groove on the cylinder tube
7. Install the front end of the cylinder tube onto the cylinder tube while
making sure that the lock ring eyelet and the lock ring installation hole on
the end of the cylinder tube are aligned.
Figure 13. Installing the front end of the cylinder tube onto the

cylinder tube
A Lock ring eyelet

B Lock ring installation hole
8. Insert the ear of the lock ring into the installation hole visible through the
eyelet.
9. Rotate the end of the cylinder tube so that the lock ring is coiled into its
groove.
Keep rotating until the lock ring is completely set in the groove.
16 HM/HS/EN/2.0.0
Figure 14. Installing the lock ring
A Lock ring ear
10. Rotate the front end of the cylinder tube so that the set screw holes on the
cylinder tube itself and the end of the cylinder tube are aligned.
11. Install the set screw with medium strength threadlocker.
Figure 15. Installing the set screw
A Set screw
B Aligned set screw installation holes
12. Place the piston mounting bush on to the rear end of the cylinder tube.
HM/HS/EN/2.0.0 17
13. Thoroughly lubricate the piston rod’s seals and push the piston rod onto
the cylinder tube.
Figure 16. Setting the cylinder tube onto the piston rod
A Piston mounting bush (11393)
14. Attach the assembly to a vice by the piston rod.
15. Take a firm hold of the cylinder tube and simultaneously pull and twist the
piston into the cylinder tube with a swift motion.
Figure 17. Installing the piston
16. Remove the piston mounting bush
18 HM/HS/EN/2.0.0
The rear end of the cylinder tube is installed in the same way as the front end.
Repeat steps 6–11 for the rear end of the cylinder tube with the piston inside
the cylinder tube.
4.5. Commissioning the hydraulic cylinder

1. Attach the bleeder fittings to the assembled hydraulic cylinder’s hose
connectors.
2. Seal the threads with hydraulic sealant.
Figure 18. Attaching the T-bleeder fittings
3. The cylinder should be pressure tested prior to commissioning:
3.1. Connect the cylinder to a hydraulic system in accordance with the

jet’s installation manual.
3.2. Spread soap solution onto the sealed surfaces (see the arrows in
figure 19) and pressurise the cylinder to 10 bar.
Any leaks should now be visible in the form of soap bubbles. If a

leak is detected, the cylinder cannot be commissioned. If this is
the case, replace any leaking seals with new ones and repeat the
pressure test.
HM/HS/EN/2.0.0 19
Figure 19. Sealed surfaces to be checked
4. If the cylinder passes the pressure test, fill the lock ring eyelets with
corrosion prevention compound (wax-based, solvent cutback, such as
Tectyl Multipurpose 506).
Figure 20. Filling the lock ring eyelets with corrosion prevention

compound
5. Install and adjust the hydraulic cylinder in accordance with the

instructions provided in the jet’s repair manual.
20 HM/HS/EN/2.0.0
Overhaul instructions B
5. Overhaul instructions B
HM/HS/EN/2.0.0 21

1 Hex screw M6 R04060802 4
2 Spring washer M6 R13060002 4
3 Locking nut M8 R31080002 1
4 Lever 10310 1
5 Hex socket screw M8 R01080402 1
6 Cable bracket 10208 1
7 Wiper 5777 1
8 O-ring T0000044 2
9 Seal ring 10289 1
22 HM/HS/EN/2.0.0

10 Rotary seal VT-025-32.3 1
11 Shaft 10378 1
12 O-ring T0000012 1
13 Valve adjuster 10291 1
14 Flow divider 10293 1
15 Pin L0308 1
16 Pin L0309 1
17 X-ring T0000009 1
18 Spiral 10079 1
19 Sleeve 10292 1
20 O-ring T0000032 3
21 Valve housing 10288 1
22 Plug R50180002 6
23 Angle fitting P0302 1
24 Hose fitting P0307 1
26 Reduction fitting P0367 1
27 Copper seal P0372 1
28 Pressure relief valve 10345 1
housing
29 O-ring T0000008 4
30 O-ring 5775 2
32 Guide band 5761 1
33 Piston 10039 1
34 Set screw M6 R05060060 1
36 Valve 10379 1
38 Slide bearing RPM-02-20 1
39 Key 10429 1
42 Wiper 5773 1
43 O-ring T0000028 2
HM/HS/EN/2.0.0 23
5.2. Replacing the hydraulic cylinder’s seals

1. Detach the cylinder according to the instructions provided in the jet’s
repair manual.
2. Detach the lever.
3. Unscrew the four screws of the cable clamp and remove the cable clamp.
Figure 21. Removing the cable clamp
4. Unscrew the screw that attaches the valve housing to the cylinder tube.
24 HM/HS/EN/2.0.0
Figure 22. Valve housing screw
5. Pull out the valve housing.
Watch out for the oil flowing out of the cylinder tube.
Figure 23. Pulling out the valve housing
6. From the front side, pull out the insides of the valve housing.
HM/HS/EN/2.0.0 25
Figure 24. Removing the insides of the valve housing
7. Force out the sleeve inside the valve housing by knocking the front surface
of the valve housing hard against a soft surface, such as a wooden desk.
Figure 25. Removing the sleeve inside the valve housing
8. Wash the parts.
9. Replace the o-rings on the outer race of the sleeve.
26 HM/HS/EN/2.0.0
Figure 26. The o-rings on the outer race of the sleeve
10. Replace the x-ring at the rear end of the flow divider.
You can use o-ring opening pliers to help with the installation. Make sure
not to leave the seal twisted.
Figure 27. Flow divider x-ring
11. Lubricate the parts and put them back into place inside the valve housing.
Make sure that the sleeve goes all the way down. The position of the
sleeve holes does not matter.
12. Press the new preassembled seal ring in its place. Ease the installation by
lubricating the seals.
13. Replace the seal in the joint of the valve housing and the cylinder tube
with a new one.
14. Replace the seals in the joints of the pressure relief valve and the valve
housing’s oil duct joints with new ones.
Petroleum jelly will help the seals stay put. Attach the screws with medium
strength threadlocker.
HM/HS/EN/2.0.0 27
Figure 28. Installing the valve housing seals
A Seal ring
15. Push the piston rod out of the cylinder tube.
Figure 29. Piston rod
16. Remove the piston seal, its o-ring and the guide band.
It is easiest to remove the piston seal by splitting it with a knife, but be

careful not to scratch the seal groove. The guide band is already split.
28 HM/HS/EN/2.0.0
17. Clean the piston rod and remove any impurities.
It is easiest to do this by using a lathe and emery cloth.
18. Install the new piston seal.
First install the o-ring and then the hard ring by using a blunt screwdriver,
for example. The seal will stretch during installation, but you can press it
deeper into the groove by hand.
19. Remove the threaded part at the rear end of the cylinder tube.
Warm it up with a hot-air gun, for example, if needed, and use the cable
clamp as an aid. If needed, use an extension shank.
Figure 31. Rear end of the cylinder tube
HM/HS/EN/2.0.0 29
20. Clean the cylinder tube.
21. Replace the o-ring in the cylinder tube groove and lubricate it.
22. Add threadlocker (medium strength) to the thread of the new part and
screw it in place.
As an aid, you can use a special tool made by splitting an old cylinder
fastening nut. It can be pressed onto the thread of the installed part
without damaging it.
Figure 32. Cylinder tube o-ring and threadlocker
A O-ring
B Threadlocker
23. Thoroughly lubricate the piston rod’s seals and push the piston rod
through the seals of the rear end of the cylinder tube.
Attach the assembly to a vice by the piston rod.
24. Place the piston mounting bush at the end of the cylinder tube and position
the guide band around the piston.
Make sure that the bevelled edge of the piston mounting bush is set
against the piston.
30 HM/HS/EN/2.0.0
Figure 33. Placing the piston mounting bush
A Guide band
B Piston mounting bush (11393)
C Bevelled edge of the piston mounting bush
25. Lubricate the piston seals and the head of the cylinder tube.
piston into the cylinder pipe with a swift motion.
At the same time, help the guide band stay in place.
Figure 34. Installing the piston in the cylinder tube
27. Remove the piston mounting bush from the end of the cylinder tube.
28. Put the valve housing back in place, making sure that the spiral enters the
hole in the middle of the piston.
HM/HS/EN/2.0.0 31
Figure 35. Installing the valve housing
29. Use new seals in the oil duct joints.
You can use petroleum jelly spray to make sure that they stay firmly in
place.
Figure 36. Oil duct seals
30. Screw in the screw that attaches the valve housing to the cylinder tube.
This screw ensures that the valve housing fits into the cylinder tube
correctly when the cylinder is assembled.
32 HM/HS/EN/2.0.0
Figure 37. Attaching the valve housing screw
31. Put the cable clamp back in place and tighten the four screws to a torque
of 9 Nm.

The pressure test can be performed with the help of accessory kit P9910. The
cylinder should be pressure tested prior to commissioning.
1. Connect the cylinder to a hydraulic system in accordance with the jet’s

installation manual.
2. Spread soap solution onto the sealed surfaces (see the arrows in figure 38)
and pressurise the cylinder to 10 bar.
Any leaks should now be visible in the form of soap bubbles. If a leak is
detected, the cylinder cannot be commissioned. If this is the case, replace
any leaking seals with new ones and repeat the pressure test.

instructions provided in the jet’s repair manual.
HM/HS/EN/2.0.0 33
34 HM/HS/EN/2.0.0
Modification instructions B
6. Modification instructions B
6.1. Modifying a hydraulic cylinder for use with an automatic

lubrication unit
This section is for retrofitting an automatic lubrication unit to an assembly that
did not originally include an automatic lubrication unit.
If an automatic lubrication unit was not supplied with the jet, the hydraulic
cylinder is probably incompatible with an automatic lubrication unit as is.
This section describes the procedure for modifying the hydraulic cylinder for
use with an automatic lubrication unit. Alternatively, you can purchase a pre-
assembled cylinder from your local Alamarin-Jet distributor.
Please contact your local Alamarin-Jet distributor to order the hydraulic

cylinder adjustment kit 11596. For more information on the automatic
lubrication unit, please refer to your jet’s installation manual.
Figure 39. Parts of the 11596 kit
Pos. Description Pcs

1 Plug 1
2 Hex socket screw M6 2
3 O-ring 2
4 Assembled pressure relief valve housing 1
1. Check whether the hydraulic cylinder is already compatible with an

automatic lubrication unit without adjustments.
This type of hydraulic cylinder is presented on the left in figure 40. If

your jet’s hydraulic cylinder is like the one of the right, proceed with the
instructions.
HM/HS/EN/2.0.0 35
Figure 40. Checking the cylinder type
2. Detach the hydraulic hoses from the hydraulic cylinder and drain the oil
from the hydraulic cylinder into a container.
Please make sure that the waste oil is appropriately disposed of.
3. Open the screws (2 pcs) on the pressure relief valve housing and remove
the angle fitting.
Figure 41. Pressure relief valve housing and angle fitting
A Pressure relief valve housing

B Angle fitting
4. Clean the output that the angle fitting was attached to and plug it with the
plug included in the adjustment kit.
36 HM/HS/EN/2.0.0
Figure 42. Plugging the hydraulic cylinder’s valve housing
5. Seal the thread with hydraulic sealant.
6. Clean the installation surfaces of the pressure relief valve housing.
7. Install the pressure relief valve housing included in the adjustment kit
along with its o-rings.
Please note the correct orientation of the pressure relief valve housing.
Lubricate the o-rings with petroleum jelly spray, for example, to help them
remain in place during installation.
8. Attach the screws with medium strength threadlocker.
HM/HS/EN/2.0.0 37
Figure 43. Installing the new pressure relief valve housing
A Hex socket screws (2 pcs)

B Pressure relief valve housing
C O-rings (2 pcs)
9. Go to section 5.3. Commissioning the hydraulic cylinder, page 33.
If the hydraulic cylinder does not function, check that the pressure
relief valve was installed in the right way around. The functioning of
the hydraulic cylinder can be re-checked once the pressure relief valve
housing has been installed in the correct orientation.
38 HM/HS/EN/2.0.0
Overhaul instructions C
7. Overhaul instructions C

The parts to be replaced in the overhaul are presented in the exploded view
below with the numbers 4, 9, 10, 12, 13, 21, 22, 23 and 24.
HM/HS/EN/2.0.0 39

1 Hex screw M6 R04060602 4
2 Spring washer R13060002 4
3 Retaining plate 10573 2
4 O-ring T0000030 1
5 Screw M3 R07030400 2
6 Linear sensor CM128AV 1
7 Plug 1/8 R50180002 2
8 Cylinder tube cover 10343 1
9 O-ring T0000008 2
10 O-ring 5775 2
11 Shield tube 10574 1
13 Guide band 5761 1
15 Magnet 201542-2 1
16 Stop collar 11192 1
17 Set screw M6 R05060060 1
18 Piston 10575 1
21 Slide bearing DryLin R RPM-02-20 1
24 Wiper 5773 1
25 Key 10429 1
7.2. Disassembling the hydraulic cylinder

1. Disconnect the sensor cable connector from the cylinder tube cover in
accordance with the instructions provided in the IO control system’s
installation and commissioning manual.
40 HM/HS/EN/2.0.0
Figure 44. Disconnecting the sensor cable connector
2. Remove the four screws on the cylinder tube cover
Figure 45. Removing the screws on the cylinder tube cover
3. Pull off the cylinder tube cover.
HM/HS/EN/2.0.0 41
Figure 46. Removing the cylinder tube cover
4. Pull the piston rod out of the cylinder.
Figure 47. Pulling out the piston rod
5. Unscrew the end of the cylinder tube.
If necessary, heat the end of the cylinder tube with a hot-air gun, for
example. Use all four of the threaded holes on the end of the cylinder tube
to avoid damaging the threads. If needed, use an extension shank.
42 HM/HS/EN/2.0.0
Figure 48. The threaded holes on the end of the cylinder tube
Figure 49. Detaching the cylinder tube from the end of the cylinder

tube
7.3. Removing the hydraulic cylinder’s seals

1. Remove the pressure seal, its o-ring and the guide band from around the
piston.
It is easiest to remove the pressure seal by cutting it with a knife, but be

careful not to scratch the seal groove. The guide band is already split.
HM/HS/EN/2.0.0 43
A The cut piston seal

B The o-ring under the piston seal
C Guide band
2. Remove the magnet and the stop collar by opening the four screws.
Figure 51. Removing the stop collar
A Screws
B Magnet
C Stop collar
The seals on the end of the cylinder tube do not need to be removed as the
end of the cylinder tube is replaced with a new one in connection with the
overhaul.
44 HM/HS/EN/2.0.0
7.4. Installing the hydraulic cylinder’s new seal kit and

assembling the hydraulic cylinder
1. Make sure that you have the following parts on hand:
• New seal kit
• Piston rod
• Cylinder tube
• Cylinder tube cover
Please note that some of the parts to be replaced are already installed on
the end of the cylinder tube included in the new seal kit.
2. Clean all parts of any dirt and shavings.
3. Clean the piston rod and remove any impurities.
It is easiest to do this by using a lathe and emery cloth.
Do not use any sharp-edged tools that could damage the seals.
4. Check that the parts are installed on the new end of the cylinder tube.
Figure 52. Checking the end of the cylinder tube
5. Replace the o-ring in the cylinder tube groove and lubricate it.
6. Apply threadlocker (medium strength) to the thread of the new cylinder

tube end and screw it in place.
As an aid, you can use a special tool made by splitting an old cylinder
fastening nut. It can be pressed onto the thread of the installed part
without damaging it. Remove the split nut after installation.
If there is a ball on the end of the cylinder tube, the special tool cannot be
used, in which case the end of the cylinder tube should be attached to a
vice to aid installation.
HM/HS/EN/2.0.0 45
Figure 53. Installing the end of the cylinder tube
A Special tool
B Cylinder tube end
C O-ring
7. Install the piston seal and the guide band.
Please note the o-ring to be placed under the piston seal.
Figure 54. Installing the seals
A Piston seal
B Guide band
C O-ring
8. Install the magnet and stop collar with the four screws.
Use medium strength threadlocker.
46 HM/HS/EN/2.0.0
Figure 55. Installing the stop collar
A Screws
B Magnet
C Stop collar
9. Thoroughly lubricate the piston rod’s seals and push the piston rod
through the seals of the rear end of the cylinder tube.
10. Attach the assembly to a vice by the piston rod.
11. Place the mounting bush to the end of the cylinder tube and position the
guide band around the piston.
A Piston seal
B Guide band
C Piston mounting bush (11393)
HM/HS/EN/2.0.0 47
piston into the cylinder tube with a swift motion.
At the same time, help the guide band stay in place.
13. Remove the piston mounting bush.
14. Lubricate the o-rings.
15. Install the o-rings and the cylinder tube cover.
16. Tighten the four screws to a torque of 9 Nm.
Figure 58. Installing the cylinder tube cover
A O-rings (3 pcs)
48 HM/HS/EN/2.0.0
Figure 59. Assembled hydraulic cylinder

1. Attach hydraulic connectors to the assembled hydraulic cylinder’s hose
outputs.
Figure 60. Attaching the hydraulic connectors
A Hose outputs (2 pcs)

B O-ring
HM/HS/EN/2.0.0 49
3. The cylinder should be pressure tested prior to commissioning:
3.1. Connect the cylinder to a hydraulic system in accordance with the

jet’s installation manual.
3.2. Spread soap solution onto the sealed surfaces (see the arrows in
figure 61) and pressurise the cylinder to 10 bar.
Any leaks should now be visible in the form of soap bubbles. If a

leak is detected, the cylinder cannot be commissioned. If this is
the case, replace any leaking seals with new ones and repeat the
pressure test.

instructions provided in the jet’s repair manual and the IO control system’s
installation and commissioning manual.
5. Attach the hydraulic hose connectors.
7. Make sure that the o-ring is in place (figure 60).
8. Attach the sensor cable to the connector on the end of the hydraulic
cylinder in accordance with the instructions provided in the IO control
system’s installation and commissioning manual.
50 HM/HS/EN/2.0.0
Figure 62. Installing the hydraulic cylinder’s connectors
A Sensor cable connector
HM/HS/EN/2.0.0 51
52 HM/HS/EN/2.0.0

Hydraulic Cylinder Overhaul Instructions Rev. 2.0 - Low

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Hydraulic Cylinder Overhaul Instructions Rev. 2.0 - Low

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Hydraulic Cylinder

• Only a person with adequate training is permitted to carry out the

Replacements may only be carried out by a person with

Special tools are needed in the replacement work.

When a cylinder is attached to a vice, padding (e.g. pieces of

Successful hydraulic cylinder overhaul is ensured with a

Table 1. The symbols used in the manual

Negligence in the performance of the procedure can endanger

Negligence in the performance of the procedures can lead to

The procedure involves minor danger or a possibility of minor

The warranty is voided if the procedure is carried out incorrectly.

Important notice or fact.

Additional information that facilitates the performance of work or

CHECK THE CONDITION/FUNCTIONING OF THE INDICATED

1.3. Threadlockers and hydraulic sealants

Medium strength threadlocker Loctite 242

2. Identifying hydraulic cylinders

Table 2. Hydraulic cylinders, corresponding seal kits and replacement

Hydraulic cylinder code Seal kit code Overhaul/modification

3. Detaching the hydraulic cylinder from the jet

4.1. Exploded view of the hydraulic cylinder

Pos. Description Code Pcs

4.2. Disassembling the hydraulic cylinder

Figure 1. Removing the set screws and fittings

Figure 2. Rotating the front end of the cylinder tube

Figure 4. Removing the cylinder tube lock ring

Figure 5. Pulling off the front end of the cylinder tube

6. Pull the piston rod out of the cylinder tube.

Figure 6. Pulling out the piston rod

4.3. Removing the hydraulic cylinder’s seals

2. Remove the o-ring located under the piston seal.

Figure 7. Removing the piston seal

A The o-ring under the piston seal

4.4. Installing the hydraulic cylinder’s new seal kit and

• New seal kit

Figure 8. Checking the seals on the ends of the cylinder tube

Figure 9. Installing the piston seal

Do not stretch the piston seal too much, as it breaks easily.

5. Lubricate the o-rings on the ends of the cylinder tube thoroughly.

Figure 10. O-ring on the rear end of the Figure 11. O-ring on the

Figure 12. Protecting the lock ring groove on the cylinder tube

Figure 13. Installing the front end of the cylinder tube onto the

A Lock ring eyelet

Figure 14. Installing the lock ring

A Lock ring ear

11. Install the set screw with medium strength threadlocker.

Figure 15. Installing the set screw

Figure 16. Setting the cylinder tube onto the piston rod

A Piston mounting bush (11393)

14. Attach the assembly to a vice by the piston rod.

Figure 17. Installing the piston

16. Remove the piston mounting bush

4.5. Commissioning the hydraulic cylinder

2. Seal the threads with hydraulic sealant.

Figure 18. Attaching the T-bleeder fittings

3. The cylinder should be pressure tested prior to commissioning:

3.1. Connect the cylinder to a hydraulic system in accordance with the

Any leaks should now be visible in the form of soap bubbles. If a

Figure 19. Sealed surfaces to be checked

Figure 20. Filling the lock ring eyelets with corrosion prevention

5. Install and adjust the hydraulic cylinder in accordance with the

5.1. Exploded view of the hydraulic cylinder