Published 4-20-2015, Control # 502-01 2-71
RT540E SERVICE MANUAL HYDRAULIC SYSTEM
OUTRIGGER EXTENSION CYLINDER
Description
The four extension cylinders (Figure 2-1) have 6.4 cm (2.5-
inch) diameter bores. Each cylinder has a retracted length of
218.1 ± 0.30 cm (85.88 ± 0.12 inches) from the center of the
rod bushing to the center of the barrel bushing. Each
cylinder’s extended length is 403.5 cm (157.87 inches). The
stroke of each cylinder is 185.4 cm (73.0 inches). A wiper
ring prevents foreign material from entering each cylinder. O-
rings and other seals prevent internal and external leakage.
The cylinder weighs approximately 42 kg (112.5 lb).
Maintenance
Disassembly
NOTE: Any maintenance requiring disassembly of the
cylinders should include replacement of all seals
and rings. A seal kit will supply the required items.
1. Remove all dirt, grease and other contaminants from
around the ports and the head
2. Using a spanner wrench, unscrew the cylinder head.
3. Remove rod and attached parts from the barrel.
NOTE: Cover the barrel opening to avoid contamination.
4. Remove the wear rings and piston seal from the outside
of the piston.
NOTE: Arranging discarded seals and rings in the order of
disassembly will aid in installation of new seals and
rings. Pay attention to how each seal and ring is
installed to avoid installing replacement seals and
rings improperly.
5. Remove the nut from the rod.
6. Remove the piston and spacer from the rod.
7. Remove the O-ring and the backup ring from the outside
of the head.
8. Remove the rod seal, wear ring and wiper ring from the
inside of the head.
9. Remove the O-ring from the rod.
Inspection
1. Clean all parts with solvent and dry with compressed air.
Inspect all parts for serviceability.
2. Inspect the barrel carefully for scoring. If barrel is
scored, it must be repaired or replaced.
3. Check rod’s piston area for damage. If it is damaged,
determine if it can be repaired or must be replaced.
4. Inspect rod for straightness. Determine if it can be
straightened or must be replaced.
5. Stone out minor blemishes and polish with a fine crocus
cloth.
6. Clean with solvent and dry with compressed air any
parts that have been stoned and polished.
Assembly
NOTE: Lubricate seals and rings with clean hydraulic oil.
1. Install the replacement wear ring, rod seal and wiper ring
in the inside of the head.
2. Install the replacement O-ring and the backup ring on
the outside of the head.
3. Install the O-ring onto the rod.
4. Lubricate the rod with clean hydraulic oil.
5. Slide the head onto the rod.
6. Install the spacer and piston on the rod.
7. Install the locknut onto the rod.
DANGER
Do not use air pressure to remove the rod. Use only a
source of controlled hydraulic oil pressure if the rod is
hard to move.
CAUTION
Exercise extreme care when handling or setting down the
rod. Damage to the rod surface may cause unnecessary
maintenance and expense.
CAUTION
When removing the seals and rings, avoid scratching the
grooved and gland surfaces.
CAUTION
Before installing new seals and rings, clean all surfaces
and carefully remove burrs and nicks. Parts displaying
excessive wear or damage should be replaced.
CAUTION
When installing new seals and rings, avoid stretching
seals or scratching the grooved or gland surfaces. Make
sure parts are clean before and during assembly. Make
sure seals and rings are installed in the proper order.
Reference Only
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