Caterpillar HCS-40 Hydraulic Cylinder Servicer Tool Operating Manual NEHS1035 - PDF DOWNLOAD

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TOOL OPERATING MANUAL Model HCS-40 Hydraulic Cylinder Servicer

SMCS: 0784

NEHS1035 October 2008

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Important Safety Information

Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all-inclusive. If a tool, procedure, work method, or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

Think Safety Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions.

An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.

WARNING When replacement parts are required for this product, Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

Failure to heed this warning can lead to premature failures, product damage, personal injury, or death.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING”, or “CAUTION”.

The Safety Alert “WARNING” label is shown below.

WARNING The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.

2

Disassembling the Cylinder. . . . . . . . . . . . 28 Threaded Gland Retainer . . . . . . . . . . . . 28 Bolted Gland Retainer . . . . . . . . . . . . . . . 30 All Cylinders. . . . . . . . . . . . . . . . . . . . . . . 31 Removing the Piston . . . . . . . . . . . . . . . . . 31 Reassembling the Cylinder . . . . . . . . . . . . 32 Maintenance Section Servicer Maintenance . . . . . . . . . . . . . . . . . 35 Attaching Hoses to HCS-40 Hydraulic Power Supply. . . . . . . . . . . . . . . . . . . . . . . 35 Installing the Hoses . . . . . . . . . . . . . . . . . . 35 Tuxco Warranty . . . . . . . . . . . . . . . . . . . . . . 36

Contents Literature Information Safety Section . . . . . . . . . . . . . . . . . . . . . . . . 3 General Information Section . . . . . . . . . . . . . 4 Operation Section . . . . . . . . . . . . . . . . . . . . . 4 Assembly Section . . . . . . . . . . . . . . . . . . . . . 4 Maintenance Section . . . . . . . . . . . . . . . . . . 4 Personal Protection/Important Information . . 4 Prohibited Action . . . . . . . . . . . . . . . . . . . . . . 4 Hazard Avoidance . . . . . . . . . . . . . . . . . . . . . 5 Safety Section Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . 5 General Information Section Description. . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assembly Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Positioning the Bench . . . . . . . . . . . . . . . . 10 Anchoring the Bench . . . . . . . . . . . . . . . . . 12 Anchoring the Tracks. . . . . . . . . . . . . . . . . 13 Connecting the Hydraulic Power Unit . . . . 15 Assembling the Portable Oil Basin . . . . . . 15 Operation Section Function of Components . . . . . . . . . . . . . . . 16 Service Bench . . . . . . . . . . . . . . . . . . . . . . 16 Adjustable Supports . . . . . . . . . . . . . . . . . 18 Spanner . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Head Stock . . . . . . . . . . . . . . . . . . . . . . . . 20 Hydraulic Torque . . . . . . . . . . . . . . . . . . . . 21 Nut Runner. . . . . . . . . . . . . . . . . . . . . . . . . 22 Indexing Cylinder. . . . . . . . . . . . . . . . . . . . 23 Pendent Control . . . . . . . . . . . . . . . . . . . . . 23 Function Switch Operation. . . . . . . . . . . . . 24 START-STOP. . . . . . . . . . . . . . . . . . . . . . . 24 EXTEND-RETRACT . . . . . . . . . . . . . . . . . 24 TORQUE-DETORQUE . . . . . . . . . . . . . . . 24 Torque Tracks. . . . . . . . . . . . . . . . . . . . . . . 24 Cylinder Service Procedure. . . . . . . . . . . . . 25 Preparing the Service . . . . . . . . . . . . . . . . 25 Mounting the Cylinder . . . . . . . . . . . . . . . . 26

Literature Information This manual should be stored with the tool group.

This manual contains safety information, operation instructions, and maintenance information.

Some photographs or illustrations in this publication show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, please consult Dealer Service Tools (DST) for the latest available information.

Safety Section The Safety section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

3

This manual contains instructions for the installation, operation, and maintenance of the HCS-40 Hydraulic Cylinder Servicer. It includes an explanation of how features of the HCS-40 function in the repair and service of hydraulic cylinders.

General Information Section The General Information section describes tooling functions and features. It provides useful information on individual parts, additional tooling, and resources.

Operation Section The Operation section is a reference for the new operator and a refresher for the experienced operator.

WARNING To avoid injury or damage to equipment, study and understand the precautions and procedures presented in this manual, before attempting to install or operate the Hydraulic Cylinder Servicer.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and its capabilities.

Safety Icon Nomenclature

Assembly Section

Personal Protection/Important Information

The Assembly section is a guide to equipment assembly and installation.

Read the manual

Maintenance Section The Maintenance section is a guide to equipment care.

Eye protection Eye protection and ear protection

Safety Section Face protection

Read all CAUTIONS, WARNINGS, and INSTRUCTIONS included with, or attached to, the product. Follow all safety precautions to avoid personal injury or property damage during system operation. TUXCO CORPORATION CANNOT BE RESPONSIBLE FOR DAMAGE OR INJURY RESULTING FROM UNSAFE PRODUCT USE, LACK OF MAINTENANCE, OR INCORRECT PRODUCT AND SYSTEM APPLICATION. Contact Tuxco Corporation, when in doubt, as to safety precautions, design criteria, or product usage.

Hand protection Respirator Inspect equipment Use proper tools

Prohibited Action

TUXCO CORPORATION 4300 Grove Ave. Gurnee, IL U.S.A. 60031-2155 Telephone: 847-244-2220 Toll Free: 800-613-6979 FAX: 847-244-7335 Website: www.tuxco.com E-Mail: moreinfo@tuxco.com

No smoking

4

Hazard Avoidance

WARNING

Bending hazard (hydraulic hose)

To prevent possible damage to your hearing, always wear ear protection when using this tool and/or working around noise generating tools.

Crushing hazard Crushing hazard (foot)

To avoid eye injury, always wear protective glasses or face shield.

Make sure no one can be injured by flying objects or debris when using tools or working on a component.

Crushing hazard (hand) Fire hazard High-pressure fluid hazard

Clean up all leaked or spilled fluids immediately.

Oil, fuel, or cleaning fluid leaked or spilled onto any hot surfaces or electrical components can cause a fire, resulting in personal injury or death.

Impact hazard (hydraulic hose) Maximum pressure Pinch point

Personal injury can result from slips or falls. DO NOT leave tools or components laying around the work area and clean up all spilled fluids immediately.

Pressurized air Projectile hazard

Personal injuries can occur as a result of using pressurized air.

Maximum air pressure at the nozzle must be below 205 kPa (30 psi) for cleaning purposes.

Wear protective clothing, protective glasses, and a protective face shield when using pressure air.

Safety alert symbol Slipping hazard Tripping hazard

Safety Warnings

To avoid injury and damage to equipment, make sure the hoist has the rated capacity to raise the largest cylinder serviced.

WARNING To avoid personal injury or death, carefully read and understand all instructions before attempting to operate any equipment or tools.

Do not operate or work on a machine unless you read and understand the instructions and warnings in this and all other applicable manuals. Contact Dealer Service Tools for replacement manuals. Proper care is your responsibility. Always follow all State and Federal health and safety laws and/or local regulations.

To keep the Servicer from tipping over and causing damage or injury, fasten the bench and torque tracks securely to the floor before use.

5

Safety Warnings (continued)

WARNING

WARNING

When using any hydraulic equipment, wear proper gloves and take precautions to prevent injury by the release of oil under high-pressure.

To prevent eye injury from flying concrete chips or dust while drilling and cleaning holes in the floor, wear a face shield and keep other personnel at a safe distance.

Always STAND CLEAR OF THE TORQUE HEAD AND SPANNER when applying torque.

To prevent injury to lungs from concrete dust, wear a respirator.

Apply torque very carefully.

Protect all personnel from possible injury from materials blown out of the mounting holes.

NEVER USE MORE TORQUE THAN IS SPECIFIED by the cylinder manufacturer.

Keep the pressure as low as possible.

Excessive pressure may lead to damage or injury.

The cone adapters are easy to use and greatly reduce set-up time. If required torque for a specific cylinder piston retaining nut should exceed 20337 N·m (15,000 ft. lbs.), use an appropriate pair of 9000T Series flat mounting adapters, which are available as an option.

Always lock the pendent control when not in use. Use of the machine by unauthorized, untrained people could result in injury.

To avoid damage or injury, read all warnings and instructions before using the Servicer.

To avoid injury from a falling cylinder, always secure the cylinder, or its parts, on the cylinder supports with the safety straps, and always fasten the supports in place with their securing plates. Only during reassembly of the cylinder, when the support under the barrel reaches the end of the bench tube, should the strap be removed to allow the barrel to move on the support roller.

Keep the pressure as low as possible. Excessive pressure may lead to damage or injury.

Keep the T-slot horizontal, so chuck wings cannot fall out.

Anytime the wings are in the T-slot but not fastened in place, a wing can slip out and cause injury.

Use only Tuxco spanner pins.

Under high torque, substitute pins may cause injury by failing in a way that throws out metal fragments. Once the spanner is in place, tighten the eight bolts in the spanner base, the nuts holding the spanner to the bench tube, and the bolt that locks the spanner plates together.

Be prepared for oil to spurt out of the cylinder when the piston rod is moved inside the barrel.

6

Safety Warnings (continued)

WARNING

WARNING

To prevent injury from falling equipment, do not allow chuck to turn until chuck has been tightened on wrench or adapter.

To prevent injury, use the proper equipment or an appropriate number of personnel to safely lift the cylinder.

When using a socket adapter, do not exceed the recommended torque limit of the adapter.

To avoid injury or damage caused by a falling cylinder, fasten the cylinder with safety straps as soon as it is placed on the cylinder supports. During service operations, keep the straps fastened as much as possible.

Make sure the securing plate of each cylinder support is snugged against the bottom of the tube it is sitting on.

These limits are: No. 914, 3/4 inch drive No. 915, 1 inch drive No. 916, 1 1/2 inch drive No. 917, 2 1/2 inch drive

107 N·m (300 ft. lb.)

136 N·m (1,000 ft. lb.)

2711 N·m (2,000 ft. lb.)

13558 N·m (10,000 ft. lb.)

Remember to use the safety straps and securing plates whenever possible.

To avoid damage or injury, do not try to move the cylinder on the cylinder supports until the securing plates have been snugged up.

Use only Tuxco spanner pins.

Under high torque, substitute pins may cause injury by failing in a way that throws out metal fragments.

For additional product support questions concerning this tool, contact the Caterpillar Dealer Service Tools Hotline at: U.S.A.: 1-800-542-8665 Illinois: 1-800-541-8665 Canada: 1-800-523-8665 World: 1-309-675-6277 Fax: 1-309-494-1355 dealerservicetool_hotline@cat.com

To avoid injury when releasing pressure, make sure that hands and fingers cannot be pinched between the bar and the head stock.

Do not attempt to hold the ratchet bar while applying torque. Stand clear of the ratchet bar and socket.

Under high torque the ratchet bar may fail, causing injury.

Before the barrel moves off the piston, the cylinder support under the barrel should be as close as practical to the open end of the barrel, and the support under the piston rod should be close to the piston end of the rod.

7

General Information Section

HCS-40 Hydraulic Cylinder Servicer.

15. Hydraulic Power Unit 1. Tail Stock

16. Torque Gauge

2. Tail Stock Chuck

17. Bench Tube

3. Safety Strap (not shown)

18. Bench

4. Head Stock Chuck

19. Pendent Control In Holder

5. Torque Adapter Assembly

20. Oil Basin (not shown)

6. Torque Cylinder

21. Oil Basin Dolly (not shown)

7. Hydraulic Nut Runner

22. Pendent Cable Holder

8. Head Stock

23. Maximum Torque Control Valve

9. Torque Track

24. Manual Valve Package

10. Head Stock Tube

25. Low Torque Monitor

11. Cylinder Support 12. Power Sleeve 13. Indexing Cylinder (not shown) 14. Spanner

8

Description

Receiving

The HCS-40 Hydraulic Cylinder Servicer is a machine that disassembles and reassembles hydraulic cylinders during service and repair.

With the Servicer, one person can perform all the necessary operations by using a hydraulically powered system. The equipment keeps the cylinder being serviced secured and properly aligned during every step of operation. Properly used, the HCS-40 services most cylinders without risking damage to the cylinder or injury to personnel.

The HCS-40 Hydraulic Cylinder Servicer is shipped covered to protect its components during transit. The standard shipment consists of one transport skid and two crates. Any accessory items ordered are packed in the crates or packaged separately.

The HCS-40 Hydraulic Cylinder Servicer consists of a specialized bench with adjustable supports to hold the cylinder or its separated parts, a tail stock and head stock to anchor all operations, the chucks and spanner wrench to connect the Servicer with the parts of the cylinder, and a hydraulic system to provide force for the various operations.

Specific parts are identified by item number in Illustration 1. The same item numbers are given in parentheses in the rest of this manual to identify parts and their relation to the whole machine.

A Servicer packed for shipment.

Remove all strapping, packing material, and tape. Uncrate the components. Inspect the Servicer and components for shipping damage, and report any damage to the delivering carrier immediately.

Unbolt the Servicer from its skid. Depending on the availability of lifting equipment and space, it may be best to move the skid to the place where the Servicer will be used, before unbolting the Servicer from the skid.

9

Assembly Section

WARNING

Installation

To avoid injury and damage to equipment, make sure the hoist has the rated capacity to raise the largest cylinder serviced.

Positioning the Bench 1. Select a level, smooth, out-of-the-way floor space.

NOTE: The Servicer must operate on a perfectly flat surface. If head stock (8) cannot easily move by hand throughout its whole range of extension, operation will not be efficient, and the Servicer and the cylinder may not remain aligned. Leveling can usually be done by placing shims, where necessary, under torque tracks (9) and the legs of bench (18).

4. Using a 11 M (36 ft.) chalk line, make two chalk marks exactly 787 mm (31 in.) apart.

Run these marks in a direction that allows the Servicer to be placed with the long sides parallel to the marks and with the head stock end of bench (18) at least 8 M (25 ft.) from the end of the marks.

18

2. Plan for adequate space on both sides of the Servicer, and at both ends, so the Servicer can be operated through its whole range. The space occupied by the standard HCS-40 as head stock tube (10) travels between its extreme positions is shown below. Allow enough room so the operator can easily work around the Servicer, and so lifting or transporting equipment can maneuver to place and remove cylinders for repair. If other equipment or a wall will limit working space, place the Servicer so there is more room at the head stock end than at the tail stock end.

9

10

18

Chalk Line Chalk Line

79 cm (31 in)

1035-04

(18) Bench.

5. Set the Servicer between the chalk lines with the outer side of the bench legs at the line.

15

8 1M

7M

3M

2.5 M

1M

(3 ft)

(22 ft)

(10 ft)

(8 ft)

(3 ft)

14 M (46 ft)

1035-03

Bench leg positioned at chalk line.

(8) Head Stock. (9) Torque Track. (10) Head Stock Tube. (15) Hydraulic Power Unit. (18) Bench.

6. Using the chalk marks as a guide, lay out torque tracks (9) straight from the head stock end of the bench.

3. It is best to install the Servicer beneath an overhead so large cylinders can be mounted safely and efficiently. If an overhead crane is not available, a swing beam mounted electric hoist can be helpful in mounting the larger cylinders.

10

7. One of the new tracks has a welded angle about half its length. The hoses that attach to the two bulkhead fittings on the rear bench leg will run behind the angle to protect them. Be certain the track with the angle is mounted to the rear bench leg.

9. Connect a hold-down to head stock (8) where it will ride on each torque track.

Installing the hold-downs should put the torque track and the base of the head stock in the relationship shown below.

8. Bolt each torque track to a bench leg at the head stock end of the bench. Connect the track so the mounting tab of the bench leg is against the inner side of the track.

(8) Head Stock.

(9) Torque Track.

56 cm (29.75 in) 1035-09

Relation of torque tracks to base of head stock.

10. Push head stock (8) as close to the bench as it can go. Pull it out to the end of the torque tracks. If head stock tube (10) binds, shim the bench legs and/or the torque tracks to level the Servicer.

(9) Torque Track.

11. When the Servicer is level, anchor it to the floor as directed in the following instructions.

WARNING To keep the Servicer from tipping over and causing damage or injury, fasten the bench and torque tracks securely to the floor before use.

11

2. Use compressed air to clean cement dust out of the holes.

Anchoring the Bench

WARNING

3. Insert one of the provided Phillips anchors through the mounting pad into each drilled hole.

To prevent eye injury from flying concrete chips or dust while drilling and cleaning holes in the floor, wear a face shield and keep other personnel at a safe distance.

4. If necessary, use a 7/8 inch bolt or bar, or other appropriate steel item, such as a driver, and tap it with a hammer to push the top of the anchor down flush with the floor surface.

To prevent injury to lungs from concrete dust, wear a respirator.

Before the HCS-40 Hydraulic Cylinder Servicer can provide 54233 N·m (40,000 ft. lb.) of torque, it must be mounted solidly to the floor.

26

1. When the Servicer bench is lined up with the chalk marks and is exactly where it is to mount to the floor, use the holes in the mounting pads of the bench legs as drill guides. With a 22 mm (7/8 in.) carbide bit, drill holes at least 64 mm (2.5 in.) deep in the concrete. Make sure the bench does not move during drilling.

27

28 1035-11

(26) Setting Tool. (27) Mounting Pad. (28) Anchor.

5. Using a .680 to 1.13 kg (24 to 40 oz.) hammer, expand the anchor with the provided setting tool. The anchor is properly expanded when the shoulder of the setting tool is flush with the top of the anchor.

26

Drilling anchor hole for bench leg.

WARNING

1035-12

Protect all personnel from possible injury from materials blown out of the mounting holes.

(26) Setting Tool.

12

6. Place a 5/8 inch heavy flat washer on the 5/8 x 38 mm (1.5 in.) long hex head cap screw.

Anchoring the Tracks

WARNING

7. Screw the bolt with the washer into the anchor and torque the bolt to 108 to 122 N·m (80 to 90 ft. lb.). Properly installed, the anchor will have a pull-out strength of about 6804 kg (15,000 lb.).

To prevent eye injury from flying concrete chips or dust while drilling and cleaning holes in the floor, wear a face shield and keep other personnel at a safe distance.

To prevent injury to lungs from concrete dust, wear a respirator.

1. Make sure the tracks are properly aligned with the chalk marks.

2. Anchor the free end of each torque track.

Use the hole in the mounting pad as a drill guide. With a 22 mm (7/8 in.) carbide bit, drill a hole at least 64 mm (2.5 in.) deep in the concrete. Make sure the track does not move during drilling.

Tightening anchor bolt to proper torque.

(9) Torque Track.

13

7. Place a 5/8 inch heavy flat washer on the 5/8 x 38 mm (1.5 in.) long hex head cap screw.

WARNING Protect all personnel from possible injury from materials blown out of the mounting holes.

8. Screw the bolt with the washer into the anchor and torque the bolt to 108 to 122 N·m (80 to 90 ft. lb.). Properly installed, the anchor will have a pull-out strength of about 6804 kg (15,000 lb.).

9. Using the procedure used previously (refer to the “Positioning the Servicer” section of this manual), check for binding when the head stock is moved.

3. Use compressed air to clean cement dust out of the hole.

4. Insert one of the provided Phillips anchors through the mounting pad into each drilled hole.

10. If the head stock tube binds, make the necessary corrections in the torque tracks.

5. If necessary, use a 7/8 inch bolt or bar, or other appropriate steel item, such as a driver, and tap it with a hammer to push the top of the anchor down flush with the floor surface.

a. With a spirit level, check both tracks for level throughout their length. If the tracks are not level, loosen the bolts in the floor anchors and shim the tracks to level.

6. Using a .680 to 1.13 kg (24 to 40 oz.) hammer, expand the anchor with the provided setting tool. The anchor is properly expanded when the shoulder of the setting tool is flush with the top of the anchor.

b. Make sure both tracks are lined up perfectly with the bench and are approximately 756 mm (29.75 in.) apart throughout their length. If not, loosen the bolts in the floor anchors and shift the tracks to position properly. c. Holding the tracks in proper position, torque the bolts again to 108 to 122 N·m (80 to 90 ft. lb.).

11. Repeat Steps 2 through 8 to anchor the remaining mounting pads.

26

27

28 1035-11

(26) Setting Tool. (27) Mounting Pad. (28) Anchor.

26

1035-12

(26) Setting Tool.

14

Connecting the Hydraulic Power Unit

Assembling the Portable Oil Basin 1. Assemble the oil basin dolly. Bolt the caster assemblies to the cross in the inner holes.

1. Uncrate the 5 hp hydraulic power supply, which has been prewired. Position it at the tail stock end of the bench with the pump ports perpendicular to the four hydraulic hoses protruding from the end of the bench.

Assembly of oil basin dolly.

2. Install the oil basin, as shown.

(15) Power Unit.

2. Carefully bend the four hydraulic hoses and attach them to the power unit using the number and color-coding provided.

3. Uncoil pendent control (19) and its prewired 8 M (25 ft.) cable. Run it under the bench to a point beyond the middle bench leg. Place pendent (19) in the pendent holder. Coil excess cable onto cable hook.

NOTE: Refer to color-coding chart on Page 34.

(20) Oil Basin. (21) Oil Basin Dolly.

4. Reach under the bench and insert the cable into the plastic cable trough. Snap the cable holder closed.

5. Fill the oil tank with 38 L (10 gal.) of DTE 24 hydraulic oil or equivalent.

6. Have a licensed electrician wire the power unit to an appropriate electrical source.

15

Operation Section Function of Components The Hydraulic Cylinder Servicer allows a cylinder to be mounted on its exact center line, so hydraulic power can be used to detorque a cap, withdraw the piston rod, detorque and torque the piston retaining nut, reassemble the cylinder, torque the cap, and drive in the rod to give the cylinder its minimum length for easy handling. The components of the Servicer are discussed in detail in the following paragraphs. Be familiar with each component and its proper use.

To identify the location of a component, refer to the “Description” section of this manual.

Numbers in parentheses after the name of a component correspond with item numbers in Illustration 1 in the “Description” section. For example, bench tube (17) is also identified as item number 17 in Illustration 1.

(2) Tail Stock Chuck. (17) Bench Tube. (18) Bench.

For a brief outline of how a component relates to other components and fits into the servicing process, see the “Outline of Operation” section of this manual.

Service Bench Bench (18) is a basic weldment, which includes a permanently attached 3 M (10 ft.) length of 102 mm (4 in.) square steel tubing, bench tube (17). Head stock tube (10), a 89 mm (3.5 in.) square steel beam 4 M (14 ft.) long, can be moved hydraulically to the left or right through the bench tube. There is also a 2.5 M (8 ft.) extension tube that mounts to the end of the 4 M (14 ft.) tube.

(1) Tail Stock.

Tail stock (1) is permanently attached to the bench to give it maximum rigidity and strength.

Moveable tail stock chuck (2) is supported by rollers that run on the bench and a square tube that slides through the tail stock. The position of the chuck may be changed by unlocking the base of the chuck, removing the locking pin from the tube, and pushing or pulling the tube. A locking pin may be inserted into the hole nearest the end of the tube. Push or pull the pin.

(1) Tail Stock. (10) Head Stock Tube. (18) Bench.

16

The tail stock chuck has a t-slot 578 mm (22.75 in.) long. Two chuck wings can be inserted into the slot and secured on the center line of the cylinder under repair.

The head stock chuck wings have 44 mm (1.75 in.) holes bored in them. The Servicer includes two pairs of cone-shaped cylinder eye mounting adapters. The smaller pair, No. 930H, fits eye bushings from 25 to 89 mm (1 to 3.5 in.) I.D. The larger pair, No. 960H, fits eye bushings from 92 to 146 mm (3.625 to 5.75 in.) I.D. Optional pair, No. 980H, fits eye bushings from 152 to 203 mm (6 to 8 in.) I.D. The mounting adapters are secured to the chuck wings with set screws, and the barrel encapsulated between them, using one of the provided 1-8 inch through bolts, tightly secured with heavy nuts and washers.

Both tail stock chuck (2) and head stock chuck have a horizontal scale stamped into their surface. This scale is used to line up the cylinder on the center line of the Servicer, before the chuck t-slot is tightened to fasten the chuck wings in place.

The cylinder rod eye is always mounted to tail stock chuck (2). Because higher torques are used to loosen and tighten piston retaining nuts, the tail stock chuck wings are of heavier construction. The tail stock chuck wings have 51 mm (2 in.) holes bored in them to accommodate the No. 930T and No. 960T mounting adapters, and the optional No. 980T set. Use the provided 1-8 inch through bolt, nuts, and washers with the No. 960T cones, and the 1-1/2-6 inch through bolts, nuts, and washers with the No. 960T and No. 980T adapters. Storage posts are located on the tail stock end of the machine.

(2) Tail Stock Chuck.

WARNING Protect all personnel from possible injury from materials blown out of the mounting holes.

WARNING The cone adapters are easy to use and greatly reduce set up time. If required torque for a specific cylinder piston retaining nut should exceed 20337 N·m (15,000 ft. lbs.), use an appropriate pair of 9000T Series flat mounting adapters, which are available as an option.

Securing cone bushing in chuck wing.

17

Adjustable Supports

WARNING

Two cylinder supports (11) are adjustable, up and down or sideways, by turning the two adjustment nuts. Each cylinder support has a securing plate held in place by two nuts.

To avoid injury from a falling cylinder, always secure the cylinder, or its parts, on the cylinder supports with the safety straps, and always fasten the supports in place with their securing plates. Only during reassembly of the cylinder, when the support under the barrel reaches the end of the bench tube, should the strap be removed to allow the barrel to move on the support roller.

Spanner Universal spanner (14) is a built-in wrench. Its basic function is to hold the gland retaining nut stationary while the hydraulic system of the Servicer turns the cylinder barrel. The spanner consists of two vertical steel plates mounted on the spanner base. The plates can move horizontally in a t-slot in the base. The base can be moved anywhere along the length of bench tube (17) and secured to the tube.

(3) Safety Strap. (11) Cylinder Support.

(3) Safety Strap. (11) Cylinder Support.

Both cylinder supports can be used on either the head stock tube or the bench tube.

(14) Spanner. (17) Bench Tube.

Each cylinder support has two slots that hold safety strap (3). The strap prevents a cylinder barrel or piston rod from falling during service operations.

18

The vertical plates of the spanner have two 1/2-13 inch tapped holes that are on the same plane as the cylinder's center line. Spanner pins screw into these holes and fit into the slots or holes in the front face of the piston rod retaining nut.

Adapter blocks are provided so the spanner can also engage retaining caps with slots or holes on the circumference of the cap. The blocks bolt into the center-line holes of the spanner plates and hold round or square spanner pins in proper position to connect with caps.

Use of spanner adapter blocks.

The HCS-40 will provide much more torque than the spanner pins can resist. While Tuxco spanner pins are made from an alloy threaded rod, they will shear if subjected to too much force.

WARNING Use only Tuxco spanner pins.

Under high torque, substitute pins may cause injury by failing in a way that throws out metal fragments. Once the spanner is in place, tighten the eight bolts in the spanner base, the nuts holding the spanner to the bench tube, and the bolt that locks the spanner plates together.

19

Head Stock Head stock (8) rests on a roller supported base. It carries head stock chuck (4), hydraulic torque (6), torque gauge (16), and hydraulic nut runner (7). The head stock chuck is mounted on a spindle which is attached to hydraulic nut runner (7) by a spline.

In preparing to take apart a cylinder, secure the eye of the cylinder barrel to head stock chuck (4) in the same way the eye of the piston is secured to the tail stock chuck. The spanner is positioned to keep the gland retainer or threaded barrel cap from turning while head stock chuck (4) is rotated counterclockwise using either hydraulic nut runner (7) or hydraulic torquing cylinder (6). The barrel unscrews from the retainer or cap. Bolt on caps do not require spanner (14).

(4) Head Stock Chuck. (6) Torque Cylinder.

(7) Hydraulic Nut Runner. (23) Maximum Torque Control Valve.

(4) Head Stock Chuck.

Barrel partially unscrewed from retaining nut.

20

Hydraulic torque (6) consists of a quick connector equipped, double-acting hydraulic cylinder. It is mounted to head stock (8) with a 25 mm (1 in.) diameter clevis pin secured by two hitch pins. The piston rod is secured to torque adapter assembly (5) by a similar pin, also secured with two hitch pins. The torque adapter has four sets of matching holes that make it easy to attach the holes in the head stock chuck plate. Two alloy 1 1/2 inch bars are used to make the connection.

Hydraulic Torque Hydraulic torque (6) is used when high torques are required to loosen barrel caps or retaining nuts. Hydraulic nut runner (7) is used when less than 5423 N·m (4,000 ft. lb.) of torque is required or when hydraulic torque (6) has broken loose the barrel cap or retaining nut.

Square drive socket adapters may be used to mount sockets in head stock chuck (4). They are optional items available from Tuxco. For high torques, however, use No. 913. If the piston retaining nut is the square type, reverse the jaws of the No. 913 wrench.

Hydraulic torque cylinder (6) has one male and one female quick connector matching the quick connectors on the two hydraulic hoses protruding from the rear torque track. When attached to hydraulic torque cylinder (6), the piston can be extended to provide counterclockwise torque to detorque, or can be retracted to provide clockwise torque for torquing.

If servicing cylinders with recessed piston retaining nuts, the large sockets may need to be welded to a custom made adapter that fits the t-slot chuck.

Torque gauge (16), located in the top of the head stock, automatically shows and records loosening and tightening torques.

No. 913 Universal High Torque T-Slot Wrench.

(16) Torque Gauge.

There is a short length of hydraulic hose equipped with a male and female quick connector that MUST BE ATTACHED to nut runner (7) when the torquing cylinder is in use.

This allows the nut runner hydraulic motor to bypass, preventing false torque readings and damage to the hydraulic motor.

At both ends of the torque cylinder stroke, the torque gauge will show a false reading indicating the pressure of the system, not applied torque.

(4) Head Stock Chuck. (5) Torque Adapter Assembly.

(6) Torque Cylinder. (7) Hydraulic Nut Runner.

(23) Maximum Torque Control Valve.

21

If a second torque stroke is required, retract the torque piston as far as possible and then use the second pair of holes in torque adapter assembly (5) to connect it to the chuck.

WARNING Always STAND CLEAR OF THE TORQUE AND SPANNER when applying torque.

Maximum torque control valve (23) is mounted underneath the nut runner bracket. The black adjustment knob protrudes from the front cover of the hydraulic nut runner mounting bracket.

This valve controls the amount of torque provided by the torquing cylinder. It will not limit the amount of torque produced by extending the cylinder.

Apply torque very carefully.

NEVER USE MORE TORQUE THAN IS SPECIFIED by the cylinder manufacturer.

TO AVOID OVER TORQUING that could damage a cylinder, ALWAYS adjust torque control valve (23) before torquing. To do this, open the valve all the way by turning the knob counterclockwise as far as it will go. In this position, the hydraulic torque will provide only 2712 N·m (2,000 ft. lb.) of torque.

Nut Runner Hydraulic nut runner (7) is attached to the head stock chuck with a splined coupling.

When the HCS-40 is wired for 60 hz current, the nut runner will turn the head stock chuck clockwise and counterclockwise at approximately 7 rpm. The nut runner produces a maximum of 5423 N·m (4,000 ft. lb.) of torque.

With torque adapter assembly (5) detached from the chuck, bottom out the torquing cylinder by fully extending or retracting the piston. Reading the yellow scale on torquing gauge (16), turn the valve clockwise until the yellow scale reading on the gauge equals the cylinder manufacturers torque specification.

Attach the torque adapter assembly and proceed.

The hydraulic nut runner uses the same two hydraulic hoses that power double acting torque cylinder (6).

Due to the nut runner’s power, it may be possible to service some cylinders without using the torque cylinder.

WARNING When using any hydraulic equipment, wear proper gloves and take precautions to prevent injury by the release of oil under high-pressure.

(7) Hydraulic Nut Runner. (16) Torque Gauge.

(23) Maximum Torque Control Valve.

22

Indexing Cylinder

Pendent Control

Telescopic head stock tube (10) is attached by a mounting plate and four 3/4 inch bolts to the head stock. The tube is moved hydraulically to the left or right through bench tube (17) to withdraw and replace piston rods.

All hydraulic circuits of the HCS-40 are controlled by switch activated, low-voltage solenoids. The switches are located in heavyduty pendent control (19) attached to the end of a 8M (25 ft.) cable.

The bench contains 1219 mm (48 in.) stroke hydraulic cylinder (13) mounted below bench tube (17). The rod of the cylinder extends from the head stock end of bench (18) and is attached by means of a clevis pin to power sleeve (12). There are pairs of holes drilled through the sides of head stock tube (10). A steel pin placed through the head stock tube holes allows the power sleeve to push or pull power sleeve (12) against the pin, moving the head stock away or toward bench (18).

The pendent control contains six button switches that are labeled START-STOP, EXTEND-RETRACT, and TORQUE-DETORQUE. There is a lock at the top of the pendent to prevent tampering with the HCS-40.

There is 19931 N·m (14,700 ft. lb.) of force available. Always be sure the head stock is free to move and that there are no obstructions in its path before activating the indexing cylinder.

(19) Pendent Control.

WARNING Always lock the pendent control when not in use. Use of the machine by unauthorized, untrained people could result in injury.

(10) Head Stock Tube. (12) Power Sleeve. (13) Indexing Cylinder. (18) Bench.

23

Function Switch Operation

Torque Tracks

START-STOP

The HCS-40 Hydraulic Cylinder Servicer can supply very high torques to loosen the gland and piston retaining nuts. In the upper torque ranges, applied torque tends to lift the cross channel at the base of head stock (8) off torque tracks (9). The torque track and the hold-downs on the ends of the cross channel prevent lifting of the head stock assembly by torque.

With the “START-STOP” switch on the cover of the panel box of hydraulic power unit (15) in the ON position, the green pendent button switch turns the hydraulic power unit on. The red switch turns the unit OFF. EXTEND-RETRACT Depressing the “EXTEND” button activates indexing cylinder (13), extending the piston.

The “RETRACT” button retracts the cylinder: The button must be kept depressed to function.

Because the head stock must ride on the torque tracks in all its positions, a stop is provided at the end of the tracks to keep the head stock from running off the end.

Micro-jogging is available by quickly pressing and releasing either button.

NOTICE

TORQUE–DETORQUE

If the head stock is at the end of the tracks, do not apply hydraulic pressure to extend the Servicer farther. This will damage the equipment.

This pair of buttons controls the flow of pressurized oil to the two hoses protruding from the rear torque track. Depending on whether the two hoses are attached to nut runner (7) or to hydraulic torque (6), the “DETORQUE” button provides either an unscrewing function or a detorquing function.

The “TORQUE” button provides either a screwing or torquing function.

Micro-jogging is available by quickly pressing and releasing either button.

24

2. If the piston rod has been positioned incorrectly, move the rod to the correct position. Unlock the tail stock chuck, remove the locking pin from the tube of the chuck, push or pull the chuck (with the piston rod attached) to the correct position, and lock the chuck in the new position.

Cylinder Service Procedure

WARNING To avoid damage or injury, read all warnings and instructions before using the Servicer.

Keep the pressure as low as possible. Excessive pressure may lead to damage or injury.

Excessive pressure requirements for disassembly or assembly are usually caused by misalignment or bent piston rods. When the piston rod is bent, it often makes servicing easier to connect the piston rod yoke to the tail stock with a chain, instead of connecting the yoke to the chuck in the usual way.

(2) Tail Stock Chuck.

3. Prepare two cylinder supports (11) to receive the cylinder.

NOTE: The number in parentheses after the name of a Servicer component corresponds to the item numbers in Illustration 1.

a. If mounting the cylinder with the aid of an overhead crane (recommended) or other lifting equipment, lower the cylinder supports below the level where they are expected to be used.

Preparing the Service 1. Estimate the distance from the piston rod yoke to the piston-retaining nut in the cylinder to be serviced. Using movable tail stock chuck (2), position the cylinder so the piston retaining nut will be beyond the head stock end of the bench. After the piston rod and the barrel are separated, this positioning will permit reaching the pistonretaining nut with a wrench that is turned by hydraulic torque (6) or nut runner (7).

b. If the cylinder must be moved onto the cylinder supports by hand, proceed as follows.

(1) If the piston rod is retracted (the preferred condition), position both cylinder supports so they are under the barrel and adjust both supports to the same height.

(2) If the piston rod is extended more than about one-third of its length, position the cylinder support with the roller under the barrel, and the support with the wood block under the piston rod. Allow for the difference in diameter between the barrel and the rod by setting the support with the block higher.

25

4. When the cylinder supports are in place, fasten with the securing plates.

2. Move the cylinder into position on the center line of the Servicer, with the piston rod toward tail stock (1) and the barrel toward head stock (8). A safety sling with an overhead crane with a rated capacity to raise more that the weight of the cylinder is the recommended lifting equipment.

5. Measure the ID's of the barrel and piston rod eyes, and select the proper conical bushings to install in the chuck wings.

Fasten item in place with the set screws.

6. Using the nut runner or hydraulic torque, turn the head stock chuck so the T-slot in the chuck is horizontal.

3. If using lifting equipment, position the cylinder on the center line of the Servicer and hold the cylinder in place with the sling. Proceed to Step 8 of this procedure.

4. If the cylinder must be positioned by hand, have cylinder supports (11) positioned and adjusted, as explained in the “Preparing the Servicer” section of this manual. Carefully move the cylinder onto the supports.

WARNING Keep the t-slot horizontal, so chuck wings cannot fall out.

Anytime the wings are in the t-slot but not fastened in place, a wing can slip out and cause injury.

5. Immediately secure the cylinder to the cylinder supports with safety straps (3).

7. Insert the chuck wings into both the head stock and tail stock chucks.

WARNING To avoid injury or damage caused by a falling cylinder, fasten the cylinder with safety straps as soon as it is placed on the cylinder supports. During service operations, keep the straps fastened as much as possible.

Make sure the securing plate of each cylinder support is snugged against the bottom of the tube it is sitting on.

Mounting the Cylinder 1. Make sure the oil ports are open on the cylinder to be repaired.

CAUTION Be prepared for oil to spurt out of the cylinder when the piston rod is moved inside the barrel.

6. As soon as possible, insert a through bolt through the chuck wings and yoke at each end of the cylinder and spin a nut onto the end of each through bolt. This action will help ensure that the cylinder cannot fall during mounting operations.

WARNING To prevent injury, use the proper equipment or an appropriate number of personnel to safely lift the cylinder.

7. Make any necessary adjustments in the cylinder supports to bring the center line of the cylinder up or down to the level of the Servicer center line.

8. After the final adjustment to the cylinder supports, turn the nuts on the securing plates finger tight.

26

13. If mounting the cylinder by hand (without the help of lifting equipment), proceed to Step 17 of this procedure.

WARNING To avoid damage or injury, do not try to move the cylinder on the cylinder supports until the securing plates have been snugged up.

14. If mounting the cylinder with the help of lifting equipment, raise the cylinder supports until they are pressing upward slightly on the cylinder.

NOTE: When a cylinder support must be adjusted upward, the securing plate must be lowered first.

9. Close the wings of tail stock chuck (2) so the bushings enter the rod eye.

10. Fasten the through bolt tightly with the appropriate washers and nuts.

15. When the cylinder supports have been adjusted, turn the nuts on the securing plates finger tight.

NOTE: The chuck wings should now be parallel with each other.

16. Immediately secure the cylinder to the cylinder supports with safety straps (3).

11. Using the indexing cylinder, move the head stock so the conical bushings in the wings of the head stock chuck will fit in the barrel eye.

WARNING

12. Secure the barrel eye following the procedures in Steps 9 and 10.

To avoid injury or damage caused by a falling cylinder, fasten the cylinder with safety straps as soon as it is placed on the cylinder supports. During service operations, keep the straps fastened as much as possible.

Make sure the securing plate of each cylinder support is snugged against the bottom of the tube it is sitting on.

(3) Safety Strap. (4) Head Stock Chuck.

27

17. Using the left-to-right scales on the chucks, shift the ends of the cylinder horizontally to bring the center line of the cylinder exactly onto the center line of the Servicer. The end of the cylinder will be centered when the inner surfaces of both wings are at the same numbers on the scale. For example, if one wing is at the left-hand "3" on the scale, the other wing should be at the right-hand "3" on the scale.

Disassembling the Cylinder Threaded Gland Retainer

NOTICE If there are any set screws installed to keep the gland retainer from turning, make sure they are backed out far enough for clearance. The Servicer will shear off any fastened set screw, which ruins the threads on the barrel.

1. If the gland retainer or cap is threaded, use either the nut runner or torquing cylinder to turn the barrel so the spanner holes or slots are horizontal.

2. Select the proper spanner pins and install in spanner (14).

WARNING Use only Tuxco spanner pins.

Under high torque, substitute pins may cause injury by failing in a way that throws out metal fragments.

Horizontal scale on chuck.

NOTE: The HCS-40 will provide much more torque than the spanner pins can resist. While Tuxco spanner pins are made from an alloy threaded rod, they will shear if subjected to too much force. Inspect the spanner pins before each use. Replace any pins that are worn or distorted.

18. Tighten the screws on each chuck to fasten the chuck wings in the t-slots.

3. If spanner pins of the proper size or shape are not available, or if the holes in the retaining nut have been damaged and will not securely hold the pins, make new holes.

Carefully drill two new holes in the face of the retaining nut or the circumference of the retaining cap. Drill the two holes exactly opposite each other (exactly 180 degrees apart).

Tightening chuck screws.

NOTE: Because the cylinder may be "sagging" slightly, tighten the upper screws on the head stock chuck first.

28

4. Move the spanner so the pins slip into the holes in the retaining nut or cap. The best procedure is to insert the pin that is carried by the spanner plate nearest to the barrel.

Then, if necessary, rotate the barrel slightly to permit the other pin to enter its hole in the retaining nut.

6. Many cylinder caps require less than 5423 N·m (4,000 ft. lb.) of torque to loosen them. Try the nut runner first. If it does not break the cap loose, switch the hoses to the hydraulic torque.

WARNING Always STAND CLEAR OF THE TORQUE AND SPANNER when applying torque.

Apply torque very carefully.

NEVER USE MORE TORQUE THAN IS SPECIFIED by the cylinder manufacturer.

Keep the pressure as low as possible.

Excessive pressure may lead to damage or injury.

(14) Spanner.

5. Tighten the nuts that secure the spanner on bench tube (17), the eight bolts in the spanner base, and the bolt that locks the spanner plates together.

WARNING To avoid injury when releasing pressure, make sure that hands and fingers cannot be pinched between the bar and the head stock.

NOTE: If the pins shear off before the gland retainer breaks loose, try the following. a. Enlarge the holes in the retainer and use larger pins. b. Tack weld the boss on the spanner plates to the nut or cap. c. Help the spanner by applying a chain wrench to the barrel and stopping the wrench handle against the bench. d. If none of these methods work, call Tuxco for other suggestions. There is a way to remove almost any retainer with the Servicer.

Spanner fastened in place.

29

Bolted Gland Retainer 1. Attempt to remove the gland retaining bolts with an impact wrench.

2. If any bolt does not come loose, position the bolt so a ratchet bar and socket can be placed on the bolt with the handle braced against the bench.

Welding spanner plates to cap.

Ratchet bar positioned to loosen bolt hydraulically.

NOTE: If the spanner pins "walk" out of the holes in the retaining nut or cap because the holes are worn, try the following.

3. With the Servicer hydraulic system, loosen the bolt by turning the head stock chuck clockwise as viewed from the tail stock.

a. Apply slight pressure against the spanner by carefully jogging the indexing cylinder. b. Hold the retaining nut or cap against the spanner with C-clamps or Vise-Grips.

WARNING

c. Drill new holes in the retaining nut or cap.

Do not attempt to hold the ratchet bar while applying torque. Stand clear of the ratchet bar and socket.

Under high torque the ratchet bar may fail, causing injury.

CAUTION Unscrewing the retainer forces it against the spanner and tends to bend the spanner plates. As soon as the plates begin to deflect toward the tail stock, take the pressure off the threads and spanner by moving the head stock out slightly with the indexing cylinder.

Use caution. Move the indexing cylinder only slightly to ensure the retainer is not pulled off of the spanner pins.

30

2. When the retainer is disconnected from the barrel, use hydraulic power to push the barrel off the piston by driving the head stock away from the bench.

All Cylinders 1. Always assume there is oil in the cylinder being serviced. Attach a hose to each port and place the open end of the hose in the oil basin. Have the oil basin under the open end of the barrel when the piston is withdrawn. Be ready for oil to spurt out of the ports any time the piston is moved inside the barrel.

NOTE: If the piston rod is bent, avoid binding by connecting the piston rod yoke to the tail stock with a chain instead of connecting the yoke to the tail stock chuck in the usual way.

WARNING Before the barrel moves off the piston, the cylinder support under the barrel should be as close as practical to the open end of the barrel, and the support under the piston rod should be close to the piston end of the rod.

3. Remove the cylinder barrel from the machine. DO NOT CHANGE THE ADJUSTMENT OF THE SUPPORT STANDS.

Basin positioned to catch oil.

WARNING

Removing the Piston

Clean up all leaked or spilled fluids immediately.

Oil, fuel, or cleaning fluid leaked or spilled onto any hot surfaces or electrical components can cause a fire, resulting in personal injury or death.

WARNING To prevent injury from falling equipment, do not allow chuck to turn until chuck has been tightened on wrench or adapter.

Personal injury can result from slips or falls. DO NOT leave tools or components laying around the work area and clean up all spilled fluids immediately.

1. Center the wrench or adapter in the chuck.

2. Snug down the chuck screws.

3. Whether using a square drive adapter and socket or the No. 913 wrench, hydraulically move the head stock toward the bench. If necessary, turn the chuck until the socket or wrench will engages the piston-retaining nut.

31

Reassembling the Cylinder

WARNING

CAUTION

When using a socket adapter, do not exceed the recommended torque limit of the adapter.

Always clean parts completely before assembly.

These limits are: No. 914, 3/4 inch drive No. 915, 1 inch drive No. 916, 1 1/2 inch drive No. 917, 2 1/2 inch drive

Follow the manufacturer's recommendations for lubrication of threads and seals.

107 N·m (300 ft. lb.)

136 N·m (1,000 ft. lb.)

2711 N·m (2,000 ft. lb.)

13558 N·m (10,000 ft. lb.)

Screw the piston-retaining nut onto the rod carefully, by hand, to avoid cross threading.

If the nut is left in the t-slot wrench and installation of the nut is started by turning the head stock chuck, resistance that indicates the beginning of cross threading will not be felt.

4. If using the No. 913 wrench, loosen the chuck screws. Tighten the wrench on the piston retaining nut. Snug down the chuck screws again. Make sure the wrench is centered by reading the scale on the chuck.

1. If the piston rod has to be removed from the Servicer, mount the piston rod. For directions and precautions, refer to the “Mounting the Cylinder” section of this manual. Make sure the correct bushings are in the chuck wings, and follow the centering procedure. Use a magnetic level to check that the piston rod is at the correct height.

5. Use the hydraulic torque to loosen the nut, operating the torque the same as when loosening the gland retainer. Refer to the “Disassembling the Cylinder” section of this manual for precautions. In some cases, it may be possible to loosen and spin the nut off with the hydraulic nut runner.

6. Back the head stock away from the piston, and remove the piston.

2. After the cylinder has been serviced, replace the gland retaining nut or cap, the piston, and the piston-retaining nut.

7. If the piston is difficult to remove, use the head stock chuck to remove it. a. Loosen the chuck screws and remove the wrench or adapter.

CAUTION

b. Push the chuck against the end of the piston rod. Insert two short lengths of 1 1/2 inch bar in the chuck wings.

Fasten the wing set screws. Tighten the wings in the chuck and pull the gland off the piston rod by carefully jogging the head stock outward.

Start installation of the piston-retaining nut by hand.

3. Mount the wrench or adapter with a socket in the head stock chuck.

4. Engage the piston-retaining nut with a wrench or socket and use either the hydraulic torque or nut runner to tighten the nut. If using the hydraulic torque, torque can be controlled. Refer to the “Hydraulic Torque” section of this manual. If using the nut runner, the finishing torque will be approximately 5243 N·m (4,000 ft. lb.).

8. If the rod is not going to be polished or serviced, leave it on the Servicer so aligning the rod and barrel for reassembly can be done easily.

9. To speed reassembly, do not change any of the support adjustments, if possible.

32

12. If necessary, make small vertical or diagonal adjustments by turning the nuts on the cylinder supports to align the piston rod and barrel with the piston rod.

Any needed adjustments are normally made at the cylinder support that is under the barrel. Turning both nuts the same amount, in the same direction, will move the barrel straight up or straight down.

Turning just one nut will move the barrel diagonally.

NOTE: Read torque from the torque gauge while the torque cylinder is at the beginning or middle of its stroke. Readings taken at the end of the stroke result in false readings.

5. Remove the wrench or adapter from the head stock chuck.

WARNING

13. Lubricate the piston and new seals.

Remember to use the safety straps and securing plates whenever possible.

CAUTION There should be little or no resistance when inserting the piston into the barrel. If there is any resistance, stop and check for misalignment, and for anything that might hinder the motion of the head stock or head stock tube.

6. Move the head stock out to accommodate the barrel.

7. Put the roller-equipped cylinder support back onto the Servicer.

8. Mount the barrel on the Servicer. For directions and precautions, refer to the “Mounting the Cylinder” section of this manual. Make sure the correct bushings are in the chuck wings. Follow the centering procedure.

14. Using indexing cylinder (13), insert the piston rod into the barrel, watching carefully for any sign of binding.

NOTE: If there is no ramp in the barrel, it may be necessary to use a piston ring compressor.

Refer to the manufacturer's instructions.

9. If using the Servicer to work on another cylinder after this cylinder was disassembled, or if any Servicer adjustment was changed while this cylinder was being repaired, make sure that alignment is correct. Check the barrel and piston rod with a magnetic level and, if necessary, adjust the cylinder supports to make the barrel and piston rod perfectly level.

CAUTION The securing plate under the cylinder support that holds the barrel must be tight enough to hold the support safely upright, but loose enough to let the head stock tube slide through the support.

10. Hydraulically move and jog the head stock so the piston is at, but not in, the opening of the barrel.

15. Continue inserting the piston rod until the opening of the barrel meets the gland retainer. Move the cylinder support under the piston rod as necessary.

11. Check the alignment of the piston with the opening of the barrel.

16. Check alignment of the gland retainer with the opening of the barrel. Make any necessary adjustments at the cylinder support that is under the barrel.

NOTICE Align the piston rod and barrel carefully to avoid damaging the cylinder during reassembly.

33

17. If the cylinder has a threaded gland retainer: a. Lubricate the threads as recommended by the manufacturer. b. Start screwing the gland retaining nut into (or cap onto) the barrel by hand.

When the barrel and piston rod are perfectly aligned, the retaining nut or cap should screw on most of the way by hand. Do not start the installation of the gland retainer using hydraulic power because there is no way to tell if the nut is cross-threading or if the alignment is improper. c. Complete installation of the retainer by following, in reverse order, the instructions in the “Disassembling the Cylinder” section of this manual. Torque to meet the manufacturer's specifications.

18. If the cylinder has a bolted gland retainer: a. Lubricate the retaining bolts as recommended by the manufacturer. b. Insert the bolts and torque them to meet the manufacturer's specifications.

19. Remove the cylinder from the Servicer by reversing the steps described in the “Mounting the Cylinder” section of this manual.

34

Attaching Hoses to HCS-40 Hydraulic Power Supply

Maintenance Section Servicer Maintenance

The six hoses that provide hydraulic power to the various cylinders and the nut runner on the HCS-40 are color-coded. This makes it easy to attach them to the power unit and to the bulkhead fittings on the rear leg.

1. Check all critical Servicer components for damage and wear before each use.

Replace damaged or worn components immediately.

2. Check the floor mounting hardware for the bench legs and torque tracks daily to make sure they are securely mounted to the floor.

Description

Color-Code

Indexing Cylinder Extend Hose

BLUE

3. Check all Servicer welds for signs of fatigue and cracks before each use.

Indexing Cylinder Retract Hose

ORANGE

Nut Runner Torque Hose

RED

4. Keep the bottom of the head stock tube lightly greased.

Nut Runner Detorque Hose

YELLOW

250" Torque Hose Extension

PURPLE

5. Change the hydraulic power unit filter as indicated by the clog gauge.

250" Detorque Hose Extension

GREEN

6. Check the hydraulic fluid level on the sight gauge weekly.

Installing the Hoses

7. Maintain the gear reducer per manufacturer’s recommendations.

1. Install the YELLOW hose to the B port on the bottom valve.

For further assistance, write or call:

2. Install the ORANGE hose to the B port on the top valve.

Tuxco Corporation 4300 Grove Ave. Gurnee, IL 60031-2155 Telephone: 847/244-2220 Toll Free: 800/613-6979 FAX: 847/244-7335

3. Install the RED hose to the A port on the bottom valve.

4. Install the BLUE hose to the A port on the top valve.

5. Install the GREEN hose to the bulkhead fitting that is marked B. 6. Install the PURPLE hose to the bulkhead fitting that is marked A. After the hoses have been attached to the power supply and the bulkhead fittings, proceed with Step 3 in the “Connecting the Hydraulic Power Unit” section of this manual.

35

TUXCO WARRANTY TUXCO CORPORATION warrants its manufactured products to be free of defective material and workmanship under normal use and service for a period of six months from time of original purchase. This warranty applies only to products which are used in accordance with all instructions as to maintenance and operation set forth in the manuals and instruction furnished by TUXCO CORPORATION with its products.

To make a warranty claim, the product must be returned to TUXCO CORPORATION with freight prepaid. This warranty does not obligate TUXCO CORPORATION to bear any costs of labor, transportation or any other charges which may arise in connection with a warranty claim. Upon receipt of the part or parts in question, a thorough examination will be conducted to determine the cause of failure. Depending upon the results of the examination, warranty may be either granted or denied, and a speedy reply will be rendered. If warranty is denied, a report of TUXCO CORPORATION's findings will be sent to the parties involved.

TUXCO CORPORATION's liability for any damage caused by a product which fails due to defective materials or workmanship and the purchaser's exclusive remedy shall be limited to the replacement or repair of (at TUXCO CORPORATION's option) the defective part or parts as originally furnished by TUXCO CORPORATION. TUXCO CORPORATION shall not be liable for any loss, damage or expenses directly or indirectly related to the use of its products or from any other cause or for consequential damages (including, without limitation, loss of time, inconvenience, and loss of production). It is expressly understood that TUXCO CORPORATION is not responsible for damage or injury caused to other products, machinery, buildings, property, or persons by reason of the installation or use of its products.

This warranty shall not apply to products sold

by TUXCO CORPORATION but manufactured in their entirety by others. Such products are warranted only to the extent of their manufacturer's warranty and whenever possible warranty claims should be handled directly with the product's manufacturer.

©2008 Caterpillar All Rights Reserved

This warranty shall be null and void if any component of a product has been (a) tampered with, disassembled, repaired or altered (except as may be authorized by TUXCO CORPORATION in writing); (b) subjected to misuse, improper maintenance, neglect, accident, or acts of God; or (c) used for purposes for which it was not designed which may attack or harm the materials used in construction of the product or which may otherwise harm the operation of the product.

Shipping damage is NOT covered by warranty.

The carrier is responsible for all repair or replacement costs resulting from damage in shipment.

THIS IS TUXCO CORPORATION'S SOLE AND EXCLUSIVE WARRANTY AND IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, WHICH ARE HEREBY EXCLUDED, INCLUDING IN PARTICULAR ALL WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. No distributor or other person is authorized to assume any liability or obligation for TUXCO CORPORATION, other than expressly provided herein.

For information on service tools or shop supplies, contact Dealer Service Tools on: Dealer Service Tools 501 S. W. Jefferson Peoria, IL U.S.A. 61630-2125 U.S.A.: 1-800-542-8665 Illinois: 1-800-541-8665 Canada: 1-800-523-8665 World: 1-309-675-6277 Fax: 1-309-494-1355 dealerservicetool_hotline@cat.com

NEHS1035 Printed in U.S.A.