Caterpillar HCS-60 Hydraulic Cylinder Servicer Tool Operating Manual - PDF DOWNLOAD

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NEHS0934-01 April 2005

TOOL OPERATING MANUAL INSTALLATION AND OPERATION INSTRUCTIONS FOR MODEL HCS-60 HYDRAULIC CYLINDER SERVICER SMCS: 0000

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 not 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.

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.

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

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

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This manual contains instructions for the installation, operation, and maintenance of the TUXCO HCS-60 Hydraulic Cylinder Servicer©.

It includes an explanation of how features of the HCS-60 function in the repair and service of hydraulic cylinders.

Table of Contents Description . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Function of Components . . . . . . . . . . . . . 9-17 Cylinder Service Procedure. . . . . . . . . . 17-25 Servicer Maintenance . . . . . . . . . . . . . . . . . 25 Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Copyright © 1995 TUXCO CORPORATION

WARNING

Safety First

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

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.

Tuxco Corporation recommends that every person who is working with the Servicer wear a hard hat, safety glasses or goggles, and appropriate clothing, in accordance with good shop safety practicesr.

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

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FIGURE 1. HCS-60 HYDROAULIC CYLINDER SERVICER

1.

Headstock chuck

21. High torque gauge

2.

Headstock chuck wing

22. Work station torquing cylinder & toggle

3.

Barrel support

23. Work station torquer quick disconnects

4.

Nut runner quick disconnects

24. Work station parking quick disconnects

5.

Hydraulic nut runner

25. Main hydraulic power source

6.

Work Station Chuck

26. Headstock torquer quick disconnects

7.

Piston rod support

27. Indexing cylinder

8.

Tailstock chuck wing

28. Headstock tube power sleeve

9.

Tailstock chuck

29. Torque track with hose channel

10. Mounting bushing storage

30. Torque track

11. Tailstock boom

31. Headstock

12. Tailstock

32. Headstock retaining plate

13. Tailstock power sleeve

33. Headstock torquer relief valve

14. Tailstock cylinder

34. Headstock torquing cylinder

15. Tailstock cylinder controls

35. Torquing cylinder toggle

16. Electrical enclosure

36. Headstock torque gauge

17. Hydraulic power unit

37. Headstock tube

18. Pendant cable

38. Work station

19. Pendant

39. Work station torquer relief valve

20. Bench base channel

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DESCRIPTION The TUXCO HCS-60 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 at every step of operation.

Basically, the HCS-60 Hydraulic Cylinder Servicer consists of a specialized bench with adjustable supports to hold the cylinder or its separated parts; tailstock, workstation, and headstock to anchor all operations; chucks and spanner wrench to connect the Servicer with the parts of the cylinder; and hydraulic system to provide force for the various operations. Specific parts are identified by item number in Figure 1 and the following list.

The same item numbers are given in parenthesis in the rest of this manual to help you identify parts and their relation to the whole machine.

FIGURE 2. Tuxco Servicer packed for shipment.

When your servicer arrives, immediately inspect it as thoroughly as you can without unpacking it. Pay particular attention to the workstation (38), hydraulic system and sheet metal parts. Note any damage on the receiving form and have the carrier's driver initial the damage notes before you sign the form.

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

RECEIVING

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

Your HCS-60 Hydraulic Cylinder Servicer has been shipped to you covered to protect its components during transit. The standard shipment consists of: 1. The body of the Servicer on a wooden skid.

This includes the bench, tailstock, workstation, and headstock. (Figure 2).

INSTALLATION

2. Torque tracks banded together on a separate skid.

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

POSITIONING THE SERVICER 2. Plan for adequate space on both sides of the Servicer and also at both ends, so the Servicer can be operated through its whole range. Figure 2 shows the space occupied by the standard HCS-60 as the headstock tube (37) and the tailstock boom (11) travel to their extreme positions. 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.

3. One or more crates containing parts and accessories.

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FIGURE 3. Positioning and space requirements of the HCS-60.

3. It is best to install the Servicer beneath an overhead crane 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 larger cylinders.

FIGURE 5. Connecting torque track to mounting boss

7. Connect a hold-down (Figure 6) to the headstock (31) where it will ride on each torque track. Installing the hold-downs should put the torque track and the base of the headstock in the relationship shown in Figure 7.

WARNING To avoid Injury and damage to equipment, make sure the hoist has the rated capacity to raise the largest cylinder you will service.

4. Using a chalk line at least 30 ft long, make two chalk marks exactly 30-1/2 inches apart. Run these marks in such a direction that the Servicer can be placed with its long sides parallel to the marks and with the headstock end of the bench at least 15 ft from the end of the marks (Figure 3).

FIGURE 6. Connecting hold-down to headstock.

FIGURE 4. Layout of chalk marks and Servicer.

8. Have a qualified electrician connect the Servicer to proper electric power as specified on the sticker in the circuit breaker box. In making electrical connections, observe local codes and/or The National Electrical Code in accordance with ANSI/NFPA 70 latest edition.

5. Torque tracks (29 & 36) must be installed under the headstock (31) and attached to the base of the bench. Using the chalk marks as a guide, lay out the torque tracks straight from the headstock end of the bench and parallel to the chalk marks.

6. With torque track (29) at the rear bolt each torque track to the appropriate mounting boss (Figure 5), which is welded to the bench base channel (20) at the headstock end of the bench. Connect the track so the track is outside the mounting boss.

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ANCHORING THE BENCH Before the HCS-60 Hydraulic Cylinder Servicer can provide torque to separate the barrel from the head, it must be mounted solidly on the floor.

WARNING To prevent eye injury by flying concrete chips or dust while you are drilling and cleaning holes in the floor, wear safety glasses, and keep other personnel at a safe distance.

To prevent Injury to your lungs by concrete dust, wear a respirator. Protect all personnel from possible injury by materials blown out of the mounting holes FIGURE 7. Relation of torque tracks to base of headstock.

1. Make sure that the bench is lined up with the chalk marks and exactly where you want to mount it to the floor.

WARNING

2. With a spirit level, check that the bench is level end-to-end and side-to-side. If it is not, insert shims under the bench base channels to level it.

To avoid possible Injury or damage to equipment, read the "FUNCTION OF COMPON E N T S " s e c t i o n o f t h is m a n u a l b e f o r e y o u operate any of the controls.

3. Use the holes in the mounting pads on the base channels as drill guides. With a 7/8inch carbide bit, drill holes at least 2-1/2 inches deep in the concrete (Figure 8). Be sure the bench does not move during drilling.

10. Move the headstock to the end of the torque tracks farthest from the bench. If the floor is perfectly flat and the tracks are completely straight and parallel, you should be able to move the headstock by hand. In some cases, the headstock must be moved hydraulically.

11. Watch for indications that the headstock is not traveling easily and smoothly, such as binding at the headstock tube (37) or jerky motion by the power sleeve (28). If there is any resistance to easy motion, you may need to shim the bench and/or the torque tracks to level the Servicer and prevent binding. (See the leveling directions in the instructions titled "Anchoring the Tracks".)

FIGURE 8. Drilling anchor hole for bench base.

12. Anchor the Servicer to the floor as directed in the following instructions.

WARNING

WARNING

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

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

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

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

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

(Figure 9).

FIGURE 11. Tightening anchor bolt to proper torque.

ANCHORING THE TRACKS WARNING To prevent eye Injury by flying concrete chips or dust while you are drilling and cleaning holes in the floor, wear safety glasses, and keep other personnel at a safe distance.

To prevent Injury to your lungs by concrete dust, wear a respirator.

1. Make sure the tracks are parallel with the chalk marks

FIGURE 9. Setting anchor flush with floor.

7. Using a 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 (Figure 10).

2. Bolt the tracks to the bench (Figure 5) putting the track with the hose channel (29) at the rear. The tracks are sometimes bowed so mount the machine end first and proceed to the end of the tracks one floor mount plate at a time, aligning the tracks with the parallel chalk tines.

FIGURE 10. Expanding the anchor.

8. Place a 5/8-inch heavy flat washer on the 5/8-inch by 1-1/2 inch hex head cap screw.

9. Screw the bolt with the washer into the anchor, and torque the bolt to 80 to 90 Ib. ft. (Figure 11). Properly installed, the anchor will have a pull-out strength of about 15,000 lbs.

FIGURE 12. Drilling anchor hole for track.

3. Use the hole in the mounting pad as a drill guide. With a 7/8-inch carbide bit, drill a hole at least 2-1/2 inches deep in the concrete (Figure 12). Be sure the track does not move during drilling.

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c. Check whether both tracks are perfectly parallel with the chalk marks and are approximately 24 1/2 inches apart throughout their length (Figure 7). If not, loosen the bolts in the floor anchors and shift the tracks to position them properly.

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

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

(Figure 9).

d. Holding the tracks in proper position, torque the bolts again to 80 to 90 lb-ft.

6. Using a 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 (Figure 10.

11. Anchor the remaining mounting pads by the procedure of steps 2 through 8.

FINAL ASSEMBLY

7. Place a 5/8-inch heavy flat washer on the 5/8-inch by 1 -1/2 inch hex head cap screw.

Install the remaining parts of the Servicer that were shipped in crates. Place them at the locations indicated in Figure 1.

8. Screw the bolt with the washer into the anchor, and torque the bolt to 80 to 90 lb. ft. Properly installed, the anchor will have a pull-out strength of about 15,000 lbs.

FUNCTION OF COMPONENTS Your patented Tuxco Hydraulic Cylinder Servicer allows you to mount a cylinder on its exact centerline so hydraulic power can be used to detorque the head, withdraw the piston rod, detorque and torque the piston retaining nut, reassemble the cylinder, torque the head, 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, so you may acquaint yourself with each component and its proper use.

9. By the same procedure used before (see POSITIONING THE SERVICER) check for binding when the headstock is moved.

10. If the headstock does not move easily and smoothly, make the necessary corrections in the torque tracks. a. With a spirit level, check whether both tracks are level throughout their length.

If not, loosen the bolts in the floor anchors and shim the tracks (Figure 13) to level them.

To identify the location of the component, refer to the DESCRIPTION chapter. Numbers in parenthesis after the name of the component are keyed to Figure 1 in the DESCRIPTION chapter.

SERVICER BENCH The bench is a basic weldment, which includes a permanently attached, 14-1/2 ft length of 5 inch square steel tubing, the bench tube. The headstock tube (37), a 4-1/2 inch square steel tube, 17 ft long, can be moved hydraulically to the left or right through the bench tube. The tailstock (12) is permanently attached to the bench to give it maximum rigidity and strength.

FIGURE 13. Placement of shim to level torque track.

b. If you must shim the tracks, level the bench again where necessary by loosening the anchor bolts, shimming the bench, and tightening the bolts to 80 to 90 lb-ft.

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To move the tailstock chuck in the opposite direction, place the locking pin to the left of the power sleeve and use the retract button.

A movable tailstock chuck (9) is supported by rollers that run on the bench. It is attached to the tailstock boom (11) that slides through the tailstock. The position of the chuck may be changed by removing the locking pin from the tailstock (Figure 14) and hydraulically moving the boom with the tailstock cylinder. This enables you to adjust the machine to mount cylinders of various lengths.

Before mounting the cylinder in the tailstock chuck (9) replace the locking pin (Figure 14), first using the control buttons to jog the locking pinholes into alignment.

FIGURE 15. Moving tailstock chuck.

Both the headstock chuck (1) and the tailstock chuck (9) have a scale die stamped into their surface (Figure 16). This scale is used to line up the cylinder horizontally on the centerline of the servicer before the socket head cap screws of the "T" - slot chuck are tightened to hold the chuck wings in place.

FIGURE 14. Removing locking pin from tailstock.

WARNING To avoid possible Injury by rapid motion of the tailstock cylinder, you must adjust the speed of the cylinder action for your operating conditions. The speed may not be properly adjusted at the factory to suit your requirements. At maximum speed, the cylinder extends one foot in one second.

The needle valve that controls the speed of the tailstock cylinder is located on the B port of the rearmost control solenoid located on the hydraulic power unit (17). To adjust the speed, loosen the locknut. Turning the knob clockwise slows the cylinder. Begin the speed adjustment by turning the knob all the way clockwise (valve dosed) and gradually adjust to the desired stroke speed.

FIGURE 16. Scale on face of chuck.

WORK STATION On the bench (Figure 1) there is a workstation (38) that allows the workstation chuck (6} to be parked hydraulically at the rear of the workstation when the cylinder barrel is being removed or moved hydraulically onto the machine centerline to remove piston retaining nuts.

To move the tailstock boom and chuck to the right, place the locking pin (Figure 14) behind the tailstock power sleeve (13). Pushing the EXTEND button on the tailstock control panel (Figure 15) will move the tailstock to the right.

Retracting the cylinder, move the pin and repeat until the tailstock chuck is in the desired position.

The workstation has a number of functions: 1. It provides a very high adjustable torque capability to remove piston retaining nuts (Figure 17).

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2. It is equipped with a hydraulic motor to spin loosened piston retaining nuts on and off with up to 4,000 Ib. ft. of torque (Figure 18).

3. It acts as a base for the universal spanner wrench used to remove threaded rod retainers (Figure 19.

FIGURE 20. Inserting Chuck Adapter.

NOTICE Use care when lifting and inserting workstation chuck adapters. They are heavy and can cause Injury If dropped or lifted improperly.

FIGURE 17. Work station torquer position.

Turn each plunger a quarter turn so that the plungers snap down into the groove in the outside circumference of the chuck adapter.

(Figure 21).

FIGURE 18. Hydraulic Nut Runner.

FIGURE 21. Locking T-Slot with retractable plungers.

NOTICE These plungers are designed only to hold an adapter in place in the chuck, not to transmit force.

FIGURE 19. Universal spanner on workstation.

Chuck adapters fit into a hex opening inside the round workstation chuck. Three sides of the hex opening have ramps that help align the adapter male hex when inserting it into the female hex of the chuck.

A T-Slot adapter comes with the machine. It is used to mount a wide range of adapters to the workstation chuck, including the Universal Torque Wrenches and 906,908,909,914, 915,916 and 917 optional adapters.

Workstation chuck adapters are held in place using the three retractable plungers located in the circumference of the chuck. Pull all three plungers out and turn them a quarter turn to keep them retracted. Insert a chuck adapter, mating its male hex with the female hex of the chuck. (Figure 21).

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When torques in excess of 25,000 lb. ft. are used it is necessary to use Tuxco's Ultra High Torque Work Station Chuck adapters. They are available in a wide range of square and hex sizes and may be ordered as Tuxco Model 975 followed by hex or square designation and size in inches or millimeters.

ADJUSTABLE SUPPORTS The cylinder support is adjustable up and down or diagonally by turning the two adjustment wheels (Figure 22). The support has a securing plate held in place by two nuts.

The support (3) used under the piston rod is held in place by a hand wheel-operated clamp (Figure 23).

FIGURE 24. Cylinder secured by safety strap.

WARNING To avoid Injury by a falling cylinder, always secure the cylinder or its parts on the cylinder supports with the safety straps (Figure 24), and always fasten the support in place with its securing nuts or hand wheel

SPANNER The Universal Spanner supplied with the machine is used in conjunction with the workstation. Its basic function is to hold a threaded cylinder head stationary while the cylinder is turned hydraulically with the headstock.

FIGURE 22. Adjusting cylinder support.

To mount the base of the Universal Spanner into the workstation, hydraulically move the workstation chuck to its parked position at the rear of the machine. Loosen the two center 1"8 work station socket head cap screws and insert the base (Figure 25). Secure the base with four bolts.

FIGURE 23. Clamping Rod Support.

Each support has two slots that hold a safety strap. The strap helps prevent a cylinder barrel or piston rod from falling during service operations.

FIGURE 25: Inserting Universal Spanner base.

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Two vertical spanner plates fit into the base.

The plates can move horizontally in the T-Slot of the base. The plates have two 1/2"-i3 tapped holes that are on the same plane as the cylinders centerline. Spanner pins fit into these holes and are inserted into holes or slots in the face of the head. The plates are then tightened together using the socket head cap screw provided, and to the base using the eight machine screws in the base (Figure 26).

HYDRAULIC SYSTEM A 7.5 hp hydraulic power unit is mounted between the rails of the machine (Figure 27).

FIGURE 27: Hydraulic Power Unit.

The hydraulic power unit has a five-gallon tank WHICH MUST BE FILLED WITH 150 VG46 HYDRAULIC OIL SUCH AS MOBIL DTE 24 OR EQUIVALENT The tank is equipped with a sight gauge and filter.

WARNING FIGURE 26: Spanner in place.

Do not operate machine before filling tank with hydraulic oil. To do so may seriously damage the power unit.

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

The power supply is controlled by D.C. solenoid valves and provides 2,800-psi oil to provide the following functions:

The HCS-60 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 sub-jected to too much force.

1. Move the tailstock chuck (9) left and right to adjust the machine to the length of the cylinder being serviced.

2. Power the headstock torquer (34) to detorque. Unscrew, screw in and torque threaded cylinder heads.

WARNING Use only Tuxco spanner pins. Under high torque, substitute pins may cause Injury by falling in a way that throws out metal fragments.

Once the spanner is in place, the eight bolts in the spanner base and the bolt that locks the spanner plates together must be tightened.

3. Power the indexing cylinder to extract and insert piston rods.

As the head is broken loose and begins to unscrew it will move toward the spanner plates. It is necessary to use the indexing cylinder to jog the barrel outward to avoid bending the spanner plates.

6. Power the workstation from its parked to its operating position.

4. Power the indexing cylinder to move the workstation to the left and to the right.

5. Power the indexing cylinder to move a loaded barrel support stand.

7. Power the workstation 60,000 Lb. ft. torquer.

8. Operate the 4,000 lb. ft. 8 r.p.m. nut runner.

Pressurized hydraulic oil is delivered to the tailstock cylinder and controlled by push buttons marked "Extend" and "Retract". (Figure 28).

13

WARNING Always lock the pendant control to prevent unauthorized use that might cause personal Injury or damage to the machine.

The pendant control has three pairs of colorcoded push buttons. The two at the cable end are marked "Start" and "Stop". They start and stop the power unit. The center pair are marked "Extend" and "Retract". They control the indexing cylinder. The top pair is marked "Detorque" and Torque" and is used to operate the headstock torquing cylinder (34), the work station torquing cylinder (22), the work station nut runner (5), and the work station parking cylinder. (Figure 31.

FIGURE 28: Moving tailstock chuck.

Four of the hydraulic functions are powered by the two hydraulic hoses at the left front corner of the machine (Figure 29).

FIGURE 29: Main Hydraulic Power Hoses.

The main hydraulic power hoses are equipped with a new type of high pressure quick disconnect that is extremely easy to use. One hose has a female quick disconnect, the other a male, thus they are indexed to all the other pairs of quick disconnects on the machine.

FIGURE 31: Pendant Controls.

The tailstock is operated by its own pair of push buttons.

To operate the headstock torquer cylinder (34) the main hydraulic power hoses must be quick connected to the two quick disconnects located at the left end of the machine. They are attached to the two hoses that run through the rear torque track (29) to the headstock torquing cylinder. (Figure 32).

The hydraulic power unit is controlled by the lockable pendant stored on the cable rack at the center of the machine (Figure 30).

FIGURE 30: Pendant and cable showing lock.

FIGURE 32: Headstock hydraulic connection

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To move the work station cross slide from its operating position to the park position the main hydraulic power hoses must be attached to the quick disconnects located on the side of the work station. (Figure 33)

FIGURE 35: Main hydraulic hoses attached to nut runner.

HEADSTOCK The headstock (31) rests on a roller-supported base. It carries the headstock chuck (1), the headstock torquing cylinder (34), the headstock torque gauge (36), the headstock torque control valve, and cone mounting bushing storage (Figure 36.

FIGURE 33: Work station hydraulic connection.

WARNING The workstation torquing cylinder (Figure 17) must always be disconnected from the workstation chuck (6) before the workstation is moved to its parked position at the rear of the bench.

To operate the workstation torquing cylinder attach the main hydraulic power hoses to the workstation torquing cylinder.

WARNING FIGURE 36: Cone mounting bushing storage.

WHEN USING THE WORK STATION TORQUER YOU MUST ATTACH THE NUT RUNNER BYPASS HOSE AS SHOWN IN FIGURE 34.

FAILURE TO DO SO WILL CAUSE THE TORQUE GAUGE TO BE INACCURATE. FAILURE TO USE THE BYPASS HOSE MAY ALSO DAMAGE THE NUT RUNNER MOTOR OR GEAR REDUCER.

Cone mounting adapters are also stored near the tailstock chuck (9) on pins inserted in holes in the tailstock boom (11). (Figure 37).

FIGURE 37: Cone mounting bushing storage.

These adapters and storage pins can be easily removed if they interfere with mounting a very long cylinder.

FIGURE 34: Bypass hose in place on nut runner motor.

To operate the hydraulic nut runner (5) remove the bypass hose and attach the main hydraulic power hoses to the nut runner. (Figure 35).

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The headstock chuck is mounted on the headstock through a steel disc and spindle, which allows the chuck to rotate around the cylinder centerline (Figure 38).

FIGURE 39: Ratchet bar turning headstock chuck.

TORQUING CYLINDERS A torquing cylinder and a toggle assembly with connecting parts convert pressure from the hydraulic pump into force to rotate the chuck of either the headstock (Figure 1) or the workstation (Figure 6).

FIGURE 38: Headstock disc and torquer.

In preparing to take apart a cylinder, secure the eye of the cylinder barrel to the headstock chuck (1) in the same way that you secure the eye of the piston rod to the tailstock chuck. As previously explained, if there is a threaded head the spanner is positioned to keep the head from moving. When the torquing cylinder rotates the headstock chuck (Figure 39), it forces the barrel of the cylinder under repair to rotate relative to its head. As a result, the barrel unscrews from the head.

The torquing cylinders are double acting, controlled by the "Detorque" and "Torque" buttons on the pendant.

The headstock torquing cylinder will provide 25,000 lb. ft. of torque, the workstation torquing cylinder, 60,000 lb. ft.

WARNING

A 1-inch square hole in the back of the spindle allows you to turn the headstock chuck and cylinder barrel manually (Figure 30) with a ratchet bar or a ratchet bar plus the optional No. 922 torque multiplier. (The 4 to 1 torque multiplier provides up to 1000 lb. ft. of torque for removing heads that require significant torque even after they have been broken loose.) This feature is often useful after heads have been broken loose hydraulically, when high torque is no longer required. With some cylinders, resistance from damaged threads or locking compounds may make ft necessary to continue turning the barrel hydraulically.

Always STAND CLEAR OF THE TORQUING CYLINDER AND SPANNER when applying torque.

Apply torque very carefully.

NEVER USE MORE TORQUE THAN SPECIFIED by the cylinder manufacturer.

IS

Both torquing cylinders are equipped with a relief valve adjustable by turning the black knob located on the headstock post (Figure 39) and near the workstation torque gauge.

The valves allow the operator to set the torquers to the factory torque specification.

Before connecting torquer to the chuck, extend the piston all the way and watch the torque gauge, adjust the valve counter clockwise for less torque, clockwise for more.

Torque cannot be adjusted all the way to zero.

In the lower ranges it is controlled by jogging the torquing cylinder.

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A linking bar on the base of the workstation (Figure 43) can be connected to the power sleeve (28). Then you can move the workstation closer to, or farther from the headstock by extending or retracting the indexing cylinder.

INDEXING CYLINDERS The telescoping headstock tube (38) is attached by a mounting plate and four 1 inch bolts to the headstock (31). This tube is moved hydraulically to the left or right through the bench tube (39) to withdraw and replace piston rods.

The indexing cylinder (27) provides the hydraulic force to move the headstock tube.

This fixed, double-acting cylinder has a 42inch stroke.

When the indexing cylinder extends, it moves the headstock tube power sleeve (28). If a pin has been put in the headstock tube to the left of the power sleeve, extending the cylinder will extend the tube. If the pin is placed to the right of the sleeve, retracting the cylinder will retract the tube (Figure 40).

FIGURE 42: Linking bar moving workstation.

Excessive pressure requirements for cylinder disassembly or assembly are usually caused by misalignment or bent piston rods. When the piston rod is bent, you can often make disassembly easier by connecting the piston rod eye to the tailstock with a chain, instead of connecting the eye to the chuck in the usual way.

WARNING

FIGURE 40: Retracting the headstock tube.

To move the barrel support away from the bench, you need only to move the power sleeve (28) against the support and continue extending the indexing cylinder. If you first insert a pin to the left of the support, extending the indexing cylinder will move both the support and the headstock tube to the left.

To avoid Injury or damage by breaking of the chain, use a chain that is rated strong enough to bear the force that will be needed to separate the barrel from the piston rod.

TORQUE TRACKS

To move the barrel support back toward the bench, extend the indexing cylinder until the hook can catch the sleeve (Figure 41).

Your HCS-60 Hydraulic Cylinder Servicer can supply very high torques to loosen and tighten heads. In the upper torque ranges, applied torque tends to lift the headstock. The torque tracks (29 and 30) and the hold-downs on the headstock base prevent lifting of the headstock assembly by torque (Figure 43).

FIGURE 41: Moving barrel support toward bench.

17

WARNING To avoid possible Injury by sudden movement of the tailstock cylinder (14), adjust the cylinder's speed of action before you move the tailstock chuck hydraulically for the first time.

4. Adjust the speed of the tailstock cylinder by the following procedure:

FIGURE 43: Track hold-down.

a. Loosen the needle valve lock nut and turn the adjustment knob fully clockwise. Hydraulic oil will not be able to flow past the needle valve.

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

b. Push the tailstock "Extend" button and turn the adjustment knob counterclockwise until the cylinder extends at the desired speed. c. Tighten the lock nut to keep the adjustment from changing.

NOTICE

5. Prepare the two cylinder supports (3 and 7) to receive the cylinder.

If the headstock is at the end of the tracks, do not apply hydraulic pressure to extend the Servicer farther. Doing so will damage the equipment.

a. If the cylinder is to be mounted with the aid of an overhead crane (recommended) or other lifting equipment, tower the cylinder supports below the level where you expect to use them.

CYLINDER SERVICE PROCEDURE

b. If you must move the cylinder onto the cylinder supports by hand, proceed as follows:

REMINDER: A number in parenthesis after the name of a Service component is a reference to Figure 1.

1. If the piston rod is retracted, position both cylinder supports so they will be under the barrel, and adjust both supports to the same height.

WARNING Read all warnings and Instructions before you use the Servicer.

2. If the piston rod is extended, position the cylinder support with the roller to be under the barrel and the support with the wood block to be under the piston rod. Allow for the difference in diameter between the barrel and the rod be setting the support with the block higher.

A. PREPARING THE SERVICER 1. Switch on the electric power at the circuit breaker box.

2. Unlock the pendant (19) and press the START button.

3. Position the headstock chuck (1) and tailstock chuck (9) so the cylinder will fit between them.

6. When the cylinder supports are in place, fasten the barrel support by tightening the securing plate finger tight with the nuts (Figure 44), and fasten the rod support by tightening the clamp with the hand wheel (Figure 23).

18

FIGURE 44: Tightening rod support clamp.

FIGURE 46: Stop bars in place to keep chuck from turning.

7. Measure the I.D. of the barrel and rod eyes.

10. Insert one headstock chuck wing (2) into the head-stock chuck (1).

8. Select a pair of conical mounting bushings that will fit each eye and install them in the headstock and tailstock chuck wings.

Secure the bushings with the set screws (Figure 45).

11. Install the bushings for the rod eye in the tailstock chuck wings (Figure 46) 12. If the cylinder has a threaded head, install the spanner base onto the workstation with the chuck in parked position. (Figure 19, page 10).

WARNING Keep the T-Slot horizontal, so the chuck wings cannot fall out. Any time the wings are in the TSIot but not clamped in place, a wing can slip out and cause injury.

B. MOUNTING THE CYLINDER 1. Make sure the oil ports are open on the cylinder to be repaired.

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

WARNING To prevent injury always use suitable equipment to lift cylinders into the machine.

FIGURE 45: Securing the cone mounting adapters.

9. Turn the headstock chuck, so the T-Slot in the chuck is horizontal, then insert a stop bar into the disc of the headstock at each side (Figure 46) of the headstock assembly, so the chuck cannot turn either way.

2. Move the cylinder into position on the centerline of the Servicer with the piston rod toward the tailstock chuck (9) and the barrel toward the headstock chuck (1).

Recommended lifting equipment is a safety sling with an overhead crane that has the rated capacity to raise more than the weight of the cylinder.

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3. If you are using lifting equipment, position the cylinder on the centerline of the Servicer and hold the cylinder there with the sling. Then go directly to step 8 in this procedure.

4. If you must position the cylinder by hand, have the cylinder supports (3 and 7) positioned and adjusted as explained in the preceding section, PREPARING THE SERVICER, Carefully move the cylinder onto the supports.

WARNING

FIGURE 48: Securing piston rod eye with through bolt.

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

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 that both cylinder supports are secured in place.

8. After final adjustment of the barrel support, turn the nuts on the securing plate finger tight.

9. After final adjustment of the rod support, turn the hand wheel to secure the support to the bench.

5. Immediately secure the cylinder to the cylinder supports (Figure 47) with the safety straps.

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

10.

Close the wings (8) of the tailstock chuck, so the bushings enter the piston rod yoke.

11. Fasten the through bolt snugly with the two nuts.

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

FIGURE 47: Cylinder secured by safety strap.

6. As soon as possible, put in the other chuck wings. Then insert a through bolt (Figure 48) through the chuck wings and eye at each end of the cylinder and spin a nut onto each end of the through bolts. This action helps to ensure that the cylinder will not fall during mounting operations.

12. Move the headstock into position, so the bushings in the wings (2) of the headstock chuck can slip into the barrel.

13. Secure the barrel eye as in steps 10 and 11 (Figure 49).

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19. Remove the two stop bars from the disc of the headstock chuck.

NOTICE The barrel support must be positioned so no projection on the barrel will strike the support as the barrel is moved.

C. DISASSEMBLING THE CYLINDER 1. THREADED HEADS.

FIGURE 49: Tightening through bolt in headstock chuck.

14. If you are mounting the cylinder by hand (without the help of lifting equipment), go directly to step 18 of this procedure.

NOTICE If there are any setscrews or other locking devices installed to keep the head from turning, make sure they are removed. The Servicer will shear off any fastened setscrew, which will then ruin the threads on the barrel or the head.

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

16. Immediately secure the cylinder to the cylinder supports with the safety straps.

a. If the head is threaded and spins out of or off the barrel, use a wrench to turn the headstock chuck so the holes or slots in the head are on a horizontal line. You may use the torquer cylinder for final positioning.

WARNING To avoid Injury or damage caused by a falling cylinder, fasten the cylinder with safety straps as soon as It Is seated on the cylinder supports. During service operations, keep the straps fastened as much as possible.

b. Select the proper spanner pins and install them in the vertical spanner plates (Figure 50).

17. Using the left-to-right scales on the chucks, shift the ends of the cylinder horizontally to bring the centerline of the cylinder exactly onto the centerline of the Servicer. You will have the end of the cylinder centered when the inner or outer 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".

18. Tighten the screws on each chuck (Figure 49) to fasten the chuck wings in the TSlots.

FIGURE 50: Spanner pins engage in crown.

NOTE: Because the cylinder may be "sagging" slightly, tighten the upper plate of the chuck first..

Use only Tuxco spanner pins. Under high torque substitute pins may cause Injury by falling in a way that throws out metal fragments.

WARNING

Tightening the chuck wings into the chucks automatically brings most cylinders to the Servlcer's vertical centerline.

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NOTE: The HCS-60 will provide much more torque than the spanner pins can resist.

While Tuxco spanner pins are made from an alloy threaded rod, they will sheer if subjected to too much force. Inspect the spanner pins before each use. If a pin is worn or distorted, replace it.

WARNING Never let a hydraulic hose get pinched or caught while you are moving parts of the Servicer. i. Fasten the torquing cylinder to the headstock rotating chuck using two torquer bars with safety clips (Figure 51).

c. If you do not have spanner pins of the proper size or shape, or if the holes in the head have been damaged so they will not securely hold pins, make new holes.

Carefully drill two new holes in the face or circumference of the crown. Drill the two holes exactly opposite each other (that is, exactly 180° apart. d. With the workstation chuck in its parked position, install the spanner base into the workstation base. (Figure 25). Secure the four socket head cap screws to hold it in place. Install the spanner plate that will be on the backside of the cylinder to be repaired. It may not be possible to install the back spanner plate after the cylinder is mounted in the servicer. The second spanner plate with the slot in it can be installed after the cylinder has been mounted and centered.

FFIGURE 51: Torquer toggle attached to chuck disc.

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

e. Move the spanner plates along the spanner base until the spanner pins line up with the holes in the head.

Apply torque very carefully.

f. With the INDEXING CYLINDER CONTROL, very carefully move the workstation or the headstock so the pins slip into the holes.

You may need to make slight adjustments in the cylinder supports or turn the barrel slightly to get the pins and holes perfectly aligned.

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. j. Using the "Detorquing" button on the control pendant apply pressure to the headstock torquing cylinder until the barrel is loosened from the head. A second stroke of the torquing cylinder may sometimes be necessary. Disconnect the yoke from the chuck disc before retracting the torquing cylinder.

g. Tighten the machine screws that secure the spanner plates to the spanner base and the socket head cap screw that fastens the two plates together.

WARNING Avoid exposure to leaks of hydraulic fluid.

Escape of fluid under pressure may cause severe personal Injury or property damage.

k. The torque required to loosen the head will be recorded by the torque gauge on the top of the headstock post (Figure 52).

h. Quick connect the main pressure hoses to the headstock torquing quick disconnects (Figure 32).

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m. As soon as you see the spanner plates begin to deflect toward the tailstock, take the pressure off the threads and spanner by moving the barrel outward slightly by jogging the indexing cylinder very carefully to the left, If you move the barrel too far you may pull the head off the spanner pins. n. To spin off a head by hand, use a ratchet wrench either with or without the optional torque multiplier to turn the headstock chuck until the barrel has separated from the head. If the cylinder is supplied with a nylon locking device or retaining compound, you will need to use the torquing cylinder or the optional torque multiplier for the whole unscrewing process.

FIGURE 52: Headstock torque gauge.

NOTE: If the pins shear off before the head breaks loose, you can::

2. BOLT-ON HEADS

(1.) Enlarge the holes in the head and use larger pins. (2.) Help the spanner by applying a chain wrench to the head and stopping the wrench handle against the workstation. (3.) Weld the spanner plates to the head.

a. Attempt to remove the head bolts with an impact wrench. b. If any bolt does not come loose when using a wrench or impact wrench, rotate the barrel so a wrench can be braced against the bench. Rotate the barrel hydraulically with the headstock to break the bolt loose.

NOTE: If the spanner pins "walk" out of the holes in a head, because the holes are worn, you can::

WARNING

(1.) By using the INDEXING CYLINDER CONTROL, apply slight pressure with the Indexing cylinder to hold the head against the spanner.

When using a breaker or ratchet bar stand clear as torque is applied because the servicer produces much more torque than some bars and sockets can safely withstand. USE EXTREME CAUTION!

(2.) Hold the head against the spanner with Cclamps or Vise-grips.

(3.) Drill new holes in the head.

(4.) Tackweld the spanner to the head.

3. ALL CYLINDERS

I. As long as there is a high reading on the torque gauge during strokes on the torquing cylinder, continue to turn the head hydraulically. When you start to see a tower reading, you can probably finish unscrewing the head with a ratchet bar attached to the 1inch square hole in the back of the spindle. If the spindle is still hard to turn, you can mount the optional toque multiplier on the Tuxco Part No. 922 on the headstock and use it to turn the spindle.

a. Assume that there is oil in the cylinder being serviced. Attach a hose to each port and place the open ends of the hoses in the oil pans, or aim ports towards the pans.

WARNING To prevent injury caused by slipping on spilled oil, always use oil absorbent material immediately on oil spills. Clean up spills promptly.

NOTICE

b. When the head is disconnected from the barrel use the indexing cylinder to move the barrel away from the bench until it is clear of the rod.

The unscrewing of the head forces it against the spanner and will bend the spanner plates if continued.

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If 25,000 lb. ft. of torque or less will be required to remove the piston retaining nut, insert the T-slot chuck adapter (Figure 20) into the chuck.

NOTE: If the piston rod is bent, avoid binding by connecting the piston rod eye to the tailstock with a chain Instead of connecting the eye to the tailstock chuck in the usual way.

a. Retract the three plungers and give them a quarter turn so they will stay retracted.

c. Put the locking pin in front of the power sleeve (23).

b. Grasp the T-slot adapter firmly and lift it into the chuck opening.

d. Pump the indexing cylinder to full extension. e. Retract the indexing cylinder. You will need to pull the barrel support back toward the open end of the barrel. To do this at the same time you are retracting the cylinder, hook the barrel support to the power sleeve (Figure 41).

c. Turn and push the adapter in until it will not go further. d. Turn the three plungers and let them snap into the groove in the circumference of the adapter.

WARNING

5. Install the Universal High Torque Wrench (Figure 53) securing it to the piston nut with two through bolts and nuts.

Before the barrel moves off the piston, the cylinder support under the barrel should be as close as is 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. f. If necessary, repeat this cycle of operations until the barrel has separated from the piston.

D. REMOVING THE PISTON RETAINING NUT 1. Make sure the piston is within reach of the workstation chuck. If it is not, hydraulically move the rod until the piston is positioned properly.

FIGURE 53: Universal High Torque Wrench Installeda.

WARNING If you are using the No. 913 Universal Wrench, to avoid possible injury make sure the wrench does not slip out of the T-slot chuck adapter.

NOTICE To avoid damage to the Servicer, you should make sure before you move the piston rod that:

6. Move the workstation toward the piston and, if necessary, turn the disc, until the socket or wrench engages the piston retaining nut.

The piston will not strike the piston rod support.

The piston rod support is locked to the bench.

Remove the spanner plates and base from the work station cross slide.

Hydraulically move the workstation chuck onto the centerline of the machine. Make sure that it is up against the stop. Secure the work station to the base with the 1"- 8 x 3" socket head cap screw provided, inserting into it the hole in the right front of the cross slide. Tighten the bolt.

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NOTICE

WARNING

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

These limits are: No. 914, 3/4 Inch drive

300 lb-ft

No. 915, 1 inch drive

750 lb-ft

No. 916, 1-1/2 Inch drive

2,000 lb-ft

No. 917, 2-1/2 inch drive

10,000 lb-ft

7.

8.

9.

Always shut off the hydraulic system before you work on the piston. To avoid injury resulting from accidental operation of the Servicer, you should switch off and lock the machine any time it is not being used to disassemble or assemble a cylinder.

E. REASSEMBLING THE CYLINDER

If you are using the No. 913 wrench, lighten the wrench on the piston retaining nut. Make sure the wrench is centered by reading the scale on the chuck. Then snug down the chuck screws.

NOTICE Always clean parts completely before you assemble them.

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

Fasten the torquing cylinder toggle to the chuck disc using two 1-1/2 inch diameter torquer pins with safety dips.

Screw the piston retaining nut onto the rod carefully by hand to avoid cross threading. If you leave the nut En the T-slot wrench and start installation of the nut with the nut runner, you will not feel the resistance that indicates the beginning of cross threading.

Connect the main hydraulic hoses to the couplings on the work station torquing cylinder (23).

10. Turn the telltale on the workstation torque gauge to zero.

11. Use the pendant "Detorquer" button switch to extend the torquing cylinder. If the torque meter reading does not drop below 4,000 lb. ft. remove the torquer pins, retract the torquer piston and repeat.

1. If the piston must be removed from the Servicer, mount the piston rod. For directions and precautions, see section B, MOUNTING THE CYLINDER. Be sure to follow the centering procedure. Use a magnetic level or tape measure to check that the piston rod is level.

12. When the torque meter reading falls below 4,000 Ib.ft., remove the nut runner bypass hose and connect the main hydraulic hoses to the nut runner (Figure 35). When the pendant "Detorque" button is pushed, the nut runner will apply up to 4,000 Ib. ft. of torque at 8 r.p.m. to remove the retaining nut. As you unscrew the piston retaining nut use the indexing cylinder to back the workstation away from the rod to relieve pressure on the threads.

Start installation of the piston retaining nut by hand.

13. Be certain that the workstation chuck and adapters are clear of the rod end, then move the workstation chuck to its park position.

3. Move the tailstock chuck, so the piston will be in front of the workstation, then lock the chuck in place.

2. After the cylinder has been serviced, replace the head, the piston, and the piston retaining nut.

NOTICE

4. Mount the adapters and wrench or socket on the workstation. See instructions in "REMOVING THE PISTON RETAINING NUT".

5. Engage the piston retaining nut with the wrench or socket.

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6. Set the maximum torque required by the cylinder specifications using the torque control knob. (Page 16).

14. If necessary, make small vertical or diagonal adjustments by turning the adjustment wheels on the cylinder supports to align the barrel with the piston rod. Any needed adjustments are normally made at the cylinder support that is under the barrel. Turning both wheels the same amount in the same direction will move the barrel straight up or straight down. Turning just one wheel clockwise will move the barrel upwards diagonally toward the opposite side.

7. Use the nut runner to tighten the retaining nut if 4,000 Lb. ft., of torque or less is required. If more torque is required, use the "Retract" stroke of the torquing cylinder.

8. Using hydraulics, move the workstation to take the workstation tooling off of the nut and clear of the rod end.

9. Use hydraulics to park the workstation.

15. Lubricate the piston and new seals.

WARNING Remembering to use the safety straps and securing plates whenever possible.

NOTICE There should be NO sign of resistance, while you are inserting the piston into the barrel. If you see any, stop and check for misalignment and for anything that might hinder the motion of the headstock or headstock tube.

10. If the barrel stayed on the Servicer during repair of the cylinder, go directly to step 3.

Otherwise, proceed to step 11 below.

11. Mount the barrel on the Servicer. For directions and precautions, see section B, MOUNTING THE CYLINDER. Make sure the correct bushings are in the chuck wings, and be sure to follow the centering procedure.

16. Applying hydraulic force with the indexing cylinder, insert the piston and rod into the barrel, watching carefully for any sign of binding, such as a change in the sound of the pump. To use the indexing cylinder for this purpose, first extend the cylinder completely, then insert the pin behind the power sleeve and retract the cylinder.

12. If you used the Servicer to work on another cylinder after this cylinder was disassembled, or if you changed any Servicer adjustment while this cylinder was being repaired, you must make sure that alignment is correct now. 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.

NOTE: If there is no ramp in the barrel, you may need to use a piston ring compressor.

See the manufacturer's instructions.

WARNING The securing plate under the barrel support must be tight enough to hold the support safety upright, but loose enough to let the headstock tube slide through the support.

13. Move the headstock so the piston is at, but not in, the opening of the barrel.

WARNING 17. Continue inserting the piston rod until the opening of the barrel meets the head. As necessary during this process, move the cylinder support under the piston rod and move the barrel support toward the headstock.

You must align the piston rod and barrel carefully to avoid damaging the seals during reassembly.

Check alignment of the head with the opening of the barrel and make any necessary adjustments at the cylinder support that is under the barrel.

26

18. If the head is threaded:

21. If you are not going on to the next job immediately, switch off the power at the circuit breaker box and lock the pendant.

a. Lubricate the threads as recommended by the manufacturer.

FOR FURTHER ASSISTANCE WRITE OR CALL:

b. Start screwing the head into or onto the barrel by hand. When the barrel and piston rod are perfectly aligned, you should be able to turn the head most of the way by hand. You should not start the installation of the head by using a ratchet bar on the headstock chuck to turn the barrel, because the leverage and weights involved would keep you from feeling any resistance. Resistance could indicate that the head is crossthreading or that alignment is not good enough.

Tuxco Corporation 4300 Grove Avenue Gurnee, IL 60031-2155 Toll Free 800/613-6979 Telephone: 847/244-2220 Fax: 847/244-7335 Websitel: www.tuxco.com E-Mail: moreinfo@tuxco.com

IMPORTANT

c. Engage the spanner with the head. See the instructions in section C, DISASSEMBLING THE CYLINDER.

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

Replace damaged or worn components immediately.

NOTE: As the head is screwed into or onto the barrel ft starts to move off the spanner pins. You must move the headstock to reposition the barrel and keep the pins engaged during this operation. See Instructions under DISASSEMBLING THE CYLINDER.

2. Check high-pressure hydraulic hoses daily for wear, cracks, and other damage.

Replace worn or damaged hoses immediately.

d. Attach the main hydraulic hoses to the head-stock torquer quick disconnects.

(Figure 32).

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

e. Disconnect the headstock torquer toggle from the headstock chuck and use a ratchet bar to turn the headstock until it is snug.

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

5. Keep the bottom of the headstock tube greased.

f. Adjust the headstock torquer relief valve (Figure 39), attach the toggle to the headstock chuck and apply torque until the gauge at the top the headstock post shows the proper value.

6. Keep the bearing surface of the workstation base lightly oiled.

7. If a retractable plunger comes loose from the workstation chuck, the outer threads may be sealed with Loctite.

g. If the first stroke does not tighten the head enough, repeat the torquing stroke.

8. Keep the wood block of the piston rod support greased.

19. If the cylinder has a bolt-on head: a .Lubricate the head bolts as recommended by.the manufacturer b. Insert the bolts and torque them to meet the manufacturer's specifications.

20. Remove the cylinder from the Servicer by reversing the steps described in the section, MOUNTING THE CYLINDER. 27

HYDRAULIC OIL REQUIREMENTS SPECIFICATION: Mobil DTE 24 or DTE 25 or equivalent.

RECOMMENDED OPERATING VISCOSITY: 100 TO 250 SUS (21-54 CS) preferred.

CAPACITY: Approx. 10 Gal. HYDRAULIC OIL FILTER: 10 micron (um) Continental Hydraulics 902200

BREAK-IN AND MAINTENANCE: Change filter element after 1st 50 hours of operation.

After that, change element every 250 hours or when the indicator shows 20 PSI.

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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.

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 twelve 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 sets 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.

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.

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.

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TUXCO CORPORATION 4300 Grove Avenue Gurnee, Illinois 60031-2155 Telephone 847-244-2220 Fax 847-244-7335 TUXCO FORM NO. 29500, MODEL HCS-6O Primed in U.S.A. O 1995 TUXCO CORPORATION

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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. 61630-2184 U.S.A.: 1-800-542-8665 Illinois: 1-800-541-8665 Canada: 1-800-523-8665 World: 1-309-675-6277 Fax: 1-309-494-1475 CSTG_Hotline@cat.com

©2005 Caterpillar All Rights Reserved

NEHS0934-01 Printed in U.S.A.