Hydraulic cylinders

Replacement of packings

Installation, operation and maintenance

Approved date:
Created by: DRK-IN
Approved by:

Doc. No.: 36761-01-2.1

 Hydraulic cylinders
36761-01-2.0

List of contents:

Page:

1 General information ....................................................................................... 3

2 Dismantling ................................................................................................. 3
2.1 ................................................................................................................... 3
2.2 ................................................................................................................... 3
2.3 ................................................................................................................... 3
2.4 ................................................................................................................... 4
2.5 ................................................................................................................... 4
2.6 ................................................................................................................... 4
3 Mounting of packings ..................................................................................... 4
3.1 ................................................................................................................... 4
3.2 ................................................................................................................... 4
3.3 ................................................................................................................... 4
3.4 ................................................................................................................... 5
3.5 ................................................................................................................... 5
4 Assembly ..................................................................................................... 6
4.1 ................................................................................................................... 6
4.2 ................................................................................................................... 6
5 Storage ....................................................................................................... 7
6 Appendices .................................................................................................. 7

List of appendices:

Appendix 1 Hydraulic cylinder ......................................................................................... 8

List of figures:

Figure 1 ....................................................................................................................... 4
Figure 2 ....................................................................................................................... 5
Figure 3 ....................................................................................................................... 5
Figure 4 ....................................................................................................................... 6
Figure 5 Hydraulic cylinder ............................................................................................. 8

2/8 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Hydraulic cylinders
36761-01-2.0

NOTE!
The present instruction manual is concerned with the situations, which, according to
the experience of FLSmidth, are the most likely to occur. An exhaustive enumeration of
all conceivable situations, which may occur during erection, operation and maintenance
of the hydraulic cylinder cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not foreseen in the
instruction manual, and which the operator is/or feels unable to handle, it is
recommended that FLSmidth is contacted without undue delay for advice on
appropriate action.

1 General information
As always in connection with hydraulic installations, maximum cleanliness must be
observed during the work with the cylinders.
The surface of the piston rod and the inner surface of the cylinder must never be
subjected to strains of any kind.
In connection with the assembly of the cylinders, the parts must be smeared with oil
similar to that normally used in the hydraulic installation.

2 Dismantling
2.1
Dismantle the cylinder and take it to room or workshop where dismantling and
assembly can be carried out without involving any risk of contamination;
moreover, the necessary lifting gear must be held available.

2.2
Place the cylinder on a clean and plane base where it can be maintained in
horizontal position.
On large cylinders, the use of dismantling tools, lifting tackle, puller and
similar equipment may be required to pull the piston out of the cylinder.
Where the workshop flow cannot be made sufficiently clean, it must be
covered with plastic sheeting.
Check that the pipe connection (04) on the bottom cover is open and not
covered by the wooden blocks.
Also check while piston is being pulled out that no contaminants are sucked
into the cylinder through the pipe connection.

2.3
Bring the piston into top position. On large cylinders the piston rod must be
carefully supported, e.g. by means of a lifting tackle with soft straps. It must
be possible to maintain the piston rod in position where it is flush with the
cylinder when the piston is being pulled out. Check with a spirit level in the
horizontal plane.
Dismantle the top cover (08). Two of the bolt holes of the cover, placed
diametrically opposite, are equipped with thread for dismantling screws which
can be used in case the cover sticks.

The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth. 36
 Hydraulic cylinders
36761-01-2.0

2.4
With caution pull the piston out of the cylinder. Check that piston rod and
cylinder are flush. Use a spirit level. Place piston and piston rod on a base
where the surfaces of the parts are protected.

2.5
Remove wear rings and old packings from piston and cylinder. Use a screw-
driver or similar tool, but avoid making burrs or any sharp edges which may
damage the new packings when latter are fitted. Afterwards, polish with high-
grade emery cloth, if required; slip generated to be carefully removed.

2.6
Clean all surfaces and packing grooves carefully. Use compressed air, a plastic
scraper and similar equipment. Avoid the use of rags which may leave fluff.
Never use cotton waste.

3 Mounting of packings
3.1
All surfaces which will be passed by the packings during mounting must be
smeared with oil.

3.2
Mount the O-rings foreseen under the Teflon packings in the grooves of piston
and cover.

3.3
With your fingers softly dent the packings (11) inwardly as indicated in Fig. 1,
and push the packing into place in groove on the cover.
The wear rings (10) have been taper cut, and are attached to the top cover by
means of clean petroleum jelly or grease.

Figure 1

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Hydraulic cylinders
36761-01-2.0

3.4
Push the scraper ring (13) into place on the cover. This must be done from
“the outside”, i.e. from the side turning away from the cylinder. Note that the
scraper ring must be placed so that the O-ring (14) is positioned as indicated
in Fig. 2.

13. Scraper ring

14. O-ring for scraper ring
Figure 2

3.5
Heat the piston packings to 200-300°C. This is best done in an oil bath, but it
can also be done on a hot iron plate.
At this temperature the Teflon packing goes soft, so that it can be stretched to
point where it can be drawn over the piston. The packing remains soft for
several hours, even when it is cooled to room temperature level.
Mount the packing by means of the two mounting tapes shown in Fig. 3. Place
the packing in the groove over the underside of piston and pull it over the
edge of piston by means of the mounting tapes which are placed 120° apart.

Figure 3

Since the piston packing has stretched during mounting, it will be necessary to
calibrate it in order to position it in the groove over the O-ring (02). To this
end, use special tools consisting of clamp (15) and a wedge (16).
Place the parts on the piston as indicated in Fig. 4. When the clamp is
tightened, the packing is forced against the O-ring. Packing to be tightened to
point where it can slide into the chamfered edge of the cylinder while the
piston is being lowered into the cylinder.

The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth. 56
 Hydraulic cylinders
36761-01-2.0

15. Clamp
16. Wedge
Figure 4

The piston packing only remains soft for a certain period of time, and after
approx. 24 hours its original shape has been restored. Therefore, the piston
must be mounted in the cylinder while the piston packing is still hot and soft
so that it can be compressed and, so to speak, calibrated in the cylinder.
Place the cut wear rings (01) in their grooves and fix them with clean grease
or petroleum jelly.

4 Assembly
4.1
Smear the piston rod with oil and mount the top cover on the piston rod. On
large cylinders, the top cover is placed in a lifting tackle and with caution led
over the horizontally placed rod. Make sure that scraper ring, wear rings and
packings around piston rod do not sustain damage. Lead the piston rod all the
way through so that the piston eventually bears against the top cover.

4.2
Smear the cylinder wall and piston with oil prior to assembly.
When the piston is mounted in the cylinder, it is again essential that the piston
rod and cylinder flush completely, i.e. that the piston rod is carefully
supported so that its position is controlled at all times.
The lead-through must be effected slowly, while, at the same time, it must be
ensured that wear rings and piston packing are squeezed together so that they
slide over the chamfer of the cylinder edge without being damaged. If
necessary, the clamp (15) can be used when mounting.
Keep an eye on the O-rings of the top cover when they slide into the cylinder.
Once the top cover has been positioned, insert and tighten a couple of the
bolts of cover. The piston rod is now controlled, and the piston can be
bottomed without any risk.
Finally, tighten the screws of the top cover. Tighten two diametrically opposite
screws at a time. Use the correct tightening torque stated on drawing.

6/8 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Hydraulic cylinders
36761-01-2.0

5 Storage
Subject to long-term storage of cylinder prior to use, the piston must be pressed
down to bottom position, and the cylinder must be filled with oil on both sides of the
piston before it is plugged and taken to place of storage.

6 Appendices
See next page.

The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth. 76
 Hydraulic cylinders
36761-01-2.0

Appendix 1 Hydraulic cylinder

01. Wear ring for piston 09. Piston rod

02. O-ring 10. Wear ring in top cover
03. Piston packing 11. Piston rod packing
04. Pipe connection in bottom cover 12. O-ring for piston rod packing
05. Bottom cover 13. Scraper ring
06. Piston 14. O-ring for scraper ring
07. Pipe connection in top cover
08. Top cover
Figure 5 Hydraulic cylinder

8/8 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.