CYLINDER REBUILD PROCEDURE - SUSPENSION, REAR

Transcription

1 CYLINDER REBUILD PROCEDURE - SUSPENSION, REAR This cylinder is precharged with nitrogen. All dry nitrogen (N 2 ) pressure MUST be relieved before cylinder is removed from the vehicle. This cylinder assembly DOES NOT have any charging valves. All charging valves are mounted on the inside, left, rear bumper and top, rear of the Axle Assembly. DISASSEMBLY The item numbers in the following procedures are in illustrations on page Remove the capscrews (31 & 32), washers (33), plate (34) and then remove the ball stud (30) from the rod end of the cylinder. Remove the shield (37). Remove the bearing (39) from the shield. 2. Remove exterior nitrogen tubing and fixtures, (42, 44, 45, 46, & 47). 3. Place the cylinder in a vertical position with the rod end up and the rod structure end down. Support the collapsed cylinder on the bottom with a block of wood. 4. Push the outside bearing carrier (18) in the housing (1) about.38 inches (10 mm) and remove the retaining wire (22). Install two eyebolts on the inside retainer (29) and carefully remove the assembly from the cylinder, using a hoist and lifting straps. 5. Place assembly on a work bench. Remove the outside bearing carrier (18). Remove the retainer (27) and scraper ring (28) from inside the bearing carrier (18). Remove the seals (17 & 20) and back-up ring (21) from inside the bearing carrier. Remove the bearing (19) from inside the bearing carrier. Remove the O-ring (23) and back-up ring (24) from the bearing carrier (18). 6. Push the inside retainer (29) into the housing 0.38 inches (9.65 mm) and remove retaining wire (7). Remove the inside retainer (29). Remove the o-ring (25) and back-up ring (26) from the retainer (29). 7. Attach an eyebolt to the upper separator (38) and remove from inside the cylinder rod (2). Remove the seals (16), the seal assembly (15), and wear rings (14) from the separator (38). 8. Cut the lock wire on the ten capscrews (11) fastened to the rod end cap (8). Loosen and remove the capscrews (11) and washers (12) from the rod end cap (8). Remove the rod end cap (8) and then remove the bearing (9) on the rod end cap. 9. Push the rod end cap retainer (10) into the rod 0.38 inches (9.65 mm). Remove the retaining wire (7) and then remove the retainer (10). 10. Attach an eyebolt to the lower separator (3) inside the housing. Remove the separator (3) using a hoist and lifting strap. 11. Remove the seal assembly (4), wear rings (5), and slydrings (6) from the lower separator (3). 12. The rod structure on the cylinder housing is welded on. The weld must be air arced and then the rod structure can be removed. After the cylinder is honed, replace the rod structure and weld according to Kress standards. The Kress Welding Standards document can be found in the Service manual, usually towards the front. 13. Wash all parts in a suitable solvent, dry and inspect these parts for wear or any damages which could cause the cylinder to fail. Repair or replace all faulty parts. Install new seals, o-rings and bearings. A Packing Kit is available when rebuilding this cylinder. Check the parts list at the end of this manual for numbers and contents of the kit. The purpose for having sized parts is as follows: 1/14/10 1 FR220102_Gr4

2 For example: A housing part number which has a scratch or a dent on the inside diameter. Instead of scrapping what is a very expensive part, you may (depending on the extent of the damage) hone the I.D. that is sized to the next larger size. There are sized parts within this cylinder and they all must have the same corresponding size within any one group or cylinder. The sizes range from A, which was originally provided, to B - which is inches (0.762 mm) larger than A, to C - which is inches (0.508 mm) larger than a B. The following pages have been inserted to aid in determining the size (A,B,C) of the parts in these assemblies. The size (A, B, or C) of each part listed in the groups below must be the same within that particular group of parts. GROUP 1 Kress Part Description Cylinder Housing Lower Separator Rod End Cap The cylinder housing (220424) is a sized part. The complete cylinder structure is , which consist of the cylinder housing (sized part) and the rod structure (220425) (non-sized part). The complete Cylinder Structure is item 1 on the attached parts list. GROUP 2 Kress Part Description Cylinder Rod Retainer Upper Separator ASSEMBLY Using the SAME hydraulic oil as the machine the cylinder will be used with, apply a film of clean oil to the inside surface of the rod (2) and housing (1) prior to assembly. Lubricate all seals, o-rings and bearings with hydraulic oil during assembly. Apply anti-seize to all capscrew threads and the surface of the capscrew head that mates to the washers. Remove all burrs from the ends of the retaining wires before installation. The rod structure must be welded back in place to the housing BEFORE assembly can commence. 1. Install the seal assembly (4), wear rings (5), and seals (6) onto the separator (3). Attach eyebolts to the separator (3). Using a hoist and lifting straps, lift and place inside of housing (1). Make sure the rings and seals remain seated in their grooves, the hollow portion of the separator goes in last. 2. Pour oil in the housing cavity until the oil level is.25 inches (6.35 mm) above the lower separator (3). 3. Install rod end cap retainer (10) into the rod (2). Install the retainer wire (7) into the groove in rod. Pull the retainer to the retainer wire, checking to be sure the wire is properly seated in the rod groove. 4. Install the rod end cap (8) onto the rod (2), aligning the holes to the threaded holes of the retainer (10). Install the capscrews (11) and washers (12) and torque them to 410 ft-lbs. (556 N m) using a triangular rotating sequence shown in the Kress Torque document. Install the bearing (9) on the rod end cap. Lock wire the capscrews in place using the procedures in the Kress Lockwiring document. 1/14/10 2 FR220102_Gr4

3 5. Install the seal assembly (15), wear rings (14), and seals (16) on the upper separator (38). 6. Stand the cylinder rod (2) up so that the rod end cap is at the bottom. Carefully push the separator (38) into the rod (2). Make sure the seals and wear rings remain properly seated. 7. Pour oil in the rod cavity until the oil level is.25 inches (6.35 mm) above the separator (38). 8. Install the o-ring (25) and back-up ring (26) into the same groove of the retainer (29) so the o- ring fits into the curved portion of the back-up ring, and the o-ring is toward the small end of the retainer. 9. Insert the retainer (29) into the rod (2) and install the retaining wire (7) into the groove in the rod. Pull the retainer to the retaining wire, checking to ensure the wire is properly seated in the rod groove. Install a temporary plug into the tapped hole. 10. Install the bearing (19) into its groove in the bearing carrier (18). Install one seal (20) in the groove next to the bearing with the sealing lip toward the bearing. Install the back-up ring (21) in the same groove with seal between the bearing and the back-up ring. 11. Install the other seal (17) in the next groove away from the bearing (small of the two center grooves) with the seal lip away from the bearing (opposite of other seal). 12. Install the scraper ring (28) in the notch at the end of the bearing carrier (18) with the small inside diameter (pointed inside edge) away from the bearing (19). Install the retainer ring (27) in the groove next to the scraper ring to hold the scraper in place. 13. Install the back-up ring (24) into the groove outside of the bearing carrier (18) with curved side of the ring toward the bearing (19) end of the retainer. Install the o-ring (23) into the same groove so it is on the bearing end side of the back-up ring and fits into the curved portion of the back-up ring. 14. Slide the bearing carrier (18) into the housing (1) with the bearing (19) end going in first. Install the retaining wire (22) into the housing groove and pull the retainer to the wire, checking to be sure the wire is properly seated in the housing groove. 15. Install exterior nitrogen tubing and fixtures, (42, 44, 45, 46, & 47). 16. Install the bearing (39) into the shield (37) groove. Remove the temporary plug from Step 8. Slide the bearing end of the shield over rod end of the housing until the shield rests against the rod (2). 17. Position the ball stud (30) through the shield end and into the rod, aligning the bolt holes and tapped holes. 18. Start two capscrews (31) and washers (33) in the area of the nipple port. Looking at this end of the rod, the nipple port is at the 7 o'clock position, see View B-B on the last illustration before the parts list. Rotate the breather hose fitting on the shield (37) to the 6 o'clock position. Put capscrews and washers (31 & 33) in the holes not covered by the bent plate (34) snug them. Install the bent plate (34) over these holes and thread the longer capscrews (32) and washers (33) into these holes. Torque all capscrews (31 & 32) to 235 ft-lbs. (319 N m). 19. Apply thread sealing compound to the threads of the Structure (41) and install it in the retainer (29). Install the cap nut (42) on the structure and properly tighten these components. 20. Rotate cylinder end to end. Install the spherical bearing (49) into the eye, using proper tooling so as not to damage the eye or bearing. Install the snap ring (43). Pump grease into the fittings, then install plugs (48). The cylinder should now be tested in an approved safety test stand. If it is not tested prior to installation in the vehicle, then after installation precharge the nitrogen chambers using the procedures in Kress Service Manual. Cycle the cylinder several times at full vehicle system pressure and check for leaks. Repair as necessary. 1/14/10 3 FR220102_Gr4

4 13, 32, 33 TORQUE TO 212 FT-LBS. 34 C C 43, 49 A A 48 VIEW C-C 13, 31, 33 TORQUE TO 212 FT-LBS. VIEW B-B 41, 42, 50, , 47 5 SECTION A-A , 12, 13 TORQUE TO 410 FT-LBS B B 41, 42 CYLINDER, SUSPENSION - REAR /14/10 4 FR220102_Gr4

5 CYLINDER, SUSPENSION - REAR Rev: Gr4 (Table Segment 1 of 2) ITEM PART NO. QTY DESCRIPTION 1* CYLINDER STRUCTURE 2* CYLINDER ROD 3* SEPARATOR LOWER SEAL ASSEMBLY OD LUYTEX WEAR RING TURCITE SLYDRING SEAL RETAINING WIRE 8* ROD END CAP BEARING RETAINER DR. BOLT.75-10NC X 2.75" LG GR WASHER.75 HARD STAINLESS WIRE.051 DIS LUYTEX WEAR RING TURCON AQ SEAL ASSEMBLY TURCITE SLYDRING SEAL SEAL - BUFFER 8.5 X.31 X BEARING CARRIER BEARING POLY PAK SEAL SEAL - DEEPZ 8.5 X.5 X RETAINING WIRE O-RING BACK-UP RING O-RING BACK-UP RING RETAINER SEAL - SCRAPER 8.5 X.25 X.38 29* RETAINER CYLINDER, SUSPENSION - REAR Rev: Gr4 (Table Segment 2 of 2) ITEM PART NO. QTY DESCRIPTION BALL STUD DR.HD.BOLT.62-11NCX2.50"LGGR DR.HD BOLT.62-11NCX3.0"LGGR FLATWASHER.62 HARD BENT PLATE 35 NOT USED 36 NOT USED SHIELD STRUCTURE COMPLETE 38* UPPER SEPARATOR BEARING NITROGEN WARNING LABEL STR 4ORS 4BOSS CAP NUT 4ORS SNAP RING STR 8ORS 8BOSS TUBE STR CLAMP.50 DIA ELBOW 90-4DRS -4BOSS PLUG HEX HD 2NPT SPHERICAL BEARING BOSS O-RING O-RING BUNA N -4 ORS * Sized parts. Please state cylinder size (A, B, C) when ordering. Included in Packing Kit NOTES: 1.) Item 1 consist of the cylinder housing (220424) and a rod structure (220425) welded together. 2.) This item is no longer supplied by Kress Corporation. For a replacement, order item instead. 1/14/10 5 FR220102_Gr4