HYDRO-LINE Cylinder Maintenance Data E-CYSL-RR001-E April 20152

Rod bushing

Do not fill rod wiper groove

Brush I.D., fill rod seal groove about 1/4 full before installing internal seals. Do not fill rod wiper groove.

TubeThoroughly brush coat or swab before assembly.

Piston

Brush coat O.D. and fill seal grooves about 1/4 full before installing piston seals.

Piston seals

Fill inside of vee before installing on piston.

Two pair of alternative size piston seal back-up rings are provided in the kit. Select the pair that assemblies in the groove with gap as shown below.

Rod wiper and seal

Rod wiper Backup Washer

Rod Seal

Fill inside of vee before installing in bushing.

Piston rodBrush coat before assembly.

Cushion spudsBrush coat before assembly.

A

C

D GF

B E

A

B

C D

F FG G

E E

Only pre-lubricated cylinder should be cleaned and re-lubricated whenever it is disassembled, such as for renewing seals.

Lubrication is Molylithium EP2. Apply as illustrated. This lubricant is available from Eaton.

Note: Specify cylinder model code when ordering replacement parts.

Permanently lubricated maintenance data

1. In almost all cases there is a circular retainer at the head end, remove the socket head screws which retain it. Otherwise, remove tie rod nuts if full front plate is used.

2. Remove circular retainer or front plate which retains rod cartridge.

3. Remove rod cartridge. To overcome friction, insert screwdriver in external groove. Pry carefully, (see figure 1: 3).

4. Clean cartridge recess in the head.

5. Lubricate the inside of the rod cartridge and the outside of the new cartridge prior to assembly.

6. Caution - Place new cartridge on rod end, being sure to use a twisting, "screwing motion" as you start it onto the rod.

7. Insert cartridge (now mounted on rod) into head recess.

8. Replace circular retainer and apply torque per chart below. Or replace front plate, and tighten tie rod nuts to original prestress (see charts on page 3 and figure 2-1 for order of tightening).

Circular retainer

To replace rod cartridge seals:

Rod cartridge seals and tube end seals

Rod end

Rod cartridge

External groove Pry

Tie rod nuts

Front plate

Figure 1

1 2 3

Torque on circular retainer socket head screws

Screw Size 1/4 - 20 5/16 - 18 3/8 - 16 7/16 - 14 5/8 - 11 3/4 - 10

Torque (ft/lb) 18 34 53 80 270 370

HYDRO-LINE Cylinder Maintenance Data E-CYSL-RR001-E April 2015 3

Cylinder ratings and torque values

N5 - AN5 - LAN5R5 - HR5 - LR5Cylinder Bore (Inches)

Hyd Pressure Ratings** Tie Rod Nut Torque

Mtg. TT Torque (ft./lbs.)†

4:1 Design Factor (Yield)

Tie Rod Dia. (Inches)

Torque (ft./lbs.)†

1 1800 3/16 3 . 5

1 - 1/2 1600 1/4 10 6

2 1500 5/16 18 12

2 - 1/2 1000 5/16 18 12

3 - 1/4 900 3/8 30 30

4 650 3/8 30 30

5 650 1/2 80 54

6 500 1/2 80 80

8 600 5/8 190 115

10 550 3/4 300 213

12 400 3/4 300 229

14 400 7/8 550 360

16 750 1 700 380

18 720 1 - 1/8 950 530

20 650 1 - 1/4 1250 700

Cylinder Bore (Inches)

N5 Pressure Ratings** Tie Rod Nut Torque (ft./lbs.)

4:1 Design Factor (Yield)

Tie Rod Dia. (Inches) N5

Mtg. TT Only

1 - 1/2 3008 3/8 30 17

2 2335 1/2 40 36

2 - 1/2 2531 1/2 80 56

3 - 1/4 2477 5/8 190 118

4 2214 5/8 190 160

5 2836 7/8 550 350

6 2406 1 700 560

7 2336 1 - 1/8 950 840

8 1975 1 - 1/4 1250 1200

10 2499 1 - 1/8 950 850

12 2069 1 - 1/4 1250 1250

14 1796 1 - 1/4 1250 1200

16 1864 1 - 1/2 2900 2800

18 1919 1 - 1/2 2900 2400

20 1822 1 - 1/2 2900 2900

** R5, LR5, AN5 & LAN5 for 200 Psi air service maximum. Based on minimum yield point of weakest component and standard piston rod diameter size.

† The above values are for lubricated threads and lubricated nut contact faces.

LR5 - LAN5 maintenance

When replacing the Rod Cartridge and Piston Seals on series LR5 or LAN5, brush the cartridge I.D., piston O.D., piston rod, tube I.D., cushion spuds and dash pots with Molylithium EP2 grease or equivalent. Fill the rod seal and piston seal grooves 1/4 full and fill the inside of the vee of the seals and rod wiper before installing.

Eaton Limited Warranty

http://www.eaton.com/Eaton/ProductsServices/Hydraulics/WarrantyTermsConditions/index.htm

To replace tube end seals:

1. Remove tie rod nuts at end of cylinder.

2. Remove head and cap from cylinder.

3. Discard the used seal and clean all parts thoroughly, including inside of tube and grooves in head and cap.

4. Continuous Ring Type Installation: The tube seal needs to be stretched for a proper fit. To do this, hold the seal with index fingers and rotate in a circular motion 2 or 3 times. This should be done while putting only light tension on the seal. Place the seal in the groove using a screwdriver to help smooth it out. Use the rounded part of the screwdriver and not a sharp edge. Be sure that the seal is flush against the outer diameter of the tube groove in head and cap.

Strip Stock Installation: Place the seal around the outer diameter in the tube groove. Make sure the seal is making contact with the outer wall of the groove. The tube seal needs to be cut 1/8" longer than where the ends meet. (Cut ends must be square.) Remove the seal from the groove. Push the two ends together and hold this point inside the groove. Work the seal into the groove using your other hand. (Do not stretch seal.)

5. Reassemble cylinder. Tighten tie rod nuts hand tight only.

6. Torque tie rod nuts in order shown in figure 2-1: 1, 2, 3, and 4. See chart at the bottom of this page for proper torque.

7. Recheck torque in same order.

2 31

1

3

2

4

Figure 2

To remove piston from rod - Loctite method:

1. Heat piston and rod to 400° - 450° F.

2. Disassemble while hot using spanner wrench or strap wrench.

3. Remove piston by turning counterclockwise.

To remove rod end stud from rod:

1. Heat rod end and stud to 400° - 450° F.

2. Unthread turning stud counter clockwise while hot.

Note: Loctite is recommended for use in the temperature range of -65° to 300°F.

Piston mounting:

1. The threads of the rod and piston must be cleaned with a non-conductive solvent.

2. Let the parts dry.

3. Apply Loctite 271 to threaded diameters up to 1.00". Apply Loctite 277 to threaded diameters over 1.00".

4. Thread the rod and piston together using a spanner wrench, impact wrench or strap wrench.

5. Quickly wipe up any loctite that runs out the end of the piston.

6. Let the parts cure for a minimum of 24 hours.

Stud mounting:

1. The threads of the stud and rod must be cleaned with a nonconductive solvent.

2. Let the parts dry.

3. Apply Loctite 271 to threaded diameters up to 1.00". Apply Loctite 277 to threaded diameters over 1.00".

4. Insert the stud into the rod approximately two threads. Use a driver, spanner wrench or strap wrench to thread the stud completely into the rod.

5. Wipe away any loctite that runs out.

6. Let parts cure for a minimum of 24 hours.

Piston and rod end stud

Piston

Piston rod

Spanner Holes

†Assemble parts within 3 minutes after application of Loctite.

Figure 4

To replace the needle valve assembly

1. Remove existing needle valve assembly by first loosening large hex 1 or 2 turns to relieve pressure. Then back out small hex until full assembly is removed. Pull out existing backup washer and needle seal from the recess and discard all parts.

2. Insert replacement needle valve assembly, using large hex to thread it into the needle valve recess.

3. After valve assembly has been fully threaded into recess and locked securely, use small hex to adjust needle for desired flow, thus controlling cushion action. Needle valve assembly is flush with cylinder head or cap surface, even in full-open needle position.

Caution: Needle valve assembly is shipped with needle in full-open position (needle is threaded fully outward, into locking nut). Needle must remain in this position when needle valve assembly is threaded into recess. A "D" seal surrounds the needle and seats against the shoulder formed by the locking nut when properly Installed.

Needle and ball check valves

Large hex

Locking nut

Small hex

Needle

Needle seal

Figure 5

To replace ball check valve assembly

1. Remove and discard existing ball-check valve assembly from cylinder.

2. Install replacement ball and strike it against its seat to peen the sealing surface. Use a hammer and a pin punch.

3a. When seal and anti-extrusion washer come assembled on the retainer nut: Insert spring on top of ball. Seal and anti-extrusion washer should remain on the retainer nut, and be installed as a unit.

3b. When retainer "D" seal and anti-extrusion washer are packaged separately from retainer nut: First, insert the "D" seal against the shoulder in the check valve recess. Then lightly grease anti-extrusion washer and spring so they will adhere to retainer nut when installing.

4 Use standard internal socket wrench to securely seat the retainer nut. Ball-check valve assembly should be flush with cylinder head and cap surface when fully seated.

Note: On HR5 and N5 hydraulic cylinders there is no ball check spring.

3b

Ball

Spring

Retainer "D" ring seal

Retainer nut

Shoulder

3a

Figure 6

Piston

Piston rod

Spanner Holes

Figure 3

© 2015 EatonAll Rights ReservedPrinted in USADocument No. E-CYSL-RR001-EApril 2015

EatonHydraulics Group USA14615 Lone Oak RoadEden Prairie, MN 55344USATel: 952-937-9800Fax: 952-294-7722www.eaton.com/hydraulics