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Parts Sheet #0510-4003_13_BC212ps
BC212
Instructions – 2
CYLINDER DISASSEMBLY INSTRUCTIONS
1. Remove Band Cylinder from machinery.
2. Loosen Screw (18).
3. Remove any foot mounting hardware if present then remove
the four Head Bolts (17) to free Cylinder Heads (7).
4. Remove the three Screws (6, 8) , Nuts (4), End Caps (1) and
Bearing Rods (2). Then remove the Shoulder Bolts (11) to free
the Carrier Bracket (3),
5. Slide Piston Bracket Assembly (22) to end of tube.
6. Remove top Dust Band (10) by lifting one end and drawing it
back across the entire length of the cylinder.
7. Remove the inner Sealing Band (9) by passing a screwdriver
or similar tool through the slot in the cylinder tube to
dislodge the band from the tube. (Take care in doing this
step to make certain that NO SCRATCHES ARE MADE in
the tube bore or slot.)
CYLINDER ASSEMBLY INSTRUCTIONS
1. CLEAN AND LUBRICATE
Thoroughly clean all components, particularly the tube bore
slot and bands. Thoroughly lubricate the tube a thin, uniform
layer of Magnalube-G
®
grease. Do not use SAE-grade
30-weight non-detergent oil.
2. READY INNER SEALING BAND
Lubricate rubber strip on both sides of new Sealing Band (9)
with grease. Insert Band into cylinder Tube (14) by passing it
sideways through slot in Tube. With rubber portion facing up,
center band in Tube so equal lengths of Band extend out
both ends.
CAUTION: Metal edges of Sealing Band are sharp. Exercise
caution to avoid injury to yourself or the Band and Tube when
inserting.
3. INSTALL PISTON BRACKET ASSEMBLY
Install new lubricated U-Cups (21) (seal lips facing out) and
Cushion Seals (24) (small end facing out) onto Piston-Bracket
Assembly (22). Install Wear Rings (23) on Piston with the
thinner edge and widest part of the flat inward, lining up the
wider flat portion with the band ramp and narrower flat with
the flat on the Piston. Place generous amounts of grease
around bore of Tube (14) on one end. Fill indentations on both
sides of Piston with grease and install Piston-Bracket
Assembly into Tube (14) by feeding Sealing Band (9) between
Piston and Bracket. Insert Piston into the greased end of Tube
and slide the length of the Tube to seat the Sealing Band in its
groove. Wipe excess grease from end.
NOTE: If Tube and Piston were greased properly, excess
grease should be present as Piston exits end of tube.
4. TRIM SEALING BAND
With a razor blade, remove rubber from extended band until
flush with the end of tube. With tin snips, trim band to length
indicated on table below. (Tolerance of +/- .032")
Cylinder Size
Trim Length From Tube
1-1/4" (32 mm)
.531" (14.86 mm)
5. INSTALL HEADS
Install new lubricated O-Rings (15) onto each Head (7). Insert
Head into Tube using a slight rocking motion until head is flush
with end of Tube. Apply Magnalube-G to threads of Head
Bolts (17) and install into head. Torque Bolts to requirements
shown below.
(†When replacing the head bolts in
actuators manufactured prior to July 1, 2006, the hole for
the head bolt will need to be drilled 0.4" [10mm] deeper
to accommodate the longer screw length.)
Repeat above
procedures for second head.
Cylinder Size
In.-Lbs. Torque
1-1/4" (32 mm)
100-110 (11.29-12.43 Nm)
6. INSTALL UPPER DUST BAND
With a razor blade, remove any rubber residue on the solid
steel surface of cleaned Dust Band (10). Place Dust Band in
slot on top of Tube (14). Remove rubber from one end of Band
flush with the end of the tube. With tin snips, trim Dust Band
to trim length requirements in Step 4. Insert trimmed Dust
Band into Head (7) positioning band above Band Clamp (16)
and tighten Screw (18). Grasp other end of Dust Band (10)
and carefully pull back out of Tube slot and back over cylinder
Head with affixed Band end. Lubricate Dust Band by filling
grooves along both sides of rubber strip with grease. Press
Dust Band back into groove in Tube.
7. INSTALL CARRIER
Position Carrier (3) on Piston-Bracket Assembly (22). Install
Shoulder Bolts (11), Washers (5) and Nuts (4) with screw
heads on port side of cylinder. Install Bearing Rods (2) in
Carrier and place End Caps (1) on Tube. Install Band
Insert (12) into pocket on End Cap (curved portion towards
carrier). Insert Spring (13) into hole of Band Insert (12).
Compress Spring and slide End Cap up to Carrier. Fasten
with Screws (6 and 8). Repeat for other end.
8. REMOVE SLACK AND AFFIX FREE END OF BAND
Work slack from Bands by moving the Carrier from the Head
with Bands secured to the opposite Head. Remove excess
rubber from free end keeping it flush with end of Tube. Cut to
trim length as before. Secure free end of Band by inserting
Band above Band Clamp (16) and tighten Screw (18).
9. CHECK ASSEMBLY
Run the Carrier Bracket (3) back and forth along the full
stroke to make certain that the cylinder is properly assem-
bled before applying air.
10. REMOUNT
OPTIONAL ACCESSORY ASSEMBLY INSTRUCTIONS
1. SHOCK ABSORBERS
On assembled cylinder, screw Impact Bolts (29) into top of
carrier End Cap with Loctite #242. Secure Shock
Brackets (28) to cylinder Heads (7) with Socket Head Cap
Screws (27) and Loctite #242. Screw the Shock Absorber (26)
into the Shock Bracket (28). Adjust the Shock Absorber
nearest the carrier to bottom out the shock at its fullest stroke.
Back out the shock one full turn and tighten the Jam Nut.
Adjust the other Shock Absorber in the same manner.
2. TUBE SUPPORTS
Follow cylinder assembly instructions through steps 4. Before
installing second cylinder Head (7) in step 5., slide Tube
Support (40) onto cylinder Tube (14).
3.
FOOT MOUNTS
On assembled cylinder, insert Screws (35) through holes in
Foot Mount Bracket (36) and install in holes on cylinder
Heads (7).
4. FLOATING MOUNT
Completely assemble cylinder. Place Pin (31), flat side
towards Carrier (3), and between the two center holes.
Place Floating Mount Clamp (32) over Pin (31) and secure to
the Carrier (3) with Screws (34) and Loctite® #242. Place
Floating Mount Bracket (33) over Pin (31) and hold in place
with a rubber band.
