Durapac RG-57, RG-59, RG-101, RG-102, RG-104 Instruction Manual

Instruction Manual

Single Acting, Collar Thread, Hydraulic
Cylinders – RG Series

Maximum Operating Pressure – 700 bar

ABSO LUTE EQUI P M ENT PTY LT D – 2 /186 Granite Street, GEEBUNG QL D 4034 – A u stralia

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Instruction Manual

This is a safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid injury or death

1.0 Product Information

DURAPAC – Hydraulic Cylinders are engineered to meet ANSI/ASME B30.1 Standards for
Performance and Safety. The RG-Series is a general purpose spring return cylinder designed for use
in production, maintenance and fabrication applications.

All RG Series cylinders feature a hard chrome cylinder bore and piston rod for maximum corrosion­resistance. When combined with the bronze overlay on the piston bearing area and low-friction
surface treatment on the gland nut, this cylinder is suitable for demanding applications. Cylinder
body mounting threads and base mounting holes are included on most models. Optional TSX tilt
saddles are available for all models from RG-102 to RG-10010.

 Hardened grooved saddle to prevent piston rod damage (except RG-101)
 Optional tilt saddles available
 Gland nut with low friction coating withstands full dead end loading
 Hard chrome plated piston rod for maximum corrosion-resistance and cylinder life
 Bronze overlay on piston bearing area reduces side load induced damage and extends

cylinder life

 Piston rod threads and base mounting holes permit easy fixture
 Hard chrome plated bore for maximum corrosion-resistance and cylinder life
 Piston rod wiper reduces contaminants
 Return springs are sized to ensure efficient piston rod return and maximum spring life
 Powder coated finish enhances appearance and reduces corrosion
 Parker industry standard high flow coupling for compatibility

Note – Durapac offers a range of piston and base attachments to suit the RG Series cylinders.

Special skill, knowledge and training may be required for a specific task and the product may not be
suitable for all jobs. The user must ultimately make the decision regarding suitability of the product
for any given task and assume the responsibility of safety for all in the work area. Contact a Durapac
representative if you are unsure of your cylinder’s suitability for a particular application.

2.0 Receiving Instructions

It is recommended prior to use that an inspection be done by qualified personnel and that any
missing or damaged parts, decals, warning/safety labels or signs are replaced with Durapac
authorised replacement parts only. Any cylinder that appears to be damaged in any way, is worn,
leaking or operates abnormally should be removed from service immediately until such time as
repairs can be made. Any cylinder that has been or suspected to have been subject to a shock load
should be removed from service immediately until inspected by a Durapac authorised service centre.
Owners and operators of this equipment should be aware that the use and subsequent repair of this
equipment may require specialised training and knowledge.

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Instruction Manual

DANGER:

 To avoid personal injury keep hands and feet away from work area during operation

 Do NOT handle pressurised hoses. Escaping oil under pressure can penetrate the skin

causing serious injury. If oil is injected under the skin, see a doctor immediately

 Stay clear of loads supported by hydraulics. A cylinder, when used as a load lifting

device, should never be used as a load holding device. After the load has been raised
or lowered, it must always be supported mechanically

WARNING:

 The system operating pressure must not exceed the pressure rating of the lowest

rated component in the system. Install pressure gauges in the system to monitor
operating pressure. It is your window to what is happening in the system

 Always wear appropriate personal protective equipment (PPE) when operating

hydraulic equipment. The operator must take precaution against injury due to failure
of the tool or work piece(s)

 Do NOT hold or stand directly in line with any hydraulic connections while pressurising

 Do NOT attempt to disconnect hydraulic connections under pressure. Release all line

pressure before disconnecting hoses

 All personnel must be clear before lowering load or depressurising the system

 Do NOT attempt to lift a load weighing more than the capacity of the cylinder

IMPORTANT:

 If at any stage, the safety related decals become hard to read, these must be replaced

 Minimum age of the operator must be 18 years. The operator must have read and

understood all instructions, safety issues, cautions and warnings before starting to
operate the equipment. The operator is responsible for this activity towards other
persons

 Do NOT lift hydraulic equipment by the hoses or couplers. Use the carrying handle or

other means of safe transport

 Hydraulic equipment must only be serviced by a qualified hydraulic technician. For

repair service, contact the Durapac authorised service centre in your area. To protect
your warranty, use only high quality hydraulic oil

3.0 Safety

Save these instructions. For your safety, read and understand the information contained within. The
owner and operator should have an understanding of this product and safe operating procedures
before attempting to use this product. Instructions and safety information should be conveyed in the
operator's native language before use of this product is authorised. Make certain that the operator
thoroughly understands the inherent dangers associated with the use and misuse of the product. If
any doubt exists as to the safe and proper use of this product as outlined in this factory authorised
manual, remove from service immediately.

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Instruction Manual

CAUTION:

 KEEP HYDRAULIC EQUIPMENT AWAY FROM FLAMES AND HEAT. Hydraulic fluid can

ignite and burn. Excessive heat will soften packings and seals, resulting in fluid leaks.
Heat also weakens hose materials and packings. For optimum performance do not
expose equipment to temperatures of 65°C (150°F) or higher. Protect all equipment
from weld spatter

 No alteration should be made to this device

3.1 Hydraulic Cylinders

 Do NOT overload equipment. Overloading can cause equipment failure and possible

personal injury

 This device is not suitable for use as a support device! As the system load is lifted,

use blocking and cribbing to guard against a falling load

 BE SURE SETUP IS STABLE BEFORE LIFTING LOAD. Cylinders should be placed on a

flat surface that can support the load. Where applicable, use a cylinder base for
added stability. Do not weld or otherwise modify the cylinder to attach a base or
other support

 Avoid situations where loads are not directly centred on the cylinder piston. Off-

centre loads produce considerable strain on cylinder and pistons. In addition, the
load may slip or fall, causing potentially dangerous results

 Distribute the load evenly across the entire saddle surface. Always use a saddle to

protect the piston (if one is provided)

 USE ONLY RIGID PIECES TO HOLD LOAD. Carefully select steel or wood blocks that

are capable of supporting the load. Never use a hydraulic cylinder as a shim or
spacer in any lifting or pressing application

 Never pressurise uncoupled couplers. Only use hydraulic equipment in a coupled

system

3.2 Hydraulic Hoses & Fluid Transmission Lines

 Avoid short runs of straight line tubing. Straight line runs do not provide for

expansion and contraction due to pressure and/or temperature changes

 Reduce stress in tube lines. Long tubing runs should be supported by brackets or

clips. Before operating the pump, connections should be tightened securely and
leak-free. Over tightening can cause premature thread failure or high pressure
fittings to burst

 Should a hydraulic hose ever rupture, burst or need to be disconnected,

immediately shut off the pump and release all pressure. Never attempt to grasp a
leaking pressurised hose with your hands. The force of escaping hydraulic fluid can
inflict injury

 Do NOT subject the hose to potential hazard such as fire, sharp objects, extreme

heat or cold or heavy impact

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Instruction Manual

 Do NOT allow the hose to kink, twist, curl, crush, cut or bend so tightly that the fluid

flow within the hose is blocked or reduced. Periodically inspect the hose for wear

 Hose material and coupler seals must be compatible with the hydraulic fluid used.

Hoses also must not come in contact with corrosive materials such as battery acid,
creosote-impregnated objects and wet paint. Never paint a coupler or hose

FAILURE TO HEED THESE WARNINGS MAY RESULT IN PERSONAL INJURY AS WELL AS PROPERTY DAMAGE.

4.0 Installation

WARNING: When hoisting the cylinder, use all of the eye bolts. Failure to do so could cause the

cylinder to drop unexpectedly. Lifting straps must be at a 45 degree or greater angle from
horizontal. See Figure 1 (below)

Figure 1 – Hoisting Cylinder

IMPORTANT: Always secure threaded port connections with high grade, non-hardening pipe

thread sealant. Teflon tape can be used if only one layer of tape is used and it is applied
carefully, two threads back, to prevent the tape from being introduced into hydraulic system,
which could cause jamming of precision-fit parts

CAUTION: DO NOT allow the piston rod to rotate when installing adaptors. Damage to the

spring may prevent piston rod retraction

4.1 Know your cylinder, its limitations and how it operates before attempting to use. If in

doubt, contact Durapac.

4.2 Make hydraulic connections; use a pump release valve or a 3-way valve and one hose

for a single-acting cylinder.

IMPORTANT: Fully hand-tighten all couplers. Loose coupler connections will block

the flow of oil between the pump and the cylinder

4.3 Check all system fittings and connections to be sure they are tight and leak free.

4.4 Check oil level in reservoir before operating pump.

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Instruction Manual

IMPORTANT:

 Always use a flat, hard surface as a cylinder support plate

 Collar threads are rated for the full capacity of the cylinder when fully engaged in

attachments

 Cylinder gland nut/stop ring is designed to take the full load, to reduce cylinder wear,

use less than the full stroke where possible

4.5 Remove air from the system – Position the cylinder so that the piston rod is pointed

down and the cylinder is lower than the pump. Advance and retract the cylinder
several times, avoiding pressure build-up. Air removal is complete when the cylinder
motion is smooth.

5.0 Operation

For complete operating instructions refer to the instruction sheet included with each pump.

5.1 Advancing and retracting the cylinder

The RG Series cylinders are a spring return cylinder and the speed of retraction is
affected by the length of the hose and other restrictions in the line.

Shift the valve on the pump to the advance position and run the pump to advance the
cylinder. To retract the cylinder, shift the valve to the retract position.

Figure 2 – RG Series Sectional Drawing

5.2 Side Load

Eliminate the presence of side load forces when using high tonnage cylinders. Side load
can occur through:

5.2.1 An eccentric load on the piston rod.

5.2.2 A horizontal load on a structure.

5.2.3 A structure and/or cylinder misalignment.

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5.2.4 Non synchronised lifting actions

IMPORTANT:

 Use only good quality hydraulic fluid. Do NOT use brake fluid, transmission fluid,

turbine oil, motor oil, alcohol, glycerine etc. Use of anything other than good quality
hydraulic oil will void warranty and damage the cylinder and application. We
recommend Durapac Hydraulic Oil or equivalent

 Equipment must only be serviced by a qualified hydraulic technician. For repair service,

contact your local Durapac authorised service centre

 Damage to hydraulic hoses may not be detected during visual inspections. For this

reason, Durapac recommends that hydraulic hoses be replaced on a regular basis

 Tighten connections as needed. Use non-hardening pipe thread compound when

servicing connections

5.2.5 Non stable cylinder base support.

To reduce cylinder offset loading, optional tilt saddles are available. Always use grease
underneath swivel saddles.

6.0 Maintenance

Instruction Manual

Figure 3 – Tilt Saddle.

Dirt, sand, etc. will quickly ruin any hydraulic system. Ensure that couplings are clean and free of
foreign matter. After each use, clean couplings and attach dust caps.

Maintenance is required when wear or leakage is noticed. Periodically inspect all components to
detect any problem that may require service and maintenance.

6.1 Check for loose connections and leaks.

6.2 Replace damaged parts immediately.

6.3 Do not exceed oil temperature above 60

o

C.

6.4 Keep all hydraulic components clean.

6.5 Use dust caps when cylinder is disconnected from the hose. Keep entire cylinder clean

to prolong cylinder life.

6.6 Wipe thoroughly clean and store cylinders upright (to prevent seal distortion) in a

clean, dry environment. Avoid temperature extremes.

6.7 Change hydraulic oil in your system as recommended in the pump instruction sheet.

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Instruction Manual

Problem

Cause

Solution

Cylinder moves but

does not maintain

pressure

Leaking connection

 Clean, reseal with thread sealant and

tighten connection

Leaking cylinder seals

 Replace worn seals
 Check for excessive contamination or wear
 Replace contaminated fluid as necessary

Malfunctioning
pump/valve

 Check pump or valve operating instructions
 Repair or replace as necessary

Cylinder leaks
hydraulic fluid

Worn or damaged seals

 Replace worn seals
 Check for excessive contamination or wear
 Replace contaminated fluid as necessary

Loose connections

 Clean, reseal with thread sealant and

tighten connection

Cylinder will not
retract or retracts
slower than normal

Closed pump release
valve

 Open pump release valve

Loose couplers

 Tighten couplers

Blocked hydraulic lines

 Clean and flush lines

Weak or broken
retraction springs

 Send to a Durapac authorised service centre

for repair

Internally damaged
cylinder

 Send to a Durapac authorised service centre

for repair

Pump reservoir too full

 Drain hydraulic fluid to correct level

Erratic Action

Air in system or pump
cavitation

 Add fluid, bleed air and check for leaks

External leakage

 Replace worn packings
 Check for excessive contamination fluid as

necessary

 Replace contaminated fluid as necessary

Sticking or binding
cylinder

 Check for dirt or leaks
 Check for bent, misaligned, worn parts or

defective packings

Cylinder does not

move

Loose couplers

 Tighten couplers

Faulty coupler

 Verify that female coupler is not locked up

(ball wedged into seat)

 Replace both male and female couplers

Improper valve position

 Close release valve or shift to new position

Low or no hydraulic
fluid in pump reservoir

 Fill and bleed the system

Air-locked pump

 Prime pump according to pump operating

instructions

Pump not operating

 Check pump’s operating instructions

Load is above the
capacity of the system

 Use the correct equipment

Cylinder extends only

partially

Low or no hydraulic
fluid in pump reservoir

 Fill and bleed the system

Load is above the
capacity of the system

 Use the correct equipment

7.0 Troubleshooting

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