Our D Series is a Non-NFPA Cylinder Series designed to be durable and cost effective.
Product Features and Benefits
| Ninja Column 1 | Ninja Column 2 |
|---|---|
| Non-Metallic Bearings | A specially compounded reinforced Teflon material is used for the piston and rod bearings, assuring low fric- tion characteristics. Bearing assembly is easily re- moved for quick replacement. |
| Non-Lube Operation | D cylinders are designed for non-lube operation. |
| Cushions | High energy absorption poppet type adjustable cush- ions are available as a standard option. Cushion ad- justing screw is normally located in position No. 4. |
| Piston Rod | Hard chrome plated steel, ground and polished. Two wrench flats standard on all bore sizes. Full male na- tional coarse threads are standard. All other threads available as options. |
| Tubing | Hard coated I.D. aluminum for corrosion resistance and low friction. |
| Seals | All dynamic seals are self-adjusting Buna-N U-cups. |
| End Caps | Machined high strength aluminum alloy. |
| Pressure Rating | 250 PSI air or “non-shock” hydraulic. |
| Temperature | Operating temperature range from a minimum of 10 deg F (-12 deg C) to a maximum of 200 deg F (93 deg C). |
| Cushions | Poppet cushions can be specified for either or both ends of the Series “D” cylinder. Standard cushion length is one inch, with optional lengths of two and four inches. Each standard cushion increases the cylinder length by one inch. Increases for longer cushions are shown in the table below. |
| Spring Extend/Return | Spring extend/return cylinders are available in standard stroke lengths up to four inches. Cylinder ZB dimensions increases by one inch whenever spring return cylinders are specified. |
| Weights and theoretical forces of cylinders | Multiply factors by the air pressure. |
D-SERIES MOUNTINGS
Flange Mount
| Model | PART NO. | E | F | R | ES | FB | RF | UF |
|---|---|---|---|---|---|---|---|---|
| 12 | 7004 | 1-29/32 | 3/8 | 1.281 | 5/8 | 1/4 | 2-5/16 | 2-3/4 |
| 24 | 7009 | 2-15/32 | 7/16 | 1.718 | 3/4 | 5/16 | 3-1/32 | 3-19/32 |
| 30 | 7026 | 2-15/32 | 7/16 | 1.875 | 3/4 | 5/16 | 3-1/32 | 3-19/32 |
| 49 | 7013 | 2-15/16 | 7/16 | 2.206 | 3/4 | 5/16 | 3-7/16 | 4 |
| 70 | 7026 | 3-3/8 | 7/16 | 2.625 | 3/4 | 5/16 | 3-31/32 | 4-1/2 |
| 96 | 7019 | 4-1/4 | 5/8 | 3.224 | 1 | 1/2 | 5-1/16 | 5-15/16 |
| 160 | 7022 | 5-1/64 | 5/8 | 4.024 | 1 | 1/2 | 6-1/16 | 7 |
Rod Clevis
| MODEL | PART NO. | A | CB | (FM) | CD | CE | CG | CW | ER | L |
|---|---|---|---|---|---|---|---|---|---|---|
| 12 | 7000 | 3/4 | 1/4 | 3/8-16 | 3/8 | 1-11/32 | 3/8 | 1/4 | 17/32 | 15/32 |
| 24,30,49,70 | 7010 | 1 | 1/2 | 3/4-10 | 5/8 | 2-5/64 | 9/16 | 5/16 | 51/64 | 27/32 |
| 96-160 | 7015 | 1 | 1/2 | 1-8 | 3/4 | 2-21/64 | 3/4 | 1/2 | 1-1/16 | 1-1/ |
Eye Bracket
| MODEL | PART NO. | E | F | FL | R | CD | DD | EW | LR | MR |
|---|---|---|---|---|---|---|---|---|---|---|
| 12 | 7002 | 1-13/16 | 1/4 | 1-1/2 | 1.281 | 3/8 | 1/4 | 1/4 | 9/16 | 7/16 |
| 24 | 7007 | 2-3/8 | 3/8 | 1-7/8 | 1.718 | 1/2 | 5/16 | 1/2 | 7/8 | 5/8 |
| 30 | 7024 | 2-3/8 | 3/8 | 1-7/8 | 1.875 | 1/2 | 5/16 | 1/2 | 7/8 | 5/8 |
| 49 | 7012 | 2-7/8 | 3/8 | 2-1/8 | 2.206 | 5/8 | 5/16 | 1/2 | 1-1/16 | 13/16 |
| 96 | 7017 | 4-1/8 | 3/8 | 3 | 3.224 | 3/4 | 1/2 | 1/2 | 1-1/4 | 1 |
| 160 | 7021 | 5-1/8 | 3/8 | 3-1/2 | 4.024 | 3/4 | 1/2 | 1/2 | 1-1/2 | 1-3/8 |
Clevis Bracket
| MODEL | PART NO. | E | F | FL | R | CW | CB | CD | DD | LR | MR |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 12 | 7001 | 1-13/16 | 1/4 | 1 | 1.281 | 3/16 | 1/4 | 3/8 | 1/4 | 9/16 | 7/16 |
| 24 | 7006 | 2-3/8 | 3/8 | 1-3/8 | 1.718 | 9/32 | 1/2 | 1/2 | 5/16 | 7/8 | 5/8 |
| 30 | 7023 | 2-3/8 | 3/8 | 1-3/8 | 1.875 | 9/32 | 1/2 | 1/2 | 1/4 | 7/8 | 5/8 |
| 49 | 7011 | 2-7/8 | 3/8 | 1-1/2 | 2.206 | 3/8 | 1/2 | 5/8 | 5/16 | 1-1/16 | 13/16 |
| 70 | 7014 | 3-3/8 | 3/8 | 2-1/8 | 2.625 | 3/8 | 1/2 | 5/8 | 5/16 | 1-11/16 | 13/16 |
| 96 | 7016 | 4-1/8 | 3/8 | 2-1/16 | 3.224 | 3/8 | 1/2 | 3/4 | 1/2 | 1-1/4 | 1 |
| 160 | 7020 | 5-1/8 | 3/8 | 2-3/8 | 4.024 | 3/8 | 1/2 | 3/4 | 1/2 | 1-1/2 | 1-3/8 |
D-SERIES SINGLE END
Single Rod End – No Cushion
| MODEL | E | TN | BC | RT | R | NT |
|---|---|---|---|---|---|---|
| 12 | 1-13/16 | — | 1.811 | 1/4-28 X 3/8 | 1.281 | 1/4-28 X 1/4 |
| 24 | 2-3/8 | 25/32 | 2.429 | 5/16-24 X 9/16 | 1.718 | 5/16-24 X 9/32 |
| 30 | 2-3/8 | 25/32 | 2.625 | 1/4-28 X 3/8 | 1.875 | 5/16-24 X 9/32 |
| 49 | 2-7/8 | 1-1/4 | 3.119 | 5/16-24 X 9/16 | 2.206 | 5/16-24 X 1/2 |
| 70 | 3-3/8 | 1-1/4 | 3.712 | 5/16-24 X 9/16 | 2.625 | 5/16-24 X 9/16 |
| 96 | 4-1/8 | 1-27/32 | 4.559 | 1/2-20 X 3/4 | 3.224 | 1/2-20 X 1/2 |
| 160 | 5-1/8 | 2-1/2 | 5.689 | 1/2-20 X 3/4 | 4.024 | 1/2-20 X 1/2 |
Single Rod End – No Cushion
| Ninja Column 1 | Ninja Column 2 | Ninja Column 3 | Ninja Column 4 | Ninja Column 5 | Ninja Column 6 | Ninja Column 7 | Ninja Column 8 | Ninja Column 9 | Ninja Column 10 | Ninja Column 11 | Ninja Column 12 | Ninja Column 13 |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| FM | ||||||||||||
| STYLE | ROD | |||||||||||
| NO.1 | NPT | DIA. | ||||||||||
| MODEL | A | D | G | C | P* | Y | SN* | XT | ZB* | CC | EE | MM |
| 12 | 1 | 5/16 | 7/8 | 5/8 | 1.968 | 1-3/32 | 2-1/32 | 1-1/6 | 3-17/32 | 3/8-16 | 1/8 | 3/8 |
| 24 | 1-1/2 | 5/8 | 1-3/16 | 3/4 | 2-3/8 | 1-15/32 | 2-39/64 | 1-11/32 | 4-35/64 | 3/4-10 | 1/4 | 3/4 |
| 30 | 1-1/2 | 5/8 | 1-3/16 | 3/4 | 2-3/8 | 1-15/32 | 2-39/64 | 1-11/32 | 4-35/64 | 3/4-10 | 1/4 | 3/4 |
| 49 | 1-1/2 | 5/8 | 1-3/16 | 3/4 | 2-7/16 | 1-27/64 | 2-39/64 | 1-11/32 | 4-35/64 | 3/4-10 | 3/8 | 3/4 |
| 70 | 1-1/2 | 5/8 | 1-3/16 | 3/4 | 2-13/32 | 1-7/16 | 2-39/64 | 1-11/32 | 4-35/64 | 3/4-10 | 3/8 | 3/4 |
| 96 | 1-5/8 | 7/8 | 1-7/16 | 1 | 2-59/64 | 1-13/16 | 3-7/64 | 1-23/32 | 5-35/64 | 1-8 | 1/2 | 1 |
| 160 | 1-5/8 | 7/8 | 1-7/16 | 1 | 2-59/64 | 1-13/16 | 3-7/64 | 1-23/32 | 5-35/64 | 1-8 | 1/2 | 1 |
Single Rod End – Front or Rear Cushion
| FM | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| FM | ||||||||||||
| STYLE | ROD | |||||||||||
| NO.1 | NPT | DIA. | ||||||||||
| MODEL | A | D | G | C | P* | Y | SN* | XT | ZB* | CC | EE | MM |
| 12 | 1 | 5/16 | 7/8 | 5/8 | 1.968 | 1-3/32 | 2-1/32 | 1-1/6 | 3-17/32 | 3/8-16 | 1/8 | 3/8 |
| 24 | 1-1/2 | 5/8 | 1-3/16 | 3/4 | 2-3/8 | 1-15/32 | 2-39/64 | 1-11/32 | 4-35/64 | 3/4-10 | 1/4 | 3/4 |
| 30 | 1-1/2 | 5/8 | 1-3/16 | 3/4 | 2-3/8 | 1-15/32 | 2-39/64 | 1-11/32 | 4-35/64 | 3/4-10 | 1/4 | 3/4 |
| 49 | 1-1/2 | 5/8 | 1-3/16 | 3/4 | 2-7/16 | 1-27/64 | 2-39/64 | 1-11/32 | 4-35/64 | 3/4-10 | 3/8 | 3/4 |
| 70 | 1-1/2 | 5/8 | 1-3/16 | 3/4 | 2-13/32 | 1-7/16 | 2-39/64 | 1-11/32 | 4-35/64 | 3/4-10 | 3/8 | 3/4 |
| 96 | 1-5/8 | 7/8 | 1-7/16 | 1 | 2-59/64 | 1-13/16 | 3-7/64 | 1-23/32 | 5-35/64 | 1-8 | 1/2 | 1 |
| 160 | 1-5/8 | 7/8 | 1-7/16 | 1 | 2-59/64 | 1-13/16 | 3-7/64 | 1-23/32 | 5-35/64 | 1-8 | 1/2 | 1 |
Single Rod End – Double Cushion
| FM | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| FM | ||||||||||||
| STYLE | ROD | |||||||||||
| NO.1 | NPT | DIA. | ||||||||||
| MODEL | A | D | G | C | P* | Y | SN* | XT | ZB* | CC | EE | MM |
| 12 | 1 | 5/16 | 7/8 | 5/8 | 1.968 | 1-3/32 | 2-1/32 | 1-1/6 | 3-17/32 | 3/8-16 | 1/8 | 3/8 |
| 24 | 1-1/2 | 5/8 | 1-3/16 | 3/4 | 2-3/8 | 1-15/32 | 2-39/64 | 1-11/32 | 4-35/64 | 3/4-10 | 1/4 | 3/4 |
| 30 | 1-1/2 | 5/8 | 1-3/16 | 3/4 | 2-3/8 | 1-15/32 | 2-39/64 | 1-11/32 | 4-35/64 | 3/4-10 | 1/4 | 3/4 |
| 49 | 1-1/2 | 5/8 | 1-3/16 | 3/4 | 2-7/16 | 1-27/64 | 2-39/64 | 1-11/32 | 4-35/64 | 3/4-10 | 3/8 | 3/4 |
| 70 | 1-1/2 | 5/8 | 1-3/16 | 3/4 | 2-13/32 | 1-7/16 | 2-39/64 | 1-11/32 | 4-35/64 | 3/4-10 | 3/8 | 3/4 |
| 96 | 1-5/8 | 7/8 | 1-7/16 | 1 | 2-59/64 | 1-13/16 | 3-7/64 | 1-23/32 | 5-35/64 | 1-8 | 1/2 | 1 |
| 160 | 1-5/8 | 7/8 | 1-7/16 | 1 | 2-59/64 | 1-13/16 | 3-7/64 | 1-23/32 | 5-35/64 | 1-8 | 1/2 | 1 |
D-SERIES DOUBLE END
Double Rod End – No Cushion
*AD and CD should be used to differentiate between ends of a double-rod-end cylinder for rod style and cushion.
| MODEL | A | AD | C | CD | ZL | ZM | FM STYLE / CC | NPT / EE | ROD DIA / MM |
|---|---|---|---|---|---|---|---|---|---|
| 12 | 1 | 1 | 7/8 | 7/8 | 4-17/32 | 5-5/32 | 3/8-16 | 1/8 | 3/8 |
| 24 | 1-1/2 | 1-1/2 | 1-3/16 | 1-3/16 | 5-35/64 | 6-19/64 | 3/4-10 | 1/4 | 3/4 |
| 30 | 1-1/2 | 1-1/2 | 1-3/16 | 1-3/16 | 5-35/64 | 6-19/64 | 3/4-10 | 1/4 | 3/4 |
| 49 | 1-1/2 | 1-1/2 | 1-3/16 | 1-3/16 | 5-35/64 | 6-19/64 | 3/4-10 | 3/8 | 3/4 |
| 70 | 1-1/2 | 1-1/2 | 1-3/16 | 1-3/16 | 5-35/64 | 6-19/64 | 3/4-10 | 3/8 | 3/4 |
| 96 | 1-5/8 | 1-5/8 | 1-7/16 | 1-7/16 | 6-35/64 | 7-35/64 | 1-8 | 1/2 | 1 |
| 160 | 1-5/8 | 1-5/8 | 1-7/16 | 1-7/16 | 6-35/64 | 7-35/64 | 1-8 | 1/2 | 1 |
Double Rod End – Single Cushion
| MODEL | A | AD | C | CD | ZL | ZM | FM STYLE / CC | NPT / EE | ROD DIA / MM |
|---|---|---|---|---|---|---|---|---|---|
| 12 | 1 | 1 | 7/8 | 7/8 | 4-17/32 | 5-5/32 | 3/8-16 | 1/8 | 3/8 |
| 24 | 1-1/2 | 1-1/2 | 1-3/16 | 1-3/16 | 5-35/64 | 6-19/64 | 3/4-10 | 1/4 | 3/4 |
| 30 | 1-1/2 | 1-1/2 | 1-3/16 | 1-3/16 | 5-35/64 | 6-19/64 | 3/4-10 | 1/4 | 3/4 |
| 49 | 1-1/2 | 1-1/2 | 1-3/16 | 1-3/16 | 5-35/64 | 6-19/64 | 3/4-10 | 3/8 | 3/4 |
| 70 | 1-1/2 | 1-1/2 | 1-3/16 | 1-3/16 | 5-35/64 | 6-19/64 | 3/4-10 | 3/8 | 3/4 |
| 96 | 1-5/8 | 1-5/8 | 1-7/16 | 1-7/16 | 6-35/64 | 7-35/64 | 1-8 | 1/2 | 1 |
| 160 | 1-5/8 | 1-5/8 | 1-7/16 | 1-7/16 | 6-35/64 | 7-35/64 | 1-8 | 1/2 | 1 |
Double Rod End – Double Cushion
| MODEL | A | AD | C | CD | ZL | ZM | FM STYLE | NPT | ROD DIA |
|---|---|---|---|---|---|---|---|---|---|
| CC | EE | MM | |||||||
| 12 | 1 | 1 | 7/8 | 7/8 | 5-17/32 | 6-5/32 | 3/8-16 | 1/8 | 3/8 |
| 24 | 1-1/2 | 1-1/2 | 1-3/16 | 1-3/16 | 6-35/64 | 7-19/64 | 3/4-10 | 1/4 | 3/4 |
| 30 | 1-1/2 | 1-1/2 | 1-3/16 | 1-3/16 | 6-35/64 | 7-19/64 | 3/4-10 | 1/4 | 3/4 |
| 49 | 1-1/2 | 1-1/2 | 1-3/16 | 1-3/16 | 6-35/64 | 7-19/64 | 3/4-10 | 3/8 | 3/4 |
| 70 | 1-1/2 | 1-1/2 | 1-3/16 | 1-3/16 | 6-35/64 | 7-19/64 | 3/4-10 | 3/8 | 3/4 |
| 96 | 1-5/8 | 1-5/8 | 1-7/16 | 1-7/16 | 7-35/64 | 8-35/64 | 1-8 | 1/2 | 1 |
| 160 | 1-5/8 | 1-5/8 | 1-7/16 | 1-7/16 | 7-35/64 | 8-35/64 | 1-8 | 1/2 | 1 |
D-SERIES ROD ENDS
D Series Rod End Dimensions
| MODEL | BORE | ROD / DIA. | A* / AD | C** / CD | AF | CC / (FM) | (SM+SF) / STYLE / NO. 2,3 / KK |
|---|---|---|---|---|---|---|---|
| 12 | 1-1/4 | 3/8 | 1 | 5/8 | 5/8 | 3/8-16 | 1/4-20 |
| 24 | 1-3/4 | 3/4 | 1-1/2 | 3/4 | 3/4 | 3/4-10 | 1/2-13 |
| 30 | 2 | 3/4 | 1-1/2 | 3/4 | 3/4 | 3/4-10 | 1/2-13 |
| 49 | 2-1/2 | 3/4 | 1-1/2 | 3/4 | 3/4 | 3/4-10 | 1/2-13 |
| 70 | 3 | 3/4 | 1-1/2 | 3/4 | 3/4 | 3/4-10 | 1/2-13 |
| 96 | 3-1/2 | 1 | 1-5/8 | 1 | 1-1/8 | 1-8 | 3/4-10 |
| 160 | 4 | 1 | 1-5/8 | 1 | 1-1/8 | 1-8 | 3/4-10 |
D-SERIES NUMBERING
For example, a 10″ stroke 4.5″ bore cylinder with a single end, non cushioned, standard rod end, front flange mounting and Viton seals would be: D 160 SE NC SL10 RA1 VS MJ
SERIES D ORDERING INFORMATION
| SERIES D ORDERING INFORMATION | |||||||||
|---|---|---|---|---|---|---|---|---|---|
| SPECIFIC INFORMATION | CODE | D | 30 | SE | NC | SL2 | RA1 | Options | |
| SERIES | D SERIES CYLINDER | D | |||||||
| BORE SIZE | 1 1/4″ BORE | 12 | |||||||
| 1 3/4″ BORE | 24 | ||||||||
| 2″ BORE | 30 | ||||||||
| 2 1/2″ BORE | 49 | ||||||||
| 3″ BORE | 70 | ||||||||
| 3 1/2″ BORE | 96 | ||||||||
| 4 1/2″ BORE | 160 | ||||||||
| END STYLE | SINGLE END | SE | |||||||
| DOUBLE END | DE | ||||||||
| CUSHION STATUS | SINGLE END | ||||||||
| NON-CUSHIONED | NC | ||||||||
| FRONT CUSHIONED | FC | ||||||||
| REAR CUSHIONED | RC | ||||||||
| DOUBLE CUSHION | DC | ||||||||
| DOUBLE END | |||||||||
| NON-CUSHIONED | NC | ||||||||
| SINGLE CUSHIONED | SC | ||||||||
| DOUBLE CUSHIONED | DC | ||||||||
| STROKE | SPECIFY STROKE LENGTH IN DECIMALS | SL | |||||||
| ROD END STYLE | SINGLE END | ||||||||
| FULL MALE THREAD “A” END | RA1 | ||||||||
| STANDARD ROD END (JAM NUT INCLUDED) | |||||||||
| REDUCED MALE THREAD “A” END | RA2 | ||||||||
| FEMALE THREAD “D” END | RA3 | ||||||||
| DOUBLE END (SUPPLY BOTH FOR DE) | |||||||||
| FULL MALE THREAD “D” END (STANDARD) | RD1 | ||||||||
| REDUCED MALE THREAD “D” END | RD2 | ||||||||
| FEMALE THREAD “D” END | RD3 | ||||||||
| ADDITIONAL OPTIONS | ROD CLEVIS AND PIN (factory assembled) | MF | |||||||
| REAR CLEVIS BRACKET & PIN (factory assembled) | MG | ||||||||
| EYE BRACKET (Not available for D70) | MH | ||||||||
| STAINLESS STEEL ROD | SS | ||||||||
| inSight® POSITION SENSOR | IN | (NOT AVAILABLE ON SOME CYLINDERS**) | |||||||
| MAGNETIC PISTON | SP | ||||||||
| METALLIC ROD WIPER | MW | ||||||||
| SPRING EXTEND | SE | ||||||||
| SPRING RETRACT | SR | ||||||||
| VITON SEALS | VS | ||||||||
| REAR FLANGE BARS | MK | ||||||||
| FRONT FLANGE BARS | MJ | ||||||||
| ROD MODIFICATION* | RM |
*Include all details of desired modification and provide engineering drawing.
| Accuracy Table for inSight® Option (IN) | ||||||||
|---|---|---|---|---|---|---|---|---|
| Bore | Stroke Length | |||||||
| 0-8″ | 8-14″ | 14-20″ | 20-30″ | |||||
| 1 3/4″ | 0.10% | 0.15% | 0.20% | 0.50% | ||||
| 2″ | 0.10% | 0.15% | 0.20% | 0.50% | ||||
| 2 1/2″ | 0.10% | 0.15% | 0.20% | 0.50% | ||||
| 3″ | 0.10% | 0.15% | 0.20% | 0.50% | ||||
| 3 1/2″ | 0.10% | 0.15% | 0.20% | 0.50% | ||||
| 4 1/2″ | 0.10% | 0.15% | 0.20% | 0.50% | ||||
**inSight® Option (IN) not available for 1-1/4 bore D Series Cylinders.
D-SERIES MAINTENANCE
D-Series Cylinder Maintenance Instructions
| Item No. | Description | Item No. | Description |
|---|---|---|---|
| 1 | Front Head | 19 ** | Retaining Ring |
| 2 ** | Bushing | 20 | Tie Rod Nuts (4) |
| 3 ** | Wiper | 21 | Lock Washers (4) |
| 4 ** | Bushing O-ring | 22 | Tie Rods (4) |
| 5 ** | Bearing Strip | 23 | Cushion Adjustment Screw Nut |
| 6 ** | Rod U-Cup | 24 | Cushion Adjustment Screw |
| 7 | Cylinder Tube | 25 | O-Ring |
| 8 * | Piston Retainer | 26 | Cylinder Insert |
| 9 | Piston | 27 ** | Cushion Poppet |
| 10 ** | Piston U-Cup | 28 ** | Front Cushion Spring |
| 11 ** | Rear Cushion Spring | 29 * | O-Ring |
| 12 | Cylinder Insert | 30 ** | Piston Bearing |
| 13 ** | Cushion Poppet | 31 * | Piston Lock Nut |
| 14 ** | Cylinder Tube Seal | 32 * | Threaded Washer |
| 15 | Rear Head | 33 | Cushion Adjustment Screw Nut |
| 16 | Retaining Ring | 34 | Cushion Adjustment Screw |
| 17 * | Piston Rod | 35 | O-Ring |
| 18 | Jam Nut |
* Available as factory assembled only ** Available as kits only. Order appropriate kit for cushion or non cushion cylinders
Cylinders are not structural units and they are designed only to push and pull. The piston rod must be properly aligned with the mating part in both the extended and retracted position. Any misalignment will cause interference and shorten the cylinder life.
Air lines must be free of all contamination. An air line filter should be used. The air supply must be clean and free of moisture. Proper lubrication is also recommended.
When rebuilding cylinders, make sure all parts are clean before reassembly and avoid introducing any dirt or chips into the cylinder. Check the piston rod (17) and the cylinder tube (7) for damage and replace either if necessary before proceeding. Pre-lubrication of all seals prior to re-assembly is recommended for ease of installation.
TO REPLACE THE ROD SEALS
Remove any rod clevis or jam nut from the piston rod end(17). Remove the retaining ring (19), rod bushing assembly (2,3,4,5) and rod U-cup (6).
Install a new U-cup (6) over the rod, taking care in passing it over the threaded part of the piston rod. Seat the seal into the bottom of the front head using a blunt instrument.
If not already assembled, install a new wiper (3) and a bearing strip (5) into the new bushing (2). Install O-ring (4) on to the bushing as well. Slide the bushing assembly over the piston rod, again taking care in passing it over the rod threads. Seat the bushing assembly into the front head (1), and reinstall the retaining ring (19).
TO REPLACE THE PISTON SEALS
Remove the front head (1) by unscrewing four tie rod nuts (20), removing the lock washers (21) and lifting the front head off the cylinder tube (7). Remove the piston rod/cylinder tube assembly from the rear head (15) and pull the piston rod assembly from the tube (7). Remove the piston U-cups (10), and the piston bearing (30).
IMPORTANT: Install new U-cups, making sure that the lips of the seals face away from each other.
Use grease to hold the new bearing (30) in place, and insert the piston rod assembly back into the cylinder tube.
NOTE: It may be necessary to temporarily compress the first piston U-cup to allow it to enter the tube. Make sure the bearing strip is not pinched between the tube and piston.
Install new cylinder tube seals (14) (either gaskets or O-rings) into the heads, and reinstall the cylinder tube. This is best done in the vertical position, with the blind end cover down. Make sure the tie rod nuts (20) and lockwashers (21) are installed on the short threaded end of the tie rods. Retighten the tie rods using equal torque on each rod per the chart below.
| Model | Torque |
|---|---|
| D-12 | 8-10 ft.lbs. |
| D-24,49,70 | 15-19 ft.lbs. |
| D-96, 160 | 22-25 ft.lbs. |
CUSHION CYLINDERS
FRONT CUSHION
Disassemble the cylinder per previous instructions. Prior to removal of the piston rod assembly, take out the cylinder insert (26). Remove the old spring (28) and cushion poppet (27) from piston rod assembly. Attach a new spring onto new poppet making sure tang on spring is firmly seated into the mating hole on the poppet. Slide the poppet/spring assembly over the piston rod, taking care in passing the poppet over the rod threads. Insert the tang in other end of the spring into the mating hole of the piston retainer (8) and stake in place. Reassemble the cylinder per previous instructions. Make sure the cylinder insert (26) is in place prior to final assembly.
NOTE: D96 and D160 cylinders use a different spring mounting method, very similar to a coarse thread. Thread the spring onto the retainer and turn until the spring tang aligns with the mating hole. Stake in place.
ear cushion Disassemble the cylinder per previous instructions. Prior to removal of the piston rod assembly, take out the cylinder insert (12). Remove the retaining ring (16) from the rear of the piston rod. Remove the cushion poppet (13) and spring (11). Install a new spring onto the rod assembly. Carefully slide a new cushion poppet over the rear of the piston rod, taking care in passing the poppet over the retainer ring groove. Install retainer ring (16). Reassemble the cylinder per previous instructions. Make sure the cylinder insert (12) is in place inside the cylinder tube.
NOTE: Front and rear springs are not interchangeable. Front cushion springs have tangs on either end, while the rear cushion springs do not. This applies to all “D” series Cylinders.
DOUBLE CUSHION
Follow instructions for front and rear cushion cylinders.
*** IMPORTANT ***
All “D”Series Cylinders utilize a poppet style cushion. There are two different styles for the D12 through D70 cylinders. The original design poppet used non-replaceable bonded sealing surfaces. The new design is similar to the D96 and the 160 poppets in that they use standard O-rings placed into grooves on the poppet. The O-rings must be assembled on the outside groove surface of the poppet, and on the inside groove using the appropriate size O-rings. Older D96 and 160 poppets used a U-cup on the inner diameter and are not interchangeable with the newer design.
REPAIR KIT PART NUMBERS:
| BUNA | ||||
|---|---|---|---|---|
| SE (SINGLE END) | ||||
| MODEL | NC | FC | RC | DC |
| NO CUSHION | FRONT CUSHION | REAR CUSHION | DOUBLE CUSHION | |
| 12 | R-20827 | R-20341 | R-20353 | R-20359 |
| 24 | R-20828 | R-20342 | R-20354 | R-20360 |
| 30 | R-21479 | R-21480 | R-21481 | R-21482 |
| 49 | R-20829 | R-20343 | R-20355 | R-20361 |
| 70 | R-20830 | R-20344 | R-20356 | R-20362 |
| 96 | R-20831 | R-20345 | R-20357 | R-20363 |
| 160 | R-20832 | R-20346 | R-20358 | R-20364 |
| BUNA | |||
|---|---|---|---|
| DE (DOUBLE END) | |||
| MODEL | NO CUSHION | SINGLE CUSHION | DOUBLE CUSHION |
| 12 | R-20347 | R-20365 | R-20371 |
| 24 | R-20348 | R-20366 | R-20372 |
| 30 | R-21485 | R-21486 | R-21487 |
| 49 | R-20349 | R-20367 | R-20373 |
| 70 | R-20350 | R-20368 | R-20374 |
| 96 | R-20351 | R-20369 | R-20375 |
| 160 | R-20352 | R-20370 | R-20376 |
| METALLIC ROD WIPER (MW) | ||
|---|---|---|
| MODEL | SINGLE END | DOUBLE END |
| D12 | R-07762 | R-20390 |
| D24 | R-07766 | R-20391 |
| D30 | R-21483 | R-21488 |
| D49 | R-07769 | R-20392 |
| D70 | R-20389 | R-20393 |
| D96 | R-07773 | R-20394 |
| D160 | R-07775 | R-20395 |





