Head Assembly - Avdel TX2000 Betriebsanleitung

R e p a i r s a n d M a j o r S e r v i c e
H e a d A s s e m b l y
The head assembly consists of three assembly kits, Cylinder Assembly Kit (part number 71600-99603), Piston Assembly Kit (part
number 71600-99604) and Head Seal Kit (part number 71600-99605) containing items 6 to 18, 21, 22, 23, 30 and 32. These
parts are only available as complete kits unless a minimum order quantity is provided in the parts list.
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Completely remove the main internal mechanism from the left and right mouldings 41, 43, as described on page 5.
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Remove the complete motor, gearbox and electrical assembly 3, 4 and 5 as described on page 6.
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Unscrew locknut 31 and jaw spreader housing 20 from the piston 18.
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Using the 3 mm and 2.5 mm allen keys remove screws 11, 23, 30, clamping the cylinder 32 to the housing 24.
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Remove the head assembly from the housing. Remove 'O' ring 56 from the housing and discard.
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Grip the head assembly in a vice using soft jaws to avoid damage.
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Using the end cap assembly tool unscrew and remove the cylinder cap assembly, items 6, 7, 8, 9 from the rear of the cylinder 32.
Care must be taken as the cylinder cap 7 will be spring loaded.
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Remove and discard the spring 10 from inside the cylinder 32.
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Push the piston 18 to the rear and out of the cylinder 32 taking care not to damage the cylinder bore.
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Using the medium screwdriver enter the rear of the cylinder 32, lever the rod seal 15 from the groove and cut through with a
scalpel taking care not to damage the cylinder bore or the seal groove. Using the spatula push the rod seal, followed by bearing
ring 16 and 'O' ring 17 to the rear and out of the cylinder. If at any time the cylinder bore or seal groove become damaged the
cylinder must be replaced.
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Using a scalpel cut through and remove the piston seal 14 from the piston 18. Then remove bearing ring 13 and 'O' ring 12. Take
care not to damage the piston when cutting the seal.
Assemble in reverse order to dismantling noting the following points:
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Clean all components before assembling.
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To aid assembly of seals apply a light coating of Molykote 111 grease to both the seals and the assembly tools.
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Lubricate the cylinder 32 bore and seal grooves with Molykote 111 grease. Insert the bearing ring 16 into place within cylinder.
With the aid of the spatula insert the 'O' ring 17. Place the rod seal 15 onto the insertion rod ensuring correct orientation. Push the
guide tube into the cylinder bore and push the insertion rod with the seal into place through the guide tube ensuring seal is
correctly seated. Pull the insertion rod out then the guide tube.
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Lubricate the piston 18 shaft and seal grooves with Molykote 111 grease and fit 'O' ring 12 and bearing ring 13. Place the piston
seal sleeve over the piston shaft, then slide the piston seal 14 over the sleeve and into position using the piston seal tool ensuring
correct orientation.
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Insert the cylinder collar into the back of the cylinder 32. Screw the piston bullet onto the piston 18 and push the piston with the seals
through the cylinder collar as far as it will go. Unscrew the bullet off the piston and remove the cylinder collar.
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Apply a light coating of Moly-lithium grease to the surface and ends of the spring 10 before inserting onto the piston 18 within the
cylinder.
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Screw the cylinder cap assembly, items 6, 7, 8, 9, into the cylinder 32 using the 'T'-bar and end cap assembly tool.
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Insert 'O' ring 56 into the housing and lubricate with Molykote 111 grease.
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Fit the head assembly to the housing 24 using the three screws 11, 23, 30, coated with Loctite
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When inserting jaw spreader housing 20 onto piston 18, screw down fully until it bottoms out on the end of the piston shaft.
Secure jaw spreader housing 20 using locknut 31.
® 243 threadlocker.
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