TM-9-2320-260-34-2

TRUCK, 5-TON, 6X6, M809 SERIES (DIESEL)

TECHNICAL MANUAL; DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE; VOLUME 2 OF 2

JULY 1994

TM-9-2320-260-34-2 - Page 615 of 863

16-35. BOOM EXTENSION CYLINDER MAINTENANCE [M819) (Contd)

Repair cylinder (9), cylinder head (7), and piston rod (18) (para. 2-10). Replace unrepairable parts.

a. Remove minor rust and corrosion, scratches, and scoring with soft. stone or crocus cloth.

Replace part if pitting is uncovered when rust or corrosion is removed. Replace parts if more

severely damaged.

b. Repair broken or cracked welds and replace broken or damaged studs (8).

1.

2.

3.

4.

5.

6.

7.

Install new outer O-ring (6) and new inner O-ring (5) on cylinder head (7).

Position snapring (1), washer (2), new wiper ring (3), and new felt washer (4) on piston rod (18) and

slide part way up piston rod (18).

Carefully work cylinder head (7) onto piston rod (18) and install new felt washer (4), and new wiper

ring (3) on bore of cylinder head (7).

Slide washer (2) down piston rod (18) against wiper ring (3) and install snapring (1) on cylinder

head (7).

Install expander (13), new compression cup (14), spacer (15), new compression cup (16) and

expander (17) on piston rod (18) with two nuts (12).

NOTE

Ž

Assistant will help with steps 6 and 7.

●

Coat all internal surfaces and parts with hydraulic oil before

assembly.

Carefully work cylinder (9) over compression cups (16) and slide cylinder (9) onto piston rod (18).

Aline studs (8) of cylinder (9) with holes in cylinder head (7) and install cylinder head (7) on

cylinder (9) with four nuts (11) and new cotter pins (10).

16-216

TM 9-2320-260-34-2