Tolomatic PB208 User manual

PB208, PB210, and PB217
1/2", 5/8" and 1-1/16" Bore
List of Parts
20
1
2
3
26
45
6
7
8
9
10
11
12
13
14
15
27
16
19
21
22
23
9
17
18
7
25
ITEM PART NO. OR CONFIG. CODE DESCRIPTION
PB208 (Disc.) PB210 PB217
1. 0920-1024 SFHCS 2
2517-1078 SHCS, SHLD 2
2. 2309-1060 Nut Shoulder 1
2517-1126 SHS, BTN 1
3. 2520-1079 Spring, bel. 1
4. 2510-1068 Tooling Plate 1
2517-1068 Tooling Plate 1
5. 2307-1007 Nut, Hex, 10-32 1
6. 2506-1020 Q-Ring, Buna-n 1
2520-1080 Q-Ring, Buna-n 1
7. 2510-1029 Ret. Ring 2
2517-1029 Ret. Ring 2
8. 2510-1058 Head 1
2517-1058 Head 1
9. 0728-1005 O-Ring, Buna-N 2
2317-1035 O-Ring, Buna-N 2
10.
2510-1051 Piston Shaft, 1/2" Stroke 1
2510-1052 Piston Shaft, 1" Stroke 1
2510-1053 Piston Shaft, 1-1/2" Stroke 1
2510-1054 Piston Shaft, 2" Stroke 1
2510-1055 Piston Shaft, 3" Stroke 1
2510-1056 Piston Shaft, 4" Stroke 1
2517-1051 Piston Shaft, 1" Stroke 1
2517-1052 Piston Shaft, 2" Stroke 1
ITEM PART NO. OR CONFIG. CODE DESCRIPTION
PB208 (Disc.) PB210 PB217
10.
2517-1053 Piston Shaft, 3" Stroke 1
2517-1054 Piston Shaft, 4" Stroke 1
2517-1055 Piston Shaft, 5" Stroke 1
2517-1056 Piston Shaft, 6" Stroke 1
11. 0915-1009 U-Cup, Buna-N 2
2517-1061 U-Cup, Buna-N 2
12. 2510-1022 Bumper 1
2520-1102 Bumper 1
13. 2510-1059 Piston 1
2517-1059 Piston 1
14.
2402-1013 Mag, Reed/Triac Switches 1
2510-1069 Magnet, Hall Effect Switch 1
2517-1069 Magnet 1
15. 2510-1038 Nut, Shoulder 1
6000-1731 SFHCS 1
16.
2510-1071 Base 1/2" Stroke PB210 1
2510-1072 Base 1" Stroke PB210 1
2510-1073 Base 1-1/2" Stroke PB210 1
2510-1074 Base 2" Stroke PB210 1
2510-1075 Base 3" Stroke PB210 1
2510-1076 Base 4" Stroke PB210 1
2517-1071 Base 1" Stroke PB217 1
2517-1072 Base 2" Stroke PB217 1
2517-1073 Base 3" Stroke PB217 1
Tolomatic • URL: http://www.tolomatic.com • Email: [email protected] • Fax: [phone] • Toll Free: 1-800-328-2174
Parts Sheet
2500-4012_07_PB208_10_17ps
PB208 Parts listing is for reference only.
All parts listed are limited to stock on hand.
Contact Tolomatic regarding availability.
(12-26-2019) PB208 IS A DISCONTINUED
PRODUCT SIZE. PARTS SHEET IS FOR
REPAIR INSTRUCTIONS ONLY.

Tolomatic • URL: http://www.tolomatic.com • Email: [email protected] • Fax: [phone] • Toll Free: 1-800-328-2174
List of Parts (Contiued)
ITEM PART NO. OR CONFIG. CODE DESCRIPTION
PB208 (Disc.) PB210 PB217
16.
2517-1074 Base 4" Stroke PB217 1
2517-1075 Base 5" Stroke PB217 1
2517-1076 Base 6" Stroke PB217 1
17. 2510-1022 Bumper 1
2317-1032 Bumper 1
18. 2510-1057 Cap 1
2517-1057 Cap 1
19. 2309-1034 Ret. Ring 2
1004-1278 Ret. Ring 2
20. 1001-1192 Linear Bearing 4
2312-1011 Linear Bearing 4
21.
2510-1091 Linear Shaft 1/2" Stroke 2
2510-1092 Linear Shaft 1" Stroke 2
2510-1093 Linear Shaft 1-1/2" Stroke 2
21.
2510-1094 Linear Shaft 2" Stroke 2
2510-1095 Linear Shaft 3" Stroke 2
2510-1096 Linear Shaft 4" Stroke 2
2517-1091 Linear Shaft 1" Stroke 2
2517-1092 Linear Shaft 2" Stroke 2
2517-1093 Linear Shaft 3" Stroke 2
2517-1094 Linear Shaft 4" Stroke 2
2517-1095 Linear Shaft 5" Stroke 2
2517-1096 Linear Shaft 6" Stroke 2
22. 2517-1025 Composite Bearing 4
2517-1062 Composite Bearing 4
23.
2510-1081 Slide Shaft 1/2" Stroke 2
2510-1082 Slide Shaft 1" Stroke 2
2510-1083 Slide Shaft 1-1/2" Stroke 2
2510-1084 Slide Shaft 2" Stroke 2
2510-1085 Slide Shaft 3" Stroke 2
2510-1086 Slide Shaft 4" Stroke 2
2517-1081 Slide Shaft 1" Stroke 2
2517-1082 Slide Shaft 2" Stroke 2
2517-1083 Slide Shaft 3" Stroke 2
2517-1084 Slide Shaft 4" Stroke 2
2517-1085 Slide Shaft 5" Stroke 2
2517-1086 Slide Shaft 6" Stroke 2
SWITCHES
25.
RT Switch, Reed, Form A, 5M Wire 1 1
RM Switch, Reed, Form A, Male Connector 1 1
BT Switch, Reed, Form C, 5M Wire 1 1
BM Switch, Reed, Form A, Male Connector 1 1
CT Switch, TRIAC, 5M Wire 1 1
CM Switch, TRIAC, Male Conn. 1 1
TT Switch, Source Hall-effect, 5M Wire 1 1
TM
Switch, Source, Hall-effect, Male Conn. 1 1
KT Switch, Sinking Hall-effect, 5M Wire 1 1
KM
Switch, Sinking, Hall-effect, Male Conn. 1 1
26. 2406-1009 Washer NA 1
27. 0905-1005 O-Ring (for use w/ magnet for
Reed and Triac Switch) 1 NA
ITEM PART NO. OR CONFIG. CODE DESCRIPTION
PB208 (Disc.) PB210 PB217
1. 0515-1198 SFHCS 2
2. 2309-1060 Nut Shoulder 1
4. 2508-1068 Tooling Plate 1
5. 2307-1007 Nut, Hex, 10-32 1
6. 2506-1020 Q-Ring, Buna-n 1
7. 2508-1078 Ret. Ring 2
8. 2508-1058 Head 1
9. 1001-1021 O-Ring, Buna-N 2
10.
2508-1051 Piston Shaft, 1/2" Stroke 1
2508-1052 Piston Shaft, 1" Stroke 1
2508-1053 Piston Shaft, 1-1/2" Stroke 1
10.
2508-1054 Piston Shaft, 2" Stroke 1
2508-1055 Piston Shaft, 3" Stroke 1
2508-1056 Piston Shaft, 4" Stroke 1
11. 2508-1108 U-Cup, Buna-N 2
12. 2508-1102 Bumper 1
13. 2508-1059 Piston 1
14. 2508-1069 Magnet 1
15. 2309-1060 Nut, Shoulder 1
16.
2508-1071 Base 1/2" Stroke PB208 1
2508-1072 Base 1" Stroke PB208 1
2508-1073 Base 1-1/2" Stroke PB208 1
2508-1074 Base 2" Stroke PB208 1
2508-1075 Base 3" Stroke PB208 1
2508-1076 Base 4" Stroke PB208 1
17. 2508-1102 Bumper 1
18. 2503-1057 Cap 1
19. 2506-1029 Ret. Ring 2
20. 2508-1109 Linear Bearing 2
21.
2508-1091 Linear Shaft 1/2" Stroke 2
2508-1092 Linear Shaft 1" Stroke 2
2508-1093 Linear Shaft 1-1/2" Stroke 2
2508-1094 Linear Shaft 2" Stroke 2
2508-1095 Linear Shaft 3" Stroke 2
2508-1096 Linear Shaft 4" Stroke 2
22. 2508-1080 Composite Bearing 2
23.
2508-1081 Slide Shaft 1/2" Stroke 2
2508-1082 Slide Shaft 1" Stroke 2
2508-1083 Slide Shaft 1-1/2" Stroke 2
2508-1084 Slide Shaft 2" Stroke 2
2508-1085 Slide Shaft 3" Stroke 2
2508-1086 Slide Shaft 4" Stroke 2
SWITCHES
25.
RT Switch, Reed, Form A, 5M Wire 1
RM S
witch, Reed, Form A, Male Conn. 1
BT Switch, Reed, Form C, 5M Wire 1
BM
Switch, Reed, Form A, Male Conn. 1
CT Switch, TRIAC, 5M Wire 1
CM Switch, TRIAC, Male Conn. 1
TT Switch, Source Hall-effect, 5M
Wire 1
TM Switch, Source, Hall-effect,
Male Conn. 1
KT Switch, Sinking Hall-effect,
5M Wire 1
KM Switch, Sinking, Hall-effect,
Male Connector 1
26. 2406-1009 Washer NA
27. 0905-1005 O-Ring (for use w/ magnet for
Reed and Triac Switch) NA
2 – Parts List PB208, PB210, PB217 Parts Sheet #2500-4012_07_PB208_10_17ps

Tolomatic • URL: http://www.tolomatic.com • Email: [email protected] • Fax: [phone] • Toll Free: 1-800-328-2174
Disassembly and Assembly Instructions
POWER-BLOCK2 DISASSEMBLY
1. To remove the Tooling Plate (#4) and Shafts (#21 or #23) first remove
the Button Head Screw (#2). Note, for later reassembly, that the cupped
surface of the Belleville Spring (#3) faces toward the Tooling Plate. Pull
on the Tooling Plate (#5). The Tooling Plate and Shafts (#21 or #23) will
slide out of the assembly.
2. Push Head (#8) into bore to expose a gap between Head and Retaining
Ring (#7). To remove the Head use a screwdriver to remove the
Retaining Ring. The Head is now free to be removed.
3. Remove the Piston/Piston Shaft Assembly from the Base (#16). Loosen
Socket Flat Head Screw (#15) to remove the Piston Shaft (#10) from the
Piston (#13). When removing the two U-Cups (#11) from the Piston
note that the flare of the U-Cups face away from each other. In looking
at the piston from the side view the two U-Cups form a “V” shape.
4. Push Cap (#18) into bore to expose a gap between Cap and Retaining
Ring (#7). Using a screwdriver remove the Retaining Ring from the Cap
side of the Base (#16). Remove the Cap from the Base.
5. To remove the Linear Bearings (#20) or the Composite Bearings (#22)
use a screwdriver to remove the two Retaining Rings (#19) from the
shaft bores of the Base (#16). The Bearings (#20 or #22) may now be
pushed out, with a screwdriver.
POWER-BLOCK2 ASSEMBLY PROCEDURE
Clean work bench and area, check that all parts are there and without any
visual damage or defects.
1. Base Assembly
PB208 and PB210 Models
(Composite and Linear Bearings) By hand press new Composite
Bearing (#22) or Linear Bearing (#20), outside chamfered side down,
into each of the two bearing bores in the Base (#16). Press an addition-
al Bearing (#22) or (#20) outside chamfered side down, into the same
two bearing holes in the Base. Bearing must be recessed to allow for
retaining ring. Using a ring spreader insert two Retaining Rings (#19) to
retain the Bearings.
PB217 Models
(Composite Bearings) Press new Composite Bearing (#22), outside
chamfered side down, into each of the two bearing bores in the Base
(#16). Press an additional Bearing (#22) outside chamfered side down,
into the same two bearing holes in the Base with an arbor press until
the bearing is flush with the front surface of the base.
(Linear Bearings) Place new Linear Bearing (#20) into each of the bear-
ing bore holes in the Base (#16). Place second Linear Bearing into each
of the bearing bore holes. Install the Retaining Rings (#19) into the
grooves in the bores to hold the Bearings in place.
2. Cap Assembly
a. Thoroughly lubricate the center bore of the base.
b. Apply Loctite #495 to the recess in the Cap (#18) then press in the
Bumper (#17) with the grooves in the Bumper facing away from the
Cap.
c. Install an O-Ring (#9) into the cap. Place a thin coat of Magnalube
®
-G
over the O-Ring. Push the Cap (#18); Bumper side in, into the counter-
bore on the back side of the Base (#16). (Note: the mounting holes on
the base are closest to the front side.)
d. Install a Retaining Ring (#7) in the groove behind the Cap (#18).
3. Piston Assembly
PB208, PB210 and PB217 Models
a. Install the two U-Cups (#11) into the two grooves on the Piston (#13)
with the flares of each U-Cup facing away from each other.
b. Apply Loctite #271 to the Piston Shaft (#10) threads and screw Shaft
into the end of the Piston (#13) which is counterbored. Hand tighten.
c. Apply Loctite #271 to the Socket Head Flat Screw (#15) and attach the
Magnet to the Piston (#13) with secured Shaft and tighten nut with the
appropriate hand wrench. DO NOT OVERTIGHTEN.
d. Place a Bumper (#12) over the Piston Shaft (#10) so that the flat side is
against the Piston.
e. Place a thin coat of Magnalube
®
-G on the Piston Shaft (#10) and
U-Cups (#11).
f. Push the Piston Rod assembly, Piston first, into the front side of the
center bore on the Base (#16).
PB220 Models
a. Apply Loctite #271 to the Socket Flat Head Screw (#15) and attach the
Piston (#13) to the flat end of the Piston Shaft (#10).
b. Install the two U-Cups (#11) into the two remaining grooves in the
Piston (#13) note that the flare of the U-Cups must face away from
each other. In looking at the piston from the side view the two U-Cups
form a “V” shape.
c. Place a Bumper (#12) over the Piston Shaft (#10) so that the flat side is
against the Piston (#13)
d. Place a thin coat of Magnalube
®
-G on the Piston Shaft (#10) and the
U-Cups (#11).
e. Push the Piston/Piston Shaft Assembly, Piston first, into the front side of
the center bore of the Base (#16).
4. Head Assembly
a. Lubricate the Quad Ring (#6) with Magnalube
®
-G and insert into the
center of the Head (#8).
b. Press the Retaining Ring (#7) flush into the center of the Head (#8).
c. Install an O-Ring (#9) onto the Head. Place a thin coat of
Magnalube
®
-G over the O-Ring and Quad Ring (#6). Guide the Head
over the Piston Shaft (#10) and push the Head (#8), flat surface in, into
the counterbore on the front side of the Base (#16).
d. Install a Retaining Ring in the groove in the counterbore in front of the
Head (#8).
5. Tooling Plate and Bearing Rod Installation
PB208 and PB210 Models
a. Clean the Hex Nut (#5) and Socket Head Flat Screw (#15) and apply
Loctite #242 to the Piston Shaft (#10) threads
b. Attach the Tooling Plate (#4) to the Piston Shaft (#10) with the Hex Nut
and Shoulder Nut. The Shoulder Nut goes on the outside of the Tooling
Plate. Adjust the position so that the end of the piston shaft is flush with
the outer surface of the Hex Nut. Tighten with the appropriate wrench-
es.
PB217 Models
a. On units with Composite Bearings only, apply a small amount of
Magnalube
®
-G into the bearings on the base. No additional lubricant is
needed with the Linear Bearings. Insert the Guide Shafts (#21 or #23)
with the drilled and tapped holes towards the Tooling Plate (#4) through
the bearings. Apply Loctite #271 to the threads of the two SHCS (#1)
and attach the Tooling Plate to the Guide Shafts (#21 or #23).
b. Apply Loctite #242 to the threads of the Button Head Screw (#2).
Attach the Tooling Plate (#4) to the Piston Shaft (#10) with the Button
Head Screw and Belleville Spring (#3). Note that the cupped surface of
the Belleville Spring (#3) faces toward the Tooling Plate. Tighten all
screws.
c. Cycle the assembly back and forth by hand to seat the Bumpers, End
Cap and Head.
6. Switch Option
Clamp for switch will fit in either of the two grooves on the top (porting)
side of the Base (#16). Secure Switch to the Base with Clamp and Set
Screw. Note the scored surface of the Switch housing should face the
base of the Power-Block2.
NOTE: Form A Reed Switches should not be used in TTL logic cir-
Parts Sheet #2500-4012_07_PB208_10_17ps
PB208, PB210, PB217 Instructions – 3
Parts Sheet #2500-4012_07_PB208_10_17ps

cuits. A voltage drop caused by the L.E.D. indicator will result.For
applications where TTL circuits are used, please contact the factory.
WARNING: An ohmmeter is recommended for testing Reed
Switches. NEVER use an incandescent light bulb as a high current
rush may damage the switch.
Reed and TRIAC switches are only recommended for signalling posi-
tion, not directly powering soleniods. For shifting a solenoid, a relay or
resistor is recommended between it and the Reed Switch. Switch rat-
ings must not be exceeded at any time.
NOTE: For Hall Effect Switch Magnet, be sure the S pole of the
magnet (indicated with black dot) is facing toward the switch (down).
TO ORDER RETROFIT KITS: SW (then the model number
and base size, and code for type of switch
needed: EXAMPLE: SWPB210RM
All Switch Kits come with
1 switch and mounting
hardware.
Female Connector 5M
Loctite® is a registered trademark of the Loctite Corporation,
www.loctite.com
Magnalube®-G is a registered trademark of the Carleton-Stuart
Corporation,
www.magnalube-g.com
SWITCH TYPE CODE
BT (Form C Reed Switch with 5-meter lead)
BM (Form C Reed Switch with 5-meter lead and QD)
RT (Form A Reed Switch with 5-meter lead)
RM (Form A Reed Switch with 5-meter lead and QD)
CT (TRIAC Switch with 5-meter lead)
CM (TRIAC Switch with 5-meter lead and QD)
KT (Hall-effect Switch (Sinking) 5-meter lead)
KM (Hall-effect Switch (Sinking) 5-meter lead and QD)
TT (Hall-effect Switch (Sourcing) 5-meter lead)
TM (Hall-effect Switch (Sourcing) 5-meter lead and QD)
REED
SWITCH
LOAD
BROWN
BLUE
(-) (-)
(+) (+)
REED
SWITCH
LOAD
BROWN
BLUE
(-) (-)
(+) (+)
OR
REED SWITCH FORM A
LABEL COLOR: RED
10VA MAX.
200 Vdc
500mA Max. Current
REED
SWITCH
COMMON
NORMALLY CLOSED
NORMALLY OPEN
BROWN
BLACK
BLUE
REED SWITCH FORM C
LABEL COLOR: YELLOW
120 Vdc/120 Vac MAX.
250mA Max. Current
HALL-EFFECT SWITCH
(SINKING)
LABEL COLOR: GREEN
Input Voltage:5-25 VDC only
Output Current: 200 mA Max.
BROWN
BLACK
BLUE
QUICK-DISCONNECT
(Applies to all switch types)
An Important Note Regarding
Field Retrofit of Quick-Disconnect
Couplers:
If replacing a Quick-Disconnect switch
manufactured before 7-1-97
it will also be necessary to replace
or rewire the female-end coupler
with the in-line splice
Female Connector 5M
HALL-EFFECT SWITCH
(SOURCING)
LABEL COLOR: WHITE
Input Voltage:5-25 VDC only
Output Current: 200 mA Max.
UNIVERSAL SWITCH WIRING DIAGRAMS AND
LABEL COLOR CODING
AC
COM
LOAD
INPUT
TRIAC
SWITCH
120Vac
Max.
MOV
BROWN
BLUE
TRIAC SWITCH
LABEL COLOR: BLUE
Max. 1Amp. Cont. Current @ 86°F
Max. .5Amp. Cont. Current @ 140°F
Peak surge current 10Amp.
NOTE: The side of the switch with
the groove indicates the sensing
surface. This must face toward the
magnet.
For complete Switch Performance
Data, refer to the Tolomatic Fluid
Power Products Catalog 9900-4000
4 – Options PB208, PB210, PB217 Parts Sheet #2500-4012_07_PB208_10_17ps
3800 County Road 116, Hamel, MN 55340 USA
http://www.Tolomatic.com • Email: [e-mail]
Phone: [phone] • Fax: [phone] • Toll Free: 1-800-328-2174
© 2022 Tolomatic 202205261056
All brand and product names are trademarks or registered trade-
marks of their respective owners. Information in this document is
believed accurate at time of printing. However, Tolomatic assumes
no responsibility for its use or for any errors that may appear in
this document. Tolomatic reserves the right to change the design
or operation of the equipment described herein and any associated
motion products without notice. Information in this document is
subject to change without notice.
Visit www.tolomatic.com for the most up-to-date technical information