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DISASSEMBLY / RE-ASSEMBLY
Preparations and Things Needed
• Have the following things ready:
- seal kit or service kit,
- screwdrivers of various sizes,
- Allen keys of various sizes.
• Move piston to one end position,
• Switch off the main switch and secure it against unintentional
switching-on.
Cleaning the Inner Sealing Band
Dirt particles can lodge between the inner sealing band and the cylinder
bore and cause leakage. Cleaning is then required.
!
Danger of eye injuries. There is danger of eye injury from fl ying
dirt particles - wear safety glasses where indicated!
- Put on safety glasses,
- reduce working pressure to 2 bar,
- move piston to one end position,
- loosen two screws (13) for outer sealing band,
- from Ø 40: unscrew set-screw (13) completely, taking care that the
clamping piece (14) is not displaced,
- lift up one end of outer sealing band (11) without creasing it (see
diagram). With shorter stroke cylinders, if the slot is too short for use
of the cleaning tool, remove the carrier with wiper O-ring and the
outer sealing band completely (see sections «Cylinder Removal,
Dismantling and Cleaning» and «Cylinder Reassembly»),
- vent cylinder on the side where the piston is
- insert appropriate blade of cleaning tool (100) into
cylinder slot up to the stop,
- draw cleaning tool along slot several times
the escaping air blows out any dirt particles,
- remove pressure and push piston to other
end position,
- pressurize the opposite side to where the
piston is, to a maximum pressure of 2 bar
- vent other side
- repeat cleaning tool operation at other end of slot,
- remove pressure and reassemble outer sealing band in reverse order.
(For pressurisation, see corresponding Installation Instructions).
CYLINDER REMOVAL, DISMANTLING AND CLEANING
!
Danger of eye injuries and cuts on fi ngers etc.
There is danger of :
- eye injuries from fl ying dirt particles and stressed springs -
wear safety glasses where indicated!
- cuts from sharp edges of inner sealing band - wear protective
gloves when working with inner sealing band.
- Put on safety glasses,
- depressurize cylinder/plant,
- disconnect load,
- dismantle cylinder as follows:
. loosen set-screw (15) and unscrew set-screw (13) completely,
. remove screws (36) and end caps (35) and (37),
. remove carrier clamping screws (38) and dismantle wiper O-ring (7)
and carrier (10) (only for 16 to 50),
. remove all screws (5) (only for 63 and 80),
. pull off cover (9) with wipers (8), springs (6) and O-rings (7) and
dismantle (only for 63 and 80)
. remove outer sealing band (11),
. remove two clamping pieces (16) for inner sealing band and two
clamping pieces (14) for outer sealing band,
. pull off two cushioning spigots (20) by inserting screwdriver carefully
between cushioning spigot and cylinder profi le (1),
. push piston and inner sealing band (17) out of cylinder bore,
. pull inner sealing band (17) out of piston,
. pull off two support rings (25) and remove spacers (29) with magnet
(30),
. remove slide shoe (28) and for 63 and 80 side wiper (31),
. remove piston seal (24) and cushioning seal (23),
- clean all parts and replace damaged or worn parts, prepare for
reassembly.
CYLINDER REASSEMBLY
- Information: Danger of cuts on fi ngers etc.
- Note the torque moments.
- Note the position of the parts on the exploded drawing.
- With cylinders from Ø 40 the magnet strips can slip out of the
cylinder profi le. Insert these into the cylinder profi le as follows
(the sealing function of your cylinder depends on this):
Inserting the magnet strips (see diagram)
- push one magnet strip in, leaving 10 mm sticking out (it must lie on
its narrow side) - or, if it had remained in the cylinder profi le, pull it
out a little,
- place the second magnet strip on its
narrow side above the fi rst magnet strip:
If the magnets repel each other: push
in the second magnet strip without turning
it over.
If the magnets attract each other: turn
the second magnet strip over i.e. 180°
(about its longitudinal axis) and then
push it in.
Installing the piston
- Clean and dry sealing bands and cylinder profi le,
- insert both slide shoes (28) into piston yoke (colour same as old
parts),
- select the two support rings (25) (colour same as old parts),
- push two spacers (29), with magnet (30) between them, into one
support ring (except on Ø 80, where magnet system is installed inside
piston),
- push the two support rings on to piston (so that fl at band guides are
on top - see diagram),
- clip the two support rings together,
- check that piston moves smoothly,
as follows:
. insert piston into cylinder bore and
slide it up and down,
- replace slide shoe and/or support ring if:
. piston is too tight, or
. piston has too much play,
- take piston out again,
- insert cushioning seals (23) (so that seal lip shows on outside),
- grease inside of cylinder bore as far as you can reach,
- grease the two support rings (25) and piston behind support rings,
- slide piston up and down a few times (long cylinders, however, should
be greased right through)
- take piston out again,
- check that cylinder bore has a complete grease fi lm, as follows:
. point cylinder at a light source and look through it,
. repeat greasing process if required,
- push on one piston seal (24) (so that groove of piston seal shows on
outside),
- push in the two side wipers (31) so that wiper lip shows on outside
(see diagram) and adjust their position (only for Ø 63 and 80),
- grease piston seal and fi ll its groove with grease,
- place inner sealing band (17) on fl at band guide of one support ring
(so that «ground edge» side lies on support ring),
- push inner sealing band through piston without creasing it,
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- push piston, end without piston seal fi rst, into cylinder bore,
- place the two side wipers on the cylinder profi le and move piston
slowly further along while checking that position of side wipers is
symmetrical (only for Ø 63 and 80),
- introduce second support ring, pressing piston down,
- slide piston to other end of cylinder so that it projects from other
end,
- put second piston seal on support ring with groove on outside,
- grease piston seal and fi ll its groove with grease,
- slide piston to the middle until inner sealing band is fl ush with cylinder
profi le at one end,
- check again that position of side wipers is symmetrical
(only for Ø 63 and 80),
- remove excess grease from ends of cylinder profi le.
Inserting the Cushioning Spigots (20)
- grease O-ring grooves (21), insert O-rings and grease them,
- grease cushioning spigots,
- push cushioning discs (22) onto cushioning spigots (20),
- hold inner sealing band on the side where it is fl ush with the cylinder
profi le and slide piston to about 100 mm from other end of cylinder
profi le,
- at that end, push centring tool
(see diagram) from above
through hole in inner sealing
band and hold it,
- insert one cushioning spigot,
angled slightly downwards,
into cylinder profi le,
- push cushioning spigot
right in with gentle upward
pressure and line it up with
cylinder profi le,
- remove centring tool,
- place clamping piece for inner sealing band (16) centrally in each
end cap (35, 37) (for position see exploded drawing) and secure it
with set-screw (15) so that the centring pin stands as far as possible
out of the end cap. Then place clamping piece for outer sealing band
(14) in each end cap (35, 37) and secure it fl ush with the end cap
with set-screw (13),
- grease face of cushioning spigot and insert O-rings (18, 19),
- at the end where the cushioning spigot is, fi t one end cap (check
position of air connection), locating centring pin of inner sealing band
clamping piece (16) in hole in inner sealing band (17). Loosen set-
screws (13, 15) and secure end cap with screws (36), tightening them
Torque Moments
screw (36) for
cylinder
end cap (35+37)
Ø 16
M4
3.25 Nm ±0.25
M4
Ø 25
M5
6 Nm ±1
M5
Ø 32
Ø 40
M6
10 Nm ±1.5
M6
Ø 50
Ø 63
M8
25 Nm ±3.8
-
Ø 80
M10
42.5 Nm ±2.5
-
DISASSEMBLY / RE-ASSEMBLY
alternately crosswise and observing the correct torque moments.
- slide piston to ca. 100 mm from other end of cylinder profi le,
- pull loose end of inner sealing band as far as possible to end of
cylinder profi le,
- push centring tool from above through hole in inner sealing band and
hold it,
- insert second cushioning spigot, angled slightly downwards, into
cylinder profi le,
- push cushioning spigot right in with gentle upward pressure and line
it up with cylinder profi le,
- remove centring tool.
Mounting end caps (see torque moments)
- grease face of cushioning spigot and insert O-rings (18, 19),
- fi t end cap, locating centring pin of inner sealing band clamping piece
(16) in hole in inner sealing band (17). Loosen set-screws (13, 15)
and secure end cap with screws (36), tightening them alternately
crosswise and observing the correct torque moments,
- position inner sealing band (17) the same distance from both ends of
cylinder profi le and tighten set-screw (15) at the end where the piston
is,
- slide piston to the other end position,
- adjust position of clamping piece (16) so that inner sealing band lies
correctly along the whole slot, without pretension or hanging loose,
- tighten set-screw (15) at this end too – see torque moments.
Checking Tension of Inner Sealing Band
Inner sealing band must be fi tted:
- without pretension,
- without hanging loose.
Completing the Cylinder (see "Torque Moments")
- Only for Ø 63 and 80:
. Put the two O-rings (7) on cover (9),
. put on the two springs (6),
. clip on wipers (8),
- lay on outer sealing band (11) and centre it,
- push both wipers (8) into carrier (10),
- place carrier (10) with wipers (8) in piston yoke (27),
- fi t wiper O-ring (7),
- tighten screws (38),
- from Ø 40: unscrew set-screw (13) completely, taking care that
clamping piece (14) is not displaced,
- insert outer sealing band centrally into the end caps,
- secure outer sealing band clamping piece (14) at each end of cylinder
with set-screw (13) – see torque moments.
screw (38) for
screw (5) for
set-screw (15) for
carrier (10)
cover (9)
I-band (17)
2.9 Nm ±0.4
-
-
M2
0.2 Nm +0.03
5.5 Nm ±0.8
-
-
M2.5
0.45 Nm +0.05
-
-
10 Nm ±1.5
-
-
M3
0.8 Nm +0.1
-
-
-
M3
0.7 Nm ±0.1
M3
0.8 Nm +0.1
-
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set-screw (13) for
O-band (11)
M2
0.2 Nm +0.03
M2.5
0.45 Nm +0.05
M3
0.8 Nm +0.1
M3
0.8 Nm +0.1
505286-001
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