cilindros hidráulicos aros

26

description

cilindros

Transcript of cilindros hidráulicos aros

  • General Operating and Assembly Instructions for Hydraulic Cylinders

    2/26 AROS Hydraulik GmbH BA0001 Issue Nov. 2012

    Contents

    1.1 Validity and target group .......................................................................................................... 3

    1.1.1 Staff qualifications .................................................................................................................... 3

    1.2 Symbols .................................................................................................................................... 4

    2 Safety Information .................................................................................................................... 4

    2.1 Correct use ............................................................................................................................... 5

    2.2 Incorrect use ............................................................................................................................. 5

    3 General information regarding material damage and damage to the product ......................... 5

    4 Scope of delivery ...................................................................................................................... 6

    5 Product ..................................................................................................................................... 7

    5.1 Performance description .......................................................................................................... 7

    5.2 Product description ................................................................................................................... 7

    5.3 Product identification ................................................................................................................ 7

    6 Transport and storage .............................................................................................................. 8

    6.1 Transporting AROS cylinders ................................................................................................... 8

    6.2 Storing AROS cylinders............................................................................................................ 8

    6.3 Non-observance of correct storage .......................................................................................... 9

    7 Assembly .................................................................................................................................. 9

    7.1 Unpacking ................................................................................................................................ 9

    7.2 Installation conditions ............................................................................................................... 9

    7.3 Assembling AROS cylinders .................................................................................................. 10

    8 Commissioning ....................................................................................................................... 11

    8.1 Filling and bleeding the AROS cylinder.................................................................................. 11

    8.2 End-position cushioning ......................................................................................................... 13

    8.3 Displacement transducers, proximity switches ...................................................................... 13

    8.4 Recommissioning ................................................................................................................... 13

    9 Operation ................................................................................................................................ 13

    10 Maintenance and repairs ........................................................................................................ 13

    10.1 Maintenance ........................................................................................................................... 13

    10.1.1 Piston-rod maintenance ......................................................................................................... 14

    10.2 Inspection ............................................................................................................................... 14

    10.2.1 Finding and rectifying faults ................................................................................................... 15

    10.3 Repairs ................................................................................................................................... 16

    11 Decommissioning and disassembling AROS cylinders ......................................................... 16

    11.1 Decommissioning ................................................................................................................... 16

    11.2 Preparation for disassembly ................................................................................................... 16

    11.3 Disassembly ........................................................................................................................... 17

    12 Replacing components ........................................................................................................... 17

    12.1 Removing the seal .................................................................................................................. 18

    12.2 Fitting the piston seals............................................................................................................ 19

    12.3 Fitting the guide seals ............................................................................................................ 22

    13 Disposal .................................................................................................................................. 26

    14 Modifications and deviations from the specification ............................................................... 26

    15 Technical Specifications ......................................................................................................... 26

    16 Contact ................................................................................................................................... 26

  • General Operating and Assembly Instructions for Hydraulic Cylinders

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    1 General

    Please refer to the information contained in this document before using AROS cylinders.

    We assume that you have read and understood this document completely before working with

    AROS cylinders.

    DIN EN ISO 4413 "Hydraulic fluid power - General rules and safety requirements for systems and

    their components" and our hazard warnings are to be observed.

    1.1 Validity and target group

    This document is valid for all AROS cylinders. Further information can be found in the relevant prod-

    uct data sheet and dimension sheet.

    This document contains important information regarding the correct and safe transport, storage, as-

    sembly, commissioning, operation, maintenance, disassembly and disposal of the product.

    The target group for this document includes assembly workers, operators, plant manufacturers,

    plant operators and service technicians.

    1.1.1 Staff qualifications

    The activities described in this document require basic knowledge of mechanical, electrical and hy-

    draulic systems as well as a sound understanding of the relevant technical terms.

    Only trained specialists and persons with relevant instruction supervised by a qualified member of

    staff are authorised to perform the activities described in this document.

    A specialist is a person who on account of their professional training, know-how and experience is

    able to recognise hazards and implement appropriate safety measures. Furthermore, a specialist is

    obliged to observe the relevant technical regulations.

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    1.2 Symbols

    Standardised symbols are used throughout to ensure tha

    safely using this document.

    General information which must be observed to ensurthe product.

    This symbol indicates a dangerous observance can result in material damage, severe phdeath.

    1. 2. 3.

    Numbered instructions which specify the sequence oftivities.

    2 Safety Information

    The General Operating and Assembly I

    safety information also reduces the risks when stor

    machine.

    Strict compliance allows accidents and material dam

    operation of the AROS cylinder.

    Keep the General Operating and Assembly Instructions accessible for

    the latest version is available at all times. Inclu

    cylinder to a third party.

    At the first sign of incorrect operation, the AROS

    vice and secured against unauthorised use.

    Further information:

    Please note the information on the AROS cylinder.

    Use the AROS cylinder only if it is in perfect working orde

    Only appropriate original spare parts from

    der to rule out the risk of injury to personnel.

    Observe the national safety regulations and standar

    inder is used.

    Observe the valid accident

    Danger

    Danger

    General Operating and Assembly Instructionsfor Hydraulic Cylinders

    AROS Hydraulik GmbH BA0001 Issue Nov. 2012

    ndardised symbols are used throughout to ensure that you can use the product quickly and

    General information which must be observed to ensurthe product.

    This symbol indicates a dangerous situation which must be avoided. Nonobservance can result in material damage, severe ph

    Numbered instructions which specify the sequence of

    Safety Information

    Operating and Assembly Instructions are for information purposes. Observing

    safety information also reduces the risks when storing, transporting and installing the product in the

    Strict compliance allows accidents and material damage to be avoided and guarantees trouble

    operation of the AROS cylinder.

    Operating and Assembly Instructions accessible for all persons to guarantee that

    the latest version is available at all times. Include the documentation when transferring

    At the first sign of incorrect operation, the AROS cylinder is to be taken out of se

    vice and secured against unauthorised use.

    Please note the information on the AROS cylinder.

    AROS cylinder only if it is in perfect working order.

    Only appropriate original spare parts from AROS HYDRAULIK GMBH

    der to rule out the risk of injury to personnel.

    Observe the national safety regulations and standards in the country i

    Observe the valid accident-prevention regulations and environmental

    General Operating and Assembly Instructions

    BA0001 Issue Nov. 2012

    t you can use the product quickly and

    General information which must be observed to ensure the optimum use of

    situation which must be avoided. Non-observance can result in material damage, severe physical injury and even

    Numbered instructions which specify the sequence of the corresponding ac-

    nstructions are for information purposes. Observing the

    ing, transporting and installing the product in the

    oided and guarantees trouble-free

    all persons to guarantee that

    de the documentation when transferring the AROS

    cylinder is to be taken out of ser-

    GMBH are to be used in or-

    ds in the country in which the AROS cyl-

    prevention regulations and environmental-protection legislation.

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    2.1 Correct use

    AROS cylinders are classified as "partly completed machinery". The AROS cylinder is only intended

    for incorporation in a machine or system taking into consideration the data and specifications con-

    tained in the valid data sheets.

    AROS cylinders are used to move loads. For this reason, the following should be observed:

    They should only be installed by a specialist.

    The operating pressure must be limited by a pressure relief valve.

    If used incorrectly, there is a risk of crushing.

    DIN EN ISO 4413 "Hydraulic fluid power - General rules and safety requirements for systems

    and their components" is to be observed.

    2.2 Incorrect use

    Only the use described in this documented is permitted. The user is responsible for risks caused by

    incorrect use.

    AROS Hydraulik GmbH assumes no liability for damage caused by incorrect use.

    Incorrect use is defined as:

    Non-observance of:

    the operating pressure specified in the assembly drawing,

    hydraulic-fluid specifications,

    operating and environmental conditions other than those specified.

    3 General information regarding material damage and damage to the

    product

    Hazards due to incorrect operation Material damage

    The product may only be used as specified in section 2.1 "Correct use".

    Surfaces relevant to correct operation (e.g. mounting surfaces, piston-rod surface) and at-

    tachments (e.g. limit switches and screw couplings) should not be damaged.

    Mixing hydraulic fluids Material damage

    Mixing hydraulic fluids of any kind is expressly forbidden (different manufacturers and/or dif-

    ferent types of fluid).

    Incorrect cleaning Material damage

    Close all openings with suitable threaded blanking plugs to prevent cleaning agents entering.

    Use only suitable cleaning fluids when cleaning AROS cylinders. Do not use aggressive clean-

    ing agents.

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    Avoid cleaning seals and connections with high pressure.

    Do not use compressed air to clean functional interfaces (spherical plain bearings, trunnion

    bearings, piston rods and seals).

    Contamination by fluids and foreign bodies Material damage

    During assembly pay attention to cleanliness to prevent foreign bodies entering the hydraulic

    lines.

    Hydraulic lines, connections and add-on components must be clean and free of swarf.

    We explicitly recommend the use of residue-free industrial wiping cloths for the removal of lu-

    bricants and other soiling.

    The AROS cylinder should only be brought into service after ensuring that all hydraulic and

    mechanical connections are properly connected.

    Leakage or spillage of hydraulic fluids Environmental damage

    Use oil-binding agents to bind leaked hydraulic oil.

    Always place an oil drain pan under the cylinder when filling and draining the AROS cylinder.

    Please note the information contained in the safety data sheet for the hydraulic fluid used.

    4 Scope of delivery

    The delivery comprises the AROS cylinder ordered by you and confirmed by us.

    Furthermore, the connections are plugged, or, alternatively, closed with cover plates. These are only

    used to protect the AROS cylinder from dirt during transport.

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    5 Product

    5.1 Performance description

    All AROS cylinders in all their different versions

    movement. The hydraulic pressure acting on the piston and ring su

    duces the motive force.

    5.2 Product description

    For detailed information on the main and functional

    to the relevant documentation (spare

    5.3 Product identification

    Every AROS cylinder has a unique consecutive commis

    inder as standard (near the cylinder base). Using t

    all matters arising at a later date

    The following data plate will only be attached at t

    version is shown below, although other versions are

    General Operating and Assembly Instructionsfor Hydraulic Cylinders

    AROS Hydraulik GmbH BA0001 Issue Nov. 2012

    Performance description

    All AROS cylinders in all their different versions and variants are intended to produce a l

    hydraulic pressure acting on the piston and ring surfaces in the cylinder barrel pr

    Product description

    For detailed information on the main and functional components of the AROS cylinder, please refer

    levant documentation (spare-parts drawing and list).

    Product identification

    Every AROS cylinder has a unique consecutive commission number, which is stamped into the cy

    inder as standard (near the cylinder base). Using this commission number, it is possib

    at a later date with regard to a specific AROS cylinder.

    The following data plate will only be attached at the express wish of the customer. The standard

    version is shown below, although other versions are available.

    General Operating and Assembly Instructions

    BA0001 Issue Nov. 2012

    and variants are intended to produce a linear

    rfaces in the cylinder barrel pro-

    components of the AROS cylinder, please refer

    sion number, which is stamped into the cyl-

    his commission number, it is possible to deal with

    he express wish of the customer. The standard

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    6 Transport and storage

    6.1 Transporting AROS cylinders

    Depending on the size of the cylinder and the conditions on-site, AROS cylinders can be transported

    using a forklift truck, a crane, or other types of lifting gear.

    Please note the following:

    Always transport AROS cylinders horizontally in the original packaging.

    Use soft lifting slings to avoid damaging the paintwork or protective coating.

    When transporting AROS cylinder on wooden blocks, ensure that no external forces act on

    the add-on components (proximity switches, connecting plates, etc.).

    We recommend that the AROS cylinder be only lifted to a height sufficient for transport.

    Secure the AROS cylinder so that it cannot shift during transportation.

    When using lifting slings, take into account their rated load-bearing capacity.

    6.2 Storing AROS cylinders

    AROS cylinders are only to be stored in dry, dust-free rooms. The primer coating suffices as external

    corrosion protection for short-term storage in this type of room.

    On request, AROS hydraulic cylinders are delivered with a 50-70-m beige coating as standard.

    The following surfaces are neither primed nor painted and are protected with anti-corrosion oil

    (Safe Coat 612 as standard):

    Fits

    Sealing surface

    Connecting surface

    Minimess coupling

    Stroke-measuring system

    Spherical plain and swivel bearings

    Grease nipple

    Inductive proximity switch

    AROS cylinders are tested with HLP32 oil. The residual oil film after testing provides for short-term

    corrosion protection inside the cylinder. Sealing plugs are used to close off the hydraulic ports.

    Do not store AROS cylinders that are prefilled with oil in places where they are subject to direct

    sunlight or other heat sources. The hydraulic pressure in the AROS cylinder can increase if the am-

    bient temperature rises.

    If stored for more than six months, the surface of the AROS cylinder must be painted, or treated with

    anti-corrosion oil. Furthermore, we recommend that AROS cylinders be rotated through 90 every

    five weeks if stored horizontally.

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    In addition, the following points should be noted in otion:

    Examine the AROS cylinders thoroughly every six mon Extend and retract AROS cylinders every six months.

    6.3 Non-observance of correct storage

    Incorrect storage can cause the seals to become bri

    7 Assembly

    Incorrect assembly, commissioning and

    accidents! These activities should only be carried

    personnel.

    7.1 Unpacking

    Unpack AROS cylinders correctly and dispose of the

    tions that apply to you.

    7.2 Installation conditions

    The AROS cylinder should not be installed under tension caused by mouThus, the mounting surfaces should be designed to ato allow for thermal expansion.

    Ensure that the AROS cylinder, and especially the pstallation.

    The AROS cylinder is to be mou

    the hydraulic cylinder.

    The following must be kept as low as possible when

    Excessive deformation of the AROS hydraulic cylinde

    loading.

    Lateral loading or bending moments

    Swivel speeds when trunnion

    Ensure that seals and other wear

    Bleed connections must be freely accessible. If pos

    stalled with the bleed connections facing upwards.

    Compare the type designation of the AROS cylinder w

    AROS cylinder.

    Fill the AROS cylinder with hydrau

    expected, sudden movement of the parts due to resid

    Danger

    General Operating and Assembly Instructionsfor Hydraulic Cylinders

    AROS Hydraulik GmbH BA0001 Issue Nov. 2012

    addition, the following points should be noted in order to keep AROS cylinders in perfect cond

    Examine the AROS cylinders thoroughly every six months. Extend and retract AROS cylinders every six months.

    observance of correct storage

    Incorrect storage can cause the seals to become brittle and the anti-corrosion oil to resinify.

    Incorrect assembly, commissioning and maintenance can lead to serious

    accidents! These activities should only be carried out by trained s

    Unpack AROS cylinders correctly and dispose of the packaging material according to the regul

    Installation conditions

    should not be installed under tension caused by mouThus, the mounting surfaces should be designed to avoid torsion of the AROS cylinder and to allow for thermal expansion.

    Ensure that the AROS cylinder, and especially the piston rod,

    The AROS cylinder is to be mounted such that the load acts axially on the centre

    the hydraulic cylinder.

    The following must be kept as low as possible when mounting AROS cylinders:

    Excessive deformation of the AROS hydraulic cylinder due to tensile or compressive

    Lateral loading or bending moments.

    Swivel speeds when trunnion-mounted requiring constant external lubrication.

    Ensure that seals and other wear relevant to maintenance are easily accessible.

    Bleed connections must be freely accessible. If possible, the AROS cylinder should be i

    stalled with the bleed connections facing upwards.

    Compare the type designation of the AROS cylinder with the order data before installing the

    Fill the AROS cylinder with hydraulic fluid before and bleed it after

    expected, sudden movement of the parts due to residual compressed air in the cylinder.

    General Operating and Assembly Instructions

    BA0001 Issue Nov. 2012

    rder to keep AROS cylinders in perfect condi-

    corrosion oil to resinify.

    maintenance can lead to serious

    out by trained specialist

    packaging material according to the regula-

    should not be installed under tension caused by mounting surfaces. void torsion of the AROS cylinder and

    iston rod, is not damaged during in-

    nted such that the load acts axially on the centre line of

    mounting AROS cylinders:

    r due to tensile or compressive

    constant external lubrication.

    are easily accessible.

    AROS cylinder should be in-

    ith the order data before installing the

    lic fluid before and bleed it after installation to prevent un-

    ual compressed air in the cylinder.

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    Use only soft straps and transport equipment when u

    beyond the basic cylinder (components, piping, etc.

    Make sure the AROS cylinder and the surrounding are

    bly work.

    Before installation, clean pipes, fitting

    tion. Use only lint-free fabri

    Hot-bent or welded pipes must be pickled, rinsed and oi

    Only state-of the-art sealants are to be used.

    Where possible, avoid the use of hydraulic fittings

    tings).

    Ensure the cylinder is installed free of

    Neither the cylinder mounting nor the loading shoul

    malfunctions and premature wear.

    The mounting position can be freely chosen within t

    Always use the tightening torques specified for screws, lo

    7.3 Assembling AROS cylinders

    Before installing the AROS cylinder, depressurise a

    that the maximum permissible lateral forces on the

    during installation. These would inevitably cause d

    interior of the cylinder tube

    When installing rod ends or other connecting elemen

    tighten them down to the stop

    Do not remove protective elements, e.g. screw plugs

    be made.

    The cylinder is to be connected according to the hy

    nents such as displacement transducers or limit swi

    cording to the electrical circuit diagram.

    Danger

    General Operating and Assembly Instructionsfor Hydraulic Cylinders

    AROS Hydraulik GmbH BA0001 Issue Nov. 2012

    Use only soft straps and transport equipment when using lifting gear. Structures extending

    beyond the basic cylinder (components, piping, etc.) are not to be used for lifting.

    Make sure the AROS cylinder and the surrounding area are clean at all times during asse

    Before installation, clean pipes, fittings etc. to remove dirt, swarf, scale and other contami

    free fabrics.

    bent or welded pipes must be pickled, rinsed and oiled.

    art sealants are to be used.

    Where possible, avoid the use of hydraulic fittings (e.g. using bent pipes rather than elbow fi

    Ensure the cylinder is installed free of tension and deformation.

    Neither the cylinder mounting nor the loading should result in lateral forces

    malfunctions and premature wear.

    The mounting position can be freely chosen within the constraints due to the risk of buckling.

    use the tightening torques specified for screws, locknuts and other accessories.

    Assembling AROS cylinders

    Before installing the AROS cylinder, depressurise all relevant systems and ensure

    that the maximum permissible lateral forces on the piston rod are not exceeded

    during installation. These would inevitably cause damage to the piston rod and the

    interior of the cylinder tube.

    When installing rod ends or other connecting elements supplied by the customer, always

    tighten them down to the stops.

    Do not remove protective elements, e.g. screw plugs, until the corresponding connection is to

    The cylinder is to be connected according to the hydraulic diagram. If applicable, electrical comp

    nents such as displacement transducers or limit switches are to be connected by a specialist a

    ing to the electrical circuit diagram.

    General Operating and Assembly Instructions

    BA0001 Issue Nov. 2012

    sing lifting gear. Structures extending

    re not to be used for lifting.

    a are clean at all times during assem-

    etc. to remove dirt, swarf, scale and other contamina-

    (e.g. using bent pipes rather than elbow fit-

    d result in lateral forces that could cause

    he constraints due to the risk of buckling.

    cknuts and other accessories.

    ll relevant systems and ensure

    ton rod are not exceeded

    amage to the piston rod and the

    ts supplied by the customer, always

    , until the corresponding connection is to

    draulic diagram. If applicable, electrical compo-

    tches are to be connected by a specialist ac-

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    8 Commissioning

    Before commissioning the AROS cylinder, check that

    peaks specified in the installation drawing will no

    on our installation drawing and the order confirmat

    Before commissioning the AROS cylinder, all screw p

    side of the cylinder from corrosion are

    All valves installed ex-works are preset and should only be adjusted by a s

    The cylinder is designed for use with mineral oils

    The sealing elements are suitable for operating tem

    Please contact us for approval if other fluids (e.g

    are to be used or other operating temperatures are

    The purity of the fluid used has a significant influ

    purity classification according to ISO 4406 must be

    We recommend that the system be thoroughly flushed

    be well filtered.

    The cylinder should not be connected to the hydraul

    8.1 Filling and bleeding the AROS cylinder

    The AROS cylinder must be bled before every commiss

    points of the AROS cylinder to ensure that it is bled comp

    pressure (approx. 250 bar) during bleeding.

    The AROS cylinder can be bled either via a bleed sc

    tomer requirements.

    Do not remove fittings, hoses and couplings be

    depressurised!

    If the AROS cylinder does not have a bleed screw, i

    the operator is responsible for the actions necessary to bleed the

    Danger

    Danger

    General Operating and Assembly Instructionsfor Hydraulic Cylinders

    AROS Hydraulik GmbH BA0001 Issue Nov. 2012

    Before commissioning the AROS cylinder, check that the operating pressure and the pressure

    peaks specified in the installation drawing will not be exceeded. Moreover, the special information

    on our installation drawing and the order confirmation are to be observed.

    Before commissioning the AROS cylinder, all screw plugs and flange covers used to protect the i

    side of the cylinder from corrosion are to be removed.

    works are preset and should only be adjusted by a s

    The cylinder is designed for use with mineral oils according to DIN 51524 (HL, HLP)

    The sealing elements are suitable for operating temperatures from

    Please contact us for approval if other fluids (e.g. water-in-oil emulsions, low

    are to be used or other operating temperatures are expected.

    he purity of the fluid used has a significant influence on the service life of the AROS cylinder. The

    purity classification according to ISO 4406 must be suitable for the most sensitive component!

    We recommend that the system be thoroughly flushed before commissioning and that the fluid used

    The cylinder should not be connected to the hydraulic system during flushing.

    Filling and bleeding the AROS cylinder

    The AROS cylinder must be bled before every commissioning. Bleed screw

    of the AROS cylinder to ensure that it is bled completely. The cylinder must be under low

    50 bar) during bleeding.

    The AROS cylinder can be bled either via a bleed screw or a Minimess coupling according

    Do not remove fittings, hoses and couplings before the cylinder is completely

    If the AROS cylinder does not have a bleed screw, it must be bled via the hydraulic port. In this case

    responsible for the actions necessary to bleed the cylinder.

    General Operating and Assembly Instructions

    BA0001 Issue Nov. 2012

    the operating pressure and the pressure

    exceeded. Moreover, the special information

    lugs and flange covers used to protect the in-

    works are preset and should only be adjusted by a specialist.

    according to DIN 51524 (HL, HLP).

    peratures from -20 C to +80 C.

    emulsions, low-flammability oils, etc.)

    ence on the service life of the AROS cylinder. The

    suitable for the most sensitive component!

    commissioning and that the fluid used

    ic system during flushing.

    leed screws must be at the highest

    letely. The cylinder must be under low

    rew or a Minimess coupling according to cus-

    fore the cylinder is completely

    t must be bled via the hydraulic port. In this case

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    Bleeding via a bleed screw:

    1. The bleed screw should only be

    the bleed screw by approx. 2 turns until the oil fl

    High risk of injury due to

    wear appropriate protective clothing and cover the

    2. After a period of time foaming oil rather than air

    has been correctly bled.

    3. Close the bleed screw.

    Bleeding via a Minimess coupling

    1. The screw cap can be removed from the Minimess coup

    without risk.

    2. Before the Minimess hose is connected to the coupli

    ceptacle must be attached to the other end

    catch the oil).

    On attaching the hose to the coupling on the AROS

    cylinder, oil will flow immediately!

    3. After a period of time foaming oil rather than air

    has been correctly bled.

    4. Remove the hose from the Minimess

    This procedure must be repeated several times for a

    the AROS cylinder. Only then has the cylinder been

    Subsequently, extend and retract the hydraulic cyli

    dispose of the oil-air mixture in accordance with the regulations

    Danger

    Danger

    General Operating and Assembly Instructionsfor Hydraulic Cylinders

    AROS Hydraulik GmbH BA0001 Issue Nov. 2012

    The bleed screw should only be partially screwed out, not completely removed. Screw out

    the bleed screw by approx. 2 turns until the oil flowing across the gap is fr

    due to oil spraying out of the opening at high pressure. Always

    wear appropriate protective clothing and cover the source of danger with a cloth!

    After a period of time foaming oil rather than air will appear. At this point the AROS cylinder

    has been correctly bled.

    lose the bleed screw.

    Bleeding via a Minimess coupling

    The screw cap can be removed from the Minimess coupling

    Before the Minimess hose is connected to the coupling on the AROS cylinder, a suitable r

    ceptacle must be attached to the other end (alternatively, a simple container can be used to

    On attaching the hose to the coupling on the AROS

    oil will flow immediately!

    After a period of time foaming oil rather than air will appear. At this point the AROS cylinder

    has been correctly bled.

    Remove the hose from the Minimess coupling and replace the cap.

    This procedure must be repeated several times for all bleeding methods until there is no more air in

    the AROS cylinder. Only then has the cylinder been correctly bled.

    Subsequently, extend and retract the hydraulic cylinder 3-5 times without load at low pressure and

    air mixture in accordance with the regulations that apply to you.

    General Operating and Assembly Instructions

    BA0001 Issue Nov. 2012

    , not completely removed. Screw out

    owing across the gap is free of bubbles.

    out of the opening at high pressure. Always

    source of danger with a cloth!

    will appear. At this point the AROS cylinder

    ng on the AROS cylinder, a suitable re-

    lternatively, a simple container can be used to

    will appear. At this point the AROS cylinder

    .

    ll bleeding methods until there is no more air in

    5 times without load at low pressure and

    apply to you.

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    8.2 End-position cushioning

    The AROS cylinder is available with or without adju

    type of cylinder. The end-position cushioning can be adjusted after loosening

    throttle check valve. The throttle screw should not

    marking.

    Please note that the end

    the stroke.

    8.3 Displacement transducers, proximity switches

    Refer to the relevant data sheet for information on

    For safety reasons, the proximity switch should notadjustment is to be carried out only at the end positions.

    8.4 Recommissioning

    Carry out recommissioning as described for initial

    9 Operation

    The AROS cylinder being only a component part, oper

    context of the machine or system in which it is ins

    issued by the manufacturer of the machine or system

    10 Maintenance and repairs

    In order to ensure that your AROS cylinde

    life, please note the following:

    10.1 Maintenance

    Generally, an AROS cylinder requires little maintenommend that the perfect operation of the AROS cylinticular attention to the following points:

    Leakage at the oil connections and the cylinder cap Mechanical damage Damage to the coating Visible wear marks Leakage around the piston rod a The purity of the hydraulic fluid

    Wear parts such as seals and guide strips should to

    intervals depend on the individual application and

    compulsory change interval for wear parts.

    Danger

    General Operating and Assembly Instructionsfor Hydraulic Cylinders

    AROS Hydraulik GmbH BA0001 Issue Nov. 2012

    position cushioning

    The AROS cylinder is available with or without adjustable end-position cushioning depending on the

    position cushioning can be adjusted after loosening

    throttle check valve. The throttle screw should not be screwed out beyond the red

    Please note that the end-position cushioning is only effective

    Displacement transducers, proximity switches

    Refer to the relevant data sheet for information on the electric connections.

    For safety reasons, the proximity switch should not be screwed in too far. Thus, the is to be carried out only at the end positions.

    Carry out recommissioning as described for initial commissioning.

    The AROS cylinder being only a component part, operational information can only be given in the

    context of the machine or system in which it is installed. Please refer to the operating instructions

    issued by the manufacturer of the machine or system in which the cylinder is installed.

    Maintenance and repairs

    In order to ensure that your AROS cylinder operates flawlessly and has a longest possible se

    Generally, an AROS cylinder requires little maintenance after commissioning. We do, however, reommend that the perfect operation of the AROS cylinder be checked at regular intervals. Pay paticular attention to the following points:

    onnections and the cylinder cap

    Damage to the coating

    Leakage around the piston rod and cylinder cap hydraulic fluid

    Wear parts such as seals and guide strips should to be replaced at regular intervals

    intervals depend on the individual application and the ambient conditions on

    compulsory change interval for wear parts.

    General Operating and Assembly Instructions

    BA0001 Issue Nov. 2012

    position cushioning depending on the

    position cushioning can be adjusted after loosening the locknut on the

    screwed out beyond the red

    position cushioning is only effective if full use is made of

    the electric connections.

    be screwed in too far. Thus, the

    ational information can only be given in the

    talled. Please refer to the operating instructions

    in which the cylinder is installed.

    r operates flawlessly and has a longest possible service

    ance after commissioning. We do, however, rec-checked at regular intervals. Pay par-

    be replaced at regular intervals. The change

    the ambient conditions on-site. Thus, there is no

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    Leakage around the piston rod and the cylinder cap

    placed.

    Refer to the system manufacturer's maintenance sche

    for spherical rod eyes, trunnions, etc.

    Extreme temperatures and contamination reduce the service lif

    der. It is thus important that you observe the info

    temperatures.

    10.1.1 Piston-rod maintenance

    Make sure the piston rod always has a protective oi

    humidity, constantly fluctuating temperatures or in

    recommend that the piston rod

    The piston rod should always be retracted during sy

    maintenance activities should be performed during l

    1. Ensure the working environment is dry. Remo

    contamination from the piston rod using fresh water

    2. Preventative maintenance should only be carried out

    son allow the piston rod to dry completely.

    3. Soak a residue-free industrial cloth in preservative oil with

    particular care to ensure that the complete piston

    If the piston rod has come into contact with chemic

    preventative maintenance as described above.

    10.2 Inspection

    We recommend that the results of the inspection be

    tion and energy efficiency of the cylinder. Compari

    allows faults to be recognised immediately and reme

    General Operating and Assembly Instructionsfor Hydraulic Cylinders

    AROS Hydraulik GmbH BA0001 Issue Nov. 2012

    Leakage around the piston rod and the cylinder cap is a sign that wear parts may need to be r

    Refer to the system manufacturer's maintenance schedule for information on the lubrication intervals

    for spherical rod eyes, trunnions, etc.

    mperatures and contamination reduce the service lif

    der. It is thus important that you observe the information on operating and ambient

    rod maintenance

    Make sure the piston rod always has a protective oil film. If the piston rod is subject to high relati

    humidity, constantly fluctuating temperatures or inclement weather (for outdoor applications), we

    recommend that the piston rod be inspected once a week to ensure it remains in perfect condition.

    The piston rod should always be retracted during system downtimes, and the following preventative

    maintenance activities should be performed during longer downtimes:

    Ensure the working environment is dry. Remove salt, sand, operational residues and other

    contamination from the piston rod using fresh water.

    Preventative maintenance should only be carried out when the piston rod is dry. For this re

    son allow the piston rod to dry completely.

    ndustrial cloth in preservative oil with the lowest

    particular care to ensure that the complete piston-rod surface is covered with preserva

    If the piston rod has come into contact with chemicals, remove these completely an

    preventative maintenance as described above.

    We recommend that the results of the inspection be documented. At the same time check the fun

    tion and energy efficiency of the cylinder. Comparing the results with previously document

    allows faults to be recognised immediately and remedial action to be taken.

    General Operating and Assembly Instructions

    BA0001 Issue Nov. 2012

    is a sign that wear parts may need to be re-

    dule for information on the lubrication intervals

    mperatures and contamination reduce the service life of the AROS cylin-

    rmation on operating and ambient

    l film. If the piston rod is subject to high relative

    clement weather (for outdoor applications), we

    it remains in perfect condition.

    stem downtimes, and the following preventative

    ve salt, sand, operational residues and other

    when the piston rod is dry. For this rea-

    est viscosity possible. Take

    rod surface is covered with preservative oil.

    als, remove these completely and carry out the

    documented. At the same time check the func-

    ng the results with previously documented values

    dial action to be taken.

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    10.2.1 Finding and rectifying faults

    In general, faults are rectified by replacing the defective components. Replace only those parts listed

    in the spare-parts list with comparable approved components of OEM quality.

    If an AROS cylinder is to be repaired, please contact AROS Hydraulik GmbH directly.

    Fault Possible cause of failure Remedy

    Leakage at the piston rod

    Worn piston-rod seals Surface irregularities caused by piston-rod wear.

    Replace the piston-rod seals Replace the piston rod

    Leakage at the hydraulic connections

    Loose fittings Damaged seal

    Torque the fittings to the correct setting Replace the seal of the fitting

    Stick-slip phenomenon

    The piston rod and the AROS cylinder as a whole are subject to lateral forces. Wear of seal components Air in the AROS cylinder Valve malfunction

    Adhere to the regulations de-scribed in section 7.2 "Installa-tion conditions" Replace the seals Bleed the cylinder again, follow-ing the instructions in section 8.1. "Filling and bleeding the AROS cylinder. Check the valves

    Cushioning effect insufficient or non-existent

    The end-position cushioning is not adjusted according to your requirements.

    Check the adjustment of the end-position cushioning and ad-just accordingly as described in section 8.2 "End-position cush-ioning".

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    10.3 Repairs

    The repair measures serve to return the AROS cylind

    to contact our sales personnel with regard to repairs.

    11 Decommissioning and disassembling AROS cylinders

    11.1 Decommissioning

    Due to the high operating pressure in the AROS cyli

    oil can cause injuries and material damage.

    Observe the following points to avoid the risk of danger:

    1. Switch off all components and connections in accord

    tions, and ensure that they cannot be restarted uni

    tem's main fuse.

    2. Depressurise the AROS c

    3. Drain the oil into a container with a capacity suff

    sure the hydraulic lines are completely emptied.

    11.2 Preparation for disassembly

    Before disassembling the AROS cylinder, a clearly legible assembly drawin

    quired (these can be found in our technical documen

    which to place the AROS cylinder and the disassembl

    Furthermore, clean professional tools and

    cylinder, no dirt should enter the hydraulic system

    pletely covered with cover plates or that plastic b

    Pay attention that the AROS cylinder, and particula

    moval. Observe the transport instructions in sectio

    during removal.

    General Operating and Assembly Instructionsfor Hydraulic Cylinders

    AROS Hydraulik GmbH BA0001 Issue Nov. 2012

    The repair measures serve to return the AROS cylinder to full working order. Please do not hesitate

    personnel with regard to repairs.

    Decommissioning and disassembling AROS cylinders

    Decommissioning

    Due to the high operating pressure in the AROS cylinder, moving parts or escaping

    oil can cause injuries and material damage.

    points to avoid the risk of danger:

    Switch off all components and connections in accordance with the manufacturer's instru

    tions, and ensure that they cannot be restarted unintentionally. If possible, remove the sy

    Depressurise the AROS cylinder completely and relieve it from all external

    Drain the oil into a container with a capacity sufficient to take the complete volume of oil. E

    sure the hydraulic lines are completely emptied.

    Preparation for disassembly

    he AROS cylinder, a clearly legible assembly drawin

    quired (these can be found in our technical documentation) as well as a stable working surface on

    which to place the AROS cylinder and the disassembled components.

    lean professional tools and a clean, tidy workplace is required. When removing the

    cylinder, no dirt should enter the hydraulic system. Thus, we recommend that all ports are co

    pletely covered with cover plates or that plastic blanking plugs are fitted.

    Pay attention that the AROS cylinder, and particularly the piston rod, is not damaged during r

    moval. Observe the transport instructions in section 6.1 when lifting and moving the AROS cylinder

    General Operating and Assembly Instructions

    BA0001 Issue Nov. 2012

    er to full working order. Please do not hesitate

    Decommissioning and disassembling AROS cylinders

    nder, moving parts or escaping

    ance with the manufacturer's instruc-

    ntentionally. If possible, remove the sys-

    ylinder completely and relieve it from all external forces.

    icient to take the complete volume of oil. En-

    he AROS cylinder, a clearly legible assembly drawing / spare-parts list is re-

    tation) as well as a stable working surface on

    required. When removing the

    . Thus, we recommend that all ports are com-

    rly the piston rod, is not damaged during re-

    n 6.1 when lifting and moving the AROS cylinder

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    11.3 Disassembly

    Note the following steps during disassembling

    1. So far as reasonably practicable, drain the hydraul

    removal. The remaining oil can be drained after rem

    2. Remove the guide and then drain the remaining hydra

    3. Pull the piston rod out o

    slings.

    4. Place the piston rod on a stable working surface pr

    rod cannot roll.

    5. Remove the seals.

    6. Clean the piston rod, its thread, the guide, the mo

    7. Pay attention that no dirt particles remain which c

    12 Replacing components

    When replacing components, proceed as described in

    the seals is described in detail below. Seal kits a

    ordered using the article number of the AROS cylind

    AROS cylinder can be clearly identified using the AROS nu

    scribed in section 5.3.

    The following explanation is based one of the seal

    various seal versions available, these may differ s

    moval and installation. If you have questions or do

    tact person in our sales department at all times.

    When handling seals unless they are to be removed and disposed of

    and ensue that the piston, the guide and the seals are free of dir

    When replacing components, please refer to the prod

    for the corresponding positions of the individual s

    General Operating and Assembly Instructionsfor Hydraulic Cylinders

    AROS Hydraulik GmbH BA0001 Issue Nov. 2012

    ng disassembling!

    So far as reasonably practicable, drain the hydraulic fluid out of the AROS cylinder before

    removal. The remaining oil can be drained after removal.

    Remove the guide and then drain the remaining hydraulic fluid.

    Pull the piston rod out of the AROS cylinder. If necessary, we recommend the

    Place the piston rod on a stable working surface prepared for this purpose. Ensure the piston

    Clean the piston rod, its thread, the guide, the mounting eyes and the protective sleeve.

    Pay attention that no dirt particles remain which could damage the seals during reassembly.

    Replacing components

    When replacing components, proceed as described in section 11.3. The removal and installation of

    the seals is described in detail below. Seal kits and other spare parts that are to be replaced

    ordered using the article number of the AROS cylinder. If the article number is no longer known, the

    ylinder can be clearly identified using the AROS number stamped in the cylinder as d

    The following explanation is based one of the seal versions available. Due to the

    various seal versions available, these may differ slightly with

    moval and installation. If you have questions or doubts, please contact your co

    tact person in our sales department at all times.

    unless they are to be removed and disposed of never use sharp objects,

    the piston, the guide and the seals are free of dirt.

    When replacing components, please refer to the product-specific spare

    for the corresponding positions of the individual seals.

    General Operating and Assembly Instructions

    BA0001 Issue Nov. 2012

    ic fluid out of the AROS cylinder before

    f the AROS cylinder. If necessary, we recommend the use of lifting

    epared for this purpose. Ensure the piston

    unting eyes and the protective sleeve.

    ould damage the seals during reassembly.

    The removal and installation of

    parts that are to be replaced can be

    er. If the article number is no longer known, the

    mber stamped in the cylinder as de-

    versions available. Due to the

    lightly with regard to their re-

    ubts, please contact your con-

    never use sharp objects,

    specific spare-parts list

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    12.1 Removing the seal

    Fig. 1

    Fig. 4

    Insert a seal puller (Fig. 2) behind the rod seal. Attention: Be careful not to damage the base of the Using the seal puller, pull the rod seal out of the The rod seal can now be removed with the finger.Follow this procedure for all other seals during di

    General Operating and Assembly Instructionsfor Hydraulic Cylinders

    AROS Hydraulik GmbH BA0001 Issue Nov. 2012

    Fig. 2

    Fig. 3

    Fig. 5

    Fig. 6

    Insert a seal puller (Fig. 2) behind the rod seal. Attention: Be careful not to damage the base of the groove.

    Using the seal puller, pull the rod seal out of the groove (Figs. 3 to 5).

    The rod seal can now be removed with the finger. Follow this procedure for all other seals during disassembly.

    General Operating and Assembly Instructions

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    12.2 Fitting the piston seals

    Fig. 7

    Place one side of the seal in the groove.

    Fig. 10

    The screwdriver can now be removed. Check that the O-ring has been correctly in-serted into the groove.

    General Operating and Assembly Instructionsfor Hydraulic Cylinders

    AROS Hydraulik GmbH BA0001 Issue Nov. 2012

    Fig. 8

    Then push the rest of the seal into the groove and check that it is sitting correctly.

    Fig. 9

    Install the Oseal groove using a flatscrewdriverblade edges Piston seal = O-Ring and PTFE seal

    Fig. 11

    Twist the preformed guide strip slightly apart and slip it over the piston.

    Fig. 12

    Insert the guide strip into its groove. Installing the guide strip first ensures that does not slip into the guidestrip groove.

    General Operating and Assembly Instructions

    BA0001 Issue Nov. 2012

    Install the O-ring in the piston-seal groove using a flat-blade screwdriver with rounded blade edges.

    Piston seal = Ring and PTFE seal

    Insert the guide strip into its

    Installing the guide strip first ensures that the PTFE seal does not slip into the guide-strip groove.

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    Fig. 13

    Please use an assembly bush and an assembly sleeve to install the PTFE seal. Place the PTFE seal over the assembly bush.

    Fig. 16

    Place the assembly bush on the end of the piston. The assembly bush should be flush with the upper edge of the installed guide strip.

    General Operating and Assembly Instructionsfor Hydraulic Cylinders

    AROS Hydraulik GmbH BA0001 Issue Nov. 2012

    Fig. 14

    Then use the assembly sleeve to push the PTFE seal to the end of the assembly bush.

    Fig. 15

    After pushing the PTFE seal to the end of the assembly bush, the assembly sleeve may be removed. We recommend that it not be removed, as it required again later.

    Fig. 17

    Using the assembly sleeve, push the PTFE seal into the groove on top of the O-ring.

    Fig. 18

    Remove the assembly bush when the PTFE seal sits completely in the groove.

    General Operating and Assembly Instructions

    BA0001 Issue Nov. 2012

    After pushing the PTFE seal to the end of the assembly bush, the assembly sleeve may be removed. We recommend that it not be removed, as it will be required again later.

    Remove the assembly bush when the PTFE seal sits completely in the groove.

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    Fig. 19

    Check whether the piston seal has been correctly installed and grease it.

    Fig. 22

    Fit the remaining guide strips as described in Figs. 4 and 5 and re-peat the calibration shown in Fig. 20. Make sure, however, that the calibration sleeve encloses all the seals.

    General Operating and Assembly Instructionsfor Hydraulic Cylinders

    AROS Hydraulik GmbH BA0001 Issue Nov. 2012

    Fig. 20

    The piston seal deforms slightly during assembly with the assembly bush. A calibration sleeve is required to return the piston seal to its original shape. Push this over the piston.

    Fig. 21

    The calibration sleeve should rmain on the piston for approx. seconds to obtain the best result.

    General Operating and Assembly Instructions

    BA0001 Issue Nov. 2012

    The calibration sleeve should re-main on the piston for approx. 10 seconds to obtain the best result.

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    12.3 Fitting the guide seals

    Fig. 23

    Insert the seal in its groove us-ing a flat-blade screwdriver with rounded blade edges.

    Fig. 26

    Perform the step shown in Fig. 25 for all guide strips.

    General Operating and Assembly Instructionsfor Hydraulic Cylinders

    AROS Hydraulik GmbH BA0001 Issue Nov. 2012

    Fig. 24

    Check that the seal has been fitted correctly.

    Fig. 25

    Deform the guide strip to suit the corresponding diameter of the guide and insert it into the correct groove.

    Fig. 27

    Check that the guide strips have been correctly installed.

    Fig. 28

    Check the groove for the PTFE seals for damage and contamintion.

    General Operating and Assembly Instructions

    BA0001 Issue Nov. 2012

    Deform the guide strip to suit the corresponding diameter of the guide and insert it into the correct

    Check the groove for the PTFE for damage and contamina-

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    Fig. 29

    Insert the O-ring into its groove.

    Fig. 32

    Make sure the non-deformed side is inserted into the groove first.

    General Operating and Assembly Instructionsfor Hydraulic Cylinders

    AROS Hydraulik GmbH BA0001 Issue Nov. 2012

    Fig. 30

    The PTFE seal can either be in-stalled using a special tool or, alter-natively, between two fingers.

    Fig. 31

    To ease fitting in the groove, dform the PTFE seal into a kidney shape.

    Fig. 33

    Then press the rest of the seal into the groove.

    Fig. 34

    Insert the rod seal.

    General Operating and Assembly Instructions

    BA0001 Issue Nov. 2012

    To ease fitting in the groove, de-form the PTFE seal into a kidney

    34

    Insert the rod seal.

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    Fig. 35

    Check that all the seals have been correctly fitted and grease them.

    Fig. 38

    Place the O-ring in the correspond-ing groove.

    General Operating and Assembly Instructionsfor Hydraulic Cylinders

    AROS Hydraulik GmbH BA0001 Issue Nov. 2012

    Fig. 36

    Use an assembly drift with a diame-ter corresponding to the inner di-ameter of the guide.

    Fig. 37

    Insert this into the guide in order to restore the PTFE seal to its original shape.

    Fig. 39

    Deform the wiper into a kidney shape as already described in Figs. 30 and 31.

    Fig. 40

    Place the wiper in the groove as described in Figs. 32 and 33.

    General Operating and Assembly Instructions

    BA0001 Issue Nov. 2012

    Insert this into the guide in order to restore the PTFE seal to its original

    Place the wiper in the groove as described in Figs. 32 and 33.

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    Fig. 41

    Reinsert the assembly drift into the guide.

    General Operating and Assembly Instructionsfor Hydraulic Cylinders

    AROS Hydraulik GmbH BA0001 Issue Nov. 2012

    Fig. 42

    Ensure that all seals have been fitted correctly.

    General Operating and Assembly Instructions

    BA0001 Issue Nov. 2012

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    13 Disposal

    All materials must be disposed of according to national statutory regulations valid in your country or according to internal company rules. Particular attention must be paid to the disposal of hydraulic fluids and components containing hy-draulic-fluid residues. When disposing of hydraulic fluids, note the information contained in the rele-vant safety data sheets.

    14 Modifications and deviations from the specification

    AROS Hydraulik GmbH assumes no responsibility for modifications to an AROS cylinder carried out by third parties or deviations from the specification, and disclaims any form of liability. Modifications to the AROS cylinder or deviations from the specification mean that the product is no longer in its original state. In all such cases, declarations given by AROS Hydraulik GmbH with regard to this product lose their validity.

    15 Technical Specifications

    Exact data for your AROS cylinder can be found in the relevant valid documents.

    16 Contact

    AROS Hydraulik GmbH

    Foehrenweg 3-11

    87700 Memmingen

    Germany

    Tel: +49 8331 8209-0

    Fax: +49 8331 8209-90

    Email: [email protected]

    Internet: www.aros-hydraulik.de