Hydrailic Cylinder Document

7/25/2019 Hydrailic Cylinder Document

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1. Safety instructions

Intended use:

The product is a hydraulic system component. According to directive "2006/42/EC" by the E

and E! #2$ these hydraulic cylinders a component that is not ready %or use and e&clusivelyintended %or installation into machinery or systems. 'ou may only use the product %or installation

into machinery or systems( )ydraulic cylinders are thus not covered by the *achinery +irective.

According to the ,ressure E-uipment +irective$ hydraulic cylinders are not to be classi%ied as

pressure vessel but as hydraulic controlling e-uipment as the pressures not the decisive %actor %or

the construction but rigidity$ dimensional stability and stability against static and dynamic

operating loads. The product is only intended %or industrial use and not %or private use. ntended

use includes having read and understood this documentation completely$ especially the a%ety

instructions1. The product may only be used ithin the data and speci%ications speci%ied in the

valid data sheets.

Improper useAny use deviating %rom the intended use is improper and thus not admissible. 3luid poer

systems A do not assume any liability %or damage caused by improper use. The user assumes

all ris5s involved ith improper use. !ot intended use o% the product includes the operation o%

the hydraulic cylinders

78 9ith higher operating pressures than intended in the data sheets and/or installation draings

28 9ith hydraulic %luids not corresponding to the speci%ications o% the data sheets

:8 9ith deviating operating and environmental conditions

48 The hydraulic cylinder must not be used as guide element in the system ;"nstallation

conditions"8.

Qualification of personnel

The activities described in this documentation re-uire basic 5noledge o% mechanics$ electrics

and hydraulics as ell as 5noledge o% the appropriate technical terms. n order to ensure sa%e

use$ these activities may only be carried out by a corresponding e&pert or an instructed person

under the direction and supervision o% an e&pert. E&perts are those ho can recogni<e potential

ha<ards and apply the appropriate sa%ety measures due to their pro%essional training$ 5noledge

and e&perience$ as ell as their understanding o% the relevant conditions pertaining to the or5 to

be underta5en. An e&pert must observe the relevant speci%ic pro%essional rules.

The product may only be used by -uali%ied persons ho have been instructed

78 To carry out the transport.28 To assemble and disassemble hydraulic and mechanical parts.

:8 To commissioning hydraulic systems and assemblies.

General safety instructions

78 =bserve the valid regulations on accident prevention and %or environmental protection.

28 observe the sa%ety regulations and provisions o% the country here the products

implemented/used.



:8 E&clusively use 3luid poer systems products in good technical order and condition.

48 =bserve all notes on the product.

>8 ,ersons ho assemble$ operate$ disassemble or maintain 3lud poer systems products must

not consume any alcohol$ drugs or pharmaceuticals that may a%%ect their ability to react and their

ability to ?udge.

68 =nly use accessories and spare parts authori<ed by the manu%acturer in order to e&clude

ha<ards to persons due to inappropriate spare parts.

@8 Comply ith the technical data and environmental conditions indicated in the product

documentation.

#8 The installation or use o% inappropriate products in sa%etyrelevant applications could result in

unintended operating conditions hen being used hich in turn could cause personal in?uries

and/or damage to property. There%ore please

=nly use a product %or sa%etyrelevant applications i% this use is e&pressly speci%ied and permitted

in the documentation o% the product. 3or e&ample in e&plosionproo% areas or in sa%etyrelated

control components ;%unctional sa%ety8.8 +o not commission the product until you can be sure that the end product ;%or e&ample a

machine or system8 here the 3luid poer systems product is installed complies ith the

countryspeci%ic provisions$ sa%ety regulations and standards o% the application.

Product- and technology-related safety instructions

The installation o% the hydraulic cylinders in the machine may result in ris5s caused by the

interaction o% hydraulic cylinder and machinery hich can only be identi%ied and minimi<ed by

means o% a ris5 assessment o% the machine. ,articularly the in%luence o% hydraulic and electric

controls on hydraulic drives generating mechanical movements re-uires a ris5 analysis and

operating instructions %or the machinery.Pressurized system!

+anger to li%e$ ris5 o% in?ury$ severe in?ury hen or5ing at systems that have not been stopped(

+amage to property(

78 *a5e sure that the hydraulic cylinder has been completely depressuri<ed.

28 +o not disconnect lines$ connections or components as long as the hydraulic cylinder is under

pressure.

:8 itch o%% all %orcetransmitting components and ports ;electric$ pneumatic$ hydraulic8

according to the manu%acturerBs instructions and secure them against restarting. % possible$

remove the main %use o% the system.

Leaing oil mist due to defectie or improperly assem"led seals!

is5 o% %ire$ ris5 o% e&plosion$ ris5 due to allergic reactions$ environmental pollution(

78 9elding or5s may only be underta5en hen the hydraulic cylinders depressuri<ed.

28 Deep open %ire and sources o% ignition aay %rom the hydraulic cylinder.

:8 *a5e sure that the earthling ;electric elding circuit8 during elding or5s at the system is

not lead via hydraulic cylinders

#lectrostatic charging!



+anger to li%e in the e&plosive area(

78 The e-uipotential bonding o% the hydraulic ATE cylinder must alays be connected in order

to prevent electrostatic charging.

$ot surfaces at hydraulic cylinders!

is5 o% in?ury( is5 o% burning(

78 =nly touch cylinder sur%aces ith protective gloves or do not or5 at hot sur%aces. +uring or

a%ter the operation$ the temperatures may e&ceed 60 FC ;740 F38$ depending on the operating

conditions.

28 Allo the hydraulic cylinder to cool don su%%iciently be%ore touching it.

:8 =bserve the protective measures o% the end machine manu%acturer.

$ydraulic fluid leaing at the hydraulic cylinder in an uncontrolled form!

is5 o% %ire( is5 o% in?ury(

78 itch the system o%% immediately ;emergency stop sitch8.

28 denti%y and remedy the cause o% the lea5age.

:8 !ever try to stop or seal the lea5 or the oil ?et using a cloth.48 Avoid direct contact ith the lea5ing oil ?et. t might be under high pressure.

>8 Carry out visual inspections %or tightness o% the hydraulic cylinder and the oil containing

components on a regular basis.

Slip hazard due to oily surfaces!

is5 o% in?ury(

78 ,rotect and mar5 the danger <one.

28 mmediately remove lea5ed hydraulic oil.

:8 se an oil binding agent in order to bind the lea5ed hydraulic oil.

48 emove and dispose o% ;see section 7: +isposal18 o% the contaminated oil binding agent.

>8 9ear the protective e-uipment prescribed %or your activity li5eE.g. sa%ety boots.

#lectrostatic charging!

+anger to li%e in the e&plosive area(

78 The e-uipotential bonding o% the hydraulic ATE cylinder must alays be connected in order

to prevent electrostatic charging

%. General &arnings of damage to property and



'amage to the product

'anger due to improper handling!

+amage to property(78 The product may only be operated according to section 2.2 "ntended use".

28 +o not 5noc5 against areas relevant %or the %unctioning ;e.g. piston rod sur%aces$ mounting

areas8 and attachment parts ;e.g. end sitches and threaded coupling8.

(i)ing hydraulic fluids!

+amage to property(

78 Any mi&ing o% hydraulic %luids o% di%%erent manu%acturers and/or o% di%%erent types o% the same

manu%acturer is generally not admissible.

Pollution "y fluids and foreign "odies!

Early ear and mal%unctions(

Ta5e the %olloing measures %or protecting the hydraulic cylinder

78 +uring assembly$ provide %or cleanliness in order to prevent %oreign bodies

E.g. elding beads or metal chips %rom getting into the hydraulic lines and causing product ear

or mal%unctions.

28 *a5e sure that all connections$ hydraulic lines and attachment parts;e.g. measuring

instruments8 are clean and %ree o% chips.

:8 3or removing lubricants or any other pollution$ use industrial residue%reeipes.

48 =nly complete cleaning processes at the hydraulic cylinder i% the hydraulic connections are

closed.

>8 Ge%ore commissioning$ ensure that all hydraulic and mechanical connections are connected.Improper cleaning!

+amage to property(

78 Cover all openings ith the appropriate protective plugs in order to prevent cleaning agents

%rom penetrating the system.

28 Chec5 that all seals and electrical plugin connections are %irmly %itted to prevent the

penetration o% cleaning agents.

:8 +o not use aggressive cleaning agents %or the cleaning. Clean the hydraulic cylinder using a

suitable cleaning li-uid.

48 +o not use a pressure asher.

>8 +o not use compressed air %or the cleaning at %unctional inter%aces li5e e.g. spherical bearings$trunnion bearings$ and piston rods and in sealing areas.

*peration &ith a lac of hydraulic fluid!

+amage to property(

78 =bserve the system manu%acturerBs speci%ications regarding the point "Control o% the hydraulic

%luid" and the prescribed remedial measures %or the control result.

Leaing or spilt hydraulic fluid!



Environmental pollution and pollution o% the ground ater(

78 se an oil binding agent in order to bind the lea5ed hydraulic oil.

28 9hen %illing and draining the hydraulic %luid$ alays put a drain tray under the )ydraulic

cylinder.

:8 =bserve the in%ormation in the sa%ety data sheet o% the hydraulic %luid and the ystem

manu%acturerBs speci%ications.

+. Scope of deliery



The scope o% delivery comprises the hydraulic cylinder as ordered by the customer observing the

ordering code and con%irmed in the order con%irmation. n Addition$ the ports are closed by

means o% blan5ing plugs and/or cover plates. They e&clusively serve as protection against

pollution o% the hydraulic cylinder during transport.

,laning plug

oer plate

. Information on this product



Performance description

A hydraulic cylinder converts hydraulic energy into a linear movement. The drive poer is

determined by the hydraulic pressure in the cylinder chamber on the piston and/or annulus area.

Product description

n the %olloing$ the main and %unctional parts o% mill type and tie rod cylinders are displayed.

783or the mounting types$ please re%er to the valid data sheet(

(ill type cylinder

C+

C

C

1 ,iston rod

% Cylinder head

+ Hine connection

a%ety bleeding

/ 3lange

0 Cylinder pipe

Cylinder base ;C+ el%aligning clevis at cylinder base8



2 3astening

3 ,iping

14 ub plate

11 ,osition measurement system ith protective pipe

5ie rod cylinder

C+

C

C

1 ,iston rod

% Cylinder head

+ Hine connection

a%ety bleeding

/ Tie rod

0 Cylinder pipe

Cylinder base ;C+ el%aligning clevis at cylinder base8

2 3astening

3 ,iping



14 ub plate

11 ,osition measurement system ith protective pipe

5+ series 6e)ample: '5+ 7 G5+ 7 S5+8

/. 5ransport and storage

5ransporting hydraulic cylinders



9ncontrolled e)tension of the piston rod and lifting of the hydraulic cylinder at set-ups 6su"

plates piping etc.8!

is5 o% in?ury or damage to property(

78 )ydraulic cylinders may only be transported as described in section "Transporting hydraulic

cylinders".

78 +uring transport$ leave the plastic plugs in the line connections. +epending on the si<e and the

situation on site$ hydraulic cylinders can be transported using a %or5li%t$ a crane or any other

li%ting gear. 9hen moving and li%ting the hydraulic cylinder$ please observe the %olloing

directives

28 Transport the hydraulic cylinder only in hori<ontal position$ in its original pac5ing$ i% possible$

or on ooden bloc5s ;prismshaped s-uared timber8 holding the hydraulic cylinder in a stable

position.

:8 ma5e sure that hen transporting the hydraulic cylinder on ooden bloc5s$ there are no %orce

e%%ects on attachment parts ;sub plates$ piping$ threaded coupling$ pro&imity sitch$ etc.8.

48 se so%t li%ting slings in order to prevent damage in the preservation or coating. +ue to thetolerances$ you must$ during li%ting$ anticipate a eight o% the hydraulic cylinder e&ceeding the

one speci%ied in the draing or in the data sheets by 70 I.3or the eight o% the hydraulic

cylinder ;ithout pac5aging8$ please re%er to the shipping documents.

5ransport using forlifts

To transport the hydraulic cylinder using %or5li%ts proceed as %ollos

1. *ove the %or5 o% the %or5li%t under the pac5aging o% the hydraulic cylinder rounder the

hydraulic cylinder secured %or transport.

%. Care%ully li%t the load %or chec5ing the position o% the canter o% gravity. Ensure a stable

position o% the canter o% gravity ;8(+. *a5e sure that the hydraulic cylinder cannot move out o% the intended position.

. ecure the hydraulic cylinder against the resulting acceleration %orces.

/. +uring transport$ only li%t the hydraulic cylinder as %ar o%% the %loor as necessary %or the

transport.



5ransport using forlifts

5ransport using lifting gear

;arning! Grea5 o% the eyebolt due to eight overload( +anger to li%e( is5 o% in?ury( +amage

to property(

1. Attach suitable li%ting gear at hydraulic cylinders using supplied and already attached eyebolts

;load chains$ li%ting slings8. The hydraulic cylinder may only be li%ted and transported in the

condition as supplied at the supplied eyebolts.

%. Care%ully li%t the hydraulic cylinder %or chec5ing the position o% the canter o% gravity. Ensure a

stable position o% the canter o% gravity ;8(

+. *a5e sure that the hydraulic cylinder cannot move out o% the intended position.

. +uring transport$ only li%t the hydraulic cylinder as %ar o%% the %loor as necessary %or the

transport.

9se of eye"olts

1. 3asten to li%ting slings o% e-ual length at both ends o% the cylinder pipe o% the hydraulic

cylinder by %orming loops. =bserve the admissible li%ting capacity o% the li%ting slings(

%. Care%ully li%t the load %or chec5ing the position o% the canter o% gravity. Ensure a stable

position o% the canter o% gravity ;8(

+. *a5e sure that the li%ting slings do not slip during li%ting.

. +uring transport$ only li%t the hydraulic cylinder as %ar o%% the %loor as necessary %or the

transport.



(anual transport

78 9herever possible$ suitable li%ting aids should be used such as e.g. carrying straps.Storing hydraulic cylinders

orrosion protection applied "y the factory

Gy de%ault$ hydraulic cylinders are primed ith a primer coat o% at least 40 Jm.

9ith cylinders and attachment parts$ the %olloing sur%aces are not primed or coated

78 All %it diameters and connection sur%aces to the customer side

28 ealing %aces %or line connection

:8 ealing %aces %or %lange connection

48 Connection sur%ace %or valve mounting

>8 nductive pro&imity sitches

68 ,osition measurement system@8 *inimises coupling

#8 pherical/plain bearing

8 Hubrication nipples

The sur%aces that are not primed are protected by means o% corrosion protection oil.

9ith short storage times in dry rooms at constant temperature$ the primer is su%%icient as e&ternal

preservation.

Storage of oil-filled hydraulic cylinders

The internal preservation o% the hydraulic cylinders is achieved by testing/%lushing or %illing ith

corrosion protection oil. 9hen storing hydraulic cylinders %illed ith oil$ a pipeline %rom the line

connection o% the annulus area to the line connection o% the piston chamber has to be attached on

the customer side. )ydraulic cylinders %illed ith oil must not be e&posed to direct solar

radiation or other sources o% heat as due to the increase in the ambient temperature$ the

)ydraulic pressure in the hydraulic cylinder increases.

Storage of more than si) months



n case o% storage o% more than si& months$ the sur%ace o% the hydraulic cylinder must be coated

or treated ith corrosion protection oil. nprotected parts li5e %itting sur%aces or mechanical

inter%aces must be protected ith corrosion protection oil.

78 ,rotect spherical bearings and %itting sur%aces %rom humidity.

28 n case o% storage ith corrosion protection oil$ completely empty the hydraulic cylinders

be%ore the commissioning.

:8 As de%ormations at the seals cannot be e&cluded$ rene the seals. n case o% improper storage$

seals may embitter and the corrosion protection oil may revivi%y.

Inspection during the storage period

n order %or the hydraulic cylinder to remain in per%ect condition during the storage period$ the

%olloing conditions have to be met

78 ub?ect the hydraulic cylinder to a care%ul inspection once per year. 9hile doing so$ observe

in particular the %olloing

• E&ternal conservationK visual inspection %or damage and rust %ormation

•

)ydraulic %luidK control ith regard to o&idation or acidi%ication• nspection and lubrication o% spherical bearings that are not maintenance%ree

• nspection o% the preservation o% %itting sur%aces or mechanical inter%aces

28 E&tend and retract the hydraulic cylinder several centimetres per year in order to prevent the

seals %rom bonding. +epending on the results$ you may have to ta5e corrective measures.

n order to prevent damage at the seals$ e recommend rotating the hydraulic cylinders by 0 FC

every si& ee5s unless they are stored vertically.

Information on paced hydraulic cylinders

78 % you open the pac5aging %or control purposes$ you have to close it again care%ully.

28 n case o% pac5aging %or carriage overseas$ enclose a ne drying agent.

0. <ssem"ly

9npacing

78 emove the hydraulic cylinder pac5aging.

28 +ispose o% the pac5aging material in accordance ith the national regulations in your country

and/or your companyinternal speci%ications/procedures.



Installation conditions

*ounting sur%aces at machines and systems must be designed so that any torsion o% the hydraulic

cylinder in the installed condition is avoided. The hydraulic cylinder must be installed so that

unanted lateral loads during operation are avoided. tro5e length$ load and cylinder mounting

must be observed in order to avoid bending and 5in5ing in every stro5e position ;e&tract %rom E

+! = 447: 7070/6.2.2.:8.

78 3asten the hydraulic cylinder so that the load acts a&ially on the canter line o% the hydraulic

cylinder.

28 ma5e sure that the hydraulic cylinder and particularly the piston rod are not damaged during

installation. The counter bearings %or spherical bearing$ trunnion$ %oot and %lange mounting must

be able to absorb the occurring %orces.

:89hen installing hydraulic cylinders and assemblies ith spherical or plain bearings it has to be

ensured that hen installing the bolt$ the bolt and/or the spherical or plain bearing is not

damaged ;i% necessary$ cool the bolt hen installing it8.

48 +esign the bolts %or cylinder mounting according to the %orces to be e&pected.=nly use the genuine bolts hen using accessories li5e clevis brac5ets etc. 9e recommend

limiting the sivel angles / tilting angles at the spherical bearings on the customer side in order

to prevent the undesired action o% %orces on mounting elements. n the %astening o% the hydraulic

cylinder at the system$ the %olloing enumeration must be 5ept to a minimum ;e&tract %rom E

+! = 447: 7070/6.2.28

• E&cessive de%ormation o% the hydraulic cylinders due to pushing or pulling load

• ntroduction o% lateral or bending loads

• ivelling velocities in the trunnion assembly re-uiring continuous e&ternal lubrication

>8 *a5e sure that the "A piston chamber" and "G annulus area" line connections are not

interchanged hen connecting the hydraulic cylinders.

Installation conditions

<ssem"ling hydraulic cylinders

78 9hen assembling sivel heads or other customer connection elements at the hydraulic

elements$ scre the sivel head to the stop. The connection elements must not be used to set

installation di%%erences.

28 emove the protective device li5e e.g. scre plugs only hen establishing the corresponding

connection.

Installing hydraulic cylinders in the system

To the li%ting and moving during installation o% the hydraulic cylinder into the system / machine$

the same rules apply as already described under



"Transport using li%ting gear".

78+uring installation into the machine / system remember that damage a the hydraulic cylinder

particularly at piston rods and mounting areas may reduce the %unctionality / standstill period.

289hen installing hydraulic cylinders and assemblies ith spherical or plain bearings$ you must

moreover ensure that hen installing the bolt$ the bolt and/ or the spherical or plain bearing is

not damaged ;i% necessary$ cool the bolt hen installing it8.

$ydraulically connecting the hydraulic cylinder

The hydraulic connection has to be established according to the speci%ications o% the hydraulic

diagram.

onnecting the electric supply

The electrical connection o% components that might already be available li5e end sitches or

position transducers must comply ith the speci%ication o% the electric circuit diagram.

. ommissioning

78 Ge%ore the installation$ clean the lines and all connection sur%aces %rom dirt$ scales$ chips$ etc.

3or that purpose$ use industrial residue%ree ipes. ,articularly elded pipes must be blan5 on

the inside and %lushed.

28 =bserve the installation instructions o% the %itting manu%acturer.

• 3ittings ith a so%t seal at the screin stud are recommended ;pipe thread = 22#7$

metric thread = 2678.



• ealants li5e hemp and 5it are not admissible as they may cause pollution and thus

mal%unctions.

• )ose lines must satis%y all applicable European and/or international standards.

:8 Chec5 the system %or tightness.

48 The connection lines should be dimensioned in accordance ith the per%ormance data in the

circuit diagram.

=illing hydraulic cylinders &ith hydraulic oil and "leeding them

The basic pollution o% the hydraulic %luid %illed in must not e&ceed the ma&imum Admissible

cleanliness class according to = 4406 ;c8 class 20/7#/7>. The cleanliness Classes speci%ied %or

the components ;li5e valves8 must be adhered to in )ydraulic systems. 3or %illing and bleeding

the hydraulic cylinders proceed as %ollos ;the starting point is a retracted hydraulic cylinder in

hori<ontal position8

1. ,rovide %or an easily readable circuit diagram o% the entire system.

%. The oil lea5ing during the bleeding process must be collected in a correspondingL container.

+. =pen the bleed scre on the piston rod side ;at the cylinder head8 o% the depressuri<edhydraulic cylinder ;see %olloing %igures8.

. % there is a threaded coupling$ you can bleed the hydraulic cylinder by connecting a

corresponding hose to the coupling ;the threaded coupling has an internal chec5 valve8.

/. et the hydraulic system so that the pressure at the hydraulic cylinder does not e&ceed appro&.

> bar.

0. itch the hydraulic system on.

. itch the control valves so that the hydraulic cylinder ants to retract at very lo velocities

;pressure at the piston rod side8. The annulus on the piston rod side o% the hydraulic cylinder is

no %illed ith oil and the e&isting air e&its via the bleed port or the threaded coupling.

2. As soon as the oil does not contain air any more$ i.e. it e&its %ree %rom bubblesK the hydraulic

accumulator has been su%%iciently bled. This is$ hoever$ only true i% the bleeding point is at the

highest point.

3. Then$ sitch o%% the hydraulic system and close the bleed scre.

14. A%ter bleeding the hydraulic %luid on the piston rod side o% the hydraulic cylinder$ bleed the

bottom side in the same ay.

11. A%terards$ the hydraulic cylinder is ready %or operation.

• !o only operate the hydraulic cylinder ith lo pressure until the hydraulic

ystem is completely bled.

•

=bserve the %luid level in the container and top up$ i% necessary.=illing and "leeding hydraulic cylinders &ith safety "leeding



=illing and "leeding hydraulic cylinders &ith safety "leeding

1. =pening cre out the bleeding bolt ma&imally to the stop$ to the sa%ety plug scre using a

he&agon rench.

%. 3illing 3ill the hydraulic cylinder ith oilK air and oil e&it.

+. Gleeding The air has been completely removed %rom the hydraulic cylinder i% the oil e&its

ithout bubbles.. Closing Tighten the bleeding bolt to the internal stop using a he&agon rench until no more

oil lea5s.

=illing and "leeding hydraulic cylinders &ith internal he)agon "leed scre&

=illing and "leeding hydraulic cylinders &ith internal he)agon "leed scre&1. =pening cre out the internal he&agon bleed scre hal% a rotation using a he&agon rench.



ithout bubbles.

. Closing cre in the internal he&agon bleed scre using a he&agon rench. Close it in an oil

tight %orm. =bserve the tor-ue(



=illing and "leeding hydraulic cylinders &ith chec ale

=illing and "leeding hydraulic cylinders &ith chec ale

1. =pening cre out the internal he&agon bleed scre at the chec5 valve hal% a rotation using a

he&agon rench.



ithout bubbles.

. Closing Close the internal he&agon bleed scre at the chec5 valve in an oil tight %orm using a

he&agon rench. =bserve the tor-ue(

=illing and "leeding hydraulic cylinders &ith threaded coupling

=illing and "leeding hydraulic cylinders &ith threaded coupling

1. Connect the pressure tapping hose cre o%% the end cap o% the threaded coupling and scre

the pressure tapping hose ith %itting onto the threaded coupling to the stop.

%. 3illing 3ill the hydraulic cylinder ith oil. Air and oil e&it and are discharged via the pressure

tapping hose.




ithout bubbles.

. Closing 9hen you scre o%% the pressure tapping hose$ the spring presses the valve poppet

bac5 onto its seat. cre the end cap o% the threaded coupling on again in order to protect the

device %rom dirt and damage.

Setting the end position cushioning

egarding the ad?ustable end position cushioning it has to be noted that the %ull cushioning

capacity can only be achieved hen the throttle valve is closed. n this connection$ you must

alays observe the in%ormation o% the valid data sheets. The in%ormation o% the data sheet is

speci%ied on the hydraulic cylinders name plate )ydraulic cylinders are supplied ith greatest

e%%ect o% the end position cushioning$ i.e. the throttling pin o% the throttle valves is screed to the

stop and closes the oil channel o% the ad?ustable end position cushioning. Gy unscreing the

throttling pin$ the velocity in the area o% the end position cushioning is increased. =bserve the

higher end stop velocity(

<d>usta"le end position cushioning &ith secured throttling pin

<d>usta"le end position cushioning &ith secured throttling pin

n order to change the %actory setting o% the end position cushioning$ scre out the throttling pin

using a he&agon rench until the desired cushioning behavior is achieved. +ue to the

securi<ation$ the throttling pin cannot be screed out o% the throttle valve completely.

<d>usta"le end position cushioning &ith loced throttling pin



<d>usta"le end position cushioning &ith loced throttling pin

78 Hoosen the throttle valve loc5 nut using a suitable tool ;ring or openend rench8 and scre

the throttling pin out using a he&agon rench until the desired cushioning behavior is achieved.

28 Then tighten the throttle valve loc5 nut. The throttling pin is positioned by tightening the loc5

nut.

=lushing the system 7 hydraulic cylinders

9hen %lushing the system$ the hydraulic cylinder must be separated %rom the system. 9hen

installing the hydraulic cylinder into the machine ;amending components$ line systems and

drives8$ it has to be ensured that the ma&imum admissible cleanliness class ;3illing hydraulic

cylinders ith hydraulic oil and bleeding them"8 %or the entire system is not e&ceeded. As many

di%%erent situations are imaginable due to di%%erent installation situations$ hydraulic %unctions o%

the hydraulic cylinder or the hydraulic system options$ please observe "3illing hydraulic

cylinders ith oil and bleeding them".

?e-commissioning after e)tended standstill

78 n the recommissioning$ observe the commissioning instructions ;Commissioning"8.

2. *peration

n%ormation on operating the hydraulic cylinder can only be provided in connection ith the

machine or system.

78 3or this in%ormation$ please re%er to the operating instructions o% the machine manu%acturer.

=perating parameters %unction and logics o% the hydraulic cylinder are available to hydraulic



e&perts in the relevant valid data sheets and the relevant valid productspeci%ic documentation

;"Technical data"8.

3. (aintenance and repair

According to +! :70>7$ maintenance means all measures %or maintaining and restoring as ell

as %or determining and evaluating the actual condition o% technical systems.

The tas5s are divided into three partial areas

• *aintenance *easures %or maintaining the target condition



• nspection *easures %or determining and evaluating the actual condition

• epair *easures %or restoring the target condition

+ue to these measures$ the %unctionality o% the hydraulic system and the hydraulic cylinders can

be ensured. 3luid poer systems systems and 3luid poer systems cylinders have the structural

prere-uisites %or high %unctionality ;operational sa%ety$ service li%e8. They only re-uire little

maintenance or5. The latter is$ hoever$ indispensable in order to ensure %unctionality.

E&perience has shon that @0 I o% the mal%unctions and damage in hydraulic systems and

hydraulic cylinders are indirectly caused by the hydraulic %luids. Conse-uently$ the primary

inspection and maintenance tas5 is the e&amination and completion o% measures to maintain the

%unctionality ;condition$ cleanliness class8 o% the hydraulic %luid. Ensure that no lubricants enter

the hydraulic circuit.

leaning and care 6maintenance8

78 Ensure absolute cleanliness in all or5s.

28 Ge%ore loosening %ittings and components$ clean the e&ternal environment using industrial

residue%ree ipes.:8 Cover all openings ith protective caps in order to prevent dirt %rom penetrating the system.

Inspection

3luid poer systems recommends documenting the inspection results

78 o that considering %unctionality and economy$ the inspection and maintenance intervals can

be ad?usted to the actual operating conditions.

28 o that by comparing the documented values$ you can identi%y %aults at an early point in time.

(aintenance schedule

78 3or the scope and time intervals o% maintenance and inspection or5s$ please re%er to the

system manu%acturerBs maintenance schedule.

(aintenance

!ormally$ hydraulic cylinders are almost maintenance%ree a%ter the commissioning. A%ter a ne

system has been commissioned$ regular chec5s are necessary in order to determine hether the

hydraulic cylinder %unctions per%ectly. +uring these chec5s$ you must particularly atch out %or

the %olloing

7. ,ossible oil lea5s at the oil ports

2. Chec5 ith regard to "rubbing mar5s" or mechanical damage at the sur%ace o% the stro5e

related piston rod running sur%aces. ubbing mar5s may be an indication o% a polluted

hydraulic system or o% inadmissible traverse loads on the hydraulic cylinder.

:. +amage to the coatings

4. ,ossible lea5age at the cylinder head or cylinder bottom>. E&treme temperatures and pollution shorten the hydraulic cylinders service li%e.

6. 'ou should there%ore provide %or regular maintenance o% the entire hydraulic system. 3or

re%erence to the speci%ic re-uirements o% the hydraulic cylinder on the operating and

ambient temperatures as ell as the oil cleanliness please re%er to the corresponding data

sheet ;see Technical data"8. 3or possible additional re-uirements$ please re%er to the



installation and maintenance instructions o% the hydraulic system and the data sheets o%

the hydraulic %luids used.

@. The replacement intervals %or ear parts li5e e.g. seals$ guide sleeves and guide rings

depend on the relevant application$ the operating conditions$ temperatures$ etc. and on the

medium -uality. !o %i&ed time has been determined %or the e&change o% these ears

parts.#. Hea5age in the area o% the piston rod and the cylinder head is an indication o% the

necessity to e&change the ear parts.

. According to the operating re-uirements$ the lubrication intervals %or sel% aligning clevis$

trunnion$ etc. must already be determined in the pro?ect planning o% the hydraulic

cylinder. The lubrication intervals are contained in the system manu%acturerBs

maintenance schedule.

?is of ignition &ith hydraulic cylinders &ith #@ maring due to insufficient maintenance

or repair!

+anger to li%e( is5 o% in?ury(

7. Chec5 regularly that the dust layer thic5ness o% dust accumulations on the hydraulic

cylinder stays belo > mm or is regularly removed so that there is no ris5 o% ignition in

the e&plosive area.2. Chec5 regularly that the e-uipotential bonding at the hydraulic cylinder remains

%unctional and connected at all timesK otherise$ there is a ris5 o% ignition due to

electrostatic charging.

:. Chec5 a%ter repair and maintenance or5s that the e-uipotential bonding at the hydraulic

cylinder is connected be%ore operation in e&plosive areas

Piston rod maintenance

n order to prevent corrosion at the piston rod$ the piston rod should alays be retracted during

standstill times. 9hen using hydraulic %luids in hydraulic cylinders li5e e.g. )3+ ;phosphoric

acid ester8$ )3A ;oilater emulsion8 or )3C ;ater glycol8$ the %olloing or5s have to be

completed ithin the scope o% the maintenance

78 The piston rod must alays be covered by a protective oil %ilm. Ensure compatibility o% the

medium used.

28 n areas ith high humidity or strongly %luctuating conditions ;e.g. temperature %luctuations or

outdoor installation8$ chec5 the protective oil %ilm every ee5. n areas ith moderate

conditions$ the protective oil %ilm can be chec5ed every month. The protective oil %ilm is

necessary in order to guarantee corrosion protection o% the e&posed piston rod. n this

connection$ the %olloing preventative maintenance is to be completedPreentatie piston rod

(aintenance

1. % possible$ the preventative maintenance or5 should be completed in a dry environment.

• sing %resh ater loosen and remove all salt$ sand and machining residues as ell other

pollution %rom the piston rod.

• +o not use steam cleaners or highpressure ater ?ets.



%. The preventative maintenance can only be completed ith a clean and dry piston rod. % there

is not su%%icient time in order to let the piston rod dry completely$ let it dry as long as possible

be%ore the maintenance. epeat the maintenance as long as you have su%%icient time.

+. oa5 an industrial residue%ree ipe ith protection oil o% lo viscosity. sing the cloth$ apply

the protection oil to the entire piston rod.

Immediate maintenance for hydraulic cylinders and piston rods after contact &ith

chemicals

A%ter contact ith chemicals$ an immediate maintenance cycle has to be completed as %ast as

possible. The immediate maintenance comprises the %olloing or5s

1. Hoosen and remove all chemical residues using a suitable cleaning agent.

%. ,er%orm the or5 steps o% the preventative maintenance.

(aintenance freAuency

The preventative maintenance described here should be completed be%ore the %irst

commissioning o% the hydraulic cylinder or a%ter standstill times.

?eplacing &ear partsn case o% -uestions or doubt$ please contact 3luid poer systems =pening the hydraulic cylinder

ill invalidate the arranty claim.

?epair

3luid poer systems o%%ers a ide range o% repair services %or your hydraulic cylinder. ,lease

send any en-uiry to your nearest 3luid poer systems service center or directly contact the

head-uarters.

Spare parts

(alfunction of the machine due to the use of incorrect spare parts!

+amage to property(

7. =nly use components listed in the productspeci%ic documentation ;parts list8.2. =nly use ne seals ith the re-uired resistance to media.

:. As the sealing material may di%%er despite being o% identical appearance$ the *aterial

number should be chec5ed. n case o% -uestions or doubt$ please contact 3luid poer

systems

4. ,lease provide the %olloing in%ormation hen ordering spare parts

• *aterial number and order number o% the hydraulic cylinder ;name plate8

• tem number o% the relevant component according to the parts list.

11. 'ecommissioning

Preparing for decommissioning

$igh operating pressure in the hydraulic cylinder and in the system!

is5 o% in?ury or damage to property caused by parts %lying around or oil lea5age during

operation(



• itch o%% all %orcetransmitting components and ports ;electric$ pneumatic$ hydraulic8

according to the manu%acturerBs instructions and secure them against restarting. %

possible$ remove the main %use o% the system.

• +epressuri<e accumulators that might e&ist on the oil side.

• nload the hydraulic cylinder %rom e&ternal %orces.

9hen decommissioning and removing the hydraulic cylinder %rom the hydraulic system$ the

%olloing must be observed

1. 3or sa%ety reasons$ you must not loosen any lines$ connections and components as long as the

system is under pressure. Hoer loads in advance$ unload the pressure accumulator$ sitch o%%

pumps and secure the system against reactivation.

%. 'ou must provide collecting tan5s that are large enough to accommodate the total oil volume.

'ecommissioning the hydraulic cylinder

78 +rain the oil into the collecting tan5 provided.

28 n this connection$ ensure complete draining o% the lines and actuators.

:8 % necessary$ carry out bleeding measures.Preparing disassem"ly

Ge%ore starting the or5s at the hydraulic cylinder$ ta5e the %olloing measures

78 ,rovide %or an easily readable assembly draing / spare parts list.

28 ,rovide %or clean$ pro%essional tools and a clean or5place.

:8 +ue to the tolerances hen li%ting the hydraulic cylinder$ anticipate a eight o% the

hydraulic cylinder e&ceeding the one speci%ied in the draing or in the data sheets by 70 I.

48 +uring the removal o% the hydraulic cylinder$ no dirt must penetrate the hydraulic system.

eal the connection points using steel plugs$ %lange covers or special plastic plugs suitable %or

that purpose.

>8 *a5e sure that the hydraulic cylinder and particularly the piston rod are not damaged.

68 se a stable support %or putting don the hydraulic cylinder and the removed parts.

'isassem"ling the hydraulic cylinder

To the li%ting and moving during removal o% the hydraulic cylinder %rom the system/ machine$

the same rules apply as already described under "Transporting hydraulic cylinders".

Preparing the hydraulic cylinder for storage7

=urther use

• 3or storing the hydraulic cylinder %or later reuse$ complete the necessary teps according

to toring hydraulic cylinder1.

11. 'isassem"ly and e)change

Preparing disassem"ly

Ge%ore starting the disassembly o% the hydraulic cylinder$ the general conditions according to

+ecommissioning" have to be met. ,rovide %or good preparation. n order %or the hydraulic

cylinder spare parts to be e&changed$ the cylinder has to be disassembled.

'isassem"ling the hydraulic cylinder



3or disassembly$ you should proceed as %ollos

78 +rain the hydraulic %luid %rom the hydraulic cylinder that is still installed to the largest

possible e&tent. The hydraulic cylinder can be completely drained as soon as it has been

removed.

28 +isassemble the cylinder head.

• ,ull the cylinder head o%% the pipe and drain the remaining hydraulic %luid %rom the pipe.

• Then pull the piston rod out o% the hydraulic cylinder using li%ting strings$ i% necessary.

• ,ut the piston rod on especially prepared bloc5s preventing the piston rod %rom rolling

aay ;ooden bloc5s$ prismshaped s-uared timber or bloc5s ith so%t$ rotating support$

ithout pollution8.

:8 % necessary$ remove the loc5ing device beteen cylinder eye and piston rod and plug the

rench into the provided bore or area. ,ut a li%ting sling around the cylinder eye so that it gets

caught hen it is loosened %rom the piston rod. !o rotate the piston rod using the rench until

the cylinder eye loosens %rom the piston rod.

48 %asten the li%ting slings at the cylinder head and sloly push it o%% the piston rod ;i% it isdi%%icult to push the cylinder head on the piston rod$ you must rotate he latter sloly8.

>8 emove the seals and clean the cylinder head care%ully using a degreasing agent ;%rom old

glue residues$ dust particles$ etc.8. Also clean the piston rod care%ully as any dirt particle may

damage the seal during the assembly. +o not %orget to clean the piston rod thread$ the cylinder

eyes and the protective cover.

#)changing components

n case o% -uestions or doubt$ please contact 3luid poer systems pvt.ltd

1%. 'isposal

• +ispose o% the individual materials according to the legal provisions.

,articular attention is necessary hen disposing o% components ith hydraulic %luid

residues.

• =bserve the disposal in%ormation in the hydraulic %luid sa%ety data sheet.



• 9hen disposing o% electric and electronic components ;e.g. position measurement

systems$ pro&imity sitches8 comply ith the countryspeci%ic legal

• ,rovisions and regulations.

#nironmental protection

Careless disposal o% the hydraulic cylinder$ its components and the oil can lead to environmental

pollution. ,lease observe the %olloing points

• +ispose o% the product/components in accordance ith the national regulations in your

country and/or your companyinternal speci%ications.

• +ispose o% oil according to the legal provisions and moreover observing the sa%ety data

sheet o% the hydraulic medium used.

1+. #)tension and conersion

'ou ill be considered responsible %or any e&tensions to or conversions o% the product. % you

underta5e any e&tensions to or conversions o% the product mar5eted by 3luid poer systems$ this

means you are changing the condition o% the product as supplied. Any statements made by 3luid

poer systems regarding this product ill then become invalid.



,lease send any -ueries you may have to the head-uarters. 3or the addresses$ please re%er to

.%luidpoersystems.com.

1. 5rou"leshooting

$o& to proceed for trou"leshooting

Troubleshooting is primarily the e&change o% the de%ective components. =nly replace the

components mentioned in the parts list ;spare parts list8 by ne$ interchangeable and tested

components in original e-uipment -uality. egarding the repair o% the de%ective hydraulic

http://www.fluidpowersystems.com/




cylinder$ please contact directly the head-uarters. 3or the addresses$ please re%er to

.%luidpoersystems.com. A%ter remedy o% the actual damage$ you should imperatively

remove the causes and/or conse-uential damage as ell. A%ter a component %ailure caused by

ear$ you must %or e&ample %lush the system and clean and/or change the oil.



Hydrailic Cylinder Document

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