cilindros hidráulicos aros
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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
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General Operating and Assembly Instructions for Hydraulic Cylinders
3/26 AROS Hydraulik GmbH BA0001 Issue Nov. 2012
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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General Operating and Assembly Instructions for Hydraulic Cylinders
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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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General Operating and Assembly Instructions for Hydraulic Cylinders
5/26 AROS Hydraulik GmbH BA0001 Issue Nov. 2012
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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6/26 AROS Hydraulik GmbH BA0001 Issue Nov. 2012
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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General Operating and Assembly Instructions for Hydraulic Cylinders
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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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General Operating and Assembly Instructions for Hydraulic Cylinders
8/26 AROS Hydraulik GmbH BA0001 Issue Nov. 2012
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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General Operating and Assembly Instructions for Hydraulic Cylinders
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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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General Operating and Assembly Instructions for Hydraulic Cylinders
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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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General Operating and Assembly Instructions for Hydraulic Cylinders
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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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General Operating and Assembly Instructions for Hydraulic Cylinders
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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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General Operating and Assembly Instructions for Hydraulic Cylinders
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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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General Operating and Assembly Instructions for Hydraulic Cylinders
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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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15/26 AROS Hydraulik GmbH BA0001 Issue Nov. 2012
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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General Operating and Assembly Instructions for Hydraulic Cylinders
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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
BA0001 Issue Nov. 2012
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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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General Operating and Assembly Instructions for Hydraulic Cylinders
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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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General Operating and Assembly Instructions for Hydraulic Cylinders
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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: info@aros-hydraulik.de
Internet: www.aros-hydraulik.de
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