Cat Electric Rope Shovel 495HF Hydraulic Crowd cylinder Instruction manual - PDF DOWNLOAD

BI619638

Bosch Rexroth B.V. ABS Hydro Cylinders

Instruction manual pertaining to the hydraulic cylinder for

Client : Bucyrus Project : 495HF Hydraulic Crowd Description : Crowd cylinder

Engineering Department Bosch Rexroth B.V. ABS Hydro Cylinders PO Box 32 5280 AA Boxtel The Netherlands

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1 CONTENTS

1

Contents ................................................................................................................................. 2

2 2.1 2.2 2.3

General information ................................................................................................................ 3 Explanation of symbols used.................................................................................................. 3 Bosch Rexroth B.V. ................................................................................................................ 4 Correspondence ..................................................................................................................... 4

3 3.1 3.2

Description of the cylinder ...................................................................................................... 6 Technical specification ........................................................................................................... 6 General description of the hydraulic cylinder.......................................................................... 6

4 4.1 4.2 4.3 4.4

Storage and handling ........................................................................................................... 10 Storage conditions................................................................................................................ 10 Short-term storage................................................................................................................ 10 Long-term storage ................................................................................................................ 10 Handling ............................................................................................................................... 11

5 5.1 5.2 5.3 5.4 5.5

Use of the cylinder................................................................................................................ 12 The installation of the cylinder in the construction................................................................ 12 Putting into operation............................................................................................................ 12 Periodic maintenance on the cylinder................................................................................... 14 Maintenance procedure cylinder rods .................................................................................. 15 Pre-stressing of the chevron type rod seals ......................................................................... 16

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2 GENERAL INFORMATION This document is intended as an aid to the installation, putting into operation, maintenance or repair of the hydraulic cylinder supplied by Bosch Rexroth B.V. Before starting work on the cylinder, the relevant sections of this instruction manual must be properly studied. The result of installation, maintenance and repair depends primarily on training, experience and good craftsmanship on the part of the personnel performing the work.

The fitting and removal of cylinders is specialized work that can only be properly carried out by qualified and experienced personnel. In the event of questions or doubts arising, always contact the Bosch Rexroth service organisation or your supplier.

The publisher of this instruction manual accepts no liability for damage, in any form whatsoever, arising as a result of incorrectly performed installation, putting into use, maintenance or repair.

2.1

EXPLANATION OF SYMBOLS USED

In this instruction manual the following symbols are used to illustrate particular instructions:

Provides the user with tips and advice by means of which certain tasks can be more simply carried out.

Tip!

Warns the user against the possibility of causing damage to the cylinder, components of the cylinder or to the environment if tasks are not carefully carried out.

Warning!

Warns the user against possible danger to personnel if tasks are not carried out with extreme care.

Danger!

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2.2

BOSCH REXROTH B.V.

Bosch Rexroth B.V. is part of the Bosch Rexroth group and specializes in the design, production and sale of special hydraulic cylinders, accumulators and pressure vessels. Bosch Rexroth B.V. occupies a leading position in the world market for large and specialized hydraulic cylinders. In addition to producing cylinders for special purposes and to designing cylinders to satisfy the special needs of clients, a wide variety of standard cylinders can also be supplied. Bosch Rexroth B.V. is ISO9001 certified.

2.2.1 ABS CYLINDERS The design of a hydraulic cylinder is the result of decades of intensive development and experience. This experience makes it possible for Bosch Rexroth B.V. to make optimum designs that satisfy the requirements that are determined by each specific application.

Only after a new or improved concept of the Hydraudyne Project Cylinder (HPC) has been proven in practice, is it raised to the level of application-based standard. in accordance with this concept, such cylinders are then given the designation ABS - (Application Based Standard) cylinder.

ABS cylinders are designed and produced by Bosch Rexroth B.V. in Boxtel, The Netherlands, for the world market. ABS cylinders are employed in the following main sectors: • Heavy Industry • Offshore, Marine & Dredging • Civil Engineering • Mining & Material Handling • Industry, Presses • Servo / simulation

2.2.2 STANDARD CYLINDERS For general industrial use, the following standard series of Hydraudyne cylinders from the Bosch Rexroth range, such as the CDL1, CDM1, CDH1, CDH2 and CDH3 can be supplied.

2.3

CORRESPONDENCE

All correspondence concerning the functioning of the cylinder and events occurring during the guarantee period can, quoting the relevant Bosch Rexroth order and partial order number, be directed to: Bosch Rexroth B.V. Customer Service Department PO Box 32 5280 AA Boxtel The Netherlands Tel : +31 - (0)411 - 651 951 Fax : +31 - (0)411 - 674 125 Orders for spare parts or requests for repair must be directed to: Basic doc.: Instr_en_301_bc2.doc Rev. 3.01, Juni 2007

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Bosch Rexroth Services B.V. PO Box 32 5280 AA Boxtel The Netherlands Tel : +31 - (0)411 - 651 951 Fax : +31 - (0)411 - 682 860 Orders for spare parts must include the following details: • Bosch Rexroth B.V. order and part order number • Name or description of the part • Drawing number of the assembly drawing • Position number of the part For example: - / 0001, O-ring, 3-, Pos. 1850 With the exception of the position numbers, all details can also be found on the text plate attached to the cylinder. The order and part order numbers are also stamped close to the oil connection at the rod end.

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3 DESCRIPTION OF THE CYLINDER This section provides an overview of the technical specifications applicable to the cylinder, as laid stated the title block of the assembly drawing (see appendix). A general description of the main components of the cylinder is also included.

Whenever the term cylinder is used this must be taken to mean a hydraulic cylinder, and whenever oil is referred to, this is intended to mean the hydraulic medium.

3.1

TECHNICAL SPECIFICATION

Rexroth type coding

: CY TOO MP5 /0360 /0250/06198 A10/DX QLDT WAN

Function Bore Rod diameter Stroke

: : : :

Design pressure bottom side Dynamic pressure bottom side Test pressure bottom side

: 27 MPa : 27 MPa : 38.5 MPa

rod side rod side rod side

: : :

32 MPa 20.1 MPa 45 MPa

Max. pushing force Max. speed “out” Max. speed “in”

: 1325 kN : 635 mm/sec : 0 mm/sec

Max. pulling force Min. speed “out” Min. speed “in”

: : :

1686 kN 663mm/sec 0 mm/sec

Hydraulic medium Required degree of cleanliness Frequency of movement

: Mineral oil : class 8 in accordance with NAS 1638 : unknown

Fitting position Design temperature Lateral forces

: -15 to 90° to horizontal : -18 to +55° Celsius : 2x gravity

Bore surface finish Rod surface coating

: Honed : C.E.C. 2.0

Drawing number assembly Weight excluding oil

: 3-136460 : 9451 kg

3.2

Double-acting cylinder (Regenerative) 360 mm 250 mm 6198 mm

GENERAL DESCRIPTION OF THE HYDRAULIC CYLINDER

In a cylinder, hydraulic energy is converted into longitudinal movement in order to drive a mechanism. The driving force is determined by the pressure in the cylinder compartments and the diameters of the bore and the rod.

The cylinder consists of the following essential components: • Piston rod Basic doc.: Instr_en_301_bc2.doc Rev. 3.01, Juni 2007

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• • • • • •

Piston Cylinder head Cylinder cover Bottom External mountings Seals

The functionality of a number of these components can be combined in one single component.

3.2.1 PISTON ROD The cylinder piston rod is made of carbon steel and is provided with a surface coating to improve the running characteristics and to prevent corrosion. The type of surface finish applied to the rod determines to a great extent the corrosion resistance of the piston rod.

In determining the diameter, a number of aspects are taken into account in the design. These aspects are: • The resistance to bending, based on the design force and on any transverse forces or frictional moments from spherical bearings • Stresses occurring as a result of the applied pressure and tensile force • Geometric requirements relating to the mounting of the piston and the attachment to the driven construction Since the seals in the cylinder head seal against the surface of the rod, it is of great importance that the rod surface is treated with the greatest possible care. Damage to the surface of the rod can lead to corrosion of the basic material and to damage to the seals, resulting in a reduced sealing efficiency.

3.2.2 PISTON By means of guides, the piston ensures that the piston rod moves concentrically with respect to the cylinder shell. Pistons mostly come in a form of construction whereby they are screwed onto the piston rod.

With both double-acting and single-acting cylinders, the piston also provides for the separation between the two compartments of the cylinder; the bottom end and the rod end. Since the piston provides directly for the generation of the cylinder force in one or both directions, it is important that a pressure difference is built up over the piston. The gap between the piston and the cylinder shell that is required to allow the piston to move is fitted with a seal, as is the narrow gap in the extension of the mounting thread.

3.2.3 CYLINDER HEAD The cylinder head combines a large number functions within one or two components, such as the guide for the piston rod, the sealing of the cylinder and the exclusion of dirt. The head is usually bolted or screwed to the cylinder shell and is designed to resist the internal pressure of the cylinder. During the outward movement of the cylinder, the piston can come into contact with the Basic doc.: Instr_en_301_bc2.doc Rev. 3.01, Juni 2007

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head. In that event, the cylinder head takes up the force exerted by the cylinder and any external load.

In addition, the cylinder head can be provided with the following facilities: • Oil connection • CIMS Mk II movement measuring system (Ceramax Integrated Measuring System) • Under-water seals • Cushioning • Valve block / connecting pipework • External mounting

3.2.4 CYLINDER SHELL The cylinder shell is manufactured from steel tube and is designed to withstand the pressure and the bending moments to which it will be subjected. The internal pressure will cause the tube to expand, which results in an enlargement of the gap in the area of the piston seal. The wall thickness of the cylinder shell is such that the enlargement of the gap remains within the predetermined limits required for the proper functioning of the bearings and the sealing of the piston.

The cylinder shell is always provided with two oil drainage points and two bleed points. These are used when the cylinder is put into or taken out of service.

3.2.5 BOTTOM The bottom forms the end cover of the cylinder and is designed to resist the internal pressure and the forces generated by the cylinder by transferring them to any external mounting present. The bottom is manufactured from carbon steel and is bolted or welded to the cylinder shell using a special procedure.

The cylinder bottom can also be provided with the following facilities: • Oil connection • Cushioning • Valve block • External mounting

3.2.6 EXTERNAL FIXINGS In order to incorporate the cylinder into the construction, at least two mechanical interfaces must be present, by means of which the forces generated can be applied to the driven part of the construction. Both interfaces are designed to withstand the maximum applied forces.

In situations in which the cylinder must drive a rotating construction, or in situations in which small alignment errors are to be expected, eyes fitted with spherical bearings are usually employed.

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3.2.7 SEALS Within the cylinder, two functionally different seals are employed: • Static seals, fitted between two parts that do not move with respect to each other, such as the seal between the piston and the piston rod. In general, these seals are of the O-ring type.

• Dynamic seals are used between two parts that move with respect to each other, such as between the piston rod and the cylinder head and between the piston and the cylinder shell.

3.2.8 GUIDES / BEARINGS The guides in the cylinder head and the guides for the piston ensure the concentric movement of the piston rod with respect to the cylinder shell. Any transverse forces or loads resulting from the weight of the cylinder itself will be transferred by the guides from the piston rod to the cylinder shell and vice versa.

Transverse forces that have not been taken into account in the design can lead to a shortened life for the guides.

Warning!

In hydraulic cylinders, three types of guide can be used, each having specific characteristics with respect to the permitted surface pressure, dry running characteristics and wear resistance. The guides are characterised particularly by the material used in their construction: • bronze bearing bushes • bearing strips from: • Luytex • PTFE / Bronze

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4 STORAGE AND HANDLING For the storage of a hydraulic cylinder, a distinction is made between short-term and long-term storage.

Short-term storage is to be understood as a storage for a maximum period of three months after delivery of the cylinder; all other cases can be said to involve long-term storage.

4.1

STORAGE CONDITIONS

The cylinder must be protected against the direct influence of the weather and be stored in dry and well-ventilated conditions. Condensation must be prevented, as well as the presence of corrosive vapours.

The part of the piston rod that extends beyond the cylinder casing must be protected against corrosion by packing the rod in Densoband, covered with Branorost paper to prevent the loss of grease at higher temperatures. Subsequently, the piston rod must be packed in Lamiflex to protect it against mechanical damage.

4.2

SHORT-TERM STORAGE

For short-term storage, that is for a period not exceeding three months, no special measures are necessary. Nevertheless, the general storage conditions as specified in § 4.1 must be observed.

4.3

LONG-TERM STORAGE

For long-term storage, the general storage conditions must be observed (see § 4.1). In addition, the cylinder must be provided internally with a corrosion-preventing medium. This medium must be compatible with the seals used and the hydraulic medium to be used in the hydraulic system in which the cylinder will be employed.

The cylinder must be filled with the hydraulic medium for 80 % of its volume. As a minimum requirement, the cleanliness of the medium must satisfy class 8 in accordance with NAS 1638. If mineral oil is used, Shell VSI concentrate 8235 must be added in a quantity amounting to 2% of the oil volume. For all other media, the supplier must be consulted as to the choice of, and the necessity for using, a Vapour Space Inhibitor. For Erifon 818, manufactured by Marston Bentley Ltd., no further addition is necessary.

Unprotected parts, such as fitting surfaces or mechanical interfaces, must be protected with Tectyl Valvoline 894.

The oil connection points must be sealed using a good quality steel screwed plug with a seal or steel flanges fitted with an O-ring.

Spherical bearings and other types of bearings must be protected with Densoband and thereafter be packed in plastic to protect them against damp.

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A bronze ice scraper may be mounted separately on the rod. The fixing bolts will be packed separately with the items delivered.

4.3.1 REQUIREMENTS FOR OPTIMUM CONDITION In order to maintain the cylinder in an optimum condition during the storage period, the following requirements must be fulfilled: The cylinder must undergo a thorough annual inspection. During this, the following must be taken into account: • Preservation; Inspection for damage and corrosion • Hydraulic medium; Check on oxidation or acidification • Inspection and greasing of non-maintenance-free spherical bearings In addition, the cylinder must be subjected to an in and out movement over several tens of millimetres to prevent the seals from sticking.

Depending on the findings, corrective action must be carried out.

4.3.2 VERIFICATION OF USABILITY If a cylinder remains in storage for longer than a year or if it is not possible in practice to satisfy the storage conditions specified in the foregoing paragraph, then before the cylinder is taken into service, it must be subjected to a thorough inspection and its usability must be confirmed by means of a functional test.

This functional test must consist of: the application of pressure to the cylinder (approximately 30 Bar) for a period of 10 minutes to establish whether there is any internal or external leakage and the hydraulic in and out movements of the cylinder The test procedure need not be repeated if a further functional test has been performed within one year of the cylinder actually being put into service. A condition for this is that on the basis of the findings, any required corrective action has been carried out.

4.4

HANDLING

For the transportation and lifting of the cylinder the following instructions must be followed: The cylinder must be transported in a horizontal position, resting on wooden blocks or, if possible, in the original packaging.

Use a soft hoisting sling to avoid damage to the preservation. The use of chains and bow shackles is only permitted if use is made of the lifting lugs fitted to the cylinder.

Provide for a stable set-up of the lifting arrangements and the slings. If necessary, use an equalizer. The centre of gravity of the cylinder can be determined experimentally.

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5 USE OF THE CYLINDER This section describes the installation, taking into service and maintenance of the hydraulic cylinder in all relevant facets. Before taking the cylinder into use, a check must be made to determine whether the cylinder has been kept in storage and whether it is directly usable. See chapter 4 ‘Storage and handling’ for more details.

5.1

THE INSTALLATION OF THE CYLINDER IN THE CONSTRUCTION

When the cylinder is installed, the following points must be taken into account: • Make as much use as possible of the available lifting points. Loads may only be applied to lifting lugs; transverse loading of the lifting lugs is not permitted. If there are no lifting points present, use must be made of wide hoisting slings capable of supporting the load.

• Use reliable hoisting facilities. Take account of the great weight of the cylinder and the separate components.

• Because of the tolerances on the outside diameter of the cylinder shell, account must be taken, when lifting it, of a weight for the cylinder assembly that is approximately 10% greater than that stated on the drawing.

• During disassembly and assembly, no dirt must be permitted to enter the hydraulic system. The connection points must be sealed in a reliable manner using steel plugs, sealing flanges or special plastic stoppers, suitable for the purpose.

• Care must always be taken to ensure that the cylinder, and in particular the piston rod, does not become damaged.

The cylinder must be installed so that it is free of stress and completely aligned to ensure that the bearings are not unnecessarily loaded. High stresses can shorten the life of the bearings.

The pipework or the hoses that are connected to the cylinder must also be mounted without stress.

Before the pipework is connected it must be carefully cleaned and must be filled and bled before the cylinder is mounted (see also § 5.2.1.).

After installation, any damage to the preservation materials must be repaired as quickly as possible in accordance with the specification listed in the title block of the drawing.

5.2

PUTTING INTO OPERATION

The hydraulic system must be filled with the correct hydraulic medium, making use of a suitable filter. As a minimum requirement, the cleanliness of the medium must satisfy class 8 in accordance with NAS 1638. Any VSI concentrate still present is compatible with the hydraulic medium and need not be removed.

After it has been determined that the system has been filled with the correct hydraulic medium and the cylinder has been installed in the construction in the correct manner, the cylinder can be put into operation.

5.2.1 LEAK OIL CONNECTIONS

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Hydraulic cylinders may be equipped with one or more leak oil connection points. The intention of these ports is to prevent pressure build up in between seals. The port can also serve as a condition monitoring of the seal system. When putting the cylinder into operation, the transport plug is to be removed from this port and the leak oil connection port is to be lead to a pressure less tank. This tank does not necessarily have to be the tank of the hydraulic system. Any tank that will not build up pressure will do. The tank has to be emptied from time to time. The interval for emptying is depending on the application of the cylinder and can not be predicted.

5.2.2 FILLING AND BLEEDING THE CYLINDER Since air is highly compressible, any air remaining in the cylinder will influence its operation. To guarantee satisfactory operation of the cylinder, it must be completely filled and bled.

An unfilled or poorly filled cylinder can cause dangerous situations to occur!

Danger!

Since a great many situations can be conceived as a result of differences in installation situations, the hydraulic operation of the cylinder or the possibilities provided by the hydraulic system, a general instruction is included here for filling and bleeding the hydraulic cylinder.

If you have any doubts concerning the manner in which your cylinder must be filled and bled, contact Bosch Rexroth B.V. or your supplier.

Tip!

The cylinder must be filled and bled in the following manner (starting from the situation in which the cylinder is fully retracted and is horizontal): • Ensure that you have a readable hydraulic circuit diagram for the whole installation. Filling and bleeding the cylinder is specialised work that can only be properly carried out by qualified and experienced personnel.

• Remove the bleed plug at the rod end of the un-pressurized cylinder. If the cylinder is correctly mounted, the bleed plug will be at the upper side of the cylinder. If a minimess coupling is present, the cylinder can be bled through a minimess hose connected to the coupling (the minimess coupling is provided internally with a non-return valve).

• Adjust the hydraulic system such that the pressure on the cylinder remains limited to approximately 5 Bar (0.5 MPa).

• Start up the hydraulic system.

• Adjust the control valves such that the cylinder moves in at a very low speed (pressure on the rod end). The rod end of the cylinder will now be filled with oil and any air present will be expelled via the bleed connection or the minimess coupling.

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• •

After a time, foaming oil will be expelled in stead of air. At the moment that the oil contains no more air, and thus ceases to foam, the cylinder is sufficiently bled. Note: this applies only if the bleed point is at the highest point.

Now shut down the hydraulic system and insert the bleed plug.

Never remove hoses, couplings or components from a system or an cylinder under pressure!

Danger!

After bleeding the compartment at the rod end of the cylinder, the other end must be bled in a comparable manner: • Remove the bleed plug on underside of the un-pressurized cylinder or attach a minimess hose to any minimess coupling present.

• Start up the hydraulic system.

• Adjust the control valves such that the cylinder moves out at a very low speed (pressure on the underside). The underside of the cylinder will now be filled with oil and any air will be expelled via the bleed connection or the minimess coupling.

• After a time, foaming oil will be expelled in stead of air. At the moment that the oil contains no more air, and thus ceases to foam, the cylinder is sufficiently bled. Note: this applies only if the bleed point is at the highest point.

• Shut down the hydraulic system and insert the bleed plug.

• The cylinder is now ready for use.

Use only approved hoses and couplings, suitable for the maximum applied pressure! Ensure good connections!

Danger!

5.3

PERIODIC MAINTENANCE ON THE CYLINDER

Normally, a hydraulic cylinder requires little or no maintenance. After a new system has been taken into operation, periodic checks must be carried out to determine that the cylinder is functioning correctly. During these checks, special attention must be paid to: • Possible leakage at the position of the oil connections • Checks for ‘running tracks’ or damage to the rod. Running tracks can be an indication of a contaminated hydraulic system.

• Damage to the preservation materials • Possible leakage around the cylinder head

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Extreme temperatures and contamination will shorten the life of the hydraulic system. Provide for good periodic maintenance of the total hydraulic system. See § 3.1. ‘Technical specification’ for the specific requirements applicable to the hydraulic cylinder with regard to temperature and oil cleanliness. Consult the installation and maintenance specifications for the hydraulic system and the specifications for the hydraulic medium for any additional requirements.

5.4

MAINTENANCE PROCEDURE CYLINDER RODS

This chapter describes the maintenance procedure for cylinder rods of hydraulic cylinders operating on water-glycol hydraulic fluids.

General It is required to lubricate the cylinder rod and to determine a specific schedule to keep the exposed rod lubricated. (Reference is made to the operating procedures of the American Petroleum Institute, API recommended practice, RP 16Q, section 4.6). Protective oil is required to enhance the corrosion protection of exposed cylinder rod according following preventive maintenance procedure.

Silicon Oil Specification: GE Silicones SF96, 50 cSt at 20 oC or an equivalent silicon oil type.

Preventive maintenance procedure The preventive maintenance should preferably be performed under dry circumstances.

Use a fresh water hose and brush to dilute and remove all salt, sand, drilling mud and other dirt from the cylinder rod. Do not use a steam cleaner or high-pressure water jet.

1. Dry the cylinder rod or let it dry. It is important to perform the preventive maintenance to a clean and dry rod. If the time frame is too short to achieve a completely dry cylinder rod, then perform the maintenance after a maximum available time span and repeat maintenance as soon as sufficient time is available.

2. Saturate a clean cloth with low-viscosity silicon oil. Apply the silicon oil to the entire cylinder rod by means of the cloth.

Preventive maintenance procedure using an automatic lubrication system 1. The preventive maintenance should preferably be performed under dry circumstances.

2. The lubrication flange must be continuously connected to a reservoir filled with silicon oil, the reservoir mounted at least one meter above the lubrication flange.

3. Retract the piston rod fully at approximately 50 mm/s.

4. Extend the piston rod fully at approximately 50 mm/s.

5. Check visually if the surface of the piston rod is completely saturated with silicon oil (no dry spots allowable).

6. If the surface of the piston rod is not completely saturated, start again with step 3.

Check the reservoir at a regular basis to avoid run out of silicon oil.

Curative maintenance procedure for cylinder rods after exposure to chemicals Upon exposure to chemicals it is essential to perform curative maintenance as soon as possible.

Curative maintenance consists of: 1. Use a steam cleaner in order to dilute and remove all residues of chemicals.

2. Perform the maintenance as specified in the preventive maintenance procedure.

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Preventive maintenance as described in this procedure should be carried out at the commissioning of the hydraulic cylinder or at the first stroke-out, subsequently once every month, to once every week for tropical conditions.

Preventive maintenance procedure for water-glycol fluids It is essential to maintain the corrosion inhibiting qualities of the water-glycol fluid within certain limits. It is advised that a check on the fluid is carried out at intervals of three to four months.

Samples to be analyzed by the fluid manufacturer on its acidity / PH-value, chlorine content, corrosion products, bacteria / fungus content, etc.

It is essential that the sample taken is representative of the fluid within the cylinder as a whole.

Follow the fluid-manufacturers recommendation with regard to fluid maintenance.

5.5

PRE-STRESSING OF THE CHEVRON TYPE ROD SEALS

Cylinders that are supplied with chevron seals of UHMWPE material are provided with removable shim rings between cylinder and packing flange. Following procedure must be applied when small leakage at the rod seal occurs: 1. Make sure that the cylinder is free from external loads and is secured in such a way that it can’t be moved in or out. The rod position has to be such that it can’t be moved in or out and the sealing flange is readily accessible.

2. Discharge pressure from the bottom side and annulus side of the cylinder and make sure that no pressure build-up can occur in the cylinder.

3. Open both air bleed valves on bottom and annulus side to release possible rest pressure, and close the air bleed valves after pressure is released.

4. Remove silicon sealing between sealing flange and cylinder head.

5. Loosen bolts; do not remove them!

6. Remove one shim ring. One shim ring consists of two circular parts which both have to be removed. Remove only one shim ring at a time because once the seals are being overcompressed they lose their sealing capacity.

7. Fasten bolts and torque them up cross-wise by means of a torque wrench. The torque that should be applied is mentioned on the assembly drawing. (Please refer to chapter 6.4.1) 8. Pressurise the cylinder and check the seals on oil tightness by moving the rod in and out several times.

9. Monitor leakage behaviour. If above procedure is not successful repeat step 1 to 8.

10. Apply a silicon sealing between sealing flange and cylinder head.

11. Restore paint on possible damaged spots on bolts, sealing flange and other parts of the cylinder.

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6 REPLACEMENT OF SPARE PARTS Study the relevant sections of this instruction manual before starting work on the cylinder.

Tip!

6.1

The fitting and removal of cylinders is specialised work that can only be properly carried out by qualified and experienced personnel. In the event of questions or doubts arising, always contact the Bosch Rexroth service organisation or your supplier.

GENERAL

Take the following measures before starting work on the cylinder: • Ensure that you have a readable assembly drawing and a copy of this instruction manual.

• Make sure that you have clean, professional tools and a clean working area.

• Make as much use as possible of the available lifting points. Loads may only be applied to lifting lugs; transverse loading of the lifting lugs is not permitted. If there are no lifting points present, use must be made of wide hoisting slings capable of supporting the load.

• Use reliable hoisting facilities. Take account of the great weight of the cylinder and the separate components.

• Because of the tolerances on the outside diameter of the cylinder shell, account must be taken, when lifting it, of a weight for the cylinder assembly that is approximately 10% greater than that stated on the drawing.

• During disassembly and assembly, no dirt must be permitted to enter the hydraulic system. The connection points must be sealed in a reliable manner using steel plugs, sealing flanges or special plastic stoppers, suitable for the purpose.

• Prevent damage to the cylinder and damage to the piston rod in particular.

• Make use of a stable set-up for installing the cylinder and the mounted components.

6.2

DRAINING THE CYLINDER

Before removing the cylinder, the hydraulic medium must be removed. An increase in the environmental temperature or heating up of the cylinder by direct sunlight can result in an increase in the hydraulic pressure in the cylinder.

Take account of a possible pressure build-up in the cylinder!

Danger!

The cylinder must be drained with care, for example by making use of one of the minimess connections present.

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6.3

REMOVING THE CYLINDER

Before starting to remove the cylinder, the general conditions as specified in § 6.1 must be satisfied. Ensure good preparation.

In order to replace any spare parts on the cylinder, the cylinder must be partially disassembled.

Limit the risks to a minimum by removing the cylinder from the construction and setting it up in a horizontal position.

Tip!

The order of disassembly is as follows: • Tap the hydraulic fluid from the cylinder (see § 6.2).

• Disassemble the cylinder head. Pull the head away from the shell, and let the remainder of the medium run out of the cylinder shell. Now use a hoisting sling to pull the piston rod out of the cylinder shell. Lay the piston rod down on specially prepared stands (stands with soft, rotating supports, free from pollution).

Never use compressed air to extend the piston rod!

Danger!

•

•

• •

For cylinders with a Ceramax® rod covering and a eye on the rod end, an optional protective tube may be used. Remove the bolts with which the protective tube is pulled against the eye and pull the tube from the eye. This will reveal the disassembly holes for the removal of the eye and/or the piston.

If necessary, remove the locking arrangement between the eye and the rod and place the key in one of the disassembly holes. Place a sling around the eye so that the eye remains hanging when it is disconnected from the rod. Now rotate the rod with the aid of the key in the disassembly holes, until the eye is separated from the rod.

If necessary, remove the protective tube from the rod. Fix a hoisting sling to the head and slide the head slowly from the rod (if it proves difficult to slide the head over the rod, rotate the rod slowly while withdrawing the head).

Remove the seals and clean the head thoroughly with the aid of a de-greasing medium (old Loctite, dust particles etc.). Also clean the rod thoroughly, since every particle of dirt can damage the seal during assembly. Do not forget to clean the thread on the rod, the eye and the protective tube.

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6.4

GENERAL ASSEMBLY INSTRUCTIONS

Do not forget to keep the components, the tools and the grease to be used in a clean condition. Dirt can cause damage to seals and other components in the hydraulic system!

Warning!

6.4.1 INSERTING BOLTS Bolts are inserted using heavy tools. Ensure that vulnerable surfaces are effectively protected by, for example, a sturdy rubber strip.

Falling bolts or blows with heavy tightening tools can result in damage!

Warning!

Before bolts are inserted, they must be visually inspected for: • Damage to the thread.

• Contamination in the form chips or burrs in the thread or on the head of the bolt (extremely important when these are used inside the cylinder).

• Cracks in the head of the bolt and in the transition from the head of the bolt to the shank.

Contamination interferes with the proper functioning of the cylinder and of other components in the hydraulic system!

Warning!

When the bolts are inserted, the thread and the surface of the head must be greased with Shell Rodina grease to prevent corrosion and to facilitate a defined tightening torque. Insert the bolts and rotate them a few turns by hand. Further tightening may be performed with a pneumatic bolt driver.

The bolts must be tightened with the torque and in the order specified on the drawing: • First tighten four bolts spread over 90 degrees crosswise.

• Thereafter, the full ring of bolts can be tightened to the specified torque value (including the bolts tightened earlier).

For stainless steel, bolts Optimol Paste White T grease must be used in stead of Shell Rodina grease.

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6.4.2 SECURING WITH LOCTITE 243 Bolts fitted inside the cylinder must be secured with Loctite 243 to prevent them vibrating loose.

This is a single-component anaerobic adhesive that hardens as it comes into contact with metal and is sealed off from oxygen. After hardening, the adhesive creates a firm bond between the two surfaces.

Technical data Loctite 243: • Temperature resistant to 150 degrees Celsius • Average strength, thus can be disassembled with normal tools (to M36) • Hardens to full strength at room temperature in 2 hours The bolts to be secured with Loctite are indicated on the assembly drawing. When bolts are to be secured with Loctite, the following procedure must be carried out: • Tapped holes and bolts must be de-greased using a brush and a de-greasing medium.

• Bolts must be blown dry with compressed air.

• Apply sufficient Loctite to the threads in the tapped hole. It is important that the total length of the thread is coated with a film of Loctite when the bolt is in position.

• The bolts can then be inserted and tightened with the specified torque.

6.4.3 SECURING BY MEANS OF CENTRE-PUNCHING The piston and the eye on the piston rod are usually secured against loosening with locking pins, tightened by means of an adjustment screw. The adjustment screw self itself is secured with Loctite and one or more centre-punch indentations.

The locking function of a centre-punch indentation is based on the deformation of the thread on the input side of the tapped hole with the aid of a hammer and a centre punch. For locking, the following steps must be followed: • Insert the hard pin, the soft pin(s) and the adjustment screw. Check that the pins are properly assembled; the adjustment screw may not extend beyond the machined surface.

• Position the centre punch a few millimetres from the tapped hole and make an indentation • Check that the material is visibly deformed.

• The adjustment screw is now secured.

6.4.4 GREASE OR SILICONE FILLING Grease filling is used to protect against corrosion of those components that have no integral protection. This is particularly applicable to bolt shanks in cylinders for under-water applications.

For greasing, Shell Rodina must be used. The application of a grease filling is indicated on the drawing.

An exception to this is in the blind holes for the bolts securing the packing flange that fall behind the ice scraper. These holes must nevertheless be filled with grease, but this is not indicated on the drawing. The filling of blind holes must be performed in accordance with the following procedure: • Ensure that tools are absolutely clean and that grease is completely without pollution.

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• • •

Using a brush, fill the blind holes with sufficient pure grease.

Use a piece of card to press out the air from behind the grease and to remove any superfluous grease.

Clean the piston rod and the ice scraper with a piece of polishing paper.

If the cylinder is mounted in the construction in such a position that the bolt heads can fill with water, the bolt heads must be filled with an acid-free silicone filler in order to reduce the possibility of corrosion.

6.4.5 SEAL WITH LOCTITE 510 All flange surfaces in the cylinder must be coated with Loctite 510 in order to guarantee a good seal and thereby prevent the ingress of moisture and the resulting corrosion.

Technical data for Loctite 510: • Temperature resistant to 200 degrees Celsius • High resistance to removal • Hardens to full strength in the mounted condition in 24 hours When components are to be mounted and sealed with Loctite, the following procedure must be followed: • Any residue of the old sealing material must be removed using a solvent or a plastic scraper.

Do not use metal tools, so as to avoid scratches.

• De-grease the surfaces with a brush and solvent. Do not use solvents based on petroleum or thinners because these leave a residue that can interfere with subsequent adhesion.

• Dry the surfaces using compressed air and / or paper.

• Apply sufficient Loctite to cover the whole surface that will be in contact when the item is assembled.

• The parts must now be immediately brought into contact and placed under pressure.

6.4.6 MOUNTING THE GUIDE STRIPS When guide strips are mounted in the cylinder head and round the piston, extra attention must be paid to keeping the components, the tools and the grease to be used in a clean condition. All waste residues will enter the cylinder, where it can result in damage to the dynamic seals or other components in the hydraulic system.

For the assembly of the guide strips, use must be made of Shell Rodina grease to hold the strips in the correct position during assembly.

For the assembly of the guide strips, the following procedure must be followed: • Ensure that the grooves for the guide strips are clean and dry.

• Give the guide strips their final form by pressing them into shape by hand.

• Check the length and the form of the guide strips; there must always be a gap of approximately 5 mm remaining in order permit the hydraulic pressure to be applied to the seals. A gap that is too small can result in the guide functioning as a seal. The ends of the guide strips must always be cut at an angle of 60 degrees in relation to the strip.

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• •

Smear the guide strip grooves with a thin coating of pure Shell Rodina grease and press the guide strips into the grooves.

The component can now be carefully assembled, with great care being taken that the guide strips actually remain enclosed in the grooves.

6.4.7 MOUNTING THE PISTON ROD SEALS Piston rod seals are loaded on one side through the internal pressure in the cylinder; on the inside of the cylinder there is always a considerably higher pressure than on the outside. This has resulted in an asymmetric design for the seal by means of which the seal can only be mounted in one specific manner.

Take note of the correct position and direction of the seals; incorrect assembly will lead to a reduced function of the sealing configuration and will finally lead to leakage!

Warning!

The correct position for the seals is clearly indicated on the assembly drawing. If necessary, additional information is included on the drawing. For the most common piston rod seals, the following overview includes an indication of the position in which the seals must be mounted (the right-hand side is the piston / pressure side).

Step seal:

Excluder:

Chevron seal:

Before mounting the seals, it is advisable to heat them in oil to a temperature of approximately 80 degrees Celsius. This will ensure that the stiff seals become more supple and therefore easier to mount.

The assembly of rod seals in a closed groove must be carried out as follows: • Place the O-ring in the groove.

• Press the seal into a kidney shape without bending it. See figure a.

• Place the seal in the compressed form into the slot and press against the bell-shaped part of the seal in order to recover the original form. See figure b.

• Check that the seal is properly mounted and is undamaged over the full circumference.

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Figure a.

Figure b.

6.4.8 MOUNTING THE PISTON SEALS Because of the internal pressure in the cylinder, piston seals are loaded alternately on one side only; depending on the load, the bottom pressure will have a higher or a lower value than the pressure on the rod end. This has resulted in a symmetrical design for the seal. This does not obviate the incorrect mounting of the seals.

Take note of the correct direction for the seals; incorrect assembly will lead to a reduced function and a possible loss of the holding function!

Warning!

The correct position for the seals is clearly indicated on the assembly drawing. If necessary, additional information is included on the drawing. For the most common piston seals the following overview indicates the position in which the seals must be mounted.

Glyd Ring:

Chevron seal (part):

For seals that must be mounted in a groove, it is advisable to heat them in oil to a temperature of approximately 80 degrees Celsius. This will ensure that the stiff seals become more supple and therefore easier to mount. Chevron seals can be directly mounted.

6.5

ASSEMBLING THE CYLINDER

Before starting to assemble the cylinder, the general conditions specified in § 6.1 must be complied with. Ensure that proper preparations are made.

The order of assembly is as follows: • Spray the rod with oil so that the head slides easily over the rod. Place the head for the rod in position and slide it slowly over the rod (if it is difficult to slide the head over the rod; turn the Basic doc.: Instr_en_301_bc2.doc Rev. 3.01, Juni 2007

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• •

• • •

• •

rod or the head slowly while assembling it). Take care that the bearing strips and the seals do not become jammed or damaged.

If applicable, fit the protective tube for the Ceramax extension on the rod.

If necessary, raise the eye for the rod and insert the key in the disassembly holes. Grease the thread. Press the eye onto the piston rod and rotate the rod slowly. Mount the eye on the piston rod in this way. Make sure that the centerline of the eye is aligned with the rod and check regularly that the threads do not become crossed. Rotate the rod until the eye lies against the shoulder of the rod. Ensure that the eye is secured by striking it with a copper mallet. Check that the original locking hole in the rod is aligned with the locking hole in the eye and fit the locking components.

Coat the protective tube with Loctite (on the contact surface and round the bolt holes) and bolt the protective tube firmly against the eye.

Spray the O-ring seal on the head, the cylinder bore and the piston seal with hydraulic medium.

Now raise the rod and slide the piston slowly into the cylinder. Apply Loctite to the contact surfaces around the tapped holes in the cylinder shell, and slide the head into the shell. Make sure that the head cannot rotate once it has been inserted in the cylinder shell to prevent damage to the O-ring seal. Now grease the bolts and insert them into the head. First, screw in all the bolts finger tight and then tighten them crosswise to the indicated torque value (see § 6.4.1).

Fill the cylinder with hydraulic medium and bleed the cylinder (see § 5.2.1.).

Apply pressure up to the design pressure and inspect the cylinder for leakage. Thereafter, the cylinder can be re-installed.

6.6

NECESSARY TOOLS / RESOURCES

When spare or wearing parts of a cylinder are replaced, the following tools and resources are required. Ensure that these are in stock so as to avoid any unnecessary delays and to prevent the occurrence of any problems.

Tools

Resources

• • •

• •

• • • • • • •

Hexagonal key Pneumatic bolt driver Calibrated torque wrench with sufficient capacity Centre punch Hammer Copper mallet Supports with soft (plastic) rotating support points Heater unit for heating seals Hoisting slings (no chains) Manometer with minimess hose

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• • • • • •

Shell Rodina grease Optimol Paste White T grease (for stainless steel bolts) Acid-free silicone filler Loctite 243 Loctite 510 Polishing paper Compressed air Oil filling

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