Asco Series 448 Rodless Band Cylinders STB STBB STBN Owner's manual

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Series

Baureihe

448

Type : STBN

STB

STBB

Sachets de pièces de rechange

VÉRINS SANS TIGE A BANDES, A CHARIOT NON GUIDÉ OU GUIDE

Spare parts kits

RODLESS BAND CYLINDERS, WITH UNGUIDED OR GUIDED CARRIER BRACKET

Ersatzteilliste

KOLBENSTANGENLOSE ZYLINDER MIT ODER OHNE SCHLITTENFÛHRUNG

NS

Ø

vérins

cylinders

Zylinder

(mm)

16 978 02 528

25 978 02 529

32 978 02 530

40 978 02 531

50 978 02 532

63 978 02 533

80 978 02 534

CODES

BESTELL-CODE

ENSEMBLE DE RECHANGE COMPLET POUR VITESSE NORMALE

COMPLETE SET OF SPARES FOR

NORMAL SPEED

KOMPLETTE ERSATZTEILPACKUNG FÜR

NORMALE GESCHWINDIGKEIT

Ø63 et 80 seulement

Ø63 et 80 only

Nur Ø63 und 80

DÉSIGNATION/COMPOSITION du sachet

DÉSIGNATION-COMPOSITION of kit

BEZEICHNUNG/INHALT DER ERSATZTEILPACKUNG

Rep.

- 1 Joint

- 2 Racleurs

- 2 Joints de couvercle (grand)

- 2 Joints de couvercle (petit)

- 2 Joints de tenon

- 2 Absorbeurs de chocs

- 2 Joints d'amortissement

- 2 Joints de piston

- 2 Patins de guidage (4 couleurs)

- 2 Racleurs latéraux

- 1 Tube de graisse

- Outil de nettoyage et outil de

centrage

- 1 O-ring

- 2 Wipers

- 2 O-rings for end cap (large)

- 2 O-rings for end cap (small)

- 2 O-rings for spigot

- 2 Cushioning discs

- 2 Cushioning seals

- 2 Piston seals

- 2 Slide shoes (4 colors)

- 2 Side wipers

- 1 Tube of grease

- Cleaning star and centring tool

- 1 O-Ring/Abstreifer

- 2 Abstreifer

- 2 O-Ringe/Deckel (groß)

- 2 O-Ringe/Deckel (klein)

- 2 O-Ringe/Dämpfzapfen

- 2 Dämpfscheiben

- 2 Dämpfdichtungen

- 2 Kolbendichtungen

- 2 Gleitschuhe (4 Farben)

- 2 seitliche Abstreifer

- 1 Tube Schmiermittel

- Reinigungsstern und

Zentrierwerkzeug

▼

7

8

18

19

21

22

23

24

28

31

1

ENSEMBLE DE RECHANGE COMPLET POUR VITESSE LENTE

COMPLETE SET OF SPARES FOR

SLOW SPEED

KOMPLETTE ERSATZTEILPACKUNG FÜR

LANGSAMLAUFAUSFÜHRUNG

ENSEMBLE DE RECHANGE COMPLET POUR VITESSE NORMALE AVEC BANDES INTERNE/EXTERNE

COMPLETE SET OF SPARES FOR

NORMAL SPEED WITH INNER/OUTER SEALING BANDS

KOMPLETTE ERSATZTEILPACKUNG NORMALE GESCHWINDIGKEIT MIT AUSSEREM ABDECKBAND UND INNEREM DICHTBAND

ENSEMBLE DE RECHANGE COMPLET POUR VITESSE LENTE AVEC BANDES INTERNE/EXTERNE

COMPLETE SET OF SPARES FOR

SLOW SPEED WITH INNER/OUTER SEALING BANDS

KOMPLETTE ERSATZTEILPACKUNG FÜR LANGSAMLAUFAUSFÜHRUNG MIT AUSSEREM ABDECKBAND UND INNEREM DICHTBAND

(1) Longueur de course du vérin (en mm) à

rajouter au code de rechange.

Exemple

de commande: 978 02 542 / 1700 mm.

En effet l'ensemble comprend: les pièces

d'usure, 1 tube de graisse + les 2 bandes

coupées à une longueur suffisante pour

adaptation à la course indiquée du vérin.

(1) Hublänge (in mm) an den Bestell-Code

für die Ersatzteilpackung hinzufügen

Beispiel für Bestellung: 978 02 542 / 1700 mm.

Die Ersatzteilpackung enthält: Verschleiß-

teile, 1 Tube Schmiermittel + 2 Bänder, die

auf den für den Zylinder angegebenen Hub

zugesohnitten sind.

(1) Cylinder stroke (in mm) to be added to

the spare parts number.

Order exemple: 978 02 542 / 1700 mm

.

The kit includes: the wearing parts, 1 tube

of grease + the 2 bands with length adapted

to the indicated cylinder stroke.

2

DÉSIGNATION/COMPOSITION du sachet

DÉSIGNATION-COMPOSITION of kit

BEZEICHNUNG/INHALT DER ERSATZTEILPACKUNG

Rep.

- 1 Joint

- 2 Racleurs

- 2 Joints de couvercle (grand)

- 2 Joints de couvercle (petit)

- 2 Joints de tenon

- 2 Absorbeurs de chocs

- 2 Joints d'amortissement

- 2 Joints de piston

- 2 Patins de guidage (4 couleurs)

- 2 Racleurs latéraux

- 1 Tube de graisse

- Outil de nettoyage et outil de

centrage

- 1 O-ring

- 2 Wipers

- 2 O-rings for end cap (large)

- 2 O-rings for end cap (small)

- 2 O-rings for spigot

- 2 Cushioning discs

- 2 Cushioning seals

- 2 Piston seals

- 2 Slide shoes (4 colors)

- 2 Side wipers

- 1 Tube of grease

- Cleaning star and centring tool

- 1 O-Ring/Abstreifer

- 2 Abstreifer

- 2 O-Ringe/Deckel (groß)

- 2 O-Ringe/Deckel (klein)

- 2 O-Ringe/Dämpfzapfen

- 2 Dämpfscheiben

- 2 Dämpfdichtungen

- 2 Kolbendichtungen

- 2 Gleitschuhe (4 Farben)

- 2 seitliche Abstreifer

- 1 Tube Schmiermittel

- Reinigungsstern und

Zentrierwerkzeug

▼

7

8

18

19

21

22

23

24

28

31

Ø

vérins

cylinders

Zylinder

(mm)

16 978 02 535

25 978 02 536

32 978 02 537

40 978 02 538

50 978 02 539

63 978 02 540

80 978 02 541

CODES

BESTELL-CODE

Ø

vérins

cylinders

Zylinder

(mm)

16 978 02 542 (1)

25 978 02 543 (1)

32 978 02 544 (1)

40 978 02 545 (1)

50 978 02 546 (1)

63 978 02 547 (1)

80 978 02 548 (1)

CODES

BESTELL-CODE

(1)

DÉSIGNATION/COMPOSITION du sachet

DÉSIGNATION-COMPOSITION of kit

BEZEICHNUNG/INHALT DER ERSATZTEILPACKUNG

Rep.

- 1 Joint

- 2 Racleurs

- 1 Bande externe

- 1 Bande interne

- 2 Joints de couvercle (grand)

- 2 Joints de couvercle (petit)

- 2 Joints de tenon

- 2 Absorbeurs de chocs

- 2 Joints d'amortissement

- 2 Joints de piston

- 2 Patins de guidage (4 couleurs)

- 2 Racleurs latéraux

- 1 Tube de graisse

- Outil de nettoyage et outil de

centrage

- 1 O-ring

- 2 Wipers

- 1 Outer sealing band

- 1 Inner sealing band

- 2 O-rings for end cap (large)

- 2 O-rings for end cap (small)

- 2 O-rings for spigot

- 2 Cushioning discs

- 2 Cushioning seals

- 2 Piston seals

- 2 Slide shoes (4 colors)

- 2 Side wipers

- 1 Tube of grease

- Cleaning star and centring tool

- 1 O-Ring/Abstreifer

- 2 Abstreifer

- 1 Außeres Abdeckband

- 1 Inneres Dichtband

- 2 O-Ringe/Deckel (groß)

- 2 O-Ringe/Deckel (klein)

- 2 O-Ringe/Dämpfzapfen

- 2 Dämpfscheiben

- 2 Dämpfdichtungen

- 2 Kolbendichtungen

- 2 Gleitschuhe (4 Farben)

- 2 seitliche Abstreifer

- 1 Tube Schmiermittel

- Reinigungsstern und

Zentrierwerkzeug

▼

7

8

11

17

18

19

21

22

23

24

28

31

Ø

vérins

cylinders

Zylinder

(mm)

16 978 02 549 (1)

25 978 02 550 (1)

32 978 02 551 (1)

40 978 02 552 (1)

50 978 02 553 (1)

63 978 02 554 (1)

80 978 02 555 (1)

CODES

BESTELL-CODE

(1)

Sachets de pièces de rechange - Spare parts kits - Ersatzteilliste

DÉSIGNATION/COMPOSITION du sachet

DÉSIGNATION-COMPOSITION of kit

BEZEICHNUNG/INHALT DER ERSATZTEILPACKUNG

Rep.

- 1 Joint

- 2 Racleurs

- 1 Bande externe

- 1 Bande interne

- 2 Joints de couvercle (grand)

- 2 Joints de couvercle (petit)

- 2 Joints de tenon

- 2 Absorbeurs de chocs

- 2 Joints d'amortissement

- 2 Joints de piston

- 2 Patins de guidage (4 couleurs)

- 2 Racleurs latéraux

- 1 Tube de graisse

- Outil de nettoyage et outil de

centrage

- 1 O-ring

- 2 Wipers

- 1 Outer sealing band

- 1 Inner sealing band

- 2 O-rings for end cap (large)

- 2 O-rings for end cap (small)

- 2 O-rings for spigot

- 2 Cushioning discs

- 2 Cushioning seals

- 2 Piston seals

- 2 Slide shoes (4 colors)

- 2 Side wipers

- 1 Tube of grease

- Cleaning star and centring tool

- 1 O-Ring/Abstreifer

- 2 Abstreifer

- 1 Außeres Abdeckband

- 1 Inneres Dichtband

- 2 O-Ringe/Deckel (groß)

- 2 O-Ringe/Deckel (klein)

- 2 O-Ringe/Dämpfzapfen

- 2 Dämpfscheiben

- 2 Dämpfdichtungen

- 2 Kolbendichtungen

- 2 Gleitschuhe (4 Farben)

- 2 seitliche Abstreifer

- 1 Tube Schmiermittel

- Reinigungsstern und

Zentrierwerkzeug

▼

7

8

11

17

18

19

21

22

23

24

28

31

Ø

vérins

cylinders

Zylinder

(mm)

16 978 02 556

25 978 02 557

32 978 02 558

40 978 02 559

50 978 02 560

63 978 02 561

80 978 02 562

CODES

BESTELL-CODE

Ø

vérins

cylinders

Zylinder

(mm)

16 978 02 563

25 978 02 564

32 978 02 565

40 978 02 566

50 978 02 567

63 978 02 568

80 978 02 569

CODES

BESTELL-CODE

Ø

vérins

cylinders

Zylinder

(mm)

16 978 02 570

25 978 02 571

32 978 02 572

40 978 02 573

50 978 02 574

63 978 02 575

80 978 02 576

CODES

BESTELL-CODE

Ø

vérins

cylinders

Zylinder

(mm)

16 978 02 577

25 978 02 578

32 978 02 579

40 978 02 580

50 978 02 581

63 978 02 582

80 978 02 583

CODES

BESTELL-CODE

3

▼

DÉSIGNATION/COMPOSITION du sachet

DESIGNATION-COMPOSITION of kit

BEZEICHNUNG/INHALT DER ERSATZTEILPACKUNG

Rep.

LOT DE 2 BAGUES DE GUIDAGE BLANCHES

SET OF 2 WHITE SUPPORT RINGS

1 SATZ MIT 2 WEISSEN STÜTZRINGEN

25 - 2 Bagues de guidage blanches - 2 White support rings - 2 weiße Stützringe

▼

DÉSIGNATION/COMPOSITION du sachet

DESIGNATION-COMPOSITION of kit

BEZEICHNUNG/INHALT DER ERSATZTEILPACKUNG

Rep.

LOT DE 2 BAGUES DE GUIDAGE ROUGES

SET OF 2 RED SUPPORT RINGS

2 SATZ MIT 2 ROTEN STÜTZRINGEN

25 - 2 Bagues de guidage rouges - 2 Red support rings - 2 rote Stützringe

▼

DÉSIGNATION/COMPOSITION du sachet

DÉSIGNATION-COMPOSITION of kit

BEZEICHNUNG/INHALT DER ERSATZTEILPACKUNG

Rep.

LOT DE 2 BAGUES DE GUIDAGE VERTES

SET OF 2 GREEN SUPPORT RINGS

2 SATZ MIT 2 GRÜNEN STÜTZRINGEN

25 - 2 Bagues de guidage vertes - 2 Green support rings - 2 grüne Stützringe

▼

DÉSIGNATION/COMPOSITION du sachet

DESIGNATION-COMPOSITION of kit

BEZEICHNUNG/INHALT DER ERSATZTEILPACKUNG

Rep.

ENSEMBLE PISTON

PISTON ASSEMBLY

KOLBENEINHEIT

27 - 1 Piston - 1 Piston - 1 Kolben

Sachets de pièces de rechange - Spare parts kits - Ersatzteilliste

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Preparations and Things Needed

• Have the following things ready:

- seal kit or service kit,

- screwdrivers of various sizes,

- Allen keys of various sizes.

• Move piston to one end position,

• Switch off the main switch and secure it against unintentional

switching-on.

Cleaning the Inner Sealing Band

Dirt particles can lodge between the inner sealing band and the cylinder

bore and cause leakage. Cleaning is then required.

!

Danger of eye injuries. There is danger of eye injury from

flying dirt particles - wear safety glasses where indicated!

- Put on safety glasses,

- reduce working pressure to 2 bar,

- move piston to one end position,

- loosen two screws (13) for outer sealing band,

- from Ø 40: unscrew set-screw (13) completely, taking care that the

clamping piece (14) is not displaced,

- lift up one end of outer sealing band (11) without creasing it (see

diagram). With shorter stroke cylinders, if the slot is too short for use

of the cleaning tool, remove the carrier with wiper O-ring and the

outer sealing band completely (see sections «Cylinder Removal,

Dismantling and Cleaning» and «Cylinder Reassembly»),

- vent cylinder on the side where the piston is

- insert appropriate blade of cleaning tool (100)

into cylinder slot up to the stop,

- draw cleaning tool along slot several times

the escaping air blows out any dirt particles,

- remove pressure and push piston to other

end position,

- pressurize the opposite side to where the

piston is, to a maximum pressure of 2 bar

- vent other side

- repeat cleaning tool operation at other end of slot,

- remove pressure and reassemble outer sealing band in reverse order.

(For pressurisation, see corresponding Installation Instructions).

CYLINDER REMOVAL, DISMANTLING AND CLEANING

!

Danger of eye injuries and cuts on fingers etc.

There is danger of :

- eye injuries from flying dirt particles and stressed springs -

wear safety glasses where indicated!

- cuts from sharp edges of inner sealing band - wear

protective gloves when working with inner sealing band.

- Put on safety glasses,

- depressurize cylinder/plant,

- disconnect load,

- dismantle cylinder as follows:

. loosen set-screw (15) and unscrew set-screw (13) completely,

. remove screws (36) and end caps (35) and (37),

. remove carrier clamping screws (38) and dismantle wiper O-ring

(7) and carrier (10) (only for 16 to 50),

. remove all screws (5) (only for 63 and 80),

. pull off cover (9) with wipers (8), springs (6) and O-rings (7) and

dismantle (only for 63 and 80)

. remove outer sealing band (11),

. remove two clamping pieces (16) for inner sealing band and two

clamping pieces (14) for outer sealing band,

. pull off two cushioning spigots (20) by inserting screwdriver carefully

between cushioning spigot and cylinder profile (1),

. push piston and inner sealing band (17) out of cylinder bore,

. pull inner sealing band (17) out of piston,

. pull off two support rings (25) and remove spacers (29) with magnet

(30),

. remove slide shoe (28) and for 63 and 80 side wiper (31),

. remove piston seal (24) and cushioning seal (23),

- clean all parts and replace damaged or worn parts, prepare for

reassembly.

CYLINDER REASSEMBLY

- Information: Danger of cuts on fingers etc.

- Note the torque moments on page 5.

- Note the position of the parts on the exploded drawing.

- With cylinders from Ø 40 the magnet strips can slip out of the

cylinder profile. Insert these into the cylinder profile as follows

(the sealing function of your cylinder depends on this):

Inserting the magnet strips (see diagram)

- push one magnet strip in, leaving 10 mm sticking out (it must lie on

its narrow side) - or, if it had remained in the cylinder profile, pull it

out a little,

- place the second magnet strip on its

narrow side above the first magnet strip:

If the magnets repel each other: push

in the second magnet strip without turning

it over.

If the magnets attract each other: turn

the second magnet strip over i.e. 180°

(about its longitudinal axis) and then push

it in.

Installing the piston

- Clean and dry sealing bands and cylinder profile,

- insert both slide shoes (28) into piston yoke (colour same as old

parts),

- select the two support rings (25) (colour same as old parts),

- push two spacers (29), with magnet (30) between them, into one

support ring (except on Ø 80, where magnet system is installed inside

piston),

- push the two support rings on to piston (so that flat band guides are

on top - see diagram),

- clip the two support rings together,

- check that piston moves smoothly,

as follows:

. insert piston into cylinder bore and

slide it up and down,

- replace slide shoe and/or support ring if:

. piston is too tight, or

. piston has too much play,

- take piston out again,

- insert cushioning seals (23) (so that seal lip shows on outside),

- grease inside of cylinder bore as far as you can reach,

- grease the two support rings (25) and piston behind support rings,

- slide piston up and down a few times (long cylinders, however, should

be greased right through)

- take piston out again,

- check that cylinder bore has a complete grease film, as follows:

. point cylinder at a light source and look through it,

. repeat greasing process if required,

- push on one piston seal (24) (so that groove of piston seal shows on

outside),

- push in the two side wipers (31) so that wiper lip shows on outside

(see diagram) and adjust their position (only for Ø 63 and 80),

- grease piston seal and fill its groove with grease,

- place inner sealing band (17) on flat band guide of one support ring

(so that «ground edge» side lies on support ring),

- push inner sealing band through piston without creasing it,

6

DISASSEMBLY / RE-ASSEMBLY GB

- push piston, end without piston seal first, into cylinder bore,

- place the two side wipers on the cylinder profile and move piston

slowly further along while checking that position of side wipers is

symmetrical (only for Ø 63 and 80),

- introduce second support ring, pressing piston down,

- slide piston to other end of cylinder so that it projects from other end,

- put second piston seal on support ring with groove on outside,

- grease piston seal and fill its groove with grease,

- slide piston to the middle until inner sealing band is flush with cylinder

profile at one end,

- check again that position of side wipers is symmetrical

(only for Ø 63 and 80),

- remove excess grease from ends of cylinder profile.

Inserting the Cushioning Spigots (20)

- grease O-ring grooves (21), insert O-rings and grease them,

- grease cushioning spigots,

- push cushioning discs (22) onto cushioning spigots (20),

- hold inner sealing band on the side where it is flush with the cylinder

profile and slide piston to about 100 mm from other end of cylinder

profile,

- at that end, push centring tool (see diagram) from above through

hole in inner sealing band

and hold it,

- insert one cushioning

spigot, angled slightly

downwards, into cylinder

profile,

- push cushioning spigot right

in with gentle upward

pressure and line it up with

cylinder profile,

- remove centring tool,

- place clamping piece for inner sealing band (16) centrally in each

end cap (35, 37) (for position see exploded drawing) and secure it

with set-screw (15) so that the centring pin stands as far as possible

out of the end cap. Then place clamping piece for outer sealing band

(14) in each end cap (35, 37) and secure it flush with the end cap with

set-screw (13),

- grease face of cushioning spigot and insert O-rings (18, 19),

- at the end where the cushioning spigot is, fit one end cap (check

position of air connection), locating centring pin of inner sealing

band clamping piece (16) in hole in inner sealing band (17). Loosen

set-screws (13, 15) and secure end cap with screws (36), tightening

them alternately crosswise and observing the correct torque

moments.

- slide piston to ca. 100 mm from other end of cylinder profile,

- pull loose end of inner sealing band as far as possible to end of

cylinder profile,

- push centring tool from above through hole in inner sealing band

and hold it,

- insert second cushioning spigot, angled slightly downwards, into

cylinder profile,

- push cushioning spigot right in with gentle upward pressure and

line it up with cylinder profile,

- remove centring tool.

Mounting end caps (see torque moments)

- grease face of cushioning spigot and insert O-rings (18, 19),

- fit end cap, locating centring pin of inner sealing band clamping

piece (16) in hole in inner sealing band (17). Loosen set-screws (13,

15) and secure end cap with screws (36), tightening them alternately

crosswise and observing the correct torque moments,

- position inner sealing band (17) the same distance from both ends

of cylinder profile and tighten set-screw (15) at the end where the

piston is,

- slide piston to the other end position,

- adjust position of clamping piece (16) so that inner sealing band

lies correctly along the whole slot, without pretension or hanging

loose,

- tighten set-screw (15) at this end too – see torque moments.

Checking Tension of Inner Sealing Band

Inner sealing band must be fitted:

- without pretension,

- without hanging loose.

Completing the Cylinder (see "Torque Moments")

- Only for Ø 63 and 80:

. Put the two O-rings (7) on cover (9),

. put on the two springs (6),

. clip on wipers (8),

- lay on outer sealing band (11) and centre it,

- push both wipers (8) into carrier (10),

- place carrier (10) with wipers (8) in piston yoke (27),

- fit wiper O-ring (7),

- tighten screws (38),

- from Ø 40: unscrew set-screw (13) completely, taking care that

clamping piece (14) is not displaced,

- insert outer sealing band centrally into the end caps,

- secure outer sealing band clamping piece (14) at each end of

cylinder with set-screw (13) – see torque moments.

7

DISASSEMBLY / RE-ASSEMBLY GB

Ø 16 M4 3.25 Nm ±0.25 M4 2.9 Nm ±0.4 - - M2 0.2 Nm +0.03 M2 0.2 Nm +0.03

Ø 25 M5 6 Nm ±1 M5 5.5 Nm ±0.8 - -

M2.5 0.45 Nm +0.05 M2.5 0.45 Nm +0.05

Ø 32 --

Ø 40 M6 10 Nm ±1.5 M6 10 Nm ±1.5 - -

M3 0.8 Nm +0.1 M3 0.8 Nm +0.1

Ø 50 --

Ø 63 M8 25 Nm ±3.8 - -

M3 0.7 Nm ±0.1 M3 0.8 Nm +0.1 M3 0.8 Nm +0.1

Ø 80 M10 42.5 Nm ±2.5 - -

cylinder

screw (36) for

end cap (35+37)

screw (5) for

cover (9)

set-screw (15) for

I-band (17)

set-screw (13) for

O-band (11)

Torque Moments

screw (38) for

carrier (10)

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Asco Series 448 Rodless Band Cylinders STB STBB STBN Owner's manual

Asco Series 448 Rodless Band Cylinders STB STBB STBN Owner's manual

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