Festo ADN-EL Series Repair Instructions Download Page 19 | Manualshive

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Festo 7ADN-KP_ADN-ELa_en

4

Repair steps

4.1

Preparation

•

Before starting the repair, remove any attachments (clamping device, end-position locking, etc.) in accordance with
the accompanying operating instructions.

•

Keep your working environment tidy.

•

Only use the spare parts and assembly aids (grease, locking agent, etc.) provided in the set of wearing parts.

Warning

Make sure that the bearing cap cannot suddenly come flying off.
•

Remove the non-return valves and tubing connection from the cylinder and depressurise the cylinder completely
so that any pressure present is not suddenly released when the cylinder is opened.

To prevent damage to sealing rims or guide surfaces, do not use pointed or sharp-edged assembly aids.

4.2

Visual inspection

Check the cylinder for visible damage that might impair its function (e.g. warping of the piston rod) as well as deposits

and scoring. The entire cylinder must be replaced if the cylinder barrel is showing signs of significant damage.

4.3

Cylinders ADN-…-KP

The description in this chapter can be used to repair cylinders of the type ADN-…-KP with the following features:

Code Description

Code Description

KP

Clamping unit KP attached

K2

Piston rod with extended male thread

A

Male thread

K5

Piston rod with special thread

I

Female thread

K8

Extended piston rod

P

Elastic cushioning rings/pads at both ends

Tl

Captive rating plate

A

External position sensing

The repair steps can be found in chapter

5 "Repairing cylinder ADN-…-KP"

.

4.4

Cylinders ADN-…-EL

The description in this chapter can be used to repair cylinders of the type ADN-…-EL with the following features:

Code Description

Code Description

ELB

End-position locking at both ends

A

External position sensing

ELV

End-position lock at front

K2

Piston rod with extended male thread

ELH

End-position locking, rear

K5

Piston rod with special thread

A

Male thread

K8

Extended piston rod

I

Female thread

Tl

Captive rating plate

P

Elastic cushioning rings/pads at both ends

The repair steps can be found in chapter

6 "Repairing cylinder ADN-…- EL"

.

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Summary of Contents for ADN-EL Series

Page 1: ...Repair instructions en Cylinder with piston rod Compact cylinder with standard hole pattern ADN KP with clamping unit and ADN EL with end position locking 7ADN KP_ADN ELa_en ...

Page 2: ...om Reproduction distribution or sale of this document or communication of its contents to others without express authorisation is prohibited Offenders will be liable for damages All rights reserved in the event that a patent utility model or design patent is registered All product designations and brand names used are the property of the owners and not explicitly identified as such All technical d...

Page 3: ...e deviations into consideration if necessary These repair instructions have been prepared with care Festo AG Co KG does not however accept liability for any errors in these repair instructions or their consequences Likewise no liability is accepted for direct or consequential damage resulting from improper use of the products More detailed information on this can be found in chapter 10 Liability T...

Page 4: ...N KP 19 4 4 Cylinders ADN EL 19 5 Repairing cylinder ADN KP 20 5 1 Structure of the covers 20 5 1 1 Structure of the bearing cap 20 5 1 2 Structure of cover with clamping unit KP 20 5 2 Removing the covers 20 5 3 Removing the piston rod from clamping unit KP 21 5 4 Replacing the piston components 22 5 5 Inserting the piston rod into the cylinder barrel 22 5 6 Repairing and attaching the covers 23 ...

Page 5: ...aning and greasing 34 7 1 Cleaning 34 7 2 Greasing 34 7 2 1 Extremely thin grease film 34 7 2 2 Thin grease film 34 7 2 3 Grease reservoir 34 8 Maintenance and care 34 9 Tools 35 9 1 Standard tools 35 9 2 Special tools 35 10 Liability 35 ...

Page 6: ...found on the Festo website www Festo com Spare parts documentation Contains an overview of the spare and wearing parts as well as information on their installation Can be found in the online spare parts catalogue on the Festo website spareparts festo com Assembly aids Contains an overview of available assembly aids such as lubricating greases locking agents maintenance tools etc aids for assembly ...

Page 7: ...elf your local Festo sales office offers the option of having the repair carried out by Festo Environment Components and equipment replaced as part of a repair must be disposed of in accordance with the locally valid environmental protection regulations 2 General product description 2 1 Functional description The piston moves in the cylinder barrel when the cylinder chamber is pressurised The pist...

Page 8: ...L 9 8 1 3 4 7 6 5 2 1 Piston rod 2 Piston rod seal 3 Bearing cap 4 End position locking at front 5 Compressed air connection end position locking 6 Slot in the piston rod for the end position locking 7 Piston one piece only ADN 20 25 32 EL 8 End cap 9 Cylinder barrel ...

Page 9: ...ax 10bar 1 4 2 3 1 Type designation 2 Serial number 3 Technical information 4 Part number The type designation on this rating plate provides the following information ADN Compact cylinder double acting standard hole pattern with clamping unit KP 32 Piston diameter 32 mm 50 Stroke 50 mm KP Clamping unit attached A Male thread P Elastic cushioning rings pads at both ends A Sensing option magnetic pi...

Page 10: ...nations and bearing cap variants This diagram provides an overview of the orientation designations for the cylinder with piston rod Orientation Festo product identification rating plate as reference point O top U underneath R right L left V front H rear ...

Page 11: ...ping unit KP This diagram is intended only to provide an overview of the individual components To order spare and wearing parts please use the online spare parts catalogue on the Festo website spareparts festo com 2 1 21 21 1 4 3 5 5 6 4 8 4 10 9 11 12 2 2 2 4 8 8 21 21 1 1 13 14 15 13 16 18 17 19 20 8 20 7 7 6 3 ...

Page 12: ...ing cartridge 8 O ring 9 Cylinder barrel 10 Piston rod male thread Only ADN KP A 11 Piston rod female thread Only ADN KP I 12 Piston Only ADN 20 32 KP 13 Seal piston 14 O ring 15 Magnet 16 Guiding band 17 Nut Only ADN 20 25 KP use screw locking agent 18 Washer Only ADN 32 100 KP 19 Hex nut Only ADN 32 100 KP use screw locking agent 20 End cap 21 Socket head screw Only ADN 80 100 KP use screw locki...

Page 13: ...ram is intended only to provide an overview of the individual components To order spare and wearing parts please use the online spare parts catalogue on the Festo website spareparts festo com 2 1 1 3 2 3 3 4 7 4 4 11 5 11 11 12 13 14 9 10 2 2 21 21 5 6 5 6 5 6 21 21 2 2 2 2 15 20 16 17 15 18 19 5 9 10 20 9 10 20 9 8 10 9 10 9 10 8 ...

Page 14: ...cap Only ADN 20 25 ELB 8 Spacer ring Only ADN 20 25 ELB 9 Locking cylinder Use screw locking agent 10 Socket head screw 11 Cylinder barrel 12 Piston rod male thread Only ADN ELB A 13 Piston rod female thread Only ADN ELB I 14 Piston Only ADN 20 32 ELB 15 Seal piston 16 O ring 17 Magnet 18 Guiding band 19 Threaded coupling Use screw locking agent 20 End cap 21 Socket head screw Only ADN 80 100 ELB ...

Page 15: ... provide an overview of the individual components To order spare and wearing parts please use the online spare parts catalogue on the Festo website spareparts festo com 2 1 1 3 2 3 3 4 4 4 7 7 7 8 9 10 19 17 18 2 2 20 20 5 6 20 20 2 2 2 2 11 16 12 13 11 14 15 5 17 18 16 17 18 16 ...

Page 16: ...ring 7 Cylinder barrel 8 Piston rod male thread Only ADN ELH A 9 Piston rod female thread Only ADN ELH I 10 Piston Only ADN 20 32 ELH 11 Seal piston 12 O ring 13 Magnet 14 Guiding band 15 Threaded coupling Use screw locking agent 16 End cap 17 Locking cylinder Use screw locking agent 18 Socket head screw 19 Spacer ring Only ADN 20 25 ELH 20 Socket head screw Only ADN 80 100 ELH use screw locking a...

Page 17: ...e an overview of the individual components To order spare and wearing parts please use the online spare parts catalogue on the Festo website spareparts festo com 2 1 1 3 2 3 3 4 7 4 4 11 5 11 11 12 13 14 2 2 23 23 5 6 5 6 5 5 6 23 23 2 2 15 16 17 15 18 20 19 21 22 5 22 9 8 10 9 10 9 10 ...

Page 18: ...g Only ADN 20 25 ELV 9 Locking cylinder Use screw locking agent 10 Socket head screw 11 Cylinder barrel 12 Piston rod male thread Only ADN ELV A 13 Piston rod female thread Only ADN ELV I 14 Piston Only ADN 20 32 ELV 15 Seal piston 16 O ring 17 Magnet 18 Guiding band 19 Nut Use screw locking agent 20 Washer Only ADN 20 25 ELV 21 Hex nut Only ADN 20 25 ELV use screw locking agent 22 End cap 23 Sock...

Page 19: ...if the cylinder barrel is showing signs of significant damage 4 3 Cylinders ADN KP The description in this chapter can be used to repair cylinders of the type ADN KP with the following features Code Description Code Description KP Clamping unit KP attached K2 Piston rod with extended male thread A Male thread K5 Piston rod with special thread I Female thread K8 Extended piston rod P Elastic cushio...

Page 20: ... cover 4 Piston rod seal 5 Location hole for clamping unit KP 5 2 Removing the covers ADN 20 to 63 KP Loosen the flange screws in the bearing cap and and end cap and remove them Pull the bearing cap away from the piston rod Remove the end cap from the cylinder barrel Loosen the flange screws in the cover with clamping unit KP and remove them Pull the cylinder barrel from the piston rod Remove any ...

Page 21: ...ing is released To remove the piston rod pressurise the compressed air connection of the clamping unit KP 1 3 to max 10 bar or insert a screw M5 or G1 8 into the thread for the compressed air connection 2 until the clamping is released Pull the piston rod out of the cover with clamping unit KP 2 3 1 Pull the clamping unit KP out of the location hole in the cover Clean the location hole and clampin...

Page 22: ...ue see table ADN 32 to 100 KP Place the washer on the piston rod Apply the screw locking agent included in the set of wearing parts to the hex nut and screw it onto the piston rod with the corresponding torque see table Type Torque ADN 20 KP 2 7 Nm ADN 25 KP 7 Nm ADN 32 KP 9 2 Nm ADN 40 KP 13 5 Nm ADN 50 KP 30 Nm ADN 63 KP 12 Nm ADN 80 KP 45 5 Nm ADN 100 KP 45 5 Nm 5 5 Inserting the piston rod int...

Page 23: ...arrel so that the first lip ring protrudes slightly at the other end of the cylinder barrel Pull the piston rod back again until the piston is sitting fully in the cylinder barrel Note This approach ensures that the sealing lips of the two lip rings sit correctly in the cylinder barrel 5 6 Repairing and attaching the covers Remove the piston rod seal 1 from the bearing cap 2 1 2 Remove the piston ...

Page 24: ...d seals as follows Area Greasing 1 Grease reservoir1 for piston rod Fill 2 3 with grease 2 External surface for bearing cap Thin film2 3 Grease reservoir1 for bearing Fill 2 3 with grease 1 See chapter 7 2 3 Grease reservoir 2 See chapter 7 2 2 Thin grease film 1 2 3 Insert the piston rod seals into the bearing cap and the cover with clamping unit KP Note Note the mounting direction individual sea...

Page 25: ...clamping unit KP 1 3 to max 10 bar or insert a screw M5 or G1 8 into the thread for the compressed air connection 2 until the clamping is released 2 3 1 Guide the cover with clamping unit KP over the mounting sleeve see chapter 9 2 Special tools onto the piston rod as far as the cylinder barrel ADN 20 to 63 KP Align the cover with clamping unit KP flush with the cylinder barrel Apply the screw loc...

Page 26: ...m ADN 63 KP 35 Nm ADN 80 100 KP Guide the bearing cap over the mounting sleeve see chapter 9 2 Special tools onto the piston rod as far as the cover with clamping unit KP Apply the screw locking agent included in the set of wearing parts to the socket head screws and screw these through the bearing cap and cover with clamping unit KP into the cylinder barrel Align the bearing cap and the cover wit...

Page 27: ...aring cap 4 Piston rod seal 6 1 2 Structure of the bearing cap with end position locking 1 4 3 2 5 1 O ring 2 Bearing 3 Bearing cap with end position locking 4 Piston rod seal 5 Fixture for the end position locking 6 2 Removing the covers Note The bearing end and intermediate cap with end position locking can only be removed from the piston rod when the end position locking is unlocked ...

Page 28: ...aring and end caps from the cylinder barrel and piston rod Only ADN 20 25 ELB ELV Pull the intermediate cap away from the cylinder barrel and piston rod Remove any residue of the screw locking agent from the threads of the screws Pull the cylinder barrel from the piston rod Remove any residue of the screw locking agent from the threads of the screws 6 3 Replacing the piston components Pull the pis...

Page 29: ...luded in the set of wearing parts to the following parts Component Greasing Inside surface of cylinder barrel Thin film1 Surface of piston rod Thin film1 Piston seal lip rings Thin film1 on outside Piston surface between lip rings grease reservoir2 Fill 2 3 with grease 1 See chapter 7 2 2 Thin grease film 2 See chapter 7 2 3 Grease reservoir Place the piston flat against the front side of the cyli...

Page 30: ...ng is showing significant damage Only with the locking cylinder disassembled Clean the thread in the locking cylinder fixture in the bearing intermediate and or end cap Clean the seat of the piston rod seal 1 in the bearing cap Clean the seat of the O ring 2 in the bearing and end caps Only ADN 20 25 ELB ELV Clean the seat of the O ring 3 in the intermediate cap 1 2 Grease the new piston rod seal ...

Page 31: ...ighten the screws using the appropriate torque see table Type Torque Flange screw ADN 20 ELB ELH ELV 9 Nm ADN 25 ELB ELH ELV 9 Nm ADN 32 ELB ELH ELV 27 Nm ADN 40 ELB ELH ELV 27 Nm ADN 50 ELB ELH ELV 35 Nm ADN 63 ELB ELH ELV 35 Nm Socket head screw ADN 80 ELB ELH 12 Nm ADN 80 ELV 8 Nm ADN 100 ELB ELH ELV 9 Nm Push the piston rod with the piston as far as possible onto the cylinder barrel To protect...

Page 32: ...N 50 ELB ELH ELV 35 Nm ADN 63 ELB ELH ELV 35 Nm Socket head screw ADN 80 ELB ELV 12 Nm ADN 80 ELH 8 Nm ADN 100 ELB ELH ELV 9 Nm 6 6 Reestablishing the functionality of the locking cylinder 6 6 1 Assembly of the locking cylinder following disassembly Only with ADN 20 25 EL Insert the spacer ring in the locking cylinder fixture in the intermediate and or end cap Screw the locking cylinder into the r...

Page 33: ...sen the lock nut 3 on the locking cylinder 1 Unscrew the screw 2 from the locking cylinder 1 2 3 1 Perform a functional test as per the operating instructions enclosed with the cylinder or can be called up on the Festo website www Festo com and commission the repaired cylinder ...

Page 34: ... cylinder barrel to produce an even lubricant film 7 2 1 Extremely thin grease film A barely continuous film of grease covers the bearing surface The grease can give a sheen to the surface however the colour of the grease must not darken it Recommendation Apply the grease using a cloth or similar dipped in the grease Remove the excess grease from the seal system components e g by drawing the assem...

Page 35: ...d The mounting sleeve for piston rods for protecting the piston rod seal and the bearing in the bearing cap while the repair is being carried out must be produced by the customer The schematic diagram is included in the information brochure Accessories equipment and tools 7Accessories_a_en Documents Further information on the special tools and schematic diagrams is included in the information broc...

Page 36: ...being further developed with regard to hardware and software The hardware status and where applicable the software status of the product can be found on the type plate of the product If the electronic documentation no matter in what form does not directly accompany the product i e if the product is not supplied together with a portable data storage medium floppy disk CD Rom removable disk Festo do...

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