Repair instructions Wear parts set for ZX series piston rodless cylinder

ZX-cylinder Variant: K and S version

In order to ensure fault-free functioning, perform maintenance strictly according to these instructions. Observe the national standards, safety regulations and accident prevention regulations.

Make certain that the drive is not under pressure and power before beginning maintenance work. Maintenance
Author: Name: Date:

work

requires

the

following

tools

and

working

materials:

Wear parts set (see Table 1.1) Cleaning and re-greasing the cylinder tube with a suitable brush Allen key (standard set of keys sufficient) Small screwdrivers (drive slit), size 1-3 Trimming punch
Checked/released: Name: A. Steinhart Date: 04.07.2007 Changed: Name: Date: Ref. - Nr. 00 54-ZXV-01-G

E. He 2 July, 2007

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Repair instructions Wear parts set for ZX series piston rodless cylinder ZX- 25 32 40 50 63
Table 1.1

Wear part set ZXV-25- stroke ZXV-32- stroke ZXV-40- stroke ZXV-50- stroke ZXV-63- stroke

Standard stroke lengths 0500/1000/1500/2000/3000/4000/5000/6000 0500/1000/1500/2000/3000/4000/5000/6000 0500/1000/1500/2000/3000/4000/5000/6000 0500/1000/1500/2000/3000/4000/5000/6000 0500/1000/1500/2000/3000/4000/5000/6000

1. Dismantling the cylinder

1.1. Unscrew the two countersunk screws (1) and remove the two clamping plates (2). 1.2. Remove the two headless pins (3), between the cover band (6) and the band seal (11).

headless pins (3)

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E. He 2 July, 2007

Checked/released: Name: A. Steinhart Date: 04.07.2007

Changed: Name: Date:

Ref. - Nr. 00 54-ZXV-01-G

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Repair instructions Wear parts set for ZX series piston rodless cylinder 1.3 . Unscrew the set screws (5) and remove the two pressure pads (4). 1.4. Pull out the cover band (6) from one end. 1.5. Unscrew the cylinder head screws (8) and carefully remove the two cylinder heads. 1.6. Guide the piston carrier (9) carefully out of the cylinder barrel (10).
(11)

1.7. Remove the band seal (11).

1.8. Remove all piston sealings (12, 13, 14, and 15) with a small slotted screwdriver. Be careful not to damage the piston carrier surface. Note: No. 13 (O ring) is only with 25 mm diameter. 1.9. Remove the U-shaped felt seal (17) from both pressure pads (4). Clean the two pressure pads, insert the new U-shaped felt seals, and then uniformly lubricate the outer facing with the grease provided.
Grease outer facing

1.10. Clean the dismantled components (head, inner/outer tube, piston carriage)

Author: Name: Date:

E. He 2 July, 2007

Checked/released: Name: A. Steinhart Date: 04.07.2007

Changed: Name: Date:

Ref. - Nr. 00 54-ZXV-01-G

We reserve the right to make technical changes 54-ZXV-01-G page 3 of 9

Repair instructions Wear parts set for ZX series piston rodless cylinder Remove the two felt strips and replace them with the new strips. The guide elements can be re-positioned.
Felt strip

Note: For the K version cut the felt strips to the correct length. Replacing the felt strips for the piston carriage (Note: does not apply for 25 mm diameter K version!) Use the length of the old felt strips.

Guide element

2. Mounting the piston sealing

Note: Do not use pointed or sharp-edged tools! 2.1. With the grease provided, generously lubricate the inner and outer running surfaces of. Note: No. 13 (O ring) is only with 25 mm diameter.
Piston sealing (14)

Packing ring (12) O ring (13)

2.2. Carefully mount the piston seal (14) with the fingers making certain of the correct position. Insert the packing ring (12) as in the illustration. Note: For 25 mm diameter, slide the O ring between no.12 and no. 14.

Author: Name: Date:

E. He 2 July, 2007

Checked/released: Name: A. Steinhart Date: 04.07.2007

Changed: Name: Date:

Ref. - Nr. 00 54-ZXV-01-G

We reserve the right to make technical changes 54-ZXV-01-G page 4 of 9

Repair instructions Wear parts set for ZX series piston rodless cylinder 2.3. Grease the inner and outer running surfaces of the damping seal (15). Insert with pressure in the inner groove from the side. Note: Direction of insertion of seal.
Groove

3. Mounting the cylinder head seals

Note: There are no smaller O rings for the 01 version 3.1. Remove the old O rings. 3.2. Then grease the O rings from the wear part set and insert in the grooves.

4. Mounting the cylinder

4.1. Lubricate the cylinder tube (10) with the grease provided, e.g. with a brush. Note: Lubricate only the inner piston surface generously and uniformly.

4.2. Grease the perimeter of the damping tube (16).

Lubricate here

Author: Name: Date:

E. He 2 July, 2007

Checked/released: Name: A. Steinhart Date: 04.07.2007

Changed: Name: Date:

Ref. - Nr. 00 54-ZXV-01-G

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Repair instructions Wear parts set for ZX series piston rodless cylinder 4.3. Grease the band seal (11) (see illustration).
Lubricate here Lubricate here

Lubricate here

Lubricate here

4.4. Insert the band seal (11) through the groove. Note: It lies loosely in the inner running surface.

4.5. Then guide the band seal (11) through the groove in the piston carriage (9). Make certain that the guide elements are flush with the facings of the piston carrier. Note: In order to maintain a defined magnet position, mount the piston with a mark on the indented groove.

mark

indented groove

Author: Name: Date:

E. He 2 July, 2007

Checked/released: Name: A. Steinhart Date: 04.07.2007

Changed: Name: Date:

Ref. - Nr. 00 54-ZXV-01-G

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Repair instructions Wear parts set for ZX series piston rodless cylinder 4.6. Carefully guide the piston carrier (9) into the cylinder barrel (10) and push through until the piston seal (14) is visible at the other end of the cylinder tube. Note: Firmly hold the band seal. Remove excess grease from the cylinder tube facing! Slide the piston carrier (9) back until the front facing of the cylinder tube (10) is flush with the piston carriage (9).

4.7. The band seal (11) must hang over on both sides, so that both cylinder heads are covered.

4.8. Screw down the cylinder heads (7) to the cylinder tube (10) with the cylinder head screws (8). Note: Tighten the screws to the specified torque.
ZX- Torque in Nm 25 32 40 50 63

6,5

12

27

27

4.9. Trimm the length of the band seal (11) so that it is flush with the outer side of the cylinder head (7).

Author: Name: Date:

E. He 2 July, 2007

Checked/released: Name: A. Steinhart Date: 04.07.2007

Changed: Name: Date:

Ref. - Nr. 00 54-ZXV-01-G

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Repair instructions Wear parts set for ZX series piston rodless cylinder

4.10 Guide the cover band (6) through the piston carrier (9) and clip into the groove of the cylinder tube (10). Cut the length of the cover band (6) so that it is flush with the outer side of the cylinder head (7).

4.11. Insert the two headless pins (3) between the cover band (6) and the band seal Note: The headless pin mechanism must point in the direction of the centre of the cylinder.
Set screw

4.12. Attach the two clamping plates (2) to the ends of the cylinder heads (7), making certain that the whole patterns of the clamping plate and the cylinder head match. Note: Tighten the screws to the specified torque.
ZX- Torque in Nm 25 32 40 50 63

Author: Name: Date:

E. He 2 July, 2007

Checked/released: Name: A. Steinhart Date: 04.07.2007

Changed: Name: Date:

Ref. - Nr. 00 54-ZXV-01-G

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Repair instructions Wear parts set for ZX series piston rodless cylinder

4.13. Mount the two pressure pads (4) with the countersunk screws (5) on the piston carriage (9). Note: Tighten the screws to the specified torque.
ZX- Torque in Nm 25 32 40 50 63

0,2

0,2

0,2

0,6

0,6

4.14. Connect the pressurised air supply.

4.15. Check the functionality and the sealing of the cylinder.

Author: Name: Date:

E. He 2 July, 2007

Checked/released: Name: A. Steinhart Date: 04.07.2007

Changed: Name: Date:

Ref. - Nr. 00 54-ZXV-01-G

We reserve the right to make technical changes 54-ZXV-01-G page 9 of 9