Maintenance Guides 1 min read

Air cylinder maintenance: seal replacement, damping adjustment and speed governor adjustment

Technical analysis: Pneumatic cylinder maintenance: seal replacement, cushioning adjustment, and speed controller tuning

Air cylinder maintenance: seal replacement, damping adjustment and speed governor adjustment

1. Meaning and purpose

This manual refers to the maintenance of pneumatic cylinders used in industrial systems. It is designed to perform routine maintenance including replacing seals, adjusting damping and adjusting the speed governor. The minimum term for this support is 200 hours of operation or every 12 months, depending on usage. This is necessary to ensure the reliability and efficiency of industrial equipment.

2. Security measures

Important: Before performing any work, perform a Lockout/Orange Flag (LOTO) procedure to ensure power is off and no hazardous energy sources are present.
Important: Use appropriate personal protective equipment (PPE), including gloves, goggles, protective clothing, a protective mask, and high-pressure equipment.
Important: Shut off the pneumatic system before starting work using appropriate valves or ventilation systems. Check that there is no pressure in the system.

3. Necessary tools and materials

Name of the tool Specification Quantity
Torque head Metric, 10–30 N·m 1
Multimeter Range 0–250 V, 0–20 A, 0–500 MΩ 1
Laser for measurement Range 1–10 m, accuracy ±0.02 mm 1
Level Corresponding to ISO 12991 1
Spanners Metric, 6–30 mm 1 set
Stands for the cylinder Metal, with rubber rings 2
Pressure washers Thickness 1.5–3 mm 4
Sealing NBR material, diameter 50–100 mm 6
Special mastic Pneumatic, ISO 46 0.5 l

4. Before service: Inspection

Point Verification Acceptance criteria Notes
1 Checking the disconnection of the pneumatic system The pressure in the system is less than 0.1 bar Use a pressure gauge
2 Checking the absence of electrical sources No power on the system Use a multimeter
3 Checking the cleanliness of surfaces There are no signs of contamination on the surface Use dry or wet paper
4 Inspection of seals There are no leaks or damage to the seals Use a micro ruler
5 Checking the speed controller The regulator does not experience improper wear Use a visual tool

5. Step by step

  1. Disabling the pneumatic system

    • Perform the LOTO procedure for the pneumatic system.
    • Check the pressure in the system using a manometer: the pressure should be less than 0.1 bar.
    • Error: Failure to shut down the system could result in personal injury or equipment damage.

  2. Dismantling the cylinder

    • Loosen the cylinder lock nuts using the appropriate size wrench.
    • Unscrew the mounting bolts using a torque head with a range of 10-30 N·m.
    • Error: incorrect unscrewing can lead to loss of components.

  3. Replacing seals

    • Remove old seals using special tools.
    • Insert the new seals using the spacers. Ensure proper fit.
    • The pressure in the system must be at least 5 bar for proper fixation.
    • Error: Improperly seated gaskets can cause leakage or damage.

  4. Extinguishing regulation

    • Use a laser to measure the quench position.
    • Set the damping to 25% of maximum power.
    • After adjustment, check the speed of the cylinder: from 0.5 to 1.5 m/s.
    • Error: Improper quenching can cause overheating or wear.

  5. Speed controller settings

    • Set the regulator to 40% power.
    • Use a multimeter to check the output pressure: 4-6 bar.
    • Error: Incorrect adjustment of the regulator can lead to non-compliance with the technical characteristics.

  6. Checking seals

    • Use a micro ruler to measure seal wear: no more than 0.5 mm.
    • Check for leaks when depressurizing.
    • Bug: Seal leaks can cause malfunctions.

6. After service: Inspection

Test Expected result Actual Pass/Fail
1 Pressure in the system 0.1–0.5 bar
2 Speed of movement 0.5–1.5 m/s
3 Origins Absent
4 Extinguishing 25-30%
5 Speed controller 4–6 bar

7. Troubleshooting

Symptom Probable cause Appropriate actions
1 Origins Worn or damaged seals Replace the seal
2 Incorrect speed Incorrect regulator setting Check and install the regulator
3 Overheating Improper quenching Adjust extinguishing
4 Inadequate performance Wrong connection Check and connect
5 Lack of movement Lack of power Check the power supply

8. Recommended maintenance schedule

The task Frequency Estimated duration Skill level
Replacement of seals Every 12 months 2 hours Average
Quenching regulation Every 6 months 1.5 hours Average
Setting the speed controller Every 6 months 1 hour Average
Inspection of seals Every 6 months 1.5 hours Average

9. Special parts

Description of the part Typical specification UNITEC-D category
Sealing HBR, diameter 50–100 mm Special seals
Speed controller Material: stainless steel, output pressure 4–6 bar Speed controllers
Pressure washers Thickness 1.5–3 mm Stands
Special mastic Pneumatic, ISO 46 Oils and lubricants

For additional components, go to our e-catalog: https://www.unitecd.com/e-catalog/

10. Links

This textbook meets the following standards:

  • DSTU 2857-2012: Standards for operation and maintenance of industrial equipment
  • EN 1434: Pneumatic systems
  • ISO 13849: Hardware security
  • CE, UkrSEPRO

Additional documents from the manufacturer can be found on the website:

  • https://www.unitecd.com/technical-documents/

Related Articles