B

1 Screw out guide bushing

Figure 3: sealing assembly

Figure 2: sealing assembly

{B} with key of supplied tool.

2
Remove seals {C, D} and guide rings {E} with a small pointed tool (Figure
2-1). Attention groove must not be damaged also on the side.
3 Insert a new o-ring into the groove.
4
Preheat seal ring in water or oil bath or with a hot air fan up to max.
100C.
5
Compress seal-ring into kidney shape. There should be no sharp kinks
(Figure 2-2 and -3).
6

Place seal-ring in compressed form in O-ring and press into groove in

direction of arrow (Figure 3).

7 Then calibrate with mandrel (chamfered 10-15 and around 30 mm long).

10lnsert new guide rings.
11 Check seriously whether the piston rods show any signs of scuffing or burrs
due to external damage. If this is the case, these markings must be removed
and the damaged places new polished with fine polishing cloth. For extreme
damage the piston rod must be exchanged. If the Piston rod has a thread it
must be lapped by an insulating tape.
12Carefully slide guide bushing {B} with fitted seals over the piston rod.
13 Fit dismantled machine parts.
Reference: Strip piston rod only down, when absolutely necessary (see

Chapter "Changing Piston Sealing").

Attention: Each time after changing the hydraulic

fluid or any other hydraulic element the hydraulic system must be bled.
It should be carried out such that:
a) The cylinder is engaged so that it can execute its full stroke. Switch to
manual mode.
b)

Reduce pressing force and dwell pressure.

c)

Engage pump and idle for two minutes.

d) Move cylinder to upper and lower position and keep buttons pushed for about two
minutes.
Move cylinder up and down by hand, after approx. 20 operating cycles of the
cylinder increase pressure to maximum. Push up and down button again for about
two minutes and execute a further approx. 20 operating strokes.
Bleeding is also possible by running through the hydraulic program in automatic mode
several times, if the cylinder travels his full stroke.
0.

1.1 Changing piston sealing in the press cylinder I ring cylinder

The sealings of the piston in the press cylinder is provided by special seals. These
seals combine minimal abrasion with optimal sealing effect.
When there are wear and tear of the seals, the seals must be exchanged with great
care.
Reference. Strip piston rod only down, when absolutely necessary:
Assembly of the piston rod
Only unscrew piston rods if they are damaged. The rods must align exactly again after
assembly. Put the piston rods assembled onto two prisms in a distance of
approximately 1000mm. Measure the true running on piston and on both piston rods
beneath the piston with a dial gauge. The tolerance of the true running must be smaller
than 0.1mm, otherwise there would be a premature abrasion. When there are smaller
cylinders, decrease the tolerance proportionally to the supporting width. If the tolerance
is bigger, unscrew piston rods and rotate piston a little bit. Tighten piston rods again and
check them once more. If the required tolerance cannot be achieved, you will have to
exchange at least one piston rod.

Proceeding for exchange of the piston seal:

Dismantling the cylinder must be carried out as far as to permit the piston to be

taken out. Remove worn seals with a pointed tool. Don't damage the groove also at the side.
Mount the new seal as follows;
See the referring assembly-drawing or below schematic:

1. In manual mode move cylinder into maximum upper position

A
2.

Danger:Install a winch between top of table and plunger x/y-adjuster

to prevent cylinder fall down.
Make sure that the winch has an additional lift of ~ 100mm.

3.

Danger: Turn off the hydraulic pumps. Activate EMERGENCY OFF

and lock it in OFF-position

4.

Remove the attachment bracket for linear encoder.

5.

Loosen bolts [K] and remove cover [L].

6.

Loosen bolts [M] and remove bushing [B],

Use two longer bolts to assist pulling.

7.

Remove piping from upper cylinder head. Loosen bolts [N] and remove the cylinder
head.

8.

Now lift the winch until the piston-seal [H] reaches to be approx. 70 mm outside of the
cylinder tube.

9.

Remove sealing ring [H] and O-Ring [J],

10. Changing the piston seal
The seals must be exchanged with great care.
Remove worn seals with a pointed tool. Don't damage the groove also at the side.

Use not sharp edged tools to expand the seal ring!Mount the new seal as follows:
Insert the O-Ring into the piston groove. Dont twist the O-Ring during
assembly!

Seal ring can be installed easily by heating in water or oil bath up to 100C.

Snap one side of the seal ring into the groove, then stretch the seal ring with the
calibration ribbon as shown and fit the seal ring into the groove.

Center the seal ring, then remove the calibration ribbon.

Sizing of the seal ring is achieved with a calibrating sleeve.

Calibratin
g
sleeve

The inside diameter of the calibrating sleeve should correspond to the cylinder
diameter. Calibrating may also be effected via the inlet bevels existing on the cylinder.
11.

Reassemble all parts of the cylinder in reverse order.

Attention: Tighten the bolts [N] crosswise with a torque of 190 Nm.

12.

Now you need to vent the hydraulic system.

Attention: Each time after changing the hydraulic fluid or any other hydraulic element the
hydraulic system must be bled. This is carried out by running through the hydraulic program
several times for itself.It should be carried out such that:
e) The cylinder is engaged so that it can execute its full stroke. Switch to
manual mode.
f) Reduce pressing force and dwell pressure.
g) Engage pump and idle for two minutes.
h) Move cylinder to upper and lower position and keep buttons pushed for about
two minutes.
Move cylinder up and down by hand, after approx. 20 operating cycles of the
cylinder increase pressure to maximum. Push up and down button again for
about two minutes and execute a further approx. 20 operating strokes.
l Reference: In many cases it is possible to mount the Turcon-rings without this
3-sectional mounting tool, for example by hand or with help of a plastic ribbon.
The ring is put into the first groove with one side, and is draw over the other edge of the
piston. To make this easier, definitely preheat the ring in water or oil bath or with a hot-air

jflU

fan up to 100C. The piston must not have sharp edges in this case.