Festo ADVU Series Setup guide

Repair
instructions (en)
Compact cylinder
ADVU/AEVU
7ADVU / AEVUa_en

2 / 29 Festo 7ADVU / AEVUa_en
Imprint
Version:
7ADVU / AEVUa_en (06.2013)
Copyright:
©Festo AG & Co. KG
P.O. Box
73726 Esslingen
Germany
Editorial team:
SC-S
Tel.:
+49 (0) 711 / 347-0
Fax:
+49 (0) 711 / 347-2144
E-mail:
[email protected]
Internet:
http://www.festo.com
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 identied
as such.
All technical data are subject to
change according to technical
updates.

3 / 29Festo 7ADVU / AEVUa_en
Preface
These repair instructions are valid for the compact cylinders listed on the title
page to the exclusion of any liability claims.
There may be deviations from the descriptions in these repair instructions
depending on the version and/or modication status of the compact cylinder.
The user must check this prior to carrying out the repair and take the 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 8 "Liability".
The relevant regulations on occupational safety, safety engineering and
interference suppression as well as the stipulations contained in these repair
instructions must be observed when working on the products.

4 / 29 Festo 7ADVU / AEVUa_en
Table of contents
1 Important information 5
1.1 About these repair instructions 5
1.2 Pictograms used in these repair instructions 5
1.3 General safety instructions 6
1.4 Orientation designations 6
2 General product description 7
2.1 Functional description of compact cylinder ADVU (double-acting) 7
2.2 Functional description of compact cylinder AEVU (single-acting, pushing/pulling) 7
2.2.1 "Pushing" functional mode 7
2.2.2 "Pulling" functional mode 8
2.3 Type codes (ascertaining the features of a cylinder) 9
3 Component overview 10
3.1 ADVU-…-P-A/-…-P-A-S2 /…-A-P-A /-…-A-P-A-S2 10
3.2 AEVU-…-P-A/ -…-P-A-S2/ …-A-P-A/ -…-A-P-A-S2 12
3.3 ADVU-125-…-P-A /-P-A-S2 /-A-P-A /-A-P-A-S2 14
4 Repair steps 15
4.1 Preparation 15
4.2 Visual inspection 15
4.3 Repairing compact cylinder ADVU…/ AEVU… 15
4.3.1 Structure of the bearing cap 15
4.3.2 Removing the bearing and end caps 16
4.3.3 Replacing the piston components 16
4.3.4 Inserting the piston rod into the cylinder barrel 18
4.3.5 Repairing the bearing and end caps ADVU-… /AEVU-… 19
4.3.6 Attaching the bearing and end caps ADVU…-… 20
4.3.7 Attaching the bearing and end caps AEVU…-… 21
4.4 Repairing compact cylinder ADVU-125-… 23
4.4.1 Structure of the bearing cap 23
4.4.2 Removing the bearing and end caps 23
4.4.3 Replacing the piston components 23
4.4.4 Inserting the piston rod into the cylinder barrel 24
4.4.5 Repairing and attaching the bearing and end caps 25
5 Cleaning and greasing 27
5.1 Cleaning 27
5.2 Greasing 27
5.2.1 Extremelythingreaselm 27
5.2.2 Thingreaselm 27
5.2.3 Grease reservoir 27
6 Maintenance and care 27
7 Tools 28
7.1 Standard tools 28
7.2 Special tools 28
8 Liability 28

5 / 29Festo 7ADVU / AEVUa_en
1 Important information
1.1 About these repair instructions
This document contains important
information about the proper repair
of the compact cylinders of type
ADVU… / AEVU….
The compact cylinders
ADVU… /AEVU…. are fully repairable
in the event of damage due to normal
wear. The entire cylinder must be
replaced in the event of damage to
the cylinder barrel.
These repair instructions do not apply
to ADVU… /AEVU… compact cylinders
with a piston diameter of 12, 16, 20
and 25 mm. These compact cylinders
can generally not be repaired and
have to be replaced.
Before carrying out a repair, the
relevant chapter in these instructions
must be read in full and followed
consistently.
For reasons of clarity, these repair
instructions do not contain complete
detailed information. The following
documents should therefore also be
available while doing repair work on
the compact cylinder:
• Operating instructions for the
relevant compact cylinder
Contains information about
the operating elements and
connections of the compact
cylinder as well as the function,
structure, application, installation,
commissioning, maintenance and
care, etc. can be 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
Contain an overview of available
assembly aids such as lubricating
greases, screw locking agents,
maintenance tools, etc. (aids
for assembly and maintenance).
Can be found in the online spare
parts catalogue on the Festo
website (www.Festo.com).
1.2 Pictograms used in these repair instructions
Warning
This sign indicates a dangerous situation for persons and/or the product. Failure to observe this warning can result
in injury to persons and/or damage to the device.
Note
This sign provides important tips and information that can make your work easier.
Environment
This sign provides information on the steps required for environmentally-friendly use of materials and equipment,
as well as the guidelines and regulations that may need to be observed.
Accessories
This sign contains information on accessories and attachments relevant to the context.
Documents
This sign contains references to other chapters or documents containing additional information.

6 / 29 Festo 7ADVU / AEVUa_en
1.3 General safety instructions
Warning
The compact cylinder must only be repaired by authorised and trained persons in accordance with the speci cations
in the technical documentation and using genuine spare parts (of the appropriate type and version).
Installation and repair by unauthorised and untrained persons, repairs using non-original spare parts or without
the technical documentation required for installation and/or repair are dangerous and therefore not permitted.
Repairs must only be carried out in conjunction with these repair instructions and the device-speci c operating
instructions.
Note
Instead of carrying out the repair yourself, your local Festo sales of ce 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.
1.4 Orientation designations
This diagram provides an overview of the orientation designations for the compact cylinder.
Orientation:
Festo = Festo logo is the point
of reference
O = top
U = underneath
R = right
L = left
V = front
H = rear

7 / 29Festo 7ADVU / AEVUa_en
2 General product description
2.1 Functional description of compact cylinder ADVU (double-acting)
The piston moves forward in the cylinder barrel when the rear cylinder chamber is pressurised. The piston rod transmits
the movement to the outside. The advanced piston rod is retracted again when the front cylinder chamber is pressurised.
6
7
8
1 3 542 1Piston rod
2Wiper seal
3Compressed air connection,
front cylinder chamber
4Bearing cap
5Piston with magnet
6Compressed air connection,
rear cylinder chamber
7End cap
with S2 / S20 / S26 / S206:
rear bearing cap
8Cylinder barrel
2.2 Functional description of compact cylinder AEVU (single-acting, pushing/pulling)
2.2.1 "Pushing" functional mode
During "pushing" functional mode, the piston rod is fully retracted through the integrated compression spring in the
front cylinder chamber. The piston moves forward in the cylinder barrel when the rear cylinder chamber is pressurised.
The piston rod transmits the "pushing" movement to the outside. The advanced piston rod is retracted again through
the spring force when the rear cylinder chamber is depressurised.
7
8
9
1 3 5 642 1Piston rod
2Wiper seal
3 Compressed air outlet with lter
nipple
4Bearing cap
5Compression spring
6Piston with magnet
7Compressed air connection,
rear cylinder chamber
8End cap
with S2 / S20 / S26 / S206:
rear bearing cap
9Cylinder barrel

8 / 29 Festo 7ADVU / AEVUa_en
2.2.2 "Pulling" functional mode
During "pulling" functional mode, the piston rod is advanced to the maximum length through the integrated compression
spring in the rear cylinder chamber. The piston moves in the cylinder barrel when the front cylinder chamber is
pressurised. The piston rod transmits the "pulling" movement to the outside. The retracted piston rod is advanced again
through the spring force when the front cylinder chamber is depressurised.
7
8
9
1 3 5 642 1Piston rod
2Wiper seal
3Compressed air connection,
front cylinder chamber
4Bearing cap
5Piston with magnet
6Compression spring
7 Compressed air outlet with lter
nipple
8End cap
with S2 / S20 / S26 / S206:
rear bearing cap
9Cylinder barrel

9 / 29Festo 7ADVU / AEVUa_en
2.3 Type codes (ascertaining the features of a cylinder)
The precise features of the current compact cylinder can be ascertained with the help of the rating plate on the cylinder.
The type designation is located directly beneath the Festo logo and describes the cylinder's features separated by
a hyphen (-).
Example:
AEVULQZ-63-25-A-P-A-S206
156 044 AN08
0,8-10 bar
1
42
3
1Type designation
2Serial number
3Technical information
4Part number
The type designation on these rating plates provides the following information:
AEVU Cylinder of type AEVU (single-acting)
LQ Square piston rod (protected against rotation)
Z"Pulling" design
63 Piston diameter 63 mm
25 Stroke 25 mm
AMale thread
PElastic cushioning rings/pads at both ends
ASensing option (magnetic piston)
S206 Through, hollow piston rod, heat-resistant seals
Note
A list and description of all possible equipment features of the compact cylinder can be found in the data sheet.
It is available on the Festo website (www.Festo.com).

10 / 29 Festo 7ADVU / AEVUa_en
3 Component overview
3.1 ADVU-…-P-A / -…-P-A-S2/…-A-P-A / -…-A-P-A-S2
ADVULQ-…-P-A / -…-P-A-S2/…-A-P-A / -…-A-P-A-S2
ADVU-…-A-P-A-S20 / -S206, ADVULQ-…-A-P-A-S20 /-S206
9
13
12
7
7
4
2
5
7
815
16
17
18
19
15
20
21
21
22
23
27
24
25
7
26
7
5
4
6
1
7
14
11
10
3
1
1
2
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).

11 / 29Festo 7ADVU / AEVUa_en
Item Designation Note
1 Flange screw Use screw locking agent (set of wearing parts)
2 Polyurethane wiper seal For cylindrical piston rod, for S6 / S26 uororubber
3 Polyurethane wiper seal For square piston rod, for S6 / S26 uororubber
4 Bearing cap
5 Bearing For cylindrical piston rod
6 Bearing For square piston rod
7 Hex nut For piston rod with male thread
8 Cylindrical piston rod with male thread
9 Square piston rod with female thread
10 Cylindrical hollow piston rod with male
thread
11 Square hollow piston rod with male thread
12 Hollow bolt Use screw locking agent (set of wearing parts)
13 Square piston rod with female thread
14 Square piston rod with male thread
15 Piston seal
16 Piston for magnet
17 O-ring
18 Magnet
19 Piston
20 Washer
21 O-ring
22 Cylinder barrel
23 Hex nut Use screw locking agent (set of wearing parts)
24 Piston rod with male thread Use screw locking agent (set of wearing parts)
25 Piston rod with female thread Use screw locking agent (set of wearing parts)
26 Hollow piston rod with male thread
27 End cap

12 / 29 Festo 7ADVU / AEVUa_en
3.2 AEVU-…-P-A/ -…-P-A-S2 /…-A-P-A/ -…-A-P-A-S2
AEVULQ-…-P-A/ -…-P-A-S2 /…-A-P-A/ -…-A-P-A-S2
AEVU-…-A-P-A-S20/ -S206, AEVULQ-…-A-P-A-S20 / -S206
9
13
12
7
7
4
2
5
7
8
16
15
17
19
20
16
21
22
22
23
24
28
25
26
7
27
7
5
4
6
29
1
7
14
11
10
3
1
1
2
18
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).

13 / 29Festo 7ADVU / AEVUa_en
Item Designation Note
1 Flange screw Use screw locking agent (set of wearing parts)
2 Polyurethane wiper seal For cylindrical piston rod, for S6 / S26 uororubber
3 Polyurethane wiper seal For square piston rod, for S6 / S26 uororubber
4 Bearing cap With seat for compression spring
5 Bearing For cylindrical piston rod
6 Bearing For square piston rod
7 Hex nut For piston rod with male thread
8 Cylindrical piston rod with male thread
9 Square piston rod with female thread
10 Cylindrical hollow piston rod with male thread
11 Square hollow piston rod with male thread
12 Hollow bolt Use screw locking agent (set of wearing parts)
13 Square piston rod with female thread
14 Square piston rod with male thread
15 Compression spring
16 Piston seal
17 Piston for magnet
18 O-ring
19 Magnet
20 Piston
21 Washer
22 O-ring
23 Cylinder barrel
24 Hex nut Use screw locking agent (set of wearing parts)
25 Piston rod with male thread Use screw locking agent (set of wearing parts)
26 Piston rod with female thread Use screw locking agent (set of wearing parts)
27 Hollow piston rod with male thread Use screw locking agent (set of wearing parts)
28 End cap
29 Filter nipple

14 / 29 Festo 7ADVU / AEVUa_en
3.3 ADVU-125-…-P-A/ -P-A-S2 /-A-P-A/ -A-P-A-S2
17
2
2
1
8
3
18
3
2
1
5
6
4
12
7
9
10
11
9
13
5
16
6
15
14
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).
Item Designation Note
1 Polyurethane wiper seal For cylindrical piston rod, uororubber for S6
2 Self-tapping screw Use screw locking agent (set of wearing parts)
3 Bearing cap
4 Bearing
5 O-ring
6 Hex nut
7 Piston rod with male thread
8 Piston rod with female thread
9 Piston seal
10 Guiding band
11 Magnetic strip
12 O-ring
13 Cylinder barrel
14 Washer
15 Hex nut
16 Piston rod with male thread Use screw locking agent (set of wearing parts)
17 Piston rod with female thread Use screw locking agent (set of wearing parts)
18 End cap

15 / 29Festo 7ADVU / AEVUa_en
4 Repair steps
4.1 Preparation
• Before starting the repair, remove any attachments (e.g. yoke plate on ADVUL) 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 or end cap, particularly with types AEVU-… / AEVUZ-… cannot suddenly come ying 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.
• Use suitable support devices.
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 signicant damage.
4.3 Repairing compact cylinder ADVU… / AEVU…
with piston diameter 32/ 40 / 50 / 63 /80 /100
The description in this chapter can be used to repair compact cylinders of type ADVU…-…/AEVU…-…:
Code Description Code Description
L Protection against rotation (e.g. yoke plate) S1 Reinforced piston rod
Q Square piston rod S2 Through piston rod
Z Pulling S6 Seals heat-resistant up to 120°C
A Male thread S20 Through, hollow piston rod
P Elastic cushioning rings/pads S26 Through piston rod, heat resistant up to 120°C
A Position sensing S206 Through, hollow piston rod, heat-resistant up to
120°C
R3 Increased corrosion protection
4.3.1 Structure of the bearing cap
1
2
4
3
1Bearing cap
2O-ring
3Bearing
4Wiper seal

16 / 29 Festo 7ADVU / AEVUa_en
4.3.2 Removing the bearing and end caps
Warning
The compression spring of the compact cylinder AEVU…-… is pretensioned. This means that the bearing and end caps
can be ejected during disassembly resulting in injury to persons and/or damage to the device.
Attach appropriate support devices.
• Loosen the screws in the bearing and end caps (the rear bearing cap on
cylinders with through piston rod (S2/ S20/ S26/ S206)) and remove them.
• Pull the bearing and end caps away from the cylinder barrel and piston rod.
4.3.3 Replacing the piston components
• Pull the piston rod out of the cylinder barrel.
• Check the cylinder barrel and piston rod for damage.
The entire cylinder must be replaced if the cylinder barrel (particularly the
bearing surface) is showing signicant damage.
ADVU…-… / AEVU…-…- basic type / -…-S2 / -…-S26
• Unscrew the hex nut (the rear part of the piston rod on cylinders with
through piston rod (S2/ S26)) from the piston rod.
• Remove the piston components from the piston rod, noting the order and
orientation.
• Remove any residue of the screw locking agent from the threads of the
piston rod and hex nut.
• Replace the components with those included in the set of wearing parts and
reassemble the piston components on the piston rod in the correct order.
Note
Make a note of the position of the slot for the compression spring on the
piston of compact cylinder AEVU…

17 / 29Festo 7ADVU / AEVUa_en
• Apply the screw locking agent contained in the set of wearing parts to
the inside of the hex nut (the rear part of the piston rod on cylinders with
through piston rod (S2/ S26)) and screw it onto the piston rod with the
corresponding torque (see table).
Type Torque
ADVU/AEVU-32 9.5 Nm
ADVU/AEVU-40 9.5 Nm
ADVU/AEVU-50 23 Nm
ADVU/AEVU-63 23 Nm
ADVU/AEVU-80 45 Nm
ADVU/AEVU-100 82 Nm
ADVU…-… / AEVU…-…-S20 / -…-S206
• Unscrew the rear part on cylinders with through hollow piston rod
(S20 / S206) from the piston rod. The screw connection between the front
piston rod and hollow bolt or the hollow bolt and rear piston rod can be
loosened during this process.
• Remove the piston components from the hollow bolt, noting the order and
orientation.
• Unscrew the hollow bolt from the piston rod.
• Remove any residue of the screw locking agent from all of the threads.
• Apply the screw locking agent included in the set of wearing parts to the
thread of the hollow bolt and screw the hollow bolt in to the front piston
rod.
Note
The next two work steps must be completed before the screw locking agent
hardens (approx. 10 min. after application).
• Replace the components with those included in the set of wearing parts
and reassemble the piston components on the assembled hollow bolt in the
correct order.
Note
Make a note of the position of the slot for the compression spring on the
piston of compact cylinder AEVU…
• Apply the screw locking agent included in the set of wearing parts to the
thread of the hollow bolt and screw the rear piston rod on to the hollow bolt
with the corresponding torque (see table).
Type Torque
ADVU/AEVU-32 9.5 Nm
ADVU/AEVU-40 9.5 Nm
ADVU/AEVU-50 23 Nm
ADVU/AEVU-63 23 Nm
ADVU/AEVU-80 45 Nm
ADVU/AEVU-100 82 Nm

18 / 29 Festo 7ADVU / AEVUa_en
4.3.4 Inserting the piston rod into the cylinder barrel
• Clean the inside surface of the cylinder barrel as described in chapter
5.1 "Cleaning".
• Apply the grease included in the set of wearing parts to the following parts:
Component Greasing
Inside surface of cylinder barrel Thin lm1)
Surface of piston rod Thin lm1)
Piston seals Thin lm1) on outside
Piston surface between piston seals (grease reservoir2)) Fill 2/3 with grease
1) See chapter 5.2.2 "Thin grease lm"
2) See chapter 5.2.3 "Grease reservoir"
• Place the piston at against the front side of the cylinder barrel and insert
the piston seal into the cylinder barrel by tilting and turning it slightly.
The lip of the piston seal must not fold back against the side of the piston.
Note
If necessary use a at and blunt-edged object to insert the piston seal into
the cylinder barrel.
• Insert the piston fully into the cylinder barrel.
• Push the piston far enough into the cylinder barrel so that the rst piston
seal 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 lips of the two piston seals sit correctly in the
cylinder barrel.

19 / 29Festo 7ADVU / AEVUa_en
4.3.5 Repairing the bearing and end caps ADVU-… / AEVU-…
• Remove the wiper seal 1from the bearing cap 2(both bearing caps on
cylinders with through piston rod (S2/ S20/S206)).
• Remove the O-ring 3from the bearing or end cap 2.
1 2 3
Warning
Check the plain bearing in the bearing cap (the front and rear bearing
caps on cylinders with through piston rod (S2/ S20/S26/S206)) for visible
damage that might impair its function, such as deposits and scoring.
The entire bearing cap must be replaced if the plain bearing is showing
signi cant damage.
• Clean the seat of the wiper seal 1and the O-ring 2.
• Grease the new wiper seal (one per bearing cap on cylinders with through
piston rod (S2/ S20/S26/S206)) as follows:
Component Greasing
1Grease reservoir2) for piston rod Fill 2/3 with grease
2External surface for bearing cap Thin  lm1)
3Grease reservoir2) for bearing Fill 2/3 with grease
1) See chapter 5.2.2 "Thin grease  lm"
2) See chapter 5.2.3 "Grease reservoir"
1 2
• Insert the new wiper seal into the bearing and end caps (both bearing caps
on cylinders with through piston rod (S2/S20 /S26 /S206)).
Note
Observe the installation position on cylinders with a square piston rod.
• Grease the new O-rings from the set of wearing parts and insert them into
the bearing and end caps (in both bearing caps on cylinders with through
piston rod (S2 / S20/S26/S206)).

20 / 29 Festo 7ADVU / AEVUa_en
4.3.6 Attaching the bearing and end caps ADVU…-…
• To protect the bearing and seals, place the appropriate mounting sleeve
(see chapter 7.2 "Special tools") on the thread of the piston rod to prevent
damage.
• Guide the bearing cap (both bearing caps on cylinders with through piston
rod (S2/S20/S26/S206)) over the mounting sleeve (see chapter
7.2 "Special tools") onto the piston rod as far as the cylinder barrel.
• Place the end cap at the other end of the cylinder barrel.
• Apply the screw locking agent included in the set of wearing parts to the
screws.
• Turn the screws through the bearing and end caps (through both bearing
caps on cylinders with through piston rod (S2/S20/S26/S206)) into the
cylinder barrel.
• Align the bearing and end caps ush with the cylinder barrel.
• Tighten the screws using the appropriate torque (see table).
Type Torque
ADVU-32 25 Nm
ADVU-40 25 Nm
ADVU-50 30 Nm
ADVU-63 35 Nm
ADVU-80 35 Nm
ADVU-100 35 Nm
• 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.