Operating manual

for hydraulic cylinders

Table of contents
Operating manual.....................................................................................................................................2
1. Preface and general information ..........................................................................................................2
1.1 About this operating manual .......................................................................................................3
1.2 Intended audience .......................................................................................................................3
1.3 Personnel qualifications................................................................................................................3
2 Symbols and signal words used.............................................................................................................4
3 Basic information about this operating manual.....................................................................................5
3.1 Scope of delivery..........................................................................................................................5
3.2 Identification................................................................................................................................6
3.3 Legal provisions............................................................................................................................6
3.4 Intended use.................................................................................................................................7
3.5 Use other than that intended.......................................................................................................8
4 Safety instructions...............................................................................................................................10
4.1 General safety instructions.........................................................................................................10
4.2 Persons responsible for safety, owner/user................................................................................13
4.3 Persons responsible for safety, qualified personnel....................................................................14
4.4 Area of application of the hydraulic cylinders.............................................................................14
5 Transport and storage..........................................................................................................................14
6 Commissioning/start-up and operation...............................................................................................15
6.1 Information on safe commissioning............................................................................................15
6.2 Rinsing the cylinder....................................................................................................................17
6.3 Venting the cylinder....................................................................................................................18
6.4 End of stroke damping................................................................................................................18
6.5 Checking the cylinders................................................................................................................19

7 Maintenance and repair .....................................................................................................................20

7.1 Monitoring the oil temperature..................................................................................................20
7.2 Checking the operating fluid.......................................................................................................21
7.3 Checking screw connections and sealing leaks...........................................................................21
7.4 Checking the seals......................................................................................................................21
7.5 Replacing the seals.....................................................................................................................22
7.6 Lubrication..................................................................................................................................23
8 Disposal ..............................................................................................................................................23
9 Trouble shooting..................................................................................................................................24
10 Production declaration......................................................................................................................24

Operating manual

1. Preface and general information

Prior to commissioning/start-up of the hydraulic cylinders, adhere to the following information as
well as all additional information contained in the corresponding descriptions.
Due to the great variety of product types and their different uses, we would like to point out that
this operating manual does not claim to be complete and it is the owner/user's responsibility to
always consider the respective use and/or specific application of the product as well as external
influences when making a risk assessment.
The following documentation contains information about possible hazards and safety information
for reasonably foreseeable situations in order to minimise the risk of danger to people and
property resulting from the use of hydraulic systems as much as possible.
In addition, we would like to point out that the guidelines for the machinery directive 2006/42/EC
state clearly that hydraulic cylinders are not included in the scope of the machinery directive. For
this reason, this directive cannot be directly applied to hydraulic cylinders.
Standards and guidelines
As purchaser of this product, please adhere to the safety standards DIN EN 982 and DIN
EN ISO 4413 for hydraulic lines and any other applicable standards.
When making a risk assessment, observe the contents of the standard EN 14121-1 (EN
1050)

1.1 About this operating manual

Operating manuals are a crucial component of this product. They facilitate its correct use. This
operating manual is intended to ensure safety-focused work on and with the hydraulic cylinders.
It contains safety instructions which must be followed. Ensure that all persons working on and
with the hydraulic cylinders have the operating manual available when working and adhere to all
the relevant information and instructions. Ensure that the operating manual is complete and in a
perfectly legible state at all times.

1.2 Intended audience

Experts, mechanics and fitters of machines and plants with expertise in the field of hydraulics.

1.3 Personnel qualifications

Expertise in the field of hydraulicsmeans that personnel must:

be able to read and understand technical specifications such as wiring diagrams and
product-specific drawings,
have knowledge of the function and design of hydraulic components.

Experts are persons whose professional training and experience has equipped them with
sufficient knowledge and who are familiar with the relevant regulations to the point that they:

can assess the work they have been entrusted with,

can detect possible hazards,
can take the necessary measures to eliminate hazards,
have the required repair and installation expertise.

2 Symbols and signal words used

DANGER
Danger to life / Severe bodily harm
Signals an imminent danger. If this danger is not avoided, it will
result in death or severe injuries.

WARNING
Injuries to persons
Signals a possible danger. If this danger is not avoided, it may
result in death or severe injuries.

CAUTION
Slight injuries / damage to property
Signals a potentially dangerous situation If this danger is not
avoided, it may result in slight injuries.

Environmental hazard
This symbol signals important information about proper handling
of substances hazardous for the environment. Non-adherence to
this information can result in severe damage to the environment.

Mandatory instructions sign

This symbol signals important information, required protective
equipment, etc.

Note
This symbol signals tips for using the product or further useful
information. It is not a signal word for dangerous or damaging
situations.

3 Basic information about this operating manual

This operating manual contains information and helps avoid danger when installing the products
in the machine. It also contains information and notes concerning transport, storage and
maintenance. Always adhere to all information contained in this operating manual to avoid
accidents and damage to property and guarantee malfunction-free operation of the products.
Adhering to this operating manual also helps:
decrease downtimes and repair costs,
increase the service life of the products.

Note
This operating manual does not replace the operating manual
for the overall machine.

3.1 Scope of delivery

The hydraulic cylinders are manufactured according to customer specifications. Check
immediately after receiving the delivery that the scope of delivery matches the shipping
documents. MBS Hydraulik GmbH & Co. KG shall not assume any liability for defects reported at
a later stage.
Report:
visible transport damage to the delivery agent immediately
visible defects / incompleteness to MBS Hydraulik GmbH & Co.KG immediately.

3.2 Identification
The hydraulic cylinders are clearly identified by a mark on the cylinder.

3.3 Legal provisions

Liability
The information, data and instructions specified in the operating manuals were up to date at the
time of going to print. No claims for previously delivered hydraulic cylinders can be asserted on
the basis of the information, illustrations and descriptions. We do not accept any liability for
damage and operating malfunctions caused by:
Improper use/use for any purpose other than that intended
Unauthorised modifications
Improper work on and with the hydraulic cylinder
Improper operation
Non-adherence to the operating manuals
Warranty
Warranty terms and conditions: Please refer to the General Terms and Conditions of
MBS Hydraulik GmbH & Co. KG
Warranty claims are to be lodged with MBS Hydraulik GmbH & Co. KG immediately after
detection of the defect or error.
The warranty shall become null and void in all cases in which no liability for damage is
assumed.

3.4 Intended use

Hydraulic cylinders:
may only be used for their intended purpose. Do not make any modifications without the
manufacturer's authorisation. Do not exceed the specified permissible values for
pressure, force, piston speed, temperature, etc.
(see description of the pressure equipment / drawing).
Only use the specified operating fluids (generally fluids on the basis of mineral oil, HL or
HLP oils). Only change the
operating fluid if it has been authorised by us. Ensure that changing the operating fluid
has no negative impact on the safety and service life of the pressure equipment.
Hydraulic cylinders are used in the industrial sector to translate hydraulic pressure into
linear movements and/or force.
Only use them with hydraulic oil.
Only use them in machines and machine lines.
Only use them for the purposes for which they were ordered and authorised to be used.
Only operate them according to the operational conditions described in this operating
manual.
Do not operate them outside of their respective capacity range.
The following specifications are also part of the intended use of this product:
Use of this product within the capacity range specified in the technical data (see
catalogue sheet).
Use in the manner described in this operating manual.
Adherence to the maintenance intervals.
Personnel qualified or trained according to their work.
Installation of spare parts with the same specifications as the original part.

Any other use is deemed improper/not in accordance with the intended use! If improper
use of a hydraulic cylinder is detected, immediately stop operation of this cylinder and
secure it against any further use.

3.5 Use other than that intended

WARNING
Injuries, damage to property or malfunctions!
Do not make modifications to the product!

It is not permissible to use the products:

For domestic use.
On pallets or tool tables in primary shaping or press equipment.
If vibrations or other physical / chemical effects may damage the product or
the seals.
On pallets or tool tables used for changing the characteristics of materials (magnetising,
radiation, photochemical procedures, etc.)
In fields subject to special guidelines, especially for equipment and machines used for the
following purposes:
In fairs and amusement parks.
For food processing or other fields subject to special hygiene regulations.
For military purposes.
In mining.
In explosive and aggressive environments (e.g. ATEX).
For medical technology.
For aeronautics.
For transport of persons.
In case of unusual operating and environmental conditions, e.g.:
If the operating pressures exceed the values specified in the catalogue sheet or the
installation drawing.
If the pressurising medium is not in accordance with the specifications.
If the volume flow exceeds the values specified in the catalogue sheet or the installation
drawing.
2\mod_1217426954101_6.doc @ 21577
Special solutions are available on request!

4 Safety instructions

4.1 General safety instructions

We assume no liability for the completeness of these safety instructions. If you have any
questions or problems, please do not hesitate to contact MBS Hydraulik GmbH & Co. KG.
The hydraulic cylinder conforms to the state of the art and is deemed safe to operate at the time
of delivery.
Hydraulic cylinders may cause danger to persons, the cylinders themselves or other property of
the owner/user, if:
non-qualified personnel work on and with the hydraulic cylinder,
the hydraulic cylinder is used improperly/for any purpose other than that intended.
The hydraulic cylinder must be configured to ensure that it fulfils its function and does not cause
danger to persons when it is correctly fitted and used according to its intended use in fault-free
operation. This also applies to its interaction and operation within the overall machine line.

Take appropriate measures to ensure that no damage to assets can occur if the hydraulic
cylinder fails.
Only operate the hydraulic cylinder when it is in a perfect state.
Retrofitting, modification or conversion of the cylinder are generally not permissible. They
always require prior consultation with MBS Hydraulik GmbH & Co. KG.
Depending on how the moving parts are installed, there is a danger of crushing and
pinching. It is the owner/user's responsibility to secure potential crushing and pinching
hazards by means of fixed guards.
Ensure that system errors cause no danger to persons or property. This applies in
particular to the use of hydraulic cylinders in any vehicles and machines used on public
roads and lifting equipment for persons. Take effects caused by accelerating, braking or
lifting and holding of weights into account.
Loads on moving parts may drop in case of system errors. For this reason, do not stay
beneath or in the movement range of moving loads.
It is the owner/user's responsibility to assess and ensure safe operation of all hydraulic
circuits using our hydraulic cylinders and all valves connected to them.
It is the owner/user's responsibility to ensure the correct function of hydraulic circuits
used for hydraulic locking of moving parts. In particular, it is the owner/user's
responsibility to check whether an additional mechanical locking system is required and
install it, if necessary.
If improper use of a hydraulic cylinder is detected, immediately stop operation of this
cylinder and secure it against any further use.
Ensure that pressure peaks and fluctuations do not create hazards. Do not exceed the
maximum permissible operating pressure.
It is the owner/user's responsibility to ensure that no buckling occurs in any lifting
position.
Prevent transverse forces from acting on the hydraulic cylinder.
Prevent warping of the hydraulic cylinder.

When using differential cylinders, Master-Slave cylinder pairs and hydraulic cylinders
equipped with end of stroke damping, take the possible pressure conversion due to the
surface ratio into account.

WARNING
Danger of injuries due to high-pressure injection (hydraulic
oil may spray due to high pressure)!
Improper connection / installation can lead to oil emerging with
high pressure at the connection points.
Only assemble/disassemble elements when no pressure is
applied to the hydraulic system.
Connect the hydraulic line according to DIN 3852/ISO 1179
Properly close unused connections.
Properly fasten all parts.

WARNING
Danger of injuries due to high-pressure injection (hydraulic
oil may spray due to high pressure)!
Wear and tear, damaged seals, ageing and incorrect installation
of the seal kit by the owner/user may lead to oil emerging with
high pressure.
Carry out a visual inspection prior to use!

WARNING
Danger of injuries due to dropping parts!
Keep hands and other body parts out of the working area.
Wear personal protective equipment!

WARNING
Danger of poisoning due to contact with hydraulic oil!
Improper connection and use, wear and tear, damage to the
seals, ageing or incorrect installation of the seal kit by the
owner/user can lead to oil emerging from the connections or
seals.
Adhere to the safety data sheet when handling hydraulic oil.
Wear personal protective equipment.

CAUTION
Damage to assembly components!
Some product types are extremely heavy. Secure these against
falling prior to transport.
For product weights, refer to the order documentation.

CAUTION
Damage to assembly components!
Transverse forces and forced conditions acting on the piston
increase its wear rate.
Install external guides.
Avoid forced conditions (redundancy) of the piston.

4.2 Persons responsible for safety, owner/user

The user/owner is any natural person or legal entity who uses the hydraulic cylinder or on whose
behalf the cylinder is used. The user/owner and/or his safety representative must ensure:
That all relevant regulations, instructions and laws are observed.
That only qualified personnel work on and with the hydraulic cylinder.
That the operating manual is available to the personnel for all work.
That non-qualified personnel are prevented from working on and with the hydraulic
cylinder.

4.3 Persons responsible for safety, qualified personnel

Qualified personnel are persons, who due to their training, experience, instruction and
knowledge about relevant standards and regulations, accident prevention regulations and
operating conditions, have been authorised by those responsible for the safety of the machine to
perform the necessary activities and who are able to recognize and avoid any dangers involved.

4.4 Area of application of the hydraulic cylinders

Seal material

Medium

Temperature range

NBR, PTFE , PU
NBR, PTFE
FPM(Viton) PTFE
Composite materials

Mineral oil
Water/glyc.
Mineral oil HFD-R
Mineral oil
Emulsion 95/5
Mineral oil
Emulsion 60/40

-20C to + 80 C
-20C to + 60 C
-20C to + 150 C
- 5C to + 55 C

Fluorocarbon. El, PTFE

- 5C to + 60 C

ATTENTION! Ensure that the maximum traverse speed does not exceed 0.5 m/s!

5 Transport and storage

Store hydraulic cylinders in a dry, dust-free area.

Seal the connections against dust during storage and transport.
When storing hydraulic cylinders for longer periods of time, we recommend filling them
with mineral oil or another suitable fluid for corrosion protection. When doing so, observe
the specifications on the corresponding data sheet of the fluid!
Do not suspend hydraulic cylinders by their cylinder eyebolts / connections, as this may
lead to an unintentional expansion of the piston rod.
Do not transport hydraulic cylinders with the piston rod expanded, as this may damage
the piston rod surface.
Protect external threads during transport.
It is the owner/user's responsibility to apply a suitable primer and varnish if the product
was supplied without a primer and varnish. Before doing so, ensure that the oil
connections are securely closed.

QM INSTRUCTIONS

6 Commissioning/start-up and operation

Do not commission/start-up the machine or the incomplete machine in which the hydraulic
cylinder is to be installed, until the machine or the incomplete machine, in which the unit is to be
installed, meets the requirements of the machinery directive.

6.1 Information on safe commissioning .

Prior to commissioning
Prior to commissioning, ensure that:

All fixtures and connections have been correctly fitted. Connected assembly components
are fastened such that they do not loosen in case of jolting or vibrations. This also
applies to external stroke stops.
The machine/machine line and/or components are filled with the correct oil.
The routed pipework is cleaned on the inside and outside, and rinsed properly before it is
screw-fitted to the hydro-cylinder.
It is the owner/user's responsibility to have a trained and instructed mechanic or trained
and instructed operating and maintenance personnel establish a proper electrical
connection.
It is the owner/user's responsibility to protect piston rods against foreseeable damage
such as dents, scratches, corrosion, etc.
It is the owner/user's responsibility to ensure that the connection was established
correctly after installation in order to prevent malfunctions.
If welding work was carried out on components after installation of the hydraulic cylinder,
ensure that mass is not transferred via the piston rod.
It is the owner/user's responsibility to ensure that hydraulic cylinders with an integrated,
electronic position detection system are electrostatically discharged prior to installation to
prevent damage to the electronic system and incorrect signals.

Installation
Always wear personal protective equipment.
When installing the cylinder, ensure that the piston rod is not in a forced position, i.e. that
no transverse forces are acting on it.
It is the owner/user's responsibility to take measures to reduce the risk of sound
emissions.
It is the owner/user's responsibility to use appropriate hardware to secure the control
system in order to prevent regulation or control system errors or unexpected start-ups.
In particular, it is the owner/user's responsibility to ensure that limit values and tolerance
ranges for humidity, voltage, barometric pressure, sources of pollution, sources of
vibration, sources of fire, explosions and other hazards are adhered to

WARNING
Danger of poisoning due to contact with hydraulic oil!
Improper connection and use, wear and tear, damage to the
seals, ageing or incorrect installation of the seal kit by the
owner/user can lead to oil emerging from the connections or
seals.
Adhere to the safety data sheet when handling hydraulic oil.
Wear personal protective equipment.

CAUTION
Damage to assembly components!
Do not exceed the maximum permissible operating pressure!

Note
Do not use sealing tape, copper rings or tapered screw
connections!

During operation
During operation, pressure is applied to the hydraulic cylinder. Use a safety device to
secure the operating pressure.
Do not operate the system without a completely connected hydraulic and electric line.
Prevent fire hazards caused by electrical components.
It is the owner/user's responsibility to ensure that the Emergency Stop system of the
machine line includes measures to prevent dangers caused by the hydraulic cylinder,
e.g. the danger of spraying oil if the hydraulic line breaks.
The surfaces of the hydraulic cylinder and attached assembly components may heat up
to temperatures that can cause burns.
It is the owner/user's responsibility to ensure that all assembly components installed on
or connected to the hydraulic cylinder are fastened such that they do not loosen in case
of jolting or vibrations. This also applies to external stroke stops.
It is the owner/user's responsibility to take into account the influence of mass
deceleration when designing and using stroke stops or end of stroke dampening.

During the design phase, the owner/user must ensure that the material and surface
treatment of piston rods and other components on the cylinder are selected to minimise
wear, corrosion and other foreseeable damage by jolting. Please inform us of the
respective parameters.
If control lines of sensors or valves break or become faulty, uncontrolled movements or
faulty feedback may occur, depending on the external conditions and loads. It is the
owner/user's responsibility to install appropriate safety measures.
If the regulating system or control system is defective (e.g. due to wear and tear)
uncontrolled or jolting movements or a piston rod jam may occur. It is the owner/user's
responsibility to install appropriate safety measures.
It is the owner/user's responsibility to ensure that a loss or critical reduction of pressure,
possibly caused by leakages, does not pose any danger to persons or the machine.
If hydraulic oil emerges due to a leakage, there is a danger of slipping.

6.2 Rinsing the cylinder

The cylinder itself is supplied cleaned and rinsed. Do not use soiled fluid. We recommend
filtering the operating fluid for this purpose. Rinse lines and connections prior to
commissioning/start-up.
If a complete machine/machine line is to be put into operation for the first time, a rinsing process
must be performed:
1. For the rinsing process, bridge all consumer connections by means of hose connections.
2. After rinsing, carefully clean all filter elements or replace them with new filter elements.

6.3 Venting the cylinder

Ensure that the hydraulic cylinder and the entire hydraulic system are vented. It may be
necessary to vent the hydro-cylinders to ensure problem-free operation. To do this, undo:
the venting screws provided for this purpose and/or
the screw connection on the side of the base or rod.

Note
If the system is not vented, malfunctions may occur!

6.4 End of stroke damping

Always consult MBS to determine the constructive design of the end of stroke damping. If the
end of stroke damping is not adapted to the specific application, the cylinder may be destroyed.
Cylinder with adjustable end of stroke damping:
If the damping is set by the user, ensure that the cylinder gently moves into the respective limit
position during the process. To check the damping effect, only gradually increase the speed of
movement to avoid excessively strong or insufficiently strong damping.

WARNING
In both cases, the cylinder could be destroyed!

6.5 Checking the cylinders

As soon as the operating temperature of the application has reached the intended value, switch
off the machine line. Directly afterwards, check:
all pipe screw connections and
all fixtures
and retighten if necessary.

WARNING
Danger of injuries due to high-pressure injection (hydraulic
oil may spray due to high pressure)!
Improper connection / installation can lead to oil emerging with
high pressure at the connection points.
Only assemble/disassemble elements when no pressure is
applied to the hydraulic system.
Connect the hydraulic line according to DIN 3852/ISO 1179
Properly close unused connections.
Properly fasten all parts.

7 Maintenance and repair

The hydraulic cylinders are low-wear cylinders and designed for long maintenance intervals.
Inspect the hydraulic cylinder at regular intervals to ensure reliable and fault-free operation. The
time and effort required for service work can be reduced by designing the machine line in a way
that makes the cylinder easily accessible. This should be taken into consideration when
installing the cylinder. The necessary maintenance intervals for hydraulic cylinders are primarily
determined by the number of retraction and extension cycles.
It is the owner/user's responsibility to ensure that the assembly components and hydraulic units
are maintained, operated, arranged and installed properly to ensure their stability and safety
during operation.
Ensure that no pressure is applied to the pressure equipment before opening it. If lines leading
to or from an operating medium are not disassembled, remove them to ensure safety.

7.1 Monitoring the oil temperature

Ensure that the maximum oil temperature does not exceed the value of +80 C (see point 2.4)
during operation! If this maximum temperature cannot be guaranteed, always provide a suitable
cooling system.

WARNING
Injuries to persons
Signals a possible danger. If this danger is not avoided, it may
result in death or severe injuries.

7.2

Checking the operating fluid

Regularly check the operating fluid for soiling or ageing so that it can be changed in time.

7.3 Checking screw connections and sealing leaks

Retightening screw connections and sealing any possible leaks are typical examples of
maintenance work. It is the owner/user's responsibility to ensure that this work is carried out as
regularly as required.

7.4 Checking the seals

A small quantity of oil emerging from the piston of a hydraulic cylinder does not necessarily
indicate a defective seal. It might be "drag oil", which accumulates in the chamber above the

piston over time. This is a normal process and does not affect the function of the cylinder.
Guide seal
Leakages on the guide are normally caused by worn or damaged seals.

Piston seal
When overhauling a cylinder, always insert new piston seals.

Replace the seal kit in case of external leakages. To guarantee high availability, we recommend
replacing the seals after a maximum of 1,000,000 cycles or 2 years. The seal kit is available as
replacement part kit. An instruction manual for replacing the seal kit is available on request.

7.5 Replacing the seals

Wear of seal elements and valves can cause uncontrolled or jolting movements or a piston rod
jam. It is the owner/user's responsibility to install appropriate safety measures. Soft seals are
wear parts. As soon as their condition requires replacement, replace the seal kit. When replacing
the seal kit, always replace all seal elements. If you have questions about the exact procedure
for different product types, please do not hesitate to contact us.
Disassembly
Check that the piston rod and cylinder pipe are free of burrs and undamaged, as
otherwise sliding the guide over the piston rod may be more difficult.
Undo the guide nut, pull the piston rod out slightly, then twist out the piston rod and the
guide together.
Remove the seals and guide rings using a suitable tool. At the same time, take care not

to damage the drill hole or the contact surfaces of the seals. Check and clean the seal
grooves. In the event of any damage, replace the guide and/or piston including the seals.
Installation
Check the surface of the piston rod and cylinder tube for damage that may lead to
premature seal defects.
When pushing the guide over the rod thread, avoid damaging the seals by means of a
slight turning movement. In addition, sealing lips can be protected by wrapping the thread
with an appropriate material.
Use a suitable tool to calibrate seals made of PTFE to the nominal diameter before
pushing the guide nut onto the piston rod.
Screw the guide into the head by hand and use the face pin wrench or hook wrench to
tighten.

CAUTION
Damage to assembly components!
Avoid damaging moving parts (rods, plungers, bolts, etc.) as well
as scrapers and seals.

7.6 Lubrication
Re-lubricate friction bearings and hinge bearings at regular intervals depending on their strain
and external operating influences.

8 Disposal
Dispose of the individual materials according to the valid guidelines and regulations as well as
the environmental conditions. Be especially cautious when disposing of assembly components
with pressure fluid residue. Observe the information concerning disposal in the safety data
sheet. When disposing of electric and electronic assembly components (e.g. position measuring
systems, proximity switches, etc.) adhere to the specific legal regulations and specifications in
your country of use.

Environmental hazard
Due to the danger of environmental pollution, have the
individual components disposed of by an authorised
specialist company.

9 Trouble shooting
If malfunctions occur during operation of the hydraulic cylinder, use the following table to
determine the possible cause of the malfunction. If the malfunction cannot be remedied by the
measures listed below, please contact MBS Hydraulik GmbH & Co. KG.
Malfunction
Leakage

Cylinder does not

move or moves too
slowly

Cause
Oil on the surface of the piston
rod

Remedy
Check the piston rod for
damage,
if necessary, replace the piston
rod, change the seal kit

Mechanical torsion

Eliminate the mechanical torsion

and replace the seal kit

Leakage at the cylinder head /

cylinder base

Replace the seal kit

Insufficient pressure at the

cylinder

Eliminate the cause for the

reduction in pressure

Cylinder design insufficiently

powerful

Check cylinder design

Moving parts blocked

Remove blockages

Leakage via the piston seal

Replace the seal kit, check the

surface of the pipe, replace the
pipe if necessary

10 Production declaration
Manufacturer
MBS Hydraulik GmbH & Co. KG
Langenkamp 21
D-32312 Lbbecke, Germany
Tel.: +49 (0) 57 41 / 34 05-0
Fax.: +49 (0) 57 41 / 34 05-15

E-Mail: info@mbshydraulik.de
www.mbshydraulik.de
Production declaration
This operating manual is valid for all hydraulic cylinders designed and manufactured according
to the guideline 2006/42/EC in its respective valid version and the valid technical regulations.
According to the EC machinery directive and EN 982, these products are components not ready
for use and only intended for installation in a machine / incomplete machine.
These products are not classed as pressure containers but as hydraulic controlling equipment
according to the pressure equipment guideline, as the main factor for their design is not pressure
but rigidity and (dimensional) stability in relation to the static and dynamic operating strain they
are subject to.
Do not commission/start up these products until you have determined that the machine /
incomplete machine in which the product is to be installed complies with the machinery directive
(89/37/EC or 2006/42/EC).
The manufacturer is obligated to provide national agencies with the specific product
documentation if requested. The technical documents according to appendix VII, part B were
created for the products.
Person responsible for documentation
Dipl.-Ing. (FH) Michael Thle, Tel.: +49(0)57 41 / 34 05-28
MBS Hydraulik GmbH & Co. KG.
Lbbecke
Lbbecke, 14 February, 2013
Version 3

Contents

General description and manual

Adhere to this additional operating manual prior to installation and

commissioning/start-up of the device. This addition is only valid for hydraulic
cylinders explicitly sold and used as ATEX cylinders.

ATTENTION

The additional operating manual contains basic information for use of cylinders
in explosive environments to be adhered to during installation, operation and
maintenance. Ensure that the mechanic and the responsible expert personnel
and owner/user read this additional operating manual prior to installation and
commissioning/start-up!

Personnel qualification and training

Ensure that the personnel for installation, inspection and maintenance have the appropriate
qualifications for this work. It is the owner/user's responsibility to clearly determine the range of
responsibility and personnel supervision. If personnel do not have sufficient knowledge, ensure that they
receive training and instruction. It is also the owner/user's responsibility to ensure that all personnel
have understood the complete contents of this additional operating manual.

Follow the standards below for carrying out maintenance work:

DIN 24343

Maintenance and inspection list for hydraulic components

DIN EN ISO 4413

Fluid power technology - General rules and safety requirements for hydraulic
systems and their components

Safety-conscious work
Always adhere to the safety information listed in this additional operating manual, the valid national and
international regulations for explosion protection and accident prevention as well as the owner/user's
internal work, operating and safety regulations.

Intended use

These units are designed for use in explosive areas according to ATEX, category II,
zones 1, 2 and category III, zones 21, 22. These units are not suitable for use in exzones other than those above.

ATTENTION

Suitability testing
For the ATEX data, refer to the type plate with the technical data. Please ensure
that this type plate is installed to guarantee safe use of the hydraulic cylinders in
explosive areas.
Also ensure that the marking permits use in the area where the cylinders are to
be used. It is the owner/user's responsibility to ensure that the ATEX regulations
are adhered to!

The supplied units are only guaranteed to be safe for operation if

used as intended. Hydraulic cylinders with an ATEX approval must not be used for
applications in which the safety of persons is dependent on the machine function
(no safety component according to EU machinery directive).

It is the owner/user's responsibility to ensure that the specified operating cycles and technical data /
capacity limits confirmed by us are adhered to. MBS Hydraulic GmbH & Co. KG supplies the
documentation, i.e. the operating manual, EC conformity declaration for the ATEX guideline and
installation declaration referring to the EC machinery directive.

The owner/user is responsible for ensuring that the installation, maintenance and safety instructions are
adhered to.

If this operating manual and the technical data are not adhered to, the
conformity declaration in accordance with 94/9/EC will become null and
void.
ATTENTION

Note:
MSB Hydraulik GmbH & Co. KG only supplies ATEX products for explosion group II. They are not suitable
for deep mining or any other mining applications.

For gases, vapours, mists:

MBS Hydraulik GmbH & Co. KG cannot supply operating materials / devices for zone 0.

For dust:
MBS Hydraulik GmbH & Co. KG cannot supply operating materials / devices for zone 20.

For gases, vapours, mists:

T3 includes T2 and T1. MBS Hydraulik GmbH & Co. KG cannot supply operating materials / devices for T5
and T6. S. IEC 60079-4

For dust:
Please adhere to the valid regulations for determining the maximum permissible surface temperature
for flammable dust clouds and immobile dust layers . S. IEC 61241-2-1.

ATEX basics
According to the ATEX guideline, the hydraulic cylinder/s can also be called "unit" hereafter.

Only operate the hydraulic cylinders once they are installed as specified. If necessary, earth them on the
ground and on the piston rods prior to commissioning/start-up, if dangerous potential differences may
occur (e.g. for insulated constructions) and it is not guaranteed that fluid piping can create a reliable
connection to earthed components.

Regularly check all moving parts for corrosion during operation and immediately shut down any affected
components

3.1 Design and classification

The following table is used for clear identification of the hydraulic cylinders. Together with the three
following identification tables, it categorises the materials and installation components used.

Group

Materials

Identification code

Cylinder pipe made of normal

steel

S235

ZS

S355
E355
or similar

Cylinder pipe made of stainless

steel
Piston rod made of normal steel

ZE
20MnV6

KS

or similar
Piston rod made of stainless steel

KE

Normal seals

NBR

Temperature range

or similar

DN

-20C to + 80 C
Seals for high temperatures

Viton

DH

Temperature range

or similar

-20C to + 160 C
Limit switch

Various materials

ES

Position measuring system

Various materials

WMS

Piston accumulator

Various materials

KS

Primer

Primer

LG

Varnish

Varnish

LL

Example
Cylinder pipe
made of
stainless steel

ZE

Piston rod
made of
normal steel

KS

Seals suitable for

high temperatures

DH

Position
detection
system

WMS

Primer

LG

3.2 Identification
The identification is determined according to the design of the device and the use of installation
components. The following table shows an overview and the ATEX marking. All drawings are intended to
be understood as sketches and may vary according to the article in question.

Normal hydraulic cylinder

Normal hydraulic cylinder

Seals and guide tapes suitable for normal

temperature range

Temperature-resistant seals and guide tapes

ATEX marking:

ATEX marking:

II 2GD ck IIC T4 (-20C < Ta < +80C)

II 2GD ck IIC T3 (-20C < Ta < +160C)

Hydraulic cylinder with limit switch

Hydraulic cylinder with limit switch

Seals and guide tapes suitable for normal

temperature range

Temperature-resistant seals and guide tapes

ATEX marking:

ATEX marking:

II 3G Ex nA II T4 (-20C < Ta < +80C)

II 3G Ex nA II T4 (-20C < Ta < +100C)

Hydraulic cylinder with limit switch and/or

position measuring system

Hydraulic cylinder with limit switch and/or

position measuring system

Seals and guide tapes suitable for normal

temperature range

Temperature-resistant seals and guide tapes

ATEX marking:

ATEX marking:

II 3G Ex nA II T4 (-20C < Ta < +80C)

II 3G Ex nA II T4 (-20C < Ta < +100C)

3.3 Technical data

Nominal operating pressure

bar

50 350

Maximum operating pressure

bar

350

Maximum speed

m/s

0.5 max. 1.0

Maximum stroke

mm

6,000

Maximum diameter

mm

600

Fluid temperature range

-20 / +80

for normal seals

-20 / +160
for special seals
Fluid viscosity

cSt

Fluid contamination level

Recommended viscosity

10 400
According to ISO 4406 Class
20/18/15

cSt

25

Application
Within the ATEX guideline, the unit is assigned to unit group II, categories 2 and 3 and can be used in
zones 1, 2, 21 and 22. The unit is designed for use in areas subject to explosive gas/air or dust/air
mixtures, mists or vapours.

According to EN 13 463-1 and EN 13 463-5, the fluid-power product is assigned to ignition protection
type "c" with a maximum surface temperature of 200C (temperature class T3).

For hydraulic limits of use such as the maximum permissible pressures, volume flows and other limit
values, refer to the valid, unit-specific documentation.
Contact the manufacturer if you wish to use the unit for any application other than those described in
the documentation.

The ignition type classification is only valid if it is not limited by use of the unit with
other components (e.g. with a hydraulic unit or in case of integration into an overall
system) and their lower classification. In this case, the lowest classification applies. If
applicable, also observe the operating manual of the other units and components.

ATTENTION

4.1 Delivery and storage

Check the units for completeness and damage on delivery. If the delivery is incomplete or there is
transport damage, immediately inform the carrier and MBS Hydraulic GmbH & Co. KG
.

4.2

Installation information

Ensure that installation, electrical connection work and commissioning/start-up are only carried
out by expert personnel according to the accepted technical regulations and the safety and
accident prevention regulations

Only use approved fastening materials for assembly

Ensure that the hydraulic cylinders are not subject to abnormal operating conditions such as
vibrations, pressure surges or large solid components in the fluid.

For electrical connection diagrams, refer to the respective supplied additional information.
Ensure that wiring and commissioning of electrical work, if required, is only carried out by expert
personnel.

4.3

Technical data, notes

To avoid danger caused by static charging, connect the head and base of the hydraulic cylinder to the
earthing connection intended for this purpose earth them properly and connect them to the customer-

provided potential equalisation connection.

4.4 Permissible traversing speed

The maximum permissible traversing speed is 0.5 m/s for cylinders with standard seals and 1 m/s for
cylinders with a lower degree of friction or Viton seals. The seals are listed in the parts list and/or
drawing.

4.5 Air in the hydraulic system

Ensure that there are no air bubbles in the hydraulic fluid. These may be caused by oil changing or
maintenance work. Quick compression can make air bubbles heat up so much that the air-gas mixture (in
the mineral oil) can self-ignite. The resulting pressure and temperature increase accelerates oil ageing
and can damage seals as well as assembly components in the hydraulic system. This process is also called
diesel effect.

Up to ten percent of air volume can be dissolved in hydraulic fluids under atmospheric pressure. If the
system pressure drops below the vapour pressure of the fluid, air bubbles will form and grow into larger
bubbles due to the oil vapour. The diesel effect can then occur during compression processes.

4.6

Earthing terminals

An earthing conductor can be connected to a point (threading/screw) on the

base of ATEX-certified cylinders. Ensure that this connection on the base is
always connected to the earthing conductor. Guarantee the earthing of the
piston rod by means of the mechanical connection to the respective machine /
machine line. Connect the earthing connections to the general earthing device
by means of the respective conductors.
ATTENTION

It is obligatory to check the potential equalisation of the parts according to the

newest version of DIN EN 13463-1. Ensure that the resistance is max. 100 .
Create a protocol for this check. Ensure that the check is only carried out by an
expert with the appropriate qualifications.

Maintenance
Proper maintenance increases operational safety and the service life of the units. For this reason,
regularly inspect the units. If legal inspection dates apply, adhere to them.
Inform the operating personnel prior to beginning maintenance and inspection work.
For personal protective measures, refer to the owner/user's safety data sheet. Take appropriate
protective measures to avoid contact with or breathing in of hazardous substances. Prior to maintenance
or inspection work, switch off all
machine line components up- and downstream of the unit and secure them against being restarted.

When replacing parts, only use original replacement parts produced by MBS Hydraulic GmbH & Co. MBS
Hydraulik GmbH & Co. will not assume any liability for damage resulting from the use of non-original
parts
.

Follow the inspection procedure below:

Visual inspection of the unit

Check the unit fastening
If necessary, check the electrical connections
Ensure that the earthing connection is stable and properly tightened
Function inspection

For further inspections, refer to the technical documentation or further maintenance instructions.

Delivery of replacement parts

Purchasers, retailers and owners/users obtaining and using replacement parts for MBS hydraulic cylinders
are obligated to adhere to 14 (6) of the BetrSichV (German ordinance on industrial safety and health)
and TRBS 1201- part 3. Within the EU all member nations have valid legal and administrative regulations
corresponding to these, which must be adhered to. Outside of the European Union, the purchaser,
retailer and owner/user are obliged to adhere to the laws, regulations and administrative specifications
concerning explosion protection valid in the location of use of the respective MBS hydraulic cylinder.

It is always the owner/user's responsibility to ensure safe, malfunction-free operation.

If you require replacement parts, please tell us the serial number of your MBS hydraulic cylinder. To find
it, refer to the type plate on the hydraulic cylinder.

According to the ATEX guidelines for explosion protection and the regulations derived from them, there
are specifications concerning permissible and prohibited (dangerous) combinations of materials. To
ensure that you adhere to these, we recommend that you use original replacement parts produced by
MBS.

Information concerning the repair of ATEX hydraulic cylinders

This information is only an excerpt of the most important specifications to be observed when repairing or
replacing parts of MBS hydraulic cylinders.
Only use MBS hydraulic cylinders according to their intended use before and after the repair. For
information regarding the intended use, the installation, commissioning/start-up and repair procedure,
please refer to the previous parts of this operating manual.

The hydraulic cylinders are mostly maintenance-free. Ensure that the following work is carried out and
recorded by a qualified person at regular intervals:

Regularly, but at least once a year, check the hydraulic connections for damage (visual
inspection).
If external leakages occur, shut down the system and carry out maintenance.
Regularly, but at least once a year, check the unit surface for accumulated dust and clean, if
necessary.
Furthermore, maintenance work guaranteeing safe and long-term use of the unit may be contained in
the product-specific technical documentation
This manual assumes that generally accepted service and operating recommendations for hydraulic
systems are adhered to.

7.1

Varnish

Only use anti-static varnish for varnishing the unit

When applying the varnish, do not exceed a total thickness of 200m.
These measures prevent electro-static discharging which may cause explosions.
Ensure that the varnish used is suitable for temperatures of at least 20C more
than the intended maximum temperature.

Summary of the safety information

If a malfunction or external damage occur, including corrosion, immediately switch off the unit.
Only operate the unit when it is installed according to all specifications. Earth the unit prior
to commissioning on the ground and the piston rodif dangerous potential differences may occur
(e.g. in case of insulated construction) and it is not guaranteed that the fluid piping can establish a
reliable connection to the earthed components.
Regularly check all moving parts for corrosion during operation and immediately shut down any
affected components
Prevent deposits on the surface as much as possible and ensure that they do not impact heat
dissipation.
Do not exceed the operating temperature of the oil.
Ensure that free heat dissipation is not impacted during operation. I.e. Do not cover the unit and
do not operate it in close proximity to heat sources.
Protect the unit from direct sunlight during operation.
Also do not varnish over or remove the type plate or type engraving to ensure that the type
designation remains legible.
Only use anti-static varnish for varnishing the unit
When applying the varnish, do not exceed a total thickness of 200m.

Danger of non-adherence to this safety information

Non-adherence to this safety information may result in danger to persons, the environment or machine
lines.
Non-adherence to the safety information will also make any claims for compensation null and void.

Original
Installation declaration for an incomplete machine(Machinery directive 2006/42/EC)
MBS Hydraulik GmbH & Co. KG.
Langekamp 21 / D-32312 Lbbecke
Authorised representative: Herrmann, Kornelius
Description and identification of the
incomplete machine:
Product description:

Order number:
Standards / series of standards /
regulations

The unit meets the relevant regulations for general machine engineering and
the explosion protection regulations in accordance with the protection class:
Ex-class II 2GD ck IIC T3 (-20C<TA<160C)

The following authority was involved in

the conformity assessment procedure
according to RL 94/9/EC, Art. 8 (1) b) ii):
The special technical documentation was
created according to machinery directive
2006/42/EC, appendix VII B .

Physikalisch-Technische Bundesanstalt (German federal physical-technical

institute / field 3.7
Bundesallee 100 / 38116 Braunschweig
Registration number: 12 ATEX DO13
The respective documentation according to RL 94/9/EC (ATEX 95) are stored in
this institutes's archive. The conformity declaration only refers to the design
and production of the components described above according to RL 94/9/EC
(ATEX 95) in accordance with the harmonised standards DIN EN 13463 - 1
(2009-01) and DIN EN 13463 - 5 (2011-10) "constructional safety".

Unit identification ATEX

II 2 GD ck IIC T3 (-20C<TA<160C)
Operating manual
Addition, ATEX operating manual

The corresponding operating manual contains important safety information

and regulations for installation, commissioning and maintenance of the
hydraulic cylinders.
The requirements of RL 94/9/EC (ATEX 95) are described in the additional ATEX
operating manual.

The following basic requirements of the

EC machinery directive 2006/42/EC have
been applied and adhered to:

1.1.2, 1.2.1, 1.2.3, 1.2.4.4, 1.2.6, 1.3.2, 1.3.4, 1.3.6, 1.3.7, 1.3.8.1, 1.4, 1.5, 1.6,
1.7.3, 1.7.4,

Responsible for compiling the technical

documentation:

MBS Hydraulik GmbH & Co. KG.

The special technical documentation was created according to Appendix VII, part B of the EC machinery directive
2006/42/EC. We undertake to transfer this documentation to the market surveillance authorities within a reasonable
time in case of a substantiated request to do so.
Do not commission/start-up the incomplete machine until you have determined that the machine in which the
incomplete machine is to be installed complies with the regulations of the machinery directive 2006/42/EC.

As purchaser of this product, please adhere to the safety standards DIN EN 982 and DIN EN ISO 4413 for
hydraulic lines and any other applicable standards. When making a risk assessment, observe the contents of
the standard EN 14121-1 (EN 1050)
______________________________________________
Herrmann, Kornelius, Managing Director / Lbbecke, 02.04.2013