PRODUCTION UTOMTION L2059 Rev. O 01/96 Instruction Sheet Swing Cylinders -- Imperial 18,8 kn and 35 kn IMPORTNT RECEIVING INSTRUCTIONS Visually inspect all components for shipping damage. If any shipping damage is found, notify carrier at once. Shipping damage is NOT covered by warranty. The carrier is responsible for all repair or replacement cost resulting from damage in shipment. INSIDE THIS INSTRUCTION SHEET DESCRIPTION...1 SPECIFICTIONS...2 PRELIMNRY INFORMTION...3 MOUNTING SPECIFICTIONS...4 Mounting Threaded Body Cylinders...4 Mounting Upper and Lower Flange Cylinders..5 INSTLLTION...6 Hydraulic Connections...6 Port Identification...6 Vent Plug... 6 ttaching Clamp rm... 7 rms for Upper Flange Body... 7 OPERTION... 8 Turning Mechanism Protection... 8 Pressure and Flow Rate... 8 MINTENNCE... 9 TROUBLESHOOTING... 9 CLMP RM MCHINING SPEC. S... 10 DESCRIPTION These swing cylinders are designed to swing 90 in a clockwise or counter-clockwise direction. They can also be used in straight clamping applications. Single-acting and double-acting swing cylinders are available. Clamp arms are not supplied with cylinders. Clamp arms can be purchased separately or made according to the specifications on page 10. Model Number Code 1 2 3 4 optional 5 6 optional S = swing cylinder T = threaded body U = upper flange L = lower flange R = right swing L = left swing S* = straight (no swing) S = singleacting D = doubleacting * Straight movement is not available on 7600 lb (35,0 kn) models. L = long stroke 35 kn only 20 = 3900 lb 18,8 kn 35 = 7600 lb 35,0 kn 1 = imperial V = Viton
SPECIFICTIONS Cylinder Specifications Capacity [lbs (kn)] 3900 (18,8) 7600 (35) 7600 (35) Long Stroke Body Style threaded body, lower flange, or upper flange mounting upper flange mounting Cylinder Type single-acting and double-acting double-acting Hydraulic Stroke [in (mm)] Effective rea [in 2 (cm 2 )] Oil Capacity [in 3 (cm 3 )] clamp 0.55 (14,0) 0.63 (16,0) 1.25 (31,8) total 1.10 (28,0) 1.18 (30,0) 1.83 (46,5) clamp 1.11 (7,16) 1.92 (12,3) 1.92 (12,3) unclamp 2.36 (15,2) 3.68 (23,7) 3.68 (23,7) clamp 1.22 (20,0) 2.27 (37,2) 3.53 (57,9) unclamp 2.60 (42,6) 4.35 (71,2) 6.77 (111,0) rm Length [inches (mm)] Operating Specifications Maximum Flow Rate Chart (also see graphs on page 3) 3900 lb (18,8 kn) Max. Clamp rm Length is 6.30" (160,0 mm) straight pull 2.17 (55) standard arm 2.76 (70,1) 3.94 (100,0) 4.72 (119,9) 6.30 (160,0) Max. Flow [in 3 /min (cc/min)] 140 (2294) 140 (2294) 75 (1229) 75 (1229) 75 (1229) 75 (1229) Max. Pressure [psi (bar)] 5000 (350) 5000 (350) 4060 (280) 2755 (190) 2320 (160) 1740 (120) Clamping Force [lbs (kn)]* 5550 (24,7) 3900 (17,3) 2925 (13,0) 1855 (8,3) 1440 (64) 920 (4,1) rm Length [inches (mm)] 7600 lb (35 kn) Max. Clamp rm Length is 7.09" (180,1 mm) includes long stroke version straight pull 2.68 (68,0) standard arm 3.15 (80,0) 3.94 (100,0) 5.50 (139,7) 7.09 (180,1) Max. Flow [in 3 /min (cc/min)] 240 (3933) 240 (3933) 120 (1966) 120 (1966) 120 (1966) 120 (1966) Max. Pressure [psi (bar)] 5000 (350) 5000 (350) 4350 (300) 3480 (240) 2465 (170) 1910 (132) Clamping Force [lbs (kn)]* 9600 (42,7) 7600 (33,8) 6215 (27,6) 4640 (20,6) 2840 (12,6) 1840 (8,2) * For double-acting cylinders. 2
Clamping Force -v- rm Length Graphs 3900 lb (18,8 kn) Models 7600 lb (35,0 kn) Models Clamping Force lbs. (kn) 6000 (26,7) 5000 (22,2) 4000 (17,8) 3000 (13,3) 2000 (8,90) 1000 (4,45) 5000 (350) 5000 (350) 4000 (275) 3000 (210) 2000 (140) 1000 (70) Pressure psi (bar) Clamping Force lbs. (kn) 10000 (44,5) 9000 (40,0) 8000 (35,6) 7000 (31,1) 6000 (26,7) 5000 (22,2) 4000 (17,8) 3000 (13,3) 2000 (8,90) 1000 (4,45) 5000 (350) 5000 (350) 4000 (275) 3000 (210) 2000 (140) 1000 (70) Pressure psi (bar) 0 1.00 (25) 2.00 (51) 3.00 (76) 4.00 (102) 5.00 (127) rm Length in. (mm) 6.00 (152) 7.00 (178) 0 1.00 (25) 2.00 (51) 3.00 (76) 4.00 (102) 5.00 (127) rm Length in. (mm) 6.00 (152) 7.00 (178) 8.00 (203) PRELIMINRY INFORMTION IMPORTNT: Failure to read and follow these instructions may lead to system malfunction or product failure, and could invalidate your warranty. (1) High flow rates can lead to excessive cylinder speed which can cause the kick-out mechanism to activate. Hydraulic pressure and cylinder speed must be adjusted to match the length of clamp arm. The clamping force also varies with the length of the clamp arm. Refer to page 2 for operating specifications. (2) Flow controls with return checks should be used to reduce swing cylinder speed to the recommended rate. The return checks help minimize back pressure that could lead to an unclamp malfunction on single-acting systems. (3) When using single-acting swing cylinders, limit the return flow back pressure to 50 psi (3,5 bar) maximum. Large diameter tubing (3/8" (10 mm) O.D. or larger) and flow controls with free flow return checks help minimize back pressure. Consult for proper system design. (4) Excessive return flow back pressure can also activate the kick-out mechanism on double-acting swing cylinders. Limit the return flow back pressure to 600 psi (42 bar) maximum. Double-acting systems should be set up for a metered-in with reverse free flow in the clamp port. (5) Clamping of the part should occur at the midpoint of the vertical travel. No clamping of part shall occur while the swing clamp is turning. Clamp arm should freely travel during the 90 rotation (avoid contact with cutter heads, tools, etc.). (6) ttaching clamp arm to cylinder plunger must be done according to the instructions on page 7. 3
MOUNTING SPECIFICTIONS Mounting Threaded Body Cylinders Threaded body cylinders can be threaded into a tapped hole, secured to the fixture using a mounting flange, threaded into the fixture and secured with a jam nut, or mounted through a clearance hole and secured with jam nuts. See illustrations below. threaded into fixture mounting flange oil connection oil connection jam nut jam nuts When a threaded body style swing cylinder is being installed in a fixture, the thread engagement should be no less than the thread engagement for the standard mounting flange. If a cylinder is being mounted using just the lower portion of the threads, the engagement should be increased for additional support. See table below for minimum thread engagement. Cylinder Capacity Minimum Thread Engagement 3900 lb (18,8 kn) 1.00" (25 mm) 7600 lb (35,0 kn) 1.25" (30 mm) 4
Mounting Upper and Lower Flange Cylinders WRNING The fixture must be capable of withstanding 5,000 psi (350 bar) hydraulic working pressure when the cylinders are manifold mounted. Manifold O-ring 0.003 D C Manifold O-ring 0.003 D B C Cylinder Capacity 3900 lb 18,8 kn 7600 lb 35,0 kn incl. long stroke Max. Oil Channel Diameter Ø 0.156" 4 mm 0.156" 4mm Fixture Hole Diameter Ø B 2.50 ±.02 63,4 ±0,4 3.05±.01 77,5±0,3 Manifold Specifications Mounting Threads C.3125-24 UNF M8x30.375-24 UNF M10x30 Minimum Thread Depth D 0.59" 15 mm 0.75" 19 mm Lubricated Mounting Bolt Torque Manifold O-Ring Dimensions I.D. x w 25-30 ft-lbs 0.171 x 0.139" 4,34 x 3,56mm 45-55 ft-lbs 0.171 x 0.139" 4,34 x 3,56mm Before a swing cylinder can be manifold mounted, the port screw plugs must be removed. The o-rings provided should be lubricated and installed in the counter-bore around the port prior to mounting and bolting down the swing cylinder. Be sure that the o-ring does not get pinched or damaged during mounting as leakage could result. To prevent leakage from the manifold mounting, provide a fixture mounting surface with flatness within 0.003 in (0,08 mm) and a surface roughness not to exceed 32 rms. Remove port screw plug. Remove port screw plug. Upper Flange o-ring o-ring Lower Flange 5
INSTLLTION Hydraulic Connections To make port connections, install fittings rated for 5000 psi (350 bar). DO NOT use thread sealant. Sealing is accomplished by using an o-ring on the fitting boss. Lubricate the o-ring prior to assembly. When designing your hydraulic circuit, remember to consider the factors listed in PRELIMINRY INFORMTION on page 3 of this Instruction Sheet. For more information about plumbing hydraulic circuits, see your Production utomation Catalog. Cylinder Ports Port Identification Cylinder Capacity 5000 psi SE Fitting 3900 lbs (18,8 kn) #4 7600 lbs (35,0 kn) #4 unclamp unclamp unclamp clamp clamp clamp Threaded Body Upper Flange Body Style (Long Stroke) Lower Flange Body Style side view side view side view Manifold Ports Manifold Ports B bottom view B bottom view B bottom view Key Port: Plunger rotates 90 and clamps B Port: Double-acting -- Plunger unclamps and rotates -90 Single-acting -- Vent Port Do not remove vent plug except to attach tubing. Vent Plug Single-acting cylinders have a vented plug on the left side of the cylinder when you are facing the hydraulic ports. To prevent entry of chips and coolant, the vent plug must not be removed. If the vent plug is subjected to a continuous coolant flood condition, attach tubing to the port using an SE fitting, and run the tubing to a non-contaminated area of the fixture. 6
ttaching Clamp rm 1. Remove the retaining ring from the top of the plunger. 2. Slide the clamp arm down over the plunger and use a pliers to push the retaining ring back onto the plunger groove. Orient the retaining ring so the retaining ring gap will face the back of the clamp arm. See illustration. 3. Move the clamp arm up until it is firmly against the retaining ring and in the desired position. While maintaining this position, torque the clamp arm bolt to specification listed below. CUTION Inadequate torquing of the clamp arm bolt could cause the arm to slip during operation. BE SURE TO USE QULITY GRDE 8 (8.8 DIN 912) SOCKET HED CP SCREWS (supplied with standard clamp arms). Clamp rm Bolt Torque Cylinder Capacity Bolt Type Lubricated Torque 3900 lbs (18,8 kn).50-20 130-150 ft-lbs (176-203 Nm) 7600 lbs (35,0 kn).625-18 270-280 ft-lbs (366-380 Nm) rms for Upper Flange Body Style To use the upper flange body style cylinders, you have to be sure that the contact bolt head will clear the upper flange during operation. The clamp arm must be long enough for the bolt head to clear the upper flange as the arm swings down. Clearance problems are most common when using the CS series standard length arm, with the final clamping position at the side of the cylinder. You may need to use the longer, CL Series clamp arm for these applications. You can cut CL series arms to meet your own requirements, or make your own custom arms according to the dimensions on page 10. L Contact Bolt (with head dia. larger than.63"[16mm]) Max. Length Maximum Contact Bolt Length Cylinder Capacity Maximum Bolt Length CS Series rm 3900 lbs (18,8 kn) 0.875" (22,2 mm) L = 2.17" (55,8 mm) 7600 lbs (35,0 kn) 1.00" (25,4 mm) L = 2.68" (68,1 mm) 7
OPERTION Swing cylinders rotate 90 during the first portion of the stroke, continuing without rotation for the final clamping stroke. The straight downward stroke is the clamping stroke of the cylinder. Clamping force must be applied only during the vertical travel, not during the swing motion. CUTION If clamping force is applied during the rotation portion of the stroke, internal plunger damage may result. To ensure maximum cylinder performance and safety; be sure all hydraulic connections, hoses, and fittings are properly sealed and fully tightened. Be sure all items are rated to withstand system pressures. Under-rated components will not withstand higher pressure. Using under-rated components will lead to equipment damage and possible personal injury. Turning Mechanism Protection The kick-out turning mechanism protection is designed to help prevent internal cylinder parts from damage caused by obstructed plunger movement, workpiece-clamp arm collision, and excessive oilflow. If the kick-out mechanism activates, release system pressure, check for the cause of the activation and correct the problem. Return the cylinder to its original position by hand or by using a wrench. a CUTION fter the kick-out mechanism has been activated, always release the hydraulic pressure in your system before returning the mechanism to its original position. Pressure and Flow Rate Clamp arm length (L) determines operating pressure setting and flow rate. See Operating Specifications Maximum Flow Rate Chart on page 2 for clamp arm length, pressure setting and flow rate. Set operating pressure and flow rate according to the limits established by the length of the clamp arm. Do not exceed the load-to-length pressure ratios. s the arm length increases, the clamping force and maximum operating pressure are reduced. CUTION It is very important that you use the correct pressure and flow settings. Operating outside these limits will cause damage to the swing cylinder. Damage caused by exceeding rated pressure and maximum flow is NOT COVERED BY WRRNTY. 8
MINTENNCE TROUBLESHOOTING Maintenance is required when wear or leakage is noticed. Occasionally inspect all components to detect any problem requiring service and maintenance. offers ready-to-use Repair Parts Kits. Repair Parts Sheets are available with assembly drawing and parts list. Contact. IMPORTNT: Consult the Repair Parts Sheet for service information as to correct assembling and disassembling. Incorrect maintenance and service such as wrong torque values may cause product malfunctions and/or personal injury. The following information is intended to be used only as an aid in determining if a problem exists. For repair service, contact your Distributor or uthorized Service Center. Problem Possible Cause Solution 1. Cylinder will not clamp/unclamp. 2. Cylinder advances part way. 3. Kick-out mechanism activated.. pump release valve open B. no oil in pump reservoir C. air in system D. couplers not fully tightened E. blocked hydraulic line F. spring broken in cylinder. oil level in pump too low B. plunger binding. oil flow too high B. Workpiece-clamp arm collision 4. Cylinder. leaking connection or clamps/unclamps loose fitting slower than normal. B. restricted hydraulic line C. pump malfunction 5. Cylinder clamps/unclamps but will not hold pressure.. seals damaged B. leaking connection C. pump malfunction 6. Cylinder leaks oil.. seals damaged B. plunger worn or damaged 7. Clamp arm does not make swing movement.. clamp arm loose B. plunger damaged.close pump release valve B. fill pump reservoir C. remove air from hydraulic system D.retighten couplers E. check valves, fittings, and tubing F. replace spring.fill pump reservoir B. replace damaged parts refer to Repair Parts Sheet.reduce oil flow B. prevent clamp arm collision refer to Turning Mechanism Protection on page 8.retighten fittings, couplers, and tubing B. check valves, fittings, and tubing C. refer to pump Instruction Sheet.replace seals refer to Repair Parts Sheet B. retighten fittings, couplers, and tubing C. refer to pump Instruction Sheet.replace seals refer to Repair Parts Sheet B. replace damaged parts refer to Repair Parts Sheet.reposition and tighten clamp arm refer to ttaching Clamp rm on page 7 B. replace damaged parts refer to Repair Parts Sheet 9
CLMP RM MCHINING SPECIFICTIONS See Pressure and Flow Rate on page 8 to correctly measure the arm length. To determine the maximum clamping force for the arm, refer to Operating Specifications Maximum Flow Rate Chart on page 2. "".08-.12 [2,1-3,0] "J" "C" "U" "V" "E" "H" "G".04-.06 [1,1-1,5] "M" "K" "N" 55-60 40-50 "B" "F" 3-PLCES "L" "R" 2-PLCES.003 [0,08] "S" "T" 63 [1,6] "D" "P" "Q" Dimensions are in inches (mm). 3900 lb (18,8 kn) 7600 lb (35,0 kn) "" 1.18 (30,0) 1.58 (40,1) "B" Max. 8.47 (215) 8.81 (224) "C" 2.31 (58,7) 2.75 (70,0) "D" 0.84 (21,3) 1.34 (34,0) "E" 1.00 (25,4) 1.18 (30,0) "F" 4.22 (107) 4.50 (114) "G" 1.38 (35,1) 1.59 (40,4) "H" 0.59 (15,0) 0.66 (16,8) "J" 1.18 (30,0) 1.38 (35,1) "K" Diameter 0.59 (15,0) 0.59 (15,0) "L" 0.41 (10,4) 0.41 (10,4) "M" Diameter 0.41 (10,4) 0.41 (10,4) "N" Thru.375-24 UNF.375-24 UNF "P" 0.50 (12,8) 0.59 (15,0) "Q" 1.00 (25,5) 1.18 (30,0) "R" 9-10 16-17 "S" Diameter Ø 1.399-1.402 (35,50-35,60) Ø 1.635-1.638 (41,50-41,60) "T" Diameter Ø 1.2604-1.2614 (32 H8) Ø 1.4965-1.4975 (38 H8) "U" 0.20-0.22 (5,1-5,5) 0.19-0.21 (4,9-5,3) "V" 0.12 (3,05) 0.12 (3,05)
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