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Hydraulics

Compact Model H 160 CA

Hydraulic Cylinders

Automation Technology

Standard version PU or PP seals Chamfering for seal mounting according to ISO 7425/1 (PU and PP), ISO 6195 C and ISO 5597 (PU) Screw-on sealing ring, for > 32, simple to install and remove Progressive cushioning, high cushioning energy, cushioning length self-optimizing to suit working conditions Floating cushioning rings: long life Non-return valve with large orifice for rapid starting Mechanical retention of piston on rod Counterbores according to DIN 3852/ CNOMO E051180N Protected thread on piston rod

Bottom-out velocity self-adjusting no


adjusting screw required

Captive bleed screws, > 32 standard

Hydraulic Cylinders

Contents: 2. 3. 4. 4. 5. Ordering code Specifications Dimensions Rod end detail MX 5

6.

MS 2

7.

ME 5

8.

ME 6

9.

MP 5

10. MT 4

11. Rod eye with spherical bearing 12. Clevis bearing 14. Weights 15. Calculations 25. Seal kits 26. Technical Data 31. Trouble Shooting Guide 34. Appendix Technical Specifications Form Drain Port Details Rod End Internal Threads
Note: Our product range also includes further cylinder types H 160 M ISO C 80 H A 60 H VBH H 250 E.

For Catalogs and product information, see documentation list BEY 000/1 1 987 760 051. For variant standard cylinders and special cylinders, please refer to BVY 015/4.

Hydraulic Cylinders

Ordering Code
Ordering code 1 2 3 4 Ordering example Series Bore Rod Mounting devices 1 H 160 CA H 160 CA 2 3 4 5 6 7 8 9 G 125 56 90 10 250 160 70 110 11 S 200 90 140 N FE 48-106 DI N 24-554 ISO 6020/2 12 A 13 11 14 140 15 I07 63 28 MT4 N PU PU 3 Hydraulic Cylinders 160 bar Compact Series 25 32 40 50 63 80 100 12 14 18 22 28 36 45 18 22 28 36 45 56 70 Double Rod, ISO standard in preparation

Single Rod M E5 M E6 M P5 M S2 MT4 MX5 N V PU PP PU PP O 3 4 G GS

5 6 7 8

Temperature range Piston seals Rod seals Cushioning

Port type

10 Stroke* 11 Stop Tube for long stroke E=-.-.-. S 12 Rod end A C T SP 13 Port locations

Front flange M DE5 Rear flange Spherical bearing M DS2 Side foot mounting M DT4 Center trunnion Front cap tapped M DX5 Normal temperature, standard with PU High temperature or low friction, standard with PP Polyurethane, N version PTFE and Viton, V version Polyurethane, N version PTFE and Viton, V version Without cushioning Cushioning at both ends Low energy cushioning, P max <70bar, D=< 125 B SP Oversized B SPP Please indicate in Full mm; >2700 mm only with factory approval With stop tube (except =2512 and 3214) Without stop tube Standard thread on rod end Thread with rod eye and spherical bearing Tenon Special (use Intervention Form, Consult Factory)

N FE 47-016

Port location to rear cap Port location to front cap

1 1 4 4 2 2 3 3 1 / 1 Standard (Recommended)

Possibilities: Mounting MT1 MT2 MS2 M E5-M E6-M P5-MT4-MX5 In full lengths for mounting MT4 Gland drains, see page 27 Interventions, Consult Factory I.. Front Cap 1 or 3 1,2,3 or 4 1 1,2,3 or 4 Rear Cap 1,2,3 or 4 1 or 3 1 1,2,3 or 4

14 Length XV (MT 4) 15 Options (consult factory) R F-.-

* When stop tube is used indicate of effective stroke plus the length of the stop tube.

Hydraulic Cylinders

Specifications
Specifications Standard Type Working pressure Maximum peak pressure Mounting position Ambient temperature Fluids Fluid viscosity Fluid temperature Filtration Rod and piston seals Bore [mm] Rod [mm] Min, stroke (mm) cushioning M E5, MS2, MX5 Recommended max. stroke M E6, M P5, MT4 Factor W for max. rad. force. (Nmm) Stroke tolerance Speed max. PU 160 bar PU 100 bar PP 160 bar Speed min. recommended PP Stroke end speed max. piston /cap cush.3 cush.4 20 mm/s 50 mm/s according to DI N 3852, ISO 1179-1 15 mm/s 40 mm/s 30 mm/s 10 mm/s PU w/o with 12 18 300 200 625 PU PP ISO 6020 / 2, DI N 24554, N FE 48.016 Tie Rods maximum 160 bar (2300 psi) dynamic for high endurance life, see page 26. Recommended minimum pressure 15 bar (215 psi); lower or higher pressures: consult factory. 240 bar (3500 psi) Unrestricted -20C + 80C for N type seals -20C + 160C for V type seals Mineral oil, such as Mobil DTE 25 or equivalent,other fluids on request 1290mm2/s -20C + 80C for N type seals -20C + 160C for V type seals Contamination equivalent to class 910 to be met with filter b25 = 75 Contamination equivalent to class 78 obtained with filtration b10 = 75 see ordering code, page 2 25 18 14 18 380 250 625 32 22 18 25 480 320 1890 40 28 22 25 600 400 2950 50 36 28 27 750 5 00 4960 63 45 36 30 800 530 7375 80 56 100 45 30 1000 660 14000 70 125 56 30 1250 830 22050 90 160 70 30 1280 850 43550 200 140 35 1400 930 6 8 8 00 110 90

0/+2 mm (accordingto ISO 8131), for lesser tolerances consult factory, 0.50 m/s 0.70 m/s 1.00 m/s 0.40 m/s 0.60 m/s 0.80 m/s 0.030 m/s 0.001 m/s 0.25 m/s 0.35 m/s 0.50 m/s

Counterboring at ports

Fluid compatibility Seal material SealMaterial PU FPM PTFE +++ = excellant * For applications in excess of >50 consult factory Mineral oil H MHV ++ + +++ +++ ++ = good H FC* ++ +++ + = acceptable = not acceptable H FD ++ +++ +++

Hydraulic Cylinders

Dimensions
Rod end detail
T C

Thread

KK

CR

MM

h A S

Bore 25 32 40 50 63 80 100 125 160 200

MM 12 18 14 22 18 28 22 36 28 45 36 56 45 70 56 90 70 110 90 140

KK M 10 1.25 M 12 1.25 M 14 1.5 M 16 1.5 M 20 1.5 M 27 2 M 33 2 M42 2 M 48 2 M 64 3

A 14 16 18 22 28 36 45 56 63 85

C 15 19 15 25 19 33 25 42 33 53 42 67 53 86 67 106 86 136

T 13 17 13 22 17 30 22 36 30 46 36 60 46 75 60 92 75 125

S 5 5 5 5 5 8 7 10 8 10 10 15 10 15 15 18 15 18

h 1 2.5 2 3 3 3 4 5 3 4.5

CR 7.5 9.5 11 13 17 23.5 29.5 38.5 44.5 59

Basic dimensions
Bore 25 32 40 50 63 80 100 125 160 200 MM 12 18 14 22 18 28 22 36 28 45 36 56 45 70 56 90 70 110 90 14 0 KK M 10 1.25 M 12 1.25 M 14 1.5 M 16 1.5 M 20 1.5 M 27 2 M 33 2 M42 2 M 48 2 M 64 3 A 14 16 18 22 28 36 45 56 63 85 B f9 24 30 26 34 30 42 34 50 42 60 50 72 60 88 72 108 88 133 108 163 GA 46.5 46.5 52 57.8 55.8 65 67 73.5 80.5 101 J 22.5 23.5 33 33.8 33.8 39 40 51.5 55.5 76 WH 2 15 25 25 25 32 31 35 35 32 32 T 13 17 13 22 17 30 22 36 30 46 36 60 46 75 60 92 75 125 EE G 1/4 G 1/4 G 3/8 G 1/2 G 1/2 G 3/4 G 3/4 G1 G1 G 1 1/4 DT* 25 25 28 34 34 42 42 47 47 58

Hydraulic Cylinders

Dimensions
H 160 CA MX 5
Y T WH GA J PJ + Stroke E DT EE H

MM KK

TG

VD A

BG ZJ + Stroke ZB + Stroke

B TG

RT

MDX 5

PK + Stroke

Tolerance to ISO 8131 Location of bleed-screws see page 13


Bore 25 E 40 +2 H 5 Y2 50 PJ 1.25 B G min 53 8

ZK + Stroke

ZM + 2x Stroke

RT M 5 0.8

TG 28.3

VD

ZJ 1 114

ZB 121

PK 1.25 54

Z K 1 Z M 2 Stroke max 139 154 25 0

32

45 +2

60

56

M61

33.2

12 12 12 9 9 13 13 9 9 10 10 9 7 7 7 7 7

128

137

58

153

178

3 00

40

63 +2

62

73

12

M 8 1.25

41.7

153

166

71

170

195

400

50

75 +2

67

74

18

M 12 1.75

52.3

159

176

73

182

207

500

63

90 +2

71

80

18

M 12 1.75

64.3

168

185

81

191

223

600

80

115 +3

82

101

24

M 16 2

82.7

190

212

92

215

246

700

100

130+3

82

101

24

M 16 2

96.9

203

225

101

230

265

800

125

165+3

86

117

27

M 22 2.5

125.9

232

260

117

254

289

1000

160

205+3

86

13 0

32

M 27 3

154.9

245

279

130

270

302

1100

200

245+3

98

165

40

M 30 3.5

190.2

299

336

160

324

356

1250

See page 4 for dimensions not stated here.

Hydraulic Cylinders

Dimensions
H 160 CA MS 2
T WH GA J DT EE

KK ST B XS A ZJ + Stroke SS + Stroke SB TS US

MDS 2

PK + Stroke

Tolerance to ISO 8131 Location of bleed-screws see page 13

XS

SV + Stroke ZK + Stroke

Bore 25 32 40 50 63 80 1 00 125 160 200

E 40+2 45
+2

H 5 5

Y 2 50 60 62 67 71 77 82 86 86 98

LH h 10 19 22 31 37 44 57 63 82 101 122

SS SB 1.25 H 13 73 73 98 92 86 105 102 131 13 0 172 6.6 9 11 14 18 18 26 26 33 39

ST 8.5 12.5 12.5 19 26 26 32 32 38 44

TS JS 13 54 63 83 102 124 149 172 210 260 311

XS 2 33 45 45 54 65 68 79 79 86 92

ZJ 1 114 128 153 159 168 190 203 232 245 299

PJ 1.25 53 56 73 74 80 93 101 117 130 165

US 72 84 103 127 161 186 216 254 318 381

PK 1.25 54 58 71 73 81 92 101 117 130 160

SV 1 88 88 105 99 93 110 107 131 130 172

ZK 1 139 153 170 182 191 215 230 254 270 324

ZM 2 154 178 195 207 223 246 265 289 302 356

Stroke max. 25 0 3 00 4 00 5 00 600 700 800 1000 1100 1250

63+2 75 90
+2 +2

115+3 130
+3

165+3 205+3 245


+3

See page 4 for dimensions not stated here.

Hydraulic Cylinders

Dimensions
H 160 CA ME 5
Y GA T F PJ + Stroke J E H

RD MM KK

EE DT

TO UO

A VE WF

VL B GF ZB + Stroke R

FB

MDE 5
Y

PK + Stroke

Tolerance to ISO 8131 Location of bleed-screws see page 13


Bore E H Y 2 50 PJ R TO 1.25 JS13 JS13 53 27 51

ZK + Stroke ZM + 2x Stroke

UO

VL

WF 2 25

FB H13 5.5

GF

R D f8 38

VE

ZB

PK 1.25 54

ZK 1 139

ZK 2 15 4

Stroke max. 250

25

40+2 45+2 63+2 75+2 90+2 115+3 130+3 165+3 205+3 245+3

65

10

25

16

121

32

60

56

33

58

70

35

10

6.6

25

42 62 62 74 74 75 88 82 105 92 125 105 150 125 170 150 210

22 22 22 25 25 29 29 29 29 32 32 31 29 32 32 32 32

137

58

153

178

3 00

40

62

73

41

87

110

35

10

11

38

166

71

170

195

4 00

50

67

74

52

105

130

41

16

14

38

176

73

182

207

5 00

63

71

80

65

117

145

48

16

14

38

185

81

191

223

6 00

80

77

93

83

14 9

180

51

20

18

45

212

92

215

24 6

700

100

82

101

97

162

200

57

22

18

45

225

101

230

265

8 00

125

86

117

126

208

250

57

22

22

58

260

117

154

189

1000

160

86

130

155

253

3 00

57

25

26

58

279

130

270

302

1100

200

98

165

190

300

360

57

25

33

76

336

160

324

356

1250

See page 4 for dimensions not stated here.

Hydraulic Cylinders

Dimensions
H 160 CA ME 6

Y T

PJ + Stroke E H

MM KK

EE

DT

TO UO

A WH FB GA ZJ + Stroke J B R

Tolerance to ISO 8131 Location of bleed-screws see page 13


Bore 25 32 40 50 63 80 100 125 160 200 E 40+2 45+2 63+2 75
+2

H 5 5

Y 2 50 60 62 67 71 77 82 86 86 98

PJ 1.25 53 56 73 74 80 93 101 117 130 165

R JS13 27 33 41 52 65 83 97 126 155 190

TO JS13 51 58 87 105 117 149 162 208 253 300

UO 65 70 110 130 145 180 200 250 300 360

F B H13 5.5 6.6 11 14 14 18 18 22 26 33

ZJ 1 114 128 153 159 168 190 203 232 245 299

Stroke max. 250 3 00 400 500 600 700 800 1000 1100 1250

90+2 115
+3 +3

130

165+3 205+3 245


+3

See page 4 for dimensions not stated here.

Hydraulic Cylinders

Dimensions
H 160 CA MP 5

E EP H T

PJ + Stroke EE DT

50>200 MS

MM
. 3 max

KK CX E

3 . max

A EX CH WH GA XO + Stroke J LT

Tolerance to ISO 8131 Location of bleed-screws see page 13


Bore 25 32 40 50 63 80 100 125 160 200 E 40+2 45
+2

H 5 5

Y 2 50 60 62 67 71 77 82 86 86 98

EP h 15 8 11 13 17 19 23 30 38 47 57

EX 10-0.12 14
-0.12

CH 42 48 58 68 85 105 130 150 185 240

CX 12-0.008 16-0.008 20-0.012 25-0.012 30-0.012 40


-0.012

LT 16 20 25 31 38 48 58 72 92 116

MS 20 22.5 29 33 40 50 62 80 100 120

PJ 1.25 53 56 73 74 80 93 101 117 130 165

XO 1.25 130 148 178 190 206 238 261 304 337 415

Stroke max. 250 300 400 500 600 700 8 00 1000 1100 1250

63+2 75+2 90+2 115


+3

16-0.12 20-0.12 22-0.12 28


-0.12

130+3 165+3 205+3 245


+3

35-0.12 44-.015 55-0.15 70


-0.20

50-0.012 60-0.015 80-0.015 100


-0.020

See page 4 for dimensions not stated here.

10

Hydraulic Cylinders

Dimensions
H 160 CA MT 4
Y T WH GA PJ + Stroke Y J H E DT EE

MM

KK

TD E UW

XV + Stroke ZB + Stroke

B TM UM

MDT 4
Y PK + Stroke

Tolerance to ISO 8131 Location of bleed-screws see page 13


Bore 25 32 40 50 63 80 100 125 160 200 E 40+2 45+2 63+2 75+2 90+2 115
+3

ZK + Stroke

ZM + 2x Stroke

H 5 5

Y 2 50 60 62 67 71 77 82 86 86 98

BD 20 25 30 40 50 60 70 90 110 13 0

PJ 1.25 53 56 73 74 80 93 101 117 130 165

TD f8 12 16 20 25 32 40 50 63 80 100

Tm h14 48 55 76 89 100 127 140 178 215 279

UM 68 79 108 129 150 191 220 278 341 439

UW 42 75 92 80 96 123 136 174 210 269

XV min. 74 93 106 86 116 129 141 157 171 202

XV max. 79 83 91 102 106 118 124 132 131 154

ZB 121 137 166 176 185 212 225 260 279 336

PK 1.25 54 58 71 73 81 92 101 117 130 160

ZK 1 139 156 170 182 191 215 230 254 270 324

ZM 2 154 178 195 207 223 246 265 289 302 356

Stroke Stroke min. max. 0 10 15 0 10 11 17 25 40 48 250 300 400 500 600 700 8 00 1000 1100 1250

130+3 165+3 205+3 245


+3

See page 4 for dimensions not stated here.

Hydraulic Cylinders

11

Dimensions
Rod eye with spherical bearing C
EN EU ZZ CN EF

* without greasing ** only bore


AX KK N

LF

CH * **

Bore 25 32 40 50 63 80 100 125 160 200

KK M 10 1.25 M 12 1.25 M 14 1.5 M 16 1.5 M 20 1.5 M 27 2 M 33 2 M 42 2 M 48 2 M 64 3

AX min. 15 17 19 23 29 37 46 57 64 86

CH 42 48 58 68 85 105 130 150 185 240 12 16 20 25

CN
0 -0.008 0 -0.008 0 -0.012 0 -0.012 0 -0.012 0 -0.012 0 -0.012 0 -0.015 0 -0.015 0 -0.02

EF max. 20 22.5 27.5 32.5 40 50 62.5 80 102.5 120

EN 10 14 16 20 22 28 35 44 55 70
0 -0.12 0 -0.12 0 -0.12 0 -0.12 0 -0.12 0 -0.12 0 -0.12 0 -0.15 0 -0.15 0 -0.2

EU min. 8 11 13 17 19 23 30 38 47 57

LF max. 16 20 25 30 35 45 58 68 92 116

M max. 40 45 55 62 80 90 105 134 156 190

N max. 17 21 25 30 36 45 55 68 78 100

Z max. 3 3 3 3 3 3 3 3 3 3

G 1 812 124 800* 1 812 124 801** 1 812 124 802** 1 812 124 803 1 812 124 804 1 812 124 805 1 812 124 806 1 812 124 807 1 8 12 124 8 0 8 1 812 124 809

30 40 50 60 80

100

CR

Trunnion bearings for center trunions


HB FN FK KC L1 L2

CO TH UL

1 FS NH

Bore 25 32 40 50 63 80 100 125 160 200

CR

CO

FK 38 0.31 45 0.31 55 0.37 65 0.37 75 0.37 95 0.44 105 0.44 125 0.50 150 0.50 200 0.58

12 +-0.018 10 +-0.043 0 0 16 +-0.018 16 +-0.043 0 0


0 20 +0 .021 16 +-0.043 0 0 0 25 +0 .021 25 +0.052 0 0 32 +0 .025 25 +0.052 0 0 40 +0 .025 36 +0.062 0 0 50 +0 .030 36 +0.062 0 0 63 +0 .030 50 +0.062 0 0 80 +0 .030 50 +0.062 0 100 +0.032 63 +0.074 -0 -

FN max. 55 65 80 90 110 140 150 195 230 300

FS 8 0.18 10 0.18 10 0.18 12 0.22 15 0.22 16 0.22 20 0.26 25 0.26 31 0.31 42 0.31

HB
. 9 +0022 0 11 +0 .27 0 11 +0 .27 0 14 +0 .27 0 18 +0 .27 0 22 +0 .33 0 26 +0 .33 0 33 +-0.39 0 39 +-0.39 0 52 +-0.46

KC +0.3 3.3 4.3 4.3 5.4 5.4 8.4 8.4 11.4 11.4 12.4

NH max. 17 21 21 26 33 41 51 61 81 101

TH 40 0.31 50
0.31

UL 63 80 90 110 150 170 210 265 325 410

L1 25 30 40 56 70 88 90 136 160 200

L2 25 30 38 45 52 60 72 87 112 150

G 1 812 130 865 1 812 130 866 1 812 130 867 1 812 130 868 1 8 12 13 0 8 6 9 1 812 130 870 1 812 130 871 1 812 130 872 1 812 130 873 1 812 130 874

60 0.37 80 0.44 110 0.44 125 0.50 160 0.50 200 0.58 250 0.65 320 0.70

12

Hydraulic Cylinders

Dimensions
Clevis bearing
LO SR CP CG

CF k7 GK FM KC d

FO

CO TA GL UK UJ RE HB

Bore 25 32 40 50 63 80 100 125 160 200

CF SR 12 16 20 25 30 40 50 60 80 100

CP h 14 30 40 50 60 70 80 100 120 16 0 200

CG +0.3 10 14 16 20 22 28 35 44 55 70

CO N9 10 16 16 25 25 36 36 50 50 63

d H 15 18 22 26 30 33 40 53 71 82 89

FM js 11 40 50 55 65 85 100 125 150 190 210

GK M6 M6 M6 M6 M6 M8 M8 M 10 M 10 M 10

GL js 13 46 61 64 78 97 123 155 187 255 285

HB H 13 9 11 13.5 15.5 17.5 22 30 39 45 48

LO 56 74 80 98 120 148 190 225 295 335

FO js 14 16 18 20 22 24 24 35 35 35 35

KC +0.3 3.3 4.3 4.3 5.4 5.4 8.4 8.4 11 11 12

RE js 13 55 70 85 100 115 135 170 200 240 300

TA js 13 40 55 58 70 90 120 145 185 260 300

UJ 75 95 120 140 160 190 240 270 320 400

UK 60 80 90 110 135 170 215 260 340 400

G 1 815 805 808 1 815 805 809 1 815 805 810 1 815 805 811 1 815 805 812 1 8 1 5 8 0 5 8 13 1 815 805 814 1 815 805 815 1 815 805 816 1 815 805 817

Trunnion bearings for center trunions


ZV

DK

DK

BU DB

JL SL YL

SK

DK h6 12 16 20 25 30 40 50 60 80 100

SL 40 50 62 72 85 100 122 145 190 235

JL 4.5 5.5 5.5 5.5 7.5 9.5 10.0 11.0 15.0 15.0

ZV 10 13 17 22 24 32 41 50 70 90

G 1 813 103 803 1 813 103 804 1 813 103 805 1 813 103 806 1 813 103 807 1 813 103 808 1 813 103 809 1 813 103 810 1 813 103 811 1 813 103 812

DK 12 16 20 25 30 40 50 60 80 100

DB 6.4 6.4 6.4 6.4 6.4 8.4 8.4 10.5 10.5 10.5

BU 15 15 18 18 20 20 25 25 30 40

SK 3 3 4 4 5 6 8 8 10 12

YL 27 40 40 40 45 62 65 80 90 120

Q
DI N 91210.9

G 1 811 038 800 1 811 038 801 1 811 038 802 1 811 038 803 1 811 038 804 1 811 038 805 1 811 038 806 1 811 038 807 1 811 038 808 1 811 038 809

M 6 12 M 6 12 M 6 16 M 6 16 M 6 16 M 8 20 M 8 20 M 10 25 M 10 25 M 10 25

Hydraulic Cylinders

13

Dimensions
Location of bleed-screws

Port type

L1

L2+

Port type

3 L1 L2+

Bore L1 25 32 40 50 63 80 100 125 160 200 55 65 70.5 74 79 86 92 98.5 102.5 123 L2 43 46 56 60 64 75 81 92 97 110

Bleed-screw S 2.5 2.5 3 3 4 4 4 4 4 M5 M5 M6 M6 M6 M8 M8 M8 M8 M8

14

Hydraulic Cylinders

Calculation
Weight of the cylinders and rod accessories (kg)
Bore 25 Rod 18 22 18 28 22 36 28 45 32 40 50 60

ME 5

1.22

1.58

3.74

3.84

5.55

5.70

7.73

8.22

ME 6

1.26

1.64

3.81

3.90

5.70

5.86

8.16

8.46

MP 5

1.13

1.52

3.22

3.31

4.94

5.10

7.30

7.60

MS 2

1.22

1.68

3.38

3.48

5.34

5.49

8.03

8.46

MT 4

1.35

1.92

4.12

4.21

6.56

6.72

9.22

9.52

MX 5 Additional Weight per 100 mm stroke

1.10

1.47

3.11

3.20

4.76

4.91

6.99

7.29

0.58 Rod eye with spherical bearing 0.20

0.64

0.76

1.06

1.12

1.62

1.44

2.20

0.40

0.70

0.70

1.10

1.10

1.50

1.50

Bore 80 Rod 36 56 45 70 56 90 70 110 90 140 1 00 125 160 200

ME 5

13.83 14.96 19.12 20.79

37.21 40.08 60.35 63.89 111.83 11776 .

ME 6

14.96 15.61 20.43 21.51

40.11 41.57 65.64

67.31

119.42 122.27

MP 5

13.48 14.13 19.27 20.05

37.31 38.77 62.95 64.63 114.15 11700 .

MS 2

13.81 14.46 19.73

20.52

37.20 38.65 61.56 63.24 111.91 114.79

MT 4

17.43

18.08 24.01 24.79

45.89 47.35

77.42

79.10

146.13 149.00

MX 5 Additional Weight per 100 mm stroke

11.90 13.55 18.15 18.93

34.96 36.42 58.49 60.17 106.06 108.91

2.16 Rod eye with spherical bearing 3.50

3.28

3.30

5.10

6.28

9.34

8.74

13.18 13.42

20.50

3.50

6.00

6.00

8.50

8.50

17.00 17.00

32.00

32.00

Calculation

Calculation of cylinders:

Cylinders can be calculated by using the diagrams shown on page 16 17.


page 17

Pressure p Force F Diameter Efficiency h

page 19

Buckling length

Sr/Sm = 0.8

Sm ME6

Fm

Example:

Stroke time 3 sec. Load-friction coefficient = 0.4 Available pressure = 80 bar To be determined: Piston and rod

Piston rod advance: Overall efficiency h = h1 h2 h1 = efficiency of cylinder 0.9 (approximate) Pm S m Pr S r P m S m 0 .8 P r S m P m 0.8 Pr 8 0 0.8 1 5 h2 = efficiency of system = = = = = 0 .8 5 Pm S m Pm Sm Pm 80

y ; y ; y ; y ;
Hydraulic Cylinders 15
D d F

page 18

Flow Q Speed v Diameter

page 21

Cushioningcapacity

tg

= 0.4

tg

= 0.4

Sm

Sr

Str

1 oke

00

0m

Sr

M = 2000 kg

Fr

M = 2000 kg

= 30

Pr = 15 bar

= 30

Pm = 80 bar

Pm = 80 bar

Pr = 15 bar

16

Hydraulic Cylinders

Calculation
Force required to move a mass:

F = 0.4 M g cos a + M g sin a = 0.4 2000 9.81 0.866 + 2000 9.81 0.5 = 16606 N = 1661 daN.
The graph on p. 17 shows the following: Force 1661 daN, h = 0.765; max. pressure 80 bar; cylinder piston 63. Piston rod return:

F = 0.4 M g cos a M g sin a = 0.4 2000 9.81 0.866 2000 9.81 0.5 = 3013.6 N = 301 daN.
No problems with force on return. Testing the buckling length: The table on pg. 19 shows the following: 80 bar for Pm; cylinder 63 28 in, L = 818 mm. For ME 6, K = 1.5 (pg. 20).

818 L = = 545 mm. 1.5 K If piston rod buckles: 2 possibilities: Select rod 45 L = secure against buckling Change type of mounting, e.g. MS2 with coefficient 0.7. H=
Test of cushioning: Average speed
1 = 0.33 m/s. 3

Correction factor F = 1.07 (pg. 22) Max. speed

1.07 0.33 = 0.356 m/s.

Cushioning capacity during rod advance (pg. 21):


M v2 2000 0.3562 M g La sin a = 2000 9.81 0.028 0.5 = 147.94 joules. 2 2 No problems with cushioning during rod advance. =

Damping capacity during rod return:

M v2 2000 0.3562 + M g La sin a = + 2000 9.81 0.026 0.5 = 381.79 joules. 2 2 The graph on pg. 23 shows the following: 350 joules for Pm 80 bar, Vmax = 0.4 m/s, thus cushioning takes place at 0.356 m/s: =

= 350 0.356/0.4 = 311.5 joules


The cylinder cannot absorb this energy. The next largest, 80, must be selected. Check of buckling for a rod of 56. Required pumping power: The graph on pg. 18 shows the following: 80 56 at 0.356 m/s advance = 110 l/min. return = 57 l/min.

Pressure p Force F Diameter Efficiency hnm

Calculation

D F

d1 F

d1 F

p[bar]
140 160 100 120 100 120 40 60 80 40 60 80 20 20

p[bar]
140 160 140 100 120 40 60 80 20
0.6 0.8 1 0.6 0.8 1

p[bar]
160 0.4 0.5 0.6
0.6 0.8 1

hm
1 0.9 0.8 0.7

Efficiency hnm (friction)

0.6 0.8 1

2
2 3 4 5 6 8 10 2

5x 2x

18
2 2 3
4 0 5 0 63 x28 x36

2 3

22

3 4 5 6 8 10

2 0 0

4 5 6 8 10

4 5 6

0x 0x 3x

18 22

4 5 6 8 10

4 5

x45 x56

20 30 40 50 60 80 100

20

28 36 x4 x5 5 6

3
30

8 1 1 1 2

20 30 40 50 60 80 100

8 0
10

20 30 40 50 60 80 100

0x

8 1

0x7 0

0 00 25 60

40 50 60 80 100

00 25

12 16 20

5x9 0x1 0x1

Hydraulic Cylinders

0 10

60 00

x70 0

1
200 300 400 500 600

200

x9

40

200 300 400 500 600

200 300 400 500 600

00

300 400 500 600

F[kN]

F[kN]

F[kN]

17

18

Hydraulic Cylinders

Calculation
Flow Q Speed v Diameter
V[m/s]
0.01

a ete

0.02 0.03 D 0.04 0.05 0.06 0.08 0.1


5 2 2 3 0 4 5 6 8 0 1 00 2 60 1 25 1 0

Q 0.2 0.3 0.4 0.5

0.1

3 4 5 6 8 10

20

30 40 50 60 80 100

V[m/s]

0.01

0.02 0.03 D d1 0.04 0.05 0.06 0.08 0.1 Q 0.2 0.3 0.4 0.5

0.1

3 4 5 6 8 10

20

30 40 50 60 80 100

200 200

V[m/s]

0.01

0.02 0.03 D d2 0.04 0.05 0.06 0.08 0.1 Q 0.2 0.3 0.4 0.5

0.1

3 4 5 6 8

10

20

30 40 50 60 80 100

300 400 500

0.5

300 400 500

0.5

300 400 500

200

0.5

Q[l/min]

2 5x 18

0 x9 00 2 70 x 60 1 6 x5 25 1 5 x4 00 56

3 2x 22

3x

0x 18

0x 22

0x

28

Q[l/min]

40 x1 00 0 2 x11 60 1 0 x9 25 1 70 x 00 1 56 0x 8 45 3x 6 36 0x 5 8 2 0x 4

Q[l/min]

Hydraulic Cylinders

19

Calculation
Buckling length: Based on load F, the free buckling length L is determined by table below. This one has to be divided by the correction factor K, according to mounting type (see page 20). The maximum stroke H of the specific application is:

H= L K
L

Max. buckling length L in mm if K = 1


Bore Rod 10 12 25 18 14 32 22 18 40 28 22 50 36 28 63 45 36 80 56 45 100 70 56 125 90 70 160 110 90 200 140 19060 13453 10964 9477 8460 7707 7121 6647 6253 5919 5630 5377 5153 4953 4773 4608 14707 10380 7857 5530 8 45 9 4493 7311 3870 6526 3442 5 9 45 3123 5492 2872 5126 2667 4822 2494 4563 2346 4340 4145 2215 2099 3972 1993 3817 1895 3677 1804 3550 1717 12604 5 93 9 8897 4179 7252 3394 6269 2923 5597 2598 5100 2356 4712 2165 4399 2009 4139 1878 3918 1764 3728 3561 1664 1574 3414 1492 3282 1416 3163 13 4 4 3055 1275 9530 4867 6727 3 425 5 4 82 2783 4739 2397 4230 2132 3854 1934 3560 1778 3323 1651 3126 1544 2959 1452 2815 2689 1371 1298 2577 1233 2477 1172 2386 1115 23 0 4 1061 7624 3928 5381 2765 4386 2246 3791 1935 3384 1721 3083 1561 2848 1436 2659 1333 2501 1247 2367 1173 2252 2151 1108 1049 2061 996 1981 947 1909 902 18 43 859 6252 3142 4413 2212 3597 1797 3109 1548 2776 1377 2529 1249 2337 1149 2182 1067 2052 998 1943 938 1848 886 1766 839 1692 797 1627 758 1568 721 1514 687 5042 2414 3559 16 9 9 2901 1380 2508 1189 2239 1057 2040 959 1885 881 1760 818 1656 765 1567 719 1491 1425 679 643 1365 610 1313 579 1265 551 1222 524 3812 1877 2691 1321 2193 1073 1895 924 1682 822 1541 745 1424 685 1329 636 1251 594 1184 558 1126 527 1075 498 1031 473 991 449 955 426 922 4 05 2941 1571 2076 1106 1692 899 1462 774 1305 688 1189 625 1098 574 1025 533 964 499 913 469 868 443 829 420 794 399 763 379 735 361 710 343 2521 1188 1779 836 1450 679 1254 5 85 1119 520 1020 471 942 433 880 402 828 376 784 353 746 333 712 315 683 298 656 283 633 26 9 611 255 1118 20 787 30 640 40 552 50 4 91 60 446 70 411 p (bar) 80 382 90 358 100 337 110 319 120 303 130 289 140 275 150 263 160 252

20

Hydraulic Cylinders

Calculation
Mounting type Load Guidance K

2 MP 5 1.5

1.5

1.5 MT 4 1

0.7

0.7 MS 2 0.5

0.7

0.7 ME 5 MX 5 0.5

1.5

1.5 ME 6 1

Hydraulic Cylinders

21

Calculation
Cushioning capacity: During deceleration of masses by end cushioning, the cushioning capacity must not be exceeded. For this reason the kinetic energy due to the inertial mass must be calculated and compared with permitted values in the diagrams on page - 23.

Calculation of kinetic energy:

A B
A

E=

1 m v2 2

A: E =

1 2 mv mg l a 2
1 mv 2+ mg la 2

A:E = B :E =

1 mv 2 mg l a sin a 2 1 mv 2 + mg l a sin a 2

B: E =

Cushioning length and masses Bore [mm] Rod [mm] front la [mm] rear piston [kg] rod* vmax[m/s] * per 50 mm stroke 0.10 0.5 0.15 0.5 0.10 0.24 0.15 0.40 0.24 0.63 0.40 0.97 0.63 0.5 0.5 0.4 0.4 1.51 0.97 2.50 0.25 1.5 3.73 2.50 6.04 0.25 0.25 0.25 25 18 19 16 0.21 32 22 20 16 0.39 18 24 26 40 28 25 26 22 25 26 50 36 28 26 28 28 26 63 45 27 26 36 27 29 80 56 31 29 45 31 29 100 70 25 29 56 25 29 125 90 30 29 160 70 30 40 110 28 40 200 90 50 53 140 45 53

0.54 0.72 0.82 1.20 1.42 2.03 2.62 3.62 4.70 6.33 8.03 11.19 15.59 20.02 29.64 37.67

v > vmax: on request

22

Hydraulic Cylinders

Calculation
Speed correction: In a typical speed profile with acceleration and deceleration, the maximum velocity vmax is greater than the average velocity vavg. This must be considered particularly with shorter strokes and must be adjusted with a correction factor F.

Vmax

s (mm) Stroke

1500

1000

500

Vmax = V x F

1.2

1.4 25 - 50 63 - 125 160 - 200

1.5

1.6

1.8

2 F

Hydraulic Cylinders

23

Cushioning energy

E = f (p) H 160 CA ... 3 ...

EU = Emax

vU vmax

EU = Absorbed energy Emax = Max. energy see characteristic curve vU = Effective operating speed vmax = Max. speed for PU D, d1 20000
E (Joule) E (Joule)

20000
200 16 0 125

10000 8000 6000 4000 2000 1000 800 600 400 200 100 80 60 40 20 10 8 6 4 2 1 0 20 40 60

10000 8000 6000 4000 2000 1000 800 600 400 200 100 80 60 40 20 10 8 6 4 2

200 160 125 100 80 63 50 40

10 800 63 50 40

80

100 120 140 160

1 0

20

40

60

80

100 120 140 160

p (bar)
D, d2 20000
E (Joule)

p (bar)
20000
E (Joule)

10000 8000 6000 4000 2000 1000 800 600 400 200 100 80 60 40 20 10 8 6 4 2 1 0 20 40 60

200 16 0 125

10000 8000 6000 4000 2000 1000 800 600 400 200 100 80 60 40 20 10 8 6 4 2

200 160 125 100 80 63 50 40


32 25

10 0 80 63 50 40

32 25

80

100 120 140 160

1 0

20

40

60

80

100 120 140 160

Applicable for PU seals. For vu > vmax, please consult us.

p (bar)

p (bar)

24

Hydraulic Cylinders

Calculation
Example:

Pm = 100 bar, V = 0.5 m/s 0.5 0.4


10 00 kg

400 1000 kg 600 kg 200 kg

300

V (m/s)

0.3 0.2 0.1 0

0k

20

Pa (bar)

60

kg

200

100

10

15

20

25

30

10

15

20

25

30

Cushioning length (mm)

Cushioning length (mm)

v = 0.5 m/s, m = 1000 k/g 0.5 0.4 0.3 0.2 0.1 0


Pm 10 0b Pm ar 60 bar Pm 30 bar

400

300

Pm 10

0 bar

Pa (bar)

V (m/s)

200

Pm 60 ba

100

Pm 30 bar

10

15

20

25

30

10

15

20

25

30

Cushioning length (mm)

Cushioning length (mm)

m = 1000 kg, Pm = 100 bar 0.5 0.4 400


0.5 m/s

300

Pa (bar)

V (m/s)

0.3 0.2 0.1 0

0.3 m/s

0.5 m/ s

200

2 0.

m/

0.1 m/s

100
0.1 m/s

10

15

20

25

30

10

15

20

25

30

Cushioning length (mm)

Cushioning length (mm)

The progressive cushioning is self-optimizing to suit the working conditions, as shown in the graphs containing variable parameters for a cylinder of 50. Therefore, the effective cushioning length depends on the cushioning energy to be absorbed; i.e. there is less lost time at lower speeds and thus shorter cycle times. This cushioning is insensitive to temperature.

Hydraulic Cylinders

25

Seal kits

Seal kits
Pos

+ 2 PU

Pos

PU

PU

y ; yy ;; yy ;;
1 2 3 4 5 6

10

12

11

Bore

25

32

40

50

63

80

100

125

160

200 837

1 817 005

828

829

830

831

832

833

834

835

836

Bore 40

25

32

50

63 45 837 927

18

22

18

18

22

36

28

1 817 006

832

833

834 924

835 925

836 926

1 817 005

922

923

Pos

G 80 36 56 83 8 928 45 839 929 100 70 840 93 0 56 838 928

Bore 125 90 841 931 70 842 932 160 110 843 933 90 841 931 200 140 844 934

PU PU

1 817 006 1 817 005

835 925

Seals are mounted in the guide ring.

Tightening torques
Bore 25 [Nm] 3 32 6.5 40 12 50 37 63 40 80 90 100 100 125 24 0 160 450 200 600

When ordering replacement caps, tubes, rods etc., please state cylinder part no.

26

Hydraulic Cylinders

Technical Data
Maximum Pressure The H160 CA cylinder range is rated at 160 bar (2300 psi) dynamic working pressure, as defined by the ISO Norm 6020 /2 for all mounting types. Higher pressures can be approved after factory consultation. An authorization to exceed 160 bar begins with the completion of the Technical Specification for Hydraulic Cylinders form in accordance with the ISO 9001 standards. Attention must be given to pressure increases in applications with differential or throttle valves. Maximum pressure inside the cylinder chamber should never exceed 240 bar (3500 psi). Minimum Pressure A certain minimum pressure is required to assure proper operation of the cylinder. We recommend a 15 bar (215 psi) minimum. However, some lower pressure applications can be approved with factory consultation. Maximum Speed To assure long cylinder life in intensive applications the maximum speed is limited by the factory. The speed is determined by the seal type, cylinder diameter and operating pressure, see page 3. If higher speeds are necessary, consult factory. Minimum Speed To avoid the Stick-Slip effect, we recommend the use of a minimum speed as indicated in page 3. If lower speeds are necessary, consult factory. Cushioning The use of cushioning is recommended at speeds greater than 20 mm /sec. (0.8 inches/sec.) to assure proper energy dissipation, without auxiliary sources, and to prevent damage to the cylinder, as well as the machine components. To avoid potential problems associated with the screw-adjustable cushioning (i.e. shock, improper adjustment by vibration or untrained personnel, leakage at screw seal, etc.) the Bosch series H160 CA has a progressive, self-adjusting cushioning system. Advantages of this cushioning system are: - progressive deceleration - short cushioning time - cushioning length in accordance with piston speed - low cushioning pressure with no pressure peaks thereby insuring the safety and endurance of the cylinder and its environment - low sensitivity to variations in pressure, temperature and moving loads - automatic limitation of the stop-speed of the piston resulting in greater safety and reliability - special design features of the check valve and floating bushings assure high capacity of oil flow resulting in fast acceleration - applications: pressure 30 to 160 bar (435 psi to 2300 psi) = cushioning 3 pressure 15 to 70 bar (215 psi to 1000 psi), low energy and shorter cushioning time = cushioning 4 Each cylinder with standard progressive cushioning has to complete its full design stroke. The use of external fixed or adjustable stops requires precautionary measures. Please discuss these measures with the factory. Piston Rod The piston rod is made of high quality steel, case hardened and chromed providing high resistance to mechanical shocks, oxidation and high life expectancy. For applications in corrosive environments we recommend as an option the use of hard-chromed stainless steel. The rod end is threaded with a chamfer thereby insuring its protection. The DIN 24554 and NFE 48.016 norms calls for only one rod end thread per piston diameter. This assures the full transfer of dynamic forces within the norms described and allows a favorable application of fittings conforming to ISO 8133. This means smaller dimensions of the fittings and of course, better prices. Piston Rod Diameter The dimensions indicated in this catalog correspond to a standard that is in preparation. The double rod, often used to reduce flow requirements, to insure identical forward and reverse movement or to command a position switch, have a naturally higher friction than is normally experienced with single rod cylinders. The rod ends selected can be different. The rod diameters in standard form, must be the same. Consult factory for variation requests. For applications where the rod is fixed and the cylinder body moves, care must be given to the radial forces on the glands.

Hydraulic Cylinders

27

Technical Data
Seals We offer as standard seals either the polyurethane (PU) or PTFE/Viton (PP). The housings for the seals are according to ISO 5597 for PU rod seals, ISO 7425-1 for PU and PP piston seals, ISO 6194-C for PU and PP rod wipers. Replacement of seals from one type to another only requires the replacement of the piston seals (piston for both seal types is the same), the tube-cap seals and the gland assembly. These seals can be used for normal mineral oil applications. For HFA, HFB, HFC and other fluids the exact fluid specification should be discussed with the factory. With PU seals higher piston speeds can be applied when pressure is < 100 bar (1450 psi) and a frequency < 3Hz. Long stroke cylinders are recommended with PU seals. Rod Gland Rod glands in gray-iron castings are screwed into place in a one-piece construction for bore diameters => 40mm. For smaller diameters the casings are 2 or 3 piece construction with grooved seal housings. Simple assembly is then assured. For replacement purposes one can specify the proper seal kit with gland or without gland. Piston The piston is of mono block design including integrated cushioning screwed, loctited and setscrew positioned onto the piston rod. The seal locations have identified positions and are designed according to ISO 7425-1 for PU and PP seals and therefore can be interchanged quite simply. Bore Sizes Bore diameters of >200mm according to ISO 6020/3, consult factory. Seals for Tube/End Caps A closed housing design with both O-ring and backup seal are aligned and supported on both sides to insure a high degree of sealing, especially for long stroke cylinders. Durability Bosch cylinders follow a set of recommended standards for durability determined by an interprofessional commission and hydraulic cylinder association group: >= 10,000,000 continuous cycles (unloaded) or 3000km (1800 miles) at 70% maximum pressure, without load on the rod, a maximum speed of 0.5 m/sec (1.75 feet/sec) with a failure rate of < 5%. Care should be used when aggressive fluids outside of the cylinder are present, for example, the use of coolants and cleaning fluid. Because of the many different compounds available on the market, please consult the factory. Buckling A cylinder engaged in mechanical compression is exposed to the possibility of buckling. As a result the stroke length is limited and depends on the operating pressure, mounting style and load guiding. The theoretical stroke as a mathematical value is indicated on page 19 and is a function of operating pressure and bore diameter. This value must be divided by the load guiding factor. This then determines the permitted stroke. Longer strokes can lead to buckling and the destruction of the cylinder. If the required stroke of your cylinder exceeds the permitted stroke, consider another type of mounting or another type of load guiding, or a larger bore size in combination with a lower pressure. Use the calculation program in hydraulic cylinder CD ROM (# 1 987 760 009) as a helpful tool. Radial Force on Piston Rod In order to avoid premature wear in the gland and seals we recommend that radial loads on the piston be reduced. The values on page 3 have been established in accordance with industrial manufacturing groups. Standard Strokes The use of stroke lengths are standardized by ISO 4393. They are required by all major automotive companies in order to limit the variety of cylinders, thereby simplifying stock keeping. The indicated stroke lengths must be stated in full mm.

28

Hydraulic Cylinders

Technical Data
Stroke Tolerances According to standard ISO 8131 the stroke tolerance is 0 /+ 2mm for strokes up to 1250mm (49 in.). For longer strokes consult factory. A reduced tolerance of +/- 0.3mm can be obtained as a higher priced option. A smaller reduction in tolerance would not take into account the elasticity of a tie rod cylinder. Recommended Maximum Strokes The recommended maximum strokes on page 3 insure a proper functioning in all applications at a maximum pressure of 160 bar (2300 psi). However, buckling must be taken into consideration. When pressures < 160 bar are used or when pulling a load, longer strokes are possible. When the cylinder is exposed to heavy mechanical loads and long strokes we recommend the ISO 6020 /1 H160M series. Minimum Strokes Cylinders with intermediate trunnion mounting MT 4 require a certain minimum stroke due to the trunnion, see page 3. For cylinders with cushioning a minimum stroke is recommended to obtain a sensible motion. If a very short stroke is required we recommend the use of a cylinder without cushioning. Please discuss this with the factory. Stop Tube In order to reduce the charge in the gland on long stroke cylinders we recommend a stop tube. Therefore the distance between piston and rod gland will increase so the cylinder becomes more stable, the life expectancy increases and proper function is provided for. This precaution is not necessary for a cylinder mounted vertically-rod down, strongly guided and without lateral movement. Stop tube length depends on the mounting type and the load guiding factor and are available in 50mm (2 in.) increments for all diameters, except the 2512 and 3214, which have limited strokes. We recommend the use of PU seals due to the associated radial forces. Tie Rod Support For cylinders with long strokes a support is necessary to stabilize the tie rod. This option can be called for in the Technical Specification for Hydraulic Cylinders form. External Support Long stroke cylinders have a tendency to bend. As a consequence, this creates high friction and premature wearing of the seals. To avoid bending these cylinders an external support in the machine is often required. This support must be provided by the machine builder. Ports Standard ports are BSPP according to ISO 8138 and ISO 6020/2. The chamfer is designed to ISO 1179. Oversize Ports The ports sizes for the H160CA cylinder series are properly sized for high speed. If oversized ports are required the position and dimensions of the ports abrogate the ISO standards. Port Positions The DIN 24554 standard recommends as standard the position 1, 1. Other port positions can be provided as indicated on page 2. Air Bleeds Integrated air bleed, non removable according to ISO 4413 and NFE EN 982 (for bore sizes larger than 32mm) are standard equipment on the end caps. ISO standard dimensions are not effected. For air bleed position see pages 13 and 25. Gland Drain Using state of the art seal technology that provides optimum sealing means that gland drains are not normally required. Only in certain stress applications, such as extend > 2 the retract speed, with long strokes, constant pressure on the seals and so on, a gland drain can be useful. For extend speed > 15 retract consult factory. The position of the gland drain is called out in the alphanumeric description i.e. RF1 or RF2, see ordering guide. Standard ISO dimensions are followed except for size 6345.

Hydraulic Cylinders

29

Technical Data
Mountings MX5 : To the standard NFE 48.016 (for description see ISO 6099) calling for a 4-bolt mounting arrangement. MX7 : Similar to the MX5, but with extended tie rods and countersunk screws in the end cap (for description see ISO 6099). MS2 : With thrust key we offer a keyway for a standardized key which reduces the load on the four mounting bolts. The Norm is in preparation. Please consult factory. Port position 2 and 4 are not available in the standard program because of interference between fittings and mounting bolts. Mounting Bolts For affixing mounting styles ME.., MS.., mounting bolts grade 12.9 and nuts grade 80 minimum are to be used. For torque values see dimension drawings in the catalog. Start-Up For the cylinder to operate as designed it is important to follow setup procedures. - the alignment of the cylinder and the load must be proper to avoid adverse load influences and premature wear - avoid radial forces on the rod - carefully clean the tubes and fittings before mounting - purge the air from the system and use a clean and filtered oil It is recommended that the cylinder rod be retracted 100% and synchronized mechanically in this position with the zero point of the load. Then fully extend the rod and be sure the load is synchronized (between the rod end and the load) at its 100% position. Cylinder Surface Protection A primer coat, for oxidation protection, is applied to all cylinders before shipping. Other finish coats can be applied by the customer over the primer coat. A white epoxy coating can be delivered on demand, recommended for applications in aggressive or high humidity environments. Shelf Life of the Cylinders All Bosch cylinders are tested with mineral oil to ISO grade IGV 046. The oil is drained and the ports sealed with a plastic plug. The residual oil protects the cylinder against rust for at least one year when the environmental conditions are dry and temperate. Cylinders with long strokes or are stored in exceptional situations, i.e. humid, very warm or very cold environments, or endure long storage periods please consult the factory. If cylinders are warehoused for more than two years we advise a seal change before cylinder installation. Accessories The rod eye C with spherical bearing can be supplied already mounted onto the cylinder. Other accessories must be ordered separately. Accessories to be warehoused already have been protected against corrosion. Cylinder Rod Boot In applications where the rod is subject to contamination the rod and seals can be protected by a boot. Please consult factory. Integrated Position Sensors Cylinders can be equipped with proximity sensors, for example a potentiometer or ultrasonic with a broad choice of input signals. The cylinder can be supplied with standard ports or in a subplate mount in NG6, NG10 & NG16. For more information consult factory. This type of cylinder will deviate from certain Norm dimensions. Loose Tolerances in Mounting Cylinders with loose tolerances such as trunnion mount, rod eye with spherical bearing etc. should be avoided in systems where tight position control is necessary. Consult factory for further information. Stroke End Position Sensors Inductive proximity switches can be installed onto the cylinder, but in certain cases special end caps must be provided. Consult factory. Piston Rod Clamping Device Clamping devices can be mounted onto the front cap of the cylinder to maintain the piston rods position during long periods of inactivity, or for safety reasons. In no case is the clamping device to be used as a brake.

30

Hydraulic Cylinders

Technical Data
CD ROM In addition to the catalog one can request the Bosch CD ROM with a calculation program for determining cylinders, as well as a CAD program in DXF format. Consult factory. Ordering number is 1 987 760 009. Description of norms ISO 6020 /2: DIN 24554 : NFE 48.016 : ISO 6020 /3: Mounting dimensions for single rod cylinders, 16 Mpa 160 bar-Part 2: compact series Limited choice (mountings, rod ends, etc.) of the ISO 6020/2 demanded by large worldwide customers and end-users. Identical to DIN 24554 but with additional mounting MX5, tenon at rod end and double rod. Mounting dimensions for single rod cylinders, 16 Mpa bar-Part 3: compact series with bores from 250 to 500 mm (10 in. - 20 in.) ISO 6099 : Identification code for mounting dimensions and mounting types ISO 6195 : Housings for rod wiper rings in reciprocating applications-dimensions and tolerances ISO 5597 : Housings for piston and rod seals in reciprocating applications-dimensions and tolerances ISO 7425 /1: Housings for elastomer-energized, plastic-faced seals-dimensions and tolerances-Part 2: Piston seal housings ISO 7425 /2: Housings for elastomer-energized, plastic-faced seals-dimensions and tolerances-Part 2: Rod seal housings ISO 8131 : Single rod cylinders, 16 Mpa (160 bar, 2300 psi) compact series-Tolerances ISO 8133 : Single rod cylinders, 16 Mpa (160 bar, 2300 psi) compact series-Mounting dimensions ISO/FDIS 8138 : Single rod cylinders, 16 Mpa (160 bar, 2300 psi) compact series-Port dimensions ISO 6547 : Piston seal housings incorporating bearing rings-Dimensions and tolerances ISO 3320 : Cylinder bores and piston rod diameters-Metric series ISO 3222 : Nominal pressures ISO 4393 : Basic series of piston strokes ISO 4395 : Piston rod thread dimensions and types DIN : Deutsches Institut fr Normung, the German standard Afnor : French norm organization NFE : French norm

Hydraulic Cylinders

31

Trouble Shooting Guide


Trouble Shooting Guide for Hydraluic Cylinders If you encounter problems with the operation of Bosch hydraulic cylinders the following information will be helpful in determining a solution. Problems can manifest in several different ways. We isolated the most common problems into six categories. Category 1 : The cylinder does not move. Category 2 : The cylinder moves too slowly. Category 3 : The cylinder moves to fast. Category 4 : The cylinder moves in spurts, or irregularly. Category 5 : The cushioning does not soften the stroke or spring back is noted. Category 6 : The cylinder does not stay on position.

Category 1 : The cylinder does not move.

CAUSE Too little pressure

SOU RCE - misadjustment of the pressure regulator - pressure drop ahead of the installation - excessive consumption ahead or leak - misalignment - friction, capacity - pressure shortage

SOLUTION - adjust - check pump and capacity of the system - disconnect the cylinder from the mechanism and align - increase pressure - increase pressure

Mechanical jamming Resisting force greater than motivating force Excessive leakage of the cylinder

- faulty piston seal (detected through the leakage - disconnect the coupling of the return piping at the valve air bleeds) cylinder/valve - check if there is a leak. if not, check the valve - if there is a leak, disconnect, change the seal, check the state of the cylinder - ball valve closed - throttle valve closed - plug on the valve air bleed - open valve - control adjustment - remove the plug

Too little flow

The valve does not reverse - side gate jammed - free by using manual auxiliary commands - ineffective reversing signal or pressure level to low - consult the schematic and the description of the installation

Category 2 : The cylinder moves too slowly.

CAUSE Too little flow -

SOU RCE throttle valve closed pump is too small valve jammed in intermediate position leaks at the connections clogged filters -

SOLUTION control adjustment re-size pump check valve re-tighten the connections disconnect and replace the filter

Resisting force greater than motivating force Leaks at the valve

- load too large for cylinder - mechanical defect - rod seals: may be bad if there are leaks at the valve air bleeds

- re-size cylinder - disconnect and repair the mechanical parts - leakage may be caused by a defect of the cylinder - disconnect hose or hard pipe, blank off air bleeds 2 and 4 and check for leakage. If there is a leak, disconnect the valve, check the state of the rod (scratches). Change the seals if damaged

32

Hydraulic Cylinders

Trouble Shooting Guide


Trouble Shooting Guide for Hydraluic Cylinders

Category 3 : The cylinder moves to fast.


CAUSE Too much flow Motivating force SOU RCE - throttle valve opening SOLUTION - control adjustment - set or adapt throttle

Category 4 : The cylinder moves in spurts, or irregularly.


CAUSE Mechanical friction Lack of pressure Resisting force slightly different from the motivating force Front guide - see category 1 - see category 1 - see category 1 SOU RCE - see category 1 - see category 1 - see category 1 SOLUTION

- poor guiding

- disconnect, change seal if necessary

Category 5 : The cushioning does not soften the stroke or spring back is noted.
CAUSE Faulty cushioning SOU RCE - faulty setting of the cushioning screw - faulty cushioning seal - deteriorated quick starting valve 100% of stroke is not reached load too large speed too high pressure too high SOLUTION - adjust the cushioning screw - disconnect and change - disconnect and change review installation see catalog technical data see catalog technical data see catalog technical data

Insufficient cushioning capacity

Category 6 : The cylinder does not stay on position


CAUSE Too much leakage of the cylinder Too much leakage of the valve Leakage at the connections - see category 1 - see category 2 - poor tightening of the connections - faulty hose or piping - leaky check valve SOU RCE - see category 1 - see category 2 - re-tighten or change the connections - check valve, clean or change if necessary SOLUTION

Hydraulic Cylinders

33

Appendix

34

Hydraulic Cylinders
To: ATUS/SPM1
3 Batch

BOSCH Automation Technology


1 2 Customer: 4 Branch/ Plant/Application:

Fax No.: 414-554-8103 Request no.:

Technical Specification for Hydraulic Cylinders


size/qty. p. a.: /

Cylinder installation position * Must be filled in


5 Piston/rod 6 Type 7 Total

Front

Rear

/ / E= NAS//=75 C/ / C

21 Port 22 Port

locations size of bleed screws of leakage drain bar bar 0 3 4 NA AH BT 0 3 4 NA AH BT

of fastening/rod end stroke stroke/support ext. E class

23 Location 24 Location 25 Max. 26 Min.

8 Effective 9 Fluid

pressure pressure *

10 Contamination 11 Fluid/ambient 12 Seal:

temp. conditions

27 Cushioning

rod/piston

13 Environmental

14 Protection: 15 Local

rod/bore K= play load *

/ / / Yes / / No Hz

28 Max. 29 Min.

speed speed time time

m/s m/s s s daN lbs. lbs.

m/s m/s s s daN lbs. lbs.

guidance factor per hour/day ampl./frequency standards

16 Lateral/vertical 17 Cycles

30 Stroke

31 Cushioning 32 Force 33 Mass

18 Impacts/shock 19 Vibration:

at rod end

20 Presrcribed 35 Remarks

34 Equivalent

mass at rod end (indirect drive)

(drawing, replacement cylinders, competitors):

36 Alphanumerical 37 Market

cylinder designation: $/unit Desired delivery date: Location: $/unit


41 Suggested

price: party:

Date of request: Tel: Fax: Date of reply: number:

38 Requesting 39 List

price (net): ref. no.:

delivery:
42 Part

40 Basic

* Circle as appropriate

Hydraulic Cylinders

35

Drain Port G1/8 H160CA


MOUNTING MDE5 25 TO 200 ME5 Y (STANDARD)

NOT ISO DIMENSION 63 45 63

8 0.5 C B 19 D G1/8

4 ALL MOUNTIINGS

MOUNTING Y (STANDARD)

ME6MP5MT4 MDT4

40 TO 200 25 32 40 50 63 80 100 125 160 8 200

B
12 11 22 17 12 12 12 12 12 12

B1

C
37 46

D
13 18 10 0 0 0 0 0 0 0

32 33 28 32 34 34 37 37

57 58 60 63 69 69 69 69

B1 C

0.5 19 D

G1/8 MOUNTING

MDS2 40 TO 200 MS2 8

G1/8 19 D

MOUNTING ME6MP5MS2 MT4MDS2MDT4 25 and 32 Y (STANDARD) C2 B2 8 E3 D2 25 32

B2
11 11

C2
26 36

D2
5 5

E3
30 32.5

15 min. G1/8

Y (STANDARD)

B1 C 0.5

36

Hydraulic Cylinders

Rod End Internal Threads


MM C KF SF

WH

AF

25 32 40 50 63 80 100 125 16 0 200

M M 12 18 14 22 18 28 22 36 28 45 36 56 45 70 56 90 70 110 90 140

KF M81 M121.25 M101.25 M161.5 M121.25 M201.5 M161.5 M272 M201.5 M332 M272 M422 M332 M482 M422 M643 M482 M803 M643 M1003

AF 14 18 16 22 18 28 22 36 28 45 36 56 63 63 56 85 63 95 85 112

C 11 17 13 21 17 25 21 33 25 42 33 53 42 67 53 86 67 106 86 136

SF 10 15 11 18 15 22 18 30 22 36 30 46 35 60 46 75 60 92 75 125

Bosch Automation Technology

NORTH AMERICA
Robert Bosch Corporation Automation Technology Division Fluid Power Products 7505 Durand Avenue Racine, Wisconsin 53406 Phone (414) 554-8595 Fax (414) 554-8103 FAXline: (888) 308-3424 www.boschat.com Robert Bosch Corporation Automation Technology Division Factory Automation Products 816 East Third Street Buchanan, MI 49107 Phone (616) 695-0151 Fax (616) 695-5363 FAXline: (888) 308-3424 www.boschat.com Robert Bosch Corporation Automation Technology Division Industrial Electronic Products 40 Darling Drive Avon, CT 06001-4217 Phone (860) 409-7070 Fax (860) 409-7080 FAXline: (888) 308-3424 www.boschat.com

EUROPE
Robert Bosch GmbH Geschftsbereich Automationstechnik Postfach 30 02 07 D-70442 Stuttgart Telefax (0711) 811-7712

For more information, you may contact your nearest Bosch distributor:

Infinite Solutions. Ultimate Performance.

Publication No. 9 535 233 846 8/98