Heavy Duty Bolted Cylinders

Transcription

1 Heavy Duty Bolted Cylinders

2 COUNT ON THE HYDRAULICS EXPERT In any hydraulics system, a combination of critical components convert power into productive, efficient motion. If you re looking for superior performance in your hydraulic products, choose components from the company that is known for designing and manufacturing some of the hardest working, most dependable equipment in the world Caterpillar. 2

3 The toughness and durability of every Cat component begins with innovative engineering. Utilizing sophisticated processes such as finite element analysis and a proprietary cylinder design tool, components are designed to meet the challenges of the most demanding applications, and harshest working environments. Caterpillar is the world s largest consumer of mobile hydraulic cylinders. The global manufacturing capabilities of Caterpillar include facilities dedicated to hydraulic cylinder manufacturing. Our manufacturing materials and processes meet or exceed ASTM, DIN, ISO, and SAE standards. We follow the 6 Sigma methodology, which provides an integrated, disciplined and proven approach for delivering exceptional quality, lower costs and enhanced lifecycle value. TABLE OF CONTENTS Overview Cylinder Design Features Selecting a Cylinder Model Code Configurator...8 Cylinder Quote Request Form...8 Custom Cylinder Request Form...9 Standard Cylinder Specifications Mounting Styles & Dimensions Design & Manufacturing...14 Service & Support...15 Contact Information...Back Cover With a reputation for building rugged and reliable equipment, Caterpillar has the manufacturing and technical capabilities, along with the testing and quality processes necessary to produce cylinders to meet your application requirements. Caterpillar can incorporate enhanced technologies such as electro-hydraulics or programmable hydraulic systems. In addition, systems can be designed to include pumps, motors, valves, fans, brakes, steering systems, hydrostatic transmissions, joysticks & much more enabling you to meet your customers unique requirements. 3

4 COUNT ON THE HYDRAULICS EXPERT Caterpillar Heavy Duty Bolted Cylinders are designed to withstand higher forces when compared to the Medium Duty Threaded Cylinder product line. This is accomplished through the use of bolted heads, thicker tube walls and higher-grade materials. This product line also offers cylinders with larger diameters and lengths. Cat cylinders feature an innovative sealing system that utilizes proprietary designs and materials to deliver superior performance. The sealing system is designed to better absorb pressure spikes, increase the ability to withstand side loading, and prevent contaminants from entering and hydraulic fluid from leaving the cylinder. The seal materials provide extended seal life across a wider temperature range, improved wear resistance and compatibility with biodegradable oils. Cat cylinder rods are induction hardened prior to chrome plating. Induction hardening prevents rod bending and chrome plating improves corrosion resistance, which allows the rods to remain rust free in excess of 96 hours during an ASTM method salt spray test. These processes also work in combination to provide increased rod protection from nicks and scratches caused by rocks and debris, which can cause decreased seal life and deterioration of the rod over time. The rods are bonded to the eyes using inertia welding, creating a superior joint for unmatched strength. Inertia welding eliminates the defects associated with arc welding known to weaken the joint. A nut attaches the cylinder piston to the rod, resulting in a higher strength joint. Cat cylinders are designed to be tougher and more robust than competitive brands, through an optimum combination of tube wall thickness and material strength. The material used resists shattering. The inner diameter of the tube is skived and burnished to assure concentricity and straightness and provide a superior finish for better sealing and longer life. The thicker tube walls allow for remanufacturing capability. KEY FEATURES The cylinders can be rehoned, up to three times in some instances, and when combined with Caterpillar's replacement seal kits, can extend the useful life of the cylinder. You can rely on a consistent product because Caterpillar uses standardized manufacturing processes and uniform, quality materials. Each cylinder is tested before it leaves our factory to ensure a quality product. As an original equipment manufacturer (OEM), you know how important it is to find a world class supplier that cares about their product as much as you do about yours. Induction hardening beneath the surface increases the rod s resistance to nicks and dents. Eye Rod Continuous Weld Inertia welding provides a continuous bond for unmatched strength. FUNCTIONAL SPECIFICATIONS Bore Diameters: 90mm to 210mm (3.5 through 8.3 ) Rod Diameters: 50mm to 150mm (2 through 5.9 ) Stroke: Up to 2,716mm (Up to ) Pressure Ratings: Up to 311 bar (Up to 4,500 psi) Media: Hydraulic Oil SAE 10W (Viscosity Requirements of SAE J300 Jun 86 for SAE Viscosity Grade 10W). If other medias are required please specify in the comments section of the Quote Request Form. Temperature: -40 C to 120 C (-40 F to 250 F) 4

5 CYLINDER DESIGN FEATURES Cap Forged or cast Piston Utilizes nuts for higher strength Piston seals are specially designed and mechanically loaded to help eliminate any piston bypass Comes standard with a wear band to assist in side-load protection Teflon or Nylon seals used depending on pressure and life requirements Port Types SAE Flange Rod Assembly Inertia/Friction Welded produces a superior bond for unmatched strength Induction hardened prior to chrome plating increases surface hardness Chrome plating allows the cylinder to exceed 96 hours rust free per the ASTM salt spray test Cylinder Assembly High strength steel tubing improves reliability Skived & burnished Assures ultimate concentricity and straightness Superior finish promotes better sealing and longer seal life Mounting Styles Standard Spherical Clevis Trunnion Rod Seals Cat proprietary sealing system improves performance through better sealing and a longer life Polyurethane U-cup rod seal Rod buffer seal Bonded-to-metal rod wiper seal Other sealing options available Additional Options Added weldments for additional functionality on the machines Cushioning Valve integration, such as counterbalance or load control for improved machine performance Position Sensing Other options available upon request Eye Bar stock or forged 5

6 SELECTING A CYLINDER STEP 1 Are the cylinder bore and rod diameters known? If yes, go to step 4. If no, go to step 2. STEP 2 Determine the bore diameter. Determining the bore diameter is an interactive process depending on your constraints. The following is an example of how the bore diameter is determined. The example assumes that the force required and system pressure are known. The equations can be used differently if you have different constraints or assumptions. Example: Known requirements: If system pressure is 300bar and minimum extension force is 600kN, the bore size can be found using this equation: Bore diameter(mm) = ( Force(kN) x 40,000 ) π x Pressure(bar) = 159.6mm Select the bore size from the charts on p that is equal to or the next size larger than the diameter that was calculated above. Selecting the size equal to or the next size larger than what you need will provide the lowest cost solution that will overcome the extension force. In the example, the next largest bore size is 160mm. To calculate the force for a given bore size and known pressure, use the following equation: π 2 Force(kN) = Pressure(bar) x x (Bore diameter mm) 40,000 If the units are different than above, convert them to metric units using the English to metric conversion equations on page 7, then use the above equations. STEP 3 Determine the rod diameter. Determining the rod diameter is an interactive process depending on your constraints. The following is an example of how a rod diameter is determined. The example assumes that the bore size, retract force required, stroke and system pressure are known. The equations can be used differently if you have different constraints or assumptions. Example: Known requirements: Bore size = 160mm, Minimum retract force = 300kN, Stroke = 1000mm, Pin to Pin Length = 1622mm and the System Pressure = 300bar: Rod diameter(mm) = ( Bore diameter(mm) ) 2 ( Retract force(kn) x 40,000 ) π x Pressure(bar) = 113.4mm In order to meet the retraction force, the rod diameter must be less than or equal to the value calculated above. Review the tables on pages to find the rod diameters available for the selected bore size, in this example 160mm. The available rod sizes for an 160mm bore are: 70, 75, 85, 90 and 110mm. All rod sizes will meet the minimum retraction force required, however, the max stroke, min and max pin to pin length, pressure rating and max full extension length must be checked to ensure it will meet the application requirements. In this example, the max full extension length, which is equal to the stroke plus the pin to pin length, is 2622mm. When all of the parameters are checked against the tables for a bore of 160mm, only a cylinder with a rod of 110mm meets all the criteria, therefore the rod size selected for this example is 110mm. 6

7 STEP 4 Determine if the bore size and rod diameter meet your other requirements. You may have cycle times, flow, and pressure constraints. Use these equations to determine if the selected bore size and rod diameter meets your other requirements. English to metric conversion: x(mm) = 25.4 x (length in inches) x(bar) = 6.9 x 10-2 x (pressure in psi) x(kn) = 4.4 x 10-3 x (force in lbf) x(lpm) = 3.8 x (flow in gpm) mm = millimeters lpm = liters per minute kn = kilonewtons psi = pound force per square inch lbf = pound force gpm = gallons per minute 1. Determine the retraction force: Retract force(kn) = Pressure(bar) x ( ) π x ((Bore diameter (mm)) 2 ( Rod diameter (mm)) 2 ) 40, Determine the extension force: Force(kN) = π x Pressure(bar) x (Bore diameter(mm)) 2 40, Determine the system pressure: Pressure(bar) = ( Force (kn) x 40,000 ) π x ( Bore diameter(mm) ) 2 4. Determine the extension cycle time: Ext cycle time(min) = π x Stroke(mm) x (Bore diameter(mm)) 2 4,000,000 x Cap flow(lpm) 5. Determine the cap end flow: Cap flow(lpm) = π x Stroke (mm) x ( Bore diameter(mm) ) 2 4,000,000 x Ext cycle time(min) 6. Determine the retraction cycle time: Retraction cycle time(min) = π x Stroke (mm) x (( Bore diameter(mm) ) ( Rod diameter(mm) ) ) 4,000,000 x Rod flow(lpm) 7. Determine the rod end flow: Rod flow(lpm) = π x Stroke (mm) x (( Bore diameter(mm) ) 2 - ( Rod diameter(mm) ) 2 4,000,000 x Retraction cycle time(min) ) 7

8 CONFIGURATOR & QUOTE REQUEST FORM STEP 5 Complete the model code configurator below. Formulate the model code configurator below and enter values in the boxes. Cylinder Type example B Bore Rod *Pin to Pin Length Stroke See Standard Cylinder Specifications on pages For combinations not listed, use the Custom Cylinder Quote Request form on page 9. *Pin to pin is the distance between pins at the fully-collapsed state (i.e. zero extension) MOUNTING STYLE Cap End SC ROD END Standard Cap = SC Clevis Cap = CC Spherical Cap = SPC Rod End SE PORT LOCATION Standard Eye = SE Clevis Eye = CE Spherical Eye = SPE See mounting styles (p ). For combinations not listed, use the Custom Cylinder Quote Request form on page 9. Port Style Rod End Cap End F 90 0 F Flange = F 0 Default 0 o (top) = 0 90 o = 90 Other = Use Custom 180 o = 180 Cylinder Quote Request form on 270 o = 270 page STEP 6 Complete a request form. If you are not able to complete the model code due to the number of available options, please complete the Custom Cylinder Quote Request Form on page 9. If you were able to complete the model code, then please complete the Cylinder Quote Request Form below.. CYLINDER QUOTE REQUEST FORM Fax to: OEM Solutions Group U.S.A.: Switzerland: Singapore: OEMSolutions@cat.com Contact (please print): Company: Fax: Phone: MODEL CODE (copy from above) B F 0 Type Bore Rod Pin to Pin Length Stroke Mounting Style Rod End Mounting Style Cap End Rod End Port Style Port Location Rod End Port Location Cap End SYSTEM INFORMATION System pressure (bar): Rod end relief (bar): Cap end relief (bar): Max force in tension (kn): Max compression force (kn): Max side loading (kn): Desired life cycles: Desired life (in service machine hours): QUANTITY & DUE DATE Quantity to Quote: Annual: Date Required: Monthly: One-time: Comments: 8

9 CUSTOM CYLINDER QUOTE REQUEST FORM DIMENSIONAL INFORMATION CUSTOM CYLINDER QUOTE REQUEST FORM Fax to: OEM Solutions Group U.S.A.: Switzerland: Singapore: Contact (please print): Company: Fax: Phone: CLC 0 CW EW 90 PP Cap Port TOD Rod Port ED 270 CP EP 180 RC B HP R RE PLEASE SPECIFY DIMENSIONS IN mm: Pin to Pin Length Bore (B): Rod (R): Pin to pin: Stroke: TOD: CW: CLC: PP: Cap port size: Cap end port location (see diagram above): CP: RC: Rod port size: Rod end port location (see diagram above): EP: EW: RE: ED: Select a rod & cap end type from pages or send an illustration showing your requirements: Rod end: Cap end: Cyl. pressure rating (bar): System pressure (bar): Rod end relief (bar): Cap end relief (bar): Max compression force (kn): Max tension force (kn): Max side loading (kn): Desired life in cycles: Desired life in machine service hours: QUANTITY & DUE DATE Quantity to Quote: Annual: Date Required: Monthly: One-time: Comments: STEP 7 Submit the form. After you have completed the appropriate request form, fax or the form to one of the contacts listed on the back of the catalog. You will receive price and availability once your request is processed. 9

10 STANDARD CYLINDER SPECIFICATIONS PP Cap Port TOD Rod Port ED CP EP RC B Pin to Pin Length = Stroke + DL HP R RE Bore (B) Rod (R) TOD PP HP ED DL Max Pin to Pin Length Max Stroke Max Extension Length Pressure Rating Bar (psi) Rod End Port Size (3900) 12.7 flange (3150) 12.7 flange (3100) 12.7 flange (3350) 12.7 flange (3650) 12.7 flange (3450) 19 flange (4250) 19 flange (4500) 19 flange (4500) 19 flange (4500) 19 flange (2800) 19 flange (4500) 19 flange (3550) 19 flange (4500) 19 flange (4500) 19 flange (4500) 19 flange (3900) 19 flange (4000) 19 flange (4100) 25.4 flange (4400) 19 flange (4500) 19 flange (4500) 19 flange (3300) 25.4 flange (3200) 25.4 flange (3300) 25.4 flange (3450) 25.4 flange (3600) 25.4 flange (3850) 25.4 flange (2900) 25.4 flange (3000) 25.4 flange (3050) 25.4 flange (4500) 25.4 flange (4500) 25.4 flange (4500) 25.4 flange (4500) 25.4 flange (4500) 25.4 flange (4500) 25.4 flange (4500) 25.4 flange (4500) 25.4 flange 10 All dimensions are in mm unless otherwise stated.

11 PP Cap Port TOD Rod Port ED CP EP RC B Pin to Pin Length = Stroke + DL HP R RE Bore (B) Rod (R) TOD PP HP ED DL Max Pin to Pin Length Max Stroke Max Extension Length Pressure Rating Bar (psi) Rod End Port Size (2350) 25.4 flange (2400) 25.4 flange (4350) 25.4 flange (4500) 25.4 flange (4500) 32 flange (2300) 32 flange (3850) 32 flange (4500) 32 flange (4500) 32 flange (4500) 32 flangeº (4500) 32 flange (4500) 32 flange (4500) 32 flange (3400) 32 flange (3400) 32 flange (4500) 32 flange (4500) 32 flange (4500) 32 flange (4500) 32 flange (4500) 32 flange (4500) 32 flange (4150) 32 flange (4050) 32 flange (4500) 32 flange (4500) 32 flange (2800) 38 flange (3650) 38 flange (2650) 38 flange (3400) 38 flange (3550) 38 flange (4100) 38 flange (4500) 38 flange (2550) 32 flange (3200) 32 flange (4500) 32 flange All dimensions are in mm unless otherwise stated. 11

12 MOUNTING STYLES AND DIMENSIONS ROD END Standard Eye Dimensions EP RE EW Bore Rod EP EW RE , , , , , , 85, 90, , 70, 75, 85, 90, , 70, 75, 85, 90, 95, 100, 105, 115, 120, , 75, 85, 90, , 70, 75, 85, 90, 100, 110, 115, , 75, 85, 90, 100, 110, 120, 130, , 130, 140, , 90, 95, 110, 115, 130, , 90, Spherical Eye Dimensions EP EW RE Bore Rod EP Change in DL From Std , 70, , 90, EW RE Clevis Eye Dimensions YK YL YM Y1 EP Bore Rod YK YL YM Y1 EP Change in DL From Std , , 80, , 90, ,

13 CAP END Standard Cap Dimensions CP PORT SIZE RC CLC CW Bore Rod CP RC CW CLC Port Size PORT THD PORT THD , 60, PORT THD PORT THD , 60, 75, PORT THD , PORT THD , 75, 80, PORT THD , 70, 75, 85, 90, PORT THD , 70, 75, 85, 90, FLANGE , 70, 75, 85, 90, 95, 100, 105, 115, 120, FLANGE , 75, 85, 90, FLANGE , 70, 75, 85, 90, 95, 100, 110, 115, FLANGE , 75, 85, 90, 100, 110, 120, 130, FLANGE , 130, 140, FLANGE , 90, 95, 110, 115, 130, FLANGE , 90, FLANGE Spherical Cap Dimensions CW RC CP PORT SIZE CLC Bore Rod CP PORT THD , 60, PORT THD , 70, 75, 85, 90, FLANGE 16 RC CW CLC Port Size Change in DL From Std. Clevis Cap Dimensions CC CP CH CL CE CG Bore CH CL CG CP CE CC Port Size Change in DL From Std PORT THD PORT THD PORT THD PORT THD PORT THD FLANGE 32 PORT SIZE Trunnion Mounting If you are interested in a Trunnion Mounted Cylinder, please fill out the Custom Cylinder Request Form and indicate Trunnion Mounting for Cap Type. A sales engineer will then contact you for further information. 13

14 BUILT TO PERFORM Caterpillar state-of-the-art design and manufacturing capabilities are enhanced through the use of the highest quality materials, a variety of heat-treatment processes and high-performance surface treatments. You can rely on Cat Heavy Duty Bolted Cylinders to deliver superior performance and provide increased lifecycle value while meeting your application requirements. 14

15 GLOBAL SERVICE AND SUPPORT Caterpillar and our dealers / distributors literally reach the four corners of the Earth offering unmatched global coverage to meet unique local needs. With nearly 200 Cat dealers (consisting of approximately 1,700 branch locations) and another 1,400 Cat Rental outlets, Caterpillar offers a distribution network unparalleled in today s business climate. LEGAL NOTICE The information in this publication, including text, images, and links, is PROVIDED AS IS BY CATERPILLAR INC. SOLELY AS A CONVENIENCE TO ITS DEALERS AND CUSTOMERS WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESSED OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR NON-INFRINGEMENT. Caterpillar Inc. assumes no responsibility for errors or omissions in this publication or other documents which are referenced by or linked to this publication. This publication could include technical or other inaccuracies, and not all products or services referenced herein are available in all areas. Changes are periodically added to the information, and Caterpillar may change the products or services described in this publication at any time. Contact your local Caterpillar dealer for further information before relying on any information contained herein. 15

16 Contact Caterpillar Add the power of fluid motion to your machines and your business with innovative hydraulic solutions from Caterpillar. For more information, please contact us at or OEM Solutions Group 100 N.E. Adams Street Peoria, IL U.S.A Phone: Fax: AIG Aoyama Building 8F Minami Aoyama, Minato-kui Tokyo, Japan Tel: Fax: P.O. Box Geneva 6, Switzerland Phone: Fax: Telex: Caterpillar Drive Private Mail Bag 4 Tullamarine Victoria 3043 Australia Tel: Fax: Tractor Road, Jurong Town Singapore Tel: Fax: Room 1701 China Life Tower No. 16 Chaoyangmenwai Avenue Chaoyang District, Beijing Tel: Fax: Caterpillar All Rights Reserved WEDQ1001 CAT, CATERPILLAR, their respective logos and "Caterpillar Yellow," as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. Materials and specifications are subject to change without notice.