Table of Contents Table of Contents About this operating manual .............. 6 Manufacturer Details................. 6 Copyright .................... 6 Liability and Warranty ................ 7 Conventions of Presentation .............. 8 1.4.1 Text Display.................. 8 1.4.2 Display of Safety and Warning Instructions ......... 9 Definitions ....................
1 | About this operating manual About this operating manual This operating manual describes in detail the use, installation, assembly and maintenance of a actuating cylinder FORTO-H. The efficiency of the actuat- ing cylinder depends primarily on correct use and careful maintenance. This operating manual serves as the leading document and is provided on deliv- ery of the product.
About this operating manual | 1 Liability and Warranty All information and instructions in this operating manual are given in good faith on the basis of our experience and knowledge to date. The products of RÖHM are subject to constant further development. RÖHM therefore re- serves the right to make any modifications and improvements deemed use- ful.
1 | About this operating manual ▪ if the operator or third parties carry out modifications or repairs to the services / products without prior permission of RÖHM. Excepted from this are damage or defects which have occurred and which were demonstrably not due to these modifications or repairs.
About this operating manual | 1 1.4.2 Display of Safety and Warning Instructions Safety and warning instructions are marked by pictograms. The signal word and the colouring show the level of danger. Observe the safety instructions to prevent personal injury and damage to property.
1 | About this operating manual Definitions 1.5.1 Manufacturer of the machine In this operating manual, the manufacturer of the machine is defined as the company which builds the machine into which the actuating cylinder is in- tegrated. 1.5.2 Manufacturer In this operating manual, the manufacturer is defined as the manufacturer of other parts, assemblies or products which are contained in or attached to the actuating cylinder such as rotary feed-throughs, o-rings, operating ma-...
About this operating manual | 1 1.5.5 Dial gage symbol Apply a dial gage or other suitable measuring instrument max. 0,005 mm for measuring of the radial and axial run-out or other test values at the indicated positions. Besides the dial gage symbol, the respective test value is specified.
2 | Safety Safety Intended Use The actuating cylinder may only be used for the following purposes: ▪ To activate rotating chucks, collet chucks, mandrels with a tensioning and loosening function for workpiece clamping in a stationary machine in compliance with all the operating conditions detailed in this operating manual.
Safety | 2 ▪ that any damaged and defective parts are replaced immediately. 2.3.2 Rotation DANGER Danger to life by being caught on or pulled into the rotating actuating cylinder Ø Before operating the actuating cylinder, carry out a risk as- sessment/hazard assessment and implement measures de- rived from this for risk minimisation.
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2 | Safety b) Although there is a new hazard or an increase in an existing risk, the ex- isting protective measures of the machine before the modification are still sufficient so that the machine can still be regarded as safe. c) A new hazard or an increase in an existing risk exists and the existing protective measures are not sufficient or suitable.
Safety | 2 Qualification of Operating and Specialist Personnel Definition of “skilled worker” A person is designated as a skilled worker when they can assess the work assigned to them and identify possible dangers based on their specialist training, knowledge and experience. They also have knowledge of the relev- ant provisions.
2 | Safety General hazards When using the actuating cylinder, residual hazards exist ▪ during assembly and set-up work. ▪ during operation. ▪ during maintenance and service work. These residual hazards cannot be completely eliminated considering the functional availability of the Clamping device. This is why the operating manual must be followed.
Safety | 2 2.6.3 Risk of burns due to hot surfaces Hazard zone Description of the hazard: The actuating cylinder may heat up during operation. There is a risk of burn- ing in case of contact with the actuating cylinder. Avoiding the hazard: Keep away from the actuating cylinder immediately after it was in operation and let it cool down before carrying out any work.
2 | Safety 2.6.4 Danger of crushing due to moving distributor housing 1 Position measuring system op- 3 Control disc tion 2 Piston housing 4 Distributor housing Hazard zone Description of the hazard: When moving the piston, there is a danger of crushing between the fixed piston housing and the moving distributor housing and the position measur- ing system/proximity switch option.
Safety | 2 2.6.5 Risk of ejection, detachment and falling of components at the actuating cylinder Description of the hazard: In case of failure of components of the actuating cylinder or non-compliance with specifications of the actuating cylinder (e.g. incorrect assembly, ex- cessive speed, excessive processing force, incorrect actuating force, insuf- ficient maintenance, wear, exceeding the service life), parts of the actuating cylinder can be ejected.
2 | Safety Miscellaneous 2.7.1 Procedure in the Event of Danger and Accidents In the event of danger and accidents, it must be ensured that first aid meas- ures can be taken immediately. 1. Shut the machine down immediately via the Emergency-Stop button. 2.
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Product description | 3 Functional description: ▪ The actuating cylinder is a double-acting hydraulic cylinder. ▪ The piston has a through hole. Optionally, a rotary feed-through can be installed at the rear end. ▪ By means of the standing distributor housing, pressurised hydraulic oil is fed to the rotating piston housing via the hydraulic connections “A”...
3 | Product description Options The following options are available for the actuating cylinder: 1 Rotary feed-through, single 7 Position measuring system 2 Rotary feed-through, double 8 Draw bar 3 Connection flange 9 Cylinder flange 4 Switch carrier with limit switch 10 Leakage oil fitting rail 5 2x M12 proximity switch (not...
Product description | 3 Technical data 3.3.1 Overview of construction sizes FORTO-H EN 25 / 80...
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3 | Product description Construction size Unit FORTO-H FORTO-H FORTO-H FORTO-H 11.5 11.5 11.5 11.5 Stroke D E h6 6x M8 6x M8 6x M10 6x M12 G3/8 G3/8 G3/8 G3/8 14.6 12.6 J1 h7 K max. K min. M20x1.5 M20x1.5 M1 H8 20.5...
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Product description | 3 Construction size Unit FORTO-H FORTO-H FORTO-H FORTO-H T min. T max. V min. V max. 37.5 37.5 37.5 37.5 Piston area A 28.8 47.1 68.9 106.8 Piston area B 31.4 49.7 103.1 Operating pressure 8 – 80 min.
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3 | Product description Construction size Unit FORTO-H FORTO-H FORTO-H 139.5 144.5 11.5 11.5 11.5 Stroke D E h6 6x M12 6x M12 6x M16 G3/8 G3/8 G1/2 17.5 J1 h7 K max. K min. 127.5 132.5 M42x3 M1 H8 M2 H8 P min.
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Product description | 3 Construction size Unit FORTO-H FORTO-H FORTO-H T min. 187.5 T max. 232.5 V min. 48.5 V max. 98.5 37.5 37.5 Piston area A 160.8 224.6 298.2 Piston area B 157.1 212.2 Operating pressure 8 – 80 min.
3 | Product description 3.3.2 Name plate The name plate can be found on the distributor housing of the actuating cyl- inder, and it contains the following information (as example): NOTICE: The information on the name plate must be adhered to. 3.3.3 Media-carrying connections Connections at the actuating cylinder:...
Product description | 3 Environmental and operating con- Quality requirement(s) ditions Relative humidity (at 40 °C) < 100% NOTE: Use in very humid conditions leads to faster corrosion and may reduce the useful life. Potentially explosive environment No, not permitted Ambient temperature at place of use +5 °C to +60 °C Ambient temperature for storage +15 °C to +70 °C Dry and wet machining...
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3 | Product description ▪ The chuck can be actuated through the actuating cylinder with pressure or tension. ▪ The maximum speed of the actuating cylinder must not be exceeded. ▪ The actuating cylinder must be attached directly to a machine spindle or by means of the cylinder flange option.
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Product description | 3 max. 2 m max. 2 m ◦ must not be immersed in the hydraulic oil inside the hydraulic tank. If ne- cessary, forced ventilation must be applied. ◦ must be resistant against temperature and hydraulic oil NOTICE The leakage oil hose should be transparent;...
3 | Product description 3.3.7 Technical control requirements 3.3.7.1 General technical control requirements ▪ The actuating cylinder can be clamped and released in an idle state or under rotation. ▪ In the event of rotation with clamping of a workpiece, either hydraulic connection “A”...
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Product description | 3 3.3.7.2 Setup mode In the “Setup mode” machine operation type ▪ it may not be possible to machine a workpiece. ▪ rotational and linear movements of axes may not overlap. ▪ linear movements of axes must be limited to maximum 2 m/min. ▪...
4 | Transport Transport WARNING Crushing injuries in the event of unsecured transport of the actuating cylinder. Falling of the actuating cylinder. Ø Use suitable hoisting gear and slings. Ø Wear personal protective equipment. Ø Do not remain under suspended loads. Pre-conditions: ▪...
Transport | 4 1. If necessary, turn the piston housing so that one of the two transport threads is at the top. 2. Fully screw the eyebolt into the transport thread. 3. Attach suitable lifting gear to eyebolt. 4. Lift the actuating cylinder and transport it in a manually-driven manner. The actuating cylinder must not wobble.
5 | Assembly Assembly Pre-conditions: ▪ Personnel qualification: Skilled worker ▪ Wear personal protective equipment ▪ The machine is switched off and protected against being switched on again ▪ Contact and centring surfaces at the machine spindle are cleaned Preparing the machine Procedure: max.
Assembly | 5 max. 0.005 mm 1 Centring surface 2 Machine spindle (example) Check concentricity at the centring surface at the machine spindle. Mounting the actuating cylinder at the machine spindle Pre-conditions: 1 Piston housing 3 Centring surface 2 Contact surface ...
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5 | Assembly Procedure: For assembly instructions for holding screws, see table below 1 Machine spindle (example) 2 actuating cylinder Assembly information for holding screws FORTO-H FORTO-H FORTO-H FORTO-H FORTO-H FORTO-H FORTO-H M8x130 M8x120 M10x125 M12x130 M12x135 M12x145 M16x150 12.9 42.2 Nm 83 Nm 144 Nm...
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Assembly | 5 max. 0.01 mm 1 Machine spindle (example) 2 Check collar 3. Check concentricity at the check collar. max. 0.1 mm 1 Machine spindle (example) 2 Control disc 4. Checking axial run-out on the control disc FORTO-H EN 41 / 80...
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5 | Assembly max. 0.08 mm 1 Flat surface on distributor 2 Piston housing housing 5. Place dial gauge on distributor housing. The standing distributor hous- ing must not wobble during the rotation of the piston housing. 42 / 80 FORTO-H EN...
Assembly | 5 Install protection against torsion (at the leakage oil fitting) 1 Protection against torsion (ex- 3 Distance ample) 2 Leakage oil fitting NOTICE: ▪ The distributor housing must be secured against turning in both rota- tional directions. To this end, protection against torsion must be provided for on the machine.
5 | Assembly Assembling options on the actuating cylinder 5.4.1 Assembling draw bar option NOTICE: To assemble the draw bar option, the actuating cylinder must be assembled in the machine and filled with hydraulic oil and ventilated. 1 Piston 4 Draw bar 2 Piston housing 5 Hexagonal 3 Machine spindle (example)
5 | Assembly 5.4.3 Assembling the position measuring system/proximity switch option Position measuring system attachment M5x12 M5x12 12.9 12.9 10 Nm 10 Nm 1 Sensor holder 3 2x locking washer 2 Position measuring system Proximity switch attachment M5x12 M5x12 12.9 12.9 10 Nm 10 Nm...
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Assembly | 5 1 2x M12 proximity switch 2 4x M12 nut NOTICE: ▪ The clamping path of the actuating cylinder can be monitored either with two proximity switches or a position measuring system. ▪ To attach and adjust the proximity switches or the position measuring system, follow their operating manuals.
5 | Assembly 2. Adjust proximity switches or position measuring system. NOTICE: See the operating manuals of the proximity switches or the position measuring system. NOTICE: See also chapter “Configuring clamping path monitoring”. 5.4.4 Assembling cylinder flange option Pre-conditions: ▪ Contact and centring surfaces at the machine spindle are cleaned ▪...
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Assembly | 5 max. 0.01 mm 1 Machine spindle (example) 2 Check collar on cylinder flange max. 0.01 mm 1 Machine spindle (example) 2 Contact surface on cylinder flange 2. Check axial run-out at the contact surface. 3. Assemble actuating cylinder on the cylinder flange. NOTICE: For the procedure, see chapter “Mounting the actuating cylinder at the machine spindle”.
5 | Assembly 5.4.5 Balancing the actuating cylinder option Pre-conditions: ▪ Personnel qualification: Skilled worker ▪ Wear personal protective equipment ▪ actuating cylinder is assembled in the machine and connected ▪ Hydraulic oil at operating temperature ▪ actuating cylinder at operating temperature ▪...
5 | Assembly 5.4.6 Assembling (simple) rotary feed-through option (FORTO-H 70/85/100) 1 4x M4x12 holding screws 3 Cover flange 2 4x Usit ring 4 Shaft sealing ring Procedure: 1. Move piston into front end position. Pressurise hydraulic connection “A” for this purpose. 2.
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Assembly | 5 M4x12 12.9 5.1 Nm 1 Rotary feed-through, single 3 4x Usit ring 2 Shaft sealing ring 3. Assemble the rotary feed-through instead of the cover flange on the piston rod. NOTICE: The holding screws must be inserted and tightened with the stated tightening torque.
5 | Assembly 5.4.7 Assembling (simple) rotary feed-through option (FORTO-H 125/150/175/200) 5/8-18 UNF 30 Nm 1 Connection flange 2 Screw plug 1. Move piston into front end position. Pressurise hydraulic connection “A” for this purpose. 2. Unscrew the screw plug from the connection flange. NOTICE: Keep the screw plug for later use.
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Assembly | 5 1 Connection flange 3 Rotary feed-through, single 2 O-ring 3. Screw rotary feed-through into the connection flange. NOTICE: The O-ring must be present on the rotary feed-through. NOTICE: For tightening torque, see the operating manual of the manufacturer of the rotary feed-through.
5 | Assembly 5.4.8 Assembling rotary feed-through (double) option (FORTO-H 125/150/175/200) 1 Shaft sealing ring 3 4x Usit ring 2 Connection flange 4 4x M4x12 holding screws 1. Move piston into front end position. Pressurise hydraulic connection “A” for this purpose. 2.
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Assembly | 5 M4x30 12.9 5.1 Nm 1 Shaft sealing ring 3 4x Usit ring 2 Connection flange 3. Fix the connection flange to the piston rod with the holding screws and the Usit rings. NOTICE: Crosswise tighten the holding screws. NOTICE: The holding screws must be inserted and tightened with the stated tightening torque.
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5 | Assembly 1 O-ring 2 O-ring 4. Ensure presence of the O-rings on the rotary feed-through. M6x16 12.9 17.4 Nm 1 Connection flange 2 Rotary feed-through 58 / 80 FORTO-H EN...
Assembly | 5 5. Fix the rotary feed-through to the connection flange with the holding screws. NOTICE: Crosswise tighten the holding screws. NOTICE: The holding screws must be inserted and tightened with the stated tightening torque. 6. Install hoses, protection against torsion, etc. on the rotary feed- through in accordance with the operating instructions of the manufac- turer of the rotary feed-through.
5 | Assembly Procedure: G3/8" 40 Nm FORTO-H 200: G1/2" 40 Nm 1 Sealing plugs 2 Screw plugs 1. Remove the sealing plugs and keep them for later use. 2. If necessary, unscrew screw plugs and screws them back in again on the other side.
Commissioning | 6 Commissioning Fill the actuating cylinder with hydraulic oil and vent out the air Pre-conditions: ▪ Personnel qualification: Skilled worker ▪ Wear personal protective equipment ▪ actuating cylinder is assembled in the machine and connected ▪ Machine in “Setup mode” machine operation type ▪...
Commissioning | 6 Carrying out a functional test Pre-conditions: ▪ Personnel qualification: Skilled worker ▪ Wear personal protective equipment ▪ Machine in “Setup mode” machine operation type ▪ Hydraulic oil at operating temperature ▪ Hydraulic pressure set to 8 bar ▪ The chuck is connected to the actuating cylinder and/or the draw bar option ▪...
6 | Commissioning 5. Make the actuating cylinder rotate with 5 min NOTICE: During the rotation, either hydraulic connection “A” or hydraulic con- nection “B” must be permanently pressurised. 6. Set the machine to “Production mode”. 7. Increase hydraulic pressure to max. 80 bar. 8.
Commissioning | 6 Procedure: WARNING Danger of crushing in the movement range between the piston housing and the distributor housing during configuration of the clamping path monitoring. Ø Do not reach into the movement range of the distributor hous- ing during configuration of the clamping path monitoring. NOTICE: The following approach is recommended by RÖHM.
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6 | Commissioning For assembly instructions for holding screws, see table below 1 Mounting screws, set lower 2 6x holding screws, level with piston housing Assembly information for holding screws FORTO-H FORTO-H FORTO-H FORTO-H FORTO-H FORTO-H FORTO-H M8x130 M8x120 M10x125 M12x130 M12x135 M12x145...
Operation | 7 Operation Production mode DANGER Danger to life by being caught on or pulled into the rotating actuating cylinder. Ø Before operating the actuating cylinder, carry out a risk as- sessment/hazard assessment and implement measures de- rived from this for risk minimisation. Information on operating the actuating cylinder: ▪...
8 | Cleaning Cleaning Information for cleaning: ▪ It is preferable to use rags, cloths, fine brushes or brooms for cleaning. ▪ Alternatively, compressed air can be used for cleaning. In this case, a minimum distance of 30 cm must be maintained, with a maximum pres- sure of 6 bar.
9 | Maintenance Maintenance Maintenance work on the actuat- Interval (hours of operation or ing cylinder after incident) Checking the actuating cylinder for 2500 h or at least 1x per half-year deformations, signs of wear, corro- sion, leaks and loose parts (screws, components, plugs, options) Check the non-return valves (con- 5,000 h or at least 1x per year...
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Maintenance | 9 Procedure: M6x10 9 Nm 1 2x pressure gauge with adapter 3 Venting screw “A” 2 Venting screw “B” WARNING Danger of crushing in the movement range between the piston housing and the distributor housing during the inspection of the non-return valves.
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9 | Maintenance 1. Unscrew venting screw “A” and “B” and screw in a pressure gauge with adapter in each case. NOTICE: Screw pressure gauge with adapter with approx. 5 – 6 Nm tightening torque into the piston housing. 2. Depressurise hydraulic connection “B”. 3.
Storage | 10 Storage Pre-conditions: ▪ Personnel qualification: Trained/instructed person ▪ Wear personal protective equipment ▪ actuating cylinder has been removed from the machine ▪ Hydraulic oil emptied ▪ actuating cylinder is clean Procedure: ▪ Close hydraulic connections and leakage oil connection. ▪...
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12 | Decommissioning and disassembly Procedure: 1. Removing options/attachments. NOTICE: Remove options and attachments according to the operating manual of the manufacturer of the options and attachments. 2. Disconnect the chuck from the actuating cylinder or from the draw bar. 3.
Disposal | 13 Disposal Pre-conditions: ▪ Personnel qualification: Skilled worker ▪ Wear personal protective equipment ▪ actuating cylinder has been removed from the machine ▪ actuating cylinder is clean Procedure: ▪ Dismantle the actuating cylinder into its respective individual parts properly and completely for disposal.
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