Assembly
Hydraulic Cylinders and Pressure Intensifiers
Before Assembly:
- Inspect the delivery for completeness and damage.
The scope of delivery includes the Hänchen product as ordered by the customer according to the order specifications and confirmed in the order confirmation.
- Remove any sealing plugs or cover plates attached for protection against contamination during transport before assembly.
| DANGER! | Risk of fatal injury due to improper assembly!
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| DANGER! | Danger to life due to high pressure!
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| CAUTION! | Risk of injury due to sharp edges and corners!
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| NOTE | Damage to the piston rod guide, the piston rod, and in the cylinder tube! During assembly and operation:
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| NOTE | Property damage due to insufficient venting!
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For cylinders with rigid mounting, such as side lugs mounting:
- Install cylinders free of stress.
For long cylinders:
- Observe thermal and expansion joints at the mounting elements.
For cylinders with movable mounting:
- Ensure that sufficient space is available between the spherical rod eye and clevis, clevis bracket or similar for pivoting and tilting.
When counter-holding the piston rod:
- Avoid damage to the rod surface.
- Preferably use hook wrenches according to DIN 1810 with a round pin or open-end wrenches.
The pressure ports are, unless otherwise specified in engineering drawings, designed for commercially available screw connections according to DIN 3852 – Part 2, Forms A and B.
Hänchen recommends the use of screw-in studs with soft seals.
- For mounting the cylinder and its accessories, use cylinder head screws with a minimum strength of 10.9.
- Observe tightening torques according to VDI 2230 for a friction coefficient µ = 0.14.
| Thread size | Tightening torque MA | Thread size | Tightening torque MA | |
| M5 | 9.5 Nm | M12 | 137 Nm | |
| M6 | 16.5 Nm | M16 | 338 Nm | |
| M8 | 40 Nm | M20 | 661 Nm | |
| M10 | 79 Nm | M24 | 1136 Nm |
Tightening torque according to VDI 2230 with minimum strength 10.9
- Observe tightening torques for screw connections and banjo bolts.
| Thread size | Screw connection with external thread |
Swivel screw connection and banjo bolts |
| G ⅛ | 18 | 18 |
| G ¼ | 35 | 45 |
| G ⅜ | 70 | 70 |
| G ½ | 90 | 120 |
| G ¾ | 180 | 230 |
| G 1 | 310 | 320 |
| G 1¼ | 450 | 540 |
| G 1½ | 540 | 700 |
Tightening torques for screw connections and banjo bolts
Venting
Hydraulic cylinders and pressure intensifiers are typically supplied with venting screws on both sides. The vent bores are suitable for measuring coupling ports.
Easy and clean venting via hoses is possible using a measuring coupling.
Identification of Venting ports on the product
- Vent hydraulic cylinders or pressure intensifiers before start-up.
Venting and measuring ports for cylinder sealing systems Servocop® or Servoseal®
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Venting and measuring ports for cylinder sealing system Servofloat®
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* For series 320, functional oil collection port
Venting and measuring ports cylinder sealing system Servobear®
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Venting port tightening torques
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Venting without Hänchen venting set
Free air in the hydraulic cylinder affects the physical properties of the hydraulic oil and has further detrimental effects on the components, operational behavior, and the fluid.
Perform venting without the Hänchen venting set as follows:
- Ensure that the venting screws are located at the highest point of the cylinder.
- Ensure that the relevant cylinder chamber is under low pressure (approx. 20 bar to 50 bar).
- Open the venting screw by approximately one to two turns.
| DANGER! | Danger to life due to pressurised fluid!
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The venting screw is designed such that air and oil can escape without completely removing it.
When bubble-free oil emerges from the gap:
- Tighten the screw again.
- Observe the tightening torque.
If there is still air in the cylinder:
- Repeat the venting process until there is no more air in the cylinder.
After complete venting:
- Slowly extend and retract the cylinder three to five times at no-load and low pressure.
Venting with Hänchen Venting Set
With the Hänchen venting set, a hydraulic cylinder can be vented cleanly and conveniently without additional tools.
Perform venting with the Hänchen venting set as follows:
- Screw measuring couplings into the venting ports.
- Ensure that the venting screws are located at the highest point of the cylinder.
- Ensure that the relevant cylinder chamber is under low pressure (approx. 20 bar to 50 bar).
- Screw the venting set onto the measuring coupling.
When bubble-free oil flows into the bottle of the venting set:
- Remove the venting set from the measuring coupling.
If there is still air in the cylinder:
- Repeat the venting process until there is no more air in the cylinder.
After complete venting:
- Slowly extend and retract the cylinder three to five times at no-load and low pressure.
The venting set is available as tools.
Flushing the lines
- Position flushing plates for the flushing process as close as possible to consumers (e.g., hydraulic cylinders, valves).
- Connect P and T lines.
- Ensure that consumers are not filled during the flushing process.
The duration of the flushing process depends on the size of the system (duration: one hour to several days).
Mount accessories
For piston rods up to 25 mm diameter (with internal thread), the screwed-in mounting components such as rod eye plains, rod balls, rod clevises, etc., are secured with adhesive.
For piston rods from 30 mm diameter, the screwed-in mounting components are secured with a radial threaded pin.
| NOTE | Damage to the seal due to heat!
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For disassembling a mounting component secured with adhesive:
- Heat the piston rod in the area of the screw-in depth to approx. 150 °C to loosen the adhesive.
When attaching a mounting component:
- Secure the mounting component with a suitable thread-locking adhesive.
| NOTE | Damage to spherical plain bearing or bearing bush due to incorrect assembly!
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Cushioning
Adjust cushioning
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Versions of cushioning adjusting screw
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Adjust hydraulic cylinder or pressure intensifier with adjustable cushioning as follows:
To increase cushioning effect:
- Turn the adjusting screw to the right.
- Secure the adjusting screw with the lock nut.
To reduce cushioning effect:
- Turn the adjusting screw to the left.
- Secure the adjusting screw with the lock nut.
Precise adjustment of the cushioning is only possible during operation.
| DANGER! | Danger to life due to pressurised fluid!
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Check maximum unscrewing as follows:
- Turn the adjusting screw in until it stops.
- When the hydraulic cylinder enters the cushioning range: Loosen the adjusting screw by one turn at a time until the cushioning effect decreases.
- If the hydraulic cylinder reaches its end position without cushioning, turn the adjusting screw a maximum of 2 to 3 turns further.
Proximity switch
| NOTE | Damage due to improper use of the proximity switch!
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| NOTE | Damage to the Hänchen product due to unsuitable proximity switches!
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Mount the proximity switch as follows:
- Lubricate the o-ring and back-up ring (e.g., with operating fluid).
- Screw the proximity switch into the designated screw-in thread on the Hänchen product.
- Unless otherwise specified, screw in the proximity switch until it reaches the mechanical stop, then turn it back by ¼ turn.
- Tighten the lock nut of the proximity switch with a maximum of 15 Nm, unless otherwise specified by the manufacturer.
By changing the screw-in depth of the proximity switch, it is possible to adjust the switching point.