INSTALLATION AND SERVICE INSTRUCTIONS

FOR ROTATING CYLINDER MODELS

HRC, ARC, UR2M AND URPC

WWW.FORKARDT.US
 Main Office
2155 Traversefield Drive
Traverse City, Mi. 49686
E-mail: sales@forkardt.us
800-544-3823 Toll Free
231-995-8300 Phone
231-995-8361 Fax

IL, IA, NE, WI, MN, ND, SD Michigan and all other states not listed China
Chris Brown Forkardt Kevin Dong
Office: 231-995-8327 Direct: 231-995-8300 1F, Bldg 2#, 458 Fute Rd. (N.),
Mobile: 231-557-5295 Fax: 231-995-8361 Shanghai Waigaoqiao F.T.Z.
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Office: 86-021-58682809-110
IN, TN, KY, OH, WV Ontario, Canada Mobile: 86-15000302788
Jim Farrell Brian Braden kdong@forkardt.us
Office: 231-995-8334 Office: 231-995-8337
Mobile: 248-765-9456 Mobile: 248-361-9616 Brazil
jfarrell@forkardt.us bbraden@forkardt.us Andre Silva
Kare Tools
KS, MO, AR, TX, LA, OK, NM, AZ, CA For Quebec, Canada R-Capitao Rabello, 113 Guarulhos
Jeremy Michael Bob Holtz Brazil, 070630
Office: 231-995-8338 Mobile: 860-481-1948 Office: 55-11-2937-9646
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For Mexico
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Mexico 78394
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Bob Holtz Fax: 52 1 444-824-9955
Mobile: 860-481-1948
bholtz@forkardt.us
INSTALLATION INSTALLATION AND APPLICATION NOTES FOR
1. Check the spindle mounting face/pilot diameter. Run-out should be <
0.0005” TIR HYDRAULIC CYLINDERS
2. Mount the cylinder to the flange/pilot. Indicate cylinder to 1” or less MOUNTING DATA– Do not lift the cylinder by the air inlet housing or
from mounting face. Should be < 0.001” put extraneous side loads on it.
3. While holding inlet assembly, check the run-out of inlet and trip rod
(if applicable). Both should be <0.002” TIR Supply air to the cylinder through curved flexible hoses to eliminate
DO NOT LIFT CYLINDER BY INLET ASSEMBLY AS IT MAY fore-shortening or vibrational loads resulting from straight runs of flexi-
CAUSE DAMAGE. USE A SLING AROUND CYLINDER BODY. ble hose or solid piping. When properly installed, there should be a few
degrees of radial freedom between the inlet housing and the rotating
DISASSEMBLY cylinder while the cylinder is stationary. Be sure to connect the drain
Special tools needed: 1/4-20x6.0” screw or threaded rod & 3/8 dia X 12” back directly to tank and do not common with other drain lines in which
lg rod with #8-32 tapped hole. back pressure may exist.
1. Remove (4) pipe plugs from rear cover
SEALS– Specially compounded O-ring seals are used. When replace-
A) CAUTION THERE MAY BE RESIDUAL PRESSURE
ment seals are necessary, order from the factory to assure proper com-
BEHIND THE PLUGS– REMOVE WITH CARE
pouds and size. Seals operate best at temperatures below 150°F. If
2. Remove rear bolts #92
cylinders must operate at temperatures above 175°F, contact our engi-
3. Using (2) cover bolts and the provided jackscrew holes, remove the
neering department giving full data.
rear cover.
4. Remove guide pins FLUIDS– We recommend the use of a good grade of hydraulic oil of
5. Remove nicks/burrs on piston rod & push on it to remove from approximately 200 SSU viscosity. The oil should be properly filtered to
housing. NOTE: If more force is required a soft face hammer or remove foreign particles. For use with fluids other than hydraulic oil,
block of wood may be used to avoid damaging the piston rod. please contact our engineering department. Oil filter should be cleaned
6. Remove (4) screws #87 then the inlet assembly from rear cover every 2 to 3 months and the hydraulic oil should be checked at least
7. Remove trapping assembly hex plug #95 and valve spacer #134. Use every 6 months and replaced when deteriorated.
1/4-20X6” screw to pull valve #97. Use tapped rod threads to pull
OPERATIONAL CAUTIONS– If the machine is operating under maxi-
#99. Remove rod bushing #13
mum hydraulic pressure and maximum speed, disassemble and check
8. Remove seals, back-up & wear rings from all details.
parts and replace the oil seal yearly.
9. Front & rear inlet covers
A) Inlet housing/bearing/shaft is a precision assembly. Check the disconnect power of the check valve by gripping a workpiece,
Disassembly NOT RECOMMENDED turning off the power, and then check to see if the workpiece is still
B) Inlet assembly is working as long as it rotates being gripped. If the part has dropped or loosened, the check valve has
smoothly. failed and needs to be serviced.
C) Only remove covers if leaking or rear only if 3rd
Port or Trip Rod
HYDRAULIC PRESSURE PSI
MODEL BORE 100 250 500 750 1000
ADDITIONAL DISASSEMBLY FOR TRIP ROD & THIRD PORT SIZE
CYLINDERS
1. Remove rear cover #51. URPC/HRC030 3” 565 1500 3000 4505 6010
2. Remove Key #’s 22, 65, 64 & 63, snap ring, seal retainer, back-up ring
and trip rod seal. URPC/HRC045 4.5” 1280 3420 7000 10500 14100
3. Inspect cover seal #23R for wear. Remove and replace if necessary.
RE-ASSEMBLY FOR TRIP ROD & THIRD PORT CYLINDERS URPC/HRC060 6” 2270 6060 12400 18700 25000
1. Replace trip rod scraper
URPC/HRC080 8” 4180 11100 22700 34400 46000
2. Install new trip rod seal and seal retainer then reinstall rear cover.
RE-ASSEMBLY
1. Install rod seal & scraper #12X and #13X with bushing #13 & #34
2. Install guide pin seals #25, piston seal & backers #9, wear strop #9A (if
applicable). PNEUMATIC PRESSURE PSI
3. Install thru-hole guide pin in piston with cross-hole at the rod end.
MODEL BORE 50 60 70 80 90 100
4. With cylinder housing on blocks, align guide pin holes & push piston
into housing.
SIZE
A) Use rubber mallet to drive the piston UR2M/ARC045 4.5” 745 890 1040 1190 1340 1490
B) Use blunt tools to insure seals & back-up seat properly
5. Blind guide pin into piston cross-hole up, make sure it is in the hole in UR2M/ARC060 6” 1040 1300 1560 1820 2080 2340
the housing.
6. Re-install inlet assembly rear cover UR2M/ARC080 8” 1920 2400 2880 3360 3840 4320
7. Re-install trapping assembly Key #’s 99, 81, 97, 97A, 134 & 95.
A) Use extreme care as O-rings may get sliced on cross-porting UR2M/ARC100 10” 3000 3750 4500 5250 6000 6750
B) Re-install pipe plugs with Teflon pipe sealant
UR2M/ARC120 12” 4400 5500 6600 7700 8800 9900
8. Re-install rear cover/inlet assembly.
A) Guide pin hole with O-ring and match with the thru hole guide pin.
(NOTE ORIENTATION OF GUIDE PINS)
 Third Port Model

Coolant Tube/ Hollow

Tail Rod Model

Solid Tail Rod Model

KEY DETAIL

017 Inlet Shaft 065 Seal Cover

17P Inlet Shaft– Third Port Model 076 O-Ring
018 Inlet Housing 077 O-Ring
019 Mounting Plate/Inlet Front Cover 77A Cover Seal
020 Bearing (Front) 086 Trip Rod/Coolant Tube
021 Snap Ring S86 Solid Trip Rod
022 Snap Ring 088 Snap Ring
23F CR or Varilip Seal 089 SHCS (Shaft to Cylinder Cover
23R CR or Varilip Seal 090 Dowel Pin
026 Cover/Shaft Seals (O-Rings) 094 Wiper Seal for Trip Rod
051 Housing Cover/Inlet Rear Cover 096 Snap Ring
052 SHCS (Rear Inlet Cover) 103 Collar– R.H. Thread
061 SHCS (Front Inlet Cover) 104 O-Ring
062 SHCS (Rear Inlet Cover) 105 Set Screw
063 Trip Rod /Plug Seal 108 Slide (Prox Sensor Holder)
064 Back-Up Ring 111 SHCS (Plate to Post)
 Standard Model–
No Trip Rod

KEY DETAIL

001 Cylinder Housing or Tube

R03 Piston (R.H. Thread)
009 Piston Packing O-Ring/T-Seal
09A Piston Ring(s)
12X Poly-Pak (Rod Packing
013 Rod Bushing
13X Wiper for Rod Bushing
014 Cover Seal (Gasket/O-Ring)
015 Rear Cover
15A Plug for Rear Cover
17B Inlet Shaft Tube w/o Bushing
018 Inlet Housing
Rear Cover 019 Mounting Plate/Inlet Front Cover
Cross-Section
020 Bearing (Front)
021 Snap Ring
022 Snap Ring
23F CR or Varilip Seal
KEY DETAIL 025 Guide Pin Seal
026 Cover/Shaft Seals (O-Rings)
081 O-Ring
034 Packing Retainer (Snap Ring)
095 Hex Plug
A35 Guide Pin– Non Thru
097 Check Valve
B35 Guide Pin– Thru
97A O-Ring for Check Valve
052 SHCS (Rear Inlet Cover)
099 Valve Actuator
061 SHCS (Front Inlet Cover)
134 Valve Spacer 063 Trip Rod/Plug Seal
65P Inlet Seal Plug
076 O-Ring
77A Cover Seal
089 SHCS (Shaft To Cylinder Cover)
92A SHCS (Rear Cover)
136 Piston Plug
 TROUBLESHOOTING WARRANTY AND SERVICE
- Rotating cylinders should be checked for abnormal leakage once per week. If
Forkardt warrants cylinder assemblies for a period of
there is an excessive leak, the cylinder may not deliver the rated draw bar force.
one (1) year from the date of shipment against defects in
INSUFFICIENT JAW PRESSURE
workmanship and material. Should service be required
A) Undersize cylinder or pressure too low.
after this period, our charges are based on our standard per
B) Improper cylinder assembly. If cylinder inlet or valves have been
diem rate plus expenses. This warranty does not cover
repaired recently, be certain that all parts, particularly gaskets, have been
abuse, normal wear or flex breakage. There is no other
properly installed.
warranty of any kind expressed or implied, with regard to
SLOW MOVING JAWS
such cylinder products, whether as to merchantability, fit-
A) Oversized cylinder or pressure too low
ness for a particular purpose, or any other matter.
B) Restricted air flow. Check size of air line. Make certain that all valves
and pressure regulator are properly sized and installed. Older piping Our service department can rebuild and warrant used
and hoses could have reduced flow area. cylinders to like new condition for less than the cost of new.
C) Improper cylinder assembly. If cylinder inlet or valves have been Ask our customer service staff for more information about
repaired recently, be certain that all parts, particularly gaskets, have our “in house” assessment and repair program.
been properly installed.
LOSS OF GRIP FORCE AT HIGH SPEEDS
A) Undersized cylinder or pressure too low.
B) Improper cylinder assembly. If cylinder inlet or valves have been
repaired recently, be certain that all parts, particularly gaskets, have
been properly installed.
C) The pressure of the return pipe is too high or the amount of leakage
is higher than standard.
D) Oil suction filter is blocked. Clean the filter and tank and replace the
hydraulic oil.
CYLINDER PISTON MOVES TOO SLOWLY
A) Restricted air flow. Check size of air line. Make certain that all
Valves and pressure regulator are properly sized and installed. Older
piping and hoses could have reduced flow area.
B) Improper cylinder assembly. If cylinder inlet or valves have been
repaired recently, be certain that all parts, particularly gaskets, have
been properly installed.
CYLINDER IS RUNNING TOO HOT
A) The viscosity of the hydraulic oil is not correct.
B) Insufficient amount of hydraulic oil in the tank. Available Options

C) Hydraulic oil is deteriorated. Clean tank and replace oil.

D) Hydraulic pressure is too high. Correct to standard value
E) An oil-cooler may be required.

FOR FURTHER ASSISTANCE CALL 800-544-3823 OR

EMAIL SALES @FORKARDT.US
PLEASE HAVE CYLINDER MODEL AND SERIAL NUMBER
READY FOR PROMPT SERVICE.

Forkardt supplies the complete chuck and actuation package to fit your CNC lathe or turning center. Our engineers will design and specify the power
chuck, drawbar, and adapters needed to integrate with your machine spindle and processing requirements.
NOTES:

All rights to this operating manual remain property of Forkardt

This manual is intended for fitting, operating and maintenance personnel. It con-
tains regulations and drawings of a technical nature which may be neither wholly
nor partially reproduced or distributed to other parties or used for competitive aims
without prior written authorization from Forkardt. Furthermore, Forkardt accepts no
liability for inaccuracy or incompleteness of this manual which is believed to be
complete and comprehensive upon going to press. If in doubt, contact should be
made with Forkardt immediately
Forkardt
2155 Traversefield Dr
Traverse City, MI 49686
231-995-8300
WWW.FORKARDT.US
Made in USA
© 2012 COPYRIGHT FORKARDT INC.
Forkardt North America
2155 Traversefield Dr.
Traverse City, MI 49686
Office: 800-544-3823
Fax: 231-995-8361
Email: sales@forkardt.us
Forkardt China
1F, Bldg 2#, 458 Fute Rd. (N.),
Shanghai Waigaoqiao F.T.S. 200131 PRC
Office: 86-021-58682809-110
Cell: 86-150003027888
Email: kdong@forkardt.us
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D-40699 Erkrath
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