Publication Part No. SK9800-100

CAUTIONThis manual contains important information for the correct installation, operation and maintenance of the

equipment described herein. All persons involved in such installation, operation, and maintenance should bethoroughly familiar with the contents. To safeguard against the possibility of personal injury or propertydamage, follow the recommendations and instructions of this manual and keep it for further reference.

WARNINGImproper use can result in personal injury. To avoid injury:• Do not use actuators to lift, support, or transport people or

loads over people without written approval from Duff-Norton.• Read all product warnings and operating instructions.

2

ContentsSection I General Introduction ................................................................................................... 3

1-1. General ............................................................................................................... 31-2. Applications ........................................................................................................ 31-3. Specifications ..................................................................................................... 31-4. Important Precautions ........................................................................................ 31-5. Warranty and Warranty Repair ........................................................................... 3

Section II Installation .................................................................................................................. 42-1. Inspection ........................................................................................................... 42-2. Clevis Pins .......................................................................................................... 42-3. Orientation .......................................................................................................... 42-4. Vent plugs ........................................................................................................... 42-5. Wiring.................................................................................................................. 42-6. Limit Switch Adjustment ..................................................................................... 4

Section III Lubrication .................................................................................................................. 53-1. Lubrication .......................................................................................................... 53-2. Motor Reducer Lubrication ................................................................................. 53-3. Motor and Reducer Bearings.............................................................................. 53-4. Clevis Pins .......................................................................................................... 5

Section IV Maintenance ............................................................................................................... 64-1. Disassembly (Refer to Figure 5-1) ...................................................................... 64-2. Screw & Tube Disassembly ................................................................................ 64-3. Gear Removal ..................................................................................................... 64-4. Screw and Nut Inspection ................................................................................... 6Table 1 ........................................................................................................................ 64-5. Lifting Nut Removal ............................................................................................ 6Table 2 ........................................................................................................................ 74-6. Cleaning ............................................................................................................. 74-7. Inspection (Refer to Figure 5-1) .......................................................................... 74-8. Assembly (Refer to Figure 5-1) ........................................................................... 7

Section V Illustrated Parts List .................................................................................................... 85-1. General ............................................................................................................... 8Figure 5-1. Exploded Illustration for Duff-NortonSuperCylinder Series.................................................................................................. 9Figure 5-2. Exploded Illustration of Duff-NortonSuperCylinder Parallel Configuation ......................................................................... 10Figure 5-3. Exploded Illustration of Duff-NortonSuperCylinder Right Angle Configuration ................................................................. 11

3

Section IGeneral Introduction

1-1. GeneralThis manual contains installation and maintenance in-structions for Duff-Norton SuperCylinders. It may besupplemented by individual instructions for the motor,brake, or gear reducer used as part of the SuperCylinder.To ensure satisfactory service, read and understand theinformation in this and any accompanyng literature.

1-2. Applications1. Industrial Use Only The linear actuators de-

scribed and illustrated in this manual are intendedfor industrial use only and should not be used tolift, support or otherwise transport people unlessyou have a written statement from Duff-Nortonwhich authorizes the specific actuator unit, as usedin your application, as suitable for moving people.

2. Do not use actuators with standard motors in ar-eas containing flammable vapors, liquids, gasesor combustible dusts or fibers. Refer to Article500 of The National Electric Code. Do not use inhighly corrosive or wet environments. Do not usein applications involving extended exposure to tem-peratures below -20°F or above 140°F.

3. The actuator rod clevis must be restrained fromrotating. The amount of restraining torque is afunction of screw geometry and load. Consult Duff-Norton for expected values.

1-3. SpecificationsTable 1-1 gives lifting capacity, speed, and horsepowerfor standard models of SuperCylinders. Other configu-rations are possible and will be labeled with ratedcapacity and electrical data.

If you need additional help, please contact Duff-Nortonat (800) 477-5002.

1-4. Important PrecautionsIn order to ensure that Duff-Norton acutators providegood service over a period of years the following pre-cautions should be taken:

1. SuperCylinders are normally supplied without con-trols. The installer must provide adequate electricalcontrols that provide motor thermal protection andincorporate limit switches to ensure that the ac-tuator is not jammed against internal or externalstops.

2. SuperCylinders do not incorporate any protectionagainst mechanical overloading, either externallyapplied or through internal jamming. In applica-tions where overloading is a possibility, appropriateelectronic or mechanical devices should be incor-porated to prevent operation of the actuator ifoverloaded.

3. Do not install an electric motor on a SuperCylinderwith horsepower rating greater than that shown inTable 1.

1-5. Warranty and Warranty RepairSubject to the conditions stated herein, Duff-Norton willrepair or replace, without charge, any parts proven to Duff-Norton’s satisfaction to have been defective in material orworkmanship. Claims must be made within one year af-ter date of shipment. Duff-Norton will not repair or replaceany parts that become inoperative because of impropermaintenance, eccentric loading, overloading, chemical orabrasive action, excessive wear, or other abuse.

Equipment and accessories not of Duff-Norton's manu-facture are warranted only to the extent that they arewarranted by the manufacturer, and only if the claimeddefect arose during normal use, applications and service.Equipment which has been altered or modified by anyonewithout Duff-Norton's authorization is not warranted byDuff-Norton. EXCEPT AS STATED HEREIN, DUFF-NORTON MAKES NO OTHER WARRANTIES, EXPRESSOR IMPLIED, INCLUDING WARRANTIES OF MER-CHANTABILITY AND FITNESS FOR A PARTICULARPURPOSE.

If you have any questions concerning warranty repair,please contact Duff-Norton. Authorization for return mustbe received from Duff-Norton before returning any equip-ment for inspection or warranty repair.

CAUTION

Do not allow actuator travel to gobeyond specified (catalog) closedheight, or serious damage to internalmechanism may result.

4

Section IIInstallation

The Duff-Norton SuperCylinder can be used in an unlim-ited number of positions and applications. Consequently,installation procedures will vary depending on the envi-ronment.

2-1. InspectionCheck the SuperCylinder for any shipping damage. Besure that motor fan does not rub fan shroud. Look for anyattached hardware, including a gearbox vent plug (reducermodels only).

2-2. Clevis PinsThe SuperCylinder should be attached with steel clevispins that are a close fit in the clevis holes. Holes areslightly oversized to accommodate pins that are the exactnominal size. Duff-Norton recommends the use of pinswith hardness of at least Rockwell C-28. Socket headcap screws or SAE grade 5 screws may be used, if theirlength is such that the threaded portion is not placed inshear.

Use of an anti-sieze compound or extreme pressuregrease on the clevis pins will reduce wear and possiblenoise. Clevis pins may be drilled and fitted with greasefittings to simplify relubrication. For extreme service, mountthe clevis pins on outboard bearings.

2-3. Orientation1. The application will usually dictate the orientation

of the SuperCylinder. In applications exposed todripping water or dirt, pointing the tube down isprefered, to reduce the entry of foreign material.

2. All major components of the SuperCylinder (motor,reducer, limit switch) can be rotated in 90° incre-ments to provide clearances where needed. Inaddition the actuator worm can be flipped end-for-end to change reducer mounting side. Non-standardorientations will be factory provided when requested.Refer to SuperCylinder catalog.

3. Factory orientation of the outer tube grease plugand vent plug is random (tube is screwed downtight). When required, the outer tube set screwscan be loosened and the tube rotated up to oneturn to relocate the grease fitting.

2-4. Vent plugsThe pumping action of the tube extension and retraction,as well as temperature changes, require that theSuperCylinder tube and the motor reducer gearbox (ifused) be vented to atmosphere.

1. Reducer venting: The motor gear reducer (if used)has a number of pipe plugs at various locations.The reducer is shipped filled with oil and with solidpipe plugs in every location. One of these plugs

should be replaced with the vented plug shippedwith the unit. In general, the plug nearest the top ofthe reducer should be replaced with the vent plug.Failure to vent the gearbox will lead to loss of oiland premature gearbox failure.

2. SuperCylinder tube venting: This vent is critical inpreventing blown out seals and/or water entry intothe actuator. Depending on the orientation of theSuperCylinder and the relubrication schedule, ex-cess grease may occaisionally be pumped out ofthis vent. This is normal and necessary.

3. Replumbing of vents in wet locations: IfSuperCylinder is subject to wet conditions, ventsshould be repositioned to prevent water entry. Theexact technique will depend on orientation and de-gree of moisture.

The reducer vent has a hex key socket. Any water thatstands in this recess will enter the reducer and causebearing failure. The tube vent has a hood; however, if anywater is collecting on this vent, the high volume of air pass-ing through the vent can suck water into the actuator. Astreet elbow can be used to cause either vent to pointdown. Another option is to replace the vent with a hosebarb fitting and attach several inches of vinyl tubing, se-cured in a downward position. Use a tubing large enoughto avoid capillary suction in the tube.

2-5. WiringWiring of motor, brake, and/or limit switch should be doneaccording to the wiring diagrams supplied with those com-ponents. All wiring should be according to local andnational electrical codes. Motor controls should be prop-erly sized to provide adequate motor overload protection.See motor nameplate as to any internal motor protection.

Three phase motors must be trial connected to check forproper phasing relative to controls and limit switches.

Wiring connections to the SuperCylinder must be madewith flexible conduit or cable to allow for movement of theactuator during its operation.

2-6. Limit Switch AdjustmentLimit switches (if fitted) are not factory set and must beadjusted to prevent jamming and damage to the actuatorand/or mating equipment.

1. Before setting limit switches, the installer shouldmake certain that the actuator has sufficient travelin both directions to produce the range of travel re-quired by the installation. If there is any questionabout this, the rod end clevis pin should be discon-nected and the rod rotated by hand, in eachdirection, to its internal stops. The length of ex-tended rod can be measured in these two extremesand the measurements used for reference whilesetting limit switches.

5

3-1. Lubrication

For severe service conditions, the actuators should belubricated more frequently using the above grease (dailyto weekly depending upon the conditions). If duty is heavy,an automatic lubrication system is strongly recommended.

1. Lubrication Points - The SuperCylinder has twogrease fittings, one in the worm housing and one atthe tube guide bushing. Mobil XHP is recommen-ed for both.

2. Frequency - The lubrication schedule will vary de-pending on the severity of use. Lubrication every50 hours of actual operation is suggested as a guide-line.

3. Quantity - During operation, there will be migrationof grease from the worm gear housing into the tubearea. There will also be grease migration from theouter tube guide bushing into the tube, and possi-bly some loss through the tube wiper seal. Theactual quantity of grease needed to replace thisgrease cannot readily be determined. Using a stan-dard hand-pumped grease gun, a rough rule ofthumb is to inject into each grease fitting one pumpof grease for every 1000 pounds of actuator capac-ity

4. Grease Loss - Over time, spent grease will accu-mulate inside the tube. A considerable volume of

Section IIILubrication

grease can exist there without noticeable effects.Depending on the orientation of the actuator, it mayeventually begin to ooze grease from the tube ventor from the wiper seal. This is not an indication of aproblem, but evidence of internal lubricant circula-tion. If these grease emissions are objectionable,the outer tube may be removed and surplus greasecleaned out.

3-2. Motor Reducer LubricationUnless loss of oil is apparent, the reducer will not nor-mally require relubrication. For most applications, MobilSHC636 synthetic gear oil is the recommended lubricant.Reducers should be filled approximately half full of oil. Apipe plug should be apparent at this level, which can beused as a level plug.

For more detailed discussion of reducer lubrication re-quirements, refer to the reducer instruction sheet.

3-3. Motor and Reducer BearingsAll standard motors for this product should have perma-nently sealed and lubricated bearings that do not requiremaintenance.

Larger models of motor reducer may have grease fittingsfor bearing lubrication. If fittings are evident on the motorreducer, they should receive one shot of grease at thesame time the actuator is relubricated.

3-4. Clevis PinsClevis pins are very subject to wear and can be a sourceof creaking or popping noises. Removal, cleaning, inspec-tion, and regreasing of clevis pins at each scheduledlubrication is recommended.

2. Remove limit switch cover.

With the clevises connected, jog actuator to its re-tracted position, making sure that the rod isextended at least 1/2” from the jam closed position.Observe white plastic limit switch nuts and be surethat neither one travels into a switch. If contact isimminent, disconnect power and screw nut awayfrom switch, as described in the next paragraph.

3. Refer to Figure 1 for limit switch nut identification.Remove the screw “A” and nut guide “B”. Rotate

the “retract” nut toward the switch until the switchjust clicks. Rotate nut 1/2 turn (5 slots) farther (toallow for drift), and install nut guide.

4. Restore power and jog the rod out for a few sec-onds, then retract it until it is cut off by the limit switch.If fine adjustment is needed, disconnect power,move nut one or two slots at a time and recheck.

The amount of drift can vary widely on Acme screwmodels without brakes. On these models, drift will,in general, be greater under light loads. When set-ting limit switches, it is best to operate Acme screwmodels at lightest expected load, and to operateball screw models at greatest expected load.

5. Jog actuator to its extended position, repeating allthe steps from paragraphs 2-4 for the “extend” switchand nut.

WARNING

Do not touch any internal parts of limitswitch unless power has beendisconnected.

Unless otherwise specified, actuators are shipped packed with grease which should be sufficient for one month of normal operation. For normal operation, the actuator should be lubricated once a month using Mobil XHP461 or XHP462 Extreme Pressure grease.

6

Other than the lubrication described in the previous sec-tion, regular maintenance should not be required. Ifdisassembly is required to repair damage or a failure, thefollowing procedure may be followed.

4-1. Disassembly (Refer to Figure 5-1)1. Remove SuperCylinder from installation and move

to a work area. Watch for oil spillage from the re-ducer vent plug.

2. Remove motor, reducer, and limit switch (if fitted).Each of these can be withdrawn after removing itsfour mounting screws.

3. Loosen two setscrews on outer tube. Unscrew tubeand pull off. Clean excess grease from screw andtube.

4. Remove four screws from each worm flange andremove flanges. Tap worm to one side.

5. Loosen two setscrews in flange of shell cap. Re-move cap with screw and tube assembly.

6. Withdraw worm with bearings.

7. Unless there is a reason for removal, leave clevisbolted to shell, as there is sealer between the twoparts.

4-2. Screw & Tube Disassembly

4-4. Screw and Nut Inspection1. Clean excess grease from the screw and nut.

Inspect the screw thread areas for any wear,pitting, gouges, spalling, brinelling, or corrosion.Any deterioration of the thread contact surfacesis cause for replacement.

2. If screw is undamaged, clamp it in a vise with softjaws and check the nut for backlash. Push backand forth on the nut, without rotation. Movementshould be no more than shown in Table 1. Use adial indicator if available.

Section IVMaintenance

Table 1

3. It is not uncommon for nuts to exhibit wear beforeany damage to the screw. If this is the case, a newnut can be fitted without screw replacement.

4-5. Lifting Nut Removal

1. Spread and remove nylon nut guide from inner endof translating tube.

2. Loosen two setscrews holding lifting nut. These areinstalled with thread locking adhesive and may re-quire heating.

3. Clamp lifting nut in vise. Insert bar in clevis holeand unscrew translating tube.

4-3. Gear Removal1. Depending on size, the nut holding on the worm

gear may be self-locking or may use a pin or a set-screw for retention. Remove pin or loosen setscrewif used.

2. Clean all grease from an area of the screw andclamp that area in a vise with soft jaws. Removethe gear nut. Use an impact wrench on hex nuts, ifavailable.

3. Pull gear from screw. There may be slight resis-tance, but this should not be a hard pull.

4. Keep bearing races together and note which onewas in each location.

1. Clamp screw in vise with soft jaws and use an im-pact wrench to loosen the stop washer bolt in theend of the screw. This bolt is installed with highstrength locking adhesive. The use of heat is rec-ommended.

2. Acme screw nuts can then be removed without pre-caution. Ball screw nuts, if already determined toneed replacement, can be screwed off, with ballsbeing lost as it comes off the screw.

3. If ball nuts are to be reused, it is recommended thatan arbor be made for capturing balls. This will elimi-nate the need to reload balls. The arbor can bemade from any stiff material and should be about2” longer than the ball nut. A piece of tubular mate-rial is easier to secure inside the nut, but a solid barcan be used. Arbor diameters are given in Table 2.

Note

If problem is isolated to worm geararea, do not disassemble tube from nut.

Screw O.DMax.

Backlash1.0" .008"1.17-2.50" .025"3.0" .050"

Note

Removal of a ball nut from the screw isnot recommended unless there is areason to do so.

7

4. Hold arbor tight against and symmetric with the endof the screw (a pilot to engage in the screw hole ishelpful). Turn the nut down the screw and continuerunning it over the arbor until it is completely off thescrew.

5. Use wire, tape, cable ties, or similar to prevent thearbor from falling through the nut.

4-6. CleaningClean all parts and inspect for wear or damage.

3. Place screw bushing (if used) and shell cap onscrew. Place load bearings on worm gear and in-stall on screw. If working load is primarily in onedirection, the bearing locations can be swappedfrom original, to increase service life.

4. Securely tighten worm gear nut and install lockingdevice, if used.

5. Fill translating tube about half full of grease (seeSection 3-1). Screw translating tube onto lifting nut.If new nut is being used, spot drill the nut threadsfor the setscrews.

Setscrews must not protrude above the surface ofthe tube, to avoid interference with nylon nut guide.

Table 2

1. Use degreasing solvent to remove grease or oil fromall parts.

2. Use clean hot water or a soap solution for generalcleaning of painted surfaces.

3. Dry parts thoroughly after cleaning.

4-7. Inspection (Refer to Figure 5-1)Inspect bearings for damaged race surfaces. Inspect sealsfor cut or brittle lips.

Replace any defective parts, using only Duff-Norton sup-plied or approved parts

4-8. Assembly (Refer to Figure 5-1)1. Install lifting nut on screw. Hold ball nut arbor against

screw and twist on nut, being careful not to loseballs.

2. Install stop washer and bolt. Use high strengththread locking adhesive on bolt.

6. Insert worm with bearings into the shell. Be sure itis pointing the right way to fit the drive and limitswitch. Do not install flanges yet.

7. Insert screw with gear and bearings into shell.Tighten shell cap to previous location, evident fromsetscrew indentations, or until bearings are com-pletely seated. Bearings should be preloaded toprovide slight drag. If parts replacement has re-sulted in the setscrews not engaging with originalindentations, lightly spot drill actuator shell at newsetscrew locations.

8. Center worm in housing and install bearing flanges(with seals), with original shims. Tighten flangescrews. Tap each end of worm to seat bearingsand recheck flange screws for tightness. Wormshould turn without binding, and also without no-ticeable end play. Add or remove shims to achievethis situation.

9. Pump grease into housing (see Section 3-1) untilgrease oozes between screw and shell cap.

10. Be sure nylon nut guide is in place.

11. Be sure guide bushing and wiper seal are in outertube. Slide outer tube over translating tube andscrew all the way onto shell cap. Tube may bebacked off up to one turn to align grease fitting.Tighten outer tube setscrews.

12. Put a few pumps of grease into the guide bushinggrease fitting. If the screw has been well greased,only a small amount is needed in the bushing areaat this time.

13. Reinstall reducer and motor, checking for any wearor damage in those components. Replace motorbearings if noisy. Reinstall limit switch. Limit switchwill require readjustment (see Section 2-6) after in-stallation of SuperCylinder.

14. Check reducer oil level after installation.

Screw O.D. Arbor Dia.1.0" .88"1.17" .88"1.5" 1.156"2.25" 1.88"2.5" 2.24"3.0" 2.50"

WARNING

Provide adequate ventilation duringthe use of cleaning agents; avoidprolonged breathing of fumes andcontact with skin. Read & followmanufacturer's instructions.

Note

Remove grease from unit and do notreuse old grease.

Before installing new parts, remove anyrust preventive, protection grease, etc.

Note

It is critical that these setscrews bespot-drilled, tightened, and securedwith thread locking adhesive.

8

Section VIllustrated Parts List

5-1. GeneralThe following exploded parts views show the componentsof the Duff-Norton SuperCylinder. Due to the wide rangeof models and configurations, exact part numbers are notshown. To order parts, contact Duff-Norton with theSuperCylinder model number (example: R0530B47-123)and the item number from the following illustrations.

This section contains an exploded illustration of the Duff-Norton SuperCylinder. The number adjacent to each parton the illustration is the index number. Keyed to this indexnumber on the parts list is the part name.

When ordering parts be sure to include:

1. The nameplate model of your unit.

2. Index number and name of part.

9

Figure 5-1. Exploded Illustration for Duff-NortonSuperCylinder Series

Warning

Use only replacementparts supplied by orapproved by Duff-Norton.Non-authorized parts maybe inadequate, resultingin serious injury or deathin event of failure.

Index No Part Name

Qty.Req.

Index No Part Name

Qty.Req.

1 Shell 1 16 Retaining ring 12 Load bearing 2 17 Guide bushing 13 Worm gear 1 18 Outer tube 14 Screw bushing 1 19 Shell (adapter) cap 15 Lock nut 5 20 Setscrew 16 Screw 1 21 Setscrew 17 Key 1 22 Vent 18 Stop disc 1 23 Grease fitting 29 Stop bolt 1 24 Grease seal 2

10 Lifting nut 1 25 Flange 211 Nut guide 1 26 Worm bearing 212 Spiral ring 2 27 Worm 113 Translating tube 1 28 Clevis bracket 114 Setscrew 1 29 Screw 415 Wiper seal 1

10

Figure 5-2. Exploded Illustration of Duff-NortonSuperCylinder Parallel Configuation

Warning

Use only replacementparts supplied by orapproved by Duff-Norton.Non-authorized parts maybe inadequate, resultingin serious injury or deathin event of failure.

Index No Part Name

Qty.Req.

101 Limit switch assembly 1102 Limit switch bracket 1103 Reducer adapter 1104 Reducer 1105 Motor 1106 Coupling 1107 C-face adapter 1

11

Figure 5-3. Exploded Illustration of Duff-NortonSuperCylinder Right Angle Configuration

Warning

Use only replacementparts supplied by orapproved by Duff-Norton.Non-authorized parts maybe inadequate, resultingin serious injury or deathin event of failure.

Index No Part Name

Qty.Req.

101 Limit switch assembly 1102 Limit switch bracket 1103 Reducer adapter 1104 Reducer 1105 Motor 1106 Coupling 1107 C-face adapter 1

SK9800-100200/0405

ECO 97552© 2005 Yale Industrial Products, Inc.

P.O. Box 7010Charlotte, NC 28241-7010

Customer Service (800) 477-5002FAX (704) 588-1994Email: duffnorton@cmworks.comwww.duffnorton.com