TABLE OF CONTENTS - Jergens · PDF fileBlock Clamps.....46 Toe Clamps.....47 Swing Clamps.....48 Hydraulic Vises Hyraulic Vises .....51 Hydraulic Accessories Pre-Fill

Power Clamping Deviceswww.jergensinc.com

Phone 800-537-4367 or 216-486-5540 • Fax: 216-481-6193 • E-mail: [email protected] • www.jergensinc.com 1

StayLock® ClampsStayLock Clamp ................................... 38 Commonly Asked Questions ............. 39 Die/Mold Clamps ............................... 40 Sensor Interlock................................. 41Large Capacity Mold Clamp ................. 42Retractable Clamps .............................. 43Rocker Clamps ..................................... 44Mini-Rocker Clamps ............................. 45Block Clamps........................................ 46Toe Clamps........................................... 47Swing Clamps....................................... 48

Hydraulic VisesHyraulic Vises ....................................... 51

Hydraulic AccessoriesPre-Fill Boosters .................................. 56Standard Boosters ................................ 58High Pressure/Volume Boosters........... 59Boosters Installation Kits ...................... 603 Second Clamping Kit ......................... 61Pre-Fill Power Pacs .............................. 61Hydraulic Intensifi er .............................. 62Air-Powered Hydraulic Pumps.............. 63 Shoebox™ Pumps............................. 64 Breadbox™ Pumps ........................... 65 Valves and Subplates ....................... 66Manual Pumps...................................... 67Pallet Decoupler Valve ......................... 68Air Circuit Controls................................ 69 Filter/Regulators ................................ 69 Gauges .............................................. 69 Muffl ers .............................................. 69 Flow Control Valve ............................. 69 2-Way and 3-Way Valves .................. 70 4-Way Valves ..................................... 70 2-Hand No Tie Down ......................... 71

Hydraulic Power ClampingIntroduction ............................................. 2Design Your Own Hydraulic System ....... 3Typical Hydraulic Circuit ......................... 4Customer Work Sheet ............................ 5Threaded Cylinder Application................ 7Installation Tips for Plumbing Hydraulic Systems ............... 8Converting Manual Power to Hydraulic Pressure .............................. 9

Hydraulic CylindersSwing Cylinder Top Flange/Manifold Mount ................. 6 Bottom Flange/Manifold Mount............ 7 Swing Cylinder Arms ........................... 8Swing Cylinder Plumbing Mount................................. 10 Plumbing Mount(Large) ..................... 11Swing Clamp ........................................ 14Flow Limit Valves .................................. 14Mounting Plate...................................... 15Retracting Clamps ................................ 16Toe Clamps........................................... 18Work Supports ...................................... 20Hollow Rod Cylinders ........................... 22Threaded Cylinders Pressure Points(Plumbing Moun) ...... 24 Miniature Cylinders ............................ 24 Manifold Mount Cylinders .................. 25 Pressure Points ................................. 25 Threaded Cylinders(Heavy Duty) ...... 26 Piston Buttons ................................ 26 Block Mountings ............................. 27 Frange Mountings........................... 27 Jam Nuts ........................................ 27Standard Cylinders Single Action ...................................... 29 Double Action .................................... 30 Mounting Brackets ............................. 31Block Cylinders Single Action ...................................... 33 Double Action .................................... 34Flange Mount Cylinders........................ 35Intensifi er Cylinders .............................. 36

Hydraulic Circuit Controls ..................... 71 Gauges .............................................. 71 2-Way Valves ..................................... 72 4-Way Valves ..................................... 72 Pressure Reducing Valve .................. 73 Pressure Switch................................. 73 Sequence Valve ................................. 73 Pilot Operated Check Valve ............... 74 Check Valve ....................................... 74 Flow Control Valve ............................. 74 Oil Reservoirs .................................... 75 Hydraulic Fluids ................................. 75 Manifold ............................................. 76 Fittings ............................................... 78 Quick Disconnect Couplers ............... 80 Flexible Hose ..................................... 80 Hydraulic Hose .................................. 80 Steel Tubing....................................... 80 Maintenance Kits ............................... 81

Pneumatic Toggle ClampsHorizontal Hold-Down Action ................ 82Enclosed Hold-Down ............................ 83Straight Line Action............................... 84Mounting Plate...................................... 85Swing Cylinders .................................... 86Mounting Blocks ................................... 88Switch Information ................................ 88

Jergens Standard ComponentsFor Fixturing and Workholding

Ball LockTM Mounting System ................ 89Locating Components........................... 90Workholding Components .................... 91Toggle Clamps ...................................... 92

TABLE OF CONTENTS

Jergens, Inc. • Jergens Way • 15700 S. Waterloo Road • Cleveland, Ohio 44110-38982

www.jergensinc.com

Information•Metric/Inch: Jergens provides products in both metric and inch sizes.Please select according to your requirements;

•Units: Unless elsewise stated, the metric units are millimeter(mm) and kilogram (kg), inch units are inch (in.) and pound (lbs);

Port and Hex sizes are in inch unless indicating;

•3D Solid Models & 2D Drawings in most formats are available on Jergens Web Site;

•Cross Reference: Jergens part numbers can be converted to competitive products;

•Technologies: No particular technologies and skills other than univeral mechanical principles are required for using Jergens products;

•Products designed and manufactured by:

Hydraulic Clamping www.jergensinc.com

Jergens Inc.Cleveland • Ohio • USA


3Phone 800-537-4367 or 216-486-5540 • Fax: 216-481-6193 • E-mail: [email protected] • www.jergensinc.com

Designing Your Own Hydraulic System

1. Calculate the force used to hold the workpiece during machining. To convert the torque applied to a fastener into holding force use the following formula:

P = T KD

Where: P = Holding Force (kN) T = Torque (N.m) D = Nominal Thread Diameter (mm) K = Friction Factor

(K Varies with material, fi nish, and lubrication, .19 to .25) Example: M12 bolt tightened to 50 N.m

P = 50 = 19 kN

(0.22 x 12)

2. Calculate the force required at each work unit. Total Force Number of work units

3. Select the style of work unit to be used at each location. Select units which can be easily mounted and will allow access for loading and unloading of the workpiece.

4. Compare the force required by each work unit with the maximum force available from the unit selected. If the required force is greater than the available force, substitute larger work units or increase the number of work units to be used.

5. Calculate the hydraulic pressure required to provide the force needed at each work unit. To determine pressure, divide the force required at the work unit by the effective piston area of the unit selected.

Force Area

The unit requiring the highest pressure determines the requirement for the entire system.

6. Determine the total volume of oil required to operate all of the work units (Volume = Piston Area x Stroke). Operating volume requirements for work units are listed in the specifi cations chart for the item.

7. Select a power source which will provide the required pressure, using the available air pressure. To determine if a power source will provide the required pressure from available air pressure, multiply the available air pressure by the boost ratio of the power source.

Example: (5 bar air pressure) (15:1 boost ratio) = 75 bar hydraulic pressure

The power source must also provide the total volume of oil required by the system. When using a standard booster, the high pressure volume of the unit must exceed the system requirement.

8. If you need help, call Jergens Technical Sales at: 1-800-JERGENS (537-4367).

= Force per unit

= Pressure


4 Jergens, Inc. • Jergens Way • 15700 S. Waterloo Road • Cleveland, Ohio 44110-3898

Circuit Diagram

Typical Installation — Two Station Milling Operation

Typical Hydraulic CircuitApplication



Work Sheet—Photocopy This Page

Description: Notes:Total Force Required kNForce Per Unit kNUnit Selected Part No. Piston AreaPressure Required bar (Pressure Must Not Exceed Limit of Unit!)

Total Volume Required cm3

Power Source Part No. Available Air Pressure bar Power Source Boost Ratio :1 *Output Pressure bar Output Volume cm3

*Must Exceed Pressure Required

Hydraulic Cylinderswww.jergensinc.com


Single Action Double Action Specifi cation 60660 60662 60664 60670 60672 60674Maximum Output Force(kN) 5.0 11.8 22.7 5.0 11.8 22.7Stroke (mm) Total 20.1 29.5 42.2 20.1 29.5 42.2 Rotating 12.2 16.8 26.2 12.2 16.8 26.2 Clamping 7.9 12.7 16.0 7.9 12.7 16.0Operating Volume Clamp(cm3) 3.8 11.8 32.0 3.8 11.8 32.4 Operating Volume Unclamp(cm3) N/A N/A N/A 7.5 23.4 65.5Minimum Operating Pressure(bar) 51.7 51.7 51.7 34.5 34.5 34.5Maximum Operating Pressure(bar) 345 345 345 345 345 345Effective Piston Area (cm2) 1.94 4.00 7.61 1.94 4.00 7.61

Download Cad Models!www.jergensinc.com

Top Flange Mount

* Mtg. Hole Counter Bore

Manifold Mounting Dimensions - Top Flange

Single Double Acting Acting Part No. Part No. A B C D E F G 60660 60670 37.5 1/4-20 8.6 26.2 22.4 14.2 21.5 60662 60672 45.9 5/16-18 11.2 31.8 25.4 13.5 26.7 60664 60674 61.8 3/8-16 15.2 43.7 34.9 19.1 35.8

C ± .005

A ± .01

F ± .01

.13

.09CLAMP FEED HOLE

.13

.09UNCLAMP FEED HOLE

(DBL ACTING ONLY)

TYP.E ± .005

G ± .01 TYP.

B TAP3 PLACES

D ± .005

Part No. Counter Bore Size 60660 60670 1/4" S.H.C.S. 60662 60672 5/16" S.H.C.S. 60664 60674 3/8" S.H.C.S.

CAUTION! DON’T ALLOW SWING ARM TO CONTACT THE WORKPIECE OR FIXTURE WHILE ROTATING.

Single Double Acting Acting Part No. Part No. A B D E F G H I J K L M N O P Q R S T 60660 60670 36.3 15.8 9.7 65.3 26.2 134.1 58.7 29.5 22.4 52.3 33.5 8.6 26.2 14.2 21.5 31.2 16.8 3.5 3/8-24 X 5/8 60662 60672 44.5 22.2 10.4 85.1 26.9 172.2 68.3 34.3 25.4 64.3 41.4 11.2 31.8 13.5 26.7 38.9 25.4 5.0 1/2-20 X 3/4 60664 60674 60.2 31.7 13.7 111.8 37.6 237.0 91.4 45.7 35.1 85.1 53.8 15.2 43.7 19.1 35.8 51.8 35.1 5.0 5/8-18 X 1

Unclamp Feed Hole Ø2.3-3.3 (Double Action Only)

(3 Places)

F ± 0.25

Ø2.3-3.3 Clamp Feed Hole

± 0.13

± 0.13

G± 0.25

± 0.13

± 0.25

Swing Cylinder – Top Flange/Manifold Mount

• Clamping capacity from 5.0-22.7kN. max.• Versatile manifold mount or conventionally plumbed• Single and Double Acting available• Available in three body sizes• Assortment of Clamping Arms (sold separately)• Popular top fl ange mounting design

These popular and highly adaptable swing style cylinders contain built in features, which allow users to simplify the design process. They are directly interchangeable with competitive products.

L

K

28°TYP.

H

JJ

M

N

I

90°

C3 PLACES

CLAMP PORT

UNCLAMP PORT(DBL ACTING ONLY)

TOTAL STROKE

CLAMPING STROKE

ROTATING STROKE

G

F

D

B

A

E

T BHCS

#4 SAE PORT2 PLACES

SR

P P

O

Q

#2 SAE PORT2 PLACES


CLAMP PORT

The piston rotates 90° to the right, but may be ordered with 90° left rotation (add - LH to clamp part no.) or no rotation (add - SP to clamp part no.)



Single Action Double Action Specifi cations 60661 60663 60665 60671 60673 60675Maximum Output Force(kN) 5.0 11.8 22.7 5.0 11.8 22.7Stroke (mm) Total 20.1 29.5 42.2 19.3 29.5 42.2 Rotating(mm) 12.2 16.8 26.2 11.4 16.3 26.2 Clamping(mm) 7.9 12.7 16.0 7.9 13.2 16.0Operating Volume Clamp(cm3) 3.77 11.80 32.12 3.77 11.80 32.45Operating Volume Unclamp(cm3) N/A N/A N/A 7.54 23.43 65.55Minimum Operating Pressure(Bar) 51.7 51.7 51.7 34.5 34.5 34.5 Maximum Operating Pressure (Bar) 345 345 345 345 345 345Effective Piston Area (cm2) 1.94 4.00 7.61 1.94 4.00 7.61

Download Cad Models!www.jergensinc.com

Bottom Flange Mount

Manifold Mounting Dimensions - Bottom Flange C ± .005

A ± .01

F ± .01

.13

.09CLAMP FEED HOLE.13.09

UNCLAMP FEED HOLE(DBL ACTING ONLY)

TYP.E ± .005

G ± .01 TYP.

B TAP5 PLACES

D ± .005

Single Double Acting Acting Part No. Part No. A B C D E F G H I J K L M N O P Q R S T 60661 60671 38.1 15.8 7.1 16.0 61.0 31.8 134.4 63.5 19.1 14.2 50.8 25.4 20.6 25.1 14.2 14.2 28.7 16.8 3.5 3/8-24 X 5/8 60663 60673 47.5 22.2 8.6 16.0 80.8 31.8 172.2 76.2 23.9 17.5 63.5 31.8 25.4 30.7 19.1 19.1 31.8 25.4 5.0 1/2-20 X 3/4 60665 60675 63.5 31.7 10.4 18.8 111.5 38.1 237.2 86.1 32.3 23.9 79.2 39.6 31.8 - - 19.1 35.1 35.1 5.0 5/8-18 X 1

Single Double Acting Acting Part No. Part No. A B C D E F G 60661 60671 39.1 1/4-20 14.2 25.1 20.6 28.7 14.3 60663 60673 48.8 5/16-18 17.5 30.7 25.4 31.8 19.1 60665 60675 64.8 3/8-16 23.9 - 31.8 34.9 19.1

CAUTION! DON’T ALLOW SWING ARM TO CONTACT THE WORKPIECE OR FIXTURE WHILE ROTATING.

± 0.25

± 0.13

± 0.13

(5 Places)

± 0.25

± 0.13

F ± 0.25

C5 PLACES

JJ

I

H

M

M

N

L

K

90°

TOTAL STROKE

ROTATING STROKE

CLAMPING STROKE

B

F

G

O

A

O

E

D

#4 SAE PORT2 PLACES

T BHCS

CLAMP PORT


Q

P

P

R S

#2 SAE PORT4 PLACES

UNCLAMP PORTTOP & BOTTOM(DBL ACTING ONLY)

CLAMP PORTTOP & BOTTOM

I

H RAD. J

J

M

M

L

K

Q

P

P

C4 PLACES

CLAMP PORTTOP & BOTTOM

UNCLAMP PORTTOP & BOTTOM(DBL ACTING ONLY)

Bottom Flange Swing Cylinders offerversatility as a through hole bottommount or top plate mounting device.

• Clamping capacity from 5.0-22.8 kN max.• Manifold mounting or standard plumbing• Single and Double Acting available• Highly adaptable fl ange mount design(Clamping Arms sold separately)

Swing Cylinder – Bottom Flange/Manifold Mount

The piston rotates 90° to the right, but may be ordered with 90° left rotation (add - LH to clamp part no.) or no rotation (add - SP to clamp part no.)

Unclamp Feed Hole Ø2.3-3.3 (Double Action Only)

Ø2.3-3.3 Unclamp Feed Hole



G

F

H

I

B

A

D E

C

G

FH

EI

B

A

C

D

Single Arms - Standard Length

Single Arms - Long

Double Arms - Long Part No. A B C D(in.) E F G H I 60936 222.3 12.7 25.4 5/16-24 12.3 16.7 12.7 15.888/15.939 22.2 60937 273.1 19.1 34.9 3/8-24 17.9 20.6 15.9 22.238/22.289 30.6 60938 279.4 31.8 47.6 5/8-18 22.2 31.8 19.1 31.763/31.814 43.3

Part No. A B C D (in.) E F G H I 60930 38.1 12.7 25.4 5/16-24 M8x1.25 12.3 27.8 15.888/15.939 21.4 60931 50.8 19.1 34.9 3/8-24 M10x1.5 17.1 39.7 22.238/22.289 29.4 60932 63.5 31.8 47.6 5/8-18 M16x2.0 22.2 47.6 31.763/31.814 42.1

Part No. A B C D (in.) E F G H I 60933 136.5 12.7 25.4 5/16-24 12.3 16.7 12.7 15.888/15.939 21.4 60934 161.9 19.1 34.9 3/8-24 17.1 20.6 15.9 22.238/22.289 29.4 60935 165.1 31.8 47.6 5/8-18 22.2 31.8 19.1 31.763/31.814 42.1 G

F

H

I

E

B

A

C

D

Swing Cylinder Arms

• Material: 4140, heat treated to Rc 32-36







Max. Arm Length vs. Pressure

30100

Medium Cylinders (2,600#) p/n’s 60662, 60672, 60663, & 60673 input pressure (bar) max. arm length (mm)

Large Cylinders (5,000#) p/n’s 60664, 60674, 60665, & 60675 input pressure (bar) max. arm length (mm)

Small Cylinders (1,100#) p/n’s 60660, 60670, 60661, & 60671 input pressure (bar) max. arm length (mm)

100120140155170190205225240260275290310325345

12210895857768635753504745424038

115120135155170190205225240260275290310325345

15314412511010090837672666360565350

130135155170190205225240260275290310325345

1621561381261141069791837873686564

Swing Cylinder - Application Information• Arm length can effect clamping pressure - See Chart and Data• Weight should be considered when utilizing modifi ed or special

arms, other than those provided by Jergens.• Speed of operation is a major consideration. All swing cylinders

MUST BE USED WITH FLOW LIMIT VALVES to dampen the rotation action.

• Care should be used when select Hydraulic Accessories - be aware of maximum operating pressures.

Swing Cylinder Arm Ratings

INPUT PRESSURE (bar)

MA

X. A

RM

LE

NG

TH

(mm

)

145 190 235 280 325

5 kN SWING CLAMP

11.8 kN SWING CLAMP

22.7 kN SWING CLAMP

50

70

90

110

130

150

170



Swing Cylinders

• Can be mounted using four #10 cap screws or the 1"-12 thread on the O.D. of the cylinder

• Optional components include the threaded mounting bracket and jam nut shown below

• Can be used as a non-rotating clamp• Maximum recommended fl ow rate is 20 cubic inches (330 cm3) per

minute per clamp (approximately 1 second clamp time)• Note: Arm length can affect clamping pressures.

See chart at right for more information.• Available in FixtureProTM Design Software

WARNING: All swing cylinders must be used with fl ow limit valves (page 14, 74) to dampen the rotating action. Please see maximum fl ow rate shown below.

These versatile swing cylinders/clamps can be used as single or double acting rotating clamps, or push/pull cylinders. The piston in the Swing Cylinders rotate 90° to the right, but may easily be changed to 90° left rotation, or to no rotation at all.

Mounting BlockDouble Arm

Accessories

Part Description Number

Mounting Block 60953 Hex Jam Nut 60964 Optional Arm 60923

STROKE 19

CLAMP 6.4

ROTATE12.7

6

*Port and thread sizes in inch

1/4-20 UNC-2B

For #10 or M5 Mtg. Screw 4 PLACES

1/8-27 NPTFRETURN OPTIONAL

1"-12 UNF-2A2 PLACES

1/8-27 NPTFCLAMP

5/16-24 CAP SCREW

Clamp Return (pull) (push)

Operating (cm3) 3 5.4Effective Piston Area (cm2) 1.6 2.8Minimum Operating Pressure (bar) 10 -Maximum Operating Pressure (bar) 210 210Maximum Output Force (kN) 3.3 6.0Stroke (mm):Full 19 19 Rotating 12.7 12.7 Clamping 6.4 6.4Weight (kg) 0.45

60680 Swing Cylinder

Specifi cations

19.1

9.4

25.4

66.7

33.325.4

12.7

(8.20)12.73±0.025 7.9

8.9

10.3

7.9

57.2

28.6

15.9 31.6

15.9

25.4

4.8

11.1

39.7



Single ArmPart

Number60921

Jam Nut Part Number 60967

Swing CylindersLarge

Accessories

Double ArmPart

Number60922

• Standard without an arm.• Single or double arms are available.• Can be mounted using four 3/8" cap screws,

or the 1 7/8"-16 O.D. thread of the cylinder.• Optional components include a jam nut or a mounting

bracket to replace old Jergens part number 60621.• Can be used as a non-rotating clamp.• Maximum recommended fl ow rate is 90 cubic inches (1475

cm3) per minute per clamp. (Approximately 1 second clamp time.)

• Note: Arm length can affect clamping pressures. See chart , page 12, for more information.

• Available in FixtureProTM Design Software

WARNING:All swing cylinders must be used with fl ow limit valves to dampen the rotating action. Please see maximum fl ow rate shown above.

Mounting BracketPart

Number60954

*Port and thread sizes in inch

73.7

52.350.8

38.1

76.2

10.2

47.832.5

25.4

12.7

25.4 Dia.

25.419.1

40.1

50.5224.0

22.4

72.9

60681 Swing Cylinder Clamp Return (pull) (push)

Operating (cm3) 24 43Effective Piston Area (cm2) 6.3 11.35Minimum Operating Pressure (bar) 15 Maximum Operating Pressure (bar) 210 Maximum Output Force (kN) 13.2 24.0Stroke (mm):Full 38.1 38.1 Rotating 25.4 25.4 Clamping 12.7 12.7Weight (kg) 2.3

Specifi cations

38.1

19.1

20.6

46.6

84.1

14.3

25.4

38.1

19.1

20.6

46.6

63.5

50.8

50.8

13.5 DRILL THRU25.45 ±0.03 REAMX 19.1 DP

7.9 DRILL THRU900 C-SINK TO 10.3BOTH SIDES3/8-16 UNC-2B THRU

7.9 DRILL THRU900 C-SINK TO 10.3BOTH SIDES3/8-16 UNC-2B THRU

13.5 DRILL THRU25.45 ±0.03 REAMX 19.1 DP

14.3

25.4

57.1

57.1 25.4

44.5

44.5 8.7 R

127



175

162.5

150

137.5

125

112.5

100

87.5

75

62.5

50

37.5

25

51 68 85 102 119 136 153 170 187 204 221

Clamping Pressure (bar)

Maximum Arm Length Vs. PressureSwing Cylinder with Single Arm

Max

imum

Arm

Len

gth

(mm

)

60681

60680



If you are currently using bolts, nuts, straps, etc. to hold a part on a fi xture, use this chart to help decide how much hydraulic holding force would be needed to convert the set-up to hydraulic clamping.

P = Induced Tension (kN)T = Torque (N.m)D = Nominal Screw Diameter (mm)K*= Friction, varies with material, fi nish, & lubricity (.19 to .25)*Above values based on K equaling .22

P= T KD

Holding Force P (kN) Thread Size D M12 M16 M20 M24

20 8 6 5 4 30 11 9 7 6 40 15 11 9 8 50 19 14 11 9 60 23 17 14 11 70 27 20 16 13 80 30 23 18 15 90 34 26 20 17 100 38 28 23 19 150 – 43 34 28 200 – 57 45 38

* Bold type represents the average torque generated by the operator with a 300mm wrench.

Torque T(N.m)

Converting Manual Power to Hydraulic Pressure

****



Swing Clamp

Part No. 61648

63.5 55.6 87.3

69.9 115.9

104.0

27.0

73.8

28.6

28.6 15.919.1

*Port sizes in inch 43

33

*Port sizes and threads in inch

Jergens Swing Clamps are designed to swing 80° away from the workpiece to allow easy accessibility for part insertion or removal. Swing Clamps may be used in any attitude. The clamping arm may be positioned to swing either to the left or right by repositioning one cap screw. The right hand swing is standard.

• Right or Left Hand Swing• 22.0 kN Clamping Force• Operates in any position• Clamp arm has 6.35 mm of vertical travel• Can be used with fl ood coolant• Available in FixtureProTM Design Software

IMPORTANT:Jergens Swing Clamps are built to operate on pre-fi ll systems allowing much larger circuits to be used. To use a Jergens Swing Clamp with a standard booster or with any other power source you must use the Flow Limit Valve shown below.

Specifi cationsPart Number 60685OperatingVolume (cm3) 26

Minimum OperatingPressure (bar) 5.5*

Maximum OperatingPressure (bar) 207

Maximum OutputForce (kN) 21.8

Weight (kg) 4.2

*5.5 bar to swing, 13.8 bar to clamp.

Flow Limit ValvesThe Flow Limit Valve restricts the fl ow of oil to dampen the rotating action of the Swing Clamp. Flow Limit Valves are not needed with 36:1 or 71:1 Air Powered Hydraulic Pumps. (Part Number 61755 or 61756).

C' Bored for M12

25.4



Ø13.5 Drill Thru (4 Holes)

Ø10.7

143.7

71.8

71.8143.7

42.5

12.7 31.8

63.5

25.4

11.9

Swing ClampApplication

For hydraulic clamping directly on the machine table, use Jergens Swing Clamps and Mounting Plates. The workpiece is positioned using Threaded Cylinders and fi xed stops. Manifolds at the edges of the table, with hydraulic quick disconnects, allow any number of clamps to be used.

Mounting plates are subplates for Swing Clamps and are designed to save fi xturing cost and allow versatility in set-ups. Mounting Plates may be bolted directly to your machine table and moved to any location on the table. Each mounting plate has pre-drilled mounting holes or can be easily adapted to your machine table or application.

Mounting Plates

Part Number

60971

• Material: Low Carbon Steel• Finish: Black Oxide• Available in FixtureProTM

Design Software

*Port sizes in inch




28.6*12.7

*Port sizes in inch

Retracting ClampsRetracting Clamps lift, then pull back over 25.4mm, to allow easy access for insertion or removal of the workpiece. The clamps are available in single acting (spring return) and double acting (air or hydraulic return) styles. The clamp strap is supplied with a removable steel pad. See page 5.48 on Master Catalog for replacement steel or brass pads.

Part Number 60601 60602 60650 60651OperatingVolume (cm3) 18.2 46.7 16.4 46.7Effective PistonArea (cm2) 7.9 20.3 7.1 20.3

Minimum OperatingPressure (bar) 1.7 1.7 1.7 1.7

Maximum OperatingPressure (bar) 207 207 207 207

Maximum OutputForce (kN) 16.3 42.2 15.0 42.2

Weight (kg) 3.85 4.54 4.31 5.67

Specifi cations

Patent Number3,337,210

Single Acting Style*

† Clamping Height Not Adjustable

Clamp Mounting Part Strap Bolt Number A B C D E F G H† J Size Size 60650 142.9 79.4 101.6 54.0 31.8 31.8 12.7 79.4 ± 1.6 30.2 25.4 x 44.5 x 127 M12 x 38 60651 142.9 111.1 114.3 82.6 31.8 23.8 14.3 79.4 ± 1.6 30.2 25.4 x 44.5 x 127 M16 x 38

Clamp Mounting Part Strap Bolt Number A B C D E F G H† J Size Size 60601 130.2 79.4 101.6 54.0 31.8 44.5 12.7 66.7 ± 1.6 28.6 25.4 x 44.5 x 127 M12 x 38 60602 130.2 111.1 114.3 82.6 31.8 30.2 14.3 66.7 ± 1.6 28.6 25.4 x 44.5 x 127 M16 x 38*Not recommended for applications where coolant or chips are prevalent. Use the double acting style for these applications. Double Acting Style



Retracting ClampsApplication

Boring Mill ApplicationThe I.D. of the casting is located with a pilot locator on its vertical face. The Retracting Clamps move into a clamping position between the ribs in the casting. When it is time to change parts, the clamps retract out of the way for easier part removal. Jergens Swing Clamps or Swing Cylinders could also be used in this application.



42.9 34.9

171.8

31.8

4.8

36.5

76.2

Toe Clamps

U.S. Patents:No. 4406445

Features• Low Profi le • Direct Mounting • 4.8mm Stroke• 13.6 kN Force• Steel or Brass Toe Insert Available• Available in FixtureProTM Design Software

Toe Insert is not supplied with the Toe Clamp. See below to order the Toe Inserts.

Specifi cationsPart Number 60631Operating Volume (cm3) 1.9Minimum OperatingPressure (bar) 13.8Maximum OutputForce (kN) 13.6

Overall Stroke (mm) 4.8

* Port size in inch

A washer (60636), to prevent damage by the cap screw, is included with each clamp. Part Number Insert

60633 Steel 60632 Brass

Toe Inserts

Hydraulic Force in kN

Pressure(bar) A B 1.0 4.1 3.4 2.0 8.2 6.8 3.4 13.6 11.3

Hydraulic Toe Clamps

176.6

Slotted for 1/2" or M12 Cap Screws



Toe ClampApplication

A Toe Clamp is used in applications where clamps cannot be on top of the workpiece due to the fact that the cutter must pass over that area. The clamp holds the workpiece against stop and down on the table. T-Slot mounting gives clamping versatility.



G Part No. A B C D E F Min. Max. H I J K L M N 63302 91 35 70 25 16 94 105 118 106 53 9.5 76 48 M6x1.0x12mm 3/8-19 BSPP/BSPT

Metric

Port N

Dia:11/32(in.)9 (Metric)

G Part No. A B C D E F Min. Max. H I J K L M N 60512 3 9/16 1 3/8 2 3/4 .990 5/8 3.69 4.15 4.65 4 3/16 2 3/32 3/8 3 1 7/8 1/4-20x3/8" 9/16-18

Inch

Thread M

Metric

Work Supports

Bolt Size Height Part Thru Tapped Tap E Port Number A A B C Min Max F G H I J K L M N 60513 1/4 5/16-24 .50 1/4-20 2.45 2.70 .49 2.36 1.12 .81 1.75 9/16-18 .5 1.5 2 63303 M6 M8x1.25x13 13 M6x1.0 62 69 13 60 28 21 44 3/8-19 13 38 51

Inch

Hydraulically-locked Work Supports differ from clamps and vises in that they do not actually exert force upon the workpiece. Rather, they are used to support the part being machined, offering resistance to any clamping forces acting counter to the direction of travel of the piston.

In a typical application, a large, thin casting is located on several tooling point pads for positioning. Work Supports will automatically adjust to support the delicate sections of the casting. When hydraulic pressure is applied, the fl oating pistons within the Work Support are locked in position and resist any downward movement exerted on the casting. After the casting is removed, the fl oating pistons return to their fully-raised position.

Specifi cationsPart 　 63303 63302Number 60513 60512OperatingVolume (cm3) 0.65 0.98Support to PressureRatio 10.5:1 21.7:1Minimum OperatingPressure (bar) 35 35Maximum OperatingPressure (bar) 210 210Maximum SupportCapacity (kN) 22.7 45.4Plunger Spring Start 9 60Force (N) Finish 30 180Weight (kg) 1 2.5

Metric Inch

* Metric ports in BSPP or BSPP



The top and bottom surfaces of the large casting must be machined to be fl at, parallel, and at a fi xed distance from each other. Jergens Work Supports eliminate defl ection at the outer edge while compensating for variations between castings. A Jergens Hollow Rod Cylinder, stud and “C” washer are used to hold the casting.

The workpiece is located and clamped on the right end by a Jergens Swing Clamp. The Work Support resists the machining forces applied to the other end of the casting. Variations between castings are compensated for by the fl oating support plunger in the Work Support.

Work SupportApplications



Tapped Hole Cylinders (Inch)

Hollow Rod Cylinders (Inch)

* With Spring Installed

Part No. Specifi cations Operating Stroke (mm) Operating (cm3) Effective Piston Area (cm2) Min. Operating Pressure (bar)* Max. Operating Pressure (bar) Max Output Force(kN) .

Hollow Rod Cylinders (Metric)

60403 604046041360414 6 4.9 6.2 7 340 21.8

6040160402604106041160412 8 11.5 12.3 7 340 44.7

60405 16.3 52.4 32.3 7 340 113.4

6 4.9 6.2 7 340 21.8

63123 8 11.5 12.3 7 340 44.7

15 52.4 32.3 7 340 113.4

Rod Dia. Port Wt. Part No. A B C† D E F G H J Size (lbs)

*60403 13/32 1 15/16 1 7/8 5/16 1 5/8 10-32 3/4 1/2 7/8 7/16-20 1.0 *60404 17/32 1 15/16 1 7/8 5/16 1 5/8 10-32 3/4 1/2 7/8 7/16-20 1.0 60401 21/32 2 1/2 2 3/16 5/16 2 7/32 10-32 7/8 3/8 1 1/4 9/16-18 2.5 60402 25/32 2 1/2 2 3/16 5/16 2 7/32 10-32 7/8 7/8 1 1/4 9/16-18 2.5 60405 1 1/64 4 3 9/16 5/8 3 1/2 1/4-28 No Boss 2 1/8 9/16-18 10.5 *Cannot increase stroke† Measured over piston in the retracted position.

Thread Depth Port Wt. Part No. A B C D E F G H J Size (lbs) 60413 3/8-16 1 15/16 1 13/16 5/16 1 5/8 10-32 3/4 1/2 7/8 7/16-20 1.0 60414 1/2-13 1 15/16 1 13/16 5/16 1 5/8 10-32 3/4 1/2 7/8 7/16-20 1.0 60410 1/2-13 2 1/2 2 3/16 5/16 2 7/32 10-32 7/8 7/8 1 1/4 9/16-18 2.5 60411 5/8-11 2 1/2 2 3/16 5/16 2 7/32 10-32 7/8 7/8 1 1/4 9/16-18 2.5 60412 3/4-10 2 1/2 2 3/16 5/16 2 7/32 10-32 7/8 7/8 1 1/4 9/16-18 2.5

Thread Depth Port Wt. Part No. A B C D E F G H J Size(BSPT) (Kg) 63123 17 64 55 8 56 M5 x 0.8 22 10 32 3/8-19 1.1

Hollow Rod CylindersHollow Rod Cylinders are ideal for converting existing fi xtures to power clamping. Replaces clamps which use double cams, fl ange nuts, draw bars, or other mechanical devices. Generally, no special machining is required, just a longer stud.


Specifi cations

Hollow Rod Cylinders can either push or pull. Two styles are available, either Through Hole or Tapped Hole. In the Through Hole style, the piston rod is hollow to accept a bolt. The Tapped Hole cylinders accept a bolt threaded into the piston. Because of the piston design, the Tapped Hole style cannot gain stroke. Removing the return springs make the Hollow Rod Cylinders suitable for air operation.



Typical, low cost conversion from manual clamping to Hollow Rod Cylinders can be accomplished by using the existing drill jig clamps and changing the stud to a longer length. Besides clamping faster than the manual method, the Hollow Rod Cylinders allow for uniform clamping forces on all strap clamps.

The Hollow Rod Cylinder is ideal for “close to the machine base” strap clamping. By mounting the clamps under the work table, a manual clamping set-up can be easily and economically converted to hydraulic clamping.

Hollow Rod Cylinder Applications



Part Body End Port Number Stroke Thread A B C D E F (Inch size)

60461 4.76 1/2-20 46 40 6.35 4.8 9.5 11 1/16-27 NPTF 60462 12.7 3/4-16 61 51 8 6.35 16.7 16 1/8-27 NPTF

Part No. 60461 60462OperatingStoke (mm) 4.76 12.4

OperatingVolume (cm3) 0.3 0.8

EffectivePiston Area (cm2) 0.62 1.26

Min. Operating Pressure (bar) 13.6 20.4

Max. OperatingPressure (bar) 680 680

Max. OutputForce (kN) 4.4 8.9

Weight (kg) 0.23 0.32

Small, fully-threaded bodies ensure easy mounting and simple length adjustments. Their small size provides high workholding forces in tight places. Threaded Cylinders have hardened piston rods, steel bodies, alloy springs and Tefl on® back-up rings which ensure trouble-free operation and long life. Not suitable for air operation. For mounting, see brackets on page 27. Jam nuts are included.

Part No. 61512 61514 63201 63202OperatingStroke (mm) 4.7 4.7 4.7 4.7

OperatingVolume (cm3) 0.6 0.6 0.6 0.6

EffectivePiston Area (cm2) 1.3 1.3 1.3 1.3

Min. Operating Pressure (bar) 28 28 28 28

Max. OperatingPressure (bar) 340 340 340 340

Max. Output Force (kN) 4.5 4.5 4.5 4.5

Weight (kg) 0.23 0.27 0.23 0.27

4.7 Stroke

• Available in FixtureProTM Design Software Part No. (Metric)63202

Part No. (Metric)63201

Note: Inch part size in inch, metric in mm, port sizes in inch.

3.2

19.1

12.7

4.7 Stroke

19.1

6.4 38.942.9

7.9

*Port sizes in inch

Jergens Pressure Points may be used with any power source and are designed to be used in restricted areas where space is at a minimum. Pressure Points can be used to eliminate part distortion during machining operations or to hold large diameter castings or rings in place while machining the upper surface. Pressure Points have hardened tool steel tips (50-60Rc). Jam nuts are included. Not suitable for air operation.

Specifi cations

Threaded CylindersPressure Points

PartNumber61512

PartNumber61514

Miniature Cylinders

Specifi cations

4.7 StrokeDIA.

DIA.

4.7 Stroke

1/8-28 BSPT



DRILL DEPTHL MIN.

.031 C BORE DIA.J MIN.

DRILL DIA.K MIN.

LOCATION

RECOMMENDEDCROSS DRILL

M DIA. DRILL

SAE STRAIGHT THREAD PORTPER SAE J514 (SEE CHART)

STROKE

A

H G E

BCD

F

Ø� Ø�Ø�

I

1/4-28 UNF-2B X 1/4 DEEP60483 THRU 60486

Part No. SAE No. Thread Size Thread Depth J K L M 60481 6 9/16-18 UNF 12.7 24.6 12.7 27.7 6.4 60482 8 3/4-16 UNF-2A 14.3 30.2 17.5 35.8 7.9 60483 16 1 5/16-12 UN-2A 19.1 48.5 31.0 50.8 12.7 60484 15 1 5/16-12 UN-2A 19.1 48.5 31.0 63.5 12.7 60485 24 1 7/8-12 UN-2A 19.1 65.0 46.0 50.8 14.3 60486 24 1 7/8-12 UN-2A 19.1 65.0 46.0 63.5 14.3

Part No. Body Thread Stroke A B C D E Dia. F G Dia. H Dia. I Hex.60481 9/16-18 UNF 4.8 35.7 9.5 12.7 3.2 9.5 6.4 4.8 12.2 3/4 60482 3/4-16 UNF-2A 12.7 43.7 9.5 14.3 3.2 16.3 9.5 6.4 16.8 7/8 60483 1 5/16-12 UN-2A 12.7 63.5 15.6 19.1 6.4 31.0 7.9 19.1 30.2 1 1/2 60484 1 5/16-12 UN-2A 25.4 76.2 15.6 19.1 6.4 31.0 7.9 19.1 30.2 1 1/2 60485 1 7/8-12 UN-2A 12.7 63.5 15.6 19.1 6.4 44.1 7.9 31.8 44.5 2 1/8 60486 1 7/8-12 UN-2A 25.4 76.2 15.6 19.1 6.4 44.1 7.9 31.8 44.5 2 1/8

61522 61524

0.79

*Port sizes in inch

Manifold Mount Cylinders • Provides for clean installation• Eliminates exposed fi ttings and plumbing• Well suited for use in custom design fi xtures

Specifi cationsPart Number 60481 60482 60483 60484 60485 60486 Operating Stroke (mm) 4.8 12.7 12.7 25.4 12.7 25.4

OperatingVolume (cm3) 0.3 1.6 6.4 12.9 14.5 29.0

Effective PistonArea (cm2) 0.60 1.26 5.06 5.06 11.40 11.40

Minimum OperatingPressure (bar) 13.6 13.6 13.6 13.6 13.6 13.6

Maximum OperatingPressure (bar) 340 340 340 340 340 340 Maximum OutputForce (kN) 2.1 4.4 17.8 17.8 40.0 40.0

Weight (kg) 0.23 0.32 0.45 0.68 0.91 1.13

Straight Thread Port

RecommendedCross DrillLocation

Dia. DrillMin. Drill

37.3Min. Drill Depth

Hex.

Pressure PointsSpecifi cations

Part Number 61522 61524OperatingStroke (mm) OperatingVolume (cm3) Effective PistonArea (cm2) Minimum OperatingPressure (bar) Maximum OperatingPressure (bar) Maximum OutputForce (kN) Weight (kg)

4.8

0.8

1.7

27.2

340.1

5.9 0.23

4.8

0.8

1.7

27.2

340.1

5.9 0.23



Not suitable for air operation.

Part No. 60463 60464 60465 60466 63213 63214 63216Operating Stroke (mm) 12.7 25.4 12.7 25.4 12.7 25.4 25.4

OperatingVolume (cm3) 6.4 13 14.5 29 6.4 13 29EffectivePiston Area (cm2) 5 5 11.4 11.4 5 5 29 Min. Operating Pressure (bar) 13.6 13.6 13.6 13.6 13.6 13.6 13.6Max. Operating Pressure (bar) 340 340 340 340 340 340 340Max. Output Force (kN) 17.8 17.8 40.1 40.1 17.8 17.8 40.1

Weight (kg) 0.454 0.68 0.91 1.14 0.454 0.68 1.14

Inch Part Body Input Ports Number Stroke Thread A B C D E F End Side 60463 1/2 1 5/16-16 3 1/4 2 7/8 2 3/4 1/4-28 x 1/4 1 7/32 7/16-20 SAE 1/8-NPT 60464 1 1 5/16-16 3 3/4 3 3/8 2 1/2 3/4 1/4-28 x 1/4 1 7/32 7/16-20 SAE 1/8-NPT 60465 1/2 1 7/8-16 3 1/4 2 7/8 2 1 1/4 1/4-28 x 1/4 1 25/32 7/16-20 SAE 1/8-NPT 60466 1 1 7/8-16 3 3/4 3 3/8 2 1/2 1 1/4 1/4-28 x 1/4 1 25/32 7/16-20 SAE 1/8-NPT

Metric 63213 13 M36 x 1.5 82 73 51 19 M6x1.0(6H)x6 31 1/4-19 BSP 1/8-28 BSP 63214 25 M36 x 1.5 95 86 64 19 M6x1.0(6H)x6 31 1/4-19 BSP 1/8-28 BSP 63216 25 M48 x 1.5 95 86 64 32 M6x1.0(6H)x6 44 1/4-19 BSP 1/8-28 BSPCylinders are supplied with a plug installed in the side port. To use side port, remove plug and install part number 61060 (7/16-20 pipe plug) to plug end port.

Inch Metric

12.7

12.7 12.7

12.7 12.7

14.3

*Port sizes in inch

Threaded CylindersHeavy-Duty

Full-threaded bodies ensure easy mounting and simple length adjustments. Their small size provides high work holding forces in tight places. Threaded Cylinders have hardened piston rods, steel bodies, alloy springs and Tefl on® back-up rings which ensure trouble-free operation and long life. Not suitable for air operation. For mounting, see bracket and jam nuts on next page.

• Compact Design• Easy Installation• Side and Rear Ports• Tapped Piston

Specifi cations

Hardened steel buttons for use on 60463 thru 60466 cylinders.

Threaded CylindersPiston Buttons

Part No. 60471

Part No. 60472

Part No. 60473



Wt. Part No. A (in.) B C D E F G (kg) 60950 1/2-20 34.9 19.1 15.9 23.8 6.4 6.4 0.06 60951 3/4-16 41.3 28.6 25.4 28.6 6.4 6.4 0.15 60959 7/8-14 50.8 19.1 38.1 38.1 9.5 8.3 0.18 60956 1 5/16-16 76.2 31.8 46.0 54.0 11.1 9.9 0.58 60957 1 9/16-16 82.6 38.1 50.8 61.9 11.1 9.9 0.88 60958 1 7/8-16 101.6 50.8 60.3 76.2 12.7 13.1 —

Wt. Part No. A (in.) B C D E (kg) 60952 1 5/16-16 41.3 12.7 31.8 6.7 0.08 60955 1 9/16-16 50.8 25.4 38.1 6.7 0.25 60954 1 7/8-16 57.2 25.4 44.5 8.3 0.28

B

Part No. 60961 60962 60963 60964 60965 60966 60967 Thread (in.) 1/2-20 3/4-16 7/8-14 1-12 1 5/16-16 1 9/16-16 1 7/8-16 Thickness (mm) 7.9 9.5 7.9 13.9 9.9 9.9 11.1Width Across Flats(mm) 19.1 28.6 33.3 41.3 47.6 57.2 76.2

1 inch =25.4 mm

• Material: Low Carbon Steel• Finish: Black Oxide

Flange Mountings

Threaded CylindersBlock Mountings

• Material: Low Carbon Steel• Finish: Black Oxide

Jam Nuts



This principle of “building block” components can be combined with various Jergens cylinders, standard components and mounting blocks or strap clamps; thus allowing an almost infi nite method of production clamping.

Threaded CylinderApplicationsBy replacing step blocks or similar mechanical devices with a threaded cylinder, manual clamping is easily adaptable into a more productive hydraulic clamping set-up.



Inch Tap Part No. A B C D E G K 60301 1.000 2 3/8 2 5/8 1 15/64 1/4-20 x 1/2 7/16 3/8 60307 1.500 2 3/8 2 5/8 1 47/64 3/8-16 x 3/4 7/16 1/2 60303 2.500 2 3/8 2 5/8 2 47/64 3/8-16 x 3/4 7/16 3/4

Metric Tap Part No. A B C D E G K 63101 25.4 60 67 31 M6 x 1.0 x 13 11 9.5 63107 38.1 60 67 44 M10 x 1.5 x 19 11 12.7 63103 63.5 60 67 69 M10 x 1.5 x 19 11 19.0

+0.0127-0.0000

+0.0005-0.0000

Standard CylindersSingle Acting

These single-acting, spring-return cylinders will operate on air or oil; all have a 1" (25.4 mm) stroke.

Single-acting cylinders are especially applicable to large circuits where cylinders are plumbed into the air side of the circuit and used to align parts in the fi xture prior to hydraulic clamping. These applications are primarily pushing type operations where the cylinder return spring pulls only the piston rod.


NOTE: Not recommended for applications where coolant or chips are prevalent. Use double acting style (next page) for these applications

Part Number 60301 60307 60303

OperatingStroke (mm) OperatingVolume (cm3) Effective PistonArea (cm2) Minimum OperatingPressure (bar) Maximum OperatingPressure (bar) Maximum OutputForce (kN) Weight (kg)

Bore Tolerances: +0.0127 Port: 9/16-18 (In.) -0.0254

Specifi cations (Inch)

25.4

7.2

2.8

3

210

6.0

0.23

25.4

20.0

7.9

2

210

16.6

0.45

25.4

51.5

20.3

2

210

42.2

1.36

Part Number 63101 63107 63103


Bore Tolerances: +0.0127 Port: 3/8-19 BSPT -0.0254

Specifi cations (Metric)

25.4

7.2

2.8

3

210

6.0

0.23

25.4

20.0

7.9

2

210

16.6

0.45

25.4

51.5

20.3

2

210

42.2

1.36



Port

Specifi cations (Metric)Part Number 63117 63113 OperatingStroke (mm) 25.4 25.4 OperatingVolume (cm3) 18 51

Effective Piston -Push 7 20 Area (cm2) -Pull 6 17 Minimum Operating Pressure (bar) 1.4 1.4

Maximum OperatingPressure (bar) 210 210

Maximum OutputForce (kN) 15.0 42.2

Weight (kg) 1.1 2

Metric Return Part Tap Port Number A B C D E F (BSPT) G H J K 63117 38.1 61.9 80 63 M10 x 1.5 x 19 1/4-19 24 32 6 12.7 63113 63.5 61.9 80 75 M8 x 1.25 x 19 1/4-19 24 32 6 19.0

Inch Return Part Tap Port Number A B C D E F G H J K 60345 1.500 2 7/16 3 1/8 2 15/32 3/8-16 x 3/4 7/16-20 31/32 1 9/32 1/4 1/2 60341 2.500 2 7/16 3 1/8 2 31/32 3/8-16 x 3/4 7/16-20 31/32 1 9/32 1/4 3/4 60350 1.500 3 1/2 4 1/2 2 15/32 1/4-20 x 1/2 9/16-18 1 7/32 2 11/32 1/4 7/16 60351 2.500 3 1/2 4 15/32 2 31/32 3/8-16 x 3/4 9/16-18 1 3/16 2 11/32 1/4 3/4 60360 1.500 4 1/2 5 1/2 2 15/32 1/4-20 x 1/2 9/16-18 1 7/32 3 11/32 1/4 7/16 60361 2.500 4 1/2 5 15/32 2 31/32 3/8-16 x 3/4 9/16-18 1 3/16 3 11/32 1/4 3/4

Metric:3/8-19 BSPTInch:9/16-18

Standard CylindersDouble Acting

Double Acting Cylinders can be used for clamping, holding positioning, staking, punching...anywhere that a heavy duty cylinder is needed. If the cylinder is mounted in the fi xture (as opposed to using mounting brackets), the fi xture should be bored to between .0005 and .0010 over the “A” dimension. Doing so will prevent an out-of-round condition of the cylinder body which could damage the piston. They may be clamped and/or returned by air or by hydraulic pressure.


Specifi cations (Inch)Part Number 60345 60341 60350 60351 60360 60361OperatingStroke (in.) 1 1 2 2 3 3OperatingVolume (cu. in.) 1.1 3.14 2.2 6.28 3.31 9.42

Effective Piston -Push 1.1 3.14 1.1 3.14 1.1 3.14Area (sq. in.) -Pull .912 2.699 .956 2.699 .956 2.699Minimum OperatingPressure (psi) 20 20 20 20 20 20

Maximum OperatingPressure (psi) 3000 3000 3000 3000 3000 3000

Maximum OutputForce (lbs.) 3300 9300 3300 9300 3300 9300

Weight (lbs.) 2.5 4.5 3.5 6.0 4.75 6.2



(2 Bolts Part Supplied) Wt. Number A B C D E F G (kg) 60907 1 1/4 1 1/2 2 3/8 1 1/2 1.00 3/4 3/8-16 x 1 3/4 0.43 60908 1 1/4 2 3 1/8 2 1/8 1.50 1 1/2-13 x 2 1/4 0.68 60909 1 1/4 3 4 3/8 3 1/4 2.50 1 1/2 5/8-11 x 3 1/4 1.25

(2 Bolts Part Tap Supplied) Wt. Number A B C D E F G H I (kg) 60901 1 1/4 3 3/4 2 3/8 1 1/2 1.00 1/2-13 3/4 2 3/8-16 x 4 1.25 60902 1 1/4 4 3 1/2 2 1/8 1.50 3/4-10 1 2 1/2-13 x 4 1/2 1.59 60903 1 1/4 4 1/2 4 3/8 3 1/4 2.50 3/4-10 1 1/2 2 5/8-11 x 5 2.15

(2 Bolts Part Tap Supplied) Wt. Number A B C D E F G H I J (kg) 60904 1 1/4 3 3/4 2 3/8 1 1/2 1.00 1/2-13 3/4 2 2 9/16 3/8-16 x 1 1/2 1.25 60905 1 1/4 4 3 1/8 2 1/8 1.50 3/4-10 1 2 2 1/2 1/2-13 x 1 1/2 1.59 60906 1 1/4 4 1/2 4 3/8 3 1/4 2.50 3/4-10 1 1/2 2 2 7/16 5/8-11 x 1 1/2 2.15

1 inch =25.4 mm

+0.0127mm -0.0254mm

1 inch =25.4 mm

1 inch =25.4 mm

Mounting Brackets are designed to save you time and money when laying out your fi xture.

All Mounting Brackets are made of low carbon steel, which is not heat-treated. This allows you to custom fi t or weld the brackets into your fi xture. The cylinder clamping area is concentric to the OD of the various cylinders to avoid distortion of the cylinder walls which may cause damage to the piston.

Spacers may be used to add height to the cylinders when using Jergens Mounting Brackets.

• Material: Low Carbon Steel• Finish: Black Oxide• Bore Tolerances: • Available in FixtureProTM Design Software

Standard CylindersMounting Brackets



Standard CylinderApplications

Holding FixtureA Single Acting Cylinder is used to locate and clamp the workpiece in a channel fi xture. The cylinder rod automatically returns when the booster pressure is released.

Vise FixtureA Double Acting Cylinder is being used to operate a Vee Jaw in the above fi xture. Hydraulic pressure is used to clamp and unclamp the jaw. Air pressure, used to return the Double Acting Cylinder, is connected to the air return line of the Booster. Jergens Double Acting Cylinders will operate with as little as 10 psi (0.69 bar)of air pressure or up to 3000 psi (210 bar) of hydraulic pressure.



Single Acting Vertical

Inch:3/8-16 threadMetric:M10x1.5Depth>13mm

Port

Tap

Dimensions (Vertical Style) Mtg. Part Screw Mtg. Number A B C D E F G H J K L M N P Size Thread

60371* 1 3/4 1 3/4 2 1/2 11/16 1 7/8 1 1/8 5/16 1 11/16 1/4 1 13/16 1/4-28 .194 1 9/16 #10 1/4-20 UNF UNC 60373 2 1/2 2 1/2 3 3/16 1 1/2 1 11/32 1 1/4 — — 2 3/32 7/16 2 11/16 3/8-24 .257 1 15/16 5/16 3/8-16 UNF UNC 60374 3 1/2 3 4 2 1 1/2 1 3/4 1 3/4 7/8 — — 3 3/8 1/2-20 — 2 1/4 5/16 3/8-16 UNF UNC 63151* 44 44 64 18 26 22 30 7 44 6 46 M6x1.0 ø5x6 40 M6 M8x1.25 (Metric) Depth>11 Depth>10*Not recommended for applications where coolant or chips are prevalent.

Dimensions (Horizontal Style) Part No. A B C D E F G H J K L M N 60372* 1 3/4 1 3/4 2 7/16 11/16 7/8 7/8 1 3/8 1 15/32 9/32 3/16 2 1/2 .194 63152 44 44 62 17.5 22 22 26 9.22 40 5 4 64 ø5x6

Inch:1/4-28Metric:M6 x 1.0Depth>11mm

Inch:9/16-18 UNFMetric:3/8-19 BSF

Inch:9/16-18 UNFMetric:3/8-19 BSF

Metric

16

*Port sizes in inch

Block CylindersSingle Acting Horizontal

• Vertical and Horizontal Styles• Simple Mounting• Compact Design

Mtg. Screw Inch:5/16-18 Metric:M8

1 inch =25.4 mmSpecifi cations (Both Styles)

Part Number 60371 60372 60373 60374 63151/63151(Metric)Operating Stroke (mm) 16 16 12.7 12.7 16Operating Volume (cm3) 12.6 12.6 18 32 12.6

Effective Piston -Push 7.9 7.9 11.4 20.3 7.9Area (cm2) -Pull Spring Spring Spring Spring Spring Return Return Return Return ReturnMaximum OperatingPressure (bar) 340 340 340 340 340

Maximum OutputForce (kN) 27.7 27.7 40.1 71.2 27.7

Weight (kg) Approx. 1 1 2.27 5 1Mounting Location X As Y X X Position Shown Position Position Position

“X” refers to double mounting hole style.“Y” refers to single mounting hole style.

Inch



Dimensions Part No. A B C D E F G H J K L M N P Stroke Q(in.) 60381 57.15 58.74 76.20 61.91 25.40 28.58 34.13 - - 7.94 7.94 53.18 6.53 49.21 12.70 3/8-24 UNF-2B 60382 57.15 71.44 76.20 74.61 25.40 28.58 34.13 - - 7.94 7.94 53.18 6.53 49.21 25.4 3/8-24 UNF-2B 60383 82.55 82.55 95.25 85.73 38.10 41.28 38.10 44.45 19.05 - - - - 57.15 12.70 1/2-20 UNF-2B 60384 82.55 95.25 95.25 98.43 38.10 41.28 38.10 44.45 19.05 - - - - - 57.15 25.40 1/2-20 UNF-2B

M8

*Port sizes in inch

Block CylindersHeavy Duty Double Acting

• Simple Mounting• Compact Design• High Output Forces

“X” refers to double mounting hole style.“Y” refers to single mounting hole style.

Specifi cationsPart Number 60381 60382 60383 60384Operating Stroke (mm)

Operating Volume (cm3)

Effective Piston -Push Area (cm3) -Pull Minimum OperatingPressure (bar)

Maximum OperatingPressure (bar)

Maximum OutputForce (kN)

Weight (kg) Approx. Mounting Location Y Position X Position

12.7

14.4 11.46.3

1.4

340

40.1

1.81

25.4

29.0 11.46.3

1.4

340

40.1

2.18

12.7

25.7 20.38.8

1.4

340

71.2

4.76

25.4

51.5 20.38.8

1.4

340

71.2

5.49



7.9 mm

10.3

23.8 68.3 (* 87.3 )

92.1 ( *111.1 )

101.6 76.2

74.6

79.4

60.3

*Port sizes in inch

Flange Mount Cylinders

• Easy Mounting• Heavy Duty• High Output Forces• Long Lasting• Available in FixtureProTM Design Software

The Jergens Heavy Duty Flange Mount Cylinders mount through holes on the fl ange of the cylinder body. This feature eliminates the need for separate mounting brackets. The cylinders can provide high forces for clamping, lifting and pressing. Not recommended with fl ood coolant applications.

Specifi cationsPart Number 62721 62722


12.7

31.1

25.2

6.8

340

90.2

2.27

25.4

63.9

25.2

6.8

340

90.2

2.95



Dimensions Across Across Part Thread Flats Tap Flats Port Number A B C D E F G H J K 60596 184.15 71.44 1 9/16-16 44.45 18.26 50.80 19.05 5/16-24 x 1/2 22.23 9/16-18 60598 236.54 100.01 1 7/8-16 63.50 18.26 63.50 19.05 5/16-24 x 1/2 22.23 9/16-18

Intensifi er Cylinders

Intensifi er Cylinders are combination air-hydraulic cylinders. An air powered cylinder is driven into a small oil reservoir which produces a nominal 8:1 or 30:1 power boost ratio, depending upon air pressure and the cylinder used. These miniature, self-contained power sources are ideal where fast action (100 operations per minute), a short stroke and high power are needed.

• 8:1 and 30:1 Boost Ratios• Self-Contained• Fast Acting• Air Controlled• Easy Recharge Without Disassembly• Available in FixtureProTM Design Software

Specifi cationsPart Number 60596 60598OperatingStroke (mm) 6.4 6.4

Force (kN) atInlet Air Pressure 8.6 bar Max. 4.3 16.86.9 bar 3.2 13.25.2 bar 2.0 9.53.4 bar 1.2 5.91.7 bar Min. 0.23 0.20Weight (kg) 1.0 2.04Ratio 8:1 30:1

For Mounting Brackets see page 27.



Intensifi er CylinderApplications

ClampingInstalled in a Jergens Mounting Bracket, the Intensifi er Cylinder provides effi cient, versatile, yet economical clamping.

PositioningA series of plates are gang loaded into the fi xture. Air operation of the intensifi er assures fast and positive positioning of the plates, after which the multiple hydraulic cylinders are used to clamp.

CrimpingThe intensifi ers may be installed at any attitude. Mounted in a vertical attitude (as shown), up to 1.5 tons (15kN) of force is available for crimping, punching, or notching.

Circuit DiagramsA fi lter/regulator and a 3-way hand valve are all that is required to control an Intensifi er Cylinder. Installation is as simple as an air cylinder but the resulting force is much greater.

Staylock Clampswww.jergensinc.com


StayLock Swing Clamp on a Tombstone Fixture

The Swing Clamp rotates 80° away from the workpiece, a l lowing easy loading and unloading of the part. In this application, the tombstone is mounted on a double pallet machining center. When the pallet rotates, the StayLock Clamp remains clamped. There is no need for an accumulator in the hydraulic system. Nor is there a chance of hydraulic h o s e s g e t t i n g t a n g l e d o r accidentally cut while the part is being machined. StayLock Swing Clamps are available in le f t -hand o r r igh t -hand swing styles.

Stays Mechanically Locked– Even When Disconnected from Hydraulic Pressure

StayLock Clamps ...the Hydraulic clamp with the mechanical advantage! With conventional power clamping, when pressure is put to the clamp, it clamps...take the pressure away (on purpose or not), it unclamps. With the StayLock Clamp's patented internal locking mechanism, hydraulic pressure is needed to clamp...and to unclamp!

StayLock Rocker Clamp Holding a Die

The Rocker Clamp is ideal for quick change clamping on dies, molds, and fi xture plates where a standard height subplate is employed. Because of the unique body design of the Rocker Clamp, it can easily be adapted with a T-slot nut mounted on the bottom. This enables the Rocker Clamp to slide in and out, making part removal easier, plus it allows for various widths of subplates or fi xture plates to be used.

StayLock Block Clamp on a Tombstone

The Block Clamp is a multi-purpose utility clamp, utilized, as any StayLock Clamp can be, in either the horizontal or vertical clamping positions. In this application, the Block Clamp (at the top o f the tombstone) is replacing step blocks and tedious manual clamping.



Once clamped, you can:• disconnect your hydraulic power source• move the fi xture, with the part still clamped, to other machines• not worry about your part unclamping due to hydraulic power failure, a cut line, or leaks in the hydraulic system

Patented positive mechanical lock minimizes:• reclamping• set-up costs• parts accidentally becoming unclamped

Jergens StayLock Clamps can provide solutions to many clamping problems. They are designed for use on:• palletized fi xtures• transfer machines• machining centers• any power clamping application• quick change on molds and dies

Use the StayLock Clamps with Jergens Air-Operated Hydraulic Pumps (described on page 63, 64, 65). One Hydraulic Pump can service several machines because there is no need to maintain hydraulic pressure when clamping StayLock Clamps. Once StayLock Clamps are in a clamping position, the hydraulic hoses can be disconnected, and the part will remain clamped indefi nitely. Once the machining cycle is completed, applying hydraulic pressure to the release port unclamps the part.

Positive Mechanical LockJergens StayLock Clamps offer a breakthrough in clamping fl exibility! These mechanically locked clamps are activated and released by hydraulic pressure. Once activated, the clamps automatically lock and will not release until hydraulic pressure is applied to the release port.

Most Commonly Asked QuestionsQ. Does the StayLock Clamp lose pressure?

A. No, it does not. Because of a patented mechanical lock, a positive locking wedge is activated when pressure is applied to the clamp port. There is no need to maintain hydraulic pressure; therefore, the power source can be disconnected. There is no pressure to lose.

Q. How do I lock StayLock Clamps in place?

A. Applying hydraulic pressure to the clamp port of a StayLock Clamp drives two internal wedges together. The two wedges form a mechanical lock and will not retract until hydraulic pressure is applied to the release port.

Q. Can these clamps be used with air?

A. No. Air pressure does not apply enough force to lock or unlock the internal wedge mechanism.

Q. How much hydraulic pressure is needed to activate the clamps?

A. The minimum pressure required on most of the StayLock Clamps is 34.5bar. The minimum and maximum pressure requirements are specifi ed for each clamp on the following pages.

Q. What is needed to set up a hydraulic system using StayLock Clamps?

A. Typically, a system includes several clamps (depending on individual requirements); a power source; a four-way, three-position, zero-leakage control valve (see page 66); and hydraulic hose and fi ttings. There is no need for an accumulator in the system.

Q. Can an air/oil booster be used with StayLock Clamps?

A. No. Boosters typically are used with standard hydraulic clamps because pressure is needed to activate and maintain the clamp in the clamping position. With a Booster set-up, there is only one hydraulic line that provides the pressure needed. StayLock Clamps need pressure to clamp and unclamp; therefore, a Booster would not provide the needed pressure to the release port to unclamp the part.

Q. Can I get technical assistance from Jergens when designing a StayLock Clamping system?

A. Yes. Jergens will assist you by providing a CAD schematic drawing of your system, including all of the part numbers needed to order the system.

For assistance, call 1-800-JERGENS (537-4367).

CUT AWAY ��EW OF TYP�CAL STAY LOC� CLA�P

P�STON

P�STONPLUG P�STON

PLUG

BODY

LOC��NGANGLE

LOC��NGP�N



9/16-18 Port

Clamp Release

M16

M16

116

110

31.8

22

92

43

27

59

145

73

52.4 54.0

50.8 19.1

88

116 92

29.4 24.6 16

22

42.9

22.2

42.9 38.1

27.0

58.7

44.5

88.1

Die/Mold Clamps

U.S. Patents:No. 4,511,127No. 4,471,293

Four models of Die/Mold Clamps are available. Part number 62801 provides 18 kN of output pressure. It is only available in the T-Slot mounting style. The T-Slot mount allows the clamp to be mounted on a machine base via a T-Slot nut, thus allowing the clamp to slide to and from the workpiece. Part number 62802 provides 45 kN of clamping force. It employs standard mounting bolts for permanent mounting to the machine base, subplate, or fixture plate. Part number 62803 also provides 45 kN of clamping force. This clamp is provided with a Sensor Interlock which, when wired to a control panel, indicates

whether the clamp is locked or not. Sensor Interlocks are available as an accessory for part numbers 62801 and 62802. Part number 62804 is similar to part number 62802, except it has a greater clamping range. It does not have mounting holes for the Sensor Interlock. Die/Mold Clamps are available with Viton® seals for high temperature applications.Ideal for:

• Injection molding machines• Die casting machines• Punch presses• Machining centers

Part Number 62803 with Sensor Interlock

Part Number 62802

• Available in FixtureProTM Design Software Part Number 62801 62802 62803 62804Operating Volume (cm3) 16.4 16.4 16.4 16.4Min Operating Pressure (bar) 34 34 34 34Max Operating Pressure (bar) 136 340 340 340Force to Pressure Ratio 13.2:1 13.2:1 13.2:1 13.2:1Clamping Range (mm) 26.2/24.1 26.2/24.1 26.2/24.1 29.2/24.6Max Output Force (kN) 18.1 45.4 45.4 45.4Weight (kg) 4.31 4.31 4.31 4.31

Specifi cations

M16

M12

Part Number 62801 T-Slot Style

Part Number 62804

92



Part No.62816

58.7

38

47.6*Port sizes and Hex in inch

Die/Mold StayLock® Clamp Applications

The Sensor Interlock (62816) can be mounted on the Die/Mold Clamp and is used to indicate that the clamping piston is engaged or disengaged. Because of the minimal movement of the clamping piston, some applications may require more than a visual method of determining if the Die/Mold Clamp is in the clamping position. The Sensor Interlock is a normally open, 110 volt, 6 amp switch. It is supplied with a 1.8 m long wire and mounting hardware to mount in the control panel of a machine. The switch contacts on the Sensor Interlock will only close when the clamping piston is within the clamping range of the Die/Mold Clamp. It is included with Part Number 62803.

Sensor Interlock

Injection Molding Press

Punch Press

The Die/Mold Clamp is mounted (either permanently, or by using T-Slots) on the injection molding machine platen. The mold is mounted on subplates. By standardizing on subplates with the same height and width, several different molds can be used on one injection molding machine. The mold is lowered into the machine, the Die/Mold Clamps are activated, hydraulic connections are removed, and the job is run. A Sensor Interlock can be added to indicate to the operator that the Die/Mold Clamp is clamping. If molds are used that have a clamping slot, either a StayLock Retractable Clamp or a StayLock Rocker Clamp can be used.Die/Mold Clamps are mounted on the Punch Press table either permanently or by using T-Slots. The top and bottom dies are slid into place, hydraulic connections are removed and the job is run.

At changeover time, the hydraulic quick disconnect fi ttings are reconnected, the die is removed and replaced with the next die, and the process is repeated. In some applications on punch presses, the Die/Mold Clamp may create a shut height problem. If this is the case, the StayLock Rocker Clamp is an excellent substitute.




C'BORED FOR 3/4" SHCS4 REQ'D.

CLAMP PORT

3

2

1

9

1

2

3

RELEASE PORT

M5 X .8 X 10MM DEEP(WILL ACCEPT #10-32)

REMOVE 1/8 NPT PLUG FOR MANIFOLD MOUNTING

M12 X 1.0 FOR OPTIONAL PROXIMITY SWITCH

7/16-20UNF SAE PORTS

4

2.56

1.15

4.962 1.34

1 DIA.

.06

.375 STROKE

CLAMPING PISTON

STAYLOCKCLAMP

ADAPTERPLATE

MOLD

PORTS

ROLLERS

SENSOR

76.250.8

25.4

50.8

76.2

25.4229

12650.8 34

102 65

29.2

25.4 Dia.

1.5

9.5

*Port sizes in inch

Large Capacity Mold Clamp

The Jergens Large Capacity Mold Clamp is used on molding machines and wherever heavy clamping forces are required. It has a clamping force of 127 kN. The clamp can be mounted either individually or in series on a manifold.

Part Number 62806Operating Volume (cm3) 115Minimum OperatingPressure (bar) 34.5

Maximum OperatingPressure (bar) 238Force to Pressure Ratio 52.6:1Clamping Stroke 9.7Maximum OutputForce (kN) 127.0

Weight (kg) 19.5

Specifi cations

Proximity SwitchThe Proximity Switch indicates the clamp’s piston position. A single switch is required for each Large Capacity Clamp. Stainless steel construction with 4.9 m, 10-30 VDC.

Typical StayLock Manifold Layout on Injection Molding Machine

Part Number 62817



M12

LED

1/2-20

40 mm

70 mm

3 3/81.56

3/47.02

7.17

1 1/16

1 1/16

7/8

ALTERNATECLAMP PORT(NORMALLY PLUGGED)

1.56

RELEASE PORT9/16-18

ALTERNATERELEASE PORT(NORMALLY PLUGGED)

3/4

CLAMP PORT

9/16-18

4 1/2

SLOT FOR 5/8 SHCS WASHERS INCLUDED2 PL

1.04

4 1.5

M16

102 38

26.4

114

19

39.627

22

182 178

19

27

39.6 86

1/2-20(in.)

*Port sizes in inch

U.S. Patents:No. 4,511,127No. 4,471,293

Retractable ClampsJergens StayLock Retractable Clamps are designed to allow quick change of molds in injection molding machines and die casting machines. The locking arm, which retracts into the clamp body for easy loading and unloading of a mold, is adaptable to clamp many standard mold slots. The Retractable Clamp is double acting and includes alternate clamp and release ports for easier hydraulic plumbing set-up. A Proximity Switch, which indicates the Retractable Clamp is in the extended or retracted position, is also available (see below).

High temperature version available, contact Technical Sales for more information

Proximity SwitchThe Proximity Switch senses the position of the clamping arm within the Retractable Clamp. Two Proximity Switches are required for each clamp. They have a stainless steel housing and are mounted in the Retractable Clamp. One Switch senses the arm extended; the other, the arm retracted. A 4.9 m cord is included with each Proximity Switch, 35-250 VAC.

Part Number 62857

Part Number 62852Operating Volume (cm3) 26.2

Minimum OperatingPressure (bar) 34.5


Force to Pressure Ratio 13.2:1

Clamping Stroke 3.3

Maximum OutputForce (kN) @ 170 (bar) 22.7

Weight (kg) 10.4

Specifi cations



42.9 17.5

Part No. 62841

Part No. 62842

M12

31.412.7

101.6

127

71.4

23.4-25.4

19.1-28.6

70 17.5

17.5 70

Rocker Clamps

U.S. Patents:No. 4,511,127No. 4,471,293

Compact design and dual mounting capability make the Jergens StayLock Rocker Clamp versat i le for many applications. The Rocker Clamps come in two styles. Part number 62841 is typically used with standard height subplates upon which the die, mold, or fi xture plate is mounted. Part number 62842 has an adjustable spindle which adapts to the height of the workpiece. Both styles of Rocker Clamps have drilled and tapped holes on the bottom of the clamp for mounting T-Slot nuts for use on slotted tables. This method of mounting allows the operator to slide the clamp to and from the workpiece for easier part loading and unloading. Bolt down mounting holes are also provided. For mounting applications, contact the Jergens Technical Sales Department.Ideal for:• Holding dies on punch presses• Molds on injection molding machines• Dies on die casting machines• Use on hydraulic fi xtures• Available in FixtureProTM Design Software

Part Number 62841

Part Number 62842

Part Number 62841 62842OperatingVolume (cm3) 11 11

Minimum Operating Pressure (bar) 34.5 34.5


Force to Pressure Ratio 12.5:1 12.5:1Clamping Range (mm) 23.4 to 25.4 2.54*Maximum OutputForce (kN) @138 bar 17.2 17.2

Weight (kg) 3.45 3.45

*After adjustment for height.

Specifi cations



M6

38.1

69.1

27.0

11.9 11.1

27.8

19.1

22.2 6.4

31.8

92.1

108.0

44.5

12.7

38.1

*Port sizes in inch

Mini-Rocker Clamps

Socket Toggle Screw

Part Number

33302 Set Screw/Jam Nut not included

Optional Toggle Pad (Shown in picture)

Part Number 43502

The StayLock Mini-Rocker Clamp is designed for small parts workholding. Like the other StayLock Clamps, the Mini-Rocker can be mounted at any angle. Clamping forces range from 0.9 kN to 3.2 kN. The Mini-Rocker can be used as a single clamp; or because of its unique port arrangement, it can be manifold mounted.

Part Number 62845* 62846**OperatingVolume (cm3) 1.3 1.3

Minimum Operating Pressure (bar) 34 34


Force to Pressure Ratio 13.2:1 13.2:1Clamping Range 2.3 2.3Clamping Force @ 238 bar 3.2 kN 3.2 kNClamping Force @ 68 bar 0.9 kN 0.9 kNWeight (kg) 0.95 0.95

* Includes four plugs & two O-Rings, SAE style, for manifold mounting

** Includes two plugs

Specifi cations



Part No. 62831

Part No. 63816

U.S. Patents:No. 4,511,127No. 4,471,293

Block Clamps

Jergens StayLock Block Clamps are multi-purpose utility clamps designed for many versatile applications. Block Clamps may be mounted for either vertical or horizontal clamping. They may be used with strap clamps or similar workholding devices for maximum adaptability (see illustration below). The Block Clamp plunger has a 1/4 - 28 thread on the I.D. for use with various contact points.


Part Number 62831Operating Volume (cu. in.) 1.1Minimum OperatingPressure (psi) 500

Maximum OperatingPressure (psi) 5,000

Force to Pressure Ratio 2:1Clamping Stroke (in.) .18Maximum OutputForce (lbs.) @ 5,000 psi 10,000

Weight (lbs.) 6.5

Specifi cations Inch

Part Number 63816Operating Volume (cm3) 18Minimum OperatingPressure (bar) 34


Force to Pressure Ratio 12.8:1Clamping Stroke (mm) 4.6Maximum OutputForce (kN) @ 351(bar) 45

Weight (kg) 2.93

Specifi cations Metric



Part No. 62811

13.5

100

70.6

2.3

50.8 28.6

140

32 36.5

132

100

70.6 132

28.6 33.3

322.3

120

*Port sizes in inch

M12

U.S. Patents:No. 4,511,127No. 4,471,293

Toe Clamps

Low Toe Style

Jergens StayLock Toe Clamps are designed for edge gripping of parts when the clamp height must be kept at a minimum, such as in a milling operation. They are available in Low Toe (62811) or High Toe (62812) styles.

Toe Clamps provide two directional clamping forces: one pushes the workpiece against a positive stop, the other pushes it down against the table or fi xture. A brass or steel insert is available on the low toe style Toe Clamp. The inserts must be ordered separately.

IMPORTANT: Jergens 62811 Toe Clamp is supplied without toe insert. Please order one of the inserts below.

• Two special washers which prevent damage by the cap screws are included with each toe clamp. To order washers separately, order Part Number 60636.


High Toe Style

Part Number Insert

60633 Steel 60632 Brass

Part Number 62812

13.5

Part Number 62811Part Number 62812Operating Volume (cm3) 8.2Minimum OperatingPressure (bar) 34


Hydraulic Force in KgfPressure (bar) A* B* 102 540 360 204 1134 816Clamping Stroke (mm) 2.3Maximum OutputForce (kN) @200 bar 11.3

Weight (kg) 3.04

Specifi cations



37.7 52.5

Jergens StayLock Swing Clamps are designed to be used when accessible loading and unloading of a workpiece is required. The clamping arm rotates 80° away from the workpiece. The Swing Clamp operates in any position and is sealed so it can be used with coolant applications.

Important: When using the High Volume Air-Powered Hydraulic Pumps (61761 and 61762), the Flow Limit Valve (shown below) must be used to limit the fl ow of hydraulic oil going to the clamp port of the Swing Clamp. This will extend the life of the clamp by minimizing the clamp arm from slamming into the clamping position.

Specifi cations

U.S. Patents:No. 4,511,127No. 4,471,293

Swing Clamps (Metric)

The Flow Limit Valve restricts the fl ow of oil to dampen the rotating action of the Swing Clamp. It is recommended that the Flow Limit Valve be used with the High Volume Air-Powered Hydraulic Pump (61761 or 61762). It is not needed with the lower volume "Shoebox" Pumps (61755 or 61756).


Flow Limit Valves

Part Number 63603

Part Number (Right Swing) 63801Part Number (Left Swing) 63802Operating Volume (cm3) 20.5Minimum Operating Pressure (bar) 6*/7

Maximum Operating Pressure (bar) 200

Force to Pressure Ratio 8.5:1Clamping Stroke (mm) 5.5Maximum Output Force (kN) @ 200 bar 18

Effective Piston Area (cm2) 8.6Weight (kg) 5.5

*5.4 bar to swing, 7 bar to clamp.

22 HEX

1/4-19 ISO PIPE

3/8-19 ISO PIPE



Jergens StayLock Swing Clamps are designed to be used when accessible loading and unloading of a workpiece is required. The clamping arm rotates 80° away from the workpiece. The Swing Clamp operates in any position and is sealed so it can be used with coolant applications.

Important: When using the High Volume Air-Powered Hydraulic Pumps (61761 and 61762, page 65), the Flow Limit Valve (shown below) must be used to limit the fl ow of hydraulic oil going to the clamp port of the Swing Clamp. This will extend the life of the clamp by minimizing the clamp arm from slamming into the clamping position.

U.S. Patents:No. 4,511,127No. 4,471,293

Swing Clamps (Inch)

The Flow Limit Valve restricts the fl ow of oil to dampen the rotating action of the Swing Clamp. It is recommended that the Flow Limit Valve be used with the High Volume Air-Powered Hydraulic Pump (61761 or 61762). It is not needed with the lower volume "Shoebox" Pumps (61755 or 61756).


Flow Limit Valves

Part Number 61648

Part Number (Right Swing) 62823Part Number (Left Swing) 62824Operating Volume (cu. in.) 1Minimum Operating Pressure (psi) 80*/300

Maximum Operating Pressure (psi) 3,000

Force to Pressure Ratio 1.3:1Clamping Stroke (in.) .18Maximum Output Force (lbs.) @ 3,000 psi 3,900

Weight (lbs.) 11

*80 psi to swing, 300 psi to clamp.

Specifi cations



www.jergensinc.com

If you are currently using bolts, nuts, straps, etc. to hold a part on a fi xture, use this chart to help decide how much hydraulic holding force would be needed to convert the set-up to hydraulic clamping.

P = Induced Tension (kN)T = Torque (N.m)D = Nominal Screw Diameter (mm)K*= Friction, varies with material, fi nish, & lubricity (.19 to .25)*Above values based on K equaling .22

P= T KD

Typical Circuit Diagram of a StayLock Clamping System

Holding Force P (kN) Thread Size D M12 M16 M20 M24

20 8 6 5 4 30 11 9 7 6 40 15 11 9 8 50 19 14 11 9 60 23 17 14 11 70 27 20 16 13 80 30 23 18 15 90 34 26 20 17 100 38 28 23 19 150 – 43 34 28 200 – 57 45 38

* Bold type represents the average torque generated by the operator with a 300mm wrench.

Torque T(N.m)

Converting Manual Power to Hydraulic Pressure

****

R

C

R

C

R

C

R

C

STAYLOCK CLAMPS

MANIFOLDS

QUICK DISCONNECTS

PUMP

4-WAY, 3-POSITION, ZERO-LEAKAGE VALVE

R = RELEASE PORTC = CLAMP PORT

Hydraulic Production Viseswww.jergensinc.com


Jergens hydraulic production vises are developed from convertional vises manufactured by Jergens, with features and advantages as illustrated below. All manual vises produced by Jergens can be modifi ed to be hydraulic vises. As conventional vises, Jergens hydraulic vises can be classifi ed into two types, of which, vise columns are for HMC, options including 3-sided, 4-sided, 6-sided, 8-sided or multi-quads.Universal base and Ball Lock base are available.Customers can purchase the hydraulic vises by referring to the part number of conter vesion of conventional vises.

Hydraulic Production Vise

Fastest Quick Change Jaw System

Maximum Jaw Machinability- Machine “Pockets” into the vise jaws, in the shape of your workpiece.Low profile clamping mechanism allows for maximum jaw machining area.

Maximum Holding Power- Load the workpieces into the vise and machine as required. Machined jaws contoured to hold your workpiece.

150mm MonoQuad

100mm MonoQuad

Single station adapter plate included

Quick change reverseable soft jaws

Production Vise Columns2, 4, 6, 8, 12 and 16 station models available.

Multiple base designs to meet any requirement



Hydraulic Production Vises

• Innovative compact design• Internal hydraulics• 21 kN clamping capacity• Operates on lower input pressure• Fully machineable jaws• Fastest quick-change jaw system• Hardened and ground steel wear rails• Easy-Flow™ base design* Jergens hydraulic vises are available in 3 different base

confi gurations. They offer the same unique features

as Jergens manual vises.

Technical Specifi cations:Hydraulic Clamping Stroke: 6.3mmOperating Volume: 6.6 cm3

Maximum Input Pressure: 275 barMinimum Input Pressure: 35 barInput Port: #4 SAE (7/16-20 UNF-2B)

Clamping Force(kN) = Input Pressure(bars) x 0.0767

Operation:Using the Jergens Hydraulic Vise handle part number 49445 or 49465 tighten vise jaws so the workpieces touch the fi xed jaw. Next,turn the handle back 1/2 turn and activate the hydraulic cylinder.Handle included with vise.

Note: Only use the Jergens Hydraulic Vise Handle Part No. 49445 or 49465 for adjustment purpose, do not use to operate vise.

Input Pressure Clamping Force (bars) (kN) 35 2.7 70 5.4 140 10.8 210 16.1 275* 21.1*Recommended Max

Clamping Force

Hydraulic Accessories Available

Part No.61725

Patent No.:3839866

Pre-Fill Boosters Kit

* See page 56-68 for standard hydraulic power sources.



100

30

85.6

25

40

12

12

75

100

125

120

380

420

100

12mm (2) PlcsLOCATING HOLES:

16mm (4) PlcsFor Sine Fixture Keys

LOCATING HOLES:

MOUNTING HOLESFor M12 SHCS (3) Plcs MOUNTING HOLES:

M10 Tap (6) Plcs

100

30

85.6

32

150

13.5 (4) Plcs

SLOTTEDMOUNTING HOLES:

380

420

175 100

52.5

63.580

150

(2) Plcs

MOUNTING HOLES For M12 SHCS:

16 mm (4) Plcs ForSine Fixture Keys

LOCATING HOLES:

100

30

85.6

20

380

420

75

150200 100

150300

Clearance HoleFor Holddown

20mm Primary Liners(2) Plcs

Universal Base

Ball Lock Base

Narrow Base

• Easy to mount directly to machine tables• Slotted mounting holes

• Designed for use with the Jergens Ball Lock™ mounting system

• Jigsaw pattern allows for “nesting” on Jergens subplate

• Designed for stand alone or fi xture plate mounting

• Slim design enables high density mounting on fi xture plates

Part Number69483

Part Number69485

Part Number69487

100mm Hydraulic Production Vises

152.4

79.4

52.39

381

101

Ø15.88

31.8

31

152.1102177.8

101

31

381

101201

Ø15.88For 5/8 Sine Keys 119.08

12.7

12.7

381

39.37

101

31



Universal Base

Ball Lock Base

Narrow Base

• Easy to mount directly to machine tables• Slotted mounting holes

• Designed for use with the Jergens Ball Lock™ mounting system

• Jigsaw pattern allows for “nesting” on Jergens subplate

• Designed for stand alone or fi xture plate mounting

• Slim design enables high density mounting on fi xture plates

Part Number69484

Part Number69486

Part Number69488

150mm Hydraulic Production Vises

32

85.6

38

150

508

555

225 150

63.5100

200

216

75

200

SLOTTED MOUNTING HOLES:13.5mm (4) Plcs

LOCATING HOLES:16mm (4) Plcs ForSine Fixture Keys

MOUNTING HOLES:For M12 SHCS (6) Plcs

20

85.6

38

150

508

555

100

200

150

300

150250

(2) Plcs

Clearance HoleFor Holddown

20mm Primary Liners

85.6

38

150

508

555

50100

75

125

200

28

28

150

150

LOCATING HOLES:16mm (4) PlcsFor Sine Fixture Keys

MOUNTING HOLES:M10 Tap (6) Plcs

LOCATING HOLES:12mm (2) Plcs

MOUNTING HOLES: For M12 SHCS (4) Plcs

215.9

98.4

229 152

152

37

Ø15.88For 5/8 Sine Keys

152

37

152252

152

37

Ø15.88 For 5/8 Sine Keys

152

152.4

28.6



Jergens Hydraulic Vises incorporate a unique, compact internal operating system. It is recommended that Jergens Power Sources be utilized. However, they will operate from machine sources or most Hydraulic Accessories. Jergens Booster Kit provides a completed power source for hydraulic vises in a compact package. The kit consists of a Jergens 30:1 pre-fi ll self-bleeding booster with filter regulator, 4 way push button actuation valve, plumbed with all fi ttings and hoses.

• Self Bleeding• Easy View Reservoir• 30:1 Boost Ratios

Kit (PN.61725) Includes• Jergens Pre-Fill Booster 61705 (30:1)• Filter Regulator• Actuator Valve

The pre-fi ll booster is ideal for use with Jergens Hydraulic vises and provide maximum effi ciency with minimum effort! Pre-fi ll boosters must be used in the upright (vertical) position. All that is required is air input and output hydraulic lines to the vises. The kit is easy to install and use.

Note: Do not use more than 270 Bar input pressure on Jergens Vises

Patent No. 3839866

Pre-Fill Boosters Kit

Specifi cationsPart Number 61705ReservoirCapacity (Litre) 0.8

High PressureVolume (cm3) 61

MinimumInput (bars) 2.7

MaximumInput (bars) 8.6

Boost Ratio 30:1MaximumOutput (bars) 258.5

Weight (kgs) 13

Part Number61725

Handle

• Ergonomic design• Machined aluminum• Special hex head for Jergens Hydraulic Vise

Part No.

49445

Hydraulic Vise Handle

Pre-Fill Booster only

(For 100 mm and 150mm hydraulic vises)

Hydraulic Accessorieswww.jergensinc.com


M8

117.8 152.4

444.5

362.0

152.4

117.8

Pre-Fill Boosters

• Self Bleeding• Easy View Reservoir• 15:1, 30:1, and 54:1 Boost Ratios

These units offer many more advantages than conventional boosters, while maintaining the same basic simplicity. The pre-fi ll booster has two automatic cycles. The fi rst cycle pre-fi lls the work circuit using low pressure with a large reservoir to provide volume. The second cycle then automatically provides high pressure, as needed. These units also provide automatic bleeding of the work circuit. This self-bleeding feature negates the need to “bleed the lines” after it is set up.

The pre-fi ll booster is ideal for any general use production system requiring maximum effi ciency with minimum effort! Pre-fi ll boosters must be used in the upright (vertical) position.

• Installation Kits Available. See Page 60.• See page 57 for Rapid Exhaust and Rapid Advance Kits,

Handles, and Mounting Bases.

Patent No. 3839866

Specifi cationsPart Number 61704 61705 61706ReservoirCapacity (cm3) 820 820 900

High PressureVolume (cm3) 110 60 33

MinimumInput (bar) 2.7 2.7 2.7

MaximumInput (bar) 8.5 8.5 5.1

Boost Ratio 15:1 30:1 54:1MaximumOutput (bar) 128 255 280

Weight (kg) 12.7 12.7 12.7

*Port sizes in inch



Valve Only

61641

Schematic

BoostersCircuit Diagrams

These kits include everything needed to convert a standard Pre-Fill Booster to high speed operation. Fittings, pre-bent tubing, and the quick exhaust valve are included.

Rapid Exhaust and Advance Kits

Graphic

Accessories

Convert your Pre-Fill Booster to a portable power source. The 62621 handle is for use when the hydraulic gage is mounted on the top of the booster.

PartNumber62621

Handle

RapidAdvance

PartNumber

62215

RapidExhaust

PartNumber62214



117.8152.4

152.4 117.8Specifi cations

Part Number 61709 61710 61711ReservoirCapacity (cm3) 246 246 295

High PressureVolume (cm3) 66 123 62

MinimumInput (bar) 1.4 1.4 1.4

MaximumInput (bar) 8.5 8.5 8.5

Boost Ratio 15:1 15:1 30:1MaximumOutput (bar) 127.6 127.6 255.1

Weight (kg) 9.07 10.88 9.98Height (mm) 265 367 367

Standard Boosters

Base 60973 can be used to mount Jergens Boosters 61709 thru 61711 in a horizontal position.

• Easy to view reservoir• 15:1 and 30:1 boost ratios• May be mounted vertically or horizontally

Valve Only

61641

The Rapid Exhaust Kit includes a valve, muffl er, and fi ttings needed to convert Booster numbers 61709 thru 61711 to high speed operation.

Standard Boosters are ideal for permanent fi xtures, special machines or O.E.M. applications.

The volume of oil available to operate the work circuit depends upon the high pressure capacity of the booster. Work circuits using standard boosters require manual bleeding.

Rapid Exhaust Kit

Installation KitsSee Page 60

Accessories

PartNumber62215

PartNumber60973

Mounting Bases

3/8" TUBE FITTING PROVIDEDFOR EACH INLET AND OUTLET PORT.



Ø8.7 for M8 Mtg. Screw

247.7

277.8

250.8 190.5

Unit must be used only in the horizontal position

• Available in 26:1, 37:1, and 64:1 boost ratios.• High output pressure• High pressure volume

GRAPHIC SCHEMATIC

Circuit Diagrams

High Pressure/Volume Boosters

Specifi cationsPart Number 61720 61721 61722Reservoir Capacity (cm3) 278.6 278.6 278.6High pressure Volume (cm3) 211.4 149.1 86.9Minimum Input (bar) 0.7 0.7 0.7Maximum Input (bar) 8.5 8.5 8.5Boost Ratio 26:1 37:1 64:1Maximum Output (bar) 221 315 544Length (mm) 500 499 495Weight (kg) 12.7 12.7 12.7



Boosters Installation KitsJergens offers four kits to simplify the installation of your Jergens booster. The kits may be used with any Jergens booster.

62203 — This kit is recommended for most applications. The kit includes everything needed to connect your air line to the booster and everything needed to connect the booster to your fi xture.

62204 — This kit should be used when the protection of a pilot check valve is not required, as in punching or staking applications.

62205 — This kit is the same as kit 62203 except the hand valve has been eliminated. Use this kit when the system will be activated by a foot valve, solenoid or pilot operated valve.

62206 — This kit should be used for punching or other applications where no check valve is required and the system will be activated by a foot valve.

Quick 4-Way Air Pilot Hydraulic Disconnect Filter/ Hand Hose Check Hose Couplings Fittings Regulator Valve Muffl er (18 Ft.) Valve (6 Ft.) 61915 as 61617 61615 62613 61108 61629 61205 61965 Req’d. (1) (2) (3) (4) (5) (6) (7) (8)

Jergens recommends the use of a gage kit with any standard booster.

Gage Kit

Part Items Included Number In Kit 62203 1, 2, 3, 4, 5, 6, 7, 8 62204 1, 2, 3, 4, 6, 7, 8 62205 1, 3, 4, 5, 6, 7, 8 62206 1, 3, 4, 6, 8

Selection Data

Part PSI / Bar Number 60711 3000 psi (207 bar) 60712 6000 psi (414 bar) 60713 10000 psi (680 bar)



3 SECOND Clamping Kit

Jergens Pre-Fill Power Pacs provide a complete portable power source. Everything required to power and control your hydraulic fi xture is included. Connect your shop air to the fi lter/regulator, and your fi xture to the hydraulic hose. The self bleeding feature and the hydraulic quick disconnects (provided) make these units the ideal power sources for job shops and production lines.

• Completely Assembled• Self Contained• Portable• Self Bleeding• Fast Set-Up

Pre-Fill Power Pacs

Selection Data Part Included In Power Pac Number Booster Accessories* 61714 61704 1, 2, 3, 5, 6, 7, 8 61715 61705 1, 2, 3, 5, 6, 7, 8*As shown on page 60.

Selection Data

Part Included in Kit Number Booster Accessories* 61717 61711 2, 3, 4, 6, 8, 9 61719 61705 1, 2, 3, 4, 5, 6, 7, 8 61716 61710 2, 3, 4, 6, 8, 9 61718 61704 1, 2, 3, 4, 5, 6, 7, 8*As shown on page 60.

To simplify the installation of Jergens power clamps, Jergens offers its 3 SECOND Clamping Kit. The Kits contain everything required to convert your shop air pressure to hydraulic power for your clamping fi xture.

61717 —This kit contains a 61711 booster, control valve, gage, hoses and fi ttings. This kit should be used for fi xtures which will remain on a machine for long periods of time, such as a vise on a milling machine.

61719 —This kit contains a 61705 booster, control valve, fi lter-regulator, pilot check valve, quick disconnects and all hose and fi ttings required. This kit should be used on machines where the fi xture changes frequently. The 61705 booster eliminates the need to bleed each fi xture after it is connected. To change the fi xture, simply switch the hydraulic hose from one fi xture to the other using quick disconnect fi ttings.



63.5

58.7

123.8

198.4

71.4

This unit is designed to be used on any machine tool with its own hydraulic system where higher pressures are needed. Jergens Intensifi ers will pre-fi ll your circuit at approximately 200 psi (13.6 bar) maximum. Once the Intensifi er sequences over to its high pressure mode, it will deliver one cubic inch of working oil at seven times the input pressure.

Circuit Diagrams

Hydraulic Intensifi er

Specifi cationsPart Number 61701

High PressureVolume (cm3) 16

MinimumInput (bar) 3.4

MaximumInput (bar) 49

Boost Ratio 7:1MaximumOutput (bar) 345

Prefi ll (bar)Adjustments 3.4-13.6

Weight (kg) 2

Not recommended withthe High Volume Pump



Pump PerformanceThe maximum output pressure at no fl ow is somewhat above the nominal ratio times the air drive pressure. This relationship will fall off due to the increased effect of the air drive return spring force (equivalent to approximately 6 psi /0.41 bar air drive at top of stroke, 8 psi /0.55 bar at bottom of stroke). Data is based on standard muffl er arrangement and on fl ooded suction.

Jergens Air-Powered Hydraulic Pumps are used as a power source to activate Hydraulic Clamps. Shop air is introduced into the Filter/Regulator and converted to hydraulic pressure. These pumps are available in two styles: the High Volume Pump (61761 and 61762) with Boost Ratios of 20:1 and 50:1 and the standard, more compact “shoebox” pump (61755 and 61756) with Boost Ratios of 36:1 and 71:1. The Air-Powered Hydraulic Pumps are easy to use, energy effi cient, versatile and affordable. They are completely self-contained and do not require any external reservoirs or motors. NOTE: See page 66 for Valve and Subplate options.

Air-Powered Hydraulic Pumps

Shoebox™ Pumps Breadbox™ Pumps

Part No. 61755 & 61756

Part No. 61761 & 61762



267

76 127

305

394 318

The “Shoebox” Pump is a low cost, compact unit used on smaller hydraulic circuits. Its small size offers the versatility of mounting on wheels (such as a workcart) and moving the pump from workstation to workstation. Like the High Volume Pump, this pump allows independent control of multiple workstations.

Air-Powered Hydraulic PumpsShoebox™ Pumps

Part Number 61755 61756Reservoir Capacity (cm3) 4916 4916Minimum Input (bar) 1.7 1.7Maximum Input (bar) 8.5 5.8Boost Ratio 36:1 71:1Maximum Output (bar) 306 408Free Flow@ 6.8 bar (cm3./min.) 1640 820

Weight (kg) 11 11

Specifi cations

A ten cubic inch (164cm3) accumulator (Part Number 62601) is available to increase the clamping speed if needed. Contact our Technical Sales Department for details.

61755 Performance Curve*120

(1.97)

80(1.31)

40(0.655)

0 1000 2000 3000 4000 5000 (69) (138) (207) (276) (345)

OUTPUT PRESSURE, PSI (BAR)

61756 Performance Curve*60

(0.983)

40(0.655)

20(0.328)

0 2000 4000 6000 8000 10000 (138) (276) (414) (552) (689)

OUTPUT PRESSURE, PSI (BAR)

LIQ

UID

FL

OW

IN3 /M

IN ( L

TR

3 /MIN

)L

IQU

ID F

LO

WIN

3 /MIN

( LT

R3 /M

IN)

* Air Drive Pressure (SOLID Lines) / Air Drive Flow (DASHED Lines)

Part Number 61757 includes: Part Number 61758 includes:

61755 36:1 Pump 61756 71:1 Pump61642 Four-way, 61642 Four-way, zero-leakage valve zero-leakage valve61647 Subplate 61647 Subplate60703 6000 psi (414 bar)gauge 60706 10,000 psi (690 bar)gauge

Pump KitsThe 61757 Pump Kit includes a 61755 Pump (36:1 Ratio), a 61642 Four-Way, Zero-Leakage Valve, a 61647 Subplate, and a 60703 gauge (6000 psi). The valve, subplate and gauge are supplied mounted on the pump.

The 61758 Pump Kit includes a 61756 Pump (71:1 Ratio), a 61642 Four-Way, Zero-Leakage Valve, a 61647 Subplate, and a 60706 gauge (10,000 psi). The valve, subplate and gauge are supplied mounted on the pump.

(6000 psi=414 bar 10000 psi=690 bar)

*Port sizes in inch



523.9

349.3

89

301.6352.4

89

323.9

292.1

High Volume Air-Powered Hydraulic PumpThe Jergens High Volume Air-Powered Hydraulic Pump converts standard and accessible low pressure shop air to hydraulic pressure up to 5000 psi/345 bar. These pumps offer large reservoir capacities and allow independent control of multiple work stations. They are designed to provide high volume output throughout the pump’s entire pressure range.

Breadbox™ Pumps

Air-Powered Hydraulic Pumps

Jergens Air-Powered Hydraulic Pumps are used as a power source to activate StayLock Clamps. Shop air is introduced into the Filter/Regulator and converted to hydraulic pressure. These pumps are available in two styles: the High Volume Pump (61761 and 61762) with Boost Ratios of 20:1 and 50:1 and the standard, more compact “Shoebox” pump (61755 and 61756) with Boost Ratios of 36:1 and 71:1. The Air-Powered Hydraulic Pumps are easy to use, energy effi cient, versatile and affordable. They are completely self-contained and do not require any external reservoirs or motors.

14 28 42 56 70 84 98 112 126 140

61761 Performance CurveKGS/CM2

LB/IN2

OUTPUT PRESSURE

700

600

500

400

300

200

100

0

OU

TP

UT

VO

LU

ME

IN3 /M

IN

11470

9831

8192

6554

4916

3277

1638

0

CM

3 /MIN

35 70 105 140 175 210 246 281 316 351

61762 Performance CurveKGS/CM2

300

250

200

150

100

50

0

4916

4096

3277

2458

1638

819

0

CM

3 /MIN

OU

TP

UT

VO

LU

ME

IN3 /M

IN

LB/IN2

OUTPUT PRESSURE

200 400 600 800 1000 1200 1400 1600 1800 2000

500 1000 1500 2000 2500 3000 3500 4000 4500 5000

Specifi cations

A ten cubic inch (164 cm3(accumulator (Part Number 62601) is available to increase the clamping speed if needed. Contact our Technical Sales Department for details.

Part Number 61761 61762Reservoir Capacity (cm3) 7210 7210Minimum Input (bar) 2.7 2.7Maximum Input (bar) 8.5 6.8Boost Ratio 20:1 50:1Maximum Output (bar) 170 340Free Flow @ 6.8 bar (cm3/min.) 11470 4916Weight (kg) 45.5 45.4

*Port sizes in inch



PORT B9/16-18

GAUGE PORT 1/4 NPT

PORT A9/16-18

4 3/16

3

1 5/8

3/4-16 PORTS(4 PLACES)

2 7/8

7/32 DIAMETERFOR #10 BOLTS

2 7/8

3 3/8

3 3/8

Ø5.6 for M6 Bolts

*Port sizes in inch

*Port sizes in inch

*Port sizes in inch

86

73

73 86

76

106.4

41.3

Valves and Subplates for Air Powered Hydraulic Pumps

Inline Subplate

Subplate for Shoebox Pump

Zero-Leakage Valve

Valve and Subplate

Part Number 61646

Part Number 61642

Part Number 61647

Part Number 61643

For inline applications, use the 61642 Valve mounted on a 61646 Subplate (Order Part Number 61643). This set-up is also recommended for use with High Volume Air-Powered Hydraulic Pumps (61761, 61762) in StayLock and standard applications. For manifold mounting, directly on the pump, the 61647 Subplate and 61642 Valve are recommended. Because the Jergens Air-Powered Hydraulic Pump provides only the necessary hydraulic pressure to clamp and unclamp the StayLock Clamps, the Four-Way, Zero-Leakage Valve is recommended to prevent the unnecessary running of the pump, thus minimizing pump maintenance and wear.



Circuit Diagram

Manual Pumps

These units offer greater versatility than screw pumps. The pumps have a built-in reservoir check valve and control. Single and two stage models are available. Applications are the same as for the screw pump but allow for larger circuits. Circuits require manual bleeding.

Lever Type

Specifi cations Pump Max. Pump Pump Plunger Pump Low-Speed High-Speed Pipe Pump Usable Working Plunger Plunger Displace- Delivery By-Pass By-Pass Thread Handle Model Oil Cap Pressure Dia. Stroke Ment (cm3/ Pressure Pressure Conn. Length Length Width Height Weight No. (cm3) (bar) (mm) (mm) (cm3) Min.) (bar) (bar) (mm) (mm) (mm) (mm) (mm) (kg)

61736 740 690 12.7 25.4 3.1 983 720 - 3/8 NPTF 508 622.3 140 159 7.3 61737 2340 690 12.7 25.4 3.1 983 720 20 3/8 NPTF 508 592.1 178 187 13.2

Manual PumpsApplication

Typical Manual Pump application on a boring mill. The clamping is a self-contained set-up for rotary indexing for large multi-side castings.



www.jergensinc.com

44.5

139.7190.5

31.8

139.7

38.1

120.7

177.8

12.776.2

19.1

The Pallet Decoupler Valve allows hydraulically clamped tooling fi xtures to maintain pressure when disconnected from their power source. The built-in pre-charged accumulator maintains pressure within a hydraulic system, compensating for slow leaks. The Pallet Decoupler Valve adds a level of security to fi xtures that must be disconnected from a power source while being moved. Ideal for use with palletized fi xtures and machining centers.

• Manifold• Accumulator• Hydraulic Connections• Hydraulic Gauge• Manual Ball Valve

Part Number 62605Includes 61965 Male Quick Disconnect

*Port sizes and Hex in inch

Pallet Decoupler Valve

Air Accessorieswww.jergensinc.com


Specifi cations

160 PSI/11barPart Number 60701 60702 60705Thread Size 1/8 NPT 1/4 NPT 1/4 NPTLocation Back Bottom BackWeight (kg) 0.07 0.11 0.11

Air Circuit ControlsAir Filter/Regulators

The fi lter element removes the solid impurities and condensates before the compressed air enters the regulator. The regulator valve supplies a preset pressure regardless of main circuit pressure as long as pressure in the main circuit is higher than that in the secondary.

Specifi cationsPart Number 61616 61617Port Size 1/4 NPT 3/8 NPTSLM Rating 1500 SLM 2260 SLMWeight (kg) 0.73 1.45

Manually adjusted control of input pressures. Allows the regulation of pressures into a work circuit. Reverse fl ow is unrestricted. Used for throttling or metering a circuit so that actuator speed meets work requirements.

Used to reduce air fl ow noise. Installation is recommended at exhaust ports of Air Control Valves.

Air Muffl ers

When sizing a pressure gauge, the maximum output of the system should be approximately 2/3 of the gauge capacity.

Air Gauges

Specifi cations

Part Number 62612 62613Thread Size 1/4 NPT 3/8 NPTWeight (kg) 0.03 0.10

Specifi cations

Part Number 61603Port Size 1/4 NPTWeight (kg) 0.14

Air Flow Control Valve



6.4

5.5

47.6

76.2

44.5

63.55.6

17.5

46.0

54.0

61.9

54.1

92.1

158.8

114.3

196.9139.7

71.3

45.2

63.0

84.1

249.2

244.5

114.370.0

88.9 76.2

87.3101.6

6.7

65.9

A variety of directional control valves are offered. Manual valves are normally two position, detented. Solenoid valves are 115V-60 Hz; other voltages are available.

Part Number 61615 61620 61621 61630 61631*Actuator Type Hand Solenoid Solenoid Treadle PedalReturn Actuator Hand Spring Solenoid Treadle SpringPort Size 3/8 NPT 3/8 NPT 3/8 NPT 3/8 NPT 3/8 NPTKV Rating 1.75 1.17 1.17 2.68 2.68Weight (kg) 1.25 2.27 2.50 1.80 1.60

*Foot Guard for 61631 Valve; Part Number 61632

Air Circuit Controls2-Way and 3-Way Air Valves

2-way valves are in-line ball valves. They are used as a shut-off valve in simple circuits.

3-way valves are similar to 2-way valves but have a third port which is generally used as a vent or exhaust.

Specifi cations

Part Number 61601 61634Type 2-way 3-wayPort Size 3/8 NPT 1/8 NPTWeight (kg) 0.37 0.10

4-Way Air Valves

Specifi cations

Part Number61601

Part Number61634

Part Number61615

Part Number61620 & 61621

Part Number61630 & 61631



Note: 1 bar = 14.507 psi 3000 psi = 207 bar 6000 psi = 414 bar10000 psi = 690 bar

Selection Data Part Number

3000 Psi 6000 Psi 10000 PsiGauge Only 60704 60703 60706Block Only 61055 61055 61055Gauge Kit* 60711 60712 60713

Specifi cationsPart Number 61304Medium Clean, dry compressed air onlyWorking Range 3.4 to 6.8 barTemperatureRange -350C to 800CAir Flow (Liter/Min.) (with Modular Valves)

283 Liter/Min. at 6.8 bar

Exhaust To atmosphere through holes in plateMounting 7/32 holes provided in subplateMaterials Clear Acrylic, brassFiltration 40 Micron requiredLubrication Recommended

Air Circuit Controls2-Hand No Tie Down

Requires the operator to use both hands when activating a work circuit. Two counterbored fi nger buttons are installed at a minimum center distance.

Hydraulic Circuit ControlsGauges

Recommended as a visual pressurized monitoring gauge to be used on all pressuring systems.

When sizing a pressure gauge, the maximum output of the system should equal approximately 2/3 of the gauge capacity.

Gauges are fi lled with glycerine in order to dampen internal movement.

Gauge blocks facilitate the installation of pressure gauges on standard boosters.

* Gauge, Block and Fittings included in kits. All Gauges 1/4" NPT, bottom ported.



Note: 1 bar = 14.507 psi3000 psi = 207 bar5000 psi = 345 bar

173.8

150.0

133.4

84.171.9

71.9 84.1

Hydraulic Circuit Controls2-Way Hydraulic Valves

2-way valves are in-line ball valves. They are used as a shut-off valve in simple circuits.

4-Way Hydraulic Valves

Specifi cationsPart Number 61643 61636 61637 61638Actuator Hand Solenoid Solenoid AirType Zero Leak (115 VAC) (115 VAC)Return Hand Spring Solenoid SpringActuator (115 VAC)Port Size 3/4-16 3/4-16 3/4-16 3/8 NPTFlow Rating 19 L/M 19 L/M 19 L/M 45 L/MPressureRating (bar) 345 345 345 345Weight (kg) 1.70 3.06 3.31 7.94

Dimensions Part Number A B C 61610 68.3 66.7 133.4 61639 76.2 50.8 108

A variety of directional control valves are offered. Manual valves are normally two position, detented. Solenoid valves are 115V-60 Hz; other voltages are available.

For 4-Way,Zero LeakageValves, SeePage 66.

Specifi cationsPart Number 61610 61639Port Size 1/4 NPT 3/8 NPTPressureRating (psi) 3000 5000

Part Number61638

Dimensions Part Number A B C D E F 61636 — 82.6 — 129.0 143.7 — 61637 — 82.6 — 129.0 — 212.7



8.7

12.7mm

8.7

6.46.4

76.2

27.9

31.8

101.6

174.5

31.8

50.825.4

141.765.1

88.9 104.8

76.2

76.2 50.8

63.5

70.0 9.557.2

Hydraulic Circuit ControlsPressure Reducing Valve

Specifi cationsPart Number 61619Port Size 3/8 NPTPressure Rating (bar) 345Regulating Range (bar) 34.5-310

Senses pressure in a circuit and may be used to start or shut down a system. A pressure switch can be used to remove the cutting tool and turn off machine in the event of loss of clamping pressure.

Hydraulic Pressure Switch

Specifi cationsPart Number 61633Port Size 1/4 NPTPressure Rating (bar) 690Regulating Range (bar) 24-345

With adjustable opening pressure, this valve may be used to control the sequence of work devices in a common circuit.

Hydraulic Sequence ValveSpecifi cations

Part Number 61640Port Size 9/16-18Pressure Rating (bar) 345Sequence Range* (bar) 34.5-206

* Factory Adjusted to sequence at 1000 psi.* 1000 psi = 69 bar

Allow individual cylinders or clamps to operate at different pressures from the same power source.

*Port sizes in inch

*Port sizes in inch

*Port sizes in inch



Hydraulic Check Valve

Hydraulic Flow Control Valve

Specifi cations

Part Number 61609Port Size 3/8 NPTPressure Rating (bar) 345Flow Rating KV 0.91Weight (kg) 0.29

• Recommended for use with Jergens Swing Clamps

Hydraulic Circuit ControlsPilot Operated Check Valve

A two-way valve used to lock pressure in a working circuit. Automatic free return fl ow is provided via air pilot operation. Designed so that loss of shop air line pressure will have no effect on the hydraulic circuit in booster applications.

Used to control the fl ow of pressure in a system, to slow the movement of individual cylinders, or decrease shock.

Allows pressure fl ow in one direction only.

Specifi cations Part NumberValve only 61629Valve withInstallation Kit 62211

Specifi cationsPart Number 61607Port Size 3/8 NPTPressureRating (bar) 345Flow Rating KV 0.97Weight (kg) 0.29

Specifi cationsPart Number 61629HydraulicPorts 3/4-16Pilot Port 7/16-20PressureRating (bar) 345

• Minimum operating pressure 500 psi (34.5 bar)

• 50:1 differential pressure• Pilot not to exceed 125 psi (8.6 bar)



0.95 Liter...........................608133.8 Liters ...........................60812208 Liters ..........................60811

0.95 Liter..........................608013.8 Liters ..........................6080219 Liters ...........................60803208 Liters .........................60804

Can be used with air pressure on top of oil to do work in your system, such as returning double acting cylinders with hydraulic pressure. The acrylic reservoir allows easy monitoring of oil level. Special baffl e plates in the top of the reservoir distribute incoming air pressure evenly against the top surface of the oil.

Hydraulic Oil Reservoirs

Part Capacity Side End Wt Number A B (cm3) Ports Ports (kg) 61750 73.0 241.3 295 9/16-18 9/16-18 1.36 61751 122.2 215.9 900 NONE 9/16-18 3.08• Maximum air operating pressure rating 125 PSI (8.6 bar).

Hydraulic FluidsFood Grade Hydraulic OilJergens Food Grade Hydraulic Oil is a blend of food grade lubricants designed for use as a hydraulic media in food packaging and other similar equipment. It is composed of 100% chemically produced synthetic lubricants and contains no petroleum hydrocarbons.

Its viscosity is 140 SUS at 37.8 °C and 725 SUS at 1.7 °C.

Hydraulic OilJergens Hydraulic Oil is specially formulated to minimize foaming and to protect metal parts from rust. It is an aircraft type oil with high wetting out and fi lm strength characteristics.

Its viscosity is 170/190 SUS at 37.8 °C and it maintains functional characteristics down to -31.7 °C.



Ø7.1

63.5

38.1

Specifi cationsMaximum Air Pressure (bar) 10.4

Maximum Vacuum (mmHg) 710Maximum Hydraulic Pressure (bar) 206Maximum Temperature 1200CMaximum Speed (rpm) 250

The six port hex manifold, with SAE straight thread ports, can be mounted in the center of several work units or used with a 61031 union to mount the manifold directly to the output port of your Jergens Booster.

Part Number 61805

Rotary CouplerSingle and Dual Passage

Hydraulic ManifoldStrip

• Material: 1215• Finish: Black Oxide

Hydraulic Hexagonal Manifold

Dimensions Number End Part Of Side Ports Ports Wt. Number Ports A(in.) B C D E (in.) F G H J K (kg) 61801 4 1/4 38.1 15.9 22.2 3/8 44.5 5.2 98.4 25.8 19.1 0.34 61802 8 1/4 38.1 15.9 22.2 3/8 133.4 5.2 187.3 25.8 19.1 0.68NOTE: Maximum operating pressure is 3000 PSI (206 bar) for all manifolds.

Dimensions Rotor Rotor Part Thread Tap Tap Port Hex Hex Tap Lockup Wt. Number A B1 B2 C1 C2 D E F G(In.) H1(In.) H2(In.) I J (kg) 61997 3/8 1/4 — 38.1 — 82.6 28.6 15.9 5/16 7/8 — — 45.2 0.23 NPT NPT 61998 3/4 1/2 1/4 69.9 38.1 195.3 49.2 22.2 1/4 1 3/8 7/8 1/4 73 1.36 NPT NPT NPT NPT






Installation Tips for Plumbing Hydraulic Systems

HoseThe use of hydraulic hose is only recommended when the need for fl exibility exists. Generally, the only hydraulic hose in an application is that used to connect the power source to the fi xture.

All hydraulic hoses expand under pressure. This uses costly energy as well as volume. Some hoses expand at a greater rate than others, even though size remains the same.

Generally speaking, an 2.5 meters length of hydraulic hose will expand at a rate absorbing 16.5 cm3 of high pressure oil at 200 bar.

When applying hose, the following is recommended:

Do Not:• Overextend bend radius of hose.• Put unnecessary strain at fi tting ends.• Subject hose to abrasive conditions.• Use hose that hasn’t been identifi ed.

Do:• Use a minimum size of 3/8" (9.5mm)I.D.• Check with factory for alternate brands.• Use fi resleeve protective covering in applications

where fl ame is present (like weld fi xtures).• Make sure power source has enough high pressure

volume to compensate for hose expansion.

TubingWhenever possible use 3/8" diameter steel fl uid line tubing for hydraulic lines. This is a low carbon, soft tube and readily available. Depending on the application, two types are recommended:

• 3/8" diameter (9.525mm) x .049 (1.245mm) wall thickness for pressures to 3000 p.s.i.(205 bar)

• 3/8" diameter (9.525mm)x .065 (1.651mm)wall thickness for pressures to 5000 p.s.i.(345 bar)

When rigid tubing is applied to air circuitry, use copper tube. This will reduce the corrosive effect of water most likely found in your air lines. Caution: Do not use copper in a high pressure hydraulic circuit!

FittingsPipe Thread FittingsUpon installation, apply a good sealing compound on threads of fi tting only. When Tefl on tape is used, overlap threads 1-1/2 to two turns tightly in direction of thread. Be careful not to extend tape over end of fi tting. Do not overtighten pipe threads as they may put unnecessary strain on pressure vessels.

Straight Thread Fittings (SAE J514)These fi ttings require no sealing material as the built-in o-ring provides a positive seal. The threads are a Class 2 straight thread with no taper. Before installation, be sure to lubricate the o-ring. Tighten these fi ttings to approximately 70-210 N.m.

The Tube FlareCut tube squarely and remove any burrs. Split fl ares may be caused by the tube being too hard, opening up of scratches and draw marks, or failure to deburr tube end.

Place nut, then sleeve onto tube with open end of nut and toe end of sleeve toward end of tube.

Flare to standard 37° angle (maximum diameter of fl are is equal to maximum diameter of sleeve). A correct fl are should extend beyond the inside diameter of toe on sleeve but not beyond outside diameter of toe on sleeve.

Never attempt to spring tube to force alignment using the fi tting installed. This can damage the fl are and wrinkle, kink or fl atten the tube. This can be avoided by using the correct tools.

See following pages for hoses, tubing and fi ttings



Pipe Straight Thread Thread 1/8 NPT x 1/4 Tube 7/16-20 x 1/4 Tube 61014 61040 1/4 NPT x 3/8 Tube 9/16-18 x 3/8 Tube 61027 61041 3/8 NPT x 1/2 Tube 3/4-16 x 1/2 Tube 61043 61042

Fittings37° Flare

Sleeves Nuts Caps Plugs Reducer 1/4 Tube 1/4 Tube 1/4 Tube 1/4 Tube 1/4 Tube Male 61001 61002 61056 61058 3/8 Tube Female 3/8 Tube 3/8 Tube 3/8 Tube 3/8 Tube 61063 61015 61016 61057 61059 1/2 Tube 1/2 Tube 61049 61050

Swivel Nut Union Branch Tees Tee 1/4 Tube 61051 3/8 Tube 3/8 Tube 61062 61023

Pipe Straight Thread Thread 1/8 NPT x 1/4 Tube 7/16-20 x 1/4 Tube 61007 61009 1/8 NPT x 3/8 Tube 9/16-18 x 1/4 Tube 61054 61030 1/4 NPT x 1/4 Tube 9/16-18 x 3/8 Tube 61008 61021 1/4 NPT x 3/8 Tube 3/4-16 x 3/8 Tube 61020 61046 3/8 NPT x 1/4 Tube 3/4-16 x 1/2 Tube 61028 61047 3/8 NPT x 3/8 Tube 61034 3/8 NPT x 1/2 Tube 61048

Pipe Straight Thread Thread 1/8 NPT x 1/4 Tube 7/16-20 x 1/4 Tube 61003 61005 1/4 NPT x 1/4 Tube 9/16-18 x 1/4 Tube 61004 61029 1/4 NPT x 3/8 Tube 9/16-18 x 3/8 Tube 61017 61018 3/8 NPT x 3/8 Tube 3/4-16 x 1/2 Tube 61064 61044 3/8 NPT x 1/2 Tube 61045

Male RunTees

7/16-20 x 1/4 Tube61032

9/16-18 x 3/8 Tube61061

Male Connectors Male Elbows Male Branch Tees

Male Male Union Ferrule Nut Connector Elbow Tee 1/8 Tube 1/8 Tube 1/8 NPT x 1/8 Tube 1/8 Tube 1/8 Tube

60201 60202 60204 60205 60207

Flareless Fittings

These fi ttings are the most common types needed to plumb Pressure Points and Screw Pumps. Use 1/8" Heavy Duty High Pressure, Fluid Line Steel Tube.

45° ELBOW3/8 NPT x 3/8 Tube

61072




Adapters

Pipe Mixed Thread Thread Metric

1/16 NPT Male 1/4 Male NPT 3/8 Tube Male 7/16-20 Male 1/4 NPT Female 1/4 Female BSP 1/4 NPT Female 1/8 ISO Female 61075 60221 60217 61077 1/8 NPT Male 7/16-20 Male 3/8 Male NPT 9/16-18 Male 1/4 NPT Female 1/4 NPT Female 3/8 Female BSP 1/4 ISO Female 61076 61082 60222 61078 9/16-18 Male 3/4-16 Male 3/4-16 Male 1/4 NPT Female 1/4 NPT Female 3/8 ISO Female 61081 61035 61079 9/16-18 Male 3/4-16 Male 3/8 Tube Female 3/8 NPT Female 60211 61036 Elbow 3/4-16 Male 3/8 NPT Female 61065

Fittings

Reducers/Expanders

Pipe Straight Thread Thread

1/4 NPT Male 9/16-18 Male 1/8 NPT Female 7/16-20 Female 61074 61033 3/8 NPT Male 7/16-20 Male 1/4 NPT Female 9/16-18 Female 61025 61080 1/2 NPT Male 3/4-16 Male 3/8 NPT Female 9/16-18 Female 61038 61037 3/4 NPT Male 3/8 NPT Female 61067 3/4 NPT Male 1/2 NPT Female 61039

Elbows & Tees

Elbows Tees 1/8 NPT Female 1/8 NPT Female 61095 61087 1/8 NPT Street 61070 1/4 NPT Female 1/4 NPT Female 61096 61088 1/4 NPT Street 61071 3/8 NPT Female 3/8 NPT Female 61097 61089 3/8 NPT Male 61066 1/2 NPT Female 1/2 NPT Female 61098 61090

Nipples & Plugs

Nipples Plugs

1/8 NPT 1/8 NPT 61083 61091 1/4 NPT 1/4 NPT 61084 61092 3/8 NPT 3/8 NPT 61085 61093 1/2 NPT 1/2 NPT 61086 61094 1/8 NPT x 3/8 NPT 7/16-20 61052 61060 1/4 NPT x 3/8 NPT 9/16-18 61053 61068 9/16-18 Union 3/4-16 60210 61069 3/4-16 Union 61031




www.jergensinc.com

Low Pressure Air HoseHose I.D. 1/4 3/8 1/2HosePart Number 61106 61108 61110FittingPart Number 61107 61109 61111

High Pressure Hydraulic HoseLength (mm) 305 457 610 914 1829Part Number276 bar 61201 61202 61203 61204 61205Part Number480 bar 61211 61212 61213 61214 61215

*Also available in 5000 psi (345 bar).

Steel Tubing Part Number Description

60209 3/8 DIA. X 305 mm

Quick Disconnect Couplers

Steel Tubing

Air Couplers

Length 7620 mm Hose Ends Hose EndsPart Number 61221 61226 61227190 bar 1/4 Hose 1/4 Npt Male 1/4 37° JIC Swivel Female

Hydraulic Hose (Build Your Own)

Hydraulic Hose

Flexible Air HoseLow pressure air hose is sold by the foot in bulk lengths. Order the total footage and number of push-on fi ttings required by using the number to the right.

Whenever possible, 3/8" (9.5mm)diameter steel tubing should be used for hydraulic lines. Jergens tubing is low carbon soft tube with .065 wall thickness. The tubing is rated at 5000 psi (345 bar).

High pressure hose is supplied assembled and to lengths indicated. Lengths are measured from end of coupling to end of coupling. Hose is 3/8" (9.5mm)ID and available in 276 bar or 480 bar rating. 3/8" female tubing fi ttings on each end.

Sleeve Nipple 3/8 NPT Female 3/8 NPT Female 61915 61965 1/4 NPT Female 1/4 NPT Male 61916 61966

Hydraulic couplers have dual checks.

Hydraulic Coupler Sleeve Nipple 1/8 NPT Female 1/8 NPT Male 61904 61950 1/4 NPT Female 1/4 NPT Male 61905 61951 1/4 NPT Female 61954 Air couplers have checks on sleeves only. *Port sizes and Hex in inch






Maintenance Kits

Jergens maintains a qualifi ed staff whose primary responsibility is to provide technical assistance to our distributors and customers.

Your direct connection number for dimensional questions, circuit assistance and troubleshootin is:

1-800-JERGENSOR

E-mail: [email protected]

Part Kit Part Kit Part Kit Part Kit Part Kit Number Number Number Number Number Number Number Number Number Number

60301 6210160302 6210260303 6210360307 6210260340 6210460341 6210560345 6218960350 6212060351 6212160360 6212060361 6212160371 6216760372 6216760373 6216860374 6216960381 6217060382 6217060383 6217160384 6217160401 6210660402 6210660403 62195

60404 6219560405 6212460410 6210660411 6210660412 6210660413 6219560414 6219560461 6212560462 6212660463 6212760464 6212860465 6212960466 6213060511 6213960512 6214060513 6219460554 6215160555 6215160593 62145(1)60594 62146(1)

60595 62147 (1)60596 6217760597 6217860598 6217960601 62102 (2) 62162 (3)60602 62103 (2) 62162 (3)60621 6215460622 6215560631 6215660650 62104 (4) 62189 (5) 62162 (3)60651 62105 (2) 62162 (3)60680 6219060681 6219660685 6213161501 6213361612 6213461514 62134

61623 6216361629 6212361640 6216461701 6213261704 6210761705 6210861709 6210961710 6210961711 6211061714 6210761715 6210861720 6217361721 6217461722 6217561736 6215961737 6216061755 6219761756 6219861761 6214461762 6214461997 6216561998 62166

62176 (6) 62801 62802 62803 6280462721 6216162722 6216162801 6217262802 6217262803 6217262804 6217262805 6230162806 6230262811 6218362812 6218362823 6218462824 6218462831 6218762841 6218562842 6218562845 6230362846 6230362852 62199

(1) Special tools required: use 62148 tool for 60556, use 62149 tool for 60597 or 60598.(2) Cylinder Kit (3) Mechanical Kit (4) Kit for cylinder with 3/8" piston (5) Kit for cylinder with 1/2" piston(6) Tool kit required for 62801, 62802, 62803, 62804

Technical Assistance

Pneumatic Clampswww.jergensinc.com


Pneumatic ClampsHorizontal Hold-Down Action

DE-STA-CO over-center toggle action linkage combined with pneumatic cylinder provides an economical holding device, easily adapted to a wide variety of applications. Units are completely assembled and ready to operate. Flanged washers are supplied with U-Bar models and on solid bar models a bolt retainer is supplied. Models 812 (305208-M) and 802-U (202208-M) are furnished with spindle assemblies.

812

802-U, 807-U, 810-U, 847-U

Jergens Max. De-Sta-Co Part Holding Weight Bar Dimensions(mm) Port Spindle Part Number Capacity(kN) (kg) Opens A B C D E G H J K Size Size Number 58120 0.68 0.21 90° 39.6 142.2 17.5 16.0 23.9 38.1 25.9 4.3 18.5 10-32 NF M5x0.8 812 58020 0.91 0.45 95° 59.4 187.7 26.9 12.7 26.9 55.9 43.7 5.6 25.4 1/8 NPT M6x1.0 802-U 58071 2.3 0.75 92° 76.2 253.0 35.1 19.1 31.8 55.9 79.5 7.1 - 1/8 NPT 5/16-18 807-S 58070 1.6 0.75 92° 76.2 233.9 35.1 19.1 31.8 55.9 63.5 7.1 49.3 1/8 NPT 5/16-18 807-U 58101 3.4 1.85 95° 96.3 308.1 45.7 31.8 45.2 73.2 88.4 8.4 - 1/8 NPT 3/8-16 810-S 58100 2.7 1.85 95° 96.3 311.9 45.7 31.8 45.2 73.2 90.9 8.4 60.7 1/8 NPT 3/8-16 810-U 58470 3.6 4.04 95° 110.2 406.4 57.2 31.8 45.2 91.2 123.2 8.6 80.8 1/8 NPT 1/2-13 847-U



8021

Jergens Max. De-Sta-Co Part Holding Weight Bar Dimensions (mm) Port Spindle Part Number Capacity(kN) (kg) Opens A B C D1 D2 E G H J K Size Size Number 58025 1.8 1.0 90° 55.6 236.5 39.6 20.1 – 38.1 49.5 57.2 5.3 19.1 1/8 NPT 1/4 or M6 8021 58080 2.0 1.3 90° 65.8 277.6 42.2 50.0 9.9 40.1 53.8 69.9 7.1 25.4 1/8 NPT 5/16 or M8 8071 58105 3.2 3.3 90° 88.9 388.6 63.5 89.9 – 55.9 72.9 101.6 8.6 40.6 1/4 NPT 3/8 or M10 8101

Pneumatic ClampsEnclosed Hold-Down

DE-STA-CO’s newest family of pneumatic workholding power hold-down clamps is ideal for dirty environments such as spot and MIG welding. Holding capacities exceed clamp Models 802-U, 807-U, and 810-U. These models also feature an enclosed, protected cylinder rod and linkages, as well as a lower and narrower mounting profi le. Clamps come with magnetic ring for sensing switches as a standard feature. Flanged washers are included with each clamp. Spindles assemblies are optional.

*Port sizes in inch



Jergens Max. De-Sta-Co Part Holding Weight Bar Dimensions Port Part Number Capacity(kN) (kg) Opens A B C D E F G H J K L Sizes Number 58171 2.4 1.05 90° 188.5 171.5 68.1 16.0 25.4 16.0 61.2 77.7 6.9 - 16.0 1/8 NPT 817-S 58170 1.6 1.05 90° 188.5 157.0 68.1 16.0 25.4 16.0 61.2 62.0 6.9 49.3 16.0 1/8 NPT 817-U 58271 2.7 2.14 88° 245.4 219.5 98.6 31.8 44.5 31.8 74.7 81.0 8.6 - 20.1 1/8 NPT 827-S 58270 1.8 2.14 88° 245.4 222.3 98.6 31.8 44.5 31.8 74.7 82.8 8.6 60.7 20.1 1/8 NPT 827-U

Jergens Max. De-Sta-Co Part Holding Weight Plunger Plunger Dimensions (mm) Port Part Number Capacity(kN) (kg) Travel Thread A B C D D1 E F G H J Size Number 58160 0.91 0.20 11.2 8-32 40.1 158.0 14.2 16.0 - 16.0 6.4 33.3 32.5 4.3 10-32 NF 816 58030 2.7 0.84 19.1 5/16-18 69.1 249.4 27.7 36.6 - 33.3 11.2 60.5 54.4 5.8 1/8 NPT 803 58300 11.3 2.91 31.8 3/8-16 82.8 357.6 26.9 35.1 41.1 41.1 15.7 76.2 50.8 8.6 1/8 NPT 830 58500 72.6 7.56 50.8 5/8-11 182.1 537.7 66.8 69.9 - 57.2 25.4 101.6 115.3 10.4 1/8 NPT 850

817-U, 827-U

817-S, 827-S

816 803

830 850

Pneumatic Clamps

Straight Line Action

Many times it is desirable to use a right angle model where space dictates. Applications such as rotary indexing tables and injection molding operations are examples. All three models can be mounted on the side of the fi xture and Models 817 and 827

can also be top mounted. Model 817 is the pneumatic version of Model 317, and it accommodates any 5/16-18 or M8 spindle assembly (not included). Model 827 can accept any 3/8-16 or M10 spindle accessory (not included).

Air powered straight-line action clamps provide an economical holding device suited to a wide variety of uses. Model 816 is supplied with an 8-32 spindle (105203). All other models are not supplied with spindle assemblies.

*Port sizes in inch



Pneumatic Clamps

These models use a roller and cam principle that allow the clamp to clamp work of inconsistent thickness and still maintain a locked condition. Four-way mounting surface offers full mounting fl exibility. Clamp arms can be altered by welding, drilling, or machining to suit the application. Standard mounting plate included.

870 (Clamp shown in closed position)

871 (Clamp shown in closed position)

Mounting Plate

EDP. NO a b c d e f

870116 55.6 44.5 3.0 25.4 44.5 M6

Jergens Max. De-Sta-Co Part Holding Weight Cylinder Dimensions (mm) Part Number Capacity(kN) (kg) Bore A B C D E F G H J K L M Number 58700 9.1 3.17 38.1 1/4 NPT 54.1 289.8 25.4 1120 38.1 6.4 25.4 - 108.0 44.5 19.8 870 58710 9.1 3.17 38.1 1/4 NPT 54.1 298.5 25.4 1260 38.1 6.4 25.4 79.5 - 44.5 19.8 871

*Port sizes in inch



Jergens De-Sta-Co Part Body Dimensions(mm) Port PartNumber Style A B C D E F G H J K L M N P Q R S T Size Number58015 Threaded 58016 Body 124.0 72.9 15.7 1 1/8-16 31.8 - - - - 36.6 - - - - - - - 7.9 #10032 8000

58215 Threaded 58216 Body 161.5 85.3 22.1 2 1/4-12 76.2 29.5 6.4 67.6 - 60.5 - - - - - - - 9.7 1/8 NPT 8200

58415 Threaded 58416 Body 156.0 80.5 22.4 1 3/4-12 54.1 24.9 - - - 49.3 - - - - - - - 9.7 1/8 NPT 8400

Series 8000, 8200, 8400

Pneumatic Clamps Swing Cylinders

These versatile pneumatic clamps provide a quick swing-and-clamp movement while exerting just the force your operation requires… without deforming delicate parts. All pneumatic swing clamps are equipped with sensing capabilities as a standard feature. Multiple mounting options allow the clamp to be adapted to the fi xture for the best use of space and to minimize installa-tion time.

8200 Series

*Port sizes in inch

3 Recessed Mounting Holes on 2.66"

Bolt Circle for 1/4" or M6 SHCS

A

C B

D ThreadUnclamp Port

ClampPort

K

T

E

(Unclamped/Open Position)

8000 Series

AC B

D Thread Unclamp Port

ClampPort

K

TF

E

(Unclamped/Open Position)

8400 Series

Jergens Travel Vertical Maximum Clamping De-Sta-Co Part Arm Spindle Duration Clamp Arm Weight Force (N) Part Number Swing Supplied Supplied Rotation Stroks Length (kg) @5.5 bar Number 58015 RH 801528 305203 11.9 9.7 57.2 0.45 100 8015 58016 LH 801528 305203 11.9 9.7 57.2 0.45 100 8016 58215 RH 821512 485203-AL 19.1 12.7 76.2 1.00 360 8215 58216 LH 821512 485203-AL 19.1 12.7 76.2 1.00 360 8216 58415 RH 841512 485203-AL 19.1 12.7 58.7 0.68 280 8415 58416 LH 841512 485203-AL 19.1 12.7 58.7 0.68 280 8416



Series 8100, 8300

Pneumatic Clamps Swing Cylinders

Jergens Travel Vertical Maximum Clamping De-Sta-Co Part Arm Spindle Duration Clamp Arm Weight Force (N) Part Number Swing Supplied Supplied Rotation Stroks Length (kg) @5.5 bar Number 58115 RH 801528 305203 11.9 9.7 57.2 0.45 100 8115 58116 LH 801528 305203 11.9 9.7 57.2 0.45 100 8116 58315 RH 821512 485203-AL 19.1 12.7 76.2 1.00 360 8315 58316 LH 821512 485203-AL 19.1 12.7 76.2 1.00 360 8316

Jergens De-Sta-Co Part Body Dimensions(mm) Port PartNumber Style A B C D E F G H J K L M N P Q R S T Size Number58115 Block 58116 Style 124.0 88.9 31.8 31.8 15.7 11.9 11.9 25.4 28.4 25.4 6.4 25.4 39.9 8.9 5.1 254.0 #10 7.9 #10032 8100

58315 Block 58316 Style 161.5 108.5 76.2 50.8 25.4 18.3 31.0 57.2 13.5 60.2 11.2 57.2 29.5 16.5 10.2 8.4 60.5 9.7 1/8 NPT 8300



www.jergensinc.com

Jergens De-Sta-Co Part Uses With PartNumber Series No. A B C D E F H Number58033 8000 35.1 17.5 27.4 13.7 5.1 1 1/8-16 12.7 801553 58233 8200 63.5 31.8 53.8 26.9 7.1 2 1/4-12 12.7 821553 58418 8400 50.8 25.4 40.6 20.3 7.1 1 3/4-12 12.7 841550

8215-SO-25 & 27

8215-SO-26 & 28

SUPPLY�5-28V DC

LOAD

BROWN

BLUE

BLACK+

–�

SUPPLY�5-28V DC

LOAD

BLUE

BLACK+

–�BROWN

Switch Information

Switching Logic Normally Open

Operating Voltage 5~28 VDC

Switching Current 50 mA max

Power Rating 1.5 Watts - WARNING: Never exceed rating (Watt=Voltage X Amperage). Permanent damage to sensor will occur.

Voltage Drop 0.5V@25 mA max (8215-SO-26 & 28) 1.2V@25 mA max (8215-SO-25 & 27)Current Consumption 7 mA@24 VDC max (8215-SO-26 & 28) 9 mA@24 VDC max (8215-SO-25 & 27)Leakage Current 0.01 mA max

LED Indicator Red (8215-SO-26 & 28) Green (8215-SO-25 & 27)Cable Robotic Grade, abrasion resistant polyurethane (PUR) jacket, PVC insulation

Operating Frequency 1000 Hz

Magnet Requirement 50 Gauss parallel

Temperature Range 14 to 158°F(-10 to +70°C)Enclosure Classifi cation IP 67 (NEMA 6)Protection Circuit Reverse Polarity, Surge Suppression

Mounting Blocks

Jergens De-Sta-Co Part Lead Part Number NPN/PNP Length Number

58407 PNP 3 Meters (118 inch cable) 8215-SO-25 58423 PNP 1.5 m with pigtail connector 8215-SO-27 58408 NPN 3 Meters (118 inch cable) 8215-SO-26 58424 NPN 1.5 m with pigtail connector 8215-SO-28

Jergens Standard Componentswww.jergensinc.com


Ball LockTM Mounting System

The Ball Lock Mounting System is used as a Quick Change Solution on the following:• CNC Machines• Palletized Fixtures• Stamping• Fabricating• Injection Molding• Packaging Machines• Assembly Machines• EDM• Robotics• Welding Fixtures

Ball Lock™ Mounting System

Jergens Master Catalog Chapter 1



Locating Components

Spring Plungers

Spring Locating Pins Spring Stops

Unlike conventional spring plungers, the Jergens SOLID DRIVE Plunger is one integral piece of steel: hex drive, plunger, and body. No set screw to separate from plunger body, no lost springs to retrieve, no need for “easy-out” tools. Best of all, when adjusting SOLID DRIVE, you can be sure the spring plunger is turning and not just a set screw.

Spring Loaded Devices

Application: to join 2 workpieces• Material: Steel, hardened to Rc 50-55 • Self-Centering and Repeatable to within ± 0.013 mm• Top and bottom half of dowel expand

seperately

Precision Expanding Dowels

Step 1: Remove the top screw, insert the dowel into the locating hole of the fi rst part, and expand the bottom half with a hex wrench.

Step 1: Replace the top screw, slide the locating hole of the second part over the dowel and expand top half with a hex wrench.

Work Jacks provide consistent support and rigidity to odd shaped work-pieces. They are designed to prevent workpiece defl ection under forces created during machining operations. Precision mated locking jaws grip the jackpost from both sides creating a vise-like action.

Work Support Jacks

Sine Fixture Keys locate jigs and fi xtures on machine tool tables and position the part in one operation. They eliminate the need to slot fi xture bases, make step fi xture keys, or drill and tap keys. Simply ream two holes.The unique expansion shaft allows the key to be locked in the fi xture from either the top or the bottom using a standard hex wrench.

Sin Fixture Keys

Step 2Step 1

Bullet Nose Pins are used for aligning two pieces of a fi xture together. The round and relieved style are used in conjunction with a matching bushing to locate radially on the round pin. The fl ats on the relieved pin prevents binding, yet allows a high degree of accuracy to be maintained.

Dowel Pins

Used as reference points for inspection applications in conjunction with Coordinate Measuring Machines to accurately measure the workpiece.

Inspection Balls





Workholding Components

Featured Products

The Jergens patented “Tru-Center” products are the only pad type on the market to provide true center line clamping. The cut-away drawing illustrates how this works. The center line of the pad and the center line of the nut always intersect at the point of contact between the pad and the workpiece.

Tru-Center™ Toggle Products

Adjustable Micro Clamps decrease des ign and set -up t imes for modular fixtures, work cubes, and standard fixtures. Without changing hole locations, clamping range from 12mm to 35mm can be achieved. The clamps are available with either smooth or serrated faces which make them ideal for clamping machined parts, castings, and rough cut stock. The clamps work with a cam action, always following the contour of the workpiece for maximum surface contact.

CAM Clamp

Measured from the centerline, each face of these low profile clamps increases 1mm from the smallest to the largest face.

ID Expansion Clamp

The ID expansion clamp is the ideal way to hold parts on an inside diameter for multiple machining on a vertical or horizontal machining center. The customer machines the mild steel clamp to match the bore of the part ensuring proper fi t. Often times the clamps can be remachined for different size jobs.

Jergens Expanding Micro Clamps allow you to fi xture more parts on your fi xture plates. The unique expanding design can hold two parts at once when used with a positive stop.

Thread Repairs & Reinforcements are Made Quickly

Jergens Keylocking Inserts are easy to use for: • repairing and reinforcing threads• Relocating holes that have been drilled or tapped in the wrong location• Fill holes that are too large

Features:• Thinwall available• Heavy duty / solid style available• Internal&Extenal threaded• Metrc & Inch are available

Threaded Inserts


Expanding MicroTM Clamps




Toggle Clamps

Jergens provides full range of toggle clamps:• Hold Down Horizontal/Vertical • Pull Action Clamps• Squeeze Action Clamps • Toggle Lock Clamp • Pneumatic Clamps

Plunger Style

Hold Down Horizontal

Pull Action Clamps

Hook Style

Heavy Duty Style

Pneumatic Clamps


Squeeze Action



Hold Down Vertical

Hold Down Vertical

Pneumatic Clamps


Documents

TABLE OF CONTENTS - Jergens · PDF fileBlock Clamps.....46 Toe Clamps.....47 Swing Clamps.....48 Hydraulic Vises Hyraulic Vises .....51 Hydraulic Accessories Pre-Fill