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HYDRAULIC POWER PACKHYDRAULIC POWER PACKHYDRAULIC POWER PACKHYDRAULIC POWER PACK HY HY HY HY 85858585+ 2EXHY20+ 2EXHY20+ 2EXHY20+ 2EXHY20

6901690169016901500500500500

DECLARATION OF COMPLIANCEDECLARATION OF COMPLIANCEDECLARATION OF COMPLIANCEDECLARATION OF COMPLIANCE EUROPEAN DIRECTIVE 98/37/CE

CENTRAL FLUID SRLCENTRAL FLUID SRLCENTRAL FLUID SRLCENTRAL FLUID SRL 37030 COLOGNOLA AI COLLI (VR)

ITALIA

WE DECLARE UNDER OUR RESPONSIBILITY THE PRODUCT

HYDRAULIC UNITHYDRAULIC UNITHYDRAULIC UNITHYDRAULIC UNIT

MODEL: HY85+2EXHY20 SERIAL NR: 6901500

CORRESPONDS WITH SAFETY HARDWARE REQUIREMENTS AS PROVIDED IN THE

ATTACHED “I” OF THE POLICY 98/37/CE AND IT FOLLOWS THE LEGISLATIVE PROVISION AS BELOW:

---- POLICY 98/37/CE (EQUIPMENTS SAFETY)POLICY 98/37/CE (EQUIPMENTS SAFETY)POLICY 98/37/CE (EQUIPMENTS SAFETY)POLICY 98/37/CE (EQUIPMENTS SAFETY)

- POLICY 89/336/CEE AND FOLLOWING MODIFICATIONS POLICY 89/336/CEE AND FOLLOWING MODIFICATIONS POLICY 89/336/CEE AND FOLLOWING MODIFICATIONS POLICY 89/336/CEE AND FOLLOWING MODIFICATIONS (ELECTROMAGNETIC COMPATIBILY)(ELECTROMAGNETIC COMPATIBILY)(ELECTROMAGNETIC COMPATIBILY)(ELECTROMAGNETIC COMPATIBILY)

TO VERIFY THE CONFORMITIES WITH LEGISLATIVE PROVISIONS WE COMPARED THE

MACHINE WITH THE FOLLOWING PRESCRIPTIVE DOCUMENTS AND TECHNICAL SPECIFICATIONS:

EN 292EN 292EN 292EN 292----1/1992, EN 2921/1992, EN 2921/1992, EN 2921/1992, EN 292----2/1992, EN 294/1992, EN 414/1993, EN 500812/1992, EN 294/1992, EN 414/1993, EN 500812/1992, EN 294/1992, EN 414/1993, EN 500812/1992, EN 294/1992, EN 414/1993, EN 50081----2/1993,2/1993,2/1993,2/1993,

EN 50082EN 50082EN 50082EN 50082----1/1991, EN 55014/1993, EN 602041/1991, EN 55014/1993, EN 602041/1991, EN 55014/1993, EN 602041/1991, EN 55014/1993, EN 60204----1/1998,1/1998,1/1998,1/1998, EN ISO 3746/1996, ISO 3898, UNI 10011, UNI 10021EN ISO 3746/1996, ISO 3898, UNI 10011, UNI 10021EN ISO 3746/1996, ISO 3898, UNI 10011, UNI 10021EN ISO 3746/1996, ISO 3898, UNI 10011, UNI 10021

CENTRAL FLUID SRLCENTRAL FLUID SRLCENTRAL FLUID SRLCENTRAL FLUID SRL Franco Ferrarese

Colognola ai Colli: 18.04.2013

LISTA TUBI CENTRALE OLEODINAMICA 6901500

DRAGFLOW OIL HOSES POWER PACK HY85+2EXHY20

Oil Length Work. Hose Connection Connection

hose Press. sizen. (mm) (bar) (") 1 2

1 660 R4 1" ¼ FEMALE - 1" ¼ - STRAIGHT FEMALE - 1" ¼ - 90°

2 1130 4SK 1" ¼ SAE6000 - 1" ¼ - STRAIGHT SAE6000 - 1" ¼ - 90°

3 1070 R2 1" ¼ SAE3000 - 1" ¼ - STRAIGHT SAE3000 - 1" ¼ - STRAIGHT

4 660 R1 1" FEMALE - 1" - STRAIGHT FEMALE - 1" - STRAIGHT

5 1600 R1 1" FEMALE - 1" - STRAIGHT FEMALE - 1" - 90°

6 740 R1 1" FEMALE - 1" - STRAIGHT FEMALE - 1" - 90°

7 870 R1 1" FEMALE - 1" - STRAIGHT FEMALE - 1" - 90°

8 680 R1 ¼" FEMALE - ¼" - STRAIGHT FEMALE - ¼" - 90°

FIRST START

Operation at the first start of the hydraulic control system: 1 - Cleaning control (pipes and flow) 2 - Oil level control (on the oil tank) See the least and the highest level on the side of oil tank If it is necessary, add other oil 3 - To fill with hydraulic oil the piston pump and motors To introduce filtered oil on the hole of full 4 - Enter ball cock must be open The levers must be in line with the pipes 5 - Manipulators levers must be in the zero point The levers must be horizontal 6 - Start diesel motor at 1/3 of the maximum power (600 l/1’) After 10” make off the diesel motor 7 - Repeat step 6 (10 times) Pump pressure around zero 8 - Regualtion: diesel motor max 1800 l/1’ Is possible to screw or unscrew the regulator 9 - To regulate the fluid quantity, move the manipulators levers 10 - Filtration: The filter element obstructed is indicated by a red signal on the filter

OPERATING INSTRUCTIONS FOR HYDRAULIC CONTROL SYSTEM

Installation of the hydraulic unit The units should be installed on level and firm ground. The smaller units should, where possible, be firmly bolted to the floor or ground. Care should be taken to ensure that the oil sight-glasses and oil drain screws are easily accessible and that there is sufficient space for removal of electric motor, pump and filter elements. Sufficient space should be allowed for a lifting tackle for the heavier items. The manholes and the plumbing from them should also be easily accessible to allow retightening of joints. The hydraulic unit should be installed such that is not subjected to large temperature variations or to adverse weather conditions in order to avoid e.g. condensation and rust formation. Caution If the equipment is cleaned with solvents such as trichlorethylene or with thinners, care must be taken to ensure that the solvent does not enter the oil reservoir via the joints. The oil resistant inner coating would otherwise be attacked by the solvent and the oil resistant varnish could in time be lifted. Where the oil is returned from an oil collection channel to the reservoir the strainer must be covered. Plumbing The hydraulic unit has to be plumbed to the control units and power cylinders in accordance with the pipe plan. The pipework of the plant should be executed using seamless precision steel pipes made of special steel (St 35) in accordance with standard DIN 2391/C, bright-annealed, scale-free and bonderised both inside and out. The bending radii of these steel pipes should be about 2,3 times the outside diameter of the pipes. Under no circumstances should smaller radii be used. The pipes should be bent cold. If, execptionally, heating cannot be avoided, it is essential to subsequently descale the pipes. This can best be achieved by a pickling purge, followed by copius flushing of the pipes with clean water. All pipe edges must be carefully deburred. The pipes should be cleaned before assembly with compressed air to remove any swarf. In the case of water-cooled units, the water flow should be regulated upstream of the cooling coil, or heat exchanger, to avoid excessive pressure in the coil or heat exchanger. A drain point should be provided at the lowest part of the cooling water pipe so that the water can be drained under freezing conditions. A shut-off valve should be provided upstream of the water flow regulator. Recheck that everything is properly connected up. Defective plumbing will usually be noticed only when the plant is started up and it is found that it does not perform as intended. It is then generally very difficult to change the plumbing. A very careful check of the

plumbing and wiring against the pipe plans and wiring diagrams and sequence charts is therefore strongly recommended. Wiring Motor Make sure that the mains supply (voltage, phase) agrees with name plate data of the motor. Then connect the motor correctly. The terminal allocation is usually found in the cover of the junction box. The motor should be switched on only when starting up the plant. Control units Make sure than the main supply (voltage, phase) agrees with the name plate of the equipment. Before starting up the plant all solenoids should be tested without pressure for proper operation. The directions given in the enclosed sheets should also be followed carefully. Level-switch Special care should be taken to ensure that the level-switches are correctly wired. Oil heater Connect in accordance with the enclosed sheet. Never switch on the heater for a prolonged period when the oil is not in circulation. Junction boxes For connection and maintenance refer to the enclosed terminal allocation and wiring diagrams. Oil tanks Recheck that everything is clean. Make sure the oil tank and pipes are scrupulously clean before filling with hydraulic fluid. It is important that this be carried out immediately before filling. If necessary the whole plant should be flushed. If the internal surfaces of the oil tanks have been painted, ensure that the fluid used is compatible with the paint. When using flame-resistant fluids it must be ensured that all hydraulic equipment in the complete plant uses seals which are resistant against flame-resistant fluids. This check should not only cover valves and pumps but must also, where applicable, be extended to screw connections and flanges. Filling with oil The oil tank should be filled to the centre of the upper sight-glass with the hydraulic fluid specified in the test certificate. If the test certificate specified Esso-Esstic 50 fluid, equivalents fluids from other suppliers can be used in accordance with the list of recommended oils given below.

The oil grade has to be chosen according to its viscosity characteristics. A viscosity of 29,5 to 45 mm2/s at the highest operating temperature should be ensured. Thus, the higher the expected operating temperature the thicker the oil is required. On the other hand thick oils cause difficulties when starting-up at low ambient temperatures so that, if necessary, oils of different viscosities should be used in winter and in summer. Filling takes place at the filler plug. The greatest possible regard must be paid to cleanliness, because the oil circuit is filtered only in the return branch. Filling should be carried out by means of a funnel fitted with a fine mesh strainer. Accumulator Do not use oxygen. Risk of explosion. The specified initial pressure refers to an empty accumulator, that is to one which does not contain hydraulic oil. Before filling, therefore, the accumulator drain cock which is located in an appropriate part of the hydraulic unit must be opened. The accumulator is not empty until the pressure side of the plant is completely depressurised with the pump switched orr (pressure gauge). If the accumulator uses an expansion balloon or diaphragm then before initial filling with gas it must first be filled with oil and then completely drained so that an oil cushion is formed which will prevent damage to the balloon or diaphragm when filling with gas takes place. In any event however the filling and operating instructions supplied by the supplier of the accumulator must be carefully followed. After filling the accumulator the drain screw should be securely tightened. The plant is now ready for use. No soldering, welding or machining work must be carried out on the accumulator. The name plate must not be overpainted, in order to maintain legibility of the data.

Gas filling apparatus The gas filling apparatus serves to fill the accumulator with nitrogen at its initial filling, for subsequent topping up and also to check the initial pressure. Application All new accumulators are filled to a pressure or 10 bar. Method of filling the accumulator The protective cap of the accumulator must be removed. The cover on the gas valve must likewise be removed. Screw the valve head on the gas valve. Ensure that the threaded spindle is screwed completely out (left-hand rotation). If the spindle protrudes the gas valve will be damaged. The adapter is screwed on to the gas cylinder. The drain valve must be closed.

Filling the accumulator The shut-off valve on the nitrogen cylinder should be slightly opened so that nitrogen can enter the accumulator. At short intervals close the shut-off valve on the nitrogen cylinder and check the accumulator pressure on the pressure gauge. When the required pressure has been reached, wait about 10 minutes for the temperature to equalise (the filling process cools the gas). After the temperature has stabilised the accumulator pressure must be checked again. If necessary refill with more nitrogen. Checking the nitrogen pressure To check the nitrogen pressure turn the threaded spindle slightly in a clockwise direction, but only until the pressure gauge registers a pressure. The valve on the nitrogen cylinder must be kept closed while this measurement is being taken. Release of nitrogen from the accumulator The threaded spindle on the valve head is turned slightly as when checking the pressure. Nitrogen can be released by means of the drain valve. It is again recommended to wait a few minutes until complete stabilisation of pressure has taken place. After completing the operation turn the spindle fully anti-clockwise. Unscrew the gas filling apparatus from the hydraulic accumulator. Replace the accumulator gas valve cap. Test the gas valve for gas-tightness by applying soap suds. Replace the protective cover. Junction boxes The junction box is made of sheet steel to protection class IP 43. It is provided with terminal strips of rated voltage 500 V. The terminals are individually numbered in sequence and wired in accordance with the terminal diagram. Stopcocks Where stopcocks are used without limit switches downstream of hydraulic pumps or in suction lines the greatest care must be taken to ensure that the pumps are never operated with the stopcock closed, otherwise the pumps could suffer severe damage. For safety reasons these stopcocks should therefore be sealed in the open position. If during maintenance work (or for some other reason) the seal is removed it is essential to ensure that the stopcock is re-sealed in the open position before the plant is again put into operation. Notice: Every stopcock in the hydraulic unit has a label with the inscription: “Do not remove the seal, unless the stopcock is equipped with a limit switch fully wired into the control circuit”.

Operation It is recommended to read carefully the maker’s instructions on pump units and motors before use. Most units are started without load, but some under load. Again other must be started in a given sequence. This is especially the case with auxiliary and accessory devices operated by the same driveshaft. Priming may also be necessary for certain pumps depending on the suction head and the frictional losses. Before strarting up make certain that all the valves in the system (especially on the suction and delivery sides) are fully open. Turn the pressure valve of the pump (the main pressure valve) to zero and check that the dump valve (allowing the fluid to be returned to the reservoir) is in the correct position. Manually rotate the motor for approx. 20 revolutions. This ensures prelubrication of the pump. Switch on the motor briefly several times and observe the direction of rotation. This can easily be verified by observing the fan blades as they come to a standstill. Rotation in the wrong direction result in severe pump damage. The direction of rotation of the motor is indicated by an arrow. Usually the direction of rotation of the pump, looked at from the drive side, is clockwise. If the motor rotation is incorrect, two leads of the motor terminals should be reversed. Important The motor must not, even momentarily, be switched on to check the direction of rotation without closing the delivery connection of the unit or connecting it to the return line, because otherwise oil will be ejected from the delivery connection. Let the pumps operate for about 10 minutes without back pressure. When starting up the plant from cold conditions, it should be operated for about 15 minutes at reduced pressure to warm up the oil (the main pressure valve should be set so that the motor is not overloaded). Trial run The dump valve of the pump should be closed and an examination made to see whether there is another connection to the reservoir via valves connected in parallel. In this case any such valve should also be closed. Slowly adjust the main pressure valve to the pressure given on the schermatic. The pressure should not, even when the equipment is warm, exceed the pressure stated on the name plate. Please note that when the oil is cold a higher pressure is present at the relief valve. It is therefore normal that the pressure drops slightly as the oil warms up. Where the installation is equipped with an accumulator, it should be noted that the accumulator is charged first, which may take some time, depending upon the capacity of the pumps, and this will be apparent by a slow increase in the gauge reading once the accumulator has reached full pressure. The pressure gauge valve is very heavily damped so that the pressure in the manometer builds up only very slowly. It is therefore necessary to depress the button for a few seconds. Partially close main pressure valve and fill the pipe system at a lower pressure.

When a plant is put into operation for the first time and the system filled with hydraulic fluid, the fluid level in the reservoir must be watched to make sure that the level does not fall below the minimum suction level. If gurgling sounds are heard in the pump (indicating presence of air) switch off the pump (indicating presence of air) switch off the pump immediately and top op with fluid. It should be noted that initial filling of the pipework, valves and fittings required additional oil which during operation will not be returned to the reservoir. For this reason, when necessary, make good by topping up with oil. Make sure that single acting cylinders are in the retracted position since their oil volume has to be accommodated by the reservoir. The temperature of the hydraulic fluid, pumps and motors must be constantly monitored. The pipework in general and particularly the unions must be continuously examinaded for leaks, and if necessary tightened. Venting During initial operation of the plant it may be necessary to vent the delivery pipes in order to obtain a smooth flow of hydraulic fluid and to reduce noise. This can be done at a suitable point in the delivery line or by slackening the delivery connection, until a bubble free flow of oil is obtained. The plant must not to be operated under load it has been vented. The cylinders and pipework must be completely vented. The cylinder must be kept in the retracted position and with pressure applied until bubble free oil emerges from the slackened vent screws. Insufficintly vented installations can be recognised by the following symptoms:

1 - Oil foam in the reservoir 2 - Loud noises 3 - Erratic movement of the piston rods or cylinders 4 - Brief clucking noises

If not specified otherwise, it is often advantageous to operate pumps or motors with variable delivery at about half stroke, so as to facilitate the initial flow. If after 10 minutes of operation the installation is still not completely vented it can nevertheless be put in to operation because the remaining air will be expelled during normal operation. The filters should be examined every 2 to 3 hours and if necessary cleaned during commissioning.

Maintenance General hints The question of maintenance, and especially of preventive maintenance of the plant, should already be considered during the design stage. By arranging to have a ball-cock in front of a pump or a distributor, it is often possible to avoid having to drain the oil reservoir in order to carry out repairs, or to have unnecessary oil spillage with all the unpleasant cleaning tasks which it entails. The operational reliability of a hydraulic plant depends primarily on meticulous maintenance. Contrary to a widespread belief, the life of almost all hydraulic components in an installation is greater than that of the mechanical components, such as, for example, ball bearings. A life of 10 years or more is nowadays by no means exceptional. As already stated above the life of a hydraulic plant is, with proper maintenance, determined by the life of its mechanical parts. In the case of pumps the life is normally limited by the life of the bearings which will last for 5.000 to 10.000 operating hours. With valves the life is governed by the number of times the valve is actuated. A life for 10 million actuations is not exceptional. The life of the pressure relief valves depends upon the active time, that is the time during which oil is by-passed. As this time is generally very difficult to determine one can only take the operating time of the whole plant as a measure of the life of the pressure relief valves. In some cases it is a wise precaution to replace the pressure relief valves 2000 to 3000 hours of operation of the plant. It is generally recommended to establish a maintenance during commissioning, which will subsequently be handed to maintenance personnel. In this manual, details can be recorded, for example, of the times at which varius parts of the plant should be inspected. The components of safety control systems should be inspected at fixed intervals both as regards condition and effectiveness. In this connection all parts should be examined for wear and performance. The interval will depend upon such factors as rate of dirt accumulation in the fluid, switching frequency, duration of use, pressure and temperature. These factors, singly or in combination, may shorten the interval which can be allowed between successive maintenance operations. The oil level should be checked continually during commissioning, subsequently at daily and weekly intervals. The main and control pressures should be checked at least once a week. The individual pressure adjustments are required, this can be an indication of wear in the pressure relief valve. The temperature should be measured not only in the oil reservoir, but also, amongst other places, at the pump bearings. A temperature increase is an indication of wear or deterioration. (Increased friction and leakage conversion of hydraulic energy into heat). Filling with oil The need for an oil change depends on several operational factors and on the degree to which the oil has aged or become contaminated. In the case of new plant with larger reservoirs (40 litres and upwards) the oil must initially be changed after 300 to 500 hours of operation. Further oil changes will depend on the prevailing circumstances. In most cases they will be required every 1500 to 3000 hours, but in any case at least once year. It is recommended to carry out the oil change with the oil operating temperature and in summer.

If, for operational reasons, the oil has to be changed in winter, then it can be carefully warmed to about 50°C in order to make it flow more easily. Immersion heaters should not be used because of their high specific heat output. Once a choice of a particular oil grade has been made one should not depart from it. If for any reason the use of a different oil cannot be avoided the plant should be thoroughly flushed with the new oil grade. The oil is drained via the drain plugs of the oil reservoir. It can also however be removed by means of a pump, either through the oil filler or at the suction pipe fitting (R 1”). Checking the oil level Assuming no leaks are present, the oil level should be checked daily after commissioning of the plant. For routine oil inspection it suffices to take an oil sample weekly and to let it run through a filter paper or a clean cloth. The colour of the residue allows certain conclusions to be drawn about the degree of aging of the oil. If the colour is a bluish black an oil change is urgently needed. Pipe fittings The pipe fittings should be retightened 20 to 30 hours after initial start up. The pipework should be checked at regular intervals for leaks. This is particularly important with underfloor pipework, because leaking oil can quickly destroy the concrete floor. Moreover there is the danger that, through loss of oil, the level in the reservoir drops and the pumps are damaged. Pipes, especially those exposed to the effects of weather, should be protected against corrosion. The usual method is to prime the pipes with red lead or to use a spray which applies a wax type corrosion proof coating. Return flow filters One of essential conditions for reliable operation of hydraulic plants is careful filtering of the hydraulic fluid. The retention of even the smallest particles of dirt in the filter elements ensures that all items of the hydraulic installation are kept in proper condition, and premature wear is avoided. During commissioning the return flow filters must be inspected every 2 to 3 hours and cleaned if necessary. Subsequently the return flow filter should be cleaned daily for a week and then according to need. The filter elements should be cleaned at least every 250 hours of operation and at every oil change. After having removed the cover screws and filter cover, the filter element can be taken out. The element should be cleaned with petrol and dried with compressed air. The filter housing should be thoroughly cleaned and rinsed at every oil change. If any residue persists after cleaning and rinsing, this should never be removed with a rag or cotton waste but instead a soft bristle brush should be used. During installation in reverse order, take care to ensure that the mating surfaces and seals are clean and undamaged.

Pressure filters Pressure filters are normally provided at points where a high fluid is required. Maintenance of a pressure filter must therefore be especially attended to. During commissioning the pressure filters should be checked every 2 to 3 hours and if necessary cleaned. Subsequently they should be cleaned daily for a week and thereafter as required. They should be cleaned at least every 250 hours of operation and at every oil change. In general the cleaning interval must be determined according to the rate of deterioration and the prevailing conditions. Before slackening the filter bowl ensure that the line is fully depressurised. The bowl can then be unscrewed. As the filter always contains some remains of oil it is best to withdraw immediately the filter element after having removed the bowl, and to let it drop into the bowl held underneath it. In this way most of the remaining oil can be collected. Now the filter element can be exchanged for a new one, and the filter bowl cleaned with petrol. Rags or cleaning wool should never be used to remove persistent residue. Instead the residue should be removed with a brush. To install the filter proceed in the reverse order. Make sure that the seals and mating surfaces are clean and undamaged. Oil bath type air filters Oil bath filters serve to clean the aspirated air by mean of a metal wool element. The filtration will, however, be satisfactory only if the element is soaked with clean oil. (Use engine oil or viscous hydraulic oil.) Generally, the air filter should be cleaned and oiled once a month, depending on operational factors and the dust load. Before removing the air filter any dirt in the area should be wiped off in order to prevent contamination of the reservoir. After removal of the clamp the element can be withdrawn and should be cleaned thoroughly with petrol. If available, dry the element with compressed air. The filter element must be carefully dried after cleaning. Finally, the element should be wetted with a few drops of oil. Overoiling reduces the effectiveness. If oiling is only possible by immersion then the excess oil should be shaken off. Air dryer The combined fitler-dryer consists of a dryer and an air filter. The dryer is filled with a drying agent. The ambient air is drawn in through the air filter and mechanically cleaned. As it passes over the drying agent the moisture in the air is removed by chemical action. Maintenance After having slackened the wing nuts for about 10 mm, the cover can be lifted and the perspex cylinder removed. The drying agent can now be removed or reactivated. After replacing the cylinder the wing nuts should be retightened.

Trouble shooting 1. Fault: No pressure. No oil delivery. Pump has no suction.

1.1 Cause: Wrong rotation of drive motor. Remedy: Read the operation instructions. Reverse the direction of rotation.

1.2 Cause: Delivery line pressurised, thus the pump cannot vent itself. Remedy: Switch to dump mode or attach hose from delivery side to reservoir. 1.3 Cause: Hydraulic fluid too viscous or too cold.

Remedy: Use a hydraulic fluid with a viscosity commensurate with the operating temperature.

1.4 Cause: In the case of variable delivery pumps: adjusted to mid delivery. Remedy: Actuate to obtain desired delivery. 1.5 Cause: Suction line leaks.

Remedy: Tighten unions, check flange gaskets, renew sealing tape, if necessary to find leak remove complete suction line and pressure test.

1.6 Cause: Valves (in valve type piston pump) stuck. Remedy: Let the oil filled plant stand for a while then briefly start the motor several times. 2. Fault: Oil delivery for a short time, then stops. Delivery ceases despite running motor. 2.1 Cause: Pump has emptied the reservoir.

Remedy: Fill up with hydraulic oil. 2.2 Cause: Suction line leaks.

Remedy: Tighten unions, check flange gaskets, renew sailing tape, if necessary, to find leak remove complete suction line and pressure test.

2.3 Cause: Coupling damaged. Remedy: Replace coupling. 2.4 Cause: Pump shaft sheared off. Remedy: Return to manufacturer for repair.

2.5 Cause: Excessive back pressure at the pump, e.g. delivery flow = leak oil flow (internal or external leakage). The pump is therefore generating the pressure but without oil flow.

3. Fault: The pump is delivering oil, but does not reach the required pressure.

(It is not the pump which determines the pressure produced but the resistance offered to it.) The pump does not produce any pressure (except a few bars due to the flow resistance in the circuit). 3.1 Cause: Dump valve in open position.

Remedy: Check operation of dump valve, if necessary remove and close connection with ball. For a normally open “dump valve” check whether the solenoid is energised.

3.2 Cause: Defective pressure relief valve. Remedy: Check or replace valve. Also check pressure regulating valve. 3.3 Cause: Pipe breakage unterneath reservoir cover. Pipe union not sufficiently tightened.

Remedy: Locate the source of the fault through the inspection cover, otherwise remove and check. In the case of valve type piston pumps and diffucult access it may be preferable to pressure test the delivery line using an external source.

3.4 Cause: Defective pressure indication. Remedy: Check or dismantle pressure gauge

3.5 Cause: The dump valve is closed but has excessive leakage in relation to the delivery rate of the pump.

Remedy: Check the operation of the dump valve, if necessary remove it and close the connection with a ball. In the case of a normally open “dump valve” check whether the solenoid is energised.

3.6 Cause: Relief valve with excessively worn conical seat resulting in more or less unhindered flow (especially with pumps with a low delivery rate).

Remedy: Check or exchange valve. Also check the control valve. 3.7 Cause: Leak oil (internal and external) is increasing. If, as a result of rotor clearances all

the oil pumped is “leaked” away, the pressure does not rise (especially with vane pumps). Remedy: Return pump to manufacturer for repair. 3.8 Cause: Pipe breakage underneath reservoir cover. Pipe union not sufficiently tightened. Remedy: Locate the source of the fault through the insertion cover, otherwise remove and

check. In the case of valve type piston pumps and difficult access it may be preferable to pressure test the delivery line using an external source.

4. Fault: Fault: Pressure oil contains air bubbles.

(Depending on the type of pump, the oil contains air during initial start-up, until all equipment is vented.)

4.1 Cause: Air is entering the suction line. Remedy: Tighten pipe unions ecc. Check flange gaskets, renew seal tape. If necessary, remove the complete suction line and pressure test.

4.2 Cause: Suction pipe end only partially covered with oil. Remedy: Top-up with hydraulic fluid.

4.3 Cause: Suction pipe too close to the return pipe. Foam from the oil return enters the suction pipe.

Remedy: Arrange for the suction and return pipe ends to be as far apart as possible. 4.4 Cause: Too high a resistance in the suction pipe. Air dissolved in the hydraulic oil can

separate out in the form of bubbles. Remedy: Increase the cross section of the suction pipe. Check the suction pipe for possible

blockages. Clean the suction filter. 4.5 Cause: Defective shaft oil seal. Remedy: Renew the oil seal and if necessary polish the contact area of the shaft. 4.6 Cause: Flanges or covers leaking. Remedy: Check O-ring or sealing compound. Check the compatibility with the hydraulic fluid

used.

5. Fault: Oil leaking from pump. 5.1 Cause: Shaft oil seal damaged by grooved shaft.

Remedy: Renew the oil seal and if necessary polish shaft area. 5.2 Cause: Shaft oil seal lip defective or oil seal unseated as a result of excessive pump

pressure. Excessive leak oil flow, leak oil pipe blocked. Possibly major defect in the pump. Remedy: Clear or enlarge the leak oil pipe. A defective pump should be replaced. 5.3 Cause: O-ring damaged during installation or through wear. Sealing paper, sealing

compound ecc. pressed out Remedy: Replace sealing items.

6. Fault: Pump is abnormally noisy - flow noises 6.1 Cause: Pump is sucking in air. Banging noises in the pump. Remedy: Check the suction pipe for leaks. Tighten pipe unions.

6.2 Cause: Cavitation in the suction pipe. The hydraulic fluid evaporates at low pressure into oil vapour which inside the pump is liquified again, producing banging noises.

Remedy: Reduce the flow resistance of the suction line. 6.3 Cause: Coupling damaged or misaligned.

Remedy: Replace or align the coupling. 6.4 Cause: Ball bearing worn. Remedy: Renew ball bearing (usually at manufactures). 6.5 Cause: Pump has seized up. Remedy: Repair pump at manufacturers.

7 Fault: Pump has seized up. 7.1 Cause: Damage through cavitation.

Remedy: Reduce flow resistance in suction pipe. 7.2 Cause: Overloading of the pump. Remedy: Do not exceed maximum rated pressure. 7.3 Cause: Dirty hydraulic fluid.

Remedy: Check oil filters, air filters as well as all other items through which impurities could enter the system.

7.4 Cause: Oil viscosity too low. Remedy: Use a hydraulic fluid having a viscosity commensurate with the operating temperature, or incorporated a cooler.

7.5 Cause: Pump life exceeded. Remedy: Renew the pump. 8 Fault: Pump overheats. 8.1 Cause: Starting or other damage.

Remedy: Do not exceed the rated pressure. Examine oil for contamination. Check coupling for alignment. Renew ball bearings (at manufacturers). Replace damaged pump.

8.2 Cause: Efficiency drops due to damage; internal leakage increased. Too hich a proportion of the energy absorbed by the pump is being converted into heat within the pump

Remedy: Do not exceed the rated pressure. Use oil with correct viscosity. 8.3 Cause: Oil temperature in reservoir rises. Remedy: Check operation or cooler and thermostat. Reduce pressure setting. Add cooler,

where applicable. 9 Fault: The oil in the unit becomes too hot. 9.1 Cause: Pressure setting.

Remedy: Reduce the pressure setting of the pressure relief valve. Reduce the amount of time during which oil passes through the dump valve. If not already included, install a dump valve.

9.2 Cause: Oil reservoir is too small. Remedy: Install an oil cooler. 9.3 Cause: Pump worn or has excessive internal leakage. Remedy: Investigate cause of damage and rectify. Return pump to manifacturer. 10 Fault: The accumulator does not reach full pressure. 10.1 Cause: The accumulator incorrectly filled.

Remedy: Check accumulator pre-fill pressure and top-up with nitrogen. 10.2 Cause: The accumulator drain cock is open, the oil returns to the reservoir. Remedy: Close the accumulator drain cock. 10.3 Cause: The pressure switch switches the pump immediately to “dump”. Remedy: Adjust the pressure switch.

MAINTENANCE OPERATIONS 7 MAINTENANCE OPERATIONS LIST

PLANT:

SUPPLY BY:

CONSTRUCTION YEAR: 7.1 - Plant cleanliness

Week 1 2 3 4 5 6 7 8 9 10

Executed

Note (pg 14)

7.2 Pipe control

Week 1 2 3 4 5 6 7 8 9 10

Executed

Note (pg 14)

7.3 Fixing pipe control

Week 1 2 3 4 5 6 7 8 9 10

Executed

Note (pg 14)

7.4 Possible oil loss control

7.4.1 Pipe

Week 1 2 3 4 5 6 7 8 9 10

Executed

Note (pg 14)

7.4.2 Flexible pipe

Week 1 2 3 4 5 6 7 8 9 10

Executed

Note (pg 14)

7.4.3 Connections

Week 1 2 3 4 5 6 7 8 9 10

Executed

Note (pg 14)

7.4.4 Hydraulic control system

Week 1 2 3 4 5 6 7 8 9 10

Executed

Note (pg 14)

7.4.5 Components

Week 1 2 3 4 5 6 7 8 9 10

Executed

Note (pg 14)

7.4.6 Cylinders

Week 1 2 3 4 5 6 7 8 9 10

Executed

Note (pg 14)

7.5 Filter

7.5.1 Oil Filter Obstruction indicator verification

Week 1 2 3 4 5 6 7 8 9 10

Executed

Note (pg 14)

7.5.2 Filter element cleanliness or substitution

Week 1 2 3 4 5 6 7 8 9 10

Executed

Note (pg 14)

7.6 Fluid

7.6.1 Fluid level control

Week 1 2 3 4 5 6 7 8 9 10

Executed

Note (pg 14)

7.6.2 Fluid temperature control

Week 1 2 3 4 5 6 7 8 9 10

Executed

Note (pg 14)

7.6.3 Fluid test

Week 1 5 9 13 17 21 25 29 33 37

Executed

Note (pg 14)

7.6.4 Fluid substitution

Work hours 5.000 10.000 15.000 20.000 25.000 30.000 35.000 40.000 45.000 50.000

Executed

Note (pg 14)

7.6.3 Oil tank cleanliness

Work hours 5.000 10.000 15.000 20.000 25.000 30.000 35.000 40.000 45.000 50.000

Executed

Note (pg 14)

7.7 Accumulator

7.7.1 Prec. control (to unload oil side)

Week 1 2 3 4 5 6 7 8 9 10

Pressure measirated

Pressure tainted

Note (pg 14)

7.7.2 Possible nitrogen loss control

Week 1 2 3 4 5 6 7 8 9 10

Executed

Note (pg 14)

7.8 Pressure switch 7.8.1 Tare control

Week 1 2 3 4 5 6 7 8 9 10

Pressure measirated

Pressure tainted

Note (pg 14)

7.9 Safety valve with electric unload

7.9.1 Tare control

Week 1 2 3 4 5 6 7 8 9 10

Pressure measirated

Pressure tainted

Note (pg 14)

7.10 Pumps

Week 1 2 3 4 5 6 7 8 9 10

T load [s]

Stop time [s]

Note (pg 14)

7.11 Cylinders

7.11.1 Manoeuvre time (with throttle open) (s) 7.11.2 Manoeuvre time (with throttle tainted) (s)

Week 1 2 3 4 5 6 7 8 9 10

Return measured

by progr.

Exite measured

by progr.

Throttle measured

by progr.

Throttle measured

by progr.

7.12 Note

Week Date Sign Week Date Sign