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Maintenance Manual
PAC
Preface
Preface
Hgglunds Drives is one of the worlds leading manufacturers of low speed,
high torque and heavy-duty hydraulic drive systems. We supply a durable
drive system that will work under the toughest conditions with a minimum
level of maintenance requirements. We have industrial and marine customers all over the world. They know that when they seek solutions, support or
service, they can trust Hgglunds Drives to be there. The Hgglunds Drives
main office and manufacturing plant is located in Mellansel, Sweden. In
addition, there are sales and service offices in 40 countries worldwide.
Our high quality drive systems are based upon our unique hydraulic piston
motors, which were developed through experience accumulated over 30
years in marine and industrial areas. Today this ongoing development work
has resulted in our PAC power unit product line. This is what powers our
drive systems. New, as well as established technical solutions contribute to
the creation of this product. The most desirable features and operating
reliability have been designed into this power unit, PAC.
Contents
Contents
1. GENERAL ........................................................................................................................ 4
1.1 Safety precautions ........................................................................................................................4
1.2 Operating principle ........................................................................................................................6
4. INSTALLATION .............................................................................................................. 11
4.1 Installation directions ..................................................................................................................11
4.2 Lifting methods and weights .......................................................................................................13
4.3 Positioning the power unit ...........................................................................................................14
4.4 Mounting of the cabinet feet ........................................................................................................14
4.5 Mounting of electric motor...........................................................................................................15
4.6 Mounting of air-oil cooler and cabinet ventilation ........................................................................16
4.7 Mounting of top cover..................................................................................................................17
4.8 Hydraulic connections .................................................................................................................17
4.9 Electric connections ....................................................................................................................18
4.10 Pipe work ..................................................................................................................................18
4.11 Extra filtration before start up ....................................................................................................21
General
1. GENERAL
1.1 Safety precautions
It is of extreme importance that the safety precautions are always followed. If you are unsure about
anything, please contact your nearest Hgglunds Drives representative for advice.
Warning signs
In this manual, you will find the following signs, which indicate a potential hazard that can or will cause
personal injury or substantial property damage. There are three levels of hazard classification:
DANGER
WARNING
CAUTION
General
Limit access to the equipment only to authorized personnel. Only perform measures on the PAC when
you are completely familiar with the function of the power unit (including the control system) as well as
the complete drive.
Service and repair of the electrical, hydraulic, and the mechanical functions require professional service personnel who are aware of risks involved.
Safety equipment necessary for the prevention of accidents during the mounting and maintenance
must be used in accordance with the regulations prevailing in the local country.
General
Prior to troubleshooting
Use the order code and other attached technical documentation to identify the features of your
unique power unit and system.
Read the attached technical documentation (this manual included) and make yourself familiar
with the PAC (control system included) as well as the complete drive.
Use safety equipment like hard hat, protective goggles, safety shoes and hearing protection.
Always ensure that there is no accumulated energy in the system prior to maintenance.
Ensure that all electric power is off and locked out.
Ensure that there is no entrapped pressure in the hydraulic system.
Ensure that no pressure will enter the hydraulic system in the power unit via the hydraulic motor,
for example loads on the shaft or winch drum.
If the hydraulic system is used for lift devices such as elevators, winches, etc., these should be
secured, or in the rest position (hanging load).
Ensure that all accumulators are discharged.
Electricity supply
Safety equipment necessary for the prevention of accidents must be provided in accordance with the
regulations prevailing in the local country.
All electrical supply levels shall be within the limits that the equipment is constructed for, see technical
documentation and maximum rating plates.
Mounting
Carefully follow the instructions and be aware of the large weights and forces involved during lifting.
Incorrect mounting and setting of electrical, hydraulic and the mechanical components can cause
personal injury or property damage.
Before starting up
Before starting up new, rebuilt or serviced drive systems, all accessories and safety arrangement
functions need to be checked and tested.
Hydraulic fluid
Be aware that most hydraulic fluids can cause personal injury and severe damage to the environment.
Check the caution sign on the container or consult the supplier. Used hydraulic fluid can contain
noxious contaminates. We recommend using the service of a professional oil company for supply and
disposal of used fluids. Never dump hydraulic fluid into water drainage or water supplies.
Bell housing
Note that there are rotating parts inside the bell housing during operation. Be careful during inspection
through the inspection hole. Replace inspection cover when finished.
Hot surfaces
Temperatures in the hydraulic system above 158 F (70 C) will create hot surfaces.
Emergency situations
Emergency shutdown: It has to be possible to turn off the electric power during an emergency situation. Only use a fire extinguisher that is approved for use on both oil products and electric equipment.
5
Operating Principle
18
20
19
17
11
7
5
4
6
13
9
12
15
8
6
4
5
7
3
12
14
15
10
16
10
1
13
Function
The function of the power unit is to provide the hydraulic motor(s) (or other hydraulic systems) with the
required flow of oil and pressure at the right time. All included parts are assembled in one (or more)
compact cabinet(s). The PAC has one or more pumps driven by one or more electric motors. The
main pump is an axial piston pump with variable displacement for closed loop systems. The electric
motor is totally enclosed fan cooled. Two different control systems are available.
Basic, for most of our drives can be configured for speed feedback control and power
limitation.
Shredder, for shredder applications.
Synchro, for friction and synchronized drives.
CAUTION
Technical Data
2. TECHNICAL DATA
2.1 Operating conditions
The standard PAC unit is designed for the conditions listed below. If the requirements are outside of
the conditions listed below, contact your Hgglunds Drives representative with your specific requirements for special design considerations.
Ambient temperature: Minimum 32 F (0 C) to a maximum 85 F (30 C).
Altitude: Maximum 3,300 feet (1000 m).
Classified Location: Unit is designed for a standard location. Units can be built for use in
classified hazardous locations. Contact your Hgglunds Drives representative for more details.
Maintain the water filter (if any) in a correct way, this is to get the required flow of water through
the water oil cooler.
Ensure you have the required flow, pressure and temperature of the cooling water (see attached
technical documentation).
Check the temperature in the hydraulic system, according to the maintenance intervals for your
specific power unit or the maximum intervals on the maintenance chart.
Clean the cooling system if the temperature in the hydraulic system is above the specified limits.
Clean and empty the cooling system (waterside) before periods of inactivity (especially if the
cooling water is not totally clean).
If cooling capacity is too low, the service life of hydraulic motor, the main
components in power unit, and the hydraulic fluid will be reduced.
Cleanliness recommendations
The system must be flushed before start up (section 4.12 Flushing before start up).
When filling the tank with hydraulic fluid it is important to fill through the quick connection (section 4.13.2 Filling up the system with hydraulic fluid).
The particle contamination level in the system should not exceed ISO/DIS 4406 16/13 (NAS
1638, class 7).
The water content shall be <0.1% and in individual applications with high demands for service
life, <0.05%.
Always use filter elements recommended and supplied by the Hgglunds Drives organization.
The hydraulic fluid should be analyzed according to the special maintenance intervals for your
specific PAC or the maximum intervals on the maintenance chart (section 5.2 Maintenance
Chart). You should be particularly careful when removing equipment for repairs or maintenance
so that dirt cannot enter the system. Components should be cleaned and free of dirt prior to
disassembly.
Do not re use hydraulic fluid that has leaked out.
7
Technical Data
Viscosity limits
Recommended
RECOMMENDED VISCOSITY
at operating temperature 40150 cSt (187-720 SSU)
100 VI
150 VI
Minimum continuous
Maximum continuous
Maximum intermittent
Viscosity n
Minimum intermittent
100
150
200
150
720
Recommended
viscosity
100
40
187
Viscosity n SSU
Viscosity n cSt
1000
VG 100
VG 46
VG 150
VG 68
10
0
10
20
30
40
50
60
70
80
90
100
!
WARNING
Technical Data
MONITORING SWITCHES
EXTERNAL FUNCTIONS
POWER UNIT
Maximum oil
Temperature switch
1
Minimum oil
Temperature switch
1
Minimum oil
level switch
1
Closed suction
line switch
1
Low charge
pressure switch
1s
0s
0s 0.5s
5s
Time delay on
&
0s
Time delay on
Electric motor started
Warning oil
temperature switch
1
Low oil
level switch
1
Return filter
switch
Drain filter
switch
High pressure
switch
0s
5s
WARNING INDICATION
0s
5s
0s
5s
The monitoring of the power unit switches are grouped in two levels according to the above logic
diagram.
The warning indication is to inform about a problem in the PAC but does not need an immediate action.
The alarm indicates a need for stopping the pump. The stop sequence is to first stop the hydraulic
motor without ramp, by setting the pump swash angle to zero. Furthermore, after a short delay stop
the electric motor.
The low charge pressure switch must be interlocked during stop and start-up of the electric motor, to
avoid alarm and give the pump time to build up the charge pressure after start.
Technical Data
The packed power unit is labeled with center of gravity and weight.
Normally the power unit package is designed for forklift truck
handling.
Center of gravity label
!
CAUTION
The absolute minimum required fork length is 51.2 in. (1300 mm).
The minimum distance between the forks is 31.5 in. (800 mm) for a 2 door PAC and 43.3 in.
(1100 mm) for a 3 door power unit.
Position forks with regards to the center of gravity.
!
DANGER
10
Installation
4. INSTALLATION
4.1 Installation directions
If the PAC is to work properly, it must be installed in accordance with these instructions. The conditions
the unit will operate in must be taken into consideration.
Improper installation, not following the instructions in this manual and in the attached technical documentation, may affect the function and/or the service life of the power unit. It is important that the
safety precautions mentioned in this manual are always followed.
H1
PAC 200D/400D/600/800
H1
PAC 100/200/300/400
A2
B1
B2
H2
H2
B2
A1
B1
A3
Cabinet Size
Type
Dimension
1
PAC 100
PAC 200
PAC 400D
PAC 400
PAC 200D
PAC 300
PAC 600
5
PAC 800
H1
89 in. (2261mm)
89 in. (2261mm)
99 in. (2515mm)
99 in. (2515mm)
H2
3 in. (76mm)
B1
66 in. (1676mm)
B2
76 in. (1949mm)
62 in. (1575mm)
A1
A2
A3
5/8-13 UNC
5/8-13 UNC
5/8-13 UNC
11
5/8-13 UNC
5/8-13 UNC
Installation
Clamp each pipe in the pipe run separately and attach it to a firm foundation to avoid vibration. The
main connections from the PAC must always be fitted to the piping with hoses.
!
CAUTION
OIL
OIL
OIL
OIL
OUT
IN
OUT
IN
When units are installed side by side, the side panels must be removed.
This makes it possible to perform service on the power unit.
12
Installation
Electric Motor
Power HP (kW) Weight* lb (kg)
30 (22)
365 (165)
40 (30)
490 (222)
50 (37)
560 (254)
60 (45)
800 (363)
75 (56)
840 (380)
100 (75)
1160 (526)
125 (93)
1540 (698)
150 (112)
1730 (785)
200 (149)
1750 (794)
250 (186)
1925 (873)
300 (224)
2500 (1134)
350 (261)
2650 (1202)
400 (298)
3500 (1587)
450 (336)
4300 (1950)
Lift the PAC with no top cover on, maximum lifting angle 90.
The absolute minimum required fork length is 51.2 in. (1300 mm).
The minimum distance between the forks is 31.5 in. (800 mm) for a 2
door power unit and 43.3 in. (1100 mm) for a 3 door power unit.
Position forks with regards to the center of gravity.
Denison Pumps
Model
P6S
Weight lb (kg)
335 (152)
P7S
753 (342)
P30S
A
484 (220)
P24S
484 (220)
P14S
335 (152)
P11S
786 (357)
Air-Oil Cooler
Size
Weight lb (kg)
AOVH-30
190 (86)
AOVH-40
350 (159)
!
DANGER
221 (100)
296 (134)
AOL-1600
AOL-950
AOL-1200
355 (161)
13
Installation
PAC 100/200/300/400
PAC 200D/400D/600/800
8 [203mm]
8 [203mm]
FLOOR OUTLINE WITHOUT AIR COOLER
32 [813mm]
32 [813mm]
36 [914mm]
32 [813mm]
32 [813mm]
32 [813mm]
40 [1016mm]
40 [1016mm]
WARNING
14
1
2
1-1 1 ADJUSTABLE
2
1. Mount the cabinet feet before filling hydraulic fluid in the tank.
2. Mount the cabinet feet before installing the electric motor(s), if they are delivered separately or
supplied by the customer.
3. Lift the power unit according to instructions in this manual (section 3.2 Lifting the packed power
unit). Be sure to follow the safety precautions.
4. Mount the cabinet feet according to the drawing below.
5. Level the PAC by the adjusting screws.
Installation
DANGER
Installation
Mount brackets with attached screws (in the drilled holes) on the PAC according to the installation drawing in attached technical documentation.
Lift up air-oil cooler. Never lift with the electric motor.
Mount the air-oil cooler on the brackets with the attached screws.
Check that all screws are properly tightened.
Connect the attached hydraulic hoses. Note that Oil In at the power unit shall be connected to
Oil Out at the air-oil cooler and vice versa. The coupling protections must be kept on until final
assembly to avoid the entrance of dirt.
For electric connections, couplings and hoses, see respective section.
Air-oil cooler must always be connected with flexible hoses.
1 1/4" JIC 37 FLARE
RECOMMENDED ELECTRICAL
PENETRATION
RECOMMENDED ELECTRICAL
PENETRATION
OIL
OIL
OIL
OIL
OUT
IN
OUT
IN
AIR
FLOW
AIR
FLOW
RUBBER FLAP
A
RUBBER FLAP
1 1/4" SAE
1 1/4" SAE
DANGER
Dimensions in (mm)
Cabinet size
Power unit
Cooler ports
A
PAC 100/200
PAC 200D
PAC 300/400
PAC 400D/600
PAC 800
74 3/8" (1889) 69 3/8" (1762) 82 3/4" (2102) 17 5/8" (448) 10 1/2" (267)
Cooler Connections
OIL IN & OIL OUT
5" (127)
1 1/4" JIC 37 male flare
16
6" (152)
1 1/2" JIC 37 male flare
Installation
NO GLUE!
Denison Pump
Main A & B
Size
Connections *
P6/P7
P11/P14
P24/P30
!
DANGER
Threaded holes **
Thread
1 1/2"
5/8-11 UNC
2"
Depth
3/4-10 UNC
Cabinet
size
1
2
3
4
5
17
** 4 screws needed/connection,
preferably with Grade 8 cap
head bolts.
Power Unit
Dimension connection
Drain line
Flushing
PAC 100/200
PAC 200D
1 1/4" SAE
1" SAE female
PAC 300/400
code 61 flange
PAC 400D/600
PAC 800
Installation
All electric equipment is intended to be installed and used by qualified personnel who are familiar with relevant safety requirements.
Safety equipment necessary for the prevention of accidents at the mounting and operating site
must be provided in accordance with the regulations prevailing in the local country.
Grounding shall be carried out according to local regulations before the electric equipment is
connected to the main voltage.
All electrical supply levels must be within the limits that the equipment is constructed for, see
technical documentation and maximum rating plate.
Junction box
Connect the cables on the screw terminals inside the junction box. Make the connections according to
the electrical drawing in the attached technical documentation.
Air-oil cooler
The voltage and connection are stamped on the rating plate. Connect the electric motor to the electrical supply. Check direction of rotation, see air stream arrow in section 4.6.
Electric motor
Major voltage connection according to designation on the rating plate.
DANGER
When sizing hoses and hydraulic piping between the motor and the power unit, a safety factor of at
least 4 times the maximum system pressure should be used for the tensile strength. Keep in mind that
the equipment may be readjusted to higher pressure in duty. Pressure losses in the pipe system
should generally be kept to a minimum but there are exceptions in certain applications. Contact a
Hgglunds Drives service representative for more information.
Hydraulic pipes
The hydraulic pipes should be of high-grade steel as per ISO 3304, DIN 2391/C or ANSI/B93.4.
Pressure test
A pressure test to 1 1/2 times the maximum working pressure should be performed on the main lines
to check for possible leakage.
Pressure tests on the main lines are best carried out using a hydraulic hand pump.
Hoses
To avoid damage caused by vibrations it is important that the PAC and the motor be connected to
pipes by means of hoses.
The hoses must be short and have the smallest possible diameter in order to obtain a small compression volume. Nevertheless, allowance must be made for the minimum permissible bending radius
according to the data provided by the supplier of the hose. Allowance must also be made for the flow
velocities listed under Pipe sizes.
Pipe flushing
The piping system must be flushed with an adequately sized flushing pump prior to starting up the
PAC unit to remove contamination introduced during assembly and/or welding. Please contact a
Hgglunds Drives service representative for proper cleaning and flushing procedure.
18
Installation
Pipe sizes
It is important that lines between the main connections of the motor and PAC are as short as possible.
This gives the following advantages:
1. Small compression volume in the hydraulic system.
This is particularly important in hydraulic systems with large and rapid load variations, and in
drives, where high speed accuracy is essential.
2. Small power losses in the hydraulic system.
3. Lower installation costs in that smaller pipe sizes and shorter pipe lengths can be used.
For a normal hydraulic system, the total pressure drop in the pressure and return line must
not be more than 5 percent of the normal working pressure.
The following flow rates are recommended values and should not be exceeded:
Main lines 15 ft/s (4.5 m/s)
Pipe couplings
It is essential that a tight and pressure rated coupling is chosen.
The following types of coupling are recommended:
Pipe coupling
Type collar coupling as per SAE J 514.
Pipe clamps
Pipes should be clamped with uniformly spaced clamps.
The distance between the clamps may not exceed 6 ft (2 m) for pipes with outside diameters between
1/2 in. (15 mm) and 1 1/2 in. (38 mm). The distance between the clamps may not exceed 9 ft (3m) for
pipes with outside diameters greater than 1 1/2 in. (38 mm).
In addition, the pipes must be clamped immediately before and after a bend. The pipes must be
clamped immediately before transition to a hose as well.
The pipe clamps shall be secured to a stable and non-vibrating surface such as concrete structure.
The pipe clamps must be of a type permitting a certain amount of axial and radial motion in the
clamped joint and have good vibration-absorbing properties.
19
Installation
!
DANGER
Handling of fittings
Inspect the sealing surfaces on the couplings visually before mounting. It must be free of any damages such as scores and cracks. Handle the couplings with care. If you drop the coupling or it has
nicks on it inspect it visually. Check that the sealing (if any) is in its right position, free from cracks and
that it is saturated with oil.
The protection and packing on the fittings must be kept on until final assembly.
Flange fittings
Clamps
Welded fittings
Contact your Hgglunds Drives representative.
Correct
Mounting of hoses
Ensure that hoses are not stressed or twisted on
installation, to prevent premature failure. Bend
radius should conform to manufacturer recommendations.
Pressure tests
Pressure tests should always take place before
flushing in order to release contamination by
stresses introduced by the pressure. The main
lines must be pressure and leakage tested to a
static pressure of 1 1/2 times the maximum expected system pressure (not above bursting pressure). The hydraulic motor and power unit must
be disconnected or protected by closed valves
during the pressure tests.
Incorrect
Cleaning
The pipes and hoses should be pre-cleaned, inspected and sealed by the supplier. If the pipes
are field bent and installed the overall system must
be flushed to reach the required cleanliness level.
20
Installation
HYDRAULIC MOTOR
A pressure filter and check valve has to be connected to the main line at the power unit. This
filter is connected on the return side of the drive
pump.
Hoses
connected
together
Flow Direction
Filter
Check valve
POWER UNIT
21
Installation
4.12 Commissioning
4.12.1 Prior to commissioning
Read and understand this complete manual and the other attached technical documentation.
Visually check the whole system for signs of damage, incorrect circuitry, security of foundations,
and that the degree of filtration of the filters are according to the data in the technical documentation.
Check that the coupling between the electric motor and pump is properly mounted.
Check that the pre charge pressure in the accumulator (optional) is in accordance with the
technical documentation.
Cleanliness
The hydraulic system must be flushed and thoroughly cleaned on the inside.
If you are uncertain about the cleanliness of the system, it must be checked prior to filling with
oil.
Pipe work
Electrical System
Check that electric motor(s) and control system and other electrical components are connected
to the correct voltages.
Check the function of electrical components and monitoring system manually. Instruments that
cannot be actuated can be checked for correct wiring and possibly operated manually. Level
switch and indication should be checked when filling the tank.
'D1' DRAIN
PORT
22
Installation
Filling
Use a fluid filling pump unit, which has a filter with a filter rating of 10 microns, or better.
New fluid is normally not filtered and will introduce dirt into the system, the
fluid must therefore always be filled through a filter. Never pour hydraulic
fluid into the tank through the air breather filter.
Always pump the fluid in through the quick connection that is marked appropriately. The quick connection is a completely rustproof quick release coupling, see figure below. The fluid filled into the system
will be filtered through the drain filter for better results.
The tank must be filled with oil to 0.79 in. (20 mm) below the maximum level on the visual level gauge
on tank before starting for the first time.
Check the function of the level switch and indication during filling up of the tank.
ON FILL HOSE
ON POWER UNIT
RETURN FILTER
OIL FILL
CONNECTION
PUMP/MOTOR CASE
DRAIN FILTER
OIL HEATER
After filling the system with fluid, open the drain line and reconnect the drain line from the hydraulic motor.
!
WARNING
Check caution sign on container and the warnings (section 2.4 Choice
of hydraulic fluid).
Avoid prolonged contact of hydraulic fluid with your skin.
Clean hydraulic fluid spills from floors immediately to prevent personal
injury.
23
Installation
Make sure the driven system and driven machine is ready to run, warn all personnel in the area
that start up is in progress.
Follow safety precautions in this manual (section 1.1 Safety precautions).
Never operate the power unit with defective instruments or control elements.
Keep flammable materials away from the power unit.
During start-up period, the hydraulic system will be filtered to remove dirt particles, therefore
keep an eye on the filter indicator during the entire start up procedure.
On cold start up, the filters may indicate bypass. After a few minutes of operating, press down the
visual indicator to reset. If the indicators will not reset after system has reached operating temperature, filter element must be inspected and changed.
STEP 1
Check fluid level in the tank and refill to about 0.79 in. (20 mm) below maximum level at visual
level gauge on tank (section 4.12.2 Filling up the system with hydraulic fluid).
Check if any components need filling with clean hydraulic fluid, such as the pump case and
motor case.
Check safety equipment.
Check that all the prescribed steps (section 4.12.1 Prior to commissioning) have been carried
out.
Make sure that all valves on the suction, pressure and inlet side of the pump, as well as any
valves on drain lines, are open.
Check that cooling water is connected and turned on if a water-oil cooler is used.
For adjustments and settings on the control system (if any) see separate instruction in attached technical documentation.
STEP 2
Starting of the PAC shall be carried out with a completely unloaded pump in short intervals.
When the hydraulic fluid is cold, some restarts may be needed in order to raise the charge
pressure.
Check that the charge pressure corresponds with data and settings on attached technical documentation.
If OK, the pump may be allowed to come on stroke and introduce flow into the unloaded hydraulic system.
Flow and pressure should be limited until lines are purged of air.
ROTATION
24
Installation
STEP 3
Run for a period at no load condition until system is stable and control is established. Checking of the
oil level may be needed due to parts of the system having been filled with fluid.
STEP 4
The hydraulic system can be loaded when the hydraulic system function is satisfactory in unloaded
running condition.
STEP 5
STEP 6
Checking
25
Installation
!
DANGER
CHARGE PRESSURE
ADJUSTMENT
COMPENSATOR
VALVE
CHARGE PRESSURE
ADJUSTMENT
Front view
Charge pressure and Pump compensator pressure level are set before the PAC leaves the factory and
consequently there is normally no need for readjustment. Always check the pressure levels in technical documentation. Professional service personnel familiar with the functions and risks involved with the pump must perform setting of pressures on the pump(s). The pressures shall be
set during operation and with the system at operating temperature. Note that pressures can change
with different viscosity.
1. Charge pressure adjustment: Remove acorn nut, loosen lock nut and adjust pressure with a
5/32" size Allen key. Clockwise adjustment will increase the pressure. The charge pressure (on
the charge pressure gauge) shall be within the following limits: 218 psi (15 bar) for P6S/ P7S &
P11S/P14S & P24S and 261 psi (18 bar) for P30S.
If other charge pressures are to be set, contact Hgglunds Drives representative for consultation.
2. When charge pressure is set: Tighten lock nut and return acorn nut. Note in the logbook or
other technical documentation.
3. If the main pressure levels are to be increased: Make sure that the piping and machine
structure can take higher pressure/higher torque delivered from the hydraulic motor.
4. Compensator pressure adjustment: Dead head the pump, then activate or move the input
signal to the control so that pressure increases in the high pressure closed circuit to the pressure limiter setting. The pressure limiter setting is reached when the pressure stops increasing
and remains steady at a given pressure level. (As shown on the gauges)
The pressure limiter setting for both A- and B-side is set on the compensator valve.
Remove acorn nut, loosen lock nut and adjust pressures with a 5/32" size Allen key, until the desired
pressure level is established. Clockwise rotation of the adjustment screw will increase the pressure.
5. When main pressures are set: Tighten lock nut and return acorn nut. Note the new pressure
level in logbook or technical documentation.
26
Maintenance
5. PREVENTIVE MAINTENANCE
5.1 Maintenance log
We recommend that a maintenance log be kept to record service/maintenance/repair, addition and
alteration of the equipment. Each note, observation or comment should be dated.
Fluid leaks.
Fluid level in the tank.
Operating temperature.
System pressure.
System performance and general condition.
Unusual noises.
Contamination indicators on the filters.
Pre-start checks
Frequent checks
(also daily)
Fluid leaks.
Fluid level in the tank.
Is the suction valve open?
Contamination indicator on the filters.
27
Unusual vibrations.
Unusual noises.
Fluid leaks.
Fluid level in the tank.
Is the unit relatively clean? Air flow paths
unrestricted?
Pressure levels normal - stable?
Actuator speeds normal - stable?
Operating temperature.
Is the drive running smoothly?
Contamination indicators on the filters.
Maintenance
Scheduled maintenance
Planned maintenance at specific time intervals, including the following checks and actions:
*
*
*
=Inspection
=Replacement
28
Maintenance
Duplex filter
1. Press in the pressure-equalizing lever on the underside of the switching lever and hold it, see
figure below.
2. Withdraw the catch knob, turn over and engage the switching lever on the other side.
3. Loosen the vent screw, only on the side where the filter is to be changed, (see picture below) 23 turns.
4. Remove the filter bowl and change filter cartridge.
It is very important during the mounting not to expose the cartridge to any dirt, therefore keep
it in the plastic cover as long as possible.
Check the O-ring and the backup ring for damage. Change parts if necessary.
5. Mount the filter bowl. Tighten by hand to stop and back off 1/8th of a turn.
6. Refill the filter by pressing the equalizing lever and hold it there until the vent screw bore is
bubble free.
7. Tighten the vent screw. Check the filter for leaks by pressing in the equalizing lever again.
CAUTION
Pressure
equalizer
lever
In this
position
you can
change
this
element
Switching
lever
29
Maintenance
Grease
When re-greasing, use only special ball bearing grease with the following properties:
Good quality lithium base or lithium complex grease.
Base oil viscosity 476-667 SSU at 104 F (100-140 cSt at 40 C).
Consistency NLGI grades 2 or 3.
Temperature range -22 F - +248 F (-30 C - +120 C), continuously.
Grease with the right properties is available from all the major lubricant manufacturers. If the type of
grease is changed and compatibility is uncertain, lubricate several times at short intervals in order to
displace the old grease.
Frame
size
Electric motor
HP (kW)
286
CAUTION
Lubrication
intervals
30 (22)
Volume of
grease
1.0 cu. in.
40 (30)
50 (37)
6 to 12 months
324-365
6 months
3 months
404-449
509
GREASE
NIPPLES
check data
250 (186)
300 (224)
350 (261)
400 (298)
5011
450 (336)
30
Maintenance
The easiest way to clean the air fins is by using compressed air or rinsing with water.
Fouling can be dealt with using a degreasing agent and a high-pressure washing system. When
using a high pressure washing system point the jet carefully parallel to the air fins.
!
WARNING
Follow the safety precautions on the container of the cleaning agent used.
Disconnect the power unit before disconnecting the Water-oil/Air-oil cooler.
Make sure that electric power is cut off before cleaning! Cleaning agent
and waste water from rinsing should not be disposed of in nature.
Re commissioning
Before the drive is restarted after a long idle period, a check should be made as to whether the
instructions supplied for the original commissioning still apply. Moreover, the following measures
should be observed.
6. CORRECTIVE MAINTENANCE
6.1 Common
Before removing any hydraulic/electric components, disconnect the power unit. Ensure that no energy
is accumulated in the system and the power is disconnected from the electric motor. Follow recommended safety procedures.
Before disassembly
31
Corrective Maintenance
Disassembly
Reassembly
!
DANGER
Always use all four lifting points when lifting the electric
motor/pump unit.
Never use the lifting ears on the electric motor to lift the
complete electric motor/pump unit.
Use only lifting equipment adapted to the weight (section 4.2
Lifting methods and weights).
Do not stand underneath hanging load
Take center of gravity into consideration during lifting.
32
Troubleshooting
6.3 Troubleshooting
Problem
Probable cause
Action
Reservoir temperature
above set limit
No servo pressure
Coupling pump/electric
Power unit fails to deliver oil motor defect
flow
Wrong direction of rotation
of hydraulic pump
33
Troubleshooting
Problem
Probable cause
Action
Excessive wear
DANGER