GENERAL USER GUIDE FOR HYDRAULIC POWER UNITS AND HYDRAULIC CONSTRUCTION GROUPS
GENERAL USER GUIDE FOR HYDRAULIC POWER UNITS AND HYDRAULIC CONSTRUCTION GROUPS
GENERAL USER GUIDE FOR HYDRAULIC POWER UNITS AND HYDRAULIC CONSTRUCTION GROUPS
User guide
The specified information is valid only for the product description. The specific nature of the product or its suitability for a particular use cannot be derived from the information we have provided. The information provided does not exempt the user from self-assessment and testing. It should be taken into account that the products we produce are subject to natural wear and aging. The property of this document and the information it contains, technical specifications and other information belongs exclusively to HİDROMAN. Permission of this company
It may not be copied or forwarded to third parties without An example configuration is illustrated on the cover page. Therefore, the delivered product may differ from the product in the picture.
Contents
1 About this manual
1.1 Related documents
2 Basic safety warnings
2.1 Proper use
2.2 Illegal use
2.3 Competence of staff
2.4 Warning notes in this manual
2.5 You must comply with this
2.6 User's obligations
3 Scope of delivery
4 Product description
4.1 Hydraulic power units
4.2 Hydraulic assemblies
4.3 Identification of the product
5 Transport and storage
5.1 Transport of hydraulic power units
5.2 Storage of hydraulic power units
6 Assembly and installation
6.1 Unpacking
6.2 Installing the hydraulic power unit
6.3 Connecting the hydraulics
6.4 Connecting the water supply
6.5 Connecting the electricity
7 Commissioning
7.1 Commissioning for the first time
7.2 Restarting after a long pause
8 Study
9 Service
9.1 Service documentation
9.2 Cleaning and maintenance (protection
9.3 Inspection, maintenance, repair
9.4 Spare parts and wearing parts
10 Deactivation
10.1 Preparation for decommissioning
10.2 Implementation of deactivation
11 Disassembly
11.1 Preparation for disassembly
11.2 Perform disassembly
12 Scrapping
13 Development and renovation
14 Troubleshooting and troubleshooting
14.1 Proceed as follows in troubleshooting
15 Technical data
16 Glossary
1 About this manual
This manual contains important information, such as safely and conveniently transporting, mounting, commissioning, maintaining, disassembling hydraulic power packs and hydraulic assemblies, and troubleshooting simple problems yourself. * Before working with the hydraulic power unit, read this manual thoroughly, especially Chapter 2 „Basic safety precautions“. Here is a general operating manual for hydraulic power units and hydraulic assemblies developed and manufactured with a customer focus. * Therefore, when reading this manual, have the product documentation ready (see Chapter 3 "Scope of delivery"). Basically, in this manual, the term "hydraulic power unit" is used synonymously for hydraulic assemblies. Therefore, the information contained also applies to hydraulic assemblies, even if they are not specifically mentioned. The concepts of "Hydraulic power unit" and "Hydraulic component groups" are given in the document points where a distinction should be made.
1.1 Related documents
* Observe the documentation for the complete machine. * Also take into account the documentation of other elements, assemblies and partially completed machines that are components of the complete machine. * Take into account the applicable laws in your country regarding accident prevention and environmental protection, as well as the general, legal and other binding provisions of European and national laws.
2 Basic safety warnings
The hydraulic power unit is manufactured according to the generally accepted rules of current technology. However, there is a risk of injury to people and property if you do not heed the following safety notes and the warning notes preceding the operating instructions in this manual. * Read this manual carefully and thoroughly before working with the hydraulic power unit.
* While reading this manual, keep the product documentation ready (see Chapter 3 "Scope of delivery").
* Keep the manual and product documentation accessible to all users at all times.
* Always give the hydraulic power unit to third parties together with the user manual and product documents.
Depending on the installation of the hydraulic power unit inside the machine, additional potential hazards arise due to the interaction between the hydraulic power unit and the complete machine. This applies in particular to the influence of the hydraulic and electrical control unit on hydraulic drives that produce motion. The manufacturer of complete machines must therefore have carried out an independent risk assessment. He should also have created an instruction manual for the complete machine based on this. This operating manual does not replace the operating manual of the complete machine.
2.1 Proper use
The difference between hydraulic power packs and hydraulic assemblies is set out below to indicate proper use.
2.1.1 Hydraulic power units
The hydraulic power unit is a partially completed machine in accordance with the EU Machinery Directive 2006/42/EG. The hydraulic power unit is not a usable machine according to the EU Machinery Directive. The hydraulic power unit is only intended to be inserted into a machine or device or to be combined with other parts to form a machine or device. The product may only be put into operation after it has been installed in the machine or device for which it is intended and if it fully meets the requirements of the EU Machinery Directive. The hydraulic power unit is not a safety component within the meaning of EU Machinery Directive 2006/42/EC.
* Comply with the operating conditions and power limits mentioned in the technical data. The hydraulic power unit is a technical working tool and is not intended for private use.
Proper use also includes your complete reading and understanding of this user manual, especially Chapter 2 "Basic safety precautions".
2.1.2 Hydraulic assemblies
The hydraulic assembly can simply be inserted into a machine or device or combined with other parts to form a machine or device.
foreseen for. The product should only be commissioned after it has been installed in the machine or device for which it is intended. The hydraulic assembly is not a safety component within the meaning of the Machinery Directive 2006/42/EC. * Comply with the operating conditions and power limits mentioned in the technical data. The hydraulic assembly is a technical working tool and is not intended for private use. Proper use also includes your complete reading and understanding of this manual, especially Chapter 2 "Basic safety warnings".
2.2 Illegal use
If you use the hydraulic power unit or hydraulic assembly in a different way than described in chapter 2.1 "Regulatory use", it is illegal to use.
2.3 Competence of staff
Assembly, commissioning, service (including maintenance, inspection, repair) and disassembly require basic mechanical, electrical, hydraulic knowledge as well as knowledge of relevant specialized concepts. Therefore, in order to ensure operational safety, these activities should only be carried out by an appropriate expert or a person who has been informed under an expert. An expert is a person who, on the basis of his specialized training, knowledge and experience, as well as his knowledge of the relevant provisions, can evaluate the tasks assigned to him, recognize possible dangers and take appropriate safety measures. The specialist must comply with the relevant specific specialized rules.
2.4 Warning notes in this manual
In this user manual, there are warning notes before the operating instructions in cases where there is a risk of injury to people and property. The precautions described must be followed to avoid hazards. Warning notes are structured as follows:
Type of danger!
Consequences * Prevention
Warning sign (warning triangle): draws attention to danger
Signal word: indicates the degree of danger
Type of hazard: indicates the type or source of the hazard
Consequences: refers to the consequences of non-compliance
Prevention: informs how to avoid danger
Table 1: Meaning of signal words
DANGER! Indicates a directly threatening, great danger that can cause serious injury or even death if the danger is not avoided.
WARNING! Indicates a potential hazard which, if not avoided, could result in serious injury or even death.
CAUTION!
3 Scope of delivery
This operating manual has been created for hydraulic power units and hydraulic assemblies. For hydraulic power units and hydraulic assemblies, the delivery consists of the original product as well as general and specific product documents. These documents are presented in the table below:
Document Power unit Assemblies
Product documents Technical specification x x Hydraulic circuit diagram x Catalog paper Hydraulic circuit diagram component list x Catalog paper Assembly drawing x Catalog paper Manufacturer's Declaration x —
General
documents
User guide
(this document) x x
Installation manual x —
4 Product description
The hydraulic power units and hydraulic assemblies to which these operating instructions relate are only intended for installation inside machines. Here, in general, there are products that are developed and produced with a customer focus. For this reason, you can learn the specific description of your product from the following documents:
• Technical specification: Explanation of conditions of use and notes on insertion into the machine
• Hydraulic circuit diagram: Functions and logical action of the product
• Component list of hydraulic circuit diagram
• Assembly drawing: Constructive type, dimensions, center of gravity information, connections, etc.
4.1 Hydraulic power units
The hydraulic power unit is a drive system for machines. In this sense, it is a partially completed machine in accordance with the Machinery Directive 2006/42/EC. According to this operating manual, a hydraulic power unit consists of at least:
• Electric motor and pump
• The pressure control device of the pump
• Oil tanks, pipe/hose installations, fittings, etc.
• Fluid level indicator
A hydraulic power unit may also include:
• hydraulic control unit
• Accumulator with independent N2 pressure vessel if required
• other protection against unforeseen pressures
• Other mechanisms for detecting defined operating states
(pressure, temperature, fill level, filter contamination)
4.2 Hydraulic assemblies
Hydraulic assemblies, e.g. valve stands, accumulator stations, drive motor - hydraulic pump units, recirculation stations for filtration and/or cooling.
4.3 Identification of the product
A clear description of the product is made as follows:
• Ticket
• Product specific documents
• Waybill and transport documents
5 Transport and storage
* eg. Observe the shipping notes on the packaging.
* Always comply with the ambient conditions specified in Chapter 15 "Technical data" during storage and transportation.
* For example, if it has to be opened for checking, seal the packaging in accordance with the delivery condition.
* As far as possibilities allow, only remove the packaging immediately before assembly.
5.1 Transport of hydraulic power units
The overturning, falling or uncontrolled position of the hydraulic power unit
life threatening due to replacement!
If the hydraulic power unit is transported in violation of the rules, it may lose its upright safety and therefore it may fall, fall or lose its position without control.
can change. * Make sure the weight of the hydraulic power unit and the position of the center of gravity.
* Place the product on a suitable surface.
* Ensure adequate upright safety with additional measures (eg anchors or winches) before removing supporting elements.
* For fixing or lifting the hydraulic power unit, only use the designated places or attachment points.
* Hydraulic power units should never be fixed or fixed by attached components (piping, hoses, control blocks, electric motors, tanks, etc.).
should not be removed.
* Take into account the maximum load capacity of the fastening tools.
* Take into account the maximum load capacity of the stackers.
* Make sure that there are no people in the danger zone who are not participating in the work.
Oil escaping under high pressure or machine operation
Danger to life due to malfunctions during operation!
Pressure-transmitting or functional elements can be damaged during illegal transport of the hydraulic power unit.
* Take care that these elements do not come into contact with fastening devices or lifting devices during transportation.
* Make sure that hydraulic power units are not fixed to or lifted from these elements.
5.1.1 Preparation for transport
Before moving, make the following preparations:
* Check the space requirement for the installation of the hydraulic power unit at the place of use.
* Check the transport path. Plan for additional free spaces next to and above the hydraulic power unit, depending on the type of transport.
* Road, bridges, crossings, etc. Check the maximum permissible payload.
* Depressurize the oil side of the accumulators after pre-starting the hydraulic power unit. If the pressure on the gas side is possible
Reduce it to a value of 2 bar (200kPa). Hydraulic power units are delivered by HİDROMAN basically without oil filling. A different situation is the document for the product.
5.1.2 Determination of the center of gravity
The location of the center of gravity is marked on the packaging with the symbol shown below, if possible.
Figure 1: Symbol for marking the center of gravity
Basically, the location of the center of gravity is indicated on the assembly drawing. Below is a schematic illustration of how the marking of the center of gravity can take place in the drawings.
Figure 2: Marking the center of gravity on the drawings
5.1.3 Using anchor points
Danger to life due to the hydraulic power unit tipping, falling or changing its position uncontrollably due to the use of unsuitable attachment points!
After prolonged use, the attachment points may no longer exist, are not strong enough, or may not be found.
* Find out which attachment points are provided from the product documentation and only use them.
* If you want to transport the hydraulic power unit after disassembly, check the stability of the attachment points.
* Whenever possible, replace any missing or faulty mounts.
* Screw in the screwed fastening points until the screw fits into the threaded hole and hand-tighten the threaded part.
* If necessary, mark inconspicuous attachment points with a well-visible color. The attachment points are annular assemblies connected to the hydraulic power unit by a welded joint or screwed connection. These serve to lift or hold the hydraulic power unit during transport. Examples for tie-down points in hydraulic power units are shown in figure 3:
Figure 3: Examples for attachment points
1 to weld
2 for screwing
5.1.4 Manual handling
Musculoskeletal system due to overload and incorrect posture
risk of injury!
There is a danger of personal injury due to excessive load and incorrect body posture during manual handling.
* Estimate realistically the load on the carriers. Muscular strength and bodily constitution in humans vary in a wide range.
* Where appropriate eg. use suitable aids such as carrying straps.
* Use appropriate lifting, lowering and transfer techniques.
5.1.5 Transport by forklift or similar stacking machines
Danger to life due to the hydraulic power unit falling or changing its position uncontrollably!
The hydraulic power unit may tip over, fall or change its position uncontrollably during illegal transportation.
* Determine a firm center of gravity position during transport with stackers.
* The hydraulic power unit should not move out of the position you have determined.
* If necessary, fix the hydraulic power unit against the resulting acceleration forces. Transport of a hydraulic power unit by stackers should only be carried out by qualified personnel, including safety training for the device in question.
Act like this:
* Curtain the fork against the contact surface of the hydraulic power unit with wooden or plastic elements to avoid damage to the paintwork during lifting and transport.
* Secure the hydraulic power unit on the forklift against tipping over. For this eg. use suitable fastening devices such as tension straps.
* Carefully lift the hydraulic power unit, taking into account the position of the center of gravity and transport it to the desired location.
* Make sure that the attached components of the hydraulic power unit do not come into contact with the clamping devices or lifting devices during transport (see Figure 4).
* Carefully place the hydraulic power unit back on the ground and remove the load securing devices.
Figure 4: Transport with forklift
5.1.6 Transport by cranes or similar lifting equipment
Danger to life due to the hydraulic power unit falling or changing its position uncontrollably!
The hydraulic power unit may tip over, fall or change its position uncontrollably during illegal transportation.
* Establish a firm center of gravity position when transporting with lifting gear.
* The hydraulic power unit should not move out of the position you have determined. If necessary, install suitable safety and/or catch devices.
Transport with cranes, eg. This is accomplished through the use of fastening devices such as lifting straps, straps or chains.
* Use the designated places or tie down points for lifting (see Figures 5 and 6).
* Make sure that the attached components of the hydraulic power unit do not come into contact with the clamping devices or lifting devices during transport. therefore use an edge guard if necessary. If straight chains are used, scratches on the paint may occur. If these surfaces are required, eg. Protect it with suitable equipment such as a cover. * Perform the raising and lowering of the hydraulic power unit slowly and carefully.
* Raise the power unit off the ground only as far as necessary.
Figure 5: Using lifting straps and tie-down points
Figure 6: Detailed view from Figure 5
5.1.7 Freight transport
Danger to life due to the hydraulic power unit tipping, falling or changing its position uncontrollably!
The hydraulic power unit may tip over, fall or change its position uncontrollably during illegal transportation.
* Fix the hydraulic power unit securely against the accelerating forces.
If necessary, consider the rules of authorized shipping companies such as sea, rail, road or air.
* Do not place the hydraulic power unit on the transport vehicle, e.g. fasten it to the loading surface or to a load-bearing structure by tensioning or screwing.
* Make sure that the attached components of the hydraulic power unit do not come into contact with the fastening devices during transportation.
* Some products, such as accumulator stands, are intended to be transported in a horizontal position. When tilting or securing products, use the provided attachment points.
5.2 Storage of hydraulic power units
Note the storage times given in Table 2.
* If the storage period exceeds the specified values, flush the hydraulic power unit with a suitable cleaning fluid before commissioning. the washing process
Perform as described in section 7.1.9 "Flushing the hydraulic system".
* If necessary, replace elements with maximum storage times, such as hoses, balancers, tanks.
Table 2: Storage times
6 Assembly and installation
This section describes the installation of the product at its own application site, as well as the connection of the product to the hydraulic system, electricity and water supply of the machine. Before installing the hydraulic power unit to the machine, refer to the operating manuals and documents of the relevant machine.
Risk of material damage and injury!
Installation of the hydraulic power unit requires basic knowledge of hydraulics.
* The hydraulic power unit must only be installed by suitably qualified personnel (see Chapter "2.3 Qualification of personnel").
6.1 Unpacking
* Remove the packaging of the product.
* Dispose of packaging material in accordance with your country's national regulations or company's internal rules.
6.2 Installing the hydraulic power unit
Risk of injury due to overturning, falling, uncontrolled position change of the hydraulic power unit!
Provide adequate stopping safety for the product.
* Observe the information on transporting the product in Chapter 5 "Transport".
* Remove the support elements only after securing the upright position in another way.
* Place the hydraulic power unit on a suitable ground. Observe the information on the total weight.
Proceed as follows to install the hydraulic power unit:
* Position the hydraulic power unit or assembly as shown in the assembly drawing of the machine.
* Make sure that the mounting surface has the same contact with the ground at all points.
* When mounting the hydraulic power unit, make sure it is level.
* Prevent possible shaking of the product with the help of suitable tools (eg height adjustment of feet, placement of an intermediate carrier).
* Fix the product at the prescribed points in the specific product documentation
6.3 Connecting the hydraulics
Risk of injury from mounting under pressure!
If you do not turn off the pressure before starting the installation, you may be injured and damage the device or parts of the assembly.
* Depressurize the required system part before installing the hydraulic power unit.
Damage to the hydraulic power unit!
The hydraulic lines and hoses that you mount in tension generate additional mechanical forces during operation, which in turn causes the hydraulic power unit and all
the life of the machine or device
6.4 Connecting the water supply
* Fasteners must be tightened according to the manufacturer's instructions!
* Connect the installations according to the circuit diagram.
6.5 Connecting the electricity
Risk of injury due to live installation!
If you do not turn off the power supply before starting the assembly, you may be injured and damage the device or parts of the assembly.
* Before installing the product, de-energize the required system part.
6.5.1 Earthing and Potential balancing
HİDROMAN hydraulic power units are delivered with the connection for the external grounding system. Potential equalization in the hydraulic power unit is only implemented if the electrical wiring of the components is included in the scope of delivery. Otherwise, potential equalization must be applied when wiring the hydraulic power unit with the machine tool builder's machine. Hydraulic power units must be grounded!
Earthing installation and potential equalization installations must have the minimum cross-section required in accordance with TSE regulations and must be yellow-green sheathed or marked.
* Before connecting the cables, ground the devices to be connected and create a potential equalization via a common balancing rail.
6.5.2 Current supply and control current installations
and connecting the power supply
* Electrical connections must be applied in accordance with the applicable rules of electrical engineering.
* Make sure the electrical current is cut off and secured against being turned on again.
* eg. prevent unintentional activation by informing about electrical work with a warning sign.
6.5.3 Connecting electrical control and monitoring devices
Connect control and monitoring devices (circuit, control, control devices or frequency converters) in accordance with the relevant documentation, taking into account the relevant safety precautions.
7 Commissioning
According to the Machinery Safety Directive 2006/42/EC, commissioning of the machine into which the hydraulic power unit is to be installed is prohibited until it has been determined that it complies with the provisions of all major regulations. Unforeseen risks may occur during the assembly of the unit to the machine. Because
The information in the machine's user manual must also be taken into account. This applies in particular to "Mechanical threats", which can arise as a result of mechanical movements of the machine connected to hydraulic power units and hydraulic power drives (cylinder, engine).
Damage to people and property!
If the hydraulic power unit is not installed correctly, people may be injured and during the Commissioning of the hydraulic power unit, the hydraulic power unit or
the device may be damaged.
* Before operating the hydraulic power unit, make sure that the hydraulic power unit is installed correctly by qualified personnel.
Hydraulic power unit damaged!
Contaminated oil can cause wear and malfunctions. Foreign bodies in particular in the suction line, e.g. welding slag and metal burrs can damage the hydraulic power unit.
* Pay close attention to cleanliness during commissioning.
* When closing the measuring connections, make sure that no dirt enters.
Risk of material damage and injury due to oil leakage!
When the blind plug is not removed and there is oil behind the blind plug, there may be an oil leak.
* Before commissioning, remove all plastic plugs and replace them with pressure-proof screw connections/flanges.
Hydraulic power unit damaged!
If you operate the hydraulic power unit without oil or with too little oil, the hydraulic power unit will be damaged.
* During commissioning or re-commissioning of a machine or device, the hydraulic power unit's oil tank as well as the suction and operating
Make sure that the installations and parts are filled with oil according to the manufacturer's instructions and that they are filled during operation.
7.1 Commissioning for the first time
7.1.1 Before commissioning
* Check the installation system in terms of occupational safety.
* Open the taps in the cold water installation (if any).
* Open the taps in the suction line (if any).
* To avoid measuring errors, open the pressure gauge bleeder (change it from "Closed" to "Open"). * Adjust electrical level control or temperature measuring device (if any) as necessary for machine operation.
7.1.2 Valve settings
* Set the pressure and flow valves to the lowest possible setting values.
* Set directional valves to home position.
* Do not energize proportional valves.
Do not make any modifications to sealed valves. Do not change the factory settings. Do not make any adjustments or modifications to valves that have been fixed at the factory in accordance with the technical data (circuit diagram or parts list).
7.1.3 Safe operation at pressure measuring points
In order to adjust the pressure valves, it is necessary to display the respective pressures. This is fixed-mounted manometers, digital pressure gauges or external measurement.
can be done with the help of connecting equipment. For this purpose, measuring couplings are attached to the hydraulic power unit. These measuring points are under pressure
high attention is essential!
Risk of injury due to improper installation under pressure!
Measuring hoses do not have a blocking or shut-off function.
* Before connecting the measuring hose to the measuring coupling, make sure that the other end of the measuring hose is pressure-tightly connected to the measuring instrument (manometer, pressure receiver).
If the scope of delivery includes a measuring hose and a measuring device connected to the measuring coupling, the connection must only be opened on the coupling side. The following figure (see Fig. 7) shows the point where a measuring tool can be safely disconnected from a pressure-transmitting measuring clutch of the hydraulic power unit.
Figure 7: Safe disconnection point of the measuring instrument (arrow)
Risk of injury due to improper installation under pressure
Measuring connections can also be mounted on the hydraulic power pack with a hex-head connector. These are for mounting under pressure.
not designed. * Disassemble them only after the associated hydraulic circuit has been depressurized.
7.1.4 Accumulator
If the hydraulic power unit is equipped with accumulators, the regulations applicable at the installation site must be observed before commissioning and during operation. There is a "Specific product user manual" next to each accumulator.
* Keep the documents delivered with the accumulator carefully. They are needed during repeated tests by experts.
is heard. * On the oil side, the hydraulic system is tightly sealed, vented (see Chapter
7.1.7 "Bleeding the complete hydraulic system of the machine") and unpressurised.
* The accumulator is filled at the prescribed gas preload pressure, in accordance with the information in the circuit diagram.
gas filling
Use only nitrogen as gas! (Nitrogen class 4.0 Purity; N2 99.99 Vol. -%)
* Only the operator is responsible for complying with the controls before the commissioning and the repeated controls.
7.1.5 Filling the hydraulic system
Proceed as follows to fill the hydraulic system with a suitable specified oil:
* Pay close attention to cleanliness when filling the hydraulic system.
* If the hydraulic power unit is dirty after transport or storage, clean the filler openings in the oil tanks before opening it.
* Never remove the filter screens in the filling openings or the filter elements of the filters during filling.
* In case of long-term transportation and storage, check whether there is water in the oil tanks and, if necessary, drain the water with the drain valve.
Recommendation: Experience has shown that the cleanliness class required for machine operation is already exceeded for new oils in original containers.
If you want to be sure of the cleanliness class, when the hydraulic power unit needs to be filled, do this with a special filtering unit.
or use a filter station with a fine filter. Proceed as follows when filling the pump housings:
* For pumps with a leaking oil connection, fill the casing with oil (see also "Specific product instruction manual").
* The oil tank, plumbing system, drives etc. Note the maximum/minimum fluid level, taking into account the volume.
7.1.6 Switching on the electricity supply
See the machine manufacturer's manual.
7.1.7 Bleeding the complete hydraulic system of the machine
See the machine manufacturer's manual.
Bleeding the hydraulic system from the highest point of the hydraulic components.
7.1.8 Commissioning
If there is no commissioning instruction for the machine to be taken into account, the following steps should be followed.
Damage to people and property
Thanks to commissioning, the functions of the machine are activated.
* Make sure existing protection mechanisms are activated.
* Start the electric motor in step operation. Check the direction of rotation.
* Flushing the hydraulic system as described in section 7.1.9.
* Command the directional valves and move the actuators in and out several times. Repeat the airing procedures. (If there is no oil foam in the oil tank,
air purge is provided if the consumer does not have knocking movements and does not produce abnormal noises).
* Operate with low pressure until the hydraulic power unit is completely bled. Increase the load step by step.
* Observe the fluid level in the oil tank and top up if necessary.
* Observation of operating temperature when the machine is fully commissioned.
* Control of external leaks; elimination of leaks; leak check at ports after a few hours of operation. To aid a systematic search or limiting errors
A matrix for "Causes of faults in hydraulic power units and their effects" is available (see Chapter 14).
7.1.9 Flushing the hydraulic system
Flushing the hydraulic system to achieve a defined degree of cleanliness of the oil prevents malfunctions and also prolongs the life of the parts. After the hydraulic power unit is installed on the machine or connected to the hydraulic system, the minimum cleanliness class requirement for the parts must be met. Hydraulic systems in general industrial applications require a cleanliness class 20/18/15 according to ISO 4406; also hydraulic systems with servo valves or high-quality regulating valves have higher requirements in terms of cleanliness class: e.g. class 19/16/13. Consider the cleaning requirements of the parts in accordance with the manufacturer's data bulletins to determine the wash target to be achieved.
Preparations:
• Preparation of spare or washing filter elements
• When needed: Preparing additional piping and hose material for arranging flushing or short-circuit connections
• Preparation of wash plates, alternative direction valves
• Depending on the situation: Preparation of washing liquid (see note below)
The same material can be used, which will also be used during the subsequent operation of the hydraulics. If another oil is used, it must be compatible with the operating agent intended for the hydraulic system and the raw materials used in the hydraulic system, especially the sealing element. Under certain conditions, the maximum allowable residual washing liquid (eg 0.5% by volume) in the operating medium may be defined (see manufacturer's information); in such a case, it must be ensured that the washing liquid is drained carefully before filling with the operating medium. In hydraulic systems with complex lines, the washing process must be planned in detail and applied carefully. This is unavoidable especially if the piping is welded and/or pickled. In the following applications, it is assumed that the washing process is carried out with the hydraulic power unit described in this user manual. If a stand-alone washing unit is used, the operating instructions for the respective unit must be observed! For washing operation, the hydraulic power unit should be brought to operating temperature whenever possible and operated with low pressure settings. Remember to disable existing pressure control circuits for flushing or set to lower flushing pressures. A general statement cannot be made for the duration of the washing. It is recommended to take periodic oil samples during washing and have them analyzed for cleaning. For example, the return piping in front of a return filter that may be present is a suitable sampling location. Based on the result, a decision should be made whether to finish the wash (once the target cleaning is achieved) or continue. The operating pressure should only be adjusted for pressure valves designed for this purpose. Never change the settings of sealed valves or factory-set valves. After the washing is finished, consideration should be given to re-establishing the operating settings of the hydraulic power unit, disassembling any possible washing connections and sealing the connection points in a pressure-tight manner. If wash plates are replaced with original valves, they must be installed according to the manufacturer's instructions.
7.1.10 The most common mistakes made during commissioning
• Oil tank is not checked
• Oil is filled without filtering
• The hydraulic system is not fully bled.
• Pressure relief valves are set too close to the working pressure (not taking into account the shut-off pressure difference)
• Pressure regulators of hydraulic pumps are adjusted higher or at the same height than the pressure relief valve.
• Unusual pump noises are not taken into account (cavitation, leaking suction line, excess air in the oil)
• Circuit break due to pressure switch is not taken into account during adjustment
• The casing of hydraulic pumps and hydraulic motors is not filled with oil before commissioning
• Adjustment values are not saved
• Personnel who did not participate in the work during commissioning are close to the device
7.2 Restarting after a long wait
In case of re-commissioning after long-term deposit, proceed as follows:
* Check:
–– oil level
–– accumulator pressure on the gas side
–– leakage of hydraulic element and plumbing system
* Follow the commissioning procedures with great care.
* Bleed the hydraulic system.
* Observe the information in the machine manufacturer's operating instructions.
8 Study
The hydraulic power unit is designed to be fitted inside another machine as a partially completed machine. Information on the operation of the hydraulic power unit can only be prepared together with the machine. You can find this information in the machine manufacturer's user manual. The functions and logic of the hydraulic power unit can be learned from the documents of the product prepared by specialist personnel in the field of hydraulics.
9 Service
HİDROMAN offers a comprehensive service for the maintenance of the hydraulic power unit. You can submit your request to a representative of HİDROMAN near you or
directly to the main factory. You can get the addresses from www.Hidroman.com.tr. Service tasks (inspection, maintenance, repairs) should be defined based on component-specific needs, operating conditions (pressures, temperatures, ambient conditions) and usage (on time, cycle times, shift work). See the machine manufacturer's manual.
In this context, an eye control should be applied:
• Unread notes and warning signs
• Leaks
• Loose and/or missing parts
• Impact symptoms
9.1 Service documentation
It is recommended to document the audit results and the measures derived therefrom.
––so that the inspection periods can be adapted to the actual working conditions, taking into account functionality and economy,
––because, thanks to benchmarking, early diagnosis of faults (preventive service) is provided.
Negative trend of test parameters, e.g. oil temperature, replacement periods of filter elements or noises indicate changes. Fault
the search matrix (see chap. 14) provides a helping hand for problem identification. Increasing temperature and/or shorter filter change periods,
indicates possible wear on pumps, control corners, sealing elements and aging of the oil and
constitutes a justification for the control of the elements. Sudden and strong temperature rise is an alarm sign and requires immediate checking of the machine.
9.2 Cleaning and maintenance (protection)
The ingress of dirt and any liquid will cause malfunctions!
Therefore, the safe operation of the hydraulic power unit/elements cannot be guaranteed. * Pay great attention to cleanliness in all work on the hydraulic power unit.
Surface damage by solvents and abrasive cleaning agents!
Abrasive cleaning agents can damage the seals of the hydraulic power unit and cause them to wear out more quickly. * Never use solvents and abrasive cleaning agents.
Damage to hydraulics and seals!
The water pressure of a high pressure washer can damage the hydraulics and seals of the hydraulic power pack.
* Do not use a high pressure washer to clean.
* Close all openings with suitable protective devices to prevent cleaning agents from entering the hydraulic power unit.
* Make sure that the gaskets and covers of the electrical connections are firmly seated so that no cleaning agent can enter.
9.3 Inspection, maintenance, repair
The recommendations are based on: the Central European climate and the burden on the environment, as in metalworking businesses. Perform a cleaning if necessary before starting inspection work. Pay attention to cleanliness during all work on the hydraulic power unit.
9.3.1 Fill level
Fill level control should be applied every 8 hours. The oil level of the hydraulic power unit is not constant. Level changes are due to the different volume requirements of the piston cylinder and differential cylinder, or the intake/discharge of oil from the hydraulic accumulators during a duty cycle. During the visual oil level check, a complete operating cycle of the machine should be observed to determine whether and how much oil should be added based on the above. The oil level must not exceed the upper mark and must not fall below the lower mark during operation. If the minimum fill level is exceeded, there is a danger that the pump will fail due to cavitation. Exceeding the maximum fill level may have occurred due to heat expansion in the oil or fluid ingress (eg water in case of internal leaks of oil-water heat exchangers). Optionally, the hydraulic power unit can be equipped with an electric level monitor. Circuit points can be learned from technical specifications and circuit diagram.
Measures in case of exceeding the maximum occupancy level:
• Expansion due to temperature rise (extra determination: Δ V = coefficient of thermal expansion x Δ T)
––Correction of fill level
• Exceeding the maximum fill level due to water ingress due to malfunction
–– Close the water valves (blocking the coolant supply)
–– Take an oil sample from the deepest point of the oil tank and check the water content
–– If a default water inlet is confirmed, end the machine run step and shut down under safe conditions
–– Have oil-water exchangers repaired or replaced if necessary according to the manufacturer's instructions
–– Implement comprehensive control measures and, depending on their consequences, implement the following measures:
• Clean, drain or change oil
• wash if necessary
• Checking the oil for the permissible water content
Measures in case of falling below the minimum occupancy level:
Risk of damage to people and property due to oil loss!
Oil loss is always linked to a leak.
* First identify the root cause of the leak and eliminate it.
* After that, fill the oil to the full fill level.
9.3.2 Oil temperature (optional)
Oil temperature control should be applied every 8 hours. Depending on the order, the hydraulic power unit can be equipped with a thermometer or an electric temperature measuring device. Contact points can be learned from technical specifications and circuit diagram. Possible causes of temperature rise are:
• Malfunction of heat exchangers
• Change of cooling water conditions
• Malfunction or incorrect adjustment of pressure valves (eg maximum pressure limitation, pump regulator, pressure reducing valve)
• Faulty operation of the heater
• Failure in the pump (wear, increase in leakage)
• Changing ambient conditions (eg increased ambient temperature)
• Changed load conditions on drives. An undesirable temperature rise must be found and remedied.
9.3.3 Contamination monitoring of filter elements (optional)
The contamination status of the filters is checked every 8 hours. HİDROMAN filters are used as standard. If the allowable differential pressure in these filters is exceeded, an optical signal is given by the appearance of a red bar. After a cold start, the red pollution indicator bar must be pressed down after the operating temperature has been reached (control function). If the rod pops out again immediately during this check, the filter element should be replaced at the end of the shift at the latest. In addition, the control devices may be designed as electrically equipped. Contact points can be learned from technical specifications and circuit diagram. If filters from other manufacturers are used, different optical or electrical contamination indicators may be integrated. In individual cases, an indicator may not be used depending on the order. Be suspicious if the pollution indicator shows no necessary change over several inspection periods. Of course, this may be an indication that the oil is clean. But this may also be due to the following reasons:
––The contamination indicator is faulty.
––The filter element is defective.
–– Possible bypass valve not closing completely (eg due to dirt particles carried in). Action: Schedule and execute a filter change after the end of the shift. If the required replacement intervals for the filter elements are shortened, the cause of the increased ingress of dirt must be identified and remedied.
Risk of injury from falling parts!
Depending on the filter size, the filter housings can have a significant weight.
* Ask for help from a second person if necessary.
Before starting work, have ready a drain pan for oil, as well as a container for the filter housing and filter element. filter element
9.3.4 Pressure values
If the behavior of the drives is changing, it is necessary to check the pressure values (eg prolongation of the cycle time, quality of the end product, etc.). Apart from this, a check-up is recommended at least every three months. We recommend keeping the pressure values within the framework of the service documentation. eg. seals attached to the accumulator safety valves indicate that the original pressure setting has not been changed. Valves that have been sealed before reaching the set pressure cannot be checked under a normal inspection. The inspection here includes that the seals are undamaged. In case of defective seal, contact the manufacturer.
9.3.5 Oil maintenance
Oil analysis should be performed at least once a year. For oil analysis, an oil sample should be taken appropriately. The oil sample should be checked in a licensed laboratory according to the oil manufacturer's information. Based on the findings, other measures should be implemented if necessary, e.g.:
• Additional filtering measure
• Oil dewatering
• Replacement The use of reconstituted oil (refined oil) should be avoided.
* In the event of an oil change, the oil must be drained completely (see
Section 10.1 "Preparing for deactivation").
At this time, attention should also be paid to the complete discharge of installations and components. You should also implement ventilation measures if necessary. The filling process is like the initial filling; Afterwards, air bleed should be applied in the hydraulic system.
9.3.6 Hydraulic accumulator
Damage to people and property!
Accumulators are a potential source of danger. Due to the gas discharged under pressure, physical and life-threatening dangers may arise. Particular care must be taken when working on hydraulic systems with accumulators, because violations of the rules can cause serious accidents.
* Never apply welding, soldering or mechanical operations on accumulators!
Damage to people and property!
If air or oxygen is used as the accumulator, there is a high risk of explosion!
If unclean gases are used, the contaminants or water content in them can cause unpredictable and uncontrollable problems.
why could it be.
* Use only nitrogen as gas in the accumulator (nitrogen class 4.0 Purity; N2: 99.99 Vol-%)!
Damage to people and property
During the discharge of nitrogen from the accumulator, the oxygen in the air is pushed out. Even death from fainting or suffocation can occur in small spaces.
* Before discharging the nitrogen gas, open the doors and windows of the room where the accumulator is located.
Damage to people and property
During the discharge of nitrogen from the accumulator, too much pressure increase can occur.
* Before discharging the nitrogen gas, open the doors and windows of the room where the accumulator is located.
There are legally prescribed controls for accumulators; they should be applied at specified intervals. Responsibility belongs to the operator. Incorrect operation of the accumulator may cause frostbite, so the gas pressure should be checked periodically according to the information in the circuit diagram.
Risk of injury!
Due to the rapid evacuation of nitrogen gas, a strong cooling occurs in the discharge elements. This causes burns in case of contact with unprotected skin. * Wear insulating gloves and avoid contact with overcooled device parts. Allow sufficient time for the overcooled appliance parts to equate to ambient temperature again! Observe the information in the battery manufacturer's user manual as well as the current version. The main maintenance measure for hydraulic accumulators is checking and adjusting the gas charging pressure. For this purpose, only the control and filling devices recommended by the manufacturer for filling the accumulator should be used. Note that the gas filling pressure should be selected depending on the temperature of the gas. At this time, care must be taken not to exceed the permissible pressure for the accumulator. Make sure the gas valve is securely closed after each check or adjustment. Before removing the hydraulic accumulators, the fluid pressure in the tank must be reduced to ambient pressure (ie no pressure). Maintenance, service and/or replacement of hydraulic accumulator components must only be carried out by adequately trained personnel (see Section 2.6 "User's Obligations"), using parts and materials whose manufacture is documented in accordance with current specifications and based on written instructions. Before an accumulator is disassembled, it must be completely depressurized on the gas side as well as on the fluid side.
9.3.7 Hose lines and compensators
Hose fittings and balancers consist of an elastic part (hose/bellows) and double-sided mounted fittings.
• Hose assemblies can optionally be delivered with:
• Friction protection (to be installed only where concrete friction occurs)
• Hose catch safety
• Splash protection (also possible with hose catch protection)
• Fire protection (only possible without hose catch)
Hose fittings and balancers are elements that require constant monitoring.
* If the following are detected during the inspection, replace them:
• Damage to the outer layer down to the inside (eg friction points, cuts or crevices).
• Significant signs of overheating, fire: charring, bubble formation or crusting due to localized heat effect (Hot Spots)
• Embrittlement of the outer layer (crack formation of the elastic part).
• Improper deformation of the elements; both unpressurized and pressurized.
• Missed spots.
• Fastener damage or deformation (sealing function impaired).
• Corrosion that reduces the operation of the fastener and its strength.
• Hose protruding from the fitting.
• Exceeding the storage and usage time.
9.3.8 Piping
Piping consists of pipes and fittings.
Connection types:
• Connection made by giving form to the pipe
• Bordel connection
• Welded ferrule connection
• Ferrule connection
• Flange connection
Inspection of piping should be done at least every six months (maybe more frequently depending on operating conditions and usage). Prior to visual inspection, cleaning may be required. Things to consider during the check:
• Corrosion
• Crack formation
• Leaks
• Sign of impact
In case of leakage in the fasteners, they should be tightened once and recorded. If there is a leak in this screw connection, the screw connection should be investigated in detail for leaks. Depending on the finding, the seals should be replaced and/or the screw joint should be replaced with the pipe piece. The same should be done for leaks in the flanges.
In case of cracks or leaks in the weld seams, the cause must be found and stopped. Affected parts must then be replaced or
must be properly repaired.
In the event of an impact, the cause must be found and stopped. Then the element and the adjacent pressure-transmitting elements are also inspected for damage.
should be checked. If necessary, these elements should be replaced or properly repaired.
In case of any sign of corrosion, the element should be checked for damage and evaluated in a subsequent reliable application. If necessary, this element should be replaced or properly repaired. In any case, corrosion protection must be provided.
9.3.9 Heat exchanger
Depending on the order, the following may be installed:
• Oil-air heat exchanger
• Oil-water heat exchanger
In case the cooling power of the heat exchanger decreases, the manufacturer's instruction manual should be consulted. In the case of using water filters in the cooling water circulation, the water filter elements should be checked every six months and cleaned if necessary. In the case of using oil-air heat exchangers, the fins must be checked regularly for contamination and cleaned if necessary.
9.3.10 External inspection of oil tanks and steel elements
The external inspection is a visual inspection and should be done at least every six months (maybe more frequently depending on operating conditions and usage).
Prior to visual inspection, cleaning may be required. Visual inspection is based on:
• Leaks
• Crack formation
• Corrosion
• Crushed due to impact.
In case of leakage in the elements screwed into the oil tank, they must be tightened once and recorded. If this point causes leakage again, the contact site should be investigated in detail for leakage. Depending on the finding, the seals and/or element should be replaced. Leaks in flanged elements should be treated in the same way.
In case of cracks or leaks in the weld seams, the cause must be found and stopped. Affected elements must then be replaced or specialized repaired.
In the event of an impact, the cause must be found and stopped. The element and adjacent elements should then be checked for damage. If necessary, these elements should be replaced or repaired in a specialized manner. In case of signs of external force effect on the oil tank, internal control should be applied on the oil tank.
In case of any sign of corrosion, the element should be checked for damage. If necessary, this element must be replaced or repaired in a specialized manner.
should be done. In any case, corrosion protection must be provided.
9.3.11 Internal inspection of the oil tank
The internal check is a visual inspection of the oil tank interior and is usually performed when the oil is changed. Oil change is made depending on the results of the oil samples taken. Before the visual inspection can be carried out, the oil must be completely drained (see also Chapter 10.1 "Preparing for decommissioning"). In case of contamination, an internal cleaning should also be applied.
Considerations during visual inspection/control:
• Corrosion
• Crack formation
• Foreign body
• In the case of screw connections, check that they are firmly seated.
walk-in oil tanks
Prerequisite: The controller must not suffer from claustrophobia and must be physically fit for movement in tight spaces! Advice: Have a second operator ready with a fire extinguisher before working inside an oil tank. If the controller must go with its whole body inside the oil tank, it must be properly roped and secured by at least one person outside the oil tank.
Preparation
For the controller's own safety:
• Before entering the oil tank, rescue aids should be prepared,
• Must remove watches and jewellery,
• Must wear a hat or bonnet,
• Must wear protective clothing (zipped tight-fitting overalls, no outer pockets),
• An ex-proof lamp should be used for lighting.
Damage to people and property!
There is a choking hazard in oil tanks. The air inside an oil tank must contain enough oxygen so that it can be breathed safely for personnel. * Open all covers and inlet openings before entering the oil tank. * Provide adequate breathing air, with separate ventilation if necessary. The cause of crack formation in the weld seams must be found and stopped. Affected weld seams must then be repaired in a specialized manner.
If foreign objects are found, they must be cleaned from the oil tanks. Their origin and the reason for the presence of foreign body
must exist. For the safe operation of the hydraulic power unit, consider the appropriate measures for the identified cause.
In case of any sign of corrosion, the affected part should be checked for damage. If necessary, the oil tank should be replaced or repaired appropriately.
should be done. In any case, durable corrosion protection must be provided.
In case of loose screw connections of piping and hoses, they must be properly tightened.
In loose screw connections, the parts that need to be fixed should be fully seated and the screw connection should be tightened properly.
9.4 Spare parts and wearing parts
People or things can be damaged by using the wrong spare parts!
Spare parts that do not match those given in the product documentation may cause mechanical hazards or malfunctions in the machine. * Only use the elements given in the product documentation (parts list). * Only use new seals with the required oil resistance.
* Felt materials may look the same but may differ; therefore check the material number.
Direct your spare parts orders to a dealer of HİDROMAN near you or directly to the main factory. Addresses: www.Hidroman.com.tr
You can get it from. * Submit your spare parts orders in writing. In case of emergency, you can also order by phone, but in writing without delay, eg. by fax, you must confirm.
* Provide the following information when ordering spare parts:
––Material number and order number of the hydraulic power unit (label)
––The material number of the element in question
––requested quantity
* type of shipping requested (eg express, regular shipping, air freight, courier service, etc.).
10 Deactivation
10.1 Preparation for decommissioning
Prepare collection vessels large enough to contain the entire volume of oil. The total volume of the hydraulic system, the oil tank, the plumbing system, the drives etc.
consists of volumes. Basically, take into account the applicable guidelines for the complete machine. If these user guides do not contain different information, follow the steps below:
* Avoid hazards from nearby machinery.
* Prevent the presence of people who are not involved in the process.
* Download loads or put something underneath.
10.2 Implementation of deactivation
* Switch off the electric current and prevent it from being switched on again (short-circuit on the supply side - bridging)
* Stop and secure the hydraulic pressure supply
* Depressurize the tank on the oil side
* Pour the oil into the previously prepared collection chamber. At this time, make sure that the piping and actuators are completely discharged. if necessary
Apply air venting measures.
* To decommission the machine, proceed as described in the Machine's complete manual.
11 Disassembly
Disassemble device parts only as needed. Basically, all parts that have been dismantled must be reassembled in the appropriate places.
11.1 Preparation for disassembly
Overturning, falling, uncontrolled position of hydraulic power unit
risk of injury due to replacement!
* Provide sufficient upright safety for the hydraulic power unit. * Find out from the documentation of the product whether it has sufficient upright safety.
* Remove the fastening of the hydraulic power unit only after securing the upright safety in another way.
Serious injuries, up to death, due to disassembly under pressure and electrical voltage!
If the hydraulic system is not depressurized, high pressure oil will gush out during disassembly. There is a danger of electric shock if the electrical voltage of the system is not turned off.
* Make sure that important parts of the hydraulic system are free of pressure and tension.
Overturning, falling, uncontrolled position of hydraulic power unit
risk of injury due to replacement!
In the filled state, due to the movements of the oil, a shift in the center of gravity of the mass occurs, so the hydraulic power unit may lose its upright stability. * Before disassembling, drain the oil from the hydraulic power unit as described in Chapter 10. "Shutting down".
Danger to life due to the hydraulic power unit tipping, falling or changing its position uncontrollably due to the use of unsuitable attachment points!
After prolonged use, the attachment points may no longer be present, strong enough, or not visible.
* Find out which attachment points are provided from the product documentation and only use them.
* If you want to transport the hydraulic power unit after disassembly, check the stability of the attachment points.
* Whenever possible, replace any missing or faulty mounts. Perform these studies in an expert manner.
* Screw in the screwed fastening points until the screw fits into the threaded hole and tighten the screw part by hand.
* If necessary, mark inconspicuous attachment points with a well-visible color.
Ensuring security:
Basically, take into account the applicable guidelines for the complete machine. If these manuals do not contain different information, follow the steps below:
* Perform circuit breaker as described in chapter 10 of this manual.
* Prevent the presence of people who are not involved in the process.
11.2 Perform disassembly
* For disassembly, follow the operating steps described in Chapter 6 "Assembly" in reverse order.
* Even though the oil has been drained beforehand, oil will continue to come from the hydraulic installation system of the hydraulic power unit or hydraulic system. Therefore, close the outlets of the installations with suitable p