TD8600005733 03e PDF

Technical Documentation
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Customer: Gebr. Pfeiffer AG
Order-no.: 22356
Codeword: Neyzar RM
Designation: Compact unit size 40
HYDAC-Comm.-no.: 8600005733-03
Material-no.: 3252486
Content:
1 Erection Safety Guidelines

Operation Safety Guidelines
Operating Materials and Supplies
Disposal of Spent/Used Oil
Scheduled Inspections and Maintenance
General operational instructions for Hydraulic Units
Functional Description
2 Parts list material-no.: 3252486

Spare parts list
Hydraulic diagram no.: 3110355
Assembly no.: 3110356
3 Circuit diagram-no.: 76427
4 Technical Data Sheets of used components

Register 1 - 9
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8600005733-03IE.doc // 18.01.2006 // Ebersohl Jörg englisch
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reg. item designation type
1 02 filling and breather filter ELF .. 3 .. 4

2 03 gear pump SNP1
3 05 flexible coupling AN11-37
4 06 e-motor BG100L
5 07 return line filter RF BN/HC
6 08 pressure relief valve DB4E
7 12; 13 directional valve 4WMM
8 15 speed control valve manifold block mounting DRVP
9 16 double throttle check valve Z2FS
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Technical Description
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Erection Safety Guidelines
General Information Pertaining to the Installation/Assembly of Hydraulic Systems and
Power Units
Note:
These instructions only provide general information on handling and dealing with the equipment supplied. For more information please refer to
the functional descriptions and/or or specific descriptions covering the facility and equipment. We would like to expressly point out that
commissioning, maintenance and repair work and work on functional components may only be performed by authorized and properly
trained/skilled personnel.
Content: page
1 General ................................................................................................................................... 2
2 Maneuvering Loads................................................................................................................ 2
3 Prevention of Falling Accidents ............................................................................................ 3
4 Fire and Explosion Hazard .................................................................................................... 3
5 Welding Work ......................................................................................................................... 3
6 Applicable Rules and Regulations (selection; not purported to be exhaustive)................ 3
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Sheet 1 of 3 / created 21.08.1995 Hertzig, A/EN / Simone.doc englisch
changed 07.06.2000 Balzert, HS-ED
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General Information Pertaining to the Installation/Assembly of Hydraulic Systems and Power Units
1 General
The proper protective clothing and gear is to be worn at all times when performing work (helmet,
protective footwear, closely fitting work clothes). Long hair is not to be worn loosely, no loose
clothing or jewelry including rings are to be worn. A hazard is posed by these items being caught
or pulled in during drilling work etc.
2 Maneuvering Loads
Individual components and assemblies are to be carefully attached and secured to hoisting gear
during erection and installation work. The lifting rings provided for this purpose are to be used and
the ropes to be guided in such a manner so that facility parts or projecting piping components are
not damaged.
Oil tank assemblies can be suspended by inserting extended pipe pieces in the reinforced
corners of the tank feet. In so doing, the rope loads are to be evenly distributed and the load not
allowed to shift in an uncontrolled manner during lifting or maneuvering. If necessary, tie-bars are
to be used.
Only suitable, intact, properly functioning hoisting gear and load suspension devices possessing
sufficient rated carrying load are to be used.
Under no circumstances is work to be performed beneath suspended loads, in other words they
are to be kept clear of at all times.
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Sheet 2 of 3 / created 21.08.1995 Hertzig, A/EN / Simone.doc englisch
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General Information Pertaining to the Installation/Assembly of Hydraulic Systems and Power Units
3 Prevention of Falling Accidents

When performing erection work at elevated levels, only safety-tested climbing equipment and
working platforms are to be used. Under no circumstances may machinery components be used
for climbing up.
When working at extremely high levels, safety belts etc. are to be worn.
All handles, steps, railings, platforms, landings, and ladders etc. are to be kept clean and free of
snow and ice.
4 Fire and Explosion Hazard

Welding, blow-torch and sanding work may not be performed unless express permission is given.
Fire or explosion hazard may be present. Smoking and open fires are only permitted in
designated areas.
5 Welding Work
Welding work on piping and the oil tank may only be done by certified welding specialists. Proof
of certification must be evidenced.
6 Applicable Rules and Regulations (selection; not purported to be exhaustive)

Accident Prevention Regulations [UVV], version dated 1 April 1993
Safety Rules and Regulations of the Trade Association of the Iron and Steel Industry
Safety Regulations Applicable to Crane Operators and Painting/Coating Personnel
Safety Marking Regulations VGB 125 DIN 4888 Parts 1 - 3
Fire Prevention Regulations (Reich Law Gazette [RMBl]), version 1940
Environmental Protection Regulations
Working Hours Regulations
Law Pertaining to the Protection of Working Youth
Maternity Protection Act
First aid to be administered in the event of accidents
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Sheet 3 of 3 / created 21.08.1995 Hertzig , A/EN / Simone.doc englisch
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General Instructions for Operation of Hydraulic Systems and Units
Note:
Content: page
1 General Safety Instructions................................................................................................... 2
2 General Instructions .............................................................................................................. 2
3 Safety Instructions for Pressure Accumulators................................................................... 3
4 Instructions for Use of Pressure Accumulators................................................................... 3
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Sheet 1 of 3 / created 30.03.1995 Hertzig, A/EN / Sibete.doc englisch
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1 General Safety Instructions

The design of hydraulic systems and units is based on the latest state of technology.
A reliable function is only guaranteed when observing all instructions, adjustments and ratings.
As the units are pressure producing and all used components are subject to fluid and gas
pressure the units may be dangerous caused by inexpert handling and if untrained personnel is
allowed for operation, maintenance and service.
Warning with inexperted and unforeseen use.
To guarantee safe operation the following items have to be observed:
2 General Instructions
As long as hydraulic systems and units are subject to hydraulic pressure or electric voltage no
interference is allowed.
Pressure accumulators are always to be depressurized at fluid side. Existing cylinder loads have
to be ceased by discharging to the oil tank.
Gas-side working is only allowed after depressuring the gas side.
Hydraulic units are only to be operated through trained personnel.
All security devices have regularly to be checked concerning their good condition.
Adjustment of leaded pressure relief valves is not allowed.
Security devices are not allowed to be removed, to be made ineffective or to be ignored due to
risk of accidents.
This operation and maintenance instruction is only valid for the HYDAC scope of supply. For all
parts not belonging to our scope of supplies please consider the instructions of the corresponding
manufacturer.
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Sheet 2 of 3 / created 30.03.1995 Hertzig, A/EN / Sibete.doc englisch
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3 Safety Instructions for Pressure Accumulators
For pressure accumulators the prevailing rules for pressure tanks at site have to be observed.
Pressure accumulators which are subject to acceptance have to be controlled by the
corresponding authority.
The allowed operating data, manufacturing data and approved seal have to be stamped on the
outside of the accumulator shell.
Besides that all rules for announcement at site and repeated tests are also valid.
4 Instructions for Use of Pressure Accumulators
The limits of gas filling pressure (p0), operating pressure during operation and operating
temperature have to be strictly observed in conformity with the allowances of the acceptance and
the stamped data at the pressure accumulator.
No welding or soldering works and no mechanical works are allowed on the accumulator shell.
Mounting or dismounting works are only to be executed after draining the pressure fluid and gas
filling pressure.
Working at the system is only allowed after draining the pressure fluid.
After connection the hydraulic piping has to be vented completely.
A new or repaired pressure accumulator has to be charged with nitrogen before starting up to the
requested gas pressure p0.
Oxygen, air or inflammable gas shall never be used due to highest explosion danger.
The lead of the used type-tested safety valve shall never be removed nor the valve set higher.
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Sheet 3 of 3 / created 30.03.1995 Hertzig , A/EN / Sibete.doc englisch
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General List for Hydraulic Systems and Power Units
Note:
Content: page
1 Application.............................................................................................................................. 2
2 Hydraulic oil............................................................................................................................ 2
3 Grease..................................................................................................................................... 2
4 Oil binding agent .................................................................................................................... 2
5 Corrosion Protection ............................................................................................................. 2
6 Cleaning agents/degreasers: ................................................................................................ 3
7 Nitrogen: ................................................................................................................................. 3
8 Filter elements/tank breather: ............................................................................................... 3
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Sheet 1 of 3 / created 24.08.1995 Hertzig, A/EN / Stoffee.doc englisch
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1 Application
This list pertains to hydraulic systems and power units operated using mineral oil H-LP according
to DIN 51524 (HM according to ISO TC 131 DP 6074) and are equipped with diaphragm and/or
piston accumulator(s).
2 Hydraulic oil
• Mineral oil HL-P DIN 51524.
• Use filter unit OF ... for filling oil and draining.
• Only the oil used for the initial filling may be used for topping off to compensate for oil loss.
3 Grease
• Lithium-based antifriction bearing grease preferably with MoS2 content for the spherical rod
eyes of the hydraulic cylinders.
• Grease according to DIN 51825/DIN 51502 K 3 N/KH 3 R for the roller bearings of the electric
motors with an insulation class of B or F.
• A grease gun is required for greasing/lubrication work.
4 Oil binding agent

In the event that oil or other hazardous fluids are spilled, the following binding agent is
recommended for clean-up work:
• CHEMADRY, made of mineral granulate, manufactured by Chemsearch, or equivalent.
5 Corrosion Protection
• Apply Valvoline -Tectyl 846-K-19 (or equivalent) using a brush.
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Sheet 2 of 3 / created 24.08.1995 Hertzig, A/EN / Stoffee.doc englisch
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6 Cleaning agents/degreasers:
The following are recommended for cleaning and degreasing work:
• ND-150 water-soluble, degreasing action, manufactured by Chemsearch, or equivalent.
• Non-linting, clean paper towels.
• No-linting cleaning cloths.
• Cleaning waste/cotton/wool
Under no circumstances may the cleaning agent be allowed to seep inside the hydraulic system
or individual components.
7 Nitrogen:
Nitrogen for initial charging of the accumulator:
• Standard nitrogen bottles with 200 bar filling pressure
• A FPK or FPU charging and testing unit is required for checking and topping off the
accumulator (diaphragm/piston accumulator)
• A nitrogen charger is required for filling pressures above or slightly below the standard
pressure of 200 bar.
8 Filter elements/tank breather:

The following is to always be kept on hand for every filter in service:
• 2 complete original filter element sets
• 1 complete reserve air filter
Replacement packages of
• SILIKA-GEL granulate, grain size 2 - 8 mm
are required for tank air breather units featuring desiccate (air dehumidifiers).
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Sheet 3 of 3 / created 24.08.1995 Hertzig , A/EN / Stoffee.doc englisch
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General Information Pertaining to Commissioning and Changing the Oil in Hydraulic
Systems
Note:
Content: page
1 Application.............................................................................................................................. 2
2 Draining Hydraulic Components of Anti-Corrosion Oil........................................................ 2
3 Draining an Oil Tank during an Oil Change.......................................................................... 2
4 Disposal .................................................................................................................................. 3
5 Available Equipment .............................................................................................................. 3
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Sheet 1 of 3 / created 12.01.1995 Hertzig, A/EN / Entsore.doc englisch
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General Information Pertaining to Commissioning and Changing the Oil in Hydraulic Systems
1 Application
The following specifications refer to hydraulic systems using the following mineral oils as the
hydraulic medium:
H-L and H-LP according to DIN 51524 (HM according to ISO TC 131 DP 6074).
The media indicated here are "water pollutants" or substances hazardous to rivers, lakes and
other bodies of water. All national and international rules and regulations currently applicable to
handling such substances are to be adhered to and shall take precedence over the following
general stipulations.
2 Draining Hydraulic Components of Anti-Corrosion Oil

Prior to commissioning a hydraulic system, the RENOLIN MR 15 anti-corrosion oil filled in the
various components (pumps, hydraulic cylinders etc.) is to be drained/removed.
This oil is to be drained into suitable receptacles making sure that none of it is spilled.
The oil is to then be collected in an oil drum.
3 Draining an Oil Tank during an Oil Change

The hydraulic medium is to be pumped into oil drums using suitable equipment or temporarily
collected in non-leaking trays of sufficient size, making sure that none is spilled.
The hydraulic medium is to then be collected in an oil drum.
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Sheet 2 of 3 / created 12.01.1995 Hertzig, A/EN / Entsore.doc englisch
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General Information Pertaining to Commissioning and Changing the Oil in Hydraulic Systems
4 Disposal
High-grade spent/used oil can be re-refined. Re-refining is possible providing the oil has not been
mixed with other types of fluids or other waste. Mixing of these substances is prohibited.
Disposal is considered to be proper when the possibility of re-refining or recycling spent/used oil
is afforded.
Depending on the quantity spilled, spilled oil is to be sopped up with rags, sawdust or a suitable
oil binder. The resulting oil-soaked waste has to be properly collected and disposed of.
The oil types indicated below are classified as belonging to "oil category 1".
"Category 1" is characterized as "re-refinable or reprocessable used/spent oil".
Limit values:
• PCB content less than 20 ppm (parts per million)
• chlorine content less than 0.2 %
Typical category 1 oils:

• motor oils
• transmission oil
• machine oil
• H-LP grade hydraulic oil
5 Available Equipment
The hydraulic stations are equipped with oil trays which catch dripping oil and prevent hydraulic
oil from spilling on the floor or penetrating the foundation while doing repair work or changing filter
elements. Oil tanks and oil trays are equipped with oil drain plugs and drain cocks.
The oil trays are to be cleaned regularly following the instructions given above.
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Sheet 3 of 3 / created 12.01.1995 Hertzig , A/EN / Entsore.doc englisch
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General Instructions for Performing Preventative Inspections and Maintenance
Note:
Content: page
1 Application............................................................................................................................ 2
2 General ................................................................................................................................. 2
3 Maintenance during Commissioning .................................................................................. 3
3.1 Filters ..................................................................................................................................... 3
3.2 Temperature .......................................................................................................................... 3
3.3 Leaks ..................................................................................................................................... 3
3.4 Fluid Level ............................................................................................................................. 3
3.5 Oil Purity ................................................................................................................................ 3
4 Scheduled Routine Maintenance ........................................................................................ 4
4.1 Alignment............................................................................................................................... 4
4.2 Monitoring of the Nitrogen Charge Pressure of Accumulators ............................................... 4
4.3 Filters ..................................................................................................................................... 4
4.4 Fluid Level ............................................................................................................................. 4
4.5 Checking the Oil Level........................................................................................................... 4
4.6 Piping System........................................................................................................................ 5
4.7 Output/efficiency.................................................................................................................... 5
4.7.1 Pressure check:................................................................................................................... 5
4.7.2 Output check: ...................................................................................................................... 5
4.7.3 Noise check:........................................................................................................................ 5
4.7.4 Check the electrical connections and the control voltage.................................................... 5
5 Scheduled Periodical Maintenance .................................................................................... 5
5.1 General.................................................................................................................................. 5
5.2 Daily to Weekly Maintenance ................................................................................................ 6
5.3 Weekly to Monthly Maintenance ............................................................................................ 6
5.4 Quarterly to Six-Monthly Maintenance ................................................................................... 7
5.5 Yearly Maintenance ............................................................................................................... 7
6 Causes of Malfunction, Troubleshooting ........................................................................... 8
6.1 General.................................................................................................................................. 8
6.2 Type of Malfunction ............................................................................................................... 8
6.3 Locating the Cause of Malfunction ........................................................................................ 8
6.4 Troubleshooting Lists........................................................................................................... 10
6.4.1 Malfunction 1: excess noise in the facility.......................................................................... 11
6.4.2 Malfunction 2: no pressure or insufficient pressure ........................................................... 12
6.4.3 Malfunction 3: unusual pressure or flow fluctuations and vibration ................................... 13
6.4.4 Malfunction 4: insufficient or no delivery............................................................................ 14
6.4.5 Malfunction 5: temperature of hydraulic fluid is excessively high ...................................... 15
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Sheet 1 of 15 / created 12.10.1994 Hertzig, A/EN / Warte.doc englisch
changed 19.08.2002 HS-ED R. Hertzig
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1 Application
These instructions apply to hydraulic systems and power units equipped with switching valves,
proportional valves and accumulators and are operated using H-LP mineral oil according to
DIN 51524 (HM according to ISO TC 131 DP 6074).
These instructions do not apply to hydraulic systems and power units equipped with highly
dynamic servo valves.
2 General
The basic prerequisites for proper, reliable operation are that the entire facility be kept clean and
properly maintained.
The operating and maintenance personnel must be thoroughly acquainted with proper operation
and applicable safety regulations right from the very beginning and maintain adherence thereto at
all times, these regulations to take precedence over any and all economic interests or production
requirements. If there are any questions concerning operational measures, the individual in
charge of maintenance operations is to be contacted.
Anything out of the ordinary, e.g. strange noises, vibration, defects, malfunction etc., is to be
reported immediately.
If work is being done to the pressurized oil system or a component of the hydraulic actuating
devices, the grating actuator is to be de-energized and the hydraulic actuating device to be
depressurized.
(Close the shut-off valve, switch off the pump, relieve the pressure in the accumulator)
Warning!
A warning sign is to be affixed to the respective switch or shut-off valve containing the following
message:
Do NOT switch on — DANGER —
All hose lines are to be checked under loading for proper installation. This applies in particular to
adherence to permissible bending radiuses, maintenance of the required freedom of motion
without tensioning, twisting or abrasion.
The facility and all its components are to be frequently checked during the first 6 months of
operation subsequent to commissioning as well as after major repair work.
Particular attention is to be accorded to checking screwed fittings. They are to be tightened, if
necessary.
N.B.:
Never tighten screwed fittings under pressure. Always relieve the pressure beforehand.
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3 Maintenance during Commissioning
3.1 Filters
All filters, in particular return-line filters, are to be cleaned daily or the filter elements changed
daily during the initial phase of operation. The advantages of keeping the facility clean and its
effect on serviceable life and functional reliability of the hydraulic systems is to be frequently
impressed upon all those involved.
3.2 Temperature
Check the temperatures of the pump and motor bearings. The temperature of the hydraulic fluid
must never be allowed to exceed 50°C or fall below 30°C during operation.
3.3 Leaks
Leaks in piping and power units are to be attended to and eliminated immediately. Screwed
fittings and mountings are to be tightened frequently during the initial phase of operation.
3.4 Fluid Level

The oil level is to be checked after filling of all the systems has been completed, despite the
presence of electric monitoring devices. If oil deficiencies are detected, all the accumulators are
to be drained towards the oil tank before refilling oil.
3.5 Oil Purity

Upon commissioning and prior to starting up production, the purity of the oil is to be checked by
taking an oil sample from the oil tank.
Required purity classification: NAS 1638 grade 8 - 9
Permissible particle count for 100 ml vol. according to particle size:

Class Particle size in µm/100 ml
5 to 15 15 to 25 25 to 50 50 to 100 > 100
7 32,000 5,700 1,012 180 32
8 64,000 11,400 2,025 360 64
9 128,000 22,800 4,050 720 128
If necessary clean the oil tank and fill it with new or regenerated oil.
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4 Scheduled Routine Maintenance
4.1 Alignment
The alignment of pumps, motors, valves and cylinders is to be checked at working temperature
and, if possible, under operating pressure as well.
4.2 Monitoring of the Nitrogen Charge Pressure of Accumulators

The nitrogen charge pressure is to be checked at regular intervals. This is to be done every two
weeks during the first two months of operation subsequent to commissioning and every 4 weeks
thereafter. Checking can be done using a charging and testing unit or, if provided for in the
facility, on the oil side.
This can be done as follows:

The accumulator (charged on the oil side) is to be hydraulically isolated from the rest of the
system via the main shut-off valve in the safety and shut-off block. The relief valve of the safety
and shut-off block to the tank is opened slowly. The continuously falling pressure can be read on
the pressure gauge as long as oil is flowing. If the pressure shown on the pressure gauge falls
abruptly, the pressure reading just taken corresponds to the initial charge pressure (p0) on the
gas side of the accumulator, as only the gas volume completely fills the accumulator at this time.
4.3 Filters
The filters are to be cleaned or their elements replaced, at the latest upon clogging being
indicated by the clogging indicator.
4.4 Fluid Level

The oil level is to be initially checked every 48 hours, despite the presence of electric monitoring
devices. Leaks in the piping systems are to be looked for and if detected attended to/eliminated
immediately.
4.5 Checking the Oil Level

Oil turning dark brown is an indication that the oil is old.
Oil turning black is an indication that contamination has been caused by external influences.
Foamy or milky oil is an indication that air bubbles are trapped in it. Cloudy or slimy oil is an
indication that water is present in the oil.
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4.6 Piping System

Check the piping system for leaks. Defective components are to be replaced, screwed fittings and
mountings are to be tightened, if necessary. Hoses and tubing are to be checked as well.
4.7 Output/efficiency
4.7.1 Pressure check:
Compare all the actual pressures with their setpoint values.
4.7.2 Output check:
Check whether the speeds present are in keeping with their setpoint values.
4.7.3 Noise check:
Check pumps, electromotors and other equipment. Excess vibration of pumps and motors is a
sign that the bearings are damaged or there are air bubbles in the oil.
4.7.4 Check the electrical connections and the control voltage.
5 Scheduled Periodical Maintenance
5.1 General
The following general preventative maintenance work has to be performed at the intervals
indicated below for the facility when in normal operation.
• The oil has to be changed or regenerated.
• Seals/gaskets in the hydraulic cylinders and valves have to be replaced.
• Pumps, valves and switching devices and magnets, hydraulic motors etc. subject to
considerable loading have to be replaced.
• Pipe connections/joints and mountings have to be inspected.
The extent and frequency of maintenance essentially depend on the facility's operating
conditions.
The following maintenance intervals are recommended and may have to be adapted as
necessary as the operating conditions require.
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5.2 Daily to Weekly Maintenance

Work to be performed, extent thereof:
• Check the hydraulic fluid level and top it off, if necessary.
• In facilities with large accumulator volumes, the accumulator is to be drained towards the tank
before being refilled.
• Check the temperatures of the hydraulic power units, valves, hydraulic cylinders, hydraulic
motors and the piping system. If excess temperatures are detected locate their cause and
remedy it.
• Check the operating pressures on the pressure gauges and at the measuring points, if
necessary.
• Check for noises, switching shocks and vibration in the hydraulic power units, hydraulic
cylinders, hydraulic motors and piping system.
• If any unusual noises, switching shocks or vibration are detected find their cause and eliminate
it.
• Check valves, hydraulic cylinders, hydraulic motors, piping and hose connections for leaks and
eliminate them.
• Check all filters for clogging/contamination (cf. clogging indicator).
5.3 Weekly to Monthly Maintenance

• Check the mounting of the equipment and elements on the hydraulic power units and the
mountings of the hydraulic cylinders and hydraulic motors.
• Tighten the screws of loose components.
• Check piping and hose/tubing (joints, connection points, flanges, screwed fittings, and places
subject to abrasion and bending).
• Repair any damaged places.
• Check indicator devices such as pressure gauges, etc.
• Check the nitrogen charge pressure of the accumulators. Top off nitrogen, if necessary, and
check the accumulator on the gas side for leaks.
• Check the filter elements.
• Check the lubrication of the pivot bearings of the hydraulic cylinders and regrease them, if
necessary.
• Check the oil temperature of the hydraulic cylinders.
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5.4 Quarterly to Six-Monthly Maintenance

• Check the settings and the functional reliability of pressure relief valves, pressure sequence
valves, pressure cut-off valves, and pressure reducing valves, flow control valves, and speed
control valves (one-way restrictors) as well as pressure gauges and pressure switches.
• Check the external appearance of the facility (check for dirt buildup and damage).
• If necessary, clean the facility and repair damage.
• Check the volumetric flow rate of oil to each actuating element (hydraulic cylinders, hydraulic
motors etc.) by timing it and compare the findings with the setpoint values.
• Check the operating pressures of each actuating element (hydraulic cylinders, hydraulic
motors etc.) and compare the findings with the setpoint values.
5.5 Yearly Maintenance

• Check the internal condition of the facility components for wearing, deposit buildup and rust.
Replace any worn or damaged components.
• Change the oil and clean the oil tank.
• Vent the hydraulic system of air.
• Change the filter elements.
• Tighten the screwed fittings of the piping.
• Check for leaks.
• Check the pressure settings and conduct a functional check.
• Check the operating temperature and settings.
• Check the electrical connections.
It is recommended that hydraulic components such as pumps, valves, monitoring devices,

hydraulic cylinders and hydraulic motors be replaced. When removed, these components should
be inspected in the shop, repaired and properly stored for reuse later on.
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6 Causes of Malfunction, Troubleshooting
6.1 General
Generally speaking, any part of the hydraulic system may be the cause of malfunction.
Successful troubleshooting presupposes sound knowledge about the function and design of the
facility and the hydraulic elements contained in it. First the malfunction cause should be identified
as to whether it is of mechanical, hydraulic or electrical origin. Before looking for the cause on site
thought should be given to the possible cause by referring to the hydraulic diagram, circuit
diagram, and functional description.
6.2 Type of Malfunction

The operating personnel should be thoroughly questioned on site or a demonstration performed
— providing this will not pose the hazard of injury or damage — in another attempt to locate the
cause of trouble as being mechanical, hydraulic or electrical in origin.
6.3 Locating the Cause of Malfunction

If the cause of malfunction cannot be clearly attributed to one of the three main causes outlined
above, then a systematic search has to be made. Looking into or answering the following
questions may help in narrowing down the cause of malfunction:
a) Can malfunction be attributed to a change in the working speeds of the

consumers/actuating elements originally set?
b) Are the original working pressure settings still present?
c) Is the operational sequence disturbed, i.e. clock rate and cycle time?
d) Has there been a failure of the entire facility or only a part thereof?
e) Did malfunction creep up slowly, did output dissipate gradually?
f) Is the facility overheated?
Category a) malfunction/failure
is caused by changes in the oil flow rate. These changes may be the result of sudden
internal leakage or pressure relief valves, flow control valves or choker valves being set too
low.
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Category b) malfunction/failure
If the oil pressure is too low, the pressure generators, pressure relief valves and pressure
regulators along with the switching sequences of pressure switches have to be checked
and leaks searched for in the tubing/piping system and control or pump components as
necessary. Accumulators are to be checked as well (loss of nitrogen, defective bladder etc.)
Category c) malfunction/failure
Malfunction/failure due to the clock rate and cycle time of consumers/actuating elements
can be caused by both electrical as well as hydraulic malfunction. The contact maker
signals of limit switches, pressure switches or timing elements may have failed. Electrical
cabling may have come loose, magnets can have burned out. Control elements such as
directional valves, pressure switches, contact manometers etc. may have failed as the result
of dirt buildup or other defects.
Category d) malfunction/failure
Sudden failure of the entire facility or a part thereof is generally attributable to pump failure,
defective couplings, ruptured springs, power failure or similar causes.
Category e) malfunction/failure
Gradual arisal of a malfunction is generally an indication of gradual clogging or dirt buildup.

Gradual power/output decrease is generally an indication of excessively worn pumps and
valves.
Category f) malfunction/failure
Overheating is the result of the inadvertent blowing of pressure relief valves, insufficient oil
levels, malfunction of cooling equipment, insufficient cooling water. Excess internal leaking
as the result of cumulative wear of control devices can eventually lead to overheating as
well. In the case of pressure-controlled pumps in particular, it has to be ensured that the
settings of the main pressure relief valves of the facility are not below the setting of the
pressure governors. The pressure governor is the setting device for the operating pressure
in this case.
Higher-level pressure relief valves have to be set at a value which is at least 5 % higher.
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The tips above are designed to facilitate locating the cause of malfunction or failure, however
there is no all-in-one solution for locating the cause of malfunction or failure. If none of the
methods suggested above prove successful, then the search should be begun with pumps and
continued in the direction of the consumers/actuating elements.
6.4 Troubleshooting Lists

Other tips for troubleshooting are provided in the following lists.
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6.4.1 Malfunction 1: excess noise in the facility
Cause Reason Remedy

1.1 Cavitation in the pump Hydraulic fluid too cold. Heat the hydraulic fluid to the
recommended temperature.
The viscosity of the hydraulic fluid is Replace the hydraulic fluid by
too high. the right variety.
Formation of steam Reduce the operating
temperature to the right
temperature;
Top off hydraulic fluid or
replace it with a suitable
variety.
The booster pump has failed. Repair the booster pump or
replace it.
Pump is running too fast. Reduce speed to the right
level.
1.2 Foaming or trapping of air The hydraulic fluid level in the tank Fill to the right level.
bubbles in the hydraulic fluid is too low.
Wrong hydraulic fluid. Replace hydraulic fluid with
the right variety.
The shaft seal lets air in. Replace seal.
Poor air venting Vent the facility of air.
1.3 Mechanical vibration Coupling is improperly aligned or Align the coupling or tighten
loose. it.
Vibration in the piping Tighten the mountings or
replace them with a more
suitable type.
Pump Worn or damaged Repair pump or replace it.
Non-suitable type Replace with more suitable
type.
Drive motor Worn or damaged Repair motor or replace it.
Non-suitable type Replace with more suitable
type.
Safety valve or pressure relief Flutters Set properly or replace with a
valve suitable valve.
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6.4.2 Malfunction 2: no pressure or insufficient pressure
Cause Reason Remedy

2.1 High pump temperature Pump worn or damaged. Repair pump or replace it.
Viscosity of fluid is too low. Replace hydraulic fluid with
the right variety.
Insufficient or improperly regulated Improve or correctly regulate
cooling. cooling efficiency. Ensure
that the cooling water flow is
not impeded.
2.2 Speed of pump is too low or The coupling or the drive motor is Remedy defect.
drive power is insufficient defective
The drive motor is too small. Use a motor of the right size.
2.3 Leakage loss from the pressure Pressure setting is wrong. Correct setting.
side to the return flow
Safety valve doesn't close as the Clean it, determine whether
result of dirt buildup or defective there is damage, repair it or
components. replace it.
Directional valve or some other Determine what is defective,
valve is open as the result of dirt adjust it, clean it, repair it or
buildup or defective components or replace it.
electrical failure.
Cylinder bore, piston rod or piston- Repair damaged components
head seal damaged. or replace them
Failure of the piston-head seal as Use seals made of the proper
the seal material is not suitable for material.
the hydraulic medium being used.
2.4 Failure of the booster pump Pump damaged, drive motor Repair pump or replace it
defective, viscosity or hydraulic fluid Reduce speed to proper level
etc. is non-suitable. Replace hydraulic fluid with
the right variety.
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6.4.3 Malfunction 3: unusual pressure or flow fluctuations and vibration
Cause Reason Remedy

Formation of steam Reduce the operating
temperature;
variety.
replace it.
level
the right variety.
Poor air venting Vent the facility of air
3.3 Mechanical vibration Coupling is improperly aligned or Align the coupling or tighten it
loose.
Vibration in the piping. Tighten the mountings or
replace them with a more
suitable type.
3.4 Fluttering of pressure relief Flutters Set properly or replace with a
valve or safety valve suitable valve.
Valve seat is damaged. Repair valve seat or replace
it.
Valve has insufficient or no damping Install a more suitable valve
effect. or a damping unit.
3.5 Valve components become Dirt buildup. Drain hydraulic fluid, clean
stuck the facility and components,
and fill with clean hydraulic
fluid.
3.6 Air bubbles trapped in the Facility has not been completely Vent facility of air, cf. section
facility, in turn causing uneven vented of air. 4 "Commissioning".
or slipping movement
Defect in the electrical system. Locate cause of trouble and
remedy it.
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6.4.4 Malfunction 4: insufficient or no delivery
Cause Reason Remedy

Formation of steam. Reduce the operating
temperature;
variety.
replace it.
level.
the right variety.
Poor air venting Vent the facility of air.
4.3 Pump worn Pump failure Repair pump or replace it.
4.4 Speed of pump is too low or The coupling or the drive motor is Remedy defect.
drive power is insufficient defective
The drive motor is too small Use a motor of the right size
4.5 Leakage loss from the pressure Pressure setting is wrong Correct setting
side to the return flow
Safety valve doesn't close as the Clean it, determine whether
result of dirt buildup or defective there is damage, repair it or
components replace it.
Directional valve or some other valve Determine what is defective,
is open as the result of dirt buildup or adjust it, clean it, repair it or
defective components or electrical replace it
failure
Damaged cylinder bore, piston rod or Repair damaged components
piston-head seal or replace them
Failure of the piston-head seal as the Use seals made of the proper
seal material is not suitable for the material
hydraulic medium being used
4.6 Pump is turning in the wrong Motor's direction of rotation is wrong Reverse the polarity of the
direction electrical connections
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6.4.5 Malfunction 5: temperature of hydraulic fluid is excessively high
Cause Reason Remedy

5.1 Overflow loss Pressure setting too high Correct setting.
Poor performance of safety valve Replace by a valve of
suitable design.
5.2 Leakage loss from the pressure Valves working poorly, Correct setting.
side to the return flow seals/gaskets defective
Clean them, determine
whether there is damage,
repair them or replace them.
Determine what is defective,
adjust it, clean it, repair it or
replace it.
Repair damaged components
or replace them.
Use seals made of the proper
material.
Hydraulic fluid doesn't have the right Remove the hydraulic fluid
viscosity (too low, too high). and fill the facility with a
hydraulic fluid possessing the
viscosity recommended by
the manufacturer.
5.3 Insufficient cooling Cooling water supply failure. Remedy malfunction.
Deposit buildup in the cooling water Clean them.
lines.
5.4 Insufficient heat dissipation Machine output has been increased Improve the cooling system
without increasing the cooling and/or increase the tank
capacity accordingly. capacity and surface area.
5.5 Overheated pump Pump is overly worn. Repair pump or replace it.
A hydraulic fluid is being used Remove the hydraulic fluid
whose viscosity is too low. and fill the facility with a
hydraulic fluid possessing the
viscosity recommended by
the manufacturer.
5.6 Hydraulic fluid circulates too The supply of hydraulic fluid is Increase the hydraulic fluid
quickly insufficient. tank.
The level of the hydraulic fluid in the Fill up the facility to the level
facility has dropped too low. recommended.
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General instructions for the Commissioning, Maintenance, Repair and
Troubleshooting of Hydraulic Systems
Note:
These instructions only provide general information on handling and dealing with the equipment supplied. For more information please
refer to the functional descriptions and/or or specific descriptions covering the facility and equipment. We would like to expressly point
out that commissioning, maintenance and repair work and work on functional components may only be performed by authorized and
properly trained/skilled personnel.
Content: page
1 Preparation in Advance of Commissioning: ....................................................................... 2
1.1 Documentation required:.......................................................................................................... 2
1.2 Preparatory work:..................................................................................................................... 2
1.3 Checking and inspection work: ................................................................................................ 2
1.4 Flushing: .................................................................................................................................. 3
1.5 Filling:....................................................................................................................................... 4
2 Commissioning ...................................................................................................................... 5
2.1 Startup: .................................................................................................................................... 5
2.2 Air venting: ............................................................................................................................... 5
2.3 Setting the pressure................................................................................................................. 6
2.4 Concluding setting and inspection/checking work: .................................................................. 6
2.5 Running-in:............................................................................................................................... 7
2.6 Miscellaneous: ......................................................................................................................... 7
3 Maintenance and Repair of the Hydraulic Facility .............................................................. 7
3.1 Maintenance methods:............................................................................................................. 8
3.2 Maintenance in a Nutshell........................................................................................................ 9
4 Inspection, Maintenance and Replacement Work: ............................................................. 9
4.1 Oil level checks: ....................................................................................................................... 9
4.2 Oil temperature monitoring:...................................................................................................... 9
4.3 Pressure checks: ..................................................................................................................... 9
4.4 Checking performance: .......................................................................................................... 10
4.5 Checking for oil leakage:........................................................................................................ 10
4.6 Checking for unusual or funny noises:................................................................................... 10
4.7 Cleaning work: ....................................................................................................................... 10
4.8 Maintenance work: ................................................................................................................. 10
4.9 Monitoring the nitrogen charge pressure in the pressure accumulators: ............................... 10
4.10 Replacement work: ................................................................................................................ 11
4.10.1 Changing the oil: .................................................................................................................. 11
4.10.2 Changing filter elements:...................................................................................................... 11
4.10.3 Changing seals and gaskets: ............................................................................................... 12
4.11 Checks and inspections to be conducted on a daily basis:.................................................... 12
5 Hydraulic Oil Recommendations........................................................................................ 13
6 Causes of Malfunction, Troubleshooting .......................................................................... 13
6.1 CETOP Recommendation (cf. RPIIH):................................................................................... 14
7 Annex .................................................................................................................................... 15
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Sheet 1 of 15 / created 13.03.1998 Briam, A/EN / Allgane1.doc englisch
changed 03.06.2005 KelberA
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General instructions for the Commissioning, Maintenance, Repair and Troubleshooting

of Hydraulic Systems
1 Preparation in Advance of Commissioning:
1.1 Documentation required:

Hydraulic circuit diagrams, electric circuit diagrams and conduit/piping diagrams; assembly
drawings and sectional drawings; parts lists; functional descriptions of the facility and individual
units/assemblies.
1.2 Preparatory work:

Upon completing erection work at the installation site, the entire facility is to be thoroughly cleaned
prior to filling it with hydraulic medium. All of the protection coatings used to preserve surfaces are
to be removed as they would be dissolved by the oil and possibly have an adverse effect.
1.3 Checking and inspection work:

• Have all the components been installed/assembled in accordance with the drawings? Are they
properly aligned, secured, mounted, connected, piped, wired etc.? Have the assembly and
installation steps been properly adhered to?
• Is the proper voltage being applied to the electric motors and control circuit?
• Has the reservoir/tank been cleaned? Has the piping been cleaned or pickled?
• Have the tubing/hoses been mounted so that they won’t buckle and aren’t twisted?
• Have the pressure accumulators been filled with the right nitrogen charge pressure?
• Has the measurement equipment and instrumentation been zeroed? Have the restrictor valves
and flow control valves been closed and the pressure control valves opened? (non-
pressurized circulation required when starting up the pumps for the first time).
• Have all the safety precautions been taken for initial startup? (telephone, walkie-talkies,
emergency off switches, safety barriers).
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1.4 Flushing:
It is recommended that the entire hydraulic system be flushed in any event. Flushing agent
recommended for practical reasons: the same hydraulic fluid which will be later used to operate the
facility. In most cases the hydraulic fluid used to flush the facility can be subsequently reused
provided it is allowed to settle, followed by being microfiltered and separated. When using a
special cleaning or flushing oil, the oil supplier is to be contacted in order to determine which
flushing oil can be used in connection with the hydraulic fluid subsequently used to operate the
facility.
Caution! Take into account the viscosity differentials and the compatibility (or lack thereof) of
various oil brands.
Prior to beginning flushing, bypass the piping upstream of the consumer; completely bypass
control stands as may prove necessary.
When flushing large facilities, the facility should be subdivided into sections, so that the
contamination level can be better gauged.
Caution! Warning!
Remove the servovalves and install flushing plates!
Flushing should be done with the oil at a temperature of between + 40° and +50°C at a flow rate of
3 to 7 m/s.
The duration of flushing depends on the size and contamination level of the facility. It should
amount to between 4 and 24 hours, however no less than 1 hour.
When filling, flushing or draining the flushing medium we recommend using Hydac’s separate,
mobile Oil–Filter Pump Transfer Units. (cf. leaflet 7.900.5/...)
This equipment can also be used for bypass filtering on a constant basis or over extended periods
of time with the facility under full load.
The pump installed in the facility can also be used for flushing. Hydac’s RC 1000 Purity Controlling
System is available for monitoring and documenting the flushing results and for automatically
controlling the flushing unit (cf. leaflet 7.951.2/...)
Generally speaking, the return flow of the flushing oil is to be filtered. Fiber glass filter elements
with a filter rating of between 3 µm and 10 µm have been shown to be suitable for this purpose
(depending on the degree of purity required). Upon completion of flushing, drain the flushing oil,
clean the reservoir, and change the filter element. Flush out long pipe sections with nitrogen.
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1.5 Filling:
The crucial prerequisite for the proper functioning of the individual hydraulic components is that a
high-quality hydraulic medium be used with a viscosity of ca. 46 mm²/s at 40°C or a viscosity
adapted to the respective temperature conditions.
Please refer to our hydraulic oil recommendations when selecting the hydraulic medium (cf.
section E).
Follow the special instructions and safety precautions of the manufacturer when using fire-resistant
fluids.
Prior to filling the facility, make sure to properly clean the bung of the oil drums (drums to be stored
in a roofed-over dry place).
Filling should always be done using a fine screen with a mesh size of 0.04 mm with the facility shut
down and depressurized. The facility return-line filter can be used for this purpose.
However, when filling small hydraulic power units it is better to use Hydac’s mobile OF 7 Oil Filter
Unit as the drum pump; when filling large hydraulic systems we recommend using Hydac’s mobile
OF 5 or OFU Oil Filter Unit (cf. leaflet 7.900.5/...).
Filling should be done slowly in order to prevent air from being trapped (bubbling).
If an oil reservoir supplied by us is used, the maximum oil filling should extend up to the upper end
of the visual area of the inspection glass with the cylinder piston rod retracted and with the
accumulators depressurized on the oil side.
During operation, the oil level should not fall below the lower end of the visual area of the
inspection glass.
When specifications relating to the oil level are made in descriptions specifically relating to the
hydraulic systems or assemblies, then these specifications are to take precedence over all other
specifications.
If the customer provides the oil reservoir, no general guidelines can be given concerning the oil
supply quantity in the reservoir, as this is dependent on the facility configuration, operation and
loading.
In any event, the oil fill quantity is to be ample.
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2 Commissioning
2.1 Startup:
Warning!
Some hydraulic pumps and motors have to be filled with hydraulic fluid prior to being started up for
the first time. Please follow the manufacturer’s instructions.
The facility is to be briefly started up subsequent to checking for the proper sense of rotation of the
pumps and the electric motors. When doing this make sure that the temperature of the hydraulic
fluid upon startup is not too low as certain manufacturer’s viscosity limits may not be fallen short of
(i.e. must be maintained).
The pumps are to initially convey back into the reservoir in a non-pressurized state.
In this connection make sure that the prime mover is properly aligned, that there is no vibration and
that no buzzing sounds or other unusual noises are to be heard.
Check piping, screwed connections, tubing/hoses and hydraulic components for leaking.
When filling the facility as a whole set the pressure setting of the pressure relief valves to low and
switch the header elements so that they enable flow to the consumers.
Warning! Watch out for extending or retracting cylinders or revolving swivel actuators and
hydraulic motors as they may pose an accident hazard.
2.2 Air venting:

The entire hydraulic system has to be vented of air in order to prevent air bubbling or being
trapped and impairing facility performance. (Follow the special operating instructions for pumps
and motors, if enclosed).
Beginning at the pump, open the air detrainer cocks and screws of the valves, cylinders, swivel
actuators and motors and proceed towards the part of the system located furthest away and at the
highest point. Do not close them again until the oil exits bubble-free.
Consumers which cannot be air-bled are to be moved back and forth several times, during which
the oil level in the reservoir is to be checked.
If the pressure is low, check to see whether functions are in accordance with the circuit diagram.
The facility should be completely detrained of air after running for ca. 20 - 30 minutes. This can be
determined by examining the cylinders and motors for smooth running (i.e. no jerky movements);
no funny or unusual noises should be heard. In addition, there should be no foaming in the oil
reservoir.
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2.3 Setting the pressure

Subject the facility to the design operating pressure by slowly adjusting the pressure relief valves.
Then set the pressure relief valves of the pumps to protect the facility against overloading. To this
end, the consumer has to be in one of its end positions, have moved to the limit stop or the flow to
the consumer has to be interrupted via shutoff/isolating elements. The system pressure is to be set
ca. 10 to 15 bar higher than the required operating pressure. Under no condition is this pressure to
exceed the permissible rated maximum pressure for the facility.
2.4 Concluding setting and inspection/checking work:

• Set the working speeds of cylinders, motors and swivel actuators on the restrictor valves, flow-
control valves and flow governors as specified by the circuit diagram.
• Set the contact pressure gauges, electro-hydraulic pressure switches, thermostats, contact
thermometers and switching times of the directional valves.
• Check the design and actual sequencing. Try out all the electrical control processes.
• Check the filter elements after 1, 8 and 24 hours of operation.
• Check the temperature of the hydraulic fluid, the pumps, pressure accumulators and the piping.
When encountering unusually high temperatures locate the source and shut down the system,
if necessary. At pressure valves whose pressure setting is too low, the pressure is transformed
into heat.
• Check the nitrogen charge pressure of the pressure accumulators.
• Upon concluding setting and inspection work, turn over the operational facility to the
customer/owner. All settings made (scale/dial and pressure readings) are to be entered in the
acceptance certificate (inspection report).
• If necessary, have the facility inspected and approved by a competent authority (TÜV
(Technical Control Association), TÜG, Germanischer Lloyd or comparable authority).
• Apart from the aforementioned inspection and monitoring work, the oil pressure is to be
checked on a regular basis. When checking high-pressure and extreme-pressure systems,
exacting guidelines apply in order to prevent hazards and accidents (cf. accident prevention
regulations).
• Work may not be done on hydraulic components unless the system has been depressurized,
i.e. always switch off the pump drive motor first and completely relieve the pressure.
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2.5 Running-in:
It is recommended that the hydraulic system only be subjected to moderate loading during the first
50 to 100 hours of operation in order to improve the surface properties, achieve smooth running,
favorable gliding behavior, and improved sealing action and, thus, to prevent wear and tear.
2.6 Miscellaneous:
Apart from the items detailed above, other operating instructions (if enclosed) for pumps, control
equipment etc. are to be consulted as necessary prior to commissioning.
3 Maintenance and Repair of the Hydraulic Facility

The prime objective of maintenance is to maintain the operability and performance of existing and
newly commissioned hydraulic systems, prevent outages and failures, while keeping the costs
associated with maintaining constant operational reliability within reasonable, economically viable
limits and to minimize repair costs in the event of malfunction or failure.
The primary cause of the impaired performance of a hydraulic system is wear and tear, with
mechanical wear and tear and chemical wear being distinguished in this connection.
Mechanical wear and tear is the result of the relative movement between materials (abrasion,
deformation, seizing, sticking etc.).
Chemical wear is the result of contact with aggressive media (corrosion, erosion, aging).
In addition, microstructural changes impair the performance of a system. They are the result of
marked alternating loading through tensile stress and compression (microstructural fracture,
deformation, coating/paint finish).
Some causes of malfunction or failure are due to forces acting from without (exerting force,
operational errors, overloading as the result of tampering with automatic control elements).
Deposit buildup, contamination, soiling, cross-sectional changes and clogging are the main
indications, with impaired quality, substandard manufacturing and total failure being the
consequences.
One of the main tasks of maintenance is to recognize normal, operation-induced wear and tear in
all the forms described above, to properly assess and record them, and to prevent excess wear
and tear.
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_____________________________________________________________________________________________________________

3.1 Maintenance methods:

According to the publication issued by the Rationalization Committee of German Industry (RKW)
Handbuch der Rationalisierung (“Rationalization Manual”) there are three basic maintenance
models:
a) facility operation until failure
b) status inspections
c) preventative maintenance
Model a) According to the “facility operation until failure” method, all the measures for preventing
wear and tear are performed, yet malfunction and failures are not attended to until they
actually occur (maintenance on an individual basis).
Objective: Maximizing the serviceable life of a facility.
Model b) The “status inspections” method includes wear prevention measures. In addition,
scheduled inspections are performed. According to this method, inspections are
performed in certain intervals in keeping with the components which wear out first.
During these inspections the increase in wear and tear is noted for each time period
and individual (topical) damage which might lead to major consequential damage is
remedied.
Objective: Maximizing the serviceable life of a facility and, to a certain extent,
protecting against unforeseen malfunction or failure.
Model c)Preventative maintenance combines all of the measures of the first two methods. In
contrast to model b), precision measurements are taken to gauge the increase in wear
and tear in certain intervals. By comparing the findings of several measurements it can
be predetermined when a system component is worn to the extent that it has to be
replaced before the functional reliability of the entire system is jeopardized.
Consequently, information is obtained on the serviceable life expectancy of wearing
parts and the necessary precautions can be taken by setting up a component
replacement schedule.
Objective: Maximizing the serviceable life of a facility and protecting against
(precluding) unforeseen malfunction or failure.
Which of the maintenance methods is preferred depends on individual requirements and economic
and operational circumstances.
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______________________________________________________________________________________________________________

3.2 Maintenance in a Nutshell

Objective Work to be performed by Means
Maintaining facility operability Periodical maintenance and Checks, inspections,
and performance inspections information, ascertaining
damage
Preventing outages Recognizing weak points and Determining/analyzing the
effectively eliminating them cause of damage
Minimizing costs in ensuring Optimizing the control of repair Scheduling repair work
operational reliability work according to urgency
Minimizing costs in the event of Scheduled and well-prepared Gathering experience by
failure repair work maintaining detailed records of
previous failures
4 Inspection, Maintenance and Replacement Work:

The oil level is to be checked prior to startup, as well as when the system has run warm. Any
leakage detected is to be investigated immediately. Marked decreases in the fill quantity must not
be allowed to occur and are to be compensated for as soon as possible --- upon shutting the
system down first. When topping off oil, the same oil grade as used for the initial filling is to be
used. Before refilling oil make sure to relieve the pressure of the accumulators on the oil side so
that the reservoir does not overflow when the accumulator is emptied.
Further checks and inspections: to be conducted every 10 - 50 hours.
4.1 Oil level checks:

Conduct a visual check of the oil level. Dark brown oil is a sign of aging. Foamy, milky oil indicates
bubbling; cloudy, slimy oil contains water. Check the contamination level of the oil every 500 hours
of operation, this to best be done by conducting a dirt particle count using particle counting
equipment and comparing the prescribed/actual values using a table or having the oil analyzed in a
laboratory or by the oil supplier.
Hydac offers an oil analysis service using the particle counting unit. Please contact us for more
information.
4.2 Oil temperature monitoring:

The oil temperature is either monitored automatically by thermostats or contact thermometers,
which trigger corresponding processes (heating – cooling), or by the operating personnel. The oil
temperatures should be between 40 and 60° C. Checks should be conducted every 10 to 50 hours.
4.3 Pressure checks:
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_____________________________________________________________________________________________________________

All of the actual pressures set are to be compared with the set values specified on the circuit
diagrams. Check the maximum system pressure, reduced-pressure circuits, cut-in pressures, filling
and control pressures. Check the cut-off and cut-in pressures on pressure control valves and
pressure switches.
4.4 Checking performance:

Check the entire operating cycle and the cycle times. Check to see whether the speed settings
present on cylinders, hydraulic motors and swivel actuators correspond to the set values. Measure
the power consumption of the electric motor and compare it with previous measurements.
4.5 Checking for oil leakage:

Measure the slippage oil rate of hydraulic pumps and motors ca. every 500 hours and compare
these values with those indicated by the manufacturer. An increase in the oil slippage rate is an
indication of increasing wear and tear.
4.6 Checking for unusual or funny noises:

Are pumps and electric motors making more noise? Has vibration and shaking increased? If so,
locate the cause and remedy it.
4.7 Cleaning work:

External cleaning of the hydraulic system. Clean or replace the filter elements of air, return-line,
pressure and suction filters. The crucial prerequisite for the proper functioning of all control and
actuator elements and mechanisms is the purity of the hydraulic fluid. Consequently, the return-line
filter or high-pressure filter is to be initially cleaned after 50 to 100 hours of operation, and every
6 weeks thereafter (or more often if the hydraulic fluid is subject to heavy contamination) using
suitable agents and methods or according to the manufacturer’s instructions. Checking the
contamination level is to be done using a pressure gauge or integrated mechanical, optical or
electrical indicator.
4.8 Maintenance work:

Leakage results in loss and impaired performance. Refill the facility using the same hydraulic fluid
as used for the initial filling. Tighten screwed pipe fittings, replace hose sections, tighten the
mountings of the hydraulic units, as vibration caused by loose retaining screws leads to damage to
threaded fittings, leaks and eventually to system failure. Periodically lubricate lube points such as
shackle toggle joints and spherical rod eyes on the hydraulic cylinders. Top off the nitrogen in the
pressure accumulators.
4.9 Monitoring the nitrogen charge pressure in the pressure accumulators:
____________________________________________________________________________________________________________
______________________________________________________________________________________________________________

If pressure accumulators are integrated in the facility, make sure to check the nitrogen charge
pressure at regular intervals: every two weeks during the first two months subsequent to
commissioning, after that every four weeks. Checking is to either be done using a charging and
testing unit, or on the oil side as follows, providing this is provided for in the facility:
The pressure accumulator is to be charged up to the maximum working pressure using the pump.
Then the pump is to be switched off, the pressure accumulator to be checked is to be isolated from
the pressure line via the main stop cock. The unloading cock leading to the tank is to be opened
slowly. The continuously falling pressure can be read by referring to a pressure gauge integrated in
the pressure line as long as the oil continues to flow. The nitrogen charge pressure of the pressure
accumulator is the pressure shown just before the pressure gauge needle suddenly jumps to zero.
4.10 Replacement work:

4.10.1 Changing the oil:
The initial filling should be changed after 500 to 1,000 hours of operation. Subsequent oil changes
should be performed every 3,000 to 5,000 hours of operation. Facilities subjected to considerable
loading (dust- and/or temperature-induced) should be refilled with fresh oil every 500 to 1,000
hours of operation. The intervals indicated here are standard values; more exact values are
dependent on the oil grade used, the operating temperature and other operating conditions. It is
inadvisable to top off relatively aged oil with fresh oil as the lubricating effect or corrosion
protection is no longer satisfactory.
Be sure to clean the bottom of the oil tank when changing the oil.
4.10.2 Changing filter elements:
Disposable fiber glass elements are to be replaced every 100 to 500 hours of operation, depending
on the load to which the system is subjected. Wire mesh elements are to be cleaned of most of
their dirt in these same intervals in a vessel containing cleaning fluid. These precleaned elements
are to be rinsed with clean cold-solvent cleaning agent and blow-dried using compressed air. Deep
filtering metal fiber elements can be cleaned by Hydac using its proprietary ultrasonic cleaning
process.
The filter elements can be fitted with a clogging indicator (optical and/or electric or electronic).
When the clogging indicator is triggered this shows that the filter element has to be replaced or
cleaned immediately.
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_____________________________________________________________________________________________________________

When no clogging indicator has been fitted, we recommend that elements be changed after ca.
every 100 to 500 hours of operation, depending on system loading, however at least once a year.
When filter elements are subjected to high dynamic loading it may prove necessary to change
them more frequently. The same applies to commissioning, repair work, oil changes etc. in the
hydraulic system.
Standard clogging indicators are not triggered unless there is a flow through the filter. As to
electrical clogging indicators, the signal can also be processed and indicated on the control panel
continuously until acknowledging the fault by eliminating it (i.e. changing the filter element and
cold-starting the system).
If the clogging indicator is only triggered upon cold-starting, this may indicate that the filter element
may not yet require changing.
4.10.3 Changing seals and gaskets:
Change the seals and gaskets of cylinders, valves etc. Change cylinder gaskets after every ca.
3,000 to 5,000 hours of operation.
All of the figures indicated above are standard values. More exact information can be obtained on
the service life of gaskets etc. or system wear by keeping detailed records of replacement work.
4.11 Checks and inspections to be conducted on a daily basis:

In the course of conducting scheduled status inspections it is recommended that the following
inspections and checks be performed on a daily basis:
• Checking the oil temperature
• Checking the oil level and the appearance of the oil
• Checking the status of the filter clogging indicator
• Checking the pressure readings on the pressure gauges
• Checking for funny or unusual sounds and noises
• Checking the piping system and individual components for leaks
• Checking the overall condition of the facility.
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______________________________________________________________________________________________________________

5 Hydraulic Oil Recommendations

The oil hydraulic system requires high-quality refined oil lubricants, which is why tried-and-tested
quality brand oils should be used. The minimum requirements to be satisfied by mineral-oil-type
hydraulic oils are specified in DIN 51524 and DIN 51525. Apart from the H, HL and HLP mineral
oils indicated there, HV oils (HLP oil containing additives for improving the viscosity/temperature
behavior), hydraulic oils with detergent properties, HD motor oils and ATF’s (automatic
transmission fluids) are used.
The selection of the hydraulic oils should be done in accordance with DIN 51519, which is based
on the internationally recognized ISO classification ISO no. 3448. Fire-resistant hydraulic fluids and
type HS-A to D synthetic oils according to VDMA 24317 and 24320 and ester-type oils (E),
fluorocarbon oils (FK), polyglycol oils (PG) and silicone oil (SI) according to DIN 51502 are to be
used in plant operations subject to fire and explosion hazard.
6 Causes of Malfunction, Troubleshooting

Generally speaking, any part or component of the hydraulic system may be the cause of
malfunction. Successful troubleshooting presupposes sound knowledge about the function and
design of the facility and the hydraulic elements contained in it. First the malfunction cause should
be identified as to whether it is of mechanical, hydraulic or electrical origin. Before looking for the
cause on site thought should be given to the possible cause by referring to the hydraulic diagram,
circuit diagram, and functional description. First the operating personnel should be thoroughly
questioned on site or a demonstration performed — providing this will not pose the hazard of injury
or damage — in another attempt to locate the cause of trouble as being mechanical, hydraulic or
electrical in origin.
If the cause of malfunction cannot be clearly attributed to one of the three main causes outlined
above, then a systematic search has to be made. The table below is designed to help in narrowing
down the cause of malfunction.
The tips given in this table are designed to facilitate locating the cause of malfunction or failure,
however there is no all-in-one solution for locating the cause of malfunction or failure. If none of the
methods suggested prove successful, then the search should be begun with the drive units (pump,
electric motor, coupling) and continued in the direction of the output elements (cylinders, hydraulic
motors, swivel actuators).
Other troubleshooting possibilities are compiled in the form of tables. Example: VDI guideline 3027
Commissioning and Maintenance of Oil Hydraulic Systems.
____________________________________________________________________________________________________________
_____________________________________________________________________________________________________________

6.1 CETOP Recommendation (cf. RPIIH):

Instructions for the Installation, Commissioning and Maintenance of Complete Oil Hydraulic
Systems
Malfunction In connection with Recommended checks/testing
Possible causes
Change in the working speeds Fluid flow Flow control valves, restrictor valves,
of cylinders, motors, swivel shutoff (isolating) elements, seals and
actuators etc. gaskets in the drive elements, internal
leaks, air trapped in the hydraulic fluid,
undercooled or overheated hydraulic
fluid, malfunctioning of directional,
proportional, servo and flow-control
valves as the result of contamination of
hydraulic fluid
Change in the working Operating pressure Pressure generating units (pump, motor,
pressure pressure boosters), pressure regulators
No or insufficient pressure and pressure relief valves, leaks,
ruptured pipe
Change in function (cycle or Electrical system Electrical and/or electronic control
sequencing), cycle times, Electronic system system, wiring, cabling, soldered points,
sequencing Hydraulic system contactors, relays, solenoids, voltage,
Mechanical system limit switches, limit switch mounting,
rules, rollers, levers, plungers, terminals
of directional valves, pressure sequence
and shutoff valves, contamination of the
hydraulic fluid
Outage of the system in part Failure of equipment or Power failure, pump wear or
or in whole assemblies as the result of malfunction, ruptured springs on valves,
defects, rupturing, wear and defective pressure accumulators,
tear clogging of the control orifices of
differential pressure-controlled valves as
the result of contamination of the
hydraulic fluid
____________________________________________________________________________________________________________
______________________________________________________________________________________________________________

7 Annex
Viscosity–Temperature Diagram for H, H-L and H-LP Mineral Oils

Example of viscosity classes: ISO VG 68
ISO VG 46
ISO VG 32
10.000
VG 68
VG 46
1.000 VG 32
(mm2/s)
100
cst
10
1
0
10
20
30
40
50
60
70
80
-30
-20
-10
Temp. ( °C )
Recommended Filter Rating–Oil Purity Classes

Hydraulic system Recommended absolute Achievable purity class1)
filter rating (ßx=>100
according to NAS 1638 according to ISO 4406
with a particle size of
5 µm-15 µm
Systems featuring 3 4 to 5 13/10 to 14/11
servovalves
Systems featuring control 5 7 to 8 15/12 to 17/14
valves
Systems featuring 10 9 18/15
proportional valves
General hydraulic 10 to 20 9 to 10 18/15 to 19/16
systems
1) as based on optimal filter design/concept
____________________________________________________________________________________________________________
_____________________________________________________________________________________________________________
Hydraulic unit for Roll Grinding Mills

Lift-and Swing System
Note!
In this description the following items are mentioned according the actual hydraulic diagram and the parts list:
Oil tank (item 1); Pump (Item 3); Coupling (Item 5); E-Motor (Item 6); Pressure Relief Valve (Item 8); Directional Valve (Item 12, 13);
Check Valve (Item 14); 1-Way Restrictor (Item 15); Double 1-Way Restrictor (Item 16)
General:
The unit, together with the hydraulic components direct mounted to the mill, serves for lifting and
swinging the grinding mills for maintenance work.
The system consists of a compact hydraulic unit with mounted drive, safety and control devices.
The lifting of the lift-and-swing column with grinding mill is effected by the force of pressure of the
hydraulic cylinder, the lowering by the dead weight with piston rod retracting.
The swinging of the grinding mill is effected by the rotary actuator.
The pump (item 3), driven by the e-motor (item 6) through coupling (item 5), is mounted in the oil
tank (item 1). The pump supplies the pressure oil of the directional valves with hand lever
(item 12 and 13).
The pressure relief valve (item 8) serves for the pressure protection of the pump.
The control of the functions "Lifting" and "Swinging" is effected by the directional valves with
manual operation (item 12 and 13).
For lifting the lift-and-swing column the directional valve (item 12) is switched into position "b".
Now the passage through the pilot controlled check valve (item 14) and the 1-way restrictor
(item 15) into the piston area of the cylinder is exposed.
For lowering the lift-and-swing column the direction valve (item 12) is switched into position "a".
In order to allow the drive of the pilot operated check valve (item 14), the pump must also be
operated during the lowering process.
Now the piston rectracts due to his dead weight and the one of the lift-and-swing column with its
mounted parts. The speed of this process can be controlled by the 1-way restrictor (item 15).
For swinging the grinding roll the directional valve (item 13) is switched into the corresponding
position.
For both swinging directions (into or out of the mill housing) the operation can be throttled by the
double 1-way restrictor (item 16).
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Page 1 von 1 / 03.11.99 Balzert, HS-ED / Hebschw_e.doc englisch
Pos Nr. Stück Benennung Type / Teile Nr. Bemerkung Lieferant Norm Werkst. Änderung
item no. quant. designation part code remarks supplier DIN material modification
0005 1 Compact unit with e-cabling
Diagram: 02 120 982 2 3110355

Assembly Drg.: 02 120 971 1 3110356
Unit No.: 35070
Hydraulic Data:
Operating Medium: mineral hydraulic oil,
HLP 46
Operating Pressure: 250 bar
Flow Rate of Pump: 5 l/min
Electric data:
Motor: 400 V - 50 Hz
Design:
Pressure Side: heavy duty type
Suction & Return Side: heavy duty type
Stück / pcs Baugruppe / subgroup Kennwort / code word Kunde / customer Datum / date Name /name 4
1 Compact unit NG40 Iran Gebr. Pfeiffer AG 16.12.05 Hölzer (-jk) 5
Blatt / sheet von / total HYDAC-Komm. / Hydac comm. Ident.- Nr. Kunden Best. Nr. / customer order no. Änderung / modification 6
1 4 8600005733 3272107 22356 Datum / date Name /name Nr. 7
1 8
GERÄTELISTE 2 9
PARTS LIST 3 10
Piping:
seamless precision steel tube DIN 2391/C
with Walform screwing
Sealing: O-Rings, Perbunan
Labelling:
units acc. to hydr. diagram with
item labels, aluminium
Language: English
Corrosion Protection:
oil tank including inside: mineral oil resistant
zinc dust primer after
sandblasting
Final coating: 2-comp. alkyd resin

lacquer
Colour: RAL 6011 (reseda green)
1 8
GERÄTELISTE 2 9
PARTS LIST 3 10
1 1 oil tank witch feet size 40, AN 18-09.1 Hydac

mat.no. 37903
1.1 1 fluid level gauge FSA-127-1.X/-/12 Hydac

mat.no. 700036
2 1 filling and breather filter ELF P 3 F 10 W 1.0 Hydac

mat.no. 320037
3 1 gear pump SNP1/3,8DCO01F Sauer

mat.no. 6004929
3A 1 hose 2SN 8PP 400P Hydac DIN20066

mat.no. 607404
4 1 pump support RV250/110/448 Raja

mat.no. 6036802
5 1 flexible coupling R24/28

consisting of:
1 gear rim 24-PUR-98Sh red Hydac

mat.no. 600098
1 nave 24/28-H7-A-GG-L=30 Hydac

mat.no. 600132
1 nave A24-9,75-N/1-K-GG-L=17 Hydac

mat.no. 600342
6 1 e-motor IMB5/V1 BG100L Siemens

capacity: 3,00kW-1450U mat.no. 687554
IP55, insulation F
400/690 V - AC
1 8
GERÄTELISTE 2 9
PARTS LIST 3 10
7 1 return line filter RF BN/HC 30 B B 20 B 1.0 Hydac

mat.no. 306549
8 1 pressure relief valve DB4E-01X-350V Hydac

mat.no. 716003
9 1 check valve cartridge type M-SR 8 KE05-1X Hydac

mat.no. 618665
10 1 pressure gauge HN60-01-E 63/400/G 1/4B Hydac

mat.no. 606890
11 1 control block mat.no. 3110450 Hydac
12 1 directional valve 4WMM 6 J5X Hydac

mat.no. 617818
13 1 directional valve 4WMM 6 E5X Hydac

mat.no. 626994
14 1 check valve sandwich plate Z2S 6 A1-6X Hydac

mat.no. 680339
15 1 speed control valve manifold DRVP-06-01.2 Hydac

block mounting mat.no. 705777
16 1 double throttle check valve Z2FS 6-2-4X/2QV Hydac

mat.no. 627311
17 3 coupling socket HP10-1-S1624-DN12 Voswinkel

mat.no. 6010149
18 3 coupling plug HP10-2-S1624-DN12 Voswinkel

mat.no. 6010172
19 1 motor protection switch Hydac
1 8
GERÄTELISTE 2 9
PARTS LIST 3 10
SPARE PARTS LIST
Reserveteilliste
Kunde Gebr. Pfeiffer AG Auftr. Nr. 22356 Ang. - Nr. Blatt 1 von 3
Customer Order -No Quot. No. Sheet of
Baugruppe Kompaktaggregat Kennwort NG40 Dispos.
Subgroup Compact unit Code Word Layout
Stück 1 Reserve 2
lfd. - Nr. Teil eingebaut Benennung Typ Teile Nr. Gruppe stückzahl Ges.Gewicht Stückpreis
Cons. No. item Inc. Items Designation Type Mat. no. Spares Gr. Qty. of Total weight Unit price
Pieces spares EURO
1 1.1 1 Flüssigkeitsstandanzeige FSA-127-1.X/-/12 700036 II 1

Fluid level gauge
2 2 1 Tankbelüftungsfilter ELF P 3 F 10 W 1.0 320037 II 1

Tank breather filter
3 3 1 Zahnradpumpe SNP1 / 3,8 DCO 01F 6004929 II 1

Gear pump
4 3A 1 Schlauch 2SN 8PP 400P 607404 I, II 1

Hose
5 5 1 Elastische Kupplung R24/28 600098 II 1

Flexible coupling 600132 600342
6 5 1 Kupplung Zahnkranz 24-PUR-98 Sh rot 600098 I, II 1

Gear rim
7 7 1 Filterelement 0030 R 020 BN3HC 1262922 I, II 4

Filter element
HYDAC GERÄTELISTE Hydac Komm. / .-Comm 8600005733 Datum/Date 17.01.06 Name M. Raimondo-cg
PARTS LIST Hydac Ident Nr. 3272107
1 Es bedeuten: 1 Explanations: Reserveteillisten unterliegen nicht dem Änderungsdienst
I Reserveteile, die bei Inbetriebnahme vorhanden sein müssen I Spares which should be available on start-up. Maßgebend für die Bestellung sind die endgültigen
II Reserveteile, mit deren Einsatz auf Grund ihres Verschleißes II Spares which are likely to be required within an Ausführungszeichnungen und -stücklisten
während eines 2-jährigen Betriebes gerechnet werden muß. operating period of two years due to the wear.
III Reserveteile, die zur Anschaffung empfohlen werden. III Recommended spares Spare parts lists are not subject to revision. Orders should
2 Preise in EURO ohne Mehrwertsteuer, falls nichts 2 Prices in EURO excluding V.A.T. be placed according to the final workshop drawings and
anderes angegeben ist. unless otherwise specified. parts lists.
SPARE PARTS LIST
Reserveteilliste
Stück 1 Reserve 2
Pieces spares EURO
8 7 1 Reparatursatz f. RF...30 I, II 4
Repair kit
9 7 1 Verschmutzungsanzeige VR 2 B.0 306822 III 1

Clogging indicator
10 8 1 Druckbegrenzungsventil DB4E-01X-350V 716003 III 1

Pressure relief valve
11 9 1 Rückschlagventil M-SR8 KE 05-1X 618665 II 1

Check valve
12 10 1 Manometer HN60-01-E 63/400/G1/4 606890 I, II 1

Pressure gauge
13 12 1 Wegeventil 4WMM 6 J 5 X / 617818 II 1

Directional valve
14 13 1 Wegeventil 4WMM 6 E 5X 626994 II 1

Directional valve
SPARE PARTS LIST
Reserveteilliste
Stück 1 Reserve 2
Pieces spares EURO
15 14 1 Rückschlagventil Z2S 6 A 1-6X 680339 II 1

Check valve
16 15 1 Drosselrückschlagventil DRVP-06-01.2 705777 III 1

Flow control check valve
17 16 1 Zwillingsdrosselrückschlagventil Z2FS 6-2-4X/2QV 627311 II 1

Double throttle check valve
0 1 2 3 4 5 6 7 8 9
HYD_DE/ 08.Sep. 2005
CAE-VERSION:
EPLAN 5.70.4
CUSTOMER -KUNDE - : GEBR. PFEIFFER AG PFEIFFER ORDER: 22356

SYSTEM NAME-BENENNUNG- : MOTOR STARTER- MOTORSTARTER- CODE: Neyzar RM
DRAWNING NUMBER-ZEICHNUNGSNUMMER- : 02 314 950 4 76427
COMMISSION-KOMMSISION- : KOM:86.0000.5733-03
MANUFACTER : : H Y D A C - TECHNOLOGY GmbH

HERSTELLER
INDUSTRIESTRASSE
D-66280 SULZBACH/SAAR
YEAR OF CONSTRUCTION-BAUJAHR- : 2006

PRODUCT-PRODUKT- : HYDRAULIC UNIT
TYP-TYP- : NG40
INSTALATION PLACE-INSTALLATIONSORT- : IN-DOOR
LOCATION-AUFSTELLUNGSORT- : IN-DOOR
DIRECTION-VORSCHRIFT- : DIN, VDE
DEGREE OF PROTCETION-IP- SCHUTZART- : IP 55
PROJECT BEGINNING-PROJEKT BEGINN- : 17.01.2006

PROJEKT LEADER-PROJEKTVERANTWORTLICHER- : MR. HÖLZER
LAST CHANGE-LETZTE ÄNDERUNG- : 17.01.2006
NUMBER OF PAGES-SEITENZAHL- : 4
2
Date
17.01.06 FRONT PAGE = Z1
KOM:86.0000.5733-03
Datum
Work
JENE
02 314 950 4 76427 + A1
Bearb. DECKBLATT
Check
Pruefer SCHNEIDER MOTOR STARTER- MOTORSTARTER- PROJEKT: Pg. 1
Change Date name standard
Änderung Datum Name Norm
Urspr./ source Ers. f. /des.for Ers. d. /des.from 76427 4 Pg.
0 1 2 3 4 5 6 7 8 9
PAGE OVERVIEW-INHALTSVERZEICHNIS- HYD1201D_E/ 18.10.05
Seite / sheet Seitenbenennung / sheet designation Änderung / change
=Z1+A1/1 FRONT PAGE

DECKBLATT
=Z1+A1/2 LIST OF CONTENTS

INHALTSVERZEICHNIS
=Z1+A1/3 CIRCUIT DIAGRAM

STROMLAUFPLAN
=Z1+A1/4 PARTS LIST

STÜCKLISTE
1 3
Date
17.01.06 LIST OF CONTENTS = Z1
KOM:86.0000.5733-03
Datum
Work
PC2
02 314 950 4 76427 + A1
Bearb. INHALTSVERZEICHNIS
Check
0 1 2 3 4 5 6 7 8 9
X1 L1 L2 L3 PE N
415V
PLUG
STECKER
ÖLFLEX-110 1 2 3 PE
20m.-
4 x1,5qmm
1 3 5
Q1
6.3-10A
2 4 6
ÖLFLEX
1 2 3 PE
U1 V2 V1
-M1
400-415V
3kW PE
POS.:3
MOTOR
POS:5
MOTOR
POS:5
2 4
Date
17.01.06 CIRCUIT DIAGRAM = Z1
KOM:86.0000.5733-03
Datum
Work
JENE
02 314 950 4 76427 + A1
Bearb. STROMLAUFPLAN
Check
0 1 2 3 4 5 6 7 8 9
- PARTSLIST -S T Ü C K L I S T E -
Component label Quantily Label Type Number Supplyer Article Number
Bauteilbezeichnung Menge Bezeichnung Typen Nummer Lieferant Artikelnummer
=Z1+A1-X1 1 CEE PLUG 400V/16A 619231 MENNEKES 3
CEE- STECKER 400V/16A
=Z1+A1-Q1 1 PROTECTIVE SWITCH 6,3-10A 690559 KLÖCKNER MOELLER PKZM0-10 (072739)
SCHUTZSCHALTER 6,3-10A
=Z1+A1-Q1 1 BOX 690565 KLÖCKNER MOELLER CI-PKZ0-G (072904)
GEHÄUSE
3
Date
17.01.06 PARTS LIST = Z1
KOM:86.0000.5733-03
Datum
Work
JENE
02 314 950 4 76427 + A1
Bearb. STÜCKLISTE
Check
____________________________________________________________________________________________________________
reg. item designation type
1 02 filling and breather filter ELF .. 3 .. 4

2 03 gear pump SNP1
3 05 flexible coupling AN11-37
4 06 e-motor BG100L
5 07 return line filter RF BN/HC
6 08 pressure relief valve DB4E
7 12; 13 directional valve 4WMM
8 15 speed control valve manifold block mounting DRVP
9 16 double throttle check valve Z2FS
____________________________________________________________________________________________________________
Group 1
Gear Pumps
Technical Information
Gear Pumps Group 1
Pump Drive Data Form
Photo copy this page and fax the completed form to

your Sauer-Sundstrand representative for assistance
in applying pumps with belt or gear drive.
Application Data
Pump Displacement cc/rev
bar
Rated System Pressure
psi
bar
Relief Valve Setting
psi
Left
Pump Shaft Rotation
Right
min-1
Pump Minimum Speed
(r pm)
min-1
Pump Maximum Speed
(r pm)
Drive Gear Helix Angle
deg.
(gear drive only)
Belt Type V
(belt drive only) Notch
Belt Tension N
(belt drive only) P
lbf
Angular Orientation of
deg.
Gear or Belt to Inlet Por t
Pitch Diameter of Gear mm

or Pulley
dw
in
Distance from Flange to mm

Center of Gear or Pulley a
in
T102 007E
Anti-clockwise pump shown.
P102 003E
14
Hydraulic Power Systems
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email: sasitaly@sauer.com
TI-GP1-E • 11/99 • 300 069

Typ / Types / Type / Tipo / Tipo / Type / Type / Tipos / ³õÿ / Type / Tyyppi / Typy / Type / TEGUND
1LA, 1LB, 1LC, 1LD, 1LF, 1LG, 1LL, 1LN, 1LP, 1LS, 1LT, 1LV,
1PG, 1PB, 1PF, 1PK, 1PP, 1PQ, 1PR
Sicherheits- und Inbetriebnahmehinweise für Niederspannungs-Asynchronmotoren

DE (gemäß Niederspannungsrichtlinie 73/23/EWG) Achshöhe: 56 bis 450 mm
Information on safety and commissioning for low voltage asynchronous motors

EN (in accordance with L. V. directive 73/23/EEC) Shaft height: 56 to 450 mm
Consignes de sécurité et de mise en service pour moteurs asynchrones à basse tension

FR (selon directive basse tension 73/23/CEE) Hauteur d'axe: 56 à 450 mm
Advertencias de seguridad y de puesta en marcha para motores asíncronos de baja tensión

ES (según las Directrices para baja tensión 73/23/CEE) Altura del eje: 56 ..... 450 mm
Avvertenze per la sicurezza e la messa in servizio di motori asincroni in bassa tensione

IT (conformemente alla direttiva per impianti impiegati in bassa tensione 73/23/CEE) Altezza asse: 56 ..... 450 mm
Säkerhets- och idrifttagningsanvisningar för lågspännings-asynkronmotorer

SV (enl. lågspänningsdirektivet 73/23/EEC) Axelhöjd: 56 ..... 450 mm
Aanwijzingen voor de veiligheid en het inbedrijfstellen van laagspanningsmotoren

NL (volgens Laagspanningsrichtlijn 73/23/EEG) Ashoogte: 56 ..... 450 mm
Instruções de segurança e de colocação em funcionamento para motores assíncronos de baixa tensão

PT (em conformidade com a directiva de baixa tensão 73/23/CEE) Altura do eixo: 56 a 450 mm
EL å®ã¥ªÿ ã¯¦ ½®º ¦÷ø¦ðª¥¦ÿ ¦

¯ ½® æ¢÷® ÷ª ðª¯½¾¼ã¥¦ ½þº ¦÷³ã¿¼ºþº ¯ º®½±¼þº ¿¦¹®ð±ÿ ½¡÷®ÿ
(÷³¹øþº¦ ¹ª ½º ¦ºº¯÷¹² õª¼¥ ¿¦¹®ð±ÿ ½¡÷®ÿ 73/23/). 56 ... 450 mm
DA Sikkerheds- og ibrugtagningsanvisninger for lavspændings-asynkronmotorer

(i henhold til lavspændingsdirektiv 73/23/EØF) Akselhøjde: 56 til 450 mm
Pienjänniteoikosulkumoottoreiden turvallisuus- ja käyttöönotto-ohjeet

FI (pienjännitedirektiivin 73/23/ETY mukaisesti) Akselikorkeus: 56 ..... 450 mm
Pokyny o bezpeènosti a uvádìní do provozu nízkonapìových asynchronních motorù

CS (podle smìrnice pro nízká napìtí 73/23/EWG) Osové výky: 56 a 450 mm
Sikkerhets- og igangsettelseshenvisninger Til lavspennings-asynkronmotorer

NO (overensstemmende med lavspenningsretningslinje 72/23/EW) akselhøyde: 56 til 450 mm
Öryggis- og notkunarleiðbeiningar Fyrir lágspennu-ósamfasa hreyfla

IS (samkvæmt reglugerð um lágspennu 72/23/EW) Öxulhæð: 56 til 450 mm
Ausgabe / Edition 11.2003 Bestell - Nr. / Order No.: 5 610 70000 36 006
DEUTSCH / ENGLISH / FRANÇAIS / ESPAÑOL / ITALIANO / SVENSKA / NEDERLANDS /
PORTUGUÊS / ELLHNIKA / DANSK / SUOMI / ÈESKY / NORSK / ÍSLENSKA
ã Siemens AG 2003 All Rights Reserved 1
ENGLISH EN
1 General information dust. Where shaft ends face upwards water must not be allowed to
Electric motors have dangerous voltage-carrying and rotating enter along the shaft.
components as well as surfaces that may become hot. All work Do not obstruct ventilation! Discharged air, also from neighbouring
involved in the transport, connection, commissioning and regular equipment, must not be sucked in again immediately.
maintenance must be carried out by qualified, responsible
specialists (note VDE 0105; IEC 364). Improper behaviour may result 5 Electrical connection
in serious injury and damage to property. The applicable national,
local and works regulations and requirements must be complied Work is only permitted to be carried out by qualified specialists on
with. the stationary motor, while disconnected and prevented from
being switched on again. This also applies for the auxiliary power
2 Intended use circuits (e.g. Anti-condensation heaters).
Check that the equipment is potential-free!
These motors are intended for commercial installations. They If the tolerance limits are exceeded that are specified in EN 60034,
comply with the harmonized standards of the EN60034 (VDE 0530) part 1 / IEC 34-1 (voltage ± 5%, frequency ± 2%, shape of curve,
series. Utilization in areas subject to explosion hazard is not symmetry) the heating effect is increased and the electromagnetic
permitted, unless expressly intended for this purpose (see additio- compatibility is affected. Please note the specifications on the rating
nal notes). In certain special cases, for example, on use in non- plate and the connection diagram in the terminal box.
commercial installations, if requirements are more strict (e.g. Connections must be made in such a way as to ensure that a
protection against contact with childrens fingers), it is the permanently safe electrical connection is maintained (no protruding
responsibility of the customer to ensure compliance on installing the wire ends); use the corresponding cable end pieces. Create a safe
equipment. earth continuity connection.
The motors are rated for ambient temperatures of -20°C to +40°C See Fig. 1 for the tightening torques for terminal board connections.
and site altitudes £ 1000 m above sea level. Any contradictory
information on the rating plate must be observed. The conditions on Clearences in air between bare live parts themselves and between
site must correspond to all rating plate specifications. bare live parts and earth must be ³ 5,5 mm (Urated £ 690 V) .
It must be ensured that the terminal box does not contain foreign
Low voltage motors are components for installation in machinery bodies, dirt or humidity. Seal any unused cable entry openings
in terms of the Machine directive 89/392/EEC. Commissioning against dust and water.
must not take place until it has been proved that the end product Inlets in the terminal box (see DIN 42925), other open inlets must
conforms with this guideline (please note EN 60204-1). be sealed with an O-ring or a suitable flat gasket, and the terminal
box itself must be sealed with the original seal so that it is dustproof
3 Transport and storage and watertight.
In the case of damage determined after delivery this must be See Fig. 2.1 for the tightening torques for cable glands and Fig. 3 for
immediately reported to the transport company; if necessary the other screws.
plant is not to be put into commission. During transportation all the Secure the featherkey on test operation without drive components.
available lifting eyes in the motor are to be used and be done up tight For motors with brakes, check that the brakes are operating perfectly
when fitted! They are only designed and built for the weight of the before commissioning.
motor. Do not load additionally. If necessary use suitable adequately
dimensioned transporting means (for example, rope guides). 6 Operation
Remove existing shipping braces before commissioning; and reuse Vibration levels of vr m s £ 3.5 mm/s (PN £ 15 kW) or vr m s £ 4.5 mm/
for subsequent transport. If motors are stored, a dry, dust-free and s (PN > 15 kW) are quite acceptable in the coupled state.
low vibration (vr m s £ 0.2 mm/s) environment is important (to avoid If deviations from normal operation occur - e.g. increased
bearing standstill damage). On long-term storage, the regrease temperatures, noises, vibration - the motor should be switched off
interval of the bearings is reduced. in the event of doubt. Determine the causes and contact the
The state of the grease is to be checked when storing for more than manufacturer if necessary. Do not disconnect protective equipment,
12 months. Should it be determined that the grease has become even under test operation.
contaminated (penetration of condensation water leads to changes Under dirty operating conditions, clean the air channels regularly.
in the consistency of the grease) then the grease must be replaced. Open any closed condensate water holes from time to time!
Irrespective of the number of operating hours, a motor which is in
Insulation resistance use should have its bearing replaced every 3 years because of the
The minimum insulation resistance of new, cleaned or repaired reduction in effectiveness of the grease.
windings should be 10 MW to earth For motors without regreasing points, bearings and/or the grease
Check the insulation resistance before commissioning. For values are to be replaced in accordance with the manufacturers instructions
W 0.5 MW/kV design voltage dry the windings. at least every three years.
For motors with regreasing points, the instructions on the lubrication
4 Installation data plate must be observed! Regreasing should be performed on
After installation, the screwed-in lifting eyes should either be running motors!
screwed in tightly or removed! Damage will be caused when operating at lower than minimum
Ensure an even underlying surface, good foot or flange fixing and radial stress in the case of motors with cylindrical roller bearings for
precise alignment for direct coupling. It is important to ensure that higher radial load. The radial stress is to be minimum 30 % of the
the mounting conditions do not cause resonance with the rotational permissible radial stress in operation (see catalogue).
frequency and the doubled supply frequency. Turn the rotor by hand In the case of motors with separate ventilation, the separately-
and listen for any unusual grinding noises. Check the direction of driven fan must be switched on throughout motor operation.
rotation in the decoupled state (note section 5).
Only mount or remove drive components (belt pulley, coupling, etc.) 7 Further information
using suitable tools (heat up), and cover to shield against contact. Information about any additional equipment, such as the different
Avoid unpermissible belt tensions (see catalogue and technical manufacturers instructions for cable connections including sealing
data). elements, shall be observed. More information is available in our
Balance see shaft end face or the ratings plate (H = Half key detailed operating and maintenance instructions. On request you
balancing, F = Full-key balancing, N = Balancing without featherkey) will be sent further details if you state the type and machine number
DIN IEC ISO 8821. Check the balance when fitting the drive element! or, you can find these under www.siemens.com/motors.
For use or storage outside, it is recommended that the motor is These notes on safety and commissioning must be retained for
installed under a sheltering object or fitted with an additional cover
future reference!
to avoid the long-term effects of direct sunlight, rain, snow, ice or
ã Siemens AG 2003 All Rights Reserved

3
Betriebsanleitung
DE Drehstrommotoren Operating instructions
Instructions de service
EN Three-phase AC Motors Instrucciones para el manejo
Manuale duso
FR Moteurs triphasés Bruksanvisning
Provozní návod
ES Motores trifásicos Äèðåêöèÿ ïðåäïðèÿòèÿ
IT Motori trifasi
SV Trefasmotorer
CS Tøífázové motory
RU ÊíàòñÙãêùà ÞÛåÝÙïàèå
1LA6/7/9, 1LP7/9, 1PP6/7/9
BG 56 ... 90 L - IM B3
1MA6/7, 1MF6/7
BG 100 ... 160 L - IM B3

BG 100 ... 160 L - IM B3 1LA6, 1MA6
Baugrößen (BG) / Frame sizes (BG) / Désignation de carcasse (BG) / Tamaños constructivos (BG) /
Grandezza costruttiva (BG) / Konstruktionsstorlekar (BG) / Velikosti (BG) / ÊåìëíÙãéàíù (BG)
(1MA) (1MA)
* (1MA)
oder oder * oder
or or
or
ou ou ou
o o
IM V 5 IM V 6 o IM V 18
oppure oppure
oppure
eller eller *
eller
IM B 3 nebo IM B 5 nebo IM V 1 IM V 3 IM B 14 nebo IM B 35
åèå åèå åèå IM B 34
IM B 6 IM B 7 IM B 8 IM V 19
Fig. 1 Bauformen / Types of construction / Formes de construction/ * s. "4 EEx e Motoren"/ see "4 EEx e motors"/ voir "4 Moteurs EEx e " /
véase "4 Motores EEx e " / cfr. "4 Motori EEx e " / se "EEx e-Motorer" /
Formas constructivas / Forme costruttive / Monteringssätt/
viz motory 4 EEx e / ñì. ìîòîðû 4 EEx e
provedení / Ìîäåëè
Bestell - Nr. / Order No.: 5 610 70000 10 000 a

DEUTSCH / ENGLISH / FRANÇAIS / ESPAÑOL / ITALIANO / SVENSKA / ÈESKY / Ðóññêèé
Ausgabe / Edition 11.03
1
ENGLISH EN
GENERAL NOTE 3 Comissioning

The data and recommendations specified in all the instructions
supplied ("Information on safety and commissioning"), and in all
WARNING
other related instructions, must always be observed in order to
avoid hazardous situations and the risk of possible injury or Before starting any work on the machine, be sure
damage. to isolate it from the power supply.
Furthermore, the pertinent national, local and plant-specific
regulations and requirements should be kept in mind! 3.1 Installation
Special designs and other versions may vary in technical details! If arranged vertically, all existing lifting eyes and possible lifting
If in doubt, be sure to contact the manufacturer, quoting the type bands (DIN EN 1492-1) and / or lashing straps (DIN EN 12195-2) must
designation and serial number (No. ..., see rating plate), or have be used to stabilize the position.
maintenance work done by one of the SIEMENS Service Centres. Built-on devices (e.g. tachometer) must not be used to help lift the
motor.
Lifting eyes that are screwed in place must be tightened or removed
1 Description after the motor has been installed.
1.1 Field of Application If the motor is installed vertically with the shaft end facing
downwards, a protective shield is recommended for the ventilator
Prescribed use of standard motors: hood in order to prevent the ingress of foreign bodies.
The motors are provided with degree of protection IP55 (see rating If the shaft end is facing upwards, a cover must be provided by the
plate) and can be used in a dusty or damp environment. A suitable equipment operator to prevent the ingress of liquids along the shaft.
superstructure or an additional cover is recommended if the motors
are deployed or stored outdoors to avoid the long-term effects of Quiet running: Exact alignment of the coupling and a well-balanced
intense, direct sunshine, rain, snow, ice and dust. If necessary, please transmission element (coupling, pulleys, fans, etc.) are essential for
consult the manufacturer or your technical department. The motors quiet vibration-free running. If necessary, the whole motor and
are tropic proof. Guide value: 60% relative humidity at a coolant transmission element should be balanced.
temperature of 40°C. BG90S/L: Double drillholes are provided for Type IM B3 in the rear feet
(see Fig. 10) to maintain the standard foot dimensions.
Ambient temperature -20°C ... +40°C
Site altitude £ 1000 m
3.2 Terminal box
If the ambient conditions deviate, this must be shown on the ratings
BG56...90L: In the case of 1LA, 1LP and 1LP motors, the top part of
plate; these data then apply.
the terminal box can be turned through 4x90 degrees.
1.2 Construction and mode of operation BG100...160L: The cast terminal box on the motor housing cannot be
Motor types: turned. In the case of motors with screw-fitted upper section of the
1LA and 1MA motors are self-cooled (with a fan). 1PP motors are terminal box this can be turned 4 times through 90 degrees (Fig. 2
supplied without their own fans. The customer must ensure that - 5.90).
there is sufficient cooling, either through a separately driven fan or, Tightening torques for screws at the electrical terminal box see
with fan drives, through the driven fan. When the fan is mounted, Fig. 5.2.
make sure that the fan hub does not obstruct the flow of air over
the cooling ribs. 1LA-BG56, 1LP and 1MF motors are self-cooled
(without a fan). 3.3 Balancing, transmission elements
In the case of the base motors the feet are screwed or cast on the A suitable device should always be used for fitting and removing the
motor housing. transmission elements (couplings, pulleys, pinions, etc.) (Fig. 7).
The screw-fitted feet on the motor housing can be changed As standard, the rotors are dynamically balanced with the half
over to alter the position of the terminal box (see Fig. 2). The thread featherkey.
in the existing drillholes in the motor housing can be tapped to fasten When fitting the transmission element, keep the type of balance in
the motor feet in retrospect. However, the stand surface of the feet mind!
must be remachined and aligned afterwards and shims fitted, if The balance status is indicated on the shaft end face or the ratings
necessary.
plate (H = Half, F = Full-key balancing, N = Balancing without
The brake connection cable is also to be considered in the case of
brake motors! featherkey).
The transmission elements must be balanced in accordance with ISO
2 Transportation and Storage 1940!
If the transmission elements are balanced with a half featherkey,
WARNING the visible, protruding part of the featherkey TP must be cut back
(see Fig. 9).
All lifting eyes on the motor must be used to transport
it. Only use the lifting eyes provided when transport- WARNING
ing machine assemblies (e.g. gearboxes, fans, pumps,
etc.). Machine assemblies must not be lifted by
attaching the hoisting gear to motor lifting eyes. The usual measures should be taken to guard
transmission elements from touch.
If the motors are stored for a long period the usable life of the grease
If a motor is started up without the transmission element attached,
on the bearings reduces. After storage periods of over 12 months the
the featherkey should be secured to prevent it being thrown out.
condition of the grease is to be checked. The grease must be replaced
if the check reveals contamination (condensation water getting into
the grease changes its consistency).
3.4 Electrical connection
The roller bearings should be replaced if the period from the time WARNING
the motor is delivered up until it is commissioned exceeds 4 years.
The service life of the motor unit is considerably reduced the longer All work on the low-voltage machine must be
it is stored. carried out by qualified skilled workers. Before work
Finished surfaces (flange surfaces, ends of shafts, etc.) should be is carried out the machine must be at a standstill,
treated with an anti-corrosion agent. disconnected and secured against switching on.
If necessary, the insulation resistance of the winding must be This applies to the auxiliary circuits as well (e. g.
checked, see Section 3.5. space heater).

EN ENGLISH
NOTE: If the openings for cables and wiring in the terminal box In the case of converter-fed motors, interference is emitted to a
are sealed with a cast skin (knockout), this must be removed in the greater or lesser degree, depending on the converter version concerned
appropriate manner (see Fig. 4). (type, interference suppression measures, manufacturer). The
Care must be taken not to damage the terminal box, the terminal instructions of the converter manufacturer regarding electromagnetic
board, the cable connections, etc. inside the terminal box! compatibility must be heeded at all times. If the use of a shielded
See Fig. 4.1 for details of the screwed connections for cables and motor cable is recommended, the shield will have the greatest effect
leads. An adapter must be screwed in for PTC thermistor connections! if it is conductively connected over a large area on the metal terminal
The terminal box must be sealed so that it is dust and water-tight. box of the motor (with a screwed metal conduit thread). Noise
voltages may occur on the sensor leads of motors with integrated
The system voltage and the frequency must agree with the data given sensors (e.g. PTC thermistors) as a result of the converter.
on the rating plate. Voltage or frequency deviations of ±5% and ±2% If the motor is operated on a converter at speeds that exceed the
respectively from the rated voltage and frequency values are permitted rated speed, the mechanical critical speeds (safe operating speed
without needing to derate the output. The connection and IEC 60034-1) must be observed.
arrangement of the terminal links must agree with the diagram Noise immunity: If the motor has an integrated sensor (e.g. a PTC
provided in the terminal box. thermistor), the owner is responsible for ensuring adequate noise
Connect the earthing conductor to the terminal with the marking. immunity by choosing a suitable sensor signal lead (possibly with
Wherever terminal clips are used (for example, to DIN 46282), shielding, connected like the motor supply lead) and evaluator.
arrange the conductors so that the clips are virtually level on both The data and recommendations specified in all the instructions
sides. This method of connection means that the ends of single supplied (Information on safety and commissioning), and in all
conductors must be bent in the shape of a U or be fitted with a other related instructions, must always be observed prior to
cable lug (see Fig. 6.1). This also applies to the green-yellow commissioning!
protective earthing conductor and the outer earthing conductor After motor installation, the brake, if fitted, should be checked for
(see Fig. 6.2). proper functioning.
Please refer to Fig. 5 for the tightening torques for the screwed
electrical connections - terminal board connections (except for
terminal strips).
4 Maintenance
The anti-condensation heater must not be switched on during Safety precautions
operation.
DANGER
3.5 Checking the insulation resistance Before starting any work on the motor or other
The insulation resistance of the windings must be measured prior equipment, particularly before opening covers over
to initial startup of the motor, or after long periods of storage or live parts, the motor must be properly isolated from
standstill (approx. 6 months). the power supply. Besides the main circuits, any
While the measurement is being taken and immediately afterwards, additional or auxiliary circuits that may be present
some of the terminals carry dangerous voltages and must not be must also be isolated.
touched. The usual "5 safety rules" (as set forth in DIN VDE
0105) are:
Insulation resistance
- Isolate the equipment
- The minimum insulation resistance of new, cleaned or
- Take effective measures to prevent
repaired windings with respect to ground is 10 MW.
reconnection
- The critical insulation resistance Rcrit is calculated first by
- Verify equipment is dead
multiplying the rated voltage UN, e.g. 0.69 kV AC, with the
- Earth and short-circuit
constant factor (0.5 MW/kV):
- Cover or fence off adjacent live parts
Rcrit = 0.69 kV x 0.5 MW/kV = 0.345 MW.
The precautions listed above should remain in force
Measurement until all maintenance work is finished and the motor
The minimum insulation resistance of the windings to ground is has been fully assembled.
measured with 500 V DC. The winding temperature should then be
25oC ± 15 oC. ATTENTION
The critical insulation resistance should be measured with 500 V DC
with the winding at operating temperature. The appropriate construction standards must be
Checking observed if any modifications or repairs are made to
If the minimum insulation resistance of a new, cleaned or repaired the motors listed (UL - Underwriters Laboratories Inc.
motor, which has been stored or at standstill for a prolonged period or CSA - Canadian Standards Association). The
of time, is less than 10 MW, this may be due to humidity. The windings markings shown on the left are used to identify these
must then be dried. motors on their respective rating plates.
After long periods of operation, the minimum insulation resistance
may drop to the critical insulation resistance. As long as the NOTE: Where motors are fitted with closed condensed water
measured value does not fall below the calculated value of the openings, these should be opened from time to time to allow any
critical insulation resistance, the motor may continue in operation. accumulated condensed water to drain away.
If it does, the motor must be stopped immediately. Condensed water openings should always be at the lowest point of
The cause must be determined, and the windings or winding sections the motor!
repaired, cleaned or dried as necessary.
Fitting new bearings, type of grease
3.6 Commissioning Under normal operating conditions, with horizontally mounted
motors and the following coolant temperatures and motor speeds,
NOTE: Electromagnetic compatibility the bearings should be changed at the intervals [h] specified below:
40°C
WARNING
... 1800 rev/min approx. 40,000 h
Emitted interference: Where the torque is very ... 3600 rev/min approx. 20,000 h
uneven (the drive of a piston-type compressor, for
NOTE: The permissible axial and transverse forces (see Catalog)
example), the inevitable result is a non-sinusoidal
must not be exceeded!
motor current, whose harmonics can lead to excessive
Irrespective of the number of operating hours, a motor which is in
system perturbation and thus excessive emitted
use should have its bearing replaced every 3 years because of the
interference.
reduction in effectiveness of the grease.
6 ã Siemens AG 2003 All Rights Reserved

ENGLISH EN
In the case of motors operating under special conditions, such as The cable entries must be approved for the explosion-endangered
a vertical motor position, heavy vibration, sudden load changes, area and be secured to prevent accidental loosening. Unused openings
frequent reversing operation, etc., the bearing should be changed at are to be closed with approved plugs.
considerably more frequent intervals than the operating hours Where the motor is mounted vertically with the shaft end at the top,
stated above. e.g. models IMV3, IMV6, IMV19 (see Fig. 1), 1MA motors must have
The motors feature deep-groove ball bearings which are provided
a cover fitted so that no objects can penetrate between the cooling
with cover plates (2ZC3 version). The cover plate material should ribs into the motor fan hood. The cover must not obstruct the cooling
withstand temperatures from -30 °C to +150 °C, e.g. polyacryl-rubber of the motor.
(ACM).
Type of grease for standard machines: UNIREX N3 (Esso); synthetic Should no details be given to the contrary in respect of mode of
greases must conform to DIN 51825-K3N. operation and tolerances in the EC sample test certificate or on the
Special greases should be indicated on the rating plate or on a rating plate the electric motors have been designed and built for
separate plate. continuous operation and infrequent repeated start-up with no
Dismantle the motor to the extent necessary. Pull off the rolling- excessive heating up when starting. The motors are only to be used
contact bearing with a suitable device (see Fig. 7). Clean the journal! for the given mode of operation shown on the rating plate.
Heat the rolling-contact bearing evenly to about 80-100 °C and press Section A in EN 60034-1 (VDE 0530, Part 1) - voltage + 5 %, frequency
on. Heavy blows (such as with a hammer, etc.) should be avoided. + 2 %, waveform, power-system symmetry - must be complied with
Any worn sealing elements (such as the shaft sealing ring, etc.) in order to ensure that any increase in temperature remains within
should also be renewed. the permitted limits. Greater deviations from the rated values can
If springless radial shaft sealing rings are used, the replacement lead to non-permissible increases in the temperature of the machine
sealing rings must also be of the springless type. and must be indicated on the rating plate.
The temperature class of the motor given on the rating plate must
Centering recess seal agree with the temperature class of the inflammable gas which may
When reassembling the motor, the bare mounting faces between the occur.
motor casing and the bearing end shields are to be sealed with a Each machine must be protected in all phases in accordance with EN
suitable non-hardening sealing material, e.g. Fluid-D. 60079-14 against unacceptable termperature rise by a current-
Tightening torques for the screws at the end shields (see Fig. 5.2). sensitive delayed circuit-breaker with phase-failure protection in
accordance with EN 60947 or with an equivalent device.
Regreasing device
In the case of motors with a regreasing device, take note of the The overcurrent protection facility with current dependent delayed
information given on the rating plate or the lubrication instruction triggering is to be selected so that the triggering time to be taken
plate! The bearings should be relubricated while the motor is from the switch characteristic curve for the protected motor ratio
running! IA / IN must not be greater than the heating up time tE of the motors.
The ratio IA / IN as well as the heating up time tE are to be found
on the rating plate. The protective device is to be set to the rated
current. In the case of delta-connected windings, the trips are to be
5 1MA and 1MF motors with connected in series with the winding phases and set to 0.58 times
increased EExe protection the rated current. If such a circuit is not possible, additional protective
measures are necessary (e.g. thermal machine protection).
Marking: CE 0158 II 2 G EEx e II T.
If the rotor is blocked, the protection device must switch off the
machine within the time tE indicated for the respective temperature
CAUTION class.
Repairs must be performed in or by authorized Sie- Electrical motors for heavy start up (running up time > 1.7 x tE-time)
mens workshops. Any repair work carried out must are to be protected by a start monitoring system in accordance with
be documented on the motor (e.g. by means of an the details given in the EC sample type test certificate.
additional plate). Thermal machine protection by means of direct temperature
monitoring of the winding is permissible if this is certified and
The information in italics is intended to serve as supplementary or indicated on the rating plate.
special information on these types of motors. Separate, common interlocked protection devices are required for
The increased hazards in areas which are exposed to the danger of each speed stage for pole reversible motors. To be recommended
explosion or firedamp necessitate that the general notes on safety are devices with EC sample type test certificate.
and commissioning are carefully complied with. In Germany, please refer to DIN 57165/VDE 0165 and ElexV when
As to Spare parts, with the exception of standardised, commercially erecting electrical installations in areas exposed to the danger of
available equivalent parts (e.g. roller bearings), only original spare explosion. In countries other than Germany, the relevant national
parts (see parts list) may be used; this applies in particular also with regulations are to be complied with in each case!
respect to gaskets and connectors. Operation on a converter must be certified. The separate instructions
Electrical machines which are protected against explosion are in line of the manufacturer must be complied with. The motors, converters
with the standards EN 60034 (VDE 0530) and EN 50014 to 50020. It and protection devices are to be marked as pertinent to each other
is permitted to use these machines in areas exposed to the danger in the case of the EExe ignition protection mode and the approved
of explosion only in accordance with the stipulations of the responsible operating data is to be laid down in the general EC sample type test
authority which also determines whether a danger of explosion certificate (VDE 0165).
exists (division into zones). The connector cable installed between the inverter and the electrical
To be observed in the case of certification additionally marked device can adversely affect the levels of the voltage peaks produced
with an X are the special stipulations in the EC sample test by the inverter. . The maximum value of the voltage peaks at the
certificate. terminals in the system Inverter-Cable-Eletrical Device must not
exceed the value stated in the manufacturers special notes.
Furthermore, the EMC Guideline must be observed.

26
DE EN FR ES
Ersatzteile, vom Werk lieferbar Spare parts, available from the works Pièces de rechange, livrables par lusine (voir exemple de Piezas de recambio, suministro desde fábrica (v. ejemplo de pedido)
(s. Bestellbeispiel) (see order example) commande)
1.00 Rodamiento D
1.00 Lagerung AS 1.00 Bearing, drive end 1.00 Palier côté entraînement .40 Escudo portacojinetes
.40 Lagerschild .40 Endshield .40 Flasque-palier .43 Anillo obturador
.43 Wellendichtring .43 Shaft sealing ring .43 Bague détanchéité .58 Arandela flexible
.58 Federscheibe .58 Resilient preloading ring .58 Rondelle élastique .60 Rodamiento
.60 Wälzlager .60 Rolling-contact bearing .60 Roulement .61 Cinta elástica para el cubo del escudo portacojinetes
.61 Federband für Lagerschildnabe .61 Spring band for endshield hub .61 Lame élastique pour moyeu du flasque (no se emplea siempre)
(nicht immer vorhanden) (not always provided) (pas toujours présente)
3.00 Rotor, completo
3.00 Läufer, komplett 3.00 Rotor, complete 3.00 Rotor, complet .88 Chaveta para ventilador
.88 Paßfeder für Lüfter .88 Featherkey for fan .88 Clavette pour ventilateur
4.00 Estator, completo
4.00 Ständer, komplett 4.00 Stator, complete 4.00 Stator, complet .07 Pata derecha de la carcasa
.07 Gehäusefuß, rechts .07 Frame foot, right .07 Patte de la carcasse, droite .08 Pata izquierda de la carcasa
ANHANG / APPENDIX / APPENDICE/ANEXO

.08 Gehäusefuß, links .08 Frame foot, left .08 Patte de la carcasse, gauche .18 Placa de características
.18 Leistungsschild .18 Rating plate .18 Plaque signalétique .19 Tornillo
.19 Schraube .19 Bolt .19 Vis .20 Tapa
.20 Abdeckung .20 Cover .20 Recouvrement .30 Angular de contacto
.30 Kontaktwinkel .30 Contakt angele .30 Equerre de contact .31 Angular exterior de puesta a tierra
.31 Erdungswinkel .31 Earthing angele .31 Equerre de mise à la terre
5.00 Caja de bornes, completa
5.00 Anschlußkasten, komplett 5.00 Terminal box, complete 5.00 Boîte à bornes, complète .03 Sello
.03 Dichtung .03 Seal .03 Joint .04 Sello
.04 Dichtung .04 Seal .04 Joint .10 Placa de bornes, completa
.10 Klemmenbrett, komplett .10 Terminal board, complete .10 Plaque à bornes, complète .11 Regletero (p. ej. para conexión con termistor PTC)
.11 Klemmleiste .11 Terminal strip(e.g. for PTC .11 Bornier (par ex. pour sonde CTP) .44 Parte superior de la caja de bornes
(z. B. für Kaltleiteranschluß) thermistor connection) .44 Partie supérieure de la boîte à bornes .70 Pisacables
.44 Anschlußkasten-Oberteil .44 Top part of terminal box .70 Etrier de serrage .71 Pisacables
.70 Klemmbügel .70 Terminal clip .71 Etrier de serrage .83 Sello
.71 Klemmbügel .71 Terminal clip .83 Joint (torique sur (HA 180...200) .84 Tapa de la caja de bornes
.83 Dichtung .83 Seal .84 Couvercle de la boîte à bornes .85 Sello
.84 Anschlußkasten-Deckel .84 Terminal box cover .85 Joint .90 Parte superior de la caja de bornes, girable en
.85 Dichtung .85 Seal .90 Parie supérieure de la boîte à bornes, 4 x 90 grados, completa (para montaje posterior)
.90 Anschlußkastenoberteil .90 Top part of terminal box, can be turned through orientable de 4 x 90 °, complète (pour montage .92 Tapa de la caja de bornes
4x90 Grad drehbar, komplett 4 x 90 degrees, complete (for retrofitting) ultérieur) .93 Sello
(für nachträglich Anbau) .92 Terminal box cover .92 Couvercle de la boîte à bornes .95 Parte superior de la caja de bornes
.92 Anschlußkasten-Deckel .93 Seal .93 Joint .98 Sello
.93 Dichtung .95 Top part of terminal box .95 Partie supérieure de la boîte à bornes .99 Placa del adaptador
.95 Anschlußkasten-Oberteil .98 Seal .98 Joint
.98 Dichtung .99 Adapter plate .99 Plaque dadaptateur 6.00 Rodamiento N
.99 Adapterplatte .10 Rodamiento
6.00 Bearing, non-drive end 6.00 Palier côté opposé à lentraînement .11 Cinta elástica para el cubo del escudo
6.00 Lagerung BS .10 Rolling-contact bearing .10 Roulement portacojinetes (no se emplea siempre)
ã Siemens AG 2003
.10 Wälzlager .11 Spring band for endshield hub .11 Lame élastique pour moyeu du flasque .20 Escudo portacojinetes
.11 Federband für Lagerschildnabe (not always provided) (pas toujours présente) .23 Anillo obturador
(nicht immer vorhanden) .20 Endshield .20 Flasque-palier
.20 Lagerschild .23 Shaft sealing ring .23 Bague détanchéité 7.00 Sistema de ventilación, completo
.23 Wellendichtring .04 Ventilador
7.00 Ventilation, complete 7.00 Ventilation, complète .40 Capota del ventilador
7.00 Belüftung, komplett .04 Fan .04 Ventilateur
All Rights Reserved
.04 Lüfter .40 Fan cowl .40 Capot du ventilateur ¡No se pueden suministrar los dispositivos para calar y extraer los
.40 Lüfterhaube rodamientos, ventiladores y órganos de accionamiento!
The devices for pressing on and pulling off the rolling-contact Les dispositifs demmanchement et dextraction pour
Auf- und Abziehvorrichtungen für Wälzlager, Lüfter und bearings, the fan and the transmission elements cannot be roulements, ventilateurs et organes de transmission ne sont
Abtriebselemente sind nicht lieferbar! ordered! pas livrables.
ã
IT SV CS RU
Siemens AG 2003 All Rights Reserved
Parti di ricambio disponibili da magazzino (vedere esempi Reservdelar, kan levereras från fabriken (se Náhradní díly, dodávané výrobcem Çàïàñíûå ÷àñòè, âîçìîæíà ïîñòàâêà ñ ôàáðèêè
di ordinazione) beställningsexempel) (viz pøíklad objednávky) (ñì. ïðèìåð çàêàçà)
1.00 Cuscinetti lato albero 1.00 Lager AS 1.00 uloení AS 1.00 Óñòðîéñòâî ïîäøèïíèêîâ AS
.40 Coperchio del cuscinetto .40 Lagersköld .40 loiskový tít .40 ïîäøèïíèêîâûå ùèòû
.43 Anello di tenuta dellalbero .43 Axeltätring .43 tìsnící krouek høídele .43 óïëîòíèòåëüíîå êîëüöî âàëà
.58 Anello elastico .58 Fjäderbricka .58 pérová podloka .58 Óïðóãàÿ øàéáà
.60 Cuscinetto a rotolamento .60 Rullager .60 valivé loisko .60 Ïîäøèïíèê êà÷åíèÿ
.61 Nastro elastico per il mozzo dello scudo .61 Fjäderband för lagersköldsnav (finns ej alltid) .61 pruná objímka pro náboj loiskového títu .61 Ïðóæèíÿùàÿ ïîëîñêà äëÿ âòóëêè ïîäøèïíèêà
di supporto (non sempre inserito) (není vdy k dispozici) (íå âñåãäà â íàëè÷èè)
3.00 Rotor, komplett
APPENDICE / BILAGA
3.00 Rotore completo .88 kil för fläkt 3.00 rotor, kompletní 3.00 Âåíòèëÿòîð, êîìïëåêò
.88 Chiavetta per ventilatore .88 pero ventilátoru .88 Ïðèçìàòè÷åñêàÿ øïîíêà äëÿ âåíòèëÿòîðà
4.00 Stator, komplett
4.00 Statore completo .07 Fot för hus, höger 4.00 statorový svazek v kostøe 4.00 Ñòîéêà, êîìïëåêò
.07 Piede di sostegno destro .08 Fot för hus, vänster .07 patka pravá .07 Ëàïà êîðïóñà, ïðàâàÿ
.08 Piede di sostegno sinistro .18 Märkskylt .08 patka levá .08 Ëàïà êîðïóñà, ëåâàÿ
.18 Targhetta dei dati .19 Skruv .18 typový títek .18 Ôèðìåííàÿ òàáëè÷êà ñ óêàçàíèåì ìîùíîñòåé
.19 Vite .20 Lock .19 roub .19 Âèíò
.20 Coperchio .30 Kontaktvinkel .20 ucpávka .20 Ïîêðûòèå
.30 Angolare di contatto .31 Jordingsvinkel .30 kontaktní úhelník .30 Êîíòàêòíûé óãîëîê
.31 Angolare di messa a terra .31 zemnící úhelník .31 Óãîëîê äëÿ çàçåìëåíèÿ
5.00 Uttagslåda, komplett
5.00 Cassetta terminale completa .03 Packning 5.00 svorkovnice, úplná 5.00 Êëåììíàÿ êîðîáêà, êîìïëåêò
/ PRILOHA
.03 Guarnizione .04 Packning .03 tìsnìní .03 Óïëîòíèòåëü
.04 Guarnizione .10 Kopplingsplint, komplett .04 tìsnìní .04 Óïëîòíèòåëü
.10 Morsettiera completa .11 Kontaktplint (t.ex. för anslutning av .10 deska svorkovnice , úplná .10 êëåììíûé ùèòîê, êîìïëåêò
.11 Morsettiera ad es. per il collegamento di PTC-termistor) .11 svorková lita (napø.pro pøipojení termistoru) .11 Çàæèìíàÿ ïëàíêà (íàïðèìåð äëÿ òåðìîðåçèñòîðà)
termistori PTC .44 Överdel till uttagslåda .44 skøíò svorkovnice vrchní èást .44 Âåðõíÿÿ ÷àñòü êëåììíîé êîðîáêè
.44 Parte superiore della cassetta terminale .70 Klämbygel .70 upínací objímka .70 Çàæèì
.71 upínací objímka
/ Ïðèëîæåíèå
.70 Staffa .71 Klämbygel .71 Çàæèì
.71 Staffa .83 Packning .83 tìsnìní .83 Óïëîòíèòåëü
.83 Anello di tenuta .84 Lock till uttagslåda .84 víko svorkovnice .84 Êðûøêà êëåììíîé êîðîáêè
.84 Coperchio della cassetta terminale .85 Packning .85 tìsnìní .85 Óïëîòíèòåëü
.85 Guarnizione .90 Överdel till uttagslåda 4 x 90 Dgrader vridbar, .90 svorkovnice,horní èást .90 Âåðõíÿÿ ÷àñòü êëåììíîé êîðîáêè
.90 Parte superiore della cassetta komplett (för montering i efterhand) otoèná o 4x90 stupòù, úplná 4x90ãðàä. ðàçâîðîòîñïîñîáíîñòü, êîìïëåêò
orientabile 4 volte di 90°, completa (per .92 Lock till uttagslåda (pro dodateènou montá) (äëÿ äîïîëíèòåëüíîãî ìîíòàæà)
montaggio successivo) .93 Packning .92 svorkovnice - víèko 92 Êðûøêà êëåììíîé êîðîáêè
.92 Coperchio della cassetta terminale .95 Överdel till uttagslåda .93 tìsnìní .93 Óïëîòíèòåëü
.93 Guarnizione .98 Packning .95 skøíò svorkovnice .95 Âåðõíÿÿ ÷àñòü êëåììíîé êîðîáêè
.95 Parte superiore della cassetta terminale .99 Adapterplatta .98 tìsnìní .98 Óïëîòíèòåëü
.98 Guarnizione .99 adapter skøínì svorkovnice .99 Ïåðåõîäíàÿ ïëàñòèíà
.99 Piastra adattatore 6.00 Lager BS
.10 Rullager 6.00 uloení BS 6.00 Óñòðîéñòâî ïîäøèïíèêîâ BS
6.00 Cuscinetti lato opposto albero .11 Fjäderband för lagersköldsnav (finns ej alltid) .10 valivé loisko .10 Ïîäøèïíèê êà÷åíèÿ
.10 Cuscinetti a rotolamento .20 Lagersköld .11 pruná objímka pro náboj loiskového títu .11 Ïðóæèíÿùàÿ ïîëîñêà äëÿ âòóëêè ïîäøèïíèêà
.11 Nastro elastico per il mozzo dello scudo .23 Axeltätring (není vdy k dispozici) (íå âñåãäà â íàëè÷èè)
di supporto (non sempre inserito) .20 loiskový tít .20 Ïîäøèïíèêîâûé ùèò
.20 Coperchio dei cuscinetti 7.00 Ventilation, komplett .23 tìsnící krouek høídele .23 óïëîòíèòåëüíîå êîëüöî âàëà
.23 Anello di tenuta dellalbero .04 Fläkt
.40 Fläktkåpa 7.00 vìtrání, úplné 7.00 Âåíòèëÿöèÿ, êîìïëåêò
7.00 Ventilatore completo .04 ventilátor .04 Âåíòèëÿòîð
.04 Ventilatore .40 kryt ventilátoru .40 Êðûøêà âåíòèëÿòîðà
.40 Cappa del ventilatore
Nasazovací a stahovací pøípravky pro valivá loiska, Ïðèñïîñîáëåíèå äëÿ ñúåìà è ìîíòàæà ïîäøèïíèêà êà÷åíèÿ,
I dispositivi per il calettamento e lestrazione di cuscinetti, På- och avdragningsanordningar för rullager, fläkt och vìtráky a prvky pohonu nedodáváme ! âåíòèëÿòîðà è âåäîìûõ ýëåìåíòîâ íå ïîñòàâëÿþòñÿ
ventilatori e elementi di trasmissione non possono essere drivdonselement kan inte levereras!
27
ordinati!
DE EN FR ES IT SV CS RU
DE - Normteile sind nach Abmessung, Werkstoff und Oberfläche im freien Handel zu beziehen.
EN - Standard commercially available parts are to be purchased in accordance with the specified dimensions, material and surface finish.
FR - Les pièces normalisées peuvent être obtenues dans le commerce daprès leurs dimensions, le matériau et létat de surface.
ES - Las piezas estándar se comprarán en comercios del ramo según las dimensiones, material y superficie especificados.
IT - Le parti standard sono reperibili sul mercato secondo le dimensioni, il materiale e la finitura della superficie.
SV - Normerade detaljer kan erhållas i öppna handeln, och skall specificeras beträffande storlek, material och ytbehandling.
CS - Normované díly lze v pøísluných rozmìrech, materiálech a povrchu nakoupit v bìných obchodech.
RU - ñòàíäàðòíûå ÷àñòè ìîæíî ïðèîáðåñòè â ñâîáîäíîé òîðãîâëå ïî ðàçìåðàì, ìàòåðèàëó è ïîâåðõíîñòè
DIN EN ISO 7089/7090

(DIN 125)
DIN EN ISO 4762 DIN EN ISO 4014 DIN EN 50262
4.05 (s. Fig. 3) (DIN 912) (DIN 931)
1.49
4.11 5.52
4.10 4.39 5.53
4.38 DIN 128 5.19 5.96
5.78 5.49
5.79
DIN EN ISO 4017 DIN EN ISO 7045
5.89 (DIN 7985)
(DIN 933)
5.91 DIN 625
7.12 DIN 471
5.94
6.29 Lagertyp:
Type of bearing:
7.49
Type de roulement:
1.60 Tipo de cojinete:
6.02 DIN 472
6.10 Tipo di cuscinetto:
Lagertyp:
Typ loiska
Òèï ïîäøèïíèêà
4.04 (s. Fig. 3) DIN 580 3.38 DIN 6885
Fig. 2
DE - Ersatzteile sind über den Vertrieb bei den jeweiligen Produktionsstätten zu bestellen.
EN - Spare parts can be ordered from the Sales departments of the particular production sites.
FR - Les pièces de rechange doivent être commandées auprès du service de vente des lieux de production respectifs.
ES - Los recambios se piden a través de la distribución de las plantas de producción respectivas.
IT - I pezzi di ricambio vanno ordinati presso i centri di distribuzione dei rispettivi stabilimenti di produzione.
SV - Reservdelar ska beställas på respektive fabriks distributionsavdelning.
CS - Náhradní díly je tøeba objednat pøes odbyt u pøísluných výrobních závodù.
RU - Çàêàçû íà çàïàñíûå ÷àñòè ïðèíèìàþò îòäåëåíèÿ ïðîäàæè ñîîòâåòñòâóþøèõ ïðîèçâîäñòâåííûõ çàâîäîâ.
E Bad Neustadt / D
UD Mohelnice / Cz
UC Frenstat / Cz
Bestellbeispiel
E Áàä Íåéøòàäò / Ãåðìàíèÿ Order example
UD Ìîõåëüíèöå / ×åõèÿ Exemple de commande 1.40 Lagerschild
UC Ôðåíøòàò / ×åõèÿ Ejemplo de pedido 1LA7 163-4AA60
Esempio di ordinazione Nr. E4A6 4567 890077
Beställningsexempel
Pøíklad objednávky
Ïðèìåð çàêàçà

1MA/1MF **) 1MA/1MF: EEx e - bescheinigte Verschraubung (5.1)
certify screwed connections (5.1) Bei Aluminium-Lagerschilden (1.40 AH90) ist in die Nabe ein Federband (1.61) eingelegt (Sicke
ã
certifier presse-étoupe (5.1) im Freistich einhaken).

Siemens AG 2002
5.91 certificar uniones atornilladas (5.1) In the case of aluminium bearing plates (1.40 AH90) a spring strip (1.61) is inserted in the hub
certificare collegamenti a vite (5.1) (hook-in bead in undercut) .
5.92 intyga skruvförband (5.1) Sur les flasques aluminium (1.40 AH90), un ressort à ruban (1.61) est inséré dans le moyeu
(Accrocher le jonc par dégagement par rainure).
schválený roubový spoj (5.1)
5.98 En las placas de cojinete de aluminio (1.40 AH90) en el cubo se halla montado un fleje de
2003 All Rights Reserved
ðåöèíçèðîâàííîå ðåçüá.ñîåäèíåíèå (5.1)

muelle (1.61) (enganchar la acanaladura en la entalladura).
5.89 Nel caso degli scudi di cuscinetti in alluminio (1.40 AH90) un nastro elastico (1.61) è inserito
nel mozzo (agganciare la nervatura nello scarico).
5.94 Hos aluminium-lagersköldar (1.40 AH90) finns ett fjäderband (1.61) i naven (fäst falsen i det
fria uttaget).
5.84 U hliníkových títù (1.40 AH90) je do loiskového náboje vloena pruná objímka (1.61) Prolisy na
5.95 této objímce musí zapadnout do zápichu za loiskovým prùmìrem
5.83 Â àëþìèíèåâûõ ïîäøèïíèêîâûõ ùèòàõ (1.40 AH90) âî âòóëêó âëîæåíà ïðóæèíÿùàÿ ïëàñòèíà(1.61)
5.52 **) (æåëîáîê)
5.90 1.40 AH90 1.61
5.49
5.53 **)
5.98 5.44
5.19
2x 5.96
5.78 5.03
5.10 5.19
5.99 5.10
5.79
5.04 5.78
6.10 6.23
5.71 5.11
5.70
4.20
1.40
4.00
IM B5 IM B3
7.40* 7.49*
7.04*
6.29
6.20
4.18 4.19
4.30 * Teile entfallen bei
4.31
3.00 3.38
* Parts not included with
1.60 4.38 * Certaines pièces sont
1.43 1.58 4.39 supprimées pour le type
1.49 * Pazas inexistentes en 1LP, 1PP, 1MF
1MA7/1MF7 * Parti non
1.49 * Delar ingår inte för
* díly odpadají u
Fig. 2 BG 56...90L
29
* ×àñòè îòñóòñòâóþò â
1LA 6/1MA 6 Bei Aluminium-Lagerschilden (1.40/6.20) ist in die Nabe entweder ein Federband (1.61/6.11)
**) 1MA/1MF: EEx e - bescheinigte Verschraubung (5.1)
30
eingelegt (Sicke im Freistich einhaken) oder ein Stahlring eingegossen.
5.91 certify screwed connections (5.1) 5.79 With aluminium end shields (1.40/6.20), either a spring band (1.61/6.11) is inserted (bead
hooked in undercut) or a steel ring is cast in the hub.
certifier presse-étoupe (5.1)
certificar uniones atornilladas (5.1) 5.70 5.78 Les flasques-paliers en aluminium comportent (1.40/6.20) soit une lame élastique (1.61/6.11)
5.92 certificare collegamenti a vite (5.1)
introduite de telle manière que le bossage vienne se placer dans la gorge, soit un anneau en
acier inséré par coulée.
intyga skruvförband (5.1) En el cubo del escudo portacojinetes de aluminio (1.40/6.20) puede haber una banda elástica
schválený roubový spoj (5.1) (1.61/6.11) cuyos abultamientos se enganchan en el canal, o hay embebido un anillo de acero.
ðåöèíçèðîâàííîå ðåçüá.ñîåäèíåíèå (5.1) Nel mozzo degli scudi in alluminio è stato (1.40/6.20) inserito o un anello in acciaio fuso, o un
5.93 nastro flessibile (1.61/6.11) il cui rilievo è innestato nelle gole.
I Lagersköldar av aluminium (1.40/6.20) är ett fjäderband (1.61/6.11) antingen inlagt i nevet
1MA/1MF: 5.98 (vulsten inpassad i underskärningen) eller ingjutet i en stålring.
U hliníkových títù (1.40/6.20) je do loiskového náboje vloena buï pruná objímka (1.61/6.11
5.90 5.94
prolisy musí zapadnout do zápichu) nebo je zde zalit ocelový krouek
Â àëþìèíèåâûõ ïîäøèïíèêîâûõ ùèòàõ (1.40 /6.20) âî âòóëêó ëèáî æåëîáîê âëîæåíà ïðóæèíÿùàÿ
5.89 ïëàñòèíà(1.61/6.11) (æåëîáîêíàñàäèòü íà êðþê) èëè âëèòî ñòàëüíîå êîëüöî
* Teile entfallen bei

5.95 1.40/6.20 1.61/6.11 * Parts not included with
5.96 * Certaines pièces sont
5.84 supprimées pour le type
5.52 **) * Pazas inexistentes en
* Parti non 1LP, 1PP, 1MF
* Delar ingår inte för
5.19 * díly odpadají u
5.19
5.93 5.78 * ×àñòè îòñóòñòâóþò â
1MA/1MF: 5.98 7.04* 7.49*

5.10 6.29
5.53 **) 6.20
6.23
5.03 6.02 6.10
5.79 5.71 (BG 160)
1MA/1MF 2x
5.78 5.11
1.47 4.20 5.70
1.40 IM B3
IM B5 4.00 3.88*
7.40*
7.12*
ã Siemens AG 2003
1.60 3.38
1.43 1.58 4.19 1MA6/1MF6
1.49 4.31 4.38 4.18
All Rights Reserved
1.49 4.30 4.39

4.08 4.11 4.10 4.31
4.07 4.38
1MA7/1MF7
Fig. 2 BG 100...160L (Bei 1..7 BG100L - Füße angegossen) / (In the case of 1..7 BG100L cast feet are involved) / (Avec 1..7 BG100L Pieds coulés) / (En 1..7 BG100L patas fijadas por fundición) /
4.39
(nel caso di 1..7 BG100L - piedi applicati mediante fusione) / (Hos 1..7 BG100L fastgjutna fötter) / (U 1.7 BG 100L nalité patky) / (â 1...7 BG 100L ëàïû ïðèâàðåíû)
Fig. 3
DE - Ausführung mit seitlich angeordnetem Anschlußkastenoberteil (4x90° drehbar)
EN - Motor with top part of terminal box mounted on side (can be turned through 4x90°)
FR - Exécution avec partie supérieure de la boîte á bornes disposé sur le côté
ES - Motor con la parte superior de la caja de bornes adosada lateralmente (puede girarse 4x90°)
IT - Esecuzione con parte superiore della cassetta terminale disposta lateralmente (orientabile 4x90°)
SV - Utförande med överdel till uttagslådan (4x90° vridbar) monterad på sidan
CS - Provedení s horní èástí svorkovnice, umístìné na stranì (otoèné o 4 x 90°)
RU - Ìîäåëü ñ ïðèäåëàííîé ñáîêó âåðõíåé ÷àñòüþ êëåììíîé êîðîáêè (4õ90° âðàùàòåëüíàÿ ñïîñîáíîñòü)
BG 100...160L
4.04
4.05
z. B. Öffnung für Kabel und Leitungen - unten

e.g. opening for cables and leads - bottom
p. e. traversées pour câbles et conducteurs - en bas
p. ej abertura pasacables - abajo
ad es. passaggio per conduttori e cavi - parte inferiore
t.ex. öppning för kabel och ledningar - nedtill
Napø. otvor pro kabely a vedení - dole
Íàïðèìåð îòâåðñòèå äëÿ ïðîâîäêè- âíèçó
Fig. 4
DE - Ausschlagen der Öffnungen für Kabel und Leitungen im Anschlußkasten
EN - Knocking out the openings for cables and leads in the terminal box
FR - Rupture des membranes de fabrication aburant les entées de câbles et de conducteurs sur la boîte á bornes
ES - Martillando las aberturas pasacables de la caja de bornes
IT - Asportare la pellicola per cavi e conduttori nella cassetta terminale
SV - Utslagning av öppningarna för kabel och ledningar i uttagslådan
CS - Vyraení otvorù pro kabely a vedení ve svorkovnici
RU - Âûáèâàíèå îòâåðñòèÿ äëÿ êàáåëåé èëè ïðîâîäîê â êëåììíîé êîðîáêå
BG 100...160L (1LA7/9, 1LP7/9, 1PP7/9)
Ausbrechöffnung (Gußhaut)
Cast iron skin
Membrane de fabrication
Membrana de fundición
Pellicola residua della colata
Gjutskorpa
Vylamovací otvor (èepièka)
âûáèòûå îòâåðñòèÿ (ëèòåéíàÿ êîðêà)

Fig. 4.1
DE - Verschraubungen mit (Blech-) Mutter (DIN EN 50262) DE - Verschraubungen mit Reduzierung und (Blech-) Mutter (DIN EN 50262)
EN - Screwed connections with (plate-) nut (DIN EN 50262) EN - Screwed connections with reducer and (plate-) nut (DIN EN 50262)
FR - Raccords à vis avec écrou (en tôle) (DIN EN 50262) FR - Raccords à vis avec réduction et écrou (en tôle) (DIN EN 50262)
ES - Atornilladuras con tuercas (para chapa) (DIN EN 50262) ES - Atornilladuras con reductores y tuercas (para chapa) (DIN EN 50262)
IT - Collegamenti a vite con dado (per lamiera) (DIN EN 50262) IT - Collegamenti a vite con riduzione e dado (per lamiere) (DIN EN 50262)
SV - Förskruvningar med (plåt-) mutter (DIN EN 50262) SV - Förskruvningar med reducering och (plåt-) mutter (DIN EN 50262)
CS- roubová spojení s (plechovou) matkou (DIN EN 50262) CS - roubová spojení s redukcí a (plechovou) matkou (DIN EN 50262)
RU- Ðåçüáîâûå ñîåäèíåíèÿ ñ ïîìîùüþ (ñàìîíàðåçàþùèõ) ãàåê RU - Ðåçüáîâûå ñîåäèíåíèÿ ñ ïîìîùüþ ïåðåõîäíûõ äåòàëåé è (ñàìîíàðåçàþùèõ)
(DIN EN 50262). ãàåê (DIN EN 50262).
M M M
Mutter O-Ring
M M
O-Ring (Fig. 5.1)
Nut O-ring (Fig. 5.1) O-ring
Ecrou Joint torique (Fig. 5.1) Joint torique
Tuerca junta tórica (Fig. 5.1) junta tórica
Dado Guarnizione a o-ring(Fig. 5.1) Guarnizione a o-ring
Mutter O-ring (Fig. 5.1) O-ring
Matka O-krouek (Fig. 5.1) O-krouek
Ãàéêà Î-êîëüöî (Fig. 5.1) Î-êîëüöî
Mutter
Nut Reduktionsstück
Anschlußkastenwand
Ecrou Adapter
Wall of terminal box
Tuerca Pièce de réduction
Paroi de la boîte á bornes
Dado Pieza reductora
Pared de la caja de bornes
Mutter Riduttore
Cassetta termina l parete
Vägg till uttagslådan Matka Reduceringsstycke
Stìna svorkovnice Ãàéêà Redukce
ñòåíêà êëåììíîé êîðîáêè M M íàñàäêà
Einbaulage Blechmutter
Installation length sheet metal nut
Emplacement pour écrou à tôle
posición del montaje tuerca para chapa
Posizione di montaggio dado di lamiera
Monteringsläge påtmutter
Poloha plechové matky
ìåñòî ïîñàäêè ãàéêè
Montage / Assembly / Montage / Montaje / Hinweis / Note / Note / Note / Nota / Observera / poznámka /
Montaggio / Montering / Montá / Ñáîðêà Óêàçàíèÿ/ïðèìå÷àíèÿ
1 DE - Verschraubung in Gehäuse einschrauben oder mit Gegenmutter befestigen, 1 DE - Die Verschraubungen dürfen ausschlieslich für Kabel ohne Bewehrung oder
(Drehmoment M). Umspinnung sowie nur für feste Installation verwendet werden.
EN - Screw connection into housing or tighten with locknut , (Torque M). EN - The cabel entries may be used only for non-armouring cables and only for
FR - Visser le raccord à vis dans le carter ou fixer avec un contre-écrou, solid installation.
(couple de serrage M). FR - Les raccords à vis ne peuvent être utilisés que pour les câbles sans armature
ES - Enroscar la atornilladura en la carcasa o sujetarla con la contratuerca, ou guipage ainsi que pour uniquement les installations fixes.
(par de giro M). ES - Las atornilladuras pueden usarse solo y exclusivamente para cable sin
IT - Avvitare il collegamento a vite sulla carcassa o fissare con controdado, armadura ni trenzado, así como sólo para la instalación fija.
(momento torcente M). IT - I collegamenti a vite devono essere utilizzati solo per cavi senza armatura
SV - Skruva i förskruvningen i huset eller fäst den med en kontermutter, o calza ed esclusivamente per installazioni fisse.
(vridmoment M). SV - Förskruvningarna får endast användas för kabel utan armering eller
CS- Naroubujte roubové spojení do bloku nebo jej upevnìte pojistnou maticí, omflätning samt endast för fasta installationer.
(toèivý moment) CS- roubová spojení se smìjí pouívat výluènì pro kabely bez výztue
RU- Ââèíòèòü ðåçüáîâîé ýëåìåíò â êîðïóñ èëè çàêðåïèòü åãî êîíòðãàéêîé, nebo opøedení a jen k pevné instalaci.
(ìîìåíò çàòÿæêè Ì). RU- Ðåçüáîâûå ñîåäèíåíèÿ äîëæíû èñïîëüçîâàòüñÿ òîëüêî äëÿ
ïðîâîäîâ áåç êàáåëüíîé áðîíè èëè îáìîòêè, à òàêæå òîëüêî äëÿ
2 DE - Leitung einführen. ñòàöèîíàðíîãî ìîíòàæà.
EN - Put cable through.
FR - Introduire la conduite. 2 DE - Bei mehrmaliger Verwendung ist auf Unversehrtheit des Kunststoffein-
ES - Introducir el cable. satzes zu achten.
IT - Introdurre il cavo. EN - The plastic insert must be undamaged at multiple use.
SV - Skjut in ledningen. FR - En cas dutilisation à plusieurs reprises, veiller vous assurer que la garniture
CS- Zaveïte vedení en plastique ne soit pas endommagée.
RU- Ââåñòè êàáåëü. ES - Al usarse varias veces, se tiene que comprobar si está intacto el inserto de
plástico.
3 DE - Hutmutter festziehen,(Drehmoment M). IT - In caso di uso ripetuto, fare attenzione che la guarnizione di plastica non sia
EN - Tighten nutcap, (Torque M). danneggiata.
FR - Serrer lécrou borgne, (couple de serrage M). SV - Vid upprepad användning är det viktigt att kontrollera att plastinsatsen inte
ES - Apretar la tuerca de sombrerete, (par de giro M). har tagit skada.
IT - Stringere il dado cieco, (momento torcente M). CS- Pøi opakovaném pouití je tøeba dbát na to, aby nedolo k pokození
SV - Dra åt toppmuttern, (vridmoment M). plastové vloky
CS- Utáhnìte uzavøenou matici, (toèivý moment) RU- Ïðè ìíîãîêðàòíîì èñïîëüçîâàíèè ïðîâåðÿòü íåïîâðåæäåííîñòü
RU- Ïðî÷íî çàòÿíóòü êîëïà÷êîâóþ ãàéêó, (ìîìåíò çàòÿæêè Ì). ïëàñòìàññîâîãî ñåðäå÷íèêà.
Fig. 5
DE - Anziehdrehmomente für Schraubenverbindungen der elektrischen Anschlüsse - Klemmenbrettanschlüsse (außer Klemmenleisten)
EN - Tightening torques for screwed electrical connections - terminal board connections (except for terminal strips)
FR - Couples de serrages des bornes de la plaque à bornes (ne concerne pas les borniers)
ES - Pares de apriete para uniones atornilladas de las conexiones eléctricas en la placa de bornes (exceptuando las regletas de bornes).
IT - Coppie di serraggio per le viti di attacco di collegamenti elettrici / dei portamorsetti (escluse morsettiere)
SV - Åtdragningsmoment för motorns huvudkopplingsplintar. (utom för hjälpkopplingsplintar)
CS - Utahovací momenty pro roubové spoje elektrických pøípojek svorkovnice (mimo svorkových lit)
RU - Ìîìåíòû çàòÿæêè ðåçüá. ñîåäèíåíèé ýë. ïîäêëþ÷åíèé-ïîäêëþ÷åíèéíà êëåììíûõ ùèòàõ(êðîìå ïîäêëþ÷åíèé íà êëåììíîé ïëàíêå)
Gewinde- Æ / Thread- Æ
Æ du filetage / Æ de la rosca
Diametro del filetto / Gängdimeter M4 M5 M6 M8 M10 M12 M16
Závit-Æ / ÐåçüáàÆ
Anziehdrehmoment
Tightening torque
Couple de serrage
min 0,8 1,8 2,7 5,5 9 14 27
Par de apriete Nm
Coppia di serraggio
Åtdragningsmoment
Utahovací moment max 1,2 2,5 4 8 13 20 40
Çàòÿæíîé ìîìåíò
Fig. 5.1
DE - Anziehdrehmoment der Kabelverschraubungen aus Metall (*) und Kunststoff (**) für direkten Anbau am Motor. Bei weiteren
Verschraubungen (z. B. Reduzierungen) sind die entsprechenden Momente gemäß Tabelle anzuwenden.
EN - Tightening torques of the cable screw connections made from metal (*) and plastic (**) for direct installation on the motor.
For other threaded attachments (e.g. reducers) the appropriate torques in the tables are to be used.
FR - Le couple de serrage des passe-câble à vis en métal (*)et en plastique (**) pour le montage direct sur le moteur.
Pour les autres raccords à vis (par ex. réductions), il faut utiliser les couples correspondants indiqués dans le tableau.
ES - Par de apriete de los racores para cables en metal (*) y plástico (**) para el montaje directo en el motor.
Tratándose de otras atornilladuras (p.ej., reductores), se tienen que aplicar los pares correspondientes de conformidad con el cuadro.
IT - Coppia di serraggio dei collegamenti a vite dei cavi in metallo (*) e materiale sintetico (**) per il montaggio diretto sul motore.
In caso di altri collegamenti a vite (p. es. riduzioni), applicare i momenti riportati nella tabella.
SV - Åtdragningsmoment för kabelförskruvningar av metall (*) och plast (**) för direkt montering på motorn.
För övriga förskruvningar (t ex reduceringar) gäller de i tabellen angivna åtdragningsmomenten
CS - Utahovací toèivý moment kabelových roubových spojení z kovu (*) a O-Ring - Dicke
plastu (**) k pøímé montái na motor. U dalích roubových spojení (napøíklad (*) (**) Joint torique
redukcí) pouijte pøísluné momenty uvedené v tabulce. junta tórica
RU - Ìîìåíòû çàòÿæêè ðåçüáîâûõ êàáåëüíûõ ââîäîâ èç ìåòàëëà (*) è Guarnizione a o-ring
ïëàñòìàññû (**) äëÿ íåïîñðåäñòâåííîé óñòàíîâêè íà ýëåêòðîäâèãàòåëå. O-ring
Ïðè èñïîëüçîâàíèè äîïîëíèòåëüíûõ ðåçüáîâûõ ýëåìåíòîâ (íàïðèìåð ïåðåõîäíûõ Nm Nm O-krouek
äåòàëåé) ñîáëþäàòü ìîìåíòû çàòÿæêè, ïðèâåäåííûå â òàáëèöå. Î-êîëüöî
min max min max mm
M 12 x 1,5 4 6
M 16 x 1,5 5 7,5 2 3
M 25 x 1,5 6 9 2
M 32 x 1,5
8 12 4 6
M 40 x 1,5
Fig. 5.2
DE - Anziehdrehmomente für Schrauben am elektrischen Anschlußkasten, Lagerschilden und Schutzleiter-Schraubverbindungen
EN - Tightening torques for screws at the electrical terminal box, endshileds and protectice conductor-screw connections.
FR - Couples de serrage pour vis - sur larmoire électrique, .flasques et raccords à vis de fils de protection
ES - Momentos de apriete para los tornillos en la caja de conexiones eléctricas, placas de los cojinetes y conexiones del conductor de puesta a tierra y conexiones roscadas.
IT - Coppie di serraggio per avvitamenti alla scatola di giunzione elettrica, scudi e collegamenti a vite del conduttore di protezione
SV - Åtdragningsmoment för skruvar på kopplingsskåp, lagerskyltar och skyddsledaranslutningar
CS - Utahovací momenty roubù v elektrickém pøípojném pouzdøe, loisek ve títu a roubových spojení na ochranném vedení.
RU - Çàòÿæíûå ñîåäèíåíèÿ äëÿ âèíòîâ íà êëåììíîé êîðîáêå, ùèòîâ ïîäøèïíèêîâ è ðåçüá. ñîåäèíåíèé çàùèòíîé ïðîâîäêè
Gewinde- Æ / Thread- Æ
Æ du filetage / Æ de la rosca
Diametro del filetto / Gängdimeter M4 M5 M6 M8 M10 M12 M16 M20
Závit-Æ / ÐåçüáàÆ
Anziehdrehmoment
Tightening torque
Couple de serrage
min 2 3,5 6 16 28 46 110 225
Par de apriete Nm
Coppia di serraggio
Åtdragningsmoment
Utahovací moment max 3 5 9 24 42 70 165 340
Çàòÿæíîé ìîìåíò
DE - Die obigen Anziehdrehmomente gelten soweit keine anderen Werte angegeben sind!
EN - The above values of tightening torque are applicable unless alternative values are given elsewhere.
FR - Les couples de serrage indiqués ci-dessus sont valables pour autant quaucune valeur spécifique ne soit donnée.
ES - Estos pares de apriete rigen mientras no se indiquen otros.
IT - Le coppie di serraggio indicate qui di sopra sono valide se non sono indicati altri valori.
SV - Ovanstående åtdragningsmoment gäller om ej andra värden angivits!
CS - Výe uvedené utahovací momenty platí, pokud nejsou udány ádné jiné hodnoty!
RU - Âûøåóêàçàííûå ìîìåíòû- äåéñòâèòåëüíû â ñëó÷àå îòñóòñâèÿ äðóãèõ óêàçàíèé

Fig. 6
DE - Anschließbare Querschnitt je nach Klemmengröße (ggf. reduziert durch Größe der Leitungseinführungen)
EN - Conductor cross-sections connectable to the various terminals (may be reduced by size of cable entries)
FR - Sections raccordables suivant la taille de la borne (réduction éventuelle par la taille des entrées de câbles)
ES - Sección conectable según tamaño del borne (en caso dado, más pequeña debido al tamaño de las entradas de línea)
IT - Diametri dei collegamenti a sec. delle misure dei morsetti (eventualmente sono ridotte le dimensioni delle aperture per i conduttori)
SV - Anslutningsbara ledarareor för olika klämstorlekar (ev. reducerat med hänsyn till genomföringens storlek)
CS - Pøipojitelný prùøez podle velikosti svorek (pøíp. zmenený velikostí kabelových vývodek)
RU - Ïîäêëþ÷àåìîå ñå÷åíèå â çàâèñèìîñòè îò ðàçìåðà êëåìì (ïðè íåîáõîäèìîñòè óìåíüøàåòñÿ çà ñ÷åò ðàçìåðà ââîäà)
... 25 mm2 ... 10 mm2 ... 25 mm2 ... 10 mm2 ... 25 mm2
DIN 46 234 DIN 46 234
Bei Anschluß mit DIN- Kabelschuh Anschluß eines einzelnen Leiters Anschluß von zwei etwa gleich dik- Anschluß eines einzelnen Leiters Bei Anschluß mit DIN- Kabelschuh
ist dieser nach unten abzuwinkeln! mit Klemmbügel. ken Leitern mit Klemmbügel. unter äußerem Erdungswinkel. unter äußerem Erdungswinkel.
If connections are made with DIN Connecting a single conductor If connections are made with DIN
cable lugs, bend the cable lugs Connecting a single conductor with Connecting two conductors of al- under the outer earthing angle. cable lugs, under the outer ear-
downwards. a terminal clip. most equal thickness with a terminal thing angle.
Lorsque le raccordement est clip. Raccordement d'un seul Lorsque le raccordement est
réalisé par cosses DIN, celles-ci Raccordement d'un seul conduc- Deux conducteurs de diamètre à conducteur à une équerre extérieu- réalisé par cosses DIN, à une
doivent être pliées vers le bas. teur à une borne à étrier. peu pré équivalents, raccordés à re de mise à la terre. équerre extérieure de mise à la
une borne à étrier. terre.
Si la conexión se efectúa con Conexión de un solo conductor bajo Si la conexión se efectúa con
terminales para cables DIN, habrá Conexión de un solo conductor con Conexión de dos conductores de el angular exterior de puesta a tierra. terminales para cables DIN, bajo
que doblarlos hacia abajo. un pisacables. diámetro aproximadamente igual, el angular exterior de puesta a tierra.
con un pisacables. Allacciamento di ogni singolo con- Nel collegamento con capocorda
Nel collegamento con capocorda Allacciamento di ogni singolo conduttore sotto angolare di messa a conforme alle norme DIN, sotto
conforme alle norme DIN, questo duttore con staffa. Allacciamento di due conduttori di terra esterno. angolare di messa a terra esterno.
va piegato verso il basso. stesso o pressocchè indentico Vid anslutning med kabelsko enl.
Vid anslutning med kabelsko enl. Anslutning av en enkelledare med spessore con staffa. Anslutning av en enkelledare under DIN under extern jordningsvinkel.
DIN skall denna bockas nedåt. klämbygel. Anslutning av två ungefär lika tjocka extern jordningsvinkel.
ledare med klämbygel. Pøi pøipojení kabelovým oèkem
Pøi pøipojení kabelovým oèkem Pøipojení jednotlivého vodièe Pøipojení jednotlivého vodièe pøi DIN pøi vnìjím zemnícím
DIN musí být toto ohnuto smìrem upínací objímkou. Pøipojení dvou zhruba stejnì vnìjím zemnícím úhelníku. úhelníku.
dolù! silných vodièù upínací objímkou.
Ïîäêëþ÷åíèå îäèíî÷íîãî Ïîäêëþ÷åíèå îäèíî÷íîãî Ïðè ïîäêëþ÷åíèè ñ ïîìîùüþ
Ïðè ïîäêëþ÷åíèè ñ ïîìîùüþ ïðîâîäà ñ ïîìîùüþ çàæèìà. Ïîäêëþ÷åíèå äâóõ ïðèìåðíî ïðîâîäà ïîä âíåøíèì DIN- êàáåëüíîãî íàêîíå÷íèêà ïîä
DIN- êàáåëüíîãî íàêîíå÷íèêà åãî îäèíàêîâûõ ïî òîëùèíå çàçåìëÿþùèì óãîëêîì. âíåøíèì çàçåìëÿþùèì óãîëêîì.
ñëåäóåò çàìîòàòü âíèç. ïðîâîäîâ ñ ïîìîùüþ çàæèìà.
Fig. 6.1 Fig. 6.2
Fig. 7
DE - Lagerwechsel
EN - Changing bearings
FR - Remplacement des roulements
ES - Cambio de cojinetes
IT - Sostituzione dei cuscinetti
SV - Lagerbyte
CS - Výmìna loiska
RU - çàìåíà ïîäøèïíèêà Zwischenscheibe (Schutz der Zentrierung im Wellenende)
Spacer washer (to protect centring bore in shaft end)
Rondelle (protection du centrage en bout darbre)
Disco intermedio (protege el centrado en el extremo del eje)
Spessore (protezione della centratura nullestremità dalbero)
Distansbricka (skydd av centreringen l axeltappen)
Vloená podloka(ochrana centrování na konci høídele)
Ïðîìåæóòî÷íàÿ øàéáà (çàùèòà öåíòðèðóþùåãî ýëåìåíòà â êîíöå âàëà)

Fig. 8
DE - Auf- und Abziehen von Abtriebselementen
EN - Pressing on and pulling off drive elements
FR - Emmanchement et extraction dorganes de transmission
ES - Calado y extracción de órganos de transmisión
IT - Calettamento ed estrazione degli elementi di transmissione Zwischenscheibe (Schutz der Zentrierung im Wellenende)
SV - På- och avdragning av drivdon Spacer washer (to protect centring bore in shaft end)
CS - Nasazování a stahování hnacích prvkù Rondelle (protection du centrage en bout darbre)
Disco intermedio (protege el centrado en el extremo del eje)
RU - Ìîíòàæ è ñíÿòèå âåäîìûõ ýëåìåíòîâ
Spessore (protezione della centratura nullestremità dalbero)
Distansbricka (skydd av centreringen l axeltappen)
Vloená podloka (ochrana centrování na konci høídele
Ïðîìåæóòî÷íàÿ øàéáà (çàùèòà öåíòðèðóþùåãî ýëåìåíòà â êîíöå âàëà)
DE - Zum Aufziehen von Abtriebselementen (Kupplung, Zahnrad, Riemenscheibe usw.), Gewinde im Wellenende benutzen und - sofern
möglich - Abtriebselemente nach Bedarf erwärmen. Zum Abziehen geeignete Vorrichtung verwenden. Es dürfen beim Auf- und Abziehen
keine Schläge (z.B. mit Hammer oder ähnlichem) oder größere als die laut Katalog zulässigen radialen oder axialen Kräfte über das
Wellenende auf die Motorlager übertragen werden.
EN -Use the tapped hole provided in the end of the shaft for fitting drive components such as couplings, gearwheels, belt pulleys, etc. and,
if possible, heat the components as necessary. Use a suitable puller tool for removing the components. Do not strike the components,
e.g. with a hammer or similar tool, when fitting or removing them and do not exert more than the maximum value of radial or axial
force - according to the catalog - transmitted to the motor bearings through the shaft extension.
FR - Pour monter les organes de transmission (accouplements, roues dentées, poulies à courroie, etc.), utiliser le taraudage du bout darbre.
Au besoin et lorsque cela est possible, chauffer les organes de transmission. Pour le démontage, utiliser un dispositif approprié. Aucun
coup (par ex. marteau) supérieur aux efforts axiaux et radiaux admissibles mentionnés au catalogue ne doit être transmis par larbre
aux roulements en cours de montage ou de démontage.
ES - Para calar los órganos de transmisión (acoplamientos, rueda dentada, polea, etc.) utilizar la rosca en el extremo del eje y - siempre
que sea posible - calentar convenientemente dichos órganos. Utilizar el dispositivo adecuado para la extracción. Durante las operaciones
de calado o extracción no golpear (p. ej. con martillo o similar) ni ejercer sobre los cojinetes del motor a través del extremo del eje
fuerzas axiales o radiales superiores a las admisibles según catálogo.
IT - Per calettare gli elementi di transmissione (giunti, ruote dentate, pulegge, ecc.), utilizzare il foro filettato nellestremità dalbero e,
se possibile, riscaldare gli elementi di transmissione . Per lestrazione vanno adoperati attrezzi adatti. Sono da evitare colpi o martellate,
e forze radiali o assiali trasmesse dallestremità dalbero ai cuscinetti maggiori di quelle consentite sec. il catalogo.
SV - Använd axeltappens gänga vid pådragning av drivdon (koppling, kugghjul, remskiva etc) och värm om möjligt upp drivdonen om så behövs.
Använd lämpliga verktyg för avdragningen. Några slag (t.ex. med hammare e.dyl.) får aldrig förekomma vid på- och avdragning, och
radiella och axiella krafter som är större än de som anges i katalogen får inte överföras till motorlagren via axeltappen.
CS -Pro nasazování hnacích prvkù (spojka, ozubené kolo, øemenice a pod.) pouijte závit na konci høídele a pokud to je moné zahøejte podle
potøeby hnací prvky. Pøi stahování pouijte vhodný pøípravek. Pøi nasazování a stahování nesmí být pouívány ádné údery (napø. kladivem
a podobnì) nebo pøenáeny pøes konec høídele na loisko motoru ádné radiální nebo axiální síly vìtí, ne je uvedeno v katalogu.
RU - Äëÿ ìîíòàæà âåäîìûõ ýëåìåíòîâ (ðåäóêòîð, çóá÷àòûé ðåìåíü, ðåìåííàÿ øàéáà è ò.ä.) èñïîëüçîâàòü ðåçüáó íà êîíöå âàëà ïî
âîçìîæíîñòè íàãðåâàòü âåäîìûå ýëåìåíòû, åñëè åñòü íåîáõîäèìîñòü. Äëÿ ñíÿòèÿ èñïîëüçîâàòü ñïåöèàëüíîå ïðèñïîñîáëåíèå. Äëÿ
ñíÿòèÿ èëè ìîíòàæà ñëåäóåò èçáåãàòü óäàðîâ(íàïðèìåð ìîëîòêîì èëè ïîäîáíûìè ïðåäìåòàìè). Íåëüçÿ äîïóñêàòü, ÷òîáû ÷åðåç êîíåö
âàëà íà ìîòîð ïåðåäàâàëèñü àêñèàëüíûå èëè ðàäèàëüíûå ñèëû, áîëüøèå ÷åì óêàçàííûå â êàòàëîãå.
Fig. 9
DE - Auswuchtung mit halber Paßfeder
EN - Balancing with half featherkey TP
FR - Equilibrage avec demi-clavette
ES - Equilibrado con media chaveta
IT - Equilibratura con mezza chiavetta
SV - Balansering med halv kil
CS - Vyváení polovièními lícovanými pery
RU - Áàëàíñèðîâêà ñ ïîëîâèíîé ïðèçìàòè÷åñêîé

Spare Parts List
Return Line Filter RF
Flow rates up to 15,000 l/min
Pressure range up to 25 bar
Material: PA 66 / AI / GGG 40 / St
1
1. MAINTENANCE 1.2. INSTALLATION
INSTRUCTIONS Before fitting the filter into the
system check that the permissible
1.1. USER INSTRUCTIONS FOR Danger
operating pressure of the system
FILTERS On no account must any does not exceed the operating
This pressure unit complies with alterations (welding, drilling, or pressure of the filter.
the regulations of the Pressure opening by force…) be carried
Observe type code label on the
Equipment Directive (97/23/EC), out on the pressure unit.
filter!
Article 3 Paragraph 3, and as
1.3. COMMISSIONING
such is not permitted to carry the
CE mark. Check that the correct filter
Information
element is fitted. Fit cover plate
and screw in cover plate bolts
It is the responsibility of the alternately (except RF 30 cover
operator to comply with the plate).
water regulations of the
country concerned. For torque values of cover plate
Information
bolts, see point 1.4.
This pressure unit must only Switch on hydraulic system and
be operated in conjunction Statutory accident prevention vent filter.
with a machine or a system. regulations, safety regulations
and safety data sheets for Check filter for leakage.
fluids must be observed. 1.4. TOOLS REQUIRED FOR
MAINTENANCE
When working on, or in the Int. hex.
Information
vicinity of, hydraulic systems, bolt,
naked flames, spark generation Torque Allen
The pressure unit must only be
and smoking are forbidden. Size value key
used in accordance with the
requirements of the operating RF 30 Hand-tight
instructions of the machine or Hydraulic oils and water RF 60/110 25 Nm SW 6
system. polluting fluids must not be
allowed to enter the soil or RF 160/240 25 Nm SW 6
watercourses or sewerage RF 330 40 Nm SW 8
systems. Please ensure safe RF 660 150 Nm SW 14
and environmentally friendly RF 950/1300 250 Nm SW 17
disposal of hydraulic oils.
Caution
The relevant regulations in the
The user must, by appropriate country concerned with regard Torque Ext.
action, (e.g. venting) prevent to ground water pollution, Size value hexagon
the formation of air pockets. used oil and waste must be
complied with. RF 2500/4000 150 Nm SW 24
RF 5200 250 Nm SW 30
Whenever work is carried out RF 6500/15000 250 Nm SW 36
on the filter, be prepared for
Caution hot oil to escape which can 1.5. SERVICE ADDRESSES
cause injury or scalding due to
Repair, maintenance work and Oil service:
high pressure or high
commissioning must only be HYDAC International
temperature.
carried out by trained Servicetechnik, Werk 6
personnel. Industriegebiet
Ensure the pressure unit has D-66280 Sulzbach/Saar
cooled down before handling. Tel.: 06897/509-333
Fax.: 06897/509-846
The stipulations of the
operating instructions of the
machine or the system must be Customer service:
followed. HYDAC International
Zentraler Kundendienst, Werk 6
Industriegebiet
D-66280 Sulzbach/Saar
Tel.: 06897/509-412
Fax.: 06897/509-634
Danger
Caution: pressure unit! Before

any work is carried out on the Or at all national and international
pressure unit, ensure the HYDAC sales and service
pressure chamber concerned centres.
(filter housing) is
depressurized.
2
2. MAINTENANCE 3. REPLACING THE 3.2. FITTING THE ELEMENT
2.1. GENERAL ELEMENT 1. Moisten sealing surfaces on the
filter housing and cover plate, as
This section describes 3.1. REMOVING THE ELEMENT well as the O-rings, if necessary,
maintenance work, which should 1. Switch off hydraulic system with clean operating fluid.
be carried out periodically. and release filter pressure.
The operational safety and life
expectancy of the filter, and CAUTION: 2. When fitting a new element,
whether it is ready for use, When fitting as inline filter: before check that the designation
depend to a large degree on opening the filter, slowly open the corresponds to that of the old
regular and careful maintenance. vent screw and release pressure. element.
2.2. MAINTENANCE PROCEDURES (Release possible pressure in the
tank)
– Spare parts must fulfil the 3. If present, fit the contamination
technical requirements specified retainer onto the new or cleaned
by the manufacturer. This is 2. Remove cover plate bolts. element by turning clockwise.
always guaranteed for HYDAC (RF 30: Unscrew cover plate
original spare parts. manually)
4. Place filter element onto the
– Keep tools, working area and element location spigot in the
equipment clean. 3. Remove cover plate. filter housing (the position of the
– After disassembling the filter, handle must be taken into
clean all parts, check for damage account).
4. Pull out filter element (with
or wear and replace parts if contamination retainer, if present)
necessary. by the handle. Examine element 5. Replace filter cover plate.
– When changing a filter element a surface for dirt residues and
high level of cleanliness must be larger particles; these can indicate
observed! 6. Screw in cover plate bolts
damage to the components.
manually; tighten alternately
2.3. INTERVAL BETWEEN (for torque values, see point 1.4.;
CHANGING ELEMENTS 5. Remove contamination retainer for RF 30: screw in cover plate
We recommend fitting the filter (if present) by turning to the left - manually).
with a clogging indicator (visual bayonet fitting.
and/or electric or electronic) to
7. Switch on hydraulic system and
monitor the filter element.
6. Replace or clean filter element vent filter at an appropriate point
If the clogging indicator responds, (only W/HC, W, V and T elements in the system.
it is necessary to change or to can be cleaned).
clean the filter element without
delay. (Only W/HC, W, V and T 8. Check filter for leakage.
elements can be cleaned). 7. Clean housing, cover plate and
contamination retainer.
If no clogging indicator is fitted,
we recommend changing the
elements after specified intervals. 8. Examine filter, especially sealing
(Changing the filter element surfaces, for mechanical damage.
depends on the design of the
filter and the conditions.) Higher
dynamic loads across the 9. Check O-rings on the clogging
element might necessitate indicator and the cover plate and
shorter intervals between replace if necessary.
changes. Shorter intervals can
also be expected during
commissioning, repairs, oil
changes etc. on the hydraulic
system.
NOTE:
Filter elements which cannot be cleaned
must be disposed of in accordance with
environmental regulations.
3
4. SPARE PARTS
4.1. SPARE PARTS DRAWING RF 30 - 1300
2.1
2.2 / 4.3
4.2
1.1
1.2 / 4.1 3
4.4
4
4.2. SPARE PARTS LIST RF 30 - 1300
Item cons. Designation Size RF 30 RF 60 RF 110 RF 160 RF 240

of Connection BB DC DC DE DE
1 Filter element See point 5. Replacement elements
1.1 Filter element As per order
1.2 O-ring 12.37 x 2.62 22 x 3.5 34 x 3.5
2 Indicator plug (VR 0 A.0) 00306006
Indicator plug /-V (VR 0 A.0) 00305928
2.1 Indicator plug VR 0 A.0
2.2 O-ring 18 x 2.5
3 Contamination retainer RF... 01202459 00245028 00246164 00245029 00246182
Contamination retainer RF...HC 01202459 01202362 01202363
4 Seal kit E RF...1.X 00307664 01267827 01270657
Seal kit E RF...1.X /-V 00303733 01267828 01270658
4.1 O-ring (element) 12.37 x 2.62 22 x 3 34 x 3.5
4.2 O-ring (cover plate) 56 x 3 63.09 x 3.53 91.67 x 3.53
4.3 O-ring (VR 0 A.0) 18 x 2.5
4.4 O-ring (tank seal) RF 30 82.14 x 3.53 110.72 x 3.53
Supplementary details (not illustrated)

Tank breather filter 246178 – – – –
Item cons. Designation Size RF 330 RF 330 RF 660 RF 950 RF 1300

of Connection DG DL DN DO DP
1.2 O-ring 48 x 3 68 x 5 97.8 x 5.33
2.2 O-ring 18 x 2.5
3 Contamination retainer RF... 00245030 00245031 00413196 00400985
Contamination retainer RF...HC 01202364 01202357 01204141
4 Seal kit E RF...1.X 00319613 00303792 00303814
Seal kit E RF...1.X /-V 00311702 00307622 01260043
4.1 O-ring (element) 48 x 3 68 x 5 97.8 x 5.33
4.2 O-ring (cover plate) 105 x 5 142 x 6 175 x 5
4.3 O-ring (VR 0 A.0) 18 x 2.5
4.4 O-ring (tank seal) RF 330 RF 660 RF 950
Supplementary details (not illustrated)

Tank breather filter – – – – –
5
4.3. SPARE PART DRAWING RF 2500 - 15000
2.1
2.2 / 3.3 3.4
3.2
1.1
1.2 / 3.1
3.5
6
4.4. SPARE PARTS LIST RF 2500 - 15000
Item cons. Designation Size RF 2500

RF 2500 RF 4000 RF 4000 RF 5200 RF 5200
of Connection B R
BU BU BV BU BV
1 Filter element See point 5. Replacement element
1.2 O-ring 68 x 5 97.8 x 5.33
No. of elements Size 3x 3x 5x 5x 4x 4x
0850 R... 0850 R... 0850 R... 0850 R... 1300 R... 1300 R...
2.2 O-ring 18 x 2.5
3 Repair kit E RF...2.X 01273117 01273119 01273121
Repair kit E RF...2.X /-V 01273118 01273120 01273122
3.1 O-ring (element) 68 x 5 97.8 x 5.33
3.2 O-ring (cover plate) 278.77 x 5.33 370 x 5 405.26 x 7
3.3 O-ring (VR 0 A.0) 18 x 2.5
3.4 Blanking plug VSTI G½ (cover plate) 00607166 (00613168)
3.5 Blanking plug VSTI G1 (drain) 00607168 (00625536)
Item cons. Designation Size RF 6500 RF 6500 RF 7800 RF 7800 RF 15000 RF 15000
of Connection B V BW BW BX BX BY
1.2 O-ring 97.8 x 5.33
No. of elements Size 5x 5x 6x 6x 10 x 10 x
1300 R... 1300 R... 1300 R... 1300 R... 1300 R... 1300 R...
2.2 O-ring 18 x 2.5
3 Repair kit E RF...2.X 01273123 01273830 01273125
Repair kit E RF...2.X /-V 01273124 01273831 01273126
3.1 O-ring (element) 97.8 x 5.33
3.2 O-ring (cover plate) 506.86 x 6.99 715 x 8.4
3.3 O-ring (VR 0 A.0) 18 x 2.5
3.4 Blanking plug VSTI G½ (cover plate) 00607166 (00613168)
3.5 Blanking plug VSTI G1 (drain) 00607168 (00625536)
Items are available complete only.
Component parts are indicated below each item in standard type.
5. REPLACEMENT ELEMENTS
5.1. MODEL CODE (R Element (also order example)) 0060 R 010 BN3HC /-V-KB
Size
0030, 0060, 0110, 0160, 0240, 0330, 0660, 0850, 0950, 1300
Type
R
Filtration in µm
BN3HC, V : 3, 5, 10, 20
BN/AM : 3, 10
P/HC : 10, 20
W/HC : 25, 50, 100, 200
AM : 40
Filter material
BN3HC Betamicron® P/HC Paper
AM Aquamicron® W/HC Stainless steel wire mesh
BN/AM Betamicron®/Aquamicron® V Stainless steel fibre
Supplementary details
V = FPM seals, filter suitable for biodegradable oils and phosphate ester (HFD-R)
W = NBR seals, filter suitable for oil water emulsions (HFA, HFC)(only for V and W/HC elements)
KB = without bypass valve
B. = special bypass cracking pressure (B1 = 1 bar, B6 = 6 bar)
6. NOTE
The information in this brochure relates to the operating conditions and applications described. For applications or
operating conditions not described, please contact the relevant technical department. Subject to technical
modifications.
7
1.1.2. Selection table - Return line indicators 1.2. TECHNICAL SPECIFICATIONS
suitable for filter types 1.2.1. Return line indicators
RF, RFD NF/
RFM MF/ BF7
RFM (except NFD...
75/165 MFD ELF7
Designation size 75/165) 1.0
VR 2 B.1 l l
VMF 2 B.1 l
VR 2 C.0 l l
VMF 2 C.0 l
General details
VR 2 D.0/-L l l
Designation of VR 2 B.1 VMF 2 B.1 VR 2 E.0 VMF 2 E.0 VR 2 ES.0
VMF 2 D.0/-L l clogging indicator (not illustrated) (not illustrated)
VR 2 E.0 l l Suitable for

filter types
all RF, RFD, RFM
(except size 75/
RFM 75/165
(please contact our
all RF, RFD, RFM
(except size 75/
RFM 75/165
(please contact our
all RF, RFD, RFM
(except size 75/165),
VMF 2 E.0 l 165), sales/techn. 165), sales/techn. NF/NFD...1.0
NF/NFD...1.0 department) NF/NFD...1.0 department)
VMF 16 E.0 l
VR 2 ES.0 l l Weights 44 g 210 g 140 g 80 g 120 g
VR 2 F.0 l l Type of indication visual, red pin visual-analogue visual-analogue

scale green-yellow-red scale green-yellow-red
VMF 2 F.0 l l
VR 2 H.0 l l l
VMF 2 H.0 l
Hydraulic details
VMF 0.6 K.0
Cracking pressure/
VR 2 LE.1 l l indication range
2 bar - 0.2 bar 0 bar to +10 bar 0 bar to +10 bar
VR 2 LZ.1/-DB l l Permissible operating pressure 7 bar 7 bar -continuous 7 bar -continuous

VR 2 LZ.1/-CN l l Permissible temperature range1) - 30 °C to +100 °C - 20 °C to +60 °C - 20 °C to +60 °C
VR 2 GC.0 l l Accuracy class - 1.6 1.6
VMF 1 UE.0 l 1)
Electrical details
VMF 0.2 UF.0 l 1)
Switching type - - -
1) only when used in suction applications
Max. switching voltage - - -
Electrical connection - - -
Max. switching output - - -

at resistive load
Switching capacity2) - -
-
Safety type (to DIN 40050) - - -
Symbols
1)
Only NBR (Perbunan) seals can be used
in the temperature range - 30° C to - 10° C.
2)
High voltage peaks sometimes occur when
inductances are switched off. Therefore the
use of protection diodes should be considered.
3 4
1. DESCRIPTION 1.3. APPLICATION
1.1. GENERAL FLUTEC pressure relief valves
DB4E are used:
According to DIN–ISO 1219,
FLUTEC pressure relief valves – as safety valves for limiting
DB4E are valves for oil hydraulic A pressure to the maximum
systems used for controlling permissible
pressure by opening the outlet to – as safety valves for cylinders,
the tank when the inlet pressure B pumps and other pressure
exceeds the spring force. generators
The damping unit fitted on the – for limiting pressure in hydraulic
pressure side ensures that a C units and control blocks
stable operation is maintained – for pressure control of hydraulic
over the whole capacity range circuits
and that the noise level is kept to D
Areas of application could be, for
a minimum. An excellent
example:
constant–pressure performance is
achieved by means of the – hydraulic units
hydrodynamic lift support. Further – elevating platforms
advantages of these valves are E 2 – mobile hydraulics
as follows:
– clamping hydraulics
– standardised installation
dimensions means that they are – relief valves on hydraulic motors
suited to many different F – force or torque limiting on drive
applications 1 elements
– their compact design provides 1.4. NOTE
space–saving installation in A Adjustment device
B Valve body When fitting the valves into
connection housings, control C Spring control blocks and housings the
blocks, etc. especially in confined D Spring plate with hydro– given torques must be observed!
installation conditions dynamic lift support
E Closing cone with damping Note port configuration!
– low hysteresis and high stability piston
ensure accurate pressure control Important
F Valve seat
– optimum system adaptation by 1 Pressure port If the connections are incorrect, or
means of various pressure ranges 2 Tank port the pressure has been incorrectly
set above the operating pressure,
– simple assembly by means of 1.2. FUNCTION the safety function of the valve is
service–friendly cartridge valve FLUTEC pressure relief valves no longer operational.
technology DB4E are direct–operated, Max. pressure across tank port 2:
– a wide range of connection spring–loaded cone seat valves 350 bar
housings is available for optimum for oil hydraulic systems. The
adaptation to a multitude of valve basically consists of a valve Please note
applications body with built–in valve seat, a The cracking pressure of the
– the zinc–plated surface is suitable hardened and polished closing valve increases by the amount of
for use in mobile applications cone and the adjustment device pressure across tank port 2!
without additional coatings. for setting the initial spring
tension. The spring applies this
In accordance with pressure force to the closing cone and
vessel regulations pressure set pushes it against the valve seat.
and lead sealed pressure relief On the opposite side of the
valves are available for oil closing cone the system pressure
hydraulic systems. acts via port 1 of the valve. If the
The corresponding valve hydraulic pressure force is below
specifications are set out in the the pre–set spring tension, the
brochure ”FLUTEC Pressure valve is closed. If the hydraulic
Relief Valves DB4 pressure set pressure force exceeds the
and lead sealed” no. E 5.163../.. pre–set spring tension, the
closing cone is lifted off the valve
seat and the operating fluid flows
from pressure port 1 to tank port
2. This limits the pressure across
port 1. To ensure that a stable
operation is maintained, the
closing cone is securely located
in the damping piston which has
to displace oil in an aperture with
each movement of the closing
cone. This produces a damping
force each time, opposing the
direction of movement.
2
4/10 Bosch Rexroth AG Industrial Hydraulics Types WMR, WMU, WMM and WMD(A) RE 22280/02.04
Function, section
Valve types WM.. are mechanical, manual operated directional
spool valves.
They control the start, stop and direction of a flow.
2 1 3 4
The directional valves basically consist of the housing (1), an
operating element (2) (roller/plunger, hand lever, rotary knob),
the control spool (3), and one or two return springs (4).
In the unoperated condition, the control spool (3) is held in
the neutral or initial position by the return springs (4) – or by a
detent with rotary knob operation.
The control spool (3) is pushed into the required control
position by means of the operating element.
Detent A T B
Directional valves with rotary knob operation are supplied with Type 4WMR 6 E5X/… (P)
a detent as standard. Directional valves with hand lever
operation are available as 2 or 3 position valves with detent.
Directional valves with a roller/plunger are generally without
detent. When using an operating element with detent, it is pos-
sible, according to the valve type, to fix any switched position.
Throttle insert
Use of the throttle insert is necessary when the operating
conditions are such, that during the switching process larger
flows can occur than the performance limits of the valve allow. 2 1 3 4
It is fitted in the P line of the directional valve.
A T B
P (P)
Type 4WMM 6 D5X/F
Type 4WM. 6 ..5X/..B..
2 1 3 4
A T B
Type 4WMDA 6 E5X/F (P)
RE 22280/02.04 Types WMR, WMU, WMM and WMD(A) Industrial Hydraulics Bosch Rexroth AG 5/10
Technical data (for applications outside these parameters, please consult us!)
General
Installation Optional
Ambient temperature range °C – 30 to + 80 (NBR seals)
– 20 to + 80 (FKM seals)
Weight kg Approx. 1.4
Hydraulic
Maximum operating Ports A, B, P bar 315
pressure Port T: For symbols A or B, port T must be used as a drain
• For WMM, WMD, WMDA bar 160 port if the operating pressure is higher than the
• For WMR, WMU bar 60 permissible tank pressure.
Maximum flow L/min 60
Flow cross-section For symbol Q 6 % of the nominal cross-section

For symbol W 3 % of the nominal cross-section
Pressure fluid Mineral oil (HL, HLP) to DIN 51524 1); fast bio-degradable
pressure fluid to VDMA 24568 (also see RE 90221); HETG
(rape seed oil) 1); HEPG (polyglycols) 2); HEES (synthetic
ester) 2); other pressure fluids on request
Pressue fluid temperture range °C – 30 to + 80 (for NBR seals)
– 20 to + 80 (for FKM seals)
Cleanliness class to ISO codes Maximum permissible degree of contamination of the pressure
fluid is to ISO 4406 (C) class 20/18/15 3)
Viscosity range mm2/s 2.8 to 500
1) Suitable for NBR and FKM seals 3) The cleanliness class stated for the components must be
2) Only suitable for FKM seals adhered too in hydraulic systems. Effective filtration prevents
faults occurring and at the same time increases the
component service life.
For the selection of filters see data sheets:
RE 50070, RE 50076 and RE 50081.
Operating force/torque
Type WMR/WMU WMM WMD
Operating pressure
Ports A, B, P bar 100 200 315
Operating force on the roller/plunger
Without tank pressure N 100 112 121
With tank pressure N 184 196 205
(pT = max. 60 bar) corresponds to 1.4 N per bar tank pressure
Operating torque max. Ncm – 150
Without tank pressure,
N 20 –
with and without detent
150 bar tank pressure N 30 –
Formula for calculating operating force N

FR = Fo.T-pressure+ pT x 1 .4
on the roller/plunger (FR) when there is a bar
tank pressure
Function, section
Valves type Z2FS 6 are double throttle/check valves of sandwich plate Flow flowing back from the actuator port A2 moves the valve seat
design. (2) against spring (5) in the direction of the throttling spool (3), causing
They are used to limit the main or pilot flow of one or two actuators. the valve to act as a check valve and allowing free-flow. Depending
upon the way in which the valve is installed, the throttling effect can
Two symmetrically arranged throttle/check valves limit the flow in
be arranged as a meter-in or meter-out control.
one direction and allow free-flow in the opposite direction.
Limiting the main fluid flow (version ..2Q..)
For meter-in control fluid passes from port A1 to port A2 via the
In order to change the velocity of an actuator (main fluid flow), the
throttling point (1), which is made up of the valve seat (2) and the
double throttle/check valve is installed between the directional valve
throttling spool (3). The throttling spool (3) is axially adjustable via
and the subplate.
the adjustment screw (4), thus allowing the throttling point (1) to be
adjusted. Limiting the pilot fluid flow (version ..1Q..)
In pilot operated directional control valves, the double throttle/check
valve is installed as a pilot choke adjustment (pilot fluid flow). It is
fitted between the main valve and the pilot valve.
4 5 2
A1 B1
3 1 A2 B2
Type Z2FS 6 –2–4X/… (meter-in)
Technical data (for applications outside these parameters, please consult us!)
General
Installation Optional
Ambient temperature range °C – 20 to + 80
Weight kg Approx. 0.8
Hydraulic
Maximum operating pressure bar 315
Maximum flow L/min 80
Pressure fluid Mineral oil (HL, HLP) to DIN 51 524;
Fast bio-degradable pressure fluids to
VDMA 24 568 (also see RE 90 221); HETG (rape seed oil);
HEPG (polyglycols); HEES (synthetic ester);
Other pressure fluids on request
Pressure fluid temperature range °C – 20 to + 80
Viscosity range mm2/s 10 to 800
Cleanliness class to ISO code Maximum permissible degree of contamination of the pressure
fluid is to ISO 4406 (C) class 20/18/15 1)
1) The cleanliness class stated for the components must be adhered too in hydraulic systems.
Effective filtration prevents faults from occurring and at the same time increases the component service life.
For the selection of filters see catalogue sheets RE 50 070, RE 50 076 and RE 50 081.
Z2FS 6 3/6 RE 27 506/12.02

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Technical Documentation

Customer: Gebr. Pfeiffer AG

Designation: Compact unit size 40

1 Erection Safety Guidelines

2 Parts list material-no.: 3252486

3 Circuit diagram-no.: 76427

4 Technical Data Sheets of used components

reg. item designation type

1 02 filling and breather filter ELF .. 3 .. 4

Erection Safety Guidelines

Erection Safety Guidelines

3 Prevention of Falling Accidents

4 Fire and Explosion Hazard

6 Applicable Rules and Regulations (selection; not purported to be exhaustive)

Operation Safety Guidelines

1 General Safety Instructions

Warning with inexperted and unforeseen use.

To guarantee safe operation the following items have to be observed:

Operation Safety Guidelines

3 Safety Instructions for Pressure Accumulators

4 Instructions for Use of Pressure Accumulators

Operating Materials and Supplies

4 Oil binding agent

Operating Materials and Supplies

8 Filter elements/tank breather:

Disposal of Spent/Used Oil

2 Draining Hydraulic Components of Anti-Corrosion Oil

3 Draining an Oil Tank during an Oil Change

Disposal of Spent/Used Oil

Typical category 1 oils:

Scheduled Inspections and Maintenance

Scheduled Inspections and Maintenance

3 Maintenance during Commissioning

3.4 Fluid Level

3.5 Oil Purity

Permissible particle count for 100 ml vol. according to particle size:

Scheduled Inspections and Maintenance

4 Scheduled Routine Maintenance

4.2 Monitoring of the Nitrogen Charge Pressure of Accumulators

This can be done as follows:

4.4 Fluid Level

4.5 Checking the Oil Level

Scheduled Inspections and Maintenance

4.6 Piping System

5 Scheduled Periodical Maintenance

Scheduled Inspections and Maintenance

5.2 Daily to Weekly Maintenance

5.3 Weekly to Monthly Maintenance

Scheduled Inspections and Maintenance

5.4 Quarterly to Six-Monthly Maintenance

5.5 Yearly Maintenance

It is recommended that hydraulic components such as pumps, valves, monitoring devices,

Scheduled Inspections and Maintenance

6 Causes of Malfunction, Troubleshooting

6.2 Type of Malfunction

6.3 Locating the Cause of Malfunction

a) Can malfunction be attributed to a change in the working speeds of the

Scheduled Inspections and Maintenance

Gradual arisal of a malfunction is generally an indication of gradual clogging or dirt buildup.

Scheduled Inspections and Maintenance

6.4 Troubleshooting Lists

Scheduled Inspections and Maintenance

6.4.1 Malfunction 1: excess noise in the facility