HYDRAULIC CYLINDER

Operating instructions
Project: SONG THAO RM

hydraulic cylinder
350/140x245
Hydrosaar part number: 3410169
Loesche Code-No.: M01M10.600.02

Hydrosaar GmbH 1
Hydraulik - Maschinenbau
Friedrichsthaler Str. 15a
66540 Neunkirchen
 HYDRAULIC CYLINDER

Content

1. Description of Design and Function .......................................................................... 3

General ..................................................................................................................... 3
Use............................................................................................................................ 3
Design ....................................................................................................................... 3
Technical Data .......................................................................................................... 4

2. General Safety Instructions....................................................................................... 5

Duty of Operator to Exercise Proper Care ................................................................ 5
Explanation of Safety Symbols Used ........................................................................ 6
Basic Safety Measures ............................................................................................. 7
Particular Risks ......................................................................................................... 7

3. Assembly / Installation .............................................................................................. 9

4. Putting into Operation ............................................................................................. 10

Supply Connections ................................................................................................ 10
De-aeration of the cylinder ...................................................................................... 10
Checks Before Initial Operational Test.................................................................... 11
Checks After the Initial Operational Test................................................................. 11

5. Assistance In The Case Of Malfunction .................................................................. 11

6. Maintenance ........................................................................................................... 11

7. Inspections and Preventive Maintenance ............................................................... 12

Recommended hydraulic fluid:................................................................................ 12

8. Assembly Drawing .................................................................................................. 13

9. Parts List ................................................................................................................. 14

EC Manufacturer’s Declaration........................................................................................ 17

Lubricating instructions for tilting bearings requiring maintenance .................................. 18

Storage- and Transportation specification for hydraulic cylinders ................................... 19

Hydrosaar GmbH 2
Hydraulik - Maschinenbau
Friedrichsthaler Str. 15a
66540 Neunkirchen
 HYDRAULIC CYLINDER

1. Description of Design and Function

General
Before putting the hydraulic cylinder into operation the following instructions are to be
observed.

Use
The hydraulic cylinder has been designed for operation of mills.

Design
The hydraulic cylinder comprises the following components:
• cylinder pipe
• piston
• piston rod
• cover large
• cover small
• cylinder cap with bearing
• cover plates
• fastening screws
• sealing set
• other associated parts

Hydrosaar GmbH 3
Hydraulik - Maschinenbau
Friedrichsthaler Str. 15a
66540 Neunkirchen
 HYDRAULIC CYLINDER

Technical Data
Dimensions and weight
Length when retracted: 1320 mm

Stroke: 245 mm

Extended length: 1565 mm

Transport weight without oil: 939 kg

Hydraulic data
Piston area: 962,1 cm2
2
Ring area: 808,2 cm

Force of pressure: 1539 kN

Tensile force: 1293 kN

Maximum oil temperature: +80°C

Minimum oil temperature: -10°C

Working pressure : 160 bar

Test pressure: 240 bar

Medium: MOBIL DTE EXCEL 68

Hydraulic connections:
Piston space: 2x DN100

Ring space: 2x DN100

Deaeration: M12x1,5

Leakage port: G1/2

Hydrosaar GmbH 4
Hydraulik - Maschinenbau
Friedrichsthaler Str. 15a
66540 Neunkirchen
 HYDRAULIC CYLINDER

2. General Safety Instructions

Duty of Operator to Exercise Proper Care

The hydraulic cylinder has been designed and built according to uniform standards and
other technical specifications. It corresponds, therefore, to the best available technology
and guarantees maximum safety.
This degree of operational safety is only achieved, however, if all required measures are
fulfilled. It is the responsibility of the cylinder’s operator to plan such measures and
monitor their implementation.
The operator must ensure, in particular, that
• the cylinder is only used for its intended purpose,
• the working pressure is limited by means of a safety valve (pressure control valve),
• the cylinder is only operated in a perfect, serviceable condition,
• the necessary protective clothing and equipment is available and utilized by operating,
maintenance and repair personnel,
• a full and legible copy of the operating instructions is always on hand where the
equipment is being used,
• only adequately qualified and authorized personnel operate, service and repair the
equipment,
• these members of personnel are regularly instructed in any matters regarding
occupational safety and environmental protection, and are familiar with the operating
instructions, in particular the instructions contained in such on safety,
• the safety instructions and warnings attached to the equipment remain in place and are
legible.
The standard on safety regulations for hydraulic equipment, EN 982, is to be observed.

Hydrosaar GmbH 5
Hydraulik - Maschinenbau
Friedrichsthaler Str. 15a
66540 Neunkirchen
 HYDRAULIC CYLINDER

Explanation of Safety Symbols Used

The following safety symbols are used in these operating instructions. These symbols are
intended to draw the reader’s attention to the adjacent text containing the safety
instructions.

This symbol indicates that there is danger to human life and health.

Danger!

This symbol indicates that there is danger to machinery, material or the environment.

Attention!

Hydrosaar GmbH 6
Hydraulik - Maschinenbau
Friedrichsthaler Str. 15a
66540 Neunkirchen
 HYDRAULIC CYLINDER

Basic Safety Measures

Keep information ready to hand:
These operating instructions are to be kept by the equipment. All persons carrying out
work on the equipment must be able to refer to the operating instructions at any time. In
addition to the operating instructions, directives within the meaning of industrial safety
legislation and regulations on the use of work materials are to be provided.
All signs on the equipment bearing information on safety and operation are to be easily
legible and kept in good condition at all times. Damaged or illegible signs are to be
replaced immediately.

Particular Risks
During normal operation
The following checks are to be carried out at least once a day:
• check the cylinders externally for any detectable damage

During maintenance
When working on the hydraulic system there is the danger of fluids spraying
under high pressure

Refer to the chapter on maintenance for further information

Position transducer
Cylinders with position transducer:
Any work on the cylinders’ electrical components must be carried out exclusively by
trained electricians.
Check the electrical equipment regularly: tighten any loose connections, replace damaged
lines and cables immediately.

Hydrosaar GmbH 7
Hydraulik - Maschinenbau
Friedrichsthaler Str. 15a
66540 Neunkirchen
 HYDRAULIC CYLINDER

During work on hydraulic and pneumatic equipment:

Any work on the cylinders’ hydraulic connections must be carried out
exclusively by staff trained in this field.
Before starting work, depressurize all hydraulic and pneumatic systems /
system parts.
When carrying out repair work, the hose assemblies should, by way of
preventive maintenance, always be replaced as well , even if there is no detectable
damage. Also take note of the instructions provided by the hose manufacturer.
(The standard maximum service life of a hydraulic hose assembly under normal
conditions, including its storage period before being put to use, is between 6 and a
maximum of 10 years)

For environmental protection:

The regulations on waste prevention and on the orderly recycling or
disposal of waste are to be observed when carrying out any work on or
with the equipment.
Particular care is to be taken when carrying out installation and
maintenance work as well as stopping operation of the equipment that no
materials which are a hazard for the groundwater, e.g. greases, oils,
coolants, solvent-containing cleaning fluids etc., pollute the soil or enter the sewers. These
materials must be collected, stored, transported and disposed of in suitable containers.

Hazards caused by "residual" energies:

Please note that various forms of energy may still be present, even after
the hydraulic equipment has been switched off, e.g.:
• in hydraulic pressure pipes and pressure vessels (cylinder)
• in live power lines

Hydrosaar GmbH 8
Hydraulik - Maschinenbau
Friedrichsthaler Str. 15a
66540 Neunkirchen
 HYDRAULIC CYLINDER

3. Assembly / Installation

The following particular dangers are to be taken into account when assembling the
cylinders:
• There is the risk of fire when welding (possible oil
contents.)
• Improperly laid lines (e.g. bending radius too small) can
cause scorching and cables to catch fire
• Faulty pressure lines and connections can cause serious
physical injuries.

All screw connections for fastening the cylinder and its mounting components should
conform with the property class 10.9 in accordance with DIN / ISO 898 T1.
Before being put into operation the hydraulic cylinder must be well de-aerated.
Pipelines and vessels are to be cleaned of dirt, scale, sand, shavings etc. before
installation.
Hot-bent or welded pipes must subsequently be pickled and rinsed.
Use only material which does not fuzz or special paper for cleaning

Before putting into operation the hydraulic cylinder must well de-aerated and the
hydraulic system rinsed.

Hydrosaar GmbH 9
Hydraulik - Maschinenbau
Friedrichsthaler Str. 15a
66540 Neunkirchen
 HYDRAULIC CYLINDER

4. Putting into Operation

In order to prevent damage to the equipment or injuries when putting the cylinders into
operation, make sure the following points are observed:
• The hydraulic cylinder may only be put into operation by qualified personnel. Such
persons must adhere to the safety instructions.
• Read the chapter "General Safety Instructions".
• Make sure that the hydraulic fluid in the system corresponds with the hydraulic fluid
permitted for the hydraulic cylinder.
• The temperatures we stipulate are to be applied if the maximum temperature given by
the hydraulic fluid producer differs from ours.
A permissible filter increases the service life of the hydraulic cylinder. Please take note of
the recommended maximum degree of contamination permitted for the hydraulic fluid in
accordance with NAS 1638.

Supply Connections
• Connect the hydraulic hose assemblies to the hydraulic cylinder.
• Switch on the hydraulic supply.
• Carry out operational test.
• De-aerate cylinder if necessary.

De-aeration of the cylinder

Before being put into operation the hydraulic cylinder must be well de-aerated.
• Under no-load pressure, open the vent screw or screws on the piston head and rod.
• Allow the air to escape.
• Do not close the vent screw or other screws until the escaping oil is free from bubbles.
• Retighten the vent screws or other screws.

Hydrosaar GmbH 10
Hydraulik - Maschinenbau
Friedrichsthaler Str. 15a
66540 Neunkirchen
 HYDRAULIC CYLINDER

Checks Before Initial Operational Test

• Check the connections to the cylinder to make sure the screws fit properly and are
tight.
• Check the hose assemblies for damage.

Checks After the Initial Operational Test

• Check all hydraulic connections to make sure they are air-tight. Tighten if necessary.
• Oil specified in the chapter on maintenance - "Inspections and Preventive
Maintenance"

5. Assistance In The Case Of Malfunction

The following safety instructions are always to be observed when remedying malfunctions
on the hydraulic cylinders – injury to persons, damage to machinery and other material
damage will thus be prevented.
Any work on the electrical and hydraulic components of the cylinders must be carried out
exclusively by trained staff.
Please read the chapter "General Safety Instructions".

6. Maintenance
In order to prevent damage to machinery or injuries when servicing the equipment, the
following points are to be observed at all times:
• Switch off all supply points and secure such against being switched on again
unintentionally.
• Depressurize all pressure units.
• Only use the operating materials stipulated.
• Only use spare parts that are included in our spare parts lists.
Please read the chapter "General Safety Instructions".

Hydrosaar GmbH 11
Hydraulik - Maschinenbau
Friedrichsthaler Str. 15a
66540 Neunkirchen
 HYDRAULIC CYLINDER

7. Inspections and Preventive Maintenance

Recommended hydraulic fluid:

Hydraulic fluid DIN 51 524 – HLP 46
Recommended oil purity class according to ISO 4406 (>2µm/>5µm/>15µm): ≤ 19/17/14

Hydrosaar GmbH 12
Hydraulik - Maschinenbau
Friedrichsthaler Str. 15a
66540 Neunkirchen
 HYDRAULIC CYLINDER

8. Assembly Drawing

Hydrosaar GmbH 13
Hydraulik - Maschinenbau
Friedrichsthaler Str. 15a
66540 Neunkirchen
 HYDRAULIC CYLINDER

9. Parts List
Comp.No. Short text Size/Dimension
Item Qantity Unit Drawing Name of standard

Parts list breakdown: 0003410169 hydraulic cylinder Size: 350/140X245

Drawing: 3410169 Cust.No.: M907003-4

0003410170 cylinder pipe ass.

0001 1,000 ST 3410170

0003410173 piston rod

0002 1,000 ST 3410173

0003231311 piston
0003 1,000 ST 3231311

0003229923 cylinder cap ass.

0004 1,000 ST 3229923

0003230003 cover large ass.

0005 1,000 ST 3230003

0003128662 cave small

0006 1,000 ST 3128662

0003139337 disk
0007 2,000 ST 3139337

0003179798 self-aligning roller bearing 190/340x120

0008 1,000 ST 23238 CC/W3

0003128821 vent pipe 10X2X320

0009 1,000 ST 3128821

0003220245 protective hoop

0010 1,000 ST 3220245

0003230257 cover plate ass.

0011 4,000 ST 3230257

7023050032 screw plug VSTI-ED G1/2A

0012 1,000 ST

7023050028 screw plug VSTI-ED M12X1,5

0013 2,000 ST

7074390039 tube fitting GE10ZLRE1/4ED

0014 1,000 ST

0006048424 cutting ring C G10ZL

0015 1,000 ST

7074270021 nut M10L

0016 1,000 ST

0006024406 cheese head screw M20X110

0017 40,000 ST ISO4762

Hydrosaar GmbH 14
Hydraulik - Maschinenbau
Friedrichsthaler Str. 15a
66540 Neunkirchen
 HYDRAULIC CYLINDER

0006023040 cheese head screw M10X40

0018 12,000 ST ISO4762

7101050127 cheese head screw M12X25

0019 8,000 ST ISO4762
7101070101 hexagonal bolt M20X25
0020 2,000 ST DIN933

7106020005 eye bolt M20

0021 2,000 ST DIN580

7103050017 grub screw M12x16

0022 1,000 ST DIN913

0000636585 look washer S12

0023 8,000 ST

7150030003 grease nipple M1R1/4"

0024 1,000 ST DIN3404

0000854378 ball valve DN 10

0037 2,000 ST

0006022781 tube fitting 1/2-TYP E 12L

0038 2,000 ST ISO8434-4

0000608438 closing plug VK12L/S

0039 2,000 ST

7074270010 nut M12L

0040 2,000 ST

0000608117 angular screw coupling SWE-12L

0041 1,000 ST ISO8434-4

0003233943 locking plate

0042 2,000 ST 3233943

0006025524 minimess indicating instrument M12X1,5 - 630BAR

0050 2,000 ST

0006031404 vent valve M12X1,5

0051 2,000 ST

7063190004 minimess indicating instrument hose 1 METER

0052 2,000 ST

0003183681 plywood plate 12DICK;RD400

0060 2,000 ST
0003205082 bearing grease SKF LGEV 2
0061 0,100 KG

0003221339 mineral oil MOBIL DTE EXCEL 68

0062 33,000 L

0003130147 sealing set 350/140

0070 1,000 ST

Hydrosaar GmbH 15
Hydraulik - Maschinenbau
Friedrichsthaler Str. 15a
66540 Neunkirchen
 HYDRAULIC CYLINDER

Comp.No. Short text Size/Dimension

Item Qantity Unit Drawing Name of standard

Parts list breakdown: 0003130147 sealing set Size: 350/140

Drawing: Cust.No.:

0006021143 piston seal T-G-R 350x325,5x8,1

0025 1,000 ST

7204060008 rod seal M3 140x165x46

0026 1,000 ST

7204740017 rod seal T23 140x160x14,6

0027 1,000 ST

7206140048 scraper 38 140x152,2x12/7,7

0028 1,000 ST

0006021110 piston guide ring 350x25x2,5

0029 4,000 ST

7208110080 rod guide ring 140x25x2,5

0030 3,000 ST

7201010831 o-ring 329,57x7

0031 2,000 ST

0006031323 back-up ring 338,4/350x2,5

0032 2,000 ST

7201010756 o-ring 158x3,5

0033 1,000 ST

7201010829 o-ring 300x5

0034 1,000 ST

7201060020 o-ring 139,07x5,33

0035 1,000 ST

0006022220 back-up ring 141,4/150x1,7

0036 2,000 ST

Hydrosaar GmbH 16
Hydraulik - Maschinenbau
Friedrichsthaler Str. 15a
66540 Neunkirchen
 HYDRAULIC CYLINDER

EC Manufacturer’s Declaration
according to Appendix II B of the EC Machinery Directive (89/392/EEC)
Hydrosaar GmbH
The manufacturer:
Friedrichsthaler Strasse 15a
66540 Neunkirchen/Germany
declares that the equipment described below: Hydraulic cylinder 3410169

your order no. : 45034895

is not a ready-to-use machine within the meaning of the EC Machinery Directive and does not, therefore,
fully conform with the requirements of this Directive!

It is forbidden to put this equipment into operation until a declaration of conformity for the entire
machine in which it is to be installed has been issued by means of the EC Machinery Directive!

Applied uniform and national standards or technical specifications

CN TC 196/WG 3 part 2 Safety requirements for forces and cylinders

DIN 21567 Shores for self-advancing supports, requirements and testing

DIN 24334 Oil-hydraulic matters, hydraulic cylinders (main dimensions)

CETOP10H Hydraulic cylinder

CETOP31A Specification for hydraulic cylinder pipes

CETOP58H Hydraulic cylinders, average series, mounting dimensions

CETOP60H Specification for piston rods in hydraulic cylinders

DIN ISO 3320 Cylinder bores and piston rod diameters

DIN ISO 3322 Cylinder pressure levels

ISO 6072 / CETOP R 814 Compatibility of hydraulic fluids with elastomers

DIN 24 347 Fluid technology – hydraulics; connection diagrams

DIN 1708, part 1 and part 2 Vessels, parts under, not under compressive stress

ZH 1/74 Safety regulations for hydraulic hose assemblies

Hydrosaar GmbH 17
Hydraulik - Maschinenbau
Friedrichsthaler Str. 15a
66540 Neunkirchen
 HYDRAULIC CYLINDER

Lubricating instructions for tilting bearings requiring

maintenance

Tilting Bearings Requiring Maintenance

Lubrication of the bearings is very important in the field of plain bearing technology.

Choice of Lubricant
The lubricant is given the tasks of preventing friction, protecting against corrosion and
effectively separating the metallic sliding surfaces. Moreover, grease can also seal the bearings.

In the interests of a transparent stock of lubricants we recommend standard commercial, anti-corrosion,

compression-proof greases with a lithium soap basis with EP and solid lubricant additives be used for the
general area of application.

Initial Lubrication
To achieve wear that is as even as possible, the lubrication technical conditions during the running in phase
are especially important.
This phase is most effective if the bearings are initially used without additional lubrication for approx. ten pivot
movements with a load. Then the actual initial lubrication must take place.

Subsequent Lubrication
In normal circumstances steel-steel tilting bearings must be lubricated periodically. In the subsequent
lubrication used lubricant residues are replaced by new lubricant and, at the same time, abrasion products
and any impurities that may have penetrated are rinsed out of the bearing. The subsequent lubrication
intervals should be specified at 4 - 6 weeks in normal operations.

Hydrosaar GmbH 18
Hydraulik - Maschinenbau
Friedrichsthaler Str. 15a
66540 Neunkirchen
 HYDRAULIC CYLINDER

Storage- and Transportation specification for hydraulic

cylinders
1. Protection against corrosion
1.1. Plant Side conservation
Hydraulic cylinders from the company HYDROSAAR are conserved through the
testing medium and with it stock holding capable up to half a year, as standards
require. Longer storage times have to be stated in the order.
In case of storage times longer than six month the manufacturer has to be conferred.
1.2. Sealing
All connections are airtight locked. Cylinders, which are delivered with an oil filling,
will be locked oiltight.

1.3. Surface protection

All plain surfaces, bearings and spot faces are corrosion protected on plant side.

2. Transport
2.1. The hydraulic cylinders have to be wrapped or boxed carefully for transport. I. e. fall,
bounce and colliding has to be prevented by adequate packing manner and
adequate packing aid.
2.2. The piston rods have to be fastened against self-acting extending.
2.3. All connections have to be locked.
2.4. In case of sticking out piston rods, the free end of the piston rod has to be protected
by packing material against all accidental damages. The contact with materials,
which have a corrosive effect on the chromium-coated piston rod, has to be avoided.

3. Storage
3.1. On arrival of the cylinder delivery the customer has to convince himself, that the
hydraulic cylinders are not damaged during transport or transloading and that the oil
sealings are in perfect condition. Damaged sealing material has to be replaced.
Damaged spots of the outside conservation have to be repaired (top coat,
anticorrosion agent, packing).
3.2. The storage of the hydraulic cylinders has only to be effected in dry rooms, free of
dust and steam, if possible at constant temperature of 20°C +/- 5%.
3.3. After expiry of the first half year the cylinders have to be turned at least every three
month, to shift the air-flow and to re-oil the surface.

3.4. In case that hydraulic cylinders, which have been stored longer than two years, the
manufacturer has to be conferred, because an exchange of the sealings can be
necessary.
3.5. Before connecting the hydraulic cylinders on the hydraulic system, the tubing has to
be rinsed with flushing oil, to guarantee that all incrustations are removed in the tube
system.

Hydrosaar GmbH 19
Hydraulik - Maschinenbau
Friedrichsthaler Str. 15a
66540 Neunkirchen