OEM Manual

ORIGINAL EQUIPMENT MANUFACTURERS (OEM) MANUAL
Gyratory Crusher
1300 × 1800
Top Service Ultra Duty
Ravenswood Gold Mine 9232510974
September 2021
Copyright © 2021 by FLSmidth Inc., All Rights Reserved.
Documents, drawings, technical manuals, and all other information contained in this manual, provided in conjunction
with the purchase of FLSmidth products and services, are the proprietary property of FLSmidth. No part of this manual
may be disclosed, copied, duplicated, photocopied, reproduced, translated, or reduced to any electronic medium or
machine-readable form without prior written consent from FLSmidth.
The data included in this manual is not to be duplicated, used, or disclosed, in whole or in part, for any purpose other
than in the operation, maintenance, and service of the machine described. Nothing contained herein should be
construed to guarantee, modify, or enhance the operational capabilities as described in the machinery specification.
This manual does not imply liability to the manufacturer for any or all operational capabilities that may be affected by the
misuse or neglect in operating or servicing this machine.
“Original instructions” are provided in the English language. As required, “translation of the original instructions” is
provided in the official community language for the area where the equipment is used
i
Table of Contents
Chapter 1: OEM Introduction
1.1 Using this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 FLSmidth Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Original Equipment Manufacturer (OEM) Documents . . . . . . . . . . . . . . . . . . . . . . . 1
Appendix A: OEM Documentation

A.1 1000657353: Lubrication and Hydraulic Power Unit . . . . . . . . . . . . . . . . . . . . . . . . 4
A.1.1 General Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
A.1.2 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
A.1.3 Hydraulic Circuit with Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
A.1.4 Cooler Unit General Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
A.1.5 Installation, Operation, and Maintenance Manual . . . . . . . . . . . . . . . . . . . . . 13
A.2 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
A.2.1 Outline Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
A.2.2 Specification Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
A.2.3 Load Characteristic Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
A.2.4 Thermal Limit Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
A.2.5 T-N & I-N Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
A.2.6 Thermistor Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
A.2.7 6 Leads Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
A.2.8 Base Plate Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
A.2.9 Space Heater Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
A.2.10 Terminal Box Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
A.2.11 Instruction Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
A.3 4394072: Temperature Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
A.3.1 Reference Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
A.4 3546610: Resistance Temperature Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
A.4.1 Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
A.5 3637375: Resistance Temperature Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
A.5.1 Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
A.5.2 Datasheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
A.6 6792192: Linear Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
A.6.1 User's Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
A.7 1000722366: Hydraulic Jack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .375
A.7.1 Pressure Gauge Instruction Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
A.7.2 Pressure Gauge Service Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .380
A.7.3 Valve and Manifold Instruction Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
ii
A.7.4 Manual Shut-Off Valve Repair Parts Sheet . . . . . . . . . . . . . . . . . . . . . . . . . .388

A.7.5 Electric Pump Instruction Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .392
A.7.6 Electric Pump Repair Parts Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
A.7.7 Hydraulic Cylinder Instruction Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .426
A.8 1000636190: Spider Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
A.8.1 Electric Pump User and Maintenance Instructions . . . . . . . . . . . . . . . . . . . .439
A.8.2 Drum Cover User and Maintenance Instructions . . . . . . . . . . . . . . . . . . . . .463
A.8.3 Follower Assembly Model and Service Parts Data . . . . . . . . . . . . . . . . . . . 467
A.8.4 Safety Valve Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .468
A.8.5 Divider Valve Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .469
A.8.6 Socket Pipe Plug Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
A.8.7 Proximity Switch Settings and Model Data . . . . . . . . . . . . . . . . . . . . . . . . . . 473
A.9 1000614463: Relief Valve and Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .474
A.9.1 Vendor Documentation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
A.10 1000625615: Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
A.10.1 Installation, Operation, and Maintenance Instructions . . . . . . . . . . . . . . . . 537
A.11 4360350: Dust Seal Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
A.11.1 Operation and Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . .543
A.12 4709790: Impact Spanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .578
A.12.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .579
A.13 3480135 & 3480108: Flow Transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .587
A.13.1 Sensor Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .588
A.13.2 Transmitter Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
A.14 3116982: RTD & Thermowell with Temperature Transmitter . . . . . . . . . . . . . . . 696
A.14.1 Sensor Quick Start Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .697
A.14.2 Transmitter Reference Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .729
A.15 3353488: Motion Failure Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .730
A.15.1 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 731
A.16 4406657: Safety Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 777
A.16.1 Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 778
A.16.2 Manual (PENDING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 779

1
Chapter 1: OEM
Introduction
1.1 Using this Manual

Whenever the installation, lubrication, maintenance, or operation of an accessory piece of equipment, which has been
furnished by FLSmidth but was fabricated by a third party, is discussed in the FLSmidth instruction manual, this
information is provided only as a courtesy, and is included as-is, with no warranty expressed or implied. This information
must be verified by consulting the original equipment manufacturer (OEM) instruction manuals, which are the ruling
documents for the accessory equipment.
As manufacturer instructions or recommendations may change over time, it is the user’s responsibility to periodically
consult the manufacturer to obtain the most up-to-date information, including maintenance instructions and recall
information.
In the event of any discrepancies, notify your FLSmidth representative immediately. Refer to FLSmidth
Offices below.
As with any mechanical equipment, there are safety concerns associated with the installation of the primary and
accessory equipment. It is absolutely essential that installers, operators, maintenance personnel, and supervisors be
instructed in safe working practices.
1.2 FLSmidth Offices

After completion of the contract, all service and spare parts will be supported by the closest FLSmidth Regional
Headquarters. Refer to http://www.flsmidth.com/en-US/Contact for the FLSmidth Office nearest you.
1.3 Original Equipment Manufacturer

(OEM) Documents
The appendix that follows contains the technical documents that accompany this manual. These documents include
installation, operation, and maintenance (IOM) manuals and relevant drawings supplied by the original equipment
manufacturers (OEMs). These documents are necessary because they provide vital information on the proper
installation, lubrication, operation, and maintenance (as applicable).

2
THIS PAGE INTENTIONALLY LEFT BLANK

3
Appendix A: OEM
Documentation

4
A.1 1000657353: Lubrication and

Hydraulic Power Unit

5
A.1.1 General Arrangement

6
A.1.2 Electrical Schematic

7
Electrical Schematic (Sheet 2)

8
²
ш
NO MORE THAN ONE WIRE SHALL BE TERMINATED IN ANY ONE
WIRE LABELS SHALL BE ORIENTATED SUCH THAT THEY READ

WIRE NUMBER LABELS SHALL BE BLACK ON WHITE
LEFT TO RIGHT ORBOTTOM TO TOP

²
²
²
²
GRAFOPLAST SI2K STYLE

TERMINAL BLOCK
-

9

10
A.1.3 Hydraulic Circuit with Parts List

11
Hydraulic Circuit with Parts List (Sheet 2)
Ø
Ø

12
A.1.4
Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED.

275 1250 275
7.5KW 4P 132M
ELECTRIC MOTOR
(2) PLACES
9/7/21
TEMPERATURE GAUGE
(2) PLACES
TEMPERATURE TRANSMITTER
(2) PLACES
2584
TEMPERATURE
TRANSMITTER
INLET POINT
Cooler Unit General Arrangement
3" ANSI-150 OUTLET POINT

WITH M16x2 THREAD 3" ANSI-150
WITH M16x2 THREAD 61-21896 - LIFTING LUG
(4) PLACES
385
4 - P22
273 885 52 150 1500 MTG HOLE CNTRS 30 1140 MTG HOLE CNTRS
MTG HOLES
1211 1800 1200
1000625615
This drawing is the sole property DRAWN BY JOB NUMBER
of BOSCH REXROTH LTD and is RAVENSWOOD GOLD
returnable on request. It is to be O.SANTILLAN
treated as confidential and not to P5131MFC
be copied or communicated to any CHECKED BY F L SMIDTH PTY LTD
2 23/07/21 Y.L. F.C. UPDATED CLIENT DRAWING NUMBER, ISSUED AS BUILT third party without the written Y.LIN
consent of BOSCH REXROTH LTD. GYRATORY CRUSHER COOLER UNIT 3 Valediction Road KINGS PARK NSW DRAWING NUMBER
1 19/04/21 Y.L. F.C. ADDED 3" ANSI ADAPTORS It may only be used for DATE
manufacture when authorised by Telephone (02) 9831-7788
0 08-12-20 O.S. Y.L. FOR MANUFACTURE BOSCH REXROTH LTD 11/09/2020 GENERAL ARRANGEMENT Fax (02) 9831-5553 20 - 34654 - 2
9232510974 — 1000702744 1
13
A.1.5 Installation, Operation, and Maintenance Manual
confidential
DCAU Procedure P5131MFC-IOM

Appendix/Supplement
Edition: 2021-07-28
Installation, Operation & Maintenance Manual Editor: DCAU/EPU
Reference: -
Engineering Ref.-Edition: -
Process management First edition

© Bosch Rexroth Pty Ltd 2015
P5131MFC-IOM
F L Smidth
P5131MFC Gyratory Crusher Lube Unit

14
IOM Manual (Sheet 2)

Page 2 / 129
Installation, Operation & Maintenance Manual P5131MFC-IOM : 2021-07-28
Installation, Operation & Maintenance Manual

Document number: P5131MFC-IOM
Revision: A
Date of Issue: 30th July 2021

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Page 3 / 129
Table of contents
Page
1 Amendments ............................................................................................................................................... 4
2 Functional Description .............................................................................................................................. 5
3 Installation, Operating and Maintenance Safety Information ................................................................ 7
3.1 General safety instructions ........................................................................................................................... 7
3.2 Intended use ................................................................................................................................................. 7
3.3 Adhere to the following instructions.............................................................................................................. 9
4 Pre-Commissioning Checklist .................................................................................................................. 11
5 Maintenance Procedures ........................................................................................................................... 12
5.1 Maintenance Log .......................................................................................................................................... 12
5.2 General Maintenance ................................................................................................................................... 12
5.3 General Service ............................................................................................................................................ 13
5.4 Routine Maintenance ................................................................................................................................... 13
5.5 Storage for extended periods of time or in an uncontrolled environment .................................................... 14
5.6 Re-Commissioning ....................................................................................................................................... 14
6 Lubrication .................................................................................................................................................. 15
6.1 Hydraulic oil .................................................................................................................................................. 15
6.2 Lubrication Schedule .................................................................................................................................... 16
7 Certified Test Sheets .................................................................................................................................. 17
7.1 Power Unit .................................................................................................................................................... 18
7.2 Electrical ....................................................................................................................................................... 20
8 Project Drawings ........................................................................................................................................ 26
8.1 Drawing register ........................................................................................................................................... 26
8.2 Test System Power Unit and Cooler Stand Hydraulic Circuit
Error! Bookmark not defined.
8.3 Test System Power Unit and Cooler Stand Gen. Arrangement
8.4 Test System Power Unit and Cooler Stand Electrical Circuit
9 Spare Parts & Consumables ..................................................................................................................... 35
9.1 Spare Parts – General .................................................................................................................................. 35
9.2 Schedule of Recommended Spare Parts ..................................................................................................... 36
9.3 Spare Parts Storage ..................................................................................................................................... 37
10 Trouble-Shooting Guide ............................................................................................................................ 38
10.1 General ......................................................................................................................................................... 38
11 Appendices ................................................................................................................................................. 41
11.1 General Assembly Instructions with Informations of the Transport of the Hydraulic Power Units ............... 41
11.3 General Operating Instructions For Hydraulic Power Units and Assemblies ............................................... 22
11.4 Equipment Data Sheets ............................................................................................................................... 61
Table of tables
Table 1: Recommended Spares ................................................................................................................................. 36
Table of figures
Figure 1: Hydraulic Power Unit Storage times ........................................................................................................... 14

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Page 4 / 129
1 Amendments
Rev. Revision Description Date

A For approval 5/08/2021

17

Page 5 / 129
2 Functional Description
Ref Hyd Circuit drg 10-34638-3
The Lubrication Skid incorporates both the hydraulic system and the lubrication system within 1 reservoir and on
one base frame. The reservoir is constructed with 2 sealed compartments to separate the 2 systems which are not
visible externally.
Hydraulic System:
The hydraulic System contains single pump motor group which is vertically mounted in a 400L Hydraulic oil
reservoir. The pump is immersed in the oil.
An inspection cover is installed on the side of the reservoir to enable access to inside the reservoir for inspection,
maintenance and cleaning.
The Oil reservoir contains 3 sight glasses and a temperature gauge to provide visual indication of the fluid level /
temperature. Temperature and Level transducers are also installed within combined unit to provide a 4-20ma
output for feedback to the main control system.
The hydraulic pump motor group consist of 5.5kW 4 pole electric motor which is direct coupled via bell housing and
flexible coupling to 11cc external gear pump. The gear pump delivers a fixed flow of 16l/min at 75 bar.
The flow from the gear pumps is delivered through hoses and connect to the duplex pressure filter. A visual
pressure gauge is installed at this point to provide a means of checking the system pressure. Pressure relief valve
Item 21 limits max pressure in this circuit to 75 Bar.
The duplex filter enables the system to operate with a spare installed clean element so in the event of a filter
blockage the oil supply can be changed to a new filter element without shutting down the system. This reduces
down time and allows for a planned maintenance action.
The filter element has a micron rating of 10 micron.
From the duplex filter, the oil supply is connected to a manifold containing a directional valve, check valve, poppet
valve and flow control valve.
The Directional valve (item 39) is used to raise the cylinder and requires a 24VDC signal, the check valve (item 41)
stops the oil leaking through the directional valve when the cylinder is raised and the poppet valve (item 40) is used
to allow the oil to travel to tank and hence lower the cylinder. The flow control valve (item 42) is used to set the
lower speed of the cylinder and is adjustable by means of a manual knob.
From the manifold the oil is returne2 via tube work to the crusher.
Installed at the Crusher base is the Mantle Relief which contains an accumulator. The accumulator acts as a
dampener and the relief is installed for pressure protection.
Main Lubrication System:
The Lubrication System contains 2 pump motor groups which are vertically mounted in a nominal 2000L oil
reservoir.
Pump groups are used as Duty and Standby for the main lubrication oil supply.
The reservoir contains 2 compartments which are separated by a weir. The oil returning from the crusher firstly
enters via the “Trash Screen” which filters out the larger particles then enters the Dirty Part of the reservoir. The oil
then weirs over into the Clean side of the reservoir.
2 inspection covers are installed on the side of the reservoir to enable access to inside the reservoir for inspection,
maintenance and cleaning.
The Oil reservoir contains 3 sight glasses and a temperature gauge to provide visual indication of the fluid level /
temperature. Temperature and Level transducers are also installed within 1 unit that provide a 4-20ma output for
feedback to the main control system.
3 x 2kW immersions heaters are installed for temperature control of the oil. The temperature of the oil must be
monitored via the control system using the 4-20ma temperature feedback and the heaters must turn on when the
oil is below 32deg C and stay on until the oil reaches 38deg C.
On cold start-up the Pumps must not be able to start until the oil temperature has reached 35deg C. This is due to
the viscosity of the oil.

18

Page 6 / 129
Main lube Oil Supply:
The 2 pump motor groups installed in the reservoir comprise 15kW 6 pole electric motors which are direct coupled
via bell housings and flexible coupling to 315 cc Rickmeier gear pumps. The gear pumps deliver a fixed flow of 280
l/min each. at 17 Bar,
Note: Only 1 pump group is required to operate at 1 time.
The flow from the gear pumps is delivered through hoses to the main manifold (see below for Main Manifold
function description).
From the main manifold the oil passes through the duplex filter then onto the air blast heat exchangers and to the
Crusher.
In between the duplex filtration, and the air blast heat exchanger, is a motorised ball valve. Control of opening of
this valve allows controlled oil flow to the Crusher by bleeding oil off back to tank. Visual Temperature and Pressure
gauges are also installed at this point.
The duplex filter enables the system to operate with a spare installed clean element so in the event of a filter
blockage the oil supply can be changed to a new filter element without shutting down the system. This reduces
down time and allows for a planned maintenance action.
The filter element has a micron rating of 20 micron.
Return Oil from the Crusher is via the return pipe which connects to the “Trash Screen” mounted in the top of the
reservoir. An RTD and visual temperature gauge are fitted to monitor the temperature of the returning oil. Trash
screen can be removed for cleaning without draining reservoir .
Main Lubrication Manifold Function Description:
Main Lube Pumps supply oil to the manifold ports P1 and P2 via check valves (items 30.1 & 30.2) to the circuit.
The check valves are in the form of a 40mm logic valve insert with Logic cover ( items 31.1 31.2 ). The logic/check
valves stop the oil from travelling back down the Pressure port of the non operational pump. Either Duty or Standby
pump can be selected via interlocked manual ball valves on the manifold ( Items 25.1, 25.2 ). Hydraulic pilot oil is
supplied to the non operational check valve, and is held closed via pilot oil from the operational pump.
Relief protection / Pressure setting is via 40mm Logic style relief valves comprising relief valve insert, relief valve
cover and relief pilot cartridge( Items 27, 28 and 29 respectively )
Logic Valves are used due to the high flow rate and high viscosity of the fluid.
Oil supply to the circuit via duplex filter and cooler is via port P3. A pressure transducer (item 32) and a visual
pressure gauge ( item 18.2) are installed to monitor the pressure in port P3.

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Page 7 / 129
3 Installation, Operating and Maintenance Safety Information

3.1 General safety instructions
The hydraulic power unit was designed and manufactured considering the provisions of directives, standards
and specifications relating to this technology.
There is, however, still a risk of personal injury or damage to property if the following safety instructions and
warnings contained in this document are not observed.
x You should read these instructions completely and thoroughly before working with the hydraulic power
unit/hydraulic assembly.
x When reading these instructions you should always have the product-specific documentation to hand
x These instructions, together with the relevant product-specific documentation, should be kept so as to be
readily accessible to all users.
x Always include the operating instructions and the product-specific documentation when passing the
hydraulic power unit/hydraulic assembly on to a third party.
Due to the interaction between the hydraulic power unit and the complete machine, the installation of the
hydraulic power unit into the machinery will result in additional potential hazards. This applies in particular to
the influence of hydraulic and electric controls on hydraulic drives generating mechanical movements.
It is therefore essential for the manufacturer of the complete machine to have undertaken an independent risk
assessment. Furthermore, the manufacturer must on this basis have prepared operating instructions for the
complete machine.
These operating instructions are no substitute for the operating instructions for the complete machine.
3.2 Intended use

As regards the specification of the intended use, explicit differentiation will be made in this document between
hydraulic power units and hydraulic assemblies.
3.2.1 Hydraulic power units

The hydraulic power unit constitutes partly completed machinery in terms of EC Machinery Directive
2006/42/EC. In terms of the EC Machinery Directive the hydraulic power unit is not considered to be a ready-
to-use machine. The hydraulic power unit is exclusively intended for integration into a machine or system or
for assembly with other components to form a machine or a system.
The product may be commissioned only if it has been integrated into the machine or system for which it is
designed and if the machine or system fully complies with the requirements of the EC Machinery Directive.
The hydraulic power unit is not considered to be a safety component in terms of EC Machinery Directive
2006/42/EC.
x You should observe the operating conditions and performance limits specified in the technical data.
The hydraulic power unit is a work appliance and not designed for private use. Intended use includes having
fully read and understood these operating instructions, especially section 3.1 “General safety instructions”.
3.2.2 Hydraulic assemblies

A hydraulic assembly is intended exclusively for integration into a machine or system or to be assembled with
other components to form a machine or system. The product may only be commissioned if it has been
integrated into the machine or system for which it is designed.
The hydraulic assembly is not considered to be a safety component or partly completed machine in terms of
EC Machinery Directive 2006/42/EC.
x You should observe the operating conditions and performance limits specified in the technical data.

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Page 8 / 129
The hydraulic assembly is a work appliance and not designed for private use. Intended use includes having
fully read and understood these instructions, especially section 3.1 “General safety instructions”.
3.2.3 Improper use

Any use of the hydraulic power unit or the hydraulic assembly other than described in section 3.2 “Intended
use” is considered as being improper.
3.2.4 Qualification of personnel

Assembly, commissioning, service (incl. maintenance, inspection, and repair) and disassembly require a basic
knowledge of mechanics, electrics and hydraulics, as well as familiarity with the associated technical terms. In
order to ensure operational safety, these activities may only be carried out by qualified technical personnel or
an instructed person under the direction and supervision of a qualified person.
Qualified personnel are those who can recognize potential hazards and apply the appropriate safety measures
due to their professional training, knowledge and experience, as well as their understanding of the relevant
conditions pertaining to the work to be undertaken. Qualified personnel must observe the rules/laws relevant
to the specific subject area.
3.2.5 Safety instructions in this document

These operating instructions contain warning signs followed by an instruction wherever there is a risk of
personal injury or damage to the equipment. The measures described for preventing these hazards must be
observed. Safety instructions are set out as follows:
Warning sign (warning triangle): Draws attention to the hazard

Signal word: Identifies the degree of hazard
Type of risk: Specifies the type or source of the hazard
Consequences: Describes the consequences of non-compliance
Precautions: Specifies how the hazard can be prevented
DANGER! Indicates an imminently hazardous situation which, if not avoided, will certainly result in
serious injury or even death.
WARNING! Indicates a potentially hazardous situation, which, if not avoided, could result in serious
injury or even death.
CAUTION! Indicates a potentially hazardous situation which, if not avoided, could result in minor
or moderate injury or damage to equipment.
If this information is disregarded, it may result in machine malfunction or breakdown.
Warning signs Meaning

Warning of a danger spot
Warning of dangerous, electrical voltage

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3.3 Adhere to the following instructions

3.3.1 General
x The regulations regarding accident prevention and environmental protection applicable in the country where
the product is used and at the workplace must be observed.
x The Bosch Rexroth warranty applies only to the configuration supplied. The warranty will not apply if the
product is incorrectly assembled, not used as intended and/or handled improperly.
x You should keep the manufacturer's data sheet on oil safety to hand and observe the safety information
contained therein.
x Only persons who have been authorized by the operator may be granted access to the immediate vicinity
of operation. This also applies during machine standstill.
x Only authorized personnel are allowed to operate the adjusting mechanisms of the components or parts,
under the proviso that the hydraulic power unit is used as intended.
x Persons, who assemble, operate, dismantle or maintain products supplied by Bosch Rexroth must not
consume any alcohol, drugs or medication that may have a detrimental effect on their reactions.
x Please observe the specific information in the following chapters regarding the product life phases.
3.3.2 Avoidance of hazards

x Before installation, check the hydraulic power unit for visible transport damage e.g. cracks, missing lead
seals, screws, protective covers.
x Rexroth hydraulic power units should be used only if in a sound technical condition.
x Hydraulic power units should be used only within the performance range specified in the technical data.
x Under no circumstances should the hydraulic power unit be subjected to inadmissible mechanical loads.
Do not place any objects on top of the power unit.
x Never remove or damage lead seals that have been fitted by Bosch Rexroth.
x Provide for sufficient stability of the hydraulic power unit.
x In this context, observe the maximum load-bearing capacity of the foundations or ground as well as that of
the attachment devices and vehicles used for transport.
x You should use only the designated attachment points.
x Avoid damage of any kind on the pressurized or functional components of the hydraulic power unit.
3.3.3 Protective measures

x Ensure that all associated safety devices pertaining to the hydraulic power unit are existent, have been
correctly installed and are fully functional. Do not displace, bypass or disable the safety devices/equipment.
x If it does become necessary to temporarily disable any safety equipment, e.g. for commissioning or
maintenance work, always take appropriate measures to ensure that no potential injury to persons or
damage to property can occur. Also observe the superordinate operating instructions for the machine or
system.
x If it does become necessary to work at height, entailing a fall hazard, suitable safety precautions must be
taken (e.g. provision of gratings, handrails or harnesses).
x The hydraulic power unit may heat up during operation. The solenoids in the hydraulic power unit become
so hot during operation that you may sustain burns. You should wear heat-proof gloves or protective
clothing.
x Suitable measures should be taken to prevent any slip hazard caused by oily surfaces that may e.g. result
from maintenance work.
x In the event of leaks, you should never allow any part of your body to come into contact with the oil jet.
Never try to stop or seal the leak or the oil jet using a cloth.
x Leaks may cause an oil mist. Take special care if there are potential ignition sources in the vicinity.

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3.3.4 Obligations of the operator

x The operator of the Bosch Rexroth hydraulic power unit must provide personnel training on the following
topics and on a regular basis:
x Observation and use of the operating instructions as well as the legal stipulations
x Intended use and operation of the Bosch Rexroth product
x Observation of the instructions from the factory security office as well as the operator’s work instructions
x What to do in an emergency
Bosch Rexroth offers training support in specific fields. An overview of the training contents is available on the
Internet via the following link http://www.boschrexroth.de/didactic

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4 Pre-Commissioning Checklist
Checkpoint Yes No N/A
Is the oil reservoir cleaned and flushed?
Is the piping properly cleaned and mounted free of stress?
Are all joints tight?

Are the lines in accordance with installation drawing/piping plan and properly
connected?
Are the couplings between the drive motors and pumps properly mounted and aligned?
Does the filter(s) have the prescribed Micron Rating?
Is the filter flow direction correct?
Has the hydraulic reservoir been filled with the appropriate oil
Do the electric motor directions of rotation correspond with those of the pumps?
Are the reservoir butterfly suction isolators open?

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5 Maintenance Procedures
5.1 Maintenance Log
To derive the maximum benefit from both routine and unplanned maintenance, it is essential to keep an
accurate history of repairs, additions and alterations to the equipment. Observations by operating and
maintenance personnel should also be recorded.
Mandatory to any records system is that each note; observation or comment is dated. If the machine record
is analysed regularly, certain trends will become evident and the utilisation time of the equipment can be
planned to include anticipated service and adjustments.
External factors peculiar to each installation exert considerable influence on the type of maintenance
operations, which will be necessary, as well as the frequency with which they would be performed.
Records should include, but not be limited to:

x A description of any signs of trouble with the equipment.
x A description of preliminary investigation and findings.
x An explanation of corrective action taken, replacement parts required and duration of down time.
5.2 General Maintenance

General maintenance should include examination for signs of problems developing, such as:
x Excessive noise and vibration
x Shocks
x Discoloured oil
x Overheating
x Oil level low
x Oil leaks
All reports of potential trouble should be recorded, investigated, and corrective action taken immediately.
Trouble-shoot and clean the unit before the disassembly or removal of a component. Perform appropriate
tests of the system before attempting repair.
Clean all assemblies and components prior to removal. Take all precautions necessary to prevent dirt entering
the system.
Before any attempt is made to remove any hydraulic component, make sure that all hydraulic pressure is
relieved and the prime mover cannot be started. If the hydraulic system is used for lift devices, these should
be secured, or in the rest position, before disconnecting equipment.
Ensure that all accumulators are discharged of pressurised hydraulic fluid prior to commencing work.
Label all parts and protect precision or machined surfaces. Do not mix parts.
Inspect all parts during disassembly for wear or damage.
If the system fluid is to be drained and re-used, make sure that drain containers are clean and covered when
not in use. Return the fluid to the reservoir only through the filling filter.
Clean all metal parts using a suitable solvent prior to re-assembly and either blow dry with compressed air, or
set aside on a clean and lint-free cloth to drain, until completely dry. Lubricate with clean system fluid during
re-assembly.
Replace all seals, gaskets and ‘O'-rings with new items of the correct size.
Apply all repair procedures in a "commonsense" manner. It is often hard to realise the forces involved in a
hydraulic system, or just how quickly these forces will react to the inadvertent disconnection of a hose, or the
mistaken movement of a control lever.

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If the need should arise to change a valve during service when oil is at a high temperature, the unit must not
be switched on as usual, but should be jogged to allow the oil to bring the valve to temperature gradually, thus
preventing thermal shock and the possible resultant failure of a new assembly.
If any pipe-work is disconnected, care must be taken to seal pipe ends, so as to prevent the ingress of foreign
matter. Ensure complete sealing at pipe connections during re-assembly, to avoid leakage of oil, or, as in the
case of suction lines, leakage of air into the system.
5.3 General Service

Should it be necessary to call for Bosch Rexroth service assistance, save time and money by preparing for the
visit by:
x Thoroughly cleaning the machine.
x Have piping diagrams, spare parts information and special tools available to assist our service
representative.
Should any part of the system, or system components, supplied by Bosch Rexroth, be dismantled during the
warranty period without the written permission and authority of Bosch Rexroth, the warranty on the effected
items shall be voided.
5.4 Routine Maintenance

Daily - for the First Week:
x Check for fluid leaks.
x Check the reservoir fluid level.
x Check the operating temperature.
x Check the system pressure.
x Check the system performance and general condition.
x Check for unusual noises.
Daily - Pre-Start Checks

x Check for fluid leaks.
x Check the reservoir fluid level.
x Ensure that the tank breather is clear of dirt build-up.
x Ensure that the suction isolator is open.

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5.5 Storage for extended periods of time or in an uncontrolled environment
5.5.1 Hydraulic Power Unit

Refer to Error! Reference source not found. below for power unit storage times and the relevant protection m
ethods. The power unit will be packed in a manner such that it would be suitable for sea freight. All components
will be supplied filled with mineral oil. All external steel components, that are not plated, will be sprayed with a
wax type protective medium.
If the hydraulic power unit is stored for more than 6 months in an uncontrolled environment or more than 12
months in controlled environment, it must be filled with oil.
Figure 1: Hydraulic Power Unit Storage times
Referring to the values stated in Error! Reference source not found., preservation is achieved by testing or f
illing of the units or components. Testing refers to a short running period using the protective medium. The
medium is then drained from the reservoir or component. All pipe connections are then plugged.
If Error! Reference source not found. states that the conservation is achieved by filling, the protective m
edium is used to test the unit or component. The protective medium remains in the component or unit. The
pipe connections are plugged using fittings or blank flanges. Reservoirs do not have to remain filled, it is
sufficient to fill the built on components, e.g. pumps, filters, valves, etc.
5.6 Re-Commissioning
Before the plant is re-started after a long idle period a check should be made as to whether the instructions
supplied for the original commissioning still apply. Moreover, the following measures should be observed:-
x Remove preservative solution and any signs of contamination.
x Check all filters and clean or replace as necessary.
x Take a sample of oil and have it analysed. Remove any water and resin from the system and if
necessary, replace with fresh oil, added only via the filling filter provided.
x Test couplings, plugs and all other sealing elements for leakage.
x The conditions of all static and dynamic (shaft) seals should be examined. If a long stand down period,
with dry storage, has been involved, it is preferable to replace these seals.
Note:
Test the function of all units under normal working pressure.

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6 Lubrication
6.1 Hydraulic oil
Specification for Oils for use with Bosch Rexroth Hydraulic Systems:
Property Petroleum based hydraulic oil

Grade ISO-VG 320
Load Rating FZG 90 test stage 11 (or greater), as described in IP334 (DIN 51354).
Properties Anti Foaming.
Non Water Retention (<0.05%).
Inhibitors to prevent oxidation, corrosion & foaming.
6.1.1 Choice of Hydraulic Fluid

Rexroth hydraulic power units are primarily designed to operate on conventional petroleum based hydraulic
oils. The hydraulic oil can be chosen in consultation with your local oil supplier, bearing the following
requirements in mind.
The oil shall fulfil FZG 90 test stage 11 described in IP334 (DIN 51354). The oil must also contain inhibitors
to prevent oxidation, corrosion and foaming. The viscosity of the mineral oil is highly dependent of the
temperature. The final choice of oil must depend on the operating temperature that can be expected or that
has been established in the system and not in the hydraulic reservoir.
High temperatures in the system greatly reduce the service life of the oil and rubber seals, as well as resulting
in low viscosity, which in turn provides poor lubrication.
Water content should be less than 0.05%.

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6.2 Lubrication Schedule
Description of Equipment Requiring Lubricant Type of Lubricant Approx Volume (Litres)

Hydraulic Power Unit ISO VG320 Hyd Oil 2400
Main Electric Motor/s Mobil Polyrem EM
Air / Cooler Electric Motor See Note (1)
Oil Filters &

Electric Motor Oil
Breathers
After The First 100 Hours z
After The First 3 Months Or 2000 Hours z
Once Every 2 Months Or 1000 Hours
Once Every 3 Months Or 2000 Hours
Once Every 6 Months Or 4000 Hours z
Legend:
= Lubrication, z = Change, = Oil analysis
Note:
It is recommended that the oil be analysed at the above intervals. The analysis should cover viscosity,
oxidation, additives and contamination. The oil must be replaced when the analysis shows it is exhausted. If
oil analysis is not possible then the oil should be replaced every 12 months or 8000 hours, whichever occurs
first.
Note (1):
The electric motor installed on the Air / Oil Cooler does not require regular / periodic greasing as it is fitted with
sealed for life bearings.
The use of oils with viscosity index improvers is not recommended, due to temporary and permanent reductions
of the viscosity.
Required oil cleanliness: ISO 4406 16/13 or better
For most mineral based hydraulic oils the temperature limits are:
Design operating temperature: 50°C (see note (2))

Maximum operating temperature: 65°C (valid for nitrile seals)
Note (2):
Oil oxidation greatly increases when the oil temperature is above 60°C.
6.2.1 Electric Motor Grease

The recommended grease for the electric motors is a polyurea based grease, with a NLG1 No 2 consistency.
Please check and follow lubrication nameplate for any special grease used in bearings. Please use identical
grease or its equivalents when maininting motor.
Excess lubrication and/or incorrect grease type may cause an increase in bearing temperature. This may lead
to an increased risk of premature bearing failure.

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7 Certified Test Sheets

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7.1 Power Unit

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7.2 Electrical

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8 Project Drawings
8.1 Drawing register
Drawing number Description

34638 Hydraulic & Lubrication Circuit
34639 Gyratory Crusher Lube Unit Gen. Arrangement
34640 Gyratory Crusher Lube Unit Electrical Circuit
34654 Gyratory Crusher Lube Unit Cooler Stand

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8.2 Hydraulic & Lubrication Circuit

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8.3 Gyratory Crusher Lube Unit Gen. Arrangement

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8.4 Gyratory Crusher Lube Unit Electrical Circuit

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8.5 Gyratory Crusher Lube Unit Cooler Stand

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9 Spare Parts & Consumables

9.1 Spare Parts – General
Depending on the use of the equipment, consideration must be given to stocking an adequate range of spare
parts. No mechanical equipment or component, which incorporates moving parts, will last indefinitely,
therefore breakdown or faults will occur at some time.
To avoid lengthy and often costly breakdown time, we recommend having highly stressed, or moving part
components, which are likely to eventually fail, available as spares.
Please note that major components such as pumps and motors are under manufacturer’s warranty only as
long as trained fitters, with special tools and adequate facilities, are responsible for dismantling these.
For other hydraulic components, which can be serviced by any competent fitter, we recommend to have service
kits available. Other components such as valve coils, electrical fuses, filter elements etc., are recommended
to be stocked.
Spare Parts are separated into the three categories, which are detailed below. The list within this section
details those products that fall into these categories by prefixing the relevant category code (C, E or R) to the
products item number.
9.1.1 Consumable Spares - Code "C"

Filter elements required for the commissioning and ongoing maintenance of the system. You should plan on
two (2) filter changes during commissioning and a further two (2) over the first twelve (12) months. This means
four (4) elements for each filter for the first twelve (12) months operation.
9.1.2 Essential Spares - Code "E"

These are items that are critical to the function of the system; these could include "Marketed Range" products
where any delay in delivery time is unacceptable, or specially imported products. You should stock a minimum
of one (1) of each item. Where there are high quantities of the item used, a spares holding of 10% is advised.
9.1.3 Recommended Spares - Code "R"

These are non-critical items that would only cause inconvenience in the case of a malfunction. Their inclusion
in this category would be due to the quantity used, or potentially long delivery time (special product).
If spare parts are required, please give detailed information of the required component to avoid untimely delay.
Please state Unit Serial No, Drawing No, item No. and description.

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9.2 Schedule of Recommended Spare Parts
CODE ITEM DESCRIPTION IDENT NUMBER QTY

2.0058 PWR20-A00-0-M
C 1 FILTER ELEMENT
R928007080 12
2.0400 PWR10-A00-0-M
C 2 FILTER ELEMENT
R928006917 4
SPR-SP-BFSK125-2X/
E 3 AIR DEHUMIDIFIER
R928049186 1
R65/315 FL-Z-W-SAE3-R
E 4 LOCAL 1
Lube Pump
AZPW-2X-011-022RRRXX&
E 5 HYDRAULIC GEAR PUMP
R940009863 1
4WE6HB6*/EG24N9K4L
E 6 DIRECTIONAL SPOOL VALVE
R940201262 1
OD1505893DSOOCK4
E 7 SCREW-IN CARTRIDGE VALVE
R940200325 1
40020421000042
E 8 GR42 T-PUR SPIDER 98SH-A LILAC LOCAL 1
Coupling Spider - Lube
ROTEX28-92SHA/T-PUR
E 9 RING GEAR R901354520 1
Coupling Spider - Hydraulic
TC04PLAH/TC130150F/T&
R 10 TEMPERATURE SWITCH
R983072453 1
NSW 20819/IH-4-2000-4
E 11 HEATER
R940003426 1
PRO/F100-TEMP
R 12 LOCAL 1
TEMPERATURE GAUGE KIT 100MM DIA0-100CPA
ABZMS-41-1X/0800/M2/AC-K14
R 13 FLOAT SWITCH
R901269280 1
LC 40 DB40E7X/
E 14 LOGIC CARTRIDGE VALVE
R900927969 1
LFA40DB2-7*/400
R 15 LOGIC COVER
R940200351 1
DBDS 6 K1X/25
E 16 PRESSURE RELIEF VALVE
R900420245 1
LC 32 A05E7X/
E 17 LOGIC CARTRIDGE VALVE
R900912585 1
LFA 32 D-7X/F
R 18 LOGIC COVER
R900905303 1
HM20-2*/250-C-K35
E 19 TRANSDUCER
R940000557 1
Table 1: Recommended Spares

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9.3 Spare Parts Storage

9.3.1 Control Valves
It is recommended that control valves be stored in a dry place, which is free of corrosive substances and
vapours. A regular check should be kept on storage conditions. Should it be necessary to store the valves
for a period exceeding three months, the valves must be filled with hydraulic oil and sealed.
Hydraulic Pumps and/or Motors

For storage of hydraulic pumps and motors over an indefinite period of time, special preservation is required
to maintain the functional readiness of the units for later commissioning:-
9.3.2 Plastic Cover

For the transport of units, the usual method to protect against influences of weather is to heat seal the
component in synthetic material. This protection provided the cover is undamaged, and the units are stored
in an enclosed and dry place, can last for several months. As this method offers little protection against
corrosion, it is not suited for overseas transport, i.e.; corrosion can set in through condensation. This kind of
protection should only be provided if units are not to be stored for more than six months.
9.3.3 Plastic Cover with Siccatives

In addition to the above precautions, siccatives should be deposited within the plastic cover. Cushions of a
diatomaceous earth or similar will absorb moisture. If storage is to exceed periods of six months, this protection
must also be considered as insufficient.
9.3.4 Plastic Cover with Siccatives and External Preservation

Provided that the packing is undamaged, and warehousing is enclosed and dry, preservation by "Tectyl 511"
offers a continuous protection against corrosion. Under these conditions, warehousing for periods of twelve
to fifteen months is permissible.
Before depositing the siccatives and heat sealing in the plastic cover, the unit is sprayed externally with "Tectyl
511". This forms a closed insulating cover. Special flushing before installation and commissioning is not
necessary as the protective coating is oil compatible.
9.3.5 Plastic Cover with Siccatives, External Preservation & Preservative Oil
In addition to steps 1, 2 and 3 above, the units are internally flushed with special preservative oil. Normal
hydraulic oils are inclined to resinify after longer periods of time, this being also influenced by prevailing
weather conditions.
When this condition occurs, disturbances may arise during later commissioning, since the necessary
lubrication film cannot immediately reach moving parts within the unit. This problem can be avoided if the
parts of the rotary group etc are rinsed and covered with the preservative oil and the pump or motor itself left
filled with that oil. This also helps to prevent internal corrosion.
If the preservation measures outlined above are used, it is permissible to store units for up to three years. An
extra rinsing before installation and commissioning is not required, as the preservative oil is compatible with
normal petroleum based hydraulic fluids.

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10 Trouble-Shooting Guide
10.1 General
The diagnosis and elimination of faults is simplified when the hydraulic circuit diagram of the system is used,
and when the oil flowing back to the tank can be observed.
As soon as wear or damage to parts is observed, all traces of contamination must be removed from the
system. When a failure has occurred, the whole system should be opened up, cleaned and filled with fresh
filtered clean oil.

Page 39 / 129
Causes Of Trouble And Its Effect In The Hydraulic Installation

Source of trouble, Flow Control Directional Output Drive
Mechanical Drive Suction Line Pump Pressure Line Return Line Pressure Valves Fluid Others
effects Valves Control Valves (motor, cylinder)
Excessive noises 1. Coupling wrongly 1.Tap or cock in the 1.Pump is running 1.Line mounts 1.Line mounts 1.Valve chatter due 1.The valve 1.Valve chatters 1.Cavitation 1.Wear of running
aligned. suction line is too fast. missing or loose. missing or loose. to dirt on valve oscillates and due to defective problems due to surfaces.
2 .Coupling loose. closed or only 2.Maximum pump 2.Poor installation. 2. Poor installation. seal. excites other solenoid or the low fluid level or 2.Control system
3. Coupling partially open. pressure exceeded. 3.Pipe bore too 3.Pipe bore too 2.Insufficient control elements voltage is too low. viscosity too high. oscillating.
defective. 2.Suction filter 3.Boost pump small. small. damping into oscillation. 2.Valve defective (fluid temperature
4. Loose mounting clogged or too defective. 4.Installation not 4.Installation not (unsuitable flow) 2.Flow noises. due to dirt or wear. is too low)
on pump and/or small (if fitted). 4.Shaft seals, or bled completely. bled. 3.Flow noises when 3.Control system 3.Flow through 2.Fluid is
motor. 3.Suction line seals on suction 5.Return terminates operating. oscillating. valve is excessive. contaminated and
5. Other blocked or leaking. side are defective. above fluid level. 4.Unsuitable 4.Pilot pressure dirty leading to
transmission 4.Suction line has 5.Pump defective. 6.Return filter characteristic variations. damage and
elements loose. (V- wrong dimensions 6.Pressure and blocked curve. 5.On valves with blockage of
belts, Toothed (i.e. pipe bore ), or return lines 5.Wrong design. adjustable damping equipment.

belts, etc.) too many bends. connected wrongly. the adjustment has 3.Fluid foams.
6. Pump or motor 5.Fluid level too 7.Control system not been
defective. low. oscillating. performed.
7. Direction of 8.Noise dampening 6.Check the
rotation wrong. not incorporated in electrical controls.
8. Noise design
dampening not
incorporated in
design (rubber-
metal mountings).
Insufficient power 1.Power 1.Internal leakages 1.Leakages 1.Excessive line 1.Operating 1.Pressure losses 1.Wrong switched 1.Viscosity too low, 1.Internal Leakage 1.In the case of
and torque at the transmission due to wear. 2.Excessive line resistance pressure set too excessive. position (e.g. causing excessive (e.g. cylinder seal pressure controls
hydraulic motor defective. 2.Unsuitable type. resistance 2.Filter blocked. low. 2.False setting. pressure less) leakage. is worn) there is a defect in
(pressure too low) 2.V-belt or Toothed 3.Pump defective 3.Pressure filter 2.Internal leakage 3.Valve defective. 2.Solenoid 2.Viscosity too high 2.Wear or running the open (or
belt slipping. 4.End-of-control blocked. due to wear. 4.Unsuitable type. defective. causing excessive surfaces . closed) loop control
3.Direction of pressure set too 3.Dirty or damaged 3.Internal leakage flow resistance. 3.Excessive circuit.
rotation wrong. low, or control valve seat due to wear. 3.Fluid foams. internal friction 2.Display
9/7/21
4.Motor defective. element defective. 4.Broken spring. 4.Excessive fluid causing low instruments are
5.Key sheared at 5.Unsuitable type. velocity. efficiency. defective.
pump or motor. (setting too low) 5.Spool jams.
Jerky cylinder or 1.Coupling wrongly Suction resistance 1.With variable 1.Installation not 1.Excessive line 1.Valve chatter due 1.Valve dirty. 1.Valve chatters 1.Hydraulic fluid 1.Stick-slip effect 1.Insufficient load
motor aligned. is excessive :- pumps, the control bled completely. resistance. to dirt on valve seat 2.Pressure losses due to defective dirty. due to the friction of counter-balance
movements. 2.Coupling loose. 1. Valve in the system is defective. 2.Filter blocked. or valve worn. excessive. solenoid or the 2.Hydraulic fluid the cylinder (e.g. lowering
(variations in 3.Coupling suction line is 2.Pump defective. 2.Insufficient voltage is too low. foams. packings being too control valve)
pressure and/or defective. partially open. 3.System damping 2.Valve defective high.
flow) 4.Loose mounting 2. Suction filter conditions react on (unsuitable type) due to dirt or wear. 2.Operation below
on pump and/or clogged or too the pump control 3.Excessive length 3.Flow through minimum
motor. small (if fitted). system. of undamped valve is excessive. recommended
5.Other 3. Suction line 4.Unsuitable pilot remote-control line. 4.Pilot pressure motor speed.
transmission blocked or leaking. valve. 4.Unsuitable variations.
elements loose (V- 4. Suction line is remote-control 5. Adjustable
belts, Toothed sized wrong. valve. damping on valves,
belts, etc.) 5. Fluid level too has not been set.
6.Pump or motor low. 6.Check the
defective electrical controls.
7.Direction of
rotation wrong.
Foaming of the 1. Suction line 1. Shaft seals on 1. Return line 1. Unsuitable fluid
hydraulic fluid. leaks. the suction side are terminates above for the duty.
2. Fluid level too defective. the fluid level.
low. 2. Case drain line 2. Vortex effect due
3. Wrongly terminates above to wrongly
designed reservoir. the fluid level. positioned lines.
9232510974 — 1000702744 1
51
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Causes Of Trouble And Its Effect In The Hydraulic Installation

Source of trouble, Flow Control Directional Output Drive
Mechanical Drive Suction Line Pump Pressure Line Return Line Pressure Valves Fluid Others
effects Valves Control Valves (motor, cylinder)
Power Take-off 1. Coupling Suction 1. Internal leakage 1. Leakages. 1. Excessive line 1. Operating 1. Flow rate set too 1. Wrong switched 1. Viscosity too 1. Internal 1. Conditions for
either does not wrongly aligned. resistance is due to wear. 2. Excessive line resistance. pressure set too low. position . low, causing leakage. starting not
turn at all or too 2. Coupling loose. excessive :- 2. Pump defective. resistance. 2. Filter blocked. low. 2. Unsuitable valve 2. Solenoid excessive 2. Wear of running fulfilled.
slowly. (no 3. Coupling 1. Valve in the 3. Inlet and return 3. Pressure filter 2. Internal Leakage type (operating defective. leakage. surfaces. 2. Electrical lines
delivery flow or defective. suction line is lines wrongly blocked. due to wear. range too low). 3. Internal leakage 2. Viscosity too 3. Excessive open-circuit
insufficient 4. Loose mounting part open. connected. 3. Dirty or 3. Valve blocked due to wear. high, causing internal friction, 3. Signalling
delivery flow) on pump and/or 2. Suction filter damaged valve due to dirt. 4. Excessive fluid excessive flow. causing low elements, such
motor. clogged or too seat. velocity. 3. Fluid foams. efficiency. as pressure or
5. Other small (if fitted). 4. Broken spring. 5. Spool jams or 4. Seizure in limit switches,
transmission 3. Suction line 5. Unsuitable type sticks. Hydraulic motor. are defective,
elements loose. blocked or (setting range 6. Manually wrongly set, or
(Toothed belts, leaking. too low) operated valves not connected.

etc.) 4. Suction line is are not open.
6. Pump or motor sized wrong.
defective. 5. Fluid level too
7. Direction of low.
rotation wrong.
Excessive 1. Reduction in 1. Pipe bore is too 1. Pipe bore is too 1. Constant 1. Flow rate set too 1. Leakage losses 1. Viscosity too 1. Losses in 1. Cooling
operating efficiency due to small, causing small, causing delivery flow is low (excessive too high. low, causing efficiency due to performance
temperature wear. high frictional high frictional too high. pump delivery 2. Pressure-less excessive wear. inadequate.
2. With variable resistances. resistances. 2. Undersized through circulation, if leakage. 2. Internal friction 2. Pressure-less oil
pumps, the 2. Pressure filter 2. Return filter valve. pressure-relief used, fails to 2. Viscosity too too high (poor circulation when
pump control blocked. blocked. 3. Pressure setting valve). switch on. high, causing level of the pump is
system is too high. 2. Valve defective. 3. Spool sticking. excessive flow efficiency). running.
defective. 4. Response time resistance. 3. Internal leakage 3. Insufficient
3. Rotational speed too long. 3. Fluid foams. losses. hydraulic fluid.

and/or delivery 4. Coolant valve
excessive. failed.
5. Thermostat set
9/7/21
too high.
6. Fan not switched
on.
7. Ambient too
high.
8. Deposits in
radiator.
Cylinder runs on. 1. Elasticity of 1. Switching time 1. Internal 1. Pilot-operated
hoses is set too short. leakage. check valve fails
excessive. 2. Defective 2. Faulty bleeding. to close, due to
2. Lines not bled solenoid,. dirty or damaged
properly. 3. Valve dirty seats.
2. Limit switch fails.
Line shocks when 1. Line mounts are Lines loose. 1. Valve switches 1. Switching time 1. Foaming of the 1. Excessive 1. In accumulator
switching takes missing or loose. too quickly. set too short. hydraulic fluid. masses or systems, throttle
place. 2. Poor installation. 2. Restrictors or 2. Unsuitable type forces. valves have not
3. Pipe bore too orifices are of valve (the 2. No damping. been fitted in
small. damaged or opening cross- front of the
4. Installation not missing. sectional area switching valves.
bled. changes too
5. Oil volume in quickly).
lines is
excessive.
The pump 1. Pump defective. Sequence valve or 1. Accumulator pre-
switches on and 2. In the case of shut-off valve charge pressure
off too often. accumulator has wrong is too low.
systems, the setting. 2. Bladder
pump is defective.
incorrectly sized. 3. Pressure switch
differential set
too low.
4. Pressure switch
set incorrectly.
9232510974 — 1000702744 1
53
11 Appendices
11.1 General Assembly Instructions with Informations of the Transport of the Hydraulic Power Units

54
RE 07009-MON/11.17
*HQHUDO$VVHPEO\,QVWUXFWLRQV 11.1.1 Replaces: 09.09English
ZLWK,QIRUPDWLRQRQWKH7UDQVSRUW
RIWKH+\GUDXOLF3RZHU8QLWV
Assembly instructions

55
The data specified below only serve to describe the

product. No statements concerning a certain condition
or suitability for a certain application can be derived
from our information. The information given does not
release the user from the obligation of own judgment
and verification. It must be remembered that our
products are subject to a natural process of wear and
aging.
‫ ף‬This document, as well as the data, specifications
and other information set forth in it are the exclusive
property of Bosch Rexroth AG. It may not be
reproduced or given to third parties without its consent.
The cover shows a sample configuration. The product
supplied may therefore differ from the photo shown.
The original assembly instructions were prepared in
German.

56

RE 07009-MON/11.17 | Assembly Instructions for Hydraulic Power Units Bosch Rexroth AG 3/20
Contents
Contents
1 About this document .......................................................................... 5
2 General safety instructions ................................................................ 5
Intended use ................................................................................. 5
Qualification of personnel ............................................................. 5
Safety instructions in this document ............................................. 5
Adhere to the following instructions .............................................. 6
3 Scope of delivery ................................................................................ 7
4 Product description ............................................................................ 7
Product identification .................................................................... 7
5 Transport and storage ........................................................................ 8
Transporting hydraulic power units ............................................... 8
Storing the hydraulic power units ................................................ 14
6 Assembly and installation ................................................................ 14
Unpacking ................................................................................... 14
Assembling the hydraulic power unit .......................................... 15
Installing the hydraulic system .................................................... 15
Connecting to the water supply .................................................. 17
Installing the electrical system .................................................... 17
7 Technical data ................................................................................... 18
8 Appendix ............................................................................................ 18
Address directory ........................................................................ 18
9 Glossary ............................................................................................. 19

57

Contents

58

1 About this document

These instructions contain important information for the safe and
appropriatetransport and assembly of hydraulic power units.
These are general assembly instructions with information on the transport
of hydraulic power units that are developed and produced in a customer-
specific way.
Information on the commissioning (incl. the filling with operating

media), the operation, maintenance and simple troubleshooting is
contained in the generaloperating instructions for hydraulic power
units and hydraulic assemblies.
2 General safety instructions

The hydraulic power unit was designed and manufactured considering
the provisions of directives, standards and specifications relating to this
technology.There is, however, still a risk of personal injury or damage to
property if the following safety instructions and warnings contained in
this document are not observed.
► You should read these instructions completely and thoroughly before working
with the hydraulic power unit/hydraulic assembly.
► Always include the operating instructions and the product-specific
documentation when passing the hydraulic power unit/hydraulic assembly on
to a third party.
2.1 Intended use

For information on the intended use please refer to the supplied general
operatinginstructions for hydraulic power units and hydraulic assemblies.
2.2 Qualification of personnel

Assembly requires a basic knowledge of mechanics, electrics and
hydraulics, as well as familiarity with the associated technical terms. In
order to ensure operational safety, these activities may only be carried
out by qualified technicalpersonnel or an instructed person under the
direction and supervision of a qualified person.
Qualified personnel are those who can recognize potential hazards and
apply theappropriate safety measures due to their professional training,
knowledge and experience, as well as their understanding of the relevant
conditions pertaining
to the work to be undertaken. Qualified personnel must observe the
rules/lawsrelevant to the specific subject area.
2.3 Safety instructions in this document

In these assembly instructions, there are safety instructions before the
stepswhenever there is a risk of personal injury or damage to the
equipment. The measures described for preventing these hazards
must be observed.

59

Safety instructions are set out as follows:
SIGNAL WORD! Type of risk!

Consequences
► Precautions

Table 1: Meaning signal words

DANGER! imminently ǡ
ǡ Ǥ
WARNING! potentially ǡ ǡ

ǡ Ǥ
CAUTION! potentially hazardous ǡ

ǡ
Ǥ
ǡ

Ǥ


The regulations regarding accident prevention and environmental protection
applicable in the country where the product is used and at the workplace must
be observed.
Only persons who have been authorized by the operator may be granted
General access to the immediate vicinity of operation. This also applies during
machine standstill.
Persons who assemble products supplied by Bosch Rexroth must not consume
any alcohol, drugs or medication that may have a detrimental affect on
their reactions.
Avoidance of hazards Before installation, check the hydraulic power unit for visible transport damage
e.g. cracks, missing lead seals, screws, protective covers.
Under no circumstances should the hydraulic power unit be subjected to
inadmissible mechanical loads. Do not place any objects on top of the power unit.

60

Provide for sufficient stability of the hydraulic power unit.

² In this context, observe the maximum load-bearing capacity of the
foundations or ground as well as that of the attachment devices and vehicles
used for transport.
² You should use only the designated attachment points.
Avoid damage of any kind on the pressurized or functional components of the
hydraulic power unit.
Protective measures If it does become necessary to work at height, entailing a fall hazard, suitable
safety precautions must be taken (e.g. provision of gratings, handrails or
harnesses).
Suitable measures should be taken to prevent any slip hazard caused by oily
surfaces that may e.g. result from maintenance work.
3 Scope of delivery
These assembly instructions have been prepared for hydraulic power units.
In addition to the actual product itself, the scope of delivery for hydraulic power
units also includes both general and product-specific documentation.
These documents are listed in the following table:
Document Power unit

Ǧ

ȋȌ
4 Product description
Hydraulic power units are drive system for hydraulic machines. In this
sense,they are considered partly completed machinery according to EC
Machinery Directive 2006/42/EC.
The hydraulic power units, for which these assembly instructions have
been prepared, are exclusively intended for installation into machinery. As
a general rule, these are products that have been developed and
manufactured to customerspecifications. For the specific description of
your product, please refer to the relevant product-specific documentation.
4.1 Product identification

The product is unambiguously identified by:
The nameplate
The product-specific documentation
The delivery note and accompanying documents

61

5 Transport and storage

► Observe the transport instructions, e.g. on the packaging.
► When storing and transporting the product, always observe the ambient
conditions specified in Chapter 15 “Technical data”.
► If the package has to be opened e.g. for inspection purposes, you should
reseal the packaging to the condition in which it was supplied.
► Wherever possible, the packaging should not be removed until directly before
assembling the unit.
5.1 Transporting hydraulic power units
WARNING! Danger to life due to tumbling, falling or uncontrolled movement of the

hydraulic power unit!
If not transported appropriately, the hydraulic power unit may lose its
stability andthus be knocked over, fall or move in an uncontrolled way.
► Check the weight and also the location of the center of gravity of the hydraulic
power unit.
► Place the product on a suitable foundation / on suitable ground.
► By means of additional suitable measures (e.g. by securing holding down
points or with the use of cranes) provide for sufficient stability before removing
any packing/transit materials or fixtures.
► Only the intended locations and attachment points should be used for securing
or lifting the hydraulic power unit.
► Hydraulic power units must never be attached to or lifted at the mounted
components (piping, hoses, manifolds, electric motors, accumulators, etc.).
► Observe the maximum load-bearing capacity of the attachment devices.
► Observe the maximum load-bearing capacity of the floor conveyors.
► Ensure that no unauthorized persons are within the hazard zone.
Danger to life due to the ejection of high-pressure oil or machine

malfunctions during operation!
In the case of improper transport of the hydraulic power unit, pressurized or
functional components may become damaged.
WARNING! ► Ensure that these components do not come into contact with the attachment
devices or lifting tools during transport.
► Ensure that hydraulic power units are not attached to or lifted at
these components.

62

5.1.1 Preparing the power unit for transport

The following preparations must be carried out before transporting the
hydraulicpower unit:
► Check the space required for the installation of the hydraulic power unit at the
place of use.
► Check the transport route. Depending on the method of transport, allow for
additional space around the hydraulic power unit.
► Check the maximum admissible load bearing capacity of the roads, bridges,
crossings, etc.
► Prior to transportation of the hydraulic power unit, depressurize the installed
accumulators on the oil side. If possible, reduce the pressure on the gas side
to a value of 2 bar (200 kPa).
Bosch Rexroth always delivers hydraulic power units without first

filling with oil. Any deviations from this rule are described explicitly in
the product-specificdocumentation. From the factory inspection there
may, however, still be oil residues in the product.
5.1.2 Determination of the center of gravity

Wherever possible, the location of the center of gravity is marked on the
packaging by the following symbol.
Fig. 1: Symbol for marking the center of gravity
The location of the center of gravity is generally specified on the

assembly drawing. The diagrams below demonstrate how to mark the
center of gravity ondrawings.
Fig. 2: Marking the center of gravity in drawings

63

5.1.3 Use of attachment points

hydraulic power unit when using unsuitable attachment points!
After a longer period of use, the attachment points may no longer be in place, be
sufficiently stable or identifiable as such.
► Refer to the product-specific documentation for the intended attachment
points and only use the ones mentioned there.
► Check the stability of the attachment points if you intend transporting the
hydraulic power unit after dismantling.
► Replace missing and/or defective attachment points, if possible. This work
should be carried out in a professional manner.
► Insert the screw-in attachment points into the tapped hole and hand-
tighten fully.
► If necessary, mark the unrecognizable attachment points using easily
visible color.
Attachment points are fixtures in the form of lugs, collars or shackles that
are connected to the hydraulic power unit by means of welded or threaded
attachment. They are designed for lifting or holding down the hydraulic
power unitduring transport.
Examples of attachment points of hydraulic power units are shown in Fig. 3:
1 2
Fig. 3: Examples of attachment points
1 Welded type
2 Screwed type
5.1.4 Manual transport
Risk of injury to persons undertaking manual lifting/handling due to

overloading and incorrect posture!
CAUTION! In the case of lifting/handling, there is the risk of damage to health due to
overloading and incorrect posture.
► The limits of the respective persons involved in manual lifting/handling
must be realistically assessed. Muscular strength and constitution differs
considerably among human beings.
► Wherever possible, suitable lifting aids should be used such as e.g. carrying straps.
► Always use appropriate techniques when lifting, setting down and
moving products.

64

5.1.5 Transport using forklifts and similar floor conveyors
WARNING! Danger to life due to falling or uncontrolled movement of the hydraulic

power unit!
If not transported appropriately, the hydraulic power unit may be knocked, fall or
move in an uncontrolled way.
► When using floor conveyors as a means of transport, ensure a stable center of
gravity position.
► The hydraulic power unit must not deviate from its intended orientation.
► Secure the hydraulic power unit against any resulting acceleration forces as
required.
When using floor conveyors, the hydraulic power unit may only be
transportedby personnel who can prove they hold the relevant
qualifications, including safety training, for the respective device.
You should proceed as follows:

► Using suitable temporary protective devices e.g. wooden or plastic elements,
protect the hydraulic power unit against the contact surface of the fork, so that
the paintwork cannot be damaged during lifting and transport.
► Secure the hydraulic power unit at the forklift against tilting. To this purpose,
fuse suitable attachment devices like e.g. tie downs.
► Carefully lift the hydraulic power unit, taking into consideration the stable
center of gravity location and transport it to the desired position.
► Ensure that the built-on components of the hydraulic power unit do not come
into contact with the attachment device or lifting tools during transport
(see Fig. 4).
► Carefully set the hydraulic power unit down again and remove the holding
down / lifting equipment and any temporary protective devices.
Fig. 4: Transport using forklifts

65

5.1.6 Transport using cranes and similar lifting tools
WARNING! Danger to life due to falling or uncontrolled movement of the hydraulic

power unit!
► When using lifting tools, ensure a stable center of gravity position.
► The hydraulic power unit must not deviate from its intended orientation. If
necessary, attach suitable safety and/or catch devices.
If using cranes as a means of transport, attachment device e.g. lifting straps,

harnesses or chains should be used.
► Use only the intended locations and attachment points when lifting (see Fig. 5
and 6).
into contact with the attachment device or lifting tools during transport.
The edges of the hydraulic power unit may cause damage to the fabric
lifting straps or harnesses. An edge protector should therefore be used if
necessary.
When using uncovered chains, scratches in the paintwork may

result. Ifnecessary, use suitable protection for these surfaces e.g.
blankets.
► Lift and lower the hydraulic power unit slowly and carefully.
► Only lift the device as far off the floor as necessary.
Fig. 5: Use of lifting straps and attachment points

66

Fig. 6: Detailed view of Fig. 5
5.1.7 Freight transport

► Secure the hydraulic power unit against any resulting acceleration forces
as required.
The various regulations of the assigned forwarding agents e.g. shipping

companies, railway companies, forwarders, airlines must be observed.
► Secure the hydraulic power unit onto the transport vehicle, e.g. by the holding
down points.
into contact with the attachment devices during transport.
► Some products need to be transported in a lying position e.g. accumulator
stands. Use the intended attachment points for laying the products down and
securing them.

67

5.2 Storing the hydraulic power units
Observe the storage times specified in

Table 2.
► If the storage time exceeds the values specified, flush the hydraulic power unit
before commissioning using a suitable flushing fluid. The flushing procedure
should be carried out as described in Chapter 7.1.9 “Flushing the hydraulic
system” of the operating instructions.
► If necessary, replace the components for which a maximum storage time is
specified e.g. hoses, compensators, accumulators.
Table 2: Storage times
Storage time in months

Protective
Storage conditions Packaging
agent
ͳʹ ʹͶ

Storage in dry rooms ͳʹ ʹͶ
ͻ ʹͶ

ͳʹ ʹͶ
͸ ͳʹ
Outdoor storage ͻ ʹͶ
ȋ
Ȍ Ͳ ͳʹ
͸ ʹͶ
Inspection with protective agent A = Mineral oil
Filling with protective agent B = Corrosion protection oil
12 6 Assembly and installation

This chapter describes the assembly of the product at its place of use as
well asthe connection of the product to the hydraulic system, the electrical
systems andthe water supply of the machine.
For information regarding the installation into the complete machine,
particularlyregarding its overall function and logic mode of operation,
please refer to the instructions and/or the documentation for the
complete machine.
CAUTION! Risk of personal injury and damage to property!

A basic knowledge of hydraulics is required for assembling the
hydraulic powerunit.
► Only qualified personnel (see Chapter “2.3 Personnel qualifications”) are
permitted to assemble the hydraulic power unit.
6.1 Unpacking
► Remove the product packaging.
► Dispose of the packaging material in accordance with the national regulations
in your country and/or your company-internal specifications/procedures.

68

6.2 Assembling the hydraulic power unit
WARNING! Risk of injury due to tumbling, falling or uncontrolled movement of the

You should ensure that the product is sufficiently stable.
► Observe the information on handling the product in Chapter 5 “Transport
and storage”.
► Any packing/transit materials, straps, props or fixtures should only be removed
if stability has been ensured by other means.
► Place the hydraulic power unit on a suitable foundation. Observe the
specifications of the overall weight.
To assemble the hydraulic power unit you should proceed as follows:

► Position the hydraulic power unit or the assembly as specified in the product-
specific documentation.
► Ensure that the footprint contact associated with mounting is consistent.
► Level the hydraulic power unit so that its longitudinal and transverse axes are
horizontal.
► Prevent possible bouncing by suitable means (e.g. height adjustment of the
feet, insertion of shims, packers).
► Securely fix the product at the mounting positions specified in the product-
6.3 Installing the hydraulic system
Risk of injury when assembling under pressure!

If you fail to depressurize the product before starting the installation, you may
suffer injury and also damage the unit or system components.
► Always depressurize the relevant part of the system before assembling the
CAUTION!
Damaging the hydraulic power unit!

When assembling hydraulic lines and hoses under mechanical stress,
they areexposed to additional mechanical forces during operation,
which reduces the service life of the hydraulic power unit and the
complete machine or system.
► Assemble the piping and hose assemblies without mechanical stress.
CAUTION!

69

CAUTION! Wear, tear and malfunctions!

The cleanliness of the hydraulic fluid has a considerable impact on the
cleanliness and service life of the hydraulic system as a whole. Any
pollution/contamination of the hydraulic fluid will result in wear and
malfunctions. In particular, foreign bodies
e.g. welding beads or metal swarf in the hydraulic lines may damage the
hydraulicpower unit.
► Always ensure absolute cleanliness.
► Assemble the hydraulic power unit free from any pollution/contamination.
► Ensure that all connections, hydraulic lines and add-on units
(e.g. measuring instruments) are clean.
► Ensure that no pollutants are able to penetrate when sealing the connections.
► Ensure that no detergents are able to penetrate the hydraulic system.
► Do not use cleaning rags/cotton waste or linty cloth for cleaning.
► Do not under any circumstances use hemp as a sealant.
Risk of injury from ejection of high-pressure oil!

If the nominal pressure is exceeded, the component may burst.
► The connection lines should be dimensioned in accordance with the
WARNING! performance data in the circuit diagram.
► You should only use components that are designed for the required pressures.

Fittings with metric or Whitworth threads may for certain sizes be mis-
matched without this being immediately evident. Fittings with threads
that are mis-matchedwill not withstand the specified nominal pressure.
► You should therefore ensure that there is no risk of confusion with respect to
WARNING! the correct screw fittings.
Remove the blanking plugs and flange covers (colored plastic) and
replace themwith pressure-resistant fittings or flanges.
► You should observe the manufacturer’s installation instructions for the screw
fittings to ensure there is no external leakage. We recommend the use of
fittings with elastic seals.
Preparation
Cleaning the lines ► Before installing, clean the connection lines to the hydraulic system, ensuring
they are free from dirt, scales, chippings, etc. Welded pipes must be blank on
the inside and flushed.
► Do not use cleaning rags/cotton waste for cleaning.

70

Hose assemblies The hose assemblies should be installed such that

² Kinking and tensile load of the hose is avoided during operation,
² The hose is not twisted or turned,
² The outer layer of the hose does not rub off through abrasion or impact,
² The weight of the hose assembly does not cause inadmissible loading.
If a hose assembly becomes detached and there is a risk of whipping, it

is advisable to fit a hose safety catch. If the hose assemblies are
equipped withloosening-resistant fittings, no safety catch is required.
6.4 Connecting to the water supply

► The fittings must be tightened according to manufacturer specifications!
► Lay the lines to the water connections provided and connect them according
to the circuit diagram.
6.5 Installing the electrical system
Risk of injury when assembling under voltage!

If you fail to switch off the power supply before assembling the product,
you maysuffer injury, destroy the product or damage system
components.
CAUTION! ► Always switch off the power supply to the relevant system component before
assembling the product.
6.5.1 Earthing and potential equalization

Hydraulic power units from Bosch Rexroth are supplied with connection
for the external earthing system. Potential equalization within the
hydraulic power unit will only occur if the electrical wiring of the
components is included in the scope of delivery. If this is not the case,
potential equalization must be carried out by themachine manufacturer
when wiring the hydraulic power unit to the machine.
The hydraulic power units must be earthed!
The earthing line and the lines for the potential equalization must
have the minimum cross-section as per VDE regulations and a
yellow-green sheathor labeling.
► Before connecting the cables, you should earth the devices that are to be
connected and provide for potential equalization via a common equalizing bar.

71

6.5.2 Laying the power supply and control cables and connecting
the electricity supply
► The electrical installation must be performed in accordance with the currently
applicable rules of electrical engineering.
► You must ensure that the power supply is disconnected and also safeguarded
against being switched on unintentionally.
► You should prevent this by e.g. using a warning sign to draw attention to
issues regarding working on the electrics.
► Carefully secure all cables to the electric motor with plastic cable clamps
against unintended loosening (swinging).
6.5.3 Installing the electrical control and monitoring equipment

Connect the control and monitoring equipment (switching devices,
open-loop or closed-loop equipment or frequency converters)
according to the relevant instructions, taking into account the
appropriate safety precautions.
CAUTION! Penetrating dirt and liquids will cause faults!

Safe function of the hydraulic power unit/components is then no longer ensured.
► Always ensure absolute cleanliness when working on the hydraulic power unit.
Damage to the surface from solvents and aggressive cleaning agents!

CAUTION! Aggressive detergents may damage the seals on the hydraulic power
unit andmake them age faster.
► Never use solvents or aggressive detergents.
7 Technical data
Please refer to the product-specific documentation for the technical
data ofthe product.
8 Appendix
8.1 Address directory

Please refer to www.boschrexroth.com for addresses of foreign subsidiaries

72

9 Glossary
Attachment points
Attachment points are fixtures in the form of lugs that are connected to
the load by means of welded or screw connections. They are used to lift or
secure the loadduring transport.
Attachment devices
Attachment devices are separate devices used to bridge the connection
betweena crane and a load in order to lift the latter. Attachment devices
are e.g. lifting straps, belts or chains.
Component
Any part with a (partial) function in the sense of the technical overall
system.Components in the hydraulic system include e.g. valves,
filters, cylinders, hydraulic connection elements.
Floor conveyors
Floor conveyors are means of transport for the horizontal transport that
are mostlyused within the company at ground level.
Line system
Any combination of lines (hoses, piping or bores) and hydraulic
connection elements allowing for the intended flow of the oil between
tanks, pumps, valves,accumulators, actuators, filters, etc.
Tank
The component in a hydraulic system that collects all the oil during
operation andstandstill. It is not used for storing hydraulic energy.

73
Bosch Rexroth AG
Industrial Hydraulics
Zum Eisengießer 1
97816 Lohr am Main
Germany
Phone +49 (0) 9352 40 30 20
my.support@boschrexroth.de
www.boschrexroth.com

74

75

11.2 General Operating Instructions For Hydraulic Power Units and Assemblies

76
RE 07009-B/09.09
*HQHUDO2SHUDWLQJ,QVWUXFWLRQV Replaces: -.-
IRU +\GUDXOLF 3RZHU 8QLWV DQG English
$VVHPEOLHV
Operating Instructions

77
The data specified below only serve to describe the

product. No statements concerning a certain condition
or suitability for a certain application can be derived
from our information. The information given does not
release the user from the obligation of own judgment
and verification. It must be remembered that our
products are subject to a natural process of wear and
aging.
‫ ף‬This document, as well as the data, specifications
and other information set forth in it are the exclusive
property of Bosch Rexroth AG. It may not be
reproduced or given to third parties without its consent.
The cover shows a sample configuration. The product
supplied may therefore differ from the photo shown.
The original operating instructions were prepared in
German.

78

RE 07009-B/09.09 | Operating Instructions for Hydraulic Power Units and Assemblies Bosch Rexroth AG 3/60
Contents
13 Contents
1 About this document .......................................................................... 5
Related documents ....................................................................... 5
2 General safety instructions ................................................................ 6
Intended use ................................................................................. 6
Improper use ................................................................................. 7
Qualification of personnel ............................................................. 7
Safety instructions in this document ............................................. 8
Adhere to the following instructions .............................................. 9
Obligations of the operator ......................................................... 10
3 Scope of delivery .............................................................................. 11
4 Product description .......................................................................... 12
Hydraulic power units.................................................................. 12
Hydraulic assemblies .................................................................. 12
Product identification .................................................................. 12
5 Transport and storage ...................................................................... 13
Transporting hydraulic power units ............................................. 13
Storing the hydraulic power units ................................................ 19
6 Assembly and installation ................................................................ 20
Unpacking ................................................................................... 20
Assembling the hydraulic power unit .......................................... 20
Installing the hydraulic system .................................................... 21
Connecting to the water supply .................................................. 22
Installing the electrical system .................................................... 23
7 Commissioning ................................................................................. 24
First commissioning .................................................................... 25
Re-commissioning after extended standstill ............................... 30
8 Operation ........................................................................................... 31
9 Maintenance ...................................................................................... 32
Maintenance documentation....................................................... 32
Cleaning and care (maintenance)............................................... 33
Inspection, maintenance, repair ...................................................... 33
Spare and wear parts ................................................................. 42
10 Decommissioning ............................................................................. 43
Preparing for decommissioning .................................................. 43
Decommissioning the hydraulic power unit ................................ 43
11 Disassembly ...................................................................................... 44
Preparing for disassembly .......................................................... 44
Disassembling the hydraulic power unit ..................................... 45
12 Disposal ............................................................................................. 46
13 Extension and conversion ............................................................... 47
14 Troubleshooting ................................................................................ 48
How to proceed with troubleshooting ......................................... 48
15 Technical data ................................................................................... 52
16 Appendix ............................................................................................ 53
Address directory ........................................................................ 53
17 Glossary ............................................................................................. 54

79

Contents Contents

80

About this document
1 About this document

These instructions contain important information on the safe and
appropriatetransport, assembly, commissioning, maintenance,
disassembly and basic troubleshooting of hydraulic power units and
assemblies.
► You should read these instructions thoroughly, and in particular Chapter 2
“General safety instructions” before working with the hydraulic power unit.
These are general operating instructions pertaining to hydraulic
power unitsand assemblies that have been developed and
manufactured to customer specifications.
► For this reason you should keep the product-specific documentation to hand
when reading these instructions (see Chapter 3 “Scope of delivery”).
Throughout these instructions the term “hydraulic power unit” is used

synonymously for hydraulic assemblies. The information contained
therein willtherefore likewise apply to hydraulic assemblies, even
where this is not explicitly stated. Wherever a differentiation needs to
be made within the document, the terms “hydraulic power unit” and
“hydraulic assembly” will
be specified.
1.1 Related documents

► You should observe the documentation for the complete machine.
► You should also observe the documentation pertaining to the other
components, assemblies and partly completed machinery, which form part of
the complete machinery.
► You should observe the generally applicable, legal or otherwise binding
European and national regulations as well as the relevant stipulations for
your country pertaining to the prevention of accidents and protection of
the environment.

81

About this document
2 General safety instructions

The hydraulic power unit was designed and manufactured considering the
provisions of directives, standards and specifications relating to this
technology. There is, however, still a risk of personal injury or damage to
property if the following safety instructions and warnings contained in this
document are not observed.
► You should read these instructions completely and thoroughly before working
with the hydraulic power unit/hydraulic assembly.
► When reading these instructions you should always have the product-specific
documentation to hand (see Chapter 3 “Scope of delivery”).
► These instructions, together with the relevant product-specific documentation,
should be kept so as to be readily accessible to all users.
► Always include the operating instructions and the product-specific
documentation when passing the hydraulic power unit/hydraulic assembly on
to a third party.
Due to the interaction between the hydraulic power unit and the complete
machine, the installation of the hydraulic power unit into the machinery
will result inadditional potential hazards. This applies in particular to the
influence of hydraulicand electric controls on hydraulic drives generating
mechanical movements.
It is therefore essential for the manufacturer of the complete machine to
have undertaken an independent risk assessment. Furthermore, the
manufacturer muston this basis have prepared operating instructions for
the complete machine.
These operating instructions are no substitute for the operating

instructions forthe complete machine.
2.1 Intended use

As regards the specification of the intended use, explicit differentiation will be
made in this document between hydraulic power units and hydraulic assemblies.
2.1.1 Hydraulic power units

The hydraulic power unit constitutes partly completed machinery in
terms of EC Machinery Directive 2006/42/EC. In terms of the EC
Machinery Directive the hydraulic power unit is not considered to be a
ready-to-use machine. The hydraulic power unit is exclusively intended
for integration into a machine or system or for assembly with other
components to form a machine or a system.
The product may be commissioned only if it has been integrated into the
machineor system for which it is designed and if the machine or system fully
complies withthe requirements of the EC Machinery Directive.
The hydraulic power unit is not considered to be a safety component

in termsof EC Machinery Directive 2006/42/EC.
► You should observe the operating conditions and performance limits specified
in the technical data.
The hydraulic power unit is a work appliance and not designed for
private use.Intended use includes having fully read and understood
these operating
instructions, especially Chapter 2 “General safety instructions”.

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General safety instructions
2.1.2 Hydraulic assemblies

A hydraulic assembly is intended exclusively for integration into a
machine or system or to be assembled with other components to form a
machine or system. The product may only be commissioned if it has been
integrated into the machineor system for which it is designed.
The hydraulic assembly is not considered to be a safety component or

partlycompleted machine in terms of EC Machinery Directive
2006/42/EC.
► You should observe the operating conditions and performance limits specified
in the technical data.
The hydraulic assembly is a work appliance and not designed for private use.
Intended use includes having fully read and understood these instructions,
especially Chapter “2 General safety instructions”.
2.2 Improper use

Any use of the hydraulic power unit or the hydraulic assembly other
than described in Chapter 2.1 “Intended use” is considered as being
improper.
2.3 Qualification of personnel

Assembly, commissioning, service (incl. maintenance, inspection, repair)
and disassembly require a basic knowledge of mechanics, electrics and
hydraulics, as well as familiarity with the associated technical terms. In
order to ensure operational safety, these activities may only be carried
out by qualified technicalpersonnel or an instructed person under the
direction and supervision of a qualified person.
Qualified personnel are those who can recognize potential hazards and
apply theappropriate safety measures due to their professional training,
knowledge and experience, as well as their understanding of the relevant
conditions pertaining
to the work to be undertaken. Qualified personnel must observe the
rules/lawsrelevant to the specific subject area.

83

2.4 Safety instructions in this document

These operating instructions contain warning signs followed by an
instructionwherever there is a risk of personal injury or damage to
the equipment. The measures described for preventing these hazards
must be observed.
Safety instructions are set out as follows:
SIGNAL WORD Type of risk!

Consequences
► Precautions

Table 1: Meaning signal words

DANGER! imminently ǡ
ǡ Ǥ
WARNING! potentially ǡ ǡ

ǡ Ǥ
CAUTION! potentially hazardous ǡ

ǡ
Ǥ
ǡ

Ǥ

ǡ

84


General The regulations regarding accident prevention and environmental protection
applicable in the country where the product is used and at the workplace must
be observed.
The Bosch Rexroth warranty applies only to the configuration supplied. The
warranty will not apply if the product is incorrectly assembled, not used as
intended and/or handled improperly.
You should keep the manufacturer's data sheet on oil safety to hand and
observe the safety information contained therein.
Only persons who have been authorized by the operator may be granted
access to the immediate vicinity of operation. This also applies during machine
standstill.
Only authorized personnel are allowed to operate the adjusting mechanisms of
the components or parts, under the proviso that the hydraulic power unit is used
as intended.
Persons who assemble, operate, dismantle or maintain products supplied by
Bosch Rexroth must not consume any alcohol, drugs or medication that may
have a detrimental affect on their reactions.
Please observe the specific information in the following chapters regarding the
product life phases.
Avoidance of hazards Before installation, check the hydraulic power unit for visible transport damage
e.g. cracks, missing lead seals, screws, protective covers.
Rexroth hydraulic power units should be used only if in a sound technical
condition.
Hydraulic power units should be used only within the performance range
specified in the technical data.
Under no circumstances should the hydraulic power unit be subjected to
inadmissible mechanical loads. Do not place any objects on top of the power unit.
Never remove or damage lead seals that have been fitted by Bosch Rexroth.
Provide for sufficient stability of the hydraulic power unit.
² In this context, observe the maximum load-bearing capacity of the
foundations or ground as well as that of the attachment devices and vehicles
used for transport.
² You should use only the designated attachment points.
Avoid damage of any kind on the pressurized or functional components of the
Protective measures Ensure that all associated safety devices pertaining to the hydraulic power unit
are existent, have been correctly installed and are fully functional. Do not
displace, bypass or disable the safety devices/equipment.
If it does become necessary to temporarily disable any safety equipment, e.g.
for commissioning or maintenance work, always take appropriate measures to
ensure that no potential injury to persons or damage to property can occur. Also
observe the superordinate operating instructions for the machine or system.
If it does become necessary to work at height, entailing a fall hazard, suitable
safety precautions must be taken (e.g. provision of gratings, handrails or
harnesses).
The hydraulic power unit may heat up during operation. The solenoids in the
hydraulic power unit become so hot during operation that you may sustain
burns. You should wear heat-proof gloves or protective clothing.

85

RE 07009-B/09.09 | Operating Instructions for Hydraulic Power Units and Assemblies Bosch Rexroth AG 10
Suitable measures should be taken to prevent any slip hazard caused by oily
surfaces that may e.g. result from maintenance work.
In the event of leaks, you should never allow any part of your body to come into
contact with the oil jet. Never try to stop or seal the leak or the oil jet using a cloth.
Leaks may cause an oil mist. Take special care if there are potential ignition
sources in the vicinity.
2.6 Obligations of the operator

The operator of the Bosch Rexroth hydraulic power unit must provide
personneltraining on the following topics and on a regular basis:
Observation and use of the operating instructions as well as the legal stipulations
Intended use and operation of the Bosch Rexroth product
Observation of the instructions from the factory security office as well as the
operator’s work instructions
What to do in an emergency
Bosch Rexroth offers training support in specific fields. An

overview of thetraining contents is available on the Internet via the
following link http://www.boschrexroth.de/didactic.

86

Scope of delivery
3 Scope of delivery
These operating instructions have been prepared for use with hydraulic
powerunits and hydraulic assemblies.
In addition to the actual product itself, the scope of delivery for hydraulic
power units and hydraulic assemblies also includes both general and
product-specificdocumentation.
These documents are listed in the following table:
Document Power unit Assembly

Ǧ

Ǥ
Ǥ
Ǥ
Ȅ

ȋȌ

Ȅ


87

Scope of delivery
4 Product description
The hydraulic power units or hydraulic assemblies, for which these
operating instructions have been prepared, are exclusively intended for
installation into machinery. As a general rule, these are products that have
been developed and manufactured to customer specifications. For the
specific description of your product, please refer to the relevant product-
specific documentation consisting of:
Product-specific documentation Technical specification: Description of the operating conditions and information
on the installation into the machinery
Hydraulic diagram: Function(s) and logic mode of operation of the product
Component list to the hydraulic diagram
Assembly drawing: Structural design, dimensions, information regarding the
center of gravity, connections, etc.
4.1 Hydraulic power units

Hydraulic power units are drive system for hydraulic machines. In this
sense, theyare considered partly completed machinery according to EC
Machinery Directive 2006/42/EC.
In accordance with these operating instructions hydraulic power units
Basic elements consist atleast of:
Electric motor and pump

Pump pressure-limiting device
Tanks, piping and hose assemblies, fittings, etc.
Fluid level gauge
Extensions In addition, a hydraulic power unit may contain:
Hydraulic control
Accumulator, with separate N2 pressure tanks, if applicable
Additional safety devices to prevent unintended pressures
Additional equipment for recording defined operating conditions
(pressure, temperature, filling level, filter contamination)
4.2 Hydraulic assemblies

Hydraulic assemblies include e.g. valve stands, accumulator stations,
drive-motorhydraulic pump unit, circulation stations for filtration and/or
cooling.
4.3 Product identification

The product is unambiguously identified by:
The nameplate
The product-specific documentation
The delivery note and accompanying documents

88

Transport and storage
5 Transport and storage

► Observe the transport instructions, e.g. on the packaging.
► When storing and transporting the product, always observe the ambient
conditions specified in Chapter 15 “Technical data”.
► If the package has to be opened e.g. for inspection purposes, you should re-
seal the packaging to the condition in which it was supplied.
► Wherever possible, the packaging should not be removed until directly before
assembling the unit.
5.1 Transporting hydraulic power units
Danger to life due to tumbling, falling or uncontrolled movement of the

If not transported appropriately, the hydraulic power unit may lose its
stability andthus be knocked over, fall or move in an uncontrolled way.
W
A
R
N
I
N
G
!
► Check the weight and also the location of the center of gravity of the hydraulic
power unit.
► Place the product on a suitable foundation / on suitable ground.
► By means of additional suitable measures (e.g. by securing holding down
points or with the use of cranes) provide for sufficient stability before removing
any packing/transit materials or fixtures.
► Only the intended locations and attachment points should be used for securing
or lifting the hydraulic power unit.
► Hydraulic power units must never be attached to or lifted at the mounted
components (piping, hoses, manifolds, electric motors, accumulators, etc.).
► Observe the maximum load-bearing capacity of the attachment devices.
► Observe the maximum load-bearing capacity of the floor conveyors.
► Ensure that no unauthorized persons are within the hazard zone.
Danger to life due to the ejection of high-pressure oil or machine

malfunctions during operation!
In the case of improper transport of the hydraulic power unit, pressurized or
functional components may become damaged.
W
A
R
N
I
N
G
!
► Ensure that these components do not come into contact with the attachment
devices or lifting tools during transport.
► Ensure that hydraulic power units are not attached to or lifted at these
components.

89

5.1.1 Preparing the power unit for transport

The following preparations must be carried out before transporting the
hydraulicpower unit:
► Check the space required for the installation of the hydraulic power unit at the
place of use.
► Check the transport route. Depending on the method of transport, allow for
additional space around the hydraulic power unit.
► Check the maximum admissible load bearing capacity of the roads, bridges,
crossings, etc.
► Prior to transportation of the hydraulic power unit, depressurize the installed
accumulators on the oil side. If possible, reduce the pressure on the gas side
to a value of 2 bar (200 kPa).
Bosch Rexroth always delivers hydraulic power units without first
filling with oil. Any deviations from this rule are described explicitly in
the product-specificdocumentation. From the factory inspection there
may, however, still be oil residues in the product.
5.1.2 Determination of the center of gravity

Wherever possible, the location of the center of gravity is marked on the
packaging by the following symbol.
Fig. 1: Symbol for marking the center of gravity
The location of the center of gravity is generally specified on the

assembly drawing. The diagrams below demonstrate how to mark the
center of gravity ondrawings.
Fig. 2: Marking the center of gravity in drawings

90

5.1.3 Use of attachment points

After a longer period of use, the attachment points may no longer be in place, be
sufficiently stable or identifiable as such.
W
A
R
N
I
N
G
!
► You should refer to the product-specific documentation for the intended

attachment points and use only the ones identified therein.
► Check the stability of the attachment points if you intend to transport the
hydraulic power unit after dismantling.
tighten fully.
► If necessary, mark any unrecognizable attachment points in a clearly
visible color.
Attachment points are fixtures in the form of lugs, collars or shackles that
are connected to the hydraulic power unit by means of welded or threaded
attachment. They are designed for lifting or holding down the hydraulic
power unitduring transport.
Examples of attachment points of hydraulic power units are shown in Fig. 3:
1 2
Fig. 3: Examples of attachment points
1 Welded type
2 Screwed type

91

5.1.4 Manual transport
CAUTION! Risk of injury to persons undertaking manual lifting/handling due to

overloading and incorrect posture!
In the case of lifting/handling, there is the risk of damage to health due to
overloading and incorrect posture.
► The limits of the respective persons involved in manual lifting/handling
must be realistically assessed. Muscular strength and constitution differs
considerably among human beings.
► Wherever possible, suitable lifting aids should be used such as e.g. carrying
straps.
► Always use appropriate techniques when lifting, setting down and moving
products.
5.1.5 Transport using forklifts and similar floor conveyors
Danger to life due to falling or uncontrolled movement of the hydraulic

power unit!
WARNING!
► When using floor conveyors as a means of transport, ensure a stable center of

gravity position.
► The hydraulic power unit must not deviate from its intended orientation.
required.
When using floor conveyors, the hydraulic power unit may only be
transportedby personnel who can prove they hold the relevant
qualifications, including safety training, for the respective device.
You should proceed as follows:
► Using suitable temporary protective devices e.g. wooden or plastic elements,
protect the hydraulic power unit against the contact surface of the fork, so that
the paintwork cannot be damaged during lifting and transport.
► Secure the hydraulic power unit at the forklift against tilting. To this purpose,
fuse suitable attachment devices like e.g. tie downs.
► Carefully lift the hydraulic power unit, taking into consideration the stable
center of gravity location and transport it to the desired position.
► Ensure that the built-on components of the hydraulic power unit do not
come into contact with the attachment device or lifting tools during transport
(see Fig. 4).
► Carefully set the hydraulic power unit down again and remove the holding
down / lifting equipment and any temporary protective devices.

92

Fig. 4: Transport using forklifts
5.1.6 Transport using cranes and similar lifting tools
Danger to life due to falling or uncontrolled movement of the hydraulic

power unit!
W
A
R
N
I
N
G
!
► When using lifting tools, ensure a stable center of gravity position.

► The hydraulic power unit must not deviate from its intended orientation. If
necessary, attach suitable safety and/or catch devices.
If using cranes as a means of transport, attachment device e.g. lifting straps,

harnesses or chains should be used.
► Use only the intended locations and attachment points when lifting (see Fig. 5
and 6).
into contact with the attachment device or lifting tools during transport

93

The edges of the hydraulic power unit may cause damage to the fabric
lifting straps or harnesses. An edge protector should therefore be used
if necessary.
When using uncovered chains, scratches in the paintwork may

result. Ifnecessary, use suitable protection for these surfaces e.g.
blankets.
► Lift and lower the hydraulic power unit slowly and carefully.
► Only lift the device as far off the floor as necessary.
Fig. 5: Use of lifting straps and attachment points
Fig. 6: Detailed view of Fig. 5

94

5.1.7 Freight transport

W
A
R
N
I
N
G
!
required.
The various regulations of the assigned forwarding agents e.g. shipping

companies, railway companies, forwarders, airlines must be observed.
► Secure the hydraulic power unit onto the transport vehicle, e.g. by the holding
down points.
into contact with the attachment devices during transport.
► Some products need to be transported in a lying position e.g. accumulator
stands. Use the intended attachment points for laying the products down and
securing them.
5.2 Storing the hydraulic power units
Observe the storage times specified in Table 2.
► If the storage time exceeds the values specified, flush the hydraulic power unit
before commissioning using a suitable flushing fluid. The flushing procedure
should be carried out as described in Chapter 7.1.9 “Flushing the hydraulic
system”.
► If necessary, replace the components for which a maximum storage time is
specified e.g. hoses, compensators, accumulators.
Table 2: Storage times
Storage time in months

Storage conditions Packaging Protective agent

ͳʹ ʹͶ

Storage in dry rooms ͳʹ ʹͶ

ͻ ʹͶ

ͳʹ ʹͶ
͸ ͳʹ
Outdoor storage
ͻ ʹͶ
ȋ
Ȍ Ͳ ͳʹ

͸ ʹͶ
Inspection with protective agent A = Mineral oil
Filling with protective agent B = Corrosion protection oil

95

Assembly and installation
6 Assembly and installation

This chapter describes the assembly of the product at its place of use as
well asthe connection of the product to the hydraulic system, the electrical
systems andthe water supply of the machine.
For information regarding the installation into the complete machine,
particularlyregarding its overall function and logic mode of operation,
please refer to the instructions and/or the documentation for the
complete machine.
CAUTION! Risk of personal injury and damage to property!

A basic knowledge of hydraulics is required for assembling the hydraulic power unit.
► Only qualified personnel (see Chapter “2.3 Personnel qualifications”) are
permitted to assemble the hydraulic power unit.
6.1 Unpacking
► Remove the product packaging.
► Dispose of the packaging material in accordance with the national regulations
in your country and/or your company-internal specifications/procedures.
6.2 Assembling the hydraulic power unit
WARNING! Risk of injury due to tumbling, falling or uncontrolled movement of the

You should ensure that the product is sufficiently stable.
► Observe the information on handling the product in Chapter 5 “Transport and
Storage”.
► Any packing/transit materials, straps, props or fixtures should only be removed
if stability has been ensured by other means.
► Place the hydraulic power unit on a suitable foundation. Observe the
specifications of the overall weight.
To assemble the hydraulic power unit you should proceed as follows:

► Position the hydraulic power unit or the assembly as specified in the product-
► Ensure that the footprint contact associated with mounting is consistent.
► Level the hydraulic power unit so that its longitudinal and transverse axes are
horizontal.
► Prevent possible bouncing by suitable means (e.g. height adjustment of the
feet, insertion of shims, packers).
► Securely fix the product at the mounting positions specified in the product-

96

6.3 Installing the hydraulic system
C Risk of injury when assembling under pressure!

AIf you fail to depressurize the product before starting the installation, you may
Usuffer injury and also damage the unit or system components.
T
I
O
N
!
► Always depressurize the relevant part of the system before assembling the

When assembling hydraulic lines and hoses under mechanical stress,
they areexposed to additional mechanical forces during operation,
which reduces the service life of the hydraulic power unit and the
complete machine or system.
C
A
U
T
I
O
N
!
► Assemble the piping and hose assemblies without mechanical stress.
Wear, tear and malfunctions!

The cleanliness of the hydraulic fluid has a considerable impact on the
cleanliness and service life of the hydraulic system as a whole. Any
pollution/contamination of the hydraulic fluid will result in wear and
malfunctions. In particular, foreign bodies
C e.g. welding beads or metal swarf in the hydraulic lines may damage the
Ahydraulicpower unit.
U
T
I
O
N
!
► Aways ensure absolute cleanliness

► Assemble the hydraulic power unit free from any pollution/contamination.
► Ensure that all connections, hydraulic lines and add-on units
(e.g. measuring instruments) are clean.
► Ensure that no pollutants are able to penetrate when sealing the connections.
► Ensure that no detergents are able to penetrate the hydraulic system.
► Do not use cleaning rags/cotton waste or linty cloth for cleaning.
► Do not under any circumstances use hemp as a sealant.
W Risk of injury from ejection of high-pressure oil!

AIf the nominal pressure is exceeded, the component may burst.
R
N
I
N
G
!
► The connection lines should be dimensioned in accordance with the

performance data in the circuit diagram.

97

► You should only use components that are designedAssembly
for the required pressures.
and installation

Fittings with metric or Whitworth threads may for certain sizes be mis-
matched without this being immediately evident. Fittings with threads
that are mis-matchedwill not withstand the specified nominal pressure.
W
A
R
N
I
N
G
!
► You should therefore ensure that there is no risk of confusion with respect to
the correct screw fittings.

98

Preparation Remove the blanking plugs and flange covers (colored plastic) and
replace themwith pressure-resistant fittings or flanges.
► You should observe the manufacturer’s installation instructions for the screw
fittings to ensure there is no external leakage. We recommend the use of
fittings with elastic seals.
Cleaning the lines ► Before installing, clean the connection lines to the hydraulic system, ensuring
they are free from dirt, scales, chippings, etc. Welded pipes must be blank on
the inside and flushed.
► Do not use cleaning rags/cotton waste for cleaning.
Hose assemblies The hose assemblies should be installed such that

² Kinking and tensile load of the hose is avoided during operation,
² The hose is not twisted or turned,
² The outer layer of the hose does not rub off through abrasion or impact,
² The weight of the hose assembly does not cause inadmissible loading.
If a hose assembly becomes detached and there is a risk of whipping,

it is advisable to fit a hose safety catch. If the hose assemblies are
equipped withloosening-resistant fittings, no safety catch is required.
6.4 Connecting to the water supply

► The fittings must be tightened according to manufacturer specifications!
► Lay the lines to the water connections provided and connect them according
to the circuit diagram.

99

6.5 Installing the electrical system
C Risk of injury when assembling under voltage!

AIf you fail to switch off the power supply before assembling the product,
you maysuffer injury, destroy the product or damage system
Ucomponents.
T
I
O
N
!
► Always switch off the power supply to the relevant system component before
assembling the product.
6.5.1 Earthing and potential equalization

Hydraulic power units from Bosch Rexroth are supplied with connection
for the external earthing system. Potential equalization within the
hydraulic power unit will only occur if the electrical wiring of the
components is included in the scope of delivery. If this is not the case,
potential equalization must be carried out by themachine manufacturer
when wiring the hydraulic power unit to the machine.
The hydraulic power units must be earthed!
The earthing line and the lines for the potential equalization must have the
minimumcross-section as per VDE regulations and a yellow-green sheath or
labeling.
► Before connecting the cables, you should earth the devices that are to be
connected and provide for potential equalization via a common equalizing bar.
6.5.2 Laying the power supply and control cables and connectingthe
electricity supply
► The electrical installation must be performed in accordance with the currently
applicable rules of electrical engineering.
► You must ensure that the power supply is disconnected and also safeguarded
against being switched on unintentionally.
► You should prevent this by e.g. using a warning sign to draw attention to
issues regarding working on the electrics.
6.5.3 Installing the electrical control and monitoring equipment

Connect the control and monitoring equipment (switching devices,
open-loop or closed-loop equipment or frequency converters)
according to the relevant instructions, taking into account the
appropriate safety precautions.

100

Commissioning
7 Commissioning
According to EC Machinery Directive 2006/42/EC, commissioning must not
be undertaken until it has been determined that the machinery into
which the hydraulic power unit is to be installed complies with the
provisions of all relevantguidelines/directives.
The combination of components may give rise to other types of
hazard. It istherefore essential that the information in the operating
instructions for the complete machine be observed.
This applies in particular to “Mechanical hazards” that may result from
mechanicalmovements of the machine initiated by the hydraulic power
units and drives (cylinders, motors).
WARNING! Risk of personal injury and damage to property!

If the hydraulic power unit is not assembled correctly, persons could be injured and
the power unit or system damaged while commissioning the hydraulic power unit.
► Ensure that the hydraulic power unit has been assembled correctly by
qualified personnel before commissioning.

Polluted oil can result in wear and malfunctions. In particular, foreign
bodies e.g. welding beads or metal swarf in the suction line may damage
the hydraulic powerunit.
CAUTION!
► When commissioning you should ensure absolute cleanliness.

► Ensure that no pollutants are able to penetrate when sealing the measuring
connections.
CAUTION! Risk of personal injury and damage to property from leaking oil!
Hydraulic fluid may leak out if the blanking plugs have not been
removed andthere is oil at the blanking plugs.
► Before commissioning, remove all plastic plugs and replace them with
pressure-resistant fittings/flanges.
CAUTION! Damaging the hydraulic power unit!

If you commission the hydraulic power unit either without oil or with insufficient oil,
the unit will be damaged.
► When commissioning or re-commissioning a machine or system, you should
ensure that the tank, as well as the suction and work lines of the hydraulic
power unit and the components are filled with oil according to the manufacturer's
specifications and that they remain filled with oil during operation.

101

Commissioning
7.1 First commissioning
7.1.1 Before commissioning

► Ensure that the line system is in good, work-safe condition.
► Open the taps in the cooling water line (if present).
► Open the taps in the suction line (if present).
► Open the pressure gauge air relief to prevent measuring errors
(change from “Closed” position to “Open”).
► Adjust the electrical level monitoring and/or temperature-measuring device
(if present) as required for operation of the machine.
7.1.2 Valve settings

► Set operating pressure valves and flow control valves to the lowest settings
possible.
► Bring directional valves into the basic position.
► Do not energize proportional valves to the command value.
Do not make any changes on sealed valves.
Do not change the factory settings. Do not set or adjust valves that,
accordingto the technical specifications (circuit diagram or parts list),
have been provided with a fixed factory setting.
7.1.3 Safe handling of pressure tapping points

When setting pressure valves the respective pressures must be
displayed. Thiscan be done by using fixed installed pressure gauges,
digital pressure displays or by connecting external measuring
equipment. To this purpose, measuring couplings have been installed
within the hydraulic power unit. As the measuringpoints can be
operated while under pressure, extreme caution is required!
W Risk of injury from inappropriate installation with system under pressure!

AMeasuring hoses have no blocking or closing function.
R
N
I
N
G
!
► Before connecting the measuring hose to the measuring coupling ensure that
the other end of the hose has been connected to the measuring equipment
(pressure gauge, pressure transducer) and that it is pressure-tight.

102

Commissioning
If the scope of delivery includes a measuring device that is connected

to bothmeasuring hose and coupling, the connection may only be
opened on the coupling side.
The following diagram (see Fig. 7) shows the position for safe separation
of themeasuring equipment from the pressurized measuring coupling of
the hydraulicpower unit.
Fig. 7: Position for safe separation of the measuring equipment (arrow)
WARNING! Risk of injury from inappropriate installation with system under pressure
Measuring connections may also be assembled with a hexagon bolt
fitting in thehydraulic power unit. These are not designed for assembly
under pressure.
► They should not be dismantled until the connected hydraulic circuit has been
depressurized.
7.1.4 Accumulator
If the hydraulic power unit includes accumulators, the instructions
applicable at the place of installation are to be complied with before
commissioning as well as during operation. “Product-specific Operating
Instructions” are supplied with eachaccumulator.
► You should ensure that these documents are kept together with the
accumulator. Experts will need these for subsequent inspections.
► On the oil side, the hydraulic power unit must be sealed tightly, bled (see
Chapter 7.1.7 “Bleeding the complete hydraulic system of the machine) and
depressurized.
► Fill the accumulator according to the information in the circuit diagram to the
prescribed pre-set gas pressure.
► The filling and measuring procedures are undertaken using a testing and filling
device (in this connection see “Product-specific operating instructions” for this
device).
Affix a label to the accumulator specifying the accumulator filling

pressure andnote this value in the circuit diagram. This will enable you
to perform a comparative control at a later date.
CAUTION! Filling with gas

Only nitrogen should be used as gas! (Nitrogen Class 4.0 purest; N2 99.99 vol. -%).
► The operator will have sole responsibility for complying with the inspection to
be carried out before commissioning as well as for subsequent inspections.

103

Commissioning
7.1.5 Filling the hydraulic system

Fill the hydraulic system with suitable oil as specified, proceeding as follows:
► When filling the hydraulic system you should ensure absolute cleanliness.
► If, after transport or storage, the hydraulic power unit is seen to be
contaminated, you should clean the filter inlets on the tank before opening.
► Under no circumstances should you remove filter screens at the filler neck
and/or the filter insert while filling.
► With longer transport or storage times, check the tank for any water present
and remove via the drain cock.
Recommendation: Experience has shown that the cleanliness class

requiredfor operation of the machine is already exceeded in the case of
new oils in theoriginal container.
If you wish to ensure that the cleanliness class is acceptable, use a
special filter unit for filling the hydraulic power unit if necessary, or
use a filter stationwith fine filter.
When filling the pump housing you should proceed as follows:
► For pumps with drain line, fill the housing with oil (see also “Product-specific
operating instructions”).
► Observe the maximum/minimum fluid levels, taking into consideration tank
volumes, line system, drives, etc.
7.1.6 Activating the electrical supply

See machine manufacturer’s operating instructions.
7.1.7 Bleeding the complete hydraulic system of the machine

See machine manufacturer’s operating instructions.
The hydraulic system should be bled at the hydraulic components at the
highestpoint.

104

Commissioning
7.1.8 Commissioning
The following steps are to be performed unless superordinate
commissioninginstructions applicable at machine level are to be
observed.
Risk of personal injury and damage to property

D
A
Commissioning will activate machine functions.
N
G
E
R
!
► Ensure that the existing safety devices are activated.
► Start the electric motor in inching mode. Check the direction of rotation.
► Flush the hydraulic system as described in Chapter 7.1.9.
► Operate the directional valves and extend and retract the actuators several
times. Repeat the bleeding processes. (Bleeding is ensured if there is no oil
foam in the tank, no jerky movements at the actuator and no abnormal noises).
► Operate the system at low pressure until the hydraulic power unit is
completely bled. Increase the load in steps.
► Observe the fluid level in the tank and refill if necessary.
► Monitor the operating temperature as it sets itself, if the machine has been in
full operation for several hours.
► Check the connection points for tightness, seal any leakage points; check the
connection points again for tightness after a few hours.
Commissioning problems The matrix for “Causes of faults and their consequences in hydraulic
power units”is available as a support mechanism in the systematic search
and/or localization of faults, (see Chapter 14).
7.1.9 Flushing the hydraulic system

Flushing the hydraulic system to attain a specified oil cleanliness class
preventsfaults and simultaneously increases the service life of the
components. After installing the hydraulic power unit into the machine
and/or after installing with
the hydraulic system, it must be ensured that the minimum requirements
are metwith respect to the cleanliness class of the components. Hydraulic
systems in general industrial applications require a cleanliness class of
20/18/15 according to ISO 4406, whereas hydraulic systems with servo
valves or control valves of higher quality demand a higher cleanliness
class e.g. 19/16/13.
You must take into consideration the cleanliness requirement

for thecomponents as specified on the manufacturers' data
sheets, when determining the flushing target.
Preparation:
Materials required Supply of replacement or flushing filter elements
If required: Supply of additional material for piping and hose assemblies for
establishing flushing and/or shorting links
Supply of flushing plates or directional valves
On a case-by-case basis: Flushing fluid (see following note)

105

Commissioning
Information on flushing fluid You can use the same medium as the one that is also to be used later
when operating the hydraulic system. When using another oil, this must
be compatiblewith the operating medium intended for use with the
hydraulic system, as well aswith the materials, particularly seals, used in
the hydraulic system. A maximum admissible residual amount of flushing
liquid in the operating medium
(e.g. 0.5 volume %) may be specified in certain circumstances (see
manufacturer’s specification); in this case, this has to be assured by
carefullydraining the flushing liquid before filling with the operating
medium.
For more complex hydraulic systems with ring and branch lines, the flushing
process must be planned in detail and undertaken with care.
This is imperative if piping within the system have been welded and
maybealso pickled.
The following statements assume that the flushing process is

undertaken usingthe hydraulic power unit described in these operating
instructions. When using a separate flushing unit, it is imperative to
observe the operating instructions pertaining to this unit!
For the flushing operation the hydraulic power unit must be brought to
operatingtemperature, if possible, and is to be operated with reduced
pressure settings. Remember either to deactivate any existing pressure
monitoring circuits for the flushing phase or to adjust them to the lower
Flushing temperature flushing pressures.
As far as the duration of flushing is concerned, no generalization can be made.
It is recommended that oil samples be taken at periodic intervals during the
flushing process and then analyzed for cleanliness. Suitable sampling points
include e.g. the return line downstream from any existing return line filter.
Flushing duration Depending on these results the decision then has to be made as to whether the
flushing operation shouldbe stopped (once the target cleanliness level has
been attained) or continued.
The operating pressure must only be set at the pressure valves

intended forthat purpose.
Never change the setting of sealed valves or valves with a fixed factory setting.
After completing the flushing process care should be taken to ensure that
the operating settings of the hydraulic power unit have been restored,
that any flushing connections have been dismantled and connection lines
sealed so as tobe pressure-tight. When replacing the flushing plates with
original valves, these are to be assembled according to manufacturer
specification.
After flushing

106

Commissioning
7.1.10 The most frequent errors during commissioning

The fluid tank is not being checked.
The system is being filled with unfiltered oil.
The fluid tank is not being checked.
Pressure relief valves are being set too close to the working pressure (closing
pressure difference is not being observed).
Pressure controllers of hydraulic pumps are being set higher than or equal to
that of the pressure relief valve.
Abnormal pump noises are not being observed (cavitation, leaky suction line,
too much air in the oil)
The switching hysteresis of pressure switches is not being considered in the
setting
Before commissioning, the hydraulic pump and hydraulic motor housings are
not being filled with oil
The settings are not being documented
During commissioning, uninvolved personnel are staying in the vicinity of the
machine
7.2 Re-commissioning after extended standstill

When re-commissioning the system after an extended standstill period, you
should proceed as follows:
► Check:
² the oil level
² the accumulator pressure on the gas side
² the tightness of the hydraulic components and the line system
► Perform switch-on procedures with increased caution.
► Bleed the hydraulic system.
► Observe the information in the operating instructions of the machine
manufacturer.

107

Operation
8 Operation
As partly completed machinery, the hydraulic power unit is intended for
installation into machinery.
Information on operating the hydraulic power unit can only be provided
in connection with the [complete] machine. For this information, please
refer to theoperating instructions of the machine manufacturer.
Information on the functional operation and logic of the hydraulic
power unitcan be obtained either from hydraulic experts or from the
product-specific documentation.

108

Operation
9 Maintenance
Bosch Rexroth offers a wide range of repair services for maintenance of
the hydraulic power unit. Please send any enquiry to your nearest Bosch
Rexroth service center or contact headquarters direct. For the addresses
please refer towww.boschrexroth.com.
Maintenance tasks (inspection, service, repair) must be defined in terms
of component-specific requirements, operating conditions (pressures,
temperatures,ambient conditions) and use (duty cycle, cycle times, shift
operation.
Please refer to the operating instructions of the machine manufacturer.
Within this framework, a visual inspection is to be undertaken to detect obvious
faults:
Incomprehensible notes or warning signs
Leaks
Loose and/or missing components
Indication of the application of external force
9.1 Maintenance documentation

It is recommended that the results of the inspections and the derived measures
required be documented,
² so that considering functionality and economy, the service intervals can be
adjusted to the actual operating conditions,
² as they offer the possibility of early fault recognition thanks to comparative
evaluation (preventive maintenance).
Any negative trend of the test parameters e.g. oil temperature,

replacement intervals of the filter elements or noise may be an
indication of changes. Thetroubleshooting matrix (see Chapter 14)
may provide help in minimizing this problem.
Gradual temperature increases and/or shorter filter replacement

intervals maybe an indication of possible wear at pumps, control
edges, seals and aging of the oil and means that an inspection should be
undertaken of all components under consideration.
An immediate high temperature increase is an alarm signal and

requires animmediate inspection of the machine.

109

Maintenance
9.2 Cleaning and care (maintenance)
Penetrating dirt and liquids will cause faults!

C
ASafe function of the hydraulic power unit/components is then no longer ensured.
U
T
I
O
N
!
► Always ensure absolute cleanliness when working on the hydraulic power unit.
C Damage to the surface from solvents and aggressive cleaning agents!

AAggressive detergents may damage the seals on the hydraulic power
unit andmake them age faster.
U
T
I
O
N
!
► Never use solvents or aggressive detergents.
C Damage to the hydraulic system and seals!

AThe water pressure of a high-pressure cleaner can damage the hydraulic
systemand seals of the hydraulic power unit.
U
T
I
O
N
!
► Do not use a high-pressure cleaner.

► Cover all openings with the appropriate protective devices in order to prevent
detergents from penetrating the hydraulic power unit.
► Check that all seals and electrical plug connections are firmly fitted to prevent
the penetration of detergents.
9.3 Inspection, maintenance, repair

Recommendations are based on the following: A Central European
climate andan environmental load as is usual in metal-processing
companies.
Before commencing the inspection, cleaning should be undertaken if necessary.

Always ensure cleanliness when working on the hydraulic power unit.
9.3.1 Filling level

The filling level should be checked at intervals of 8 operating hours.
While the hydraulic power unit is in operation, the oil level will not remain
Oil level constant.
Level changes result from the different volume requirements of plunger
and differential cylinder and/or the absorption/delivery of oil in
hydraulic accumulatorsduring a working cycle.
Due to the variable conditions mentioned above a complete working cycle
of the machine must be observed when undertaking the visual inspection
of the oil level.This will enable you to determine whether the oil needs to
be refilled or topped up,and if so, by how much.

110

During operation, the oil level must
neither exceed the upper mark nor fall Maintenance
belowthe lower mark. If the minimum
filling level is undershot, there is a risk
of pump failure due to cavitation.
If the maximum filling level is
exceeded, this may have been caused
by the thermal expansion of the oil
or by fluid entry (e.g. water in the
case of internalleaks of the oil/water
heat exchanger.

111

Maintenance
Fluid level indicator The hydraulic power unit can also be equipped with an electrical fluid
level indicator. The switching points can be seen from the technical
specification andthe circuit diagram.
Measures to be taken if the maximum filling level is exceeded:

Maintenenance, repair
Expansion due to temperature increase

(Approximate determination: Δ V = Thermal expansion coefficient x Δ T)
– Correcting the filling level
Exceeding the maximum filling level due to suspected water ingress
² Close the water valves (shut-off the cooling water supply)
² Draw an oil sample at the lowest point of the tank and check for water content
² If the suspected water ingress is confirmed, you should complete the machine
working cycle and then shut down safely.
² Repair the oil/water heat exchanger according to the manufacturer's
specifications or replace if necessary
² Perform more extensive control measures and implement the following
measures depending on these results:
Clean or drain and change the oil

Undertake a flushing process, if necessary
Check the oil for admissible water content
Measures to be taken if the minimum filling level is undershot:
CAUTION! Risk of personal injury and damage to property from oil loss!
An oil loss is always associated with leakage.
► First identify and remedy the actual cause of the leakage.
► Only then should you top up the oil to the correct level.
9.3.2 Oil temperature (optional)

The oil temperature should be checked at intervals of 8 operating hours.
The hydraulic power unit may be equipped with an optical thermometer or
electrical temperature-measuring device, depending on the order
specification. The switching points can be seen from the technical
specification and the circuit diagram.
Possible causes of Possible causes of a temperature increase include:

temperature increase Malfunctioning of the heat exchangers
A change in the cooling water conditions
Malfunctioning or incorrect setting of the pressure valves
(e.g. maximum pressure limitation, pump controller, pressure relief valve)
Malfunctioning of the heating system
Fault at the pump (wear, increased leakage)
A change in ambient conditions (e.g. increased ambient temperature)
A change in load conditions at the drives
In the case of an inadmissible temperature increase, the causes are to be

determined and rectified.

112

Maintenance
9.3.3 Filter clogging indicator (optional)

The contamination level of the filters should be checked at intervals of 8
operatinghours.
Bosch Rexroth filters will be used as standard.
With these filters, if the admissible back/differential pressure is
exceeded, anoptical signal is output, i.e. a red pin becomes visible.
After a cold start, the red pin on the filter clogging indicator is to be pushed
in afterthe operating temperature has been reached (check function). With
Cold start this control, if the pin jumps out again immediately, the filter element
must be replaced at the end of the shift at the latest.
In addition, the monitoring equipment may be electrical for evaluation at
control level. The switching points can be seen from the technical
specification and thecircuit diagram.
When using filters from other manufactures, different optical or
electrical filter clogging indicators may be installed. In individual cases
and depending on theorder specification, this control may have been
dispensed with.
You should be wary if the filter clogging indicator still does not
indicate that areplacement is necessary after several inspection
intervals. Of course, this may be an indication that the oil is clean. It
may, however, also be due to thefollowing reasons:
² The filter clogging indicator is defective.

² The filter element is defective.
² A bypass valve, if present, does not close properly
Maintenance, repair
(e.g. due to penetration of dirt particles).
Measures: Plan and carry out a filter replacement at the end of the shift.
If the intervals between necessary replacement of the filter elements become shorter,
the reason for the increased deposition of dirt is to be identified and remedied.
WARNING!
Risk of injury from falling parts!
Depending on filter size, the filter housings may be quite heavy.
► If necessary, ask a second person for help.
Before commencing the work, prepare receptacles for oil, as well as for filter
housing and filter element.
When dismantling and assembling the filter element, please refer to the operating
instructions of the filter manufacturer.
You should dispose of the filter elements according to the national or
operator-specific regulations.

113

Maintenance
9.3.4 Pressure values

The pressure values must be checked if the behavior of the drives
changes (e.g.cycle time extension, end product quality, etc). Otherwise,
one control at least every six months is recommended.
We recommend recording the pressure values within the scope
of themaintenance documentation.
Lead seals, e.g. on the accumulator safety valves provide information that
Lead seals the original pressure setting has not been changed. Without attaining the
set pressure,the sealed valves cannot be checked within the scope of a
normal inspection. The inspection here comprises a check to ensure the
lead seals are intact.
If the lead seals defective, contact the manufacturer.
9.3.5 Oil maintenance

An oil analysis should be performed at least once per year.
An oil analysis entails drawing a sample of oil in a professional
manner. The oil sample must be checked in a suitable laboratory in
accordance with the oilmanufacturer's specifications.
Depending on the result, it may be necessary to implement more measures, e.g.:
Maintenance, repair
Filtration (measures)
Dehydrogenation
Changing the oil
The use of recycled oil (recovered oil) is to be avoided.
► If the oil is changed, it must be drained completely (in this connection see also
Chapter 10.1 “Preparing for decommissioning”).
You must also ensure that the lines and actuators have been completely drained.
You may also have to carry out bleeding measures, if necessary.
As with the initial filling, the hydraulic system must be bled after each
subsequent refill.

114

Maintenance
9.3.6 Hydraulic accumulators
W Risk of personal injury and damage to property!

Accumulators are a potential source of hazards. Leaking pressurized
gas mayresult in serious injury or even death.
Particular care must be taken when working on hydraulic systems with
A
Raccumulators, as inappropriate behavior may result in serious injury.
N
I
N
G
!
► Never perform welding or soldering work or any mechanical processing on

accumulators!
Risk of personal injury and damage to property!

If air or oxygen is used as an accumulator medium, there is a high risk of
explosion!If uncleaned gases are used, the contaminating substances
contained therein or
W the water content may lead to unforeseeable and uncontrollable behavior of the
Adevice.
R
N
I
N
G
!
► Only use nitrogen as gas in the accumulator

(Nitrogen Class 4.0 purest; N2: 99.99 Vol-%)!

AWhen draining the nitrogen from the accumulator, the atmospheric
oxygen will bedisplaced. In very small rooms, this may result in fainting or
Reven suffocation.
N
I
N
G
!
► Before discharging the nitrogen accumulator pressure, the doors and windows
of the room in which the accumulator is located must be opened.

AThe draining of the nitrogen from the accumulator may result in an
excessiveincrease in pressure.
R
N
I
N
G
!
► Before discharging the nitrogen accumulator pressure, the doors and windows
of the room in which the accumulator is located must be opened.
There are legally prescribed inspections for accumulators, which have to be

undertaken at defined intervals. This is the responsibility of the operator.

115

In order for the accumulator to function as intended, the gas pre-charge is to be
Maintenance
checked periodically according to the information in the circuit diagram.
Risk of injury!
Due to the fast discharge of the gas pressure, the components and
component parts affected will be subjected to extreme cooling. In extreme
cases, contact withunprotected skin may even result in supercooling in the
form of burns!
C
A
U
T
I
O
N
!
► You should wear thermal gloves and avoid contact with the supercooled
components. Wait for a reasonable period of time until the supercooled
components have reached ambient temperature once more!

116

Maintenance
Regarding the maintenance of hydraulic accumulators, you should

observe the relevant stipulations of ISO 4413 (Chapter 7.3.2.2) in its
current version, as well as those in the operating instructions of the
accumulator manufacturer.
Gas filling pressure The essential maintenance required for hydraulic accumulators
entails theverification and setting of the gas filling pressure.
To this purpose, only those testing and filling devices and procedures
may beused, which are recommended by the manufacturer for filling
accumulators.
Please note that the gas filling pressure must be selected according to
the gastemperature.
In this connection, it must be ensured that the admissible accumulator
pressure isnot exceeded. Ensure that the gas valve is securely closed after
each inspection or adjustment.
Before dismantling hydraulic accumulators, the liquid pressure in the accumulator

Dismantling from the system must be reduced to ambient pressure (i.e. be in a depressurized condition).
Service, maintenance and/or replacement of hydraulic accumulator
componentsmay only be carried out by sufficiently trained personnel
Maintenance instructions for (see Chapter 2.6 “Obligations of the operator”) on the basis of written
hydraulic accumulators instructions and by using parts and materials, the manufacture of which
has been certified as being in accordance with current specifications.
Before dismantling an accumulator, it must be completely depressurized on

both the liquid and the gas side.
9.3.7 Hose assemblies and compensators

Hose assemblies and compensators consist of an elastic part
(hose/diaphragm)and fittings mounted on both sides.
Optional components • Hose assemblies are optionally available with:

Abrasion protection (only apply at the places where there really is abrasion)
Hose safety catch
Splash guard (also possible with hose safety catch)
Fire protection (only possible with hose safety catch)
Hose assemblies and compensators are components requiring

constantmonitoring.

117

Maintenance
Maintenance, repair ► They should be replaced if one of the following conditions is determined
during inspection:
Damage of the outer layer down to the core
(e.g. abrasion points, cuts or cracks).
Visible traces of overheating, fire: Carbonization, blistering or fouling due to
partial heat impact (hot spots).
Embrittlement of the outer layer (formation of cracks in the elastic part).
Deformation not corresponding to the original shape of the components in both
depressurized and pressurized condition.
Leaks.
Damage or deformation of the fitting (sealing function impaired).
Corrosion of the fitting reducing function and stability.
Hose working loose from the fitting.
Storage time and service life exceeded.
9.3.8 Piping
The piping consists of the pipes and the connection
elements.Connection types:
Form-type fitting
Flare-type fitting
Welded conical fitting
Compression joint
Flange connection
The piping must be checked at least once every six months (or more
frequentlydepending on operating conditions and use).
In order to allow for a visual inspection, prior cleaning may be required.
There is an inspection for:
Corrosion
Crack formation
Leaks
Indication of the application of external force
Maintenance, repair In the case of leaks at fittings, the latter are to be re-tightened once and
this then recorded. If there are still leaks at these fittings, these must be
carefully checked for the cause of the leakage. Depending on the findings,
the seals mayneed to be renewed and/or the fitting replaced with a pipe
section. In the case ofleaks at flanges, you should proceed in a similar
manner.
In the case of crack formation or leaks at welded seams, the cause has to
be determined and remedied. Afterwards, the components concerned are to be
replaced or repaired in a professional manner.
If there are signs of an application of external force the cause must be
determined and remedied. Afterwards, the component and also adjacent
pressurized components are to be checked for damage and assessed with
respect to further reliable use. If necessary, these components are to be
replacedor repaired in a professional manner.
If there are signs of corrosion the component is to be checked for
damage andassessed with respect to further reliable use. If necessary, this
component is to be replaced or repaired in a professional manner. You
must in all cases provide for corrosion protection.

118

Maintenance
9.3.9 Heat exchanger

The following may be installed, depending on the order:
Oil-vacuum heat exchangers
Oil-water heat exchangers
In case of reduced cooling power If the cooling power of the heat exchanger is reduced, you should follow the
manufacturer's operating instructions.
When using water filters in the cooling water circuit, the water filter elements are
to be checked at least once every six months and cleaned if necessary.
When using oil-vacuum heat exchangers, the lamellae must be checked regularly
for contamination and cleaned if necessary.
9.3.10 External inspection of tanks and steel components

The external inspection is a visual one and must be undertaken at least
once every six months (or more frequently depending on operating
conditions and use).
In order to allow for a visual inspection, prior cleaning may be required.
Visual inspection There is a visual inspection for:
Leaks
Crack formation
Corrosion
Dents due to the application of external force
Maintenance, repair In the case of leaks at components screwed into the tank the latter are
to be re-tightened once and this then recorded. If there are still leaks at
this point, the contact point must be carefully checked for the cause of the
leakage. Depending on the result, seals are to be renewed and/or the
component replaced. In the caseof leaks at flange-mounted components,
you should proceed in a similar manner.
In the case of crack formation or leaks at welded seams, the cause must be
determined and remedied. Afterwards, the components concerned are to be
replaced or repaired in a professional manner.
If there are signs of an application of external force the cause must be
determined and remedied. Afterwards, the component and also adjacent
components are to be checked for damage and assessed with respect to
furtherreliable use. If necessary, these components are to be replaced or
repaired in aprofessional manner.
If there are signs of an application of external force on the tank, an internal

inspection of the tank should be undertaken.
If there are signs of corrosion the component is to be checked for

damage andassessed with respect to further reliable use. If necessary, this
component is to be replaced or repaired in a professional manner. You
must in all cases provide for corrosion protection.

119

Maintenance
9.3.11 Internal inspection of the tank

The internal inspection is a visual inspection of the tank on the inside and
is generally performed when the oil is changed. Oil change will depend on
the resultof oil samples taken.
In order to perform the visual inspection, you must first of all completely
drain the oil (in this connection see also Chapter 10.1 “Preparing for
decommissioning”). Ifthere is any contamination, internal cleaning must
also be carried out.
There is a visual inspection/inspection for:
Corrosion
Crack formation
Foreign bodies
In the case of screw connections, you must ensure that they are sitting correctly
Particular characteristics with walk-in tanks

Prerequisite: The inspector must not suffer from claustrophobia and
must bephysically fit enough to move around in a confined space!
Recommendation: Before commencing the work inside a tank, you should inform the
fire department and/or a first aider/paramedic or ensure that they are on standby.
If the inspector has to move his whole body completely into the oil tank, he must be
suitably harnessed and secured by at least a second person outside the oil tank.
Preparation
Preparation
For his own safety, the inspector must:
Prepare a means of rescue before entering the tank,
Take off watch and jewelry,
Wear a cap or a hair net,
Wear protective clothing (tight-fitting overall with zips and no outside pockets),
A lamp suitable for explosive atmospheres must be used

There is a risk of suffocation inside tanks.
The breathable air in a tank must contain sufficient oxygen for it to
remainbreathable for the relevant personnel without posing any
D risks.
A
N
G
E
R
!
► Before entering the tank, open all manholes and access openings.
► Ensure sufficient ventilation with breathable air, if necessary by means of
forced ventilation.
Maintenance, repair In the case of crack formation at welded seams, the cause must be
determinedand remedied. Afterwards, the welded seams concerned are to
be repaired in a professional manner.
If foreign bodies are detected they are to be removed from the tank. Their
originand the cause of their presence must be established. Depending on
the cause established, suitable measures must be introduced to ensure
safe operation of the hydraulic power unit.
If there are signs of corrosion the location concerned is to be checked
for damage and assessed with respect to further reliable use. If
necessary, the tankmust be replaced or repaired professionally. You
must in all cases provide for medium-resistant corrosion protection.
If piping and hose fittings are loose the former must be tightened professionally.
If screw connections are loose the parts to be secured must sit correctly and
the screw connection tightened professionally.

120

Maintenance
9.4 Spare and wear parts
Risk of personal injury and damage to property due to the use of incorrect
spare parts!
Spare parts not complying with the ones listed in the product-specific
documentation may cause mechanical hazards or malfunctioning of the
WARNING! machine.
► Only use components listed in the product-specific documentation (parts list).

► Only use new seals with the required resistance to media.
► As the sealing material may differ despite being of identical appearance, the
material number should be checked.
Please send your spare part orders to your nearest Bosch Rexroth service
centeror directly to the headquarters. For the addresses, please refer to
www.boschrexroth.com.
Ordering spare parts ► Spare parts should be ordered in writing. In urgent cases you can also order by
phone, but you are kindly requested to confirm your order in writing e.g. by fax.
► Please provide the following information when ordering spare parts:
² Material number and order number of the hydraulic power unit (nameplate)
² Material number of the respective component
² Required quantity
► The required type of dispatch (e.g. as parcel, freight, air freight, by courier etc.).

121

43
10 Decommissioning
10.1 Preparing for decommissioning

You must provide a collecting tank that is large enough to accommodate
the totaloil volume.
The total volume of the hydraulic power unit comprises the volumes of
the tank,the line system, the drives, etc.
As a basic principle you should observe the related instructions for the
Ensuring safety complete machine. Unless otherwise specified in these operating
instructions, you shouldcomplete the following steps:
► Avoid dangers caused by adjacent machines.
► Do not allow uninvolved persons to remain in the area concerned.
► Loads should be lowered or safely supported
10.2 Decommissioning the hydraulic power unit

► Switch off the electrical power and ensure that it cannot be switched on (short-
circuit - bridge the supply side)
► Switch off and secure the hydraulic pressure supply.
► Depressurize the accumulator on the oil side
► Drain the oil into the collecting tank provided. In this connection, ensure
complete draining of the lines and actuators. If necessary, carry out bleeding
measures.
► Decommission the machine as described in the overall machine instructions.

122

44
11 Disassembly
Only disassemble the component parts as far as is necessary to

undertakethe required work. As a basic principle, all disassembled
parts should be professionally reassembled at the intended place.
11.1 Preparing for disassembly
Serious injury due to the hydraulic power unit falling over or from
D
uncontrolled movements!
A
N
G
E
R
!
► Ensure sufficient stability of the hydraulic power unit.

► Regarding the question as to whether the stability is sufficient, please refer to
the product-specific documentation.
► Only loosen the fixings of the hydraulic power unit, if applicable, if stability has
been ensured in another way.
Serious injury or even death when undertaking the disassembly under

pressure and with electrical voltage applied!
If the hydraulic system is not depressurized, high-pressure oil will leak
while dismantling. If the electrical voltage of the system is not switched
off, there is arisk of electric shock.
D
A
N
G
E
R
!
► Ensure that the relevant parts of the hydraulic system are depressurized and
de-energized.
Serious injury due to the hydraulic power unit falling over or from
uncontrolled movements!
When the unit is full, movements of the oil will cause displacement of the
center ofgravity, which may result in the hydraulic power unit losing its
stability.
D
A
N
G
E
R
!
► Before dismantling, drain the oil from the hydraulic power unit as described in
Chapter 10. “Decommissioning”.

After a longer period of use, the attachment points may no longer be in place, or
sufficiently stable or no longer identifiable as such more.
WARNING!
► Refer to the product-specific documentation for the intended attachment

points and only use the ones mentioned there.

123

► Check the stability of the attachment points if you intend transporting the
hydraulic power unit after dismantling. 45
tighten fully.
► If necessary, mark the unrecognizable attachment points using easily visible
color.

124

Disassembly
Ensuring safety:
As a basic principle you should observe the related instructions for the
completemachine. Unless otherwise specified in these instructions,
complete the following steps:
► Complete the decommissioning as described in Chapter 10 of these
operating instructions.
► Do not allow uninvolved persons to remain in the area concerned.
11.2 Disassembling the hydraulic power unit

► When disassembling you should perform the work steps described in
Chapter 6 “Assembly” but in reverse order.
Residual oil flow ► Despite prior draining of the oil, some oil will still seep out of the hydraulic line
system of the hydraulic power unit and/or the hydraulic system. All line outlets
should therefore be closed using suitable plugs.
After disassembly is complete, you should observe the information in

Chapter 5 regarding safe transportation of the product.

125

Disassembly
12 Disposal
Careless disposal of the hydraulic power unit, its components and the oil can lead
to pollution of the environment. Please therefore observe the following points:
► Dispose of the product/components in accordance with the national
regulations in your country and/or your company-internal specifications.
► Dispose of oil according to the currently applicable safety data sheets.

126

Extension and conversion
13 Extension and conversion

You will be considered responsible for any extensions to or
conversions of theproduct.
If you undertake any extensions to or conversions of the product
Declarations become invalid marketed by Bosch Rexroth, this means you are changing the condition of
the product as supplied. Any statements made by Bosch Rexroth regarding
this product will thenbecome invalid.
For hydraulic power units this means the following:
Hydraulic power units are partly completed machinery in terms of

EC Machinery Directive 2006/42/EC. Together with the product-
specific documentation, you have received a declaration of
incorporation for these products. In the case of extension to or
conversion of the hydraulic power unit,this declaration will become
invalid.
Please send any queries you may have to your nearest Bosch Rexroth
servicecenter or directly to the headquarters. For the addresses, please
refer to www.boschrexroth.com.

127

Extension and conversion
14 Troubleshooting

D
DependingA on the system, troubleshooting may give rise to a wide range of
potentialNhazards.
G
E
R
!
► Troubleshooting must only be undertaken when the safety equipment is active!

► You must proceed with extreme caution if you have to deactivate this safety
equipment in order to search for errors/faults. If possible, you should operate the
machine in set-up mode with reduced performance data when identifying faults!
Successful troubleshooting within a hydraulic power unit requires precise

knowledge of the set-up and the mode of operation of the individual
components.The combination of hydraulic and electrical systems and
electronics makes the troubleshooting even more complex.
For effective troubleshooting, the circuit diagrams (hydraulic and
electrical, if applicable), parts lists, any functional diagrams and other
documents must beavailable.
14.1 How to proceed with troubleshooting

► Always work systematically and focused, even when under time pressure.
Random and imprudent disassembly and readjustment of settings can, in the
worst-case scenario, result in the inability to determine the original cause of
the fault.
► You should first get a general idea of how the hydraulic power unit works in
conjunction with the entire system.
► Try to establish whether the hydraulic power unit was working properly in
conjunction with the entire system before the problem first occurred.
► Try to determine any changes within the entire system into which the hydraulic
power unit is integrated:
Control questions Were any changes made to the operating conditions or operating range of the
hydraulic power unit?
Were any changes or repair work undertaken on the entire system (machine/
system, electrics, control) or on the hydraulic power unit?
If so: What were they?
Was the hydraulic power unit or machine used as intended ?
How did the malfunction become apparent?
► Try to get a clear idea of the cause of the fault.

If necessary, ask the actual (machine) operator

128

Troubleshooting
14.1.1 Overview of the impact of defects

The following tables contain errors/faults and their consequences, the
causes ofwhich are not exclusively attributable to the hydraulic power
unit. The listed errorsources, possible causes and remedies refer
exclusively to the hydraulic power unit. You will also frequently have to
look at the control system or connection technology when seeking the
causes of faults.
The following list is meant as an aid, but does not claim to be comprehensive.
Tabular classification of the impact of defects:
“A” Excessive / abnormal noises
“B” Insufficient power / torque / pressure in the drives
“C” Irregular drive movements (pressure and volume
fluctuations)“D” Operating or oil temperature too high
“E” Contaminated oil
Table 3: Impact of defect “A”: Excessive / abnormal noises
Malfunction Possible causes Remedy

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Ǥ
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Ͷ ǡǡ

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ȋȌ Ǥ

129

Troubleshooting
Table 4: Impact of defect “B”: Insufficient power, torque or pressure at the drives
Fault Possible causes Remedy
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Table 5: Impact of defect “C”: The pump is switched on or off too frequently
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ǡǦ

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Table 6: Impact of defect “D”: Oil temperature too high

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130

Troubleshooting
Table 7: Impact of defect “E”: Contaminated oil

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131

Appendix
15 Technical data
Please refer to the product-specific documentation for the technical
data of theproduct.

132

Appendix
16 Appendix
16.1 Address directory

Please refer to www.boschrexroth.com for addresses of foreign subsidiaries

133

Glossary
17 Glossary
Assembly
An assembly comprises two or more components and/or assemblies
that arepreassembled in a suitable form (also see hydraulic
assembly).
Attachment points
Attachment points are fixtures in the form of lugs that are connected to
the load by means of welded or screw connections. They are used to lift or
secure the loadduring transport.
Attachment devices
Attachment devices are separate devices used to bridge the connection
betweena crane and a load in order to lift the latter. Attachment devices
are e.g. lifting straps, belts or chains.
Component
Any part with a (partial) function in the sense of the technical overall
system.Components in the hydraulic system include e.g. valves,
filters, cylinders, hydraulic connection elements.
Danger
Potentially occurring event having a detrimental impact on life and/or body.
Danger area, hazard area
Any area in a machine and/or around a machine, in which a person may be
exposed to a hazardous situation.
Decommissioning
Preparation for an extended standstill of the device/system with the
options forre-commissioning or disassembly.
Drive (actuator), hydraulic
Component converting the hydraulic energy of the oil into mechanical energy
(e.g. hydraulic motors, cylinders).
Extended standstill
e.g. shutdown for several weeks
Floor conveyors
Floor conveyors are means of transport for the horizontal transport that
are mostlyused within the company at ground level.
Hazard
Potential source of damage
Hydraulic accumulator
Gas pressure tank: Bladder-type accumulator, diaphragm-type accumulator and
piston-type accumulator
Hydraulic assembly
Hydraulic assemblies include e.g. valve stands, accumulator stations,
drive-motorhydraulic pump unit, circulation stations for filtration and/or
cooling.
Hydraulic assemblies are not covered by the scope of EC Machinery
Directive2006/42/EC and therefore do not constitute partly completed
machinery.
Hydraulic fluid
Generally valid designation for hydraulic fluids in hydraulic systems; in these
operating instructions, the term “oil” is used in line with actual practice.
Hydraulic power unit
A hydraulic power unit is the drive system for hydraulic machines.
The hydraulic power unit constitutes partly completed machinery in
terms of the EC Machinery Directive 2006/42/EC. Drives are explicitly
not regarded ascomponents of the hydraulic power unit.

134

Glossary
Hydraulic system
The term “hydraulic system” describes a combination of hydraulic power
units, assemblies or components that are only set up and connected
hydraulically at theplace of use.
A hydraulic system is basically part of a machine. A hydraulic system
itself,however, does not constitute a machine.
Hydraulics (Fluid technology)
Transfer, control and distribution of energy using a pressurized, fluid medium.
Injury
Physical injury or damage to health
Leak
A leak is the unwanted outflow of any liquid from the closed hydraulic line system
and/or the pressurized components, which is sufficient to form a drop.
Lifting tool
Devices and equipment for lifting loads, e.g. bridge cranes, gantry cranes, winches.
Line system
Any combination of lines (hoses, piping or bores) and hydraulic
connection elements allowing for the intended flow of the oil between
tanks, pumps, valves,accumulators, actuators, filters, etc.
Machinery
“Machinery” is “an assembly of linked parts or components, at least one of which
moves, joined together for a specific application.”
For the complete definition of the term “machinery”, please refer to EC Machinery
Directive 2006/42/EC.
Maximum operating pressure
The maximum pressure with which the hydraulic system or parts of the
systemmay be operated under uniform (constant) conditions.
Nominal pressure
Nominal pressure is a certain pressure value assigned to a
component, a hydraulic line system or a hydraulic system as
designation, specifying that itbelongs to a certain pressure level.
Oil
Generally valid designation for hydraulic media in hydraulic systems; in these
operating instructions, the term “oil” is used in the practical sense.
Partly completed machinery
Definition taken from the EC Machinery Directive 2006/42/EC:
“Partly completed machinery” is an “assembly which is almost machinery but which
cannot in itself perform a specific application. A drive system is partly completed
machinery. Partly completed machinery is only intended to be incorporated
into or assembled with other machinery or other partly completed machinery or
equipment, thereby forming machinery to which this Directive applies.”
Pressure
Physical unit: Force per unit area [N / m2= Pascal]; [1 bar = 100 kPa]

135

Glossary
Product-specific documentation
The product-specific documentation complements the “General
operating instructions for hydraulic power units and hydraulic
assemblies” (this document)by adding specific information pertaining to
your product.
The product-specific documentation consists of:
Technical specification: Description of the operating conditions and information
on the installation into the machinery
Hydraulic diagram: Function(s) and logic mode of operation of the product
Component list to the hydraulic diagram
Assembly drawing: Structural design, dimensions, information regarding the
center of gravity, connections, etc.
Safety equipment
Safety equipment means components of machinery that serve the
protection ofhuman beings from all potential dangers resulting from the
machine.
System
In this document, the term “system” in terms of the EC Machinery Directive
2006/24/EC is used synonymously with the term “machine”.
Tank
The component in a hydraulic system that collects all the oil during
operation andstandstill. It is not used for storing hydraulic energy.

136

Glossary

137

Glossary

138

Glossary

139
Bosch Rexroth AG
Industrial Hydraulics
Zum Eisengießer 1
97816 Lohr am Main
Germany
Phone +49 (9352) 18-0

Fax +49 (9352) 18-40
documentation@boschrexroth.de
www.boschrexroth.de

140

11.3 Equipment Data Sheets

141

142
A.2 Motor

143
A.2.1 Ausenco Document No. V-10496302-0002-0083

Outline Dimensions
Certified Final
6 Dec 2020
1000656664 Rev: 01
FLSmidth NO.
106251-00-FLS-EL-SCH-007_A

144
A.2.2 Specification Table

Ausenco Document No. V-10496302-0002-0088
106251-00-FLS-EL-SPE-001_A
FLSmidth NO. 1000656657
Certified Final
6 Dec 2020

145
Specification Table (Sheet 2)
Certified Final
6 Dec 2020

146
A.2.3 Load Characteristic Curve

106251-00-FLS-EL-DSH-002_A Ausenco Document No. V-10496302-0002-0079
Certified Final
6 Dec 2020
FLSmidth NO. 1000656662 Rev: 01

147
A.2.4 Thermal Limit Curves

106251-00-FLS-EL-DSH-003_A
Ausenco Document No. Certified Final
V-10496302-0002-0080 6 Dec 2020

148
A.2.5 T-N & I-N Curve
1000656661 Rev: 01
Certified Final
6 Dec 2020
FLSmidth NO.
106251-00-FLS-EL-DSH-001_A

149
A.2.6 Thermistor Wiring Diagram

Certified Final
6 Dec 2020
1000656658 Rev: 01
106251-00-FLS-EL-WIR-001_A
FLSmidth NO.

150
A.2.7 6 Leads Schematic

106251-00-FLS-EL-SCH-005_A Ausenco Document No. V-10496302-0002-0081
Certified Final
6 Dec 2020

151
A.2.8 Base Plate Schematic

1000656668 Rev: 01
Certified Final
6 Dec 2020
FLSmidth NO.
106251-00-FLS-EL-SCH-011_A

152
A.2.9 Space Heater Schematic

106251-00-FLS-EL-SCH-006_A Ausenco Document No. V-10496302-0002-0082
Certified Final
6 Dec 2020

153
A.2.10 Terminal Box Schematic

1000656665 Rev: 01
Certified Final6 Dec 2020
FLSmidth NO.
106251-00-FLS-EL-SCH-008_A

154
Terminal Box Schematic (Sheet 2)

1000656666 Rev: 01
Certified Final
6 Dec 2020
FLSmidth NO.
106251-00-FLS-EL-SCH-009_A

155
Ausenco Document No. V-10496302-0002-0086 Terminal Box Schematic (Sheet 3)
1000656667 Rev: 01
Certified Final
6 Dec 2020
FLSmidth NO.
106251-00-FLS-EL-SCH-010_A

156
A.2.11 Instruction Manual
TECO Instruction Manual
Squirrel Cage Induction Motors
Whilst Motors are installed awaiting commissioning they must be adequately

protected against the elements, all external components in particular the shaft
extension and external labyrinth seals at the drive end must be fully covered
to avoid water ingress entering the motor body whilst stationery.
Please ensure that both the non drive end and drive end antifriction bearings
are fully purged with sufficient grease at first start up/commissioning
with the recommended grade and quantity of grease.

157
Instruction Manual (Sheet 2)
Teco Installation and Maintenance Manual

TEFC Squirrel Cage Induction Motors
TECO Electric & Machinery Co. Ltd.

Table of Contents
Table of Contents ................................................................................................ 2
Chapter 1: MOTOR DESCRIPTION .................................................................... 4
Chapter 2: TECHNICAL DATA............................................................................ 5
Chapter 3: INSTALLATION AND COMMISSIONING .......................................... 6

3.1. INSPECTION UPON RECEIPT. ...............................................................6
3.2. STORAGE ............................................................................................6
3.3. TRANSPORTATION ..............................................................................9
3.4. INSTALLATION. ................................................................................. 10
3.5. MOUNTING. ...................................................................................... 10
3.6. COUPLING & ALIGNMENT. ................................................................. 10
3.7. INSTALLATION FOR BELT DRIVE ........................................................ 13
3.8. ELECTRICAL CONNECTIONS ............................................................... 13
3.9. AUXILIARY DEVICES .......................................................................... 15
Chapter 4: OPERATING INSTRUCTIONS......................................................... 17

4.1. EXAMINATION BEFORE START. .......................................................... 17
4.2. STARTING OPERATION. ..................................................................... 19
4.3. CAUTIONARY POINTS TO NOTE: ........................................................ 21
Chapter 5: ROUTINE MAINTENANCE ................................................................ 23

5.1. IMPORTANCE OF DAILY INSPECTION.................................................. 23
5.2. POINTS TO NOTE WHEN STARTING.................................................... 23
5.3. TEMPERATURE RISE. ......................................................................... 23
5.4. VIBRATION. ...................................................................................... 24
5.5. NOISE. ............................................................................................. 25
5.6. ODOUR. ............................................................................................ 26
5.7. MEASUREMENT OF THREE PHASE CURRENT. ...................................... 26
5.8. MOTOR APPEARANCE. ....................................................................... 27
Chapter 6: PERIODIC MAINTENANCE ............................................................ 28

6.1. REGULAR INSPECTION & MAINTENANCE. ........................................... 28
6.2. CLEANING OF COILS, DRYING & VARNISHING TREATMENT. ................ 31
Teco Electric and Machinery Company 2
Manual Number: IOM ~ TEFC Rev.01

158

6.3. VARNISH. ......................................................................................... 33
6.4. KEY POINTS FOR MAINTENANCE & INITIAL OPERATION INSPECTION AFTER
LONG STORAGE. ............................................................................... 33
6.5. RECORDS OF OPERATION AND MAINTENANCE. ................................... 35
6.6. POINTS TO NOTE ON DISASSEMBLY. .................................................. 36
Chapter 7: BEARINGS ..................................................................................... 37

7.1. MAINTENANCE OF ROLLING BEARING. ............................................... 37
7.2. NOISE OF BEARING. .......................................................................... 42
7.3. VIBRATION. ...................................................................................... 42
7.4. REGULAR INSPECTION. ..................................................................... 42
Chapter 8: Troubleshooting. ........................................................................... 44

8.1. FAULT FINDING & RECOGNITION ....................................................... 44


159

Chapter 1: MOTOR DESCRIPTION

This manual applies to Teco model series types as follows:
AEEB, AEVB, AEHB, AEMB, AEUB, AEHD, AEJE, AFJE, AEJU, AEJH and AFJH.
The motors are of Cast Iron Construction, Totally Enclosed Fan Cooled, Squirrel
Cage Induction type designed for operation on a 415/1000/3,300/6,600V/ 3 Phase
50Hz supply system equipped with grease lubricated anti friction type bearings.
SAFETY WARNING
The following instruction address the more common situations
encountered in motor installation, operation and maintenance. For the
TECO warranty to remain valid, the motor must be installed and
operated in strict accordance with the outline drawing, motor nameplate
and these instructions and must not be altered or modified in any
unauthorized manner.
During the installation & operation of motors in heavy industrial
applications there is a danger of live electrical parts and rotating parts.
Therefore to prevent injury and/or damage the basic planning work for
transport, assembly, installation & operation needs to be carried out by
authorized and competent personnel. Points in this manual that are
boxed and headed “DANGER”, “CAUTION” or “NOTE"(see below) should
be observed as they indicate possible danger to personnel and/or the
potential of equipment damage.
This prompt is used when there is an immediate hazard that WILL

result in severe personal injury or death if correct procedures are not
followed.
This prompt is used to warn against potentially unsafe practices that

COULD result in personal injury and/or property damage if correct
procedures are not followed.
This prompt is used when an operation, condition, or information is of

sufficient importance to warrant highlighting


160

Chapter 2: TECHNICAL DATA

This manual covers a power outputs ranging through to 1500kW with varying
frame sizes and speeds etc.
For motor technical data refer to appropriate motor data sheet.


161

Chapter 3: INSTALLATION AND COMMISSIONING
3.1. INSPECTION UPON RECEIPT.

Check the following points upon receipt:
a. Is the nameplate rating identical to your order?
b. Do dimensions and colour comply with your specification?
c. Are the nameplate ratings for the heater, temperature detector etc.
identical with what you ordered?
d. Is there any damage due to transportation?
e. Is the original transportation shaft lock fitted to the drive end shaft?
f. Are all accessories in good order?
g. If there are any specific requirements, please check if they conform with
your specification.
3.2. STORAGE
When storing motor, the following procedures should be undertaken.
3.2.1. Place.
a. It should be dry, well-ventilated and not subject to direct sunlight, dust or
corrosive gas.
b. It should not be located close to a boiler or freezer.
c. It should be entirely free from vibration and have easy access.
d. Motor should be stored on pallets to prevent moisture ingress.
3.2.2. During storage, the insulation resistance should be kept above the specified
values as follows:-
a. Stator: Above 50MΩ measured with 1000VDC megger.
b. If the motor has absorbed moisture as evidenced by low insulation
resistance, it must be dried with external heat until it is thoroughly dry and
the value of insulation resistance exceeds the minimum requirements.
c. Measurement of insulation resistance should be performed once every
month.
d. Anti-condensation heaters should always be connected where fitted.

162

3.2.3 Insulation resistance test should be performed before making high voltage
test.
a. Use 500VDC megger to measure insulation resistance.
i. Stator: Over 50MΩ between windings.
ii. Stator: Over 50MΩ between windings and earth.
b. High Voltage Test
i.This test can be undertaken only after the values of insulation resistance in
item 3.2.3 (a) are assured.
ii. The value of testing voltage is (1000 + 2E) X 0.8 where E: rated voltage.
3.2.4. Care should be taken to keep parts such as the fitting surface, key, shaft
extension and axial centre hole free of any foreign matter. Grease should
also be generously applied to stop rust.
3.2.5. The shaft should also be rotated by hand a few revolutions once per month.
3.2.6. If practical, a test run should be performed once every three months.
3.2.7. Clean the motor thoroughly, and replenish grease before the machine is put
back to operation.
3.2.8. The ventilation system should be covered to avoid the entry of foreign
matter or insects. It should be thoroughly cleaned before use.
3.2.9. Make sure the hoisting hook is correctly connected to eye bolts or lugs of
motors before hoisting.
Parts such
h as fan
f cowl,
l terminal
i l boxes,
b etc. which
hi h h
have their
h
own lifting facilities can only carry their own weight.
They should not be used for lifting the entire motor.


163

An accident could occur if the motor eyebolt/lifting hook is overloaded.

They are suitable for the motor weights only.
Do not lift motor and load combined with motor lifting hook.
3.2.10. Points to note when hoisting:

a. Do not twist steel wires.
b. Make sure eye bolts have been firmly screwed in.
c. Keep the sling vertical when moving/lifting motor.
Fig. 1
Please keep the sling vertical when lifting / moving the motor.
Fig. 2
Motor is fitted with lifting points (arrowed). These points are designed to lift
motor weight only.
Teco Electric and Do
Machinery
not use Company
other hooks or handles to lift motor. 8

164

3.3. TRANSPORTATION
To keep the rotating parts of motor from moving, thus causing damage
during Transportation, they should be held securely as follows:
3.3.1. Motors fitted with a retaining plate/bracket to secure the shaft must have it
fitted during transportation. Please retain this device for future
transportation of the motor.
3.3.2. After receiving motor, remove all securing studs, nuts, etc. before putting
motor into operation. (Fig.3)
Fig 3
Shaft Locks are fitted as standard and these should be fitted during
installation and should only be removed once the pulleys and guards are
ready to be fitted. The motor must not be transported without the shaft lock
fitted, damage to bearings caused by shaft locks being removed or moisture
ingress whilst awaiting commissioning is not covered under motor warranty.


165

3.4. INSTALLATION.
3.4.1. Site conditions for motor installation:

Standard site conditions for installation of motors are as follows:
a. Ambient temperature: -200C~400C.
b. Humidity: Relative humidity below 90% RH for totally enclosed type.
c. Elevation: Below 1000 metres.
d. Should the installation be in an industrial zone, it should be free of explosive
gases and liquids.
e. Foundation should be strong so as not to induce vibration.
3.4.2. Ventilation and Space.

a. Installation should be well ventilated.
b. The area should be large enough to facilitate heat dissipation and
maintenance.
3.4.3. Foundation.
Use rigid and solid sole plate or common bed as the foundation.
3.5. MOUNTING.
3.5.1. An adequate motor support (which is the responsibility of others) is very

important. It must have sufficient rigidity to maintain alignment between
the motor and its driven load. Inadequate or improperly designed motor
supporting structures can lead to serious vibration and alignment problems.
3.6. COUPLING & ALIGNMENT.
Two pole motors and motors larger than Frame 315M must not be coupled to
the driven equipment by means other than direct connection.
Please refer to TECO if belt connection is to be used.


166

3.6.1. Installation.
Field application of a coupling to the motor shaft should follow the
procedures recommended by the coupling manufacturer. Under no
circumstances may the motor shaft be modified as to configuration or
diameter without the approval of Teco Australia. The motor shaft extension
must not be subjected to either extreme heat or cold during coupling
installation. If it is necessary to exert axial force on the shaft, either
continuously or intermittently, during coupling application, it must be
properly restrained axially to prevent bearing damage.
3.6.2. After the motor has been properly aligned with the driven equipment and
the hold down bolts have been installed and tightened, at least two dowel
pins should be installed diagonally opposite motor feet.
The exposed rotating parts should be covered to prevent accidents.
3.6.3 Alignment.
Motors must always be accurately aligned. Incorrect alignment can lead to

bearing failure, vibration and even shaft fracture. As soon as bearing
failure or vibration is detected, the alignment should be checked.
In aligning the motor (and rotor) axially with the driven equipment,
consideration should be given to the axial shaft expansion and increase in
shaft centre line height due to thermal effects.
Shaft height growth (change in shaft centre line elevation) for TEFC
machines can be calculated as follows,
Growth =(0.0005) x (motor foot to shaft centre line dimension [in mm]).


167

3.6.4 It is desirable, in normal operation that the motor operates, so that no axial
force is exerted on the coupling.
The motor shaft and the driven shaft should be aligned within the following
tolerances in both angular and parallel alignment (refer Table 1).
Units in mm
TIR Solid Flexible
Total Indicated Coupling coupling
Runout
Dimension C Medium, Low speed up to 2500 0.04 0.05
RPM
High speed over 2500 RPM 0.03 0.03

Dimension A Medium, Low speed up to 2500 0.03 0.04
RPM
High speed over 2500 RPM 0.03 0.03
Table 1
3.6.5 Angular misalignment is the amount by which the centre lines of the driver
and driven shaft are skewed. It can be measured using a dial indicator set
up as shown in fig 4. The couplings are rotated together through 360
degrees so that the indicator does not measure runout of the coupling hub
face. The shaft should be forced against either the in or out extreme of
their end float while being rotated.
Fig. 4 Fig. 5
3.6.6 Parallel misalignment is the amount by which the centre lines of the driver
and the driven shafts are out of parallel. It can be measured using the dial
indicator as shown in fig. 5. Again the couplings are rotated together
through 360 degrees so that the indicator does not measure runout of the
coupling hub outside diameter.


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3.6.7 After the motor has been properly aligned with the driven equipment and
the hold down bolts have been installed and tightened, at least two dowel
pins should be installed diagonally opposite motor feet.
3.7. INSTALLATION FOR BELT DRIVE
Do not hammer the conveyance devices such as coupling, belt sheaves, chain
wheels, gears, pulleys etc. onto the motor shaft. Those shaft fitments should
be fitted and removed only by means of suitable devices. Heat shrinking may
be a better alternative to avoid damaging bearings and other components.
3.7.1. Small, medium and large motors within frame sizes up to and including 315
frame are designed for use with belt transmission or direct coupling.
3.7.2. The diameter ratio between conveyance sheaves should not be greater 5 to
1 for flat belts, and 8 to 1 for V-belts. It is also advisable to limit the belt
velocity to under 35m/sec to limit belt abrasion and vibration. The smaller
the outer diameter of the V-belt sheave, the greater the shaft bending
stress will be. If bending stress is in excess of the shaft fatigue stress, the
shaft may break. If concerned please inform TECO of the size of the
sheaves and belt details for checking.
Place the sheave and belt as close as possible to the motor body and
shaft shoulder to reduce the bending moment and improve shaft life.
3.8. ELECTRICAL CONNECTIONS
3.8.1. The rated conditions of operation for the motors are as shown by the
nameplate. Within the limits given below, of voltage and frequency variation
from the nameplate values, the motor will continue to operate but with

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performance characteristics that may differ from those at the rated
conditions:
x +/- 10% of rated voltage
x +/- 5% of rated frequency
x +/- 10% combined voltage and frequency variation so long as frequency
variation is no more than +/- 5% of rated value.
Operating the motor at voltage and frequencies outside of the above limits
can result in both unsatisfactory motor performance and damage to/or
failure of the motor.
3.8.2. Motor connections should be carried out in accordance with the details
applicable to the appropriate supply voltage as shown on the motor
nameplate and should be undertaken by suitably qualified personnel.
3.8.3. The main lead box furnished with the motor has been sized to provide
adequate space for the make up of the connections between the motor lead
cables and the incoming power cables.
The bolted joints between the motor lead and the power cables must be
made and insulated in a workman-like manner following the best trade
practices and in accordance with the minimum requirements of the current
Australian Standards.
3.8.4. The motors are provided with grounding pads and/or bolts for the
connection of earthing.
The motor must be grounded by a proper connection to the electrical

grounding system and in accordance with the minimum requirements of the
Australian Standards.
Motors fitted with insulated bearings and rotor grounding brushes which are
used on VVVF Drives must be effectively earthed to the supply system.


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3.9. AUXILIARY DEVICES
3.9.1. Please refer to your specification and the motor nameplate to determine if
the motor is fitted with thermal winding protection devices.
The following are the most common:
One set (one per phase – total 3 off) of PTC winding thermistors.
Two sets (two per phase – total 6 off) of PTC winding thermistors.
One set (one per phase – total 3 off) of PT100 winding Resistance
Temperature Detectors (RTD’s).
Two sets (two per phase – total 6 off) of PT100 winding Resistance
Temperature Detectors (RTD’s).
3.9.2. Where specified motors may also be equipped with PT100 bearing
Resistance Temperature Detectors (RTD’s).
3.9.3. Thermistors are positive temperature coefficient type (1000 ohm @ tripping
temperature) refer to specification table for tripping temperature.
They are a tripping device only and not a temperature detector.
Thermistor leads should be connected to an appropriate thermistor control
relay from a reputable supplier.
3.9.4. RTD’s where fitted are of the platinum type (PT100) with a reference
temperature of 0°C at 100:.
RTD leads should be connected to an appropriate motor protection system
from a reputable supplier.
Recommended temperature settings for RTD’s are as per table 2 below.
DEVICE TYPE LOCATION ALARM TRIP

RTD PLATINIUM 100: @ 0OC WINDING 1400C 1500C
RTD PLATINIUM 100: @ 0OC DE & NDE BEARING 900C 950C
Table 2


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Thermistors and/or RTD’s should not be meggered or tested at a

voltage above 2.5Volts.
Should the motor thermal protection circuit trip indicating over

temperature the cause/s should be thoroughly investigated before a
restart is attempted.
Failure to do so may lead to permanent damage or failure of the motor.
3.9.5. Where specified motors may be equipped with internal space heaters (check
for nameplate), to prevent the ingress of moisture into the motor insulation
system whilst motor is idle.
The incoming supply to the heaters should be in accordance with the details
contained on the heater nameplate.
The heater circuit should be inter-locked with the motor starter so as to de-
energise heaters when the motor is running.
Anti Condensation Heaters may be LIVE when the motor is switched

off. Isolate supply at all times before working on the motor.


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Chapter 4: OPERATING INSTRUCTIONS

4.1. EXAMINATION BEFORE START.
4.1.1. After motor is installed the following points should be noted:-

a. Check all wiring is correct and in accordance with connections appropriate to the
supply voltage as shown on motor nameplate.
b. Is the incoming cable size adequate?
c. Are all connections tight and properly insulated?
d. Check the rating of fuses, starter/contactor are correct & operating normally.
e. Check motor is correctly earthed especially if supplied via a VVVF drive.
f. Make sure starter/switches are set in correct position.
g. Check heater circuit if fitted is de-energised when motor is in operation.
h. Check bearings are filled with the correct quantity and grade of grease.
4.1.2. Measurement of insulation resistance.

a. Rated voltage below 1000V, measure with 500VDC megger.
b. In accordance with IEEE-43 clause 9.3 standards, refer to following formula:
R (M:) = > (Rated Voltage + 1) x 10
1000
c. If a new winding has a low insulation resistance reading moisture ingress is
generally the problem. Drying the winding through the proper application of
heat will normally increase the insulation resistance to an acceptable level.
Following are several accepted methods for applying heat to a winding:
i. If the motor is equipped with anti condensation heaters these can be can be
energised to heat the winding.
ii. Direct current (as from a DC welder) can be passed through the winding. The
total current should not exceed approximately 50% of rated full load current.
Delta wound motors have six leads and the three phases should be connected
into one series circuit.
iii. Heated air can be either blown directly into the motor or into a temporary
enclosure surrounding the motor. The source of heated air should preferably


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be electrical as opposed to fuelled (such as kerosene) where a malfunction of
the fuel burner could result in carbon deposits entering the motor.
Caution mustt b
be exercised,
i d when
h heating
h ti theth motor
t withith any source
of heat other than self-contained space heaters, to raise the
winding temperature at a gradual rate to allow any entrapped
moisture to vaporise and escape without rupturing the insulation.
The entire heating cycle should extend over 15-20 hours.
Ensure adequate guarding is provided so live parts cannot be touched.
iv. Insulation resistance measurements can be made while the winding is being
heated. However, they must be corrected to 400C for evaluation since the
actual insulation resistance will decrease with increasing temperature. As an
approximation for a new winding, the insulation resistance will approximately
halve for each 100C increase in insulation temperature above the dew point
temperature.
d. Should the resistance fail to attain the specified value even after drying,
careful examination should be undertaken to eliminate all other possible
causes, if any.
4.1.3. Power Supply

a. Is the capacity of the power supply adequate?
b. Do voltage and frequency of supply match with those on the nameplate?
c. Voltage variation should be confined to within +/-10% of the rated value
and the phase to phase voltages should be balanced.


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4.1.4. Bearing Lubrication
Grease Lubricated Type.
The bearings
i are initially
i i i ll lubricated
l bi d with
i h the
h correct grade
d of grease at
the factory. After installation, long storage and at initial start
up/commissioning the bearings must be fully purged with new grease.
Please refer to section 7.
a. Refer to the section “Maintenance of Bearing” for maintenance procedures

and grease type.
4.1.5. Other Points to note

a. Make sure the transmission system, including belts, screws, bolts, nuts and
set pins are in good condition.
b. Dismantle all locks which fasten the moveable parts of the motor during
transportation, and turn the shaft by hand (if practical) to check if it moves
freely.
c. Check if there is any evidence of foreign matter inside the motor before
starting.
d. Make sure the items above are examined. Test the motor with or without
load. Record and check according to “Maintenance” at 15 minute intervals
during the first three hours of operation. Then conduct regular examinations
after longer intervals. If problems are experienced test without load to
ascertain whether it is a load, structure, alignment or motor issue.
4.2. STARTING OPERATION.
4.2.1. Starting Load.

The initial test involves running the motor without load. Unless specified, a
motor is designed to start with light load, which is then gradually increased
to full load, as the motor accelerates to full speed.
4.2.2. Starting.

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a. Motor can be restarted if the initial start fails. Three attempts are
permissible when the motor is at ambient (cold) temperature. Two starts in
succession are permitted when motor is at normal running temperature.
Smaller motors have a more frequent starting cycle.
b. Should an additional start be necessary beyond the conditions stated above,
the following restrictions should be noted:
i. Let the motor cool down for 60 minutes before a full load restart.
ii. Let the motor cool down for 30 minutes before a no load restart.
iii. Two inching starts can be regarded as one normal start.
c. If the motor rotor fails to start turning after two seconds, shut off power
supply immediately. This can result from:
i. Too low a voltage at the motor terminals.
ii. The load is too large for motor rating.
iii. The load has seized mechanically.
iv. Electrical connections incorrect.
v. Single phase power has been applied.
vi. Any combination of the above.
Note – Investigate thoroughly and take corrective action before attempting a
restart.
4.2.3. Direction of Rotation.

a. Motors are generally bi-directional. Some 2 pole and low noise motors are
uni directional only. If motor is uni-directional the fan cowl will be fitted with
a direction of rotation arrow.
b. If direction of rotation must be changed on a bi-directional motor, cut
power and wait until the motor stops, then interchange any two of the three
incoming phase leads.
4.2.4. Power Supply. Voltage/Current.

a. Check if the voltage and frequency of the power supply are identical to that
shown on the nameplate.


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b. Voltage variation should be confined to within +/-10% of nameplate
voltage, and the three phase voltages should be balanced.
c. Check if the phase currents of the motor, without load, are within +/-5% of
the average values.
4.2.5. Frequency.
Frequency variation should be confined to within +/-5% of the nameplate
frequency. The aggregate variation of voltage and frequency should be
confined to within +/-10% of the absolute value of the rating.
4.2.6. Run Up Time.
The Run Up time is llonger ffor motors connected

d to a load
l d with
h a large inertia.
However, if the run up time exceeds what is deemed normal or there is
abnormal noise, the motor and load should be examined to establish the
cause before attempting a restart.
4.3. CAUTIONARY POINTS TO NOTE:
4.3.1. Bearings:
a. The motor is fitted with grease lubricated bearings. Following initial start up
the bearing temperatures should be closely monitored. A rapid rate of rise
in bearing temperature is more indicative of impending trouble, however,
when greasing an expected higher temperature is normal and should
equalize after a period of time.
b. When the rate of bearing temperature rise is less than 1°C per half hour,
the bearing temperature is considered to be stabilised.
c. If the total bearing temperature exceeds 100°C, the motor should be shut
down immediately and subsequent checks be undertaken.


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4.3.2. Vibration:
a. The ideal values generally for motors are figures below 2.8mm/sec.
If vibration exceeds this level, an examination of the motor, load, structure
etc, should be made to determine the cause, the first check to undertake
would be to run the motor un-coupled and check if the vibration is still
evident, see section 5.4 Vibration.
4.3.3. Starting:
a. If the motor acceleration time exceeds the typical ramp time for this
application, shut off the power immediately.
Investigate thoroughly and take corrective action before attempting to
restart.
b. It should be recognised that each start of an induction motor subjects the
motor to current greater than full load current with resulting heating of the
stator and rotor windings. Each start can produce more heat than is
produced and dissipated by the motor under a full load condition.
c. The starting duty for which the motor is designed must not be exceeded if
long motor life is expected. Abnormally low terminal voltage and/or
excessive load torque during motor start up can cause lengthened
acceleration times during which the rotor ventilation is reduced. This can
cause rotor damage or lead to shortened rotor life.


178

Chapter 5: ROUTINE MAINTENANCE

5.1. IMPORTANCE OF DAILY INSPECTION.
5.1.1. Normally electric motors do not fail suddenly. It happens over time, and
regular inspection will detect a problem before a serious situation develops.
If operators in the plant are alert, faults can be detected early and action
taken to eliminate trouble.
Daily inspection, can be performed without interrupting the end user’s
normal operation.
5.1.2. Do not overlook any minor irregularities. If necessary, stop the machine
immediately to check and repair. Essentially, inspections should be
performed by the operator daily. But a maintenance technician should also
check the machine once a week together with the operator.
5.2. POINTS TO NOTE WHEN STARTING.

a. Check power supply to see if voltage and frequency are normal.
b. Is starter set at starting position?
c. Are there sparks during start?
d. Is the motor accelerating normally?
5.3. TEMPERATURE RISE.

5.3.1. The temperature of a motor is often determined by measuring the
temperature of the frame. This is not indicative of actual internal
winding operating temperature, however, this method can often be
referred to and compared with previous readings. If the temperature is
found to be higher than usual please check the following possibilities.
DO NOT MAKE TEMPERATURE READINGS WITH THE SENSE OF TOUCH.

Often the temperature of a motor is determined by touch. Human hands can only
tolerate temperatures below 600C. Most motors safely operate at temperatures
greater than this, therefore, the sense of touch should not be used. Temperature
readings by hand are also inaccurate. Readings should be made using a
thermometer probe or non-contact infra red thermometer.


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5.3.2. Main causes of high temperature:
a. Motor Conditions
i. Voltage and frequency variation of power source is in excess of
tolerance.
ii. Unbalanced three phase voltage, open circuit or poor contact.
iii. Insufficient or excessive lubrication.
iv. Abnormal frequency of starts.
v. Single-phasing due to open circuit or short circuit.
vi. Damaged starter or improper operation.
vii. Blocked ventilation ducts.
viii. Motors cooling vents blocked.
b. Due to load or mechanical conditions:
i. Overload.
ii. Defective transmission coupling.
iii. Poor installation causing overload.
iv. High ambient temperature or radiant heat emitted from driven load
or surroundings.
5.4. VIBRATION.
5.4.1. Main causes inducing vibration:

i. Unbalanced load.
i. Misalignment of couplings.
ii. Unbalanced belt-sheaves.
iii. Improper couplings with belts or chains.
iv. Unsuitable foundation or poor installation.
v. Unbalanced motor rotor.
vi. Serious abrasion to motor or load machine drive bearing.
vii. Defective bearing or subsequent bearing damage.
5.4.2. No matter what causes the vibration, if it is not eliminated, the following
faults may develop:
i. Bearing damage.

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ii. Deformation of shaft.
iii. Loose parts or couplings.
5.5. NOISE.
5.5.1. Points to Note.

Not all noise is the result of a fault or abnormality. For instance, wind and
slight electromagnetic sounds are perfectly normal. They will remain at the
same level no matter how long the motor is in operation. Generally the
louder the noise, the larger the vibration amplitude will be.
5.5.2. Bearing Sound.

i. Bearing noise is a guide to the condition of the motor bearings
without dismantling the motor.
ii. Normal bearing sound in general is continuous, not intermittent. The
sound may tend to increase with the age of the bearings, but its
increase is gradual and hardly noticeable by the ear.
iii. Abnormal bearing sound is intermittent, rarely continuous.
iv. Some motors will emit noise when unloaded or after greasing due to
skating. This is normal and temporary.
5.5.3. Abnormal bearing sound generally develops from the following causes:
i. Foreign matter in grease.
ii. Scratches on the contact surface of the bearing.
iii. Rust on the contact surfaces of the bearing due to moisture ingress.
iv. Poor quality of grease or wrong type of grease.
v. Insufficient grease (the sound could be continuous).
5.5.4. Causes of abnormal electromagnetic sound:

i. Single phasing.
ii. Short circuit in windings.
iii. Unbalanced air gap resulted from serious bearing wear.


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5.6. ODOUR.
5.6.1. Causes of motor odours:

i. Short circuit or over current causing overheating of varnish.
ii. Poor lubrication due to insufficient or contaminated grease.
5.7. MEASUREMENT OF THREE PHASE CURRENT.
5.7.1. Causes & effects

When load current is above the rating on the nameplate, it means the
motor may be overloaded. However, the cause of over current is not
confined to overloading, but may be caused by poor coupling installation,
transmission structure, excessive high or low voltage, etc.
a. Causes of unbalanced three phase current.
i. Unbalanced three phase voltage.
ii. Open circuit in power distribution lines.
iii. Poor switch contact.
iv.Open or short circuit in winding.
v. Open circuit at power transformer.
b. Effects:
i. Overheating of the windings causing fire or short circuit.
ii. Vibration of motor.
iii. Reduction of motor output torque.
c. Causes of wavering of ammeter indicator:

The characteristics of devices such as compressor or press are apt to cause
wavering of the indicator. Other causes are,
i. Poor contact of switches.
ii. Uneven mechanism.
iii. Unbalanced air gap due to serious bearing aberration.
iv.Broken conductors of squirrel cage rotor.


182

5.8. MOTOR APPEARANCE.
5.8.1. Reasons for Cleaning
a. Excessive dust or oil accumulation on the motor surface leading to the

clogging of ventilation channels between cooling ribs will reduce the motors
cooling efficiency.
b. Keeping the motor and equipment clean will improve appearance and
longevity.
Motors should never be cleaned or disturbed whilst the motor is in

operation.


183

Chapter 6: PERIODIC MAINTENANCE
6.1. REGULAR INSPECTION & MAINTENANCE.
For safety, properly trained personnel must only carry out maintenance
and repairs.
Some testing, such as insulation resistance, usually requires the motor

to be fully stopped and isolated from any power supply/supplies.
High temperatures may arise under operating conditions on the motor

surfaces, so that touching should be prevented or avoided.
Keep away from moving and live parts.
Unless deemed necessary, do not remove guards whilst assessing the
motor.
6.1.1. Major points in regular inspection and maintenance:

a. Routine inspection and maintenance are usually performed by operators
with the sense of touch, sight, smell and simple meters. But it is difficult to
detect trouble such as insulation deterioration etc. unless the motor is
stopped and checked.
b. Replacement of worn-out parts will increase longevity and prevent
breakdown.
c. Regular inspection and maintenance is important in preventing breakdown
and lengthening service life.
c. Owing to the varied uses and environments motors are placed in, it is
difficult to set periods for regular inspection and maintenance. However, it
has to be performed at least once every 6 months. Generally, the inspection
time is determined by the following factors:


184

i. Ambient conditions.
ii. Start and stop frequency.
iii. Trouble with components affecting motor functions.
iv. Parts which wear (eg. bearings).
v. The important position of a motor in operation of a factory, mine etc.
should be fully recognised. Therefore, its condition should be monitored,
especially when it is operating in severe conditions.
6.1.2. Motor Windings.

a. For measurement of insulation resistance and tests to determine quality of
insulation resistance, please refer to measures stated in Section 4.1.2.
b. Inspection of coil end:
i. Grease and dust accumulated on coil may cause insulation
deterioration and a reduction in cooling efficiency.
ii. Moisture.
iii. Discolouring from original colour. Overheating mainly causes this.
c. Stator wedges, is there any change from their original position?
d. Is the tie wire at the coil ends in correct position with no movement?
6.1.3. Bearings.
a. Please refer to section 7 for bearing maintenance.
6.1.4. Cleaning the interior of the motor.

a. After a motor has been in operation for some time, accumulation of dust,
carbon powder and grease etc., on the inside is unavoidable, and may
cause damage. The inside should therefore, be regularly cleaned and
examined to assure reliable performance.
b. Points to note during cleaning:
i. If using compressed air or a blower (Typically for squirrel cage only).
x Compressed air should be free of moisture.
x Maintain air pressure at 4kg/cm2, since high pressure can cause
damage to coils.


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ii. Vacuum – Recommended for wound rotor/slip ring type.
Vacuum cleaning can be used, both before and after other methods of
cleaning, to remove loose dirt and debris. It is a very effective way to
remove loose surface contamination from the winding. Vacuum cleaning
tools should be non-metallic to avoid any damage to the winding insulation.
iii. Wiping.
Surface contamination on the winding can be removed using a soft, lint-free
cloth. If the contamination is oily, the cloth can moistened (not dripping
wet) with a safety type petroleum solvent. In hazardous locations, a solvent
such as inhibited methyl chloroform may be used, but must be used
sparingly and immediately removed. While this solvent is non-flammable
under ordinary conditions, it is toxic and proper health and safety
precautions should be followed while using it.
Solvents of any type should never be used on windings provided with

abrasion protection. Abrasion protection is a grey, rubber-like coating
applied to the winding end-turns.
Adequate ventilation must always be provided in any area where solvents

are being used to avoid the danger of fire, explosion or health hazards. In
confined areas (such as pits), each operator should be provided with an air
line respirator, a hose mask, or self-contained breathing apparatus.
Operators should wear goggles, aprons and suitable gloves. Solvents and
their vapours should never be exposed to open flames or sparks and
should always be stored in approved safety containers.
6.1.5. Clean the exterior of the motor.

a. The inlet air openings should not be allowed to accumulate any dirt,
dust, slurry, lint, etc. that could restrict free air movement.
b. Totally enclosed fan cooled motors require special cleaning
consideration. The external fan must be cleaned thoroughly since any
dirt build up not removed can lead to balance issues and vibration.

186

Motors should never be cleaned or disturbed whilst the motor is in

operation.
6.1.6. Checking motor installation and coupling.

a. Installation:
i. Is foundation solid?
ii. Are all bolts and/or nuts tight and in good order?
b. Coupling:
i. Is coupling in good order?
ii. Are fasteners tight and in good order?
6.2. CLEANING OF COILS, DRYING & VARNISHING TREATMENT.

Age, constant heating and cooling and other factors may cause insulation
deterioration. Also, salt deposits or grease may lower insulation resistance.
Steam cleaning, drying and re-varnishing may be necessary if the motor has
been flooded or showing deterioration from age.
6.2.1. Cleaning:
a. If the coils are slightly contaminated, compressed air, cloth or a nylon brush
can be used to do the cleaning. However, when contamination is serious,
thorough washing has to be performed. The cleaning methods are as
follows:
b. Cleaning with water:
i. This method is applicable to motors having been immersed in water or
insulated with no cotton yarn and paper materials.
ii. After washing, dry immediately.
iii. Cleaning with steam.
x If the motor has been immersed in sea-water or a chemical solution, clean
with steam after washing thoroughly.
x Steam pressure must be kept between 2 – 4 kg/cm2. High pressure may
cause insulation damage.

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c. Steam temperature should be maintained between 500C – 800C.
d. After cleaning, dry immediately.
6.2.3. Drying Method.

a. Application:
i. Drying after cleaning.
ii. Motor has absorbed moisture.
b. Hot air method (using heater and blower).
i. Parts to be dried are surrounded inside a steel plate leaving an inlet and an
outlet for hot air. Hot air will enter the inlet to dry parts (stator, rotor, etc.),
and will leave via the outlet carrying away moisture.
ii. The temperature within the area surrounded by the steel plate should be
maintained at 900C – 1000C.
c. Drying with infrared ray lamp:
i. Install the infrared ray lamp in a baking area surrounded with steel plate
with openings at the bottom.
ii. This method can cause partial overheating. So attention must be paid to the
parts heated and the temperature must be kept below 1000C.
d. Drying method with electric current:
i. The winding must have a minimum insulation resistance above 0.5MΩ
measured with 500VDC megger before using this method so as to avoid a
short circuit.
ii. Lock the rotor (short the secondary winding of the wound rotor motor),
apply rated voltage of approximately 5% - 10% to the winding.
iii. Temperature control settings:
Squirrel cage rotor induction motor: 700C – 800C for the stator.
e. Measurement of insulation resistance.
i. Measure the insulation resistance periodically during drying.
ii. At the initial stage of drying, insulation resistance may decline slightly.
When it returns to normal, the drying process is complete.
iii. When the current method is applied, be sure to turn off the power to
measure insulation resistance.


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6.3. VARNISH.
Kind of Varnish
JIS-W-25 or W-28 are highly recommended.
a. Method of Varnish Treatment
i. Dipping method: Immerse windings completely into varnish until no
air bubbles appear.
ii. Pouring Method: Pour varnish completely over windings
Note: Let varnish drip to dry after dipping or pouring. Changing position of
the motor will obtain an even coverage.
b. Curing of Varnish
i. Set oven temperature at 110oC.
ii. Curing time should be 12 – 16 hours
iii. Ensure ventilation is adequate during curing. Combustible gases are
present.
To ensure adequate insulation the above procedure should be repeated.
6.4. KEY POINTS FOR MAINTENANCE & INITIAL OPERATION

INSPECTION AFTER LONG STORAGE.
6.4.1. If the motor has been out of service in excess of three months, careful
inspection should be made before putting the motor into operation again.
6.4.2. When the motor is not in operation, the following precautionary measures
should be undertaken:
The place for storage should be dry and well-ventilated. If the motor has to
be placed at work site for some time, it should be completely covered and
stored on pallets to prevent dust and moisture contamination.
Inspection and maintenance prior to storage.
Please refer to “Regular Inspection and Maintenance” (Section 6.1).


189

6.4.3. Items to be examined prior to initial operation.
a. Cleaning:
x Outside of motor.
x Motor interior.
b. Measurement of insulation resistance:

Measurement of insulation resistance and standards to determine quality if
Insulation resistance, please refer to measures stated in Section 4.1.2.
Measurement of insulation resistance.
6.4.4. Drying: If the motor has absorbed moisture, it must be dried.
6.4.5. Examination of bearings.

Turn the motor shaft by hand (if practical) to see if it rotates smoothly and
if there is any unusual noise.
6.4.6. Replenishment of grease. (Refer to bearing maintenance Section 7).
6.4.7. Switches and starters.

Clean off dust and any foreign matter etc.
Check if the operation is normal.
Are the moving parts functioning smoothly?
Check if all bolts and nuts are tight and in good order.
6.4.8. Examination and maintenance of standby motor.
Important: The purpose of a standby motor is to substitute as an

emergency motor if the motor in operation breaks down, this motor should
not be exposed to induced vibration whilst stationery.
It is important to always maintain the standby motor in top condition.
Maintenance should be performed strictly according to items and notes
stated previously.


190

6.5. RECORDS OF OPERATION AND MAINTENANCE.
6.5.1. Objective:
a. Fully understand the site conditions of the motor in operation and discover
any abnormalities in advance.
b. Prevent the neglect and act of maintenance.
c. Map pertinent maintenance plans after fully understanding the operation of
motor.
d. Assess the life of parts to determine the quantity of spare parts to be kept.
e. To plan the number of spare motors and replace or repair the motors in
operation according to a schedule.
6.5.2. Records of operation.

a. A maintenance card in table form is acceptable.
b. Principle contents:
i. Serial number of machine
ii. Model
iii. Three phase voltage
iv. Three phase current
v. Temperature of a motor in operation
vi. Ambient temperature, humidity, weather, date and time
vii. Time of start and stop
viii. Special remarks
ix. Operator’s name


191

6.6. POINTS TO NOTE ON DISASSEMBLY.
a. Disassemble according to the pre-set steps.
b. Necessary tools should be ready before disassembly.
c. Mark the disassembled parts so as to facilitate re-assembly.
d. Place parts, bolts and nuts etc, in a box to avoid misplacing.
e. Avoid damage to heavy parts during transportation.
f. Dust accumulation on coil-end, ducts etc., should be cleaned during
disassembly.
g. Coat parts with light oil.
h. Note if there is any shaft deflection or bearing damage when re-assembling.
i. Disassemble and assemble bearing according to the bearing maintenance
manual.
For safety and to prevent equipment damage properly trained

personnel must only carry out maintenance and repairs.


192

Chapter 7: BEARINGS
7.1. MAINTENANCE OF ROLLING BEARING.
Whilst Motors are iinstalled

ll d awaiting
i i commissioning
i i i theyh must be adequately
protected against the elements, all external components in particular the shaft
extension and external labyrinth seals at the drive end must be fully covered
to avoid water ingress entering the motor body whilst stationery.
Please ensure that both the non drive end and drive end antifriction bearings
are fully purged with sufficient grease at first start up/commissioning
with the recommended grade and quantity of grease.
7.1.1. General.
Bearings play a very important role in motor performance. It is essential to
keep bearings in good order for the motor to operate at optimum
performance. For this reason, please maintain bearings according to this
manual.
7.1.2. Motors within frame sizes D180 and below are complete with sealed for life
Bearings. (Unless the specification dictates these need to be re-greasible)
This type of bearing is a non maintainable item and has been pre packed
with grease and fitted with containment shields at point of manufacture.
These bearings do not require greasing for the life of the bearing.
7.1.3. Motors within frame sizes D200 and larger are equipped with through flush
greasing facilities.
Grease replenishment is required, if the motor has been out of service for 3
months or more and should also be carried out on initial start and at regular
intervals thereafter.
a. Replenishment of grease is recommended when the motor is running.
b. Clean the grease nipple and open the grease drain (if applicable) prior to
greasing. Restore after greasing.
c. A slight leakage of grease between the flinger and bearing cover is normal
and assists in totally sealing the bearing from ingress of dust and foreign
matter.

193

7.1.4. Grease Lubricated Type.
Keeping the bearing lubricant in top condition is extremely important in the
maintenance of bearings. It is a prerequisite of extended bearing life to
replenish grease using the correct grade, quantity and time interval, please
do not mix different types of grease.
The reasons for grease replenishment are:
a. Assure the rolling contact surface has no metal to metal contact.
b. Form a lubrication membrane on the rolling contact surface to reduce noise.
c. Purge the motor of old and contaminated grease, please ensure that the
grease in the discharge chute is pliable and will allow new grease to enter.
d. The presence of the correct grade and quantity of grease reduces corrosion,
protects and seals the bearing and lowers vibration.
7.1.5. Grease replenishment period:
The life of grease varies depending on model, speed, temperature,
operational conditions etc., it is, therefore, impossible to determine the
exact time interval for replenishment.
However, under normal conditions the greasing interval is shown in Table 3
can be used as a guide.


194

!
Bearing Speed(RPM)
Number 600 720 750 900 1000 1200 1500 1800 3000 3600
62XX 10 19000 18000 17500 16500 15500 14500 12500 11000 6000 4500
63XX 12 18000 17000 16500 15000 14500 13000 11000 9000 4500 3500
72XX 13 17500 16500 16000 14500 14000 12000 10000 8500 4000 3000
73XX 14 16500 15500 15000 13500 12500 11000 9000 7000 3500 2500
15 16500 15500 15000 13500 12500 11000 9000 7000 3000 2000
16 16000 15000 14500 13000 12000 10500 8500 6500 2500 1500
17 16000 14500 14000 12500 11500 10000 8000 6000 2500 1500
18 15500 14000 13500 12000 11000 9500 7500 5500 2500 1500
20 14500 13000 12500 11000 10000 8500 6000 4500
22 13500 12000 11500 10000 9000 7500 5500 4000
24 13000 11500 11000 9000 8000 6500 4500 3500
26 12000 10500 10000 8500 7500 6000 4000 3000
28 11500 10000 9500 8000 7000 5500 3500 2500
30 11000 9500 9000 7000 6500 4500 3000 2000
32 10500 8500 8500 6500 5500 4000 3000 2000
34 10000 8000 8000 6000 5500 4000 2500 1500
36 9500 7500 7500 5500 5000 3500
38 9000 7000 7000 5000 4500 3000
!
Bearing Speed(RPM)
Number 600 720 750 900 1000 1200 1500 1800
NU2XX 14 14000 12500 12000 10500 9500 8000 6000 4500
NU3XX 15 13500 12000 11500 11000 9000 7000 5500 4000
16 13000 11500 11000 9500 8500 6500 5000 3500
17 12500 11000 10500 9000 8000 6000 4500 3000
18 12000 10500 10000 8500 7500 5500 4000 2500
20 11000 9500 9000 7000 6000 4500 3000 2000
22 10000 8500 8000 6000 5500 4000 2500 1500
24 9000 7500 7000 5500 4500 3500 2000 1500
26 8500 7000 6500 5000 4000 3000 1500 1000
28 8000 6000 6000 4500 3500 2500 1000 500
30 7000 5500 5500 4000 3000 2000 1000 500
32 6500 5000 5000 3500 2500 1500 500 500
34 6000 4500 4500 3000 2500 1500 500
36 5500 4000 4000 2500 2000 1000 500
38 5000 4000 3500 2500 1500 1000 500
40 5000 3500 3000 2000 1500 1000
44 4000 3000 2500 1500 1000 500
48 3500 2500 2500 1000 1000 500
Table 3.
Remarks:
a. Please refer to lubrication nameplate fitted and follow the
recommended schedule stated.

195

b. The data as shown in Table 3 and/or lubrication nameplates are the
maximum recommended intervals under good conditions, please
consider site conditions, as a shortening of these periods may be
necessary.
7.1.6. Type of grease:

TECO motors can utilise different types of grease including Shell Gadus &
Mobil Polyrex EM Grease which has been selected based on the proposed
application.
Please check on the lubrication nameplate to confirm the type of grease
installed. Please use identical grease when servicing or alternatively
lubricants of different brands that have been established as being
equivalent in the areas of composition, physical properties and thickeners.
7.1.7. Amount of grease replenishment:

Amount of grease replenishment depends on the type, size and construction
and the bearings. For the maximum quantity used in one replenishment of
each bearing, as a guide, please refer to Table 4.
Please refer to lubrication nameplate fitted and follow the recommended
quantity stated.
7.1.8. Key points to note with grease filling:

Filling method for grease relief type bearing.
Use a good quality grease gun to pump grease through the grease nipple
into the bearings. The old contaminated grease is forced to drain out of the
discharge chute. While greasing it is recommended that the greasing
procedure is undertaken whilst the motor is running. The discharge outlet
may not be visible on some models, grease should be pumped in at the
recommended quantity and the sound of bearing should return to normal.
It is advisable to grease when the motor is operating as old grease is
expelled more easily.


196

Bearing No. Amount of ! Bearing No. Amount of

replenishment replenishment!
62XX 6210 30g ! 63XX 6310 40g
72XX 6212 40 ! 73XX 6312 60
NU2XX 6213 50 ! NU3XX 6313 80
222XX 6214 50 ! 223XX 6314 80
6215 60 ! 6315 100
6216 60 ! 6316 100
6217 80 ! 6317 120
6218 80 ! 6318 120
6220 100 ! 6320 160
6222 120 ! 6322 220
6224 120 ! 6324 270
6226 140 ! 6326 300
6228 160 ! 6328 400
6230 180 ! 6330 450
6232 200 ! 6332 500
6234 250 ! 6334 600
6236 300 ! 6336 700
6238 350 ! 6338 800
6240 400 ! 6340 900
6244 450 ! 6344 900
6248 500 ! 6348 900
Table 4.
*Fill new grease until it displaces the old grease completely.
Do not grease the motor whilst it is at standstill. If there is a draw-out

device for grease, draw out the used grease after greasing, please leave
excess grease on the rake as this will further protect the exit port from
moisture entry.
WARNING
Stay clear of rotating parts while relubricating motor when it is in
operation.
7.1.9. Temperature of bearing.

Temperature of the bearing will rise slightly, but this is temporary while
greasing and will return to normal a few minutes after greasing. Brief
temperature variations are of no concern, grease should be pumped in
sparingly to avoid excess temperatures being experienced.


197

7.1.10. Selection of grease gun.

There are two types of grease gun. High pressure lever type and hand press
type. As the hand press type has a lower force, grease replacement will
take more time. Greasing can be achieved quickly by using a lever type gun,
however, care should be taken to adjust the pressure and rate to avoid
excessive grease entry which may enter the motor’s interior.
7.2. NOISE OF BEARING.

a. Normal noise.
Noise is congenital to movement of the bearing. Generally bearing noise
that has a continuous rhythm with no sudden change is normal.
b. Abnormal noise.
It is difficult to detect the early stages of bearing failure with the human
ear. It takes a lot of experience and a sharp ear to detect abnormal noise.
Any sudden change in bearing noise should be investigated. Motors with
roller bearings at the drive end can emit more rotational noise than a ball
bearing and it is normal to hear skating/skidding of the rolling elements.
7.3. VIBRATION.
If the vibration of the bearing is unusually high, please test with vibroscope.
The preferred level for vibration should be below 2.8mm/sec. If the values
exceed this figure, an investigation should be undertaken to find and rectify
the problem.
7.4. REGULAR INSPECTION.
7.4.1. Regular monthly inspection.

Grease replenishment (refer to Section 7.1) and the motor lubrication plate.


198

7.4.2. Regular yearly inspection.
It is important to undertake regular inspection every year when the machine
is out of service for maintenance.
7.4.3. Inspection Notes.

a. Electrical etching.
When there are dark spots on bearing surface or outside the face of outer
ring and / or inside face of bearing housing, please check with a microscope
to see if they look like pock marks or fish scales which could be the result of
electrical etching due to poor installation etc.
b. Motors on VVVF Drives.
All TECO motors are suitable for running on VVVF drives, however, this does
depend on the application, kilowatt demand and speed range. TECO
recommend that when motors of 280/315 frame and above be fitted with at
least an insulated bearing at the non drive end and rotor grounding brush
fitted at the drive end, this is not categorical that this feature must be fitted,
purely a recommendation based on TECO’s experience, please consult with
the engineering specification whether the motor supplied requires this
feature.
c. Precision of installation.
The degradation of the bearing may be the result of misalignment due to
sinking foundations etc, after the motor has been in use for a long period.
Regularly check and record the alignment of couplings, and make
adjustments as necessary.
The bearing is a high precision component, it is important to avoid ingress

of dust, moisture and foreign matter. A hammer or similar object must not
be used during the cleaning and installation of the bearing.


199

Chapter 8: Troubleshooting.
8.1. FAULT FINDING & RECOGNITION
Kind of Symptom Cause Remedy

Fault
Fail to Motionless Power-off Consult power
start without And soundless company
load Switch-off Switch-on
No fuse Install fuse
Broken wires Check wires and
repair
Broken lead Check leads and
repair
Faulty winding Check winding and
repair
Fuse blowing – Short circuit Check circuit
(Circuit Breaker Incorrect wiring Check wiring
trips off, slow Poor contact in circuit Check and repair
start with switches
electromagneti Broken wiring Check and repair
c noise Poor contact of Check and repair
starting switch
Incorrect connection Check and repair
of starting switch
Overload Fuse blowing – Insufficient capacity Replace fuse or
after start Fail to restart of fuse or breaker breaker
due to circuit Overload Lighten load
breaker High load at low Check circuit
tripping voltage capacity and reduce
load


200

Kind of Fault Symptom Cause Remedy

Overload after start Overheating Overload or Lighten Load
of Motor Intermittent
Overload
Under-voltage Check circuit capacity
and power source
Over-voltage Check power source
Ventilation duct Remove the foreign
clogged matter in the duct
Ambient Lower ambient
temperature temperature
0
exceeds 45 C
Friction between Repair
rotor and stator
Fuse blowing Install the specified
(Single phase fuse
rotating)
Poor contact of Check and repair
circuit switches
Poor contact of Check and repair
starting switch
Unbalanced three Check circuit or
phase voltage consult power
company
Speed falls Voltage drop Check circuit and
sharply power source
Sudden overload Check machine
Single phase Check circuit and
rotating repair
Switch overheat Insufficient Replace switch
capacity of switch
High load Lighten load


201

Overload after Bearing Overheat Misalignment Re-align
start between motor
and load
Not enough Fully purge
grease bearings with
grease
High bearing Replace damaged
noise bearing
Noise Electro-magnetic Occurrence from Check noise not
noise induced by first operation normal
electricity Sudden sharp Short circuit of
noise and windings. Repair.
smoking
Bearing noise Not enough Fully purge
grease bearings with
grease
Deterioration of Clean bearing
grease and re-grease
Excessive noise Replace the
damaged bearing
Mechanical noise Loose belt sheaf Adjust key and
caused by lock the screw
machinery Loose coupling Adjust the
position of
couplings and
tighten
Loose screw Tighten screw
Fan rubbing Adjust fan
position


202


Noise Mechanical noise Rubbing as a result Clean motor
caused by of ingress of interior and
machinery foreign matter ventilation ducts
Wind noise Noise induced by
air flowing through
ventilation ducts
Induced by Repair machine
conveyance
machine
Vibration Electro-magnetic Short circuit of Repair
vibration windings
Open circuit of Repair
rotor
Vibration Unbalanced rotor Repair
Unbalanced fan Repair
Mechanical Broken fan blade Replace fan
vibration Un-symmetrical Align central points
centres between
belt sheaf
Central points of Adjust the central
couplings do not lie points of couplings
on the same level on the same level
Improper mounting Lock the mounting
installation screw
Motor mounting Reinforce mounting
bed is not strong bed
Remarks:
i. Circuit switches: This includes knife switch, electromagnetic switch, fuse and
other connection switches etc.
ii. Starting switches: This includes Delta-Star starter, compensate starter,
reactance starter, resistor starter, starting controllers etc.


203
A.3 4394072: Temperature Transmitter

204
A.3.1 Reference Manual
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4 Sensor 2 Degraded
Home Overview
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3 Low Saturation
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5 Low Alarm
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2 Manual Setup 4 Sensor 1 Connection
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VIEW CONFIG
TAG
PV
UNITS
SENSOR 1 TYPE
CONNECTION
SENSOR 2 TYPE
CONNECTION
UPPER RANGE VALUE
LOWER RANGE VALUE
DAMPING VALUE
HIGH ALARM
LOW ALARM
HIGH SATURATION
LOW SATURATION
BACK TO MENU
EXIT MENU
LOI MENU
VIEW CONFIG
SENSOR CONFIG SENSOR CONFIG
UNITS VIEW SENSOR
RERANGE SENSOR CONFIG SENSOR CONFIG
LOOP TEST BACK TO MENU SENSOR 1 CONFIG
DISPLAY EXIT MENU SENSOR 2 CONFIG
EXTENDED MENU BACK TO MENU
EXIT MENU UNITS EXIT MENU
CHNG ALL
SENSOR 1 UNITS
SENSOR 2 UNITS
DIFFRNTL UNITS
AVERAGE UNITS
1ST GOOD UNITS
BACK TO MENU
EXIT MENU
RERANGE
ENTER VALUES ENTER VALUES
BACK TO MENU LRV
EXIT MENU URV
BACK TO MENU
LOOP TEST EXIT MENU
SET 4 MA
SET 20 MA
SET CUSTOM
END LOOP TEST
BACK TO MENU
EXIT MENU
DISPLAY
SENSOR 1 (on/off)
SENSOR 2 (on/off)
ANALOG (on/off)
PV (on/off)
AVG (on/off)
1ST GD (on/off)
DIFF (on/off)
RANGE % (on/off)
MINMAX 1 (on/off)
MINMAX 2 (on/off)
MINMAX 3 (on/off)
MINMAX 4 (on/off)
BACK TO MENU
EXIT MENU
EXTENDED MENU
CALIBRAT
DAMPING
VARIABLE MAP
TAG
ALM SAT VALUES
PASSWORD
SIMULATE
HART REV
HOT BACK CONFIG
DRIFT ALERT
TC DIAG CONFIG
MIN MAX TRACK
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SENSOR 2 CALIB
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DAMPING
PV DAMP
SENSOR 1 DAMP
SENSOR 2 DAMP
DIFFRNTL DAMP
AVERAGE DAMP
1ST GOOD DAMP
BACK TO MENU
EXIT MENU
EXTENDED MENU VARIABLE MAP

CALIBRAT RE-MAP PV
DAMPING RE-MAP 2V
VARIABLE MAP RE-MAP 3V
TAG RE-MAP 4V
ALRM SAT VALUES BACK TO MENU
PASSWORD EXIT MENU
SIMULATE
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HOT BU CONFIG ALARM SAT VALUES
DRIFT ALERT ROSEMNT VALUES
TC DIAG CONFIG NAMUR VALUES
MIN MAX TRACK OTHER VALUES
BACK TO MENU BACK TO MENU
EXIT MENU EXIT MENU
PASSWORD
PASSWD ENABLE
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BACK TO MENU
EXIT MENU
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SIMULATE SNSR 1
SIMULATE SNSR 2
END SIMUL
BACK TO MENU
EXIT MENU
HART REV
HART REV 7
HART REV 5
BACK TO MENU
EXIT MENU
HOT BACK CONFIG

HOT BACK MODE
HOT BACK PV
HOT BACK RESET
BACK TO MENU
EXIT MENU
DRIFT ALERT
DRIFT MODE
DRIFT LIMIT
DRIFT UNITS
DRIFT DAMP
BACK TO MENU
EXIT MENU
TC DIAG CONFIG CONFIG SNSR 1
CONFIG SNSR 1 SENSOR 1 MODE
CONFIG SNSR 2 TRIGGER CONFIG
BACK TO MENU TRIGGER VIEW
EXIT MENU SNSR OHM VIEW
BASELINE RE-SET
MIN MAX TRACK BASELINE VIEW
MIN-MAX MODE BACK TO MENU
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RESET VALUES
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338
A.4 3546610: Resistance Temperature

Detector

A.4.1
WHEN ORDERING SPECIFY SENSING ELEMENT, CASE LENGTH, NUMBER OF

LEADS, ARMOR LENGTH, AND LEAD LENGTH.
S201168PE75Z48C12 EXAMPLE OF MODEL NUMBER
S201168 SPECIFICATIONS DRAWING NUMBER.
PE SENSING ELEMEN T:
PM = 100 OHM ±.06%, .00385 PLATINUM; 8
PD = 100 OHM ±.12%, .00385 PLATINUM; 8
PE = 100 OHM ±.5%, .00385 PLATINUM.
Drawing
75 CASE LENGTH A IN .1" INCREMENTS (75 = 7.5 ").

MINIMUM A = 40 (4.0") [102];
MAXIMUM A = 480 (48.0") [1219].
Z NUMBER OF LEADS:
Y = 2 LEADS PER ELEMENT;
Z = 3 LEADS PER ELEMENT.
48 ARMOR LENGTH B IN INCHES.

C
12 LEAD LENGTH C IN INCHES.
9/7/21
1. ELEMENTS (2): PLATINUM.
2. RESISTANCE (EXCLUDING LEADWIRE RESISTANCE):
PM PLATINUM: 100.00 OHMS ±.06% (100.06/99.94) AT 0°C (32°F), R/T
TABLES #5 - 100 (°C) AND #6 -100 (°F);
PD PLATINUM: 100.00 OHMS ±.12% (100.12/99.88) AT 0°C (32°F), R/T
TABLES #5 - 100 (°C) AND #6 -100 (°F);
PE PLATINUM: 100.0 OHMS ±.5% (100.5/99.5) AT 0°C (32°F), R/T TABLES
#5 -100 (°C) AND #6 -100 (°F).
3. TEMPERATURE RANGE: - 50°C TO 260°C ( -58°F TO 500°F).
4. INSULATION RESISTANCE: 100 MEGOHMS MINIMUM AT 1 00 VOLTS DC,
BETWEEN ELEMENTS AND LEADS TO PROBE CASE.
5. LEADS: AWG #2 2, STRANDED, TFE INSULATED.
6 TOLERANCE ON ARMOR LENGTH:
71" [1803] AND UNDER: +2/ -0" [+51/- 0];
72" TO 119" [1829 TO 3023]: +4/- 0" [+102/- 0]; www.minco.com
120" [3048] AND OVER: +6/ -0" [+152/-0].
7. CASE: STAINLESS STEEL, COPPER ALLOY TIP.
8 THE PM & PD ELEMENT RESISTANCE THERMOMETERS WILL MEET THE
RESISTANCE-TEMPERATURE RELATIONSHIP AND TOLERANCES
SPECIFIED IN EN 60751 (IEC 751), PM = CLASS A ; PD = CLASS B.
Print Date: 08/17/2011 15:55
9232510974 — 1000702744 1
339
340
A.5 3637375: Resistance Temperature

Detector

A.5.1
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Print Date: 04/18/2016 07:2
9232510974 — 1000702744 1
341
342
A.5.2 Datasheet
Tip-sensitive RTDs
CUT-TO-LENGTH
Overview Model numbers

The probe sensing tip is constructed of copper alloy which is Element Model for probe diameter:
twenty times more conductive than stainless steel. The sensors 0.188" 0.215" 0.250"
react more quickly to changes and indicate tip temperature (4.8 mm) (5.5 mm) (6.4 mm)
instead of stem temperature which increases accuracy. Minco Single element RTDs: No armor over leads
recommends 0.250" diameter probes for use in thermowells. Platinum (0.00392 TCR)
S54PA S51PA S53PA
Specifications 100 Ω ±0.5% at 0°C
Temperature range: -50 to 260°C (-58 to 500°F). Platinum (0.00385 TCR)
100 Ω ±0.06% at 0°C S554PM S551PM S553PM
Case: Stainless steel with copper alloy tip. (Meets EN60751, Class A)
Minimum case length: Platinum (0.00385 TCR)
Single element probes: 2.8" (71.1 mm). 100 Ω ±0.1% at 0°C S854PD S851PD S853PD
Dual element probes: 4.0" (101.6 mm). (Meets EN60751, Class B)
Maximum case length: Platinum (0.00385 TCR)
S884PE S881PE S883PE
48" (1220 mm), longer on special order. 100 Ω ±0.5% at 0°C
Leads: 2, 3, or 4 leadwires, stranded copper with PTFE insula- Copper (0.00427 TCR)
S54CA S51CA S53CA
tion. AWG 22, except 0.188" diameter dual probes AWG 24. For 10 Ω ±0.2% at 25°C
2-lead RTDs add 0.03 Ω per foot (0.05 Ω per foot for 0.188" Nickel (0.00672)
S54NA S51NA S53NA
diameter dual probes) of combined case and lead length to 120 Ω ±0.5% at 0°C
element tolerance. Copper (CA, CC) models must have 3 leads. Single element RTDs: With armor over leads
Time constant: 2.0 seconds typical in moving water. 3.0 sec- Add element code
S154__ S151__ S153__
(Ex: S154__ = S154NA)
onds for dual element models.
Dual element RTDs: No armor over leads
Pressure rating: 100 psi (6.9 bar).
Platinum (0.00392 TCR)
S59PA S56PA S57PA
Insulation resistance: 100 Ω ±0.5% at 0°C
Single element probes: 1000 megohms min. at 500 VDC, Platinum (0.00385 TCR)
leads to case. 100 Ω ±0.06% at 0°C S559PM S556PM S557PM
Dual element probes: 100 megohms min. at 100 VDC, (Meets EN60751, Class A)
between elements and leads to case. Platinum (0.00385 TCR)
100 Ω ±0.1% at 0°C S859PD S856PD S857PD
Vibration: Withstands 10 to 2000 Hz at 20 G’s min. per (Meets EN60751, Class B)
MIL-STD-202, Method 204, Test Condition D.
Platinum (0.00385 TCR)
S889PE S886PE S887PE
Shock: Withstands 100 G’s min. sine wave shock of 100 Ω ±0.5% at 0°C
8 milliseconds duration. Copper (0.00427 TCR)
S56CC S57CC
Specification and order options 10 Ω ±0.5% at 25°C
Nickel (0.00672)
S56NA Model number from table S59NA S56NA S57NA
120 Ω ±0.5% at 0°C
125 Case length: Dual element RTDs: With armor over leads
Specify in 0.1" increments (Ex: 125 = 12.5 inches)
Add element code
Y Number of leads per sensing element: S159__ S156__ S157__
(Ex: S159__ = S159NA)
Y = 2 leads
Z = 3 leads Specify and order products at:
X = 4 leads (PD only)
www.minco.com/sensors_config
36 Lead length in inches
S56NA125Y36 = Sample part number Specifications subject to change
1 Delta Park Blvd, #12 Brampton, ON L6T 5G1

Page 3-2 | Tel 905-457-6322 or 1-800-794-5883
Fax 905-457-4716 or 1-800-830-7122
sales@mod-tronic.com www.mod-tronic.com

343
Datasheet (Sheet 2)
Tip-sensitive Thermocouples
CUT-TO-LENGTH
PROBES
Overview Model numbers
The probe sensing tip is constructed of copper alloy which is Model for probe diameter:
twenty times more conductive than stainless steel. The sensors 0.188" 0.215" 0.250"
react more quickly to changes and indicate tip temperature (4.8 mm) (5.5 mm) (6.4 mm)
instead of stem temperature. The result is better accuracy in Single junction TC354 TC356 TC358
thermowells, bearings, and other installations. Minco recom- Dual junction TC355 TC357 TC359
mends 0.250" diameter probes for use in thermowells.
• Copper alloy tip for fast response
Specification and order options
• Accurate sensing to 260°C (500°F)
TC356 Model number from table
• Non-armor models can be user-shortened
T Junction type:
E = Chromel-Constantan
Specifications J = Iron-Constantan
Temperature range: -184 to 260°C (-300 to 500°F). K = Chromel-Alumel
T = Copper-Constantan
Case: Stainless steel with copper alloy tip.
G Junction grounding:
Minimum case length: 2.5" (63.5 mm). G = Grounded
Maximum case length: 48" (1220 mm), longer on special order. U = Ungrounded
Leads: Solid thermocouple wire, AWG 20 (except AWG 24 on 200 Case length:
Specify in 0.1" increments: Ex: 200 = 20.0 inches
model TC355). Specify PTFE insulation, stainless steel overbraid,
S Covering over leadwires:
or stainless steel armor. T = PTFE only
Time constant: Typical value in moving water: G = Glass braid only
S = Stainless steel overbraid
Grounded junction: 1.5 seconds.
A = Stainless steel armor
Ungrounded junction: 7 seconds.
24 Lead length in inches
Pressure rating: 100 psi (6.9 bar).
TC356TG200S24 = Sample part number
Insulation resistance: 10 megohms minimum at 100 VDC,
leads to case, ungrounded junctions only. Specify and order products at:
www.minco.com/sensors_config
Vibration: Withstands 10 to 2000 Hz at 20 G’s minimum per
MIL-STD-202, Method 204, Test Condition D.
Shock: Withstands 100 G’s min. sine wave shock of
8 milliseconds duration.
Specifications subject to change
1 Delta Park Blvd, #12 Brampton, ON L6T 5G1
| Tel 905-457-6322 or 1-800-794-5883

Fax 905-457-4716 or 1-800-830-7122
Page 3-3
sales@mod-tronic.com www.mod-tronic.com

344
A.6 6792192: Linear Transducer

345
A.6.1 User's Guide
1BSU#5-&.,43
BTL7-A/C/E/G5 _ _ -M _ _ _ _ -K(8)-SR32/SR115/_ _ _

User’s Guide
english

346
User's Guide (Sheet 2)
www.balluff.com

347
1 Notes to the user 5

1.1 Validity 5
1.2 Symbols and conventions 5
1.3 Scope of delivery 5
1.4 Approvals and markings 5
2 Safety 6
2.1 Intended use 6
2.2 Reasonably foreseeable misuse 6
2.3 General safety notes 6
2.4 Explanation of the warnings 6
2.5 Disposal 6
3 Construction and function 7

3.1 Construction 7
3.2 Function 7
4 Installation and connection 8

4.1 Installation guidelines 8
4.2 Preparing for installation 8
4.3 Installing the BTL 9
4.3.1 Installation recommendation for hydraulic cylinders 9
4.4 Electrical connection 10
4.4.1 Connector SR32 10
4.4.2 Connector SR115 10
4.4.3 Cable connection 11
4.5 Shielding and cable routing 11
5 Startup 12
5.1 Starting up the system 12
5.2 Operating notes 12
6 Calibration procedure 13
6.1 Programming inputs 13
6.2 Calibration procedure notes 13
6.3 Calibration procedure overview 14
6.3.1 Teach-in 14
6.3.2 Adjusting 15
6.3.3 Reset 15
7 Teach-in 16
8 Adjusting 17
9 Resetting all values (reset) 19
10 Technical data 20
10.1 Accuracy 20
10.2 Ambient conditions 20
10.3 Supply voltage (external) 20
10.4 Output 20
10.5 Input 20
10.6 Dimensions, weights 21
www.balluff.com english 3

348

BTL7-A/C/E/G5 _ _ -M _ _ _ _ -K(8)-SR32/SR115/_ _ _
Magnetostrictive Linear Position Sensor – Rod Style
11 Accessories 22
11.1 Magnets 22
11.2 Connector type S32 23
11.2.1 Freely configurable 23
11.2.2 Preassembled 23
11.3 Connector type S115, preassembled 24
11.4 Calibration box 24
12 Type code 25
13 Appendix 26
13.1 Converting units of length 26
13.2 Part label 26
4 english

349
1 Notes to the user
1.1 Validity The CE Mark verifies that our products

meet the requirements of the current
This guide describes the construction, function and setup
EMC Directive.
options for the BTL magnetostrictive linear position sensor
with analog interface. It applies to types
BTL7-A/C/E/G5 _ _ -M _ _ _ _ -K(8)-SR32/SR115/_ _ _
(see Type code on page 25). The BTL meets the requirements of the following product
standard:
The guide is intended for qualified technical personnel. – EN 61326-2-3 (noise immunity and emission)
Read this guide before installing and operating the BTL.
Emission tests:
– RF emission
1.2 Symbols and conventions
EN 55011
Individual instructions are indicated by a preceding
triangle. Noise immunity tests:
Ź Instruction 1 – Static electricity (ESD)
EN 61000-4-2 Severity level 3
Action sequences are numbered consecutively: – Electromagnetic fields (RFI)
1. Instruction 1 EN 61000-4-3 Severity level 3
2. Instruction 2 – Electrical fast transients (burst)
EN 61000-4-4 Severity level 3
Note, tip – Surge
This symbol indicates general notes. EN 61000-4-5 Severity level 2
– Conducted interference induced
by high-frequency fields
1.3 Scope of delivery EN 61000-4-6 Severity level 3
– BTL – Magnetic fields
– 6 mounting screws EN 61000-4-8 Severity level 4
– Condensed guide
More detailed information on the guidelines,
The magnets are available in various models approvals, and standards is included in the
and must be ordered separately. declaration of conformity.
1.4 Approvals and markings
Not for BTL7-…-F_ _
US Patent 5 923 164
The US patent was awarded in connection with this pro-
duct.

350

BTL7-A/C/E/G5 _ _ -M _ _ _ _ -K(8)-SR32/SR115/_ _ _
2 Safety
2.1 Intended use 2.4 Explanation of the warnings

The BTL magnetostrictive linear position sensor, together Always observe the warnings in these instructions and the
with a machine controller (e.g. PLC), comprises a position measures described to avoid hazards.
measuring system. It is intended to be installed into a
machine or system and used in the industrial sector. The warnings used here contain various signal words and
Flawless function in accordance with the specifications in are structured as follows:
the technical data is ensured only when using original
Balluff accessories. Use of any other components will void SIGNAL WORD
the warranty.
Hazard type and source
Opening the BTL or non-approved use are not permitted Consequences if not complied with
and will result in the loss of warranty and liability claims Ź Measures to avoid hazards
against the manufacturer.
The individual signal words mean:
2.2 Reasonably foreseeable misuse
NOTICE!
The products are not intended for the following Identifies a hazard that could damage or destroy the
applications and areas and may not be used there: product.
– in safety related applications where personal safety
depends on functioning of the device DANGER
– in explosion hazard areas The general warning symbol in conjunction with the
– in the food sector signal word DANGER identifies a hazard which, if not
avoided, will certainly result in death or serious injury.
2.3 General safety notes
Installation and startup may only be performed by
2.5 Disposal
qualified personnel with basic electrical knowledge.
Qualified personnel are persons whose technical Ź Observe the national regulations for disposal.
training, knowledge and experience as well as knowledge
of the relevant regulations allows them to assess the work
assigned to them, recognize possible hazards and take
appropriate safety measures.
The operator is responsible for ensuring that local safety

regulations are observed.
In particular, the operator must take steps to ensure that a
defect in the BTL will not result in hazards to persons or
equipment.
If defects and unresolvable faults occur in the BTL, take it
out of service and secure against unauthorized use.
6 english

351
3 Construction and function
BTL7…-SR32 Ø 79
Damping zone1)
34 40-1 Nominal length = 60 Ø 64
6 Measuring range 30°
1)
Ø 18 h6
Ø D1
Ø 6.4
Ø 11
Magnet 2)
86
G
11.5
Mounting Version D1 G
25 surface
…-K-… 10.2 mm Thread
M4x4/6 deep
20.5
6
…-K8-… 8 mm No thread
BTL7…-SR115 BTL7… cable

~18
20
6 holes to fasten
the BTL
20.5
1) Unusable area
20.5 2) Not included in scope of delivery
Fig. 3-1: BTL7-…-K(8)-…, construction and function
3.1 Construction 3.2 Function

Electrical connection: The electrical connection is made The BTL contains the waveguide which is protected by an
via a cable or a connector (see Type code on page 25). outer stainless steel tube (rod). A magnet is moved along
the waveguide. This magnet is connected to the system
Housing: Housing containing the processing electronics. part whose position is to be determined.
Fastening: For secure fastening, tighten the BTL with The magnet defines the position to be measured on the
cylinder screws (ISO 4762, M6 × 16 - A2-70) at all waveguide.
6 mounting holes (see Fig. 3-1). All screws must be
tightened with 3.5 Nm. An internally generated INIT pulse interacts with the
The BTL with Ø 10.2 mm has an additional thread at the magnetic field of the magnet to generate a torsional wave
end of the rod to support larger nominal lengths. in the waveguide which propagates at ultrasonic velocity.
Magnet: Defines the position to be measured on the The component of the torsional wave which arrives at the
waveguide. Magnets are available in various models and end of the waveguide is absorbed in the damping zone to
must be ordered separately (see Accessories on prevent reflection. The component of the torsional wave
page 22). which arrives at the beginning of the waveguide is
converted by a coil into an electrical signal. The travel time
Nominal length: Defines the available measuring range. of the wave is used to calculate the position. Depending
Rods with various nominal lengths from 25 mm to on the version, this information is made available as a
7620 mm are available depending on the version of the BTL: voltage or current output with a rising or falling gradient.
– Ø 10.2 mm: Nominal length from 25 mm to 7620 mm
– Ø 8 mm: Nominal length from 25 mm to 1016 mm
Damping zone: Area at the end of the rod that cannot be

used for measurements, but which may be passed over.

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BTL7-A/C/E/G5 _ _ -M _ _ _ _ -K(8)-SR32/SR115/_ _ _
4 Installation and connection
4.1 Installation guidelines 4.2 Preparing for installation

Non-magnetizable material Installation note: We recommend using non-
magnetizable material to mount the BTL and magnet.
Non-magnetizable material
Horizontal assembly: For horizontal assembly with
nominal lengths > 500 mm, support the rod and tighten it
at the end if necessary (only possible with a diameter of
10.2 mm).
Magnet
1)
Hydraulic cylinder: If installed in a hydraulic cylinder,
Min. Ø D2 = Minimum diameter of the bore (see Tab. 4-1)
ensure that the minimum value for the bore diameter of the
Fig. 4-1: Installation in non-magnetizable material support piston is complied with (see Tab. 4-1).
Fitting bore: The mounting surface of the BTL must make

Magnetizable material
full contact with the supporting surface. A suitable O-ring
If using magnetizable material, the BTL must be protected must completely seal the bore, i.e. the countersink for the
against magnetic interference through suitable measures O-ring must be produced in accordance with Fig. 4-3.
(e.g. spacer ring made of non-magnetizable material, a
suitable distance from strong external magnetic fields).
Fitting bore
Magnet Spacer ring made of non-magnetizable

material
Countersink for
O-ring 15.4×2.1
Fig. 4-3: Fitting bore for installing the BTL with O-ring
Magnet: Various magnets are available for the BTL (See

min. Ø D21)
Accessories on page 22).
Magnet Spacer ring made of non-magnetizable

material
1)
Min. Ø D2 = Minimum diameter of the bore (see Tab. 4-1)
Fig. 4-2: Installation in magnetizable material
Tube diameter Bore diameter D2

10.2 mm At least 13 mm
8 mm At least 11 mm
Tab. 4-1: Bore diameter if installed in a hydraulic cylinder
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4 Installation and connection (continued)
4.3 Installing the BTL The slide element can be screwed on or bonded.
Ź Secure the screws so they cannot be loosened or lost.
Ź Select a suitable adhesive.
NOTICE!
Slide surface
Interference in function Flow gap
Piston rod
Improper installation can compromise the function of the
Rod
BTL and result in increased wear.
Ź The mounting surface of the BTL must make full
contact with the supporting surface.
Ź The bore must be perfectly sealed (O-ring/flat seal).
Slide element
Ź For secure fastening, tighten the BTL with cylinder
screws (ISO 4762, M6 × 16 - A2-70) at all 6 mounting Fig. 4-5: Detailed view and top view of slide element
holes.
Ź All screws must be tightened with 3.5 Nm. There must be a gap between the slide element and piston
Ź Install the magnet (accessories). bore that is sufficiently large for the hydraulic oil to flow
Ź From 500 mm nominal length: support the rod and through.
tighten it at the end if necessary (only possible with a
diameter of 10.2 mm). Options for fixing the magnet:
– Screws
– Threaded ring
4.3.1 Installation recommendation for hydraulic – Press fitting
cylinders – Notches (center punching)
If you seal the hole with a flat seal, the max. operating
pressure will be reduced in accordance with the larger If installed in a hydraulic cylinder, the magnet
pressurized surface. should not make contact with the rod.
If installing horizontally in a hydraulic cylinder (nominal
lengths > 500 mm), we recommend affixing a slide element The hole in the spacer ring must ensure optimum guidance
to protect the rod end from wear. of the rod by the slide element.
Magnet
Dimensioning of the detailed solutions is the Fixing of magnet
responsibility of the cylinder manufacturer.
The slide element material must be suitable for the

appropriate load case, medium used, and application
temperatures. E.g. Torlon, Teflon or bronze are all possible
materials.
Slide element
Magnet
Spacer ring
Fig. 4-6: Fixing of magnet

Fig. 4-4: Example 1, BTL installed with slide element
An example of how to install the BTL with a supporting rod
is shown in Fig. 4-7 on page 10.

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4.4 Electrical connection

Magnet Depending on the model, the electrical connection is made
(e.g. BTL-P-1028-15R)
using a cable or a connector (BTL7…-SR32, BTL7…-SR115).
The connection or pin assignments for the respective version
can be found in Tab. 4-2 to Tab. 4-4.
Note the information on shielding and cable

routing on page 11.
Supporting rod made of non-magnetizable material
Fig. 4-7: Example 2, BTL installed with supporting rod
4.4.1 Connector SR32
Pin -A510 -G510 -C500 -C570 -E500 -E570

1 Not used1) 0…20 mA 20…0 mA 4…20 mA 20…4 mA
2 0V
3 10…0 V 10…–10 V 10…0 V3) Fig. 4-8: Pin assignment of SR32 (view
from above on BTL), 8-pin M16
4 La (programming input) circular plug
5 0…10 V –10…10 V 0…10 V3)

6 GND2)
7 10…30 V
8 Lb (programming input)
1)
Unassigned leads can be connected to the GND on the controller side but not to the shield.
2)
Reference potential for supply voltage and EMC-GND.
3)
The voltage outputs may exhibit a minimal offset to the harmonized current output.
Tab. 4-2: Connection assignment BTL7…-SR32
4.4.2 Connector SR115
Pin -A510 -G510 -C500 -C570 -E500 -E570

1 0 V (pin 3) Not used1)
2 0 V (pin 5)
3 10…0 V 10…–10 V Not used1) Fig. 4-9: Pin assignment of SR115 (view
from above on BTL), 8-pin M12
4 La (programming input) circular plug
5 0…10 V –10…10 V 0…20 mA 20…0 mA 4…20 mA 20…4 mA

6 GND2)
7 10…30 V
8 Lb (programming input)
1)
2)
Tab. 4-3: Connection assignment BTL7…-SR115
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4.4.3 Cable connection
Wire color -A510 -G510 -C500 -C570 -E500 -E570

YE yellow Not used1) 0…20 mA 20…0 mA 4…20 mA 20…4 mA
GY gray 0V
PK pink 10…0 V 10…–10 V 10…0 V3)
RD red La (programming input)
GN green 0…10 V –10…10 V 0…10 V3)
2)
BU blue GND
BN brown 10…30 V
WH white Lb (programming input)
1)
2)
3)
The voltage outputs may exhibit a minimal offset to the harmonized current output.
Tab. 4-4: Cable assignment BTL7… cable
4.5 Shielding and cable routing Cable length

BTL7-A/G Max. 30 m1)
Defined ground!
The BTL and the control cabinet must be at the BTL7-C/E Max. 100 m1)
same ground potential. 1)
Prerequisite: Construction, shielding and routing preclude the effect of any
external noise fields.
Shielding
Tab. 4-5: Cable lengths BTL7
To ensure electromagnetic compatibility (EMC), observe
the following:
– Connect the BTL and controller using a shielded cable.
Shielding: Braided copper shield with minimum 85%.
– Connector version: Shield is internally connected to
connector housing.
– Cable version: On the BTL side the cable shielding is
connected to the housing.
Ground the cable shielding on the controller side
(connect with the protective earth conductor).
Magnetic fields
The position measuring system is a magnetostrictive
system. Ensure that there is sufficient distance between
the BTL, holding cylinder and strong, external magnetic
fields.
Cable routing
Do not route the cable between the BTL, controller, and
power supply near high voltage cables (inductive stray
noise is possible).
The cable must be routed tension-free.
Bending radius for fixed cable

The bending radius for a fixed cable must be at least five
times the cable diameter.

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5 Startup
5.1 Starting up the system
DANGER
Uncontrolled system movement
When starting up, if the position measuring system is
part of a closed loop system whose parameters have not
yet been set, the system may perform uncontrolled
movements. This could result in personal injury and
equipment damage.
Ź Persons must keep away from the system’s
hazardous zones.
Ź Startup must be performed only by trained technical
personnel.
Ź Observe the safety instructions of the equipment or
system manufacturer.
1. Check connections for tightness and correct polarity.

Replace damaged connections.
2. Turn on the system.
3. Check measured values and adjustable parameters
and readjust the BTL if necessary.
Check for the correct values at the null point

and end point, especially after replacing the
BTL or after repair by the manufacturer.
5.2 Operating notes
– Regularly check function of the BTL and all associated

components.
– Take the BTL out of operation whenever there is a
malfunction.
– Secure the system against unauthorized use.
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6 Calibration procedure
Output BTL Unit Min. Null Indication Indication End Max. Error
gradient value value for for teach-in value value value
adjustment
Rising BTL7-A… V −0.5 0 2.0 4.0 +10.0 +10.5 +10.5
BTL7-G… V −10.5 −10.0 2.0 4.0 +10.0 +10.5 +10.5
BTL7-C… mA 0 0 6.0 12.0 20.0 20.4 20.4
BTL7-E… mA 3.6 4.0 6.0 12.0 20.0 20.4 3.6
Falling BTL7-A… V +10.5 +10.0 2.0 4.0 0 −0.5 −0.5

BTL7-G… V +10.5 +10.0 2.0 4.0 −10.0 −10.5 −10.5
BTL7-C… mA 20.4 20.0 6.0 12.0 0 0 20.4
BTL7-E… mA 20.4 20.0 6.0 12.0 4.0 3.6 3.6
Tab. 6-1: Value table for teach-in and inverting
6.1 Programming inputs Values for null and end point

Programming inputs La and Lb must be used in order to – Any desired position of the magnet can be used as the
make settings. A programming input at 10 to 30 V null or end point. However, the null and end points may
corresponds to activation (high active). not be reversed.
The Balluff BTL7-A-CB02-… adjusting box can be used for – The absolute null and end points must lie within the
this (see Accessories on page 22). minimum or maximum range of what can be output
(see value table).
Automatic deactivation! The last set values are always saved, regardless
If no signals are transmitted via the of whether the setting was ended using the
programming inputs for approx. 10 min, programming inputs or automatically after
programming mode is automatically ended. 10 min have expired.
Value table for teach-in and inverting

6.2 Calibration procedure notes
The following examples refer to BTL with 0 to
Prerequisites 10 V or 4 to 20 mA output.
– Programming inputs are connected.
– The BTL is connected to the system controller.
– Voltage or current values from the BTL can be read
(using a multimeter, the system control or the adjusting
box).
BTL
Calibration box Supply
8-pin 6-pin
Adapter cable with connector Adapter cable with

(socket) connector (luster terminal)
Fig. 6-1: Connecting the BTL7-A-CB02-S… adjusting box

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6 Calibration procedure (continued)
6.3 Calibration procedure overview
6.3.1 Teach-in Before

The factory set null point and end point is replaced by a
new null point and end point. The null point and end point After
can be set separately, the output gradient changes.
New end point
The detailed procedure for teach-in is described
on page 16.
Steps:
Ź Move magnet to the new null position.
Ź Read new null point by activating the programming
inputs. Fig. 6-3: Reading new end point
The current end point remains the same.
Only with BTL7-C/E…:
Ź The gradient of the current output can be inverted by
activating the programming inputs.
Before For example, a rising output gradient is changed to
a falling gradient. The voltage outputs are not
inverted.
After
New null point
Fig. 6-2: Reading new null point
Ź Move magnet to the new end position.

Ź Read new end point by activating the programming
inputs.
The current null point remains the same.
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359
6 Calibration procedure (continued)
6.3.2 Adjusting Ź Move magnet to the new end position.

Ź Read new end point by pressing the buttons.
The detailed procedure for adjusting is Ź Set the new end value by pressing the buttons.
described on page 17 ff.
The factory set null point and end point is replaced by a

new start point and end point and the associated output New end value
values can be adjusted. The start and end values can be
adjusted as you like up to the limits. Before
Adjustment is possible from serial number
120615000xxxxx xx onwards.
After
Steps
Ź Move magnet to the new start position. New end point
Ź Read new start point by pressing the buttons.

Ź Set the new start value by pressing the buttons.
Fig. 6-5: Adjust a new end value

Before
After 6.3.3 Reset

New start value
Restoring the BTL to its factory settings.
New null point
The detailed procedure for the reset is
described on page 19.
Fig. 6-4: Adjust a new start value

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7 Teach-in
NOTICE!
Interference in function
Displayed values (example)
Teach-in while the system is running may result in
malfunctions.
Ź Stop the system before performing teach-in. At 0…10 V At 4…20 mA
Initial situation:
– BTL with magnet within measuring range 5.39 V 9.15 mA
Activate teach-in
Ź Activate a for at least 4 s. > 4 s a 4.00 V 12.00 mA
Indication for teach-in is displayed.
The current position value is displayed again once 5.39 V 9.15 mA
the button is released.
Set null point

Ź Bring magnet to the new null point. 1.04 V 4.82 mA
Ź Activate a for at least 2 s. > 2 s a
The new null point is set. 0.00 V 4.00 mA
Set end point

Ź Bring magnet to the new end point. 9.89 V 19.13 mA
Ź Activate b for at least 2 s. > 2 s b
The new end point is set. 10.00 V 20.00 mA
Inverting the characteristic curve (only with BTL7-C/E)

Ź Simultaneously activate a and b for at least 4 s. > 4 s a b 3.60 mA
Error value is displayed.
The characteristic curve of the output is inverted 14.85 mA
once released.
End teach-in
Ź Briefly activate a and b simultaneously (< 1 s). < 1 s a b 10.50 V 3.60 mA
The output indicates the error value during
activation.
Current position value is displayed. 10.00 V 4.00 mA
Any of the individual steps for settings can be

selected. The teach-in process can be ended at
any time.
Programming line La = a
Programming line Lb = b
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8 Adjusting
NOTICE!
Adjustment while the system is running may result in Displayed values (example)
malfunctions.
Ź Stop the system before performing adjustment. At 0…10 V At 4…20 mA
Initial situation:
– BTL with magnet within measuring range 5.39 V 9.15 mA
Activate adjusting
Ź Activate b for at least 4 s. > 4 s b 2.00 V 6.00 mA
Indication for adjustment is displayed.
The current position value is displayed again once 5.39 V 9.15 mA
the button is released.
Set start point

Ź Bring magnet to the new start point. 1.04 V 4.82 mA
Ź Activate a for at least 2 s. > 2 s a
The new start point is set with the last valid start 0.00 V 4.00 mA
value.
a
Adjust start value a
Ź The start value can be changed using a and b . 0.00 V 4.00 mA
The gradient of the curve changes (see page 15).
0.90 V 7.20 mA
b
b
Ź End calibration procedure: Briefly activate a and b < 1 s a b 2.00 V 6.00 mA

simultaneously (< 1 s).
Set position value is saved. 0.90 V 7.20 mA
For setting the end point, adjusting the end value,

and ending adjustment, see page 18.

selected. The adjustment process can be
ended at any time.

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8 Adjusting (continued)
Displayed values (example)
At 0…10 V At 4…20 mA
Set end point

Ź Bring magnet to the new end point. 9.89 V 19.13 mA
Ź Activate b for at least 2 s. > 2 s b
The new end point is set with the last valid end 10.00 V 20.00 mA
value.
a
Adjust end value
a
Ź The end value can be changed using a and b . The
10.00 V 20.00 mA
gradient of the curve changes (see page 15).
8.00 V 16.80 mA
b
b
Ź End calibration procedure: Briefly press a and b < 1 s a b 2.00 V 6.00 mA
simultaneously (< 1 s).
Set position value is saved. 8.00 V 16.80 mA
End adjustment
Ź Briefly activate a and b simultaneously (< 1 s). < 1 s a b 10.50 V 3.60 mA
The current position value is displayed once the
buttons are released. 7.63 V 18.56 mA

selected. The adjustment process can be
ended at any time.
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9 Resetting all values (reset)
NOTICE!
Resetting the values while the system is running may
result in malfunctions.
Ź Stop the system before performing the reset.
The reset function can be used to restore all the settings

to the factory settings. For a reset the magnet may also be Displayed values (example)
located outside the measuring range.
At 0…10 V At 4…20 mA
5.39 V 9.15 mA
Activate reset
Ź Simultaneously activate a and b for at least 4 s. > 4 s a b 10.50 V 3.60 mA
Reset
Ź Simultaneously activate a and b for at least 4 s. > 4 s a b 0.00 V 4.00 mA
After activation:
All values are reset. 9.89 V 19.13 mA
Current position value is displayed.
Reset is deactivated.
Abort reset
Resetting can be aborted without any changes

being saved after the Activate reset step.
Ź Briefly activate a and b simultaneously (< 1 s). < 1 s a b
Current position value is displayed.

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10 Technical data
10.1 Accuracy 10.3 Supply voltage (external)

The specifications are typical values for the Voltage, stabilized5) 10…30 V DC
BTL7-A/C/E/G… at 24 V DC and room temperature, with
a nominal length of 500 mm in conjunction with the Ripple ≤ 0.5 Vss
BTL-P-1013-4R, BTL-P-1013-4S, BTL-P-1012-4R or Current draw < 120 mA
BTL-P-1014-2R magnet. (at 24 V DC)
The BTL is fully operational immediately, with full accuracy
after warm-up. Inrush current ≤ 500 mA
Reverse polarity protection6) Up to 36 V
For special versions, other technical data may Overvoltage protection Up to 36 V
apply. Dielectric strength 500 V AC
Special versions are indicated by the suffix -SA (GND to housing)
on the part label.
Repeat accuracy 10.4 Output

Typical ±10 μm
Sampling rate BTL7-A… Output voltage 0…10 V and 10…0 V
Dependent on the nominal length 250 μs…5.7 ms Load current ≤ 5 mA
At nominal length = 500 mm 500 μs BTL7-C… Output current 0…20 mA/20…0 mA
Non-linearity at Load resistance ≤ 500 ohms
Nominal length ≤ 500 mm ±50 μm BTL7-E… Output current 4…20 mA/20…4 mA
Nominal length > 500 to ≤ 5500 mm ±0.01% FS Load resistance ≤ 500 ohms
Nominal length > 5500 mm ±0.02% FS BTL7-G… Output voltage −10…10 V and 10…−10 V
Temperature coefficient1) ≤ 30 ppm/K Load current ≤ 5 mA
Max. detectable velocity 10 m/s Short-circuit resistance Signal cable to 36 V
Signal cable to GND
10.2 Ambient conditions2)

10.5 Input
Ambient temperature −40…+85°C
Ambient temperature for UL ≤ +80°C Programming inputs La, Lb: High-active
(only BTL7-…-KA…) BTL7-_5_ _-… 10…30 V DC
Storage temperature −40…+100°C
Overvoltage protection Up to 36 V
Relative humidity ≤ 90%,
non-condensing
Rod pressure rating (when installed in 1)
Nominal length 500 mm, magnet in the middle of the measuring range
hydraulic cylinders) 2)
For UL: Use in enclosed spaces and up to a height of 2000 m above
For Ø 8 mm ≤ 250 bar sea level.
For Ø 10.2 mm ≤ 600 bar 3)
Individual specifications as per Balluff factory standard
Shock rating 150 g/6 ms 4)
Resonant frequencies excluded
Continuous shock 150 g/2 ms 5)
For UL: The BTL must be externally connected via a limited-energy circuit
per EN 60068-2-273), 4) as defined in UL 61010-1, a low-power source as defined in UL 60950-1,
Vibration 20 g, or a class 2 power supply as defined in UL 1310 or UL 1585.
per EN 60068-2-63), 4) 10…2000 Hz 6)
A prerequisite is that no current can flow between GND and 0 V in the
Degree of protection per IEC 60529 event of polarity reversal.
Connector SR32/SR115 IP67
(when attached)
Cable IP683)
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10 Technical data (continued)
10.6 Dimensions, weights
Rod diameter 8 mm or 10.2 mm

Nominal length
For Ø 8 mm 25…1016 mm
For Ø 10.2 mm 25…7620 mm
Weight Approx. 2 kg/m
(depends on length)
Housing material Stainless steel
Flange material Stainless steel
Rod material Stainless steel
Rod wall thickness
For Ø 8 mm 0.9 mm
For Ø 10.2 mm 2 mm
Housing mounting Flange with 6 holes
BTL7-…-K_ _
Cable material PUR;
cULus 20549
80°C, 300 V,
internal wiring
Cable temperature –40…+90°C
Cable diameter Max. 7 mm
Permissible bending radius
Fixed routing ≥ 35 mm
Moved ≥ 105 mm
BTL7-…-F_ _
Cable material PTFE
No UL approval available
Cable temperature –55…+200°C
Cable diameter Max. 7 mm
Permissible bending radius
Fixed routing ≥ 35 mm
Moved No permissible bending
radius

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11 Accessories
Accessories are not included in the scope of delivery and BTL-P-1013-4R, BTL-P-1013-4S, BTL-P-1012-4R,
must be ordered separately. BTL-P-1014-2R:
Weight: < 15 g
Housing: Aluminum
11.1 Magnets
BTL-P-1013-4R Included in the scope of delivery for the

BTL-P-1013-4R, BTL-P-1013-4S, BTL-P-1012-4R:
Spacer: 8 mm, material: polyoxymethylene
(POM)
BTL5-P-4500-1 magnet (solenoid):

Weight: Approx. 90 g
Housing: Plastic
Operating
BTL-P-1013-4S temperature: –40…+ 60°C
BTL-P-1028-15R (special accessories for

applications with a supporting rod):
Weight: Approx. 68 g
Housing: Aluminum
120°
BTL-P-1012-4R
Ø 65
Ø 54
Ø 28
Ø 4.3 8
Fig. 11-2: BTL-P-1028-15R special accessories
BTL-P-1014-2R
Fig. 11-1: Magnet installation dimensions
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11 Accessories (continued)
11.2 Connector type S32 11.2.2 Preassembled

Straight connector, molded, M16, 8-pin
Various cable lengths can be ordered, e.g.
11.2.1 Freely configurable
BCC S518-0000-1Y-133-PS0825-050
BKS-S 32M-00 (Order code: BCC0L21): Cable length 5 m
Order code: BCC00TT 66
Straight connector, M16 per IEC 130-9, 8-pin
Ø 20
Fig. 11-5: Connector type S32 (preassembled)
~ 62 Angled connector, molded, M16, 8-pin

Various cable lengths can be ordered, e.g.
Fig. 11-3: Connector BKS-S32 M-00 BCC S528-0000-1Y-133-PS0825-050
(Order code: BCC0L2A): Cable length 5 m
BKS-S 33M-00
Ø 20
Order code: BCC00UP
Angled connector, M16 per IEC 130-9, 8-pin
Ø6-Ø8
~ 54
31 46
Ø 18
37.2
48.5
Fig. 11-6: Connector type S32 (preassembled)
Ø 20 Pin Color
Fig. 11-4: Connector BKS S 33M-00 1 YE yellow

2 GY gray
3 PK pink
4 RD red
5 GN green
6 BU blue
7 BN brown
8 WH white
Tab. 11-1: S32 (preassembled) pin assignment

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11 Accessories (continued)
11.3 Connector type S115, preassembled 11.4 Calibration box

BKS-S115-PU-_ _ BTL7-A-CB02-S32
Straight connector, molded-on cable, M12, 8-pin Scope of delivery:
Various cable lengths can be ordered, e.g. – Calibration box
BKS-S115-PU-05 (Order code: BCC00YF): Cable – 2 adapter cables, each approx. 0.3 m
length 5 m – Condensed guide
43
BTL7-A-CB02-S115
Ø 13.5
M12x1
Scope of delivery:
– Calibration box
Fig. 11-7: Connector BKS-S115-PU-_ _ – 2 adapter cables, each approx. 0.3 m
– Condensed guide
BKS-S116-PU-_ _
BTL7-A-CB02-K
Angled connector, molded-on cable, M12, 8-pin
Various cable lengths can be ordered, e.g. Scope of delivery:
BKS-S116-PU-05 (Order code: BCC00YW): Cable – Calibration box
length 5 m – 2 adapter cables, each approx. 0.3 m/0.6 m
– Condensed guide
M12x1
28
Fig. 11-8: Connector BKS-S116-PU-_ _
Fig. 11-9: Connector BKS-S116-PU-_ _, outlet
Pin Color
1 YE yellow
2 GY gray
3 PK pink
4 RD red
5 GN green
6 BU blue
7 BN brown
8 WH white
Tab. 11-2: BKS-S115/S116-PU-_ _ pin assignment
24 english

369

BTL7-A/C/E/G5 _ _ -M _ _ _ _ -K(8)-SR32/SR115/_ _ _
1BSU#5-&.,43
12 Type code
BTL7 - E 5 0 0 - M0500 - K - SR32
Interface:
A = Analog interface, voltage output 0…10 V
G = Analog interface, voltage output −10…10 V
C = Analog interface, current output 0…20 mA
E = Analog interface, current output 4…20 mA
Supply voltage:
5 = 10…30 V DC
Output gradient:
00 = Rising (e.g. C_00 = 0…20 mA); only with BTL7-C/E
10 = Rising + falling (e.g. A_10 = 10…0 V and 0 to 10 V); only with BTL7-A/G
70 = Falling (e.g. C_70 = 20…0 mA); only with BTL7-C/E
Nominal length (4-digit):

M05
M0500 = Metric specification in mm, nominal length 500 mm (M0025…M7620)
Rod version, fastening:

K= Flange with 6 holes, O-ring, rod diameter 10.2 mm
K8 = Flange with 6 holes, O-ring, rod diameter 8 mm
Electrical connection, radial:

SR32 = 8-pin, M16 plug per IEC 130-9
SR115 = 8-pin, M12 plug
K05 = Cable, 5 m (PUR)
F05 = Cable, 5 m (PTFE)

370
Micropulse Accessories
W Style Magnets & Floats
Product Magnet, Spacer Magnet, Spacer Magnet, Spacer Magnet, Spacer
Type Ø32 ring Ø32 open ring Ø25 ring Ø22 ring
BTL
W
Ordering Code - Magnet BTL-P-1013-4R* BTL-P-1013-4S* BTL-P-1012-4R* BTL-P-1014-2R

Ordering Code - Spacer BTL Z-P-1013-4R-SPACER SPACER BTL-P-1013-DS BTL Z-2-1012-4R-SPACER N/A
Material AL AL AL AL
Weight 12 g 12 g 12 g 10 g
Magnet Speed any any any any
Operating/Storage -40…+100°C -40…+100°C -40…+100°C -40…+100°C
Temperature
*Spacer is included with these magnets
Product Magnet Magnet Magnet Magnet

Type Barrel float Barrel float Bullet float Sphere float
Ordering Code BTL2-S-3212-4Z BTL2-S-4414-4Z BTL2-S-6216-8P BTL2-S-5113-4K
Material Stainless 316 Stainless 316 Stainless 316 Stainless 316

Weight 20 g 35 g 66 g 34 g
Operating/Storage -40…+120°C -40…+120°C -40…+120°C -40…+120°C
Temperature
Water Displacement 35 mm 30 mm 41 mm 26 mm
Pressure (static) 24 bar (348 psi) 20 bar (290 psi) 15 bar (217 psi) 40 bar (580 psi)
www.balluff.com 33

371
Micropulse
W Style Accessories
Product Molded Molded
Straight Connector Right-angle Connector Straight Connector Right-angle Connector
Type 8-pin female 8-pin female 8-pin female 8-pin female
Ordering Code BKS-S 32M-_ *_ BKS-S 33M-_*_ BKS-S 232-PU-_*_ BKS-S 233-PU-_*_
Material CuZn, nickel plated CuZn, nickel plated CuZn, nickel plated CuZn, nickel plated
Contact Surface 0.8 μm Au 0.8 μm Au 0.8 μm Au 0.8 μm Au
Solder Connection 00 option only 00 option only N/A N/A
Cable 7 x 0.25 mm2/AWG 24 7 x 0.25 mm2/AWG 24 7 x 0.25 mm2/AWG 24 7 x 0.25 mm2/AWG 24
Cable Diameter 6.35 mm ± 0.35 mm 6.35 mm ± 0.35 mm 6.35 mm ± 0.35 mm 6.35 mm ± 0.35 mm
Allowable Cable Diameter 6…8 mm 6…8 mm N/A N/A
Cable Material PUR PUR PUR PUR
Environmental Rating IP 67 (when installed) IP 67 (when installed) IP 67 (when installed) IP 67 (when installed)
For additional connectors, * Indicate cable length in ordering code in meters

see pages 107-114 (consult factory for longer lengths)
00 = connector only (only available for BKS-S 32M and BKS-S 33M)
02 = 2 meter cable
05 = 5 meter cable
Product Jam nut Jam nut

Type 3/4"-16 UNF M18 x 1.5
Note:
Jam nut not needed for
in-cylinder applications
Ordering Code BTL-5-JAM-NUT BTL-A-FK01-E-M18x1.5
Application W housing H housing

Material Stainless steel Stainless steel
34

372
Single-Ended Cordsets
BKS-S 32M-60
Order Code: BCC00UC
Basic features Environmental conditions

Application Transducer Cable temperature, drag chain -25...60 °C
Approval/Conformity CE Cable temperature, fixed routing -50...80 °C
EAC Cable temperature, flexible routing -25...80 °C
WEEE Protection degree IP67
Electrical connection Material

Bending radius min., fixed cable 5xD Cable jacket material, note Shielded
Bending radius min., flexible cable 10 x D Cable jacket, material PUR
Cable PUR Shielded black, 60.00 m, Material contact carrier PBT
Drag chain compatible
Material contacts Bronze
Cable diameter D 6.00 mm ±0.15 mm
Material cover nut Brass
Cable, bending cycles min. 2 million
Material grip Brass
Conductor cross-section 0.25 mm²
Connection M16x0.75-Female, Straight, 8-pin
Connector configuration Straight
Mechanical data
Number of conductors 8 Acceleration max., drag chain 5 m/s²
Number of pins 8 Cable jacket, color black
System assembled Cable length L 60.00 m
Cable properties Drag chain compatible
Electrical data Horizontal travel permitted, drag 5m

chain
Conductor construction 4x2 twisted-pair Tightening torque pigtail 0.6 Nm
Operating voltage Ub 60 VDC / 60 VAC Traverse speed max., drag chain 200 m/min
Rated current (40 °C) 5.0 A Vertical travel permitted, drag chain 2m
Remarks
Cable construction acc. to UL-AWM Style 20549
Halogen-free per DIN VDE 0472 Part 815
Silicone-free
Flame resistance per UL FT2
Enclosure rating per IEC 60529, only in screwed state with the associated mating piece.
1/2
Internet www.balluff.com eCl@ss 9.1: 27-06-03-11
Subject to change without notice: 325721 ETIM 6.0: EC001855
BCC00UC_0.47_2020-03-06

373
Single-Ended Cordsets
BKS-S 32M-60
Order Code: BCC00UC
Connector Drawings
PIN 1: yellow
PIN 2: gray
PIN 3: pink
PIN 4: red
PIN 5: green
PIN 6: blue
PIN 7: brown
PIN 8: white
Wiring Diagrams
2/2
BCC00UC_0.47_2020-03-06

374

3DUW%7/350$*1(7
Mechanical Accessories
BTL-P-1013-4R
Order Code: BAM013L
Basic features Material

Principle of operation BTL magnet, rod Housing material Aluminum
Environmental conditions Mechanical data

Ambient temperature -40...100 °C Application weight 12.00 g
Storage temperature -40...100 °C Dimension Ø 32 x 8 mm
Inside diameter 13.0 mm
Mounting Through-hole 4.3 mm (2x)
Pressure rating max. 600 bar
1/1
BAM013L_0.45_2020-08-04

375
A.7 1000722366: Hydraulic Jack

Assembly

376
A.7.1 Pressure Gauge Instruction Sheet
Instruction Sheet
POWERFUL SOLUTIONS. GLOBAL FORCE. Gauges

L505 Rev D 08/16
Index:
English .................................................... 1-3
Français .................................................. 4-7
Deutsch ................................................ 8-11
Italiano ................................................ 12-15
Español............................................... 16-19
Nederlands ......................................... 20-23
Português ........................................... 24-27
Polski .................................................. 28-31
WARNING: Wear proper personal
protective gear when operating hy-
1.0 IMPORTANT RECEIVING
draulic equipment.
INSTRUCTIONS
WARNING: Stay clear of loads
Visually inspect all components for shipping
supported by hydraulics. A cylinder,
damage. Shipping damage is not covered by
when used as a load lifting device,
warranty. If shipping damage is found, notify
should never be used as a load holding device.
carrier at once. The carrier is responsible for
After the load has been raised or lowered, it
all repair and replacement costs resulting from
must always be blocked mechanically.
damage in shipment.
WARNING: USE ONLY RIGID
SAFETY FIRST PIECES TO HOLD LOADS. Carefully
®
2.0 SAFETY ISSUES

®
select steel or wood blocks that are

capable of supporting the load. Never use a
Read all instructions, warnings hydraulic cylinder as a shim or spacer in any
and cautions carefully. Follow lifting or pressing application.
all safety precautions to avoid
personal injury or property damage during sys- DANGER: To avoid personal
tem operation. Enerpac cannot be responsible injury keep hands and feet
for damage or injury resulting from unsafe away from cylinder and
product use, lack of maintenance or incorrect workpiece during operation.
product and/or system operation. Contact En- WARNING: Do not exceed equipment
erpac when in doubt as to the safety precau- ratings. Never attempt to lift a load
tions and operations. If you have never been weighing more than the capacity of
trained on high-pressure hydraulic safety, con- the cylinder. Overloading causes equipment
sult your distribution or service center for a free failure and possible personal injury.
Enerpac Hydraulic safety course.
Never set the relief valve to a higher
Failure to comply with the following cautions pressure than the maximum rated
and warnings could cause equipment damage pressure of the pump. Higher settings
and personal injury. may result in equipment damage and/or
A CAUTION is used to indicate correct operat- personal injury.
ing or maintenance procedures and practices WARNING: The system operating
to prevent damage to, or destruction of equip- pressure must not exceed the
ment or other property. pressure rating of the lowest rated
A WARNING indicates a potential danger that component in the system. Install pressure
requires correct procedures or practices to gauges in the system to monitor operating
avoid personal injury. pressure. It is your window to what is
happening in the system.
A DANGER is only used when your action or
lack of action may cause serious injury or even
death.
1

377
Pressure Gauge Instruction Sheet (Sheet 2)
CAUTION: Avoid damaging added stability. Do not weld or otherwise

hydraulic hose. Avoid sharp bends modify the cylinder to attach a base or other
and kinks when routing hydraulic support.
hoses. Using a bent or kinked hose Avoid situations where loads are not
will cause severe back-pressure. Sharp bends directly centered on the cylinder
and kinks will internally damage the hose plunger. Off-center loads produce
leading to premature hose failure. considerable strain on cylinders and plungers.
Do not drop heavy objects on In addition, the load may slip or fall, causing
hose. A sharp impact may cause
®
potentially dangerous results.
internal damage to hose wire Distribute the load evenly across the
strands. Applying pressure to a damaged hose entire saddle surface. Always use a
may cause it to rupture. saddle to protect the plunger.
IMPORTANT: Do not lift hydraulic
equipment by the hoses or swivel
couplers. Use the carrying handle or IMPORTANT: Hydraulic equipment
other means of safe transport. must only be serviced by a qualified
hydraulic technician. For repair
CAUTION: KEEP HYDRAULIC service, contact the Authorized ENERPAC
EQUIPMENT AWAY FROM Service Center in your area. To protect your
FLAMES AND HEAT. Excessive warranty, use only ENERPAC oil.
heat will soften packings and seals, resulting in
fluid leaks. Heat also weakens hose materials WARNING: Immediately replace
and packings. For optimum performance do worn or damaged parts by genuine
not expose equipment to temperatures of ENERPAC parts. Standard grade
150°F [65°C] or higher. Protect hoses and parts will break causing personal injury and
cylinders from weld spatter. property damage. ENERPAC parts are designed
to fit properly and withstand high loads.
DANGER: DO NOT HANDLE
PRESSURIZED HOSES. Escaping
oil under pressure can penetrate the 3.0 DESCRIPTION
skin, causing serious injury. If oil is injected
Your Enerpac gauge is designed primarily to
under the skin, see a doctor immediately.
function as a visual measuring device for ob-
WARNING: Only use hydraulic serving the hydraulic operating condition of
cylinders in a coupled system. Never your system. The use of a hydraulic gauge is
use a cylinder with unconnected recommended with every hydraulic system
couplers. If the cylinder becomes extremely to insure that the operating ratings of the hy-
overloaded, components can fail draulic components within the system are not
catastrophically causing severe personal exceeded.
injury.
In high-production applications, once the hy-
WARNING: BE SURE SETUP IS draulic system pressure settings have been
STABLE BEFORE LIFTING LOAD. adjusted for production runs, your hydraulic
®
Cylinders should be placed on a flat gauge should be disconnected from the hy-
surface that can support the load. draulic system. This can be done by complete
Where applicable, use a cylinder base for removal from the system or by installation of
Gauge Adaptor Specifications

Part Number Thread Dimensions
A B C L
GA-1 8/
3 ” NPT 2/
1 ” NPT /
3 ”
8 NPT 2.81 in. (71 mm)
GA-2 8/
3 ” NPT 2/
1 ” NPT /
3 ”
8 NPT 6.10 in. (139 mm)
GA-3 8/
3 ” NPT 4/
1 ” NPT /
3 ”
8 NPT 5.25 in. (133 mm)
GA-4 4/
1 ” NPT 2/
1 ” NPT /
3 ”
8 NPT 4.38 in. (111 mm)

378
a shut-off valve between the gauge and the or pipe wrenches, as they may damage the
high-pressure line. high-pressure fittings.
Should the hydraulic gauge be left in opera- 5.0 OPERATION
tion continuously, the calibration of the gauge
may be greatly affected, requiring recalibration The gauge should be operated at pressures
or complete replacement. Shut-off valves are which do not normally exceed 75% of full
recommended as added protection for any hy- scale.
draulic gauge that may be subjected to high Using the gauge to read less than 10% of the
cycle rates or pressure fluctuations. full scale can result in an erroneous reading.
IMPORTANT: The gauge should be checked
for accuracy on a periodic basis, especially
when the pressure measurement is critical and
a gauge failure or inaccuracy will create a haz-
(1)
ard to personnel or property.
75%
(2)
Pump
outlet port
(3)
A B Hose or
coupler
L
10%
(1) Gauge
(2) Shut-off Valve
(3) Gauge Adaptor
4.0 INSTALLATION 6.0 REPAIR AND SERVICE INFORMATION
NOTE: When making hydraulic connections, Enerpac gauges are precalibrated by the fac-
use high quality sealing compound only on the tory to within ±1% and ±11/2% of the full scale.
threads of the male NPT fittings. If you use Tef- For recalibration, please refer to your local
lon tape, do not tape the first thread. Use tape phone or business directory. For warranty and/
sparingly. Loose Teflon tape in your pump or or repair service, send your gauge to the near-
cylinder can cause malfunctions and damage. est Enerpac Service Center.
Wrap tape so that it tightens upon assembly
(clockwise with the threads facing you). Install 6.1 Glycerin Gauge Maintenance
your hydraulic gauge where it is easily read- For maintenance, please contact your nearest
able but well protected against damage from authorized Enerpac Service Center. The pro-
external sources. cedure for filling the glycerin gauge is covered
1. Remove the hydraulic oil outlet plug(s) from in Enerpac’s Instruction Sheet, L2561.
your pump.
2. Apply sealant (or Teflon tape) to male
NPT threads. Make connections as
pictured above. When tightening hydraulic
connections and fittings, use the proper
open-end wrenches. Do not use crescent

379
Enerpac Worldwide Locations e-mail: info@enerpac.com internet: www.enerpac.com
Australia and New Zealand Japan The Netherlands, Belgium,

Actuant Australia Ltd. Applied Power Japan LTD KK Luxembourg,
P.O. Box 6867, Wetherill Park, NSW 1851 Besshocho 85-7 Central and Eastern Europe,
Block V Unit 3, Regents Park Estate Kita-ku, Saitama-shi 331-0821, Japan Baltic States, Greece, Turkey
391 Park Road, Regents Park NSW 2143 T +81 48 662 4911 and CIS countries
Australia F +81 48 662 4955 ENERPAC B.V.
T +61 287 177 200 sales-jp@enerpac.com Galvanistraat 115, 6716 AE Ede
F +61 297 438 648 P.O. Box 8097, 6710 AB Ede
sales-au@enerpac.com Middle East, Egypt and Libya The Netherlands
ENERPAC Middle East FZE T +31 318 535 911
Brazil Office 423, LOB 15 F +31 318 535 848
Power Packer do Brasil Ltda. P.O. Box 18004, Jebel Ali, Dubai sales-nl@enerpac.com
Rua Luiz Lawrie Reid, 548 United Arab Emirates
09930-760 - Diadema (SP) - Brazil T +971 (0)4 8872686 Enerpac Integrated Solutions B.V.
T +55 11 5687 2211 F +971 (0)4 8872687 Spinelstraat 15, 7554 TS Hengelo
Toll Free: 0800 891 5770 sales-ua@enerpac.com P.O. Box 421, 7550 AK Hengelo
vendasbrasil@enerpac.com The Netherlands
T +31 74 242 20 45
Norway
China (Taicang) F +31 74 243 03 38
Sales Office Norway
Actuant (China) Industries Co. Ltd. integratedsolutions@enerpac.com
Unit 524, Nydalsveien 28, 0484 Oslo
No. 6 Nanjing East Road, P.O. Box 4814, Nydalen 0422 Oslo
Taicang Economic Dep Zone South Africa and other English
Norway
Jiangsu, China speaking African countries
Tel: +47 91 578 300
T +86 0512 5328 7500 Enerpac Africa Pty Ltd.
insidesalesnorway@enerpac.com
F +86 0512 5335 9690 No. 5 Bauhinia Avenue
Toll Free: +86 400 885 0369 Cambridge Office Park
Russia Block E
sales-cn@enerpac.com
Rep. office Enerpac Highveld Techno Park
Russian Federation Centurion 0157
France, Switzerland, North Africa and
Admirala Makarova Street 8 Republic of South Africa
French speaking African countries
125212 Moscow, Russia T: +27 12 940 0656
ENERPAC
T +7 495 98090 91 sales-za@enerpac.com
Une division d’Actuant France S.A.S.
F +7 495 98090 92
Zone Orlytech Bâtiment 516
sales-ru@enerpac.com United Kingdom and Ireland
1 allée du commandant Mouchotte
CS 40351 ENERPAC UK Ltd.
Southeast Asia, Hong Kong 5 Coopies Field
91550 Paray-Vieille-Poste and Taiwan
France Morpeth, Northumberland
Actuant Asia Pte Ltd. NE61 6JR, England
T +33 1 60 13 68 68 83 Joo Koon Circle
F +33 1 69 20 37 50 T +44 1670 5010 00
Singapore 629109 sales-uk@enerpac.com
sales-fr@enerpac.com T +65 68 63 0611
F +65 64 84 5669
Germany and Austria USA, Latin America and Caribbean
Toll Free: +1800 363 7722
Actuant GmbH ENERPAC World Headquarters +27 12
sales-sg@enerpac.com
P.O. Box 300113 P.O. Box 3241
D-40401 Düsseldorf Milwaukee WI 53201-3241 USA
South Korea
Willstätterstrasse 13 N86 W12500 Westbrook Crossing
Actuant Korea Ltd.
D-40549 Düsseldorf, Germany Menomonee Falls, Wisconsin 53051
3Ba 717, Shihwa Industrial Complex T +1 262 293 1600
T +49 211 471 490
Jungwang-Dong, Shihung-Shi, F +1 262 293 7036
F +49 211 471 49 28
Kyunggi-Do User inquiries:
sales-de@enerpac.com
Republic of Korea 429-450 T +1 800 433 2766
T +82 31 434 4506 Distributor inquiries/orders:
India
F +82 31 434 4507 T +1 800 558 0530
Actuant India Private Limited
sales-kr@enerpac.com F +1 800 628 0490
No. 10, Bellary Road, Sadashivanagar,
Bangalore, Karnataka 560 080 Technical inquiries:
Spain and Portugal techservices@enerpac.com
India ENERPAC SPAIN, S.L.
T +91 80 3928 9000 sales-us@enerpac.com
Avda. Valdelaparra N° 27 3ª - L8
info@enerpac.co.in
28108 Alcobendas (Madrid), Spain
T +34 91 884 86 06
Italy
F +34 91 884 86 11
ENERPAC S.p.A.
sales-es@enerpac.com
Via Canova 4
All Enerpac products are guaranteed against
20094 Corsico (Milano)
Sweden, Denmark defects in workmanship and materials for as
T +39 02 4861 111
Finland and Iceland long as you own them.
F +39 02 4860 1288
Enerpac Scandinavia AB
sales-it@enerpac.com
Kopparlundsvägen 14, For the location of your nearest authorized
721 30 Västerås Enerpac Service Center, visit us at
Sweden www.enerpac.com
T +46 (0) 771 41 50 00
scandinavianinquiries@enerpac.com

380
A.7.2 Pressure Gauge Service Instructions
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E\ SU\LQJ LW XS ZLWK D EOXQW LQVWUXPHQW EHLQJ FDUHIXO QRW WR NOTE: *O\FHULQH IORZV PXFK IDVWHU ZKHQ LW LV KHDWHG DERYH
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8VLQJDIXQQHOILOOWKHJDXJHXQWLOWKHOLTXLGEHJLQVWRDSSHDU IRUPWLQ\KDUGWRUHPRYHEXEEOHVDIWHUVHYHUDOGD\VRQWKHVKHOI
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CAUTION: Gauges filled with glycerine or silicone
9HU\ WKLFN IOXLGV VXFK DV JO\FHULQH DW URRP WHPSHUDWXUH
cannot be used on applications where strong
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oxidizing agents are present. A chemical reaction,
RYHUIORZWKURXJKWKHILOOLQJKROHEHIRUHWKHJDXJHDSSHDUVWR
ignition or explosion may result. Oxidizing agents include
EHIXOORQWKHIDFH $IWHUWKHOLTXLGKDVVHWWOHGDWWKHERWWRP
but are not limited to oxygen, chlorine, nitric acid, and
RIWKHJDXJHFRQWLQXHWRILOOVORZO\DOORZLQJWKHOLTXLGWROHYHO
hydrogen peroxide. Completely fluorinated or chlorinated
RIIVHYHUDOWLPHVXQWLOWKHSURSHUDPRXQWRIOLTXLGKDVEHHQ
fluids such as HALOCARBON 4.2 should be used.
DGGHG 6HH)LJXUH
For Enerpac Glycerine-filled 4" Gauges /,48,'),//)/8,'$0%,(177(03(5$785(5$7,1*6

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VROLGLI\IUHH]H
X = 1 1/4" - 1 1/2" Fill Fluid Allowable Operating Range
(33 - 39 mm)
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Table 1, Allowable Ambient Temperature Ratings

Figure 1

381
Pressure Gauge Service Instructions (Sheet 2)
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Australia Germany, Switzerland, Mexico Spain, Portugal
ENERPAC, Applied Power Australia Ltd. Austria, Eastern Europe ENERPAC Applied Power ENERPAC
Block V Unit 3 ENERPAC Mexico S.A. de C.V. Applied Power International S.A.
Regents Park Estate Applied Power GmbH Avenida Principal Avda. Camino de lo Cortao
391 Park Road P.O. Box 300113 La Paz #100 21 - Nave 3
Regents Park NSW 2143 D-40401 Düsseldorf Fracc. Industrial La Paz San Sebastian de los Reyes
(P.O. Box 261) Australia Germany 42092 Pachuca, Hidalgo 28709 Madrid
Tel: +61 297 438 988 Tel: +49 211 471 490 Tel: +52 771 337 00 Spain
Fax: +61 297 438 648 Fax: +49 211 471 49 28 Fax: +52 771 838 00 Tel: +34 91 661 11 25
Fax: +34 91 661 47 89
Canada Hong Kong The Netherlands, Belgium,
Actuant Canada Corporation ENERPAC Luxembourg, Sweden, Denmark, USA, Latin America
6615 Ordan Drive, Unit 14-15 Room 907 Workingberg Norway, Finland, United Kingdom, and Caribbean
Mississauga, Ontario L5T 1X2 Commercial Building Ireland ENERPAC
Tel: +1 905 564 5749 41-47 Marble Road ENERPAC B.V. P.O. Box 3241
Fax: +1 905 564 0305 North Point Storkstraat 25 6101 N. Baker Road
Tel: +852-2561 6295 P.O. Box 269, 3900 AG Veenendaal Milwaukee, WI 53209 USA
Toll Free: Fax: +852-2561 6772 The Netherlands Tel: +1 262 781 6600
Tel: +1 800 268 4987 Tel: +31 318 535 911 Fax: +1 262 781 1049
Fax: +1 800 461 2456 India Fax: +31 318 525 613
ENERPAC +31 318 535 848 User inquiries:
China Hydraulics (India) Pvt Ltd UK, Ireland +1 800 433 2766
Applied Power China Ltd. Plot No. A-571 Tel: +44 01527 598 900 Distributor inquiries/orders:
1F, 269 Fute N. Road MIDC, TTC Industrial Area Fax: +44 01527 585 500 +1 800 558 0530
Waigaoqiao Free Trade Zone Mahape-400 701
Pudong New District Navi Mumbai, India Singapore
Shanghai, 200 131 Tel: +91 22 769 47 78 Applied Power Asia Pte Ltd
China Fax: +91 22 769 84 73 No. 8, Ang Mo Kio,
Tel: +86 21 5866 9099 Industrial Park 2
Fax: +86 21 5866 7156 Italy #01-00
ENERPAC Singapore 569500
France, Turkey, Greece, Applied Power Italiana S.p.A. Thomson Road, P.O. Box 114
Africa, Middle East Via Canova 4 Singapore 915704
ENERPAC S.A. 20094 Corsico (Milano) Tel: +65 484 5108
B.P. 200 Tel: +39 2 486 111 00 Fax: +65 484 5669
Parc d’Activités Fax: +39 2 486 012 88
du Moulin de Massy South Korea
F-91882 Massy CEDEX (Paris) France Japan ENERPAC
Tel: +33 1 601 368 68 Applied Power Japan Ltd. Applied Power Korea Ltd.
Fax: +33 1 692 037 50 1-1-11, Shimomae 163-12 Dodang-Dong
Toda-shi Wonmi-Ku, Buchun-shi
Saitama Pref. Kyunggi-Do
Japan 335-0016 Republic of Korea
Tel: +81-48-430-2311 Tel: +82 32 675 08 36
Fax: +81-48-430-1117 Fax: +82 32 675 30 02/73
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382
A.7.3 Valve and Manifold Instruction Sheet
Instruction Sheet
Needle Valves, Check Valves

& Split-Flow Hydraulic Manifolds
L1966 Rev. G 02/2021

DANGER: To avoid personal injury keep hands and
Index:
feet away from cylinder and workpiece during
English: ................................................................................. 1-4 operation.
Français: ................................................................................5-8
WARNING: Do not exceed equipment ratings. Never
Deutsch: ..............................................................................9-12 attempt to lift a load weighing more than the capacity of
Italiano: ..............................................................................13-16 the cylinder. Overloading causes equipment failure and
Español:.............................................................................17-20 possible personal injury. The cylinders are designed for a max.
Nederlands: .......................................................................21-24 pressure of 700 bar [10,000 psi]. Do not connect a jack or cylinder
to a pump with a higher pressure rating.
Never set the relief valve to a higher pressure than the
Repair Parts Sheets for this product are available from the Enerpac
maximum rated pressure of the pump. Higher settings may
web site at www.enerpac.com, or from your nearest Authorized
result in equipment damage and/or personal injury.
Enerpac Service Center or Enerpac Sales office.
WARNING: The system operating pressure must not
1.0 IMPORTANT RECEIVING INSTRUCTIONS exceed the pressure rating of the lowest rated component
Visually inspect all components for shipping damage. Shipping in the system. Install pressure gauges in the system to
damage is not covered by warranty. If shipping damage is found, monitor operating pressure. It is your window to what is happening
notify carrier at once. The carrier is responsible for all repair and in the system.
replacement costs resulting from damage in shipment.
CAUTION: Avoid damaging hydraulic hose. Avoid sharp
SAFETY FIRST bends and kinks when routing hydraulic hoses. Using a
bent or kinked hose will cause severe back-pressure.
2.0 SAFETY ISSUES Sharp bends and kinks will internally damage the hose leading to
Read all instructions, warnings and cautions carefully. premature hose failure.
Follow all safety precautions to avoid personal injury
Do not drop heavy objects on hose. A sharp impact
or property damage during system operation.
may cause internal damage to hose wire strands.
Enerpac cannot be responsible for damage or injury resulting from ®
Applying pressure to a damaged hose may cause it to

unsafe product use, lack of maintenance or incorrect product and/
rupture.
or system operation. Contact Enerpac when in doubt as to the
safety precautions and operations. If you have never been trained IMPORTANT: Do not lift hydraulic equipment by the
on high-pressure hydraulic safety, consult your distribution or hoses or swivel couplers. Use the carrying handle or other
service center for information about an Enerpac hydraulic safety means of safe transport.
course.
CAUTION: Keep hydraulic equipment away from
Failure to comply with the following cautions and warnings could flames and heat. Excessive heat will soften packings
cause equipment damage and personal injury. and seals, resulting in fluid leaks. Heat also weakens
A CAUTION is used to indicate correct operating or maintenance hose materials and packings. For optimum performance do not
procedures and practices to prevent damage to, or destruction of expose equipment to temperatures of 150°F [65°C] or higher.
equipment or other property. Protect hoses and cylinders from weld spatter.
A WARNING indicates a potential danger that requires correct DANGER: Do not handle pressurized hoses. Escaping
procedures or practices to avoid personal injury. oil under pressure can penetrate the skin, causing serious
A DANGER is only used when your action or lack of action may injury. If oil is injected under the skin, see a doctor
cause serious injury or even death. immediately.
WARNING: Wear proper personal protective gear when WARNING: Only use hydraulic cylinders in a coupled
operating hydraulic equipment. system. Never use a cylinder with unconnected couplers. If
the cylinder becomes extremely overloaded, components
WARNING: Stay clear of loads supported by hydraulics. can fail catastrophically causing severe personal injury.
A cylinder, when used as a load lifting device, should
WARNING: BE SURE SETUP IS STABLE BEFORE
never be used as a load holding device. After the load has
LIFTING LOAD. Cylinders should be placed on a flat
®
been raised or lowered, it must always be blocked

surface that can support the load. Where applicable, use a
mechanically.
cylinder base for added stability. Do not weld or otherwise
WARNING: USE ONLY RIGID PIECES TO HOLD LOADS. modify the cylinder to attach a base or other support.
Carefully select steel or wood blocks that are capable of
®
Avoid situations where loads are not directly centered on

supporting the load. Never use a hydraulic cylinder as a
the cylinder plunger. Off-center loads produce considerable
shim or spacer in any lifting or pressing application.
strain on cylinders and plungers. In addition, the load may
slip or fall, causing potentially dangerous results.

383
Valve and Manifold Instruction Sheet (Sheet 2)
Distribute the load evenly across the entire saddle V-91 Snubber Valve
surface. Always use a saddle to protect the plunger.
This valve is infinitely adjustable for metering oil out of a gauge to
prevent snapping of the gauge pointer when load or pressure is
suddenly released. It is also usable as a shut-off valve to protect
the gauge during high cycling applications. Maximum pressure is
IMPORTANT: Hydraulic equipment must only be serviced
10,000 psi [700 bar].
by a qualified hydraulic technician. For repair service,
contact the Authorized ENERPAC Service Center in your AM-21 Split-Flow Hydraulic Manifold
area. To protect your warranty, use only ENERPAC oil.
This manifold functions as a split-flow valve, allowing simultaneous
WARNING: Immediately replace worn or damaged parts control of two single-acting hydraulic cylinders. The manually
with genuine ENERPAC parts. Standard grade parts will operated needle valves can be used for flow metering or as shut-
break causing personal injury and property damage. off valves. Maximum pressure is 10,000 psi [700 bar].
ENERPAC parts are designed to fit properly and withstand high
AM-41 Split-Flow Hydraulic Manifold
loads.
This manifold functions as a split-flow valve, allowing simultaneous
3.0 DESCRIPTION control of up to four single-acting hydraulic cylinders. The
V-82, V-182 and V-8F Two-Way Manual Needle Valve manually operated needle valves can be used for flow metering
or as shut off valves. Maximum pressure is 10,000 psi [700 bar].
V-82 and V-182
Designed to operate at 10,000 psi [700 bar] 4.0 INSTALLATION
from either port this valve can be used as a 1. For most applications, including load holding, install the valve so
shut-off valve or metering valve in hydraulic that the load pressure acts against the seat, not the valve stem
circuits. seals. This will increase safety and protect the life of the valve.
Install V-82, V-182, V-8F and V-91 valves so that the direction
of flow is the same as the direction of the arrow on the side of
the valve. Install V-66, V-66NV and V-66F valves so that the
V-8F
fitting from the check ball port is plumbed directly into the
The V-8F valve operates only as a metering valve and features cylinder port.
increased metering capability for control of cylinder speed during 2. Use correct fittings. V-82 and V-8F valves have 3/8" NPTF
load lowering. fittings. V-66, V-66NV and V-66F valves have 3/8" NPTF
CAUTION: V-8F valves are not designed for use as shut- fittings. V-182 valves have 1/4" NPTF fittings. V-91 valves
off valves. have 1/2" NPTF fittings. AM-21 and AM-41 manifolds have
3/8" NPTF fittings.
3. Use 1-1/2 wraps of Teflon tape (or similar thread sealant)
V-66 and V-66NV Two-way Manual Flow Control on fittings, leaving the first complete thread free of tape or
Check Valve sealant to prevent sealant from entering the hydraulic system.
Tighten fittings securely.
When this valve is opened, flow is free in
both directions. When this valve is CAUTION: Connections should be snug and leak-free.
closed, flow is checked from the cylinder. Overtightening connections promotes thread failure and
The cylinder port is marked CYL. The may cause high pressure fittings to rupture at less than
V-66 and V-66NV valve can also be used rated capacity.
to hold a load in case system pressure is WARNING: Shut-off and safety valves should be close-
lost. This valve also has a built in relief coupled to cylinders. NEVER allow pressurized hoses in
valve that is set to 11,500 psi [790 bar]. a load-holding circuit.
4. Tighten handle to close valve. Loosen handle to open valve.
IMPORTANT: Models V-66 and V-66NV: Relief valve is located NOTE: V-8F and V-66F valves have knurled knobs rather than
inside hole under free flow port. DO NOT plug this hole or attempt handles.
to use it as a secondary port. WARNING: Turn handle only as far as the stop.
Overtightening or subjecting the handle to excessive
V-66F Two-way Manual Flow Control Check Valve force will weaken and strip internal spindle threads,
(Fine Metering) creating a safety hazard. Use only fingers to tighten knurled
knobs. NEVER use extension handles.
With careful monitoring of system operation, the V-66F can
be used as a flow control and metering valve for applications
requiring slow lowering of loads. This valve also has a built in relief
valve that is set to 11,500 psi [790 bar].
CAUTION: V-66F valves are not designed for load
holding applications.
IMPORTANT: Model V-66F: Relief valve is located inside hole

under free flow port. DO NOT plug this hole or attempt to use it
as a secondary port.

384
5.0 SPECIFICATIONS, V-82, V-182, V66, V-66NV, V-8F and V-66F
Metered/
Free Flow Checked
[97.79] Direction Direction
3.85
[97.0]
3/8" NPTF
3.82
3/8" NPTF (V-82)
[50.8]
2.00
1/4" NPTF (V-182)
4
[31.8]
1.25
3.50
[88.9]
2.50
V-82 and V-182 V-66 and V-66NV
[63.5]
1.00 1.00
[25.4] [25.4]
Metered/
Free Flow Checked
[107.4]
[98.3]
Direction Direction
3.87
4.23
3/8" NPTF 3/8" NPTF
[50.8]
[41.1]
2.00
1.62
2.88 3.50
[73.2]
V-8F [88.9]
V-66F
All dimensions in inches [mm]
4Models V-66, V-66NV and V-66F: Relief valve is

located inside hole under free flow port. DO NOT plug
this hole or attempt to use it as a secondary port.
6.0 SPECIFICATIONS, V-91
63.5
[2.50] V-91
31.8
[1.25]
[3.50]
89.0
1/2" NPTF
4,8 1/2" NPTF

[ø 0.19]
[1.25]
31.8
[0.63]
16.0
37
31.8 [1.44]
[1.25]
63.5
[2.50]

385
7.0 SPECIFICATIONS, AM-21
6.00
[152.4]
0.50
[12.7]
ø 0.28
[7.1] 5.00 AM-21
0.50
[127.0]
[12.7]
2.50 0.50
[63.5] [12.7]
[98.6 - 98.9]
3.88 - 3.89
1.00 3/8" NPTF

[25.4] (all ports)
0.50
[41.3]
1.63
[12.7]
3.00 1.00 0.50

[76.2] [25.4] 1.63 [12.7]
[41.3]
8.0 SPECIFICATIONS, AM-41
12.00
[304.8]
0.50
[12.7]
ø 0.28 11.00
[7.1] [279.4]
AM-41
2.50
[63.5]
0.50
[98.6 - 105.7]
3.88 - 4.16
3/8”NPT
3/8" NPTF [12.7]
[12,7]
(all ports)
ports)
0.50
[41.3]
1.00
1.63
[25.4] [12.7]
1.63
3.00 1.00
[41.3]
[76.2] [25.4]

386
NOTES:

387
www.enerpac.com

388
A.7.4 Manual Shut-Off Valve Repair Parts Sheet
Repair Parts Sheet
POWERFUL SOLUTIONS. GLOBAL FORCE. Manual Shut-Off Valves

V82, V182, V91, AM21 & AM41
L4042 Rev. A 10/12 For Date Codes Beginning with the Letter “O”
To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.

Enerpac recommends that all kit components be installed to insure optimum performance of the repaired product.
Figure 1 - Manual Shut-Off Valve Identification
V82 V182
V91
AM21
AM41

389
Manual Shut-Off Valve Repair Parts Sheet (Sheet 2)
Figure 2 - Valve Spindle Assembly

6
7
4 TORQUE TO
50 FT-LBS
[67.7 Nm]
8
3
KIT V82K
(ASSEMBLED VIEW)
BODY OR MANIFOLD
(APPEARANCE WILL VARY)
Repair Parts List (Refer to figure 2)

Item Part Number Qty. Description Item Part Number Qty. Description
1 ✜★ B1010203 1 O-Ring, Viton 5 ★ 1 Dust Cap
2 ✜★ B1010564 1 Backup Ring 6 ★ 1 T-Handle
3 ★ 1 Stem 7 ★ 1 Set Screw
4 ★ 1 Bonnet 8 (not available) 1 Roll Pin, 5/32 x 1/2" Steel
★ Included in V82K Valve Spindle Repair Kit. ✜ Items can be ordered separately.
Notes:
The parts included in the V82K Valve Spindle Repair Kit will fit all valve models shown in Figure 1 (see previous page).
Items 1 and 2 can be ordered seperately if needed. Items 3 through 7 are available only in the V82K repair kit.
Item 8 is not available for purchase from Enerpac (obtain part locally).
Valve body or manifold is not available as a service part. If damaged, a complete replacment valve must be ordered.

390
Valve Spindle Replacement instructions:
1. Relieve all pressure. Be sure that pressure gauge indicates zero (0) psi/bar.
2. Carefully remove roll pin (item 8). Save roll pin for later use during reassembly.
3. Loosen bonnet (item 4). Unscrew and remove old valve assembly (items 1 through 7).
4. Inspect body or manifold for wear and contamination.
Note: Use new parts from V82K Valve Spindle Repair Kit during the following steps:
5. Screw the stem (item 3) all the way into the bonnet (item 4).
6. Install stem and bonnet assembly (items 1 through 4) into the body or manifold.
7. Torque the bonnet (item 4) to 50 ft-lbs [67.7 Nm].
8. Place dust cap (item 5) onto bonnet (item 4) and then place T-handle onto stem.
9. Line-up the set screw (item 7) with the flat on the stem. Tighten set screw until snug.
10. Reinstall roll pin (item 8) into appropriate hole in body or manifold.
NOTES:

391

Australia and New Zealand Germany and Austria South Korea South Africa and other English
Actuant Australia Ltd. ENERPAC GmbH Actuant Korea Ltd. speaking African countries
Block V Unit 3 P.O. Box 300113 3Ba 717, Shihwa Industrial Complex Enerpac Africa Pty Ltd.
Regents Park Estate D-40401 Düsseldorf Jungwang-Dong, Shihung-Shi, No. 5 Bauhinia Avenue
391 Park Road Willstätterstrasse 13 Kyunggi-Do Cambridge Office Park
Regents Park NSW 2143 D-40549 Düsseldorf, Germany Republic of Korea 429-450 Block E
(P.O. Box 261) Australia T +49 211 471 490 T +82 31 434 4506 Highveld Techno Park
T +61 (0)2 9743 8988 F +49 211 471 49 28 F +82 31 434 4507 Centurion 0157
F +61 (0)2 9743 8648 sales-de@enerpac.com sales-kr@enerpac.com South Africa
sales-au@enerpac.com T: +27 12 940 0656
India Spain and Portugal
Brazil ENERPAC Hydraulics Pvt. Ltd. ENERPAC SPAIN, S.L. United Kingdom and Ireland
Power Packer do Brasil Ltda. No. 1A, Peenya Industrial Area Avda. Los Frailes, 40 – Nave C & D ENERPAC Ltd.,
Rua dos Inocentes, 587 IInd Phase, Bangalore, 560 058, India Pol. Ind. Los Frailes Bentley Road South
04764-050 - Sao Paulo (SP) T +91 80 40 792 777 28814 Daganzo de Arriba Darlaston, West Midlands
T +55 11 5687 2211 F +91 80 40 792 792 (Madrid) Spain WS10 8LQ
F +55 11 5686 5583 sales-in@enerpac.com T +34 91 884 86 06 England
Toll Free: 0800 891 5770 F +34 91 884 86 11 T +44 (0)121 50 50 787
vendasbrasil@enerpac.com Italy sales-es@enerpac.com F +44 (0)121 50 50 799
ENERPAC S.p.A. sales-uk@enerpac.com
Canada Via Canova 4 Sweden, Denmark, Norway, Finland
Actuant Canada Corporation 20094 Corsico (Milano) and Iceland USA, Latin America and Caribbean
6615 Ordan Drive, Unit 14-15 T +39 02 4861 111 Enerpac Scandinavia AB ENERPAC
Mississauga, Ontario L5T 1X2 F +39 02 4860 1288 Fabriksgatan 7 P.O. Box 3241
T +1 905 564 5749 sales-it@enerpac.com 412 50 Gothenburg Milwaukee WI 53201 USA
F +1 905 564 0305 Sweden T +1 262 293 1600
Toll Free: Japan T +46 (0) 31 799 0281 F +1 262 293 7036
T +1 800 268 4987 Applied Power Japan LTD KK F +46 (0) 31 799 0010 User inquiries:
F +1 800 461 2456 Besshocho 85-7 scandinavianinquiries@enerpac.com T +1 800 433 2766
customer.service@actuant.com Kita-ku, Saitama-shi 331-0821, Japan Distributor inquiries/orders:
T +81 48 662 4911 The Netherlands, Belgium, T +1 800 558 0530
China F +81 48 662 4955 Luxembourg, F +1 800 628 0490
Actuant (China) Industries Co. Ltd. sales-jp@enerpac.com Central and Eastern Europe, Technical inquiries:
No. 6 Nanjing East Road, Baltic States, Greece, Turkey techservices@enerpac.com
Taicang Economic Dep Zone Middle East, Egypt and Libya and CIS countries sales-us@enerpac.com
Jiangsu, China ENERPAC Middle East FZE ENERPAC B.V.
T +86 0512 5328 7500 Office 423, LOB 15 Galvanistraat 115
F +86 0512 5335 9690 P.O. Box 18004, Jebel Ali, Dubai 6716 AE Ede
Toll Free: +86 400 885 0369 United Arab Emirates P.O. Box 8097
sales-cn@enerpac.com T +971 (0)4 8872686 6710 AB Ede
F +971 (0)4 8872687 The Netherlands All Enerpac products are guaranteed
France, Switzerland, North Africa sales-ua@enerpac.com T +31 318 535 911 against defects in workmanship and
and French speaking African F +31 318 535 848 materials for as long as you own them.
countries Russia sales-nl@enerpac.com
ENERPAC Rep. office Enerpac For the location of your nearest authorized
Une division d’ACTUANT France S.A. Russian Federation Enerpac Integrated Solutions B.V. Enerpac Service Center, visit us at
ZA de Courtaboeuf Admirala Makarova Street 8 Opaalstraat 44 www.enerpac.com
32, avenue de la Baltique 125212 Moscow, Russia 7554 TS Hengelo
91140 VILLEBON /YVETTE T +7 495 98090 91 P.O. Box 421
France F +7 495 98090 92 7550 AK Hengelo
T +33 1 60 13 68 68 sales-ru@enerpac.com The Netherlands
F +33 1 69 20 37 50 T +31 74 242 20 45 101711
sales-fr@enerpac.com Singapore F +31 74 243 03 38
Actuant Asia Pte Ltd. integratedsolutions@enerpac.com
83 Joo Koon Circle
Singapore 629109
T +65 68 63 0611
F +65 64 84 5669
Toll Free: +1800 363 7722

392
A.7.5 Electric Pump Instruction Sheet
Instruction Sheet
POWERFUL SOLUTIONS. GLOBAL FORCE. ZE3-6 and ZW4-5
L2647 Rev. C 04/13
Index:
English: .................... 1-17 Portuguese..........110-127
Français:..................18-36 Suomalainen .......128-144
Deutsch: ..................37-55 Norsk...................145-161
Italiano:....................56-73 Svensk ................162-178
Español: ..................74-91
Nederlands:...........92-109
Repair Parts Sheets for this product are available from the Enerpac
web site at www.enerpac.com, or from your nearest Authorized
Enerpac Service Center or Enerpac Sales office.
1.0 IMPORTANT RECEIVING INSTRUCTIONS
Visually inspect all components for shipping damage. Shipping
damage is not covered by warranty. If shipping damage is found,
notify carrier at once. The carrier is responsible for all repair and DANGER: To avoid personal injury keep hands and
replacement costs resulting from damage in shipment. feet away from cylinder and workpiece during
operation.
SAFETY FIRST WARNING: Do not exceed equipment ratings. Never
attempt to lift a load weighing more than the capacity of the
2.0 SAFETY ISSUES
cylinder. Overloading causes equipment failure and
Read all instructions, warnings and cautions carefully. possible personal injury. The cylinders are designed for a max.
Follow all safety precautions to avoid personal injury or pressure of 10,000 psi (700 bar). Do not connect a jack or cylinder
property damage during system operation. Enerpac to a pump with a higher pressure rating.
cannot be responsible for damage or injury resulting
from unsafe product use, lack of maintenance or incorrect product Never set the relief valve to a higher pressure than the
and/or system operation. Contact Enerpac when in doubt as to the maximum rated pressure of the pump. Higher settings may
safety precautions and operations. If you have never been trained on result in equipment damage and/or personal injury.
high-pressure hydraulic safety, consult your distribution or service WARNING: The system operating pressure must not
center for a free Enerpac Hydraulic safety course. exceed the pressure rating of the lowest rated component
Failure to comply with the following cautions and warnings could in the system. Install pressure gauges in the system to
cause equipment damage and personal injury. monitor operating pressure. It is your window to what is
happening in the system.
A CAUTION is used to indicate correct operating or maintenance
procedures and practices to prevent damage to, or destruction of CAUTION: Avoid damaging hydraulic hose. Avoid sharp
equipment or other property. bends and kinks when routing hydraulic hoses. Using a
bent or kinked hose will cause severe back-pressure. Sharp
A WARNING indicates a potential danger that requires correct bends and kinks will internally damage the hose leading to
procedures or practices to avoid personal injury. premature hose failure.
A DANGER is only used when your action or lack of action may
Do not drop heavy objects on hose. A sharp impact may
cause serious injury or even death.
cause internal damage to hose wire strands. Applying
pressure to a damaged hose may cause it to rupture.
®
WARNING: Wear proper personal protective gear when

operating hydraulic equipment.
IMPORTANT: Do not lift hydraulic equipment by the hoses
or swivel couplers. Use the carrying handle or other means
WARNING: Stay clear of loads supported by hydraulics. of safe transport.
A cylinder, when used as a load lifting device, should never
be used as a load holding device. After the load has been CAUTION: Keep hydraulic equipment away from
raised or lowered, it must always be blocked mechanically. flames and heat. Excessive heat will soften packings
and seals, resulting in fluid leaks. Heat also weakens
WARNING: USE ONLY RIGID PIECES TO HOLD LOADS. hose materials and packings. For optimum performance do not
Carefully select steel or wood blocks that are capable of expose equipment to temperatures of 150 °F (65 °C) or higher.
®
supporting the load. Never use a hydraulic cylinder as a shim

®
Protect hoses and cylinders from weld spatter.

or spacer in any lifting or pressing application.

393
Electric Pump Instruction Sheet (Sheet 2)
DANGER: Do not handle pressurized hoses. WARNING: Do not use electric pumps in an explosive
Escaping oil under pressure can penetrate the skin, atmosphere. Adhere to all local and national electrical
causing serious injury. If oil is injected under the skin, codes. A qualified electrician must do installation and
see a doctor immediately. modification.
WARNING: Only use hydraulic cylinders in a coupled WARNING: Start the pump with the valve in the neutral
system. Never use a cylinder with unconnected position to prevent accidental cylinder operation. Keep
couplers. If the cylinder becomes extremely overloaded, hands clear of moving parts and pressurized hoses.
components can fail catastrophically causing severe personal
WARNING: These pumps have internal factory adjusted
injury.
relief valves, which must not be repaired or adjusted
WARNING: BE SURE SETUP IS STABLE BEFORE except by an Authorized Enerpac Service Center.
LIFTING LOAD. Cylinders should be placed on a flat
CAUTION: To prevent damage to pump electric motor,
®
surface that can support the load. Where applicable, use a

check specifications. Use of incorrect power source will
cylinder base for added stability. Do not weld or otherwise
damage the motor.
modify the cylinder to attach a base or other support.
Avoid situations where loads are not directly centered on 3.0 SPECIFICATIONS
the cylinder plunger. Off-center loads produce 3.1 Performance Chart (see Performance Chart below)
considerable strain on cylinders and plungers. In
addition, the load may slip or fall, causing potentially dangerous 3.2 Flow Charts (see Figure 1)
results.
Distribute the load evenly across the entire saddle
4.0 INSTALLATION
surface. Always use a saddle to protect the plunger.
Install or position the pump to ensure that air flow around the
motor and pump is unobstructed. Keep the motor clean to
IMPORTANT: Hydraulic equipment must only be ensure maximum cooling during operation.
serviced by a qualified hydraulic technician. For repair
service, contact the Authorized ENERPAC Service 4.1 Reservoir Breather Cap (See Figure 2)
Center in your area. To protect your warranty, use only For shipping purposes, a shipping plug (A) is installed in the
ENERPAC oil. breather port on the top of the reservoir. Before using replace
the shipping plug with the breather cap (B). NOTE: The breather
WARNING: Immediately replace worn or damaged
port (B) is separate from the oil fill port (C). Oil fill port (C) uses a
parts by genuine ENERPAC parts. Standard grade parts
SAE #10 plug.
will break causing personal injury and property damage.
ENERPAC parts are designed to fit properly and withstand high
loads. B
Figure 2, ZE & ZW Breather Installation

394
FLOW CHARTS
ZE3 Series ZE4 Series ZE5 Series
1000 1000 1000
Oil Flow (in3/min)

Oil Flow (in3/min)
Oil Flow (in3/min)

900 900 900
800 800 800
700 700 700
600 600 600
500 500 500
400 400 400
300 300 300
200 200 200
100 100 100
0 0 0
0 2,000 4,000 6,000 8,000 10,000 0 2,000 4,000 6,000 8,000 10,000 0 2,000 4,000 6,000 8,000 10,000
Pressure (psi) Pressure (psi) Pressure (psi)

ZE3 series single-stage ZE4 series single-stage ZE5 series single-stage
ZE3 series two-stage ZE4 series two-stage ZE5 series two-stage
ZE6 Series ZW4 Series ZW5 Series

1000
Oil Flow (in3/min)
Oil Flow (in3/min)
Oil Flow (in3/min)

1000 1000
900 900 900
800 800 800
700 700 700
600 600 600
500 500 500
400 400 400
300 300 300
200 200 200
100 100 100
0 0 0
0 2,000 4,000 6,000 8,000 10,000 0 1,000 2,000 3,000 4,000 5,000 0 1,000 2,000 3,000 4,000 5,000
Pressure (psi) Pressure (psi) Pressure (psi)
ZE6 series single-stage ZW4 series single-stage ZW5 series single-stage
ZE6 series two-stage ZW4 series two-stage ZW5 series two-stage
PERFORMANCE CHART
Pump Operation Output Flow Rate Motor Size Relief Valve Sound
Series Adjustment Level
(in3/min) Range
100 psi 700 psi 5,000 psi 10.000 psi hp RPM (psi) (dBA)
Single-stage 43 43 42 40 1,000 -
ZE3 1.0 1750 75
Two-stage 450 385 42 40 10,000
Single-stage 64 64 62 60 1,000 -
ZE4 1.5 1750 75
Two-stage 650 600 62 60 10,000
Single-stage 128 126 123 120 1,000 -
ZE5 3.0 1750 75
Two-stage 850 825 123 120 10,000
Single-stage 220 215 210 200 1,000 -
ZE6 7.5 3450 10,000 80
Two-stage 900 890 210 200
Single-stage 64 63 60 1,000 -
ZW4 NA 1.0 1750 5,000 75
Two-stage 350 305 60
Single-stage 128 126 120 1,000 -
ZW5 NA 1.5 1750 5,000 75
Two-stage 650 602 120
Output flow rate is listed at 60 Hz.

Flow rate will be approximately 5/6 of these values at 50Hz.

395
4.2 Pump Mounting 4.5 Hydraulic Connections

Refer to Figure 3 for mounting dimensions to secure the pump to Apply 1-1⁄2 wraps of Teflon tape
a fixed surface. or other suitable sealant to the
hydraulic hose fitting, leaving the
1, 2 Gal. (4-8 L) 2.5 Gal, (10 L) 5 Gal, (20 L) 10 Gal, (40 L) first complete thread free of tape
in. (mm) in. (mm) in. (mm) in. (mm) or sealant as shown in Figure 5.
A 9.46 (240) 12.0 (305) 16.6 (421) 19.9 (505)
Figure 5
B 3.75 (95) 11.0 (279) 15.6 (396) 18.9 (480)
C 16.28 (414) 17.6 (446) 17.6 (446) 17.6 (446) Thread hose(s) into outlet port(s) of the valve (see valve body for
port identification).
D 9.00 (229) 12.0 (305) 12.0 (305) 12.0 (305)
Extend hose to valve port “A”
E 2.86 (73) 0.5 (13) 0.5 (13) 0.5 (13)
Retract hose to valve port “B” (if applicable).
F 3.64 (92) 2.8 (71) 2.8 (71) 2.8 (71)
Gauge to valve port “GA, GB, or GP”.
G M8 x 1.25 Ø .34 (8.6) diameter through hole
0.25 (6) deep (“GA” measures “A” port pressure, “GB” measures “B” port
pressure, “GP measures pump pressure down stream of system
check).
5.0 OPERATION
Warning: Pumps with optional pressure transducer,
review sections 5.7, 6.4 A-B, and 6.5 A-C on
“AUTOMODE” before starting pump.
Warning: Pumps with optional pressure switch, review
sections 5.8 before starting pump.
1. Check the oil level of pump and add oil if necessary.

2. Make sure the shipping plug has been removed and the
breather cap is installed. (See section 4.1)
3. Place manual control valve (if equipped) in the Neutral
Figure 3
position.
4. Connect unit to power. Wait 2 seconds (LCD units, wait until
4.3 Electrical Connections "OK" is displayed) before pressing any button on shroud or
THE PUMP IS FACTORY EQUIPPED WITH THE COMMON pendant. NOTE: During the boot sequence, the
ELECTRICAL PLUG FOR A GIVEN VOLTAGE, ALTERING THE microprocessor identifies any button operation as a potential
PLUG TYPE SHOULD ONLY BE DONE BY A QUALIFIED malfunction and prevents the motor from starting. Reset by
ELECTRICIAN, ADHERING TO ALL APPLICABLE LOCAL disconnecting power for 10 seconds.
AND NATIONAL CODES. 5. For motor On/Off and valve operation, see sections 5.1 – 5.6
for your specific configuration instructions.
1. The disconnect and line circuit protection to be provided by customer.
Line circuit protection to be 115% of motor full load current at 5.1 Manual Valve 2
maximum pressure of application (see Figure 1). Operation

2. For more information, refer to pump name plate for power rating.
VM32 (See Fig. 6)
4.4 Fluid Level 1. Advance
Check the oil level of the pump prior to start-up, if necessary add 2. Retract 1
oil by removing the SAE #10 plug from the cover plate (see Fig.
2). The reservoir is full when the oil level reaches the top of the Shroud On/off=
sight glass. (Fig. 4). Toggle Motor On or Off
Tank Pressure
Figure 6
Tank is full when
oil level is here.
VM33, VM33L, VM43,
VM43L (See Fig. 7)
3 - In Use
1. Advance
4 and 8 liter 10 - 40 liter 2. Retract B A
3. Neutral
Figure 4 Shroud On/Off =
Toggle Motor On or Off 2 1
IMPORTANT: Add oil only when all system components are fully
retracted, or the system will contain more oil than the reservoir 3
can hold. Figure 7

4

396
One Two Three

motor off. Note: The main operations menu text will change from
button button button “OK” to “AUTO” to notify the operator that the pump WILL take
control when the HI PRESS pressure value is reached.
Up arrow 3. AUTOMODE ON and LO PRESS greater than 0
¤ ¤ ¤
Down arrow The pump will de-energize the motor / electric valve when the HI
PRESS value is reached and re-energize the motor / electric
ON / OFF valve when the LO PRESS value is reached, acting as a pressure
make up pump. Note: For an additional notice to the operator,
the main operations menu text will change from “AUTO” to
“AUTO ON” and the LCD backlight will flash when the pump
reaches HI PRESS and takes control of making up pressure.
Figure 8, Pendant Button Variations Warning: When the LCD backlight is flashing and “AUTO
ON” is displayed, the pump will automatically start the
5.2 VE33 and VE43 Electric Valves with 3-Button motor or energize the valve to rebuild system pressure
Pendant Operation without input from the operator. Set “AUTOMODE” to off and
disconnect electrical power to pump before working on pump or
Also known as a Remote Pump - oil flow and motor are both
hydraulic system.
controlled by the pendant (see Fig. 8).
a. Control Buttons
1. Up Arrow = Momentary Advance
2. Down Arrow = Momentary Retract i. Before “HI PRESS” value is reached:
3. On/Off = Toggle Motor On or Off Pendant buttons and shroud On / Off button function as
described in sections 5.1 – 5.4.
Shroud On/Off = Toggle motor On or Off
ii. After “HI PRESS” value is reached:
5.3 VE32D Electric Valve with 1-Button Pendant Operation Press and release any button on pendant (if applicable) or
Also known as a Dump Pump - Oil flow and motor are both shroud stops the automatic cycle and “AUTO” is shown on
controlled by the pendant. The pump will run and the cylinder the LCD. (Pressing the pendant Down-Arrow (if applicable)
will advance when the pendant button is pressed. Releasing the will also retract the cylinder. Pressing the motor On/Off
button will stop the pump and the cylinder will retract button will also de-energize the motor).
automatically (see Fig. 8). To restart the automatic cycle, press and release the
1. Up Arrow = Momentary Advance pendant Up-Arrow button (if applicable) or the motor On/Off
button (See section 5.1– 5.4).
Shroud On/Off = Toggle Motor Off Only
Caution: Due to motor coast down, valve shift time, and
5.4 Valves with foot switch (see Fig. 9) system oil capacitance, always set the user adjustable
A. All valves except VE32D relief valve 200 psi above the “SET PRES” or “HI
PRESS” value to prevent pressure spikes.
1. Momentary advance or motor on
5.6 Automatic Pump Operation With Pressure Switch Option
2. Momentary retract (if applicable)
Shroud On/Off = Toggle Motor On or Off With the optional pressure switch installed, the electric motor
will automatically stop and re-start at a user defined setting. This
B. VE32D valves
setting is entered via the pressure switch adjusting screw.
1. Not used Figure 9
1. Connect unit to power, the LCD will show “OK”.
2. Momentary advance
2. Operate pump via section 5.1 - 5.4.
Shroud On/Off = Toggle Motor Off
3. When the “A” port pressure reaches the user defined limit,
5.5 Automatic Pump Operation With Pressure the pressure switch opens, the motor is de-energized, the
Transducer Option LCD screen shows “AUTO ON” and the back light will flash
(the microprocessor is now aware that a pressure switch is
In addition to the normal operation details listed above, pumps controlling the pump).
with the optional pressure transducer have the ability to react
automatically at a user-defined pressure value. The specific Warning: When the LCD backlight is flashing and
operation of the motor / electric valve is factory set by pump “AUTO ON” is displayed, the hydraulic system is under
model. See the “Pump-Model-Matrix”, Page 16, Table 3 for pressure and the pump will automatically start the motor
details by pump model number. See section 6.4 A-B and to rebuild system pressure without input from the operator.
6.5 A – C for setting the pressure values. Release hydraulic pressure and disconnect electrical power to
pump before working on pump or hydraulic system.
A. AUTOMODE
4. When the “A” port pressure drops 115-550 psi, the pressure
1. AUTOMODE OFF switch closes and the motor is re-energized.
The pump displays pressure as a simple pressure gauge, no 5. Pressing and releasing any button on the pendant (if
additional actions will be performed regardless of HI PRESS and applicable) or shroud will stop this automatic cycle.
LO PRESS values. Note: The normal operations menu shows a. If the pressure switch is closed (motor energized) when
“OK” in the text area when AUTOMODE is set to OFF. the button is pressed, “AUTO” is shown on the LCD.
2. AUTOMODE ON withLO PRESS OFF b. If the pressure switch is open (motor de-energized) when the
When the HI PRESS pressure value is reached, the pumps will button is pressed, “P Switch Open” is shown on the LCD.
either shift the valve (VE33 and VE43 electric valve) or turn the c. Pressing the motor activation button (Section 5.1 - 5.4)
reactivates the automatic pressure switch operation.
5

397
d. Pressing the pendant Down-Arrow (if applicable) will also the main interface between the operator and the pump. With the
retract the cylinder. use of these four-button switches all functions and settings that
5.7 Relief Valve Adjustment are described in the following can be activated.
Z-Class pumps are equipped with one user adjustable relief CAUTION: Make sure that the plastic overlay, that
valve (see Figure 10.) It can be adjusted as follows: protects the LCD screen and the button switches, is not
1. Install a gauge on the pump. If a unit is equipped with broken or otherwise damaged. Never punch the button
optional pressure transducer, verify AUTOMODE is off. (See switches with a sharp or pointed instrument, use fingertips only.
section 6.1C for more details). Clean the overlay regularly with a damp cloth; never use
2. Start the pump to allow the oil to warm. aggressive or abrasive detergents.
3. Loosen the set screw locking nut. A. Boot Sequence
4. Shift the control valve and build pressure in the system. When the pump is connected to electrical power the LCD screen
Using an Allen wrench, turn the set screw counter-clockwise will show: “FIRMWARE” x.x for 1 second, then “Model xx" for 0.5
to decrease pressure and clockwise to increase pressure. seconds, and then "Motor UN/1P/3P" for 0.5 seconds. Additional
NOTE: To get an accurate setting, decrease the pressure to information may appear depending on model and installed
a point below the final setting and then slowly increase the accessories. See section 8.0 for more detailed information.
pressure until it reaches the final setting. This is setup information about your pump that maybe needed for
5. Tighten the locking nut when the desired pressure is set. service. The boot sequence is finished successfully when the text
6. Shift the control valve to the neutral position, allowing the display on the LCD screen shows “OK” (sequence takes
system pressure to return to 0 psi. approximately 2 seconds).
7. Recheck the final pressure setting by shifting the control The micro-controller will automatically recognize the optional
valve and pressurizing the system. pressure transducer (if equipped). In this case the reading after
the boot process is “OK” in the text display and the current
Relief valve body (DO NOT TURN relief
pump-pressure on the numeric display.
valve body.)
B. LCD Operational Buttons
The CB is equipped with four button switches, from left to right
Set screw
Locknut
Figure 10
On/Off / Menu / Down Arrow / Up Arrow
6.0 LCD ELECTRICAL USE INSTRUCTIONS • The On/Off button toggles the motor ON and OFF. The motor
OFF function is available on this button even if the pump is
The LCD version of the Z-class Pump is driven and operated by
NOT in the local mode but is operated by using the pendant.
a set of two boards: the Power Board (PB) and the Control Board
(CB), connected to each other by a flat cable. • The Menu button enables the operator to step from normal
operational mode into menus. With repeated pressing the
On the PB are the terminals for the main power supply, the operator steps through the various menus. Pressing the
motor power supply and all peripherals such as fan, valve Menu button also saves any changes made. To return to the
solenoids, pendant, pressure switch, pressure transducer, oil normal operational mode, press and hold the Menu button
temperature switch, and oil level switch. The PB also contains for two seconds or don’t push any button for 60 seconds.
the transformer, circuit breaker, rectifier and drivers.
• The Down Arrow and Up Arrow buttons serve two purposes.
CAUTION: The CB is an electrostatic sensitive device. When the display shows one of the menus, the Down Arrow
Special care has to be taken while handling this board and Up Arrow buttons are used to step through the menu’s
(i.e.: ESD wristbands). options. When the pump is placed in Local Mode, the Down
Arrow and Up Arrow buttons switch the B and A electric
6.1 LCD Function
solenoids (the pendant is non-operational in local mode).
Screen 1 Text display C. Menus Available
The software provides the operator with the following Menus:
Number
display • Units - this menu is only available when the optional pressure
SET
00000000 transducer is installed. Set the pressure units to
0000.0 PSI MPa

BAR
PSI / BAR / MPa, with psi being the default setting.
The hidden menus for "AUTOMODE" (HI PRESS and LO
HOURS CYCLES PRESS) and Calibration of the digital gauge are accessed
LOW MOTOR from this menu.
VOLTAGE OVERLOAD • Motor - display the motor hour meter and on/off cycle
counter (nonresetable)
• Low Volt - display the low voltage hour-meter (nonresetable)
• Advance - display the Advance solenoid hour meter and
on/off cycle counter (nonresetable)
• Retract - display the Retract solenoid hour meter and on/off
Besides the pendant, which is used to switch the motor on/off cycle-counter (nonresetable)
and operate the valves, the CB with its four-button switches is • Local - set the pump local mode on/off
6

398
• Language - set the language of the display to English / The Motor Overload fault is displayed when the electric current
Spanish / French / Italian / German / Portuguese, with drawn by the motor exceeds the pre-set limit of the internal
English being the default setting circuit breaker. (The internal circuit breaker will automatically
• Diagnose – display to show input signals from the pendant reset once the condition has been corrected; however, the
and other electrical accessories operator must clear the fault and then press the motor on/off
6.2 Fault Conditions button to restart the motor).
Any fault will shut down and prevent pump from starting. E. Oil Temperature (requires optional float/temperature
A. Clearing a Fault Condition from the LCD switch)
After the fault causing problem has been corrected, clear the fault Display: "OIL TEMP"
message from the LCD by disconnecting electrical power from the
pump, wait until all characters clear the LCD (~ 10 seconds), then Screen 5
reconnect power.
B. Power Failure
OIL TEMP
Display: "POWER OFF"
Screen 2
POWER
OFF The Oil Temperature Fault is displayed when the temperature of the
oil inside the reservoir exceeds 175 ºF (80 °C).
F. Oil Level (requires optional level / temperature switch)
Display: "OIL LEVEL"
Screen 6
The Power Off fault is displayed when the main power supply drops
to 65% or less of nominal voltage. The pump will automatically shut OIL LEVEL
off the valves and the motor, and display “Power Off” on the LCD.
NOTE: Power Off is also displayed for several seconds after the unit
is disconnected from electrical power.)
C. Button Fault
Display: "Button Fault"
Screen 3
The Oil Level Fault is displayed when the oil level inside the
reservoir drops below 1.3" (34 mm) from bottom.
BUTTON 6.3 Warning Conditions
FAULT All warnings notify operator of abnormal operating condition,
however, allow pump to continue operating. Warnings will
automatically clear once issue has been resolved.
A. Low Voltage
Display: "LOW VOLT"
Low Voltage
The Button Fault is displayed when the microprocessor detects
any button press during the boot sequence or if shroud on/off Screen 7
button is held in for more than 3 seconds.
D. Motor Overload LOW VOLT

Display: "MTR OVLD"
LOW
Motor Overload VOLTAGE
Screen 4
MTR OVLD
A “Low Voltage" condition is defined as an operating condition
MOTOR with the main power supply is at or below 80% of nominal
OVERLOAD voltage. While running the pump under this condition, the “Low
Voltage” signal will flash on the LCD and the Low Voltage hours
will be counted and stored on the control board. Normal pump
operation is still provided.
7

399
CAUTION: For optimized pump performance it is _________________________________________________________

recommended NOT to run the pump at Low Voltage General note for all hour and cycle displays:
condition. HOURS DISPLAYED
6.4 LCD Menus - up to 9999.9 the display will show decimal hours
(Also refer to Table 1, Quick Reference Chart (QRC) located after - between 10,000 - 99,999 whole hours will be displayed
Section 9.0) (decimal "." is not displayed).
A. Normal Operation - over 99,999 hours the meter starts over at 0.0 reading
decimal hours
Screen 8
CYCLES DISPLAYED
- over 99,999 cycles the meter starts over at 0
OK _________________________________________________________
0 PSI
D. "Low Volt" Menu
Screen 11
LOW VOLT
.0
HOURS CYCLES
(See Screen 8.) LCD screen on a Z-class pump. CB has booted
successfully (OK); the pressure reading is 0 psi. Enter into the
menus by pressing the Menu button. See QRC step #1.
B. "Units" Menu
Screen 9
(See Screen 11.) This screen allows the operator to read the
number of hours the pump has been operated in low-voltage
SET
UNITS condition. Step forward by pressing the Menu button. See QRC
PSI MPa step #4.
BAR
E. "Advance" Menu
Screen 12
ADVANCE
(See Screen 9.) This screen allows the operator to set the unit of
188
HOURS CYCLES
pressure-measurement by pressing the Down (Up) Arrow
buttons. PSI, BAR, Mpa are the options with PSI being the
default. Save setting and step forward by pressing the Menu
button. See QRC step #2.
C. "Motor" Menu
Screen 10
(See Screen 12.) This screen allows the operator to read the number
MOTOR of hours (On/Off cycles) the Advance solenoid has been operated.
4.8 Toggle between hours and cycles by pushing either the Down or Up
Arrow buttons. Step forward by pressing the Menu button. See
HOURS CYCLES QRC step #5.
F. "Retract" Menu
Screen 13
RETRACT
number of hours (On/Off cycles) the motor has been operated.
Toggle between hours and cycles by pushing either the Down
334
HOURS CYCLES
or Up Arrow button. Step forward by pressing the Menu button.
See QRC step #3.
number of hours (On/Off cycles) the Retract solenoid has been

400
operated. Toggle between hours and cycles by pushing either Screen 17

the Down or Up Arrow button. Step forward by pressing the
Menu button. See QRC step #6.
G. "Local" Menu DIAGNOSE
Screen 14
10001 PSI
SET
LOCAL Press
OFF
(See Screen 17.) Diagnose screen with Pendant motor button
pushed.
Screen 18
(See Screen 14.) This screen allows the operator to toggle the Local
Press
mode ON or OFF, default is OFF. With Local mode ON, the shroud
buttons replace the pendant buttons as the method to operate the DIAGNOSE
pump (NOTE: The word "Local" replaces "OK" on the "Normal
Operations" display and the pendant buttons become deactivated). 01001 PSI
Local mode will provide operation of the pump if the pendant or

pendant cord is damaged. Toggle Local mode ON or OFF by
pressing the Down (Up) Arrow button. Save setting and step
forward by pressing the Menu button. See QRC step #7.
H. "Language" Menu
(See Screen 18.) Diagnose screen with Pendant Advance button pushed.
Screen 15
Screen 19
SET
ENGLISH
Press DIAGNOSE
00101 PSI
With a language shown on the text display the operator can change
the display language by pressing the Down (Up) Arrow buttons. Save
(See Screen 19.) Diagnose screen with Pendant Retract button pushed.
setting and step forward by pressing the Menu button. See QRC
step #8. 6.5 LCD Hidden Menus - available when the optional
I. "Diagnose" Menu pressure transducer is installed
A. “AUTOMODE” Menu
Screen 16
Screen 20
14
SET
DIAGNOSE SET
AUTOMODE
00001 PSI
OFF
(not used) (See Screen 20.) This screen allows the operator to toggle Off
Fan and On the pump’s ability to automatically control motor /
Pendant DOWN ARROW button electric valve functions. To access this menu, go to the “UNITS”
menu, then press and hold the ON/OFF button in for 7 seconds,
Pendant UP ARROW button
ENTRY CODE will appear. Then press and hold ON/OFF and Up-
Pendant ON/OFF button
Arrow buttons for 7 seconds.
(See Screen 16.) This screen allows the operator to troubleshoot
OFF - the pump displays pressure as a simple pressure gauge,
several pendant problems by displaying if the microprocessor has
received a signal from the pendant button. No signal indicates the no additional actions will be performed.
problem is most likely with the pendant keypad or pendant cord. ON – the pump will de-energize or energize the motor / electric
Use Local mode to operate pump until problem can be corrected. valve when the hydraulic pressure reaches operator defined
See QRC step #9.
9

401
levels, similar to a pressure switch pump. These levels are set in D. “Calibration ” Menu
two menus (HI PRESS and LO PRESS) that become available
when AUTOMODE is ON. The main operating menu text will Screen 23
change from “OK” to “AUTO” to notify the operator that the pump
will take control when certain limits are met. The specific SET
operation of the motor / electric valve is factory set by pump CAL PT A
model. See the “Pump-Model-Matrix”, Page 15, Table 3 for details
by pump model number. 0 PSI
B. “HI PRESS” Menu

Screen 21
SET
HI PRESS
(See Screen 23.) This screen allows the operator to adjust the pressure
10500 PSI
value shown on the LCD to match a master gauge. To access this
menu, go to “UNITS” menu.
Then press and hold the ON/OFF button in for 7 seconds, ENTRY
CODE will appear. Then press and hold both Down-Arrow and Up-
Arrow buttons for 7 seconds. See Table 2 “Z-Class Pump Calibration”
for adjustment steps.
(See Screen 21.) This screen allows the operator to set the high-pressure
limit for the pump to de-energize the motor / electric valve. Maximum 7.0 MAINTENANCE
value is 10,500 psi.
Frequently inspect all system components for leaks or damage.
Caution: Due to motor coast down, valve shift time, and Repair or replace damaged components. Electrical components,
system oil capacitance, always set the user adjustable for example, the power-cord, may only be repaired or replaced by
relief valve 200 psi above the “HI PRESS” value to a qualified electrician, adhering to all applicable local and national
prevent pressure spikes. codes.
C. “LO PRESS” Menu 7.1 Check Oil Level
Check the oil level of the pump prior to start-up, and add oil, if
Screen 22
necessary, by removing the fill port cap. Always be sure cylinders
SET are fully retracted before adding fluid to the reservoir. See Figure 2.
LO PRESS 7.2 Change Oil and Clean Reservoir
OFF Enerpac HF oil is a crisp blue color. Frequently check oil condition
for contamination by comparing pump oil to new Enerpac oil. As
a general rule, completely drain and clean the reservoir every 250
hours, or more frequently if used in dirty environments.
NOTE: This procedure requires that you remove the pump from
the reservoir. Work on a clean bench and dispose of used oil
(See Screen 22.) This screen allows the operator to set the low-pressure according to local codes.
limit for the pump to re-energize the motor / electric valve. Maximum 1. Unscrew the 13 bolts holding the coverplate to the reservoir
value is 50 psi less than the current HI PRESS value. When LO PRESS and lift the pump unit out of the reservoir. Be careful not to
is set to a value higher than OFF, the pump will operate like a pressure damage the filter screen.
switch pump, de-energizing the motor / electric valve at the HI PRESS 2. Pour all oil out of the reservoir.
value and re-energizing the motor / electric valve at the LO PRESS value.
3. Thoroughly clean the reservoir and reservoir magnet with a
For an additional notice to the operator, when pump is latched into this
suitable cleaning agent.
“pressure switch” mode, the operating menu text will change to “AUTO
ON” and the LCD back light will flash. 4. Remove the pick-up filter screen for cleaning. (Do not pull on
the screen or the bottom of the intake to avoid possible
Caution: Setting the LO PRESS value too close to the damage.) Clean the screen with solvent and a soft brush.
HI PRESS value may cause the pump to cycle on and Reinstall.
off too often. Frequent starting and stopping of the 5. Reassemble the pump and reservoir, installing a new
motor will increase wear and reduce the life of the pump. Use reservoir gasket.
appropriate valving in the hydraulic circuit to ensure that the 6. Fill the reservoir with clean Enerpac hydraulic oil. The
pump does not cycle on and off more than 3 times per minute. reservoir is full when oil level is in middle of the sight gauge
(see figure 4).
7.3 Changing the Filter Element (optional)
A return line filter may be ordered as an accessory to the pump. The
filter element should be replaced every 250 hours, or more
frequently in dirty environments. The filter manifold is equipped with
a 25 psi (1,7 bar) bypass to prevent over pressure rupture if filter
plugging occurs. Filter element replacement part number is PF25.
10

402
8.0 ACCESSORY INSTALLATION display will update in 50 psi increments. When it changes
rapidly, the display will update in 1000 psi increments.
The pressure transducer, heat exchanger, pressure switch,
pendant / foot switch, valve solenoids (A) and (B) are supplied 8.2 Pressure Switch Installation (Requires LCD
with connectors that plug into the proper plug-ins found on the Electric. Not compatible with pressure transducer
electrical power board (Figure 11). option, electric valves, or locking manual valves)
For further information and instructions on accessories see the Install pressure switch onto desired gauge port on valve
following web links: manifold. “GA” measures “A” port pressure, “GB” measures “B”
Pressure Transducer port pressure (if applicable), and “GP” measure pump pressure
http://www.wika.de/pdf/betriebsanleitungen/ba_m_1x.pdf before the control valve. Note Factory installed pressure
switches use port “GA”.
Level/Temp Switch Disconnect unit from electrical power supply before opening
http://www.barksdale.com/products/level/PDF_level/Pg02_7.pdf electrical box. Remove LCD half and one small hole plug from
http://www.barksdale.com/products/templ/PDF_temp/ml1s.pdf back panel. Route pressure switch wire through back panel,
connect to power board (see figure 11), and secure strain relief.
Pressure Switch Install shroud half.
http://www.barksdale.com/products
9.0 TROUBLESHOOTING (SEE TROUBLE-SHOOTING
Heat Exchanger GUIDE)
http://nmbtc.com/ (in the menu bar slide the mouse over
"products" and watch a sub-menu to show up. Click on "cooling Only qualified hydraulic technicians should service the pump or
solutions", click on "product catalog" in the list on the right-hand system components. A system failure may or may not be the
side and again click on "dc fan". In the following dialogue-screen result of a pump malfunction. To determine the cause of the
enter 5920PL-05W-B40 into the Search-field and click "go".) problem, the complete system must be included in any
diagnostic procedure.
8.1 Pressure Transducer Installation (Requires LCD
The following information is intended to be used only as an aid
Electric. Not compatible with pressure switch in determining if a problem exists. For repair service, contact
option.) your local Authorized Enerpac Service Center.
Install pressure transducer into desired gauge port on valve
manifold. "GA" measures "A" port pressure, "GB" measures "B"
port pressure (if applicable), and "GP" measures pump pressure
before the control valve. NOTE: Factory installed pressure
transducers use port "GA".
Disconnect unit from power supply before opening electrical
box. Remove LCD half and one small hole plug from back panel.
Route wire through back panel, connect to power board (see
figure 11), and secure strain relief. Install shroud half.
The microprocessor will automatically detect the pressure
transducer and add the "Units" and "AUTOMODE" menus
during the following power up. Initial pressure transducer offset
and gain values are permanently stored in the microprocessor
memory and allow the pressure transducer to be used without
further setup. If refinement is needed to certify the LCD reading
to a master gauge, see Table 2 for calibration procedure when
using port "GA". "Contact Enerpac on procedure changes when
using port "GB" or "GP".
NOTE: Pump models with remote VE33 or VE43 electric valves,
boot sequence will also show "PRES PORT (A/B)", A = GA, B =
GB. This is the pressure port the microprocessor is
programmed for the pressure transducer to measure. The
location of the pressure transducer must match this value for
proper operation of AUTOMODE. Factory default is A. Contact
Enerpac Technical Service for procedure to move pressure
transducer setting to B port.
Variable Rate Display of Pressure
The pressure transducer is very accurate and measures
pressure real time. To aid the operator when pressure is
changing rapidly, Z-Class provides a variable rate display.
Pressure values are updated 5x per second on the display.
The microprocessor will automatically change the increment
value based on rate of pressure change, increments are 50, 100,
500, and 1000 psi. When the rate of pressure change is slow, the
11

403
Line in Replaceable fuse F1
Motor leads
Flat ribbon
cable terminal
Oil-level switch
Temperature switch
Pendant
Pressure switch
Filter
Retract
Pressure transducer
Advance
Heat exchanger fan
Replaceable fuse F3
Figure 11, Electric Power Board Configuration
12

404
Trouble-shooting Guide
Problem Possible Cause Action*
Pump will not start Fault condition See section 5.0 Operation and 6.2 Fault Conditions for details
Pendant does not function Pump in local mode See Section 6.4G, Local Menu
See Section 6.4I, Diagnose Menu
Pendant damage See authorized service center
Motor stops under load Low voltage See Section 6.2B and 6.3A
Turn off other electric loads
Use heavier gauge extension cord
Electric valve will not No power or wrong voltage Connect to correct power source per pump name plate
operate Solenoid cable disconnected or damaged Connect, repair, or replace cable
Valve out of adjustment See authorized service center
Pump fails to build Low oil level Add oil per section 4.4
pressure or less than full Relief valve set too low Adjust per section 5.7
pressure External system leak Inspect and repair or replace
Internal leak in pump See authorized service center
Internal leak in valve See authorized service center
Internal leak in system component See authorized service center
Pump builds full pressure, Load greater than cylinder capacity at full pressure Reduce load or add cylinder capacity
but load does not move Flow to cylinder blocked Check hydraulic couplers for full engagement
Cylinder drifts back on its External system leak Inspect all hydraulic connections and replace or repair
own Internal leak in a system component See authorized service center
Non-load holding valve used See authorized service center
Single-acting cylinder will No load on a "load return" cylinder Add load

not return Return flow restricted or blocked Check couplers for full engagement
Locking valve used Run motor while retracting
Valve malfunction See authorized service center
Cylinder return spring broken See authorized service center
Double-acting cylinder will Return flow restricted or blocked Check couplers for full engagement
not return Locking valve used Run motor while retracting
Valve malfunction See authorized service center
Pump runs hot Advance or retract flow restricted Check couplers for full engagement
High ambient temperature Install heat exchanger for hydraulic oil
Pump pressure goes Cylinder comes to a sudden stop (i.e., strokes out) Set user adjustable relief valve 200 psi above "HI PRESS" valve
above "HI PRESS" value to redirect excess oil flow.
AUTOMODE does not Pressure transducer installed in pressure port other Move pressure transducer to “GA” (see section 8.1). Change
work correctly with VE33 than GA microprocessor setting to “GB” (see Authorized Service
or VE43 valves Center).
After boot-up LCD shows Pressure switch circuit is open and press transducer Check power board pressure switch jumper for being lose or
"P switch open" is installed missing (see Fig. 11).
Remove pressure switch or pressure transducer from pump.
LCD display shows Loose jumper on power board Check power board for lose or missing jumper at filter (see fig.
"FILTER" 11).
* For LCD versions, also see sections 6.2 Fault Conditions, 6.3 Warning Conditions and 6.4 LCD Menus.
13

Table 1, QRC : Quick Reference Chart
Step Switch Text Expected reading / symbol / status Units Comments
I M t s display digital display
1 OK default reading "OK" after power on and boot sequence

2 X UNITS PSI save previous setting and step forward to select units,
default is psi
X " BAR step through units using either the Up or
X " MPA the Down Arrow button
X " PSI
hidden menu
2a X UNITS hold for 7 seconds

X X ITEM CODE hold for 5 seconds
AUTOMODE ON/OFF toggle between on and off using the Arrow-buttons
X HI PRESS value of upper pressure limit for Automode increase/decrease value by using the Arrow-buttons
default value is 10500
X LO PRESS value of lower pressure limit for Automode increase/decrease value by using the Arrow-buttons
default value is OFF
hidden menu
2b X UNITS hold for 7 seconds
X X ITEM CODE hold for 5 seconds
CAL PT A 0 psi start calibration process, see calibration reference chart for
further instructions
3 X MOTOR number of hours HOURS save previous setting and step forward to select
14
hour-meter function
9/7/21
X " number of cycles CYCLES
4 X LOW VOLT number of hours at low volt, read 0 HOURS select low-voltage check function
5 X ADVANCE number of hours HOURS select hour-meter function
X " number of cycles CYCLES only if solenoid valve is attached
6 X RETRACT number of hours HOURS select hour meter-function
X " number of cycles CYCLES only if solenoid valve is attached
7 X LOCAL OFF select local mode
X " ON toggle between on and off
X " OFF
8 X ENGLISH select language, default is English
X ESPANOL
X FRANCAIS step through languages using either
X ITALIANO the Up- or the Down-Arrow button
X DEUTSCH
X PORTUGUES
X ENGLISH save with Menu button

9 X DIAGNOSE 00001 the digital display is expected to show processor inputs
that are "turned on"
10001 with pendant Motor-button pushed
01001 with pendant Arrow-up button pushed
00101 with pendant Arrow-down button pushed
psi psi-reading present, if pressure transducer is attached and
has been recognized during boot-up
10 X OK hold for 2 seconds to return to "OK" run mode
9232510974 — 1000702744 1
405
406
Table 2, Z-class Pressure Transducer Calibration

No. Operator action LCD Reading Comments
1 Connect master gauge to port A (Advance port) (also connect hand pump if Note - There are two methods of producing the needed pressure in steps 11 and 15, using the pumps "Motor" or
applicable - see comments) separate "Hand pump". Connect a hand pump only if it will be used to create pressure in steps 11 and 15, and verify
Z-Class pump user adjustable relief valve is set higher than maximum pressure used is step 15.
2 Connect electrical power to pump. FIRMWARE x.x, then "OK" 0 psi Boot sequence
3 Firmware 5.5 and earlier - At main screen, press the Menu button once to display SET PRES xxxx psi xxxx psi is the current pressure value of SET PRES
screen "SET PRES". Skip step 4.
4 Firmware 5.6 and later - At main screen, press the Menu button once to display UNITS psi psi is the current unit of pressure measurement
screen "UNITS". Skip step 3.
5 Press and hold the ON/OFF button for seven seconds ENTRY CODE First step into the hidden calibration mode

6 Press and hold the Arrow-up and Arrow-down button together for seven seconds CAL PT A 0 psi Start of calibration process. The advance-solenoid will be powered up to access the pressure transducer through
valve-port A
7.a "Motor" method - Open the pump's user adjustable relief valve and verify both CAL PT A 0 psi Calibrate the zero-offset, point "A"
pump LCD and master gauge read zero
7.b "Hand pump" method - Open the hand pump's user control valve and verify both CAL PT A 0 psi Calibrate the zero-offset, point "A"
pump LCD and master gauge read zero
8 Press the Menu button to accept the pressure value into temporary memory SAVE A no
9 Press one Arrow button to change from "no" to "yes" SAVE A yes Confirm the pressure data should be stored to memory
10 Press the Menu button once CAL PT B 2000 psi Calibrating gain is done with two points, starting with point "B"
2000 psi
15
11.a "Motor" method - Press and release the shroud's ON/OFF motor-button to switch CAL PT B CAL PT B can be set at any pressure value greater than zero. First obtain the pressure value on the master gauge
9/7/21
the pump motor on. Reading the master gauge, apply a pressure of 2000 psi by (ie 2250 psi) then use the arrow buttons to match the LCD value to the master gauge.
closing the pump's user adjustable relief valve
11.b "Hand pump" method - Close the hand pump's control valve. Reading the master CAL PT B 2000 psi CAL PT B can be set at any pressure value greater than zero. First obtain the pressure value on the master gauge (ie
gauge, apply a pressure of 2000 psi 2250 psi) then use the arrow buttons to match the LCD value to the master gauge.
12 Press the Menu button to accept the pressure value into temporary memory SAVE B no
13 Press one Arrow button to change from "no" to "yes" SAVE B yes Confirm the pressure data should be stored to memory
14 Press the Menu button once CAL PT C 8000 psi Calibrating gain is done with two points, finishing with point "C"
15 Reading the master gauge, apply a pressure of 8000 psi CAL PT C 8000 psi CAL PT C can be set at any pressure value greater than CAL PT B. First obtain the pressure value on the master gauge
(ie 7500 psi) then use the arrow buttons to match the LCD value to the master gauge.
16 Press the Menu button to accept the pressure value into temporary memory SAVE C no
17 Press one Arrow button to change from "no" to "yes" SAVE C yes Confirm the pressure data should be stored to memory
18 Press the Menu button once USE DFLT off Re-confirm calibration data. Leave "off" to proceed with new calibration data. Only set to "on" to change calibration
data back to factory default settings. Press Arrow button to change.
19 Press the Menu button once CAL PT A 0 psi Save calibration data to permanent memory
20 Press and hold the Menu button for three seconds to step out of the calibration OK 0 psi Calibration complete, motor stops and electric valves release pressure.
mode
9232510974 — 1000702744 1
Table 3, Z-class / LCD-version / Pump-Model-Matrix
What happens when _____ button is pushed in
Available with Pressure Transducer Option
normal operation mode (“OK” is displayed on LCD)
Pendant Button LCD Panel Action when HI_PRES Max value Action when LO_PRES Max value for LO_PRES (NA - Additional comments
Button (SET_PRES) value is for HI_PRES value is reached (NA - firmware 5.5 and earlier)
reached (SET_PRES) firmware 5.5 and earlier)
Pump Pump Pump type valve pendant foot Item Motor Arrow Arrow up Motor
No. type code switch On/Off down On/Off
1 manual ZxxxxxLx any manual none NA Motor & Fan na - na - na - toggle off 10,500 psi on 50 psi less than HI_PRES current
w/LCD ZxxxxxHx (if attached) no no pendant no pendant on/off value. 0 means LO_PRES is
pendant

turned off.
2 Adv / Zxx2xxSx VE32 3-button Option Motor & Fan na - na - disabled momentary on off off 10,500 psi on 50 psi less than HI_PRES current 3 button pendant used but only Up and Down
Hold / (if attached) disabled (advance) value. 0 means LO_PRES is Arrow buttons are active
Ret turned off.
Solenoid B na - momentary na - disabled off off na
disabled on (retract)
3 Dump Zxx1xxDx VE32-D 1-button Option Motor & Fan na - na - disabled momentary on off off 10,500 psi na - can not change na - can not change LO_PRES up-arrow now on the middle button-position,
(if attached) disabled (advance) LO_PRES value from off value from off using pin #2 of pendant
Solenoid A na - na - disabled momentary on off off na - can not change

disabled (advance) LO_PRES value from off
4 TW- Zxx2xxTx-Ex VE42-E TW 2-button NA Motor & Fan toggle na - disabled no change off na Note - na - LO_PRES is not na - LO_PRES is not available on time out off (after 20 seconds of no advance
16
Enerpac (if attached) on/off 11,600 psi available on TW pumps TW pumps button activity)
9/7/21
Note - Solenoid A off na - disabled momentary off switch off in auto-cycle to na - LO_PRES is not rapid valve cycle ~0.5 seconds after motor shut
11,600 psi auto-cycle on/off stop advancing available on TW pumps down command to release pump pressure after
(advance/retract) motor stops spinning
Solenoid B on na - disabled momentary off switch on in auto-cycle to na - LO_PRES is not rapid valve cycle ~0.5 seconds after motor shut
(retract) auto-cycle on/off start retracting available on TW pumps down command to release pump pressure after
6 remote Zxx3xxSx VE33 / VE43 3-button Option Motor & Fan toggle no change no change toggle when HI_PRES is reached 10,500 psi na na Pump type 6 is the default factory setting. 0
3/4-way Zxx4xxSx (if attached) on/off on/off only the valve shuts off, means LO_PRES is turned off. Default
motor continues running manufacturer setting is AUTO MODE off &
LO_PRES is 0
ZxxxxxWx none none Solenoid A no off momentary on off off on 50 psi less than HI_PRES current
change (advance) value. 0 means LO_PRES is
turned off
Solenoid B no momentary off off off off na

change on (retract)
9232510974 — 1000702744 1
407
408
Table 3, Z-class / LCD-version / Pump-Model-Matrix

What happens when _____ button is pushed in
Available with Pressure Transducer Option
normal operation mode (“OK” is displayed on LCD)
Pendant Button LCD Panel Action when HI_PRES Max value Action when LO_PRES Max value for LO_PRES (NA - Additional comments
Button (SET_PRES) value is for HI_PRES value is reached (NA - firmware 5.5 and earlier)
reached (SET_PRES) firmware 5.5 and earlier)
Pump Pump Pump type valve pendant foot Item Motor Arrow Arrow up Motor
No. type code switch On/Off down On/Off
7 TW Zxx2xxTx VE42-Q TW 2- NA Motor & Fan toggle na - disabled no change off na Note - na - LO_PRES is not na - LO_PRES is not available on time out off (after 20 seconds of no advance
button (if attached) on/off 10,000 psi available on TW pumps TW pumps button activity)

Note - 10,000 Solenoid A off na - disabled momentary off switch off in auto-cycle to na - LO_PRES is not rapid valve cycle ~0.5 seconds after motor shut
psi auto-cycle on/off stop advancing available on TW pumps down command to release pump pressure after
Solenoid B on na - disabled momentary off switch on in auto-cycle to na - LO_PRES is not rapid valve cycle ~0.5 seconds after motor shut
(retract) auto-cycle on/off start retracting available on TW pumps down command to release pump pressure after
8 Jog ZxxxxxKx any manual 1 or 2- Option Motor & Fan toggle momentary momentary on toggle off 10,500 psi on 50 psi less than HI_PRES current safety feature: Arrow-up and arrow-down
button (if attached) on/off on on/off value. 0 means LO_PRES is buttons switch off motor when pump is running
turned off. on toggle-on
17
9/7/21
9232510974 — 1000702744 1
409

Australia and New Zealand Germany and Austria South Korea South Africa and other English
Actuant Australia Ltd. ENERPAC GmbH Actuant Korea Ltd. speaking African countries
Block V Unit 3 P.O. Box 300113 3Ba 717, Shihwa Industrial Complex Enerpac Africa Pty Ltd.
Regents Park Estate D-40401 Düsseldorf Jungwang-Dong, Shihung-Shi, No. 5 Bauhinia Avenue
391 Park Road Willstätterstrasse 13 Kyunggi-Do Cambridge Office Park
Regents Park NSW 2143 D-40549 Düsseldorf, Germany Republic of Korea 429-450 Block E
(P.O. Box 261) Australia T +49 211 471 490 T +82 31 434 4506 Highveld Techno Park
T +61 (0)2 9743 8988 F +49 211 471 49 28 F +82 31 434 4507 Centurion 0157
F +61 (0)2 9743 8648 sales-de@enerpac.com sales-kr@enerpac.com South Africa
sales-au@enerpac.com T: +27 12 940 0656
India Spain and Portugal
Brazil ENERPAC Hydraulics Pvt. Ltd. ENERPAC SPAIN, S.L. United Kingdom and Ireland
Power Packer do Brasil Ltda. No. 1A, Peenya Industrial Area Avda. Los Frailes, 40 – Nave C & D ENERPAC Ltd.,
Rua Luiz Lawrie Reid, 548 IInd Phase, Bangalore, 560 058, India Pol. Ind. Los Frailes Bentley Road South
09930-760 - Diadema (SP) T +91 80 40 792 777 28814 Daganzo de Arriba Darlaston, West Midlands
T +55 11 5687 2211 F +91 80 40 792 792 (Madrid) Spain WS10 8LQ
F +55 11 5686 5583 sales-in@enerpac.com T +34 91 884 86 06 England
Toll Free: 0800 891 5770 F +34 91 884 86 11 T +44 (0)121 50 50 787
vendasbrasil@enerpac.com Italy sales-es@enerpac.com F +44 (0)121 50 50 799
ENERPAC S.p.A. sales-uk@enerpac.com
Canada Via Canova 4 Sweden, Denmark, Norway, Finland
Actuant Canada Corporation 20094 Corsico (Milano) and Iceland USA, Latin America and Caribbean
6615 Ordan Drive, Unit 14-15 T +39 02 4861 111 Enerpac Scandinavia AB ENERPAC
Mississauga, Ontario L5T 1X2 F +39 02 4860 1288 Fabriksgatan 7 P.O. Box 3241
T +1 905 564 5749 sales-it@enerpac.com 412 50 Gothenburg Milwaukee WI 53201 USA
F +1 905 564 0305 Sweden T +1 262 293 1600
Toll Free: Japan T +46 (0) 31 799 0281 F +1 262 293 7036
T +1 800 268 4987 Applied Power Japan LTD KK F +46 (0) 31 799 0010 User inquiries:
F +1 800 461 2456 Besshocho 85-7 scandinavianinquiries@enerpac.com T +1 800 433 2766
customer.service@actuant.com Kita-ku, Saitama-shi 331-0821, Japan Distributor inquiries/orders:
T +81 48 662 4911 The Netherlands, Belgium, T +1 800 558 0530
China F +81 48 662 4955 Luxembourg, F +1 800 628 0490
Actuant (China) Industries Co. Ltd. sales-jp@enerpac.com Central and Eastern Europe, Technical inquiries:
No. 6 Nanjing East Road, Baltic States, Greece, Turkey techservices@enerpac.com
Taicang Economic Dep Zone Middle East, Egypt and Libya and CIS countries sales-us@enerpac.com
Jiangsu, China ENERPAC Middle East FZE ENERPAC B.V.
T +86 0512 5328 7500 Office 423, LOB 15 Galvanistraat 115
F +86 0512 5335 9690 P.O. Box 18004, Jebel Ali, Dubai 6716 AE Ede
Toll Free: +86 400 885 0369 United Arab Emirates P.O. Box 8097
sales-cn@enerpac.com T +971 (0)4 8872686 6710 AB Ede
F +971 (0)4 8872687 The Netherlands All Enerpac products are guaranteed
France, Switzerland, North Africa sales-ua@enerpac.com T +31 318 535 911 against defects in workmanship and
and French speaking African F +31 318 535 848 materials for as long as you own them.
countries Russia sales-nl@enerpac.com
ENERPAC Rep. office Enerpac For the location of your nearest authorized
Une division d’ACTUANT France S.A. Russian Federation Enerpac Integrated Solutions B.V. Enerpac Service Center, visit us at
ZA de Courtaboeuf Admirala Makarova Street 8 Opaalstraat 44 www.enerpac.com
32, avenue de la Baltique 125212 Moscow, Russia 7554 TS Hengelo
91140 VILLEBON /YVETTE T +7 495 98090 91 P.O. Box 421
France F +7 495 98090 92 7550 AK Hengelo
T +33 1 60 13 68 68 sales-ru@enerpac.com The Netherlands
F +33 1 69 20 37 50 T +31 74 242 20 45 012313
sales-fr@enerpac.com Southeast Asia, Hong Kong F +31 74 243 03 38
and Taiwan integratedsolutions@enerpac.com
Actuant Asia Pte Ltd.
83 Joo Koon Circle
Singapore 629109
T +65 68 63 0611
F +65 64 84 5669
Toll Free: +1800 363 7722

410
A.7.6 Electric Pump Repair Parts Sheet
Repair Parts Sheet
ZE/ZW Electric Pump
L2648 Rev. JU 08/2019 For Date Codes Beginning with the Letter “A”
To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.

Enerpac recommends that all kit components be installed to insure optimum performance of the repaired product.
Index:
English. . . . . . . . . . . . 1-11 Português . . . . . . . . 36-39
Français . . . . . . . . . . 16-19 Suomalainen . . . . . . 40-43
Deutsch . . . . . . . . . . 20-23 Norsk . . . . . . . . . . . . 44-47
Italiano . . . . . . . . . . . 24-27 Svensk. . . . . . . . . . . 48-51
Español . . . . . . . . . . 28-31 ѝ᮷ . . . . . . . . . . . . . 52-55
Hollands . . . . . . . . . 32-35 ᪥ᮏㄒ . . . . . . . . . . . 56-59
2 3
2
Important: To ease removal of motor (item 54),
Notes: the cable tie mount (item 60) should be removed
1. Apply Loctite #545 to threads. 1 first. A light oil (WD-40 or equivalent) should be
150 sprayed on the motor shaft and allowed time
2. Apply Loctite #243 to threads. 2
to soak.
3. Torque capscrews in a crossing pattern to ensure even sealing of gasket. 3
Figure 1, Pump Assembly
Repair Parts List for Figure 1

DC9379025SR 1 Reservoir 4 L (Includes 31 DC9972025SR 1 Reservoir 40 L (Includes
32,35,36 and 37) 32,33,34,35 and 37)
DC8136025SR 1 Reservoir 8 L (Includes 32 ★★DC9596026 2 Reservoir Decal
31 32,35,36 and 37) 33 C187018 1 Magnet (10 L, 20 L & 40 L)
DC9970025SR 1 Reservoir 10 L (Includes 34 DD1425245 1 1/2" Flush Plug w/Sealant
32,33,34,35 and 37) DC85900SR 1 Sight Glass 4 L and 8 L
DC9971025SR 1 Reservoir 20 L (Includes 35 DC2621223SR 1 3" Sight Glass 10 L
32,33,34,35 and 37) DD1367223SR 1 5" Sight Glass 20 L
1 Continued on Page 2

411
Electric Pump Repair Parts Sheet (Sheet 2)
Repair Parts List for Figure 1, continued

35 DC9969223SR 1 7" Sight Glass 40L 60 DC9741017 2 Cable Tie Mount
36 DC8249006 1 Plug SAE#8, Magnet (4L & 8L) 61 DC9876647 1 6" Black Cable Tie
37 ★ DC9551920 1 Reservoir & MPE Gasket DC9684900 1 Encl Asm 1P 115V
38 DC9542920 2 Handle,10L,20L,40L DD2238900 1 Encl Asm 1P 115V (TW)
38A DC9895101 4 Lift Plate 10L,20L,40L DC9685900 1 Encl Asm 3P LOW 1.5 HP
39 CBE819028-1E 8 BHCS M8X16 mm DD2241900 1 Encl Asm 3P LOW 1.5 HP (TW)
40 CBE1080120-2A 8 Lock Nut M8 DC9695900 1 Encl Asm 3P HIGH 1.5 HP
DC9666920 1 Skid Bar 4L & 8L W/Heat Ex. 62 DD2242900 1 Encl Asm 3P HIGH 1.5 HP (TW)
41
DC9590920 1 Skid Bar 4L & 8L WO/Heat Ex. DC9699900 1 Encl Asm 3P LOW 3 HP
42 See Fig. 2 Basic Assembly (See DD2356900 1 Encl Asm 3P LOW 3 HP (TW)
43 ★ S3037 13 Copper Gasket Fig. 4) DC9871900 1 Encl Asm 3P HIGH 3 HP
44 CBE619028-1A 13 SHCS M6-1X16 DD2357900 1 Encl Asm 3P HIGH 3 HP (TW)
45 DC9467070 1 Handle 4L and 8L DC9881900 1 Encl Asm 1P 230V US
46 DA7570217 1 Velcro Strap DD2239900 1 Encl Asm 1P 230V US (TW)
48 DC9538021 2 Lock Nut 20MM DC9882900 1 Encl Asm 1P 230V EU
49 CBE817028-1E 4 BHCS M8 X 12 DD2240900 1 Encl Asm 1P 230V EU (TW)
52 DC9436009 4 Dome Plug 16MM 63 DC9936076 1 Seal, Electrical Enclosure
53 DC9437009 3 Dome Plug 20MM 64 DC9686900 1 Front Enclosure Asm (See Fig. 3)
◆ DC9658259 1 Motor 1 HP 1PH 115/230V 65 CBE615028-1A 6 SHCS M6X1X10
◆ DC9659259 1 Motor 1.5 HP 1PH 115/230V 66 CAE1060108-1A 6 6MM Washer
DC9801259 1 Motor 1 HP 1PH 115/230V 67 ★★ DC9920026 1 Decal, Read Instruction
DC9802259 1 Motor 1.5 HP 1PH 115/230V 68 ★★ DC9921026 1 Decal Hot Surface
DC9803259 1 Motor 1 HP 3PH 200V ★★ DC9953026 1 Decal, ZE Class
69
DC9804259 1 Motor 1 HP 3PH 230/460V ★★ DC9954026 1 Decal, ZW Class
DC9805259 1 Motor 1 HP 3PH 575V ★ DC9356037 1 Valve Gasket
70
DC9806259 1 Motor 1.5 HP 3PH 200V ★ F786167 1 Valve Gasket VM32
54
DC9807259 1 Motor 1.5 HP 3PH 230/460V See Page 10 1 Control Valve
71
DC9808259 1 Motor 1.5 HP 3PH 575V DC6665098 1 Cover Plate (if no valve)
DC9809259 1 Motor 3 HP 3PH 200V 75 DC2749768 1 Return Tube
DC9810259 1 Motor 3 HP 3PH 230/460V CBE843028-1A 6 SHCS M8X80
DC9811259 1 Motor 3 HP 3PH 575V 76 CBE825028-1A 6 SHCS M8X30
DC9812259 1 Motor 7.5 HP 3PH 230/460V CBE837028-1A 4 SHCS M8X60
DC9813259 1 Motor 7.5 HP 3PH 575V 78 DC9734960SR 2 Valve Cord
DC9822259 1 Motor 7.5 HP 3PH 200V 79 ★★ DC9922026 2 Decal, High Voltage
55 44968E 1 Rubber Ball, 3/8" Dia. 70 Duro 80 ★★ DC9950026 1 Safety Decal, No Lift
57 CBE1025046-1B 4 Motor Mounting Bolt DC9956038 1 Adapter SAE#10 to 3/4"
138 NPTF ZW pump (not shown)
58 DC2669127 3 Wire Nut
DC9990960 1 Motor Cord Asm. 1PH 139 DC9955268 1 Fill Pipe ZW pump (not shown)
DC9899960 1 Motor Cord Asm. 1.5 HP 3PH 148 Not Available 1 Decal, Product Spec ZE (DC6661026)
59
DC9735960 1 Motor Cord Asm. 3 & 7.5 HP 149 ★★ CJ193026 1 Clockwise Rotation Decal
3PH 150 DD4308251 1 Hardened Motor Key
★★ Items included in and available only as part of Decal Kit ZEDK. TW = Torque Wrench Pumps.
★ Items included in Seal Kit ZE3K. (Models ending in QHR or EHR)
◆ Includes motor on/off switch.
NOTE: For valve and manifold Repair Parts Sheet listings, see Valve and Manifold Chart on page 10.

412
Torque to Torque to
72 - 84 in-lbs. 1 50 - 55 ft-lbs.
[8.1 - 9.5 Nm] 26 10 11 [68 - 74 Nm]
30
This view shows parts for oil filter
Used only on and heat exchanger assemblies
models without (optional accessories)
heat exchanger
assembly
12B, 19B, 20B

13A
13B
12A Torque to
15 - 18 ft-lbs.
29 28 [20 - 24 Nm] 2X Torque to 126
27 20 - 22 ft-lbs.
[27 - 30 Nm]
20B
21 Torque to
45 - 47 ft-lbs. 19B
24 [61 - 64 Nm]
25 1 12B
Torque to
22 15 -18 ft-lbs. 126 129 20A 127
23 [20 - 24 Nm]
2 Torque to
Torque to 301A 45 - 47 ft-lbs.
5 - 7 in-lbs 301B 15 [61 - 64 Nm]
[0,5 - 0,8 Nm]
19A 2
Notes:
301C
Torque to 1 Apply Loctite 545 to threads before installation.
15 - 18 ft-lbs. Torque to
[20 - 24 Nm] 18 15 - 18 ft-lbs. 2 Location of breather assembly (item 301A or
[20 - 24 Nm]
301B) and adapter (item 301C) on pump
coverplate (item 15) will vary, depending on pump
date of manufacture.
17
Figure 2, Basic Assembly

10 Pump Element 1 see RPS L2596 for MPE 24 ★ DC9271167 1 Copper Gasket
11 F100094-246 1 Fitting 5-4 FTX-S 25 ★ DC9551920 1 Pump Gasket
12A F100097-16 1 Fitting, Standard Pump 26 CBE621028-1A 2 SHCS, M6 X 20
12B F100097-16 2 Fitting, Heat Exc. Pump 27 DC9663920 1 Tube, ASM Steel, ZE
13A DC9335646 1 Hose, Bypass 8" DC9600268 1 Intake Tube, 1.6" 4L & 8L
13B DC9416646 1 Hose, Heat Exc. Pump 23" DC9601268 1 Intake Tube, 2" 10L
28
15 DC9451101 1 Cover Plate, ZE DC9524268 1 Intake Tube, 3" 20L
17 B1007006 1 Plug SAE #10 DC9603268 1 Intake Tube, 6.5" 40L
18 B1006006 1 Plug, Socket, SAE #8 29 DC9178118 1 Intake Filter
19A B1006006 2 Plug, SAE #8 Std. Pump 30 DC9643646 1 Return Hose, Heat Exc.
19B DC9273097 2 Fitting, Heat Exc. Pump 126 DC9639299 2 Clamp, Heat Exc. Pump
20A ★ B1908503 1 O-Ring, Oil Filter Pump 127 DC8046646 1 Hose, Oil Filter Pump
20B ★ B1908503 2 O-Ring, Heat Exc. Pump 129 DC8035038 1 Adapter, 5/8 Hose
21 DC9173690 1 Connector Fitting 301A DC8250006 1 Breather Assy (Std.)
22 ★ BSS0368D 1 Back-up 301B DC9558920 1 Breather Assy (Europe)
23 ★ B1012803 1 O-Ring 301C F100096-38 1 Adapter Fitting
★★ Items included in Seal Kit ZE3K.

413
Figure 3, Front Enclosure

Item Part Number Qty. Description
100 DC9453424 1 Front Enclosure ZE

101 DC8178827 1 PCB LCD Control Board
103 ★ DC9560026 1 Keypad LCD 4 Button
104 ★ DC9559026 1 Overlay LCD 4 Button
105 DC9428008 4 Screw Hi-Lo #8x12
107 DC9951405 1 Velcro
108 DC9740969 1 Ferrite
140 ★★DC9929026 1 Decal, Wire Schematic
★Only available as part of DC9560900SR
★★Only available in decal kit ZEDK

414
Wire harnesses, items 220 and 221, not shown.

Contactor cable, item 222, not shown.
Figure 4, Rear Enclosure

85 E1001181 1 Push-on Connector 208 DC9536380 1 Circuit Breaker, 25 AMP
87 DC9645268 1 Insulation Tube 209 See Fig. 5 1 Fuse, Primary
200 DC9670101 1 Bracket 210 DC8156378 1 Fuse, Sec F3, 3.5A, Slow-Blow
201 See Fig. 5 2 Contactor 3PH 211 DC9678199 1 Terminal Strip
DC9919980 1 SSR RM1A23D75 1PH 212 DC9677008 2 Screw 1" #6 Hi-Lo
202 See Fig. 5 1 Overload 3PH 213 CAE1060108-1A 4 6MM Flat Washer
203 CBE419028-1A 2 M4X.7X16 SHCS 214 CBE619028-1A 3 M6X1X16 SHCS
204 CBE629028-1A 1 M6X1X40 SHCS 215 CCE1060108-6A 2 6MM Star Washer
205 DC9452424 1 Rear Enclosure 216 CBE1060120-1D 3 6MM Nut
DC8181827 1 Pwr Board, SSR, LV, 1 PH DC9736960 1 Power Cord 115V
Pwr Board, SSR, LV, 1 PH 217 DC9737960 1 Power Cord 230V EU
DD2243827 1 (Models ending in QHR or EHR)
DC9738960 1 Power Cord 208V US
DC8182827 1 Pwr Board Low Volt 3 PH 218 DC9683021 2 Locking Nut, 25 MM
206 Pwr Board Low Volt 3 PH DC9735960 1 Motor Cord ZE 3PH
DD2228827 1 (Models ending in QHR or EHR)
219 DC9899960 1 Motor Cord ZE 3PH 1.5HP
DC8183827 1 Pwr Board High Volt 3 PH DC9990960 1 Motor Cord ZE 1PH
Pwr Board High Volt 3 PH DC9730960 1 Power Wire Harness
DD2229827 1 (Models ending in QHR or EHR) 220
DC9892960 1 Wire Harness PB To SSR
207 DC9428008 6 Screw Hi-Lo #8X1/2 DC9729960 1 Overload Wire Harness
221
DC9533380 1 Circuit Breaker, 8 AMP DC9893960 1 Cable TB600 to SSR
208 DC9534380 1 Circuit Breaker, 12 AMP 222 DC9949960 1 Connector Cable
DC9535380 1 Circuit Breaker, 15 AMP
5

Figure 5, Electrical Component Chart - ZE/ZW Electric Pumps
Motor Voltage Range Full Load Full Load Contactor Overload Relay Overload Relay Primary Fuse
50 Hz/60 Hz Hp [kW] 50 Hz/60 Hz Amps Amps (item 201, Fig. 4) (item 202, Fig. 4) Setting, Amps (item #209, Fig. 4)
@ 50 Hz @ 60 Hz
DC9658259 1.0 [0.75] 115-120 12.4 10 single phase N/A N/A DC9592378 (1A)
208-240 6.2 5 single phase N/A N/A DC9591378 (0.75A)
DC9659259 1.5 [1.1] 115-120 16.8 15.4 single phase N/A N/A DC9592378 (1A)
208-240 8.4 7.7 single phase N/A N/A DC9591378 (0.75A)

DC9803259 1.0 [0.75] 200 4.8 3.9 DC9692389 DC9723980 5.1 DC9732378 (0.6A)
(LC1D12BD) (LRD10)
DC9804259 1.0 [0.75] 190-220 / 208-240 4 3.6 DC9692389 DC9723980 4.5 DC9732378 (0.6A)
(LC1D12BD) (LRD10)
1.0 [0.75] 380-440 / 440-480 2 1.8 DC9692389 DC9721980 2.2 DC2777378 (0.4A) 50Hz
(LC1D12BD) (LRD7) DC2778378 (0.25A) 60Hz
DC9805259 1.0 [0.75] 575 1.8 1.4 DC9692389 DC9721980 1.6 DC9731378 (0.2A)
(LC1D12BD) (LRD7)
DC9806259 1.5 [1.1] 200 6.2 5.2 DC9692389 DC9724980 6.5 DC9732378 (0.6A)
(LC1D12BD) (LRD12)
DC9807259 1.5 [1.1] 190-220 / 208-240 5.4 4.8 DC9692389 DC9723980 6 DC9732378 (0.6A)
6
(LC1D12BD) (LRD10)
9/7/21
1.5 [1.1] 380-440 / 440-480 2.7 2.4 DC9692389 DC9722980 3 DC2777378 (0.4A) 50Hz
(LC1D12BD) (LRD8) DC2778378 (0.25A) 60Hz
DC9808259 1.5 [1.1] 575 2.4 1.9 DC9692389 DC9722980 2.5 DC9732378 (0.6A)
(LC1D12BD) (LRD8)
DC9809259 3.0 [2.2] 200 12.6 10 DC9692389 DC9726980 13 DC9732378 (0.6A)
(LC1D12BD) (LRD16)
DC9810259 3.0 [2.2] 190-220 / 208-240 10.4 9.2 DC9691389 DC9726980 11 DC9732378 (0.6A)
(LC1D25BD) (LRD16)
3.0 [2.2] 380-440 / 440-480 5.2 4.6 DC9692389 DC9723980 5.5 DC2777378 (0.4A) 50Hz
(LC1D12BD) (LRD10) DC2778378 (0.25A) 60Hz
DC9811259 3.0 [2.2] 575 4.4 3.5 DC9692389 DC9723980 4 DC9732378 (0.6A)
(LC1D12BD) (LRD10)
DC9812259 7.5 [5.6] 190-220 / 208-240 20.8 18 DC9691389 DC9728980 22 DC9732378 (0.6A)
(LC1D25BD) (LRD22)
7.5 [5.6] 380-440 / 440-480 10.4 9 DC9691389 DC9726980 11 DC2777378 (0.4A) 50Hz
(LC1D25BD) (LRD16) DC2778378 (0.25A) 60Hz
DC9813259 7.5 [5.6] 575 7.2 6.8 DC9691389 DC9725980 7 DC9732378 (0.6A)
(LC1D25BD) (LRD14)
DC9822259 7.5 [5.6] 200 20.6 19.4 DC9691389 DC9728980 22 DC9732378 (0.6A)
(LC1D25BD) (LRD22)
9232510974 — 1000702744 1
415
416
DC8181827 and DD2243827 Single Phase/SSR Power Board
Heat exchanger fan

Secondary fuse
(item 210) Pressure transducer
ADVANCE
PRESS TR FAN
Advance Filter
RETRACT
FILTER
Retract
TEMP PRESS SW
PENDANT
Pressure switch
Pendant
OIL
Oil temperature switch
Oil level switch
Flat ribbon cable terminal
(RED)
FL3 (BLACK) Terminal to

(BLACK)
A1/A2 on SSR
FL1
FL2 Primary fuse Line in Motor and
(item 209) SSR leads
Figure 6, Power Board Diagram, Single Phase SSR
Single Phase Transformer Tapping Single Phase Transformer Tapping

100-115 Volts - “B” Voltage 230 Volts - “E” Voltage (Europe & Austrailia)
Lead Connect to Terminal Lead Connect to Terminal
FL 1 QC 3 FL 1 QC 1
FL 2 QC 6 FL 2 QC 2
FL 3 QC 7 FL 3 QC 5
Single Phase Transformer Tapping

208 Volts - “I” Voltage (USA & Canada)
Lead Connect to Terminal
FL 1 QC 1
FL 2 QC 3
FL 3 QC 6

417
DC8182827 and DD2228827 Three Phase Low-Voltage Power Board
Heat exchanger fan

Secondary fuse
Pressure transducer
ADVANCE
FAN
(item 210)
PRESS TR
Filter
RETRACT
Advance
FILTER
PENDANT
Retract
PRESS SW
Pressure switch
TEMP
Pendant
OIL
Oil level switch
CONTACT
BRAKER
Contactor coil
(RED) Overload relay

FL3 (BLACK)
FL1 (BLACK)
FL2 Primary fuse Line in

(item 209)
Figure 7, Power Board Diagram, Three Phase, Low Voltage
Three Phase Transformer Tapping Three Phase Transformer Tapping

200 Volts 240 Volts
Lead Connect to Terminal Lead Connect to Terminal
FL 1 QC 1 FL 1 QC 1
FL 2 QC 3 FL 2 QC 2
FL 3 QC 6 FL 3 QC 5

418
DC8183827 and DD2229827 Three Phase High-Voltage Power Board
Heat exchanger fan

Secondary fuse
(item 210) Pressure transducer
ADVANCE
FAN
PRESS TR
Advance
RETRACT
Filter
FILTER
Retract
PENDANT
PRESS SW
Pressure switch
TEMP
Pendant
OIL
Oil level switch
CONTACT
BRAKER
Contactor coil
(BLACK)
Overload relay
FL1
Primary fuse Line in

(item 209)
Figure 8, Power Board Diagram, Three Phase, High Voltage
Three Phase Transformer Tapping (High Voltage)

Voltage Lead Connect to Terminal
400 Volts FL 1 QC 5
440 Volts FL 1 QC 4
480 Volts FL 1 QC 3
575 Volts FL 1 QC 2

419
Figure 9, ZE Pump (Viewed From Back of Enclosure)
Repair Parts and Instruction Sheets Valve and Manifold Chart (Cont'd)
for Optional Accessories
Model Repair Sheet No.
See Repair and
Model Repair Sheet No. VE42QM (DC6403950) L2617
Instruction Sheet
VE43 L2600
F ZPF Filter Kit L2628
VM22 L2649
H ZHE - E3 Heat Exchanger L2656
VM32 L2614
L ZLS - U4 Level / Temp Switch L2630 VEW43 and VEW43P L2708
P ZPS - U4 Pressure Switch L2631 3-T-P-B-I (VM33) L2613
T ZPT - U4 Pressure Transducer L2627 3-T-P-B-X (VM33L) L2613
U ZCF-2 Footswitch L2629 4-T-P-B-I (VM43) L2613
4-T-P-B-X (VM43L) L2613

- Z-Class Pendant L2625
VM43LPS (Date Code “A”) L2633
VM43LPS (Date Code “B”) L2699

Valve and Manifold Chart L2646
SAE PORT MANIFOLD (ZW PUMP)
Model Repair Sheet No. VP SERIES MANIFOLD (ZW PUMP) L2646
VE32 L2612 1 STATION DO3 (ZW PUMP) L2708
VE33 L2600 2 STATION DO3 (ZW PUMP) L2646
4 STATION DO3 (ZW PUMP) L2646

VE42E (DC6167950) L2617
VE42TQ L2908
VE42EM (DC6402950) L2617
VE42TQM L2908
VE42Q (DC6443950) L2617 VE42TE L2908
VE42TEM L2908
10

420
Figure 10, Rollbar Assembly

250 DC9464070 2 Cross Brace 4L, 8L 255 DC9466268 2 Roll Bar Side 4L and 8L
251 CBE817028-1E 4 M8 X 12 BHCS 256 DC9693268 2 Roll Bar Spacer 4L 8L
252 CBE833028-1B 4 M8 X 50 HSCH Screw 256 DC9460268 2 Roll Bar Spacer 10L
253 CBE819028-1E 8 M8-1X16 mm BHCS 256 DC9461268 2 Roll Bar Spacer 20L
254 CBE1080120-2A 8 M8 Lock Nut 256 DC9462268 2 Roll Bar Spacer 40L
255 DC9618920 2 Roll Bar Side 10, 20, and 40 257 CBE837028-1B 4 M8 X 60 HSCH Screw
ROLL BAR KITS

ZRB-04 4L & 8L
ZRB-10 10L
ZRB-20 20L
ZRB-40 40L
11

421
SUGGESTIONS FOR EFFECTIVE TROUBLESHOOTING: b. In Column B below, the possible causes for the
1. Utilize the LCD Screen as much as possible. The LCD symptoms are listed. The two major categories are
Screen of the Pump is a fault indicator as well as a 1) Faults External to the Pump, and 2) Faults Within
controller. It can indicate most of the possible faults in the Pump.
the system. Within these major categories, there are two sub-
2. Ensure the power supply to the pump is of the correct categories:
voltage and capacity. The power cable, plugs and 1. the Single Phase Pumps, and
sockets should be checked for proper condition. 2. the Three Phase Pumps.
3. Suggested sequence for successful troubleshooting Study the possible causes as per these suggestions in
of the electrical systems: Column B and proceed to Column C. In Column C below,
a. Identify the symptoms in the pump, use the list of various remedial actions to be taken are listed.
Symptoms in Column A of this Guide below.
Trouble-shooting Guide
Column A Column B Column C
Symptoms Probable Causes Remedial Actions to be Taken
SECTION 1 External to the Pump
Pump 1. Low voltage or no voltage in the external 1. Check the external power supply and correct the fault. Is the voltage
does power supply (Single Phase) correct? Maximum deviation of +/- 10% from the Nominal Voltage
not start is permissible. Is the power cable too long? Are the power socket
and plug in good working condition? Is the power source or the
generator capable enough to drive the pump at full load?
2. Check the external power supply for correct voltages in all phases. Is
2. One or more phases in the power supply the voltage correct? Maximum deviation of +/- 10% from the Nominal
Voltage is permissible. Is the power cable too long? Are the power
socket and plug in good working condition? Is the power source or the
generator capable enough to drive the pump at full load?
SECTION 1B, Within the Pump System
1. FAULT Conditions 1. Check for FAULT Conditions:
(See ZE/ZW Instruction Sheet for fault codes) (See ZE/ZW Instruction Sheet for fault codes)
a) Does the LCD display reads "BUTTON a) Check whether any LCD button is stuck. If yes, loosen the LCD
FAULT"? board mounting screws and realign the LCD Board. Or, the key
pad is defective, replace the LCD Board. OR. The pendant keypad
was actuated prematurely during power boot-up.
b) Does the Display read "MOTOR b) Check Probable Causes in Column B of Section 1B.
OVERLOAD"? c) Hydraulic oil temperature is too high. Check the system pressure.
c) Does the Display read "OIL TEMP"? Install a Heat Exchanger OR if the oil temperature is OK, check
the TEMP/LEVEL switch and the cable. If defective, replace. Go to
the DIAGNOSE section of the LCD Screen to check functioning of
all switches OR if no TEMP/LEVEL switch is used in the system,
check electrical push-on connector in the header pins TEMP
inside the E-Box. The push-on connector might have become
loose.
d) Does the Display read "OIL LEVEL"? d) Hydraulic oil level in the reservoir is too low. Fill the reservoir
to the recommended level with the specified hydraulic oil, OR,
if the level is OK, check the TEMP/LEVEL Switch functions and
the connecting cable. If no TEMP/LEVEL Switch is used in the
system, check the electrical shorting plug in the Header pins
inside the E-Box. The push-on connector might have become
loose.
2. The power cord is damaged 2. Check the power cord for any loose wires or burnt wire ends.
Replace the cable, if found defective. Use the correct size cable,
adequate to the load.
3. Wires in the power incoming terminal block 3. Check that all terminals are tight in the power terminal block, inside
are loose the E-Box. Disconnect the power supply. Open the E-Box. Check
the terminals for any burnt marks or loose connections.
4. Measure, with a DMM (Digital Multi Meter), 4. If the voltages are not correct, go back to Section 1, "External to the
the incoming voltage in the power terminal Pump".
block
12

422
Trouble-shooting Guide, cont.

SECTION 1B-1, Single-phase Pumps
Pump does 1. Is the LED D602, center right of the power 1. If the LED is lit, the DC voltage is OK, go to Step 6. below. If the LED
not start board, illuminated whenever the Motor is is not lit, continue to Step 2.
turned ON?
2. The circuit breaker, near the power terminal 2. The circuit breaker will automatically reset itself, after an overload
block, is tripped. "MOTOR OVELOAD" will occurrence. If the contact is not made even after cooling down time,
appear on the LCD Screen. unplug the circuit breaker and check the continuity of the Circuit
Breaker terminals. Replace with a correct capacity Circuit Breaker.
3. The circuit breaker might have become loose 3. Insert the circuit breaker firmly into its socket holders.
in its socket holders
4. The transformers primary fuse, near the 4. If blown, replace with a correct capacity fuse.
circuit breaker:
5. The transformer primary tappings flying leads 5. Insert the flying leads of the primary side of the transformer correctly.
Refer to the Transformer Tappings Chart. Contact the Service Partner
or ENERPAC Tech Service.
6. The motor leads on the MOTOR Terminal 6. Check and if loose, tighten the leads.
Block on the PCB:
7. The power leads, L1 & T1, to the SSR 7. Check and tighten.
8. The firing voltage leads, A1 and A2, to the 8. Check and tighten the firing control terminals . Also check for the
SSR correct polarity.
9. The SSR firing voltage cable on the PCB 9. Insert the SSR firing cable firmly into the 2 pin PCB socket. If the plug
end or cable is damaged, replace the cable.
10. If the firing LED of the SSR is illuminated, 10. Replace the SSR.
incoming voltage to the SSR is all right.
11. The wire nuts inside the motor terminal box 11. Open the motor terminal box and check and tighten all wire nuts.
Check the wiring is as per the wiring decal.
12. If the motor supply voltage is correct 12. Check and replace the motor.
SECTION 1B-2, Three-phase pumps:

1. Is the LED D602, center right of the power 1. If the LED is lit, the DC voltage is OK, go to Step 6. below. If the LED
board, illuminated whenever the Motor is is not lit, continue to Step 2 below.
turned ON?
2. The transformer primary fuse 2. If blown, replace with a correct capacity fuse.
3. The transformer primary tappings flying leads 3. Insert the flying leads of the primary side of the transformer correctly.
Refer to the Transformer Tappings Chart. Contact the Service Center
or ENERPAC Tech Service.
4. The two power leads to the Printed Circuit 4. a) Tighten the two power leads to the PCB Terminal Block.
Terminal Block b) Measure the voltage: the DMM should read 208/230/400/480/575
volts according to the incoming voltage.
5. The Contactor Coil Leads, A1 and A2 on the 5. a) Measure, with a DMM, the coil voltage. It should read at least 18
Contactor: VDC.
b) If the coil voltage is OK, switch the power OFF and check whether
the contacts set is free to close and open. If the contacts set is tight
or closes and opens with difficulty, replace the contactor.
c) If the coil voltage is OK, and the contact set closes/opens without
any difficulty, replace the contactor. The contactor coil is defective.
6. The 3 phase power leads on the Contactor, 6. If loose, tighten the power leads to the contactor.
L1, L2, and L3
7. The motor leads from the Overload Relay, 7. Tighten the motor leads from the Overload Relay.
T1, T2, and T3
8. The wire nuts inside the motor terminal box 8. Open the motor terminal box and check and tighten all wire nuts.
9. The motor wire leads are not set correctly for 9. Open the motor terminal box and check the wiring with reference to
the incoming voltage the supplied voltage and the wiring decal inside the motor terminal
box. If the voltage supplied is OK and wiring is alright, check and
replace the motor.
13

423
Trouble-shooting Guide, cont.

SECTION 2 External to the Pump
Motor stops 1. Low voltage in the external power supply 1. Check the external power supply and correct the fault.
under normal (Single-Phase system) Is the voltage correct? Maximum deviation of +/- 10% from the
condition Nominal Voltage is permissible. Is the power cable too long? Are
the power socket and plug in good working condition? Is the power
source or the generator capable enough to drive the pump at full
load?
2. One or more phases in the power supply 2. Check the external power supply for correct voltages in all phases.
defective (3-Phase system) Is the voltage correct? Maximum deviation of +/- 10% from the
Nominal Voltage is permissible. Is the power cable too long? Are
the power socket and plug in good working condition? Is the power
source or the generator capable enough to drive the pump at full
load?
SECTION 2B - Within the Pump System:

1. The power cord is damaged. 1. Check the power cord for any loose wires or burnt wire ends.
2. Wires in the power incoming terminal block 2. Check that all terminals are tight in the power terminal block, inside
are loose the E-Box.
3. Check the incoming voltage in the power 3. If the voltages are not correct, go back to Section 2, "External to
terminal block the pump", Nos. 1 and 2.
4. Has the operator pressed two buttons 4. Operator Error. Two buttons cannot be pressed simultaneously.
simultaneously?
SECTION 2B-1 - Single-phase Pumps

a. The power leads to the SSR are loose a. Check and tighten the power leads, L1 and T1, to the SSR
b. The motor leads on the MOTOR Terminal b. Tighten the motor leads on the MOTOR Terminal Block on the PCB
Block on the PCB loose
c. The wire nuts inside the motor terminal box c. Open the motor terminal box and check and tighten all wire nuts
are loose
SECTION 2B-2 - Three-phase Pumps

a. The 3-phase power leads on the Contactor a. Tighten the power leads to the contactor.
are loose
b. The motor leads from the Overload Relay are b. Tighten the motor leads from the Overload Relay.
loose
c. The wire nuts inside the motor terminal box c. Open the motor terminal box and check and tighten all wire nuts.
are loose
SECTION 33
Pump and 1. The pendant cable is damaged. 1. Check and replace the pendant cable.
solenoid 2. The pendant key pad is damaged. 2. Change the pendant.
valves do not 3. The system is in LOCAL Mode. 3. Switch the LOCAL Mode to OFF. (See ZE/ZW Instruction Sheet)
work
14

424
Trouble-shooting Guide,
SECTION 4
Pump runs 1. The solenoid cable is damaged. 1. Check and replace the solenoid cable.
OK. Electric 2. The solenoid cables are interchanged. 2. Check whether the correct cable is inserted in the respective
solenoid solenoids. SOL A and B are marked on the rear side of the
valves do not electrical box.
function 3. The solenoid valve plunger is not free 3. Check the valve manually, if not operational, change the solenoid.
4. The DC Solenoid voltage not correct. 4. Open the E-Box:
• Solenoid A, (Advance ): Does the LED lamp, D513, top left of the
power board, illuminate?
- If the LED is lit, the DC voltage is OK. Check whether the
solenoid cable pins are loose in the header, ADVANCE, top left of
the board.
- If the LED is not illuminated, the DC Voltage is not correct: Check
the Secondary AC Fuse F3, top center tiny glass fuse: If blown,
replace the fuse.
- If the AC Fuse F3 is good: the AC Primary Circuit is defective:
Follow the steps above.
• Solenoid B ( Retract ): Does the LED lamp, D523, top center of
the power board, illuminate?
- If the LED is illuminated, the DC voltage is OK. Check whether the
solenoid cable pins are loose in the header, RETRACT, top left of
the board.
- If the LED is not illuminated, the DC Voltage is not correct: Check
the Secondary AC Fuse F3, top center tiny glass fuse: If blown,
replace the fuse.
- If the AC Fuse F3 is OK, the AC Primary Circuit is defective.
Contact the Service Center or the ENERPAC Tech Service
5. The pump configuration is wrong 5. Check whether the correct pump model is selected on the LCD
Screen.
- If Pump Model Number 1 is selected: No solenoid will activate
- If Pump Model Number 2 is selected: Only solenoid B will work
- If Pump Model Number 3 is selected: Only solenoid A will work
- If Pump Model Number 8 is selected: No solenoid will activate
- Contact the Service Center or Enerpac's Tech Service
SECTION 5
Pump and 1. The pump is on AUTO Mode and the system 1. If needed, turn the AUTO mode off by pressing any of the LCD
solenoid pressure is above the set HI-PRESS value Keypad buttons
valves do not
work. The
LCD Screen is
flashing AUTO
ON.
(Note: this step

not applicable
to Pallet
De-coupling
pumps)
SECTION 6
"AUTO MODE" Contact the Service Center or ENERPAC Tech Service.
or "DWELL
MODE" does
not work
15

425
www.enerpac.com

426
A.7.7 Hydraulic Cylinder Instruction Sheet
Instruction Sheet
High Tonnage Hydraulic Cylinders

HCG-Series and HCR-Series
L4174 Rev. D 1/2
Table of Contents:
Section Page
1.0 IMPORTANT RECEIVING

INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.0 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.0 CONFORMANCE TO NATIONAL AND
INTERNATIONAL STANDARDS . . . . . . . . . . . . . . .3
4.0 PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . .3
5.0 LIFTING THE CYLINDER . . . . . . . . . . . . . . . . . . . .3
6.0 SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
7.0 AVOIDING SIDE LOAD . . . . . . . . . . . . . . . . . . . . . .5
8.0 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
9.0 INSPECTION, MAINTENANCE & STORAGE . . . . .5
10.0 RELIEVING TRAPPED PRESSURE . . . . . . . . . . .6 Safety Alert Symbols are used in conjunction with certain
Signal Words that call attention to safety messages or property
11.0 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . .6 damage messages and designate a degree or level of hazard
seriousness. The Signal Words used in this manual are
12.0 PRODUCT DATA . . . . . . . . . . . . . . . . . . . . . . . . . .7 WARNING, CAUTION and NOTICE.
WARNING Indicates a hazardous situation that, if not

1.0 IMPORTANT RECEIVING INSTRUCTIONS
avoided, could result in death or serious
Visually inspect all components for shipping damage. Shipping personal injury.
damage is not covered by warranty. If shipping damage is
found, notify carrier at once. The carrier is responsible for
Indicates a hazardous situation that, if not
all repair and replacement costs resulting from damage in CAUTION
avoided, could result in minor or moderate
shipment.
personal injury.
2.0 SAFETY
Indicates information considered important,
NOTICE
2.1 Introduction but not hazard related (e.g. messages
Read all instructions carefully. Follow all recommended safety relating to property damage). Please note
precautions to avoid personal injury as well as damage to the that the Safety Alert Symbol will not be used
product and/or damage to other property. Enerpac cannot be with this signal word.
responsible for any damage or injury from unsafe use, lack of
maintenance or incorrect operation. Do not remove warning 2.2 Hydraulic Cylinder Safety Precautions
labels, tags, or decals. In the event any questions or concerns (HCG-Series and HCR-Series)
arise, contact Enerpac or a local Enerpac distributor for
clarification.
If you have never been trained on high-pressure hydraulic
WARNING
safety, consult your distributor or service center for information Failure to observe and comply with the following
about an Enerpac Hydraulic Safety Course. precautions could result in death or serious personal
This manual follows a system of safety alert symbols, signal injury. Property damage could also occur.
words and safety messages to warn the user of specific • Read and completely understand the safety precautions and
hazards. Failure to comply with these warnings could result instructions in this manual before operating the cylinder or
in death or serious personal injury, as well as damage to the preparing it for use. Always follow all safety precautions and
equipment or other property. instructions, including those that are contained within the
The Safety Alert Symbol appears throughout this procedures of this manual.
manual. It is used to alert you to potential physical • Operating procedures will vary, depending on the system
injury hazards. Pay close attention to Safety Alert arrangement. Always read, follow and completely
Symbols and obey all safety messages that follow this symbol understand all manufacturer's instructions when operating
to avoid the possibility of death or serious personal injury. pumps, valves and all other devices used with the cylinders.
Follow all safety precautions contained in the manufacturer's
manuals.

427
Hydraulic Cylinder Instruction Sheet (Sheet 2)

• Always wear appropriate personal protective equipment be used as a load holding device. After the load has been
(P.P.E.) when operating hydraulic equipment. Be sure to raised or lowered, it always must be cribbed mechanically.
wear eye protection, work gloves and protective clothing. • Be certain that the load is centered and covers the entire
Use of additional P.P.E. safety items such as dust mask, plunger saddle surface. Avoid situations where loads are not
non-skid safety shoes, hard hat, and hearing protection directly centered on the plunger saddle. The load may slip or
(used as appropriate for the conditions) will reduce the fall, causing potential danger.
chance of personal injuries. The use of these items may also • Lift only dead weight loads. Avoid lifting live weight loads.
be required by local regulations or laws.
• Be especially careful when lifting loads such as partially filled
• Do not handle pressurized hoses. Escaping oil under storage tanks, in which the center of gravity could move or
pressure can penetrate the skin. If oil is injected under the shift during lifting. Be aware that the distribution of some
skin, see a doctor immediately. loads can change quickly and without warning.
• Do not pressurize disconnected couplers. • Do not use the cylinder to lift people. Do not allow people to
• Use hydraulic cylinders only in a coupled system. Never use a be on top of the load during lifting or lowering.
cylinder with uncoupled couplers. • Keep all personnel clear of the work area while lifting or
• Do not remove or disable the pump relief valve. lowering is in progress. To avoid personal injury, keep hands
• Do not remove or disable the cylinder relief valve (if and feet away from cylinder and load during operation.
equipped). • Maintain communication with the operator at all times during
• The system operating pressure must not exceed the pressure lifting or lowering to avoid accidents. Use hand signals, two-
rating of the lowest rated component in the system. way radios or other appropriate forms of communication (as
• Install pressure gauge(s) in the system to monitor operating required by applicable laws and regulations) if the load is not
pressure. It is your window to see what is happening in the visible to the operator.
system. • Operate pump and valve as required to ensure that the load
• Never set a relief valve to a higher pressure than the is lifted and lowered evenly and at a controlled rate.
maximum rated pressure of the pump and cylinder. If ratings • Closely watch the load at all times during lifting and lowering.
are different, relief valve setting should not exceed the Stop lifting or lowering immediately if the load becomes
setting of the lowest rated component (pump or cylinder). unstable or appears to be lifting or lowering unevenly.
• The HCG-Series and HCR-Series cylinders are designed • Stay clear of loads supported only by hydraulics. As required,
for a maximum working pressure of 10150 psi [700 bar]. Do follow the lifted load with cribbing.
not connect a pump with a higher pressure rating to these • Always be certain that hydraulic pressure is fully relieved
cylinders. and that the load is fully removed from the cylinder(s) before
• Do not exceed equipment ratings. Never attempt to lift a disconnecting hydraulic hoses, loosening hydraulic fittings,
load weighing more than the rated capacity of the cylinder. or performing any cylinder disassembly or repair procedures.
Overloading may cause equipment failure and possible
personal injury. CAUTION
• Be sure setup is stable before lifting load. Cylinders should
be located on a firm and level surface capable of supporting Failure to observe and comply with the following
the full load. precautions could result in minor or moderate personal
• Where applicable, use a cylinder base plate to provide added injury. Property damage could also occur.
stability. If desired, the cylinder can be bolted to the base • Be careful to avoid damaging hydraulic hoses. Avoid sharp
plate, using the bolt holes in the bottom of the cylinder base. bends and kinks when routing hydraulic hoses. Do not
(Note: An accessory base plate is available from Enerpac for exceed the minimum bend radius specified by the hose
the HCG-50 and HCR-50 Series models. Base plate must be manufacturer. Using a bent or kinked hose will cause severe
user-fabricated for all other models). back-pressure. Sharp bends and kinks will internally damage
• Do not weld, drill or otherwise modify a cylinder to attach a the hose, leading to premature hose failure.
base plate or other support unless approved in writing by • Do not drop heavy objects on hoses. A sharp impact may
the Enerpac Engineering Department. Use only the provided cause internal damage to hose wire strands. Applying
bolt holes. pressure to a damaged hose may cause it to rupture.
• Always perform a visual inspection of the cylinder before • Do not lift hydraulic equipment by the hoses or couplers. Use
placing it into operation. If any problems are found, do not the cylinder lifting eyes and appropriately rated lifting equipment.
use the cylinder. Have the cylinder repaired and tested by • Keep hydraulic equipment away from flames and heat.
an Enerpac Authorized Service Center before it is returned Excessive heat will soften packings and seals, resulting in
to service. fluid leaks. Heat also weakens hose materials and packings.
• Never use a cylinder that is leaking oil. Do not use a cylinder • For optimum performance, do not expose hydraulic
that is damaged, altered or in need of repair. equipment to temperatures of 150˚F [65˚C] or higher. Protect
• Always lift the cylinder using a hoist, crane or other suitable all hydraulic equipment from weld spatter.
lifting device of sufficient rated capacity. Use only the • Immediately replace worn or damaged parts with genuine
supplied cylinder lifting eyes to attach the cylinder to the Enerpac parts. Enerpac parts are designed to fit properly
lifting device. Replace any missing or damaged lifting eyes. and to withstand high loads. Non-Enerpac parts may break
• Allow only trained and experienced personnel to supervise or cause the product to malfunction.
and perform lifting and lowering procedures.
• Be certain that no persons are working on or near any NOTICE
cylinders before lifting or lowering of the load begins. Alert all
personnel in advance that lifting or lowering is about to occur. • Hydraulic equipment must only be serviced by a qualified
• Use suitable cribbing of rigid construction to hold loads. hydraulic technician. For repair service, contact the Enerpac
Authorized Service Center in your area.
• Never use a hydraulic cylinder as a shim or spacer in any
lifting or pressing application. • To help ensure proper operation and best performance, use
of Enerpac oil is strongly recommended.
• A cylinder when used as a load lifting device, should never

428
1 1
4
2 2
4
3 3
9 9
HCR-Series
(double-acting
hydraulic return)
4 4
11
8 5
6 10
HCG-Series
(single-acting 6
load return)
12
7 7
Key:
1. Saddle 6. Cylinder Base 10. Safety Relief Valve
2. Plunger 7. Hydraulic Coupler, Advance 11. Hydraulic Coupler, Retract
3. Stop Ring 3/8"-18 NPTF 3/8"-18 NPTF
4. Lifting Eye 8. Plug 12. Tilt Saddle (optional accessory)
5. Vent Port 9. Collar Threads
Figure 1, Major Features and Components, HCG-Series and HCR-Series Hydraulic Cylinders (Typical)
2.3 Additional References Capacities range from 62 to 1196 US tons [550 to 10644 kN].
Consult the applicable industry and/or government standards Refer to the product data markings on the cylinder base for the
in your country or region for additional safety precautions and capacity rating of your cylinder model.
work rules applicable to hydraulic cylinders, jacks and other All standard production HCG and HCR cylinders are designed
similar lifting equipment. for 10150 psi [700 bar] maximum working pressure.
In the USA, refer to the following publications: A hardened grooved saddle is standard equipment on all
• Code of Federal Regulations - Title 29 Occupational Safety models. A user-installable tilt saddle is available as an optional
and Health Standards (U.S. Government Publishing Office, accessory.
732 North Capitol Street, NW, Washington, DC 20401-0001. Refer to Section 12 of this manual for cylinder weights, oil
www.gpo.gov). volumes, dimensions and additional specifications.
• ASME B30.1 Standards - Jacks (American Society of
Mechanical Engineers, Two Park Avenue, New York, NY
5.0 LIFTING THE CYLINDER
10016-5990. www.asme.org). All cylinders are equipped with TWO pre-installed lifting eyes.
In the European Union, refer to the standards and directives Always use BOTH lifting eyes when hoisting the cylinder.
listed in the product's EU Declaration of Incorporation. A copy Lifting straps or chains must be positioned at an angle where
of this document is packed separately with the cylinder. they will not interfere with the cylinder base. Use of a spreader
bar is recommended. See Figure 2.
3.0 CONFORMANCE TO NATIONAL AND
INTERNATIONAL STANDARDS
Enerpac declares that this product has been tested
and conforms to applicable standards and is
compatible to all CE Requirements. A copy of an EU OK
Declaration of Incorporation is enclosed with each shipment of OK
this product.
4.0 PRODUCT DESCRIPTION

Enerpac HCG-Series and HCR-Series high tonnage hydraulic
cylinders are an ideal solution for a wide variety of commercial
and industrial lifting applications.
HCG-Series models are single-acting with hydraulic advance Figure 2, Lifting Arrangements (typical)
and load return. Manual force will be required to retract the
plunger if no load is present.
HCR-Series models are double-acting with hydraulic advance
and return. The hydraulic return feature allows greater control
during lowering and provides positive retraction of the plunger.
Note that the HCR-Series cylinders are not designed for pulling
applications.
3

429

6.0 SETUP
1. Tilt Saddle 2. Plunger 3. Threaded Stud
6.1 Hydraulic Pump Requirements
Hydraulic pumps are sold separately and are not included with
the cylinders. 1
A hand-operated hydraulic pump can be used to operate a
smaller HGC or HCR-Series cylinder. However, a large size 2
cylinder (or a series of coupled cylinders) will typically require
the use of an electric, air or gas powered hydraulic pump. Apply Loctite ®242 3
Whichever type of pump is used, be certain that the pump Thread Sealant
reservoir is capable of holding a sufficient amount of hydraulic
oil to operate the cylinder (or set of cylinders) to full extension.
Figure 3, CATS Series Tilt Saddle Accessory (typical)
If used with HCG-Series single-acting cylinders, the pump must
be equipped with a pressure release valve. If used with HCR-
6.4 Hydraulic Connections
Series double-acting cylinders, the pump must be equipped
with a four-way directional control valve. These valves may be The HCG series cylinders are equipped with one 3/8"-18 NPTF
either manual or remote operated. female coupler. This coupler provides hydraulic flow for both
advance and retract functions.
The pump must also be equipped with a separate safety
pressure relief valve that opens if the system working pressure The HCR series cylinders are equipped with two 3/8"-18 NPTF
exceeds 10150 psi [700 bar]. Verify that the pump safety relief female couplers, one for advance side hydraulic flow and one
valve is adjusted to the proper setting before using the pump for retract side hydraulic flow.
with the cylinder(s). Refer to Figure 1, items 7 and 11 for locations.
6.2 Hydraulic Oil Requirements Be certain that all couplers are fully connected, so that hydraulic
flow is not blocked or restricted.
Use of Enerpac HF Series ISO 32 hydraulic oil is recommended.
Enerpac HF oil is available at your local Enerpac Distributor or All hoses, fittings and other hydraulic components in the circuit
Authorized Service Center. must be rated for at least 10150 psi [700 bar] operation.
NOTICE HCR-Series cylinders are double-acting. In both
NOTICE operational modes, return oil flow (from the non-pressurized
side of the cylinder) must be directed back to the hydraulic
• Failure to use the correct oil type (high-quality ISO 32 reservoir. Check for proper flow before placing the equipment
hydraulic oil) may result in damage to cylinder hydraulic into operation.
components and will void the product warranty.
• Be sure that the oil is clean. The oil cleanliness should 6.5 Air Removal
be maintained to a maximum level of 18/16/13 per the Trapped air must be removed from the hydraulic cylinder and
ISO 4406 standard. If the oil develops a milky, cloudy or hose before placing the system into operation. If multiple
dark appearance, it should be changed immediately. cylinders are to be used, it is recommended that air be
• To avoid overfilling and possible equipment damage, add removed from each cylinder individually. Refer to the following
oil to the pump reservoir only after all cylinder plungers are procedure:
completely retracted and system pressure is released. 1. Position the pump so it is located higher than the cylinder.
• When using a hand-operated pump to power the cylinder(s), 2. Place the cylinder in the vertical position, with the base
it is permissible to use a high-quality brand of ISO 15 located on a flat and level surface. Be sure that there is no
hydraulic oil. The lower oil viscosity will result in reduced load on the plunger.
pumping effort, especially in cold weather conditions.
3. Using the hydraulic pump and valve, advance and retract
6.3 Tilt Saddle (optional accessory) the plunger as required to remove trapped air. Refer to the
procedure for your cylinder series:
The Enerpac CATS Series tilt saddle is available as an optional
accessory. If ordered with a HGC or HCR-Series cylinder, the HCG-Series models: Fully advance the plunger, being
tilt saddle is shipped separately and must be installed on the careful to avoid pressure build-up at full extension.
cylinder before use, as described in the following procedure. Completely relieve hydraulic pressure, then manually push
the plunger into the cylinder base until it is fully retracted
Install the tilt saddle as described in the following steps. Refer Repeat this process until the plunger advances smoothly.
to Figure 3 for installation details. Use of a hydraulic pump equipped with a vacuum valve
1. Remove the existing center bolt and standard saddle from will help aid plunger retraction.
the plunger bore. HCR-Series models: Fully advance and retract the
2. Inspect the mating surfaces of the plunger bore and the plunger, being careful to avoid pressure build-up at full
tilt saddle lower half. Mating surfaces must be free of dust, extension and full retraction. Repeat this process until
dirt, moisture or corrosion. plunger motion is smooth in both directions.
3. Apply service-removable thread locking compound 4. Fully retract the plunger after completing air removal
(Loctite ® 243 or equivalent) to the threaded stud at the procedures. Check oil level in pump hydraulic reservoir.
bottom of the tilt saddle. Add oil if oil level is low.
4. By hand, gently engage the threads of the threaded stud 5. Repeat steps 1 through 4 for all cylinders to be used in the
with the threads of the tapped hole at the center of the hydraulic circuit.
plunger. Check for free movement. Be sure the stud is not
cross-threaded.
5. Rotate the tilt saddle clockwise several turns, until it is fully
seated in the plunger bore.
.
4

430

6.6 Cylinder Base Support NOTICE It is mandatory that the operator has a full
Be certain to provide adequate support for the cylinder base. understanding of all instructions, safety precautions and
All HCR and HCG-Series cylinders require a flat and stable applicable safety regulations before operating any high force
lifting surface that is capable of supporting the load without hydraulic equipment. If questions or concerns, contact your
settling. A steel plate or steel bars of appropriate size should local Enerpac Distributor or Authorized Service Center.
be placed between the cylinder base and the ground or other
lifting surface. See Figure 4. 8.1 Operation - HCG-Series
CAUTION Use of HCG-Series or HCR-Series To advance: Operate pump and valve so that pressurized oil
cylinders on surfaces such as sand, mud or dirt may flow is directed in a controlled rate from the pump reservoir to
result in loss of load and/or damage to cylinder. the advance coupler of the cylinder.
Base mounting holes are provided on all models. Refer to To retract: Operate pump and valve so that oil flow is directed
Section 12.3 for mounting hole locations and dimensions. at a controlled rate from the cylinder advance coupler back to
Mounting bolts are not included with the cylinder and must be the pump reservoir. Note that additional hydraulic components
provided by the user. may be required to control the rate at which the plunger retracts
under load.
NOTICE HCG-Series cylinders contain no plunger return
spring. External force will be required to fully retract an HCG-
Series cylinder if it is not under load. Use of a hydraulic pump
OK
equipped with a vacuum valve will help aid cylinder retraction.
8.2 Operation - HCR-Series

To advance: Operate pump and valve so that pressurized oil
flow is directed from the pump reservoir to the advance coupler
of the cylinder.
To retract: Operate pump and valve so that pressurized oil
flow is directed from the pump reservoir to the retract coupler
Rough and Flat and stable of the cylinder. Note that additional hydraulic components may
unstable surface surface with steel plate be required to control the rate at which the plunger retracts
under load.
Figure 4, Cylinder Base Support
8.3 Vent Port (HCG-Series Only)
7.0 AVOIDING SIDE LOAD On HCG-Series models, a built-in vent port provides vacuum
Plan ahead to eliminate the presence of side load forces (offset relief and pressure equalization for the cylinder plunger cavity.
loading) when using hydraulic cylinders. Side load can occur The vent port is located near the top of the cylinder base. See
as a result of one or more of the following conditions: Figure 1, item 5.
• An eccentric load on the plunger. • A horizontal load on a Periodically check that the vent port passage is free of dirt or
structure. • A shifting center of gravity. • Structure and/or cylinder other obstructions.
misalignment. • Non-synchronized lifting actions. • Non-stable
8.4 Retract Side Safety Relief Valve
cylinder base support.
(HCR-Series Only)
It is understood that some side load will occur in many lifting
situations. However, the user should do everything possible to HCR-Series models include a retract side safety relief valve. It is
minimize or eliminate this condition. located near the top of the cylinder base. See Figure 1, item 10.
The possibility of side load can be reduced by ensuring that The valve is designed to relieve retract chamber pressure in the
the cylinder base is located on a flat and hard surface, capable event that hydraulic flow is directed to the advance side of the
of supporting the cylinder and the load without settling. cylinder while the retract side hose is disconnected. It is factory
set at approximately 862-896 bar [12500-13000 psi].
To help reduce the effects of side load that cannot be eliminated,
use of the CATS Series tilt saddle is strongly recommended. WARNING Do not remove, alter or disable the retract
The CATS series tilt saddle helps compensate for initial side safety relief valve. Do not readjust the valve setting.
misalignment of the load and the saddle surface. It reduces Failure to observe this instruction may result in possible
saddle edge loading, which can result in an undesirable off- catastrophic failure of the cylinder. Serious personal injury
center load being applied to the plunger. This item is available could result.
as an optional accessory for all HCG-Series and HCR-Series
cylinders. Refer to Section 6.3 for additional information. 9.0 INSPECTION, MAINTENANCE & STORAGE
• Periodically check the hydraulic system for loose
8.0 OPERATION
connections leaks and obvious problems. Replace any
Operation procedures will vary, depending on hydraulic pump damaged components immediately.
type, valve configuration and other factors. For detailed
• Monitor the oil temperature during operation. Do not exceed
operating instructions and related information, refer to the
oil temperatures above 150°F [65°C].
instruction sheet included with your pump. Also follow the
additional instructions and precautions contained in sections • Install dust cap(s) and plug(s) after the hydraulic hoses are
8.1 through 8.4 of this manual. disconnected from the cylinder.
• Keep all hydraulic components clean.
If using multiple HCR-Series cylinders: Without load, verify that
all plungers advance and retract in the same direction when • Periodically check the tilt saddle (if equipped) for free
the control valve is shifted. If necessary, relieve pressure and movement. If required, disassemble, clean and lubricate the
properly reconnect any reversed hydraulic hoses. tilt saddle. Use white lithium grease.
• Change the hydraulic oil at the recommended interval shown
in the pump instruction sheet. Change the oil immediately if
5

431

contamination is suspected. Trapped hydraulic pressure can cause a loosened coupler
• Store cylinders in the upright position, in a clean, dry and to dislodge unexpectedly with great force. Serious
secure location. Keep stored cylinders and hoses away from personal injury or death will result if the coupler becomes
heat and direct sunlight. a projectile and strikes persons working in the area.
• If repairs are required, refer to the Enerpac website for the A sudden escape of pressurized hydraulic oil may also
repair parts sheet applicable to your cylinder model. occur if a coupler is loosened while trapped hydraulic
NOTICE Hydraulic equipment must only be serviced by a pressure is present. Serious personal injury or death could
qualified hydraulic technician. For repair service, contact the result if a high pressure oil stream penetrates the skin.
Enerpac Authorized Service Center in your area. Use only the Enerpac CT-604 coupler bleed tool to relieve
trapped hydraulic pressure within the cylinder.
10.0 RELIEVING TRAPPED PRESSURE
WARNING Never use a hammer and punch (or other
Hydraulic pressure can sometimes become trapped within
a hydraulic cylinder. This condition can occur in both single similar method) to unseat a coupler check ball that is under
and double-acting cylinders, but is most likely to happen in pressure. Serious personal injury or death could result due
a double-acting cylinder that has been exposed to changing to the sudden and uncontrolled escape of high pressure
ambient temperatures. oil. Use only the Enerpac CT-604 coupler bleed tool to
relieve trapped pressure within the cylinder.
A common indication of trapped pressure is when mating hose
and cylinder couplers will not engage, or are unusually difficult 11.0 TROUBLESHOOTING
to engage.
Refer to the troubleshooting guide when diagnosing cylinder
If a trapped pressure condition is suspected, always use the operational problems. Please note that the troubleshooting
Enerpac model CT-604 coupler bleed tool (available from your guide is not all-inclusive, and should be considered only as
Enerpac distributor) to safely relieve any remaining pressure. an aid to help diagnose the most common possible problems.
WARNING Never attempt to relieve trapped hydraulic For repair service, contact your nearest Enerpac Authorized
pressure within the cylinder by loosening a coupler on the Service Center. As required, also refer to the troubleshooting
cylinder base. information provided with your hydraulic pump or power unit.
Troubleshooting Guide
Symptom Possible Cause Solution
1. Plunger will not a. Pump release valve open. Close pump release valve.
advance.
b. Directional control valve not in proper position. Shift directional control valve to proper position.
c. Coupler not fully tightened. Tighten coupler.
d. Pump oil level is low. Add oil to pump reservoir as required. See Section 6.2.
e. Pump malfunctioning. Repair or replace pump as required.
f. Cylinder load rating too low for application. Use a cylinder with a higher load rating.
g. Cylinder seals leaking. Repair or replace cylinder.
2. Plunger advances a. Oil level in pump is low. Add oil to pump reservoir as required. See Section 6.2.
only part way.
b. Coupler is not fully tightened. Tighten coupler.
c. Cylinder plunger binding. Repair or replace cylinder.
3. Plunger advances a. Air in hydraulic system. Remove air from hydraulic system. See Section 6.5.
erratically.
b. Cylinder plunger binding. Repair or replace cylinder.
4. Plunger advances a. Leaking connection. Repair leaking connection.
more slowly than
b. Coupler not fully tightened. Tighten coupler.
normal.
c. Pump malfunctioning. Repair or replace pump as required.
5. Plunger advances, but a. Pump malfunctioning. Repair or replace pump as required.
will not hold.
b. Leaking connection. Repair leaking connection.
c. Incorrect system set-up. Check hose connections at pump and cylinders.
d. Cylinder seals leaking. Repair or replace cylinder.
6. Cylinder leaks oil. a. Worn or damaged cylinder seals. Repair or replace cylinder.
b. Internal cylinder damage. Repair or replace cylinder.
c. Loose connection. Tighten or repair connection.
7. Plunger will not retract a. Pump release valve closed. Open pump release valve.
or retracts more
b. Directional control valve not in proper position. Shift directional control valve to proper position.
slowly than normal.
c. Pump reservoir is overfilled. Drain oil from pump reservoir as required.
d. Improper hose connections. Check hose connections.
e. Narrow hose restricting oil flow. Replace with larger diameter hose.
f. Internal cylinder damage. Repair or replace cylinder.
8. Oil leakage from a. Coupler not fully tightened. Tighten coupler.
external relief valve.
b. Restriction in return line. Remove restriction from return line.
c. Relief valve setting incorrect. Check relief valve setting.
d. Relief valve damaged or contaminated. Repair or replace relief valve.
6

432

12.0 PRODUCT DATA
Models rated at 150 US Tons [1497 kN] or lower. Models rated at 200 US Tons [1985 kN] or higher.
90˚
60˚
J U J U
30˚ 30˚
W
W
E E
F F K
K
X X
I I
B B
A A
3/8"-18 NPTF 3/8"-18 NPTF
Z
H H Z
V V
D D
Refer to Sections 12.1, 12.2 and 12.3 Tilt Saddle - Optional Accessory, All Models
for the dimensions applicable to your
cylinder model. Use this graphic as a
reference.
J1
5˚
K1
Figure 5, Dimensions, HCG-Series and HCR-Series

433
Refer to Figure 5 for dimensions A through K1

12.1 Dimensions, HCG-Series and HCR-Series (imperial)
Saddle
Base to Top to * Std. Tilt Saddle (accessory)
Collapsed Extended Outside Cyl. Bore Plunger Protrusion
Cylinder Advance Retract Saddle
Height Height Diameter Diameter Diameter from
Model Port Port Diameter Dia. Height
Plunger
Number Model
A B D E F H I J K J1 K1 No.
in in in in in in in in in in in
HCG/HCR-502 7.20 9.17 5.12 3.94 2.76 1.50 1.77 1.97 0.12 2.80 1.34 CATS-50
HCG/HCR-504 9.17 13.11 5.12 3.94 2.76 1.50 1.77 1.97 0.12 2.80 1.34 CATS-50
HCG/HCR-506 11.14 17.05 5.12 3.94 2.76 1.50 1.77 1.97 0.12 2.80 1.34 CATS-50
HCG/HCR-508 13.62 21.50 5.12 3.94 2.76 1.50 2.17 1.97 0.12 2.80 1.34 CATS-50
HCG/HCR-5010 15.59 25.43 5.12 3.94 2.76 1.50 2.17 1.97 0.12 2.80 1.34 CATS-50
HCG/HCR-5012 17.56 29.37 5.12 3.94 2.76 1.50 2.17 1.97 0.12 2.80 1.34 CATS-50
HCG/HCR-1002 7.95 9.92 6.89 5.31 3.74 1.50 2.56 2.95 0.12 2.80 1.18 CATS-101
HCG/HCR-1004 9.92 13.86 6.89 5.31 3.74 1.50 2.56 2.95 0.12 2.80 1.18 CATS-101
HCG/HCR-1006 11.89 17.80 6.89 5.31 3.74 1.50 2.56 2.95 0.12 2.80 1.18 CATS-101
HCG/HCR-1008 14.92 22.80 6.89 5.31 3.74 1.50 3.15 2.95 0.12 2.80 1.18 CATS-101
HCG/HCR-10010 16.89 26.73 6.89 5.31 3.74 1.50 3.15 2.95 0.12 2.80 1.18 CATS-101
HCG/HCR-10012 18.86 30.67 6.89 5.31 3.74 1.50 3.15 2.95 0.12 2.80 1.18 CATS-101
HCG/HCR-1502 8.66 10.63 8.46 6.50 4.72 1.61 2.76 3.70 0.12 3.82 1.54 CATS-150
HCG/HCR-1504 10.63 14.57 8.46 6.50 4.72 1.61 2.76 3.70 0.12 3.82 1.54 CATS-150
HCG/HCR-1506 12.60 18.50 8.46 6.50 4.72 1.61 2.76 3.70 0.12 3.82 1.54 CATS-150
HCG/HCR-1508 15.63 23.50 8.46 6.50 4.72 1.61 3.54 3.70 0.12 3.82 1.54 CATS-150
HCG/HCR-15010 17.60 27.44 8.46 6.50 4.72 1.61 3.54 3.70 0.12 3.82 1.54 CATS-150
HCG/HCR-15012 19.57 31.38 8.46 6.50 4.72 1.61 3.54 3.70 0.12 3.82 1.54 CATS-150
HCG/HCR-2002 9.09 11.06 9.84 7.48 5.51 1.85 3.11 4.45 0.12 4.96 1.69 CATS-200
HCG/HCR-2004 11.06 15.00 9.84 7.48 5.51 1.85 3.11 4.45 0.12 4.96 1.69 CATS-200
HCG/HCR-2006 13.03 18.94 9.84 7.48 5.51 1.85 3.11 4.45 0.12 4.96 1.69 CATS-200
HCG/HCR-2008 16.06 23.94 9.84 7.48 5.51 1.85 3.82 4.45 0.12 4.96 1.69 CATS-200
HCG/HCR-20010 18.03 27.87 9.84 7.48 5.51 1.85 3.82 4.45 0.12 4.96 1.69 CATS-200
HCG/HCR-20012 20.00 31.81 9.84 7.48 5.51 1.85 3.82 4.45 0.12 4.96 1.69 CATS-200
HCG/HCR-2502 9.49 11.46 11.02 8.46 6.69 2.09 3.11 5.49 0,16 6.89 2.70 CATS-300
HCG/HCR-2504 11.46 15.39 11.02 8.46 6.69 2.09 3.11 5.49 0,16 6.89 2.70 CATS-300
HCG/HCR-2506 13.43 19.33 11.02 8.46 6.69 2.09 3.11 5.49 0,16 6.89 2.70 CATS-300
HCG/HCR-2508 16.97 24.84 11.02 8.46 6.69 2.09 4.09 5.49 0,16 6.89 2.70 CATS-300
HCG/HCR-25010 18.94 28.78 11.02 8.46 6.69 2.09 4.09 5.49 0,16 6.89 2.70 CATS-300
HCG/HCR-25012 20.91 32.72 11.02 8.46 6.69 2.09 4.09 5.49 0,16 6.89 2.70 CATS-300
HCG/HCR-3002 11.65 13.62 12.01 9.25 7.87 2.28 3.98 5.49 0,16 6.89 2.70 CATS-300
HCG/HCR-3004 13.62 17.56 12.01 9.25 7.87 2.28 3.98 5.49 0,16 6.89 2.70 CATS-300
HCG/HCR-3006 15.59 21.50 12.01 9.25 7.87 2.28 3.98 5.49 0,16 6.89 2.70 CATS-300
HCG/HCR-3008 17.56 25.43 12.01 9.25 7.87 2.28 3.98 5.49 0,16 6.89 2.70 CATS-300
HCG/HCR-30010 19.53 29.37 12.01 9.25 7.87 2.28 3.98 5.49 0,16 6.89 2.70 CATS-300
HCG/HCR-30012 21.50 33.31 12.01 9.25 7.87 2.28 3.98 5.49 0,16 6.89 2.70 CATS-300
HCG/HCR-4002 12.64 14.61 13.78 10.63 8.66 2.91 4.37 6.27 0,16 8.27 3.07 CATS-400
HCG/HCR-4004 14.61 18.54 13.78 10.63 8.66 2.91 4.37 6.27 0,16 8.27 3.07 CATS-400
HCG/HCR-4006 16.57 22.48 13.78 10.63 8.66 2.91 4.37 6.27 0,16 8.27 3.07 CATS-400
HCG/HCR-4008 18.54 26.42 13.78 10.63 8.66 2.91 4.37 6.27 0,16 8.27 3.07 CATS-400
HCG/HCR-40010 20.51 30.35 13.78 10.63 8.66 2.91 4.37 6.27 0,16 8.27 3.07 CATS-400
HCG/HCR-40012 22.48 34.29 13.78 10.63 8.66 2.91 4.37 6.27 0,16 8.27 3.07 CATS-400
HCG/HCR-5002 13.54 15.51 15.75 12.01 9.84 3.11 4.76 7.06 0,16 9.06 3.07 CATS-500
HCG/HCR-5004 15.51 19.45 15.75 12.01 9.84 3.11 4.76 7.06 0,16 9.06 3.07 CATS-500
HCG/HCR-5006 17.48 23.39 15.75 12.01 9.84 3.11 4.76 7.06 0,16 9.06 3.07 CATS-500
HCG/HCR-5008 19.45 27.32 15.75 12.01 9.84 3.11 4.76 7.06 0,16 9.06 3.07 CATS-500
HCG/HCR-50010 21.42 31.26 15.75 12.01 9.84 3.11 4.76 7.06 0,16 9.06 3.07 CATS-500
HCG/HCR-50012 23.39 35.20 15.75 12.01 9.84 3.11 4.76 7.06 0,16 9.06 3.07 CATS-500
HCG/HCR-6002 13.86 15.83 16.93 12.99 10.63 3.35 4.76 7.65 0,16 9.84 3.27 CATS-600
HCG/HCR-6004 15.83 19.76 16.93 12.99 10.63 3.35 4.76 7.65 0,16 9.84 3.27 CATS-600
HCG/HCR-6006 17.80 23.70 16.93 12.99 10.63 3.35 4.76 7.65 0,16 9.84 3.27 CATS-600
HCG/HCR-6008 19.76 27.64 16.93 12.99 10.63 3.35 4.76 7.65 0,16 9.84 3.27 CATS-600
HCG/HCR-60010 21.73 31.57 16.93 12.99 10.63 3.35 4.76 7.65 0,16 9.84 3.27 CATS-600
HCG/HCR-60012 23.70 35.51 16.93 12.99 10.63 3.35 4.76 7.65 0,16 9.84 3.27 CATS-600
HCG/HCR-8002 15.91 17.87 19.88 15.16 12.60 3.94 5.63 8.83 0,16 10.83 3.41 CATS-800
HCG/HCR-8004 17.87 21.81 19.88 15.16 12.60 3.94 5.63 8.83 0,16 10.83 3.41 CATS-800
HCG/HCR-8006 19.84 25.75 19.88 15.16 12.60 3.94 5.63 8.83 0,16 10.83 3.41 CATS-800
HCG/HCR-8008 21.81 29.69 19.88 15.16 12.60 3.94 5.63 8.83 0,16 10.83 3.41 CATS-800
HCG/HCR-80010 23.78 33.62 19.88 15.16 12.60 3.94 5.63 8.83 0,16 10.83 3.41 CATS-800
HCG/HCR-80012 25.75 37.56 19.88 15.16 12.60 3.94 5.63 8.83 0,16 10.83 3.41 CATS-800
HCG/HCR-10002 17.40 19.37 22.44 17.32 13.39 4.49 6.02 9.81 0,16 11.81 4.22 CATS-1000
HCG/HCR-10004 19.37 23.31 22.44 17.32 13.39 4.49 6.02 9.81 0,16 11.81 4.22 CATS-1000
HCG/HCR-10006 21.34 27.24 22.44 17.32 13.39 4.49 6.02 9.81 0,16 11.81 4.22 CATS-1000
HCG/HCR-10008 23.31 31.18 22.44 17.32 13.39 4.49 6.02 9.81 0,16 11.81 4.22 CATS-1000
HCG/HCR-100010 25.28 35.12 22.44 17.32 13.39 4.49 6.02 9.81 0,16 11.81 4.22 CATS-1000
HCG/HCR-100012 27.24 39.06 22.44 17.32 13.39 4.49 6.02 9.81 0,16 11.81 4.22 CATS-1000
* Dimension "I" is applicable to HCR Models only.

8

434
Refer to Figure 5 for dimensions A through K1

12.2 Dimensions, HCG-Series and HCR-Series (metric)
Saddle
Cyl. Base to Top to * Std. Tilt Saddle (accessory)
Collapsed Extended Outside Plunger Protrusion
Cylinder Bore Advance Retract Saddle
Height Height Diameter Diameter from
Model Diameter Port Port Diameter
Plunger Dia. Height
Number Model
A B D E F H I J K J1 K1
No.
mm mm mm mm mm mm mm mm mm mm mm
HCG/HCR-502 183 233 130 100 70 38 45 50 3 71 34 CATS-50
HCG/HCR-504 233 333 130 100 70 38 45 50 3 71 34 CATS-50
HCG/HCR-506 283 433 130 100 70 38 45 50 3 71 34 CATS-50
HCG/HCR-508 346 546 130 100 70 38 55 50 3 71 34 CATS-50
HCG/HCR-5010 396 646 130 100 70 38 55 50 3 71 34 CATS-50
HCG/HCR-5012 446 746 130 100 70 38 55 50 3 71 34 CATS-50
HCG/HCR-1002 202 252 175 135 95 38 65 75 3 71 30 CATS-101

HCG/HCR-1004 252 352 175 135 95 38 65 75 3 71 30 CATS-101
HCG/HCR-1006 302 452 175 135 95 38 65 75 3 71 30 CATS-101
HCG/HCR-1008 379 579 175 135 95 38 80 75 3 71 30 CATS-101
HCG/HCR-10010 429 679 175 135 95 38 80 75 3 71 30 CATS-101
HCG/HCR-10012 479 779 175 135 95 38 80 75 3 71 30 CATS-101
HCG/HCR-1502 220 270 215 165 120 41 70 94 3 97 39 CATS-150

HCG/HCR-1504 270 370 215 165 120 41 70 94 3 97 39 CATS-150
HCG/HCR-1506 320 470 215 165 120 41 70 94 3 97 39 CATS-150
HCG/HCR-1508 397 597 215 165 120 41 90 94 3 97 39 CATS-150
HCG/HCR-15010 447 697 215 165 120 41 90 94 3 97 39 CATS-150
HCG/HCR-15012 497 797 215 165 120 41 90 94 3 97 39 CATS-150
HCG/HCR-2002 231 281 250 190 140 47 79 113 3 126 43 CATS-200

HCG/HCR-2004 281 381 250 190 140 47 79 113 3 126 43 CATS-200
HCG/HCR-2006 331 481 250 190 140 47 79 113 3 126 43 CATS-200
HCG/HCR-2008 408 608 250 190 140 47 97 113 3 126 43 CATS-200
HCG/HCR-20010 458 708 250 190 140 47 97 113 3 126 43 CATS-200
HCG/HCR-20012 508 808 250 190 140 47 97 113 3 126 43 CATS-200
HCG/HCR-2502 241 291 280 215 170 53 79 140 4 175 69 CATS-300

HCG/HCR-2504 291 391 280 215 170 53 79 140 4 175 69 CATS-300
HCG/HCR-2506 341 491 280 215 170 53 79 140 4 175 69 CATS-300
HCG/HCR-2508 431 631 280 215 170 53 104 140 4 175 69 CATS-300
HCG/HCR-25010 481 731 280 215 170 53 104 140 4 175 69 CATS-300
HCG/HCR-25012 531 831 280 215 170 53 104 140 4 175 69 CATS-300
HCG/HCR-3002 296 346 305 235 200 58 101 140 4 175 69 CATS-300
HCG/HCR-3004 346 446 305 235 200 58 101 140 4 175 69 CATS-300
HCG/HCR-3006 396 546 305 235 200 58 101 140 4 175 69 CATS-300
HCG/HCR-3008 446 646 305 235 200 58 101 140 4 175 69 CATS-300
HCG/HCR-30010 496 746 305 235 200 58 101 140 4 175 69 CATS-300
HCG/HCR-30012 546 846 305 235 200 58 101 140 4 175 69 CATS-300
HCG/HCR-4002 321 371 350 270 220 74 111 159 4 210 78 CATS-400
HCG/HCR-4004 371 471 350 270 220 74 111 159 4 210 78 CATS-400
HCG/HCR-4006 421 571 350 270 220 74 111 159 4 210 78 CATS-400
HCG/HCR-4008 471 671 350 270 220 74 111 159 4 210 78 CATS-400
HCG/HCR-40010 521 771 350 270 220 74 111 159 4 210 78 CATS-400
HCG/HCR-40012 571 871 350 270 220 74 111 159 4 210 78 CATS-400
HCG/HCR-5002 344 394 400 305 250 79 121 179 4 230 78 CATS-500
HCG/HCR-5004 394 494 400 305 250 79 121 179 4 230 78 CATS-500
HCG/HCR-5006 444 594 400 305 250 79 121 179 4 230 78 CATS-500
HCG/HCR-5008 494 694 400 305 250 79 121 179 4 230 78 CATS-500
HCG/HCR-50010 544 794 400 305 250 79 121 179 4 230 78 CATS-500
HCG/HCR-50012 594 894 400 305 250 79 121 179 4 230 78 CATS-500
HCG/HCR-6002 352 402 430 330 270 85 121 194 4 250 83 CATS-600
HCG/HCR-6004 402 502 430 330 270 85 121 194 4 250 83 CATS-600
HCG/HCR-6006 452 602 430 330 270 85 121 194 4 250 83 CATS-600
HCG/HCR-6008 502 702 430 330 270 85 121 194 4 250 83 CATS-600
HCG/HCR-60010 552 802 430 330 270 85 121 194 4 250 83 CATS-600
HCG/HCR-60012 602 902 430 330 270 85 121 194 4 250 83 CATS-600
HCG/HCR-8002 404 454 505 385 320 100 143 224 4 275 87 CATS-800
HCG/HCR-8004 454 554 505 385 320 100 143 224 4 275 87 CATS-800
HCG/HCR-8006 504 654 505 385 320 100 143 224 4 275 87 CATS-800
HCG/HCR-8008 554 754 505 385 320 100 143 224 4 275 87 CATS-800
HCG/HCR-80010 604 854 505 385 320 100 143 224 4 275 87 CATS-800
HCG/HCR-80012 654 954 505 385 320 100 143 224 4 275 87 CATS-800
HCG/HCR-10002 442 492 570 440 340 114 153 249 4 300 107 CATS-1000
HCG/HCR-10004 492 592 570 440 340 114 153 249 4 300 107 CATS-1000
HCG/HCR-10006 542 692 570 440 340 114 153 249 4 300 107 CATS-1000
HCG/HCR-10008 592 792 570 440 340 114 153 249 4 300 107 CATS-1000
HCG/HCR-100010 642 892 570 440 340 114 153 249 4 300 107 CATS-1000
HCG/HCR-100012 692 992 570 440 340 114 153 249 4 300 107 CATS-1000
* Dimension "I" is applicable to HCR Models only.

9

435
Refer to Figure 5 for dimensions U through Z

12.3 Base Mounting Holes and Collar Threads, HCG-Series and HCR-Series
Base Mounting Holes Collar Threads
Cylinder Angle
Minimum Number Thread
Model Bolt Circle Thread Size From Thread Length
Thread Depth of Holes Size
Number Coupler
U V Z W X
in mm mm in mm mm in mm
HCG/HCR-502 4.13 105 M12 x 1.75 0.87 22 2 90° M130 x 2 0.79 20
HCG/HCR-504 4.13 105 M12 x 1.75 0.87 22 2 90° M130 x 2 0.79 20
HCG/HCR-506 4.13 105 M12 x 1.75 0.87 22 2 90° M130 x 2 0.79 20
HCG/HCR-508 4.13 105 M12 x 1.75 0.87 22 2 90° M130 x 2 0.79 20
HCG/HCR-5010 4.13 105 M12 x 1.75 0.87 22 2 90° M130 x 2 0.79 20
HCG/HCR-5012 4.13 105 M12 x 1.75 0.87 22 2 90° M130 x 2 0.79 20
HCG/HCR-1002 5.91 150 M12 x 1.75 0.87 22 2 90° M175 x 3 1.57 40

HCG/HCR-1004 5.91 150 M12 x 1.75 0.87 22 2 90° M175 x 3 1.57 40
HCG/HCR-1006 5.91 150 M12 x 1.75 0.87 22 2 90° M175 x 3 1.57 40
HCG/HCR-1008 5.91 150 M12 x 1.75 0.87 22 2 90° M175 x 3 1.57 40
HCG/HCR-10010 5.91 150 M12 x 1.75 0.87 22 2 90° M175 x 3 1.57 40
HCG/HCR-10012 5.91 150 M12 x 1.75 0.87 22 2 90° M175 x 3 1.57 40
HCG/HCR-1502 7.28 185 M12 x 1.75 0.87 22 2 90° M215 x 3 1.85 47

HCG/HCR-1504 7.28 185 M12 x 1.75 0.87 22 2 90° M215 x 3 1.85 47
HCG/HCR-1506 7.28 185 M12 x 1.75 0.87 22 2 90° M215 x 3 1.85 47
HCG/HCR-1508 7.28 185 M12 x 1.75 0.87 22 2 90° M215 x 3 1.85 47
HCG/HCR-15010 7.28 185 M12 x 1.75 0.87 22 2 90° M215 x 3 1.85 47
HCG/HCR-15012 7.28 185 M12 x 1.75 0.87 22 2 90° M215 x 3 1.85 47
HCG/HCR-2002 8.46 215 M12 x 175 0.87 22 3 60° M250 x 3 2.17 55

HCG/HCR-2004 8.46 215 M12 x 175 0.87 22 3 60° M250 x 3 2.17 55
HCG/HCR-2006 8.46 215 M12 x 175 0.87 22 3 60° M250 x 3 2.17 55
HCG/HCR-2008 8.46 215 M12 x 175 0.87 22 3 60° M250 x 3 2.17 55
HCG/HCR-20010 8.46 215 M12 x 175 0.87 22 3 60° M247 x 3 2.17 55
HCG/HCR-20012 8.46 215 M12 x 175 0.87 22 3 60° M247 x 3 2.17 55
HCG/HCR-2502 9.65 245 M12 x 175 0.87 22 3 60° M280 x 3 2.44 62

HCG/HCR-2504 9.65 245 M12 x 175 0.87 22 3 60° M280 x 3 2.44 62
HCG/HCR-2506 9.65 245 M12 x 175 0.87 22 3 60° M280 x 3 2.44 62
HCG/HCR-2508 9.65 245 M12 x 175 0.87 22 3 60° M280 x 3 2.44 62
HCG/HCR-25010 9.65 245 M12 x 175 0.87 22 3 60° M280 x 3 2.44 62
HCG/HCR-25012 9.65 245 M12 x 175 0.87 22 3 60° M280 x 3 2.44 62
HCG/HCR-3002 10.24 260 M16 x 2 0.98 25 3 60° M305 x 3 2.36 60

HCG/HCR-3004 10.24 260 M16 x 2 0.98 25 3 60° M305 x 3 2.36 60
HCG/HCR-3006 10.24 260 M16 x 2 0.98 25 3 60° M305 x 3 2.36 60
HCG/HCR-3008 10.24 260 M16 x 2 0.98 25 3 60° M305 x 3 2.36 60
HCG/HCR-30010 10.24 260 M16 x 2 0.98 25 3 60° M305 x 3 2.36 60
HCG/HCR-30012 10.24 260 M16 x 2 0.98 25 3 60° M305 x 3 2.36 60
HCG/HCR-4002 11.81 300 M16 x 2 0.98 25 3 60° M350 x 3 2.95 75

HCG/HCR-4004 11.81 300 M16 x 2 0.98 25 3 60° M350 x 3 2.95 75
HCG/HCR-4006 11.81 300 M16 x 2 0.98 25 3 60° M350 x 3 2.95 75
HCG/HCR-4008 11.81 300 M16 x 2 0.98 25 3 60° M350 x 3 2.95 75
HCG/HCR-40010 11.81 300 M16 x 2 0.98 25 3 60° M350 x 3 2.95 75
HCG/HCR-40012 11.81 300 M16 x 2 0.98 25 3 60° M350 x 3 2.95 75
HCG/HCR-5002 13.39 340 M24 x 3 1.42 36 3 60° M400 x 3 3.15 80

HCG/HCR-5004 13.39 340 M24 x 3 1.42 36 3 60° M400 x 3 3.15 80
HCG/HCR-5006 13.39 340 M24 x 3 1.42 36 3 60° M400 x 3 3.15 80
HCG/HCR-5008 13.39 340 M24 x 3 1.42 36 3 60° M400 x 3 3.15 80
HCG/HCR-50010 13.39 340 M24 x 3 1.42 36 3 60° M400 x 3 3.15 80
HCG/HCR-50012 13.39 340 M24 x 3 1.42 36 3 60° M400 x 3 3.15 80
HCG/HCR-6002 14.57 370 M24 x 3 1.42 36 3 60° M430 x 3 3.54 90

HCG/HCR-6004 14.57 370 M24 x 3 1.42 36 3 60° M430 x 3 3.54 90
HCG/HCR-6006 14.57 370 M24 x 3 1.42 36 3 60° M430 x 3 3.54 90
HCG/HCR-6008 14.57 370 M24 x 3 1.42 36 3 60° M430 x 3 3.54 90
HCG/HCR-60010 14.57 370 M24 x 3 1.42 36 3 60° M430 x 3 3.54 90
HCG/HCR-60012 14.57 370 M24 x 3 1.42 36 3 60° M430 x 3 3.54 90
HCG/HCR-8002 17.32 440 M24 x 3 1.42 36 3 60° M505 x 3 4.33 110

HCG/HCR-8004 17.32 440 M24 x 3 1.42 36 3 60° M505 x 3 4.33 110
HCG/HCR-8006 17.32 440 M24 x 3 1.42 36 3 60° M505 x 3 4.33 110
HCG/HCR-8008 17.32 440 M24 x 3 1.42 36 3 60° M505 x 3 4.33 110
HCG/HCR-80010 17.32 440 M24 x 3 1.42 36 3 60° M505 x 3 4.33 110
HCG/HCR-80012 17.32 440 M24 x 3 1.42 36 3 60° M505 x 3 4.33 110
HCG/HCR-10002 19.69 500 M24 x 3 1.42 36 3 60° M570 x 3 4.92 125

HCG/HCR-10004 19.69 500 M24 x 3 1.42 36 3 60° M570 x 3 4.92 125
HCG/HCR-10006 19.69 500 M24 x 3 1.42 36 3 60° M570 x 3 4.92 125
HCG/HCR-10008 19.69 500 M24 x 3 1.42 36 3 60° M570 x 3 4.92 125
HCG/HCR-100010 19.69 500 M24 x 3 1.42 36 3 60° M570 x 3 4.92 125
HCG/HCR-100012 19.69 500 M24 x 3 1.42 36 3 60° M570 x 3 4.92 125
10

436
12.4 Specifications, HCG-Series and HCR-Series

Cylinder
Cylinder Model Stroke Maximum Capacity Effective Area Oil Capacity Weight *
Class
Number
in mm US Ton Tonnes kN in2 cm2 in3 cm3 lb Kg
HCG/HCR-502 1.97 50 50 62 56 550 12.17 78.5 23.96 393 37 17
HCG/HCR-504 3.94 100 50 62 56 550 12.17 78.5 47.93 785 46 21
HCG/HCR-506 5.91 150 50 62 56 550 12.17 78.5 71.89 1178 54 25
HCG/HCR-508 7.87 200 50 62 56 550 12.17 78.5 95.86 1571 68 31
HCG/HCR-5010 9.84 250 50 62 56 550 12.17 78.5 119.82 1963 76 34
HCG/HCR-5012 11.81 300 50 62 56 550 12.17 78.5 143.78 2356 84 38
HCG/HCR-1002 1.97 50 100 113 102 1002 22.19 143.1 43.67 716 74 34
HCG/HCR-1004 3.94 100 100 113 102 1002 22.19 143.1 87.35 1431 90 41
HCG/HCR-1006 5.91 150 100 113 102 1002 22.19 143.1 131.02 2147 105 48
HCG/HCR-1008 7.87 200 100 113 102 1002 22.19 143.1 174.70 2863 131 59
HCG/HCR-10010 9.84 250 100 113 102 1002 22.19 143.1 218.37 3578 146 66
HCG/HCR-10012 11.81 300 100 113 102 1002 22.19 143.1 262.05 4294 161 73
HCG/HCR-1502 1.97 50 150 168 153 1497 33.14 213.8 65.24 1069 124 56
HCG/HCR-1504 3.94 100 150 168 153 1497 33.14 213.8 130.48 2138 148 67
HCG/HCR-1506 5.91 150 150 168 153 1497 33.14 213.8 195.73 3207 172 78
HCG/HCR-1508 7.87 200 150 168 153 1497 33.14 213.8 260.97 4276 209 95
HCG/HCR-15010 9.84 250 150 168 153 1497 33.14 213.8 326.21 5346 233 106
HCG/HCR-15012 11.81 300 150 168 153 1497 33.14 213.8 391.45 6415 257 116
HCG/HCR-2002 1.97 50 200 223 202 1985 43.95 283.5 86.51 1418 179 81
HCG/HCR-2004 3.94 100 200 223 202 1985 43.95 283.5 173.02 2835 212 96
HCG/HCR-2006 5.91 150 200 223 202 1985 43.95 283.5 259.53 4253 244 111
HCG/HCR-2008 7.87 200 200 223 202 1985 43.95 283.5 346.04 5671 306 139
HCG/HCR-20010 9.84 250 200 223 202 1985 43.95 283.5 432.55 7088 338 153
HCG/HCR-20012 11.81 300 200 223 202 1985 43.95 283.5 519.06 8506 371 168
HCG/HCR-2502 1.97 50 250 286 259 2541 56.27 363.1 110.77 1815 236 107
HCG/HCR-2504 3.94 100 250 286 259 2541 56.27 363.1 221.55 3631 279 127
HCG/HCR-2506 5.91 150 250 286 259 2541 56.27 363.1 332.32 5446 322 146
HCG/HCR-2508 7.87 200 250 286 259 2541 56.27 363.1 443.09 7261 407 184
HCG/HCR-25010 9.84 250 250 286 259 2541 56.27 363.1 553.87 9076 457 207
HCG/HCR-25012 11.81 300 250 286 259 2541 56.27 363.1 664.64 10892 500 227
HCG/HCR-3002 1.97 50 300 341 310 3036 67.23 433.7 132.34 2169 350 159
HCG/HCR-3004 3.94 100 300 341 310 3036 67.23 433.7 264.68 4337 404 183
HCG/HCR-3006 5.91 150 300 341 310 3036 67.23 433.7 397.02 6506 458 208
HCG/HCR-3008 7.87 200 300 341 310 3036 67.23 433.7 529.36 8675 512 232
HCG/HCR-30010 9.84 250 300 341 310 3036 67.23 433.7 661.71 10843 566 257
HCG/HCR-30012 11.81 300 300 341 310 3036 67.23 433.7 794.05 13012 620 281
HCG/HCR-4002 1.97 50 400 450 409 4008 88,75 572.6 174.70 2863 501 227
HCG/HCR-4004 3.94 100 400 450 409 4008 88,75 572.6 349.39 5726 570 258
HCG/HCR-4006 5.91 150 400 450 409 4008 88,75 572.6 524.09 8588 638 289
HCG/HCR-4008 7.87 200 400 450 409 4008 88,75 572.6 698.79 11451 707 321
HCG/HCR-40010 9.84 250 400 450 409 4008 88,75 572.6 873.49 14314 775 352
HCG/HCR-40012 11.81 300 400 450 409 4008 88,75 572.6 1,048.18 17177 843 383
HCG/HCR-5002 1.97 50 500 575 522 5114 113.25 730.6 222.92 3653 706 320
HCG/HCR-5004 3.94 100 500 575 522 5114 113.25 730.6 445.85 7306 797 361
HCG/HCR-5006 5.91 150 500 575 522 5114 113.25 730.6 668.77 10959 887 402
HCG/HCR-5008 7.87 200 500 575 522 5114 113.25 730.6 891.70 14612 977 443
HCG/HCR-50010 9.84 250 500 575 522 5114 113.25 730.6 1114.62 18265 1067 484
HCG/HCR-50012 11.81 300 500 575 522 5114 113.25 730.6 1337.55 21918 1158 525
HCG/HCR-6002 1.97 50 600 673 611 5987 132.57 855.3 260.97 4276 836 379
HCG/HCR-6004 3.94 100 600 673 611 5987 132.57 855.3 521.94 8553 940 427
HCG/HCR-6006 5.91 150 600 673 611 5987 132.57 855.3 782.90 12829 1044 474
HCG/HCR-6008 7.87 200 600 673 611 5987 132.57 855.3 1043.87 17106 1148 521
HCG/HCR-60010 9.84 250 600 673 611 5987 132.57 855.3 1304.84 21382 1252 568
HCG/HCR-60012 11.81 300 600 673 611 5987 132.57 855.3 1565.81 25659 1356 615
HCG/HCR-8002 1.97 50 800 916 831 8149 180.44 1164.2 355.21 5821 1340 608
HCG/HCR-8004 3.94 100 800 916 831 8149 180.44 1164.2 710.41 11642 1485 674
HCG/HCR-8006 5.91 150 800 916 831 8149 180.44 1164.2 1065.62 17462 1631 740
HCG/HCR-8008 7.87 200 800 916 831 8149 180.44 1164.2 1420.82 23283 1777 806
HCG/HCR-80010 9.84 250 800 916 831 8149 180.44 1164.2 1776.03 29104 1922 872
HCG/HCR-80012 11.81 300 800 916 831 8149 180.44 1164.2 2131.24 34925 2068 938
HCG/HCR-10002 1.97 50 1000 1196 1085 10644 235.68 1520.5 463.94 7603 1858 843
HCG/HCR-10004 3.94 100 1000 1196 1085 10644 235.68 1520.5 927.88 15205 2031 921
HCG/HCR-10006 5.91 150 1000 1196 1085 10644 235.68 1520.5 1391.83 22808 2205 1000
HCG/HCR-10008 7.87 200 1000 1196 1085 10644 235.68 1520.5 1855.77 30411 2379 1079
HCG/HCR-100010 9.84 250 1000 1196 1085 10644 235.68 1520.5 2319.71 38013 2552 1158
HCG/HCR-100012 11.81 300 1000 1196 1085 10644 235.68 1520.5 2783.65 45616 2726 1236
* Weights for HCR-Series shown. Weights for HCG-Series are slightly less.
11

437
www.enerpac.com

438
A.8 1000636190: Spider Lubrication

System

439
A.8.1 Electric Pump User and Maintenance Instructions
User and maintenance instructions
FlowMaster II rotary driven

/ V AC, / Hz,
 phase electric pump
Models  ( lbs) and  ( lbs), series “A”
Date of issue March 
Form number 
Version 

440
Pump User and Maintenance Instructions (Sheet 2)
Contents
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Explanation of signal words
for safety . . . . . . . . . . . . . . . . . . . . . . . . . 
Description. . . . . . . . . . . . . . . . . . . . . . . 
Appropriate use . . . . . . . . . . . . . . . . . . . 
Pump specifications . . . . . . . . . . . . . . . . 
Electric pump
performance specifications. . . . . . . . . . . 
Inspection . . . . . . . . . . . . . . . . . . . . . . . . 
Damaged pumps . . . . . . . . . . . . . . . . 
Motor wiring diagram . . . . . . . . . . . . . . . 
Pump dimensions . . . . . . . . . . . . . . . . . . 
Installation . . . . . . . . . . . . . . . . . . . . . . . 
Operation . . . . . . . . . . . . . . . . . . . . . . . . 
Prime pump . . . . . . . . . . . . . . . . . . . . . . 
Crankcase oil service interval . . . . . . . . . 
Disassembly . . . . . . . . . . . . . . . . . . . . . . 
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Crankrod and eccentric . . . . . . . . . . . . . . 
Reciprocating tube . . . . . . . . . . . . . . . . . 
Crankrod . . . . . . . . . . . . . . . . . . . . . . . . . 
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 
Crankrod and eccentric . . . . . . . . . . . . . . 
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Parts list . . . . . . . . . . . . . . . . . . . . . . . . . 
Repair kits . . . . . . . . . . . . . . . . . . . . . . . . 
Tool and consumable list. . . . . . . . . . . . . 
Troubleshooting . . . . . . . . . . . . . . . . . . 
Warranty . . . . . . . . . . . . . . . . . . . . . . . . 
* Indicates change.

441
Safety Explanation of signal

words for safety
• Read and carefully observe these
installation instructions before installing,
operating or troubleshooting FlowMaster NOTE
II rotary driven AC electric pump. Assembly Emphasizes useful hints and
must be installed, maintained and recommendations as well as
repaired exclusively by persons familiar information to prevent property damage
with instructions. and ensure efficient trouble-free
• Install assembly only after safety operation.
instructions and this guide have been read
and are completely understood.
• All required parts, tools, and equipment
are defined and listed within this manual.
• Review parts list and nomenclature prior CAUTION
to disassembly or operation. Indicates a dangerous situation that can
• Adequate personal protection must be lead to light personal injury if
used to prevent splashing of material on precautionary measures are ignored.
skin or in eyes.
• Always disconnect power source
(electricity, air or hydraulic) from pump
when it is not being used.
• This equipment generates very high
grease pressure. Extreme caution should
be used when operating this equipment as WARNING
material leaks from loose or ruptured Indicates a dangerous situation that
components can inject fluid through skin may lead to death or serious personal
and into body. If any fluid appears to injury if precautionary measures are
penetrate skin, seek attention from a ignored.
doctor immediately.
• Do not treat injury as a simple cut. Tell
attending doctor exactly what type of fluid
was injected.
• Any other use not in accordance with
instructions will result in loss of claim for DANGER
warranty or liability. Indicates a dangerous situation that will
• Do not misuse, over-pressurize, modify lead to death or serious personal injury
parts, use incompatible chemicals, fluids, if precautionary measures are ignored.
or use worn and/or damaged parts.
• Do not exceed stated maximum working
pressure of pump or of lowest rated com-
ponent in system.
• Always read and follow fluid manufactur-
er’s recommendations regarding fluid
compatibility and use of protective cloth-
ing and equipment.
• Failure to comply may result in death or
serious injury.

442
Description Appropriate use Inspection

FlowMaster II rotary AC electric pump uses All pump models are exclusively designed to If over pressurizing of equipment is believed
an AC motor and two stage planetary pump and dispense lubricants using electric to have occurred, contact factory authorized
gear drive. power. Specifications are shown in Pump warranty and service center for inspection.
Grease output is proportional to pump specifications († Table , page ). Do not Specialized equipment and knowledge is
revolutions per minute. Pump is primarily exceed maximum specification ratings. required for repair of pump.
designed for centralized lubrication systems Annual inspection by factory authorized
such as single line parallel, single line pro- warranty and service center is
gressive and two line systems. NOTE recommended.
Pump is driven by rotary motion of elec- Pumps are not recommended for airless
tric motor. Rotary motion is converted to spray systems. They should be con-
reciprocating motion through an eccentric verted from : to : gear ratio.
crank mechanism. Reciprocating action Please contact technical services for Damaged pumps
causes pump cylinder to move up and down. component requirement.
Unit is positive displacement double-acting Do not use any pump that appears to be
pump, as grease output occurs during both damaged, badly worn or operates abnor-
up and down strokes. mally. Remove pump from service and con-
During down stroke, pump cylinder is tact factory authorized warranty and service
extended into grease. Through combination center for repairs. A listing of authorized
of shovel action and vacuum generated in warranty and service centers is available
pump cylinder chamber, grease is forced into upon request.
pump cylinder. Simultaneously, grease is
discharged through outlet of pump. Volume
of grease during intake is twice amount of
grease output during one cycle.
During upstroke, inlet check closes, and
one half of grease taken in during previous
stroke is transferred through outlet check
and discharged to outlet port. Typical output
of pump is shown in Pump performance
(† Table , page ).
Refer to Motor wiring diagram († Fig. ,
page ) for pump motor.
Table  Table 
Pump performance Pump specifications
Operating temperature – to  °F (– to  °C)

Temperature @  rpm ) @  rpm ) Operating voltage / V AC, / Hz,  phase
Motor speed   rpm @  Hz,   rpm @  Hz
 °F ( °C) . in/min ( cm/min) . in/min ( cm/min) Pump speed  rpm @  Hz,  rpm @  Hz
 °F ( °C) . in/min ( cm/min) . in/min ( cm/min) Motor power / HP (, kW)
 °F (– °C) . in/min ( cm/min) . in/min ( cm/min) Output/pump cycle . in (, cm)
Pump outlets / NPTF internal

Maximum outlet pressure   psi ( bar)
Current drawing † Table  and Table , (page )
) Test conducted with Alvania NLGI  at   psi ( bar) back pressure.

443
NOTE NOTE
Use of motor starter and/or relay may Properly sized over current circuit
be required when connecting motor to protection fuses or circuit breakers are
system controller or as required by required and must meet local codes and
application. Refer to system control electrical safety requirements.
manual for further information.
Fig. 
NOTE
Motor wiring diagram Connections on Motor wiring diagram
Single phase († Fig. , page ) are for counter-
clockwise rotation facing end opposite
shaft. To reverse rotation, interchange
Low voltage High voltage leads  and .
1,3,8 4 2,J,5 1 4 2,3,8

W2 U2 V2 W2 U2 V2
J,5
U1 V1 W1 U1 V1 W1
Line Line

444
Fig. 
Pump dimensions
8.78 in 16.07 in
(223 mm) (408 mm)
3.78 in 13.91 in
(96 mm) (353 mm)
2.72 in
2.27 in (58 mm) (69 mm)
∅ 1.25 in
(∅ 32 mm)
4.25 in
(108 mm)
2.75 in (70 mm)
6.75 in (171 mm)
Dimensions 2.25 in (57 mm)
Model Dimension “A” Dimension “B” (4×) ∅ 0.28 in (∅ 7 mm)

2.25 in
(57 mm) (4×) 1/4-20
 . in ( mm) . in ( mm)
 . in ( mm) . in (  mm) 3.90 in
(99 mm)

445
Fig. 
NOTE
Pump was tested in lightweight oil left in Typical installation
to protect pump from corrosion. Flush
55
pump before connecting it to system to 84 78
prevent contamination of grease with 37
79
residual oil. 77
80
82
83
81
NOTE
Typical installation († Fig. ) is only for
selecting and installing system
components. Contact Lincoln
representative for assistance in
designing a system to suit
specific needs. Item Description
 Motor
 Outlet
Installation 

Safety unloader
 V AC or  V AC
 Outlet shut-off
 Material supply line
 Connect material supply line () to
pump outlet () († Fig. ).  Follower plate ( for  lbs ( kg) drum only)
 Install safety unloader () in open  Drum cover   lbs ( kg)
Drum cover   lbs ( kg)
outlet port.
 Install high pressure shut-off valve ()  Auxiliary motor mount
in material supply line ().  Field installed fuse
DANGER
Do not connect electrical wiring prior to
lock out/tag out procedure.
Failure to comply will result in death
or serious personal injury.

446
Table  Table 
WARNING
Do not exceed maximum stated Electric FlowMaster II pump Electric FlowMaster II pump
pressure. Install high pressure shut-off
 V AC , / Hz : gear ratio,  stage  V AC , / Hz : gear ratio,  stage
valve () to ensure pressure remains Back pressure Current Back pressure Current
below   psi ( bar).
psi (bar) rpm A ) psi (bar) rpm A )
Failure to comply may result in death
or serious injury.
 ()  ./.  ()  ./.
  ()  ./.   ()  ./.
  ()  ./.   ()  ./.
 Connect V AC power supply to solenoid   ()  ./.   ()  ./.
valve. Refer to Table  and Table  to   ()  ./.   ()  ./.
  ()  ./.   ()  ./.
fuse motor.
 Connect power to motor leads.
 Mount motor () onto drum cover ()
using auxiliary mount ().
) Fuse for  A ) Fuse for  A
NOTE
If it is necessary to drill mounting holes
into reservoir cover, refer to Fig. ,
page  for hole pattern and dimensions.

447
Operation Crankcase oil service

interval
• Check oil level after every  hours of
WARNING machine operation, or monthly.
Do not exceed maximum stated pres- • Change oil after every   hours of
sure. Install relief valve to ensure pres- machine operation or every year.
sure remains below   psi ( bar). • Use SAE W motor oil in all units
Use only high pressure components. used in an ambient temperature of
Failure to comply may result in death – to  °F (– to  °C). For ambient
or serious personal injury. temperatures of – to  °F
(– to  °C), use Mobil Aero HFA low
temperature oil.
• Oil level should be at indicating dot on dip-
Prime pump stick (middle of crankshaft).
• Use W motor oil  oz. (, l).
 Remove pump outlet line from
outlet port () († Fig. , page ).
 With pump in a full container of lubri-
cant, energize pump. DANGER
 Purge air from pump. Do not exceed maximum rated outlet
 Verify lubricant is flowing evenly pressure. Pumps are not equipped with
from pump. high pressure shut off valve.
 Stop pump. Failure to comply will result in death
 Attach pump outlet line to or serious personal injury.
outlet port ().
NOTE
Never allow pump to run dry of lubri-
cant. Dry pump quickly speeds up, cre-
ating friction heat that can damage
seals. Monitor supply lubricant level and
refill when necessary.
Failure to comply may result in dam-
age to equipment.

448
Disassembly  Remove shaft adapter ().

 Using a pick, remove gear
 Using rubber mallet and piece of brass or
other suitable piece of soft metal, tap on
box o-ring (). crank rod () inside housing ().
Pump  Loosen screws () holding  Pull eccentric () and crank rod () out of
shaft cover () on pump top of pump housing ().
 Place pump into vise. housing () († Fig. ).
 Remove dipstick () († Fig. ).  Remove retaining ring () from
 Drain crankcase oil from crankcase. pump shaft ().
 Remove housing cover screws ().  Remove pump shaft () by pushing
 Remove housing cover () pump shaft on retaining ring () side.
and gasket ().  Remove retaining ring () from NOTE
 Remove electric motor () mounting housing tube () († Fig. ). Slight force may be necessary to
screws () with lock washers ().  Remove shovel plug () from remove eccentric () and crank rod ()
 Remove electric motor (). housing tube (). from housing ().
 Using pick, remove motor o-ring.  Remove spiral retaining ring ().
 Using hex head wrench, remove gear box  Loosen and remove housing tube ().
mounting screws (), washers () and  Remove bronze bearing () from
gear box () († Fig.  and Fig. ). housing tube ().
 Loosen and remove screws () holding  Using flat, blunt tool, remove o-ring ()
first stage gear set (), spacer () and from housing tube ().
final stage gear set () in place.  Remove back up washer () from
 Remove first stage gear set (), housing tube ().
spacer () and final stage gear set ()  Using flat, blunt tool, remove o-ring ()
from gear box. from housing tube ().
Fig.  Fig.  Fig. 
31 33 56
34 55 54
7 44
35 37 57
36 64 53
45 58
37
46 59
48
52 60
40
74,75 61
62
Fig. 
63
73
72 38
66 67 68
70
69
71 37
65


449
Crankrod and  Remove steel backup ring ().  Turn tool counter-clockwise to remove
 Place plunger link rod () in a vise. lower bushing and plunger () from
eccentric  Using open-ended wrench, loosen plunger link rod ().
plunger link rod () and remove from  Remove plunger ().
 Remove pivot screws () from outlet pin ().  Remove check rod from () lower bush-
crankrod () († Fig. ).  Remove plunger link rod (). ing and plunger ().
 Using /- bolt, press out  Remove retainer clip () from  Remove ball () from lower bushing
wrist pin bushing (). plunger link rod (). and plunger ().
 Remove crank rod ().  Using blunt tool, remove o-ring ()  Remove spring () from link rod ().
from plunger link rod ().
NOTE  Remove back up washer () from
Wrist pin bushings () often stick in plunger link rod ().
wrist pin anchor (). It may be  Remove o-ring () from Reciprocating tube
necessary to use /– bolt from plunger tube ().
kit  to remove wrist pin  With crank rod in a vise and using special  Loosen check seat housing () with
tool (T) († Fig. ) provided in tool kit, / in hex head wrench.
bushings ().
remove plunger link rod () († Fig. ).  Remove check seat housing () from
 Place end of plunger link rod () into reciprocating tube ().
hole of special tool (T).  Remove ball cage (), check ball ()
 Align outlet hole of plunger link rod () and o-ring seals () from
 Remove wrist pin anchor () from with hole in special tool (T). check seat housing ().
reciprocating tube () († Fig. ).  Insert pin included in tool kit   Remove lower bushing () from recip-
 Pull cup seal () out of through tool and into plunger link rocating tube ().
wrist pin anchor (). rod () outlet hole.  Remove lower cup seal () from recip-
rocating tube ().
Fig.  Fig. 
8 22
12
9 23
13
11
14
60 15
10 16 24
25
17
18
Fig.  19
T1
20
26
28
21 27
29
30


450
Crankrod Fig. 
1
 Using hex head wrench, loosen and 2
3
remove flat head screws () from 4
eccentric () († Fig. , page ). 7
 Remove counterbalance weights (). 6
 Remove outer () and inner () retaining 5
4
ring from both sides of crank rod (). 3
 Place crank rod () on supplied  / in 2
1
(, mm) diameter steel pipe.
 Drive crank eccentric () out of
ball bearing ().
 Drive ball bearing () out of crank rod ().


451
Assembly Pump  Apply Loctite® ® to threads of upper

bushing and plunger end ().
 Install ball () into lower bushing and  Thread upper bushing and
Crankrod and plunger () († Fig. ). plunger end () into outlet pin ().
 Insert check rod () into  Torque to – in-lbf
eccentric pump plunger (). (,–, Nm).
 Place spring () onto the check rod ().  Install back-up washer () in
 Place crank rod () on  / in (, mm)  Thread plunger link rod () into wrist pin anchor ().
diameter steel pipe from kit. pump plunger ().  Place new cup seal () inside
 Install ball bearing assembly () into  Insert lower bushing pump plunger () wrist pin anchor ().
crank rod () († Fig. , page ). into tool (T) († Fig. , page ).  Clean threads of wrist pin anchor ().
 Place eccentric () in ball bearing ().  Align hole in lower bushing pump  Install o-ring () on
 Place one end of inner retaining ring () plunger () with hole in wrist pin anchor ().
on top of eccentric (). supplied tool (T).  Insert upper bushing and plunger
 Squeeze other end of retaining ring ()  Insert pin into hole of tool (T) and into end () into wrist pin anchor ()
toward center and slide retaining ring () lower bushing pump plunger (). and tighten.
into place.  Torque lower bushing pump plunger ()  Place wrist pin anchor () in a vise.
 Place one end of outer retaining ring () to torque of – in-lbf  Tighten wrist pin anchor () to torque of
on top of inner retaining ring (). (,–, Nm). – ft.lbf. (– Nm).
 Squeeze other end of retaining ring ()  Install steel back up ring () onto  With wrist pin anchor () still in vise,
toward center and slide retaining ring () threads of upper bushing and align crankrod/eccentric assembly ()
into place. plunger end (). holes with wrist pin anchor () holes.
 Align holes of counter-balance  Slide o-ring () onto upper bushing and  Install wrist pin bushings () through
weights () with threaded holes of plunger end (). crank rod () and into
eccentric () and place on eccentric ().  Install retaining clip () on upper bush- wrist pin anchor ().
 Insert flat head screws () into coun- ing and plunger end ().  Apply Loctite® ® to threads of
ter-balance weight () and torque flat  Install o-ring () on upper bushing and wrist pin bushing screws ()
head screws () to torque of plunger end (). († Fig. , page ).
– in-lbf (,–, Nm).  Place outlet pin () into a vise.
Fig. 
8 22
9 23
13
14
15
10 16 24
25
17
18
19
20
26
28
21 27
29
30


452
NOTE  Slide lower bushing and plunger ()  Insert bronze bearing () into
For ease of installation of lower cup, use into reciprocating tube () with housing tube ().
small piece of tubing to slide lower cup o-ring () near bottom of  Position crankrod assembly () over top
into reciprocating tube () and over reciprocating tube (). of pump housing () and lower into
pump plunger.  Install steel check cage () into pump housing () († Fig. ).
reciprocating tube ().  Align crank rod () with shaft ()
 Install ball () into steel check cage (). mounting hole.
 Apply Loctite® ® or equivalent to
threads of check seat housing ().
 Thread check seat housing () into
 Insert and thread wrist pin bushing reciprocating tube () and tighten using NOTE
screws () into crankrod (). / in hex key.
Failure to align key () on shaft and key
 Torque bushing screws () to torque of  Torque to – ft-lbf (– Nm). way in eccentric () will result in damage
– in-lbf (,–, Nm).  Remove crank rod () from vise. to equipment.
 Install cup seal () with slotted side  Insert o-ring () into
toward center of reciprocating housing tube () († Fig. ).
tube () († Fig. ).  Place back up washer () into
 Place new o-ring () on lower bushing housing tube ().
and plunger ().  Insert o-ring () into housing tube ().
Fig.  Fig.  Fig. 
7
56
57
58
59
5
12
60
11
Fig.  Fig. 
7
25 44
37
45
46
24
39
26
47
28 48
27
29
30 40


453
 While aligning key () on shaft () with  Place gear box () on  Install pump cover ().
eccentric key way (), slide shaft () into pump housing ().  Install screws () with o-rings () into
eccentric () († Fig. , page ).  Install four gear box mounting pump cover ().
 Install retaining ring () on shaft. (). screws () and washers () in gear  Torque screws () to torque of
 Install shaft cover () on pump (). box () and into pump housing (). – in-lbf (,–, Nm).
 Insert and thread screws () with lock  Torque gear box mounting screws () to  Install o-ring () in outlet pin mounting
washers () into shaft cover () and a torque of – in-lbf (,–, Nm)*. hole groove of pump housing ().
pump housing ().  Install electric motor o-ring () in  Install back up washer () inside outlet
 Install shaft adapter () inside groove of gear box (). pin nut ().
pump housing ().  Place electric motor () on  Install o-ring () inside outlet
 Install gear box o-ring () in pump pump housing (). pin nut ().
housing () groove († Fig. ).  Insert electric motor mounting  Line up outlet pin and thread outlet pin
 Position final stage gear set () in screws () with lock washers () into nuts () into pump housing ().
gear box (). gear box () and electric motor ().  Torque to – ft-lbf (,–, Nm).
 Place spacer () on top of final stage  Torque mounting screws () to torque  Fill crankcase with oil up to indicator dot
gear set (). of – in-lbf (,–, Nm) on dipstick.
 Insert first stage gear set () into († Fig. ).  Install crank case oil dip stick and torque
gear box ().  Insert retaining ring () into second to – in-lbf (,–, Nm).
 Install screws () through gear sets ( groove of housing tube ().
and ) and spacer () into  Install shovel plug () into
gear box (). housing tube (). NOTE
 Torque screws () to - in-lbf  Install spiral retaining ring (). Refer to Crankcase oil service (page )
(,–, Nm)*.  Install new cover gasket () on for oil recommendations.
pump housing ().
Fig. 
73
72 38
66 67 68
70
69
71 37
65
Fig.  Fig. 
31 33 34
35
37
36
37 64 54
52
53
55
60 74,75 60
61
62
63
* Indicates change.


454
Fig. IPB 
1
2
3
4
7
6
5
4
3
2
1 8
9
11
12
13
15
10 14
16
17
18
19
20
21
22
23
24
25
26
28
27
29
30


455
Fig. IPB 
31 32
33
34
35
36 44
45
37 46
47
38 48
39 49
40 50
41
42 51
43
52 53
54
55
56
57
58
59
60
61
62
63


456
Fig. IPB 
75
74
73
72
71
70
69
68
67
66
65
64


457
Parts list
Item Description Part Quantity Item Description Part Quantity
 Flat head screw (/- x  /)    Woodruff key  

 Counter weight    Pump shaft  
 Retaining ring    Retaining ring  
 Retaining ring    Ball bearing  

 Crank eccentric    Shaft seal  ) 
 Ball bearing    Screws  
 Crank rod    Lock washer  

 Outlet pin    Bearing cover  
 O-ring (nitrile)  ) )   O-ring  ) 
 Upper bushing and plunger  )   Retaining ring  

 Pivot screw    Ball bearing  
 Wrist pin bushing    Retaining ring  
 Wrist pin anchor    Drain plug  

 O-ring  )   Backup washer  ) 
 Backup washer  ) )   O-ring  ) 
 Cup seal (polyurethane)  ) )   O-ring  ) 

 Steel back-up ring  ) )   Outlet pin nut  
 O-ring  ) )   Bronze bearing  
 Retainer clip  ) )   O-ring (polyurethane)  ) 

 Plunger link rod See chart   Backup washer  ) 
 Spring  )   O-ring (nitrile)  ) 
 Check rod    Housing tube See chart 

 Ball (/ in)  )   Retaining ring  
 Lower bushing and plunger  )   Shovel plug  
 Reciprocating tube See chart   Retaining ring  

 Cup Seal (polyurethane)  )   Motor  
 O-ring (nitrile)  )   Screw  
 Ball cage    First stage gear set  

 Ball (/ in)  )   Spacer  
 Check seat    Final stage gear set  
 Dipstick with o-ring    Screw  

 O-ring  )   Lock washer  
 Self-threading screw (# x /)    O-ring  ) 
 Gasket (screw)  )   Gear box housing  

 Housing cover    Shaft, adapter  
 Cover gasket (nitrile)  )   Lock washer (/)  
 Pump housing    Screw (/- x )  

 O-ring  )   Safety unloader  
Non–common repair parts

Part
Model  Model 
 Plunger link rod  

 Reciprocating tube  
 Housing tube  
) Included in  repair kit.

) Included in  repair kit.


458
Repair kits Tool and consumable list
Kit number  / in open end wrench

 / in open end wrench
Item Description Part Quantity / in open end wrench
 in adjustable wrench
 O-ring (nitrile)   / in hex head wrench
 Upper bushing and plunger   / in hex head wrench
 Backup washer  
/ in hex head wrench
 Cup seal (polyurethane)   / in hex head wrench
 Steel back-up ring   / in hex head wrench
 O-ring  
/ in drive socket
 Retainer clip   / in socket
 Ball (/ in)   / in socket
 Lower bushing and plunger  
Flat screwdriver . in (, mm) wide . in (, mm) thick
Pick to remove seals and spiral retaining rings
Kit number  Small snap ring pliers
Item Description Part Quantity
Special tool kit

 O-ring (nitrile)  
 O-ring   Tool kit 
 Backup washer  
 Cup seal (polyurethane)   Phillips screwdriver

 Steel back-up ring   / in hex head wrench
 O-ring   Hammer
 Retainer clip   Torque wrench (ft-lbf and in-lbf)
 Spring   Hex head socket adapters (required to torque hex head screws)
 Ball (/ in)   Loctite® ® medium strength thread lock or equivalent
 Cup Seal (polyurethane)  
 O-ring (nitrile)  
 Ball (/ in)  
 O-ring  
 Gasket (screw)  
 Cover gasket (nitrile)  
 O-ring  
 Shaft seal  
 O-ring  
 Backup washer  

 O-ring  
 O-ring  
 O-ring (polyurethane)  

 Backup washer  
 O-ring (nitrile)  
 O-ring  


459
Troubleshooting
Condition Possible cause Corrective action
Pump does not run. Pump is seized or damaged. Disassemble pump and repair any parts that
are damaged or worn.
Incorrectly wired. Check wiring diagram.
Pump speeds up or runs erratically. Low level of grease or reservoir is empty. Fill reservoir.
Follower plate is stuck and separated from grease. Check follower plate and container for damage.
Pump piston or checks are worn. Disassemble pump and repair.
Pump runs, but output is low. Faulty inlet check (, ), faulty discharge check (, ) Replace faulty components.
or damaged o-ring ().
Seepage from housing cover (). Cup seal () or o-ring () worn out. Check seals and replace if necessary.
Pump is noisy. Crankcase needs oil. Fill with oil.
Pump does not build pressure. Worn wrist pin bushing (). Check bushings and replace if necessary
Foreign material holding lower check open. Dismantle and clear check.
Consider adding grease filter to system.
Motor runs, but no pump output. Gear set or adapter shaft stripped or broken. Dismantle and replace damaged part.


460
This page left intentionally blank.


461
This page left intentionally blank.


462
Warranty
The instructions do not contain any information on the warranty.
This can be found in the General Conditions of Sales, available at:
www.lincolnindustrial.com/technicalservice or www.skf.com/
lubrication.
skf.com | lincolnindustrial.com
® SKF and Lincoln are registered trademarks of the SKF Group.
® Loctite and  are registered trademarks of Henkel Corporation.
© SKF Group 

The contents of this publication are the copyright of the publisher and may not be reproduced (even
extracts) unless prior written permission is granted. Every care has been taken to ensure the accuracy
of the information contained in this publication but no liability can be accepted for any loss or damage
whether direct, indirect or consequential arising out of the use of the information contained herein.
March  · Form  Version 

463
A.8.2 Drum Cover User and Maintenance Instructions
User and maintenance instructions
Drum cover assemblies for

AC electric FlowMaster pumps
Models  for use with * FlowMaster electric pump on  lb. ( kg) drum and
 for use with * FlowMaster electric pump on  lb. ( kg) drum
Date of issue February 
Form number 
Version 
* Indicates change.

464
Cover User and Maintenance Instructions (Sheet 2)
Fig. IPB 
Model  ( lb. ( kg) drum cover)
6 9
5
4
3 10
2 11
12
14
13
Parts list
Item Description Quantity   Item Description Quantity  
 Cover gasket     Angle bracket   

 Drum cover     Lockwasher (/)   
 Gasket     Hex nut (/-)   
 Hex nut (/-)     Hex head screw (/- x /)   
 Lockwasher (/) in     Lockwasher (/ in)   
 Washer     Hex lock nut (/-)  -- 
 Hex head screw (/- x /)     Gasket  -- 

 Washer     Cover plate  -- 
 Hex head screw (/- x )     Hex head screw (/- x /)  -- 

465
Fig. IPB 
Model  ( lb. ( kg) drum cover)
6 10
18 5
4
3
8
11
17
12
16
2
15
14
13

466
Warranty
The instructions do not contain any information on the warranty.
This can be found in the General Conditions of Sales, available at:
www.lincolnindustrial.com/technicalservice or
www.skf.com/lubrication.
skf.com | lincolnindustrial.com
® SKF and Lincoln are registered trademarks of the SKF Group.
© SKF Group 

The contents of this publication are the copyright of the publisher and may not be reproduced (even
extracts) unless prior written permission is granted. Every care has been taken to ensure the accuracy
of the information contained in this publication but no liability can be accepted for any loss or damage
whether direct, indirect or consequential arising out of the use of the information contained herein.
February  · Form  Version 

467
A.8.3 Follower Assembly Model and Service Parts Data
FOLLOWER ASSEMBLY
MODEL 270982
ø 1.020
SERVICE PARTS
Part Qty. Description
50169 6 Slotted Hex Hd. Machine Screw
51304 6 Hex Lock Nut
66186 6 Washer, Lock 1/4 LT 2N
270720 1 O-Ring
270977 1 Wiper Plate
One Lincoln Way © Copyright 2009

Printed in USA
Section - K5
St. Louis, MO 63120-1578
Phone +1.314.679.4200
Fax +1.800.424.5359 Web site: Page - 29
www.lincolnindustrial.com
JAN - 2009 Form 403804

468
A.8.4 Safety Valve Drawing
Stat
State:
e: Relea
Released,
sed, 01:02PM
01:02PM 10, Nov 2020, P
Pat
attiti Kimzey
Kimzey

469
A.8.5 Divider Valve Specifications

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Divider Valve Specifications (Sheet 3)

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472
A.8.6 Socket Pipe Plug Drawing
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473
A.8.7 Proximity Switch Settings and Model Data

474
A.9 1000614463: Relief Valve and

Accumulator

475
A.9.1 Vendor Documentation Manual
FLSmidth
3235 Schoenersville Road • Bethlehem, PA 18017-2103 • USA
Tel +1 610 264 6900 • Fax +1 610 264 6802
www.flsmidth.com
HYDRAULIC RELIEF VALVE &

ACCUMULATOR ASSEMBLY
10316021
VENDOR DOCUMENTATION MANUAL
60117022,
60117057,Ver. 1.0
Ver. 1.0

476
Vendor Documentation Manual (Sheet 2)
Index
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2 FLS Document No. 60083907,

)/6'RFXPHQW1R9HU Ver. 1.0

477
Prior To Commencement of Installation,

Operation and / or Maintenance, this
manual should be reviewed in its
entirety.
All Maintenance / Hydraulic Work must
be performed by Qualified Hydraulic
Technicians and all plant safety
procedures and rules must be followed.


478
1.0 Description
The FFE Hydraulic Pressure relief valve & Accumulator Manifold Assembly consists of 2
pressure relieving elements mounted on a custom manifold :
i) Pilot operated Cartridge type logic element operating in a pressure relieving mode.
ii) Accumulator – Bladder Type, 5 Gallon Capacity
Refer to attached FLS drawing 10 for a general arrangement, Schematic and parts list.
A 1,000 psi ( 68 Bar ) Pressure gauge and isolation valve are included in the assembly and
connected to tapping Port PT1
If necessary, a pressure transmitter can be mounted to a second tapping port PT for remote
monitoring of hydraulic system pressure


479
2.0 Specifications
2.1 Dimensions
Approximate overall dimensions 19”W x 13”D x 52”H (483mm x 330mm x 1321mm)
Dry Weight 515 Lb ( 234 Kg )
2.2 Connections
1. Pressure Inlet from Pump Skid 3/4” SAE Code 61 4-Bolt 3000 lb Flange
2. Pressure Outlet to Crusher 3” SAE Code 61 4-Bolt 3000 lb Flange
3. Relief Discharge to Tank 3” SAE Code 61 4-Bolt 3000 lb Flange
2.3 Materials of Construction

Logic Manifold ( Item 20 ) Ductile Iron
Logic Cover ( Item 30 ) Ductile Iron
Logic Element ( Item 40 ) Carbon Steel
Spacer Block ( Item 45 ) Ductile Iron
Seals Buna N
Accumulator Housing (Item 70) Carbon Steel
Bladder ( Item 70 ) Nitrile Rubber
Needle Valve (Item 60) Carbon Steel
2 Valve Manifold (Item 55) 216 Stainless Steel
Relief Sandwich (Item 32) Steel/Aluminum
Blanking Plate (Item 36) Aluminum
2.4 Performance
Fluid Temp rating -40 OF to +200 OF ( -40 OC to +93 OC )
Fluid Viscosity Range 35 to 1760 SUS ( 2.8 to 380 mm2/s )
Assembly Pressure Rating 1 3,000 psi ( 207 Bar )
Pressure Relief Set Point Range 1 100 to 1450 psi ( 7 to 100 Bar )
Factory Pressure Relief Set Point 400 psi ( 27.6 Bar )
Adjustment Sensitivity ¼ turn = 100 psi (¼ turn = 6.9 Bar )
Accumulator Charging Medium Nitrogen
Accumulator Charging Pressure 300 psi ( 20.7 Bar )
1
- Valve must not be set above 1,000 psi ( 69 Bar) relief pressure set point. Use at higher
pressures will result in damage to crusher components.


480
3.0 Operation
The Relief Valve is a pilot operated, balanced piston type relief valve. See figure below for a
view of the valve internals.
At Rest, the spool separates Port A ( Pressure Port connected to the 3” Line to the crusher and
the ¾” supply line from the Hydraulic pump ) from Port B (Tank Port - Connected to the 3”
return line to the Hydraulic oil reservoir)
The Cartridge valve is a pilot operated poppet valve without an area differential.
Pressure setting is via the pilot valve (3). The pilot valve itself is a direct operating pressure
relief valve
Pressure present at Port A is fed via the pilot supply orifice (7) to the spring side (6) of the
spool (5). When pressure in the system at Port A is less than the value set in the pilot valve (3),
the same pressure is acting on opposite ends of the spool. Since the spool end areas are the
same, the pressure forces are equal and the spring (10) therefore holds the spool in the closed
position and ports A and B are separated from one another.
When the system pressure at Port A reaches the level set at the pilot valve, the pilot valve opens
and fluid begins to flow from A to Tank via port Y. As a result of this flow, a pressure drop
occurs across orifice (7) which causes a difference in pressure between the ends of the main
spool (5). When the upward force produced by a product of the pressure drop and the spool
area becomes greater than the spring force (10), the spool moves upwards and excess fluid flow
can flow from A to B and thus to Tank


481
4.0 Installation
4.1 Location & Orientation

The Assembly must be located within 15 Feet ( 4.5m ) of crusher mounting flange.
Additionally the Assembly must be installed with the accumulator Vertically orientated as
illustrated in drawing 10.
4.2 Field Connections

1. Pressure Inlet from Hydraulic Pump Skid - 3/4” SAE Code 61 4-Bolt 3000 lb Flange
2. Pressure Outlet to Crusher - 3” SAE Code 61 4-Bolt 3000 lb Flange
3. Relief Discharge to Tank - 3” SAE Code 61 4-Bolt 3000 lb Flange
The manifold assembly is provided with a mating Code 61 socket weld flanges and hardware
sets for each of the 3 connections that must be welded to the connecting pipe. Note the O-ring
must be removed from the Socket weld flange whilst the flange is welded to the pipe.
Refer to Crusher lube and hydraulic Schematic drawing located in Crusher IOM manual
Section 7 for additional piping requirements.
4.3 Installation
The assembly is supplied cleaned and flushed ready for installation into hydraulic piping
system. Ensure that the hydraulic system has been cleaned and flushed prior to the relief
manifold installation.
Any contamination could cause an orifice to become blocked, or pilot valve to get stuck open
thereby affecting valve performance.
Additionally, so as to reduce the risk of contamination during storage, do not remove the
Connection covers until immediately prior to installation.
Refer to attached Rexroth Documents RE 07300 and RE 0790 for additional instructions


482
5.0 Commisioning and Adjustment
5.1 Relief Valve : The Relief Valve is supplied factory set to relieve at 400 psi (27.6 psi ) and
no adjustment is necessary. However if adjustment of the pressure relief set point is found to be
necessary, it can be varied by adjustment of the pilot valve in the cover ( Under the black cap).
Remove Black Cap and

adjust Relief Set point here
Clockwise = Raise set point / Anti-Clockwise = Lower Set Point.

Adjustment Sensitivity : ¼ turn = 100 psi ( 6.9 Bar )
WARNING : Valve must not be set above 1,000 psi ( 69 Bar) relief pressure set point. Use
at higher pressures will result in damage to crusher components.
5.2 Accumulator : Charge with Nitrogen to 300 PSI ( 20.7 Bar ) using the charging kit
provided with the manifold assembly and according to the vendor instructions provided later in
this document.
The accumulator will periodically have its pressure checked and re-charged as detailed in the
vendor instructions provided later in this document.


483
)/6'RFXPHQW1R9HU

484


485


486


487
Bill of Material
Material: R978050607 Description: 43AS-15166-PL FLS ACCUM STD W/PRES

TRANS
Sales Order: 896608 Item: 10 Reqd Qty: 1 PC
Customer: FL SMIDTH INC PO: 015472
BETHLEHEM
Item No. Tech.Pos. Component No. Quantity Unit
Description
Drawing No.
0001 1.00 PC
TOROMOCHO CRUSHER
--------------------------------------------------------------------------------
0180 - 1.00 PC
HS43-A37-3532-A Hydraulic Schematic
--------------------------------------------------------------------------------
0190 - 1.00 PC
43AS-15166-0-C Accumulator Stand
--------------------------------------------------------------------------------
0200 90 R978049433 1.00 PC
43AS-15145-1-C ACCUM STAND DETAIL
--------------------------------------------------------------------------------
0210 R978049524 1.00 PC
MAN ASSY AGA16636
--------------------------------------------------------------------------------
0020 - 1.00 PC
AGA-16636-0-C MANIFOLD ASSEMBLY
--------------------------------------------------------------------------------
0030 20 R978015052 1.00 PC
AGA 14591-1 MANIFOLD BLOCK
--------------------------------------------------------------------------------
0040 30 R900970641 1.00 PC
LFA 50 DBS2-7X/100
RD21050
LOGIC CARTRIDGE COVER
*
--------------------------------------------------------------------------------
0050 R900003290 4.00 PC
SOCKET HEAD SCREW ISO4762-M20X120-10.9
MOUNTING BOLTS
(FOR TECH POS #: 30 & 45)
*
--------------------------------------------------------------------------------
0052 32 R978045336 1.00 PC
RV10-20F-S03S-N-23/M69 RELIEF SANDWICH
LOGIC CARTRIDGE VALVE
*
--------------------------------------------------------------------------------
0054 R978800651 4.00 PC
O-RG SZ 2-012 FPM 90SH
Page No. 1 of 4 Date Printed 01/18/2011


488
Bill of Material
Sales Order: 896608 Item: 000010
Description
Drawing No.
--------------------------------------------------------------------------------
0056 34 R978839480 1.00 PC
CP6NN-1X/A-01
--------------------------------------------------------------------------------
0010 R978813594 1.00 PC
AGA 8980 COVER SZ 6 (127443)
--------------------------------------------------------------------------------
0020 2910150162 4.00 PC
SOCKET HEAD SCREW ISO4762-M5X20-10.9
--------------------------------------------------------------------------------
0030 R978800651 4.00 PC
O-RG SZ 2-012 FPM 90SH
--------------------------------------------------------------------------------
0058 R978701392 4.00 PC
SHCS M5X60MM D912-12.9
--------------------------------------------------------------------------------
0060 40 R900946636 1.00 PC
LC 50 DB40D7X/-004
RD21050
--------------------------------------------------------------------------------
0070 R978800619 1.00 PC
O-RG SZ 2-337 FPM 70SH WAS 009560
--------------------------------------------------------------------------------
0080 45 R978815798 1.00 PC
43AP-0046-1 LFA50D19/22 SPACER BLOCK
--------------------------------------------------------------------------------
0090 R900017457 4.00 PC
R-RING 13X2,3X2,62NBR90
RN181.14
--------------------------------------------------------------------------------
0200 R978800151 3.00 PC
PARKER 4HP5ON-S PLUG HOLHEX/SH SAE BUNA
--------------------------------------------------------------------------------
0210 R978800154 1.00 PC
PARKER 12HP5ON-S PLUG HOLHEX/SH SAE BUNA
--------------------------------------------------------------------------------
0220 55.1,55.2 R978040995 2.00 PC
MANIFOLD PTM-V-I-S-4PM BLOCK AND BLEED
--------------------------------------------------------------------------------
0230 R910109355 4.00 PC
SHCS M6 X 40 -8.8 DIN912
--------------------------------------------------------------------------------
0240 R978811253 1.00 PC
RED ADPT NPT TO SAE .5-4 22-48
--------------------------------------------------------------------------------
0245 R978800016 1.00 PC
MALE CON 8-8S NPT 37 PUA20-01-00


489
Bill of Material
Description
Drawing No.
--------------------------------------------------------------------------------
0246 R978802866 1.00 PC
SWIVEL NUT CON 8-8S NPT 37 PUA20-15-00
--------------------------------------------------------------------------------
0250 R978049559 2.00 PC
PARKER 6-8FLO-S MALE PIPE CONN
--------------------------------------------------------------------------------
0255 R978704475 1.00 PC
PARKER 6R6LO-S 4615426000
--------------------------------------------------------------------------------
0256 R978881565 1.00 PC
PARKER 6C6LO-S SWIVEL NUT ELBOW 90
--------------------------------------------------------------------------------
0270 50 R978886007 1.00 PC
PRESS GAUGE 2 1/2/1000PUA31-11A -4 SAE
--------------------------------------------------------------------------------
0275 60 R978800004 1.00 PC
DV08-01.X/12 00705022 8PUA21-16SHUT OFF
--------------------------------------------------------------------------------
0280 R978704398 1.00 PC
PARKER 6-4F5OLO-S 4615256400
--------------------------------------------------------------------------------
0282 R978809126 1.00 PC
PARKER 4F5OHAO-S STR THRD UNION
--------------------------------------------------------------------------------
0285 65 OPTIONAL
R978013929 1.00 PC
PRESS
PRESS TRANS
TRANS (SEE FLS PARTS LIST & IOM MANUAL)
2088G4S22A1M5Q4
--------------------------------------------------------------------------------
0290 70 R978049484 1.00 PC
ACCUM 5-100-61-CX02-LT-CE OILAIR
--------------------------------------------------------------------------------
0300 R978800277 1.00 PC
O-RG SZ 2-228 NBR 70SH WAS 007922
--------------------------------------------------------------------------------
0310 R978804217 2.00 PC
ANCHOR 32SF-2 SPLIT FLG 2 CODE 60/61
--------------------------------------------------------------------------------
0320 R910220264 4.00 PC
ZYL.SCHR.M 12X 40 -10.9 DIN 912 #130NM
--------------------------------------------------------------------------------
0330 80 1531316026 2.00 PC
CLAMPING BANDTIGHT BSLP 10-50L 218-228
RD50170
--------------------------------------------------------------------------------
0340 R900089123 4.00 PC
HEXAGON SCREW ISO4017-M8X16-8.8-A3C
--------------------------------------------------------------------------------


490
Bill of Material
Description
Drawing No.
0350 R978804494 4.00 PC
WASHER 5/16"SAE
--------------------------------------------------------------------------------
0360 R900003068 4.00 PC
SOCKET HEAD SCREW ISO4762-M10X25-8.8A3C
--------------------------------------------------------------------------------
0370 R978804495 4.00 PC
WASHER 3/8"SAE


491
16 FLS Document No. 69010137, Ver. 1.0


492


493


494


495


496


497


498


499


500


501


502


503


504


505


506


507


508


509


510


511


512
Instruction
Manual
for the
INSPECTING THE CONDITION OF Accumulator
DELIVERY
After unpacking the accumulator, inspect it for possible
damage caused during transit. 3 2
1 4
1. Inspect the Locknut and the Jamnut and bleeder plug
for tightness.
2. Check the precharge tag. The accumulator is either
precharged to 25psi (1.7 bar) for shipping purpose or
charged to a pressure specified on the purchase order.
3. Check that the working pressure stamped on the 9
accumulator shell is equal to, or greater than, the
maximum pressure of the system.
7
PROTECTION & PRECAUTIONS
1. Protective Gloves: 10 6
Use chemical resistant gloves, if needed, to avoid
prolonged or repeated skin contact from the clean- 14 13
11 12 8 5
ing solutions or solvents.
2. Eye protection:
Use safety glasses before performing any maintenance SPARE PARTS
on the accumulator.
1. Shell
OTHER PRECAUTIONS: 2. Bladder 8. Spacer
3. Plug & Poppet Assembly 9. Locknut
DO NOT operate the accumulator beyond the allowable
4. Anti Extrusion Ring 10. Name Plate
working pressure and temperature limitations stamped or
5. Metal Back Up Ring 11. Valve Cap
attached to the product.
6. "O" Ring 12. Hex Jamnut
Use only the tools recommended in this manual to perform
7. Rubber Back Up (Not available for 1 quart and 13. Protective Cap
the maintenance procedures.
1 gallon sizes) 14. Bleeder Plug
Use only DRY NITROGEN for charging accumulator.
NEVER USE OXYGEN OR AIR, due to risk of explosion.
Use only valve cores approved for accumulator service and
NEVER USE AN AUTOMOTIVE TYPE VALVE CORE.
PRECHARGING: 9
1. Use DRY NITROGEN ONLY to precharge the
accumulator.
8
2. Use the charging assembly recommended in this
manual to charge the accumulator to the required 5
precharge if it is not already charged at the factory.
3. Check the charging valve for leaks using snoop or soap
water. 4
4. Tighten the jamnut at the gas valve stem and also
the locknut on the fluid port with a wrench.
5. Tighten the protective cap on the gas valve stem to
hand tight.
6. Check the gas precharge pressure periodically. This
must be done after all the hydraulic system pressure is 3 6
released. The precharge must be checked once in the
first week of operation, and then every six months dur- 7 2 1
ing normal working or every month during high cycling
or high temperature condition.
TOOLS
INSTALLATION:
The accumulator should be mounted vertically with fluid 1. Charging & Gauging Assy - P.N. CG-3000 6. Ratchet Wrench (Corresponds to elastic
port on bottom and gas valve on top with supporting brack- 2. Valve Core Tool - P.N. 11-501 stop nut and bleeder plug size)
ets and saddles specifically designed for accumulator 3. Spanner Wrench - P.N. 11-502 7. Bladder Pull Rod - P.N. 11-503
mounting. For other type of mounting, consult factory. 4. Open End Box Wrench (Corresponds to 8. Rubber Mallet
Fluid port must not be used to support the accumulator. valve stem wrench flats width) 9. Tool Box
Do not weld any support to the accumulator. For ease of 5. Open End Box Wrench (Corresponds to
maintenance and periodic checking of the precharge, an hex jamnut size)
automatic discharge valve fitted between the accumulator
and the system pressure line is recommended.
OLAER GROUP COMPANY

38 COMPANY
OLAER GROUP FLS Document No. 60083907,

513
DISASSEMBLY
Instructions for disassembling the

accumulator.
Release all the hydraulic system pressure in a safe

manner (eg: bleed valve or automatic discharge valve
installed in the system). Remove the accumulator
from the hydraulic system and place it horizontally in
a vice or a clamping device. Protect the clamping
jaws with wood or rubber so as not to damage the
accumulator shell.
1. Remove the protective cap on the gas 2. Remove the valve sealing cap from the
valve. valve adaptor.
3. Connect a suitable charging & gauging assem- 4. Remove the valve adaptor from the gas valve body. 5. Remove the valve core if the gas valve body has a
bly to the valve adaptor and release all the nitrogen (2 piece valve stem design) core inside. (1 piece valve stem design)
precharge pressure from the accumulator until the
gauge reads zero.
6. Remove the jamnut and the name plate from the 7. Remove the bleeder plug from the fluid port. 8. Remove the locknut and then remove the spacer.
gas valve body. While removing the jamnut hold the Loosen locknut with a spanner wrench by turning
gas valve body with a wrench so that the bladder will 2 or 3 threads, then push the fluid port body into the
not rotate. accumulator shell if there is no hydraulic pressure. *
9. Push the fluid port body into the shell and remove 10. Slide the anti-extrusion ring off of the fluid port. 11 . By squeezing the bladder discharge as much air
the back-up ring , “O” ring and the metal back-up ring. Carefully fold the anti-extrusion ring until it's suffi- as possible by hand, then pull the bladder out slowly
ciently folded to allow removal from the shell and re- through the fluid port opening of the shell.
move fluid port from the shell.
* If the fluid port body does not go inside, then there is some hydraulic pressure left inside the accumulator. If this happens, do not attempt to do any maintenance. Consult the factory.

514
ASSEMBLY
Cleaning & Inspection

Clean all the metallic parts of the accumulator with
an organic solvent. Avoid exposing the rubber parts
to the solvent to prevent any attack on the rubber.
Inspect the condition of the metallic components of
the fluid port (poppet, spring, stop nut and piston)
and replace the complete fluid port assembly if any
of the components are damaged. Push the poppet
valve head to make sure it slide freely through the
guide in the fluid port. Clean the bladder with
isopropyl alcohol or equivalent. Inspect the bladder
for any visual damages. Replace if necessary. 1. Squeeze the bladder to discharge air from it by 2. Then install the valve adaptor to a torque value of
Check that there is no corrosion inside or outside of rolling it up from the bottom. 90 in.lbs (10 Nm). (For the two piece valve stem
the shell. Replace all parts considered defective. design).
The “O” Rings and back up rings must be replaced.
3. Then install the valve core to a torque value of 4. Lubricate the accumulator shell and the bladder 5. Reinstall the name plate and the jamnut. Do not
4 in.lbs. (.45 Nm). (For the one piece valve stem either with the medium used in the system or a simi- tighten the jamnut.
design). lar product. Attach the bladder pull rod to the valve
and fold the bladder and pull into the shell. Avoid
twisting the bladder while pulling it into the shell.
6. Insert the fluid port and the anti-extrusion ring into 7. Slide the anti-extrusion ring over the fluid port. 8. Install a charging and gauging assembly on the
the shell. Pull the fluid port through the port opening. gas valve and put a low precharge of 30 psig (2 bar)
to seat the fluid port and the anti-extrusion ring in
place.
9. Hammer slightly the fluid port body at various 10. Install the metal back up, O-ring, rubber back up 11. Tighten the locknut .
angles using plastic hammer. and spacer in that order.


515
12. Install the bleeder plug and tighten it. 13. Rotate the accumulator shell around its axis to
lubricate its inner wall evenly all around.
14. Using a charging and gauging assembly, 15. Remove charging and gauging assembly, install
precharge to the desired pressure at a moderate rate, valve cap and protective cap. Retighten the
using DRY NITROGEN only. Check the valve for Assembly locknut & jamnut.
leaks with snoop or soap water.
STORAGE:
Accumulator storage instructions OILAIR ORIGINAL EQUIPMENT LIMITED
If after reassembly, the accumulators are stored, they must be charged with a low nitrogen pressure of 25 psi (1.5 bar)
and store in a cool and dry area. The fluid port must be sealed. The accumulator can be stored in any position. WARRANTY
The protective cap on the gas charging valve must be securely tightened to protect it from any shock.
OILAIR warrants each of its products against original
Attach a label to the accumulator stating that they must be precharged before installing in the system. defects in materials and/or workmanship and will repair
or replace any product which is determined by OILAIR,
within one (1) year of its installation, to be defective or
If the accumulator is stored for longer than 6 years, all the elastomeric components (bladder, seals etc.) must be below the manufacturing standards of OILAIR, including
replaced. warranty of merchantability, fitness for the purpose intended,
consequential and incidental damage of liability.
This Original Equipment Warranty which anticipates instal-
lation by third parties, expressly excludes warranty of
BLADDER STORAGE INSTRUCTIONS: merchantability, fitness for the purpose and consequential
or incidental damage liability.
DO NOT OPEN PLASTIC BAG UNTIL READY FOR INSTALLATION.
DO NOT USE RAZOR OR SHARP OBJECTS TO OPEN THE PLASTIC BAG. OPERATION OF ANY OILAIR ACCUMULATOR OR
COMPONENT BEYOND THE MANUFACTURER'S
0
Bladder in the plastic bag must be stored in a cool (preferably below 72 F), dry and dark place out of direct sunlight, WORKING PRESSURE LIMITATIONS, OR IN VIOLATION
fluorescent light, ultraviolet light and away from electrical and welding equipment. OF ANY OPERATING OR SERVICE INSTRUCTION
STAMPED OR ATTACHED TO THE PRODUCT,
Direct sunlight or fluorescent light may cause the bladder to weather check and/or dry rot, which appears on the bladder EXPRESSLY VOIDS THIS WARRANTY AND MAY BE
surface as cracks. DANGEROUS TO LIFE AND PROPERTY.
11505 West Little York Houston, Texas 77041 Tel: (713) 937-8900 Fax: (713) 937-0438/937-1516
copyright 1994 OilAir Hydraulics, Inc. OLAER GROUP COMPANY Printed in USA Bulletin #MMM94
41COMPANY
OLAER GROUP FLS Document No. 60083907,

516
BOTTOM REPAIRABLE ASSEMBLY

1/ Squeeze the bladder to discharge the air from it.
Lubricate the inside of the shell by turning it around its
axis. Use either the process fluid or a similar liquid (to
approximate. 10% of the accumulator volume for
capacities up to 5 liters or 5% for higher capacities). If the
liquid is low in viscosity (lower than 5cSt) consult OLAER.
2/ Lubricate the bladder and insert it into the accumulator

shell. Check that the bladder is not folded or twisted. For a
large capacity accumulators, use a suitable tool (a bladder
extractor).
3/ Put on nameplate,..
4/.., tighten lock nut,..
5/ and gas valve.
Fluid port end
6/ Insert the fluid port and the anti-extrusion ring in the

shell.
7/ Pull the fluid port once the fluid port and the anti-
extrusion ring are inserted in the shell.


517
8/ Install the O-ring first, and then the back-up ring on

the fluid port.
9/ Make sure the back-up ring is not twisted, (using an

appropriate tool)
10/ Put the flange washer and the locking ring on the fluid
port . Tighten up with a C spanner.
11/ Make sure the components are centered by striking

lightly the fluid port body at various angle using a rubber
mallet
12/ Tighten bleed plug on the fluid port.
CHARGING PROCESS
13/ Before charging the accumulator with nitrogen, turn

Pre-charging
the accumulator shell around its axis to lubricate its inner Volume of
time
wall evenly. Immediately after this operation, charge the accumulator
1 to 1.5 bar in
bladder slowly with nitrogen to a pressure of 1 to 1.5 bar in liters
seconds
with the accumulator in the horizontal position. It is most
important the bladder stretches uniformly prior to it
closing the poppet valve at the bottom of the Accumulator. 1 10
5 20
As a guide see charging process table. 10 40
50 120
100 200
Please note this is a slow process and should be done with
200 400
a Nitrogen bottle regulator.
When above 1.5 bar, continue charging

to the required pressure.


518
BLADDER ACCUMULATOR MANUAL

Operation & maintenance
A. Storage
1. Accumulators
Short term Storage:
When stored in a stable, non-severe environment, accumulators can be left in their original
packing for a number of weeks without fear of deterioration.
Long Term Storage:
If the units are to be stored for longer periods of time, it is important that the bladder is
maintained in its natural, unstressed shape within the body and that any deterioration of
components through corrosion is prevented.
We advise that accumulators be filled with system (or preservation) fluid to exclude air from
the shell cavity and prevent condensation. This is especially important where the system
fluid is of low viscosity e.g. water based. (See COMMISSIONING).
Procedure:
Exhaust any existing pre charge pressure from the bladder and remove the valve core. Then
replace the valve core and cap to maintain atmospheric pressure within the bladder.
Invert the accumulator, fluid port upwards, and fill with system fluid until the residual space
between bladder and shell is filled. In certain circumstances it may not be desirable (or safe)
to use the system fluid. In this case a compatible fluid should be used for preservation.
Seal off the fluid port opening with a pressure-tight plug.
This procedure is a general recommendation only. Where severe conditions are prevalent
special precautions might be need to be considered.
2. Spare bladders
Rubber compounds specified by Olaer fall into the category of low susceptibility or high
resistance to deterioration by ageing.
Details of material classification and shelf life expectancy can be found in BS3574: 1989 and
our Technical Specifications, Tech Spec 105.
Ideal storage conditions:
Stored under ideal conditions bladders have an expected shelf life of 5 years.


519
- Stored in a stress-free condition either due to natural shape or by partially inflating to

natural size using nitrogen gas.
- At temperature between -5ºC and +5ºC.
- In a "Valeron" packaging away from heat or rotational electrical equipment. This special
packaging is designed by OLAER, and available on request.
Storage conditions less than ideal:
Where ideal storage conditions cannot be met, bladders have an expected shelf life of 1-3
years if they are stored as follows:
- Stored in a stress-free condition due to natural shape or by partially inflating with

compressed air or nitrogen gas, so that they stand lay flat without bending or folding.
Bladders should not be stacked.
- At temperature up to 25ºC.
- Stored in darkness either in a dark room or covered with clean, opaque polythene and away
from direct sunlight, heat or rotational electrical equipment.
Inspection before use:
- Inflate to not more than 1½ times natural diameter.

- Visually examine seams for defects and surface for crazing.
- Immerse in water to inspect for leakage or perforations.
NOTE: Bladders not stored properly will be subject to attack from ozone, heat or UV
light. Cracking will develop within one year.
For full details of storage recommendations for bladders refer to our technical Specification,
Tech Spec 105.
B. Installation
1. Inspection of accumulator
All OLAER Fawcett Christie accumulators are thoroughly inspected prior to despatch from our
factory and are ready for installation following pre charging.
After unpacking the accumulators, inspection of the accumulators is recommended for possible
damage during transit. The following items should be checked:-
a) Check the following items for tightness : all nuts, screws, locking rings, bleed screws,
adaptors and fittings, as applicable.
b) Check that the maximum pressure of the accumulator is equal to or greater than the
maximum pressure of the system.(see interpretation of markings).


520
2. Installation recommendations
a) all accumulators are supplied un-pre charged from the factory unless requested. Prior to
applying hydraulic pressure to the system all accumulators must be pre charged with nitrogen
(for pre charging see commissioning).
b) It will be necessary to check the gas pre charge pressure at regular intervals (see routine
maintenance). Consideration should therefore be given to the following:
- The provision of a safety block fitted between the accumulator and fluid pressure line to
enable isolation of hydraulic system pressure.
- The location of the gas charging valve with regard to the potential for accidental damage and
safe discharge of high-pressure gas.
- The provision of a warning label (in addition to that provided on the accumulator nameplate)
stating "PRECHARGED WITH N2 GAS AT ....BAR".
It is necessary to ensure that the accumulator is protected from over-pressurization. General

protection is usually provided by the hydraulic system relief valve, which should be set at no
higher than 10% above the maximum working pressure (MWP) of the accumulator. Specific
protection for the accumulator can be provided in the following ways:
- A hydraulic relief valve located in a safety block will prevent both liquid and gas side over-
pressurization.
- A fusible plug will relive gas side pressure in the event of a fire.
- A burst disc will relieve gas side over-pressurization.
On storage applications a check valve fitted between pump and accumulator will ensure non-
reversal of the pump.
For maximum efficiency and service life, accumulators should be mounted vertically where
possible, fluid port facing down.
For fluid port and gas connection threads see our catalogue. If it is necessary to adapt to
another size, special adaptors are available.
A range of clamps, support brackets and other accessories are available to assist in
installation. Their use is strongly recommended.
C. Commissioning
Important notes
1. Use only oxygen-free, dry nitrogen gas.

2. All accumulators are supplied un-pre charged unless a pre charge pressure is specified
when ordering. Prior to applying hydraulic pressure to the system all accumulators must be
pre charged with nitrogen.
3. Check details of accumulator on label and shell for maximum working pressure. The
maximum hydraulic pressure must not exceed the MPW of the accumulator.


521
4. Always use the nitrogen pressure regulator valve when accumulator shell pressure rating is
lower than gas pressure in nitrogen cylinder.
5. Pre charges vary with operating conditions. check with our technical department if no pre
charge has been previously recommended. For a guide the following values can be used:
- storage application: 90% of minimum allowable system pressure
- shock application: 60% of flow pressure at accumulator position
- pulsation damper: 70% of mean pumping pressure
NB: Allowing pre charge to fall below 20% of maximum system pressure may cause
premature failure of the bladder.
- Ensure that the bladder and shell inner are adequately lubricated with system fluid before
commencing pre charging. This is especially important where the system fluid is of low
viscosity eg water based.
Pre charging procedure
The following procedure should be adopted for safe pre charging of accumulators. All pre
charging equipment specified is detailed in our catalogue.
For accumulators having a shell working pressure less than the nitrogen source, refer to fig 2.
For accumulators having a shell working pressure equal to or greater than the nitrogen source
refer to fig.3.
For accumulators fitted with a back-up-bottle or remote charging point, refer to fig.5.
For high-pressure accumulators the gas valve is fitted with a replaceable 'Schrader-type' core.
Ensure that this is correctly tightened before attempting to pre charge.


522
Procedure 1.- Using a nitrogen pressure regulator
1. Remove protective cap(1) if fitted and sealing cap (2).

2. Attach regulator(3) to nitrogen cylinder (4).
3. Attach charging set (5) to accumulator gas valve assembly (6) and connect charging hose
(7) between regulator (3)and charging set connection.
4. Back off regulator handle (8)anti-clockwise until loose, check gas bleed valve (9) on
charging set is closed and screw hand wheel (10) clockwise to open gas valve. Do not screw
knob down tight.
5. Open nitrogen cylinder valve by turning key (11), cylinder pressure will register on right-
hand gauge (12). This pressure should be checked against the required pre charge pressure.
6. Turn handle (8) clockwise until outlet pressure on left-hand gauge (13) registers 10%
higher than required pre charge pressure. When pressure ont he charging set and outlet
gauges are equal, close nitrogen cylinder cap.
7. Turn hand wheel (10) anti-clockwise to seal gas valve.
8. Crack bleed valve (9) to exhaust gas from charging hose and remove hose from charging
set and replace hose connection sealing cap.
9. Close bleed valve, turn hand wheel (10) clockwise to open gas valve. Do not screw knob
down tight. Crack bleed valve (9) to vent down to required pre charge pressure. Close bleed
valve.
10. Turn hand wheel (10) anti-clockwise to reseal gas valve, crack bleed valve and remove
charging set from accumulator.
11. Test gas valve for leaks using a leak detection spray or a soapy water solution.
12. Replace sealing cap (2), tighten with pliers, and protective cap if fitted.
Procedure 2.- Nitrogen pressure regulator not required fig 2,3,4.
1. Remove protective cap (1) if fitted and sealing cap (2).

2. Attach charging set to accumulator gas valve assembly (6).
3. Connect charging hose (7) to nitrogen cylinder (4) using the appropriate adaptor, and
attach the free end to the charging set.
4. Turn hand wheel (10) clockwise to open gas valve> Do not screw knob down tight. Slowly
open nitrogen cylinder by turning key(11).
5. Allow pressure on the gauge (14) to read slightly in excess of required pre charge and then
close nitrogen cylinder valve.
6. Turn hand wheel (10) anti-clockwise to seal gas valve.


523
7. Crack bleed valve (9) to exhaust gas from charging hose and remove hose from charging
set and replace hose connection sealing cap.
Procedure 3.- Permanent charging set fitted fig.4
Follow step of procedures 1 or 2 as appropriate but connect to the permanent charging set as
shown in fig4.
D. Routine maintenance
When a new accumulator has been in service for a short period, the pre charge should be
checked to ensure there is no leakage. Subsequent checks need only be at 6 monthly
intervals.
When checking the pre charge of an accumulator installed in a system, the accumulator must
be isolated from the system pressure and the fluid removed by carefully opening the bleed
valve and collecting the fluid in a suitable receptacle. Alternatively, shut the system down and
release the fluid pressure back to tank.
Fit a charging set (without charging hose) ensuring the bleed valve is closed and cap is fitted
to the charging connector.
Turn hand wheel clockwise and check pre charge

NB: Do not screw knob down tight.
Replenish if required, following steps of procedures 1 or 2 appropriately.(see commissioning)
E. Servicing
1. Re-certification for continued safe use
In Australia most gas-loaded accumulators fall within the requirements of the AS3788
pressure equipment in service inspection.
Key points of this standard include:
- Requirements to determine the safe operating limits of the accumulator and record the fact
that these are not exceeded by the system pressure.
- Preparation of a written scheme of examination for accumulators used to store energy above
certain limits.
- Establishing a maintenance procedure and carrying out regular safety checks and
examinations.
Full details can be found under re certification
F. Accumulator disassembly


524
Please refer to bottom / top repairable assembly unit.
Cleaning and inspection
1. Clean all metallic components with an organic solvent.

2. Inspect the condition of all components within the fluid port.
3. Check the fluid port poppet valve to ensure free movement.
4. Inspect the bladder for any visible signs of damage. (cracking or surface abrasion)
5. Inspect the shell, both inside and outside for signs of corrosion.
6. Replace any parts found or considered to be defective.
7. Replace the following parts irrespective of condition : anti extrusion ring, 'O' ring, back-up
ring, 'O' ring.
NB: the 'heart' of a bladder accumulator is the bladder itself. OLAER strongly recommends
that all elastomeric components are replaced during servicing/re-certification.


525
TECSPEC 105 - Guide to bladder storage and shelf life

OLAER Fawcett Christie TECHNICAL SPECIFICATION
GUIDE TO BLADDER STORAGE AND SHELF LIFE
Std No : Tec Spec 105
REF Rev: A2
FCH TS 1003
FCH TS 1005 Page: 1 of 1
OLAER CRP 904
Rubber components are susceptible to premature aging over time. Some factors accelerate this aging
process such: Exposure to UV, ozone and electrical fields. This specification details the recommended
storage conditions and shelf life for rubber components used in accumulators.
The following rules must be applied to ensure optimum storage of elastomeric parts (bladders etc.)
Note: the complex packaging mentioned below is manufactured and marketed by OLAER. An
alternative but less effective packaging material is opaque polythene wrapping sealed to prevent free
access of air.
The rules described below are applicable to bladders. These rules should be adapted as appropriate
for other rubber parts.
COMMON RULES
Parts must be stored:

- indoors in a stress (deformation) free condition, inflated to atmospheric pressure.
- at an ambient temperature below 25ºC.
- relative humidity shall be such that condensation does not occur.
- protected from light sources in particular direct sunlight or strong artificial light.
- protected from any equipment capable of generating ozone and electrical fields, e.g. mercury vapor
lamps, high voltage equipment, combustion gases etc.
SPECIAL RULES
Case 1: Without complex packaging

Bladders with "light" valve body in original packaging or not: store flat (e.g. on shelves)
Bladders with "heavy" valve body : suspended by valve body.
Case 2: Part in complex packaging

All types of part: store flat.
The complex packaging is tightly sealed with the bladder slightly inflated to give them their original
form.
The packaging date must be marked on the packaging.
Bladders can be stacked; maximum 3 levels for bladders volumes > 5L.
Case 3: Part integrated in an accumulator body

Maintain the bladders inflated at accumulator inflation pressure P0, or a storage pressure (max.5bar)
In the case of long term storage (exceeding 6 months), bladders must be stored at storage pressure


526
only (max 5 bar).
STORAGE PERIOD
The period (in years) indicated guarantees a potential identical to original potential on de stocking.
The part can be considered as new within this period.
Rubber Case 1 Case 2 Case 3

Nitrile 1 5 5
Hi nitrile 3 5 5
Butyl 3 5 5
EPDM 3 5 5
Neoprene 3 5 5
Hydrin 3 5 5
Natural
1 5 5
Rubber
Viton 2 3 3


527
PRECHARGING INSTRUCTIONS
FOR 5000 PSI
BLADDER ACCUMULATORS
PRECHARGING INSTRUCTIONS FOR
5000 PSI BLADDER ACCUMULATORS
IMPORTANT
USE DRY NITROGEN GAS ONLY to precharge the accu-
mulator.
Check the precharge tag attached to the accumulator.
The accumulator will either be precharged to 25 psig(1.7
bar) for shipping purpose or to the pressure specified
on the purchase order. If the accumulator does not have
the correct precharge, it must be precharged to the re-
quired level using only DRY NITROGEN GAS, before it is
installed in the hydraulic system. Charging Kit
Precharge pressures vary according to the application CG-5000
and operating conditions. Please seek technical support
from the factory if you are not sure about the correct
precharge. Incorrect Precharge pressure can lead to
reduced accumulator performance, reduced bladder life
expectancy, and even bladder failure. It is very impor-
tant to have the correct precharge. As a guidance, the
following values can be used.
Energy Storage:
90% of the minimum system pressure
Pulsation dampening:
70% of the system mean operating pressure
Shock absorption:
75% of the system working pressure.
Precharge must never be below 25% of the maximum
system pressure. Charging Head Assembly Hose Assembly
Always use a pressure regulator valve on the nitrogen CG-5013 CG-5010
bottle when the accumulator shell pressure is lower than
the gas pressure in the nitrogen cylinder.
Ensure bladder is thoroughly lubricated with system fluid
before precharging.
Whenever you have to replace the gas valve core, re-
place it with a valve core approved for accumulator ser-
vice. NEVER USE AN AUTOMOTIVE TYPE VALVE CORE.
CHECKING PRECHARGE
Check the precharge pressure only after the hydraulic
pressure has been completely released. When a new
accumulator is installed, the precharge pressure should
be checked to ensure that there is no leakage. This
should be performed once during the first week of op-
eration, and then every six months thereafter. Under high
cycling or high temperature conditions, the precharge MS Valve 11-5-309 Air Chuck CG-3002
should be checked once every month.
RECOMMENDED CHARGING KITS FOR

5000 PSI BLADDER ACCUMULATORS
Assembly
Type Capacity Part No:
Standard
Accumulator 2.5 to 15 Gallon CG-5000
Top Repairable
Accumulator 2.5 to 15 Gallon CG-5000
Tank Valve CG-3005 Bleed Valve CG-3009


528

PRECHARGING
PRECHARGING PROCEDURE FOR 5000 PSI STANDARD ACCUMULATORS
1. Remove the protective cap and the seal cap. 2. Open the valve adapter by securing the bottom hex 3. Close the bleed valve on the charging and gauging 4. Install Charging and Gauging Assembly on the
with a wrench while turning the top hex counter assembly. accumulator by screwing the air chuck to the gas
clockwise. valve Hand tighten sufficiently to prevent any leakage.
Connect the hose to the nitrogen bottle regulator.
5. Remove the seal cap from the gas charging tank 7. Close the valve adapter by securing the bottom hex 8. Open the bleed valve to bleed of nitrogen in the 10. Replace the valve seal cap and the protective cap.
valve and connect the swivel connector on the hose with a wrench while turning the top hex clockwise. hose. Disconnect the charging assembly from the
assembly. Hand tighten sufficiently to prevent leakage. Make sure the valve is completely closed. accumulator and the gas bottle. 11. Check precharge pressure once in the first week of
operation, and then every six months during normal
6. Open the regulator valve on the nitrogen bottle 9. Check for leakage through the valve adapter by soap working or every month during high cycling or high
carefully to let nitrogen flow at a slow rate into the solution or snoop. If the adapter is leaking, then temperature condition.
accumulator. Proceed to charge until the accumulator retighten the top hex. If leakage persists then replace
reaches desired precharge pressure. Close the the valve adapter.
regulator and let the nitrogen stabilize and obtain
gauge reading. Adjust the pressure if necessary.
PRECHARGING PROCEDURE FOR 5000 PSI TOP REPAIRABLE ACCUMULATORS
1. Remove the protective cap and the seal cap. 2. Open the valve adapter by securing the bottom hex 3. Close the bleed valve on the charging and gauging 4. Install Charging and Gauging Assembly on the
with a wrench while turning the top hex counter assembly. accumulator by screwing the air chuck to the gas
clockwise. valve Hand tighten sufficiently to prevent any leakage.
Connect the hose to the nitrogen bottle regulator.
5. Remove the seal cap from the gas charging tank 7. Close the valve adapter by securing the bottom hex 8. Open the bleed valve to bleed of nitrogen in the 10. Replace the valve seal cap and the protective cap.
valve and connect the swivel connector on the hose with a wrench while turning the top hex clockwise. hose. Disconnect the charging assembly from the
assembly. Hand tighten sufficiently to prevent Make sure the valve is completely closed. accumulator and the gas bottle. 11. Check precharge pressure once in the first week of
leakage. operation, and then every six months during normal
9. Check for leakage through the valve adapter by soap working or every month during high cycling or high
6. Open the regulator valve on the nitrogen bottle solution or snoop. If the adapter is leaking, then temperature condition.
carefully to let nitrogen flow at a slow rate into the retighten the top hex. If leakage persists then replace
accumulator. Proceed to charge until the accumulator the valve adapter.
reaches desired precharge pressure. Close the
regulator and let the nitrogen stabilize and obtain
gauge reading. Adjust the pressure if necessary.
11505 West Little York Houston, Texas 77041 Tel: (713) 937-8900 Fax: (713) 937-0438
© copyright 1997 OilAir Hydraulics, Inc. OLAER GROUP COMPANY Printed in USA Bulletin #MM5-97
OLAER GROUP COMPANY

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536
A.10 1000625615: Oil Cooler

537
A.10.1 Installation, Operation, and Maintenance

Instructions
7270 S. 13TH St. Ste 201

Oak Creek, WI 53154
Phone: (414) 768-7420
Fax: (414) 762-0632
OCS Oil Coolers
Installation, Operation, and Maintenance Instructions
RECEIVING
Inspection:
Inspect unit for shipping damage (especially core) before uncrating. Rotate fan, which should move freely. Note that
one blade is wired to guard on some models for shipping. Remove wire before rotating fan.
Handling:
Exercise care to avoid damage to core. All units are shipped with wood skids facilitating forklift handling. Lifting holes
are provided.
Storage:
Units are normally finish coated with a black powder coat polyester paint. Do not paint core as this may impair airflow
and heat transfer. All openings are sealed with appropriate pipe plugs, pipe caps, thread protectors, and flange covers
at the factory. Be sure these are in place.
INSTALLATION
LOCATION
Insure that no obstructions impede either discharge or inlet air flow. If unit is mounted in wall, provide ample room
ventilation. Cooler should be oriented to take advantage of prevailing winds to avoid recirculation and the resultant
loss of cooling effect. Expected wind direction on hot, summer days should especially be anticipated. Ductwork on
housing of unit adds airflow static resistance, which must be overcome with extra fan capacity. Ducting should be
larger in area than heat exchanger core face and contain only straight runs and long radius turns.
Units should not be located in corrosive atmospheres as rapid deterioration of casing, cooling element, fan and motor
may take place resulting in shortened life and unnecessary replacement expense.
FOUNDATION AND MOUNTING
Flexible connections or non-rigid plumbing (hangers and right-angle bends) should be used to allow thermal
expansion of core, insulation from vibration and freedom from static loading. Piping should be sized based on design
flow and pressure drop requirements and not on the oil cooler supply and return tapping sizes.
A strainer or filter located ahead of the cooler or the heat source, depending on the type of service, should be installed
to trap scale; dirt or sludge that may be present in piping and equipment, or that may accumulate. A thermostatic or
spring loaded by-pass relief valve installed ahead of the cooler will be found helpful to hasten warm-up and relieve the
system of excessive pressures, as well as to control the oil temperature in certain installations. These accessories
should be considered in the original heat rejection and piping computations.
Young Touchstone OCS Oil Coolers are designed for operation with oil pressures of 200 psi maximum and
temperatures of 400qFmaximum.
FAN BLADE CLEARANCE

For coolers shipped less motor, assemble the fan bushing and tighten the bolts to the torque provided in the taper
lock bushing instructions. After assembly, the fan blades should be checked for tip clearance around the fan ring. In
most cases, the fan shroud attachment bolt holes are slotted to allow vertical adjustment for centering of the fan
position.
This form is shipped with product

Revised October 2016
Part Number 368228
Sheet 1 of 5
REV D

538
IOM Instructions (Sheet 2)
7270 S. 13TH St. Ste 201

Oak Creek, WI 53154
Phone: (414) 768-7420
Fax: (414) 762-0632
OCS Oil Coolers
START UP PRECAUTIONS- PIPING CONNECTIONS
Figures 1 & 2 below show typical one pass cooler connections for high oil flow rates. Figures 3 & 4, show typical two
pass cooler connections for low oil flow rates. If connection type is not provided in specification documents, consult
the factory or a factory representative as damage or inefficient operation can result.
All OCS coolers are manufactured with standard single (1) or two (2) pass pipe connections. All piping connections are
capped at the factory for shipment. Prior to start up, check the unused connection to assure that the pipe cap is
secure to prevent leaks during system operation.

Part Number 368228
Sheet 2 of 5
REV D

539
7270 S. 13TH St. Ste 201

Oak Creek, WI 53154
Phone: (414) 768-7420
Fax: (414) 762-0632
OCS Oil Coolers
MAINTENANCE
TYPE D DIRECT DRIVE COOLERS
Connect motor only to a power supply of the same characteristics as stamped on the motor nameplate. For single
speed motors, follow wiring diagram attached to motor casing or located in the motor conduit box. For multispeed
motors, follow diagram included with control when furnished. Before starting motors, turn over fan by hand to
eliminate possible motor burnout should the fan have become damaged in shipment. Observe operation carefully after
motor is started for the first time. Turn on electric power. Make sure fan is rotating counterclockwise (looking down
the air stream) and drawing air over the motor, through the core, and out the core guard or discharge opening.
Running fan in wrong direction will result in poor air flow and inefficient operation.
TYPE E EXTERNAL DRIVE COOLERS
If drive requires vee belts, sheave alignment and correct belt tension must be maintained to transmit sufficient power
to fan and prevent excessive belt and bearing wear. Locate the idler sheave on the slack side of the belt drive. Belt
guards are provided by Young Touchstone on smaller coolers. Larger units must have guarding by the owner of the
cooler or OEM.
The assembly of sheaves and/or fans utilizing taper lock bushings requires clean surfaces and proper alignment of
bushing to sheave/fan. Initially snug the pull-up bolts, assuring correct fit of tapered mated surfaces. With torque
wrench, torque bolts in an alternating pattern to recommend torque. With a light hammer, tap between the pull-up
bolts, check torque, if necessary, re-torque to specifications.
LUBRICATION
Lubricate motor according to instructions furnished with motor.
GENERAL INSPECTION
Inspect the unit regularly for loose bolts and connections, rust and corrosion and dirty or clogged cooling element
(core).

Part Number 368228
Sheet 3 of 5
REV D

540
7270 S. 13TH St. Ste 201

Oak Creek, WI 53154
Phone: (414) 768-7420
Fax: (414) 762-0632
OCS Oil Coolers
EXTERNAL CLEANING
Dirt on fins reduces airflow and cooling capacity. Dirt on fan blades could reduce air output, unbalance fan or overload
motor. Dirt on motor reduces motor ventilation and cooling, causing overheating and possible burnout.
At least once each year, remove dust and greasy deposits from cooling element fins, motor, fan blades and fan
shroud.
Use a stiff brush or air nozzle for loose dirt or a mild organic alkaline cleaning solution with brush for solid or greasy
deposits. Do not bend or damage cooling element fins. Care must be taken not to damage fan blades as resulting out-
of-balance condition may cause vibration, damage to motor bearings, and possible motor burnout due to overheating.
To clean heavy deposits on outside of core, remove core and tank assembly, plug all openings, and immerse in a mild
organic alkaline solution such as Chemetall Gardoclean S 5219. A 5% to 10% concentration with water is typical,
depending on soil load, and the solution should be heated to 140 to 160F to increase effectiveness. Agitation of the
core increases effectiveness and ultrasonic equipment can be effective for breaking up deposit particles. The length of
time required to accomplish cleaning is dependent upon the degree of fouling. Do not use a caustic solution boil out
tank for cleaning, as damage to the core fins will result. The wash cycle should be followed by one 60 sec rinse cycle
with clean water.
INTERNAL CLEANING
Once a year, piping should be disconnected and a degreasing agent or flushing oil circulated through the unit to
remove sludge from turbulators and internal tube surfaces to return the unit to full capacity. For degreasing,
Chemetall Gardoclean S 5219 as indicated above may be used. A pump and filtration system can be used to circulate
the degreasing agent or flushing oil and capture deposit particles. Ideally the solution should be circulated in reverse
direction to the normal flow. If degreasing solution as recommended above is used, an oil flush of the core should
follow soon after to avoid rust formation on steel surfaces. A thorough cleaning of the entire system is preferable to
avoid carry over from unclean piping, pump and accessories. If this is done, filter or strainer should be removed and
necessary adjustment or removal of by-pass valve effected. Regular cleaning or replacement of filter or strainer will
help maintain a clean and efficiently operating system.
SERVICE
When ordering replacement parts or making inquiry regarding service, always provide model, part, and serial numbers
which can be obtained from the nameplate located on the plenum panel on the back side of the cooler.

Part Number 368228
Sheet 4 of 5
REV D

541
7270 S. 13TH St. Ste 201

Oak Creek, WI 53154
Phone: (414) 768-7420
Fax: (414) 762-0632
OCS Oil Coolers
CHANGE HISTORY TABLE
Rev. ECN Description By Date
New Release 1/1/00
A 3/20/06
B 06191 Replaced drawing ALM 6/23/06
C 10402 Consolidated info into one pdf file; recommended cleaner was Fine Organics BLT 10/27/10
2223 and Keychem 06000; added wash cycle note
D 16359 Add Fan Blade Clearance section; update file format, torque chart, and piping DES 10/17/16
diagrams

Part Number 368228
Sheet 5 of 5
REV D

542
A.11 4360350: Dust Seal Blower

543
A.11.1 Operation and Maintenance Instructions
Operating and Maintenance Instructions

3BA Regenerative Blowers

544
Operation and Maintenance Instructions (Sheet 2)

545
INSTALLATION & OPERATING MANUAL

3BA REGENERATIVE BLOWERS
Table of Contents
Section: Page Number:
1. Safety 4
1.1 General Safety Precautions 4
1.2 Clothing and Protective Gear 4
1.3 Electrical Safety 4
1.4 Vacuum and Gauge Pressure Safety 5
1.5 Installation/Start-up 5
1.6 Maintenance Procedures 6
1.7 Hot Surfaces 6
1.8 Hearing Protection 6
1.9 Safety Guidelines for Transport of the unit 7
2. Technical Data 8
Table 1: 3 Phase, Single Stage, 50 Hertz 10
Table 2: 3 Phase, Single Stage, 60 Hertz 11
Table 3: 3 Phase, Two/Three Stage, 50 Hertz 12
Table 4: 3 Phase, Two/Three Stage, 60 Hertz 13
Table 5: Single-phase, 50 Hz 14
Table 6: Single-phase, 60 Hz 14
Table 7: Single Stage – Approx. Temperature Rise 16
Table 8: Two/Three Stage – Approx. Temperature Rise 17
Table 9: Tightening Torque Specifications 18
3. Installation 20
3.1 Installation Procedure 21
4. Start-up 23
4.1 Start-up Procedure 23
4.2 Potential Risks For Operators 23
5. Maintenance and Servicing 24

5.1 Troubleshooting Chart 25
5.2 Lifting 27
5.3 Storage 28
5.4 Disposal 28
6. Exploded-View Drawings 29
3BA1 Single-Stage 29
3BA1 Two-Stage 30
3BA1943 Two-Stage 31
3BA7 Single-Stage 32
3BA7 Two-Stage 33
Warranty Statement 34

546
1. Safety
1.1 General Safety Precautions
WARNING: Improper operation of 3BA units can result in serious or

even fatal injuries. Please make sure all personnel have read and
understood this manual before operating the unit.
All personnel should familiarize themselves with the units’ specifications

and be careful not to exceed the unit’s capacity.
Transport, installation, operation, shut-down, maintenance and disposal of

3BA units should be carried out by qualified professionals.
Do not attempt to start or run the unit unless it has been completely
assembled. Particular attention should be paid to: the vacuum
pump/compressor cover, the muffler on the inlet and discharge
connections, and the fan guard.
The standard 3BA unit must never come into contact with flammable
substances.
1.2 Clothing and Protective Gear
It is recommended that all personnel wear proper protective gear while operating
the unit. This may include eye protection, gloves and helmets.
Please be aware that it is possible for hair and clothing to be pulled into the unit.
Avoid wearing loose-fitting clothing near the unit while it is operating and wear a
hairnet if necessary.
1.3 Electrical Safety
Electrical installation should only be done by qualified electricians. Before

doing any electrical work on a 3BA unit, please ensure that power to the unit
has been disconnected. Do not attempt to open the unit’s terminal box until you
have made certain that the unit is not connected to a power source.
The terminal box must be kept free of dirt and moisture at all times. Make sure
the terminal box cover and cable entries are tightly sealed so they remain
dustproof and waterproof. Check the terminal box regularly to make sure it is
sealed and free of debris and moisture.

547
1.4 Vacuum and Gauge Pressure Safety
In order to avoid dangerous situations associated with vacuum and gauge

pressure, please utilize secure mounting elements, connections, lines, fittings,
and containers. Pipes/hoses must be securely connected to the inlet and
discharge connections. The inlet and discharge connections and the pipes/hoses
connected to them must not be closed, clogged, or soiled. Check regularly to
ensure that these connections and mountings are not becoming unseated. If
necessary, support pipes and hoses to ensure that there is no tension on the
connections. Failure to observe these precautions can lead to sudden
evacuation of hazardous fluids or dangerous suction that can pull hair or
clothing into the unit.
1.5 Installation/Start-up
The unit and any lines connected to it must be securely installed. In particular,
the feed pipes must be securely routed, e.g. in cable ducts, in the floor, etc.
If a separate control panel or other such interface will be used to start and stop
the unit, it should be installed in an area with an unobstructed view of the unit to
ensure that it is not switched on while being serviced.
Excess vibration can cause damage to the unit and/or unsafe conditions. Install
the unit on a solid foundation or a solid mounting surface. Check screw
glands/unions for strength and firm seating.
Cables and pipes should be installed in a recess in the floor or duct so they do
not present a tripping hazard.
To ensure sufficient cooling of the unit, ventilation screens and openings must
remain clear. Ensure that discharge air from other units cannot be pulled into the
unit.
Make sure that the inlet and pressure lines are clearly marked to avoid confusion.
Interchanged inlet and pressure lines can lead to damage to the unit and/or
serious injury.
Install a filter in the inlet pipe and replace it regularly. If particulates or debris
enter the unit, the blades of the impellers can be damaged and blades could
potentially break off, potentially creating a hazardous situation.
If re-starting the unit after it has been idle for a long period of time, measure the
insulation resistance of the motor. If values are less than 1 k Ω per volt of nominal
voltage, the winding may be too dry.

548
If the unit is installed or stored in an environment with a temperature of over

104°F (40°C) be aware that the winding may be damaged and the grease might
need to be changed more often.
1.6 Maintenance Procedures
Before beginning work on the pump-motor unit, please take the following
precautions:
• Make sure power has been completely disconnected

• Wait for the unit to come to a complete stop.
• Allow the unit time to cool.
• Shut off lines and release pressure
• Make certain that no vacuum or gauge pressure is present in the lines/tanks to
be opened.
• Make sure that no fluids can escape
Please note that the rotating impeller is accessible when the inlet and discharge
connections are open. Do not reach into the unit through open connections or
insert objects into the unit through any openings. Serious injury could occur. If
the unit is running without piping or tubing, provide the inlet and discharge of the
unit with either additional mufflers or piping of a sufficient length to prevent
access to the impeller.
Check regularly to ensure the terminal box is free of any dirt or foreign
substances and there is no moisture or humidity present. Make certain the
terminal box cover and cable entries are tightly closed.
1.7 Hot Surfaces
During operation, the surface of the unit can reach temperatures of 320° F
(160° C). It is advisable to cover the unit with suitable touch protection (e.g. a
perforated plate or wire cover). Do not touch the unit during operation, and allow
time to cool after shut-down. Temperature-sensitive parts such as lines or
electronic components should not come into contact with the surface of the unit.
1.8 Hearing Protection
Make certain any missing or defective silencers are replaced. Noise emitted by
the unit can cause serious hearing damage. Conduct a noise measurement test
while the unit is running. If the unit operates over 90 dB(A), please place a
warning sign in the area where the unit has been installed and make certain that

549
any personnel working in the vicinity wear ear protection at all times while the
unit is running.
1.9 Safety Guidelines for Transport of the unit:
Prior to transport and handling, please make sure that all components are
properly assembled and secure. Any machinery used to transport these units
must have the proper lifting capacity. Please consult the table on page 27 to find
the weight of the unit being handled. Do not stand or walk under suspended
loads.
If a 3BA unit has come in contact with any dangerous substances, it must
be decontaminated before being sent to Airtech for repair evaluation.

550
2 Technical Data
These operating instructions cover the Airtech 3BA side channel vacuum pumps
and compressors supplied with standard TEFC motors. Other configurations are
available including V-belt driven units, units with explosion proof motors,
mechanical seals, magnetic drives, coatings and modifications for high pressure
service. Airtech can provide any combination of modifications to meet your
application requirements. Such blowers, however, are outside the scope of this
manual.
Description
All regenerative blowers are dynamic compression devices and utilize a non-
contacting impeller to accelerate the gas and a specially designed housing to
compress the gas. Cooling is accomplished by using the motor fan to blow air
over the housing. In larger models, the housing is specially designed with
cooling fins to allow a wider range of operation. Both the inlet and outlet ports
have built-in silencers and mesh screens. Both the inlet and outlet have an
inside connection thread corresponding to DIN ISO 228. On larger units, multiple
suction and discharge connection configurations may be available.
The wetted parts are constructed of Aluminum on all models. The blower shares
a bearing with the motor. The seal between the bearing and the motor is not gas
tight in most models, therefore these blowers are not recommended for handling
of toxic or explosive gases. (Contact Airtech Vacuum, Inc. for additional options
if explosive or toxic gases will be handled.)
A full range of accessory items are available, including vacuum or pressure relief
valves, check valves, suction filters, motor starters, vacuum/pressure cross-over
valves, and in-line filters.
Application/Installation Environment
CAUTION! These blowers are designed for use in general industry.

Suitable personnel protection according to OSHA requirements is
provided, but the equipment should not be operated in residential settings.
Airtech blowers can be operated as either vacuum pumps or compressors. They

are suitable for use with air having a relative humidity up to 90 percent, but not
generally suitable for handling corrosive or erosive gases. Special versions for
toxic or aggressive gases may be available. Use of the standard blower in
aggressive environments may cause damage to the blower or exposure to gases
being handled in the local environment.

551
CAUTION! Dangerous (flammable or explosive) or aggressive (corrosive)

gases should not be handled by the standard blower.
Handling of flammable or aggressive gases and vapors may be possible by using

a specially configured or modified blower. Contact factory for additional
information. The standard blower is not suitable for operation in explosive
environments as defined by NFPA 70. Contact factory for assistance.
CAUTION! The ambient and suction temperatures should be between 40

and 105 F. For temperatures outside this region, please contact the
factory.
The maximum permissible pressure difference for vacuum or pressure is

dependent on the motor rating (See Tables 1 to 4 for detailed information by
model number.) and power supply frequency. The figures in Tables 1 to 4 are
computed assuming an ambient temperature of 77 F (25 C) and a local
barometric pressure of 1013 mbar (sea level). Operation at an ambient
temperature of 104 F (40C) is the maximum permissible, and will result in a
reduction of 10 percent on maximum vacuum or pressure attainable by the unit.
For temperatures between 77 F and 104 F, reduce the maximum pressure
reduction is a linear function of temperature.

552
Table 1. Three-phase, Single Stage, 50 Hertz
Rated Voltage Motor Open Flow Maximum Sound

Model Power Current Capacity Pressure Pressure
HP/kW (Amps) CFM/m3/hr (mbar) Level (dBA)
3BA1300-7AT06 .33/.25 200-240/345-415 2.1/1.2 48/82 -100/100 53
2BA1300-7AT16 .54/.4 200-240/345-415 2.6/1.5 48/82 -120/130 53
3BA1400-7AT06 .94/.7 200-240/345-415 3.8/2.2 84/142 -120/120 63
2BA1400-7AT16 1.15/.85 200-240/345-415 4.2/2.4 84/142 -160/160 63
3BA1400-7AT26 1.75/1.3 200-240/345-415 5.7/3.3 84/142 -170/200 63
3BA1500-7AT06 1.15/.85 200-240/345-415 4.2/2.4 120/204 -100/100 64
3BA1500-7AT16 1.75/1.3 200-240/345-415 5.7/3.3 120/204 -170/170 64
3BA1500-7AT26 2.15/1.6 220-250/415-460 7.5/4.3 120/204 -200/190 64
3BA1500-7AT36 2.96/2.2 200-240/345-415 9.7/5.6 120/204 -220/270 64
3BA1530-7AT16 1.75/1.3 200-240/345-415 5.7/3.3 165/280 -120/110 65
3BA1530-7AT26 2.15/1.6 200-240/345-415 7.5/4.3 165/280 -160/150 65
3BA1530-7AT36 2.96/2.2 200-240/345-415 9.7/5.6 165/280 -220/230 65
3BA1600-7AT06 2.15/1.6 200-240/345-415 8.5/4.9 188/320 -160/150 69
3BA1600-7AT16 2.96/2.2 200-240/345-415 9.7/5.6 188/320 -190/190 69
3BA1600-7AT26 4.04/3.0 200-240/345-415 12.5/7.2 188/320 -260/270 69
3BA1600-7AT36 5.4/4.0 200-240/345-415 13.0/7.5 188/320 -290/360 69
3BA1630-7AT06 2.15/1.6 200-240/345-415 8.5/4.9 240/408 -160/150 69
3BA1630-7AT16 2.96/2.2 200-240/345-415 9.7/5.6 240/408 -190/190 69
3BA1630-7AT26 4.04/3.0 200-240/345-415 12.5/7.2 240/408 -260/270 69
3BA1630-7AT36 5.4/4.0 200-240/345-415 15.6/9.0 240/408 -260/290 69
3BA1800-7AT06 5.4/4.0 200-240/345-415 15.6/9.0 280/476 -200/200 70
3BA1800-7AT16 7.4/5.5 200-240/345-415 23/13.3 280/476 -300/300 70
3BA1800-7AT26 10/7.5 200-240/345-415 29/16.7 280/476 -320/430 70
3BA1830-7AT06 5.4/4 200-240/345-415 15.6/9 400/680 -150/140 76
3BA1830-7AT16 7.4/5.5 200-240/345-415 23/13.3 400/680 -200/190 76
3BA1830-7AT26 10/7.5 200-240/345-415 29/16.7 400/680 -270/260 76
3BA1900-7AT06 10.8/8 200-240/345-415 31.5/18.2 568/965 -190/190 74
3BA1900-7AT16 16.8/12.5 200-240/345-415 48.5/28 568/965 -290/280 74
3BA1900-7AT36 25/18.5 200-240/345-415 64.5/37 568/965 -362/462 74
3BA1930-7AT16 16.8/12.5 200-240/345-415 48.5/28 744/1264 -290/280 71
3BA1930-7AT36 25/18.5 200-240/345-415 64.5/37 744/1264 -310/310 71
3BA1930-7AT36 25/18.5 200-240/345-415 64.5/37 744/1264 -310/310 71
3BA7310-0AT167 .75/.55 200-240/345-415 2.8/1.6 40/68 -250/250 57
3BA7410-0AT167 1.5/1.1 200-240/345-415 5.4/3.1 50/84 -300/380 58
3BA7510-0AT168 2/1.5 200-240/345-415 7.5/4.3 70/120 -370/650 64
3BA7510-0AT268 3/2.2 200-240/345-415 9.7/5.6 70/120 -310/430 64
3BA7610-0AT168 3/2.2 200-240/345-415 9.7/5.6 96/163 -310/430 65
3BA7610-0AT368 4.4/3.3 200-240/345-415 13/7.5 96/163 -500/750 65

553
Table 2. Three-phase, Single-stage, 60 Hz
Rated Motor Open Flow Maximum Sound

Model Power Voltage Current Capacity Pressure Pressure
3BA1300-7AT06 .39/.29 220-250/415-460 1.74/1.0 60/102 -100/100 56
2BA1300-7AT16 .67/.5 220-250/415-460 2.6/1.5 60/102 -150/160 56
3BA1400-7AT06 1.12/.83 220-250/415-460 3.75/2.15 105/179 -130/130 64
3BA1400-7AT16 1.28/.95 220-250/415-460 4.35/2.5 105/179 -160/160 64
3BA1400-7AT26 2/1.5 220-250/415-460 5.5/3.2 105/179 -210/200 64
3BA1500-7AT06 1.28/.95 220-250/415-460 4.35/2.5 150/255 -80/70 70
3BA1500-7AT16 2/1.5 220-250/415-460 5.5/3.2 150/255 -150/140 70
3BA1500-7AT26 2.7/2.05 220-250/415-460 7.5/4.4 150/255 -220/210 70
3BA1500-7AT36 3.4/2.55 220-250/415-460 9.0/5.3 150/255 -260/290 70
3BA1530-7AT16 2/1.5 220-250/415-460 5.7/3.3 200/340 -90/80 71
3BA1530-7AT26 2.7/2.05 220-250/415-460 7.6/4.4 200/340 -260/270 70
3BA1530-7AT36 3.4/2.55 220-250/415-460 10.3/6.0 200/340 -260/250 70
3BA1600-7AT06 2.7/2.05 220-250/415-460 7.5/4.4 235/400 -160/150 72
3BA1600-7AT16 3.4/2.55 220-250/415-460 9.0/5.3 235/400 -190/190 72
3BA1600-7AT26 4.6/3.45 220-250/415-460 12.0/6.5 235/400 -240/230 72
3BA1600-7AT36 6.1/4.6 220-250/415-460 15.2/8.5 235/400 -320/310 72
3BA1630-7AT06 2.7/2.05 220-250/415-460 7.5/4.4 300/510 -160/150 72
3BA1630-7AT16 3.4/2.55 220-250/415-460 9.0/5.3 300/510 -190/190 72
3BA1630-7AT26 4.6/3.45 220-250/415-460 12.0/6.5 300/510 -240/230 72
3BA1630-7AT36 6.1/4.6 220-250/415-460 15.2/8.5 300/510 -260/260 72
3BA1800-7AT06 6.1/4.6 220-250/415-460 15.2/8.5 350/595 -160/160 74
3BA1800-7AT16 8.4/6.3 220-250/415-460 20/11.2 350/595 -300/280 74
3BA1800-7AT26 11.5/8.6 220-250/415-460 27.5/15 350/595 -350/400 74
3BA1830-7AT06 6.2/4.6 220-250/415-460 15.2/8.5 500/850 -90/90 79
3BA1830-7AT16 8.4/6.3 220-250/415-460 20/11.2 500/850 -180/180 79
3BA1830-7AT26 11.5/8.6 220-250/415-460 27.5/15 500/850 -270/260 79
3BA1900-7AT06 12.1/9 220-250/415-460 31.5/18.2 710/1207 -150/140 79
3BA1900-7AT16 19.5/14.5 220-250/415-460 50/29 710/1207 -270/260 79
3BA1900-7AT36 28.7/21.3 220-250/415-460 68/39 710/1207 -382/422 79
3BA1930-7AT16 19.5/14.5 220-250/415-460 50/29 930/1581 -270/260 75
3BA1930-7AT36 28.7/21.3 220-250/415-460 68/39 930/1581 -300/280 75
3BA7210-0AT167 1.1/.83 220-250/415-460 3.75/2.15 35/60 -270/320 62
3BA7310-0AT167 1.1/.83 220-250/415-460 3.75/2.15 48/82 -260/250 62
3BA7410-0AT167 2/1.5 220-250/415-460 5.5/3.2 60/102 -340/370 62
When operating at altitudes above 3280 feet (1000 m) above mean sea level, contact Airtech Inc.
CAUTION! Operation of the unit outside the recommended range of

pressures and ambient conditions will result in shorted operating life.

554
Table 3. 3 Phase, Two/Three Stage, 50 Hertz
Motor Open Flow Maximum Sound

Rated Power
Model Voltage Current Capacity Pressure Pressure
HP/kW
(Amps) CFM/m3/hr (mbar) Level (dBA)
3BA1310-7AT26 .94/.7 200-240/345-415 3.8/2.2 48/81.6 -120/120 55
3BA1410-7AT36 2.15/1.6 200-240/345-415 7.5/4.3 84/142.8 -200/190 66
3BA1410-7AT46 2.96/2.2 200-240/345-415 9.7/5.6 84/142.8 -320/420 66
3BA1510-7AT46 4.04/3.0 200-240/345-415 12.5/7.2 121.6/206.7 -340/410 72
3BA1510-7AT56 5.39/4.0 200-240/345-415 17.4/10 121.6/206.7 -390/440 72
3BA1610-7AT36 2.9/2.2 200-240/345-415 9.7/5.6 188/319.6 -190/190 73
3BA1610-7AT26 4.04/3.0 200-240/345-415 12.5/7.2 188/319.6 -260/270 73
3BA1610-7AT36 5.39/4.0 200-240/345-415 13.0/7.5 188/319.6 -290/360 73
3BA1610-7AT46 7.41/5.5 200-240/345-415 23/13.3 188/319.6 -420/500 73
3BA1610-7AT56 10.1/7.5 200-240/345-415 29/16.7 188/319.6 -420/610 73
3BA1640-7AT36 5.39/4.0 200-240/345-415 13.0/7.5 280/476 -290/360 74
3BA1640-7AT46 7.41/5.5 200-240/345-415 23/13.3 280/476 -420/500 74
3BA1640-7AT56 10.1/7.5 200-240/345-415 29/16.7 280/476 -420/610 74
3BA1810-7AT16 7.4/5.5 200-240/345-415 23/13.3 280/476 -420/500 74
3BA1810-7AT26 10.1/7.5 200-240/345-415 29/16.7 280/476 -320/430 74
3BA1810-7AT36 14.8/11 200-240/345-415 29/16.7 280/476 -430/600 74
3BA1810-7AT46 20.2/15 200-240/345-415 56.5/32.5 280/476 -460/670 74
3BA1840-7AT26 10.1/7.5 200-240/345-415 29.0/16.7 280/476 -320/430 74
3BA1840-7AT36 14.8/11.0 200-240/345-415 48.5/28.0 280/476 -430/600 74
3BA1910-7AT16 16.8/12.5 200-240/345-415 48.5/28 624/1061 -290/280 74
3BA1910-7AT36 26.95/20.0 200-240/345-415 69/40 624/1061 -443/502 74
3BA1910-7AT46 33.51/24.98 200-240/345-415 90/52 624/1061 -443/592 84
3BA19437AT26 20.1/15 200-240/345-415 59/34 1200/2040 -160/170 75
3BA19437AT36 26.8/20 200-240/345-415 69/40 1200/2040 -250/230 75
3BA19437AT46 33.5/25 200-240/345-415 90/52 1200/2040 -310/280 75
3BA7220-0AT567 2/1.5 200-240/345-415 7.5/4.3 28/48 -370/650 58
3BA7320-0AT467 1.5/1.1 200-240/345-415 5.4/3.1 40/68 -300/380 58
3BA7320-0AT567 2/1.5 200-240/345-415 7.5/4.3 40/68 -480/450 59
3BA7420-0AT267 2/1.5 200-240/345-415 7.5/4.3 50/84 -480/450 61
3BA7420-0AT567 4.4/3.3 200-240/345-415 13/7.5 50/84 -500/750 61
3BA7520-0AT268 3/2.2 200-240/345-415 9.7/5.6 70/120 -470/460 64
3BA7620-0AT368 4.4/3.3 200-240/345-415 13/7.5 96/163 -500/750 68
3BA7620-0AT468 5.4/4 200-240/345-415 14/8.1 96/163 -370/650 67
3BA7620-0AT568 7.5/5.5 200-240/345-415 19.9/11.5 96/163 -520/750 68
3BA7630-0AT668 10.1/7.5 200-240/345-415 29/16.7 96/163 -420/610 77

555
Table 4. 3 Phase, Two/Three Stage, 60 Hertz

Rated Motor Open Flow Maximum Sound
Model Power Voltage Current Capacity Pressure Pressure
3BA1310-7AT26 1.11/.83 220-250/415-460 3.75/2.15 60/102 -130/130 61
3BA1410-7AT36 2.7/2.05 220-250/415-460 7.5/4.4 105/179 -220/210 69
3BA1410-7AT46 3.4/2.55 220-250/415-460 9.0/5.3 105/179 -350/440 69
3BA1510-7AT46 4.6/3.45 220-250/415-460 12.0/6.5 152/258 -380/360 74
3BA1510-7AT56 6.1/4.6 220-250/415-460 15.2/8.5 152/258 -410/480 74
3BA1610-7AT36 3.4/2.55 220-250/415-460 9.0/5.3 235/400 -190/190 76
3BA1610-7AT26 4.6/3.45 220-250/415-460 12.0/6.5 235/400 -240/230 76
3BA1610-7AT36 6.4/4.8 220-250/415-460 16.5/9.8 235/400 -320/310 76
3BA1610-7AT46 8.4/6.3 220-250/415-460 20/11.2 235/400 -440/440 76
3BA1610-7AT56 11.5/8.6 220-250/415-460 27.5/15.0 235/400 -440/670 76
3BA1640-7AT36 6.1/4.6 220-250/415-460 15.2/8.5 350/595 -320/310 78
3BA1640-7AT46 8.4/6.3 220-250/415-460 20.0/11.2 350/595 -440/440 78
3BA1640-7AT56 11.5/8.6 220-250/415-460 27.5/15.0 350/595 -440/670 78
3BA1810-7AT16 8.4/6.3 220-250/415-460 20.0/11.2 350/595 -440/440 78
3BA1810-7AT26 11.5/8.6 220-250/415-460 27.5/15.0 350/595 -350/400 78
3BA1810-7AT36 17/12.6 220-250/415-460 50.2/29.0 350/595 -460/600 78
3BA1810-7AT46 23.3/17.3 220-250/415-460 60.0/34.5 350/595 -490/750 78
3BA1840-7AT26 11.5/8.6 220-250/415-460 27.5/15.0 350/595 -350/400 78
3BA1840-7AT36 17/12.6 220-250/415-460 50.2/29.0 350/595 -460/600 78
3BA1910-7AT16 19.5/14.5 220-250/415-460 50.0/29.0 780/1326 -270/260 84
3BA1910-7AT36 31/23 220-250/415-460 72 /42 780/1326 -443/433 84
3BA1910-7AT46 38.9/28.9 220-250/415-460 90/52 780/1326 -443/542 84
3BA19437AT26 23.4/17.5 220-250/415-460 63/36.5 1440/2447 -120/110 84
3BA19437AT36 30.8/23 220-250/415-460 72/42 1440/2447 -190/180 84
3BA19437AT46 38.8/28.9 220-250/415-460 90/52 1440/2447 -265/230 84
3BA7220-0AT567 2.7/2.05 220-250/415-460 7.5/4.4 35/60 -500/740 62
3BA7320-0AT467 2/1.5 220-250/415-460 5.5/3.2 48/82 -340/370 63
3BA7320-0AT567 2.7/2.05 220-250/415-460 7.5/4.4 48/82 -430/410 63
3BA7420-0AT267 2.7/2.05 220-250/415-460 7.5/4.4 60/102 -430/410 66
3BA7420-0AT567 5.1/3.8 220-250/415-460 13.5/7.8 60/102 -510/850 66
3BA7520-0AT268 3.4/2.55 220-250/415-460 9/5.3 84/143 -500/450 70
3BA7620-0AT368 5.1/3.8 220-250/415-460 13.5/7.8 115/196 -510/850 71
3BA7620-0AT468 6.1/4.6 220-250/415-460 15.2/8.5 115/196 -480/500 71
3BA7620-0AT568 8.4/6.6 220-250/415-460 22.5/12.6 115/196 -520/820 72
3BA7630-0AT668 11.5/8.6 220-250/415-460 27.5/15 115/196 -440/670 80
3BA7530-7AT76 6.2/4.6 220-250/415-460 16.3/9.5 82/139 -639/729 73

556
Table 5. Single Phase, 50 Hertz

3BA1100-7AS05 0.27/0.2 230 1.45 24/40 -60/70 50
3BA1200-7AS05 0.33/0.25 115/230 3.5/1.7 35/60 -100/100 50
3BA1300-7AS15 0.5/0.37 115/230 5.4/2.7 48/82 -110/110 53
3BA1330-7AS15 0.5/0.37 115/230 5.4/2.7 60/102 -110/110 54
3BA1400-7AS25 1.47/1.09 115/230 13/6.5 84/142 -149/189 64
3BA1410-7AS25 2/1.49 115/230 22/11 84/142.8 -279/259 66
3BA1500-7AS35 2/1.49 115/230 22/11 120/204 -189/199 64
3BA7210-0AS75 0.74/0.55 115/230 13/6.5 28/48 -229/289 57
3BA7220-0AS75 2/1.49 115/230 19.4/9.7 29/49 -371/600 57
3BA7310-0AS75 1.26/0.93 115/230 15.2/7.6 40/68 -249/351 58
3BA7320-0AS75 2/1.49 115/230 19.4/9.7 40/68 -401/550 59
3BA7410-OAS45 1.47/1.09 115/230 13/6.5 50/84 -299/381 59
Table 6. Single Phase, 60 Hertz

3BA1100-7AS05 0.31/0.23 230 1.3 30/51 -75/80 53
3BA1200-7AS05 0.38/0.28 115/230 5/2.8 48/82 -112/112 53
3BA1300-7AS15 0.6/0.44 115/230 6.0/3.0 60/102 -130/139 56
3BA1330-7AS15 0.6/0.44 115/230 6.0/3.0 74/126 -130/139 57
3BA1400-7AS25 1.74/1.29 115/230 14.0/7.0 105/179 -179/189 64
3BA1410-7AS25 2.35/1.75 115/230 24.0/12.0 105/179 -249/229 69
3BA1500-7AS35 2.35/1.75 115/230 24.0/12.0 150/255 -179/179 70
3BA7210-0AS75 0.84/0.63 115/230 14.2/7.1 35/60 -259/309 62
3BA7220-0AS75 2.35/1.75 115/230 20.6/10.3 35/60 -421/660 62
3BA7310-0AS75 1.47/1.09 115/230 18.0/9.0 48/82 -279/391 62
3BA7320-0AS75 2.35/1.75 115/230 20.6/10.3 48/82 -391/541 63
3BA7410-OAS45 1.74/1.29 115/230 14.0/7.0 60/102 -338/391 62

557
Operation of any blower is possible at 87 Hertz without modification in most

cases. When using a VFD to operate the blower at this frequency, refer to the
nameplate for limits on vacuum and pressure, current draw and motor
performance.
If your specific model number is not listed above, please consult the nameplate
on the unit for electrical data. If the model you are installing is listed above,
please confirm the data on the nameplate. Data in Tables 1 through 4 is subject
to change and is approximate. Be sure to confirm necessary operating data what
that on the nameplate before commissioning the unit.
CAUTION! Do not operate any 3BA blower above 87 Hz without

consultation with the factory. Failure of the blower motor is possible when
operating out of range. Consult with the factory for assistance.

558
Expected temperature rise of the handled gas at maximum allowable pressure

differential and when operating at sea level is indicated below:
Table 7: Single Stage – Approximate Temperature Rise
Maximum Rise at 50 Hz speed Maximum Rise at 60 Hz speed

Blower Model
Degrees F Degrees C Degrees F Degrees C
3BA1100-7..0. 115 64 136 76
3BA1200-7..0. 65 36 101 56
3BA1300-7..0. 90 50 77 43
3BA1300-7..1. 90 50 140 78
3BA1300-7..2. 90 50 158 88
3BA1400-7..0. 99 55 86 48
3BA1400-7..1. 129 72 122 68
3BA1400-7..2. 149 83 167 93
3BA1500-7..0. 86 48 72 40
3BA1500-7..1. 115 64 97 54
3BA1500-7..2. 138 77 122 68
3BA1500-7..3. 203 113 180 100
3BA1500-7..6. 248 138 248 138
3BA1600-7..0. 81 45 68 38
3BA1600-7..1. 145 81 104 58
3BA1600-7..2. 171 95 176 98
3BA1600-7..3. 225 125 185 103
3BA1600-7..6. 248 138 194 108
3BA1600-7..7. 248 138 248 138
3BA1800-7..0. 104 58 104 58
3BA1800-7..1. 153 85 185 103
3BA1800-7..2. 248 138 221 123
3BA1900-7..0. 97 54 95 53
3BA1900-7..1. 182 101 155 86
3BA1900-7..3. 230 128 212 118
3BA1943-7..2. 85 47 75 42
3BA1943-7..3. 130 72 100 56
3BA1943-7..4. 180 100 140 78
3BA7210-0..1.. 126 70 142 79
3BA7310-0..1.. 142 79 142 79
3BA7310-0..2.. 178 99 187 104
3BA7410-0..1.. 194 108 214 119
3BA7510-0..1.. 199 111 232 129
3BA7510-0..2.. 248 138 234 130
3BA7610-0..1.. 244 136 255 142
3BA7610-0..3.. 244 136 255 142

559
Table 8: Two/Three Stage – Approximate Temperature Rise
Maximum Rise Maximum Rise

Blower Model at 50 Hz speed at 60 Hz speed
Degrees F Degrees C Degrees F Degrees C
3BA1310-7..2. 127 71 165 92
3BA1410-7..3. 154 86 149 83
3BA1410-7..4. 181 101 180 100
3BA1510-7..4. 190 106 176 98
3BA1510-7..5. 194 108 201 112
3BA1610-7..1. 92 51 86 48
3BA1610-7..2. 129 72 118 66
3BA1610-7..3. 176 98 167 93
3BA1610-7..4. 221 123 190 106
3BA1610-7..5. 246 137 266 148
3BA1610-7..7. 176 98 167 93
3BA1610-7..8. 176 98 248 138
3BA1810-7..1. 113 63 80 45
3BA1810-7..2. 185 103 140 78
3BA1810-7..3. 248 138 248 138
3BA1910-7..1. 119 66 115 64
3BA1910-7..2. 203 113 169 94
3BA1910-7..3. 248 138 274 152
3BA1910-7..4. 248 138 274 152
3BA7220-0..2.. 131 73 171 95
3BA7220-0..5.. 165 92 230 128
3BA7320-0..5.. 178 99 255 142
3BA7420-0..2.. 192 107 176 98
3BA7420-0..5.. 250 139 243 135
3BA7520-0..2.. 192 107 216 120
3BA7520-0..7.. 257 143 262 128
3BA7530-0..7.. 250 121 250 121
3BA7620-0..3.. 255 142 259 144
3BA7620-0..5.. 255 142 262 146
3BA7630-0..6.. 248 138 248 138

560
Table 9: Tightening Torque Specifications
For non-electrical connections

Thread Ft-lbs maximum torque Nm maximum torque
M4 2.43 3.3
M5 3.25 4.4
M6 6.49 8.8
M8 19.47 26.4
M10 34.10 46.2
M12 56.76 77
For electrical connections

Thread Ft-lbs torque Nm torque
M4 0.6 to 0.9 0.8 to 1.2
M5 1.3 to 1.8 1.3 to 1.8
For metal threaded glands/unions

M12x1.5 3 to 4.5 4 to 6
M16x1.5 3.7 to 5.5 5 to 7.5
M20x1.5 4.4 to 6.6 6 to 9
M32x1.5 5.9 to 8.9 8 to 12
M40x1.5 5.9 to 8.9 8 to 12
For plastic threaded glands/unions

M12x1.5 1.5 to 2.6 2 to 3.5
M16x1.5 2.2 to 3 3 to 4
M20x1.5 3 to 3.7 4 to 5
M32x1.5 3.7 to 5.2 5 to 7
M40x1.5 3.7 to 5.2 5 to 7

561
Operating above the indicated maximum pressure or vacuum would overload the
motor and/or overheat the unit. In addition to the maximum allowable pressure
difference, careful consideration should be given to matching the motor
protection devices (provided by others) to the expected current draw. In no case
should the blower be operated with inadequate motor overload protection.
Since regenerative blowers are dynamic compression devices, the performance

limits shown in Tables 1 to 4 are applicable only for a gas with the same specific
gravity, dynamic viscosity and chemical characteristics as air. For gases with
different physical properties than air, the limits will be different from those shown
in the tables. Please contact Airtech for assistance in determining the proper
blower size and configuration if handling gases other than air.
A vacuum relief valve or pressure relief valve should always be installed at the
suction or discharge of the regenerative blower. This will prevent operation
outside the applicable ranges shown in Tables 1 to 4. If the relief valves were
not specified in the ordering process, please contact Airtech for details, price and
availability of the needed valves before commissioning the unit. Failure to use
the proper relief valve may result in failure of the blower due to operation outside
the applicable limits; any such failure is outside the scope of Airtech’s standard
warranty.
WARNING! Be sure to install the necessary personnel protection devices if

unexpected shut-down of the unit presents danger of death or injury.

562
3. Installation
As illustrated in Figure 1, the Airtech 3BA blower can be installed in any physical
configuration.
CAUTION! Regenerative blowers can have surface temperatures in excess

of 320° F. To avoid burns or other physical injury, take care to avoid
contact with the surfaces of the blower during and immediately after
operation.
To ensure adequate cooling of the blower during operation, install the blower with
the minimum clearance as indicated in the table below.
Minimum installation clearances, 3BA blowers
Range Distance from fan guard Distance from cover

to closest obstruction. (opposite of fan) to
(inches/mm) closest obstruction.
(inches/mm)
3BA11 through 3BA14 1.4/34 0.79/20
3BA15 through 3BA19 2.1/53 1.57/40
3BA72 and 3BA73 1.3/34 1.18/30
3BA74 through 3BA76 2.1/54 1.18/30
Please note that it may be desirable, where possible, to allow for larger
clearances to allow access for maintenance or repair personnel. The noted
clearances are to ensure adequate air flow for cooling only and are a minimum
requirement.
Failure to allow for the noted clearances may result in premature failure of the
blower due to lack of cooling, even if all other precautions are taken as
recommended. For specific advice about installations requiring closer
clearances, please contact Airtech, Inc. for recommendations.
Airtech regenerative blowers can be mounted in any configuration, either

horizontally or vertically mounted. It is not usually necessary to bolt the smaller
blowers to a rigid surface during operation, though this may be desirable to
reduce pipe vibration, movement and noise. Larger models should be bolted in
place, especially when installed vertically, to prevent possible rotation, damage
or injury due to start-up torque.
CAUTION! For installations at altitudes greater than 3250 Feet above sea
level there will be a loss in capacity. Please contact your factory
representative for assistance in determining the extent of the loss of
capacity likely at your specific location.

563
WARNING! Be sure to follow all local codes and regulations with respect
to installation and operation of the blower. The blower motor should be
wired to a branch circuit disconnect and all other safety devices
recommended by the relevant sections of NFPA 70, National Electrical
Code, and in accordance with all applicable state and local regulations and
requirements.
3.1 Installation Procedure
Perform the installation exactly in accordance with the following steps:
1. For vacuum operation, connect the suction pipe to connection A, and for
pressure operation connect the pressure pipe to connection B (See Figure 1).
Install startup screens before startup to protect pump from debris.
CAUTION! Design your

piping system to avoid
unnecessary pressure
loss, which may
significantly affect the
operation of any
regenerative blower.
Contact your Airtech
representative for
assistance in designing
and configuring an
appropriate piping system
for your application.
For alternation between

vacuum and pressure in any
application, changeover valves are available. Use of the changeover valve
allows the same connection to be used for both vacuum and pressure.
2. The electrical data shown in Tables 1 to 4 (pages 10-14) should be confirmed

by examination of the motor data plate on your 3BA blower. The standard motor
features Class F insulation as a standard and are UL recognized for applications
in both Canada and the United States (CUL). Motors are IEC design IP55, equal
to a NEMA TEFC motor design. The connection diagram for the motors can be
found in the inside of the terminal box cover. Be sure to confirm that your
electrical supply has sufficient capacity to operate the blower according to the
nameplate requirements.

564
3. A magnetic motor starter should always be used to connect the motor to the
power supply. It is advisable to use thermal overload motor starters to provide
maximum protection for the motor and wiring. All cabling used on starters should
be secured with good quality cable clamps.
We recommend that the motor starters used feature a time delay trip on high
amperage to avoid nuisance trips on start-up. When the unit is started cold, over
amperage may be experienced for a short time due to the higher resistance of
the windings at lower temperatures.
If using a change over or solenoid valve, ensure that the voltage connected to
the valve matches that shown on the valve instructions or nameplate. Most
valves are rated for 110 Volts 60Hz or 220 Volts 50 Hz. Connection of these
valves to higher voltages may result in immediate valve failure.
WARNING! The electrical installation should be made by a qualified

electrician and in complete compliance with all NFPA 70 (National Electrical
Code) requirements along with all state and local code requirements. The
main disconnect and motors starters are assumed to be provided by
others.
4. Install the necessary relief valves and confirm their proper operation.

565
4. Start-up
CAUTION! Do not start the blower motor more than 10 times in one hour.
If multiple and frequent start-ups are required by your application, install a
minimum run timer in the motor control circuit to avoid decreased motor
life and possible fire due to over-starting of the motor.
1.1 Start-up Procedure
1. Before operation, confirm the correct direction of rotation by jogging (switching

rapidly on and off) the motor and observing the motor fan rotation in the same
direction as the arrow. If the direction of rotation is incorrect, lock out the power
and switch two leads (three phase) or rewire (single phase) to effect the opposite
rotation direction. Recheck the direction of rotation before proceeding.
2. Do not operate the blower at pressure or vacuum ranges that exceed those
shown in Tables one through four for the model being installed. This can be
achieved by use of the recommended relief valve shown in Table 5.
Note: Relief valves that have been factory pre-set have a label indicating the set
pressure and an arrow indicating the direction of flow. The arrow will point into
the pipe when installed in vacuum applications and out of the pipe when installed
in pressure applications. Do not re-set the relief valve if it has been pre-set from
the factory.
In the event the relief valve setting needs to be reset, adjust the set screw to
increase or decrease the tension on the spring. Place the blower in operation
and note the current draw of the motor. When the current draw of the motor is
near the maximum noted on the motor nameplate, tighten the locking nut on the
valve and proceed.
3. When checking the current draw of the motor with an ammeter, be sure to
confirm the voltage at the motor junction box. Low voltage conditions may result
in difficulty starting or in unexpected motor failure or motor starter trips.
1.2 Potential Risks For Operators
Noise emission: Free field noise limits are indicated in Tables 1-4 (pages 10-14).
Hearing protection is not normally required at the expected noise generation
levels in the table; however, local conditions may result in higher ambient noise.
If this is the case and local noise exceeds OSHA recommended levels for
expected exposure time (typically 85 dBA for eight hours), hearing protection
should be used.

566
5. Maintenance and Servicing
WARNING! Be sure the power supply is disconnected and locked out

before attempting to do any maintenance on the unit. It is critical that the
unit be locked out from starting during maintenance as severe injury or
death could result from exposure to high voltage or rotating parts.
CAUTION! Allow the blower to cool to a surface temperature of less than

100 F before attempting maintenance. Prolonged exposure to
temperatures above 120F can cause severe burns.
Clean the blower surfaces periodically to avoid build up of dust or other debris.
Build up of debris can cause overheating and premature failure of the blower.
If an inlet filter is being use, ensure that it remains clean during operation by
examining the filter cartridge for debris build up. Replace dirty or clogged filter
cartridges.
On pressure units, periodically clean the inlet mesh screen to avoid loss of
capacity. If an external inlet filter is used, the
filter element should be cleaned monthly or as
frequently as required by local conditions.
Excessive pressure drop will develop from use
of clogged or dirty filters. This pressure drop
will degrade blower performance and increase
operating temperatures, leading possibly to
premature pump failure.
To replace the filter, remove the wing nut and

cover. Remove the element and either clean
with compressed air or replace. Reassemble in reverse order.
For vacuum applications, the optional in-line vacuum filter must be cleaned
regularly, depending on local conditions. Cleaning can be achieved by blowing
out with compressed air. If cleaning is not possible, replace the cartridge.
Access the cartridge by unhooking the relevant clips and removing the cover.
CAUTION! Do not attempt to check the

filter cartridge during operation of the
blower. Only check the cartridge after
disconnecting the power from the blower
and locking out the power to prevent an
unexpected start.

567
Bearings are grease-packed for life.
5.1 Troubleshooting Chart

Fault Cause Remedy Responsible
Party
Motor does Two or more Check fuses, terminals, etc.. Electrician
not start, no power legs for source of interruption and
noise. interrupted correct.
Motor does One power Check fuses, terminals, etc.. Electrician
not start, supply lead for source of interruption and
humming interrupted correct.
noise. Impeller is Open blower cover, remove Service
jammed. debris, clean. Technician
Check impeller clearance and
reset if necessary.
Defective Replace impeller. Service
Impeller Technician
Defective Replace defective bearing. Service
Bearing Technician
Trip of motor Incorrect Ensure starter setting is Electrician
starter at starter settingcorrect (check current on
start-up nameplate)
Winding short- Megger motor Electrician
circuit
Motor Inspect filters, mufflers and Operator
overloaded connection pipes and clean
due to as required.
operation of
pump at Check relief valve operation.
excessive Reset or replace as
differential necessary.
pressures.
Impeller See above fault Motor does Operator
Jammed not start, humming noise,
cause jammed impeller.
Excessive Lime or other Decalcify or clean unit as Operator
Power deposits required (see Maintenance
Consumption Chart)
No Vacuum Severe leak in Close off pump and run Operator
or Pressure. system deadheaded to confirm pump
is operating properly. If so,
find and fix leak in the
system.
Wrong Check air flow direction and Operator
direction of change direction of rotation if Electrician
rotation necessary.

568
Fault Cause Remedy Responsible

Party
Insufficient System too Use larger system Operator
Vacuum small
Inlet piping Increase pipe diameter to Operator
too long or too reduce pressure loss in inlet
small. piping. Contact Airtech for
assistance in determining
correct pipe size.
Leak at Check for leaks and repair if Operator
connection to necessary.
vacuum
system.
Density of gas Consider increased limits on Airtech
handles operation due to density Engineering
different from differences. Consult Airtech,
air. Inc. for assistance.
Change in Clean impeller and examine Service
impeller for wear. Replace if Technician
geometry due necessary.
to erosion
Inlet filter Change filter element; Operator
clogged. remove clog.
Vacuum relief Reset or replace vacuum Operator
valve relief valve. Contact Airtech
incorrectly set. for assistance.
Seal Replace seal. Service
defective. Technician
Abnormal Flow speed Clean pipes or use larger Operator
flow noises. too high. pipes to connect unit to
process.
Muffler soiled. Clean muffler inserts, replace Operator
if necessary.
Abnormal Ball bearing Replace bearing if required. Service
running noise defective or Technician
insufficient
lubrication on
bearing.
Compressor Seals on Tighten muffler connection. Operator
leaky muffler Replace gasket if necessary.
defective.
Seals in motor Replace as necessary. Service
area defective Technician

569
WARNING! Before attempting an on-site repair, ensure that a qualified

electrician has disconnected the motor from the power supply so that
accidental starting of the motor is impossible.
After repairing the unit, be sure to follow the instructions noted in this manual in
the Installation section (page 20).
5.2 Lifting
For smaller units (less than 65 lbs/ 30 kgs), it may be possible to lift the units
manually. When doing so, be sure to understand the weight of the unit being
lifted and to follow good lifting safety procedures.
Model Weight Model Weight

Lbs/kgs Lbs/kgs
3BA1300-7AT06 20/9 3BA1310-7AT26 33/15

2BA1300-7AT16 22/10 3BA1410-7AT36 55/25
3BA1400-7AT06 29/13 3BA1410-7AT46 59.5/29
3BA1400-7AT26 37.5/17 3BA1510-7AT46 86/39
3BA1500-7AT06 40/18 3BA1510-7AT56 97/44
3BA1500-7AT16 46.5/21 3BA1610-7AT26 104/47
3BA1500-7AT26 51/23 3BA1610-7AT36 119/54
3BA1500-7AT36 55/25 3BA1610-7AT46 163/74
3BA1600-7AT06 57.5/26 3BA1610-7AT56 172/78
3BA1600-7AT16 64/29 3BA1640-7AT36 128/58
3BA1600-7AT26 75/34 3BA1640-7AT46 172/78
3BA1600-7AT36 90.5/41 3BA1640-7AT56 181/82
3BA1800-7AT06 128/58 3BA1810-7AT16 250/113
3BA1800-7AT16 143/65 3BA1810-7AT26 260/118
3BA1800-7AT26 150/68 3BA1810-7AT36 316/143
3BA1900-7AT06 265/120 3BA1810-7AT46 341/155
3BA1900-7AT16 314/142 3BA1840-7AT26 260/118
3BA19437AT26 417/190 3BA1840-7AT36 316/143
3BA19437AT36 463/210 3BA1910-7AT16 409/186
3BA19437AT46 509/231 3BA1910-7AT36 455/206
3BA7210-0AT167 35.3/16 3BA1910-7AT46 500/226
3BA7310-0AT167 35.3/16 3BA7220-0AT567 61.7/28
3BA7410-0AT167 50.7/23 3BA7320-0AT567 66.1/30
3BA7510-0AT168 57.3/26 3BA7420-0AT267 72.7/33
3BA7510-0AT268 63.9/29 3BA7420-0AT567 86/39
3BA7610-0AT168 70.5/32 3BA7520-0AT268 88.2/40
3BA7610-0AT368 77.2/35 3BA7620-0AT368 106/48
3BA7530-0AT768 200/91 3BA7620-0AT568 143/65
3BA7630-0AT668 207/94

570
When lifting 3BA15 through 3BA19 (but not 3BA1943 units) or the 3BA75
through the 3BA76, use the eye bolt provided (eye bolts are not included on
smaller units). One attachment point should be sufficient. Ensure that the crane
is rated for the weight being lifted.
For the 3BA1943, use the eye bolt and the holes in the feet of the blower to lift
and maintain a balanced load.
5.3 Storage
The 3BA units should be stored in a clean, dry environment. If stored in an area
with a humidity of greater than 80 percent, store in a closed container with
desiccant drying agents to avoid damage.
5.4 Disposal
Dispose in accordance with all local health and safety regulations.
Spare parts list are available from your local Airtech service center. Please
contact your local Airtech representative for assistance.
For additional assistance, please contact:
Airtech, Inc.,
301 Veterans Boulevard
Rutherford, NJ, 07070
Phone: 1-201-569-1173
Fax: 201-569-1696.

571

572

573

574

575
Airtech, Inc. (“Company”) Warranty Statement
Company warrants that on the date of shipment to Purchaser the goods will be of the
kind and quality described herein, merchantable, and free of all defects in workmanship
and materials.
If within one year from the date of initial operation, but not more than eighteen months
from date of shipment by the Company, of any item of the goods, Purchaser discovers
that such item was not as warranted above and promptly notifies Company in writing
thereof, Company shall remedy such defect by, at the Company’s option, adjustment,
repair or replacement of the item and any affected part of the good. Purchaser shall
assume all responsibility and expense for removal, reinstallation and freight in
connection with the foregoing remedy. The same obligations and conditions shall
extend to replacement items furnished by the Company hereunder. Company shall have
the right of disposal of items replaced by it. Purchaser shall grant Company access to
the goods at all reasonable times in order for Company to determine any defect in the
goods. In the event that adjustment, repair or replacement does not remedy the defect,
the Company and Purchaser shall negotiate in good faith an equitable adjustment in the
contract price.
The Company’s responsibility does not extend to any item of the goods which has not
been manufactured and sold by the Company. Such item shall be covered only by the
express warranty, if any, by the manufacturer thereof. The Company and its suppliers
shall also have no responsibility if the goods have been improperly stored, handled or
installed, or if the goods have not been operated or maintained according to their ratings
or according to the instructions in Company or supplier furnished manuals, or if
unauthorized repairs or modifications have been made to the goods.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES (EXCEPT

TITLE) INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS, AND CONSTITUTES THE ONLY WARRANTY
OF COMPANY WITH RESPECT TO THE GOODS.
The forgoing states Purchaser’s exclusive remedy against Company and its suppliers for
any defect in the good or for failure of the goods to be as warranted, whether
Purchaser’s remedy is based on contract, warranty, failure of such remedy to achieve its
essential purpose, tort (including negligence), strict liability, indemnity, or any other legal
theory, and whether arising out of warranties, representations, instructions, installations,
or defects from any cause.
Neither Company nor its suppliers shall be liable, whether in contract, warranty, failure of
a remedy to meet its essential purpose, tort (including negligence), strict liability,
indemnity or any other legal theory, for loss of use, revenue or profit or for cost of capital
or of substitute use or performance or for indirect, liquidated, incidental or consequential
damages or for any other loss or cost of a similar type, or for claims by Purchaser for
damages of Purchaser’s customers.

576

577

578
A.12 4709790: Impact Spanner

579
A.12.1 Specifications
Impact Spannner
TMFN 30-40

580
Specifications (Sheet 2)

581

582

583

584

585

586

587
A.13 3480135 & 3480108: Flow

Transmitters

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ਜ਼ᴹ China RoHS㇑᧗⢙䍘䎵䗷ᴰབྷ⎃ᓖ䲀٬Ⲵ䜘Ԧරਧࡇ㺘0068, 0078 and 0183 Temperature

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Part Name Lead Mercury Cadmium
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This table is proposed in accordance with the provision of SJ/T11364.
O: ᜿Ѫ䈕䜘ԦⲴᡰᴹ൷䍘ᶀᯉѝ䈕ᴹᇣ⢙䍘Ⲵਜ਼䟿൷վҾGB/T 26572ᡰ㿴ᇊⲴ䲀䟿㾱≲
O: Indicate that said hazardous substance in all of the homogeneous materials for this part is below the limit
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X: Indicate that said hazardous substance contained in at least one of the homogeneous materials used for this part is
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Spare Parts Descriptions for Assemblies
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A.16 4406657: Safety Coupling

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A.16.2 Manual (PENDING)

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ORIGINAL EQUIPMENT MANUFACTURERS (OEM) MANUAL

Appendix A: OEM Documentation

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

A.7.4 Manual Shut-Off Valve Repair Parts Sheet . . . . . . . . . . . . . . . . . . . . . . . . . .388

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

1.1 Using this Manual

1.2 FLSmidth Offices

1.3 Original Equipment Manufacturer

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

THIS PAGE INTENTIONALLY LEFT BLANK

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

A.1 1000657353: Lubrication and

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

A.1.1 General Arrangement

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

A.1.2 Electrical Schematic

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

Electrical Schematic (Sheet 2)

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

Electrical Schematic (Sheet 3)

NO MORE THAN ONE WIRE SHALL BE TERMINATED IN ANY ONE

WIRE LABELS SHALL BE ORIENTATED SUCH THAT THEY READ

LEFT TO RIGHT ORBOTTOM TO TOP

GRAFOPLAST SI2K STYLE

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

Electrical Schematic (Sheet 4)

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

A.1.3 Hydraulic Circuit with Parts List

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

Hydraulic Circuit with Parts List (Sheet 2)

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED.

3" ANSI-150 OUTLET POINT

A.1.5 Installation, Operation, and Maintenance Manual

DCAU Procedure P5131MFC-IOM

Process management First edition

P5131MFC Gyratory Crusher Lube Unit

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

IOM Manual (Sheet 2)

Installation, Operation & Maintenance Manual

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

IOM Manual (Sheet 3)

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

IOM Manual (Sheet 4)

Rev. Revision Description Date

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

IOM Manual (Sheet 5)

Main Lubrication System:

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

IOM Manual (Sheet 6)

Main lube Oil Supply:

Main Lubrication Manifold Function Description:

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

IOM Manual (Sheet 7)

3 Installation, Operating and Maintenance Safety Information

3.2 Intended use

3.2.1 Hydraulic power units

3.2.2 Hydraulic assemblies

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702744 1

IOM Manual (Sheet 8)

3.2.3 Improper use

3.2.4 Qualification of personnel

3.2.5 Safety instructions in this document