Instruction Manual Moving Floor Host

Operating Instructions
Moving Floor system
Hydraulic Installation
Molenmaker Techniek B.V.
Wagenmakersstraat 14
8601 VA Sneek
Tel: +31 515 – 434 226

Internet: www.molenmaker-techniek.nl
E-Mail: info@molenmaker-techniek.nl
Revision 0 Date: 29-9-2021
System Information
Client: Host Biogas B.V.
Year: 2021
Order number MTS: 2021178
Project manager MTS: N. Thalens
Date: 29 September 2021
Operations and maintenance manual Moving Floor System 2

Contents
Technical data ............................................................................................................................ 4
Preface ........................................................................................................................................ 5
Chapter 1 Introduction ............................................................................................................... 7
1.1 Purpose of the hydraulic installation ........................................................................... 7
1.2 Circumstances of use ................................................................................................... 7
1.3 Personal protection gear .............................................................................................. 7
Chapter 2 Safety Measures ......................................................................................................... 8
2.1 Safety measures for the staff ............................................................................................ 8
2.2 Organizational measures to increase safety ..................................................................... 8
2.3 Safety precautions for the installation .............................................................................. 9
2.3.1 General ...................................................................................................................... 9
2.3.2 Hydraulics ................................................................................................................. 9
2.4 Emergency Situation ........................................................................................................ 9
Chapter 3 Installation of the system ......................................................................................... 10
Chapter 4 Maintenance............................................................................................................. 12
4.1 General ........................................................................................................................... 13
4.2 Hydraulic system ............................................................................................................ 14
4.2.1 Checking the hydraulic installation ......................................................................... 14
4.2.2 Servicing the installation ......................................................................................... 15
4.2.2.1 Taking an oil sample ........................................................................................ 15
4.3.1 Replacing the oil...................................................................................................... 16
4.3.1.1 Draining the oil................................................................................................. 16
4.3.1.2 Filling the system with oil ................................................................................ 16
4.3.1.3 Commissioning................................................................................................. 17
4.3.2 Replacement of hydraulic hoses .............................................................................. 17
4.3.3 Replacement of seals ............................................................................................... 17
4.4 Electric system ............................................................................................................... 18
4.5 Mechanical components ................................................................................................. 18
4.6 Recommended spare parts .............................................................................................. 18
Chapter 5 Malfunctions ............................................................................................................ 19
5.1 Searching for the cause of a malfunction ....................................................................... 19
5.1.1 Determining the cause of a malfunction ................................................................. 19
5.2 List of malfunctions ....................................................................................................... 21
Chapter 6 Disposal ................................................................................................................... 24
6.1 General precautions ........................................................................................................ 24
6.2 Removing the oil and hydraulic components ................................................................. 24
6.2.1 Disassembling the hydraulic components ............................................................... 24
6.3 Disassembling the remaining parts ................................................................................ 25
Appendix I Technical data ....................................................................................................... 26
I.1 General ......................................................................................................................... 26
I.2 Cylinders ...................................................................................................................... 26
I.3 Pump unit ..................................................................................................................... 27
I.4 Hydraulic oil ................................................................................................................. 27
I.5 Electrical data ............................................................................................................... 27
Appendix II Hydraulic diagram ............................................................................................... 28
Appendix III Technical drawings ............................................................................................. 29
Appendix IV IIB-declaration ................................................................................................... 30
Appendix V Test reports .......................................................................................................... 31
Appendix VI Technical documentation ................................................................................... 32

Technical data
Total installed power: 11 kW
Electrical current: 400/690V 50 Hz 3 phase + N
Number of pumps: 2
Volume of reservoir: 150 liter
Oil type: Mobil DTE 32
Cilinder diameter: ø160 mm
Piston rod diameter: ø90 mm
Stroke: 700 mm
Number of cylinders: 2

Preface
This manual contains all de information that is needed for the proper use of the hydraulic in-
stallation.
The manual is intended for people who will be working with the hydraulic installation and for
people who will be maintaining and possibly repairing the installation.
When intending to perform maintenance or repairs, be sure to read at least the chapters “Safe-
ty measures”, “Maintenance” and “Failures”, before you start with the work.
Two copies of this manual are supplied with the installation. One copy should be kept in the
vicinity of the installation, so that it can be consulted in case there are questions or concerns
with regard to the operation of the installation. The second copy should be kept in a secure
location, so that it can be consulted in case the first copy is damaged or lost. New copies of
this manual can be ordered from Molenmaker Techniek B.V.
This manual contains the following chapters:
In Chapter 1 “Introduction” the purpose of the installation and a few circumstances of use are
discussed.
Chapter 2 “Safety Measures” describes the most important safety measures that have to be
taken in order to be able to safely work with this installation.
In Chapter 3 “Installation of the system” the initial installation of the hydraulic system is de-
scribed.
Chapter 4 “Maintenance” describes the necessary maintenance work to the installation and the
associated time intervals. Here you will also find how to order parts from Molenmaker Tech-
niek B.V.
In Chapter 5 “Malfunctions” an explanation is given about how you can solve certain failures
that may occur with the installation by yourself.
Chapter 6 “Disposal” describes what steps to take to properly dispose of the installation at a
time when the installation does not have a functional value to you any longer.
In Appendix I the most important technical data of the installation are listed, broken down
into the main components.
Appendix II contains the hydraulic diagram and parts list.
Appendix III contains various technical drawings and a list of drawing numbers.
Appendix IV contains the IIB-declaration.
Appendix V contains the test reports.

Appendix VI contains the technical documentation of the purchased parts.
For information about supplied parts (parts of the installation not manufactured in the
Molenmaker Techniek B.V. factory), we refer to the manuals and technical data sheets of
those parts. Please pay particular attention to safety measures described in these documents,
before you start working with the installation.
Nothing from this publication may be reproduced by means of photo off-set, microfilm or any
other medium, without the written approval of Molenmaker Techniek B.V. This also applies
to the related drawings and diagrams.
Molenmaker Techniek B.V. reserves the right to modify parts at any moment, without prior or
direct notification of the client. The contents of this manual may also be altered without prior
notice.
Some information from manuals of supplied parts has been integrated into this manual. It is
evident that Molenmaker Techniek B.V. cannot guarantee the accuracy and completeness of
this information. Therefor we recommend reading the manuals of supplied parts as well.
Molenmaker Techniek B.V. cannot be held liable for any damage that may occur as a result of
incorrect use of the installation, improper safety measures, use of non-original build replace-
ment parts, incorrectly done repairs, or incorrect settings. We recommend having repairs exe-
cuted by us.
Molenmaker Techniek B.V. wishes you much success with this installation

Chapter 1 Introduction
1.1 Purpose of the hydraulic installation
The purpose of the hydraulic installation is the movement of the hydraulic cylinders for a
moving floor system.
1.2 Circumstances of use
The installation is intended to be used indoors.
1.3 Personal protection gear

The following personal protection gear must be used at all times while working with the in-
stallation:
 Safety shoes
 Hearing protection
 Snug fitting coveralls

Chapter 2 Safety Measures
This chapter provides information about the safety measures to be taken when working with
the hydraulic installation. These measures are separated into measures for the staff, organiza-
tional measures to increase safety, and measures to be taken with the hydraulic installation
itself.
2.1 Safety measures for the staff
 Only qualified staff is allowed to work with the installation. Also be aware of the mini-
mum age by law of the staff that is working on or operating the installation.
 It is not allowed for the staff to be wearing long hair loosly, to be wearing loose fitting
clothing, to be wearing jewelry including rings. There is a risk of serious injury.
 Inexperienced staff may only work with the installation when they are supervised by an
experienced staff member.
 All staff that will be working on or operating the installation, has to acquaint themselves
with this manual before starting the work. In particular the Chapter “Safety Measures” is
of high importance.
 Maintenance and repair staff, who will be working on the installation, are required to read
the relevant chapters of this manual before starting the work.
 Only mechanics with specific hydraulic knowhow and experience are allowed to perform
maintenance or repairs to the hydraulic system.
 It is required to wear safety shoes while working with the installation.
 It is required to wear hearing protection while working with the installation.
2.2 Organizational measures to increase safety
As the owner / operator of the installation you are required to inform your staff of the follow-
ing measures:
 This manual is to be kept with the installation at all times.

 Various (local) laws and regulations have to be followed. Accidents and environmental
pollution are to be prevented.
 Operation of the installation has to be stopped immediately, as soon as there is any signif-
icant change to the installation.
 It is not permitted to change or alter the installation in such a way that safety might be
compromised, for example by (dis)assembling safety components, safety valves or by
welding to the frame. In case you want to make such changes, you are required to consult
with Molenmaker Techniek B.V. beforehand.
 All tools used have to be suitable for the work that is to be performed.
 Maintenance or repair work can only be performed when the installation is completely
stopped with the electrical motors switched off. Make sure the motors cannot be activated
unexpectedly.

 Make sure that there is a first aid kit nearby.

 It is important to know the location and mode of operation of fire extinguishers.
 All spare parts have to comply with the technical specifications and standards.
 It is important to know the procedure to report a fire, and what means to fight a fire are
available.
 The installation can only be used, when it is in good technical condition. Faults and fail-
ures and malfunctions that can influence safety, have to be remedied immediately.
 Hydraulic hoses have to be replaced as soon as they are showing any sign of wear.
2.3 Safety precautions for the installation

The installation is built with the latest hydraulic technology, especially with regard to safety
considerations. Despite this situations may arise in which there is danger to the users, by
standers or material assets in the area. Below we will describe some situations in which dan-
ger may arise and which precautions are to be taken.
2.3.1 General
 Do not experiment with the installation.
 Make sure that unauthorized staff and others remain at a safe distance from the installation
at all times.
 Make sure that all warning signs and labels and all operating instructions on the installa-
tion remain clearly readable. Replace these with new ones when needed.
 Always read the chapters “Maintenance” and “Failures” before you attempt to resolve a
problem with the installation.
2.3.2 Hydraulics
 Make sure there is no hydraulic pressure left in pipes and hoses, before you start mainte-
nance or repair work. The pressure can be lowered by operating the control valve multiple
times while the electric motor is off.
 Make sure that the hydraulic oil is not hot while doing maintenance or repair work to the
system. There is a burn risk.
 Oil can be ejected from pipes or hoses through miniscule punctures, which are invisible to
the naked eye. Do not search for oil leakages using your hand. Pressurized oil can easily
puncture or cut through a hand, leading to very serious injury. If hydraulic oil does get
under your skin, it is important to immediately notify a doctor who is familiar with this
type of injury.
2.4 Emergency Situation
In case of an emergency, you have to do the following:
 Press one of the emergency stop buttons. All movement in the system will stop and the
hydraulic power unit will be stopped.

Chapter 3 Installation of the system
This chapter describes how the hydraulic system should be installed. Also refer to the hydrau-
lic diagram (drawing 2021178-H001) and the parts list in appendix II that belongs with the
hydraulic diagram.
The hydraulic system is designed and documented according the NEN-EN-ISO 4413:2010
norm. The symbols used in the (design of) the hydraulic system are according NEN 3348,
matching with ISO 1219-1.
For a number of components used, documentation can be found in appendix X.
 Connect all hoses and pipes to the hydraulic power unit.

 Make sure to connect the A-ports to the rod sides and the B-ports to the bottom sides of
the cylinders. The A and B can be found on the manifold blocks.
 Check if all couplings and bolts are firmly secured.

 If there is a drain valve, make sure it is closed.
 Secure the drain plug into the reservoir.
 Make sure there is plenty of new, clean oil of the prescribed kind. (See appendix I) The
reservoir should be filled with approximately 150 liters of oil.
 It is recommended to use a filling-system when filling the reservoir. A filler-system con-
sists of a pump that pumps 15 to 20 liters per minute, combined with a pressure filter of 5
mm. A purity class of ISO 17/15/12 (NAS 6) should be reached. The NAS-class can be
determined using a particle counter.
 Unscrew the filler cap off the reservoir.
 Fill the reservoir via the fill-opening until the oil level is equal with the top of the oil level
gauge on the side of the reservoir.
 Make sure that no contamination can enter the system while filling the reservoir.
 Screw the filler cap back onto the reservoir.
 Make sure the pump can pump the oil around without pressure.
 Start the electric motor, but shut it off immediately afterwards.
 Check if the cooling fan of the electric motor is rotating in the correct direction, using the
arrow on the fan-cover.

 Start the electric motor again, but shut it off immediately afterwards.
 Repeat this a number of times (3).
 Start the electric motor and leave it running for 5 minutes.
 Activate valve V01.
 Activate valve V02. The cylinder will go in or out.
 Bleed the couplings on the cylinder by screwing them a little loose (½ turn).
 Screw the coupling back in if oil leaks out.
 Make sure the cylinder moves smoothly.
 Activate valve V03 and bleed the other cylinder also.
 Add extra oil if necessary.
 Have the installation perform one complete operating cycle.
 Add oil again if necessary.
 If oil has leaked out during these steps, this has to be cleaned off the installation.

Chapter 4 Maintenance
When you order spare parts from us, we will need the following information from you:
Project. Host Moving Floor

Order Number. 2021178
Quantity, length, or number of liters.
Description of the article in the parts list.
Part Number.
Number of the drawing or parts list where the part is shown.
Manufacturer’s part number shown on the part itself.
The preferred mode of transportation.
Your shipping address.

Wagenmakersstraat 14
8601 VA Sneek
Tel. 0515 – 434 226
Fax. 0515 – 439 717
www.molenmaker-techniek.nl
If you order spare parts from other suppliers, these spare parts must at least comply with the
same technical requirements as the original parts. We recommend ordering spare parts from
In this chapter the maintenance instructions for this installation are described. When you fol-
low these instructions, the installation will function without problems. We recommend famil-
iarizing yourself with the documentation of the various components as well.
The maintenance instructions for the various parts of the installation are listed in the next par-
agraphs and also in the maintenance diagram on the next page. The maintenance-intervals
listed in the maintenance diagram are a guideline. In case of heaver or lighter operating cir-
cumstances, one can decide to deviate from the intervals in the maintenance diagram.

Maintenance Diagram
1x per 10 years
1x per 15 years
1x per 5 years
1x per month
1x per year
A general check of the hydraulic installation;
1 X
(look for leakages, check oil level and filters)
2 Major service X
3 Replacement of hydraulic hoses X
4 Replacement of hydraulic oil X
5 Replacement of the seals in valves and cylinders X
6 Grease bearings in rod and bottom eye X
4.1 General
Staff members who will be maintaining the installation, have to read this chapter.
It is not allowed to alter the installation in any way that may influence the safety of the instal-
lation, for example by removing safety components or safety valves.
All tools have to be suited for the work that is to be performed.
Damaged or worn parts have to be replaced.
Pay close attention to the correct installation of parts.
Make sure that all markings with warnings and instructions on the installation, remain clearly
visible and readable. Replace these with new ones when necessary.
Ensure that bolts and nuts are tightened at the correct torque, following the diagram below on
this page. Use a torque wrench to do this.
Torque [Nm]
Bout M6 M8 M10 M12 M14 M16 M20 M24 M30 M36
8.8 10 25 49 86 135 210 410 710 1450 2500
10.9 14 35 69 120 190 295 580 1000 2000 3400
12.9 17 41 83 145 230 355 690 1200 2400 4000
RVS
7 16 33 56 89 136 274 264 503 573
A4-70

4.2 Hydraulic system
Only mechanics with specific hydraulic knowledge and experience are allowed to perform
maintenance or repairs on this hydraulic system.
It is self-evident that any alteration made to the hydraulic system, without notifying Mo-
lenmaker Techniek B.V. beforehand, will void any warranty-claim made.
Maintenance and repair work can only be carried out when all pumps are shut off. Therefore,
make sure that none of the electric motors can be turned on unexpectedly.
Maintenance and repair work can only be carried out when there is no hydraulic pressure left
in the pipes and the hoses. In some cases one can release pressure by operating the control
valve various times, while the pump is shut off. Sometimes it is possible to lower pressure
through a measuring coupling or by slightly loosening a coupling. Be aware of thin oil jet
sprays.
Ensure that all components have cooled off enough, before you start working.
Leaked oil can make the surroundings of the installation very slippery. Use oil pans and ab-
sorbent cloth to clean up leaked oil right away.
It is a good common practice to maintain a logbook of the installation. In this logbook a num-
ber of things can be logged, such as the dates of oil replacements, seal replacements etc.
4.2.1 Checking the hydraulic installation
The best way to check the hydraulic installation is to follow the normal direction of the oil
flow in the system. Therefore take the following steps in succession:
 Check the oil level before startup of the installation.

 Add a small amount of oil if this is needed. Adding oil can never be a substitute for an oil
replacement. In case of abnormal oil loss, the cause of this loss has to be found and re-
paired immediately.
 Check the reservoir, the pump, the pressure pipes/hoses and the return pipes/hoses for
leakages.
 Check the filter. If the filter element is dirty, they have to be replaced.

4.2.2 Servicing the installation
It is recommended to plan routine maintenance of the installation after a certain number of

operating hours. The proper interval between two routine maintenance moments depends on
the operating conditions. This interval can vary between one and five years. But shorter or
longer intervals can be desirable. In all cases there should be a routine maintenance of the
installation taking place after the first 500 operating hours.
Routine maintenance consists of the following work:
 Check if all pipes, hoses and couplings are securely fastened.

 Clean the outside of all components and pipes. Especially dust must be removed. Also
remove loose and peeled paint.
 Take an oil sample (see below).
 Replace the oil if necessary (see the next paragraph).
 Replace a hose if it has a (beginning of a) crack.
 Touch up the coating where necessary.
4.2.2.1 Taking an oil sample
The oil has to be in optimal condition in order to prevent problems in the hydraulic installa-
tion. The installation will not continue to function correctly if the oil contains water or if the
oil is contaminated. When there is water in the oil there will be rust in the system which will
be very damaging to the various components. Contamination of the oil will cause excessive
wear and\or the clogging of components.
To determine whether there is water or contamination in the oil, one can take an oil sample.
You can take an oil sample by following these steps:

 Make sure the installation is running.
 Make sure you have an oil pan ready that is sufficiently large.
 Connect a measuring hose to one of the measuring connections on block BB01.
 Let the measuring hose flush with oil for 10 seconds and catch this oil in the oil pan.
 Take a completely clean bottle and fill it with the oil coming out of the measuring hose.
There are special sampling bottles available.
 Stop the installation.
 Disconnect the measuring hose.
 Send the oil sample to a specialized sampling company. In their examination report it will
be determined if the oil has to be replaced or has to be purified /filtered. The purity of the
oil has to be at least ISO 19/17/14 (NAS 8). The NAS class can be determined using a
particle counter.

4.3.1 Replacing the oil
If you want to replace the oil, you have to drain the old oil first, before you can add new oil to
the system. After you have filled the installation with new oil, the installation has to be com-
missioned again. How to do this step by step can be read in the following paragraphs.
4.3.1.1 Draining the oil
 Determine that the installation is in its resting position.

 Place a sufficiently large oil pan or oil container underneath the drain plug of the hydrau-
lic tank. The oil tank contains approximately 150 liters.
 Check and make sure that the oil is not hot. There is a risk of getting burned.
 Disconnect the drain plug from the tank.
 Open the drain valve if there is one on the system.
 Let the oil flow into the oil pan or oil container without allowing it to spill.
 Wait until the oil flow has stopped. The oil has now been removed from the system. The
cylinders and valves do not have to be drained.
 Disassemble the cover from the oil tank and inspect the inside of the tank.
 Clean the inside of the tank.
 Take the filter elements out of the filters and replace these with new ones. We recommend
to keep at least 2 pieces of each type of filter element with the installation.
 Dispose of the used oil and used filter elements in an environmentally friendly manner.
 Secure the tank cover onto the tank. Make sure the sealing rubber is properly placed un-
derneath the cover.
 Close the drain valve if there is one on the system.
 Place the drain plug back into its position.
4.3.1.2 Filling the system with oil
 Reconnect all pipes and hoses that have been disconnected.

 Check if all the couplings and all the bolts in the flanges are securely fastened.
 Determine that there is enough clean oil of the correct specification at hand. The tank has
to be filled with approximately 150 liters of oil.
 It is recommended to use an oil filling system when filling the oil tank. The oil filling sys-
tems will exist of a pump of 15-20 liters per minute and a fine pressure filter of 5mm. The
oil that is going into the system should have a purity class of ISO 17/15/12 (NAS6). The
NAS class can be determined using a particle counter.
 Unscrew the filler cap of the tank.
 Fill the tank trough the fill opening until the oil level is at the top of the oil gauge (nomi-
nal level).
 Make sure that it is not possible for any contamination to enter the system while filling.
 Screw the filler cap bank onto the fill opening.

4.3.1.3 Commissioning
 Make sure the pump can pump the oil around without pressure.
 Start the electric motor, but shut it off immediately afterwards.
 Check if the cooling fan of the electric motor is rotating in the correct direction, using the
arrow on the fan-cover.
 Start the electric motor again, but shut it off immediately afterwards.
 Repeat this a number of times (3).
 Start the electric motor and leave it running for 5 minutes.
 Activate valve V01.
 Activate valve V02. The cylinder will go in or out.
 Bleed the couplings on the cylinder by screwing them a little loose (½ turn).
 Screw the coupling back in if oil leaks out.
 Make sure the cylinder moves smoothly.
 Activate valve V03 and bleed the other cylinder also.
 Add extra oil if necessary.
 Have the installation perform one complete operating cycle.
 Add oil again if necessary.
 If oil has leaked out during these steps, this has to be cleaned off the installation.
4.3.2 Replacement of hydraulic hoses
When replacing hydraulic hoses, always make sure that the new hoses can withstand at least
the pressure for which the old hoses have been designed. Read the specifications of the hoses
to determine this. Also use the same type of hose connectors and fasteners, in order to ensure
that the hoses will have the same amount of room for movement as originally intended.
4.3.3 Replacement of seals
Consult the documentation to determine which seals are used in the various components. Be
sure to have new seals on site before you disassemble any components. The existing seals in
the system can probably not be used again.
In order to replace the seals in a cylinder it is necessary that the cylinder is disassembled from
the installation. Take care not to spill any oil. Make sure that the connection points for the
ducts or the hoses are plugged.

4.4 Electric system
Only mechanics / electricians with specific knowledge and experience are allowed to work on
the system.
The electric components in the system do not require maintenance.
When performing maintenance on the electric cables of the pump unit, make sure the installa-
tion is disconnected from any electric current.
When welding is performed on or near the installation, the installation has to be disconnected
from any electric current. The welding clamp has to be connected close to where the welding
is taking place.
Any time the cable of the electric motor has been disconnected, it is important to double
check the rotational direction of the pumps. This can be checked by shortly switching the
electric motor on and off. The rotational direction of the fan on the electric motor has to be the
same as the direction of the arrow on the fan cover.
4.5 Mechanical components
The bearings in the cylinder bottom eye and the rod eye require maintenance. Use a grease
pistol and wait till grease comes out of the bearing.
4.6 Recommended spare parts
We recommend to keep the following spare parts in stock:
Recommended Spare Parts

Quantity Description Type
20 liters Oil viscosity class 32

2 Return filter element CR 091 C10N
1 Pressure switch SCPSD-250-14-17
1 Control valve D1VW002CNTW
1 Control valve RPE3-063H11/23050E5T1

Chapter 5 Malfunctions
When there is a malfunction in the hydraulic installation, one has to determine first whether it
is an electric, hydraulic of mechanical malfunction. By deducting logically, one can often
determine the cause of the malfunction. In order to help you solve a malfunction, we have
compiled a list of possible malfunctions and possible remedies. See paragraph 5.2.
Always read the chapter “Maintenance” before attempting to remedy a malfunction. Do not
experiment. Call, fax or email with Molenmaker Techniek B.V. if you cannot resolve the mal-
function.
We recommend having repairs done by mechanics from Molenmaker Techniek B.V. Our me-
chanics have the proper knowledge and experience for this work.
The installation can only be used if it is in good technical shape. Any malfunction that could
influence the safety has to be resolved instantly.
Below are some considerations with regard to finding the cause of a malfunction in the instal-
lation.
5.1 Searching for the cause of a malfunction
All components in the hydraulic diagram have a part number. Especially when locating the
cause of a malfunction and when seeking assistance by phone from Molenmaker Techniek
B.V., it is convenient to mention this number. When it is necessary to replace a component, it
is important to only use original parts. This way you can be ensured that the system will func-
tion well afterwards.
When there has been a malfunction, it is important to inspect the entire system, not only the
component that has caused the malfunction.
5.1.1 Determining the cause of a malfunction
Every search for the cause of a malfunction should have a logical and systematic order. You
have to ask the following questions successively:
 Is the electric motor turning?

 Is there excessive vibration and/or a lot of noise?
 Are any of the cylinders hindered in their movement?
 Is the oil level where it should be?
 In the oil temperature too high or too low?
 Is hydraulic pressure present, everywhere where this is to be expected?
 Is there hydraulic pressure in places where this is not to be expected?
 Is there sufficient voltage going to the electrically operated valves?
 Are the oil and the filters in good condition?

If you are not the operator of the system yourself, ask the operator the following:
 What sort of malfunction is it and what is the effect on the system?

 How long has there been a malfunction?
 Has he or she made any alterations to the system?
When the cause of a malfunction has been determined and it is necessary to disassemble a
component, perform this work in the following order:
The O-ring(s) that make up the seal between the component and the rest of the system, proba-
bly have to be replaced as well. Make sure these are at hand before you start.
 Determine that the hydraulic installation has been shut off and can’t be started unexpect-
edly.
 Make sure there is no pressure in the system.
 Always take care of clean surroundings when disassembling hydraulic components.
 Only use clean and lint-free cloth.
 Remove all loose and peeled paint.
 Be aware of possible oil leakages when disassembling components.
 Make sure that disconnected ducts and hoses are capped or closed off by using plastic
bags.
 Never disassemble hydraulic components outdoors.
 Carefully follow disassembly and re-assembly instructions.
 After replacing components the installation should idle for at least 5 minutes, so that con-
taminations can be filtered out of the oil.
 Check the filter element and replace it if necessary.
 Add oil if needed.
 Dispose of defective components, soiled cloth and used filter elements is an environmen-
tally friendly way.

5.2 List of malfunctions
In the list below you can find possible malfunctions and their remedies.
Malfunction The electric motor is not turning.

Question Answer Action
Determine the cause of the thermal relay
tripping.
Has the electric motor been shut off yes  Reset the thermal relay.
by the thermal relay? no  If the thermal relay trips again instantly,
then wait a little while and try to reset it
again.
Has the control system (e.g. PLC) no  See the documentation of the control system
shut off the electric motor? yes  for possible causes.
Can the pump pump the oil around no  Determine why the recirculation valve has
without pressure? yes  been activated.
yes  Determine why one of the phases is discon-
Is one of the phases disconnected
no  nected.
yes  Check if there is voltage in the connection
Can the fan be rotated?
no  box.
The electric motor is probably
Replace the electric motor
broken
The pump doesn’t supply oil and/or is making excessive

Malfunction noise (cavitation).
yes 
Is the oil level too low? Add oil to the tank.
no 
yes 
Is the suction valve closed? Open the valve.
no 
Is there a loose coupling somewhere yes 
Tighten the coupling.
in the suction duct? no 
Has the suction duct been narrowed yes 
Replace or repair the suction duct.
or damaged? no 
yes  Replace the oil. Possibly use oil with a low-
Is the oil too viscous?
no  er viscosity.
Is the pump sucking in air at the
yes 
pump axle? Replace the axle seal.
no 
The pump is probably broken. Replace or repair the pump.

Malfunction A pump is making excessive noise (mechanical).

yes  Adjust the working pressure of the pump to
Is the oil pressure too high?
no  the correct value.
Is there excessive vibration in the yes  Tighten the fastenings of the ducts.
pressure ducts? no  Possibly use hoses instead of ducts.
Is there a defect in the mechanical yes 
Replace the coupling.
coupling of the pump? no 
The pump is probably broken. Repair or replace the pump.
Malfunction A safety valve is making noise.

yes 
Is the oil too hot? See the next malfunction in this list.
no 
yes 
Is the safety valve dirty? Clean the safety valve.
no 
The safety valve is probably bro-
Replace or repair the safety valve.
ken.
Malfunction The oil is getting too hot.

yes 
Is the oil level too low? Add oil to the system.
no 
Adjust the safety valve to a pressure that is
yes 
Is the working pressure too high? approximately 20 bars above the desired
no 
working pressure in the system.
Does the control valve switch off at no 
Adjust the control system.
the end of the stroke of the cylinder? yes 
Is the oil too thin? (Not enough vis- yes  Replace the oil. Possibly use a type with a
cosity) no  higher viscosity.
Is there internal leakage in a compo- yes 
Replace or repair the broken component.
nent? no 
Lower the working pressure.
Is the pump or the valves overload- yes 
Replace the component with a different
ed? no 
type.
Have the operating conditions Consult with Molenmaker Techniek B.V.
yes 
changed? regarding an alteration of the system.

Malfunction A pump is not delivering its working pressure.

Remark: The pressure in a system is dependent on the load that is placed on the different users in
the system (cylinders or hydraulic motors). If these are working without or with a limited load,
the working pressure will be low. This should not be considered a malfunction.
yes 
Is the oil level too low? Add oil to the system.
no 
Change the pressure setting of the safety
Is the safety valve set for a pressure yes  valve to the value it should be. Try to de-
that is too low? no  termine the cause of the unwanted change
in setting.
yes  Check the safety valve for damage and dirt.
The safety valve opens to soon.
no  Possibly install a stronger spring.
Is the piston seal in one of the cylin-
ders broken? Check this by slightly
loosening the coupling on the return yes 
Replace the piston seal.
side of the cylinder. If oil coming out no 
under pressure, then the piston seal is
broken.
The pump is probably broken. Replace or repair the pump.
Malfunction A cilinder does not move evenly.

yes 
Is there air in the cylinder? Bleed the cylinder until all the air is out.
no 
Is there air in the hydraulic system? yes  Bleed the system until all the air is out.
Malfunction An electrical valve won’t switch.

Is there voltage supplied to the no  Consult the documentation of the control
valve? yes  system.
Is there sufficient voltage supplied to no  Determine why the valve does not receive
the valve? yes  sufficient voltage.
yes 
Has the coil of the valve bunt out? Replace the coil.
no 
yes 
Is the valve dirty? Clean the valve.
no 
The valve is probably broken. Replace the valve.

Chapter 6 Disposal
Disposal of the installation entails that all fluids have to be removed from the installation and
all parts have to be disassembled as far as possible.
This chapter will describe which measures to take before you start with the disassembly, how
to remove the oil and disassemble the hydraulic components, and what to be aware of while
disassembling the rest of the parts of the installation.
6.1 General precautions
 Make sure the pumps are off and cannot be started unexpectedly.
 Make sure there is no pressure left in any of the ducts or hoses. In some cases the pressure
can be lowered by operating the control valve several times while the pump is off. Some-
times the pressure can be reduced trough a measuring coupling or by slightly loosening a
coupling. Be aware of thin oil jets.
6.2 Removing the oil and hydraulic components

 Place a sufficiently large oil pan or oil container underneath the drain plug of the hydrau-
lic tank. The oil tank contains approximately 150 liters.
 Check and make sure that the oil is not hot. There is a risk of getting burned.
 Disconnect the drain plug from the tank.
 Open the drain valve if there is one on the system.
 Let the oil flow into the oil pan or oil container without allowing it to spill.
 Wait until the oil flow has stopped. The oil has now been removed from the system
 Remove the filter elements.
 Dispose of the oil and the used filter elements in an environmentally friendly way.
6.2.1 Disassembling the hydraulic components

 Place a sufficiently large oil pan underneath the components that are to be disassembled.
Be aware that oil can come out of cylinders, valves and ducts or hoses.
 Disassemble the hydraulic components.
 Disassemble the hydraulic tank.
 Dispose of the hydraulic components in an environmentally friendly way.

6.3 Disassembling the remaining parts
 Work carefully when disassembling the remaining parts.

 Be sure to know exactly what you are disassembling and the weight that is released when
the part is removed.
 Re-use parts if possible or take them to a specialized recycling company.
 Disassemble the system into separate parts as far as possible, in order to be able to sepa-
rate the different materials.
 Clean fluids and grease of all the parts.
 Sort the parts in steel, brass, copper, aluminum and synthetic materials.
 Dispose of all the different materials separately.
The following diagram will indicate what type of materials is in the different parts of the in-
stallation.
Synthetic
Copper Aluminum
Part Steel materials
alloy alloy
(plastics)
Cylinder x x
Pump unit x
Electric motors x x x x
Oil tank x
Hydraulic ducts x
Pipe clamps x x
Hydraulic components x x
Hydraulic hoses x x

Appendix I Technical data
I.1 General
Project : Moving Floor Host

Year : 2021
Order number MTS : 2021178
Voltage : 400/690V 50 Hz 3 phase + N

Total installed power : 11 kW
Dimensions of pump unit : 0,975 x 0,6 x 1,2 m

Weight of pump unit : 250 kg
Weight of cylinder : 170 kg
Noise level at 1 m. distance from the pump unit : < 80 dB(A)
Color of pump unit : RAL 5010

Color of cylinder : RAL 5010
I.2 Cylinders
Number of cylinders : 2
Cylinder diameter : ø160 mm
Piston rod diameter : ø90 mm
Length of stroke : 700 mm
Difference in volume of cylinders : 7 liter

I.3 Pump unit
Stroke volume of the pumps : 14,1 cm3 + 9,6 cm3

Flow of the pumps at 1500 rpm : 20 l/min + 14 l/min
Maximum pressure of the pumps : 230 bar + 250 bar
Power of the electric motor : 11 kW
Volume of the oil tank : 150 liter
I.4 Hydraulic oil
Total oil volume of the system : 200 liter

Oil brand : Mobil DTE 32
Type : DIN 51524-2 HLP

ISO viscosity grade : 32
Density at 15°C : 0,871 kg/liter
Viscosity at 40 °C : 31,5 mm2/s
Viscosity at 100 °C : 4,5 mm2/s
Viscosity index : 98
Condensation point : -27 °C
Flash Point : 220 °C
All relevant details regarding the oil can be found on the oil safety data sheet in appendix X.
I.5 Electrical data
Voltage of the electrical valves : 230 VDC

Switching and holding current of the valves : 1,25 A

Appendix II Hydraulic diagram

Appendix III Technical drawings
The following drawings can be found in this attachment:
2021178 A001 Pump unit As built

2021178 C001 Cylinder 160-90x700 As built

Appendix IV IIB-declaration

Appendix V Test reports

Appendix VI Technical documentation
The documentation of the parts that are supplied by third parties is collected in this appendix.
Consult this documentation for maintenance instructions and/or operating principles.
It is not possible for Molenmaker Techniek B.V. to translate all documentation in English.
We apologize in advance for any text that might not be in English.


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Operating Instructions

Moving Floor system

Molenmaker Techniek B.V.

Tel: +31 515 – 434 226

Client: Host Biogas B.V.

Order number MTS: 2021178

Project manager MTS: N. Thalens

Date: 29 September 2021

Operations and maintenance manual Moving Floor System 2

Operations and maintenance manual Moving Floor System 3

Total installed power: 11 kW

Electrical current: 400/690V 50 Hz 3 phase + N

Volume of reservoir: 150 liter

Oil type: Mobil DTE 32

Cilinder diameter: ø160 mm

Piston rod diameter: ø90 mm

Operations and maintenance manual Moving Floor System 4

This manual contains the following chapters:

Appendix II contains the hydraulic diagram and parts list.

Appendix IV contains the IIB-declaration.

Appendix V contains the test reports.

Operations and maintenance manual Moving Floor System 5

Appendix VI contains the technical documentation of the purchased parts.

Operations and maintenance manual Moving Floor System 6

1.1 Purpose of the hydraulic installation

1.2 Circumstances of use

The installation is intended to be used indoors.

1.3 Personal protection gear

Operations and maintenance manual Moving Floor System 7

Chapter 2 Safety Measures

2.1 Safety measures for the staff

2.2 Organizational measures to increase safety

 This manual is to be kept with the installation at all times.

Operations and maintenance manual Moving Floor System 8

 Make sure that there is a first aid kit nearby.

2.3 Safety precautions for the installation

2.4 Emergency Situation

In case of an emergency, you have to do the following:

Operations and maintenance manual Moving Floor System 9

Chapter 3 Installation of the system

For a number of components used, documentation can be found in appendix X.

 Connect all hoses and pipes to the hydraulic power unit.

 Check if all couplings and bolts are firmly secured.

Operations and maintenance manual Moving Floor System 10

Operations and maintenance manual Moving Floor System 11

Project. Host Moving Floor

Molenmaker Techniek B.V.

Operations and maintenance manual Moving Floor System 12

All tools have to be suited for the work that is to be performed.

Damaged or worn parts have to be replaced.

Pay close attention to the correct installation of parts.

Operations and maintenance manual Moving Floor System 13

4.2 Hydraulic system

4.2.1 Checking the hydraulic installation

 Check the oil level before startup of the installation.

Operations and maintenance manual Moving Floor System 14

4.2.2 Servicing the installation

It is recommended to plan routine maintenance of the installation after a certain number of

Routine maintenance consists of the following work:

 Check if all pipes, hoses and couplings are securely fastened.

4.2.2.1 Taking an oil sample

You can take an oil sample by following these steps:

Operations and maintenance manual Moving Floor System 15