Binder 4

R
Table
Manual hydraulic
1 HSU technical data and settings K-217
2 Circuit diagram 128462-CC
3 Hydraulic circuit diagram 128462-C

128463-C
128464-C
128465-C
4 Hydraulic parts list 128462-P

128463-P
128464-P
128465-P
5 Assembly drawing 128462-A

128463-A
128464-A
128465-A
6 General function description of

hydraulic system K-319
Detailed description of function of
HSU included components K-318
7 Installation of hydraulic system K-320
8 HSU valve position indication K-367
9 Oil filling filter circulation K-321
2011/301912/Tb/Table hydraulic
10 Flushing K-326
11 HSU starting of hydraulic system K-322
12 HSU service and maintenance K-323

Maintenance routine hydraulic
equipment Q-111
13 HSU general directions K-227
14 General directions use accumulators K-229
15 Commissioning Kit S1650233
16 Hydraulic Power Unit Pump Logic HSL301912
2011/301912/Tb/Table hydraulic
K-217
Technical data and settings
070327
Order no. 1019226 / 1020746
Customer´s ref. VO:301912
Hydraulic circuit diagram 128462-C, 128463-C, 128464-C, 128465-C, 128462-CC
Part list 128462-P, 128463-P, 128464-P, 128465-P
Dimentional drawing 128462-A, 128463-A, 128464-A, 128465-A
HSU
Tank volume: 300 litres (upper mark on level gauge)
Indicated level High: litres Low: 150 litres Very low: 100 litres
Flow P1 / P2 / P3 9 litres 9 litres litres
Working pressure 240 bar
Saftey valve setting 260 bar (lower value:-13%)
Indicated pressure High: bar Low: bar Very low: bar
Electric motors P1 and P2 4,0 kW 1430 rpm 400 / 50 V / Hz
Electric motor P3 0,75 kW 1500 rpm 400 / 50 V / Hz
Cooler medium °C l/min
Heater 1,0 kW 400 / 50 V / Hz
ACCUM. (Pressure side)

Volume 50 litres Preloaded: 125 bar
Extended by gas holder Volume: litres
Saftey block 300 bar
ACCUM. (Tank side)

Volume litres Preloaded: bar
HVP
Pressure red. At output port: A,B,C,D,E,F Setting: Full pressure bar
Pressure red. At output port: Setting: bar
Relief valve at port: Setting: bar
Local accum. P-side / Volume: litres Preloaded: bar
Extended by gas holder litres Volume: litres
Saftey block bar
Local accum. T-side / Volume: litres Preloaded: bar

Local accum. P-side / Volume: litres Preloaded: bar
Extended by gas holder Volume: litres
Saftey block bar
Local accum. T-side / Volume: litres Preloaded: bar
Distribueras: Ersätter: Godk.: Ansv.: Tillhör: Typ: Sid.:

KA,BTG 041130 KA 1/1
Hydraulic parts list
Customer / P.O no.: Cethar Vessels Limited Parts list no.: 128462-P
Project: Vandana Vidyut LTD Circuit diagram: 128462-C
CCI order No.: VO 301912 Dim. drawing: 128462-A
Drawn: 2010-10-20 Sign.: PP

Checked: 2010-10-20 Sign.: BS
Rev. Date Sign. Alteration

A 110210 PP Changed Pos 6 and 16
REC. SPARES
DEL.
POS QTY DESCRIPTION TYPE ITNO NOTE MANUFACT COMM. 2YR 5YR TIME
2 HPU-9-4-300-50A-M-H-CP
1 1 Gear pump GHP2-D-9 742-00-009 P1 Marzocchi
2 1 Conn. Flange 1RG38-C 723-08-100 Marzocchi
4 1 Bell house LS253-200-2,2-4 400-73-044 OMT
5 1 Shaft coupling ND61-200-28 400-71-029 OMT
6 1 Electric motor 380-415V 50Hz WU-DA112MR-4-4KW-4/6
B5 128969 M1 Busck
11 1 Gear pump GHP2-D-9 742-00-009 P2 Marzocchi
14 1 Bell house LS253-200-2,2-4 400-73-044 OMT
15 1 Shaft coupling ND61-200-28 400-71-029 OMT
16 1 Electric motor 380-415V 50Hz WU-DA112MR-4-4KW-4/6
B5 128969 M2 Busck
21a 1 Oil tank 300L 128514 128514 Frenzak
21b 1 Cover left 128519 128519 Frenzak
21c 1 Cover right 128520 128520 Frenzak
22a 1 Frame 124706 124706 Frenzak
Parts list no.: 128462-P 1(3)

DEL.
22b 2 Extra frame 104423 104423 Frenzak
22c 1 Frame for el.cabinet 105049 105049 Frenzak
23 1 Oil tray 124707 124707 Frenzak
24 1 Heater OE341-1000W/K7T/TSDO
1103 401-70-212 SL24 Backer
25 1 Drain valve 7640-1/4" 401-73-001 Oil sample Valvex
26a 1 Level/Temp.switch HMCK-VVTA90-
V1=380/V2=445 102282 SL26a Hemomatik 1 1 2 week
26b 1 Level/Temp.switch HMCK-VVTA90-
V1=380/V2=445 102282 SL26b Hemomatik
27a 1 Temp.switch HMCK-TA90 L=335 105210 Hemomatik 1 1 3 week
27b 1 Temp.switch HMCK-TA90 L=335 105210 Hemomatik
28a 1 Air breather SA115G1L03A(SA8P10A-
G1") 402-50-024 MP Filtri 1 1 2 week
28b - Filter Element A8L03 MP Filtri 2 5 2 week
29 1 Level gauge LVA-30-T-A-PM12-SO1 402-50-002 MP Filtri
30a 1 Return oil filter MPF100-2-AG3/P10NB/T 402-50-140 MP Filtri
30b 1 incl.of vis. ind. V1 1,4 BAR 402-50-280 MP Filtri 1 1 2 week
30c - Filter Element MF100-2-P10NB 402-50-150 MP Filtri 2 5 2 week
31 1 Ball valve three way SKT-3 R 1" 401-73-050 Alentec
32 1 Drain valve 7640-1/2" 401-73-003 Valvex
33a 1 Pressure filter DFDK-BH/HC-060-QAC10-
C1,0/-A5 440-15-011 Hydac
33b - Filter Element 0060 D 010 BH3HC 440-15-012 Hydac 2 5 2 week
34a 1 Pressure filter DFDK-BH/HC-060-QAC10-
C1,0/-A5 440-15-011 Hydac
34b - Filter Element 0060 D 010 BH3HC 440-15-012 Hydac 2 5 2 week
37a 1 Oil cooler LOC-004-4-D-A-0-00-S25-0-
0-0 401-70-380 M3 Oiltech
37b 1 Ball valve three way SKT-3 R 1" 401-73-050 Alentec
LOC-004-4-D-A-0-00-S25-0-
37c 1 Oil cooler 0-0 401-70-380 M4 Oiltech
37d 1 Ball valve three way SKT-3 R 1" 401-73-050 Alentec
38a 1 Return oil filter MPF100-2-AG3/P10NB/T 402-50-140 MP Filtri
38b - Filter Element MF100-2-P10NB 402-50-150 MP 2 5 2 week
38c 1 Pressure switch LAY-600-002-311-11 401-70-160 SP38 Hemomatik 1 1 2 week

DEL.
39a 1 Hose 1SN3/4" L=0,600
IR3/4"90°K+IR3/4"-45° 401-70-790 K=short Hydroscand
39b 1 Hose 1SN3/4" L= Hydroscand
39c 1 Hose 1SN3/4" L=0,600
IR3/4"90°K+IR3/4"-45° 401-70-790 K=short Hydroscand
39d 1 Hose 1SN3/4" L= Hydroscand
39e 1 Hose 1SN3/4" L= Hydroscand
39f 1 Hose 1SN3/4" L= Hydroscand
41 1 Valve block unit (cons. of pos.
42-59)
42 1 Pressure control valve LV25PC 128578 Hawe 1 1 2 week
43 1 Pressure control valve LV25PC 128578 Hawe
44 1 Flow control valve BC2-0,8 200-52-708 Hawe 1 1 2 week
45 1 Flow control valve BC2-0,8 200-52-708 Hawe
46 1 Pressure limiting valve CMV2C-315 200-41-825 Hawe 1 1 2 week
47 1 Ball valve PKH-DN6-112A 105215 MHA Zentgraf
48 1 Needle valve NV08-20A-0-N 302-01-040 Hydraforce 1 1 2 week
53 2 Measure nipple SMK20-G1/4"-PC 401-73-202 Temeto
54a 1 Pressure gauge 2757-DIM100-R3/8"/0-250 403-00-210 Wika 1 1 2 week
54b 1 Hose SMS20/M-2000(M16X2-1/4") 401-76-041 Temeto
54c 1 Pressure gauge panel 103780 103780 PMC Hydraulics
55 1 Valveblock 105073 105073 PQS France
59a 1 Pressure Transmitter PA 3521 105023 SP59a IFM
59b 1 Pressure Transmitter PA 3521 105023 SP59b IFM
60 1 Hand pump PMS25 480-40-000 Oleoweb
61 1 Check valve FT257/6-38 401-81-920 Tognella
62a 1 Bladder acc. incl.of burst disk Precharged
(ASME) EHV50-300-G2 ASME 401-70-347 125bar Oiltech
62b - Incl. of burst disc BD-W-0360-1/4-CE 401-70-366 CE-marked Oiltech
62c 2 Holder FK-220-2 401-70-360 Oiltech
62d 1 Bracket K2 401-70-362 Oiltech
62e 1 Rubber ring G-222 401-70-363 Oiltech
64a 1 Safety block DI20-G2 250BAR CE 401-70-335 Oiltech
64b 1 Measure nipple SMK20-G1/4"-PC 401-73-202 Temeto
65a 1 Pressure red.valve PBHB-LAN 100744 Sun

DEL.
65b 1 Valveblock 127089 127089 Kinnex
65c 1 Pressure relief valve MVP6C 200-41-103 Hawe
65d 1 Measure nipple SMK20-G1/4"-PC 401-73-202 Temeto
1 Mounting details Mounting details HSU-CP 105074 PMC Hydraulics
1 Electric cabinet AK1-PLC 1000x1000 SL-montage



A 110210 PP Changed Hose & Fitting kit
REC. SPARES
DEL.
2 HVP-HP unit 1-2
100 1 Prop. Directional valve DHZO-A-071-S3/20 202-80-075 Atos 1 1 2 week
110 1 Directional valve DHI-0611-X24DC 202-10-101 Atos 1 1 2 week
111 1 Flow control valve HQ-013/30 202-53-102 Atos
121 1 Flow control valve HQ-014/30 202-53-103 Atos 1 1 2 week
160 1 Valve block NG6 FB03-7-8866-GT-STÅL/GG 401-20-517
PMC Hydraulics
2 Consol for FB03 49CJ340 420-15-110 Svetsman
161 1 Subplate for FB03 SAMBORR.A-A/B-B FB03-
complete 103580 PMC Hydraulics 1 1 2 week
165 1 Valve panel 128500 128500 Frenzak
170 1 Ball valve KHB16-SR-SW09 401-73-040 Hydac
DEL.
250 1 Directional valve DHI-0631/2-X24DC 202-10-105 Atos
261 1 SAMBORR.A-A/B-B FB03-
Subplate for FB03 complete 103580 PMC Hydraulics
1 Mounting details
Mounting details HVP 103578 PMC Hydraulics
9 Connector w. Cable 152N30011-EJ EL 404-00-005 OEM Autom.
1 SmartTrak 2 SL-montage
2 HOSE & FITTING KIT

2 Hose Kit Ø16-1/2"-1500-G1/2" 102702 Hydroscand


REC. SPARES
DEL.
2 HVP-LP1 unit 1-2
100 1 Prop. Directional valve DHZO-A-071/S5/20 202-80-076 Atos 1 1 2 week
PMC Hydraulics
170 1 Ball valve KHB20-SR 401-73-041 Hydac
220 1 Directional valve DHI-0611/A-X24DC 202-10-108 Atos 1 1 2 week
DEL.
230 1 Directional valve SV08-30-0-N-00 302-00-400 Hydraforce
1 Solenoid DG-24V D.C/08-6306024- 302-09-041 Hydraforce
240 1 Logic Element DKDS-XHN 126106 SUN
262 1 Valveblock Stay-Put 126080 126080 Kinnex
1 Mounting details



REC. SPARES
DEL.
2 HVP-LP2 unit 1-2
100 1 Prop. Directional valve DHZO-A-071/S5/20 202-80-076 Atos 1 1 2 week
PMC Hydraulics
170 1 Ball valve KHB20-SR 401-73-041 Hydac
220 1 Directional valve DHI-0611/A-X24DC 202-10-108 Atos 1 1 2 week
DEL.
230 1 Directional valve SV08-30-0-N-00 302-00-400 Hydraforce
1 Solenoid DG-24V D.C/08-6306024- 302-09-041 Hydraforce
262 1 Valveblock Stay-Put 126080 126080 Kinnex
1 Mounting details


A As Built 110210 PP CN
Filling of nitrogen (N2) gas.
62b burst disc
62
AK1-PLC 1000x1000
22
37b 37d 54
~2475
OIL FILLING: G1"

T
OIL FILLING: G1"
37c M4
29 39a
39c
25 M3 37a 39f
64
21 39e
24
65 39d
23
39b
P1
P2
This drawing and the design is the property of AB Gustaf Terling. It is strictly confidential and must not be copied, traced or loaned whitout our permission.
2000 ~210 1200 ~150
55 57 58 59 32
46 47 48 53 26a-VVTA90
OIL OUTLET: G1/2"
42 43 44 45 Customer : Cethar Vessels Limited
26b-VVTA90
Project : Vandana Vidyut LTD
VO No. : 301912
n14 (4x) 11 12 13 14 15 16 M2
P1 : n 30S (Parker EO-2)
34-SP34 P2 : n 16S (Parker EO-2)
T : n 35L (Parker EO-2)
OIL SAMPEL: G1/4" Weight : ~730kg (Without oil)
Tank volume : 300 l
DRAIN: G1/2" : Lifting points
850
Hydraulic circuit diagram : 128462-C

33-SP33
Part list :128462-P
HPU-HP/LP:128462-A
27a-TA90 HVP-HP:128463-A
HVP-LP1:128464-A
HVP-LP2:128465-A
27b-TA90
175
DRAWING MADE BY AB GUSTAF TERLING

1 2 3 4 5 6 M1 This drawing is the property of CCI Valve
Technology AB. It is strictly confidential and
CCI Valve Technology AB
must not be copied, traced or loaned without Box 602, 661 29 SÄ FFLE SW ED EN
28 60 their permission. Valves
31 61
30 DRAWN 2010-10-20 SIGN. PP
38-SP38
CHECKED 2010-10-20 SIGN. BS
ASSEMBLY DRAWING
25 1950 PART OF
MAT.
VANDANA HPU-HP/LP unit 1-2
MOD SCALE REG. REPLACES
No. Qty. Amendment. Date. Ins. Check. No. Qty. Amendment. Date. Ins. Check. No. Qty. Amendment. Date. Ins. Check. W.O. 301912 1:12 REPLACES BY
128462-A A
25 900
165
261
251
SMART TRAK 2
250
221
YV250
F 220
YV220 211
E
YV210 D 210
YV200A C 200
YV200B 120
B
YV120
121
YV110
A 110
YV100B
111
This drawing and the design is the property of CCI Valve technology AB. It is strictly confidential and must not be copied, traced or loaned whitout our permission.
YV100A
100
161
1200
1300
160
P-FLUSHING
P
170
Customer : Cethar Vessels Limited
T-FLUSHING Project : Vandana Vidyut LTD
VO No. : 301912
T
172 P : Ø16S (Parker EO-2)
T : Ø18L (Parker EO-2)
P-FLUSHING : Ø16S (Parker EO-2)
T-FLUSHING : Ø18L (Parker EO-2)
A-B: Ø16S (Parker EO-2)
C-F: Ø12S (Parker EO-2)
75
Ø14 (4x) Weight : ~120kg
= = 21 Hydraulic circuit diagram : 128463-C

DRAIN: G1/2" 250 Part list : 128463-P
950 HSU-HP/LP unit 1-2:128462-A
HVP-HP unit 1-2: 128463-A
HVP-LP1 unit 1-2:128464-A
This drawing is the property of CCI Valve
their permission. Valves
DRAWN 2010-10-20 SIGN. PP

ASSEMBLY DRAWING
PART OF
MAT.
VANDANA HVP-HP unit 1-2
128463-A
25 900
165
262
261
230
YV250A 251
SMART TRAK 2
250
YV250B
221
YV220
E
220
YV210 F
211
C
YV230
D 210
YV200A
241 200
YV200B
120
240
YV120
121
B
YV110
110
A
YV100B
111
YV100A 100
Junction Box 150x150
161
1200
1300
160
P-FLUSHING
P Customer : Cethar Vessels Limited

VO No. : 301912
170 T-FLUSHING
P : Ø20S (Parker EO-2)
T T : Ø22L (Parker EO-2)
172 P-FLUSHING : Ø16S (Parker EO-2)
75

950 HSU-HP/LP unit 1-2:128462-A

ASSEMBLY DRAWING
PART OF
MAT.
VANDANA HVP-LP1 unit 1-2
128464-A
25 900
165
262
261
230
YV250A 251
SMART TRAK 2
250
YV250B
221
YV220
E
220
YV210 F
211
C
YV230
D 210
YV200A
241 200
YV200B
120
240
YV120
121
B
YV110
110
A
YV100B
111
YV100A 100
Junction Box 150x150
161
1200
1300
160
P-FLUSHING
P Customer : Cethar Vessels Limited

VO No. : 301912
170 T-FLUSHING
P : Ø20S (Parker EO-2)
T T : Ø22L (Parker EO-2)
172 P-FLUSHING : Ø16S (Parker EO-2)
75

950 HSU-HP/LP unit 1-2:128462-A

ASSEMBLY DRAWING
PART OF
MAT.
VANDANA HVP-LP2 unit 1-2
128465-A
General function description K-319
of hydraulic systems Valid until 130616
1. Construction of hydraulic systems
The hydraulic system is dimensioned in accordance with this specific system to be able
to control CCI’s actuators.
Performances, data and adjustments may be seen from "technical data" in K-217. The
hydraulic system consists of a hydraulic supply unit (HSU) which supplies each panel or
valve block with pressurized oil. HSU's function and operation mode are described be-
low. For a detailed description of each component please see K-318. The number of
panels/blocks and limits for each unit are shown in the circuit diagram.
2. Hydraulic Supply Unit – HSU
The different components of HSU can be read in detail from the schedule of parts and it
appears from the circuit diagram and other documentation how these are composed.
HSU is constructed of two firm gear pumps and is working with two hydraulic pressure
control valves which keeps the pressure level within given limits. A condition for this
principle is that the pressure side in the hydraulic system is completed with one or se-
veral accumulators. When the pressure reaches the set working pressure, i.e. the upper
level of the normal pressure level, the pressure control valve will change to a position
when the oil is led directly from the pump via the pressure filter back to the tank.
When the pressure level has fallen ca. 13% it will return to the position for refilling of
the accumulator. Normally the pumps are used alternately and one at a time, but if the
pressure should fall to a level which is below "pressure low" this will be indicated by a
pressure indicator and then also the standby pump will be started. This will run until
the pressure indicator which indicates "pressure low" has been restored to the normal
position and in addition to that a predetermined time and then be stopped. If the pump
flow should not be sufficient due to some trouble this will be indicated by either a se-
parate pressure indicator or after a given time. If the pressure should rise to a level
that is higher than normal also this will be indicated by a pressure indicator, "pressure
high", and if the pressure should rise still more there is a hydraulic pressure relief valve
that will protect the system. In this position there will still be function left, but with
the consequence that the hydraulic oil will be hot. The HSU is equipped with double
pressure filters which have electric indication for exchange of filter cartridge.
A ball valve is mounted in the valve block where a manual unloading of the pressure can
be made. This is connected to the pressure side and by that also connected (not separa-
ted) accumulators will be emptied this way if the ball valve is opened. "The unloading
valve" is at first hand meant to facilitate service and maintenance, but may well be
used at the starting up to control the pressure during a shorter time.

CCI Masterpärmar, PDF 050311 KA Beskrivning 1/3
It must under no circumstances be opened during operation. Setting of the right position
may be seen from the instruction in K-367. The working pressure can be read on the
pressure gauge if it is mounted as per the diagram.
The return oil should during operation be led through one or several ball valves directly
to the tank as the return flow will vary and sometimes be very big. This would give a ve-
ry bad filtration if you had mounted a permanent oil return filter. Filtration is made by
the pressure filter mounted on the main pumps. All oil entering into the system is filte-
red by these filters. When "normal" pressure level is reached in the system, oil from
the main pump is led via the pressure filter to tank. However, the 3-way ball valve (pos.
31) should be reset at installation to facilitate the starting up and the flushing. Then the
return oil will be led via a flushing filter to tank and in this way the dirt that already is
in the pipe system will be prevented from reaching the tank. If the filter should be
blocked up this will be shown on the visual filter indicator. In the flushing position the
accumulators must not be connected and instructions for this will be found under the
heading "flushing". Normally the system has a separate outlet for flushing. The oil level
in the tank can be read directly on a level gauge and when the level is below "level
low", due to some leakage, this will be indicated via an electric level indicator so that
the oil can be filled. If the level then will sink still more, to "very low" this will be indi-
cated by further one level indicator and if this happens there is too little oil in the tank
to run the HSU. Also the temperature may be seen from the thermometer in the level
gauge and if this should rise to "temperature high" this will be indicated by a temperatu-
re indicator.
Filter circuit / cooling - OPTION. The HSU can as an option be equipped with a sepa-
rate motor pump for cooling or/and filtration of the oil. The oil cooler is normally an air
cooler but can also be a water cooler. In this circuit a filter can be installed.
This unit should always be in operation. A pump called P3 sucks the oil from the return
side of the tank and pumps the oil via the cooler and the filter to the middle section of
the tank. The oil is then "ventilated" over a plate (baffle) in order then to be able to
reach the suction pipes of the main pumps.
If filter is mounted in this circuit it will be provided with electric indication for ex-
change of the filter cartridge.

3. Accumulator(s)
The accumulators are dimensioned and preloaded as per the demands that are made re-
garding stroke times and necessary backup volumes. They can either be placed in con-
nection to HSU or near to the hydraulic valves which should control CCI’s actuators.
The accumulators are normally equipped with safety blocks where you have a pressure
relief valve and also can unload the accumulators. (In some cases also close.) Placing
and number may be seen from drawings as well as from technical data.
Please note that some accumulators can be meant for a special function and are in this
case separated from the system. If so, this must be observed at service. Before starting
up or service the instructions and diagram for the accumulator must be read to reduce
the risk of an accident. Accumulators which are not unloaded may cause unexpected
movements.
4. Hydraulic valves for control of CCI’s actuators
Each pos. No. of the pump is intended for a predetermined function which may be seen
from K-318.

Detailed description of K-318
function of included components Valid until 130616
1. Explanation of contents
Below you will find a table of the main components, which are installed, in the hydrau-
lic system. Each separate function has been dedicated an own pos. No. in order to sim-
plify the handling from construction to running maintenance. This list should be used as
a "reference part" to understand the intention with the separate component. Thus, in
this table there can be separate components included that are not installed in the hy-
draulic system in question. These you can then leave out of consideration. All installed
parts are shown in the hydraulic diagram and schedule of parts and all pos. Nos. are re-
ferring to these. For a general description of the function and mode of operation we
refer to K-319. For the performances and the settings of the separate components we
refer to data sheets and technical data in K-217. For the normal position of the diffe-
rent valves we refer to K-367.
Pos. Designation Function
1.11 Gear pump Main pump P1/P2.
4.14 Bell house Connects main pump with the electric

motor.
5.15 Coupling Transmission of power from electric
motor to pump.
6.16 Electric motor Run main pump P1/P2.
21 Oil tank Tank for hydraulic oil.
The volume is adapted to the system.
22 Tank cover Tank cover.

23 Oil tray Placed under HSU to catch overflow
and leakage, if any.
26 Level/temp. indicator Combined level and temperature
indicator which usually indicates "le-
vel low", "level very low" and "temp.
high".
27 Oil heater/thermostat - Preheating of oil. Is used at low
ambient OPTION temperature.
28 Air filter Filtrates the air that is exchanged

during operation.

CCI Masterpärmar, PDF 070307 PA Beskrivning 1/5
29 Level stick Mounted on tank. Shows present max.
& min. oil level.
30 Flushing filter Is used during starting up and flushing
for filtering of the oil.
31 3-way ball valve Shifts the oil return flow between

filter and tank.
32 Ball valve For emptying of oil from tank.
33/34 Pressure filter Is used as pressure filter to filter the

oil. Totally there are 2 pcs. filters
that can be exchanged during
operation.
Please see separate instruction for

this. The filters have an electric indi-
cation for exchange of filter cartrid-
ge.
42/43 Pressure control valve Controls the pressure level in the

hydraulic system during operation.
46 Pressure relief valve Is used as safety valve.
37 Cooler / filter unit - OPTION Pump unit P3/M3 can be installed as

an option. It can be provided with oil
cooler and/or oil filter in order to
continuously filtrate and cool the oil.
The oil cooler is normally cooled with
air but can also be provided with wa-
ter cooling of the oil.
47 Ball valve Connects pressure pipe with tank to

make "unloading" of pressure possible.
Suitable to use at service and mainte-
nance. Should normally be closed.
49 Hand pump - OPTION To be able to manually pressurize the

hydraulic system.
50 Pressure indicator Indicates at "very low pressure".

Please also see technical data.

51 Pressure indicator Indicates at "low pressure". Please al-

so see technical data.
52 Pressure indicator Indicates at "high pressure". Please al-

so see technical data.
54 Pressure gauge For reading of system pressure.
55 Valve block On and in this block the hydraulic val-

ves are collected for a "clean and easy
mounting".
62-63 Accumulator Is dimensioned as per the demands

which are made concerning the stroke
times and necessary backup volumes.
Requires also some surrounding equip-
ment for increased security.
64 Safety block Pressure relief, unloading and closing

of the accumulator, if any.
2. Explanation of the position numbers of the hydraulic valves which are con-
trolling CCI’s valves
The first figure indicates the channel from which the function is controlled, i.e. which
one of CCI’s valves that is controlled. This may be seen from other documentation. In
the normal case channel 1 and 3 are used to control steam valves and channel 2 and 4
to control water valves. Henceforth the channel will be named "*" in the below mentio-
ned table. The two following figures indicate the function (function code).
Pos. Channel Code Function

*00 * 00 Prop. valve for controlling of the CCI
valve. Controlled from channel "*".
*01 * 01 Additional flow control valve in connection

with control position.
*02 * 02 Pressure reducing valve in connection with

control position.
*10 * 10 Directional control valve to open the CCI


*11 * 11 Flow control valve in connection with

opening.

opening.
*20 * 20 Directional control valve to close the CCI

*21 * 21 Flow control valve in connection with

closing.

closing.
*30 * 30 Spare number for additional hydraulic

functions.
*40 * 40 Spare number for additional hydraulic

functions.
*50 * 50 Valve for stop function. Function is shown

in diagram.
*51 * 51 Flow control valve in connection with stop

motion.

stop motion.
*60 * 60 Valve block on which the other hydraulic

valves are mounted.
*70 * 70 Ball valve for closing of pressure pipe.
*71 * 71 Ball valve which is used to connect P and

T during flushing.
*72 * 72 Check valve on return channel which

prevents "back-pressure".
*80 * 80 Locally placed accumulator (P). Can be

separated from other accumulators.
*82 * 82 Locally placed gas holders (P) to

increase working volume of the
accumulator.

*85 * 85 Pressure relief, unloading and closing of

accumulator, if any.
*90 * 90 Locally placed accumulator which is

connected to return pipe.
Example
Pos. No. 100 is a prop. valve for control position of the (steam) valve which is connec-
ted to channel 1.
Pos. No. 222 is a reducing valve for closing of the (water) valve which is connected to
channel 2.

Installation of K-320
hydraulic system Valid until 130910
1. General instructions
Installation of a hydraulic system should be made in accordance with current circuit dia-
gram, schedule of parts and other compiled documentation. Please check that no dama-
ges have arisen during transport before installation is started. Also see to it that all ac-
companying components are available.
Read all instructions and signs, if any, through which can be placed on the different
units, for instance caution signs.
2. Environment and placing
The hydraulic equipment such as HSU, HVP and HVB should not be placed in an environ-
ment which is exposed to dust, dirt or big fluctuations in temperature. See to it that
the placing admits ventilation enough. Surface finishing should be adapted to the pre-
sent circumstances. The hydraulic equipment should also be sheltered from rain and
wind if it is placed outdoors. The HSU and HVP should be placed horizontally. To facili-
tate coming service, repairs and normal handling (operation) the equipment should be
placed easily accessible. Take also sound levels and environment for potential operators
into consideration. Please also consider that fluid spillage, if any, must not reach ex-
haust that does not have a sufficiently dimensioned oil separator.
3. Pipe / Hose
The circuit diagram should state dimensions of pipe, pressure levels and flows so that
the pipe system can be dimensioned in the right way. This may also be seen from other
documentation.
When selecting pipes and hoses we refer to information from the manufacturer regar-
ding pressure levels. Pipes should be seamless and calculated as per DIN 2391/C
(SS2353) or current internal standard. When selecting hoses the outer environment as
well as the suitability should be taken into consideration. Pipes should be carefully stap-
led and when possible this also applies to hoses. Use couplings within current pressure
classes.
Example of types of couplings are cutting rings (Ermeto) and JIC 37°. Avoid too high
flow rates and as a rule of thumb (not possible in all cases) the following pipes can be
used. Suction pipes max. 1 m/s, return pipes max. 3 m/s, pressure pipes max. 7 m/s.

Installation of K-320
hydraulic system Valid until 130910
4. Electric connection
All electric connections of the hydraulic equipment should be made according to cur-
rent documentation. The connection should be made by certificated staff. Qualifica-
tion in accordance with the regulations of each country.
5. Cleanliness
A very important factor within the hydraulics is cleanliness and especially in connection
with installation. All open ports must be sealed with for instance plastic plugs until just
before end mounting. Pipes should be burred and carefully scoured out before moun-
ting. Couplings should be kept in sealed bags/boxes as long as possible. Hoses should
be cleaned separately before mounting. Cleaned and already tested units (HSU, blocks,
valves etc.) should be kept clean and plugged. Strive to get such a clean environment as
possible.
6. Hydraulic fluid
When selecting hydraulic fluid the temperature and the environment should be taken
into consideration. Select a fluid which follows DIN 51524/part 2 (HL-P). See also re-
commended fluids under opening 9.
7. Security
An installation of a hydraulic system should be made by qualified staff in order to mini-

mize the risk of potential accidents and problems when starting up as well as during
operation. Carefully follow given instructions and safety regulations. Control the con-
nection an extra time before start of pumps (incorrectly connected users can cause ma-
terial damage as well as physical damage). Pipe couplings should be tightened with the
right moment and should be follow-up tightened after some time's use.

Valve position indication K-367
Giltigt t.o.m. 130616

CCI Masterpärmar, pdf PA 1/1
Fluid filling - K-321
Filter circulation Giltigt t.o.m. 130910
When filling fluid into a hydraulic system it is of great importance to bear the following
things in mind.
Selection of fluid should be done with regard to the components, the environment and
the ambient temperature as well as the working condition. Please see opening 9 for re-
commended fluids. When calculating the total fluid quantity also the volume of the pipe
system and the hydraulic actuators should be included.
The tank volume may be seen from the technical data and its level can be read on the
level gauge. Predetermined levels are indicated by level indicators (see technical data).
A very important factor is cleanliness in connection with filling of fluid.
The hydraulic actuators should be filled separately before end mounting of hoses/pipes,
if possible. It may be difficult to get rid of air in the actuator if this is not made and it
is especially difficult on the underside of the actuator if the outgoing rod pistons are
pointing downwards. Below you will find instructions of fluid filling into the HSU. Please
also see instructions regarding installation and flushing.
FILLING MUST NOT BE MADE WITH PRESSURIZED ACCUMULATORS IF CONSIDERATION IN-

TO PRESSURIZED FLUID VOLUME HAS NOT BEEN TAKEN.
2. Filling of fluid into the HSU
The system must be filled with CLEAN FLUID.

3 different ways of filling fluid into the system are possible.
1. Clean fluid shall be pumped into the tank via ball valve pos. 32 (fluid outlet/inlet
G 1/2").
2. Clean fluid shall be pumped into the tank via connection T3 on the valve block.
When filling fluid into the system a separate "filter pump unit" shall be used. Inlet
fluid shall be filled to level ISO 16/13 (10µm absolute).
3. If no separate pump is available you may fill fluid via return fluid filter by
removing the cover. DO NOT REMOVE FILTER CARTRIDGE!!

Flushing K-326
Valid until 130911
In connection with installation of new and repair of existing hydraulic systems it is in

practise impossible to entirely eliminate the risk of dirt coming into the system.
For that reason it is necessary to flush the system before starting up.
The HSU with belonging hydraulic valves do not need to be flushed and should be kept
isolated during flushing.
Flushing should be made by the same type of fluid which is intended for the normal ope-
ration. If the fluid is not exchanged after the flushing is made the degree of purity must
be controlled against current demands before a normal starting up.
If more flushings will be made you should start with the one that is furthest away from
the unit and also connect just one "flushing loop" at a time.
Preparations
In order to avoid "fouled" fluid causing damage to (destroying) components the following
measures should be taken before flushing. The flushing can then be made by the main
pumps P1 and P2.
1. Installation and fluid filling should be made in accordance with separate

instructions before flushing can be made.
2. Shunt past the hydraulic actuators by connecting the pipe ends (at the actuator)
by means of a hose and plug the connections in the actuator. Pse see sketch.
3. Connect the pipes which should be flushed to the pressure and return outlets,
marked "P" and "T", via hoses (service kit). Pse see sketch.
4. Set the return valve (3-way ball valve) in position for flushing (pos. 31).
5. Shut off all accumulators. Also the unloading valves, if any, in the safety block
should be closed.
6. Close the ball valves to each HVP/HVB (pos. No. 170/270/370/470 etc.).
7. Close the "unloading ball valve" on the unit (pos. 47).
8. Set valves on the filter/cooling unit in position for circulation and start P3.
Pse note: Check the direction of rotation.
9. Start both pumps P1 and P2.
During flushing
In order to reach the best result of the flushing, please make the following checks:
Flushing K-326
Valid until 130911
10. The fluid temperature should be ca. 40•C.
11. The flushing should go on continuously in 40-50 hours.
12. The filters should be checked regularly via indicators.
13. Find leakages and check the fluid level in the tank continuously via level gauge
and indicator.
14. The pressure gauge indicates pressure drops in pipes (if it is mounted on the unit
as per the diagram). The pressure should not exceed 100 bar so that the pressure
control valve (pos. 42, 43) will not influence the flushing.
After flushing
To finish the flushing and to return to the starting position, please do as follows:
15. Switch off the pumps P1, P2 and P3.
16. Open the "unloading ball valve" on the unit (pos. 47).
17. Change to the pipes which are left to flush and repeat from the beginning. If all
pipes are flushed the pipe assembly should be restored as per the diagram
and the installation instructions. Pse see sketch.
18. Open to the accumulators and the respective HVP/HVB. The unloading valves in
the safety block should be closed.
19. Change all filter elements on HSU (please also see general instructions).

Starting of the K-322
hydraulic system Giltigt t.o.m. 130910
Starting should be made by qualified staff who is well up in the way the specific hydrau-
lic system is constructed and is working.
Accompanying documentation should have been read through and should be the basis of
the starting up.
The function may be seen from the circuit diagram. The settings of pressures and flows
may be seen from the technical data. The characteristics, performances and function of
the valves may be seen from the functional description and the data sheets of the sepa-
rate components. For setting of ball valves please see opening 9. The installation should
be checked in accordance with compiled drawing base and installation instructions.
The flushing of the pipe system should be made in accordance with instructions. The
hydraulic system should be filled with oil as per instructions.
2. Preparings
1. Check the oil level in the tank. The oil should be exchanged after flushing,
alternatively the purity degree should be checked. Oil must not be filled into tank
when the accumulators are pressurized.
Filters which have been used during flushing should be exchanged. Please also
see flushing instructions.
2. See to it that the flushing outlets "P" and "T" are plugged.
3. Set the flushing valve (pos. 31) in position for oil flow directly to tank.
4. Close to accumulators (isolate). The drain valves in the safety block should be
closed.
5. Open "the unloading valve" on the HSU (pos. 47).
6. Pressure valves and flow valves should be adjusted before installation. If not, all
unknown pressure levels should be lowered and the flows be limited in order then
to be set as per compiled documentation. Some readjustment of especially the
flows can be necessary to achieve specified times during real service conditions.
7. Check that all actuators are filled with oil. If not, these should be filled.
8. Check that all actuators can be run to full stroke (normal operation) and that
they are completely installed.
9. Please note that some of these may move directly when starting up the main
pumps.

Solenoids to the directional control valves/prop.valves should be de-energized if

no other information is given.
10. Open the ball valves to respective panel/block (pos. 170/270/etc.).
Starting up
11. Start filter/cooling pump P3 if mounted on the HSU - OPTION.

N.B. Check the direction of rotation.
12. Start P1.

N.B. Check direction of rotation. Let the pump work unloaded in ca. 5 minutes.
The oil is now circulating back to the tank via "the unloading valve" (pos. 47). The
pressure gauge which is mounted on the HSU indicates ca. 0 bar.
Please note that some cylinders may move. Please see hydraulic circuit diagram.
13. Close "the unloading valve" (pos. 47) somewhat so that the pressure will rise to ca.
20-30 bar. Note that some actuators may move.
This valve can be used to control the pressure in connection with the starting up
and in this way you can avoid resetting of already set pressure valves.
N.B. If this is completey closed when the accumulators are disconnected the
unloading valve (pos. 42/43) will start controlling the pressure by a too small oil
quantity and it will then shift position too often (it is clattering). This must not
happen as the valve is not made to manage this. Therefore do not close the
"unloading valve" more than that the pressure is reaching ca. 75% of set value.
Please also note that this way of controlling the pressure will generate heat in the
tank and should therefore only be used in the beginning of the starting up in order
to control the function and test for leaks before the accumulators are connected.
(In order to reduce the risk of accidents if any pipe or hose has been wrongly
installed. If this valve is quickly opened this will immediately lead to pressure
drop in the pressure pipe.)
14. Run all actuators to full stroke, one at a time. This is made by activating the prop.
valves and the directional control valves in accordance with the circuit diagram.
Please note that some valves (fail close/open) must be activated so that the
actuator can be run with the other prop. and directional control valves.
15. Let out air as much as possible.
16. Find leakages, if any, and check regularly that the oil level in the tank is
sufficient.
17. Open to the accumulator(s) (let the drain valves on the safety block be closed).
18. Close "the unloading valve" (pos. 47) entirely.

The pressure will now slowly rise to normal working pressure. Please see technical
data and functional description for the HSU.
19. Repeat the running of all actuators to full stroke, one at a time and see to it that
there is full function. This is also made to get rid of air.
20. Compare stroke times and pressure settings with the technical data and given
demands.
21. Adjust for an optimal function.
22. Make a final and extra careful ocular inspection of pipes and hoses with regard to
leakage, if any. Note this and take steps before normal operation.
23. Switch off P1.
24. Drain slowly the oil that is accumulated, by for the purpose intended drain valves
on the safety block, to ca. 0 bar. Please see opening 9.
Note that some actuators can be intended for a certain function and therefore
they can be pressurized despite the pressure pipe is non-pressurized as they are
separated by a check valve.
25. Open slowly "the unloading valve" (pos. 47).
26. Start P2.

N.B. Check the direction of rotation. Let the pump run unloaded in ca. 5 minutes.
The oil is now circulating back to tank via "the unloading valve" (pos. 47). The
pressure gauge which is mounted on the HSU is indicating ca. 0 bar.
Note that some actuators may move.
27. Close "the unloading valve" (pos. 47) somewhat so that the pressure will rise to ca.
20-30 bar. See to it that all drain valves on the safety blocks, if any, are closed.
Note that some actuators may move. Let the pump run in this position ca. 1 min.
28. Close "the unloading valve" (pos. 47) entirely.

The pressure will no slowly rise to normal working pressure. Please see technical
data and functional description for the HSU.
29. Switch off P2.
30. Drain slowly the oil that is accumulated, by for the purpose intended drain valves
on the safety block, to ca. 0 bar.
Note that some acutators may be intended for a certain function and therefore
they can be pressurized despite the pressure pipe is non-pressurized as they are
separated by a check valve.

31. Check the oil level in the tank and refill when necessary. Please see instructions
foroil filling.
32. Close "the unloading valve" (pos. 47) entirely. See to it that all drain valves on
safety blocks, if any, are closed.
33. Stop P3 - OPTION.
34. Change filter cartridge in the pressure filter that has been used, the flushing filter
and the circulation filter, if mounted OPTION. Please see separate instructions
for this.
35. Set all ball valves in position for normal operation. See opening 9.
The hydraulic system is now ready to be started in normal operation. However, all actu-
ators should be run another times to full stroke to get rid of the air that may remain in
the system. This should be done when the system has been out of operation for at least
some hours so that the air that is bound inside the oil will be separated.

Service and K-323
maintenance Giltigt t.o.m. 130910
1. General instruction
A regular and a periodical supervision of a hydraulic system is a condition of a long life

and low operating costs.
Suitable measures, interval of time and required purity of degree of the hydraulic oil
may be seen from Q-111. The hydraulic system has installed indicators for warning of
wrong pressure, temperature and oil levels. There are also indicators of silted up fil-
ters. This in order to take necessary measures as early as possible to prevent unnecessa-
ry stops of operation. Below you will find instructions how to exchange filter during
operation.
2. Exchange of pressure filter (pos. 33/34) "during operation"
1. Stop one of the electric motors M1/M2 due to which filter that shall be changed.
2. Wait for approx. 5 min.
3. Screw off the filter bowl. It should be possible to turn this manually when it has
been loosened.
4. Exchange the filter cartridge. Be very particular about the cleanliness.
5. Remount the filter bowl (with new cartridge).
8. Start the electric motor again.

It is preferable if the exchanged filter is "reconnected" when the pressure control
valve (pos. 42/43) has switched the pump flow to non-pressurized circulation, i.e.
when the pumps do not pressurize the actuator, as the venting of the filter is then
made automatically.
3. Exchange of circulation filter "during operation" - OPTION
1. Stop pump P3.
2. Check that the electrical indication that has warned of silted up filter has retur-
ned to the normal position. This is a proof of the fact that the oil is no longer
flowing through the silted up filter. The function of the indicator is based upon a
pressure drop over the filter.
3. Dismount the cover of the filter. Exchange filter cartridge. Be very particular
about the cleanliness.
4. Remount the filter cover.
5. Start pump P3 again. Very important.

Service and K-323
maintenance Giltigt t.o.m. 130910
4. Exchange of flushing filter (pos. 30)
1. Please see opening 9 for detailed instruction how to set the below mentioned
hydraulic valves.
2. Set the 3-way ball valve (flushing valve, pos. 31) which is mounted on the return
pipe in position for oil return directly to the tank.
3. Check that the visual indication that has warned of silted up filter has returned
to the normal position. This is a proof of the fact the the oil is no longer flowing
through the silted up filter. The function of the indicator is based upon a pressure
drop over the filter.
6. Dismount the cover of the filter. Exchange filter cartridge. Be very particular
about the cleanliness.
7. Remount the filter cover.
8. Select if the flushing filter should be used, or not, by means of valve 31.

Maintenance routine Q-111
Hydraulic equipment 110711
Hydraulic oil Equipment
Quality See General Directions - Use Customer CCI Valve Technology
Viscosity See General Directions - Use Order number 1019226 / 1020746
Operating temperature See General Directions - Use (max70°C) Customer`s ref. VO:301912
Degree of purity ISO 18/14 Circut diagram 128462-C - 128465-C
Fill volume See K-217 Schedule of parts 128462-P - 128465-P
Maintenance instuction See General Directions - Use
Start-up instuction See K-322
Interval
pos. Measure Month Year
Impurity analysis 6
Scheduled exchange 2
Pressure filter Hydraulic oil
Cleaning of tank 2
Exchange of filter when indication is made, however min. 1
Exchange of filter when indication is made, however min. 1

Accumulator Retur filter
See sep. instruction for accumulator

Check pre-loading 1
External cleaning and check of leakage 1

Reading of pressure level 1
Check of temperature 1
Exchange of air filter 1
Inspection and cleaning of hydraulic oil cooler. 1
Others

FG3 070328 QA Blankett 1/1
General Directions — Use
General Directions
-
Use
1
CONTENTS 4.3 Filling of hydraulic oil 7

4.3.2 Filling 7
1 GENERAL 4.4 Flushing of the hydraulic system 8
4.4.2 Before flushing 8
2 LIFTING, TRANSPORTATION AND 4.4.3 Flushing 8
STOCK-KEEPING 3 4.4.4 After flushing 8
2.2 Before lifting and transportation 3 4.5 Starting-up 9
2.3 Lifting by means of fork truck 3 4.5.2 Before starting-up 9
2.4 Lifting by means of crane 3 4.5.3 Venting of pumps 9
2.5 Packing 4 4.5.4 Starting-up 10
2.6 Transportation 4
2.7 Stock-keeping 4 5 SUPERVISION AND
MAINTENANCE 11
3 INSTALLATION 4 5.2 Documentation 11
3.2 Before installation 4 5.3 Materials for supervision and
3.3 Placing 4 maintenance 11
3.3.1 Surroundings 4 5.4 Exchange of filter 11
3.3.2 Space for mounting 5 5.5 Hydraulic hoses 11
3.3.3 Mounting 5 5.6 Analyzis of oil 11
3.4 Hydraulic connection 5 5.7 Exchange of oil 11
3.4.2 Pipes and couplings 5 5.8 Lubrication of electric motor 12
3.4.3 Hydraulic hose 5 5.9 Daily supervision 12
3.4.4 Fixing of the cramps 6 5.10 Monthly supervision and maintenance 12
3.4.5 Mechanically-controlled valves 6 5.11 Yearly supervision and maintenance 12
3.4.6 Air purger 6
3.5 Cleanliness 6 6 DISPOSAL 13
3.6 Connection to source of power 6
7 LOCATION OF ERRORS 14
4 USE 6
4.1 Selection of hydraulic oil 6 8 EMERGENCY 15
4.1.2 Recommended oil quality 7 8.1 Fire 15
4.1.3 Viscosity 7 8.2 Overflow of oil 15
4.2 Degree of purity - hydraulic oil 7 8.3 Personal exposure to hydraulic oil 15
1 GENERAL
The manual should be carefully read before transportation, installation and mounting are begun and also
before the equipment is put into operation. The whole of the manual has to be given to the people who are
responsible for the supervision, operation and maintenance.
The hydraulic equipment must not be put into work until the machine or plant in which the hydraulic equip-
ment will be included is complying with the requirements as per the machinery directive of EU.
The hydraulic equipment is manufactured in compliance with EN 982, Safety of machinery - Safety require-
ments for fluid power systems and their components - Hydraulics.
The hydraulic equipment must not be used to anything else but the application intended!
Hydraulic and electric installation, use and maintenance must be made by employees with documented
qualifications and experience from each field. Necessary details for a normal maintenance should be kept in
stock by the user. Spare parts should be kept in stock depending upon the user’s demands for accessibility.
A properly installed and maintained hydraulic equipment has a high reliability and will operate faultlessly
for many years. Follow the recommendations in this manual and take the utmost possible precautions and
carefulness at each measure or operation in the system.
The quality and the condition as well as the degree of purity of the fluid transmitting the power in the
system are of decisive importance for the reliability and the life of a hydraulic system. Secure the de-
gree of purity by regular fluid-tests and analyzes so that the degree of purity recommended by us is
kept.
2
2 LIFTING, TRANSPORTATION AND STOCK-KEEPING

2.1 General
Weight and dimensions appear from the technical documentation under opening 1.
When lifting and transporting the hydraulic equipment it is of great importance that it is han-
dled with care. The hydraulic equipment which has a vertically mounted motor-pump unit has a
very high position of the centre of gravity and in order to prevent dumping the hydraulic unit
must always be load-secured. Avoid rapid accelerations, retardations and rotations when the
equipment is removed. Lifting and transportation must always be made as low as possible.
2.2 Before lifting and transportation

Before lifting and transportation do as follows:
• Unload accumulators that may have been pressurized.
• Empty the hydraulic unit of hydraulic oil.
• Plug all hydraulic connections.
• Dismount pipes and components, if any, which can run the risk of being damaged in
connection with lifting and transportation. Plug and mark connections so that it clearly
and distinctly appears how to remount the parts.
2.3 Lifting by means of fork truck

When lifting by means of forks only assigned lifting points (fig. 1) may be used. Make sure that
the truck has the necessary lifting capacity and that the forks of the truck are long enough. The
lifting points are marked out on the hydraulic unit and on the assembly drawings, if any. Load
secure the hydraulic unit on the forks with straps or the like in order to prevent dumping. If the
oil tank unit has an inclined bottom wooden wedges must be used in accordance with fig. 2 in
order to prevent tipping. If the hydraulic unit will be removed a rather long distance it is suit-
able to hoop or to screw the hydraulic unit on a pallet if possible.
2.4 Lifting by means of crane

When lifting by means of crane only the lifting eye bolts or the assigned lifting points in-
tended for the purpose may be used. Lifting of the complete unit must not be made in lifting
eye bolts of separate components or in pipes. All the lifting eye bolts intended for the purpose
must be used during lifting. Make sure that the crane and the lifting equipment have the re-
quired lifting capacity and that the lifting equipment is long enough (fig. 3). If the lowest as-
signed lifting points are used for lifting the lifting equipment must be secured so that no risk of
sliding and by that dumping will arise.
Fig. 1 Fig. 2 Fig. 3
3
2.5 Packing
When selecting type of packing mode of transportation, distance and destination must be taken into con-
sideration and also under what circumstances the equipment will be stored before mounting. In connec-
tion with all packing the equipment has to be secured in or on the packing in order to prevent the equip-
ment from moving or being damaged during transport. If the packed equipment has a high centre of grav-
ity this must be specified on the packing by marking (fig. 1).
Fig. 1 Marking of centre of gravity
2.6 Transportation
Always inform the forwarding agent on the bill of carriage about the contents of the load. Transportation
of a hydraulic unit containing nitrogen accumulator (dangerous goods) must be effected in accordance
with the existing regulations of each country.
2.7 Stock-keeping
On delivery the hydraulic components are internally protected by a thin oil film. This protection is suffi-
cient to store the hydraulic equipment during tempered conditions indoors in ca. 12 months. During non-
tempered conditions the hydraulic equipment must not be stored more than 3 months. If the hydraulic
equipment has to be stored for a longer time than stated above it should be put into operation in order to
let the hydraulic components have a new protecting oil film. If the hydraulic equipments have been stored
for quite a long time without protecting measures the vital components should be dismounted, cleaned
and rubbed with oil before the equipment will be used again.
3 INSTALLATION
3.1 General
At the installation it is important that the hydraulic equipment is installed in such a way that the condi-
tions for a satisfactory operation are received and that the equipment will be easy of access for supervi-
sion, tending and maintenance.
3.2 Before installation

Check that no damages have arisen during transport and that all the intregral parts are included. Read
through the accompanying documentation. Check that the required installation material is available. When
in doubt regarding selection of dimensions of pipes and hoses, please get in touch with the supplier.
3.3 Placing
3.3.1 Surroundings
Hydraulic equipments must not be placed extremely dusty or moist environments, or in environments with
big changes i the temperature.
If the equipment is placed outdoors it must be kept out of the weather. When placed outdoors the equip-
ment depending upon climate conditions may be completed with an additional heater or cooler.
4
3.3.2 Space for mounting

The space where the hydraulic equipment will be mounted must be carefully ventilated and dimen-
sioned with regard to installed output. At small spaces or high outputs an enlarged ventilation or
cooling of the oil may be necessary in order to secure the recommended working temperature. The
distance to walls and other stationary objetcts must be
as big that there is a space for inspection, service and re-
pairs. The space to the wall must allow lifting and dis-
Dismounting space
mounting of the electric motor inclusive of the requireed electric motor
hoisting accessories. If there is a mounted immersion
heater this will require a dismounting space too. The hy-
draulic unit must be placed so that the level gauge is in full
view and that discharge and filling of hydraulic oil and ex-
change of filter can be easily done.
Dismounting
space
3.3.3 Mounting
immersion
The hydraulic unit is placed horizontally and fastened heater
to the foundation. Preferably use anti-vibrations mount
which will reduce the sound level and the vibrations.
We recommend that the hydraulic unit is mounted on
an oil overflow plate in order to prevent leakage and over-
flow, if any, from uncleaning the surroundings. When dimensioning the oil overflow plate an esti-
mate should be made if the volume of the oil overflow plate should be related to the volume of the
oil hydraulic tank.
3.4 Hydraulic connection
3.4.1 General
The hydraulic connection must be made in accordance with the hydraulic circuit diagram. Pipes
and hoses must have pressure classes and flow areas that at the very least correspond to those
stated in the hydraulic diagram. When having long pipe lengths or low temperatures bigger dimen-
sions than the stated ones can be required. Use hydraulic hoses between the hydraulic unit and the
pipe system and also between the pipe system and the operating devices if possible.
3.4.2 Pipes and couplings

The selected pipes must be seamless as per DIN2391/C with for the installation required surface
treatment. Pipe couplings of the type cutting ring tube fittings, flared tube fittings or the like must
be used when coupling pipes together. In systems where pulsations or pressure impulses can be
feared and where high demands upon density are made couplings with soft sealing should be used.
3.4.3 Hydraulic hose

The hydraulic hose must be of a good quality and fulfil current standards. At the mounting the sup-
plier’s recommendations regarding length, least bending radius and turning have to be observed.
The hydraulic hose is open-dated. Do not mount a hose which has an older date-line than recom-
mended by the manufacturer. Mount or protect the hose in order to prevent mechanical wearing.
5
3.4.4 Fixing of the cramps

The pipes and the hoses must be fixed to the base with the below recommended distances.
• ø = < 16 mm, 1 cramp per 1 metre.
• ø = 16 - 30 mm, 1 cramp per 1,5 metre.
• ø = > 30 mm, 1 cramp per 2 metres.
Fixing of the cramps must also be made immediately before and after a pipe bend. The pipes must be
mounted carefully protected and must not invite being used as steps or a ladder. Pipes and hoses that are
mounted in close vicinity to the operator’s place must be protected so that the operator cannot be hurt
in connection with leakage, pipe- or hose breaks.
3.4.5 Mechanically-controlled valves

Mechanically-controlled valves must be mounted in such a way that they cannot be damaged by the oper-
ating devices.
3.4.6 Air bleeds

It may be necessary to de-air the highly placed parts of the hydraulic system in connection with starting-
up as well as service and repairs. Air bleeds should therefore be mounted in such places in the system
where it may be feared that venting can be required.
3.5 Cleanliness
In connection with installation of hydraulic systems it is of greatest importance that a high degree of
cleanliness is maintained. Many of the problems that arise in connection with the starting-up can be de-
rived from badly or incorrectly cleaned pipes, hoses and coupling components. Pipes must be burred in-
side and outside. After burring and bending the pipes must be cleaned by flushing with detergent liquid
or be ”shot clean” with ”Jetcleaner” or an equally good cleaning method. Cleaning by means of com-
pressed air is not enough. Hydraulic hoses are cleaned in the similar way. Hydraulic connections must be
kept closed until just before mounting. Connectors and other hydraulic components must be kept pro-
tected until just before mounting.
Teflon tape, flax and such sealing material must not be used in connection with hydraulic installa-
tions. Strive to get such a clean mounting environment as possible.
3.6 Connection to source of power

Connection to source of power must be made in accordance with the circuit diagram intended for this
purpose. The installation must be executed by qualified employees in compliance with current harmo-
nized standards. All the connected hydraulic equipments must be provided with disconnectors in the
power supply circuit irrespective of source of power. If the source of power is electricity disconnec-
tors in compliance with EN 60204-1 paragraph 5.3 must be mounted.
4 USE
4.1 Selection of hydraulic oil
4.1.1 General
In a hydraulic system the hydraulic oil is transmitting the power at the same time as it is lubricating the
hydraulic components inside. In order to receive a long life of the system it is important to select a hy-
draulic oil of a good quality.
6
4.1.2 Recommended oil quality

The selected oil must have a high viscosity index and contain supplements that prevent oxidation, corro-
sion and frothing in accordance with international standards (DIN 51524 and 51535). We recommend
that mineral oils belonging to group H-LP as per DIN 51524 part 2 are used.
Viscosity mm2/s
4.1.3 Viscosity
The viscosity of a hydraulic oil is depending on the temperature.
The final selection of oil is depending upon the working tempera-
ture at which the hydraulic system will operate.
For standard industrial applications we recommend that a
working temperature of ca. 30-50°C and that a viscosity at this
temperature in the interval 32 - 68 mm2/s are tried to attain.
The adjoining diagram is showing the relation between viscosity
and temperature for hydraulic oils type H-LP 32, 46 and 68.
4.2 Degree of purity – hydraulic oil Temperature °C

As mentioned in a previous chapter the degree of purity of the hy-
draulic oil is to a great extent of vital importance for the reliability and the life of the hydraulic system.
Regular tests and analyses of the oil should be made in order to secure the recommended degree of pu-
rity.
In standard industrial applications we recommend, if the technical documentation under opening 1
does not specify otherwise, a degree of purity that at least complies to 18/14 as per ISO 4406. In
simpler systems with intermittent duty a degree of purity corresponding to 20/17 can be considered as
acceptable.
4.3 Filling of hydraulic oil
4.3.1 General
The utmost possible cleanliness must be maintained when filling oil into a hydraulic system. In order to
secure the purity degree of the oil also a new oil must be filtrated before it is filled into the system This
should be done by pumping the oil to the tank of the system via the filling cap by means of a filling unit
provided with a filter. Some hydraulic units are equippd with a filling device which is intended for this
purpose and which is mounted ahead of the ordinary oil return filter.
4.3.2 Filling
• Determine the necessary oil quantity. The quantity of the hydraulic unit is evident from the
technical documentation. To this the volume of the pipe system and the operating devices must be
added.
• Before the oil is filled up the closed connections between pumps and tanks must be opened and
ventings, if any, of immersed pump bodies must be opened.
• The cylinders and motors should if possible be filled with oil in connection with mounting.
• Observe the level gauge or the level stick of the tank during filling so that the right quantity is filled
up.
• Observe that the cylinders must have the rod piston in its innermost position and that the accumula-
tors must be unloaded before filling up to the upper marking of the level gauge.
There is a risk of flooding if this is not observed.
7
4.4 Flushing of the hydraulic system
4.4.1 General
In connection with installation of new and repair of existing hydraulic systems it is in practise impossible
entirely to eliminatet the risk of dirt coming into the system. For that reason it is necessary to flush big-
ger hydraulic systems before starting-up. Smaller hydraulic systems, where the cleanliness can be se-
cured by separate cleaning of pipes and hoses, do normally not need to be flushed
4.4.2 Before flushing

• The unit that will be used must be equipped with an amply sufficient oil return filter and if possible
also a pressure filter. The filters must have a degree of filtration that comes up to ß10 = 75 or better.
The degree of filtration ß10 = 75 means that if the oil before the filter contains N articles bigger or
equal 10 µm it contains N - N/75 particles after the filter. This means that 98,6 % of the particles
have been filtrated away.
• Connect the unit to the pressure- and return pipes of the system.
• By-pass past cylinders and motors by connecting the pipe ends with a hose and plug the connections
in the cylinders and the motors.
• By-pass past the hydraulic valves which are mounted at other places of the system.
• Close existing stop- and relief valves to the accumulators.
4.4.3 Flushing
In order to attain the best result of the flushing, do as follows.
• The flushing should be made by the same type of oil by which By-pass
the system is meant to work at normal operation. past users
with hose
• The oil temperature should be ca. 40°C.
• The flow rate should be 5 - 6 m/s.
By-pass
• Secure that all parts in the system are flushed through. past valves
with hose
Flush one circuit at a time.
• The flushing should proceed during at least 2 hours for smaller
systems and for a considerable time for bigger systems.
• The filters which are used during flushing should be currently
controlled by way of indicators.
• Check leakage, if any, and the oil level of the tank continuously.
4.4.4 After flushing

• Restore all the pipe assembly as per the hydraulic
diagram. Flushing unit
• Open existing stop valves to the accumulators.
• Change filter cartridges of the filters which have been
used during flushing.
8
4.5 Starting-up
4.5.1 General
Starting-up of the hydraulic system must be made by employees with required qualifications and
knowledge of the system in question. Read this chapter through and also the technical documentation.
4.5.2 Before starting-up

Before starting-up check that:
• the hydraulic unit is connected in compliance with the circuit diagram and that all the couplings
are screwed.
• the hydraulic unit is connected in compliance with the electric circuit diagram and that it is pro-
vided with an electric disconnector.
• hydraulic oil of the right quality and viscosity is filled up to the upper marking of the tank.
• the pipe system is separately cleaned alternatively flushed in accordance with paragraph 4.4 and
that new filter cartridges have been mounted.
• shut-off cocks, if any, between the pump and the tank are open.
• refrigerant, if any, is connected and connected-on.
• existing relief valves are set in a way that starting-up can be made when the system is
unloaded.
• pressure gauges are mounted so that required controls of set working pressures can be made.
• electric motors have the right direction of rotation. The direction of rotation will be seen from the
sign which is mounted on or in close vicinity to the electric motor. Pse see fig. below. The direc-
tion of rotation is controlled by a quick start - stop operation.
If the direction of rotation is wrong the pump can be damaged.
4.5.3 Venting of pumps

Some pump types require that the existing air is evacuated and that the pump is filled with oil before
starting.
Gear pumps and fixed vane pumps

Normally, no special measure is required when gear pumps are started up.
Piston pumps and variable vane pumps

When using these types of pumps the pump body must be filled with pure hydraulic oil before the first
starting. This is done by dismounting of the draining connection on the top side of the pump and refill-
ing of oil. The refilled oil must be of the same type as the one in the rest of the system. In case the
pump is vertically mounted in the tank the pump body must be filled before mounting of the pump.
9
Radial piston pumps

This type of pump must always be de-aired before starting-up irrespective of mounting. If the pump is
mounted immersed in the oil hydraulic tank there is a separate venting nipple mounted on the top side of
the filler cap marked by a sign. Pse see figure below .
The venting is made as follows:
1. Dismount the screw of the venting nipple before the oil is filled into the oil hydraulic tank.
2. Fill oil to the upper marking of the level gauge and let the tank stand idle for ca. 10 minutes in order to
let the oil fill the pump body and evacuate the air.
3. Mount the screw of the venting nipple again.
The screw of the venting must always be closed. Avluftning av pumphus
If the pump may be able to suck air this way the pump göres under oljepåfyllning.
will not work. Venting of the pump body
should be done during oil filling.
4.5.4 Starting-up
Be watchful for noise and leakage and be always prepared to quickly turn off the plant if anything un-
expected would occur. Please observe that the system can be constructed in such a way that some op-
erating devices may move directly when starting-up.
Before starting-up is made special instructions, if any, under opening 3 in this manual must be carefully
read through. Starting-up should be made by stages with the greatest caution as mentioned below:
• Start existing cooler- and heating functions, if any. Check the directions of rotation and that no leakage
occurs in these circuits.
• Lower the preset pressure of the pressure relief valve of the pump and the pressure compensator, if
any, so that the pump is started unloaded.
• Start the pump. Check that flow is passing out of the pressure pipe by observing the pressure gauge or
by loosening of a pipe coupling. If no flow is passing within a minute, stop the pump and find the reason.
In many hydraulic systems pressure pipes must be vented at start. Undo a pipe- or a hose coupling as
near the pump as possible and let oil bleed out. After that let the pump work unloaded for ca. 3
minutes. Check that no exceptional noise is coming from the pumps and that no leakage is occuring.
• Reset the setting of the pressure relief valve of the pump and the pressure compensator, if any, so that
the system is pressurized.
• Check that the system is working with the pressure settings that the hydraulic diagram states.
• Test all functions, one by one. Run cylinders backwards and forwards a number of times in order to
evacuate existing air, if any.
• Check that the cylinders are working with the right stroke time and that the motors are giving the right
number of revolutions. Adjust if necessary with existing valves, if any.
• Air pockets can arise in the operating devices and other highly placed parts of the pipe system. Air in
the system will often lead to receipt of a wrong function. De-air the system by means of mounted air
bleeds until all the air is evacuated.
• During starting-up air may be mixed into the hydraulic oil. In most cases this will result in the pump
giving noise in the form of rattlings and cracks. Run the pump for short periods and let the system rest
until the air has been separated from the oil in the tank.
• The air which is evacuated from the system during starting-up must be replaced by hydraulic oil. Control
the oil level in the oil hydraulic tank continuously during starting-up and fill up oil if necessary.
• Control that the system is able to maintain the recommended working temperature.
10
5 SUPERVISION AND MAINTENANCE
5.1 General
A regular supervision and maintenance of the hydraulic system are necessary to guarantee the reliability
and the life of the system. The below mentioned intervals for supervision, maintenance and change of
components are our recommendations. Depending upon the operation of the system and the surround-
ings the length of the interval may be adjusted.
5.2 Documentation
Instructions for supervision and maintenance should be documented and make a part of the normal qual-
ity system of the company. A journal of fluid-tests and results from analyzes of the hydraulic oil should
be documented. A journal of filter- and oil change should be kept.
5.3 Materials for supervision and maintenance

During all cleaning drying clothes or cotton rags must be used. Twist or other rags that can contaminate
the system must not be used. If bigger leakages or overflow arise absorbents intended for this purpose
have to be used. Do not use sawdust or similar uncleaning absorbents.
5.4 Exchange of filter

If the technical documentation does not state otherwise we recommend that the filter cartridges are
exchanged at the below mentioned interval. Replaced filter cartridges are composed of dangerous
waste.
• After flushing of the system in connection with starting-up.
• After ca. 50 working hours.
• After that every thousandth hour (ca.).
• When the indicator of the filter gives indication.
5.5 Hydraulic hoses

The hydraulic hoses grow older and must therefore be controlled and exchanged at even intervals. The
length of the intervals is depending upon the type of duty and the surroundings.
5.6 Analysis of oil

Tests and analyses should be made every 6th month if not the outcome from previous tests or the type
of duty requires anything else. The test can be made through the measuring nipple of the main pressure
pipe by means of a testing equipment intended for this purpose. Before the test is made the oil has to be
diverted back to the tank for some minutes so that pollutions in the measuring nipple, if any, disappear.
The analysis should aim at viscosity, oxidation, percentage of water, additive and degree of purity. In
most cases the oil supplier or other independent testing laboratories can supply holders for testing and
make the analysis of the oil and also recommend suitable measurements.
5.7 Exchange of oil

To give general recommendations concerning point of time when the oil has to be exhanged is difficult.
Type of duty, operating temperature, surroundings and the result of the tests are factors which should
determine when the oil has to be exhanged. As a point of aim the oil should be exchanged at least once
a year. In connection with exchange of oil the hydraulic oil tank has to be cleaned inside and the inter-
nal surface finish should be inspected. Touch-up paint if necessary. Replaced hydraulic oil is composed
of dangerous waste.
11
5.8 Lubrication of electric motor

Smaller electric motors have as a rule permanently lubricated bearings. Electric motors of the size 200
and over that have lubricant nipples intended for this purpose (see fig.) and must be regularly lubri-
cated. Clean the nipple carefully and lubricate the bearings with the bearing grease recommended by
the manufacturer.
Lubricant nipple Lubricant
5.9 Daily supervision

At the daily supervision the following has to be done:
• Check the oil level in the tank.
• Check the temperature of the hydraulic oil.
• Check the indicators of the filters.
• Check that no leakage is occuring on or around the hydraulic unit.
• Check that no abnormal noise is occuring.
5.10 Monthly supervision and maintenance

At the monthly supervision the following has to be done:
• Make the daily supervision.
• Wipe the hydraulic unit on the outside. It will in this way be easier to discover leakage, if any, in
time at the same time as the risk of pollutions coming into the systems at other services and repairs
will be diminished.
• Check number of revolutions and speeds so that no changes of the system parameters have happened.
• Check the preloading pressure of existing accumulators, if any.
• Stop the plant and let it rest for some time so that sludge and condensing water, if any, are collected
on the bottom. Then empty some oil from the drain cock in order to remove sludge and water.
Drained oil must be treated as dangerous waste.
• Check all the system so that no leakage is occuring. The checking must also include existing hydraulic
cylinders and hydraulic motors.
5.11 Yearly supervision and maintenance

Atthe yearly supervision the following must be done:
• Make the monthly supervision.
• Exchange the air filter of the oil hydraulic tank.
• Exchange hydraulic oil and clean the tank inside.
• If there is an air cooler mounted the cooling coil and the fan blade have to be carefully checked and
cleaned.
• If there is an oil water cooler mounted this should be dismounted so that an inspection can be made
that the cooler has not been silted-up.
12
6 DISPOSAL
6.1 General
Hydraulic equipment which is included in this general direction will be taken out of operation for recov-
ery. The greater part of the equipment is recoverable, but it also contains components which consist of
dangerous waste. Before the equipment is taken to recovery it must be dismounted and cleaned in order
to separate the dangerous waste.
6.2 Dangerous waste

The below mentioned components are composed of dangerous waste and must be separated.
• Hydraulic oil
• Filter cartridges
• Oiled absorbents which have been used during dismounting and cleaning.
The dangerous waste must be kept separated and be stored in a way that ensures safety until the waste
is taken caren of. Dangerous waste must be treated in accordance with existing rules and regulations in
each country.
6.3 Dismounting
1. Preparations
1. Disconnect the equipment from all sources of power.
2. Clean the equipment on the outside.
3. Decompress and evacuate precharged nitrogen from accumulators, if any.
Caution! There is a risk of suffocation at discharge

in insufficiently ventilated spaces.
4. Make sure that the rod pistons of the cylinders, if any, are in their innermost position.
5. Drain the hydraulic oil from the tank.
2. Accomplishment
Dismount:
1. Electric equipment
2. Pipe and hose which connect unit with cylinders and motors and empty them of hydraulic
oil.
3. Cylinders and motors and empty them of hydraulic oil.
4. Electric motors, pumps, valves, filters, pipes, hoses and empty them of hydraulic oil.
5. The cover of the oil tank. Empty the tank of hydraulic oil.
All components that have been in touch with hydraulic oil should be rinsed and washed with
a degreasing compound containing no hydrocarbon. Assort dangerous waste separately,
source sort steel and metal as far as possible. See to it that all material is taken care of or
is recovered.
Caution! Avoid hot works on painted surfaces. Hot works in material which is
painted with an epoxy product may set air pollutions free dangerous to the health.
13
7 LOCATION OF ERRORS
ERRORS CAUSE REASON
TOO LOW PRESSURE 1. pressure relief valve a. too low set pressure
or below the pressure indi- half-open b. worn seat
cated in the diagram. c. pollutions in the seat
d. spring fracture
2. pump defect see point 5 - 12

3. too big inner leakage a. worn sealings in cylinders or motors
b. worn valves or distributors
c. too low oil viscosity
4. too big pressure drop a. too high oil viscosity

b. weakly dimensioned oil passages
c. stop in oil passages
TOO LOW PUMP FLOW 5. throttled suction connec- a. suction filter too small or silted-up
or below the flow indicated in tion b. suction pipe shut off
the diagram. c. suction pipe too small or silted-up
6. the pump sucks no oil a. check the oil level

b. de-air the pump body
7. air comes into the system a. through suction pipe in the tank
b. through couplings on the suction side
c. through shaft seal on the pump
d. through air-mixed oil
8. the tank is air-proof The air filter of the tank silted-up
9. something wrong with the a. check the shaft coupling
power transm. b. too high or too low number of revolutions
10. high viscosity see data sheet for the pump
11. internal defect in the a. inner sealings damaged

pump b. jamming blades, pressure plates or pistons
c. main parts not tightened
d. inner parts damaged
12. worn pump exchange of pump
PUMP GIVING NOISE 13. cavitation a. throttled inlet: see point 5

deviating from normal noise. b. high viscosity: see point 10
14. air is coming in see point 7
15. worn pump too big play in bearings and pressure plates.
OVERHEATING 16. too high max. pressure the set pressures of the valves too high.
the oil temperature exceeding
recommended temperature 17. supplied power not active a. press. contr. closing valve does not work
b. discharge at cycle end does not function
c. modification of hydraulic system necessary
18. high internal leakage see point 3
19. high pressure drop see point 4
20. inferior oil capacity increase the oil capacity of the tank
21. unsufficient cooling a. supply more cooling

b. the cooling medium not effective
22. high friction a. wrong internal installation of pump
b. lack of lubrication where necessary
c. inferiorly lubricating hydraulic oil
WRONG MOTIONS 23. air in the system a. de-air highly placed parts of the system
operating devices b. eliminate air entrainment, see point 7
14
ERRORS CAUSE REASON
WRONG MOTIONS 24. valves closed a. valves closed by pollutions or other reasons
operating devices at operation
25. cylinders closed a. faulty internal mounting of cylinder

b. illegitimated radial loads
c. jamming fastening parts
26. high pressure drop see point 4
27. varying pressure in a. too small accumulator

accumulator b. bigger accumulator is required because of
leakage
c. wrong preloading pressure
ABNORMAL WEAR 28. the oil contains noxious a. too old hydraulic oil
compared with operating particles b. filter not effective
time in question
29. inferior lubrication a. too inferior quality of the hydraulic oil
b. too low viscosity for the working temp
30. too high work. press. compared with max. pressure for pumps and
valves
31. defective shaft coupling abnormal shaft loads
8 EMERGENCY
8.1 Fire
Standard hydraulic oils are normally not classified as flammable goods. If a moist of oil is occurring there
will be a risk of fire.
If fire is breaking out:
• Evacuate the premises.
• Call the fire brigade. If the plant contains any nitrogen loaded accumulator there may be a risk
of explosion in connection with fire. Inform the fire brigade.
• Extincton media: Carbon dioxide, foam, powder.
• Avoid inhalation of flue gases.
8.2 Overflow of oil

Prevent discharge into drain. If smaller overflows have occurred embankment and pick-up by means of
suitable absorber. If there is a bigger discharge please get in touch with the authorities concerned.
Used/rejected oil has to be treated as dangerous waste.
8.3 Personal exposure to hydraulic oil

Always check with industrial technical data sheet concerning information about the oil to which the per-
son has been exposed. Standard hydraulic oils have normally a low acute toxic effect if swallowed down
and will not be absorbed in acute toxic quantities through the skin.
First aid at:
Inhalation: In the event of dizziness or nausea, remove the injured person to fresh air.
If symptoms persist, obtain medical attention.
Skin exposure: Remove immediately contaminated clothing and wash affected skin with soap
and water. If persistent irritation occurs, obtain medical attention. If high pres-
sure injection injuries occur, obtain medical attention immediately.
Splashes in the eyes: Flush the eyes with copious quantities of water. If persistent irritation occurs,
obtain medical attention.
Ingestion: Do NOT induce vomiting. Do not drink or eat. Obtain medical attention.
15
Our address
is
as follows:
OFFICE, WORKSHOP, STOCK

GOTHENBURG
Askims Verkstadsväg 15
Box 1013, SE-436 21 ASKIM
Tel. +46 31-28 98 40, Fax +46 31-28 64 01
PDF- K-dokument,
K-227_E, 130911,
e-mail: info@pmchydraulics.se
Website: http://www.pmchydraulics.se
16
General Directions—Use—Accumulators
1 GENERAL
The hydraulic equipment included in this manual contains one or several hydraulic accumulators.
An accumulator is a nitrogen filled pressure vessel where the gas is separated from the hydraulic oil
by a piston, a rubber membrane or a rubber blow. Pressurized hydraulic oil is stored in the accu-
mulator by compression of the nitrogen. An accumulator always poses a potential hazard in con-
nection with service and maintenance of the hydraulic system and also in connection with fire.
These directions should be carefully read before transportation, installation and mounting are be-
gun and before the equipment is put into operation.
2 TRANSPORTATION
2.1 Before transportation

Make sure that the accumulator is unloaded and emptied of hydraulic oil. Plug the hydraulic con-
nection of the accumulator in order to prevent leakage during transportation.
2.2 Packing
Load secure the accumulator on the packing in order to prevent the accumulator from moving or
being damaged.
2.3 Transportation
When an accumulator is containing compressed nitrogen it has to be treated as dangerous goods.
Always inform the forwarding agent about the contents of the load. Transportation has to be ef-
fected in accordance with the existing regulations of each country.
3 INSTALLATION
If the accumulator is separately delivered and will be installed observe the following.
3.1 Placing
Accumulators are preferably vertically mounted with the hydraulic connection downwards. Signs
must be visible and it must be possible to reach the venting screws, if any. Make also sure that
there is a space for the preloading device. Gas holders combined with bigger accumulators are ver-
tically mounted with the connection downwards. There should be a possibility of closing between
the accumulator and the gas holder (it should be possible to seal or to lock in
open position in order enable the burst disc to protect both the accumulator
and the gasholder) and also to empty the gas holder without being necessary
to empty the accumulator of gas. Pse see adjoining figure. Soft sealings or
flared tube fittings should be used at the gas side.
3.2 Fixing
Fixing cramps and brackets intended for this purpose should be used. Small
membrane accumulators are fixed by a fixing cramp. Piston- and blow accu-
mulators smaller than 20 litres are fixed by two cramps. Bigger accumulators
and more exposed installations require that a bracket is used too.
1
General Directions—Use—Accumulators
Pse see adjoining figure. Do not weld support or the like directly in the accumulator.
No other machining of the accumulator must be made. Pipings to the
accumulator must not be loaded and the cramps must be carefully fixed.
3.3 Protection
If damage by accumulator with belonging fittings may involve hazard the accumulator
and belonging fittings must be built-in or be protected by covers which have been added to.
3.4 Accessories
Safety block must be used when the accumulator is installed in order to increase the security
and to simplify at the maintenance and service. The block has to be mounted in direct connection
to the accumulator. Shut-off cock between accumulator and main pipe is preferable. Burst disc or
fuse should be used when the system has a larger quantity of gas compressed in accumulators and
gas holders. These are meant to protect the gas side against unpermitted pressure levels that may
arise in the event of errors at the safety valves, if any, or if fire is breaking out.
3.5 Marking
The accumulator must always be marked with a caution sign as
per adjoining figure or the like. If the system is constructed in a
way that the accumulator contains pressurized fluid after the
system has been shut off a separate caution sign with warning
about this has to be mounted near to the accumulator.
4 SUPERVISION AND MAINTENANCE
4.1 Supervision
Check the precharge pressure of the accumulator in connection with the monthly supervision. Use
the precharge equipment intended for this purpose. Follow the enclosed service- and installation
directions for the accumulator in question.
4.2 Maintenance
The maintenance work and the repairs of the accumulators must only be made by qualified and
competent employees. Always ensure that the accumulator is unloaded before any work is
started. Follow the enclosed service- and installation directions for the accumulator type in ques-
tion.
5 EMERGENCY SITUATION
K-229/E, Giltigt t.o.m. 130910, pdf-arkivet
5.1 Fire
If fire is breaking out:
• Evacuate the premesis
• If the plant contains any nitrogen loaded accumulator there may be a risk of explosion in
connection with fire. Inform the fire brigade!
2
A Added Pos. 17 and 18 101022 PP CN
12 13 14 15 17 18
This drawing and the design is the property of AB Gustaf Terling. It is strictly confidential and must not be copied, traced or loaned whitout our permission.
10
P-FLUSHING
11
T-FLUSHING
1 7 8 9
2 5
6
16
3

must not be copied, traced or loaned without Box 602, 661 29 SÄFFLE SWEDEN
DRAWN: SIGN. PP
2010-05-12
CHECKED: 2010-05-12 SIGN. CN

ASSEMBLY DRAWING
PART LIST: 126161-P
MAT.
Commissioning Kit 12-25/10-DUPLEX
W.O. REPLACES BY
126161-A A
Hydraulic parts list: Commissioning Kit 12-25/10-DUPLEX
CCI Article No.: S1650233 Parts list no.: 126161-P
Dim. drawing: 126161-A

Checked: 2010-05-12 Sign.: CN

A 101022 PP Added Pos 17 and 18
B 101102 PKA Changed ITNO for Pos 7,8,9,17,18
REC. SPARES
DEL.
1 Commissioning Kit 12-25/10-DUPLEX 126161

1 2 Filter Element MF100-2-A03HB 402-50-156 MP Filtri
2 2 Filter Element 0060 D 010 BH3HC 440-15-012 Hydac
3 1 Pressure gauge 2750-DIM63/0-250 403-00-104 Wika
Hose SMS20/M-630A(M16X2-
4 2 1/4") 401-73-216 Temeto
5 1 Precharge equipment CGH-3000 401-70-310 Oiltech
6 1 Flow control valve FT1251/2-01-14-MA 401-81-502 Tognella
7 5 O-ring kit (4pcs) Ø8,73x1,78 104563 PMC Hydraulics

8 2 O-ring kit (5pcs) Ø12,42x1,78 125604 PMC Hydraulics
O-ring kit NG16 (7pcs) Ø34,52x3.53 4pcs
9 1 Ø20,29x2.62 3pcs 128300 PMC Hydraulics
Hose Kit 2SN-1/2"-1000-DKSO16-
10 1 G1/2"inv 103015 Parker
Hose Kit 2SN-1/2"-1000-DKLO18-
11 1 G1/2"inv 103016 Parker
12 2 Fitting GE12SR-1/2 100177 Parker
DEL.
16 1 Filling Hose 125944 PMC Hydraulics
17 2 Adapter 7005-08-08 111153 Hydroscand
18 2 Adapter 7201-08-08 401-76-071 Hydroscand

A 2011-01-29 First issue Pah
REV DATE DESCRIPTION SIGN
Project: Vandana Vidyut

Customer: Cethar Vessels LTD
CCI Vo No: 301912
PREPARED BY DATE TITLE:
Pah 2011-01-29 Hydraulic Power Unit Pump Logic

CHECKED BY DATE
Pah 2011-01-29 DOCUMENT NUMBER: HSL301912

HYDRAULIC SUPPLY LOGIC (HSL)
Logic diagram
1. Application
The Hydraulic Supply Logic HSL serves to control and monitor one hydraulic supply
unit, with two pumps. In case of deviation from normal operation (error), a fault is
produced. The latter is signalized on two different priority levels: WARNING, if the
personnel has sufficient time for correcting actions and FAULT, if immediate
interlocking actions are required. As long as FAULT is not present, the supply unit
service is like "undisturbed".
The HSL consists of one programmable controller mounted inside a cabinet and a
touch display on cabinet door.
2. Function
One pump is chosen to be operating as a continuously running pump. The second
pump will be acting as a stand by pump, which will be started only if the system
pressure falls under the P-low set point. The standby pump will then be running during
a present period of time, 5 minutes. If the pressure still is on or below the P-low set
point the stand by pump continue running.
Fault P-too low will occur when pressure is on or below too low setpoint.
The Hydraulic Supply Logic System will switch running and standby pumps after a
present period of time, 24 hours. The reason for this is to achieve same total running
time for both pumps.
Input signals from the hydraulic supply unit, to the controller (PLC)
Alarm/Warning Degree of signal Signal from Set point Action

Pressure too low Fault P‐transmitter 130 bar / 1 sec No action
335 mm from tank
Oil level too low Fault Level switch lid / 5 sec Stop pumps
HPU Stop button
HPU Stop Fault SB1 0 sec Stop pumps
Undervoltage Fault Undervoltage relay ‐10% / 2 sec Stop pumps
Pressure low Warning P‐transmitter 190 bar / 1 sec Start standby pump
Stop pumps.
Automatic re‐start
Pressure high Warning P‐transmitter 250 bar / 10 sec at pressure low.
270 mm from tank
Oil level low Warning Level switch lid / 5 sec No action
Start standby
Oil temp high Warning Temp switch 65°C / 1 sec cooler
Oil temp too high Warning Temp switch 80°C / 1 sec No action
Over current P1 Warning Thermal protection 0,1 sec Start next pump
Over current P2 Warning Thermal protection 0,1 sec Start next pump
Over current P3 Warning Thermal protection 0,1 sec Stop pump/fan
Over current P4 Warning Thermal protection 0,1 sec Stop pump/fan
P1 don't start Warning Motor contactor 0 sec Start next pump
P2 don't start Warning Motor contactor 0 sec Start next pump
P3 don't start Warning Motor contactor 0 sec Pump don't start
P4 don't start Warning Motor contactor 0 sec Pump don't start
Safety switch P1 Warning Safety switch QF1 Off / 0 sec Start next pump
Safety switch P2 Warning Safety switch QF2 Off / 0 sec Start next pump
Safety switch P3 Warning Safety switch QF3 Off / 0 sec Stop pump
Safety switch P4 Warning Safety switch QF4 Off / 0 sec Stop pump
Filter failure P1 Warning Filter dP switch dP>5 bar / 10 sec No action
Filter failure P2 Warning Filter dP switch dP>5 bar / 10 sec No action
dP>1,6 bar / 10
Filter failure P3 Warning Filter dP switch sec No action
dP>1,6 bar / 10
Filter failure P4 Warning Filter dP switch sec No action
Handoperated Input signals
MANUAL MODE Motors can be started and stopped manually by buttons on

touch screen, if “pressure high” or “level too low” are not activated.
AUTO MODE Unit is in Auto operation.
OFF (0): Unit is off.
Output from the controller (PLC) to touch screen/HMI display.
Alarm/Warning Degree of signal Signal from Note

Pressure too low Fault P‐transmitter
Oil level too low Fault Level switch
HPU Stop Fault HPU Stop button SB1
Undervoltage Fault Undervoltage relay
Pressure low Warning P‐transmitter
Two pumps running Warning P‐transmitter
Pressure high Warning P‐transmitter
Oil level low Warning Level switch
Oil temp high Warning Temp switch
Oil temp too high Warning Temp switch
Over current P1 Warning Thermal protection
P1 don't start Warning Motor contactor
Safety switch P1 Warning Safety switch QF1
Filter failure P1 Warning Filter dP switch
Beside processing of HSU signals, the following signals are available for the plant
control system. (DCS)
• A sum No Warning signal
• A sum No Fault signal
• HPU in AUTO mode
• Pump 1 running signal
• Pump 2 running signal
In case of a warning or fault condition, the touch screen/HMI display will show which
warning or fault condition is present.
Note: Oil pressure, oil level and oil temp are supervised by redundant instruments.
The logic for this is based on “one of two”.

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2 Circuit diagram 128462-CC

3 Hydraulic circuit diagram 128462-C

4 Hydraulic parts list 128462-P

5 Assembly drawing 128462-A

6 General function description of

7 Installation of hydraulic system K-320

8 HSU valve position indication K-367

9 Oil filling filter circulation K-321

11 HSU starting of hydraulic system K-322

12 HSU service and maintenance K-323

13 HSU general directions K-227

14 General directions use accumulators K-229

15 Commissioning Kit S1650233

16 Hydraulic Power Unit Pump Logic HSL301912

ACCUM. (Pressure side)

ACCUM. (Tank side)

Pressure red. At output port: Setting: bar

Distribueras: Ersätter: Godk.: Ansv.: Tillhör: Typ: Sid.:

Drawn: 2010-10-20 Sign.: PP

Rev. Date Sign. Alteration

Parts list no.: 128462-P 1(3)

Parts list no.: 128462-P 2(3)

Parts list no.: 128462-P 3(3)

Parts list no.: 128462-P 4(3)

Drawn: 2010-10-20 Sign.: PP

Rev. Date Sign. Alteration

2 HOSE & FITTING KIT

Parts list no.: 128463-P 2(2)

Drawn: 2010-10-20 Sign.: PP

Rev. Date Sign. Alteration

2 HOSE & FITTING KIT

Parts list no.: 128464-P 2(2)

Drawn: 2010-10-20 Sign.: PP

Rev. Date Sign. Alteration

2 HOSE & FITTING KIT

Parts list no.: 128465-P 2(2)

62b burst disc

OIL FILLING: G1"

2000 ~210 1200 ~150

Hydraulic circuit diagram : 128462-C

DRAWING MADE BY AB GUSTAF TERLING

Ø14 (4x) Weight : ~120kg

= = 21 Hydraulic circuit diagram : 128463-C

DRAWN 2010-10-20 SIGN. PP

CHECKED 2010-10-20 SIGN. BS

P Customer : Cethar Vessels Limited

Ø14 (4x) Weight : ~130kg

= = 21 Hydraulic circuit diagram : 128464-C

DRAWN 2010-10-20 SIGN. PP

CHECKED 2010-10-20 SIGN. BS

P Customer : Cethar Vessels Limited

Ø14 (4x) Weight : ~130kg

= = 21 Hydraulic circuit diagram : 128465-C

DRAWN 2010-10-20 SIGN. PP

CHECKED 2010-10-20 SIGN. BS

1. Construction of hydraulic systems

2. Hydraulic Supply Unit – HSU

Distribueras: Ersätter: Godk.: Ansv.: Tillhör: Typ: Sid.:

Distribueras: Ersätter: Godk.: Ansv.: Tillhör: Typ: Sid.:

4. Hydraulic valves for control of CCI’s actuators

Distribueras: Ersätter: Godk.: Ansv.: Tillhör: Typ: Sid.:

Pos. Designation Function

1.11 Gear pump Main pump P1/P2.

01 01 Additional flow control valve in connection

02 02 Pressure reducing valve in connection with

10 10 Directional control valve to open the CCI

11 11 Flow control valve in connection with

12 12 Pressure reducing valve in connection with

20 20 Directional control valve to close the CCI

21 21 Flow control valve in connection with

22 22 Pressure reducing valve in connection with

30 30 Spare number for additional hydraulic

40 40 Spare number for additional hydraulic

50 50 Valve for stop function. Function is shown

51 51 Flow control valve in connection with stop

52 52 Pressure reducing valve in connection with

60 60 Valve block on which the other hydraulic

70 70 Ball valve for closing of pressure pipe.

71 71 Ball valve which is used to connect P and

72 72 Check valve on return channel which

80 80 Locally placed accumulator (P). Can be

82 82 Locally placed gas holders (P) to

85 85 Pressure relief, unloading and closing of

90 90 Locally placed accumulator which is