Operacion y Mantenimiento Stacker PDF

ThyssenKrupp Industrial Solutions
Operation and maintenance manual

(Mechanical part)
STACKER
TYPE STD-4500/29.5x1.2
(930-ST-110)
Volume M1
Project: SHOUGANG / IRON ORE PROJECT (Package 6)
Order-No.: N-033-00114
Year of construction 2013/2014
Fig.: 225-STD4500-D01
ThyssenKrupp Industrial Solutions AG

BU Resource Technologies
Ernst-Heckel-Straße 1
D-66386 St.Ingbert-Rohrbach
Phone: (06894) 599 - 0
Facsimile: (06894) 599 - 468
Internet: www.thyssenkrupp-industrial-solutions.com
March 20, 2015 225 E - SHOUGANG Stacker STD-4500 (930-ST-110) Cover sheet M1 - 1
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List of revisions
Document : Operation and maintenance manual (Mechanical part)

Volumes M1 + M2
Machine : Stacker
Type STD-4500/29.5x1.2
Machine no. : 930-ST-110
Order no. : N-033-00114
First issue March 20,

– –
2015
Revision Date Revised chapter/Page Description of revision
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INTRODUCTORY REMARKS
Dear customer,
This operation and maintenance manual

STACKER STD-4500 (Mechanical part)
is divided into the following chapters:
1. GENERAL SECTION
(Volume M1)
2. OVERVIEW IRON ORE HANDLING SYSTEM

(Volume M1)
3. DESCRIPTION OF MACHINE AND ASSEMBLY GROUPS

(Volume M1)
4. OPERATION
(Volume M1)
5. MAINTENANCE
(Volume M1)
6. SUPPLIERS’ DOCUMENTATION
(Volumes M1 + M2)
The individual tables of contents for the chapters 1 to 6 contain headings which
permit rapid access to the requested subject and serve as guide together with the
characteristics given in the footers.
The chapters of the operation and maintenance manual are each provided with
consecutive page numbers (for example: chapter 1, pages 1 - 30).
Only the mechanical part of the stacker is described in this operation and maintenance
manual.
The part on the hydraulical equipment is contained in the hydraulical operating

instructions and the part on the electrical equipment and control system is contained
in the electrical operating instructions. It is recommended always to use these
operating instructions in conjunction with the mechanical operation and maintenance
manual for reference.
The scope of supplies also includes the spare parts catalogue, which – in addition to
the normal contents – includes piece weights and drawing numbers and group lists of
the assembly units.
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1 GENERAL SECTION
1. GENERAL SECTION
(Volume M1)

(Volume M1)

(Volume M1)
4. OPERATION
(Volume M1)
5. MAINTENANCE
(Volume M1)
(Volumes M1 + M2)
Access to chapter 1 "GENERAL SECTION" is facilitated by table of contents and by

footers.
March 20, 2015 225 E - SHOUGANG Stacker STD-4500 (930-ST-110) Chapter 1 - 1

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TABLE OF CONTENTS
1.1 GENERAL ............................................................................... 5

1.1.1 User guide ............................................................................................... 5
1.1.2 Liability and warranty ............................................................................... 7
1.1.3 Copyright ................................................................................................. 8
1.1.4 Technical modifications ........................................................................... 8
1.2 GENERAL SAFETY INSTRUCTIONS ..................................... 8
1.2.1 Principles ................................................................................................. 8
1.2.2 Modifications and spare parts .................................................................. 9
1.2.3 Personnel .............................................................................................. 10
1.2.4 Noise pollution ....................................................................................... 12
1.2.5 Residual risks during daily operation ..................................................... 12
1.2.6 Disposal of consumables and process materials ................................... 12
1.2.7 Fire Protection ....................................................................................... 13
1.2.8 Post Earthquake Evaluation .................................................................. 14
1.2.9 Designated use of the machine/plant..................................................... 15
1.3 GENERAL OPERATING INSTRUCTIONS ............................ 16
1.3.1 General Information ............................................................................... 16
1.3.2 Equipment Testing ................................................................................. 16
1.3.3 No-Load Commissioning of the System................................................. 17
1.3.4 Safety Instructions relating to the operation ........................................... 17
1.4 GENERAL MAINTENANCE PRINCIPLES ............................ 18
1.4.1 Safety instructions relating to maintenance ........................................... 18
1.4.2 Inspection .............................................................................................. 21
1.4.3 Maintenance .......................................................................................... 23
1.4.3.1 Cleaning instructions .................................................................................... 24
1.4.3.2 Lubricating instructions ................................................................................. 25
1.4.3.3 Instructions relating to oil hydraulic system................................................... 26
1.4.3.4 Instructions relating for the replacement of wear parts.................................. 28
1.4.4 Repair .................................................................................................... 29
1.4.5 Spare part stocks ................................................................................... 30

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1.1 GENERAL
1.1.1 User guide
The operation and maintenance manual is designed to familiarize the user with the
machine/plant and its intended use.
This manual has been prepared by TKIS and must be observed in every detail by those
responsible for the transport, assembly, commissioning, operation and maintenance of
the machine/plant, as well as the disposal of all consumables and process materials.
Only by following the instructions in this manual can errors be avoided in operating and
servicing the machine/plant, thus ensuring troublefree operation.
The manual contains important information on how to operate the machine/plant safely,
properly and most efficiently. Observing this information helps to avoid danger, reduce
repair costs and downtimes and increase both the reliability and the life of the machine/
plant.
The manual must always be available, wherever the machine/plant is in use.
The descriptions contained in the manual are given on the assumption that only skilled
personnel who have received adequate training will be employed in operation the
machine/plant.
The manual does not include instructions and guidelines for major repair work. TKIS
can provide skilled and qualified personnel to carry out inspections and repairs if re-
quired
The manual includes numerous instructions to be regarded as warning of potential

dangers. However, the user is responsible for training the operating staff on site and
ensuring that the safety regulations are complied with.
The operating and maintenance manual contains various types of warnings, each
consisting of a symbol and text. The design of the warning varies depending on the
type, nature and severity of the hazard.

The following symbols and designations are used in the manual to highlight instructions
of particular importance:
Danger!
This draws attention to risks/hazards which may occur with the activities
described. In case of “Danger” reference is made to hazards or circum-
stances which could cause injury to persons. If you expose yourself or
other people to this risk, death or severe injury may be the consequence.
Adhere strictly to the safety regulations and proceed with the utmost care.
Caution!
This draws attention to risks may occur with the activities described.
In case of “Caution” reference is made to activities which could cause
damage to the machine/plant or other objects.
Note!
Includes additional information and tips for operating the machine/plant
skillfully and economically.
Definitions:
right = on the right-hand side looking in conveying direction
left = on the left-hand side looking in conveying direction
• = instructions (in stated order)
– = listing in text
/ = or
TKIS = ThyssenKrupp Industrial Solutions AG

1.1.2 Liability and warranty
TKIS explicitly exclude all liability and warranty claims for damage or operational
malfunctions caused by:
• disregarding any information / instructions included in the manual;
• incorrect operation;
• any use of the machine other than the designated use;
• insufficient servicing;
• use of consumables (particularly lubricants) not explicitly approved by the
manufacturer;
• use of spare parts not approved by the manufacturer;
• conversions and modifications not approved by the manufacturer.
The contractually agreed warranty and liability provisions for the supply of the
machine/plant remain applicable.
Note!
The operating licence for the machine is issued by the manufacturer upon
successful commissioning.
It is valid for the whole lifetime of the machine or other design-related
criteria such as operating hours and load cycles while complying strictly
with the operating conditions agreed between manufacturer and owner.
In the present case, the machine has been rated and dimensioned for a
maximum lifetime of 25 years or max. 200.000 operating hours.
After arriving at one of these limits the operating licence expires forever. It
will also expire upon unusual occurrences such as accidents or overloads
of the machine.
Every further use of the machine under the circumstances mentioned
before takes exclusively place at owner’s risk then.
After that the reissue of the operating licence requires the general over-
haul of the machine to be realised by the manufacturer or a specialist
company or the express written declaration of the manufacturer.
Irrespective of that the operating licence is only valid if all maintenance
and inspection intervals prescribed, as well as the maintenance instruct-
tions are kept, too.

1.1.3 Copyright
TKIS reserve all rights in connection with this documentation, including those relating to
patent registration or utility-model registration. Without our previous written consent,
this documentation may neither be disclosed to third parties nor be reproduced without
our permission nor be used in any other unauthorized manner.
1.1.4 Technical modifications
TKIS reserve the right to change designs as a result of technical developments. Recent
modifications may not yet have been included in the drawings and texts of this manual.
1.2 GENERAL SAFETY INSTRUCTIONS

1.2.1 Principles
The machine/plant has been manufactured in accordance with recognized safety rules.
Nevertheless its use may constitute a risk to life and limb of the user or third parties, or
cause damage to the machine/plant and to other material property.
These safety instructions must be observed by all persons responsible for the trans-
port, assembly, commissioning, operation and maintenance of the machine/plant, as
well as the disposal of consumables and process materials. We recommend that the
owner obtains signed confirmation that the safety instructions have been read and
understood by his personnel.
The machine/plant must only be used in a perfect technical condition in accordance

with its designated use and the instructions set out in the manual, and only by safety-
conscious persons who are fully aware of the risks involved in operating the machine/
plant.
Any functional disorders, especially those affecting the safety of the machine/plant,
should therefore be rectified immediately.
In addition to the operation and maintenance manual, all other generally applicable
legal and mandatory regulations relating to accident prevention and environmental
protection must be observed.
These compulsory regulations may also deal with the handling of hazardous sub-
stances and wearing of personal protective gear.
Observe all safety instructions and warning signs attached to the machine/plant.
Ensure that safety instructions and warning signs attached to the machine/plant are
always complete and perfectly legible.

In the event of safety-relevant modifications or changes in the behaviour of the

machine/plant during operation, stop the machine/plant immediately and report the
malfunction to the responsible person.
Never make any modifications, additions or conversions to the machine/plant which

might affect safety without the supplier’s approval. This also applies to the installation
and adjustment of safety devices and valves as well as to welding work on load-
bearing elements.
Hydraulic hose pipes are to be exchanged at appropriate intervals, even if no safety-

related defects are visible!
Adhere to prescribed intervals or those specified in the operating and maintenance

manual for routine checks and inspections.
When carrying out maintenance work only use tools and workshop equipment suitable
for the task in hand.
Measures must be taken to guarantee that the machine/plant is only operated in a safe
and fully operational condition.
Do not operate the machine/plant unless all safety devices and facilities are correctly
installed and are fully operational.
These operation and maintenance instructions must be supplemented by instructions

covering the duties involved in supervising and notifying special internal company fea-
tures such as job organization and working sequences.
1.2.2 Modifications and spare parts
For safety reasons, conversions and modifications are prohibited unless previously
approved by TKIS.
The use of accessories and spare parts not approved by TKIS may cause unfore-
seeable hazards.

1.2.3 Personnel
Danger!
It is prohibited for the operating personel to drink alcohol and take drugs or
other perception-affecting medicine before and during working hours!
Personnel entrusted with work on the machine/plant must have read the operation and
maintenance manual and in particular the chapter on safety before beginning work.
Reading the instructions after work has begun is too late. This applies especially to
persons working only occasionally on the machine/plant, e.g. during setting up or
maintenance.
Only persons wearing the statutory protective clothing may acces the machine/plant.
Personnel must, at the very least, wear a safety helmet and safety shoes.
For safety reasons, long hair must be tied back or otherwise secured, garments must
be close-fitting and jewellery - such as rings - must not be worn. Injury may result from
getting up in the machinery or from rings catching on moving parts.
Use protective equipment wherever required by the circumstances or by law.
Protective clothing!
Safety helmet!
Safety shoes!
Protective gloves!
Protective goggles!
Familiarize all personnel with all safety devices and warning signals before allowing
access to the machine/plant. The operating personnel must be familiar with the location
of the emergency-stop switches.

Danger!
Operators must be familiar with all safety regulations and safety devices in
order to react immediately in case of emergency.
The user is responsible for training his staff accordingly and to keep the
training standards at a high level.
Safety regulations and safety devices must be checked regularly and must
not be rendered inoperative.
Any work on and with the machine/plant must be carried out only by reliable personnel
who are able to carry out the job both physically and mentally. Statutory minimum age
limits must be observed.
Employ only trained or instructed staff and set out clearly the individual responsibilities
of the personnel for operation, set-up, maintenance and repair.
With regard to staff, this operation and maintenance manual distinguishes between:
- Operating personnel with the exclusive task of operating the machine;
- Maintenance personnel entrusted with maintenance, inspection and repair
duties, which include cleaning and lubricating parts of the machine/plant, as well
as the replacement of spare and wear parts, the disassembly and assembly of
components and all kinds of repair work;
- Supervisory personnel responsible for giving the appropriate directions in
connection with the work that is to be carried out and for supervising any such
work.
Define the machine operator’s responsibilities - also with regard to observing traffic
regulations - giving the operator the authority to refuse instructions by third parties that
are contrary to safety.
Work on the electrical system and equipment of the machine/plant must be carried out
only by a skilled electrician or by instructed persons under the supervision and guid-
ance of a skilled electrician and in accordance with electrical engineering rules and
regulations applicable or valid at the place of operation.
Work on the safety-related controls of the machine/plant may only be carried out by
specially trained personnel. TKIS does not assure a garanty or a responsibility for
accidents or damages due to a work on safety-related control units being carried out by
persons not authorized by TKIS.
Work on the hydraulic system must be carried out only by personnel with specialist
knowledge and experience of hydraulic equipment.
Persons being trained or instructed, or persons taking part in a general training course
may only work on the machine/plant under the supervision of an experienced person.

1.2.4 Noise pollution
Depending on the intended use of the machine/plant, noise emissions occur which can
only be measured during operation. Immediately after commissioning the user has to
ensure that, according to local regulations, the noise level is measured at all operating
positions (e.g. for maintenance and inspection, control station).
When the permissible limits are exceeded, the operating personnel

must wear protective equipment such as ear protectors.
1.2.5 Residual risks during daily operation
The machine has been designed taking into account the contractually agreed safety
requirements.
However, risks may nevertheless occur during machine/plant operation.
Its use may constitute a risk:

- to the life and limb of the user´s operating/servicing personnel, or
- to third parties, or
- cause damage to the plant or to other material property.
1.2.6 Disposal of consumables and process materials
Ensure that all consumables and process materials are disposed of

properly with no environmental impact. All applicable national regula-
tions for the protection of the environment must be complied with.

1.2.7 Fire Protection
Observe the legal regulations governing fire protection and prevention and supplement
them with the company’s own instructions. Consult the insurance company’s fire
experts for this purpose.
Appoint supervisory personnel responsible for all matters concerning fire prevention
and fire fighting and provide them with the necessary authority.
Managerial staff and engineers must give the appropriate advisory support.
The supervisor must inspect the fire fighting equipment and installations at regular
intervals to ensure that they are always ready for use. Particular attention must be paid
to areas which can easily catch fire.
Personnel entrusted with supervisory and fire-fighting tasks must have attended first-
aid courses. First-aid points must be provided.
Display the fire protection rules at several points on the plant.
All personnel must receive instruction in fire protection measures. Fires must be re-
ported immediately.
The assembly units and assembly groups which heat up during operation due to the
electrical and/or mechanical load to which they are subjected, must be monitored by
the staff responsible for this equipment. This applies, for example, to blowers, gear
units, bearings, motors.
The user must provide an adequate number of hand-held fire-extinguishers at easily

accessible places. Fire extinguishers must be easily accessible and must not be hidden
behind other objects.
Personnel must be familiarized with the use of fire extinguishers so that they can fight
fires using the type of extinguishers suitable for the particular fire.
The operating, maintenance and servicing personnel must be trained to watch out for
potentially dangerous fire situations, to report them and, if necessary, to eliminate
them.
This manual is not a fire-prevention instruction. The user is responsible for adhering to
the national, state and local regulations in consultation with the local authorities.
We recommend that the following procedures be adopted:

- Use water on burning wood, rubbish, fabrics, jute, paper, belts etc.
- Always use CO2 or dry (powder) extinguishers on burning liquids
(mineral oil, petrol, oil, paint, tar etc.).
- Always use CO2 or dry (powder) extinguishers on burning cables,
motors, electrical equipment etc.

1.2.8 Post Earthquake Evaluation
Earthquakes, even at low intensity, may damage the structure of the machine/plant.
Therefore, after each earthquake, an extensive inspection of the machine/plant
according to the recommendations specified in this manual and the local applicable
specifications must be carried out.
All structures are designed according to the contractually predetermined earthquake

intensity.
Any inspection plan to be prepared by the user must be based on national specific
standards, guidelines and laws.
Recommendations specified herein have to be integrated into the overall plan of the
user.
This plan shall include:

- the organisation of the inspection team,
- a list of risks for the machines and structures sorted by priorities.
The inspection team shall consist of structural engineers and/or design engineers
experienced in the design of structures exposed to earthquakes. A detailed inspection
and valuation of the structures and machines shall be carried out. Personnel expe-
rienced in maintenance and operation shall carry out an inspection and valuation of the
mechanical and electrical system as well as the control system of the machine.
It is necessary that the inspection team has an inspection list arranged according to
priority of danger.
For inspection and valuation of damage the priority shall be specified as follows:
- First priority:
damage to the supporting structure anchors and foundations including foundation
settlement;
- Second priority:
operational related damage.
The scope of the inspection shall be consistent with the intensity of the earthquake:
- minor earthquakes:
inspection for misalignment;
- moderate earthquakes:
damage may occur both in the linings and claddings as well as to the utility
service lines. Misalignments due to foundation movement are also possible;
- strong earthquakes:
damage to the supporting structure and the mechanism may occur. Inspection of
all supporting elements and mechanical components is necessary.
In case of doubt after a minor earthquake, it would be better to carry out a complete
inspection in order to find, at early stage, even minor damage that may lead to conse-
quential damage.

1.2.9 Designated use of the machine/plant
Only use the machine/plant within the limits of its designated use, which are specified
in the contract of supply for the machine/plant.
TKIS cannot be held liable for any damage resulting from any misuse. The risk of such
misuse lies entirely with the user.
Operating the machine/plant within the limits of its designated use also involves
observing the instructions set out in the operating manual and complying with the
maintenance directives.
Caution!
Only operate the machine/plant in its original condition and only use spare
and wear parts supplied or approved by TKIS.
Modifications must be carried out by TKIS or be technically approved by TKIS. TKIS

cannot be held liable for damage resulting from spare parts or wear parts delivered by
third parties or for modifications that have not been carried out or approved by TKIS.

1.3 GENERAL OPERATING INSTRUCTIONS

1.3.1 General Information
We strongly recommended that the assistance of TKIS staff is sought for the initial
start-up process, not only for warranty reasons, but also for:
- inspecting the machine/plant,
- determining the optimum performance,
- instructing the operating staff,
- giving additional information on the mode of operation, maintenance and repair.
1.3.2 Equipment Testing
Before the equipment is powered, all checks and tests which can be carried out should
be completed including:
• compliance with applicable codes, standards, specifications, drawings and

manuals;
• checking the tightening torques of HSFG bolts;
• checking all pipings for leaks;
• checking the adjustment torques of couplings and brakes;
• checking the brake settings (if any);
• ensure the correct fluid level in all gearboxes, fluid couplings etc.;
• ensure all equipment is lubricated in accordance with the manufacturer’s

specification;
• ensure all moving parts are properly protected;
• complete a functional check on all safety devices and emergency stops;
• complete a general visual inspection for any obvious damage.

1.3.3 No-Load Commissioning of the System
The System must be operated without load first, in order to confirm the proper function-
ing of components.
Prior to and during no-load commissioning of the System, the following instructions,
which are the responsibility of the supervisory staff, must be followed:
- All technical and operational safety rules and regulations have been established,
and must be complied with.
- All operating personnel must know the location of all emergency shutdown
switches and all local control switches.
- The System must have been inspected, and foreign materials etc. removed.
1.3.4 Safety Instructions relating to the operation
Operate the machine/plant only if all protective and safety-oriented devices such
as removable guards and emergency shutdown equipment, sound-proofing ele-
ments and exhausters are in place and fully operational.
Keep a log book in which the following information is recorded on a daily basis:
- starting and finishing times of work,
- responsible equipment operator and responsible supervisory personnel of the
machine/plant,
- material throughput,
- downtimes and reasons,
- maintenance and repair work carried out, including the name of the person(s)
carrying out the work,
- unusual occurrences.
Organize shift changes so that the shifts overlap. This ensures that all important
information, in addition to that entered in the log book, is passed on.
It is strictly forbidden to pass under moving or rotating plant parts. Do not touch moving
or rotating parts.
When working at or with the machine, always wear the specified protective gear.
Any possible sources of ignition, such as sparks, current leakage, overheating, etc.
must be avoided.
All braking systems must be checked to ensure that they are in perfect working order.
Check the machine/plant at least once per working shift for obvious damage and de-
fects. Report any changes (including changes in the machine’s working behaviour) to
the responsible person immediately. If necessary, shut the machine/plant down imme-
diately and lock it.

Repair any malfunctions immediately.
During the start-up and shutdown procedures always watch the indicator instruments/
displays in accordance with the manual!
Frequent starting and shutdown operations may affect the machine.
Before starting up the machine/plant, make sure that no-one is at risk.
Give warning signals!
1.4 GENERAL MAINTENANCE PRINCIPLES

Servicing work is intended to maintain and restore the required condition of the
machine/plant, as well as to determine and assess its current condition.
Servicing work comprises

- Maintenance,
- Inspection,
- Repair.
Repair work must be carried out on schedule in accordance with the specified scope of
work.
1.4.1 Safety instructions relating to maintenance
Danger!
Do not carry out cleaning, inspection and maintenance work unless the
machine/plant is shut down.
Caution!
For the safety of the machine and for your own safety all maintenance
work must be carried out on time. Do not postpone maintenance work.
The manufacturer does not accept liability for damage resulting from
maintenance work that is not carried out or has not been carried out on
time.
Observe the adjusting, maintenance and inspection activities and intervals set out in
the manual, including information on the replacement of parts and equipment. Only
skilled personnel are allowed to carry out the work.

Brief operating personnel before beginning maintenance work, and appoint a person to
supervise the activities.
In any work concerning the operation, conversion or adjustment of the machine/plant

and its safety-oriented devices or any work related to maintenance, inspection and
repair, always observe the start-up and shutdown procedures set out in the manual and
the information on maintenance work.
Do not carry out work on the machine/plant unless it is shut down.
If the machine/plant is completely shut down for maintenance and repair work, it must
be secured against inadvertent starting by:
• Locking the principal control elements and removing the key and/or attaching a
warning sign to the main switch.
Before restarting the machine/plant after repair work, check that all safety devices are
fitted and in working order.
After electrical assembly or repair work is completed, check the protection system (e.g.
earth resistance.
To avoid the risk of accidents, individual parts and large assemblies being moved for
replacement purposes should be carefully attached to lifting tackle and secured.
Use only suitable and technically perfect lifting gear and suspension systems with ade-
quate lifting capacity.
Never work or stand under suspended loads.
Loads must be fastened and crane operators instructed by experienced persons only.
The banksman giving the instructions must be within sight or sound of the operator.
For carrying out overhead assembly work always use specially designed safety-
oriented ladders and working platforms. Never use machine parts as a climbing aid.
Wear a safety harness when carrying out maintenance work at heights.
Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow
and ice.
Always tighten up any bolted connections that have been loosened during mainte-
nance and repair work.
Any safety devices removed for set-up, maintenance or repair purposes must be
refitted and checked immediately upon completion of the maintenance and repair work.
Ensure that all consumables and replaced parts are disposed of safely and
ecologically.
Use only original fuses with the specified current rating. Shut down the machine/plant
immediately when faults occur in the electrical system.
Work on the electrical system or equipment may only be carried out by a skilled
electrician or by specially instructed personnel under the control and supervision of a
skilled electrician and in accordance with the applicable electrical engineering rules.

If provided for in the regulations, the power supply to parts of machines and plants on
which inspection, maintenance and repair work is to be carried out must be cut off.
Before starting any work, check that the shutdown parts are de-energized and connect
to earth or short-circuit them in addition to insulating adjacent live parts and elements.
The electrical equipment of the machine/plant is to be inspected and checked at regu-

lar intervals. Defects such as loose connections or scorched cables must be rectified
immediately.
Necessary work on live parts and elements must be carried out only in the presence of
another person who can cut off the power supply in case of danger by actuating the
emergency stop or main power switches. Cordon off the working area with a red-and-
white safety chain and set up a warning sign. Use insulated tools only.
Before starting work on high-voltage assemblies and after cutting off the power supply,
the supply cable must be connected to earth and components, such as capacitors,
short-circuited with an earth rod.
Carry out welding, flame-cutting and grinding work on the machine/plant only if this has
been expressly authorized, as there may be a risk of explosion and fire.
Before carrying out welding, flame-cutting and grinding operations clean the machine/
plant and its surroundings from dust and other inflammable substances and make sure
that the premises are adequately ventilated (risk of explosion).
Check all lines, hoses and bolted connections regularly for leaks and obvious damage.
Repair damage immediately. Splashed oil may cause injury and fire.
Depressurize all system sections and pressure pipes to be removed in accordance with
the specific instructions for the unit concerned before carrying out any repair work.
Hydraulic lines must be routed and fitted properly.

Ensure that connections are not mixed up. The fittings, lengths and quality of the hoses
must comply with the technical requirements.
When handling oil, grease and other chemical substances observe the product-related
safety regulations.
Be careful when handling hot consumables. There is a risk of burning or scalding.

1.4.2 Inspection
Caution!
Inspection is intended to recognize well in advance any essential repair
works in order to be able to make the necessary preparation and to carry
out the work.
Check the plant at least once per shift for obvious damage and defects.
Report any changes (including changes in the machine’s working behav-
iour) to the responsible person immediately.
In the event of malfunctions, stop the machine/plant immediately and lock
it. Have any defects rectified immediately.
Recommendations concerning General Supervision of Machinery Condition
Machinery and equipment should not continue to be operated until they fail completed.
Four techniques are commonly used to monitor the condition of the equipment. These
are the four senses: touch, hearing, smell and sight.
These four senses can recognize:

1) any increases or decreases in temperature (touch and smell),
2) any increases or decreases in vibration (touch),
3) any change in noise or sound from the machine (hearing),
4) any visual or observed changes and problems (sight).
Each technique helps in determining to what extent a mechanical fault exists and if it is
increasing.
Temperature
Bearing temperatures can be roughly felt by touching them with a hand. Overheating is
often first detected by smell coming from hot plastics or oil.
Higher temperature often indicates that a bearing is acting abnormally. Too high tem-
perature can be detrimental to the bearing, lubricant, shaft and seals.
Causes of high bearing and lubrication temperatures can be insufficient or excessive

lubrication, contaminated lubricants, overloading, bearing damage, faulty installation,
insufficient bearing clearances, and improper or failed seals.
Check the temperature of bearings periodically. Any significant change in temperature

is usually a good indication that a problem exists, especially if the operating conditions
of the machine have not been altered.

Danger!
Bearings, couplings, brakes, gear units, electric motors, engines and their
components may become so hot that you risk being burnt when touching
them.
Vibration
Another method commonly used to “feel” the condition of a machine is to determine

how much vibration exists on the machine. By touching the bearing, high temperature
and vibrations can be felt. The amount of vibration cannot be measured this way, but it
can be compared with the vibrations from yesterday or several weeks ago.
Listening
Another method used to identify irregularities on machinery and equipment is to listen

for changes in sounds coming from machines while operating under normal load and
speed conditions.
This can be done by placing a screwdriver blade on the bearing housing and, in a safe
position, allowing your ear to touch the screwdriver handle and listen to the internal
sounds coming from the bearing.
Abnormal noises may be detected and traced to a specific component of the machine
by experienced maintenance personnel.
Grinding, squeaking and other irregular sounds can point to worn bearings.
The squeaking noise is often caused by inadequate lubrication.
Insufficient bearing clearances can make a metallic sound.
Indentations in the outer ring raceway will produce smooth, clear sounds.
Ring damage caused by shock loads or hammer blows leads to sounds varying in
frequency according to the operating speed of the machine.
Intermittent noises probably indicate damage to the rotating members.
Contamination in the bearing produces a rough grinding sound. Damaged bearings
produce irregular and loud noises. Good bearings run smoothly and produce a
constant humming sound.
Sight
Maintenance personnel can simply observe the equipment to see if there is anything
out of the ordinary happening.
Check for any apparent oil leaks or grease leaks around seal areas or if any of the
bearing housings are loose, cracked or improperly assembled. Check the lubricant.
Discoloration or darkening of the oil is usually a good indication that the lubricant is
either contaminated or worn out. It is also very important to check whether there is
sufficient lubricant. Is the lubricant the proper one for the application? Check whether
the air vent is free from obstructions.

Take a small sample of used oil and compare it with new oil. If the used oil is cloudy in
appearance, water has more than likely mixed with it, therefore, the oil must be re-
placed.
Dark or thick oil is a sure sign of contamination or that the oil has started to carbonise.
Overheating may have caused this problem.
1.4.3 Maintenance
It is important that maintenance is performed only by well-trained and competent per-

sonnel.
Trained and skilled personnel are able to recognize malfunctions before they occur and
to take the necessary preventive measures.
Malfunctions caused by inadequate or improper maintenance may result in high repair

costs and long downtimes. Therefore, regular maintenance is a must.
The functional safety, disruption-free operation and service life of the machine/plant all
depend on proper cleaning, inspection and servicing.
Check the machine/plant at the specified intervals (inspection intervals, servicing inter-
vals) for proper operation, state of lubrication and wear.
Replace or repair all damaged/worn parts.
Check the paintwork at regular intervals (period depends on operating place) for cor-
rosion. Properly touch up all damaged areas.
Have all instrumentation and control devices/electrical interlocks checked for proper
functioning at regular intervals by qualified personnel.
Note!
Periods when the plant is shut down for repairs must also be used for
scheduled servicing work.
Different operating conditions necessitate wear tests, inspections, maintenance and

repairs to be carried out at different intervals. A suitable routine inspection schedule
has to be prepared in accordance with the operating conditions.
The servicing table is a guideline for inspection and maintenance work.
Danger!
For maintenance and repair work strictly follow the general safety
instructions.

Note!
For lubricating the machine/plant please refer to chapter 5.
As recommended for the initial start-up, you are advised to have repairs carried out by
TKIS staff the first time. In that way, your maintenance staff will have the opportunity of
taking part in an intensive training course.
1.4.3.1 Cleaning instructions
Check the level of contamination of the machine/plant every day. Do not allow material
to accumulate or cake.
This may disrupt the operation of the mechanical plant parts and increase the level of
wear.
Danger!
Do not carry out cleaning, servicing or repair work unless the machine/
plant is shut down. Secure the system against inadvertent restarting.
Only use appropriate tools in perfect condition.
Always clean the assembly groups in question before commencing servicing work.
Before cleaning the machine/plant with water or steam (high-pressure steam jet
cleaners) or other detergents, cover/tape up all openings in which water/steam/
detergents are not allowed to penetrate for safety and/or operational reasons.
Electric motors and control cabinets are particularly susceptible to moisture.
Danger!
Always wear safety masks when carrying out cleaning work with high-
pressure or steam jet cleaners.
Do not use aggressive detergents.
Do not direct the spraying jet at electrical devices, relays and controlcabinets/boxes,
intake filters and ventilation filters or greased surfaces.
Always hold the spray nozzle at an adequate distance from the surface being cleaned
and do not direct the spray jet directly at these surfaces.
Clean places which are difficult to reach with suitable equipment such as special
brushes.

When cleaning is completed, completely remove the covers/tapes.
After cleaning check all lubricant and oil lines for leaks, loose fittings, scouring and
damage. Immediately rectify or repair any defects!
1.4.3.2 Lubricating instructions
In order to maintain the operational reliability and achieve an adequate service life of
the machine/plant, it is essential to use lubricants most suitable for the individual
application.
It is not possible to fully describe the lubricants, simply by providing the guide values
indicated in the table of lubricants.
The responsibility for the correct choice of the lubricants - taking into account the local
circumstances and working conditions in industrial plants as well as the latest develop-
ments of lubrication technology - lies exclusively with the lubricant supplier.
TKIS cannot be held liable for defects or damage resulting from the use of unsuitable
or improper lubricants.
It is therefore recommended that only high-quality lubricants from reputed firms which
meet our guide values are used.
Special attention must be paid to the following:
Danger!
For safety reasons, all work in connection with lubrication must be carried
out only with the machine/plant shut down and at operating temperature.
Carry out lubrication in accordance with the lubricating instructions speci-

fying the lubrication intervals, the kind of lubricants to be used and the
quantities. Insufficient lubrication may cause damage to the machine
parts.
For recommended lubricants please refer to the table of lubricants

(chapter 5).
This guideline does not exclude the use of lubricants with the same properties but of
another make. However, do not mix lubricants.

Storage of lubricants:
- Store lubricants such as oil and grease in clean, closed containers (tins, cans,
barrels, etc.) to keep them clean and dry.
- Containers must be labelled differently, possibly using different colours according

to their different content. Containers must be closed immediately after removing
the required amount of oil or grease.
- Consumables must be ecologically stored in a safe place.
- Keep the lubricants in a dry, cool place.
- Please note the respective national regulations for environmental protection.
1.4.3.3 Instructions relating to oil hydraulic system
Reliable operation of oil hydraulic systems primarily depends on proper maintenance.

It is impossible to specify exact maintenance intervals.
The correct maintenance intervals are a matter of experience. The only thing that is
important is that maintenance is carried out regularly.
Danger!
On the basis of the existing safety regulations, persons not directly re-
quired for operating the plant have to leave the site or keep well away
from the plant when it is commissioned.
The general instructions given below may occasionally be superseded by special

instructions:
• When the machine/plant is assembled, care must be taken that everything is kept
absolutely clean.
• Pipes must be cut square. The use of cutting rollers is prohibited. Note special
instructions applying to pipe welding.
• When welding is carried out, care must be taken to prevent welding current from
flowing through any hydraulic appliance to avoid welding of internal parts.
• Pipes must be cleaned prior to installation.
• Pipes must be installed free of strain.
• Sealing with hemp and putty is not permitted.

• Pump suction lines must be carefully sealed to prevent air from being taken in.
Leakage oil lines must be installed to ensure that the pumps and motor casings
always remain filled with oil; they must not be connected to pressure and drain
lines.
• Before filling the liquid, tanks and pipes must be flushed, subjected to a pressure
test and checked once again to see if they are clean.
• It is therefore highly recommended to carefully check the piping and wiring on the
basis of the circuit diagram before filling the hydraulic fluid into the tank.
• Solenoid valves and pressure switches must be checked with respect to the type
of current and voltage.
• Pumps and their electro motors must be aligned. Possible misalignment between
the motor and the pump may cause the pump to fail prematurely. The operation
of the pumps and their motors must not be impaired by an improper installation
and connection of pipes.
• If not already delivered in a ready-for-operation state, accumulators must be

provided with the specified nitrogen charge before being incorporated into the
system. It is advisable to mark the gas prepressure on the accumulator itself (e.g.
using a sticker) and also in the circuit diagram to allow future comparative checks
to be carried out if necessary.
• ISO VG oil selected to meet the respective climatic conditions and/or ambient
temperatures must be used. The hydraulic oil must always be filtered during
filling.
• Prior to their initial start-up, the pumps and motors must be filled through the
leakage oil port.
• During start-up the pressure settings of the pressure relief valves must be kept
low at first, except for the type-tested pressure relief valves for hydraulic systems
which do not allow for any variation because of their predetermined and leaded
fixed-value setting.
• Cylinders must be installed without strain. They must not be subject to transverse
forces as this may cause malfunctions and premature wear.
• The fluid level must be checked constantly during commissioning. When the plant
has been commissioned, check the fluid level every day at first and every week
later on.
• During commissioning and the first hours of operating, filters must be checked
frequently, and, if necessary, changed.
• In case optical or electrical clogging indicators are available, filter elements must
be replaced as indicated.

• Breathers must be checked at regular intervals and the filter cartridge be

replaced, if necessary.
• The operating temperature must be measured not only in the oil tank but also at
the bearing points of the pumps. A temperature rise indicates wear (growing
friction and leakage by converting hydraulic energy into heat).
• The frequency of changing system fluids depends on several operating factors

and is governed by the degree of ageing and pollution.
Regular laboratory tests of the hydraulic oil must be carried out especially in case
of large oil quantities.
• The preliminary pressure on the nitrogen side of accumulators must be checked

at regular intervals if necessary. Do not check unless the oil side of the accumu-
lators is completely depressurized.
• It is recommended to check at regular intervals the correct alignment of the

energy converters (pumps, motors, cylinders etc.) at operating temperature and,
if possible, under operating pressure. This includes attachment bolts, screws,
connections, pipes, couplings, etc.
• The hydraulic piping system must be checked for leaks at regular intervals.
Do not tighten up bolted connections unless the system is depressurized.
• Depending on the environmental conditions, disks of oil/air coolers must be

cleaned at regular intervals.
• Decalcify oil/water coolers from time to time.
• The frequency depends on the hardness of the cooling water used.
• Store pumps, valves, cylinders etc. in a dry place away from moist air.
• The storage rooms must be free from caustic materials and vapours. A fill of
anticorrosive oil is recommended. This oil must be compatible with the future oil
grade. The oil film remaining after draining the anticorrosive oil must not affect
future use.
1.4.3.4 Instructions relating for the replacement of wear parts
Danger!
Note the safety instructions relating to maintenance in chapter 5.

To avoid the risk of accidents, individual parts and large assemblies being moved for
replacement purposes should be carefully attached to lifting tackle and secured.
Use only suitable and technically perfect lifting gear and suspension systems with
adequate lifting capacity. Never work or stand under suspended loads.
Loads should be fastened and crane operators instructed by experienced persons only.
The banksman giving the instructions must be within sight or sound of the operator.
For carrying out overhead assembly work always use specially designed or otherwise
safety-oriented ladders and working platforms. Never use machine parts as a climbing
aid. Wear a safety harness when carrying out maintenance work at heights.
Danger!
Do not carry out maintenance and repair work unless the machine/plant is
shut down.
Replace worn components without delay. Worn components are less stable and are
liable to break more easily.
Do not re-use seals and safety elements that have been removed.
Always use new bolts, nuts and washers when putting assembly groups and parts back
in place.
Do not leave tools or other devices on/in the machine/plant.
Observe the rules and regulations for the prevention of accidents when welding work is
carried out.
During electric welding, secure the earthing cable near the part being welded. Do not
route the welding current return line over movable machine elements (e.g. shafts,
bearings). For bridging fit a cable with across section adequate for the welding current
and for the distance to be covered by the current.
Restore the machine/plant to its original state when repair work is completed. Put pro-
tective and safety devices back in place. Make sure that the machine/plant is working
properly by carrying out a trial run.
1.4.4 Repair
Repair work is intended to restore the required condition of the machine/plant by

replacing defective components.

1.4.5 Spare part stocks
Continuous operation and operational readiness of the machine/plant can only be

ensured when important spare and wear parts are kept in stock.
Please order spare parts using the information contained in the spare parts list.
Our guarantee only refers to the original spare parts delivered by us.
Note!
We expressly point out that we do not assume any liability for spare parts
and accessories which have not been delivered by us. Foreign products
may have a negative effect on the characteristic features of the machine/
plant and impair safety.
Damage caused by using products other than the original spare parts and
accessories are excluded from the warranty.
Please note that parts manufactured by us and subsuppliers are often subject to
special production and delivery specifications. But you may rest assured that we shall
always offer you state-of-the-art spare parts which correspond to the latest legal
regulations.

2 OVERVIEW IRON ORE HANDLING SYSTEM

1. GENERAL SECTION
(Volume M1)

(Volume M1)

(Volume M1)
4. OPERATION
(Volume M1)
5. MAINTENANCE
(Volume M1)
(Volumes M1 + M2)
Access to chapter 2 "OVERVIEW IRON ORE HANDLING SYSTEM" is facilitated by

table of contents and by footers.

Blank page

TABLE OF CONTENTS
2.1 OVERVIEW OF IRON ORE HANDLING SYSTEM .................. 5

2.1.1 General description.................................................................................. 5
2.1.2 Description of package 3 ......................................................................... 8
2.1.3 Description of package 6 and 3.2 ............................................................ 8
2.1.4 Description of package 10 ..................................................................... 10
2.2 GENERAL TECHNICAL REQUIREMENTS ........................... 12
2.2.1 Basic design criteria............................................................................... 12
2.3 MATERIAL FLOW ................................................................. 15
2.3.1 Conveyor route 1 (from iron ore mine to stockyard P4) ......................... 15
2.3.2 Conveyor route 2 (from stockyard P4 to stockyard P6) ......................... 15
2.3.3 Conveyor route 3 (from stockyard P4 to stockyard P10) ....................... 15
2.3.4 Conveyor route 4 (from stockyard P4 to ship loading) ........................... 16
2.3.5 Conveyor route 5 (from stockyard P6 to stockyard P10) ....................... 16
2.3.6 Conveyor route 6 (from stockyard P10 to ship loading) ......................... 16
2.3.7 Conveyor route 7 (from stockyard P6 to ship loading) ........................... 17

Blank page

2.1 OVERVIEW OF IRON ORE HANDLING SYSTEM

On drawing “GENERAL LAYOUT - PACKAGE 3, 6, 3.2 & 10” (TKIS-Number 4560142) a
general overview of the entire handling system including definition of different packages
and coordinates is given.
Furthermore, the principles of materials handling and the different conveyor routes can
be seen on drawing “FLOWSHEET Package 3, 6, 3.2, 10” (TKIS - Number 4553613).
2.1.1 General description
The iron ore handling system “Shougang Hierro Peru“ is divided into several packages
with partly different responsibilities for supply. Because of ore processing, the handling
system must be capable of transporting three different types of iron ore: oxide ore, pri-
mary ore and iron ore concentrate with material properties as shown in chapter 2.2.1.
The handling system, which has an overall length of roughly 21 km, is capable of trans-
porting three different types of iron ore from mine to ships.
The different types of iron ore are generated by two different crushing units and by the
beneficiation plant.
The first crushing unit is installed within the mine right after mineral extraction. Primary
crushed ore (oxide ore) is directly transported to package 4 where the secondary
crushing unit is installed. The result after secondary crushing is primary ore.
The final stage of ore processing is reached in the beneficiation plant in package 7,
where primary ore is further processd into ore concentrate which is a higher quality
product of 63% to 69% iron (Fe) compared to oxide and primary ore.
Amongst other the conveyor belt system consists of several conveyors of different belt
width, speed and mass flow, three blending beds for storage and homogenization of
material, several devices for stockyard management, belt scales for mass flow super-
vision and diverter gates for realizing different conveyor routes.
Following schedule gives an overview of the design layout of the entire handling
system including the responsibilities of supply.
Package Content Supplier
Mineral exploitation: targeted detonation followed by By others

1
shovel & truck
Primary crushing with cone crusher TKIS

2
Product: oxide ore BU Mineral Processing
Conveyor belt system consisting of 3 conveyors, TKIS

including one horizontal curved conveyor, and 2
3 BU Mineral Processing
transfer towers
Product: oxide ore
Secondary crusher with following stockpile Sandvik

4
Product: primary ore

Package Content Supplier
Downhill conveyor ThyssenKrupp

5
Product: primary ore Robins, Inc.
Materials handling system consisting of 4 conveyors, TKIS,

2 transfer towers and a stockpile with a stacker and a
6 BU Materials Handling
drum reclaimer
Beneficiation plant By others

7
Products: primary ore and iron ore concentrate
Materials handling system consisting of 6 conveyors, TKIS,

5 transfer towers and a stockpile with a stacker and a
10 BU Materials Handling
bucket wheel reclaimer
Products: primary ore and iron ore concentrate
One conveyor and one transfer tower to bypass the TKIS,

3.2 stockpiles
BU Materials Handling
Further documentation of operation and maintenance manual of the materials handling

system particularly refers to packages 3, 6, 10 and 3.2, supplied by TKIS, BU Materials
Handling, Rohrbach.
Basically, the different conveying routes allow the operator to transport either ore con-
centrate or primary ore from stockyard to ships. The handling system is designed for
annual transportation of approx. 22 million tons material in average.
Basically, the operator can choose from several different conveying routes of the hand-
ling system that offer various ways of material transport. As consequence, downtimes
of the entire conveying system because of defective devices or components can be
reduced to a minimum.
• Route 1
From the iron ore mine to
stockyard P4
Nominal conveyor capacity of 3.050 t/h (=design)
Maximum conveyor capacity of 3.400 t/h
• Route 2
From stockyard P4 to
stockyard P6
via stacker 930-ST-110

• Route 3
stockyard P10
via beneficiation plant P7 and
Nominal conveyor capacity from stockyard P4 to plant P7 of 3.000 t/h (=design)
Maximum conveyor capacity from stockyard P4 to plant P7 of 3.400 t/h
Nominal conveyor capacity from plant P7 to stockyard P10 of 1.500 t/h (=design)
Maximum conveyor capacity from plant P7 to stockyard P10 of 1.800 t/h
• Route 4
transfer tower TT 4-10
via stacker 930-ST-110 and
via package 3.2
• Route 5
stockyard P10
via drum reclaimer 931-RC-110 and
via beneficiation plant and
Nominal conveyor capacity from stockyard P6 to plant P7 of 3.000 t/h (=design)
Maximum conveyor capacity from stockyard P6 to plant P7 of 3.400 t/h
Nominal conveyor capacity from plant P7 to stockyard P10 of 1.500 t/h (=design)
Maximum conveyor capacity from plant P7 to stockyard P10 of 1.800 t/h
• Route 6
transfer tower TT4-10
via bucket wheel reclaimer 945-RC-100
• Route 7
transfer tower TT4-10
via drum reclaimer 931-RC-110 and
bypassing conveyors 931-CB-120 (new) and 812-CB-260 (package 3.2)

2.1.2 Description of package 3
Three conveyors enable material transport from crushing unit one to crushing unit two.
The entire equipment includes:
• The belt conveyor 812-CB-110 leaving the mine
• The horizontal curved belt conveyor 812-CB-210/240
• Belt scale 812-WE-110
• The belt conveyor 812-CB-250 heading to the secondary crushing unit
The curved conveyor is equipped with a belt scale in order to measure the amount of
oxide ore which is transported to the secondary crushing unit.
A further special characteristic of the curved conveyor is a steplessly variable take-up
winch on the tail end of the conveyor which provides correct tension forces depending
on the different operating conditions.
2.1.3 Description of package 6 and 3.2
The operation of the iron ore handling system provides the possibility of primary ore
storing and reclaiming from the blending bed located in package 6 as well as to by-
pass the storage for direct transport of primary ore to the shiploading system.
Stored material which is reloaded to the conveyor belt system can be either directly
transported to the shiploading system or continued to the beneficiation plant for further
processing.
Storage yard management is enabled by the travelling stacker 930-ST-110 with a

nominal stacking capacity of 4500 t/h and the drum reclaimer 931-RC-110 with a
nominal reclaiming capacity of 3000 t/h.
The stacker with a luffing and slewing conveyor boom and tripper car is used for
stacking the material in a stockpile. Usually, the machine shall be used in the semi-
automatic mode. In this case, the pile can be built up in the cone shell method.
The drum-type bucket wheel reclaimer is designed for operation in two reclaiming
directions. Lateral rakes cause the material to be reloaded to slide down the slope to
the foot of the stockpile, where it gets reclaimed by the buckets and then transferred
onto the cross belt conveyor inside the drum. From there, the material is discharged to
the yard conveyor.
Both devices are designed to travel linearly on rail tracks. In case of the stacker, the
stockyard conveyor is installed between the rails. It is basically possible to form tri-
angular or trapezoid shaped stockpiles on both sides of the rail track. In case of the
drum reclaimer, the stockpiles, which are reclaimed front-end, are situated between the
rails.
In first stage commissioning, the maximum entire pile length is 522.5 m. There shall be
no more than two piles in order to gain appropriate storage capacity.
If required at a later stage, the capacity of the blending bed can be increased up to a
maximum entire pile length of 989 m. In order to ensure appropriate storage capacity a
maximum number of four blending beds is recommended.

The equipment of packages 6 and 3.2 consists of:

• The stockpiling belt conveyor 930-CB-110
• Belt scale 930-WE-110 (ATTENTION: Belt scale 930-WE-110 will be installed on
conveyor 830-CB-110 of package 5)
• Tripper car & boom conveyor of stacker 930-ST-110 for the storage in stockpile P6
• Buckets & cross conveyor of drum reclaimer 931-RC-110 for unloading stockpile P6
• The reclaiming belt conveyor 931-CB-110
• Diverter chute 931-DV-110
• The belt conveyor 841-CB-110 heading to the beneficiation plant
• Transfer hopper 842-BN-110
• The belt conveyor 842-CB-110 for bypassing the stockpile P6
• Transfer hopper 812-BN-260
• The belt conveyor 812-CB-260 for bypassing the stockpile P6, the beneficiation
plant and stockpile P10
• The belt conveyor 931-CB-120 (new conveyor which is not part of the supply of
TKIS) for bypassing the beneficiation plant and stockpile P10
Among others, the main function of the belt scale 930-WE110 is to measure the quan-
tity of material that is meant to be stored in stockpile P6.
Whereas the belt scale 841-WE-110 measures the amount of reclaimed material which
is further transported to the beneficiation plant.
Two-way diverter chutes moved by electrical actuators enable the operator to choose
different ways of material flow. The gate positions are monitored by inductive proximity
switches so that the operator is always fully aware of the selected conveyor route.
Future plannings for the ore handling system include a conveyor which is nearly
parallel oriented to conveyor 841-CB-110. In future, diverter chute 842-DV-110 controls
on which conveyor the material coming from conveyor 842-CB-110 is transferred onto.
With the help of diverter chute 931-DV-110 reclaimed primary ore can be either
discharged onto conveyor 841-CB-110 for further processing or onto “new” conveyor
931-CB-120 for continuous transport to ships without further processing.
Other ways of material flow are also realized by the stacker being capable of forward-
ing material, which is not meant to be stored on a stockpile, onto designated belt con-
veyors by the use of transfer hoppers. Therefore, tripper car and boom conveyor of the
stacker has to be positioned and aligned at predefined transfer positions depending on
the chosen conveyor route.

2.1.4 Description of package 10
The operation of the iron ore handling system provides the possibility of iron ore con-
centrate storing and reclaiming from the blending bed located in package 10.
Reloaded material is further transported to the ship loading system. As an alternative,
there is the aforementioned possibility to bypass the blending bed and to convey
primary ore directly to the ship loading system.
Storage yard management is enabled by the travelling stacker 941-ST-110 with a

nominal stacking capacity of 1500 t/h and the bucket wheel reclaimer 945-RC-100 with
a nominal reclaiming capacity of 6000 t/h. The stacker with a luffing and slewing
conveyor boom and tripper car is used for stacking the material in a stockpile. Usually,
the machine shall be used in the semi-automatic mode. In this case, the pile can be
built up in the cone shell method.
During reclaiming, the material is reloaded by the bucket wheel and transferred to the
boom conveyor and further through the central chute to the stockyard belt conveyor.
In general, reclaiming of the material can be controlled manually, taking into considera-
tion the configuration of the pile. In principle, after having made the first cut in manual
mode, reclaiming is made automatically.
Both devices are designed to travel linearly on rail tracks with the stockyard conveyors
installed in between.
The maximum entire pile length is 560 m. There shall be no more than two piles in
order to gain appropriate storage capacity.
The equipment of package 10 consists of:

• The belt conveyor 851-CB-110 leaving the beneficiation plant
• The belt conveyor 851-CB-120
• The stockpiling belt conveyor 941-CB-110
• Tripper car & boom conveyor of stacker 941-ST-100 for the storage in stockpile P10
• Bucket wheel reclaimer 945-RC-100 for unloading stockpile P10
• The stockyard belt conveyor 945-CB-120
• The belt conveyor 861-CB-110
• The belt conveyor 861-CB-120 heading to the coast
The conveyors 851-CB-110, 851-CB-120 and 941-CB-110 as well as the both stock-
yard devices exclusively convey iron ore concentrate, whereas conveyors 945-CB-120,
861-CB-110 and 861-CB-120 are capable of transporting ore concentrate and primary
ore.
With help of the belt scale 861-WE-110 the amount of material which is conveyed to
the ship loading system can be measured.

Two-way diverter chutes moved by electrical actuators enable the operator to choose
different ways of material flow. The gate positions are monitored by inductive proximity
switches so that the operator is always fully aware of the selected conveyor route.
Future plannings for the ore handling system include a conveyor interconnecting the
conveyors 851-CB-110 and 945-CB-120.
By use of this interconnection, iron ore concentrate can be directly transported to the
shipyard without being stored in the blending beds of package 10.
By that time, the operator will be able to choose either way by adjusting the settings of
diverter chute 851-DV-110.

2.2 GENERAL TECHNICAL REQUIREMENTS

2.2.1 Basic design criteria
Material to be handled
Property Unit Oxide ore Primary ore Ore concentrate
Bulk density kg/m³ 2.500 2.500 2.600

Physical properties solid, solid, solid,
highly abrasive highly abrasive highly abrasive
Flowing characteristic free - flowing free - flowing adhesive
Grain size mm < 300 < 40 <1
Angle of repose ° 36 36 36
Moisture content % 3-9 3-9 3-9
Ambient temperature °C +8 to +40 +8 to +40 +8 to +40
Environmental conditions
Country : Peru
Location : Shougang Hierro
Altitude : Sea level
Ambient temperature : +8°C / +32°C
Design temperature : +40°C
Relative humidity of the air : 85%
Average annual rain fall : 10.8 mm
Seismicity : 0.46g
Air : Highly corrosive
(Maritime climate, dusty, sand)
Corrosion category
(ISO12944 part 2) : C3
Operating conditions
Operation : Indoor and outdoor

Working hours per day : 24h
Start-ups per hour of conveyor : 6

Power supply and voltages
Incoming power supply

for mobile machine : 4.16kV ±5%, 3 - phase, 60Hz ±2%
Power for conveyor motors > 200kW : 4.16kV ±5%, 3 - phase, 60Hz ±2%
Power for motors
incl. machines ≤ 200kW : 460V ±5%, 3 - phase, 60Hz ±2%
Lighting on mobile machines : 230V, 3 - phase, 60Hz, neutral
Others on mobile machines : 230V, 3 - phase, 60Hz, neutral
Control voltage on mobile machines : 230V, 60Hz, grounded
Control voltage on conveyors : 120V, AC
PLC Input/Output
on mobile machines : 24V, DC
Maintenance circuit
on mobile machines : 460V, 3 - phase, 60Hz
Analog signal : 4 - 20mA in 4-conductor circuitry
Elevations
Elevation of ground : + 794.500 (Feeding point 812-CB-210/240

+ 802.000 (System point package 3 and 4)
Top of stockyards : + 33.000 (P6)
+ 38.500 (P10)
Top of rails : + 33.200 (stockyard P6)
+ 38.700 (stockyard P10)
Rails
Stacker 930-ST-110 : A 75 tensile strength 880 n/mm²

Drum Reclaimer 931-RC-110 : A 100 with tensile strength 880 n/mm²
Stacker 941-ST-100 : A 75 tensile strength 880 n/mm²
Bucket Wheel Reclaimer 945-RC-100 : A 75 tensile strength 880 n/mm²

Capacities
Package 3 : 3050 t/h nominal

3400 t/h maximum
Package 6
stocking conveyor : 4500 t/h nominal
4800 t/h maximum
remainder of conveyors : 3000 t/h nominal
3400 t/h maximum
Package 10
Conveyors from
beneficiation to stockyard : 1500 t/h nominal
1800 t/h maximum
Conveyors from
stockyard to ship loading : 6000 t/h nominal
6600 t/h maximum
Package 3.2 : 4500 t/h nominal

4800 t/h maximum

2.3 MATERIAL FLOW

Following conveyor routes only show the parts of the conveyor belt systems which are
in the scope of supply of TKIS, BU Materials Handling, Rohrbach.
2.3.1 Conveyor route 1 (from iron ore mine to stockyard P4)
Belt conveyor 812-CB-110

Belt conveyor 812-CB-210/240
2.3.2 Conveyor route 2 (from stockyard P4 to stockyard P6)

Tripper car 930-ST-110
Boom conveyor 930-ST-110

Transfer hopper 842-BN-110
Diverter chute 842-DV-110

2.3.4 Conveyor route 4 (from stockyard P4 to ship loading)

Transfer hopper 812-BN-260
Cross conveyor 931-RC-110

Boom conveyor 945-RC-100

Belt conveyor 945-CB120

Cross conveyor 931-RC-110


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3 DESCRIPTION OF MACHINE AND ASSEMBLY

GROUPS
1. GENERAL SECTION
(Volume M1)

(Volume M1)

(Volume M1)
4. OPERATION
(Volume M1)
5. MAINTENANCE
(Volume M1)
(Volumes M1 + M2)
Access to chapter 3 "DESCRIPTION OF MACHINE AND ASSEMBLY GROUPS" is

facilitated by table of contents and by footers.

Blank page

TABLE OF CONTENTS
3.1 OPERATING CONDITIONS .................................................... 5

3.1.1 Site .......................................................................................................... 5
3.1.2 Climatic conditions ................................................................................... 5
3.1.2.1 Ambient temperatures .................................................................................... 5
3.1.2.2 Humidity ......................................................................................................... 5
3.1.2.3 Wind ............................................................................................................... 5
3.1.2.4 Precipitation ................................................................................................... 5
3.1.2.5 Site altitude .................................................................................................... 5
3.1.2.6 Earthquake ..................................................................................................... 5
3.1.3 Material data ............................................................................................ 5
3.1.4 Design / Operation ................................................................................... 6
3.1.5 Designated use ........................................................................................ 7
3.1.6 Organizational instructions ...................................................................... 8
3.1.6.1 General .......................................................................................................... 8
3.1.6.2 Selection and qualification of personnel.......................................................... 9
3.1.6.3 Description of personnel tasks........................................................................ 9
3.2 DESIGN AND FUNCTION ..................................................... 12
3.2.1 General .................................................................................................. 12
3.2.2 Layout - Stockyard ................................................................................. 12
3.2.3 Main assembly units .............................................................................. 13
3.2.3.1 Travel gear ................................................................................................... 14
3.2.3.2 Slewing gear ................................................................................................ 17
3.2.3.3 Hoisting gear ................................................................................................ 19
3.2.3.4 Boom ............................................................................................................ 20
3.2.3.5 Boom conveyor ............................................................................................ 21
3.2.3.6 Tripper car .................................................................................................... 26
3.2.4 Accessories ........................................................................................... 29
3.2.4.1 Manual central lubrication systems ............................................................... 29
3.2.4.2 Automatic central lubrication system - Slewing gear ..................................... 31
3.2.4.3 Water spray system ...................................................................................... 33
3.3 TECHNICAL DATA................................................................ 36
3.3.1 Travel gear ............................................................................................ 36
3.3.2 Slewing gear .......................................................................................... 37
3.3.3 Hoisting gear.......................................................................................... 38
3.3.4 Boom conveyor ...................................................................................... 39
3.3.5 Tripper car ............................................................................................. 41
3.3.6 Accessories ........................................................................................... 42

3.3.6.1 Manual central lubrication systems - Travel gear / Tripper car ...................... 42
3.3.6.2 Automatic central lubrication system - Slewing gear ..................................... 42
3.3.6.3 Water spray system - Water supply .............................................................. 42
3.3.7 Monitoring devices ................................................................................. 43
3.4 SAFETY REGULATIONS ...................................................... 44
3.4.1 General safety instructions for structural steelwork /
mechanical engineering ......................................................................... 44
3.4.2 General safety instructions, electrical system ........................................ 45
3.4.3 General hydraulic safety instructions ..................................................... 45
3.4.4 Fire prevention ....................................................................................... 46
3.4.5 Fire fighting ............................................................................................ 46
3.5 GENERAL LAYOUT .............................................................. 49
3.5.1 Stacker STD-4500/29.5x1.2 .................................................................. 49

3.1 OPERATING CONDITIONS

3.1.1 Site
The stacker STD-4500, that will be used on the stockyard of an iron ore mine near
Shougang Hierro / Peru, is intended for the stockpiling of iron ore.
3.1.2 Climatic conditions

3.1.2.1 Ambient temperatures
Max. : + 32 °C
Min. : + 8 °C
3.1.2.2 Humidity
Max. : 85 %rel.
3.1.2.3 Wind
Maximum velocity : 90 km/h = 25 m/s
Design velocity : 130 km/h = 36 m/s
3.1.2.4 Precipitation
Average annual rainfall : 10.8 mm
3.1.2.5 Site altitude

Site altitude above sea level : +33.000 m
3.1.2.6 Earthquake
Statical replacement load : 0.46 g
3.1.3 Material data
Material Density (γ) Grain size Moisture Angle of

3
t/m (mm) content repose
Iron ore 2.5 < 40 max. 3-9 % 36 °

3.1.4 Design / Operation
The design of the stacker is based on the German federal regulations valid at the time
of construction, such as DIN, VDI, VDE, ISO, FEM, as well as on the international IEC
standards applicable to electrical equipment. In particular, attention should be paid to
the ISO 5049 regulations.
- ISO 5049 / 1 Mobile continuous handling equipment, part 1
- Guidelines for the design of steel structures
- ISO 5049 / 2 Mobile continuous handling equipment, part 2
- Guidelines for the design of mechanical components
Beyond the above standard, it is possible to operate the stacker up to a maximum wind
speed of 83 km/h as specified in the contract.
If the stacker is out of operation, a maximum wind speed of 150 km/h is admissible
provided the stacker is positioned in a special parking position and tied down to the
ground by means of wire ropes.
Handling capacity
- Nominal mass flow : 4.500 t/h
- Design mass flow : 4.800 t/h
Operating time : 24 hours / day
Stockyard
- Arrangement : in the open
- Stockpile arrangement : in line (in future additional stockpiles parallel)
- Type of stockpile (cross section) : triangular stockpile
- Cross section of stockpile : approx. 266 m2
- Width of stockpile : approx. 38 m
- Height of stockpile : approx. 14 m
- Length of stockpile (roof) : 2 x approx. 253 m (1.Stage)
4 x approx. 190 m (2.Stage)
Stacking method : CHEVRON
Main geometry data
Boom
- Length : 29.5 m
(horizontal distance between
hinge point and discharge pulley)
Boom - Hoisting
- Hoisting angle in operation : - 15 ° to + 15 °
- Average hoisting speed of the : 3 m/min.
discharge pulley

Boom - Slewing
- Slewing angle in operation : - 110 ° to + 110 °
- Slewing speed of the : max. 20 m/min.
discharge pulley
Stacker - Travelling
- Travel speed : 5 to 20 m/min.
- Track gauge : 7m
Weights (without stationary equipment)

- Stacker incl. boom ballast : approx. 250 t
- Boom ballast (Concrete) : approx. 74.5 t
3.1.5 Designated use
This machine may nevertheless constitute a risk if it is improperly used by unskilled

personnel.
The stacker is designed specifically for the transportation of iron ore in accordance with
the specifications on the stockyard of an iron mine near Shougang / Peru.
It is intended for, and restricted to, this purpose alone. Using the stacker for purposes
other than those mentioned above is considered contrary to its designated use and is
regarded as misuse.
If materials other than those specified above are to be handled, then the manufac-
turer´s confirmation that this is acceptable must first be obtained.
The stacker may only be operated in an area with ambient temperatures ranging
between 8 ° and + 32 °C.
The stacker may only be operated within the specified working ranges and no longer as
for that service time provided for per annum. Exceeding the maximum permissible
handling capacity and the maximum service time will overload the stacker.
Apart from the a.m. risks resulting from a violation of the stipulations relating to the
designated use of the machine, exceeding the capacity of the machine may also cause
material spillage and chute clogging.
Any other use of the stacker contrary to its designated use - such as the transport of
persons, the fastening, lifting and/or transporting of loads - is prohibited. The manu-
facturer cannot be held liable for damages resulting from such misuse. The risk then
entirely lies with the user.

3.1.6 Organizational instructions

3.1.6.1 General
This section contains organizational instructions for the user/supervisory personnel of

the stacker intended to ensure a safe operation. Attention is to be paid to the
designated use of the stacker (see chapter 3.1.5).
Should the responsibilities of the personnel overlap, or a different organizational

structure be in place, all organizational and safety instructions are to be applied by
anology.
The user is to observe the information and rules contained in this operating and
maintenance manual which are based on the relevant regulations and recognized
technical rules for safe and proper working practices during operation and servicing
(= including inspection, maintenance and repair) of the stacker. The official national
rules and regulations are to be adhered to.
The following instructions are intended for the supervisory personnel:
- In addition to the operation and maintenance manual, observe the legislation and
other binding regulations concerning accident prevention and pollution, and
instruct personnel accordingly.
- Check that the personnel are working safely in accordance with the instructions
set out in the operation and maintenance manual and that they are aware of the
risks and hazards involved.
- Prohibit unauthorized persons from gaining access to the stacker. Access may
only be gained to the stacker with the permission of the machine operator /
supervisory personnel.
- The stacker must be inspected and approved by the responsible supervisory

personnel before being returned to service.
- Instruct that work on the travel gears and brake systems are only to be carried
out by skilled personnel which have been specially trained for such work.
- Have a comprehensive annual inspection (main annual inspection) of the stacker

carried out by qualified and skilled personnel and supervisory personnel.
- Protect the stacker against unintentional restarting before carrying out mainte-
nance work by locking the main switch, removing the key and attaching warning
signs.
- Spare parts must comply with the technical requirements specified by the manu-
facturer. These requirements are always complied with if original spare parts are
used.

- Have all the safety devices checked according to schedule to ensure that they
are all in perfect working condition (see Chapter 5.1.2.2).
- Observe the generally applicable safety instructions (Chapter: Safety

Instructions) and the special safety instructions for operation (Chapter 4.1.2),
maintenance (Chapter 5.1.1.1) and repair (Chapter 5.2.1.1).
3.1.6.2 Selection and qualification of personnel
- Work may be carried out on the stacker by reliable personnel only.
- The machine operator shall have the statutory minimum age and have adequate
technical knowledge.
In particular, he must be able to recognize the consequences of faults made
during stacker operation and to take appropriate measures in all situations which
may arise during operation.
- It must be ensured that only personnel which has been instructed to do so works
on the stacker.
- Cleaning work on the stacker may be carried out by unskilled helpers only if they
have been familiarized with the safety regulations.
3.1.6.3 Description of personnel tasks
Each member of staff is only to carry out tasks for which he is qualified and has
received authorization by the user.
Operating personnel
One person is normally required as machine operator for normal stacker operation.
The tasks of the machine operator may be carried out only by trained personnel which
has received authorization from the user.
The operating personnel must also be familiar with this operating and maintenance
manual before work is started on or with the stacker.
In particular, the operators must have read and understood the sections containing the
safety instructions, and must be capable of applying the information contained therein
to the benefit of a safe stacker operation.
It is also assumed that the operators are essentially and generally familiar with the
overall function of the stockyard and with the plant, plant sections and mobile
machinery located there, and their operation.

Before the actual work is started, the machine operator must satisfy himself that:
- no persons are standing in the hazard area of the stacker;
- the stacker is in perfect technical condition;
- the working area and hazard area of the stacker are clear of other mobile
machinery and plant sections employed in the stockyard as a whole;
- the working area and hazard area are adequately demarcated such that access
cannot be gained to them unnoticed or unintentionally;
- any maintenance, servicing or repair work has been completed and the
associated personnel has all left the stacker and removed all foreign objects,
tools, etc.
Should it be necessary to observe the repaired components in operation follow-
ing a repair, this may be carried out only by personnel fully familiar with the func-
tion and operation of the stacker. In such cases, the stacker may only be
operated in manual mode, and with particular attention on the part of the machine
operator;
- the equipment downstream of the stacker which is required for subsequent

conveying of the material is also operational.
To check this, the machine operator must patrol and inspect the working area and the
stacker before starting work.
Any faults detected here must be rectified if possible by the machine operator should
they fall within his responsibilities; otherwise, he must report them to the superior
responsible. The superior must then arrange for the fault to be rectified before the
machine operator starts the stacker.
Use of the stacker within the limits of its designated use includes performance by the
machine operator of the following tasks:
- Checking and ensuring that all conditions (as listed before) are met before work
is started;
- Switching on the stacker and commencing work in accordance with the proce-
dure stipulated;
- Observing proper functioning of the stacker, all machine movements, and inde-
pendent control of the various stacker drives, according to the operating mode;
- Observing all display instruments, lamps and acoustic signals in the cab and on
the local control station, both for the stacker, and for other plant and machinery
interlocked with the stacker;
- Observing all plant and machinery working in the vicinity of the stacker and not
interlocked with it;

- Intervening in the event of any unusual occurrences or events deviating from

normal operation of the stacker, for example by cancelling automatic operation,
reversing individual components, or if necessary, shutting down the stacker;
- Reporting stoppages, faults and defects to the responsible supervisory personnel

and ensuring until the faults are rectified that personnel cannot be injured and the
stacker cannot be damaged;
- The machine operator must refrain from performing any working practice that is
contrary to safety;
The above activities represent the minimum requirements of the tasks of the operating
personnel, and should not be considered as limits of responsibilities.
The operating personnel may be entrusted with further duties if appropriately qualified.
The operator must lay down responsibilities clearly in such cases.
Other personnel
In addition to the operating personnel, additional personnel are required for operating
the stacker and for performing maintenance, servicing and repair work.
These personnel must be appropriately qualified in accordance with the general

national statutory requirements and other binding rules and regulations.
Such personnel working on the stacker must also read and understand the operating
and maintenance manual, and in particular the sections dealing with safety. It is too
late to read the operating and maintenance manual once work has started.

3.2 DESIGN AND FUNCTION

3.2.1 General
Type of the stacker: STD - 4500 / 29.5 x 1.2

Definition:
STD = Stacker with boom slewing gear
4500 = Stacking capacity (t/h)
29.5 = Length of the boom* (m)
(*Boom hinge point - Centre of the dischage pulley)
1.2 = Belt width - Boom belt (m)
3.2.2 Layout - Stockyard
The stacker (1) with all its appertaining equipment serves to stack the specified bulk
material into piles.
1 1 1
Fig.: 225-STD4500-301

3.2.3 Main assembly units
The stacker consists of the following main assembly units:
4
A 2
A
6
1 1
Fig.: 225-STD4500-302
(1) Travel gear

(2) Slewing gear
(3) Hoisting gear
(4) Boom
(5) Boom conveyor
(6) Tripper car
Note!
For details on the electrical equipment, the safety- and monitoring devices
see the separate electric documentation.

3.2.3.1 Travel gear
3.2.3.1.1 General
The stacker with its tripper car is supported on the parallel rails at eight points by
means of a system of different runner wheel bogies.
In total, the travel gear comprises 24 runner wheels provided with a flange on both
sides. There is the same number of runner (12 pieces) wheels on both rails.
The runner wheels are arranged as follows:
- The portal with the tripper car is supported on the rails by one six-wheel bogie
(1), one four-wheel bogie (2) and three driven two-wheel bogies (3).
- The tripper car is supported on each rail by one three-wheel bogie (4), one non-
driven two-wheel bogie (5) and one non-driven single-wheel (6) support.
Each of the two three-wheel bogies (4) consists of a non driven two-wheel bogie
(5) and one driven single-wheel support (6).
A rail clamp (7) installed at one two-wheel-bogie of each six wheel-bogie is activated
during switch-off of the stacker.
During the stacker is travelling, the rails are cleaned from foreign matters by means of
bar-type rail clearers (8). The four rail clearers arranged at the corners of the stacker
are equipped with a plow-type clearer (9).
Buffers (10) at the travel gear and stops at both ends of the runway protect the stacker
if the monitoring system for limiting the travelling length should fail.

9
8
6
8
5
8
6
4
5
10
10
7
2
1
9
3
10
10
9
Fig.: 225-STD4500-303

3.2.3.1.2 Drive units
One drive unit is composed of an E - motor (1), which is directly flange-connected to

the planetary gearbox (2). A brake drum (3) and a drum brake (4) is arranged on the
2nd shaft end of the E - motor.
The working area of brake drum and brake is secured by means of a protective hood
(5).
The planetary gearbox is connected by the hollow shaft (6) and the shrink disk (7) to
the drive shaft (8) which drives the respective runner wheel (9). The runner wheels are
shrunk on the drive shaft or the runner wheel axle.
To absorb the reaction force of the output torque provision has been made for a torque
mount (10).
4 3 5
10
2
7 8 9
Fig.: 225-STD4500-304

3.2.3.2 Slewing gear
3.2.3.2.1 General
The slewing gear of the stacker consists of a single-row ball-race slewing connection
(1) with external toothing, as well as of two drive units (2) laterally attached to the ball-
race slewing connection.
A A
A-A
B-B
1 2
1 B 2
Fig.: 225-STD4500-305

3.2.3.2.2 Drive units
The drive units consist each of an E- motor (1), an overload coupling unit (2) with
flanged-on brake drum (3), a drum brake (4) and a combination of bevel and planetary
gearbox (5). A drive pinion (6), mounted on the drive shaft, meshes with the external
toothing of the ball-race slewing connection and provides for the slewing motion.
Protective covers (7) around the drive pinion and external toothing of the ball-race
slewing connection serve as a toothed rim protection to safeguard the working zone.
1 2 3
B
A
5
A
4 3
B-B
Fig.: 225-STD4500-306

3.2.3.3 Hoisting gear
3.2.3.3.1 General
The hoisting and lowering movements of the boom are effected by one hydraulic cy-
linder (1). The respective hydraulic power pack (2) is installed on the slewing part.
The hydraulic cylinder is connected to both the slewing section and the boom by
means of hinged bearings (3) and (4).
Note!
For details on the hydraulic equipment, please refer to the separate
hydraulic documentation.
A 4
3
2 A
Fig.: 225-STD4500-307

3.2.3.4 Boom
3.2.3.4.1 General
The boom (1) which can be lifted and lowered is supported in pivot bearings (2).
A counterweight (3) is compensating the weight of the boom.
On both sides of the boom there is a walkway (4) allowing a safe access to the
mechanical- and electrical parts.
The whole boom conveyor is covered by means of hoods to protect it against dust (5).
A
2
1
A
A-A
5
4 4
Fig.: 225-STD4500-308

3.2.3.5 Boom conveyor
3.2.3.5.1 General
By means of a transfer chute, the material is directed from the tripper car (1) to the
boom conveyor (2). The transfer chute consists of the stationary upper part (3) which is
fixed to the tripper car, and the slewable lower part (4), which is fixed to the boom.
Both chute parts are designed in a way that allows the formation of material beds for
impact absorbing inside the chute.
By means of the chute lower part, the material is directed to the material guide (5) with
subjacent impact idlers (6) arranged within the material feeding zone.
At the tip (7) of the boom, the handling material is discharged onto the pile.
2 1
Z
7
Z A A-A
1
2 3 4
2 5
Fig.: 225-STD4500-309

3.2.3.5.2 Drive unit
With belt conveyors, the power from the drive pulley is transmitted to the belt by
friction.
8The hollow-shaft drive unit consists of an E-motor (1), a hydraulic coupling (2) with
MTS, a flexible coupling (3) with brake drum, a drum brake (4), a shaft-mounted bevel
wheel gearbox (5) and a flange coupling (6). The working areas of the couplings and
the brake are secured by means of protective hoods (7), the E-motor and the gearbox
have shields (8).
The drive unit is mounted on a frame (9) and is attached to the drum shaft through a
shrink disc (10) providing a power grip connection.
To absorb the reaction power resulting from the driven end torque, the frame rests in a
flexible way on a torque support (11) which is fixed to the boom structure.
A
5 8 7 2 7 8 1
9 A
3 6
A-A B
7
B-B
4
10
11
Fig.: 225-STD4500-310

3.2.3.5.3 Pulleys
The drive pulley (1) provided with friction lagging is supported in pillow blocks (2) on
the boom structure.
In front of the drive pulley, a safety belt cleaner (3) is arranged, on that side of the belt
bearing no material, to prevent foreign matter from being pulled in between the pulley
and belt.
The discharge pulley (4) is supported in movable pillow blocks (5) at the boom
structure.
At the discharge pulley, a pre (6) and a main belt scraper (7) are arranged on the
contaminated side of the belt.
1 A 4
X Z
2
X
5
Z
A 3
7 6
Fig.: 225-STD4500-311

3.2.3.5.4 Idler stations
Along the handling line (carrying strand), the idlers are arranged in such a way that the
desired troughing of the conveyor belt will be obtained. Here, the belt is running over
idler stations (1), each consisting of three plain idlers, and within the feeding zone over
seven idler stations (2), consisting of three impact idlers.
Behind the drive pulley, the conveyor belt throughing will be rolled in by using an
adapted idler station (3) with a reduced throughing angle.
In the zone of the discharge pulley, the conveyor belt troughing will be rolled out by
using an adapted idler station (4) with reduced throughing angles, too.
In the return strand, the conveyor belt is running over idler stations (5) each being
equipped with one idler.
To guide the belt, provision has been made for one negatively troughed idler station
(6), equipped with two plain idlers.
In front of and behind the belt guide stations mentioned before, there are installed idler
stations (7) being equipped with stronger idlers.
G
C
B F
D
A E
D E
A
F
B
G
C
3 2 5 4
A-A C-C E-E G-G
7 1
B-B 6 D-D F-F
Fig.: 225-STD4500-312

3.2.3.5.5 Take-up device
The boom conveyor is equipped with an adjustable hydromechanical spindle take-up

device, acting on to the take-up pulley (1).
The take-up bearings (2) are guided in the supporting structure by two take-up
carriages (3) that can be moved forwards and backwards.
The belt tension required is produced by two hydraulic cylinders (4), via a hydraulically-
operated hand pump, ensuring the shifting of the take-up carriages and the pulley.
The nuts (5) of the two take-up spindles (6) are tightened as soon as the correct belt
tension is reached.
The belt tension or oil pressure produced is readable on a pressure gauge of the hand
pump.
The two hydraulic cylinders can be discharged now.
4 2 1 6 4 2 1 6
3 5 3 5
Fig.: 225-STD4500-313

3.2.3.6 Tripper car
3.2.3.6.1 General
The tripper car (1) is intended to ensure the transfer of material from the stockyard belt
conveyor (2) to the stacker boom conveyor (3). The tripper car is coupled to the stacker
portal (4) by means of a bolt (5).
The tripper car travelling on pairs of supports (6) and single supports (7), which are
equipped with non-driven runner wheels, is drawn / shifted by means of the stacker.
The tripper car is executed as a sectional steel welding structure.
Stairs (8) and walkways (9) on the tripper car ensure a safe acces to the mechanical
and electrical parts and to the E-house (10).
2
10
1
A
8
9
4 5 6 7 6 7
Fig.: 225-STD4500-314

3.2.3.6.2 Pulleys
The discharge pulley (1) is supported in pillow blocks (2) at the tripper car structure.
Beneath the discharge pulley are arranged a pre- (3) and a main belt scraper (4) on the
contaminated side of the belt
Two return pulleys (5) provided with rubber lagging, supported in pillow blocks (6) too,
are installed to ensure running of the belt loop back onto the belt structure of stacking
conveyor.
A hold-down device (7) with 2 wheels is provided to avoid too far lift-off of the belt
during start-up or no load-run.
Z 6 5
A 7
A 7
A
6 5
A
Z
A-A 1
7
3 4
Fig.: 225-STD4500-315

3.2.3.6.3 Idler stations
Along the handling line (carrying strand) of the tripper car, the idlers are arranged in
such a way that the desired troughing of the conveyor belt will be obtained.
Here, the belt is running over idler stations (1), each equipped with three plain idlers.
In front of the discharge pulley, the belt troughing will be rolled out by using two idler
brackets with reduced troughing angle (2).
In the return strand, between discharge- and first return pulley, the conveyor belt is
running over two idler stations (3), each equipped with one idler.
B
A
A
B
A-A B-B 2
1
Fig.: 225-STD4500-316

3.2.4 Accessories
3.2.4.1 Manual central lubrication systems
3.2.4.1.1 Travel gear
All 4- / 3- / 2-wheel bogies as well as the single wheel supports of the travel gear have
one central lubrication point which serves to lubricate, by means of a progressive distri-
butor (1), the shaft bearings and sealings of all runner wheels (2).
1 1
A-A
A
2
1 B 1 1
B-B C
C-C
B C
Fig.: 225-STD4500-317

3.2.4.1.2 Tripper car
In the area near the discharge pulley (1) and the upper bend pulley (2) as well as the
lower bend pulley (3), there is located each one central lubrication point which serves
to lubricate, by means of a progressive distributor, the bearings and sealings of the
corresponding pulley.
1 A A-A
1 1
2 2
2
3
3 3
Fig.: 225-STD4500-318

3.2.4.2 Automatic central lubrication system - Slewing gear
The slewing gear is equipped with two central lubrication systems to ensure the
lubrication of the following components:
- 1st lubrication system (1)
ball-race slewing connection - raceway and labyrinths (1a),
- 2nd lubrication system (2)
the tooth of drive pinions and ball-race slewing connection (2a),
The lower drive shaft bearings (3) are in hand lubrication made.
The central lubrication systems consist of the electrically operated grease pumps (4)
with grease tank.
2
4 1a
A-A
3 A
1
4 1
2
1a 2a
>>> Cont’d on the following page!

Fig.: 225-STD4500-319

One of them supplies the ball race slewing connection with grease, via the main distri-
butor (5) and the four sub-distributors (6).
The other one supplies, via a distributor (7), the tooth flanks of both the ball race
slewing connection and the drive pinions. The grease arrives at the lubrication points
via pipes (8).
Two safety valves (9) protect the whole system.
The grease tank is equipped with a level indicator, and a warning signal is given, if
there is a lack of grease.
4 4
9 9
8 6 6
Lubrication system (1) Lubrication system (2)
Fig.: 225-STD4500-320

3.2.4.3 Water spray system
The Stacker is equipped with a water spray system for dust supression. Nozzles
located at every transfer point produce spray mist to control the dust formation.
Fig.: 225-STD4500-321
Along the pile length four water feeding points are installed (in 1st stage two). Depend-
ing on which working area is chosen the water hose of stacker can be connected to
each feeding point via Kamlock coupling (1). Water supply is at every feeding point.
From there the water is supplied via hose reel to the piping system of the stacker.
At hose reel and feeding points are gate valves installed to ensure a safe change of
working area. The piping system distributes the water to the control cabinets and from
there to the spray points.

During stacking every transfer point is sprayed.

These are:
- (1) Transfer chute from tripper car to boom conveyor
- (2) Skirting of boom conveyor
- (3) Boom conveyor discharge to stockpile
1 2
1
A
Fig.: 225-STD4500-322

Near every transfer point is a control cabinet installed.
The control cabinet is equipped with a diaphragm valve (1) to start and stop spraying
and a valve (2) to regulate the flow to the nozzles. The pipeing system is also fitted with
strainer (3) and monometer (4) for water pressure monitoring.
1 2
3 4
Fig.: 225-STD4500-323

3.3 TECHNICAL DATA

3.3.1 Travel gear
Runner wheels - Number total : 24

thereof driven : 12 (Portal)
Runner wheel diameter : 630 mm
Track gauge : 7m
Rails : A 75
Travelling speed : 5 to 20 m/min.
Travel length (operational) : 672.3 m (1.Stage)
1.122.3 m (2.Stage)
Drive units - Number : 12

each consisting of:
- Electric motor : Type 132 M
N = 8.6 kW, 460 V, 3 Ph, 60 Hz
n = 1.800 min-1
+ brake drum ø 160 mm
(on 2nd shaft end)
- Brake : Drum brake Type TE-S 160
with Elhy-thruster EB 120/40
Braking moment: set to 80 Nm
- Gearbox : Planetary gearbox
Type BK 80
i = 171.5
Rail clearers - Number : 4 (at portal travel gear)

: 12 (at tripper car)
Rail clamp - Number : 2, hydraulically operated,

Type: CTHV-LH-150-045-LE-06
Holding power 150 kN / clamp
Buffers at stacker
Type : Type 018112-200x200-A
Number : 2 x at front side + 4 x at rear side

3.3.2 Slewing gear
Slewing speed : n = 0.010 - 0.10 U/min.

Max. slewing speed
of the discharge pulley : 20 m/min
Boom slewing angle max. : + 110 ° / - 110 °
Drive unit - Number : 2

consisting of:
- Electric motor : Type: 100 L
N = 2.54 kW, 460 V, 3 Ph, 60 Hz,
n 1 = 1.800 min-1
- Coupling : Overload coupling
Type KTR - SI 3 with Rotex 55
- Brake : Drum brake
Type TE 160
with Elhy-thruster EB 120/40
- Gearbox : Planetary gearbox
Type SC 6004
i = 1871
Slewing connection - number : 1

Execution : Large-diameter antifriction bearing
with external toothing, z = 135
Type: 061.60.3000/200.41.1522
Slewing gear pinions - number : 2
Pitch circle-ø: 384 mm, z = 16
Buffers - number : 2
Type: 125 x 190

3.3.3 Hoisting gear
Boom inclination : - 15 ° to + 15 °
Average hoisting speed
of discharge pulley : 3 m/min
Type of the hoisting gear : Hoisting gear with hydraulic cylinder
Hydraulic equipment
Hydraulic power pack - Number : 1

- Place of installation : on the slewing part
- Motor : Electric motor, N = 25.3 KW
Hydraulic cylinder - Number : 1
- Hinge-centre distance : 3155 mm (min.) - 4948 mm (max.)
- Speed : 290 mm/min
Note!
For details on the hydraulic equipment, please refer to the separate hydraulic
documentation.

3.3.4 Boom conveyor
Axial distance : 33.350 mm (min.) / 33.650 mm (max.)

Troughing : 35 °
Belt speed : 4.0 m/s
Drive unit - Number : 1

consisting of:
- Electric motor : Type: 315 L
N = 186 kW, 460 V, 3 Ph, 60 Hz
n 1 = 1.800 min-1
- Couplings : Hydraulic coupling
Type 487 TVVFNJ-Z with MTS
Flexible coupling
Type GBT 214 - 315/118
- Brake : Drum brake
Type SBH 315
with Elhy-thruster EB 500-60
- Gearbox : Shaft-mounted bevel and spur wheel gearbox
Type KSZg 280 Rü Pu Lü
i = 14.82
Pulleys:
- Drive pulley - Number : 1

Dimensions : ø 630/650 x 1400 mm
Pillow blocks : 2 x SNL 3134 TNF
- Discharge pulley - Number : 1

Dimensions : ø 630 x 1400 mm
Pillow blocks : 2 x 23132 CCK/W33
Belt : Type: ST 800 - 8/4 W

Width: 1200 mm

Take-up device - Mode of actuation : Spindle take-up device

(at conveyor head)
assisted by the
Hydraulic set P80/RC254G101
Idlers:
- Carrying idlers - Number : 96

- Impact idlers
Number : 21
- Return idlers
Number : 20
- Return idlers - Number : 3

- Training idlers - Number : 2

Belt cleaners:
- Pre cleaner - Number : 1

Type : Starclean® Type 834.285n.11
Article no. : 90-834.285.n11
for belt width 1200 mm
(at the discharge pulley)
- Main cleaner - Number : 1

Article no. : 90-832.056n.11
- Safety belt cleaner - Number : 1

Type : Plough-type belt cleaner
(at drive pulley)

3.3.5 Tripper car
Belt width : 1200 mm

Troughing : 35 °
Belt speed : 4.2 m/s
Pulleys
- Discharge pulley - Number : 1

- Bend pulley - Number : 2

Idlers:
- Carrying idlers - Number : 147

- Return idlers - Number : 2

Belt cleaner:
- Pre belt cleaner - Number : 1

Type : Starclean® Type 624
Article no. : 90-624-08.285nl.11
- Main belt cleaner - Number : 1

Article no. 90-832.56n.11-2100
Hold-down device - Number : 2

Execution : with 2 wheels ø 500 x 90 mm per device

Cable reel - Number : 1 (tandem reel)

- Type : HMIV26/73/5/88-6kV+1S+8R32+6LWL
- Cable type : 2 Power cables with integrated
: optical fibre
Hose reel - Number : 1 (tandem reel)

- Type : HGNSCH4/15/43/78S11/2"-10bar
- Hose type : 1SN EN 853 DN 40 (1 ½ “)
3.3.6 Accessories
3.3.6.1 Manual central lubrication systems - Travel gear / Tripper car
Type of lubrication (Travel gear) : manual lubrication of the bearing + sealings

of the wheel shafts by means of 1 distribu-
tor with 1 grease nipple at each wheel
bogie and single wheel support
Type of lubrication (Tripper car) : manual lubrication of the bearing + sealings
of the discharge and bend pulleys by
means of 1 distributor with 1 grease nipple
each arranged in the area of the cor-
responding pulley
3.3.6.2 Automatic central lubrication system - Slewing gear
Pump - Number : 2x1

Pump - Type : P205-10XYBU-1KR+1SVP
Tank - Capacity : 10 l
Lubrication intervals : adjustable
Lubrication points
- Lubrication part 1a / Number : ball-race slewing connection / 12
- Lubrication part 1b / Number : sealing of ball-race slewing connection / 12
- Lubrication part 2 / Number : lubrication keys at drive pinions / 4
Manually-operated part
- Lubrication part 3 / Number : lower drive shaft bearings / 2
3.3.6.3 Water spray system - Water supply
Water pipes
on the stacker and the tripper car : PE 32 mm
Feeding pressure : 6 - 6.9 bar
Water flow : 6 m³ / h

3.3.7 Monitoring devices
General
- Anemometer
Travel gear
- Proximity switches - travel way synchronisation
- Emergency limit switch - end of runway
- Rotary encoder - Travel position
- Limit switch - Travel gear brakes opening
- Limit switch - Rail clamp opening
Slewing gear
- Cam-operated limit switch - Slewing range limiting
- Emergency-off switch - End of slewing motion
- Limit switch - Slewing gear brake opening
- Proximity switch - Storm locking device opening
Hoisting gear
- Limit switch - Hoisting angle for slewing under tripper car
- Inclination sensor - Hoisting angle
- Tilt switch - Stockpile distance and collision protection
Boom conveyor
- Belt misalignment switch - Belt tail and head ends
- Pull-cord emergency switch
- Belt slip monitoring
- Limit switch - Brake opening
Tripper car
- Belt misalignment switch
- Pull-cord emergency switch
- Laser probe - Material detection
- Tilt switch - Chute clogged
- Proximity switch - Hose uncoupled feeding point
Note!
The above-mentioned recapitulation of control equipment does only re-
present an extract from the complete list! For the complete list, as well as
further details, please refer to the separate electric documentation.

3.4 SAFETY REGULATIONS

3.4.1 General safety instructions for structural steelwork /
mechanical engineering
- The stacker must be kept clean. Spillage, accumulations of grease and other
soiling must be removed immediately. All drives, motors, bearing points and
electrical equipment must be kept clean.
- The belt conveyors, the scrapers and the material transfer points must be kept
clean.
- Access may be gained to service walkways and other sealed off areas only when
the stacker is stationary, and with particular attention to the safety regulations.
Danger!
It is prohibited to leave the walkways and step onto the machine structure
and/or belt conveyors.
Life may be at risk if this rule is not observed!
- Keep the brakes clear of dirt, rust, oil and grease. Clear any soiling immediately!
Caution!
Brakes which are not in perfect condition are a hazard to personnel and the
stacker!
- During hours of darkness the stacker must be sufficiently illuminated.
- Damage, cracked paintwork, loose screws, and deformation of load bearing

components must be immediately reported to TKIS. Deformation of and cracks in
the load-bearing components may be repaired only upon consultation with TKIS
and with the express approval of TKIS.
Caution!
Cracks and deformation are an indication of overloading of the component in
question. To prevent further damage, the cause of overload must be
determined and rectified without delay.
- Welding, flame-cutting and grinding work on load-bearing components may

impair the stability of the stacker. Such work is prohibited without the express
written approval from and instruction by TKIS.

Caution!
TKIS absolves itself of all responsibilty and liability for short and/or long-term
damage to the stacker resulting from contravention of the rules and
regulations.
3.4.2 General safety instructions, electrical system
- It is prohibited to work on the stacker when it is in a non-interlocked condition,

except for repair and maintenance purposes.
- The interlocking system may be rendered inoperative by bridging switches only in

exceptional cases, for example during repair work, and not during normal
operation.
Caution!
Measures must be taken to ensure the safety of the personnel and the
stacker when working in a non-interlocked condition.
Starting the drive will be announced by special optical and audible signals.
- It is prohibited to disable and/or to carry out unauthorized modifications or

settings on safety equipment.
- No changes may be made to the software (PLC).
3.4.3 General hydraulic safety instructions
- Work on the hydraulic equipment is only to be carried out by people who have
special knowledge and experience of hydraulics!
- Check all lines, hoses and screwed joints regularly for tightness and for visible
damage!
Danger!
Oil spouting out, can lead to injury or fire!
- Before starting any repair work on open sections and pressure lines, the relevant
assembly group areas must be depressurized!
- Hydraulic lines must be professionally routed and checked! Connections must not
be mixed up! Take care when replacing hoses that they have the correct length
and quality!

- Valves are only to be repaired by authorized and qualified personnel!
3.4.4 Fire prevention
- Inflammable materials such as oil, grease, paint and wire wool must be stored
somewhere fire proof.
- It is also advisable to avoid situations and conditions that could cause fire, such
as the overheating of bearings and belts, and the build up of dirt and dust on
electric motors etc.
- Any type of damage to a fire extinguisher as well as their deficiency must be

reported immediately to the relevant supervisory staff.
- Welding and flame-cutting work must be carried out with extreme care. The work
must be supervised by someone with a hand-operated fire extinguisher.
- To guarantee a continuous supervision of the stacker, inspections must be

carried out every two hours during downtimes between repair and servicing work,
and also on Sundays and holidays.
- The device must be inspected immediately after welding or flame-cutting work is

finished. Then 1 hour later a further inspection should be carried out and
thereafter every 2 hours.
3.4.5 Fire fighting
- In case of a fire in an area of the stacker every available person must take part in
fighting the fire.
- Every fire must be fought with a suitable fire extinguishing substance.
- Small fires are to be fought immediately, in case of bigger fires give fire alarm in
the first place and start fire fighting then.
- Check whether ventilating-, air conditioning- and dedusting units are discon-
nected (Danger of fire extension).
- The responsible supervisory staff must be informed.
- In case of fires in electrical equipment and/or cables, these are to be made dead.
- Should it be impossible to make the LV-systems dead immediately

(up to 1000 V), such fires are only to be fought by using suitable fire fighting
means (Powder / CO2). When doing so a safety distance of 1 m is to be kept.

Caution!
When using CO 2 -fire extinguishers in closed rooms, there is a danger of
suffocation. Such rooms are to be left upon fire fighting immediately.
- Every use of fire extinguishers must be reported to the responsible supervisory

staff.
- Used fire extinguishers must be replaced immediately by full and operative ones.

Blank page

3.5 GENERAL LAYOUT

3.5.1 Stacker STD-4500/29.5x1.2
Drawing - No. : 4553414

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4 OPERATION
1. GENERAL SECTION
(Volume M1)

(Volume M1)

(Volume M1)
4. OPERATION
(Volume M1)
5. MAINTENANCE
(Volume M1)
(Volumes M1 + M2)
Access to chapter 4 "OPERATION" is facilitated by table of contents and by footers.

Blank page

TABLE OF CONTENTS
4.1 GENERAL NOTES .................................................................. 5

4.1.1 Operator training ...................................................................................... 5
4.1.2 Safety instructions relating to operation ................................................... 5
4.2 OPERATION FACILITIES ....................................................... 7
4.2.1 Switching- and control elements .............................................................. 7
4.2.1.1 General notes ................................................................................................. 7
4.3 NORMAL OPERATION ........................................................... 8
4.3.1 General .................................................................................................... 8
4.3.2 Checks before work is started ................................................................. 8
4.3.3 Operation modes ..................................................................................... 9
4.3.4 Stacking ................................................................................................. 10
4.3.4.1 CHEVRON method ...................................................................................... 10
4.3.5 Lubrication of the ball-race slewing connection ..................................... 12
4.4 SPECIAL OPERATING CASES ............................................ 13
4.4.1 Emergency stop ..................................................................................... 13
4.4.2 Precautionary measures in case of storm .............................................. 14
4.4.3 Local operation ...................................................................................... 14
4.4.4 Changing location .................................................................................. 15
4.4.5 Parking position ..................................................................................... 15
4.4.6 Working together with other machines................................................... 15
4.4.7 Extended downtime ............................................................................... 16
4.4.7.1 Stopping ....................................................................................................... 16
4.4.7.2 Preservation ................................................................................................. 16
4.4.7.3 Recommissioning ......................................................................................... 17
4.5 OPERATIONAL FAULTS ...................................................... 18
4.5.1 Fault elimination instructions ................................................................. 18

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4.1 GENERAL NOTES

4.1.1 Operator training
This operation and maintenance manual of the stacker does not obviate the need for
training and instruction.
Operation of the stacker requires relevant expertise and prior knowledge of the safety
requirements.
This operation and maintenance manual (TKIS) and the separate electrics and hydrau-
lics documentation provide the operating personnel with the necessary instructions for
operation. It must be ensured at all times that the stacker is operated as specified, see
chapter 1.2.9 and 3.1.5.
The operating personnel must read the operation and maintenance manual, and in
particular the operating safety instructions (see chapter 4.1.2) prior to commencing
work. It is too late to read the operation and maintenance manual once work has
started. Note the fire fighting instructions.
The operating personnel must be familiar with the location and operation of the safety
devices (see also description of the electrical equipment).
4.1.2 Safety instructions relating to operation
- Each and every mode of operation that affects safety is prohibited.
- In the event of malfunctions stop the stacker immediately and lock it. Have any
defects rectified immediately.
The following instructions concerning accident prevention and safety of both the
operating personnel and the stacker must be observed during operation of the stacker:
- Read and observe the general safety instructions for work on the stacker
(see chapter 3.4).
- Operate the stacker in perfekt condition only. Note the safety devices, and do not
remove them. Do not bridge the safety devices or render them inoperative. Do
not make alterations to the stacker or change the settings yourself.
- Before starting work, ensure that no one is standing in the working area of the
stacker. Ensure that no one is endangered by the stacker starting-up or by the
starting of individual drives. Give a warning signal. During operation, no persons
may stand in the area of moving components (e.g. travel gear).
- Before starting the stacker, check that all drives and their brakes are in perfect
condition.
- Observe the start warnings and displays. Carry out the starting on and shutdown
procedures in the stipulated order.

- Should the stability be impaired, for example due to overloading of the boom or
material accumulations stop the stacker immediately and inform the supervisory
personnel.
- If there is a risk of collision with another machine, give warning signals to make
the operator of the equipment in question aware of the danger. Stop the stacker
immediately and inform the supervisory personnel.
- Do not operate the stacker at wind speeds exceeding 20 m/sec.
- Work only with the required lighting during hours of darkness or of poor visibility.
- Abstain from any hazardous working procedures, e.g. attachments of loads, or

overloading the belt conveyors.
- In the event of malfunction, stop the stacker immediately and protect against
unauthorized restarting.
Report the fault or damage and have it rectified immediately.
- Stop the stacker immediately if human life is at risk, for example due to careless
behavior in the vicinity of the material transfer points or travel gears.
- Leave the operator’s cab during breaks in operation only after all drives have
been switched off. At the end of a work period, secure the stacker additionally
against against unauthorized use.
- Individual drives may be operated locally only during inspection, maintenance

and repair works.
- Work should be carried out only by appropriately personnel who have been
instructed to do so.
- Observe the particular safety regulations for maintenance and repair work
contained in chapter 5.
- Prior to commissioning the stacker, make sure that the stacker is mechanically
ready for operation.
Prior to commissioning, the following requirements have to be met:
- The working zone of the stacker must be free from obstacles of any kind, such as
maintenance vehicles, working platforms, loose ladders etc.
- The material conveying route must be free from tools, cleaning devices, etc.
- All drive units are mechanically ready for operation, if:

- all gearboxes are filled with oil and closed,
- all covers have been mounted,
- all lubricating points have been supplied with grease.
- The belt is in perfect condition and properly tensioned.

4.2 OPERATION FACILITIES

4.2.1 Switching- and control elements
4.2.1.1 General notes
For securing the movements of the stacker, switching and control elements are pro-
vided which limit the motions by interrupting the power supply. Since these elements
substantially contribute to the overall safety, keeping them in a perfect condition and
working order is an absolute must.
These switching and control elements must be inspected and their operation must be
checked by a responsible person at shorter intervals.
Danger!
The personnel are in no case allowed to put limit switches out of
operation.
Defective limit switches must be replaced immediately.
Note!
The switching- and control elements are provided to ensure a proper
stacker operation and an appropriate coordination of the different
operations of the main assembly groups.
For detailed information on the equipment, as well as a list of the
complete equipment, see the separate electric documentation.

4.3 NORMAL OPERATION

4.3.1 General
The stacker travelling on rails is used to stack material into piles.
Via the tripper car conveyor, passing through a transfer chute, the material is trans-
ported to the stacker conveyor from where it is discharged onto the pile to be built up.
The boom can be operated by both the slewing- and the hoisting gears, in order to
enable this way different discharge positions- and directions.
4.3.2 Checks before work is started
Before operations are started, check the stacker for visible faults and damage. Imme-
diately report any changes and visible wear to the responsible person/authority.
Each time the stacker is started, the operation of safety limit switches, operational limit
switches, emergency limit switches and emergency-stop push-buttons must be tested
first.
To ensure operational safety, all switches, proximity switches and straight edges must
be cleared of dust and caked material, and lubricated if necessary.
Flexible cables and water hoses must be checked for chafing and damage each time
the stacker is used. Cables with damaged insulation must be replaced immediately, as
well as leaky water pipings.
The following checks, which are to be carried out before work is started, are also
included in the maintenance table:
• find out, whether the system is waiting for the lubrication of the ball-race slewing
connection, in this context, please also refer to chapter 4.3.4.
Realize the lubrification work, if necessary.
• check the level of soiling of the stacker daily. A cleaning must be done when, for
instance, the belt pulleys and idlers did become soiled due to caking material;
• check all scrapers for caked material. Check the level of wear and the operation
of the scrapers;
• check the oil level of gearboxes and the hydraulic system;
• check gear units, bearings and brake thrustors for running noises and leaks;
• carry out a visual inspection of the brakes on all drives.

4.3.3 Operation modes
The stacker is equipped with control devices which allow the following operating
modes:
- Unlocked operation = manual local operation
In this mode, it is possible to separately switch on and -off the drives of the
individual components from the local control stations. The unlocked operation is
exclusively to be used for emergency-, repair- and setting purposes.
- Interlocked operation = manual control of the stacker from the control desk
inside the E-House cabin arranged on the Tripper Car platform.
In the interlocked operation mode, all drives are interlocked against each other.
Thus, the drives of the conveying systems are stopped according to a pre-
determined order when switching off the stacker, while all safety- and monitoring
units remain in operation.
- Automatic operation
Depending upon the preselection, it is possible to switch on and -off the auto-
matic stacking according to the Chevron method from the central control room or
from the operating desk in the E-House.
Note!
Please refer to the detailed description included in the separate docu-
mentation regarding the electrical equipment.
Caution!
Special operation notes:
- Before the stacker is shut down, all conveying installations have to be
run empty.
- It is not allowed to run the conveying installations with overload.
- Damaged top covers of the belts have to be vulcanized.
- Incrustations and cakings of the handled material on the chutes,
pulleys, idlers and scrapers have to be removed.
- Prior to longer shut-down periods the belts have to be cleaned and
released.
- Prior to recommissioning, the stacker has to be run in no-load
operation.

4.3.4 Stacking
For reasons of process engineering (great variations with respect to the grain sizes),
the automatic stacking is carried out according to the Chevron method.
4.3.4.1 CHEVRON method
The CHEVRON stacking method is used to create a mixed stockpile, i.e. different sorts
of material (grain size, quality, …) are piled-up in such way that an optimal blending
effect is obtained over the whole stockpile length.
4.3.4.1.1 Building-up a stockpile
At the control desk, there is preselected the pile where the material is to be placed.
Then, the stacker is positioned in its lowest working step condition within the pre-
selected pile.
Following the start of the work in automatic mode, the stacker is travelling to and from
between the two ends of the stacking zone (beginning of end cone slope). At the end
points, the software program calculates a height dependent standstill time in order to
achieve an optimum formation of the end cones without serious end flattening. As soon
as the probe installed on the tripper car detects missing material (for a time span of
approx. 20s), the travel gear of the stacker is stopped with a certain time delay after
running the boom conveyor belt empty. All other automatic functions remain in stand-by
condition, so that the automatic stacking can be continued, as soon as the existence of
material is detected.
During the formation of the stockpile, the tilt switches fixed at the boom head for
detecting the contact with the material stockpiled, initiates a stepwise hoisting of the
boom until the latter has reached its uppermost working position.
During the last hoisting motion of the boom, i.e. before the stockpile is filled completely,
a signal is given in due time to the operator for evacuating the conveying line. If the
order “evacuation of the conveying line” does not get activated, the stacking operation
is stopped automatically as soon as the stockpile is filled completely. Thereafter, the
material remaining on the stacker can be evacuated manually.
Upon stopping of the stacking operation, the stacker remains in its end position.
After having started the stacking operation in accordance with the CHEVRON method,
all functions are carried out automatically and controlled by probes and limit switches
fixed at the stacker.
For having extended an existing CHEVRON stockpile, the boom will be positioned as
close as possible to the existing material pile in manual operation. Thereafter, the
automatic operation can be started.
If during stacking operation, the ball-race slewing connection needs to be lubricated

(please also refer to chapter 4.3.5), the automatic operation will not be stopped. The
lubrication sequence will be carried out at the next opportunity (next stop of the boom
conveyor).

4.3.4.1.2 Stacking „CHEVRON“
Future pile
Future pile
Future pile
Fig.: 225-STD4500-401

4.3.5 Lubrication of the ball-race slewing connection
The ball-race slewing connection including the tooth must be lubricated weekly. This is
also necessary during the first years of operation when the slewing gear is not required
yet for stacking two further stockpiles on the other side of the rails.
The date of the next lubrication is indicated to the operator by the control system of the
installation in time. When this moment is reached, the operator must first carry out the
lubrication sequence. Stacking or changing location will not be possible until the
lubrication sequence is complete.
For the lubrication, the operator must only realize a complete slewing cycle of the
boom; the lubrication itself takes place automatically by means of the central lubrication
system provided for the slewing gear.
To effect a complete slewing cycle, the operator must bring the boom in its uppermost
position.

4.4 SPECIAL OPERATING CASES

4.4.1 Emergency stop
In a dangerous situation, the operation of the stacker can be stopped by actuating

emergency stop pushbuttons resp. pull-rope switches.
Such pushbuttons are installed in different places of the stacker; the pull-rope switches
responsible for an emergency stop are installed at the travel gear and along the boom
and Tripper car conveyor.
Following an emergency stop:
• determine the hazard or damage, and provide first aid if necessary:
• rectify the fault or have it rectified.
Note!
More information details are to be taken from the electro-technical
documentation manual.
Note!
An emergency-off might possibly result in an overfilling of the transfer
chute arranged between both the tripper car belt conveyor and the
boom belt conveyor. In such case, the chute is to be emptied by
operating the boom belt conveyor in manual mode.
To protect the skirting in case of a possible chute overfilling due to an

emergency-off, lifting / lowering of the boom is not possible until the
level probe inside the chute does not indicate a fault signal any more,
i.e. after emptying of the chute.

4.4.2 Precautionary measures in case of storm
The stacker operation is possible in an unrestricted manner up to a wind speed of

20 m/s. As soon as the wind speed exceeds this value, one has to proceed as follows:
• Run stacker empty.
• Move the stacker into the parking position and close the rail clamps.
Caution!
When a wind velocity of 20 m/s is reached, a wind warning is given out. The
warning will be transmitted to the CCR.
In case the maximum wind speed of 23 m/s is exceeded, a second warning
is given out indicating that the stacker has to be immediately moved into
parking position and secured. In this case, the current operation mode
(automatic or manual) will be stopped, and it will only be possible to travel
to the parking position which has to be pre-selected at the operator panel.
4.4.3 Local operation
Local operation, i.e. starting individual drives for inspection, maintenance or repair
work, is only possible after it has been enabled from the local control station or the
control desk. In this operational mode all drives can be operated from their local control
box.
Caution!
Take care not to bring the stacker into possible hazardous situations, most
safe guards are disabled.
The local mode may only be enabled by authorized persons and only after
all the necessary precautions have been taken.
Observers must also be deployed.

4.4.4 Changing location
The pile is changed in manual operation. When doing so, attention should be paid to
the following:
• evacuation of stockyard stacking belt conveyor and stacker boom belt conveyor;
• preselection of “changing location“ at the control desk;
• the boom is to be brought into the uppermost out-of-service position;
• the boom needs to be positioned parallely to the runway, if necessary;
• move the stacker and inspect at the same time its runway and environment
concerning possible hindrances and such ones to be expected.
4.4.5 Parking position
On principle, when being out-of-operation for a longer period of time, the stacker must
be brought into one of its parking positions.
When being in the parking position, the stacker is to be switched-off. The rail clamps
and the brakes of all drive mechanisms, with the exception of that ones pertaining to
the slewing drive mechanism, are closed automatically then.
If the stacker is not travelling and conveying material for a certain time, the rail clamps
are also closed automatically for safety reasons, even if the power supply of the
stacker is not switched-off. The rail clamps will be opened again automatically during
the next start warning.
This way, the stacker is protected against uncontrolled movements.
In case of storm warnings, the machine needs to be locked additionally; also refer to
chapter 4.4.2 “Precautionary measures in case of storm”.
4.4.6 Working together with other machines
When auxiliary machines are being or are to be used in the proximity of the stacker, the
person in charge must ensure that the machine operator is informed at all times on the
nature, extent and location of work being carried out by these other machines.

4.4.7 Extended downtime

4.4.7.1 Stopping
For extended downtime periods, e.g. for large-scale repair work, the following
measures must be taken:
• bring the stacker into its park position, see chapter 4.4.5;
• protect the stacker to be put into service again;
• close all engineering rooms and the operator’s cab.
Various servicing work is to be carried out, depending on the time involved, during and
after long downtime periods as well as starting operations again.
4.4.7.2 Preservation
A number of preservation measures must be taken prior longer downtime periods

(i.e. several months):
• repaint areas where the paintwork is damaged;
• coat bare metal areas of mechanical moving parts with a preservation agent
which can be removed at a later stage;
Caution!
Never treat the friction surfaces of the brakes with preservation agent or oil.
The brakes will otherwise cease to be effective.
• completely fill the gear units with preservation oil;
• fill labyrinth glands with grease. Do not wipe away grease which has oozed out,
or the grease collar;
• clean and dry the engineering rooms;
• clean the stacker of dust and caked-on material;
• cover rubber belts to protect them from solar radiation.

4.4.7.3 Recommissioning
• Remove the different preservations and clean the stacker;
• carry out a complete maintenance procedure on the stacker, i.e. control oil
fillings, brake drums and disks, and check the brakes for their easy-running;
• check all settings and reset if need be (brakes, couplings, belts, etc.);
• lubricate all grease points by means of the central lubrication system(s) resp.
manually;
• carry out a maintenance procedure on the electrical installation according to the

instructions of the respective manual.

4.5 OPERATIONAL FAULTS

4.5.1 Fault elimination instructions
Note!
The major functions of the stacker are monitored during operation. Faults
occuring in any of these functions cause an alarm and/or shut down the
stacker / plant.
Additional information about other faults than that described in the following
are given in the documentations of the respective sub-suppliers.
Fault Cause Elimination
Switching-off of the One of the tilt switches at the • Turn on the travel, slewing
following drives: boom head did become and hoisting gears
activated, e.g. due to a contact
- Travel gear with the pile Run boom and/or the
- Boom slewing gear stacker out of danger zone
- Boom hoisting gear
Belt skewing Cakings on pulleys resulting • Readjust belt cleaner resp.

from insufficient cleaning of safety belt cleaner,
the belt exchange segments resp.
cleaner strips
Drive- / take-up pulley • Realign drive- / take-up

incorrectly aligned pulley
Belt top cover defective • Repair defective area
Several idler stations are not • Align idler stations

at right angles to the running
direction
Belt slip monitoring device at Slipping of the belt on the • Tension belt
the boom belt conveyor did drive pulley due to insufficient
respond belt tension

5 MAINTENANCE
1. GENERAL SECTION
(Volume M1)

(Volume M1)

(Volume M1)
4. OPERATION
(Volume M1)
5. MAINTENANCE
(Volume M1)
(Volumes M1 + M2)
Access to chapter 5 "MAINTENANCE" is facilitated by table of contents and by footers.

Blank page

TABLE OF CONTENTS
5.1 MAINTENANCE AND INSPECTION ....................................... 5

5.1.1 General notes .......................................................................................... 5
5.1.1.1 General safety instructions for servicing work ................................................. 6
5.1.2 Servicing table ......................................................................................... 9
5.1.2.1 Servicing intervals .......................................................................................... 9
5.1.2.2 Inspection and servicing tables ..................................................................... 10
5.1.3 Lubrication ............................................................................................. 28
5.1.3.1 General ........................................................................................................ 28
5.1.3.2 Lubrication tables ......................................................................................... 28
5.1.3.3 Drawings showing the lubrication points ....................................................... 38
5.1.3.4 Lubricants - Comparative tables ................................................................... 44
5.1.4 Servicing of individual components........................................................ 55
5.1.4.1 Brakes .......................................................................................................... 55
5.1.4.2 Belt conveyors .............................................................................................. 57
5.1.5 Corrosion protection .............................................................................. 65
5.1.5.1 Temporary corrosion protection .................................................................... 65
5.1.5.2 Corrosion protection coat ............................................................................. 65
5.2 REPAIR ................................................................................. 66
5.2.1 General notes on repair work................................................................. 66
5.2.1.1 Safety instructions ........................................................................................ 67
5.2.2 Handling of structural components ........................................................ 70
5.2.3 Lifting gears and attachments ................................................................ 71
5.2.3.1 Lifting gears .................................................................................................. 71
5.2.3.2 Lifting prodedure .......................................................................................... 71
5.2.3.3 Fastening ropes............................................................................................ 73
5.2.3.4 Fastening chains .......................................................................................... 74
5.2.3.5 Screwed eyelets ........................................................................................... 75
5.2.3.6 Load brackets ............................................................................................... 75
5.2.3.7 Protection of fastening means and loads ...................................................... 76
5.2.3.8 Underlayers for loads ................................................................................... 77
5.2.4 Repair instructions for special components ........................................... 78
5.2.4.1 General ........................................................................................................ 78
5.2.4.2 Travel gear ................................................................................................... 78
5.2.4.3 Slewing gear ................................................................................................ 79
5.2.4.4 Hoisting gear ................................................................................................ 82
5.2.4.5 Boom conveyor ............................................................................................ 84
5.2.4.6 Cutting, dismounting and re-installation of the conveyor belt ........................ 85
5.2.5 Antifriction bearings - mounting and dismounting .................................. 94
5.2.5.1 Foreword ...................................................................................................... 94
5.2.5.2 Mounting ...................................................................................................... 94
5.2.5.3 Dismounting ............................................................................................... 102
Blank page

5.1 MAINTENANCE AND INSPECTION

5.1.1 General notes
Always note the general safety instructions for servicing work (Chapter 5.1.1.1)
during maintenance.
The servicing work to be carried out is

- summarized in tabular form in a maintenance schedule (Chapter 5.1.2) in the
corresponding sections covering the inspection and servicing required for the
main assembly units and assembly groups. A copy of the maintenance schedule
must be available on the stacker and stored in a location where it is easily
accessible and well protected.
The notes on lubrication (Chapter 5.1.3.1) include general lubricating instructions.
The lubrication tables (Chapter 5.1.3.2) include the lubricants to be applied for the
different assembly groups of the stacker, the mode of lubrication, the lubricant designa-
tions according to DIN 51502 and the ISO viscosity classes according to DIN 51519.
Lubrication schedules are contained in the drawings showing the lubrication points
(Chapter 5.1.3.3) required for the corresponding assembly groups.
Some lubricants of different international manufacturers meeting these standards are

listed in the lubricants - comparative table (Chapter 5.1.3.4).
The term “inspections” refers to checks (visual inspections and inspections carried out
with the aid of special equipment such as measuring instruments) made by competent
and responsible supervisory staff or by authorized experts.

5.1.1.1 General safety instructions for servicing work
Note the general safety instructions for operating and servicing the stacker
(see Chapters 1.2 + 1.4 + 3.4 + 4.1.2 + 5.1.1.1 + 5.2.1.1).
Caution!
Always carry out servicing work at the stipulated intervals. Do not post-
pone servicing work. TKIS accept no liability for any damage resulting from
servicing work which has not been carried out, which has not been carried
out in time or which has been carried out incorrectly.
- Servicing work may only be carried out when the stacker has been immobilized.
- Before work is started on the stacker, make sure that the stacker in the working
area has been disconnected from the electric power supply.
- Use only suitable and tested tools which are in perfect condition.
- Do not leave tools or other equipment in or on the stacker after work has been
completed.
- When handling oil, grease and other chemical substances, observe the product
related safety regulations.
- Do not open covers, lids, flaps and hoods on the stacker during operation.
5.1.1.1.1 Neutralising the power supply / releasing stored energy
Personnel and stacker must be protected against damage when service, maintenance
and repair work is carried out. Such damage can be caused by unexpected current
flow, the stacker or individual machine components starting up or stored energy being
suddenly released, such as, for example, fluids which are under pressure.
This protection is given by interrupting the power supply and depressurizing and
releasing stored energy in accordance with specified procedures and by safeguarding
these measures.
Danger!
De-energize the plant or individual components prior to starting any work!
Secure this condition in such a way that it is impossible to undo by un-
authorized persons!
Observe the safety and accident prevention regulations!

5.1.1.1.2 Spheres of responsibility and prerequisites
The operator of the stacker must define spheres of authority and responsibility for all
activities and locations.
Every employee who has authorised access to the stacker and who is authorised to
work on the stacker must be fully aware of the hazards which this entails and the safety
measures which are available to prevent the hazards.
All members of staff working on the stacker must be instructed in the work and
measures to be done on the stacker early.
All members of staff working on the stacker must be aware of the sequence planned of
the measures to be done.
They must be acquainted with all switches, valves, actuating devices and warning
equipment.
The shutting down and disconnection of electrical energy sources must be carried out
or supervised by a qualified electrician.
5.1.1.1.3 Carrying out work
- Define all spheres of responsibility!
- Shut down the stacker according to the specifications given in the resp.
chapter of the electro-technical operating and maintenance manual!
- A sign should be placed on the switch panel in the control room, indicating that
work is in progress and prohibiting the actuation of all switches.
- The control room must be secured to prevent unauthorised access.
- Isolate the working area in question from the power supply using disconnecting
devices. Power disconnecting devices include, for example, all hand-operated
power circuit breakers, isolating switches, slide valves, slide stops, line valves,
stops and other such devices.
- Manually safeguard the disconnecting devices against unauthorised actuation

using locks. The keys must be kept under the supervision of the person in
charge.
- Stored energy, such as that in capacitors, springs, elevated components, rotating

flywheels, hydraulic systems and air, gas, steam or water pressure must be dis-
persed, released or switched off using methods such as earthing, repositioning,
locking, draining, supporting etc.
- The supervisory person in charge must make absolutely sure that the working
area is free of energy and is disconnected from the power supply. Only then can
be given the go-ahead for the service and repair work to be carried out.

5.1.1.1.4 Disconnecting the power supply / releasing stored energy in sections of the plant
If, for technical reasons, only a section of the stacker must be made safe, proceed as
follows:
- Shut down the stacker according to the specifications given in the resp.
chapter of the electro-technical operating and maintenance manual!
- Secure the disconnecting device with a lock to prevent it being switched on

again.
- Disperse and/or release the stored energy.
- By actuating push-buttons and/or by means of other operating checks, check that

the section to be shut down has, in fact, been de-activated.
- Following the test, return the operating monitoring elements to their neutral
position.
After the supervisor has made sure that the working area is isolated from the power
supply and is de-energised, the go-ahead for service and maintenance work to be
carried out can be given.
5.1.1.1.5 Returning the plant to its operational state
Following completion of the work, the supervisor must make certain that the repaired or
serviced machine is in good and safe order.
- All persons must leave the area in question.
- Remove the mechanical lock from the power disconnecting devices and remove
the disconnecting device.
- Switch the stacker on, proceeding in accordance with the resp. chapter of
the electro-technical operating and maintenance manual.
- Subject the repaired or serviced area to a test run.
After the test run has been carried out and it has been ensured that the stacker is safe
and in full working order, the stacker is returned to the interlocked state.

5.1.2 Servicing table
This section shows the necessary inspections and servicing work on the assembly
units of the stacker in abbreviated form in tables.
The inspections and servicing work are to be carried out at certain servicing intervals.
5.1.2.1 Servicing intervals
Servicing intervals are:

- fixed times (servicing dates)
or
- a certain number of operating hours
(3-shift operation, assuming 7 working days).
The following table gives a summary of the servicing intervals abbreviated by

D (= daily), W (= weekly) and M (= monthly); these abbreviations also being used in the
following tables.
Servicing Servicing time Number of

interval operating hours
(oh)
D daily / each time before the machine is started up 24
W weekly approx. 160
M1 monthly approx. 670
M3 3-monthly (every quarter year) approx. 2000
M6 6-monthly (every half year) approx. 4000
M12 12-monthly (annually) approx. 8000
The respective inspection/servicing job is to be carried out when the first applicable
servicing interval has been reached, e.g. an oil change is to be carried out when
- approx. 15000 operating hours (oh) have been run, even if 2 years have not been
worked (24 months) or
- 2 years (24 months) have been exceeded even though the machine has not
reached 15000 oh.
The servicing intervals (servicing times and number of operating hours) according to
which the servicing work is to be carried out are proposals and recommendations of
TKIS.
The frequency of servicing work however depends on operating conditions prevailing at

the place of operation, such as
- the period of operation,
- the operating conditions,
- wear.

The stacker operating conditions are therefore to be kept under observation. If

necessary the scheduled time intervals for inspections and servicing work are to be
reduced or increased in due course.
5.1.2.2 Inspection and servicing tables
The servicing tables contain:

- the inspections/servicing work to be carried out in abbreviated form (listed in a
numerical order of the assembly units)
- the section numbers give reference to the detailed description of the respective
inspections/servicing work (e.g. 5.1.4. ..),
- the black dots indicating the applicable servicing intervals (D to M12) at which the
servicing work in question should be carried out. The longer servicing intervals
always include the shorter ones. In other words a daily servicing job will also be
part of the weekly, monthly, 3-monthly, 6-monthly and 12-monthly servicing
routines whenever such servicing intervals are marked with a dot in the table.
With increasing operational experience, deviations to these intervals may prove to be

advisable, meaning that certain intervals can be extended while others should be made
shorter. For all servicing jobs, the servicing regulations in the preceding section must
be strictly adhered to.
In addition to the yearly inspections, it is strongly recommended that an annual general

inspection of the stacker be carried out by an inspection engineer from TKIS.
Caution!
The first irregular maintenance interval during the running-in period of the
stacker is not listed in the table.These intervals should be taken from the
supplier’s data in chapter 6.
This maintenance work should definetely be carried out, as in general the
intervals are shorter than the regular maintenance intervals.
Abbreviations used in the maintenance table:
Lub. pt. = Lubrication point

(in accordance with the lubrication tables and the accompanying
drawings showing the lubrication points in chapter 5.1.3)
Chpt. = Chapter
if rqd. = if required
E. Doc. = Electro - Documentation
H. Doc. = Hydraulic - Documentation

Item Assembly units see ... Servicng intervals
• Inspection- / Servicing work D W M1 M3 M6 M12

to be carried out
1 TRAVEL GEAR
1.1 Motor E. Doc.
• Check for unusual noise •

(relubricate bearings if rqd.)
1.2 Brake Chpt. 6

5.1.4.1
• Check the fixation of the protec- •
tion hood
• Check the function •

(reset if rqd.)
• Check condition of brake lining •

(replace if rqd.)
1.3 Electro-hydraulic thrustor Chpt. 6
• Check operation fluid •

(replace defective thrustor if
rqd.)
1.4 Gearbox Chpt. 6

(replace defective bearings if
rqd.)
• Check for oil marks •

(replace seals if rqd.)
• Check oil level •

(glass sight gauge / dipstick,
refill oil, resp. change oil if rqd.)
1.5 Shrink disk Chpt. 6
• Check correct fit of the screws •

by using a torque wrench

Item Assembly units see ... Servicing intervals

to be carried out
1.6 Runner wheels
• Check for unusual noise, •

blocking or slipping through
(relubricate bearings, replace
defective parts if rqd.)
• Check for wear •

(replace defective parts if rqd.)
1.7 Rail cleaner
• Check condition of the cleaning •

elements
(replace cleaning element(s) if
rqd.)
1.8 Rail
• Check condition •
(correct aligning or replace rail if
rqd.)
1.9 End stops
(replace the end stop(s) if rqd.)
1.10 Earthing shoes
1.11 Rail clamp Chpt. 6
• Check connections and lines for •

leakages/damages

(replace clamping pieces and
carry out a function test if rqd.)
• Check oil level of hydraulic •

power pack


to be carried out
2 SLEWING GEAR
2.1 Motor E. Doc.

2.2 Overload coupling Chpt. 6
• Check fixation of the protection •

hood
• Check the flexible elements •

(replace if rqd.)
• Check the alignment •

(correct if rqd.)
2.3 Brake Chpt. 6

5.1.4.1
tion hood

(reset if rqd.)

(replace if rqd.)

rqd.)


to be carried out
2.5 Gearbox Chpt. 6

rqd.)


2.6 Slewing connection Chpt. 6

(relubricate bearings and
toothing, replace defective parts
if rqd.)
• Check tightening torque of the •

fastening screws
• Check oil drawn from the •

respective bores on the slewing
connection
(indication of further use of the
oil or of excessive wear)
2.7 Drive pinion

toothing, if rqd.)



to be carried out
2.8 Cam-operated limit switch -

drive pinion and coupling

toothing, replace defective parts
if rqd.)

2.9 Cable passage
• Check the condition of the •

cables
• Check the correct positioning •

and functioning (flexibility) of the
cables


to be carried out
3 HOISTING GEAR
3.1 Hinge points

- Boom - Main hinges
- Hydraulic cylinder - Hinges
3.2 Hydraulic equipment H. Doc.

(Hoisting gear)
3.2.1 Motor

3.2.2 Flexible coupling

(replace if rqd.)

(correct if reqd.)
3.2.3 Pump

(replace defective bearing(s) if
rqd., replace the pump in case
of need)

• Check the operating pressure •

(replace defective pump if rqd.)
3.2.4 Oil tank
• Check for oil level •

(refill operating fluid if rqd.)
• Check of the filter element (re- •

place dirty filter element if rqd.)


to be carried out
3.2.5 Operating fluid
• Check the condition of the oil •

(black, muddy, slimy? - then
carry out an oil change)
3.2.6 Valve block

3.2.7 Pressure relief valves

• Check the operating pressure •

(correct operating pressure if
rqd.)
3.2.8 Proportional valves / Solenoid

valves

3.2.9 Oil filter
• Check the condition •

(replace filter if rqd.)
3.2.10 Piping / Clamps

(replace defective fittings if rqd.)
3.2.11 Hoses

(replace defective hose if rqd.,
replace hoses after max.
5 years!)


to be carried out
3.2.12 Add-on flange connection
3.2.13 Hydraulic cylinder



to be carried out
4 BOOM CONVEYOR
4.1 Motor E. Doc.

4.2 Hydraulic coupling Chpt. 6

tion hood

(correct if rqd.)
4.3 Flexible coupling Chpt. 6

tion hood

(replace if rqd.)

(correct if rqd.)
4.4 Brake Chpt. 6

5.1.4.1
tion hood

(reset if rqd.)

(replace if rqd.)

rqd.)


to be carried out
4.6 Shrink disk Chpt. 6

4.7 Gearbox Chpt. 6

rqd.)


4.8 Flange coupling between

gearbox and drive pulley

4.9 Pulleys Chpt. 6

defective bearings if rqd.)
• Check of the friction and rubber •

linings (replace it if rqd.)
• Remove material incrustations •
4.10 Idlers Chpt. 6

(replace defective idler(s) if rqd.)
• Check the impact rings / •

supporting disks
(replace if rqd.)


to be carried out
4.11 Impact idlers Chpt. 6
• Check surfaces for wear •

(replace if rqd.)

(if rqd.)
4.12 Belt Chpt. 6

5.1.4.2
• Check for straight run •
(correct if rqd.)
• Check the surfaces and edges •

for wear marks and damages
(repair of damages if rqd.)
• Check the belt tension •

(retension belt if rqd. or if
reserve for take-up length is
used up, shorten the belt)
4.13 Screw take-up device 5.1.4.2.4

(align if rqd.)

(lubricate screws if rqd.)
4.14 Belt cleaner Chpt. 6

5.1.4.2.5
• Check the cleaning elements •
(replace element(s) if rqd.)
• Check the correct close-lying to •

the belt
(resetting if rqd.)


to be carried out
4.15 Chute - Lower part

(replace worn-out wear plates,
min. thickness of wear lining:
5 mm; remove jammed material
and material incrustations)
• Check the dust sealing 5.1.4.2.6 •

(reset or replace sealing
elements if rqd.)
4.16 Skirting
• Check of well centered material •

feeding
(correct if rqd.)

(replace of worn-out wear
plates, min. thickness of wear
lining: 5 mm; remove jammed
material)
• Check the dust sealing 5.1.4.2.6 •

(reset or replace sealing
elements if rqd.)


to be carried out
5 TRIPPER CAR
5.1 Pulleys Chpt. 6

• Check of the rubber lining •

(replace it if rqd.)
5.2 Idlers Chpt. 6

(replace defective idler(s) if rqd.)
• Check the rubber linings of the •

return idlers
(replace if rqd.)
5.3 Hold-down pulley

5.4 Belt cleaner Chpt. 6

5.1.4.2.5
• Check the cleaning elements •
(replace element(s) if rqd.)
• Check the correct close-lying to •

the belt
(resetting if rqd.)


to be carried out
5.5 Transfer chute

(replace worn-out wear plates,
min. thickness of wear lining:
5 mm; remove jammed material
and material incrustations)
5.6 Cable reel E. Doc.
5.6.1 Motor

• Check of the slip rings and •

brushes
(clean or replace slip rings and
brushes if rqd.)
5.6.2 Magnetic coupling
• Check of the dampening ring •

(replace defective dampening
ring if rqd.)
5.6.3 Gearbox

rqd.)
• Check for lubricant marks •

5.6.4 Drum
5.6.5 Guiding device


to be carried out
6 ACCESSORIES
6.1 Central lubrication systems
6.1.1 Automatically-operated Chpt. 6

lubrication system:
- Slewing gear

(fill up the tank of lubricant if
rqd.)
• Check for untightnesses •

(repair untightnesses
immediately, replace damaged
pipes immediately)
>>> See the instructions

of the manufacturer
6.1.2 Manually-operated Chpt. 6

lubrication system
- Travel gear / Tripper car
• Check for untightnesses •

pipes immediately)
>>> See the instructions

of the manufacturer
6.2 Water spray system - Water Chpt. 6

supply
•
• Check for untightnesses
pipes / hoses immediately)


to be carried out
7 SAFETY EQUIPMENT AND

MONITORING DEVICES
( ELECTRICAL EQUIPMENT )
• Check the proper function of •

safety and limit switches and
have them cleaned
(exchange immediately the
defective switches, probes, ini-
tiators;
retightening of the fixing screws
at the switches and support
brackets,
new setting of switching
distance if rqd.)
>>> el. specialists
• Check electrical wear parts and •

cables for wear / damages
(exchange immediately the
defective parts if rqd.)
>>> el. specialists
• Check the correct fit of •

terminals / connections
>>> el. specialists


to be carried out
8 STEEL STRUCTURE
General
• Report any cracks in the steel •

structure to the responsible staff
• Verification of the temporary 5.1.5.1 •

corrosion protection for sufficient
layer thickness
• Verification of the coating for 5.1.5.2 •

damages
• Check the screw connections •

(if rqd. retightening with
respective torque)

5.1.3 Lubrication
5.1.3.1 General
All moving components must be correctly lubricated to ensure that the stacker can be
operated in such a way as to cause the minimum in wear and faults. Lubrication should
therefore be recognised as a very important aspect.
Lubrication can only fulfil its purpose when the appropriate lubricant for a component is
selected and when the lubricant is applied in an uncontaminated condition. It is there-
fore particularly important to maintain a high level of cleanliness when handling
lubricants.
Fresh lubricants should always be kept in a closed container - at best in the original
packaging - and transported directly to their place of application. The containers should
only be opened directly before the lubricant is to be applied.
Only the oils and grease specified should be used.
Only the belt idlers are lubricated for lifetime.
5.1.3.2 Lubrication tables
Hereby are differed:
Grease lubrication
- Some of the components are connected to a central lubrication system.
- Some of the components are filled with grease which must be changed regularly.
- Some of the components must regularly be relubricated with a grease gun or a

brush.
Oil lubrication
- Some of the stacker components are filled with lubricating oil- or hydraulic oil
filling, which must be changed regularly.

Used abbreviations in the lubrication tables:
Lub. pt. = Lubrication point
Fig. = Figure
No. = Number
Chpt. = Chapter
if rqd. = if required
The changing- and re-lubrication intervals are listed in operating hours (oh) or in month
(M).
Positioning of the lubrication points:
Example: 1 . 2 ⇒ Lubrication point ( e. g. Gearbox )

⇓
Main assembly unit ( e. g. Travel gear )

5.1.3.2.1 Grease lubrication
- Automatic central grease lubrication
The stacker is equipped with 2 central lubrication systems for the slewing gear.
The pumps of the central lubrication systems are each driven by an electric motor.
Caution!
Keep the central lubrication systems clean and only fill the grease tank with
clean lubricants.
- Table indicating points to be supplied with grease by the automatic central

lubrication system
Item / Lubrication Lubrication No. Lubricant Initial Refilling Refilling

Fig. system points fill intervall quantity
(per
lub. Pt.) l / kg
l / kg
Automatic central lubrication systems (Accessories) ► Lubrication points see chapter 5.1.3.3.6
6.1 Central lubrica- Tank 1 SHELL 10 * The central lubrica-

1)
tion system / + piping GADUS + 2 ** tion system will
Slewing gear S2 V220 2 be switched on
(Slewing Greasing points: once a week
- Running surface of the 1 ” 4
connection) ball-race slewing con- during a slewing
nection
- Sealing of the ball-race 1 ” 1
movement over
slewing connection the complete
slewing range.
6.2 Central lubrica- Tank 1 SHELL 10 * The central lubrica-
1)
tion system / + piping GADUS + 2 ** tion system will
Slewing gear S2 V220 2 be switched on
(Drive pinions) Greasing points: once a week
- Toothing of ball-race 4 ” 3
slewing connection and during a slewing
drive pinions
movement over
the complete
slewing range.
6.3 Hand greasing Lower drive 2 SHELL 0.5 6M 0.1
(via lubricating shaft bearing GADUS
pipes) S2 V220 2
1)
See also manufacturer’s documentation in chapter 6! *: Tank capacity **: Piping capacity

- Manual grease lubrication
General
Those lubrication points which do not have to be regreased very often and/or those
assembly units which cannot be greased by a central lubrication system must be
greased manually.
The manual lubricating points are equipped with lube fittings/lubricating nipples and
must be greased with a manual grease gun or a grease lubrication pistol.
When adding or replacing lubricant, only pure premium bearing grease should be used.
Bearings and labyrinths are filled with lithium saponified grease at initial assembly.
Grease of differing soap bases must not be mixed. When changing to grease with a
different soap base, the entire grease content including the lube lines must be washed
out using benzine or a similar substance.
Do not lubricate the labyrinths using high pressure lubricating units. High pressure can
destroy the sealing rings.
Before lubrication:
• Clean lubricating fittings/lubricating nipples and the nozzle of the grease gun
before applying it.
• Remove old, soiled and resinified grease from the lubrication point area.
During lubrication:
• Thoroughly grease the lubrication points (e.g. antifriction bearings, labyrinths)

until a collar of grease forms
or
• Lubrications points, where the emerging grease is not visible, are to be regreased
in accordance with the lubrication intervals by using a fixed grease quantity.
Pillow blocks are to be regreased during operartion.
When changing grease (e.g. antifriction bearings):
• Use only grease in accordance with the lubrication table (see section 5.1.3.2).
Do not mix different kinds of grease.
• Clean bearing casings before opening them.
• Open bearing casing and remove antifriction bearings. If it is not possible to
change the lubricant any other way.
• Remove old, soiled and resinified lubricant from inside the bearing. If necessary,
rinse the bearing and casing and dry.
• Fill 1/3 to 1/2 of the bearing cage with grease.
• Fit bearings.

After greasing:
• Do not wipe lubricating fittings / lubricating nipples!
Caution!
Work in a clean manner! Even slight soiling of the grease affects the service
life of the bearings.

- Table of manual grease lubrication points
Pos. / Component Lubrication Lubricant Initial Changing Relubri- Relubri-

Fig. points fill interval cation cation
( per component ) ( per interval quantity
lub. ( per
pt. ) lub.
pt. )
No. No. kg kg
Travel gear ► Lubrication points see chapter 5.1.3.3.1
1.1 Motor 12 see - - - - - -

132 M type
plate
1.3 Runner 12 Bearing 2 SHELL 0.5 - 3M 0.07
wheel (via GADUS
ø 630 lubricant S2 V220 2
(driven) distributor)
Labyrinth 3 “ 0.3 - 3M 0.05

seals (via
lubricant
distributor)
1.4 Runner 12 Bearing 2 SHELL 0.5 - 3M 0.07
wheel (via GADUS
ø 630 lubricant S2 V220 2
(non- distributor)
driven)
Labyrinth 2 “ 0.3 - 3M 0.05
seals (via
lubricant
distributor)
1.5 Hydraulic 2 Springs - SHELL - - 1M if rqd.
rail clamp GADUS
CTHV-LH- Guide - S2 V220 2 - - 1M if rqd.
150-045- posts
1)
LE-06
Float block - “ - - 1M if rqd.
assembly
Lever - ” - - 1M if rqd.
assembly
Slewing gear ► Lubrication points see chapter 5.1.3.3.2
2.1 Motor 2 see - - - - - -

100 L type
plate
2.3 Slewing 1 Flange 2 SHELL 0.05 - 2500 oh 0.01
gear bearing GADUS 6M
limit switch S2 V220 2
1)
See also manufacturer’s documentation in chapter 6!

Pos. / Component Lubrication Lubricant Initial Changing Relubri- Relubri-

Fig. points fill interval cation cation
( per component ) ( per interval quantity
lub. ( per
pt. ) lub.
pt. )
No. No. kg kg
Boom conveyor ► Lubrication points see chapter 5.1.3.3.4
4.1 Motor 1 see - - - - - -

315 L type
plate
4.2 Gearbox 1 Labyrinth 2 SHELL 0.18 - 6M if rqd.
KSZg 280 sealing GADUS
Rü Pu Lü S2 V220 2
1)
4.4 Drive 1 Pillow block 2 SHELL 3.0 - 3M 0.1

pulley SNL GADUS
3134 TNF S2 V220 2
(bearing +
labyrinth
seals)
4.5 Discharge 1 Pillow block 2 SHELL 3.0 - 3M 0.1
pulley SNL GADUS
3036 TNF S2 V220 2
(bearing +
labyrinth
seals)
4.6 Spindle 2 Surface 1 SHELL 0.1 - 1M 0.05
GADUS
S2 OGH
0/00
Tripper car ► Lubrication points see chapter 5.1.3.3.5
5.1 Discharge 1 Pillow block 2 SHELL 5.8 - 3M 0.19

pulley SNL GADUS
3152 TNF S2 V220 2
(Bearing +
labyrinth
seals via
lubricant
distributor)
5.2 Return 2 Pillow block 2 SHELL 5.8 - 3M 0.19
pulley SNL GADUS
3152 TNF S2 V220 2
(Bearing +
labyrinth
seals via
lubricant
distributor)
1)

5.1.3.2.2 Oil lubrication
General
The oil should only be changed when the gear units are at operating temperature.
Only unused brand gear oil should be used.
Oil designation and viscosity class is given on the rating plate of the gear unit.
Oils from different manufacturers should, however, not be mixed.
A switch from mineral to synthetic oils is only allowed with the express permission of
TKIS. Never mix synthetic and mineral oils.
The oil level must not under any cicumtances be allowed to fall below the specified
marking and should be checked when the gear unit is at a standstill and has cooled
down. Wait for at least 10 minutes after a drive has been shut down before taking a
measurement.
Note!
Before a gear unit is opened, all dirt must be carefully removed. It must be
ensured that no impurities, such as shifting sand etc. are allowed to enter
the gear unit when oil is being put in.
The oil level markings on the dipstick are always to be taken as the measure for the
amount of oil to be added. Always fill the oil up to the upper marking, but not beyond.
All permanent magnets on screw plugs, at the oil drain point, on the oil dip-stick and at
other points on the gear unit must be cleaned thoroughly.
To clean the inside of the housing, use oil with the same specification, but with a lower
viscosity.
After oil has been put in, the opened inspection hole cap must be freshly sealed.
The gear units may reach a temperature of up to approx. 90° C at rated output. Higher
temperatures of up to 120° C are only permitted for brief periods.
For temperatures which are permanently above 100° C, TKIS must be consulted.
Note!
Appropriate examination of used oil in the laboratory can provide extra
information with regard to further suitability of the oil (longer service times)
and wear of bearings and/or toothed components.

- Table of components which must have their oil filling changed
Pos. / Component Lubrication Oil Initial First Following

Fig. points fill change intervals
( per component ) ( per after
lub.
pt. )
No. No. l
1.2 Gearbox 12 Filling 1 SHELL 37 500-1000 1400-

1)
BK 80 opening OMALA oh 5600 oh
S2 G 320 (dep. on
temp.)
12-24 M
Slewing gear ► Lubrication points see chapter 5.1.3.3.2
2.2 Gearbox 2 Filling 1 SHELL 31 100 oh 2000-

1)
SC 6004 opening OMALA 2500 oh
S2 G 320 12 M
4.2 Gearbox 1 Filling 1 SHELL 30 250 oh 5000 oh

KSFg 280 opening OMALA (if rqd.) 8-9M
1)
Rü Pu Lü S2 G 320 -------------
1000 oh all
3M others
after:
5000 oh
12 M
Tripper car ► Lubrication points see chapter 4.1.3.3.5
5.3 Cable reel 1 Spur 1 SHELL 2.5 10000 oh 10000 oh

HMIV26/73/5/88- gearbox OMALA
6kV+1S+8R32+6LWL S4 WE 150
5.4 Hose reel 1 Spur 1 ADDINOL 12.6 10000 oh 10000 oh
HGNSCH4/15/43/78S gearbox ECO GEAR
2)
1 ½ “- 10 bar 220
1)
2)
More information details are to be taken from the electro-technical documentation manual.

- Table of components which must have their hydraulic oil changed
Pos. / Componente Lubrication Hydraulic oil Initial First Following

Fig. points fill change intervals
( per component ) ( per after
lub.
pt. )
No. No. l
1.5 Hydraulic 2 Hydraulic 1 SHELL 6.7 3M 12 M

rail clamp power pack TELLUS
CTHV-LH-150- S2 M 46
1)
045-LE-06
Hoisting gear ► Lubrication points see chapter 5.1.3.3.3
3.1 Hydraulic 1 Tank 1 SHELL 370 6M 6M

2)
equipment TELLUS
S2 M 46 (de- (de-
Points to be supplied:
- Cylinder for the
pending pending
hoisting gear upon the upon the
result of result of
the oil the oil
sample sample
analysis) analysis)
4.3 Hydraulic 1 Filler 1 SHELL 20 15000 oh 15000 oh

coupling plug TEGULA
487 TVVFN-Z 32
1)
1)
2)
For details, please refer to the hydraulic documentation!

5.1.3.3 Drawings showing the lubrication points
5.1.3.3.1 Travel gear
1.3 1.3
1.5
Z
A
A-A
1.4 B 1.4 1.4

B-B C
C-C
B C
1.1
1.2
Fig.: 225-STD4500-501

5.1.3.3.2 Slewing gear
A A
B-B
A-A
2.1 2.2
C-C
B
B
C 2.3
Fig.: 225-STD4500-502

5.1.3.3.3 Hoisting gear
3.1
Fig.: 225-STD4500-503

5.1.3.3.4 Boom conveyor
A
Z
4.4 A 4.5 4.6

Z
4.4
B
B 4.2 4.3 4.1
Fig.: 225-STD4500-504

5.1.3.3.5 Tripper car
5.4 5.3 5.2 Z
5.2
5.1
Fig.: 225-STD4500-505

5.1.3.3.6 Automatic central lubrication system - Slewing gear (Accessories)
6.2
A-A
A
6.3
6.1
6.1
6.2
6.1 6.2 6.3
Fig.: 225-STD4500-506

5.1.3.4 Lubricants - Comparative tables

In the comparative table given below, the lubricants - oils and greases - of different
manufacturers, which are arranged according to lubricant quality, are compared with
one another.
The lubricants of the same quality of different manufacturers are all regarded by TKIS
as being totally equivalent. The sequence of the manufacturers in the individual
columns does not imply any order of rank or assessment.
Provided a particular lubricant type of a particular manufacturer is not expressly pre-
scribed in the above individual instructions for maintenance, the firm operating the
machine has a free choice of lubricant supplier.

Gear oils acc. to DIN 51517
Marking acc. to DIN 51502 CLP Mineral Oil
March 20, 2015

ISO VG 100 150 220 320 460 680
eni Blasia 100 Blasia 150 Blasia 220 Blasia 320 Blasia 460 Blasia 680
ARAL Degol BG 100 Degol BG 150 Degol BG 220 Degol BG 320 Degol BG 460 Degol BG 680
AVIA GEAR RSX 100 AVIA GEAR RSX 150 AVIA GEAR RSX 220 AVIA GEAR RSX 320 AVIA GEAR RSX 460 AVIA GEAR RSX 680
AVIA AVILUB GEAR CLP 100 AVILUB GEAR CLP 150 AVILUB GEAR CLP 220 AVILUB GEAR CLP 320 AVILUB GEAR CLP 460 AVILUB GEAR CLP 680
BP Energol GR-XP 100 Energol GR-XP 150 Energol GR-XP 220 Energol GR-XP 320 Energol GR-XP 460 Energol GR-XP 680
Alpha SP 100 Alpha SP 150 Alpha SP 220 Alpha SP 320 Alpha SP 460 Alpha SP 680
Optigear BM 100 Optigear BM 150 Optigear BM 220 Optigear BM 320 Optigear BM 460 Optigear BM 680
CASTROL Optigear EP 100 Optigear EP 150 Optigear EP 220 Optigear EP 320 Optigear EP 460 Optigear EP 680
Tribol 1100/100 Tribol 1100/150 Tribol 1100/220 Tribol 1100/320 Tribol 1100/460 Tribol 1100/680
RENOLIN CLP 220 RENOLIN CLP 320 RENOLIN CLP 460

RENOLIN CLP 100 RENOLIN CLP 150 RENOLIN CLP 680
FUCHS RENOLIN CLP 220 Plus RENOLIN CLP 320 Plus RENOLIN CLP 460 Plus
RENOLIN CLP 100 Plus RENOLIN CLP 150 Plus RENOLIN CLP 680 Plus
RENOLIN HighGear 220 RENOLIN HighGear 320 RENOLIN HighGear 460
FUCHS
GEARMASTER CLP 100 GEARMASTER CLP 150 GEARMASTER CLP 220 GEARMASTER CLP 320 GEARMASTER CLP 460 GEARMASTER CLP 680
225 E - SHOUGANG Stacker STD-4500 (930-ST-110)

Lubritech
KLÜBER Klüberoil GEM 1-100 N Klüberoil GEM 1-150 N Klüberoil GEM 1-220 N Klüberoil GEM 1-320 N Klüberoil GEM 1-460 N Klüberoil GEM 1-680 N
MOBIL Mobilgear 600 XP 100 Mobilgear 600 XP 150 Mobilgear 600 XP 220 Mobilgear 600 XP 320 Mobilgear 600 XP 460 Mobilgear 600 XP 680
SHELL Omala S2 G 100 Omala S2 G 150 Omala S2 G 220 Omala S2 G 320 Omala S2 G 460 Omala S2 G 680
(formerly: Omala 100) (formerly: Omala 150) (formerly: Omala 220) (formerly: Omala 320) (formerly: Omala 460) (formerly: Omala 680)
CARTER EP 150 CARTER EP 220 CARTER EP 320 CARTER EP 460 CARTER EP 680
TOTAL CARTER EP 100
CARTER XEP 150 CARTER XEP 220 CARTER XEP320 CARTER XEP 460 CARTER XEP 680
Chapter 5 - 45
Marking acc. to DIN 51502 CLP HC Synthetic Oil
March 20, 2015

ISO VG 100 150 220 320 460 680
eni Blasia SX 100 Blasia SX 150 Blasia SX 220 Blasia SX 320 --- ---
ARAL --- --- Degol PAS 220 Degol PAS 320 --- ---
AVIA AVIA SYNTOGEAR PE 100 AVIA SYNTOGEAR PE 150 AVIA SYNTOGEAR PE 220 AVIA SYNTOGEAR PE 320 AVIA SYNTOGEAR PE 460 AVIA SYNTOGEAR PE 680
BP --- --- --- --- --- ---
Alphasyn EP 150 Alphasyn EP 220 Alphasyn EP 320 Alphasyn EP 460 Alphasyn EP 460
CASTROL ---
Optigear Synthetic PD 150 Optigear Synthetic PD 220 Optigear Synthetic PD 320 Optigear Synthetic PD 460 Optigear Synthetic PD 680
FUCHS RENOLIN UNISYN CLP 100 RENOLIN UNISYN CLP 150 RENOLIN UNISYN CLP 220 RENOLIN UNISYN CLP 320 RENOLIN UNISYN CLP 460 RENOLIN UNISYN CLP 680
FUCHS GEARMASTER SYN 100 --- GEARMASTER SYN 220 GEARMASTER SYN 320 GEARMASTER SYN 460 GEARMASTER SYN 680
Lubritech

KLÜBER Klübersynth GEM 4-100 N Klübersynth GEM 4-150 N Klübersynth GEM 4-220 N Klübersynth GEM 4-320 N Klübersynth GEM 4-460 N Klübersynth GEM 4-680 N
Mobil SHC Gear 150 Mobil SHC Gear 220 Mobil SHC Gear 320 Mobil SHC Gear 460 Mobil SHC Gear 680
MOBIL Mobil SHC 627
Mobil SHC 629 Mobil SHC 630 Mobil SHC 632 Mobil SHC 634 Mobil SHC 636
SHELL --- Omala S4 GX 150 Omala S4 GX 220 Omala S4 GX 320 Omala S4 GX 460 Omala S4 GX 680
(formerly: Omala HD 150) (formerly: Omala HD 220) (formerly: Omala HD 320) (formerly: Omala HD 460) (formerly: Omala HD 680)
TOTAL --- CARTER SH 150 CARTER SH 220 CARTER SH 320 CARTER SH 460 CARTER SH 680
Chapter 5 - 46
Marking acc. to DIN 51502 CLP E Biodegradable Oil
March 20, 2015

ISO VG 100 150 220 320 460 680
eni --- --- --- --- --- ---
ARAL --- --- --- --- --- ---

AVIA --- --- --- --- --- ---
BP --- --- --- -- --- ---
Tribol BioTop 1418/220

CASTROL --- BioTrans 150 Tribol BioTop 1418/320 --- ---
BioTrans 220
FUCHS PLANTOGEAER 100 S PLANTOGEAR 150 S PLANTOGEAR 220 S PLANTOGEAR 320 S PLANTOGEAR 460 S PLANTOGEAR 680 S
FUCHS
GEARMASTER ECO 100 GEARMASTER ECO 150 GEARMASTER ECO 220 GEARMASTER ECO 320 GEARMASTER ECO 460 GEARMASTER ECO 680
Lubritech

KLÜBER Klüberbio CA 2-100 Klüberbio EG 2-150 Klübersynth GEM 2-220 Klübersynth GEM 2-320 Klüberbio CA 2-460 ---
MOBIL --- --- --- --- --- ---
SHELL --- --- --- --- --- ---
TOTAL CARTER BIO 100 CARTER BIO 150 CARTER BIO 220 CARTER BIO 320 CARTER BIO 460 ---
Chapter 5 - 47
Marking acc. to DIN 51502 CLP PG Synthetic Oil
March 20, 2015

ISO VG 100 150 220 320 460 680
eni --- Blasia S 150 Blasia S 220 Blasia S 320 Blasia S 460 ---
ARAL --- --- Degol GS 220 Degol GS 320 Degol GS 460 Degol GS 680
AVIA --- AVIA GEAR VSG 150 AVIA GEAR VSG 220 AVIA GEAR VSG 320 AVIA GEAR VSG 460 AVIA GEAR VSG 680
BP --- Enersyn SG-XP 150 Enersyn SG-XP 220 Enersyn SG-XP 320 Enersyn SG-XP 460 ---
Alphasyn GS 150 Alphasyn GS 220 Alphasyn GS 320 Alphasyn GS 460

CASTROL Tribol 800/100 Alphasyn PG 150 Alphasyn PG 220 Alphasyn PG 320 Alphasyn PG 460 Tribol 800/680
Tribol 800/150 Tribol 800/220 Tribol 800/320 Tribol 800/460
FUCHS RENOLIN PG 100 RENOLIN PG 150 RENOLIN PG 220 RENOLIN PG 320 RENOLIN PG 460 RENOLIN PG 680
FUCHS
GEARMASTER PGP 100 GEARMASTER PGP 150 GEARMASTER PGP 220 GEARMASTER PGP 320 GEARMASTER PGP 460 GEARMASTER PGP 680
Lubritech

KLÜBER Klübersynth GH 6-100 Klübersynth GH 6-150 Klübersynth GH 6-220 Klübersynth GH 6-320 Klübersynth GH 6-460 Klübersynth GH 6-680
MOBIL --- --- --- --- --- ---
SHELL --- Omala S4 WE 150 Omala S4 WE 220 Omala S4 WE 320 Omala S4 WE 460 Omala S4 WE 680
(formerly: Tivela S 150) (formerly: Tivela S 220) (formerly: Tivela S 320) (formerly: Tivela S 460) (formerly: Tivela S 680)
TOTAL --- CARTER SY 150 CARTER SY 220 CARTER SY 320 CARTER SY 460 CARTER SY 680
Chapter 5 - 48
Hydraulic oil acc. to DIN 51524
Marking acc. to DIN 51502 HLP
March 20, 2015

ISO VG 10 22 32 46 68 100
eni OSO 10 OSO 22 OSO 32 OSO 46 OSO 68 OSO 100
Vitam GF 32 * Vitam GF 46 * Vitam GF 68 *

* zinc-free / ** zincous
ARAL Vitam GF 10 * Vitam GF 22 * Vitam GF100 *

Vitam GX 32 ** Vitam GX 46 ** Vitam GX 68 **
AVIA FLUID RSL 32 AVIA FLUID RSL 46 AVIA FLUID RSL 68 AVIA FLUID RSL 100
AVIA AVIA FLUID RSL 10 AVIA FLUID RSL 22

AVILUB FLUID SF 32 * AVILUB FLUID SF 46 * AVILUB FLUID SF 68 * AVILUB FLUID SF 100 *
Bartran 22 * Bartran 32 * Bartran 46 * Bartran 68 * Bartran 100 *

BP Energol HLP-HM 10 **
Energol HLP-HM 22 ** Energol HLP-HM 32 ** Energol HLP-HM 46 ** Energol HLP-HM 68 ** Energol HLP-HM 100 **
Hyspin AWS 22 ** Hyspin AWS 32 ** Hyspin AWS 46 ** Hyspin AWS 68 ** Hyspin AWS 100 **
Hyspin AWS 10 **
CASTROL Hyspin ZZ 22 * Hyspin ZZ 32 * Hyspin ZZ 46 * Hyspin ZZ 68 * Hyspin ZZ 100 *
Hyspin ZZ 10 *
Tribol 943 AW-22 * Tribol 943 AW-32 * Tribol 943 AW-46 * Tribol 943 AW-68 * Tribol 943 AW-100 *
Renolin B 3 VG 10 ** Renolin B 10 VG 32 ** Renolin B 15 VG 46 ** Renolin B 20 VG 68 ** Renolin B 30 VG 100 **

FUCHS Renolin B 5 VG 22 **
Renolin ZAF B 10 HT * Renolin ZAF B 32 HT * Renolin ZAF B 46 HT * Renolin ZAF B 68 HT * Renolin ZAF 100 BB *
FUCHS
Renolin B 3 ** Renolin B 5 ** Renolin B 10 ** Renolin B 15 ** Renolin B 20 ** Renolin B 30 **
Lubritech

KLÜBER --- --- LAMORA HLP 32 LAMORA HLP 46 LAMORA HLP 68 ---
Mobil DTE 22 ** Mobil DTE 24 ** Mobil DTE 25 ** Mobil DTE 26 **

MOBIL --- Mobil DTE 10 Excel 100 *
Mobil DTE 10 Excel 22 * Mobil DTE 10 Excel 32 * Mobil DTE 10 Excel 46 * Mobil DTE 10 Excel 68 *
SHELL Tellus S2 V 15 (HLVP) Tellus S2 M 22 Tellus S2 M 32 Tellus S2 M 46 Tellus S2 M 68 Tellus S2 M 100

(formerly: Tellus T 15) (formerly: Tellus 22) (formerly: Tellus 32) (formerly: Tellus 46) (formerly: Tellus 68) (formerly: Tellus 100)
Azolla ZS 10 ** Azolla ZS 22 ** Azolla ZS 32 ** Azolla ZS 46 ** Azolla ZS 68 ** Azolla ZS 100 **

TOTAL Drosera MS 10 * Azolla AF 22 * Azolla AF 32 * Azolla AF 46 * Azolla AF 68 * Azolla AF 100 *
Chapter 5 - 49
Grease acc. to DIN 51825
Marking acc. to DIN 51502 KP Grease Antifriction bearings, Part 1
March 20, 2015

ISO VG KP2K-20 KPF2K-20 KP3K-20
Application Multi-purpose grease (Lithium soap) Multi-purpose grease (Lithium soap+Graphite or MoS 2 ) Multi-purpose grease (Lithium soap)
[ Temperature range -20 °C to +120 °C ] [ Temperature range -20 °C to +120 °C ] [ Temperature range -20 °C to +120 °C ]
eni GR MU EP 2 Agip GR SM Agip GR MU EP 3
ARAL Aralub HLP 2 Aralub 4320 ---
AVIA AVIALITH 2 EP AVIALITH 2 F AVIALITH 3 EP

Energrease LS-EP 2 Energrease L21 M

BP Energrease LS-EP 3
Energrease LZ 2 Minegrease LM EP 680
Longtime PD 2 Olistamoly 2
Olista Longtime 3
Olista Longtime 2 Molub-Alloy 777-2 NG
CASTROL Olista Longtime 3 EP
Spheerol EPL2 Molub-Alloy 777-2 ES
Spheerol EPL 3
Tribol 3020/1000-2 Molub-Alloy 860/460-2 ES
* NLGI 2/3 - Harmonization grade for KP 2 K-20 and KP 3 K-20
RENOLIT FEP 2 RENOLIT DURAPLEX EP 3

FUCHS RENOLIT FLM 2
RENOLIT H 443-HD 88* RENOLIT H 443-HD 88 *
LAGERMEISTER LP 2
FUCHS
LAGERMEISTER BF 2 STABYL MO 500 STABYL L 120
Lubritech LAGERMEISTER EP 2

UNIMOLY GL 402
KLÜBER CENTOPLEX 2 EP CENTOPLEX 3 (K3K-10)
Klüberlub BEM 41-122
MOBIL Mobilux EP 2 Mobilgrease Special Mobilux EP 3
SHELL GADUS S2 V220 2 Gadus S2 V220AC 2 ---

(formerly: Alvania EP(LF)2) (formerly: Retinax HD 2)
MULTIS EP 2
MULTIS MS 2 MULTIS EP 3
TOTAL MULTIS COMPLEX EP 2
MULTIS COMPLEX HV 2 Moly MULTIS COMPLEX EP 3
BIOMULTIS EP 2
Chapter 5 - 50
Grease acc. to DIN 51825
Marking acc. to DIN 51502 KP Grease Antifriction bearings, Part 2
March 20, 2015

ISO VG KP2K-30 KPHC2K-50 KP2R-20
Heavy load grease (saltwater-proof) Low-temperature grease High-temperature grease
Application
Base stock viscosity >600mm2/s (Polycarbamide thickener)
[ Temperature range -30 °C to +120 °C ] [ Temperature range -50 °C to +120 °C ] [ Temperature range -20 °C to +180 °C ]
eni Autol TOP 2000 --- AUTO TOP 2000 High Temp
* without DIN-designation
ARAL --- --- ---

AVIACAL 2 LD
AVIA AVIA SYNTOGREASE PE-T ---
AVIALITH 2 WL
Energrease SY 2202
BP Energrease LCX 6002 ---
(KPHC2K-40)
Spheerol LCX 6002 Spheerol SY 2202 (KPHC2K-40)

CASTROL Firetemp XT 2
Tribol 3020/1000-2 Tribol 4747/220-2 (KPHC2K-40)
RENOLIT PU-FH 300

FUCHS RENOLIT CA-LZ RENOLIT HI-TEMP 100
RENOLIT PU-MA 2
FUCHS URETHYN E/M 2

LAGERMEISTER 3000 PLUS STABYL LT 50
URETHYN MP 2

Lubritech
Klüberlub BE 41-542 * ISOFLEX TOPAS L 152

KLÜBER STABUTHERM GH 462 *
STABURAGS NBU 30 * ISOFLEX TOPAS NCA 52
MOBIL --- Mobiltemp SHC 32 ---
SHELL Gadus S2 V145KP 2 AeroShell Gtrease 22 Gadus S3 T220 2

(formerly: Retinax EPL 2) (formerly: Stamina Grease EP 2)
TOTAL CERAN XM 720 MULTIS COMPLEX SHD 100 ALTIS HV 1
Chapter 5 - 51
Lubricants for gears acc. to DIN 51509
Marking acc. to DIN 51502 GP
March 20, 2015

ISO VG GP0/00H-30 OGPF0/00-10
Application Fluid gear grease (Lithium soap) Adhesive lubricant for open gearbox (with Graphite+sprayable) - KDV-Toothed Rim
[ Temperature range -30 °C to +140 °C ] [ Temperature range -10 °C to +140 °C ]
eni Autol fluid gear grease ZSA FIN 332 F
ARAL --- Aralub MKA-Z 1

* bright product without graphite
AVIA AVIA LITHOPLEX 00 EP AVIA ALUPLEX 0 RHS
BP --- ---
Tribol 3020/1000-0 Molub-Alloy 936 SF Heavy

CASTROL Tribol 3020/1000-00 Molub-Alloy 9790/2500-0
Longtime PD 00 Molub-Alloy 3710-0/00 *
FUCHS RENOLIT GFW 00 ---
CEPLATTYN KG 10 HMF
FUCHS
GEARMASTER LI 400 CEPLATTYN KG 10 HMF 1000
Lubritech CEPLATTYN KG 10 HMF 2500

GRAFLOSCON C-SG 0 ULTRA
MICROLUBE GB 0
KLÜBER GRAFLOSCON C-SG 1000 ULTRA
MICROLUBE GB 00
GRAFLOSCON C-SG 2000 ULTRA
MOBIL Mobilith SHC 007 ---
SHELL Gadus S2 V220 00 (GP00G-30) Gadus S2 OGH 0/00

(formerly: Alvania GL00) (formerly: Malleus OGH)
MULTIS EP 0
TOTAL MULTIS EP 00 COPAL OGL 0
MULTIS COMPLEX SHD 00
Chapter 5 - 52
Lubricants for gears acc. to DIN 51509
Marking acc. to DIN 51502 GP
March 20, 2015

ISO VG Special Lubricant (not standardized) Special Lubricant (not standardized) Special Lubricant (not standardized)
Application Graphitic adhesive lubricant for Graphitic adhesive lubricant for Adhesive lubricant - FLUID without graphite for
immersion lubrication of open gearboxes manual lubrication of open gearboxes spray lubrication of open gearboxes
[ Temperature range 0 °C to +140 °C ] [ Temperature range -30 °C to +250 °C ] [ Temperature range 0 °C to +140 °C ]
eni --- --- ---
ARAL --- --- ---

AVIA --- --- ---
BP --- --- ---

* black products / ** clear product, no graphite
Molub-Alloy 8031/1500 *
Optifluid 4
CASTROL Molub-Alloy 8031/3000 * Optimol Paste PL
Optifluid 4 EP
Molub-Alloy 8031/6000 *
FUCHS --- --- ---
CEPLATTYN 100 MV
FUCHS CEPLATTYN 300 CEPLATTYN GT 10
CEPLATTYN 100 HV
Lubritech CEPLATTYN BL WHITE CEPLATTYN SF 30
CEPLATTYN GT 3 (without C)

Klüberfluid C-F 1 ULTRA
Klüberfluid C-F 2 ULTRA Klüberfluid C-F 3 UItra **
GRAFLOSCON A-G 1 ULTRA
KLÜBER Klüberfluid C-F 3 ULTRA ** Klüberfluid C-F 4 UItra **
Klüberplex AG 11-462 **
Klüberfluid C-F 4 ULTRA ** Klüberfluid C-F 8 UItra **
Klüberfluid C-F 8 ULTRA **
MOBIL --- --- ---
SHELL --- --- ---
TOTAL --- --- ---
Chapter 5 - 53
Lubricants for Turbo couplings
Marking acc. to DIN 51502 HLP CLP
March 20, 2015

ISO VG Hydraulic oil HLP 32 acc. to DIN 51524, Part 2 Oils CLP 32 acc. to DIN 51517, Part 3
Temperature up to -20 °C up to -27 °C up to -54 °C up to -20 °C up to -27 °C up to -54 °C
range
eni --- Oso 32 --- --- Blasia 32 ---
ARAL Vitam GF 32 Vitam GF 32 --- Degol BG 32 Degol BG 32 ---

* fully synthetic compressor oil
AVIA --- AVIA FLUID RSL 32 --- --- AVIA GEAR RSX 32-S ---
Bartran 32 Bartran 32
BP --- --- --- ---
Energol HLP-HM 32 Energol HLP-HM 32
Hyspin ZZ 32 Hyspin ZZ 32 Alpha EP 32 Alpha EP 32

CASTROL Alphasyn T 46 ---
Hyspin AWS 32 Hyspin AWS 32 Alpha VT 32 Alpha VT 32
Renofluid TF 1500
FUCHS Renolin B 10 VG 32 Renolin Unisyn OL 32 -- Renolin ZAF B 32 HT Renolin Unisyn OL 32
Renolin ZAF B 32 HT
FUCHS
Renolin B 10 --- --- --- --- ---
Lubritech

Klüberfood 4 NH1-32 Klüberfood 4 NH1-32
LAMORA HLP 32 (to -45 °C) (to -45 °C)
KLÜBER --- --- ---
(to -12 °C) (Klüber Summit HySyn (Klüber Summit HySyn
FG 32, to - 45 °C) * FG 32, to - 45 °C) *
Nuto H32 Mobil DTE 24 Mobil SHC 524

MOBIL --- --- ---
Mobil DTE 24 Mobil DTE 10 Excel 32 Mobil DTE 10 Excel 32
SHELL Tellus S2 M 32 Tellus S4 ME 32 Tellus S4 VX Tegula V 32 Tegula V 32 ---

(formerly: Tellus 32) (formerly: Tellus EE 32) (formerly: Tellus Arctic)
AZOLLA VTR 32 AZOLLA VTR 32

TOTAL --- --- --- ---
EQUIVIS HE 32 EQUIVIS HE 32
Chapter 5 - 54
5.1.4 Servicing of individual components

5.1.4.1 Brakes
- Safety instructions
All work carried out on the brake system affects safety, the entire machine and/or
components thereof.
The following measures must be taken before work is carried out on the brake system:
- Brakes / Travel gear, Drum brake Type TE-S 160
Never put more than 1 brake out of operation. For more extensive service and
repair work or in the event of storm warnings, drive the stacker into the parking
position and tie it down, if necessary.
- Brake / Slewing gear, drum brake Type: TE 160
For more extensive service and repair work or in the event of storm warnings,
shut down and lock the stacker.
- Brake / Boom conveyor, drum brake Type: SBH 315
Move the boom into horizontal position.

For more extensive service and repair work or in the event of storm warnings,
shut down the stacker.
Once a week, and following emergency braking, the following inspections must be
carried out:
- function of the brake,
- lifting of the brake shoes / pistons,
- wear of linings,
- condition of brake drums,
- reserve stroke of releasing device,
- free movement of the brake-rod linkage,
- pretensioning of brake spring,
- setting of limit switches.

In addition to the weekly inspection, the brakes must also be checked if:
- braking time increases,
- the brakes are applied due to the emergency off button being pressed,
- a limit switch indicates wear in one of the linings or insufficient lifting,
- the machine is not operated over a longer period of time.
Danger!
The brakes must not be locked open using auxiliary mechanical equipment,
as this may subsequently be forgotten following completion of the work.
Following completion of the work, the set values must all be checked.
An additional coat of paint given to brakes and/or couplings can lead to impaired move-
ment of the joints and dirtying of the drum friction surfaces. This also impairs the safety
of the brakes.
The friction surfaces must be kept absolutely free of any kind of lubricant.
Danger!
The friction surfaces are very hot following braking. They will cause burning
if touched.
For service and repair work:
- Only original spare parts may be used!

The use of non-original brake linings holds the risk of faulty operation of the
brakes and is a safety risk!
- Replace brake linings at the minimal lining thickness!
- Brakes with automatic adjustment are not service-free and must also be checked
on a regular basis.
The automatic adjustment feature can become worn when the brakes are applied
very frequently. In case of wear, the adjustable stops on the lining lever must be
adjusted at regular intervals.
The safety of the brakes depends on regular and careful servicing.

5.1.4.2 Belt conveyors
Dirty drums, idlers and belts cause misalignment of the belt. In the case of extreme belt
misalignment, the belt can come into contact with the adjacent steel construction
causing wear and ultimately, destruction.
Note!
Belt misalignment causes the pulleys or pulley linings to become unevenly
worn and leads to one part of the pulley taking more strain than another.
This leads to increased wear and shorter service life of the belt, pulleys
and idlers.
Other factors can, however, lead to belt misalignment. In addition to a misaligned

pulley, a crooked vulcanizing position of the belt leads to misalignment. Equally, idler
supports which are positioned at an incorrect angle to the belt direction will also cause
belt misalignment.
In case of misalignment, first find the cause of the problem and then apply the suitable
measures to rectify the fault.
Misalignment caused by an incorrectly aligned take-up pulley can only be rectified by

repositioning the take-up pulley to the correct angle.
Note!
Pulleys must always be at a right angle to the belt direction. Never use the
pulleys to make the belt straight. This would lead to increased wear of
both pulleys and bearings.
An incorrectly vulcanized belt must be re-vulcanized. Misalignment caused by idler

supports which are not at a right angle to the direction of the conveyor must only be
rectified by repositioning the supports.
If measures are taken to correct belt misalignments which are not specific to the cause
of the misalignment, the belt will be subjected to permanent strain. This will decrease
the service life of machinery and increase wear.
Caking on the pulleys and idlers causes increased strain of the belt. Check the belt
wipers and adjust as necessary or replace the wiper rubber/wiper plate/ wiper block.
Caution!
Replace any defective, non-rotating conveyor idlers immediately. The high
amount of frictional heat creates a fire hazard.

Danger!
Cleaning and servicing of the boom conveyor may only be carried out
when the conveyor is at a standstill. It must be ensured that the conveyor
cannot be started accidentally. Failure to observe these regulations can
lead to serious injury or death.
As any other machine, belt conveyors must be inspected and serviced at regular inter-
vals.
Because of varying conditions of application, there can only be given some general
recommendations for a trouble-free operation and for quick finding and making good of
failures.
Depending on the varying operation conditions, in each case special supervisory
means and particular requirements for maintenance will apply and determine the
frequency of checks to be made.
5.1.4.2.1 Regular check of conveyor belts and of conveying routes
During the first weeks of operation, pay particular attention to belt elongation. This is of
great importance to plants which have no automatic take-up devices. Greater sagging
of the belt between the idlers indicates too small a belt tension, whereas vibrating in the
lower belt strand indicates too great tension. Consider fluctuation in temperature
between day and night and set tension accordingly.
Abrasion marks and grooves at the return belt are a hint for non-turning and worn idlers
that must be either made easy going again or must be replaced. At regular intervals,
the inner side of the belt must be cleaned of adhesive material and foreign particles, in
order to prevent material being caked between the pulleys and the belt. Otherwise
damages at the running side of the belt cannot be avoided.
All alignment and anti-skewing devices shall be checked at regular intervals. Slip
monitors and emergency pull switches should be tested daily for their functioning.
Dirt incrustations at pulleys and idlers should be removed. When doing so do not beat
against the idlers.
Loose screw connections at the structure and at the stations should be re-tightened.
Conveyors without automatic take-up devices have to be released of stresses in case

of a total shut-down.

5.1.4.2.2 Supervision of drive, take-up and return stations as well as of feeding and
transfer stations
Supervise pulleys and belt cleaners and if necessary adjust and check the functioning
of their bearings.
Notchy pulley cleaning scrapers, worn belt cleaner blades and brush segments should
be renewed. Use only good material for the scraper cleaners.
Check whether material’s coming off the belt and remove, if necessary.
Take care that material is fed onto belt well in the centre and if necessary correct
feeding device.
Check condition of lateral guide ribs and sealing strips and reset, if required.
All parts for the belt conveyor should be kept clean. During cleaning the conveyor must
not be in operation.
Lubricate points that need lubrication according to instructions (lubrication intervals,

lubricant types and quantities). With lubricating make sure that handled material does
not come into contact with oil and grease.
Check in particular feeding and transfer devices for jammed material and remove it as
soon as possible.

5.1.4.2.3 Correcting the belt run
When the belt runs out of track, corrections start ahead of the point where tracking
begins in belt running direction.
The drive pulley has been checked during the alignment preparations; it is in horizontal
position and standing normal to the belt axis. Material caking has been removed. No
further changes should be made at this point.
The belt follows the reduction in tension, i.e. it runs towards the edge of the pulley
which has been adjusted by releasing the spindle.
Fig.: 225-STD4500-507
Caution!
Do not try to correct the belt run by adjusting the pulleys as this will cause
substantial damage to the belt in the long run. Only adjust the pulleys
when the pulley axle is not positioned at a right angle to the belt’s running
direction.
If the belt runs oblique, the correction is to be done by means of the idler stations
arranged in front of the pulley. The idler stations are fixed at the construction in such
way that a lateral adjustment is possible.

For adjusting the position of the idler sets, proceed as follows:

- To fetch the belt over - set the idler station against belt running direction
- To push the belt aside - reset the idler station in belt running direction
Fig.: 225-STD4500-508
Or as a rule of thumb: The point where the belt first touches the idler determines the
direction in which the belt runs.
Adjust 3 to 4 idler sets a little bit at the point where the skew run commences, and
watch the effect this has on the belt run, before continuing the adjusting work. Mark the
respective sets as to facilitate a later finding.
Note!
To obtain the required straight run, it may be possibly be necessary to
adjust a larger number of idler sets.
The alignment of the belt lower run is effected in the same way as in the upper one. To
avoid a misalignment of the belt in the return strand, there are installed two negatively
throughed idler stations in the return strand, serving as guide unit.

5.1.4.2.4 Tensioning the belt
The boom belt conveyor has been equipped with a take-up device, which can be ad-
justed by screws. During the first weeks of the belt conveyor’s operation, the elongation
of the belt has to be checked at short intervals.
To tension the belt, the left and right take-up carriages (1) and the take-up pulley (2),
mounted thereon, have to be displaced on the supporting structure by inserting (with
spacers, if necessary) and acting of the hydraulic cylinders (3) till the pre-tensioning
required of the belt is obtained. The nuts (4) are than tightened.
The hydraulic cylinders can be relieved and removed subsequently.
When tightening the screw nuts, care has to be taken that the pulley axis is always at
right angles to the belt centre.
Note!
Never correct a possible misalignment of the belt by moving the take-up
pulley!
As soon as the tensioning length of maximally 800 mm is used completely, the belt
must be shortened.
2 4
3 1
Fig.: 225-STD4500-509

5.1.4.2.5 Cleaning of the belt
To clean the boom conveyor, provision has been made for two belt cleaners (1) ar-
ranged at the discharge pulley.
The discharge pulley of the tripper car is also equipped with two belt cleaners (2) to
clean the longitudinal belt conveyor.
Although these cleaners are maintenance-free to a very large extent, they have, how-
ever, to be reset from time to time. If required, possibly worn or damaged cleaning
plates are to be exchanged.
For having foreign particles prevented from getting between pulley and belt, a plough-
type belt cleaner (3), serving as a safety cleaner, is arranged in front of the point where
the belt enters in the drive pulley of the boom conveyor.
The rubber scraper blade of the plough-type belt cleaner must be replaced when the
max. wear is reached. This is the case when the supporting angle iron is at a distance
of only 10 mm from the belt.
B A
Z
A-A
B 3
Z
2
Fig.: 225-STD4500-510

5.1.4.2.6 Sealing - Transfer zone
The skirting is sealed with sliding rubber seals.
If the seals are worn so far that material escapes laterally:

• Loosen the clamping nuts (1) and lower the rubber seal (2) until the rubber rests
on the belt (3) without any significant force. Tighten the clamping nuts again.
1
Z
2
Fig.: 225-STD4500-511
The condition of all seals that have been installed within the feeding
zone need to be checked at regular intervals, and they need to be
replaced, if necessary.

5.1.5 Corrosion protection

5.1.5.1 Temporary corrosion protection
Surfaces which cannot be given a permanent corrosion protection for functional

reasons (shafts, axles, bolts, clamping sets etc.) are to be protected by means of a
temporary preventive against corrosion (Tectyl, Shell Ensis oils, Molikote etc.).
When selecting the product, additional characteristic features like lubrication, creep
properties etc. are to be taken into account.
This preventive against corrosion is to be made new in accordance with the instruc-
tions of the respective manufacturer at regular intervals.
5.1.5.2 Corrosion protection coat
Damages to the corrosion protection coat have to be touched-up according to the

“corrosion protection specification”.

5.2 REPAIR
5.2.1 General notes on repair work
Caution!
These general instructions have to be noted whenever repair work is
carried out.
The safety instructions contained in chapter 1 must also be observed.
Danger!
Do not carry out repair work on the stacker unless it is shut down.
Also, block the equipment to prevent unintentional and unauthorized start-
up.
• Stackers faults/damages must be immediately reported to the supervisory

staff/department responsible.
Only have repairs on the electrical equipment and control systems carried out by
qualified electricians.
Caution!
Never postpone repair work as this may cause accidents and consider-
ably damage the equipment and plant.
• Have the stacker thoroughly inspected once a year (annual main inspection) by
responsible experts in co-operation with the supervisory staff. Have any faults or
damages repaired immediately. Consult TKIS if necessary.
• Coordinate repair work with any scheduled inspections and servicing work with
respect to time and place.
• Replacement parts must meet the technical requirements specified by the manu-
facturers. This is always guaranteed when original spare parts are used.
• Always keep a complete set of wear parts on stock. Replace damaged or worn
parts and/or refurbish.
• Assembly groups and parts must be disassembled and/or assembled in the work-
shop (for reasons of space and safety).
• Thoroughly inspect the condition (or have it inspected) of all parts of the steel
structures of the stacker once every year.
• Have service fluids, working stocks, consumables and replaced parts disposed of
safely and properly.

• Always observe the safety regulations and the accident prevention rules applying
to repair work.
Always observe the safety regulations (in chapter 5.2.1.1) when carrying out repair
work.
Note!
The instructions contained in these descriptions do not exclude the use of
other procedures and routines which prove more suitable for the job to be
carried out under the conditions prevailing at site.
But such other procedures and routines may never put at risk the safety of
the repair staff, of the stacker and its components.
5.2.1.1 Safety instructions
Before repair work is started, have skilled and qualified electricians take the following
”5 safety measures”:
- Disconnect the machine from the power supply.
- Lock the machine to prevent it from being switched on again.
- Make sure that no components are live.
- Earth and short-circuit the equipment.
- Cover or screen off neighbouring components which are live.
• Fit a sign showing the period of disconnection from power, the supervisor’s
name, etc.
• Only have electronic transmitters of the control systems serviced/dismantled

replaced/installed by qualified staff. Have functional tests carried out after
installation work.
• Thermal overload fuses of the drives may only be set and/or replaced by qualified
electricians.
• Props, suspension facilities and supports which are required for assembly/ dis-
mantling work must be of suitable design and have the necessary load-bearing
properties. Take the necessary precautions and safety measures to prevent
overturning, slipping and falling.
Caution!
Only use approved hoists with sufficient carrying capacity for dismantling
and assembly work.

• Only use suitable climbing aids, lifting devices, pull jacks, rope winches etc. of
adequate load lifting capacity for dismantling and fitting of subassemblies and
components of the stacker.
• The load-bearing structure is to be designed for having auxiliary dismantling/

reassembly aids such as suspension lugs, rope pulleys and sheaves, support
tubes etc. secured to it (e.g. by welding). The manufacturer is to be consulted
about the dimensions of and attachment routine for these auxiliary aids and the
corresponding safety aspects.
Danger!
Diagonal lifting of loads with lifting tackle is forbidden.
Risk of accidents. To lift or move a load which cannot be lifted vertically,
always use several hoists/rope winches and safety ropes for holding
purposes. The job routine is to be determined and discussed with the
repair staff in advance and the work is to be carried out in the presence of
a responsible supervisor.
• Do not use dismantled seals, fixing and safety elements again.
• Do not leave any tools or other equipment lying around on the stacker.
• Tighten all bolts which are loosened during repair work to the specified tightening
torques. Do not use high-strength friction grip bolts again.
• Only carry out welding, flame-cutting and grinding work on the equipment if this
has been expressly allowed.
• During welding work, observe all rules and regulations for the prevention of
accidents. For welding work (arc welding) the earthing cable is to be fixed next to
the part to be welded. During welding, the welding current return flow must not
pass over moving machine components (shafts, ball bearings, etc.) Use a cable
of adequate cross section suitable for the welding current and current flow path
for bridging purposes.
• Special care must be taken when carrying out welding work near conveyor belts
and other rubber parts. Cover the conveyor belt to protect it from flying sparks,
scale or spatters.
• Keep all means of access such as steps, catwalks, stairs, etc. in a condition fit for
use and free of soiling.
• Note the safety regulations for oil, grease and other chemical substances when
working with them.
• Attaching loads to or supporting loads on the main supporting structure of the

shiploader or its secondary structures is only allowed at the points especially
provided for this purpose, taking into account the maximum permissible loads.

• Always consult TKIS whenever the stability of the stacker is endangered by the
repair work (e.g. due to a shift of the centre of gravity when dismantling heavy
assembly groups).
• Do not loosen or tighten any pipe connections of the hydraulic system as long as
the system is under pressure.
• During repair work, seal off all opened pipes and hoses with plastic caps or
rubber plugs to prevent soiling.
• Put the stacker back into its original condition after repair work. Make sure that
the stacker is in perfect working order by carrying out a test run.

5.2.2 Handling of structural components
The structural components are exposed to high stresses during operation, and feature
high pressures at the bearing points.
• Parts made of nonferrous metals like bronze, red bronze, bearing metal, are to be
treated carefully. A forcing and hammering of soft nonferrous metals brings a
flowing of the metal about, and avoids an adaptation to the appertaining parts.
• Clean the nonferrous structural components carefully, and lubricate or check

them for defects/damages, where required.
• Take care that structural components with machined or carrying surfaces do not
become damaged.
• Protect the structural components by oil / corrosion protection agent when they
have to be stored in the open for a longer period of time.
• Structural components with machined surfaces must always be placed on sub-

layers/special supports, and never on the ground.
Prior to the re-assembling of structural components / sub-assemblies:
• Remove the corrosion protection agent from all machined surfaces by using a
suitable solvent.
• Filled-in protective/preservation oil must be fully drained off all hollow spaces,
e.g. gearbox housings, tanks. They need to be flushed only then when the
manufacturer does require such a procedure.
• Inspect the components for corrosion or damages which could handicap the
operation of the plant.
• The components are to be properly aligned during assembly, and a clean

lubricant is to be applied.
• Protect carrying surfaces and inner spaces against dirt and dust.
• Clean pipe- and hose connections, as well as fittings prior to the assembly.
Check in particular that points for pollutions where grease and oil are passing
through.
• Repair and make good slight damages for being able to reach the fit provided for.
• Use new greased screws, nuts and washers.
• Retighten screwed connections which have got loose during the realization of the
repair work, taking into account the tightening torques given.

5.2.3 Lifting gears and attachments

5.2.3.1 Lifting gears
Lifting gears are that equipment which is most used for the handling of heavy structural
components. Load suspension means like attachment ropes and hooks represent the
critical points between the load and the lifting gear. A sufficient dimensioning/rating of
the lifting gears and the load suspension means, as well as a safe attachment are pre-
requisites for a safe lifting.
The weights of the sub-assemblies and structural components are indicated in the
spare parts catalogue to allow for a good choice of the auxiliary means, e.g. lifting
blocks, cranes, chain hoists.
Prior to the application of hydraulically-operated lifting blocks, check their proper

functioning. Use only lifting blocks equipped with an adjusting ring. They allow for a
mechanical propping of the load, and prevent it from lowering.
Before having lifted heavy loads, make use of a pressure gauge to check the weight.
5.2.3.2 Lifting prodedure
• Prior to the lifting procedure, determine the weight of the load.
• The size and shape of the load upon which will depend :
- the type of fastening, e.g. loop, cage or loop with special facilities;
- the fastening/load suspension means to be used, e.g. rope, chain, screw-
connected, load brackets;
- the load angle of the fastening means.
• Select the size of the fastening means provided taking into account that its
carrying capacity must not be exceeded.
• Consult a supervising person when there does exist an unclearness about:

- the right fastening type
- the size selected of the fastening means
- the type of fastening means.
• Have the fastening means carefully checked for damages/defects. Exclude

defective ones from being used.
• Do not overload the fastening means, and protect them against sharp edges of
the load for example by sackcloth, corner staffs, shuttering panels.
• Protect blank/finished surfaces of the load from damaging by the fastening

means. Fasten the protection material to the load/load suspension means to
avoid a falling down when being loosened.

• If the load is fastened in a big height, attention will be paid to the following:
- Make use of the existing access means. When not being existing/accessible,
utilize a ladder of an admissible type. Secure the ladder against sliding and
tilting.
- Use both hands for climbing. Have the fastening means approached with the
help of the lifting gear, e.g. the crane.
• Following the fastening, stretch the fastening means by hand, as far as possible.
If it has to be stretched by crane, avoid injuries due to squeezing, and keep an
eye on the finger position.
• To the crane driver must be clearly given the prescribed / stipulated signals to
move the load.
Before lifting the load:

• Remove materials which lie loose on the load.
• Secure not used rope/chain ends.
• Call on all persons to leave the zone of danger.
• Check whether the load is safe and symmetrical at all points.
• Check whether there is the possibility that the fastening means and the load are
getting reciprocally damaged.
If the load is fully held by the lifting gear and slightly lifted:
• Check the load brake.
• Check the fastening of the load at all points once again.
• Move the load over free areas, if possible.
• Give warning signals when there are persons within the zone of danger.
Placing of the load:

• Have the load slowly deposited on a sufficient stable underlayer. Align the under-
layer once again before having placed the load on it.
• Remove the fastening means and check both the latter and the load for possible
damages.

5.2.3.3 Fastening ropes
Fastening ropes are lighter than fastening chains, with the same carrying capacity.
Because of the smaller bending radii, however, ropes are more difficult to handle and
more susceptible to damages. Fastening ropes are good for being used in case of
straight lifting procedures or around corners with a large radius. The size of the steel
rope will depend upon the total diameter.
• Protect the fastening ropes from influences of the weather, solvents, high
temperatures and chemicals.
• Take care that no knots are formed in the steel ropes. In this case, the rope must
no longer be used.
• Protect the ropes from sharp edges by having enlarged the corner radius by
means of corner staffs or blocks. The use of sackcloth and shuttering panels is
possible as well.
• Fix the fastening ropes correctly to the hook:

- Fix every individual strand to the hook in order to avoid a reeving at the hook.
- Never use an individual fastening rope since the load could rotate. As a conse-
quence of this, the steel rope could be untwisted and the splicing be drawn off.
• Do not fully turn the steel rope around a crane hook. The sharp radius will cause
damage to the rope.
• Check the fastening ropes for:

- Broken or cut wires.
- Rust and corrosion.
- Knots and bends.
- Damages to the eyelets.
• Do not bend the eyelets of the fastening ropes around corners.
• Utilize load brackets when lifting components where a fastening rope has been
wound around.
5.2.3.3.1 Rope clamps
The rope clamps are to be mounted in such a way that the clamp foot is pressing
against the long rope end, and the clamp bracket against the short rope end. Always
insert a rope thimble.
After the rope has been putted into service and tensioned, tighten the clamping nuts
once again. Inspect the latter at regular intervals and re-tighten them, in case of need,
for having compensated the rope elongation and the reduction of the diameter.

5.2.3.4 Fastening chains
Fastening chains, made of alloyed steel, are more robust and flexible, but not as
shock-proof as fastening ropes. Their size will depend upon the diameter of the chain
link.
• Do not allow for knots in the fastening chains. They will lead to a weakening of
the chain strands and can also cause a bending or another failure of the chain
links.
• The fastening chain can be shortened by having it hanged in once again in the
chain or the main hinge, as well as with the help of a grab hook. Never shorten
the chain by twisting, knots or bolts.
• Protect the fastening chains from sharp edges, which might bend the chain links.
For doing so, make use of timbers or corner staffs.
• During the lifting procedure, always turn out, by twisting, the hook opening off the
pull of the loop for having avoided that the hook slips out as soon as the loop
gets tensioned.
• Check the fastening chains for:

- Notches, cracks, accuracy to size and wear,
- Bent chain links, welding burrs, bent or open hooks, elongation,
- Rust and corrosion.
• When all strands of a fastening chain are hanged in once again in the main
hinge, the admissible lifting force of the whole loop can be increased by 50 %.
5.2.3.4.1 Hooks
Normally, the carrying capacity is punched into the hook.
• Hooks with snap should be given preference.

5.2.3.5 Screwed eyelets
The size of the screwed eyelets will depend upon the shaft diameter of their threads.
One distinguishes between screwed eyelets of normal type and screwed eyelets with
an extension.
• Screwed eyelets of normal type (without extension) must be used for vertical
lifting of a load only.
• In case of lifting work with certain load angles, e.g. with several fastening ropes,
make use of screwed eyelets with an extension only.
• The eyelets must be fully fastened to avoid bending of the shaft.
• Use screwed eyelets of correct size.
• Check the condition of the thread to ensure a correct fit of the eyelet, as well as a
flush-mounting of the extension. Do not use eyelets with drawn out or cracked
threads.
• Use only eyelets suitable for admissible loads to ensure a full mesh of the thread
with the standard screw holes.
• Inspect the eyelets for bent or cracked shafts.
• Utilize hardened washers for having the edge of the eyelet correctly placed. The
thickness, however, must not exceed two thread turns.
5.2.3.6 Load brackets
Load brackets are closed fastening means which cannot slip out. Their size depends
upon the diameter of the body, and not upon the bolt. One distinguishes between
anchor load brackets and chain load brackets.
• Avoid a lateral pull at the body of the load bracket.
• Take care that the bolts of the load bracket suit best.
• The same admissible load applies for anchor- or chain load brackets, as well as
for screwed- or socket pins.
Danger!
Never replace load bracket pins by usual screws.
Risk of fracture!
The admissible lifting capacity sinks when the load brackets are used for load angles
unlike 90°.

5.2.3.7 Protection of fastening means and loads
• Protect the fastening ropes from sharp edges. Use materials by which the radius
becomes enlarged, such as corner staffs (at the right and at the left), bands,
timber blocks, sackcloth, shuttering panels. Thus, finished surfaces of the load
are also protected from getting damaged by the steel rope.
Fig.: 225-STD4500-512
• Protect the fastening chains from sharp edges. Use materials by which the radius
becomes enlarged, such as corner staffs (at the right and at the left), bands,
timber blocks, sackcloth, shuttering panels. Thus, finished surfaces of the load
are also protected from getting damaged by the chain.
Fig.: 225-STD4500-513

5.2.3.8 Underlayers for loads
• Take care that the underlayer bearing the total weight of the load, is stable and
uniform. Use only underlayers made of hardwood with an almost quadratic cross-
section.
• Protect finished surfaces by having upholstered the underlayer, e.g. with the help
of sackcloth, pressboards, bands.
• Loads which can move or roll, such as shafts, round forged pieces and rings are
to be fastened by wedges. When propping the load, take care that the hands will
not become squeezed by a moving load.
Fig.: 225-STD4500-514
• In case of several underlayers, use underlayers of same height only. Put the
underlayers under the load in a stable and unform way. Do not use round, worn
out or broken underlayers.
• Compensate possible unevenesses underneath the underlayers.
• Create, with the help of underlayers, a hollow space under the load to allow for
an easy placing and mounting of the fastening means.
Fig.: 225-STD4500-515

5.2.4 Repair instructions for special components

5.2.4.1 General
The stacker is designed in such a way that most of the maintenance works can be
carried out without using special tools. Only for the exchange of the ball-race slewing
connection at the slewing gear as well as for exchanging the hinge connections or the
hoisting cylinder, it is necessary to use erection brackets.
Note!
Prior to the execution of greater works needing several days, it is to be
obtained a long-term weather forecast and, if possible, the work to be
carried out during stable weather!
5.2.4.2 Travel gear
- Bogies
Wind conditions: maximum wind speed 10 m/s
Caution!
Repair works on the travel gear requiring a lifting of travel gear compo-
nents or of a complete corner must exclusively be carried out at those
times, when it is expected that the a. m. values will not be passed during
the repair time. It is permitted to lift only one corner.
• Move the stacker into parking position and secure it there.
• Have the rail clamps applied.
• Close the brakes.
• Disconnect the cables and the lubrication pipes.
• For supporting the travel gear bogie, arrange hydraulic jacks at the corresponding
place marked with a pump signboard.
Dismount the bogie bolt.
• Roll the bogie out of the support area and lift it out.

- Drive unit:
• Disconnect the cables.
• Remove the shrink disk from the drive shaft.
• Pull off the gearbox.
5.2.4.3 Slewing gear
- Drive unit / drive pinions
• Move stacker into parking position and secure it there.
• Disconnect the cables and the lubrication pipes.
• Remove the fastening screws.
• Lift off the drive unit.
• Dismount the pinion.
- Exchange of the slewing connection
Prerequisite:
Carrying out the works specified in the following will only be possible on the condition
that the wind speed to be expected will not exceed 10 m/s.
Caution!
The slewing connection must not be dismounted, respectively replaced,
when the wind speeds to be expected are higher than those indicated
above!
Preparatory works:
• In this context, please refer to the following drawings / documentation:

- Drawing 4555065 Slewing gear arrangement
- Drawing 4553667 SH.1-5 Portal SH.1-5
- Drawing 4553670 SH.1-6 Slewing part SH.1-6
- Documentation Technical data sheet RotheErde / Large Diameter
16-29236/60.1.43040 Slewing Bearing

• Evacuate completely the material from the boom conveyor.
• Position the stacker with closed brakes and rail clamps at that place where the
repair work will be made.
• Bring the boom in perpendicular with the rail. In this position, the 4 presses’
points of both the portal and the slewable section become covered. In this
context, see drg. No. 4553667 and drg. No. 4553670.
• Bring the boom into the horizontal position (0 ° - boom inclination).
• Secure the boom at its front and rear end by fixing each two ropes at an angle of
approx. 45 degrees while taking into account a rope force of approx. 30 kN.
• Remove all electric cables leading through the slewing connection from the portal
to the slewable section.
• Remove the lubrication pipes.
• Remove the sealing between upper- and lower portion of chute.
• Dismount the protective housing of the slewing connection tooth.
• Open the brake of the drive unit and have the latter detached then; lift it by
approx. 250 mm, and prop it. This way, the drive pinion does no longer obstruct
the replacement of the slewing connection.
• Dismount the drive pinion pertaining to the cam-operated limit switch.
• Place 4 hydraulic presses on the above-mentioned presses’ points. The presses

must be suitable to bear a load of 650 kN each.
To have controlled the occurring load in a better way, each press is to be
equipped with a pressure gauge.
• Because of the fact that the slewing connection must be pulled off in transport
direction of the stockyard conveyor, sufficient place is to be provided for on the
circular platform. To dismount the slewing connection, a free space of at least 70
mm must remain to the side. Have the railing on the circular platform dismounted
partly, if required.
Note!
For facilitating the dismounting of the slewing connection, it is recom-
mendable to arrange supports in dismounting direction on the circular
platform and within the zone inside the slewing connection. The upper
edge of the supporting structure must comply with the lower edge of the
slewing connection.

Exchange of the slewing connection
• Upon termination of the preparotory works, the HS-connections of the slewing

connection need to be removed and with the help of the four presses, the
slewable section is to be lifted to such extent that the slewing connection
becomes free for being pulled off its position in horizontal direction by means of
chain hoists (to be lifted by 50 mm).
• During installation of the new slewing connection, care must be taken that the
hardness gap points „S“ of both the outer and the inner rings, come to lie on the
steel structure in accordance with drawing no. 4555065.
• To fix the new slewing connection, make use of new HS-screws. The latter are to
tightened with the help of a hydraulic device by applying the torque given as per
drawing No. 4555065.
• The replacement of the slewing connection requires in any case the installation of
a new drive pinion.
If the pinion of the cam-operated limit switch is worn-out, it will be replaced as
well.
Caution!
The cam-operated limit switch must be set new. All switch positions must
be checked by slewing the boom.
Contacts which have been set incorrectly can bring damages to the
stacker about.
• Thereafter, the tooth space between drive pinion and slewing conenction must be
checked and corrected, in case of need.
The adjustment takes place by horizontal slewing of the complete drive
mechanism in its fastening bore until the tooth space desired of 0.7 - 1.0 mm is
reached.
• Finally, the preparatory works necessary for being able to dismount the slewing
connection are to be made undone.
Note!
To ensure that the exchange of the slewing connection is carried out
correctly, we recommend the assistance of a TKIS service engineer.

5.2.4.4 Hoisting gear
- Exchange of the hydraulic hoisting cylinder
Prerequisite:
Carrying out the works specified in the following will only be possible on the condition
that the wind speed to be expected will not exceed 10 m/s.
Caution!
The hydraulic cylinder must not be dismounted, respectively replaced,
when the values to be expected are higher than those indicated above!
Preparatory works:
• In this context, please refer to the following drawings / documentation:

- Drawing 4553676 SH.1-3 Boom rear part SH.1-3
- Documentation Hydraulic equipment
• Evacuate completely the material from the boom conveyor.
• Position the stacker with closed brakes and rail clamps at that place where the
repair work will be made.
• Bring the boom in perpendicular with the rail. Make sure that the brake of the
slewing drive mechanism is closed.
• Bring the boom into the - 1°-position (top of boom lowered).
• A vertical auxiliary support is to be fastened on the portal in such way that the
web plates of the boom rear part’s main beams come to rest centred on the
support points; the support has to be arranged at a distance of approx. 3000 mm
from the slewing centre and must be capable of bearing a load of 230 kN.
The height of the supporting structure must permit a boom incline of 0° in
supported condition.
A displacement of the supporting structure on the portal must be excluded.
Note!
The supporting structure, which must be fabricated, does not form part of
our scope of supplies. To ensure that the exchange of the hoisting clinder
is carried out correctly, we recommend the assistance of a TKIS service
engineer.

• Lift the boom at slow speed for having reduced the space between the auxiliary
support and the boom rear part to approx. 5 mm only.
• Discharge the hydraulic cylinder on the piston side, as follows: Unscrew the micro
hose from the pressure gauge supplied and have it screw-connected to the micro
coupling on the piston side. Drain the oil into a receptacle and reduce the
pressure till the oil flow stops.
As the boom without load is tail-heavy, its end does become lowered due to the
oil drain till it touches the auxiliary support. By means of the micro hose screwed
connection, the oil quantity is to be regulated in such way that a smooth place-
ment at slow speed of the boom rear part is ensured.
Connect the pressure gauge to the micro hose and check whether the pressure is
= 0 bar.
Make sure that the boom rear part cannot slide from the auxiliary support.
Exchange of the hydraulic cylinder:
• Disconect all hydraulic pipes and electric cables on the hydraulic cylinder.
• Replace the hydraulic cylinder. Reconnect the hydraulic pipes and electric
cables. Ensure the proper functioning of the complete hydraulic system in
accordance with the respective documentation.
• Lower the boom. This way, the rear part lifts off the auxiliary support. Remove the
latter then.
Note!
To ensure that the exchange of the hydraulic cylinder is carried out
correctly, we recommend the assistance of a TKIS service engineer.

5.2.4.5 Boom conveyor
- Drive unit
• Disconnect the cables.
• Remove the fastening screws of the torque supports.
• Remove the screw connections of the flange coupling.
• Pull of the drive unit.
- Pulleys
• The boom is to be brought in horizontal position for being secured there.
• Dismount the belt cleaner.
• Release the belt.
• Dismount the drive mechanism of the drive pulley as described before.

Remove the fastening screws of the pillow-blocks.
Note!
All pulleys are connected with the shaft or the axle via locking elements.
Prior to commissioning of the new pulleys, the belt has to be checked for
correct tension.

5.2.4.6 Cutting, dismounting and re-installation of the conveyor belt
The dismounting, as well as the re-installation of conveyor belts is very time-consuming

and expensive and causes longer standstill periods.
Therefore, in each case is to be checked, whether this work must be done or whether
there is another more favourable solution to solve the existing problem.
The following situations require the measures indicated below:

- In case of a completely worn out and destroyed belt, there must be installed a
new one. The installation of the new belt can take place with the help of the old
one. For doing so, the new belt to be installed must be connected with the old
one. By pulling off the old belt, the new belt will be installed.
- If the belt has become locally damaged, it will be cut at the damaged point and
vulcanised together again with an overlapping. When the belt length is not
sufficient enough to do so, or when the damage is too big, an intermediate piece
with two connecting points must be inserted by vulcanisation.
In this case, take care that the distance between the two connecting points to be
vulcanised is so far that they do not come in contact with the drive pulley during
belt run at the same time.
- If the conveyor belt does hinder works, e.g. the disassembly of a pulley, it will be
checked whether the belt by dismounting of the pulley or shifting of another one
can first be detensioned to such an extent to allow for a dismounting of the pulley
concerned without a cutting of the belt.
The old belt to be replaced

is often used for having installed a new one.
There are two possibilities:

- The old belt will be cut and its end connected to the new one by means of clips,
connectors with six prongs or a cold-bonding agent. By having wound or dis-
mounted the old belt, the new one is installed.
- A rope which must be accordingly longer than the endless length of the old belt
will be fixed to the belt. So, when the old belt is dismounted, a rope is inserted
with the help of which the new belt is installed.
This procedure shows that the selection of the joints is of particular importance. The
joint must allow for the handling of the new belt (belt winding).
Danger!
Before having cut the belt, it has to make sure that it does not become
automatically unwound from the drum, especially in case of steep belt
conveyors. This can bring a danger of persons about!

5.2.4.6.1 Re-installation of the belt
- Preparatory work connected with the installation of the belt
Prior to the execution of the installation work, a local inspection and a preparatory talk
with the engineers and the personnel involved must take place. The discussions serve
the purpose of fixing the sequence of the installation work, the auxiliary equipment and
helpers, as well as the corresponding responsibilities.
The point where the new belt is jacked up/suspended, the most favourable way of belt
installation and the points for the endless making of the belt and for the insertion of
intermediate pieces, if necessary, must also be fixed in common.
- Jacking up/suspension of the belt winding
The type of belt installation does fully depend upon the local conditions.
The belt winding will be suspended in portable winding blocks, the simplest execution
of which is equipped with open U-shaped bearings for receiving the axle journals. The
bearings must be secured by bolts or brackets. In case of smaller plants, portable cable
winches are good for having jacked up the belt.
In case of greater differences in height, the belt is to be upwards installed by applying

suitable pulling means.
To allow for a straight installation of the belt, the belt winding must stand or hang in
right angle to the belt conveyor axle, as well as in the middle, in front of, behind, under
or above the system.
- Installation of the belt
Prior to the installation of the belt, remove lubricating oil- and grease from all parts
coming in direct contact with the belt. Do not draw the belt over sharp sectional irons or
other components. Install deflecting rolls at these points.
The installation of the belt itself does also depend on the local conditions. Smaller belts
can be manually installed or with a grab- or a lifting device.
Before having mounted the belt, it must be checked whether the carrying side of the
belt is coming to lie in the carrying strand in direction to the top or in the return strand in
direction to the bottom. If the carrying side of the belt is not marked by a stamp, the
carrying side will be identified with the help of the cutting face at the beginning of the
belt by the thicker cover.
With a belt winding, the carrying side lays in most cases outside. When the jacked up
belt is wound from the top, the outer cover does lay on the belt conveyor to the top as
well.
When turning the belt winding in such a way that the belt is wound off from the bottom,
the outer cover will lie to the bottom.

Should the belt be installed with the help of a rope, a pull iron will be fastened at the
beginning of the belt. It consists in most cases of two plates or stronger flat irons with a
number of bores.
The belt end will be fitted with the respective holes and clamped between the pull iron
parts by means of strong machine screws. At the pull iron part, there has been cut by
burning or welded a strong eyelet serving the purpose of receiving the pull hook.
To avoid that the two cut belt edges are becoming blocked by the troughing idlers
during installation, they will be bevelled or bound up in a trough-shaped way.
Detachable connections are sufficient mostly. Heavy hinged connections are well-
proved and offer the advantage that the hinge half at the end of the head piece can be
re-used frequently.
Whether the belt needs first to be installed in the carrying strand or in the return strand
is dependent upon the system, and will not least be determined by the position of the
working place of the vulcanizers to realize the intermediate- or endless connections.
The pull cord must be inserted in the middle of the belt structure.
If the rope winch or the tractive machine do not allow for a work above the head of the
belt conveyor, the rope is to be led out of the plant at the side by means of folding- or
return rolls. The rolls must be fixed in such way to avoid a damaging or deformation of
the belt structure during installation of the belt.
Note!
When the belt will be installed in a plant with V-shaped idlers, the rope
does often get clamped into the idler gap. This can be avoided by having
fixed to the pull iron a rope guide in form of a slit tube piece. The rope lays
in the tube and will be lifted and guided by an oblique fork head while the
tube piece is passing over the troughing idler gap.
During the installation of the belt, an erector runs with the beginning of the belt and
observes its correct getting into line.
Danger!
Breaking ropes, hooks or idlers act and destroy like projectiles. The
erector must go behind the beginning of the belt and not on level with the
rope.
If in case of ropes coming out at the side, persons are entrusted with the
observation of the folding- and return rolls, they should never stand within
the rope- or pulling angle.
A further erector observes the winding up and the possible deceleration of the belt at
the winding block. In case of long belt conveyors, there are helpers positioned at cer-
tain distances. The erectors standing at that+ point, where the belt is wound off, and at
the inlet of the beginning of the belt, as well as the operator of the rope winch or the
tractive machine, must be given the possibility to communicate directly one with
another or by means of telecommunication systems.

The installation of the belt takes place at creeping speed for being able to stop the work
in case of danger or in case of the occurrence of another hindrance at any time.
When doing so, the site manager only is entitled to give the command "pull" while the
command "stop" must be given by all persons involved.
5.2.4.6.2 Endless making
- Preparation of the vulcanising point
Work can only be done in a proper and workmanlike manner at a correctly installed
vulcanising point by using faultless and appropriate tools.
- Structure of working surface
Fig.: 225-STD4500-516
( 1 ) Belt ( 2 ) Lower vulcanising plate ( 3 ) Traverses
( 4 ) Planks ( 5 ) Supporting structure
At the working place provided, there will either be dismounted the complete belt sup-
porting structure of respective length and the working table installed at the bottom, or
there will be detached the troughing idler sets of the carrying strand, as well as the
working tables mounted on to the lateral beams of the plant. The central part of the
working surface will be formed by the sub-structure of the vulcanising device.
The sub-traverses will be placed across the plant on to the lateral beams. The lower
heating plates of the vulcanising device will be put on top of them.
The working surface should be in the plain with the upper edges of the lateral troughing
idler sets, if possible. This can be achieved by having placed wooden planks or
squared timbers under the sub-traverses on the attachment points. The working
surface required depends upon the structure and the width of the belt.

Fig.: 225-STD4500-517
Furthermore, with the help of squared timbers and wooden planks, a lateral working
surface (1) is to be created for being able to work by gradations on a folded back belt
end (2) starting from the carrying side.
This working surface, however, will be insufficient in case of steel chord belts. To en-
sure a proper execution of the work, each a lateral working surface is necessary in
front of (3) and behind the vulcanising point (1).
The length of a lateral working surface depends upon the structure and the width of the
belt.
The longer the tables, the better and more exactly the alignment of the belt ends.
With the help of squared timbers and wooden planks, these lateral working surfaces
will be built in such way that all three working surfaces are on the same level.

- Tensioning and catching of the conveyor belt
As soon as the belt is installed, and the sub-structure of the installation point is built-up,
both the belt ends are pulled against each other prior to the endless making, i.e. the
belt will be tensioned.
There are two possibilities to tension the belt:
- During installation of the belt, the sufficient long belt end is pulled over the work-
ing table provided, and catched and fixed approx. 5 - 10 m in front of the table by
means of tensioning beams. By means of the pulling device, the beginning of the
belt will be further pulled over the working table until the belt comes to lie on the
plant as tensioned as possible.
Then, at a distance of approx. 5 - 10 m in front of the working table, the beginning
of the belt will also be firmly anchored by means of a tensioning beam or a catch
device. After having loosened the pulling device now, both the belt ends are lying
in a de-tensioned condition on the working table to allow for the alignment- and
connecting work.
- The two belt ends will be squeezed off by using tensioning beams. On each side
of the plant, a grab hoist will be fixed between the tensioning beams of the belt
ends. Thereafter, both the belt ends will be pulled against each other until the belt
comes to lay on the plant in a tensioned condition. The two belt ends will also be
firmly anchored then approx. 5 - 10 m in front of the working table by means of
tensioning beams or catch devices.
This kind of work offers the advantage that the slag of the belt, starting from the
two sides, will be drawn nearer, whereas in the first case, the belt material with
one belt end needs to be pulled around the whole plant.
Fig.: 225-STD4500-518

- Weather- and dust protection
When preparing the working place, the protection against weather and dust is playing
an essential rôle.
Moisture, dust and sunlight are declared enemies. They are not only acting in a sepa-
rating way, but they do also avoid a proper jig welding or do bring bubble formation
about.
When realizing the installation work in the open, a tent of sufficient size is to be put up
over the working place. The length of the tent must also take the lateral working tables
into account.
Its height is to be selected in such way that a clearance of approx. 2 m will remain
above the working surface to allow for an upright standing of the installation personnel
during the execution of the work.
The width of the tent should provide for a space of each approx. 1 m at the side of the
working table for making possible to work.
The roof of the tent will be kept in the middle by means of a ridge bar for ensuring the
drain away of rain water and for avoiding the formation of water bags.
The tarpaulins need to be properly fixed. The side tarpaulins must go up to the ground.
This is absolutely necessary as protection against dust and wind. In case of cold or
humid weather, the interior of the tent can be heated up by infrared or air heaters. Care
has to be taken that the working table is sufficiently lighted.
- Vulcaniser
During vulcanisation, the plastic condition of the raw rubber is converted into the
desired flexible condition. Joints of conveyor belts and points to be repaired will be
vulcanised on the site by means of mobile devices. The vulcanising work is to be
realised at a certain constant temperature, as well as with sufficient pressure.
- Heaters
The temperatures required for the execution of the vulcanising work are reached with
the help of heating plates. Electrically heated up plates have less weight and can be
easily handled on the site.

- Vulcanising press
The pressure to be applied during the vulcanisation of belt joints varies depending
upon the thickness and the structure of the belt.
Because of the fact that the pressure is to be absorbed by the traverses and the
tensioning bolts, the maximum pressure will very heavily influence the dimensions and
the weights of the presses and, thus, their handiness during the execution of the
installation work.
Presses made of light metal, divided into individual pairs of traverses, have proved
successful.
Depending on the specific pressures applied, one distinguishes between:

a) Traverses with pressure screws /
max. surface pressure up to 8 da N/cm² (sufficient for belts with textile ply)
b) Traverses with light hydraulic press /
surface pressure 10 - 12 da N/cm² (sufficient for heavy textile belts and light steel
chord belts)
- Accessories
Bars (edge bars) serving the purpose of propping the joint laterally belong to the
vulcaniser as well. The bars are to be made of flat steel having a width of approx. 60 up
to 80 mm. For ensuring that the pressure applied by the press is fully placed on to the
joint, the bars must be 1 to 1.5 mm weaker than the belt, and they must in no case
exceed the belt thickness. In addition to that, heating sheets can be placed between
the belt and the heating plates, in particular, when the heating surface will be
composed of several heating plate pairs. Material: Depending upon the size of the
surface: steel plate approx. 1.5 mm thick, or 3 mm thick light metal plate.
The plate dimensions are to be selected in such way that they, at the side, will be in
true alignment with the heating plate edge, and that they project each approx. 100 mm
in direction of the belt. Should there be the need to have two sheets arranged one
beside the other because of the width of the heating surface, the joint of the heating
sheets must have an offset against the joint of the heating plates.
The heating sheets are capable of compensating the pressure in longitudinal direction,
and are thus avoiding a print of the heating plate edges on the belt or a possibly drifting
away of the putted together heating plates.
Furthermore, when positioning the heavy heating plates on to the belt, a better align-
ment of them is possible by sliding, without having displaced the joint.
Two pairs of tensioning beams, which will be clamped on to the belt, are required for
having catched the belt ends or for having the ends pulled against the other during
tensioning.
5.2.4.6.3 Vulcanisation of the conveyor belts
Information for the vulcanisation of conveyor belts, please consult the documents of the
respective belt manufacturer, which are included in chapter 6.

5.2.4.6.4 Commissioning / Re-commissioning of the belt conveyor
Following the endless making of the belt, the vulcanising press, the working table and
the auxiliary structure required will be dismounted. The idler sets removed from the
carrying- and return strands will be re-installed, aligned and fixed.
- Tensioning of the belt
The belt will be tensioned following the re-arrangement of the plant. In case of weight-
loaded take-up stations, the weight propped is to be re-installed.
- Start-up of the belt
Prior to the re-start of the belt conveyor, the whole plant need to be inspected. Tools
remaining lying down or plant components which have been deposited on the carrying
strand, screws etc. are to removed. Have the carrying strand claened with a broom if
necessary. Check that the conveyor has been released for operation by all craftsmen
working on the different sections.
In case of longer axial distances, some mechanics are to be positioned along the plant
within sight and call. During the first start-up, which is initiated by a short switching
pulse, the belt covers a distance of approx. 10 to 50 m depending upon the overall
length of the plant. When doing so, the belt will first be correctly placed on the idler
sets.
Then, a second switching pulse will be given. One should wait for the reaction of the
mechanics positioned along the plant thereafter.
When there are no objections, the belt can continue its run, and the straight run is to be
observed frequently.
If the belt starts to run off-centre, this will not yet give raise to interrupt the test run.
Both the belt and the plant must adapt to each other. Tensions within the belt must
compensate. This can best be obtained during running of the belt at full load, if
possible. Only then, the belt will be fully tumbled, and it will loose its initial rigidity and
be sufficiently guided by the plant.
- Alignment of the belt
The alignment of a belt, in particular of a longer one, requires in the first place patience,
a clear and rational thinking and acting. Even if the belt runs against some points at the
beginning, the plant must not be stopped directly. The belt edge does not become
damaged so fast. The alignment of the belt is only possible in running condition where
the consequences of the corrections made can be observed.
Note!
In this context, please also refer to point 5.1.4.2.3 of the chapter 5.1.4
"Servicing of individual components".

5.2.5 Antifriction bearings - mounting and dismounting

5.2.5.1 Foreword
Skill and cleanliness when mounting ball and roller bearings are prerequisites for
ensuring satisfactory performance and preventing premature bearing failure. Mounting
should preferably be carried out in a dry, dust-free room away from metal working
machines or other swarf or dust producing machines.
5.2.5.1.1 Preparations for mounting
Before mounting the bearings all the necessary parts, tools and equipment should be
at hand and the order in which the various components should be mounted determined
from instructions or drawings, if available.
All components of the bearing arrangement (housings, shafts etc.) should be carefully
cleaned and any burrs removed; unmachined internal surfaces of cast housings should
be free from core sand. The dimensional and form accuracy of all components sur-
rounding the bearing should be checked. The bearings will only perform satisfactorily if
the prescribed tolerances are adhered to.
The bearings should be left in their original packages until immediately before mounting
so that they do not become dirty. Generally the preservative with which new bearings
are coated before leaving the factory need only be removed from the outside cylindrical
surface and bore of the bearing, unless the bearing is to be grease lubricated and used
at very high or very low temperatures. In such cases the bearings should be washed
and dried to prevent any detrimental effect on the lubricating properties of the greases
used for such extremes of temperature. Bearings which have become contaminated
because of improper handling (damaged package etc.) should also be washed and
dried before mounting.
Bearings, which when taken from their original package, have a relatively thick, greasy
layer of preservative have been hot-dipped and should also be washed and dried (hot
dipping is still used, principally on large-size bearings).
Suitable solvents for antifriction bearings are for example: white spirit, paraffin or
similar.
Bearings which are supplied ready-greased and fitted with shields or seals on both
sides should never be washed before mounting.
5.2.5.2 Mounting
It is very important that the bearing rings, cages or rolling elements do not receive di-
rect blows during mounting as this willcause damage. Under no circumstancesshould
pressure be applied to one ring inorder to mount the other ring. Beforemounting, the
seating surfaces should belightly smeared with oil.

5.2.5.2.1 Bearings with cylindrical bore
The ring having the tighter fit is generally mounted first. Small bearings, for which a
light interference fit is recommended, may be positioned on their seatings by applying
light hammer blows to a soft metal drift or preferably to a length of tubing placed
against the bearing ring face. The blows should be evenly distributed around the
bearing ring to prevent it from tilting on its seating. Mounting dollies (fig 1) permit the
mounting force to be applied centrally and hence uniformly over the ring face.
When a large number of bearings are to be mounted it is usual to employ mechanical
or hydraulic presses. If a non-separable bearing is to be pressed into position on the
shaft and in the housing at the same time, a mounting ring should be placed between
the bearing and the dolly (fig 2) so that the mounting force can be applied evenly to
both inner and outer rings.
Fig. 1 Fig. 2
The use of this method is particularly recommended where self-aligning bearings are to
be mounted as tilting of the outer ring when entering the bearing housing must be
avoided. As an alternative to the mounting ring, a dolly with two contact faces, one for
the inner and one for the outer ring face, can be used (fig 3). The two contact faces
must lie in the same plane.
With separable bearings, the inner and outer rings can be mounted independently
which greatly facilitates assembly, particularly where both rings are to have an inter-
ference fit. When entering the shaft with the inner ring already mounted into the
housing containing the outer ring, care must be taken that they are correctly aligned
to avoid scoring the raceways and rolling elements.
Fig. 3

Larger bearings cannot always be pressed on to the shaft or into the housing in the
cold state because of the heavy mounting force required (mounting force increases
with bearing size). The bearing, bearing rings or housings (hubs etc.) are therefore
heated before being mounted.
The requisite temperature difference between the bearing ring and its seating depends
on the amount of interference and the seating diameter. The bearings should not, how-
ever, be heated to more than 125°C since the structure of the bearing material may
change with resultant alterations to dimensions and hardness. Local overheating must
also be avoided. Bearings which are fitted with shields or seals should not be heated
before mounting, because this would adversely affect the lubricant.
Bearings may be heated in an oil bath or a heating cabinet. If an electric hot plate is
used, the bearings should be turned over a number of times to ensure even heating.
The inner rings of cylindrical roller bearings, which have either no flanges or only one
flange may be heated prior to mounting using an induction heating tool or a light alloy
heating ring, both of which can also be used for dismounting.

5.2.5.2.2 Bearing adjustment
Contrary to other bearings with cylindrical bore, the internal clearance of angular
contact ball bearings and taper roller bearings is established during mounting. These
bearings are normally arranged so that they can be adjusted against each other in a
back-to-back or face-to-face configuration, one bearing ring being axially displaced
during adjustment to give the required internal clearance or preload in the bearing
arrangement. Whether clearance or preload is required depends on the operating
conditions. The decisive factors in determining suitable values are the conditions
prevailing when the bearings have reached their operating temperature under load.
The clearance in the bearing arrangement should then be virtually zero.
When, in operation, differential thermal expansion of the shaft, housing and bearing
occurs, causing a reduction in bearing internal clearance, the bearings are generally
adjusted so that there will be sufficient clearance in service to prevent preload. The
internal clearance in the bearings when mounted must correspond to the expected
reduction in clearance when in operation. Bearings are only initially preloaded when
differential thermal expansion under operation will cause an increase in internal
clearance or when accurate and stiff support of the shaft is required (e.g. pinion
bearing arrangements).
There is a definite relationship between the radial and axial internal clearance of
angular contact ball bearings and taper roller bearings. It is therefore sufficient to
determine one of these values - usually the axial clearance - and to see that this is
obtained when mounting.
The requisite axial clearance or preload is obtained by loosening or tightening an

adjustment nut on the shaft or in the housing bore, by inserting calibrated washers or
shims, or by arranging for suitable spring loading.
The method of measuring clearance or preload largely depends on the arrangement

and number of bearings to be mounted. For example, the axial clearance can be
measured using a dial gauge fixed to the housing as shown in fig 4 (a hub bearing
arrangement).
Fig. 4
Where taper roller bearings are concerned, the shaft or housing should be turned a few
times during adjustment and before measuring to ensure that the rollers are correctly
positioned against the guide flange. If this is not the case the measurements may be
inaccurate and the required adjustment not obtained.

5.2.5.2.3 Bearings with tapered bore
The inner rings of bearings with tapered bore are always mounted with an interference
fit. The degree of interference is not determined by the selected shaft tolerance but by
the amount the bearing is driven up the tapered seating of the shaft or up the adapter
or withdrawal sleeve. During mounting bearing radial internal clearance (see clearance
tables) is reduced.
The clearance reduction is a measure of the degree of interference.
Self-aligning ball bearings with Normal radial internal clearance are driven up on to the
taper until the outer ring can still be easily rotated but a slight resistance is felt when
the outer ring is swivelled out.
With spherical roller bearings either the reduction in radial internal clearance or the
axial displacement of the bearing on its seating is used as a measure of the fit. The
initial radial internal clearance and the expansion of the inner ring produced by the
interference fit are relatively large, and with the exception of small bearings, the radial
internal clearance before and after mounting can be measured quite simply using feeler
gauges having blades with a thickness of 0.03 mm or more.
Before measuring, the bearing should be rotated a few times so that the rollers assume
their correct positions. The clearance is always measured between the outer ring and
an unloaded roller. During measurement, the roller at the measuring point should be
lightly pressed inwards against the guide ring between the two rows of rollers. The
measured clearance value should be the same for both rows of rollers.
For smaller spherical roller bearings, and where space does not allow the use of feeler
gauges, the axial drive-up on the tapered seating must be used as a measure of the
degree of interference. However, since it is generally difficult to accurately determine
the initial position from which the axial drive up is to be measured, it is recommended
that the more reliable feeler gauge method be used wherever possible.
The table overleaf gives guideline values for clearance reduction and axial drive-up
applicable to spherical roller bearings with tapered bore. If these are followed, the fit
obtained will be adequate, particularly if the larger values of clearance reduction are
followed.

The minimum values for clearance reduction quoted in the table mainly apply to
bearings with Normal radial internal clearance, when the actual initial clearance is close
to the lower limit for Normal. The quoted minimum value for the residual clearance will
still be less than or equal to the residual clearance obtained after mounting.
Heavy loads, high speeds or a large temperature difference between inner and outer
rings when external heat is applied, generally make a relatively large residual
clearance necessary. In such cases bearings having a radial internal clearance greater
than Normal (C3 order C4) should be used and the drive up arranged to give the
maximum value for clearance reduction.
1)
Bearing bore Radial internal clearance prior to mounting Reduction in Axial drive-up Minimum permissible
diameter radial internal residual clearance 2)
clearance after mounting
taper 1:12 taper 1:30
d Normal C3 C4 on diameter on diameter
mm min max min max min max min max min max min max Normal C3 C4
mm mm mm mm
30 40 0,035 0,050 0,050 0,065 0,065 0,085 0,020 0,025 0,35 0,4 - - 0,015 0,025 0,040
40 50 0,045 0,060 0,060 0,080 0,080 0,100 0,025 0,030 0,4 0,45 - - 0,020 0,030 0,050
50 65 0,055 0,075 0,075 0,095 0,095 0,120 0,030 0,040 0,45 0,6 - - 0,025 0,035 0,055
65 80 0,070 0,095 0,095 0,120 0,120 0,150 0,040 0,050 0,6 0,75 - - 0,025 0,040 0,070
80 100 0,080 0,110 0,110 0,140 0,140 0,180 0,045 0,060 0,7 0,9 1,75 2,25 0,035 0,050 0,080
100 120 0,100 0,135 0,135 0,170 0,170 0,220 0,050 0,070 0,75 1,1 1,9 2,75 0,050 0,065 0,100
120 140 0,120 0,160 0,160 0,200 0,200 0,260 0,065 0,090 1,1 1,4 2,75 3,5 0,055 0,080 0,110
140 160 0,130 0,180 0,180 0,230 0,230 0,300 0,075 0,100 1,2 1,6 3,0 4,0 0,055 0,090 0,130
160 180 0,140 0,200 0,200 0,260 0,260 0,340 0,080 0,110 1,3 1,7 3,25 4,25 0,060 0,100 0,150
180 200 0,160 0,220 0,220 0,290 0,290 0,370 0,090 0,130 1,4 2,0 3,5 5,0 0,070 0,100 0,160
200 225 0,180 0,250 0,250 0,320 0,320 0,410 0,100 0,140 1,6 2,2 4,0 5,5 0,080 0,120 0,180
225 250 0,200 0,270 0,270 0,350 0,350 0,450 0,110 0,150 1,7 2,4 4,25 6,0 0,090 0,130 0,200
250 280 0,220 0,300 0,300 0,390 0,390 0,490 0,120 0,170 1,9 2,7 4,75 6,75 0,100 0,140 0,220
280 315 0,240 0,330 0,330 0,430 0,430 0,540 0,130 0,190 2,0 3,0 5,0 7,5 0,110 0,150 0,240
315 355 0,270 0,360 0,360 0,470 0,470 0,590 0,150 0,210 2,4 3,3 6,0 8,25 0,120 0,170 0,260
355 400 0,300 0,400 0,400 0,520 0,520 0,650 0,170 0,230 2,6 3,6 6,5 9,0 0,130 0,190 0,290
400 450 0,330 0,440 0,440 0,570 0,570 0,720 0,200 0,260 3,1 4,0 7,75 10 0,130 0,200 0,310
450 500 0,370 0,490 0,490 0,630 0,630 0,790 0,210 0,280 3,3 4,4 8,25 11 0,160 0,230 0,350
500 560 0,410 0,540 0,540 0,680 0,680 0,870 0,240 0,320 3,7 5,0 9,25 12,5 0,170 0,250 0,360
560 630 0,460 0,600 0,600 0,760 0,760 0,980 0,260 0,350 4,0 5,4 10 13,5 0,200 0,290 0,410
630 710 0,510 0,670 0,670 0,850 0,850 1,090 0,300 0,400 4,6 6,2 11,5 15,5 0,210 0,310 0,450
710 800 0,570 0,750 0,750 0,960 0,960 1,220 0,340 0,450 5,3 7,0 13,3 17,5 0,230 0,350 0,510
800 900 0,640 0,840 0,840 1,070 1,070 1,370 0,370 0,500 5,7 7,8 14,3 19,5 0,270 0,390 0,570
900 1000 0,710 0,930 0,930 1,190 1,190 1,520 0,410 0,550 6,3 8,5 15,8 21 0,300 0,430 0,640
1000 1120 0,770 1,030 1,030 1,300 1,300 1,670 0,450 0,600 6,8 9,0 17 23 0,320 0,480 0,700
1120 1250 0,830 1,120 1,120 1,420 1,420 1,830 0,490 0,650 7,4 9,8 18,5 25 0,340 0,540 0,770
1)
Valid for solid steel shafts only
2)
The residual clearance must be checked in cases where the initial radial internal clearance is
in the lower half of the tolerance range and where large temperature differentials between the
bearing rings can arise in operation. The residual clearance must not be less than the minimum
values quoted above.

5.2.5.2.4 Aids to mounting
„ These parts are not included in the TKIS-delivery! “
Small bearings are mounted on a tapered shaft seating or withdrawal sleeve using a
shaft nut, or on an adapter sleeve using the appropriate lock nut. The nut may be
tightened by applying light hammer blows to a metal drift inserted in the recesses of the
nut. Where greater force is required a hook spanner or impact spanner may be used.
For large bearings mounting is simplified by using the hydraulic nut and oil injection
method.
The hydraulic nut is mounted on a thread adjacent to the tapered seating or on the
threaded section of the sleeve and then tightened against the side face of the bearing
inner ring or to about a nut or end cap fitted to the shaft.
With the oil injection method, oil under high pressure is introduced between the mating
surfaces forming an oil film which separates and lubricates them, thereby greatly
reducing the frictional resistance.
The pressure is obtained using an oil injector or high pressure pump, oil being fed via
holes to distribution grooves in the shaft (fig 5).
This method is mainly used where the bearing is to be mounted directly on a tapered
journal but it is also useful where tapered sleeves, particularly with-drawal sleeves, are
used. The holes and distribution grooves in the shaft, needed if the oil injection method
is to be used, must be considered when designing the bearing seating.
Fig. 5
Figs 6 to 8 show the mounting of a spherical roller bearing on a tapered journal (Fig 6),
on an adapter sleeve (Fig 7) and on a withdrawal sleeve (Fig 8).
Fig 6 also shows the use of the hydraulic nut in conjunction with the oil injection
method. Fig 9 shows the mounting of a spherical roller bearing on a withdrawal sleeve
incorporating ducts for pressurised oil. The with-drawal sleeve is pressed into the
bearing bore by tightening the bolts against the end plate.
Fig. 6 Fig. 7
Fig. 8 Fig. 9
5.2.5.2.5 Test running
After mounting, the bearings are lubricated and the quietness of operation and the
temperature checked during a test run. The quietness can be ascertained by pressing
the end of a wooden stick or a screwdriver against the bearing housing and placing the
ear at the other end. Normally the noise produced is an even "purring". Whistling or
screeching sounds indicate defective lubrication.
An uneven rumbling or hammering noise is in most cases due to dirt or damage which
may have been caused to the bearing during mounting. Abnormally high temperatures
can arise from too much lubricant, or too little clearance in the bearing, faulty
machining of the seatings, radial or axial compression of the bearing or excessive seal
friction.
5.2.5.3 Dismounting
If the bearings are to be used again after removal, the dismounting force should, on no
account, be applied through the rolling elements. With non-separable bearings, the ring
having the looser fit should be dismounted first. Depending on the size and type of
bearing, rings having an interference fit can be dismounted with the aid of the tools and
accessories described in the following.
5.2.5.3.1 Bearings with cylindrical bore
Small bearings may be removed from their seatings by applying light hammer blows to
a suitable drift around the ring face, or by a bearing puller. The claws of the puller
should be placed against the side face of the ring to be removed (fig 10) or an adjacent
component. Dismounting is made easier if, when designing the bearing arrangement,
slots are provided in the shaft and housing shoulders to accommodate the claws of the
puller, or tapped holes provided in the shoulders to take withdrawal screws.
Larger bearings mounted with an interference fit generally require greater force to
dismount, particularly if, after a long period of service, fretting corrosion has occurred.
The oil injection method considerably facilitates dismounting in such cases.
Fig. 10 Fig. 11
To dismount cylindrical roller bearing inner rings without flanges, or with only one
flange, special aids have been developed which heat the ring rapidly without heating
the shaft to any degree so that the expanded ring can easily be removed.
Electrical induction heaters (fig 11) comprise a number of coils energised by alter-
nating current. The coils are so arranged that the ring to be withdrawn is placed in an
alternating magnetic field. The eddy currents thus produced cause rapid heating and
expansion of the ring.
Large heaters are generally provided with a temperature cut-out and are connected to
the mains via a time relay to prevent excessive heating of the induction coils and inner
ring.
The inner rings must be demagnetised after heating. The use of electric withdrawal
tools becomes economic when bearings of the same size are frequently mounted and
dismounted (e.g. axlebox bearings or rolling mill bearings).
When cylindrical roller bearing inner rings (up to some 400 mm bore) are to be dis-
mounted, or when larger rings are only to be removed infrequently, it is simpler and
less costly to use a so-called thermo-withdrawal ring. This is a slotted ring with handles
(fig 12) usually of light alloy.
The bore of the withdrawal ring is the same as the raceway diameter of the inner ring.
The ring is heated on a hot plate, by a heating, coil or by flame to 200 to 220°C and
then placed around the inner ring raceway, which has first been coated with an
oxidation-resistant, viscous oil to ensure satisfactory heat transfer.
By clamping the withdrawal ring around the inner ring, using the handles, rapid
expansion of the inner ring can be achieved.
Fig. 12
5.2.5.3.2 Bearings with tapered bore
Bearings mounted on an adapter sleeve can be removed by first loosening the lock nut a
few turns and then using a hammer and tubular drift or special segmental drift (fig 13).
Only a few hammer blows to the inner ring face are required.
When dismounting bearings on withdrawal sleeves, the axial locking device (shaft nut,
end cover etc.) is removed. The withdrawal nut is then screwed on to the threaded
section of the sleeve and tightened until the sleeve comes free. If the threaded section
of the sleeve protrudes beyond the shaft end or shaft shoulder, a support ring should
be inserted in the sleeve bore to prevent distortion and damage to the thread when the
nut is tightened (fig 14).
Fig. 14
Fig. 13
The dismounting of large bearings from tapered journals, adapter or withdrawal sleeves
is greatly eased if a hydraulic nut is used, or if the oil injection method is employed.
After injecting pressurised oil between the mating surfaces, the bearing separates
suddenly from its seating. Some form of stop must therefore be provided, for example,
a shaft nut or end plate, to limit the axial movement of the bearing.
Fig 15 illustrates the removal of a spherical roller bearing from a tapered seating by the
oil injection method. Figs 16 and 17 show dismounting of a spherical roller bearing on
an adapter and withdrawal sleeve using the hydraulic nut; fig 18 shows the removal of
a withdrawal sleeve using the oil injection method in conjunction with a withdrawal nut.
Fig. 15 Fig. 16
Fig. 17 Fig. 18
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6 SUPPLIERS’ DOCUMENTATION
1. GENERAL SECTION
(Volume M1)

(Volume M1)

(Volume M1)
4. OPERATION
(Volume M1)
5. MAINTENANCE
(Volume M1)
(Volumes M1 + M2)
Access to chapter 6 "SUPPLIERS’ DOCUMENTATION" is facilitated by table of

contents and by footers.
March 20, 2015 225 E - SHOUGANG STD-4500 (930-ST-110) Chapter 6 - 1

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TABLE OF CONTENTS
Volume M1: Chapter 6.1 to 6.3.1 / Volume M2: Chapter 6.4 to 6.10.1
6.1 TRAVEL GEAR ....................................................................... 5

6.1.1 Drive unit A - BK80 ................................................................................. 5
6.1.2 Rail clamps .............................................................................................. 7
6.2 SLEWING GEAR ..................................................................... 9
6.2.1 Drive unit A - SC 6004 ............................................................................ 9
6.3 HOISTING GEAR .................................................................. 11
6.3.1 Hydraulic equipment .............................................................................. 11
6.4 BOOM CONVEYOR .............................................................. 13
6.4.1 Drive unit A - KSZg 280 Rü Pu Lü ........................................................ 13
6.5 BELT ..................................................................................... 15
6.5.1 Steelcord belt ......................................................................................... 15
6.5.2 Hydraulic set for belt tensioning ............................................................. 17
6.6 BELT CLEANERS ................................................................. 19
6.6.1 Pre-cleaners and main cleaners ............................................................ 19
6.7 PULLEYS .............................................................................. 21
6.7.1 Pulley documentation ............................................................................ 21
6.8 IDLERS ................................................................................. 23
6.8.1 Idler documentation ............................................................................... 23
6.9 CENTRAL LUBRICATION SYSTEMS (ACCESORIES) ........ 25
6.9.1 Manual and automatic lubrication systems ............................................ 25
6.10 WATER SPRAY SYSTEM (ACCESORIES) ........................ 27
6.10.1 Boom and tripper car ........................................................................... 27

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6.1 TRAVEL GEAR

6.1.1 Drive unit A - BK80
 Gearbox BK-80
− Operating and maintenance instructions

with arrangement drawing 4558202
and lubricant chart
 Drum brake TE-S 160 with Elhy-thruster EB 120/40
− Mounting, Adjustment and Maintenance of drum brakes TE
− Drum brakes TE 160: Technical data sheets
− General notes
− Electrohydraulic thrusters ELHY®: Users manual, series EB
− Inductive sensor BI5U-M18-AP6X: Technical data sheets

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Operating- and Maintenance Instructions
Customer:
Order number - Customer:
Order number - TKF: N-033-00114 – Shougang
Gearbox type: BK 80
G 28 682 – G 28 687 – “L”
Serial number:
G 28 676 – G 28 681 – “R”
Delivery:
Quantity Description Drawing
12 Travel drive – STD 4500 4558202-01
This document may only be passed into the hands of third with the written consent of TKF. All
documents belonging to it are protected by copyright. A reproduction, even partially, is not
allowed. Violation of the copyright will have legal consequences.
Order data
Technical Data - Gearbox
Drive power P = 8,6 kW
Input speed n1 = 1800 min-1
Ratio i = 171,5
Weight (without oil) G = 318 kg
Oil type ISO VG 220
Oil quantity Q = approx. 37 l
Drive mechanism (optional)

Brake incl. thruster Type TE-S 160/120-40
Technical Data – Lubrication system (optional)

Oil pump
Pump capacity Q =
Motor power P =
Fan
Motor power P =
Technical Data – Auxiliary drive (optional)

Motor power P =
Motor speed N =
Corrosion protection at the time of delivery

Internal parts of gearbox
Shaft ends
Corrosion protection period
Transport
Storage
Packing
Table of Contents
1 Caution
2 Preparing and performing installation
3 Starting up
4 Maintenance
- Gearbox -
5 Overhaul
5.1 Correct load distribution of a bevel gear

5.2 Adjustment of bevel gear
6 Storage of the Gear unit
7 Annexes
1 Caution
It is presumed that fundamental project work as well as all work with regard to
transport, assembly, installation, starting-up, maintenance and repair is performed by
qualified personnel or supervised by skilled labour taking overall responsibility. Make
absolutely sure that no voltage is applied at all while work is being done on the geared
motor. Drive must also be secured against switching on.
Any deviation from normal operating conditions (increased power consumption, tem-
perature vibrations, noise etc.) or warning signals by monitoring equipment suggest
malfunction. Inform the responsible maintenance personnel at once to prevent the
trouble from getting worse and causing, directly or indirectly, serious physical injury or
material damage.
∆ In case of doubt disconnect the machine immediately!
2 Preparing and performing installation
- Lifting devices on the drive are designed to carry the drive weight
- The foundation (base) should be of adequate size and vibration-proof
- Install gear unit rigid and braceless
- Ensure sufficient ventilation
- Make use of tapped hole (DIN 332) to suit fastening to the shaft end
- Avoid shocks on shafts (bearing damage!)
- Preferably use flexible coupling between output shaft and driven machine
- Fit output elements to shaft end or secure feather key before starting the motor
- Use torque arm with rubber buffer on shaft mounting gearboxes
Before mounting the gearbox, put the separately attached ring on the machine shaft!
Loose labyrinth-ring attached
wheel shaft
To be sealed with sealing

compound after erection
3 Starting up
- check oil-level
Oil filling quantities aren’t exact. Before starting up, the oil level is to be checked
by means of oil-level plugs, oil-level gauge or oil dipstick.
- prior to starting-up, remove vent plug from vent screw if necessary
4 Maintenance
Gearbox
- regular oil level check
- change lubricant every 10.000 working hours or after two years at the latest
- lubricant changing intervals will be twice as long if synthetic products are used
- extreme working conditions (high air humidity, aggressive media and large tem
perature variations) call for reduced lubricant changing intervals
∆ Synthetic and mineral lubricants must not be mixed either for filling of for disposal!
Assembly and disassembly of the shrink-disc
The shrink-disc is supplied ready to be installed and should therefore not be disman-
tled. The shrink-disc may not be clamped without fitting the shaft.
The shaft must be fitted or the hub pushed onto the shaft in the area of the shrink-disc
seat.
The tightening bolts must then be tightened evenly around the circumference until the
front side face of the outer ring and inner ring is flush. The state of clamping can thus
be monitored visually.
To disassemble, loosen all screws evenly in sequence. If the outer ring does not auto-
matically separate from the inner ring, a number of tightening bolts may be removed
and screwed into the neighbouring forcing-off threads.
Any rust on the shaft in front of the hub must be removed before the shaft is removed
or the hub is taken from the shaft.
Removed shrink-discs only need to be dismantled, cleaned, and regreased before refit-
ting if they are very dirty. In this event, a solid lubricant with a coefficient of friction of µ
= 0.04 or better is to be used.
Protecting hood
to be sealed with sealing compound

after erection of shrink disc
5 Overhaul
5.1 Correct load distribution of a bevel gear
The picture shows the correct load distribution of a bevel wheel Cyclo-Palloid-Toothing.
As the load distribution does not run over the whole tooth width, a certain tolerance
with the positioning of the wheels is admissible when being assembled. The teeth can
be slightly staggered in operation, without having the load concentrated on the ends of
the teeth.
With the assembly, the load distribution must be checked and care should be taken,
that it will be aligned as shown on the diagram.
The picture shows typical examples of load distributions, which have not been adjusted
correctly and the required corrections to be made.
5.2 Adjustment of bevel gear
Place the bevel wheel gear into the housing lower part and adjust tooth meshing.
For this purpose the surfaces of the tooth flanks will be painted with “marking-blue”.
The bevel pinion shaft must be turned by hand and the load distribution of the bevel
wheel has to be checked and adjusted.
Then, the circumferential backlash is checked by means of two clock indicators, which
will be used at the bevel pinion and wheel.
The difference between two measured values is the direct measure of the circumferen-
tial backlash.
Guidelines for backlash relative to normal module
Module m Circumferential backlash
0.3 - 1.0 0.03 - 0.06

1.0 0.06 - 0.08
2.0 0.08 - 0.11
3.0 0.10 - 0.13
4.0 0.12 - 0.14
5.0 0.14 - 0.17
6.0 0.15 - 0.18
7.0 0.16 - 0.19
8.0 0.18 - 0.20
8.0 - 10.0 0.20 - 0.25
10.0 - 12.0 0.25 - 0.30
12.0 - 14.0 0.30 - 0.35
14.0 - 16.0 0.35 - 0.40
16.0 - 18.0 0.40 - 0.45
18.0 - 21.0 0.45 - 0.50
Care should be taken, that the backlash is checked and set at different places at the
circumference of the gears.
Is backlash set too small, oil film is in danger to be chocked off.
In case of too large backlash there will appear a shock on load alternation and the load
distribution will grow worse.
6 Storage of the gear unit

When being delivered, the gear unit has been cleaned, preserved and packed.
If the gear unit need to be stored, this should be made in a dry room at relatively con-
stant temperature.
When the gear unit must be stored in the open, then it should be placed on timber
blocks and protected by a tarpaulin or some other material. We recommend to protect
it in addition against sun and rain influences.
When being stored for a longer period in humid environment and/or at varying temper-
ature, then the gear unit must be filled with corrosion protection oil which should reach
above the antifriction bearings.
The gearbox is to be protected against environmental loads like ozone, ultraviolet radi-
ation, dust, pollution, moisture, varying temperatures, shocks etc. ) .Bright items have
got a corrosion protection. They need to be inspected or touched-up, if necessary.
If the gearbox is stored in an humid environment and/or at varying temperatures for a

longer period of time, it has to be filled with oil going beyond the antifriction bearings.
Under these circumstances, the maximum storage time of the gearbox is 2 years.
TKF is not prepared to assume a guarantee for damages to the gearbox / drive mech-
anism or for consecutive damages resulting from the non-observance of these instruc-
tions.
7 Annexes
- Drawing no 4558202-01
- Brake incl. thruster
- Inductive sensor
- Lubricant chart
Schmierstofftabelle für Offene-, Stirnrad-, Kegel/Kegelstirnrad- und Planetengetriebe
Lubricant Chart for Open-, Spur-, Bevel-, and Planetary Gear Units
Viskosität
Viscostiy
DIN 51502/ 51825 bei 40°C
[mm²/s] / NLGI
Renolin CLP 100 Mobilgear 627 Ultra 100, Omala 100
100 Aral Degol BG 100 Energol GR-XP 100 Alpha SP 100 Spartan EP 100
Renolin CLP 100 Plus Mobilgear XMP 100 Optigear BM 100 Omala F 100
Tribol 1100/100 Oest Gearol CLP 100

Mineral Oil
Mineralöle
Renolin CLP 220

Mobilgear 630 Ultra 220, Omala 220
220 Aral Degol BG 220 Energol GR-XP 220 Alpha SP 220 Spartan EP 220 Renolin CLP 220 Plus
Mobilgear XMP 220 Optigear BM 220 Omala F 220
Renolin Highgear 220
CLP Renolin CLP 320
Renolin CLP 460
Renolin CLP 680 Mobilgear 636 Optigear 680, Omala 680
100 - - - - Renolin Unisyn CLP100 - Optigear Synthetic A 100 - Tribol 1510/100 -
150 Aral Degol PAS 150 Enersyn HTX 150 - - Renolin Unisyn CLP150 Mobilgear SHC XMP 150 Optigear Synthetic A 150 Omala HD 150 Tribol 1510/150 Oest Synthgetriebeöl 150 (PAO)
CLP 220 Aral Degol PAS 220 Enersyn HTX 220 - Spartan SEP 220 Renolin Unisyn CLP220 Mobilgear SHC XMP 220 Optigear Synthetic A 220 Omala HD 220 Tribol 1510/220 Oest Synthgetriebeöl 220 (PAO)
Synthetische Öle
HC 320 Aral Degol PAS 320 Enersyn EP-XF 320 - Spartan SEP 320 Renolin Unisyn CLP320 Mobilgear SHC XMP 320 Optigear Synthetic A 320 Omala HD 320 Tribol 1510/320 Oest Synthgetriebeöl 320 (PAO)
Synthetic Oil
680 - - - - Renolin Unisyn CLP680 Mobilgear SHC XMP 680 - - Tribol 1510/680 Oest Synthgetriebeöl 680 (PAO)
100 - Enersyn SG-XP 100 - - Renolin PG 100 Glygoyle 11 (V40=85mm²/s) Optiflex A 100 - Tribol 800/100 -
150 Aral Degol GS 150 - Alphasyn PG 150 - Renolin PG 150 Glygoyle 22 Optiflex A 150 Tivela S 150 Tribol 800/150 -
CLP 220 Aral Degol GS 220 Enersyn SG-XP 220 Alphasyn PG 220 Glycolube 220 Renolin PG 220 Glygoyle HE 220 Optiflex A 220 Tivela S 220 Tribol 800/220 Oest Gearol PG 220
PG 320 Aral Degol GS 320 Enersyn SG-XP 320 Alphasyn PG 320 - Renolin PG 320 Glygoyle HE 320 Optiflex A 320 Tivela S 320 Tribol 800/320 Oest Gearol PG 320
460 Aral Degol GS 460 Enersyn SG-XP 460 Aklphasyn PG 460 Glycolube 460 Renolin PG 460 Glygoyle HE 460 Optiflex A 460 Tivela S 460 Tribol 800/460 Oest Gearol PG 460
680 Aral Degol GS 680 Enersyn SG-XP 680 - - Renolin PG 680 Glygoyle HE 680 Optiflex A 680 Tivela S 680 Tribol 800/680 Oest Gearol PG 680
100 Aral Degol BAB 100 - - - Plantogear 100 S - - - - Oest Bio Getriebeöl CLP 100
Biolog. abbaub. Öl
Biodegradable Oil
150 - Biogear SE 150 - - Plantogear 150 S - - - Tribol BioTop 1418/150 Oest Bio Getriebeöl CLP 150
220 Aral Degol BAB 220 Biogear SE 220 - - Plantogear 220 S - Optisynt BS 220 Omala EPB 220 Tribol BioTop 1418/220 Oest Bio Getriebeöl CLP 220
CLP HCE
320 - - - - Plantogear 320 S - Optisynt BS 320 Omala EPB 320 Tribol BioTop 1418/320 Oest Bio Getriebeöl CLP 320
460 Aral Degol BAB 460 - - - Plantogear 460 S - Optisynt BS 460 Omala EPB 460 Tribol BioTop 1418/460 -
680 - - - - Plantogear 680 S - - - - -
GP 0 H-30 0 Aral Fließfett AN 0 - - Fibax EP 370 (GP 0 M-20!) RENOLIT CX-EP 0 - Longtime PD 0 - Tribol 3020/1000-0 Oest Getriebefett EP 0.2 A
Grease Gear Units
GP 00 H-30 00 Aral Aralub MFL 00 Energrease LS-EP 00 -

Grease TCL 435
RENOLIT GFW 00 (GP 00 K-20) Mobil SHC 007 Longtime PD 00 - Tribol 3020/1000-00 Oest Mehrzweckfett LT 00 EP
Schmierfette
(GP 00-000 K-50!)

GP 000 H-30
Getriebe
000 - - CLS Grease RENOLIT SF 7-041 - Olit CLS 000 - Tribol 3020/1000-000 Oest Spezialfett LT 000 EP
GPHC1 0 N-30 0 Eural Grease EP 0 - - - - - Obeen UF 0 - - -
GPHC1 000 N-30 000 - - - - - - Obeen UF 000 - - -
KP 1 H-20 1 Aral Aralub HLP 1 Energrease LS-EP 1 - Beacon EP 1 RENOLIT Duraplex EP 1 Mobilux EP 1 Longtime PD 1 - Tribol 4020/220-1 Oest Mehrzweckfett LT 1EP
Schmierfette Wälzlager
Grease Antifr.Bearings
RENOLIT Duraplex EP2 Alvania EPLF 2

KP 2 H-20 2 Aral Aralub HLP 2 Energrease LS-EP 2 Speerol EPL 2 Beacon EP 2
RENOLIT FEP 2
Mobilux EP 2 Longtime PD 2
Alavania WR 2
Tribol 4020/220-2 Oest Mehrzweckfett LT 190 EP
RENOLIT Duraplex EP 3
KP 3 H-20 3 Aral Aralub MKL 3 Energrease LS-EP 3 - Beacon EP 3
RENOLIT FEP 3
Mobilux EP 3 Olista Longtime 3 - - -
KPHC1 1 H-20 1 - - - - - - Obeen UF 1 - - -
KPHC1 2 H-20 2 - - - - - Mobilgrease FM 462 Obeen UF 2

Cassida EPS 2
Cassida HDS 2
- -
KPHC1 3 H-20 3 - - - - - - Obeen UF 3 - - -

1 Vollsynthetischer Schmierstoff, physiologisch unbedenklich, USDA H1 registriert / Syntehic Lubricant USDA H1 approved
Ernst-Heckelstr. 1, 66386 St. Ingbert-Rohrbach
Postfach 4260, 66377 St. Ingbert-Rohrbach
Tel.(06894)599-0
Telefax (06894)599-468
E-Mail: info.industrial-solutions@thyssenkrupp.com
http://www.thyssenkrupp-industrial-solutions.com
Montage, Einstellung und Wartung B 06 20 134 E-DE-EN
Mounting, Adjustment and Maintenance Seite / page 1/6
für Trommelbremsen TE nach DIN 15 435 mit externer Bremsfeder
of drum brakes TE according to DIN 15 435 with external brake spring 08.2001
Bezeichnungen einer Trommelbremse Nur gültig in Verbindung mit

Allgemeine Hinweise
Components of Drum Brake Valid in connection only with

General Notes
B 06 20 176 E
Anhand Bild 1 sollen die wesentlichen Bauteile einer Trommelbremse erläutert werden:
For essential components of drum brake please see picture 1 and find the following explanations:
Zugstange Nachstellung
tension rod readjusting unit
Zuglasche Winkelhebel
shackle knee lever
Bremshebel Federrohreinheit
brake lever spring tube componentry
Bremsbacke mit Bremsbelag Lüftgerät

brake shoe c/w lining thruster
Grundplatte
base plate
Bild / picture 1
Grundplatte: Mit vier Befestigungsbohrungen, deren Durchmesser und Abstände nach DIN genormt sind,
wird die Bremse auf der Unterkonstruktion befestigt.
base plate: With four mounting holes, which positions are standardized according to DIN,
the brake is mounted on a base frame or construction.
Bremshebel: Umschliessen mit den gelenkig gelagerten Bremsbacken die Bremstrommel und
übertragen in Verbindung mit Zugspindel und Winkelhebel die Bremskraft.
brake lever: Hinged with the brake shoes, they surround the brake drum and in connection with pull rod and
knee-lever they apply the braking force is generated by the torque spring.
Federrohr: Besteht aus Rohr, Spindel, Feder, Kolbenplatte und Bremsmomentskala.
Durch die einstellbare Feder wird die Bremskraft übertragen.
spring tube: Consists of tube, rod, torque spring, piston plate and torque-scale.
The adjustable braking force is generated by the torque spring.
Lüftgerät: Dient zum öffnen der Bremse und arbeitet gegen die Federkraft. Die zum lüften benötigte Energie wird
entweder elektro-hydraulisch, elektrisch über Magnet, hydraulisch oder pneumatisch erzeugt.
Am weitesten verbreitet sind die elektro-hydraulischen Lüftgeräte. Sie bieten aufgrund der robusten und
thruster:
betriebsicheren Bauweise in den meisten Einsatzfällen die beste Lösung.
Is used to open the brake and is acting against the spring force. The energy, required for release, is
generated by electro-hydraulic, electric with solenoid, hydraulic or pneumatic. The most common
thrusters are the electro-hydraulic ones. Due to the robust and safe construction the electro-hydraulic
thruster is the best solution in most of the cases.
Zugspindel: Sie ist das mit am höchsten beanspruchte Bauteil der Bremse,
da die gesamte Bremskraft hierüber auf die beiden Bremshebel übertragen wird.
Bei allen SIBRE Bremsen ist die Zugspindel aus rostfreiem Material mit gerolltem Gewinde gefertigt.
pull rod: Its function is to transmit the braking force to the two brake levers,
and therefore it is the most stressed component of the brake.
All SIBRE brakes the pull rod is made of stainless steel with a rolled thread.
Zuglasche: Die Zuglasche bildet die Verbindung zwischen Zugspindel und dem vom Lüftgerät abgewandten
Bremshebel. Die Zuglasche kann auch durch eine Bolzenverbindung ersetzt sein.
shackle: The shackle is the hinge between pull rod and the brake lever. The shackle could be a pin-junction as well.
Nachstell- Die Nachstellung dient zum Ausgleich des Belagverschleiss, ist aber im Nachstellweg je Bremshub
ung: begrenzt. Daher ist je nach Anwendungsfall eine zusätzliche manuelle Verschleissnachstellung vom

Wartungspersonal durchzuführen.
readjusting The readjusting unit is used for compensation of lining wear, however its compensation capacity per
unit: braking cycle is limited. Therefore an additional manual wear compensation carried out by maintenance
personnel is requested according to the specific application.
Winkelhebel: Am Winkelhebel sind die Federrohreinheit und das Lüftgerät befestigt. Hier findet die Kraftübersetzung
von grossem Feder- oder Lüftweg und kleiner Kraft auf kleine Wege am Bremshebel und hohe Kräfte statt.
knee lever: Spring tube component and thruster are mounted to the knee-lever. Here, the transformation from large
stroke and small force into small stroke and high force is realized.
Siegerland Bremsen Fon: +49 (0)27 73 / 9400-0
Auf der Stücke 1 - 5 Fax: +49 (0)27 73 / 9400-10
35708 HAIGER e-mail: info@sibre.de
GERMANY internet: http://www.sibre.de
h:\documentation\pmd-documentation\030 drum brakes\010 TE\DE-EN TE 08-01.pmd
B 06 20 134 E-DE-EN Montage, Einstellung und Wartung
Seite / page 2/6 Mounting, Adjustment and Maintenance
08.2001 of drum brakes TE according to DIN 15 435 with external brake spring
Nur gültig in Verbindung mit

Allgemeine Hinweise
Valid in connection only with
Resthubeinstellung General Notes
B 06 20 176 E
Bild / picture 2 Adjustment of Reserve Stroke
Zugstangenstellmuttern
connecting rods Der Resthub muss bei geschlossener und eingebauter Bremse
adjusting nut eingestellt werden. Dabei sollte das Lüftgerät zunächst ganz
eingefahren und dann durch drehen an der
Zugstangenstellmutter auf 20% (ca. 10 mm) des Gesamthubs
herausgezogen werden.
Die Gesamthublängen sind jeweils im Abschnitt Lüftgeräte
angegeben.
The reserve stroke must be adjusted when brake is mounted
on the base frame and in closed position. First, set thruster
piston to its lower end position and afterwards lift the piston by
turning the tension rod adjusting nut, until piston is lifted by
20% (approx. 10 mm) of total stroke.
For total stroke values please see chapter technical data.
Das Maß X ist zeichnerisch nicht verbindlich. Es dient lediglich

Bremsbackenbolzen Bemsbackenklemmfeder
als Hinweis, wo der Resthub gemessen werden kann.
brake shoe pin brake shoe clamping spring
The dimension X is constructional not relevant. It just shows

an example, where reserve stroke can be measured.
Durch den Resthub wird verhindert, dass die Bremse "auf Block" fährt und
keine Bremskraft an der Trommel erzeugt.
The reserve stroke avoids, that the brake is "on block" position and
no more braking force is generated on the drum.
Achtung:
* Wird kein Resthub eingestellt, kann dies zum Versagen der Bremse führen.
Caution:
Non-adjustment of reserve stroke may lead to a failure of brake function.
Achtung:
Auch bei Bremsen mit Nachstellung ist eine ständige Kontrolle des Resthubs in jedem Fall erforderlich.
* Je nach Anwendungsfall muss eine zusätzliche manuelle Verschleissnachstellung erfolgen.

Caution:
Also for brakes with readjusting unit a continous control of reserve stroke is indispensible.
Depending on the application, an additional manual compensation of lining wear is requested.
Bei Bremsen mit zusätzlicher Notlüftung und/oder hydraulischer Verzögerung ist darauf zu achten,
dass auch diese Zusatzeinrichtungen mit entsprechendem Resthub eingestellt werden.
In case of brakes fitted with additional hydraulic damping and/or an additional emergency release,
it is essential, that the reserve stroke of these optional features is adjusted as well.


Die Montage der Bremse wird in radialer Richtung Allgemeine Hinweise
wie folgt durchgeführt General Notes
B 06 20 176 E
The Installation of the brake from one side of the

brake drum is accomplished as follows
Bild / picture 3
Lüftgerät
thruster
Brems-
hebel
brake-
1.Bremsbackenabstand durch drehen der
lever
Zugstangenstellmutter auf Maß 5 mm größer
als Bremstrommeldurchmesser stellen.
Adjust brake shoe clearance to 5 mm larger than
brake drum diameter,
by turning the connecting rod adjusting nut.
2.Grundplattenbolzen 1 aus dem

Bremsbackenhebel ziehen.
Pull base plate pin 1 out of brake arm.
Grundplattenbolzen 1 Grundplatte
base plate
` 3.Bremsbackenhebel hochschwenken.
Swing brake arm upwards.
base plate pin 1
` 4.Grundplatte unter der Bremstrommel durchschieben.

Push base plate underneath brake drum.
5.Bremse in radialer und axialer Richtung

Bild / picture 4 mittig ausrichten.
Line-up brake in working position ( adjust brake
approximately in radial and axial directions ).
6.Bremsbackenhebel wieder zurückschwenken und

durch Grundplattenbolzen 1
` mit der Grundplatte verbinden.
Swing down break arm and fix to base plate with
base plate pin 1.
7.Lüftgerät einbauen.
Install release thruster.
8.Grundplatte befestigen.
Fix base plate.
Bild / picture 5
* 9.Maximal zulässige Abweichung zu den
Bremsenachsen +/- 0,3 mm .
Â Permissable misaligument for all brake axles:
max. +/- 0.3 mm .
connecting rods adjusting nut
Zugstange
tie rod

Bei der Einstellung der Bremse geht man wie folgt vor Nur gültig in Verbindung mit
Allgemeine Hinweise
The adjustment of the brake is accomplished as follows Valid in connection only with
General Notes
1.Lüftgerät
B 06 20 176 E
Bild / picture 6 ausschalten ( Bremse eingefallen )
Resthub X 20% des Switch off release thruster ( close brake ).
Zugstangenstellmuttern Gesamthubes (ca. 10 mm)
connecting rods reserve stroke X 20% of
adjusting nut 2.Durch drehen der Zugstange an der Zugstangenstellmutter
max. storke (approx. 10mm)
Lüftgerät-Resthub X einstellen ( Bild 6 ).
Adjust release thruster reserve stroke X by turning
the connecting rod adjusting nut ( picture 6 ).
3.Durch drehen der Federstellmutter gewünschtes

Bremsmoment an der Skala einstellen
( Oberkante Federdruckteller = Bezugskante ) und
gegebenenfalls Lüftgerät-Resthub X korrigieren ( Bild 6 +7 ).
Adjust desired braking torque by turning the spring adjusting nut.

The torque is indicated on scale ( using top edge of bottom
spring plate as reference point ).
Bild / picture 7 If necessary, adjust release thruster reserve stroke X
Federstellmutter
spring adjusting nut ( picture 6+7 ).
4.Einstellung der gleichmässigen Backenlüftung entfällt durch

Skala Verwendung einer Drehkopplung ( Bild 8 ), d. h.:
scale - gleichmässiger Luftspalt an beiden Bremsbacken
Federrohr - Justierung der Bremse bei Montage
spring tube - keine Anschläge an den Bremsbackenhebeln
- stabiler Stand der gelüfteten Bremse, auch bei
Belagverschleiss
The adjustment of the equal clearance is no longer
necessary due to the brake shoe synchronisation linkage
( picture 8 ) i.e.:
Bild / picture 8 - equal clearance of both brake shoes
- centering of the brake during installation
Drehkopplung - a stable configuration of the lifted brake even after brake
Synchronisation
linkage
- shoe wear, adjustable end stops on brake arms are eliminated
Einstellen der Nachstellung

Adjust compensator unit
( Bild / picture 9 )
Bild / picture 9 Stellschraube
adjustment screw
`
1.Mitnehmerschraube der Nachstellung in der
Mitnehmerbohrung ganz nach unten drücken.
Kontermutter
lock nut Push driving pin down in guide hole as far as it can go.
2.Stellschraube im Winkelhebel so weit zurückdrehen,
Mitnehmerschraube
driving pin
bis die Mitnehmerbohrung frei ist.
Return adjustment screw in the brake lever
Mitnehmerbohrung until guide hole is exposed.
guide hole 3.Bremse mehrmals lüften und wieder einfallen lassen, die
Mitnehmerschraube der Nachstellung ist jetzt positioniert.
Lift brake lever several times fully (with release thruster)
and close again.
Achtung: 4.Stellschraube im Winkelhebel wieder so weit eindrehen,
Die Nachstellung dient zum Ausgleich des Belagverschleiss,
ist aber im Nachstellweg je Bremshub begrenzt. dass ein kleiner Luftspalt von etwa 0,2 mm zwischen
Daher ist je nach Anwendungsfall eine zusätzliche manuelle
Verschleissnachstellung vom Wartungspersonal durchzuführen. Stellschraube und Mitnehmerschraube vorhanden ist,
Kontermutter anziehen ( Bild 9 ).
Caution:
The readjusting unit is used for compensation of lining wear, Turn adjustment screw in brake lever down until there is a
however its compensating capacity per unit braking cycle is
limited. Therefore an additional manual wear compensation carried small split of approximately 0.2 mm between adjustment
out by maintenance personnel is requested according to the screw and driving pin, tighten lock nut ( picture 9 ).
specific application.


Bremsbackenwechsel Allgemeine Hinweise
Replacement of the brake shoes General Notes
B 06 20 176 E
Der Bremsbackenwechsel kann ohne Zerlegen der Bremse erfolgen:

The shoes are replaced without dismantling the brake.
Proceed as follows:
1. Zugstange durch drehen an der Zugstangenstellmutter so weit aus der Verschleissnachstellung

herausschrauben, dass sich die neuen Bremsbacken montieren lassen.
Unscrew connecting rod out of the readjusting unit by turning the connecting rod adjusting nut
until the new brake shoes can be installed.
2. Bremsbackenklemmfedern entspannen und Bremsbackenbolzen entfernen ( Bild 10 ) .

Release brake shoe clamping spring and remove brake shoe pins ( picture 10 ) .
` 3. Bremsbacken nach oben herausschwenken.

Lift brake shoe upwards and out.
4. Neue Bremsbacken in umgekehrter Reihenfolge montieren.

Install new brake shoes in reverse order.
5. Bremsbackenklemmfeder wieder spannen.

Refit clamping spring.
6. Readjust
Bremse neu einstellen.
brake.
Bild / picture 10
Ersatzteilliste / Spare Parts List Nur gültig in Verbindung mit

Allgemeine Hinweise
6 8 General Notes
B 06 20 176 E
1 5
3 7
Pos. / pos. Benennung / description

1 Bremsbacke komplett / brake shoe complete
2 Bremsbelag mit Niet / brake lining with rivets
3 Bolzen komplett / pin complete
4 Buchsen komplett / bushing complete
5 Federeinheit komplett / spring in tube complete
6 Zugspindel mit Zuglasche / tension bracket with rod
7 Lüftgerät / thruster
8 Verschleißnachstellung / lining wear compensator
Bei Bestellung von Ersatzteilen bitte angeben / when ordering spare parts, please advise :
vollständige Bremsenbezeichnung, z.B. für TE 400/ 80/6

complete brake ident-no., e.g. for TE 400/ 80/6
Fabr.Nr. lt. Typenschild, z.B. 009576

Fabr.No. acc. to name plate, e.g. 009576
Menge, Position und Benennung, z.B. 2 Stck. Pos. 6, Zugspindel mit Zuglasche
Quantity, position and description, e.g. 2 pcs. pos. 6 , tension bracket with rod

T1-2.3
S2-10.5
Drum Brakes TE 160
M 1501 293 E-EN-2002-11
spring applied, thruster released
Page 1 / 2
When ordering please advice:

- order-no., e.g. for TE 160/220/50
- power supply voltage of thruster
- with or without autom. wear compensator
- optional features such as limit switch manual release,
drum, coupling, covering cap
Mbr. (Nm) torque

Brake type
No. Thruster unit µ = 0,4 A B C H
TE 160/120/40 1 EB 120/40 45 - 125 575 110 73 395
TE 160/220/50 2 EB 220/50 55 - 230 610 162 100 400
Alterations reserved
SIBRE Siegerland-Bremsen GmbH – Auf der Stücke 1-5 – D-35708 Haiger, Germany
Tel.: +49 2773 94000 – Fax: +49 2773 9400-10 – e-mail: info@sibre.de – www.sibre.de
P:\CATALOGUES\EN CATALOGUES\DOC-CATALOGUE\08 TE Drum Brakes\T1-2.3 EN TE 160 2002-11.doc
T1-2.4
S2-10.5
Drum Brakes TE 160
M 1501 293 E-EN-2002-11
Page 2 / 2
The drum brake TE 160 offer a particularly usability for compact-drives, e. a. vertical
mounting, travel drives. Our scope of supply is beneath the brake also mounting console
for adapting gearbox and motor as well as coupling/brake-drum and steel-cover.
Originalbetriebsanleitung
Allgemeine Hinweise B 06 20 176 E-DE-EN

Seite / page 1/8
General Notes 03.2006
1. Allgemeines / General Notes

Die vorliegende Betriebsanleitung ( BA ) ist Bestandteil der Bremsenlieferung.
Sie sollte stets in der Nähe der Bremse aufbewahrt werden.
Nur eine genaue Kenntnis der BA gewährleistet einen störungsfreien Betrieb der Bremse.
Es liegt daher im Interesse unseres Kunden, dass die BA von den für den Transport, die Montage und Bedienung
Verantwortlichen gelesen, verstanden und in allen Punkten beachtet wird.
This Operation Manual ( OM ) forms an integral part of the brake delivery and therefore
should be kept next to the brake.
Only a detailed reading of this OM ensures troublefree operation of the brake.
Therefore, it is in our clients interest to make sure that the personnel in charge of maintenance
read and understand this OM very carefully and follow all instructions.
Hinweis / Notice : Für Schäden und Betriebsstörungen, die aus der Nichtbeachtung der BA resultieren,
übernehmen wir keine Haftung.
We assume no liability for damages or interruptions to operation
occuring due to non-observance of this OM .
Die in dieser BA behandelte Bremse ist für den stationären Einsatz in allgemeinen Kraft-und
Arbeitsmaschinen ausgelegt worden.
The brake referred to in this OM was designed for stationary operation in general power engine and
machinery applications.
Die Bremse darf nur unter Beachtung der von uns angegebenen "Technischen Leistungsmerkmale"
eingesetzt werden.
Diese sind entweder in unseren Technischen Datenblättern enthalten oder wurden durch unsere Verkaufsabteilung
vertraglich zugesichert. Bei Nichtbeachtung ist die Haftung durch uns ausgeschlossen.
The brake must be operated only under observance of our "technical capacity characteristics" directions.
These are either included in our technical data sheets or were contracted with our sales department.
In case of non-observance we assume no liability.
Die hier beschriebene Bremse entspricht dem technischen Stand zum Zeitpunkt der Drucklegung dieser BA .
The brake described in this OM constructed to state of the art technology at the time of printing.
Im Interesse der Weiterentwicklung behalten wir uns das Recht vor, Änderungen vorzunehmen,
die unter Beibehaltung der wesentlichen Merkmale zur Steigerung ihrer Leistungsfähigkeit und
Sicherheit für zweckmäßig erachtet werden.
We reserve the right to make alterations for further development,
which take account of the essential criteria required to increase capacity and safety.
Das Urheberrecht an dieser BA verbleibt bei der Firma SIBRE Siegerland-Bremsen GmbH.
Die BA darf ohne unsere Zustimmung weder vollständig noch teilweise vervielfältigt,
zu Zwecken des Wettbewerbs unbefugt verwertet oder Dritten zur Verfügung gestellt werden.
The copyright of this OM remains in the hands of SIBRE Siegerland-Bremsen GmbH .
This OM must not be reproduced either in part or complete, used for purposes of competition,
handed over to any third party without our written permission.
Wenden Sie sich bitte mit allen technischen Fragen an unser Unternehmen.
Please contact our head office for any technical questions.
Siegerland Bremsen
Auf der Stücke 1- 5
35 708 HAIGER
GERMANY
Fon: +49 (0)2773 / 9400 - 0

Fax: +49 (0)2773 / 9400 - 10 Siegerland Bremsen Fon: +49 (0)27 73 / 9400-0
e-mail: info@sibre.de Auf der Stücke 1 - 5 Fax: +49 (0)27 73 / 9400-10
internet: http://www.sibre.de 35 708 HAIGER e-mail: info@sibre.de
h:\documentation\pmd-documentation\010 general notes\DE-EN GENERAL NOTES 03-06.pmd
B 06 20 176 E-DE-EN
Seite / page 2/8
Allgemeine Hinweise
03.2006 General Notes
2. Sicherheitshinweise / Safety Notes
- Die Bremsen sind zur Erfüllung von sicherheitstechnischen Aufgaben in der Gesamtanlage ausgelegt und
hergestellt. Aufgrund dieser wichtigen Funktion setzen wir voraus, dass das Wartungs-, Service- und
Instandhaltungspersonal unserer Kunden beziehungsweise des Endbetreibers der Gesamtanlage oder
der Bremsen über alle grundsätzlichen Kenntnisse im Umgang mit sicherheitsrelevanten Bauteilen verfügt.
- The brakes are designed and manufactured for the fulfillment of safety-relevant tasks for the complete equipment.
Due to this important function we assume that our clients and the plant owners or brake owners service and
maintenance personnel at site are aware of the basic rules for handling of safety relevant components.
Hierzu gehören insbesondere : / Especially, but not limited to :

> geeignete Ausbildungsqualifikation.
> suitable qualifications.
> geeignete Werkzeuge, Messmittel und Hilfsstoffe.

> suitable tools, measuring instruments and devices.
> Kenntnisse über die allgemeinen Unfall-Verhütungs-Vorschriften ( UVV ) .

> knowledge of the general rules for prevention of accidents.
> Kenntnisse über die jeweils für die Anlage gültigen besonderen UVV .
> knowledge about the plant-specific rules for prevention of accidents.
> Kenntnisse über die Betriebsvorschriften und den Betriebsablauf der Gesamtanlage.
> knowledge of the operating instructions and the plant operating process.
> Kenntnisse im Umgang und Betrieb elektrischer und hydraulischer Anlagen und deren UVV .
> knowledge of handling of electric and hydraulic components and the relevant rules
for prevention of accidents.
> Kenntnisse im Umgang mit Hebezeugen.

> knowledge of handling of lifting equipment.
> Kenntnisse im Umgang mit gefährlichen Stoffen.

> knowledge of handling of dangerous goods.
> Kenntnisse der einschlägigen Umweltschutzvorschriften.

> knowledge of the appropriate rules for environmental protection.
- Die Bremse ist nach dem neuesten Stand der Technik gebaut und wird betriebssicher ausgeliefert.
Eigenmächtige Veränderungen, die die Betriebssicherheit beeinträchtigen, sind nicht zulässig.
- The brake is manufactued according to the latest state of the art of technology and is supplied as an
operationally reliable unit. Unauthorized alterations influencing the operational safety are forbidden.
Dies sind insbesondere, jedoch nicht ausschließlich : / Such alterations especially, but not limited to :
< Lösen von Bolzen und Schraubenverbindungen.
< loosening of bolt and screw connections.
< Entfernen von Zusatzeinrichtungen ( z.B. Endschalter, Schutzvorrichtungen, usw. ).

< removing optional features such as limit switches, protection devices, etc. .
< in zusammengebautem Zustand Behandlung durch Farben, Lacke, Öle, Konservierungsmittel.

< treatment with paint, coatings, oils and rust protectors when assembled.
< spanabhebende, formändernde oder mechanische Behandlung von Bauteilen

der Bremse.
< machining, shaping or other mechanical treatment Siegerland Bremsen Fon: +49 (0)27 73 / 9400-0
of brake components. 35 708 HAIGER e-mail: info@sibre.de
Seite / page 3/8
- Die Bremse darf nur im Rahmen der im Leistungs- und Liefervertrag festgelegten Bedingungen eingesetzt werden.
- The brake must be exclusively used according to the conditions stipulated in the performance and delivery
contract.
- Der Kunde hat dafür zu sorgen, dass die mit der Montage, dem Betrieb, der Pflege und Wartung sowie der
Instandsetzung beauftragten Personen die BA gelesen und verstanden haben und
diese in allen Punkten beachten, um :
- The client must ensure that the personnel in charge of mounting, operation, service, maintenance and
repair works have read and understood the OM and will follow its instructions in detail in order to:
* Gefahren für Leib und Leben des Benutzers und Dritter abzuwenden.
* avoid any risk to life and limb of the operater and any third party.
* die Betriebssicherheit der Bremse sicherzustellen.

* ensure the operational safety of the brake.
* Nutzungsausfall und Umweltbeeinträchtigungen durch falsche Handhabung auszuschließen.

* exclude interuptions of working process and environmental damage due to incorrect handling.
* Beim Transport, der Montage und Demontage, der Bedienung sowie Pflege und Wartung, sind die
einschlägigen Vorschriften zur Arbeitssicherheit und zum Umweltschutz zu beachten.
* During transport, assembly and disassembly, operation and service / maintenance, the relevant
regulations for prevention of accidents and environmental damage must be taken into account.
* Die Bremse darf nur von autorisiertem, ausgebildetem und eingewiesenem Personal bedient,
gewartet beziehungsweise instandgesetzt werden.
* Only authorized, trained and practiced personnel are permitted to operate, maintain and repair the brake.
* Alle Arbeiten sind sorgfältig und unter dem Aspekt "Sicherheit" durchzuführen.
* All work must be done carefully and in full consideration of safety aspects.
* Arbeiten an der Bremse dürfen nur bei Stillstand durchgeführt werden. Das Antriebsaggregat muss gegen
unbeabsichtigtes Einschalten gesichert werden ( z.B. durch Abschließen des Schlüsselschalters
oder das Entfernen der Sicherungen in der Stromversorgung ). An der Einschaltstelle ist ein Hinweisschild
anzubringen, aus dem hervorgeht, dass an der Bremse gearbeitet wird.
* All work on the brake must be done during standstill. The drive unit must be secured against unintentional
switching on, e.g. by locking the key switch or removal of fuse in power supply.
At switching point, a sign must be attached giving notice that the brake is being serviced.
* Das Antriebsaggregat ist sofort außer Betrieb zu setzen, wenn während des Betriebes Veränderungen an der
Bremse festgestellt werden, wie z. B. veränderte Laufgeräusche.
* The drive unit must be shut down immediately when alterations to the brake are noticed during operation,
e.g. unusual operating noises.
* Die Bremse muss durch entsprechende Schutzvorrichtungen gegen Berühren gesichert sein.
* The brake must be secured against unintentional contact by means of suitable protectors.
* Beim Einbau der Bremse in Geräte oder Anlagen ist der Hersteller der Geräte oder Anlagen dazu verpflichtet,
die in dieser BA enthaltenen Vorschriften, Hinweise und Beschreibungen
mit in seine Betriebsanleitung aufzunehmen.
* When mounting the brake in equipment or plants, the manufacturer of such equipment or plant is obliged to
include the instruction, restrictions and descriptions of this OM in their operating manual.

35 708 HAIGER e-mail: info@sibre.de
B 06 20 176 E-DE-EN
Seite / page 4/8
Allgemeine Hinweise
3. Hinweiskennzeichnung in der Betriebsanleitung /

Explanation of symbols used in Operation Manual
In der BA enthaltene wichtige Anweisungen, die die Sicherheit sowie den Betriebsschutz
betreffen, sind wie folgt besonders hervorgehoben :
The OM contains important instructions relating to saftey and operational protection.
These are marked as follows :
Empfehlung :
Schrauben DIN 933 Festigkeitsklasse 8.8 oder höher einsetzen.
Vor Inbetriebnahme und Probelauf müssen diese fest angezogen sein.
Recommendation :
Use screws DIN 933, property class 8.8 or higher.
These must be tightened properly prior to commissioning and testing procedure.
Konterung nicht lösen, ansonsten kann dies zu Fehlfunktionen der Bremse führen.
Do not unlock. Danger of brake failure.
Nach dem Einstellen Kontermutter wieder anziehen, ansonsten

kann dies zu Fehlfunktionen der Bremse führen.
Re-lock after adjustment. Danger of brake failure.
G Dieses Zeichen weist auf Einstellungen hin, bei deren Nichtbeachtung

Personen- oder Sachbeschädigungen eintreten können.
Non-observance of adjustments marked with this symbol may result in
personal or material damage.
3 Einschlägige elektrische, hydraulische und pneumatische

Unfall-Verhütungs-Vorschriften ( UVV ) beachten.
Follow the relevant rules for prevention of accidents for electrical,
hydraulical and pneumatical equipment.
2 Einstellanweisung befolgen.
Follow the adjustment instructions.
S Umweltschutzvorschriften beachten.
Follow the regulations for enviromental protection.
y Quetschgefahr.
Danger of crushing.
Ü Geeignete Werkzeuge oder Messinstrumente verwenden.

Use suitable tools and measuring instruments.

Seite / page 5/8
4. Kundenseitige Bremsenmontage, Einstellung und Inbetriebnahme /

Adjustment and Installation made by the customer
Die SIBRE Bremsen werden als funktionsfähige, komplett montierte Einheiten ausgeliefert.
Da Montage, Einstellung und Inbetriebnahme dem jeweiligen Anwendungsfall angepasst werden müssen,
sind vom Kunden folgende Punkte durchzuführen :
SIBRE brakes are supplied as fully functional, completely assembled unit.
As assembly, adjustment and commissioning must be adapted to the actual conditions of use,
the following points must be carried out buy the customer :
1. Einbau der Bremse auf die Unterkonstuktion.

2 Installation of the brake on the base frame.
3 2. Anschluss des Lüftgerätes ( elektrisch, hydraulisch, pneumatisch ).

Connection of the release unit ( electrical, hydraulic, pneumatic ).
3. Einstellung der gewünschten Bremskraft.

Adjustment of the required braking torque.
4. Einstellung der Hebel- und Bremsbackenanschläge, sofern keine Backenklemmfeder

und Drehkopplung vorhanden ist.
Adjustment of lever and brake shoe limit stoppers, if brake shoe clamping springs
and synchronisation linkage are not fitted to the brake.
5. Einstellung des Resthubs des Lüftgerätes.

Reserve stroke adjustment of release unit.
6. Einstellen der Bremsbelag-Verschleiß-Nachstellung.

Adjustment of brake pad wear compensator unit.
2
7. Einstellung von Zubehörteilen wie Endschalter, Handlüftungen und Zusatzlüftzylinder.
Adjustment of optional features such as limit switches, manual release devices,
additional release cylinders.
3 8. Einschleifen der Bremsbeläge, Tragbild muss bei Volllastbetrieb 70% betragen.

Running in procedure of linings. Contact pattern must be minimum 70% for operation and full load.
9. Probelauf und Kontrolle der Inbetriebnahmepunkte.

Testing operation and check-up of installation.
Achtung:
G Die Bremse wird immer als funktionsfähige Einheit ausgeliefert, ist jedoch niemals im
Auslieferungszustand ohne kundenseitige Einstellung betriebsbereit.
CAUTION:
G The brake is always supplied as an operative unit, but is never ready for operation without
adjustments carried out on site by the client's maintenance personnel.
Für alle Fragen zur Montage und Einstellung stehen unsere MitarbeiterInnen für Beratungen zur Verfügung.
Auf Wunsch können die Montage- und Einstellarbeiten auch durch uns ausgeführt werden.
If you have any questions regarding mounting and adjustment please do not hesitate to contact our
specialists, either at one of our agencies or directly at Haiger.

B 06 20 176 E-DE-EN
Seite / page 6/8
Allgemeine Hinweise
5. Probelauf / Testing Procedure
Nach sachgemäßer Durchführung und Beachtung aller Anweisungen kann ein Probelauf erfolgen.
After all instructions have been carried out and correct installation is complete a testing procedure
can be carried out.
Achtung / Caution
- es müssen alle Punkte ausgeführt sein.
- all instructions must have been carried out.
- es dürfen nur Einstellungen an den in der BA angegebenen Teilen vorgenommen werden.
- adjustments must be made only to parts mentioned in the OM.
- die einzelnen Punkte sind jeweils zu überprüfen.
- every individual step must be re-checked.
Vor der endgültigen Inbetriebnahme muss ein Probelauf durchgeführt werden.

Prior to final commissioning, a testing procedure must be accomplished.
Dabei ist wie folgt vorzugehen : / Proceed as follows :

1. Schritt / 1st. step
Mindestens 20 Bremszyklen ohne Last.
Dabei muss die Bremse gegen die drehende Trommel / Scheibe arbeiten.
Dies dient insbesondere auch zum einschleifen der Bremsbeläge.
Diese müssen ein Tragbild von mindestens 70% haben.
Insbesondere bei Hubwerken, wo die Bremsen überwiegend als Haltebremsen und nur im Notaus als
Stoppbremse arbeiten, ist das einschleifen der Bremsbeläge erforderlich.
Wird dies nicht durchgeführt, kann die Last durchrutschen !
Minimum 20 braking cycles without load. The brake must be working against the rotating drum / disc.
This procedure is particularly for running in the linings. The lining contact pattern must be at least 70% .
The running in of linings is of special importance particularly in hoisting mechanisms, where the brakes are
mostly used as holding brakes and only as stopping brakes in cases of emergency stop.
If this is not carried out the load may slide down !
2. Schritt / 2nd. step
Mindestens 100 Bremszyklen mit halber Nennlast.
Dabei muss die Bremse ebenfalls gegen die drehende Trommel / Scheibe arbeiten.
Minimum 100 braking cycles with 50% of nominal load.
Again, the brake must be working against the rotating drum / disc.
3. Schritt / 3rd. step
Mindestens 20 Bremszyklen bei Volllast. Die Bremse muss hierbei wie im späteren Dauerbetrieb arbeiten.
Minimum 20 braking cycles with full load. The brake must be working as in continuous operation.
Während des 1., 2. und 3. Schrittes müssen folgende Punkte ständig kontrolliert werden:
During carrying out of steps 1., 2. and 3. the following points must be constantly checked:
- Kontrolle des Resthubes am Lüftgerät - check of thruster reserve stroke
- optische Kontrolle Bremsbelag ( Tragbild ) - optical check of brake lining ( contact pattern )
- Kontrolle der Belag-Verschleiß-Nachstellung - check of pad wear compensator unit
- Kontrolle der Anbauteile - check of optional features
- Kontrolle der Schraubenverbindungen - check of bolted connections
- auf Laufgeräusche achten - listen to operating noises
Die Kontrollergebnisse sind in einem Probelaufprotokoll aufzunehmen. Werden Abweichungen zu den Punkten
der BA festgestellt, kann keine Inbetriebnahme der Bremse erfolgen. Die Abweichungen sind zu korrigieren
und der Probelauf muss mit Schritt 1 neu begonnen werden.
The results of this procedure must be written down in a testing procedure log. If differences to points
contained in this OM are noted the brake cannot be accepted. Differences must be corrected and the
testing procedure must be carried out again from point 1. .
Nach Beachtung dieser Punkte und Sicherstellung aller Bremsenfunktionen

kann die Inbetriebnahme vorgenommen werden. Siegerland Bremsen Fon: +49 (0)27 73 / 9400-0
After observance of these points and checking of all Auf der Stücke 1 - 5 Fax: +49 (0)27 73 / 9400-10
brake functions the commissioning can be carried out. 35 708 HAIGER e-mail: info@sibre.de
Seite / page 7/8
6. Wartungs- und Inspektionsintervalle /
Maintenance and Inspection Intervals
Alle SIBRE Bremsen sind durch ihre robuste Bauweise für den langlebigen Einsatz unter höchsten
Einsatzbedingungen geeignet.
Durch die ausgebuchsten Lagerstellen, die Bolzen aus rost- und säurebeständigem Material,
die Edelstahlspindeln und die verzinkten DIN-Teile, garantiert die SIBRE Bremse bei geringer
Pflege und sachgemässer Behandlung einen sicheren Betrieb über viele Jahre.
Due to their robust construction, all SIBRE brakes are suitable for long lasting operation
under the hardest operating conditions.
All bearings and linkages are bushed as far as necessary, pins are made of rust and acid-resistant steel,
rods made of stainless steel and all DIN-parts are galvanized. These high qualitiy materials ensure that the
SIBRE brakes can operate safely over long periods with minor maintenance and correct handling.
G
Vom Hersteller sind zur Einhaltung der Betriebssicherheit folgende Kontrollen vorgeschrieben:
In order to maintain the operational safety of the brake, the manufacturer stipulates that the
following inspections are carried out:
TÄGLICHE KONTROLLEN / DAILY CONTROL
* Optische Kontrolle der Bremsbeläge sowie der Trommel / Scheibe.
* visual check of brake linings and brake drum / disc.
* Resthubkontrolle am Lüftgerät bei geschlossener Bremse.
* check of reserve stroke with brake in closed position.
* eingestelltes Bremsmoment bei geschlossener Bremse.
* check of adjusted brake torque with brake in closed position.
* Kontrolle der Hebel-Einstellschrauben bei geöffneter Bremse
( durch ziehen am Hebelgestänge --> Bremse darf nicht instabil sein ).
* check of lever adjustment bolts with brake in released position
( by pulling on lever --> brake must not be instable ).
G BEI ANLAGEN MIT HOHER SCHALTHÄUFIGKEIT SIND DIESE KONTROLLEN BEI JEDEM
SCHICHTWECHSEL VORZUNEHMEN
ON PLANTS WITH A HIGH OPERATING FREQUENCY, THESE CHECKS MUST BE DONE
AFTER EACH SHIFT
WÖCHENTLICHE KONTROLLEN ( zusätzlich ) / WEEKLY CONTROL ( additional )
G * Sichtkontrolle aller Schrauben und Bolzenverbindungen.

* visual check of screw and bolt connections.
* Kontrolle aller Anbauteile ( Endschalter, Handlüftungen usw. ) .
* check of optional features ( limit switches, manual release etc. ) .
S * Ölstandkontrolle bei Hydraulikanlagen.

* check of hydraulic unit oil level.
QUARTALSWEISE KONTROLLEN ( zusätzlich ) / QUARTERLY CONTROL ( additional )
2 * Komplett-Kontrolle der gesamten Bremse.

* complete check of entire brake system.
3
* Prüfung der elektrischen Anschlussleitungen.
* check of power supply wiring.
* Kontrolle der hydraulischen oder pneumatischen Verrohrung.
S * check of hydraulic or pneumatic piping.
* Ölkontrolle bei Hydraulikanlagen ( Ölstand, Ölbeschaffenheit ) .
* check of oil in hydraulic unit ( level and condition ) .
Ü * Kontrolle der Bremsbacken, Bremsbeläge und Bremstrommel / Bremsscheibe.

* check of brake shoes, brake linings and brake drum / disc.
* gegebenenfalls Messung der Anpresskraft der Bremse.
* check of brake clamping force if necessary.
Bei Anlagen mit geringer Schalthäufigkeit, kann die Komplettkontrolle

gegebenenfalls auch alle sechs Monate durchgeführt werden.
In case of low duty frequency, the overall check may be 35 708 HAIGER e-mail: info@sibre.de
carried out every six months only. GERMANY internet: http://www.sibre.de
B 06 20 176 E-DE-EN
Seite / page 8/8
Allgemeine Hinweise
7. Ersatzteilhaltung / Stockkeeping of spare parts
Eine Bevorratung der wichtigsten Ersatz- und Verschleißteile am Aufstellungsort ist eine wichtige
Voraussetzung für die ständige Einsatzbereitschaft der Bremse.
The stockkeeping of essential spare and wear parts at site is an important requirement for continuous
brake operation readiness.
Bei Ersatz- und Verschleißteil- Bestellungen sind folgende Daten anzugeben:

When ordering spare and wear parts, please enclose the following details:
Teil-Nr. Benennung / Grösse Plan-Nr. Stückzahl Fabr.-Nr. / Kom.-Nr.

part no. designation / size plan no. quantity fabrication-no. / Kom.-no.
Die Größenbezeichnung einer Bremse entspricht dem Trommel- oder Scheibendurchmesser.

Dem Typenschild und Maßblatt der Bremse können entsprechende Angaben entnommen werden.
The brake size designation corresponds to the drum or disc diameter.
The relevant data is contained in the data sheet and identification plate.
G Nur für die von uns gelieferten Original-Ersatzteile übernehmen wir eine Garantie.
We only give a warranty for original spare parts supplied by SIBRE.
Achtung: Wir machen ausdrücklich darauf aufmerksam, dass nicht von uns gelieferte Ersatzteile und
Zubehör auch nicht von uns geprüft und freigegeben sind. Der Einbau und/oder die Verwendung
solcher Produkte kann daher unter Umständen konstruktiv vorgegebene Eigenschaften der
Bremse negativ verändern und dadurch die aktive und/oder passive Sicherheit beeinträchtigen.
Für Schäden, die durch die Verwendung von nicht Original-Ersatzteilen und Zubehör entstehen,
ist jedwede Haftung und Gewährleistung seitens des Unternehmens
SIBRE Siegerland-Bremsen GmbH ausgeschlossen.
Caution: Your special attention is drawn to spare parts and optional features not supplied by
SIBRE: such parts are not inspected or approved by us.
Mounting and/or use of such parts may have a negative influence on the stated
constructional characterictics of the brake. For damages incurred due to use of such parts,
any warranty of liability whatsoever issued by
SIBRE Siegerland-Bremsen GmbH is excluded.
Bitte beachten Sie, dass für Einzelkomponenten oft besondere Fertigungs- und Lieferspezifikationen
bestehen und wir Ihnen stets Ersatzteile nach dem neuesten technischen Stand und nach den neuesten
gesetzgeberischen Vorschriften anbieten.
Please note that special production and delivery specifications often apply to individual parts
and that we continuously strive to offer spare parts in state of the art design and to the latest
legislative regulations.
Für nicht bei uns genietete oder geklebte Bremsbeläge und Bremsbacken übernehmen wir
keine Haftung und Gewährleistung.
Anschraubbare Bremsbacken fallen nicht unter diese Regelung.
Any warranty and liability for linings and brake shoes not bonded or riveted at SIBRE is excluded.
Bolted brake shoes are not subject to this regulation.

Electrohydraulic Thrusters ELHY®
Users manual, series EB
EMG Automation GmbH

Factory ELTMA
Technical rates
Type Rated Stroke C-spring Brake / Re- Power con- Current at Volume Weight
force setting force 1) sumption 2) 400 V 2)
min…max
N mm N (kp) N W A l kg
Series acc. to DIN 15430
Short travel types
EB 120-40 120 40 C 60 50… 75 130 0,4 1,2 7,5

C 120 100… 150
EB 220-50 220 50 C 120 110… 160 160 0,4 2,6 9,3
C 180 160… 230
C 220 200… 290
EB 300-50 300 50 C 120 140… 180 140 0,3 1,8 9,6
C 200 220… 260
C 270 260… 310
EB 500-60 500 60 C 180 170… 220 200 0,4 2,6 13,1
C 320 370… 450
C 500 540… 680
EB 800-60 800 60 C 450 460… 560 260 0,5 4,3 19,0
C 800 740…1060
EB 1250-60 1250 60 C 450 460… 560 380 0,6 4,3 20,6
C 800 740…1060
C 1250 1200…1630
EB 2000-60 2000 60 C 700 660… 900 500 0,7 9,0 32,8
C 1300 1240…1600
C 2000 1900…2500
EB 3000-60 3000 60 C 700 460… 690 550 0,9 10,1 39,0
C 2500 2080…3000
C 3200 2540…3690
EB 6300-80 6300 80 800 1,6 10,6 43,5
Long travel types
EB 500-120 500 120 C 180 110… 220 200 0,4 3,5 14,8
C 320 280… 450
C 500 390… 680
EB 800-120 800 120 C 450 350… 560 380 0,5 6,0 23,0
C 800 420…1060
EB 1250-120 1250 120 C 450 350… 560 380 0,6 6,0 24,2
C 800 420…1060
C 1250 770…1630
EB 2000-120 2000 120 C 700 430… 900 500 0,7 9,0 32,8
C 1300 870…1600
C 2000 1300…2500
EB 3000-120 3000 120 550 0,9 10,1 39,0
EB 6300-120 6300 120 800 1,6 10,6 43,5
Series acc. to TGL 35868
Short travel types
EB 12/50 220 50 C 12 110… 160 160 0,4 2,6 9,3

C 18 160… 230
C 22 200… 290
EB 20/50 300 50 C 12 140… 180 140 0,3 1,8 9,6
C 20 220… 260
C 27 260… 310
EB 50/50 500 50 C 18 170… 210 200 0,4 2,6 13,1
C 32 370… 440
C 50 540… 660
EB 80/60 800 60 C 45 460… 560 260 0,5 4,3 19,0
C 80 740…1060
EB 125/60 1250 60 C 45 460… 560 380 0,6 4,3 20,6
C 80 740…1060
C 125 1200…1630
EB 150/60 1500 60 C 45 460… 560 400 0,7 4,3 20,6
C 80 740…1060
C 125 1200…1630
EB 250/60 2500 60 C 70 660… 900 500 0,7 9,0 32,8
C 130 1240…1600
C 200 1900…2500
Long travel types
EB 50/100 500 100 C 18 130… 220 200 0,4 3,2 14,5

C 32 310… 450
C 50 440… 680
EB 80/160 800 160 C 45 280… 560 260 0,5 6,0 23,0
C 80 200…1060
EB 125/160 1250 160 C 45 280… 560 380 0,6 6,0 24,2
C 80 200…1060
C 125 480…1630
EB 150/160 1500 160 C 45 280… 560 400 0,7 6,0 24,2
C 80 200…1060
C 125 480…1630
EB 250/160 2500 160 C 70 280… 900 500 0,7 12,2 39,5
C 130 620…1600
C 200 900…2500
EB 320/100 3200 100 C 70 460… 840 550 0,9 10,6 39,5
C 250 2080…3000 3)
C 320 2540…3690 3)
EB 630/120 6300 120 800 1,6 10,6 43,5
All technical rates are intermediate values at +20°C thrusters temperature.
1) Rates for thrusters with internal brake / resetting spring
2) Rates at mechanical end position of the piston, increased rates during travel, at -25°C the current is 1,5 times higher than at +20°C
3) Stroke limitation: 60 mm
Ambient temperatures
Temperature range Service medium Code Comments
-25°C … +40°C Transformer oil Actuating times are maybe longer than usual when starting operation
at temperatures below 0°C. Lowering times remain nearly un-effected.
above +50°C … max. +80°C Transformer oil W... Special versions up to +80°C, ask manufacturer for details
below -25°C … max. -50°C Silicone oil F Heater not required, ask manufacturer if necessary
Service medium,
maintenance
Brand: SHELL Cover plug
Type of oil: Diala Oil DX (dried)
Viscosity: 18 mm² / s at +20 °C
800 mm² / s at -30°C Filling entry
Other fluids on request.
ELHY® Thrusters are usually filled with Shell

Diala Oil DX for service within ambient
temperature range -25°C to +40°C. Other Filling level
temperatures possibly need special fluids. In
every case it is a “long-life“ filling. Never change Regulation plug
the service medium as long as the thruster is in
good condition and free of leakage. Thus
ELHY® Thrusters are nearly free of mainte-
nance.
When refilling a unit after repair, please always

use a permitted fluid.
Important: The filling meets the requirements if
the fluid level reaches the lower edge of the
entry, when the ELHY® Thruster stands in EB 300-…6300-, EB 20/…630/
vertically position an the piston rod is fully
retracted. Close the filling entry and run the
thruster through a few strokes to move enclosed
air to the top of the unit. Check filling level again
and top up if necessary. Finally close the filling Cover plug(s)
entry tightly.
Filling entry
The thruster will not produce full power if the Regulation
volume of service fluid is incomplete. plug
Because the medium will expand during
operation, filling above permitted level will lead
to higher internal pressure which possibly can
result into leakage.
Attention:
Never mix different fluids! Regulation plug
Drain the thruster completely
before changing the service Cover plug
medium. Füllstand
EB 220-50, EB 12/50 EB 120-40
Series acc. to DIN 15430 Series acc. to TGL 35868

Time settings Type Adjustable lowering time Type Adjustable lowering time
min. max. min. max.
ELHY® Thrusters are usually operating brake s s s s
systems. Thus the most important time EB 120-40 … S 0,5 15,0 EB 12/50 … S 1,3 11,0
settings are for brake movement (lowering EB 220-50 … S 1,3 11,0 EB 20/50 … S 1,5 6,0
time). Approximate rates for the adjustable EB 300-50 … S 0,8 6,0 EB 50/50 … S 0,8 6,0
lowering time settings are shown inside the EB 500-60 … S 1,0 7,0 EB 80/60 … S 1,3 11,0
tables (valid for: thrusters including lowering EB 800-60 … S 1,3 10,0 EB 125/60 … S 1,2 9,0
valve, +20°C, rated weight loads). EB 1250-60 … S 1,2 9,0 EB 150/60 … S 1,1 8,0
EB 2000-60 … S 1,3 8,0 EB 250/60 … S 2,0 10,0
Detailed setting instructions depend to the EB 3000-60 … S 1,2 6,0
application of use. Therefore they have to be EB 50/100 … S 1,5 10,0
determined by the manufacturer. Please send EB 500-120 … S 1,8 12,0 EB 80/160 … S 2,5 15,0
all necessary information about the required EB 800-120 … S 2,4 14,0 EB 125/160 … S 2,3 14,0
service conditions with your order / enquiry. EB 1250-120 … S 2,2 13,0 EB 150/160 … S 2,2 13,0
EB 2000-120 … S 2,8 12,0 EB 250/160 … S 3,5 15,0
EB 3000-120 … S 2,5 10,0 EB 320/100 … S 2,5 11,0
EB 6300-120 … S 2,0 8,0 EB 630/120 … S 2,0 8,0
Electrical design Additional equipment Position indicators
Motor Lifting valve (H), Lowering valve (S),
3-ph squirrel cage motor, 2-pole Throttle valve (D)
Sensors
construction acc. to VDE 0530, Stepless adjustment of operation times is Analogue stroke sensor (La)
performance details refer to „Technical possible if valves are internally mounted. INTERNALLY MOUNTED!
rates“ or type plate, insulation class F Adjustment is realizable by a regulation PLEASE NOTE WIRING DIAGRAM
plug and can only be done when the INSIDE TERMINAL BOX.
Modes of operation thrusters stands in an upright
Continuous duty S1 and ON/OFF duty S3 Integrated transducer
position. After removing the cover plug Connection: terminal board
max. 2000 c/h, up to 100% duty factor on top of the thruster, the regulation plug
(exceptions: EB 6300-80, EB 6300-120, (Option: plug connector)
is ready to use. (see pics. 1 ... 3). Output: 4 .. 20 mA
EB 630/120, see type plate), Tools: 8 mm hexagonal key; except of
technical rates changes for ambient Supply voltage: 17 … 30 V DC
types EB120-40, EB220-50, EB12/50
temperatures above +50°C, contact ma- - they require a slit screw driver Magnetic inductive sensors (Lk…*)
nufacturer for assistance if necessary The range of adjustment covers 0 up to 6 INTERNALLY MOUNTED!
Power supply turns (0 = CLOSED = max. prologation). PLEASE NOTE WIRING DIAGRAM
230/400 V AC, 50/60 Hz, 3-ph Standard factory setting: 3 turns, starting INSIDE TERMINAL BOX.
… 690 V AC 50/60 Hz, 3-ph from CLOSED position Connection: terminal board
Standard factory setting: double voltage, Ask manufacturer for more details and (Option: plug connector)
windings “star” (Y) connected adjustment graphs. Contact: NO
(Option: NC or NC+NO)
Type of enclosure Brake/Resetting spring (C spring) Switching power: max. 10 W
IP56 (Option: IP66) The internally mounted C spring gene- Switching voltage: max. 250 V AC/DC
rates the brake / resetting force. Switching current: max. 0,5 A
Electrical connection Service life: up to 109 cycles
Regulation/Damping spring (R spring)
3/6/7 pole terminal board,
Mounted on top of the lifting rod, the R
earthing screw
spring damps the aperiodic transient of Limit switches
(Option: plug connector) (Standards shown hereafter, others available)
the brake. (Special application: version
Cable gland for controlled braking) Mechanical limit switch (Lm…*)
M25x1,5 (option Pg 21) for cable sizes Type: M3R 330-11y Schmersal
Protective hood, Special scraper
up to 4 x 1,5mm² (max. ∅ 20mm) Voltage: 24 … 250 V AC/DC
Option for additional protection of lifting
rod’s sealing system. Rated current: 2,5 A
Continuous current: max. 6 A
Mechanical design Quick resetting Contact: alternating
Resetting times can be reduced by Type of enclosure: IP65
Service positions approximately 15% by using of motor
capacitors, or by short-circuiting the Inductive limit switch (Li…*)
Vertical, lifting rod up: no limits
Vertical, lifting rod down: pay attention to stator winding via capacitor. Ask Type: IFL 15-333-10/01YAG Schmersal
mode of operation! Contact manufacturer manufacturer for details. Voltage: 15 … 250 V AC/DC
for assistance if necessary. Output current: max. 200 mA
Horizontal and intermediate positions: Heater Contact: NC + NO
type plate to be on side! Contact ma- Up to -25°C (Service medium: trans- Switching distance: 15 mm
nufacturer for assistance if necessary. former oil) or -40°C (Service medium: Type of enclosure: IP65
silicone oil) is no heater required. Below (* Number of switches (SG) and signals:
Service medium -50°C a pre-heating function is realizable „2“ = 1xSG, Full stroke pos. of lifting rod
Shell Diala Oil DX, by using the stator winding. Ask „5“ = 1xSG, Lifting rod retracted
already filled for operation manufacturer for details. „7“ = 1xSG, Intermediate position
Coating, protection against corrosion Electronic brake controls „3“ = 2xSG, Full stroke pos. of lifting rod
2 components polyacrylic, single layer Regulated variations of braking torques + lifting rod retracted
coating, hit and scratch resistant, dried and times are possible by frequency con- „4“ = 2xSG, Full stroke pos. of lifting rod
trolled BRAKEMATIC® controls. Ask ma- + intermediate position
thickness 80 µm (Option: special coating
nufacturer for details or special brochure. „6“ = 2xSG, Lifting rod retracted
systems up to 240 µm dried thickness + intermediate position
available, contact manufacturer for more
information) Ask manufacturer for details and
Special applications, availabilities of various switch / sensor
Colours modifications combinations.)
Standard colour RAL5008, grey blue
Ask manufacturer for more information
(Option: other colours acc. to RAL chart)
regarding ELHY® version for controlled
braking, substitution models, adaptations
and special series.
Type code EB 1250-60 C... R H II Z W... T Lm... BL ...V / ...Hz
EB 125/60 B S I Zd F K Li... X..

.
ELHY® Type
Brake / Resetting spring D Lk...
Regulation spring, Version for controlled braking
Lifting valve, Lowering valve, Throttle valve
La
Construction code (depend on mounting position and mechanical connection)
Protective hood , Special scraper
High temperature design + temperature class, Low temperature design
Class of protection against corrosion
Sensors, Limit switches
Adaptations, Special modifications
Electrical connection details (Voltage / Frequency)
2 Setting into operation
• Rates of ELHY® refer to type plate (1)
• ELHY® Thrusters are completely filled with service fluid

ready for use, medium type see type plate (1)
• No unauthorized opening permitted. Leakage will cause

change of technical rates, or failure.
• Vertical service position, lifting rod (2) up (other positions

1 possible, please pay attention to information “Service
positions” on page 4)
• If ELHY® Thrusters are equipped with internal brake

springs (code “C…” shown within type name on type
3 plate), make sure that the brake movement has no
spring or weight load.
• Slewability of the thruster must be guaranteed.

Transverse forces must not act upon lifting rod. Check
easy movement of pin connections.
• Execute the electrical connection according to the

schematic shown inside the terminal box lid (3). Any
phase sequence is permitted. (please pay attention to
information “Power supply” on page 4)
6 pole terminal board

• Keep terminal box clean. Check whether the seal is
undamaged and the in right position. Close the terminal
box tightly. Check the seal of the cable gland and
readjust if necessary.
• If painting the unit after installation, protect the lifting rod

and seals from contact with paint. Paint can damage the
seals and result to leakage!
Attention:
Never open a hot ELHY ® Thruster!
Expanding hydraulic medium can
cause severe injuries. Before open
for servicing, cool down the unit to
room temperature.
- Subject to changes -
EMG Automation GmbH

Factory ELTMA
Am Pfefferbach 20
39387 Oschersleben
Germany
Phone: +49 (0) 3949 928 - 500

Fax 1: +49 (0) 3949 928 - 585
Fax 2: +49 (0) 3949 928 - 513
e-Mail: info@emg-eltma.de
http: www.emg-eltma.de
BA_GB 06/2008
Inductive sensor
BI5U-M18-AP6X
■ Threaded barrel, M18 x 1

■ Chrome-plated brass
■ Factor 1 for all metals
■ Magnetic field immune
■ Extended temperature range
■ High switching frequency
■ DC 3-wire, 10…30 VDC
■ NO contact, PNP output
■ Cable connection
Wiring diagram
Type BI5U-M18-AP6X
Ident-No. 1635100
Rated operating distance Sn 5 mm

Mounting condition flush
Assured sensing range ð (0,81 x Sn) mm
Repeatability
Functional principle
ð2%
Temperaturdrift 10 % Inductive sensors detect metal objects con-
ð ± 15 %, ð -25 °C v ï +70 °C tactless and wear-free. Due to the patented
Hysteresis 3…15 % ferrite-less 3-coil system, uprox® factor 1 sen-
Ambient temperature -30…+85 °C sors have distinct advantages compared to
conventional sensors. They detect all metals
Operating voltage 10…30VDC at the same switching distance, are magnetic
Residual ripple ð 10 % Uss field immune and feature large switching dis-
DC rated operational current ð 200 mA
tances.
No-load current I0 ð 15 mA
Residual current ð 0.1 mA
Rated insulation voltage ð 0.5 kV
Short-circuit protection yes/ cyclic
Voltage drop at Ie ð 1.8 V
Wire breakage / Reverse polarity protection yes/ complete
Output function 3-wire, NO contact, PNP
Protection class ÷
Switching frequency 1.5 kHz
Design threaded barrel, M18 x 1

Dimensions 54 mm
Housing material Metal, CuZn, chrome-plated
Material active face Plastic, PBT
End cap Plastic, EPTR
Max. tightening torque housing nut 25 Nm
Connection cable
Cable quality 5.2 mm, LifYY, PVC, 2 m
Cable cross section 3 x 0.34 mm
2
Vibration resistance 55 Hz (1 mm)

Shock resistance 30 g (11 ms)
Protection class IP67
MTTF 874years acc. to SN 29500 (Ed. 99) 40 °C
Switching state LED yellow

Edition • 2012-06-23T02:39:57+02:00
1/3 Hans Turck GmbH & Co.KG ñ D-45472 Mülheim an der Ruhr ñ Witzlebenstraße 7 ñ Tel. 0208 4952-0 ñ Fax 0208 4952-264 ñ more@turck.com ñ www.turck.com
Inductive sensor
BI5U-M18-AP6X
Mounting instructions minimum distances

Distance D 2xB
Distance W 3 x Sn
Distance T 3xB
Distance S 1.5 x B
Distance G 6 x Sn
Diameter of the active area B Ø 18 mm

Edition • 2012-06-23T02:39:57+02:00
Inductive sensor
BI5U-M18-AP6X
Accessories
Type code Ident-No. Short text Dimension drawing
BST-18B 6947214 Fixing clamp for threaded barrel devices, with dead-stop; ma-
terial: PA6
QM-18 6945102 Quick-mount bracket with dead-stop; material: Chrome-plat-

ed brass Male thread M24 x 1.5. Note: The switching dis-
tance of proximity switches can be reduced by the use of
quick-mount brackets.
MW-18 6945004 Mounting bracket for threaded barrel devices; material: Stain-
less steel A2 1.4301 (AISI 304)
BSS-18 6901320 Mounting bracket for smooth and threaded barrel devices;
material: Polypropylene
Edition • 2012-06-23T02:39:57+02:00
6.1.2 Rail clamps
 Rail clamps - Type CTHV-LH-150-045-LE-06
− Rail clamps CTHV-LH-150-045-LE-06 (Rail A 75)

Installation manual
(Document Package No.: 200-112-46205)
− Rail clamps CTHV-LH-150-045-LE-06 (Rail A 75)

O & M Manual
− Hydraulic power units HPT-10-SSRC-ALL

Installation manual
− Hydraulic power units HPT-10-SSRC-ALL

Operational & Maintenance Manual

Blank page

Sheet Number:
RAIL CLAMPS
Hillmar
Hillmar Industries Ltd.
CXHV-LH-…-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
7371 Vantage W ay PARTS & SVC Form Number: Rev:
Delta, BC V4G 1C9 ENGLISH
P:604 946-7115 F:604 946-0329
info@hillmar.com www.hillmar.com Company / Project Reference: Date: Page: Document Package No.: Rev:
ThyssenKrupp / Shougang 14 FEB 07 1 of 12 200-112-46205 H
C:\Dokumente und Einstellungen\Harald Hof\Eigene Dateien\Aufträge Job\O&M\Montage+Bedienungsanleitung\2012-06-11\Aenderung HBG\200-112-46205_H CXHV-LH-150-200-ALL INSTALLATION MANUAL.doc
INSTALLATION MANUAL
RAIL CLAMPS
CTHV-LH-150-045-LE-06
Rail A 75
Motor Voltage 460 V 3 Ph 60 Hz
Control Voltage 24 V DC
Po. 30258828
PATENTED PRODUCT
PATENT No. WO2009/092156 A1
HILLMAR WORKS HAVE A FULLY REGISTERED ISO 9001: 2008 QUALITY ASSURANCE PROGRAMME (QCB #01-1525)
H TM ADDED NOTE IN SECTION 2 14MAR11

G TM ADDED INDICATOR EXPLANATION 09DEC10
F TM GENERAL REVISION 16APR10
Rev. Apr. By R E V I S I O N S Date Rev. Apr. By R E V I S I O N S Date
Storm Brakes • Thruster Disc Brakes • Thrusters • Industrial Disc Brakes • Hydraulic Power Units • Cable Reels
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
INDEX PAGE
Cover Page 1
Index Page 2
Installation 3
Rail clamp & handpump operation 4
Indicator explanation 5
Allowable roller adjustment 6
Eccentric pin adjustment 7
Limit switch setting LE-clamp 8
Limit switch setting RP-clamp 9
Power unit installation 10
Rail clamp paper test 11
Bolt tightening torques 12
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
1.0 INSTALLATION
SHIPPING POSITION
CAUTION:
All rail clamps are shipped without hydraulic fluid.
Customer must first fill hydraulic fluid in
accordance with Recommended Hydraulic Fluid
of Hydraulic Power Unit Installation Manual.
AFTER HYDRAULIC PRESSURE IS

1.1 CAGING FORK REMOVAL
SUPPLIED, CLAMP RETRACTS
ALLOWING RETAINING
TO BE REMOVED
STORE STOP AS INDICATED
- Caution: All clamps are shipped in released
position. Each clamp may only be activated by
removing the caging fork as shown.
NOTE: Hydraulic pressure must be applied to

hydraulic cylinder prior to fork removal.
1.2 MOUNTING FLANGE
- The clamp enclosure must be matched to

customer flange. Careful attention must be
made to contract installation dimensions as
shown on contract specification sheet.
CUSTOMER
MOUNTING
FLANGE
TOP OF RAIL
1.3 INSTALLATION CHECK
Check guide wheel (roller) contact with the

rail. Refer to Contract Specific Documents for
specific details.
Check clearance heights. Refer to O&M

CLEARANCE
Manual for contract Rail Clamp Specification
HEIGHT Sheet.
TOP OF RAIL Check rail clamp serrated shoe contact with

paper bite test. Refer to Section 7.0 & Rail
Clamp QC Document No. 200-112-45727
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
1.4 CLAMP OPERATION

CUSTOMER HAND PUMP
TO CONNECT Connect power to hydraulic power unit in

POWER order to activate the clamp.
NOTE: In the case of LE model rail clamps,

which are supplied with integrally mounted
power units this may be accomplished by
means of the built in hand pump.
TOP OF RAIL
1.5 HAND PUMP OPERATION
Needle Valve – NV1

NOTE: This valve must be opened at all
NV1 times when the clamp is in normal operation.
This valve must close before the hand pump
can be operated.
CAUTION: Applying excessive pressure to

the cylinder will cause severe damage to the
PRESSURE LINE
hydraulic cylinder.
NOTE: The hand pump is provided with a

relief valve, which is set to protect the
HYDRAULIC CYLINDER
hydraulic cylinder from over pressure.
Holding the clamp in the released position
under hydraulic pressure for long periods of
time is not recommended, as system leakage
will ultimately cause the clamp to set.
CAUTION: Do not operate the machine

without first interlocking the release limit
switch with machine drive. If power is not
available and the machine has to be operated
without the limit switch being interlocked,
reinstall the caging fork to hold the clamp
permanently in the release position.
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
2.0 INDICATOR WORKING EXPLANATIONS
WHITE ZONE (10)

WHITE ZONE
LE The white zone is called clamp release zone that rail

clamp releases to the end of the zone but due to the
work of the motor drift takes place. This drift
downwards is generally 3-4mm. Thus if the clamp is
released in this zone, all is 100% correct.
BLUE ZONE (35)
BLUE ZONE
The blue zone is called the clamp clearance zone. If

the clamp is released and in white zone as described
above, the clearance of the shoes away from the rail
is correct.
GREEN ZONE
GREEN ZONE (45)
The green zone is the clamp working zone. The

clamp is working correctly if it is setting at any point in
the green zone.
RED ZONE
The red zone is called danger zone. This zone

requires that the clamp must be adjusted.
RED ZONE (10)
Note: When clamps are specified at µ = 0.25, then

the clamping forces at the rail are very high thus
causing bite of 0.3-0.5mm. This will cause the clamp
to drift 15-25mm in the green zone.
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
3.0 ALLOWABLE ROLLER ADJUSTMENT – WITH ECCENTRIC PIN

1. Set the brake.
INDICATOR BAR
2. If indicator bar is below
RD
ROLLER
recommended 1/3 of green
LOCKING PAD zone – rotate eccentric pin to –
PIVOTING
BOLT (minus) direction.
3. If indicator bar is above
+1 0 -1 recommended green zone –
+2
+3
-2
-3
rotate eccentric pin to + (plus)
STICKER direction.
4. Release the brake.
5. Remove link bolt. The locking
ECCENTRIC PIN pad will hang on pivoting bolt.
6. Use locking pad to turn
GUIDE LINK eccentric pin to new position.
7. Lock the pad to the lever.
LINK BOLT
8. Mount and back link bolt and
guide link (do not over-tighten).
9. Secure the eccentric pin
position by locking plate.
10. Both eccentric pins to be
locked at same position.
11. Each eccentric pin has 2.5mm
eccentricity, which allows
adjustment from 0mm to 5mm
in lateral direction at the top of
the lever. This translates to
0mm to 1.66mm at the lever
shoe (0.83mm on each side of
the rail).
CAUTION: Before any adjustment a

check must be made to ensure rail
clamp shoes are not damaged or worn.
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
3.1 ECCENTRIC PIN ADJUSTMENT

LINK PIN ON
HYDRAULIC CYLINDER Notes:
Link pins (cap screws) are locktited in position
to avoid them coming loose, thus they should
+1 0 -1 LINK
+2 -2 not be removed.
+3 -3
'A'
LINK PIN CAP SCREW
SOCKET HEAD
CAP SCREW
Adjustment Tool
Remove adjustment tool and place onto the

eccentric adjustment pin.
ECCENTRIC This can be done without removing retraction

ADJUSTMENT PIN link or link pins.
+1 0 -1
+2 -2
+3 -3
ADJUSTMENT
PIN WRENCH
Caution should be taken if link pins are

loosened. Replace with new and apply locktite
(red). Hillmar Spec Sheet No. 560-601-45502
VIEW ON ‘A’
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
4.0 LIMIT SWITCH SETTING

4.1 TWO STAGE LIMIT SWITCH (LE MODEL)
WHITE ZONE (10)
LE
1 CLAMP FULLY RELEASED
10
2 MOTOR START (TO RELEASE CLAMP)

20
3 CLAMP RELEASE INDICATION ON

ROTATE
BLUE ZONE (35)
ECCENTRIC PIN
IN + DIRECTION 4 CLAMP RELEASE INDICATION OFF
30
POSITION 2 STAGE LIMIT SWITCH SYSTEM

CLAMP SET POINT 1 LSA - CLOSED LSB - OPEN
15
AFTER INSTALLATION
GREEN ZONE (45)
2 LSA - CLOSED LSB - CLOSED
3 LSA - CLOSED LSB - CLOSED
4 LSA - OPEN LSB - CLOSED
ROTATE CONTACTS LSA - CLAMP RELEASE SWITCH

ECCENTRIC PIN CONTACTS LSB - CLAMP RECHARGE SWITCH
IN - DIRECTION
NOTE:
RED ZONE (10)
CLAMP OUT OF ADJUSTMENT

RAIL CLAMPS WITH INTEGRALLY MOUNTED
INDICATOR HYDRAULIC POWER UNITS INCORPORATE A DOUBLE
POLE DOUBLE THROW SWITCH (2 STAGE) LIMIT SWITCH.
EACH SET OF CONTACTS ARE DESIGNED TO:
1) INDICATE WHEN CLAMP IS RELEASED.
2) RECHARGE SYSTEM (eg. SIGNAL THAT PUMP MOTOR
MUST BE RUN TO BRING THE CLAMP BACK TO ITS FULLY
RELEASED POSITION.)
WHITE = PRESSURE LOSS ALLOWABLE DRIFT (DOUBLE POLE DOUBLE
THROW SWITCH FOR POWER UNIT RECHARGE)
BLUE = FROM FULL SET TO FULL RELEASE
GREEN = SAFE CLAMPING ZONE
RED = DANGER LOSS OF CLAMPING FORCE
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
4.2 LIMIT SWITCH – SINGLE STAGE LIMIT SWITCH AND PRESSURE SWITCH (RP MODEL)
RP
1 CLAMP FULLY RELEASED
PRESS. SWITCH (PUMP SHUT OFF)
20
BLUE ZONE (45)
2 CLAMP RELEASE INDICATION ON

ROTATE
ECCENTRIC PIN
IN + DIRECTION 3 CLAMP RELEASE INDICATION OFF
30
SINGLE STAGE PRESSURE

POSITION
LIMIT SWITCH SWITCH
CLAMP SET POINT 1 LS1 - CLOSED PS - OPEN
15
AFTER INSTALLATION
GREEN ZONE (45)
2 LS1 - CLOSED PS - CLOSED
3 LS1 - OPEN PS - CLOSED
ROTATE CONTACTS LS1 - CLAMP RELEASE SWITCH

ECCENTRIC PIN CONTACTS PS - PRESSURE SWITCH
IN - DIRECTION
NOTE:
RED ZONE (10)
CLAMP OUT OF ADJUSTMENT

RAIL CLAMPS WITH INTEGRALLY MOUNTED
INDICATOR HYDRAULIC POWER UNITS INCORPORATE A SINGLE
POLE DOUBLE THROW SWITCH (SINGLE STAGE) LIMIT SWITCH.
SWITCH CONTACTS ARE DESIGNED TO:
1) INDICATE WHEN CLAMP IS RELEASED.
2) RECHARGE SYSTEM (eg. SIGNAL THAT PUMP MOTOR
MUST BE RUN TO BRING THE CLAMP BACK TO ITS FULLY
RELEASED POSITION.)
BLUE = FROM FULL SET TO FULL RELEASE
GREEN = SAFE CLAMPING ZONE
RED = DANGER LOSS OF CLAMPING FORCE
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
5.0 HYDRAULIC POWER UNIT INSTALLATION

(CTHV-LE SERIES)
1. The overall Rail Clamp height has been

dramatically reduced thus providing much
more installation options i.e. 1. sillbeam,
2.truck assembly, 3.at the end of a truck etc.
2. The Hydraulic Power Unit is accessible from

the side of the clamp.
3. Each Power Unit is installed as a two-piece

assembly. The unit is light and can easily be
lifted by a single person.
6.0 HYDRAULIC POWER UNIT INSTALLATION

(CBHV-LE SERIES)
1. The overall Rail Clamp height has been

dramatically reduced thus providing much
more installation options i.e. 1. sillbeam,
2.truck assembly, 3.at the end of a truck etc.
2. The Hydraulic Power Unit is accessible from

the side of the clamp.
3. Each Power Unit is installed as single

assembly, thus allowing ease of replacement
and maintenance. Simply undo the mounting
bolts hydraulic and electric lines and then
complete unit can be removed by
maintenance personnel. The unit is light and
can easily be lifted by a single person.
7.0 HYDRAULIC HOSE & FITTINGS
1. All hydraulic hose & fittings must be inspected

for leaks during commissioning.
2. It is not common to have or detect a leak. If a
leak occurs simply tighten.
3. Reason for leaks:
- Vibration during transport
- Elevated ambient temperature during
commissioning.
- Oil viscosity
4. Note it is impossible to prevent such minor
problems 100% of the time.
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
8.0 RAIL CLAMP PAPER TEST

1. Once the clamp has been installed, all

connections correctly made. I.e. the clamp
is fully operational. A paper test should be
conducted.
2. Open (release) the clamp and place a plain

piece of paper between the serrated shoes
and the rail.
3. Set the clamp to clamp onto the paper.

TOP OF RAIL 4. Release the clamp.
PAPER SERRATED SHOES 5. Remove the paper.
6. The paper test should show knife like cuts

across the surface of the paper in the shape
of the serrated shoes.
7. Repeat this procedure at 10meter intervals

along the rail for all clamps.
9.0 REFERENCE MANUAL
9.1 TCD-CSM MANUAL

KNIFE LIKE CUTS Refer to Document No. 240-401-62333
PAPER TEST 9.2 O & M MANUAL

KNIFE LIKE CUTS SHOULD CONFIRM THAT A MINIMUM OF Refer to Document No. 200-112-46204
50% SHOE CONTACT BETWEEN THE SHOE AND THE RAIL
9.3 HPT O & M MANUAL
Refer to Doc. No. 100-510-45436 for CBHV
Refer to Doc. No. 100-510-62234 for CTHV
9.4 HPT INSTALLATION MANUAL

Refer to Doc. No. 100-510-45905 for CBHV
Refer to Doc. No. 100-510-45781 for CTHV
Sheet Number:
ALL PRODUCTS
Hillmar
ALL
BOLT TIGHTENING TORQUES
Job Number:
7371 Vantage W ay PRODUCTION Form Number: Rev:

Delta, BC V4G 1C9 ENGLISH 500-005-56398
P:604 946-7115 F:604 946-0329
14 FEB 07 12 of 12 200-112-46205 H
10.0 BOLT TIGHTENING TORQUES

Tightening Torques (FOR METRIC COARSE THREAD BOLTS AND SCREWS)

Tightening Torque MAX (Nm)
Thread
Property Classes
Diameter
CL 5.6 CL 8.8 CL 10.9 CL 12.9 A2/A4 – CLASS 70 SS
M4 1.37 3.0 4.4 5 2.2
M5 2.70 5.9 8.7 10 4.3
M6 4.6 10 15 18 7.3
M8 11 25 36 43 17.7
M10 22 49 72 84 35.5
M12 39 85 125 145 61.3
M16 95 210 310 365 147.1
M20 184 425 610 710 285.1
M22 250 580 820 960
M24 315 730 1050 1220
M27 470 1100 1550 1800
M30 1450 2100 2450
M33 1970 2770 3330
M36 2530 3560 4280
THE TORQUE FIGURES IN THE TABLE ARE:
1. FOR COEFFICIENT OF FRICTION µ = 0.14 (FASTENERS WITHOUT COATING (SELF COLOUR) &
SLIGHTLY LUBRICATED. ADDITIONAL LUBRICATION IS LEADING TO OVERLOADING CONDITION.)
2. FOR RECOMMENDED INDUCED STRESS ON BOLTS ≈ 80% OF FY (YIELD STRESS) DUE TO

APPLIED TORQUE.
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
ThyssenKrupp / Shougang 14 FEB 07 1 of 18 200-112-46204 D
C:\Dokumente und Einstellungen\Harald Hof\Eigene Dateien\Aufträge Job\O&M\Montage+Bedienungsanleitung\2012-06-11\Aenderung HBG\200-112-46204_D CXHV-LH-150-200-ALL O & M MANUAL.doc
O & M MANUAL
RAIL CLAMPS
CTHV-LH-150-045-LE-06
Rail A 75
Po. 30258828
PATENTED PRODUCT
PATENT No. WO2009/092156 A1
D TM ADDED RED ZONE IN SECTION 6.0 22JUL11

C TM GENERAL REVISION 16APR10
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
INDEX PAGE
Cover Page 1
Index Page 2
Operation Description CTHV-rail clamps 3

Operation Description CBHV-rail clamps 4
Mechanism and Power Unit Removal 5

Spring Removal 6
Maintenance
Lubrication 7
Maintenance Schedule 8
Trouble Shooting Rail Clamp 9
Parts
Parts Ordering Instruction 10
General Assembly 11
Mechanism Assembly 12
Rail Package Assembly 13
Limit Switch Assembly 14
Wedge Assembly 15
Guide Wheel Assembly 16
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
ENCLOSURE MECHANISM 1.0 OPERATION DESCRIPTION

TOP
1.1 TRUCK MOUNT WITH POWER UNIT LE

MODEL
MOTOR
HYDRAULIC
POWER UNIT MOUNTING SIDE
TO THE CRANE This rail clamp is a truck mount rail clamp that
STRUCTURE comes complete with an integrally mounted
FLOATING
FEATURE hydraulic power unit HPT-10-SSRC. Details of
this power unit are covered in the contract
specific, O & M and installation manuals.
TOP OF RAIL
ENCLOSURE BASE SHOE GUIDE ROLLER
CTHV-LH-LE
ENCLOSURE 1.2 TRUCK MOUNT WITHOUT POWER UNIT RP

MECHANISM
TOP MODEL
This rail clamp is a truck mount rail clamp and

MOTOR is operated via a remote mounted hydraulic
MOUNTING SIDE power unit. Details of this power unit are
TO THE CRANE
STRUCTURE
covered in the contract specific, O & M and
FLOATING installation manuals.
FEATURE
TOP OF RAIL
ENCLOSURE BASE SHOE GUIDE ROLLER
CTHV-LH-RP
CAUTION:
Unless indicated all clamps are static devices and should under no circumstances be operated dynamically
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
1.3 BEAM MOUNT WITH POWER UNIT LE

MODEL
MOUNTING SIDE
POWER TO THE CRANE
UNIT STRUCTURE This rail clamp is a beam mount rail clamp

ENCLOSURE
that comes complete with an integrally
mounted hydraulic power unit HPT-10-
SSRC. Details of this power unit are
MECHANISM covered in the contract specific, O & M and
installation manuals.
FLOATING
FEATURE
TOP OF RAIL
SHOE GUIDE ROLLER
CBHV-LH-LE
1.4 BEAM MOUNT WITHOUT POWER UNIT

RP MODEL
This rail clamp is a beam mount rail clamp

MOUNTING SIDE
TO THE CRANE
and is operated via a remote mounted
ENCLOSURE
STRUCTURE hydraulic power unit. Details of this power
unit are covered in the contract specific, O
& M and installation manuals.
MECHANISM
FLOATING
FEATURE
TOP OF RAIL
SHOE GUIDE ROLLER
CBHV-LH-RP
CAUTION:
Unless indicated all clamps are static devices and should under no circumstances be operated dynamically
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
MECHANISM AND POWER UNIT REMOVAL

1 2
4
7
CAUTION
6
COMPONENTS ARE UNDER VERY
HIGH SPRING LOAD AND MAY
CAUSE PERSONAL INJURY. DO NOT
ATTEMPT DISASSEMBLY UNLESS
MECHANISM IS CAGED.
1.5 CLAMP MECHANISM REMOVAL
1. Remove rail clamp enclosure cover (item 1).

2. Release clamp and cage spring chamber by inserting caging fork (item 2).
3. Disconnect electrical supply (item 3) and remove unit to maintenance area. Be sure clamp
jaws clear the rails when lifting.
4. Remove limit switch (item 4) from mechanism leaving it connected to junction box.
5. Use manual release nut to release the brake.
6. Release pressure and allow bottom spring plate to rest on snap rings.
7. Close needle valve fully and then disconnect hydraulic hose to cylinder.
8. Remove two mounting plate bolts and lift power unit assembly off (item 5).
9. Remove vertical guide bar bolts (item 6) two places.
10. Remove mechanism and set on a press.
1.6 SPRING CHAMBER DISASSEMBLY
1. Place the mechanism in a press with at least 200mm (8") of stroke and at least 10 tonnes
(22050 lb) capacity. Ensure that the mechanism is secured and cannot move.
2. Ensure bottom spring plate is resting on snap rings.
3. Extend the press cylinder until the press cylinder rod rests on top of the spring plate.
4. Lock the press cylinder in position so that it will hold the spring load.
5. Remove only two capscrews, diagonally opposed. Screw in the guide rods (at least 250mm
long) thru top spring plate (into item 7) with thread matching the removed capscrews.
6. Remove the remaining two capscrews.
7. Carefully and slowly release the press cylinder to extend the springs and release their load.
*Reassemble in reverse of steps 7 to 1. Torque the capscrews for grade five or grade 8.8 bolts.
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
1.7 RAIL CLAMP SPRING REMOVAL
CAUTION
COMPONENTS ARE UNDER VERY HIGH SPRING LOAD AND MAY CAUSE PERSONAL INJURY.
DO NOT ATEMPT DISASSEMBLY UNLESS MECHANISM IS CAGED
PRESS GUIDE RODS

REFER TO GUIDE
ROD TABLE A
MIN 200 mm
STROKE
A A
SECURE CLAMP
MECHANISM TO TYP. RAIL CLAMP
THE PRESS MECHANISM
TOP SPRING PLATE
RAIL CLAMP SIZE DIM. A

060-100 M20
150-200 M24
REMOVE TWO
300/400/600/800/1000 M30
CAPSCREWS AND
VIEW A-A
REPLACE WITH
GUIDE RODS
A
FULL THREADED
OR
250mm (10")
50mm (2")
A
GUIDE ROD SPECIFICATIONS
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
2.0 MAINTENANCE
2.1 LUBRICATION
5 1
4
2
ITEM DESCRIPTION RECOMENDED LUBRICATION OR GREASE
1 Springs TEXACO NLGI EPI
2 Guide posts TEXACO NLGI EPI
Lubrication for float block

3 TEXACO NLGI EPI
assembly
4 Lubrication for lever assembly TEXACO NLGI EPI
Fittings; fasteners coat with SILVER GRADE

5 LOCTITE
protective coating ANTI –SEIZE 76732
1. Check that hydraulic fluid being used to operate the rail clamps is clean and free of contamination
2. Check all hydraulic fittings for signs of rust and/or corrosion. If this appears coat with rust inhibitor or
other rust protective compound
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
2.2 MAINTENANCE SCHEDULE

5 1
SHIPPING POSITION
7
3
2
6
TIME INTERVAL (MONTHS)

DESCRIPTION CYCLES
1 2 3 4 5 6 7 8 9 10 11 12
Check that guide rollers are the only part of the mechanism in
-
contact with the rail when clamp is released.
Be sure the serrations on the shoes are sharp and not
-
flattened (Conduct paper test and replace if not knife sharp).
Check that shoes fully contact rail when clamp is applied. 500
Lubricate spring assembly guide rods EP2 Grease (item 7). 500
Lubricate float feature plates (item 4) using the grease nipples
supplied. Also lubricate vertical guide bar using a small brush 500
to ensure complete coverage with grease
Make sure that the springs are clean, as dirt may peel the
paint when spring coils contact each other. Lubricate springs 1500
with EP2 Grease (Item 5)
Inspect eccentric pins, lubricate as required (item 6). 1500
Check that clamp is operating within prescribed range (item
-
1).
Adjust wedge as per adjustment instructions (item 3). 500
Note: Inspection should be based on months or cycles
whichever comes first, warranty claims will be based on
-
provision of maintenance records corresponding to cycle
counts as prescribed above.
* LUBRICATION POINTS
Guide Wheel Assembly
- Every 2 years or 8000 operation hours
Inspect & repack with grease if necessary.
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
3.0 TROUBLE SHOOTING
PROBLEM REMEDY
Clamp will not engage…………………………….. • Check flow control valve to ensure it exhausts
properly.
• Verify that the rail jaws are free from obstruction.
• Check to ensure that the solenoid valve in the
hydraulic circuit is functioning properly.
• Check that full spring chamber movement is realized.
Clamp will not release……………………………. • Check to ensure that the motor is turning in the
proper direction.
• Check that the relief valve has not been set too low.
• Check that the needle valves on the manifold block
are in the proper position.
• Check that the solenoid valve coil is functioning
properly.
Actuator not extending as designed……………. • Check for rail obstruction, damage or foreign objects.
• Check the spring assembly for proper operation.
• Check that there is no binding between the guide rod
bushings and the guide rod (caution should be
exercised as considerable energy is stored within the
spring assembly when the springs are caged. This is
also the case when the spring assembly is fully
extended).
Actuator over extends…………………………… • Check that serrated shoes are not damaged.
• Check rail for wear oil damage.
• Check the guide roller.
Unusual serrated shoe wear…………………… • Check the rail clamp adjustment for the proper
working range.
• Check rail clamp operating sequence, be sure that it
is not releasing or engaging while moving along the
rail.
• Check fluid pressure to ensure that sufficient
pressure is available to fully release the clamp.
Unusual rail wear……………………………….. • Check actuator rod operating range.
• Check that the rail clamp shoes are not making
contact with the rail while the rail clamp is moving
along the rail.
Clamp will not stay released…………………... • Check for fluid leaks.
• Check that there is enough fluid pressure to fully
retract the spring assembly.
Clamp setting is showing red zone indication…… • Check that serrated shoes are not damaged.
• Clamp requires readjustment using eccentric
adjustment screw or if this is not enough adding
shims behind wedge. Maximum 2mm per wedge per
side.
• Check rail tolerance. If the rail is not within tolerance,
contact Hillmar as new levers may be required.
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
4.0 PARTS
4.1 PARTS ORDERING INSTRUCTIONS

HOW TO ORDER SPARE PARTS
1) FIND THE PART ON THE HILLMAR PARTS LIST FORM.

2) CONSTRUCT THE PART NUMBER AS SHOWN BELOW.
3) REPORT SERIAL NUMBER ON EQUIPMENT.
4) ORDER THE REQUIRED PARTS.
SPARE PARTS ORDERING FORMAT:
JOB NUMBER – PAGE NUMBER – ITEM NUMBER - DESCRIPTION
SAMPLE: X10-210-12345JB-12-1-MECHANISM ASSEMBLY
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
4.2 GENERAL ASSEMBLY

1 9 7 4 3 8 16
*
2 6 12 13 5 10 11 14 15
ITEM DESCRIPTION QUANTITY

1 Mechanism Assembly 1
2 Rail Package 1
3 Limit Switch Assembly 1
4 Wedge Assembly 1
5 Guide Wheel & Frame Assembly 2
6 Cylinder Assembly 1
7 Rail Clamp Enclosure 1
8 Manual Release Screw/Caging Fork 1
9 Internal Power Unit (FOR LE ONLY) 1
10 Capscrew – HH 4
11 Lock Washer 4
12 Vertical Guide Block 2
13 Float Block 2
14 Capscrew – HH 4
15 Lock Washer 4
16 El. Motor (FOR LE ONLY) 1
SPARE PARTS ORDERING:

* LUBRICATION POINTS (2 PLACES)
Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
4.3 MECHANISM ASSEMBLY

ITEM
1 1
2 1
1
4 2
2
1
7 2
2
1
1
11 2
12 2

Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
4.4 RAIL PACKAGE ASSEMBLY


1 Lever 2
2 Guide Wheel Frame Assembly 1
3 Guide Wheel Assembly 1
4 Serrated Shoe 1 set
5 Socket Head Cap Screw 2
6 Washer 2

Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
4.5 LIMIT SWITCH ASSEMBLY

8 7
6 5 4

1 Mounting Bracket 1
2 Limit Switch 1
3 Actuator Assembly 1
4 Capscrew – ph 2
5 Hex Nut 2
6 Lockwasher 2
7 Capscrew – HH 2
8 Lockwasher 2

Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
4.6 WEDGE ASSEMBLY

ITEM DESCRIPTION QTY

1 CYLINDER ASSEMBLY 1
2 WEDGE INSERT KIT 1
3 SEAL KIT 1
4 LINK KIT 1

Sheet Number:
RAIL CLAMPS
Hillmar
CXHV-LH-…-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
4.7 GUIDE WHEEL & FRAME ASSEMBLY

1 2 3 4 5
7 6 9 6 8

1 Hex Head Cap Screw M16 2
2 Washer Locking Ø16mm 2
3 Hex Head Cap Screw M12 4
4 Washer Locking Ø12mm 4
5 Base Plate 1
6 Side Plate 2
7 Socket Head Cap Screw M12 2
8 Guide Wheel 1
9 Pin Kit Assembly 1

Sheet Number:
ALL PRODUCTS
Hillmar
ALL
WARRANTY TERMS & CONDITIONS
Job Number:

Delta, BC V4G 1C9 ENGLISH 711-111-52532 G
P:604 946-7115 F:604 946-0329
14 FEB 07 17 of 18 200-112-46204 D
5.0 STANDARD WARRANTY TERMS & CONDITIONS

Standard warranty is 12 months from startup or 18 months from shipment whatever comes first.
5.1 Manufacturer’s Warranty – Hillmar Manufactured 5.4 Limit of Hillmar’s Responsibility

Parts Only Supplied and consumable items such as oil, grease, fuel and filters
There are no warranties, express or implied, made by either the will be furnished or paid for by the customer at Hillmar’s regular billing
distributor of the manufacturer of new Hillmar equipment except the rates on usual credit terms. Supplies and consumable items
manufacturer's warranty against defects, material and workmanship furnished by the customer must, therefore, meet or exceed the
set out below:: manufacturer’s specifications.
The manufacturer warrants each new product made by the Premium freight charges (such as air express or air fare charges for
manufacturer to be free from defects in material and workmanship, its transportation of personnel, tools and for replacement parts) and
obligation and liability under this warranty being limited to replacing other expenses will be paid for by the customer at Hillmar’s regular
free of charge at its factory, any part proving defective under normal billing rates on usual credit terms. Signed and approve records are
use and service within twenty four (24) months from the date of initial required.
sale or eighteen (18) months from start up whichever comes first.
This warranty is in lieu of all other warranties, express or implied and It is a condition of this warranty that the customer shall properly
the obligation and liability of the manufacturer under this warranty maintain and operate the equipment and comply with all the service
shall not include any transportation or other charges or consequential requirements and recommendations of Hillmar or the manufacturer.
damages or delay resulting from the defect. Any operation beyond Labour or parts furnished to make repairs required as a result of
rated capacity or the improper use or application of the product or the improper or careless operating practices, lack of adequate daily
substitution of any parts not approved by the manufacturers is operating maintenance, willful or accidental damage or normal wear
covered only by such warranties as are made by their manufacturers. and tear are not covered by warranty and will be paid for by the
customer at Hillmar’s regular billing rates on usual credit terms.
This warranty is expressly in lieu of any other warranties, express or
implied, including any implied warranty of merchantability of fitness Warranty claims will not be allowed unless Hillmar is notified in
for a particular purpose and of any other obligations or liability on the writing, by fax or other such means at the time of failure and before
part of the manufacturer and Hillmar Industries Ltd. neither assumes the expiration date of warranty. Failed parts must be submitted,
nor authorizes any other person to assume for it any other liability in freight prepaid, to Hillmar for inspection before any warranty claim will
connection with such equipment. be allowed.
The liability of Hillmar under this warranty is limited to the repair or

replacement of defective parts as provided herein (Note: all
5.2 Hillmar’s Responsibility for Labour Performed at components manufactured by others which are an integral part of our
Hillmar’s Premises unit, will be warranted in accordance with the original equipment
Labour required within the service territory of Hillmar for the repair or manufacturer’s conditions), and Hillmar, its employees, agents and
replacement of parts which are found to be defective in material or contractors shall not under any circumstances be liable for any
workmanship under the terms of the manufacturer’s warranty will personal injuries (including death) to any person (including the
normally be done by Hillmar during other than regular working hours if customer or any subsequent purchaser) or for any loss or damage to
an emergency exists, but the customer will pay the difference property or business either direct, indirect or consequential, whether
between Hillmar’s billing rates for such labour at its regular straight to the equipment or to any other property of the customer or
time billing rates on usual credit terms. subsequent purchaser of any other third party caused or contributed
to by the work performed by Hillmar hereunder or by the delivery,
operation or possession of the equipment by Hillmar or any other
5.3 Additional Condition of Warranty person or by any defect in material or workmanship or by any default
• The equipment will be checked and adjusted at Hillmar’s shop or negligence of Hillmar, its employees, agents and contractors or by
prior to shipment to the customer and instructions supplied other cause or reason whatsoever. In addition, in no case shall
concerning its maintenance. Hillmar be liable for loss of profits, income or use of the equipment
• It is a condition of this warranty that the P.M. program, as whether or not caused or contributed to by the negligence or default
included with the maintenance manual, must be followed and of Hillmar. The terms contained in this policy are in lieu of all other
records kept of such; otherwise Hillmar’s warranty will not apply. warranties either express, statutory or implied, including any warranty
• It is also a condition of this warranty that the customer shall of merchantability or fitness for a particular purpose.
properly maintain an on-site or nearby supply of spare parts
appropriate to the service conditions experienced with the 5.5 Parts Supplied by Others
equipment. Parts used in the manufacture of Hillmar Products are warranted only
• Charges and costs incurred by Hillmar necessary to expedite by such warranties as are issued by those manufacturers.
parts, which should have been immediately available as on-site
spares, will be paid by the customer.
Sheet Number:
ALL PRODUCTS
Hillmar
ALL
Job Number:

P:604 946-7115 F:604 946-0329
14 FEB 07 18 of 18 200-112-46204 D
6.0 STANDARD WARRANTY COVERAGE DETAILS
6.1 Warranty Parts Shipping: 6.6 Simple Parts Repair & Replacement
• CIF to port of entry only by Hillmar Industries Ltd. It is • Hillmar reserves the right to request as a condition of parts
customer’s responsibility to clear customs and transfer to replacement under warranty. The item which requires
the job site. minimum time to replace, repair or fix shall be completed by
• Premium shipping such as air freight shall be solely at the customer at no cost to Hillmar, i.e., at customer’s
customer discretion and cost. expense.
• Examples of such parts would be single items such as
motors, pumps, valves, etc.
6.2 Existing Faulty Parts Shipping Back:
• Customer has to pay CIF, Port of Vancouver (to Hillmar).
• If the existing damaged parts are requested by Hillmar to be 6.7 Field Service During Warranty Period:
sent back and customer fails to do so within certain time • When any field service is requested, a Purchase Order is
frame (60 days after request), the replacement warranty required from customer. Customer is entitled to request a
parts will be billed to the customer. field service cost estimate before issuing the Purchase
Order.
6.3 Warranty Replacement Parts:

• Hillmar will, at its option, 6.8 Authorized Field Service Labour
(i) repair the product using new or refurbished parts or • Field Service required on the products shall be governed by
(ii) replace the product with a new or refurbished product. the Hillmar Service Terms & Conditions document number,
500-005-65376.
For the purpose of this warranty, “refurbished” means a
product or a part that has been returned to its original 6.9 Labour and Incidental Costs
specification. Accepted warranty parts which have been • Labour costs incurred by the removal and replacement of a
replaced become the sale property of Hillmar. Hillmar product or part, while performing warranty work,
Credit shall not be issued for returned warranty parts. shall be the responsibility of the customer. Hillmar also
disclaims any liability for incidental and consequential
6.4 Warranty for Warranty Replacement Parts: damage including but not limited to, repair labour, rental
• The replacement parts are under one year warranty after vehicle, hotel and travel costs or any other inconvenience
customer’s receiving the parts, not from the time when costs.
these replacement parts are installed.
• This new warranty covers the replacement parts only.
6.5 Warranty Coverage:

• Warranty covers replacement parts only, not the installation
cost of replacement parts.
7.0 EXENTED WARRANTY TERMS & CONDITIONS

This Warranty is only applicable on contracts for which Hillmar has agreed and charged for such extended warranty conditions.
All conditions as outlined on Standard Warranty (Section 1) are applicable to any extended warranty.
Extended warranty conditions do not cover:
7.1 Non Hillmar Proprietary Parts
All parts supplied to Hillmar by third parties are subject to Hillmar supplier warranties. Hillmar cannot extend warranty conditions
beyond a maximum of 12 months from start up.
7.2 Items Subject to Wear
Items such as brake shoes, linings, rail clamp guide rollers, etc which are subject to wear during use are not subject to extended
warranty.
Sheet Number:
HYDRAULIC POWER UNITS
Hillmar
HPT-10-SSRC-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
ThyssenKrupp / Shougang 15JAN07 1 of 10 100-510-45781 E
INSTALLATION MANUAL
C:\Dokumente und Einstellungen\Harald Hof\Eigene Dateien\Aufträge Job\O&M\Montage+Bedienungsanleitung\2012-06-11\100-510-45781_E HPT-10-SSRC INSTALLATION MANUAL.doc

HPT-10-SSRC-ALL
E TM UPDATED WITH MB1-V2 31MAR11

D TM GENERAL REVISION 19MAR10
Document Template # 710-101-01336
Sheet Number:
Hillmar
HPT-10-SSRC-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
INDEX
1.0 MODELS COVERED BY THIS MANUAL ........................................................................................................ 2
2.0 REFERENCE MANUAL .................................................................................................................................... 3
3.0 REMOVAL OF CAGING FORK ........................................................................................................................ 3
4.0 FACTORY SETTINGS ...................................................................................................................................... 3

5.0 INSTALLATION ................................................................................................................................................ 3

5.1 LOCATION AND MOUNTING ....................................................................................................................... 3
5.2 PREPARATION FOR INSTALLATION - MAINTAINING CLEANLINESS ...................................................... 3
5.3 SPECIFICATIONS ......................................................................................................................................... 3
5.4 RECOMMENDED HYDRAULIC FLUID ......................................................................................................... 4
5.5 FILLING THE RESERVOIR ........................................................................................................................... 4
6.0 OIL LEVEL SETTING ....................................................................................................................................... 5
7.0 FIELD INSTALLATION & START-UP ............................................................................................................. 6

7.1 CHECK .......................................................................................................................................................... 6
7.2 SETTING INSTRUCTIONS ........................................................................................................................... 6
7.3 COMPONENTS IN MANIFOLD ..................................................................................................................... 6
8.0 SYSTEM SET-UP ............................................................................................................................................. 7
8.1 HPT-10-SSRC MODELS ............................................................................................................................... 7
9.0 RAIL CLAMP HYDRAULIC PRINCIPLES........................................................................................................ 7
9.1 OPERATING PRINCIPLES ........................................................................................................................... 7
9.2 CYCLING OF HYDRAULIC POWER UNIT ................................................................................................... 8
9.3 LIMIT SWITCH 2 STAGE LIMIT SWITCH ..................................................................................................... 8
9.4 OPERATING SEQUENCE EXPLANATION .................................................................................................. 8
10.0 TEST PORT ...................................................................................................................................................... 9
11.0 FLUSHING HYDRAULIC LINES ...................................................................................................................... 9
12.0 MOST COMMON ERRORS IN COMMISSIONING........................................................................................ 10
13.0 ELECTRICAL .................................................................................................................................................. 10
1.0 MODELS COVERED BY THIS MANUAL
HPT-10-SSRC-MB1-005 HPT-10-SSRC-MB1-020
Sheet Number:
Hillmar
HPT-10-SSRC-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
2.1 TCD-CSM MANUAL

Refer to Document No. 240-401-62333 (Rail Clamp)
2.2 O & M MANUAL

Refer to Document No. 100-510-62234
3.0 REMOVAL OF CAGING FORK

Clamps are shipped in their retracted position and are held in that position by the retraction-caging fork. See rail
clamp installation data sheet page. Refer to Rail Clamps Installation Manual for caging fork removal
procedures.
4.0 FACTORY SETTINGS

All clamps are pre-set at the factory therefore no adjustments are required. Should there be any sign of
irregular operation. Refer to the Operation and Maintenance Manual and Contract Specific Manual.
5.0 INSTALLATION
5.1 LOCATION AND MOUNTING

The power unit should be located as close as possible to the equipment it is designed to operate.
A suitably designed mounting pad should be built in a location that ensures adequate support and
protection.
5.2 PREPARATION FOR INSTALLATION - MAINTAINING CLEANLINESS

• Power units and brakes are shipped primed and ready for connection.
• Ensure dirt is not introduced into the system during installation (e.g., hose ends, reservoir filler).
• Be sure that the hydraulic fluid used is compatible with the area in which the equipment is being
installed. See below for reservoir oil requirements.
• Flush the hydraulic system before making hydraulic connections:
Apply clean pressurized air to hydraulic hose and pipes to ensure any debris is blown out.
Prime all hose and pipe with hydraulic oil to minimize air entrapment (cap ends
once full with oil if necessary).
Make all connections to power unit and brake secure.
• Be sure the relief and pressure settings conform to settings required for equipment being operated.
• Cycle system to purge any remaining entrapped air.
5.3 SPECIFICATIONS
Reservoir size 10 Liters

Accumulator pre-charge pressure See Contract System Components Settings
Pressure settings See Contract System Components Settings
Temperature and level switch:
Temperature and level switch 82°C (maximum)
Oil Level Half Reservoir Level (minimum)
Note:
The HPT 10-SSRC hydraulic power unit has been designed to operate Hillmar CTHV-LE model rail clamps.
Each unit is designed and sized to match the clamp into which it is installed.
Sheet Number:
Hillmar
HPT-10-SSRC-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
5.4 RECOMMENDED HYDRAULIC FLUID
Ambient Temperature: (°C) -40 to 10 * -25 to 25* -15 to 40* 0 to 40* 10 to 50*
ISO Standard 3448 VG15 VG22 VG32 VG68 VG100
Exxon Univis N15 Univis N22 Univis N32 Univis N68 Univis N100
Shell Tellus T15 Tellus T22 Tellus T32 Tellus T68 Tellus T100
NOTE:
The hydraulic fluids below cover the ambient temperature range of -40 to 40°C*.
- CHEVRON hydraulic fluid 5606A
- TEXACO hydraulic fluid 5606H
* Temperature ranges may vary slightly. Refer to manufacturer data sheets for exact operating criteria.
5.5 FILLING THE RESERVOIR

The reservoir oil level is correct when oil just appears in the window of the top sight glass (brakes applied).
To fill, remove cap from the filler neck, unscrew reservoir breather plug two full turns then fill to the level
as above refit and tighten both plugs.
HYDRAULIC RESERVOIR OIL LEVEL GAUGE
OIL LEVEL
AT BRAKE
SET POSITION
DO NOT
OVERFILL OIL LEVEL
AT BRAKE
RELEASED
POSITION
1. Check that the Reservoir has been filled with correct oil.
2. Check that all connections to cylinders have been completed.
Note: System must be run to ensure all trapped air in supply lines has been ejaculated from these
hydraulic lines.
Sheet Number:
Hillmar
HPT-10-SSRC-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
Delta, BC V4G 1C9 ENGLISH 122-511-58531
P:604 946-7115 F:604 946-0329
6.0 OIL LEVEL SETTING

MOTOR-PUMP
HORIZONTALLY MOUNTED
ON RAIL CLAMP ENCLOSURE
CONDUIT CONNECTOR
OR DIRECT WIRING TO
JUNCTION BOX HAND PUMP
TEMP LEVEL SWITCH
TANK TOP PLATE
OIL LEVEL GAUGE

RESERVOIR
MAX
84
94
(154)
HIGH
150
50
LOW
MIN
57
MINIMUM LEVEL OF OIL

REQUIRED FOR PUMP
SUCTION
(420)
NOMINAL RESERVOIR CAPACITY: 10 L
SITE LEVEL GAUGE

MAX OIL LEVEL: 6.7 L
MIN OIL LEVEL: 3.7 L
TEMP LEVEL SWITCH

HIGH OIL LEVEL: 3.5 L
LOW OIL LEVEL: 2.6 L
MIN LEVEL FOR PUMP: 2.5 L

CAUTION:
LOW OIL LEVEL ON TEMP LEVEL SWITCH MUST BE ABOVE MINIMUM OIL LEVEL
FOR PUMP SUCTION.
Sheet Number:
Hillmar
HPT-10-SSRC-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
7.0 FIELD INSTALLATION & START-UP
7.1 CHECK
1. Check that the Reservoir has been filled with correct oil.
2. Check that all connections to cylinders have been completed.
3. Note: System must be run to ensure all trapped air in supply lines has been ejaculated from these
hydraulic lines.
4. Understand System Hydraulic Schematic as shown on hydraulic power unit nameplate circuit diagram.
Refer to contract document section.
7.2 SETTING INSTRUCTIONS
The basic function of the power pack is to supply hydraulic power to operate the cylinder(s) of braking
devices. It has a pump to draw oil from a hydraulic tank through an in-tank strainer and in-line filter to a
manifold. The manifold then re-directs oil to the brakes. The manifold is built using the following
components:
7.3 COMPONENTS IN MANIFOLD

As some components listed below are optional, refer to Hydraulic Schematic in TCD-CSM for components
in manifold.
<CV1> Check valve allows flow from the pump and prevents back flow to the pump.
<SV1> Solenoid valve allows set/release of storm brakes. Energized, it builds up high pressure to
release the brakes; de-energized, it dumps the oil to the tank to set the brakes. Normally
open.
<RV1> Relief valve controls the maximum system pressure.
<RV> Relief valve for hand pump set at maximum system pressure.
<FC1> Flow control valve controls the flow rate from the cylinder. It can be adjusted to achieve
required rail clamp setting time.
<G1> Pressure gauge shows the system pressure.
<NV1> Needle valve isolates the solenoid valve for hand pump use. Normally open.
<NV2> Needle valve isolates the manifold block and hand pump. Normally close.
A temperature and level switch is in the reservoir installed to monitor the temperature of the system and to
check the oil level in the tank. The switch cuts the pump-motor when temperature exceeds switch setting
and/or when oil level falls below 1/2 tank level.
Sheet Number:
Hillmar
HPT-10-SSRC-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
8.0 SYSTEM SET-UP
For all pressure settings and hydraulic schematic, refer to TCD-CSM.
8.1 HPT-10-SSRC MODELS
8.1.1 GENERAL PROCEDURES

All the valves are factory preset. Setting up the hydraulic system is simple and may be achieved by
the following procedures:

1. Has oil reservoir been filled.
2. Check all needle and flow control valves are in the following positions:
<NV1> - Open <FC1> - Open <RV1> - Back off
3. Energize <SV1>. This will allow oil to flow to the brake cylinder.
4. Jog start the pump-motor, check that its rotation is correct. If it is correct, start the motor.
5. Adjust <RV1> until <G1> reads required setting (see Storm Brake Pressure Settings).
6. Check for leaks, check flow.
7. Cycle the power unit to extend and retract the brake numerous times until air is purged from
the system.
8. Adjust flow control valve <FC1> to achieve required storm brake set time.
8.1.2 PRESSURE SWITCH <PS> SETTING

Refer to Storm Brake Device release pressure settings.
1. Turn on the pump-motor.
2. Energize <SV>.
3. Adjust <PS> until the pump-motor cuts off at the upper setting. The switch has a fixed
deadband, and the lower setting is approximately at 10 bar below the upper setting.
4. Lock the pressure switch.
8.1.3 HAND PUMP TEST/USE

1. Turn off the pump-motor
2. Close the black knob <NV1> fully. Open <NV2> In-line valve.
3. Actuate the hand pump to release the brake.
4. Open the black knob <NV1> to release pressure and set the brake. Close <NV2>.
9.0 RAIL CLAMP HYDRAULIC PRINCIPLES

Refer to Hydraulic Power Unit O & M Manual.
9.1 OPERATING PRINCIPLES

Hillmar Industries hydraulic power units (HPT-10-SSRC), which release rail clamp, are NOT constant
running. They operate only as long as it takes to release the device.
It is very important that they do not run continuously for more than two (2) minutes.
Continuous running for longer than two minutes may result in overheating of the hydraulic oil and
subsequent component damage or machine shutdown.
NOTE: High oil temperature switch has been installed to ensure unit will shut down if oil temperature rises
above 180 °F.
Sheet Number:
Hillmar
HPT-10-SSRC-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
Rapid cycling of the unit will also result in the same problems.
The units are designed to provide for a maximum of ten (10) release/set cycles per minute.
The power units are equipped with a 180° F temperature switch, which must be interlocked in series with
the combined level switch to provide over temperature protection.
To provide for proper electrical hook-up, start-up and operation, the hydraulic operation should be well
understood by the system installers.
9.2 CYCLING OF HYDRAULIC POWER UNIT

Rapid cycling of the hydraulic power unit (i.e. pump motor starts and stops in excess of 4 to 6 times per
hour, i.e. more than once every 10 to 15 minutes) indicates a problem. Refer to Document #100-510-
62098 for System Leakage Troubleshooting.
9.3 LIMIT SWITCH 2 STAGE LIMIT SWITCH

Refer to Rail Clamp O&M Manual Document #200-112-46205 and check to ensure that the switch is set to
operate correctly.
9.4 OPERATING SEQUENCE EXPLANATION

Refer to Operating & Maintenance Manual for Hydraulic Power Unit.
A control signal to release the brakes is sent manually from a control cab switch or automatically from a
traverse relay to the pump motor contactor and the normally open solenoid valve.
1. Pump motor starts.

2. Normally open solenoid valve closes.
3. Hydraulic oil is sent to the brake actuator (hydraulic cylinder).
4. Clamp fully released.
5. Accumulator begins charging (pressure switch system only).
6. Pressure switch is tripped or 2nd stage of 2 stage limit switch is tripped.
7. Pump motor contactor drops out due to pressure switch trip or 2nd stage of 2 stage limit switch. Pump
motor stops.
8. SOLENOID VALVE REMAINS ENERGIZED.
9. Clamps remain released.
10. Hydraulic system internal leakage causes approximately a 3mm extension of springs. See limit switch
adjustment data sheet.
11. Pressure switch cuts in due to pressure drop or 2nd stage of 2 stage limit switch cuts in due to
movement of bottom spring plate. This activates the pump motor.
12. Pump motor contactor pulls in starting pump motor.
13. Pump motor runs 1-3 seconds.
GO TO STEP 6 REPEAT CYCLE.
Should a power failure occur or the release clamp signal be removed:
14. Springs in clamp actuator push oil through the lines and solenoid valve back to tank thus causing the
device to set.
Sheet Number:
Hillmar
HPT-10-SSRC-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
10.0 TEST PORT

Test port can be used for optional Test & Service Equipment, such as back pressure test equipment or
bleeding system.
11.0 FLUSHING HYDRAULIC LINES
Here are 10 suggestions for successful system flushing:
1. Never flush a system with actual components, such as pumps, motors, cylinders, valves and other
precision components in place. Instead, install spool pieces, jumpers, or dummy pieces in place of the
real components.
2. Remove the filter elements in the main lines to be flushed.
3. Use a flushing velocity of 2 to 2-1/2 times anticipated system flow rates.

o
4. If practical, it is advantageous to use warm (about 185 F) flushing fluid.
5. Design the flushing procedure like the whole system:
• always flush only in one direction of flow

• flush each circuit branch off the main branch one at a time, starting with the one closest to the
flushing pump, and proceeding downstream. It may be necessary to install block valves in the
system to achieve this pattern.
• in blind runs, provide vertical dirt traps by including short standpipes below the level of the branch
piping.
6. Never use system pumps as flushing pumps. Generally, a hydrodynamic pump, such as centrifugal
pump, will provide adequate head, greater flow rates, will operate more economically, and will better
tolerate contaminants circulating during flushing.
7. Always use a clean-up filter in the flushing system. Be sure its capacity matches the flow rates used.
Micrometer rating should be as fine as practical, but no greater than proposed system filter rating.
8. If possible, use an auxiliary flushing fluid reservoir to avoid trapping contaminants in the system’s
reservoir.
9. Establish a fluid sampling schedule to check contamination levels to determine when to stop.
Sheet Number:
Hillmar
HPT-10-SSRC-ALL
INSTALLATION MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
10. After flushing, take every precaution to avoid introducing contaminants while reinstalling working
components.
12.0 MOST COMMON ERRORS IN COMMISSIONING
Apart from maintenance, commissioning is possibly the single most important process affecting the service
life and correct function of a hydraulic installation.
Obviously, therefore, it is essential to eliminate as many errors as possible from the commissioning process.
The most common errors are:

1. Forgetting to filter the fluid put into the system.
2. Forgetting to check over the installation before starting commissioning (involving subsequent
modifications and waste of fluid).
3. Forgetting to bleed parts of the system.
4. Setting pressure relief valves too close to the working pressure.
5. Setting pump pressure regulators higher than or the same as the pressure relief valve.
6. Not flushing servo systems for the correct length of time.
7. Not taking any notice of abnormal pump noises (cavitation, suction line leaks, excessive air in the fluid).
8. Neglecting lateral strain on cylinder rods (i.e. installation errors).
9. Not bleeding cylinders (leading to seal damage).
10. Setting limit switches too finely.
11. Setting pressure switches without allowance for switching hysteresis.
12. Not filling hydraulic pump and motor bodies with fluid before the first start.
13. Failing to keep a record of settings.
14. Not locking or sealing setting devices.
15. Allowing too many people around the installation during commissioning.
13.0 ELECTRICAL
Reference should be made to the electrical wiring diagram supplied in the TCD-CSM.
All electrical installation should be in accordance with local codes and practices.
NOTE: Hillmar is not responsible for the electrical design for the installation of the brakes.
Sheet Number:
Hillmar
HPT-10-SSRC-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
ThyssenKrupp / Shougang 17MAR10 1 of 13 100-510-62234 C
OPERATIONAL & MAINTENANCE MANUAL

HPT-10-SSRC-ALL
Coil Voltage 24 V DC
C:\Dokumente und Einstellungen\Harald Hof\Eigene Dateien\Aufträge Job\O&M\Montage+Bedienungsanleitung\2012-06-11\100-510-62234_C HPT-10-SSRC O&M MANUAL.doc
C TM UPDATED WITH MB1-V2 31MAR11

B TM GENERAL REVISION 19MAR10
Sheet Number:
Hillmar
HPT-10-SSRC-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
INDEX
1.0 MODELS COVERED BY THIS MANUAL ........................................................................................................ 2
2.0 REFERENCE MANUAL .................................................................................................................................... 3

2.1 TCD-CSM MANUAL ...................................................................................................................................... 3
2.2 INSTALLATION MANUAL ............................................................................................................................. 3
3.0 OPERATION DESCRIPTION ........................................................................................................................... 3
3.1 INTRODUCTION ........................................................................................................................................... 3
3.2 DESIGN FEATURES ..................................................................................................................................... 3

4.0 MAINTENANCE ................................................................................................................................................ 4
5.0 LEAKAGE POINT CHECK ............................................................................................................................... 5
6.0 LONG TERM STORAGE .................................................................................................................................. 5
7.0 TROUBLE SHOOTING..................................................................................................................................... 6
8.0 STANDARD WARRANTY TERMS & CONDITIONS ....................................................................................... 7
9.0 STANDARD WARRANTY COVERAGE DETAILS........................................................................................... 8
10.0 EXENTED WARRANTY TERMS & CONDITIONS .......................................................................................... 8
11.0 SPARE PART LIST ........................................................................................................................................... 9

11.1 GENERAL ASSEMBLY ................................................................................................................................. 9
11.2 RESERVOIR ASSEMBLY ........................................................................................................................... 10
11.3 PUMP MOTOR ASSEMBLY KIT ................................................................................................................. 11
11.4 HAND PUMP ASSEMBLY & KIT .................................................................................................................. 12
11.5 MANIFOLD ASSEMBLY AND KIT (MB1-V2-SV-HP) ................................................................................... 13
1.0 MODELS COVERED BY THIS MANUAL
Sheet Number:
Hillmar
HPT-10-SSRC-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
2.1 TCD-CSM MANUAL

Refer to Document No. 240-401-62333 (Rail Clamp)
2.2 INSTALLATION MANUAL

Refer to Document No. 100-510-45781
3.0 OPERATION DESCRIPTION

3.1 INTRODUCTION
This power unit is designed to operate at various pressures, be sure the pressure setting matches the
equipment being operated (see Pressure Settings in TCD-CSM Manual). Each unit is assembled with
special care and attention paid to cleanliness and access to parts for inspection and maintenance.
The system is a zero leakage system thus all system leaks must be eliminated as soon as they are
diagnosed. It is important that the unit is shipped and stored in the upright position. This ensures that the
components housed in the enclosure function as designed.
3.2 DESIGN FEATURES
• A robust design ensures reliable performance.

• Modular design makes components easily removable and replaceable.
• A cycle counter is provided for programmed-maintenance and is visible through a sight window on the
standard junction box.
• An in-line, high-pressure filter provides system protection.
• SAE O-ring oil ports eliminate oil leaks.
• The electrical junction box is centrally located and pre-wired for easy installation.
• A hand pump with a built-in relief valve allows for manual operation with cylinder and seal protection
from over-pressure situations.
• A sight level gauge is supplied for visual indication of oil level in the reservoir.
• Anodized aluminum components resist corrosion and ensures long life
• A heavy-duty motor sized to meet specific customer power requirements.
• A pressure gauge and a relief valve provides system pressure monitoring and over-pressure
protection.
Caution
Do not bypass the temp level switch on start up or at any time during operation. Serious damage to
the hydraulic system may result as a consequence of this procedure.
Sheet Number:
Hillmar
HPT-10-SSRC-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
4.0 MAINTENANCE
It is a condition of Hillmar warranty that the customer provides proof of maintenance in writing when a warranty
claim is made. Should it become necessary to store equipment for an extended period of time, the following
procedure should be taken:
• All hydraulic components should be primed with oil and ensure protection of electrical components within
enclosure.
• Operate hydraulic system and brake(s) once a month to avoid serious deterioration of components.
HPT-SSRC
3 2
HPT-SSRC MAINTENANCE SCHEDULE

Maintenance Time Intervals (Months)
Description Cycles
1 2 3 4 5 6 7 8 9 10 11 12 24
CHECK HYDRAULIC FLUID LEVEL - SIGHT GAUGE (1) 500
CHECK PRESSURE DEVELOPED - PRESSURE GAUGE (2) 500
CHECK ALL HYDRAULIC LINES AND FITTINGS TO BE
SURE THERE ARE NO LEAKS IN THE SYSTEM. (REFER 500
TO LEAKAGE POINT CHECK IN NEXT SECTION)
CHECK ALL SETTINGS (RESET IF NECESSARY) 1000
CHECK HAND PUMP (3) OPERATION (SEE INSTRUCTION
1000
INSIDE POWER UNIT ENCLOSURE)
CHECK FOR CORRECT RELEASE TIME (ADJUST FLOW
1000
CONTROL IF NECESSARY)
CHANGE FILLER BREATHER (4) 2000
DRAIN HYDRAULIC TANK AND REPLACE FLUID 2000
REPLACE FILTER (5) 2000
Sheet Number:
Hillmar
HPT-10-SSRC-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
5.0 LEAKAGE POINT CHECK
4
CHECKING A POWER UNIT FOR LEAKS

1. Check all JIC connections, ensure that they are tight, especially connections that may have been loosened
during installation.
2. Cycle the brakes off and on to ensure that no oil is coming out of the breather. If the tank is overfilled oil will
come out of the breather (4). – THIS HAPPENS FREQUENTLY.
3. Pressurize the system for a few minutes and check for visible leaks.
4. Use the hand pump to pressurize the system and check for leaks around the hand pump (3).
5. Ensure that bottom tank plug (2) is tight and that sight level gauge (1) fittings are tight.
Caution
Your Hillmar Hydraulic Power Unit is a static system (not constant running). It is essential
that the system be kept leak free to ensure maximum operating trouble free life.
6.0 LONG TERM STORAGE
The power unit must be stored indoors in a cool and clean place away from excessive humidity. The power
unit must be stored in such a way that the components are protected from falling objects or equipment.
The power unit does not require further surface treatment for indoors storage for up to 3 months. For storage
up to 1 year, cover completely with plastic to protect from dust. It is recommended that control valves be stored
in a dry place, free of corrosive substances and vapors. A regular check should be kept on storage conditions.
Should it be necessary to store the valves for a period exceeding three months, the valves must be filled with
hydraulic oil and sealed.
Sheet Number:
Hillmar
HPT-10-SSRC-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
7.0 TROUBLE SHOOTING
PROBLEM: REMEDY:
Noisy Pump Verify oil level

Check that suction to pump is clear
Check for correct hydraulic fluid
Check that the pump is not defective or has been damaged
Check in-line filter
Check that no air is entering the suction line
Loss of Pressure Oil level too low, add oil

In-line Filter clogged
Pump rotating in wrong direction, reverse phase
Pump damaged, replace
Relief Valve not closing, replace
Solenoid Valve not operating, replace coil or valve
Excessive leakage in the system, check seals in piston and
manifold
Brakes Fail to Retract Faulty pump, replace

Piston seals failed, replace
System pressure too low, reset system
Solenoid valve not operating, replace coil or valve
Slow or Erratic Actuation Dirt in system, flush hydraulics and replace oil
Fluid level low, add oil
Incorrect hydraulic fluid, replace
Excessive internal leakage, check seals
Damaged or worn pump, replace
Piston or cylinder is binding check cylinder
Incorrect drive speed, check motor
Pump runs continuously Relief valve setting too low, reset

Solenoid valve not operating, replace coil or valve
Pump is running in wrong direction, check direction
Excessive leakage in system, check seals
Check actuator rod operating range
Pump starts and stops Faulty valve in manifold, check valves

frequently System requires re-calibration, reset system
Hand pump handle moves Faulty hand pump, replace

under normal operation Access check valve 2 springs, stretch, reset and test
Unusual rail wear Hydraulic cylinder or system leakage, check seals
Sheet Number:
ALL PRODUCTS
Hillmar
ALL
Job Number:

P:604 946-7115 F:604 946-0329
10 DEC 09 7 of 13 100-510-62234 C
8.0 STANDARD WARRANTY TERMS & CONDITIONS

Standard warranty is 12 months from startup or 18 months from shipment whatever comes first.
8.1 Manufacturer’s Warranty – Hillmar Manufactured 8.4 Limit of Hillmar’s Responsibility

Parts Only Supplied and consumable items such as oil, grease, fuel and filters
There are no warranties, express or implied, made by either the will be furnished or paid for by the customer at Hillmar’s regular billing
distributor of the manufacturer of new Hillmar equipment except the rates on usual credit terms. Supplies and consumable items
manufacturer's warranty against defects, material and workmanship furnished by the customer must, therefore, meet or exceed the
set out below:: manufacturer’s specifications.
The manufacturer warrants each new product made by the Premium freight charges (such as air express or air fare charges for
manufacturer to be free from defects in material and workmanship, its transportation of personnel, tools and for replacement parts) and
obligation and liability under this warranty being limited to replacing other expenses will be paid for by the customer at Hillmar’s regular
free of charge at its factory, any part proving defective under normal billing rates on usual credit terms. Signed and approve records are
use and service within twenty four (24) months from the date of initial required.
sale or eighteen (18) months from start up whichever comes first.
This warranty is in lieu of all other warranties, express or implied and It is a condition of this warranty that the customer shall properly
the obligation and liability of the manufacturer under this warranty maintain and operate the equipment and comply with all the service
shall not include any transportation or other charges or consequential requirements and recommendations of Hillmar or the manufacturer.
damages or delay resulting from the defect. Any operation beyond Labour or parts furnished to make repairs required as a result of
rated capacity or the improper use or application of the product or the improper or careless operating practices, lack of adequate daily
substitution of any parts not approved by the manufacturers is operating maintenance, willful or accidental damage or normal wear
covered only by such warranties as are made by their manufacturers. and tear are not covered by warranty and will be paid for by the
customer at Hillmar’s regular billing rates on usual credit terms.
This warranty is expressly in lieu of any other warranties, express or
implied, including any implied warranty of merchantability of fitness Warranty claims will not be allowed unless Hillmar is notified in
for a particular purpose and of any other obligations or liability on the writing, by fax or other such means at the time of failure and before
part of the manufacturer and Hillmar Industries Ltd. neither assumes the expiration date of warranty. Failed parts must be submitted,
nor authorizes any other person to assume for it any other liability in freight prepaid, to Hillmar for inspection before any warranty claim will
connection with such equipment. be allowed.
The liability of Hillmar under this warranty is limited to the repair or

replacement of defective parts as provided herein (Note: all
8.2 Hillmar’s Responsibility for Labour Performed at components manufactured by others which are an integral part of our
Hillmar’s Premises unit, will be warranted in accordance with the original equipment
Labour required within the service territory of Hillmar for the repair or manufacturer’s conditions), and Hillmar, its employees, agents and
replacement of parts which are found to be defective in material or contractors shall not under any circumstances be liable for any
workmanship under the terms of the manufacturer’s warranty will personal injuries (including death) to any person (including the
normally be done by Hillmar during other than regular working hours if customer or any subsequent purchaser) or for any loss or damage to
an emergency exists, but the customer will pay the difference property or business either direct, indirect or consequential, whether
between Hillmar’s billing rates for such labour at its regular straight to the equipment or to any other property of the customer or
time billing rates on usual credit terms. subsequent purchaser of any other third party caused or contributed
to by the work performed by Hillmar hereunder or by the delivery,
operation or possession of the equipment by Hillmar or any other
8.3 Additional Condition of Warranty person or by any defect in material or workmanship or by any default
• The equipment will be checked and adjusted at Hillmar’s shop or negligence of Hillmar, its employees, agents and contractors or by
prior to shipment to the customer and instructions supplied other cause or reason whatsoever. In addition, in no case shall
concerning its maintenance. Hillmar be liable for loss of profits, income or use of the equipment
• It is a condition of this warranty that the P.M. program, as whether or not caused or contributed to by the negligence or default
included with the maintenance manual, must be followed and of Hillmar. The terms contained in this policy are in lieu of all other
records kept of such; otherwise Hillmar’s warranty will not apply. warranties either express, statutory or implied, including any warranty
• It is also a condition of this warranty that the customer shall of merchantability or fitness for a particular purpose.
properly maintain an on-site or nearby supply of spare parts
appropriate to the service conditions experienced with the 8.5 Parts Supplied by Others
equipment. Parts used in the manufacture of Hillmar Products are warranted only
• Charges and costs incurred by Hillmar necessary to expedite by such warranties as are issued by those manufacturers.
parts, which should have been immediately available as on-site
spares, will be paid by the customer.
Sheet Number:
ALL PRODUCTS
Hillmar
ALL
Job Number:

P:604 946-7115 F:604 946-0329
10 DEC 09 8 of 13 100-510-62234 C
9.0 STANDARD WARRANTY COVERAGE DETAILS
9.1 Warranty Parts Shipping: 9.6 Simple Parts Repair & Replacement
• CIF to port of entry only by Hillmar Industries Ltd. It is • Hillmar reserves the right to request as a condition of parts
customer’s responsibility to clear the custom and transfer to replacement under warranty. The item which requires
the job site. minimum time to replace, repair or fix shall be completed by
• Premium shipping such as air freight shall be solely at the customer at no cost to Hillmar, i.e., at customer’s
customer discretion and cost. expense.
• Examples of such parts would be single items such as
motors, pumps, valves, etc.
9.2 Existing Faulty Parts Shipping Back:
• Customer has to pay CIF, Port of Vancouver (to Hillmar).
• If the existing damaged parts are requested by Hillmar to be 9.7 Field Service During Warranty Period:
sent back and customer fails to do so within certain time • When any field service is requested, a Purchase Order is
frame (60 days after request), the replacement warranty required from customer. Customer is entitled to request a
parts will be billed to the customer. field service cost estimate before issuing the Purchase
Order.
9.3 Warranty Replacement Parts:

• Hillmar will, at its option, (i) repair the product using new or 9.8 Authorized Field Service Labour
refurbished parts or (ii) replace the product with a new or • Field Service required on the products shall be governed by
refurbished product. For the purpose of this warranty, the Hillmar Service Terms & Conditions document number,
“refurbished” means a product or a part that has been 500-005-65376.
returned to its original specification. Accepted warranty
parts which have been replaced become the sale property 9.9 Labour and Incidental Costs
of Hillmar. Credit shall not be issued for returned warranty • Labour costs incurred by the removal and replacement of a
parts. Hillmar product or part, while performing warranty work,
shall be the responsibility of the customer. Hillmar also
9.4 Warranty for Warranty Replacement Parts: disclaims any liability for incidental and consequential
• The replacement parts are under one year warranty after damage including but not limited to, repair labour, rental
customer’s receiving the parts, not from the time when vehicle, hotel and travel costs or any other inconvenience
these replacement parts are installed. costs.
• This new warranty covers the replacement parts only.
9.5 Warranty Coverage:

• Warranty covers replacement parts only, not the installation
cost of replacement parts.
10.0 EXENTED WARRANTY TERMS & CONDITIONS

This Warranty is only applicable on contracts for which Hillmar has agreed and charged for such extended warranty conditions.
All conditions as outlined on Standard Warranty (Section 1) are applicable to any extended warranty.
Extended warranty conditions do not cover:
10.1 Non Hillmar Proprietary Parts
All parts supplied to Hillmar by third parties are subject to Hillmar supplier warranties. Hillmar cannot
extend warranty conditions beyond a maximum of 12 months from start up.
10.2 Items Subject to Wear
Items such as brake shoes, linings, rail clamp guide rollers, etc which are subject to wear during use are
not subject to extended warranty.
Sheet Number:
Hillmar
HPT-10-SSRC-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
ThyssenKrupp / Shougang 10 DEC 09 9 of 13 100-510-62234 C
11.0 SPARE PART LIST
11.1 GENERAL ASSEMBLY
5 4 3 2

1 Tank Assembly with Enclosure 1
2 Motor-Pump Assembly 1
3 Manifold Assembly and Kit 1
4 Hand Pump Assembly and Kit 1
5 Hydraulic Assembly 1
6 Electrical Assembly 1

Sheet Number:
Hillmar
HPT-10-SSRC-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
11.2 RESERVOIR ASSEMBLY

1 2 3
5 6 7
16
10
4
8
11
12
9 15 14 13

1 Tank top plate 1
2 Capscrew – SH 2
3 Lock – washer – high collar 2
4 Baffle plate 1
5 Lock washer 8
6 Threaded insert 8
7 Capscrew – HH 8
8 Level gauge 1
9 Adaptor 1
10 Tank gasket 1
11 Tank 1
12 Pipe nipple 1
13 Adaptor 1
14 Adaptor 1
15 Temp/ level switch 1
16 Adaptor 1
17 Filler Breather 1

Sheet Number:
Hillmar
HPT-10-SSRC-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
11.3 PUMP MOTOR ASSEMBLY KIT
10 3 4 6 7 8
BOX SHOWN
ROTATED 180°
NAMEPLATE
5
1LO
STD BOX
9 1 2
NOTE: - HPT-10-LE MUST USE MOTOR WITH JUNCTION BOX MOUNTED 180° FROM FEET (OPTIONS = F/180)
- HPT-10-RP MUST USE MOTOR WITH STANDARD JUNCTION BOX MOUNTED 90° FROM FEET

1 Capscrew – HH 4
2 Lockwasher 4
3 Capscrew – HH 4
4 Lockwasher 4
5 Pump 1
6 Coupling – pump side 1
7 Coupling insert 1
8 Coupling – motor side 1
9 Pump- motor adaptor 1
10 Motor 1

Sheet Number:
Hillmar
HPT-10-SSRC-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
11.4 HAND PUMP ASSEMBLY & KIT
2

1 Manifold block 1
2 Hand pump 1

Sheet Number:
Hillmar
HPT-10-SSRC-ALL
O & M MANUAL
Job Number:
275-214-01666
P:604 946-7115 F:604 946-0329
11.5 MANIFOLD ASSEMBLY AND KIT (MB1-V2-SV-HP)


SV1 SOLENOID VALVE 1
G1 PRESSURE GAUGE 1
NV1 NEEDLE VALVE 1
NV2 NEEDLE VALVE 1
NV3 NEEDLE VALVE 1
CV1 CHECK VALVE 1
FC1 FLOW CONTROL VALVE 1
RV1 RELIEF VALVE 1
FT1 FILTER (IN LINE) 1
SC SOLENOID COIL 1
TP TEST POINT 1

6.2 SLEWING GEAR

6.2.1 Drive unit A - SC 6004
 Gearbox SC 6004

and lubricant chart
 Overload coupling KTR - SI 3 with ROTEX® 55 coupling
– KTR-SI Type DK / SR / SGR: Operating-/Assembly instructions
− ROTEX® Torsionally flexible jaw type coupling Design BTAN and SBAN:
Mounting instructions
− SYNTEX® Backlash-free overload system: Operation, Assembly, Adjustment
 Drum brake TE-S 160 with Elhy-thruster EB 120/40
− Mounting, Adjustment and Maintenance of drum brakes TE
− Drum brakes TE 160: Technical data sheets
− General notes
− Electrohydraulic thrusters ELHY®: Users manual, series EB
 Large-diameter slewing bearing 061.60.3000.200.41.1522
− Technical data sheet (Rothe Erde No. 16-29236 / 60.1.43040)

Blank page

Customer:
Order number - TKF: N-033-00114 – Shougang
Gearbox type: SC 6004
Serial number: G 28 664 + G 28 665
Delivery:
2 Slew Drive Unit- STD 4500 4557749-04
This document may only be passed into the hands of third with the written consent of TKF. All
documents belonging to it are protected by copyright. A reproduction, even partially, is not
1
Page 2 of 40
Order data
Drive power P = 2,54 kW
Input speed n1 = 1800 min-1
Ratio i = 1871
Oil type ISO VG 220
Oil quantity Q = approx. 31 l

Flex. Coupling KTR-SI 3 – Rotex 55
Brake incl. thruster TE 160/120-40
Inductive sensor Bi5U-M18-AP6x
2
Page 3 of 40
Table of Contents
1 Introduction ..................................................................................... 5
1.1 General......................................................................................................... 5
1.2 Symbols used................................................................................................ 6
1.3 Product identification ...................................................................................... 7
1.4 Instructions to the operator .............................................................................. 8
1.5 Training / Instruction of staff ............................................................................ 8
2 Safety Instructions ............................................................................ 9
2.1 General instructions ........................................................................................ 9
2.2 Use according to regulations............................................................................ 9
2.3 Residual risks ................................................................................................ 9
2.4 Safety instructions........................................................................................ 10
3 Delivery / Transport / Storage .......................................................... 11
3.1 Scope of delivery ......................................................................................... 11
3.2 Transport .................................................................................................... 11
3.3 Storage ...................................................................................................... 12
4 Installation ..................................................................................... 13
4.1 General....................................................................................................... 13
4.2 Assembly.................................................................................................... 14
4.3 Alignment ................................................................................................... 15
4.4 Output coupling / Flanged joint ...................................................................... 15
5 Lubrication .................................................................................... 16
5.1 General....................................................................................................... 16
5.2 Oil temperature ............................................................................................ 17
5.3 Pressure lubrication (optional) ........................................................................ 17
5.4 Monitoring of the oil pressure (optional)........................................................... 18
5.5 Double filter system (optional) ........................................................................ 18
5.6 Oil filling ..................................................................................................... 19
5.7 Environmental protection............................................................................... 19
6 Putting into operation / Operation ..................................................... 20
6.1 General....................................................................................................... 20
6.2 Putting into service, Run-in phase / Installation of spare gearboxes ..................... 20
6.3 Putting into operation ................................................................................... 21
6.4 Heating elements (optional) ........................................................................... 21
6.5 Lubrication system (optional) ......................................................................... 22
7 Maintenance / Repairs / Waste disposal / Recycling ............................ 23
7.1 Inspection and Maintenance .......................................................................... 23
7.2 Maintenance works tob e carried out regularly .................................................. 24
7.3 Miscellaneous .............................................................................................. 26
7.4 Lubrication .................................................................................................. 27
7.5 Monitoring of the oil grade ............................................................................. 27
7.6 Cleaning oft he gearbox ................................................................................ 28
7.7 Drainage of the oil trap arranged underneath the fluid coupling .......................... 28
7.8 Welding work............................................................................................... 28
7.9 Disposal / Recycling ..................................................................................... 29
Page 4 of 40
8 Shut-down..................................................................................... 30
8.1 Short-term shutdown (gearbox mounted) ........................................................ 30
8.2 Long-term shut-down (gearbox is not mounted) ............................................... 30
8.3 Storage / Actions to be taken during storage .................................................... 31
8.4 Actions to be taken during long-term shut-down ............................................... 32
9 Malfunctions / Causes / Corrective actions......................................... 34
9.1 General....................................................................................................... 34
10 Annexes ...................................................................................... 40
4
Page 5 of 40
1 Introduction
1.1 General
These operating- and maintenance instructions written by ThyssenKrupp Fördertechnik GmbH

- BU Materials Handling - (hereinafter called TKF) is delivered with the gearbox, in order to
allow the following operations to be safely done by persons who are entitled and trained ap-
propriately:
- Transport
- Handling
- Installation
- Operation
- Maintenance
- Repair
- Disassembly
- Disposal
The original version of these operating- and maintenance instructions has been written in
German, and versions in other languages are available. The operating- and maintenance in-
structions reflect the state of the art at the time of production. TKF reserves the right to revise
these operating- and maintenance instructions at any time, without the present document
loses its validity.
The non-compliance with these operating- and maintenance instructions can have adverse
health and safety effects and can cause damages to property. This manual contains infor-
mation about the safe, proper and efficient operation of the gearbox. Moreover, the compli-
ance with these operating- and maintenance instructions helps minimize risks, repair costs
and downtimes, as well as improves the reliability of the product.
The operating- and maintenance instructions must at any time be available to the operational
staff. All persons working on or with the gearbox
- to mount or install it
- to operate the machine, including repair of failures during operation
- to remove built-on- and auxiliary equipment
- to carry out maintenance- and repair works
must have free access to this document.
5
Page 6 of 40
1.2 Symbols used
Danger!
Here emphasis is put on dangers associated with the activity described, involv-
ing a certain risk to persons. If you expose yourself or other persons to danger
you will risk your life or that of other persons or a serious accident.
All danger signs must be read. The instructions given must be followed at any
time!
Caution!
Here emphasis is put on dangers associated with the activity described and
where non-compliance may result in damages to the product or auxiliary
equipment.
All precautionary measures must be taken at any time!
Note:
This term is used to draw attention to procedures or a sequence of procedures
that are of particular importance. The instructions associated with this term are
to be observed to ensure proper functioning.
This sign is used to identify specific operating instructions or – sequences to be

• followed in the given order!
– This sign is used to identify items in listings.
6
Page 7 of 40
1.3 Product identification
Each gearbox supplied by TKF is clearly identified with the help of the type plate. From the
following figure can be seen the type plate and the data given on it.
A Manufacturer
B Order number
C Serial number
D Gearbox type
E Capacity
F Input speed
G Ratio
H Weight
I Oil type
J Oil quantity
K Year of construction
Note:
The data given in the fields B, C and D are to be added to each correspond-
ence with TKF.
7
Page 8 of 40
1.4 Instructions to the operator
This operating- and maintenance manual is part of the delivery. The operator is obliged to
ensure that the operational staff complies with the instructions given in it.
The operator must complete the instructions given in this manual by the applicable statutory
regulations with regard to safety at work and environmental protection. Moreover, the com-
pleted document must include instructions with regard to work control and reporting, taking as
basis the specific conditions on the spot, such as organization of the work, work flow and skill
of the operational staff involved.
The following regulations are to be observed too:
- Statutory regulations with regard to accident prevention
- Codes of practice with regard to safe and proper functioning
The operator is not allowed to carry out any retro-fittings or modifications on the gearbox or
the drive mechanism that might have an adverse effect on its safety, unless they have not
been expressly approved by TKF.
The same goes for the installation and setting of safety devices and any type of welding work
to be carried out on the gearbox.
All spare parts must be in conformity with the technical specifications of TKF.
The original spare parts of TKF correspond with these specifications.
The unit may only be operated by trained and specially instructed personnel. The operator is
obliged to assign responsibilities for maintenance and repair.
To be able to give guarantee, TKF must be informed about the date of commissioning.
In the event the instructions given in this manual are not complied with, claims under a guar-
antee against TKF are lost. TKF repudiates each and every claim put in after damage due to
non-compliance.
1.5 Training / Instruction of staff
The operator must inform the operational staff about the applicable safety regulations, and
must it train as to handle safety devices mounted on or near the gearbox.
The mode of instruction must correspond with the qualification of the personnel.
The operator must ensure that the instructions were fully understood and must achieve their
application. These measures are necessary to ensure that the personnel are aware of the risks
and safety issues connected with the equipment.
Keeping of the instructions should be checked at regular intervals.
We recommend that those involved in courses should be requested by the operator to confirm
their attendance by signature.
8
Page 9 of 40
2 Safety Instructions
2.1 General instructions
The gearbox has been designed in accordance with the state of the art and all applicable safe-
ty regulations.
Certain risks, injury to users or third, damages to the system or other parts, however, cannot
be totally excluded, if:
- the unit is operated by staff not specially trained and instructed,

- the unit is not used according to regulations,
- the drive mechanism is not maintained / serviced properly.
2.2 Use according to regulations

The gearbox has been designed to transmit the torque and speed from a drive unit to a driven
unit.
The technical specifications must be taken into account for all applications.
They are enclosed with this operating manual or mentioned in the data sheet furnished with
the gearbox.
Any other use is considered to be not in accordance with the regulations. The operator and
user are held responsible for damages due to an improper use of the gearbox. The same ap-
plies to unauthorized modifications made on the product.
The proper use also includes the observation of the instructions given in the present manual in
view of:
- Safety
- Operation
- Maintenance
- Mounting.
Caution!
A no-load operation of the gearbox can entail damages to the bearings.
2.3 Residual risks

Even if all safety instructions are complied with, there is a residual risk of injury and damage
arising out of the operation of the gearbox.
Danger!
Risk of injury from rotating parts of the gearbox
The gearbox must feature the necessary safety devices to prevent accidental
contact with rotating parts. The gearbox must not run without properly mount-
ed safetydevices.
9
Page 10 of 40
2.4 Safety instructions

The gearbox may only be used for the intended purpose and when in proper working order. It
must be operated in conformity with the instructions given in this operating manual! Any de-
fect or fault having a detrimental effect on the safety must be rectified without delay!
All persons involved in the assembly, the operation and the repair of the gearbox must have
read and fully understood this operating manual.
This manual must be kept near the gearbox, accessible to each and every authorized person.
TKF undertakes no responsibility for damages due to non-compliance with this operating
manual. The appropriate safety instructions and other generally accepted practices regarding
safety and health must be adhered to.
When carrying out inspection-, maintenance- and repair works on the gearbox and devices,
always follow the instructions given in this manual!
The responsibilities in conjunction with various inspection- and maintenance tasks must be
clearly defined. Otherwise, there might be an increased risk of damage and injury. If safety-
relevant failures or changes are observed during operation of the gearbox, the drive mecha-
nism must be immediately stopped and the responsible department and person must be in-
formed. Only suitably trained and authorized personnel may work on the gearbox. It must be
ensured that all legal requirements as to minimum age of staff are complied with!
2.4.1 Operation of the gearbox

The gearbox may only be operated when fully assembled and in proper working order.
All safety devices and safety-relevant equipment, e.g. protective hoods that can be detached,
etc., must be in mounted and proper condition before the gearbox may be started!
2.4.2 Maintenance / Troubleshooting

The maintenance schedule part of this manual must always be kept. A suitable workplace is
imperative for the proper maintenance of the equipment.
If the machine train in which the gearbox is installed needs to be stopped to enable mainte-
nance- or repair works to be done, it must be protected against unintended switching on.
- Lock all main operating devices like switches, locks and valves and remove the key, as
well as
- fix warning signs to the main operating devices.
Secure the drive mechanism against unintended rotational movement.
Tighten screws that may have been loosened during repair- or maintenance work! If neces-
sary, use a torque spanner to secure the screws.
If the execution of works required the safety devices to be removed, they must immediately be
checked after remounting for their proper functioning!
When replacing components by using lifting gears, ensure the safety of the parts to be han-
dled, in order to avoid accidents! Make only use of lifting gears that are in technically perfect
state and that have sufficient lifting power!
Ensure the safe and environmentally compatible disposal of all substances and replaced parts
according to the statutory regulations.
10
Page 11 of 40
3 Delivery / Transport / Storage

3.1 Scope of delivery
Unless agreed otherwise, the gearbox is supplied in working order, but without oil filling. Ex-
ternal parts of the gearbox (shaft ends, etc.) are treated with an anticorrosive agent (TECTYL
846/TECTYL 502). The interior of the gearbox is protected by means of a preservative oil (e.g.
SHELL VSI* OIL, CASTROL ALPHA SP220S, Texaco Regal R&O VSI). This oil contains volatile
matters that protect from corrosion for a limited period. The gearbox must be made airtight, in
order to keep the gases escaping from the anticorrosive agent in the gearbox.
If the gearbox features additional components (couplings, lubrication system, etc.), separate
operating instructions for these components will be attached to this manual. Upon receipt of
the delivery the goods must be inspected to ensure that they are complete and free of dam-
ages. If this is not the case, TKF is immediately to be informed in writing. TKF’s general terms
of business apply.
3.2 Transport
Note:
Gearbox and accessories must get a PVC shrink-wrap and, if possible, be
boxed with desiccants (see packing guidelines according to HPE standard).
Danger!
Risk of injury due to falling parts!

Make only use of lifting lugs appropriate for the weight and size of the deliv-
ery/packing.
The packing has been jointly selected with the forwarding- and packing agent to satisfy the
demands on the transport, the range and the size of the delivery.
• Prior to the transport, it must be made sure that the gearbox is properly secured against
slipping / working loose.
• Jerks and shocks (e.g. due to bumpy roads) are to be avoided.
• Always comply with the applicable regulations on safety at work!
• Make use of timber blocks when laying ropes around sharp edges.
• Pipes are to be protected against damages.
11
Page 12 of 40
Lifting lugs at the upper part of the housing are not intended for the transport of the drive unit,
but they may only be used to detach the upper part of the housing, if not stated otherwise.
The gearbox is best transported by using appropriate ropes and shackles to be fixed to the
lifting lugs and eyes provided for.
The lifting lugs and eyes are marked with this symbol.
3.3 Storage
Prior to the delivery, the gearbox has been treated with an anticorrosive agent. The corrosion
protection lasts 12 months starting from date of delivery at the latest (gearbox packed, ready
for shipment), insofar as the gearbox is not opened, as well as protected against atmospheric
exposure (rain, snow, etc.).
Note:
The location at which the unit needs to be stored must meet the requirements
specified in chapter 8.3.
Caution!
Danger of damages to the gearbox due to corrosion!
If the gearbox is stored for more than six months, the outer protective coats must be regularly
inspected and made new, if necessary.
Caution!
Before applying any protective coats to the gearbox, protect the seals from
getting contaminated by paint or anticorrosive agent (cover with tape).
Adhesive
Tape
0-Ring
Note:
TKF shall not be held liable for damages caused by improper preservation or
storage of gearbox or individual parts as soon as the purchaser has accepted
responsibility!
12
Page 13 of 40
4 Installation
4.1 General
To assure a proper functioning, the gearbox must be placed on a flat and vibration-free foun-
dation. If the gearbox has to run with minimum noise emission, there must be taken actions to
enable the gearbox to be uncoupled from its base (e.g. dampers).
The shaft ends are treated with an anticorrosive agent. It must be stripped by using a solvent
before mounting couplings or other attachments. Solvents must not have an aggressive effect
on seals, paint or metal. Never use abrasives.
Caution!
The corrosion protection must be removed in the first place. While doing so,
avoid damages to seals and surfaces!
Use the threaded hole at shaft end to mount the drive components (e.g. couplings, wheels,
drums, pulleys, etc.).
A forced mounting causes damage to antifriction bearings, fitting keys, flanges and teeth.
Caution!
Danger of damages to the machine due to the use of unsuitable tools! Never
proceed to a forced mounting.
The gearbox is to be connected with other machines by means of screw joint in
accordance with the general arrangement drawing.
For more details on the installation of drive components, please refer to the documents en-
closed herewith.
13
Page 14 of 40
4.2 Assembly
Note:
Only specially instructed personnel may install the gearbox with the aid of suit-
able tools and equipment. Never use hammers or other striking tools or tools
with pointed and sharp edges!
When aligning the gearbox, see to it that all lubrication points are freely acces-
sible. Actions are to be taken to protect against contact with rotating parts. The
safety regulations applicable on the spot must be adhered to. Electrical con-
nections and circuits are made available by the client.
Note:
Fitting dimensions and other details connected with the installation are to be
taken from the enclosed data sheet.
Caution!
When laying separately supplied lubrication pipes, it must be made certain that
the plugs to prevent the pipes from getting dirty are removed.
Insufficient lubrication causes damages to the bearings!
14
Page 15 of 40
4.3 Alignment
The gearbox must be brought in line with the driven machine with the utmost care, even if
self-aligning couplings are used.
Note:
Always observe the manufacturer’s instructions regarding the machines!
The offset between both the input shaft and the output shaft must be minimal.
The values obtained are to be documented.
• Angular misalignment max. 0,01 mm / 100 mm referred to the

biggest diameter
• Offset max. 0,025 mm of the shaft axes to
each other
Note:
During alignment one shaft shall be fixed and the other one be turned in one
direction only, in order to ensure exact measurement. Furthermore, thermal
expansions have to be taken into account.
4.4 Output coupling / Flanged joint

The coupling/flanged joint consists of two halves. The output shaft of the gearbox is a solid
forged part featuring a flange. The flange situated on the output side is, as a rule, a flange
with shrink disk. The two parts are connected with each other by hydraulically tightened
screws. So a frictionally engaged joint is obtained. The joint can be easily disassembled (re-
duction of downtimes when replacing a gearbox). The alignment of the flanges to each other
is assured by centering and bores. If the couplings show no marks, the coupling halves are
manufactured so precisely to enable them to be arbitrarily mounted with each other. The axial
movement must be so small to avoid the occurrence of inadmissible wobbling. Two oil
grooves in the coupling hubs ensure an optimal oil distribution along the conical sleeve during
mounting/dismounting.
15
Page 16 of 40
5 Lubrication
5.1 General
Note:
Oil filling: The gearbox is delivered without oil filling!
To lubricate TKF drive units, only use gear lubricant oils recommended by TKF. Generally, the
lubricants are part of the extent of operating- and maintenance works.
The gear lubricant oils recommended by TKF contain additives protecting the equipment from
corrosion and extending the service life thanks to reduced wear in the mixed friction area. The
use of gear lubricant oils not in compliance with the standards required voids TKF’s warranty.
The oil viscosity and quantity given on the type plate of the gearbox is binding.
The use of a product with different viscosity is only permitted after consultation with TKF. The
purity of the product affects the reliability and the useful life of gearbox and lubricant. TKF
therefore recommends using only pure and clean oil. If large volumes of oil are needed, it
might be necessary to clean the oil at regular intervals and to carry out analyses, in order to
determine whether the oil has to be changed. Do not mix oils of different grades. When chang-
ing to a new product, consult the respective manufacturer to find out whether his product is
compatible with the old one, as incompatibilities and contaminations by residual oil cannot be
excluded. When changing to a product differing widely from the old one, the gearbox must be
flushed with the new oil before oil is filled in. Ensure that the residual oil is removed from the
gearbox, as far as possible.
Caution!
Ensure that the lubricant oil will not be mixed with other substances. Never
flush the gearbox by means of petroleum or other cleansing agents as resi-
dues of these substances could remain in the gearbox.
In case of changed operating conditions (ambient temperatures, speed, load
cycles), it might be necessary to replace the lubricant oil by a product of higher
or lower viscosity. Under certain conditions the use of synthetic oil might be
required. Before using synthetic oil, consult TKF.
16
Page 17 of 40
5.2 Oil temperature

The operating temperature depends on the present ambient temperature and the strain on the
gearbox.
Caution!
Ensure that the maximally admissible oil sump temperature will not be exceed-
ed.
TKF advises monitoring this temperature regularly.
Contact TKF if the oil exceeds the admissible temperature range due to high
ambient temperature. High temperatures shorten the useful life of the oil con-
siderably.
Caution!
Monitoring of the oil temperature
TKF advises recording the temperatures regularly.
If the oil temperature increases during comparable operating conditions, there
is a possibility of damage to the drive unit. In order to avoid a major damage or
even a total failure, the drive unit should be inspected carefully.
Note:
If bearing temperatures above 120°C are measured, stop the drive unit imme-
diately and carry out an inspection.
5.3 Pressure lubrication (optional)

The circulating lubrication is a separate system, mounted on its own frame. It is delivered in a
ready-to-be-mounted-state, with all connecting pieces.
The required oil comes from the gearbox. The circulating lubrication is installed next to the
gearbox.
Ensure that the operating- and control voltage goes with the energy supply existent on the
spot. The air supply to the cooler must not be disturbed.
The operating- and maintenance instructions regarding the lubrication system are enclosed
with this manual.
Caution!
The oil level in the gearbox should be checked after the first operation. Add oil,
if necessary!
For further information about the operation of the system, please refer to chapter 6.
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5.4 Monitoring of the oil pressure (optional)

The gearbox features a pressure switch triggering an acoustic or visual signal as soon as the
oil pressure drops below the minimally admissible value.
The operating pressure is reached shortly after switching on the pump.
Caution!
Increase of the oil pressure during operation:
If the oil pressure gauge shows an increased value while the operating tem-
perature is within the normal range, inspect the lubrication points as they might
be blocked. For details on the oil pressure control, please refer to the docu-
ment enclosed with this manual.
The connection to the electrical mains is incumbent on the client.
5.5 Double filter system (optional)

The filter has been equipped with a maintenance indicator. As soon as the differential pres-
sure exceeds the given value, a signal for changing the filter is triggered. The process se-
quence to be followed when replacing the filter is described in the document enclosed with this
manual.
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5.6 Oil filling

The gear lubricant oil is to be filled through the openings marked. The data given on the type
plate are decisive. Use a filter or a fine screen to fill the oil.
Note:
The oil level must be in the middle of the sight class or at the top mark of the
dipstick.
During starting-up, the lubricant oil is distributed in the gearbox, or in the lubri-
cation system (optional). As this may possibly lower the oil level, it must be
checked after a short operating time. The oil is only allowed to be filled up at
standstill of the gearbox!
Caution!
The oil level must be checked as often as possible when the gearbox is not
inclined and at standstill. This is the only way to safely measure the oil level.
In case of gearboxes featuring no sight glass or dipstick, the oil is to be filled

until it escapes from the outlet.
5.7 Environmental protection

Caution!
Oil, grease and waste containing lubricant can cause serious damage to the
environment.
Make sure that lubricants are never spilled, and that they cannot penetrate into
the ground, sewage system or groundwater. Lubricants must be disposed in
accordance with the statutory regulations.
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6 Putting into operation / Operation

6.1 General
To put into operation the gearbox, the instructions given in the chapters 3, 4 and 5 are to be
complied with.
If it is a matter of gearboxes with fixed sense of rotation (marking on the gearbox) see to it that
the connection to the driven component is carried out correctly.
Pull off the tape from the shafts and remove all transport securities, provided that the anticor-
rosive agent has already been washed off (see chapter 3.1).
Before being put into service, the gearbox must be filled with oil (see chapter 5).
6.2 Putting into service, Run-in phase / Installation of spare gearboxes

Inspect the monitoring- and control equipment prior to the start-up.
Check the oil level of the gearbox and, if necessary, of the lubrication system, as well as of
other built-on components.
Start the drive unit and gradually increase the speed to 50% of the rated speed. Operate the
gearbox with a load that is equivalent to about 25% of the rated torque until the maximally
admissible oil temperature is reached. Gradually increase the load to about 40% of the rated
torque, and operate the gearbox in this state for about 3 hours. After that, gradually increase
the load to 70% of the rated torque, and operate the gearbox in this state for further 3 hours
prior to its operation at rated torque. During putting into operation, pay attention to abnormal
noises and inadmissibly high temperatures. Monitor and register the current consumption of
the drive unit. On guarantee grounds, the record is to be made available to TKF.
Note:
As a rule, bevel wheel gearboxes feature a paired taper roller bearing at the
input shaft. Before starting up the bearing must be filled with 10 l warm oil
through the marked opening. In case of low ambient temperatures, the oil
must have a temperature of about 50°C and must continuously be filled, in
order to enable the viscous oil to be dissolved. Starting up of the gearbox has
to take place immediately after filling.
During putting into operation, pay attention to abnormal noises, leaks and temperature of bearings.
Note:
After about 10 operating hours at full load, take the following actions:
- Check the contact pattern on the tooth flanks of all pinions and wheels.
- Check the temperature of bearings.
- Inspect all screw joints and tube fittings for tightness.
- Inspect the complete gearbox for leaks.
After about 1000 operating hours or 12 months, take the following action:
- Oil change
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6.3 Putting into operation

The gearbox must run without load for a period of at least 15 minutes to ensure sufficient lu-
brication and safe operation, in particular if it is a matter of gearboxes featuring splash lubri-
cation.
Note:
6.4 Heating elements (optional)

Heating elements are used to ensure a minimum oil sump temperature prior to starting-up
and during operation.
Heating shall take place as a function of ambient temperature and oil viscosity in accordance
with the following values:
Caution!
There is a risk of damage to bearings and teeth due to insufficient lubrication.
When starting up the gearbox with load, ensure that the oil sump temperature
is not below the following values:
Oil type / Viscosity Minimum oil sump temperature

CLP / 150 + 0°C
CLP / 220 + 5°C
CLP / 320 + 10°C
CLP / 460 + 15°C
Heating should be stopped as soon as the oil sump temperature exceeds the values men-
tioned by 5°C.
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6.5 Lubrication system (optional)

The oil is sucked off by means of the oil pump from the gearbox housing. Check both the
pump and the fan for the right sense of rotation by brief switch on. Inspect the filter during
putting into service, and clean it, if necessary.
Note:
The oil level in the gearbox must be checked after having operated the pump
for the first time, because oil must possibly be added.
Operating data:
- Ambient temperature:
The lubrication system is only allowed to be operated at certain oil tem-
peratures. The pump may be damaged due to a too high oil viscosity
because of a too low temperature in the pipe system of the cooler.
• Start: T Öl >+10°C
• Stop: T Öl < +5°C
- Pressure switch on double filter:
The pressure switch is set to 5 bar and has two switch states:
• p < 5 bar: Filter is free.
• p > 5 bar: Filter is blocked and must be changed out.
- Pressure switch on output line:
• p < 0.5 bar: Switch is open  Pump is out of operation
• p > 0.5 bar: Switch is closed  Pump is in operation
- Oil pump:
• ON: Ambient temperature > +10°C
• OFF: Ambient temperature < +5°C
- External oil cooler:
• ON: Pump in operation and oil sump temperature >
80°C
• OFF: Pump out of operation or oil sump temperature <
70°C
Note:
Under certain conditions, the oil pump is also enabled to be started at tem-
peratures below +5 °C:
• If the oil sump is constantly heated.
• If the oil sump temperature is constantly above +5°C.
• If the pressure switch closes 5 seconds after the pump start.
For more details on the lubrication system, please refer to the respective document enclosed
with this manual.
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7 Maintenance / Repairs / Waste disposal / Recycling

7.1 Inspection and Maintenance
This chapter describes the inspection- and maintenance works to be carried out regularly on
the gearbox and other components (lubrication system, etc.). The applicable safety regula-
tions are always to be complied with.
All inspection- and maintenance works are to be documented, to enable at any time to be a
good judge of the plant. This documentation also makes easier the search for the causes in
case of problems and damages. Through regular maintenance problems and defects are early
detected and so downtimes and damages to the plant avoided.
Caution!
Never touch rotating parts, not even during the execution of inspection- and
maintenance works!
Danger!
In case of an accidental rotation of shafts, there is a danger of serious

injury due to rotating parts (couplings, etc.).
Before detaching covers (protective hoods, inspection covers, housing parts), ensure that the
drive unit is stopped, not able to start or to be started accidentally.
Note:
All maintenance works are to be carried out by specialist technicians or service
personnel. Before starting these works, the gearbox has to be fully shut down.
• Lock all operating devices (switches, valves) and remove the key. Set up
warning signs.
• Ensure that the gearbox cannot be started when carrying out maintenance
works.
• After a disassembly, the gearbox is only allowed to be started again after
full assembly, provided that it is in a technically perfect condition.
• Take precautions near the gearbox to prevent lubricant or oil mist from igni-
tion.
• During filling with lubricant, oil mist, that is inflammable, can escape.
Note:
Prior to the removal of the inspection cover, clean the area around it. Small
parts like screws, nuts, bolts, tools, etc. should never be laid down near the
opened inspection cover.
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7.2 Maintenance works to be carried out regularly
Period of time Controls

Daily Inspection for abnormal noises, signs of leaks or overheating.
The surface temperature of the gearbox housing is not allowed to ex-
ceed
95°C during operation. Dust deposits that may cause inadmissibly high
temperatures must be removed.
The oil pan that belongs to the fluid coupling (optional) is to be inspect-
ed, and water collections must be drained off.
Weekly At standstill of the gearbox: Check the oil level and add oil, if necessary.
Monthly Re-lubricate all seals in accordance with TKF’s inspection- and mainte-
nance chart (see Annex).
Top up grease as long as fresh grease becomes visible at the grease
collar.
Both the removal and the disposal of the used grease must be made in
accordance with the applicable statutory regulations.
at least Take an oil sample during operation of the gearbox.
every 3 months Oil change must possibly be done as a function of the result obtained
when making the oil analysis.
Every 12 months Inspection of the accessible tooth’s planes of action through the inspec-
tion holes.
7.2.1 Lubrication chart

The inspection- and maintenance chart for the gearbox TKF delivered is enclosed with this
manual.
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Page 25 of 40
7.2.2 Oil quantity and Oil level
Danger!
Only check the oil level of the gearbox at standstill, after a brief downtime (ap-
prox. 10 minutes).
Note:
The vertical installation (input gear or output gear arranged vertically down-
wards) is only allowed to be done having made provision for an oil level con-
trol.
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7.2.3 Oil change

• Drain the used oil while still warm.
• Flush the gearbox by means of fresh oil, if necessary.
• Refill the gearbox with fresh oil till the given oil level is reached. To do so, use a filter or
a fine screen.
Note:
Clean the area surrounding the opening. Do not lay down parts (screws, nuts,
bolts, tools, etc.) next to the opening.
7.2.4 Lubricant
Make only use of lubricants that have been released by TKF before. A summary of the lubri-
cants TKF released is attached to this manual.
7.3 Miscellaneous
• The surface temperature of the gearbox housing, that is to be monitored, if necessary,
must not exceed 95°C during operation. A suitable position to monitor the admissible
temperature of the gearbox housing is within the area of the bearings on the drive unit.
Dust deposits on the gearbox causing inadmissibly high temperatures are not permitted,
because there is a danger of dust explosions.
• Parts or equipment belonging to the gearbox are not allowed to be extended or modified
without TKF’s written approval.
• Should the gearbox be located in a potentially explosive area, the improper or faulty in-
stallation may bring about inadmissibly high temperatures.
• The use of the gearbox is only allowed to take place under admissible conditions and
within the limits.
• The gearbox must not be flooded.
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7.4 Lubrication
Since the gearbox has already been put into operation on the test stand and subsequently
flushed, the first oil change is necessary after approx. 2000 operating hours.
Note:
Check under critical environmental conditions (high level of contamination,
presence of aggressive gases in the air, high ambient- and oil temperature,
high loads, etc.), whether the intervals provided for oil changes are sufficient
enough. If there is any doubt, please get in touch with TKF.
The oil must be drained while still warm (operating temperature). For this pur-
pose open the oil drain plug. If the oil is heavily contaminated, the gearbox will
be flushed by using fresh oil.
TKF recommends changing the oil after 5000 operating hours at the latest or
at least once a year.
Before being filled with fresh oil, the gearbox has to be flushed with plenty of
oil.
Check the oil level regularly and top up with oil, if necessary.
If the gearbox is not used for some time, it will have to be operated every two
weeks for 4 hours, or to be filled with anticorrosive agent.
The filter elements of gearboxes featuring a lubrication system are to be
checked regularly and cleaned, if necessary. For the actions to be taken to
clean the filters, please refer to the corresponding operating instructions en-
closed with this manual.
Many gearboxes have lubricators for bearings and seals. The gearboxes are
delivered in lubricated condition. As a function of the operating conditions, re-
lubrication should take place after 2500 to 5000 operating hours.
The rotary shaft seals must be lubricated, in order to avoid damages to the
lips. The lubricant used must be consistent with the oil.
Protect the seals and the shaft ends against contamination before applying the
paint.
Shut-down the gearbox prior to starting such works.
7.5 Monitoring of the oil grade

It is not possible to avoid condensation of water inside the gearbox during operation. In order
to prevent the gearbox from corrosion and damages, the oil must be analyzed at least every 3
months while taking an oil sample during operation. When observing foreign particles, chemi-
cal changes or inadmissibly high water content, the oil must be changed immediately.
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7.6 Cleaning of the gearbox
All points that are lubricated by means of grease have to be cleaned regularly.
Danger!
Never use a pressure washer to clean the gearbox.
The gearbox is allowed to be cleaned by a water pressure of maximally 5 bars.

Never turn the water jet directly towards the labyrinth covers.
7.7 Drainage of the oil trap arranged underneath the fluid coupling
The oil trap that is arranged underneath the fluid coupling must be checked daily. In case of
water, the oil trap needs to be drained completely.
Danger!
The oil trap may be filled up to the top with water due to rainfall or cleaning
work, and oil of the fluid coupling cannot be safely collected.
7.8 Welding work

Do not carry out welding work on the gearbox!
Caution!
Driving and driven components connected to the gearbox have to be earthed
as to avoid current passage. A current passage can bring about major damag-
es to the bearings and the teeth, or a total failure of the gearbox.
If pipes have to be connected by welding to the oil inlet or outlet,

isolators must be placed between the flanges.
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7.9 Disposal / Recycling

Materials used to carry out maintenance works may be hazardous and must be disposed of in
accordance with specific regulations.
For the disposal of lubricants and cleaning agents, the regulations applicable on the spot are
to be complied with.
Caution!
Oil, grease and waste containing lubricant may lead to serious damage to the
environment. Those materials must be disposed of by a specialist company.
• Oil, grease and waste containing lubricant must be brought to a waste col-
lection point. They must be subsequently handed over to a specialist com-
pany.
• For the disposal of complete gearboxes, comply with the applicable statuto-
ry regulations.
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8 Shut-down
8.1 Short-term shutdown (gearbox mounted)
Caution!
Avoid condensation of water in the gearbox during storage.
TKF recommends taking the following actions to protect the components:

• If the gearbox is shut-down for more than 2 weeks, it must be operated
every two weeks for at least 4 hours.
Note:
This short-time operation has the purpose to cover all parts with an oil film, in
order to prevent them from corrosion.
Observe the instructions given in chapter 8.2 and 8.3 if it will not be possible to
operate the gearbox short-time, as described before.
8.2 Long-term shut-down (gearbox is not mounted)

TKF recommends taking the following actions to protect the components:
• Drain the operating oil off the gearbox.
• Fill the gearbox with preservation oil up to the operating level to protect it against corro-
sion.
• Every bore visible from the outside is to be sealed by means of an adequate plastic plug.
• Cover the labyrinth- and rotary shaft seals between shaft and cover with tape.
Klebeband
Tape
0-Ring
• Apply a long-term anticorrosive agent (TECTYL 846) on external, machined surfaces.

• Do not operate the gearbox or turn the shafts in idle state.
Caution!
Before applying protective coatings to the gearbox, protect the seals from con-
tamination by paint or anticorrosive agent (cover with tape).
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Note:
Remove all seals at the end of the shut-down period. Drain the preservative oil
off the gearbox, and flush it by making use of the recommended operating oil.
After that, fill the gearbox with operating oil up to the specified level.
Note:
TKF shall not be held liable for damages caused due to improper preservation
after the purchaser has accepted responsibility!
8.3 Storage / Actions to be taken during storage

The location at which the gearbox is to be stored must meet the specified requirements.
• TKF recommends storing the gearbox in a dry room and protecting it from shocks and
vibrations.
• To prevent the bearings from brinelling, shocks and vibrations beyond 0.05 mm and 60 Hz
are not allowed to appear in the storage area. If the values mentioned before are exceed-
ed, the gearbox must be placed on a vibration reducing support.
• The storage shall take place at temperatures below +10°C and over +50 °C, and the rela-
tive humidity must not exceed 60 %.
• Ensure that the gearbox is not exposed to air with an increased degree of salt and acidity.
• Seal each and every drill hole visible from the outside by means of an adequate plastic
plug. The gearbox is delivered with sealed drill holes.
• Protect the labyrinth- and rotary shaft seals between shaft and cover by using a tape.
Adhesive
Tape
0-Ring
• If the gearbox is stored for more than 6 months, inspect the protective coats on the ma-
chined surfaces regularly and renew, if necessary.
Note:
Period of preservation:
− 6 months if stored in the open and protected against wind and wetness
(rain, snow)
− 1 year if stored in a dry room
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Caution!
There is a risk of damage to the gearbox due to corrosion!
Note:
TKF shall not be held liable for damages to the gearbox or components caused
due to improper preservation / storage after the purchaser has accepted re-
sponsibility!
8.4 Actions to be taken during long-term shut-down

Note:
TKF recommends proceeding as described in chapter 8.2.
Note:
Take the following actions if the procedure described in chapter 8.2 is not ap-
plicable. The demands on the environment, described in chapter 8.3, are still
to be satisfied, but the inspection intervals and the preservation mode change.
• Storage in the open:
− The preservation is to be inspected after 3 months. Having removed
the
inspection hole cover, inspect the interior of the gearbox for rusty
spots. If there are no rusty spots, start preservation.
− No corrosive spots: Apply an anticorrosive agent like “TECTYL 502” for
example. TKF recommends using a spray gun to preserve the gearbox
inside. Turn the shafts slowly by hand during spraying. After that, close
the inspection hole cover and seal the labyrinth- and rotary shaft seals
between shaft and cover.
− Corrosive spots: Consultation with TKF to fix a procedure that is appro-
priate to achieve the readiness for service again.
− This procedure is to be repeated every 3 months.
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Note:
• Storage in a building:
the
example. TKF recommends using a spray gun to preserve the gearbox
− Corrosive spots: Consultation with TKF to fix a procedure that is appro-
priate to achieve the readiness for service again.
Note:
The corrosion protection of external, machined surfaces has to be renewed
after preservation of the internal parts of gearbox.
Caution!
There is a danger of damages due to corrosion. The storage period should not
exceed 3 years.
Note:
TKF shall not be held liable for damages to the gearbox or components caused
due to improper preservation / storage after the purchaser has accepted re-
sponsibility!
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9 Malfunctions / Causes / Corrective actions

9.1 General
Danger!
Adjustments and changes that have an effect on functioning of the machine

necessitate TKF’s written approval. In case of non-compliance with the instruc-
tions given in this manual TKF is not liable to respond in damages. In such a
case the rights under a guarantee are lost.
Note:
The instructions given in chapter 2 are to be adhered to.
To judge a failure of the gearbox, the machines built on have to be inspected
too. The noises and vibrations produced by the gearbox in all operating states
must be as low as possible. Every deviating behavior is to be regarded as ab-
normal. The respective actions to eliminate the failure are to be taken.
To repair the failure the drive unit is to be shut down and to be secured against
unintentional start-up, and information signs are to be set up.
Note:
The repair of failures that occur within the guarantee period is only incumbent
on TKF.
Even on expiration of the guarantee period, TKF should be entrusted with the
repair of failures the cause for which cannot be determined clearly.
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Possible malfunctions – Causes and corrective actions
Malfunction Possible cause Corrective actions

Unusual gearbox noises Operation out of the admissible pa- Inspect the bearing / toothed items,
rameters (load, rotational speed, etc.) replace, if necessary
Oil level is too low Check the oil level, top up with oil, if
necessary
Oil level is too high Check the oil level, drain the oil, if nec-
essary
Wrong oil type Drain the oil, flush and refill the gearbox
with the right oil type
Damage to the tooth Inspect for damages to the teeth, re-
place defective items
Consultation with TKF
Bearing play has increased Adjust the bearing play

Damage to bearing Replace damaged bearing
Check the alignment
Ring gear has come loose due to over- Fix the ring gear
load
Toothed wheel has come loose due to Fasten the toothed wheel
overload
Incorrect alignment Separate and realign the parts
Backlash is too big Adjust the backlash correctly
Noises in pump area Fastening bolt has come loose Fasten the bolts, replace defective bolts,
if necessary
Noises in gearbox Idle speed is in critical range Increase the idle speed
Gearbox is operated at critical rotational Avoid critical rotational speeds
speed (unusual noises only occur at
certain speeds for example)
Noises in the zone of pump Oil level is too low (suction noise) Check the oil level, adapt it, if necessary
Leakage in suction pipe (pump draws Tighten the screws
air) Inspect for leakage
Pump is defective Inspect the oil pump, repair or replace,
if necessary
Oil pressure is too low Wrong sense of rotation (cooling sys- Reverse sense of rotation of motor
tem)
Filter is clogged Clean the filter
Oil level is too low Top up with oil
Inspect for leaks
Oil viscosity is too low Change the oil, only use recommended
products
Suction pipe is clogged Clean the suction pipe
Pressure control valve is defective Replace the defective parts
Oil pump is defective Inspect the oil pump, repair or replace,
if necessary
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Malfunction Possible cause Corrective action

Clogging indicator of the double filter Filter is clogged Replace the filter in accordance with the
has triggered operating instructions for the filter sys-
tem, clean the clogged filter
Error in the lubrication system See „Operating instructions“ for lubrica-
tion system
Foaming / water in the oil Water in the oil Let analyze the oil condition
Inspect for water ingress
Inspect the seals
Oil cooler / Radiator is defective Inspect for leakages in the cooling
system, seal it, if necessary
Repair or replace the defective parts
Condensation of water due to cold Protect the housing from draught ap-
draught on the housing propriately
Oil level is too high Check the oil level, adapt it, if necessary
Gearbox is contaminated by oil Insufficient sealing on the housing or Seal the partition joint
the partition joint
Labyrinth seal is contaminated by oil Check the oil level, clean the labyrinth
seal, if necessary
Leakage Oil level is too high Check the oil level, drain the oil, if nec-
essary
Fan is clogged / dirty Clean the fan
Insufficient sealing on the housing or Inspect the seals, replace them, if nec-
the partition joint essary, seal the partition joint
Leaky shafts / labyrinth covers Inspect the rotary shaft seals, replace, if
necessary
Mount the sealing lips in such a way
that the oil reflux is not disturbed
Leaky oil drain Replace and fasten the seal on the oil
drain
Leaky dipstick Replace the seal and fasten the dipstick
Leakage in oil pressure line Tighten the screw joint
Leaky fan Inspect the oil barrier under the fan
Leaky cooler Replace the cooler insert
Bearing temperature has increased Oil level is too low Check the oil level, top up with oil, if
necessary
essary
Oil is too old Check date of last oil change, change
the oil, if necessary
Oil pump is defective Inspect the oil pump, replace it, if nec-
essary
Damage to the bearing Replace the defective bearing
Oil reflux is blocked on the bearing Adjust the connection or the seal in
such a way that the oil reflux is not
blocked
Seal is too tight Loosen the seal
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Page 37 of 40

Bearing temperature has increased Operation out of the admissible pa- Inspect for damages
rameters (load, rotational speed, etc.) Comply with the operating instructions
Fan clogged /dirty Clean the fan
Incorrect alignment Align the parts correctly
Wrong bearing seat Check the bearing play, re-adjust, if
necessary
Inspect the shaft for smooth running in
no-load condition
Operating temperature has increased Oil level is too low Check the oil level, top up with oil, if
necessary
Oil is heavily contaminated Change the oil
Fan clogged / dirty Clean the filter
Oil flow through the cooler is too low Clean the oil filter
due to the dirty filter
Oil pump is defective Inspect the pump, repair or replace, if
necessary
For cooling systems featuring a fan: Air Clean the parts, if necessary
inlet, fan hood or gearbox housing are
dirty
For cooling systems featuring a radia- Clean the radiator
tor: Deposits on the radiator
Oil pressure is too low Set the cutting-off pressure to minimum
value
For gearboxes featuring a cooling sys- Open the valves in the lines, inspect the
tem: Cooling rate is too low oil cooler for flow impediments
Coolant temperature is too high Check the temperature, regulate, if
necessary
Gearbox is overloaded Reduce the drive power
Wear on the gearbox Operation out of the admissible pa- Check the bearing / toothed parts,
necessary
Oil is oxidized or contaminated Oil change
Check keeping of maintenance intervals
Faulty alignment Separate and re-align the parts
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Wear on the gearbox Gearbox is exposed to abrasive media Inspect the seals
Oil change
Inspect the bearing and the toothed
parts for damages
Vibrations from the outside Inspect the drive unit / foundation
Uncouple the gearbox, if necessary
Insufficient lubrication Check the oil level / oil grade
Damage to the bearing Inspect the lubrication system
parts for damages, replace, if necessary
Operation out of the admissible pa- Inspect the bearing and the toothed
rameters (load, rotational speed, etc.) parts for damages, replace, if necessary
Current passage Inspect the bearing and the toothed


Faulty or incorrectly mounted coupling Dismount and replace the coupling
Bearing not correctly mounted on the Check the bearing play, re-adjust, if
shaft necessary
Bearing not correctly mounted / incor- Inspect for impacts, search for the
rectly aligned causes if the old bearings are dis-
mounted
Corrosion Inspect the seals
Check suitability of lubricant to corrosion
protection
Check the lubrication of bearings
Faulty maintenance during downtimes
(see chapter 8)
Bearings are exposed to abrasive media Inspect the seals
Drain the oil, flush and refill the gearbox
with fresh oil
Inspect the bearings for damages,
replace, if necessary
Inappropriate storage Inspect all parts for damages, replace, if
necessary
Operation out of the admissible pa- Consultation with TKF

Damage to the shaft rameters (load, rotational speed, etc.)
Unilateral overload Consultation with TKF

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Page 39 of 40

Damage to the tooth Check the lubrication system
Inspect the bearings / toothed items,
Operation out of the admissible pa- Inspect the bearings / toothed items,
Current passage Inspect the bearings / toothed items,

Vibrations from the outside Inspect the drive unit / foundation,

uncouple the gearbox, if necessary
Metal bore chips in the filter Damage to the bearing See damage to the bearings
Damage to the tooth See damage to the tooth
Lubrication is impaired Check the oil condition / lubrication
system
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Page 40 of 40
10 Annexes
- Drawing no. 4557749-04

- Flex. coupling
- Inductive sensor
- Lubricant chart
40
Viskosität
Viscostiy
DIN 51502/ 51825 bei 40°C
[mm²/s] / NLGI

Mineral Oil
Mineralöle
Renolin CLP 220

CLP Renolin CLP 320
Renolin CLP 460
Synthetische Öle
Synthetic Oil
Biolog. abbaub. Öl
Biodegradable Oil
CLP HCE
680 - - - - Plantogear 680 S - - - - -
Grease Gear Units

Grease TCL 435
Schmierfette
(GP 00-000 K-50!)

GP 000 H-30
Getriebe
GPHC1 000 N-30 000 - - - - - - Obeen UF 000 - - -

RENOLIT FEP 2
Alavania WR 2
RENOLIT FEP 3
KPHC1 1 H-20 1 - - - - - - Obeen UF 1 - - -

Cassida EPS 2
Cassida HDS 2
- -
KPHC1 3 H-20 3 - - - - - - Obeen UF 3 - - -

Tel.(06894)599-0
Telefax (06894)599-468
KTR Kupplungstechnik KTR-N 46310 EN
KTR-SI
GmbH sheet: 1 of 17
D-48407 Rheine Operating-/Assembly instructions
edition: 2
KTR-SI
type DK
(ratchet design)
type SR
(synchronous design)
KTR-SI size 0 to 5
type SGR
(locked synchronous
design)
KTR-SI size 6 to 7
®
KTR-SI with torsionally flexible ROTEX coupling
Please note protection Drawn: 04.07.12 Pz/Koh Replaced for: KTR-N 13.10.11 (and 46111)
mark ISO 16016. Verified: 09.07.12 Pz Replaced by:
KTR-SI
GmbH sheet: 2 of 17
edition: 2
KTR-SI is a torque limitating overload system with positive locking. It protects the following
components against destruction.
Type DK (ratchet design) re-engages in case of overload every 15° into the following
sinking.
Type SR (synchronous design) re-engages in case of overload after a rotation (360°).
Type SGR (locked synchronous design) merely is destined to determine the torque without
having any ratching operation. In case of overload a signal is transmitted via a limit switch, a
mechanical separation of driving and driven side = ratching is not possible.
Table of Contents
1 Technical Data
2 Hints
2.1 Coupling Selection
2.2 General Hints
2.3 Safety and Advice Hints
2.4 General Hints to Danger
2.5 Proper Use
2.6 Hint Regarding the Finish Bore
3 Storage
4 Assembly
4.1 Components of the Couplings
4.2 Layers of Disk Springs
4.3 General Assembly Hints
4.4 Assembly of the KTR-SI Coupling
4.5 Assembly of KTR-SI with Torsionally Flexible ROTEX® Coupling
4.6 Disassembly of the Coupling / Replacement of Spare Parts
4.7 Assembly of the Coupling
4.8 Adjustment of Torque – KTR-SI Size 0 to 5
4.10 Setting Diagrammes – Type DK
4.11 Setting Diagrammes – Type SR/SGR
4.12 Advices for the Use of Drive Components
4.13 Assembly of the Limit Switch
4.14 Waste Disposal
4.15 Spares Inventory, Customer Service Addresses
5 Maintenance
KTR-SI
GmbH sheet: 3 of 17
edition: 2
1 Technical Data
Illustration 1: KTR-SI design FT Illustration 2: KTR-SI design KT Illustration 3: KTR-SI design LT
Table 1: Dimensions
Dimensions [mm]
KTR-SI
Bore d
size d1 D2 DA d2 d3 l1 l2 l3 l4
Pilot bore Max.
0 7 20 41,0 48 55 38 28 4,0 6,5 3,0 7,5
1 10 25 60,0 70 82 50 38 4,0 8,0 6,0 11,5
2 14 35 78,0 89 100 60 52 5,0 10,0 5,0 12,0
3 18 45 90,5 105 120 80 65 5,0 12,0 8,5 21,0
4 24 55 105,0 125 146 100 78 6,5 15,0 11,0 27,0
5 30 65 120,5 155 176 120 90 6,5 17,0 12,0 33,0
2)
6 40 80 136,0 160 200 130 108 7,0 20,0 14,0 39,0
7 2) 50 100 168,0 200 240 160 135 8,0 25,0 15,0 46,0
Dimensions [mm]
KTR-SI
H=stroke
size l5 l7 l8 L L1 L2 z
DK SR SGR
0 9 27,5 8 38,5 51,0 66,0 6 x M5 1,4 1,2 0,6
1 9 33,0 10 52,0 70,0 85,0 6 x M5 2,3 1,8 0,8
2 9 39,0 12 61,0 78,0 100,0 6 x M6 2,4 2,0 1,1
3 10 47,0 12 78,0 96,0 125,0 6 x M8 2,7 2,2 1,2
4 9 52,5 16 100,0 124,5 152,5 6 x M10 1) 3,7 2,5 1,2
1)
5 9 57,5 18 113,5 140,0 171,0 6 x M12 4,6 3,0 1,6
6 2) 9 64,0 20 119,0 150,0 183,0 6 x M12 1) 5,0 3,5 2,5
2) 1)
7 9 72,0 25 141,0 175,0 213,0 6 x M16 5,5 4,0 2,7
1) type T4 SR and SGR: tightening torques according to12.9
2) size 6: dimension t = 15 mm; size 7: dimension t = 21 mm
Table 2: Torques and weight

Torques Weight
KTR-SI [Nm] with
size Disk spring layers type DK Disk spring layers type SR and SGR max.
T1 T2 T3 T4 T1 T2 T3 T4 bore [kg]
0 2,5-5 5-20 - 20-40 5-10 10-40 - - 0,41
1 6-12 12-25 25-55 55-100 12-25 25-50 50-100 - 1,30
2 12-25 25-50 50-120 120-200 25-50 50-100 100-200 - 2,27
3 25-50 50-100 100-250 200-450 50-100 100-200 200-450 - 3,88
4 50-100 100-200 200-500 500-1000 100-200 200-400 400-800 800-2000 8,34
5 85-250 230-600 300-1000 600-2000 170-450 350-900 600-1800 1200-3400 13,51
6 180-480 360-960 720-1950 1600-3300 300-750 600-1500 1200-3000 2900-5800 21
7 250-520 500-1050 1000-2100 2000-3600 550-1100 1100-2200 2200-4400 3000-8200 37
KTR-SI
GmbH sheet: 4 of 17
edition: 2
1 Technical Data
®
Illustration 4: KTR-SI with torsionally flexible ROTEX coupling
Table 3: Dimensions
Cap screws
Dimensions [mm]
® DIN EN ISO
KTR-SI ROTEX
Max. bore H=stroke 4762 – 12.9
size size
DA DH dH E l1 l2 L Type TA
dmax. d1 Mxl
DK SR [Nm]
19 24 40 18 16 25 22,0 1)
0 20 55 38,5 1,4 1,2 M5 x 10 5,5
28 38 65 30 20 35 28,5
24 28 55 27 18 30 24,0
1 25 82 52,0 2,3 1,8 M5 x 12 8,1
38 45 80 38 24 45 32,5
28 38 65 30 20 35 28,0
2 35 100 61,0 2,4 2,0 M6 x 16 14
48 60 105 51 28 56 38,0
38 45 80 38 24 45 32,0
3 45 120 78,0 2,7 2,2 M8 x 18 34
55 70 120 60 30 65 43,0
48 60 105 51 28 56 38,0
4 55 146 100,0 3,7 2,5 M10 x 20 67
75 95 160 80 40 85 56,5
55 70 120 60 30 65 44,0
5 65 176 113,5 4,6 3,0 M12 x 30 115
90 110 200 100 45 100 62,0
6 100 80 115 200 225 113 50 110 72,0 119,0 5,0 3,5 M12 x 30 115
7 110 100 125 240 255 127 55 120 78,0 141,0 5,5 4,0 M16 x 35 290
1) DIN 6912 – 8.8
For torques see table 2: With sizes 5 to 7 higher torques can be transmitted due to an additional feather key in the flange connection
®
KTR-SI – ROTEX .
KTR-SI
GmbH sheet: 5 of 17
edition: 2
2 Hints
2.1 Coupling Selection
CAUTION!
! To review the coupling selection please consult with KTR Kupplungstechnik GmbH.
2.2 General Hints
Please read through these mounting instructions carefully before you set the coupling into operation.
Please pay special attention to the safety instructions!
The mounting instructions are part of your product. Please keep them carefully and close to the coupling.
The copyright for these mounting instructions remains with KTR Kupplungstechnik GmbH.
2.3 Safety and Advice Hints
STOP DANGER! Danger of injury to persons
! CAUTION! Damages on the machine possible
ATTENTION! Pointing to important items
2.4 General Hints to Danger
DANGER!
STOP With assembly, operation and maintenance of the coupling it has to be made sure that the
entire drive train is secured against unintentional engagement. You can be seriously hurt by
rotating parts. Please make absolutely sure to read through and observe the following
safety instruction.
All operations on and with the coupling have to be performed taking into account “safety first”.
Please make sure to disengage the drive unit and the power packs in service before you perform your work.
Secure the drive unit against unintentional engagement, e. g. by providing hints at the place of engagement or
removing the fuse for current supply.
Do not touch the operation area of the coupling as long as it is in operation.
Please secure the coupling against unintentional touch. Please arrange for the corresponding protection
devices and caps.
2.5 Proper Use
You may only assemble, operate and maintain the coupling if you
have carefully read through the mounting instructions and understood them
had technical training
are authorized to do so by your company
The coupling may only be used in accordance with the technical data (see table 1 to 3). Unauthorized
modifications on the coupling design are not admissible. We do not take any warranty for resulting damages. To
further develop the product we reserve the right for technical modifications. The KTR-SI described in here
corresponds to the technical status at the time of printing of these mounting instructions.
KTR-SI
GmbH sheet: 6 of 17
edition: 2
2 Hints
2.6 Hint Regarding the Finish Bore
DANGER!
STOP The maximum permissible bore diameters d (see
table 1 and 3 in chapter 1 - Technical Data) must not
be exceeded. If these figures are disregarded, the
coupling may tear. Rotating particles may cause
serious danger.
If the bore of the hub is machined by the customer,

the coupling needs to be disassembled (see chapter
4.6).
The concentricity or true running (see illustration 5)
needs to be adhered to.
Please make absolutely sure to observe the figures
for dmax.
Illustration 5: concentric running and axial running
Please align the hubs carefully when machining the
finish bore.
CAUTION!
! The buyer is responsible for all subsequently made machinings to unbored or pilot bored
and to finish machined coupling parts. KTR does not assume any warranty claims resulting
from insufficient remachining.
Table 4: Recommended combinations of fit acc. to DIN 748/1

Bore [mm]
Shaft tolerance Bore tolerance
above to
50 k6 H7
50 m6 (KTR-Standard)
If a feather key is intended to be used in the hub, it should correspond to the tolerance ISO JS9 (KTR-Standard)
with normal operating conditions or ISO P9 with heavy operating conditions (frequently alternating torsional
direction, shock loads, etc.). (Applies only in combination with a ROTEX® coupling): Preferably the keyway should
be positioned between the cams. For the axial fastening by set screws the tapping should be positioned on the
keyway with the exception of Al-D which should be positioned opposite to the keyway.)
The transmissible torque of the shaft/hub connection must be checked by the buyer, and he is responsible for the
same.
3 Storage
The coupling hubs are supplied in preserved condition and can be stored in a dry and roofed place for 6 - 9
months.
CAUTION!
! Humid storage rooms are not suitable.
Please make sure that there is no condensation. The best relative air humidity is less than
65%.
KTR-SI
GmbH sheet: 7 of 17
edition: 2
4 Assembly
The coupling is supplied in assembled condition.
4.1 Components of the Couplings
Components KTR-SI size 0 to 5
Component Quantity Designation

1 1 hub
2 1 flange ring (type DK)
3 1 shifting ring (type DK)
4 1 ball bearing cage
5 1 circlip
6 1 slide bush
7 1 setting nut
8 s. table 5 disk spring (set)
9 1 axial needle bearing
1) Illustration 6: KTR-SI size 0 to 5
10 1 axial disk
11 1 securing screw
1) at size 0: bearing balls (1 set)
Components KTR-SI size 6 to 7

1 1 hub
2 1 flange ring (type DK)
3 1 shifting ring (type DK)
6 1 slide bush
7 1 setting nut
9 1 bearing balls (set)
12 setting screws
s. table 6
13 securing nut
setscrew
14 6 Illustration 7: KTR-SI size 6 to 7
DIN EN ISO 4029
15 1 additional ring
Components KTR-SI with torsionally flexible ROTEX® coupling

KTR-SI
1 1
(complete coupling)
® 1)
2 1 ROTEX -SI flange
®
3 1 ROTEX spider
®
4 1 ROTEX hub
cap screws
5 6
DIN EN ISO 4762 – 12.9
setscrew
6 1
DIN EN ISO 4029
®
1) from ROTEX size 75 with additional feather key on the
Illustration 8: KTR-SI with torsionally flexible ROTEX® coupling
front side
KTR-SI
GmbH sheet: 8 of 17
edition: 2
4 Assembly
4.2 Layers of Disk Spring
Disk spring layer with KTR-SI size 0 to 5
Table 5: Disk springs

Layers of disk Type DK, SR and SGR
springs T1 T2 T3 T4
KTR-SI
0 to 5 0 to 5 1 to 5 0 1 to 5
size
Projection
Description 6x1S 5x1M 5x1L 4x1L 3x2L
Arrangement of setting screw with KTR-SI size 6 to 7
Illustration 9: Arrangement of setting screw
Table 6: Disk springs

Layers of disk
T1 T2 T3 T4
springs
KTR-SI
6 7 6 7 6 7 6 7
Size
Number of
components
3 6 12 12
12.1, 12.3,
12.4, 13
Type DK
Projection
Description 13x1M 17x1S 13x1M 17x1S 13x1M 17x1S 11x1L 15x1M

Type SR and SGR
Projection
Description 13x1M 15x1M 13x1M 15x1M 13x1M 15x1M 11x1L 13x1L
KTR-SI
GmbH sheet: 9 of 17
edition: 2
4 Assembly
4.3 General Assembly Hints
ATTENTION!
We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
®
Light heating of the KTR-SI coupling or ROTEX hub (approx. 80 °C) allows for an easier mounting on the shafts.
DANGER!
STOP Touching the heated coupling or hub, respectively, may cause burns. Please wear safety
gloves.
Please make sure the perfect technical condition of the KTR-SI overload system.
Please only use original KTR components (no exernally supplied parts).
4.4 Assembly of the KTR-SI Coupling
Assemble the KTR-SI coupling (component 1) on the shaft of the driving or driven side.
Please provide for an end plate to axially secure the KTR-SI coupling (see illustration 5 in chapter2.6).
4.5 Assembly of KTR-SI with Torsionally Flexible ROTEX® Coupling
Mount the KTR-SI coupling (component 1) or ROTEX®

hub (component 4) on the shafts of the driving or driven
side.
Provide for an end plate for the axial locking of the KTR-SI
coupling (see illustration 5 in chapter 2.6).
Screw the ROTEX®-SI flange (component 2) to the KTR-
SI coupling hand-tight for the time being.
Tighten the screws crosswise by a suitable torque key to Illustration 10: KTR-SI with a torsionally flexible
the tightening torques TA mentioned in table 3. ROTEX ® coupling
®
Insert the ROTEX spider (component 3) in the cam area
of the ROTEX® hub.
Shift the power packs in axial direction until the distance
dimension E has been reached (see illustration 11).
If the power packs are firmly assembled, the distance
dimension E has to be set by shifting the hubs axially on
the shafts.
Lock the hubs by tightening the set screws
DIN EN ISO 4029 via a cup point (for tightening torques
TA see KTR-N 40210).
Illustration 11: assembly of coupling
CAUTION!
! Please make sure with the assembly that the distance dimension E (see table 3) is adhered
to in order to assure that the coupling components do not get in contact during the
operation.
If this instruction is not observed, the coupling may be damaged.
ATTENTION!
Please consider our assembly instructions KTR-N 40210 additionally when using the
®
ROTEX coupling.
KTR-SI
GmbH sheet: 10 of 17
edition: 2
4 Assembly
4.6 Disassembly of the Coupling / Replacement of Spare Parts
Only valid for size 0 to 5:

Disassemble the locking screw (component 11)
and setting nut (component 7).
Remove the locking disk (component 5) from the
hub.
Remove the disk springs (component 8) and the Illustration 12: KTR-SI size 0 to 5
shifting ring (component 3).
ATTENTION!
Please note the disk spring layer for the assembly.
Only valid for size 6 to 7:

Unscrew the locking nuts (component 13).
Remove the set screws (component 14) and
afterwards disassemble the setting nut
(component 7).
Continuation of disassembly with all sizes: Illustration 13: KTR-SI size 6 to 7

Remove the shifting ring (component 3) and flange
ring (component 2) from the hub (component 1).
Remove the slide bush (component 6) and the axial needle bearing or ball bearings, respectively
(component 9).
CAUTION!
! For sizes 0, 6 and 7 bearing balls are mounted between hub (component 1) and flange
ring (component 2) instead of the needle bearing (see illustration 6 and 7).
4.7 Assembly of the Coupling
The assembly is done in reverse order with the disassembly (see chapter 4.6). For that purpose please note the
exploded drawings illustration 12 and 13. Factory-provided components may have to be re-lubricated.
ATTENTION!
Greasing by usual greases has to be done.
CAUTION!
! Please note the disk spring layer for the assembly as per chapter 4.2.
KTR-SI
edition: 2
4 Assembly
Dependent of the arrangement in layers of the disk spring used the desired torque can be set by adjusting the
screw setting nut in the area of the torque:
Fix the hub (component 1) against twisting.

Unscrew the locking screw (component 11).
Screw the setting nut (component 7) manually to the disk springs (component 8) against a stop
(zero point backlash-free prestress of disk spring).
Choose any reference point of the setting nut (component 1) versus a scale mark of the shifting ring
(component 3).
Insert the face spanner into the respective bores of the
setting nut (see illustration 14).
The accurate torque is adjusted by turning the setting nut
(component 1) clockwise.
ATTENTION!
For torque setting please note the setting
diagrammes of the respective sizes (see
diagramme 1 to 6 in chapter 4.10).
Having set the torque the setting nut (component 1) is

secured against loosening by means of the locking screw Illustration 14: adjustment of torque – KTR-SI size 0 to 5
(component 11).
If KTR-SI has been set to the requested torque following these operating/assembly instructions, the level of the
ratchet torque can be considered as a reference value only. For more accurate setting the ratchet torque should
be investigated by means of a suitable measuring system. In order to achieve the optimum accuracy, the ratchet
torque needs to be reviewed after the initial ratching and reset, if necessary.
KTR-SI
edition: 2
4 Assembly
Dependent of the arrangement in layers of the disk spring used the desired torque can be set by adjusting the
screw setting nut in the area of the torque:
ATTENTION!
KTR supplies the coupling in pre-assembled condition as a standard. Continue with item 2
torque setting.
If a new assembly has been performed or the buyer has made modifications subsequently,
please go on with item 1 preparation of torque setting.
1. Preparation of torque setting
Fix the hub (component 1) against twisting.

Unscrew the locking nuts (component 13).
Turn the setting screws (component 12) manually counter-clockwise against a stop (contact between internal
disk springs and setting nut).
Remove each the first one out of the three set screws arranged twice (component 14) and afterwards unscrew
the second set screw.
Turn the setting nut (component 7) manually against a stop.
Afterwards turn back the setting nuts counter-clockwise until the balance of the three set screws is flush with
three out of the total of six keyways of the hub.
Turn in the three set screws (component 14) in order to lock the setting nut by positive fit on the hub.
Afterwards counter the set screws each by the second set screw.
2. Adjustment of torque
Screw the setting screws (component 12) manually with only little effort to the disk springs (component 8)
against a stop ( backlash-free contact between disk springs and pressure ring).
Tighten the setting screws (component 12) stepwise evenly
in several revolutions (max. 360°) clockwise to the
requested torque (6/6 corresponds to one complete
revolution). The torque can be set by means of a hexagon
socket wrench (component 16).
ATTENTION!
For torque setting the setting diagrammes
of each size need to be observed (see
diagramme 7 to 8 in chapter 4.10).
Having set the torque the setting screws (component 12)

are secured against loosening by locking nuts (component
13) (see illustration 15).
Illustration 15: adjustment of torque – KTR-SI size 6 to 7
If KTR-SI has been set to the requested torque following these operating/assembly instructions, the level of
ratchet torque can only be considered as a reference value. For more accurate setting the ratchet torque should
be investigated by means of a suitable measuring system. In order to achieve the optimum accuracy, the ratchet
torque needs to be reviewed after the initial ratching and reset, if necessary.
KTR-SI
edition: 2
4 Assembly
Transmittable torque Transmittable torque

[Nm] [Nm]
50 120
T4
T4 100
40
80
30
T3
60
T2
20
40
T2
T1
10
20
T1
0 0
0 5 10 15 20 25 0 3 6 9 12 15 18 21 24 27 30 33 36
Torsion of the setting nut [number of indents] Torsion of the setting nut [number of indents]
Diagram 1: KTR-SI 0 Diagram 2: KTR-SI 1

[Nm] [Nm]
250 600
T4
T4
500
200
400
150
T3
300
T3
100
200
T2
50 T2
T1 100
T1
0 0
0 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 0 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114

[Nm] [Nm]
1200 2000
T4
1000
1600
T4
800
1200 T2/T3
600
T3 800
400
T2 max. = 605 Nm at 48 indents
T2 400
200 T1
T1
0 0
0 6 12 18 24 30 36 42 48 54 60 0 8 16 24 32 40 48 56 64 72 80 88 96 104 112 120 128 136 144
KTR-SI
edition: 2
4 Assembly

[Nm] [Nm]
3500 3500
T4 T4
3000 3000
2500 2500
2000 2000
T3 T3
1500 1500
1000 T2 1000 T2
500 T1 500 T1
0 0
0/6 3/6 6/6 9/6 12/6 15/6 18/6 0/6 3/6 6/6 9/6 12/6 15/6 18/6
Twisting of disk spring dowel pin [number of grooves] Twisting of disk spring dowel pin [number of grooves]

[Nm] [Nm]
50 120
T2 T3
100
40
80
30
60 T2
20
T1 40
T1
10
20
0 0
0 3 6 9 12 15 18 21 24 27 30 33 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42

[Nm] [Nm]
300 600
T3
T3
250 500
200 400
150 T2
300
T2
100 200
T1
T1
50 100
0 0
0 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 0 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
KTR-SI
edition: 2
4 Assembly

[Nm] [Nm]
2400 4000
T4 T4
2100 3500
1800 3000
1500 2500
T2/T3
1200 2000
900 1500
T3
T2 1000
600
T2 max. = 1050 Nm at 40 indents T1
300 500
T1
0 0
0 6 12 18 24 30 36 42 48 54 0 16 32 48 64 80 96 112 128 144

[Nm] [Nm]
6000 10000
T4 T4
5000
8000
4000
6000
T3
3000 T3
4000
2000
T2
T2
2000
1000 T1
T1
0 0
0/6 3/6 6/6 9/6 12/6 15/6 18/6 0/6 3/6 6/6 9/6 12/6 15/6 18/6
Twisting of disk spring dowel pin [number of grooves] Twisting of disk spring dowel pin [number of grooves]
4.12 Advices for the Use of Drive Components
With the use of drive components, e. g. sprockets, belt pulleys or gear wheels radial forces have to be expected
during the operation. For the FT design the customer should provide for a separate bearing of the drive
component. The non-positive connection of the drive components with the overload hub is done by screwing by
using usual standard screws of property class 10.9.
For the designs KT and LT the drive components are mounted to the coupling hub and screwed to the flange ring.
The resulting radial force on the drive element should be in the level of the bearing in order to avoid twisting of the
drive elements and consequently the flange ring.
If torsional vibrations of the overall drive have to be expected, we would recommend to lock the screw by
means of a suitable screw locking.
Do not give any axial pressure on the coupling. The drive element needs a corresponding bearing.
For higher torque shocks an extra feather key can be used for additional positive locking power transmission.
KTR-SI
edition: 2
4 Assembly
4.13 Assembly of the Limit Switch
The limit switch should be assembled in the keyway of the shifting ring (see illustration 16). The positions and
dimensions of the keyway are shown in table 7.
Table 7: Position of the limit switch

Dimensions [mm]
KTR-SI H=stroke
size l4 l5 ØD4 Type
DK SR SGR
0 7,5 9 50,0 1,4 1,2 0,6
1 11,5 9 72,5 2,3 1,8 0,8
2 12,0 9 90,5 2,4 2,0 1,1
3 21,0 10 112 2,7 2,2 1,2
4 27,0 9 140 3,7 2,5 1,2
5 33,0 9 170 4,6 3,0 1,6
6 39,0 9 190 5,0 3,5 2,5
7 46,0 9 230 5,5 4,0 2,7
Illustration 16: mechanical limit switch
Operation
Due to the axial stroke of the shifting ring produced by overload a mechanical limit switch or inductive sensor may
be activated. In this way a control signal is produced which can be analysed for shifting off the drive.
Assembly
The sensor has to be mounted in a solid device in order to ensure a smooth operation. The sensor should be
protected against dirt and potential mechanical disorders.
Adjustment
When the overload coupling slips, the shifting ring makes an axial thrust (see table 7). The sensor or limit switch,
respectively, has to be mounted within this shifting range. In order to adapt the mechanical limit switch and the
shifting process to the machine, the limit switch has to be adjusted accordingly. For that purpose the shifting
process can be regulated after opening the cover plate on the tappet.
CAUTION!
! We recommend to use a limit switch!
Please make absolutely sure to inspect the operation of the limit switch before dispatch of
the machine. Please also observe the operating instructions for the sensor or limit switch,
respectively. The axial stroke of the shifting ring must not be blocked by other components.
As soon as the limit switch or sensor is activated (overload: activating the overload
coupling) the drive should be stopped immediately.
For higher speeds corresponding brake devices may be necessary.
KTR-SI
edition: 2
4 Assembly
4.14 Waste Disposal
For the sake of environmental protection we would ask you to dispose of the products in accordance with the
current legal specifications or guidelines, respectively at the end of their service life.
Metal
All metal components need to be cleaned and delivered to scrap metal.
4.15 Spares Inventory, Customer Service Addresses
A basic requirement to guarantee the operational readiness of the coupling is a stock of the most important spare
parts on site.
Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage
under www.ktr.com.
CAUTION!
! KTR does not take any liability or warranty for the use of spare parts and accessories which
have not been supplied by KTR and the resulting damages.
5 Maintenance
The KTR-SI overload hub is finish bored and provided with grease filling. With normal drive conditions this grease
filling is sufficient during the overall service life. In case of extreme drive conditions or heavy dirt, respectively, the
KTR-SI has to be regularly inspected for its operation. If KTR-SI is ordered in a pilot-bored design, the customer
has to disassemble it in order to place a finish bore.
CAUTION!
! During the subsequent assembly it needs to be lubricated by usual grease.
KTR Kupplungstechnik ROTEX® KTR-N 40221 E
GmbH mounting instructions sheet: 1
D-48407 Rheine design BTAN and SBAN edition: 2
The ROTEX® BTAN / SBAN is a failsafe torsionally flexible jaw type coupling with brake drum or
brake disk. It is able to compensate for shaft displacements caused by, for example, inaccuracies in
production, heat expansion etc.
General Hints
Please read through these mounting instructions carefully before you set the coupling into operation.
Please pay special attention to the safety instructions!
The mounting instructions are part of your product. Please keep them carefully and close to the
coupling.
The copyright for these mounting instructions remains with KTR Kupplungstechnik GmbH.
Safety and Advice Hints
STOP DANGER ! Danger of injury to persons.
! CAUTION ! Damages on the machine possible.
F ATTENTION ! Pointing to important items.
General Hints to Danger
DANGER !
STOP With assembly, operation and maintenance of the coupling it has to be made sure
that the entire drive train is protected against unintentional engagement. You can
be seriously hurt by rotating parts. Please make absolutely sure to read through
and observe the following safety instructions.
• All operations on and with the coupling have to be performed taking into account "safety first".
• Please make sure to disengage the power pack before you perform your work.
• Protect the power pack against unintentional engagement, e. g. by providing hints at the place of
engagement or removing the fuse for current supply.
• Do not touch the operation area of the coupling as long as it is in operation.
• Please protect the coupling against unintentional touch. Please provide for the necessary
protection devices and caps.
Proper Use
You may only assemble, operate and maintain the coupling if you
• have carefully read through the mounting instructions and understood them
• and if you are authorized and have proper skills
The coupling may only be used in accordance with the technical data (see ROTEX® catalogue).
Unauthorized modifications on the coupling design are not admissible. We do not take any warranty
for resulting damages. To further develop the product we reserve the right for technical modifications.
The ROTEX® BTAN / SBAN described in here corresponds to the technical status at the time of
printing of these mounting instructions.
Urheberschutz Gezeichnet: 14.09.00 Sha Ersatz für: KTR-N v. 21.03.85 Verteiler

gemäß DIN 34 Geprüft: 22.09.00 Sha Ersetzt durch: W K V VA M
Basically the coupling is supplied in individual parts. Before assembly the coupling has to be controlled for
completeness.
Components of ROTEX® BTAN

Component Quantity Designation Component Quantity Designation
1 1 standard hub 4 1 brake drum
2 1 spider 5 see table 1 cap screws DIN 912
3 1 FN hub 6 2 grup screws DIN 916
standard - spiders
spider hardness marking
(shore) (colour)
92 ShA yellow
95/98 ShA red
natural white
64 ShD-F with green
marking of teeth
®
picture 1: ROTEX BTAN
Components of ROTEX® SBAN

1 1 standard hub 4 1 brake disk
®
picture 2: ROTEX SBAN
Components of ROTEX® SBAN with cranked brake disk

1 1 standard hub 4 1 cranked brake disk
®
picture 3: ROTEX SBAN with cranked brake disk

Mounting Hint
DANGER !
STOP The maximum permissible bore diameters d1max and
d2max (see ROTEX® catalogue) must not be exceeded. If
these figures are disregarded, the coupling may tear.
Rotating parts may cause serious danger.
• Hub bores machined by the customer have to observe

concentric running or axial running, respectively (see
picture 4).
• Please make absolutely sure to observe the figures for
d1max and d2max.
• Carefully align the hubs when the finish bore is brought
in.
• Please provide for a setscrew or an end plate for the
axial fastening of the hubs. picture 4: concentric and axial running
Assembly of the hubs
F
ATTENTION !
We recommend to check bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
Heating the hubs slightly (approx. 80° C) allows for an easier installation onto the shaft.
DANGER !
STOP Touching the heated hubs may cause burns.
We would recommend to wear safety gloves.
Assembly of the coupling
CAUTION !
For the assembly please make sure that the distance dimension E (table 2) is kept to
! ensure that the spider can be moved axially when in operation.
Disregarding this hint may cause damage on the coupling.
• Assemble the FN hub with the brake drum / brake disk. Tighten the screws with a suitable torque wrench to
the tightening torques TA (see picture 5).
F
ATTENTION !
Before tightening the screws please put Loctite 243 on the threads.
• Assemble the hub and the FN hub with the brake drum / brake disk onto the shaft of the driving side and the
driven side. Put the FN hub onto the shaft end where the bigger mass moment of inertia becomes effective.
The max. braking torque must not be bigger than the max. torque (Tkmax) of the coupling (see picture 6).
• Secure the hubs by fastening the grub screws DIN 916 with splined cup point or by an end plate.
• Install the spider inside the cams of the hub (see picture 7).
• Push the machines to be connected together until the distance dimension E is achieved.

Assembly of the coupling
picture 5 picture 6
Example: Assembly of the SBAN

with cranked brake disk.
picture 7
CAUTION !
Having set the coupling into operation, the tightening torque of the screws and wear of
! spider have to be inspected in usual maintenance intervals and exchanged, if necessary.
Table 1:
coupling size 28 38 42 48 55 65 75 90 100 110 125 140 160 180
screw size M M6 M8 M8 M8 M10 M10 M12 M16 M16 M20 M20 M20 M24 M24
quantity z 8 8 12 12 8 12 15 15 15 15 15 15 15 18
tightening torque
17 41 41 41 83 83 120 295 295 580 580 580 1000 1000
TA [Nm]
Displacements
The displacement figures shown in table 2 offer sufficient safety to compensate for environmental influences
like, for example, heat expansion or lowering of foundation.
CAUTION !
In order to ensure a long lifetime of the coupling, the shaft ends have to be aligned
! accurately. Please absolutely observe the displacement figures indicated (see table 2). If
the figures are exceeded, the coupling will be damaged.
Please note:
• The displacement figures mentioned in table 2 are maximum figures which must not arise in parallel. If radial
and angular displacement arises at the same time, the permissible displacement values may only be used in
part.
• Please check with a dial gauge, ruler or feeler whether the permissible displacement figures of table 2 can be
observed.

Displacements
angular displacements radial displacements axial displacements
∆KW [mm] = L1 max. - L1 min. Lmax. [mm] = L + ∆KA
picture 8: displacements
Example: displacements at the BTAN
Technical Data
ROTEX® SBAN type 1
®
ROTEX BTAN type 1 with cranked brake disk
® ® ®
ROTEX BTAN type 2 ROTEX SBAN ROTEX SBAN type 2
with cranked brake disk
picture 9: dimensions

Technical Data
Table 2:
coupling size 28 38 42 48 55 65 75 90 100 110 125 140 160 180
Installation dimensions
distance dimension E 20 24 26 28 30 35 40 45 50 55 60 65 75 85
dimension s 2,5 3 3 3,5 4 4,5 5 5,5 6 6,5 7 7,5 9 10,5
dimension b 15 18 20 21 22 26 30 34 38 42 46 50 57 64
dimension dH 30 38 46 51 60 68 80 100 113 127 147 165 190 220
dimension DH 65 80 95 105 120 135 160 200 225 255 290 320 370 420
dimension L 90 114 126 140 160 185 210 245 270 295 340 375 425 475
dimension l1 / l2 35 45 50 56 65 75 85 100 110 120 140 155 175 195
Threads for setscrews (until size 110 incl., larger sizes on request)
dimension G M6 M8 M8 M8 M10 M10 M10 M12 M12 M16 M16 M20 M20 M20
dimension t 15 15 20 20 20 20 25 30 30 35 40 45 50 50
tightening torque TA 4,8 10 10 10 17 17 17 40 40 80 80 140 140 140
Displacements
max. axial displacement
1,5 1,8 2,0 2,1 2,2 2,6 3,0 3,4 3,8 4,2 4,6 5,0 5,7 6,4
∆Ka [mm]
max. radial displacement at
0,25 0,28 0,32 0,36 0,38 0,42 0,48 0,50 0,52 0,55 0,60 0,62 0,64 0,68
n=1500 1/min. ∆Kr [mm]
max. radial displacement at
0,17 0,19 0,21 0,25 0,26 0,28 0,32 0,34 0,36 0,38 - - - -
n=3000 1/min. ∆Kr [mm]
∆Kw [degree] 0,9 1,0 1,0 1,1 1,1 1,2 1,2 1,2 1,2 1,3 1,3 1,2 1,2 1,2
max. angular displacement
at n=1500 1/min.
1,05 1,35 1,70 2,00 2,30 2,70 3,30 4,30 4,80 5,60 6,50 6,60 7,60 9,00
∆Kw [mm]
∆Kw [degree] 0,8 0,8 0,8 0,9 1,0 1,0 1,0 1,1 1,1 1,1 - - - -
max. angular displacement
at n=3000 1/min.
0,84 1,10 1,40 1,60 2,00 2,30 2,90 3,80 4,20 5,00 - - - -
∆Kw [mm]
Table 3: Dimensions of BTAN

1)
coupling size 28 38 42 48 55 65 75 90 100 110 125 140 160 180
dimension P 6,5 7,5 9,5 10,5 12,5 13,5 15,5 18,5 20,5 23,5 27,5 30,5 34,5 38,5
160 x 60 30 31
200 x 75 35 36 38 39 41
250 x 95 43 44 46 47 49 50 52
dimension N1 315 x 118 55 56 58 59 61 64
at brake drum 400 x 150 68 69 71 72 74 77 79 82
2)
ØDB x B 500 x 190 87 89 92 94 97 101 104
630 x 236 107 110 112 115 119 122 126 130
710 x 265 123 126 130 133 137 141
800 x 300 144 147 151 155
160 x 60 52 53
200 x 75 62 63 65 66 68
250 x 95 76 77 79 80 82 83 85
dimension N2 315 x 118 95 96 98 99 101 104
at brake drum 400 x 150 118 119 121 122 124 127 129 132
2)
ØDB x B 500 x 190 151 153 156 158 161 165 168
630 x 236 185 188 190 193 197 200 204 208
710 x 265 212 215 219 222 226 230
800 x 300 244 247 251 255
1) from size 100 on request
2) The dimensions N1 and N2 in the table are rounded off by 0,5 mm.

Technical Data
Table 4: Dimensions of SBAN

1)
coupling size 28 38 42 48 55 65 75 90 100 110 125 140 160 180
dimension NSBAN 28,5 37,5 40,5 45,5 52,5 61,5 69,5 81,5 89,5 96,5 112,5 124,5 140,5 156,5
Classification of ROTEX® SBAN - coupling / size of brake disk
A x GS Bxf
200 x 12,5 90 x 15 x x
250 x 12,5 140 x 15 x x x x
315 x 16 205 x 20 x x x x x
400 x 16 290 x 20 x x x x x x x
500 x 16 390 x 20 x x x x x x x x
630 x 20 520 x 25 x x x x x x x x x
710 x 20 600 x 25 x x x x x x x x x
800 x 25 690 x 30 x x x x x x x
900 x 25 790 x 30 x x x x x
1000 x 25 890 x 30 x x x x x
1) form size 100 on request
Table 5: Dimensions of SBAN with cranked brake disk

1)
coupling size 28 38 42 48 55 65 75 90 100 110 125 140 160 180
dimension P 6,5 7,5 9,5 10,5 12,5 13,5 15,5 18,5 20,5 23,5 27,5 30,5 34,5 38,5
250 58 67 70 75
300 68 73 80 90 97
350 83 90 99 107
400 110 122 130
dimension N1
460 107 119 127 134
at nominal Ø of
2) 515 107 119 127 134 150 162
the brake disk
610 107 119 127 134 150 162 178 194
710 104 116 124 131 147 159 175 191
810 110 118 125 141 153 169 185
915 169 185
250 5 14 17 22
300 12 17 24 33 41
350 4 11 20 28
400 28 40 48
dimension N2
460 28 40 48 55
at nominal Ø of
2) 515 28 40 48 55 71 83
the brake disk
610 28 40 48 55 71 83 99 115
710 28 40 48 55 71 83 99 115
810 40 48 55 71 83 99 115
915 99 115
1) from size 100 on request
2) In the table the N1 dimensions are rounded off by 0,5 mm and the N2 dimensions are rounded off by 0,2 mm.
Table 6: Dimensions of SBAN with cranked brake disk

nominal Ø
250 300 350 400 460 515 610 710 810 915
brake disk
dimension A 250 300 356 406 457 514 610 711 812 915
dimension B 128 181 210 260 311 368 464 565 660 760
dimension f 6 13 16 13 16 16 16 19 25 25
dimension F 36 41 54 54 54 54 54 54 54 54


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                    
        
                

 
      
  
  
 
     
     
         
   
         
         
     
   
    
      
          
 
            
Bezeichnungen einer Trommelbremse Nur gültig in Verbindung mit

Allgemeine Hinweise
Components of Drum Brake Valid in connection only with

General Notes
B 06 20 176 E
Anhand Bild 1 sollen die wesentlichen Bauteile einer Trommelbremse erläutert werden:
For essential components of drum brake please see picture 1 and find the following explanations:
Zugstange Nachstellung
tension rod readjusting unit
Zuglasche Winkelhebel
shackle knee lever
Bremshebel Federrohreinheit
brake lever spring tube componentry
Bremsbacke mit Bremsbelag Lüftgerät

brake shoe c/w lining thruster
Grundplatte
base plate
Bild / picture 1
Grundplatte: Mit vier Befestigungsbohrungen, deren Durchmesser und Abstände nach DIN genormt sind,
wird die Bremse auf der Unterkonstruktion befestigt.
base plate: With four mounting holes, which positions are standardized according to DIN,
the brake is mounted on a base frame or construction.
Bremshebel: Umschliessen mit den gelenkig gelagerten Bremsbacken die Bremstrommel und
übertragen in Verbindung mit Zugspindel und Winkelhebel die Bremskraft.
brake lever: Hinged with the brake shoes, they surround the brake drum and in connection with pull rod and
knee-lever they apply the braking force is generated by the torque spring.
spring tube: Consists of tube, rod, torque spring, piston plate and torque-scale.
Lüftgerät: Dient zum öffnen der Bremse und arbeitet gegen die Federkraft. Die zum lüften benötigte Energie wird
entweder elektro-hydraulisch, elektrisch über Magnet, hydraulisch oder pneumatisch erzeugt.
Am weitesten verbreitet sind die elektro-hydraulischen Lüftgeräte. Sie bieten aufgrund der robusten und
thruster:
betriebsicheren Bauweise in den meisten Einsatzfällen die beste Lösung.
Is used to open the brake and is acting against the spring force. The energy, required for release, is
generated by electro-hydraulic, electric with solenoid, hydraulic or pneumatic. The most common
thrusters are the electro-hydraulic ones. Due to the robust and safe construction the electro-hydraulic
thruster is the best solution in most of the cases.
Zugspindel: Sie ist das mit am höchsten beanspruchte Bauteil der Bremse,
da die gesamte Bremskraft hierüber auf die beiden Bremshebel übertragen wird.
Bei allen SIBRE Bremsen ist die Zugspindel aus rostfreiem Material mit gerolltem Gewinde gefertigt.
pull rod: Its function is to transmit the braking force to the two brake levers,
and therefore it is the most stressed component of the brake.
All SIBRE brakes the pull rod is made of stainless steel with a rolled thread.
shackle: The shackle is the hinge between pull rod and the brake lever. The shackle could be a pin-junction as well.
Nachstell- Die Nachstellung dient zum Ausgleich des Belagverschleiss, ist aber im Nachstellweg je Bremshub
ung: begrenzt. Daher ist je nach Anwendungsfall eine zusätzliche manuelle Verschleissnachstellung vom

readjusting The readjusting unit is used for compensation of lining wear, however its compensation capacity per
unit: braking cycle is limited. Therefore an additional manual wear compensation carried out by maintenance
personnel is requested according to the specific application.
von grossem Feder- oder Lüftweg und kleiner Kraft auf kleine Wege am Bremshebel und hohe Kräfte statt.
knee lever: Spring tube component and thruster are mounted to the knee-lever. Here, the transformation from large

Allgemeine Hinweise
B 06 20 176 E
Bild / picture 2 Adjustment of Reserve Stroke
connecting rods Der Resthub muss bei geschlossener und eingebauter Bremse
adjusting nut eingestellt werden. Dabei sollte das Lüftgerät zunächst ganz
eingefahren und dann durch drehen an der
Zugstangenstellmutter auf 20% (ca. 10 mm) des Gesamthubs
herausgezogen werden.
angegeben.
The reserve stroke must be adjusted when brake is mounted
on the base frame and in closed position. First, set thruster
piston to its lower end position and afterwards lift the piston by
turning the tension rod adjusting nut, until piston is lifted by
20% (approx. 10 mm) of total stroke.
For total stroke values please see chapter technical data.

als Hinweis, wo der Resthub gemessen werden kann.
The dimension X is constructional not relevant. It just shows

an example, where reserve stroke can be measured.
Achtung:
* Wird kein Resthub eingestellt, kann dies zum Versagen der Bremse führen.
Caution:
Achtung:
* Je nach Anwendungsfall muss eine zusätzliche manuelle Verschleissnachstellung erfolgen.

Caution:
Bei Bremsen mit zusätzlicher Notlüftung und/oder hydraulischer Verzögerung ist darauf zu achten,
dass auch diese Zusatzeinrichtungen mit entsprechendem Resthub eingestellt werden.
In case of brakes fitted with additional hydraulic damping and/or an additional emergency release,


Die Montage der Bremse wird in radialer Richtung Allgemeine Hinweise
B 06 20 176 E

Bild / picture 3
Lüftgerät
thruster
Brems-
hebel
brake-
1.Bremsbackenabstand durch drehen der
lever
Zugstangenstellmutter auf Maß 5 mm größer
als Bremstrommeldurchmesser stellen.
Adjust brake shoe clearance to 5 mm larger than
brake drum diameter,
by turning the connecting rod adjusting nut.
2.Grundplattenbolzen 1 aus dem

Bremsbackenhebel ziehen.
Grundplattenbolzen 1 Grundplatte
base plate
base plate pin 1
` 4.Grundplatte unter der Bremstrommel durchschieben.

5.Bremse in radialer und axialer Richtung

Bild / picture 4 mittig ausrichten.

durch Grundplattenbolzen 1
` mit der Grundplatte verbinden.
base plate pin 1.
Install release thruster.
Fix base plate.
Bild / picture 5
* 9.Maximal zulässige Abweichung zu den
Bremsenachsen +/- 0,3 mm .
Â Permissable misaligument for all brake axles:
max. +/- 0.3 mm .
connecting rods adjusting nut
Zugstange
tie rod

Bei der Einstellung der Bremse geht man wie folgt vor Nur gültig in Verbindung mit
Allgemeine Hinweise
The adjustment of the brake is accomplished as follows Valid in connection only with
General Notes
1.Lüftgerät
B 06 20 176 E
Bild / picture 6 ausschalten ( Bremse eingefallen )
Resthub X 20% des Switch off release thruster ( close brake ).
Zugstangenstellmuttern Gesamthubes (ca. 10 mm)
connecting rods reserve stroke X 20% of
adjusting nut 2.Durch drehen der Zugstange an der Zugstangenstellmutter
max. storke (approx. 10mm)
Lüftgerät-Resthub X einstellen ( Bild 6 ).
Adjust release thruster reserve stroke X by turning
the connecting rod adjusting nut ( picture 6 ).
3.Durch drehen der Federstellmutter gewünschtes

Bremsmoment an der Skala einstellen
( Oberkante Federdruckteller = Bezugskante ) und
gegebenenfalls Lüftgerät-Resthub X korrigieren ( Bild 6 +7 ).
Adjust desired braking torque by turning the spring adjusting nut.

The torque is indicated on scale ( using top edge of bottom
spring plate as reference point ).
Bild / picture 7 If necessary, adjust release thruster reserve stroke X
Federstellmutter
spring adjusting nut ( picture 6+7 ).
4.Einstellung der gleichmässigen Backenlüftung entfällt durch

Skala Verwendung einer Drehkopplung ( Bild 8 ), d. h.:
scale - gleichmässiger Luftspalt an beiden Bremsbacken
Federrohr - Justierung der Bremse bei Montage
spring tube - keine Anschläge an den Bremsbackenhebeln
- stabiler Stand der gelüfteten Bremse, auch bei
Belagverschleiss
necessary due to the brake shoe synchronisation linkage
( picture 8 ) i.e.:
Bild / picture 8 - equal clearance of both brake shoes
Synchronisation
linkage
- shoe wear, adjustable end stops on brake arms are eliminated
Einstellen der Nachstellung

Adjust compensator unit
Bild / picture 9 Stellschraube
adjustment screw
`
1.Mitnehmerschraube der Nachstellung in der
Mitnehmerbohrung ganz nach unten drücken.
Kontermutter
lock nut Push driving pin down in guide hole as far as it can go.
2.Stellschraube im Winkelhebel so weit zurückdrehen,
Mitnehmerschraube
driving pin
bis die Mitnehmerbohrung frei ist.
Return adjustment screw in the brake lever
Mitnehmerbohrung until guide hole is exposed.
guide hole 3.Bremse mehrmals lüften und wieder einfallen lassen, die
Lift brake lever several times fully (with release thruster)
and close again.
Achtung: 4.Stellschraube im Winkelhebel wieder so weit eindrehen,
Die Nachstellung dient zum Ausgleich des Belagverschleiss,
ist aber im Nachstellweg je Bremshub begrenzt. dass ein kleiner Luftspalt von etwa 0,2 mm zwischen
Verschleissnachstellung vom Wartungspersonal durchzuführen. Stellschraube und Mitnehmerschraube vorhanden ist,
Kontermutter anziehen ( Bild 9 ).
Caution:
The readjusting unit is used for compensation of lining wear, Turn adjustment screw in brake lever down until there is a
however its compensating capacity per unit braking cycle is
limited. Therefore an additional manual wear compensation carried small split of approximately 0.2 mm between adjustment
out by maintenance personnel is requested according to the screw and driving pin, tighten lock nut ( picture 9 ).
specific application.


Replacement of the brake shoes General Notes
B 06 20 176 E

Proceed as follows:
1. Zugstange durch drehen an der Zugstangenstellmutter so weit aus der Verschleissnachstellung

herausschrauben, dass sich die neuen Bremsbacken montieren lassen.
Unscrew connecting rod out of the readjusting unit by turning the connecting rod adjusting nut
until the new brake shoes can be installed.
2. Bremsbackenklemmfedern entspannen und Bremsbackenbolzen entfernen ( Bild 10 ) .

Release brake shoe clamping spring and remove brake shoe pins ( picture 10 ) .



6. Readjust
Bremse neu einstellen.
brake.
Bild / picture 10

Allgemeine Hinweise
6 8 General Notes
B 06 20 176 E
1 5
3 7

vollständige Bremsenbezeichnung, z.B. für TE 400/ 80/6

complete brake ident-no., e.g. for TE 400/ 80/6


T1-2.3
S2-10.5
Drum Brakes TE 160
M 1501 293 E-EN-2002-11
Page 1 / 2
When ordering please advice:

- order-no., e.g. for TE 160/220/50
- power supply voltage of thruster
- with or without autom. wear compensator
- optional features such as limit switch manual release,
drum, coupling, covering cap
Mbr. (Nm) torque

Brake type
No. Thruster unit µ = 0,4 A B C H
TE 160/120/40 1 EB 120/40 45 - 125 575 110 73 395
TE 160/220/50 2 EB 220/50 55 - 230 610 162 100 400
T1-2.4
S2-10.5
Drum Brakes TE 160
M 1501 293 E-EN-2002-11
Page 2 / 2
The drum brake TE 160 offer a particularly usability for compact-drives, e. a. vertical
mounting, travel drives. Our scope of supply is beneath the brake also mounting console
for adapting gearbox and motor as well as coupling/brake-drum and steel-cover.

Seite / page 1/8

eingesetzt werden.
Siegerland Bremsen
35 708 HAIGER
GERMANY
Fon: +49 (0)2773 / 9400 - 0

B 06 20 176 E-DE-EN
Seite / page 2/8
Allgemeine Hinweise









der Bremse.
Seite / page 3/8
contract.



B 06 20 176 E-DE-EN
Seite / page 4/8
Allgemeine Hinweise

Empfehlung :
Recommendation :



y Quetschgefahr.
Danger of crushing.


Seite / page 5/8







2


Achtung:
CAUTION:

B 06 20 176 E-DE-EN
Seite / page 6/8
Allgemeine Hinweise
can be carried out.
Achtung / Caution



Seite / page 7/8
G
AFTER EACH SHIFT



3


B 06 20 176 E-DE-EN
Seite / page 8/8
Allgemeine Hinweise




EMG Automation GmbH

Factory ELTMA
Technical rates
min…max
Short travel types
EB 120-40 120 40 C 60 50… 75 130 0,4 1,2 7,5

C 120 100… 150
EB 220-50 220 50 C 120 110… 160 160 0,4 2,6 9,3
C 180 160… 230
C 220 200… 290
EB 300-50 300 50 C 120 140… 180 140 0,3 1,8 9,6
C 200 220… 260
C 270 260… 310
EB 500-60 500 60 C 180 170… 220 200 0,4 2,6 13,1
C 320 370… 450
C 500 540… 680
EB 800-60 800 60 C 450 460… 560 260 0,5 4,3 19,0
C 800 740…1060
EB 1250-60 1250 60 C 450 460… 560 380 0,6 4,3 20,6
C 800 740…1060
C 1250 1200…1630
EB 2000-60 2000 60 C 700 660… 900 500 0,7 9,0 32,8
C 1300 1240…1600
C 2000 1900…2500
EB 3000-60 3000 60 C 700 460… 690 550 0,9 10,1 39,0
C 2500 2080…3000
C 3200 2540…3690
EB 6300-80 6300 80 800 1,6 10,6 43,5
Long travel types
EB 500-120 500 120 C 180 110… 220 200 0,4 3,5 14,8
C 320 280… 450
C 500 390… 680
EB 800-120 800 120 C 450 350… 560 380 0,5 6,0 23,0
C 800 420…1060
EB 1250-120 1250 120 C 450 350… 560 380 0,6 6,0 24,2
C 800 420…1060
C 1250 770…1630
EB 2000-120 2000 120 C 700 430… 900 500 0,7 9,0 32,8
C 1300 870…1600
C 2000 1300…2500
EB 3000-120 3000 120 550 0,9 10,1 39,0
EB 6300-120 6300 120 800 1,6 10,6 43,5
Short travel types
EB 12/50 220 50 C 12 110… 160 160 0,4 2,6 9,3

C 18 160… 230
C 22 200… 290
EB 20/50 300 50 C 12 140… 180 140 0,3 1,8 9,6
C 20 220… 260
C 27 260… 310
EB 50/50 500 50 C 18 170… 210 200 0,4 2,6 13,1
C 32 370… 440
C 50 540… 660
EB 80/60 800 60 C 45 460… 560 260 0,5 4,3 19,0
C 80 740…1060
EB 125/60 1250 60 C 45 460… 560 380 0,6 4,3 20,6
C 80 740…1060
C 125 1200…1630
EB 150/60 1500 60 C 45 460… 560 400 0,7 4,3 20,6
C 80 740…1060
C 125 1200…1630
EB 250/60 2500 60 C 70 660… 900 500 0,7 9,0 32,8
C 130 1240…1600
C 200 1900…2500
Long travel types
EB 50/100 500 100 C 18 130… 220 200 0,4 3,2 14,5

C 32 310… 450
C 50 440… 680
EB 80/160 800 160 C 45 280… 560 260 0,5 6,0 23,0
C 80 200…1060
EB 125/160 1250 160 C 45 280… 560 380 0,6 6,0 24,2
C 80 200…1060
C 125 480…1630
EB 150/160 1500 160 C 45 280… 560 400 0,7 6,0 24,2
C 80 200…1060
C 125 480…1630
EB 250/160 2500 160 C 70 280… 900 500 0,7 12,2 39,5
C 130 620…1600
C 200 900…2500
EB 320/100 3200 100 C 70 460… 840 550 0,9 10,6 39,5
C 250 2080…3000 3)
C 320 2540…3690 3)
EB 630/120 6300 120 800 1,6 10,6 43,5
Service medium,
maintenance

nance.

entry tightly.
Filling entry
Attention:
medium. Füllstand
EB 220-50, EB 12/50 EB 120-40

min. max. min. max.
EB 2000-60 … S 1,3 8,0 EB 250/60 … S 2,0 10,0
EB 2000-120 … S 2,8 12,0 EB 250/160 … S 3,5 15,0
EB 3000-120 … S 2,5 10,0 EB 320/100 … S 2,5 11,0
EB 6300-120 … S 2,0 8,0 EB 630/120 … S 2,0 8,0
Sensors
types EB120-40, EB220-50, EB12/50
earthing screw
and special series.
EB 125/60 B S I Zd F K Li... X..

.
ELHY® Type
La








Attention:
room temperature.
EMG Automation GmbH

Factory ELTMA
Am Pfefferbach 20
39387 Oschersleben
Germany
Phone: +49 (0) 3949 928 - 500

Fax 1: +49 (0) 3949 928 - 585
Fax 2: +49 (0) 3949 928 - 513
BA_GB 06/2008
Inductive sensor
BI5U-M18-AP6X

Wiring diagram
Type BI5U-M18-AP6X
Ident-No. 1635100

Repeatability
ð2%
tances.
Protection class ÷

Dimensions 54 mm
Connection cable
2


Edition • 2012-06-23T02:39:57+02:00
Inductive sensor
BI5U-M18-AP6X

Distance D 2xB
Distance W 3 x Sn
Distance T 3xB
Distance S 1.5 x B
Distance G 6 x Sn

Edition • 2012-06-23T02:39:57+02:00
Inductive sensor
BI5U-M18-AP6X
Accessories
terial: PA6

Edition • 2012-06-23T02:39:57+02:00
ThyssenKrupp Rothe Erde
Technical Data Sheet

Rothe Erde Large Diameter Slewing Bearing
Material No.: 82071410

Drawing No.: 061.60.3000.200.41.1522
Rothe Erde No.: 16-29236 / 60.1.43040
Customer: ThyssenKrupp Industrial Solutions, St. Ingbert
Reference: Order 30256379/MANG Pos. 6 of 09.12.2013
Application: Stacker 930-St-110

Project No.: Shogang Hierro / Peru
Specification: SES 21000 Index 00
Contact: ThyssenKrupp Rothe Erde GmbH

Lippstadt Factory
Application Engineering & Service
Beckumer Straße 87
D-59555 Lippstadt
Tel.: 02941 / 741-3290
Fax.: 02941 / 741-3400
E-Mail: service.rotheerde@thyssenkrupp.com
ThyssenKrupp Rothe Erde GmbH Chairman of the Supervisory Board: Dr.-Ing. Karsten Kroos
Tremoniastraße 5 - 11, 44137 Dortmund Management Board: Dipl.-Kfm. Winfried Schulte (Chairman), Dr. Arno Schuppert
Telefon: +49 (0) 231 186-0, Company domicile: Dortmund
Telefax: +49 (0) 231 186-2500 Commercial court: Local Court Dortmund, HRB 10591
e-mail: rotheerde@thyssenkrupp.com VAT-ID-Nr.: DE811460194
Internet: www.thyssenkrupp-rotheerde.com Tax No.: 112/5795/0833
Refer to protection notice ISO 16016. Offenders will be held liable for the payment of damages.
Design Dept. / D. Holtkötter
Date: 30.01.2014 Rothe Erde No.: 16-29236 Page 1 of 23
Document No.: 13617_00 Drawing No.: 061.60.3000.200.41.1522
Table of contents
1 Revision status ....................................................................................................... 4

2 Bearing data........................................................................................................... 5
2.1 Main dimensions and weight .............................................................................. 5
2.2 Material data ................................................................................................... 5
2.3 Information regarding the fixing of the slewing bearing .......................................... 5
2.4 Gearing data.................................................................................................... 6
2.5 Pinion requirements .......................................................................................... 6
2.5.1 Tip Relief .................................................................................................. 6
2.5.2 Flank hardness ......................................................................................... 7
2.6 Environmental conditions .................................................................................. 7
3 Calculation ............................................................................................................. 8
3.1 Coordinate system ........................................................................................... 8
3.1.1 Term definition for applied loads .................................................................. 9
3.2 Raceway calculation ....................................................................................... 10
3.2.1 Raceway loads ........................................................................................ 10
3.2.2 Bearing life calculation corresponding to raceway load under (see above) ........ 11
3.3 Gearing calculation ......................................................................................... 11
3.3.1 Tooth root stress accord. to Wißmann ........................................................ 11
4 Lubrication ........................................................................................................... 12
5 Installation, Lubrication and Maintenance Instructions for Bearings ............................... 13
5.1 Transport and Handling ................................................................................... 13
5.2 Storage:........................................................................................................ 13
5.3 Installation .................................................................................................... 14
5.3.1 Preparation of installation ......................................................................... 14
5.3.2 Bolted connection .................................................................................... 15
5.3.3 Bolts outer ring ....................................................................................... 15
5.3.4 Bolts inner ring........................................................................................ 16
5.3.5 Gearing (Adjustment of the backlash) ......................................................... 17
5.3.6 Operation temperature ............................................................................. 17
5.4 Lubrication: ................................................................................................... 18
5.4.1 Lubrication Raceway ................................................................................ 18
5.4.2 Re-lubrication quantities and intervals for raceway system............................. 18
5.4.3 Notes .................................................................................................... 19
5.4.4 Lubrication Gear ...................................................................................... 19
5.4.5 Re-Lubrication Gear ................................................................................. 19
5.5 Inspection ..................................................................................................... 20
5.5.1 Bolt check .............................................................................................. 20
5.5.2 Check of the sealing system ...................................................................... 20
5.5.3 Check of the raceway system .................................................................... 21
5.5.4 Check of the gear .................................................................................... 22
5.5.5 Grease sampling / analyses ...................................................................... 22

5.6 Disposal at the end of the useful life .................................................................. 23
5.7 ThyssenKrupp Rothe Erde Service assistance ..................................................... 23
Enclosure:
Drawing 061.60.3000.200.41.1522
1 Revision status
Revision status Date Issued by Checked by Modifications

00 30.01.2014 D. Holtkötter V. Hertel new document
2 Bearing data
2.1 Main dimensions and weight

Outer diameter DA 3307,2 mm
Inner diameter DI 2825 mm
Height H 160 mm
Weight approx. 2063 kg
2.2 Material data

Inner ring(s) 42CRMO4V
Outer ring(s) 42CRMO4V
2.3 Information regarding the fixing of the slewing bearing

Bolts Bolts
Unit
Outer ring Inner ring
Hole circle diameter 3115 2891 mm
Number of bolts 96 96
Bolt size 24 24
Borehole distribution equal equal
Clamping length 170 180 mm
Property class of bolts DIN
EN ISO 898-1: 2013, 10.9 10.9
also used for bolts >M39
Tightening factor 1,6 1,6
Stress cross section 352,49 352,49 mm²
Nom. Preload 70 70 %
Loctite necessary between
no no
the contact surfaces
Coefficient of friction in the
thread + under the bolt head 0,140 0,140
support
Thread of the bolts rolled
no no
after heat treatment
239,8 239,8 kN
Assembly pretensioning
force 149,88 149,88 kN
We assume that no bolts with particular characteristics (coating, cross-sections) are used
on your part.
The customer must check whether a sufficient space has been taken into consideration
for the tightening tools used.
The bolt design with the a.m. data is based on a torsion-resistant and bending-stiff
companion structure.
Please check the clamping length of the fastening bolts.

We would like to point out that a clamping length less than 5 times of the thread diameter
can cause an early loss of the bolt preload and that therefore in such cases a regular
check of the preload has to be carried out. In principle a sufficient preload of the bolts has
to be guaranteed for the complete service life.
If the bolt size is ) or the tightening factor Alpha-A is smaller than

1.6 or the nominal bolt preload is higher than 70% pretensioning by a hydraulical
tensioning device is recommended.
Irrespective of the tightening procedure the minimum assembly preload FM, min has to be
ensured.
If the bolts are preloaded by a hydraulical tensioning device (axial torsionfree) threads
with large play, however, with full shaft have to be used (e.g. as per DIN 2510). The nut
height has to be determined with the bolt supplier.
2.4 Gearing data

Wheel Pinion
External gear External gear
Module m 24 mm
Number of teeth z 135 16
Addendum modification xm 12 12 mm
Addendum reduction km -2,4 -1,05 mm
Tooth width b 131 136 mm
Gearing quality DIN 12 10
Theoretical centre distance a 1834,95 mm
Pressure angle 20
Helix angle 0
Helix direction
Basic rack tooth profile DIN 867:1986
Number of drives 2 equally spaced
2.5 Pinion requirements

2.5.1 Tip Relief
Rothe Erde requires a tip relief in form of an involute.
The Radius R must blend into the addendum flank without forming an edge.
Ca = 0,24 mm
h = 9,6 - 14,4 mm
R = 2,4 - 3,6 mm
2.5.2 Flank hardness

HVmin = 675 (tooth flanks ground)
2.6 Environmental conditions

The bearing is suitable for operating temperatures ranging from -25 °C to 60 °C.
This considers that all bearing rings will equally heat up or cool down respectively.
For higher or lower operating temperatures and/or temperature differences between the
outer and inner rings we must be advised beforehand for our review.
3 Calculation
The dimensioning was established from the following listed load cases which have been
determined from your details.
This calculation assumes that our Instructions for Installation, Lubrication and
Maintenance are carried out.
We assume that, either through turbulence or other enviromental influences that no

higher as the above defined loads occur.
If higher loads or other load combinations occur Rothe Erde has to be informed about
these loads for review.
We assume that the drives are equally spaced at the circumference so that no resulting
radial forces can affect the raceway system.
3.1 Coordinate system
3.1.1 Term definition for applied loads
Axial load
Radial load
Tilting moment
Torque
3.2 Raceway calculation

The calculated static safety in the following table refers to the specifically most loaded raceway.
This calculation is subject to a bearing installation into a torsion-resistant and bending-stiff companion structure.
3.2.1 Raceway loads

Axial load Radial load Tilting moment Speed Amount Type of rotation Static raceway safety
Load Description Fa[kN] Fr[kN] Mk[kNm] n of time
case [1/min] [%] Actual Required
1 1/3 wind in y-direction 1622 11 807 0,120 80 Slewing motions 5,37 1,45
2 Wind in y-direction 1622 34 819 0,120 15 Slewing motions 5,32 1,45

Wind
3 1622 41 825 0,120 5 Slewing motions 5,3 1,45
Travelling position
Wind
4 1622 111 936 0 0 --- 4,99 1,45
Out of operation
3.2.2 Bearing life calculation corresponding to raceway load under (see above)
Load cases taken as basis: 1-3
DIN ISO 281 (L10) as well as corresponding analyses in the offices of ThyssenKrupp
Rothe Erde GmbH are the basis for the bearing life calculation. For large diameter
slewing bearings this bearing life can only be regarded as a benchmark. It is not part of
any warranty.
Hours Rotations
Nominal total bearing life: 79 067 569 283
3.3 Gearing calculation

3.3.1 Tooth root stress accord. to Wißmann
Perm. Perm.
Torque Torque Tangential
Description tangential bending
bearing pinion force
force stress
[kNm] [kNm] [kN] [kN] [N/mm²]
normal service 128 39,51
load - --- - 273,39 180
166 51,23
295 91,05
short-time
- --- - 546,78 360
maximum load
348 107,41
813 250,93
survival load 90% bmax
- --- - 697,15
459
1177 363,27
4 Lubrication
Upon supply of the bearing, the raceway is filled with a lithium-saponified grease
according to the RE-Catalogue, latest edition.
Please refer to the special Rothe Erde Installation, Lubrication and Maintenance
Instructions where re-greasing intervals and amounts are mentioned.
5 Installation, Lubrication and Maintenance Instructions for Bearings
5.1 Transport and Handling
DANGER
Danger of life by overhead load
Do NOT step underneath the load
Use suitable slings
Use suitable lifting devices
Like any other machine component bearings also require careful handling. Transport and
storage is to be carried out only in horizontal position with suitable lifting tools / load
securing devices. Bearing weight without crate is approx. 2063 kg. Radial impacts must
be absolutely avoided.
If the bearing is delivered without transport bolts, the transport threads will be marked in
Attention: The chain angle ß may not exceed max. 60°.
5.2 Storage:
Caution
Sensitive surface
Do not open the packing with a
sharp blade
Surface may be damaged
The storage of the bearing has to be done in horizontal position.
The non coated outer surfaces of the bearing are protected with the anti-corrosion agent
VCI 369 H/10 (P) and the raceway system is filled with grease.
Maximum permissible storage periods:

approx. 6 months - roofed storage areas,
approx. 12 months - closed, temperature-controlled rooms (temperature > 12°C).
During storage or partly assembled bearings please note chapter: Lubrication / Notes
Longer storage periods will require a special packing!
5.3 Installation
5.3.1 Preparation of installation
CAUTION
Risk of skin irritation caused by
preservative
Safety gloves must be worn for
removal
If delivery is done with a transport cross bracing, this will have to be

removed/dismounted before installation.
The installation of the bearing has to be done in the vertical axis of rotation!
The preservation has to be removed from the contact surfaces of the bearing and the
gear. This can be done with an alkaline cleaner.
Attention: Prevent any cleaner from contacting the seals and from entering into the
raceways! Do not paint the seals!
A flat contact surface free from grease and oil is required for the bearing installation.
The bearing contact surfaces have to be checked with regard to evenness deviation. Max.
acceptable evenness deviation, acc. to DIN EN ISO 1101 is 0,3 mm. Over a sector of
180° this maximum value may only be reached once.
DANGER
Entrapment hazard when putting the load
down
Location control before putting the
load down
Mind the staff
The unhardened zone between the beginning and the end of the raceway hardening is
marked on the inner resp. outer diameter of each bearing ring by a punched-
(type plate).
For the geared ring the hardness gap is marked on the axial surface.
For a ring with po be positioned outside of the main load
area.
If the main area of operation is known for the application, then the soft spot position is
also to be placed at the circumferentially loaded ring outside of the main load area.
Possible enclosed supplies, seals, O-rings, grease nipples etc. have to be used.
5.3.2 Bolted connection

Attention: Check the bolt lengths, in the loaded bolt section at least six free thread turns
and the minimum bolt length must be assured.
The surface pressure under the bolt head or nut must not exceed the acceptable limit
values.
When exceeding the surface pressure limit, suitable washers have to be used.
Information, see www.thyssenkrupp-rotheerde.com
5.3.3 Bolts outer ring

Connect the bearing with the companion structure and check the congruence of the bolt
holes in the bearing with the bore holes of the companion structure! To aid bearing
positioning 3 evenly distributed guide pins can be used.
With nonconfirmity the bearing could be slightly distorted /deformed.
Insert all bearing fixing bolts M 24 of strength class 10.9 hand-tight.
Pretension the bolts carefully crosswise (see sketch) to 954 Nm with a suitable tool (when
using a torque wrench). If the bolts are pretensioned with a hydraulic or electrical torque
wrench, they must be pretensioned to 1060 Nm as described before.
The a.m. tightening torque is based on slightly oiled threads, nuts and contact surfaces
as well as on bolts and nuts without surface coating (tot. µ = 0.14).
Provide for a complete revolution after the 8th bolt crosswise. The pretension of the bolt
having been tightened first is influenced by the tensioning of the further bolts. Thus it is
necessary to provide for at least two revolutions.
5.3.4 Bolts inner ring

Connect the bearing with the companion structure and check the congruence of the bolt
holes in the bearing with the bore holes of the companion structure! To aid bearing
positioning 3 evenly distributed guide pins can be used.
With nonconfirmity the bearing could be slightly distorted /deformed.
Insert all bearing fixing bolts M 24 of strength class 10.9 hand-tight.
Pretension the bolts carefully crosswise (see sketch) to 954 Nm with a suitable tool (when
using a torque wrench). If the bolts are pretensioned with a hydraulic or electrical torque
wrench, they must be pretensioned to 1060 Nm as described before.
The a.m. tightening torque is based on slightly oiled threads, nuts and contact surfaces
as well as on bolts and nuts without surface coating (tot. µ = 0.14).
Provide for a complete revolution after the 8th bolt crosswise. The pretension of the bolt
having been tightened first is influenced by the tensioning of the further bolts. Thus it is
necessary to provide for at least two revolutions.
5.3.5 Gearing (Adjustment of the backlash)
DANGER
Entanglement hazard due to exposed gear
Keep hands away from moving parts
The point of maximum deviation of the pitch circle from circularity is marked by three
green teeth. If possible the backlash has to be adjusted at this point and must be always
checked at each drive after final assembly.
At the teeth marked in green it must be assured , even if there is no pinion adjustment
possibilities, that the backlash will be 0,03 0,04 x module, min. 0,72 mm.
5.3.6 Operation temperature
The bearing is suitable for operating temperatures ranging from -25 °C to 60 °C. This
considers that all bearing rings will equally heat up or cool down respectively.
5.4 Lubrication:
5.4.1 Lubrication Raceway
Caution
Risk of skin irritation caused by lubricants
Safety gloves must be worn when handling
lubricants
On delivery the bearing is adequately greased.
The grease filling shall reduce friction, seal and protect against corrosion. That is why re-
lubrication has to be done always copiously so that a grease collar of fresh grease will
form over the whole circumference of the bearing gap resp. seals.
Preferably the lubricants listed in the table hereinafter should be used. These raceway
greases are exclusively KP 2 K-greases, i.e. lithium saponified mineral oils of the NLGI-
class 2 with EP additives.
The lubricants listed hereinafter can be mixed with each other.
To provide for an equal grease distribution in the bearing raceway system the use of an
automatic lubrication system is recommended.
This has to be adjusted to pulsed intervals.
When automatic lubrication systems are in service the pumpability of the lubricant has to
be confirmed by the lubrication system manufacturer.
Lubricant specific questions have to be clarified with the lubricant producer.

Note: Lubricants can be water-polluting and hazardous; the national laws and regulations
have to be observed.
5.4.2 Re-lubrication quantities and intervals for raceway system

The first re-lubrication of the raceways is done immediately after installation.
The greases listed in the table have been released for our bearings and have been tested
with regard to compatibility with the spacers and seals used by ThyssenKrupp Rothe
Erde.
Raceway
Producer Name Temperature in °C

Aral Aralub HLP 2 -30 up to +120
Castrol Spheerol EPL 2 -20 up to +140
Fuchs Lubritech Lagermeister EP 2 -20 up to +130
Mobil Mobilux EP 2 -20 up to +130
Klüber CENTOPLEX EP 2 -20 up to +120
Shell Gadus S2 V220 2 -25 up to +130
TOTAL Multis EP 2 -25 up to +120
The re-lubrication quantity for the raceway shall be min. 1,54 liter per week.
If necessary the re-lubrication quantity has to be adapted to the work cycles.
It has to be distributed acc. to the number of lubrication holes.
5.4.3 Notes
Manuel re-lubrication is done during rotation or slewing of the bearing.
Before and after long periods of equipment disuse (approx. 3 months) a re-lubrication is
absolutely required. This also applies to delayed commissioning and / or partly
assembled equipment / bearings, where preservation of exposed metallic bearing
surfaces and bolt holes must be performed immediately. The preservation must be
regularly inspected, it must be assured, that no corrosion can occur.
Alternatively for partly assembled bearings a storage environment equivalent to long-term
packaging can be created.
- preservation of the exposed metallic surfaces e.g. threads and holes/drillings

- 0 % (permanent temperature and humidity
control).
- Temperature range -20° + 40°
With partly assembled bearings/slewing rings an inspection after 24 months by

ThyssenKrupp Rothe Erde is meaningful.
In view of the different parameters and operating conditions these can only be reference
values.
5.4.4 Lubrication Gear

The gearing has to be lubricated with a suitable grease before starting in operation.
ThyssenKrupp Rothe Erde recommends using an automatic lubrication system for the
gearing system. Recommendation about lubrication intervals and quantity must be
specified by the manufacturer of application.
When automatic lubrication systems are in service the pumpability of the lubricant has to
be confirmed by the lubrication system manufacturer.
Lubricant specific questions have to be clarified with the lubricant producer.
Note: Lubricants can be water-polluting and hazardous; the national laws and regulations
have to be observed.
5.4.5 Re-Lubrication Gear
The tooth flanks must always be coated with an adequate lubricating film.
Suitable greases are named in the following table:
Gear
Producer Name Temperature

Aral Aralub MKA -Z 1 -10°C up to +180°C
Castrol Mollub Alloy 9790/2500-1 -20°C up to +90°C
Fuchs Lubritech Ceplattyn KG 10 HMF -10°C up to +140°C
Klüber GRAFLOSCON C-SG 0 ultra -30°C up to +200°C
Mobil Mobilgear OGL 461 -20°C up to +120°C
Shell Malleus OGH -10°C up to +200°C
TOTAL AD Plus -25°C up to +150°C
Gear greases with comparable characteristics and properties can also be used.
5.5 Inspection
5.5.1 Bolt check
It must be assured that throughout the whole service life of the bearing an adequate high
bolt pretension will be maintained. Due to practical experiences a retightening of the bolts
is recommended for compensation of the settling phenomena.
For a bearing with surface coating we recommend a re-tightening of the bearing fixing
bolts after approx. one day.
5.5.2 Check of the sealing system

The seals and the sealing system should be checked at least every 6 months.
If the bearing is equipped with a sealing compound at the ring segments these must be
checked and if necessary reconditioned after consulting ThyssenKrupp Rothe Erde.
Any dirt/contamination must be removed.

If the seals are damaged they have to be replaced.
When cleaning the equipment/machine attention must be paid that no cleaning fluids will
get into contact with the seals or penetrate the raceways.
All seals have to be sufficiently protected by the companion structure against mechanical
damage, heavy dirt, direct sun rays and water jet, if needed by a dirt-deflector.
5.5.3 Check of the raceway system
Danger
Exceeding the maximum permissible wear
rates involves the risk of accidents and
danger of life
When reaching the wear limits the
machine must be put out of
operation
Safety instructions
While in operation it must be assured that the wear limits of the bearing will not be reached.
With regard to further information (sketches / procedures) see www.thyssenkrupp-
rotheerde.com.
The resulting wear must be regularly determined and recorded.
The procedure is included in the manual.
In case of open questions ThyssenKrupp Rothe Erde must be contacted.
After a longer operating time the bearing clearances will increase.
The structural integrity can be ascertained by the following measurement.
During commissioning measuring points have to be defined at the bearing and at the
companion structure and / or the distances of the bearing rings to each other have to be
determined (see sketch).
In regular intervals these measurements have to be repeated and the results have to be
documented.
The control measurements must always be made under the same load conditions and in
the same positions.
The measured difference compared to the measurement made during commissioning
gives the incurred bearing clearance.
Measurement method: Reduction measurement

Max. acceptable increase of bearing clearance 3,3 mm.
Using the example of a roller bearing / ball bearing:
Measuring points Basic Control Control measurement

measurement measurement
Measuring point 1
Measuring point 2
Measuring point 3
Measuring point 4
Inspector
Date
Signature
While in operation it must be ensured that the wear limits of the bearing will not be
exceeded!
5.5.4 Check of the gear

In the course of the service life smoothing from the running-in process and gearing wear
appear. A reliable wear limit value strongly depends on the application. Acc. to
experience the acceptable value can amount up to 0.1 x module per tooth flank.
5.5.5 Grease sampling / analyses

To give a more precise statement on the raceway condition adequate, lubricant samples
should be taken out of the raceway system in addition to the wear measurements.
Both of these results taken together allow a more exact assessment of the wear condition
and provide for further coordination and procedure.
We suggest a yearly inspection procedure together with wear measurements.
The bearing has grease sampling holes and these shall be located in the main load area.
A suitable grease sampling set can be obtained from ThyssenKrupp Rothe Erde GmbH,
please contact sales.rotheerde@thyssenkrupp.com.
We suggest an inspection procedure together with wear measurements as follows:
Removal of the locking screws at the grease sampling holes.

Each grease sample has to be taken during a slow rotation of the bearing with the
help of the sampling set.
Analysis of the grease sample by ThyssenKrupp Rothe Erde GmbH, D - 59555
Lippstadt, Beckumer Str. 87, Application Engineering & Service Dept.
Closure of sampling holes.
Using the example of a ball bearing / roller bearing:
5.6 Disposal at the end of the useful life
Instruction
Disposal may involve environmental risks
Follow the directives for waste
disposal
Mind the national laws
At the end of the useful life the bearing has to be dismantled. All lubricants, seals and
plastic parts have to be disposed in accordance with the waste guidelines in force.
Bearing rings and rolling elements have to be recycled.
5.7 ThyssenKrupp Rothe Erde Service assistance

For a continuous and undisturbed operation of our bearings we offer our following
service:
Maintenance / Reconditioning /
Installation Others
Inspection Maintenance
Judgement of the Wear measurements Repair Trainings

contact surfaces /
laser measurement Check of bolts General overhaul Technical support
Bearing installation Lubrication analysis
Reference Seal exchange

measurements
Commissioning
6.3 HOISTING GEAR

6.3.1 Hydraulic equipment
Hydraulic power pack (arranged on the slewing part)

with
1 hydraulic cylinder for hoisting gear
Note!
For details on the hydraulic equipment, please refer to the separate
hydraulic documentation.

Blank page

Operation and maintenance manual

(Mechanical part)
STACKER
TYPE STD-4500/29.5x1.2
(930-ST-110)
Volume M2
Project: SHOUGANG / IRON ORE PROJECT (Package 6)
Order-No.: N-033-00114
Year of construction 2013/2014
Fig.: 225-STD4500-D01

Ernst-Heckel-Straße 1
D-66386 St.Ingbert-Rohrbach
Phone: (06894) 599 - 0
Facsimile: (06894) 599 - 468
Internet: www.thyssenkrupp-industrial-solutions.com
Blank page
6.4 BOOM CONVEYOR

6.4.1 Drive unit A - KSZg 280 Rü Pu Lü
 Gearbox KSZg 280 Rü Pu Lü

and lubricant chart
 Accessories for gearbox
− Axial-impeller: General technical information
− Axial-impeller: Important information for installation and operation
− Back stop RSCI 70: Installation and maintenance instructions Freewheel Type RSCI
− Shrink disk TAS 3071-185: Mounting instructions for 3071 - 3051 - 3091 - 3073 - 3061
− STOZ oil pump: Pump catalogue
− Flow sensor SI5010: Technical data sheets
− Flow monitors SI5010: Operating instructions
− Resistance thermometer and thermocouples: Manual
− Resistance thermometer and thermocouples: Important references
− Adapter E40096: Technical data sheet
− Socket EVC008: Technical data sheet
 Hydraulic coupling 487 TVVFNJ-Z
– Turbo couplings with constant fill:

Installation and operating manual
– MTS Mechanical Thermal Switch Unit:

Installation and operating manual
 Flexible coupling Nor-Mex® GBT 214 - 315/118
– Flexible coupling Nor-Mex® GBT, GTW, GBS

Assembly and operating instructions

 Drum brake SBH 315 with Elhy-thruster EB 500/60
− Mounting, Adjustment and Maintenance of drum brakes SBH
− Drum brakes SBH: Technical data sheet
− General notes
− Options for drum brakes: Lining wear compensator device
− Electrohydraulic Thrusters ELHY®: Users manual, series EB

Customer:
Order number - TKIS: N-033-00114 - Shougang
Gearbox type: KSZg 280 RüPuLü
Serial number: G 28 624 – Design “R”
Delivery:
1 Gear Drive Unit – STD 4500 4556411-03
This document may only be passed into the hands of third with the written consent of TKIS.
All documents belonging to it are protected by copyright. A reproduction, even partially, is not
Page 2 of 43
Order data

Drive power P = 186 kW
Input speed n1 = 1800 rpm
Ratio i = 14,82
Oil type ISO VG 220
Oil quantity Q = 30 l

Hydr. Coupling TVVFN-Z 487
Flex. coupling GBT 214/315-118
Brake incl. thruster SBH 315/500-60
Technical Data – Lubrication system (optional)

Oil pump
Pump capacity Q =
Motor power P =
Fan
Motor power P =
Technical Data – Actuating drive (optional)

Motor power P =
Motor speed N =
Page 3 of 43
Table of Contents
1 Introduction ................................................................................... 5
1.1 General ............................................................................................................ 5
1.2 Symbols used .................................................................................................. 6
1.3 Product identification......................................................................................... 7
1.4 Instructions to the operator ................................................................................ 8
1.5 Training / Instruction of staff .............................................................................. 8
2 Safety Instructions .......................................................................... 9
2.1 General instructions .......................................................................................... 9
2.2 Use according to regulations .............................................................................. 9
2.3 Residual risks ................................................................................................... 9
2.4 Safety instructions .......................................................................................... 10
3 Delivery / Transport / Storage ........................................................ 11
3.1 Scope of delivery ............................................................................................ 11
3.2 Transport ....................................................................................................... 11
3.3 Storage ......................................................................................................... 12
4 Installation ................................................................................... 13
4.1 General .......................................................................................................... 13
4.2 Assembly ....................................................................................................... 14
4.3 Alignment ...................................................................................................... 15
4.4 Output coupling / Flanged joint ........................................................................ 15
5 Lubrication .................................................................................. 16
5.1 General .......................................................................................................... 16
5.2 Oil temperature .............................................................................................. 17
5.3 Pressure lubrication (optional) .......................................................................... 17
5.4 Monitoring of the oil pressure (optional) ............................................................ 18
5.5 Double filter system (optional) .......................................................................... 18
5.6 Oil filling ........................................................................................................ 19
5.7 Environmental protection ................................................................................. 19
6 Putting into operation / Operation ................................................... 20
6.1 General .......................................................................................................... 20
6.2 Putting into service, Run-in phase / Installation of spare gearboxes ..................... 20
6.3 Putting into operation ...................................................................................... 21
6.4 Heating elements (optional) ............................................................................. 21
6.5 Lubrication system (optional) ........................................................................... 22
Page 4 of 43
7 Maintenance / Repairs / Waste disposal / Recycling .......................... 23

7.1 Inspection and Maintenance ............................................................................ 23
7.2 Maintenance works tob e carried out regularly ................................................... 24
7.3 Miscellaneous................................................................................................. 26
7.4 Lubrication ..................................................................................................... 27
7.5 Monitoring of the oil grade ............................................................................... 27
7.6 Cleaning oft he gearbox................................................................................... 28
7.7 Drainage of the oil trap arranged underneath the fluid coupling ........................... 28
7.8 Welding work.................................................................................................. 28
7.9 Disposal / Recycling ........................................................................................ 29
8 Shut-down................................................................................... 30
8.1 Short-term shutdown (gearbox mounted) .......................................................... 30
8.2 Long-term shut-down (gearbox is not mounted) ................................................ 30
8.3 Storage / Actions to be taken during storage ..................................................... 31
8.4 Actions to be taken during long-term shut-down ................................................ 32
9 Malfunctions / Causes / Corrective actions....................................... 34
9.1 General .......................................................................................................... 34
10 Spiral bevel gear (optional) ............................................................ 40
10.1 Contact pattern ............................................................................................... 40
10.2 Circumferential backlash ................................................................................. 41
11 Annexes ...................................................................................... 43
Page 5 of 43
1 Introduction
1.1 General
These operating- and maintenance instructions written by ThyssenKrupp Resource Technolo-

gies - BU Materials Handling - (hereinafter called TKIS) is delivered with the gearbox, in order
to allow the following operations to be safely done by persons who are entitled and trained
appropriately:
- Transport
- Handling
- Installation
- Operation
- Maintenance
- Repair
- Disassembly
- Disposal
The original version of these operating- and maintenance instructions has been written in
German, and versions in other languages are available. The operating- and maintenance in-
structions reflect the state of the art at the time of production. TKIS reserves the right to revise
these operating- and maintenance instructions at any time, without the present document
loses its validity.
The non-compliance with these operating- and maintenance instructions can have adverse
health and safety effects and can cause damages to property. This manual contains infor-
mation about the safe, proper and efficient operation of the gearbox. Moreover, the compli-
ance with these operating- and maintenance instructions helps minimize risks, repair costs
and downtimes, as well as improves the reliability of the product.
The operating- and maintenance instructions must at any time be available to the operational
staff. All persons working on or with the gearbox
- to mount or install it
- to operate the machine, including repair of failures during operation
- to remove built-on- and auxiliary equipment
- to carry out maintenance- and repair works
must have free access to this document.

Page 6 of 43
1.2 Symbols used
Danger!
Here emphasis is put on dangers associated with the activity described, involv-
ing a certain risk to persons. If you expose yourself or other persons to danger
you will risk your life or that of other persons or a serious accident.
All danger signs must be read. The instructions given must be followed at any
time!
Caution!
Here emphasis is put on dangers associated with the activity described and
where non-compliance may result in damages to the product or auxiliary
equipment.
All precautionary measures must be taken at any time!
Note:
This term is used to draw attention to procedures or a sequence of procedures
that are of particular importance. The instructions associated with this term are
to be observed to ensure proper functioning.
This sign is used to identify specific operating instructions or – sequences to be

• followed in the given order!
– This sign is used to identify items in listings.

Page 7 of 43
1.3 Product identification
Each gearbox supplied by TKIS is clearly identified with the help of the type plate. From the
following figure can be seen the type plate and the data given on it.
A Manufacturer
B Order number
C Serial number
D Gearbox type
E Capacity
F Input speed
G Ratio
H Weight
I Oil type
J Oil quantity
K Year of construction
Note:
The data given in the fields B, C and D are to be added to each correspond-
ence with TKIS.
Page 8 of 43
1.4 Instructions to the operator
This operating- and maintenance manual is part of the delivery. The operator is obliged to
ensure that the operational staff complies with the instructions given in it.
The operator must complete the instructions given in this manual by the applicable statutory
regulations with regard to safety at work and environmental protection. Moreover, the com-
pleted document must include instructions with regard to work control and reporting, taking as
basis the specific conditions on the spot, such as organization of the work, work flow and skill
of the operational staff involved.
The following regulations are to be observed too:
- Statutory regulations with regard to accident prevention
- Codes of practice with regard to safe and proper functioning
The operator is not allowed to carry out any retro-fittings or modifications on the gearbox or
the drive mechanism that might have an adverse effect on its safety, unless they have not
been expressly approved by TKIS.
The same goes for the installation and setting of safety devices and any type of welding work
to be carried out on the gearbox.
All spare parts must be in conformity with the technical specifications of TKIS.
The original spare parts of TKIS correspond with these specifications.
The unit may only be operated by trained and specially instructed personnel. The operator is
obliged to assign responsibilities for maintenance and repair.
To be able to give guarantee, TKIS must be informed about the date of commissioning.
In the event the instructions given in this manual are not complied with, claims under a guar-
antee against TKIS are lost. TKIS repudiates each and every claim put in after damage due to
non-compliance.
1.5 Training / Instruction of staff
The operator must inform the operational staff about the applicable safety regulations, and
must it train as to handle safety devices mounted on or near the gearbox.
The mode of instruction must correspond with the qualification of the personnel.
The operator must ensure that the instructions were fully understood and must achieve their
application. These measures are necessary to ensure that the personnel are aware of the risks
and safety issues connected with the equipment.
Keeping of the instructions should be checked at regular intervals.
We recommend that those involved in courses should be requested by the operator to confirm
their attendance by signature.
Page 9 of 43
2 Safety Instructions
2.1 General instructions
The gearbox has been designed in accordance with the state of the art and all applicable safe-
ty regulations.
Certain risks, injury to users or third, damages to the system or other parts, however, cannot
be totally excluded, if:
- the unit is operated by staff not specially trained and instructed,

- the unit is not used according to regulations,
- the drive mechanism is not maintained / serviced properly.
2.2 Use according to regulations

The gearbox has been designed to transmit the torque and speed from a drive unit to a driven
unit.
The technical specifications must be taken into account for all applications.
They are enclosed with this operating manual or mentioned in the data sheet furnished with
the gearbox.
Any other use is considered to be not in accordance with the regulations. The operator and
user are held responsible for damages due to an improper use of the gearbox. The same ap-
plies to
unauthorized modifications made on the product.
The proper use also includes the observation of the instructions given in the present manual in
view of:
- Safety
- Operation
- Maintenance
- Mounting.
Caution!
A no-load operation of the gearbox can entail damages to the bearings.
2.3 Residual risks

Even if all safety instructions are complied with, there is a residual risk of injury and damage
arising out of the operation of the gearbox.
Danger!
Risk of injury from rotating parts of the gearbox
The gearbox must feature the necessary safety devices to prevent accidental
contact with rotating parts. The gearbox must not run without properly mount-
ed safety
devices.
Page 10 of 43
2.4 Safety instructions

The gearbox may only be used for the intended purpose and when in proper working order. It
must be operated in conformity with the instructions given in this operating manual! Any de-
fect or fault having a detrimental effect on the safety must be rectified without delay!
All persons involved in the assembly, the operation and the repair of the gearbox must have
read and fully understood this operating manual.
This manual must be kept near the gearbox, accessible to each and every authorized person.
TKIS undertakes no responsibility for damages due to non-compliance with this operating
manual. The appropriate safety instructions and other generally accepted practices regarding
safety and health must be adhered to.
When carrying out inspection-, maintenance- and repair works on the gearbox and devices,
always follow the instructions given in this manual!
The responsibilities in conjunction with various inspection- and maintenance tasks must be
clearly defined. Otherwise, there might be an increased risk of damage and injury. If safety-
relevant failures or changes are observed during operation of the gearbox, the drive mecha-
nism must be immediately stopped and the responsible department and person must be in-
formed. Only suitably trained and authorized personnel may work on the gearbox. It must be
ensured that all legal requirements as to minimum age of staff are complied with!
2.4.1 Operation of the gearbox

The gearbox may only be operated when fully assembled and in proper working order.
All safety devices and safety-relevant equipment, e.g. protective hoods that can be detached,
etc., must be in mounted and proper condition before the gearbox may be started!
2.4.2 Maintenance / Troubleshooting

The maintenance schedule part of this manual must always be kept. A suitable workplace is
imperative for the proper maintenance of the equipment.
If the machine train in which the gearbox is installed needs to be stopped to enable mainte-
nance- or repair works to be done, it must be protected against unintended switching on.
- Lock all main operating devices like switches, locks and valves and remove the key, as
well as
- fix warning signs to the main operating devices.
Secure the drive mechanism against unintended rotational movement.
Tighten screws that may have been loosened during repair- or maintenance work! If neces-
sary, use a torque spanner to secure the screws.
If the execution of works required the safety devices to be removed, they must immediately be
checked after remounting for their proper functioning!
When replacing components by using lifting gears, ensure the safety of the parts to be han-
dled, in order to avoid accidents! Make only use of lifting gears that are in technically perfect
state and that have sufficient lifting power!
Ensure the safe and environmentally compatible disposal of all substances and replaced parts
according to the statutory regulations.
Page 11 of 43
3 Delivery / Transport / Storage

3.1 Scope of delivery
Unless agreed otherwise, the gearbox is supplied in working order, but without oil filling. Ex-
ternal parts of the gearbox (shaft ends, etc.) are treated with an anticorrosive agent (TECTYL
846/TECTYL 502). The interior of the gearbox is protected by means of a preservative oil (e.g.
SHELL VSI* OIL, CASTROL ALPHA SP220S, Texaco Regal R&O VSI). This oil contains volatile
matters that protect from corrosion for a limited period. The gearbox must be made airtight, in
order to keep the gases escaping from the anticorrosive agent in the gearbox.
If the gearbox features additional components (couplings, lubrication system, etc.), separate
operating instructions for these components will be attached to this manual. Upon receipt of
the delivery the goods must be inspected to ensure that they are complete and free of dam-
ages. If this is not the case, TKIS is immediately to be informed in writing. TKIS’s general
terms of business apply.
3.2 Transport
Note:
Gearbox and accessories must get a PVC shrink-wrap and, if possible, be
boxed with desiccants (see packing guidelines according to HPE standard).
Danger!
Risk of injury due to falling parts!

Make only use of lifting lugs appropriate for the weight and size of the deliv-
ery/packing.
The packing has been jointly selected with the forwarding- and packing agent to satisfy the
demands on the transport, the range and the size of the delivery.
• Prior to the transport, it must be made sure that the gearbox is properly secured against
slipping / working loose.
• Jerks and shocks (e.g. due to bumpy roads) are to be avoided.
• Always comply with the applicable regulations on safety at work!
• Make use of timber blocks when laying ropes around sharp edges.
• Pipes are to be protected against damages.
Page 12 of 43
Lifting lugs at the upper part of the housing are not intended for the transport of the drive unit,
but they may only be used to detach the upper part of the housing, if not stated otherwise.
The gearbox is best transported by using appropriate ropes and shackles to be fixed to the
lifting lugs and eyes provided for.
The lifting lugs and eyes are marked with this symbol.
3.3 Storage
Prior to the delivery, the gearbox has been treated with an anticorrosive agent. The corrosion
protection lasts 12 months starting from date of delivery at the latest (gearbox packed, ready
for shipment), insofar as the gearbox is not opened, as well as protected against atmospheric
exposure (rain, snow, etc.).
Note:
The location at which the unit needs to be stored must meet the requirements
specified in chapter 8.3.
Caution!
Danger of damages to the gearbox due to corrosion!
If the gearbox is stored for more than six months, the outer protective coats must be regularly
inspected and made new, if necessary.
Caution!
Before applying any protective coats to the gearbox, protect the seals from
getting contaminated by paint or anticorrosive agent (cover with tape).
Adhesive
Tape
0-Ring
Note:
TKIS shall not be held liable for damages caused by improper preservation or
storage of gearbox or individual parts as soon as the purchaser has accepted
responsibility!
Page 13 of 43
4 Installation
4.1 General
To assure a proper functioning, the gearbox must be placed on a flat and vibration-free foun-
dation. If the gearbox has to run with minimum noise emission, there must be taken actions to
enable the gearbox to be uncoupled from its base (e.g. dampers).
The shaft ends are treated with an anticorrosive agent. It must be stripped by using a solvent
before mounting couplings or other attachments. Solvents must not have an aggressive effect
on seals, paint or metal. Never use abrasives.
Caution!
The corrosion protection must be removed in the first place. While doing so,
avoid damages to seals and surfaces!
Use the threaded hole at shaft end to mount the drive components (e.g. couplings, wheels,
drums, pulleys, etc.).
A forced mounting causes damage to antifriction bearings, fitting keys, flanges and teeth.
Caution!
Danger of damages to the machine due to the use of unsuitable tools! Never
proceed to a forced mounting.
The gearbox is to be connected with other machines by means of screw joint in
accordance with the general arrangement drawing.
For more details on the installation of drive components, please refer to the documents en-
closed herewith.
Page 14 of 43
4.2 Assembly
Note:
Only specially instructed personnel may install the gearbox with the aid of suit-
able tools and equipment. Never use hammers or other striking tools or tools
with pointed and sharp edges!
When aligning the gearbox, see to it that all lubrication points are freely acces-
sible. Actions are to be taken to protect against contact with rotating parts. The
safety regulations applicable on the spot must be adhered to. Electrical con-
nections and circuits are made available by the client.
Note:
Fitting dimensions and other details connected with the installation are to be
taken from the enclosed data sheet.
Caution!
When laying separately supplied lubrication pipes, it must be made certain that
the plugs to prevent the pipes from getting dirty are removed.
Insufficient lubrication causes damages to the bearings!
Page 15 of 43
4.3 Alignment
The gearbox must be brought in line with the driven machine with the utmost care, even if
self-aligning couplings are used.
Note:
Always observe the manufacturer’s instructions regarding the machines!
The offset between both the input shaft and the output shaft must be minimal.
The values obtained are to be documented.
• Angular misalignment max. 0,01 mm / 100 mm referred to the

biggest diameter
• Offset max. 0,025 mm of the shaft axes to each
other
Note:
During alignment one shaft shall be fixed and the other one be turned in one
direction only, in order to ensure exact measurement. Furthermore, thermal
expansions have to be taken into account.
4.4 Output coupling / Flanged joint

The coupling/flanged joint consists of two halves. The output shaft of the gearbox is a solid
forged part featuring a flange. The flange situated on the output side is, as a rule, a flange
with shrink disk. The two parts are connected with each other by hydraulically tightened
screws. So a frictionally engaged joint is obtained. The joint can be easily disassembled (re-
duction of downtimes when replacing a gearbox). The alignment of the flanges to each other
is assured by centering and bores. If the couplings show no marks, the coupling halves are
manufactured so precisely to enable them to be arbitrarily mounted with each other. The axial
movement must be so small to avoid the occurrence of inadmissible wobbling. Two oil
grooves in the coupling hubs ensure an optimal oil distribution along the conical sleeve during
mounting/dismounting.
Page 16 of 43
5 Lubrication
5.1 General
Note:
Oil filling: The gearbox is delivered without oil filling!
To lubricate TKIS drive units, only use gear lubricant oils recommended by TKIS. Generally,
the lubricants are part of the extent of operating- and maintenance works.
The gear lubricant oils recommended by TKIS contain additives protecting the equipment from
corrosion and extending the service life thanks to reduced wear in the mixed friction area. The
use of gear lubricant oils not in compliance with the standards required voids TKIS’s warranty.
The oil viscosity and quantity given on the type plate of the gearbox is binding.
The use of a product with different viscosity is only permitted after consultation with TKIS. The
purity of the product affects the reliability and the useful life of gearbox and lubricant. TKIS
therefore recommends using only pure and clean oil. If large volumes of oil are needed, it
might be necessary to clean the oil at regular intervals and to carry out analyses, in order to
determine whether the oil has to be changed. Do not mix oils of different grades. When chang-
ing to a new product, consult the respective manufacturer to find out whether his product is
compatible with the old one, as incompatibilities and contaminations by residual oil cannot be
excluded. When changing to a product differing widely from the old one, the gearbox must be
flushed with the new oil before oil is filled in. Ensure that the residual oil is removed from the
gearbox, as far as possible.
Caution!
Ensure that the lubricant oil will not be mixed with other substances. Never
flush the gearbox by means of petroleum or other cleansing agents as resi-
dues of these substances could remain in the gearbox.
In case of changed operating conditions (ambient temperatures, speed, load
cycles), it might be necessary to replace the lubricant oil by a product of higher
or lower viscosity. Under certain conditions the use of synthetic oil might be
required. Before using synthetic oil, consult TKIS.
Page 17 of 43
5.2 Oil temperature

The operating temperature depends on the present ambient temperature and the strain on the
gearbox.
Caution!
Ensure that the maximally admissible oil sump temperature will not be exceed-
ed.
TKIS advises monitoring this temperature regularly.
Contact TKIS if the oil exceeds the admissible temperature range due to high
ambient temperature. High temperatures shorten the useful life of the oil con-
siderably.
Caution!
Monitoring of the oil temperature
TKIS advises recording the temperatures regularly.
If the oil temperature increases during comparable operating conditions, there
is a possibility of damage to the drive unit. In order to avoid a major damage or
even a total failure, the drive unit should be inspected carefully.
Note:
If bearing temperatures above 120°C are measured, stop the drive unit imme-
diately and carry out an inspection.
5.3 Pressure lubrication (optional)

The circulating lubrication is a separate system directly on the gearbox or mounted on its own
frame. It is delivered in a ready-to-be-mounted-state, with all connecting pieces.
The required oil comes from the gearbox. The separate circulating lubrication is installed next
to the gearbox.
Ensure that the operating- and control voltage goes with the energy supply existent on the
spot. The air supply to the cooler (optional) must not be disturbed.
The operating- and maintenance instructions regarding the lubrication system are enclosed
with this manual.
Caution!
The oil level in the gearbox should be checked after the first operation. Add oil,
if necessary!
For further information about the operation of the system, please refer to chapter 6.
Page 18 of 43
5.4 Monitoring of the oil pressure (optional)

The gearbox features a pressure switch or a flow indicator triggering an acoustic and/or visual
signal as soon as the oil pressure and the flow velocity drops below the minimally admissible
value.
The operating pressure is reached shortly after switching on the pump.
Caution!
Increase of the oil pressure during operation:
If the oil pressure gauge shows an increased value while the operating tem-
perature is within the normal range, inspect the lubrication points as they might
be blocked. For details on the oil pressure control, please refer to the docu-
ment enclosed with this manual.
The connection to the electrical mains is incumbent on the client.
5.5 Double filter system (optional)

The filter has been equipped with a maintenance indicator. As soon as the differential pres-
sure exceeds the given value, a signal for changing the filter is triggered. The process se-
quence to be followed when replacing the filter is described in the document enclosed with this
manual.
Page 19 of 43
5.6 Oil filling

The gear lubricant oil is to be filled through the openings marked. The data given on the type
plate are decisive. Use a filter or a fine screen to fill the oil.
Note:
The oil level must be in the middle of the sight class or at the top mark of the
dipstick.
During starting-up, the lubricant oil is distributed in the gearbox, or in the lubri-
cation system (optional). As this may possibly lower the oil level, it must be
checked after a short operating time. The oil is only allowed to be filled up at
standstill of the gearbox!
Caution!
The oil level can only be checked when the gearbox is not inclined and at
standstill. This is the only way to safely measure the oil level.
In case of smaller gearboxes without sight glass or dipstick, the oil is to be

filled until it escapes from the outlet.
5.7 Environmental protection

Caution!
Oil, grease and waste containing lubricant can cause serious damage to the
environment.
Make sure that lubricants are never spilled, and that they cannot penetrate into
the ground, sewage system or groundwater. Lubricants must be disposed in
accordance with the statutory regulations.
Page 20 of 43
6 Putting into operation / Operation

6.1 General
To put into operation the gearbox, the instructions given in the chapters 3, 4 and 5 are to be
complied with.
If it is a matter of gearboxes with fixed sense of rotation (marking on the gearbox) see to it that
the connection to the driven component is carried out correctly.
Pull off the tape from the shafts and remove all transport securities, provided that the anticor-
rosive agent has already been washed off (see chapter 3.1).
Before being put into service, the gearbox must be filled with oil (see chapter 5).
6.2 Putting into service, Run-in phase / Installation of spare gearboxes

Drive Units / Gearboxes ≥ 500 kW (frequency controlled, without hydr. coupling)
Start the drive unit and gradually increase the speed to 50% of the rated speed. Operate the
gearbox with a load that is equivalent to about 25% of the rated torque until the maximally
admissible oil temperature is reached. Gradually increase the load to about 40% of the rated
torque, and operate the gearbox in this state for about 3 hours. After that, gradually increase
the load to 70% of the rated torque, and operate the gearbox in this state for further 3 hours
prior to its operation at rated torque. During putting into operation, pay attention to abnormal
noises and inadmissibly high temperatures. Monitor and register the current consumption of
the drive unit. On guarantee grounds, the record is to be made available to TKIS.
Note:
During putting into operation, pay attention to abnormal noises, leaks and temperature of bearings.
Note:
- Check the contact pattern on the tooth flanks of all pinions and wheels.
After about 1000 operating hours or 12 months, take the following action:
- Check the oil quality and change the oil if necessary!
Page 21 of 43
6.3 Putting into operation

Drive Units / Gearboxes < 500 kW (frequency controlled or with hydr. coupling)
The gearbox must run without load for a period of at least 15 minutes to ensure sufficient lu-
brication and safe operation, in particular if it is a matter of gearboxes featuring splash lubri-
cation.
Note:
Note:
6.4 Heating elements (optional)

Heating elements are used to ensure a minimum oil sump temperature prior to starting-up
and during operation.
Heating shall take place as a function of ambient temperature and oil viscosity in accordance
with the following values:
Caution!
There is a risk of damage to bearings and teeth due to insufficient lubrication.
When starting up the gearbox with load, ensure that the oil sump temperature
is not below the following values:
Oil type / Viscosity Minimum oil sump temperature

CLP / 150 + 0°C
CLP / 220 + 5°C
CLP / 320 + 10°C
CLP / 460 + 15°C
Heating should be stopped as soon as the oil sump temperature exceeds the values men-
tioned by 5°C.
Page 22 of 43
6.5 Lubrication system (optional)

The oil is sucked off by means of the oil pump from the gearbox housing. Check both the
pump and the fan for the right sense of rotation by brief switch on. Inspect the filter during
putting into service, and clean it, if necessary.
Note:
The oil level in the gearbox must be checked after having operated the pump
for the first time, because oil must possibly be added.
Operating data:
- Ambient temperature:
The lubrication system is only allowed to be operated at certain oil tem-
peratures. The pump may be damaged due to a too high oil viscosity
because of a too low temperature in the pipe system of the cooler.
• Start: T Öl >+10°C
• Stop: T Öl < +5°C
- Pressure switch on double filter:
The pressure switch is set to 5 bar and has two switch states:
• p < 5 bar: Filter is free.
• p > 5 bar: Filter is blocked and must be changed out.
- Pressure switch on output line:
• p < 0.5 bar: Switch is open  Pump is out of operation
• p > 0.5 bar: Switch is closed  Pump is in operation
- Oil pump:
• ON: Ambient temperature > +10°C
• OFF: Ambient temperature < +5°C
- External oil cooler:
• ON: Pump in operation and oil sump temperature >
80°C
• OFF: Pump out of operation or oil sump temperature <
70°C
Note:
Under certain conditions, the oil pump is also enabled to be started at tem-
peratures below +5 °C:
• If the oil sump is constantly heated.
• If the oil sump temperature is constantly above +5°C.
• If the pressure switch closes 5 seconds after the pump start.
For more details on the lubrication system, please refer to the respective document enclosed
with this manual.
Page 23 of 43
7 Maintenance / Repairs / Waste disposal / Recycling

7.1 Inspection and Maintenance
This chapter describes the inspection- and maintenance works to be carried out regularly on
the gearbox and other components (lubrication system, etc.). The applicable safety regula-
tions are always to be complied with.
All inspection- and maintenance works are to be documented, to enable at any time to be a
good judge of the plant. This documentation also makes easier the search for the causes in
case of problems and damages. Through regular maintenance problems and defects are early
detected and so downtimes and damages to the plant avoided.
Caution!
Never touch rotating parts, not even during the execution of inspection- and
maintenance works!
Danger!
In case of an accidental rotation of shafts, there is a danger of serious

injury due to rotating parts (couplings, etc.).
Before detaching covers (protective hoods, inspection covers, housing parts), ensure that the
drive unit is stopped, not able to start or to be started accidentally.
Note:
All maintenance works are to be carried out by specialist technicians or service
personnel. Before starting these works, the gearbox has to be fully shut down.
• Lock all operating devices (switches, valves) and remove the key. Set up
warning signs.
• Ensure that the gearbox cannot be started when carrying out maintenance
works.
• After a disassembly, the gearbox is only allowed to be started again after
full assembly, provided that it is in a technically perfect condition.
• Take precautions near the gearbox to prevent lubricant or oil mist from igni-
tion.
• During filling with lubricant, oil mist, that is inflammable, can escape.
Note:
Prior to the removal of the inspection cover, clean the area around it. Small
parts like screws, nuts, bolts, tools, etc. should never be laid down near the
opened inspection cover.
Page 24 of 43
7.2 Maintenance works to be carried out regularly
Period of time Controls

Daily Inspection for abnormal noises, signs of leaks or overheating.
The surface temperature of the gearbox housing is not allowed to ex-
ceed
95°C during operation. Dust deposits that may cause inadmissibly high
temperatures must be removed.
The oil pan that belongs to the fluid coupling (optional) is to be inspect-
ed, and water collections must be drained off.
Weekly At standstill of the gearbox: Check the oil level and add oil, if necessary.
Monthly Re-lubricate all seals (except Taconite-seals).
Top up grease as long as fresh grease becomes visible at the grease
collar.
Both the removal and the disposal of the used grease must be made in
accordance with the applicable statutory regulations.
at least Take an oil sample during operation of the gearbox.
every 3 months Oil change must possibly be done as a function of the result obtained
when making the oil analysis.
Drive Units/Gearboxes
P Mot ≥ 500 kW Re-lubricate the Taconite-seals
Every 12 months Inspection of the accessible tooth’s planes of action through the inspec-
tion holes.
Page 25 of 43
7.2.1 Oil quantity and Oil level
Oil level
max.
min.
Dipstick: The oil level must be between the Oil level eye: The oil level must be in the
marks. middle of the eye.
Danger!
Only check the oil level of the gearbox at standstill, after a brief downtime (ap-
prox. 10 minutes).
Note:
The vertical installation (input gear or output gear arranged vertically down-
wards) is only allowed to be done having made provision for an oil level con-
trol.
Page 26 of 43
7.2.2 Oil change

• Drain the used oil while still warm.
• Flush the gearbox by means of fresh oil, if necessary.
• Refill the gearbox with fresh oil till the given oil level is reached. To do so, use a filter or
a fine screen.
Note:
Clean the area surrounding the opening. Do not lay down parts (screws, nuts,
bolts, tools, etc.) next to the opening.
7.2.2 Lubricant
Make only use of lubricants that have been released by TKIS before. A summary of the lubri-
cants TKIS released is attached to this manual.
7.3 Miscellaneous
• The surface temperature of the gearbox housing, that is to be monitored, if necessary,
must not exceed 95°C during operation. A suitable position to monitor the admissible
temperature of the gearbox housing is within the area of the bearings on the drive unit.
Dust deposits on the gearbox causing inadmissibly high temperatures are not permitted,
because there is a danger of dust explosions.
• Parts or equipment belonging to the gearbox are not allowed to be extended or modified
without TKIS’s written approval.
• Should the gearbox be located in a potentially explosive area, the improper or faulty in-
stallation may bring about inadmissibly high temperatures.
• The use of the gearbox is only allowed to take place under admissible conditions and
within the limits.
• The gearbox must not be flooded.
Page 27 of 43
7.4 Lubrication
Since the gearbox has already been put into operation on the test stand and subsequently
flushed, the first oil change is necessary after approx. 2000 operating hours.
Note:
Check under critical environmental conditions (high level of contamination,
presence of aggressive gases in the air, high ambient- and oil temperature,
high loads, etc.), whether the intervals provided for oil changes are sufficient
enough. If there is any doubt, please get in touch with TKIS.
The oil must be drained while still warm (operating temperature). For this pur-
pose open the oil drain plug.
TKIS recommends changing the oil after 5000 operating hours at the latest or
at least once a year.
Before being filled with fresh oil, the gearbox has to be flushed with plenty of
oil.
Check the oil level regularly and top up with oil, if necessary.
If the gearbox is not used for some time, it will have to be operated every two
weeks for 4 hours, or to be filled with anticorrosive agent.
The filter elements of gearboxes featuring a lubrication system are to be
checked regularly and cleaned, if necessary. For the actions to be taken to
clean the filters, please refer to the corresponding operating instructions en-
closed with this manual.
Many gearboxes have lubricators for bearings and seals. The gearboxes are
delivered in lubricated condition. As a function of the operating conditions, re-
lubrication should take place after 2500 to 5000 operating hours.
Gearboxes with non-contact seals – Taconite – see point 7.2
The rotary shaft seals must be lubricated, in order to avoid damages to the
lips. The lubricant used must be consistent with the oil.
Protect the seals and the shaft ends against contamination before applying the
paint.
Shut-down the gearbox prior to starting such works.
7.5 Monitoring of the oil grade

It is not possible to avoid condensation of water inside the gearbox during operation. In order
to prevent the gearbox from corrosion and damages, the oil must be analyzed regularly. For
this purpose an oil sample should be taken during the operation. When observing foreign par-
ticles, chemical changes or inadmissibly high water content, the oil must be changed immedi-
ately.
Page 28 of 43
7.6 Cleaning of the gearbox
All points that are lubricated by means of grease have to be cleaned regularly.
Danger!
Never use a pressure washer to clean the gearbox.
The gearbox is allowed to be cleaned by a water pressure of maximally 5 bars.

Never turn the water jet directly towards the labyrinth covers.
7.7 Drainage of the oil trap arranged underneath the fluid coupling
The oil trap that is arranged underneath the fluid coupling must be checked daily. In case of
water, the oil trap needs to be drained completely.
Danger!
The oil trap may be filled up to the top with water due to rainfall or cleaning
work, and oil of the fluid coupling cannot be safely collected.
7.8 Welding work

Do not carry out welding work on the gearbox!
Caution!
Driving and driven components connected to the gearbox have to be earthed
as to avoid current passage. A current passage can bring about major damag-
es to the bearings and the teeth, or a total failure of the gearbox.
If pipes have to be connected by welding to the oil inlet or outlet,

isolators must be placed between the flanges.
Page 29 of 43
7.9 Disposal / Recycling

Materials used to carry out maintenance works may be hazardous and must be disposed of in
accordance with specific regulations.
For the disposal of lubricants and cleaning agents, the regulations applicable on the spot are
to be complied with.
Caution!
Oil, grease and waste containing lubricant may lead to serious damage to the
environment. Those materials must be disposed of by a specialist company.
• Oil, grease and waste containing lubricant must be brought to a waste col-
lection point. They must be subsequently handed over to a specialist com-
pany.
• For the disposal of complete gearboxes, comply with the applicable statuto-
ry regulations.
Page 30 of 43
8 Shut-down
8.1 Short-term shutdown (gearbox mounted)
Caution!
TKIS recommends taking the following actions to protect the components:

• If the gearbox is shut-down for more than 2 weeks, it must be operated
every two weeks for at least 4 hours.
Note:
This short-time operation has the purpose to cover all parts with an oil film, in
order to prevent them from corrosion.
Observe the instructions given in chapter 8.2 and 8.3 if it will not be possible to
operate the gearbox short-time, as described before.
8.2 Long-term shut-down (gearbox is not mounted)

TKIS recommends taking the following actions to protect the components:
• Drain the operating oil off the gearbox.
• Fill the gearbox with preservation oil up to the operating level to protect it against corro-
sion.
• Every bore visible from the outside is to be sealed by means of an adequate plastic plug.
• Cover the labyrinth- and rotary shaft seals between shaft and cover with tape.
Klebeband
Tape
0-Ring
• Apply a long-term anticorrosive agent (TECTYL 846) on external, machined surfaces.

• Do not operate the gearbox or turn the shafts in idle state.
Caution!
Before applying protective coatings to the gearbox, protect the seals from con-
tamination by paint or anticorrosive agent (cover with tape).
Page 31 of 43
Note:
Remove all seals at the end of the shut-down period. Drain the preservative oil
off the gearbox, and flush it by making use of the recommended operating oil.
After that, fill the gearbox with operating oil up to the specified level.
Note:
TKIS shall not be held liable for damages caused due to improper preservation
after the purchaser has accepted responsibility!
8.3 Storage / Actions to be taken during storage

The location at which the gearbox is to be stored must meet the specified requirements.
• TKIS recommends storing the gearbox in a dry room and protecting it from shocks and
vibrations.
• To prevent the bearings from brinelling, shocks and vibrations beyond 0.05 mm and 60 Hz
are not allowed to appear in the storage area. If the values mentioned before are exceed-
ed, the gearbox must be placed on a vibration reducing support.
• The storage shall take place at temperatures below +10°C and over +50 °C, and the rela-
tive humidity must not exceed 60 %.
• Ensure that the gearbox is not exposed to air with an increased degree of salt and acidity.
• Seal each and every drill hole visible from the outside by means of an adequate plastic
plug. The gearbox is delivered with sealed drill holes.
• Protect the labyrinth- and rotary shaft seals between shaft and cover by using a tape.
Adhesive
Tape
0-Ring
• If the gearbox is stored for more than 6 months, inspect the protective coats on the ma-
chined surfaces regularly and renew, if necessary.
Note:
Period of preservation:
− 6 months if stored in the open and protected against wind and wetness
(rain, snow)
− 1 year if stored in a dry room
Page 32 of 43
Caution!
There is a risk of damage to the gearbox due to corrosion!
Note:
TKIS shall not be held liable for damages to the gearbox or components
caused due to improper preservation / storage after the purchaser has accept-
ed responsibility!
8.4 Actions to be taken during long-term shut-down

Note:
TKIS recommends proceeding as described in chapter 8.2.
Note:
Take the following actions if the procedure described in chapter 8.2 is not ap-
plicable. The demands on the environment, described in chapter 8.3, are still
to be satisfied, but the inspection intervals and the preservation mode change.
• Storage in the open:
the
example. TKIS recommends using a spray gun to preserve the gearbox
− Corrosive spots: Consultation with TKIS to fix a procedure that is ap-
propriate to achieve the readiness for service again.
Page 33 of 43
Note:
• Storage in a building:
the inspection hole cover, inspect the interior of the gearbox for rusty
example. TKIS recommends using a spray gun to preserve the gearbox
− Corrosive spots: Consultation with TKIS to fix a procedure that is ap-
propriate to achieve the readiness for service again.
Note:
The corrosion protection of external, machined surfaces has to be renewed
after preservation of the internal parts of gearbox.
Caution!
There is a danger of damages due to corrosion. The storage period should not
exceed 3 years.
Note:
TKIS shall not be held liable for damages to the gearbox or components
caused due to improper preservation / storage after the purchaser has accept-
ed responsibility!
Page 34 of 43
9 Malfunctions / Causes / Corrective actions

9.1 General
Danger!
Adjustments and changes that have an effect on functioning of the machine

necessitate TKIS’s written approval. In case of non-compliance with the in-
structions given in this manual TKIS is not liable to respond in damages. In
such a case the rights under a guarantee are lost.
Note:
The instructions given in chapter 2 are to be adhered to.
To judge a failure of the gearbox, the machines built on have to be inspected
too. The noises and vibrations produced by the gearbox in all operating states
must be as low as possible. Every deviating behavior is to be regarded as ab-
normal. The respective actions to eliminate the failure are to be taken.
To repair the failure the drive unit is to be shut down and to be secured against
unintentional start-up, and information signs are to be set up.
Note:
The repair of failures that occur within the guarantee period is only incumbent
on TKIS.
Even on expiration of the guarantee period, TKIS should be entrusted with the
repair of failures the cause for which cannot be determined clearly.
Page 35 of 43
9.2 Possible malfunctions – Causes and corrective actions
Malfunction Possible cause Corrective actions

Unusual gearbox noises Operation out of the admissible pa- Inspect the bearing / toothed items,
necessary
essary
Damage to the tooth Inspect for damages to the teeth, re-
place defective items
Consultation with TKIS
Bearing play has increased Adjust the bearing play

Damage to bearing Replace damaged bearing
Check the alignment
Ring gear has come loose due to over- Fix the ring gear
load
Toothed wheel has come loose due to Fasten the toothed wheel
overload
Incorrect alignment Separate and realign the parts
Backlash is too big Adjust the backlash correctly
Noises in pump area Fastening bolt has come loose Fasten the bolts, replace defective bolts,
if necessary
Noises in gearbox Idle speed is in critical range Increase the idle speed
Gearbox is operated at critical rotational Avoid critical rotational speeds
speed (unusual noises only occur at
certain speeds for example)
Noises in the zone of pump Oil level is too low (suction noise) Check the oil level, adapt it, if necessary
Leakage in suction pipe (pump draws Tighten the screws
air) Inspect for leakage
Pump is defective Inspect the oil pump, repair or replace,
if necessary
Oil pressure is too low Wrong sense of rotation (cooling sys- Reverse sense of rotation of motor
tem)
Filter is clogged Clean the filter
Oil level is too low Top up with oil
Inspect for leaks
Oil viscosity is too low Change the oil, only use recommended
products
Suction pipe is clogged Clean the suction pipe
Pressure control valve is defective Replace the defective parts
Oil pump is defective Inspect the oil pump, repair or replace,
if necessary
Page 36 of 43

Clogging indicator of the double filter Filter is clogged Replace the filter in accordance with the
has triggered operating instructions for the filter sys-
tem, clean the clogged filter
Error in the lubrication system See „Operating instructions“ for lubrica-
tion system
Foaming / water in the oil Water in the oil Let analyze the oil condition
Inspect for water ingress
Inspect the seals
Oil cooler / Radiator is defective Inspect for leakages in the cooling
system, seal it, if necessary
Repair or replace the defective parts
Condensation of water due to cold Protect the housing from draught ap-
draught on the housing propriately
Gearbox is contaminated by oil Insufficient sealing on the housing or Seal the partition joint
the partition joint
Labyrinth seal is contaminated by oil Check the oil level, clean the labyrinth
seal, if necessary
Leakage Oil level is too high Check the oil level, drain the oil, if nec-
essary
Fan is clogged / dirty Clean the fan
Insufficient sealing on the housing or Inspect the seals, replace them, if nec-
the partition joint essary, seal the partition joint
Leaky shafts / labyrinth covers Inspect the rotary shaft seals, replace, if
necessary
Mount the sealing lips in such a way
that the oil reflux is not disturbed
Leaky oil drain Replace and fasten the seal on the oil
drain
Leaky dipstick Replace the seal and fasten the dipstick
Leakage in oil pressure line Tighten the screw joint
Leaky fan Inspect the oil barrier under the fan
Leaky cooler Replace the cooler insert
Bearing temperature has increased Oil level is too low Check the oil level, top up with oil, if
necessary
essary
Oil pump is defective Inspect the oil pump, replace it, if nec-
essary
Damage to the bearing Replace the defective bearing
Oil reflux is blocked on the bearing Adjust the connection or the seal in
such a way that the oil reflux is not
blocked
Seal is too tight Loosen the seal
Page 37 of 43

Bearing temperature has increased Operation out of the admissible pa- Inspect for damages
rameters (load, rotational speed, etc.) Comply with the operating instructions
Fan clogged /dirty Clean the fan
Wrong bearing seat Check the bearing play, re-adjust, if
necessary
Inspect the shaft for smooth running in
no-load condition
Operating temperature has increased Oil level is too low Check the oil level, top up with oil, if
necessary
Oil is heavily contaminated Change the oil
Fan clogged / dirty Clean the filter
Oil flow through the cooler is too low Clean the oil filter
due to the dirty filter
Oil pump is defective Inspect the pump, repair or replace, if
necessary
For cooling systems featuring a fan: Air Clean the parts, if necessary
inlet, fan hood or gearbox housing are
dirty
For cooling systems featuring a radia- Clean the radiator
tor: Deposits on the radiator
Oil pressure is too low Set the cutting-off pressure to minimum
value
For gearboxes featuring a cooling sys- Open the valves in the lines, inspect the
tem: Cooling rate is too low oil cooler for flow impediments
Coolant temperature is too high Check the temperature, regulate, if
necessary
Gearbox is overloaded Reduce the drive power
Wear on the gearbox Operation out of the admissible pa- Check the bearing / toothed parts,
necessary
Oil is oxidized or contaminated Oil change
Check keeping of maintenance intervals
Faulty alignment Separate and re-align the parts
Page 38 of 43

Wear on the gearbox Gearbox is exposed to abrasive media Inspect the seals
Oil change
parts for damages
Damage to the bearing Inspect the lubrication system
Operation out of the admissible pa- Inspect the bearing and the toothed
rameters (load, rotational speed, etc.) parts for damages, replace, if necessary
Current passage Inspect the bearing and the toothed


Bearing not correctly mounted on the Check the bearing play, re-adjust, if
shaft necessary
Bearing not correctly mounted / incor- Inspect for impacts, search for the
rectly aligned causes if the old bearings are dis-
mounted
Corrosion Inspect the seals
Check suitability of lubricant to corrosion
protection
Check the lubrication of bearings
Faulty maintenance during downtimes
(see chapter 8)
Bearings are exposed to abrasive media Inspect the seals
Drain the oil, flush and refill the gearbox
with fresh oil
Inspect the bearings for damages,
Inappropriate storage Inspect all parts for damages, replace, if
necessary
Operation out of the admissible pa- Consultation with TKIS

Damage to the shaft rameters (load, rotational speed, etc.)
Unilateral overload Consultation with TKIS

Page 39 of 43

Damage to the tooth Check the lubrication system
Inspect the bearings / toothed items,
Operation out of the admissible pa- Inspect the bearings / toothed items,
Current passage Inspect the bearings / toothed items,

Vibrations from the outside Inspect the drive unit / foundation,

uncouple the gearbox, if necessary
Metal bore chips in the filter Damage to the bearing See damage to the bearings
Damage to the tooth See damage to the tooth
Lubrication is impaired Check the oil condition / lubrication
system
Page 40 of 43
10 Spiral bevel gear (optional)

10.1 Contact pattern
The correct contact pattern of a cyclo-palloid tooth is shown in the following picture. The con-
tact pattern has to be adjusted by skilled labour during mounting. Slight wobblings are normal
and have no effect on reliability. The contact pattern detected in no-load condition while man-
ually turning the bevel pinion shaft will be adjusted, if necessary.
Correct position of the contact pattern on a newly Correct position of the contact pattern on a
mounted Klingelnberg spiral tooth (without load). Klingelnberg spiral tooth (with load).
Adjustment of the contact pattern when mounting the spiral bevel gear:
The shaft has to be jointly positioned with the distance bush in accordance with the gearbox
drawing.
Height displacement of contact pattern

Contact pattern Possibility for adjustments Objective
Page 41 of 43
Lateral displacement of contact pattern

Contact pattern Possibility for adjustments Objective
10.2 Circumferential backlash

Block the bevel pinion shaft and turn the bevel wheel to the lower stop. Install the dial gauge
and turn the bevel wheel to the upper stop. The difference in values measured on both the
stop points is the circumferential backlash.
Contact flank Dial gauge
Spacewidth
Bevel pinion shaft

(to block) Bevel wheel
Caution!
With too little backlash lubrication of the tooth flanks is not assured (seizure,
damages to the tooth). Alternating sense of rotation or strong load fluctuations
possibly require a particular circumferential backlash.
Page 42 of 43
Guidelines for backlash with reference to the module m
Moduel m Backlash in mm
0.3 – 1.0 0.03 – 0.06
1 0.06 – 0.08
2 0.08 – 0.11
3 0.10 – 0.13
4 0.12 – 0.14
5 0.14 – 0.17
6 0.15 – 0.18
7 0.16 – 0.19
8 0.18 – 0.20
8 - 10 0.20 – 0.25
10 – 12 0.25 – 0.30
12 – 14 0.30 – 0.35
14 – 16 0.35 – 0.40
16 – 18 0.40 – 0.45
18 – 21 0.45 – 0.50
The backlash shall be measured and adjusted at different circumferential positions on the
bevel gear.
Caution!
In case of too large backlash there will appear a shock on load alternation and
the load distribution will grow worse.
Page 43 of 43
11 Annexes
- Drawing no. 4556411-03
- Shrink disc
- Backstop
- Fan
- Resistance thermometer
- Pump
- Flow indicator
- Hydr. Coupling incl. MTS
- Flex. Coupling
- Encoder
- Lubricant Chart
Viskosität
Viscostiy
DIN 51502/ 51825 bei 40°C
[mm²/s] / NLGI

Mineral Oil
Mineralöle
Renolin CLP 220

CLP Renolin CLP 320
Renolin CLP 460
Synthetische Öle
Synthetic Oil
Biolog. abbaub. Öl
Biodegradable Oil
CLP HCE
680 - - - - Plantogear 680 S - - - - -
Grease Gear Units

Grease TCL 435
Schmierfette
(GP 00-000 K-50!)

GP 000 H-30
Getriebe
GPHC1 000 N-30 000 - - - - - - Obeen UF 000 - - -

RENOLIT FEP 2
Alavania WR 2
RENOLIT FEP 3
KPHC1 1 H-20 1 - - - - - - Obeen UF 1 - - -

Cassida EPS 2
Cassida HDS 2
- -
KPHC1 3 H-20 3 - - - - - - Obeen UF 3 - - -

Tel.(06894)599-0
Telefax (06894)599-468
General technical information
WingFan axial-impeller
The WingFan axial impellers supplied by us are technical 3.3 The limits as to 3.1 only apply if there are neither
products whose operational and functional capabilities do not bending vibrations in operation (e. g. operation near a
depend on the quality guaranteed by us only, but from the critical speed etc. nor torsional vibrations.)
application and the operating conditions with our customer
and their customers, too. 3.4 Please, note in connection with 3.2 and 3.3 that
lt is thus of mutual interest to us that the following technical there will be vibrations in every rotating system. lt
details are noted by the customer. is therefore necessary that each manufacturer
makes sure by tests that there are no inadmissibly
high sympathetic vibrations in connection with the
1. General mounting of the unit and/or the place of mounting
and that the values as to VDI 2056 are not
1.1 The axial impeller is an important component of a exceeded „practically“. These phenomena are not
ventilator or unit. The ventilator manufacturer has to only a property of the axial impeller, and
make the correct axial impeller selection himself, when unfortunately they are unknown till the
developing the unit. As specialists we support our development of a unit has been finished.
customers with advice and proposals on the basis of the
operating conditions being as comprehensive as possible 3.5 The manufacturer has to dimension the hub bore and the
when given to us (e.g. all details available for the axial shaft connection in accordance with the torque to be
impeller corresponding to the specification DIN 24 166). transmitted.
With direct starting asynchronous motors having power
1.2 The technical details indicated for our products are based levels >= 5,5kw, problems will be experienced if the
on empirical values, which we have gathered by tests maximum bore of the WingFan hub recommendations
under similar to practical conditions. These are average are exceeded as starting moments of inertia can be in
values where manufacturing tolerances may occur to the excess of 12 times the nominal running conditions, which
accepted limits in the industry concerned. lt should be must be considered at the design stage and stated when
determined by extensive tests in applying these values the order is placed.
that in practice customer’s theoretical selection of the
impellers is correct and suitable to be used under his or 3.6 In mounting the impeller, the manufacturer must
his customer’s usual operating conditions. Upon request provide for an axial safety sufficient for the application.
we can assist you in determining the test conditions. In the case where light metal center bosses are used,
the thermal expansion at higher temperatures must be
1.3 With special consideration to 1.2 the manufacturer must considered.
also consider carefully any possible consequent damage
and warranty claims which could result from an impeller 3.7 When the impellers are supplied without center bosses,
failure. That is why higher safety factors should be taken the user must determine the admissible limits by tests
into account if necessary when selecting the impeller e. g. himself.
in reducing our admissible working data, selection of a
strengthened axial impeller or similar. 3.8 If the impellers are used for higher stresses and
speeds than indicated in our brochures, permission
must be obtained by WingFan and confirmed in
2. Air duty writing.
2.1 The data indicated in our brochure only apply in 4. Machining Limits
connection with the measuring arrangement stated and
when the impeller is used in connection with the housing Machining limits at the values of our products stated
and impeller inlet recommended by us. (among others weight, dimensions, performance details,
limits) may occur to the accepted limits in the industry
2.2 For arrangements varying from 2.1 we can give probable concerned.
results only, which must be checked by the manufacturer.
5. Transport and mounting by the customer
2.3 Losses on the suction side and pressure side must be
added to the characteristic curve of the impeller and the 5.1 Our axial impellers are under exact control till dispatch
unit resp. has been effected. Although the goods are carefully
packed and it is indicated on the packing to be handled
with care, they may be damaged in transit by rail or by
3. Strength road. If so, we ask for a statement of facts to be sent to
WingFan immediately upon receipt of the goods.
3.1 The impellers may only be used within the respective
limits of the brochure for speed, temperature etc. 5.2 lt is of course a condition of the limits as to 3. that the
state of our impellers upon delivery is also preserved
3.2 The limits as to 3.1 only apply if there is no essential when being handled and mounted by our customers.
additional unbalance (e. g. concentric running errors of
the shaft, through dirt accumulation, thermal distorsion, 5.3 It is recommended that trials are carried out upon
stresses produced by shocks, mounting etc.). As the receipt, as well as mounting of the impeller, to establish
residual unbalance may under certain circum-stances if damage in accordance with 5.1 and 5.2 (in special
change in operation, a regular examination is necessary unbalance) has not been noticed and to eliminate it
and if need be the rebalancing of the impeller. before effecting delivery.
02. January 2007 FB-10-17E-01 1/1

Important information for installation and operation
WingFan Axial-Impeller
It is possible that foreign bodies could get
caught by the air flow. Even the smallest
From the legal point of view our product is foreign particles could cause significant
not a final product, but a component, damage because of the high tip-speed. In
which only after being assembled with this context, for example, the severe
other components can be considered a consequences when birds are caught up
“finished product”. by aircraft turbine engines.
For this reason, the user is responsible for Our impellers are balanced per DIN ISO
the implementation incorporation of the 1940 procedures. The operating procedure
axial impeller. Therefore, special attention for an impeller up to 900 mm diameter
is to be given to the fact that impellers are (provided nothing else has been agreed) is
relatively sensitive products that are based on 1400 rpm. Balancing is carried
dynamically loaded and (as all rotating out by decreasing material at the hubs,
and moving parts) can endanger human blades and / or the attachment of weights
life. in the form of flat washers at the hub or
rivets on the blades.
Consequently,installation,
commissioning and test-runs must be If the impellers are disassembled, in order
carried out under observance of to replace a blade with a spare-blade, or
standard accident prevention to modify the pitch angle, any guarantee
practices. is considered null and void. We
recommend sending to us the impellers to
The major reason for the destruction of an be repaired or modified. If this is not
axial impeller is caused by the blade-tips possible, all parts are to be marked before
touching other components. The distance disassembling, in order to eliminate the
between blade-tip and housing, ring- possibility of improper mounting (wrong
housing and other components, have to be position of parts to each other). We also
set as to provide adequate tip-clearance advise to balance the repaired / modified
not allow at no time the slightest contact impeller afterwards. Unbalanced impellers
even under heavy load conditions, e.g. by can vibrate which may cause damage to
means of pushing, vibrations, moment of the blades, hubs, bearings and so on. A
reaction at start-stop operation. In case situation, which is comparable to the
the impeller is driven by a combustion flutter of a steering wheel or other
engine being installed in plant equipment phenomenon in case, the wheels of a car
or machines, vibrations may be notably are unbalanced.
heavy (e.g. bearing onto rubber-metal
components). Every impeller has a specific self-induced
vibration (natural frequency) depending
However, not only radial distances are among other things on the number, length
playing an important role, but axial and material of blades. Your mechanical
clearances are to be considered as well. design has its specific features as well,
Especially at the start-up phase and at facts which we normally do not know.
higher temperatures, due to their elasticity They are characterized, for example, by
the blades tend to bend in the axial revolutions per minute (energizing
direction. Depending on blade-length, frequency), type of drive (combustion
blade-material, acceleration and engine with torsional vibrations), quantity
resistances, it is possible that the blade-tip of struts towards engine mountings and so
can be bent approx. 60 mm. Therefore, on.
the engine mountings and protective
grilles are to be positioned accordingly.
02 January 2007 FB-10-16E-02 1/1

Important information for installation and operation
polyamide is to be observed.
Temperatures below zero generally lead to
embrittlement of the plastic materials and
Please avoid resonance, i.e. the consequently have an influence on the
coincidence of natural frequency and physical characteristics. Possibly these
energizing frequency. circumstances may lead to premature
Depending on intensity and duration, failure of the blades caused by external
resonance leads to breakage and foreign bodies through e.g. ice formation
negatively affects noise production. in the housing.
Impellers manufactured completely out of
aluminium are very sensitive to vibrations. General terms of allowable tip-speeds are
Less sensitive are impeller-types with an not possible, because the basic conditions;
aluminium hub and blades made out of drive type, temperature etc. are of
synthetic materials, because of better significant importance.
absorption characteristics of plastic
materials. Please send us your inquiry.
As a supplier of ”impeller“ components the

final application is not known in many
cases.
Therefore an “improper” application could
result in risks to the user or third parties.
Furthermore, possible influences to the
impeller materials (aluminium, polyamide)
mechanical properties by means of
chemicals and other mediums, e.g. strong
oxidants, or halogens etc. Paint used to
paint equipment for example, the paint
used may contain, softeners making the
plastic materials brittle and consequently
unsuitable.
Moreover, risks may occur by an improper

application i.e. when plastic materials are
operating in explosive areas because
polyamide tends to give off an
electrostatic charge due to its electrical
resistance. In such cases it is absolutely
necessary to use an antistatic material
“PACAS”. Even sunlight may have a long
term effect on material characteristics
and may cause damage due to its
ultraviolet rays.
Temperature has to be taken into account,

especially with regard to the polyamide
blade materials. A difference between the
air temperature and the radiant heat is
required because the irradiation of the
cooler on the impellers during standstill
may lead to a higher temperature charge
than during operation. Max. 110°C for
02 January 2007 FB-10-16E-02 2/1
Installation and Maintenance Instructions Freewheel Type RSCI
To avoid premature failure of the freewheel or possible machine malfunction, installa-

tion of the freewheel should be carried out by suitably qualified personnel and accord-
ing to the following instructions.
STIEBER will not accept liability in cases of non-compliance with these instructions!
STIEBER GmbH
PO Box 10 53 80 www.stieber.de
D-69043 Heidelberg, Tel +49 (0)6221 30 47 0, Fax +49 (0)6221 30 47 31
last changes 05.08.2010 page 1/6
Description:
The main components of RSCI backstops are: Outer race, inner race, and cage assembly
with sprags which centrifugally disengage at normal running speed. RSCI backstops must be
installed so that the inner race overruns.
The maximum permissible overrunning speed quoted in the table must not be exceeded.
To ensure that the sprags are fully disengaged during overrunning, the overrunning speed
must not fall below the minimum quoted in the table.
Please refer to STIEBER if this may occur.
All limits quoted in the table should be met to ensure trouble free operation.
Prior to Installation:
Ensure that the specified concentricity between inner and outer race is maintained.
STIEBER GmbH
The inner race should be fitted to a shaft of h6 or j6 tolerance.
The mounting register for the outer race should be to h7 or g7 tolerance.
The freewheeling direction should be checked prior to installation.
If reversal of the freewheeling direction is required, simply reverse unit on shaft.(See removal
of cage.)
When installing the outer race, use bolts of 8.8 quality or better, and tighten to the torque
level specified in the table below.
Caution: Risk of Injury!

When the transport safety device is removed, the backstop should always be held so
that the bore is horizontal, otherwise the outer race may slip from the cage.
Installation:
The unit should be unpacked and installed in a clean, dry working environment.
Ensure no debris enters the unit during installation.
Installation as a complete assembly: (Preferred)

• Fit the inner race on to the shaft, ensuring alignment of the keyways.
• Any axial loading used should be applied only to the inner race.
• The inner race must be retained axially on the shaft - circlips are suitable.
• Fit the outer race to its register using the specified bolts.
Inner and Outer race installed separately: (Due to size of unit)

• First install the inner race and cage onto the shaft as described above.
• Position the outer race over the inner assembly whilst slightly rotating the inner race in
the freewheeling direction.
This procedure is simplified if the sprags are rotated to their disengaging position and
held there by means of an O-Ring.
• Fit the outer race to its register using the specified bolts.
STIEBER GmbH
Tightening
Thread In Removal
Size Torque
Outer Race Thread Cage
[Nm]
20 M6 9,9 M3
25 M6 9,9 M3
30 M6 9,9 M3
35 M6 9,9 M3
40 M8 24 M3
45 M8 24 M3
50 M8 24 M3
60 M10 47 M4
70 M10 47 M4
80 M10 47 M4
80M M10 47 M4
90 M12 82 M4
90M M12 82 M4
100 M16 200 M5
100M M16 200 M5
130 M16 200 M5
180 M20 390 M5
180 M M20 390 M5
180-II M20 390 M5
180-II M M24 670 M5
220 M20 390 M5
220 M M24 670 M5
220-II M24 670 M5
220-II M M30 1350 M5
240 M20 390 M5
240 M M24 670 M5
240-II M24 670 M5
240-II M M30 1350 M5
260 M24 670 M5
260 M M24 670 M5
260-II M24 670 M5
260-II M M30 1350 M5
300 M24 670 M5
300 M M24 670 M5
300-II M24 670 M5
300-II M M24 670 M5
300 -M - HL M24 670 M5
STIEBER GmbH
After installation:
After installation, ensure that the backstop can be rotated in the required direction.
The drag torque produced when freewheeling, is about 1/1000 of the torque capacity of the
backstop.
Removal of cage assembly from inner race / Installation:

Because of maintenance, or reversal of freewheeling direction on units with non-standard
asymmetric inner races, it may be necessary to remove the sprag cage from the inner race.
Removal:
• Remove circlip from inner race.
• Screw suitable bolts into the removal holes in of the cage disk. Do not use bolts which
are long enough to contact sprags!
• Using the removal bolts pull the cage from the inner race, whilst slightly rotating the cage
in the freewheeling direction.
Installation:
• Slide the cage assembly on to the inner race, slightly rotating the cage in the freewheel-
ing direction.
• Ensure that the driver pin on the face of the cage disk locates in the gap formed by the
ends of the circlip.
The cage can be installed without removal of the outer race if the inner race, shaft and
cage can be rotated whilst the cage is slid along the inner race.
• Reinstall second circlip, ensuring the gap formed by its ends accommodates the driver
pin on the face of the cage disk.
Dismantling:
Dismantling / removal is achieved by following the installation procedure in reverse se-
quence.
Lubrication and Maintenance (When overrunning speed exceeds the specified mini-
mum):
Below 100mm bore size no additional lubrication is required if the acceleration and decelera-
tion time is less than 20 seconds.
Above 100mm bore size, or if acceleration and deceleration time exceeds 20 seconds, oil or
grease lubrication should be provided.
All gear and hydraulic oils with a minimum viscosity of at least 32mm²/s are suitable.
In general, where the shaft is horizontal, an oil level which immerses the outer diameter of
the sprag cage to a depth of 2mm is sufficient.
If the shaft is not horizontal please contact STIEBER.
If grease lubrication is used, greases of consistency class II, or softer are recommended.
The grease should be replaced after a maximum period of two years whether or not in opera-
tion.
STIEBER GmbH
For grease replacement the freewheel must be removed, cleaned, inspected, greased and
reinstalled.
Backstops which do not require lubrication need to be protected against corrosion.
All common corrosion inhibitors provide sufficient lubrication.
RSCI Technical data:

max. Overrunning Speed max. max.
Grease
Size Torque [rpm] Driving Speed Concentricity Error
[ml]
[Nm] min. max. [rpm] [mm]
20 424 750 14500 315 0,3 10

25 638 725 14300 300 0,3 11
30 750 700 11400 290 0,3 11
35 1100 670 10500 280 0,3 12
40 1600 630 7600 260 0,3 14
45 1824 610 6600 255 0,3 15
50 2800 560 6100 235 0,3 17
60 4700 510 5300 210 0,4 28
70 6100 470 4100 195 0,4 31
80 9000 440 3600 180 0,4 36
80M 11600 375 4000 155 0,4 46
90 11200 410 2700 170 0,4 40
90M 17400 350 3000 145 0,4 51
100 21000 355 2700 145 0,6 69
100M 32000 340 2400 140 0,6 82
130 31500 330 2400 135 0,6 79
180 63000 285 1300 115 0,6 103
180 M 100000 220 1300 90 0,6 161
180-II 126000 285 1300 115 0,6 228
180-II M 200000 220 1300 90 0,6 340
220 85000 265 1100 110 0,6 135
220 M 136000 205 1100 85 0,6 187
220-II 170000 265 1100 110 0,6 292
220-II M 272000 205 1100 85 0,6 396
240 104000 250 1100 105 0,6 146
240 M 166000 195 1100 80 0,6 202
240-II 208000 250 1100 105 0,6 322
240-II M 332000 195 1100 80 0,6 429
260 130000 240 1000 100 0,6 161
260 M 200000 185 1000 75 0,6 223
260-II 260000 240 1000 100 0,6 355
260-II M 400000 185 1000 75 0,6 473
300 156000 225 1000 90 0,6 180
300 M 250000 175 1000 70 0,6 249
300-II 312000 225 1000 90 0,6 402
300-II M 624000 175 1000 70 0,6 528
300 -M - HL 250000 175 2000 70 0,6 249
STIEBER GmbH
Flow sensors
SI5010
SID10ADBFPKG/US
Flow monitor
Compact type for adapter
Plug and socket
Process connection: internal thread
M18 x 1.5 for adapter
Pressure rating: 300 bar
1: LED display
2: setting pushbutton
Application liquids and gases

Electrical design DC PNP
Output normally open / closed programmable
Operating voltage [V] 19...36 DC
Current rating [mA] 250
Short-circuit protection pulsed
Reverse polarity protection yes
Overload protection yes
Voltage drop [V] < 2.5
Current consumption [mA] < 60
Max. temperature gradient of
medium [K/min] 300
Pressure rating [bar] 300
Liquids
Medium temperature [°C] -25...80
Setting range [cm/s] 3...300
Greatest sensitivity [cm/s] 3...100
Gases
Medium temperature [°C] -25...80
Setting range [cm/s] 200...3000
Greatest sensitivity [cm/s] 200...800
ifm electronic gmbh • Teichstraße 4 • 45127 Essen — We reserve the right to make technical alterations without prior notice. — GB — SI5010 — 27.11.2007
SI5010
Adjustment of the switch point pushbuttons
Switch point accuracy [cm/s] ± 2...± 10 *)
Hysteresis [cm/s] 2...5 *)
Repeatability [cm/s] 1...5 *)
Power-on delay time [s] 10
Response time [s] 1...2 ***) / 1...10 ****)
Temperature drift [cm/s x 1/K] 0.1 **)
Operating temperature [°C] -25...80
Protection IP 67, III
Shock resistance DIN IEC 68-2-27:50 g (11 ms)
Vibration resistance DIN EN 60068-2-6:20 g (55...2000 Hz)
EMC EN 61000-4-2 ESD: 4 kV CD / 8 kV AD
EN 61000-4-3 HF radiated: 10 V/m
EN 61000-4-4 Burst: 2 kV
EN 61000-4-6 HF conducted: 10 V
Housing material stainless steel (304S15); PC (Makrolon); PBT-GF 20; EPDM/X (Santoprene)
Materials (wetted parts) stainless steel (316S12); O-ring: FPM 8 x 1.5 gr 80° Shore A
Function display LED 10 LEDs, three-colour
Connection M12 connector
Remarks *) for water; 5...100 cm/s; 25°C (factory setting)
**) for water; 5...100 cm/s; 10...70°C
***) for liquids and temperature gradient 1 K/min
****) for gases
Wiring
P = programming wire (for remote adjustment)

ifm electronic gmbh • Teichstraße 4 • 45127 Essen — We reserve the right to make technical alterations without prior notice. — GB — SI5010 — 27.11.2007
Operating instructions
Flow monitors
UK
SI5010
704621 / 01 08 / 2010
Contents
1 Preliminary note��3
1.1 Symbols used��3
2 Safety instructions��3
3 Functions and features��4
3.1 Application area ��4
3.2 Operating principle flow monitoring��4
3.3 Communication (IO-Link)��4
4 Installation��5
4.1 Installation location��5
4.2 Sources of interference in the pipe system��6
4.3 Mounting operation��6
5 Electrical connection��7
6 Operating and display elements��7
7 Set-up and settings for water��8
7.1 Change the switch point (optional)��8
7.2 High flow adjustment (optional)��9
8 Additional settings (optional)��9
8.1 Low flow adjustment��9
8.2 Configure the switching output��9
8.3 Restore the factory setting (reset)��10
8.4 Lock / unlock the unit��10
8.5 Remote adjustment��10
9 Error during adjustment��10
10 Operation�� 11
11 Maintenance�� 11
12 Scale drawing��12
13 Technical data��12
2
1 Preliminary note
1.1 Symbols used
► Instruction
> Reaction, result
[…] Designation of buttons, switches or indications
→ Cross-reference
Important note
Non-compliance can result in malfunctions or interference. UK
2 Safety instructions
• Please read the product description prior to set-up of the unit. Ensure that the
product is suitable for your application without any restrictions.
• The unit conforms to the relevant regulations and EC directives.
• Improper or non-intended use may lead to malfunctions of the unit or to unwan-
ted effects in your application.
• That is why installation, electrical connection, set-up, operation and mainte-
nance of the unit must only be carried out by qualified personnel authorised by
the machine operator.
3
3 Functions and features
3.1 Application area
The unit monitors the flow of liquid and gaseous media.
3.2 Operating principle flow monitoring
• The unit detects the flow speed to the calorimetric measuring principle and
switches the output:
-- output closed if medium is flowing / output open if no medium is flowing.
This applies to the unit on delivery: output = normally open. In case of need you
can change the output to normally closed (→ 8.2). It then applies: output open
if medium is flowing.
• If the flow speed increases, the switching status changes when the switch point
is reached.
• If the flow speed falls again, the switching status changes if the value "SP
minus hysteresis" is reached.
The hysteresis changes with the flow speed and it is essentially influenced by
the set monitoring range.
It is 2...5 cm/s for the setting 5...100 cm/s (= factory setting), it increases with
higher flow speeds.
• The typical response time of the unit is 1...10 s. It can be influenced by the
setting of the switch point:
-- Low switch point = quick reaction with rising flow.
-- High switch point = quick reaction with falling flow.
3.3 Communication (IO-Link)
• The unit is laid out for bidirectional communication. So, the following options
are possible:
-- Remote evaluation (transmission of the process data).
-- Remote parameter setting (adjustment / output function).
Device-specific parameter lists for IO-Link parameter setting are available at:
www.ifm.com → Select your country → Data sheet direct:
4
4 Installation
Using process adapters the unit can be adapted to different process connections.
• Adapters have to be ordered separately as accessories.
A correct fit of the unit and ingress resistance of the connection are only en-
sured using ifm adapters.
• For small flow rates ifm adapter blocks are available.
4.1 Installation location
General
• The sensor tip is to be completely UK
surrounded by the medium.
• Insertion depth of the sensor: minimum
12 mm.

Recommended
• For horizontal pipes: mounting from
the side.
• For vertical pipes: mounting in the rising
pipe.
Conditional
• Horizontal pipe /mounting from the bot-
tom: if the pipe is free from build-up.
• Horizontal pipe /mounting from the
top: if the pipe is completely filled with
medium.
To avoid
• The sensor tip must not be in contact
with the pipe wall.
• Do not mount in downpipes that are
open at the bottom!
5
4.2 Sources of interference in the pipe system
Components integrated in the pipes, bends, valves, reductions, etc. lead to turbu-
lence of the medium. This affects the function of the unit.
Recommendation: Adhere to the distances between sensor and sources of inter-
ference:

D = pipe diameter; S = sources of interference
4.3 Mounting operation

►► Ensure that the system is free of pressure during installation.
►► Ensure that no media can leak at the mounting location during installa-
tion.

►► Grease the threads of the process connection (1), adapter (2) and nut (3).
Note: The sensor tip (A) must not be in contact with grease.
►► Screw the suitable adapter into the process connection.
►► Place the flow monitor onto the adapter and tighten the nut. Tightening torque
25 Nm. Ensure that the unit is correctly oriented.
6
5 Electrical connection
The unit must be connected by a qualified electrician.
The national and international regulations for the installation of electrical
equipment must be adhered to.
Voltage supply to EN 50178, SELV, PELV.
►► Disconnect power.
►► Connect the unit as follows:
1
L+
2 UK
2 1
Teach
4
OUT1/Data
3 4 3
L
• OUT1 / Data = switching signal for flow limit value and data channel for bidirectional
communication
• Teach = input for teach signal
6 Operating and display elements

1: Operation display
• The green LEDs indicate the current flow (the LEDs 0 to 9 represent the range between
no flow and maximum flow).
• A lighting LED indicates the position of the switch point (orange = output closed, red =
output open).
2, 3: Setting buttons for adjustment and configuration
7
7 Set-up and settings for water
(For media other than water → 8.1: Low flow adjustment).
►► Switch on the supply voltage.
>> All LEDs light and go out again step by step. During this time the output is
closed (if configured as normally open). The unit is in the operating mode.
►► Let the normal flow circulate in the installation.
►► Check the display and determine further actions.
The factory setting is suitable for the appli-
1 cation.
►► No further settings are required.
Your normal flow is below the representation
range of the display.
2 2 setting options:
►► Change the switch point (→ 7.1).
►► Carry out high flow adjustment (→ 7.2).
Your normal flow exceeds the representation
3 range of the display (LED 9 flashes).
►► Carry out high flow adjustment (→ 6.2).
You can restore the factory setting any time. (→ 8.3).

7.1 Change the switch point (optional)
For the factory setting the switch point is at LED 7. A change makes sense if:
• the display shows example 2.
• the flow fluctuates much or pulsates.
• if a faster response time of the unit is requested (low switch point = fast re-
sponse with rising flow, high switch point = fast response with falling flow).
►► Briefly press the pushbutton or .
>> The switch point LED flashes.
►► Press the pushbutton or as often as required. Each press of the push-
button shifts the LED by one position in the indicated direction.
Note: If no pushbutton is pressed for 2 s, the unit returns to the operating mode
with the newly set value.
8
7.2 High flow adjustment (optional)
The unit determines the existing flow as normal flow and adapts the display repre-
sentation (all LEDs except the switch point LED light green).
►► Let the normal flow circulate in the installation.
►► Press the pushbutton and keep it pressed.
>> LED 9 lights, after approx. 5 s it flashes.
►► Release the pushbutton.
The unit is now adapted to your flow conditions. It passes into the operating mode,
the display should now show example 1.
UK
Note: The adjustment affects the switch point: It is increased proportionally (maxi-
mum up to LED 7).
Remote adjustment → 8.5.
8 Additional settings (optional)
8.1 Low flow adjustment
If the unit is used in media other than water, you should additionally adapt the unit
to the minimum flow.
Note: The following adjustment must only be carried out after the high flow adjust-
ment.
►► Let the minimum flow circulate in the installation or ensure flow standstill.
►► Press the pushbutton and keep it pressed.
►► Release the pushbutton. The unit adopts the new value and passes into the
operating mode.
Remote adjustment → 8.5.
8.2 Configure the switching output
The unit is delivered as normally open. In case of need you can change the output
to normally closed:
►► Press the pushbutton for at least 15 s.
>> After 10 s the current setting is displayed: LEDs 5...9 light orange (= output
normally open).
>> After approx. 15 s LEDs 0...4 flash orange.
►► Release the pushbutton. The output is changed to normally closed operation.
For a new changeover repeat the operation.
9
8.3 Restore the factory setting (reset)
►► Press the pushbutton for at least 15 s.
>> After approx. 15 s LEDs 0...9 flash orange.
►► Release the pushbutton. All settings are reset to the factory setting:
-- operating area: 5 ...100 cm/s for water
-- switch point: LED 7
-- output function: NO
-- unlocked.
8.4 Lock / unlock the unit
The unit can be locked electronically to prevent unintentional settings.
►► Press both setting pushbuttons simultaneously for at least 10 s in the operating
mode.
>> The indication goes out, the unit locks or unlocks.
On delivery: unlocked.
8.5 Remote adjustment
You can adapt the unit to new flow conditions any time.
• Apply the operating voltage for > 5 ... < 10 s to Pin 2 = high flow adjustment.
• Apply the operating voltage for > 10 ... < 15 s to Pin 2 = low flow adjustment.
This adjustment does not affect the switch point (the relative position is not chan-
ged).
9 Error during adjustment

If no adjustment is possible, all LEDs flash red. The unit then passes into the
operating mode with unchanged values.
Possible cause /aid:
►► Read chapter 4 Installation.
Error during installation. Check whether all requirements have
been met.
The difference between maximum flow and ►► Increase the flow difference and carry
minimum flow is too small. out the adjustment once again.
The sequence high flow /low flow adjust- ►► Carry out the two adjustment operations
ment was not adhered to. again in the right sequence.
10
10 Operation
After every power on all LEDs light and go out again step by step (during this time
the output is closed if configured as normally open). The unit is then ready for
operation.
In case of power failure or interruption all settings remain.
Operating indicators
Green LED bar: Current flow within the represen-
tation range.
Indication of the switch point (SP): UK

- LED orange: output closed.
- LED red: output open.
LED 9 flashes: current flow above the

representation range.
LED 0 flashes: current flow far below the represen-

tation range.
Interference indicator
Short circuit at the switching output:
The operating indicator and red LEDs light

alternately.
If the short circuit has been rectified, the unit imme-
diately passes into the normal operating state.
The current operating state is displayed.
Display OFF Operating voltage too low (< 19 V) or failed.
(no LED lights): Ensure a correct voltage supply.
11 Maintenance
Recommended maintenance:
►► Check the sensor tip for build-up from time to time.
►► Clean it using a soft cloth. Stubborn build-up (e.g. lime) can be removed using
a common vinegar cleaning agent.
11
12 Scale drawing
1 2
50 63
27
M12 x1
113
14
22
65
60
3
45
8,2
1: LED bar display

2: set button
3: tightening torque 25 Nm
13 Technical data

Application area.........................................................................................Liquids and gases
Operating voltage [V].........................................................................................19 ... 36 DC1)
Current rating [mA]...........................................................................................................250
Short-circuit protection, pulsed; reverse polarity / overload protection
Voltage drop [V]..............................................................................................................< 2.5
Current consumption [mA] ..............................................................................................< 60
Power-on delay time [s]....................................................................... 10, optically indicated
Communication interface .................................................................................... IO-Link 1.0
Baud rate [kBAUD]......................................................................................................... 38.4
12
Liquids
Medium temperature [°C] .................................................................................... -25 ... +80
Setting range [cm/s]..................................................................................................3 ... 300
Greatest sensitivity [cm/s] ..........................................................................................3...100
Temperature gradient [K/min] .........................................................................................300
Gases
Medium temperature [°C] .................................................................................... -25 ... +80
Setting range [cm/s]............................................................................................200 ... 3000
Greatest sensitivity [cm/s].....................................................................................200 ... 800
Switch point accuracy [cm/s] ................................................................................± 2...± 102)
Hysteresis [cm/s] ..........................................................................................................2...52) UK
Repeatability [cm/s] ......................................................................................................1...52)
Temperature drift [cm/s x 1/K].........................................................................................0.13)
Response time [s] .......................................................................................................1 ... 10
Pressure resistance [bar].................................................................................................300
Operating temperature [°C] .................................................................................... -25 ... 80
Protection rating ........................................................................................................... IP 67
Protection class ..................................................................................................................III
Shock resistance [g] .............................................................. 50 (DIN / IEC 68-2-27, 11 ms)
Vibration resistance [g] ................................................... 20 (DIN / IEC 68-2-6, 55-2000 Hz)
Housing materials ......................stainless steel 316L / 1.4404; stainless steel 304 / 1.4301;
PC (Makrolon); PBT-GF 20; EPDM/X (Santoprene)
Materials (wetted parts) ........................................................... stainless steel 316L / 1.4404
O-ring: FPM 8x1.5 gr 80° Shore A
EMC
EN 61000-4-2 ESD: ................................................................................ 4 kV CD / 8 kV AD
EN 61000-4-3 HF radiated: ...................................................................................... 10 V/m
EN 61000-4-4 Burst: ..................................................................................................... 2 kV
EN 61000-4-6 HF conducted: ....................................................................................... 10 V
1)
to EN50178, SELV, PELV;
2)
for water; 5...100 cm/s; 25°C (factory setting)
3)
for water; 5...100 cm/s; 10...70°C
The sensor conforms to the standard EN 61000-6-2
More information at www.ifm.com
13
Important References Important Refernces
Resistance thermometers in pipe or mineral insulated construction Thermocouples in pipe or mineral insulated construction
consist in principle of three major components : consist in principle of two major components :
1. TTemperature
emperature sensitive section 1. TTemperature
emperature sensitive section
Contains the thermal sensing element in form of a glass or ceramic platinum resistor This is in priciple the entire length of the thermocouple ( TC ). The front tip of course must be
located at the point of measuring.
2. Interconnection section
Interconnects the sensing with the cable connection section. 2. Cable connection section
Connection point for the cable necessary for further signal processing
3. Cable connection section
Connection point for the cable necessary for further signal processing TC‘s in pipe construction ( metal or ceramic protection tube ) must not be bended.
Mineral insulated metal sheathed thermocouples may be bende under following asumptions:
Measuring resistors of glass are usually suitable for temperatures up to approx. 400 °. Special
constructions can be designed for higher temperatures. A ) The bending radius must no be below 5 times outside diameter in mm.
Measuring ceramic resistors in chip design are suitable for temperatures up to 500 °. Special B ) The measuring tip must not be bent on a length of min. 20 mm.
construction can be designed for higher temperatures. C ) The area of approximately ca. 50 mm beyond the connection sleeve resp. the connection
Ceramic measuring resistors in wire-wound design can be used up to 650 °. See also EN 60751. socket must not be bent in any case.
Special construction can be designed for higher temperatures. D ) In the area of the measuring tip ( approx. 25 mm ) no welding or soldering is allowed. By
The temperature compatibility of the protective tube and the inner conductors using soldering processes at mineral insulatet cables outside this section, the temperature
must be taken into consideration ! See also DIN 43772. may not exeed 900 °C.
If the interconnection part is constructed from a pipe with inner ceramic capillary rod, this part E ) In the area of the measuring tip ( approx. 20 mm ) squeeze - and /oder sticking screw joints
may not bent in any case! must not be used .
F) TC‘s, especially mineral insulated metal sheathed TC‘s, can not shortened by the customer
If the interconnection part is constructed as a mineral insulated cable, this part can be bent under
following assumptions : The min. and max. temperature rang of the specific TC is given by the standard DIN EN 60584.
Guidlines for the operating temperature range are given in DIN 43712 and DIN EN 61515.
A ) The bending radius may not be beyond 5 to 7 times the outside diameter in mm.
B ) The measuring tip may not be bent in any case on a length of min. 75 mm. The operating temperature range may be deviate from this significantly depending of the
protection tube material used. See also DIN 43772 and DIN 43734
C ) In the area of the measuring tip ( approx. 75 mm ) no welding or soldering is allowed.
Squeeze - and /oder sticking screw joints must not be used in this area. In the case of connecting the cables to the connector, the local rules and safety guidelines are
D ) The area of approximately ca. 50 mm beyond the connection sleeve resp. the connection always to be considered .
socket must not be bent in any case. In case of that the connection section is constructed as a sleeve with firmly connected cable (WL /
In the case of connecting the cables to the connector, the local rules and safety guidelines are WLS - construction), the temperature at the sleeve may not exeed 100 °C. In special constructions
always to be considered . temperatures up to 240 °C are allowed here.
In case of that the connection section is constructed as a sleeve with firmly connected cable (WL / Constructions with firmly mounted pin connectors ( jacks or plugs ), the temperature at that point
WLS - construction), the temperature at the sleeve may not exeed 100 °C. In special constructions may not exeed 100 °C. While using TEFLON - insolated cables and special potting resin tem-
temperatures up to 240 °C are allowed here. peratures up to 180 °C for mini - or standard plugs and up to 240 °C for round connectors are
allowed.
Constructions with firmly mounted pin connectors ( jacks or plugs ), the temperature at that point
may not exeed 100 °C. While using TEFLON - insolated cables and special potting resin tem- The connection scheme to the measuring equipment is depending to the connection diagram
peratures up to 180 °C for mini - or standard plugs and up to 240 °C for round connectors are resp. the marking on the connection socket.
allowed.
The connection scheme to the measuring equipment is depending to the connection diagram
resp. the marking on the connection socket.
RÖSSEL-Messtechnik GmbH & Co RÖSSEL-Messtechnik GmbH RÖSSEL Nederland RÖSSEL-Messtechnik GmbH & Co RÖSSEL-Messtechnik GmbH RÖSSEL Nederland
Lohstrasse 2; DE-59368 Werne Spenerstrasse 1; DE-01309 Dresden Eikenlaan 253d; NL-2404BP Alphen a/d Rijn Lohstrasse 2; DE-59368 Werne Spenerstrasse 1; DE-01309 Dresden Eikenlaan 253d; NL-2404BP Alphen a/d Rijn
Fon: +49 (0) 2389 409-0 Fon: +49 (0) 351 31225-0 Fon: +31 (0) 172 49 31 41 Fon: +49 (0) 2389 409-0 Fon: +49 (0) 351 31225-0 Fon: +31 (0) 172 49 31 41
Fax: +49 (0) 2389 409-80 Fax: +49 (0) 351 31225-25 Fax: +31 (0) 172 49 50 43 Fax: +49 (0) 2389 409-80 Fax: +49 (0) 351 31225-25 Fax: +31 (0) 172 49 50 43
Mail: info@roesselwerne.de Mail: info@roesseldresden.de Co Mail: info@rossel.nl Co Mail: info@roesselwerne.de Mail: info@roesseldresden.de Co Mail: info@rossel.nl Co
Wichtige Hinweise Wichtige Hinweise
Widerstandsthermometer in Rohr - oder Mantelausführung Thermoelemente in Rohr - oder Mantelausführung
bestehen prinzipiell aus drei wesentlichen Komponenten : bestehen prinzipiell aus zwei wesentlichen Komponenten :
1. TTemperaturempfindlicher
emperaturempfindlicher TTeil eil
1. TTemperaturempfindlicher
emperaturempfindlicher TTeil eil
Er erstreckt sich prinzipbedingt über die gesamte Länge des Thermoelementes wobei die
Enthält den Messwiderstand aus Glas oder Keramik als Sensorelement.
Spitze am eigentlichen Meßort plaziert werden muß.
2. V erbindungsteil
Verbindungsteil
2. Anschlußteil
Verbindet den Sensor mit dem Anschlußteil.
Anschlußmöglichkeit für das zur weiteren Signalverarbeitung notwendige Kabel.
3. Anschlußteil
Anschlußmöglichkeit für das zur weiteren Signalverarbeitung notwendige Kabel. Thermoelemente in Rohrausführung ( metallisches oder keramisches Schutzrohr ) dürfen generell
nicht gebogen werden.
Messwiderstände aus Glas sind normalerweise für Temperaturen bis ca. 400 °C geeignet.
Mantelthermoelemente können unter folgenden Vorrausetzungen gebogen werden:
Sonderausführungen können für höhere Temperaturen ausgelegt werden.
A ) Der Biegeradius darf den Wert 5 x Außendurchmesser nicht unterschreiten.
Messwiderstände aus Keramik in Flachschichtausführung sind für Temperaturen bis max. 500 °C
geeignet. Sonderausführungen können für höhere Temperaturen ausgelegt werden. B ) Die Meßspitze darf auf einer Länge von min. 20 mm nicht gebogen werden.
Messwiderstände aus Keramik in drahtgewickelter Bauform können bis max. 650 °C eingesetzt C ) Der Bereich von ca . 50 mm unterhalb der Verbindungshülse bzw. des Sockels darf ebenfalls
werden. Siehe hierzu auch die EN 60751. nicht gebogen werden.
Sonderausführungen sind für höhere Temperaturen geeignet.
D ) Im Bereich von ca. 25 mm unterhalb der Meßspitze darf nicht geschweißt oder gelötet
In jedem FFall
all ist die TTemperaturbeständigkeit
emperaturbeständigkeit des verwendeten Schutzrohres und werden. Bei Hartlötungen an Mantelthermoelementen ist darauf zu achten, daß die
Innenleiters zu beachten ! Siehe hierzu auch DIN 43772. Löttemperatur 900 °C nicht überschreitet.
Ist der Verbindungsteil als Rohr mit eingesetztem Keramikstab ausgeführt, so darf dieser Teil E) Quetsch - oder Klemmverschraubungen dürfen nur außerhalb der in Punkt B und C spezifi
keinesfalls gebogen werden ! zierten Bereiche eingesetzt werden.
Ist der Verbindungsteil als Mantelleitung ausgeführt, so kann dieser Teil unter folgenden Voraus- F ) Thermoelemente, speziell Mantelthermoelemente, können durch den Kunden keinesfalls
setzungen gebogen werden: gekürzt werden.
A ) Der Biegeradius darf den Wert 5 ... 7 x Außendurchmesser in mm nicht unterschreiten. Die minimale bzw. maximale Temperaturgrenze für den jeweiligen Thermoelementtyp ist in der
DIN EN 60584 enthalten.
B ) Die Meßspitze darf auf einer Länge von min. 75 mm nicht gebogen werden.
Konkrete Richtlinien für den Anwendungstemperaturbereich geben die DIN 43712 und die
C ) Im Bereich der Meßspitze ( ca. 75 mm ) darf nicht gelötet oder geschweißt werden. DIN EN 61515 an.
Quetsch - und /oder Klemmverschraubungen dürfen in diesem Bereich nicht verwendet
werden. Die Grenzen der Anwendungstemperatur können je nach verwendetem Schutzrohrwerkstoff
erheblich davon abweichen. Siehe hierzu auch DIN 43772.
D ) Der Bereich von ca. 50 mm unterhalb der Verbindungshülse bzw. des Sockels darf ebenfalls
Beim Anschluß der Kabel an den Anschlußteil sind in jedem Fall die örtlichen Vorschriften und
nicht gebogen werden.
Sicherheitsrichtlinien zu beachten.
Beim Anschluß der Kabel an den Anschlußteil sind in jedem Fall die örtlichen Vorschriften und
Sicherheitsrichtlinien zu beachten. Ist der Anschlußteil als Verbindungshülse mit fest angeschlossener Anschlußleitung ausgeführt (AL
/ALS - Ausführung ),so darf die Temperatur der Hülse 100 °C nicht überschreiten. In Sonderaus-
Ist der Anschlußteil als Verbindungshülse mit fest angeschlossener Anschlußleitung ausgeführt (WL
führungen können hier Temperaturen bis 240 °C zugelassen werden.
/WLS - Ausführung ),so darf die Temperatur der Hülse 100 °C nicht überschreiten. In Sonderaus-
führungen können hier Temperaturen bis 240 °C zugelassen werden.
Bei Bauformen mit fest angeschlossenem Stecker/Kupplung darf die Temperatur an dieser Stelle
Bei Bauformen mit fest angeschlossenem Stecker/Kupplung darf die Temperatur an dieser Stelle 100 °C nicht überschreiten. Bei Verwendung Teflon - isolierter Leitungen und spezieller Verguss-
100 °C nicht überschreiten. Bei Verwendung Teflon - isolierter Leitungen und spezieller Verguss- massen können hier bis 180 °C für Mini -oder Standardstecker und bis 240 °C für Rundstecker
massen/Anschlußtechniken können hier bis 180 °C für Mini -oder Standardstecker und bis 240 zugelassen werden.
°C für Rundstecker zugelassen werden.
Der messtechnische Anschluß ergibt sich aus dem Anschlußdiagramm bzw. der Kennzeichnung
Der messtechnische Anschluß ergibt sich aus dem Anschlußdiagramm bzw. der Kennzeichnung
des Anschlußsockels.
des Anschlußsockels.
RÖSSEL-Messtechnik GmbH & Co RÖSSEL-Messtechnik GmbH RÖSSEL Nederland RÖSSEL-Messtechnik GmbH & Co RÖSSEL-Messtechnik GmbH RÖSSEL Nederland
Lohstrasse 2; DE-59368 Werne Spenerstrasse 1; DE-01309 Dresden Eikenlaan 253d; NL-2404BP Alphen a/d Rijn Lohstrasse 2; DE-59368 Werne Spenerstrasse 1; DE-01309 Dresden Eikenlaan 253d; NL-2404BP Alphen a/d Rijn
Fon: +49 (0) 2389 409-0 Fon: +49 (0) 351 31225-0 Fon: +31 (0) 172 49 31 41 Fon: +49 (0) 2389 409-0 Fon: +49 (0) 351 31225-0 Fon: +31 (0) 172 49 31 41
Fax: +49 (0) 2389 409-80 Fax: +49 (0) 351 31225-25 Fax: +31 (0) 172 49 50 43 Fax: +49 (0) 2389 409-80 Fax: +49 (0) 351 31225-25 Fax: +31 (0) 172 49 50 43
Mail: info@roesselwerne.de Mail: info@roesseldresden.de Co Mail: info@rossel.nl Co Mail: info@roesselwerne.de Mail: info@roesseldresden.de Co Mail: info@rossel.nl Co
Accessories
E40096
Adapter
M18 x 1.5 - G ½
Pressure rating [bar] 300

Housing material stainless steel (316S12)
Remarks probe length with adapter = 21 mm
ifm electronic gmbh · Teichstraße 4 · D-45127 — We reserve the right to make technical alterations without prior notice. — GB - E40096 - / — 06.03.2003
Essen
Connection technology
EVC008
ADOAH043MSS0005H04
Socket
For sensors with

M12 connector
Free from silicone

Free from halogen
gold-plated contacts
Electrical design DC PNP

Operating voltage [V] 10...36 DC
Current rating [A] 4
Design angled
Operating temperature [°C] -25...90
Protection IP 67 / IP 68 / IP 69K, II
Material body housing: TPU black transparent; sealing: Viton
Material nut brass; nickel-plated
Tightening torque for knurled nut
[Nm] 0.6...1.5
Function display
Operation LED green
Switching status LED 2 x yellow
Connection PUR cable / 5 m;
4 x 0.34 mm² (42 x Ø 0.1 mm); Ø 4,9 mm; halogen-free
Sheath colour black
Wiring
Core colours
BK black
BN brown
BU blue
WH white
ifm electronic gmbh • Teichstraße 4 • 45127 Essen — We reserve the right to make technical alterations without prior notice. — GB — EVC008 — 05.04.2007
Voith Turbo
Installation and Operating Manual

(Original installation and operating manual)
3626-011000 en
Turbo Couplings with Constant Fill

including design as per Directive 94/9/EC
ATTENTION!
Please read this manual, at any rate, prior to installation and commissio-
ning, and keep it for further use!
1)
Serial No. 
2)
Coupling type  
Year of manufacture 
Weight  kg
Power transmission  kW
Input speed  rpm
Operating fluid mineral oil
water
3
Filling volume  dm (liters)
Nominal response
 °C
temperature of fusible plugs
Connecting coupling type
Sound pressure level LPA,1m  dB
Installation position horizontal
vertical
Drive via outer wheel
inner wheel
Please consult Voith Turbo in case that the data on the cover sheet are incomplete.
1)
Please indicate the serial number in any correspondence ( Chapter 19, Page 80).
2)
T...: oil / TW...: water.
Turbo Couplings with constant fill Voith Turbo GmbH & Co. KG | Installation and Operating Manual
Contents
1 Technical Data ..................................................................................................5
2 Declaration of Manufacturer ............................................................................7

2.1 Declaration regarding assemblies and components...........................................7
2.2 EC Conformity Declaration (RL 94/9/EC, Annex X.B) ........................................8
3 Preface ...............................................................................................................9
3.1 General Information ............................................................................................9
4 Safety ...............................................................................................................10
4.1 Notes and Symbols ...........................................................................................10
4.2 Proper use ........................................................................................................11
4.3 Improper use.....................................................................................................11
4.4 Constructional modifications .............................................................................11
4.5 General information with regard to dangerous situations .................................12
4.6 Remaining risks ................................................................................................14
4.7 What to do in case of accidents........................................................................14
4.8 Important information with regard to operation .................................................15
4.9 Staff qualification ..............................................................................................17
4.10 Follow-up of product .........................................................................................17
5 Transport and Storage ...................................................................................18

5.1 As delivered condition .......................................................................................18
5.2 Scope of supply ................................................................................................ 18
5.3 Transport ..........................................................................................................18
5.4 Lifting ................................................................................................................19
5.5 Storage / Packing / Preservation ......................................................................22
5.5.1 Storage of turbo coupling..................................................................................22
5.5.2 Storage of flexible elements .............................................................................23
6 Voith Turbo Couplings with Constant Fill ....................................................24

6.1 Function ............................................................................................................24
6.2 Type designation...............................................................................................25
6.3 Examples for coupling types .............................................................................27
6.3.1 Connecting coupling on the input side ..............................................................27
6.3.2 Connecting coupling on the output side ............................................................28
7 Tightening torques .........................................................................................29

7.1 Set screws and fixing bolts ...............................................................................29
7.2 Fusible plugs, filler plugs, sight glasses, blind- and nozzle screws ..................30
7.3 Fastening screws ..............................................................................................30
8 Installation of Basic Coupling Type T ..........................................................31

8.1 Tools .................................................................................................................31
8.2 Preparation .......................................................................................................32
8.3 Mounting ...........................................................................................................34
8.4 Mounting devices .............................................................................................. 36
9 Installation of Basic Coupling Type TN ........................................................37

9.1 Mounting ...........................................................................................................38
Subject to modification due to technical development.
Installation and Operating Manual, 3626-011000 en.
10 Alignment ........................................................................................................40
10.1 Flexible connecting couplings ...........................................................................40
10.1.1 Connecting couplings on the input side (outer wheel drive) .............................40
2014-01 / Rev. 9. Printed in Germany.
10.1.2 Connecting coupling on the output side (outer wheel drive) .............................41
10.2 Laid lengths and type allocations
turbo coupling / flexible connecting coupling ....................................................42
10.3 Alignment tolerances ........................................................................................42
10.4 Alignment ..........................................................................................................43
11 Operating fluids .............................................................................................. 45

11.1 Requirements to be fulfilled by the operating fluid mineral oil ..........................45
11.2 Mineral oils ........................................................................................................46
2
Voith Turbo GmbH & Co. KG | Installation and Operating Manual Turbo Couplings with constant fill
11.2.1 Usable operating fluids ..................................................................................... 46

11.2.2 Operating temperature frequently above 100°C ............................................... 46
11.2.3 Proposed operating fluids ................................................................................. 46
11.3 Proposed operating fluids for special requirements ......................................... 47
11.4 Requirements to be fulfilled by the operating fluid 'water' ................................ 48
11.4.1 Usable operating fluids ..................................................................................... 48
11.4.2 Water used as operating fluid for turbo couplings with centrifugal valves
(types .............................................................................................. 48
12 Fill, Filling Check and Draining ..................................................................... 50

12.1 Filling the coupling ............................................................................................ 51
12.1.1 How to fill couplings installed in horizontal position .......................................... 51
12.1.2 How to fill couplings installed in vertical position .............................................. 52
12.2 Filling check ...................................................................................................... 53
12.2.1 Level check for couplings installed in horizontal position ................................. 53
12.2.2 Level check for couplings installed in vertical position ..................................... 53
12.3 Draining the coupling ........................................................................................ 54
12.3.1 How to drain couplings without delay chamber
that are installed in horizontal position ............................................................. 54
12.3.2 How to drain couplings with delay chamber
that are installed in horizontal position ............................................................. 54
12.3.3 How to drain couplings installed in vertical position ......................................... 55
13 Commissioning .............................................................................................. 56
14 Operation ........................................................................................................ 58
15 Maintenance, Servicing ................................................................................. 58

15.1 Outside cleaning ............................................................................................... 61
15.2 Flexible connecting coupling ............................................................................ 62
15.2.1 How to check the flexible elements for wear .................................................... 62
15.2.2 Maintenance intervals....................................................................................... 63
15.3 Bearings ........................................................................................................... 63
15.3.1 Bearing lubrication when mineral oil is used as operating fluid ........................ 63
15.3.2 Bearing lubrication when water is used as operating fluid................................ 63
15.3.3 Replacement of bearings / re-lubrication......................................................... 63
15.4 Fusible plugs .................................................................................................... 64
15.4.1 Fusible plugs in couplings not suitable
for use in potentially explosive atmospheres .................................................... 65
15.4.2 Fusible plugs in couplings suitable
for the use in potentially explosive atmospheres .............................................. 66
16 Assembly Check-, Commissioning and Maintenance Report ................... 67

16.1 Assembly check report ..................................................................................... 68
16.2 Commissioning report ...................................................................................... 70
16.3 Maintenance report for general maintenance................................................... 71
16.3.1 Maintenance report for flexible connecting coupling ........................................ 72
17 Coupling Disassembly ................................................................................... 73

17.1 Preparation ....................................................................................................... 73
17.2 Removal ........................................................................................................... 74
17.2.1 Removal using the hydraulic removal device ................................................... 75
17.2.2 Removal using the mechanical removal device ............................................... 76
18 Troubleshooting ............................................................................................. 77
19 Queries, Orders placed for Service Engineers and Spare Parts ............... 80
20 Temperature monitoring ................................................................................ 81

20.1 MTS mechanical thermal switch unit for pre-warning ...................................... 81
20.2 BTS non-contacting thermal switch unit ........................................................... 82
20.2.1 BTS non-contacting thermal switch unit for pre-warning .................................. 82
20.2.2 BTS-Ex non-contacting thermal switch unit for limiting the maximum
surface temperature ......................................................................................... 83
20.3 BTM non-contacting thermal measuring unit for pre-warning .......................... 84
3
21 Spare parts information .................................................................................86

21.1 Spare parts for type 154 T ................................................................................87
21.2 Spare parts for types 206 - 274 T .....................................................................87
21.3 Spare parts for types T and TN ........................................................................88
21.3.1 Spare parts for types 366 - 1150 T ...................................................................89
21.3.2 Spare parts for types 366 - 650 TN ..................................................................89
21.4 Spare parts for types 274 TV / TVV ..................................................................91
21.5 Spare parts for types TV / TVV and TVN / TVVN .............................................92
21.5.1 Spare parts for types 366 - 1150 TV / TVV.......................................................93
21.5.2 Spare parts for types 366 - 650 TVN / TVVN ...................................................93
21.6 Spare parts for types TVVS and TVVSN ..........................................................94
21.6.1 Spare parts for types 422 - 1150 TVVS ............................................................95
21.6.2 Spare parts for types 422 - 650 TVVSN ...........................................................95
21.7 Spare parts for type 154 DT .............................................................................96
21.8 Spare parts for types 206 DT and 274 DT / DTV .............................................97
21.9 Spare parts for types 1150 DT / DTV ............................................................... 98
22 Spare Parts Information - Connecting Couplings .....................................100

22.1 Connecting coupling on the input side ............................................................100
22.1.1 Flexible pad coupling type EPK .....................................................................100
22.1.2 Flexible element coupling type EEK ..............................................................100
22.1.3 Flexible cam coupling type ENK ....................................................................101
22.2 Connecting couplings on the output side ........................................................101
22.2.1 Coupling Nor-Mex G ......................................................................................101
23 Representatives - Voith Turbo GmbH & Co. KG ........................................103
24 Index ..............................................................................................................106

4
1 Technical Data
Information required for use in potentially explosive atmospheres:
marking:
Ambient temperature, if deviating
°C
from -25 °C Ta +40 °C
max. surface temperature
(T3= 200 °C, T4= 135 °C, °C
or deviating)
1)
Temperature monitoring MTS for pre-warning
2)
BTS for pre-warning
2)
BTS-Ex for limitation of max.
surface temperature for Voith
Turbo couplings acc. to
EC Directive 94/9/EC
Maximum permissible
temperature of turbo coupling
when switching on the motor:
°C
Nominal response temperature of
°C
temperature monitoring
3) 3
Max. permissible filling volume dm (liters)
Fusible plug (SSS) SSS
SSS-X
Overload (see Chapter 4.8),
causing the thermal fuse (fusible
plug/s and/or BTS-Ex) to respond,
requires the power supply to be
switched off after
s (sec)
An additional monitoring of the Yes
output speed is required to switch No
off the power supply before the
fusible plugs respond.
After switching on the motor,
monitoring of output speed has to s (sec)
begin after
4)
Diameter of input mm
4)
Diameter of output mm
Replacement of ball and roller
h
bearings after
Table 1
1)
MTS: Mechanical thermal switch unit (see Chapter 20.1).
2)
BTS: Non-contacting thermal switch unit (see Chapter 20.2).
3)
Applies if filling volume is not indicated on the cover sheet.
4)
Diameter and fit of hub or shaft to be joined by means of shaft-hub connection.
5
Additional information/data required for use in potentially explosive

atmospheres:

6
2 Declaration of Manufacturer
2.1 Declaration regarding assemblies and components
Since 29 December 2009, a new Machinery Directive 2006/42/EC has to be applied
bindingly in the member states of the European Community.
Voith turbo couplings of Product Group 'Start-up Components', as defined by the new
Machinery Directive 2006/42/EC and the explanations of the guidelines published in
December 2009 to implement the machinery directive, are neither "Machinery" nor
"incomplete machinery" but assemblies or components.
As our products are no incomplete machinery, we do not issue a declaration of

incorporation as per Machinery Directive 2006/42/EC.
Also, an EC Declaration of Conformity must not be issued, neither the CE marking be

provided, unless specified by other EC directives or regulations.
Voith as certified company ensures that the basic safety and health requirements for
their products are always be met by internal quality management systems and by
applying harmonized standards.
The technical documentation for Voith products is so comprehensive that they may be
installed reliably into machinery or incomplete machinery, and a safe operation of the
complete machinery with regard to the products is also possible later on when
observing this documentation.
Issued in Crailsheim, Germany

th
On January 10 , 2014
Name of Mr. J. Hagedorn,

the undersigned General Manager - Start-up Components

Signature
7
2.2 EC Conformity Declaration (RL 94/9/EC, Annex X.B)

as confirmation of accordance of the assembly with Directive 94/9/EC
The manufacturer Voith Turbo GmbH & Co. KG,

Voithstraße 1, D-74564 Crailsheim
hereby declares that the machinery described below:
Designation
Turbo coupling with constant fill
Serial No. see shipping documents
complies with the provisions of the following harmonized standards in the version valid
on the date of signature:
EN ISO 12100-1 / -2 Safety of machinery - basic concepts and general principles for design
Part 1: Terminology, methodology
Part 2: Technical principles
EN 1127-1 / -2 Explosive atmospheres, explosion prevention, basic concepts and
methodology
EN 13463-1 Non-electrical equipment for use in potentially explosive atmospheres, Part 1.
Basic method and requirements
EN 13463-5 Non-electrical equipment intended for use in potentially explosive
atmospheres, Part 5: Protection by constructional safety 'c'
EN 13463-8 Non-electrical equipment for potentially explosive atmospheres, Part 8:
EN 1710 Equipment and components intended for use in potentially explosive

atmospheres in underground mines
as well as with the following European and national standards and technical
specifications in the version valid on the date of signature:
TRBS 2153 Avoidance of ignition hazards resulting from electrostatic charging
Each modification by the customer on the parts supplied, invalidates the declaration.
Issued in Crailsheim, Germany

th
On January 10 , 2014
Name des Hr. J. Hagedorn,

the undersigned General Manager - Start-up Components
Signature
8
3 Preface
3.1 General Information

This manual will support you in using the turbo coupling with connecting coupling in a
safe, proper and economical way.
If you observe the information contained in this manual, you will

increase the reliability and lifetime of the coupling and installation,
avoid any risks,
reduce repairs and downtimes.
This instruction must

always be available at the machine site,
be read and used by every person who transports the coupling, works on the
coupling or commissions the same.
The coupling has been manufactured according to the latest design standard and
approved safety regulations. Nevertheless, the user's or third party's life may be
endangered or the machine or other property impaired in case of improper handling or
use.
Spare parts:
Spare parts must comply with the requirements specified by Voith. This is guaranteed
when original spare parts are used.
Installation and/or use of non-original spare parts may negatively change the
mechanical properties of the Voith turbo couplings, and may thus impair safety.
Voith is not liable for any damages resulting from the use of non-original spare parts.
Use only appropriate workshop equipment for maintenance. Professional maintenance

and/or repair can only be guaranteed by the manufacturer or an authorized specialist
workshop.
This manual has been issued with utmost care. However, in case you need any further
information, please contact:
Voith Turbo GmbH & Co. KG

Start-up Components
Voithstr. 1
74564 Crailsheim
GERMANY
Tel. +49 7951 32-0
Fax. +49 7951 32-480

startup.components@voith.com
www.voithturbo.com/startup-components
© Voith Turbo 2014.

Distribution as well as reproduction of this document, utilization and communication of
its contents are prohibited unless expressly permitted. Offenders will be held liable for
the payment of damages. All rights reserved in case of the grant of a patent, or the
registration of a utility model or design.
Voith Turbo reserves the right for modifications.
9
4 Safety
4.1 Notes and Symbols

The safety notes contained in this operating manual are particularly marked with safety
symbols according to DIN 4844.
Damage / Signal word Definition Consequences Symbol

harm to...
Persons EX-PROTEC- Notes to Ex- Danger of explosion
Property TION! protection
Persons DANGER! Imminent danger Fatal or most serious

injuries (crippling)
Persons WARNING! Potentially Fatal or most serious

dangerous injuries possible
situation
Persons CAUTION! Less dangerous Minor or moderate

situation injuries possible
Persons Suspended Potentially Fatal or most serious

Property loads! dangerous injuries possible
situation
Persons Warning of Fire hazard

Property inflammable
materials
Persons Use goggles Risk of loss of sight
Persons Use ear Hearing damage

protection
Material ATTENTION! Potentially Possible damage to

harmful situation the product
its environment
Note! Application Efficient in operation

Information! details and
other useful
information
Table 2
Marking with the Ex-symbol ( ) indicates possible hazards which have to be

observed only for the use in potentially explosive atmospheres.
If apart from the symbol for EX-protection ( ) there is another symbol ( or ),

adhere to the instructions for operation also beyond potentially explosive atmospheres.
10
4.2 Proper use
The turbo coupling with constant fill is provided to transmit the torque from the drive
motor to the driven machine.
The power permitted during stationary operation at a specific input speed and a
specific coupling fill (operating fluid and filling) is entered on the cover sheet of this
manual. Any other use beyond that described herein, e.g. for higher powers, higher
speeds, other operating fluids or operating conditions that have not been agreed upon,
is considered improper use.
Proper use also includes observing this Installation and Operating Manual and
complying with the inspection and maintenance instructions.
The manufacturer is not liable for damages resulting from improper use. The risk has
to be borne solely by the user.
EX-PROTECTION! / ATTENTION!
If not indicated accordingly in Chapter 1, it is not allowed to use this coupling in
potentially explosive atmospheres!
Please check by means of the marking whether the coupling is approved for
potentially explosive atmospheres.
Note!
If the zonal classification changes, the operator has to check whether it is still
allowed to operate the turbo coupling in that zone.
4.3 Improper use

Please see the corresponding information as to dangerous situations in the respective
chapters.
4.4 Constructional modifications

DANGER!
Constructional modifications not done properly on the turbo coupling can cause
personal injury and damage to property!
Modifications, attachments or conversions on the turbo coupling are only allo-

wed with the approval of Voith Turbo GmbH & Co. KG, Crailsheim.
11
4.5 General information with regard to dangerous situations
For all work performed on the turbo coupling, please observe the local regula-
tions for the prevention of accidents!
DANGER!
Hazards while working on the turbo coupling:

There is the risk of injury by cutting, squeezing and cold burns in case of
minus degrees.
Never touch the turbo coupling without wearing protective gloves!
Start to work on the coupling only after it has cooled down below 40 °C as
otherwise there is the risk of burning!
Ensure that there is sufficient light, a sufficiently big working space and good
ventilation when working on the turbo coupling.
Switch off the unit in which the coupling is installed and secure the switch
against switching on.
For all work performed on the turbo coupling ensure that both, drive motor
and driven machine have stopped running and startup is absolutely impos-
sible!
Hot surfaces:
The coupling temperature rises during operation.
For protective Please provide a guard for protection against contact with the coupling!
cover, see However, ventilation of coupling must not be impaired.
Chapter 13 Never use fluids to cool down the coupling!
Rotating parts:
For protective Rotating parts, such as the turbo coupling itself and exposed shaft parts
cover, see need to be protected by a protective cover against contact with and entry of
Chapter 13 loose parts!
Never operate the coupling without these protective covers!
Noise:
See cover The turbo coupling generates noise during operation.
sheet, for If the A-classified equivalent sound pressure level LPA, 1m exceeds 80 dB(A)
sould this may cause hearing damage!

pressure level Wear ear protection!
Electric shock:
Contact with exposed terminals, lines and components may cause serious or
even fatal injuries!
In case of a failure, even potential-free assemblies may carry a corresponding
supply voltage during operation.
12
Overspeed:
This refers only to installations where overspeed (exceeding the rated speed)
is possible:
Check whether the entire system is equipped with a device which safely pre-
vents overspeed (for example brake or backstop).
For rated speed, please see the cover sheet.
Extreme ambient temperatures:

Extreme ambient temperatures may result in thermal overload of the turbo
coupling, thus causing the fusible plugs to melt and injure seriously persons
in its surroundings, and damage the turbo coupling!
For operating medium water:
Ambient temperature must be above freezing point of operating fluid! The
frozen operating fluid may damage the coupling.
Adhere to the temperature limits indicated (see Chapter 4.8)!
Spraying-off and leaking out operating fluid:

In case of thermal overload of turbo coupling, the fusible plugs respond.
Operating fluid leaks out through these fusible plugs.
If the fusible plugs spray off, immediately switch off the drive!
Electrical devices located near the coupling need to be splash-guarded!
Please make sure that the spraying-off operating fluid cannot get in contact
with persons! Danger of burning!
Persons being in the surrounding of turbo coupling have to wear goggles.
Hot operating fluid spraying off means a risk of losing sight!
Make sure that spraying off operating fluid cannot get into contact with hot
machine parts, heaters, sparks or open flames! There is a risk of fire!
In order to prevent danger (e.g. risk of slipping, risk of fire) caused by
escaping oil, clean up the area immediately!
Catch spraying solder of fusible plugs.
Collect operating oil leaking out to prevent contact with parts (motor, belt)
which might ignite or catch fire.
Please provide a catch pan of sufficient size, if required!
Please pay attention to the information contained in the safety data sheets!
Fire hazard:
After the fusible plugs responded, spraying off oil may ignite on hot surfaces
causing fire, as well as releasing toxic gases and vapor. There is a risk of
burning and intoxication, as well as a risk of harm to machines, environment
and property.
Immediately switch off the driving machine when the fusible plugs respond.
Please pay attention to the information contained in the safety data sheets!
13
Check of methane content before working on the turbo coupling:

In order to guarantee the safety during underground installation, mainte-
nance and removal when working on the turbo coupling with a housing of
aluminum alloy and the protective cover removed, the methane content has
to be checked locally using appropriate instruments. Before starting and
while performing this work, the methane content in the area of the turbo
coupling must not exceed the permissible limit value (e.g. 1 % vol. in Russia).
Should this value be exceeded, the work has to be stopped until the value
falls again below the limit value.
4.6 Remaining risks
DANGER!
Improper use or mal-operation may cause death, serious injuries or minor
injuries as well as damage to property and the environment.
Only persons who are sufficiently qualified, trained and authorized are allowed
to work on or with the turbo coupling!
Please pay attention to the warnings and safety information!
4.7 What to do in case of accidents
WARNING!
Please observe the local codes of practice! Subject to modification due to technical development.
14
4.8 Important information with regard to operation
ATTENTION!
If irregularities are found during operation, immediately switch off the drive unit!
Power transmission:
The cover sheet of this manual indicates the possible power transmission at
a specific input speed and a specific coupling filling (operating fluid and
quantity). These values describe a permissible working point for the statio-
nary operation of the coupling.
Voith Turbo's approval is required for a stationary operation of the coupling
at a different working point.
Operating fluid:
Use only the operating fluid indicated on the cover sheet of this manual!
Operate the turbo coupling only with the filling quantity stated on the cover
sheet of this manual.
Too little filling results in thermal overload of the coupling, and in case of too
much filling, the coupling may be damaged by internal pressure.
Warming up on start-up:
On start-up, the turbo coupling warms up more than during stationary opera-
tion due to the increased slip. Please provide sufficient intervals between
start-ups to avoid thermal overload!
Starting characteristic of turbo couplings with delay chamber:

On start-up, the operating fluid flows from the delay chamber into the turbo
coupling working chamber. On standstill, the operating fluid returns into the
delay chamber. Please provide sufficient intervals (a few minutes!) between
the starts to get a correct starting characteristic!
Coupling temperature:
Please consult Voith Turbo, if the turbo coupling shall be used for ambient
temperatures
- below -25 °C for operating fluid oil
- below 0 °C for operating fluid water (freezing point)! For technical
Please also see the order documents. data, see
Chapter 1,
Overheating may damage the coupling! Page 5
The nominal coupling temperature will not be exceeded for the planned appli-
cation as long as sufficient ventilation is provided.
The following applies only to couplings in potentially explosive atmospheres:
Make sure that the air surrounding the turbo coupling does not exceed the
permissible value.
15
Fusible plugs:
The fusible plugs protect the turbo coupling against damage due to thermal
overload.
For technical Switch off the drive motor immediately on response of one of the fusible
data, see plugs!
Chapter 1, Use original fusible plugs only with the response temperature indicated on
Page 5 the cover sheet of this operating manual!
For monitoring Monitoring devices:

devices, see Check whether the existing monitoring devices are in a state ready for opera-
Chapter 20, tion.
page 81 Repair any defective monitoring device immediately!
Never bypass safety devices!
Blocking:
Blocking of the driven machine may cause overheating of the turbo coupling
and response of the fusible plugs thus endangering persons as well as the
turbo coupling and environment.
Immediately switch off the driving machine!
EX-PROTECTION!
Overload of the coupling:

After the thermal fuse responded, switch off the power supply after the time
required in Chapter 1 at the latest.
In case of multi-motor drive, switch off the whole system!
For technical If an additional monitoring of the overload is required, monitor the output
data, see speed.
Chapter 1, If the output speed falls below the input speed by more than 10%, immediate-
page 5 ly switch off the power supply.
It is necessary to switch off the power supply as otherwise the max. surface
temperature indicated cannot be met.
Note!
The coupling will be overloaded in cases where
the driven machine blocks

the driven machine is loaded excessively during nominal operation and/or during
start-up
(consult Voith Turbo).
16
Connecting couplings: For connecting

couplings, see
Connecting couplings of type EPK: Chapter 22,
After the flexible elements of an EPK connecting coupling broke (shearing), Page 100
switch off the drive immediately!
In case of multi-motor drive, switch off the whole system!
We recommend regularly checking the condition of the pads for wear.
Connecting couplings of types ENK, EEK, Nor-Mex G:

In case of too heavily worn flexible elements, there is the risk that parts of the
connecting coupling touch/hit each other.
- Fire and explosion hazard due to sparking!
- Danger to life due to flying debris!
Risk of damage to the driving and driven machine!
4.9 Staff qualification

Only qualified and authorized professional staff are allowed to perform work, such as
transportation, storage, installation, electrical connection, commissioning, operation,
maintenance, servicing and repair.
Qualified professional staff in the sense of these basic safety information are persons
who are familiar with transportation, storage, installation, electrical connection,
commissioning, maintenance, servicing and repair and who have got the necessary
qualifications relevant to their job performed.
This staff must be trained, instructed and authorized to:

operate and service machines in a professional manner in accordance with the
technical safety standards
use lifting appliances, slings (ropes, chains, etc.) and lifting points in an expert
manner
professionally dispose of media and their components, e.g. lubricating grease
service and use safety devices in a manner that ensures compliance with safety
standards
prevent accidents and provide first aid.
Staff to be trained may only perform work on the turbo coupling under supervision of a
qualified and authorized person.
The staff in charge of any work to be done on the coupling must

be reliable,
have the legal minimum age,
be trained, instructed and authorized with regard to the intended work.
4.10 Follow-up of product

We are under legal obligation to follow up on the behavior of our products, even after
shipment.
Therefore, please inform us about anything that might be of interest to us. For You will find our
example: address on
change in operating data, page 9
experience gained with the unit,
recurring problems,
problems experienced with this installation and operating manual.
17
5 Transport and Storage
5.1 As delivered condition
The turbo coupling is delivered completely, with mounted connecting coupling (if
included in the scope of supply).
The turbo coupling is delivered completely, with mounted primary coupling flange.
For filling of The turbo coupling is not filled. If the scope of supply includes the operating fluid, it
coupling, see will be delivered in a separate container.
Chapter 12, The operating himself will fill in the operating fluid.
page 50 Other accessories are supplied as loose parts.
Basic type T...: Fixing bolt and holding disk are supplied in addition.
ATTENTION!
Dispose of the packing and used parts in accordance with the stipulations of the
country of installation!
5.2 Scope of supply

The turbo coupling will be supplied as indicated on the cover sheet.
A set of fusible plugs is supplied as spare one.
Additional parts belonging to the scope of supply, such as connecting coupling, fusible
plugs, temperature monitoring, mounting and removal device, etc. will be stated in the
order confirmation.
5.3 Transport
EX-PROTECTION!
In potentially explosive atmospheres it is only allowed to transport the coupling
Chapter 13, in suitable packing. This packing has to meet the same minimum requirements
page 56 as the protective cover.
WARNING!
Falling parts may seriously injure or kill you!
Secure the coupling sufficiently; pay attention to the center of gravity position
and use the provided lifting points!
For masses,
see Use appropriate transportation means and slings (ropes, chains, etc.)!
Cover sheet
Incorrect handling of the turbo coupling may cause bruising of upper and lower
limbs and seriously injure persons.
Skilled staff only is allowed to carry out transportation!
18
5.4 Lifting
DANGER!
Fastening and lifting of coupling

Improper fastening and lifting of the turbo coupling may cause personal injury
and damage to property!
The coupling may be lifted only on the lifting points provided (see the following
pictures).
When fastening and lifting the turbo coupling ensure not to damage the ribbing
of the coupling by lifting appliances or load carrying attachments. Damaged ribs
may result in an unbalance of the coupling, thus causing an uneven running of
the machine!
Do not walk or stay under suspended loads!
Lifting appliances, load carrying attachments, lifting points

Observe the turbo coupling weight (see cover sheet)!
Lifting appliances (e.g. crane, high-lift truck), slings (ropes, chains, etc.) and
lifting points (swivels, thread size as for items 1830 and 0780, see Chapter 7.3)
need to be
- checked and approved,
- sufficiently dimensioned and in sound condition, and
- only authorized and trained persons are allowed to operate the same!
Read the operating instructions of lifting appliances, slings (ropes, chains, etc.) and lif-
ting points!
Damaged load carrying attachments or those with insufficient carrying capacity

may break under load, with the consequence of most serious or even fatal inju-
ries!
Check the lifting appliances and load carrying attachments for
sufficient carrying capacity (for weight, see cover sheet),
sound condition.
Eyebolts are prohibited!

Please use swivels as shown on the following pictures!
If a connecting coupling is fixed, remove it to allow the screwing in of swivels.

19
Proper fastening of a Voith turbo coupling (as an example):

Remove the flexible connecting coupling (if any).
Screw suitable swivels (thread size as for items 1830 and 0780, see Chapter 7.3) into
the coupling as shown on the pictures, and attach slings (ropes, chains, etc.).
Do not unscrew existing screws for this purpose, use the provided threads:
Fig. 1
DANGER!
Slings (ropes, chains, etc.) must not be slung around the coupling for lifting and
turning!
Keep out of reach of suspended loads, and observe the general guidelines for
the prevention of accidents!
As long as the Voith turbo coupling is not mounted between the driving and
driven machine, secure it against tilting and sliding.
Danger of life and risk of injury caused by falling load, tilting or sliding of the
coupling!
For turning the coupling, fasten it to the slings (ropes, chains, etc.) as shown below:

Fig. 2
20
DANGER!
Always use at least 2 slings (ropes, chains, etc.) for lifting.
For turning, please use 2 slings (ropes, chains, etc.) on each side!
Fig. 3
Fig. 4
Carefully set the coupling down on a wooden board / pallet, and secure it against
tilting.
21
5.5 Storage / Packing / Preservation
5.5.1 Storage of turbo coupling
As delivered condition:
The as delivered condition of the Voith Turbo Couplings depends on the mode of
transport and the storage period:
Condition No. 1 represents the as delivered standard. For deviations, please see the
order documents.
- Transport
No. Packing / Measures taken
- admissible storage period
- Device to suit transportation
- Overland / air transport
- Weather protection through means of
1 - Storage up to 6 months
transportation
indoors (building)
- Packed in PE foil
- Device to suit transportation
- Sharp edges protected
- Shrink-wrapped in PE foil
- Sea transport
- Desiccant according to DIN 55473 / 55474
2 - Storage up to 6 months
- Water-proof cardboard or wooden box/crate
indoors (building)
- Inside of box/crate lid lined with sealed
ribbed sheets (Akylux). PVC foil is put
underneath butt joints.
- Sea transport
3 - Storage up to 12 months - As stated in 2
indoors (building) - Improved preservation
- Sea transport - As stated in 2
4 - Storage up to 24 months - Shrink-wrapped in aluminum sandwich foil
indoors (building) instead of PE foil
Table 3
Opening of the packaging:

Foils, that have been opened for inspection upon receipt, are to be re-closed airtight
for further storage. Use a new desiccant, if necessary.
Extension of the storage period:

The allowable storage period may be extended maximal three times according to the
following descriptions. To do so, it is necessary to check the packaging and to possibly
replace it.
After replacing the desiccant, close the foil packings airtight.
External preservation / re-preservation:

Renew the external preservation according to the allowable storage period. Spray
bright metal parts (hub bores, brake disks, etc.) with Houghton Ensis DWG2462.
Internal preservation / re-preservation:

Renew the internal preservation annually (for Condition No. 4: every 2 years). Wet the
turbo coupling inside with an oil selected from the selection list.
Turbo coupling on bearings or mounted (turnable):
For re-preservation, fill the turbo coupling with oil above the axis of rotation center and
rotate the turbo coupling input and output at least once.

Turbo coupling mounted (non-turnable):
Fill the turbo coupling up to the upper fusible plug.
Then drain the oil and close the plug on the turbo coupling according to the specified
procedure. The oil may remain in the turbo coupling for other scheduled re-
preservations if it is ensured that prior to commissioning, the turbo coupling is filled
with fresh oil (oil quantity according to design documents).
22
Selection list for internal preservation agents:

Supplier Designation
ARAL Aral Oil KONIT SAE 20W-20
Mobil Mobilarma 524 (SAE 30)
Houghton Ensis Engine Oil 20
Wintershall Wintershall Antikorrol 20W-20
The recommended operating fluids may also be used for preservation.
Table 4
Protect the turbo coupling against weather and environmental influences if it is in-
stalled in a machine that is not set into operation. Renew the external re-preservation
every 6 months, internal re-preservation once a year.
If necessary, clean the turbo coupling outside before performing re-preservation. For outside
Proceed for external and internal re-preservation as described above. cleaning, see
Chapter 15.1
ATTENTION!
When storing couplings of type "TW" below 0°C, drain the water! Danger of
frost!
Remove the flexible elements (item 1920) prior to cleaning the coupling compo-
nents and applying the long-term preservation!
5.5.2 Storage of flexible elements
EX-PROTECTION!
The storage period of flexible elements (item 1820) until they are used in the
connecting coupling must not exceed 4 years.
The storage area has to be dry and free from dust.
Do not store flexible elements (item 1820) together with chemicals, solvents,
fuels, acids, etc. They need to be protected against light with a high content of
UV rays.
23
6 Voith Turbo Couplings with Constant

Fill
6.1 Function
Blade wheels Shell

Fig. 5
The Voith turbo coupling is a hydrodynamic coupling working to the Föttinger principle.
Its main elements consist of two blade wheels - the pump impeller and the turbine
wheel - enclosed by a shell. Both wheels are provided with bearings relative to each
other. The power is transmitted with hardly any wear, there is no mechanical contact
between the power-transmitting parts. A constant amount of operating fluid is in the
coupling.
The mechanical energy provided by the drive motor is converted into kinetic energy of
the operating fluid in the connected pump impeller. In the turbine wheel, this kinetic
energy is reconverted into mechanical energy.
Three conditions are to be considered with regard to the coupling function:
Standstill:
The whole operating fluid rests in the
coupling.
Fig. 6
24
Starting condition:
The pump impeller accelerates the ope-
rating fluid with increasing motor speed
causing a circulating flow in the working
chamber. The whole blade space of the
turbine wheel is flooded, and the turbine
wheel starts to move as a result of the
kinetic energy of the fluid flow. The coup-
ling characteristic curve determines the
torque curve during start-up.
Fig. 7
Nominal operation:
During nominal operation, only the torque
required by the driven machine is trans-
mitted. The low speed difference bet-
ween pump impeller and turbine wheel
(the so-called rated slip) results in a
stationary flow condition in the coupling.
Fig. 8
6.2 Type designation

For hydrodynamic couplings with constant fill, the type designation is determined as For type
follows: designation,
see the cover
sheet of this
1 2 3 4 5 6 7 8 9 10 11 12 operating manual
Example: 562 T VVS03

562 T VV S 03
25
1 Coupling size (profile diameter in mm)

possible sizes: 154, 206, 274, 366, 422, 487, 562, 650, 750, 866, 1000,
1150
2 Number of hydrodynamic circuits

T: single-circuit coupling
DT: double-circuit coupling
3 Material
"no code letter": Silumin
U: ferrous product
4 Operating fluid
"no code letter": mineral oil
W: water (please consult Voith regarding anti-freezing
agents
5 Delay chamber
"no code letter": without delay chamber
V: with delay chamber
VV: with enlarged delay chamber
6 Draining of delay chamber

"no code letter": time-dependent draining without dynamic refill
F: with centrifugal valves (normally they are open on
standstill)
Y: with dynamic refill
7 Shell
"no code letter" standard design
S: designed as annular chamber
8 Turbo coupling connection

"no code letter": designed for flexible connecting coupling mounted on
the outer wheel side.
N: designed for primary coupling flange and flexible
connecting coupling mounted on the coupling shaft.
9 Design status
First design
"old": A, B, C, E, G, H, J
"new": 01, 02, 03, 04, 05, 06, 07, 08, 09, 10,
10 Throttle plate
"no code letter": without throttle plate
D: with throttle plate
11 Design
"no code letter": standard design
-X: special constructional design
-Z: hydrodynamic special design
12 Possible supplementary information in plain text
26
6.3 Examples for coupling types
6.3.1 Connecting coupling on the input side
Type T (basic type): Type T V:
Fig. 9 Fig. 10
Type T VV: Type T VVS :
Fig. 11 Fig. 12
Type DT : Type DT V:
Fig. 13 Fig. 14
27
6.3.2 Connecting coupling on the output side
Type T N (basic type):
Fig. 15
Type T VN:
Fig. 16
Type T VVN :
Design 1
__ _ __ _ __
Design 2
Fig. 17
Type T VVSN :
Design 1
__ _ __ _ __
Design 2
Fig. 18
28
7 Tightening torques
ATTENTION!
Tighten all screws using a torque-adjustable torque wrench!
1)
Filler plug, Blind screw, Fusible plug, item 0260
1)
item 0390 item 0394 Blind screw, item 0265
Nozzle screw,
item 0455 / 0456
Fastening screw,
item 1830
(for TN: 0780)
Set screw,
item 1845
Fixing bolt,
item 0050
Hexagon Screw,
item 1870
1)
Blind screw, item 0394 /
1)
Fusible plug, item 0395 / Fastening screw,
2)
Sight glass, item 0396 item 1660
Fig. 19
1)
For arrangement and quantity, see the tables in Chapter 15.4.
2)
From size 366.
7.1 Set screws and fixing bolts

The tightening torque for set screw (item 1845) and fixing bolt (item 0050) depends on
their dimension of thread:
Tightening torque in Nm
Thread M6 M8 M10 M12 M16 M20 M24 M30 M36 M42
Set screw 4 8 15 25 70 130

Fixing bolts 23 46 80 195 380 660 1350 2350 3750

Table 5
The tightening torques for set screws apply to property classes
as per DIN EN ISO 898-5 / ISO 898-5.
The tightening torques for fixing bolts apply to screws with property class 8.8 or higher
(as per DIN EN ISO 898-1), oil-moistened and relevant shaft journal material.
29
7.2 Fusible plugs, filler plugs, sight glasses, blind- and nozzle screws
Tightening torque in Nm (dimension of thread)
Coupling Fusible plug, Filler plug, Blind screw, Sight glass, Nozzle screw,
size items items item 0455,
0395 / 0260 item 0390 0394 / 0265 item 0396 item 0456
154 8 (M8) 13 (M10) 8 (M8)
206 13 (M10) 20 (M12x1.5) 13 (M10)
274 13 (M10) 30 (M14x1.5) 13 (M10)
366 to 650 50 (M18x1.5) 80 (M24x1.5) 50 (M18x1.5) 50 (M18x1.5) 48 (M16x1.5)
750 to 1150 144 (M24x1.5) 235 (M36x1.5) 144 (M24x1.5) 144 (M24x1.5) 48 (M16x1.5)
Table 6
7.3 Fastening screws
Tightening torque in Nm (dimension of thread)

1) 1) 1)
Coupling Fastening screw , Fastening screw , Socket head screw Hexagon Screw
size
Nor-Mex G, EPK,
3)
items 1830 / 0780 Item 1660 item 1816 Item 1870
154 9 (M6)
206 23 (M8)
274 68 (M12) 80 (M12)

1)
366 68 (M12) 80 (M12) 49 (M10) 23 (M8)
1)
422 68 (M12) 80 (M12) 49 (M10) 46 (M10)
1)
487 68 (M12) 80 (M12) 49 (M10) 46 (M10)
2)
562 68 (M12) 195 (M16) 125 (M12) 46 (M10)
2)
650 135 (M16) 380 (M20) 200 (M14) 46 (M10)
750 135 (M16) 380 (M20) 46 (M10)
866 250 (M20) 380 (M20) 80 (M12)

1000 250 (M20) -- -- 80 (M12)
1150 580 (M27) -- -- 80 (M12)

Table 7
1)
Screws with property class 8.8 or higher
(as per DIN EN 20898-1 / DIN EN ISO 898-1) are used.
2)
Screws with property class 10.9 or higher
(as per DIN EN 20898-1 / DIN EN ISO 898-1) are used.
3)
See Fig. 68, Chapter 22.2.1, page 101.
30
8 Installation of Basic Coupling Type T
DANGER!
Please observe, in particular, Chapter 4 (Safety) when working on the turbo
coupling!
Outer wheel drive:

The coupling is mounted on the driven machine shaft, and then coupled with the
drive motor via a flexible connecting coupling.
Inner wheel drive (special case):

The coupling is mounted on the drive motor shaft, and then coupled with the driven
machine shaft via a flexible connecting coupling.
8.1 Tools
EX-PROTECTION!
When using or assembling an Ex-coupling use only tools approved for appli-
cation in potentially explosive atmospheres.
Avoid sparking!
Observe standards EN 1127-1 Annex A and EN 1127-1 Chapter 7,
EN 1127-2 Annex B and EN 1127-2 Chapter 7.
This list makes no claim to be complete, check in detail with the assembly plan.
Tools:
Set of open-end wrenches For dimension
Set of ring spanners of thread, see
Socket wrench box (containing hexagon spanners, ratchet, etc.) Chapter 7,
Set of Allan keys page 29
Screwdrivers
Torque wrenches
Hammer, rubber mallet
Set of files
Wire brush
Measuring equipment: For dial gauges,

Dial gauge with holder see
Caliper gauge Chapter 10.4,
External screw-type micrometer according to shaft diameter page 43
Inside micrometer according to hub diameter
Mounting auxiliaries:
Auxiliaries for alignment of motor and gearbox (fastening screws),
e.g. shims for motor and gearbox pedestals (0.1 0.3 0.5 1.0 3.0mm).
Grinding cloth, graining 100, 240
Lifting appliances and load carrying attachments:

Crane. For swivel sizes,
Two shackles with appropriate slings (ropes, chains, etc.) for lifting the coupling. see
Observe Figs. 20 and 21 on page 34 ! Chapter 7.3,
page 30,
Adjustable chains or ropes with sufficient tensile strength (see individual weights).
item 1830 for T,
item 0780 for TN
31
8.2 Preparation
Fig. 22, Check the length of fixing bolt if the length of the shaft journal, on which the
page 35 coupling is mounted, was changed or not indicated to Voith Turbo.
Check the shaft journals of drive motor and driven machine for true radial running.
Clean fitting surfaces on shaft journals and hubs using emery cloth, and check the
fitting dimensions.
In case of mounting, degrease flanges that are to be bolted.
Slightly oil the threads of bolts.
EX-PROTECTION!
Shafts that are connected to the turbo coupling by means of a flexible
connecting coupling, must not exceed 80 °C during operation.
Apply a thin film of lubricant to the shaft journals.
Note!
Use a lubricant with the following characteristics:
Operating temperature range: -
water and wash-out resistant,
protection against fretting corrosion and corrosion.
Proposed lubricants:
Supplier Designation Note
Dow Corning Molykote G-N Plus Paste
Molykote G-Rapid Plus Paste
Molykote TP 42
Fuchs gleitmo 815
Liqui Moly LM 48 Montagepaste
Dow Corning Molykote D 321 R Anti-Friction Coating
Hazardous
Castrol Optimol Paste White T substance!
Paste MP 3
Table 8 Subject to modification due to technical development.
32
ATTENTION!
Keys should be provided with sufficient back clearance, be axially fixed and
run smoothly in the keyways.
Ensure that the balancing method is the same for the shaft and hub. Our
parts are marked according to DIN ISO 8821 / ISO 8821:
- H: Half-key convention,
- F: Full-key convention.
For coupling hubs of sizes 154, 206 and 274 with a key or half-key convention, a
compensation groove can be provided opposite for balancing of unbalance.
For coupling hubs with a key and full-key convention, an identical compensation
groove is provided opposite for balancing of unbalance.
The grooves usable for key connections are marked with Example
H (Half; = half-key convention) or illustration:
F (Full; = full-key convention) on the front of the coupling hub. Fig. 22,
When using a shaft-hub connection with page 35
- one (1) key,
- balancing to half-key convention,
- and should the key be longer than the hub,
remove the key accordingly to avoid unbalance.
Insert the keys.

Prepare suitable tools and lifting appliances; observe the turbo coupling weight! For lifting
appliances, see
Chapter 5.4
Note!
The weight of the turbo coupling is indicated on the cover sheet. The weight is also
stamped with figure stamps on the outer diameter of the coupling flange, if it exceeds
100 kg.
WARNING!
may break under load, with the consequence of most serious or even fatal
injuries!
sound condition.
33
8.3 Mounting
Note!
For mounting the turbo coupling, we recommend using the mounting and removal
devices that can be procured as accessory from Voith Turbo for couplings from size
274.
ATTENTION!
The use of unsuitable working means or methods may cause damage to pro-
perty.
On mounting, do not use
pressure plates,
hammers,
welding torches.
For couplings using water as operating fluid, the hub bore is provided with a
solid film lubricant. The lubricant most not be removed!
Fix the coupling to a suitable lifting

appliance.
Careful warming up of the coupling

hub (to approx. 80 °C) facilitates the
mounting.
Fig. 20
Position the hub on the relevant shaft

journal.
Insert the supplied holding disk.

Note!
For couplings up to size 274 remove
the circlip before inserting the holding

disk, and then re-insert it.
For couplings from size 366, secure
the holding disk against twisting by
means of a roll pin.
Fig. 21
34
ATTENTION!
Depending on the design of the shaft, the coupling hub must be in contact with
the shaft collar or the end face of shaft journal.
Coupling sizes 154 and 206: Coupling sizes 274 to 1150:

Insert a suitable and slightly oiled Slightly oil the mounting spindle. For mounting
threaded rod in the shaft of the rele- Mount the coupling on the shaft jour- devices, see
vant machine. nal using the mounting spindle, the Chapter 8.4,
Mount the coupling on the shaft spacer tube and the holding disk. page 36
journal using a nut and a spacer tube.
Observe the backlash of the key!
Holding disk
Fixing bolt
Roll pin
Compensation
groove, if provided
Fig. 22
Check the holding disk for proper seat. Chapter 7.1,

Tighten the fixing bolt to the specified tightening torque. page 29
The connecting coupling hub has to be secured axially! Usually this is achieved
by means of a set screw pressing on the key. Axial butting to a shaft collar and
securing by means of a holding disk and fixing bolt are also possible. Provide a
spacer ring between hub and shaft collar, if necessary.
Fix the hub to a suitable lifting appliance.

Careful warming up of the connecting coupling hub (to approx. 80 °C) facilitates the
mounting.
Mount the flexible connecting coupling hub on the relevant shaft journal.
Tighten the set screw in the connecting coupling hub, if necessary.
Move the connecting coupling hub with the relevant machine next to the turbo coup-
ling. Observe the correct number and proper seat of the flexible elements in the
connecting coupling!
Fix the machine slightly.

Align the drive. Chapter 10,
Record the mounting process (see Chapter 16). page 40
If the turbo coupling is connected with a flexible pad coupling of type EPK, check Chapter 22.1.1,
that the sheet-metal holder (item 1860) and the ring (item 1810) do not touch. page 100
Record the mounting process (see Chapter 16).
35
8.4 Mounting devices

The following mounting devices are available at Voith Turbo for turbo couplings of
basic type T:
n SW1 B C
A
L2
L1
Fig. 23
A: Mounting spindle L1: Total length

B: Original holding disk L2: Length of spacer tube
C: Coupling hub n: Dimension of mounting spindle
thread
SW1: Width across flats
Coupling L1 L2 n SW1 Article No. of Article No. of

sizes in mm in mm in mm mounting spindle spacer tube
274 520 135 M10 17 TCR.10659840 TCR.10659880

M12 19 TCR.10659850 TCR.10659890
M16 24 TCR.10659860 TCR.10659900
M20 30 TCR.10659870 TCR.10659910
366, 422 520 190 M10 17 TCR.10659840 TCR.11110660
M12 19 TCR.10659850 TCR.11110670
M16 24 TCR.10659860 TCR.11054200
M20 30 TCR.10659870 TCR.11054210
487, 562, 780 245 M16 24 TCR.11110620 TCR.11110680
650, 750 M20 30 TCR.10457720 TCR.10457860
M24 36 TCR.10457730 TCR.10457870
M30 46 TCR.10457740 TCR.10457880
866, 1000, 1150 480 M20 30 TCR.11110630 TCR.11110690
1150 M24 36 TCR.11110640 TCR.11110700

M30 46 TCR.11071880 TCR.11072020
M36 55 TCR.11110650 TCR.11110710
M42 65 TCR.11071890 TCR.11072030
36
9 Installation of Basic Coupling Type TN
DANGER!
coupling!
ATTENTION!
The use of unsuitable working means or methods may cause damage to pro-
perty.
On mounting, do not use
pressure plates,
hammers,
welding torches.
The application is an outer wheel drive. Here the primary coupling flange is mounted
on the motor shaft. Then the turbo coupling is connected with the primary coupling
flange and coupled to the driven machine shaft through a flexible connecting coupling.
37
9.1 Mounting
Have the tools at hand according to Chapter 8.1.

page 32 Make the necessary preparations according to Chapter 8.2.
Connecting coupling
Fastening screw,
item 0780 Set screw
Primary coupling flange 1
Set screw
Version 1
___ _ ___ _ ___
Version 2
Set screw
Primary coupling flange 2
Fig. 24
Mount the primary coupling flange on the motor shaft and secure it with the relevant
set screw in axial direction. Careful warming up of the hub (to approx. 80 °C)
facilitates the mounting.
Mount the connecting coupling hub on the coupling shaft and secure it with the
relevant set screw in axial direction.
Position the turbo coupling in front of the primary coupling flange.
In the event of complete balancing, balancing marks (e.g. 0/0, 1/1, 2/2 etc.) are
provided at the outer periphery of turbo coupling and the primary coupling flange.
Ensure that the balancing marks match!

38
ATTENTION!
Prior to tightening the bolts (item 0780), push the external spigot of turbo
coupling manually into the internal spigot of the primary coupling flange.
Do not tighten the bolts (item 0780) before the two flange surfaces touch each
other without any gap, otherwise there is the risk to damage the centerings!
Correct! Incorrect!
1. No
gap!
Do not cant!
2. Tighten
Fig. 25
Fix the turbo coupling to the primary coupling flange using the relevant bolts (item For tightening
0780). torque, see
Insert the flexible element into the connecting coupling hub. Chapter 7.3,
page 30
WARNING!
Fix the slings (ropes, chains, etc.) to the drive motor only!
Fixing the slings to the coupling may cause damage.
Move the mounted drive motor / turbo coupling unit to the driven machine and
slightly bolt the drive motor.
Align the drive. Chapter 10
Record the mounting process (see Chapter 16, page 67).
39
10 Alignment
DANGER!
coupling!
10.1 Flexible connecting couplings
A flexible connecting coupling couples the turbo coupling with a shaft journal.
After the alignment, deviations of position remain between turbo coupling and shaft
journal. The flexible connecting coupling absorbs these deviations of position.
EX-PROTECTION!
The connecting couplings supplied by Voith meet the requirements for the use
in potentially explosive atmospheres.
If connecting couplings are used that are not included in the Voith scope of
supply, an explosion-proof approval is required, as otherwise there is the risk of
explosion!
10.1.1 Connecting couplings on the input side (outer wheel drive)
Connecting couplings available at Voith Turbo for turbo couplings of basic type T:
Flexible roller coupling Flexible pad coupling

type ERK: type EPK:
L
T
|

DT
L L
Fig. 26 Fig. 27
40
Flexible element coupling Flexible element coupling

type EEK-M: type EEK-E:
L
L
Fig. 28 Fig. 29
Flexible cam coupling Flexible cam coupling

type ENK-SX: type ENK-SV:
L L
Fig. 30 Fig. 31
10.1.2 Connecting coupling on the output side (outer wheel drive)
Connecting couplings available at Voith Turbo for turbo couplings of basic type TN:
Flexible connecting coupling
type Nor-Mex G:
L
Fig. 32
41
10.2 Laid lengths and type allocations turbo coupling / flexible

connecting coupling
Laid lengths L for flexible connecting couplings, as shown in Chapter 10.1:
Laid lengths L in mm
Coupling
size and ERK with EPK EEK-E EEK-M ENK-SX ENK-SV Nor-Mex G
type coupling
143 +1 - - - - - -
165 +1 - - - - - -
183 +1 - - - - - -
223 +1 - - - 110.5 ±1.5 56.5 ±1.5 -
255 +1 78 ±1 - - 158.5 ±2 67 ±2 -
295 +1 78 ±1 159 ±2 67 ±2 158.5 ±2 67 ±2 -
- 78 ±1 159 ±2 67 ±2 158.5 ±2 67 ±2 178.5 +1
- 102 ±1 173 ±2 72 ±2 173 ±2 72 ±2 200.5 +1.5
- 106 ±1 190 ±2 88 ±2 190 ±2.5 87.5 ±2.5 223.5 +1.5
- 116 ±1 221 ±2 103 ±2 221 ±2.5 102.5 ±2.5 269.5 +2
- 152 ±1.5 274 ±2.5 126 ±2.5 274 ±2.5 125.5 ±2.5 311.5 +2
)
311.5 +2 *
- 163 ±1.5 - - 276 ±2.5 127.5 ±2.5
335.0 +2.5
- 189 ±1.5 - - - - -
- 210 ±1.5 - - - - -
- 210 ±1.5 - - - - -
- 210 ±1.5 - - - - -
Table 9
)
* Laid length L = 311.5 for Nor-Mex G - size 265
Laid length L = 335 for Nor-Mex G - size 295
ATTENTION!
In order to avoid any constraining forces, it is vital to observe the laid lengths!
Observe, in particular, displacements due to temperature changes.
EX-PROTECTION!
If shaft ends axially protrude the connecting coupling hub, measure the dimen-
sions to make sure that a distance of 6mm to the turbo coupling is kept.
10.3 Alignment tolerances

Excessive misalignment may cause damage to the material.
Observe the values for true radial and axial running under all operating con-
ditions.
Observe, in particular, displacements due to temperature changes.
42
Note!
The smaller the radial and angular displacement between turbo coupling and shaft
journal
the higher the lifetime and reliability of the machine,
the smoother the operation.
The maximum permissible alignment tolerances apply to:

radial runout in the radial plane of flexible elements (maximum permissible radial
deflection of dial gauge!)
axial runout, measured over the largest connecting coupling diameter (maximum
permissible axial deflection of dial gauge!).
Maximum permissible alignment tolerances for the radial and axial deflection of
dial gauge when using the connecting couplings shown in Chapter 10.1:
Coupling sizes Speed range

in rpm
154 to 274 0.4 mm 0.4 mm 0.3 mm 0.2 mm

366 to 487 0.6 mm 0.4 mm 0.3 mm 0.2 mm
562 to 1150 0.8 mm 0.6 mm 0.4 mm 0.3 mm
Table 10
The values mentioned above describe the maximum permissible radial and axial deflection of
dial gauge!
ATTENTION!
Observe the maximum permissible speed!
It is not allowed to exceed the maximum permissible speed!
You will find the maximum permissible speed on the cover sheet of this opera-
ting manual.
Maximum speed:
(see cover sheet)
10.4 Alignment
Note!
For alignment, support the motor feet using shims or foil sheets. It would be advan-
tageous to use claws for adjusting screws on the foundation for lateral movement of
the input unit.
Alignment methods and their accuracy:
Method Accuracy
LASER optical very accurate
Dial gauges accurate
Feeler gauge, depth gauge, caliper gauge less accurate
Table 11
43
Proposals on how to fit dial gauges:
Fig. 33 Fig. 34
Fig. 35 Fig. 36
Procedure:
Chapters 8 or 9, Mount the turbo coupling.

page 31 or 37
Align the input shaft to the output shaft.

Fix the motor and gearbox (input and output unit) to the foundation - stability de-
pends on the whole unit and has to be guaranteed!
For alignment Check the alignment after tightening all screws, and correct it, if necessary.
tolerances, see In case of misalignment on connecting couplings, an unequal gap forms on the
Chapter 10.3, periphery.
page 42
Chapter 16, Document the alignment.

page 67
44
11 Operating fluids
ATTENTION!
Use only the operating fluid mentioned on the cover sheet of this operating
manual.
Unsuitable operating fluids may damage the turbo coupling permanently!
Consult Voith Turbo if you want to use an operating fluid not mentioned.
ATTENTION!
Operating fluids are detrimental to health and may pollute the environment.
Dispose of used operating fluid via an authorized collecting station in accor-
dance with the national statutory provisions.
Make sure that no operating fluid gets into the ground or water!
DANGER!
Hot operating fluid could spray off from defective components or fusible plugs,
seriously injuring persons!
Maintain the turbo coupling regularly!
Experts only are allowed to work on the turbo coupling!
11.1 Requirements to be fulfilled by the operating fluid mineral oil

)
Viscosity class ................................
ISO VG 32 to DIN ISO 3448 *
2
Viscosity on start-up .......................
less than 15000 mm /s (cSt)
Pour point ................................ 4 °C below the minimum ambient temperature or
lower
Flash point ................................greater than 180 °C and at least 40 °C above the
nominal response temperature of the fusible plugs
Fire point .........................................
at least 50 °C above the max. surface temperature
(only relevant for couplings (see Chapter 1)
used in potentially explosive
atmospheres ( ))
Resistance to aging ........................
aging-resistant refined product
Cleanliness grade ...........................
Minimum requirements:
21/19/16 as per ISO 4406
Sealing compatibility .......................

NBR (Nitril-Butadien caoutchouc) and
FPM/FKM (fluor caoutchouc)
Advantageous additional qualities
FE 8 test: Abrasion of rolling elements < 30 mg

D7,5 / 80-80 Abrasion of cage < 100 mg
)
* In special cases, ISO VG 10 - 46 can be used
45
11.2 Mineral oils
11.2.1 Usable operating fluids

)
Hydraulic oils HLP 32 to DIN 51524, Part 2 *
Lubricating oils CLP 32 to DIN 51517, Part 3
)
Steam turbine oils LTD 32 to DIN 51515, Part 1 *
HD engine oils SAE 10 W
ATF type A Suffix A (TASA) and type Dexron II, IID, IIE, III, MERCON
M-891205 and M 921253
)
* In special cases, ISO VG 10 - 46 can be used
11.2.2 Operating temperature frequently above 100°C
FPM/FKM is recommended as sealing material; when selecting the mineral oil, ensure
that it provides excellent oxidation resistance.
11.2.3 Proposed operating fluids
Pour Flash Fire

Supplier Designation point point point Class FE8 Test
in °C in °C in °C satisfied
Addinol Hydraulic oil HLP 32 -21 195 HLP
Agip Agip Oso 32 -30 204 HLP
Agip Blasia 32 -29 215 CLP
Avia Avia Fluid RSL 32 -27 214 237 HLP
Gear RSX 32 S -33 210 231 CLP
BP Energol HLP-HM 32 -30 216 HLP
Castrol Alpha EP 32 -27 218 250 CLP yes
Hyspin SP32 -28 200 HLP yes
Hyspin AWS 32 -27 200 HLP
CEPSA HIDROSIC HLP 32 -24 204 HLP
EP 125 -30 206 HLP
ExxonMobil DTE 24 -27 220 HLP
Mobilfluid 125 -30 225 CLP/HLP
Mobil SHC 524 -54 234 234 HLP
Fuchs Renolin MR10 -30 210 HLP
Renolin B10 -24 205 HLP
Klüber Lamora HLP 32 -18 200 HLP
Kuwait Q8 Haydn 32 -30 208 232 HLP

Petroleum Q8 Holst 32 -30 208 234 HLP
Optimol Hydo MV 32 -38 209 234 HLP
Ravenol Hydr. oil TS32 -24 220 HLP

Shell Tegula Öl 32 -33 210 HLP
Tegula V32 -33 211 HLP yes
Tellus S32 -30 215 HLP
SRS - Wintershall Wiolan HS 32 -24 220 240 HLP
Salzbergen Wintershall Wiolan HF 32 -27 200 240 HLP yes
Texaco Rando HD 32 -30 196 246 HLP
Total Azolla ZS 32 -27 210 220 HLP
Table 12
46
Operating fluids for low-temperature application:
Pour Flash Fire

Supplier Designation point point point Class FE8 Test
in °C in °C in °C satisfied
Castrol AWS 10 -39 160 HLP
Texaco Capella Oil WF 32 -39 188 HLP
Aral Vitam GF 10 -40 165 HLP
Texaco Capella Oil WF 22 -51 166 HLP
Shell Morlina 10 -57 150 HLP
Table 13
The above oil list is a recommendation and does not claim to be complete.
ATTENTION!
- The values mentioned for the pour point, flash and fire point are approximate
values and data originating from the oil suppliers. These may vary and Voith
Turbo does not assume any warranty!
Country-specific production of the basic oil may result in different values.
- In case of critical applications, we recommend consulting the respective oil
supplier!
11.3 Proposed operating fluids for special requirements
Operating fluid suitable for the use in the food industry

Supplier Designation Pour point Flash point Class
in °C in °C
Klüber Summit HySyn FG 32 -45 >230 HLP
Note: USDA H1-Registration satisfies the FDA requirements.
High-flash point operating fluid

in °C in °C
Fuchs Renosafe DU 46 -33 305 HFD-U
Note: Fuchs Renosafe DU 46 is a high-flash point pressure fluid of viscosity class
ISO VG 46 and contains neither chlorinated hydrocarbons nor phosphorus
acid ester. The density of this fluid is lower than the density of water.
Biodegradable operating fluid

in °C in °C
Fuchs Plantosyn 3268 -36 230 HEES
Note: Fuchs Plantosyn 3268 is a quickly biodegradable fluid of viscosity class ISO
VG 46 corresponding to VDMA 24568. The water risk class is 1 and the
density of this fluid is lower than the density of water.
47
11.4 Requirements to be fulfilled by the operating fluid 'water'
ATTENTION!
It is allowed to fill in water only in a coupling of type TW!
Sealing compatibility ................................

NBR (Nitril-Butadien caoutchouc)
pH-value
The water used should

to the greatest possible extent, be free from solid matters,
contain only a low amount of salt,
contain only a low concentration of other additives.
11.4.1 Usable operating fluids
Normally, drinking water satisfies these requirements.
You will find the 11.4.2 Water used as operating fluid for turbo couplings with centrifugal
type designation valves (types
of your turbo
coupling on the For turbo couplings with centrifugal valves it is necessary to add a low amount of
cover sheet of this grease to the water. The grease guarantees a permanent functioning of the centrifugal
operating manual. valves.
In the as delivered condition, the corresponding amount of grease is already in the
working chamber of the coupling.
ATTENTION!
s neces-
sary to add a low amount of grease to the water!
Amount of grease required:
Coupling size 366 422 487 562 650 750 866

Amount of grease 80 g 100 g 120 g 150 g 180 g 210 g 240 g
Table 14
Requirements to be fulfilled by the grease:

Consistency class 2 to NLGI

Thickeners anorganic thickener (gel),
non-alkaline when water is added
Service temperature -
Material compatibility NBR (Nitril-Butadien caoutchouc)
Table 15
48
Proposed greases:
Supplier Designation
Agip GR NF
Aral Aralub HTR 2
Autol PRECIS Bentonit grease
Avia Aviation 2 EP
BP Energrease HTG 2
ELF Staterma Mo 2
ESSO HT Grease 275
Fuchs Renogel FHT 2
Klüber Pentamo GHY 133
Mobil Mobiltemp SHC 100
Oest High melting-point grease 4854
Optimol Optitemp HT 2
Shell Darina Grease 2
Texaco Thermatex FRA 1
Total Caloris 2
Valvoline High melting-point grease w-k
Wintershall Wiolub HTF 940
Table 16
The above grease list is a recommendation and does not claim to be complete.
49
12 Fill, Filling Check and Draining

The quantity and type of operating fluid used substantially determines the perfor-
mance of the coupling.
A too high quantity stresses the drive motor more on start-up and results in a higher
stall torque.
A too low quantity thermally loads the coupling more and results in a low stall
torque.
DANGER!
coupling!
CAUTION!
Operating fluids may cause irritations or inflammation when in contact with
skin and mucous membranes.
Please observe the instructions stated in the safety data sheets.
Please always wear safety goggles for any work to be done in connection
with the operating fluid!
Should you get any operating fluid in your eyes, rinse them immediately
using a lot of water and consult a physician without delay!
After finishing work, carefully clean your hands with soap.
Start to work on the coupling only after it has cooled down below 40 °C as
otherwise there is the risk of burning!
Impurities in the operating fluid cause higher wear on the coupling and
damages to bearings so that there is no explosion protection any no longer.
Make sure that any containers, funnels, filling tubes, etc. used for filling the
coupling, are clean.
ATTENTION!
Observe the quantity to be filled in that is indicated on the cover sheet of this
operating manual.
An overfilling is not permitted! This would lead to an undue high internal
pressure in the coupling, which may destroy the coupling.
Fill and drain the coupling only after it has cooled down.
Do not mix different types of operating fluids.

Use only the operating fluid mentioned on the cover sheet of this operating
manual.
Ensure that the original sealing rings used are in sound condition.
Note!
You will find the tightening torques in Chapter 7, from page 29, please observe
Fig. 19 on page 29.
50
12.1 Filling the coupling

Note!
Turbo couplings are shipped unfilled.
If operating fluid is included in the scope of supply, it is shipped in a separate
container.
For quantity,
12.1.1 How to fill couplings installed in horizontal position see cover sheet
Couplings of sizes 154 - 274:

Turn the coupling until the fillter plug (item 0390) is on top.
Couplings of sizes 366 - 1150:
Turn the coupling until the filler plug (item 0390) that is closest to the sight glass
(item 0396) is on top.
Remove the filler plug.
Remove the top fusible plug (item 0395 or item 0260) for pressure compensation.
For grease
For turbo couplings with centrifugal valves and water used as operating medium quantity, see
(type TW...F ...), upon refilling, fill in a certain amount of grease into the working Chapter 11.4.2,
chamber of the coupling. page 48
Fill in the specified operating fluid quantity ( Chapter 11) through a fine strainer For operating
- mesh size 25 µm for turbo couplings using oil as operating medium fluid and filling
- mesh size quantity, see
through the filter plug opening. cover sheet
Tighten the filler plug.
If the coupling is provided with a sight glass (item 0396), tighten the sight glass.
Direction of rotation Direction of rotation

Vertical Vertical
axis axis
z z
3 Counting 3 Counting
Filling level 2 direction 2 direction
1 1
Sight glass or fusible plug Sight glass or fusible plug
Fig. 37
Turn the coupling until the operating fluid is just visible on the sight glass (if exis-
ting) or until the operating fluid can be seen on the (still) removed fusible plug, but
is not yet leaking out.
Determine the number z of the flange screws from the sight glass to the vertical z = _____
axis. The first screw is the one in counting direction, after the intersection line
through the sight glass or the fusible plug.
For assembly test
For later filling level checks, record the number z of screws determined. In
report, see:
addition, mark the coupling or the protective cover. Chapter 16.1,
page 68
If not yet done, tighten the fusible plug.
For tightening
After a trial run (with protective cover!), check the coupling for leaks.
torques, see
Chapter 7.2,
page 30
51
12.1.2 How to fill couplings installed in vertical position
Shell (item 0190) positioned on top: Outer wheel (item 0300) positioned on top:
Fusible plug /
Blind screw
Level mark
Level check device
Screw plug
Connection for
level check device
Fig. 38
Remove the two top screws

(either two fusible plugs or two blind screws).
Remove the screw plug.
Fill the specified operating fluid quantity through a fine strainer (mesh size 30µm)
into a screw hole. The other screw hole serves for pressure compensation.
Re-close the screw holes on top using the screws (items 0260, 0265, 0394, or
0395). Rotate the coupling with nominal speed for a short time to let the operating
fluid spread evenly.
Remove again two screws being on top.
The level check Fit the level check device to the connection provided for this purpose.
device is available
Provide the level mark on the coupling or protective cover for later level checks.
at Voith Turbo as
accessory for Remove the level check device.
couplings from
Tighten slackened screws.
size 366
Tightening torque for the screw plug: 30 Nm (M14x1.5).
After a trial run (with protective cover!), check the coupling for leaks. Subject to modification due to technical development.
52
12.2 Filling check

You will find the filling quantity on the cover sheet of this operating manual.
12.2.1 Level check for couplings installed in horizontal position
Note!
From size 366 turbo couplings are equipped with a sight glass in the outer wheel;
the position of the sight glass is marked by an arrow.
If no sight glass is provided, turn the coupling until a fusible plug is on top. Then Fig. 37:
unscrew and remove this fusible plug. Page 51
Turn the coupling until the operating fluid is just visible on the sight glass or until the
operating fluid can be seen on the removed fusible plug, but is not yet leaking out.
Determine the number z of the flange screws from the sight glass or fusible plug to For number z,
the vertical axis. The first screw is the one in counting direction, after the inter- see Chapter 12.1,
section line through the sight glass or fusible plug. Page 51
Compare the number of screws determined with the number of screws determined
during filling. Please observe the marking provided additionally on the coupling or
guard.
In case of deviations, correct the filling quantity!
Re-insert and tighten any removed fusible plug. For tightening
After a trial run (with protective cover!), check the coupling for leaks. torques, see
Chapter 7.2,
Page 30
12.2.2 Level check for couplings installed in vertical position Fig. 38,
Page 52
Note!
The level of couplings from size 366 is checked using a level check device. This
level check device is available as accessory at Voith Turbo.
Couplings up to size 274 need to be drained for the level check, and then be re-
filled.
Remove a screw being on top (fusible plug or blind screw) for ventilation purposes. Fig. 38,
Page 52
Remove the screw plug.
Fit the level check device to the connection provided for this purpose.
Compare the level with the marking that was provided when filling in. Chapter 12.1.2,
page 52
In case of deviations, correct the filling quantity!
Remove the level check device.

Tighten slackened screws.

After a trial run (with protective cover!), check the coupling for leaks.
53
12.3 Draining the coupling
ATTENTION!
Improper disposal of operating fluid may cause most severe damages to the en-
vironment! On disposal, please observe the applicable laws and the producers'
or suppliers' instructions!
Provide suitable containers to collect the operating fluid.
12.3.1 How to drain couplings without delay chamber that are installed in
horizontal position
Turn the coupling until one fusible plug faces the bottom.
Remove this fusible plug.
For tightening For ventilation, remove one opposite filler or fusible plug.
torques, see
After the coupling has drained, insert and retighten the plugs. Use original sealing
Chapter 7.2,
rings only.
Page 30
12.3.2 How to drain couplings with delay chamber that are installed in
horizontal position
Turn the coupling until one fusible plug faces the bottom.
Remove this fusible plug.
For ventilation, remove one opposite filler or fusible plug.
Wait until the coupling working chamber has drained.
Coupling size 274: Coupling sizes 366 to 1150:

Re-insert and tighten the fusible and filler Remove the nozzle screw (item
plugs. 0455 / 0456).
Switch on the drive motor for about half a Turn the coupling until the nozzle
minute to maximal one minute. The screw hole faces the bottom.
operating fluid in the delay chamber
Wait until the delay chamber has
drains into the working chamber. Please
drained.
observe the safety regulations!
Tighten the nozzle screw.
Remove the fusible plug again.
Table 17
For tightening Turn the coupling until the opening of the fusible plug is at the bottom.
torque, see
After the working chamber of the coupling has fully drained, re-insert and tighten
Chapter 7.2,
the plugs.
page 30
54
12.3.3 How to drain couplings installed in vertical position
For ventilation, remove one blind screw or fusible plug on the top side of the Fig. 38,
coupling. Page 52
Up to coupling size 274: From coupling size 366:
Remove one blind screw or fusible Remove the connection for the level
plug being at the bottom check device.
Table 18
After the coupling has drained, re-insert and tighten the plugs.
Tightening torque for the connection: 80 Nm (M24x1.5).
Note!
On account of its design, the coupling cannot completely drain when installed!
55
13 Commissioning
DANGER!
coupling!
A commissioning not performed properly could cause personal injuries, or harm
to property and the environment!
Experts only are allowed to perform commissioning, in particular, first starting
of the turbo coupling!
Secure the machine against unintentional switching on!
Please check with reference to the marking whether the coupling is approved
for potentially explosive atmospheres.
Provide a protective cover (e.g. perforated plate, size of holes approx. 10-12
mm) around the coupling. This protective cover has to:
prevent intrusion of damaging foreign particles (stones, corrosive steels,
etc.).
withstand the impacts to be expected without excessive damages, thus
preventing contact of the coupling with the protective cover. Especially
couplings with outer parts made of aluminum must not get in contact with
corrosive steel or iron.
collect spraying solder of fusible plugs.
collect operating fluid leaking out to prevent contact with parts (motor,
belt) that might ignite or catch fire.
provide sufficient ventilation to maintain the maximum surface tempera-
ture specified.
A perforated plate with 65% hole cross section enclosing the coupling on
all sides does not reduce the ventilation (consult Voith, if necessary).
guarantee safety distances to prevent hazard zones being reached (DIN
EN ISO 13857).
For constructional proposals for protective covers, please contact Voith
Turbo.
The turbo coupling is not equipped with insulated ball and roller bearings!
The passage of current and stray currents may come from connected machi-
nes (e.g. VFD).
In order to avoid static charging, it is not allowed to install the turbo coupling
with an insulation on both sides.
Provide an equipotential bonding between the input and output end.
Provide machines on which overspeed is possible, with a device preventing
safely overspeed (example: brake or backstop).
DANGER!
Loose clothes, long hair, jewelry, rings or loose parts could get stuck and be
drawn in, or wound up causing serious injuries, damage to the turbo coupling or
harm to the environment.
Only wear close-fitting clothes when working!
Cover long hair in a hair net!
Do not wear jewelry (e.g. necklaces, rings, etc.)!
Never operate the coupling without protective cover!
56
ATTENTION!
Never operate the turbo coupling without operating fluid!
On account of the type of bearings used for standard turbo couplings of
sizes 366, 422, 487, 562, 650, 750, 866, 1000 and 1150, at least one standstill
within three months is required.
On account of the type of bearings used for the standard turbo couplings of
sizes 154, 206 and 274, at least one standstill per week is required.
Check that the flexible connecting coupling has no mechanical contact.
Check the reference dimension on the connecting couplings prior to commis-
sioning (see Chapter 15.2.1).
For technical
If you use a BTS-Ex to limit the maximum surface temperature, make sure not data, see
to exceed the maximum permissible temperature of the turbo coupling when Chapter 1,
switching on the motor. Page 5
After installing and filling the coupling, commission the same paying atten-
tion to any irregularities.
Document the commissioning phase (see commissioning report, Chap-
ter 16.2).
EX-PROTECTION! / Note!
A marking according to Directive 94/9/EC and EN13463 has been provided on the
periphery of the couplings. The marking specifies in what potentially explosive
atmospheres and under what conditions the use is permitted.
Example:
Note!
The turbo coupling may be used for any direction of rotation.
The direction of rotation of driven machine may be specified! The direction of rota-
tion of the motor must be in accordance with the specified direction of rotation of
the driven machine!
If the motor is started with star/delta connection, switch over from star to delta after
2...5 seconds at the latest.
In case of a multi-motor drive, you should determine the load of the individual
motors. Great differences regarding motor load may be balanced by an appropriate
adjustment of the respective coupling filling volumes. However, do not exceed the
maximum permissible coupling filling level!
57
14 Operation
DANGER!
coupling!
An operation presupposes the successful commissioning according to Chap-
ter 13.
Perform the necessary maintenance work time-/operating time-based according to

Chapter 15.
If nevertheless any malfunctions occur, eleminiate such according to Chapter 18.
15 Maintenance, Servicing
Definition of terms according to IEC 60079:
Maintenance and Repair: A combination of all activities conducted in order to maintain

an item in a condition or to re-store it to a condition that meets the requirements of the
respective specification and ensures performance of the required functions.
Inspection: An activity involving the thorough examination of an item in order to provide

a reliable statement as to the condition of said item, performed without disassembly or,
if necessary, by only partial disassembly, supplemented by measures such as the
taking of measurements.
Visual inspection: A visual inspection is an inspection in which visible defects, such as

missing screws or bolts, are identified without the use of access equipment or tools.
Close-up inspection: An inspection in which, in addition to the areas covered by the

visual inspection, defects such as loose bolts, that can only be detected by using
access equipment, e.g. mobile stair steps (if required) and tools are identified. For
close-up inspections, a housing does not usually need to be opened or the power to
the equipment be cut off.
Detailed inspection: An inspection in which, in addition to the areas covered by the

close-up inspection, defects such as loose connections, that can only be detected by
opening housings and/or using tools and test equipment (if required) are identified.
Maintenance/repair measures may only be carried out by skilled, trained and

authorized personnel or persons trained by Voith Turbo.
Components may only be replaced by original spare parts.

Regularly clean equipment used in potentially explosive atmospheres. The intervals
are specified by the operator according to the environmental impact to which the
equipment is exposed on the jobsite, e.g. in case of a dust accumulation of approx.
0.2 ... 0.5 mm.
After the maintenance and/or repair, all barriers and notices which have been
removed have to be returned to their original positions.
58
DANGER!

coupling!
On account of improper courses of action and insufficient access paths, per-

sons may fall and be seriously injured.
Please always keep access paths free to the turbo coupling!
Possible consequences of improper servicing and maintenance could be death,

serious or minor injuries, damage to property and harm to the environment.
Skilled persons only are allowed to carry out maintenance and repair work!
Switch off the unit in which the coupling is installed and secure the switch
against switching on.
For all work performed on the turbo coupling ensure that both, the drive motor
and the driven machine have stopped running and a start-up is absolutely im-
possible.
Re-mount all protective covers and safety devices immediately after completion
of the servicing and maintenance work, and check their function!
59
Maintenance schedule:
Time Maintenance work

Routine inspection Inspect the machine for irregularities
every 500 operating hours, (visual inspection: for leaks, noise, vibrations).
every 3 months, at the latest
Check the foundation bolts of the machine,
and if necessary, re-tighten them with the
specified torque.
3 months after commissioning, at Check the electrical system for sound
the latest, condition if temperature monitoring is required
then every year in Chapter 1 (detailed inspection).
Connecting couplings Check the flexible elements (item 1820), and
EEK, ENK, Nor-Mex G: replace them by sets of original spare parts
3 months after commissioning at when the wear limit has been reached; if
the latest, they are worn, metallic contact of the
then every year, however, every connecting coupling halves may cause
4,000 operating hours at the latest sparking.
and/or deviatingly to 15.2.2 There is the danger of fire and explosion!
(See Chapters 15.2 and 22).
Connecting couplings Check the flexible elements (item 1820), and
ERK, EPK: replace them by sets of original spare parts
3 months after commissioning at when the wear limit has been reached; if
the latest, they are worn, the flexible elements may
then every year and/or deviatingly break.
to 15.2.2
After 3 years or 5 years (for ERK Replace the flexible elements by sets of
and EPK couplings) of use original spare parts.
If mineral oil is used as operating - Change the operating fluid or
fluid: check it for aging and
Every 15000 operating hours - determine the remaining service life
(see records, Chapter 16)!
Consult the operating fluid supplier with regard
to the permissible values
(see Chapters 11 and 12).
On response of a fusible plug Replace all fusible plugs and change the
operating fluid ( Chapter 15.4).
Check the operating conditions (Chapter 1).
Check the devices provided for temperature
monitoring (see Chapter 20: MTS, BTS(ex),
BTM).
In case of leaks On the occasion of an overhaul, have shaft
sealing rings, sealing rings and flat seals
replaced by skilled persons authorized by
Voith.
In case of noise, vibrations Have the cause determined and eliminated by
skilled persons authorized by Voith.

In case of impurities Cleaning ( Chapter 15.1).

After contact with materials Replace the flexible elements by sets of
against which NBR (Nitril- original spare parts.

Butadien-caoutchouc) and PUR
(polyuretane) are not or only
partially resistant (close-up
inspection).
Table 19
Carry out any maintenance work and routine inspections according to the report.
Record the maintenance work carried out (for report forms, see Chapter 16.3).
60
EX-PROTECTION!
For explosion-proof couplings, the following maintenance work needs to be
carried out in addition:
Maintenance intervals Maintenance work

In case of impurities or a dust Cleaning ( Chapter 15.1).
layer thickness of 0. .5 mm or
more
It is the customer's own responsibility
to define maintenance intervals
according to the environmental
influences prevailing on the jobsite.
For maintenance interval, Replacement of ball and roller bearings
see Chapter 1 ( Chapter 15.3.3).
Table 20
EX-PROTECTION!
It is vital to carry out all maintenance work according to the schedule in order
to guarantee a proper operation within the meaning of the explosion-protec-
tion.
Immediately remove any combustible layers of dust on the turbo couplings.
If the machine is not cleaned in regular intervals, there is the risk of fire and
explosion!
To ensure a good ventilation of the coupling, it is vital to check and clean the
protective cover in regular intervals.
If a fusible plug has responded, immediately cover or close the opening that
occurred in order to prevent the ingress of combustible dust into the coup-
ling.
15.1 Outside cleaning
ATTENTION!
Please ensure that the cleaning agent is compatible with the sealing mate-
rials used, NBR and FPM/FKM!
Do not use high-pressure cleaning equipment!
Be careful with gaskets. Do not apply a water and compressed-air jet.
Clean the coupling with a grease solvent, as and when required.

61
15.2 Flexible connecting coupling
15.2.1 How to check the flexible elements for wear

Chapter 10.1,
page 40
Connecting coupling of type Connecting coupling type
ERK, EEK, EPK, Nor-Mex G: ENK:
Reference
dimension
Reference
dimension
Turn the turbo coupling until the flexible elements touch without load.
Provide markings opposite on the hub Measure the distance of the rollers in
and the flange or the 2nd hub. direction of rotation on the outer dia-
meter of the hub.
Turn the turbo coupling in the opposite direction until the flexible elements touch
without load.
Measure the distance of the markings Measure the distance of the rollers in
in peripheral direction on the outer direction of rotation on the outer dia-
diameter of the hub or on the ring in meter of the hub.
the area of the outer diameter. The reference dimension is the
Document the reference dimension. smallest value of both measurements.
Chapter 16, Document the reference dimension.
page 67
Permissible reference diamentions of the flexible connecting couplings in mm

Coupling ERK EPK EEK-E ENK-SX Nor-Mex G
size EEK-M ENK-SV
154 <6
206 <6 > 14
274 <8 <8 > 14
366 < 12 <8 > 15 < 12
422 < 12 <8 > 16 < 12
487 < 12 < 9 > 16 < 11
562 < 12 < 11 > 13 < 10
650 < 12 < 10 > 13 <7
750 < 12
866 < 12
1000 < 12
1150 < 12
Table 21
Note!
Unusually quickly worn flexible elements may be a sign of improper alignment!
62
15.2.2 Maintenance intervals
If, based on the previous wear, wear of 80% of the table value is to be expected until
the next check is performed, replace the flexible elements or shorten the maintenance
intervals accordingly.
On account of changed operating conditions, an increase in wear has to be conside-
red.
ATTENTION!
Re-align the unit if the connected machines were displaced while replacing the
flexible elements.
15.3 Bearings
15.3.1 Bearing lubrication when mineral oil is used as operating fluid
Please observe the following in order to guarantee lubrication of the bearings:
ATTENTION!
On account of the type of bearings used for standard turbo couplings from
size 366, at least one standstill is necessary within three months.
On account of the type of bearings used for standard turbo couplings up to
size 274, at least one standstill is necessary within one week.
Note!
Couplings of all sizes can be provided with special bearings that allow continuous
operation and contain a lifetime grease filling.
15.3.2 Bearing lubrication when water is used as operating fluid
The turbo coupling bearings are filled with lifetime grease when water is used as
operating fluid. Re-lubrication is not necessary.
15.3.3 Replacement of bearings / re-lubrication

EX-PROTECTION!
On the occasion of an overhaul of the turbo couplings, have the bearings
replaced / re-lubricated by skilled persons authorized by Voith.
For replacement
of roller bearings,
see Chapter 1,
page 5
63
15.4 Fusible plugs
The fusible plugs protect the turbo coupling against damage due to thermal
overload.
For nominal When the nominal response temperature is reached, the solder core of the fusible
response plugs melts and the operating fluid leaks out.
temperature of
fusible plugs,
see cover sheet Fusible plugs are identified by
the engraved nominal response temperature in °C,
a color coding:
Nominal response tem- Color coding Operating fluid

perature Oil Water
95 °C without (tinned) X X
110 °C yellow X X
125 °C brown X -
140 °C red X -
160 °C green X -
180 °C blue X -
Table 22
WARNING!
Use original fusible plugs only with the required nominal response tempera-
ture (see cover sheet), as well as the required version SSS or SSS-X (see
Chapter 1)!
Do not replace any fusible plugs by blind screws!
Do not alter the arrangement of the fusible plugs.
When water is used as operating fluid, only fusible plugs with a max. nominal
response temperature of 110 °C are permitted!
ATTENTION!
There is a MTS and/or BTS switching element or a blind screw opposite the
sight glass (position is marked by an arrow).
Insert a weight-tolerated BTM blind screw opposite the BTM switching
element to avoid unbalance.
Do not insert the BTM switching element opposite a sight glass, blind screw
or fusible plug having a lighter weight. There is the risk of unbalance!
For tightening After one fusible plug has responded, replace all fusible plugs, and change the
torque, see operating fluid.

Chapter 7.2,
page 30
64
15.4.1 Fusible plugs in couplings not suitable for use in potentially explosive
atmospheres
Number and position of fusible plugs, blind screws and switching elements for outer
wheel drive (inner wheel drive):
Outer wheel (item 0300) Shell (item 0190)

Fusible Blind MTS, BTS, Sight Fusible Blind MTS, BTS
Coupling 3) 4)
plug screw BTM glass plug screw switching
size and 2)
switching element
type 2)
Item 0395 Item 0394 element Item 0396 Item 0260 Item 0265
1)
1 (1 ) - (2) - (1) - - (-) - (-) - (-)
1)
2 (2 ) - (2) - (1) - - (-) - (-) - (-)
1)
1 (1 ) - (2) - (1) - - (-) 1 (1) 1 (-)
1)
2 (2 ) - (2) - (1) - - (-) - (-) - (-)
1)
1 (1 ) - (2) - (1) - - (-) 1 (1) 1 (-)
1)
2 (2 ) - (2) - (1) - - (-) - (-) - (-)
- (-) 5 (5) 1 (1) 1 1 (1) 1 (1) - (-)
- (-) 7 (7) 1 (1) 1 2 (2) - (-) - (-)
- (-) 7 (7) 1 (1) 1 2 (2) - (-) - (-)
- (-) 7 (7) 1 (1) 1 2 (2) - (-) - (-)
5) 5)
- (-) 5 (5) 1 (1) 1 3 (3) 1 (1 ) - (-)
- (-) 5 (5) 1 (1) 1 2 (2) 2 (2) - (-)
5) 5)
- (-) 5 (5) 1 (1) 1 3 (3) 1 (1 ) - (-)
- (-) 3 (3) 1 (1) 1 4 (4) - (-) - (-)
3 (3) - (-) - (-) 1 - (-) 4 (4) 1 (1)
6 (6) 1 (1) 1 (1) 1 - (-) - (-) - (-)
- (-) 5 (5) 1 (1) 1 4 (4) - (-) - (-)
8 (8) 3 (3) 1 (1) 1 - (-) - (-) - (-)
Table 23
1)
Radial arrangement
2)
The MTS, BTS or BTM switching element is inserted instead of a blind screw.
3)
The blind screw opposite the BTM has to be replaced by the counterweight.
4)
Position is marked by an arrow.
5)
ATTENTION!
and 1150 are arranged in the outer wheel.
If a brake is used, select the position of the fusible plugs so that they do not
spray onto the brake.

Please check that and, if necessary, change the fusible plugs for the opposite
blind screws.
65
15.4.2 Fusible plugs in couplings suitable for the use in potentially explosive
atmospheres
Number and position of fusible plugs, blind screws and switching elements for outer
wheel drive (inner wheel drive):
Outer wheel (item 0300) Shell (item 0190)

Coupling size Fusible Blind MTS / BTS Sight Fusible Blind MTS / BTS
4)
and type plug screw switching glass plug screw switching -
2) 2)
Item 0395 Item 0394 element Item0396 Item 0260 Item 0265 element
1 (1 )
1)
- (2) - - - (-) - (-) -
2
1)
(2 ) - (2) - - - (-) - (-) -
1
1)
(1 ) - (2) - - - (-) 1 (1) -
2
1)
(2 ) - (2) - - - (-) - (-) -
1
1)
(1 ) - (2) - - - (-) 1 (1) -
2
1)
(2 ) - (2) - - - (-) - (-) -
2 (2) 3 (3) 1 1 - (-) 2 (2) -
4 (4) 3 (3) 1 1 - (-) 2 (2) -
2 (4) 5 (3) 1 1 - (-) 2 (2) -
2 (4) 5 (3) 1 1 - (-) 2 (2) -
3 (2) 2 (3) 1 1 - (-) 3 (3) -
3 (2) 2 (3) 1 1 - (-) 4 (4) -
3)
- (2) 5 (3) 1 1 3 (-) - (3) -
3)
- (2) 5 (3) 1 1 3 (-) 1 (4) -
2 (-) 3 (5) 1 1 - (2) 2 (-) -
3 (-) 2 (5) 1 1 - (3) 3 (-) -
3 (-) 2 (5) 1 1 - (3) 4 (1) -
3)
- (-) 5 (5) 1 1 3 (3) - (-) -
3)
- (-) 5 (5) 1 1 3 (3) 1 (1) -
- (-) 3 (3) 1 1 4 (4) - (-) -
6 (6) 1 (1) 1 1 - (-) - (-) -
4 (-) 1 (5) 1 1 - (4) 4 (-) -
8 (8) 3 (3) 1 1 - (-) - (-) -
Table 24
1)
Radial arrangement
2)
The MTS or BTS switching element is inserted instead of a blind screw.
3)
Applies only if a BTS-Ex switch unit is used.
4)
Position is marked by an arrow.
ATTENTION!
If a brake is used, select the position of the fusible plugs so that they do not
spray onto the brake.
This needs to be checked. In case of any deviation, please consult Voith.
Note!
A thermal monitoring system can prevent that operating fluid is sprayed off
(see Chapter 20, page 81). Thermal monitoring systems are available at Voith Turbo
as accessories.
66
16 Assembly Check-, Commissioning and

Maintenance Report
DANGER!
coupling!
Document all assembly work performed in the assembly check report (Chapter 16.1).
Document the commissioning process in the commissioning report (Chapter 16.2).
Document the maintenance work performed on the flexible connecting coupling
in the maintenance report for the flexible connecting coupling (Chapter 16.3.1).
Document the maintenance performed on the turbo coupling in the maintenance
report for the general maintenance (Chapter 16.3).
Use copies of the samples, if necessary.

67
16.1 Assembly check report

Confirm the check X and/or enter the required values.
Voith turbo coupling Operating fluid of turbo coupling

Size / type (Chapter 19): Filling: l
Serial No. (Chapter 19): Manufacturer:
Coupling approved for potentially
yes / no Designation:
explosive atmospheres
Motor
Serial No. Assembly works were carried out
Input speed rpm by / on:
Rated power kW
Name:
Driven machine / gearbox Date:
Serial No. Signature:
Completion notice /
Assembly - check step Explanations
dimensions
Check of see order
fixing bolt length (item 0050) documents
1) Nominal: [mm]
Measurement of true radial running of driven machine
specification ACTUAL: [mm]
Nominal: [mm]
Measurement of diameter 1) of driving machine
1) Nominal: [mm]
Measurement of true radial running of driven machine
Nominal: [mm]
Measurement of diameter 1) of driven machine
Nominal: [mm]
Diameter 1) of input Chapter 1
ACTUAL: [mm]
Nominal: [mm]
Diameter 1) of output Chapter 1
ACTUAL: [mm]
Check of back clearance of key (input side) Chapter 8.2
Check of back clearance of key (output side) Chapter 8.2
Key moves easily in the keyway of input hub Chapter 8.2
Key moves easily in the keyway of output hub Chapter 8.2
Method applied:
Check of the input side shaft-hub connection.
Chapter 8.2 semi-inserted key
Balancing method corresponds to DIN ISO 8821 and ISO 8821
fully-inserted key
Method applied:
Check of output side shaft-hub connection.
Chapter 8.2 semi-inserted key
Balancing method corresponds to DIN ISO 8821 and ISO 8821
fully-inserted key
Cleaning of input side shaft and hub and application of lubricant Chapter 8.2
Cleaning of output side shaft and hub and application of lubricant Chapter 8.2
Connecting coupling hub Torque,
Set screw (item 1845) tightened with torque Chapter 7.1
Torque,
Fixing bolt tightened (item 0050) tightened with torque
Chapter 7.1
When installing type TN:
Are the balancing marks of the primary coupling flange in the Chapter 9.1
proper position?
Desired: [mm]
Measurement of installation dimension "L" Chapter 10.2
ACTUAL: [mm]
Table 25
1)
Dimensions of shaft and/or hub to be connected by means of the shaft-hub connection.
68
Completion notice /
Assembly - check step Explanations
dimensions
Tightening of foundation bolts Chapter 10.4
Mounting of coupling
Chapter 7.3
Tightening of bolts (item 1830)
MTS / BTS / BTM (if required)
Chapter 1, 20
Check of installation position according to operating manual
MTS / BTS / BTM (if required)
Chapter 1, 20
Check of electrical functioning
Mounting of guard according to recommendation Chapter 13
Equipotential bonding between input and output end Chapter 13
Filling in of operating fluid into coupling Chapter 12
For horizontally installed couplings only:
Chapter 12.1 Z= screws
Determination of the number of screws "Z" for filling
For vertically installed coupling only:
Fill level check device has been used. Chapter 12.1.2
Fill level has been marked on the coupling.
Enter alignment
Check of alignment of turbo coupling
values
Radial running of motor shaft is OK
Entering the alignment values (see Chapter 10.3):
RADIAL AXIAL
Viewing from the motor towards driven machine
(true radial running) (true axial running)
Please mark with a cross where applicable
- Data from dial gauge
Data from shaft center offset
- Data (dial gauge) from turbo coupling

Data (dial gauge) from shaft center displacement
- AXIAL values measured on Ø: . . . . . . . . . . . . . mm

Displacements during operation (are to be indicated by the machine manufacturer):
Observe displacements resulting from an increase in temperature or from mechanical movements.
Enter only those values that change the above-ascertained alignment values.
- Radial (e.g.) different thermal expansion - input / output) . . . . . . . . . mm
- Axial (e.g. angular displacements) . . . . . . . . . mm
- Linear expansion (f . . . . . . . . . mm
Table 26
69
16.2 Commissioning report

X or enter the respective values.
Voith turbo coupling Commissioning was carried out

Size / type (Chapter 19): after Oper. hrs.
Serial No. (Chapter 19):
Name:
Coupling approved for yes / no Date:
potentially explosive atmospheres: Signature:
Commissioning - check step Explanations Completion notice
Checks prior to switching on the drive motor:

Execution of assembly check steps
Chapter 16.1
Filled in assembly check report, Chapter 16.1
Applies only to couplings that are used in potentially explosive
atmospheres:
Chapter 4.2
Check according to the marking whether the coupling is approved for
the use in potentially explosive atmospheres.
For horizontally installed couplings only:
Chapter 12.2 / Z= . . . . . . . screws
Check of filling level - Z
For vertically installed coupling only:
Fill level check device has been used. Chapter 12.2.2 /
Fill level was compared with the previously made fill level marking. Difference= . . . . . . mm
Fixing of a protective cover over the turbo coupling
Chapter 13
(for design, see Chapter 13).
Check whether the unit was earthed with a grounding cable (16mm²).
Applies only to installations where overspeed is possible:
Provide the unit with a device that reliably prevents overspeeds Chapter 7
(e.g. brake or backstop).
Determination of next standstill of coupling for maintenance services. Chapter 13
Checked whether there is any contact in the area of the flexible Chapter 10.1,
connecting coupling. Chapter 15.2
The reference dimension on the connecting couplings was checked. Chapter 15.2
Applies only when a BTS-Ex is used as temperature monitoring
system:
Chapter 1
Securing that the maximum permissible turbo coupling temperature is
not exceeded when switching on the motor!
Check of foundation bolts
Checks during the test run:

Motor run-up is normal
Coupling is tight
Check of floor and environment for oil moistening,
oil did not leak out
Machine operation is normal
Noises are normal
Checks after switching off the drive motor:

Coupling is tight

Check of switch units for temperature monitoring 1), if applicable

1)
Performance of visual inspection
1)
Removal of dust deposits
1)
Check of electrical system
Table 27
1)
See separate operating manual / Chapter 20
70
16.3 Maintenance report for general maintenance
Confirm the check or performance of the work by an "X"

and/or enter the respective values.
Voith turbo coupling The maintenance work was performed

Size / type (Chapter 19): after Oper. hrs.
Name:
Maintenance - check step Explanations Completion notice

Check for irregularities
(every 500 h, every 3 months, at the latest)
- Coupling is tight
- Machine operation is normal
- Noises are normal
- Check of protective cover Chapter 13
- Check of foundation bolts
1)
Check of switch units for temperature monitoring , if applicable
(every 3 months)
1)
- Performance of visual inspection
1)
- Removal of dust deposits
1)
- Check of electrical system
(after 3 months, then every year)
Operating fluid (every 15000 h)

- Check of operating fluid
- Determination of remaining operating time / . . . . . . . . hours
- Change of operating fluid Chapter 12
Ball and roller bearings (for the intervals, see Chapter 1)

- Replacement of ball and roller bearings Chapter 15.3.3
Cleaning of coupling (after every contamination)

- Cleaning performed Chapter 15.1
Table 28
1)
See separate operating manual / Chapter 20
71
16.3.1 Maintenance report for flexible connecting coupling
Confirm the check or performance of the work by an "X"

and/or enter the respective values.
Voith turbo coupling The maintenance work was performed

Size / type (Chapter 19): at Oper. hrs.
Name:
Flexible connecting coupling installed (see cover sheet):
EEK-E ENK-SV
ERK EPK Nor-Mex G
EEK-M ENK-SX
Replace flexible elements after a
60 60 36 36 36
max. period of [months]
Permissible reference dimension
(see Chapter 15.2.1):
80% value [mm]
Maintenance work: EEK, ENK, Nor-Mex G

ERK, EPK connecting couplings
Commissioning
Replacement
New flexible
Check, and
Check, and
Check, and
Check, and
Check, and
necessary
necessary
necessary
necessary
necessary
Maintenance work
replace, if
replace, if
replace, if
replace, if
replace, if
element
Operating time [months] 0 3 12 24 36 48 60

Flex. element 1 Actual ref. dimension
(new condition) Name
Date
Signature
Reduced operating time [months]
(see Chapter 15.2.2)
st
(1 replacem.) Name
Date
Signature

nd
(2 replacem.) Name
Date
Signature
Table 29
72
17 Coupling Disassembly
DANGER!
coupling!
Unauthorized or unintentional switching on of the machine could result in death

or serious injury!
Before beginning to work on the turbo coupling, switch off the main switch of
the drive motor and secure it against being switched on!
For all work performed on the turbo coupling ensure that both, the drive motor
and the driven machine have stopped running and a start-up is absolutely
impossible.
Note!
This chapter describes the disassembly of turbo couplings of basic type T.
Couplings of basic type TN are disassembled in reverse order according to Chap-
ter 9, page 37.
17.1 Preparation
Prepare suitable tools and lifting appliances; observe the turbo coupling weight!
Note!
The weight of the turbo coupling is indicated on the cover sheet. The weight is also
stamped with figure stamps on the outer diameter of the coupling flange, if it exceeds
100 kg.
WARNING!
may break under load, with the consequence of most serious or even fatal
injuries!

sound condition.
Do not walk or stay under suspended loads!
Fix the coupling to a suitable lifting appliance. For lifting

appliances, see
Chapter 5.4
73
17.2 Removal
CAUTION!
It is not allowed to use an impact screwdriver to apply the torque!
Note!
From size 274,
- mounting and removal devices are available at Voith Turbo as accessories
and - mechanical removal spindles to remove the turbo coupling are necessary.
Hydraulic puller spindles are available from size 422.

We recommend using the hydraulic puller spindles from size 562 in order to be able to
reliably apply the necessary forces.
For removal
devices,
see Chapters
17.2.1 and Puller spindle
17.2.2
Substructure
Fig. 39
Coupling sizes 154 and 206:

After removing the fixing bolt, turbo couplings of sizes 154 and 206 are removed by
inserting a suitable, slightly oiled screw.
Coupling size 274: Coupling sizes 366 to 1150:

Remove the circlip, fixing bolt and Remove the fixing bolt and holding
holding disk. disk.
For lubricants, Put the threaded ring, supplied Apply lubricant to the thread of the
see together with the removal device, into puller spindle.
Chapter 8.2 the coupling hub. Screw the puller spindle into the
Secure the threaded ring using the thread of coupling hub.
circlip.
Apply lubricant to the thread of the
puller spindle.
Screw the puller spindle into the the
internal thread of the threaded ring.
Table 30
Support the puller spindle by a substructure.
Remove the coupling using the puller spindle.
74
17.2.1 Removal using the hydraulic removal device
Very high forces with a low torque can be applied with the hydraulic removal device so
that no substructure below the removal device (Fig. 39) is necessary for absorbing the
force.
Hydraulic removal devices available at Voith Turbo for turbo couplings of basic type T:
Smax H
5 mm
SW2 D SW1 A Q K C
Fig. 40
A: Puller spindle L: Total length

C: Coupling hub Q: Dimension of puller spindle thread
D: Thrust bolt Smax maximum removal dimension
H: Stroke SW1: Width across flats (spindle)
K: Piston SW2: Width across flats (thrust bolt)
Coupling sizes L H Q SW1 SW2 Smax Article No. of

in mm in mm in inch in mm in mm in mm puller spindle
422, 487 406 15 G 1-¼ 36 24 58 TCR.10063480
562, 650 580 15 G 1-½ 36 125 TCR.10450060
750, 866, 1000, 1150 1161 15 G 2-¼ 36 36 310 TCR.10668200
Table 31
Procedure:
1. Unscrew the thrust bolt (D) until reaching the maximum removal dimension Smax.
2. Apply lubricant to the thread of puller spindle (A) and to the thread of thrust bolt For lubricants,
(D). see
3. Screw the puller spindle (A) via SW1 hexagon, up to the stop, into the thread of Chapter 8.2
coupling hub (C).
WARNING!
If the dimension 5 mm is not observed, there is the risk of seizing of the thread
(wear).
The pressure chamber of the hydraulic removal device is subject to high

pressure and must not be opened!
4. Screw in the thrust bolt (D), stop 5 mm before the limit stop.
5. Unscrew the thrust bolt (D).
6. Screw the puller spindle (A) via SW1 hexagon, up to the stop, into the thread of
coupling hub (C).
7. Repeat steps 4 to 6 until the coupling can be easily removed with SW1.
75
17.2.2 Removal using the mechanical removal device
A very careful preparation is necessary for removing the coupling with the mechanical
puller spindle in order to apply the necessary high forces without damaging the thread.
To do so, it is necessary to support the puller spindle by a substructure (see Fig. 39).
CAUTION!
It is not allowed to use an impact screwdriver to apply the torque to turn the
puller spindle!
To do so, it is necessary support the puller spindle by a substructure (Fig. 39).
For lubricants, Please use the recommended lubricant.
see
Chapter 8.2
Mechanical removal devices available at Voith Turbo for turbo couplings of basic
type T:
SW Q A C
Fig. 41
A: Puller spindle Q: Dimension of thread of puller spindle

C: Coupling hub SW: Width across flats
L: Total length
Coupling sizes L Q SW Article No. of

in mm in inch in mm puller spindle
274 360 G¾ 36 TCR.10657260
366 350 G1 46 TCR.10457520
422, 487 460 G 1-¼ 55 TCR.11055700
562, 650 650 G 1-½ 60 TCR.11054150

750, 866, 1000, 1150 1000 G 2-¼ 55 TCR.10670710

Table 32
Note!
To facilitate removal, hydraulic removal devices are available at Voith Turbo for
couplings from size 422 (see Chapter 17.2.1).
76
18 Troubleshooting
DANGER!
coupling!
The following table is intended to help finding the cause of malfunctions or problems
quickly and to take remedial action, if necessary.
Malfunction Possible cause(s) Remedial action
Starting behavior of Coupling is not filled with Check and correct the filling level. Chapter 12,
driven machine is the correct quantity of page 50 ff.
not as expected. operating fluid.
1)
The operating conditions Consult Voith Turbo .
have changed.
Driven machine Driven machine is blocked Eliminate blocking or the cause of

does not reach the or overloaded. overload.
specified speed.
Coupling is not filled with Check and correct the filling level. Chapter 12,
the correct quantity of page 50 ff.
operating fluid.
Drive motor does Changeover from start to Changeover from star to delta
not reach normal delta too late. should be made after 2...5s at the
operation within the latest.
expected time.
Drive motor is electrically Have the drive motor checked by
or mechanically not in authorized personnel.
order.
Operating fluid leaks A fusible plug responded Clarify the cause for the overload. Chapter 15.4,
out of the coupling. due to overload (excess Replace all fusible plugs and change page 64
temperature). the operating fluid.
The coupling is leaking. Eliminate the leak, check, in

particular, tightening torques and
seal rings of fusible and filler plugs
as well as sight glasses and, if
necessary, check the switching
element of the thermal switch unit.
If the leak cannot be eliminated,
1)
please consult Voith Turbo .
Table 33
77
An existing thermal The coupling was Clarify the cause for the Chapter 20,
monitoring unit overloaded. overload, and avoid another page 81
(MTS, BTS or BTM) has overload.
responded.
Check and correct the filling Chapter 12.2,
level. page 53
Thermal monitoring unit Check the monitoring unit. Chapter 20,

(MTS, BTS or BTM) is page 81
defective.
Uneven running of the Foundation fixing is Retighten the foundation

machine. loose. fixing.
(Increased vibration)
Align the machine.
The machine is not Align the machine. Chapter 10,

aligned. page 40
Machine is not balanced. Clarify the cause and

eliminate the unbalance.
Flexible elements of Replace the flexible elements Chapter 15.2,

connecting coupling are in sets. page 62
defective.
Re-align the machine, if
necessary.
Bearings are damaged. Eliminate the bearing damage

1)
consult Voith Turbo in case
of a bearing damage on the
turbo coupling.
Loose screw connections Check the coupling

components for damages,
and replace the same, if
necessary.
Check the alignment of the

machine.
Tighten the screws and bolts

with the specified tightening
torque.
1)
Please consult Voith Turbo if a malfunction occurs which is not included in this
table.
Table 33
1)
see Chapter 19, page 80.
78

Premature wear of Alignment error Eliminate the cause for alignment error.
flexible element
Re-align the unit.
Check the flexible elements for wear.
Impermissible Eliminate the cause for excessive tempe-
temperatures rature.
Replace the flexible element.
Re-align the machine, if necessary.
Contact with Check the coupling components for
aggressive media. damages, and replace the same, if
necessary.
Replace the flexible element.
Re-align the machine, if necessary.
Eliminate the cause for contact with
aggressive media.
Excessive torque Eliminate the cause for excessive torque.
Check the filling level.
Chapter 12.2,
page 53
Roller wear / breakage Flexible elements are Replace damaged coupling components.
of connecting worn
Re-align the unit.
coupling
EEK, ENK, Nor-Mex G Shorten maintenance intervals
Excessive torque Check the coupling design.
1)
Consult Voith Turbo .
Install the new coupling.
Re-align the unit.
1)
Please consult Voith Turbo if a malfunction occurs which is not included in this
table.
Table 34
1)
see Chapter 19, page 80.
79
19 Queries, Orders placed for Service

Engineers and Spare Parts
In case of
queries
orders placed for service engineers
spare parts orders
commissioning
we need ...
A B the serial number and type designation of

the turbo coupling.
You will find the serial number and type

designation either on the outer wheel /
shell (A) or on the coupling periphe-
ry (B).
The serial number is stamped with figure
stamps.
For couplings intended for the use in po-
tentially explosive atmospheres, you will
find the Ex marking on the coupling
periphery (B).
Fig. 42
When placing an order for a service engineer, or for a commissioning or service

assignment, we need, in addition
the turbo coupling installation site,
the address of a contact person,
details of the malfunction / problem occurred.
When placing a spare parts order, we need, in addition,

the destination for the spare parts shipment.
For Please contact our local Voith representative

representatives, (outside business hours, contact the Emergency Hotline).

see Chapter 23
80
20 Temperature monitoring
EX-PROTECTION!
The thermal switch units MTS and BTS can be used in potentially explosive
atmospheres to monitor the temperature. The signals serve for pre-warning. The
MTS or BTS do not limit the maximum surface temperature.
The BTS-Ex is available as safety device for limiting the maximum surface
temperature, and can be used as thermal switch-off device.
Also in this case, it is not allowed to replace the existing fusible plugs by fusible
plugs with different nominal response temperatures or by blind screws.
Never bypass safety devices!
DANGER!
Electric voltages may kill or severely injure you!
A qualified electrician has to properly carry out the connection to the electric
supply network considering the system voltage and the maximum power con-
sumption!
The system voltage has to be in conformity with the system voltage indicated on
the nameplate!
There has to be a corresponding electrical protection by a fuse on the network
side!
20.1 MTS mechanical thermal switch unit for pre-warning

Functioning:
Operating Manual
On excess temperature, the switching element 3626-011800 is
releases a pin. The pin activates a switch on
available for the
coupling rotation. This signal, for example, may
MTS
trip an alarm or switch off the drive motor. The
Switch switching element needs to be replaced. (see web page).
ATTENTION!
In case of inner wheel drive and blocking of
driven machine, the function is no longer
guaranteed!
Switching element
Fig. 43
The MTS is available for turbo couplings of all sizes.

For arrangement, please see the table in Chapter 15.4.1.

The switch is available in two designs:
enclosed [protection IP 65],
suitable for use in potentially explosive atmospheres
type of protection: II 2G EEx d IIC T6 (PTB 03 ATEX 1067 X).
(PTB 03 ATEX 1067 X).
81
20.2 BTS non-contacting thermal switch unit
20.2.1 BTS non-contacting thermal switch unit for pre-warning
Operating Manual Functioning:

3626-011500 is On excess temperature, the switching ele-
available for the ment gives a specific signal to the initiator.
BTS This signal is transferred to an evaluator and
may, for example,
(see web page).
- trigger an alarm
- or switch off the drive motor.
Initiator After the coupling has cooled down, the

switching element is again ready for service; it
does not have to be replaced.
Switching element
Fig. 44
The BTS is provided for turbo couplings from size 206.

Switching element and initiator are
cast in plastic,
insensitive to dirt,
suitable for use in potentially explosive atmospheres
type of protection: II 2G EEx ia IIC T6 (PTB 00 ATEX 2048 X).
(ZELM 03 ATEX 0128 X).
EX-PROTECTION!
As the control circuit of the evaluator is not intrinsically safe, provide an appro-
priate isolating switch amplifier between evaluator and initiator!
Isolating switch amplifier type KFD2-SOT2-Ex2 (24 V DC)

type of protection: II (1) GD [EEx ia] IIC (PTB 00 ATEX 2035).
Isolating switch amplifier type KFA6-SOT2-Ex2 (230 V AC)

type of protection: II (1) G [EEx ia] IIC (PTB 98 ATEX 2164).
82
20.2.2 BTS-Ex non-contacting thermal switch unit for limiting the maximum
surface temperature
Functioning:
On excess temperature, the switching ele-
ment gives a specific signal to the initiator.
This signal is sent to an isolating switch
amplifier and has to enforce the switch-off of EX-
the drive motor. PROTECTION!
Use a BTS-Ex approved by Voith for this app- Observe the
lication. separate
Initiator After the coupling has cooled down, the Operating Manual
switching element is again ready for service; it
3626-019600 of
does not have to be replaced.
BTS-Ex
(see web page).
Switching element
Fig. 45
The BTS-Ex is provided for turbo couplings from size 366.
The BTS-Ex is provided for use in potentially explosive atmospheres as per Directive
RL 94/9/EC in Equipment Group II, Equipment Category 2G and 2D ( II 2GD).
EX-PROTECTION!
The BTS-Ex for limiting the maximum surface temperature is approved only in
connection with the components supplied by Voith according to BTS-Ex opera-
ting manual.
Use of original Voith spare parts is imperative in case of a replacement demand.
The evaluator serves to transmit control commands from potentially explosive

atmospheres into non-explosive areas and to safely isolate intrinsically safe and
non-intrinsically safe circuits.
Make sure not to exceed the maximum permissible temperature of the turbo For technical
coupling when switching on the motor. data, see
Chapter 1,
Page 5
83
20.3 BTM non-contacting thermal measuring unit for pre-warning
Operating Manual Functioning:

3626-019800 is BTM blind The temperature sensor permanently
available for the screw transmits a measuring signal to the an-
BTM tenna. This signal is sent to an evalua-
tor with 4 channels.
(see web page) The measured temperatures of every
channel are indicated on the evaluator.
In addition, the measured temperatu-
res are output as 4-20 mA signals.
Furthermore, two relay outputs are

available per measuring channel with
switching thresholds (e.g. pre-warning,
switch-off) adjustable via the keyboard
on the evaluator.
Antenna Temperature sensor

Fig. 46
The BTM is provided for turbo couplings from size 366.
DANGER!
The BTM is not provided for use in potentially explosive areas as per Directive
94/9/EC.

84
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Voith Turbo GmbH & Co. KG | Installation and Operating Manual
85
Turbo Couplings with constant fill
21 Spare parts information
Considering the great variety, please find in the following only the basic designs of
turbo couplings with constant fill.
Notes!
Spare parts:
Spare parts must comply with the requirements specified by Voith. This is guaran-
teed when original spare parts are used.
Installation and/or use of non-original spare parts may negatively change the me-
chanical properties of the Voith Turbo coupling and thus have an adverse impact
on the safety.
Voith is not liable for any damages resulting from the use of non-original spare
parts.
You will find the type of your turbo coupling on the cover sheet of this operating
manual.
If a flexible connecting couplings belongs to the scope of supply, you will find the
type also on the cover sheet of this operating manual. For matching possibilities of
turbo coupling and flexible connecting coupling, please refer to Chapter 10.2.
Observe Chapter 6.2 (type designation) and 19 (Queries, Orders placed for Ser-
vice Engineers and Spare Parts).
The customer is only allowed to perform the following work:
Replacement of fusible plugs (item 0395 / 0260) (Chapter 15.4).
Replacement of flexible elements (item 1820) (Chapters 15.2, 16.3.1, 22).
Work according to maintenance report (Chapter 16.3).
Changing of operating fluid (Chapter 11)
Mounting of parts for which tightening torques are indicated (Chapter 7).
All remaining work may be performed by Voith personnel only.
EX-PROTECTION!
If the coupling is used in potentially explosive atmospheres (as per Directive
94/9/EC), the use of original parts that have been released for use in hazardous
areas is allowed only.
DANGER!
Unauthorized changes or retrofits are not allowed to be performed on the coup-
ling!
Do not retrofit accessories or equipment originating from other manufacturers!
Any changes or conversions performed without the prior written consent of
Voith Turbo will result in the loss of any warranty!

coupling!
ATTENTION!
Professional maintenance or repair can only be guaranteed by the manufacturer!
86
21.1 Spare parts for type 154 T
0390
0660
0090
0670
1845
0040
0130
0070
0170
0050
0080
0190
0545
0300
0395
Fig. 47
21.2 Spare parts for types 206 - 274 T
0390 0190
0230
0670 0090
1)
1845
0040
Illustration showing
0130 connecting coupling
0070 type ERK as an
0170 example.
0050
0080
0545
0300
0265 For connecting
0660 couplings, see
0395 Chapter 22,
page 100
Fig. 48
1)
Not shown!
Screws and standard parts Wearing parts Coupling main parts

206 206 206

Item 154 274 Item 154 274 Item 154 274
No. Description T T No. Description T T No. Description T T
0050 Fixing bolt x x 0130 Grooved ball bearing x x 0040 Coupling hub x x
0070 Circlip x x 0170 Radial shaft sealing ring x x 0080 Holding disk x x
0230 Filler plug x 0395 Fusible plug x x 0090 Inner wheel x x
0265 Blind screw x 0545 Flat seal x x 0190 Shell x x
0390 Filler plug x x 0660 Flexible element x x 0300 Outer wheel x x
1845 Set screw x 0670 Hub x x
87
88
0050 0394
1)
0395
0396 Standard parts
0390
0994
0820 0170
0130
0320
0545 2)
0175
Wearing parts
2)
0165 0265
1)
0260 0210 0140
0160
21.3 Spare parts for types T and TN
0080
0990
0300
0100
0090
0040
0190
Coupling main parts 0830
Fig. 49

21.3.1 Spare parts for types 366 - 1150 T

0390 0396 1)
0260
0300 0265
1830 0190 Upper part:
1810 0090 Illustration showing
0320
connecting coupling
0990 type EEK-M as
0210
0820 example
0040
1845
0100
0080
0170
0050 0175
2)
1800 0165
2) Lower part:
1820 0160
connecting coupling
0994 0830 type EEK-E as
0545 0140 example
0394 0130
1)
0395
Fig. 50
21.3.2 Spare parts for types 366 - 650 TN

1)
0390 0396 0260
0265
0300
0190
0780 0090
0990 0320
0820 0210
1845 0100
0040
0170
2)
0175
2)
0165
0160
0770 0830 For connecting
0994 0140 couplings, see
0545 0130 Chapter 22,
0394 page 100
1)
0395
Fig. 51
1)
For arrangement and quantity, see the tables in Chapter 15.4.
2)
Only for continuous operation or operating fluid water (TW...).

Item No. Description T TN Item No. Description T TN Item No. Description T TN
0050 Fixing bolt x 0130 Grooved ball bearing x x 0040 Coupling hub / shaft x x
0265 Blind screw x x 0140 Grooved ball bearing x x 0080 Holding disk x
0390 Filler plug x x 0160 Radial x x 0090 Inner wheel x x
0394 Blind screw x x 0165 Shaft sealing ring x x 0100 Rivet-/screw-/clamping ring x x
0396 Sight glass x x 0170 Radial x x 0190 Shell x x
0780 Hexagon Screw x 0175 Shaft sealing ring x x 0300 Outer wheel x x
1830 Hexagon Screw x 0210 Tolerance ring x x 0770 Primary coupling flange x
1845 Set screw x x 0260 Fusible plug x x 0830 Sealing ring cover x x
0320 Tolerance ring x x 0990 Connecting cover x x
0395 Fusible plug x x 1800 Hub x
0545 Flat seal x x 1810 Ring / flange x
0820 O-ring x x
0994 Flat seal x x
1820 Flexible element x
89
90
- blank page -

21.4 Spare parts for types 274 TV / TVV
0390
1840
0190
1830
0230
0090
1800
1820
0170 Illustration showing
1845 connecting
coupling
0070 type ENK-SV as
example.
0040
0050
0080
0130
0300
0545
0410
0994
1810
0265
0395
Fig. 52
For connecting
couplings, see
Chapter 22,
page 100

Item 274 274 Item 274 274 Item 274 274
No. Description TV TVV No. Description TV TVV No. Description TV TVV
0050 Fixing bolt x x 0130 Grooved ball bearing x x 0040 Coupling hub x x
0070 Circlip x x 0170 Radial shaft sealing ring x x 0080 Holding disk x x
0230 Filler plug x x 0395 Fusible plug x x 0090 Inner wheel x x
0265 Blind screw x x 0545 Flat seal x x 0190 Shell x x
0390 Filler plug x x 0994 Flat seal x x 0300 Outer wheel x x
1830 Hexagon Screw x x 1820 Flexible element x x 0410 Delay x x
1840 Spring washer x x chamber
1845 Set screw x x 1800 Hub x x
1810 Ring / flange x x
91
21.5 Spare parts for types TV / TVV and TVN / TVVN
92
21.5.1 Spare parts for types 366 - 1150 TV / TVV

0390 0396 0260
1)
0455 0265
0300 0190
1830 0820
1810
0090
1820
0210
1800 0040
5) 0100 connecting coupling
1845
0080 0170 type EPK as an
0050 0175
2) example.
4) 2)
0510 0165
0800 0160
1870 0830
1880
0140
0410
0994 0130
0545 0320
1) 3)
0394, 0395 1000
Fig. 54
21.5.2 Spare parts for types 366 - 650 TVN / TVVN

1)
0390 0396 0260
0455 0265
0780 0190
0800 0100
Upper part:
0820 0090
Flange design 1
0510
4) 0140 (long laid length)
0130
1845
5) 0040
0770
0170
2)
0410 0175
0160 Lower part:
0320
0165
2) Flange design 2
0994
0830 (short laid length)
0545
For type TVVN only.
0300 0210
0394
1) 3)
0395 1000 For connecting
Fig. 55 couplings, see
1)
2)
For arrangement and quantity, see the tables in Chapter 15.4. Chapter 22,
3)
tion! page 100
4)
5)
For sizes 366 and 422 inserted in the delay chamber groove.
In case of a not ex-proof coupling: Set screw is optional for connecting couplings ENK-SV, ENK-SX and EPK.
For an ex-proof coupling: Set screw is standard

Item TV TVN Item TV TVN Item TV TVN
No. Description TVV TVVN No. Description TVV TVVN No. Description TVV TVV
0394 Blind screw x x 0165 shaft sealing ring x x 0100 Rivet-/screw-/clamping ring x x

0455 Nozzle screw x x 0175 shaft sealing ring x x 0300 Outer wheel x x
0780 Hexagon Screw x 0210 Tolerance ring x x 0410 Delay chamber x x
1830 Hexagon Screw x 0260 Fusible plug x x 0770 Primary coupling flange x
1845 Set screw x 0320 Tolerance ring x x 0800 Bearing support cover x x
1870 Hexagon Screw x 0395 Fusible plug x x 0830 Sealing ring cover x x
1880 Spring washer x 0510 O-ring x x 1000 Valve insert (type T...F...) x x
0820 O-ring x x 1800 Hub x
0545, 0994 Flat seal x x 1810 Ring / flange x
1820 Flexible element x 1860 Sheet-metal holder x
93
21.6 Spare parts for types TVVS and TVVSN
94
21.6.1 Spare parts for types 422 - 1150 TVVS

1)
0390 0396 0260
0455 0265
1840 0300
0190 Upper part:
0100
4) 0090
0510 0160 type ENK-SV as
1820 0165
2)
example.
5) 2)
1845 0175
0080 0170
0050 0130
1800 0040 Lower part:
0410 0140 Illustration showing
0800
0210 type ENK-SX as
1810
0320 example.
0994
0545 1000
3)
1)
0394, 0395
Fig. 57
21.6.2 Spare parts for types 422 - 650 TVVSN

1)
0390 0396 0260
0455 0265
0780 0190
0800 0100
0090 Upper part:
0820
4) 0140 Flange design 1
0510 (long laid length)
1845
5) 0130
0770 0040
0170
2)
0175
0160 Lower part:
0410 2) Flange design 2
0165
(short laid length)
0830
0994
0210
0545
0320
0300
1)
0394, 0395 1000
3)
For connecting
Fig. 58
1)
For arrangement and quantity, see the tables in Chapter 15.4. couplings, see
2)
Chapter 22,
3)
he illustration! page 100
4)
For size 422 inserted in the delay chamber groove.
5)
In case of a not ex-proof coupling: Set screw is optional for connecting couplings ENK-SV, ENK-SX and EPK.
For ex-proof coupling: Set screw is standard.

Item TVV- TVV- Item TVV- TVV- Item TVV- TVV-
No. Description S SN No. Description S SN No. Description S SN

0394 Blind screw x x 0165 Shaft sealing ring x x 0100 Rivet-/screw-/clamping ring x x
0455 Nozzle screw x x 0175 Shaft sealing ring x x 0300 Outer wheel x x
0780 Hexagon Screw x 0210 Tolerance ring x x 0410 Delay chamber x x
1830 Hexagon Screw x 0260 Fusible plug x x 0770 Primary coupling flange x
1840 Spring washer x 0320 Tolerance ring x x 0800 Bearing support cover x x
1845 Set screw x x 0395 Fusible plug x x 0830 Sealing ring cover x x
0510, 0820 O-ring x x 1000 Valve insert (type T...F...) x x
0545, 0994 Flat seal x x 1800 Hub x
1820 Flexible element x x 1810 Ring / flange x
95
21.7 Spare parts for type 154 DT
0390
0395
0660
0305
1845
0090
0040
Illustration showihng
connecting coupling 0070
type ERK. 0050 0130
0170
0080
0670
0300
0390
0545
0395
Fig. 59
For connecting
couplings, see
Chapter 22,
page 100

Item No. Description Item No. Description Item No. Description
0050 Fixing bolt 0130 Grooved ball bearing 0040 Coupling hub
0070 Circlip 0170 Radial shaft sealing ring 0080 Holding disk
0390 Filler plug 0395 Fusible plug 0090 Inner wheel
1845 Set screw 0545 Flat seal 0300 Outer wheel
0660 Flexible element 0305 Outer wheel
0670 Hub
96
21.8 Spare parts for types 206 DT and 274 DT / DTV
0395
0660
0300 0390
0070 1230
1)
Upper part:
1)
1250 type DT with
connecting coupling
0080 0040 type ERK.
0050
2)
1845
0130
1820 0170
1800 Lower part:
type DTV with
1830
1840 type ENK-SV.
1)
0410 0175
0390
0395
0994
0545 0305
Fig. 60
1)
Only for continuous operation or operating fluid water (DTW...). For connecting
2)
In case of not ex-proof coupling: Set screwt optional for connecting couplings ENK-SV. couplings, see
For ex-proof coupling: Set screw is standard. Chapter 22,
page 100
Screws and Standard parts Wearing parts Coupling main parts

Item DT / Item Item
No. Description DTV No. Description DT DTV No. Description DT DTV
0050 Fixing bolt x 0130 Grooved ball bearing x x 0040 Coupling hub x x
0070 Circlip x 0170 Radial shaft seal ring x x 0080 Holding disk x x
0390 Filler plug x 0175 Radial shaft seal ring x x 0090 Inner wheel x x
1830 Hexagon Screw x 0395 Fusible plug x x 0300 Outer wheel x x
1840 Spring washer x 0545 Flat seal x x 0305 Outer wheel x x
1845 Set screw x 0660 Flexible element x x 0410 Delay chamber x
0994 Flat seal x 0670 Hub x x
1230 O-ring x x 1250 Oil retaining ring x x
1820 Flexible element x x 1800 Hub x x
1810 Ring / Flange x x

97
98
0050 0390
Standard parts
0820 1)
0170 0395
0130
0320 0396
0545
Wearing parts 0390
0545
1)
0396
0395 0820
0320 0140
0170
0080
21.9 Spare parts for types 1150 DT / DTV
0800
0180
0045
0300
0100
0090
0995
0040
0090
Coupling main parts 0100
0305
1)
For arrangement and quantity, see the tables in Chapter 15.4. 0180
Radial shaft sealing ring 0175 is not shown. 0800
Fig. 61

1820 1830 1810 0390 0550 0560 0540 0995 0540 0560 0550 0390
0840 0840
0810 0810
0300
0800 0800
0110 Upper part:
0046
0070 0100 0040
type DT with
type EPK.
1860
0130
1800 0050
1845 0080 0140
1865 0045
Lower part:
2) type DTV with
0175
connecting coupling
0170
1880 type EPK.
0320
0820
1835
1840
1830
1) 1)
0410 0510 0530 0395 0994 0545 0395
0470 0396 0396
0405 0405
Fig. 62 For connecting

1)
couplings, see
For arrangement and quantity, see the tables in Chapter 15.4. Chapter 22,
2)
Only for continuous operation or operating fluid water page 100
Screws and Standard parts Wearing parts Coupling main parts

Item Item Item
No. Description DT DTV No. Description DT DTV No. Description DT DTV
0046 Circlip x x 0130 Grooved ball bearing x x 0040 Coupling hub x x
0050 Fixing bolt x x 0140 Grooved ball bearing x x 0045 Threaded ring x x
0070 Roll pin x x 0170 Radial shaft seal ring x x 0080 Holding disk x x
0110 Hexagon Screw x x 0175 Radial shaft seal ring x x 0090 Inner wheel x x
0390 Filler plug x x 0320 Tolerance ring x x 0100 Clamping ring x x
0396 Sight glass x x 0395 Fusible plug x x 0300 Outer wheel x x
0470 Spring washer x x 0405 Sealing ring x x 0410 Delay chamber x
0530 Hexagon Screw x x 0510 Sealing ring x 0800 Sealing ring cover x x
0540 Hexagon Screw x x 0545 Flat seal x x 0995 Intermediate piece x x

0550 Hexagon Nut x x 0820 O-ring x x 1800 Hub x x
0560 Spring washer x x 0994 Flat seal x 1810 Ring / Flange x x
0810 Hexagon Screw x x 1820 Flexible element x x 1860 Sheet-metal holder x x

0840 Spring washer x x 1865 Sheet-metal holder 2 x x
1830 Hexagon Screw x x
1835 Hexagon Nut x
1840 Spring washer x
1845 Set screw x x
1870 Hexagon Screw x x
1880 Spring washer x x
99
22 Spare Parts Information -

Connecting Couplings
22.1 Connecting coupling on the input side
22.1.1 Flexible pad coupling type EPK
1)
1845
1870 1880
1860
1820
1800
1) 1830 1840
1845 see Fig. 27 on page 40 1810
Fig. 63
Item No. Description ENK EEK EPK Item No. Description Item No. Description ENK EEK EPK
1)
1830 Hexagon Screw x x x 1820 Flex. element 1800 Hub x x x
1840 Spring washer x x x 1810 Ring / flange x x x
1845 Set screw x x x 1860 Sheet-metal holder x
1870 Hexagon Screw x
1880 Spring washer x
1)
Various lengths of flexible elements are available
22.1.2 Flexible element coupling type EEK

Outer shaft hub, type EEK-E Inner shaft hub, type EEK-M
1845 1845
1800 1800
1820 1830 1820 1830
1840 1810 1840 1810
Fig. 64 Fig. 65
100
22.1.3 Flexible cam coupling type ENK

Outer shaft hub, type ENK-SX Inner shaft hub, type ENK-SV
1800 1800
1820
1830 1840 1820 1830 1840
1) 1810 1) 1810
1845 1845
Fig. 66 Fig. 67
1)
Set screw is not shown here, see Figs. 30 and 31 on page 41.
22.2 Connecting couplings on the output side

22.2.1 Coupling Nor-Mex G
1845
0770
1845 1845
1845
Turbo Coupling
1816
1815
0770 1811
1820
1800
Input side Output side
Fig. 68

Item No. Description Item No. Description Item No. Description
1816 Socket head screw 1820 Flexible element 0770 Primary coupling flange 1
1845 Set screw 0770 Primary coupling flange 2
1800 Hub
1811 Flange hub
1815 Claw ring
101
102
- blank page -

23 Representatives -
West-Europe:
Germany ( VTCR ): Great Britain ( VTGB ): Sweden ( VTSN ): Poland ( VTPL ):
Voith Turbo GmbH & Co. KG Voith Turbo Limited Voith Turbo AB Voith Turbo sp.z o.o.
Start-up Components 6, Beddington Farm Road Finspångsgatan 46
Voithstr. 1 CRO 4XB CROYDON, SURREY 16353 SPÅNGA-STOCKHOLM 97-371 WOLA KRZYSZTOPORSKA
74564 CRAILSHEIM GREAT BRITAIN SWEDEN POLAND
GERMANY Phone: +44-20-8667 0333 Phone: +46-8-564-755-50 Phone: +48-44 646 8848
Phone: +49-7951 32-409 Fax: +44-20-8667 0403 Fax: +46-8-564-755-60 Fax: +48-44-646 8520
Fax: +49-7951 32-480 e-mail: Turbo.UK@voith.com e-mail: voithturbo.sweden@voith.com e-mail: voithturbo.polska@voith.com
e-mail: startup.components@voith.com Emergency Hotline (24/7):
Emergency Hotline (24/7):
www.voithturbo.com/startup- Phone: +44-20-8667 0333 Switzerland: Phone: +48-44 646 8519
components see Germany ( VTCR )
Service: Greece: Romania ( VTRO ):
Phone: +49 7951 32-1020 see Germany ( VTCR ) Voith Turbo S.R.L.
Fax: +49 7951 32-554 Pipera Business Tower,
e-mail: vtcr-ait.service@voith.com Greenland: 10th Floor, 2nd Office
see Denmark ( VTDK ) East-Europe: Blv. Dimitrie Pompeiu 8
Phone: +49 7951 32-599
020337 BUCHAREST
Ireland: Albania: ROMANIA
Austria: see Great Britain ( VTGB ) see Hungary ( VTHU ) Phone: +40-31-22 36100
Indukont Antriebstechnik GmbH Fax: +40-21-22 36210
Badenerstraße 40 Italy ( VTIV ): Bosnia Herzegowina: e-mail: voith.romania@voith.com
2514 TRAISKIRCHEN Voith Turbo s.r.l. see Hungary ( VTHU )
AUSTRIA Via G. Lambrakis 2 Russia ( VTRU ):
Phone: +43-2252-81118-22 42122 REGGIO EMILIA Bulgaria: Voith Turbo O.O.O.
Fax: +43-2252-81118-99 ITALY see Hungary ( VTHU ) Branch Office Moskau
e-mail: info@indukont.at Phone: +39-05-2235-6714 Nikolo Yamskaya ul. 21/7, str. 3
Fax: +39-05-2235-6790 Croatia: 109240 MOSKAU
e-mail: info.voithturbo@voith.com see Hungary ( VTHU ) RUSSIA
Belgium ( VTBV ):
Voith Turbo S. A. / N. V. Phone: +7 495 915-3296 ext. 122
Liechtenstein: Czech Republic ( VTCZ ): Fax: +7 495 915-3816
Square Louisa 36 Voith Turbo s.r.o.
1150 BRÜSSEL see Germany ( VTCR ) mobil Herr Bulanzev: +7 919 108 2468
Hviezdoslavova 1a e-mail: voithmoscow@Voith.com
BELGIUM 62700 BRNO
Phone: +32-2-7626100 Luxembourg:
see Belgium ( VTBV ) CZECH REPUBLIC Voith Turbo
Fax: +32-2-7626159 Phone: +420-543-176163
e-mail: voithturbo.be@voith.com Branch Office Novokusnetsk
Netherlands ( VTNT): Fax: +420-548-226051 ( Shcherbinin, Anatoliy )
Voith Turbo B.V. e-mail: info@voith.cz Skorosnaya ul. 41, Liter B1
Denmark ( VTDK ):
Voith Turbo A/S Koppelstraat 3 654025 NOVOKUSNETSK
7391 AK TWELLO Estonia: Kemerovskaya oblast
Egegårdsvej 5 see Poland ( VTPL )
4621 GADSTRUP THE NETHERLANDS RUSSIA
DENMARK Phone: +31-571-2796-00 Phone/Fax: +7 3843 311 109
Fax: +31-571-2764-45 Hungary ( VTHU ): mobil: +7 9132 802 110
Phone: +45-46 141550 Voith Turbo Kft.
Fax: +45-46 141551 e-mail: voithnederland@voith.com e-mail: voith22@bk.ru
Felvég Útca 4
e-mail: postmaster@voith.dk 2051 BIATORBÁGY
Norway ( VTNO ): Serbia:
Voith Turbo AS HUNGARY see Hungary ( VTHU )
Faroe Islands:
Gamle Leirdals vei 3 Phone: +36-23-312 431
see Denmark ( VTDK )
1081 OSLO Fax: +36-23-310 441 Slovak Republic:
NORWAY e-mail: vthu@voith.com see Czech Republic ( VTCZ )
Finland ( Masino ):
Masino Oy Phone: +47 2408 4800
Fax: +47 2408 4801 Kosovo: Slovenia:
Kärkikuja 3
e-mail: info.turbo.norway@voith.com see Hungary ( VTHU ) see Hungary ( VTHU )
01740 VANTAA
FINLAND
Portugal: Latvia: Ukraine ( VTUA ):

Phone: +358-10-8345 500
see Spain ( VTEV ) see Poland ( VTPL ) Voith Turbo Ltd.
Fax: +358-10-8345 501
e-mail: sales@masino.fi Degtyarivska Str. 25 of 23, building 1
Spain ( VTEV ) : Lithuania: 04119 KIEV
Voith Turbo S. A. see Poland ( VTPL ) UKRAINE

France ( VTFV ):
Voith Turbo S. A. S. Avenida de Suiza 3 Phone: +380-44-489 4621
P.A.L. Coslada Macedonia: Fax: +380-44-489 4621
21 Boulevard du Champy-Richardets
28820 COSLADA (MADRID) see Hungary ( VTHU ) e-mail: Dmitriy.Kalinichenko@Voith.com
93166 NOISY-LE-GRAND CEDEX
FRANCE SPAIN
Phone: +33-1-4815 6903 Phone: +34-91-6707816 see also Poland ( VTPL )
Fax: +33-1-4815 6901 Fax: +34-91-6707841
e-mail: voithfrance@voith.com e-mail: info.voithturbo@voith.com
103
North America:
Southern- + Middle Amerika: Africa: Near + Middle East:
Canada ( VTC ):
Voith Turbo Inc. Brazil ( VTPA ): Algeria: Bahrain:
171 Ambassador Drive, Unit 1 Voith Turbo Ltda. see France ( VTFV ) see United Arabian Emirates ( VTAE )
L5T 2J1 MISSISSAUGA, ONTARIO Rua Friedrich von Voith 825
CANADA Botswana:
02995-000 JARAGUÁ, SÃO PAULO -
Phone: +1-905-670-3122 see South Africa ( VTZA ) Iran ( VTIR ):
SP
Fax: +1-905-670-8067 BRAZIL Voith Turbo Iran Co., Ltd.
Egypt:
e-mail: information@voithusa.com Phone: +55-11-3944 4393 1st Floor, No. 215
Copam Egypt
e-mail: Info@voithusa.com Fax: +55-11-3941 1447 East Dastgerdi Ave.
33 El Hegaz Street, W. Heliopolis
e-mail: info.turbo-brasil@voith.com Modarres Highway
Emergency Hotline (24/7): 11771 CAIRO
19198-14813 TEHRAN
Phone: +1-905-738-1829 Emergency Hotline (24/7): EGYPT
IRAN
Phone: +55-11-3944 4646 Phone: +202-22566 299
Phone: + 98-21-2292 1524
Fax: +202-22594 757
Fax: + 98-21-2292 1097
Mexico ( VTX ): e-mail: copam@datum.com.eg
Colombia ( VTKB ): e-mail: voithturbo.iran@voith.ir
Voith Turbo S.A. de C.V.
Alabama No.34 Voith Turbo Colombia Ltda. Gabon:
Col. Nápoles Delg. Benito Juarez Calle 17 No. 69-26 see France ( VTFV )
Centro Empresarial Montevideo Iraq:
C.P. 03810 MÉXICO, D.F.
11001000 BOGOTÁ, D.C. Guinea: see United Arabian Emirates ( VTAE )
MÉXICO
COLOMBIA see France ( VTFV )
Phone: +52-55-5340 6970
Fax: +52-55-5543 2885 Phone: +57 141-20590 Ivory Coast:
Fax: +57 141-17664 Israel ( VTIL ):
e-mail: vtx-info@voith.com see France ( VTFV )
e-mail: voith.colombia@voith.com Voith Turbo Israel Ltd.
Lesotho: Tzvi Bergman 17
Chile ( VTCI ): see South Africa ( VTZA ) 49279 PETACH
U.S.A. ( VTI ):
Voith Turbo S. A. ISRAEL
Voith Turbo Inc.
Av.Pdte.Eduardo Frei Montalva 6115 Marocco ( VTCA ): Phone: +972-3-9131 888
25 Winship Road
8550189 SANTIAGO DE CHILE Voith Turbo S.A. Fax: +972-3-9300 092
YORK, PA 17406-8419
(CONCHALI) Rue Ibnou El Koutia, No. 30 e-mail: tpt.israel@voith.com
UNITED STATES
CHILE Lot Attawfiq Quartier Oukacha
Phone: +1-717-767 3200
Phone: +56-2-944-6900 20250 CASABLANCA
Fax: +1-717-767 3210
Fax: +56-2-944-6950 MAROCCO Jordan,
e-mail: VTI-Information@voith.com
e-mail: VoithTurboChile@voith.com Phone: +212 522 34 04 41 Kuwait,
Emergency Hotline (24/7): Fax. +212 522 34 04 45 Lebanon,
Phone: +1-717-767 3200 e-mail: info@voith.ma Oman,
Ecuador:
e-mail: VTIServiceCenter@voith.com Qatar,
see Colombia ( VTKB ) Mauretania: Saudi Arabia,
Peru ( VTPE ): see Spain ( VTEV ) Syria:
Voith Turbo S.A.C. Yemen:
Mozambique: see United Arabian Emirates ( VTAE )
Av. Argentinia 2415 see South Africa ( VTZA )
LIMA 1
PERU Namibia:
Phone: +51-1-6523014 see South Africa ( VTZA ) Turkey ( VTTR ):
Fax: +51-1-6383424
e-mail: Israel.Jahnsen@Voith.com Niger: Birlik Mah. 415. Cadde No. 9/5
see France ( VTFV ) 06610 ÇANKAYA-ANKARA
see also Brazil ( VTPA ) TURKEY
Senegal: Phone: +90 312 495 0044
see France ( VTFV ) Fax: +90 312 495 8522
Venezuela: e-mail: info@aserman.com.tr
see Colombia ( VTKB ) South Africa ( VTZA ):
Voith Turbo Pty. Ltd.
16 Saligna Street United Arabian Emirates ( VTAE ):
Hughes Business Park P.O.Box 263461
1459 WITFIELD, BOKSBURG Plot No. TP020704
SOUTH AFRICA Technopark, Jebel Ali
Phone: +27-11-418-4000 DUBAI
Fax: +27-11-418-4080 UNITED ARAB EMIRATES
e-mail: info.VTZA@voith.com Phone: +971-4 810 4000
Emergency Hotline (24/7): Fax: +971-4 810 4090

Phone: +27-11-418-4060 e-mail: voith-middle-east@voith.com
Swaziland:
see South Africa ( VTZA )
Tunesia:
see France ( VTFV )
Zambia:
Zimbabwe:
104
East Asia:
Australia: South-East Asia: Korea ( VTKV ):
Voith Turbo Co., Ltd.
China:
Australia ( VTAU ): Brunei: Room # 1717, Golden Tower
see Hongkong ( VTEA )
Voith Turbo Pty. Ltd. see Singapore ( VTSG ) Officetel 191
Branch Office Sydney Chungjung-Ro 2-Ka
Voith Turbo Power Transmission
503 Victoria Street Saedaemoon-Ku
(Shanghai) Co., Ltd. ( VTCB )
2164 WETHERILL PARK, NSW India ( VTIP ): 120-722 SEOUL
Bejing Branch
AUSTRALIA Voith Turbo Private Limited SOUTH KOREA
18 Floor, Tower F, Phoenix Place
Phone: +61-2-9609 9400 Transmissions and Engineering Phone: +82-2-365 0131
5A Shuguang Xili, Chaoyang District
Fax: +61-2-9756 4677 P.O. Industrial Estate Fax: +82-2-365 0130
100028 BEIJING
e-mail: vtausydney@voith.com 500 076 NACHARAM-HYDERABAD e-mail: paul.lee@voith.com
P.R. CHINA
Emergency Hotline (24/7): INDIA Phone: +86-10-5665 3388
Phone: +61-2-9609 9400 Phone: +91-40-27173 561+592 Fax: +86-10-5665 3333
Fax: +91-40-27171 141 Macau:
e-mail: vtau_spare_parts@voith.com e-mail: VT_Industry_China@Voith.com
e-mail: info@voithindia.com see Hongkong ( VTEA )

New Zealand (VTNZ ): Phone: +91-99-4906 0122 Voith Turbo Power Transmission
Mongolia ( VTA-MON ):
Voith Turbo NZ Pty. Ltd. e-mail: vtip.service@voith.com (Shanghai) Co. Ltd. ( VTCN )
Suite 31060 Cook Street Representative Office Shanghai
2nd Floor Serkh Bogd Co. Ltd.
1010 AUCKLAND No. 265, Hua Jin Road
Office Building United Nations Street 4,
NEW ZEALAND Indonesia: Xinzhuang Industry Park
Khoroo Chingeltei District
Phone: +64 935 89078 PT Voith Turbo 201108 SHANGHAI
ULAANBAATAR
Fax: +64 935 89070 JI. T. B. Simatupang Kav. 22-26 CHINA
MONGOLIA
e-mail: VTNZ@voith.com Talavera Office Park, 28th. Fl. Phone: +86-21-644 286 86
Phone: +976 7010 8869
12430 JAKARTA Fax: +86-21-644 286 10
e-mail: Daniel.Bold@Voith.com
INDONESIA e-mail: VT_Industry_China@Voith.com
Phone: +62 21 7599 9848
Fax: +62 21 7599 9846 Philippines:
e-mail: vike.aryanti@voith.com Service Center ( VTCT ):
see Taiwan ( VTTI )
Voith Turbo Power Transmission
(Shanghai) Co. Ltd.
Malaysia: Taiyuan Branch
Taiwan ( VTTI ):
see Singapore ( VTSG ) No. 36 Workshop, TISCO,
Voith Turbo Co. Ltd.
No. 73, Gangyuan Road
Taiwan Branch
030008 TAIYUAN, SHANXI
No. 3 Taitang Road,
Myanmar: P.R. CHINA
Xiaogang District
see Singapore ( VTSG ) Phone: +86 351 526 8890
81246 KAOHSIUNG
Fax: +86 351 526 8891
TAIWAN, R.O.C.
e-mail: VT_Industry_China@Voith.com
Phone: +886-7-806 1806
Singapore ( VTSG ) Fax: +886-7-806 1515
Voith Turbo Pte. Ltd. e-mail: vtti@voith.com.tw
Phone: +86 21 4087 688
10 Jalan Lam Huat e-mail: Hongjun.Wang@voith.com
Voith Building
737923 SINGAPORE
SINGAPORE Hongkong ( VTEA ):
Phone: +65-6861 5100 Voith Turbo Ltd.
Fax: +65-6861-5052 908, Guardforce Centre,
e-mail: sales.singapore@voith.com 3 Hok Yuen Street East,
HUNGHOM, KOWLOON
HONG KONG
Thailand: Phone: +85-2-2774 4083
see Singapore ( VTSG ) Fax: +85-2-2362 5676
e-mail: voith@voith.com.hk
Vietnam:
see Singapore ( VTSG ) Japan ( VTFC ):
Voith Turbo Co., Ltd.
9F, Sumitomo Seimei Kawasaki Bldg.
11-27 Hlgashida-chou, Kawasaki-Ku,
Kawasaki-Shi,
210-0005 KANAGAWA
JAPAN
Phone: +81-44 246 0335
Fax: +81-44 246 0660

e-mail: fvc-taki@fsinet.or.jp
105
24 Index
Accident,
What to do in case of an accident ....... 14 Grease, Requirements ........................ 48
Alignment ...................................... 40, 43 Greases, proposed greases ................ 49
Alignment tolerances ........................... 42
Ambient temperatures ......................... 13 Hazards ............................................... 10
As delivered condition ......................... 18 How to check
the flexible elements for wear.............. 62
Assembly check report ........................ 67
Hydraulic removal device .................... 75
Bearing lubrication .............................. 63
Improper use ....................................... 11
Bearings .............................................. 63
Information, spare parts ...................... 86
Blind screw .................................... 87, 91
Inner wheel drive ................................. 31
Blockage of output .............................. 16
Installation
Blocking ............................................... 16
Basic type T ................................... 31
BTM ..................................................... 84 basic type TN ................................. 37
BTS ..................................................... 82
BTS-Ex ................................................ 83 Keys .................................................... 33
Catch pan ............................................ 13 Laid lengths L ...................................... 42

Commissioning .............................. 56, 80 Level check
Commissioning report ......................... 70 Horizontal position ......................... 53
Connecting couplings .................. 40, 100 Vertical position ............................. 53
Constructional examples ..................... 27 Level check device .............................. 52
Constructional modifications ............... 11 Lifting................................................... 19
Coupling temperature .......................... 15 Lifting appliances ................................ 19
Data, additional ..................................... 6 Maintenance ........................................ 58

Bearings ........................................ 63
Declaration of incorporation .............. 7, 8
Flexible connecting coupling ......... 62
Direction of rotation ............................. 57 Fusible plugs ................................. 64
Disassembly ........................................ 73 Outside cleaning ............................ 61
Draining ............................................... 54 Maintenance intervals ......................... 63
Horizontal position with Maintenance report ....................... 67, 71
delay chamber ............................... 54
Maintenance schedule ........................ 60
Horizontal position without
delay chamber ............................... 54 Maintenance/repair ............................. 86
Vertical position ............................. 55 Manufacturer's declaration ................ 7, 8
Mechanical removal device ................. 76
Electrical components ......................... 12 Methane content,
Electrical devices ................................ 13 Check of methane content .................. 14
EPK, EEK, ENK ................................. 100 Mineral oils .......................................... 46
Equipotential bonding .......................... 56 Monitoring devices .................. 16, 66, 81
BTM ............................................... 84
Fill BTS................................................ 82
Horizontal position ......................... 51 BTS-Ex .......................................... 83
Vertical position ............................. 52 MTS ............................................... 81
Filling check ........................................ 53 Mounting ............................................. 34
Filling the coupling .............................. 51 Mounting and removal devices............ 74

Fire hazard .......................................... 13 Mounting devices .......................... 34, 36
Fire point ............................................. 45 MTS ..................................................... 81
Fixing bolt .................... 35, 87, 91, 96, 97 Multi-motor drive.................................. 57

Flash point ..................................... 45, 47
Noise ................................................... 12
Flexible connecting couplings ............. 40
Follow-up of product ............................ 17
Oil list .................................................. 47
Function .............................................. 24
Operating fluides
Fusible plugs ..................... 13, 16, 18, 64 Proposed operating fluids .............. 46
Fusible plugs for normal use ............... 65 Operating fluids ....................... 15, 18, 45
Fusible plugs suitable for use in Requirements .......................... 45, 47
potentially explosive atmospheres ...... 66 water .............................................. 48
106
Operation............................................. 58 Selection and qualification of staff ....... 17

Ordering a service engineer ................ 80 Serial No.............................................. 80
Ordering spare parts ........................... 80 Servicing, maintenance ....................... 58
Orders ................................................. 80 Set screw................... 87, 91, 96, 97, 100
Outer wheel drive .......................... 31, 37 Sight glass ..................................... 53, 99
Overload .................................. 13, 15, 16 Signal words ........................................ 10
Overload of coupling ........................... 16 Sound pressure level........................... 12
Spanner wrench .................................. 74
Packing................................................ 22 Spare parts ...................................... 9, 86
pH-value .............................................. 48 Spare parts information ....................... 86
Pour point ...................................... 45, 47 1150 DT / DTV ............................... 98
Power transmission ............................. 15 154 DT ........................................... 96
Preparation .................................... 32, 73 154 T.............................................. 87
206 - 274 T .................................... 87
Preservation ........................................ 22 206 DT and 274 DT / DTV ............. 97
Primary coupling flange ..................... 100 274 TV / TVV ................................. 91
Proper use ........................................... 11 T and TN ........................................ 88
Proposed operating fluids TV / TVV and TVN / TVVN ............. 92
for special requirements ...................... 47 TVVS and TVVSN.......................... 94
Protective cover ....................... 12, 56, 61 Standstill ........................................ 57, 63
Star / delta connection ........................ 57
Qualification ......................................... 17 Starting characteristic .......................... 15
Queries ................................................ 80 Storage .......................................... 18, 22
Switching off
Re-lubrication ...................................... 63 in case of coupling overload ................ 16
Remaining risks ................................... 14 Symbols............................................... 10
Removal .............................................. 74
Removal device Technical Data ...................................... 5
hydraulic ........................................ 75 Temperature monitoring .................. 5, 81
mechanical..................................... 76 Test report ........................................... 68
Removal devices ................................. 74 Tightening torques......................... 29, 30
Repair .................................................. 86 Tools.................................................... 31
Replacement of bearings .................... 63 Transport ............................................. 18
Report / Protocol ..................... 68, 70, 71 Troubleshooting................................... 77
Representatives ................................ 103 Type designation ................................. 25
Risk classes ........................................ 10
Warming up ................................... 12, 15
Safety .................................................. 10 Wear of flexible elements .................... 62
Scope of supply ................................... 18 What to do in case of accidents .......... 14
Sealing material for an Working on the turbo coupling ............ 12
operating temperature above 100°C ... 46
107

Start-up Components
Voithstr. 1
74564 Crailsheim
GERMANY
Tel. +49 7951 32-0
Fax. +49 7951 32-480
www.voithturbo.com/
startup-components

108
Voith Turbo
Installation and Operating Manual
3626-011800 en
MTS
Mechanical Thermal Switch Unit
including design as per Directive 94/9/EC
ATTENTION!
Please be sure to read this manual prior to installation and commissioning
and keep it for further use!
MTS,
Mechanical, Thermal Switch Unit Voith Turbo GmbH & Co. KG | Installation and Operating Manual
Contents
1 Preface...............................................................................................................3
1.1 General information ............................................................................................3
1.2 Proper use ..........................................................................................................4
2 Safety .................................................................................................................5
2.1 Notes and symbols .............................................................................................5
2.2 General information as to hazards .....................................................................6
2.3 Staff qualification ................................................................................................7
2.4 Product observation............................................................................................7
3 Applications, Characteristics of MTS.............................................................8
4 Function of MTS ...............................................................................................9

4.1 Switching element ............................................................................................10
4.2 Switch ...............................................................................................................10
4.3 Interaction of MTS components .......................................................................10
5 Technical Data ................................................................................................11

5.1 Switching element ............................................................................................11
5.2 Switch ...............................................................................................................12
5.2.1 Switch ExM 61 D ..............................................................................................13
6 Installation.......................................................................................................13
6.1 As delivered condition, scope of supply ...........................................................13
6.2 Installation of switching element and switch ....................................................14
6.3 Connection .......................................................................................................17
6.3.1 Connection of switch ExM 61 D (additional information) ................................17
7 Maintenance....................................................................................................18
8 Troubleshooting .............................................................................................19
9 Queries, Orders placed for Service Engineers and Spare Parts ...............20
10 Spare Parts Information.................................................................................21

10.1 Switching elements...........................................................................................21
10.2 Switch ...............................................................................................................21
11 Representatives Voith Turbo GmbH & Co. KG............................................24
12 Index ................................................................................................................27
2
MTS,
Voith Turbo GmbH & Co. KG | Installation and Operating Manual Mechanical, Thermal Switch Unit
1 Preface
1.1 General information

This manual will support you in using the mechanical thermal switch unit (MTS) in a
safe, proper and economical way. If you observe the information contained in this
manual, you will
– increase the reliability and lifetime of the installation,
– avoid any risks,
– reduce repairs and downtimes.
This manual must

– always be available at the MTS site,
– be read and used by every person who works on the unit.
The mechanical thermal switch unit is manufactured to the latest design standards
and approved safety regulations. Nevertheless, the user's or third parties' life may be
endangered or the unit and other material assets impaired in case of improper hand-
ling or use.
Spare parts:
Spare parts must comply with the requirements determined by Voith.
This is guaranteed when original spare parts are being used.
Installation and/or use of non-original spare parts may negatively change the mecha-
nical properties of the Voith Turbo coupling and thus have an adverse impact on the
safety.
Voith is not liable for damages resulting from use of non-original spare parts.
Only personnel qualified and trained in commissioning, maintenance and repair is

allowed to do this work.
This manual was issued with utmost care, However, in case you should need any
further information, please contact:

Start-up Components
Voithstr. 1
74564 Crailsheim
GERMANY
Tel. +49 7951 32-0
Fax. +49 7951 32-480

www.voithturbo.com/startup-components
© Voith Turbo 2012.

The reproduction, distribution and utilization of this document as well as the communi-
cation of its contents to others without express authorization is prohibited. Offenders
will be held liable for the payment of damages. All rights reserved in the event of the
grant of a patent, utility model or design.
Voith Turbo reserves the right for modifications.
3
MTS,
1.2 Proper use

The mechanical thermal switch unit for advance warning (MTS) monitors the tempera-
ture of Voith turbo couplings.
Use for another purpose, e.g. for operating conditions which were not agreed, is not
considered as proper use.
Proper use also includes observing the installation and operating manual.
The manufacturer is not liable for damages resulting from improper use and the risk is
to be borne solely by the user.

4
MTS,
2 Safety
2.1 Notes and symbols

The safety notes included in this instruction manual are particularly marked with safety
marks according to DIN 4844:
Damage/ Signal word Definition Consequences Symbol

harm to...
Persons EX-PRO- Notes to Ex- Explosion hazard
Property TECTION! protection
Persons DANGER! imminent danger fatal or most serious

injuries (crippling)
Persons WARNING! dangerous situation fatal or most serious

possible injuries possible
Persons CAUTION! less dangerous slight or minor

situation injuries possible
Persons warning of com- fire hazard

Property bustible materials
Persons use goggles risk of losing sight,

risk of going blind
Persons Use ear protection hearing damage
Property ATTENTION! harmful situation damage possible to

possible – the product
– its environment
– Note! application hints and efficient in operation
Information! other useful infor-
mation
Table 1
Marking with the Ex-symbol ( ) indicates possible hazards which have to be ob-
served only if applied in explosion hazardous areas.
5
MTS,
2.2 General information as to hazards
WARNING!
– For all work performed on the mechanical thermal switch unit please observe
the local regulations for prevention of accidents as well as the regulations
for installation of electrical equipment!
– For the use of mechanical thermal switch unit in hazardous areas (switch
type ExM 61 D) observe the local regulations applicable to electrical equip-
ment in hazardous areas! Modifications on the switch including connecting
cable are not permitted.
DANGER!
Work performed on the mechanical thermal switch unit:

– The contact with uncovered or exposed terminals, cables and equipment
may cause fatal or most serious injuries!
– In the event of a failure, also assemblies potential-free during operation may
carry a corresponding supply voltage.
Work performed on the turbo coupling:

– For all work performed on the turbo coupling ensure that both, drive mo-
tor/engine and driven machine have stopped running and startup is absolute-
ly impossible!
– Start to work only after the coupling has cooled down below 40˚C, otherwise
there is a risk of burns!
– Please also observe the installation and operating manual of turbo coupling!
Noise:
– The turbo coupling generates noise during operation.
If the A-classified equivalent sound pressure level exceeds 80 dB(A) this may
cause hearing damage!

Sound pressure
level see sepa- Wear ear protection!
rate instruction
manual
6
MTS,
Sprayed-off and discharged operating fluid:

– In the event of thermal overload of the turbo coupling the fusible plugs res-
pond. Operating fluid is discharged through these fusible plugs.
– If the fusible plugs spray off, immediately switch off drive!
– Electrical devices located near the coupling need to be protected against
spraying!
– Please ensure that the sprayed-off operating fluid cannot get in contact with
persons! Danger of burning!
– Persons being in the surrounding of turbo coupling have to wear goggles.
Spraying off hot operating fluid means a risk of losing sight!
– Make sure that spraying operating fluid cannot get into contact with hot
machine parts, heaters, sparks or open flames! There is a risk of fire!
– In order to prevent danger (e.g. risk of skidding, risk of fire) caused by esca-
ping oil, remove same immediately!
– Please provide a catch pan of sufficient size, if required!
2.3 Staff qualification
The staff in charge of any work on the mechanical thermal switch unit must
– be reliable,
– have the legal minimum age,
– be trained, instructed and authorized for the intended work.
– at use in potentially explosive atmosphere observe EN 1127-1 Annex A and
EN 1127-1 Section 7. Only use tools admissible in potentially explosive areas.
Avoid sparking.
2.4 Product observation
We are under legal obligation to observe our products, even after shipment.
Please therefore inform us about anything that might be of interest to us. For example: You will find
– changed operating data, our address
on page 3
– experience gained with the unit,
– recurring problems,
– problems experienced with this installation and operating manual.
7
MTS,
3 Applications,
Characteristics of MTS
The mechanical thermal switch unit (MTS) is a monitoring system for Voith turbo
couplings.
– The MTS provides easy temperature monitoring of turbo couplings.
– In case of overtemperature and, dependent on the application, shutdown of

drive motor/engine can be arranged or the user be warned.
– We recommend drive motor/engine shutdown.
– If the overtemperature is detected in time, the loss of coupling fill through the fusib-
le plugs can be avoided. Downtimes are reduced.
– The MTS switching element needs to be replaced after switching operation.
EX PROTECTION!
The thermal switching element MTS is used in potentially explosive areas to
monitor the temperature. The signals indicate pre-alarm. The MTS does not limit
the maximum surface temperature.

8
MTS,
4 Function of MTS
The mechanical thermal switch unit (MTS) consists of two components:
– switching element
– switch
turbo coupling
switching element
switch
bracket
Fig. 1
9
MTS,
4.1 Switching element
– The switching element is inserted into the turbo coupling outer wheel instead of a
blind screw, thus providing a thermal contact between switching element and ope-
rating fluid.
– In exceptional cases, when the space is restricted, it is permitted to install the swit-
ching element in the coupling shell. Please consult Voith Turbo.
– A spring-loaded pin and a chamber filled with solder is integrated in the switching
element. The response temperature of switching element corresponds to the res-
ponse temperature of solder.
– Below the response temperature the solder keeps the pin in its original position.
When the response temperature is reached, the solder releases the pin and a
compression spring presses the pin outside.
– After each MTS response, the switching element is no longer fit for use and has to
be replaced.
4.2 Switch
– Dependent on the space available, the switch is installed parallel or in radial posi-
tion to the turbo coupling axis. The switch is provided with a pivotable switching fin-
ger.
– The switch is wired as snap-action connection with a make-and-break contact.
4.3 Interaction of MTS components

If the turbo coupling with screwed in switching element rotates, then the switching will
permanently pass the switch.
The pin of released switching element actuates the switching finger during coupling
rotation causing the switch to switch over.
DANGER!
Following any shut-down the control system is to be locked in a way that
prevents automatic re-start.
Shut-down must be acknowledged!
For max. permis- The coupling may only be restarted

sible tempera- - if the triggered MTS switching element has been replaced and
ture, see opera-
- if the coupling temperature is below the maximum permissible temperature

ting manual of
allowed during motor start!
turbo coupling,
Chapter 1,
Technical Data
ATTENTION!
In the event of inner wheel drive and a blocked driven machine the function of
MTS is no longer guaranteed!
10
MTS,
5 Technical Data
5.1 Switching element
color coding color coding color coding
M18 x 1.5
M10
M24 x 1.5
~ 4.5
~ 8.5 ~ 10.5
~ 16.5 ~ 24.5 ~ 25
~ 37.5 ~ 33 ~ 57.5
Fig. 2
The following switching elements are available for the different coupling sizes:
Dimension of thread M10 M18 x 1.5 M24 x 1.5
Nominal response
140°C 95 / 110 / 125 / 140 / 160°C 110 / 125 / 140 / 160°C
temperature
Response tolerance ± 5 °C
at 110°C: – 10°C
Suitable for coupling sizes… 154…274 366…650 750…1330
-1 -1 -1
Peripheral speed max. 50.5 ms max. 72 ms max. 72 ms
Wrench size across flats 16 27 32
Tightening torque 22 Nm 60 Nm 144 Nm
Table 2
Note!
– The switching element is marked on the housing with article number and res-
ponse temperature.
– The nominal response temperature of switching element is determined in
connection with the coupling design.
– The response temperature can, additionally, be recognized from a color co-
ment.
ding:
Response temperature Color coding

95°C without color coding (tinplated)

110°C yellow
125°C brown
140°C red
160°C green
Table 3
11
MTS,
5.2 Switch
switching finger
39
21
10
11
85 54.5
21
40
52
Only for flush-
type switch
ExM 61 D 5
5.3
4
nameplate
Fig. 3
Switch, type EM 61 D 1Ö/1S ExM 61 D

Switching capacity 400 V AC, 6 A 250 V AC - 5 A (AC 15)
230 V DC, 0.25 A 230 V DC - 0.16 A (DC 13)
24 V DC, 4.5 A
Minimum load 24 V, 20 mA 20 V, 100 mA
Permissible ambient
-40°C…+80°C -20°C…+60°C
temperature
Degree of protection
IP65 IP65
to DIN EN 60529
Short circuit
16 A gL/gG D-fuse 5 A (slow blow)
protection
Certificates / CSA - LR 85005 - 6 II 2G Ex d IIC T6 Gb
Type of protection UL- File E 57648 A 300 P 300 (PTB 03 ATEX 1069 X).
Project 98 ME 41537 A 300 P 300 II 2D Ex tb IIIC T80°C Db IP65
CCC-2010010305418204 (PTB 03 ATEX 1069 X).
Connection cable entry: M20 x 1.5 4- core PVC cable
(a cable gland for a cable dia- H05 VV-F 0.75 mm²
meter of 5…13 mm and two length: 5 m

plugs)
BU: blue Wiring diagram PE
BN: brown 1 (BU) (GN/YE)
21 13
BK: black
GN/YE: green / yellow
22 14 2 (BN) 4 (BK)
Table 4
12
MTS,
5.2.1 Switch ExM 61 D
Application:
Switch ExM 61 D complies with the European standards for explosion protection
EN 60079-0, EN 60079-1 and EN 60079-3 and is therefore designed for use in the
explosive areas of zone 1 and 2 as well as zone 21 and 22 as per DIN EN 60079-14
and EN 61241-14.
Design / Function:
Switch ExM 61 D contains an explosion-proof contact unit, type ExM 14.
The contact unit is provided with cast-in cable.
The contact unit contains a single-pole double-throw switch (SPDT switch) (jacket
color: blue, brown, and black).
6 Installation
DANGER!
– Observe, in particular, chapter 2 (Safety)!
– On installation please observe that all components are potential-free!
– Fusible plugs
Fusible plugs protect the turbo coupling against damages due to thermal
overload. Even when the MTS is used, the fusible plugs must not get repla-
ced by blind screws or by fusible plugs with other rated response temperatu-
res!
6.1 As delivered condition, scope of supply

– Switching element with seal ring and
– switch
are normally shipped as loose parts, together with the turbo coupling.
Note!
Standard combinations of switching element and fusible plugs:
Response temperatures
Switching element Fusible plugs Color coding
160°C 180°C blue

140°C 160°C green

125°C 160°C green
110°C 140°C red

Table 5
The correlation between switching element and fusible plug may vary according to the Switching
project design. Different response temperatures of the switching element (95°, 110°, elements:
125°, 140° and 160°) are also available. Chapter 10.1,
Please contact Voith Turbo. page 21
Please also refer to order documents.
13
MTS,
6.2 Installation of switching element and switch
ATTENTION!
To avoid any damage install the switching element and the switch after instal-
ling and prior to filling the turbo coupling.
Instead of a blind screw, insert the switching element with seal ring into the turbo
coupling outer wheel.
1)
In case of an input side connecting coupling type ERK and sizes 206 and 274 previously
screw in the intermediate piece.
Note!
In exceptional cases, when the space is restricted, it is permitted to install the swit-
ching element in the coupling shell! Please consult Voith Turbo.
Sizes 154 ... 1330: Sizes 206 and 274

with connecting coupling
Type ERK and intermediate
1)
piece :
øF
øF
a
a H
H
Axial Installation
Radial Installation
øF
øF
a
+2
5
a
Fig. 4
1)
Intermediate piece required for connecting coupling Type ERK and sizes 206 and 274 only.
14
MTS,
Installation dimensions for switching element and switch:
Type of Installation Pitch circle Distance Distance

turbo distance diameter ~H [mm] ~H [mm]
coupling a [mm] Ø F [mm] for connecting coupling
type ERK
154 T 2-0.5 147 92.5 92.5

154 DT 2-0.5 147 114.5 114.5
206 T 2-0.5 196 106.0 129.0
206 DT 2-0.5 196 146.0 169.0
274 T 2-0.5 268 146.5 169.5
274 DT 2-0.5 268 184.5 207.5
366 T 4-1 350 178.0 –
422 T 4-1 396 191.0 –
487 T 4-1 470 213.0 –
562 T 4-1 548 233.0 –
650 T 4-1 630 274.0 –
750 T 4-1 729 325.5 –
866 T 4-1 840 363.5 –
866 DT 4-1 840 607.5 –
1000 T 4-1 972 376.5 –
1000 DT 4-1 972 679.5 –
1150 T 4-1 1128 465.5 –
1150 DT 4-1 1128 790.5 –
1330 DT 4-1 1302 919.5 –
Table 6
15
MTS,
ATTENTION!
– Never install the switch with lateral or angular offset!
– Correct switching function is not guaranteed in case of faulty alignment!
correct! wrong! wrong!
correct! wrong! wrong!
Fig. 5
– The bracket is not Voith's scope of supply!

– Provide a bracket of sufficient stability!
Install the switch on the pitch circle diameter of switching element, on a bracket,
parallel or radial to the turbo coupling axis.
Fig. 4, Set the distance between switching finger and switching element to installation dis-
page 14 tance a!
Put the switching finger in the correct position.

16
MTS,
6.3 Connection
Note!
– Wiring of MTS is not our scope of supply!
– If switching element and fusible plugs are installed in the same outer part,
we basically recommend to switch off the drive on response of MTS!
– The electrical connection may only be carried out by an authorized person.
– We recommend to design the switch connection in a way so that both over-
temperature and cable break result in an overtemperature warning (connect
break contact).
Connect the switch, observe the switching capacity. Protect the connecting cables Chapter 5.2,
against damage due to environmental influence! page 12
The connection cable has to be fixed and laid in a way that it is protected against
mechanical damages.
6.3.1 Connection of switch ExM 61 D (additional information)
Switch ExM 61 D is metal-enclosed. The housing is equipped with an external safety

earth terminal for a maximum of 4 mm². Connection is effected via a cable cast into
the housing of the contact unit. The connecting cable of this switch needs to be fixed
and laid in a manner that it is sufficiently protected against mechanical damages.
It is not allowed to perform any rebuilding or alteration on the switch, which may affect
the explosion protection. Furthermore, DIN EN 60079-14 and EN 61241-14 shall apply
for the installation of electric equipment in potentially explosive areas.
For proper functioning, the switch is to be attached in such a manner that the contact
travel required for switching can safely be reached. During assembly, please observe
that displacing the switch is avoided in any case, even in case of failure. Under no cir-
cumstances must the switch be actuated beyond its inner stop as this may damage
the switch. The switch housing must not be used as a stop. The switch can be
mounted in any desired position.
17
MTS,
7 Maintenance
DANGER!
Please observe, in particular, chapter 2 (Safety) when working on the MTS!
Maintenance schedule:
Time Maintenance work

After response of Replace switching element and then put switching
switching element finger in correct position.
Regularly We recommend quarterly maintenance per the
(maintenance interval following steps:
depends on dust content 1. Check actuator for easy operation.
in the ambient air of the
2. Remove all debris or particles.
switch)
3. Put the switching finger in the correct position.
Table 7
Record all maintenance works in a maintenance book.
ATTENTION!
Danger on account of “release“ of engine. Prevent engine start by disconnec-
ting the connection lines!

18
MTS,
8 Troubleshooting
DANGER!
Please observe, in particular, chapter 2 (Safety) when working on the MTS!
EX-PROTECTION!
You must not change devices which are operated in hazardous areas. Repairs
are not permitted – replace the unit.
The following table serves to find the cause of failures or problems quickly and to take
remedial action, if necessary.
Operating fluid is lost Response temperatures of Please consult Voith Chapter 6.1,
1)
through the fusible switching element and Turbo . page 13
plugs during fusible plugs do not match.
operation, the MTS
switching element did The switching finger was Put the switching finger in Chapter 6.2,
not respond. not in the correct position. the correct position. page 14
The switch is not properly Check the wiring, correct it, Chapter 6.3,
connected. if necessary. page 17
1)
Please consult Voith Turbo , in the event of a malfunction which is not
included in this table.
Table 8
1)
Chapter 9, page 20
19
MTS,
9 Queries, Orders placed for Service

Engineers and Spare Parts
In the event of
– queries
– orders placed for service engineers
– spare parts orders
we need the serial No. and type designation of turbo coupling on which the MTS is
used.
Type T Type TDM-SAE
serial No. / serial No. /

type designation type
designation
Fig. 6 Fig. 7
If an order is placed for a service engineer we need, in addition,

– the turbo coupling site,
– the contact person and his/her address,
– details of the occurred problem.
In the event of a spare parts order we need, in addition,

– the destination of spare parts shipment.
Please first contact your local Voith representation (see Chapter 11).
You may also contact the following addresses:

Voithstr. 1
D-74564 Crailsheim, Germany

Tel. +49 7951 32-1881

Fax. +49 7951 32-480
Outside business hours:

Tel. +49 7951 32-1666
Fax. +49 7951 32-903
coupling-service@voith.com
www.voith-coupling-service.com
20
MTS,
10 Spare Parts Information
ATTENTION!
A professional repair can only be guaranteed by the manufacturer!
10.1 Switching elements
Intermediate-
MTS-Switching elements Sealing ring 1)
piece
Use for Turbo Thread Nominal Color Material-No. Material-No. Material-No.

coupling size dimen- response
sion tempera-
ture
154 – 274 T / DT M10 140°C red TCR.11954250 TCR.03658010 TCR.11959520

95°C - TCR.11978290
110°C yellow TCR.11052260
366 – 650 T M18 x 1.5 125°C brown TCR.11052270 TCR.03658018
140°C red TCR.11052240
160°C green TCR.10671780
110°C yellow TCR.12390160
750 – 1330 T / DT M24 x 1.5 125°C brown TCR.11052220 TCR.03658024
140°C red TCR.10474190
160°C green TCR.11952190
Table 9
1)
Intermediate piece required for connecting coupling Type ERK and sizes 206 and 274 only.
10.2 Switch
Switch type Material-No.
EM 61 D 1Ö/1S TCR.11960720
(ambient temperature -40°C…+80°C)
(replacing TCR.10672530, ambient temperature -20°C…+80°C)

ExM 61 D TCR.11974010
(replacing TCR.10672540)
Table 10
21
MTS,
22
Mechanical, Thermal Switch Unit
- blank page -

- blank page -
MTS,
Mechanical, Thermal Switch Unit
23
MTS,
11 Representatives

            
Voith Turbo GmbH & Co. KG Chr. Boznos and Son S. A. Voith Turbo S. A.
Start-up Components 12, K. Mavromichali Street Avenida de Suiza 3
Voithstr. 1   P.A.L. Coslada
  GREECE   
GERMANY Phone: +30-210-422 5134 SPAIN
Tel.: +49-7951 32-0 Fax: +30-210-422 5159 Phone: +34-91-6707816
Fax: +49-7951 32-480 e-mail: info@boznos.gr Fax: +34-91-6707841
e-mail: startup.components@voith.com e-mail: info.voithturbo@voith.com
www.voithturbo.com/startup-components     
Voith Turbo Limited    
6, Beddington Farm Road Voith Turbo AB
     Finspångsgatan 46
Indukont Antriebstechnik GmbH GREAT BRITAIN  
Badenerstraße 40 Phone: +44-20-8667 0333 SWEDEN
  Fax: +44-20-8667 0403 Phone: +46-8-564-755-50
AUSTRIA e-mail: Turbo.UK@voith.com Fax: +46-8-564-755-60
Phone: +43-2252-81118-22 e-mail: voithturbo.sweden@voith.com
Fax: +43-2252-81118-99 
e-mail: info@indukont.at see Great Britain ( VTGB ) 
see Germany ( VTCR )
       
Voith Turbo S. A. / N. V. Voith Turbo s.r.l.
Square Louisa 36 Via G. Lambrakis 2
    
BELGIUM ITALY
Phone: +32-2-7626100 Phone: +39-05-2235-6714
Fax: +32-2-7626159 Fax: +39-05-2235-6790
e-mail: voithturbo.be@voith.com e-mail: info.voithturbo@voith.com
    

Voith Turbo A/S see Germany ( VTCR )
Egegårdsvej 5
  
DENMARK see Belgium ( VTBV )
Phone: +45-46 141550
Fax: +45-46 141551   
e-mail: postmaster@voith.dk Voith Turbo B.V.
Koppelstraat 3
      
Masino Oy THE NETHERLANDS
Kärkikuja 3 Phone: +31-571-2796-00
  Fax: +31-571-2764-45
FINLAND e-mail: voithnederland@voith.com
Phone: +358-10-8345 500
Fax: +358-10-8345 501    
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Gamle Leirdals vei 3
     
Voith Turbo S. A. S. NORWAY
21 Boulevard du Champy-Richardets Phone: +47 2408 4800
   Fax: +47 2408 4801
FRANCE e-mail: info.turbo.norway@voith.com
Phone: +33-1-4815 6903

Fax: +33-1-4815 6901 

e-mail: voithfrance@voith.com see Spain ( VTEV )
24
MTS,
 
 Voith Turbo     
see Hungary ( VTHU ) Branch Office Novokusnetsk see France ( VTFV )
( Shcherbinin, Anatoliy )    
  Skorosnaya ul. 41, Liter B1 Voith Turbo Ltda. 
see Hungary ( VTHU )   Rua Friedrich von Voith 825 see South Africa ( VTZA )
Kemerovskaya oblast     

 RUSSIA 
Copam Egypt
see Hungary ( VTHU ) Phone/Fax: +7 3843 311 109 BRAZIL
33 El Hegaz Street, W. Heliopolis
mobil: +7 9132 802 110 Phone: +55-11-3944 4393
 
 e-mail: voith22@bk.ru Fax: +55-11-3941 1447
see Hungary ( VTHU ) EGYPT
e-mail: info.turbo-brasil@voith.com
Phone: +202-22566 299

         Fax: +202-22594 757
see Hungary ( VTHU )
Voith Turbo s.r.o. Voith Turbo Colombia Ltda. e-mail: copam@datum.com.eg
Hviezdoslavova 1a   Calle 17 No. 69-26

  see Czech Republic ( VTCZ ) Centro Empresarial Montevideo
see France ( VTFV )
CZECH REPUBLIC  
Phone: +420-543-176163  COLOMBIA 
Fax: +420-548-226051 see Hungary ( VTHU ) Tel.: +57 141-20590 see France ( VTFV )
e-mail: info@voith.cz Fax: +57 141-17664
    e-mail: wmo_voith_tpt@etb.net.co  
 Voith Turbo Ukraine TOW see France ( VTFV )
see Poland ( VTPL )    
Degtyarivska Str. 25, building 1
Voith Turbo S. A. 
  see South Africa ( VTZA )
    Av.Pdte.Eduardo Frei Montalva 6115
UKRAINE
Voith Turbo Kft.    
Phone: +380-44-489 4621    
Felvég Útca 4 
Fax: +380-44-489 4621 Voith Turbo S.A.
  CHILE
e-mail: Dmitriy.Kalinichenko@Voith.com Rue Ibnou El Koutia, No. 30
HUNGARY Phone: +56-2-944-6900
Fax: +56-2-944-6950 Lot Attawfiq Quartier Oukacha
Phone: +36-23-312 431 see also Poland ( VTPL )  
Fax: +36-23-310 441 e-mail: voithturbo.chile@voith.cl
MAROCCO
e-mail: www.magyar.voithturbo.hu Tel:. +212 522 34 04 41
   
Voith Turbo S.A.C. Fax. +212 522 34 04 45
 e-mail: info@voith.ma
Av. Argentinia 2415
see Poland ( VTPL )
   
PERU 
     Phone: +51-1-6523014 see Spain ( VTEV )
see Poland ( VTPL ) Voith Turbo Inc. Fax: +51-1-6383424 
171 Ambassador Drive, Unit 1 e-mail: Israel.Jahnsen@Voith.com
     see South Africa ( VTZA )
see Hungary ( VTHU ) CANADA see also Brazil ( VTPA )

Phone: +1-905-670-3122 see South Africa ( VTZA )
    Fax: +1-905-670-8067
Voith Turbo sp.z o.o. e-mail: information@voithusa.com 
Majków Du y 74 see France ( VTFV )
      
POLAND Voith Turbo S.A. de C.V. 
Phone: +48-44 646 8848 Alabama No.34 see France ( VTFV )
Fax: +48-44-646 8520 Col. Nápoles Delg. Benito Juarez
e-mail: voithturbo.polska@voith.com         
MÉXICO Voith Turbo Pty. Ltd.
    Phone: +52-55-5340 6970 16 Saligna Street
Voith Turbo S.R.L. Fax: +52-55-5543 2885 Hughes Business Park
Pipera Business Tower, e-mail: vtx-info@voith.com   
10th Floor, 2nd Office SOUTH AFRICA
see also U.S.A. ( VTI ) Phone: +27-11-418-4007
Blv. Dimitrie Pompeiu 8
  Fax: +27-11-418-4080
    e-mail: info.vtza@voith.com
ROMANIA Voith Turbo Inc.
Phone: +40-31-22 36100 25 Winship Road

Fax: +40-21-22 36210    see South Africa ( VTZA )

e-mail: voith.romania@voith.com UNITED STATES
Phone: +1-717-767 3200 
    Fax: +1-717-767 3210 see France ( VTFV )
Voith Turbo O.O.O. e-mail: VTI-Information@voith.com

Branch Office Moskau 
Nikolo Yamskaya ul. 21/7, str. 3 see South Africa ( VTZA )
 
RUSSIA 
Phone: +7 495 915-3296 see South Africa ( VTZA )
Fax: +7 495 915-3816
mobil Herr Bulanzev: +7 919 108 2468
e-mail: voithmoscow@Voith.com
25
MTS,
      

      
see United Arabian Emirates ( VTAE ) Voith Turbo Pty. Ltd. see Hongkong ( VTEA ) Sae-Rim Voith Corporation
Branch Office Sydney Room #1408, Dae Chong Bldg., 143-
 503 Victoria Street Voith Turbo GmbH & Co. KG ( VTCB ) 48
see United Arabian Emirates ( VTAE )     Representative Office Beijing Samsung-Dong, Kangnam-Gu
AUSTRALIA Unit 808, Di Yang Tower, No. H2 C.P.O. Box 9666
    Phone: +61-2-9609 9400 Dongsanhuanbeilu, Chaoyang District  
Voith Turbo Iran Co., Ltd. Fax: +61-2-9756 4677   SOUTH COREA
1st Floor, No. 215 e-mail: vtausydney@voith.com CHINA Phone: +82-2-557 4368
East Dastgerdi Ave. Phone: +86-10-8453 6322/23 Fax: +82-2-563 7734
Modarres Highway     Fax: +86-10-8453 6324 e-mail: vskorea@hanafos.com
  Voith Turbo NZ Pty. Ltd. e-mail: VT_Industry_China@Voith.com
IRAN Level 3, 310/60 Cook Street 
Phone: + 98-21-2292 1524   Voith Turbo Power Transmission see Hongkong ( VTEA )
Fax: + 98-21-2292 1097 NEW ZEALAND (Shanghai) Co. Ltd. ( VTCN )
e-mail: voithturbo.iran@voith.ir Phone: +64 935 89078 Representative Office Shanghai 
Fax: +64 935 89070 No. 265, Hua Jin Road see Taiwan ( VTTI )
 e-mail: VTNZ@voith.com  
see United Arabian Emirates ( VTAE ) CHINA    
Phone: +86-21-644 286 86 Voith Turbo Co. Ltd.
      Fax: +86-21-644 286 10 Taiwan Branch
Voith Turbo Israel Ltd. e-mail: VT_Industry_China@Voith.com No. 3 Taitang Road,
Tzvi Bergman 17  Xiaogang District.
  see Singapore ( VTSG ) Service Center ( VTCT ):   
ISRAEL Voith Turbo Power Transmission TAIWAN, R.O.C.
Phone: +972-3-9131 888  (Shanghai) Co. Ltd. Phone: +886-7-806 1806
Fax: +972-3-9300 092 see Singapore ( VTSG ) Taiyuan Branch Fax: +886-7-806 1515
e-mail: tpt.israel@voith.com No. 36 Workshop, TISCO, e-mail: vtti@voith.com.tw
    No. 73, Gangyuan Road
 Voith Turbo Private Limited   
 Transmissions and Engineering P.R. CHINA
 P.O. Industrial Estate Phone: +86 351 526 8890
    Fax: +86 351 526 8891
 INDIA e-mail: VT_Industry_China@Voith.com
  Phone: +91-40-27173 561+592
 Fax: +91-40-27171 141    
 e-mail: info@voithindia.com Voith Turbo Ltd.
see United Arabian Emirates ( VTAE ) 908, Guardforce Centre,
 3 Hok Yuen Street East,
    see Singapore ( VTSG )  
Voith Turbo Güç Aktarma Tekni i Ltd. ti. HONG KONG
Birlik Mah. 415. Cadde No. 9/5  Phone: +85-2-2774 4083
  see Singapore ( VTSG ) Fax: +85-2-2362 5676
TURKEY e-mail: voith@voith.com.hk
Phone: +90 312 495 0044 
Fax: +90 312 495 8522 see Singapore ( VTSG )    
e-mail: info@aserman.com.tr Voith Turbo Co., Ltd.
 9F, Sumitomo Seimei Kawasaki Bldg.
      see Singapore ( VTSG ) 11-27 Hlgashida-chou, Kawasaki-Ku,
P.O.Box 263461 Kawasaki-Shi,
Plot No. TP020704      
Technopark, Jebel Ali Voith Turbo Pte. Ltd. JAPAN
 10 Jalan Lam Huat Phone: +81-44 246 0335
UNITED ARAB EMIRATES Voith Building Fax: +81-44 246 0660
Phone: +971-4 810 4000   e-mail: fvc-taki@fsinet.or.jp
Fax: +971-4 810 4090 SINGAPORE
e-mail: voith-middle-east@voith.com Phone: +65-6861 5100
Fax: +65-6861-5052
e-mail: sales.singapore@voith.com

see Singapore ( VTSG )

see Singapore ( VTSG )
26
MTS,
12 Index
Applications ..................................... 8 Proper use....................................... 4

As delivered condition.................... 13
Qualification..................................... 7
Catch pan ........................................ 7 Queries.......................................... 20
Characteristics................................. 8
Color coding .................................. 11 Representatives............................. 24
Connection .................................... 17 Response temperature .................. 11
Electrical devices ............................. 7 Safety .............................................. 5

Scope of supply ............................. 13
Function........................................... 9 Serial No........................................ 20
Fusible plugs ................................... 7 Sound pressure level....................... 6
Spare parts...................................... 3
Hazardous areas ............................. 6 Spare parts information ................. 21
Hazards ........................................... 5 Spare parts order........................... 20
Switch
Installation ............................... 13, 14 Function ................................... 10
Installation dimensions .................. 15 Switching element
Function ................................... 10
Maintenance .................................. 18 Symbols........................................... 5
Maintenance schedule................... 18
Technical data
Noise ............................................... 6 Switch ................................ 12, 13
switching element .................... 11
Order place for a service engineer 20 Tools................................................ 7
Overload .......................................... 7 Troubleshooting............................. 19
Overtemperature ............................. 8 Type designation ........................... 20
Prevention of accidents ................... 6 Wiring ............................................ 17
Product observation......................... 7
27
Start-up Components
Voithstr. 1
74564 Crailsheim
GERMANY
Tel. +49 7951 32-0
Fax. +49 7951 32-480
www.voithturbo.com/
startup-components

28
BAWN 006-GBR-1
8/2011
Assembly and operating instructions TSCHAN®

Flexible coupling
®
Nor-Mex GBT, GTW, GBS
TSCHAN GmbH Zweibrücker Straße 104 D-66538 Neunkirchen-Saar

Telefon: +49(0) 6821 866 0 Telefax: +49(0) 6821 883 53 www.tschan.de
Content
Chapter Page
1 Notes on safety ................................................................................................................ 2

2 Function ........................................................................................................................... 3
2.1 Appropriate Use......................................................................................................... 3
3 Marking of the coupling .................................................................................................... 4
4 Storage ............................................................................................................................ 4
5 Construction ..................................................................................................................... 5
6 Technical data .................................................................................................................. 6
7 Assembly ......................................................................................................................... 8
7.1 Pay attention before the assembly ............................................................................ 8
7.2 Finished borehole ...................................................................................................... 9
7.3 Installing coupling .................................................................................................... 10
8 Adjusting coupling .......................................................................................................... 11
8.1 Angular misalignment DKw ....................................................................................... 12
8.2 Radial displacement DKr .......................................................................................... 12
8.3 Axial displacement................................................................................................... 13
9 Operation ....................................................................................................................... 14
9.1 Check of Direction of Rotation ................................................................................. 17
10 Maintenance................................................................................................................... 19
10.1 Wear Inspection on the Buffer Ring ......................................................................... 19
10.2 Wear limit of elastic buffers...................................................................................... 20
10.3 Changing the elastic intermediate ring .................................................................... 21
10.4 Assembly brake drum/disk....................................................................................... 22
11 Waste Disposal .............................................................................................................. 22
1 Notes on safety
The present assembly and operating instruction (AOI) constituents a part of the coupling
supply. Always keep the AOI near the coupling well accessible.
The German version of this manual is the predominant and binding version.
Make sure that all persons charged with the assembly, operating, service, and maintenance
have read and understood the AOI and follow all the points:
- Avert hazards for body and live of the user and third parties.
- Ensure the operating safety of the coupling.
- Avoid the loss of use and environmental impairment through false handling.
In the case of transport, mounting, dismounting and maintenance, attention is to be paid to

the relevant regulations for industrial safety and for environmental care.
The coupling may only be operated, mounted, serviced and maintained by authorised and
trained personnel.
bawn006-gbr-1 Nor-MexÒ GBT, GTW, GBS -2-

The user must take into account that the bolting elements of coupling parts may be adversely
affected by the heat produced by a brake disk/ brake drum due to the resultant friction. Make
sure that the combination of the employed brake lining with the material of the brake disk/
brake drum does not lead to sparks or impermissible thermal growth. The brake disk is
normally made of steel, and the brake drum is normally made of cast iron with nodular
graphite. In case of any doubt, please consult the supplier!
In the interest of further development, we reserve the right to make changes which serve
technological progress.
By the use of accessories and spare parts, which were not originally manufactured by
TSCHAN GmbH, we are not responsible for any resulting damage or liability or guarantee.
2 Function
The coupling Nor-Mex ® -GBT, GTW, GBS is a torsionally elastic and puncture-proof claw
coupling.
It balances out angular, radial, and axial shaft misalignments within defined limits. The
coupling transfers the torque via pressure loadable, elastic buffers of Perbunan (Pb) which
are joined together as an intermediate ring.
The elastic intermediate ring can cushion impacts and torsional vibrations; it is oil-tight and
electrically conductive.
The elastic intermediate ring can be changed without axially shifting the machine.
The coupling is usable in every sense of rotation and installation position.
2.1 Appropriate Use
· The coupling must only be operated in normal industrial atmospheres. Since aggressive
media may attack the coupling components, screws and elastic buffer rings, they
represent a risk for the operational safety of the coupling. Consult TSCHAN GmbH in
such cases.
· In order to ensure a faultless, lasting operation of the coupling it must be laid out accord-
ing to the layout instructions e.g. DIN 740 part 2 (or also catalogue Nor-Mex Ò) with an
operating facture corresponding to the operating conditions.
· Apart from incorporating a finished bore hole with parallel key groove (see “7.2 Finished
borehole”) no further changes can be carried out on the coupling.
· The coupling may only be used within the framework of the conditions defined in the
performance and delivery contract.
· Every change of the conditions of use or the operating parameters necessitates a new
verification of the coupling layout.

3 Marking of the coupling
The product line Nor-Mex ® has its hardness in Shore (A) indicated on the elastic intermedi-
ate ring.
4 Storage
On receipt of the goods, the supply is to be checked immediately for completeness and
correctness. Possible damages incurred during transit and / or missing parts are to be
notified in writing.
The coupling parts can be stored in their delivered standard-state for 6 months in a dry,
roofed place at normal room temperature. For a longer storage duration a long-term preser-
vation is necessary (consult TSCHAN GmbH). The elastic intermediate ring must not be
subjected to ozone containing mediums, direct solar influence or strong light sources with
ultraviolet-light. The relative humidity must not exceed 65%. In the case of proper storage the
characteristics of the elastic intermediate ring remain unchanged for almost up to three years.

5 Construction
1. Pan-head screw DIN 912

2. Locking washer (caging-washer)
1 Pan-head
3. screw DINpart
Claw ring 912102
2 Locking4. washer
Flange(caging-washer)
hub part 104
3 Claw ring
5. part 102…0X3
Elastic intermediate ring part 010
4 Flange6.hubCoupling
part 104hub part 108
5 Elastic7.intermediate
Brake drum ring part
part 010
500
6 Coupling
8. flange FE/FG part
Twiflex-brake disk102…0X4
part 506
9. Locking washer (caging-washer)
10. Hexagon head screw DIN 933
®
Fig. 1 Construction Nor-Mex GBT, GTW
Details:
Claw ring (Pos. 3) and flange hub (Pos. 4), coupling hub (Pos. 6) and brake drum/disk (Pos.
7/8) are always delivered screwed together.
Balanced parts are match marked to each other.

6 Technical data
®
Fig. 2 Nor-Mex GBT, GTW
Table 1 Technical Data:

size TCnom TCpeak TCnom TCpeak
Nor-Mex Pb72 Pb72 Pb82 Pb82
[Nm] [Nm] [Nm] [Nm]
112 150 310 230 540
128 250 500 380 650
148 390 800 600 1350
168 630 1300 980 1800
194 1050 2000 1650 2400
214 1500 3100 2400 4200
240 2400 4800 3700 6200
265 3700 7500 5800 8300
295 4900 10000 7550 10500
330 6400 13000 9900 14500
370 8900 18200 14000 20000
415 13200 27000 20500 27000
Table 2 Nor-Mex ® GBT :

d5 DB-B TBR nmax d2 d6 d4 d7 lE lG LG C S1 S2 z x M x Ls MA m
max max undrilled
-1
[mm] [Nm] [Nm] [min ] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] DIN 933 8.8 [Nm] [kg]
112 200-75 450 4200 46 42 64,5 68 60 58 133 11,0 3,5±1,0 15±1,0 6 x M8 x 20 25 10,2
128 200-75 550 4200 53 52 74,5 85 70 68 154 16,0 3,5±1,0 16±1,0 6 x M8 x 25 25 13,0
148 250-95 1000 3400 65 58 92,5 94 80 78 176 16,0 3,5±1,0 18±1,0 6 x M10 x 25 49 21,5
250-95 3400 19,0 8 x M10 x 30 27,8
168 1600 75 72 104,5 118 90 87 198 3,5±1,5 21±1,5 49
315-118 2700 8,0 8 x M10 x 30 37,0
194 315-118 2750 2700 85 85 121,5 138 100 97 221 16,5 3,5±1,5 24±1,5 8 x M12 x 30 85 45,4
315-118 2700 19,0 55,6
214 3350 95 92 135,5 153 110 107 243 4,0±2,0 26±2,0 9 x M12 x 35 85
400-150 2100 12,5 71,4
450-150 2100 18,0 83,5
240 4200 100 102 146,0 168 120 117 267 4,0±2,0 30±2,0 10 x M12 x 35 85
500-190 1700 9,0 110,5
265 500-190 8700 1700 115 120 164,0 198 140 137 310 22,0 5,5±2,5 33±2,5 10 x M16 x 40 210 134,4
500-190 1700 30,0 10 x M16 x 40 210 155,5
295 9800 130 130 181,0 214 150 147 334 8,0±2,5 37±2,5
630-236 1360 5,0 10 x M16 x 45 210 209,1
630-236 1360 11,0 240,2
330 10600 135 150 208,0 248 160 156 356 8,0±2,5 40±2,5 10 x M16 x 45 210
710-265 1200 0,0 278,3
370 710-265 13500 1200 160 170 241,0 278 180 176 399 15,0 8,0±2,5 43±2,5 11 x M16 x 45 210 332,0
415 710-265 16000 1200 180 185 275,0 308 200 196 441 25,0 8,0±2,5 45±2,5 12 x M16 x 55 210 414,3

Table 3 Nor-Mex ® GTW:
d5 A-G TBR nmax d2 d6 d4 d7 lE lG LG C1 C2 S1 S2 z x M x Ls MA m
max max undrilled
-1
[mm] [Nm] [Nm] [min ] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] DIN 933 8.8 [Nm] [kg
250-12,7 4580 55,8 2,5 6 x M8 x 16 9,0
112 450 46 42 64,5 68 60 58 133 3,5±1,0 15±1,0 25
300-12,7 3820 53,8 -2,5 6 x M8 x 22 12,0
128 300-12,7 550 3820 53 52 74,5 85 70 68 154 60,8 4,5 3,5±1,0 16±1,0 6 x M8 x 25 25 14,7
148 300-12,7 1000 3820 65 58 92,5 94 80 78 176 67,8 11,5 3,5±1,0 18±1,0 6 x M10 x 25 49 18,8
356-12,7 3225 81,8 28,8
168 1600 75 72 104,5 118 90 87 198 2,5 3,5±1,5 21±1,5 8 x M10 x 30 49
406-12,7 2825 84,8 31,6
406-12,7 2825 90,8 40,6
194 2750 85 85 121,5 138 100 97 221 8,5 3,5±1,5 24±1,5 8 x M12 x 30 85
457-12,7 2510 87,8 45,6
406-12,7 2825 96,8 9 x M12 x 30 50,2
214 3350 95 92 135,5 153 110 107 243 14,5 4,0±2,0 26±2,0 85
457-12,7 2510 93,8 9 x M12 x 35 55,2
457-12,7 2510 67,2
240 4200 100 102 146,0 168 120 117 267 100,8 21,5 4,0±2,0 30±2,0 10 x M12 x 35 85
514-12,7 2230 72,2
457-12,7 2510 90,8
265 8700 115 120 164,0 198 140 137 310 115,8 36,5 5,5±2,5 33±2,5 10 x M16 x 35 210
514-12,7 2230 95,8
514-12,7 2230 117,0
295 9800 130 130 181,0 214 150 147 334 123,8 44,5 8,0±2,5 37±2,5 10 x M16 x 35 210
610-12,7 1880 128,0
514-12,7 2230 148,0
330 10600 135 150 208,0 248 160 156 356 129,8 50,5 8,0±2,5 40±2,5 10 x M16 x 40 210
610-12,7 1880 159,0
610-12,7 1880 143,8 11 x M16 x 40 210,9
370 13500 160 170 241,0 278 180 176 399 64,5 8,0±2,5 43±2,5 210
711-12,7 1615 140,8 11 x M16 x 45 226,6
610-12,7 1880 160,8 12 x M16 x 40 280,8
711-12,7 1615 157,8 12 x M16 x 45 296,2
415 16000 180 185 275,0 308 200 196 441 81,5 8,0±2,5 45±2,5 210
812-12,7 1410 329,2
151,8 12 x M16 x 50
915-12,7 1255 359,6
The torque TCnom and TCpeak is valid for:

- Intermediate rings of Perbunan Pb72 and/or Pb82,
- Ambient temperatures of -30 °C to +60 °C,
- Operation within the stipulated alignment values.
During the layout of the coupling according to DIN 740 part 2 (or also catalogue Nor-Mex®)
different factors must be considered:
- with higher temperatures a corresponding temperature factor Su
- according to the starting frequency a starting factor Sz
- in dependence on the operating conditions an impact factor, SA, SL
With circumferential speeds of more than 22 m/s, we recommend to balance the coupling.
For GBS see installation drawing

7 Assembly
7.1 Pay attention before the assembly
· Danger of injuries!
· Disconnect the drive before carrying out any work on the coupling!
· Secure the drive against unintentional re-start and rotation!
· Incorrectly tightened bolts can cause serious personal injuries and
property damages!
· Assemble the coupling outside of the danger zone. Take care that
suitable transportation means are at disposal and that the transpor-
tation ways are free of obstacles.
· In compliance with accident prevention regulations, you are
obliged to protect all freely rotating parts by means of permanently
installed guards/ covers against unintentional contact and falling
down objects.
· To avoid sparks, the covers for couplings used should be made of
stainless steel!
· As a minimum, the covers have to fulfil the requirements of protec-
tion type IP2X.
· The covers have to be designed to prevent dust from depositing on
the coupling.
· The cover must not contact the coupling or impair the proper
function of the coupling.
· Make sure that the intended rotational speeds and torques as well as the ambient tem-
peratures do not exceed the values indicated in “6 Technical Data”.
· The maximum permissible borehole diameter must not be exceeded.
· Check whether the shaft hub connections can safely transmit the occurring operating
torques.
· The standard TSCHAN tolerance for the finished boreholes is fit H7.
· Standard parallel key slot is according to DIN 6885 page 1.
· Check the dimensions and tolerances of shafts, hub boreholes, parallel key and slot.
· Adjust setscrews as required.

7.2 Finished borehole
For the completion of the finished borehole in a coupling hub, pay attention to following
procedure:
· Clean the coupling hub of preservatives.
· Tighten the coupling hub to the faces labelled with éand carefully align the coupling hub.
· The indicated values in table 2 and 3 for ød2max and ød6max are valid for a parallel key
connection according to DIN 6885/1 and must not be exceeded.
· Choose the borehole fit so that during the union with the shaft tolerance a wringing fit
and/or an interference fit as for example at H7/m6 is carried out.
· Provide a setscrew for axial securing on the hub back above the parallel key slot.
In the case of other shaft hub connections consultation with TSCHAN GmbH is necessary.
· The maximum indicated borehole diameters are valid for a parallel

key connection according to DIN 6885/1 and must not be exceeded.
· In the case of transgression of these values the coupling can
sever.
· Through flying away fragments danger exists!

7.3 Installing coupling
· Remove the elastic intermediate ring (Figure

3, pos. 1).
· Clean the borehole of the flange hub and the
shaft end before installing. The surfaces must
be clean, dry and grease-free.
· Use suitable installation aids and hoists such
as cranes or pulley blocks in the case of
bigger couplings.
· Pull the pre-mounted coupling halves in the
intended position on the shaft ends (Figure 3,
pos. 2).
Fig. 3
Reference:
For easier installation a uniform warming of the hub to 80 °C to 120 °C is safe.
§ Warning!
§ Only work with gloves as a protection against hot parts of the

coupling!
· Mount the hub so that the shaft ends

are flush with the interior borehole
opening (Figure 4).
Pay attention to possible differing
agreements!
· Secure possible available setscrews
by tightening with an adhesive e.g.
Loctite 222 against automatic loosen-
ing and flying out.
Fig. 4
bawn006-gbr-1 Nor-MexÒ GBT, GTW, GBS - 10 -

ATTENTION!
Let the hot hub cool off to ambient temperature before the introduction of the interme-
diate ring.
· For easier mounting the elastic intermediate

ring can be provided with a slip additive (e.g.
Talcum) before introduction.
· Fit the intermediate ring into one half of the
coupling
· Push the shaft end with the mounted
coupling halves together (Figure 5).
· Adjust the coupling according to the follow-
ing specifications in “8 Coupling adjustment”.
Fig. 5
8 Adjusting coupling
§ Injury hazard!
§ Switch-off the drive before all work on the coupling!

§ Secure the drive against unintentional switching on and rotating!
§ Reference:
§ An exact alignment of the coupling increases the service life of the
elastic intermediate ring.
§ Do not exceed the maximum permissible displacement values. The
overstepping of these values results in coupling damage and
breakdown!
· When aligning the cold equipment take into account the expected thermal growth of the
components, so that the permissible misalignment values for the coupling are not
exceeded in operation.
· Be aware that the coupling under misalignment imposes restoring forces on the adjacent
shafts and bearings. Take into account that the larger the misalignment, the greater the
restoring forces will be.
· The displacements values indicated in the tables 4 to 6 are maximum permissible guide
numbers.
We recommend not to fully utilise these values during the alignment, so that in operation
sufficient reserves remain for thermal expansions, foundation settlements etc.
· In special cases with high demands on quiet running or high rotating speeds it is possible
that, in the three displacement levels, an alignment accuracy of £ 0,1 mm is necessary.
· If the coupling is mounted in a closed housing / casing so that a subsequent alignment is
not possible any more, it must be guaranteed that the geometry and fit accuracy of the
contact surfaces in operation aligns the shafts exactly within the mentioned tolerances.

8.1 Angular misalignment DKw
· Measure on the face of the

external diameter a complete
rotation (360°). Determine in this
case the greatest deviation DKw1
as well as the smallest deviation
DKw2 (Figure 6).
· Calculate the angular misalign-
ment DKw = DKw1 - DKw2.
· The values in table 4 are valid for
a reference rotation speed of
1500 min-1.
Fig. 6
Table 4 Maximum permissible displacement values - angular:

Size 112 128 148 168 194 214 240 265 295 330 370 415
DKw max [mm] 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3
8.2 Radial displacement DKr
· Measure a complete rotation (360°).

Determine in this case the greatest
deviation DKr1 as well as the smallest
deviation DKr2 (Figure 7).
· Calculate the radial displacement
DKr = 0,5 x (DKr1 - DKr2). Pay atten-
tion to the operational sign of the
measured values.
· The values of table 5 are valid for a
reference rotation speed of
1500 min-1.
Fig. 7
Table 5 Maximum permissible displacement values - radial:

Size 112 128 148 168 194 214 240 265 295 330 370 415
DKr max [mm] 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3

8.3 Axial displacement
· Measure the axial S1 gap measurement

according to figure 8.
· Keep, when aligning the gap measurement S,
to the maximum permissible tolerance X
according to table 6.
ATTENTION!
If greater axial displacements are expected in
operation, consultation with TSCHAN GmbH is
necessary.
Fig. 8
Table 6 Recommended alignment values - axial:

Size 112 128 148 168 194 214 240 265 295 330 370 415
S [mm] 3,5 3,5 3,5 3,5 3,5 4 4 5,5 8 8 8 8
X [mm] ±1 ±1 ±1 ±1,5 ±1,5 ±2 ±2 ±2,5 ±2,5 ±2,5 ±2,5 ±2,5

9 Operation
When using the coupling attention is to be paid to its characteristics (see „6 Technical data”).
These can in no case be exceeded without having a written agreement from TSCHAN
GmbH.
In order to guarantee a faultless, lasting operation of the coupling, it must be laid out accord-
ing to the regulations e.g. DIN 740 part 2 (or according to catalogue Nor-Mex Ò) with an
operating factor corresponding to its operating conditions.
Every change of the conditions of use or the operating parameters makes an inspection of
the coupling layout urgently necessary.
§ Injury danger!
§ Secure the drive against unintentional switch-on and rotating!
§ Due to incorrectly tightened screws parts can fly away and cause
serious injuries to persons and damage to material!
§ Check before commissioning the coupling the alignment and all
screw fastenings for their specified tightening torque and/or firm
seating!
§ Before commissioning the plant install all protective devices
against unintentional touching of free moving and/or rotating parts.
§ To avoid sparks coverings in stainless steel should be used.
§ The coverings must fulfil at least the protection type IP2X.
§ The covering is to be so designed that it does not deposit dust onto
the coupling parts.
§ The covering must not touch the coupling or influence it in its
functioning.
Pay attention during the operation of the coupling to:

§ Changed running noises
§ Occurring vibrations
Attention!
· If irregularities are found during operation of the coupling, the drive must be
immediately switched off.
· Detect according to the following table 7, “Operating faults and their possible causes” the
faults and remove.
The listed faults are some examples which are supposed to facilitate fault location.
· For fault finding and elimination all machine components and operating states are
to be considered!

Table 7 Operating faults and their possible causes:
Trouble Cause Risk Warning Correction

Irregular Alignment fault Considerable - Disconnect drive
running increase in - Remove cause for alignment fault
noises/ coupling tempera- - Re-align coupling
vibrations ture. Premature - Inspect elastomer for wear
wear of elastic
buffers. Increased
reaction forces act
on connected
machines.
Elastomer Coupling claws - Disconnect drive
worn out strike against - Check coupling components for
each other. Spark damages and replace parts, if nec-
formation, claw essary
fracture, in- - Replace elastomer
creased reaction
forces.
Unbalance Considerable - Disconnect drive
increase in - Verify balance state of plant compo-
coupling tempera- nents and correct it, if necessary
ture. Premature - Inspect elastomer for wear
wear of elastic
buffers. Increased
reaction forces act
on connected
machines
Loose Flying off parts - Disconnect drive

screw can cause serious - Check coupling parts for damages,
connec- injuries and replace parts, if necessary
tions considerable - Verify alignment of coupling
damages. - Tighten screws to the specified
tightening torque and secure them
against working loose, if necessary,
- Inspect elastomer for wear
Premature Alignment fault Considerable - Disconnect drive
wear of increase in - Remove cause for alignment fault
elastomer coupling tempera- - Re-align coupling
ture. Increased - Inspect elastomer for wear
reaction forces act
on connected
machines.

Trouble Cause Risk Warning Correction
Unaccept- Material proper- - Disconnect drive
able ties of elastic - Replace elastomer
tempera- buffers change. - Re-align coupling
tures The torque - Adjust ambient temperature
transmission
capability is
adversely af-
fected.
Contact Material proper- - Disconnect drive
with ties of elastic - Check coupling parts for damages
aggressive buffers change. and replace parts, if necessary
products The torque - Replace elastomer
transmission - Verify alignment of coupling
capability is - Prevent contact with aggressive
adversely af- products
fected.
Torsional Considerable - Disconnect drive

vibrations increase in - Analyse and eliminate cause for
in the drive coupling tempera- torsional vibrations
line ture. Premature - Check coupling parts for damages
wear of elastic and replace parts, if necessary
buffers. Increased - Replace elastomer and consult
reaction forces act TSCHAN GmbH concerning even-
on connected tual use of another Shore-hardness
machines. - Verify coupling alignment
Claw break- Wear limit Coupling is - Disconnect drive

age of elas- destroyed. - Replace coupling
tomer Connected - Inspect the elastomer for wear at
exceeded machines can be shorter intervals
===> affected, too.
contact of
claws
Overload Coupling is - Disconnect drive
due to too destroyed. - Verify coupling design in coopera-
high torque Connected tion with TSCHAN GmbH
machines can be - Replace coupling
affected, too. - Install larger coupling, if necessary

9.1 Check of Direction of Rotation
§ Injury danger!
§ Due to incorrectly screwed on screws, parts can fly away and
cause person and material damage!
§ Check before commissioning the coupling the alignment and all
screw fixings for their specified tightening torque and/or firm seat-
ing!
§ Before commissioning the plant all protective devices against
unintentional touching of free moving and/or rotating parts must be
installed.
§ To avoid sparks coverings should be made of stainless steel!
§ The covering is to be designed in such a way that it does not
deposit dust onto the coupling parts.
§ The covering must not touch the coupling and/or influence it in its
function.
· Remove the fixing screws on the

claw ring and push it back (Figure 9,
Pos. 1).
· Secure the claw ring against uninten-
tional displacement.
· Cut through the intermediate ring at a
connecting part (Figure 9, pos. 2).
· Pull out the intermediate ring. Start at
the cut through connecting part.
Fig. 9
· Attention!
· Make sure, that the coupling halves can not move axially during the
sense of rotation test.
· The coupling half with the pulled back claw ring must remain
stationary during the sense of rotation test.
· The rotating half must not touch the stationary half!
· Check the direction of rotation.

· Cut through a new intermediate ring at a connecting part and fit it between coupling hub
and flange.
· To obtain an easier mounting one can provide the new elastic intermediate ring with a slip
additive before its introduction (e.g. talcum powder).

Attention!
The bearing surface of the claw ring and flange hub must be clean, dry and grease-
free. Balanced parts are position marked to each other.
· Mount the claw ring in its marked position with

respect to the hub. Pay attention that the join-
ing parts do not tilt on the centring seat and to
the position of the abrasive marking. (see
chapter 10).
· Slightly tighten the screws uniformly.
· Tighten the claw ring threaded joint with the
tightening torque MA stipulated in table 8 (Fig-
ure 10).
· Check the alignment of the coupling according
to the specifications in „8 Coupling adjust-
ment”.
Fig. 10
Table 8 Tightening torques MA of the claw ring threaded joint:

Size 112 128 148 168 194 214 240 265 295 330 370 415
DIN 912- 8.8 M8 M8 M10 M10 M10
DIN 912-10.9 M12 M12 M14 M14 M16 M16 M16
MA [Nm] 25 25 49 49 49 125 125 200 200 310 310 310

10 Maintenance
The elastic coupling Nor-Mex ®- GBT, GTW, GBS have in operation a low-maintenance.
Reaching the wear limit of the elastic intermediate ring depends on the operating parameters
and the conditions of use.
In the case of routine monitoring work on the plant check:
· Alignment of the coupling
· Elastomer state
· Remove dust deposits from the coupling parts and the intermediate ring
10.1 Wear Inspection on the Buffer Ring
§ Danger of injuries!
§ Disconnect the drive before carrying out any work on the
coupling!
Perform a visual inspection and a wear inspection of the buffer ring after
2000 hours, or after 3 months at latest, after the first start-up of the equip-
ment. If only minor wear or no wear is observed, further inspections of the
plant can be carried out at regular intervals of 4000 hours, however, at
least once a year, if the operating modes and conditions of the plant
remain unchanged. However, should you observe excessive wear on the
occasion of this first inspection already, check whether the cause for the
problem is listed in table 7 “Operation faults and possible causes”. In such
a case, the inspection intervals must be adapted to the prevailing service
conditions.
On the occasion of routine inspections or maintenance work on the drive equipment, or after
3 years at latest:
· Replace the elastic buffer ring.
· If the wear limit has been reached or exceeded, replace the buffer ring immediately,
irrespective of the inspection intervals of the equipment.
· Check the alignment of the coupling.
· Remove dust deposits from the coupling components and buffer ring.

10.2 Wear limit of elastic buffers
Replace the elastic buffer ring as soon as the

coupling has a distinct torsional backlash, or if
the minimum buffer thickness (PDmin, Fig. 11)
acc. to table 9 has been reached.
Fig. 11 Buffer thickness
Table 9 Minimum buffer thickness PDmin:

Size 112 128 148 168 194 214 240 265 295 330 370 415
PDmin [mm] 9 9 10 10 10 10 11 12 13 14 16 17

10.3 Changing the elastic intermediate ring
§ Injury hazard!
· Remove the holding-down screws

on the claw ring and push it back
(Figure 12, Pos. 1)
· Cut through the intermediate ring at
a connecting joint (Figure 12, Pos.
2)
· Pull out the intermediate ring. Begin
at the cut through connecting joint.
· For easier mounting, the new
intermediate ring can be provided
with a slip additive before introduc-
tion (e.g. Talcum powder).
· Cut through the new intermediate
ring at a connecting joint and posi-
tion it between coupling flange and Fig. 12
flange hub.
Attention!
The bearing surface of the claw ring and flange hub must be clean, dry and grease-
free. Balanced parts are position marked to each other.
· Mount the claw ring in its marked position

with respect to the hub. Pay attention that
the joining parts do not tilt on the centring
seat and to the position of the abrasive
marking. (see chapter 10).
· Slightly tighten the screws uniformly.
· Tighten the claw ring threaded joint with the
tightening torque MA stipulated in table 8
(Figure 13).
· Check the alignment of the coupling
according to the specifications in „8 Cou-
pling adjustment”.
Fig. 13

10.4 Assembly brake drum/disk
Attention!
The contact surfaces of coupling hub and brake drum/disk must be clean, dry and free
of grease. Balanced parts are match marked to each other.
· Place the brake drum/disk in their proper

position as marked. Make sure that the parts do
not get canted at the centering seats when join-
ing them.
· Slightly tighten the screws.
· Tighten the screwed connections of brake
drum/disk to the proper torque MA specified in
table 10.
· Check the alignment of the coupling according
to the instructions given in chapter 8 ‘Coupling
Alignment“.
Fig. 14
Table 10 Tightening torques MA- for brake drum/disk threaded joints:

Size 112 128 148 168 194 214 240 265 295 330 370 415
DIN 933- 8.8 8 8 10 10 12 12 12 16 16 16 16 16
MA-BS [Nm] 25 25 49 49 85 85 85 210 210 210 210 210
Warning!
§ Before commissioning the plant install all protective devices

against unintentional touching of free rotating parts.
§ To avoid sparks coverings in stainless steel should be used.
§ The covering is to be so designed that it does not deposit dust
onto the coupling parts.
§ The covering must not touch the coupling or influence it in its
functioning.
When using accessories and spare parts which were not originally manufactured by
TSCHAN GmbH, no liability or guarantee for any damages will be accepted.
11 Waste Disposal
The waste disposal has to occur according to the specific regulations of the respective user
country.

Montage, Einstellung und Wartung
B 06 20 123 E-DE-EN
Mounting, Adjustment and Maintenance
für Trommelbremsen SBH nach DIN 15435 Seite / Page 1/6
of drum brakes SBH according to DIN 15435 06.2006
Bezeichnungen einer Trommelbremse
Components of Drum Brake Nur gültig in Verbindung mit
Allgemeine Hinweise
Anhand der Abb. 1 sollen die wesentlichen Bauteile einer Trommelbremse erläutert werden: Valid in connection only with
For essential components of drum brakes please see Fig. 1 and find the following explanations: General Notes
B 06 20 176 E
Lüftgerät
Zugstange release thruster
tension rod
Zug- Winkelhebel
lasche knee lever
shackle
Bremshe- Federrohreinheit
bel spring tube componentry
brake lever
Bremsbacke mit Bremsbe- Nachstellung
lag readjusting unit
brake shoe c/w lining
Grundplatte
base plate
Bild / picture 1
Grundplatte: Mit vier Befestigungsbohrungen, deren Durchmesser und Abstände nach DIN genormt sind, wird die
Bremse auf der Unterkonstruktion befestigt
base plate: with four mounting holes, which positions are standardized acc. to DIN, the brake is mounted on a base
frame or construction.
Bremshebel: Umschließen mit den gelenkig gelagerten Bremsbacken die Bremstrommel und übertragen in Verbindung
mit Zugspindel und Winkelhebel die Bremskraft.
brake lever: hinged with the brake shoes, they surround the brake drum and in connection with pull rod and knee-
lever they apply the braking force is generated by the torque spring.

spring tube: consists of tube, rod, torque spring, piston plate and torque-scale.
Lüftgerät: Dient zum öffnen der Bremse und arbeitet gegen die Federkraft. Die zum Lüften benötigte Energie wird
entweder elektrohydraulisch, elektrisch über Magnet, hydraulisch oder pneumatisch erzeugt. Am weitesten
verbreitet sind die elektrohydraulischen Lüftgeräte. Sie bieten aufgrund der robusten und betriebsicheren
Thruster:
Bauweise in den meisten Einsatzfällen die beste Lösung.
is used to open the brake and is acting against the spring force. The energy, required for release, is
generated by electro-hydraulic, electric with magnet, hydraulic or pneumatic. The most common
thrusters are the electro-hydraulic ones, well known as "Eldro" . Due to the robust and safe construction
the Eldro-thruster is the best solution in most of the cases.
Zugspindel: Sie ist das mit am höchsten beanspruchte Bauteil der Bremse, da die gesamte Bremskraft hierüber auf
die beiden Bremshebel übertragen wird. Bei allen SIBRE Bremsen ist die Zugspindel aus rostfreiem
Material mit gerolltem Gewinde gefertigt.
pull rod: its function is to transmit the braking force to the two brake levers, and therefore it is the most stressed
component of the brake. All SIBRE brakes the pull rod is made of stainless steel with a rolled thread.
shackle: the shackle is the hinge between pull rod and the brake lever. The shackle could be a pin-junction as well.
Nachstell- Die Nachstellung dient zum Ausgleich des Belagverschleiß, ist aber im Nachstellweg je Bremshub
ung: begrenzt. Daher ist je nach Anwendungsfall eine zusätzliche manuelle Verschleißnachstellung vom
readjusting
unit:
The readjusting unit is used for compensation of lining wear, however its compensating capacity per
breaking cycle is limited. There for an additional manual wear compensation carried out by maintenance
personel is requested according to the specific application.
von großem Feder- oder Lüftweg und kleiner Kraft auf kleine Wege am Bremshebel und hohe Kräft statt.
knee lever: spring tube component and thruster are mounted to the knee-lever. Here, the transformation from large
h:\documentation\pmd-documentation\030 drum brakes\031 sbh\DE-EN SBH 06-06.pmd

B 06 20 123 E-DE-EN
Seite / Page 2/6 für Trommelbremsen SBH nach DIN 15435
06.2006 of drum brakes SBH according to DIN 15435

Allgemeine Hinweise
B 06 20 176 E
Adjustment of Reserve Stroke

>< X
Der Resthub muß bei geschlossener und eingebauter Bremse
Bild / picture 2 eingestellt werden. Dabei sollte das Lüftgerät zunächst ganz
eingefahren und dann durch Drehen an der Zugstangenstellmutter
auf 20% (ca. 10 mm) des Gesamthubs herausgezogen werden.
angegeben.
The reserve stroke must be adjusted when brake is mounted on
the base frame and in closed position. First, set thruster piston
to its lower end position and afterwards lift the piston by turning
the tension rod adjusting nut, until piston is lifted by
20% (ca.10 mm) of total stroke. For total stroke values please
see chapter technical data.

Bemsbackenklemmfeder als Hinweis, wo der Resthub gemessen werden kann.
Bremsbackenbolzen
brake shoe pin brake shoe clamping The dimension X is constructional not relevant. It just shows an
spring example, where reserve stroke can be measured.
Achtung:
*
Wird kein Resthub eingestellt, kann dies zum Versagen der Bremse führen.
CAUTION:
Achtung:
* Je nach Anwendungsfall muß eine zusätzliche manuelle Verschleißnachstellung erfolgen.

Caution:
Bei Bremsen mit zusätzlicher Notlüftung, hydraulischer Verzögerung ist darauf zu achten, dass auch diese
Zusatzeinrichtungen mit entsprechendem Resthub eingestellt werden.
In case of brakes fitted with additional hydraulic damping or an additional emergency release,

B 06 20 123 E-DE-EN
für Trommelbremsen nach DIN 15435 SBH mit externer Bremsfeder
Seite / Page 3/6
of drum brakes according to DIN 15435 SBH with external Brake spring 06.2006
Die Montage der Bremse wird in radialer Richtung Nur gültig in Verbindung mit
Allgemeine Hinweise
B 06 20 176 E
Bild / picture 3
Lüftgerät
release thruster
1.Bremsbackenabstand durch Drehen der Zugstangen-

stellmutter auf Maß 5mm größer als Bremsscheiben-
durchmesser stellen.
Adjust brake shoe clearance to 5mm larger than
brake drum diameter by turning the cinnecting rod
Backen- adjusting nut.
hebel
break- 2.Grundplattenbolzen 1 aus dem Bremsbackenhebel
arm
ziehen.
Grundplatte Grundplatten-
base plate bolzen 1
base plate pin 1 ` 4.Grundplatte unter der Bremstrommel durchschieben.
Bild / picture 4 5.Bremse in radialer und axialer Richtung

mittig ausrichten.

durch Grundplattenbolzen 1 mit der Grundplatte
`
verbinden.
base plate pin 1.
Install release thrustor.
Fix base plate.
*
9.Maximal zulässige Abweichung zu den
Bremsenachsen +/- 0,3 mm.
(Siehe Hinweise Montagefehler)
Â
Permissable misaligument for all brake axles:
Bild / picture 5 max. +/- 0,3 mm.
(see "Mistakes in mounting brakes")
connecting rods
adjusting nut
Zugstange
tie rod

B 06 20 123 E-DE-EN
Seite / Page 4/6 für Trommelbremsen nach DIN 15435 SBH mit externer Bremsfeder
06.2006 of drum brakes according to DIN 15435 SBH with external Brake spring

Bei der Einstellung der Bremse geht man wie folgt vor Allgemeine Hinweise
The adjustment of the brake is accomplished as follows General Notes
B 06 20 176 E
Bild / picture 6 X
Resthub X 20% des
Gesamthubes (ca. 10 mm )
1.Lüftgerät ausschalten ( Bremse eingefallen )
Switch off release Trustor ( close brake )
>< reserve stroke X 20% of
max.storke (ca. 10 mm ) 2.Durch Drehen der Zugstange an der Zugstangenstellmutter
Zugstangenstellmuttern Lüftgerät-Resthub X einstellen. ( Bild 6 )
connecting rods
Adjust release Lüftgerät reserve stroke X by turning
adjusting nut
the connecting rodadjusting nut. ( picture 6 )
3.Durch Drehen der Federstellmutter gewünschtes

Bremsmoment an der Skala einstellen ( Oberkante
Federdruckteller = Bezugskante ) und gegebenenfalls
Lüftgerät-Resthub X korrigieren. ( Bild 6 + 7 )
Adjust desired braking torque by turning the spring
Bild / picture 7
adjusting nut. The torque is indicated on scale ( using top
edge of bottom spring plate as reference point ).
If necessary, adjust release thruster reserve stroke X.
Skala ( picture 6 + 7 )
scale
Federstellmutter 4.Einstellung der gleichmäßigen Backenlüftung entfällt durch

spring adjusting nut Verwendung einer Drehkopplung ( Bild 8 ), d.h.:
Federrohr - gleichmäßiger Lüftspalt an beiden Bremsbacken
spring tube - Justierung der Bremse bei Montage
Endlagensicherung - stabiler Stand der gelüfteten Bremse, auch bei
safty split sping Belagverschleiss
Bild / picture 8 necessary due to the brake shoe synchronisation linkage
( picture 8 ) i.e.:
- equal clearance of both brake shoes
synchronisation
linkage
shoe wear
5.Einstellung der Verschleißnachstellung :

Adjust lining wear compensator :
`
Bild / picture 9
1.Mitnehmerschraube der Verschleißnachstellung in der
Mitnehmerbohrung ganz nach oben drücken.
Push driving pin upwards in guide hole as far as it can go.
Mitnehmerschraube 2.Stellschraube im Winkelhebel so weit zurückdrehen, bis
driving pin die Mitnehmerbohrung frei ist.
Return lining wear adjustment screw in the brake lever
Mitnehmerbohrung
guide hole until guide hole is exposed.
3.Bremse mehrmals lüften und wieder einfallen lassen, die
Kontermutter
Lift brake lever several times fully (with release thrustor)
lock nut
and close again.
Stellschraube
4.Stellschraube im Winkelhebel wieder so weit eindrehen,
adjustment screw dass ein kleiner Luftspalt von etwa 0,2 mm zwischen Stell-
Achtung:
Die Nachstellung dient zum Ausgleich des Belagverschleiß, schraube und Mitnehmerschraube vorhanden ist,
ist aber im Nachstellweg je Bremshub begrenzt. Kontermutter anziehen. ( Bild 9 )
Verschleißnachstellung vom Wartungspersonal durchzuführen. Turn adjustment screw in brake lever down until there is a
CAUTION: small split of approximately 0,2 mm between adjustment
The readjusting unit is used for compensation of lining wear, screw and driving pin, tighten lock nut. ( picture 9 )
however its compensating capacity per unit breaking cycle is
limited. There for an additional manual wear compensation carried 5.Die Bremse ist nun betriebsbereit.
out by maintenance personnel is requested according to the
specific application. The brake is now ready for operation.
Mounting, Adjustment and Maintenance Seite / Page 5/6
für Trommelbremsen SBH nach DIN 15435
of drum brakes SBH according to DIN 15435 06.2006

Replacement of the shoes General Notes

B 06 20 176 E

Proceed as follows:
1. Festanschläge für Bremsbackenhebel lösen ( Bild 8 ). (nicht bei Bremsen mit Drehkopplung)
Release limit stops for brake arms ( picture 8 ). (not for brakes with synchronisations linkage)
2. Zugstange durch Drehen an der Zugstangenstellmutter so weit aus der Nachstellung herausschrauben,
dass sich die neuen Bremsbacken montieren lassen.
Unscrew connecting rod out of readjusting unit by turning the connecting rod adjusting nut until the new
brake shoes can be installed.
3. Bremsbackenklemmfedern entspannen und Bremsbackenbolzen entfernen. ( Bild 10 )
Release brake shoe clamping spring and remove brake shoe pins.( picture 10 )

7. Bremse neu einstellen.

Readjust brake.
Bild / picture 10
brake shoe pin brake shoe clamping
spring
B 06 20 123 E-DE-EN
Seite / Page 6/6 für Trommelbremsen SBH nach DIN 15435
06.2006 of drum brakes SBH according to DIN 15435

Allgemeine Hinweise
General Notes
B 06 20 176 E
7
5
2
6
1
8
3

vollständige Bremsenbezeichnung, z.B. für SBH 400/ 80/6

complete brake ident-no., e.g. for SBH 400/ 80/6

T1-2.5
S2-10.5
Drum Brakes SBH acc. to DIN 15435
M 500 6500 E-EN-2013-07
Thruster sizes
1 = Ed 23/5 10 = EB 220-50
When ordering please advise: 2 = Ed 30/5 20 = EB 300-50
- brake type and thruster e.g. SBH 250/23/5 3 = Ed 50/6 30 = EB 500-60
- power supply voltage for thruster 4 = Ed 80/6 40 = EB 800-60
- with our without lining wear compensator 5 = Ed 121/6 50 = EB 1250-60
- options
6 = Ed 201/6 60 = EB 2000-60
Torque Range
Brake- Thruster
in Nm at A B C D E F G H J K L M N P Q R d kg*
Type size
μ = 0,4
1 / 10 50 - 325 160
SBH 200 520 320 200 270 90 160 750 55 145 160 130 10 75 70 96 14 28
2 / 20 50 - 425 160
1 / 10 50 - 325 530 160 870
SBH 250 2 / 20 50 - 425 530 160 400 250 284 110 200 870 65 180 190 155 10 95 90 113 18 40
3 / 30 50 - 850 570 195 910
1 / 10 50 - 475 640 160 965
SBH 315 2 / 20 50 - 600 640 160 480 315 330 125 240 965 80 220 230 185 15 118 110 135 18 52
3 / 30 150 - 1200 650 195 995
4 / 40 150 - 1950 650 195 995
2 / 20 150 - 600 760 160 1050
3 / 30 150 - 1200 760 195 600 400 407 160 300 1085 100 270 280 230 15 150 140 167 22 82
SBH 400
4 / 40 150 - 1950 760 195 1085
5 / 50 150 - 2250 840 240 600 400 490 160 300 1095 100 270 280 230 15 150 140 167 22 88
3 / 30 400 - 1420 900 195 1330
SBH 500 4 / 40 400 - 2300 900 195 710 500 490 190 355 1330 130 325 340 285 13 190 180 190 22 130
5 / 50 400 - 3400 900 240 1330
6 / 60 400 - 5700 900 240 1330
P:\CATALOGUES\EN CATALOGUES\DOC-CATALOGUE\08 TE Drum Brakes\T1-2.5 EN SBH 2013-07.doc

Seite / page 1/8

eingesetzt werden.
Siegerland Bremsen
35 708 HAIGER
GERMANY
Fon: +49 (0)2773 / 9400 - 0

B 06 20 176 E-DE-EN
Seite / page 2/8
Allgemeine Hinweise









der Bremse.
Seite / page 3/8
contract.



B 06 20 176 E-DE-EN
Seite / page 4/8
Allgemeine Hinweise

Empfehlung :
Recommendation :



y Quetschgefahr.
Danger of crushing.


Seite / page 5/8







2


Achtung:
CAUTION:

B 06 20 176 E-DE-EN
Seite / page 6/8
Allgemeine Hinweise
can be carried out.
Achtung / Caution



Seite / page 7/8
G
AFTER EACH SHIFT



3


B 06 20 176 E-DE-EN
Seite / page 8/8
Allgemeine Hinweise




T1-22
Options for Drum Brakes M 1501 272 E-EN-2001-01
Lining Wear Compensator Device
The purpose of this device is to compensate for the wear of brake linings. With correct adjustment, the wear
compensator will maintain an almost constant reserve stroke. Inspection of reserve stroke is necessary even with a
correct adjustment of wear compensator, especially during commissioning and the inital time of commercial
operation.
Mode of Operation
assumption: the wear compensator is correctly adjusted according to our manual. When opening and closing the
brake, the position of the drive pin ( 70.9 ) remains unchanged, until the reserve stroke of the thruster is reduced
due to the wear of the linings. Upon decrease of reserve stroke, the adjusting bolt ( 72 ) will contact the drive pin
( 70.9 ) when closing the brake. The drive pin is rotated counter clock-wise by a certain angle. The sliding ring
( 70.7 ) is rotated by the same degree as the drive pin. The threaded sleeve
( 70.4 ) does not move because the back stop needle bearing ( 70.5 ) is rotating free in counter clock-wise
direction. With the subsequent release of the brake, the edge of the drive pin drilling will contact and rotate the
drive pin and the sliding ring in clock-wise direction. When rotated clock-wise, the back stop needle bearing is
locked and transfers the rotation onto the threaded sleeve. When rotating the threaded sleeve, the tension rod
( 57 ) is screwed into the wear compensator, reducing the distance between the two brake arms, ergo between the
lining surfaces. Thus, the reserve stroke is increased. Depending on the amount of wear per brake application, the
wear compensator may need several operating cycles, until the initial reserve stroke level is reached again. At this
point, the drive pin will touch the adjusting bolt and the drilling for drive pin respectively when opening and closing
the brake, however, there is not further rotation of the drive pin. If the initial reserve stroke level should not be
reached again, a re-adjustment of wear compensator is required. If the reserve stroke level should be continuously
reduced in spite of having re-adjusted the wear compensator, the wear rate per stop exceeds the compensating
capacity of the wear compensator and an additional manual wear compensation is required. The quadring seals
( 70.6 ) avoid any dust or dirt to enter into the system and they generate sufficient friction to protect the device from
vibrations.
P:\CATALOGUES\EN CATALOGUES\DOC-CATALOGUE\08 TE Drum Brakes\T1-22 EN wear compensator 2001-01.docx
EMG Automation GmbH

Factory ELTMA
Technical rates
min…max
Short travel types
EB 120-40 120 40 C 60 50… 75 130 0,4 1,2 7,5

C 120 100… 150
EB 220-50 220 50 C 120 110… 160 160 0,4 2,6 9,3
C 180 160… 230
C 220 200… 290
EB 300-50 300 50 C 120 140… 180 140 0,3 1,8 9,6
C 200 220… 260
C 270 260… 310
EB 500-60 500 60 C 180 170… 220 200 0,4 2,6 13,1
C 320 370… 450
C 500 540… 680
EB 800-60 800 60 C 450 460… 560 260 0,5 4,3 19,0
C 800 740…1060
EB 1250-60 1250 60 C 450 460… 560 380 0,6 4,3 20,6
C 800 740…1060
C 1250 1200…1630
EB 2000-60 2000 60 C 700 660… 900 500 0,7 9,0 32,8
C 1300 1240…1600
C 2000 1900…2500
EB 3000-60 3000 60 C 700 460… 690 550 0,9 10,1 39,0
C 2500 2080…3000
C 3200 2540…3690
EB 6300-80 6300 80 800 1,6 10,6 43,5
Long travel types
EB 500-120 500 120 C 180 110… 220 200 0,4 3,5 14,8
C 320 280… 450
C 500 390… 680
EB 800-120 800 120 C 450 350… 560 380 0,5 6,0 23,0
C 800 420…1060
EB 1250-120 1250 120 C 450 350… 560 380 0,6 6,0 24,2
C 800 420…1060
C 1250 770…1630
EB 2000-120 2000 120 C 700 430… 900 500 0,7 9,0 32,8
C 1300 870…1600
C 2000 1300…2500
EB 3000-120 3000 120 550 0,9 10,1 39,0
EB 6300-120 6300 120 800 1,6 10,6 43,5
Short travel types
EB 12/50 220 50 C 12 110… 160 160 0,4 2,6 9,3

C 18 160… 230
C 22 200… 290
EB 20/50 300 50 C 12 140… 180 140 0,3 1,8 9,6
C 20 220… 260
C 27 260… 310
EB 50/50 500 50 C 18 170… 210 200 0,4 2,6 13,1
C 32 370… 440
C 50 540… 660
EB 80/60 800 60 C 45 460… 560 260 0,5 4,3 19,0
C 80 740…1060
EB 125/60 1250 60 C 45 460… 560 380 0,6 4,3 20,6
C 80 740…1060
C 125 1200…1630
EB 150/60 1500 60 C 45 460… 560 400 0,7 4,3 20,6
C 80 740…1060
C 125 1200…1630
EB 250/60 2500 60 C 70 660… 900 500 0,7 9,0 32,8
C 130 1240…1600
C 200 1900…2500
Long travel types
EB 50/100 500 100 C 18 130… 220 200 0,4 3,2 14,5

C 32 310… 450
C 50 440… 680
EB 80/160 800 160 C 45 280… 560 260 0,5 6,0 23,0
C 80 200…1060
EB 125/160 1250 160 C 45 280… 560 380 0,6 6,0 24,2
C 80 200…1060
C 125 480…1630
EB 150/160 1500 160 C 45 280… 560 400 0,7 6,0 24,2
C 80 200…1060
C 125 480…1630
EB 250/160 2500 160 C 70 280… 900 500 0,7 12,2 39,5
C 130 620…1600
C 200 900…2500
EB 320/100 3200 100 C 70 460… 840 550 0,9 10,6 39,5
C 250 2080…3000 3)
C 320 2540…3690 3)
EB 630/120 6300 120 800 1,6 10,6 43,5
Service medium,
maintenance

nance.

entry tightly.
Filling entry
Attention:
medium. Füllstand
EB 220-50, EB 12/50 EB 120-40

min. max. min. max.
EB 2000-60 … S 1,3 8,0 EB 250/60 … S 2,0 10,0
EB 2000-120 … S 2,8 12,0 EB 250/160 … S 3,5 15,0
EB 3000-120 … S 2,5 10,0 EB 320/100 … S 2,5 11,0
EB 6300-120 … S 2,0 8,0 EB 630/120 … S 2,0 8,0
Sensors
types EB120-40, EB220-50, EB12/50
earthing screw
and special series.
EB 125/60 B S I Zd F K Li... X..

.
ELHY® Type
La








Attention:
room temperature.
EMG Automation GmbH

Factory ELTMA
Am Pfefferbach 20
39387 Oschersleben
Germany
Phone: +49 (0) 3949 928 - 500

Fax 1: +49 (0) 3949 928 - 585
Fax 2: +49 (0) 3949 928 - 513
BA_GB 06/2008
Inductive sensor
BI5U-M18-AP6X

Wiring diagram
Type BI5U-M18-AP6X
Ident-No. 1635100

Repeatability
ð2%
tances.
Protection class ÷

Dimensions 54 mm
Connection cable
2


Edition • 2012-06-23T02:39:57+02:00
Inductive sensor
BI5U-M18-AP6X

Distance D 2xB
Distance W 3 x Sn
Distance T 3xB
Distance S 1.5 x B
Distance G 6 x Sn

Edition • 2012-06-23T02:39:57+02:00
Inductive sensor
BI5U-M18-AP6X
Accessories
terial: PA6

Edition • 2012-06-23T02:39:57+02:00
6.5 BELT
6.5.1 Steelcord belt
 Type ST 800 - 8/4 W (Boom conveyor)
− Splice layout 1200 ST 800 8/4 W
− Operating- and Maintenance Instruction & Splice checking
− Storage and handling instructions for PHOENOCORD Steel cord conveyor belts
and PHOENOKIT ST

Blank page

Project Shougang, 930-ST-110
splice layout 1200 ST800 8/4 W
05.11.2014
belt running direction B.v.Heimburg
1 1
2 2
... ...
42 42
43 43
44 44
45 45
46 46
... ...
86 86
87 87
100 600 100
800
Drawing not true to scale

© Copyright PHOENIX Conveyor Belt Systems GmbH
05.11.2014
B.v.Heimburg
splice assembly
6,5 mm top cover rubber
2,0 mm bonding rubber
3,4 mm cords + intermediate rubber 3,3 x 4,0 mm
2,0 mm bonding rubber
2,5 mm bottom cover rubber
nominal belt thickness: 15,4 mm
condition of cable surface

05.11.2014
B.v.Heimburg
T [°C]
vulcanisation
temperature
press
dismounting
temperature
curing time t [min]
vulcanization parameters for PHOENIX splice rubber

pressure: 12...14 bar
temperature: 155 °C (+/- 5 K)
vulcanization time: 50 min
press dismounting temperature: < 60°C

PHOENIX CONVEYOR BELT SYSTEMS
Post Box 900854 - 21048 Hamburg
Phone: +49 40 / 7667-1
Fax: +49 40 / 7667-2411
1. Operating- and Maintenance Instruction
To avoid conveying interruptions caused by installation or conveyor belt

conditions, continuous inspections of the complete installation (drive,
construction, take-up station respectively take-up loop, tail end, conveyor
belt and splices) is necessary. A difference is made between:
Inspection I
Inspection II
Inspection III.
1.1. Inspection I
The inspection I should be performed daily by the installation operator.

In this context the following has to be considered:
• Profile of the clearing gauge of the conveyor belt system

• Condition of the suspensions as well as the frame of the carrying
construction
• Conveyor belt running characteristic in the whole installation (drive or
head end to tail end)
• Condition of the conveyor belt and its splices
• Damages or faults on the carrying-, guide- and pressure-idlers, as
"caking" or clinging of material, attrition, bearing damages, hard
running or tightened carrying- and guide-idlers, corrosion of the
surface shell
• Unusual noise
PHOENIX CONVEYOR BELT SYSTEMS GMBH page 2
Phone: +49 40 / 7667-1
Fax: +49 40 / 7667-2909
1.2. Inspection II
An inspection II should be performed weekly by a qualified staff of the

installation operator. The items listed under point 1 (inspection I) are
examined more precisely and documented. Noticed damages and faults
have to be removed as soon as possible.
1.3. Inspection III
The inspection III should be performed annually in accordance to the

given guarantee and in co-operation with the belt supplier.
On this occasion all unusual characteristics, specially damages on the

conveyor belt and the splices are noted in an inspection report by the
belt supplier. In addition to this appropriate proceedings are shown to
eliminate or repair the damages.
The following pages contain

- "conveyor belt inspection report" as well as a
- "conveyor belt installation plan"
Phone: +49 40 / 7667-1
Fax: +49 40 / 7667-2909
CONVEYOR BELT INSPECTION REPORT

No.
Client _____________________________________
Mine _____________________________________
Belt Type _____________________________________
Delivery _____________________________________
Putting into Operation _____________________________________
Name of Conveyor _____________________________________
Conveyor Data Centre Distance ______________________ m
Lift ______________________ m
Motor Power ______________________ kW
Capacity ______________________ t/h
Conveyed material ______________________
Speed ______________________ m/s
Drive Layout 1 Head Pulley _______
2 Head Pulleys _______
Intermediate Drive _______
Tail Drive _______
Number of splices _____________________________________
Splice Length _____________________________________
Splice Scheme _____________________________________

Phone: +49 40 / 7667-1
Fax: +49 40 / 7667-2909
Date ________________
Participants ___________________________________
(Client)
___________________________________
___________________________________
___________________________________
___________________________________
(Others) ___________________________________
___________________________________
___________________________________
___________________________________
___________________________________
(Phoenix) ___________________________________
___________________________________
___________________________________
___________________________________
___________________________________
___________________________________
Inspection of 1. Splices
1.1 During Standstill _____
1.2 During Crawling Speed _____
1.3 During Normal Speed _____
2. Belt Part Lengths

2.1 During Standstill _____
2.2 During Crawling Speed _____
2.3 During Normal Speed _____
Phone: +49 40 / 7667-1
Fax: +49 40 / 7667-2909
Inspection Results:
Actions which has to be carried out:
Last inspection ___________________________________
Report No. ___________________________________
Next Inspection ___________________________________
Date _______________
Signatures _____________________ _____________________

Phone: +49 40 / 7667-1
Fax: +49 40 / 7667-2909
Conveyor Belt Installation Plan
Client _________________________________________________________
Place of installation: _________________________________________________________
Order No. _________________________________________________________
Scope of supply: _________________________________________________________
Phoenix Ref. _________________________________________________________
Installation discussion of: _________________________________________________________
Participants: _________________________________________________________
_________________________________________________________
_________________________________________________________
1. Conveyor Data
1.1 Centre distance (m) ___________________________________________
1.2 Lift (m) ___________________________________________
1.3 Gradient (gon) ___________________________________________
1.4 Installed motor power (kW) ___________________________________________
1.5 Belt speed (m/s) ___________________________________________
1.6 Capacity (t/h) ___________________________________________
1.7 Conveyed material ___________________________________________
1.8 Lump size (mm) ___________________________________________
1.9 Drive layout ___________________________________________
1.10 Pulley diameter drive (mm) ___________________________________________
1.11 Snub pulley diameter (mm) ___________________________________________
1.12 Tail pulley diameter (mm) ___________________________________________
1.13 Idler spacing upper run (mm) ___________________________________________
1.14 Idler diameter upper run (mm) ___________________________________________
1.15 Idler spacing bottom run (mm) ___________________________________________
1.16 Idler diameter bottom run (mm) ___________________________________________
1.17 Trough upper run (gon) ___________________________________________
1.18 Trough bottom run (gon) ___________________________________________
1.19 Feeding Garland idlers, 3-fold, with buffer rings, trough (gon) ________
Garland idlers, 5-fold, with buffer rings, trough (gon) ________
Troughing idlers, 3-fold, trough (gon) ________

Phone: +49 40 / 7667-1
Fax: +49 40 / 7667-2909
1.20 Transition length at tail (mm) ___________________________________________
1.21 Transition length at head (mm) ___________________________________________
1.22 Transport of people upper run: yes / no
bottom run: yes / no
2. Belt construction
2.1 Width (mm) __________________________________________
2.2 Nominal breaking strength (N/mm) __________________________________________
2.3 Cover thickness (mm) __________________________________________
2.4 Quality __________________________________________
2.5 Thickness (mm) __________________________________________
2.6 Weight (kg/m) __________________________________________
2.7 PHOENOTEC reinforcement Top cover, diameter / pitch (mm) _____________
Bottom cover, diameter / pitch (mm) _____________
2.8 Electric induction loops __________________________________________
2.8.1 Manufacturer / System __________________________________________
2.8.2 Spacing of loops (m) __________________________________________
2.8.3 Assembly of loops cold / cured / where? ________________________
2.9 Remarks __________________________________________
__________________________________________
3. Single lengths and packing

3.1 Total length (m) __________________________________________
3.2 Length per reel (m) __________________________________________
3.3 Number of single lengths __________________________________________
3.4 Spare length (m) __________________________________________
3.5 Maximum reel diameter (mm) __________________________________________
3.6 Maximum reel width (mm) __________________________________________
3.7 Kind of packing a) single round reel __________
b) double reel __________
c) flat reel __________
3.8 External core diameter (mm) __________________________ Metal / timber
3.9 Internal core square (mm) __________________________________________
3.10 Outside belt / reel protection __________________________________________

Phone: +49 40 / 7667-1
Fax: +49 40 / 7667-2909
4. Belt transport / Pulling-in

4.1 Who undertakes belt transport on site ___________________________________________
4.2 Safety stop ___________________________________________
4.3 Pulling-in device ___________________________________________
4.4 Pulling-in winch ___________________________________________
4.5 Pulling-in cradle ___________________________________________
4.6 Pulling-in coiler ___________________________________________
4.7 Reeling trestle ___________________________________________
4.8 Who undertakes pulling-in? ___________________________________________
4.9 Who undertakes tensioning? ___________________________________________
4.10 Auxiliariy devices for tensioning ___________________________________________
4.11 Other ___________________________________________
___________________________________________
___________________________________________
5. Pulling-in process
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
Phone: +49 40 / 7667-1
Fax: +49 40 / 7667-2909
Sketch
6. Curing
6.1 Number of splices / auxiliary splice ___________________________________________
6.2 Splice scheme ___________________________________________
6.3 Splice length (mm) ___________________________________________
6.4 Step length (mm) ___________________________________________
6.5 Number of steps ___________________________________________
6.6 Special ramp, top side / bottom side ___________________________________________
6.7 Use of PHOENOTEC in ts/bs ___________________________________________
6.8 Use of breaker ___________________________________________
6.9 Splice marks ___________________________________________
6.10 Curing time (min) ___________________________________________
6.11 Curing temperature (°C) ___________________________________________

Phone: +49 40 / 7667-1
Fax: +49 40 / 7667-2909
6.12 Pump pressure (bar) ___________________________________________
6.13 Specific pressure (bar) ___________________________________________
6.14 Installation management ___________________________________________
6.15 Supervision ___________________________________________
6.16 Time per splice (h) ___________________________________________
6.17 Number of shifts ___________________________________________
6.18 Number of splicers per shift ___________________________________________
6.19 Number of assistants per shift ___________________________________________
6.20 Number of splicers and assistants per shift ___________________________________________
6.21 1. shift from ________________ to ________________
2. shift from ________________ to ________________
3. shift from ________________ to ________________
4. shift from ________________ to ________________
6.22 Travel time, arrival (min) ___________________________________________
6.23 Travel time, departure (min) ___________________________________________
6.24 Work on weekends and holidays ___________________________________________
6.25 Splice kits supplier ___________________________________________
6.26 Splice kits consignee ___________________________________________
6.27 Splice kits delivery dates 1. lot ________________ 2. lot _________________
3. lot ________________ 4. lot _________________
5. lot ________________ 6. lot _________________
6.28 Storage on site ___________________________________________
6.29 Field vulcanizer supplier ___________________________________________
6.30 Type of field vulcanizer ___________________________________________
6.31 Field vulcanizer dimensions (mm) ___________________________________________
6.32 Power per platen (kW) ___________________________________________
6.33 Number of traverses (pairs) ___________________________________________
6.34 Current provided ___________________________________________
6.35 Voltage ___________________________________________
6.36 Splicing station provided by ___________________________________________
6.37 Splicing station dimensions (mm) ___________________________________________
(see F ) ___________________________________________
6.38 Lighting ___________________________________________
6.39 Transport of field vulcanizer supervised by ___________________________________________
6.40 Transport by truck / train / car / other ___________________________________________

Phone: +49 40 / 7667-1
Fax: +49 40 / 7667-2909
7. Miscellaneous
7.1 Special difficulties ___________________________________________
7.2 Conveyor is aligned by laser ___________________________________________
7.3 Conveyor is aligned manually ___________________________________________
7.4 Authorized signatory for time sheet ___________________________________________
7.5 Contact person of client ___________________________________________
7.6 Control, time-clock to be used ___________________________________________
7.7 The General Installation Conditions are accepted ___________________________________________
8. Start of splicing works ___________________________________________
9. End of splicing works ___________________________________________
10. Test run / Commissioning ___________________________________________
Date _______________
Signatures _____________________ _____________________

Phone: +49 40 / 7667-1
Fax: +49 40 / 7667-2909
2. Splice checking
The “splices” have to checked continouosly during the complete

splicing procedure.
The splicing instructions have to be followed strictly.
A supervisor is recommended.
After opening of the vulcanizing press a last optical check and buffing
work to achieve a plane surface, especially on the transition areas
(skives as well as cover cuts) have to be done.
Once the splice is manufactured and in operation it shall be inspected
viaually as the rest of the belt.
Another possibility to check the splice is X-ray. Thus irretations of the

splice scheme or blisters in the cable area can thus be recognized.
Storage and Handling Instructions
for
PHOENOCORD Steel Cord Conveyor Belts
and PHOENOKIT ST
PHOENOCORD Steel Cord Conveyor Belts
Foreword
In general it is recommended to follow the guidelines according to ISO 5285.
All relevant safety regulations – specifically according to local laws – must be followed.
Packing
The steel cord conveyor belts are packed on steel drums with a square hole in the center in
order to accept a traverse.
Protection: The belts will be covered with “jalousie”.
Round Reel
Strapping
The belting including the “jalousie” will be lashed circumferentially by steel strapping.
The strapping has a suitable guaranteed minimum breaking load and is resistant to
degradation for the storage conditions.
Humidity
The belts should be kept free from humidity.
Harmful materials
The belts should be protected from other harmful material (e.g. acids, oil, caustic solutions...).
Storage
The conveyor belts should preferably be stored indoors.
The reels must be stored with the central axis horizontal.
Lifting
The preferred method is to insert a steel bar of suitable size through the centre hole and
attach a chain sling hanging down from the traverse or the spreader bar of a lifting
apparatus to the protruding ends of the bar. See also photograph on page 1.
The spreader bar attachments should be wider than the belt width in order to avoid edge or
reel damages.
Don’t apply a sling around the circumference of a reel!

PHOENOKIT ST
The splice material has a limited shelf life.

The production date of the material is printed on the packing.
It is absolutely necessary to transport and store the splice material under the below
mentioned conditions.
Before the use of the splice material it has to be checked whether it is still usable.
Transport
During the entire time of transport the material has to be kept at a temperature of max.
18 °C.
Direct sunshine and rain to the material has to be avoided during transport.
Storage
For the storage of the splice material the temperature must not exceed 18°C. The material
may not be exposed to direct sunlight. The material has to be kept indoor and dry.
6.5.2 Hydraulic set for belt tensioning
 Hydraulic set P80/RC254G101 for belt tensioning (Boom conveyor):

Component information
− Hydraulic hand pumps: Instruction Sheet L1763
− Hydraulic cylinders: Instruction Sheet L1608
− Gauges: Instruction Sheet L505
− Hydraulic Hose / Fittings: Instruction Sheet L2255

Blank page

Instruction Sheet
®
Hydraulic Hand Pumps
L1763 Rev I 12/05
Index:
English ..................................................................1-7
Français ............................................................. 8-14
Deutsch............................................................ 15-22
Italiano ............................................................. 23-29
Español ............................................................ 30-36
Nederlands....................................................... 37-44
Portuguese....................................................... 45-51
........................................................... 52-58
...............................................................59-64
Svenska.............................................................65-71
WARNING: Stay clear of loads supported
Repair Parts Sheets for this product are available by hydraulics. A cylinder, when used as a
from the Enerpac web site at www.enerpac.com, or load lifting device, should never be used
from your nearest Authorized Enerpac Service Center as a load holding device. After the load
or Enerpac Sales office. has been raised or lowered, it must always be
blocked mechanically.
1.0 IMPORTANT RECEIVING
WARNING: USE ONLY RIGID PIECES
INSTRUCTIONS TO HOLD LOADS. Carefully select steel
®
Visually inspect all components for shipping damage. or wood blocks that are capable of
®
Shipping damage is not covered by warranty. If supporting the load. Never use a hydraulic cylinder
shipping damage is found, notify carrier at once. The as a shim or spacer in any lifting or pressing
carrier is responsible for all repair and replacement application.
costs resulting from damage in shipment. DANGER: To avoid personal injury
keep hands and feet away from cylinder
SAFETY FIRST and workpiece during operation.
2.0 SAFETY ISSUES WARNING: Do not exceed equipment
Read all instructions, ratings. Never attempt to lift a load
warnings and cautions weighing more than the capacity of the
carefully. Follow all safety cylinder. Overloading causes equipment
precautions to avoid personal injury or property failure and possible personal injury. The cylinders are
damage during system operation. Enerpac cannot be designed for a max. pressure of 700 bar [10,000 psi].
responsible for damage or injury resulting from unsafe Do not connect a jack or cylinder to a pump with a
product use, lack of maintenance or incorrect product higher pressure rating.
and/or system operation. Contact Enerpac when in DANGER: Never set the relief valve to a
doubt as to the safety precautions and operations. If higher pressure than the maximum rated
you have never been trained on high-pressure pressure of the pump. Higher settings
hydraulic safety, consult your distribution or service may result in equipment damage and/or
center for a free Enerpac Hydraulic safety course. personal injury. Do not remove relief valve.
Failure to comply with the following cautions and WARNING: The system operating
warnings could cause equipment damage and pressure must not exceed the pressure
personal injury. rating of the lowest rated component in
A CAUTION is used to indicate correct operating or the system. Install pressure gauges in the
maintenance procedures and practices to prevent system to monitor operating pressure. It is your
damage to, or destruction of equipment or other window to what is happening in the system.
property. CAUTION: Avoid damaging hydraulic
A WARNING indicates a potential danger that hose. Avoid sharp bends and kinks when
requires correct procedures or practices to avoid routing hydraulic hoses. Using a bent or
personal injury. kinked hose will cause severe back-
pressure. Sharp bends and kinks will internally
A DANGER is only used when your action or lack of damage the hose leading to premature hose failure.
action may cause serious injury or even death.
Do not drop heavy objects on hose. A
WARNING: Wear proper personal sharp impact may cause internal damage
protective gear when operating hydraulic ®
to hose wire strands. Applying pressure to

equipment. a damaged hose may cause it to rupture.
IMPORTANT: Do not lift hydraulic Avoid situations where loads are not
equipment by the hoses or swivel directly centered on the cylinder plunger.
couplers. Use the carrying handle or other Off-center loads produce considerable
means of safe transport. strain on cylinders and plungers. In
addition, the load may slip or fall, causing potentially
CAUTION: Keep hydraulic equipment dangerous results.
away from flames and heat. Excessive
heat will soften packings and seals, Distribute the load evenly across the entire
resulting in fluid leaks. Heat also weakens saddle surface. Always use a saddle to
hose materials and packings. For optimum protect the plunger.
performance do not expose equipment to
temperatures of 65 °C [150 °F] or higher. Protect
hoses and cylinders from weld spatter. IMPORTANT: Hydraulic equipment must
only be serviced by a qualified hydraulic
DANGER: Do not handle pressurized technician. For repair service, contact the
hoses. Escaping oil under pressure can Authorized ENERPAC Service Center in
penetrate the skin, causing serious injury. your area. To protect your warranty, use only
If oil is injected under the skin, see a doctor ENERPAC oil.
immediately. WARNING: Immediately replace worn or
WARNING: Only use hydraulic cylinders in damaged parts by genuine ENERPAC
a coupled system. Never use a cylinder parts. Standard grade parts will break
with unconnected couplers. If the cylinder causing personal injury and property
becomes extremely overloaded, damage. ENERPAC parts are designed to fit properly
components can fail catastrophically causing severe and withstand high loads.
personal injury. CAUTION: Always use the handle to carry
WARNING: BE SURE SETUP IS STABLE the pump. Carrying the pump by the hose
BEFORE LIFTING LOAD. Cylinders may damage the hose and/or the pump.
should be placed on a flat surface that can
®
support the load. Where applicable, use a

cylinder base for added stability. Do not
weld or otherwise modify the cylinder to attach a
base or other support.
SPECIFICATIONS – Use this instruction sheet for the following hand pump models.
Hand Pump Specifications
Model Type Maximum Pressure Oil Volume per Stroke Usable Oil Capacity
(Speed) Rating psi [bar] in 3 [cm 3] in3 [cm3]
EHF-65 1 6,500 [440] .16 [2.62] 22 [360]
P-18 1 2,850 [200] .16 [2.62] 22 [360]
P-25 1 2,500 [170] .58 [9.51] 231 [3786]
P-39, 1003 1 10,000 [700] .16 [2.62] 43 [705]
P-50 1 5,000 [340] .29 [4.75] 231 [3786]
P-51 1 3,000 [210] .25 [4.09] 50 [820]
P-141, 1001 1 10,000 [700] .055 [.90] 20 [328]
P-391, 1004 1 10,000 [700] .151 [2.47] 55 [900]
Stage 1 Stage 2 Stage 1 Stage 2

P-80, 1006 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 140 [2295]
P-84 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 140 [2295]
P-142, 1002 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 20 [328]
P-142AL 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 9.0 [148]
P-202 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 55 [900]
P-77 2 200 [14] 10,000 [700] .63 [16.0] .094 [2.41] 47 [769]
P-392, 1005 2 200 [14] 10,000 [700] .687 [11.26] .151 [2.47] 55 [900]
P-392AL 2 200 [14] 10,000 [700] .687 [11.26] .151 [2.47] 55 [900]
P-462 2 200 [14] 10,000 [700] 7.69 [126.00] .29 [4.75] 462 [7572]
P-464 2 200 [14] 10,000 [700] 7.69 [126.00] .29 [4.75] 462 [7572]
P-801 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 250 [4095]
P-802 2 400 [28] 10,000 [700] 2.40 [39.34] .15 [2.46] 155 [2540]
P-842 2 400 [28] 10,000 [700] 2.40 [39.34] .15 [2.46] 155 [2540]
2
3.0 DESCRIPTION 3.2 Models P-18/P-39, 1003/P-80, 1006/
P-84/P-801, P-77
3.1 Models P-141, 1001; P-142, 1002; Figure 2 and the corresponding table below show the
P-202; P-391, 1004; P-392, 1005; P-802; main components of these hand pump models.
P-842 Model P-84 is equipped with a 4-way, 3-position
Figure 1 and the corresponding table show the main valve for use with double-acting cylinders. To convert
components of hand pump models P-141, P-142, P- models P-18 or P-39 to foot operation, order Kit PC-10.
202, P-391, P-392, P-802, and P-842. The dual-
purpose vent/fill cap acts as a pressure relief valve in
case of accidental reservoir pressurization. To A
provide an access port at the rear of the reservoir for
remote valves, use a return-to-tank kit. See the Table B
1 for kit model numbers. A
A
D B
A
B
B
E B
C
P842
Figure 2
B
D WARNING: These pumps are operated
with a non-vented reservoir. If the
reservoir is subjected to high pressure,
Figure 1 the casing may rupture, causing
personal injury and/or equipment damage.
NEVER attempt to return more oil to the reservoir
than it is capable of holding.
Table 1
Fig. 1 P-141, 1001 P-142, 1002 P-202 P-391, 1004 P-392, 1005 P-802 P-842
A Release Valve Release Valve Release Valve Release Valve Release Valve Release Valve 4-Way Valve
B 1 /4 NPTF 1 /4 NPTF 1 /4 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF
Outlet Port Outlet Port Outlet Port Outlet Port Outlet Port Outlet Port Outlet Port
C Vent/Fill Vent/Fill Vent/Fill Vent/Fill Vent/Fill Vent/Fill Vent/Fill
Cap Cap Cap Cap Cap Cap Cap
D Mounting Mounting — — — Mounting Mounting
Slots Slots Slots
E — — — — — Return-to-Tank —
Port
Return-to PC-20 PC-20 PC-25 PC-25 PC-25 — —
-Tank Kit
Table 2
Fig. 2 P-18 P-39, 1003 P-77 P-80, 1006 P-84 P-801
A Release Valve Release Valve Release Valve Release Valve Release Valve Release Valve
B 3/8 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF
Outlet Port Outlet Port Outlet Port Outlet Port Outlet Port Outlet Port
C Fill Plug Fill Plug Fill Plug Fill Plug Fill Plug Fill Plug
D — — — 1/4 NPTF — 1/4 NPTF
Return-to-Tank Port Return-to-Tank Port
3
3.3 Models P-462 and P-464 Table 4 and 5
Figure 3 and the table below show the main features Fig. 4 & 5 P-25 P-50 P-51
of hand pump models P-462, for use with single- A Release Valve Release Valve Release Valve
acting cylinders, and P-464, for use with double- B 1/4 NPTF 1/4 NPTF 1/4 NPTF
Outlet Port Outlet Port Outlet Port
acting cylinders.
C Vent/Fill Cap Vent/Fill Cap Vent/Fill Cap
4.0 INSTALLATION
C
4.1 Connecting the Pump
D 1. Thread hose into pump outlet. Use 1 1/2 wraps of
Teflon tape (or suitable thread sealant) on hose
B
fitting, leaving the first complete thread free of tape
to ensure that tape does not shed into hydraulic
system, causing damage. Trim loose ends.
A 2. Install a pressure gauge in-line from the pump for
added safety and better control.
3. Connect the hose(s) to your cylinder or tool.
P-462/464F3
NOTE: For single-acting cylinders, connect one

hose from the pump to the cylinder. For double-
acting cylinders, connect two hoses. Connect
Figure 3, Models P-462, P-464 one hose from the pressure port of the pump to
the pressure port of the cylinder. Connect another
hose from the retract port of the pump to the
Table 3 retract port of the cylinder.
Fig. 3 P-462 P-464
A 3-Way 2-Position Valve 4-Way 3-Position Valve 4.2 Pump Venting
B 3/8 NPTF Outlet Port 3/8 NPTF Outlet Port
See table below to determine if your pump should be
C Vent/Fill Plug Vent/Fill Plug
operated with a vented or non-vented reservoir.
D Handle Clip Handle Clip
Vented pumps provide slightly better performance.
For pumps with nylon reservoir, turn vent/fill cap 1/4
turn counter-clockwise to vent. For other pumps, see
3.4 Models P-25, P-50, and P-51 decal on pump. Close vent prior to transporting
pump to prevent oil leakage. P-80, P-801, and P-84
Figure 4 shows hand pump models P-25 and P-50,
are vented by turning the valve counterclockwise. To
both of which are equipped with a handle that
close the vent, turn the valve clockwise.
operates in both directions. Figure 5 shows the P-51
hand pump. The main components of these pumps
are listed in the table below. VENTING OPTIONS
EHF-65 ..........non-vented P-202 ......................either
P-18 ...............non-vented P-391, 1004 ............either
P-25 ........................either P-77 ......................vented
P-39, 1003 .....non-vented P-392, 1005 ........... either
C P-50 ........................either P-392AL ................vented
A P-51 ......................vented P-462 ....................vented
B P-80, 1006 ..............either P-464 ....................vented
P-84 ........................either P-801 .............non-vented
P-141, 1001 ............either P-802 ......................either
P-142, 1002 ............either P-842 ......................either
P-142AL.........non-vented
4.3 Pump Position

Figure 4, Models P-25 and P-50 See table below to determine the correct operating
position for your pump, horizontal or vertical. The P-80,
P-801, and P-84 cannot be vented when operated vertically.
C OPERATING POSITION
EHF-65. . . . . . . . . either P-202 . . . . . . . . . either
A P-18 . . . . . . . . . . . either P-391, 1004 . . . . . either
P-25 . . . . horizontal only P-77 . . . . . . . . . . either
P-39, 1003 . . . . . . either P-392, 1005 . . . . . either
B P-50 . . . . horizontal only P-392AL . . . . . . . . either
P-51 . . . . horizontal only P-462. . . horizontal only
P-80, 1006 . . . . . . either P-464 . . . horizontal only
P-84 . . . . . . . . . . . either P-801 . . . . . . . . . either
P-51F5
P-141, 1001 . . . . . either P-802 . . . . . . . . . . either

P-142, 1002 . . . . . either P-842 . . . . . . . . . either
Figure 5, Model P-51 P-142AL . . . . . . . either
4
NOTE: When operating the pump in the vertical CAUTION: Close release valve finger
position, the hose end must be pointed down, or the tight ONLY. Using tools on release valve
pump will pick up air and will not build pressure properly. can damage it and cause the pump to
malfunction.
5.0 OPERATION
2. Operate pump handle to deliver hydraulic power
to system. Pressure will be maintained until
5.1 Before Using the Pump release valve is opened.
1. Check all system fittings and connections to be 3. Open release valve (turn counter-clockwise) to
sure they are tight and leak free. release pressure, allowing oil to flow back to the
2. Check oil level in reservoir before operating reservoir.
pump. See "Adding Oil to the Pump" on page 7.
5.4 Single-Acting Applications with 3-Way,
2 Position Manual Valve
CAUTION: NEVER add extensions to
pump handle. Extensions cause 1. Shift valve handle to position 1 as shown in Figure 7.
unstable pump operation. 2. Operate pump handle to deliver hydraulic power
to the system. Pressure will be maintained until
WARNING: In certain situations the the valve is shifted.
pump handle can "kick back". Always
3. To allow oil to return to the reservoir, shift valve
keep your body to the side of the pump,
handle to position 2.
away from the line of force of the handle.
NOTE: To reduce handle effort at high pressure, take 2 2
short strokes. Maximum leverage is obtained in the
last 5° of stroke.
5.2 Using Two-Speed Pumps

These pumps provide 2-stage flow. Under no-load,
the pump operates in the high flow first stage for
rapid advance. When the load is contacted, the pump
1 1
automatically shifts to the second stage for building
pressure. For P-462 or P-464 models, when pump
pressure reaches approximately 200 psi [14 bar], you
must momentarily stop pumping and raise the handle A A
to shift to the high pressure stage. For P-802 or
P-842 models, when pump pressure reaches
approximately 400 psi [28 bar], you must momentarily
stop pumping and raise the handle to shift to the high
pressure stage. After the pump shifts, pumping takes
1 2
less effort.
Figure 7
NOTE: For best performance, operate pump handle
at moderate speed during the high flow first stage.
Rapid handle speed in the first stage will prevent the 5.5 Double-Acting Applications with 4-Way,
pump from delivering full volume of oil.
3 Position Manual Valve
5.3 Single-Acting Applications with Pumps with 4-way control valves are designed to
Release Valve operate double-acting cylinders. See Figure 8 for
valve positions.
1. Close release valve by turning clockwise, as
shown in Figure 6. N
A B
A B
Figure 6 Figure 8a
5
5.6 Relief Valve Adjustment
A B A B A B
All pumps contain a factory set relief valve to prevent
over-pressurization of the system. Lower pressure
settings can be obtained. Contact your Authorized
I
Enerpac Service Center.
A N B
6.0 AIR REMOVAL
Removing air from the hydraulic system will help the
Figure 8b cylinder to advance and retract smoothly (see figure 9).
1. Position lever on 4-way valve to select function as 6.1 Pump With Single-Acting Cylinder (A)
follows: 1. Vent pump reservoir (for vented pumps only) and
(A) Flow to Port "A"; port "B" returns flow to the close release valve.
reservoir 2. Position pump at higher elevation than cylinder.
(N) Neutral; ports "A" and "B" are blocked 3. Position cylinder with the plunger end down (up if
(B) Flow to port "B"; port "A" returns flow to the using pull cylinder). See Figure 9 below.
reservoir 4. Operate pump to fully extend the cylinder (retract
if using pull cylinder).
5. Open release valve to retract cylinder (extend if a
pull cylinder). This will force the trapped air to
move up to the pump reservoir.
6. Repeat the above steps as necessary.
N
7. Add oil if necessary. See page 7.
8. Return vent/fill cap to operating position.
B
A 6.2 Pump With Double-Acting Cylinder (B)
A
1. Vent pump reservoir (for vented pumps only).
B 2. Position pump at higher elevation than cylinder.
3. Put cylinder in horizontal position with ports up.
See Figure 9.
Figure 8c 4. Fully advance and retract the cylinder 2 to 3 times.
5. Repeat the above steps as necessary.
2. Operate pump to perform work. 6. Add oil if necessary. See page 7.
3. Change valve positions as needed. 7. Return vent/fill cap to operating position.
WARNING: Operate double-acting 7.0 MAINTENANCE

cylinder only when both hoses are
connected to the pump. If one coupler Use only Enerpac hydraulic oil with these pumps to
is left unconnected, high pressure will promote long pump life and to protect your warranty.
build behind the coupler which could cause Viton and EPR seal kits are available for some hand
personal injury and/or equipment damage. pumps. Contact your Enerpac representative for more
information on these products and their applications.
air
air
A B
Figure 9
6
7.1 Adding Oil to the Pump
B, C
Check oil level regularly.
A
WARNING: Always add oil with
cylinders fully retracted (extended if
pull cylinders) or the system will contain
more oil than the reservoir can hold.
1. Remove vent/fill cap from reservoir.
2. Fill reservoir only to level mark shown on pump.
3. Remove air from system if necessary. See page 6.
Recheck oil level after removing air.
4. Return vent/fill cap to proper position. Figure 10
NOTE: Non-vented hand pumps require air in the
reservoir to function properly. If the reservoir is 7.4 Changing the Oil
completely filled, a vacuum will form preventing 1. Drain all oil and refill with clean Enerpac oil every
oil from flowing out of the pump. 12 months. If pump is used in dirty environments,
change the oil more often.
7.2 Keeping Oil Lines Clean
2. Remove vent/fill cap or plug from reservoir.
When coupler halves are disconnected, always screw 3. Tilt pump to drain out old oil.
on dust caps. Use every precaution to guard unit
against entrance of dirt because foreign matter may 4. Fill reservoir only to level mark shown on pump.
cause pump, cylinder, or valve failure. 5. Replace the vent/fill cap or plug.
6. Dispose of used oil properly.
7.3 Lubricating the Pump
To extend pump life and improve performance,
8.0 TROUBLESHOOTING GUIDE
lubricate the beam pin (A), cross pin (B), and piston
head (C) regularly, using roller bearing grease. See The following information is intended as an aid in
Figure 10. determining if a problem exists. For repair service,
contact the Authorized Enerpac Service Center in
your area.
TROUBLESHOOTING
Problem Possible Cause Solution
Cylinder does not 1. Oil level in pump reservoir is 1. Add oil according to the Maintenance instructions on
advance, advances low. page 6.
slowly, or advances in 2. Release valve open. 2. Close the release valve.
spurts.
3. Loose hydraulic coupler. 3. Check that all couplers are fully tightened.
4. Load is too heavy. 4. Do not attempt to lift more than rated tonnage.
5. Air trapped in system. 5. Remove air according to the instructions on page 6.
6. Cylinder plunger binding. 6. Check for damage to cylinder. Have cylinder serviced by
a qualified hydraulic technician.
Cylinder advances, but 1. Leaking connection. 1. Check that all connections are tight and leak free.
does not hold pressure. 2. Leaking seals. 2. Locate leak(s) and have equipment serviced by a
3. Internal leakage in pump. qualified hydraulic technician.
3. Have pump serviced by a qualified hydraulic technician.
Cylinder does not retract, 1. Release valve closed. 1. Open release valve.
retracts part way, or 2. Pump reservoir is over-filled. 2. Drain oil level to full mark. See page 7 instructions for
retracts more slowly than adding oil.
3. Loose hydraulic coupler.
normal.
4. Air trapped in system. 3. Check that all couplers are fully tightened.
5. Hose I.D. too narrow. 4. Remove air according to the instructions on page 6.
6. Cylinder retraction spring 5. Use larger diameter hydraulic hose.
broken or other cylinder 6. Have cylinder serviced by a qualified hydraulic
damage. technician.
7
Fiche d’instructions
Pompes á Main Hydrauliques

L1763 Rev I 12/05
Les vues éclatées de ce produit sont disponibles sur
le site Enerpac www.enerpac.fr. Vous pouvez
également les obtenir auprès de votre réparateur
agréé Enerpac ou auprès d'Enerpac même.
1.0 INSTRUCTIONS IMPORTANTES

RELATIVES À LA RÉCEPTION
Inspecter tous les composants pour vous assurer
qu’ils n’ont subi aucun dommage en cours
d’expédition. Les dommages subis en cours de
transports ne sont pas couverts par la garantie. S’ils
sont abîmés, aviser immédiatement le transporteur,
qui est responsable des frais de réparation et de
remplacement résultant de dommages en cours de AVERTISSEMENT : UTILISER
transport. SEULEMENT DES PIÈCES RIGIDES
®
®
POUR SOUTENIR LES CHARGES.
LA SÉCURITÉ AVANT TOUT ! Sélectionner avec précaution des blocs
d’acier ou de bois capables de supporter la charge.
2.0 SÉCURITÉ Ne jamais utiliser un vérin hydraulique comme cale
ou intercalaire d’appui pour les applications de
Lire attentivement toutes les levage ou de pressage.
instructions et mises en garde et
tous les avertissements. Suivre DANGER : Pour écarter tout risque
toutes les précautions pour éviter de blessure personnelle, maintenir
d’encourir des blessures personnelles ou de les mains et les pieds à l’écart du
provoquer des dégâts matériels durant le vérin et de la pièce à usiner durant
fonctionnement du système. Enerpac ne peut pas l’utilisation.
être tenue responsable de dommages ou blessures AVERTISSEMENT : Ne pas dépasser les
résultant de l’utilisation risquée du produit, d’un valeurs nominales du matériel. Ne jamais
mauvais entretien ou d’une application incorrecte du essayer de soulever une charge d’un
produit et du système. En cas de doute sur les poids supérieur à la capacité du vérin. Une
précautions ou les applications, contacter Enerpac. surcharge entraînera la panne du matériel et risque
Respecter les mises en garde et avertissements de provoquer des blessures corporelles. Les vérins
suivants sous peine de provoquer des dégâts sont conçus pour une pression maximale de 700 bar.
matériels et des blessures corporelles. Ne pas connecter de cric ou de vérin à une pompe
affichant une pression nominale supérieure.
Une mise en garde ATTENTION sert à indiquer des
procédures d’utilisation et de maintenance correctes DANGER: Ne jamais régler la soupape de
qui visent à empêcher l’endommagement voire la sûreté à une pression supérieure à la
destruction du matériel ou d’autres dégâts. pression nominale maximale de la pompe
sous peine de provoquer des dégâts
Un AVERTISSEMENT indique un danger potentiel qui matériels et/ou des blessures corporelles. Ne pas retirer
exige la prise de mesures particulières visant à écarter le limiteur de pression.
tout risque de blessure.
AVERTISSEMENT : La pression de
La mention DANGER n’est utilisée que lorsqu’une fonctionnement du système ne doit pas
action ou un acte de négligence risque de causer des dépasser la pression nominale du
blessures graves, voire mortelles. composant du système affichant la plus
AVERTISSEMENT : Porter un équipement petite valeur. Installer des manomètres dans le
de protection personnelle adéquat pour système pour surveiller la pression de
utiliser un appareil hydraulique. fonctionnement. Ils permettent de vérifier ce qui se
passe dans le système.
AVERTISSEMENT : Rester à l’écart de ATTENTION : Éviter d’endommager les
charges soutenues par un mécanisme tuyaux hydrauliques. Éviter de les plier et
hydraulique. Un vérin, lorsqu’il est utilisé de les tordre en les mettant en place. Un
comme monte-charge, ne doit jamais tuyau plié ou tordu entraînera un fort
servir de support de charge. Après avoir monté ou retour de pression. Les plis et coudes prononcés
abaissé la charge, elle doit être bloquée par un endommageront par ailleurs l’intérieur du tuyau,
moyen mécanique. provoquant son usure précoce.
8
Ne pas faire tomber d’objets lourds sur le Lorsqu'applicable, utiliser une base de vérin pour
tuyau. Un fort impact risque de causer accroître la stabilité. Ne pas souder ou modifier le vérin
®
des dégâts intérieurs (torons métalliques). de quelque façon que ce soit pour y fixer une base ou
L’application d’ une pression sur un tuyau un autre dispositif de support.
endommagé risque d’entraîner sa rupture.
Éviter les situations où les charges ne sont
IMPORTANT : Ne pas soulever le matériel pas directement centrées sur le piston du
hydraulique en saisissant ses tuyaux ou ses vérin. Les charges décentrées imposent un
raccords articulés. Utiliser la poignée de trans- effort considérable au vérins et pistons. En
port ou procéder d’une autre manière sûre. outre, la charge risque de glisser ou de tomber, ce qui
crée un potentiel de danger.
ATTENTION : Garder le matériel
hydraulique à l’écart de flammes et Répartir la charge uniformément sur toute la
d’une source de chaleur. Une forte surface d'appui. Toujours utiliser un
température amollira les garnitures et les coussinet d'appui si des accessoires non
joints et provoquera par conséquent des fuites. La filetés sont utilisés.
chaleur affaiblit également les matériaux et les garnitures
du tuyau. Pour une performance maximale, ne pas IMPORTANT : Le matériel hydraulique doit
exposer le matériel à une température supérieure ou uniquement être réparé par un technicien
égale à 65 °C [150 °F]. Protéger tuyaux et vérins de hydraulique qualifié. Pour toute réparation,
projections de soudure. contacter le centre de réparation ENERPAC
agréé le plus proche. Pour assurer la validité de la
DANGER : Ne pas manipuler les tuyaux
garantie, n’utiliser que de l’huile ENERPAC.
sous pression. L’huile sous pression qui
risque de s’en échapper peut pénétrer dans AVERTISSEMENT : Remplacer
la peau et provoquer des blessures graves. immédiatement les pièces usées ou
En cas d’injection d’huile sous la peau, contacter endommagées par des pièces ENERPAC
immédiatement un médecin. authentiques. Les pièces de qualité
standard se casseront et provoqueront des blessures et
AVERTISSEMENT : Utiliser des vérins
des dégâts matériels. Les pièces ENERPAC sont
hydrauliques uniquement dans un système
conçues pour s’ajuster parfaitement et résister à de
couplé. Ne jamais utiliser un vérin en présence
fortes charges.
de raccords déconnectés. La surcharge du
vérin peut avoir des effets désastreux sur ses PRÉCAUTION : Toujours porter la pompe
composants, qui peuvent causer des blessures graves. par son levier. Si la pompe est portée par le
flexible, le flexible ou la pompe risque d’en
AVERTISSMENT : S'assurer de la stabilité
souffrir.
de l'ensemble avant de lever une charge.
®
Le vérin doit être placé sur une surface plane

capable de supporter la charge.
FICHE TECHNIQUE - Utiliser cette notice d’emploi pour les modèles de pompe à main suivants.
Fiche Technique
Modèle Type Pression nominale Volume d’huile Capacité d’huile
(Vitesse) max. psi [bar] par coup in 3 [cm 3] utilisable in3 [cm3]
EHF-65 1 6,500 [440] .16 [2.62] 22 [360]
P-18 1 2,850 [200] .16 [2.62] 22 [360]
P-25 1 2,500 [170] .58 [9.51] 231 [3786]
P-39, 1003 1 10,000 [700] .16 [2.62] 43 [705]
P-50 1 5,000 [340] .29 [4.75] 231 [3786]
P-51 1 3,000 [210] .25 [4.09] 50 [820]
P-141, 1001 1 10,000 [700] .055 [.90] 20 [328]
P-391, 1004 1 10,000 [700] .151 [2.47] 55 [900]
1ère étape 2e étape 1ère étape 2e étape
P-80, 1006 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 140 [2295]
P-84 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 140 [2295]
P-142, 1002 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 20 [328]
P-142AL 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 9.0 [148]
P-202 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 55 [900]
P-77 2 200 [14] 10,000 [700] .63 [16.0] .094 [2.41] 47 [769]
P-392, 1005 2 200 [14] 10,000 [700] .687 [11.26] .151 [2.47] 55 [900]
P-392AL 2 200 [14] 10,000 [700] .687 [11.26] .151 [2.47] 55 [900]
P-462 2 200 [14] 10,000 [700] 7.69 [126.00] .29 [4.75] 462 [7572]
P-464 2 200 [14] 10,000 [700] 7.69 [126.00] .29 [4.75] 462 [7572]
P-801 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 250 [4095]
P-802 2 400 [28] 10,000 [700] 2.40 [39.34] .15 [2.46] 155 [2540]
P-842 2 400 [28] 10,000 [700] 2.40 [39.34] .15 [2.46] 155 [2540]
9
3.0 DESCRIPTION 3.2 Modèles P-18/P39, 1003/P-80, 1006/
P-84/P-801, P-77
3.1 Modèles P-141, 1001/P-142, 1002/ La figure 2 et le tableau correspondant montrent les
P-202/P-391, 1004/P-392, 1005/P802, et pièces principales de ces modèles de pompe à main.
P-842 Les modèles P-84 sont équipés d’un distributeur à 4
La figure 1 et le tableau qui l’accompagne ci-dessous voies et 3 positions destiné aux vérins à double effet.
montrent les pièces principales des modèles de Pour convertir les modèles P-18 ou P-39 pour
pompe à main P-141, P-142, P-202, P-391, P-392, l’utilisation au pied, commander le jeu PC-10.
P802, et P842. Le bouchon reniflard à deux fonctions
(aération et remplissage) sert à dissiper la pression en A
cas de mise sous pression accidentelle du réservoir.
Pour fournir un orifice d’accès à l’arrière du réservoir B
à l’intention des vannes à distance, utiliser un jeu de A
retour au réservoir. Le tableau ci-dessous donne les
numéros de modèle des différents jeux.
D B
A
A B
B
C
E B
P842
Figure 2
C
AVERTISSEMENT : Ces pompes
fonctionnent avec un réservoir non aéré.
Si le réservoir est soumis à une pression
B élevée, le carter risque d’éclater et de
D
causer des blessures et (ou) des dégâts matériels. NE
JAMAIS essayer de renvoyer au réservoir plus d’huile
qu’il ne peut en contenir.
Figure 1
Tableau 1
Fig. 1 P-141, 1001 P-142, 1002 P-202 P-391, 1004 P-392, 1005 P-802 P-842
A Robinet de Robinet de Robinet de Robinet de Robinet de Robinet de Distributeur 4
décharge décharge décharge décharge décharge décharge voies
B Orifice de sortie Orifice de sortie Orifice de sortie Orifice de sortie Orifice de sortie Orifice de sortie Orifice de sortie
1 /4 NPTF 1 /4 NPTF 1 /4 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPT
C Bouchon reniflard Bouchon reniflard Bouchon reniflard Bouchon reniflard Bouchon reniflard Bouchon reniflard Bouchon reniflard
D Encoches de Encoches de — — — Encoches de Encoches de
montage montage montage montage
E — — — — — Oriface de retour —
au réservoir
Jeu de PC-20 PC-20 PC-25 PC-25 PC-25 — —
retour au
réservoir
Tableau 2
Fig. 2 P-18 P-39, 1003 P-77 P-80, 1006 P-84 P-801
A Robinet de décharge Robinet de décharge Robinet de décharge Robinet de décharge Distributeur Robinet de décharge
4 voies 3 positions
B Orifice de sortie Orifice de sortie Orifice de sortie Orifice de sortie Orifice de sortie Orifice de sortie
3/8 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF
C Bouchon de Bouchon de Bouchon de Bouchon de Bouchon de Bouchon de
remplissage remplissage remplissage remplissage remplissage remplissage
D — — — Oriface de retour — Oriface de retour
au réservoirt 1 /4 NPTF au réservoirt 1 /4 NPTF
10
3.3 Modèles P-462 et P-464
La figure 3 et le tableau ci-dessous montrent les
éléments principaux des modèles de pompe à main 2. Par mesure de prudence et pour permettre de
P-462, pour vérins à simple effet, et P-464, pour surveiller la pression plus aisément, poser un
vérins à double effet. manomètre sur la conduite sortant de la pompe.
C
3. Raccorder le ou les flexibles au vérin ou outil.
NOTE : Dans le cas des vérins à simple effet,
D brancher un flexible entre la pompe et le vérin.
Pour les vérins à double effet, raccorder deux
B flexibles. Connecter un flexible entre l’orifice de
pression de la pompe et l’orifice de pression du
A vérin. Brancher l’autre entre l’orifice de rentrée de
la pompe et l’orifice de rentrée du vérin.
P-462/464F3
4.2 Aération de la pompe

Le tableau ci-dessous permet de déterminer si la
pompe doit être utilisée avec un réservoir équipé de
Figure 3, P-462 ry P-464
mise à l'air ou non. Les pompes équipées de
réservoir avec mise à l'air ont généralement de
Tableau 3 meilleures performances. Pour les pompes avec
Fig. 3 P-462 P-464 réservoir nylon, tourner le bouchon de mise à l'air de
A Distributeur 3 voies 2 positions Distributeur 4 voies 3 positions 90° dans le sens inverse des aiguilles d'une montre.
B Orifice de sortie 3/8 NPTF Orifice de sortie 3/8 NPTF Pour les autres modèle voir les instructions sur
C Bouchon reniflard Bouchon reniflard l'autocollant. Toujours fermer la mise à l'air avant de
D Attache-levier Attache-levier transporter la pompe.
3.4 Modèles P-25, P-50 et P-51 La mise à l'air du réservoir sur les pompes P-80, P-
801 et P84 s'effectue par l'ouverture du bouchon
La figure 4 illustre les modèles de pompe à main P- dans le sens inverse des aiguilles d'une montre. Pour
25 et P-50, lesquels sont tous deux équipés d’un refermer la mise à l'air, tourner la valve dans le sens
levier fonctionnant dans les deux sens. La figure 5 des aiguilles d'une montre.
représente la pompe à main P 51. Les éléments
principaux de ces pompes sont indiqués dans le OPTIONS D’AÉRATION
tableau ci-dessus. EHF-65. . . . . . . . . . . . non aéré P-202. . . . . . . sans importance
P-18. . . . . . . . . . . . . . non aéré P-391, 1004 . . sans importance
P-25. . . . . . . . sans importance P-77 . . . . . . . . . . . . . . . . . aéré
C
C P-39, 1003. . . . . . . . . non aéré P-392, 1005 . sans importance
B
A A P-50. . . . . . . . sans importance P-392AL . . . . . . . . . . . . . aéré
P-51 . . . . . . . . . . . . . . . . . aéré P-462 . . . . . . . . . . . . . . . . aéré
B P-80, 1006 . . . sans importance P-464 . . . . . . . . . . . . . . . . aéré
P-84. . . . . . . . sans importance P-801. . . . . . . . . . . . . non aéré
P-141, 1001 . . sans importance P-802. . . . . . . sans importance
P-51F5
P-142, 1002 . . sans importance P-842. . . . . . . sans importance

P-142AL. . . . . . . . . . . non aéré
Fig. 4, Modèles P-25 and P-50 Fig. 5, Modèle P-51
4.3 Position de la Pompe
Tableau 4 et 5
Fig. Voir le tableau ci-dessous pour déterminer la position
4, 5 P-25 P-50 P-51 de service correcte pour (horizontale ou verticale). La
A Robinet de décharge Robinet de décharge Robinet de décharge mise à l'air du réservoir sur les pompes P80-P801 et
B Orifice de sortie Orifice de sorti Orifice de sorti P84 est impossible quand la pompe est à la verticale.
3/8 NPTF 3/8 NPTF 3/8 NPTF
C Bouchon reniflard Bouchon reniflard Bouchon reniflard POSITION DE SERVICE
EHF-65 . . . . . . sans importance P-202 . . . . . . sans importance
4.0 INSTALLATION P-18. . . . . . . . sans importance P-391, 1004 . sans importance
P-25 . . . horizontale seulement P-77 . . . . . . . sans importance
P-39, 1003 . . . sans importance P-392, 1005 . . sans importance
4.1 Raccordement de la pompe P-50 . . . horizontale seulement P-392AL . . . . . sans importance
P-51 . . . horizontale seulement P-462 . . horizontale seulement
1. Visser le flexible dans l’orifice de la pompe. P-80, 1006 . . sans importance P-464 . . horizontale seulement
Entourer le raccord de flexible de 1 1/2 tour de P-84. . . . . . . . sans importance P-801 . . . . . . sans importance
ruban Téflon (ou utiliser un matériau d’étanchéité P-141, 1001 . . sans importance P-802. . . . . . . sans importance
qui convient), en ne couvrant pas le premier filet P-142, 1002 . . sans importance P-842 . . . . . . sans importance
P-142AL . . . . sans importance
afin d’éviter que des lambeaux de ruban
pénètrent dans le circuit hydraulique et causent
des dégâts. Couper les parties qui dépassent.
11
NOTE : Quand la pompe est utilisée en position PRÉCAUTION : Serrer le robinet de
verticale, le côté flexible doit être dirigé vers le bas décharge à la main UNIQUEMENT.
sinon la pompe risque d’attirer de l’air et de ne pas L’emploi d’outils sur le robinet de
donner la pression qui convient. décharge peut l’endommager et risque
de causer un mauvais fonctionnement de la pompe.
5.0 FONCTIONNEMENT
2. Actionner le levier de la pompe afin d’alimenter le
5.1 Avant d’utiliser la pompe circuit en puissance hydraulique. La pression est
1. Vérifier tous les raccords et toutes les connexions du maintenue jusqu’à ce que le robinet de décharge
circuit pour s’assurer de leur intégrité et leur soit ouvert.
étanchéité. 3. Ouvrir le robinet de décharge (en le tournant vers
2. Vérifier le niveau d’huile dans le réservoir avant de la gauche) pour dissiper la pression, ce qui
faire fonctionner la pompe. Voir "Appoint d’huile permet le retour de l’huile vers le réservoir.
dans la pompe", page 14.
5.4 Applications à simple effet avec
PRÉCAUTION : NE JAMAIS ajouter de distributeur manuel à 3 voies et 2
rallonges au levier de la pompe, sous positions
peine de déstabiliser le fonctionnement de
la pompe. 1. Placer la manette du distributeur en position 1,
comme le montre la figure 7.
AVERTISSEMENT : Il peut arriver que le
2. Actionner le levier de la pompe afin d’alimenter le
levier de la pompe revienne brusquement
circuit en puissance hydraulique. La pression est
en arrière. Toujours se tenir sur le côté de
maintenue jusqu’à ce que le distributeur change de
la pompe, hors de portée du levier.
position.
NOTE : Pour réduire l’effort à exercer sur le levier aux 3. Pour laisser l’huile revenir au réservoir, placer la
pressions élevées, pomper par petits coups. L’effet de manette du distributeur en position 2.
levier maximum est obtenu dans les cinq derniers
degrés de la course du levier.
2 2
5.2 Utilisation des pompes à deux vitesses
Ces pompes fournissent un débit en deux étapes. À
vide, la pompe fonctionne en première étape à débit
élevé pour assurer une sortie rapide du vérin. Quand
il y a contact avec la charge, la pompe passe
automatiquement à la deuxième étape afin de donner
de la pression. Dans le cas des modèles P-462 ou 1 1
P-464, lorsque la pression de la pompe est de l’ordre
de 200 psi [14 bar], il faut s’arrêter de pomper
momentanément et relever le levier pour passer à
l’étape haute pression. Dans le cas des modèles P- A A
802 ou P-842, lorsque la pression de la pompe est de

l’ordre de 400 psi [28 bar], il faut s’arrêter de pomper
momentanément et relever le levier pour passer à
l’étape haute pression. Après ce changement
d’étapes, la pompe s’actionne avec moins d’effort. 1 2
NOTE : Pour optimiser les performances, actionner le

levier de la pompe à vitesse modérée durant la première Figure 7
étape à débit élevé. Si l’on pompe trop vite dans la 5.5 Applications à double effet avec
première étape, le volume d’huile fourni ne sera pas distributeur manuel à 4 voies et 3
suffisant. positions
Les pompes équipées de distributeurs à 4 voies sont
5.3 Applications à simple effet avec robinet conçues pour faire fonctionner des vérins à double
de décharge effet. La figure 8, illustre les positions du distributeur.
1. Fermer le robinet de décharge en le tournant vers
la droite, comme l’illustre la figure 6. N
A B
A B
Figure 6
12
Figure 8a possible de régler ce robinet sur une pression moins
élevée. Contacter le Service après-vente agréé
A B
Enerpac le plus proche.
A B A B
6.0 PURGE DE L’AIR

L’élimination de l’airdu circuit hydraulique aide le
I
vérin à sortir et rentrer en douceur. Voir figure 9.
A N B
6.1 Pompe associée à un vérin à simple
effet (A)
Figure 8b
1. Positionner la manette du distributeur à 4 voies 1. Aérer le réservoir de la pompe (pompes aérées
selon la fonction désirée : uniquement) et fermer le robinet de décharge.
(A) Débit vers l’orifice "A" ; retour depuis l’orifice 2. Positionner la pompe plus haut que le vérin.
"B" vers le réservoir 3. Positionner le vérin côté piston vers le bas (ou le
(N) Neutre ; orifices "A" et "B" bouchés haut s’il s’agit d’un vérin à traction). Voir figure 9.
(B) Débit vers l’orifice "B", retour depuis l’orifice 4. Actionner la pompe pour faire sortir le vérin
"A" vers le réservoir jusqu’au bout (le faire rentrer s’il s’agit d’un vérin
à traction).
5. Ouvrir le robinet de décharge pour faire rentrer le
vérin (le faire sortir s’il s’agit d’un vérin à traction).
L’air piégé est ainsi forcé à remonter vers le
réservoir de la pompe.
6. Répéter les opérations ci-dessus, au besoin.
N
7. Ajouter de l’huile si nécessaire. Voir page 14.
B 8. Remettre le reniflard en position de service.
A
A 6.2 Pompe associée à un vérin à double
B effet (B)
1. Aérer le réservoir de la pompe (pompes aérées
uniquement).
Figure 8c 2. Positionner la pompe plus haut que le vérin.
3. Positionner le vérin en position horizontale, orifices
2. Actionner la pompe selon le service désiré. vers le haut. Voir figure 9 ci-dessous.
3. Changer le distributeur de position quand cela 4. Faire sortir et rentrer le vérin jusqu’au bout, deux ou
s’avère nécessaire. trois fois.
5. Répéter les opérations ci-dessus, au besoin.
AVERTISSEMENT : Ne faire fonctionner 6. Ajouter de l’huile si nécessaire. Voir page 14.
un vérin à double effet que lorsque les 7. Remettre le bouchon reniflard en position de service.
deux flexibles sont connectés à la
pompe. Si un raccord est laissé 7.0 ENTRETIEN
débranché, une pression élevée risque de se Utiliser uniquement de l’huile hydraulique Enerpac
constituer derrière le raccord, d’où risques de avec ces pompes afin d’en prolonger la durée de vie
blessures et (ou) de dégâts matériels. et de protéger la validité de la garantie. Des jeux
d’étanchéité Viton et EPR peuvent être fournis pour
5.6 Réglage du robinet de décharge certaines pompes à main. Demander plus
Toutes les pompes sont munies d’un robinet de d’informations sur ces produits et leurs applications
décharge réglé en usine qui permet d’empêcher le au représentant Enerpac.
circuit de se pressuriser plus que nécessaire. Il est
air
air
A B
Figure 9
13
7.1 Appoint d’huile à la pompe (C) régulièrement en utilisant de la graisse pour
roulements à rouleaux. Voir figure 10
Vérifier régulièrement le niveau d’huile.
AVERTISSEMENT : Les vérins doivent B, C
être complètement rentrés (ou sortis si A
vérins de traction) quand l’huile est
ajoutée, sinon le circuit risque de
renfermer plus d’huile que le réservoir ne peut en
contenir.
1. Retirer le bouchon reniflard du réservoir.
2. Remplir le réservoir en s’arrêtant au repère marqué
sur la pompe.
3. Éliminer l’air du circuit si nécessaire. Voir page 13.
Revérifier le niveau d’huile après cette opération.
4. Remettre le bouchon reniflard sur la position qui Figure 10
convient.
7.4 Vidange d’huile
NOTE : Les pompes à main non aérées ont besoin
d’air dans le réservoir pour fonctionner 1. Vider toute l’huile et faire le plein d’huile Enerpac
correctement. Si le réservoir est rempli à ras bord, propre tous les 12 mois. Si la pompe est utilisée
un effet de vide se crée empêchant l’huile de sortir dans des conditions de grande saleté, changer
de la pompe. l’huile plus souvent.
2. Retirer le bouchon reniflard ou le bouchon de
7.2 Protection des conduites d’huile contre
remplissage du réservoir.
les saletés
3. Pencher la pompe pour faire partir toute l’huile
Quand les deux moitiés d’un raccord sont séparées, usée.
toujours protéger les ouvertures par des capuchons 4. Remplir le réservoir en s’arrêtant au repère marqué
anti-poussière. Prendre toutes les mesures sur la pompe.
nécessaires pour protéger l’appareil contre la 5. Remettre le bouchon reniflard ou de remplissage.
pénétration de saletés, car les corps étrangers
6. Jeter l’huile usée selon les méthodes appropriées.
peuvent provoquer une défaillance au niveau de la
pompe, du vérin ou des soupapes. 8.0 GUIDE DE DÉPANNAGE
Les informations qui suivent sont à utiliser à titre de
7.3 Lubrification de la pompe
guide pour déterminer l’existence d’un problème.
Pour prolonger la durée de vie de la pompe et en Pour les réparations, contacter le Service après-
améliorer les performances, lubrifier l’axe du vente agréé Enerpac le plus proche.
balancier (A), l’axe transversal (B) et la tête de piston
GUIDE DE DÉPANNAGE
Problème Cause possible Solution
Le vérin ne sort pas, sort 1. Niveau d’huile insuffisant 1. Ajouter de l’huile suivant les instructions d’entretien de
lentement ou sort par à- dans le réservoir de la la page 14.
coups. pompe. 2. Fermer le robinet de décharge.
2. Robinet de décharge 3. Vérifier que tous les raccords sont bien serrés.
ouvert. 4. Ne pas tenter de soulever plus que la charge nominale.
3. Raccord hydraulique 5. Éliminer l’air suivant les instructions de la page 13.
desserré. 6. Vérifier l’état du vérin. Faire réparer le vérin par un
4. Charge trop importante. technicien qualifié en hydraulique.
5. Air piégé dans le circuit.
6. Piston du vérin coince.
Le vérin sort mais ne 1. Fuite aux connexions. 1. Vérifier l’intégrité et l’étanchéité de toutes les
maintient pas la pression. 2. Fuite aux joints. connexions.
3. Fuite interne dans la 2. Localiser la ou les fuites et faire réparer le matériel par
pompe. un technicien qualifié en hydraulique.
3. Faire réparer la pompe par un technicien qualifié en
hydraulique.
Le vérin ne rentre pas, 1. Robinet de décharge fermé. 1. Ouvrir le robinet de décharge.

rentre partiellement ou 2. Réservoir de la pompe trop 2. Vider de l’huile pour redescendre au repère plein.
rentre plus lentement qu’il rempli. Instructions pour l’appoint d’huile à la page 14.
ne devrait. 3. Raccord hydraulique 3. Vérifier que tous les raccords sont bien serrés.
desserré. 4. Éliminer l’air suivant les instructions de la page 13.
4. Air piégé dans le circuit. 5. Utiliser un flexible hydraulique à plus grand diamètre.
5. Diamètre intérieur du 6. Faire réparer le vérin par un technicien qualifié en
flexible trop petit. hydraulique.
6. Ressort de rappel du vérin
cassé ou autre problème de
vérin.
14
Bedienungsanleitung
Hydraulische Handpumpen
L1763 Rev I 12/05
Das Ersatzteilblatt für dieses Produkt finden Sie auf

der Enerpac Website www.enerpac.com, oder bei
Ihrem nächstgelegenen authorisierten Enerpac
Service Center oder einem Enerpac Vertriebsbüro.
1.0 WICHTIGE VERFAHRENSHINWEISE

FÜR DEN EMPFANG:
Alle Komponenten auf sichtbare Transportschäden
inspizieren. Transport-schäden sind nicht von der
Garantie gedeckt. Werden solche Schäden
festgestellt, ist unverzüglich das
Transportunternehmen zu verständigen. Das
Transportunternehmen ist für alle Reparatur- und
WARNUNG: Beim Betrieb hydraulischer
Ersatzkosten, die auf Transportschäden
Anlagen geeignete Schutzkleidung und
zurückzuführen sind, verantwortlich. –ausrüstung tragen.
SICHERHEIT GEHT VOR

WARNUNG: Von Lasten fernhalten, die
2.0 SICHERHEITSFRAGEN durch ein Hydrauliksystem abgestützt
werden. Ein als Lastenhebegerät
Alle Anleitungen, Warnungen und eingesetzter Zylinder darf niemals als ein
Vorsichtshinweise sorgfältig Lastenhaltegerät verwendet werden. Nach Heben
durchlesen. Beachten Sie alle oder Senken der Last muß diese stets auf
Sicherheitsvorkehrungen, um Verletzungen oder mechanische Weise gesichert werden.
Sachschäden während des Systembetriebs zu WARNUNG ZUM SICHERN VON
vermeiden. Enerpac ist weder für Schäden noch LASTEN STETS NUR STARRE TEILE
®
Verletzungen haftbar, die durch einen fahrlässigen VERWENDEN. Zum Abstützen von Lasten
Gebrauch des Produkts, mangelhafte Instand-
®
sorgfältig dazu geeignete Stahl- oder

haltung oder eine unvorschriftsmäßige Anwendung Holzblöcke auswählen. Bei Hebe- oder
des Produkts und/oder des Systems verursacht Drückanwendungen keinesfalls einen
werden. Bei evtl. Fragen in bezug auf Hydraulikzylinder als Abstandsstück oder –halter
Sicherheitsvorkehrungen und Betriebsabläufe verwenden.
wenden Sie sich bitte an ENERPAC. Wenn Sie an
GEFAHR: Zur Vermeidung von
keinerlei Sicherheitsschulungen im Zusammenhang Verletzungen während des Betriebs
mit Hochdruck-hydraulikanlagen teilgenommen Hände und Füße von Zylinder und
haben, fordern Sie von Ihrer Vertriebs- und Werkstück fernhalten.
Kundendienstzentrale einen kostenlosen Enerpac-
Hydraulik-Sicherheitskurs an. WARNUNG: Die zugelassene Nennleistung
der Geräte nicht überschreiten. Keine Last
Ein Mißachten der folgenden Vorsichtshinweise und zu heben versuchen, deren Gewicht das
Warnungen kann zu Geräteschäden und Hebevermögen des Zylinders übersteigt.
Verletzungen führen. Überlasten verursachen Maschinenausfälle und
können zu Verletzungen führen. Die Zylinder wurden
Mit einem VORSICHTSHINWEIS wird auf
für einen max. Druck von 700 bar konstruiert. Keinen
ordnungsgemäße Betriebs- oder Wartungsverfahren
Heber oder Zylinder an eine Pumpe mit einer höheren
und –praktiken hingewiesen, um Schäden an den nominalen Druckleistung anschließen.
Geräten oder anderen Sachwerten bzw. deren
Zerstörung zu vermeiden. GEFAHRENSHINWEIS: Das
Überdruckventil keinesfalls auf einen
Eine WARNUNG verweist auf eine potentielle höheren Druck als den maximal zulässigen
Verletzungsgefahr, die durch ordnungsgemäße Druck der Pumpe einstellen. Höhere
Verfahren oder Praktiken vermieden werden kann. Einstellungen können zu Geräteschäden und/oder
Ein GEFAHRENSHINWEIS wird nur dann gegeben, Verletzungen führen. Nicht das Druckbegrenzungs-
wenn eine bestimmte Handlung oder die Ventil entfernen!
Unterlassung einer bestimmten Handlung schwere WARNUNG: Der System-betriebsdruck
oder tödliche Verletzungen zur Folge haben kann. darf den zulässigen Nominaldruck der
System-komponente mit der niedrigsten
Nennleistung nicht überschreiten. Zur
15
Überwachung des Betriebsdrucks sind Manometer im WARNUNG: In einem gekoppelten
System zu installieren. Dies ist das Fenster zu den System dürfen nur Hydraulikzylinder
Abläufen im System. verwendet werden. Niemals einen
Zylinder mit unverbundenen Kupplungen
VORSICHT: Beschädigungen am
verwenden. Bei einer extremen Überlastung des
Hydraulikschlauch vermeiden. Beim
Zylinders können dessen Komponenten einen
Verlegen der Hydraulik-schläuche enge
Sprungvollausfall erleiden, was schwere Verletzungen
Bögen und Abknicken vermeiden. Der
hervorrufen kann.
Einsatz eines gebogenen oder geknickten Schlauchs
führt zu einem hohen Rückstau. Starke Biegungen und WARNUNG: Sicherstellen, dass die
Knickstellen schädigen den Schlauch auf der anlage stabilisiert, bevor eine last
Innenseite und führen zu dessen vorzeitigem Ausfall. angehoben wird. Der Zylinder sollte auf
®
einer ebenen Oberfläche aufsitzen, die fest
Keine schweren Gegenstände auf den
genug ist, um die Last abzustützen. Wenn
Schlauch fallen lassen. Starke
möglich einen Zylinderfuß verwenden, um größere
Erschütterungen können Schäden an
Stabilität zu gewährleisten. Keine Schweißarbeiten
®
den im Schlauchinnern verlaufenden

oder andere Änderungen am Zylinder vornehmen, um
Drahtlitzen verursachen. Ein Schlauch, auf den Druck
einen Zylinderfuß oder andere Abstützungen
ausgeübt wird, kann bersten.
anzubringen.
WICHTIG: Hydraulische Geräte weder an
Situationen vermeiden, in denen die Lasten
den Schläuchen noch den
nicht direkt über dem Kolben des Zylinders
Gelenkanschlüssen anheben. Dazu den
ausgerichtet sind. Seitlich versetzte Lasten
Tragegriff oder eine andere sichere
führen zu erheblicher Belastung der
Transportmethode verwenden.
Zylinder und Kolben. Außerdem könnte die Last ins
VORSICHT: Hydraulische Geräte von Rutschen geraten oder fallen, was zu äußerst
Flammen und Hitzequellen gefährlichen Situationen führen kann.
fernhalten. Zu hohe Temperaturen
Die Last gleichmäßig über die gesamte
weichen Füllungen und Dichtungen auf
Fläche des Druchstückes verteilen. Den
und bewirken Flüssigkeitslecks. Große Hitze schwächt
Kolben immer mit einem Druckstück
außerdem die Schlauchmaterialien und –dichtungen. Zur
schützen, wenn keine Zusatzgeräte mit
Gewährleistung einer optimalen Leistung darf die Anlage
Gewinde benutzt werden.
keinen Temperaturen über 65°C ausgesetzt werden. sdle eps
Außerdem müssen Schläuche und Zylinder beim WICHTIG: Hydraulische Geräte müssen
Schweißen vor Funkenschlag geschützt werden. von einem qualifizierten Hydrauliktechniker
gewartet werden. Bei Reparaturarbeiten an
GEFAHR: Nicht mit unter Druck stehenden
die autorisierte ENERPAC-
Schläuchen hantieren. Unter Druck
Kundendienstzentrale der jeweiligen Region wenden.
austretendes Öl kann in die Haut
Zur Aufrechterhaltung der Garantie nur ENERPAC-Öl
eindringen und schwere Verletzungen
verwenden.
verursachen. Falls Öl unter die Haut gelangt, ist sofort
ein Arzt aufzusuchen.
TECHNISCHE DATEN - Diese Bedienungsanleitung ist für die nachstehenden Handpumpen-Modelle zu benutzen.
Technische Daten
Modell Typ Maximaler Nenndruck Ölvolumen per Hub Nutzbares Öltank
(Druckstufen) psi [bar] in 3 [cm 3] Fassungsvermö gen in3 [cm3]
EHF-65 1 6,500 [440] .16 [2.62] 22 [360]
P-18 1 2,850 [200] .16 [2.62] 22 [360]
P-25 1 2,500 [170] .58 [9.51] 231 [3786]
P-39, 1003 1 10,000 [700] .16 [2.62] 43 [705]
P-50 1 5,000 [340] .29 [4.75] 231 [3786]
P-51 1 3,000 [210] .25 [4.09] 50 [820]
P-141, 1001 1 10,000 [700] .055 [.90] 20 [328]
P-391, 1004 1 10,000 [700] .151 [2.47] 55 [900]
Stufe 1 Stufe 2 Stufe 1 Stufe 2

P-80, 1006 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 140 [2295]
P-84 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 140 [2295]
P-142, 1002 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 20 [328]
P-142AL 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 9.0 [148]
P-202 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 55 [900]
P-77 2 200 [14] 10,000 [700] .63 [16.0] .094 [2.41] 47 [769]
P-392, 1005 2 200 [14] 10,000 [700] .687 [11.26] .151 [2.47] 55 [900]
P-392AL 2 200 [14] 10,000 [700] .687 [11.26] .151 [2.47] 55 [900]
P-462 2 200 [14] 10,000 [700] 7.69 [126.00] .29 [4.75] 462 [7572]
P-464 2 200 [14] 10,000 [700] 7.69 [126.00] .29 [4.75] 462 [7572]
P-801 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 250 [4095]
P-802 2 400 [28] 10,000 [700] 2.40 [39.34] .15 [2.46] 155 [2540]
P-842 2 400 [28] 10,000 [700] 2.40 [39.34] .15 [2.46] 155 [2540]
16
WARNUNG: Abgenutzte oder beschädigte
Teile unverzüglich durch ENERPAC-
Originalteile ersetzen. Standardteile
anderer Hersteller versagen und
verursachen Verletzungen und Sachschäden. A
ENERPAC-Teile werden so konstruiert, daß sie richtig A
B
passen und hohen Lasten standhalten.
E B
VORSICHT: Benutzen Sie zum Tragen der
Pumpe stets den Griff. Wird die Pumpe
P842
beim Tragen am Schlauch gehalten, kann
der Schlauch und/oder die.Pumpe
beschädigt werden.
C
3.0 BESCHREIBUNG
B
3.1 Modelle P-141, 1001/P-142, 1002/P- D
202/P-391, 1004/P-392, 1005/P-802,

und P-842 Abbildung 1
In Abbildung 1 und in der dazugehörigen 3.2 Modelle P-18/P-39, 1003/P-80, 1006/P-
nachstehenden Tabelle werden die
84/P-801, P-77
Hauptkomponenten der Handpumpen-Modelle P-
141, P-142, P-202, P-391, P-392, P-802 und P-842 In Abbildung 2 und in der dazugehörigen
gezeigt. Der Verschlußdeckel des Entlüftungs nachstehenden Tabelle werden die
/Einfüllstutzens dient bei unvorhergesehenem Hauptkomponenten dieser Handpumpen-Modelle
Druckaufbau im Tank als Sicherheitsventil. Um eine gezeigt. P-84 Modelle sind mit einem 4-Wege-Ventil
Zugangsöffnung für externe Ventile im hinteren Teil mit drei Stellungen ausgestattet, das für den Betrieb
des Tanks bereitzustellen, wird ein Tankrücklauf-Satz mit doppeltwirkenden Zylindern vorgesehen ist. Zum
benutzt. Siehe nachstehende Tabelle für Umbau der Modelle P-18 oder P-39 auf
Modellnummern des Satzes. Fußhebelbedienung bestellen Sie den Satz PC-10.
Tabelle 1
Abbidldung 1 P-141, 1001 P-142, 1002 P-202 P-391, 1004 P-392, 1005 P-802 P-842
A Ablassventil Ablassventil Ablassventil Ablassventil Ablassventil Ablassventil 4-Wege-Ventil
B 1/4 NPTF 1/4 NPTF 1/4 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF
Ölanschluß Ölanschluß Ölanschluß Ölanschluß Ölanschluß Ölanschluß Ölanschluß
C Entlüft.- Entlüft.- Entlüft.- Entlüft.- Entlüft.- Entlüft.- Entlüft.-
/Einfülldeckel /Einfülldeckel /Einfülldeckel /Einfülldeckel /Einfülldeckel /Einfülldeckel /Einfülldeckel
D Montage schlitze Montage schlitze — — — Montage schlitze Montage schlitze
E — — — — — Tankrücklauf- —
öffnung
Tankrücklauf PC-20 PC-20 PC-25 PC-25 PC-25 — —
Satz
Tabelle 2
Abbidldung 2 P-18 P-39, 1003 P-77 P-80, 1006 P-84 P-801
A Ablassventil Ablassventi Ablassventi Ablassventil 4-Wege-Ventil Ablassventil
3 Stellungen
Ölanschluß Ölanschluß Ölanschluß Ölanschluß Ölanschluß Ölanschluß
C Öleinfüllstutzen Öleinfüllstutzen Öleinfüllstutzen Öleinfüllstutzen Öleinfüllstutzen Öleinfüllstutzen
D — — — 1/4 NPTF — 1/4 NPTF

Tankrücklauf-öffnung Tankrücklauföffnung
17
A
B C
A A
B
D B
B Abbildung 4, Modelle P-25 und P-50
C
C
A
Abbildung 2
B
ACHTUNG: Diese Pumpen werden mit
einem nicht entlüfteten Tank betrieben.
Falls der Tank hohem Druck ausgesetzt
P-51F5
wird, kann das Gehäuse brechen.
Verletzungen und/oder Schäden können die Folge
sein. NIEMALS versuchen, mehr Öl in den Tank Abbildung 5, Modelle P-51
zurückzuleiten, als dieser fassen kann.
Tabelle 4 und 5 for Modelle P-25, P-50, P-51
Abbildungen 4, 5 P-25 P-50 P-51
3.3 Modelle P-462 and P-464 A Ablassventil Ablassventil Ablassventil
B 1/4 NPTF 1/4 NPTF 1/4 NPTF
In Abbildung 3 aufund in der nachstehenden Tabelle Ölanschluß Ölanschluß Ölanschluß
werden die Hauptleistungsmerkmale der C Entlüft.-/ Entlüft.-/ Entlüft.-/
Handpumpen-Modelle P-462, für den Betrieb mit Einfüllstutzen Einfüllstutzen Einfüllstutzen
einfachwirkenden Zylindern, und P-464, für

doppeltwirkende Zylinder, gezeigt. 4.0 INSTALLATION
C
4.1 Anschließen der Pumpe
D
1. Schrauben Sie den Schlauch mit dem Gewinde in
den Ausgang der Pumpe ein. Benutzen Sie für die
Schlauchanschlüsse 1 1/2 Lagen Teflonband (oder
B
ein anderes geeignetes Gewindedichtungsmittel),
wobei der erste volle Gewindegang frei bleiben
A
muß, um zu verhindern, daß das Band reißt und in
das System gelangt und Schaden verursacht.
Lose Enden abschneiden.
P-462/464F3
2. Installieren Sie in der von der Pumpe kommenden

Leitung ein Druckmeßgerät, um erhöhte Sicherheit
und verbesserte Kontrolle zu gewährleisten.
3. Schließen Sie den Schlauch (bzw. die Schläuche)
Abbildung 3, Modelle P-462 und P-464 an den Zylinder oder das Werkzeug an.
HINWEIS: Bei einfachwirkenden Zylindern wird ein
Tabelle 3 Schlauch von der Pumpe zum Zylinder
Abbildung 3 P-462 P-464 angeschlossen. Bei doppeltwirkenden Zylindern
A 3-Wege-Ventil, 2 Stellungen 4-Wege-Ventil, 3
werden zwei Schläuche angeschlossen. Schließen
Stellungen
B 3 /8 NPTF Ölanschluß 3 /8 NPTF Ölanschluß Sie einen Schlauch vom Druckanschluß der Pumpe
C Entlüft.-/Einfüllstutzen Entlüft.-/Einfüllstutzen am Druckanschluß des Zylinders an. Schließen Sie
D Griffklemme Griffklemme einen zweiten Schlauch vom Einfahranschluß der
Pumpe an den Einfahranschluß des Zylinders an.
3.4 Modelle P-25, P-50, und P-51
4.2 Entlüften der Pumpe
In Abbildung 4 werden die Handpumpen-Modelle P-
Entnehmen Sie der nachstehenden Tabelle, ob Ihre
25 und P-50 gezeigt, die beide mit einem Griff
Pumpe mit einem entlüfteten oder nicht entlüfteten
ausgestattet sind, der in zwei Richtungen arbeitet.
Tank betrieben werden soll. Entlüftete Pumpen bieten
Abbildung 5 zeigt die Handpumpe P-51. Die
eine geringfügig bessere Leistung. Bei Pumpen mit
Hauptkomponenten dieser Pumpen sind in der
Nylontank wird der Entlüftungs-/Einfülldeckel zur
nachstehenden Tabelle aufgeführt.
18
Entlüftung eine Vierteldrehung gegen den hohem Druck Kraft zu sparen, führen Sie kurze Züge
Uhrzeigersinn gedreht. Bei anderen Pumpen ist das aus. Die größte Pumpwirkung wird in den letzten 5
an der Pumpe angebrachte Hinweisschild zu Grad des Zuges erzielt.
beachten. Die Entlüftungsöffnung muß vor dem
Transport der Pumpe geschlossen werden, um ein 5.2 Verwendung von Pumpen mit zwei
Ölverlust zu vermeiden. Die Pumpen P-80, P-801 und Geschwindigkeiten
P-84 werden belueftet indem das Ventil entgegen
dem Uhrzeigersinn aufgedreht wird. Zum Schliessen Diese Pumpen bieten einen zweistufigen Förderstrom.
Ohne Belastung arbeitet die Pumpe in der ersten Stufe
des Ventils ist dises im Uhrzeiger zu drehen.
mit hohem Förderstrom für schnelles Ausfahren.
Sobald Kontakt mit der Last besteht, stellt sich die
ENTUFTÜNGSOPTIONEN
Pumpe automatisch in die zweite Stufe um, um Druck
EHF-65 . . . . . . . . nicht entlüftet P-202 . . . . . . . . beides möglich
P-18. . . . . . . . . . . nicht entlüftet
aufzubauen. Bei Modellen P-462 oder P-464: Wenn
P-391, 1004. . . . beides möglich
P-25 . . . . . . . . . beides möglich P-77 . . . . . . . . . . . . . . . entlüftet der Pumpendruck ungefähr 200 psi erreicht, muß man
P-39, 1003 . . . . . . nicht entlüftet P-392, 1005. . . . beides möglich das Pumpen kurzzeitig unterbrechen und den Griff
P-50 . . . . . . . . . beides möglich P-392AL. . . . . . . . . . . . entlüftet
P-51 . . . . . . . . . . . . . . . entlüftet
heben, um damit in die zweite Stufe (hoher Druck) zu
P-462 . . . . . . . . . . . . . . entlüftet
P-80, 1006 . . . . . . nicht entlüftet P-464 . . . . . . . . . . . . . entlüftet schalten. Bei Modellen P-802 oder P-842: Wenn der
P-84. . . . . . . . . . . nicht entlüftet P-801. . . . . . . . . . nicht entlüftet Pumpendruck ungefähr 400 psi erreicht, muß man das
P-141, 1001. . . . beides möglich P-802 . . . . . . . . beides möglich
P-142, 1002. . . . beides möglich P-842 . . . . . . . . beides möglich
Pumpen kurzzeitig unterbrechen und den Griff heben,
P-142AL . . . . . . . nicht entlüftet um damit in die zweite Stufe (hoher Druck) zu schalten.
Nachdem sich die Pumpe umgestellt hat, ist weniger
Kraftaufwand zum Pumpen erforderlich.
4.3 Pumpenstellung
HINWEIS: Um die optimale Leistung zu erzielen, wird
Entnehmen Sie der nachstehenden Tabelle die der Pumpengriff in der ersten Stufe (hohe
entsprechende Betriebsstellung für Ihre Pumpe, Fördermenge) mit mittlerer Geschwindigkeit betätigt.
horizontal oder vertikal. Die Pumpen P-80, P-801 und P- Rasche Betätigung des Pumpengriffs in der ersten
84 koennen bei vertikalem Einsatz nicht belueftet werden. Stufe verhindert, daß die Pumpe die maximale
Fördermenge liefert.
BETRIEBSSTELLUNG
EHF-65. . . . . . . beides möglich P-202 . . . . . . . . beides möglich 5.3 Einfachwirkende Anwendungen mit
P-18 . . . . . . . . . beides möglich P-391, 1004 . . . beides möglich
P-25 . . . . . . . . . nur horizontal P-77 . . . . . . . . . beides möglich Ablassventil
P-39, 1003 . . . . beides möglich P-392, 1005 . . . beides möglich
P-50 . . . . . . . . . nur horizontal P-392AL . . . . . . beides möglich 1. Schließen Sie das Ablassventil durch Drehen im
P-51 . . . . . . . . . . nur horizontal P-462 . . . . . . . . . nur horizontal Uhrzeigersinn, wie in Abbildung 6.
P-80, 1006 . . . . beides möglich P-464 . . . . . . . . . nur horizontal
P-84 . . . . . . . . beides möglich P-801 . . . . . . . . beides möglich
P-141, 1001 . . . beides möglich P-802 . . . . . . . . beides möglich
P-142, 1002 . . . beides möglich P-842 . . . . . . . . beides möglich
P-142AL . . . . . . beides möglich
HINWEIS: Wenn die Pumpe in vertikaler Stellung

betrieben wird, muß der Ausgang (Schlauchseite) nach
unten zeigen, andernfalls saugt die Pumpe Luft an und
kann den Druck nicht ordnungsgemäß aufbauen.
5.0 BETRIEB Abbildung 6

VORSICHT: Das Ablassventil NUR
5.1 Vor Inbetriebnahme der Pumpe fingerfest schließen. Wird das
Ablassventil mit einem Werkzeug
1. Prüfen Sie alle Systemanschlüsse und
umgestellt, so kann es beschädigt
Verbindungen, um sicherzustellen, daß diese fest
werden und einen Ausfall der Pumpe verursachen.
sitzen und dicht sind.
2. Prüfen Sie den Ölstand im Tank, bevor die Pumpe 2. Betätigen Sie den Pumpengriff, um Hydraulikdruck
betrieben wird. Siehe "Auffüllen der Pumpe mit in das System einzubringen. Der Druck wird solange
Öl" auf Seite 21. gehalten, bis das Ablassventil geöffnet wird.
VORSICHT: Bringen Sie NIEMALS eine 3. Öffnen Sie das Ablassventil (Drehung gegen den
Verlängerung am Pumpengriff an. Uhrzeigersinn), um den Druck abzulassen. Das Öl
Verlängerungen führen dazu, daß die fließt nun wieder in den Tank zurück.
Pumpe beim Betrieb instabil wird.
5.4 Einfachwirkende Anwendungen mit
ACHTUNG: Unter gewissen Umständen manuellem 3-Wege-Ventil mit 2
kann der Pumpengriff "zurückschlagen". Stellungen
Achten Sie darauf, daß Sie stets seitlich
zur Pumpe stehen, und daß sich Ihr Körper 1. Ventilgriff in Stellung 1 bringen, wie in Abbildung 7.
außerhalb der Reichweite des Griffs befindet. 2. Betätigen Sie den Pumpengriff, um Hydraulikdruck
HINWEIS: Um bei der Betätigung des Griffs bei in das System einzubringen. Der Druck wird
solange gehalten, bis das Ventil umgeschaltet wird.
19
3. Bringen Sie den Ventilgriff in Stellung 2, damit das 1. Der Ventilhebel des 4-Wege-Ventils wird zur
Öl wieder in den Tank zurückfließen kann. Funktionsauswahl wie folgt geschaltet:
2 2 (A) Ausgang zum Anschluß "A", Anschluß "B"
dient als Rücklauf zum Tank
(N) Neutralstellung, Anschlüsse "A" und "B" sind
gesperrt
(B) Ausgang zum Anschluß "B", Anschluß "A"
dient als Rücklauf zum Tank
1 1
A A
N
1 2
B
A
Abbildung 7 A
B
5.5 Doppeltwirkende Anwendungen mit
manuellem 4-Wege-Ventil mit 3 Stellungen
Abbildung 8c
Pumpen mit 4-Wege-Ventilen sind zur Verwendung
mit doppeltwirkenden Zylindern konstruiert. 2. Betätigen Sie die Pumpe, um die Arbeit
Ventilstellungen, siehe Abbildung 8. auszuführen.
N 3. Ändern Sie die Ventilstellung nach Bedarf.
ACHTUNG: Doppeltwirkenden Zylinder
A B nur dann in Betrieb nehmen, wenn beide
Schläuche an der Pumpe angeschlossen
sind. Wenn eine Kupplung frei bleibt,
A B
baut sich hoher Druck hinter der Kupplung auf, was
zu Verletzungen und/oder Schäden führen kann.
5.6 Einstellung des Druckbegrenzungsventils

Alle Pumpen sind mit einem werkseitig eingestellten
Druckbegrenzungsventil ausgestattet, um Überdruck
Abbildung 8a im System zu verhindern. Das Ventil kann auf
niedrigere Druckwerte eingestellt werden. Wenden
Sie sich an Ihr autorisiertes Enerpac Service Center.
A B A B A B
6.0 ENTLÜFTUNG
Durch das Entfernen von Luft aus dem
I Hydrauliksystem wird geschmeidiges Ausfahren und
Einfahren des Zylinders erreicht. Siehe Abbildung 9.
A N B
Abbildung 8b
Lüft
Lüft
A B
Abbildung 9
20
6.1 Pump With Single-Acting Cylinder (A) 3. Wenn erforderlich, entfernen Sie die Luft aus dem
System. Siehe Seite 20. Prüfen Sie den Ölstand
Pumpe mit einfachwirkendem Zylinder (A): nach dem Entlüften nochmals.
1. Pumpentank entlüften (nur bei entlüfteten 4. Bringen Sie den Entlüftungs-/Einfülldeckel wieder
Pumpen) und Ablassventil schließen. in der vorschriftsmäßigen Stellung an.
2. Die Pumpe in einer höheren Lage als den Zylinder HINWEIS: Nicht entlüftete Handpumpen benötigen
positionieren. Luft im Tank, um ordnungsgemäß zu funktionieren. Ist
3. Den Zylinder so aufstellen, daß das Kolbenende der Tank vollständig gefüllt, so bildet sich ein
nach unten zeigt (nach oben bei Zugzylinder). Vakuum, das verhindert, daß Öl aus der Pumpe
Siehe Abbildung 9. abfließen kann.
4. Pumpe betätigen, um den Zylinder voll
auszufahren (Zugzylinder voll einfahren). 7.2 Reinhalten der Ölleitungen
5. Druckentlastungsventil öffnen, um den Zylinder Werden die Kupplungsteile getrennt, so müssen stets
einzufahren (Zugzylinder ausfahren). Dadurch Staubkappen aufgeschraubt werden. Führen Sie alle
wird die eingeschlossene Luft nach oben in den erforderlichen Vorsichtsmaßnahmen aus, um das
Pumpentank gepreßt. Eindringen von Verunreinigungen in die Pumpe zu
6. Die obigen Schritte so oft wie nötig wiederholen. verhindern, da Fremdkörper zum Versagen der
Pumpe, des Zylinders oder des Ventils führen
7. Wenn erforderlich, Öl auffüllen. Siehe Seite 21.
können.
8. Den Entlüftungs-/Einfülldeckel wieder in die
Betriebsstellung bringen. 7.3 Schmierung der Pumpe
6.2 Pumpe mit doppeltwirkendem Zylinder Um die Lebensdauer der Pumpe zu verlängern und
(B) die Leistung zu erhöhen, schmieren Sie den
Tragbolzen (A), den Querbolzen (B) und den
1. Pumpentank entlüften (nur bei entlüfteten Zylinderkopf (C) regelmäßig mit Rollenlager-
Pumpen). Schmierfett. Siehe Abbildung 10.
2. Die Pumpe in einer höheren Lage als den Zylinder
positionieren. B, C
3. Den Zylinder in die waagerechte Stellung bringen,
A
wobei die Anschlüsse nach oben gerichtet sind.
Siehe Abbildung 9.
4. Den Zylinder zwei- bis dreimal voll aus- und
einfahren.
5. Die obigen Schritte so oft wie nötig wiederholen.
6. Wenn erforderlich, Öl auffüllen. Siehe diese Seite 21.
7. Den Entlüftungs-/Einfülldeckel wieder in die
Betriebsstellung bringen. .
Abbildung 9
7.0 MAINTENANCE 7.4 Ölwechsel
Benutzen Sie für diese Pumpen nur Enerpac- 1. Lassen Sie alle 12 Monate das gesamte Öl ab und
Hydrauliköl, um eine lange Lebensdauer der Pumpen füllen die Pumpe mit reinem Enerpac-Öl auf.
zu erreichen und den Garantieschutz aufrecht zu Führen Sie den Ölwechsel öfter aus, wenn die
erhalten. Viton- und EPR-Dichtungssätze sind für Pumpe in schmutziger Umgebung eingesetzt wird.
einige Pumpen erhältlich. Wenden Sie sich an die
2. Nehmen Sie den Entlüftungs-/Einfülldeckel vom
zuständige Enerpac Vertriebsstelle, um Informationen
Tank ab.
über diese Produkte und ihre Anwendung zu
erhalten. 3. Kippen Sie die Pumpe, um das Altöl abzulassen.
4. Füllen Sie den Tank nur bis zur Füllmarkierung an
7.1 Auffüllen der Pumpe mit Öl der Pumpe.
Prüfen Sie den Ölstand regelmäßig. 5 Entlüftungs-/Einfülldeckel bzw. -stopfen wieder
anbringen.
ACHTUNG: Füllen Sie nur dann Öl auf,
wenn die Zylinder voll eingefahren (bzw. 6. Das Altöl ist vorschriftsmäßig zu entsorgen.
bei Zugzylindern ausgefahren) sind, 8.0 ANLEITUNG ZUR FEHLERSUCHE
andernfalls enthält das System mehr Öl,
als der Tank aufnehmen kann. Die folgende Information soll helfen, um feststellen zu
können, ob eine Fehlfunktion vorliegt. (Seite 22) Für
1. Entfernen Sie den Entlüftungs-/Einfülldeckel vom
die Durchführung von Reparaturarbeiten wenden Sie
Tank.
sich an das autorisierte ENERPAC Service-Center in
2. Füllen Sie den Tank nur bis zur Füllmarkierung an Ihrem Gebiet.
der Pumpe.
21
EHLERSUCHE
Fehlfunktion Mögliche Ursache Behebung
Zylinder fährt nicht 1. Zu niedriger Ölstand im Tank der 1. Öl gemäß Wartungsanweisungen auf Seite 21.
aus, fährt zu Pumpe. 2. Ablassventil schließen.
langsam aus, oder 2. Ablassventil offen. 3. Überprüfen, ob alle Kupplungen vollständig festgezogen
setzt beim 3. Hydraulikkupplung lose. sind.
Ausfahren aus. 4. Zu schwere Last. 4. Nicht versuchen, eine größere Last als die Nennlast zu
5. Eingeschlossene Luft im System. heben.
6. Zylinderkolben klemmt. 5. Luft gemäß Anweisungen auf Seite 20.
6. Auf Schaden am Zylinder prüfen. Zylinder von einem
zugelassenen Hydrauliktechniker warten lassen.
Zylinder fährt aus, 1. Undichte Verbindung. 1. Prüfen, ob alle Verbindungen festgezogen und dicht
hält den Druck aber 2. Undichte Dichtungen. sind.
nicht. 3. Innere Leckage in der Pumpe. 2. Leckstellen auffinden und das Gerät von einem
qualifizierten Hydrauliktechniker warten lassen.
3. Pumpe von einem qualifizierten Hydrauliktechniker
warten lassen.
Zylinder fährt nicht 1. Ablassventil geschlossen. 1. Ablassventil öffnen.

ein, fährt nur 2. Tank der Pumpe überfüllt. 2. Ölstand durch Ablassen bis zur Vollmarkierung senken
teilweise ein oder 3. Lose Hydraulikkupplung. Anweisungen zum Auffüllen von Öl, siehe Seite 21.
fährt langsamer als 4. Eingeschlossene Luft im System. 3. Überprüfen, ob alle Kupplungen vollständig festgezogen
normal ein. 5. Zu geringer Schlauchdurchmesser. sind.
6. Rückstellfeder des Zylinders ist 4. Luft entfernen, gemäß Anweisungen auf Seite 20.
gebrochen, oder anderer Schaden am 5. Hydraulikschlauch mit größerem Durchmesser
Zylinder liegt vor. benutzen.
6. Zylinder von einem qualifizierten Hydrauliktechniker
warten lassen.
22
Manuale d’istruzione
Pompe Oleodinamiche Manuali
L1763 Rev I 12/05

L’esploso delle parti di ricambio per questo prodotto
è ottenibile sul sito web www.enerpac.com, oppure
chiamando il Centro Assistenza Autorizzato a voi più
vicino , o il ns. ufficio commerciale.
1.0 NOTA IMPORTANTE

Ispezionare visivamente tutti i componenti per
identificare eventuali danni di spedizione e, se
presenti, avvisare prontamente lo spedizioniere. I
danni subiti durante la spedizione non sono coperti
dalla garanzia vigente. Lo spedizioniere è il solo
responsabile per i costi di riparazione o di sostituzione
conseguenti a danni avvenuti durante la spedizione. AVVERTENZA: UTILIZZARE SOLO
ATTREZZI RIGIDI PER IL SOSTEGNO
®
2.0 INFORMAZIONI SULLA SICUREZZA ®
DEI CARICHI. Selezionare con cura
blocchi in acciaio o in legno capaci di
Leggere attentamente tutte le
supportare il peso del carico. Non ricorrere mai a un
istruzioni, le avvertenze e le
cilindro idraulico come cuneo o spessore in
precauzioni. Durante il
applicazioni di sollevamento o pressatura.
funzionamento del sistema, rispettare tutte le norme
di sicurezza onde evitare infortuni o danni PERICOLO: Per evitare lesioni
all'apparecchiatura. L'Enerpac declina ogni personali, durante la lavorazione
responsabilità per danni risultanti da un uso tenere le mani e i piedi lontano dal
improprio del prodotto, dalla mancata manutenzione cilindro e dal pezzo in lavorazione.
o dall'applicazione errata del prodotto e del sistema. AVVERTENZA: Non superare mai la
In caso di dubbio in materia di sicurezza o capacità nominale dell'apparecchiatura.
applicazioni, rivolgersi all'Enerpac. Se si richiedono Non tentare mai di sollevare un peso
informazioni sulle norme di sicurezza per sistemi superiore alla capacità del cilindro, dato
idraulici ad alta pressione, rivolgersi al distributore o che il sovraccarico può causare guasti
al centro di riparazione di zona in grado di fornire all'apparecchiatura e possibili infortuni all'operatore. I
gratuitamente un corso di addestramento in materia cilindri sono stati studiati per una pressione massima
di sicurezza idraulica autorizzato dalla Enerpac. pari a 700 bar. Non collegare un martinetto o un
La mancata osservanza delle seguenti precauzioni cilindro a una pompa la cui pressione nominale è
potrebbe portare a seri danni all'apparecchiatura e a superiore.
lesioni personali. PERICOLO: Non impostare mai la valvola
Una PRECAUZIONE indica le corrette procedure di di scarico a una pressione superiore a
azionamento o manutenzione per evitare danni quella massima nominale della pompa.
all'apparecchiatura o all'ambiente circostante. Un'impostazione superiore può arrecare
danni all'apparecchiatura e/o provocare infortuni
Un'AVVERTENZA indica un potenziale pericolo che
all'operatore. Non rimuovere la valvola di sicurezza.
richiede la messa in pratica delle procedure corrette
per evitare infortuni. AVVERTENZA: La pressione di esercizio
del sistema non deve superare il valore
Un PERICOLO indica una situazione in cui un'azione
nominale prefissato per il componente
o la mancanza di azione può causare gravi lesioni
dalla pressione più bassa. Installare nel
personali se non il decesso.
sistema un manometro per tenere sotto controllo la
AVVERTENZA: Indossare un'attrezzatura pressione di esercizio.
di protezione appropriata durante il
PRECAUZIONE: Evitare di arrecare
funzionamento dell'apparecchiatura.
danni al tubo idraulico flessibile. Evitare
AVVERTENZA: Stare lontano da carichi di piegare o arricciare il tubo flessibile
sospesi e sostenuti idraulicamente. Un durante l'uso, poiché gli strozzature
cilindro utilizzato per sollevare un carico possono provocare gravi contropressioni. Le
non deve mai essere impiegato anche per piegature e gli strozzature acute possono
il loro sostegno. Dopo aver alzato o abbassato un danneggiare internamente il tubo flessibile e
peso, è necessario che questo venga sempre provocarne quindi un guasto prematuro.
bloccato in maniera meccanica.
23
Non lasciar cadere oggetti pesanti sul tubo disposto su una superficie piana, in grado di sostenere il
flessibile, dato che l'impatto potrebbe carico. Se possibile, usare una base per il cilindro, per
danneggiarne i fili dell'armatura. La messa aumentarne la stabilità. Non saldare ne modificare in
®
sotto pressione di un tubo flessibile danneggiato può alcun modo il cilindro allo scopo di collegarvi una base o
causarne la rottura. un altro supporto.
IMPORTANTE: Non sollevare Evitare situazioni in cui i carichi non siano
apparecchiature idrauliche mediante il tubo perfettamente centrati rispetto allo stelo del
flessibile o i giunti orientabili. Servirsi della cilindro stresso. I carichi disassati esercitano
maniglia per trasporto o di un altro mezzo di notevoli sollecitazioni sui cilindri e steli. Inoltre,
trasporto sicuro. il carico potrebbe scivolare o cadere, con risultati
potenzialmente pericolosi.
PRECAUZIONE: Tenere
l'apparecchiatura idraulica lontano da Distribuire il carico uniformemente sull'intera
fiamme e sorgenti di calore. Il calore superficie della testa del pistone. Usare
eccessivo ammorbidisce le guarnizioni, sempre una testina per proteggere lo stelo
provocando perdite di fluido. Il calore indebolisce altresì il quando non si usano attacchi filettati.
materiale di cui è composto il tubo flessibile. Per garantire sdle eps
le migliori prestazioni, non esporre l'apparecchiatura a

IMPORTANTE: Affidare la manutenzione
temperature superiori a 65°C (150°F). Proteggere i tubi
delle apparecchiature idrauliche solamente a
flessibili e i cilindri da scintille o scaglie di saldatura.
un tecnico specializzato. Per richiedere un
PERICOLO: Non maneggiare i tubi flessibili intervento di assistenza, rivolgersi al centro di
sotto pressione. Eventuali fuoriuscite d'olio assistenza ENERPAC autorizzato di zona. Per usufruire
sotto pressione possono penetrare sotto la dei termini di garanzia, utilizzare esclusivamente olio
cute e provocare gravi lesioni. Se l'olio penetra sotto la idraulico ENERPAC.
pelle, rivolgersi immediatamente a un medico.
AVVERTENZA: Sostituire immediatamente le
AVVERTENZA: Utilizzare i cilindri idraulici parti usurate o danneggiate con pezzi di
solo se i giunti del sistema sono ricambio ENERPAC originali. I pezzi di
debitamente accoppiati. Se il sovraccarico ricambio di qualità standard si potrebbero
del cilindro diventa eccessivo, i componenti rompere più facilmente e arrecare danni alla propria
possono guastarsi irreparabilmente e provocare gravi persona e all'ambiente circostante. I pezzi di ricambio
lesioni personali. ENERPAC sono stati concepiti per adattarsi
perfettamente al sistema e per sopportare condizioni di
AVVERTENZA: Prima di sollevare il carico,
carico elevate.
assicurarsi che la configurazione
dell'intera apparecchiatura sia
®
perfettamente stabile. Il cilindro deve essere
DATI TECNICI – Consultare il presente Manuale di istruzioni per informazioni sui modelli elencati nella seguente tabella.
Dati Technici
Modello Tipo Pressione max. Quantità olio per Quantità olio utilizzabile
(velocità) Nominale psi [bar] corsa in 3 [cm 3] in3 [cm3]
EHF-65 1 6,500 [440] .16 [2.62] 22 [360]
P-18 1 2,850 [200] .16 [2.62] 22 [360]
P-25 1 2,500 [170] .58 [9.51] 231 [3786]
P-39, 1003 1 10,000 [700] .16 [2.62] 43 [705]
P-50 1 5,000 [340] .29 [4.75] 231 [3786]
P-51 1 3,000 [210] .25 [4.09] 50 [820]
P-141, 1001 1 10,000 [700] .055 [.90] 20 [328]
P-391, 1004 1 10,000 [700] .151 [2.47] 55 [900]
Fase 1 Fase 2 Fase 1 Fase 2

P-80, 1006 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 140 [2295]
P-84 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 140 [2295]
P-142, 1002 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 20 [328]
P-142AL 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 9.0 [148]
P-202 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 55 [900]
P-77 2 200 [14] 10,000 [700] .63 [16.0] .094 [2.41] 47 [769]
P-392, 1005 2 200 [14] 10,000 [700] .687 [11.26] .151 [2.47] 55 [900]
P-392AL 2 200 [14] 10,000 [700] .687 [11.26] .151 [2.47] 55 [900]
P-462 2 200 [14] 10,000 [700] 7.69 [126.00] .29 [4.75] 462 [7572]
P-464 2 200 [14] 10,000 [700] 7.69 [126.00] .29 [4.75] 462 [7572]
P-801 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 250 [4095]
P-802 2 400 [28] 10,000 [700] 2.40 [39.34] .15 [2.46] 155 [2540]
P-842 2 400 [28] 10,000 [700] 2.40 [39.34] .15 [2.46] 155 [2540]
24
3.0 DESCRIZIONE 3.2 Modelli P-18/P-39, 1003/P-80, 1006/P-
84 e P-801, P-77
3.1 Modelli P-141, 1001/P-142, 1002/P- La figura 2 e la tabella che segue mostrano i
202/P-391, 1004/P-392, 1005/P-802 e componenti principali e le loro caratteristiche per i
P-842 suddetti modelli. I modelli P-84 incorporano una
La figura 1 e la tabella che segue mostrano i valvola a 4 vie e 3 posizioni per l’impiego con cilindri
componenti principali e le loro caratteristiche per i a doppio effetto. Se si desidera azionare col piede i
modelli P-141, P-142, P-202, P-391, P-392, P802, e modelli P-18 o P-39, ordinare il Kit PC-10.
P-842. Il tappo di sfiato/riempimento funziona anche
da valvola di sicurezza nel caso di pressurizzazione A
fortuita del serbatoio. Per collegare una valvola in
linea alla parte posteriore del serbatoio, utilizzare un B
kit per ritorno al serbatoio. I numeri di modello del kit A

sono riportati nella tabella che segue.
A D B
A
B
B
E B
C
P842
Figura 2
C
AVVISO: Queste pompe utilizzano un

serbatoio non ventilato. Se sul
B
D
serbatoio agisce una elevata pressione,
la carcassa può spezzarsi e causare
infortuni e/o danni alle apparecchiature. MAI
Figura 1 TENTARE di aggiungere olio al serbatoio in
quantità maggiore alla sua capacità.
Tabella 1
Fig. 1 P-141, 1001 P-142, 1002 P-202 P-391, 1004 P-392, 1005 P-802 P-842
A Valvola di rilascio Valvola di rilascio Valvola di rilascio Valvola di rilascio Valvola di rilascio Valvola di rilascio Valvola a 4 vie
B Bocca olio Bocca olio Bocca olio Bocca olio Bocca olio Bocca olio Bocca olio
1/4 NPTF 1/4 NPTF 1/4 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF
C Tappo di sfiato/ Tappo di sfiato/ Tappo di sfiato/ Tappo di sfiato/ Tappo di sfiato/ Tappo di sfiato/ Tappo di sfiato/
riempimento riempimento riempimento riempimento riempimento riempimento riempimento
D Asole di Asole di — — — Asole di Asole di
montaggio montaggio montaggio montaggio
E — — — — — di ritorno a serbatoio —
Kit per PC-20 PC-20 PC-25 PC-25 PC-25 — —
ritorno al
serbatoio
Tabella 2
Fig 2 P-18 P-39, 1003 P-77 P-80, 1006 P-84 P-801
A Valvola di rilascio Valvola di rilascio Valvola di rilascio Valvola di rilascio Valvola di rilascio Valvola di rilascio
B Bocca olio Bocca olio Bocca olio Bocca olio Bocca olio Bocca olio
C Tappo di Tappo di Tappo di Tappo di Tappo di Tappo di
riempimento riempimento riempimento riempimento riempimento riempimento
D — — — di ritorno a — di ritorno a
serbatoio 1/4 NPTF serbatoio serbatoio 1/4 NPTF
25
3.3 Modelli P-462 e P-464 Table 4 and 5
La figura 3 e la tabella che segue mostrano le Fig 4, 5 P-25 P-50 P-51
A Valvola di rilascio Valvola di rilascio Valvola di rilascio
caratteristiche principali dei modelli P-462, da
B Bocca olio Bocca olio Bocca olio
utilizzare con cilindri a semplice effetto, e dei modelli 1/4 NPTF 1/4 NPTF 3/8 NPTF
P-464, da utilizzare con cilindri a doppio effetto. C Tappo di sfiato/ Tappo di sfiato/ Tappo di sfiato/
riempimento riempimento riempimento
C
D
4.0 INSTALLAZIONE
B
4.1 Collegamento della pompa
1. Collegare un tubo flessibile alla bocca olio.
A Avvolgere sui raccordi nastro di teflon (o simile
materiale di tenuta per filettature) per un giro e
mezzo e lasciare il primo filetto completamente
P-462/464F3
libero dal nastro, per evitare che pezzi di nastro si

stacchino e penetrino nel sistema oleodinamico,
causando danni. Rifilare le estremità del nastro.
2. Per ulteriore controllo della pompa e maggiore
Figura 3, Modelli P-25 e P-50 sicurezza, installare in linea un manometro.
Tabella 3 3. Collegare i tubi flessibili all’attrezzo o al cilindro.
Fig. 3 P-462 P-464
NOTA: Per cilindri a semplice effetto, collegare un
A Valvola a 3 vie e 2 posizioni Valvola a 4 vie e 3 posizioni
B Bocca olio 3/8 NPTF Bocca olio 3/8 NPTF
tubo flessibile fra la pompa ed il cilindro. Per cilindri a
C Tappo di sfiato/riempimento Tappo di sfiato/riempimento doppio effetto, collegare due tubi flessibili. Collegare
D Fermaglio della leva Fermaglio della leva un tubo tra le bocche di uscita della pompa e del
cilindro, ed un altro tra le bocche di ritorno della
pompa e del cilindro.
3.4 Modelli P-25, P-50 e P-51 4.2 Ventilazione della pompa

La figura 4 mostra i modelli P-25 e P-50, entrambi Consultare la tabella che segue per stabilire se la
muniti di leva azionabile in entrambe le direzioni. La propria pompa deve funzionare con serbatoio
figura 5 mostra il modello P-51. I componenti ventilato o meno. Le pompe ventilate hanno
principali di queste pompe sono riportati nella tabella prestazioni leggermente migliori. Nelle pompe con
che segue. serbatoio in nylon, ruotare il tappo di
sfiato/riempimento di 1/4 di giro in senso antiorario
per eseguire la ventilazione. Per altri modelli, vedere
l’adesivo sulla pompa stessa. Prima di spostare la
C pompa, chiudere l’apertura di ventilazione per evitare
B
A perdite di olio. P-80, P-801, y P-84 se ceban girando
la válvula contra las agujas del reloj. Para cerrar el
cebado, girar la válvula según las agujas del reloj.
OPZIONI DI VENTILAZIONE
EHF-65 . . . . . . . . non-ventilata P-202 . . . . . . . . . . . . entrambe
P-18. . . . . . . . . . . non-ventilata P-391, 1004 . . . . . . . entrambe
P-25 . . . . . . . . . . . . . entrambe P-77 . . . . . . . . . . . . . . ventilata
P-39, 1003 . . . . . . non-ventilata P-392, 1005 . . . . . . . entrambe
Figura 4, Modelli P-25 e P-50 P-50 . . . . . . . . . . . . . entrambe P-392AL . . . . . . . . . . . ventilata
P-51 . . . . . . . . . . . . . . ventilata P-462 . . . . . . . . . . . . . ventilata
P-80, 1006 . . . . . . . . entrambe P-464 . . . . . . . . . . . . . ventilata
P-84 . . . . . . . . . . . . . entrambe P-801 . . . . . . . . . . . non-vented
C
P-141, 1001 . . . . . . . entrambe P-802 . . . . . . . . . . . . entrambe
A P-142AL . . . . . . . non-ventilata
B
4.3 Posizione di funzionamento della
pompa
P-51F5
Consultare la tabella che segue per determinare la

giusta posizione di funzionamento, orizzontale o
Figura 5, Model No. P-51 verticale, della pompa. La P-80, P-801, y la P-84 no
podrán cebarse cuando estén trabajando
verticalmente.
26
POSIZIONE DI
5.3 Utilizzo con valvola di rilascio su cilindri
FUNZIONAMENTO a semplice effetto
EHF-65 . . . . . . . . . . entrambe P-202 . . . . . . . . . . . entrambe
P-18 . . . . . . . . . . . . . entrambe P-391, 1004 . . . . . . entrambe
1. Chiudere la valvola di rilascio ruotando la manopola
P-25 . . . . . . . . solo orizzontale P-77 . . . . . . . . . . . . entrambe in senso orario, come mostrato nella figura 6.
P-39, 1003 . . . . . . . . entrambe P-392, 1005 . . . . . . . entrambe
P-50 . . . . . . . . solo orizzontale P-392AL . . . . . . . . . . entrambe
P-51 . . . . . . . . solo orizzontale P-462. . . . . . . solo orizzontale
P-80, 1006 . . . . . . . entrambe P-464 . . . . . . . solo orizzontale
P-84 . . . . . . . . . . . . . entrambe P-801 . . . . . . . . . . . entrambe
P-142AL . . . . . . . . . entrambe
NOTA: Quando una pompa è in posizione verticale,

l’estremità del tubo flessibile dev’essere rivolta verso
il basso, altrimenti la pompa aspirerà aria e non andrà
in pressione. Figura 6
ATTENZIONE: Serrare la manopola
SOLAMENTE a mano. L’uso di attrezzi può
danneggiare la valvola di rilascio e causare
5.0 FUNZIONAMENTO
un malfunzionamento della pompa.
5.1 Prima dell’utilizzo 2. Azionare la leva per fornire pressione

oleodinamica al sistema. La pressione si mantiene
1. Controllare tutti i raccordi ed i collegamenti del finché si tiene aperta la valvola di rilascio.
sistema, assicurandosi che siano ben serrati e
3. Aprire la valvola di rilascio (ruotare la manopola in
privi di perdite.
senso antiorario) per ridurre la pressione e fare
2. Prima di azionare la pompa, controllare il livello tornare l’olio nel serbatoio.
dell’olio. Vedere "Rabbocco dell’olio" a pagina 29.
5.4 Utilizzo con valvola manuale a 3 vie e 2
posizioni su cilindri a semplice effetto
ATTENZIONE: MAI AGGIUNGERE
prolunghe alla leva di azionamento. Una 1. Portare la leva di comando della valvola sulla
prolunga può causare funzionamento posizione 1, come mostrato nella figura 7.
instabile. 2. Azionare la leva di pompaggio per fornire
AVVISO: In certe condizioni la leva di pressione oleodinamica al sistema. La pressione
azionamento può ruotare rapidamente si mantiene finché si tiene sulla posizione 1 la leva
all’indietro. Rimanere sempre ai lati della della valvola.
pompa, fuori della portata della leva. 3. Portare la leva della valvola sulla posizione 2, per
fare tornare l’olio nel serbatoio.
NOTA: Per ridurre lo sforzo esercitato sulla leva ad
elevate pressioni, azionarla a brevi corse. Il leveraggio 2 2
massimo si ottiene negli ultimi 5 gradi di ogni corsa.
5.2 Utilizzo delle pompe a due fasi

Le pompe qui descritte funzionano a due fasi. In
assenza di carico le pompe funzionano in una prima
fase ad elevata portata, per ottenere un’estensione
rapida. A contatto col carico, le pompe passano 1 1
automaticamente alla seconda fase, per andare in

pressione. Nei modelli P-462 o P-464, quando la
pressione raggiunge i 200 psi circa, è necessario A A
interrompere temporaneamente il pompaggio e
sollevare la leva per passare alla fase ad elevata
pressione. Nei modelli P-802 o P-842, quando la
pressione raggiunge i 400 psi circa, è necessario
interrompere temporaneamente il pompaggio e 1 2
sollevare la leva per passare alla fase ad elevata
pressione. A passaggio della pompa alla seconda Figura 7
fase avvenuto, il pompaggio richiede uno sforzo
minore. 5.5 Utilizzo con valvola manuale a 4 vie e 3
NOTA: per ottenere prestazioni ottimali, azionare la
posizioni su cilindri a doppio effetto
leva a velocità moderate durante la prima fase ad Le pompe munite di valvole a 4 vie sono progettate
elevata portata. Un azionamento rapido della leva per azionare cilindri a doppio effetto. La figura 8 a le
durante la prima fase impedirebbe alla pompa di posizioni della leva di comando della valvola.
erogare la quantità massima di olio.
27
di essa aumenterà fino a valori elevati, con pericolo
N
di infortuni e/o danni alle apparecchiature.
A B
5.6 Regolazione della valvola di sicurezza
A B
Tutte le pompe incorporano una valvola di sicurezza
regolata in fabbrica per evitare la
sovrapressurizzazione del sistema. È possibile
regolare la valvola su pressioni inferiori. Rivolgersi al
Centro di Assistenza Autorizzato ENERPAC più vicino.
Figura 8a 6.0 ESTRAZIONE DELL’ARIA

L’estrazione dell’aria dal sistema oleodinamico
A B A B A B consente al pistone di avanzare e ritornare
regolarmente. Vedere la figura 9.
I 6.1 Pompe con cilindro a semplice effetto (A)

A N B 1. Ventilare il serbatoio della pompa (solamente
pompe ventilate) e chiudere la valvola di rilascio.
Figura 8b 2. Collocare la pompa più in alto del cilindro.
3. Orientare il cilindro con l’estremità del pistone in
1. Posizioni della leva di comando e funzioni della basso (in alto se si utilizza un cilindro a tiro). Vedere
valvola a 4 vie la figura 9.
(A) Mandata alla bocca "A", l’olio torna nel 4. Azionare la pompa in modo da fare avanzare
serbatoio attraverso la bocca "B". completamente il pistone (farlo ritornare se si
(N) Blocco, le bocche "A" e "B" sono chiuse. impiega un cilindro a tiro).
(B) Mandata alla bocca "B", l’olio torna nel 5. Aprire la valvola di rilascio per fare ritornare il
serbatoio attraverso la bocca "A". pistone (farlo avanzare per il cilindro a tiro). L’aria
intrappolata nel cilindro verrà aspirata verso il
serbatoio.
6. Ripetere le suddette operazioni tante volte quanto
necessario.
N 7. Se necessario, aggiungere olio. Vedere "Rabbocco
dell’olio" a pagina 29.
B
A 8. Riportare il tappo di sfiato/riempimento sulla
A
posizione di funzionamento.
B
6.2 Pompe con cilindro a doppio effetto (B)
1. Vent pump reservoir (for vented pumps only).
Figura 8c
2. Position pump at higher elevation than cylinder.
2. Azionare la pompa per fornire pressione 3. Put cylinder in horizontal position with ports up.
oleodinamica al sistema. See Figure 9.
3. Portare la leva di comando su altre posizioni, a 4. Fully advance and retract the cylinder 2 to 3 times.
seconda delle necessità. 5. Repeat the above steps as necessary.
AVVISO: Azionare cilindri a doppio effetto 6. Se necessario, aggiungere olio. Vedere "Rabbocco
solamente quando entrambi i tubi flessibili dell’olio" a pagina 29.
sono collegati alla pompa. Se una bocca 7. Riportare il tappo di sfiato/riempimento sulla
resta non collegata, la pressione a monte posizione di funzionamento.
aira
aira
A B
Figura 9
28
7.0 MANUTENZIONE 7.3 Lubrificazione della pompa
Per garantire la validità della garanzia ed estendere la Per prolungare la durata della pompa e migliorarne le
durata della pompa, usare solamente olio idraulico prestazioni, lubrificare regolarmente il perno (A), lo
Enerpac. Per alcune pompe manuali sono disponibili spinotto (B) e la testa del pistone (C), utilizzando
guarnizioni Viton ed EPR. Per ulteriori informazioni su grasso per cuscinetti a rulli. Vedere la figura 10.
questi prodotti e sulle loro applicazioni, rivolgersi al
concessionario Enerpac. B, C
A
7.1 Rabbocco dell’olio
Controllare regolarmente il livello dell’olio..
AVVISO: Aggiungere olio solamente
con il pistone completamente rientrato
(completamente avanzato se si utilizza
un cilindro a tiro), altrimenti il sistema
conterrà olio in quantità superiore alla capacità
del serbatoio.
Figura 10
1. Togliere il tappo di sfiato/riempimento dal
serbatoio. 7.4 Sostituzione olio
2. Riempire il serbatoio solo fino al livello 1. Ogni 12 mesi, scaricare tutto l’olio e rabboccare
contrassegnato sulla pompa. usando olio Enerpac pulito. Sostituire l’olio più
3. Se necessario, estrarre l’aria dal sistema. (Vedere frequentemente se si adopera la pompa in
pagina 28.) Ricontrollare il livello dell’olio dopo la ambienti di lavoro sporchi.
disaerazione. 2. Togliere il tappo del serbatoio.
4. Ricollocare in posizione il tappo di 3. Inclinare la pompa e lasciare scaricare tutto l’olio
sfiato/riempimento. usato.
NOTA: Le pompe manuali non ventilate richiedono 4. Riempire il serbatoio solo fino al livello
aria nel serbatoio per funzionare idoneamente. Se il contrassegnato sulla pompa.
serbatoio è completamente pieno, si forma una zona
5. Ricollocare in posizione il tappo del serbatoio.
di depressione che impedisce l’erogazione dell’olio.
6. Smaltire l’olio usato attenendosi alle normative
7.2 Pulizia delle linee dell’olio vigenti.
Quando le bocche sono scollegate, avvitare sempre su 8.0 GUIDA ALLA RICERCA DEI GUASTI
di esse i tappi parapolvere. Esercitare ogni possibile
precauzione per evitare l’introduzione di sporcizia nella Le informazioni qui di seguito riportate sono di ausilio
pompa, poiché sostanze estranee possono causare per determinare se esiste un problema. Per
guasti alla pompa, al cilindro o alla valvola. assistenza tecnica, rivolgersi al Centro di Assistenza
Autorizzato ENERPAC più vicino.
GUIDA ALLA RICERCA DEI GUASTI

Problema Possibili Cause Soluzione
Il pistone non 1.Basso livello dell’olio nel serbatoio. 1. Aggiungere olio come descritto nella sezione MANUTENZIONE.
avanza, avanza 2.Valvola di rilascio aperta. 2. Chiudere la valvola di rilascio.
lentamente o 3.Collegamento oleodinamico allentato. 3. Verificare che tutti i collegamenti siano ben serrati.
avanza a scatti. 4.Carico troppo pesante. 4. Non tentare di sollevare un carico più pesante del valore
5.Aria intrappolata nel sistema. nominale.
6.Grippaggio del pistone. 5. Estrarre l’aria come descritto in "Estrazione dell’aria".
6. Verificare eventuali danni al pistone/cilindro. Rivolgersi ad un
tecnico idraulico qualificato.
Il pistone avanza 1.Perdita in un collegamento. 1. Verificare che tutti i collegamenti siano ben serrati e privi di
ma non 2.Le guarnizioni non tengono. perdite.
mantiene la 3.Perdita interna nella pompa. 2. Localizzare le perdite e, per le riparazioni, rivolgersi ad un
pressione. tecnico idraulico qualificato.
3. Rivolgersi ad un tecnico idraulico qualificato.
Il pistone non 1 Valvola di rilascio chiusa. 1. Aprire la valvola di rilascio.

ritorna, ritorna 2.Serbatoio troppo pieno. 2. Scaricare l’olio fino al livello contrassegnato. Vedere
parzialmente o 3.Collegamento oleodinamico allentato. "Rabbocco dell’olio."
ritorna più 4.Aria intrappolata nel sistema. 3. Verificare che tutti i collegamenti siano ben serrati.
lentamente 5.Diametro interno del tubo flessibile 4. Estrarre l’aria come descritto in "Estrazione dell’aria".
del normale. troppo piccolo. 5. Usare un tubo flessibile di diametro maggiore.
6.Molla di richiamo nel cilindro rotta o 6. Rivolgersi ad un tecnico idraulico qualificato.
altro danno nel cilindro.
29
Hoja de Instrucciones
Bombas Hidráulics Manuales

L1763 Rev I 12/05
Las hojas de despiece para este producto estan
disponibles en la página web de Enerpac en la dirección
www.enerpac.com,o en su centro de Asistencia Técnica
ó punto de venta Enerpac mas cercano.
1.0 IMPORTANTES INSTRUCCIONES DE

RECEPCIÓN
Inspeccione visualmente todos los componentes
para verificar si hay daños de envío. Debido a que la
garantía no ampara daños por envío, si los hubiese,
infórmeselo inmediatamente a la empresa de
transportes, puesto que ésta es responsable de
todos los gastos de reparaciones o reemplazo que sostener carga. Después de que la carga haya sido
resulten por daños de envío. levantada o descendida, debe bloquearse siempre
en forma mecánica.
SEGURIDAD PRIMERO
ADVERTENCIA: USE SÓLO PIEZAS
2.0 ASPECTOS DE SEGURIDAD RÍGIDAS PARA SOSTENER CARGAS.
®
®
Seleccione cuidadosamente bloques de
Lea todas las instrucciones, acero o de madera capaces de soportar la
advertencias y precauciones. carga. Nunca use un cilindro hidráulico como calza o
Acate todas las precauciones de separador en aplicaciones de levantamiento o presión.
seguridad para evitar lesiones personales o daños a la
propiedad durante la operación del sistema. PELIGRO: Para evitar lesiones
ENERPAC no puede ser responsable de daños o personales, mantenga las manos y
lesiones que resulten de no usar el producto de forma los pies alejados del cilindro y pieza
segura, falta de mantenimiento o aplicación de trabajo durante la operación.
incorrecta del producto y/u operación del sistema. ADVERTENCIA: No sobrepase el valor
Comuníquese con ENERPAC si tuviese dudas sobre nominal del equipo. Nunca intente
las precauciones de seguridad o sobre las levantar una carga que pese más de la
aplicaciones. Si nunca ha sido capacitado en capacidad del cilindro. Las sobrecargas
seguridad hidráulica de alta presión, consulte a su ocasionan fallas del equipo y posibles lesiones
distribuidor o centro de servicio para obtener un curso personales. Los cilindros están diseñados para
de seguridad gratis denominado ENERPAC Hydraulic. resistir una presión máxima de 700 bar. No conecte
El no cumplir con las siguientes precauciones y un gato o cilindro a una bomba cuyo valor nominal de
advertencias podría causar daños al equipo y presión es mayor que el indicado.
lesiones personales. PELIGRO: Nunca fije la válvula de
Una PRECAUCIÓN se utiliza para indicar seguridad a una presión más alta que el
procedimientos y prácticas de operación o máximo valor nominal de presión de la
mantenimiento correctos para evitar daños o la bomba. Los ajustes más altos pueden
destrucción de equipo u otra propiedad. resultar en daños al equipo y/o lesiones personales.
No remover la válvula de seguridad.
Una ADVERTENCIA indica un potencial peligro que
requiere de procedimientos o prácticas correctos ADVERTENCIA: La presión de operación
para evitar lesiones personales. del sistema no debe sobrepasar el valor
nominal de presión del componente con el
Un PELIGRO se utiliza sólo cuando su acción o falta valor nominal más bajo en el sistema.
de acción podría causar lesiones graves o incluso la Instale manómetros de presión en el sistema para
muerte. vigilar la presión de operación. Es su ventana a lo que
ADVERTENCIA: Use el equipo de está sucediendo en el sistema.
protección personal adecuado cuando PRECAUCIÓN: Evite dañar la manguera
opere equipo hidráulico. hidráulica. Evite pliegues y curvas
agudos al guiar las mangueras
ADVERTENCIA: Manténgase alejado de hidráulicas. Usar una manguera con
las cargas soportadas por sistemas pliegues o curvas puede causar severa
hidráulicos. Cuando un cilindro se utiliza contrapresión. Los pliegues y curvas agudos
como dispositivo para levantar carga, causarán daños internos la manguera, lo que
nunca debería usarse como dispositivo para ocasionará que ésta falle prematuramente.
30
No deje caer objetos pesados sobre la superficie plana capaz de soportar la carga. De ser
manguera. Un impacto directo puede necesario, utilice una base de cilindro para mayor
causar daños internos a las hebras de estabilidad. No suelde ni modifique el cilindro en modo
®
alambre de la manguera. Aplicar presión a una alguno para fijarle una base u otro medio de soporte.
manguera dañada puede ocasionar que se quiebre.
Evite las situaciones en las cuales las
IMPORTANTE: No levante el equipo cargas no estén directamente centradas
hidráulico por las mangueras o sobre el émbolo del cilindro. Las cargas
acopladores giratorios. Use el mango de descentradas producen un esfuerzo
transporte u otros medios para considerable sobre los cilindros y los émbolos.
transportarla con seguridad. Adeás, la carga podria resbalar o caerse, creando
situaciones potencialmente peligrosas.
PRECAUCIÓN: Mantenga el equipo
hidráulico alejado de las llamas y el Distribuya la carga uniformemente sobre
calor. El calor en exceso ablandará las la superficie total del asiento del cilindro.
juntas y sellos, lo que resultará en Siempre utilice un asiento para proteger el
fugas de líquidos. Asimismo, el calor debilita los émbolo cuando no se usen accesorios
materiales de la manguera y juntas. Para lograr un roscados.
rendimiento óptimo, no exponga el equipo a
IMPORTANTE: Únicamente técnicos
temperaturas de 65 °C [150 °F] o mayores. Proteja las
calificados en sistemas hidráulicos habrán
mangueras y cilindros de salpicaduras de soldadura.
de prestarle servicio al equipo hidráulico.
PELIGRO: No manipule mangueras bajo Comuníquese con el Centro de Servicio
presión. El aceite que escape bajo ENERPAC autorizado en su zona para prestarle
presión puede penetrar la piel y causar servicio de reparaciones. Use únicamente aceite
lesiones graves. Si se inyecta aceite bajo ENERPAC a fin de proteger su garantía.
la piel, consulte a un médico inmediatamente.
ADVERTENCIA: Reemplace
ADVERTENCIA: Use cilindros inmediatamente las piezas gastadas o
hidráulicos únicamente en sistemas dañadas por piezas ENERPAC genuinas.
acoplados. Nunca use un cilindro si los Las piezas de clasificación estándar se
acopladores no están conectados. Si el romperán, lo que causará lesiones personales y daños
cilindro se sobrecarga, los componentes a la propiedad. Las piezas ENERPAC están diseñadas
pueden fallar calamitosamente, lo que causaría para encajar debidamente y resistir altas cargas.
lesiones personales graves.
ATENCION: Siempre acarree la bomba
ADVERTENCIA: Asegurese que el tomándola del asa. Si la acarrea de la manguera
equipo sea antes de levantar la carga. puede dañar la manguera y/o la bomba.
El cilindro debe colocarse sobre una
®
ESPECIFICACIONES – Use esta hoja de instrucciones para los siguientes modelos de bombas manuales.
Especificaciones
Modelo Tipo Presión máxima Volumen de aceite por Capacidad de aceite
(velocidad) psi [bar] embolada pulg3 [cm 3] pulg3 [cm3]
EHF-65 1 6,500 [440] .16 [2.62] 22 [360]
P-18 1 2,850 [200] .16 [2.62] 22 [360]
P-25 1 2,500 [170] .58 [9.51] 231 [3786]
P-39, 1003 1 10,000 [700] .16 [2.62] 43 [705]
P-50 1 5,000 [340] .29 [4.75] 231 [3786]
P-51 1 3,000 [210] .25 [4.09] 50 [820]
P-141, 1001 1 10,000 [700] .055 [.90] 20 [328]
P-391, 1004 1 10,000 [700] .151 [2.47] 55 [900]
Etapa 1 Etapa 2 Etapa 1 Etapa 2
P-80, 1006 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 140 [2295]
P-84 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 140 [2295]
P-142, 1002 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 20 [328]
P-142AL 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 9.0 [148]
P-202 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 55 [900]
P-77 2 200 [14] 10,000 [700] .63 [16.0] .094 [2.41] 47 [769]
P-392, 1005 2 200 [14] 10,000 [700] .687 [11.26] .151 [2.47] 55 [900]
P-392AL 2 200 [14] 10,000 [700] .687 [11.26] .151 [2.47] 55 [900]
P-462 2 200 [14] 10,000 [700] 7.69 [126.00] .29 [4.75] 462 [7572]
P-464 2 200 [14] 10,000 [700] 7.69 [126.00] .29 [4.75] 462 [7572]
P-801 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 250 [4095]
P-802 2 400 [28] 10,000 [700] 2.40 [39.34] .15 [2.46] 155 [2540]
P-842 2 400 [28] 10,000 [700] 2.40 [39.34] .15 [2.46] 155 [2540]
31
3.0 DESCRIPCION 3.2 Modelos P-18/P-39, 1003/P-80, 1006/
P-84/P-801, P77
3.1 Modelos P-141, 1001/P-142, 1002/P- La Figura 2 y la tabla correspondiente a continuación
202/P-391, 1004/P-392, 1005/P-802/P-842 muestran los componentes principales de estos
La Figura 1 y la tabla correspondiente a continuación modelos de bombas manuales. Los modelos P-84
muestran los componentes principales de los están equipados con una válvula de 4 vías y 3
modelos de bombas manuales P-141, P-142, P 202, posiciones para uso con cilindros de doble efecto.
P-391, P-392, P-802, y P-842. La tapa de doble Para convertir los modelos P-18 ó P-39 a
propósito de ventilación/llenado actúa como una accionamiento por pedal, pida el conjunto PC-10.
válvula de alivio de presión en el caso de ocurrir una
presurización accidental del depósito. Para proveer A
una conexión de acceso en la parte trasera del
depósito para las válvulas remotas, use un conjunto B
de retorno al tanque. Vea la tabla a continuación para A
los números de modelos de los conjuntos.
A D B
A
B
B
E B
C
P842
Figura 2
C
ADVERTENCIA: Estas bombas

funcionan con un depósito sin
B
ventilación. Si el depósito es sometido
D
a alta presión, la envuelta puede
Figura 1 romperse y causar lesiones personales y/o daños
al equipo. NUNCA trate de devolver más aceite al
depósito del que es capaz de contener.
Tabla 1
Fig. 1 P-141, 1001 P-142, 1002 P-202 P-391, 1004 P-392, 1005 P-802 P-842
A Válvula de alivio Válvula de alivio Válvula de alivio Válvula de alivio Válvula de alivio Válvula de alivio Válvula de 4 vías
B Conexión de Conexión de Conexión de Conexión de Conexión de Conexión de Conexión de
salida 1/4 NPTF salida 1/4 NPTF salida 1/4 NPTF salida 3/8 NPTF salida 3/8 NPTF salida 3/8 NPTF salida 3/8 NPTF
C Tapa de Tapa de Tapa de Tapa de Tapa de Tapa de Tapa de
ventilación/ ventilación/ ventilación/ ventilación/ ventilación/ ventilación/ ventilación/
llenado llenado llenado llenado llenado llenado llenado
D Ranuras Ranuras — — — Ranuras Ranuras
de montaje de montaje de montaje de montaje
E — — — — — Retorno al depósito —
Conjunto PC-20 PC-20 PC-25 PC-25 PC-25 — —
de retorno
al tanque
Tabla 2
Fig. 2 P-18 P-39, 1003 P-77 P-80, 1006 P-84 P-801
A Válvula de alivio Válvula de alivio Válvula de alivio Válvula de alivio Válvula de 4 vías Válvula de alivio
y 3 posiciones
B Conexión de salida Conexión de salida Conexión de salida Conexión de salida Conexión de salida Conexión de salida
C Tapón de Tapón de Tapón de Tapón de Tapón de Tapón de
D — — — etorno al depósito — etorno al depósito
1/4 NPTF 1/4 NPTF
32
3.3 Modelos P-462 y P-464 Tabla 4 y 5
Fig.4/5 P-25 P-50 P-51
La Figura 3 y la tabla a continuación muestran las
A Válvula de alivi Válvula de alivi Válvula de alivi
características principales de los modelos de
B Conexión de Conexión de Conexión de
bombas manuales P-462 para uso con cilindros de salida1/4 NPTF salida1/4 NPTF 1salida/4 NPTF
simple efecto y P-464 para uso con cilindros de
C Tapón de Tapón de Tapón de
doble efecto. ventilación/llenado ventilación/llenado ventilación/
llenado
C
4.0 INSTALACION
D
4.1 Conexión de la bomba
B 1. Enrosque la manguera en la salida de la bomba.
Ponga 1 1/2 vueltas de cinta de teflón (o sellador
de roscas adecuado) en los racores de la
A
manguera, dejando el primer hilo de rosca sin
encintar para asegurar que no se desprendan
pedazos de cinta y entren al sistema hidráulico y
P-462/464F3
causen daño. Recorte las puntas sueltas.

2. Instale un manómetro en línea desde la bomba
para mayor seguridad y mejor control.
Figura 3, Modelos P-462 y P-464 3. Conecte la(s) manguera(s) a su cilindro o
herramienta.
Tabla 3
Fig. 3 P-462 P-464 NOTA: Para cilindros de simple efecto, conecte
A Válvula de 3 vías Válvula de 4 vías una manguera de la bomba al cilindro. Para
y 2 posiciones y 3 posiciones cilindros de doble efecto, conecte dos
B Conexión de salida 3/8 NPTF Conexión de salida 3/8 NPTF mangueras. Conecte una manguera de la
C Tapón de ventilación/llenado Tapón de ventilación/llenado
conexión de presión de la bomba a la conexión
D Grapa de asa Grapa de asa
de presión del cilindro. Conecte otra manguera de
la conexión de retracción de la bomba a la
conexión de retracción del cilindro.
3.4 Modelos P-25, P-50 y P-51
4.2 Ventilación de la bomba
La Figura 4 muestra los modelos de bombas manuales
P-25 y P-50, los cuales están equipados con una Vea la tabla a continuación para determinar si su
palanca que funciona en ambos sentidos. La Figura 5 bomba debe funcionar con un depósito con
en la página muestra la bomba manual P-51. En la ventilación o uno sin ventilación. Las bombas con
tabla a continuación se detallan los componentes ventilación proporcionan un rendimiento ligeramente
principales de estas bombas. mejor. Para las bombas con depósitos de nylon, gire
la tapa de ventilación/llenado 1/4 de vuelta en
sentido contrahorario para la ventilación. Para las
demás bombas, vea la calcomanía en la bomba.
C Cierre la ventilación antes de transportar la bomba
A para impedir el escape de aceite. P-80, P-801, y P-
B
84 se ceban girando la válvula contra las agujas del
reloj. Para cerrar el cebado, girar la válvula según las
agujas del reloj.
OPCIONES DE VENTILACION
EHF-65 . . . . . . . . . . sin ventilación P-202 . . . . . . cualquiera de los dos

P-18 . . . . . . . . . . . . sin ventilación P-391, 1004 . cualquiera de los dos
P-25. . . . . . . cualquiera de los dos P-77 . . . . . . . . . . . con ventilación
Figura 4, Modelos P-25 ay P-50 P-39, 1003 . . . . . . . sin ventilación P-392, 1005 . cualquiera de los dos
P-50 . . . . . . . cualquiera de los dos P-392AL . . . . . . . . con ventilación
P-51 . . . . . . . . . . . con ventilación P-462 . . . . . . . . . . con ventilación
P-80, 1006 . . cualquiera de los dos P-464 . . . . . . . . . . con ventilación
C P-84. . . . . . . cualquiera de los dos P-801 . . . . . . . . . . . sin ventilación
P-141, 1001. . cualquiera de los dos P-802 . . . . . . cualquiera de los dos
A P-142, 1002. . cualquiera de los dos P-842 . . . . . . cualquiera de los dos
P-142AL . . . . . . . . . sin ventilación
B
P-51F5
Figura 5, Model o P-51
33
4.3 Posición de la bomba NOTA: Para mejor rendimiento, accione la palanca
de la bomba a velocidad moderada durante la
Vea la tabla a continuación para determinar la posición primera etapa de caudal alto. La velocidad rápida de
correcta de funcionamiento de su bomba, horizontal o la palanca en la primera etapa impedirá que la bomba
vertical. La P-80, P-801, y la P-84 no podrán cebarse alimente el volumen total de aceite.
cuando estén trabajando verticalmente.
POSICION DE FUNCIONAMIENTO
5.3 Aplicaciones de simple efecto con
válvula de alivio
EHF-65 . . . . . cualquiera de los dos P-202 . . . . . . cualquiera de los dos
P-18 . . . . . . . cualquiera de los dos P-391, 1004 . cualquiera de los dos 1. Cierre la válvula de alivio girándola en sentido
P-25. . . . . . . . horizontal solamente P-77 . . . . . . . cualquiera de los dos
P-39, 1003 . . cualquiera de los dos P-392, 1005. . cualquiera de los dos horario, como se muestra en la Figura 6.
P-50. . . . . . . . horizontal solamente P-392AL . . . . cualquiera de los dos
P-51. . . . . . . . horizontal solamente P-462 . . . . . . horizontal solamente
P-80, 1006 . . cualquiera de los dos P-464 . . . . . . horizontal solamente
P-84 . . . . . . . cualquiera de los dos P-801 . . . . . cualquiera de los dos
P-141, 1001 . cualquiera de los dos P-802 . . . . . . cualquiera de los dos
P-142, 1002 . cualquiera de los dos P-842 . . . . . . cualquiera de los dos
P-142AL . . . . cualquiera de los dos
NOTA: Cuando se hace funcionar la bomba en

posición vertical, el extremo de la manguera debe
estar apuntando hacia abajo, de lo contrario la
bomba chupará aire y su presión no aumentará
adecuadamente.
5.0 FUNCIONAMIENTO Figura 6
ATENCION: Cierre la válvula de alivio

5.1 Antes de usar la bomba apretándola a mano SOLAMENTE. El
1. Revise todos los racores y conexiones del uso de herramientas puede dañar la
sistema para asegurar que estén apretados y sin válvula y averiar la bomba.
fugas. 2. Accione la palanca de la bomba para alimentar
2. Revise el nivel de aceite en el depósito antes de potencia hidráulica al sistema. Se mantendrá la
hacer funcionar la bomba. Vea "Adición de aceite presión hasta que se abra la válvula de alivio.
a la bomba" en la página 35. 3. Abra la válvula de alivio (en sentido contrahorario)
ATENCION: NUNCA añada extensiones para quitar presión, dejando que el aceite fluya de
a la palanca de la bomba. Las vuelta al depósito.
extensiones causan el funcionamiento
inestable de la bomba. 5.4 Aplicaciones de simple efecto con
ADVERTENCIA: En ciertas situaciones válvula manual de 3 vías y 2 posiciones
la palanca de la bomba puede dar un 1. Cambie la palanca de la válvula a la posición 1
"contragolpe". Siempre mantenga el como se muestra en la Figura 7.
cuerpo a un lado de la bomba, lejos de 2. Accione la palanca de la bomba para alimentar
la línea de fuerza de la palanca. potencia hidráulica al sistema. Se mantendrá la
NOTA: Para reducir el esfuerzo de la palanca a alta presión hasta que cambie la válvula de posición.
presión, acciónela en tramos cortos. Se obtiene 3. Para que el aceite regrese al depósito, cambie la
máxima fuerza en los últimos 5 grados de la carrera. palanca de la válvula a la posición 2.
2 2
5.2 Utilización de bombas de dos
velocidades
Estas bombas proporcionan un caudal de 2 etapas.
Sin carga, la bomba funciona en la primera etapa de
caudal alto. Cuando se hace contacto con la carga,
la bomba automáticamente cambia a la segunda
etapa para aumentar la presión. Para los modelos 1 1
P-462 ó P-464, cuando la presión de la bomba llega

aproximadamente a 200 psi (14 bar), debe parar
momentáneamente de bombear y levantar la palanca A A
para cambiar a la etapa de presión alta. Para los
modelos P-802 ó P-842, cuando la presión de la
bomba llega aproximadamente a 400 psi (28 bar),
debe parar momentáneamente de bombear y
levantar la palanca para cambiar a la etapa de 1 2
presión alta. Después que la bomba cambie, se
necesita hacer menos esfuerzo para bombear. Figura 7
34
5.5 Aplicaciones de doble efecto con 6.0 PURGA DEL AIRE
válvula manual de 4 vías y 3 posiciones
La purga del aire del sistema hidráulico permitirá que
Las bombas con válvulas de control de 4 vías están el cilindro se extienda y se retraiga suavemente. Vea
diseñadas para accionar cilindros de doble efecto. la Figura 9.
Vea la Figura 8 en la página 13 para las posiciones de
la válvula. 6.1 Bomba con cilindro de simple efecto (A)
N
1. Abra el respiradero del depósito de la bomba
(para bombas con ventilación solamente) y cierre
A B la válvula de alivio.
2. Coloque la bomba más elevada que el cilindro.
A B
3. Coloque el cilindro con el extremo del émbolo
hacia abajo (arriba en caso de cilindro de
tracción). Vea la Figura 9.
4. Haga funcionar la bomba para extender
totalmente el cilindro (retraer en caso de cilindro
de tracción).
Figura 8a
5. Abra la válvula de alivio para retraer el cilindro
A B A B A B (extender en caso de cilindro de tracción). Esto
empujará el aire retenido hacia el depósito de la
bomba.
I 6. Repita los pasos anteriores según sea necesario.
7. Añada aceite si es necesario. Vea la página 35.
A N B
8. Vuelva a poner la tapa de ventilación/llenado en
Figura 8b posición de funcionamiento.
11. Coloque la palanca en la válvula de 4 vías para 6.2 Bomba con cilindro de doble efecto (B)
seleccionar la función de la siguiente manera:
1. Abra el respiradero del depósito de la bomba
(A) Paso al orificio "A"; el orificio "B" devuelve el (para bombas con ventilación solamente).
aceite al depósito
2. Coloque la bomba más elevada que el cilindro.
(N) Neutro; los orificios "A" y "B" están
3. Ponga el cilindro en posición horizontal con las
bloqueados
conexiones hacia arriba. Vea la Figura 9.
(B) Paso al orificio "B"; el orificio "A" devuelve el
4. Extienda y retraiga totalmente el cilindro 2 a 3 veces.
aceite al depósito
5. Repita los pasos anteriores según sea necesario.
6. Añada aceite si es necesario. Vea la página 35.
7. Vuelva a poner la tapa de ventilación/llenado en
posición de funcionamiento.
N
A
B 7.0 MANTENIMIENTO
A
Use únicamente aceite hidráulico Enerpac con estas
B
bombas para prolongar la duración de la bomba y
proteger su garantía. Los juegos de sellos Viton y
Figura 8c EPR están disponibles para algunas bombas
manuales. Para más información acerca de estos
2. Haga funcionar la bomba para realizar el trabajo. productos y sus aplicaciones, póngase en
3. Cambie las posiciones de la válvula según sea comunicación con el representante de Enerpac.
necesario.
ADVERTENCIA: Haga funcionar el cilindro 7.1 Adición de aceite a la bomba
de doble efecto solamente cuando las dos
Revise el nivel de aceite regularmente.
mangueras están conectadas a la bomba.
Si se deja un acoplador desconectado, se ADVERTENCIA: Siempre añada aceite
acumulará alta presión detrás del acoplador lo que con los cilindros totalmente retraídos
podría causar lesiones corporales y/o daño al equipo. (extendidos en el caso de cilindros de
tracción) de lo contrario el sistema
5.6 Ajuste de la válvula de alivio sobrepasará la capacidad de aceite del depósito.
1. Quite la tapa de ventilación/llenado del depósito.
Todas las bombas tienen una válvula de alivio ajustada
en la fábrica para impedir la sobrepresurización del 2. Llene el depósito solamente hasta la marca de
sistema. Se pueden obtener ajustes de presión más nivel indicada en la bomba.
bajos. Póngase en contacto con el centro de servicio
autorizado Enerpac.
35
3. Purgue el aire del sistema si es necesario. Vea la B, C
página 51. Vuelva a revisar el nivel de aceite
A
después de purgar el aire.
4. Vuelva a poner la tapa de ventilación/llenado en la
posición apropiada.
NOTA: Las bombas manuales sin ventilación
requieren aire en el depósito para funcionar
correctamente. Si el depósito está totalmente lleno,
se formará un vacío que impedirá la salida de aceite
de la bomba.
Figura 10
7.2 Limpieza de las líneas de aceite 7.4 Cambio del aceite
Cuando se desconecte las mitades del acoplador, 1. Cada 12 meses, vacíe todo el aceite y vuelva a
siempre coloque tapas guardapolvo. Tome todas las llenar con aceite Enerpac. Si la bomba funciona
precauciones debidas para proteger la bomba contra en ambientes sucios, cambie el aceite más
la entrada de suciedad. La materia extraña puede frecuentemente.
causar la falla de la bomba, el cilindro o la válvula..
2. Quite la tapa de ventilación/llenado del depósito.
7.3 Lubricación de la bomba 3. Incline la bomba para vaciar el aceite viejo.
4. Llene el depósito solamente hasta la marca de
Para prolongar la duración de la bomba y mejorar su
nivel indicada en la bomba.
rendimiento, lubrique el pasador de soporte (A),
pasador transversal (B) y la cabeza del pistón (C) 5. Vuelva a poner el tapón o tapa de
regularmente con grasa para cojinetes de rodillos. ventilación/llenado.
Vea la Figura 10 a continuación. 6. Deseche el aceite viejo como es debido.
8.0 GUIA DE LOCALIZACION DE AVERIAS

La información siguiente está destinada sólo a
ayudar a determinar si existe alguna avería. Para las
reparaciones, diríjase al centro de servicio autorizado
Enerpac de su zona.
Aire
Aire
A B
Figure 9
GUIA DE LOCALIZACION DE AVERIAS

Problema Causa posible Solución
El cilindro no se extiende, lo 1. Bajo nivel de aceite en la bomba. 1. Añada aceite de acuerdo a las instrucciones de Mantenimiento en
hace lentamente o 2. La válvula de alivio está abierta. la página 35.
irregularmente. 3. El acoplador hidráulico está suelto. 2. Cierre la válvula de alivio.
4. La carga es demasiado pesada. 3. Revise que todos los acopladores estén totalmente apretados.
5. Aire retenido en el sistema 4. No trate de izar más del tonelaje nominal.
6. Atascamiento del émbolo del cilindro. 5. Purgue el aire de acuerdo a las instrucciones en la página 35.
6. Revise si el cilindro está dañado. Pida que lo repare un técnico
experto en sistemas hidráulicos.
1. Fugas en las conexiones. 1. Revise que todas las conexiones estén apretadas y sin fugas.
El cilindro se extiende, pero
2. Fugas en los sellos. 2. Ubique la(s) fuga(s) y haga reparar el equipo por un técnico
no retiene la presión
3. Fuga interna en la bomba. experto en sistemas hidráulicos.
3. Haga reparar la bomba por un técnico experto en sistemas
hidráulicos.
1. Válvula de alivio cerrada.
El cilindro no se retrae, lo 1. Abra la válvula de alivio.
2. El depósito de la bomba está lleno en
hace parcialmente o más 2. Vacíe el aceite hasta la marca "full" (lleno). Vea las instrucciones
exceso.
lentamente que lo normal. en la página 35.
3. El acoplador hidráulico está suelto
4. Aire retenido en el sistema. 3. Revise que todos los acopladores estén totalmente apretados.
5. D.I. de la manguera demasiado 4. Purgue el aire de acuerdo a las instrucciones en la página 35.
estrecho. 5. Use una manguera hidráulica de mayor diámetro.
6. El resorte de retracción del cilindro está 6. Haga reparar el cilindro por un técnico experto en sistemas
roto o existe otro daño en el cilindro. hidráulicos.
36
Instructieblad
Hydraulische Handpompen
L1763 Rev I 12/05
Reparatie/Onderdelenlijsten voor deze produkten zijn

te downloaden van de Enerpac Website
www.enerpac.com of verkrijgbaar via uw Enerpac
Service Centre of vertegenwoordiger.
1.0 BELANGRIJKE INSTRUCTIES BIJ

ONTVANGST
Controleer visueel alle onderdelen op schade
opgelopen tijdens de verzending. Schade opgelopen
tijdens de verzending wordt niet door de garantie
gedekt. Als schade opgelopen tijdens de verzending
wordt gevonden, de transporteur hier onmiddellijk van
op de hoogte stellen. De transporteur is
verantwoordelijk voor alle reparatie- of WAARSCHUWING: Blijf uit de buurt van
vervangingsonkosten als gevolg van opgelopen ladingen die hydraulisch worden
ondersteund. Een cilinder die wordt
schade tijdens de verzending.
gebruikt als een hefinrichting mag nooit
worden gebruikt als een lasthouder. Nadat de lading
VEILIGHEID VOOROP omhoog of omlaag is gebracht, moet deze altijd
mechanisch worden geblokkeerd.
2.0 VEILIGHEIDSKWESTIES
WAARSCHUWING: GEBRUIK ENKEL
Lees nauwkeurig alle instructies, STIJVE MATERIALEN OM DE
®
waarschuwingen en let op- ® LADINGEN VAST TE HOUDEN. Kies met

gedeelten. Volg alle zorg stalen of houten blokken die een
veiligheidsvoorzieningen om lading kunnen ondersteunen. Gebruik nooit een
persoonlijk letsel of schade aan eigendom te hydraulische cilinder als een pakkingschijf of een
voorkomen als het systeem in werking is. Enerpac afstandstuk in enige toepassing waarbij opheffen of
kan niet verantwoordelijk worden gesteld voor drukken wordt gebruikt.
schade of letsels als gevolg van onveilig gebruik van
dit product, gebrek aan onderhoud, of onjuiste GEVAAR: Om persoonlijk letsel te
toepassing van het product of het systeem. Neem voorkomen, handen en voeten
contact op met Enerpac mocht u twijfels hebben over weghouden van de cilinder en het
veiligheidsvoorzieningen en werkingen. Als u nooit werkstuk tijdens de bediening.
een opleiding in hogedruk hydraulische veiligheid WAARSCHUWING: Niet de nominale
hebt gevolgd neem dan contact om met uw verdeel- waarden van de machines overschrijden.
of servicecentrum voor een gratis veiligheidscursus Probeer nooit om een lading op te heffen
van Enerpac Hydraulic. die meer weegt dan de capaciteit van de
cilinder. Overladen veroorzaakt falen van de machine
Het niet volgen van deze waarschuwing
en mogelijk persoonlijk letsel. De cilinders zijn
sboodschappen en voorzorgsmaatregelen kan ontworpen voor een maximale druk van 700 bar.
schade aan de machine en persoonlijk letsel Geen vijzel of cilinder op een pomp aansluiten die
veroorzaken. een hogere drukwaarde heeft.
LET OP wordt gebruikt om correcte bedienings- en GEVAAR: Nooit de ontlastklep instellen
onderhoudsprocedures en praktijken aan te duiden op een hogere druk dan de maximaal
om schade aan, of vernietiging van, machines of nominale druk van de pomp. Hogere
andere eigendom te voorkomen. instellingen kunnen schade aan de
WAARSCHUWING wijst op een mogelijk gevaar dat machine en/of persoonlijk letsel tot gevolg hebben.
de juiste procedures en praktijken vereist om Verwijder niet de ontlastklep.
persoonlijk letsel te voorkomen. WAARSCHUWING: De bedieningsdruk
GEVAAR wordt enkel gebruikt als uw actie of gebrek van het systeem mag de nominale
aan actie ernstig letsel of zelfs de dood tot gevolg drukwaarde van het onderdeel met de
kan hebben. laagste waarde in het systeem niet
overschrijden. Installeer drukmeters in het systeem
WAARSCHUWING: Draag de juiste om de bedieningsdruk te controleren. Op die manier
persoonlijke beschermende kleding bij het weet u wat er in het systeem gebeurt.
werken met hydraulische machines.
37
LET OP: De hydraulische slang niet WAARSCHUWING: Gebruik hydraulische
beschadigen. Vermijd ombuigen en knikken cilinders enkel in een aangesloten
bij het aanbrengen van de hydraulische systeem. Nooit een cilinder gebruiken met
slangen. Een gebogen of geknikte slang koppelingen die niet aangesloten zijn. Als de
gebruiken kan ernstige tegendruk van de afvoerstroom cilinder uiterst overladen is, kunnen onderdelen op een
veroorzaken. Scherpe ombuigingen en knikken catastrofistische manier falen wat ernstig persoonlijk
beschadigen de slang aan de binnenkant wat tot letsel kan veroorzaken.
vroegtijdig falen van de slang kan leiden.
WAARSCHUWING: Zorg dat de
Geen zware objecten op de slang laten apparatuur stabiel is opgezet alvorens
vallen. Een scherpe impact kan interne lasten te heffen. De cilinder dient op een
®
schade aan de draadvezels van de slang vlakke ondergrond geplaatst te worden die
®
veroorzaken. Druk uitoefenen op een slang die de last kan dragen. Gebruik waar mogelijk
beschadigd is, kan scheuren van de slang tot gevolg een ondersteuning voor de cilinder voor extra stabiliteit.
hebben. De cilinder mag niet gelast of op een andere manier
aangepast worden voor het bevestigen van een voetstuk
BELANGRIJK: Hydraulische machines niet
of andere ondersteuning.
bij de slangen of de wartelkoppelingen
opheffen. Gebruik de draaghandgreep of Vermijd situaties, waarbij de last niet
een ander middel om de machine veilig te aangrijpt in het hart van de cilinderplunjer.
transporteren. Niet-centrisch aangrijpende lasten
veroorzaken aanzienlijke spanningen in de
LET OP: Houd de hydraulische
cilinder en de plunjer. Bovendien kan de last wegglijden
machine weg van vlammen en hitte.
of vallen, wat tot gevaarlijke situaties leidt.
Buitenmatige hitte verzacht de pakkingen
en afdichtingen wat tot vloeistoflekken Verdeel de last gelijkmatig over het gehele
kan leiden. Hitte verzwakt ook slangmaterialen en zadeloppervlak. Gebruik altijd een zadel om
pakkingen. Voor optimale prestaties de machines niet de plunjer te beschermen, wanneer geen
blootstellen aan temperaturen van 65°C (150°F) of hulpstukken met schroefdraad worden
hoger. Bescherm slangen en cilinders tegen lasspetters. gebruikt.
GEVAAR: Slangen die onder druk staan, BELANGRIJK: Hydraulische machines
niet aanraken. Als olie die onder druk staat mogen enkel door een bevoegd hydraulisch
ontsnapt, kan het door de huid dringen wat technicus van onderhoud worden voorzien.
ernstige letsel kan veroorzaken. Als olie onder de huid Voor reparaties dient u contact op te nemen
wordt geïnjecteerd, onmiddellijk een arts raadplegen. met een nabijgelegen bevoegd ENERPAC
servicecentrum. Om uw garantie te beschermen, enkel
ENERPAC olie gebruiken.
SPECIFICATIES – Deze handleiding is bedoeld voor de volgende handpompen.

SPECIFICATIES
Model Type Toelaatbare Druk Olie Volume per Slag Nuttige Inhoud Olietank
(Snelheid) psi [bar] in 3 [cm 3] in3 [cm3]
EH-65 1 6,500 [440] .16 [2.62] 22 [360]
P-18 1 2,850 [200] .16 [2.62] 22 [360]
P-25 1 2,500 [170] .58 [9.51] 231 [3786]
P-39, 1003 1 10,000 [700] .16 [2.62] 43 [705]
P-50 1 5,000 [340] .29 [4.75] 231 [3786]
P-51 1 3,000 [210] .25 [4.09] 50 [820]
P-141, 1001 1 10,000 [700] .055 [.90] 20 [328]
P-391, 1004 1 10,000 [700] .151 [2.47] 55 [900]
1 E Trap 2 E Trap 1 E Trap 2 E Trap
P-80, 1006 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 140 [2295]
P-84 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 140 [2295]
P-142, 1002 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 20 [328]
P-142AL 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 9.0 [148]
P-202 2 200 [14] 10,000 [700] .221 [3.62] .055 [90] 55 [900]
P-77 2 200 [14] 10,000 [700] .63 [16.0] .094 [2.41] 47 [769]
P-392, 1005 2 200 [14] 10,000 [700] .687 [11.26] .151 [2.47] 55 [900]
P-392AL 2 200 [14] 10,000 [700] .687 [11.26] .151 [2.47] 55 [900]
P-462 2 200 [14] 10,000 [700] 7.69 [126.00] .29 [4.75] 462 [7572]
P-464 2 200 [14] 10,000 [700] 7.69 [126.00] .29 [4.75] 462 [7572]
P-801 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 250 [4095]
P-802 2 400 [28] 10,000 [700] 2.40 [39.34] .15 [2.46] 155 [2540]
P-842 2 400 [28] 10,000 [700] 2.40 [39.34] .15 [2.46] 155 [2540]
38
WAARSCHUWING: Versleten of 3.2 Model P-18/P-39, 1003/P-80, 1006/P-
beschadigde onderdelen onmiddellijk met 84/P-801, P-77
authentieke ENERPAC onderdelen In afbeelding 2 en de bijbehorende tabel daaronder
vervangen. Standaardonderdelen breken, worden de hoofdonderdelen van deze handpompen
wat tot persoonlijk letsel en schade aan eigendom kan weergegeven. De P-84 is uitgerust met een 4-weg klep
leiden. ENERPAC onderdelen zijn zodanig ontworpen met 3 standen voor gebruik met dubbelwerkende
dat ze precies passen en hoge ladingen kunnen cilinders. Voor het ombouwen van model P-18 of P-39
weerstaan.
voor voetbediening bestelt u set PC-10.
VOORZICHTIG: Draag de pomp ALTIJD
aan het handvat. Als de pomp aan de slang A
wordt gedragen of gesleept, kan de slang en
de pomp beschadigd raken. B
A
3.0 OMSCHRIJVING
3.1 Model P-141, 1001/P142, 1002/P-202/P-

391, 1004/P-392, 1005/P-802, P-842
In afbeelding 1 en de bijbehorende tabel daaronder
worden de hoofdonderdelen van handpompen P-141, D B
P-142, P-202, P-391, P-392, P-802 en P-842
B
weergegeven. De ontlucht-/vuldop met dubbele functie
werkt als een drukontlastventiel bij onvoorziene C
drukverhoging in het reservoir. Om te voorzien in een
toegangspoort aan de achterkant van het reservoir voor
op afstand bediende kleppen, kunt u een
tankterugloop-set gebruiken. Zie onderstaande tabel Afbeelding 2
voor het modelnummer van de sets.
WAARSCHUWING: Deze pompen

werken met een reservoir zonder
ontluchting. Als het reservoir
A blootgesteld wordt aan te hoge druk,
A kan de behuizing barsten, hetgeen lichamelijk
B
letsel en/of schade aan het apparaat kan
E B veroorzaken. Probeer NOOIT meer olie naar het
reservoir terug te voeren dan het kan bevatten.
P842
B
D
Afbeelding 1
Tabel 1
Afbeedlding 1 P-141, 1001 P-142, 1002 P-202 P-391, 1004 P-392, 1005 P-802 P-842
A Ontlastventiel Ontlastventiel Ontlastventiel Ontlastventiel Ontlastventiel Ontlastventiel 4-weg klep
B 1/4 NPTF 1/4 NPTF 1/4 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF
Uitlaatpoort Uitlaatpoort Uitlaatpoort Uitlaatpoort Uitlaatpoort Uitlaatpoort Uitlaatpoort
C Ontlucht-/vuldop Ontlucht-/vuldop Ontlucht-/vuldop Ontlucht-/vuldop Ontlucht-/vuldop Ontlucht-/vuldop Ontlucht-/vuldop
D Montage-sleuven Montage-sleuven — — — Montage-sleuven Montage-sleuven
E — — — — — Tankteruglooppoort —
Tank- PC-20 PC-20 PC-25 PC-25 PC-25 — —
terugloop
set
Tabel 2
Afbeedlding 2 P-18 P-39, 1003 P-77 P-80, 1006 P-84 P-801
A Ontlastventiel Ontlastventiel Ontlastventiel Ontlastventiel 4-weg klep Ontlastventiel
Uitlaatpoort Uitlaatpoort Uitlaatpoort Uitlaatpoort Uitlaatpoort Uitlaatpoort
C Vuldop Vuldop Vuldop Vuldop Vuldop Vuldop
D — — — 1/4 NPTF — 1/4 NPTF
Tankteruglooppoort Tankteruglooppoort
39
3.3 Models P-462 and P-464 Tabel 4 en 5
Afbeelding P-25 P-50 P-51
In afbeelding 3 en de tabel daaronder worden de 4, 5
belangrijkste voorzieningen weergegeven van de P- A Ontlastventiel Ontlastventiel Ontlastventiel
462, voor gebruik met enkelwerkende cilinders, en P- B 1/4 NPTF 1/4 NPTF 1/4 NPTF
464, voor gebruik met dubbelwerkende cilinders. Uitlaatpoort Uitlaatpoort Uitlaatpoort
C Ontlucht-/vuldop Ontlucht-/vuldop Ontlucht-/vuldop
C
4.0 INSTALLATIE
D
4.1 Aansluiten van de pomp

B
1. Draai de slang in de pompuitlaat. Wikkel
anderhalve slag teflon-tape (of geschikt
A schroefdraadafdichtmiddel) rond de
slangaansluiting, waarbij de eerste volledige gang
wordt vrijgelaten om er zeker van te zijn dat de
P-462/464F3
tape niet in het hydraulische systeem terecht

komt en lekkage en/of schade veroorzaken. Knip
de losse uiteinden af.
2. Installeer een manometer tuseen de pomp en
Afbeelding 3, P-462 en P-50 cilinder voor grotere veiligheid en een betere
systeembediening.
Tabel 3
3. Sluit de slang(en) aan op uw cilinder of
Afbeelding 3 P-462 P-464 gereedschap.
A 3-weg klep met 2 standen 4-weg klep met 3 standen OPMERKING: Bij enkelwerkende cilinders wordt één
B 3/8 NPTF Uitlaatpoort 3/8 NPTF Uitlaatpoort slang tussen de pomp en de cilinderaangesloten. Bij
C Ontlucht-/vuldop Ontlucht-/vuldop
dubbelwerkende cilinders worden twee slangen
D Pompstang Pompstang
aangesloten. Sluit één slang aan tussen de drukpoort
van de pomp en de drukpoort van de cilinder. Sluit
een andere slang aan tussen de terugtrekpoort van
3.4 Model P-25, P-50, and P-51 de pomp en de terugtrekpoort van de cilinder.
In afbeelding 4 worden de P-25 en P-50
weergegeven, die beide uitgerust zijn met een
4.2 Ontluchten van de pomp
pompstang die in beide richtingen werkt. In Zie onderstaande tabel om te bepalen of uw pomp
afbeelding 5 wordt de P-51 handpomp weergegeven. dient te werken met een reservoir met of zonder
De hoofdonderdelen van deze pompen vindt u in de ontluchting. Pompen met ontluchting leveren een
tabel daaronder. beter werkrendement. Bij pompen met een nylon
reservoir wordt de ontlucht-/vuldop 1/4 slag tegen de
klok in gedraaid om te ontluchten. Zie voor andere
pompen de sticker op de pomp. Sluit het ventiel
C voordat u de pomp vervoert om olielekkage te
B
A voorkomen. De P-80, P-801 en P-84 kunnen ontlucht
worden door het ventiel linksom open te draaien (met
de klok mee). Om de ontluchting te sluiten moet het
ventiel tegen de klok in dicht worden gedraaid.
ONTLUCHTEN
EHF-65. . . . . . . . . . nicht belueftet P-202 . . . . . . . . . beides möglich
P-18 . . . . . . . . . . . nicht belueftet.. P-391, 1004 . . . . beides möglich
P-25 . . . . . . . . . beides moeglich P-77 . . . . . . . . . . . nur horizontal
Afbeelding 4, P-25 en P-50 P-39, 1003 . . . . . . nicht belueftet P-392, 1005 . . . . beides möglich
P-50 . . . . . . . . . beides moeglich P-392AL . . . . . . . . nur horizontal
P-51 . . . . . . . . . . . nur horizontal P-462 . . . . . . . . . . nur horizontal
C P-464 . . . . . . . . . . nur horizontal
P-80, 1006 . . . . . beides möglich
P-84 . . . . . . . . . . beides möglich P-801 . . . . . . . . . . nicht belueftet
A P-141, 1001 . . . . beides möglich P-802 . . . . . . . . . beides möglich
P-142, 1002 . . . . beides möglich P-842 . . . . . . . . . beides möglich
B P-142AL . . . . . . . . . nicht belueftet
4.3 Stand van de pomp

P-51F5
Zie onderstaande tabel om de juiste bedrijfsstand

voor uw pomp te bepalen. De P-80, P-801 en P-84
Afbeelding 5, Model P-51 kunnen niet geventileerd worden als de pomp vertikaal
gebruik wordt. Die Pumpen P-80, P-801 und P-84
koennen bei vertikalem Einsatz nicht belueftet werden.
40
olievolume kan leveren.
STANDEN
EHF-65 . . . . . . beide mogelijk P-202 . . . . . . . beide mogelijk 5.3 Enkelwerkende toepassingen met
P-18 . . . . . . . . beide mogelijk P-391, 1004 . . beide mogelijk
P-25 . . . . . . alleen horizontaal P-77 . . . . . . . . beide mogelijk ontlastventiel
P-39, 1003 . . . beide mogelijk P-392, 1005 . . beide mogelijk
P-50 . . . . . . alleen horizontaal P-392AL . . . . . beide mogelijk 1. Sluit het ontlastventiel door het met de klok mee
P-51 . . . . . . alleen horizontaal P-462 . . . . alleen horizontaal te draaien, zoals in afbeelding 6.
P-80, 1006 . . . beide mogelijk P-464 . . . . alleen horizontaal
P-84 . . . . . . . . beide mogelijk P-801 . . . . . . beide mogelijk
P-141, 1001 . . beide mogelijk P-802 . . . . . . . beide mogelijk
P-142, 1002 . . beide mogelijk P-842 . . . . . . . beide mogelijk
P-142AL. . . . . beide mogelijk
OPMERKING: Wanneer de pomp in de verticale

stand gebruikt wordt, moet het slanguiteinde naar
beneden wijzen, anders zuigt de pomp lucht aan en
komt hij niet goed op druk.
5.0 BEDRIJF
Afbeelding 6
5.1 Voordat u de pomp gebruikt VOORZICHTIG: Sluit het ontlastventiel
1. Controleer of alle aansluitingen en verbindingen ALLEEN met de hand. Het gebruik van
van het systeem stevig vastzitten en niet lekken. gereedschap op het ontlastventiel kan
het ventiel beschadigen en storing in de
2. Controleer het oliepeil in het reservoir voordat u pomp veroorzaken.
de pomp gebruikt. Zie "Olie bijvullen in pomp" op
pagina 43. 2. Bedien de pompstang om hydraulische druk over
VOORZICHTIG: Breng NOOIT te brengen op het systeem. De druk blijft
verlengstukken aan op de pompgreep. gehandhaafd totdat het ontlastventiel geopend
Verlengstukken leiden ertoe dat de wordt.
pomp bij bedrijf onstabiel wordt. 3. Open het ontlastventiel (tegen de klok in draaien)
om de druk te ontlasten. De olie stroomt nu terug
WAARSCHUWING: Ga NOOIT vlak naar het reservoir.
boven de pompgreep staan. In
bepaalde situaties kan de pompgreep 5.4 Enkelwerkende toepassingen met
"terugslaan". Houd uw lichaam altijd handbediende 3-weg klep met 2
naast de pomp en uit het bereik van de greep om
standen
lichamelijk letsel te voorkomen.
1. Schakel de ventielhendel in stand 1 zoals in
OPMERKING: Om bij hoge druk de uitgeoefende
afbeelding 7.
kracht op de greep te verminderen, moeten de slagen
kort zijn. De grootste pompwerking wordt verkregen 2. Bedien de pompstang om hydraulische druk over
in de laatste 5 graden van de slag. te brengen op het systeem. De druk blijft
gehandhaafd totdat de stand van het ventiel
5.2 Het gebruik van tweetraps wordt veranderd.
handpompen 3 Schakel de ventielhendel naar stand 2 om de olie
terug te laten stromen naar het reservoir.
Deze pompen voorzien in een lage-en hogedruktrap.
Onbelast werkt de pomp in het eerste trap (lage druk) 2 2
met hoge stromingssnelheid om de ljlgang. Wanneer

er contact gemaakt wordt met de last, schakelt de
pomp automatisch over naar de tweede trap om druk
op te bouwen. Bij P-462 of P-464 moet u even
stoppen met pompen wanneer de pompdruk circa 14
bar (200 psi) bereikt, en de pompstang omhoog
brengen om over te schakelen naar het 1 1
hogedruktrap. Bij P-802 of P-842 moet u even
stoppen met pompen wanneer de pompdruk circa 28
bar (400 psi) bereikt, en de pompstang omhoog
A A
brengen om over te schakelen naar het
hogedruktrap. Nadat de pomp is overgeschakeld,
kost het pompen minder moeite.
OPMERKING: Bedien de pompstang tijdens de
eerste trap met de hoge stromingssnelheid met 1 2
matige snelheid om het beste werkrendement te
verkrijgen. Een hoge snelheid van de greep in het
eerste stadium maakt dat de pomp niet het volledige Afbeelding 7
41
5.5 Dubbelwerkende toepassingen met 2. Bedien de pomp om het werk uit te voeren.
handbediende 4-weg klep met 3 standen 3. Verander de stand van de klep naar behoefte.
Pompen met 4-weg regelkleppen zijn ontworpen om WAARSCHUWING: Bedien de
dubbelwerkende cilinders te bedienen. Zie afbeelding dubbelwerkende cilinder alleen
8 voor de klepstanden. wanneer beide slangen op de pomp zijn
aangesloten. Als één koppelstuk
N onaangesloten blijft, wordt hoge druk opgebouwd
achter het koppelstuk, wat lichamelijk letsel en/of
A B schade aan het apparaat kan veroorzaken.
A B
5.6 Afstellen van het ontlastventiel
Alle pompen hebben een in de fabriek ofgesteld
ontlastventiel om te hoge druk in het systeem te
voorkomen. Lagere drukinstellingen zijn mogelijk.
Neem contact op met uw erkende servicecentrum
van Enerpac.
Afbeelding 8a
A B A B A B 6.0 VERWIJDEREN VAN LUCHT
Het verwijderen van lucht uit het hydraulische
systeem helpt de cilinder soepel uitschuiven en
I
terugtrekken. Zie afbeelding 9.
A N B
6.1 Pomp met enkelwerkende cilinder (A)
Afbeelding 8b 1. Ontlucht het pompreservoir (alleen bij pompen
1. Plaats de hefboom op de 4-weg klep als volgt om met ontluchting) en sluit het ontlastventiel.
de werking te selecteren:
2. Stel de pomp hoger op dan de cilinder.
(A) Stroom naar poort "A"; poort "B" voert de
3. Plaats de cilinder met de plunjer naar beneden
stroom terug naar het reservoir
(omhoog bij gebruik van een trekcilinder). Zie
(N) Neutraal; poort "A" en "B" zijn geblokkeerd afbeelding 9.
(B) Stroom naar poort "B"; poort "A" voert de 4. Bedien de pomp om de cilinder volledig uit te
stroom terug naar het reservoir schuiven (terug te trekken bij gebruik van een
trekcilinder).
5. Open het ontlastventiel om de cilinder terug te
trekken (uit te schuiven als het een trekcilinder
betreft). Hierdoor wordt de opgesloten lucht naar
boven naar het pompreservoir gestuwd.
N 6. Herhaal bovenstaande stappen zonodig.
B 7. Vul zonodig olie bij. Zie pagina 43.
A 8. Zet de ontlucht-/vuldop terug in de bedrijfsstand.
A
B 6.2 Pomp aangesloten op dubbelwerkende
cilinder (B)
1. Ontlucht het pompreservoir (alleen bij pompen
Afbeelding 8c met ontluchting).
lucht
lucht
A B
Figure 9
42
2. Stel de pomp hoger op dan de cilinder.
B, C
3. Zet de cilinder horizontaal met de poorten
omhoog. Zie afbeelding 9. A
4. Laat de cilinder 2 tot 3 keer volledig uitschuiven

en terugtrekken.
5. Herhaal bovenstaande stappen zonodig.
6. Vul zonodig olie bij. Zie pagina 43.
7. Zet de ontlucht-/vuldop terug in de bedrijfsstand.
7.0 ONDERHOUD
Afbeelding 10
Gebruik uitsluitend Enerpac hydraulische olie voor
deze pompen om een lange levensduur voor de 7.4 Olie verversen
pompen te bevorderen en uw garantie te
1. Tap om de 12 maanden alle olie af en vul de pomp
beschermen. Viton en EPR afdichtingssets zijn
met schone Enerpac olie. Ververs de olie vaker als
verkrijgbaar voor sommige handpompen. Neem
de pomp in een vuile omgeving wordt gebruikt.
contact op met uw Enerpac vertegenwoordiger voor
meer informatie over deze produkten en de 2. Neem de ontlucht-/vuldop of -stop van het
toepassingen ervan. reservoir.
3. Houd de pomp schuin om de oude olie eruit te
7.1 Olie bijvullen in de pomp laten lopen.
Controleer het oliepeil regelmatig. 4. Vul het reservoir niet hoger dan tot het peilteken
op de pomp.
WAARSCHUWING: Vul altijd olie bij met 5. Breng de ontlucht-/vuldop of -stop weer aan.
de cilinders volledig teruggetrokken
(uitgeschoven wanneer het trekcilinders 6. VOER GEBRUIKTE OLIE OP DE JUISTE WIJZE
betreft), anders komt er meer olie in het AF.
systeem dan het reservoir kan bevatten.
1. Neem de ontlucht-/vuldop van het reservoir. 8.0 PROBLEMEN OPLOSSEN
2. Vul het reservoir niet hoger dan het peilteken op
de pomp. De volgende informatie is bedoeld om te helpen
bepalen of er sprake van een probleem is. Zie pagina
3. Verwijder zonodig de lucht uit het systeem. Zie
44. Neem voor reparatieservice contact op met het
pagina 42. Controleer het oliepeil opnieuw nadat
erkende servicecentrum van Enerpac in uw gebied.
de lucht verwijderd is.
4. Breng de ontlucht-/vuldop weer in de juiste stand.
OPMERKING: Handpompen zonder ontluchting
hebben lucht nodig in het reservoir om goed te
kunnen werken. Als het reservoir volledig gevuld
is, wordt er een vacuüm gevormd, waardoor olie
niet uit de pomp kan stromen.
7.2 Schoonhouden van de olieleidingen

Schroef altijd stofdoppen op losgekoppelde
koppelstukken. Voer alle voorzorgsmaatregelen uit
om het apparaat te beschermen tegen
binnendringend vuil, ter voorkoming von storing in
pomp, cilinder en ventiel.
7.3 Smeren van de pomp

Om de levensduur van de pomp te verlengen en de
prestaties te verbeteren, moeten de draagpen (A),
dwarspen (B) en zuigerkop (C) regelmatig met
rollagervet worden gesmeerd. Zie afbeelding 10.
43
PROBLEMEN OPLOSSEN
Probleem Mogelijke Oorzaak Oplossing
Cilinder schuift niet, 1. Oliepeil in pompreservoir is te laag. 1. Vul olie bij volgens de onderhoudsinstructies op pagina 43.
langzaam of onregelmatig 2. Ontlastventiel open. 2. Sluit het ontlastventiel.
uit. 3. Hydraulisch koppelstuk is los. 3. Controleer of alle koppelstukken goed vastzitten.
4. Belasting is te hoog. 4. Probeer niet een grotere last te heffen dan de toelaatbare last.
5. Lucht opgesloten in systeem. 5. Verwijder de lucht volgens de instructies op pagina 42.
6. Plunjer klemt in cylinder. 6. Controleer de cilinder op schade. Laat de cilinder door een
bevoegd hydrauliek technicus repareren.
Cilinder schuift uit, maar 1. Cilinder schuift uit, maar blijft niet op 1. Controleer of alle verbindingen dicht zihn en niet lekken.
blijft niet op druk. druk. 2. Spoor lek(ken) op en laat het apparaat door een bevoegd
2. Lekkende afdichtingen. hydrauliek technicus repareren.
3. Inwendige lekkage in pomp. 3. Laat de pomp door bevoegde hydraulische technicus repareren.
Cilinder trekt niet, 1. Ontlastventiel dicht. 1. Open het ontlastventiel.

gedeeltelijk of langzamer 2. Pompreservoir is te vol. 2. Pompreservoir is te vol. Tap olie af tot volmerkteken. Zie instructies
terug dan normaal. 3. Hydraulisch koppelstuk is los. voor bijvullen van olie op pagina 43.
4. Lucht opgesloten in het systeem. 3. Controleer of alle koppelstukken goed vastzitten.
5. Slangbinnendiameter te klein. 4. Verwijder lucht volgens instructies op pagina 42.
6. Cilinderterugtrekveer gebroken of 5. Gebruik slang met grotere diameter.
andere schade aan cilinder. 6. Laat de cilinder door bevoegde hydraulische technicus repareren.
44
Folha de Instruções
Bombas Hidráulicas Manuais

L1763 Rev I 12/05
Folhas de Instrução para este produto estão

disponíveis no Site de Enerpac - www.enerpac.com,
ou no Centro de Serviço Autorizado mais próximo,
ou com o Escritório de Vendas Enerpac.
1.0 INSTRUÇÕES IMPORTANTES NO

RECEBIMENTO
Inspecione visualmente todos os componentes
verificando se houve avarias durante o transporte.
Avarias no transporte não são cobertas pela garantia.
Caso haja avarias no transporte, avise o
transportador imediatamente. O transportador é
responsável por todos os custos de consertos e ADVERTÊNCIA: Mantenha distância de
substituições decorrentes de avarias ocorridas no cargas apoiadas por cilindros hidráulicos.
transporte. Um cilindro, quando utilizado como
dispositivo de levantamento, jamais deve
SEGURANÇA EM PRIMEIRO LUGAR ser usado como dispositivo de sustentação de carga.
Depois de haver sido levantada ou baixada, a carga
2.0 ASSUNTOS DE SEGURANÇA deve sempre ser bloqueada mecanicamente
Leia cuidadosamente todas as ADVERTÊNCIA: USE SOMENTE PEÇAS

instruções, advertências e avisos RÍGIDAS PARA APOIAR AS CARGAS.
®
sobre precaução. Siga todas as ®

Selecione cuidadosamente blocos de
recomendações de segurança para evitar lesões madeira ou ferro que sejam capazes de
pessoais ou danos à propriedade durante a operação sustentar a carga. Nunca use um cilindro hidráulico
do sistema. Enerpac não pode ser responsável por como um calço ou espaçador em qualquer aplicação
danos ou lesões pessoais resultantes do uso de levantamento ou prensagem.
indevido do produto, falta de manutenção ou
operação inadequada do produto e/ou sistema. Entre PERIGO: Para evitar lesões
em contato com Enerpac quando houver dúvidas pessoais mantenha mãos e pés
sobre as recomendações de segurança e operações. longe do cilindro e da área de
Se você nunca recebeu treinamento em segurança trabalho durante a operação.
na hidráulica de alta pressão, consulte o seu ADVERTÊNCIA: Não exceda a capacidade
distribuidor ou centro de serviço sobre um curso de do equipamento. Nunca tente levantar uma
segurança hidráulica Enerpac. carga mais pesada que a capacidade do
Falhas no cumprimento das advertências e avisos de cilindro. Excesso de carga pode causar
precaução podem causar lesões pessoais e avarias falhas no equipamento e possíveis lesões pessoais. Os
ao equipamento. cilindros são projetados para uma pressão máxima de
700 bar [10.000 psi]. Não faça a ligação entre um
PRECAUÇÃO é usada para indicar a operação macaco ou um cilindro com uma bomba com
correta ou os procedimentos e métodos de capacidade maior de pressão.
manutenção para prevenir o dano, a destruição do
equipamento ou outras propriedades. PERIGO: Nunca ajuste uma válvula de
ADVERTÊNCIA indica um perigo potencial que exige alívio com pressão maior que a
procedimentos ou métodos corretivos para evitar capacidade de pressão máxima da
lesões pessoais. bomba. Ajustes maiores podem resultar
em danos ao equipamento e/ou lesões pessoais. Não
PERIGO é usado somente quando a ação ou a falta remova a válvula de alívio.
da mesma podem causar lesões sérias ou mesmo a
morte. ADVERTÊNCIA: A pressão de operação
do sistema não deve exceder a
ADVERTÊNCIA: Use equipamentos capacidade de pressão do componente
individuais de proteção quando acionar de menor capacidade no sistema. Instale
equipamentos hidráulicos. manômetros de pressão no sistema para monitorar a
pressão de operação. É a sua janela para o que está
acontecendo no sistema.
45
PRECAUÇÃO: Evite danificar mangueiras ADVERTÊNCIA: Use somente cilindros
hidráulicas. Evite curvas ou dobras hidráulicos num sistema acoplado. Nunca
pronunciadas quando direcionar as use um cilindro com engates não
mangueiras hidráulicas. O uso de uma conectados. Caso o cilindro se torne
mangueira curvada ou dobrada causará aumento na extremamente sobrecarregado, os componentes
pressão de retorno. Curvas ou dobras pronunciadas podem falhar catastroficamente, causando severas
danificarão a mangueira internamente, levando a um lesões pessoais.
desgaste prematuro.
ADVERTÊNCIA: ESTEJA CERTO QUE A
Não derrube objetos pesados na MONTAGEM É ESTÁVEL ANTES DE
mangueira. Um forte impacto pode LEVANTAR A CARGA. Os cilindros devem
®
®
causar danos à trama interna de aço da ser colocados em superfícies planas que
mangueira. A aplicação de pressão em podem apoiar a carga. Quando aplicável, use uma
uma mangueira danificada pode causar a sua ruptura. base de cilindro Enerpac para aumentar a
estabilidade. Não faça soldas ou, de qualquer forma,
IMPORTANTE: Não levante o modifique o cilindro para acrescentar uma base ou
equipamento hidráulico pela mangueira ou outro apoio.
pelos engates. Use manoplas ou outros
meios mais seguros para o transporte. Evite situações em que as cargas não
estão centradas na haste do cilindro.
PRECAUÇÃO: Mantenha o Cargas fora de centro podem causar
equipamento hidráulico longe do calor e deformações consideráveis nas hastes e
das chamas. O calor excessivo amolece nos cilindros. Além disto, a carga pode escorregar ou
vedações e selos, resultando em cair, causando resultados potencialmente perigosos.
vazamento de fluídos. O calor também enfraquece o
material das mangueiras e das juntas. Para um Distribua a carga uniformemente em toda a
desempenho otimizado não exponha o equipamento a superfície do assento. Use sempre um
temperatura maiores que 65 °C [150 °F]. Proteja assento para proteger a haste.
mangueiras e cilindros dos respingos de solda.
PERIGO: Não manuseie mangueiras IMPORTANTE: Somente técnicos em

pressurizadas. O escape do óleo sob hidráulica, devidamente qualificados,
pressão pode penetrar na pele, causando devem fazer a manutenção de
lesões sérias. Se o óleo penetrar na pele, procure um equipamentos hidráulicos. Para serviços
médico imediatamente. de manutenção, entre em contato com o Centro de
Serviço Autorizado Enerpac em sua área. Para
proteger sua garantia, use somente óleo Enerpac.
ESPECIFICAÇÕES – Use esta folha de instrução para os seguintes modelos de bomba

Especificações das Bombas Manuais
Modelo Tipo Pressão Máxima Volume de óleo por Capacidade utilizável de
(velocidade) Nominal bar [psi] {mPa} bombada cm 3 [pol. 3] óleo cm 3 [pol. 3]
EHF-65 1 6,500 [440] {44} .16 [2.62] 22 [360]
P-18 1 2,850 [200] {20} .16 [2.62] 22 [360]
P-25 1 2,500 [170] {17} .58 [9.51] 231 [3786]
P-39, 1003 1 10,000 [700] {70} .16 [2.62] 43 [705]
P-50 1 5,000 [340] {34} .29 [4.75] 231 [3786]
P-51 1 3,000 [210] {21} .25 [4.09] 50 [820]
P-141, 1001 1 10,000 [700] {70} .055 [.90] 20 [328]
P-391, 1004 1 10,000 [700] {70} .151 [2.47] 55 [900]
Primeiro Segundo Primeiro Segundo

Estágio Estágio Estágio Estágio
P-80, 1006 2 350 [25] {2,5} 10,000 [700] {70} .99 [16.23] .15 [2.46] 140 [2295]
P-84 2 350 [25] {2,5} 10,000 [700] {70} .99 [16.23] .15 [2.46] 140 [2295]
P-142, 1002 2 200 [14] {1,4} 10,000 [700] {70} .221 [3.62] .055 [.90] 20 [328]
P-142AL 2 200 [14] {1,4} 10,000 [700] {70} .221 [3.62] .055 [.90] 9.0 [148]
P-202 2 200 [14] {1,4} 10,000 [700] {70} .221 [3.62] .055 [.90] 55 [900]
P-77 2 200 [14] {1,4} 10,000 [700] {70} .63 [16.0] .094 [2.41] 47 [769]
P-392, 1005 2 200 [14] {1,4} 10,000 [700] {70} .687 [11.26] .151 [2.47] 55 [900]
P-392AL 2 200 [14] {1,4} 10,000 [700] {70} .687 [11.26] .151 [2.47] 55 [900]
P-462 2 200 [14] {1,4} 10,000 [700] {70} 7.69 [126.00] .29 [4.75] 462 [7572]
P-464 2 200 [14] {1,4} 10,000 [700] {70} 7.69 [126.00] .29 [4.75] 462 [7572]
P-801 2 350 [25] {2,5} 10,000 [700] {70} .99 [16.23] .15 [2.46] 250 [4095]
P-802 2 400 [28] {2,8} 10,000 [700] {70} 2.40 [39.34] .15 [2.46] 155 [2540]
P-842 2 400 [28] {2,8} 10,000 [700] {70} 2.40 [39.34] .15 [2.46] 155 [2540]
46
ADVERTÊNCIA: Substitua imediatamente 3.2 Modelos P-18/P-39, 1003/P-80, 1006/P-
peças gastas ou danificadas por peças 84/P-801, P-77
genuínas Enerpac. Peças não genuínas podem
quebrar, causando lesões pessoais ou danos à Figura 2 e a tabela correspondente mostram os
propriedade. As peças Enerpac são projetadas para se principais componentes destas bombas manuais. A
encaixar adequadamente e sustentar cargas pesadas. bomba P-84 é equipada com válvula de 4-vias, 3-
posições para uso com cilindro de dupla ação. Para
PRECAUÇÃ0: Use sempre a alavanca para transformar as bombas P-18 ou P-39 em modelos de
carregar a bomba. Carregar a bomba pela acionamento por pedal, adquira o Kit Pc-10.
mangueira pode danificar a mangueira e/ou
a bomba. A
3.0 DESCRIÇÃO B
A
3.1 Modelos P-141, 1001; P-142, 1002; P-202;
P-391, 1004; P-392, 1005; P-802; P-842
A figura 1 e a tabela correspondente mostram os
principais componentes das bombas manuais P-141,
P-142, P-202, P-391, P-392, P-802, e P-842. A
função dupla da tampa de respiro/abastecimento D B
atua como uma válvula de alívio de pressão no caso
de pressurização acidental do reservatório. Para ter B
acesso à saída posterior do reservatório para as C
válvulas de montagem à distância, use o conjunto
retorno para reservatório. Consulte a Tabela 1 para
os modelos dos conjuntos.
Figure 2
AVISO: Estas bombas são acionadas

A com um reservatório sem respiro. Se o
A
B reservatório for submetido à alta
E B
pressão, poderá ocorrer ruptura,
causando lesões pessoais e/ou danos ao
P842 equipamento. NUNCA tente fazer retornar mais
óleo para o reservatório do que a capacidade do
equipamento.
C
B
D
Figura 1
Tabela 1
Fig. 1 P-141, 1001 P-142, 1002 P-202 P-391, 1004 P-392, 1005 P-802 P-842
A Válvula Válvula Válvula Válvulae Válvula Válvula Válvula
de alivio de alivio de alivio de alivio de alivio de alivio de 4 vias
B 1/4 NPTF Saída 1/4 NPTF Saída 1/4 NPTF Saída 3/8 NPTF Saída 3/8 NPTF Saída 3/8 NPTF Saída 3/8 NPTF Saída
de Pressão de Pressão de Pressão de Pressão de Pressão de Pressão de Pressão
C Tampa de Respiro/ Tampa de Respiro/ Tampa de Respiro/ Tampa de Respiro/ Tampa de Respiro/ Tampa de Respiro/ Tampa de Respiro/
abastecimento abastecimento abastecimento abastecimento abastecimento abastecimento abastecimento
D Montagem Furo — — — Furo Furo
alongado alongado alongado
E — — — — — Conjunto de retorno —
reservatório
Conjunto de PC-20 PC-20 PC-25 PC-25 PC-25 — —
-retorno ao
reservatório
Tabela 2
Fig. 2 P-18 P-39, 1003 P-77 P-80, 1006 P-84 P-801
A Válvula Válvula Válvula Válvula Válvula Válvula
de alivio de alivio de alivio de alivio de alivio de alivio
B 3/8 NPTF Saída 3/8 NPTF Saída 3/8 NPTF Saída 3/8 NPTF Saída 3/8 NPTF Saída 3/8 NPTF Saída
de Pressão de Pressão de Pressão de Pressão de Pressão de Pressão
C Bujão de Bujão de Bujão de Bujão de Bujão de Bujão de
abastecimento abastecimento abastecimento abastecimento abastecimento abastecimento
D — — — 1/4 NPTF Conjunto de — 1/4 NPTF Conjunto de
retorno reservatório retorno reservatório
47
3.3 Modelos P-462 and P-464 4.0 INSTALAÇÃO
Figura 3 e a tabela correspondente mostram as
principais características da bomba manual P462 4.1 Conectando a Bomba
para uso com cilindro de simples ação, e da bomba 1. Rosqueie a mangueira na saída da bomba. Use
P-464, para uso com cilindro de dupla ação. uma ou duas voltas de fita Teflon, (ou selante
apropriado para rosca) na conexão da mangueira,
C
deixando o primeiro filete completamente livre
para garantir que pedaços de fita não entrem no
D sistema hidráulico, causando danos. Corte as
pontas soltas.
B
2. Instale o manômetro na linha da bomba para
maior segurança e melhor controle.
A 3. Conecte a mangueira(s) no cilindro ou ferramenta.
NOTA: Para cilindros de simples ação, conecte
uma mangueira entre a bomba e o cilindro. Para
P-462/464F3
cilindros de dupla ação, conecte duas mangueiras.

Conecte uma mangueira entre a conexão de
pressão da bomba e a conexão avanço do.
Figure 3, Modelos P-462, P-464 4.2 Sangria de ar da Bomba
Tabela 3
Consulte a tabela abaixo para determinar se a bomba
Fig. 3 P-462 P-464
A Válvula de 2-posições e 3-vias Válvula de 3-posições e 4-vias
pode ou não ser acionada com um reservatório com
B Saída de pressão 3/8 NPTF Saída de pressão 3/8 NPTF respiro. Bombas com respiro apresentam um melhor
C Bujão de respiro/abastecimento Bujão de respiro/abastecimento desempenho. Para bombas com reservatório de
D Grampo da alavanca Grampo da alavanca plástico, gire o bujão de respiro/abastecimento em _
de volta no sentido horário para sangria. Para outras
3.4 Modelos P-25, P-50, and P-51 bombas, consulte a etiqueta colada na bomba. Feche
o respiro antes de transportar a bomba para evitar
Figura 4 mostra as bombas manuais P-25 e P-50, vazamento de óleo. P-80, P-801 e P-84 são ventiladas,
ambas equipadas com alavanca que trabalha nos girando-se a válvula de alívio no sentido anti-horário.
dois sentidos. Figura 5 mostra a bomba manual P- Para fechar o respiro, gire a válvula no sentido horário.
51. Os principais componentes destas bombas são
listados na tabela abaixo. OPCÕES DE RESPIRO
EHF-65 . . . . . . . . Sem respiro P-202 . . . . . . . . . . . . . ambos

P-18 . . . . . . . . . . Sem respiro P-391, 1004. . . . . . . . . ambos
P-25 . . . . . . . . . . . . . . ambos P-77 . . . . . . . . . . . . . . respiro
P-39, 1003 . . . . . Sem respiro P-392, 1005 . . . . . . . . ambos
C
P-50 . . . . . . . . . . . . . . ambos P-392AL . . . . . . . . . . . respiro
A P-51 . . . . . . . . . . . . . . respiro P-462 . . . . . . . . . . . . . respiro
B P-80, 1006. . . . . . . . . . ambos P-464 . . . . . . . . . . . . . respiro
P-84 . . . . . . . . . . . . . . ambos P-801 . . . . . . . . . Sem respiro
P-141, 1001. . . . . . . . . ambos P-802 . . . . . . . . . . . . . ambos
P-142, 1002. . . . . . . . . ambos P-842 . . . . . . . . . . . . . ambos
P-142AL . . . . . . . Sem respiro
4.3 Posicionamento da Bomba

Consulte a tabela abaixo para determinar o
Figure 4, Bombas P-25, P-50 e P-51 posicionamento horizontal ou vertical de sua bomba
P-80, P-801 e P-84 não podem ser ventiladas,
quando acionadas verticalmente.
C
A POSICIONAMENTO DE
OPERAÇÃO
EHF-65 . . . . . . . . . . . . ambos
B P-18 . . . . . . . . . . . . . . . ambos P-202 . . . . . . . . . . . . . ambos
P-25 . . . . . Somente Horizontal P-391, 1004 . . . . . . . . ambos
P-39, 1003 . . . . . . . . . . ambos P-77 . . . . . . . . . . . . . . ambos
P-50 . . . . . Somente Horizontal P-392, 1005 . . . . . . . . . ambos
P-51F5
P-51 . . . . . Somente Horizontal P-392AL. . . . . . . . . . . . ambos

P-80, 1006 . . . . . . . . . ambos P-462 . . . Somente Horizontal
Figura 5, Bomba P-51 P-84 . . . . . . . . . . . . . . . ambos P-464 . . . Somente Horizontal
P-141, 1001 . . . . . . . . . ambos P-801 . . . . . . . . . . . . . ambos
Tabelas 4 e 5 P-142, 1002 . . . . . . . . . ambos P-802 . . . . . . . . . . . . . . ambos
P-142AL . . . . . . . . . . . ambos P-842 . . . . . . . . . . . . . ambos
Fig. 4 e 5 P-25, P-50, P-51
A Válvula de alívio
B 1/4 NPTF Saída de pressão NOTA: Quando a bomba estiver funcionando na
C Bujão de respiro/abastecimento posição vertical, a ponta na qual a mangueira está
conectada, deve estar virada para baixo, ou haverá sucção
de ar, e a bomba não atingirá a pressão adequada.
48
5.0 OPERAÇÃO 2. Acione a alavanca para liberar força hidráulica no
sistema. A pressão será mantida até que a válvula
5.1 Antes de Usar a Bomba de alívio seja aberta.
3. Abra a válvula de alívio (gire sentido anti-horário)
1. Verifique todas as conexões para garantir que elas para liberar a pressão, permitindo que o óleo
estão apertadas e sem vazamento. retorne para o reservatório.
2. Verifique o nível de óleo do reservatório antes de
acionar a bomba. Consulte "adicionando óleo na 5.4 Aplicações de Simples Ação com Válvula
bomba" na página 7. Manual de 3 vias e 2 posições
PRECAUÇÃO: NUNCA acrescente 1. Mude a alavanca da válvula para a posição 1 como
extensões na alavanca da bomba.
mostrado na Figura 7.
Extensões podem causar instabilidade
no funcionamento da bomba. 2. Acione a alavanca para liberar força hidráulica no
sistema. A pressão será mantida até que seja
ADVERTÊNCIA: Em certas situações a mudada a posição da válvula.
alavanca da bomba pode "retornar
3. Para permitir que o óleo retorne para o reservatório,
inesperadamente". Mantenha sempre
mude a alavanca da válvula para a posição 2.
seu corpo ao lado da bomba, longe da
linha de movimento da alavanca. 2 2
NOTA: Para reduzir o esforço da alavanca em alta

pressão, acione com bombadas curtas. A ação máxima
da alavanca é obtida nos últimos 5° do curso.
5.2 Usando Bombas de Duas Velocidades 1 1
Estas bombas fornecem dois estágios de fluxo.

Quando não há carga, a bomba funciona no primeiro
A A
estágio de alta vazão para um avanço rápido. Quando
a carga é atingida, a bomba automaticamente passa
para o segundo estágio para atingir a pressão. Nas
bombas P-462 ou P464, quando a pressão na bomba
2
atinge aproximadamente 14 bar [200 psi] você deve, 1
momentaneamente, parar o bombeamento e levantar

a alavanca, mudando para o estágio de alta pressão. Figura 7
Nas bombas P-802 ou P842, quando a pressão
atingir aproximadamente 28 bar [400 psi], você deve, 5.5 Aplicações de Dupla Ação com Válvula
momentaneamente, parar o bombeamento e levantar Manual de 4 vias e 3 posições
a alavanca, mudando para o estágio de alta pressão. Bombas com válvula de controle de 4-vias são
Após a mudança de estágio de pressão, o projetadas para acionar cilindros de ação dupla.
bombeamento requer menos esforço. Consulte Figura 8 para posições da válvula.
NOTA: Para melhor desempenho, acione a alavanca
da bomba em velocidade moderada no estágio de alta N
vazão. Movimentos rápidos da alavanca no primeiro
estágio evitam a liberação de todo o volume de óleo. A B
5.3 Aplicações de Simples Ação com

A B
Válvula de alívio
1. Feche a válvula de alívio girando-a no sentido
horário como mostrado na Figura 6.
Figura 8a
A B A B A B
Figura 6 I
A N B
PRECAUÇÃO: Feche a válvula de alívio
SOMENTE com aperto dos dedos. Uso de
ferramentas na válvula de alívio pode danificá- Figura 8b
la e causar mau funcionamento na bomba.
49
1. Posicione a alavanca da válvula de 4 vias para 4. Acione a bomba para distender completamente o
selecionar as funções conforme abaixo: cilindro (faça-o retornar, ao usar cilindro de atracação).
(A) Fluxo da saída "A"; saída "B" o fluxo retorna 5. 5Abra a válvula de alívio para que o cilindro retorne
para o reservatório (faça-o distender, ao usar cilindro de atracação). Isto
(N) Neutro, saídas "A" e "B" estão bloqueadas forçará o movimento do ar preso para o reservatório
da bomba.
(B) Fluxo para a saída "B"; saída "A" retorna o
fluxo para o reservatório 6. Repita os passos acima tantas vezes quanto for
necessário.
7. Adicione óleo caso haja necessidade. Veja página 7.
8. Retorne o bujão de respiro/abastecimento para a
posição de acionamento.
N 6.2 Bomba com cilindro de Dupla Ação (B)

B 1. Abra o respiro do reservatório da bomba
A
A (somente para bombas com respiro).
B 2. Coloque a bomba em posição mais alta que o
cilindro.
3. Coloque o cilindro em posição horizontal com as
Figure 8c saídas voltadas para cima. Consulte Figura 9.
2. Acione a bomba para executar o trabalho. 4. Faça o cilindro avançar e retornar por 2 a 3 vezes.
3. Mude as posições da válvula conforme necessário. 5. Repita os passos acima tantas vezes quanto for
necessário.
ADVERTÊNCIA: Acione o cilindro de
dupla ação somente quando ambas as 6. Adicione óleo caso haja necessidade. Consulte
mangueiras estiverem conectadas na §7.1.
bomba. Se um engate não estiver 7. Retorne o bujão de respiro/abastecimento para a
conectado, haverá aumento de alta pressão por posição de acionamento.
trás do mesmo, o que pode causar lesões
pessoais e/ou danos no equipamento. 7.0 MANUTENÇÃO
Use somente óleo Enerpac com estas bombas para
5.6 Ajuste da válvula de Alívio assegurar uma vida longa e proteção da garantia.
Todas as bombas são fornecidas com a válvula de Vedações de Viton e EPR estão disponíveis para
alívio pré-ajustada de fábrica para evitar excesso de algumas bombas manuais. Contate o representante
pressão no sistema. Ajustes menores de pressão Enerpac para maiores informações sobre produtos e
podem ser obtidos. Entre em contato com o Centro suas aplicações.
de Serviço Enerpac Autorizado.
7.1 Adicionando óleo na bomba
6.0 SANGRANDO O AR Verifique regularmente o nível de óleo.
A remoção do ar do sistema hidráulico ajuda nas ADVERTÊNCIA: Sempre adicione óleo
operações de avanço e retorno do cilindro (Consulte com o cilindro totalmente retraído
Figura 9). (distendido no caso do cilindro de
atracação) ou o sistema terá mais óleo
6.1 Bomba com Cilindro de Simples Ação (A) que a capacidade do reservatório.
1. Abra o respiro do reservatório da bomba (somente 1. Remova o bujão de respiro/abastecimento do
para bombas com respiro) e feche a válvula de alívio. reservatório.
2. Coloque a bomba em posição mais alta que o cilindro. 2. Encha o reservatório somente até o nível indicado
3. Coloque o cilindro com a haste virada para baixo na bomba.
(virada para cima no caso de cilindro de atracação). 3. Remova o ar do sistema, se necessário. Consulte
Consulte Figura 9 abaixo. página 6. Verifique novamente o nível de óleo
após a remoção do ar.
ar
ar
A B
Figure 9
50
4. Retorne o bujão de respiro/abastecimento à 2. Remova o bujão de respiro/abastecimento do
posição apropriada. reservatório.
NOTA: Bombas manuais sem respiro necessitam 3. Incline a bomba para drenar o óleo antigo.
de ar no reservatório para funcionar 4. Encha o reservatório somente até o nível indicado
adequadamente. Se o reservatório estiver na bomba.
completamente cheio, haverá formação de vácuo
5. Reponha o bujão de respiro/abastecimento.
evitando que o óleo saia da bomba.
6. Disponha, adequadamente, do óleo usado.
7.2 Mantenha as Linhas de Óleo Limpas
Quando as duas metades dos engates estiverem 8.0 SOLUÇÕES DE PROBLEMAS
desconectadas, utilize sempre a tampa guarda-pó
contra sujeira e poeira. Use todos os cuidados A seguinte informação deve ajudar na determinação
necessários para evitar a entrada de sujeira, uma vez de um problema, caso ele exista. Para serviços de
que elementos externos podem causar falhas na manutenção, entre em contato com o Centro de
bomba, no cilindro ou na válvula. Serviço Enerpac Autorizado de sua região.
7.3 Lubrificando a Bomba

Para prolongar a vida e melhorar o desempenho da
bomba, lubrifique os pinos (A) e (B) e a cabeça do
pistão (C) regularmente, usando graxa apropriada
para rolamentos. Consulte Figura 10.
B, C
Figura 10
7.4 Trocando o óleo
1. Drene todo o óleo e encha com óleo Enerpac
limpo a cada 12 meses. Se a bomba é utilizada
em um ambiente sujo, troque o óleo com mais
freqüência.
SOLUÇÕES DOS PROBLEMAS

Problema Causa Possível Solução
Cilindro não avança, avança 1. O nível de óleo no reservatório 1. Adicione óleo conforme as instruções de manutenção na página 50.
vagarosamente, ou avança da bomba está muito baixo. 2. Feche a válvula de alívio
aos trancos 2. Válvula de alívio está aberta. 3. Verifique se todos os engates estão totalmente apertados.
3. Conexão hidráulica está solta. 4. Não tente levantar carga maior que a capacidade nominal do
4. Carga está acima da capacidade cilindro
nominal do cilindro 5. Sangre o ar conforme as instruções na página 50.
5. Existe ar preso no sistema 6. Verifique se há avarias no cilindro. Faça com que o cilindro seja
6. Atrito na haste do cilindro consertado por um técnico qualificado em hidráulica.
Cilindro avança, mas não 1. Conexão com vazamento 1. Verifique se todos as conexões estão apertadas e sem vazamento.
sustenta a pressão. 2. Vedações com vazamento 2. Localize o vazamento(s) e faça com que o equipamento seja
3. Bomba com vazamento interno consertado por um técnico qualificado em hidráulica
3. Faça com que a bomba seja consertada por um técnico qualificado
em hidráulica
Cilindro não retorna, retorna 1. Válvula de alívio fechada 1. Abra a válvula de alívio
parcialmente ou retorna mais 2. Reservatório da bomba está 2. Drene o nível de óleo até a marca "full" (cheio). Consulte as
lentamente que o normal. cheio demais instruções na página 51 para acrescentar óleo.
3. Engate hidráulico está solto. 3. Verifique se todos os engates estão totalmente apertados.
4. Existe ar preso no sistema 4. Remova o ar conforme as instruções na página 50.
5. Diâmetro interno da mangueira 5. Use mangueiras hidráulicas com diâmetro maior
muito estreito 6. Faça com que o cilindro seja consertado por um técnico qualificado
6. Mola de retorno quebrada no em hidráulica.
cilindro de retração ou outra
avaria no cilindro
51
L1763 Rev I 12/05
®
®
52
sman eps
®
EHF-65 1 6,500 [440] .16 [2.62] 22 [360]

P-18 1 2,850 [200] .16 [2.62] 22 [360]
P-25 1 2,500 [170] .58 [9.51] 231 [3786]
P-39, 1003 1 10,000 [700] .16 [2.62] 43 [705]
P-50 1 5,000 [340] .29 [4.75] 231 [3786]
P-51 1 3,000 [210] .25 [4.09] 50 [820]
P-141, 1001 1 10,000 [700] .055 [.90] 20 [328]
P-391, 1004 1 10,000 [700] .151 [2.47] 55 [900]
P-80, 1006 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 140 [2295]
P-84 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 140 [2295]
P-142, 1002 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 20 [328]
P-142AL 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 9.0 [148]
P-202 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 55 [900]
P-77 2 200 [14] 10,000 [700] .63 [16.0] .094 [2.41] 47 [769]
P-392, 1005 2 200 [14] 10,000 [700] .687 [11.26] .151 [2.47] 55 [900]
P-392AL 2 200 [14] 10,000 [700] .687 [11.26] .151 [2.47] 55 [900]
P-462 2 200 [14] 10,000 [700] 7.69 [126.00] .29 [4.75] 462 [7572]
P-464 2 200 [14] 10,000 [700] 7.69 [126.00] .29 [4.75] 462 [7572]
P-801 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 250 [4095]
P-802 2 400 [28] 10,000 [700] 2.40 [39.34] .15 [2.46] 155 [2540]
P-842 2 400 [28] 10,000 [700] 2.40 [39.34] .15 [2.46] 155 [2540]
53
A
B
A
A
A
B D B
E B
B
P842 C
B
D
54
B
C
P-462/464F3
A
D
C
A
B
55
B
P-51F5
A
C
2 2
1 1
A A
1 2
56
N
A B
A B N
B
A
A
B
A B A B A B
A N B
A B
57
B, C
58
L1763 Rev I 12/05
®
®
®
sman eps
59
A
B
A
A
A
B
D B
E B
B
P842
C
B
D
60
P-462/464F3
B
C
A
D
C
A
B
61
B
P-51F5
A
C
2 2
1 1
A A
1 2
A B
A B
A B A B A B
A N B
62
N
B
A
A
B
B, C
A B
63
64
Instruktionsblad - Svenska
Hydrauliska handpumpar
L1763 Svenska Rev I 12/05
Reservdelar till den här produkten finns tillgängliga på
Enerpacs webbsida på adressen www.enerpac.com, eller hos
din närmaste auktoriserade återförsäljare för Enerpac eller på
Enerpacs försäljningskontor.
1.0 VIKTIGA INSTRUKTIONER FÖRE ANVÄNDNING

Gör en visuell undersökning av alla komponenter för att se
eventuella transportskador. Transportskador täcks inte av
garantin. Om du upptäcker en transportskada skall du
omedelbart informera leverantören. Leverantören ansvarar för
alla kostnader för reparationer och byten som uppstår på
grund av transportskada.
SÄKERHET FARA: Håll händer och fötter på behörigt

avstånd från cylinder och arbetsstycke för att
2.0 SÄKERHETSFRÅGOR undvika personskada vid användningen.
Läs samtliga instruktioner, varningar
och meddelanden noggrant. Följ VARNING: Överskrid inte utrustningens
samtliga säkerhetsföreskrifter för att märkningsuppgifter. Försök aldrig lyfta en last
undvika personskada eller skada på egendom under som väger mer än cylindern klarar.
användningen. Enerpac ansvarar inte för skador som uppstår Överbelastning orsakar skada på utrustningen
på grund av oaktsam användning, brist på underhåll eller och möjlig personskada. Cylindrarna är utformade för ett
felaktig användning och/eller systemhantering. Kontakta maximalt tryck på 700 bar [10 000 psi]. Anslut inte ett uttag
Enerpac om du är osäker på något som gäller eller en cylinder till en pump med högre tryckmärkning.
säkerhetsanvisningarna och hanteringen. Kontakta
återförsäljaren för att få en säkerhetsutbildning kostnadsfritt för FARA: Ställ aldrig in en tryckbegränsningsventil
Enerpacs hydraulik, om du aldrig tidigare har fått utbildning i till ett högre tryck än det maximala tryck som
hydraulisk säkerhet för högtryckslösningar. anges för pumpen. Högre inställningar kan leda
Om du underlåter att följa anvisningarna och varningarna kan till skada på utrustningen och/eller personskada.
det leda till skada på utrustningen eller personskada. Avlägsna inte tryckbegränsningsventilen.
Ett OBS-meddelande används för att indikera korrekta drifts- VARNING: Systemets arbetstryck får inte
och underhållsprocedurer för att förhindra skada på överskrida den komponent som har det lägsta
utrustningen eller egendom. märktrycket i systemet. Installera tryckmätning i
En VARNING indikerar en potentiell fara som kräver korrekta systemet för att övervaka arbetstrycket. Detta är
metoder eller övningar för att undvika personskada. din möjlighet att få inblick i vad som händer i systemet.
FARA används endast om du riskerar allvarlig personskada
eller till och med livet på grund av en åtgärd eller brist på OBS! Undvik att skada den hydrauliska slangen.
åtgärd. Undvik skarpa böjar och att slangarna snor sig
VARNING: Använd rätt skyddsutrusning när du när du drar dem. Om du använder en böjd eller
hanterar hydrauliska utrustningar. snodd sladd kan det orsaka högt baktryck.
Skarpa böjar och öglor skadar slangen invändigt, vilket leder
till att den går sönder i förväg.
VARNING: Håll dig på avstånd från last som drivs
med hydraulik. En cylinder som används som en Tappa inte tunga föremål på slangen. Om du gör
enhet för lyft av last skall aldrig användas som en ®
det kan det leda till invändiga skador på slangens
enhet för hållning av last. Efter att lasten har höjts linor. Om det anläggs tryck på en skadad slang
eller sänkts måste den spärras mekaniskt. kan det leda till att slangen går av.
VARNING: ANVÄND ENDAST FASTA DELAR VIKTIGT: Lyft inte den hydrauliska utrustningen i
FÖR ATT HÅLLA LASTEN. Välj noggrant ut block slangarna eller kopplingarna. Använd ett handtag
®
av stål eller trä som klarar av att stödja lasten. eller något annat transportsätt.
Använd aldrig en hydraulcylinder som mellanlägg i någon lyft-
eller trycktillämpning.
65
OBS! Förvara den hydrauliska utrustningen på Fördela lasten jämnt över hela sadelns yta.
behörigt avstånd från hög värme. Överdriven Använd alltid en sadel för att skydda kolven.
värme kan leda till att packningar och tätningar
mjukas upp och att vätska läcker ut. Värmen försvagar även
slangen och packningarna. För optimal prestanda skall
utrustningen inte utsättas för temperaturer på 65 °C [150 °F] VIKTIGT: Hydraulisk utrustning får endast
eller högre. Skydda slangar och cylindrar från svetsloppor. underhållas av en hydraulisk fackman. Kontakta
dit närmaste auktoriserade ENERPAC Service
FARA: Hantera inte slangar med tryck. Olja som Center för reparation och underhåll. Använd
läcker ut under tryck kan penetrera huden, vilket endast ENERPAC-olja för att skydda garantin.
kan orsaka allvarlig skada. Om oljan skulle
penetrera huden skall du omedelbart uppsöka läkare. VARNING: Ersätt slitna eller skadade delar
omedelbart med ENERPACS originaldelar. Andra
VARNING: Använd hydraulcylindrar i ett inkopplat delar kan gå sönder och orsaka personskada eller
system. Använd aldrig en cylinder med oanslutna skada på egendom. ENERPACS delar är
kopplingar. Om cylindrarna överbelastas kan utformade för att passa perfekt och stå emot höga
komponenterna gå söner med katastrofalt resultat, belastningar.
vilket kan orsaka allvarligpersonskada. OBS! Använd alltid handtaget för att bära
pumpen. Om du bär pumpen i slangen kan det
VARNING: SÄKERSTÄLL ATT leda till skada på slangen och/eller pumpen.
INSTALLATIONEN ÄR STABIL INNAN NÅGON
®
LAST LYFTES. Cylindrar bör placeras på en plan

yta som stöder lasten. Använd vid behov en
bottenplatta för extra stabilitet. Utför inga svetsarbeten eller
andra modifieringar för att montera cylindern till en
bottenplatta eller annat stöd.
Undvik situationer där lasten inte är direkt

centrerad mot cylinderkolven. Last som inte är
centrerad orsakar avsevärd belastning på
cylindrar och kolvar. Dessutom kan lasten halka eller ramla av,
vilket kan leda till allvarliga skador.
SPECIFICATIONER – Använd instruktionskortet för följande handpumpmodeller.

Specifikationer för handpumpar
Modell Typ Maximalt tryck Oljevolym per slag Oljevolym
(Hastighet) Märkning psi [bar] in3 [cm3] in3 [cm3]
EHF-65 1 6,500 [440] .16 [2.62] 22 [360]
P-18 1 2,850 [200] .16 [2.62] 22 [360]
P-25 1 2,500 [170] .58 [9.51] 231 [3786]
P-39, 1003 1 10,000 [700] .16 [2.62] 43 [705]
P-50 1 5,000 [340] .29 [4.75] 231 [3786]
P-51 1 3,000 [210] .25 [4.09] 50 [820]
P-141, 1001 1 10,000 [700] .055 [.90] 20 [328]
P-391, 1004 1 10,000 [700] .151 [2.47] 55 [900]
1:a steget 2:a steget 1:a steget 2:a steget

P-80, 1006 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 140 [2295]
P-84 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 140 [2295]
P-142, 1002 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 20 [328]
P-142AL 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 9.0 [148]
P-202 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 55 [900]
P-77 2 200 [14] 10,000 [700] .63 [16.0] .094 [2.41] 47 [769]
P-392, 1005 2 200 [14] 10,000 [700] .687 [11.26] .151 [2.47] 55 [900]
P-392AL 2 200 [14] 10,000 [700] .687 [11.26] .151 [2.47] 55 [900]
P-462 2 200 [14] 10,000 [700] 7.69 [126.00] .29 [4.75] 462 [7572]
P-464 2 200 [14] 10,000 [700] 7.69 [126.00] .29 [4.75] 462 [7572]
P-801 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 250 [4095]
P-802 2 400 [28] 10,000 [700] 2.40 [39.34] .15 [2.46] 155 [2540]
P-842 2 400 [28] 10,000 [700] 2.40 [39.34] .15 [2.46] 155 [2540]
66
3.0 BESKRIVNING 3.2 Modeller P-18/P-39, 1003/P-80, 1006/
3.1 Modeller P-141, 1001; P-142, 1002; P-84/P-801, P-77
P-202; P-391, 1004; P-392, 1005; P-802; P-842 Bild 2 och överensstämmande tabell visar
Bild 1 och korresponderande tabell visar huvudkomponenterna för dessa modeller av handpumpar.
huvudkomponenterna för handpumpmodellerna P-141, P- Modell P-84 är utrustad med en 4-vägs, 3-positionsventil för
142, P-202, P-391, P-392, P-802 och P-842. Den användning med dubbelverkande cylindrar. Beställ satsen
dubbelverkande ventilen verkar som tryckbegränsningsventil PC-10 för att omvandla modellerna P-18 eller P-39 till
vid tryck i behållaren. Använd en sats för Återgång-till-tank för fotmanövrerade modeller.
att erbjuda en åtkomstport för ventilerna till den bakre delen
av behållaren. Se tabell 1 för satsernas modellnummer.
A
B
A
A
B
E B
P842
D B
C
B
C
B
D
Bild 1 Bild 2
VARNING: De här pumparna drivs med en

ventillös behållare. Om behållaren utsätts för
högt tryck kan det leda till bristningar, vilket
kan orsaka personskada och/eller skada på
utrustningen. Försök ALDRIG att fylla på mer olja i
behållaren än den har kapacitet för.
Tabell 1
Fig. 1 P-141, 1001 P-142, 1002 P-202 P-391, 1004 P-392, 1005 P-802 P-842
A Avlastningsventil Avlastningsventil Avlastningsventil Avlastningsventil Avlastningsventil Avlastningsventil 4-vägsventil
B 1 /4 NPTF 1 /4 NPTF 1 /4 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF
Utloppsöppning Utloppsöppning Utloppsöppning Utloppsöppning Utloppsöppning Utloppsöppning Utloppsöppning
C Lufthål/Tank- Lufthål/Tank- Lufthål/Tank- Lufthål/Tank- Lufthål/Tank- Lufthål/Tank- Lufthål/Tank-
påfyllning påfyllning påfyllning påfyllning påfyllning påfyllning påfyllning
D Monterings- Monterings- — — — Monterings- Monterings-
skåror skåror skåror skåror
E — — — — — Tankretur —
Tankretur- PC-20 PC-20 PC-25 PC-25 PC-25 — —
Sats
Tabell 2
Fig. 2 P-18 P-39, 1003 P-77 P-80, 1006 P-84 P-801
A Avlastningsventil Avlastningsventil Avlastningsventil Avlastningsventil Avlastningsventil Avlastningsventil
Utloppsöppning Utloppsöppning Utloppsöppning Utloppsöppning Utloppsöppning Utloppsöppning
C Fyllnadsplugg Fyllnadsplugg Fyllnadsplugg Fyllnadsplugg Fyllnadsplugg Fyllnadsplugg
D — — — 1/4 NPTF — 1/4 NPTF
Tankretur Tankretur
67
3.3 Modeller P-462, P-464 4.0 Installation
Bild 3 och tabellen nedan visar huvudfunktionerna för 4.1 Ansluta pumpen
handpumpmodellerna P-462, för användning med 1. Trä i slangen i pumpens utlopp. Använd ett och ett halvt
enkelverkande cylindrar, och P-464, för användning med varv tejp i lämpligt material vid monteringen av slangen och
dubbelverkande cylindrar. låt den första slangfibern vara helt fri från tejp för att
undvika att tejpen kommer i kontakt med hydraulsystemet.
C Detta kan annars leda till skador. Klipp lösa delar.
2. Installera en tryckmätning för pumpen för högre säkerhet
och bättre kontroll.
D
3. Anslut slangen/slangarna till cylindern eller verktyget.
Obs! Anslut en slang från pumpen till cylindern för
B enkelverkande cylindrar. Anslut två slangar för
dubbelverkande cylindrar. Anslut en slang från pumpens
tryckport till cylinderns. Anslut en annan slang från
A pumpens tillbakagångsport till cylinderns.
4.2 Pumpens ventilsystem

P-462/464F3
Se tabellen nedan för att avgöra om pumpen ska drivas med

en behållare med eller utan ventilsystem. Ventildrivna pumpar
erbjuder något bättre prestanda. Vrid ventilen/locket en
fjärdedels varv moturs för att öppna den på pumpar med
Bild 3, Modeller P-462, P-464 behållare i nylon. Se pumpdekalen på andra pumpar. Stäng
ventilen före transport för att förhindra oljeläckage. P-80,
Tabell 3 P-801 och P-84 ventileras genom att vrida ventilen
Fig. 3 P-462 P-464 moturs. För att stänga ventilationen, vrid ventilen
A 3/2-positionsventil 4/3-positionsventil medurs.
B 3/8 NPTF Utloppsöppning 3/8 NPTF Utloppsöppning
C Lufthål/Tankpåfyllning Lufthål/Tankpåfyllning
D Handtagsklämma Handtagsklämma VENTILATION
EHF-65 ........Utan ventilation P-202 .....................Antingen
3.4 Modeller P-25, P-50, P-51
P-18 ............Utan ventilation P-391, 1004 ...........Antingen
Bild 4 visar handpumpmodellerna P-25 och P-50, som båda P-25 .......................Antingen P-77.............Med ventilation
är utrustade med ett handtag som går att manövrera i båda P-39, 1003 ..Utan ventilation P-392, 1005 .......... Antingen
riktningarna. Bild 5 visar handpumpen P-51. P-50 .......................Antingen P-392AL.......Med ventilation
Huvudkomponenterna för dessa pumpar anges i tabellen P-51.............Med ventilation P-462...........Med ventilation
P-80, 1006 .............Antingen P-464...........Med ventilation
nedan.
P-84 .......................Antingen P-801 ..........Utan ventilation
P-141, 1001 ...........Antingen P-802 .....................Antingen
P-142, 1002 ...........Antingen P-842 .....................Antingen
P-142AL ......Utan ventilation
C
A
B
4.3 Pumpposition
Se tabellen nedan för att avgöra korrekt arbetsposition för
pumpen (horsontellt eller vertikalt). P-80 , P-801 och P-84
kan inte ventileras när de används i vertikalt läge.
ARBETSPOSITION
Bild 4, Modeller P-25, P-50
EHF-65 . . . . . . . . Antingen P-202 . . . . . . . . . Antingen
P-18 . . . . . . . . . . Antingen P-391, 1004 . . . . Antingen
P-25 . . . Endast horisontellt P-77 . . . . . . . . . . Antingen
C P-39, 1003. . . . . . Antingen P-392, 1005. . . . . Antingen
P-50 . . . Endast horisontellt P-392AL . . . . . . . Antingen
A P-51 . . . Endast horisontellt P-462 . Endast horisontellt
P-80, 1006 . . . . . Antingen P-464 . Endast horisontellt
B P-84 . . . . . . . . . . Antingen P-801 . . . . . . . . Antingen
P-141, 1001. . . . . Antingen P-802 . . . . . . . . . Antingen
P-142, 1002. . . . . Antingen P-842 . . . . . . . . . Antingen
P-142AL . . . . . . . Antingen
P-51F5
Bild 5, Model P-51 Obs! Vid användning av pumpen i vertikalt läge måste slangen
peka nedåt, annars kan pumpen ta in luft och då byggs inte
Tabell 4 - 5
Fig. 4 & 5 P-25 P-50 P-51
trycket upp ordentligt.
A Avlastningsventil Avlastningsventil Avlastningsventil
B 1/4 NPTF 1/4 NPTF 1/4 NPTF
Utloppsöppning Utloppsöppning Utloppsöppning
C Lufthål/Tank- Lufthål/Tank- Lufthål/Tank-
påfyllning påfyllning påfyllning
68
5.0 DRIFT
5.1 Innan du använder pumpen 5.4 Enkelverkande tillämpningar med 3-vägs,
1. Kontrollera att systemets alla kopplingar är täta och manuell 2-positionsventil
befriade från läckage. 1. Vrid ventilhandtaget till position 1 enligt bil 7.
2. Kontrollera oljenivån i behållaren innan pumpen tas i bruk. 2. Manövrera pumphandtaget för att leverera hydraulisk kraft till
Se "Fylla på olja på pumpen", sidan 7. systemet. Trycket bibehålls tills ventilen växlas.
3. För att tillåta återflöde till behållaren vrider du ventilhandtaget
OBS! Koppla ALDRIG in några tillägg till till position 2.
pumphandtaget. Tillägg orsakar instabil drift
för pumpen.
VARNING: I vissa lägen kan det hända att

2 2
pumphandtaget "slår tillbaka". Stå alltid med
kroppen på pumpens sida, på avstånd från
handtagets rörelsebana.
Obs! För att minska handtagets kraft vid högt tryck är det
viktigt att dra korta drag. Maximal effekt uppnås vid slagets
sista 5°.
1 1
5.2 Använda tvåhastighetspumpar

Dessa pumpar erbjuder ett tvåstegsflöde. Utan belastning
arbetar pumpen i det första stadiet med högt flöde, vilket ger A A
snabb avancering. När lasten anbringas växlar pumpen
automatiskt till det andra stadiet för att bygga upp trycket. För
modellerna P-462 eller P-464 måste du omedelbart avbryta
pumpningen och höja handtaget för att växla till
högtrycksläget när pumptrycket uppnår 200 psi [14 bar]. För 1Bild 7 2
modellen P-802 eller P-842 måste du omedelbart avbryta
pumpningen och höja handtaget för att växla till 5.5 Dubbelverkande tillämpningar med 4-vägs, manuell 3-
högtrycksläget när pumptrycket uppnår 400 psi [28 bar]. Efter positionsventil
att pumpen har växlat kräver pumpningen mindre kraft. Pumpar med 4-vägs reglerventiler är utformade för att driva
dubbelverkande cylindrar. Se bild 8 för ventilpositioner.
Obs! För att uppnå bästa prestanda ska du arbeta med
pumphandtaget under en måttlig hastighet med det första
stadiet. Hög hastighet i första stadiet förhindrar pumpen från Bild 8a
att leverera full oljevolym. N
5.3 Enkelverkande tillämpningar med avlastningsventil B

A
1. Stäng tryckbegrängninsventilen genom att vrida den
medurs, enligt Bild 6.
A B
Bild 6
A B A B A B
OBS: Stäng av avlastningsventil en med finarna.

En för hård åtdragning kan förstøura ventilen.
I
2. Manövrera pumphandtaget för att A N B
leverera hydraulisk kraft till systemet. Trycket bibehålls
tills tryckbegränsningsventilen öppnas. Bild 8b
3. Öppna tryckbegränsningsventilen (vrid moturs) för att
släppa på trycket och låta oljan flöda tillbaka in i
behållaren.
69
1. Placera spaken på 4-vägsventilen för att välja funktion 5. Öppna tryckbegränsningsventilen (dra tillbaka om du
enligt följande: använder en dragcylinder). Detta gör att luften som finns i
(A) Flöde till port "A"; port "B" sänder tillbaka flödet till pumpbehållaren släpps ut.
behållaren 6. Upprepa stegen ovan enligt behov.
(N) Neutral; portarna "A" och "B" är spärrade 7. Tillsätt olja vid behov. Se sidan 7.
(B) Flöde till port "B"; port "A" sänder tillbaka flödet till 8. Återställ ventilen/locket till arbetsläge.
behållaren.
2. Sätt igång pumpen för att starta arbetet. 6.2 Pump med dubbelverkande cylinder (B)
3. Ändra ventilposition enligt behov. 1. Ventilera pumpbehållaren (endast för pumpar med ventil).
2. Placera pumpen högre än cylindern.
3. Ställ cylindern i horisontellt läge med öppna portar. Se
bild 9.
4. Öka och minska cylindern 2 till 3 gånger.
5. Upprepa stegen ovan enligt behov.
N 6. Tillsätt olja vid behov. Se sidan 7.
7. Återställ ventilen/locket till arbetsläge.
B
A
A 7.0 UNDERHÅLL
B Använd endast Enerpacs hydraulolja för dessa pumpar för att
främja lång livslängd och skydda garantin. Viton och EPR
tätningssatser finns tillgängliga för vissa handpumpar.
Bild 8c Kontakta din återförsäljare för Enerpac för ytterligare
information om produkterna och dess tillämpningsområden.
VARNING: Använd endast den dubbelverkande
cylindern när båda slangarna är anslutna till 7.1 Fylla på olja på pumpen
pumpen. Om kopplaren inte ansluts kan det bli Kontrollera oljenivån regelbundet
för högt tryck bakom kopplaren, vilket kan
orsaka personskada och/eller skada på utrustningen. VARNING: Tillsätt alltid oljan när cylindrarna
är helt förminskade (tillbakadragna om det är
5.6 Tryckbegränsningsventil dragcylindrar). Annars kommer systemet att
Alla pumpar innehåller en fabriksinstallerad innehålla mer olja än behållaren har kapacitet
tryckbegränsningsventil för att undvika övertryck i systemet. för.
Det går att erhålla lägre tryckinställningar. Kontakta ditt
auktoriserade Enerpac Service Center. 1. Avlägsna ventilen från behållaren.
2. Fyll endast behållaren till nivåmarkeringen som visas på
6.0 LUFTUTSLÄPP pumpen.
Att avlägsna luft ur hydraulsystemet hjälper cylindern att öka 3. Avlägsna luft från systemet vid behov. Se sidan 6.
och minska mjukt och smidigt (se bild 9). Kontrollera oljenivån på nytt efter att du har luftat enheten.
4. Återställ ventilen till arbetsläge.
6.1 Pump med enkelverkande cylinder (A)
1. Ventilera pumpbehållaren (endast för pumpar med ventil) Obs! Pumpar som inte har ventiler kräver luft i behållaren för
och stäng tryckbegränsningsventilen. att fungera korrekt. Om behållaren är helt fylld bildas ett
2. Placera pumpen högre än cylindern. vakuum som förhindrar olja från att flöda ut i pumpen.
3. Placera pumpen med kolvändan nedåt (uppåt om du
använder en dragcylinder) Se bild 9 nedan.
4. Starta pumpen för att dra ut cylindern helt (dra tillbaka om
du använder en dragcylinder)
luft
luft
A B
Bild 9
70
7.2 Hålla oljeledningarna rena B, C
När kopplarens halvor inte är anslutna skall du alltid skruva på
dammkåpor. Vidta alla försiktighetsåtgärder som är möjliga, A
eftersom smuts kan orsaka att pumpen, cylindern eller
ventilen slutar fungera.
7.3 Smörja pumpen

För att förlänga livslängden för pumpen och förbättra
prestandan skall du smörja tappen (A), krysstappen (B) och
kolvbotten (C) regelbundet med en roller insmord i lagerfett.
Se bild 10.
Bild 10
7.4 Byta olja
1. Dränera all olja och fyll på ny och ren olja från Enerpac i
12-månadersintervall. Om pumpen används i smutsiga
miljöer är det lämpligt att byta olja oftare.
2. Avlägsna ventilen eller pluggen från behållaren.
3. Luta pumpen för att tömma ut all olja.
4. Fyll endast behållaren till nivåmarkeringen som visas på
pumpen.
5. Avlägsna ventilen eller pluggen.
6. Hantera oljeavfallet på ett korrekt sätt.
8.0 FELSÖKNING
Följande information är avsedd att vara en hjälp för att
fastställa ett existerande problem. Kontakta dit närmaste
auktoriserade ENERPAC Service Center för reparation och
underhåll.
FELSÖKNING
Problem Möjlig orsak Lösning
Cylindern ökar inte i volym, 1. Oljenivån i pumpbehållaren är låg. 1. Fyll på olja enligt instruktionerna under
den ökar långsamt eller den Underhåll på sidan 6.
ökar ryckvis. 2. Tryckbegränsningsventilen är öppen. 2. Stäng tryckbegränsningsventilen.
3. Lös hydraulisk kopplare. 3. Kontrollera att alla kopplare är helt åtdragna.
4. Lasten är för tung. 4. Försök inte lyfta mer än den kraft som anges.
5. Luft i systemet. 5. Släpp ut luft enligt instruktionerna under på sidan 6.
6. Cylinderkolv kärvar. 6. Kontrollera om cylindern har några skador. Se till att
cylindern underhålls av en kvalificerad hydraultekniker.
Att avlägsna luft ur 1. Läckande anslutning. 1. Kontrollera att alla anslutningar är fria från läckage.
hydraulsystemet hjälper 2. Läckande packningar. 2. Lokalisera läckage och se till att en hydraulisk tekniker
cylindern att öka och reparerar utrustningen.
minska mjukt och smidigt 3. Internt läckage i pumpen. 3. Se till att pumpen underhålls av en kvalificerad
(se bild 9). hydraultekniker.
Cylindern minskar inte, 1. Tryckbegränsningsventilen är stängd. 1. Öppna tryckbegränsningsventilen.

minskar delvis eller minskar 2. Pumpens behållare är överfylld. 2. Töm oljenivån till markeringen för fullt. Se sidan 7 för
långsammare än normalt. instruktioner om hur du fyller på olja.
3. Lös hydraulisk kopplare. 3. Kontrollera att alla kopplare är helt åtdragna.
4. Luft i systemet. 4. Släpp ut luft enligt instruktionerna under på sidan 6.
5. Slang I.D. för trång. 5. Använd en hydraulslang med större diameter.
6. Cylinderåtergångsfjädern är trasig eller 6. Se till att cylindern underhålls av en kvalificerad
det finns en annan cylinderskada. hydraultekniker.
71
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391 Park Road ENERPAC GmbH Technical Inquiries:
Regents Park NSW 2143 P.O. Box 300113 techsupport@enerpac.com.sg
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Technical Inquiries: Japan and Baltic States
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709B Diyang Building Jebel Ali, Dubai New Romney, TN28 8QF
Xin No. 2 United Arab Emirates United Kingdom
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100028 China
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P.O. Box 8097 Fax: +7-495-9809092 Tel: +1 262 781 6600
6710 AB Ede Fax: +1 262 783 9562
The Netherlands All Enerpac products are guaranteed against User inquiries:
Tel: +31 318 535 936 defects in workmanship and materials for as long +1 800 433 2766
Fax: +31 318 535 951 as you own them. For your nearest authorized Distributor inquiries/orders:
Enerpac Service Center, visit us at +1 800 558 0530
www.enerpac.com Technical Inquiries:
12/05
ECM0411017
Instruction Sheet
Hydraulic Cylinders
L1608 Rev C 10/06

Index:
English.....................................................................1-3
Français...................................................................4-7
Deutsch ................................................................ 8-11
Italiano.................................................................12-15
Español .............................................................. 16-19
Nederlands......................................................... 20-23
Portuguese .........................................................24-27
Norwegiain ..........................................................28-30
..............................................................31-34
..............................................................35-37
Repair Parts Sheets for this product are A DANGER is only used when your action or lack
available from the Enerpac web site at of action may cause serious injury or even death.
www.enerpac.com, or from your nearest
WARNING: Wear proper personal
Authorized Enerpac Service Center or Enerpac
protective gear when operating
Sales office.
hydraulic equipment.
1.0 IMPORTANT RECEIVING WARNING: Stay clear of loads
INSTRUCTIONS supported by hydraulics. A cylinder,
Visually inspect all components for shipping when used as a load lifting device,
damage. Shipping damage is not covered by should never be used as a load holding device.
warranty. If shipping damage is found, notify After the load has been raised or lowered, it
carrier at once. The carrier is responsible for all must always be blocked mechanically.
repair and replacement costs resulting from WARNING: USE ONLY RIGID
damage in shipment. PIECES TO HOLD LOADS.
SAFETY FIRST Carefully select steel or wood blocks
that are capable of supporting the load. Never
2.0 SAFETY ISSUES use a hydraulic cylinder as a shim or spacer in
Read all instructions, warnings any lifting or pressing application.
and cautions carefully. Follow DANGER: To avoid personal
all safety precautions to avoid injury keep hands and feet
personal injury or property damage during away from cylinder and
system operation. Enerpac cannot be workpiece during operation.
responsible for damage or injury resulting from
unsafe product use, lack of maintenance or WARNING: Do not exceed equipment
incorrect product and/or system operation. ratings. Never attempt to lift a load
Contact Enerpac when in doubt as to the safety weighing more than the capacity of
precautions and operations. If you have never the cylinder. Overloading causes equipment
been trained on high-pressure hydraulic safety, failure and possible personal injury. The
consult your distribution or service center for a cylinders are designed for a max. pressure of
free Enerpac Hydraulic safety course. 700 bar [10,000 psi]. Do not connect a jack or
cylinder to a pump with a higher pressure rating.
Failure to comply with the following cautions
and warnings could cause equipment damage DANGER: Never set the relief valve
and personal injury. to a higher pressure than the
maximum rated pressure of the
A CAUTION is used to indicate correct pump. Higher settings may result in equipment
operating or maintenance procedures and damage and/or personal injury. Do not remove
practices to prevent damage to, or destruction relief valve.
of equipment or other property.
WARNING: The system operating
A WARNING indicates a potential danger that pressure must not exceed the
requires correct procedures or practices to pressure rating of the lowest rated
avoid personal injury. component in the system. Install pressure
gauges in the system to monitor operating Distribute the load evenly across the
pressure. It is your window to what is entire saddle surface. Always use a
happening in the system. saddle to protect the plunger.
CAUTION: Avoid damaging
hydraulic hose. Avoid sharp bends IMPORTANT: Hydraulic equipment
and kinks when routing hydraulic must only be serviced by a qualified
hoses. Using a bent or kinked hose will cause hydraulic technician. For repair
severe back-pressure. Sharp bends and kinks service, contact the Authorized
will internally damage the hose leading to ENERPAC Service Center in your area. To
premature hose failure. protect your warranty, use only ENERPAC oil.
Do not drop heavy objects on WARNING: Immediately replace worn

hose. A sharp impact may cause or damaged parts by genuine
internal damage to hose wire ENERPAC parts. Standard grade
strands. Applying pressure to a damaged hose parts will break causing personal injury and
may cause it to rupture. property damage. ENERPAC parts are
designed to fit properly and withstand high
IMPORTANT: Do not lift hydraulic loads.
equipment by the hoses or swivel
couplers. Use the carrying handle or 3.0 INSTALLATION
other means of safe transport.
1. Make hydraulic connections. Use a pump
CAUTION: KEEP HYDRAULIC with a release valve or a 3-way valve and
EQUIPMENT AWAY FROM one hose for single-acting cylinders (1). Use
FLAMES AND HEAT. Excessive a pump with a 4-way valve and two hoses
heat will soften packings and seals, resulting in
fluid leaks. Heat also weakens hose materials
and packings. For optimum performance do not
expose equipment to temperatures of 65°C
[150°F] or higher. Protect hoses and cylinders
from weld spatter.
DANGER: DO NOT HANDLE
PRESSURIZED HOSES. Escaping
oil under pressure can penetrate the
skin, causing serious injury. If oil is injected
under the skin, see a doctor immediately. for double-acting cylinders (2).
WARNING: Only use hydraulic IMPORTANT: Double-acting cylinders must
cylinders in a coupled system. Never have both couplers connected.
use a cylinder with unconnected Fully hand-tighten all couplers. Loose
couplers. If the cylinder becomes coupler connections will block the flow of oil
extremely overloaded, components can fail between the pump and the cylinder.
catastrophically causing severe personal injury. 2. Remove air from the cylinder as shown
WARNING: BE SURE SETUP IS below.
STABLE BEFORE LIFTING LOAD. Single-acting cylinders: Position the cylinder
Cylinders should be placed on a flat so that the plunger is pointed down and the
surface that can support the load. cylinder lower than the pump. Fully extend
Where applicable, use a cylinder base for and retract the cylinder 2 or 3 times.
added stability. Do not weld or otherwise Double-acting cylinders: Lay the cylinder on
modify the cylinder to attach a base or other its side and have the couplers facing up.
support. Fully extend and retract the cylinder 2 or 3
Avoid situations where loads are not times.
directly centered on the cylinder 3. Do not allow plunger to rotate when installing
plunger. Off-center loads produce adaptors. Damage to the spring may result in
considerable strain on cylinders and plungers. rotating the plunger preventing retraction.
In addition, the load may slip or fall, causing NOTE: Collar threads are rated for the full
potentially dangerous results. capacity of the cylinder when fully engaged in
attachments.
2
air
air
NOTE: The use of cylinder attachments or 5.0 MAINTENANCE

extensions reduces the cylinder capacity by at
1. Use only Enerpac oil with these cylinders.
least 50%.
The use of any other oil may invalidate your
4.0 OPERATION warranty.
2. Use dust caps when cylinders are
Operate the hydraulic pump to advance and
disconnected from the hose. Keep entire
retract the cylinder. Some single-acting
cylinder clean to prolong cylinder life.
cylinders are spring-return, others are load-
return. The speed of retraction is affected by 3. Store cylinders upright to prevent seal
the length of the hose and other restrictions in distortion.
the line. Double-acting cylinders are powered 6.0 TROUBLESHOOTING
in both directions by the pump.
These cylinders should be repaired only by
The cylinder stop ring is designed to take the Authorized Enerpac Technical Service Centers.
full load. However, to reduce cylinder wear, use Single-acting cylinders are spring-loaded and
less than full stroke when possible. require special disassembly techniques to
prevent personal injury.
PROBLEM POSSIBLE CAUSE

Cylinder will not advance. Pump release valve open.
Coupler not fully tightened.
Oil level in pump is low.
Pump malfunctioning.
Load is too heavy for cylinder.
Cylinder advances part way. Oil level in pump is low.
Cylinder plunder binding.
Cylinder advances in spurts. Air in hydraulic system.
Cylinder plunger binding.
Cylinder advances slower than normal. Leaking connection.
Cylinder advances but will not hold. Cylinder seals leaking.
Leaking connection.
Incorrect system set-up.
Cylinder leaks oil Worn or damaged seals
Internal cylinder damage.
Loose connection.
Cylinder will not retract or retracts slower Pump release valve is closed.
than normal. Coupler not fully tightened.
Pump reservoir over-filled.
Narrow hose restricting flow.
Broken or weak retraction spring.
Cylinder damaged internally.
Oil leaking from external relief valve. Coupler not fully tightened.
Restriction in return line.
3
Vérins Hydrauliques
L1608 Rev C 10/06
Les vues éclatées de ce produit sont
disponibles sur le site Enerpac
www.enerpac.fr. Vous pouvez également les
obtenir auprès de votre réparateur agréé
Enerpac ou auprès d'Enerpac même.
Inspecter tous les composants pour vous
assurer qu’ils n’ont subi aucun dommage en
cours d’expédition. Les dommages subis en
cours de transports ne sont pas couverts par la
garantie. S’il sont abîmés, aviser particulières visant à écarter tout risque de
immédiatement le transporteur, qui est blessure.
responsable des frais de réparation et de
remplacement résultant de dommages en La mention DANGER n’est utilisée que
cours de transport. lorsqu’une action ou un acte de négligence risque
de causer des blessures graves, voire mortelles.
LA SÉCURITÉ AVANT TOUT !
AVERTISSEMENT : Porter un
2.0 SÉCURITÉ équipement de protection
personnelle adéquat pour utiliser un
Lire attentivement toutes les appareil hydraulique.
instructions et mises en garde
AVERTISSEMENT : Rester à l’écart
et tous les avertissements.
de charges soutenues par un
Suivre toutes les précautions pour éviter
mécanisme hydraulique. Un vérin,
d’encourir des blessures personnelles ou de
lorsqu’il est utilisé comme monte-charge, ne
provoquer des dégâts matériels durant le
doit jamais servir de support de charge. Après
fonctionnement du système. Enerpac ne peut
avoir monté ou abaissé la charge, elle doit être
pas être tenue responsable de dommages ou
bloquée par un moyen mécanique.
blessures résultant de l’utilisation risquée du
produit, d’un mauvais entretien ou d’une AVERTISSEMENT : UTILISER
application incorrecte du produit et du SEULEMENT DES PIÈCES
système. En cas de doute sur les précautions RIGIDES POUR SOUTENIR LES
ou les applications, contacter Enerpac. En CHARGES. Sélectionner avec précaution des
l’absence d’une formation aux mesures de blocs d’acier ou de bois capables de supporter
sécurité à prendre en présence de liquides la charge. Ne jamais utiliser un vérin
sous haute pression, consulter un centre de hydraulique comme cale ou intercalaire d’appui
distribution ou de réparation Enerpac pour pour les applications de levage ou de pressage.
suivre un cours gratuit sur ce thème. DANGER : Pour écarter tout
Respecter les mises en garde et risque de blessure personnelle,
avertissements suivants sous peine de maintenir les mains et les pieds
provoquer des dégâts matériels et des à l’écart du vérin et de la pièce à usiner durant
blessures personnelles. l’utilisation.
Une mise en garde ATTENTION sert à AVERTISSEMENT : Ne pas
indiquer des procédures d’utilisation et de dépasser les valeurs nominales du
maintenance correctes qui visent à empêcher matériel. Ne jamais essayer de
l’endommagement voire la destruction du soulever une charge d’un poids supérieur à la
matériel ou d’autres dégâts. capacité du vérin. Une surcharge entraînera la
panne du matériel et risque de provoquer des
Un AVERTISSEMENT indique un danger
blessures personnelles. Les vérins sont
potentiel qui exige la prise de mesures
conçus pour une pression maximale de 700
4
bar. Ne pas connecter de cric ou de vérin à une AVERTISSEMENT : Utiliser des
pompe affichant une pression nominale vérins hydrauliques uniquement dans
supérieure. un système couplé. Ne jamais utiliser
DANGER : Ne jamais régler la un vérin en présence de raccords
soupape de sûreté à une pression déconnectés. La surcharge du vérin peut avoir
supérieure à la pression nominale des effets désastreux sur ses composants, qui
maximale de la pompe sous peine de provoquer peuvent causer des blessures graves.
des dégâts matériels et/ou des blessures AVERTISSMENT : S'assurer de la
personnelles.Ne pas retirer le limiteur de pression stabilité de l'ensemble avant de
lever une charge. Le vérin doit être
AVERTISSEMENT : La pression de
placé sur une surface plane capable
fonctionnement du système ne doit
de supporter la charge. Lorsqu'applicable,
pas dépasser la pression nominale
utiliser une base de vérin pour accroître la
du composant du système affichant la plus
stabilité. Ne pas souder ou modifier le vérin de
petite valeur. Installer des manomètres dans le
quelque façon que ce soit pour y fixer une base
système pour surveiller la pression de
ou un autre dispositif de support.
fonctionnement. Ils permettent de vérifier ce
qui se passe dans le système. Éviter les situations où les charges
ne sont pas directement centrées sur
ATTENTION : Éviter d’endommager
le piston du vérin. Les charges
les tuyaux hydrauliques. Éviter de les
décentrées imposent un effort considérable au
plier et de les tordre en les mettant en
vérins et pistons. En outre, la charge risque de
place. Un tuyau plié ou tordu entraînera un fort
glisser ou de tomber, ce qui crée un potentiel
retour de pression. Les plis et coudes
de danger.
prononcés endommageront par ailleurs
l’intérieur du tuyau, provoquant son usure Répartir la charge uniformément sur
précoce. toute la surface d'appui. Toujours
utiliser un coussinet d'appui si des
Ne pas faire tomber d’objets
lourds sur le tuyau. Un fort impact accessoires non filetés sont utilisés.
risque de causer des dégâts IMPORTANT : Le matériel
intérieurs (torons métalliques). L’application d’ hydraulique doit uniquement être
une pression sur un tuyau endommagé risque réparé par un technicien hydraulique
d’entraîner sa rupture. qualifié. Pour toute réparation,
IMPORTANT : Ne pas soulever le contacter le centre de réparation ENERPAC
matériel hydraulique en saisissant agréé le plus proche. Pour assurer la validité
ses tuyaux ou ses raccords articulés. de la garantie, n’utiliser que de l’huile
Utiliser la poignée de transport ou procéder ENERPAC.
d’une autre manière sûre. AVERTISSEMENT : Remplacer
ATTENTION : Garder le matériel immédiatement les pièces usées ou
hydraulique à l’écart de endommagées par des pièces
flammes et d’une source de ENERPAC authentiques. Les pièces de qualité
chaleur. Une forte température standard se casseront et provoqueront des
amollira les garnitures et les joints et blessures et des dégâts matériels. Les pièces
provoquera par conséquent des fuites. La ENERPAC sont conçues pour s’ajuster
chaleur affaiblit également les matériaux et les parfaitement et résister à de fortes charges.
garnitures du tuyau. Pour une performance
maximale, ne pas exposer le matériel à une
température supérieure ou égale à 65 °C [150 3.0 INSTALLATION
°F]. Protéger tuyaux et vérins de projections de 1. Effectuer les branchements hydrauliques.
soudure. Utiliser une pompe avec une soupape de
DANGER : Ne pas manipuler les sûreté ou une soupape à 3 voies et un
tuyaux sous pression. L’huile sous flexible pour les vérins à simple effet (1).
pression qui risque de s’en échapper Utiliser une pompe avec une soupape à 4
peut pénétrer dans la peau et provoquer des voies et deux flexibles pour les vérins
blessures graves. En cas d’injection d’huile sous double effet (2).
la peau, contacter immédiatement un médecin.
5
réduit la capacité du vérin d’au moins 50 %.
4.0 FONCTIONNEMENT
Actionner la pompe hydraulique pour sortir et
rétracter le vérin. Sur certains vérins à simple
effet, la rétraction se fait par ressort, sur
d’autres, sous l’action de la charge. La vitesse
de rétraction est fonction de la longueur du
flexible et d’autres facteurs affectant la
pression de la conduite. Les vérins à double
effet sont assistés par la pompe dans les deux
sens.
La bague d’arrêt du vérin est conçue pour
supporter la charge complète. Toutefois, dans
IMPORTANT : Les deux raccords la mesure du possible, ne pas utiliser le vérin à
d’accouplement des vérins à double effet fond de course afin de réduire l’usure.
doivent être branchés.
5.0 ENTRETIEN
Bien serrer tous les raccords
d’accouplement à la main. Des raccords 1. Utiliser exclusivement de l’huile Enerpac
mal serrés bloqueraient le flux d’huile entre avec ces vérins. L’usage de toute autre
la pompe et le vérin. huile pourrait entraîner l’annulation de la
2. Pomper l’air du vérin comme illustré ci- garantie.
dessous. 2. Utiliser des capuchons pare-poussière
Vérins à simple effet : Positionner le vérin lorsque les flexibles ne sont pas raccordés
plus bas que la pompe, le piston étant dirigé aux vérins. Veiller à garder le vérin
vers le bas. Sortir et rétracter complètement entièrement propre afin de prolonger sa vie.
le vérin 2 ou 3 fois. Vérins à double effet : 3. Ranger les vérins à la verticale pour éviter
Poser le vérin sur son côté, les raccords la déformation des joints.
d’accouplement étant dirigés vers le haut.
Sortir et rétracter complètement le vérin 2 6.0 DÉPANNAGE
ou 3 fois. La réparation de ces vérins doit être confiée
3. Lors d'operations de montage d'accessoires exclusivement à un centre de réparation
sur le piston, veuillez bloquer le piston en Enerpac agréé. Les vérins à simple effet sont
rotation pour eviter d'endomager le ressort chargés par ressort et exigent des techniques
de rappel. de montage spéciales pour éviter les risques
d’accident.
NOTE : Lorsque les raccords sont engagés à
fond dans les accessoires, la capacité
nominale de leur filetage correspond à la
capacité totale du vérin complètement sorti.
NOTE : L’usage d’accessoires ou d’extensions
air
air
6
PROBLÈME CAUSE POSSIBLE
Le cylindre ne sort pas. Soupape de sûreté de la pompe ouverte.
Raccord d’accouplement pas complètement
serré.
Niveau d’huile de la pompe bas.
Mauvais fonctionnement de la pompe.
Le vérin sort partiellement. Charge trop lourde pour le vérin.

Niveau d’huile de la pompe bas.
serré.
Le vérin sort par à-coups. Piston du vérin grippé.

Air dans le circuit hydraulique.
Piston du vérin grippé.
Le vérin sort plus lentement que la normale. Fuite de raccord.

serré.
Le vérin sort mais ne tient pas la charge. Fuites aux joints.

Fuite de raccord.
Configuration du système incorrecte.
Fuite d’huile au vérin. Joints usés ou endommagés.

Dommages internes.
Raccord desserré.
Le vérin ne se rétracte pas ou se rétracte Soupape de sûreté de la pompe fermée.

plus lentement que la normale. Raccord d’accouplement pas complètement
serré.
Réservoir de la pompe trop plein.
Écoulement réduit par un flexible trop petit.
Ressort de rétraction cassé ou faible.
Dommages internes du vérin.
Fuite d’huile à la soupape de sûreté externe. Raccord d’accouplement pas complètement

serré.
Blocage partiel de la conduite de retour.
7
Bedienungsanleitung
Hydraulikzylinder
L1608 Rev C 10/06
Das Ersatzteilblatt für dieses Produkt finden Sie

auf der Enerpac Website www.enerpac.com,
oder bei Ihrem nächstgelegenen authorisierten
Enerpac Service Center oder einem Enerpac
Vertriebsbüro.

FÜR DEN EMPFANG:
Alle Komponenten auf sichtbare
Transportschäden inspizieren. Transport-
schäden sind nicht von der Garantie gedeckt.
Werden solche Schäden festgestellt, ist
unverzüglich das Transportunternehmen zu oder anderen Sachwerten bzw. deren
verständigen. Das Transportunternehmen ist Zerstörung zu vermeiden.
für alle Reparatur- und Ersatzkosten, die auf
Transportschäden zurückzuführen sind, Eine WARNUNG verweist auf eine potentielle
Verletzungsgefahr, die durch ordnungsgemäße
verantwortlich.
Verfahren oder Praktiken vermieden werden
SICHERHEIT GEHT VOR kann.
Ein GEFAHRENSHINWEIS wird nur dann
2.0 SICHERHEITSFRAGEN gegeben, wenn eine bestimmte Handlung oder
Alle Anleitungen, Warnungen die Unterlassung einer bestimmten Handlung
und Vorsichtshinweise schwere oder tödliche Verletzungen zur Folge
sorgfältig durchlesen. haben kann.
Beachten Sie alle Sicherheitsvorkehrungen, WARNUNG: Beim Betrieb
um Verletzungen oder Sachschäden während hydraulischer Anlagen geeignete
des Systembetriebs zu vermeiden. Enerpac ist Schutzkleidung und –ausrüstung
weder für Schäden noch Verletzungen haftbar, tragen.
die durch einen fahrlässigen Gebrauch des
Produkts, mangelhafte Instand-haltung oder WARNUNG: Von Lasten fernhalten,
eine unvorschriftsmäßige Anwendung des die durch ein Hydrauliksystem
Produkts und/oder des Systems verursacht abgestützt werden. Ein als
werden. Bei evtl. Fragen in bezug auf Lastenhebegerät eingesetzter Zylinder darf
Sicherheitsvorkehrungen und Betriebsabläufe niemals als ein Lastenhaltegerät verwendet
wenden Sie sich bitte an ENERPAC. Wenn Sie werden. Nach Heben oder Senken der Last
an keinerlei Sicherheitsschulungen im muß diese stets auf mechanische Weise
Zusammenhang mit Hochdruck- gesichert werden.
hydraulikanlagen teilgenommen haben, WARNUNG ZUM SICHERN VON
fordern Sie von Ihrer Vertriebs- und LASTEN STETS NUR STARRE
Kundendienstzentrale einen kostenlosen TEILE VERWENDEN. Zum
Enerpac-Hydraulik-Sicherheitskurs an. Abstützen von Lasten sorgfältig dazu
Ein Mißachten der folgenden geeignete Stahl- oder Holzblöcke auswählen.
Vorsichtshinweise und Warnungen kann zu Bei Hebe- oder Drückanwendungen keinesfalls
Geräteschäden und Verletzungen führen. einen Hydraulikzylinder als Abstandsstück
oder –halter verwenden.
Mit einem VORSICHTSHINWEIS wird auf
ordnungsgemäße Betriebs- oder GEFAHR: Zur Vermeidung von
Wartungsverfahren und –praktiken Verletzungen während des
hingewiesen, um Schäden an den Geräten Betriebs Hände und Füße von
Zylinder und Werkstück fernhalten.
8
WARNUNG: Die zugelassene die Anlage keinen Temperaturen über 65°C
Nennleistung der Geräte nicht ausgesetzt werden. Außerdem müssen
überschreiten. Keine Last zu heben Schläuche und Zylinder beim Schweißen vor
versuchen, deren Gewicht das Hebevermögen Funkenschlag geschützt werden.
des Zylinders übersteigt. Überlasten GEFAHR: Nicht mit unter Druck
verursachen Maschinenausfälle und können stehenden Schläuchen hantieren.
zu Verletzungen führen. Die Zylinder wurden Unter Druck austretendes Öl kann in
für einen max. Druck von 700 bar konstruiert. die Haut eindringen und schwere Verletzungen
Keinen Heber oder Zylinder an eine Pumpe mit verursachen. Falls Öl unter die Haut gelangt,
einer höheren nominalen Druckleistung ist sofort ein Arzt aufzusuchen.
anschließen.
WARNUNG: In einem gekoppelten
GEFAHRENSHINWEIS: Das System dürfen nur
Überdruckventil keinesfalls auf Hydraulikzylinder verwendet
einen höheren Druck als den werden. Niemals einen Zylinder mit
maximal zulässigen Druck der Pumpe unverbundenen Kupplungen verwenden. Bei
einstellen. Höhere Einstellungen können zu einer extremen Überlastung des Zylinders
Geräteschäden und/oder Verletzungen führen. können dessen Komponenten einen
Nicht das Druckbegrenzungs-Ventil entfernen! Sprungvollausfall erleiden, was schwere
WARNUNG: Der System- Verletzungen hervorrufen kann.
betriebsdruck darf den zulässigen WARNUNG: Sicherstellen, dass die
Nominaldruck der System- anlage stabilisiert, bevor eine last
komponente mit der niedrigsten Nennleistung angehoben wird. Der Zylinder sollte
nicht überschreiten. Zur Überwachung des auf einer ebenen Oberfläche
Betriebsdrucks sind Manometer im System zu aufsitzen, die fest genug ist, um die Last
installieren. Dies ist das Fenster zu den abzustützen. Wenn möglich einen Zylinderfuß
Abläufen im System. verwenden, um größere Stabilität zu
VORSICHT: Beschädigungen am gewährleisten. Keine Schweißarbeiten oder
Hydraulikschlauch vermeiden. andere Änderungen am Zylinder vornehmen,
Beim Verlegen der Hydraulik- um einen Zylinderfuß oder andere
schläuche enge Bögen und Abknicken Abstützungen anzubringen.
vermeiden. Der Einsatz eines gebogenen oder Situationen vermeiden, in denen die
geknickten Schlauchs führt zu einem hohen Lasten nicht direkt über dem Kolben
Rückstau. Starke Biegungen und Knickstellen des Zylinders ausgerichtet sind.
schädigen den Schlauch auf der Innenseite Seitlich versetzte Lasten führen zu erheblicher
und führen zu dessen vorzeitigem Ausfall. Belastung der Zylinder und Kolben. Außerdem
Keine schweren Gegenstände auf könnte die Last ins Rutschen geraten oder
den Schlauch fallen lassen. Starke fallen, was zu äußerst gefährlichen Situationen
Erschütterungen können Schäden führen kann.
an den im Schlauchinnern verlaufenden Die Last gleichmäßig über die
Drahtlitzen verursachen. Ein Schlauch, auf den gesamte Fläche des Druchstückes
Druck ausgeübt wird, kann bersten. verteilen. Den Kolben immer mit
WICHTIG: Hydraulische Geräte einem Druckstück schützen, wenn
weder an den Schläuchen noch den keine Zusatzgeräte mit Gewinde benutzt
Gelenkanschlüssen anheben. Dazu werden.
den Tragegriff oder eine andere sichere WICHTIG: Hydraulische Geräte
Transportmethode verwenden. müssen von einem qualifizierten
VORSICHT: Hydraulische Geräte Hydrauliktechniker gewartet werden.
von Flammen und Hitzequellen Bei Reparaturarbeiten an die autorisierte
fernhalten. Zu hohe ENERPAC-Kundendienstzentrale der
Temperaturen weichen Füllungen und jeweiligen Region wenden. Zur
Dichtungen auf und bewirken Flüssigkeitslecks. Aufrechterhaltung der Garantie nur ENERPAC-
Große Hitze schwächt außerdem die Öl verwenden.
Schlauchmaterialien und –dichtungen. Zur
Gewährleistung einer optimalen Leistung darf
9
WARNUNG: Abgenutzte oder Einfachwirkende Zylinder: Den Zylinder so
beschädigte Teile unverzüglich durch ausrichten, daß der Kolben nach unten zeigt
ENERPAC-Originalteile ersetzen. und der Zylinder sich unterhalb der Pumpe
Standardteile anderer Hersteller versagen und befindet. Den Zylinder zwei- oder dreimal
verursachen Verletzungen und Sachschäden. voll aus- und einfahren.
ENERPAC-Teile werden so konstruiert, daß sie Doppelwirkende Zylinder: Den Zylinder auf
richtig passen und hohen Lasten standhalten. die Seite legen, so daß die Kupplungen
nach oben zeigen. Die Zylinder zwei- oder
dreimal voll aus- und einfahren.
3.0 INSTALLATION 3. Falls Sie einen Adapter an das Kolbenende
1. Hydraulikanschlüsse. Eine Pumpe mit anschrauben wollen, vermeiden Sie auf alle
Auslöseventil oder Dreiwegeventil und Faelle dass der Kolben dabei verdreht wird.
einem Schlauch für einfachwirkende Dies koennte sonst zu einer Beschaedigung
der Rueckzug-Feder fuehren, was die
Kolbenbewegung blockieren koennte.
HINWEIS: Die Muffengewinde sind auf die
volle Nennkraft des Zylinders ausgelegt,
solange sie vollkommen in die Zusatzgeräte
eingeschraubt sind.
HINWEIS: Die Verwendung von Zylinder-
Zusatzgeräten oder Verlängerungen verringert
die Zylinder-Nennkraft um wenigstens 50%.
4.0 BETRIEB
Die Hydraulikpumpe zum Aus- und Einfahren
des Zylinders betätigen. Einige
einfachwirkende Zylinder werden mit
Zylinder (1) verwenden. Eine Pumpe mit Federkraft zurückgezogen, andere unter
Vierwegeventil und zwei Schläuchen für Belastung. Die Geschwindigkeit des
doppelwirkende Zylinder (2) verwenden. Zurückziehens hängt von der Länge des
WICHTIG: Bei doppelwirkenden Zylindern
Schlauches und anderen Verengungen in der
müssen beide Kupplungen angeschlossen
Leitung ab. Doppelwirkende Zylinder werden in
sein.
beiden Richtungen durch die Pumpe bewegt.
Alle Kupplungen von Hand vollkommen fest
ziehen. Lose Kupplungsanschlüsse führen Der Zylinder-Sperring ist darauf ausgelegt, die
zur Einschränkung des Ölstromes zwischen volle Belastung zu tragen. Allerdings sollte der
der Pumpe und dem Zylinder. Zylinder nicht vollkommen ausgefahren
werden, um die Abnutzung gering zu halten.
2. Die Luft gemäß der untenstehenden
Abbildung aus dem Zylinder entfernen.
Lüft
Lüft
10
5.0 WARTUNG 6.0 FEHLERSUCHE
1. Mit diesen Zylindern nur Enerpac-Öl Diese Zylinder sollten nur von einer Enerpac-
verwenden. Die Verwendung von anderen Vertragskundendienststelle repariert werden.
Ölsorten kann zum Verfall der Garantie Einfachwirkende Zylinder stehen unter
führen. Federdruck und es müssen besondere
2. Falls die Zylinder vom Schlauch getrennt Methoden beim Zerlegen verwendet werden,
werden, Staubschutzkappen anbringen. Um um Körperverletzungen zu verhindern.
die Lebensdauer des Zylinders zu
verlängern, den gesamten Zylinder sauber
halten.
3. Die Zylinder aufrecht lagern, um die
Verwindung der Dichtungen zu vermeiden.
PROBLEM MÖGLICHE URSACHE

Zylinder fahren nicht aus. Pumpen-Druckentlastungsventil offen.
Kupplung nicht ganz festgezogen.
Ölstand in der Pumpe ist zu niedrig.
Pumpe schadhaft.
Zylinder fährt nur teilweise aus. Last zu schwer für den Zylinder.
Ölstand in der Pumpe ist zu niedrig.
Zylinder fährt stoßweise aus. Zylinderkolben klemmt.

Luft im Hydrauliksystem.
Zylinderkolben klemmt.
Zylinder fährt langsamer als normal aus. Undichte Verbindung.

Pumpe schadhaft.
Zylinder fährt aus, hält aber nicht. Zylinderdichtungen undicht.

Pumpe schadhaft.
Undichte Verbindung.
Anlage falsch installiert.
Zylinder leckt Öl. Abgenutzte oder schadhafte Dichtungen.

Innere Zylinderschäden.
Loser Anschluß.
Zylinder fährt nicht zurück oder zieht sich Pumpen-Druckentlastungsventil ist

langsamer als normal zurück. geschlossen.
Sammelbehälter der Pumpe überfüllt.
Engstelle im Schlauch schränkt Ölstrom ein.
Rückstellfeder schadhaft oder zu schwach.
Innere Zylinderschäden.
Leckage am äußeren Entlastungsventil. Kupplung nicht ganz festgezogen.

Engstelle in der Rücklaufleitung.
11
Manuale d’istruzione
Cilindri idraulici
L1608 Rev C 10/06

L’esploso delle parti di ricambio per questo
prodotto è ottenibile sul sito web
www.enerpac.com, oppure chiamando il
Centro Assistenza Autorizzato a voi più vicino ,
o il ns. ufficio commerciale.
1.0 NOTA IMPORTANTE
presenti, avvisare prontamente lo spedizioniere.
I danni subiti durante la spedizione non sono
coperti dalla garanzia vigente. Lo spedizioniere
è il solo responsabile per i costi di riparazione o AVVERTENZA: Indossare
di sostituzione conseguenti a danni avvenuti un'attrezzatura di protezione
durante la spedizione. appropriata durante il funzionamento
dell'apparecchiatura.
INFORMAZIONI SULLA SICUREZZA
AVVERTENZA: Stare lontano da
2.0 INFORMAZIONI SULLA SICUREZZA carichi sospesi e sostenuti
idraulicamente. Un cilindro utilizzato
Leggere attentamente tutte le
per sollevare un carico non deve mai essere
istruzioni, le avvertenze e le
impiegato anche per il loro sostegno. Dopo
precauzioni. Durante il
aver alzato o abbassato un peso, è necessario
funzionamento del sistema, rispettare tutte le
che questo venga sempre bloccato in maniera
norme di sicurezza onde evitare infortuni o
meccanica.
danni all'apparecchiatura. L'Enerpac declina
ogni responsabilità per danni risultanti da un AVVERTENZA: UTILIZZARE SOLO
uso improprio del prodotto, dalla mancata ATTREZZI RIGIDI PER IL
manutenzione o dall'applicazione errata del SOSTEGNO DEI CARICHI.
prodotto e del sistema. In caso di dubbio in Selezionare con cura blocchi in acciaio o in
materia di sicurezza o applicazioni, rivolgersi legno capaci di supportare il peso del carico.
all'Enerpac. Se si richiedono informazioni sulle Non ricorrere mai a un cilindro idraulico come
norme di sicurezza per sistemi idraulici ad alta cuneo o spessore in applicazioni di
pressione, rivolgersi al distributore o al centro sollevamento o pressatura.
di riparazione di zona in grado di fornire PERICOLO: Per evitare lesioni
gratuitamente un corso di addestramento in personali, durante la lavorazione
materia di sicurezza idraulica autorizzato dalla tenere le mani e i piedi lontano
Enerpac. dal cilindro e dal pezzo in lavorazione.
La mancata osservanza delle seguenti AVVERTENZA: Non superare mai la
precauzioni potrebbe portare a seri danni capacità nominale
all'apparecchiatura e a lesioni personali. dell'apparecchiatura. Non tentare mai
Una PRECAUZIONE indica le corrette di sollevare un peso superiore alla capacità del
procedure di azionamento o manutenzione per cilindro, dato che il sovraccarico può causare
evitare danni all'apparecchiatura o all'ambiente guasti all'apparecchiatura e possibili infortuni
circostante. all'operatore. I cilindri sono stati studiati per
una pressione massima pari a 700 bar. Non
Un'AVVERTENZA indica un potenziale
collegare un martinetto o un cilindro a una
pericolo che richiede la messa in pratica delle
pompa la cui pressione nominale è superiore.
procedure corrette per evitare infortuni.
PERICOLO: Non impostare mai la
Un PERICOLO indica una situazione in cui
valvola di scarico a una pressione
un'azione o la mancanza di azione può causare
superiore a quella massima nominale
gravi lesioni personali se non il decesso.
della pompa. Un'impostazione superiore può
12
arrecare danni all'apparecchiatura e/o AVVERTENZA: Prima di sollevare il
provocare infortuni all'operatore. Non carico, assicurarsi che la
rimuovere la valvola di sicurezza. configurazione dell'intera
apparecchiatura sia perfettamente
AVVERTENZA: La pressione di
stabile. Il cilindro deve essere disposto su una
esercizio del sistema non deve
superficie piana, in grado di sostenere il carico.
superare il valore nominale prefissato
Se possibile, usare una base per il cilindro, per
per il componente dalla pressione più bassa.
aumentarne la stabilità. Non saldare ne
Installare nel sistema un manometro per tenere
modificare in alcun modo il cilindro allo scopo
sotto controllo la pressione di esercizio.
di collegarvi una base o un altro supporto.
PRECAUZIONE: Evitare di arrecare
danni al tubo idraulico flessibile. Evitare situazioni in cui i carichi non
siano perfettamente centrati rispetto
Evitare di piegare o arricciare il tubo
allo stelo del cilindro stresso. I carichi
flessibile durante l'uso, poiché gli strozzature
disassati esercitano notevoli sollecitazioni sui
possono provocare gravi contropressioni. Le
cilindri e steli. Inoltre, il carico potrebbe
piegature e gli strozzature acute possono
scivolare o cadere, con risultati potenzialmente
danneggiare internamente il tubo flessibile e
pericolosi.
provocarne quindi un guasto prematuro.
Non lasciar cadere oggetti pesanti Distribuire il carico uniformemente
sul tubo flessibile, dato che l'impatto sull'intera superficie della testa del
potrebbe danneggiarne i fili pistone. Usare sempre una testina
dell'armatura. La messa sotto pressione di un per proteggere lo stelo quando non si
tubo flessibile danneggiato può causarne la usano attacchi filettati.
rottura. IMPORTANTE: Affidare la
manutenzione delle apparecchiature
IMPORTANTE: Non sollevare
idrauliche solamente a un tecnico
apparecchiature idrauliche mediante
specializzato. Per richiedere un
il tubo flessibile o i giunti orientabili.
intervento di assistenza, rivolgersi al centro di
Servirsi della maniglia per trasporto o di un
assistenza ENERPAC autorizzato di zona. Per
altro mezzo di trasporto sicuro.
usufruire dei termini di garanzia, utilizzare
PRECAUZIONE: Tenere esclusivamente olio idraulico ENERPAC.
l'apparecchiatura idraulica
lontano da fiamme e sorgenti di AVVERTENZA: Sostituire
calore. Il calore eccessivo immediatamente le parti usurate o
ammorbidisce le guarnizioni, provocando danneggiate con pezzi di ricambio
perdite di fluido. Il calore indebolisce altresì il ENERPAC originali. I pezzi di ricambio di
materiale di cui è composto il tubo flessibile. Per qualità standard si potrebbero rompere più
garantire le migliori prestazioni, non esporre facilmente e arrecare danni alla propria
l'apparecchiatura a temperature superiori a persona e all'ambiente circostante. I pezzi di
65°C (150°F). Proteggere i tubi flessibili e i ricambio ENERPAC sono stati concepiti per
cilindri da scintille o scaglie di saldatura. adattarsi perfettamente al sistema e per
sopportare condizioni di carico elevate.
PERICOLO: Non maneggiare i tubi
flessibili sotto pressione. Eventuali
fuoriuscite d'olio sotto pressione 3.0 INSTALLAZIONE
possono penetrare sotto la cute e provocare
gravi lesioni. Se l'olio penetra sotto la pelle, 1. Effettuare i collegamenti idraulici. Con i
rivolgersi immediatamente a un medico. cilindri ad effetto singolo (1), usare una
pompa con una valvola di scarico o una
AVVERTENZA: Utilizzare i cilindri
valvola a 3 vie ed un tubo flessibile. Usare
idraulici solo se i giunti del sistema
una pompa con una valvola a 4 vie e due
sono debitamente accoppiati. Se il
tubi flessibili per i cilindri a doppio effetto (2).
sovraccarico del cilindro diventa eccessivo, i
componenti possono guastarsi irreparabilmente
e provocare gravi lesioni personali. IMPORTANTE: nei cilindri a doppio effetto
devono essere collegati entrambi gli attacchi.
13
4.0 FUNZIONAMENTO
Azionare la pompa idraulica per estendere e
retrarre il cilindro. Alcuni cilindri ad effetto
singolo effettuano la corsa di ritorno sotto
l’effetto di una molla, altri sotto l’azione di un
carico. La velocità di retrazione è influenzata
dalla lunghezza del tubo flessibile idraulico e
da altre ostruzioni presenti nella tubazione. I
cilindri a doppio effetto sono azionati dalla
pompa sia in estensione che in retrazione.
La ghiera di finecorsa del cilindro è progettata
per assorbire l’intero carico. Volendo
comunque ridurre l’usura del cilindro, usare
una corsa sempre inferiore alla massima
consentita.
Serrare a fondo manualmente tutti gli

attacchi. Se gli attacchi sono lenti, il flusso 5.0 MANUTENZIONE
dell’olio tra la pompa e il cilindro si blocca. 1. Con questi cilindri usare solo olio Enerpac.
2. Rimuovere l’aria dal cilindro come indicato L’uso di qualsiasi altro olio può far decadere
qui di seguito. Cilindri ad effetto singolo: la garanzia.
disporre il cilindro in modo che lo stantuffo 2. Utilizzare i cappellotti di protezione quando
sia rivolto verso il basso ed il cilindro si trovi i cilindri sono scollegati dal tubo flessibile.
ad un’altezza inferiore rispetto alla pompa. Mantenere pulito il cilindro per prolungarne
Estendere e retrarre a fondo il cilindro due o la durata utile.
tre volte.
3. Conservare i cilindri in posizione verticale,
Cilindri a doppio effetto: disporre il cilindro per evitare la deformazione delle
su un fianco, con gli attacchi rivolti verso guarnizioni.
l’alto. Estendere e retrarre a fondo il cilindro
due o tre volte.
6.0 INDIVIDUAZIONE E SOLUZIONE DEI
3. Non permettete al pistone di ruotare mentre PROBLEMI
installate gli adattatori. La molla può
Questi cilindri devono essere riparati solo
danneggiarsi ruotando il pistone, e non
presso i Centri di Assistenza Autorizzati
permettere più il ritorno.
Enerpac. I cilindri ad effetto singolo sono
NOTA: le filettature con collare sono garantite precaricati a molla e pertanto richiedono
per l’intera capacità del cilindro solo quando speciali tecniche di smontaggio per evitare
sono completamente inserite negli accessori. infortuni.
NOTA: l’uso di prolunghe o di accessori del
cilindro riduce la capacità del cilindro di almeno
il 50%.
aira
aira
14
PROBLEMA POSSIBILE CAUSA
Il cilindro non si estende. La valvola di scarico della pompa è aperta.
L’attacco non è completamente serrato.
Il livello dell’olio nella pompa è insufficiente.
La pompa non funziona bene.
Il cilindro si estende solo parzialmente. Il carico è eccessivo in relazione al cilindro.

Il livello dell’olio nella pompa è insufficiente.
Il cilindro si estende a scatti. Lo stantuffo del cilindro è grippato.

Presenza di aria nell’impianto idraulico.
Lo stantuffo del cilindro è grippato.
Il cilindro si estende troppo lentamente. Perdita dalle connessioni.

La pompa non funziona bene.
Il cilindro si estende ma non mantiene la Perdita nelle guarnizioni del cilindro.

posizione. La pompa non funziona bene.
Perdita dai collegamenti.
Errato approntamento dei componenti
dell’impianto.
Il cilindro perde olio. Guarnizioni consumate o danneggiate.

Il cilindro è danneggiato internamente.
I collegamenti sono allentati.
Il cilindro non si retrae o si retrae troppo La valvola di scarico della pompa è chiusa.
lentamente. L’attacco non è completamente serrato.
Il serbatoio della pompa è troppo pieno.
Il tubo flessibile, troppo stretto, riduce il
flusso.
La molla di retrazione è debole o rotta.
Il cilindro è danneggiato internamente.
Perdita di olio dalla valvola di scarico L’attacco non è completamente serrato.

esterna. C’è un’ostruzione nella tubazione di ritorno.
15
Cilindros Hidraúlicos
L1608 Rev C 10/06
Las hojas de despiece para este producto estan
disponibles en la página web de Enerpac en la
dirección www.enerpac.com,o en su centro de
Asistencia Técnica ó punto de venta Enerpac
mas cercano.

RECEPCIÓN
Inspeccione visualmente todos los
componentes para verificar si hay daños de
envío. Debido a que la garantía no ampara
daños por envío, si los hubiese, infórmeselo
inmediatamente a la empresa de transportes, Un PELIGRO se utiliza sólo cuando su acción
puesto que ésta es responsable de todos los o falta de acción podría causar lesiones graves
gastos de reparaciones o reemplazo que o incluso la muerte.
resulten por daños de envío. ADVERTENCIA: Use el equipo de
protección personal adecuado
SEGURIDAD PRIMERO cuando opere equipo hidráulico.
2.0 ASPECTOS DE SEGURIDAD ADVERTENCIA: Manténgase
alejado de las cargas soportadas
Lea todas las instrucciones, por sistemas hidráulicos. Cuando
advertencias y precauciones. un cilindro se utiliza como dispositivo para
Acate todas las precauciones levantar carga, nunca debería usarse como
de seguridad para evitar lesiones personales o dispositivo para sostener carga. Después de
daños a la propiedad durante la operación del que la carga haya sido levantada o
sistema. ENERPAC no puede ser responsable descendida, debe bloquearse siempre en
de daños o lesiones que resulten de no usar el forma mecánica.
producto de forma segura, falta de
mantenimiento o aplicación incorrecta del ADVERTENCIA: USE SÓLO
producto y/u operación del sistema. PIEZAS RÍGIDAS PARA
Comuníquese con ENERPAC si tuviese dudas SOSTENER CARGAS. Seleccione
sobre las precauciones de seguridad o sobre cuidadosamente bloques de acero o
las aplicaciones. Si nunca ha sido capacitado de madera capaces de soportar la carga.
en seguridad hidráulica de alta presión, Nunca use un cilindro hidráulico como calza o
consulte a su distribuidor o centro de servicio separador en aplicaciones de levantamiento o
para obtener un curso de seguridad gratis presión.
denominado ENERPAC Hydraulic. PELIGRO: Para evitar lesiones
El no cumplir con las siguientes precauciones personales, mantenga las
y advertencias podría causar daños al equipo y manos y los pies alejados del
lesiones personales. cilindro y pieza de trabajo durante la operación.
Una PRECAUCIÓN se utiliza para indicar ADVERTENCIA: No sobrepase el

procedimientos y prácticas de operación o valor nominal del equipo. Nunca
mantenimiento correctos para evitar daños o la intente levantar una carga que pese
destrucción de equipo u otra propiedad. más de la capacidad del cilindro. Las
sobrecargas ocasionan fallas del equipo y
Una ADVERTENCIA indica un potencial posibles lesiones personales. Los cilindros
peligro que requiere de procedimientos o están diseñados para resistir una presión
prácticas correctos para evitar lesiones máxima de 700 bar. No conecte un gato o
personales. cilindro a una bomba cuyo valor nominal de
presión es mayor que el indicado.
16
PELIGRO: Nunca fije la válvula de componentes pueden fallar calamitosamente,
seguridad a una presión más alta lo que causaría lesiones personales graves.
que el máximo valor nominal de ADVERTENCIA: Asegurese que el
presión de la bomba. Los ajustes más altos equipo sea antes de levantar la
pueden resultar en daños al equipo y/o carga. El cilindro debe colocarse
lesiones personales. No remover la válvula de sobre una superficie plana capaz de
seguridad. soportar la carga. De ser necesario, utilice una
ADVERTENCIA: La presión de base de cilindro para mayor estabilidad. No
operación del sistema no debe suelde ni modifique el cilindro en modo alguno
sobrepasar el valor nominal de para fijarle una base u otro medio de soporte.
presión del componente con el valor nominal Evite las situaciones en las cuales las
más bajo en el sistema. Instale manómetros de cargas no estén directamente
presión en el sistema para vigilar la presión de centradas sobre el émbolo del
operación. Es su ventana a lo que está cilindro. Las cargas descentradas producen un
sucediendo en el sistema. esfuerzo considerable sobre los cilindros y los
PRECAUCIÓN: Evite dañar la émbolos. Adeás, la carga podria resbalar o
manguera hidráulica. Evite pliegues caerse, creando situaciones potencialmente
y curvas agudos al guiar las peligrosas.
mangueras hidráulicas. Usar una manguera
Distribuya la carga uniformemente
con pliegues o curvas puede causar severa
sobre la superficie total del asiento
contrapresión. Los pliegues y curvas agudos
del cilindro. Siempre utilice un
causarán daños internos la manguera, lo que
asiento para proteger el émbolo
ocasionará que ésta falle prematuramente.
cuando no se usen accesorios roscados.
No deje caer objetos pesados sobre IMPORTANTE: Únicamente técnicos
la manguera. Un impacto directo calificados en sistemas hidráulicos
puede causar daños internos a las habrán de prestarle servicio al
hebras de alambre de la manguera. Aplicar equipo hidráulico. Comuníquese con
presión a una manguera dañada puede el Centro de Servicio ENERPAC autorizado en
ocasionar que se quiebre. su zona para prestarle servicio de
IMPORTANTE: No levante el equipo reparaciones. Use únicamente aceite
hidráulico por las mangueras o ENERPAC a fin de proteger su garantía.
acopladores giratorios. Use el mango ADVERTENCIA: Reemplace
de transporte u otros medios para transportarla inmediatamente las piezas gastadas
con seguridad. o dañadas por piezas ENERPAC
PRECAUCIÓN: Mantenga el genuinas. Las piezas de clasificación estándar
equipo hidráulico alejado de las se romperán, lo que causará lesiones
llamas y el calor. El calor en personales y daños a la propiedad. Las piezas
exceso ablandará las juntas y sellos, lo que ENERPAC están diseñadas para encajar
resultará en fugas de líquidos. Asimismo, el debidamente y resistir altas cargas.
calor debilita los materiales de la manguera y
juntas. Para lograr un rendimiento óptimo, no
exponga el equipo a temperaturas de 65 °C 3.0 INSTALACION
[150 °F] o mayores. Proteja las mangueras y
cilindros de salpicaduras de soldadura. 1. Conecte los componentes hidráulicos.
Utilice una bomba con una válvula de alivio
PELIGRO: No manipule o válvula de 3 vías y una manguera para los
mangueras bajo presión. El aceite cilindros de acción única (1). Utilice una
que escape bajo presión puede bomba con una válvula de 4 vías y dos
penetrar la piel y causar lesiones graves. Si se mangueras para los cilindros de doble
inyecta aceite bajo la piel, consulte a un acción (2).
médico inmediatamente.
IMPORTANTE: Los cilindros de doble
ADVERTENCIA: Use cilindros acción deberán tener ambos acopladores
hidráulicos únicamente en conectados.
sistemas acoplados. Nunca use un Apriete todos los acopladores con la mano.
cilindro si los acopladores no están Las conexiones flojas bloquearán el flujo del
conectados. Si el cilindro se sobrecarga, los
17
un 50% como mínimo.
4.0 FUNCIONAMIENTO
Accione la bomba hidráulica para extender y
retraer el cilindro. Algunos cilindros de acción
única tienen retorno por acción de resorte,
otros tienen retorno por acción de la carga. La
velocidad de retracción se ve afectada por la
longitud de la manguera y otras restricciones
en la línea. Los cilindros de doble acción son
impulsados en ambos sentidos por la bomba.
El casquillo de tope del cilindro está diseñado
para aceptar toda la carga. Sin embargo, para
aceite entre la bomba y el cilindro. reducir el desgaste del cilindro emplee, siempre
que sea posible, menos del total de la carrera.
2. Purgue el aire del cilindro como se muestra
a continuación. Cilindros de acción única: 5.0 MANTENIMIENTO
Coloque el cilindro de modo que su émbolo
funcione hacia abajo y el cilindro esté 1. Utilice con estos cilindros aceite hidráulico
colocado en posición más baja que la Enerpac exclusivamente. El empleo de
bomba. Extienda y retraiga el cilindro por cualquier otro aceite hidráulico puede
completo 2 ó 3 veces. invalidar la garantía.
Cilindros de doble acción: Coloque el 2. Utilice tapas guardapolvo cuando los
cilindro sobre su costado con los cilindros estén desconectados de la
acopladores hacia arriba. Extienda y manguera. Mantenga limpio el cilindro en su
retraiga el cilindro por completo 2 ó 3 veces. totalidad para prolongar la vida útil del
mismo.
3. NO PERMITIR QUE EL VASTAGO 3. Almacene los cilindros en posición vertical
GIRE CUANDO SE ESTEN INSTALANDO para evitar la distorsión de los sellos.
LOS ADAPTADORES. EL RESORTE PUEDE
DANARSE CUANDO SE GIRE EL VASTAGO
HACIENDO QUE ESTE NO RETORNE. 6.0 LOCALIZACION DE AVERIAS
NOTA: Las roscas de la camisa están La reparación de estos cilindros debe

graduadas para la capacidad total del cilindro efectuarse únicamente en centros autorizados
cuando están totalmente acoplados los de servicio técnico de Enerpac. Los cilindros
accesorios. de acción única están bajo carga de resorte y
requieren el uso de técnicas especiales de
NOTA: El empleo de accesorios o extensiones
desarmado para evitar las lesiones personales.
del cilindro reduce la capacidad del cilindro en
aire
aire
18
PROBLEMA CAUSA POSIBLE
El cilindro no avanza. La válvula de alivio de la bomba está abierta.

El acoplador no está completamente
apretado.
El nivel de aceite en la bomba está bajo.
Mal funcionamiento de la bomba.
El cilindro avanza parcialmente. Carga demasiado pesada para el cilindro.

El nivel de aceite en la bomba está bajo.
apretado.
El cilindro avanza de forma irregular. Agarrotamiento del émbolo del cilindro.

Aire en el sistema hidráulico.
Agarrotamiento del émbolo del cilindro.
El cilindro avanza más lento que lo normal. Fugas en la conexión.

apretado.
Mal funcionamiento de la bomba.
El cilindro avanza pero no retiene su Fugas en sellos del cilindro.

posición. Mal funcionamiento de la bomba.
Fugas en la conexión.
Conexión incorrecta del sistema.
Fugas de aceite en el cilindro. Sellos desgastados o dañados.

Daños internos en el cilindro.
Conexiones flojas.
El cilindro no se retrae o se retrae más lento La válvula de alivio de la bomba está

que lo normal. cerrada.
apretado.
Depósito de la bomba excesivamente lleno.
Restricción del flujo en la manguera.
Resorte de retracción roto o debilitado.
Daños internos del cilindro.
Fugas de aceite por la válvula de alivio El acoplador no está completamente

externa. apretado.
Restricción en la línea de retorno.
19
Instructieblad
Hydraulische Cilinders
L1608 Rev C 10/06

Reparatie/Onderdelenlijsten voor deze
produkten zijn te downloaden van de Enerpac
Website www.enerpac.com of verkrijgbaar via
uw Enerpac Service Centre of
vertegenwoordiger.

ONTVANGST
opgelopen tijdens de verzending. Schade
opgelopen tijdens de verzending wordt niet door
de garantie gedekt. Als schade opgelopen
tijdens de verzending wordt gevonden, de vereist om persoonlijk letsel te voorkomen.
transporteur hier onmiddellijk van op de hoogte GEVAAR wordt enkel gebruikt als uw actie of
stellen. De transporteur is verantwoordelijk voor gebrek aan actie ernstig letsel of zelfs de dood
alle reparatie- of vervangingsonkosten als tot gevolg kan hebben.
gevolg van opgelopen schade tijdens de
WAARSCHUWING: Draag de juiste
verzending. persoonlijke beschermende kleding
VEILIGHEID VOOROP bij het werken met hydraulische
machines.
2.0 VEILIGHEIDSKWESTIES WAARSCHUWING: Blijf uit de buurt
Lees nauwkeurig alle van ladingen die hydraulisch
instructies, waarschuwingen worden ondersteund. Een cilinder
en let op-gedeelten. Volg alle die wordt gebruikt als een hefinrichting mag
veiligheidsvoorzieningen om persoonlijk letsel nooit worden gebruikt als een lasthouder. Nadat
of schade aan eigendom te voorkomen als het de lading omhoog of omlaag is gebracht, moet
systeem in werking is. Enerpac kan niet deze altijd mechanisch worden geblokkeerd.
verantwoordelijk worden gesteld voor schade WAARSCHUWING: GEBRUIK
of letsels als gevolg van onveilig gebruik van ENKEL STIJVE MATERIALEN OM
dit product, gebrek aan onderhoud, of onjuiste DE LADINGEN VAST TE HOUDEN.
toepassing van het product of het systeem. Kies met zorg stalen of houten blokken die een
Neem contact op met Enerpac mocht u twijfels lading kunnen ondersteunen. Gebruik nooit
hebben over veiligheidsvoorzieningen en een hydraulische cilinder als een pakkingschijf
werkingen. Als u nooit een opleiding in of een afstandstuk in enige toepassing waarbij
hogedruk hydraulische veiligheid hebt gevolgd opheffen of drukken wordt gebruikt.
neem dan contact om met uw verdeel- of
GEVAAR: Om persoonlijk letsel
servicecentrum voor een gratis
te voorkomen, handen en
veiligheidscursus van Enerpac Hydraulic.
voeten weghouden van de
Het niet volgen van deze waarschuwing cilinder en het werkstuk tijdens de bediening.
sboodschappen en voorzorgsmaatregelen kan
WAARSCHUWING: Niet de
schade aan de machine en persoonlijk letsel
nominale waarden van de machines
veroorzaken.
overschrijden. Probeer nooit om een
LET OP wordt gebruikt om correcte lading op te heffen die meer weegt dan de
bedienings- en onderhoudsprocedures en capaciteit van de cilinder. Overladen
praktijken aan te duiden om schade aan, of veroorzaakt falen van de machine en mogelijk
vernietiging van, machines of andere persoonlijk letsel. De cilinders zijn ontworpen
eigendom te voorkomen. voor een maximale druk van 700 bar. Geen
WAARSCHUWING wijst op een mogelijk vijzel of cilinder op een pomp aansluiten die
gevaar dat de juiste procedures en praktijken een hogere drukwaarde heeft.
20
GEVAAR: Nooit de ontlastklep aangesloten zijn. Als de cilinder uiterst
instellen op een hogere druk dan de overladen is, kunnen onderdelen op een
maximaal nominale druk van de catastrofistische manier falen wat ernstig
pomp. Hogere instellingen kunnen schade aan persoonlijk letsel kan veroorzaken.
de machine en/of persoonlijk letsel tot gevolg WAARSCHUWING: Zorg dat de
hebben. Verwijder niet de ontlastklep. apparatuur stabiel is opgezet
WAARSCHUWING: De alvorens lasten te heffen. De
bedieningsdruk van het systeem mag cilinder dient op een vlakke
de nominale drukwaarde van het ondergrond geplaatst te worden die de last kan
onderdeel met de laagste waarde in het dragen. Gebruik waar mogelijk een
systeem niet overschrijden. Installeer ondersteuning voor de cilinder voor extra
drukmeters in het systeem om de stabiliteit. De cilinder mag niet gelast of op een
bedieningsdruk te controleren. Op die manier andere manier aangepast worden voor het
weet u wat er in het systeem gebeurt. bevestigen van een voetstuk of andere
ondersteuning.
LET OP: De hydraulische slang niet
beschadigen. Vermijd ombuigen en Vermijd situaties, waarbij de last niet
knikken bij het aanbrengen van de aangrijpt in het hart van de
hydraulische slangen. Een gebogen of cilinderplunjer. Niet-centrisch
geknikte slang gebruiken kan ernstige aangrijpende lasten veroorzaken aanzienlijke
tegendruk van de afvoerstroom veroorzaken. spanningen in de cilinder en de plunjer.
Scherpe ombuigingen en knikken beschadigen Bovendien kan de last wegglijden of vallen, wat
de slang aan de binnenkant wat tot vroegtijdig tot gevaarlijke situaties leidt.
falen van de slang kan leiden. Verdeel de last gelijkmatig over het
Geen zware objecten op de slang gehele zadelopperviak. Gebruik altijd
laten vallen. Een scherpe impact een zadel om de plunjer te
kan interne schade aan de beschermen, wanneer geen
draadvezels van de slang veroorzaken. Druk hulpstukken met schroefdraad worden gebruikt.
uitoefenen op een slang die beschadigd is, BELANGRIJK: Hydraulische
kan scheuren van de slang tot gevolg hebben. machines mogen enkel door een
BELANGRIJK: Hydraulische bevoegd hydraulisch technicus van
machines niet bij de slangen of de onderhoud worden voorzien. Voor reparaties
wartelkoppelingen opheffen. Gebruik dient u contact op te nemen met een
de draaghandgreep of een ander middel om de nabijgelegen bevoegd ENERPAC
machine veilig te transporteren. servicecentrum. Om uw garantie te
LET OP: Houd de hydraulische beschermen, enkel ENERPAC olie gebruiken.
machine weg van vlammen en WAARSCHUWING: Versleten of
hitte. Buitenmatige hitte verzacht beschadigde onderdelen onmiddellijk
de pakkingen en afdichtingen wat tot met authentieke ENERPAC
vloeistoflekken kan leiden. Hitte verzwakt ook onderdelen vervangen. Standaardonderdelen
slangmaterialen en pakkingen. Voor optimale breken, wat tot persoonlijk letsel en schade
prestaties de machines niet blootstellen aan aan eigendom kan leiden. ENERPAC
temperaturen van 65°C (150°F) of hoger. onderdelen zijn zodanig ontworpen dat ze
Bescherm slangen en cilinders tegen precies passen en hoge ladingen kunnen
lasspetters. weerstaan.
GEVAAR: Slangen die onder druk 3.0 INSTALLATIE
staan, niet aanraken. Als olie die
onder druk staat ontsnapt, kan het 1. Sluit de hydraulische slangen aan. Gebruik
door de huid dringen wat ernstige letsel kan een pomp met een ontlastkraan of een 3-
veroorzaken. Als olie onder de huid wordt wegklep en één slang voor enkelwerkende
geïnjecteerd, onmiddellijk een arts raadplegen. cilinders (1). Gebruik een pomp met een 4-
wegklep en twee slangen voor
WAARSCHUWING: Gebruik
dubbelwerkende cilinders (2).
hydraulische cilinders enkel in een
aangesloten systeem. Nooit een BELANGRIJK: Bij dubbelwerkende
cilinder gebruiken met koppelingen die niet cilinders moeten beide koppelingen
aangesloten zijn.
21
4.0 WERKING
Stel de hydraulische pomp in werking om de
cilinder uit en terug te laten lopen. Sommige
enkelwerkende cilinders zijn uitgevoerd met
veerterugloop en andere met lastterugloop.
De terugloopsnelheid wordt beïnvloed door de
lengte van de slang en andere
stroomweerstanden in de leiding.
Dubbelwerkende cilinders worden in beide
richtingen door een pomp aangedreven.
De cilinderstopring is ontworpen om de volle

kracht op te kunnen nemen. Gebruik echter,
indien mogelijk, niet de gehele slag om
Draai alle koppelingen volledig met de hand slijtage van de cilinder te verminderen.
vast. Onvolledig aangedraaide koppelingen
blokkeren de oliestroom tussen de pomp en
5.0 ONDERHOUD
de cilinder.
2. Verwijder lucht uit de cilinder zoals 1. Gebruik uitsluitend olie van Enerpac in deze
hieronder wordt afgebeeld. Enkelwerkende cilinders. Bij gebruik van andere olie kan de
cilinders: Plaats de cilinder zodanig dat de garantie vervallen.
plunjer naar beneden gericht is en de 2. Gebruik stofkappen wanneer er geen
cilinder lager ligt dan de pomp. Laat de slangen op de cilinders zijn aangesloten.
cilinder 2 à 3 keer uit en terug lopen. Houd de hele cilinder schoon voor een
Dubbelwerkende cilinders: Leg de cilinder langere levensduur.
op de zijkant en zorg dat de koppelingen 3. Bewaar de cilinders rechtop om vervorming
naar boven gericht zijn. Laat de cilinder 2 à van de afdichtingen te voorkomen.
3 keer uit en terug lopen.
3. Voorkom meedraaien van de plunjer
wanneer toebehoren als zadels of andere 6.0 OPLOSSEN VAN STORINGEN
hulpstukken worden gemonteerd. Verdraaien Deze cilinders mogen alleen bij een erkend
van de plunjer kan de veer beschadigen technisch servicecentrum van Enerpac
waardoor de plunjer niet meer terugloopt. gerepareerd worden. In enkelwerkende
NB: De buitendraad van de cilinder is berekend cilinders wordt veerkracht gebruikt voor de
op de volle capaciteit van de cilinder, mits de terugloop en daarom is een speciale
hulpstukken volledig zijn opgeschroefd. demontagetechniek vereist om lichamelijk
letsel te voorkomen
NB: het gebruik van cilinderhulpstukken
vermindert de capaciteit van de cilinder met ten
minste 50%.
lucht
lucht
22
PROBLEEM MOGELIJKE OORZAAK
Cilinder komt niet naar buiten. Pompontlastkraan open.

Koppeling niet volledig aangedraaid.
Oliepeil in pomp te laag.
Pomp werkt niet.
Cilinder gaat slechts gedeeltelijk uit. Last is te zwaar voor cilinder.

Oliepeil in pomp is te laag.
Cilinder gaat schoksgewijs uit. Plunjer van cilinder loopt vast.

Lucht in hydraulisch systeem.
Plunjer van cilinder loopt vast.
Cilinder gaat langzamer uit dan normaal. Lekkende verbinding.

Pomp werkt niet.
Cilinder gaat uit, maar blijft niet op druk. Cilinderafdichting lekt.

Pomp werkt niet.
Lekkende verbinding.
Systeem niet correct opgezet.
Cilinder lekt olie. Afdichtingen versleten of beschadigd.

Cilinder inwendig beschadigd.
Losse verbinding.
Cilinder loopt niet of langzamer dan normaal Pompontlastkraan gesloten.

terug. Koppeling niet volledig aangedraaid.
Te veel olie in pomp.
Te nauwe slang beperkt stroming.
Terugloopveer gebroken of zwak.
Cilinder inwendig beschadigd.
Olie lekt uit extern ontlastkraan. Koppeling niet volledig aangedraaid.

Stroomweerstand in retourleiding.
23
Cilindros Hidráulicos
L1608 Rev C 10/06

Folhas de Instrução para este produto estão
disponíveis no Site de Enerpac -
www.enerpac.com, ou no Centro de Serviço
Autorizado mais próximo, ou com o Escritório
de Vendas Enerpac.

RECEBIMENTO
Inspecione visualmente todos os componentes
verificando se houve avarias durante o
transporte. Avarias no transporte não são
cobertas pela garantia. Caso haja avarias no mesmo a morte.
transporte, avise o transportador imediatamente. ADVERTÊNCIA: Use equipamentos
O transportador é responsável por todos os individuais de proteção quando
custos de consertos e substituições decorrentes acionar equipamentos hidráulicos.
de avarias ocorridas no transporte.
ADVERTÊNCIA: Mantenha distância
SEGURANÇA EM PRIMEIRO LUGAR de cargas apoiadas por cilindros
2.0 ASSUNTOS DE SEGURANÇA hidráulicos. Um cilindro, quando
utilizado como dispositivo de levantamento,
Leia cuidadosamente todas jamais deve ser usado como dispositivo de
as instruções, advertências e sustentação de carga. Depois de haver sido
avisos sobre precaução. Siga levantada ou baixada, a carga deve sempre
todas as recomendações de segurança para ser bloqueada mecanicamente
evitar lesões pessoais ou danos à propriedade
durante a operação do sistema. Enerpac não ADVERTÊNCIA: USE SOMENTE
pode ser responsável por danos ou lesões PEÇAS RÍGIDAS PARA APOIAR AS
pessoais resultantes do uso indevido do produto, CARGAS. Selecione cuidadosamente
falta de manutenção ou operação inadequada blocos de madeira ou ferro que sejam capazes
do produto e/ou sistema. Entre em contato com de sustentar a carga. Nunca use um cilindro
Enerpac quando houver dúvidas sobre as hidráulico como um calço ou espaçador em
recomendações de segurança e operações. Se qualquer aplicação de levantamento ou
você nunca recebeu treinamento em segurança prensagem.
na hidráulica de alta pressão, consulte o seu PERIGO: Para evitar lesões
distribuidor ou centro de serviço sobre um curso pessoais mantenha mãos e
de segurança hidráulica Enerpac. pés longe do cilindro e da área
Falhas no cumprimento das advertências e de trabalho durante a operação.
avisos de precaução podem causar lesões ADVERTÊNCIA: Não exceda a
pessoais e avarias ao equipamento. capacidade do equipamento. Nunca
PRECAUÇÃO é usada para indicar a tente levantar uma carga mais
operação correta ou os procedimentos e pesada que a capacidade do cilindro. Excesso
métodos de manutenção para prevenir o dano, de carga pode causar falhas no equipamento e
a destruição do equipamento ou outras possíveis lesões pessoais. Os cilindros são
propriedades. projetados para uma pressão máxima de 700
bar [10.000 psi]. Não faça a ligação entre um
ADVERTÊNCIA indica um perigo potencial macaco ou um cilindro com uma bomba com
que exige procedimentos ou métodos capacidade maior de pressão.
corretivos para evitar lesões pessoais.
PERIGO: Nunca ajuste uma válvula
PERIGO é usado somente quando a ação ou a de alívio com pressão maior que a
falta da mesma podem causar lesões sérias ou capacidade de pressão máxima da
24
bomba. Ajustes maiores podem resultar em causando severas lesões pessoais.
danos ao equipamento e/ou lesões pessoais. ADVERTÊNCIA: ESTEJA CERTO
Não remova a válvula de alívio. QUE A MONTAGEM É ESTÁVEL
ADVERTÊNCIA: A pressão de ANTES DE LEVANTAR A CARGA.
operação do sistema não deve Os cilindros devem ser colocados
exceder a capacidade de pressão do em superfícies planas que podem apoiar a
componente de menor capacidade no sistema. carga. Quando aplicável, use uma base de
Instale manômetros de pressão no sistema cilindro Enerpac para aumentar a estabilidade.
para monitorar a pressão de operação. É a sua Não faça soldas ou, de qualquer forma,
janela para o que está acontecendo no modifique o cilindro para acrescentar uma
sistema. base ou outro apoio.
PRECAUÇÃO: Evite danificar Evite situações em que as cargas
mangueiras hidráulicas. Evite curvas não estão centradas na haste do
ou dobras pronunciadas quando cilindro. Cargas fora de centro
direcionar as mangueiras hidráulicas. O uso de podem causar deformações consideráveis nas
uma mangueira curvada ou dobrada causará hastes e nos cilindros. Além disto, a carga
aumento na pressão de retorno. Curvas ou pode escorregar ou cair, causando resultados
dobras pronunciadas danificarão a mangueira potencialmente perigosos.
internamente, levando a um desgaste Distribua a carga uniformemente em
prematuro. toda a superfície do assento. Use
Não derrube objetos pesados na sempre um assento para proteger a
mangueira. Um forte impacto pode haste.
causar danos à trama interna de IMPORTANTE: Somente técnicos
aço da mangueira. A aplicação de pressão em em hidráulica, devidamente
uma mangueira danificada pode causar a sua qualificados, devem fazer a
ruptura. manutenção de equipamentos hidráulicos.
IMPORTANTE: Não levante o Para serviços de manutenção, entre em
equipamento hidráulico pela contato com o Centro de Serviço Autorizado
mangueira ou pelos engates. Use Enerpac em sua área. Para proteger sua
manoplas ou outros meios mais seguros para garantia, use somente óleo Enerpac.
o transporte. ADVERTÊNCIA: Substitua
PRECAUÇÃO: Mantenha o imediatamente peças gastas ou
equipamento hidráulico longe do danificadas por peças genuínas
calor e das chamas. O calor Enerpac. Peças não genuínas podem quebrar,
excessivo amolece vedações e selos, causando lesões pessoais ou danos à
resultando em vazamento de fluídos. O calor propriedade. As peças Enerpac são projetadas
também enfraquece o material das para se encaixar adequadamente e sustentar
mangueiras e das juntas. Para um cargas pesadas.
desempenho otimizado não exponha o
equipamento a temperatura maiores que 65 °C 3.0 INSTALAÇÃO
[150 °F]. Proteja mangueiras e cilindros dos Faça as conexões hidráulicas. Use uma
respingos de solda. bomba com válvula de alívio ou uma válvula de
PERIGO: Não manuseie mangueiras 3 vias e uma mangueira para cilindros de
pressurizadas. O escape do óleo sob simples ação (1). Use uma bomba com válvula
pressão pode penetrar na pele, de 4 vias e duas mangueiras para cilindros de
causando lesões sérias. Se o óleo penetrar na dupla ação (2).
pele, procure um médico imediatamente. IMPORTANTE: Ao utilizar cilindros de dupla
ADVERTÊNCIA: Use somente ação, verifique se os dois engates estão
cilindros hidráulicos num sistema conectados. Todos os engates deverão ser
acoplado. Nunca use um cilindro com apertados manualmente. Engates soltos
engates não conectados. Caso o cilindro se bloqueiam o fluxo de óleo entre a bomba e o
torne extremamente sobrecarregado, os cilindro.
componentes podem falhar catastroficamente,
25
4.0 OPERAÇÃO
Acione a bomba hidráulica para fazer com que
o cilindro avance ou retorne. Há cilindros de
simples ação com retorno por mola, outros
são de retorno por carga. A velocidade de
retorno depende do comprimento da
mangueira e outras restrições na linha.
Cilindros de dupla ação são acionados nos
dois sentidos pela bomba.
O anel de parada do cilindro foi projetado para
suportar a carga total. Entretanto, para reduzir
o desgaste no cilindro, utilize o curso menor,
2. Sangre o ar do cilindro conforme sempre que possível.
demonstrado abaixo.
5.0 MANUTENÇÃO
Cilindros de simples ação: Posicione o
cilindro de tal forma que a haste fique voltada 1. Use somente óleo hidráulico Enerpac com
para baixo e o cilindro esteja posicionado estes cilindros. A utilização de qualquer
abaixo do nível da bomba. Distenda e retraia a outro óleo pode invalidar a sua garantia.
haste do cilindro por 2 ou três vezes. 2. Use conexões guarda-pó nos engates das
Cilindros de dupla ação: Coloque o cilindro mangueiras quando elas não estiverem
na posição horizontal com os engates voltados conectadas aos cilindros. Mantenha o
para cima. Distenda e retraia a haste do cilindro totalmente limpo para prolongar a
cilindro por 2 ou três vezes. sua vida útil.
3. Ao instalar adaptadores, não permita que a 3. Enquanto os cilindros não estiverem em
haste faça um movimento giratório. A mola uso, guarde-os na posição vertical para
pode ser danificada, caso ocorra um giro da evitar deformação das vedações.
haste, impedindo o seu retorno.
NOTA: Para que os cilindros operem em sua 6.0 IDENTIFICAÇÃO DE PROBLEMAS
capacidade total, a rosca do colarinho deve
Estes cilindros deverão ser consertados apenas
estar completamente rosqueada no dispositivo
nos Centros de Serviço Autorizado Enerpac. Os
correspondente.
cilindros de simples ação que são do tipo
NOTA: O uso de acessórios ou extensões no retorno por mola necessitam técnicas especiais
cilindro reduz a sua capacidade em pelo de desmontagem para evitar lesões pessoais.
menos 50%.
ar
ar
26
PROBLEMA CAUSAS POSSÍVEIS
Cilindro não avança. 1. A válvula de alívio da bomba está aberta.
2. O engate hidráulico não está.
completamente apertado.
3. O nível de óleo na bomba está baixo.
4. Mau funcionamento da bomba.
5. Carga além da capacidade do cilindro.
Cilindro avança parcialmente. 1. O nível de óleo na bomba está baixo.
2. O engate hidráulico não está
3. Engripamento da haste do cilindro.
Cilindro avança aos trancos. 1. Ar no sistema hidráulico.
2. Engripamento da haste do cilindro.
Cilindro avança mais devagar que o normal. 1. Vazamento de óleo na conexão.
2. O engate hidráulico não está
Cilindro avança mas não sustenta a carga. 1. Vazamento nas vedações do cilindro.
3. Vazamento de óleo na conexão.
4. Montagem inadequada do sistema.
Há vazamento de óleo no cilindro. 1. Vedações gastas ou danificadas.
2. Danos internos no cilindro.
3. Conexão solta.
Cilindro não retorna ou retorna mais devagar 1. Válvula de alívio da bomba está fechada.
que o normal. 2. O engate hidráulico não está
3. Excesso de óleo no reservatório da bomba.
4. Mangueira estreita, restringindo o fluxo.
5. Mola de retração quebrada ou enfraquecida.
6. Cilindro danificado internamente.
Vazamento de óleo na válvula externa de 1. O engate hidráulico não está
alívio. completamente apertado.
2. Restrição na linha de retorno.
27
Instruksjonsark
Hydrauliske sylindre
L1608 Rev C 10/06
Reservedeleark for dette produktet kan fås på ADVARSEL: Nødvendig verneutstyr

Enerpacs nettside, www.enerpac.com, eller fra skal benyttes ved bruk av hydraulisk
ditt nærmeste autoriserte Enerpac servicesenter utstyr.
eller Enerpac salgskontor.
ADVARSEL: Hold avstand fra last som
1.0 VIKTIGE INSTRUKSJONER FOR MOTTAK er støttet av hydraulikk. Sylindre som
Se nøye etter om noen av delene har fått skade benyttes til løfting av last skal aldri
under transport. Transportskader dekkes ikke benyttes til holding av last. Etter at lasten er
av garantien. Dersom det oppdages hevet eller senket, skal den alltid blokkeres
transportskade, skal transportør øyeblikkelig mekanisk.
underrettes. Transportøren er ansvarlig for alle
reparasjoner og erstatningskostnader som ADVARSEL: KUN SOLIDE DELER
oppstår på grunn av skade under transport. SKAL BENYTTES TIL HOLDING AV
LAST.
SIKKERHETEN I HØYSETET Velg nøye ut klosser av stål eller tre som er
sterke nok til å holde lasten. Hydrauliske
2.0 SIKKERHET sylindre skal aldri benyttes som mellomlegg eller
Les alle instruksjoner, advarsler avstandsstykke i forbindelse med løfting eller
og forsiktighetsregler nøye. For pressing.
å unngå personskade og skade
på eiendom ved drift av systemet, skal alle FARE: For å unngå
sikkerhetsforskrifter følges nøye. Enerpac kan personskade, skal hender og
ikke holdes ansvarlig for skade som oppstår føtter holdes borte fra sylinder
som følge av utrygg bruk av produktet, mangel og arbeidsstykke ved drift.
på vedlikehold eller feil bruk av produkt og/eller
system. ADVARSEL: Ikke overstig
utstyrsklassifiseringen. Løft aldri last
Ta kontakt med Enerpac dersom du har som er tyngre enn sylinderens
spørsmål angående sikkerhetsforskrifter og kapasitet. Overbelastning kan forårsake feil på
bruk. Dersom du aldri har fått opplæring i utstyr og fare for personskade. Sylindrene er
hydraulisk høytrykkssikkerhet kan du ta kontakt utviklet for et maksimalt trykk på 700 bar [10
med ditt distribusjons- eller servicesenter for å 000 psi]. Jekker og sylindre må ikke kobles til
delta på Enerpacs kostnadsfrie pumper med høyere trykklasse.
hydraulikksikkerhetskurs. Mangel på
overholdelse av disse forsiktighetsreglene og FARE: Still aldri inn høyere trykk for
advarslene kan forårsake person- og sikkerhetsventilen enn maksimalt trykk
utstyrsskade. for pumpen. Høyere trykk kan føre til
utstyrsskade og/eller personskade.
FORSIKTIG benyttes til å angi riktige drifts- eller Sikkerhetsventilen må ikke fjernes.
vedlikeholdsprosedyrer og –praksis for å unngå
skade på utstyr eller annen eiendom. ADVARSEL: Systemets driftstrykk skal
ikke overgå trykket for
ADVARSEL angir en potensiell skade der systemkomponenten med lavest
korrekt prosedyre eller praksis må følges for å trykklasse. Installer trykkmålere i systemet for å
unngå personskade. overvåke driftstrykket. På denne måten kan du
se hva som skjer i systemet.
FARE benyttes kun dersom dine handlinger eller
mangel på handlinger kan forårsake alvorlig FORSIKTIG: Unngå å skade den
skade eller dødsfall. hydrauliske slangen. Unngå bøying og
krølling ved legging av hydrauliske
28
slanger. Bruk av bøyd eller krøllet slange skaper Skjev last skaper vesentlig belastning
kraftig mottrykk. Bretter og krøller skaper indre på sylindre og stempler. I tillegg kan
skader i slangen som kan føre til at den får lasten skli eller falle, og dermed skape
forkortet levetid. potensielt farlige situasjoner. Fordel
sdle.eps
lasten jevnt over trykkhodet. Trykkhode skal

Tunge gjenstander må ikke slippes alltid benyttes til å beskytte stempelet.
på slangen. Kraftige støt kan
forårsake indre skader på slangens VIKTIG: Hydraulisk utstyr skal kun
metalltråder. En skadet slange kan sprekke repareres av en kvalifisert
dersom den utsettes for trykk. hydraulikkingeniør. Kontakt ditt
områdes autoriserte ENERPAC-
VIKTIG: Hydraulisk utstyr skal ikke servicesenter ved behov for reparasjoner. For å
løftes i slangen eller i svivelkoplingene. beskytte garantien, skal kun ENERPAC-olje
Benytt bærehåndtakene eller andre benyttes.
trygge transporteringsmetoder.
ADVARSEL: Utslitte eller skadede
FORSIKTIG: HYDRAULISK deler skal øyeblikkelig erstattes med
UTSTYR SKAL HOLDES BORTE originale ENERPAC-deler. Vanlige deler
FRA ÅPEN ILD OG VARME. vil brekke, og dermed forårsake personskade og
Ekstrem varme mykner pakninger og skade på eiendom. ENERPAC-deler er korrekt
forseglinger, og dette forårsaker væskelekkasje. tilpasset, og tåler kraftig last.
Varme svekker også slangematerialene og
pakningene. For best ytelse bør ikke utstyret 3.0 INSTALLASJON
utsettes for temperaturer over 65 °C. Slanger og 1. Koble til hydraulikktilkoblingene. Bruk en
sylindre skal vernes mot sveisesprut. pumpe med senkeventil eller 3-veisventil og
slange til enkeltvirkende sylindere (1). Bruk en
FARE: SLANGER UNDER TRYKK pumpe med 4-veisventil og to slanger
SKAL IKKE HÅNDTERES. Lekkasje til dobbeltvirkende sylindere (2).
av olje under trykk kan trenge gjennom
huden, og dermed forårsake alvorlig skade.
Dersom olje trenger gjennom huden skal lege
øyeblikkelig oppsøkes.
ADVARSEL: Hydrauliske sylindre skal

kun benyttes i forbindelse med
koplede systemer. Sylindre skal aldri VIKTIG: Begge koplinger må være tilkoblet
benyttes med utilkoplede koplinger. Dersom dobbeltvirkende sylindere. Håndstram alle
sylinderen blir utsatt for ekstrem overlast, kan koplinger godt. Løse koplingstilkoblinger
komponenter få katastrofale feil som kan blokkerer oljestrømmen mellom pumpen og
forårsake alvorlig personskade. sylinderen.
ADVARSEL: KONTROLLER AT 2. Fjern luft fra sylinderen som vist under.

INSTALLASJONEN ER STABIL FØR ENKELTVIRKENDE SYLINDERE: Plasser
LØFTING. sylinderen på en slik måte at stempelet peker
Sylindre skal plasseres på et flatt nedover og at sylinderen er lavere enn pumpen.
underlag som kan tåle lasten. Bruk sylinderbunn Trekk sylinderen helt ut og tilbake to-tre ganger.
til å øke stabiliteten hvis dette er nødvendig.
Sylinderen skal ikke sveises eller endres på DOBBELTVIRKENDE SYLINDERE: Legg
noen annen måte for å feste bunn eller annen sylinderen på siden med koplingene opp. Trekk
støtte. sylinderen helt ut og tilbake to-tre ganger.
Unngå å plassere last på en slik måte 3. Stempelet skal ikke rotere ved montering av
at den ikke er sentrert på sylinderens koplinger. Rotering kan føre til skade på
stempel. stempelet, og hindre tilbaketrekkingen.
MERK: Flensgjengene er merket for sylinderens
maksimale kapasitet når disse er helt festet i
koblingene.
29
Luft
Luft
A B
MERK: Bruk av sylinderkoblinger eller 5.0 VEDLIKEHOLD

–forlengelser reduserer sylinderkapasiteten med 1. Bruk kun Enerpac-olje i disse sylindrene. Bruk
minst 50 %. ® av andre oljer kan ugyldiggjøre garantien.
2. Bruk støvhette når sylindre kobles fra
4.0 DRIFT slangen. Sørg for at hele sylinderen er ren for å
Start hydraulikkpumpen for å starte fremkjøring forlenge sylinderens levetid.
og retur av sylinderen. Noen enkeltvirkende 3. Oppbevar sylindre i oppreist stilling for å
sylindre har fjærretur, mens andre har lastretur. unngå forskyvning av forseglingen.
Tilbaketrekkingshastigheten avhenger av
lengden på slangen og andre begrensninger i 6.0 FEILSØKING
slangen. Dobbeltvirkende sylindre drives i begge Disse sylindrene skal kun repareres av Enerpacs
retninger av pumpen. Sylinderens stoppring er autoriserte tekniske servicesentre.
utviklet til å tåle full last. For å unngå slitasje på Enkeltvirkende sylindre er fjærbelastede, og skal
sylinderen, bør imidlertid ikke full slaglengde demonteres i henhold til bestemte metoder for å
brukes hvis dette er mulig. unngå personskade.
PROBLEM MULIG ÅRSAK

1. Sylinderen fremkjøres ikke. Pumpens senkeventil er åpen.
Koplingen er ikke fullstendig tilstrammet.
Lavt oljenivå i pumpen.
Pumpen fungerer ikke som den skal.
Lasten er for tung for sylinderen.
2. Sylinderen fremkjøres delvis. Lavt oljenivå i pumpen.
Koplingen er ikke fullstendig tilstrammet.
Sylinderens stempel henger seg fast.
3. Sylinderen fremkjøres rykkvis. Luft i hydraulikksystemet.

Sylinderens stempel henger seg fast.
4. Sylinderen fremkjøres tregere enn Lekkasje i tilkobling.
normalt. Koplingen er ikke fullstendig tilstrammet.
Pumpen fungerer ikke som den skal.
5. Sylinderen fremkjøres, men holdes ikke Sylinderforseglingen lekker.

på plass. Pumpen fungerer ikke som den skal.
Lekkasje i tilkobling.
Feil systemoppsett.
6. Sylinderen lekker olje. Utslitte eller skadede forseglinger.
Intern sylinderskade.
Løs tilkobling.
7. Sylinderen trekkes ikke tilbake, eller Pumpens senkeventil er lukket.
trekkes tilbake tregere enn normalt. Koplingen er ikke fullstendig tilstrammet.
Pumpetanken er overfylt.
Smal slange hindrer gjennomstrømningen.
Skadet eller svak tilbaketrekkingsfjær.
Innvendig skade i sylinderen.
8. Oljelekkasje fra ekstern sikkerhetsventil. Koplingen er ikke fullstendig tilstrammet.
Hindring i returslange.
30
L1608 Rev C 10/06
®
®
blkd.eps
Dexceed.eps
sgls.eps
undr.eps
gge.eps
hosbnd.eps
drag.eps
sman.eps
inject.eps
bdyhit.eps
®
stblty.eps
32
33
34
L1608 Rev C 10/06
sgls.eps
undr.eps
®
blkd.eps
Dexceed.eps
danger.eps
gge.eps
®
®
36 37
®
®
36 37
Australia Germany, Switzerland, Singapore

ENERPAC, Applied Power Australia Ltd. Austria, Eastern Europe Actuant Asia Pte. Ltd.
Block V Unit 3 ENERPAC 25 Serangoon North Ave. 5
Regents Park Estate Applied Power GmbH #03-01 Keppel Dlgihub
391 Park Road P.O. Box 300113 Singapore 554914
Regents Park NSW 2143 D-40401 Düsseldorf, Germany Thomson Road
(P.O. Box 261) Australia Tel: +49 211 471 490 P.O. Box 114
Tel: +61 297 438 988 Fax: +49 211 471 49 28 Singapore 915704
Fax: +61 297 438 648 Tel: +65 6484 5108
India Fax: +65 6484 5669
Brazil ENERPAC Hydraulics
Power Packer do Brasil Ltda. (India) Pvt. Ltd. South Korea
Rua dos Inocentes, 587 Plot No. A/571 ENERPAC
04764-050 - Sao Paulo (SP) MIDC, TTC Industrial Area Applied Power Korea Ltd.
Tel: +55 11 5687 2211 Mahape-400 701 163-12 Dodang-Dong
Fax: +55 11 5686 5583 Navi Mumbai, India Wonmi-Ku, Buchun-shi
Toll Free in Brazil: Tel: +91 22 778 1779 Kyunggi-Do
Tel: 000 817 200 3949 Fax: +91 22 778 1473 Republic of Korea
vendasbrasil@enerpac.com Tel: +82 32 675 08 36
Italy Fax: +82 32 675 30 02/73
Canada ENERPAC
Actuant Canada Corporation Applied Power Italiana S.p.A. Spain, Portugal
6615 Ordan Drive, Unit 14-15 Via Canova 4 ENERPAC
Mississauga, Ontario L5T 1X2 20094 Corsico (Milano) Applied Power International S.A.
Tel: +1 905 564 5749 Tel: +39 02 4861 111 Avda. Camino de lo Cortao
Fax: +1 905 564 0305 Fax: +39 02 4860 1288 21 - Nave 3
Toll Free: San Sebastian de los Reyes
Tel: +1 800 268 4987 Japan 28709 Madrid
Fax: +1 800 461 2456 Applied Power Japan Ltd. Spain
Technical Inquiries: 1-1-11, Shimomae Tel: +34 91 661 11 25
techservices@enerpac.com Toda-shi, Saitama Pref. Fax: +34 91 661 47 89
Japan 335-0016
China Tel: +81 48 430 2311 USA, Latin America
Actuant China Ltd. Fax: +81 48 430 1117 and Caribbean
1F, 269 Fute N. Road ENERPAC
Mexico
Waigaoqiao Free Trade Zone P.O. Box 3241
ENERPAC Applied Power 6100 N. Baker Road
Pudong New District
Mexico S. de R.L. de C.V. Milwaukee, WI 53209 USA
Shanghai, 200 131, China
Avenida Principal, La Paz #100 Tel: +1 262 781 6600
Tel: +86 21 5866 9099
Fracc. Industrial La Paz Fax: +1 262 783 9562
Fax: +86 21 5866 7156
42092 Pachuca, Hidalgo User inquiries:
Tel: +52 771 71 33700 +1 800 433 2766
Actuant China Ltd. (Beijing)
Fax: +52 771 71 35232 Distributor inquiries/orders:
709A Xin No. 2
Toll Free in Mexico: +1 800 558 0530
Diyang Building
Tel: 001 800 590 0130 Technical Inquiries:
Dong San Huan North Rd.
Beijing City, 100028, China The Netherlands, Belgium, techservices@enerpac.com
Tel: +86 10 845 36166 Luxembourg, Sweden, Denmark,
Fax: +86 10 845 36220 Norway, Finland, United
Kingdom, Ireland
France, Turkey, Greece,
Africa, Middle East ENERPAC B.V.
Storkstraat 25
ENERPAC S.A.
P.O. Box 269, 3900 AG Veenendaal
B.P. 200
The Netherlands
Parc d’Activités
Tel: +31 318 535 911
du Moulin de Massy
Fax: +31 318 525 613
F-91882 Massy CEDEX (Paris)
+31 318 535 848
France
UK, Ireland
Tel: +33 1 601 368 68
Tel: +44 01527 598 900
Fax: +33 1 692 037 50
Fax: +44 01527 585 500
All Enerpac products are guaranteed against defects in workmanship and materials for as long as you own them.
For your nearest authorized Enerpac Service Center, visit us at www.enerpac.com 092501
Instruction Sheet
®
Gauges
L505 Rev C 10/01
Index:
English.........................................................1-3
Français.......................................................4-7
Deutsch .....................................................8-11
Italiano.....................................................12-15
Español ...................................................16-19
Nederlands..............................................20-23
Portuguese..............................................24-27
1.0 IMPORTANT RECEIVING WARNING: Wear proper personal

INSTRUCTIONS protective gear when operating
Visually inspect all components for shipping
damage. Shipping damage is not covered by WARNING: Stay clear of loads
warranty. If shipping damage is found, notify supported by hydraulics. A cylinder,
carrier at once. The carrier is responsible for all when used as a load lifting device,
repair and replacement costs resulting from should never be used as a load holding
damage in shipment. device. After the load has been raised or
lowered, it must always be blocked
SAFETY FIRST mechanically.
2.0 SAFETY ISSUES WARNING: USE ONLY RIGID
Read all instructions, warnings PIECES TO HOLD LOADS.
®
and cautions carefully. Follow

®
Carefully select steel or wood blocks

all safety precautions to avoid that are capable of supporting the load. Never
personal injury or property damage during use a hydraulic cylinder as a shim or spacer in
system operation. Enerpac cannot be any lifting or pressing application.
responsible for damage or injury resulting from DANGER: To avoid personal
unsafe product use, lack of maintenance or injury keep hands and feet
incorrect product and/or system operation. away from cylinder and
Contact Enerpac when in doubt as to the workpiece during operation.
safety precautions and operations. If you have
WARNING: Do not exceed
never been trained on high-pressure hydraulic
equipment ratings. Never attempt to
safety, consult your distribution or service
lift a load weighing more than the
center for a free Enerpac Hydraulic safety
capacity of the cylinder. Overloading causes
course.
equipment failure and possible personal injury.
Failure to comply with the following cautions
Never set the relief valve to a higher
and warnings could cause equipment damage
pressure than the maximum rated
and personal injury.
pressure of the pump. Higher
A CAUTION is used to indicate correct settings may result in equipment damage
operating or maintenance procedures and and/or personal injury.
practices to prevent damage to, or destruction
WARNING: The system operating
of equipment or other property.
pressure must not exceed the
A WARNING indicates a potential danger that pressure rating of the lowest rated
requires correct procedures or practices to component in the system. Install pressure
avoid personal injury. gauges in the system to monitor operating
A DANGER is only used when your action or pressure. It is your window to what is
lack of action may cause serious injury or even happening in the system.
death.
CAUTION: Avoid damaging added stability. Do not weld or otherwise
hydraulic hose. Avoid sharp bends modify the cylinder to attach a base or other
and kinks when routing hydraulic support.
hoses. Using a bent or kinked hose will cause
Avoid situations where loads are not
severe back-pressure. Sharp bends and kinks
directly centered on the cylinder
will internally damage the hose leading to
plunger. Off-center loads produce
premature hose failure.
considerable strain on cylinders and plungers.
Do not drop heavy objects on In addition, the load may slip or fall, causing
hose. A sharp impact may cause potentially dangerous results.
internal damage to hose wire
®
Distribute the load evenly across the

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

Part Number Thread Dimensions
A B C L
GA-1 /
3 "
8 NPT /
1 "
2 NPT /
3 "
8 NPT 2.81 in. (71 mm)
GA-2 /
3 "
8 NPT /
1 "
2 NPT /
3 "
8 NPT 6.10 in. (139 mm)
GA-3 /
3 "
8 NPT /
1 "
4 NPT /
3 "
8 NPT 5.25 in. (133 mm)
GA-4 /
1 "
4 NPT /
1 "
2 NPT /
3 "
8 NPT 4.38 in. (111 mm)
2
complete removal from the system or by connections and fittings, use the proper
installation of a shut-off valve between the open-end wrenches. Do not use crescent
gauge and the high-pressure line. or pipe wrenches, as they may damage the
Should the hydraulic gauge be left in operation high-pressure fittings.
continuously, the calibration of the gauge may 5.0 OPERATION
be greatly affected, requiring recalibration or
complete replacement. Shut-off valves are The gauge should be operated at pressures
recommended as added protection for any which do not normally exceed 75% of full
hydraulic gauge that may be subjected to high scale.
cycle rates or pressure fluctuations. Using the gauge to read less than 10% of the
full scale can result in an erroneous reading.
Pump IMPORTANT: The gauge should be checked
outlet port for accuracy on a periodic basis, especially
when the pressure measurement is critical and
(1) Hose or a gauge failure or inaccuracy will create a
coupler
hazard to personnel or property.
75%
(2)
(3)
A B
(1) Gauge
10%
(2) Shut-off Valve
(3) Gauge Adaptor
4.0 INSTALLATION
6.0 REPAIR AND SERVICE INFORMATION
NOTE: When making hydraulic connections,
use high quality sealing compound only on the Enerpac gauges are precalibrated by the
threads of the male NPT fittings. If you use factory to within ±1% and ±11/2% of the full
Teflon tape, do not tape the first thread. Use scale. For recalibration, please refer to your
tape sparingly. Loose Teflon tape in your pump local phone or business directory. For warranty
or cylinder can cause malfunctions and and/or repair service, send your gauge to the
damage. Wrap tape so that it tightens upon nearest Enerpac Service Center.
assembly (clockwise with the threads facing
you). Install your hydraulic gauge where it is 6.1 Glycerin Gauge Maintenance
easily readable but well protected against For maintenance, please contact your nearest
damage from external sources. authorized Enerpac Service Center. The
1. Remove the hydraulic oil outlet plug(s) from procedure for filling the glycerin gauge is
your pump. covered in Enerpac's Instruction Sheet, L2561.
2. Apply sealant (or Teflon tape) to male NPT
threads. Make connections as pictured
above. When tightening hydraulic
3
®
Manomètres
L505 Rev C 10/01
Inspecter tous les composants pour vous
assurer qu’ils n’ont subi aucun dommage en
cours d’expédition. Les dommages subis en
cours de transports ne sont pas couverts par
la garantie. S’il sont abîmés, aviser
immédiatement le transporteur, qui est
responsable des frais de réparation et de
remplacement résultant de dommages en
cours de transport.
mortelles.
LA SÉCURITÉ AVANT TOUT !
AVERTISSEMENT : Porter un
2.0 SÉCURITÉ équipement de protection
Lire attentivement toutes les personnelle adéquat pour utiliser un
instructions et mises en garde appareil hydraulique.
et tous les avertissements. AVERTISSEMENT : Rester à l’écart
Suivre toutes les précautions pour éviter de charges soutenues par un
d’encourir des blessures personnelles ou de mécanisme hydraulique. Un vérin,
provoquer des dégâts matériels durant le lorsqu’il est utilisé comme monte-charge, ne
fonctionnement du système. Enerpac ne peut doit jamais servir de support de charge. Après
pas être tenue responsable de dommages ou avoir monté ou abaissé la charge, elle doit être
blessures résultant de l’utilisation risquée du bloquée par un moyen mécanique.
produit, d’un mauvais entretien ou d’une AVERTISSEMENT : UTILISER
application incorrecte du produit et du SEULEMENT DES PIÈCES
®
système. En cas de doute sur les précautions ®
RIGIDES POUR SOUTENIR LES

ou les applications, contacter Enerpac. En CHARGES. Sélectionner avec
l’absence d’une formation aux mesures de précaution des blocs d’acier ou de bois
sécurité à prendre en présence de liquides capables de supporter la charge. Ne jamais
sous haute pression, consulter un centre de utiliser un vérin hydraulique comme cale ou
distribution ou de réparation Enerpac pour intercalaire d’appui pour les applications de
suivre un cours gratuit sur ce thème. levage ou de pressage.
Respecter les mises en garde et DANGER : Pour écarter tout
avertissements suivants sous peine de risque de blessure personnelle,
provoquer des dégâts matériels et des maintenir les mains et les pieds
blessures personnelles. à l’écart du vérin et de la pièce à usiner durant
Une mise en garde ATTENTION sert à l’utilisation.
indiquer des procédures d’utilisation et de AVERTISSEMENT : Ne pas
maintenance correctes qui visent à empêcher dépasser les valeurs nominales du
l’endommagement voire la destruction du matériel. Ne jamais essayer de
matériel ou d’autres dégâts. soulever une charge d’un poids supérieur à la
Un AVERTISSEMENT indique un danger capacité du vérin. Une surcharge entraînera la
potentiel qui exige la prise de mesures panne du matériel et risque de provoquer des
particulières visant à écarter tout risque de blessures personnelles.
blessure. Ne jamais régler la soupape de sûreté
La mention DANGER n’est utilisée que à une pression supérieure à la pression
lorsqu’une action ou un acte de négligence nominale maximale de la pompe sous
risque de causer des blessures graves, voire peine de provoquer des dégâts matériels et/ou
4
des blessures personnelles. immédiatement un médecin.
AVERTISSEMENT : La pression de AVERTISSEMENT : Utiliser des
fonctionnement du système ne doit vérins hydrauliques uniquement
pas dépasser la pression nominale dans un système couplé. Ne jamais
du composant du système affichant la plus utiliser un vérin en présence de raccords
petite valeur. Installer des manomètres dans le déconnectés. La surcharge du vérin peut avoir
système pour surveiller la pression de des effets désastreux sur ses composants, qui
fonctionnement. Ils permettent de vérifier ce peuvent causer des blessures graves.
qui se passe dans le système.
AVERTISSMENT : S'assurer de la
ATTENTION : Éviter d’endommager stabilité de l'ensemble avant de
®
les tuyaux hydrauliques. Éviter de les lever une charge. Le vérin doit être
plier et de les tordre en les mettant en placé sur une surface plane capable
place. Un tuyau plié ou tordu entraînera un fort de supporter la charge. Lorsqu'applicable,
retour de pression. Les plis et coudes utiliser une base de vérin pour accroître la
prononcés endommageront par ailleurs stabilité. Ne pas souder ou modifier le vérin de
l’intérieur du tuyau, provoquant son usure quelque façon que ce soit pour y fixer une
précoce. base ou un autre dispositif de support.
Ne pas faire tomber d’objets Éviter les situations où les charges
lourds sur le tuyau. Un fort impact ne sont pas directement centrées sur
®
risque de causer des dégâts le piston du vérin. Les charges

intérieurs (torons métalliques). L’application d’ décentrées imposent un effort considérable au
une pression sur un tuyau endommagé risque vérins et pistons. En outre, la charge risque de
d’entraîner sa rupture. glisser ou de tomber, ce qui crée un potentiel
de danger.
IMPORTANT : Ne pas soulever le
matériel hydraulique en saisissant Répartir la charge uniformément sur
ses tuyaux ou ses raccords articulés. toute la surface d'appui. Toujours
Utiliser la poignée de transport ou procéder utiliser un coussinet d'appui si des
d’une autre manière sûre. accessoires non filetés sont utilisés.
ATTENTION : Garder le matériel IMPORTANT : Le matériel
hydraulique à l’écart de flammes et hydraulique doit uniquement être
d’une source de chaleur. Une forte
réparé par un technicien hydraulique
température amollira les garnitures et
les joints et provoquera par conséquent des fuites. La qualifié. Pour toute réparation, contacter le
chaleur affaiblit également les matériaux et les centre de réparation ENERPAC agréé le plus
garnitures du tuyau. Pour une performance maximale, proche. Pour assurer la validité de la garantie,
ne pas exposer le matériel à une température n’utiliser que de l’huile ENERPAC.
supérieure ou égale à 65 °C [150 °F]. Protéger tuyaux
et vérins de projections de soudure.
AVERTISSEMENT : Remplacer
immédiatement les pièces usées ou
DANGER : Ne pas manipuler les endommagées par des pièces
tuyaux sous pression. L’huile sous ENERPAC authentiques. Les pièces de qualité
pression qui risque de s’en échapper standard se casseront et provoqueront des
peut pénétrer dans la peau et blessures et des dégâts matériels. Les pièces
provoquer des blessures graves. En cas ENERPAC sont conçues pour s’ajuster
d’injection d’huile sous la peau, contacter parfaitement et résister à de fortes charges.
Caractéristiques des adaptateurs de manomètre

N° de référence Dimensions des filetages
A B C L
GA-1 /
3 "
8 NPT /
1 "
2 NPT /
3 "
8 NPT 71 mm (2.81 in.)
GA-2 /
3 "
8 NPT /
1 "
2 NPT /
3 "
8 NPT 139 mm (6.10 in.)
GA-3 /
3 "
8 NPT /
1 "
4 NPT /
3 "
8 NPT 133 mm (5.25 in.)
GA-4 /
1 "
4 NPT /
1 "
2 NPT /
3 "
8 NPT 111 mm (4.38 in.)
5
4.0 INSTALLATION
3.0 DESCRIPTION NOTE : Lors des branchements hydrauliques,
Le manomètre Enerpac est conçu utiliser un composé d'étanchéité de haute
principalement pour servir de dispositif de qualité uniquement sur les filetages des
mesure visuel permettant d'observer l'état du raccords NPT mâles. Si du ruban Téflon est
circuit hydraulique. Son usage est utilisé, ne pas couvrir le premier pas du
recommandé avec chaque circuit hydraulique filetage. Ne pas utiliser trop de ruban. La
afin d'assurer que les valeurs nominales de pénétration de morceaux de ruban Téflon dans
fonctionnement des composants hydrauliques la pompe ou le vérin peut causer des
du circuit ne sont pas dépassées. problèmes de fonctionnement et des
dommages. Enrouler le ruban de manière à ce
Dans les applications de production intensive, qu'il se serre lors de l'assemblage. (Enrouler
une fois les réglages de pression du circuit vers la droite, le filetage face à soi.) Installer le
hydraulique effectués pour les cycles de manomètre hydraulique à un endroit où il est
production, le manomètre hydraulique doit facile de le lire, mais qui est bien protégé des
être déconnecté du circuit hydraulique. Cela sources de dommages externes.
peut se faire en le retirant complètement du 1. Enlever le(s) bouchon(s) de la sortie d'huile
circuit ou en installant un robinet d'arrêt entre hydraulique de la pompe.
le manomètre et la conduite haute pression.
2. Appliquer du composé d'étanchéité (ou du
Si le manomètre est laissé continuellement en ruban Téflon) aux filetages NPT mâles.
service, son étalonnage en souffrira Effectuer les branchements comme illustré
grandement, nécessitant un ré-étalonnage ou ci-dessus. Pour serrer les branchements et
un remplacement total. Les robinets d'arrêt raccords hydrauliques, utiliser les clés
sont recommandés car ils offrent une plates adéquates. Ne pas utiliser de clés à
protection supplémentaire pour les molette ou à tubes car elles risquent
manomètres hydrauliques soumis à des cycles d'endommager les raccords haute
rapides ou des fluctuations de pression. pression.
5.0 UTILISATION
Le manomètre doit être utilisé à des pressions
ne dépassant pas normalement 75 % de sa
(1) capacité maximale.
L'utilisation du manomètre pour des valeurs
inférieures à 10 % de sa capacité maximale
risque de donner des relevés inexacts.
Orifice
de sortie IMPORTANT : Vérifier la précision du
de la manomètre à intervalles réguliers, en
pompe (2) particulier quand la mesure de pression est
critique et qu'une panne du manomètre ou un
Flexible ou relevé inexact risque de présenter un danger
(3) raccord au personnel ou au matériel.
A B
(1) Manomètre
(2) Robinet d'arrêt
(3) Adaptateur de manomètre
6
75%
10%
6.0 INFORMATIONS POUR LA

RÉPARATION ET L'ENTRETIEN
Les manomètres Enerpac sont étalonnés à
l'avance en usine à ±1 % - ±11/2 % près de leur
capacité maximale. Pour les ré-étalonner,
prière de se reporter à l'annuaire téléphonique
local ou aux pages jaunes. Pour toute
réparation couverte ou non par la garantie,
envoyer le manomètre au centre Enerpac
agréé local.
6.1 Entretien des manomètres à bain d’huile

Pour l’entretien , contactez le centre de
réparation Enerpac le plus proche. La
procédure de remplissage du manomètre est
décrite dans le document L2561.
7
Bedienungsanleitung
®
Manometer
L505 Rev C 10/01

FÜR DEN EMPFANG:
Alle Komponenten auf sichtbare
Transportschäden inspizieren. Transport-
schäden sind nicht von der Garantie gedeckt.
Werden solche Schäden festgestellt, ist
unverzüglich das Transportunternehmen zu
verständigen. Das Transportunternehmen ist für
alle Reparatur- und Ersatzkosten, die auf
Transportschäden zurückzuführen sind,
verantwortlich.
SICHERHEIT GEHT VOR Ein GEFAHRENSHINWEIS wird nur dann
gegeben, wenn eine bestimmte Handlung
2.0 SICHERHEITSFRAGEN oder die Unterlassung einer bestimmten
Alle Anleitungen, Warnungen Handlung schwere oder tödliche Verletzungen
und Vorsichtshinweise zur Folge haben kann.
sorgfältig durchlesen. WARNUNG: Beim Betrieb
Beachten Sie alle Sicherheitsvorkehrungen, hydraulischer Anlagen geeignete
um Verletzungen oder Sachschäden während Schutzkleidung und –ausrüstung
des Systembetriebs zu vermeiden. Enerpac ist tragen.
weder für Schäden noch Verletzungen haftbar,
die durch einen fahrlässigen Gebrauch des WARNUNG: Von Lasten fernhalten,
Produkts, mangelhafte Instand-haltung oder die durch ein Hydrauliksystem
eine unvorschriftsmäßige Anwendung des abgestützt werden. Ein als
Produkts und/oder des Systems verursacht Lastenhebegerät eingesetzter Zylinder darf
werden. Bei evtl. Fragen in bezug auf niemals als ein Lastenhaltegerät verwendet
Sicherheitsvorkehrungen und Betriebsabläufe werden. Nach Heben oder Senken der Last
wenden Sie sich bitte an ENERPAC. Wenn Sie muß diese stets auf mechanische Weise
an keinerlei Sicherheitsschulungen im gesichert werden.
Zusammenhang mit Hochdruck- WARNUNG ZUM SICHERN VON
hydraulikanlagen teilgenommen haben, LASTEN STETS NUR STARRE
®
fordern Sie von Ihrer Vertriebs- und ®
TEILE VERWENDEN. Zum

Kundendienstzentrale einen kostenlosen Abstützen von Lasten sorgfältig dazu
Enerpac-Hydraulik-Sicherheitskurs an. geeignete Stahl- oder Holzblöcke auswählen.
Ein Mißachten der folgenden Bei Hebe- oder Drückanwendungen
Vorsichtshinweise und Warnungen kann zu keinesfalls einen Hydraulikzylinder als
Geräteschäden und Verletzungen führen. Abstandsstück oder –halter verwenden.
Mit einem VORSICHTSHINWEIS wird auf GEFAHR: Zur Vermeidung von
ordnungsgemäße Betriebs- oder Verletzungen während des
Wartungsverfahren und –praktiken Betriebs Hände und Füße von
hingewiesen, um Schäden an den Geräten Zylinder und Werkstück fernhalten.
oder anderen Sachwerten bzw. deren WARNUNG: Die zugelassene
Zerstörung zu vermeiden. Nennleistung der Geräte nicht
Eine WARNUNG verweist auf eine potentielle überschreiten. Keine Last zu heben
Verletzungsgefahr, die durch ordnungsgemäße versuchen, deren Gewicht das Hebevermögen
Verfahren oder Praktiken vermieden werden kann. des Zylinders übersteigt. Überlasten
verursachen Maschinenausfälle und können
zu Verletzungen führen. Die Zylinder wurden
8
für einen max. WARNUNG: In einem gekoppelten
System dürfen nur
Das Überdruckventil keinesfalls auf
Hydraulikzylinder verwendet
einen höheren Druck als den
werden. Niemals einen Zylinder mit
maximal zulässigen Druck der
unverbundenen Kupplungen verwenden. Bei
Pumpe einstellen. Höhere Einstellungen
einer extremen Überlastung des Zylinders
können zu Geräteschäden und/oder
können dessen Komponenten einen
Verletzungen führen.
Sprungvollausfall erleiden, was schwere
WARNUNG: Der System- Verletzungen hervorrufen kann.
betriebsdruck darf den zulässigen
WARNUNG: Sicherstellen, dass die
Nominaldruck der System-
anlage stabilisiert, bevor eine last
komponente mit der niedrigsten Nennleistung
®
angehoben wird. Der Zylinder sollte
nicht überschreiten. Zur Überwachung des
auf einer ebenen Oberfläche
Betriebsdrucks sind Manometer im System zu
aufsitzen, die fest genug ist, um die Last
installieren. Dies ist das Fenster zu den Abläufen
abzustützen. Wenn möglich einen Zylinderfuß
im System.
verwenden, um größere Stabilität zu
VORSICHT: Beschädigungen am gewährleisten. Keine Schweißarbeiten oder
Hydraulikschlauch vermeiden. andere Änderungen am Zylinder vornehmen,
Beim Verlegen der Hydraulik- um einen Zylinderfuß oder andere
schläuche enge Bögen und Abknicken Abstützungen anzubringen.
vermeiden. Der Einsatz eines gebogenen oder
Situationen vermeiden, in denen die
geknickten Schlauchs führt zu einem hohen
Lasten nicht direkt über dem Kolben
Rückstau. Starke Biegungen und Knickstellen
des Zylinders ausgerichtet sind.
schädigen den Schlauch auf der Innenseite
Seitlich versetzte Lasten führen zu erheblicher
und führen zu dessen vorzeitigem Ausfall.
Belastung der Zylinder und Kolben. Außerdem
Keine schweren Gegenstände auf könnte die Last ins Rutschen geraten oder
den Schlauch fallen lassen. Starke fallen, was zu äußerst gefährlichen
®
Erschütterungen können Schäden Situationen führen kann.

an den im Schlauchinnern verlaufenden
Die Last gleichmäßig über die
Drahtlitzen verursachen. Ein Schlauch, auf den
gesamte Fläche des Druchstückes
Druck ausgeübt wird, kann bersten.
verteilen. Den Kolben immer mit
WICHTIG: Hydraulische Geräte einem Druckstück schützen, wenn
weder an den Schläuchen noch den keine Zusatzgeräte mit Gewinde benutzt
Gelenkanschlüssen anheben. Dazu werden.
den Tragegriff oder eine andere sichere
WICHTIG: Hydraulische Geräte
Transportmethode verwenden.
müssen von einem qualifizierten
VORSICHT: Hydraulische Geräte Hydrauliktechniker gewartet werden.
von Flammen und Hitzequellen Bei Reparaturarbeiten an die autorisierte
fernhalten. Zu hohe ENERPAC-Kundendienstzentrale der
Temperaturen weichen Füllungen und jeweiligen Region wenden. Zur
Dichtungen auf und bewirken Flüssigkeitslecks. Aufrechterhaltung der Garantie nur ENERPAC-
Große Hitze schwächt außerdem die Öl verwenden.
Schlauchmaterialien und –dichtungen. Zur
Gewährleistung einer optimalen Leistung darf WARNUNG: Abgenutzte oder
die Anlage keinen Temperaturen über 65°C beschädigte Teile unverzüglich durch
ausgesetzt werden. Außerdem müssen ENERPAC-Originalteile ersetzen.
Schläuche und Zylinder beim Schweißen vor Standardteile anderer Hersteller versagen und
Funkenschlag geschützt werden. verursachen Verletzungen und Sachschäden.
ENERPAC-Teile werden so konstruiert, daß sie
GEFAHR: Nicht mit unter Druck richtig passen und hohen Lasten standhalten.
stehenden Schläuchen hantieren.
Unter Druck austretendes Öl kann in 3.0 BESCHREIBUNG
die Haut eindringen und schwere Verletzungen
Ihr Enerpac-Manometer dient in erster Linie als
verursachen. Falls Öl unter die Haut gelangt,
visuelle Meßvorrichtung zur Beobachtung des
ist sofort ein Arzt aufzusuchen.
hydraulischen Betriebszustands Ihres
Systems. Die Verwendung eines
9
Hydraulikmanometers ist für jedes
Hydrauliksystem empfohlen, um
sicherzustellen, daß die Betriebsnennwerte
der Hydraulikkomponenten innerhalb des
Systems nicht überschritten werden. (1)
Bei Hochleistungsanwendungen sollte das
Hydraulikmanometer vom Hydrauliksystem
getrennt werden, nachdem die
Druckeinstellungen des Hydrauliksystems für
Produktionsläufe angepaßt wurden. Dies kann
durch den vollständigen Ausbau aus dem
System oder durch den Einbau eines (2)
Sperrventils zwischen dem Manometer und
der Hochdruckleitung erfolgen.
(3)
Sollte das Hydraulikmanometer andauernd in A B
Betrieb sein, könnte die Eichung des
Manometers erheblich beeinträchtigt werden, C
wodurch eine Nacheichung oder der
vollständige Austausch des Manometers
erforderlich würde. Sperrventile werden als L
zusätzliche Schutzvorrichtung für jedes
Hydraulikmanometer empfohlen, das raschen (1) Manometer
Betriebszyklen oder Druckschwankungen (2) Sperrventil
ausgesetzt ist. (3) Manometeradapter
4.0 EINBAU
HINWEIS: Beim Herstellen hydraulischer
Anschlüsse hochwertiges Dichtungsmittel nur
auf die Gewinde der Steckverschraubungen
auftragen. Bei Verwendung von Teflon-Band
Pumpenausl das erste Gewinde nicht überkleben. Das
aßanschluß Band sparsam verwenden. Lose Teile des
Teflon-Bandes können in der Pumpe oder im
Schlauch oder Zylinder zu Störungen und Schäden führen.
Kuppler Das Band so umwickeln, daß es beim
Zusammenbau festgezogen wird. (Nach
rechts, wobei die Gewinde Ihnen zugewandt
sind). Das Hydraulikmanometer an einer Stelle
anbringen, an der es leicht abgelesen werden
kann, doch vor Schäden durch
Außeneinwirkungen gut geschützt ist.
1. Den (die) Hydrauliköl-Auslaßstopfen von
der Pumpe abnehmen.
2. Dichtungsmittel (oder Teflon-Band) auf die
Technische Daten des Manometeradapters

Teilenummer Gewindeabmessungen
A B C L
GA-1 /
3 "
8 NPT /
1 "
2 NPT 3 "
8 / NPT 71 mm (2.81 in.)
GA-2 /
3 "
8 NPT /
1 "
2 NPT 3 "
8 / NPT 139 mm (6.10 in.)
GA-3 /
3 "
8 NPT /
1 "
4 NPT 3 "
8 / NPT 133 mm (5.25 in.)
GA-4 /
1 "
4 NPT /
1 "
2 NPT 3 "
8 / NPT 111 mm (4.38 in.)
10
Außengewinde auftragen. Die Anschlüsse
wie oben dargestellt vornehmen. Zum 75%
Anziehen der Hydraulikanschlüsse und -
verschraubungen zweckmäßige
Gabelschlüssel verwenden. Keine
Rollgabelschlüssel oder Rohrzangen
verwenden, da sie Hochdruck-
verschraubungen beschädigen können.
5.0 BETRIEB
Das Manometer sollte bei Drücken betrieben
werden, die normalerweise 75% des
Skalenendwerts nicht überschreiten.
Meßwerte, die kleiner als 10% des
Skalenendwerts sind, können auf einer
10%
fehlerhaften Ablesung beruhen.
WICHTIG: Das Manometer sollte regelmäßig
auf seine Genauigkeit überprüft werden, vor
allem wenn die Druckmessung von kritischer
Bedeutung ist und ein Manometerausfall oder 6.0 REPARATUR- UND
ungenaue Messungen eine Gefahr für WARTUNGSINFORMATIONEN
Belegschaft oder Anlagen darstellen.
Enerpac-Manometer werden werkseitig auf eine
Genauigkeit von ±1 % – ±11/2 % des
Skalenendwerts vorgeeicht. Zur Ausführung
einer Nacheichung bitte das örtliche
Telefonbuch oder die Gelben Seiten zu Rate
ziehen. Im Gewährleistungsfall und/oder zu
Reparaturzwecken das Manometer an das
nächstgelegene Enerpac-
Kundendienstzentrum einsenden.
6.1 Wartung des Glyzerin-gefüllten

Manometers
Für Wartungszwecke wenden Sie Sich bitte an
die nächstgelegene authorisierte Enerpac
Service Werkstatt. Der Vorgang des Füllens
eines Manometers mit Glyzerin wird
beschrieben in der Enerpac
Bedienungsanleitung L2561.
11
Foglio Istruzione
®
Manometri
L505 Rev C 10/01
1.0 NOTA IMPORTANTE
presenti, avvisare prontamente lo spedizioniere.
I danni subiti durante la spedizione non sono
coperti dalla garanzia vigente. Lo spedizioniere
è il solo responsabile per i costi di riparazione o
di sostituzione conseguenti a danni avvenuti
durante la spedizione.
INFORMAZIONI SULLA SICUREZZA AVVERTENZA: Stare lontano da

carichi sospesi e sostenuti
2.0 INFORMAZIONI SULLA SICUREZZA
idraulicamente. Un cilindro
Leggere attentamente tutte le utilizzato per sollevare un carico non deve mai
istruzioni, le avvertenze e le essere impiegato anche per il loro sostegno.
precauzioni. Durante il Dopo aver alzato o abbassato un peso, è
funzionamento del sistema, rispettare tutte le necessario che questo venga sempre
norme di sicurezza onde evitare infortuni o bloccato in maniera meccanica.
danni all'apparecchiatura. L'Enerpac declina AVVERTENZA: UTILIZZARE SOLO
ogni responsabilità per danni risultanti da un ATTREZZI RIGIDI PER IL
®
uso improprio del prodotto, dalla mancata ®
SOSTEGNO DEI CARICHI.

manutenzione o dall'applicazione errata del Selezionare con cura blocchi in acciaio o in
prodotto e del sistema. In caso di dubbio in legno capaci di supportare il peso del carico.
materia di sicurezza o applicazioni, rivolgersi Non ricorrere mai a un cilindro idraulico come
all'Enerpac. Se si richiedono informazioni cuneo o spessore in applicazioni di
sulle norme di sicurezza per sistemi idraulici sollevamento o pressatura.
ad alta pressione, rivolgersi al distributore o
al centro di riparazione di zona in grado di PERICOLO: Per evitare lesioni
fornire gratuitamente un corso di personali, durante la lavorazione
addestramento in materia di sicurezza tenere le mani e i piedi lontano
idraulica autorizzato dalla Enerpac. dal cilindro e dal pezzo in lavorazione.
La mancata osservanza delle seguenti AVVERTENZA: Non superare mai la
precauzioni potrebbe portare a seri danni capacità nominale dell'apparec-
all'apparecchiatura e a lesioni personali. chiatura. Non tentare mai di sollevare
un peso superiore alla capacità del cilindro,
Una PRECAUZIONE indica le corrette dato che il sovraccarico può causare guasti
procedure di azionamento o manutenzione per all'apparecchiatura e possibili infortuni
evitare danni all'apparecchiatura o all'operatore.
all'ambiente circostante.
Non impostare mai la valvola di
Un'AVVERTENZA indica un potenziale scarico a una pressione superiore a
pericolo che richiede la messa in pratica delle quella massima nominale della
procedure corrette per evitare infortuni. pompa. Un'impostazione superiore può
Un PERICOLO indica una situazione in cui arrecare danni all'apparecchiatura e/o
un'azione o la mancanza di azione può causare provocare infortuni all'operatore.
gravi lesioni personali se non il decesso. AVVERTENZA: La pressione di
AVVERTENZA: Indossare esercizio del sistema non deve
un'attrezzatura di protezione superare il valore nominale prefissato
appropriata durante il funzionamento per il componente dalla pressione più bassa.
dell'apparecchiatura. Installare nel sistema un manometro per tenere
sotto controllo la pressione di esercizio.
12
PRECAUZIONE: Evitare di arrecare Evitare situazioni in cui i carichi non
danni al tubo idraulico flessibile. siano perfettamente centrati rispetto
Evitare di piegare o arricciare il tubo allo stelo del cilindro stresso. I carichi
flessibile durante l'uso, poiché gli strozzature disassati esercitano notevoli sollecitazioni sui
possono provocare gravi contropressioni. Le cilindri e steli. Inoltre, il carico potrebbe
piegature e gli strozzature acute possono scivolare o cadere, con risultati potenzialmente
danneggiare internamente il tubo flessibile e pericolosi.
provocarne quindi un guasto prematuro.
Distribuire il carico uniformemente
Non lasciar cadere oggetti pesanti sull'intera superficie della testa del
sul tubo flessibile, dato che l'impatto pistone. Usare sempre una testina
potrebbe danneggiarne i fili per proteggere lo stelo quando non si
®
dell'armatura. La messa sotto pressione di un usano attacchi filettati.

tubo flessibile danneggiato può causarne la
IMPORTANTE: Affidare la
rottura.
manutenzione delle apparecchiature
IMPORTANTE: Non sollevare idrauliche solamente a un tecnico
apparecchiature idrauliche mediante specializzato. Per richiedere un intervento di
il tubo flessibile o i giunti orientabili. assistenza, rivolgersi al centro di assistenza
Servirsi della maniglia per trasporto o di un ENERPAC autorizzato di zona. Per usufruire
altro mezzo di trasporto sicuro. dei termini di garanzia, utilizzare
PRECAUZIONE: Tenere esclusivamente olio idraulico ENERPAC.
l'apparecchiatura idraulica AVVERTENZA: Sostituire
lontano da fiamme e sorgenti di immediatamente le parti usurate o
calore. Il calore eccessivo ammorbidisce le danneggiate con pezzi di ricambio
guarnizioni, provocando perdite di fluido. Il ENERPAC originali. I pezzi di ricambio di
calore indebolisce altresì il materiale di cui è qualità standard si potrebbero rompere più
composto il tubo flessibile. Per garantire le facilmente e arrecare danni alla propria
migliori prestazioni, non esporre persona e all'ambiente circostante. I pezzi di
l'apparecchiatura a temperature superiori a ricambio ENERPAC sono stati concepiti per
65°C (150°F). Proteggere i tubi flessibili e i adattarsi perfettamente al sistema e per
cilindri da scintille o scaglie di saldatura. sopportare condizioni di carico elevate.
PERICOLO: Non maneggiare i tubi
flessibili sotto pressione. Eventuali 3.0 DESCRIZIONE
fuoriuscite d'olio sotto pressione Questo manometro Enerpac è concepito
possono penetrare sotto la cute e provocare principalmente come indicatore visivo per il
gravi lesioni. Se l'olio penetra sotto la pelle, controllo delle condizioni di esercizio dei
rivolgersi immediatamente a un medico. sistemi oleodinamici. Si consiglia l’impiego di
AVVERTENZA: Utilizzare i cilindri un manometro apposito per sistemi
idraulici solo se i giunti del sistema oleodinamici per assicurarsi che le pressioni a
sono debitamente accoppiati. Se il cui sono sottoposti i componenti del sistema
sovraccarico del cilindro diventa eccessivo, i non superino i loro valori nominali.
componenti possono guastarsi Nelle applicazioni a flussi di produzione
irreparabilmente e provocare gravi lesioni elevati, dopo che le pressioni del sistema
personali. oleodinamico sono state regolate sui valori
AVVERTENZA: Prima di sollevare il adatti alle fasi di produzione, occorre
carico, assicurarsi che la scollegare dal sistema stesso il manometro
oleodinamico; si può eseguire questa
®
configurazione dell'intera
apparecchiatura sia perfettamente operazione rimuovendo lo strumento dal
stabile. Il cilindro deve essere disposto su una sistema oppure installando un rubinetto
superficie piana, in grado di sostenere il d’isolamento tra lo strumento e la linea ad alta
carico. Se possibile, usare una base per il pressione.
cilindro, per aumentarne la stabilità. Non Se si lascia il manometro oleodinamico
saldare ne modificare in alcun modo il cilindro ininterrottamente in funzione, si possono
allo scopo di collegarvi una base o un altro modificare grandemente i suoi parametri di
supporto. taratura e ne può conseguire la necessità di
13
Specifiche del raccordo per manometro
Codice Diametro della filettatura
A B C L
GA-1 /
3 "
8 NPT 1 "
2 / NPT /
3 "
8 NPT 71 mm (2.81 in.)
GA-2 /
3 "
8 NPT 1 "
2 / NPT /
3 "
8 NPT 139 mm (6.10 in.)
GA-3 /
3 "
8 NPT 1 "
4 / NPT /
3 "
8 NPT 133 mm (5.25 in.)
GA-4 /
1 "
4 NPT 1 "
2 / NPT /
3 "
8 NPT 111 mm (4.38 in.)
una nuova taratura o la sostituzione dello oleodinamico in un punto di facile osservazione,

strumento. Si suggerisce di impiegare rubinetti ma ben protetto da possibili fonti di danni
d’isolamento, per ulteriore protezione, per ogni esterni.
manometro oleodinamico che possa essere
1. Rimuovere dalla pompa i tappi delle
sottoposto a pressioni cicliche elevate o a
bocche di mandata dell’olio idraulico.
fluttuazioni di pressione.
2. Applicare il sigillante (o il nastro di teflon) ai
filetti dei raccordi NPT maschio. Eseguire i
collegamenti come su illustrato. Per serrare
tutti i raccordi oleodinamici servirsi di chiavi
fisse adatte. Non utilizzare chiavi registrabili
(1) o giratubi, perché si possono danneggiare i
raccordi per alte pressioni.
5.0 FUNZIONAMENTO
Bocca di Il manometro deve funzionare a pressioni che

mandata in genere non superino il 75% del fondo scala.
della pompa A valori minori del 10% del fondo scala
(2)
l’indicazione del manometro può essere errata.
Tubo flessibile
o raccordo IMPORTANTE – Occorre verificare
(3) periodicamente la precisione del manometro,
A B soprattutto quando la misura della pressione è
essenziale e un’imprecisione o un guasto dello
C strumento creerebbero una condizione di
rischio per il personale o l’attrezzatura.
L
(1) Manometro
(2) Rubinetto d’isolamento
(3) Raccordo per manometro
4.0 INSTALLAZIONE
NOTA – Quando si eseguono i collegamenti
oleodinamici, usare composto sigillante di alta
qualità soltanto sui filetti dei raccordi NPT
maschio. Se s’impiega nastro di teflon, non
avvolgerlo intorno al primo filetto. Non usare
troppo nastro; se esso si allenta e penetra nella
pompa o nel cilindro, può causare
malfunzionamenti e danni. Avvolgere il nastro in
modo che si serri sul gruppo (in senso orario con
i filetti verso sé stessi). Installare il manometro
14
I manometri Enerpac vengono tarati in fabbrica
entro ±1% - ±11/2% del fondo scala. Se
75% occorre rieseguire la taratura, consultare le
pagine gialle alla voce appropriata. Per
interventi di riparazione o in garanzia, rivolgersi
al Centro di assistenza Enerpac più vicino alla
propria sede.
6.1 Manutenzione manometri

Per la manutenzione, prego contattare il Vs.
Centro Servizi Enerpac più vicino. La
procedura di riempimento del liquido nel
manometro è quella descritta nel foglio
d’istruzione L2561.
10%
6.0 INFORMAZIONI SULLA RIPARAZIONE

E ASSISTENZA
15
®
Manómetros
L505 Rev C 10/01
RECEPCIÓN
Inspeccione visualmente todos los
componentes para verificar si hay daños de
envío. Debido a que la garantía no ampara
daños por envío, si los hubiese, infórmeselo
inmediatamente a la empresa de transportes,
puesto que ésta es responsable de todos los
gastos de reparaciones o reemplazo que
resulten por daños de envío.
SEGURIDAD PRIMERO ADVERTENCIA: Manténgase
2.0 ASPECTOS DE SEGURIDAD alejado de las cargas soportadas
por sistemas hidráulicos. Cuando
Lea todas las instrucciones,
un cilindro se utiliza como dispositivo para
advertencias y precauciones.
levantar carga, nunca debería usarse como
Acate todas las precauciones
dispositivo para sostener carga. Después de
de seguridad para evitar lesiones personales o
que la carga haya sido levantada o
daños a la propiedad durante la operación del
descendida, debe bloquearse siempre en
sistema. ENERPAC no puede ser responsable
forma mecánica.
de daños o lesiones que resulten de no usar el
producto de forma segura, falta de ADVERTENCIA: USE SÓLO PIEZAS
mantenimiento o aplicación incorrecta del RÍGIDAS PARA SOSTENER
®
producto y/u operación del sistema. ®
CARGAS. Seleccione
Comuníquese con ENERPAC si tuviese dudas cuidadosamente bloques de acero o de
sobre las precauciones de seguridad o sobre madera capaces de soportar la carga. Nunca
las aplicaciones. Si nunca ha sido capacitado use un cilindro hidráulico como calza o
en seguridad hidráulica de alta presión, separador en aplicaciones de levantamiento o
consulte a su distribuidor o centro de servicio presión.
para obtener un curso de seguridad gratis PELIGRO: Para evitar lesiones
denominado ENERPAC Hydraulic. personales, mantenga las
El no cumplir con las siguientes precauciones manos y los pies alejados del
y advertencias podría causar daños al equipo cilindro y pieza de trabajo durante la
y lesiones personales. operación.
Una PRECAUCIÓN se utiliza para indicar ADVERTENCIA: No sobrepase el
procedimientos y prácticas de operación o valor nominal del equipo. Nunca
mantenimiento correctos para evitar daños o intente levantar una carga que pese
la destrucción de equipo u otra propiedad. más de la capacidad del cilindro. Las
sobrecargas ocasionan fallas del equipo y
Una ADVERTENCIA indica un potencial
posibles lesiones personales.
peligro que requiere de procedimientos o
prácticas correctos para evitar lesiones Nunca fije la válvula de seguridad a
personales. una presión más alta que el máximo
valor nominal de presión de la
Un PELIGRO se utiliza sólo cuando su acción
bomba. Los ajustes más altos pueden resultar
o falta de acción podría causar lesiones graves
en daños al equipo y/o lesiones personales.
o incluso la muerte.
ADVERTENCIA: La presión de
ADVERTENCIA: Use el equipo de
operación del sistema no debe
protección personal adecuado
sobrepasar el valor nominal de
cuando opere equipo hidráulico.
presión del componente con el valor nominal
más bajo en el sistema. Instale manómetros
16
de presión en el sistema para vigilar la presión Evite las situaciones en las cuales las
de operación. Es su ventana a lo que está cargas no estén directamente
sucediendo en el sistema. centradas sobre el émbolo del
PRECAUCIÓN: Evite dañar la cilindro. Las cargas descentradas producen un
manguera hidráulica. Evite pliegues esfuerzo considerable sobre los cilindros y los
y curvas agudos al guiar las émbolos. Adeás, la carga podria resbalar o
mangueras hidráulicas. Usar una manguera caerse, creando situaciones potencialmente
con pliegues o curvas puede causar severa peligrosas.
contrapresión. Los pliegues y curvas agudos Distribuya la carga uniformemente
causarán daños internos la manguera, lo que sobre la superficie total del asiento
ocasionará que ésta falle prematuramente. del cilindro. Siempre utilice un
No deje caer objetos pesados sobre asiento para proteger el émbolo
la manguera. Un impacto directo cuando no se usen accesorios roscados.
®
puede causar daños internos a las IMPORTANTE: Únicamente técnicos

hebras de alambre de la manguera. Aplicar calificados en sistemas hidráulicos
presión a una manguera dañada puede habrán de prestarle servicio al
ocasionar que se quiebre. equipo hidráulico. Comuníquese con
IMPORTANTE: No levante el equipo el Centro de Servicio ENERPAC autorizado en
hidráulico por las mangueras o su zona para prestarle servicio de
acopladores giratorios. Use el reparaciones. Use únicamente aceite
mango de transporte u otros medios para ENERPAC a fin de proteger su garantía.
transportarla con seguridad. ADVERTENCIA: Reemplace
PRECAUCIÓN: Mantenga el inmediatamente las piezas gastadas
equipo hidráulico alejado de las o dañadas por piezas ENERPAC
llamas y el calor. El calor en genuinas. Las piezas de clasificación estándar
exceso ablandará las juntas y sellos, lo que se romperán, lo que causará lesiones
resultará en fugas de líquidos. Asimismo, el personales y daños a la propiedad. Las piezas
calor debilita los materiales de la manguera y ENERPAC están diseñadas para encajar
juntas. Para lograr un rendimiento óptimo, no debidamente y resistir altas cargas.
exponga el equipo a temperaturas de 65 °C
[150 °F] o mayores. Proteja las mangueras y 3.0 DESCRIPCION
cilindros de salpicaduras de soldadura.
Los manómetros Enerpac están diseñados
PELIGRO: No manipule
primordialmente para funcionar como
mangueras bajo presión. El aceite
dispositivos medidores con indicadores
que escape bajo presión puede
visuales para controlar las condiciones de
penetrar la piel y causar lesiones graves. Si se
funcionamiento de un sistema hidráulico. Se
inyecta aceite bajo la piel, consulte a un
recomienda usar un manómetro hidráulico en
médico inmediatamente.
todo sistema hidráulico para asegurarse de no
ADVERTENCIA: Use cilindros exceder los valores nominales de
hidráulicos únicamente en funcionamiento de los componentes
sistemas acoplados. Nunca use un hidráulicos del sistema.
cilindro si los acopladores no están
En casos de sistemas de alta producción, una
conectados. Si el cilindro se sobrecarga, los
vez que se ha ajustado la presión del sistema
componentes pueden fallar calamitosamente,
hidráulico para producción, se debe
lo que causaría lesiones personales graves.
desconectar el manómetro hidráulico del
ADVERTENCIA: Asegurese que el sistema. Esto puede hacerse retirándolo
equipo sea antes de levantar la completamente del sistema, o instalando una
®
carga. El cilindro debe colocarse válvula de corte entre el manómetro y la línea

sobre una superficie plana capaz de de alta presión.
soportar la carga. De ser necesario, utilice una
En caso que el manómetro hidráulico se deje
base de cilindro para mayor estabilidad. No
funcionando de manera continua, se puede
suelde ni modifique el cilindro en modo alguno
alterar de forma significativa la calibración del
para fijarle una base u otro medio de soporte.
manómetro, lo cual hará necesario recalibrarlo
o sustituirlo. Se recomienda usar válvulas de
17
Especificaciones de adaptador de manómetro
N° pieza Dimensiones de rosca
A B C L
GA-1 /
3 "
8 NPT 1 "
2 / NPT /
3 "
8 NPT 71 mm (2.81 in.)
GA-2 /
3 "
8 NPT 1 "
2 / NPT /
3 "
8 NPT 139 mm (6.10 in.)
GA-3 /
3 "
8 NPT 1 "
4 / NPT /
3 "
8 NPT 133 mm (5.25 in.)
GA-4 /
1 "
4 NPT 1 "
2 / NPT /
3 "
8 NPT 111 mm (4.38 in.)
corte como protectores para todos los contra daños causados por fuentes externas.
manómetros hidráulicos sujetos a ritmos
1. Quite el tapón (los tapones) de la(s) salida(s)
acelerados de trabajo o fluctuaciones grandes
de aceite hidráulico de la bomba.
de presión.
2. Aplique pasta selladora (o cinta de Teflon) a
las roscas NPT macho. Haga las
conexiones de la manera arriba ilustrada. Al
apretar las conexiones y adaptadores
hidráulicos, utilice llaves de tuercas del
(1) tamaño adecuado. No utilice llaves
ajustables ni llaves de tubería, ya que éstas
Lumbrera pueden dañar los adaptadores para presión
de salida alta.
de bomba
5.0 FUNCIONAMIENTO
Manguera o El manómetro debe usarse a presiones que
(2) acoplador normalmente no excedan el 75% del valor de
deflexión completa de la aguja.
(3) Si se usa el manómetro para leer una presión

A B menor que el 10% de su valor de deflexión
completa, se puede obtener una indicación
C errónea.
IMPORTANTE: Compruebe la precisión del
L manómetro periódicamente, especialmente si
el valor medido es de importancia crítica y si la
falla o imprecisión del manómetro puede crear
(1) Manómetro riesgos al personal o la propiedad.
(2) Válvula de corte
(3) Adaptador para manómetro
4.0 INSTALACION
NOTA: Al hacer las conexiones hidráulicas,
aplique pasta selladora de alta calidad
solamente a las roscas de los conectores NPT
macho. Si se usa cinta de Teflon, no coloque la
cinta sobre la primera rosca. Utilice poca
cantidad de cinta. Los pedazos sueltos de
cinta de Teflon que ingresen a la bomba o el
cilindro pueden causar averías y daños.
Envuelva la cinta de modo que la misma se
apriete durante el armado. (En sentido horario
cuando se miran las roscas de frente.) Instale
el manómetro hidráulico de modo que pueda
leerse fácilmente y que esté bien protegido
18
Los manómetros Enerpac se calibran en la
75% fábrica con un margen de tolerancia de ±1% y
±11/2% del valor de deflexión completa de su
aguja. Para recalibrarlos, consulte la guía
telefónica o comercial de la localidad. Para
trabajos bajo garantía y/o reparaciones, envíe
el manómetro al Centro de servicio Enerpac
más cercano.
6.1 Mantenimiento del Manómetro de

Glicerina.
Para el mantenimiento, por favor contacte con
su centro de servicio Enerpac mas cercano. El
procedimiento para el mantenimiento del
manómetro de glicerina se contempla en la
10% Hoja de Instrucciones de Enerpac, L2561.
6.0 INFORMACION DE REPARACION Y

MANTENIMIENTO
19
Instructieblad
®
Manometers
L505 Rev C 10/01
ONTVANGST
opgelopen tijdens de verzending. Schade
opgelopen tijdens de verzending wordt niet door
de garantie gedekt. Als schade opgelopen
tijdens de verzending wordt gevonden, de
transporteur hier onmiddellijk van op de hoogte
stellen. De transporteur is verantwoordelijk voor
alle reparatie- of vervangingsonkosten als
gevolg van opgelopen schade tijdens de
verzending. WAARSCHUWING: Draag de juiste
persoonlijke beschermende kleding
VEILIGHEID VOOROP bij het werken met hydraulische
machines.
2.0 VEILIGHEIDSKWESTIES
WAARSCHUWING: Blijf uit de
Lees nauwkeurig alle buurt van ladingen die hydraulisch
instructies, waarschuwingen worden ondersteund. Een cilinder
en let op-gedeelten. Volg alle die wordt gebruikt als een hefinrichting mag
veiligheidsvoorzieningen om persoonlijk letsel nooit worden gebruikt als een lasthouder.
of schade aan eigendom te voorkomen als het Nadat de lading omhoog of omlaag is
systeem in werking is. Enerpac kan niet gebracht, moet deze altijd mechanisch worden
verantwoordelijk worden gesteld voor schade geblokkeerd.
of letsels als gevolg van onveilig gebruik van WAARSCHUWING: GEBRUIK
dit product, gebrek aan onderhoud, of onjuiste ENKEL STIJVE MATERIALEN OM
®
toepassing van het product of het systeem. ®
DE LADINGEN VAST TE HOUDEN.

Neem contact op met Enerpac mocht u Kies met zorg stalen of houten blokken die een
twijfels hebben over veiligheidsvoorzieningen lading kunnen ondersteunen. Gebruik nooit
en werkingen. Als u nooit een opleiding in een hydraulische cilinder als een pakkingschijf
hogedruk hydraulische veiligheid hebt gevolgd of een afstandstuk in enige toepassing waarbij
neem dan contact om met uw verdeel- of opheffen of drukken wordt gebruikt.
servicecentrum voor een gratis
veiligheidscursus van Enerpac Hydraulic. GEVAAR: Om persoonlijk
letsel te voorkomen, handen
Het niet volgen van deze waarschuwing en voeten weghouden van de
sboodschappen en voorzorgsmaatregelen kan cilinder en het werkstuk tijdens de bediening.
schade aan de machine en persoonlijk letsel
veroorzaken. WAARSCHUWING: Niet de
nominale waarden van de machines
LET OP wordt gebruikt om correcte overschrijden. Probeer nooit om een
bedienings- en onderhoudsprocedures en lading op te heffen die meer weegt dan de
praktijken aan te duiden om schade aan, of capaciteit van de cilinder. Overladen
vernietiging van, machines of andere veroorzaakt falen van de machine en mogelijk
eigendom te voorkomen. persoonlijk letsel.
WAARSCHUWING wijst op een mogelijk Nooit de ontlastklep instellen op een
gevaar dat de juiste procedures en praktijken hogere druk dan de maximaal
vereist om persoonlijk letsel te voorkomen. nominale druk van de pomp. Hogere
GEVAAR wordt enkel gebruikt als uw actie of instellingen kunnen schade aan de machine
gebrek aan actie ernstig letsel of zelfs de dood en/of persoonlijk letsel tot gevolg hebben.
tot gevolg kan hebben.
20
WAARSCHUWING: De persoonlijk letsel kan veroorzaken.
bedieningsdruk van het systeem
WAARSCHUWING: Zorg dat de
mag de nominale drukwaarde van apparatuur stabiel is opgezet
het onderdeel met de laagste waarde in het
®
alvorens lasten te heffen. De
systeem niet overschrijden. Installeer cilinder dient op een vlakke
drukmeters in het systeem om de ondergrond geplaatst te worden die de last
bedieningsdruk te controleren. Op die manier kan dragen. Gebruik waar mogelijk een
weet u wat er in het systeem gebeurt. ondersteuning voor de cilinder voor extra
LET OP: De hydraulische slang niet stabiliteit. De cilinder mag niet gelast of op een
beschadigen. Vermijd ombuigen en andere manier aangepast worden voor het
knikken bij het aanbrengen van de bevestigen van een voetstuk of andere
hydraulische slangen. Een gebogen of ondersteuning.
geknikte slang gebruiken kan ernstige
Vermijd situaties, waarbij de last niet
tegendruk van de afvoerstroom veroorzaken.
aangrijpt in het hart van de
Scherpe ombuigingen en knikken
cilinderplunjer. Niet-centrisch
beschadigen de slang aan de binnenkant wat
aangrijpende lasten veroorzaken aanzienlijke
tot vroegtijdig falen van de slang kan leiden.
spanningen in de cilinder en de plunjer.
Geen zware objecten op de slang Bovendien kan de last wegglijden of vallen,
®
laten vallen. Een scherpe impact wat tot gevaarlijke situaties leidt.
kan interne schade aan de
Verdeel de last gelijkmatig over het
draadvezels van de slang veroorzaken. Druk
gehele zadelopperviak. Gebruik altijd
uitoefenen op een slang die beschadigd is,
een zadel om de plunjer te
kan scheuren van de slang tot gevolg
beschermen, wanneer geen
hebben.
hulpstukken met schroefdraad worden
BELANGRIJK: Hydraulische gebruikt.
machines niet bij de slangen of de BELANGRIJK: Hydraulische
wartelkoppelingen opheffen. Gebruik machines mogen enkel door een
de draaghandgreep of een ander middel om bevoegd hydraulisch technicus van
de machine veilig te transporteren. onderhoud worden voorzien. Voor
LET OP: Houd de hydraulische reparaties dient u contact op te nemen met
machine weg van vlammen en een nabijgelegen bevoegd ENERPAC
hitte. Buitenmatige hitte verzacht servicecentrum. Om uw garantie te
de pakkingen en afdichtingen wat tot beschermen, enkel ENERPAC olie gebruiken.
vloeistoflekken kan leiden. Hitte verzwakt ook
WAARSCHUWING: Versleten of
slangmaterialen en pakkingen. Voor optimale
beschadigde onderdelen onmiddellijk
prestaties de machines niet blootstellen aan
met authentieke ENERPAC
temperaturen van 65°C (150°F) of hoger.
onderdelen vervangen. Standaardonderdelen
Bescherm slangen en cilinders tegen
breken, wat tot persoonlijk letsel en schade aan
lasspetters.
eigendom kan leiden. ENERPAC onderdelen
GEVAAR: Slangen die onder druk zijn zodanig ontworpen dat ze precies passen
staan, niet aanraken. Als olie die en hoge ladingen kunnen weerstaan.
onder druk staat ontsnapt, kan het
door de huid dringen wat ernstige letsel kan
veroorzaken. Als olie onder de huid wordt 3.0 BESCHRIJVING
geïnjecteerd, onmiddellijk een arts raadplegen.
Uw manometer van Enerpac is voornamelijk
WAARSCHUWING: Gebruik bestemd voor gebruik als een visueel
hydraulische cilinders enkel in een meetinstrument voor het observeren van de
aangesloten systeem. Nooit een hydraulische bedrijfsstaat van uw systeem.
cilinder gebruiken met koppelingen die niet Het gebruik van een hydraulische manometer
aangesloten zijn. Als de cilinder uiterst wordt bij elk hydraulisch systeem aanbevolen
overladen is, kunnen onderdelen op een om te verzekeren dat de toelaatbare
catastrofistische manier falen wat ernstig bedrijfsdruk van de hydraulische onderdelen
21
Gegevens manometeradapter
Onderdeel-nummer Draadafmetingen
A B C L
GA-1 /
3 "
8 NPT /
1 "
2 NPT /
3 "
8 NPT 71 mm (2.81 in.)
GA-2 /
3 "
8 NPT /
1 "
2 NPT /
3 "
8 NPT 139 mm (6.10 in.)
GA-3 /
3 "
8 NPT /
1 "
4 NPT /
3 "
8 NPT 133 mm (5.25 in.)
GA-4 /
1 "
4 NPT /
1 "
2 NPT /
3 "
8 NPT 111 mm (4.38 in.)
niet worden overschreden. of drukschommelingen.
4.0 INSTALLATIE
OPMERKING: Gebruik bij het maken van
hydraulische aansluitingen alleen op de
(1) schroefdraad van mannetjes NPT-
koppelstukken een afdichtingsmiddel van
goede kwaliteit. Laat, indien u Teflon-tape
gebruikt de eerste volledige gang vrij. Wees
spaarzaam met tape. Losse Teflon-tape in uw
pomp of cilinder kan storingen of schade tot
Uitlaatpoort gevolg hebben. Wikkel de tape zodanig dat
pomp (2) deze bij montage strak trekt. (Met de klok mee
en de schroefdraad naar u toe gericht.)
Behuizing of Installeer uw hydraulische manometer op een
(3) koppelstuk plaats waar deze gemakkelijk af te lezen is,
A B maar voldoende beschermd is tegen
beschadiging van buitenaf.
C 1. Verwijder de plug(gen) van de
hydrauliekolie-uitlaat van uw pomp.
L 2. Breng afdichtingsmiddel (of Teflon-tape)
aan op de mannetjes NPT-schroefdraden.
(1) Manometer Maak de aansluitingen die hierboven zijn
afgebeeld. Gebruik bij het aandraaien van
(2) Afsluiter
hydraulische aansluitingen en fittingen de
(3) Manometeradapter juiste steeksleutels. Gebruik geen starter-
of pijpsleutels, aangezien deze de
In toepassingen met hoge productie dient uw hogedrukfittingen kunnen beschadigen.
hydraulische manometer van het hydraulische
systeem afgekoppeld te worden wanneer de 5.0 BEDIENING
drukinstellingen voor het hydraulische
systeem eenmaal zijn uitgevoerd. Dit kan De manometer dient gebruikt te worden bij
bewerkstelligd worden door de manometer drukken die normaliter niet meer dan 75% van
geheel uit het systeem te verwijderen, of door de volle schaal mogen bedragen.
een afsluiter tussen de manometer en de Het gebruik van de manometer voor het
hogedrukleiding te installeren. aflezen van drukken die minder dan 10% van
Indien de hydraulische manometer de volle schaal bedragen, kan een foutieve
voortdurend in bedrijf wordt gelaten, kan de meting tot gevolg hebben.
kalibratie van de manometer aanzienlijk worden BELANGRIJK: De nauwkeurigheid van de
aangetast, waardoor herkalibratie of volledige manometer dient van tijd tot tijd gecontroleerd
vervanging is vereist. Afsluiters worden te worden, vooral wanneer de drukmeting van
aanbevolen als aanvullende bescherming voor kritiek belang is en onnauwkeurigheid of falen
iedere hydraulische manometer die mogelijk van de manometer een gevaar kan opleveren
onderhevig kan zijn aan hoge cyclusfrequenties
22
voor personeel of eigendom.
75%
10%
6.0 OVER REPARATIE EN ONDERHOUD

Manometers van Enerpac zijn in de fabriek
gekalibreerd tot op ±1% - ±11/2 % nauwkeurig
van de volle schaal. Raadpleeg uw plaatselijke
telefoonboek of gouden gids voor
herkalibratie. Stuur uw manometer naar het
dichtstbijzijnde Servicecentrum van Enerpac
voor service onder de garantie en/of reparatie.
6.1 Onderhoud Glycerine Gevulde

Manometers
Neem contact op met een Enerpac Service
Centre voor het bijvullen van glycerine gevulde
manometers. De bijvulprocedure is
beschreven in handleiding L-2561.
23
®
Manômetros
L505 Rev C 10/01

RECEBIMENTO
Inspecione visualmente todos os
componentes verificando se houve avarias
durante o transporte. Avarias no transporte
não são cobertas pela garantia. Caso haja
avarias no transporte, avise o transportador
imediatamente. O transportador é responsável
por todos os custos de consertos e
substituições decorrentes de avarias
ocorridas no transporte.
ADVERTÊNCIA: Use equipamentos
SEGURANÇA EM PRIMEIRO LUGAR individuais de proteção quando
acionar equipamentos hidráulicos.
2.0 ASSUNTOS DE SEGURANÇA
Leia cuidadosamente todas ADVERTÊNCIA: Mantenha
as instruções, advertências distância de cargas apoiadas por
e avisos sobre precaução. cilindros hidráulicos. Um cilindro,
Siga todas as recomendações de segurança quando utilizado como dispositivo de
para evitar lesões pessoais ou danos à levantamento, jamais deve ser usado como
propriedade durante a operação do sistema. dispositivo de sustentação de carga. Depois
Enerpac não pode ser responsável por danos de haver sido levantada ou baixada, a carga
ou lesões pessoais resultantes do uso deve sempre ser bloqueada mecanicamente.
indevido do produto, falta de manutenção ou
ADVERTÊNCIA: USE SOMENTE
operação inadequada do produto e/ou
PEÇAS RÍGIDAS PARA APOIAR AS
®
sistema. Entre em contato com Enerpac ®
CARGAS. Selecione
quando houver dúvidas sobre as
cuidadosamente blocos de madeira ou ferro
recomendações de segurança e operações.
que sejam capazes de sustentar a carga.
Se você nunca recebeu treinamento em
Nunca use um cilindro hidráulico como um
segurança na hidráulica de alta pressão,
calço ou espaçador em qualquer aplicação
consulte o seu distribuidor ou centro de
de levantamento ou prensagem.
serviço sobre um curso de segurança
hidráulica Enerpac. PERIGO: Para evitar lesões
Falhas no cumprimento das advertências e pessoais mantenha mãos e
avisos de precaução podem causar lesões pés longe do cilindro e da
pessoais e avarias ao equipamento. área de trabalho durante a operação.
PRECAUÇÃO é usada para indicar a ADVERTÊNCIA: Não exceda a
operação correta ou os procedimentos e capacidade do equipamento. Nunca
métodos de manutenção para prevenir o tente levantar uma carga mais
dano, a destruição do equipamento ou outras pesada que a capacidade do cilindro. Excesso
propriedades. de carga pode causar falhas no equipamento
e possíveis lesões pessoais.
ADVERTÊNCIA indica um perigo potencial
que exige procedimentos ou métodos Nunca ajuste uma válvula de alívio
corretivos para evitar lesões pessoais. com pressão maior que a
PERIGO é usado somente quando a ação ou capacidade de pressão máxima da
a falta da mesma podem causar lesões sérias bomba. Ajustes maiores podem resultar em
ou mesmo a morte. danos ao equipamento e/ou lesões pessoais.
24
ADVERTÊNCIA: A pressão de ADVERTÊNCIA: ESTEJA CERTO
operação do sistema não deve QUE A MONTAGEM É ESTÁVEL
®
exceder a capacidade de pressão ANTES DE LEVANTAR A CARGA.
do componente de menor capacidade no Os cilindros devem ser colocados
sistema. Instale manômetros de pressão no em superfícies planas que podem apoiar a
sistema para monitorar a pressão de carga. Quando aplicável, use uma base de
operação. É a sua janela para o que está cilindro Enerpac para aumentar a
acontecendo no sistema. estabilidade. Não faça soldas ou, de
qualquer forma, modifique o cilindro para
PRECAUÇÃO: Evite danificar acrescentar uma base ou outro apoio.
mangueiras hidráulicas. Evite curvas
ou dobras pronunciadas quando Evite situações em que as cargas
direcionar as mangueiras hidráulicas. O uso não estão centradas na haste do
de uma mangueira curvada ou dobrada cilindro. Cargas fora de centro
causará aumento na pressão de retorno. podem causar deformações
Curvas ou dobras pronunciadas danificarão a consideráveis nas hastes e nos cilindros.
mangueira internamente, levando a um Além disto, a carga pode escorregar ou cair,
desgaste prematuro. causando resultados potencialmente
perigosos.
Não derrube objetos pesados na
mangueira. Um forte impacto Distribua a carga uniformemente
em toda a superfície do assento.
®
pode causar danos à trama

interna de aço da mangueira. A aplicação de Use sempre um assento para
pressão em uma mangueira danificada proteger a haste.
pode causar a sua ruptura.
IMPORTANTE: Não levante o IMPORTANTE: Somente técnicos
equipamento hidráulico pela em hidráulica, devidamente
mangueira ou pelos engates. Use qualificados, devem fazer a
manoplas ou outros meios mais seguros manutenção de equipamentos hidráulicos.
para o transporte. Para serviços de manutenção, entre em
contato com o Centro de Serviço Autorizado
PRECAUÇÃO: Mantenha o Enerpac em sua área. Para proteger sua
equipamento hidráulico longe do garantia, use somente óleo Enerpac.
calor e das chamas. O calor
excessivo amolece vedações e selos, ADVERTÊNCIA: Substitua
resultando em vazamento de fluídos. O calor imediatamente peças gastas ou
também enfraquece o material das danificadas por peças genuínas
mangueiras e das juntas. Para um Enerpac. Peças não genuínas podem
desempenho otimizado não exponha o quebrar, causando lesões pessoais ou danos
equipamento a temperatura maiores que 65 à propriedade. As peças Enerpac são
°C [150 °F]. Proteja mangueiras e cilindros projetadas para se encaixar adequadamente
dos respingos de solda. e sustentar cargas pesadas.
PERIGO: Não manuseie 3.0 DESCRIÇÃO

mangueiras pressurizadas. O Seu manômetro Enerpac é projetado para,
escape do óleo sob pressão pode principalmente, funcionar como um
penetrar na pele, causando lesões sérias. Se dispositivo de medição visual na observação
o óleo penetrar na pele, procure um médico das condições hidráulicas da operação de
imediatamente. seu sistema. Recomenda-se a utilização de
ADVERTÊNCIA: Use somente um manômetro hidráulico em qualquer
cilindros hidráulicos num sistema sistema hidráulico para garantir que a
acoplado. Nunca use um cilindro capacidade nominal de operação dos
com engates não conectados. componentes hidráulicos dentro do sistema
Caso o cilindro se torne extremamente não é ultrapassada.
sobrecarregado, os componentes podem Em aplicações de alta produtividade, uma vez
falhar catastroficamente, causando severas que a pressão hidráulica do sistema for
lesões pessoais. estabelecida para o lote de produção, o seu
25
Especificações do Adaptador do Manômetro
Referência Dimensões das Roscas

A B C L
GA-1 /
3 "
8 NPT 1 "
2 / NPT /
3 "
8 NPT 71 mm (2.81 in.)
GA-2 /
3 "
8 NPT 1 "
2 / NPT /
3 "
8 NPT 139 mm (6.10 in.)
GA-3 /
3 "
8 NPT 1 "
4 / NPT /
3 "
8 NPT 133 mm (5.25 in.)
GA-4 /
1 "
4 NPT 1 "
2 / NPT /
3 "
8 NPT 111 mm (4.38 in.)
manômetro hidráulico deve ser desligado do 4.0 INSTALAÇÃO

sistema. Isto pode ser feito com sua remoção
16. NOTA: Ao fazer ligações hidráulicas, use
completa do sistema ou pela instalação de
selantes de alta qualidade, somente nas
uma válvula de bloqueio entre o manômetro e
roscas macho dos conectores NPT. Se utilizar
a linha de alta pressão.
fita Teflon, não passe a fita na primeira rosca.
Caso o manômetro hidráulico seja mantido Use a fita cuidadosamente. Pedaços de Fita
continuamente em operação, a calibragem do Teflon na sua bomba ou no seu cilindro podem
manômetro pode ser severamente afetada, causar mau funcionamento ou danos. Passe a
exigindo uma nova aferição ou completa fita de forma a ficar apertada depois da
substituição. Válvulas de bloqueio são montagem (no sentido horário com as roscas
recomendadas como proteção adicional para voltadas para você). Instale o seu manômetro
qualquer manômetro hidráulico que seja hidráulico em um local de fácil leitura, mas
submetido a condições de altos ciclos ou bem protegido contra danos de origem
flutuações de pressão. externa.
1. Remova o bujão(ões) da saída de óleo
hidráulico de sua bomba.
2. Aplique selante (ou fita Teflon tape) nas
roscas macho NPT. Faça as conexões
(1) conforme mostrado acima. Quando apertar
as conexões e acessórios hidráulicos, use
a chave de boca no tamanho apropriado.
Não utilize grifos ou alicates de pressão,
uma vez que podem danificar os
acessórios de alta pressão.
(2) 5.0 OPERAÇÃO

Saída da
bomba O manômetro deve trabalhar com pressões
que normalmente não excedam 75% da
(3) escala total.
Mangueira ou
A B
conector
Usar o manômetro para valores menores que
C 10% da escala total pode resultar em leituras
erradas.
L IMPORTANTE: O manômetro deve ser

periodicamente verificado quanto à precisão,
especialmente quando a medida de pressão é
(1) Manômetro
crítica e uma falha do manômetro ou falta de
(2) Válvula de bloqueio precisão podem criar riscos para as pessoas
(3) Adaptador do Manômetro ou propriedades.
26
75%
10%
6.0 REPAIR AND SERVICE INFORMATION

Enerpac gauges are precalibrated by the
factory to within ±1% and ±11/2% of the full
scale. For recalibration, please refer to your
local phone or business directory. For warranty
and/or repair service, send your gauge to the
nearest Enerpac Service Center.
6.1 Manutenção do Manômetro com

Glicerina
Para manutenção, por favor entre em contato
com o Centro de Serviços Enerpac mais
próximo. O procedimento para abastecimento
do manômetro com glicerina está descrito na
Folha de Instruções Enerpac L 2561.
27
Australia Hong Kong Singapore

ENERPAC, Applied Power Australia ENERPAC Applied Power Asia Pte Ltd
Ltd. Room 907 Workingberg No. 8, Ang Mo Kio,
Block V Unit 3 Commercial Building Industrial Park 2
Regents Park Estate 41-47 Marble Road #01-00
391 Park Road North Point Singapore 569500
Regents Park NSW 2143 Tel: +852-2561 6295 Thomson Road
(P.O. Box 261) Australia Fax: +852-2561 6772 P.O. Box 114
Tel: +61 297 438 988 Singapore 915704
Fax: +61 297 438 648 India Tel: +65 484 5108
ENERPAC Fax: +65 484 5669
Canada Hydraulics (India) Pvt Ltd
Actuant Canada Corporation Plot No. A-571 South Korea
6615 Ordan Drive, Unit 14-15 MIDC, TTC Industrial Area ENERPAC
Mississauga, Ontario L5T 1X2 Mahape-400 701 Applied Power Korea Ltd.
Tel: +1 905 564 5749 Navi Mumbai, India 163-12 Dodang-Dong
Fax: +1 905 564 0305 Tel: +91 22 769 47 78 Wonmi-Ku, Buchun-shi
Fax: +91 22 769 84 73 Kyunggi-Do
Toll Free:
Republic of Korea
Tel: +1 800 268 4987 Italy Tel: +82 32 675 08 36
Fax: +1 800 461 2456 ENERPAC Fax: +82 32 675 30 02/73
Applied Power Italiana S.p.A.
China Spain, Portugal
Via Canova 4
Applied Power China Ltd. 20094 Corsico (Milano) ENERPAC
1F, 269 Fute N. Road Tel: +39 02 4861 1110 Applied Power International S.A.
Waigaoqiao Free Trade Zone Fax: +39 02 4860 1288 Avda. Camino de lo Cortao
Pudong New District 21 - Nave 3
Shanghai, 200 131 Japan San Sebastian de los Reyes
China Applied Power Japan Ltd. 28709 Madrid
Tel: +86 21 5866 9099 1-1-11, Shimomae Spain
Fax: +86 21 5866 7156 Toda-shi Tel: +34 91 661 11 25
Saitama Pref. Fax: +34 91 661 47 89
France, Turkey, Greece,
Japan 335-0016
Africa, Middle East USA, Latin America
Tel: +81-48-430-2311
ENERPAC S.A. Fax: +81-48-430-1117 and Caribbean
B.P. 200 ENERPAC
Parc d’Activités Mexico P.O. Box 3241
du Moulin de Massy ENERPAC Applied Power 6100 N. Baker Road
F-91882 Massy CEDEX (Paris) Mexico S.A. de C.V. Milwaukee, WI 53209 USA
France Avenida Principal Tel: +1 262 781 6600
Tel: +33 1 601 368 68 La Paz #100 Fax: +1 262 783 9562
Fax: +33 1 692 037 50 Fracc. Industrial La Paz
42092 Pachuca, Hidalgo User inquiries:
Germany, Switzerland,
Tel: +52 771 337 00 +1 800 433 2766
Austria, Eastern Europe
Fax: +52 771 838 00 Distributor inquiries/orders:
ENERPAC
+1 800 558 0530
Applied Power GmbH The Netherlands, Belgium,
P.O. Box 300113 Luxembourg, Sweden, Denmark,
D-40401 Düsseldorf Norway, Finland, United
Germany Kingdom, Ireland
Tel: +49 211 471 490 ENERPAC B.V.
Fax: +49 211 471 49 28 Storkstraat 25
P.O. Box 269, 3900 AG Veenendaal
The Netherlands
Tel: +31 318 535 911
Fax: +31 318 525 613
+31 318 535 848
UK, Ireland
Tel: +44 01527 598 900
Fax: +44 01527 585 500
For your nearest authorized Enerpac Service Center, visit us at www.enerpac.com 092501
Instruction Sheet
®
Hydraulic Hose / Fittings

L2255 Rev. O 06/04
Index:
English:........................................................................... 1-4 Italiano:....................................................................... 12-16
Français:..........................................................................5-8 Español: ......................................................................17-20
Deutsch: ........................................................................9-11 Nederlands: .................................................................21-24
IMPORTANT RECEIVING INSTRUCTIONS

Visually inspect all components for shipping damage. If any shipping
damage is found, notify carrier at once. Shipping damage is NOT
covered by warranty. The carrier is responsible for all repair or
replacement cost resulting from damage in shipment.
DESCRIPTION
Enerpac supplies three different types of hydraulic hoses: thermoplastic,
heavy duty rubber, or nylon. The thermoplastic hose has four layers,
including two high strength steel wire braids. The rubber hose is
reinforced with two layers of braided steel webbing. The nylon hose has
an exterior plastic coating.
WARNING
Do not use Enerpac hoses in systems exceeding 10,000 psi [700 bar].
HOSE COMPARISON
Hose 700 Series Thermoplastic 800 Series Nylon 900 Series Rubber
Design Factor 4 to 1 2 to 1 2 to 1
Increase in length may be May expand under pressure

Expansion Low
significant for small systems
Less flexible Less flexible, but more Most flexible at low temperatures, but
Flexibility
tolerant to tight bends tight bends can lead to damage
Less tolerant to different types

Tolerance to Fluids Inert to most fluids Inert to most fluids
of fluid
Tolerance to Heat Sensitive to heat Sensitive to heat More tolerant to heat
Durability of Outer
Abrasion-resistant Abrasion-resistant Easily abused
Covering
Tolerance to High
Very tolerant Tolerant Less tolerant
Pressure Cycling
SAFETY INFORMATION
To avoid personal injury during system operation, read and follow all
CAUTIONS, WARNINGS, and INSTRUCTIONS included with or attached
to each product. ENERPAC CANNOT BE RESPONSIBLE FOR DAMAGE
RESULTING FROM UNSAFE USE OF PRODUCT, LACK OF
MAINTENANCE, OR INCORRECT PRODUCT OR SYSTEM
APPLICATION. Contact Enerpac when in doubt about applications and
safety precautions.
WARNING
Be certain that ALL system components, including couplers, fittings, pipes,
and tubing, are rated for the maximum operating pressure of the system. The
system operating pressure must not exceed the pressure rating of the lowest
rated component in the system or system failure may occur, resulting in serious
personal injury or equipment damage.
WARNING
Always wear proper personal protective gear, when operating hydraulic
equipment.
WARNING
Make sure that all system components are protected from
external sources of damage, such as excessive heat, flame, weld
spatter, moving machine parts, sharp edges, and corrosive
chemicals. Do not expose hoses to temperatures of 150°F [65°C]
or higher.
WARNING
NEVER make or break hydraulic connections while the
system is under pressure.
WARNING
Wear proper personal protective gear when operating
WARNING
Do not handle hoses under pressure. Replace damaged
hoses immediately. Hydraulic fluid escaping through a small
hole can penetrate the skin, causing serious injury. If oil is
injected under the skin, see a doctor immediately.
CAUTION
Do not use hydraulic hose to carry hydraulic components
such as pumps or cylinders.
CAUTION
Use only the manufacturer's recommended fluid. Do not mix fluids in a
system. Use only fluids that are compatible with system components, or seals and
hoses will be damaged. Synthetic and fireproof fluids require special seals and
hoses. Contact the nearest authorized service center or the manufacturer for
recommendation.
(2)
INSTALLATION
Hydraulic Hoses
1. Before operating, visually inspect the system.
2. Check to be sure there are no cracks, kinks, cuts, or other damage
which might cause the hose to leak. Rubber guards protect crimped
areas at each end of the hose.
3. Make sure all hose ends, couplers, or union ends are R=4½ in.
clean and threads are in good condition. R=11,4 cm
4. Hose should not be twisted or bent too sharply. The
bend radius should always be at least 4.5 inches
(11,4 cm). Always use as few bends as possible.
5. Do not drop heavy objects on hose. A sharp impact
may cause internal damage to hose wire strands.
Applying pressure to a damaged hose may cause it
to rupture.
6. Make sure all hose connections between pump and
cylinder are tight and leak free. Do not over-tighten connections or
use tools to tighten connections. Excessive torque may cause
premature thread failure and may cause high pressure fittings to split
at pressure lower than rated capacity. When using quick disconnect
fittings, make sure the fittings are correctly and completely fastened
together.
Fittings and Tubing

The following guidelines should be used whenever fittings are used in
hydraulic systems.
1. Care must be taken that threaded fittings are not cross-threaded.
2. Be sure connections are sealed using high grade pipe thread sealer.
3. Tape or sealing compound should be confined to threaded areas only.
Keep first thread free of tape to avoid pieces of tape getting into the
system.
CAUTION
Use care to ensure that pieces of tape do not enter the hydraulic system.
Pieces of tape in the fluid impairs fluid flow, causing system malfunctions.
4. Vibration and system shock-loads are the primary cause of

fitting/tubing leaks. Use commercially available tube supports to
extend the life of your system. The most critical area to use a tube
support is 4-7 inches behind a fitting.
5. Tubing is not rigid. Long runs must be supported. Unsupported
sections can lead to premature fitting failure. Always hard mount
valves and gauges. Never allow tubing to be their sole support!
(3)
MAINTENANCE
This section refers to components commonly found in a hydraulic system.
General
1. Keep the components clean at all times. Many hydraulic service
problems are caused by dirt and/or metallic particles in the hydraulic
system. To avoid these problems, the use of proper maintenance
including rust prevention and cleanliness will help extend the life of
your hydraulic system.
2. Use only an approved clean hydraulic fluid and change fluid as
recommended by the manufacturer. Change fluids more often if unit is
used under extreme conditions.
3. Change or clean the filter in the system periodically if one is used.
Hydraulic Hoses
1. Hydraulic hoses should be left in carton until needed.
2. Store hoses at a temperature between 50º to 75ºF [10º to 24ºC ] and
at a humidity between 20 and 70 percent.
3. Never store hoses in a hot, damp room, in direct sunlight or near heat
sources.
4. Do not stack hoses. The weight of the pile will tend to flatten the hose
on the bottom. Hanging in a rack is preferred.
5. Do not carry or drag hydraulic assemblies by pulling or pushing on
couplings or hoses.
Fittings and Couplers

1. All coupler threads, either male or female, must be kept clean and
lubricated regularly. Cover couplers with dust caps when not
connected to system. Do not remove covers or plugs until component
is ready to be used.
2. Keep dust caps on couplers when not in use. Make certain that all
unused couplers are sealed with dust caps/thread protectors.
3. Be sure all hose connections are free of grit and grime.
(4)
Bedienungsanleitung
®
Hydraulikschlauch / Fittings
L2255 Rev. O 06/04
WICHTIGE ANWEISUNGEN FÜR DIE EINGANGSKONTROLLE
Unterziehen Sie alle Teile einer Sichtkontrolle auf eventuelle
Transportschäden. Wird ein solcher Schaden festgestellt,
benachrichtigen Sie unverzüglich den Spediteur. Transportschäden sind
von der Gewährleistung NICHT abgedeckt. Der Spediteur haftet für alle
Reparatur- und Austauschkosten, die sich aus einer Beschädigung beim
Transport ergeben.
BESCHREIBUNG
Enerpac liefert Hydraulikschläuche aus drei verschiedenen
Werkstofftypen: Thermoplast, Hochleistungsgummi oder Nylon. Der
Thermoplastschlauch hat vier Lagen, einschließlich zwei hochfesten
Stahldrahtgeflechten. Der Gummischlauch ist mit zwei Lagen aus
geflochtenem Stahlgurtband verstärkt. Der Nylonschlauch weist eine
äußere Kunststoffbeschichtung auf.
ACHTUNG
Verwenden Sie keine Enerpac-Schläuche in Systemen, deren Druck 700 bar
[10,000 psi] übersteigt.
VERGLEICH DER SCHLAUCHTYPEN

Thermoplast der Nylon der
Schlauch Gummi der Reihe 900
Reihe 700 Reihe 800
Konstruktionsfaktor 4 zu 1 2 zu 1 2 zu 1
Längenausdehnung möglicherweise kann sich unter Druck ausdehnen

Ausdehnung gering
signifikant für kleine Systeme
weniger biegsam, doch verträglich- am biegsamsten bei niedrigen

Biegsamkeit weniger biegsam Temperaturen, doch enge Biegungen
er für enge Biegungen können zu Schäden führen
Flüssigkeits- inert für die meisten inert für die meisten weniger verträglich für ver-
verträglichkeit Flüssigkeiten Flüssigkeiten schiedene Flüssigkeitsarten
Wärmeverträglichkeit wärmeempfindlich wärmeempfindlich wärmeverträglicher
Haltbarkeit der falsche Benutzung leicht

abriebfest abriebfest
äußeren Umkleidung möglich
Verträglichkeit von
sehr verträglich verträglich weniger verträglich
Hochdruckzyklen
(5)
SICHERHEITSINFORMATIONEN
Um Verletzungen während des Systembetriebs zu vermeiden, lesen und

befolgen Sie bitte alle VORSICHTS- und ACHTUNGS-Hinweise sowie die
ANWEISUNGEN, die jedem Produkt beiliegen oder daran angebracht
sind. ENERPAC HAFTET NICHT FÜR SCHÄDEN, DIE AUF
FAHRLÄSSIGEN GEBRAUCH DES PRODUKTS, MANGELHAFTE
INSTANDHALTUNG ODER UNSACHGEMÄSSE PRODUKT- UND
SYSTEMANWENDUNG ZURÜCKZUFÜHREN SIND. Wenden Sie sich an
Enerpac, sofern Sie Fragen zur Produktanwendung oder zu den
Sicherheitsmaßnahmen haben.
ACHTUNG
Stellen Sie sicher, daß ALLE Systemkomponenten, einschließlich Kupplern,
Fittings, Leitungen und Röhren für den maximalen Betriebsdruck des Systems
ausgelegt sind. Der Systembetriebsdruck darf nicht höher sein als der
Nennbetriebsdruck der Systemkomponente mit dem niedrigsten Druck;
andernfalls kann es zum Ausfall des Systems kommen, was zu schweren
Verletzungen oder zu Geräteschäden führen kann.
ACHTUNG
Tragen Sie beim Bedienen hydraulischer Geräte bitte stets zweckmäßige
Schutzkleidung.
ACHTUNG
Stellen Sie sicher, daß keine Systemkomponenten
schädlichen Außeneinwirkungen wie übermäßiger Hitze, offenem
Feuer, Schweißspritzern, beweglichen Maschinenteilen, scharfen
Gegenständen und korrodierenden Chemikalien ausgesetzt sind.
Setzen Sie die Schläuche keinen Temperaturen über 65 °C
[150°F] aus.
ACHTUNG
Verbinden oder trennen Sie NIEMALS hydraulische
Anschlüsse, während das System unter Druck steht.
ACHTUNG
Tragen Sie beim Bedienen hydraulischer Geräte bitte
zweckmäßige Schutzkleidung.
ACHTUNG
Handhaben Sie keine Schläuche, die unter Druck stehen.
Ersetzen Sie beschädigte Schläuche sofort. Hydraulikflüssigkeit,
die durch eine kleine Öffnung austritt, kann die Haut
durchdringen und schwere Verletzungen verursachen. Suchen
Sie sofort einen Arzt auf, falls Öl unter die Haut eindringt.
VORSICHT
Verwenden Sie Hydraulikschläuche nicht zum Tragen von
Bestandteilen des Hydrauliksystems, wie z.B. Pumpen oder
Zylindern.
VORSICHT
Verwenden Sie nur die vom Hersteller empfohlene Hydraulikflüssigkeit.
Mischen Sie nicht verschiedene Flüssigkeiten in einem System. Verwenden Sie nur
Flüssigkeiten, die mit den Systemkomponenten verträglich sind; sonst werden
Dichtungen und Schläuche beschädigt. Synthetische und feuerfeste Flüssigkeiten
erfordern spezielle Dichtungen und Schläuche. Entsprechende Empfehlungen
erhalten Sie vom autorisierten Service-Center bzw. vom Hersteller.
(6)
ANBRINGUNG
Hydraulikschläuche
1. Das System vor dem Betrieb einer Sichtprüfung unterziehen.
2. Sicherstellen, daß keine Risse, Knickstellen, Einschnitte oder andere
Beschädigungen vorliegen, die zur Undichtheit des Schlauchs führen
können. Gummischoner schützen die gebördelten Bereiche an jedem
Schlauchende.
3. Sicherstellen, daß alle Schlauchenden, Kuppler und R=4½ in.
Verschraubungsenden sauber und die Gewinde in R=11,4 cm
gutem Zustand sind.
4. Der Schlauch sollte nicht zu stark verdreht oder
gebogen werden. Der Biegeradius sollte stets
mindestens 11,4 cm (4.5 inches) betragen. Stets
möglichst wenige Biegungen verwenden.
5. Keine schweren Gegenstände auf den Schlauch
fallen lassen. Durch starke Stöße können die
Drahtsträhnen im Schlauch beschädigt werden. Wird
ein beschädigter Schlauch unter Druck gesetzt, kann er bersten.
6. Sicherstellen, daß alle Schlauchverbindungen zwischen Pumpe und
Zylinder fest sitzen und dicht sind. Die Verbindungen nicht zu fest
anziehen und dazu keine Werkzeuge verwenden. Durch übermäßiges
Anzugsmoment kann es zu vorzeitigem Gewindeversagen und zum
Platzen der Hochdruckfittings bei Drücken unterhalb des Nenndrucks
kommen. Bei der Verwendung von Schnellfittings sicherstellen, daß
die Fittings richtig und vollständig aneinander befestigt sind.
Fittings und Rohrleitungen

Die folgenden Richtlinien sollten beachtet werden, wenn Fittings in
Hydrauliksystemen verwendet werden.
1. Vorsicht walten lassen, damit die Gewindefittings nicht schief
eingeschraubt werden.
2. Sicherstellen, daß die Anschlüsse mit einem hochwertigen
Rohrgewindedichtmittel abgedichtet werden.
3. Klebestreifen oder Dichtmittel dürfen sich nur im Gewindebereich
befinden. Den ersten Gewindegang nicht mit Band umwickeln, um zu
verhindern, daß Bandstücke in das System gelangen.
VORSICHT
Vorsicht walten lassen, um sicherzustellen, daß keine Bandstücke in das
Hydrauliksystem eindringen. Bandstücke in der Hydraulikflüssigkeit behindern den
Flüssigkeitsstrom und verursachen Systemstörungen.
4. Vibrationen und Stoßbelastungen des Systems stellen die primäre

Ursache von Fitting-/Röhrenlecks dar. Handelsübliche Röhrenträger
verwenden, um die Lebensdauer des Systems zu verlängern. Der
wichtigste Bereich für den Einsatz eines Röhrenträgers ist 10-18 cm
hinter einem Fitting.
5. Rohrleitungen sind nicht starr. Lange Leitungsstränge müssen
gestützt werden. Ungestützte Abschnitte können zum vorzeitigen
Fittingversagen führen. Ventile und Meßgeräte immer fest anbringen.
Niemals zulassen, daß sie nur von Rohrleitungen gestützt werden!
(7)
WARTUNG
Dieser Abschnitt bezieht sich auf Komponenten, die üblicherweise in einem
Hydrauliksystem vorgefunden werden.
Allgemeines
1. Alle Komponenten stets sauber halten. Viele Hydraulikprobleme, die
Wartung erfordern, werden durch Schmutz und/oder Metallteilchen im
Hydrauliksystem verursacht. Durch ordnungsgemäße Wartung
einschließlich Rostverhütung und Reinlichkeit können diese Probleme
vermieden und die Lebensdauer des Hydrauliksystems verlängert
werden.
2. Nur zugelassene saubere Hydraulikflüssigkeit verwenden und die
Flüssigkeit gemäß der Herstellerempfehlung wechseln. Die
Flüssigkeiten öfter wechseln, wenn das Gerät unter extremen
Bedingungen eingesetzt wird.
3. Falls ein Filter in dem System verwendet wird, diesen regelmäßig
austauschen oder reinigen.
Hydraulikschläuche
1. Hydraulikschläuche sollten im Karton verbleiben, bis sie benötigt
werden.
2. Schläuche bei einer Temperatur zwischen 10 ºC und 24 ºC [50 ºF und
75 ºF ] und einer Luftfeuchtigkeit zwischen 20 und 70 Prozent lagern.
3. Schläuche niemals in einem warmen, feuchten Raum, bei direkter
Sonneneinstrahlung oder in der Nähe von Wärmequellen lagern.
4. Schläuche nicht stapeln. Das Gewicht des Stapels kann zur
Abplattung des untersten Schlauchs führen. Das Aufhängen in einem
Gestell ist vorzuziehen.
5. Hydraulikausrüstungen nicht tragen oder ziehen, indem an
Verbindungsstücken oder Schläuchen gezogen oder geschoben wird.
Fittings und Kuppler

1. Alle Kupplergewinde, sowohl Außen- als auch Innengewinde, müssen
sauber gehalten und regelmäßig geschmiert werden. Kuppler mit
Staubschutzkappen abdecken, wenn sie nicht an das System
angeschlossen sind. Abdeckungen oder Stopfen nicht entfernen, bis
die Komponente einsatzbereit ist.
2. Staubschutzkappen an nicht verwendeten Kupplern lassen.
Sicherstellen, daß alle nicht verwendeten Kuppler mit
Staubschutzkappen/Gewindeschonern abgedichtet sind.
3. Sicherstellen, daß alle Schlauchverbindungen frei von Grobstaub und
Verunreinigungen sind.
(8)
Notice d'emploi
®
Flexible hydraulique/raccords
L2255 Rév. O 06/04
INSTRUCTIONS IMPORTANTES POUR LA RÉCEPTION
Inspecter toutes les pièces en vue de dommages subis pendant
l'expédition. Signaler immédiatement au transporteur les dommages
constatés. Les dommages survenus pendant l'expédition NE SONT PAS
couverts par la garantie. Le transporteur est responsable de tous les frais
de réparation et de remplacement résultant de dommages subis lors du
transport.
DESCRIPTION
Enerpac offre trois différents types de flexibles hydrauliques :
thermoplastique, caoutchouc haute résistance et nylon. Le flexible
thermoplastique est constitué de quatre couches dont deux de tresse
acier haute résistance. Le flexible en caoutchouc est renforcé par deux
couches d'acier tressé. Le flexible en nylon est pourvu d'une couche
extérieure en plastique.
AVERTISSEMENT
Ne pas utiliser les flexibles Enerpac sur des systèmes dont la pression est
de plus de 700 bar [10,000 psi].
COMPARAISON DES FLEXIBLES

Flexible Thermoplastique série 700 Nylon série 800 Caoutchouc série 900
Coefficient de
4à1 2à1 2à1
sécurité
L'augmentation de longueur Expansion possible sous pression
Expansion Faible peut être considérable pour de
petits systèmes
Moins flexible mais plus Flexibilité maximum à basses tem-

Flexibilité Moins flexible pératures mais les coudes aigus
tolérant aux coudes aigus peuvent causer des dommages
Moins tolérant à divers types

Tolérance aux fluides Inerte à la plupart des fluides Inerte à la plupart des fluides
de fluides
Tolérance à la
Sensible à la chaleur Sensible à la chaleur Plus tolérant à la chaleur
chaleur
Durabilité du revête-
Résistant à l'abrasion Résistant à l'abrasion Facilement endommagé
ment extérieur
Tolérance à la fluctu-
Très tolérant Tolérant Moins tolérant
ation haute pression
INFORMATIONS POUR LA SÉCURITÉ
Pour éviter les accidents corporels pendant le fonctionnement du
système, lire et respecter toutes les MISES EN GARDE,
AVERTISSEMENTS et INSTRUCTIONS accompagnant ou apposés sur
chaque produit. ENERPAC DÉCLINE TOUTE RESPONSABILITÉ EN CAS
DE DOMMAGES MATÉRIELS OU PERSONNELS RÉSULTANT D'UN
USAGE DANGEREUX DU PRODUIT, D'UN MANQUE D'ENTRETIEN OU
DE L'USAGE INCORRECT DU PRODUIT OU DU SYSTÈME. En cas de
doute en ce qui concerne les applications ou les mesures de sécurité,
contacter Enerpac.
AVERTISSEMENT
S'assurer que TOUS les composants du système, y compris les raccords,
tuyaux et tubulures sont classifiés pour la pression de service maximum du
système. La pression de service du système ne doit pas excéder la pression
nominale du composant dont la capacité est la plus faible, pour éviter une
défaillance du système pouvant causer des blessures graves et des dommages
matériels.
AVERTISSEMENT
Toujours porter un équipement de protection personnelle adéquat pendant
l'utilisation du matériel hydraulique.
AVERTISSEMENT
S'assurer que tous les composants sont protégés des
sources de dommages externes tels que chaleur excessive,
flammes, éclaboussures de soudure, pièces mobiles, bords
coupants, produits chimiques corrosifs. Ne pas exposer les
flexibles à des températures de 65 °C [150°F] ou plus.
AVERTISSEMENT
NE JAMAIS brancher ou débrancher des éléments
hydrauliques lorsque le système est sous pression.
AVERTISSEMENT
Porter un équipement de protection personnelle adéquat
pendant l'utilisation du matériel hydraulique.
AVERTISSEMENT
Ne pas manipuler les flexibles sous pression. Remplacer
immédiatement tout flexible endommagé. Le fluide hydraulique
s'échappant sous pression par un trou de petite taille peut
pénétrer la peau et causer des blessures graves. Si de l'huile est
injectée sous la peau, consulter immédiatement un médecin.
ATTENTION
Ne pas utiliser les flexibles hydrauliques pour transporter
des composants tels que les pompes ou les vérins.
ATTENTION
Utiliser exclusivement le fluide recommandé par le fabricant. Ne pas mélanger
les fluides dans un système. L'usage de fluides incompatibles avec les composants
causerait des dommages aux joints et flexibles. Les fluides synthétiques et
ignifuges exigent l'usage de joints et flexibles spéciaux. Contacter le centre de
réparations agréé le plus proche ou le fabricant pour les recommandations.
(10)
INSTALLATION
Flexibles hydrauliques
1. Inspecter le système avant de l'utiliser.
2. S'assurer de l'absence de fissures, vrillages, coupures ou autres
dommages susceptibles de causer une fuite du flexible. Les
sertissages de chacune des extrémités du flexible sont munis de
protections en caoutchouc.
3. S'assurer que toutes les extrémités de flexibles, R=4½ in.
raccords ou raccords union sont propres et que les R=11,4 cm
filets sont en bon état.
4. Le flexible ne doit être ni vrillé, ni coudé trop
abruptement. Le rayon de courbure doit toujours
être de 11,4 cm (4.5 inches) minimum. Toujours
utiliser le moins de coudes possible.
5. Ne pas laisser tomber d'objets lourds sur le flexible.
Un choc violent peut endommager la trame interne
du flexible. La mise sous pression d'un flexible
endommagé peut causer sa rupture.
6. S'assurer que tous les branchements de flexibles entre la pompe et le
vérin sont serrés et ne fuient pas. Ne pas serrer excessivement les
branchements ni utiliser des outils pour le serrage. Un serrage
excessif peut fausser le filetage et causer la rupture des raccords à
haute pression à des pression inférieures à la capacité nominale. Si
des raccords rapides sont utilisés, s'assurer qu'ils sont branchés
correctement et engagés à fond.
Raccords et tubulures
Les directives suivantes doivent être utilisées lorsque des raccords sont
utilisés sur un système hydraulique.
1. Veiller à ne pas fausser le filetage des raccords.
2. Utiliser un produit d'étanchéité pour filetage de haute qualité pour
assurer l'étanchéité des branchements.
3. Le ruban ou le composé d'étanchéité ne doit être utilisé que sur le
filetage. Laisser le premier filet exposé pour éviter que des fragments
de ruban pénètrent dans le circuit.
ATTENTION
Veiller à ce qu'aucun fragment de ruban d'étanchéité ne pénètre dans le
circuit hydraulique. La présence de tels fragments gênerait l'écoulement du fluide,
causant le mauvais fonctionnement du système.
4. Les vibrations et les charges par à-coups sont la principale cause des
fuites de raccords ou de la tubulure. Utiliser des supports de tubes du
commerce pour prolonger la vie utile du système. Le point le plus
critique pour de tels supports se trouve à 10 à 18 cm des raccords.
5. La tubulure n'est pas rigide. Les sections longues doivent être
soutenues. L'absence de supports peut causer la défaillance
prématurée des raccords. Toujours monter les valves et manomètres
sur des pièces rigides. Ne jamais les laisser être uniquement soutenus
par la tubulure !
(11)
ENTRETIEN
Cette section concerne les composants courants des systèmes hydrauliques.
Généralités
1. Les composants doivent toujours être propres. Beaucoup de
problèmes hydrauliques sont causés par la présence de saleté et/ou
de particules métalliques dans le circuit. Pour éviter ces problèmes,
adopter une routine de prévention de la rouille et de propreté qui
contribuera à prolonger la vie utile du système hydraulique.
2. Utiliser exclusivement un fluide hydraulique approuvé et le changer
selon les recommandations du fabricant. Les fluides doivent être
changés plus fréquemment si la machine est utilisée dans des
conditions éprouvantes.
3. Si le circuit est équipé d'un filtre, le changer ou le nettoyer
périodiquement.
Flexibles hydrauliques
1. Les flexibles hydrauliques doivent être laissés dans le carton jusqu'à
ce qu'ils soient utilisés.
2. Entreposer les flexibles à une température de 10 à 24 °C (50 à 75°F)
et une humidité relative de 20 à 70 pour cent.
3. Ne jamais entreposer les flexibles dans un local chaud et humide, à la
lumière directe du soleil ni près de sources de chaleur.
4. Ne pas empiler les flexibles. Le poids de la pile aurait tendance à
écraser le flexible du dessous. Il est préférable de les ranger sur un
rack.
5. Ne pas transporter ni traîner les ensembles hydrauliques en les
soulevant, les tirant ou les poussant par les flexibles.
Raccords
1. Tous les filets de raccords, mâles ou femelles doivent être maintenus
propres et lubrifiés régulièrement. Couvrir les raccords avec des
capuchons à poussière lorsqu'ils ne sont pas branchés sur le
système. Ne pas retirer les capuchons ou bouchons d'un composant
avant qu'il ne soit prêt à être utilisé.
2. Laisser les capuchons à poussière sur les raccords lorsqu'ils ne sont
pas utilisés. S'assurer que tous les raccords inutilisés sont protégés
par des capuchons à poussière/protecteurs de filet.
3. Veiller à ce que les branchements de flexibles soient exempts de
saletés et de cambouis.
(12)
Hoja de instrucciones
®
Manguera hidráulica / adaptadores

L2255 Rev. O 06/04
INSTRUCCIONES IMPORTANTES PARA LA RECEPCION
Inspeccione visualmente todos los componentes para ver si han sufrido
daños durante el transporte. Si existe algún deterioro comuníqueselo
inmediatamente al transportista. Los daños ocurridos durante el
transporte NO están cubiertos por la garantía. El transportista debe
responder de los costos de reparación o reemplazo de las piezas debido
a daños ocurridos durante el transporte.
DESCRIPCION
Enerpac suministra tres tipos diferentes de mangueras hidráulicas: de
plástico térmico, de caucho para servicio severo y de nilón. La manguera
de plástico térmico tiene cuatro capas, dos de las cuales tienen trenzado
de acero de alta resistencia. La manguera de caucho está reforzada con
dos capas de trenzado de acero. La manguera de nilón tiene un
revestimiento exterior de plástico.
ADVERTENCIA
No utilice las mangueras Enerpac en sistemas cuya presión exceda los 700
bar [10,000 psi].
COMPARACION ENTRE MANGUERAS

Manguera Serie 700 de plástico térmico Serie 800 de nilón Serie 900 de caucho
Factor de diseño 4a1 2a1 2a1
El aumento de longitud puede ser Puede expandirse ante presión

Expansión Baja
excesivo para sistemas pequeños
Menos flexible, pero más toler- Más flexible a bajas temperat-

Flexibilidad Menos flexible uras, pero las dobladuras
ante a las dobladuras extremas pueden dañarla
Inerte a la mayoría de los flui- Inerte a la mayoría de los flui- Menos tolerante a diferentes
Tolerancia a fluidos
dos dos tipos de fluido
Tolerancia al calor Sensible al calor Sensible al calor Más tolerante al calor
Durabilidad de reves-
Resistente a abrasiones Resistente a abrasiones Fácil de dañar
timiento exterior
Tolerancia a ciclos
Muy tolerante Tolerante Menos tolerante
de alta presión
INFORMACION SOBRE SEGURIDAD
Para evitar lesiones personales mientras el sistema está funcionando, lea
y observe toda la información encontrada en los AVISOS,
ADVERTENCIAS e INSTRUCCIONES que acompañan el producto.
ENERPAC NO SE HACE RESPONSABLE DE LOS DAÑOS O LESIONES
CAUSADOS POR EL USO INSEGURO DEL PRODUCTO, LA FALTA DE
MANTENIMIENTO, O LA APLICACION INCORRECTA DEL PRODUCTO Y
SISTEMA. Ante cualquier duda sobre las aplicaciones y medidas de
seguridad, póngase en contacto con Enerpac.
ADVERTENCIA
Asegúrese que TODOS los componentes del sistema, incluso los
acopladores, adaptadores y tubos tengan la capacidad necesaria para trabajar
con la presión máxima de trabajo del sistema. La presión de funcionamiento del
sistema no debe sobrepasar el régimen de presión del componente de presión
más baja en el sistema. De lo contrario, se puede causar la falla del sistema, lo
cual puede resultar en lesiones personales graves y daños al equipo.
ADVERTENCIA
Siempre use el equipo protector personal apropiado cuando maneje el
equipo hidráulico.
ADVERTENCIA
Asegúrese que todos los componentes del sistema estén
protegidos de fuentes dañinas externas, tales como calor
excesivo, llamas, salpicaduras de soldadura, piezas mecánicas
móviles, bordes afilados y productos químicos corrosivos. NO
exponga las mangueras a temperaturas mayores o iguales que
65°C [150°F].
ADVERTENCIA
NUNCA conecte ni desconecte componentes hidráulicos
mientras el sistema se encuentre presurizado.
ADVERTENCIA
Siempre use el equipo protector personal apropiado cuan-
do maneje el equipo hidráulico.
ADVERTENCIA
No manipule las mangueras presurizadas. Reemplace las
mangueras dañadas de inmediato. El fluido hidráulico que se
escapa a presión a través de un agujero pequeño tiene fuerza
suficiente para penetrar la piel, causando lesiones graves. Si se
inyecta fluido en la piel, consulte a un médico de inmediato.
ATENCION
No utilice la manguera hidráulica para levantar
componentes hidráulicos, tales como las bombas y cilindros.
ATENCION
Utilice únicamente los fluidos recomendados por el fabricante. No mezcle
fluidos diferentes en un mismo sistema. Utilice únicamente fluidos compatibles
con los componentes del sistema, de lo contrario se dañarán los sellos y
mangueras. Los fluidos sintéticos y a prueba de incendios requieren el uso de
sellos y mangueras especiales. Comuníquese con el centro de servicio autorizado
más cercano o con el fabricante para las recomendaciones del caso.
(14)
INSTALACION
Mangueras hidráulicas
1. Antes de usar el sistema, inspeccione visualmente todos sus
componentes.
2. Asegúrese que la manguera no tenga roturas, dobladuras, cortes ni
otros daños que pudieran causar fugas. Unos protectores de caucho
protegen las zonas engarzadas de cada extremo de la manguera.
3. Asegúrese que los extremos de la manguera, R=4½ in.
acopladores y juntas estén limpios y que sus roscas R=11,4 cm
estén en buenas condiciones.
4. La manguera no debe estar torcida ni doblada hasta
quebrarla. El radio de curvatura debe medir un
mínimo de 11,4 cm (4.5 inches). Utilice la cantidad
mínima de dobladuras posible.
5. No deje caer objetos pesados sobre la manguera.
Un fuerte impacto puede causar daños internos a
los alambres de la manguera. Si se aplica presión a
una manguera dañada se podría causar su rotura.
6. Asegúrese que todas las conexiones entre la bomba y el cilindro
estén bien apretadas y libres de fugas. No apriete las conexiones en
exceso ni utilice herramientas para apretarlas. El apriete excesivo de
las conexiones causa la falla prematura de las roscas y puede hacer
que los adaptadores de alta presión se rompan a una presión menor
que su capacidad nominal. Si se usan adaptadores de desconexión
rápida, asegúrese que éstos se encuentren instalados de modo
correcto y completo.
Adaptadores y tubería
Observe las recomendaciones siguientes cuando se utilicen adaptadores
en un sistema hidráulico.
1. Tenga cuidado de evitar trasroscar los adaptadores roscados.
2. Asegúrese de sellar las conexiones con un elemento sellador de
tubos de buena calidad.
3. La cinta adhesiva o pasta selladora debe aplicarse únicamente a las
roscas. No aplique cinta adhesiva a la primera rosca para evitar que
partículas de la misma ingresen al sistema.
ATENCION
Evite que partículas de cinta adhesiva ingresen al sistema hidráulico. Los
pedazos de cinta adhesiva perjudican el caudal del fluido y causan averías en el
sistema.
4. Las cargas por vibración y cargas de choque del sistema son las
causas principales de la falla de adaptadores/tuberías. Utilice
soportes de tubería disponibles en el mercado para prolongar la vida
útil del sistema. La zona más crítica en la cual se debe colocar un
soporte de tubería es a unos 10-18 cm de cada adaptador.
5. Los tubos no son rígidos. Los tramos largos necesitan soporte. Las
secciones sin soportes instalados pueden causar la falla prematura
de los adaptadores. Las válvulas y manómetros siempre deben
instalarse con un montaje firme. Nunca permita que el tubo sea el
único medio de soporte.
(15)
MANTENIMIENTO
Esta sección describe componentes hallados comúnmente en un sistema hidráulico.
Generalidades
1. Mantenga los componentes limpios en todo momento. Muchos de los
problemas en los sistemas hidráulicos son causados por la presencia
de tierra y/o partículas en el sistema hidráulico. Para evitar estos
problemas, utilice procedimientos de mantenimiento apropiados,
incluyendo mantenimiento preventivo y procedimientos de prevención
de herrumbre y de limpieza, para prolongar la vida útil del sistema
hidráulico.
2. Utilice únicamente fluido hidráulico limpio de tipo aprobado y cambie
el fluido con la frecuencia recomendada por el fabricante. Cambie los
fluidos con mayor frecuencia si se trabaja en condiciones extremas.
3. Si el sistema utiliza un filtro, cámbielo o límpielo periódicamente.
Mangueras hidráulicas
1. Deje las mangueras hidráulicas en su caja hasta el momento de
usarlas.
2. Guarde las mangueras a una temperatura de 10° a 24°C [50° a 75°F],
con una humedad relativa de 20 a 70%.
3. Nunca guarde las mangueras en un lugar caliente y húmedo, ni las
exponga a la luz solar directa o a fuentes de calor.
4. No apile las mangueras. El peso de la pila tiende a aplastar la
manguera en el fondo de la misma. Es preferible colgarlas en un
estante.
5. No transporte ni arrastre los conjuntos hidráulicos tirando ni
empujando los acoplamientos y las mangueras.
Adaptadores y acopladores
1. Todas las roscas de los acopladores, sean macho o hembra, deben
mantenerse limpias y lubricarse periódicamente. Cubra los
acopladores con tapas guardapolvo cuando no estén conectados al
sistema. No quite las tapas o tapones hasta que el componente esté
listo para usarse.
2. Mantenga las tapas guardapolvo colocadas en los acopladores
cuando no estén en uso. Asegúrese que todos los acopladores no
utilizados estén sellados con tapas guardapolvo/protectores de rosca.
3. Asegúrese que todas las conexiones de manguera estén libres de
partículas extrañas y suciedad.
(16)
Manuale di istruzioni
®
Raccordi e tubi oleodinamici

L2255 Rev. O 06/04
IMPORTANTI ISTRUZIONI AL RICEVIMENTO
Ispezionare visivamente tutti i componenti per accertare eventuali danni
derivanti dal trasporto. Se del caso, sporgere subito reclamo all’impresa
di trasporti. I danni di trasporto NON sono coperti dalla garanzia.
L’impresa di trasporti è responsabile degli stessi e deve rispondere di
tutti i relativi costi di riparazione e sostituzione dei componenti.
DESCRIZIONE
La Enerpac offre tre tipi di tubi flessibili per applicazioni oleodinamiche:
termoplastici, di gomma per servizio gravoso e di nylon. I tubi
termoplastici sono costituiti da quattro strati, comprese due guaine di
fibre di acciaio intrecciate ad alta resistenza. I tubi di gomma sono
rinforzati con due strati di fibre di acciaio intrecciate. I tubi di nylon hanno
un rivestimento esterno di plastica.
AVVISO
Non usare tubi flessibili Enerpac in impianti a pressione superiore a 700 bar
[10,000 psi].
CONFRONTO TRA I TUBI FLESSIBILI

Termoplastici
Tubo flessibile Di nylon serie 800 Di gomma serie 900
serie 700
Fattore di esecuzione 4 a 1 2a1 2a1
In impianti piccoli l’aumento di Possono dilatarsi se soggetti

Dilatazione Bassa
lunghezza può essere rilevante a pressione
Di grado inferiore, ma resistono Di grado superiore a basse tem-

Flessibilità Di grado inferiore perature, ma curvature di raggio
meglio a curvature di raggio ridotto ridotto possono danneggiarli
Compatibilità con Inerti nei confronti della Inerti nei confronti della mag- Inferiore, a seconda del tipo
i fluidi maggior parte dei fluidi gior parte dei fluidi di fluido
Resistenza termica Sensibili al calore Sensibili al calore Superiore
Resistenza del rives-

Antiabrasione Antiabrasione Si danneggiano facilmente
timento esterno
Resistenza a sol-
lecitazioni cicliche Superiore Normale Inferiore
di alta pressione
INFORMAZIONI SULLA SICUREZZA
Per evitare infortuni o danni alle cose durante il funzionamento del
sistema, leggere tutte le ISTRUZIONI ed i segnali di AVVISO e di
ATTENZIONE. Attenersi rigorosamente agli stessi. LA ENERPAC NON È
RESPONSABILE DI DANNI O DI LESIONI RISULTANTI DA USO
IMPROPRIO DEL PRODOTTO, MANCANZA DI MANUTENZIONE OD
UTILIZZO NON CORRETTO DEL PRODOTTO E/O DEL SISTEMA AD
ESSO COLLEGATO. In caso di dubbio sulle applicazioni del prodotto e
sulle precauzioni di sicurezza, rivolgersi alla ENERPAC.
AVVISO
Accertarsi che la pressione nominale di TUTTI i componenti del sistema,
compresi i raccordi e le tubazioni rigide e flessibili, sia adeguata alla massima
pressione di esercizio del sistema stesso. La pressione di esercizio del sistema
non deve superare la pressione nominale dei componenti del sistema stesso
aventi la minima pressione nominale; in caso contrario, il sistema si può guastare
e ne possono derivare infortuni gravi o danni all’attrezzatura.
AVVISO
Per evitare infortuni, quando si lavora con apparecchiature oleodinamiche
indossare sempre indumenti protettivi adeguati.
AVVISO
Accertarsi che tutti i componenti del sistema siano protetti
da fonti esterne di danno, quali temperature eccessive, fiamme,
spruzzi di saldatura, componenti di macchine in movimento, orli
affilati e sostanze chimiche corrosive. Non esporre i tubi flessibili
a temperature uguali o maggiori di 65 °C [150°F].
AVVISO
NON collegare né scollegare MAI componenti oleodinamici
mentre il sistema è sotto pressione.
AVVISO
Quando si lavora con apparecchiature oleodinamiche,
indossare indumenti protettivi adeguati.
AVVISO
Non maneggiare tubi flessibili sotto pressione. Sostituire
immediatamente i tubi flessibili danneggiati. Il fluido
oleodinamico emesso attraverso piccoli fori può penetrare
sotto la pelle e causare lesioni gravi. In tale circostanza,
richiedere immediatamente assistenza medica.
ATTENZIONE
Non usare un tubo flessibile oleodinamico per trasportare
componenti quali pompe o cilindri.
ATTENZIONE
Usare solo i fluidi raccomandati dalla casa costruttrice. Non miscelare fluidi
in un sistema. Usare solo fluidi compatibili con i componenti del sistema,
altrimenti si danneggiano le guarnizioni e i tubi flessibili. I fluidi sintetici e ignifughi
richiedono guarnizioni e tubi flessibili speciali. A tale riguardo, consultare il centro
di assistenza autorizzato più vicino o la casa costruttrice.
(18)
INSTALLAZIONE
Tubi flessibili oleodinamici
1. Prima dell’utilizzo, controllare a vista il sistema.
2. Verificare l’assenza di incrinature, attorcimenti, tagli o altri danni che
potrebbero causare perdite dai tubi flessibili. Servirsi di manicotti di
gomma per proteggere tutte le estremità calettate o immorsate dei
tubi flessibili.
3. Verificare che tutte le estremità, i raccordi o le R=4½ in.
estremità giuntate dei tubi flessibili siano puliti e che R=11,4 cm
i filetti siano in buone condizioni.
4. Non attorcere né piegare secondo curvature
eccessive i tubi flessibili. Il raggio di curvatura non
deve mai essere minore di 11,4 cm (4.5inches). Fare
sempre in modo che i tubi flessibili il minor numero
possibile di curvature.
5. Non fare cadere oggetti pesanti su un tubo flessibile.
Un urto può causare danni interni agli strati di fibre
intrecciate. Applicando pressione ad un tubo flessibile danneggiato se
ne può causare la rottura.
6. Verificare che tutti i collegamenti dei tubi flessibili con pompe e cilindri
siano saldi e a tenuta. Non serrare troppo i raccordi né servirsi di
attrezzi per serrarli. Coppie di serraggio eccessive possono causare
danni prematuri ai filetti e far sì che i raccordi soggetti ad alta
pressione si spezzino a una pressione inferiore a quella nominale.
Quando si usano raccordi a disinnesto rapido, verificare che siano
collegati in modo corretto e completamente fissati l’uno con l’altro.
Raccordi e tubi
Ogniqualvolta si usano raccordi in impianti oleodinamici, adottare le
seguenti linee guida.
1. Fare attenzione a che i filetti dei raccordi filettati non si impegnino in
modo errato.
2. Verificare che i raccordi siano a tenuta servendosi di un apposito
sigillante per filetti di alta qualità.
3. Avvolgere il nastro o applicare il composto sigillante solo in
corrispondenza della filettatura. Non avvolgere il nastro sul primo
filetto, per evitare che pezzi di nastro possano penetrare nell’impianto.
ATTENZIONE
Fare attenzione a prevenire che pezzi di nastro penetrino nell’impianto
oleodinamico. Pezzi di nastro nel fluido possono ostacolarne il flusso e causare
malfunzionamenti dell’impianto.
4. Le principali cause di perdita da raccordi e tubi sono le vibrazioni e i

carichi impulsivi dell’impianto. Per prolungare la durata dell’impianto,
utilizzare per i tubi supporti reperibili in commercio. Il punto più critico di
un tubo, che occorre sostenere, si trova a 10-18 cm dietro un raccordo.
5. Poiché i tubi non sono rigidi, quando si sviluppano per lunghi tratti
occorre sostenerli. Le sezioni non sostenute possono causare guasti
prematuri dei raccordi. Eseguire sempre un fissaggio adeguato dei
manometri e delle valvole che si installano; non servirsi mai dei soli
tubi per sostenerli.
(19)
MANUTENZIONE
Questa sezione pertiene ai componenti comunemente usati in impianti oleodinamici.
Operazioni generali
1. Mantenere sempre puliti i componenti. Gran parte dei problemi degli
impianti oleodinamici dipendono da sporco e/o particelle metalliche
nell’impianto oleodinamico. Per evitare questi problemi e prolungare
la durata dell’impianto, adottare procedure di manutenzione
adeguate, comprendenti pulizia e prevenzione della ruggine.
2. Usare solo fluidi oleodinamici di tipo approvato e cambiare il fluido
seguendo le istruzioni della casa costruttrice. Se l’impianto funziona
in condizioni estreme, cambiare i fluidi più spesso.
3. Se nell’impianto si usano filtri, pulirli o sostituirli periodicamente.
Tubi flessibili oleodinamici

1. I tubi flessibili oleodinamici vanno lasciati nella confezione fino al
momento di usarli.
2. Conservare i tubi flessibili a temperature comprese tra 10 e 24°C [50-
75°F].
3. Non conservare mai tubi flessibili in un locale caldo e umido, alla luce
solare diretta o vicino a fonti di calore.
4. Non impilare tubi flessibili. Il peso della pila farebbe appiattire il tubo
flessibile sul fondo. È preferibile appenderli.
5. Non trasportare né trascinare gruppi oleodinamici tirando o
spingendo raccordi o tubi flessibili.
Raccordi
1. I filetti di tutti i raccordi, sia maschio sia femmina, vanno mantenuti
puliti e lubrificati regolarmente. Quando i tubi non sono collegati
all’impianto, chiuderli con tappi parapolvere. Non rimuovere né tappi
né coperture da un componente fino al momento di usarlo.
2. Tenere i tappi parapolvere sui raccordi quando non li si usano.
Verificare che tutti i raccordi non usati siano a chiusura ermetica
mediante materiale di protezione dei filetti e tappi parapolvere.
3. Verificare che sui raccordi dei tubi flessibili non ci siano né impurità né
sporco.
(20)
Handleiding
®
Hydraulische slang/fittingen
L2255 Rev. O 06/04
BELANGRIJKE INSTRUCTIES BIJ ONTVANGST
Controleer alle onderdelen op transportschade. Als er sprake is van
transportschade, waarschuw dan onmiddellijk de vervoerder.
Transportschade valt NIET onder de garantie. De vervoerder is
aansprakelijk voor alle kosten van reparatie of vervanging als gevolg van
beschadiging tijdens vervoer.
BESCHRIJVING
Enerpac levert drie verschillende soorten hydraulische slangen:
thermoplastisch, zware kwaliteit rubber of nylon. De thermoplastische
slang bestaat uit vier lagen, inclusief twee lagen zeer sterke gevlochten
staaldraad. De rubberen slang is versterkt met twee lagen gevlochten
staal. De nylon slang heeft een kunststof buitenlaag.
WAARSCHUWING
Gebruik geen Enerpac slangen in systemen met een werkdruk hoger dan
700 bar [10,000 psi].
VERGELIJKING VAN DE SLANGEN

Thermoplastisch
Slang Nylon 800 serie Rubber 900 serie
700 serie
Ontwerpfactor 4 tot 1 2 tot 1 2 tot 1
Toename in lengte kan significant zijn Kan onder druk uitzetten

Uitzetting Gering
voor kleine systemen
Minder buigzaam, maar meer tole- Meest buigzaam bij lage tem-
Buigzaamheid Minder buigzaam peraturen, maar scherpe bocht-
rant voor scherpe bochten en kunnen schade veroorzaken
Tolerantie voor Inert met meeste Minder tolerant voor verschil-

Inert met meeste vloeistoffen
vloeistoffen vloeistoffen lende soorten vloeistof
Tolerantie voor hitte Gevoelig voor hitte Gevoelig voor hitte Meer tolerant voor hitte
Duurzaamheid van
Schuurbestendig Schuurbestendig Makkelijk beschadigd
buitenste laag
Tolerantie voor Minder tolerant

Zeer tolerant Tolerant
hogedrukcycli
VEILIGHEIDSINFORMATIE
Lees alle OPMERKINGEN, WAARSCHUWINGEN en INSTRUCTIES
aangebracht op, of verpakt bij elk product. Volg alle
veiligheidsvoorschriften op ter vermijding van persoonlijk letsel.
ENERPAC IS NIET AANSPRAKELIJK VOOR SCHADE VOORTVLOEIEND
UIT ONVEILIG GEBRUIK VAN HET PRODUCT, GEBREK AAN
ONDERHOUD OF ONJUISTE PRODUCT- EN/OF
SYSTEEMTOEPASSING. Neem contact op met Enerpac wanneer er
twijfel bestaat over toepassingen of de voorzorgsmaatregelen t.a.v. de
veiligheid.
WAARSCHUWING
Controleer of ALLE systeemonderdelen, inclusief koppelingen, fittingen, pijpen
en slangen berekend zijn op de maximale nominale bedrijfsdruk van het systeem. De
bedrijfsdruk van het systeem mag de maximale nominale druk van het onderdeel in
het systeem met de laagste capaciteit niet te boven gaan, anders kan het systeem
defect raken, wat kan leiden tot ernstig lichamelijk letsel of materiële schade.
WAARSCHUWING
Draag altijd de juiste persoonlijke beschermingsmiddelen tijdens het gebruik
van hydraulische apparatuur.
WAARSCHUWING
Zorg ervoor dat alle onderdelen van het systeem beschermd
worden tegen schade van buitenaf, zoals overmatige hitte,
vlammen, lasspetten, bewegende machinedelen, scherpe randen
en corrosieve chemicaliën. Stel slangen niet bloot aan
temperaturen van 65°C [150°F] of hoger.
WAARSCHUWING
NOOIT hydraulische verbindingen maken of verbreken terwijl
het systeem onder druk staat.
WAARSCHUWING
Draag altijd de juiste persoonlijke beschermingsmiddelen
tijdens het gebruik van hydraulische apparatuur.
WAARSCHUWING
Hanteer geen slangen die onder druk staan. Vervang
beschadigde slangen onmiddellijk. Hydraulische vloeistof die
door een kleine opening ontsnapt, kan de huid doordringen en
leiden tot ernstig letsel. Raadpleeg onmiddellijk een arts als olie
onder de huid doordringt.
OPGELET
Draag hydraulische onderdelen zoals pompen of cilinders
niet aan de hydraulische slangen.
OPGELET
Gebruik uitsluitend de vloeistof die door de fabrikant wordt aanbevolen. Meng
geen vloeistoffen in een systeem. Gebruik uitsluitend vloeistoffen die compatibel zijn
met de systeemonderdelen, anders kunnen afdichtingen en slangen schade oplopen.
Synthetische en brandbestendige vloeistoffen vereisen speciale afdichtingen en
slangen. Neem contact op met het dichtstbijzijnde servicecentrum of de fabrikant
voor een aanbeveling.
(22)
INSTALLATIE
Hydraulische slangen
1. Inspecteer het systeem op het oog alvorens het te gebruiken.
2. Verzeker u ervan dat er geen scheuren, knikken, sneden of andere
beschadigingen van de slang aanwezig zijn die kunnen leiden tot
lekkage. Rubberen beschermstukken beschermen de oppersingen
aan de uiteinden van de slang.
3. Controleer of alle uiteinden van de slangen, alle R=4½ in.
koppelingen of uiteinden van de verbindingen schoon R=11,4 cm
zijn en of de schroefdraden in goede staat verkeren.
4. De slang mag niet gedraaid of te scherp gebogen
worden. De straal van de bocht dient altijd ten minste
11,4 cm [4.5 inches]
te bedragen. Gebruik altijd zo min mogelijk bochten.
5. Laat geen zware voorwerpen op de slang vallen. Een
zware schok kan inwendige beschadiging aan de
bewapening van
de slang tot gevolg hebben. Een beschadigde slang kan
onder druk scheuren.
6. Controleer of alle verbindingen tussen de slang en pomp en cilinder
goed vastzitten en niet lekken. Draai de verbindingen niet te vast aan
en gebruik geen gereedschap om de verbindingen vast te draaien.
Een te hoog aanzetmoment kan leiden tot voortijdig defect raken van
de schroefdraden en kan tot gevolg hebben dat hogedrukfittingen
splijten bij een druk die lager ligt dan de nominale capaciteit.
Controleer, wanneer snelontkoppelingsfittingen worden gebruikt, of
de fittingen volledig en op juiste wijze aan elkaar bevestigd zijn.
Fittingen en slangen
De volgende richtlijnen moeten in acht genomen worden wanneer
fittingen gebruikt worden in hydraulische systemen.
1. Zorg ervoor dat fittingen met schroefdraad niet verkeerd aan elkaar
worden geschroefd.
2. Zorg ervoor dat de verbindingen met behulp van hogekwaliteit
pijpschroefdraad-afdichtmiddel worden afgedicht.
3. Tape of afdichtmiddel mag uitsluitend op de gedeelten met
schroefdraad worden aangebracht. Op de eerste gang mag geen tape
worden aangebracht om te vermijden dat stukjes tape in het systeem
terechtkomen.
OPGELET
Wees voorzichtig dat er geen stukjes tape in het hydraulische systeem
terecht komen. Stukjes tape in de vloeistof belemmeren de vloeistofstroming, wat
kan leiden tot storingen in het systeem.
4. Trilling en schokbelasting van het systeem zijn de belangrijkste

oorzaak van lekkage van fittingen/slangen. Gebruik commercieel
verkrijgbare slangsteunen om de levensduur van uw systeem te
verlengen. Het meest kritieke gebied voor het gebruik van een
slangsteun is de 10-18 cm na een fitting.
5. Slangen zijn niet stijf. Lange stukken moeten ondersteund worden.
Gedeelten die niet ondersteund worden, kunnen leiden tot het
voortijdig defect raken van fittingen. Monteer kleppen en meters altijd
op een harde ondergrond. Slangen mogen nooit de enige steun zijn!
(23)
ONDERHOUD
In dit hoofdstuk worden onderdelen besproken die vaak in een hydraulisch systeem
worden aangetroffen.
Algemeen
1. Houd de onderdelen te allen tijde schoon. Veel hydraulische
onderhoudsproblemen worden veroorzaakt door vuil en/of
metaaldeeltjes in het hydraulische systeem. Het toepassen van de
juiste onderhoudspraktijken, met inbegrip van roestwering en
schoonhouden, helpt bij het verlengen van de levensduur van uw
hydraulische systeem.
2. Gebruik uitsluitend een goedgekeurde, schone hydraulische vloeistof
zoals aanbevolen door de fabrikant. Ververs de vloeistoffen vaker als
het apparaat onder extreme omstandigheden wordt gebruikt.
3. Verwissel of reinig het filter in het systeem, indien aanwezig, van tijd
tot tijd.
Hydraulische slangen
1. Laat hydraulische slangen in de doos totdat ze nodig zijn.
2. Bewaar slangen bij temperaturen tussen 10° en 24°C [50° en 75°F] en
bij een vochtigheidsgraad tussen 20 en 70 procent.
3. Bewaar slangen nooit in een hete, vochtige ruimte, in direct zonlicht of
in de buurt van hittebronnen.
4. Stapel slangen niet op. Het gewicht van de stapel kan de onderste
slangen in de stapel pletten. Ophangen in een rek verdient de
voorkeur.
5. Til of sleep hydraulische apparatuur niet door aan koppelingen of
slangen te trekken of ertegen te duwen.
Fittingen en koppelingen
1. Alle binnen-en buitendraden van koppelingen moeten
schoongeouden en regelmatig gesmeered worden. Dek de
koppelingen af met stofdoppen wanneer zij niet aangesloten zijn op
een systeem. Verwijder afdekkingen of pluggen pas als het onderdeel
gereed is om gebruikt te worden.
2. Houd de stofdoppen op de koppelingen wanneer ze niet in gebruik
zijn. Controleer of alle ongebruikte koppelingen afgedicht zijn met
stofdoppen/schroefdraadbeschermers.
3. Zorg ervoor dat alle slangverbindingen vrij van gruis en vuil zijn.
(24)
(25)
(26)
(27)
Africa Actuant China Ltd. (Beijing) Italy Spain, Portugal
ENERPAC Middle East FZE 709A Xin No. 2 ENERPAC S.p.A. ENERPAC
P.O. Box 18004 Diyang Building Via Canova 4 C/San José Artesano 8
Jebel Ali, Dubai Dong San Huan North Rd. 20094 Corsico (Milano) Pol. Ind.
United Arab Emirates Beijing City, 100028 China Tel: +39 02 4861 111 28108 Alcobendas
Tel: +971 (0)4 8872686 Tel: +86 10 845 36166 Fax: +39 02 4860 1288 (Madrid) Spain
Fax: +971 (0)4 8872687 Fax: +86 10 845 36220 Japan Tel: +34 91 661 11 25
Australia Central and Eastern Europe Applied Power Japan Ltd. Fax: +34 91 661 47 89
ENERPAC, Applied Power Australia Ltd. ENERPAC B.V. 1-1-11, Shimomae Middle East, Turkey ,
Block V Unit 3, Regents Park Estate Storkstraat 25 Toda-shi Caspian Sea, Greece
391 Park Road, Regents Park NSW 2143 P.O. Box 269, 3900 AG Veenendaal Saitama Pref. ENERPAC Middle East FZE
(P.O. Box 261) Australia The Netherlands Japan 335-0016 P.O. Box 18004
Tel: +61 297 438 988 Tel: +31 318 535 936 Tel: +81 484 30 1055 Jebel Ali, Dubai
Fax: +61 297 438 648 Fax: +31 318 535 951 Fax: +81 484 30 1066 United Arab Emirates
Brazil France Tel: +971 (0)4 8872686
The Netherlands, Belgium, Luxembourg,
Power Packer do Brasil Ltda. ENERPAC Fax: +971 (0)4 8872687
Sweden, Denmark, Norway, Finland
Rua dos Inocentes, 587 Une division de ACTUANT s.a. ENERPAC B.V. United Kingdom, Ireland
04764-050 - Sao Paulo (SP) B.P. 200 Storkstraat 25 ENERPAC Ltd., P.O. Box 33
Tel: +55 11 5687 2211 Parc d’Activités P.O. Box 269, 3900 AG Veenendaal New Romney, TN28 8QF
Fax: +55 11 5686 5583 du Moulin de Massy The Netherlands United Kingdom
Toll Free in Brazil: F-91882 Massy CEDEX France Tel: +31 318 535 911 Tel: +44 01797 363 639
Tel: 0800 891 5770 Tel: +33 1 601 368 68 Fax: +31 318 525 613 Fax: +44 01527 585 500
vendasbrasil@enerpac.com Fax: +33 1 692 037 50 +31 318 535 848 USA, Latin America
Canada Germany, Austria, Switzerland, Russia Technical Inquiries Europe: and Caribbean
Actuant Canada Corporation and CIS (excl. Caspian Sea Countries) techsupport.europe@enerpac.com ENERPAC
6615 Ordan Drive, Unit 14-15 ENERPAC Applied Power GmbH Singapore P.O. Box 3241
Mississauga, Ontario L5T 1X2 P.O. Box 300113 Enerpac Asia Pte. Ltd. 6100 N. Baker Road
Tel: +1 905 564 5749 D-40401 Düsseldorf 25 Serangoon North Ave. 5 Milwaukee, WI 53209 USA
Fax: +1 905 564 0305 Germany #03-01 Keppel Digihub Tel: +1 262 781 6600
Toll Free: Tel: +49 211 471 490 Singapore 554914 Fax: +1 262 783 9562
Tel: +1 800 268 4987 Fax: +49 211 471 49 28 Thomson Road User inquiries:
Fax: +1 800 461 2456 India P.O. Box 114 +1 800 433 2766
Technical Inquiries: ENERPAC Hydraulics (India) Pvt. Ltd. Singapore 915704 Distributor inquiries/orders:
techservices@enerpac.com Plot No. A/571 Tel: +65 64 84 5108, +65 64 84 3737 +1 800 558 0530
China MIDC, TTC Industrial Area 1800 363 7722 Technical Inquiries:
Actuant China Ltd. Mahape-400 701 Fax: +65 64 84 5669 techservices@enerpac.com
1F, 269 Fute N. Road Navi Mumbai, India Technical Inquiries:
Waigaoqiao Free Trade Zone Tel: +91 22 2778 1472 chee@actuant.com.sg
Pudong New District Fax: +91 22 2778 1473 South Korea
Shanghai, 200 131 China Actuant Korea Ltd.
Tel: +86 21 5866 9099 3Ba 717, Shihwa Industrial Complex,
Fax: +86 21 5866 7156 Jungwang-Dong, Shihung-Shi, Kyunggi-Do
Republic of Korea 429-450
Tel: +82 31 434 4506
Fax: +82 31 434 4507 030504
For your nearest authorized Enerpac Service Center, visit us at www.enerpac.com
6.6 BELT CLEANERS

6.6.1 Pre-cleaners and main cleaners
 Pre-belt cleaners
− Starclean® / Article no. 90-834.285.n11

(Boom conveyor-Discharge pulley)
Starclean® / Article no. 90-624-08.285nl.11
(Tripper car-Discharge pulley)
STARCLEAN® - Conveyor belt cleaner Type 620, 622 and 624:

Operating Instructions
 Main belt cleaners - Tripper car (Discharge pulley)
− Starclean® / Article no. 90-832.56n.11

(Boom conveyor-Discharge pulley)
Starclean® / Article no. 90-832.56n.11-2100)
(Trpper car-Discharge pulley)
STARCLEAN® - Conveyor belt scraper Types 830, 832 and 834:

Installation and operating instructions

Blank page

F.E. Schulte Strathaus GmbH & Co. KG
Runtestraße 42
59457 Werl / Germany
Tel.: +49 (0) 2922 9775-0
Fax: +49 (0) 2922 9775-75
Copy of original Installation and

STARCLEAN®- Conveyor-belt Cleaner

Type 620, 622 and 624
with lever type tensioning device

for cleaning conveyor belts at the pulley
and below the belt
Installation and operating instructions of STARCLEAN®-Conveyor-belt Cleaner Type 620/622/624 Version: 09/2014 page 1 / 22
1 Important Safety Information and Safety Notes ........................................................................ 3
1.1 Manufacturer, Copyright .......................................................................................................................... 3
1.2 Scope of the Installation and Operating Instructions ............................................................................... 3
1.3 Key: (Meanings of symbols) .................................................................................................................... 3
1.4 General Safety Notes .............................................................................................................................. 4
1.5 Notes for Usage / Usage in potentially Explosive Areas ......................................................................... 5
1.6 Special Safety Notes ............................................................................................................................... 5
2 Description of the STARCLEAN® Conveyor-belt Cleaner ......................................................... 6

2.1 Purpose and Usage (Designated Use) .................................................................................................... 6
2.1.1 Information on selecting and positioning the scraper on the conveyor ................................................... 6
2.1.1.1 Conveyed material ................................................................................................................................... 6
2.1.1.2 Condition of the belt / Condition of belt joints .......................................................................................... 7
2.1.1.3 Belt tension .............................................................................................................................................. 7
2.1.2 Information on selecting and positioning the scraper on the conveyor ................................................... 8
2.2 Description of Components ..................................................................................................................... 8
2.2.1 Scraper-blades for use as Primary Scraper: ........................................................................................... 9
2.2.2 Scraper blades for use as Secondary Scraper: .................................................................................... 10
2.2.3 Blade-bases Type 0, 2 and 4................................................................................................................. 10
2.2.4 Lever-Type Tensioning Device .............................................................................................................. 11
2.3 Technical Data and Recommendations for Pre-tensioning ................................................................... 11
2.3.1 Pre-Tensioning ...................................................................................................................................... 11
2.3.1.1 Recommended adjusting value of the spring length LF ......................................................................... 12
3 Start-Up .......................................................................................................................................12
3.1 General .................................................................................................................................................. 12
3.2 Transport ............................................................................................................................................... 12
3.3 Installation / Start-Up ............................................................................................................................. 13
3.3.1 Assembly Steps Primary Scraper .......................................................................................................... 13
3.3.2 Assembly and Notes for Conveyor Belt Cleaners with Type 85 and 285 Scraper Blades .................... 14
3.3.3 Draw-in Points and Openings ................................................................................................................ 15
3.3.4 Start-Up ................................................................................................................................................. 15
3.3.5 Mounting Distance ................................................................................................................................. 15
3.3.5.1 Illustration of Distances Lsk1 and Lsk2 ................................................................................................. 15
(Blade-base Axis / Conveyor-belt Surface) for Primary Scrapers ........................................................................ 15
3.3.6 Examples for Positioning ....................................................................................................................... 18
3.3.6.1 Example for Positioning Art.-Nr.: 90-622.18n.?? (Figure 8) .................................................................. 18
3.3.6.2 Example for Positioning Art.-Nr.: 90-622.283n.?? (Figure 9) ................................................................ 18
3.3.6.3 Example for Positioning Art.-Nr.: 90-622.58n.?? (Figure 10 ................................................................. 19
4 Maintenance / Disposal..............................................................................................................19
4.1 General .................................................................................................................................................. 19
4.2 Maintenance Notes ................................................................................................................................ 19
4.3 Maintenance Checks / Maintenance Intervals / Special Maintenance .................................................. 20
4.4 Trouble shooting .................................................................................................................................... 20
4.5 Replacement of Scraper-blades ............................................................................................................ 21
4.6 Disposal ................................................................................................................................................. 21
5 Part Numbers / Ordering Replacement Parts ...........................................................................21

5.1 Sample Order of Conveyor-belt Cleaners ............................................................................................. 21
5.2 Sample Order for Replacement Parts ................................................................................................... 21
6 Declaration of Conformity .........................................................................................................22
1 Important Safety Information and Safety Notes
1.1 Manufacturer, Copyright

Manufacturer:
F.E. Schulte Strathaus GmbH & Co. KG Tel.: 0049 (0) 2922 9775 0
Runtestraße 42 E-Mail: info@schulte-strathaus.de
D-59457 Werl
Copyright:
Reprint, reproduction or disclosure of these installation and operating instructions, including their storage
and use on optical and electronic data carriers – except for reference copies for training and/or
operational purposes – are subject to manufacturer’s written consent.
1.2 Scope of the Installation and Operating Instructions
These installation and operating instructions (Art.-No.: 95-MA-620-09-2014) apply to all conveyor
belt cleaners of the Types 620, 622, 624, irrespective of the other accessory components
described in the following (Type or number of scrapers, blade-base Types and lengths or
mounting parts) are being used.
Please keep these installation and operating instructions together with the other system
documentation and make it available for installation and operating personnel!
1.3 Key: (Meanings of symbols)
Warns of a hazard point / Pay special attention or read.
Do not switch on / Make sure that the band system is not turned on during installation
Warning: potentially explosive atmosphere
1.4 General Safety Notes
 These Installing and Operating Instructions address to expert staff trained by the
manufacturer, since these persons are qualified – due to their education, experience and
briefing as well as their knowledge of all relevant standards, provisions, accident prevention
regulations and working conditions – to perform the required tasks and to identify and avoid
any potential dangers arising
 To secure the warranty, assembly and start-up should be carried out by manufacturer’s
expert staff.
 The instructions contained in this Operating Manual must be observed fully without any
proviso. In the event of contravention, the manufacturer shall not assume any liability
whatsoever for any damage caused to man or machine.
 Since conveyor-belt cleaners are generally installed in belt-conveyor installations, the

manufacturers of these cleaning systems and the operators installing them shall comply
with the provisions of the Machinery Directive valid currently.
 Conveyor-belt cleaners made by Schulte Strathaus Co. may only be used for their original
purpose, i.e. to clean conveyor belts at the planned points.
 As a rule, only the manufacturer’s spare parts may be used to ensure the warranted
functions.
 Any jobs shall be performed in compliance with the relevant regulations of local authorities
and legislation.
 These Safety Notes do not in any way claim to be exhaustive. For questions and problems
you are requested to contact the manufacturer.
®
 STARCLEAN Type 620 / 622 and 624 conveyor-belt cleaner corresponds to the latest
state of the art as of time of delivery.
 It may only be installed and operated in perfect working condition. The

system operator shall generally perform the installation conforming to the relevant rules for
the prevention of accidents to meet operating safety standards.
 Retrofits, modifications or conversions are generally prohibited, as they may affect work
safety.
1.5 Notes for Usage / Usage in potentially Explosive Areas
 The conditions under which the conveyor-belt cleaner is to work (e.g. underground,
potentially explosive areas, etc.) shall be clarified with the operator.
 In all sectors of industry without any special requirements, belt cleaner systems can be
used as demanded
Operating temperature range: - 45°C to + 70°C
Maximum belt speed must not be exceeded, and the operative range must always be
clarified with the manufacturer.
Usage in potentially explosive areas:
 Conveyor-belt cleaning systems of Group I Category M2 shall only be fitted with one-
piece strips or scraper blades made of plastics fit for underground hard coal mining.
Please request information from the manufacturer.

Relative belt speed must not exceed 6 m/s.
Surface temperature must not exceed 150° C.
Operating temperature of scrapers from – 45°C to + 40° C
Labeling = CE Ex I M2
Group I Category M2 conveyor-belt cleaning systems may only be used with belt conveyors
that can be switched off as soon as an explosive atmosphere forms.
 Group II Category 2D conveyor-belt cleaning systems may only be used with

dusts whose minimum ignition energy exceeds 3 mJ.
Relative belt speed must not exceed 6 m/s.
Surface temperature must not exceed 150° C.
Operating temperature of scrapers – 45°C to + 40°C
Labeling = CE Ex II 2D
 All conductive parts of the conveyor-belt cleaning systems shall be grounded with a
6
electrical resistance smaller than 10 .
1.6 Special Safety Notes
®
 Prior to executing any Type of work on STARCLEAN conveyor-belt cleaners, power
supply to the belt conveyor must be disconnected and secured against unauthorized
connection.
 Permission from the operator of the belt-conveyor must be requested before

commencement of any welding and cutting works!
®
 Upon installation of a STARCLEAN conveyor-belt cleaner, make sure the welding torch
and/or other welding equipment to be used conform to the relevant regulatory provisions
(explosion protection, FLP etc.).
 During welding and cutting jobs any components sensitive to heat such as the conveyor
belt, for instance, must be covered. If needed, a fire watch is required.
2 Description of the STARCLEAN® Conveyor-belt Cleaner
2.1 Purpose and Usage (Designated Use)
®
The STARCLEAN - conveyor-belt cleaner Type 620/622/624 is primarily used as a primary scraper
to clean conveyor-belt residues off the surface of the conveyor-belt directly at the discharge pulley.
The scraper blades are pressed onto the conveyor-belt surface in a pre-defined manner by a lever
type tensioning device in order to carefully scrape any residues and caked-on materials from the
conveyor-belt.
Depending on the width of the belt and the consistency of the material, various combinations of scraper
blades and blade-bases may be required to achieve an optimal cleaning result.
When used as a primary scraper, this Type of cleaner may be for reversible belt systems.
In certain cases, this cleaner may also be used together with secondary blades “below the
belt”. Please contact the manufacturer.
When used as a secondary scraper, reversible operation is not possible!
2.1.1 Information on selecting and positioning the scraper on the conveyor

When selecting the scraper blades and its installation point on the conveyor system, the following
points must be considered because they have significant effects on the scraper’s functionality, the
scraping results and the system’s functional safety.
o Conveyed material (coarse, fine, dry, wet, abrasive)

o Belt speed
o Belt tension
o Condition of belt, belt joints
o Pulley diameter
o Chute geometry (Width, incline of outlet slide)
2.1.1.1 Conveyed material

With coarse material, the secondary scraper’s segment foot must be placed far enough below the
discharge pulley that no wedge-shaped catchment area is formed in which pieces of the conveyed
material stick and damage the belt.
Wedge-shaped catchment
Narrow
With fine material and/or small chutes, a short blade (K) must be used. It can be installed behind the 6
o’clock position in the track direction. In so doing, make sure that, when tensed, the blade moves 1 to
2 cm in the direction of the blade-base.
Scraped off, strongly adhering material should fall as freely as possible.
In any case, the material must be finer than the gap between the segment foot and the belt.
Primary scrapers should always be mounted in the "shadow" of the discharge pulley. Depending on
the blade type and blase-base type, the distance between blade-base axis and conveyor-belt must be
maintained as exactly as possible (s. Table 2).
2.1.1.2 Condition of the belt / Condition of belt joints

If the belt and its joints are in bad condition, usable segment types and the degree of pre-tension
must be selected carefully. With older systems, it is best to get the scraper manufacturer’s advice.
2.1.1.3 Belt tension

When installing the secondary scraper on the track, the pre-tension of the scraper blade is achieved
through the spring effect of the foot and the counterforce of the conveyor belt. If the scraper blade’s
pre-tension deflects the belt by more than 2 cm, the belt tension must be increased, and or a counter-
pressure roller installed.
We recommend a clearance (L1) of > 80 mm between primary and secondary scraper
The clearance (L2) between scraper blade of the secondary scraper and the rear panel of the chute
should be > 80mm.
L2
L1
Figure 1
2.2 Description of Components

Pos. 1 Mounting base with lever type tensioning device
Pos. 2 Scraper blades (here type 281, 282 and 283)
Pos. 3 Mounting base with end support
Pos. 3.1 End support
Pos. 4 Tubular blade base (here type 2)
Pos. 5 Tensioning screw
Pos. 5.1 Tension spring
Pos. 6 Tension sleeve
Pos. 7 Tensioning lever
Pos. 8 Safety screw with counter nut
For STARCLEAN® versions type 622 D and 624 D (recommended for more than 9 pockets), a
second item 1 “Mounting base with tensioning device” is installed instead of item 3 “Mounting base
with end support.
5 5.1 6 7 1 2 3
3.1
8 4 Figure 1
2.2.1 Scraper-blades for use as Primary Scraper:
o Scraper blades of Types 18, 81, 82 as well as 281, 282 and 283 made of highly wear-resistant
polyurethane.
The scraper blades for general industrial use are green in colour and are labelled "n".
Type 18 Type 81 Type 82
o Scraper blades Type 85, 285
This type consists of a polyurethane footing with an integrated tungsten carbide blade.
It is not allowed to use the segments type 85,285 when the belt connection is made with mechanical
fasteners or when the belt is damaged. We recommend to use no segments on belt stampings.
Type 85 Type 85L Type 285 Type 285L

2.2.2 Scraper blades for use as Secondary Scraper:
o Segments of type 50, 53, 53S, 56 und 56k with polyurethane segment feet and
scraper blades made of highly resistant steel or carbide.
The type 50 segments can be used with mechanical joints.

It is not allowed to use the segments type 53, 53s,56 and 56k when the belt connection is made with
mechanical fasteners or when the belt is damaged.
We recommend to use no segments on belt stampings.
Type 50 Type 56 Type 56K
Type 53 and 53S segments are

specially suited for small drum
diameters and conveyed materials
that require low pre-tensioning
force.
Type 53 Type 53S
2.2.3 Blade-bases Type 0, 2 and 4
Blade-base pockets
Standard blade base Tubular blade-base Reinforced tubular blade-base

Type 0 (SKN) Type 2 (SKV) Type 4 (SKX)
2.2.4 Lever-Type Tensioning Device
The lever-type tensioning device serves to produce the right contact pressure of the scraper-blades.
Pre-tension is achieved by twisting the blade base while increasing the spring force. There for you have
to dismount the protective covering (Item 11).
Mounting the tensioning device is possible on both sides of the conveyor. To this it might be necessary
to transpose the spring support (Item 9) 180°. For that purpose the screws (Item 10) have to be
loosened and the spring support has to be turned in the opposite direction. Set in screws again and set
tight.
9 10 11
Figure 2
2.3 Technical Data and Recommendations for Pre-tensioning
2.3.1 Pre-Tensioning
The width of the scraper strip and number of scraper blades depend on the width of the
conveyor belt and the recommended number of scraper blades.
The blade bases have a pitch of 100 mm to hold the scraper blades.
For Types 18, 81 and 281, the scraper blade width is 100 mm (single-wide scraper), for Types
82 and 282 the scraper blade width is 200 mm (double-wide scraper), and for Type 283 the
scraper blade width is 300 mm (triple-wide-scraper).
The calculation of pre-tension is based on the number and width of a single scraper blade (= number of
blade base pockets) always.
α
V
Figure 3
2.3.1.1 Recommended adjusting value of the spring length LF
Always start with low pre-tension, but increase within the given limits in table 1 until the cleaning result ist
sufficient.
Blade type Pre-tension FV in β in Calculation formula for the spring adjustment LF

N N
18 100 - 150 31,4 LF = 170 – ((Number of blade base pockets x FV) / (Number
81 150 - 250 23,5 of tensioning devices x β))
82 300 - 500 47 Example:
281 150 - 250 22,4 90-622-08.18n.13, Favored pre-tension FV = 150 N per
282 300 - 500 44,8 scraper blade:
283 450 - 750 67,2
85 100 - 150 32,5 LF = 170 mm – ((13 x 150 N) / (1 x 31,4 N)) = 108 mm
285 200 - 300 65
56 180 - 250 24,5 In special cases only.
53 120 - 200 42,8
Table 1
3 Start-Up
3.1 General
Installation and start-up, in particular, must only be performed by the appropriate, specially
trained, skilled staff in compliance with the relevant regulations in force. In case of contravention,
the manufacturer shall assume no responsibility whatsoever for any damage caused to ma n or
machine or for any consequential loss.
3.2 Transport
The conveyor-belt cleaners of types 620, 622, 624 are generally delivered as assemblies:
a) Mounting base with lever type tensioning device
b) Mounting base with end support (alternatively: second tensioning device)
c) Blade base Type 0, 2 or 4
d) Scraper blades
During transport, any damage and the impact of external forces must be avoided at all costs.
Damaged parts must not be used – risk of injury!
3.3 Installation / Start-Up
Before installation always ensure that the conveyor system is disconnected from the
power supply and cannot be started up by third parties.
If modifications are made to the product, especially during installation, disassembly

or exchange of parts or during the fitting of new parts or if changes are made to
installed parts which were not permitted by the manufacturer, the warranty is void
and any subsequent defects are excluded
It is absolutely necessary to examine and assess the quality of the belt and
especially the joints. If there is any doubt, please request that the manufacturer
assess the suitability of the selected scraper blade type.
3.3.1 Assembly Steps Primary Scraper

For all primary scraper the distance Lsk1 or Lsk2 between the blade-base and the belt surface must
be maintained as accurately as possible for all primary scrapers (see figures 4, 5, 6, 7). The
distances depend on the type of the scraper blade, the pulley-diameters including belt and the
blade-base type. For measurements please refer to table 2 (page 14).
If necessary, the belt cleaners can be installed in rotation around the axis of the pulley in the
distance Lsk1 / Lsk2.
Ideally, the belt cleaner is installed in the “shadow” of the pulley. Depending on the situation
on-site, other positions are possible. In case of doubt contact the manufacturer.
When using scraper blades of Type 85/285, please observe the special notes under item
3.3.2
1. Mounting and positioning oft he mounting base with lever type tensioning-device according to
specifications (figures 4-7).
If needed, the mounting base may be installed in rotation around the axis of the blade-base.
2. Installation and alignment of the mounting base with end support.

Note! The blade base must be mounted parallel to the discharge pulley of belt.
If needed, the mounting base may be installed in rotation around the axis oft the blade-base.
3. Mounting and positioning of the blade-base.

When mounting the blade-base, ensure that the scraper blades used are positioned centred on the
conveyor belt. It may be necessary to shorten the ends of the blade bases to achieve the correct
fit.
4. Insertion of the scraper blades into the blade-base. Please make sure that the primary scrapers of
type 85 / 285 are inserted in an alternating fashion of short and long versions, starting with a long
one at the outside
5. Tighten all screwed joints (mounting base, blade-base, etc.)
6. Position the scraper blades on the conveyor belt by twisting the blade base.
7. Position the tension-lever (Item 7) in an angle of approx. 45° (see α Fig. 3) against the force-direction on
the hexagonal part oft the blade base. Position the safety screw (Item 8) in an 90° angle to one of the
surfaces of the blade base. Tighten the screw and use counter nut.
8. Attach the tension-sleeve (Item 6) to the tension-lever (Item 7).
9. Turn in the tensioning screw (Item 5) into the tensioning sleeve (Item 6) until favored pre-tension is
reached. (Refer to table 1, page 9)
10. Pre-tensioning and test run:

If necessary raise pre-tension carefully, especially with scraper blades type 85 / 285.
Start the test run. Make sure that no persons are at risk. Observe the cleaning level for a few
minutes.
If residues remain on the belt surface, increase the pre-tension to 4. If this is not sufficient,
further increase the pre-tension. Please refer to the pre-tension recommendations in table 1
(page 9).
Note the wear of the conveyor belt, in particular when using tungsten carbide scraper
blades.
Carefully observe the effectiveness of the scraper during the first days of operation. The
surface of the conveyor belt must align with the tungsten carbide, and the scraper blades must
align with the conveyor belt.
If afterwards the pre-tension of the tensioning device should still be insufficient, please contact the
manufacturer.
3.3.2 Assembly and Notes for Conveyor Belt Cleaners with Type 85 and 285 Scraper
Blades
For Type 85 and 285 blades, follow the installation steps as described in chapter 3.3.1. Take
special care to ensure sufficient clearance of the blade-base axis and parallelism to the
pulley!
It is imperative that the blade-base axis be parallel to the pulley axis!
The blade strip should be installed at the pulley in such manner that the spatulas of the scraper blades
Types 85 and 285 are located in the “shadow” of the pulley (in the examples between the 8:30 and 6
o’clock position) and the scraper blades are protected from falling materials during start-up and shut-
down of the belt system.
Depending on the situation on-site, other positions are possible. In case of doubt, these should be
clarified with the manufacturer.
When installing the scraper blades, please note that the snap-in footings of the scraper blades are
always on the same side as the pulley; otherwise they will not work.
Short and long scraper blades must be installed alternately in the blade-base. The separation between
scraper blades is 100 mm, and the spatulas are 110 mm long, resulting in the fact that the spatulas
always overlap.
For belt widths of 1,000 mm and more, the first and last blades are installed at double length of 210 mm
(Type 285). This provision was made to prevent a 110-mm-long scraper blade (Type 85) from bouncing
onto the pulley if the conveyor belt should be misaligned.
Figure 10 illustrates the blade strip.
Type 85 and 285 blades can be used until the tungsten carbide inserts are worn off completely.
We recommend that the scraper spatula and the polyurethane blade footing be replaced.
3.3.3 Draw-in Points and Openings
Note! Secure all openings and draw-in points between the scraper blades and the conveyor belt
against accidental draw-in according to the applicable rules for prevention of accidents.
Note! Installation into existing belt-conveyor systems must be performed in compliance with the
Machinery Directive for Belt-Conveyor Systems.
3.3.4 Start-Up
1. Switch on belt conveyor and check specifications and the scraping behaviour .
2. If necessary, reset pre-tension, i.e. increase or decrease pre-tension conforming to the rules for
prevention of accidents.
The pre-tension values in table 1 are approximate. Depending on remaining residues on the belt,
pre-tension may be increased or decreased. When faced with specific cleaning problems, users
are requested to contact the manufacturer.
3.3.5 Mounting Distance
3.3.5.1 Illustration of Distances Lsk1 and Lsk2

(Blade-base Axis / Conveyor-belt Surface) for Primary Scrapers
Figure 4
Type 18
Scraper
Figure 5
Type 81 / 82
Scraper
Figure 6
Type 281 / 282 / 283
Scraper
Figure 7
Type 85 / 285
Scraper
Table 2: Distance Lsk1 / Lsk2 (Bladebase axis / conveyor-belt-surface)
[mm]
Scraper-
18 81 / 82 281 / 282 / 283 85 / 285 85L / 285L
type
Bladebase Bladebase Bladebase Bladebase Bladebase
Pulley Typ 2 Typ 2 Typ 2 Typ 2 Typ 2
diameter Typ 0 Typ 4 Typ 0 Typ 4 Typ 0 Typ 4 Typ 0 Typ 4 Typ 0 Typ 4
[mm] Lsk1 Lsk2 Lsk1 Lsk2 Lsk1 Lsk2 Lsk1 Lsk2 Lsk1 Lsk2
160 69 73
200 63 67
250 57 61
300 53 62 56 64
350 46 54 52 59
400 40 45 63 74 / 80* 63 74 / 80* 49 55 63 74
500 67 74 / 80* 67 74 / 80* 43 49 67 74
630 67 74 / 80* 67 74 / 80* 40 44 67 74
800 74 / 80* 74 / 80* 40 40 65
1000 74 / 80* 74 / 80* 59
1200 74 / 80* 74 / 80* 59
Notes * for * for For damaged belts or in case of
viscous, viscous, heavier strain on the scraper
sticky sticky blades, the distance may be
material material reduced.
Intermediate values must be interpolated!
3.3.6 Examples for Positioning
3.3.6.1 Example for Positioning Art.-Nr.: 90-622.18n.?? (Figure 8)
3.3.6.2 Example for Positioning Art.-Nr.: 90-622.283n.?? (Figure 9)
3.3.6.3 Example for Positioning Art.-Nr.: 90-622.58n.?? (Figure 10
4 Maintenance / Disposal
4.1 General
Optimum cleaning results and a long service life can be achieved only if the cleaner is maintained
according to the relevant maintenance guidelines.
4.2 Maintenance Notes
Note!
Exchange scraper blades only after switching off and securing the belt system. Adhere to the
valid accident prevention regulations.
Although the cleaner is low-maintenance, the following points must be checked on a regular basis :
1. Are the scraper strips free of residue? Clean if necessary.

2. Is the pre-tension correct? Correct if necessary.
3. Are all screws tight? Tighten if necessary.
4. Do all scraper-blades sit snugly at the belt according to specifications? Check freedom of
movement of the blade axis if necessary.
5. Does the blade wear allow further use? If the blades are worn, they must be replaced in order to
prevent damage to the belt
6. Are the scraper blades free from damage? Replace blades if necessary.
7. Can the blade-base be turned freely for tensioning? Clean if necessary.
4.3 Maintenance Checks / Maintenance Intervals / Special Maintenance
 Weekly – for 3-shift operation

 Every 2 weeks – for 2-shift operation
 Every 3 weeks – for 1-shift operation
In winter, belt-cleaning systems must be maintained with special care (and at shorter intervals
than specified). This precautionary measure prevents the conveyor belt from being damaged
by frozen material, for example, when the conveyor system is re-commissioned.
The system manufacturer shall not assume any responsibility for damage caused by incorrect
assembly, faulty maintenance and material deposits.
In wintertime, it is essential to remove any ice or snow from the scraper and check it´s
proper function before starting the conveyor. (Risk of belt damages)
A similar approach must be taken for such materials as gypsum and clay. After de-commissioning the
conveyor, these materials tend to solidify to such an extent that the surface of the hardened materials
may attack the belt and cause damage to the system after re-commissioning the conveyor
installation.
For conveyor belts operated with mechanical joints it is recommended that scraper systems be checked
daily. This check-up serves to prevent damaged mechanical joints from damaging the belt-cleaning
system.
We would also like to draw your attention to the fact that mechanical joints can impact the service life of
the scraper blades in the system and induce premature wear.
It must therefore be ensured that the mechanical joints are countersunk in the cover on the pulley
side of the belt. This will considerably extend the service life of the scraper blades.
4.4 Trouble shooting
Should malfunctions occur in the scraper system, make sure to observe the following notes:
“Poor cleaning results“
Cause Action
The scraper blade does not sit snugly at the belt. Check that installation conforms to operation
instructions.
Scraper blade is defective or worn. Replace scraper blade
Scraper blade strip or scraper blade is soiled. Clean scraper blades and scraper
Check freedom of movement of the scraper blade

Scraper-blades do not sit uniformly at the
strip and the blade-base. Check whether
conveyor belt.
installation conforms to operation instructions.
4.5 Replacement of Scraper-blades
1. Turn off the conveyor system pursuant to accident prevention regulations

2. Release the pre-tensioned tensioning device
3. Hang out the tension sleeve (item 7) of the tension lever (item 6); turn the blade base off the belt
4. Move the snap-in footing of the blade-bases against the direction of the undercut of the snap-in footing.
5. Pull the worn scraper blades out of the blade-base.
6. Drive in new blades until the footing snaps in.
7. Continue as described in 3.3.1.
Once the blades are worn we recommend that you always replace all scraper-blades in the
blade strip!
4.6 Disposal
The polyurethane blades must not be disposed in the regular residential refuse. Please contact
your local waste treatment plant or the manufacturer. All other parts may be recycled.
5 Part Numbers / Ordering Replacement Parts

5.1 Sample Order of Conveyor-belt Cleaners
®
Example: Art. No. 90-620-05.85n.05 = STARCLEAN Conveyor-belt cleaner
- with lever-type tensioning device Type 620-05
- with blade-base Type 0 (standard blade-base SW 36)
- with scraper blades Type 85n (n = industrial quality)
- with 5 blade pockets in the blade-base for belt width of 600 mm
®
Example: Art. No. 90-622-08.81n.09 = STARCLEAN
Conveyor-belt cleaner
- with lever-type tensioning device Type 620-08
- with blade-base Type 2 (tubular blade-base 60 mm)
- with scraper blades Type 81n (n = industrial quality)
- with 9 blade pockets in the blade-base for belt width of 1,000 mm
®
Example: Art. No. 90-624-08.283v.15 D = STARCLEAN Conveyor-belt cleaner
- with double (on both sides) lever-type tensioning device Type 620-08
- with blade-base Type 4 (tubular blade-base 60mm
- with scraper blades Type 283v (v = Loba quality with ATEX approval)
- with 15 blade pockets in the blade-base for belt width of 1,600 mm
5.2 Sample Order for Replacement Parts

Original order XYZ dated
®
STARCLEAN 90-624-08.85n-13
1. Replacement blades Type 85n for scrapers with 13 pockets

2. Replacement blade-base Type 4 with 13 pockets
6 Declaration of Conformity
Konformitätserklärung
Declaration of Conformity
 Im Sinne der ATEX-Richtlinie 94/9/EG, Anhang VIII, Kategorie I M2 und II 2D
according to ATEX-Directive 94/9/EC, Appendix VIII, Category I M2 and II 2D
 Im Sinne der Maschinenrichtlinie 2006/42/EG, Anhang II 1 B

according to Machinery Directive 2006/42/EC, Appendix II 1 B
erklärt in alleiniger Verantwortung, dass die Fördergurt-

®
Reinigungssysteme Typ STARCLEAN der Baureihen
240, 620, 622, 624, 627, 628, 630, 720, 722, 724, 820, 822,
940, 942, 950, 952, 960, 962, 970, 972, 980 und 982
auf die sich diese Erklärung bezieht mit der Richtlinie 94/9/EG (ATEX)
und der Maschinenrichtlinie 2006/42/EG übereinstimmen
declares in sole responsibility that the Coneyor-Belt-Cleaning

®
Systems Type STARCLEAN of our productline
240, 620, 622, 624, 627, 628, 630, 720, 722, 724, 820, 822,
940, 942, 950, 952, 960, 962, 970, 972, 980 and 982
that are subject to this declaration are meeting the requirements set forth
in Directive 94/9/EC (ATEX) and the Machinery Directive 2006/42/EC
Angewandte Normen:
für die Richtlinie 94/9/EG (ATEX): EN 1127-1, EN 1127-2, EN 13463-1

für die Richtlinie 2006/42/EG: EN 349, EN ISO 12100-1+2, EN ISO 13857, EN ISO 14118-1
Applicable standards:
for the Directive 94/9/EC (ATEX): EN 1127-1, EN 1127-2, EN 13463-1

for the Directive 2006/42/EC: EN 349, EN ISO 12100-1+2, EN ISO 13857, EN ISO 14118-1
F. E. Schulte Strathaus GmbH & Co. KG hinterlegt die gemäß 94/9/EG, Anhang VIII (ATEX) geforderten
Unterlagen bei benannter Stelle:
F. E. Schulte Strathaus GmbH & Co. KG will archive the documents required according to 94/9/EC (ATEX),
Appendix VIII at the following location:
EXAM GmbH, Bochum, EU-Code 0158
Bevollmächtigter der Fa. F.E. Schulte Strathaus GmbH & Co. KG

für die Zusammenstellung aller technischer Unterlagen: Herr H.-J. Kröning_____
Name
Werl, den 05.01.2010
F.E. Schulte Strathaus GmbH & Co. KG Geschäftsführer
Angabe zum Unterzeichner Unterschrift
Runtestraße 40
59457 Werl / Germany
Tel.: +49 (0) 2922 9775-0
Fax: +49 (0) 2922 9775-75
Installation and operating

instructions
STARCLEAN® conveyor belt scraper

Types 830, 832 and 834
with snap-action tensioning device

for cleaning conveyor belts at the pulley and below the belt
Alternative mountingplate
SPV-840
Installation manual for STARCLEAN® scraper Types 830/832/834 Version: 04.09.2014 Page 1 / 29
1 Important safety informaton and instructions .......................................................................... 3
1.1 Manufacturer, Copyright ............................................................................................................................. 3
1.2 Scope of installation and operating manual ............................................................................................... 3
1.3 Key: (Meanings of symbols) ....................................................................................................................... 3
1.4 General safety instructions......................................................................................................................... 4
1.5 Instructions for use / for use in potentially explosive environments ........................................................... 5
1.6 Special safety instructions.......................................................................................................................... 5
2 Description of the STARCLEAN® conveyor belt scraper .......................................................... 6

2.1 Purpose and tasks (intended use) ............................................................................................................. 6
2.1.1 Information on selecting and positioning the scraper on the conveyor ...................................................... 6
2.1.1.1 Conveyed material ..................................................................................................................................... 7
2.1.1.2 Condition of the belt / Condition of belt joints............................................................................................. 7
2.1.1.3 Belt tension................................................................................................................................................. 7
2.1.2 Information on selecting and positioning the scraper on the conveyor ...................................................... 8
2.1.3 Installation options of the Tensioning device ............................................................................................. 8
®
2.2 Description of STARCLEAN Type 83x components ................................................................................ 9
2.2.1 Scraper-blades for use as Primary Scraper: ............................................................................................ 10
2.2.2 Scraper blades for use as Secondary Scraper: ....................................................................................... 11
2.2.3 Blade-bases Types 0, 2 and 4 ................................................................................................................. 12
2.2.4 Snap-action tensioning device ................................................................................................................. 13
2.3 Technical data and recommended pre-tensioning ................................................................................... 14
2.3.1 Primary Scrapers ..................................................................................................................................... 14
2.3.2 Secondary Scrapers ................................................................................................................................. 14
3 Start-up .......................................................................................................................................14
3.1 General..................................................................................................................................................... 14
3.2 Transport .................................................................................................................................................. 14
3.3 Installation / start-up ................................................................................................................................. 15
3.3.1 Assembly Steps (A: Primary Scraper, B: Secondary Scraper) ................................................................ 15
3.3.2 Assembly and Notes for Conveyor Belt Cleaners with Type 85 and 285 Scraper Blades ...................... 17
3.3.3 Retraction points and openings ............................................................................................................... 17
3.3.4 Start-up..................................................................................................................................................... 17
3.3.5 Mounting Distance ................................................................................................................................... 18
3.3.5.1 Illustration of Distances Lsk1 and Lsk2 .................................................................................................... 18
(Blade-base Axis / Conveyor-belt Surface) for Primary Scrapers ........................................................................ 18
3.3.5.2 Illustration of Maximum Distances Lx and Ly........................................................................................... 20
3.3.6 Examples for Positioning.......................................................................................................................... 22
3.3.6.1 Example for Positioning Item No.: 90-832.81n.?? (Figure 17)................................................................. 22
3.3.6.2 Example for Positioning Item No.: 90-830.18n.?? (Figure 18) ................................................................. 23
3.3.6.4 Example for Positioning Item No.: 90-830.56nk.?? (Figure 20) ............................................................... 24
3.3.6.6 Example for Positioning Item No.: 90-834.53Sn.?? (Figure 22) ............................................................. 25
3.3.6.7 Example for Positioning Item No.: 90-832.85n.?? (Figure 23) ................................................................ 25
4 Maintenance / disposal ..............................................................................................................26

4.1 General..................................................................................................................................................... 26
4.2 Maintenance instructions ......................................................................................................................... 26
4.3 Maintenance inspection / maintenance intervals / special maintenance ................................................. 26
4.4 Troubleshooting ....................................................................................................................................... 27
4.5 Replacing a scraper blade ....................................................................................................................... 27
4.6 Disposal.................................................................................................................................................... 27
5 Order numbers / ordering replacement parts...........................................................................28

5.1 Sample order for scraper systems ........................................................................................................... 28
5.2 Sample order for replacement parts ........................................................................................................ 28
6 Declaration of Conformity .........................................................................................................29
Installation manual for STARCLEAN® scraper Types 830,832,834 Version: 04.09/2014 Page 2 / 29
1 Important safety informaton and instructions
1.1 Manufacturer, Copyright

Manufacturer:
F.E. Schulte Strathaus GmbH & Co. KG Tel.: 0049 (0) 2922 9775 0
Runtestraße 42 E-Mail: info@schulte-strathaus.de
D-59457 Werl
Copyright:
Reprinting, reproduction and distribution of this installation and operating manual to third parties,
including storage and use on optical and electronic storage media, except for internal use for training and
operation, are prohibited without written consent of the manufacturer
1.2 Scope of installation and operating manual
This installation and operating manual (item No.: 95-MA-830-09-2013) applies to all conveyor belt
scraper systems in lines 830, 832, 834, regardless of which of the line’s components described below
are being used (scraper blade types and number, blade-base types and lengths, or installation
equipment).
Keep this installation and operating manual together with the machine documentation for future
reference, and make them accessible to the installation and operating personnel!
1.3 Key: (Meanings of symbols)
Warns of a hazard point / Pay special attention or read.
Do not switch on / Make sure that the band system is not turned on during installation
Warning: potentially explosive atmosphere
1.4 General safety instructions
 This operating manual is intended for technical personnel trained by the manufacturer
because – due to their training, experience, instruction and knowledge of the relevant
standard, guidelines, accident preventon regulations and operating conditions – these
people are able to perfom the required activities whilte at the same time recognising
potential hazards and preventing them.
 To maintain the warranty, installation and start-up should be carried out by the
manufacturer`s technical personnel.
 The instructions in the operating manual must be followed without exception. The
manufacturer shall bear no liability for damages to persons or machines due to non-
compliance.
 Because the conveyor belt scrapers are generally installed into conveyor belt systems, the
manufacturers of these systems or the operator who has installed the scrapers must
comply with the provisions of the applicable machine guidelines.
 Schulte Strathaus conveyor belt scrapers must be used only in keeping with intended use
for cleaning conveyor belts at the positions provided for this.
 In order to ensure the guaranteed functions, only replacement parts from the manufacturer
are to be used.
 During all work, the applicable local regulations and legislation must be observed.
 There is no claim that these safety instructions are complete. If there are questions or
problems, please contact the manufacturer.
 STARCLEAN conveyor belt scraper type 830 / 832 and 834 reflects the state of the art at
the time of delivery.
 It must be installed and operated only in perfect condition, and installation by the operator
of the system must be configured safely accodring to the relevant accident prevention
regulations.
 Retrofitting, modification and conversion are completely prohibited because these may
affect worker safety.
1.5 Instructions for use / for use in potentially explosive environments
 It must be clarified with the operator under what conditions the scraper is to be used (such
as underground, in potentially explosive environments, etc.).
 In all industries where no special demands are placed, the scrapers can be used as needed.
Temperature range for use: - 45°C to + 70°C
The maximum conveying speed must not be exceeded, and the area of use must always be
cleared with the manufacturer.
Use in potentially explosive environments:
 For conveyor belt cleaning systems of Group I Category M2, only beams or segments
made from plastics approved for underground bituminous coal mining must be used.
You can obtain information on this from the manufacturer.
The conveyor belt’s relative speed must not exceed 6 m per second.
The surface temperature of 150°C must not be exceeded.
Temperature range for the scraper: -45°C to +40°C
Designation = CE Ex I M2
Conveyor belt cleaning systems of Group I Category M2 can only be used on belt conveyors
that can be switched off if the atmosphere becomes potentially explosive.
 Conveyor belt cleaning systems of Group II Category 2D must be used only in

connection with dusts whose minimum ignition energy is greater than 3 mJ.
The conveyor belt’s relative speed must not exceed 6 m per second.
The surface temperature of 150°C must not be exceeded.
Temperature range for the scraper: -45°C to +40°C
Designation = CE Ex II 2D
 All conductive parts of the conveyor belt cleaning systems must be earthed with a leakage
6
resistance to earth of less than 10 .
1.6 Special safety instructions
 Before any work begins on STARCLEANconveyor belt scrapers, the belt conveyor’s voltage
supply must be switched off and secured against unauthorised activation.
 Before welding and cutting work begins, approval for this work must be obtained from the
operator of the belt system!
 When the STARCLEAN conveyor belt scraper is installed before use of a welding torch
and/or other welding equipment, inspection must be made to ensure compliance with legal
regulations (explosion protection, firedamp protection, etc.).
 During welding and cutting work, heat-sensitive components, such as the conveyor belt, must
be covered. If necessary, a fire watch is required.
2 Description of the STARCLEAN® conveyor belt scraper
2.1 Purpose and tasks (intended use)
®
The STARCLEAN - conveyor belt scraper type 830/832/834 is intended primarily for use in scraping
material residue from the conveyor belt directly at the discharge pulley as a primary scraper
For this, scraper blades / scraper blades are pressed by a snap-action tensioning device to the surface
of the conveyor belt to carefully scrape off material remaining or adhering to the belt.
Depending on the width of the belt and the consistency of the conveyed material, various combinations
of scraper blades and blade-bases may be necessary to achieve optimal scraping results.
When used as a primary scraper, this type of cleaner may be for reversible belt systems.
In certain cases, this cleaner may also be used together with secondary blades "below the belt". This
is particularly recommended for materials that tend to stick to the belt. requiring regular hinging out and
cleaning of the conveyor-belt cleaner.
By loosening the locking mechanism on the snap-action tensioning device, the scraper can easily be
relaxed and the scraper blades hinged away.
When used as a secondary scraper, reversible operation is not possible!

When selecting the scraper blades and its installation point on the conveyor system, the following
points must be considered because they have significant effects on the scraper’s functionality, the
scraping results and the system’s functional safety.
o Conveyed material (coarse, fine, dry, wet, abrasive)

o Belt speed
o Belt tension
o Condition of belt, belt joints
o Pulley diameter
o Chute geometry (Width, incline of outlet slide)
2.1.1.1 Conveyed material
With coarse material, the secondary scraper’s segment foot must be placed far enough below the
discharge pulley that no wedge-shaped catchment area is formed in which pieces of the conveyed
material stick and damage the belt.
Wedge-shaped catchment
Narrow
With fine material and/or small chutes, a short blade (K) must be used. It can be installed behind the 6
o’clock position in the track direction. In so doing, make sure that, when tensed, the blade moves 1 to
2 cm in the direction of the blade-base.
Scraped off, strongly adhering material should fall as freely as possible.
In any case, the material must be finer than the gap between the segment foot and the belt.
Primary scrapers should always be mounted in the "shadow" of the discharge pulley. Depending on
the blade type and blase-base type, the distance between blade-base axis and conveyor-belt must be
maintained as exactly as possible (s. Table 2).
2.1.1.2 Condition of the belt / Condition of belt joints

If the belt and its joints are in bad condition, usable segment types and the degree of pre-tension
must be selected carefully. With older systems, it is best to get the scraper manufacturer’s advice.
2.1.1.3 Belt tension

When installing the secondary scraper on the track, the pre-tension of the scraper blade is achieved
through the spring effect of the foot and the counterforce of the conveyor belt. If the scraper blade’s
pre-tension deflects the belt by more than 2 cm, the belt tension must be increased, and or a counter-
pressure roller installed.
We recommend a clearance (L1) of > 80 mm between primary and secondary scraper
The clearance (L2) between scraper blade of the secondary scraper and the rear panel of the chute
should be > 80mm.
L2
L1
Figure 1
2.1.3 Installation options of the Tensioning device

The mounting plate with snap action tensioning device as well as the mounting plate with pivot bearing
could be installed in different ways on the belt conveyor. Here is an overview of the most common
installation options.
CUT A-A
The mounting base can be shortend

on site from the marker
Mountinbracket type 830
In the oval hole a hexagon screw can be

placed rotation free
Figure 2
2.2 Description of STARCLEAN® Type 83x components
Pos. 1 Scraper blade bar
Pos. 1.1 Scraper blades (here type 81)
Pos. 1.1.1 Scraper blades (here type 56)
Pos. 1.2 Blade-base types 0, 2 or 4 (here type 2)
Pos. 2 Mounting base with snap-action tensioning device and pivot bearing
Pos. 2.1 Locking mechanism
Pos. 2.2 Locking gear
Pos. 2.2.1 Blade-base actuator
Pos. 2.2.2 Snap-in element
Pos. 2.2.3 Locking screw with counter nut
Pos. 2.2.4 fine adjustment screw
Pos. 3 Mounting base with pivot bearing
Pos. 3.1 Collar
Pos. 3.2 Locking screw
Pos. 3.3 Pivot bearing 3.3.1 from plastic for standard use or
Pos. 3.3 Pivot bearing 3.3.2 from steel for use in potentially explosive environments
®
For STARCLEAN versions type 832 D and 834 D (recommended for 15 pockets and more), item 2
"Mounting base with tensioning device" is installed instead of item 3 "Mounting base with pivot
bearing"
1.2
1 1.1
3
3.2
2 3.1
2.1
1
2.2
Figure 3
2.1
2.2.4 2.2.2
2.2.1
1.1.1
3.3
2.2.3
Figure 4
Pos. 4 Secondary scraper blade type 56 (with description of main components)
Scraper blade
Segment foot Segment axe

Clamping
Figure 5
2.2.1 Scraper-blades for use as Primary Scraper:
o Scraper blades of Types 18, 81, 82 as well as 281, 282 and 283 made of highly wear-resistant
polyurethane.
The scraper blades for general industrial use are green in colour and are labelled "n".
o Scraper blades Type 85, 285
This type consists of a polyurethane footing with an integrated tungsten carbide blade.
It is not allowed to use the segments type 85,285 when the belt connection is made with mechanical
fasteners or when the belt is damaged. We recommend to use no segments on belt stampings.
Type 85 Type 85L Type 285 Type 285L
2.2.2 Scraper blades for use as Secondary Scraper:
o Segments of type 50, 53, 53S, 56 und 56k with polyurethane segment feet and
scraper blades made of highly resistant steel or carbide.
The type 50 segments can be used with mechanical joints.

It is not allowed to use the segments type 53, 53s,56 and 56k when the belt connection is made with
mechanical fasteners or when the belt is damaged.
We recommend to use no segments on belt stampings.
Type 50 Type 56 Type 56K
Type 53 and 53S segments are

specially suited for small drum
diameters and conveyed materials
that require low pre-tensioning
force.
Type 53 Type 53S
2.2.3 Blade-bases Types 0, 2 and 4
Blade-base pockets
Standard blade-base Tubular blade-base Reinforced tubular blade-base

Type 0 (SKN) Type 2 (SKV) Type 4 (SKX)
2.2.4 Snap-action tensioning device
The snap-action tensioning device serves to produce the right contact pressure of the scraper-blades.
Pre-tension is achieved by twisting the blade-base together with the scrapers and the locking gear.
The locking gear has to be mounted in that way, as the vertical side oft he notches shows in the
direction of the scraper segment
The snap-action tensioning device can only be pretensioned in the lever direction of the locking
gear.
a) Positions of the lever
Locking pin
Lever
Safety plate
Snap-in element with

fine adjustement
SW 36
X Position “Right“  Pre-tensioning can be performed clockwise only.

Y Position “0“  Installation and maintenance position. No pretension can be generated
Z Position “Left“  Pre-tensioning can be performed counterclockwise only.

If necessary the safety plate has to be mounted in the opposite way.
Loosen the two M8 hexagon socket screws, and turn the Safety Plate
around. Tighten the screws again thoroughly.
Attention! Pre-tensioning in opposite direction can damage the tensioning mechanism.
b) Releasing the pre-tensioned Snap-action Tensioning Device
1. Turn the blade-base with a wrench WS 36 slightly in direction of the lever.
2. Lift lever up and shift to "0" position. Now the device is not locked and the scraper can be twisted in
any direction.
2.3 Technical data and recommended pre-tensioning
2.3.1 Primary Scrapers
The scraping width and number of scraper blades depend on the width of the conveyor belt. For Types
18, 81 and 281, the scraper blade width is 100 mm, for Types 82 and 281 the scraper blade width ist
200 mm and for Type 283 the scraper blade width is 300 mm.
2.3.2 Secondary Scrapers
The scraping width and number of scraper blades depend on the width of the conveyor belt. For types
50, 53, 53S, 56K and 56 each segment foots are 100 mm wide.
The scraper blades must be used alternately in short and long versions in the blade-base pockets. The
blase-bases have a pocket division (pitch) of 100 mm, and the scraper blades have a working width of
120 mm, so that the blades always overlap
For belt widths from 1600 mm on, the use of two tensioning devices is recommended, depending on the
consistency of the material to be cleaned off. The part number includes the additional identification “D”.
3 Start-up
3.1 General
Installation and especially start-up must be performed only by suitably trained technical personnel in
compliance with applicable regulations. The manufacturer shall bear no liability for damages to persons
or machines or any consequential damages due to non-compliance.
3.2 Transport
Types 830, 832, 834 are only delivered as assemblies:
a) Mounting base with snap-action tensioning device

b) Mounting base with pivot bearing (alternatively: second snap-action tensioning device)
c) Blade-base of type 0, 2 or 4
d) Scraper blades
 During transport, all damage and external forces must be completely prevented. Damaged
components must not be installed – risk of injury!
3.3 Installation / start-up
Before installation make absolutely certain that power to the belt system has been
switched off and cannot be reactivated by third parties.
If changes have been made to the product – especially during installation, deinstallation,
part replacement, installation of new parts or changes to installes parts – and these are
not approved by the manufacturer, the warranty is void for defects occuring thereafter.
The locking pin/lever of the snap-action tensioning device must be turned to position
„0“!
It is absolutely necessary to examine and evaluate the condition of the belt, and
especially of the belt connections. When in doubt, contact the manufacturer to judge the
suitability of the type of scraper chosen.
You need:
 Wrench size WS 36 to turn the blade--base in ordert o pre-tensioning the scraper blades
 Wrench size WS 17
 Wrench size WS 13
 Hexagon socket wrench WS 6
3.3.1 Assembly Steps (A: Primary Scraper, B: Secondary Scraper)
A: Primary Scraper: The distance Lsk1 or Lsk2 between the blade-base and the belt surface must be
maintained as accurately as possible for all primary scrapers (see figures 7, 8, 9, 10). The distances
depend on the type of the scraper blade, the pulley-diameters including belt and the blade-base type.
For measurements plere refer to table 1 (page 19).
If necessary, the belt cleaners can be installed in rotation around the axis of the pulley in the distance
Lsk1/ Lsk2.
Ideally, the belt cleaner is installed in the "shadow" of the pulley. Depending on the situation on-site,
other positions are possible. In case of doubt contact the manufacturer.
When using scraper blades of Type 85/285, please observe the special notes under item 3.3.2
B: Secondary Scraper: For all secondary scrapers, the distance Ly of the blade-base to the belt
surface must be maintained as accurately as possible (see figures 11 - 16). This is particularly important
when using scraper blades of type 53S. If the distance is correct, the blade axis runs parallel to the
conveyor belt. For measurements please refer to table 2 (page 22). The scraper blades must preferably
be positioned directly underneath the discharge pulley or a counter pressure cylinder, whereby the
blade of the short blade is positioned directly underneath the pulley. If the belt is sufficiently thick and/or
when used in connection with a primary scraper, secondary may also be installed below the belt. In this
care, the pre-tension must not be set too high in order to prevent excessive lifting to the belt.
1st Mounting and positioning of the mounting base with snap-action tensioning device according to
specifications (primary scraper: figures 7-10, secondary scraper: figures 11-16). If needed, the mounting
base may be installed in rotation around the axis of the blade-base.
2nd Installation and alignment of the mounting base with end support.
Note! The scraper blades must be mounted parallel to the discharge pulley of belt.
If needed, the mounting base may be installed in rotation around the axis of the blade-base.
3rd Mounting and positioning of the blade-base.

When mounting the blade-base, ensure that the scraper blades used are positioned centred on the
conveyor belt. It may be necessary to shorten the ends of the blade-bases to achieve the correct fit.
4th Installation of the blade-base actuator 2.2.1 with the snap-in element 2.2.2, the fine adjustment
screw 2.2.4 should fit with the countersink in the blade base actuator 2.2.1. snap-in element
2.2.2 so ausrichten dass es mittig auf dem blade-base actuator 2.2.1 positioniert ist. Tighten
the screws 2.2.4.
Lever
2
2.1
2.2.2
1.1.
1
2.2.1
2.2.3 2.2 Snap-in element
with fine adjustement
2.2.4
Locking Pin
Figure 6
5th Insertion of the scraper blades into the blade-base. Please make sure that the secondary
scrapers and the primary scrapers of type 85 / 285 are inserted alternating short and long
versions, respectively. (85 / 285 start on the outside with a long scraper blade; secondary
scrapers start on the outside with the short scraper blade). Tighten all screwed joints.
6th Position the scraper blades on the conveyor belt by twisting the snap-action tensioning
device.
7th Turn the lever in tensioning direction.
8th Place the snap-in element with fine adjustement 2.2 on the blade-base, looking that the
locking pin fits into the first or second notch.
9th Tighten the locking screw 2.2.3 and counter with the nut.
10th Tighten the screw sorowly.
11th Pre-tensioning and test run:

Pre-tension the blades slightly while turning the blade-base with help oft the wrench WS 36.
Make sure that increasing the tension with scrapers type 85/285 is done very carefully!
Start the test run. Make sure that no persons are at risk. Observe the cleaning level for
a few minutes.
If residues remain on the belt surface, increase the pre-tension. If this is not sufficient, further
increase the pre-tension.
12th Fine-adjustment is practicable by loosen one of the fine adjustement screw 2.2.4 while tighten
the second fine adjustement screw. At this, the snap-in element 2.2.2 and the blade-base
actuator 2.2.1 turn relativ to each other. Tighten both fine adjustement screws 2.2.4.
Using snap-action tensioning devices on both sides, make sure that the locking pin fits
perfect into the notches on both locking gears.
13th If necessary shorten the overlaping ends of the blade-base. Do leave enough space to be able
to place the wrench WS 36 for further action.
Watch the wear of the conveyor belt, in particular when using tungsten carbide scraper blades.
Carefully observe the effectiveness of the scraper during the first days of operation. The surface of the
conveyor belt must align with the tungsten carbide, and the scraper blades must align with the conveyor
belt.
If afterwards the pre-tension of the snap-action tensioning device should be insufficient, please contact
the manufacturer.
3.3.2 Assembly and Notes for Conveyor Belt Cleaners with Type 85 and 285 Scraper
Blades
For Type 85 and 285 blades, follow the installation steps as described in chapter 3.3.1. Take
special care to ensure sufficient clearance of the blade-base axis and parallelism to the pulley!
It is imperative that the blade-base axis be parallel to the pulley axis!
The scraper blade bar should be installed at the pulley in such manner that the blades of the scraper
blades Types 85 and 285 are located in the „shadow“ of the pulley (in the examples between 8:30 and 6
o’clock position) and the scraper blades are protected from falling materials during start-up and shut-
down of the belt system.
Depending on the situation on-site, other positions are possible. In case of doubt, these positions should
be clarified with the manufacturer.
When installing the scraper blades, please note that the snap-in footings of the scraper blades are
always on the same side as the pulley; otherwise they will not work.
Short and long scraper blades must be installed alternately in the blade-base. The separation between
scraper blades is 100 mm, and the blades are 110 mm rsp. 210 mm wide, resulting in the fact that the
blades always overlap.
For belt widths of 1000 mm and more, the first and last blades are installed at double width of 210 mm
(Type 285). This provision was made to prevent a 110 mm wide scraper blade (Type 85) from bouncing
onto the pulley if the conveyor should be misaligned.
Figure 10 illustrates the blade blades.
Type 85 and 285 blades can be used until the tungsten carbide inserts are worn off completely. We
recommend that the scraper blade and the polyurethane blade footing be replaced.
3.3.3 Retraction points and openings
Attention! Secure all openings and snagging points between the scraper and conveyor belt
against reaching and catching according to the accident prevention regulations.
Attention! For installation in existing belt conveyor systems, the provisions of the machine
guidelines for belt conveyor systems must be observed.
3.3.4 Start-up
1. Turn the belt system on and check the default values and scraper behaviour.
2. If necessary, readjust the pre-tension, i.e. increase or decrease it in compliance with accident
prevention regulations.
For special cleaning problems please contact the manufacturer.
3.3.5 Mounting Distance
3.3.5.1 Illustration of Distances Lsk1 and Lsk2

(Blade-base Axis / Conveyor-belt Surface) for Primary Scrapers
Figure 7
Type 18
Cleaner
Figure 8
Type 81 / 82
Cleaner
Figure 9
Type 281 / 282 / 283
Cleaner
Figure 10
Typ 85 / 285
Cleaner
Table 1: Distance Lsk1 / Lsk2 (Bladebase axis / conveyor-belt-surface)

[mm]
Scraper-
18 81 / 82 281 / 282 / 283 85 / 285 85L / 285L
type
Bladebase Bladebase Bladebase Bladebase Bladebase
Pulley Typ 2 Typ 2 Typ 2 Typ 2 Typ 2
diameter Typ 0 Typ 4 Typ 0 Typ 4 Typ 0 Typ 4 Typ 0 Typ 4 Typ 0 Typ 4
[mm] Lsk1 Lsk2 Lsk1 Lsk2 Lsk1 Lsk2 Lsk1 Lsk2 Lsk1 Lsk2
160 69 73
200 63 67
250 57 61
300 53 62 56 64
350 46 54 52 59
400 40 45 63 74 / 80* 63 74 / 80* 49 55 63 74
500 67 74 / 80* 67 74 / 80* 43 49 67 74
630 67 74 / 80* 67 74 / 80* 40 44 67 74
800 74 / 80* 74 / 80* 40 40 65
1000 74 / 80* 74 / 80* 59
1200 74 / 80* 74 / 80* 59
Notes * for * for For damaged belts or in case of
viscous, viscous, heavier strain on the scraper
sticky sticky blades, the distance may be
material material reduced.
Intermediate values must be interpolated!
3.3.5.2 Illustration of Maximum Distances Lx and Ly
(Blade-base Axis / Conveyor-belt Surface) for Secondary Scrapers
Figure 11
Type 50
Cleaner
Figure 12
Type 50K
Cleaner
Figure 13
Type 53
Cleaner
Figure 14
Type 53S
Cleaner
Figure 15
Typ 56K
Cleaner
Figure 16
Typ 56
Cleaner
Table 2:
(Clearance Lxmax and Ly (Blade-basis Axis / conveyor-belt
surface)
[mm]
Blade-base
Typ 2
Typ 0 Typ 4
Blade-type Lxmax Ly Ly
50 195 69 81
50K 145 69 81
53 100 71 83
53S 20 71 83
56K 135 71 83
56 180 71 83
Notes
3.3.6 Examples for Positioning
3.3.6.1 Example for Positioning Item No.: 90-832.81n.?? (Figure 17)
3.3.6.4 Example for Positioning Item No.: 90-830.56nk.?? (Figure 20)
3.3.6.6 Example for Positioning Item No.: 90-834.53Sn.?? (Figure 22)
4 Maintenance / disposal
4.1 General
Only maintenance according to the applicable maintenance guidelines can ensure the scraper’s optimal
cleaning behaviour and long service life.
4.2 Maintenance instructions
Attention!
The scraper blades must be replaced only when the belt system is switched off and secured.
Accident prevention regulations must be observed.
Although the scraper is very low-maintenance, the following points should be checked regularly:
1. Are the scraper blades free of build-up? Clean, if necessary.

2. Is the pre-tension correct? Correct, if necessary.
3. Are the screws all tight? Tighten, if necessary.
4th Do the scraper blades lie perfectly against the belt? Check the segment axis movement, if
necessary.
5th Are the scraper blades too worn to use?
If the segments are worn, they must be replaced to prevent belt damage!
6th Are the scraper blades damaged? Replace the segments, if necessary.
7. Can the blade-base still freely turn for tensioning? Clean, if necessary.
4.3 Maintenance inspection / maintenance intervals / special maintenance

The maintenance required depends on many factors, such as the material conveyed, the condition of
the belt, etc., and can vary. Following installation the actual maintenance effort is to be determined and
organised accordingly. The following are reference values:
 Every week – in 3-shift operation

 Every 2 weeks – in 2-shift operation
 Every 3 weeks – in 1-shift operation
In wintertime, the scraper systems must be maintained with special care (and more often than
indicated). This prevents damage to the conveyor belt the next time the belt is turned on, such as due to
frozen material.
The manufacturer assumes no liability for damages due to improper installation, deficient maintenance
and material deposits.
In wintertime, it is essential to remove any ice or snow from the scraper and check it´s proper
function before starting the conveyor. (Risk of belt damages)
A similar procedure must also be used with materials such as gypsum and clay. After the belt system
has stopped, conveyed materials have a tendency to become so hard that after the system is restarted
the conveyor belt surfaces grip may cause damage.
In belt systems running with mechanical connections, the scraper systems should be inspected daily.
These inspections are to ensure that damaged mechanical connections do not in turn damage the
scraper system.
It should be noted that mechanical joints influence the lifespan of the scraper blades used, and may
cause them to wear out prematurely. Therefore it must be ensured that the mechanical connections can
also get into the cover plate on the running side. This will significantly extend the life of the scraper
blades.
4.4 Troubleshooting
If the scraper system malfunctions, follow the instructions below:
“Poor cleaning results“
Causes Resolution
The scraper blades do not lie against the belt. Check installation against the operating manual.
Scraper blades are defective or worn. Replace the scraper blades.
Scraper blade bar or scraper blades are dirty. Clean the scraper blade bar and scraper.
Check the mobility of the scraper blade bar and the

Scraper blades do not lie uniformly on the
blade-base. Check installation against the
conveyor belt.
operating manual.
4.5 Replacing a scraper blade

1st Stop the belt system according to accident prevention regulations.
2nd Loosen the pre-tensed scraper blades:
- Turn the blade-base slightly towards the locking lever, using a 36 w.s. wrench.
- Lift the locking lever and set to position “0“. The locking mechanism is now disengaged, and the
scraper blades may be twisted at will.
3rd Release the tension of the scraper blade bar.
4th Move the segment foot’s clamping hook against the clamping hook’s indentation.
5th Pull the segment out of the blade-base.
6th Insert a new segment until the clamping hook clicks in.
7. Described further at 3.3.1.
After the segments have worn, we recommend always replacing all scraper blades in the scraper
blade bar!
4.6 Disposal
The polyurethane segments cannot be disposed of with household waste. Please contact your local
waste disposal company or the manufacturer. All other components can be taken for metal recycling.
5 Order numbers / ordering replacement parts
5.1 Sample order for scraper systems
®
Example: Item No. 90-830.85n.07 = STARCLEAN scraper system
- with snap-action tensioning device type 830
- with blade-base type 0 (standard blade-base SW 36)
- with scraper blades type 85n (n = industrial quality)
- with 7 segment receiving pockets in the blade-base for belts 800 mm wide
®
Example: Item No. 90-832.81n.09 = STARCLEAN scraper system
- with snap-action tensioning device type 832
- with blade-base type 2 (tube blade-base  60 mm)
®
Example: Item No. 90-834.283n.15 D = STARCLEAN scraper system
- with two snap-action tensioning devices type 830
- with blade-base type 4 (reinforced tube blade-base  60mm)
5.2 Sample order for replacement parts
Original order XYZ from ......

®
STARCLEAN 90-834.85n-13
1. Replacement blades type 85n for scraper with 13 pockets
2. Replacement blade-base type 4 with 13 pockets
6 Declaration of Conformity
Konformitätserklärung
 Im Sinne der ATEX-Richtlinie 94/9/EG, Anhang VIII, Kategorie I M2 und II 2D
according to ATEX-Directive 94/9/EC, Appendix VIII, Category I M2 und II 2D
 Im Sinne der Maschinenrichtlinie 2006/42/EG, Anhang II 1 B

according to Machinery Directive 2006/42/EC, Appendix II 1 B

erklärt in alleiniger Verantwortung, dass die Fördergurt-
®
Reinigungssysteme Typ STARCLEAN der Baureihen
240, 262, 264, 420, 422, 424, 511, 513, 521, 523, 620, 622, 624, 627,
628, 630, 720, 722, 724, 820, 822, 830, 832, 834,940, 942, 950, 952,
960, 962, 970, 972, 980 ,982, 984 und 995 auf die sich diese Erklärung bezieht
mit der Richtlinie 94/9/EG (ATEX) und der Maschinenrichtlinie 2006/42/EG
übereinstimmen.
declares in sole responsibility that the Coneyor-Belt-Cleaning

®
Systems Type STARCLEAN of our productline
240, 260, 262, 264, 320, 322, 324, 430, 432, 434, 620, 622, 624, 627, 628, 629,
720, 722, 724, 820, 822, 824,830, 832, 834, 960, 962, 964, 970, 972, 974, 980,
982 und 984 that are subject to this declaration are meeting the requirements
set forth in Directive 94/9/EC (ATEX) and the Machinery Directive 2006/42/EC.
Angewandte Normen:
für die Richtlinie 94/9/EG (ATEX): EN 1127-1, EN 1127-2, EN 13463-1

für die Richtlinie 2006/42/EG: EN 349, EN ISO 12100-1+2, EN ISO 13857, EN ISO 14118-1
Applicable standards:
for the Directive 94/9/EC (ATEX): EN 1127-1, EN 1127-2, EN 13463-1

for the Directive 2006/42/EC: EN 349, EN ISO 12100-1+2, EN ISO 13857, EN ISO 14118-1
F. E. Schulte Strathaus GmbH & Co. KG hinterlegt die gemäß 94/9/EG, Anhang VIII (ATEX) geforderten
Unterlagen bei benannter Stelle:
F. E. Schulte Strathaus GmbH & Co. KG will archive the documents required according to 94/9/EC (ATEX),
Appendix VIII at the following location:
EXAM GmbH, Bochum, EU-Code 0158
Bevollmächtigter der Fa. F.E. Schulte Strathaus GmbH & Co. KG

für die Zusammenstellung aller technischer Unterlagen: Herr H.-J. Kröning_____
Name
Werl, den 05.01.2012
F.E. Schulte Strathaus GmbH & Co. KG Geschäftsführer
Angabe zum Unterzeichner Unterschrift
6.7 PULLEYS
6.7.1 Pulley documentation
 Drive pulley and discharge pulley (Boom conveyor)

Discharge pulley and bend pulley (Tripper car)
− Technical documentation for Pulleys

Blank page

Technical
Documentation
for
Pulleys
Customer: ThyssenKrupp Industrial

Solutions AG
Purchase order : 30263572/TINT
Order Customer: 4087

Contents
1. TRANSPORT 3
2. STORAGE 4
3. ASSEMBLY OF PLUMMER BLOCK UNITS AND TAKE-UP BLOCK

UNITS 6
3.1. SNL housing and take-up block with Taconite sealing 6
Please read these recommendations before executing the assembly work! 6
3.2. SNL housing and take-up block with labyrinth sealing (TS) 9
3.3. SNL housing with double-lip seal (TG) 12
4. MAINTENANCE 17
4.1. General information 17
4.2. Bearings 18
4.3. Rubber coating 20
5. SCOPE OF SUPPLY 21
6. APPENDIX 21
Koch Manutention Mecanique
Parc Industriel Sud, ZL Edison Tel. +33 3879586-00

11, rue Jean Baptiste Dumaire Fax +33 3879586-78
F- 57201 Sarreguemines
2
1. Transport
Belt pulleys and plummer block units can be transported by means of appropriate
means of transportation on palettes or in cases or short loose on the truck, by
means of suitable transport. The pulleys must be fastened on the palettes by
means of tightening straps. Pulley with ceramic coatings may be sent only by
suitable boxes or casing, to make sure that the pulley not on the ceramic lie.
Convenient lifting devices that are in compliance with the current regulations
(spreaders) must be used for discharge. Loading and unloading by means of
forklift trucks is admissible. To unload the pulley from the truck it will be used
Polytex slings (DIN EN 1492-2) according to the protocol (see picture 1).
Attaching of the load lifting appliances to the tightening straps or to the

plummer block units is not admissible.
Lifting protocol Picture 1

3
2. Storage
The general storage conditions must correspond to the later application of the
pulleys and must not lead to any premature deterioration.
The pulleys must be stored at a roofed and dry place before installation.
The pulleys must be placed on the block housings, so that the rubber
coating of the pulleys not charged.
The minimum ground clearance must be at least 100 mm.

Leave the pulleys in the transport racks or on the palettes. Do not stack the
pulleys.
For any withdrawal from or rearranging within the storage area, appropriate lifting
devices (spreaders) must be used.
Do not remove the cover of the drive journal of the pulleys permanently prior to
installation. After visual examinations for corrosion damages, the covers must be
replaced.
If necessary, all bare axle or shaft journals must undergo a subsequent
anticorrosive treatment.
If outdoor storage is inevitable, appropriate measures must be taken in order to

guarantee stability even on a dirt surface. Rubberised pulleys must not be
exposed to direct sun (UV radiation). The pulley body and the probably mounted
plummer block units must be stored in such a way that they are all around
protected against atmospheric influences. Use appropriate protective covers in
order to avoid the formation of condensation water.

4
2.1 Storage of Natural and Synthetic Rubber Products as per DIN 7716
In order to maintain rubber materials properties unchanged and optimum, the

following storage recommendations must be observed.
Storage rooms for rubber products should be kept cool and dry. The storage
temperature should be +25° (+-2° C) and may not exceed or go below -10 °.
Disregarding the recommended temperature ranges will shorten the rubber products
shelf life.
All rubber materials must be stored away from heat producing equipments/and or
heating devices. The relative humidity should not exceed 65 %.
Always keep rubber materials away from direct sunlight and other sources of light with
UV radiation properties because this may give rise to ozone production that is
damaging rubber materials. Rubber materials must be therefore protected against
light under cover. Rubber materials should not come in direct contact with foreign
materials especially solvent, oils, greases and other contaminants. Rubber covered
drive pulleys - bend pulleys or others must be stored in such a way that no
deformation (by its own weight) is caused when being kept on the ground (they should
be stored in a relaxed condition free from tension, compression or other deformation).

5
3. Assembly of plummer block units and take-up block units
3.1. SNL housing and take-up block with Taconite sealing
Please read these recommendations before executing the assembly work!

1. Make sure that the environment is clean. Check dimensional and shape accuracy
of the shaft seating.
2. To ensure reliability and a long service life, machine the support surface with a
roughness of Ra < 12,5 µm, the planicity should be to IT7.
3. If the housing is mounted onto an adapter sleeve, determine the position of the
housing. The grease nipple arranged at one side of the housing cap should be placed
opposite to the sleeve nut in order to facilitate lubrication. If the housings are mounted
onto the shaft ends, the grease nipple should be placed on the same side as the end
cover. It is necessary to consider the complete housing since the housing base and
cap will only fit together as supplied.
4. Fix the housing on the support surface by means of the fastening screws (fig. 3.1).
Belt pulleys are always executed with a fixed and a movable bearing.
The fixed bearing of a drive pulley is always mounted on the journal side.
5. Slide the V-ring arranged in front of the bearing together with the labyrinth seal in
the right position onto the shaft. The sealing lip of the V-ring gasket must point
towards the bearing that will be mounted later! Arrange the split counter ring above
the V-ring gasket and the labyrinth seal. Since the two parts of the counter rings are
not interchangeable, make sure during assembly that they bear the same marking.
6. Mount the bearing on the shaft – either directly onto a stepped shaft or using an
adapter sleeve in case of a conical bore. The tight seating of the bearing is reached
when the radial play reduction coefficients respectively the axial shifting indicated in
table 3.5 are met. Check the radial play of the spherical roller bearing prior to
installation using a feeler gauge and mark the original position. Then completely fill
the bearing with the provided grease. Supply the rest of the recommended grease
quantity from one side into the housing base.

6
7. Mount the second seal in the same way as described under item 5. If the housing is
to be mounted on shaft ends, this second seal is omitted and an end cover is inserted
in the corresponding groove in the housing base (item 12) instead before placing the
cap over the base.
8. Fasten the labyrinth seals on the shaft by means of the hollow round cords and
align the O-rings on the split labyrinth seals.
9. Lay the shaft with bearings and seals in the housing base, taking special care that
the O-rings are not damaged.
10. Place the locating rings – if needed – at each side of the housing.
NB: Only use locating rings for fixed bearing arrangements, except for CARB bearings
that must be fixed in axial direction at both sides of the external ring by means of
locating rings.
11. Carefully align the housing. The vertical markings on the housing base ends and
on the side faces showing the seating centre can facilitate this. Then slightly tighten
the fastening screws in the base.
12. Lay the housing cap over the base and tighten the connecting bolts to the torque
recommended in table 3.4. Since the caps and bases of one housing are not
interchangeable with those of other housings, it should be made sure that the cap and
base bear the same marking.
13. Fully tighten the fastening screws in the housing base. The recommended
tightening torques are given in table 3.4.
14. Finally, before the first test run and with the shaft rotating, supply grease via the
nipple until it exudes at the labyrinth seals. The same grease as that used for
lubrication of the bearings should be used to lubricate the seals.

7
Fig. 3.1: Bearing assembly with Taconite seal /ND (SKF data)
Fig. 3.2: Take-up block units (SKF data)

8
3.2. SNL housing and take-up block with labyrinth sealing (TS)
Please thoroughly read these recommendations before executing the assembly

work!
of the shaft seatings.
5. Slip the labyrinth seal arrange in front of the bearing in the right position onto the
shaft.
6. Mount the bearing on the shaft - either directly onto a stepped shaft or using an
table 3.5 are met. Check therefore the radial play of the spherical roller bearing prior
to installation using a feeler gauge and mark the original position. Then completely fill

9
7. Slip the second labyrinth seal in the right position onto the shaft. If the housing is to
be mounted on shaft ends, this second seal is omitted and an end cover is inserted in
the corresponding groove in the housing base (item 11) instead before placing the
cap over the base.
8. Lay the shaft with bearings and labyrinth seals in the housing base.
NB: Only use locating rings for fixed bearing arrangements, except for CARB
bearings that must be fixed in axial direction at both sides of the external ring by
means of locating rings.
10. Carefully align the housing. The vertical markings on the housing base ends and
on the side faces showing the seating centre can facilitate this. Then slightly tighten
the fastening screws in the base.
13. Finally, with the shaft rotating, fit the hollow round silicone rubber cords into the
grooves of the labyrinth seals using a screwdriver.

10
Fig.3.3: Bearing assembly with labyrinth seal / TS (SKF data)

11
3.3. SNL housing and take-up block with double-lip seal (TG)
Please thoroughly read these recommendations before executing the assembly

work!
of the shaft seatings.
5. Fit one half of the seal into each of the grooves in the housing base. Fill the space
between both sealing lips with grease. If the housings are arranged at shaft ends, fit
an end cover into the second housing groove instead of the seal.
6. Mount the bearing on the shaft - either directly onto a stepped shaft or using an
table 3.5 are met. Check therefore the radial play of the spherical roller bearing prior
to installation using a feeler gauge and mark the original position. Then completely fill
7. Lay the shaft with bearings and seals in the housing base.

12
NB: Only use locating rings for fixed bearing arrangements, except for CARB
bearings that must be fixed in axial direction at both sides of the external ring by
means of locating rings.
9. Carefully align the housing. The vertical markings on the housing base ends and on
the side faces showing the seating centre can facilitate this. Then slightly tighten the
fastening screws in the base.
10. Fit the remaining seal halves into each of the grooves in the housing cap and fill
the space between the two sealing lips with grease.

13
Fig.3.3: Bearing assembly with double-lip seal / TG (SKF data)

14
Housing Recommended tightening torque [Nm]
Connecting bolts Fastening screws
SNL 509 50 90
SNL 510 50 90
SNL 511 80 220
SNL 512 80 220

SNL 513 80 220
SNL 515 80 220
SNL 516 80 430

SNL 517 80 430
SNL 518 150 430
SNL 519 150 430

SNL 520 200 430
SNL 522 200 750
SNL 524 200 750

SNL 526 350 750
SNL 528 350 1400
SNL 530 350 1400

SNL 532 350 1400
SNL 3134 350 750
SNL 3136 350 750

SNL 3138 350 750
SNL 3140 350 1400
SNL 3144 350 1400
SNL 3148 400 1400
SNL 3152 400 2400
SNL 3156 400 2400
SNL 3160 400 2400
SNL 3164 400 2400
SNL 3168
Table 3.4: Connecting bolts and fastening screws: tightening torques (SKF data)

15
1 2
Bearing bore Radial bearing play Axial shifting s Minimum admissible final play
reduction cone 1:12 after installation of bearings
with bearing play
above up to Min max min max Normal C3 C4
mm mm Mm mm mm mm mm mm mm
40 50 0,025 0,030 0,4 0,45 0,020 0,030 0,050

50 65 0,030 0,040 0,45 0,6 0,025 0,035 0,055
65 80 0,040 0,050 0,6 0,75 0,025 0,040 0,070
80 100 0,045 0,060 0,7 0,9 0,035 0,050 0,080
100 120 0,050 0,070 0,75 1,1 0,050 0,065 0,100
120 140 0,065 0,090 1,1 1,4 0,055 0,080 0,110
140 160 0,075 0,100 1,2 1,6 0,055 0,090 0,130
160 180 0,080 0,110 1,3 1,7 0,060 0,100 0,150
180 200 0,090 0,130 1,4 2,0 0,070 0,100 0,160
200 225 0,100 0,140 1,6 2,2 0,080 0,120 0,180
225 250 0,110 0,150 1,7 2,4 0,090 0,130 0,200
250 280 0,120 0,170 1,9 2,7 0,100 0,140 0,220
280 315 0,130 0,190 2,0 3,0 0,110 0,150 0,240
315 355 0,150 0,210 2,4 3,3 0,120 0,170 0,260
355 400 0,170 0,230 2,6 3,6 0,130 0,190 0,290
400 450 0,200 0,260 3,1 4,0 0,130 0,200 0,310
Table 3.5: Installation of spherical roller bearings with conical bore (SKF data)
1
Only applicable to solid steel shafts and axles.
2
It is imperative to check the final play if the radial play was in the inferior half of the tolerance
range before installation and if there are wide temperature differences between the internal
and external ring during operation; it must be made sure that the final play is not below the
specified minimum values.

16
4. Maintenance
4.1. General information
In order to avoid deteriorations during operation, systematic and regular checks of the
pulley body and the plummer block units are recommended.
In addition to checks in the course of daily operation, scheduled inspections should be

made to check the following:
• Do the pulleys rotate smoothly and noiseless?

• Is the rubber coating clean and intact?
• Are the bearings and sealing systems sufficiently greased?
• Is the admissible service temperature of the plummer blocks observed?

17
4.2. Bearings
In most of the applications of bearings, the grease quantity supplied during the
bearing assembly or after an inspection is enough to meet the needs until the next
routine inspection. The bearings should be regreased after 6 months at least.
Permanent lubrication of self-greasing labyrinth seals is admissible. In this case,
grease is forced into the seals until a grease ring exudes from the labyrinths.
Under certain service conditions, however, such as high rotational speeds (> 1000
U/min), service temperatures (> 70°) or stress, it might be necessary to reduce the
greasing intervals. Suitable greases for this purpose are lithium-saponified roller
bearing greases, the quality of which depends on the country of origin. We
recommend therefore the heavy-duty multi-purpose grease Shell Gadus S3 V220 21
that is suitable for temperatures ranging from – 20°C up to + 140°C.
All bearings, housings and labyrinth seals will be packed 100%. The required grease
quantities for regreasing are specified in table 4.1 below.
In this context, we explicitly refer to the detailed maintenance instructions of

the bearing manufacturers.
1
State of the art, subject to modifications

18
2
Housing Grease Grease quantity [g] for
Regreasing
SNL 509 Shell Alvania RL2 10

SNL 3168 Shell Alvania RL2
Table 4.1: Grease quantities (SKF)
2
State of the art, subject to modifications

19
4.3. Rubber coating
The rubber coatings are subject to a natural rubbing wear during operation. In addition
to this, dirt on the pulley surface and on the running surface of the belt as well as a
non-uniform distribution of the belt traction forces and particularly the belt extension
slip of drive pulleys might result in a super proportional wear effect.
In order to guarantee a maximum possible service life, the following advice should be
observed:
• Adhering material should immediately be removed from the pulley surface.
• The resistance of the existing rubber coating to oil, grease and chemical
substances should be checked. If the rubber coating is improperly subject to
such substances, it might swell or disintegrate.
• Unnecessary exposition to UV radiation should be avoided. Reserve pulleys

should be stored at a weatherproof place.
• Examine the rubber coatings for damages regularly, checking out particularly
the joints and the lateral surfaces of the coating segments. Any damages
should be repaired immediately.
• Clean the bearing and the running surface of the belt. Appropriate belt cleaning
systems serve to reduce the abrasive effect of adhering material onto the
rubber coating of the pulley.

20
5. Scope of supply
According to order documents
6. Appendix
3
Locking assembly inner Tightening screws Tightening torque per
diameter screw
[mm] [Nm]
60 M8 41
65 M8 41
70 M10 83
75 M10 83
80 M10 83
85 M10 83
90 M10 83
95 M10 83
100 M12 145
110 M12 145
120 M12 145
130 M12 145
140 M14 230
150 M14 230
160 M14 230
170 M14 230
180 M14 230
190 M14 230
200 M14 230
Table 6.1: Data sheet locking assembly TLK 133 (Tollok data)
3
DIN 912 / 12.9

21
3
Locking assembly inner Tightening screws Tightening torque per
diameter screw
[mm] [Nm]
170 M14 230

180 M14 230
190 M14 230
200 M14 230

220 M16 355
240 M16 355
260 M16 355

280 M20 690
300 M20 690
320 M20 690

340 M20 690
360 M22 930
380 M22 930

400 M22 930
420 M22 930
440 M22 930
460 M22 930
480 M22 930
500 M22 230
Table 6.2: Data sheet locking assembly TAS 3015 (TAS Schäfer data)
3
DIN 912 / 12.9

22
6.8 IDLERS
6.8.1 Idler documentation
 Carrying idlers, impact idlers, return idlers, training idlers

(Boom conveyor + Tripper car)
− General technical documentation for rollers (Contractor No. KD-ET-M-03001)

Blank page

SHOUGANG
PROJECT
TÍTULO TKIS Nº PAGE

GENERAL Technical Documentation For Rollers 1/5
CONTRACTOR Nº REV.
KD-ET-M-03001 A
REVISIONS
IT: ISSUE A - PRELIMINARY C - FOR INFORMATION E - FOR CONSTRUCTION G - AS BUILT
TYPE H - CANCELED
B - FOR APPROVAL D - FOR QUOTATION F - AS PURCHASED
Rev. IT Description By Chec Appr Aut. Date

.
A B INITIAL ISSUE GWQ LWW 13/03/15
SHOUGANG
PROJECT

CONTRACTOR Nº REV.
KD-ET-M-03001 A
INDEX
ITEM DESCRIPTION PAGE
1.0 PRODUCTION DECRIPTION 3
2.0 TRANSPORTATION 3
3.0 STORAGE 4
4.0 ASSEMBLY 4
5.0 OPERATION 4
6.0 MAINTENANCE 4
7.0 REPAIR 5
SHOUGANG
PROJECT

CONTRACTOR Nº REV.
KD-ET-M-03001 A
1.0 PRODUCTION DECRIPTION
Shanghai Keda heavy industry Group Co.,Ltd idlers are designed either for installation
into a rigid supporting structure or for suspension into garlands,according to the shaft end
design.
Our idlers are composed of the following main components
Idler cylinder
Welded special idler cylinder (Material Q235B or Q345B) in compliance with Chinese
standard GB13793-2008. The idler cylinder and bearing house are welded together.The
idler jacket is provided with a plastic coat.Bearing seat in tolerance zone N7,cylinder
shape tolerance with Chinese standard GB/T1182-1996 .
For heavy loads, the idler botton is optionally available as bearing support turned from
the solid.
Axle
The idler axle is made of round bar steel(20) in accordance with Chinese standard
GB/T3078. The axle ends are machined in consideration of the design specifications
Roller bearing
Grooved ball bearing in accordance with Chinese standard GB/T276-94,standard
tolerance in accordance with Chinese standard GB307-84,radial tolerance range C4
with glass fiber reinforced polyamide 6.6.The roller bearings are provided with lifetime
lubrication and thus maintenance-free
Sealing system and locking element
The bearing are sealed from the outside by means of a multiple labyrinth,a dust cao
and a waterproof cap.At the rear side,the bearing is sealed by means of a lamellar
sealing disc.
The bearing are locked by means of circlip (GB894.1-86)
2.0 TRANSPORTATION
Rollers shall be put in vacuum PE or aluminium foil bags with dessicant in it, and the
bags shall be in a wooden box according to the HPE regulation so that they form
appropriate form of transportation. The transportation of loose idlers is not allowed.
Lifting devices in accordance with the relevant regulations must be used for discharge
and reloading. Grabs, buckets or electromagnets are prohibited for loading.
When being lifted, the wooden box must hang balanced.

SHOUGANG
PROJECT

CONTRACTOR Nº REV.
KD-ET-M-03001 A
Do not attach the lifting device to the tightening straps or to the axle ends of the rollers.
3.0 STORAGE
The general storage condition must ensure that no premature deterioration occurs
during the 18 month outdoor storage period.
Use appropriate lifting devices to reload the rollers.
The minimum ground clearance must be at least 100mm. storage of secured stack is
allowed. A maximum of 2 packages may be stacked.
Stacking of the packing is not admissible on unreinforced ground.
For outdoor storage, appropriate measures must be taken to guarantee stability on
reinforced ground. Use appropriate protective covers in order to prevent the formation
of condensation water.
4.0 ASSEMBLY
Attention shall be given to the installation of belt conveyor rollers, since the assembly
quality is critical for the functionality of the belt conveyor and the service life of the idler.
Support elements for the idler must be mounted vertically with regard to the belt
running direction. Holders and support elements must be connected firmly with the
conveyor system in order to avoid shifting or loosening.
The rollers shall be installed by a slight strike either with hand or with a rubber or
plastic hammer. No metal hammer is allowed. Do not support the rollers impulsively on
the axle ends during installation. .
5.0 OPERATION
In case of failure of one idler, the recommendation is that the whole conveyor shall be
stopped. If impossible, the lowering device shall be used to disengage the idler.
If, due to material accumulation, an idler turns completely or partly in the material,
remove the adhering material.
Soiling of the contact surface might cause the following damage to the idler:
Rubber wear of the roller body
Freezing of the material during prolonged stop
Insufficient heat exchange, danger of overheating and fire
Soiling and deterioration of the sealing system
6.0 MAINTENANCE
6.1 General Instructions
In order to prevent any interference during operation, the rollers shall be examined
systematically and regularly.
Apart from checks during daily operation, scheduled inspection of both the stopped
and running conveyor shall be made every one month to check the following:
SHOUGANG
PROJECT

CONTRACTOR Nº REV.
KD-ET-M-03001 A
Does the roller rotate smoothly and noiselessly?

Is the idler jacket intact?
Is the axial locking effect still sufficient?
Maintenance work must never be performed on rollers during operation!

If the potential damages are not borne in mind, then subsequent damage to the belt
conveyor and to the entire conveyor system might happen.
7.0 REPAIR
Repair of standard idlers is not allowed.
When dismounting rollers that will still be used in the future, the rotational sense must
be clearly marked.
When installing the dismounted rollers, maintain the previous rotational sense.
In order to repair the idler garland, replace the failed idler.
6.9 CENTRAL LUBRICATION SYSTEMS (ACCESORIES)

6.9.1 Manual and automatic lubrication systems
 Arrangement drawings
− LUBRICATION PIPING / Tripper car belt pulleys: Dwg. no. 4554941
− CENTRAL LUBRICATION SYSTEM / Travel gear: Dwg. no. 4554921
− CENTRAL LUBRICATION SYSTEM / Slewing gear: Dwg. no. 4554942
 User manual / Documentation
− Cover sheet / Contents
 Lubrication plans and parts lists
− Central lubrication system / Tripper car belt pulleys (18 Lubrication points):
Drawing A867.340 Bl.2 with parts list
− Central lubrication system / Travel gear (24 Lubrication points):

− Central lubrication system / Slewing gear (24+4+2 Lubrication points):

 Pump stations
− Pump station 205-10XYBU-1KR+1SVP in case:

Part- / Drawing no. 655-45326-6 with parts list
 User manuals
− Multiline pump Model 205: User manual (2.1EN-18003-D11)
− Quicklub - Progressive metering devices for Grease and Oil

Model SSV, SSV-E and SSVM:
User manual / Operating instructions (2.2EN-20001-J11)
− Pump P205 / Article no.245-00101-1: Motor datasheet (FSB/014/J/10)
− Ultrasonic sensor: Data sheet (9.3A-70004-C05)

Blank page

User manual
Documentation
OBJECT : Zentralschmieranlagen
CODE : SHOUGANG
CUSTOMER : Thyssenkrupp Industrial

Solutions AG
Postfach 42 60
66377 St. Ingbert
ORDER-N° : 260439
SUPPLIER : SKF Lubrication System

Germany GmbH
POSTFACH 1263
69183 WALLDORF
SKF Lubrication Systems Germany GmbH

1/2
Hauptverwaltung, Standort Walldorf Standort Berlin Standort Hockenheim
Heinrich-Hertz-Str 2-8 Motzener Str. 35/37 2. Industriestr. 4
D-69190 Walldorf · Deutschland 12277 Berlin 68766 Hockenheim
Tel. +49(0)6227 33-0 Tel. +49(0)30 72002-0 Tel. +49(0)6205 27-0
Fax. +49(0)6227 33-259 Fax. +49(0) 30 72002-111 Fax. +49(0)6205 27-101
Geschäftsführer: Volker Pieschel Sitz der Gesellschaft Registergericht Schweinfurt, HRB 6841 Ust-IDNr. DE814727059
CONTENTS:
Lubrication plans and parts lists
Manual lubrication Plan, Part list A867.340 Bl.1
Automatic lubrication Plan, Part list A867.340 Bl.4
Automatic lubrication / Plan, Part list A867.340 Bl.7

Hand Schmierung
Pumpstations
P205 in case Plan, Part list 655-45326-4
User manuals:
P205 User manual 21DE-18003-E11
Metering device SSV User manual 22DE-20001-J11
Motor Datasheet 245-00101-1
Ultraschallsensor Datasheet 93G-70004-C05
2/2
Pos.2+5 aus Angebot
Pos.5 on offer
2.1-2.4 2.1-2.4 2.1-2.4
6 5 6 5 6 5
4 3 4 3 4 3
2 1
2.5 2 1 2.5 2 1 2.5
2.6-2.9 2.6-2.9 2.6-2.9
2.10 2.10 2.10
2.11 2.11 2.11
Anziehmomentangaben
TIGHTENING TORQUE INDICATIONS
11 ±0,55Nm
Rückschlagventil CHECK VALVE
SSV... Kunde / Fahrzeughersteller Benennung
15 ±1,5Nm
1 2 Verschlußschraube CLOSURE PLUG
ZSA für Shougang 18SST
3 4 CLS FOR SHOUGANG 18SST
15 ±1,5Nm Thyssen Krupp
5 6
SSV-N, SSV-NP Versuchs-Nr./Auftrags-Nr.
10 ±1Nm Steckverschraubung
PUSH-IN FITTING
Schneidringverschraubung D 22.9.14 Helmut Datum Name 260439
17 ±1,7Nm FERRULE FITTING
C 26.3.14 HelmutBearb. 31.10.13 Gr Schema / Ablagennummer Blatt
Eingangsverschr. INLET FITTING
10 ±1Nm (trocken) DRY B 21.3.14 HelmutGepr. 31.10.13 bgoeggerle
7,5 ±0,75Nm (geölt) LUBRICATED A 27.1.14 Alexan Norm
A867.340Bl.2 von
Befestigungsschr. FASTENING SCREW Zust. Änderung Datum Name (Ers.f.:
SW
)
Parts List
CLS
PBM/024/B/06
CLS for Shougang
Order No. 260439
Drawing No. A867.340Bl.2 Index D
Item Pcs. Description Part No.
2.1 3 ST MET.DEV. SSV 6-E-K-RV6VA/CLOSED 619-46800-1

2.2 6 ST SCREW,HEX. 8.8 M 6X 45C 200-13092-3
2.3 6 ST TOOTH LOCK WASHER ST J 6,4Z 210-12161-3
2.4 6 ST NUT,HEX 8 M 6C DG 207-12135-5
2.5 72 M TUBE,NIRO 1.4571 D 6,0X1,0 106-35203-4
12
2.6 0 ST SCREW,THREAD.ROLLING 3,5X 9,5VA 206-13710-7
2.7 72 ST TUBE CLAMP 1.4571 D 6(1X) 226-13716-1
2.8 12 ST TUBE CLAMP 1.4571 D 6(2X) 226-13716-2
2.9 12 ST TUBE CLAMP 1.4571 D 6(3X) 226-13716-3
2.10 24 ST TB.FITT.VA G 6-L 223-13615-5
2.11 18 ST TB.FITT.VA GE 6-LL M 10X1,0K 223-13658-5
A867.340Bl.2 Index D eng.doc Subject to change without notice page 1 of 1

LINCOLN GmbH  Postfach 1263  D-69183 Walldorf  Tel +49 (6227) 33-0  Fax +49 (6227) 33-259
Pos.3 aus Angebot
Pos.3 on offer
3.1,3.5-3.7 3.2,3.5-3.7 3.8 3.3,3.5-3.7 3.1,3.5-3.7 3.4-3.7

3.9-3.12 6 5
3.8 8 7 8 4 3 8 7 6 5
6 5 6 5 2 1 6 5 4 3
4 3 4 3 4 3 2 1
2 1 2 1 2 1
3.8
3.13
3.13 3.13
3.14 3.9-3.12 3.14
Anziehmomentangaben
11 ±0,55Nm
15 ±1,5Nm ZSA für Shougang 24 SST
1 2 Verschlußschraube CLOSURE PLUG
3 4 Thyssen Krupp CLS FOR SHOUGANG 24 SST
15 ±1,5Nm
5 6
PUSH-IN FITTING D 22.9.14 Helmut Datum Name 260439
17 ±1,7Nm Schneidringverschraubung
FERRULE FITTING C 26.3.14 HelmutBearb. 11.11.13 Gr Schema / Ablagennummer Blatt
Eingangsverschr. INLET FITTING
B 20.3.14 HelmutGepr. 11.11.13 bgoeggerle
10 ±1Nm (trocken) DRY A867.340Bl.3
A 27.1.14 Alexan Norm von
7,5 ±0,75Nm (geölt) LUBRICATED
Befestigungsschr. FASTENING SCREW Zust. Änderung Datum Name SW (Ers.f.:
)
Parts List
CLS
PBM/024/B/06
CLS for Shougang
Order No. 260439
3.1 2 ST MET.DEV. SSV 8/4-E-K-RV6VA/CLOSED 619-46562-8

3.2 1 ST MET.DEV. SSV 8-E-K-RV6VA/CLOSED 619-46562-9
3.5 10 ST SCREW,HEX. 8.8 M 6X 45C 200-13092-3
3.7 10 ST NUT,HEX 8 M 6C DG 207-12135-5
3.8 72 M TUBE,NIRO 1.4571 D 6,0X1,0 106-35203-4
11
3.10 72 ST TUBE CLAMP 1.4571 D 6(1X) 226-13716-1
3.11 20 ST TUBE CLAMP 1.4571 D 6(2X) 226-13716-2
3.12 2 ST TUBE CLAMP 1.4571 D 6(4X) 226-13716-4
3.13 24 ST TB.FITT.VA G 6-L 223-13615-5

Pos.4 im Angebot Pos.4a im Angebot
Pos.4 on offer Pos.4a on offer
4.1 4.1.1
4.1.9 4.1.10,4.1.11
4.7
M 4.8,4.9 M 4.1.6,4.1.7
4.2,4.4-4.6 4.1.12
4.10 4.1.2-
4.11 4.1.5 4.1.14
4.12-4.18 8 7 4.1.16
6 5
4 3 8 7
6 5
4.1.13
2 1 4.12-4.18
4 3
2 1
4.1.17
4.12-4.18 4.19 4.3-4.6
4.1.14- 4.1.18
6 5 6 5 6 5 6 5
4.1.16 4.1.17
4 3 4 3 4 3 4 3
2 1 2 1 2 1 2 1
4.20 4.20
Anziehmomentangaben
11 ±0,55Nm
15 ±1,5Nm
1 2 Verschlußschraube CLOSURE PLUG ZSA für Shougang
3 4
15 ±1,5Nm Thyssen Krupp CLS FOR SHOUGANG
5 6
PUSH-IN FITTING
17 ±1,7Nm Schneidringverschraubung D 22.9.14 Helmut Datum Name 260439
FERRULE FITTING
Eingangsverschr. INLET FITTING C 26.3.14 HelmutBearb. 14.11.13 Gr Schema / Ablagennummer Blatt
10 ±1Nm (trocken) DRY B 20.3.14 HelmutGepr. 14.11.13 bgoeggerle
7,5 ±0,75Nm (geölt) LUBRICATED A 27.1.14 Alexan Norm
A867.340Bl.4 von
Befestigungsschr. FASTENING SCREW
Zust. Änderung Datum Name SW (Ers.f.:
)
Parts List
CLS
PBM/024/B/06
CLS for Shougang
Order No. 260439
Pos.4
4.1 1 ST PUMP STATION 205-10XYBU-1KR+1SVP I.CASE 655-45326-6

4.2 1 ST MET.DEV. SSV 8/4-K-RV6VA/GE10VA 619-46645-5
4.3 4 ST MET.DEV. SSV 6-K-RV6VA/GE6VA 619-46381-6
4.4 10 ST SCREW,HEX. 8.8 M 6X 45C 200-13092-3
4.6 10 ST NUT,HEX 8 M 6C DG 207-12135-5
4.7 6 M TUBE,NIRO 1.4571 D 10,0X1,5 106-35203-2
4.8 6 ST TUBE CLAMP 1.4571 D10(1X) DG 226-13673-1
4.9 6 ST SCREW,HEX A2 M 6X 12 200-13607-5
4.10 2 ST TB.FITT.VA G10-L 223-13615-6
4.11 66 M TUBE,NIRO 1.4571 D 6,0X1,0 106-35203-4
14
4.13 66 ST TUBE CLAMP 1.4571 D 6(1X) 226-13716-1
4.14 16 ST TUBE CLAMP 1.4571 D 6(2X) 226-13716-2
4.15 8 ST TUBE CLAMP 1.4571 D 6(3X) 226-13716-3
4.16 8 ST TUBE CLAMP 1.4571 D 6(4X) 226-13716-4
4.17 4 ST TUBE CLAMP 1.4571 D 6(5X) 226-13716-5
4.18 4 ST TUBE CLAMP 1.4571 D 6(6X) 226-13673-6
4.19 22 ST TB.FITT.VA G 6-L 223-13615-5
Pos 4a
4.1.1 1 ST PUMP STATION 205-10XYBU-1KR+1SVP I.CASE 655-45326-6

4.1.2 1 ST MET.DEV. SSV 8/4-K-RV6VA/GE10VA 619-46645-5
4.1.3 2 ST SCREW,HEX. 8.8 M 6X 45C 200-13092-3
4.1.4 2 ST TOOTH LOCK WASHER ST J 6,4Z 210-12161-3
4.1.5 2 ST NUT,HEX 8 M 6C DG 207-12135-5
4.1.6 2 ST BUTTON HEAD LUBR.FITT.ST AM10X1,0-16Z 251-14045-8
4.1.7 4 ST TB.FITT.VA GE 6-LL M 10X1,0K 223-13658-5
Parts List
CLS
PBM/024/B/06
CLS for Shougang
Order No. 260439
4.1.9 6 M TUBE,NIRO 1.4571 D 10,0X1,5 106-35203-2

4.1.10 6 ST TUBE CLAMP 1.4571 D10(1X) DG 226-13673-1
4.1.11 6 ST SCREW,HEX A2 M 6X 12 200-13607-5
4.1.12 2 ST TB.FITT.VA G10-L 223-13615-6
4.1.13 30 M TUBE,NIRO 1.4571 D 6,0X1,0 106-35203-4
4.1.14 42 ST SCREW,THREAD.ROLLING 3,5X 9,5VA 206-13710-7
4.1.15 30 ST TUBE CLAMP 1.4571 D 6(1X) 226-13716-1
4.1.16 6 ST TUBE CLAMP 1.4571 D 6(2X) 226-13716-2
4.1.17 10 ST TB.FITT.VA G 6-L 223-13615-5
4.1.18 2 ST TB.FITT.VA GE 6-LL M 10X1,0K 223-13658-5

400 800 ohne Tür gezeichnet
DRAWN WITHOUT DOOR 1:10
19
20
A A
1000
400 Schmierstoff
GREASE
10
11
13
150
13
0
1 4 5 6 7 3 bei Montage geschweißt und gebohrt Schema/schematic layout
50
150
100
U
A-A
23
2 18 8 9 10 17 15 14 16
ø10
M
50
Schmierstoff
GREASE
K E Alt
Oberflächen nach
J D DIN ISO 1302
Neu
~ Rz100 Rz25 Rz6,3 Rz1
H C
375
275
G B Allgemeintoleranzen nach 0,5-6 >6-30
DIN ISO-mK 2768 >30-120 >120-400 >400-1000
F A in +/-mm 0,1 0,2 0,3 0,5 0,8
Index Datum Name Index Datum Name Name Datum Werkstoff
Volumen: Kanten ISO/128 Erstellt afriesen 29.08.2014
DIN ISO -0,1 Methode 1 Geprüft bgöggerle 03.09.2014
Masse: 13715 -0,3
Archiviert
Benennung Maßstab
PUMPENSTATION 205-10XYBU-1KR+1SVP I.SCHR
1:5
PUMP STATION 205-10XYBU-1KR+1SVP I.CASE
890 Typ V-Nr. Format Blatt
Schutz-
960 P205 vermerk A 2
nach Zeichnungs-Nr. / Sach-Nr. von
Ersatz für: DIN 34
beachten
Ersetzt durch: 655-45326-6 SW
Parts List
PBM/017/F/06
Product Description: PUMP STATION 205-10XYBU-1KR+1SVP I.CASE
Part-/Drawingno.: 655-45326-6 Index 0
Offer-/Orderno.:
Item Pcs Unit Description Part No.

1 1 ST CONTR.BOX 800x1000x400 ROUGH 237-11093-1
2 1 ST BOTTOM PLATE,ONE-PIECE 5001.014 236-10606-7
3 0,8 M STEEL,L 80X 80X 8 S235JR 1.0037 101-35047-8
4 1 ST P205-M070-10XYBU-1KR-460 655-41263-9
5 4 ST SCREW,HEX 8.8 M10X 30C 200-12008-4
6 4 ST WASHER ST 10 C -200HV 209-13077-2
7 4 ST RIVET,BLIND NUT ST M 8 A3C CR 1,5-4,5 206-10290-5
8 1 ST TB.FITT.VA GE10-S G 1/4A 223-12452-9
9 1 ST TB.FITT.VA SV10-S 223-12564-3
10 1 ST WASHER A4 18 -200HV 209-13683-9
11 1 ST TB.STUD VA EL10-S 223-14244-7
12 1 ST VALVE SVP -350-S12 624-28362-1
13 1 M TUBE,NIRO 1.4571 D 10,0X1,5 106-35203-2
14 1 ST CABLE GLAND PL M16X1,5 237-13497-2
15 1 ST JAM NUT MS M16X1,5 237-13496-2
16 1 ST CABLE GLAND PL M20X1,5 237-13497-3
17 1 ST JAM NUT MS M20X1,5 237-13496-3
18 35 M CABLE,OELFLEX 810 4X0,75MM2 113-35077-8
19 1 ST ADHES.LAB.LOGO LC/SKF 127X101TRANSPARENT 810-53389-1
20 1 ST TYPE LABEL D/GB/ES 70X 45 810-55013-2
Änderungen vorbehalten Ausgabedatum: 12.11.2014 Seite 1 von 1
LINCOLN GmbH * Postfach 1263 * D-69183 Walldorf * Tel +49 (6227) 33-0 * Fax +49 (6227) 33-259
User Manual
Multiline Pump Model 205
2.1EN-18003-D11
501 7p07
Subject to modifications
SKF Lubrication Systems Germany GmbH ● Heinrich Hertz-Str. 2-8 D-69190 Walldorf Tel. +49(0) 6227 33-0 ● Fax: +49 (0) 6227 33-259
User Manual
2.1EN-18003-D11
Table of Contents
Page Page
Preface .... ........ .............. ....................... ...................... ...... 2 Operati ng I nstructi ons
Safety Instructions Commissioning . ...................... ............... ....... ............... ...... 8
Hazard marking in the operating instructions .............. ...... 3 … when grease is dispensed .................. ............... ...... 8
Staff qualification and training ................ ...................... ...... 3 … when fluid lubricants are dispensed .... ............... ...... 9
Hazards resulting from failure to observe the Adjustment of the lubricant output .......... ....... ............... .... 10
saf ety instructions ..... ....................... ...................... ...... 3
Safety-conscious working ...................... ...................... ...... 3 Maintenance and Repair
Safety instructions Assembly and disassembly of pump elements ............ .... 11
… for the User/Operator .................. ...................... ...... 4
… for maintenance, inspection and installation work ... 4 Troubleshooting .................... ............... ....... ............... .... 12
Unauthorized modification and spare parts Technical Data . ...................... ............... ....... ............... .... 13
production . ........ .............. ....................... ...................... ...... 4
Inadmissible operating modes ............... ...................... ...... 4 Component Parts of the Pump 205 ........... ............... .... 14
Appropriate use .............. ....................... ...................... ...... 4
Appendix: Dimensions ......... ...................... ............... .... 18
Identification Code ....... ....................... ...................... ...... 5
Operating Mode ............ ....................... ...................... ...... 6 Data Sheet ....... ...................... ...................... ............... .... 24
Pump elements .............. ....................... ...................... ...... 7
Erection and Installation EC Declaration of Conformi ty ............. ....... ............... .... 27
Erection of the pump ...... ....................... ...................... ...... 8
Electric connection ......... ....................... ...................... ...... 8
Preface
The Owner`s Manual The Operating Instructions
is itended to familiarize the user with the pump/lubrication contain important information for the safe, correct and
system and to be enable him to use it adequately economic operation of the pump/lubrication system. Their
must always be available on the site where the observance will help avoid hazards,
pump/lubrication system is in operation reduce repair costs and downtime,
must be read and used by all persons who are charged increase the reliability and prolong the service life of the
with working with the pump/lubrication system, e. g. pump/lubricat ion system.
- Operation, including adjustment, troubleshooting during must be supplemented by the respective national regula-
operation, elimination of production waste, maintenance, tions concerning the prevention of accidents and prot ection
disposal of process materials of the environment.
- Maintenance (inspection, repairs) and/or General
- Transport
This Owner’s Manual only refers to the high-pressure
Persons who do not have a good command of the multiline pumps of the 205 series.
English language must be informed by the user of the
pump/lubrication system on the contents of the Owner’s It is intended for the personnel charged with the installa-
Manual, particularly the Safety Instructions, before tion, operation and maintenance of the pump.
they carry out the work.
Pag 2 f 28
User Manual
2.1EN-18003-D11
Safety Instructions
The Operating Instructions include general instructions Staff Qualification and Training
which must be followed when a pump/lubricating unit is
installed, operated or serviced. Therefore, it is absolutely The staff responsible for operation, maintenance, inspec-
necessary for the fitter and specialist/user to read the Op- tion and installation must be adequately qualified f or these
erating Instructions before a unit is installed and put int o jobs.
operation. The Operating Instructions must always be The user must properly regulate the field of responsibility
available on the site where the machine/system is installed. and supervision of the personnel.
All general safety instructions contained in this main If the personnel is not in command of the necessary ex-
chapter on safety must be observed as well as all special pertise, they must receive the appropriate training and in-
safety instructions given in other main chapters. structions. If necessary, this can be done by the manu-
facturer/supplier on behalf of the machine user.
Hazard Marking in the Operating Furthermore, the user must ensure that the contents of t he
Instructions Operating Instructions are fully understood by the per-
sonnel.
Hazards Resulting from Failure to Observe

Safety symbol
acc. to DIN 4844-W9
the Safety Instructions
Failure to heed the safety warnings may result in damage
1371 a94
to equipment and the environment and/or personal injury.
The notes referring to safety contained in the Operating
Failure to observe the safety notes may result in the loss of
Instructions whose failure to observe them may result in
all claims for damage.
personal injury are marked by t he symbol above.
As an example, in the following we list some dangers which
may result from failure to observe the warnings:
- failure of machine/system to fulfill important functions
Safety symbol - failure of specified methods for maintenance and repair
acc. to DIN 4844-W8
- personal injury due to electrical, mechanical and
4273 a00
chemical influences
This symbol warns of an electrical current. - danger to the environment due to leakage of harmful
materials
If ignoring the safety note might result in machine dam-
ages and malfunction, the word CAUTION is added.
Warnings directly fixed to the machine must always be Safety-Conscious Working
observed and must be kept in completely legible condi-
tion. Observe:
- the safet y instructions given in the Operat ing Instruc-
tions,
- the prevailing national regulations for the prevention of
accidents
- any working and shop regulations and accident preven-
tion measures of the user
When handling lubricants and other chemical substances,
observe the safety prescriptions valid for the product.
P 3 f 28
User Manual
2.1EN-18003-D11
Safety Instructions, continuation
Safety Instructions for the User/Operator Unauthorized Modification and Spare Parts
Production
If warm or cold machine parts present hazards, t he cus-
tomer must protect them against accidental contact. Alteration and modif ications of the machine are only al-
Do not remove protection devices for moving parts while lowed if approved by the manufacturer.
the machine is in operation. Original spare parts and accessories authorized by the
Leakages of harmful materials must be disposed of so as manufacturer ensure safe operation.
not to jeopardize neither persons nor the environment. The If other parts are used, the manuf acturer may be released
requirements of the law must be satisfied. from its liability f or the resulting consequences.
Danger caused by electrical current must be excluded (for
det ails refer to the applicable specif ications of VDE and the
local power supply companies).
Inadmissible Operating Modes
The operational safety of the supplied products is only
granted if the product is operated according to the instruc-
Safety Instructions for Maintenance, In- tions given in the chapter “Appropriate use“ of the Owner’s
spection and Installation Work Manual. The maximum ratings listed in the Technical Data
must never be exceeded.
The user must make sure that all maintenance, inspection
The commissioning of the product (pump/pump unit) is
and installation work is executed by authorized and quali-
forbidden within t he EU until it has been stated that the
fied experts who have thoroughly read the Operating In-
structions. machine concerned on which the product will be mount ed
is in conformity with the EU guidelines.
On no account may work be done on the machine while the
machine is in operation. Follow all notes f or shutting down
the machine as described in the Operating Instructions. Appropriate Use
Decontaminate pumps and pump units delivering harmful
materials. The pump model 205 is exclusively designed for use in
centralized lubrication systems f or dispensing lubricant s.
Reassemble all safety and prot ection devices immediately
after completion of the cleaning procedure. The maximum ratings mentioned in the Technical Data,
particularly the maximum operating pressure of 350 bar,
Dispose of material harmful to the environment in accor- must not be exceeded.
dance with the applicable official regulations.
The multiline pump model 205 is a central lubrication pump
Before putting the pump/pump unit into operation, ensure with 1 to 5 pump elements and thus 1 to 5 out lets. The high
that all points given in the chapter “Commissioning“ are pump operating pressure of 350 bar allows the pump to be
fulfilled. used as a multiline pump for the direct supply of lubrication
points and also as a central lubrication pump in large-sized
progressive systems.
The great diversity of pump models allows the 205 multiline
pump to be used for a wide range of applications, e.g.
- machines in the beverage industry
- machines in t he conveying technology (cranes, drives for
conveyors, conveyor worms)
- machines in the construction industry
- eccentric presses, forging machines n
Any other use is not in accordance with the instructions and
will result in the loss of claims for guarantee and liability.
Pag 4 f 28
User Manual
2.1EN-18003-D11
Identification Code
The complete pump unit is defined by a t ype code on the nameplate.
Code examples: P205 - M 070 - 4 XY N - 5 K6 - 380-420 / 440-480

P205 - M 070 - 5 X B - 1 K7 - 380-420 / 440-480
P205 - F 280 - 4 XY BU - 1 K7
P205 - M 700 - 8 XY BU - 2 K6 - 380-420 / 440-480
P205
Basic type (housing assembly)
Housing assembly for all pump models
Drive assembly
M = Three-phase flanged motor
The motor designation with extension e. g. for voltages,
frequencies, explosion-proof design is added to the type code
F = Free shaft end
Gear ratio i
280 = i = 280 : 1
700 = i = 700 : 1
070 = i = 70 : 1
Reservoir assembly
4 = 4 l pl astic reservoir
5 = 5 l sheet metal reservoir
8 = 8 l pl astic reservoir
XY = Reservoir for grease and oil
N = Reservoir wit hout level control

BU = Reservoir wi h level control
Note: The ultrasonic sensor is equipped with 2 switching points: High- and low-level control.
If only one low level control is desired, the corresponding contacts must be connected. A 24 VDC supply
voltage is required for the sensor.
Pump element assembly
1 bis 5 = Number of the pump elements
K5 = piston diameter 5 mm
KR = Pump element adjustable, piston diameter 7 mm
Extensions for the motor designation, e. g.

380-420, 440-480 = Standard mul i-range motor for network rated
volt ages 380-420 V/50 Hz and 440-480 V/60 Hz
000 = pump without motor, however with connecting flange
P 5 f 28
User Manual
2.1EN-18003-D11
Mode of Operation
The pump essentially consists of the main components

shown in Fig. 1-1.
The worm gear 6 reduces the speed of the driver motor to
the speed of the eccentric shaft.
The eccent ric shaft 4 causes the piston lodged in the
pump element 5 to move to and from, with the result that
the lubricant is sucked and dispensed to t he outlet via a
check valve.
The eccent ric shaft simultaneously drives the stirring
paddle 3. The rotating movement of the stirring paddle
makes sure that the lubricant is homogenized and di-
rected into the suction boreholes of the pump element.
5018p 07
Fig. 1-1 Sectional drawing of the pump 205

1 - Housing 5 - Pump element
2 - Lubricant reservoir 6 - Worm gear
3 - Stirring paddle with scraper 7 - Drive motor
4 - Eccentric shaft 8 - Level control
Pag 6 f 28
User Manual
2.1EN-18003-D11
Mode of Operation, continuation
Pump element
Suction phase
10 03a95
Fig. 1-2 The pump element sucks in lubricant

1- Eccentric 2- Piston 3- Spring 4- Check valve
Dispensation phase
10 04a95
Fig. 1-3 The pump element dispenses lubricant

1- Eccentric 2- Piston 3- Spring 4- Check valve
Pump element with adjustable lubricant output

The mode of operation (suction and supply phase) is the
same as that of the pump elements with an invariable lu-
bricant out put.
The lubricant outputs are adjustable f rom 0.04 to
0. 18 ccm/stroke, or 0.7 to 3 ccm/min.
The pump element s are factory-adjusted to the maximum
lubricant output; the adjusting dimensions “S” should be
29 ± 0.1 mm (see fig. 2-1).
Fig. 1-4 Adjustable pumpelement

P 7 f 28
User Manual
2.1EN-18003-D11
Erection of the pump Electric connection

Requirements on the installation site:
- protected from dust and dirt
- safe against atmospheric influences (not e the type of CAUTION!
protection of the electric motor) All electrical works should be carried out
- enough space for opening the reservoir cover and exe- only by qualified personnel.
cuting the maintenance work (the required space de-
pends on the pump size) 4273 a00
- even, solid and vibration-free installation site Electric connection of the dri ve motor:
Depending on the pump design, it may be necessary to
Terminal wiring diagram under the cover of the terminal
connect the drive. The direction of rotation of the pump
box
and thus that of the driving shaft is clockwise.
Fuse protection in accordance with the national regula-
In the case of pumps with a free shaft end or an oscillating
tions in force; rated current consumption: see motor data
drive take care that the max. admissible speed of the
sheet in annex
drive or number of strokes is adhered to (see Technical
Data). For special motors, please see the technical data on the
motor type plate
Protect the drive motor against overcurrent/overload.
Observe local regulations.
Electric connection of the level controls:

Refer t o the respective terminal diagrams in the annex
and to the elect rical wiring diagram
Commissioning … when grease is dispensed

Pumps with low speed of the stirring paddle
Before commissioning the pump fill the reservoir with
(< 10 rotations)
lubricant.
In the case of pumps with a slow drive (speed of the stir-
ring paddle up to approx. 10 rpm) fill in so much oil for the
ATTENTION ! first operation that the pump elements are entirely cov-
When filling the reservoir pay attention ered by oil.
that no dirt or foreign particles enter the Then fill in the grease to be dispensed by the pump.
reservoir. Â Swit ch the pump on.
Always refill the reservoir in time. Â Retighten the pump element if the pump is equipped with
the maximum number of pump elements. Wait until the
1371 a94 Avoid contamination in the pump area. grease emerges from all t he outlet ports.
Do not touch internal parts of the reservoir while the pump is Â Adjust the desired outputs at the adjustable pump ele-
in operation. Risk of injury due to the stirring paddle. ments.
All system components which are connected downstream of Â Swit ch the pump off.
the pump and on which the hydraulic pump pressure has an Â Connect the tube lines which are filled with grease to the
influence (e.g. progressive plunger metering devices, tube outlet ports.
lines, tube fittings, hoses) must be designed for maximum The system is ready for operation.
system pressure.
The lubricant output of adjustable pump elements can be
Mount supply lines professionally. Screw components changed any time (see „Adjustments of the pump ele-
together firmly. ment“). To do so, the outlet tube fitting has to be removed.
Protect each pump element against overpressure by means
of an adequate safety valve (max. opening pressure:
350 bar).
Pag 8 f 28
User Manual
2.1EN-18003-D11
Operating Instructions, continuation
Pumps with speed of sti rring paddle > 10 rpm Commissioning when fluid lubricants are
dispensed
Â Unscrew any closure plug or pump element from the
housing. Â Switch the pump on.
Â Switch the pump on. Â As soon as the lubricant emerges from the outlet ports
The pump elements remain adjusted to zero delivery until switch the pump off and connect the lubricant feed lines.
grease leaks from the threaded hole in the housing. The system is ready for operation.
The time required for this ranges from 5 minutes for very
fast running pumps to 5 hours for extremely slow running
pumps. The ambient temperature and grease consistency
have a significant impact on the time required.
Â Retighten the pump element if the pump is equipped with
the maximum number of pump elements. Wait unt il the
grease emerges from all the outlet ports.
Â Adjust the desired outputs on the pump elements.
Â Switch the pump off.
Â Screw the closure plug in again.
Â Connect the tube lines which are filled with grease to the
out let ports.
The system is ready for operation.
The lubricant output of adjustable pump element s can be
changed any time (see „Adjustments of the pump ele-
ment“). To do so, the outlet tube fitting has t o be removed.
P 9 f 28
User Manual
2.1EN-18003-D11
Operating Instructions, continuation
Adjustment of the lubricant output
B-P203-020d08
Fig. 2-1 Sectional view: adjustable element

1 - Adjusting spindle SW 16 (width over flats) Determine deviation for maximum adjusting measure “Smax “:
2 - counternut SW 24 Â Loosen count ernut 2 (fig. 2-1).
3 - pump element body SW 27
4 - gasket 5 - pump cylinder Â Unscrew adjusting spindle 1 out of pump element body 3.
6 - control piston 7 - delivery piston
S max - max. adjusting measure of the adjusting spindle
Â Screw counternut 2 completely onto t he adjusting spin-
dle 1.
Â Determine and note down maximum adjusting measure
IMPORTANT “S max“. Deviation = S max – 29 mm
Before adjusting the output volume exactly, IMPORTANT
determine the maximum adjusting measure
“Sm ax“. The determined deviation must be consid-
6001a 02 ered for each adjusting measure:
max. adj. measure “Smax “, e.g. ….. 29.5 mm
600 1a02
- deviation …….....….….…..…….. + 0.5 mm
required output volume, e.g. 0.14 ccm/stroke
- adjusting measure “S“ (fig. 2-1) ….. 28 mm
S 0,14 = S + deviation
Adj. measure “S 0,14“ …. 28 + 0,5 = 28,5 mm
Adjustment of the lubrication output:

Â Remove pressure relief valve from pump element KR.
Â Determine adjusting measure S (including deviation) for
the required output volume by means of the output diagram
(fig. 2-2).
Â Loosen count er nut 3 (fig. 2-1) while holding in position
pump element body 2.
Â Adapt adjusting measure S at the adjusting spindle 1.
- Increase “S“ …………………... increase output
- Reduce “S“ …………………..….. reduce output
417 9a99
Â Fix pump element body 3 and secure position of adjusting
Fig. 2-2 Lubrication output diagram
3
spindle with counternut 2.
A - Lubrication output cm /min
3
B - Lubrication output cm /stroke
S - Adjusting measure in mm (without deviation)
Pag 10 f 28
User Manual Wa¿ne
2.1EN-18003-D11
Maintenance and Repair
Assembly and disassembly of pump

ATTENTION ! elements
Before undertaking any repair on the pump Preli minary works
observe the following instructions.
Â Switch the pump off and clean it on the outside.
1371 a94 Â If the pump is filled with grease, the grease can remain in
the pump. Fluid lubricants must be drained (unscrew the
closure plug or the pump element).
Switch the drive motor or mechanical drive off and protect it
from inadvertent restart. Risk of injury by the stirring pad- Â If the stirring paddle stays ahead of a pump element which
dle. must be disassembled, turn it until it is on the opposite side.
Slowly loosen the pressure connection fittings on the pump ATTENTION !
elements in order to decrease the pressure in the pump
and in the system. The delivery pistons cannot be exchanged!
Risk of injury due to lubricant splashing under high pres- When assembling or disassembling several
sure. pump elements take care that each delivery
piston remains in the pump cylinder. The
Repairs may only be carried out by qualified, skilled per- delivery pistons are adjusted in the pump
sonnel using originalreplacement parts. cylinder with a tolerance of only few mi-
1371 a94
Provided that the pump dispenses only clean lubricant, it crometers.
does not need any particular maintenance. Since the drive
shaft and the pump elements are covered by the lubricant Disassembl y of pump elements
which is fed by the pump they are lubricated automatically.
Â Unscrew the tube line from the outlet port of the pump
They are however subject to a natural wear which depends element.
on the operating time and operating pressure and must
therefore be replaced. Â Apply the fork wrench at the threaded plug of the pump
element 3 (Fig.2-1) and carefully unscrew the pump ele-
ment.
IMPORTANT Assembly of pump elements
For cleaning reservoirs made of plastic do Â Unscrew the closure plug.
not use polar organic solvents such as al-
cohol, methyl alcohol, acetone or similar. Â Screw the pump element into the housing by hand and
60 01a02
then tighten it using a fork wrench (SW 27). Tightening
torque: 30 - 35 Nm.
Â If fluid lubricants are dispensed, fill them into the reservoir.
Â Put the pump into operation (see chapter „Operating In-
structions“).
Maintenance of the ultrasonic sensor (Reservoir "…XYBU")

Â Keep the sensor face absolutely clean.
Repl acement of gears or drive motors

Â Before assembling gears or drive motors apply a special
paste (e.g. Klüber paste 46MR401) at the boreholes and
shaft ends
P 11 f 28
User Manual
2.1EN-18003-D11
Troubleshooting
Fault: The pump does not dispense the lubricant
Cause: Remedy … by operator personnel
Reservoir empty Â Fill the reservoir with lubricant and vent t he pump, if nec-
essary.
NOTE
Depending on the ambient temperature
and/or the lubricant it may be that the pump
elements need about 10 minutes to be fully
6001a 02
operative.
Cause: Remedy … by serivce personnel

Air bubbles in the lubricant Â Loosen the threaded outlet fitting at the pump element and
let the pump operate until the lubricant emerges without air
bubbles.
Suction borehole of the pump element clogged Â Disassemble the pump element and check whether foreign
particles are lodged in the suction borehole. Remove
them, if there are any.
Check valve defective or clogged Â Replace check valve .
Delivery o r control pist on worn Â Replace p ump e lem ent.
Motor d efective Â Replace motor.
Fault: Blockage in the progressive system connected downstream of the pump

Cause: R emedy … by service personnel
Bearing, lines or progressive metering device clogged Â Find out the cause of the blockage and eliminate it. I f the
The fault can be identif ied as follows: blockage is due to a progressive metering device, discon-
a) grease leaking from the pressure relief valve nect all connecting lines one af ter another until the pump
b) the indicator pins fitted to the metering device pistons resumes delivery. The blockage is locat ed in the tube line of
are not moving t he fitting which was the last to be unscrewed
IMPORTANT Service address:
All the repairs which are beyond the knowl- 6.)/XEULFDWLRQ6\VWHPV*HUPDQ\*PE+

edge of the user’s personnel must be car- Abt. Zentraler Kundendienst
ried out by 6.)experts. Postfach 1263
For this, return the defective pump to the D-69183 Walldorf
60 01a02
repair department of the Walldorf works or
call for a specialist who will carry out the
repair on site.
Pag 12 f 28
User Manual
2.1EN-18003-D11
Technical Data
Number of outlets ........... ....................... ...................... .. 1 to 5
NOTE NOTE
If the pump is equipped with its maximum On request with electric level control.
number of pump elements (i.e. 5) the
thread hole G 1/4 of the filler fitting can be 60 01a02
6001 a02 used as filling connection.
NOTE
Threaded connection ..... ....................... ..................... G 1/4” i
Plastic reservoirs are not fully resistant t o
Filling connection (accessory):
glycol and polyglycol oils and greases.
(part no. 304-17571-1) ... ....................... ..................... G 1/4” i
60 01a02
or (part no. 304-17574-1) ...................... ..................... G 1/2” i
1)
max. operating pressure ..................... ..................... 350 bar
Kind of drive:
1)
protection required by means of an adequate overpressure - with worm gear
valve: - with worm gear and free shaft end
Pressure relief valves with thread for all types of reservoirs: - with worm gear and flange for three-phase AC motor
SVEVT-350-G1/4AD6 .... ....................... ....... SN 624-28070-1
SVEVT-350-G1/4AD8 .... ....................... ....... SN 624-28714-1 Ratio ......... ...................... ......................... 700: 1 280:1 70:1
Suitable lubricants: Rated speed of drive:

- ............ .................. Lubricating grease up to NLGI grade 2 1340 rpm .. ...................... ....................... ...................... . 50 Hz
- ............ ...................... ..................NLGI grade 3 on request Min. speed of the stirring paddle ............ ...................... . 2 rpm
- ............ ...... Mineral oils with a viscosity of min. 20 mm 2 / s (lower speeds on request, depending on t he lubricant and
temperature)
Max. speed of the stirring paddle ........... ............... ...... 35 rpm
IMPORTANT
When changing the type of grease or refill-
NOTE
ing different grease you have to check
whether the greases are fully miscible. In the case of lubricating grease of NLGI
6001 a02 grades 1 - 3 the speed of the eccentric
shaft must not exceed 20 rpm.
60 01a02
Lubricant output per piston stroke:
for pump element K5 piston Ø 5 mm ..... ................... 0.10 ccm
for pump element K6 piston - Ø 6 mm .. ................... 0.15 ccm Sound level ..................... ....................... ............... < 70 dB(A)
for pump element K7 piston - Ø 7 mm .. ................... 0.22 ccm Einsatztemperatur
for pump element KR, adjustable .......... ........ 0.04 – 0.18 ccm - for pumps without Ultraschallsensor .... ...... –20 C bis + 80 C
Lubricant output during continuous operation .......... see t able - für Pumpen inkl. Ultraschallsensor ...... ...... –20 C bis + 70 C
(depending on the ratio and drive speed) Gewichte:
Gehäuse ... ...................... ....................... ..................... 2.66 kg
Ratio 70:1 280:1 700:1 Get riebe 1-stufig (70:1) ... ....................... ..................... 0.95 kg
Get riebe 2-stufig (280:1, 700:1) ............. ..................... 2.03 kg
K5 115 ccm 29 ccm 11 ccm Drehst rommotor .............. ....................... ..................... 3.02 kg
K6 172 ccm 43 ccm 17 ccm freies Wellenende ........... ....................... ..................... 0.61 kg
K7 253 ccm 63 ccm 25 ccm Behälter 4XYN ................ ....................... ............... ...... 1.45 kg
Behälter 5XYN ................ ....................... ............... ...... 2.19 kg
KR 46-200 ccm 11.5-52 ccm 5-22 ccm
Behälter 8XYN ................ ....................... ............... ...... 1.72 kg
Ultraschallsensor ............ ....................... ..................... 0.20 kg
Pump element K5, K6, K7, KR .............. ............... ...... 0.15 kg
NOTE
In the case of 60 H z mot ors the lubricant
output is increased by 20%.
Electric equipment
Three-phase flanged motor:
6001 a02
Technical data on enclosed motor data sheet (see annex)
Accessories: (depending on the grade of equipment of the
The lubricant outputs listed above are valid for a lithium soap pump)
grease of NLGI grade 2 (basic oil viscosity mm²/s at 40°C) at Sensor for low- and high-level control (ultrasonic sensor) for
room temperature. At lower temperatures (below 0°C), the grease (reservoir “XYBU”) see technical data sheet (see
lubricant output may decrease depending on the grease cha- annex)
racteristics.
Output per hour

(with mot or dirven pumps, speed 1340 rpm):
Reservoir sizes ............. ....................... .............. 4, 5 or 8 dm 3
P 13 f 28
User Manual
2.1EN-18003-D11
Component Parts of the Pump 205
5020p 07
Pag 14 f 28
User Manual
2.1EN-18003-D11
Component Parts of the Pump 205, continuation
Pos. Designation Qty. Part no. Pos. Designation Qty. Part no.
1.1 Housing 1 313-19694-1 9 Reservoir, assy. 1

1.2 Rotary shaft seal 20x32x7 1 220-13059-1 4XYN (4l plastic) 655-28734-1
Housing, assy. 1 555-32116-1 5XYN (5l metal sheet) 655-28735-1
2.1 Intermediate bott om with 1 455-24460-1 8XYN (8l plastic) 655-28736-1
grooved ball bearing 9.1 Lid for 4l and 8l reservoirs 1 444-24234-1
2.2 Hexagon socket head screw 5 201-13668-5 9.2 Stirring paddle, assy. 1
M 6x16 C microencapsulated
for 4l and 8l reservoirs 555-32113-1
2.3 Washer A 6,4 C 3 209-13011-5
for 5l reservoir 555-32117-1
2.4 Washer A 6,4 C 2 209-13011-5
9.3 Fixed paddle 2 455-24465-1
3 O-ring 137x3 1 219-13084-1
10 Adapter ring 1 455-24459-1
4 Retaining ring A 20x1, 2 1 211-12164-5
11 O ring 210x5 1 219-13730-9
5.1 Eccentric shaft 1 455-24458-1
20 Drive, assy. 1
5.2 Feather key A 5x5x28 1 214-12174-3
Gear 70:1 a. motor 0,09 kW 380- 245-13932-1
5.3 Axial bearing washer 2 250-14175-1 415/420-480V, 50 Hz
5.4 Needle bearing with inner ring 1 250-14006-8 Gear 70:1 a. motor 0,09 kW 245-13935-1
20x35x17 290/500V, 50 Hz
6 Hexagon socket head screw 4 201-12594-3 20.1 Three-phase a.c. flanged motor 1
M 5x30 C 0,09 kW, 1500 min-1 380- 245-13504-5
6.1 USIT ring 6,2x9,2x1,0 4 220-12238-7 415/420-480V, 50 Hz
6.2 Nut M5 C 4 207-14176-1 0,09 kW, 1500 min-1 290/500V, 245-13590-1
50 Hz
7 Sealing ring 40 x 70 x 0,5 1 306-19713-1
20.2 Packing 50,0 x 80,0 x 0,5 1 306-19714-1
8 Pump element 1
20.3 Hexagon head screw M 5 x 16C 3 200-13017-9
with piston ∅ 5 mm 600-26875-2
20.4 Gear i = 70 : 1 1 246-14174-1
Hydraulic lubrication nipple 1 251-14045-9
Sonar-sensor
adjustable 655-28716-1 1 664-36972-4
205U1-5BL-L190 EEX
8.1 Closure plug M22 x 1,5 x 12 303-19285-1
- Ultrasonic sensor 1 237-12464-1
8.2 Sealing ring ∅ 22,2 x ∅ 27 x 1,5 306-17813-1 (st andard)
- Locking 1 237-10254-1
P 15 f 28
User Manual
2.1EN-18003-D11
Component Parts for Drive “Free Shaft End“
5021p 07
Pos. Designation Qty. Part no. Pos. Designation Qty. Part no.
21 D rive for free shaf t end with 21.9 Sealing ring 50,0 x 80,0 x 0,5 1 306-19714-1
Gear 70 : 1 drive 205-F070 1 655-28733-1 21.10 Hexagon head screw M 5 x 16C 4 200-13017-9
Gear 280 : 1 drive 205-F280 1 655-28740-1 21.12 Gear
Gear 700 : 1 drive 205-F700 1 655-28732-1 - Reducing 70 : 1 1 246-14174-1
21.1 R adial seal 12 x 32 x 7 1 220-13087-3 - Reducing 280 : 1 1 246-14174-2
21.2 R etaining ring I 32 x 1, 2 1 211-12448-3 - Reducing 700 : 1 1 246-14174-3
21.3 R etaining ring A 12 x 1,0 2 211-12164-2
21.4 Angular ball bearing D 12/32x10 1 250-10683-6
21.5 Feather key A 4 x 4 x20 1 214-12173-6
21.6 D rive shaft 1 455-24462-1
21.7 Feather key A 3 x 3 x 20 1 214-12173-7
21.8 Bearing flange 1 455-24461-1
Pag 16 f 28
User Manual
2.1EN-18003-D11
Component Parts for Drive “Double Gear and Motor“
5022p 07
Pos. Designation Qty. Part no.
22 D rive, assy. 1
Gear 280 :1, motor 0,09 kW
- 380-415, 50Hz/420-480V, 60Hz 245-13933-1
- 290/500V, 60Hz 245-13936-1
Gear 700 :1, motor 0,09 kW
- 380-415, 50 Hz/420-480V, 60Hz 245-13934-1
- 290/500V, 50Hz 245-13937-1
22.1 Three-phase motor 0,09 kW 1
- 380-415, 50Hz/420-480V, 60Hz 245-13504-5
- 290/500V, 50Hz 245-13510-2
22.2 Sealing ring 50,0 x 80,0 x 0,5 1 306-19714-1
22.3 H exagon head screw M 5 x 16 C 3 200-13017-9
22.4 Gear 1
R educing 280 : 1 246-14174-2
R educing 700 : 1 246-14174-3
P 17 f 28
User Manual
2.1EN-18003-D11
Annex: Dimensions
Dimensioned drawing for pump 205, single-stage gear, 4/8l plastic reservoir, motor drive
5023p 07
Pag 18 f 28
User Manual
2.1EN-18003-D11
Annex: Dimensions, continuation
Dimensioned drawing for pump 205, single-stage gear, 4/8l plastic reservoir, free shaft end
5024p 07
P 19 f 28
User Manual
2.1EN-18003-D11
Dimensioned drawing for pump 205, single-stage gear, 5l sheet metal reservoir, motor drive
5025p 07
Pag 20 f 28
User Manual
2.1EN-18003-D11
Dimensioned drawing for pump 205, single-stage gear, 5l sheet metal reservoir, free shaft end
5026p 07
P 21 f 28
User Manual
2.1EN-18003-D11
Dimensioned drawing for pump 205, two-stage gear, 4/8l plastic reservoir, motor drive
5027p 07
Dimensioned drawing for pump 205, two-stage gear, 5l sheet metal reservoir, motor drive
5029p 07
Pag 22 f 28
User Manual
2.1EN-18003-D11
Dimensioned drawing for pump 205, two-stage gear, 4/8l plastic reservoir, free shaft end
5028p 07
Dimensioned drawing for pump 205, two-stage gear, 5l sheet metal reservoir, free shaft end
5030p 07
P 23 f 28
User Manual
2.1EN-18003-D11
Data Sheet
Motor data sheet

Standard motors for pump model 205
Multi rage motors Single range motor Uni ts
Pump model 205 205
Motor type DIM 56B4 DIM 56B4
Frequency f 50 60 50 [Hz]
Nominal power P 0.09 0.11 0,09 [kW]

-1
Nominal speet n 1340 1610 1340 [min ]
Rated troque M 0.64 0.65 0.64 [Nm]
Nominal current IN 0.78 at 220-240 V …….. 0.62 at 290 V [A]
0.45 at 380-415 V …….. …….. [A]
…….. 0.78 at 243-277 V …….. [A]
…….. 0.45 at 420-480 V 0.36 at 500 V [A]
Starting current ratio IA / IN 2.6 2.6 2.9 [A]
Power factor cos ϕ 0.67 0.67 0.62
Efficiency η 57 57 52 [%]
Frame size 56 56
Type of construction B 14/V18 B 14/V18
Type of portection IP 55 56
Insulations class F F
Weight ca. 2.9 aporox. 2.9 [kg]
Flange Ø 80 Ø 80 [mm]
Shaft end Ø 9 x 20 Ø 9 x 20 [mm]
The multi range motors can be connected to the followi ng networks:

220/380 V ± 5%, 50Hz
230/400 V ± 10%, 50Hz
240/415 V ± 5%, 50Hz
254/440 V ± 5%, 60Hz
265/460 V ± 5%, 60Hz
Other voltages and/or special designs available on request.
The single range motor can be connected to the following networks:

290/500 V ±10%, 50Hz
Motor wit hout gear part no. 245-13510-2

Motor wit h gear 70 : 1 part no. 245-13935-1

Pag 24 f 28
User Manual
2.1EN-18003-D11
Data Sheet, continuation
Data Sheet for Ultrasonic Sensor

Reservoi r size: Part no.: Hysteresis „High level“ HV 20mm
Hysteresis „Low level“ HL 70mm
4 L plastic reservoir 664-36939-1 Switching point fault 0.17% / K
5 L sheet metal reservoir 664-36939-2 Supply:
8 L plastic reservoir 664-36939-3 Rated operational voltage UE 24 VDC
Operational voltage range UB 20.. .30 VDC
Description of operation Admissible residual ripple 10%
This remote sensor is a solid st ate proximity type f or 24 VDC Open-circuit power consumption <60 mA
which uses the echo delay-time method for distance sensing. It Switching output:
senses a sound-reflecting object which enters the sound cone Rated normal current IE <200 mA
from any direction. The objects to be sensed may be solid or Voltage drop UD <3 V
liquid. Spurious switch-on pulse suppressed
Switching function „High level“: NO contact,
switching on plus
Installation
„Low level“: NC contact,
Figure I (dimensions in mm) switching on plus
Any mounting position Typical values:
Keep a free space around the sound cone of a distance “x“ Availability delay 250 ms
(x = 60 mm) from reflecting objects (figure II) Reflection area 10 x 10 mm2
Ultrasonic frequency 400 kHz
Connection Switching frequency 8 Hz
By means of cable socket (figure III) part no. 237-13442-2 Resolution 1 mm
Pin Type of protection IP 65
1 L+ DC 20...30 V
2 S1 Switching output „high-level“(NO) EX protection – relevant data:
3 L- Ground (GND) Accordance wit h the 94/9/EC (ATEX) Directive is proved by
4 S2 Switching output „low-level“(NC) compliance with the EN 50021, EN 50281-1-1 and EN
The connections are polarised, short-circuit proof and over- 60947-5-2 standards.
load-proof. In the case of electrical faults it is recommended to
use shielded lines. Appropriate use
Use in explosive areas
Zone 2 following classification II 3G
Operation (explosive gas atmosphere)
Switching range (figure IV) Zone 22 following classification II 3D
a Unusable blind zone (explosive dust atmosphere)
b Sensing range Special conditions for safe operation:
c Overfill range The area around the push-in fitting has to be protected
HV Hysteresis „High level“ against mechanical damage.
HL Hysteresis „Low level“
The objects are sensed reliably in the set switching range The push-in fitting has to be secured by means of a locking
within an opening angle of the sound cone of 5°. I f the re- mechanism (part no. 237-10254-1) to prevent a separation
flecting conditions are good, the objects can also be sensed by hand.
outside of the sound cone. Keep the blind zone “a“ free from After unpacking protect the push-in fitting against serious
objects. These would lead to undefined switching states. Take concentrat ions of dust or water.
care that the surface of the transducer is clean! Installation and start-up
The devices have been admitted for an ambient tempera-
Display:
ture of - 20°C to +70°C.
Reservoir empty H2 is lit
Filling level 0K H2 is not lit The devices may be erected, connected and started up by
Reservoir full H1 is lit authorized and qualified personnel only.
Supply voltage H3 is lit: green Knowledge regarding the assignment of the classif ication
Overf ull signal H3 is lit: red to the respective allowed explosive areas is a prerequisite.
The push-in fitting must never be connected or discon-
Technical Data nected while voltage is applied.
Ambient temperature -25...70° C Maintenance and trouble-shooting
Sensing range 50...500mm 1)
The devices do not require any maintenance.
1)
measured from t he housing surface
Sensing distance „High level“ S1 60mm* The devices may not be modified.
Sensing distance „Low level“ S2 depends on the Repairs on the devices are not possible.
reservoir size
In the case of a replacement, observe the points described
above.
P 25 f 28
User Manual
2.1EN-18003-D11
Data Sheet, continuation
Data sheet for Ultrasonic Sensor, continuation

Installation
6333 b04
Fig. II
Connection
633 2b04
Fig. I Height 30 mm
6334 b04
Fig. III
Operation
Voll Leer
S1 S2
1 1
H1 H2 H3
an aus rot
S1 S2
1 1
H1 H2 H3
an aus grün
S1 S2
0 1
H1 H2 H3
aus aus grün
S1 S2
0 0
H1 H2 H3
aus an grün
S1 - Schaltabstand Voll
S2 - Schaltabstand Leer
Niveau steigend
B-P205-090a11 Niveau fallend

Fig. IV
Pag 26 f 28
User Manual
2.1EN-18003-D11
Original Language
D GB F E I
EG- EC Declaration Déclaration CE Declaració n CE Dichiarazione CE
Kon formitätserklärung of conformity de conformité de con formid ad di conformità
Hiermit erklären wir, dass die Herewith we declare that the Par la présente, nous décla- Por la presente, declaramos Si dichiara che l prodot to da
Bauart von model of rons que le produit ci-dessous que el modelo suministrado noi fornito
Multiline Pump 205

in der von uns gelieferten in the version supplied by us dans la version dans laquele en la versión suministrada nella versione da noi fornita
Ausführung den Bestimmun- corresponds to the provisions nous le livrons est conforme corresponde a las è conforme a tutti i requisiti
gen allen einschlägigen of all pertinent fundamental aux réglementations régissant disposiciónes de los requisitos basilari prescritti in termini di
grundlegenden Sicherheits- health and safety require- toutes les exigences fonda- pertinentes y fundamentales sicurezza e di salute, incluse
und Gesundheitsanforderun- ments, including all modifica- mentales de sécurité et celles de salud y seguridad en su le modific he vigenti al
gen entspricht, einschließlich tions of this directive valid at relatives à la santé, y compris redacción vigente en el momento della dichiarazio-
deren zum Zeit punkt der the time of the declaration. les amendements en vigueur momento de instalación. ne.
Erklärung geltenden Ände- Applied harmonized stan- au moment de la présente Normas armonizadas Norme armonizzate applica-
rungen. dards in partic ular: déclaration. utilizadas, partic ularmente: te in particolare:
Angewendete harmonisierte Normes harmonisées, notam-
Normen, insbesondere: ment :
Maschin enrichtlinie Machinery Directive Directive machines Directiva de máquinas Direttiva Macchine
2006/42/EG 2006/42/EC 2006/42/CE 2006/42/CE 2006/42/CE
DIN EN ISO 12100 – Teil 1 & 2 – Part 1 & 2 – Parties 1 & 2 – Parte 1 & 2 – Parte 1 e 2
Sicherheit von Maschinen Safety of machinery Sécurité de machines Seguridad de máquinas Sicurezza delle macchine
Grundbegriffe, allgemeine Basic terms, general design Notions fondamentales, directi- Términos básicos, axiomas Concetti basilari, principi
Gestaltungsleitsätze guidelines ves générales d’élaboration generales de diseño guida generali
DIN EN 908
Pumpen und Pumpen geräte Pumps and pump units Pompes et grou pes Bombas y equipos de Pompe e dispositivi
für Flüssigkeiten for liquids de pompes p our liquides bombas para líquidos di pompag gio per liquidi
Allgemeine sicherungs- Exigences en matière Prescripci ones generales Requisiti generali di sicurezza
General safety requirements
technische Anforderungen de sécurit é technique referente a la seguridad tecnica
EMV-Richtlinien EMC directives Réglementations CEM Directivas CEM Direttive EMC

2009/19/EG 2009/19/EC 2009/19/CE 2009/19/CE 2009/19/CE
Kraftfahrzeug Automotive véhicules automobile vehículo autoveicolo
2004/108/EG 2004/108/EC 2004/108/CE 2004/108/CE 2004/108/CE
DIN EN 61000-…
Fachgrundnormen: Generic emission standards: Normes fondamentales : Normas especiales fundam.: Norme specific he fondam.:
- Störaussendung - Emitted interference - Emission de parasites - Emisión de interferencias - Emissione di interferenze
… Teil 6-4 a) … Part 6-4 a) … Partie 6-4 a) … Parte 6-4 a) … Parte 6-4 a)
… Teil 6-3 b) … Part 6-3 b) … Partie 6-3 b) … Parte 6-3 b) … Parte 6-3 b)
- Störfestigkeit - Noise immunity - Résistance aux brouillages - Resistencia a interferencias - Resistenza alle interferenze
… Teil 6-2 a) … Part 6-2 a) … Partie 6-2 a) … Parte 6-2 a) … Parte 6-2 a)
b) b) b) b) b)
… Teil 6-1 … Part 6-1 … Partie 6-1 … Parte 6-1 … Parte 6-1
a) a) a) a) a)
für Industriebereiche for industrial environment pour domaine industriel para áreas ndustriales per settore industria le
b)
für Wohnbereich, Geschäfts- b) for residential, commercial b)
pour domaines de l’habitation, b) para áreas resi denciales, b)
per il settore residenziale,
und Gewerbebereiche sowie and light industry des magasi ns et de l’artisanat comerciales e industriales commerciale, industria le e
Kleinbetriebe ainsi que des petites tanto como pequeñas per le piccole imprese
entrepris es empresas
Doku mentations- Responsable du Service Encargado/a de la Responsabile della

Documentation agent
b evollmächtigter de documentation documentación do cumentazione
Wolfgang Studer • Heinrich-Hertz-Str. 2-8 • 69190 Walldorf
Walldorf, Nov 30, 2009, Dr.-Ing. Z. Paluncic

Director Research & Development
P 27 f 28
User Manual
2.2EN-20001-J11
Quicklub - Progressive Metering Devices

for Grease and Oil
Model SSV, SSV-E and SSV M
B-SSV-000a11
User Manual
2.2EN-20001-J11
Manufacturer:
SKF Lubrication Systems Germany GmbH
Heinrich Hertz-Str. 2-8 D-69190 Walldorf
Tel. +49(0) 6227 33-0 Fax: +49 (0) 6227 33-259
E-Mail: Lubrication-germany@skf.com
© SKF All rights reserved
P 2 f2
User Manual
2.2EN-20001-J11
Table of Contents
Page Page
Introduction Operation
Explanation of Symbols Used ........................................... 4 Applications ................................................................... 10
User’s Responsibility ........................................................ 4 Lubricant Distribution within the Metering Device ............ 12
Environmental Protection .................................................. 4 Phase 1 + 2 .............................................................. 12
Service ............................................................................. 4 Phase 3 - 5 ............................................................... 13
Monitoring of the Operation ............................................ 14
Safety instructions System-dependent monitoring .................................. 14
Appropriate Use ............................................................... 5 Visual monitoring ...................................................... 14
General Safety Instructions ............................................... 5 Electrical monitoring (microprocessor control) ........... 15
Accident Prevention Regulations ...................................... 5 Pressure relief valve ................................................. 15
Operation, Maintenance, Repair ....................................... 5 Determining the Lubricant Output by Combining Outlets . 16
Installation ........................................................................ 5 Tube Fittings, Screw-Type ........................................ 16
Tube Fittings, Push-in-Type (main metering device) .. 17
Installation Tube Fittings, Push-in-Type
Tube Fittings, Screw-Type ................................................ 6 (secondary metering devices) ................................... 18
Main- and secondary Metering devices ........................ 6
Tube Fittings, Push-in Type .............................................. 6 Troubleshooting ........................................................... 19
Metering Devices ......................................................... 6
Check Valves .............................................................. 6 Technical Data
Connection of the High-pressure Hose and Metering Devices ........................................................... 21
the Pressure Plastic Tube ........................................... 7 Lines .............................................................................. 21
Pressure Plastic Tubes and High-pressure Hoses ............ 8 Push-in-Type Tube Fittings ............................................ 21
Tightening torques ......................................................... 21
Description Dimensions .................................................................... 22
Progressive Metering Devices Model SSV, SSV-E Metering Devices Model SSV 6 to 22 &
and SSV M ....................................................................... 9 SSV6-E to 22-E ........................................................ 22
Progressive Plunger Metering Devices – General ........ 9 Metering Devices SSV M 6 to 12 .............................. 22
Features of a Progressive Metering Device ................. 9
Different of Features from SSV, SSV-E and SSV M ... 10 EC Declaration of incorporation .................................. 23
Further Information can be found in the following manuals:
Technical Description Quicklub - Pump 203
Technical Description for “Electronic Control Units” of pump 203:

1)
Printed-Circuit Board 236-13857-1 - Model H
1)
Printed-Circuit Board 236-10697-1 - Model V10 - V13
1)
Printed-Circuit Board 236-13870-3 - Model M 00 - M 15
1)
Printed-Circuit Board 236-13870-3 - Model M 16 - M 23
Installation Instructions
Parts Catalogue
List of Lubricants
Planning and Layout of Quicklub Progressive Systems
1)
The model designation of the printed-circuit board is part of the pump model designation indicated on the pump nameplate,
e. g. : P 203 - 2XN - 1K6 - 24 - 1A1.10 - V10
P 3 f 24
User Manual
2.2EN-20001-J11
Introduction
Explanation of Symbols Used

The following description standards are used in this manual: Furthermore, you will find the following text symbols in this
Safety Instructions manual:
Structure of safety instructions: Listing of applicable statements
Pictogram - Subpoint of applicable statements
Signal word 1. Determination of the number or sequence of contents
Danger text Procedural instruction
- Danger note
- How to avoid danger User's Responsibility
The following pictograms are used in this manual and are To ensure the safe operation of the unit, the user is responsi-
combined with the corresponding signal words: ble for the following:
1. The pump / system shall be operated only for the intend-
ed use (see next chapter "Safety Instructions") and its
design shall neither be modified nor transformed.
2. The pump / system shall be operated only if it is in a
proper functioning condition and if it is operated in ac-
cordance with the maintenance requirements.
1013A94 4273a00 6001a02 3. The operating personnel must be familiar with this User
- ATTENTION - ATTENTION - NOTE Manual and the safety instructions mentioned within and
observe these carefully.
- CAUTION - CAUTION - IMPORTANT
- WARNING - WARNING 7KHFRUUHFWLQVWDOODWLRQDQGFRQQHFWLRQRIWXEHVDQGKRVHVLI
The signal words give the seriousness of danger if the follow- QRWVSHFLILHGE\6.)LVWKHXVHU
VUHVSRQVLELOLW\
ing text is not observed: /LQFROQ*PE+ZLOOJODGO\DVVLVW\RXZLWKDQ\TXHVWLRQVSHU
WDLQLQJWRWKHLQVWDOODWLRQ
ATTENTION refers to faults or damages on
machines.
CAUTION refers to bad damages and possi- Environmental Protection
ble injuries. Waste (e.g. used oil, detergents, lubricants) must be dis-
WARNING refers to possible dangerous inju- posed of in accordance with relevant environmental regula-
ries. tions.
NOTE indicates improved operation of the
device.
IMPORTANT indicates special operating fea- Service
tures of the device.
7KHSHUVRQQHOUHVSRQVLEOHIRUWKHKDQGOLQJRIWKHSXPS
Example: V\VWHPPXVWEHVXLWDEO\TXDOLILHG,IUHTXLUHG6.)
RIIHUV\RXIXOOVHUYLFHLQWKHIRUPRIDGYLFHRQVLWHLQVWDOODWLRQ
ATTENTION! DVVLVWDQFHWUDLQLQJHWF:HZLOOEHSOHDVHGWRLQIRUP\RX
When making use of other than the tested DERXWRXUSRVVLELOLWLHVWRVXSSRUW\RXSXUSRVHIXOO\
spare parts, serious damage may affect
your device. ,QWKHHYHQWRILQTXLULHVSHUWDLQLQJWRPDLQWHQDQFHUHSDLUV
DQGVSDUHSDUWVZHUHTXLUHPRGHOVSHFLILFGDWDWRHQDEOHXV
1013A94
WRFOHDUO\LGHQWLI\WKHFRPSRQHQWVRI\RXUSXPSV\VWHP
7KHUHIRUHDOZD\VLQGLFDWHWKHSDUWPRGHODQGVHULHVQXPEHU
RI\RXUSXPSV\VWHP
P f2
User Manual
2.2EN-20001-J11
Safety Instructions
Appropriate Use Installation

Use the SSV, SSV-E and SSV M lubricant metering devices Install the metering devices at a suitable location in ac-
only for dispensing lubricants in centralized lubrication sys- cordance with the lubrication diagram.
tems.
It is recommended that the metering devices be installed in
Suitable Lubricants such a way that the outlets are not close to the chassis or
The progressive metering devices model SSV can be used the attaching plate. This will facilitate troubleshooting in the
for dispensing case the system is blocked.
2
- mineral oils of at least 40 mm /s (cST) or The main metering devices with indicator pin must be
installed in such a way that the indicator pin is easily visible.
- greases up to the penetration class NLGI 2
When the push-in type fittings are used, note the follow-
IMPORTANT ing:
For the metering device inlet use only push-in type
It must nevertheless be ensured that the fittings (R 1/8) with reinforced collar and sealing ring.
oils or greases used do not alter their con-
For the outlet tube fittings of the SSV divider valve
sistency significantly in the course of time or
6001a02 under the influence of temperature or (M 10x1) depending on the design of the lubricant line, for
pressure. example
- high-pressure plastic hose (Ø 4.1 x 2.3) use valve bodies
with reinforced collar only, or,
General Safety Instructions
- pressure plastic tube (Ø 6 x 1.5) use valve bodies with
The progressive centralized lubrication system connected knurled collar only
to the Quicklub pump model 203 must always be secured For the outlet fittings of the SSV M divider divider valve
with a pressure relief valve. (M 8x1) pressure plastic tube (Ø 4 x 1) use valve bodies
Lincoln SSV, SSV-E and SSV M lubricant metering devices with knurled collar only.
are state of the art.
Incorrect use may result in bearing damage caused by NOTE
poor or over-lubrication.
Each outlet which will be used must be equipped with a In the case of construction machines or
check valve. agricultural machines use high pressure
plastic hoses for the lubricant feet lines. In
In the case of the metering devices model SSV 6 to 12 or 6001a02 such cases the outlet fittings of the sec-
SSV6-E to 12-E and SSVM 6 to 12 the outlets 1 and/or 2 ondary metering devices and the connec-
must never be closed. tion fittings to the lubricant points must
Unauthorized modifications or changes to an installed have a reinforced collet.
system are not admissible. Any modification must be
subject to prior consultation with the manufacturer of the 8VHRQO\WKHPDLQDQGIHHGOLQHVVSHFLILHGE\6.)DQG
lubrication system.
DGKHUHWRWKHVSHFLILHGV\VWHPSUHVVXUHV.
Use only original Lincoln spare parts (see Parts Catalogue)
or the parts approved by SKF.
Regulations for Prevention of Accidents
To prevent accidents, observe all city, state and federal
Operation, Repair and Maintenance safety regulations of the country in which the product will
Authorized and instructed personnel who are familiar with the be used.
centralized lubrication systems should only perform repair. Avoid the operation with
- unapproved parts.
- insufficient or contaminated lubricants.
CAUTION!
Danger of injury in the case of serious
corrosion of metering device surfaces:
An increasing corrosion of the surfaces will
cause the balls pressed in to lose their hold.
Under pressure, they may suddenly burst
1013A94 out and cause injuries.

For applications in corrosive environments,
use metering devices in stainless steel
version only.
P 5 f 24
User Manual
2.2EN-20001-J11
Installation
Tube Fittings, Screw type

Main- and secondary metering devices
Inlet tube fittings, straight and 90°
As inlet fitting use only tube fittings R1/8” thread.
Check valves
Install one complete check valve in each outlet bore that will
be used, see fig. 1.
Install one closure plug in each outlet borehole that will not be
used. Exception: outlet bore 1 & 2 on sizes6 to22. Check
valves must be installed in both bores.
1 coupling nut 3 valve body with seal and

2 ferrule clamp ring
4239a99
Fig. 1 Single parts of the check valve
Tube Fittings, Push-in type

Metering devices
Inlet tube fittings, straight and 90 °
IMPORTANT
For the inlet fittings use only tube fittings
with reinforced collet 1a (fig. 2) and
sealing ring 1b at the thread.
6001a02
1a Collet
1008a98 1b Sealing ring
Fig. 2 Inlet fittings
Check valves
A check valve must be mounted to the corresponding
metering device outlet of each feed line in order to be able
to precisely meter the predefined amount of lubricant.
Main metering device
Use check valves type A, Fig.3 with reinforced collet 1a
and smooth flange (Part no. 226-14091-4).
Secondary metering device
Use check valves type B, Fig. 3 with standard collet 2a
and knurled flange (Part no. 226-14091-2).
NOTE
On construction machines or agricultural
machines use high-pressure plastic hoses.
1009a98 In such cases the check valves of the

6001a02 secondary metering devices must have a
Fig. 3 The different types of check valve
reinforced collet and smooth flange.
A Check valve with reinforced collet

B Check valve with knurled collet
P 6 f2
User Manual
2.2EN-20001-J11
Installation, continuation
Tube Fittings, Push-in Type, continuation

Connection of High-pressure Hose and Pressure Plastic Tube
High-pressure range (main metering device)
IMPORTANT
Only main lines (NW 4.1 x 2.3 mm) with
threaded sleeve and hose stud may be
connected to the inlet fitting and the check
6001a02 valves with reinforced collar.
4156a98
Fig. 4 Check valve with reinforced collet and hose stud
Low-pressure range (secondary metering device)

Connect the pressure plastic tube (Ø6x1.5 mm) to the check
valve with standard collet (knurled collet) and to the inlet
fittings towards the lubrication point (knurled collet).
NOTE
Special cases, such as applications for
construction machines or agricultural ma-
chines, require the use of check valves
6001a02 and inlet fittings (towards the lube point)
with reinforced collet also for the low-
pressure range. Refer to Parts Catalog.
The pressure plastic tubes are marked with white lines
4157a98 (Fig. 5) as an installation aid.
Fig. 5 Check valve with knurled collet and pressure plastic tube Cut the pressure plastic tube off at one of the white lines
before it is mounted. Then insert the pressure plastic tube
into the fitting up to the next white mark.
This will ensure a correct installation of the pressure plastic
tube in the tube fitting.
Protective cap for push-in type fittings

Push-in type fittings, check valves and pressure relief valves
can be closed with a protective cap in order to avoid contami-
nation.
Designation .......................................................... Part No.

Protective cap ................................................. 432-24313-1
00002632
Fig. 6 Push in type fitting with protective cap

P 7 f 24
User Manual
2.2EN-20001-J11
Installation, continuation
Pressure Plastic Tubes and High-pressure Hoses

Pressure plastic tubes Ø6 x 1.5 mm NOTE
Use the pressure plastic tubes only in the low-pressure Adhere to the pressures and bending radi-
area, i.e. between secondary metering device and lubrica- uses mentioned in the chapter ”Technical
tion point. Data” when installing the parts and operat-
6001a02 ing the device.
High-pressure hose NW 4.1 x 2.3 mm

Use the high-pressure hose in the high-pressure area, i.e.
between the pump, main metering device and secondary
metering devices.
Adhere to the pressures and bending radiuses mentioned
in the chapter ”Technical Data” when installing the parts
and operating the device.
Installing the threaded sleeves and hose studs on the
high-pressure hose
Screw threaded sleeve, item 1 Fig. 7, counterclockwise
onto high-pressure plastic hose 2 until illustrated dimen-
sion of 11 mm is reached. Then screw hose stud 3 into
threaded sleeve 1.
1028a96
IMPORTANT
Before screwing the parts 1, 2 (inside and
Fig. 7 Preassembly of threaded sleeves and hose studs on the
high pressure hose
outside) and 3, rub them with oil.
NOTE
6001a02
1 Threaded sleeve The outside diameter of the high-pressure
2 High pressure hose NW 4.1 x 2.3 mm hose may show variations in dimension. In
3 Hose stud
such a case, press the threaded sleeve 1
at the end where it will be screwed onto
the high-pressure hose so that it becomes
oval in shape (1 to 2 mm). This will prevent
the high-pressure plastic hose from being
pushed out of the sleeve when the hose
stud is screwed.
NOTE
When using the special adjusting gauge
432-23007-1 (see Parts Catalog) screw
threaded sleeve counterclockwise onto
6001a02 high-pressure plastic hose until the gauge
inserted in the sleeve begins to rise.
1029a96
Fig. 8 Preassembly of threaded sleeve by means of adjusting

gauge
1 Threaded sleeve
2 High pressure hose NW 4.1 x 2.3 mm
3 Adjusting gauge 432 23077 1
P 8 f2
User Manual
2.2EN-20001-J11
Description
Progressive Metering Devices Model SSV, SSV-E and SSV M

Progressive plunger metering devices - general
The progressive metering devices
- are piston-operated metering devices;
- automatically (progressively) dispense the lubricant fed
by the pump to the connected lubrication points;
- model SSV or SSV-E have a lubricant output of 0.2
ccm per outlet and piston stroke;
- model SSV M have a lubricant output of 0.07 ccm
per outlet and piston stroke;
- when one or more outlets are closed (see ”Combining
outlets”) they can dispense a double or multiple lubri-
cant quantity;
- are available with 6 to 12 outlets or up to 22 outlets;
- offer the option of combining several lubrication points
into one centralized lubrication point.
- meter the supplied lubricant into predetermined single
quantities.
- can be monitored visually (SSV, SSV-E and SSV M) or
electronically (SSV and SSV-E).
- in the SSV-E version include an emergency lubrication
fitting.
Any blockage in a lubrication circuit is indicated by grease
leaking from the respective pressure relief valve.
10002709
Fig. 9 Metering device type SSV 8
Features of a Progressive Metering Device

The term ”progressive” refers to the special features of
the lubricant distribution within the metering devices,
e.g.
- the successive movements of the individual pistons
within the metering device due to the supplied lubricant
being under pressure;
- the pistons move in a predetermined order and the cy-
cles are repeated constantly;
- each piston must have completed its movement fully
before the next piston can be moved, no matter whether
the lubricant is dispensed continuously or intermittently;
- the pistons operate interdependently of one another;
10002710
- no lubrication point, which is connected to the system,
is omitted.
Fig. 10 SSV 8 with piston detector
P 9 f 24
User Manual
2.2EN-20001-J11
Description, continuation
Progressive Metering Devices Model SSV, SSV-E and SSV M, continuation

Different features of SSV, SSV-E and SSV M
The SSV-E progressive metering device consists of an
SSV progressive metering device and an emergency lu-
brication fitting E (fig. 11). Time for troubleshooting can be
reduced significantly by using e. g. a hand-lever gun in
combination with the emergency lubrication fitting.
The SSV, SSV-E and SSV M progressive metering devic-
es operate similarly. Apart from their outer dimensions
they also differ in the following data:
SSV and SSV-E

Lubricant output per outlet and stroke ......................... 0.2ccm
Maximum operating pressure ..................................... 350 bar
Minimum operating pressure ........................................ 20 bar
Maximum differential pressure between 2 outlets ....... 100 bar
Outlet connection for tube ................................ Ø 4 and 6 mm
B-SSV-020a11
Fig. 11 Differences between SSV M and SSV/SSV E SSV M

E Emergency lubrication fitting Lubricant output per outlet and stroke ....................... 0.07ccm
Maximum operating pressure ..................................... 200 bar
Minimum operating pressure ........................................ 20 bar
Maximum differential pressure between 2 outlets ......... 40 bar
Outlet connection for tube .......................................... Ø 4 mm
Mode of Operation
Applications
1205a95
Fig. 12 Central lubrication point

Quicklub progressive metering devices offer the option of
combining several lubrication points on a machine to one
or more central lubrication points, as shown in Fig. 12,
which illustrates this basic feature.
4024b95
Fig. 13 Possible pump connections

1 Hand operated pump
2 Pneumatically operated pump
3 Electrically operated pump
4 Lubrication fitting block

5 Hand operated filling pump
When they are used in connection with hand-operated

pumps, pneumatic or electric pumps the progressive me-
tering devices are a simple and low-cost centralized lubri-
cation system (see Fig. 13).
P 0 f2
User Manual
2.2EN-20001-J11
Applications, continuation
4025a95
Fig. 14 Multiline pump expanded by a progressive metering device
Progressive metering devices can be used in two-line or

single-line centralized lubrication systems in order to in-
crease the number of outlets of multiline pumps or to sub-
divide the single metering devices and measuring valves
(Fig. 12 to 16) also as secondary metering devices in
large and small oil circulating systems.
1207a95
Fig. 15 Two line system expanded by a progressive metering

device
1206a95
Fig. 16 Single line system expanded by a progressive metering

device
P 11 f 24
User Manual
2.2EN-20001-J11
Lubricant distribution inside the metering device

The 5 following illustrations show the piston movements and When the lubricant supply is interrupted
the depending lubricant distribution to the individual outlets. - The pistons come to a halt;
NOTE - Lubricant is no longer dispensed to the lubrication point.
Illustrations fig. 17 to 21 show the se- When the lubricant is supplied to the metering device again,
quence of delivery only of outlets 2, 7, 5, 3 the cycle begins from the point where it had been interrupted.
and 1. Delivery of the residual outlets 8, 6
6001a02 and 4 is derived from the logical pumping
until the complete metering device cycle
has finished. The functional principle of
SSV is identical with SSV M metering
devices.
Phase 1
The lubricant enters the metering device from above
(white arrow) and flows to the right-hand end of piston A.
Piston A (black arrow) moves to the left under the pres-
sure of the lubricant, causing the lubricant ahead of the
left-hand end of piston A to be dispensed to outlet 2
(dashed arrow).
Lubricant under pump pressure
Lubricant under delivery pressure of the piston
Lubricant, without pressuress

2007a99
Fig. 17 Phase 1
Phase 2
Once piston A has reached its left-hand final position, the
junction channel to the right-hand end of piston B is
opened.
The lubricant, which arrives from above (white arrow),
also moves piston B (black arrow) to the left and causes
the lubricant quantity ahead of the left-hand end of piston
B to be dispensed to outlet 7 (dashed arrow).
Lubricant, without pressuress

2008a95
Fig. 18 Phase 2
P 2 f2
User Manual
2.2EN-20001-J11
Lubricant Distribution within the Metering Device, continuation

Phase 3
Once piston B has reached its left-hand final position, the
junction channel to the right-hand end of piston C is
opened.
The lubricant, which flows from above (white arrow)
moves piston C (black arrow) to the left, causing the lubri-
cant quantity ahead of the left-hand end of piston C to be
dispensed to outlet 5 (dashed arrow).
2009a95 Lubricant, pressureless
Fig. 19 Phase 3
Phase 4
The channel of piston C to the right-hand end of piston D
is now open (black arrow).
The lubricant which is fed from above (white arrow)
moves piston D to the left, causing the lubricant quantity
ahead of the left-hand end of piston D to be dispensed out
of the metering device via outlet 3 (dashed arrow).
2010a95
Lubricant, pressureless
Fig. 20 Phase 4
Phase 5
In phase 4, piston D had opened the junction channel to
the left-hand end of piston A.
The lubricant flowing in (white arrow) moves piston A to
the right (black arrow), causing the lubricant quantity to be
dispensed to outlet 1(dashed arrow).
In the subsequent distribution sequence, pistons B - D are
moved from the left to the right one after the other.
A complete distribution sequence is finished and a new
cycle can begin.

2011a95 Lubricant, pressureless

Fig. 21 Phase 5
P 13 f 24
User Manual
2.2EN-20001-J11
Monitoring of the Operation

System-dependent monitoring
The main metering device B (fig. 22) and the secondary
metering devices are connected by a high-pressure
hose G. This feature automatically causes the linkage of
the progressive system connected downstream of the
pump.
If only one piston does not move in any metering device
or if the metering device can no longer dispense any lub-
ricant via its outlets, this metering device will block itself.
If one of the secondary metering devices is blocked, the
main metering device is also blocked. The whole progres-
sive system installed downstream of the pump stops op-
erating.
The fundamental internal structure of the progressive
metering device guarantees the self-monitoring of the se-
quence within the metering device.
The linkage makes it possible to monitor the operation of
the whole system.
1064b95
A pressure relief valve E Pressure plastic tube
Fig. 22 Example of a lubrication system B Main metering device SSV 6 F Secondary metering
C Secondary metering device SSV 8 device SSV 12
D Secondary metering device SSV 6 G High pressure plastic hose
Visual monitoring
The metering devices can be equipped with an indicator
pin which is connected to the piston and moves back and
forth during lubricant distribution.
If there is a blockage in the system, the indicator pin stops
moving.
NOTE
It is also possible to electrically check the
movements of the indicator pin or any
blockage in the system by means of a
6001a02 control switch (KS) or a proximity switch
(KN).
Fig. 23 Indicator pin installed on metering device 1011b96
Components of the control pin tube fitting

Closure plug M 11x1x5 MS, assy. (pos. 1) ..........519-32123-1
P f2
User Manual
2.2EN-20001-J11
Monitoring of the Operation, continuation

Electrical monitoring (microprocessor control)
A piston detector (initiator), which has been installed on
a metering device instead of a piston closure plug
(M 11 x 1), monitors the pump operating time and brings
it to a close after all the pistons of this metering device
have dispensed their lubricant quantity.
If there is a blockage in the system or if the pump reser-
voir is empty, the piston detector can no longer record the
piston movements. The switching off signal is not trans-
mitted to the control unit. A fault signal occurs.
NOTE
For the system monitoring it is recom-
00002634 mended that one SSV-N metering device
with pre-assembled piston detector be
Fig. 24 Piston detector installed on the metering device
6001a02 used per lubrication circuit. These special
metering devices must be ordered sepa-
rately for each lubrication system. Refer to
the Parts Catalogue.
The pre-assembled metering devices have the designa-
tion SSV ... - N (they are available for SSV 6, 8, 10
and 12). They must be installed in the system instead of a
normal metering device.
Applications:
Metering device -
Control unit / pump
piston detector
M08-23 / P203
SSV -NE MF01,02 / P223
6001a02
MDF01,02,03 / P233
SSV -N PLC external
SSV -NP control unit
Pressure relief valve

The whole system can be monitored visually via the pres-
sure relief valve. If lubricant is leaking at the pressure re-
lief valve during the distribution sequence, this indicates
that there is a blockage in the system.
IMPORTANT
In the case of the progressive metering
devices models SSV6 to 22 and SSV6-E
to 22-E outlets 1 and/or 2 must never be
6001a02 closed, otherwise the system will block
owing to the structure of the metering
device.
4092a97 NOTE
Fig. 25 Pressure relief valve Pressure relief valves to be ordered sepa-
rately (see parts catalogue).
P 15 f 24
User Manual
2.2EN-20001-J11
Operation, continuation
Determining the Lubricant Output by Combining Outlets

Tube Fittings, Screw-Type
1012c96
Fig. 26 Install the outlet fittings and closure plugs in accordance with the dosage
1 Inlet fitting 4 Closure plug (M 11 x 1), piston 7 Cutting ring
(with chamfered)
2 Delivery hole of the piston 5 Outlet fitting assembly 8 Coupling nut
3 Closure plug (M 10x1) with with hex. 6 Valve body with clamping ring (brass) 9 Junction channel
socket head, installed
The output quantities can be raised by closing outlet Never remove closure plug 4 (M 11x1 chamfered) on
boreholes. the piston side or remove it only for installing a piston de-
tector.
IMPORTANT
The structure of the progressive metering NOTE
devices would be blocked if outlet 1
Never use closure plug 3 (M 10 x 1,
and/or 2 is closed (with SSV 6-22).
Fig. 20, 21) as a piston closure plug 4 (G
6001a02 Never close outlet 1 and/or 2 ! 1/8) on older models of metering devices.
6001a02
Install an outlet fitting assembly 5 (M 10x1) in each outlet
borehole which will be used. Refer to Fig. 26, 27, 28. Clamping ring 6 closes the junction channels 9 to the
other outlet channels.
IMPORTANT
Always use valve body 6 in conjunction
with clamping ring.
6001a02
P 6 f2
User Manual
2.2EN-20001-J11
Determining the Lubricant Output by Combining Outlets, continuation

Tube Fittings, Push-in-Type (main metering device)
B-SSV-030b11
Fig. 27 Install the push in type outlet fittings and the closure plugs in accordance with the dosage
1 Inlet fitting (optionally with protective 3 Closure plug (M 10x1) with with hex. 5 Valve body assembly
1)
cap ) socket head, installed (with reinforced collar)
2 Delivery borehole of the piston 4 Closure plug (M11x1), 6 Junction channels
piston, (chamfered)
1)
on demand
NOTE
In the case of construction machines or
agricultural machines use high-pressure
hoses for the lubricant feed lines. In this
6001a02 case, secondary metering devices (see
fig. 26) must also be equipped with check
valves with reinforced collet (standard
flange, see fig. 3).
NOTE
In the case of push-in type fittings the
clamping ring is always a firm component
of the valve body 5.
6001a02
P 17 f 24
User Manual
2.2EN-20001-J11
Determining the Lubricant Output by Combining Outlets, continuation

Tube Fittings, Push-in Type (secondary metering devices)
B-SSV-030a11
Fig. 28 Install the push in type outlets fittings and closure plugs in accordance with the dosage
1 Inlet fitting 3 Closure plug (M 10x1) with hex. socket 5 Valve body assembly
head, installed (with knurled collar)
2 Delivery borehole of the piston 4 Closure plug (M11x1), 6 Junction channels
piston (chamfered)
Single lubricant output

- The simple lubricant output is the lubricant quantity dis-
pensed by a piston per stroke and per outlet borehole to
one lubrication point. It amounts to 0.2 cm³ on SSV
and 0.07 cm³ on SSV M.
Double or multiple lubricant output
If one or more lubrication points require a double or a
multiple lubricant amount, this can be performed by clos-
ing one or more outlets.
As shown in fig. 29, outlet borehole 10 has been closed.
The lubricant quantity supplied by this outlet flows out of
the metering device via outlet 8.
Total quantity at outlet 8:
1014b96
- is the quantity of outlet 8
Fig. 29 Single, double and triple lubricant output
- plus the lubricant quantity of outlet 10.
... x Outlet quantity (1x: single, 2x: double, etc.)
If a triple quantity is needed (at outlet 1), close the outlet
1 .. 10 Outlet numbers
A Clamping ring (brass) borehole located above the discharge borehole. Refer to
outlets 3 and 5 on fig. 29.
P 8 f2
User Manual
2.2EN-20001-J11
Troubleshooting
Fault: Blockage in the downstream progressive system
Cause: Correction:
Bearing, lines or metering device clogged. Find out which is the cause of the blockage and rectify it in
accordance with he following example:
In the case of the metering devices SSV 6 to 22 and Allow pump to run (see ”To trigger an additional lubrication
SSV6-E to 22-E the outlet boreholes 1 and/or 2 are closed. cycle”).
The fault can be identified by: Loosen all high pressure hose connections G one after the
other from the main metering device B (fig. 30) leading to
a) grease leaking at the pressure relief valve; the secondary metering devices. If f. ex. grease or oil
b) the fact that the indicator pins installed on the metering emerges under pressure from outlet 1 of main metering
devices (if any) no longer move; device B, the blockage will be found in the lubrication cir-
c) the fault signal of the signal lamp (if any) or LED display cuit of the secondary metering device D.
NOTE
If there is a blockage in the downstream
system, the main lines are under pressure.
In such a case, it is difficult to detach the
6001a02 push-in type connecting parts of the main
line. Relieve the system by removing the
closure plug on the push-in type pressure
relief valve or, if any, by removing the filling
nipple.
Let the pump run.
Disconnect all lubricant feed lines E from secondary me-
tering device D one after the other. If f. ex. grease or oil
emerges under pressure from outlet 3 of metering device
D, the blockage will be found in the line of outlet 3 or in the
connected bearing.
Pump the blocked bearing or line through by means of a
manual pump.
NOTE
When checking the individual outlets, keep
each outlet loosened for quite a while
because per each motor revolution there is
6001a02 only one piston stroke. A complete cycle of
all metering devices requires several
1064b95
strokes.
Fig. 30 Example of a lubrication system Check pressure relief valve A. Replace it, if necessary.
A pressure relief valve B Main metering device
C Secondary metering device D Secondary metering device

SSV 8 SSV 6
E Pressure plastic tubes F Secondary metering device
SSV 12
G High pressure plastic hose
P 19 f 24
User Manual
2.2EN-20001-J11
Troubleshooting, continuation
Fault: Blockage in the downstream progressive system, continuation
Cause: Correction:
Metering device blocked Replace the metering device or clean it in accordance with
the following procedure:
Remove all tube fittings.
Unscrew the piston closure plugs.
If possible, try to eject the piston using a smooth drift
(Ø smaller than 6 mm).
IMPORTANT
The pistons are precision-fitted into the
holes. Mark the pistons with regard to their
installation position and direction after they
6001a02 have been removed. They must not be
exchanged.
Thoroughly clean the metering device bodies in fat-
dissolving washing agent, blow them through with com-
pressed air.
Press free the slant ducts (Ø 1.5 mm) at the thread ends of
the piston holes using a pin.
Clean the metering devices again and blow them through.
Reassemble the metering devices.
Replace the copper washers.
Before the tube fittings are reassembled, the metering
devices should be pumped with oil several cycles by
means of a manual pump. Check that the pressure in the
metering device does not exceed 25 bar (362.8 psi).
If the pressure is higher, replace the metering device.
Fault: Differing lubricant amounts at the lubrication points
Cause: Correction:
Lubricant metering not correct Check the lubricant metering acc. to the lubrication chart
Respective valve body has been assembled without clamp- Remove the valve body and install a clamping ring.
ing ring
Setting of the pause time or lubricating time incorrect Check the time setting. Refer to the corresponding setting
in the respective “Operating Instructions”.
Fault: Over- or underlubrication of the lubrication points
Cause: Correction:
Setting of the lubricating time or pause time incorrect Check the time setting at the printed circuit boards. Refer
to the corresponding setting in the respective “Operating
Instructions”.
Tab. 1 Troubleshooting, continuation

P 20 f 2
User Manual
2.2EN-20001-J11
Technical Data
Metering Devices Lines

Metering Device Model SSV and SSV-E High-pressure hose (∅ 4.1 x 2.3 mm)
Lubricant output per outlet and per stroke ................. 0.2 ccm Min. bursting pressure
Max. operating pressure ........................................... 350 bar (in connection with hose clamp, screwed) ................. 600 bar
Min. operating pressure .............................................. 20 bar Min. bending radius ................................................... 35 mm
Max.differential pressure Min. temperature ...................................................... – 40 °C
between two outlets .................................................. 100 bar Max. temperature ..................................................... + 60 °C
Outlet connection for tube ................................ Ø 4 and 6mm
Inlet connection ........................................................... G 1/8 Pressure plastic hose (∅ 6 x 1.5 mm)
Outlet connection ..................................................... M 10x1 Min. bending radius ..................................................... 50 mm
Operating temperature ............................ – 40 °C to +200 °C Bursting pressure at 20° C ........................... approx. 210 bar
Metering Device Model SSV M Min. temperature ...................................................... – 40 °C
Max. temperature ..................................................... + 60 °C
Lubricant output per outlet and per stroke ............... 0.07 ccm
Max. operating pressure ........................................... 200 bar
Min. operating pressure .............................................. 20 bar Screw-Type and Push-in Type Tube Fittings
Max.differential pressure High pressure range, p max. .................................... 350 bar
between two outlets .................................................... 40 bar Inlet tube fittings of the metering devices
Outlet connection for tube ......................................... Ø 4mm Outlet fittings, main metering device
Inlet connection ........................................................... G 1/8
Outlet connection ....................................................... M 8x1 Low-pressure range, p max. ..................................... 250 bar
Operating temperature .............................. – 25 °C to +70 °C Outlet fittings, secondary metering devices
Inlet fittings to the lubrication point
Tightening torques
Metering Device Model SSV and SSV-E Metering Device Model SSV M
Closure plug (piston) in metering device ..................... 18 Nm Closure plug (piston) in metering device ....................... 6 Nm
Closure plug (outlets) in metering device .................... 15 Nm Closure plug (outlets) in metering device ...................... 6 Nm
Inlet fitting in metering device Inlet fitting in metering device
- screw-type ............................................................... 17 Nm - screw-type ............................................................... 17 Nm
- plug-type .................................................................. 10 Nm - plug-type .................................................................. 10 Nm
Outlet fitting in metering device Outlet fitting in metering device
- screw-type ............................................................... 11 Nm - screw-type ............................................................... 10 Nm
- plug-type .................................................................. 11 Nm - plug-type .................................................................... 8 Nm
Compression nut onto outlet fitting, screw-type Compression nut onto outlet fitting, screw-type
- plastic tube ............................................................... 10 Nm - plastic tube ................................................................ 5 Nm
- steel tube ................................................................. 11 Nm - steel tube ................................................................. 10 Nm
Control pin tube fitting in metering device .................... 18 Nm Control pin in metering device .................................... 10 Nm
Piston detecteur (N) in metering device ...................... 15 Nm Install metering device
Proximity switch (KN) on metering device ................... 18 Nm - dry ............................................................................. 6 Nm
Install metering device - oiled ........................................................................ 4,5 Nm
- dry ........................................................................... 10 Nm
- oiled ........................................................................ 7,5 Nm Metering device type SSV M flange
Install metering device .................................................. 6 Nm
P 21 f 24
User Manual
2.2EN-20001-J11
Technical Data, continuation
Dimensions
Metering Devices Model SSV6 to 22 & SSV6-E to 22-E Metering Devices Model SSV M 6 to SSV M 12
2012a95 2012a99
Model SSV & SSV-E Dimensions A in Model SSV M Dimensions A in mm

mm 6 48,5
6 60 8 60
8 75 10 71,5
10 90 12 83
12 105
14 120
16 135
18 150
20 165
22 180
P 22 f 2
User Manual
2.2EN-20001-J11
Original Language
D GB F E I
EC Declaration of Déclaration CE Declaración CE Dichiarazione CE di
EG- Einbauerklärung
incorporation d'incorporation de incorporación incorporazione
Hiermit erklären wir, dass die Herewith we declare that the Par la présente, nous décla- Por la presente, declaramos Si dichiara che il prodotto da
Bauart von model of rons que le produit ci-dessous que el modelo suministrado noi fornito
Metering Devices SSV / SSV-E / SSV M

in der von uns gelieferten in the supplied version is dans la version dans laquelle en la versión suministrada es nella versione da noi fornita è
Ausführung zum Einbau in intended to be incorporated nous le livrons, est destiné à destinada a ser incorporada destinato all’installazione in
eine Maschine bestimmt ist into machinery and must not être installé sur une machine en una máquina y que su una macchina e che la relati-
und dass ihre Inbetriebnahme be put into service until the et que sa mise en service est puesta en servicio está va messa in esercizio resta
solange untersagt ist, bis machinery into which it is to interdite tant qu’il n’aura pas prohibida antes de que la vietata fino all’avvenuto
festgestellt wurde, dass die be incorporated has been été constaté que la machine máquina en la que vaya a ser accertamento della conformità
Maschine, in die das o. g. declared in conformity with sur laquelle le produit men- incorporada haya sido della macchina nella quale il
Produkt eingebaut werden the provisions of the relevant tionné ci-dessus doit être in- declarada conforme a las suddetto prodotto deve
soll, den Bestimmungen aller fundamental requirements on stallé est conforme aux régle- disposiciones de los essere installato con tutti i
einschlägigen grundlegenden health and safety, including all mentations régissant toutes requisitos pertinentes y requisiti basilari prescritti in
Sicherheits- und Gesund- modifications of this directive les exigences fondamentales fundamentales de salud y termini di sicurezza e di
heitsanforderungen ent- valid at the time of the decla- de sécurité et celles relatives à seguridad en su redacción salute, incluse le relative
spricht, einschließlich deren ration. The manufacturer la santé, y compris les amen- vigente en el momento de modifiche vigenti al momento
zum Zeitpunkt der Erklärung undertakes to make available dements en vigueur au mo- instalación. El fabricante se della dichiarazione. Il costrut-
geltenden Änderungen. Der any technical documents in ment de la présente décla- obliga a hacer disponible tore si impegna a mettere a
Hersteller verpflichtet sich, printed version (following ration. Le fabricant s’engage, documentos técnicos (según disposizione la documenta-
technische Dokumente (gem. Annex VII Part B) to subna- en cas de demande justifiée, à anexo VII parte B) en versión zione tecnica (ai sensi
Anhang VII Teil B) bei be- tional authorities in the case fournir sous forme écrite aux imprimida a entes dell’Allegato VII partel B) in
gründeter Anfrage zum o. g. of reasonable request regard- organismes nationaux respec- uniestatales a petición forma scritta relativa al sum-
Produkt einzelstaatlichen ing the above mentioned tifs les documents techniques fundada referente al producto menzionato prodotto dietro
Stellen in gedruckter Form zur product. (suivant Annexe VII, Partie B) arriba mencionado. richiesta motivata presso le
Verfügung zu stellen. relatifs au produit ci-dessus. singole sedi nazionali.
Angewendete harmonisierte Applied harmonized stand- Normes harmonisées, notam- Normas armonizadas Norme armonizzate applicate
Normen, insbesondere: ards in particular: ment : utilizadas, particularmente: in particolare:
Maschinenrichtlinie Machinery Directive Directive machines Directiva de máquinas Direttiva Macchine
2006/42/EG 2006/42/EC 2006/42/CE 2006/42/CE 2006/42/CE
DIN EN ISO 12100 – Teil 1 & 2 – Part 1 & 2 – Parties 1 & 2 – Parte 1 & 2 – Parte 1 e 2
Sicherheit von Maschinen Safety of machinery Sécurité de machines Seguridad de máquinas Sicurezza delle macchine
Grundbegriffe, allgemeine Basic terms, general design Notions fondamentales, direc- Términos básicos, axiomas Concetti basilari, principi
Gestaltungsleitsätze guidelines tives générales d’élaboration generales de diseño guida generali
DIN EN 809
Pumpen und Pumpengeräte Pumps and pump units Pompes et groupes Bombas y equipos de Pompe e dispositivi
für Flüssigkeiten for liquids de pompes pour liquides bombas para líquidos di pompaggio per liquidi
Allgemeine sicherungs- Exigences en matière Prescripciones generales Requisiti generali di sicurezza
General safety requirements
technische Anforderungen de sécurité technique referente a la seguridad tecnica
EMV-Richtlinien EMC directives Réglementations CEM Directivas CEM Direttive EMC

2009/19/EG 2009/19/EC 2009/19/CE 2009/19/CE 2009/19/CE
Kraftfahrzeug Automotive véhicules automobile vehículo autoveicolo
2004/108/EG 2004/108/EC 2004/108/CE 2004/108/CE 2004/108/CE
DIN EN 61000-
Fachgrundnormen: Generic emission standards: Normes fondamentales : Normas especiales fundam.: Norme specifiche fondam.:
- Störaussendung - Emitted interference - Emission de parasites - Emisión de interferencias - Emissione di interferenze
a) a) a) a) a)
Teil 6-4 Part 6-4 Partie 6-4 Parte 6-4 Parte 6-4
b) b) b) b) b)
- Störfestigkeit - Noise immunity - Résistance aux brouillages - Resistencia a interferencias - Resistenza alle interferenze
a) a) a) a) a)
b) b) b) b) b)
a) a) a) a) a)
für Industriebereiche for industrial environment pour domaine industriel para áreas industriales per settore industriale
b) b) b) b) b)
für Wohnbereich, Geschäfts- for residential, commercial pour domaines de l’habitation, para áreas resi denciales, per il settore residenziale,
und Gewerbebereiche sowie and light industry des magasins et de l’artisanat comerciales e industriales commerciale, industriale e
Kleinbetriebe ainsi que des petites tanto como pequeñas per le piccole imprese
entreprises empresas
Dokumentations- Responsable du Service Encargado/a de la Responsabile della

Documentation agent
bevollmächtigter de documentation documentación documentazione
Wolfgang Studer • Heinrich-Hertz-Str. 2-8 • 69190 Walldorf
Walldorf, Nov 30, 2009, ppa. Dr.-Ing. Z. Paluncic

Director Research & Development
P 23 f 24
Motordatenblatt
Motor datasheet
FSB/014/J/10
LINCOLN intern
Sachnummer:
Article nr.: 245-00101-1 FEN Motor-Code-Nr. B3-15
Pumpentyp
Type of pump P205
Folgende Daten wurden aus dem Lieferantenmotorblatt übernommen
Following data are taken from manufacturer´s datasheet.
Hersteller
Manufacturer VEM
Typ
K21R56G4
Type
Spannung U [V]
265/460 +/-5%
Voltage
Frequenz f [Hz]
60 +/-2%
Frequency
Nennleistung P [kW]
0.11
Nominal power
–1
Nenndrehzahl n1 / n2 [min ]
1800/ 1690
Nominal speed
Nennstrom I [A]
Nominal current 0.53/ 0.31
Anzugsstrom 3,5 x Nennstrom
Starting current Nominal current
Nenndrehmoment M [Nm]
2,3
Nominal torque
Wirkungsgrad η
63%
Efficiency
Leistungsfaktor cos φ
0,68
Power factor
Betriebsart
S1
Mode of operation
Bauform IM Anordnung bei Blick auf Lüfterrad
Type of construction B14
Configuration in view of fan wheel
Baugröße
56
Klemmenkasten LINKS
Frame size Terminal box LEFT
Schutzart IP
55
Kabelverschraubung LÜFTERSEITIG
Enclosure Cable gland FAN-SIDED
Isolierstoffklasse Typenschild OBEN
F/ ausgenutzt nach B
Insulation class Type label ABOVE
Flansch [mm]
80
Flange
Welle [mm]
9x20
Shaft
Gewicht [Kg]
4.4
Weight
Explosionsschutz
Explotion proof
NEMA
NEMA
Besch. Nr UL
Certificate No. UL
Sonderausführung elektrisch
Special design electrical
Sonderausführung mechanisch
Special design mechanical
13.10.2014 Atk Atik

-------------------------------- ------------------------------------------- ----------------------------------------
Datum Name Unterschrift
Motordatenblatt 245-00101-1.doc
Data Sheet
Ultrasonic Sensor
9.3A-70004-C05
Functional Description Technical Data
The ultrasonic sensor is a solid-state proximity type switch for Ambient temperature ....................................- 25...70°C
24 VDC, which uses the echo delay time method for distance Sensing range...............................................50...500 mm *
sensing. It senses a sound-reflecting object, which enters the Sensing distance “high level” ... S1...............60 mm *
sound cone from any direction. The objects to be sensed can Sensing distance “low level” S2 ...................depends on the
be solid, liquid or powdery. .... ................... reservoir size
Hysteresis “high level”............... HV ..............20 mm
Installation Hysteresis “low level” ................ HL ..............50 mm
Figure I (dimensions in mm) Switching point default ..................................0.17% / K
Mounting position: any *measured on the housing surface
Keep free space around the sound cone of a distance "x"
(= 60 mm) from reflecting objects (Figure II) Supply:
Rated operational voltage UE ...............24 VDC
Connection Operating voltage range ........... UB ...............20...30 VDC
By means of cable socket (Figure III) part no. 237-13442-4 Admissible residual ripple .............................10 %
(included in the scope of delivery) Open-circuit ..................................................< 60 mA
Pin Switching Output:

1 L+ DC 20...30 V Rated normal current ................ Ie.................≤ 200 mA
2 S1 Switching output "High level" (NO) Voltage drop ............................. Ud ...............≤3 V
3 L- Ground (GND) Spurious switch-on pulse ..............................suppressed
4 S2 Switching output "Low level" (NC) Switching function “high level”: ....................NO contact,
switching on
The connections are polarized, short-circuit proof and “plus”
overload-proof. In the case of electrical faults we recommend “low level” .....................NC contact;
to use shielded lines. switching on
“plus”
Switching Range (Figure IV) Typical Values:
a Unusable blind zone Availability delay ...........................................250 ms
b Sensing range Reflection area..............................................10 x 10 mm²
c Overfill range Ultrasonic frequency .....................................400 kHz
HV Hysteresis high level Switching frequency......................................8 Hz
HL Hysteresis low level Resolution.....................................................1 mm
Protection .....................................................IP 65
The objects are sensed reliably in the set switching range
within an opening angle of the sound cone of approx. 5°. If the
reflecting conditions are good, the objects can also be sensed
outside the sound cone.
Keep the blind zone "a" free from objects. These would cause
undefined switching states.
Take care that the surface of the transducer is clean!
Display:
Reservoir empty: H2 is lit
Filling level O.K. H2 is not lit
Reservoir full H1 is lit
Supply voltage: H3 is lit: green
Overfill signal: H3 is lit: red
Part Numbers
Ultrasonic sensor adjusted for reservoir: Part no.:
4L (pump 205) 664-36939-1

5L (pump 205) 664-36939-2
8L (pump 205) 664-36939-3
10L (pump 215) 664-36939-4
30L (pump 215) 664-36939-5
100L (pump ZPU 08/14/24) 664-34009-3
Special Accessories
Cable socket with 5 m cable, part no. 237-13429-6*
Cable socket with 10 m cable, part no. 236-10022-7*
Interlock protection for EX-area 237-10254-1
* in combination with interlock protection also applicable in the
EX-area
Page 1 of 3
Data Sheet
Ultrasonic Sensor
9.3A-70004-C05
Relevant Data for EX- Protection:

The accordance with directive 94/9/EEC (ATEX) is proved by
the compliance with the standards EN 50021, EN 50281-1-1
and EN 60947-5-2
Appropriate Use
Application in areas subject to explosion hazards
Zone 2 according to classification II 3G (gas atmosphere)
Zone 22 according to classification II 3D (dust atmosphere)
Special conditions for safe operation:
• Protect the environment of the push-in type connection
against mechanical damages.
• Secure the push-in type connection with an interlock
protection (part no. 237-10254-1) to make a separation by
hand impossible.
• Protect plug against dust or water when unpacking.
Installation and start-up
• The admissible ambient temperature for the devices is
- 20°C to +70°C.
• Installation, connection and start-up of the devices must
be carried out by authorized and qualified personnel.
• The installation requires knowledge regarding the
assignment of classifications to the allowed areas subject
to explosion hazards.
• The push-in type connection must not be connected or
separated when voltage is applied.
Maintenance and Troubleshooting
• The devices do not require maintenance.
• The devices must not be modified at all.
• Repairs of the devices are not possible.
• In the case of replacement consider the above points.
Page 2 of 3
Page 3 of 3
6.10 WATER SPRAY SYSTEM (ACCESORIES)

6.10.1 Boom and tripper car
 Arrangement drawings
− PIPING LAYOUT / Water spray system STD 4500:

Dwg. no. 4556637 Sheet 1 + 2
 Component information
− GEMÜ 9698 - Motorized linear actuator + 693 / 698 - Motorized diaphragm valves:
Operating instructions

Blank page

693, 698, 9698
GEMÜ 9698 - Motorized Linear Actuator
GEMÜ 693 / 698 - Motorized Diaphragm Valves
GB OPERATING INSTRUCTIONS
GEMÜ 693 GEMÜ 698
GEMÜ 9698
693, 698, 9698

Contents
1 Notes for your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.2 Explanation of symbols and signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.3 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.4 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.5 Tools required for installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2 Manufacturer's information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.1 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.2 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.3 Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.4 Operation and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3 Mechanical installation and mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.1 Installation of the GEMÜ 693 / 698 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.2 Installation / mounting of the GEMÜ 9698 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.3 Mounting of a diaphragm valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.4 Manual override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.2 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.2.1 Internal wiring diagram with connection on terminal strip . . . . . . . . . . . . . . . . . . . . .9
4.2.1.1 Functional module AE - OPEN / CLOSE control
with additonal end position feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.2.1.2 Functional module AP - OPEN / CLOSE control
with potentiometer output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.2.2 Connection with Hirschmann connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.2.2.1 Functional module AE - OPEN / CLOSE control
with additonal end position feedback and
Hirschmann connector N 6 R AM2 (Design: 6027) . . . . . . . . . . . . . . . . . . . . . . . . .11
4.2.2.2 Functional module AP - OPEN / CLOSE control
with potentiometer output and
Hirschmann connector N 6 R AM2 (Design: 6027) . . . . . . . . . . . . . . . . . . . . . . . . .11
4.2.3 With mounted controller GEMÜ 1283 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
6 Order data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

6.1 Order data for GEMÜ 9698 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
7 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
8 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
8.1 Dimensions - GEMÜ 9698 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
8.2 Dimensions - GEMÜ 693 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
8.3 Dimensions - GEMÜ 698 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Goods return declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
9 EC Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
693, 698, 9698 2/20

1 Notes for your safety
Please read the following notes carefully and observe them!
1.1 General notes

In order for the motorized linear actuator to function properly, the following conditions must
be fulfilled:
· proper transport and storage

· installation and commissioning by trained personnel
· operation in accordance to these operating instructions
· proper maintenance
Therefore, you must observe
· the information contained in these operating instructions

· the relevant safety regulations for the installation and operation of electric systems
· that this device must not be used in areas exposed to the danger of explosion.
The regulations, standards and directives mentioned in these operating instructions apply
only for Germany. If the GEMÜ 9698 (693/698) is used in other countries, the applicable
local regulations must be observed.
1.2 Explanation of symbols and signs

Important information in these operating instructions is emphasized by the following
symbols:
Endangerment of human life or health and/or considerable material

damage can occur if these instructions are not observed.
This symbol indicates Notices that provide important information on

your GEMÜ 9698 (693/698).
1.3 Safety notes

WARNING:
Electric shock can cause serious burns and fatal injuries!
· Only qualified and trained electricians are permitted to install, connect
and start up the GEMÜ 9698 (693/698)
· Make sure that the host devices are electrically safe
· Ensure compliance with the electrical data requirements
3/20 693, 698, 9698

1.4 Correct use
The GEMÜ 9698 is a motorized linear actuator for mounting on diaphragm valves.
A diaphragm valve with a built-on plastic valve body is supplied as GEMÜ type 693, or with
a metal valve body as GEMÜ type 698. The actuator performs a linear movement, which is
transferred to the diaphragm of the valve body by means of a spindle.
The actuator is built to protection class IP65.
1.5 Tools required for installation and connection

· Screwdriver (5 mm flat head) for loosening the cover and any potentiometer component
· Screwdriver (PH1 Philips head) for fixing the limit switch
· Screwdriver (3 mm flat head) for connecting power supply and signal cable to the
standard model terminal strip and for adjustment screws
· Various open-end wrenches and hexagon sockets for mounting the body
· Hexagon allen key (1.5 mm) for trigger cams
2 Manufacturer's information
2.1 Delivery
Inspect the product immediately upon delivery for missing parts or damage.
The delivery documents indicate the scope of delivery.
Compare the order numbers to determine that the correct model has been delivered and
that the order is complete.
The motorized linear actuator is already checked at the factory for function.
2.2 Functions
The motorized linear actuator is driven by means of a synchronous motor.
The power supply voltage must be 24V AC, 120V AC or 230V AC, 50 / 60 Hz, depending
on the model (voltage tolerance: +10%).
The change in frequency from 50 to 60 Hz results in reduction of the stroke time
from 20 sec. to 16 sec.
The motor transmits force via a toothed belt creating a rotary movement.
The rotary movement is converted into a lifting movement by means of a ball screw.
The valve CLOSED position set at the factory is suitable for up to 10 bar for sizes
DN 15 - 25 and up to 6 bar (4 bar for Teflon diaphragm DN 50) for sizes DN 32 - 50.
The valve end travel positions "OPEN" and "CLOSED" are achieved by limit switches.
The micro-switches (change-over contact) are wired internally as follows:

The break contact of the change-over contact to which the A.C. voltage is connected
opens when the trigger cam is actuated and the power supply is interrupted.
The make contact is closed, which allows a limit switch signal to be picked up
(e.g.: activation of a signal lamp).
693, 698, 9698 4/20

The potentiometer installed at the factory enables continuous detection of the position of
the actuator.
Optionally a three-point controller (GEMÜ 1283) can be added, which makes it possible to
control the actuator via a signal from 0 / 4 - 20 mA as a set value or via keys.
(As a special version, the GEMÜ 1283 position controller can also be used as a process
controller.
In this case, both the set value and the actual value can be defined externally.)
At a set value of 0 / 4 mA the actuator runs to the CLOSED position and at 20 mA to the
OPEN position (see GEMÜ 1283 operating instructions).
2.3 Versions
The actuator is available in the following versions:
GEMÜ 9698: actuator without mounted valve body (e.g. as replacement actuator)
GEMÜ 693: actuator with mounted plastic diaphragm valve body (diaphragm valve)
GEMÜ 698: actuator with mounted metal diaphragm valve body (diaphragm valve)
All models are available in the standard version (OPEN - CLOSED), optionally with or
without potentiometer or with a mounted GEMÜ 1283 controller.
Detailed information on the various versions can be found in the order specifications
(see pages 14-17).
2.4 Operation and adjustment

The GEMÜ 9698 actuator is set in the open position when delivered.
The potentiometer component (if ordered) is disconnected from the transmission and must
be attached with the included screw after adjustment (see page 7).
The GEMÜ 693 / 698 motorized valves are set in the "OPEN" position when delivered. No
additional parts are required before installing the unit directly into the system. The motorized
valves can be installed directly in the system.
When mounting a GEMÜ 1283 controller, parameters can be changed or adjusted

according to the specific system; for information on this, please read the GEMÜ
1283 operating instructions!
WARNING:
Adjustments on the GEMÜ 9698 are conducted with the cover removed
and the unit connected to the power supply. Electric shock can cause
serious burns and fatal injuries. Therefore, adjustments must be
performed only by qualified electricians.
5/20 693, 698, 9698

Adjusting the actuator
1. Setting the CLOSED limit switch:
(Prerequisite: valve body and diaphragm are already mounted; (see chapter 3))
· Loosen cover screws (with 5mm flat-head screwdriver) and remove cover
· Using PH 1 Philips head screwdriver, loosen limit switch fixing screws 5, but do not remove
· Turn adjustment screw 4 (3mm flat head screwdriver) to position roller lever of the
CLOSED limit switch approx. 1 mm above the lower spindle guide
· Connect power supply to terminal 2 (L) and terminal 3 (N) → actuator runs to the CLOSED position
· Hold indicator spindle on the red marking → actuator closes completely, until motor stalls
· Release indicator spindle
· Disconnect power supply
· Loosen trigger cam screw using hexagon allen key (size 1.5)
· Press indicator spindle downward and fasten the trigger cam screw so that the cam
actuates the roller lever of the CLOSED limit switch = switch point
· Continue to turn adjustment screw 4 1 1/2 revolutions clockwise (jam safety).
(By continuing to turn the screw clockwise it is possible to reduce the pre-tension of the
diaphragm somewhat, which will increase the life of the diaphragm; however, if it is turned
too far, the valve will no longer seal properly)
· Check for leaks
· Fix CLOSED limit switch by means of limit switch fixing screws 5
2. Setting the OPEN limit switch:
(Prerequisite: Valve body and diaphragm already mounted (see chapter 3), CLOSED limit
switch set (see above))
· Using PH 1 Philips head screwdriver, loosen limit switch fixing screws 6, but do not remove)
· Drive actuator to OPEN direction past CLOSED limit switch and reverse towards
CLOSED until the CLOSED limit switch shuts off
· Turn the adjustment screw 3 clockwise to position the OPEN limit switch upward until it
stops (3mm flat blade screwdriver)
· Move actuator towards OPEN direction until the stroke length in the table below is
reached and switch off immediately → stroke length must correspond exactly.
· Turn the adjustment screw 3 anticlockwise to position the OPEN limit switch downward
until the switch point is made (audible click)
· Fix OPEN limit switch with limit switch fixing screws
DN: 15/25 32/40 50
stroke length in mm: 7.9 13.2 17.7
3 4
OPEN CLOSED
limit limit
switch switch
6 5
roller lever lower spindle guide
693, 698, 9698 6/20

3. Setting the potentiometer (functional module AP):
(Prerequisite: Valve body and diaphragm are already mounted (see chapter 3),
CLOSED limit switch and OPEN limit switch are set (see above))
a) Installation of potentiometer:
· To install the potentiometer support plate, loosen the 4 motor mount screws
· Push support plate in between (Caution: do not lift motor too much → otherwise toothed belt
will slip)
· Replace long screws with short screws (on potentiometer)
b) Setting the potentiometer:
· When the 9698 is delivered, the potentiometer is swiveled away from the actuator
· Connect power supply to terminal 2 (L) and terminal 3 (N)
→ actuator runs to the CLOSED position until limit switch shuts off
· Turn toothed gear of potentiometer (DN 50: lowest gear) clockwise until it reaches the stop
· Turn gear back 3 teeth
· Press potentiometer support plate onto the actuator gear and fix with enclosed screw
· To adjust the tooth clearance, loosen the other screw of the potentiometer support plate
(on the opposite side of the potentiometer)
· There must be some play in the toothed gear of the potentiometer:
Move plate anticlockwise: increases play in toothed gear
(Move plate clockwise: reduces play of toothed gear)
· Fix the potentiometer support plate screws
Toothed gear
increases play in gear
potentiometer support plate
reduces play in gear
Fixing screw
Loosen screw to adjust

play in gear
3 Mechanical installation and mounting
3.1 Installation of the GEMÜ 693 / 698

The GEMÜ 693 / 698 valves require no mechanical modification or additional extensions.
The valves can be installed directly into pipes by the chosen connection:
butt weld spigots, clamp connections or threaded connections (see pages 15-16).
3.2 Installation / mounting of the GEMÜ 9698

The GEMÜ 9698 motorized linear actuator must be connected to a diaphragm valve (then
corresponding to a GEMÜ 693 or 698).
Please note the following:
The GEMÜ 9698 actuator is in the open position when delivered.
The limit switches are not set, since this is only possible after the valve has been mounted.
The limit switch fixing screws are loose.
3.3 Mounting of a diaphragm valve

Mounting the valve body and diaphragm:
· Loosen cover screws (with 5mm flat-head screwdriver) and remove cover
· Connect power supply to terminal 2 (L) and 3 (N) → actuator runs to the CLOSED position
7/20 693, 698, 9698

· Switch off power supply
· for DN 15 / 25: Place washer and compressor on actuator shaft
for DN 32 / 40: Spring washers in the following arrangement: Place actuator----( ( ( ( ) ) ) )
and compressor on actuator shaft
for DN 50: Spring washers in the following arrangement:
Place actuator----( ( ) ) ( ( ) ) ( ( and compressor on actuator shaft
· Turn diaphragm until stop - do not turn too far!
· Turn diaphragm back at least 180° but no more than 270° back to angled position,
so that the diaphragm tab lines up with small groove in the distance piece
· Connect power supply to terminal 1 (L) and (N) → actuator runs to the OPEN position
· Disconnect power supply as soon as the diaphragm lies loosely approx. 2 - 3 mm in
the depression of the lower part of the distance piece (exception: DN 50)
(With DN 50, the ball bearing spindle must not touch the lower spindle guide (see photo
on p. 6), since this will otherwise be destroyed, i.e. the diaphragm is outside of the
depression in the max. OPEN position and is only pressed in by the screws)
· Mount body and tighten 4 fastening screws in cross pattern until a small compression
bulge is visible on all 4 diaphragm sides
· Check for external leakage and tighten screws, if necessary. Retighten after use if
needed.
3.4 Manual override

Perform the following steps if you need the manual override:
· Unscrew position indicator transparent cover 1

· and pull out together with adapter 2
This unit forms the hand crank 3
· Remove the plug 4 on the actuator outer surface
· Press adapter 2 tightly into the opening 5
· Crank into desired valve position (in the direction on label)
If the actuator is equipped with a potentiometer, use of the emergency

hand crank may cause the potentiometer to move out of adjustment.
After a manual override, therefore, the potentiometer should be set
again according to chapter 2.4, before the actuator is operated again.
1
2
4
4
693, 698, 9698 8/20

4 Electrical connections
4.1 Procedure
· The on-site cable ends must be connected to the terminal strip according to the
connection diagram for the standard version
· With a mounted controller, the included connector must be connected to the on-site
cable ends (power supply and signal cable) according to the respective connection
diagram (see pages 10-13)
4.2 Connection diagram
4.2.1 Internal wiring diagram with connection to terminal strip

Functional module AE Functional module AP
open Synchronous closed open Synchronous closed

motor motor
Actual value
Option
potentiometer
10 KΩ
linear
closed
closed
open
open
PE
PE
N
N
Diagram shows CLOSED position - cam has actuated S2 (limit switch CLOSED) → break
contact was opened.
CAUTION:
The potentiometer will be destroyed if both the limit switch
and the potentiometer are connected to terminals 5-8.
Therefore, connect either the limit switch or the potentiometer!
Never connect both!
9/20 693, 698, 9698

4.2.1.1 Functional module AE
OPEN / CLOSE control with additional end position feedback
1 2 3 4 5 6 7 8
Pin Description
1 L1, motor voltage for direction of travel OPEN
2 L1, motor voltage for direction of travel CLOSED
3 N, reference voltage
4 , PE, protective conductor
5 n. c.
6 Us, S2 end position CLOSED [Us = Ub]
7 Us, S2 end position OPEN [Us = Ub]
8 n. c.
4.2.1.2 Functional module AP

OPEN / CLOSE control with potentiometer output
1 2 3 4 5 6 7 8
Pin Description
5 n. c.
6 Us -, actual value potentiometer signal voltage
7 Us , actual value potentiometer signal output
8 Us +, actual value potentiometer signal voltage
693, 698, 9698 10/20

4.2.2 Connection with Hirschmann connector
4.2.2.1 Functional module AE

OPEN / CLOSE control with additional end position feedback
and Hirschmann connector N 6 R AM2 (Design: 6027)
1 2
6 3
5 4
Pin Description
4 n. c.
5 Us, S2 end position CLOSED [Us = Ub]
6 Us, S2 end position OPEN [Us = Ub]
4.2.2.2 Functional module AP

OPEN / CLOSE control with potentiometer output
and Hirschmann connector N 6 R AM2 (Design: 6027)
1 2
6 3
5 4
Pin Description
4 Us +, actual value potentiometer signal voltage
5 Us -, actual value potentiometer signal output
6 Us , actual value potentiometer signal voltage
11/20 693, 698, 9698

4.2.3 With mounted controller GEMÜ 1283
Connection diagram 1283 000 Z XX 01 00 ...
1
required when actuator and
controller power supply are
different
2
identical
Connection diagram 1283 000 Z XX 01 01 ...
1
different
2
identical
693, 698, 9698 12/20

5 Technical data
Working medium Ambient conditions of GEMÜ 698
Corrosive, inert, gaseous and liquid media which have Ambient temperature -10 ... +55° C
no negative impact on the physical and chemical Storage temperature -15 ... +55° C
properties of the body and diaphragm material.
Permissible temperatures of GEMÜ 693

Working medium temperature of GEMÜ 693 Storage temperature -15 to +55° C
Valve body PVC-U 5 to 60° C
Valve body ABS -20 to 60° C
Power consumption
Valve body PP 5 to 80° C
10 VA
Valve body PVDF -20 to 80° C
The permissible operating pressure depends on the working
medium temperature Rating
Continuously rated
Working medium temperatur of GEMÜ 698
Operating temperature max. 150° C Operating time
(depending on the medium wetted materials)
Standard design approx. 20 sec.
Ambient temperature of GEMÜ 693

Protection class
Valve body PVC-U / PP 5 to 55° C
IP 65 acc. to DIN 40050
Valve body ABS / PVDF -10 to 55° C
Cable gland
2 x PG 13.5
6 Order data
6.1 Order data for GEMÜ 9698
13/20 693, 698, 9698

Pressure / temperature correlation for plastic
Temperature in °C
-20 -10 ±0 5 10 20 25 30 40 50 60 70 80
(plastic body)
Valve body material permissible operating pressure in bar
PVC-U Code 1 - - - 10.0 10.0 10.0 10.0 8.0 6.0 3.5 1.5 - -
ABS Code 4 10.0 10.0 10.0 10.0 10.0 10.0 10.0 8.0 6.0 4.0 2.0 - -
PP-H Code 70/71 - - - 10.0 10.0 10.0 10.0 8.5 7.0 5.5 4.0 2.7 1.5
PVDF Code 20 10.0 10.0 10.0 10.0 10.0 10.0 10.0 9.0 8.0 7.1 6.3 5.4 4.7
Data for extended temperature ranges on request. Please note that the ambient temperature and medium temperature generate a combined
temperature at the valve body which must not exceed the above values.
Operating Kv Weight O-ring material for

pressure value (actuator only) valve bodies with union ends
MG DN EPDM / FPM PTFE [m³/h] [kg] Diaphragm material O-ring material
15 5.6 CSM EPDM
25 20 0 - 10 bar 0 - 6 bar 8.2 2.35 NBR EPDM
25 10.5 FPM FPM
32 18.0 EPDM EPDM
40 0 - 6 bar 0 - 6 bar 2.90
40 25.0
PTFE FPM
50 50 0 - 6 bar 0 - 4 bar 46.0 3.30
Other combinations on request
All pressures are gauge pressures. Operating pressure values were
determined with static operating pressure applied on one side of a
closed valve. Sealing at the valve seat and atmospheric sealing is Valve body material Code
ensured for the given values. PVC-U, grey 1
Information on operating pressures applied on both sides and for
high purity media on request. ABS 4
Kv values determined at p1 = 6 bar, EPDM diaphragm material,
Kv values: Tolerance ±10%. MG = diaphragm size PVDF 20
Inliner PPH - natural 70
Body configuration Code Inliner PPH - grey acc. to RAL 7032 71
2/2 way D
Diaphragm material Code
Connection Code NBR 2
Spigots DIN for socket welding 0 FPM 4
Flanges EN 1092 / PN10 / form B EPDM 14
(ex DIN 2501 / PN10 / form C)
length EN 558-1, series 1 PTFE/EPDM, PTFE laminated 52
ISO 5752, basic series 1 4
Union ends with DIN insert (socket) 7 Voltage / Frequency Code
Spigots for IR butt welding 20 24 V 50/60 Hz C4
Spigots for IR butt welding, BCF 28 120 V 50/60 Hz G4
Spigots - inch 30 230 V 50/60 Hz L4
Union ends with inch insert (socket) 33
Flanges ANSI class 125/150 RF,
Functional module Code
length EN 558-2, series 1 OPEN / CLOSE control
ISO 5752, basic series 1 39 with additional end position feedback AE
Union ends with DIN insert OPEN / CLOSE control
(IR butt welding) 78 with potentiometer output AP
For overview of available valve bodies see datasheet page 8
Order example 693 15 D 0 1 14 L4 AE

Type 693
Nominal size 15
Body configuration (code) D
Connection (code) 0
Valve body material (code) 1
Diaphragm material (code) 14
Voltage / Frequency (code) L4
Functional module (code) AE
693, 698, 9698 14/20

Operating pressure [bar] Weight [kg]
Diaphragm size DN EPDM/FPM PTFE Butt weld spigots
15 2.7
25 20 0 - 10 0-6 2.8
25 3.1
32 7.0
40 0-6 0-6
40 7.5
50 50 0-6 0-4 11.5
All pressures are gauge pressures. Operating pressure values were determined with static operating pressure applied on one side of a closed
valve. Sealing at the valve seat and atmospheric sealing is ensured for the given values.
Information on operating pressures applied on both sides and for high purity media on request.
Kv values [m³/h]
DIN DIN 11850 DIN 11850 DIN 11850 SMS 3008 ASME BPE EN ISO
MG DN series 1 series 2 series 3 1127
Code 0 Code 16 Code 17 Code 18 Code 37 Code 59 Code 60
15 4.1 4.7 4.7 4.7 - - 7.4
25 20 6.3 7.0 7.0 7.0 - 4.4 13.2
25 13.9 15.0 15.0 15.0 12.6 12.2 16.2
32 25.3 27.0 27.0 27.0 26.2 - 30.0
40
40 29.3 30.9 30.9 30.9 30.2 29.5 32.8
50 50 46.5 48.4 48.4 48.4 51.7 50.6 55.2
Kv values determined acc. to IEC 534 standard, inlet pressure 6 bar, ∆ p 1 bar, stainless steel valve body and soft elastomer diaphragm.
MG = Diaphragm size
Body configuration Code Connections Code

Tank bottom valve body B** Flanges
Flanges EN 1092 / PN16 / form B,
2/2-way body D length EN 558-1, series 1,
Multi-port design M** ISO 5752, basic series 1 8
T-body T* Flanges ANSI class 125/150 RF,
length MSS SP-88 38
* For dimensions see T Valves brochure
Flanges ANSI class 125/150 RF,
** Dimensions and versions on request or according to customer length EN 558-2, series 1,
requirements ISO 5752, basic series 1 39
Clamp connections
Clamps ASME BPE for pipe ASME BPE,
Connections Code length ASME BPE 80
Butt weld spigots Clamps following ASME BPE for pipe
Spigots DIN 0 EN ISO 1127, length EN 558-1, series 7 82
Spigots DIN 11850, series 1 16 Clamps ASME BPE for pipe ASME BPE,
Spigots DIN 11850, series 2 17 length EN 558-1, series 7 88
Spigots DIN 11850, series 3 18
Clamps DIN 32676 for pipe DIN 11850,
Spigots DIN 11866, series A 1A
length EN 558-1, series 7 8A
Spigots JIS-G 3447 35
Spigots JIS-G 3459 36 Clamps SMS 3017 for pipe SMS 3008,
Spigots SMS 3008 37 length EN 558-1, series 7 8E
Spigots BS 4825, Part 1 55 For overview of available valve bodies see data sheet page 8
Spigots ASME BPE 59
Spigots EN ISO 1127 60
Threaded connections
Threaded sockets DIN ISO 228 1
Threaded spigots DIN 11851 6
One side threaded spigot, other side
cone spigot and union nut, DIN 11851 62
Aseptic unions on request
15/20 693, 698, 9698

Valve body material Code Diaphragm material Code
EN-GJL-250, (GG25) 8 FPM 4
EN-GJS-400-18-LT (GGG 40.3), PFA lined 17 EPDM max. 130°C* 12**
EN-GJS-400-18-LT (GGG 40.3), PP lined 18 EPDM max. 150°C* 13**
1.4435 - BN2 (CF3M), investment casting Fe<0.5% 32 EPDM max. 90°C* 14
1.4435 (ASTM A 351 CF3M, ≙ 316L), EPDM max. 150°C* 16**
34*
investment casting EPDM max. 150°C* 17**
1.4408, investment casting 37 PTFE/EPDM convex PTFE loose max. 150°C* 5E**
1.4408, investment casting, PFA lined 39 PTFE/FPM convex PTFE loose max. 150°C* 5F
1.4435 (316L), forged body 40 * Steam sterilization temperature / 20 min
1.4435 (BN2), forged body Fe<0.5% 42 ** Material complies with FDA requirements
EN-GJS-400-18-LT (GGG 40.3),
83
hard rubber lined
* Material equivalency 316 L Supply voltage Code
24 V ± 10% C
120 V ± 10% G
230 V ± 10% L
Mains frequency Code

50/60 Hz 4
Functional module Code

OPEN / CLOSE control
with additional end position feedback AE
OPEN / CLOSE control
with potentiometer output AP
Valve body surface finish, internal contour Code

Ra ≤ 6.3 μm blasted internal/external 1500*
Ra ≤ 6.3 μm electropolished internal/external 1509*
Ra ≤ 0.8 μm mechanically polished internal, blasted external 1502
Ra ≤ 0.8 μm electropolished internal/external 1503
Ra acc. to DIN 4768; at defined reference points * only investment cast design
Order example 698 25 D 60 34 12 L 4 AE 1500

Type 698
Nominal size 25
Body configuration (code) D
Connection (code) 60
Valve body material (code) 34
Diaphragm material (code) 12
Supply voltage (code) L
Mains frequency (code) 4
Functional module (code) AE
Surface finish (code) 1500
693, 698, 9698 16/20

7 Information
Note concerning the EC Machinery Directive 2006/42/EC:
A Declaration of Incorporation in accordance with the EC Machinery Directive 2006/42/EC
accompanies this product.
For incorporation in an installation classed as a machine:
The commissioning is prohibited until it has been determined that the machine (plant) in which this
product is to be incorporated complies with the provisions of the EC Machinery Directive
2006/42/EC.
Handling, assembly and commissioning, in addition to setting and adjustment of the machine must
be performed only by authorised specialist staff.
Note: Connection and adjustment of the machine must be performed only by authorised service
personnel. The manufacturer shall assume no liability for damages resulting from improper use or
unauthorized actions. In case of doubt, please contact us before initial operation.
8 Dimensions
8.1 Dimensions - GEMÜ 9698
All dimensions in mm
17/20 693, 698, 9698

8.2 Dimensions - GEMÜ 693 8.3 Dimensions - GEMÜ 698
Actuator dimensions Actuator dimensions

of GEMÜ 693 [mm] of GEMÜ 698 [mm]
MG DN A A1 MG DN A A1
25 15 - 25 222 82 25 15 - 25 222 82
40 32 - 40 271 131 40 32 - 40 271 131
50 50 278 138 50 50 278 138
MG = Diaphragm size MG = Diaphragm size

The dimensions of the valve bodies see The dimensions of the valve bodies see
data sheet of GEMÜ 693. data sheet of GEMÜ 698.
693, 698, 9698 18/20

Goods return declaration (copy specimen)
Legal regulations for the protection of the environment and personnel require that you include the
completed and signed goods return declaration with the dispatch documents.
If this declaration is not completed or not included with the dispatch documents, your return
will not be processed!
If the valve / device was operated with poisonous, corrosive, flammable, aggressive or water-
endangering media, all medium wetted parts must be emptied carefully, decontaminated and rinsed.
Select an appropriate transport container, label it with the name of medium which the valve / device
had made contact. This serves to avoid personal injury or damage to property from remains of media.
Company details: Valve / device information
Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Year of manufacture: . . . . . . . . . . . . . . . . . . . . . . . .
......................................... Serial number: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contact person . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ambient temperature: . . . . . . . . . . . . . . . . . . . . . . .
Telephone number . . . . . . . . . . . . . . . . . . . . . . . . . Media: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fax number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .........................................
E-Mail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .........................................
Reason for return: Concentration: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
......................................... .........................................
......................................... .........................................
......................................... Operating temperature: . . . . . . . . . . . . . . . . . . . . . .
......................................... Operating pressure: . . . . . . . . . . . . . . . . . . . . . . . .
......................................... Viscosity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
......................................... Solids content: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Please tick the relevant warning labels:
radioactive explosive corrosive poisonous harmful bio- oxidising harmless

to health hazardous
We herewith declare that the returned parts were cleaned and that according to danger protection
regulations there is no danger from remains of media for persons or for the environment.
Location, Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stamp / signature . . . . . . . . . . . . . . . . . . . . . . . . . .
19/20 693, 698, 9698

9 EG-Konformitätserklärung
According to annex VII of the Directive

97/23/EC
Hereby we, GEMÜ Gebr. Müller GmbH & Co. KG
Fritz-Müller-Straße 6-8
D-74653 Ingelfingen
declare that the equipment listed below complies with the safety requirements of
the Pressure Equipment Directive 97/23/EC.
Description of the equipment - product type
Diaphragm valve
GEMÜ 693, GEMÜ 698
Notified body: TÜV Rheinland

Berlin Brandenburg
Number: 0035
Certificate no.: 01 202 926/Q-02 0036
Conformity assessment procedure:
*88237958*
Module H
Valves DN ≤ 25 comply with section 3§3 of the Pressure Equipment Directive

97/23/EC. They are not identified with a CE label as per Pressure Equipment
Directive 97/23/EC and no conformity is declared.
Subject to alteration · 11/2012 · 88237958
Management
VALVES, MEASUREMENT
AND CONTROL SYSTEMS
GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG · Fritz-Müller-Str. 6-8 · D-74653 Ingelfingen-Criesbach
Phone +49 (0) 7940/123-0 · Telefax +49 (0) 7940/123-224 · info@gemue.de · www.gemue.de

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ThyssenKrupp Industrial Solutions

Operation and maintenance manual

Year of construction 2013/2014

ThyssenKrupp Industrial Solutions AG

Document : Operation and maintenance manual (Mechanical part)

Order no. : N-033-00114

First issue March 20,

Revision Date Revised chapter/Page Description of revision

This operation and maintenance manual

2. OVERVIEW IRON ORE HANDLING SYSTEM

3. DESCRIPTION OF MACHINE AND ASSEMBLY GROUPS

The part on the hydraulical equipment is contained in the hydraulical operating

2. OVERVIEW IRON ORE HANDLING SYSTEM

3. DESCRIPTION OF MACHINE AND ASSEMBLY GROUPS

Access to chapter 1 "GENERAL SECTION" is facilitated by table of contents and by

March 20, 2015 225 E - SHOUGANG Stacker STD-4500 (930-ST-110) Chapter 1 - 1

March 20, 2015 225 E - SHOUGANG Stacker STD-4500 (930-ST-110) Chapter 1 - 2

1.1 GENERAL ............................................................................... 5

March 20, 2015 225 E - SHOUGANG Stacker STD-4500 (930-ST-110) Chapter 1 - 3

March 20, 2015 225 E - SHOUGANG Stacker STD-4500 (930-ST-110) Chapter 1 - 4

The manual must always be available, wherever the machine/plant is in use.

The manual includes numerous instructions to be regarded as warning of potential

March 20, 2015 225 E - SHOUGANG Stacker STD-4500 (930-ST-110) Chapter 1 - 5

right = on the right-hand side looking in conveying direction

left = on the left-hand side looking in conveying direction

• = instructions (in stated order)

TKIS = ThyssenKrupp Industrial Solutions AG

March 20, 2015 225 E - SHOUGANG Stacker STD-4500 (930-ST-110) Chapter 1 - 6

1.1.2 Liability and warranty

• disregarding any information / instructions included in the manual;

• any use of the machine other than the designated use;

• use of spare parts not approved by the manufacturer;

• conversions and modifications not approved by the manufacturer.

March 20, 2015 225 E - SHOUGANG Stacker STD-4500 (930-ST-110) Chapter 1 - 7

1.1.4 Technical modifications

1.2 GENERAL SAFETY INSTRUCTIONS

The machine/plant must only be used in a perfect technical condition in accordance

March 20, 2015 225 E - SHOUGANG Stacker STD-4500 (930-ST-110) Chapter 1 - 8

In the event of safety-relevant modifications or changes in the behaviour of the

Never make any modifications, additions or conversions to the machine/plant which

Hydraulic hose pipes are to be exchanged at appropriate intervals, even if no safety-

Adhere to prescribed intervals or those specified in the operating and maintenance

These operation and maintenance instructions must be supplemented by instructions

1.2.2 Modifications and spare parts

March 20, 2015 225 E - SHOUGANG Stacker STD-4500 (930-ST-110) Chapter 1 - 9

Use protective equipment wherever required by the circumstances or by law.

March 20, 2015 225 E - SHOUGANG Stacker STD-4500 (930-ST-110) Chapter 1 - 10

March 20, 2015 225 E - SHOUGANG Stacker STD-4500 (930-ST-110) Chapter 1 - 11

1.2.4 Noise pollution

When the permissible limits are exceeded, the operating personnel

1.2.5 Residual risks during daily operation

However, risks may nevertheless occur during machine/plant operation.

Its use may constitute a risk:

1.2.6 Disposal of consumables and process materials

Ensure that all consumables and process materials are disposed of

March 20, 2015 225 E - SHOUGANG Stacker STD-4500 (930-ST-110) Chapter 1 - 12

1.2.7 Fire Protection

Display the fire protection rules at several points on the plant.

The user must provide an adequate number of hand-held fire-extinguishers at easily

We recommend that the following procedures be adopted:

March 20, 2015 225 E - SHOUGANG Stacker STD-4500 (930-ST-110) Chapter 1 - 13

1.2.8 Post Earthquake Evaluation

All structures are designed according to the contractually predetermined earthquake