User Manual PDF

UM-GB-A
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POWER UNITS AND

HYDRULIC SISTEMS
♦
USER MANUAL
1 Power units installation
1 Placement
1.1 Pipe connections.
1.2 Flush-through testing.
1.3 Filling the system.
1.4 Electrical connections.
2 Starting procedure.
2.1 Starting.
3 Maintenance and repairs.
3.1 Preventative maintenance.
3.2 Regular maintenance.
3.3 Troubleshooting guide.
4 Reccomendations and adjustement.
4.1 Trasnsport and hoisting.
4.2 Hydraulic fluids.
4.3 Accumulators.
4.4 Health-related problems.
5 Storage, demolition and disposal.
6 Commissioning programme.
7 Standard preventive maintenance programme.
8 Appendix
8.1 Demands for hydraulic fluid
8.2 Filtration.
Fraz. Cadriano - 40057 GRANAROLO DELL’EMILIA (BO) Via Andrea Costa, 11/2
Tel. 051-765555 (3 linee r.a.) - Tel. 051-6065111 - Telefax 051-766699 - Telefax 051-6065190
Sito web: www.oleobi.it E.mail: [email protected]
POWER UNITS AND HYDRAULIC SYSTEMS
USER MANUAL
1. POWER UNITS INSTALLATION.
1.1 Placement
Before installing the oil pumping unit, make sure that enough space is left around it to carry out maintenance. There must
also be adequate space to allow you to connect the unit’s intake and outlet pipes as well as its auxiliary systems (water,
power, and the like). The unit has to be placed in a clean and well-ventilated area, away from heat sources. When
transporting the unit, do not lift it by the parts attached to the tank: always use the parts marked as suitable for lifting or
use a forklift, inserting the forks under the tank. The unit must be placed on a fixed base. If the base needs to be
strengthened, ensure that the unit is stable and will not shift when in operation.
1.2 Pipe connections.

Only qualified technicians should connect the pipes from the oil-pumping unit to the machinery it is serving. Keep inlet
and outlet sealed to keep out dust or dirt. The system’s designer must provide all pipe sizes and specifications. Avoid
sharp bends, keep curves to a minimum and use as few fittings as possible as each fitting is a potential spillage point.
Steel piping must rest on regularly-spaced supports and should never be forced or modified once they are in place.
Flexible piping must be assembled following the manufacturer’s instructions, recalling that under pressure flexible pipes
contract. They must therefore be sufficiently long to prevent undue stress on their end points. For steel piping, use DIN
2391 standard continuous pipes (without welding points) max. hardness HRB75. The end point of the pipe must be cut at
90º from its axis. It has to be clean and without welding flashes. The exact size and specifications of fittings must be
agreed upon with the unit or system supplier. In general we recommend using flat faces with washers, rather than cone-
shaped faces with sealing ribbons or liquids. For welded fittings, take great care in particular to avoid leaving welding
flashes or residues inside the pipes. All pipes must be easily taken apart. When bending steel piping, ensure that liquid
flow-through will not be reduced. Pipes must be placed so as not to obstruct control panels, valves and monitoring
equipment. Keep all pipes clean.
1.3 Flush-through testing.

The system/unit is supplied clean, however we recommend the following action be taken after the unit is set in place. As
the unit/system has been cleaned before leaving the factory, the best way to flush through the system is to use a separate
filter/pump/motor unit. The flush pump should be able to generate a pressure in excess of the one produced by the unit
being installed. Temporarily by-pass actuators and the more delicate valves. Use, if possible, the same fluid that the unit
will normally pump. If flushing is to be done with the same system/unit pump, follow the procedures outlined in
“2. Starting procedure” and follow these instructions:
a) Always keep pressure low during flush-through;
b) Ensure the flush-through fluid is clean and compatible with the fluid that will be used by the unit/system;
c) Regularly check filter blockage gauges and immediately replace them if necessary;
d) When flushing is complete, change filters.
We recommend that a specialist in filtration be asked to examine the fluid used for flushing once the testing is complete.
1.4 Filling the system.

The tank is clean when it leaves the factory. Ensure it is still clean and if necessary clean it before filling it. To avoid
contamination, when filling use either a separate pump with filter or the unit’s own pump. Filter even new oil added to
the tank. Ensure the tank is filled to proper level, keeping in mind that the oil level will drop once the unit is set in
motion and the oil starts to fill pipes and actuators. Check fluid level regularly. Use the proper filter as described in the
circuit plans and specifications sheets. Always follow the supplier’s instructions for your particular unit. A clean
system/unit will be more efficient, will suffer fewer spills and will work longer. Check with the unit’s supplier if you
have any questions. Never mix different fluid types and grades.
1.5 Electrical connections.

Check that network voltage and the motor’s listed specifications are the same. Check that instrument voltage is correct.
Ensure the correct connection of phases.
Checking that electrical connections are correctly made ensures that the motor will turn
correctly. Every time the unit or the system has to be disconnected from the power network,
check again that all electrical connections are properly made.
POWER UNITS AND HYDRAULIC SYSTEMS - USER MANUAL- MDU-GB-A - Page 1 of 23

2. STARTING PROCEDURE
Before starting, check that:
a) all electrical and fluid connections on the system conform to plan
b) the tank is filled with oil to the correct level
c) all fittings are properly in place
d) inlet and outlet valves are open (if present)
e) pressure control valves are calibrated
f) where necessary, pump sheaths must be filled with the clean fluid required for your particular unit/system
g) if a pressure tank is attached to the system, ensure that it has reached the specified pre-load pressure. By law, a
pressure tank attached to one of these units/systems may be shipped unpressurised. If it is already pressurised, a
shipping label will indicate the tank is under pressure. Ensure the valve is shut.
h) Starting the unit must take place safely. All staff must be made aware of moving parts.
2.1 Starting
a) start and stop the electric motor a few times to ensure that it is turning over in the proper direction.
b) start the unit and check for spills or strange noises
c) After ten minutes, check unit stability and oil level, and if necessary add oil. Immediately stop any oil spillage.
d) While the system is working on low pressure, manually operate the actuators, bleeding the system. Repeat a few
times. Gradually raise pressure until you reach the specified load.
e) While the system is working, changing the flow rate can be used to check actuators speed. Since flow rate
control valves can be hard to adjust under pressure, de-pressurise pipes before adjusting.
f) Bleed air from the unit/system through the air vents (if present) or check with your supplier.
g) Check for spillages, high temperatures, and excess noise. Ensure the electric motor is working within
manufacturer’s specifications.
h) Check fluid levels and monitor the inside of the tank. If oil changes colour, this may indicate that air is being
mixed in.
i) Check that pressure, flow rate and electric motor comply with supplier’s test certificate. If any of them differs,
contact supplier immediately to prevent warranty being voided.
Under no circumstances ever stay near to pressure pipes, particulary if these are flexible type.
3 MAINTENANCE AND REPAIRS

Qualified personnel must carry out all installation and maintenance work. It is the user’s responsibility to comply with all
health and safety regulations.
3.1 Preventative maintenance

The following controls have to be carried out regularly every week or longer intervals if recommended by the supplier
(see Standard Preventative Maintenance Programme, item 7)
3.1.1 Outside cleaning. Makes locating, and therefore immediately repairing, possible spills easier.
3.1.2 Fluid Levels. Regularly check fluid levels. When the unit has only just been installed, carry out checks
regularly until you have worked out an optimal control frequency. Immediately track unusual fluid spills and
identify their cause. Always top up tank with the same oil. Fire-resistant fluid must be added following
manufacturer’s instructions. Immediately change contaminated oil. Filter the full amount of fluid within the tank to
ensure the necessary level of cleanliness. Used oil must be disposed of in accordance with health and safety
regulations.
3.1.3 Fluid temperature. High temperatures alter the chemical make-up of oil and damage the system.
Hydrocarbons decay rapidly under heat.
Be carefull to hot parts (tank, pipe, connections and other parts) that are in contact with the
fluid.
3.1.4. Filters. Regularly check filter blockage gauges. If gauges indicate “blockage” immediately replace filters.
Failure to replace filters may void warranty.
3.1.5 Accumulators. Check that pre-load pressure complies with manufacturer’s recommendations.
Before checking pre-load pressure, fluid must be completely de-pressurised inside

accumulator by means of the appropriate device (see 4.3)

3.1.6 Pipes. Check pipes for spills, and repair or replace all defective pipes. Check fitting tightness. Keep supports
level where necessary.
3.1.7 Heat exchanger. Clean oil-water exchangers every year. Depending upon the type of water used and upon
actual working experience, frequency may vary. Water filters must, however, be checked more frequently. Oil-air
exchangers’ checks vary depending on the facilities in which the system operates. Cleaning the radiating elements
will ensure proper airflow and avoid reduced thermal efficiency.
3.1.8 Technical specifications. Check the unit’s technical specifications and working conditions to ensure
compliance with the required values. Inspect filters, blockage gauges, air outlets, ensure that pressure and flow
gauges have been calibrated and blocked in compliance with the recommended values. Check tank washers,
electrical connectors, etc. Check fluid temperature.
3.2 Regular maintenance.

All units must undergo regular maintenance every so often. Depending on the unit, the time between one maintenance
and the next may vary between 1 and 5 years. Whatever the time period suitable for your unit, ensure that maintenance is
regularly carried out. Follow manufacturer's instructions. Check fluid for contamination, and filter or replace it as
necessary. Clean air and oil filters as well as magnetic filtering units. If necessary, clean tank pipes, pumps and valves.
Carry out controls being careful to avoid letting dirt into the system. Fittings, supports, and any damaged or worn parts
must be replaced. Check all pipe fitting and tighten or replace as necessary. A proper maintenance will replace used parts
with new ones and used parts are sent back to the manufacturer for checking. We recommend you keep a record of the
unit maintenance episodes and carry out control at the stated intervals for your unit.

Oil pumping units built for the required operating conditions and correctly installed should function for many years
without problems. However, in spite of all precautions problems may occur, in which case you must identify the cause
and fix as soon as possible. The notes on the next pages present a general troubleshooting guide. Identifying the source of
problems will be easier if you can refer to the fluid circuit plan. Identifying malfunctioning is often assisted by observing
the return flow into the fluid tank.
Worn or damaged parts may leave residues in the system. These residues must be removed. If
you are unsure, or if significant spillages occur, disassemble the entire system, clean it and
reassemble it again filling it with clean new oil.
3.4 TROUBLESHOOTING GUIDE FOR HYDRAULIC CIRCUITS
The following tables report a list of possible problems. The list is not exhaustive :, only the main problems reported in
circuits are mentioned. Repair advice is based on our experience . Qualified technical staff are available for all repairs.
In the case of repairs undertaken by yourself, ensure the highest standards of cleanliness during disassembly and
reassembly of parts.
! Contamination reduces the life of the hydraulic circuit
1 – PUMPS AND MOTORS
1.1 – Insufficient or no output

1 - Cause incorrect pump rotation, coupling key loose
♦ Solution correct electrical connections. Check that the key is in place.
2 - Cause oil level is too low
♦ Solution top up reservoir
3 - Cause clogged strainer or too small
♦ Solution clean or replace
4 - Cause incorrect pressure control setting
♦ Solution adjust setting
5 - Cause suction gate valve closed, or partially closed
♦ Solution adjust open or replace
6 - Cause air bubbles in the circuit
♦ Solution bleed circuit of air and allow air to settle out of oil in tank
7 - Cause suction joints allowing air into system
♦ Solution change seals or replace
8 - Cause broken pump shaft
♦ Solution (overloading or poor alignment of the pump): change shaft

9 - Cause incorrect fluid for application

♦ Solution check system specification reference to H.F. fluids. Replace fluid
10 - Cause oil too cold (viscositytoo high)
♦ Solution heat oil to recommended temperature
11 - Cause pump not primed
♦ Solution no air bleederdevice on the discharge. (loosen one connector on this pipe and bleed)
12 - Cause suction height excessive
♦ Solution reduce the height. Check pump specification re H.F. fluids
13 - Cause pump rotation speed too high
♦ Solution reduce rotation speed to recommended level
14 - Cause sealed reservoir (airtight tank) air intake blocked
♦ Solution install newair intake or air filter with sufficient capacity
1.2 – Noisy pump or motor
1 - Cause cavitation
♦ Solution prime pump circuit (also refer to 1.1 –11 and 10.2) adjust or control the hydraulic
motor deceleration
2 - Cause entry of air via the intake line joints
♦ Solution change the connector or seals and check pipe airtightness
3 - Cause shaft seal allowing entry of air
♦ Solution change seal. Check shaft alignment
4 - Cause aeration
♦ Solution bleed the circuit (see also 10.2)
5 - Cause air intake system in reservoir clogged or missing
♦ Solution clean or install air intake system
6 - Cause strainer is too small
♦ Solution install a larger strainer or clean it
7 - Cause diameter of pump intake too small or pipe blocked
♦ Solution replace with larger diameter pipe. Remove blockage. Check fluid velocity
8 - Cause air intake at pump housing
♦ Solution adjust torque of housing bolts , and ensure that seals are compatible with fluid used
9 - Cause broken vane spring
♦ Solution change cartridge. If premature, investigate cause
10 - Cause worn or damage in the pump motor
♦ Solution repair or replace if problem aoocurs early in unit’s life, investigate cause
11 - Cause pump or motor subjected to strain on mounting
♦ Solution check alignment of the mounting and tighten nuts evenly
12 - Cause contamination in supply circuit
♦ Solution remove the contaminants and if necessary clean the circuit
13 - Cause contaminated circuit
♦ Solution drain system, flush and fill to NAS 1638 Class 8 ISO 18/14. Have the particles analysed to
determine type and size
14 - Cause Flattened intake suction pipe
♦ Solution replace
15 - Cause oil temperature too high
♦ Solution check the circuit design to establish the cause (cooler) see also 1.3. System heat extraction
capacity must match power losses
16 - Cause boost pump failure
♦ Solution find cause and repair boost pump
17 - Cause noisy tank (resonance)
♦ Solution change tank position or attachment, install an anti-noise system. Re-locate pump
18 - Cause flexible intake hose seepage
♦ Solution replace flexible hose
19 - Cause vibrations in circuit (component resonance)
♦ Solution find the cause and repair (see also 12.1)
20 - Cause other pump or motor defects
♦ Solution if problem does not match any on this list, return to the factory
21 - Cause oil level too low
♦ Solution top-up reservoir. Check for system leaks
22 - Cause incorrect functioning of the intake valve
♦ Solution repair or remove valve

23 - Cause fluid mismatch

♦ Solution replace with reference to H.F. Standards
24 - Cause rotation speed too high
♦ Solution adjust to recommended speed
1.3 – Pump or motor giving off too much heat
1 - Cause fluid mismatch
♦ Solution replace with reference to H.F. Standards
2 - Cause excessive fluid velocity in the circuit
♦ Solution revise pipe size or moderate flow
♦ Solution to up reservoir
4 - Cause pump or motor rotary assembly worn
♦ Solution replace cartridge. If problem occurs early in unit?s list, investigate cause
5 - Cause radial or axial load too high
♦ Solution adjust alignment and radial load to pump limit specification
6 - Cause increase in the initial speed because of modification of the circuit
♦ Solution check maximum pressure; if necessary change type of pump (flow too high) and install
suitably sized pipes
7 - Cause poorly sized heat exchanger
♦ Solution increase heat exchanger capacity of the heat exchanger (see also 14.1)
8 - Cause blocked or contaminated heat exchanger
♦ Solution find the cause and repair (deposits, tartar, bacteria in the water circuit)
9 - Cause too little difference between set maximum and operating pressure
♦ Solution increase set maximum pressure or reduce operating pressure
10 - Cause relief valve set too high
♦ Solution adjust to correct setting
11 - Cause error in the choice of the relief valve
♦ Solution replace with one to meet specification
12 - Cause relief valve malfunction
♦ Solution repair or replace
13 - Cause error in the internal seals
♦ Solution replace with reference to H-F. Standard
14 - Cause filter clogged or too small causing excessive pressure drop
♦ Solution clean filter or replace cartridge, change the filter
15 - Cause rotation speed too high
♦ Solution reduce to recommended pump specification speed
♦ Solution check pump priming and bleed circuit (see also 1.1 and 10.2)
17 - Cause aeration
♦ Solution bleed the circuit (see also 10.2)
18 - Cause air intake clogged
♦ Solution clean the system (see also 1.1)
♦ Solution drain system, flush and fill to NAS 1638 Class8. ISO 18/14, and if necessary scour the pipe
and clean them again
20 - Cause flattened inlet pipe
♦ Solution replace the inlet pipe
21 - Cause boost pump failure
♦ Solution determine cause and repair boost pump
22 - Cause other defects in the pump or motor
♦ Solution if problem does not match any on list, return to factory
1.4 – Lack of pressure from the pump or motor
1 - Cause incorrect pressure setting
♦ Solution locate valve and adjust setting
2 - Cause relief valve malfunctio
♦ Solution locate unit, clean, adjust, repair or replace
3 - Cause faulty electrical circuit (solenoids)
♦ Solution check the electrical circuit and signal to appropriate solenoids
4 - Cause leak in the circuit (cylinders)
♦ Solution check seals and replace any faulty ones

5 - Cause error in the circuit assembly

♦ Solution check the pipework and rectify accordingly
6 - Cause broken pump shaft or shaft key missing
♦ Solution find the cause (pump subjected to strain?). Change the shaft; put the key back in place
7 - Cause incorrect setting of the by-pass contacts
♦ Solution modify contacts setting (pressure switches)
8 - Cause no flow from the pump
♦ Solution see 1.1
9 - Cause poor fluid quality
♦ Solution drain system, flush and fill to NAS 1638 Class 8. ISO 18/14 and H.F. Specification
10 - Cause faulty drive mechanism
♦ Solution find the cause and repair mechanism
11 - Cause drive mechanism belt slips
♦ Solution adjust or replace belt
♦ Solution drain system, flush and fill to NAS 1638 Class 8. ISO 18/14
13 - Cause poor seals and coverings, suspect fluid compatibility
♦ Solution replace with recommended parts with reference to H.F. Specification
1.5 – Loss of motor speed
1 - Cause supply pressure too low
♦ Solution increase pressure
2 - Cause back pressure too high
♦ Solution check the circuit
3 - Cause front plate not making contact (port plate)
♦ Solution strip vane motor and repair
4 - Cause worn or damaged motor (wear by abrasive particles)
♦ Solution replace or repair. If problem occurs early in unit’s life, investigate cause
♦ Solution check the circuit (heat exchanger). See also 1.3
1.6 – Poor speed control
1 - Cause excessive system leakage relating to fluid temperature change
♦ Solution identify critical unit (s), repair, replace or incorporate compensated flow
1.7 – The motor does not work
1 - Cause torque too low
♦ Solution check – increase the initial pressure if necessary
2 - Cause large internal or drain leak
♦ Solution check internal parts. Deterioration by contamination or cavitation. Repair or replace
3 - Cause faulty O-rings on front plate
♦ Solution replace O-rings and check that front plate runs freely. (check axial balance)
4 - Cause Inadequate pump flow
♦ Solution repair or replace with a pump producing greater flow (check input power)
5 - Cause motor too small (displacement)
♦ Solution replace with a larger model (set slower speed)
1.8 – Too much play in the shaft
1 - Cause defective bearing
♦ Solution replace bearing
2 - Cause too high a radial or axial load
♦ Solution ensure that the maximum authorised load is not exceeded. Install lot-shaft if necessary
3 - Cause badly balanced coupling (eccentric throw)
♦ Solution balance or change the coupling
1.9 – Leak in the pump or motor
1 - Cause insufficient sealing on connections
♦ Solution check seals
2 - Cause poor sealing of the shaft seal
♦ Solution look for the cause of seal weakness
3 - Cause damaged mating faces
♦ Solution remove imperfections on the faces or preferably send the pump or motor for repair or
Replacement

4 - Cause no deceleration valve on the motor circuit (braking pressure too high = destruction of the
motor)
♦ Solution install a deceleration valve and feed valves (c’balance and check)
2 – DIRECTIONAL VALVES
2.1 – Sticking spools

1 - Cause sticking spool due to distortion
♦ Solution loosen fixing screws and tighten evenly (check flatness of contact areas)
2 - Cause particles in circuit
♦ Solution drain system, flush and fill to NAS 1638 Class 8. ISO 18/14
♦ Solution drain system, flush and fill with reference to H.F. Standard, NAS 1638 Class 8.
ISO 18/14
4 - Cause water in circuit
♦ Solution check cooling system with reference to temperature cycle and reservoir condensation
(see also 14.2)
5 - Cause thickening of anticorrosion oil (as a result of being stored too long)
♦ Solution clean the spool and if necessary circulate the oil to get rid of the deposits
6 - Cause error in valve assembling
♦ Solution carefully follow the section diagram in the service literature
7 - Cause wrong connectors
8 - Cause oil pump too high
♦ Solution see 10.3 and 14.1
9 - Cause oil speed too high (loss on load and unbalancing of the spool (Bernoulli forces))
♦ Solution install a valve with a larger capacity
10 - Cause piping subjected to strain (longitudinal extension) causing valve distortion
♦ Solution piping too short or establish compensation curves only for large differences in temperature,
and pressure
11 - Cause oil too cold
♦ Solution heat system to recommended temperature
12 - Cause faulty spool
♦ Solution repair or replace spool (be careful of the state of the bore in the body)
13 - Cause drain line under pressure or missing (on externally drained valves)
♦ Solution establish an independent direct drain line to the tank
2.2 – The solenoid does not work
1 - Cause burnt out solenoid
♦ Solution check for cause and replace
2 - Cause blocked spool
3 - Cause no current at solenoid
♦ Solution check cables and fuses for power supply to solenoid
4 - Cause fault in the electrical circuit
♦ Solution check circuit. Note: the solenoid may burn out for the following reasons:
a) under voltage,
b) over voltage,
c) two solenoids energized at the same time,
d) unbalancing of the spool,
e) back pressure in the drain,
f) temperature too high in the hydraulic circuit change in the resistance value and therefore
increased consumption,
g) increasing heating,
h) distortion of the nylon core support and guide
2.3 – The two stage distributor does not work
2 - Cause no pressure
♦ Solution check the circuit (see also 1.4, 5.2 and 5.3
3 - Cause no pilot line
♦ Solution install line (see 2.1)

4 - Cause blocked pilot line

♦ Solution clean line (passage narrowed by a build up of silt). See if there is a blocked calibrating
orifice
5 - Cause slide does not go back
♦ Solution choke block not set correctly, check that the diaphragm screw in the electric pilot is not
blocked
2.4 – The valve gives off too much heat
1 - Cause temperature in the circuit too high
♦ Solution check circuit and cooling system
♦ Solution follow the user’smanual (for special fluids consult the factory). Drain system, flush
and fill to H.F. Standard and filtration Class 8 NAS 1638. ISO 18/14
3 - Cause dirty circuit
♦ Solution Drain system, flush and fill to NAS 1638 Class 8. ISO 18/14
4 - Cause fault in the electrical circuit
♦ Solution check electrical circuit
6 - Cause faulty spool (jamming by particles)
♦ Solution service or replace spool
2.5 – Noisy valve
1 - Cause valve is too small (high fluid velocity)
♦ Solution increase valve and pipe size
1 - Cause vibrations in circuit
♦ Solution tighten the pipe (see 12.1)
1 - Cause no choke pack
♦ Solution install a choke pack
1 - Cause spool incompatible with the circuit
♦ Solution change to an appropriate spool
♦ Solution check to see if the circuit is dirty (see also 2.1 and note)
2.6 – Leak in the valve
1 - Cause poor connection seals
♦ Solution check seals (special fluids and compatible seals)
2 - Cause defective or badly assembled seal
♦ Solution change the seal and lubricate it
3 - Cause sealed parts not tightened to correct setting
♦ Solution tighten to required torque specification
4 - Cause fault in the valve or spool
♦ Solution crack in the body? Change the valve or body
5 - Cause drain line under pressure
♦ Solution install an independent drain line to tank
6 - Cause no drain line
♦ Solution install the drain line to tank
3 – SERVO-VALVES
3.1 – Blocked servo-valve

NOTE: we strongly recommend that you send worn servo-valve to specialist department for repairs.
1 - Cause dirty supply tube
♦ Solution check that the circuit is clean, if not clean it (stripping, flushing etc.)
2 - Cause clogged filter
♦ Solution check the cleanliness of the circuit and the filter or replace the cartridge element
3 - Cause mechanical return of the slide. Blocked feedback
♦ Solution establish the cause (valve under strain) change the valve
4 - Cause valve under strain (distorded body)
♦ Solution loosen valve and then tighten evenly
3.2 – The servo-valve does not work
1 - Cause fault in electrical circuit
♦ Solution check the electrical circuit and amplifier

2 - Cause damaged magnetic circuit

♦ Solution repair or replace the circuit
3 - Cause no differential current
♦ Solution check electrical network
4 - Cause no pressure
♦ Solution check the circuit (see also 1.4, 1.5 and 5.3)
5 - Cause dirty supply tube
5 - Cause clogged filter
6 - Cause mechanical return of the slide
7 - Cause valve under strain
♦ Solution follow the instruction laid down
9 - Cause oil too thick
♦ Solution flush the valve and if necessary change it, replace oil
♦ Solution reduce the initial pressure or increase the coolant
11 - Cause valve capacity too small
♦ Solution install a valve with larger capacity
12 - Cause faulty valve
♦ Solution change valve (see note)
3.3 – The servo-valve gives off too much heat
1 - Cause error in the current
♦ Solution check the current and electronic base plate, if necessary modify it
1 - Cause mechanical return of the slide. Blocked feedback
4 – CHECK VALVES
4.1 – Blocked check valve

1 - Cause spool tight, not free
♦ Solution loosen the screws and then tighten them evenly
2 - Cause assembly error
♦ Solution follow the assembly instruction
3 - Cause check valve seat out of line
♦ Solution install a new seat and check that it is positioned correctly
4 - Cause tight pilot piston
♦ Solution find the cause and repair or change pilot piston
5 - Cause missing drain line
♦ Solution install drain line directly to the tank
6 - Cause drain line pressurized
♦ Solution install a separate drain line direct to the tank
7 - Cause other causes
4.2 – Leak in the valve
1 - Cause faulty check valve
♦ Solution repair or replace the check valve and check the cleanliness of the circuit
2 - Cause external leaks
♦ Solution replace seals, refer to compatible materials, H.F. Standards
3 - Cause loose assembly
♦ Solution rectify
4.3 – Resonance in the valve
1 - Cause timing block missing
♦ Solution install this circuit (stronger diaphragm srew or spring)

5 – PRESSURE LIMITERS
5.1 – Cavitation in the pressure limiters

1 - Cause faulty seat
♦ Solution replace the part
2 - Cause faulty pilot cap
♦ Solution repair or replace the pilot
3 - Cause oil speed too high
♦ Solution install a limiter, with greater capacity
4 - Cause poor quality oil
♦ Solution follow user’s manual. Refere to H.F.Standards
5 - Cause dity circuit
♦ Solution drain system, flush and fill to NAS 1638 Class 8. ISO 18/14. Examine particles
in the filters
6 - Cause pulsating limiter
♦ Solution foaming or polluted fluid. Decant it, bleed. If necessary change the fluid
5.2 – Pressure limiter blocked
1 - Cause limiter under pressure (tight spool)
♦ Solution loosen the nuts and then tighten them evenly
♦ Solution operate the pump at low pressure or install a heating system: Heat to recommended
temperature
3 - Cause piping under stress (valve distortion)
♦ Solution install piping elbows to compensate (only if there are very big differences in temperature)
4 - Cause drain line under pressure or missing
♦ Solution install a drain line or separate it from tank return
5.3 – Pressure limiter does not work

1 - Cause broken limiter spring
♦ Solution replace spring
2 - Cause limiter blocked open
♦ Solution see 2.3 and 1.4
3 - Cause no pressure in the limiter
♦ Solution incorrectly mounted pilot head: Vent valve malfunction
5.4 – The limiter gives off too much heat
1 - Cause temperature in the circuit too high
♦ Solution incorrect pressure setting
2 - Cause oil speed too high
♦ Solution install a limiter with increased capacity
6 – FLOW REGULATORS
6.1 – The regulator does not work

1 - Cause regulator under stress (installation distortion)
♦ Solution loosen the screws, then tighten them evenly
2 - Cause faulty compensating spool
♦ Solution replace spool, check condition of the liners, possible scratching by abrasive
particles if the oil is dirty
3 - Cause faulty metering spool
♦ Solution replace slide
4 - Cause blocked check valve
♦ Solution check valve and the seat and, if necessary, replace them (broken spring)
5 - Cause blocked metering spool
♦ Solution replace spool. Check condition of the liner, if necessary, change valve: Check
calibrated orifices
6 - Cause faulty compensating element (sealing parts)

7 - Cause blocked metering valve

♦ Solution check the cleanliness of the circuit, check calibrated orifices
8 - Cause broken spring
♦ Solution replace spring
9 - Cause corrosion
♦ Solution if necessary, clean or change
10 - Cause regulator error
♦ Solution install an appropriate regulator
7 – ANTI–SHOCK VALVES
7.1 – The anti–shock system does not work

1 - Cause broken spring
♦ Solution replace the spring
2 - Cause contaminated fluid
♦ Solution clean the circuit. Reference to NAS 1638 Class 8. ISO 18/14
3 - Cause blocked valves or sleeve linings
♦ Solution replace the valve or sleeve liner. Disassemble the parts and ensure their correct assembly
8 – ACTUATING CYLINDERS
8.1 – Actuating cylinders working too freely

1 - Cause faulty piston or seals
♦ Solution service or replace
2 - Cause excessive oil leak on the rod guide
♦ Solution check drive/head, replace any faulty parts
3 - Cause pressure too high or too low
♦ Solution check the operating pressure at no load and with load to control joints friction
8.2 – blocked actuator

8.3 – Unsteady operation
1 - Cause cylinder barrel not circular
♦ Solution . Barrel worn or scratched by the interaction of the rod and the piston in operation:
rework the barrel or replace
2 - Cause load variations
♦ Solution install a counterbalance valve and check valve
3 - Cause pressure variation (stick-slip)
♦ Solution check the circuit (12.1). At slow speed examine the tightening of mechanical joints.
(Pulsating feed)
9 – FILTERS
9.1 – Weak filtering

1 - Cause mesh too coarse
♦ Solution install a filter with finer mesh
2 - Cause blocked filter, oil by-passes
♦ Solution clean the filter and, if necessary, also the circuit: Analyse the reason for the appearance of
particles on the filter element. Reference NAS 1638 Class 8. ISO 18/!4
3 - Cause error in installation
♦ Solution keep flow direction
4 - Cause damaged magnetic elements
♦ Solution install new magnetic elements
5 - Cause clogged elements
♦ Solution install new element, if they cannot be cleaned. Analyse the reason for the presence of
particles on the filter element
6 - Cause external leak from tubing/piping (threads)
♦ Solution seal using teflon or loctite
7 - Cause circuit error
♦ Solution modify the circuit so as to position the filter in the right place, if possible with a 10 micron
Mesh

10 – TANKS
10.1 – Oil pollution

1 - Cause contaminated access to reservoir
♦ Solution replace the seals ensuring they are air tight
♦ Solution drain and flush the circuit. Have the particles analysed to determine their nature and thus
their origin. Reference NAS 1638 Class 8. ISO 18/!4
3 - Cause incorrect air filter
♦ Solution install suitable filter
4 - Cause faulty air filter
♦ Solution replace filter or clean element
5 - Cause clogged circuit and tubes
♦ Solution clean and scour then clean them again and flush the circuit, watch for any particles on the
filter elements
10.2 – Aeration
♦ Solution de-foam, then top-up reservoir,
2 - Cause non filled circuit
♦ Solution de-foam, then put circuit into operation and fill. Check for leaks
3 - Cause poor reservoir design
♦ Solution install a decantig baffle plate in the tank
4 - Cause return pipe flowing above oil level
♦ Solution install pipe below oil level
♦ Solution too great a depression in suction; check piping capacity and length, as well as filtering
capacity of the strainer (see 1.2
6 - Cause oil of poor quality
♦ Solution follow user’s manual. Reference NAS 1638 Class 8. ISO 18/!4
7 - Cause too weak a depression by the air intake
♦ Solution modify the tank’s air entry system (see 1.1)
8 - Cause poor assembly of the return pipe
♦ Solution the mounting of a tee on the return pipe involves the Venturi’s phenomenon if the median
branch is not tight in case of depression
10.3 – Temperature too high
1 - Cause ncooling system absent
♦ Solution install a heat exchanger or modify the tank for thermal exchange surface
2 - Cause poorly adapted heat exchanger
♦ Solution increase the capacity of the heat exchanger or the tank thermal exchange surface
3 - Cause thermal exchange surface too small
♦ Solution increase the thermal exchange surface
4 - Cause ambient temperature too high
♦ Solution change the position of the tank or install a cooler
5 - Cause circuit too close to heat source
♦ Solution check the distance between tank and the heat source and, if necessary, mount an
insulation shield. Follow safety rules
6 - Cause circuit pressure too high
♦ Solution modify initial pressure
7 - Cause misinterpretation of the installation
♦ Solution modify the installation
8 - Cause faulty elements in circuit
♦ Solution replace elements
9 - Cause no oil level indicator
♦ Solution install a sight level gauge or use dip stick
11 – COUPLINGS
11.1 – Coupling becomes hot

1 - Cause poor axial alignment
♦ Solution align coupling pump and drive mechanism accurately

2 - Cause electrical fault (electrical coupling)

♦ Solution repair
3 - Cause coupling error
♦ Solution use correct coupling
4 - Cause rigid coupling
♦ Solution install a coupling with greater flexibility
5 - Cause faulty bearings
♦ Solution replace bearings
6 - Cause eccentric coupling
♦ Solution balance coupling or replace
7 - Cause coupling misaligned or loose
♦ Solution loosen the nuts and then tighten them evenly
12 – PIPING
12.1 – Vibrations
1 - Cause badly secured piping
♦ Solution improve support fittings
2 - Cause pressure variations in the circuit
♦ Solution check the link between pumps and valves (excess strain on the flexible hose)
3 - Cause incorrect axial alignment
4 - Cause resonance in the hollow housing (chassis plates etc.)
♦ Solution use ant-noise system for the plates and cover the chassis with concrete during sealing
5 - Cause no ant-shock circuit
♦ Solution revise circuit
6 - Cause foaming in the circuit
♦ Solution look for the cause (see also 10.2)
7 - Cause instability of the relief valve
♦ Solution check relief valves (see also 5.1)
8 - Cause pulsating flow from the pump, ripple
♦ Solution check pulsating flow on an oscillograph and, if necessary, change the pump
9 - Cause air in the circuit
♦ Solution badly drained circuit (see also 12.1)
12.2 – Insufficient water-air tightness
1 - Cause seals incorrectly mounted
♦ Solution install seals following instructions
2 - Cause no seals
♦ Solution install seals
3 - Cause faulty seals
♦ Solution replace seals
4 - Cause loose connections
♦ Solution tighten connections
5 - Cause faulty installation of the pipes
♦ Solution refer to assembly instructions
12.3 – Contamination
1 - Cause circuit not cleaned
♦ Solution clean circuit (see also 1.2)
2 - Cause circuit not scoured
♦ Solution scour and clean circuit again
3 - Cause scale deposits on pipes
♦ Solution descale pipes, clean circuit and re-assemble pipes
4 - Cause poor welding (scale deposits coming off gradually)
♦ Solution check welding points and follow assembling instructions (see also 10.1)
13 – ACCUMULATORS
13.1 – The accumulator is not functioning

1 - Cause damaged or porous
♦ Solution return is to supplier for repair: NOTE: specify type of fluid so that lining is compatible

2 - Cause pressure in the circuit is too low

♦ Solution increase initial pressure. Check pre-charge
3 - Cause pressure differential too close
♦ Solution increase differential
4 - Cause faulty linings and joints (piston accumulators)
♦ Solution replace lining or joints
5 - Cause error in assembling the accumulator
♦ Solution follow assembly instructions. Service or replace
13.2 – Accumulator giving off too much heat
1 - Cause excessive flow rate
♦ Solution install a restriction valve and reduce the speed
2 - Cause pressure too high
♦ Solution reduce the initial pressure
3 - Cause dirty circuit
♦ Solution clean or scour the circuit then clean it again (see also 1.2)
14 – OIL COOLER
14.1 – Poor cooling

1 - Cause starting temperature of the heat exchanger too high
♦ Solution revise oil/water path rate
2 - Cause clogged water circuit
♦ Solution clean the water circuit
3 - Cause fan power too weak (aerotherm)
♦ Solution if possible increase the power or consult the supplier
4 - Cause inadequate heat exchanger
♦ Solution change the cooler
5 - Cause defect in the heat exchanger water supply
♦ Solution check the water inlet (choose the piping closest to the pumping)
6 - Cause faulty fan (aerotherm)
♦ Solution repair the fan
7 - Cause error in the manufacturing of the cooler
♦ Solution change the heat exchanger
8 - Cause uprated system
♦ Solution check that heat exchanger is adequate for the uprated system
9 - Cause heat exchange capacity heat exchanger insufficient and recycling of the oil too rapid
♦ Solution use a larger heat exchanger or increase the capacity pf the tank
14.2 – Water emulsion in the oil
1 - Cause fractured heat exchanger
♦ Solution repair the circuit and completely drain out the oil several times if necessary until there is no
trace of water
2 - Cause condensation. Heat exchanger has its core incorporated in tank
♦ Solution condensation appears when water temperature is very low, and there is little oil in tank
(core exposed) Check circuit to verify.
15 – MISCELLANEOUS
15.1 – Contamination
1 - Cause poor quality pipework scale
♦ Solution follow assembly instructions. Pipe without annealing, scouring elding and greasing
2 - Cause exposed oil passages
♦ Solution place the covers during the assembling and flush before starting up (see also 1.2)
3 - Cause faulty filtering
♦ Solution improve filtering (see also 9.1)
4 - Cause cylinder rods let dust in
♦ Solution install scraper joints, anti.dust collars or boots
15.2 – Aeration
1 - Cause air in the circuit
♦ Solution bleed air from circuit (see also 10.2)

3 - Cause return pipe above oil level
♦ Solution install return pipe below oil level and adapt oil diffusers, if necessary
15.3 –Temperature variation
1 - Cause no thermostat on the heat exchanger
♦ Solution install a thermostat
2 - Cause erratic heat exchanger water flow
♦ Solution check the heat exchanger’s water circuit and thermostat or the electrical circuit. Also check
water temperature
3 - Cause suspect pressure control system
♦ Solution revise system
4 - Cause faulty thermostat
♦ Solution repair or replace
5 - Cause current leak (damp atmosphere)
♦ Solution check resistance with a diameter pressure. If necessary, use the version with the protection
cover
6 - Cause faulty electrical circuit
♦ Solution check circuit
4. RECOMMENDATIONS AND ADJUSTMENT
4.1 Transport and hoisting.

When hoisting the hydraulic power unit using cables or chains, attach them to the eyebolts provided for the purpose. The
hoisting angle should never exceed 90°.
♦ Never stand under the load while it is being moved.

♦ Only ever use equipment that is suitable for the weight of the hydraulic power unit being
hoisted.
♦ Never hoist the hydraulic power unit with the tank full of fluid or with any component that
has not been fully assembled.
When hoisting the hydraulic power unit using a forklift truck, make sure you:
♦ balance the load over the forks,
♦ carefully insert the forks under the full depth of the pallet, if used,
♦ check that the load is completely stable before moving it,
♦ keep the load as low as possible and in the correct position during transport,
♦ do not carry out any sudden starting, braking or steering manoeuvres.
We recommend that hydraulic power units are shipped from the manufacturer and/or distributor to the customer without
any hydraulic fluid in them
Under no circumstances ever ship a hydraulic power unit with the tank full of hydraulic fluid.

4.2 Hydraulic fluids.

Choose the most appropriate fluid for the work concerned. The heart of any hydraulic power unit is the fluid used and a
careful initial choice together with correct maintenance can ensure its safe and efficient use, along with a long service
life. Refined mineral oil is still the base used for most applications. It offers good value for money, good lubricating
properties and can be enhanced by a variety of additives that enable its useful life, corrosion and wear protection to be
improved.
Advice on how to choose the correct fluid is normally provided by the pump manufacturer or the supplier of the
hydraulic power unit. Choosing the wrong grade could lead to higher wear, higher energy consumption and lower
efficiency.
Chemical substances are used instead of mineral oil in some applications for reasons of biodegradability, longer useful
life or operating conditions at special temperatures. The most common substances are phosphoric esters and the
polyglycols. Both have special characteristics and cost more than oils. Consult the manufacturers for further information.
Fluids offering high fire resistance represent another extremely important category. They become essential when it is
necessary to ensure high safety levels in areas where any fluid leaks could burst into flames or drop onto hot surfaces. As
with the chemical substances referred to above, this category of fluids could also require special seals and materials.
The sale of these fluids is linked to the type of equipment and operating pressures concerned, meaning that it is always
best to consult the manufacturer before making your purchase.
The International Standards Organisation (ISO) has issued a standard (ISO 6743) that lists the various different oil
grades.
The following table relates ISO and DIN classification to DENISON specifications
Fluid code Spec. Mass Description

ISO DIN DENISON grams / litre
HH H 800/900 Pure mineral oil
HL HL HF1 800/900 Petroleum base with additive package without
antiwear
HF1A 800/900 Tractor and transmission fluids.
No criteria for stability
HM HLP HF2 800/900 Petroleum base oils with additive package including
anti-wear.
HLP-D 800/900 As HLP + detergent and dispergent additives
HF2A 800/900 Crankcase oils
HF0 800/900 Premium hydraulic oils, which require vane and
piston pump
wear-test
HV HV HF2-2A-0 800/900 Petroleum base oils with additive package including
anti-wear and a viscosity improver
HR HF1 800/900 Petroleum base oils with additive package including a
viscosity improver and without ant-wear
HFA HSA 974/994 Oil in water emulsion with flammable content
< 20%
HFAE Oil in water emulsion + anti-wear
HFAS Aqueous solution less polluting to waste water than
HFAE
HFB HSB HF3 925/970 Invert emulsion with flammable content < 60%
HFC HSC HF4 1050/1090 Water-glycols with water content >35%
HFD, HFD-R HSD HF5 1070/1200 Phosphate esters waterfree synthetic fluids
HFD-S 1070/1200 Chlorinated hydrocarbons
HFD-T 1070/1200 Mixtures of phosphate esters-chlorinated
hydrocarbons with a heavy petroleum fraction
HFD-U 910/920 Organic esters
HETG 920/935 Glycerine ester = native oil
HEES HSD-N 920/930 Synthetic esters
HEPG PAG 1016/1040 Polyglycols

ISO 6743 provides information on viscosity or flowing capacity. For example, VG 32, 46, 68 all measure kinematic
viscosity at the standard temperature of 40°C
Viscosity Medium viscosity Limits of kinematics viscosity

ISO cSt cSt at 40°C
n° at 40°C Minimum Maximum
ISO VG 2 2,20 1,98 2,42
ISO VG 3 3,20 2,88 3,52
ISO VG 5 4,60 4,14 5,06
ISO VG 7 6,80 6,12 7,48
ISO VG 10 10,00 9,00 11,00
ISO VG 15 15,00 13,50 16,50
ISO VG 22 22,00 19,80 24,20
ISO VG 32 32,00 28,80 35,20
ISO VG 46 46,00 41,40 50,60
ISO VG 68 68,00 61,20 74,80
ISO VG 100 100,00 90,00 110,00
ISO VG 150 150,00 135,00 165,00
ISO VG 220 220,00 198,00 242,00
ISO VG 320 320,00 288,00 352,00
ISO VG 460 460,00 414,00 506,00
ISO VG 680 680,00 612,00 748,00
The following table indicates which fluid types optimise pump and engine performance by catalogue rating.
Fluid code Catalogue rating

ISO DIN DENISON PISTON units VANE and GEAR units
HF0 FULL FULL

HL HL HF1 FULL Ltd
HF1A FULL Ltd
HM HLP HF2 Ltd FULL
HF2A Ltd FULL
HFB HSB HF3 Ltd Ltd
HFC HSC HF4 Ltd Ltd
HFD, HSD HF5 Ltd Ltd
HFD-R
Legend:
FULL = The maximum performance specifications set out in the technical documentation can be achieved. You should,
however, check the optimum viscosity value recommended to achieve maximum service life.
Ltd = Using these fluids will generally lead to a reduction in the component's speed of rotation, operating pressure and
service life. It is advisable to contact the manufacturer to ensure their approval.
Irrespective of the fluid chosen, once the system has been filled with it you should take the greatest possible care to
ensure the machine continues to offer its peak performance. To achieve this, we advise you to replace the fluid after
approximately 2000 - 4000 hours' work and to continually monitor the following between changes:
Appearance of the fluid Contaminant Cause

Air bubbles Air Air has entered the circuit. Fluid level too low.
Intake seal leak. Outlet pipes higher than fluid
level.
Dark colour Oxidation products Overheating (another fluid has entered the circuit)
Water separation Water Water has entered the circuit (check water/oil heat
exchangers)
Impurities in suspension or Solid foreign body Dirt. Abrasive material. Ageing products
deposits particles
Smell of burnt oil Ageing products Overheating
Milky turbidity Water or foam Air or water has entered the circuit

Cleanliness undoubtedly plays a decisive role in helping the components of a system achieve a long service life. Make
sure that the filters are of an appropriate type and undergo correct maintenance. Make sure that they also work at low
workloads, keeping any particles entering the system to a minimum. Keep the fluid topped up to its correct maximum
level and if the fluid is of a type containing water, make sure that the supplier's recommendations are followed where the
acidity, type of water and respective percentages are concerned. Try to keep the temperature at the maximum
performance level recommended for the majority of the fluids.
The fluid should be transferred from the barrel to the

system using a pump and filter to ensure that the system
is not contaminated during filling.
4.2.1 Storing fluids. Fluids should be stored in a covered area at workshop temperature to reduce the effects of
condensation and the barrels should be placed in a horizontal position to prevent any contamination of the bottom of the
barrels themselves.
Here is one example of how

water can enter a barrel
In addition, further precautions are required for fire-resistant fluids, given that some of these categories of fluids contain
water. The checks carried out should be appropriate for the percentage contained and be in accordance with the
manufacturer's correction procedure. Antifreeze protection is particularly important. Many of these fluids require special
seal materials as well as special attention regarding compliance with the related standards in force (Italian law 626/94).
!
If systems with different hydraulic fluids are being used in the same installation, it is advisable to
fit labels indicating the type of fluid being used. These labels should be located by each
system/power unit's filling point.
4.3 Accumulators.
Accumulators should be considered part of a System under Pressure according to the Italian accident prevention body.
As such they are also governed by the laws concerning pressure systems and transportable gas cylinders.
1) The safe operating limits must be established.
2) The relevant registrations must be kept up to date.
3) The accumulators must be supplied with all the information and special markings required.
4) The accumulators must be precharged with nitrogen (absence of oxygen)
5) The accumulators must comply with Directive 97/23/EEC (PED).
4.3.1 Identification and checking. Every accumulator must be fitted with an identification plate showing the type of
accumulator, maximum admissible use pressure and internal test number. In addition, the serial number must be punched
on the cylinder body and marked by the relevant regulatory authorities. Before installing a new accumulator, always
make sure that it has not been damaged during shipping. Don't forget to remove the protective cap when connecting the
accumulator to the hydraulic circuit.
The user is responsible for ensuring that the accumulator undergoes the correct maintenance.
4.3.2 Installing an accumulator. The accumulator must be installed safely and appropriately in the system. The
hydraulic circuit must include a shut-off valve, a drain valve and pressure-relief valve (safety valve). Accumulators are in
most cases installed close to their respective user units, taking care to provide sufficient space around the gas valve and
bottom connection in order to facilitate access.
Under no circumstances ever weld supports onto an accumulator
4.3.3 Accumulator inspections. Accumulators must only be serviced and inspected by suitably qualified personnel.
4.3.4 Precharging. You need to carry out two basic operations when an accumulator has been specially supplied
precharged to order or when it has been completely drained or disassembled: precharging with gas and the related check.
4.3.4.1 Precharging with gas. This consists in inflating the elastic bladder with nitrogen. The precharging
pressure is chosen taking pressure changes linked to changes in the operating temperature into account. It ought
in particular to be borne in mind that the preloading pressure specified upon ordering should always be for a
temperature of +20°C, while the accumulator's use limits may extend from -10°C to +80°C. Preloading requires
an industrial compressed nitrogen cylinder. The operation can be carried out either before or after the
accumulator has been installed in the hydraulic circuit, but must always be done with the gas valve on top. If the
accumulator has already been installed, release the hydraulic circuit pressure before precharging.
Never under any circumstances use oxygen.
4.3.4.2 Checking the precharging pressure. This check should be carried out:
1) before commissioning the accumulator,
2) once during the first week of use,
3) at regular intervals during use (such as every 6 months),
4) whenever any changes are noted in the operation of the installation.
4.3.5 Commissioning. You can start using the accumulator once you have made sure that the calibration pressure of
the hydraulic circuit's safety valve does not exceed the accumulator's maximum admissible pressure. The accumulator
operates entirely automatically once you start using it and only requires you to check the nitrogen pressure at regular
intervals.
4.3.6 Maintenance and repair. Follow the manufacturer's recommendations scrupulously when carrying out any
disassembly and repair operations on the accumulator. It is, however, important to remember that you need to release the
hydraulic circuit pressure and precharging pressure before disassembling the bladder or connector. The accumulator can
then be removed from the installation.
WARNING: always release the hydraulic circuit pressure and precharging pressure before
disassembling the bladder or connector.
4.3.7. Safety valves. These are the last devices protecting the equipment and people operating close to it if the other
control devices in the system fail. These valves should therefore be built and installed to the highest standards, and
undergo scrupulous maintenance.
4.3.7.1 Fitting. Carry out the following checks:
a) Make sure that the valve supplied is the same as that recommended by the manufacturer for its intended use,
also checking the characteristics and specifications on the valve certificate that should be supplied as part of the
equipment's documentation. Never use valves in applications other than those indicated on the valves or their related
certificates.
b) The valve must be fitted in a zone that is easily accessible for maintenance.
c) Shut-off devices should not be installed between the valve and tank unless specifically provided for and
declared by the manufacturer of the equipment and approved by the relevant standards in force.
4.3.7.2 Maintenance and regular inspections.
a) Make sure that the valve does not show any visible signs of wear or damage.
b) Check that there are no fluid leaks from the valve.
c) Scrupulously follow the manufacturer's recommendations.
4.4 Health-related problems as per Italian law 626/94.
The equipment must be operated taking health risk factors into account. Where hydraulic equipment is concerned, these
factors normally concern the system's fluid, which is in most cases mineral oil. If synthetic fluid or fire-resistant fluid is
being used, consult the fluid manufacturer to obtain the technical information sheet providing full details of health-
related matters, given that the risks can vary considerably depending on the particular fluid concerned.
All Italian hydraulic fluid manufacturers are now able to provide technical information sheets on each type of product in
accordance with the requirements of Italian law 626/94.
The risk factors where mineral oils are concerned can be summarised as follows (although we also recommend you to
obtain all the information you can from the manufacturers).
There are no significant health risks if the oils are used correctly.
4.4.1 Ingestion. Only slight oral toxicity - do not induce vomiting, administer one litre of milk and consult a
physician.
4.4.2 Inhalation. The low volatility of mineral oils means there is no risk of vapour with the exception of in systems
that are exposed to high temperatures - avoid mixing different oils. In the event of overexposure, move into fresh air,
loosen clothing and keep the patient warm and rested.
4.4.3 Contact with the eyes and skin. Frequent or prolonged contact with the skin can cause dermatitis. Splashes in
the eyes can cause irritation. Good standards of industrial hygiene are recommended (including the use of gloves,

protective cream, protective eyewear and regular changes of contaminated clothing). In the event of direct contact with
the skin, wash thoroughly with soap and water. If mineral oil splashes in the eyes, rinse abundantly with water.
4.4.4 Aspiration. This depends on the viscosity. Above 40°C and below 7°C it is highly dangerous and can cause
pneumonia. In the event of aspiration, hospitalise immediately, calling an ambulance with oxygen.
4.4.5 Extinction in the event of fire. Carbon dioxide, dry chemical foams.
4.4.6 Leaks. Dry with absorbent materials. Do not allow to contaminate water sources.
5. STORAGE, DEMOLITION AND DISPOSAL
5.1 Storage.
In a dry place. The machine may suffer damage if it is kept in a place at extreme temperatures while awaiting
installation. Never expose the machine to temperatures below -10°C or above 60°C.
Protect electrical parts particularly well against dust and external agents.
Never place the machine or its parts on structures that have not been made for the purpose.
Never place materials or equipment on the machine.
5.2 Demolition and disposal.

Follow the general disassembly procedure below to dismantle the machine:
• Disconnect from the electricity supply
• Release the hydraulic circuit pressure and precharge pressure of the accumulators
• Drain the hydraulic oil tanks
• Disconnect all the electrical cables
• Disconnect the mechanical parts
WARNING: Use appropriate Individual Protective Devices when handling waste.
5.2.1 Disposing of the machine. Waste resulting from the demolition of the machine must be disposed of in a manner
that respects the environment, avoiding pollution of the ground, air and water. Always make sure that you comply with
the relevant local legislation in force.
Remember that waste refers to any substance or object that the holder disposes of or has decided to or is required to
dispose of (Italian Legislative decree No. 22 of 5 February 1997). Waste resulting from the demolition of the machine is
classified as special waste.
5.2.2 Demolition materials. Demolition materials are non-hazardous waste that can be recovered in accordance with
the Italian Ministerial Decree of 5 February 1998:
a) ferrous materials, aluminium, stainless steel, copper
b) plastic materials
c) electronic circuit boards
5.2.3 Recommendations for appropriate waste disposal.
• Ferrous materials. These are recyclable materials (secondary raw materials) to be taken to an appropriate
authorised collection centre.
• Plastic materials.
1. Recycling permitted where carried out.
2. Disposal in groundfill sites for waste similar to urban waste (category 1 Italian Presidential Decree
915/82 and committee resolution or in accordance with the regulations of the receiving countries, if
outside Italy).
3. Incineration permitted in installations with post-combustion and dust control systems before emission
into the atmosphere.
• Electrical installation. Disposal in groundfill sites for waste similar to urban waste (category 1 Italian
Presidential Decree 915/82 and committee resolution or in accordance with the regulations of the receiving
countries, if outside Italy).
• Used mineral oil. Take to appropriate authorised collection centre (Consorzio Obbligatorio Oli Usati in Italy).
It is strictly prohibited to dispose of used oil in drains or any other location.

6. COMMISSIONING PROGRAMME
The following checks have been completed (if applicable)
Description Yes / No Notes Operator's signature Date

Visual examination of the circuit.
Circuit operating test.
Check of positioning location.
Accessibility for maintenance.
Appropriate support for piping.
Check for any external leaks.
No tank contamination.
Circuit identification plate.
All openings protected (plastic
caps).
Filter elements installed and
clean.
Electrical terminations fitted with
terminals.
Electrical voltage check.
Reference arrows present.
Check on paint, finishes, colours
and types.
Check that hose positions comply
with plans.
7. STANDARD PREVENTIVE MAINTENANCE PROGRAMME
Recommend intervals (*)

Operation Daily Weekly Monthly 6 Months Year
External cleaning √
Fluid level √
Fluid temperature √
Condition of fluid (Sample) √
Filter indicators √
Intake filter (if present) √
Air breather (if present) √
Noise level √
Check pressure settings √
Check flow rate settings √
Accumulators (check precharge) √
Pipes (leaks or damage) √
Hoses (leaks or damage) √
Clean heat exchanger √
Check transmission coupling √
Electrical equipment (check for √
damage)
(*) The maintenance intervals should be determined not only taking the manufacturer's recommendations into account
but also knowledge gained from local experience, the availability of spare parts in the warehouse or the ease with which
they can be procured, as well as the importance and age of the equipment and the severity of the conditions in which it is
used.

8 APPENDIX
8.1 DEMANDS FOR HYDRAULIC FLUID
Different hydraulic systems put different demands on the hydraulic fluid, depending on the type of system and how the
system is used.
The most important requirements for fluids are:

8.2 FILTRATION
Grade of filtration:
♦ Nominal filtration indicates that 90-98 %
by weight of all particles larger than
10µm should be separated under
specified cicustances. The test method
does not limit the largest particle allowed
through the filter.
♦ Absolute filtration indicates the largest
spherical particle that can pass the filter.
The test method only gives information
about the largest “hole” in the filter
cartridge.
♦ The “Beta” value filtration indicates the
relation between the number of particles
of a certain size (X) before and after
passing the filter under specified
circustances.
The relation can be expressed as follow:
Nf βX = Beta value for particles larger than Xµm

βX = were: Nf = Number of particles larger than Xµm per unit of volume before passing the filter.
Ne Ne = Number of particles larger than Xµm per unit of volume after passing the filter.
Example: β10 = 4 means that there 4 times as many particles larger than 10µm before than after passing the filter
The “Beta” value can be converted into an efficiency value as follows:
Example: Efficiency = the ability of the filter to remove particles larger than Xµm
100
Efficiency = 100 - (%)
βX
Example: β10 ≥ 20 gives the efficiency E10 = 100 - 100/20 = 95% (the filter removes 95% of al particles larger than
10µm
β Value Efficiency %
1 0
2 50
20 95
50 98
100 99
1000 99,99
♦ Absolute filtration usually indicates “ Beta” values larger than 75. Example: 10µm absolute filtration corresponds to
approx. β10 ≥ 75.
♦ Nominal grade of filtration can not be translated into absolute grade of filtration or “ Beta” value.

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UM-GB-A

POWER UNITS AND

POWER UNITS AND HYDRAULIC SYSTEMS

1. POWER UNITS INSTALLATION.

1.2 Pipe connections.

1.3 Flush-through testing.

1.4 Filling the system.

1.5 Electrical connections.

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3 MAINTENANCE AND REPAIRS

3.1 Preventative maintenance

Before checking pre-load pressure, fluid must be completely de-pressurised inside

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3.2 Regular maintenance.

3.3 Troubleshooting guide.

3.4 TROUBLESHOOTING GUIDE FOR HYDRAULIC CIRCUITS

! Contamination reduces the life of the hydraulic circuit

1 – PUMPS AND MOTORS

1.1 – Insufficient or no output

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9 - Cause incorrect fluid for application

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23 - Cause fluid mismatch

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5 - Cause error in the circuit assembly

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2.1 – Sticking spools

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4 - Cause blocked pilot line

3.1 – Blocked servo-valve

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2 - Cause damaged magnetic circuit

4.1 – Blocked check valve

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5.1 – Cavitation in the pressure limiters

5.3 – Pressure limiter does not work

6.1 – The regulator does not work

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7 - Cause blocked metering valve

7.1 – The anti–shock system does not work

8.1 – Actuating cylinders working too freely

8.2 – blocked actuator

9.1 – Weak filtering

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10.1 – Oil pollution

11.1 – Coupling becomes hot

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2 - Cause electrical fault (electrical coupling)

13.1 – The accumulator is not functioning

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2 - Cause pressure in the circuit is too low

14.1 – Poor cooling

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4. RECOMMENDATIONS AND ADJUSTMENT

4.1 Transport and hoisting.

♦ Never stand under the load while it is being moved.

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4.2 Hydraulic fluids.

Fluid code Spec. Mass Description