I&M manual

Installation andMaintenance Manual

PAC

Installation and Maintenance Manual, Power Unit PAC

2

PrefaceHgglunds Drives is one of the worlds leading manufacturers of low speed,high torque and heavy-duty hydraulic drive systems. We supply a durabledrive system that will work under the toughest conditions with a minimumlevel of maintenance requirements. We have industrial and marine custom-ers all over the world. They know that when they seek solutions, support orservice, they can trust Hgglunds Drives to be there. The Hgglunds Drivesmain office and manufacturing plant is located in Mellansel, Sweden. Inaddition, there are sales and service offices in 40 countries worldwide.

Our high quality drive systems are based upon our unique hydraulic pistonmotors, which were developed through experience accumulated over 30years in marine and industrial areas. Today this ongoing development workhas resulted in our PAC power unit product line. This is what powers ourdrive systems. New, as well as established technical solutions contribute tothe creation of this product. The most desirable features and operatingreliability have been designed into this power unit, PAC.

This manual provides necessary information for installation and maintenanceof the PAC. In order to find particular information, just search for the appli-cable section as listed in the table of contents. However, changes in theequipment may occur. Therefore, we reserve the right to introduce amend-ments in the manual, as we deem necessary without notice or obligations.

Before starting the installation and/or maintenance, the manual must beread and thoroughly understood in all respects. All involved personnel shallread and acknowledge the safety precautions that are stated in section 1.1.

The content in this manual is subject to change without notice orobligation. Therefore, information contained herein should always

be confirmed with Hgglunds Drives or its representatives.

Orig

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Preface

3Installation and Maintenance Manual, Power Unit PAC Contents

Contents1. GENERAL ........................................................................................................................ 41.1 Safety precautions ........................................................................................................................41.2 Operating principle ........................................................................................................................62. TECHNICAL DATA ........................................................................................................... 72.1 Operating conditions .....................................................................................................................72.2 Cooling water ................................................................................................................................72.3 Requirements for hydraulic fluid cleanliness .................................................................................72.4 Choice of hydraulic fluid ................................................................................................................82.5 Power unit monitoring ...................................................................................................................93. HANDLING OF THE PACKED POWER UNIT ............................................................... 103.1 Storage of the packed power unit ...............................................................................................103.2 Lifting the packed power unit ......................................................................................................104. INSTALLATION .............................................................................................................. 114.1 Installation directions ..................................................................................................................114.2 Lifting methods and weights .......................................................................................................134.3 Positioning the power unit ...........................................................................................................144.4 Mounting of the cabinet feet ........................................................................................................144.5 Mounting of electric motor...........................................................................................................154.6 Mounting of air-oil cooler and cabinet ventilation ........................................................................164.7 Mounting of top cover..................................................................................................................174.8 Hydraulic connections .................................................................................................................174.9 Electric connections ....................................................................................................................184.10 Pipe work ..................................................................................................................................184.11 Extra filtration before start up ....................................................................................................214.12 Commissioning ........................................................................................................ 224.12.1 Prior to commissioning ...........................................................................................................224.12.2 Filling up the system with hydraulic fluid ................................................................................224.12.3 Initial start up procedure ........................................................................................................244.13 Pump settings and adjustments ................................................................................................265. PREVENTIVE MAINTENANCE ..................................................................................... 275.1 Maintenance log ..........................................................................................................................275.2 Maintenance chart ......................................................................................................................275.3 Filter change ...............................................................................................................................285.4 Inspection of hydraulic fluid .........................................................................................................295.5 Lubrication of electric motor ........................................................................................................305.6 Air breather change ....................................................................................................................305.7 Cleaning of Air-Oil cooler ............................................................................................................315.8 Power unit out of service .............................................................................................................316. CORRECTIVE MAINTENANCE .................................................................................... 316.1 Common .....................................................................................................................................316.2 Change of hydraulic pump/electric motor assembly ...................................................................326.3 Troubleshooting ...........................................................................................................................337. DISPOSING OF POWER UNIT ...................................................................................... 34


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1. GENERAL1.1 Safety precautionsIt is of extreme importance that the safety precautions are always followed. If you are unsure aboutanything, please contact your nearest Hgglunds Drives representative for advice.

Warning signsIn this manual, you will find the following signs, which indicate a potential hazard that can or will causepersonal injury or substantial property damage. There are three levels of hazard classification:

GeneralLimit access to the equipment only to authorized personnel. Only perform measures on the PAC whenyou are completely familiar with the function of the power unit (including the control system) as well asthe complete drive.Service and repair of the electrical, hydraulic, and the mechanical functions require professional ser-vice personnel who are aware of risks involved.Safety equipment necessary for the prevention of accidents during the mounting and maintenancemust be used in accordance with the regulations prevailing in the local country.

CAUTION is used to indicate the presence of a hazard, which will orcan cause minor personal injury or property damage if the warning isignored.

DANGER is used to indicate the presence of a hazard, which willcause severe personal injury, death, or substantial property damageif the warning is ignored.

WARNING is used to indicate the presence of a hazard, which cancause severe personal injury, death, or substantial property damageif the warning is ignored.

General

CAUTION!

DANGER!

WARNING!

5Installation and Maintenance Manual, Power Unit PAC

Prior to troubleshooting Use the order code and other attached technical documentation to identify the features of your

unique power unit and system. Read the attached technical documentation (this manual included) and make yourself familiar

with the PAC (control system included) as well as the complete drive. Use safety equipment like hard hat, protective goggles, safety shoes and hearing protection. Always ensure that there is no accumulated energy in the system prior to maintenance. Ensure that all electric power is off and locked out. Ensure that there is no entrapped pressure in the hydraulic system. Ensure that no pressure will enter the hydraulic system in the power unit via the hydraulic motor,

for example loads on the shaft or winch drum. If the hydraulic system is used for lift devices such as elevators, winches, etc., these should be

secured, or in the rest position (hanging load). Ensure that all accumulators are discharged.

Electricity supplySafety equipment necessary for the prevention of accidents must be provided in accordance with theregulations prevailing in the local country.All electrical supply levels shall be within the limits that the equipment is constructed for, see technicaldocumentation and maximum rating plates.

MountingCarefully follow the instructions and be aware of the large weights and forces involved during lifting.Incorrect mounting and setting of electrical, hydraulic and the mechanical components can causepersonal injury or property damage.Before starting upBefore starting up new, rebuilt or serviced drive systems, all accessories and safety arrangementfunctions need to be checked and tested.

Maintenance and serviceFollow the maintenance intervals for your specific PAC or the maximum intervals on the maintenancechart (section 5.2 Maintenance Chart) and keep a maintenance log. Regular and correct mainte-nance is necessary for reliable and safe operation.Only use spare parts recommended and supplied by the Hgglunds Drives organization.

Hydraulic fluidBe aware that most hydraulic fluids can cause personal injury and severe damage to the environment.Check the caution sign on the container or consult the supplier. Used hydraulic fluid can containnoxious contaminates. We recommend using the service of a professional oil company for supply anddisposal of used fluids. Never dump hydraulic fluid into water drainage or water supplies.

Bell housingNote that there are rotating parts inside the bell housing during operation. Be careful during inspectionthrough the inspection hole. Replace inspection cover when finished.

Hot surfacesTemperatures in the hydraulic system above 158 F (70 C) will create hot surfaces.Emergency situationsEmergency shutdown: It has to be possible to turn off the electric power during an emergency situa-tion. Only use a fire extinguisher that is approved for use on both oil products and electric equipment.

General


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1.2 Operating principleMain components1. Hydraulic pump2. Drain valve3. Sight glass4. Charge pressure gauge5. Servo pressure gauge6. Main pressure gauge B port7. Main pressure gauge A port8. Air breather9. Drain filter10. Return filter11. Electric motor12. Filter switch13. Suction valve limit switch14. Charge pressure switch15. Electrohydraulic stroker16. Oil heater17. Terminal box18. Oil Cooler19. Temperature switch20. Level switch

Note: Changes from the picture and maincomponents table above may occur.

FunctionThe function of the power unit is to provide the hydraulic motor(s) (or other hydraulic systems) with therequired flow of oil and pressure at the right time. All included parts are assembled in one (or more)compact cabinet(s). The PAC has one or more pumps driven by one or more electric motors. Themain pump is an axial piston pump with variable displacement for closed loop systems. The electricmotor is totally enclosed fan cooled. Two different control systems are available.Control systems availableSpider: A small, compact and configurable con-trol system. It can health monitor the power unitand can control one or two pumps with three pre-programmed functions: Basic, for most of our drives can be config-

ured for speed feedback control and powerlimitation.

Shredder, for shredder applications. Synchro, for friction and synchronized drives.MCA: For special control functions, normally basedon PLC and control cards.Note: It is also possible to control the PAC fromexternal control systems provided by the customer.

The PAC is a very flexible product with a wide rangeof options. This makes it possible to select a stan-dard power unit to fulfill the features needed inmany different applications. This installation andmaintenance manual is intended to cover all stan-dard options. It may not cover all details on spe-cial power units, which differ from the standardPAC concept.

It is important to check theother attached technicaldocumentation to identifythe features of your uniquepower unit.

Operating Principle

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CAUTION!


2. TECHNICAL DATA2.1 Operating conditionsThe standard PAC unit is designed for the conditions listed below. If the requirements are outside ofthe conditions listed below, contact your Hgglunds Drives representative with your specific require-ments for special design considerations.

Ambient temperature: Minimum 32 F (0 C) to a maximum 85 F (30 C).Altitude: Maximum 3,300 feet (1000 m).Classified Location: Unit is designed for a standard location. Units can be built for use inclassified hazardous locations. Contact your Hgglunds Drives representative for more details.

2.2 Cooling waterThe cooling system is primarily designed to operate with clean water.When there are particles in the water, larger than 0.02 in. (0.5 mm), a water filter must be used.It is important to: Maintain the water filter (if any) in a correct way, this is to get the required flow of water through

the water oil cooler. Ensure you have the required flow, pressure and temperature of the cooling water (see attached

technical documentation). Check the temperature in the hydraulic system, according to the maintenance intervals for your

specific power unit or the maximum intervals on the maintenance chart. Clean the cooling system if the temperature in the hydraulic system is above the specified limits. Clean and empty the cooling system (waterside) before periods of inactivity (especially if the

cooling water is not totally clean).

Technical Data

If cooling capacity is too low, the service life of hydraulic motor, the maincomponents in power unit, and the hydraulic fluid will be reduced.

2.3 Requirements for hydraulic fluid cleanlinessThe PAC is equipped with filters on the drain and return line(s). In order to obtain rated service life it isimportant to follow recommendations concerning cleanliness levels and maintenance requirements.

Cleanliness recommendations The system must be flushed before start up (section 4.12 Flushing before start up). When filling the tank with hydraulic fluid it is important to fill through the quick connection (sec-

tion 4.13.2 Filling up the system with hydraulic fluid). The particle contamination level in the system should not exceed ISO/DIS 4406 16/13 (NAS

1638, class 7). The water content shall be


8

Check caution sign on container or consult the supplier. Avoid prolonged contact of hydraulic fluid with your skin. Use services of a professional oil supplier for disposal of used fluids,

and filter elements. Never dump hydraulic fluid into drainage or water supplies. Clean hydraulic fluid spills from floors immediately to prevent injury.

2.4 Choice of hydraulic fluidThe power unit is primarily designed to operate on conventional petroleum based hydraulic fluids.Consultation with an Hgglunds Drives service representative is recommended when choosing yourhydraulic fluid.

The hydraulic fluid has to fulfill the following requirements: Have FZG (90) fail stage minimum 11 described in IP 334 (DIN 51354). Contain inhibitors to prevent oxidation, corrosion and foaming. Have a viscosity within the prescribed interval for both PAC (see below) and hydraulic motor at

operating temperature (measured in the motor case). Have a water content of


2.5 Power unit monitoringIf the monitoring function is not included in a control system supplied with the PAC, the followingfunction must be fulfilled in the system.

The monitoring of the power unit switches are grouped in two levels according to the above logicdiagram.The warning indication is to inform about a problem in the PAC but does not need an immediate action.The alarm indicates a need for stopping the pump. The stop sequence is to first stop the hydraulicmotor without ramp, by setting the pump swash angle to zero. Furthermore, after a short delay stopthe electric motor.

The low charge pressure switch must be interlocked during stop and start-up of the electric motor, toavoid alarm and give the pump time to build up the charge pressure after start.

Technical Data

EXTERNAL FUNCTIONS

WARNING INDICATION

STOP ELECTRIC MOTOR1s 0sTime delay on

STOP HYDRAULIC MOTOR

Time delay off

Time delay off

Time delay off

Time delay on

Time delay off

0s 5s

0s 5s

11

1

1

1

1

0s 5s

1

High pressure

Drain filterswitch

switch

Maximum oilTemperature switch

POWER UNIT

11

1

1

&10.5s0s

0s5s

Electric motor started

Return filter

Low oil

Warning oil

Low charge

Closed suction

Minimum oil

Minimum oil

level switch

temperature switch

switch

pressure switch

line switch

level switch

Temperature switch

MONITORING SWITCHES


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3.2 Lifting the packed power unit

The packed power unit is labeled with center of gravity and weight.Normally the power unit package is designed for forklift truckhandling.

Center of gravity is high, see label on the power unit. Avoid rapid acceleration, deceleration and turns while

moving the equipment. Position the forks according to the instructions below.

Lifting with fork lift The absolute minimum required fork length is 51.2 in. (1300 mm). The minimum distance between the forks is 31.5 in. (800 mm) for a 2 door PAC and 43.3 in.

(1100 mm) for a 3 door power unit. Position forks with regards to the center of gravity.

Parts that are delivered separately The package is always labeled with the weight. Packages on shipping skids are designed for forklift truck handling only. Some other packages may be lifted with a lifting crane, always check the label on the package.

Do not stand underneath hanging load. Use only lifting equipment adapted to the weight on the

label of the package.

Center of gravity label

3. HANDLING OF THE PACKED POWER UNIT3.1 Storage of the packed power unitAt delivery, the hydraulic components are protected internally by an oil film (containing rust preventingadditives). This provides sufficient protection for indoor storage in air conditioned premises for up to12 months.

The PAC and included parts should be stored indoors, in dry, vibration free and dust free conditions. Itshould not be stored for more than three months in non-air conditioned premises. (That also includesparts belonging to the power unit that are delivered separately).Place the power unit where it will not be exposed to direct sunlight or extreme cold to avoid condensa-tion.

If storage time exceeds the above mentioned limits, then the powerunit must be operated so that the hydraulic system is lubricated with

new fluid. (section 5.8 Power unit out of service)

Technical Data

CAUTION!

DANGER!

11


4. INSTALLATION4.1 Installation directionsIf the PAC is to work properly, it must be installed in accordance with these instructions. The conditionsthe unit will operate in must be taken into consideration.Improper installation, not following the instructions in this manual and in the attached technical docu-mentation, may affect the function and/or the service life of the power unit. It is important that thesafety precautions mentioned in this manual are always followed.

In order to achieve air circulation requirements, you should neverplace the power unit directly against a wall or similar obstruction. Ifthis is the case then contact your Hgglunds Drives representative.

Installation

Cabinet Size 1 2 3 4 5Type PAC 100 PAC 300 PAC 400D

Dimension PAC 200 PAC 400 PAC 600H1 89 in. (2261mm) 89 in. (2261mm) 99 in. (2515mm) 99 in. (2515mm) 106 1/2 in. (2705mm)H2 1/2 in. (13mm) 1/2 in. (13mm) 1/2 in. (13mm) 1/2 in. (13mm) 3 in. (76mm)B1 55 1/8 in. (1400mm) 80 3/4 in. (2051mm) 66 in. (1676mm) 105 in. (2667mm) 121 3/4 in. (3092mm)B2 51 1/8 in. (1299mm) 76 in. (1949mm) 62 in. (1575mm) 100 in. (2540mm) 117 3/4 in. (2991mm)A1 39 3/8 in. (1000mm) 39 3/8 in. (1000mm) 53 1/4 in. (1353mm) 53 1/4 in. (1353mm) 53 1/4 in. (1353mm)A2 35 3/8 in. (899mm) 35 3/8 in. (899mm) 49 1/4 in. (1251mm) 48 1/2 in. (1232mm) 48 1/4 in. (2526mm)A3 82 5/8 in. (2099mm) 82 5/8 in. (2099mm) 81 1/2 in. (2070mm) 81 1/2 in. (2070mm) 103 1/4 in. (2623mm)M 5/8-13 UNC 5/8-13 UNC 5/8-13 UNC 5/8-13 UNC 5/8-13 UNC

PAC 800PAC 200D

PAC 100/200/300/400 PAC 200D/400D/600/800

MH2

H1

B1

B2

A3A1

A2

H1

H2 B1

B2


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Placing the power unitTake into consideration the following when placing the PAC unit: Place on a firm level foundation to avoid vibrations. To ease maintenance and service (section 4.3 Positioning the power unit). Protect from weather, airborne sprays, heavy contamination and radiated heat. To ensure proper ventilation for cooling purposes and for the electric motor and air-oil cooler. To minimize pipe runs.Clamp each pipe in the pipe run separately and attach it to a firm foundation to avoid vibration. Themain connections from the PAC must always be fitted to the piping with hoses.

When units are installed side by side, the side panels must be removed.This makes it possible to perform service on the power unit.

If air-oil cooler is mounted at a location other than onthe power unit, beware that the cooler will start with-out notice and has sharp edges.

Installation

CAUTION!

REMOVE SIDE PANELS

IN

OIL

OUT

OIL

IN

OILOIL

OUT

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4.2 Lifting methods and weights

Do not stand underneath a hanging load. Use only lifting equipment adapted to the weight of the power unit

(check rating plate inside the cabinet). Center of gravity is high, see label on cabinet. Do not lift the power unit with hydraulic fluid in the tank, or with the

front bar disassembled.

Lifting with ropes and/or chainsLift the PAC with no top cover on, maximum lifting angle 90.

Lifting with fork lift The absolute minimum required fork length is 51.2 in. (1300 mm). The minimum distance between the forks is 31.5 in. (800 mm) for a 2

door power unit and 43.3 in. (1100 mm) for a 3 door power unit. Position forks with regards to the center of gravity.

*This is the weight for astandard electrical motor,more accurate weight fora specific motor can befound on the rating plate.

The total weight of the power unit is stampedon the rating plate located on the Junction box

door inside the cabinet.

Always use all four lifting points whenlifting the power unit.

Power HP (kW) Weight* lb (kg)30 (22) 365 (165)40 (30) 490 (222)50 (37) 560 (254)60 (45) 800 (363)75 (56) 840 (380)100 (75) 1160 (526)125 (93) 1540 (698)

150 (112) 1730 (785)200 (149) 1750 (794)250 (186) 1925 (873)300 (224) 2500 (1134)350 (261) 2650 (1202)400 (298) 3500 (1587)450 (336) 4300 (1950)

Electric Motor

Model Weight lb (kg)P6S 335 (152)P7S 335 (152)

P11S 484 (220)P14S 484 (220)P24S 753 (342)P30S 786 (357)

Denison Pumps

Size Weight lb (kg)AOVH-30 190 (86)AOVH-40 350 (159)AOL-950 221 (100)AOL-1200 296 (134)AOL-1600 355 (161)

Air-Oil Cooler

Installation

B A A B

DANGER!


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4.4 Mounting of the cabinet feetThe cabinet feet (optional) minimizes the vibrations and makes it easier to level the PAC. They aredelivered separately within the cabinet and have to be mounted according to the following instructions:1. Mount the cabinet feet before filling hydraulic fluid in the tank.2. Mount the cabinet feet before installing the electric motor(s), if they are delivered separately or

supplied by the customer.3. Lift the power unit according to instructions in this manual (section 3.2 Lifting the packed power

unit). Be sure to follow the safety precautions.4. Mount the cabinet feet according to the drawing below.5. Level the PAC by the adjusting screws.

Be careful while mounting thecabinet feet. Follow the safetyprecautions in section Liftingmethods and weights

4.3 Positioning the power unitThe following minimum space must be left around the PAC, to ensure proper ventilation and providesufficient working space for easier maintenance. Heavier maintenance such as changing the pump/motor assembly will demand larger working space.The PACs may not be installed side by side without the facing side panels being removed.It is important that all pipes for both water and hydraulics are mounted properly to allow for sufficientworking space for maintenance.

Installation

21

AD

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ABLE

211-

1

WARNING!

40 [1016mm]

32 [813mm]32 [813mm]

32 [813mm]

8 [203mm] 8 [203mm]

36 [914mm]

40 [1016mm]

32 [813mm] 32 [813mm]

PAC 200D/400D/600/800FLOOR OUTLINE WITH AIR COOLER

FLOOR OUTLINE WITHOUT AIR COOLER

REF. FLOOR OUTLINEDISTANCES SHOWN ARE MINIMUM

FLOOR OUTLINE WITH AIR COOLER

FLOOR OUTLINE WITHOUT AIR COOLER

PAC 100/200/300/400

REF. FLOOR OUTLINEDISTANCES SHOWN ARE MINIMUM

15


4.5 Mounting of electric motorIn certain cases the electric motor(s) are delivered separately. The following instructions are appli-cable for these cases only.

1. Remove the top cover from the power unitLoosen the screws that keep the top cover on the frame. Mount lifting eyebolts in their holes on thecorners of the top cover, and lift the top cover away. If range of lift is insufficient, front panel and frontbeam of the power unit can be removed.

2. Remove the sound baffleTake the sound baffle off and put it in a place where it cannot be damaged. When putting back, theinsulation material must be turned upwards.

3. Unpack the electric motor(s)Unpack the electric motor and check it for external damage. Also, check that all rating plate data is thesame as in the attached technical documentation.

4. Check the shaft coupling(s)Check that the axial shaft coupling clearance is in conformance with the coupling manufacturer speci-fications.

5. Lift the electric motorFirst, use the top mounted lifting ear and lift to position the electric motor vertically. Then lift with alllifting ears. Never let the electric motor stand on the shaft coupling.Two different types of lifting equipment may be needed in order to lift the electric motor.

6. Mount the electric motor in the power unitLift the electric motor into the PAC. It is important that it is hanging perpendicular. Fit the shaftcoupling through inspection hole into the nylon star coupling without causing any damage to it. Theconnection box on the electric motor must be positioned as shown in the picture on page 6 (section 1.2Operating principle). Lower motor to a position approximately 0.2 in. (5 mm) above bell housing.Place greased bolts in the holes and tighten by hand.

7. Tighten bolts to the bell housingInspect that there is an axial clearance on the shaft coupling through the inspection hole in the bellhousing, and then tighten the attached bolts to the bell housing.

8. Assemble top cover and sound baffleAssemble in reverse order according to point 1 and 2.When the top of the electric motor is below the sound baffle, a piece of thin sheet aluminum must beformed into a cylinder or a hexagon and be placed over the fan cover. It must be secured to the heatshield by way of rivets to allow the electric motor to draw in cooling air from the area above the heatshield (the area where the cooling air inlet is located).The hole in the sound baffle must be located straight above the electric motor and be slightly smallerthan the cross section of the fan cover.

For connection of electric motor refer to page 18 (section 4.9 Electric connections). Do not stand underneath a hanging load. Use all lifting ears when the electric motor is hanging free. Use only lifting equipment adapted to the weight on the rating plate. No hands/fingers between electric motor and bell housing during assembly.

Installation

DANGER!


16

4.6 Mounting of air-oil cooler and cabinet ventilationNormally the air-oil cooler is delivered separately and is to be mounted on the power unit. The follow-ing instructions are applicable for these cases only. (Changes may occur from the drawing and/ortechnical documentation.) Mount brackets with attached screws (in the drilled holes) on the PAC according to the installa-

tion drawing in attached technical documentation. Lift up air-oil cooler. Never lift with the electric motor. Mount the air-oil cooler on the brackets with the attached screws. Check that all screws are properly tightened. Connect the attached hydraulic hoses. Note that Oil In at the power unit shall be connected to

Oil Out at the air-oil cooler and vice versa. The coupling protections must be kept on until finalassembly to avoid the entrance of dirt.

For electric connections, couplings and hoses, see respective section. Air-oil cooler must always be connected with flexible hoses.

Beware of airborne particles inthe outgoing air flow

If the air-oil cooler becomesloose it can cause severe per-sonal injury.

Note: There must be an opening in the loweredge of the rubber flap, to allow the cooling airfrom the electric motor fan to exit.

A B C D E OIL IN & OIL OUT1 PAC 100/2002 PAC 200D3 PAC 300/400 59 3/8" (1508) 54 5/8" (1387)4 PAC 400D/600 62 5/8" (1591) 57 7/8" (1470)5 PAC 800 74 3/8" (1889) 69 3/8" (1762) 82 3/4" (2102) 17 5/8" (448) 10 1/2" (267) 1 1/2" JIC 37 male flare

6" (152)1 1/4" JIC 37 male flare

Cooler ports Motor drain port

48 5/8" (1235) 43 7/8" (1114) 71 1/2" (1816)

75 1/2" (1918)

15 1/4" (387)

19 3/8" (492)

5" (127)

Power unitCabinet sizeDimensions in (mm)

Cooler Connections

Installation

D

E

BA

C

AB

D

E

C

AIRFLOW

1 1/4" SAERUBBER FLAP

RECOMMENDED ELECTRICALPENETRATION

1 1/4" JIC 37 FLARE

INOUT

OILOIL

A B A B

FLOWAIR

RUBBER FLAP

1 1/4" JIC 37 FLARE

PENETRATIONRECOMMENDED ELECTRICAL

1 1/4" SAE

INOUT

OILOIL

BA

D

DANGER!

17


4.7 Mounting of top coverIf the power unit is placed outdoors, the top cover should be sealed using sealing strip. Do not useglue to seal the top cover! It is recommended that you place the unit so the air intake is turned awayfrom dusty environments.

4.8 Hydraulic connectionsDuring mounting of the hydraulic connections the following points must be kept in mind: The coupling protections must be kept on until final assembly. It is important that all pipes are properly mounted to allow for sufficient working space for main-

tenance of the PAC. Always use hoses to connect pump with piping.Professional service personnel aware of risks involved must perform all measurements in the hydrau-lic system. Be especially cautious when connecting the A and B connections (high pressure).

Do not make anymeasures or performmaintenance if thehydraulic system ispressurized.

*SAE-flange J 518, code 62, 414bar (6000 psi) 90 connectionshave to be used.

** 4 screws needed/connection,preferably with Grade 8 caphead bolts.

Installation

Drain line Flushing1 PAC 100/2002 PAC 200D3 PAC 300/4004 PAC 400D/6005 PAC 800

Cabinet size Power Unit

Dimension connection

1 1/4" SAE code 61 flange 1" SAE female

Thread DepthP6/P7

P11/P14P24/P30 2" 3/4-10 UNC

Denison Pump Size

Main A & B Connections *

Threaded holes **

1.06 in. (27 mm)5/8-11 UNC1 1/2"

NO GLUE!

DANGER!


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4.10 Pipe workWhen sizing hoses and hydraulic piping between the motor and the power unit, a safety factor of atleast 4 times the maximum system pressure should be used for the tensile strength. Keep in mind thatthe equipment may be readjusted to higher pressure in duty. Pressure losses in the pipe systemshould generally be kept to a minimum but there are exceptions in certain applications. Contact aHgglunds Drives service representative for more information.

Hydraulic pipesThe hydraulic pipes should be of high-grade steel as per ISO 3304, DIN 2391/C or ANSI/B93.4.

Pressure testA pressure test to 1 1/2 times the maximum working pressure should be performed on the main linesto check for possible leakage.Pressure tests on the main lines are best carried out using a hydraulic hand pump.

HosesTo avoid damage caused by vibrations it is important that the PAC and the motor be connected topipes by means of hoses.The hoses must be short and have the smallest possible diameter in order to obtain a small compres-sion volume. Nevertheless, allowance must be made for the minimum permissible bending radiusaccording to the data provided by the supplier of the hose. Allowance must also be made for the flowvelocities listed under Pipe sizes.

Pipe flushingThe piping system must be flushed with an adequately sized flushing pump prior to starting up thePAC unit to remove contamination introduced during assembly and/or welding. Please contact aHgglunds Drives service representative for proper cleaning and flushing procedure.

4.9 Electric connectionsSafety precautions All electric equipment is intended to be installed and used by qualified personnel who are famil-

iar with relevant safety requirements. Safety equipment necessary for the prevention of accidents at the mounting and operating site

must be provided in accordance with the regulations prevailing in the local country. Grounding shall be carried out according to local regulations before the electric equipment is

connected to the main voltage. All electrical supply levels must be within the limits that the equipment is constructed for, see

technical documentation and maximum rating plate.Junction boxConnect the cables on the screw terminals inside the junction box. Make the connections according tothe electrical drawing in the attached technical documentation.

Air-oil coolerThe voltage and connection are stamped on the rating plate. Connect the electric motor to the electri-cal supply. Check direction of rotation, see air stream arrow in section 4.6.

Electric motorMajor voltage connection according to designation on the rating plate.

Installation of electrical equipment must in mostcountries be installed by licensed electricians(reference local laws and regulations).

Installation

DANGER!

19


Pipe sizesIt is important that lines between the main connections of the motor and PAC are as short as possible.This gives the following advantages:

1. Small compression volume in the hydraulic system.This is particularly important in hydraulic systems with large and rapid load variations, and indrives, where high speed accuracy is essential.

2. Small power losses in the hydraulic system.3. Lower installation costs in that smaller pipe sizes and shorter pipe lengths can be used.

For a normal hydraulic system, the total pressure drop in the pressure and return line mustnot be more than 5 percent of the normal working pressure.

The following flow rates are recommended values and should not be exceeded:Main lines 15 ft/s (4.5 m/s) Drain lines 5 ft/s (1.0 m/s)

4. Lower noise level.In certain systems, where very small compression volumes are required, higher flow ratesare acceptable with possible increase in noise. Contact Hgglunds Drives representative inthese specific cases.

When dimensioning hose and pipe lengths between the drain connections of the motor and the PAC,keep in mind that the total pressure drop to the drain connections of the motor must not exceed 14.5PSI (1 bar). The pressure drop through the PAC is 7.25 PSI (0.5 bar).Pipe couplingsIt is essential that a tight and pressure rated coupling is chosen.The following types of coupling are recommended:

Non-welded couplings are preferredNon welded couplings provide the most clean piping installation as compared to a welded pipe sys-tem.

Welded couplings (socket or butt type)When using welded couplings, the pipes should be machined, normalized, and pickled. The pipesmust then be brushed, rinsed internally and blown clean before flushing.

Pipe couplingType collar coupling as per SAE J 514.

Pipe clampsPipes should be clamped with uniformly spaced clamps.The distance between the clamps may not exceed 6 ft (2 m) for pipes with outside diameters between1/2 in. (15 mm) and 1 1/2 in. (38 mm). The distance between the clamps may not exceed 9 ft (3m) forpipes with outside diameters greater than 1 1/2 in. (38 mm).In addition, the pipes must be clamped immediately before and after a bend. The pipes must beclamped immediately before transition to a hose as well.The pipe clamps shall be secured to a stable and non-vibrating surface such as concrete structure.The pipe clamps must be of a type permitting a certain amount of axial and radial motion in theclamped joint and have good vibration-absorbing properties.

Installation


20

ClampsThe normal distance between clamps: Pipe diameter less than 1 in. (25.4 mm)

space clamps 60-80 in. (1524-2032 mm)apart.

Pipe diameter greater than 1 in. (25.4 mm)space clamps 80-100 in. (2032-2540 mm)apart.

The pipes must be clamped immediately beforeas well as after a bend and immediately beforetransition to a hose.

Welded fittingsContact your Hgglunds Drives representative.

Mounting of hosesEnsure that hoses are not stressed or twisted oninstallation, to prevent premature failure. Bendradius should conform to manufacturer recommen-dations.

Pressure testsPressure tests should always take place beforeflushing in order to release contamination bystresses introduced by the pressure. The mainlines must be pressure and leakage tested to astatic pressure of 1 1/2 times the maximum ex-pected system pressure (not above bursting pres-sure). The hydraulic motor and power unit mustbe disconnected or protected by closed valvesduring the pressure tests.

Handling of fittingsInspect the sealing surfaces on the couplings visually before mounting. It must be free of any dam-ages such as scores and cracks. Handle the couplings with care. If you drop the coupling or it hasnicks on it inspect it visually. Check that the sealing (if any) is in its right position, free from cracks andthat it is saturated with oil.

The protection and packing on the fittings must be kept on until final assembly.

Correct

Incorrect

Flange fittingsThe screws must be tightened crosswise.

JIC-fittings (SAE J514, ISO 8434)Tighten fittings by hand, then tighten 1/4 to 1/2turn more using an appropriate wrench. Do notover tighten the fittings.Use correct size tools, fittings can be damagedand difficult to remove.

Be aware that all fittings may expand because ofheat and vibrations. All fittings must be checkedand retightened.

Storage of included componentsThe included components must be stored in the same way as the power unit (section 3.1 Storage ofthe packed power unit). Notice that the packing must not be removed during storage.

Do not work on the pipe system if the hydraulic system is pressurized.Use necessary safety equipment during installation of the pipe system.Usual safety requirements for each step must be followed.

Installation

CleaningThe pipes and hoses should be pre-cleaned, in-spected and sealed by the supplier. If the pipesare field bent and installed the overall system mustbe flushed to reach the required cleanliness level.

DANGER!

21


4.11 Extra filtration before start upA pressure filter and check valve has to be con-nected to the main line at the power unit. Thisfilter is connected on the return side of the drivepump.Recommended filtration degree 10 = 75 or bet-ter.

The size of the filter should be matched to that ofthe pump concerned, so that the pressure dropacross the filter is not excessive and that the maxi-mum pressure/flow ratings for the filter is not ex-ceeded.

The main lines should be connected together atthe motor enabling the entire system to be filtered,see the figure to the right.The maximum flow from the power unit should befiltered through the main circuit for at least twohours on small installations and considerablylonger on larger ones.Use extreme caution to ensure pump is stroked insynchronization with free flow direction of checkvalve.

Use a check valve sized for the oil flow.When using the main pump the maximumpressure should be reduced.

Example of a pipe installation whichis convenient and could easily be

sound insulated

Installation

Filter

Check valve

Hosesconnected

together

Flow Direction

HYDRAULIC MOTOR

POWER UNIT


22

4.12 Commissioning4.12.1 Prior to commissioning Read and understand this complete manual and the other attached technical documentation. Visually check the whole system for signs of damage, incorrect circuitry, security of foundations,

and that the degree of filtration of the filters are according to the data in the technical documen-tation.

Check that the coupling between the electric motor and pump is properly mounted. Check that the pre charge pressure in the accumulator (optional) is in accordance with the

technical documentation.Cleanliness The hydraulic system must be flushed and thoroughly cleaned on the inside. If you are uncertain about the cleanliness of the system, it must be checked prior to filling with

oil.

Pipe work Are the couplings properly tightened? Is the pipe work properly cleaned? Is the pipe work mounted free of stress? Are the lines in accordance with installation drawing/piping plan?Electrical System Check that electric motor(s) and control system and other electrical components are connected

to the correct voltages. Check the function of electrical components and monitoring system manually. Instruments that

cannot be actuated can be checked for correct wiring and possibly operated manually. Levelswitch and indication should be checked when filling the tank.

4.12.2 Filling up the system with hydraulic fluid

Installation

Before filling Check that the correct type and quality of

hydraulic fluid is used. Do not mix differenttypes of hydraulic fluid without first checkingwith manufacturers.

Check that the barrel with hydraulic fluid andtank/hoses are not contaminated with wateror other substances.

Follow instructions for handling of couplingsand hoses (section 4.10 Pipework).

Plug the drain connection D (motor) toprevent non filtered fluid being filled into thehydraulic motor case, when filling the systemthe first time.

Fill the pump case with filtered hydraulic oilthrough the D1 port on the pump. Whenfinished filling the pump case, replace theplug/hose connected to the D1 port.

'D1' DRAINPORT

23


ON FILL HOSE ON POWER UNIT

OIL FILLCONNECTION

PUMP/MOTOR CASE

RETURN FILTER

OIL HEATER

DRAIN FILTER

FillingUse a fluid filling pump unit, which has a filter with a filter rating of 10 microns, or better.

Always pump the fluid in through the quick connection that is marked appropriately. The quick connec-tion is a completely rustproof quick release coupling, see figure below. The fluid filled into the systemwill be filtered through the drain filter for better results.The tank must be filled with oil to 0.79 in. (20 mm) below the maximum level on the visual level gaugeon tank before starting for the first time.Check the function of the level switch and indication during filling up of the tank.

After filling the system with fluid, open the drain line and reconnect the drain line from the hydraulic motor.

New fluid is normally not filtered and will introduce dirt into the system, thefluid must therefore always be filled through a filter. Never pour hydraulicfluid into the tank through the air breather filter.

Check caution sign on container and the warnings (section 2.4 Choiceof hydraulic fluid).

Avoid prolonged contact of hydraulic fluid with your skin. Clean hydraulic fluid spills from floors immediately to prevent personal

injury.

System is full whenhydraulic fluid is at 5/8up into the sight glass

Installation

WARNING!


24

4.12.3 Initial start up procedureImportant Note! Make sure the driven system and driven machine is ready to run, warn all personnel in the area

that start up is in progress. Follow safety precautions in this manual (section 1.1 Safety precautions). Never operate the power unit with defective instruments or control elements. Keep flammable materials away from the power unit. During start-up period, the hydraulic system will be filtered to remove dirt particles, therefore

keep an eye on the filter indicator during the entire start up procedure.On cold start up, the filters may indicate bypass. After a few minutes of operating, press down thevisual indicator to reset. If the indicators will not reset after system has reached operating tempera-ture, filter element must be inspected and changed.

STEP 1 Immediately before starting Check fluid level in the tank and refill to about 0.79 in. (20 mm) below maximum level at visual

level gauge on tank (section 4.12.2 Filling up the system with hydraulic fluid). Check if any components need filling with clean hydraulic fluid, such as the pump case and

motor case. Check safety equipment. Check that all the prescribed steps (section 4.12.1 Prior to commissioning) have been carried

out. Make sure that all valves on the suction, pressure and inlet side of the pump, as well as any

valves on drain lines, are open. Check that cooling water is connected and turned on if a water-oil cooler is used.For adjustments and settings on the control system (if any) see separate instruction in attached tech-nical documentation.

STEP 2 Start with unloaded pump at short intervalsStarting of the PAC shall be carried out with a completely unloaded pump in short intervals. When the hydraulic fluid is cold, some restarts may be needed in order to raise the charge

pressure. Check that the charge pressure corresponds with data and settings on attached technical docu-

mentation. If OK, the pump may be allowed to come on stroke and introduce flow into the unloaded hydrau-

lic system. Flow and pressure should be limited until lines are purged of air.Check that the charge pressure is still OK.

Immediately make sure that thepump has the correct direction

of rotation. Otherwise, thepump will be damaged. The

correct direction of rotation isevident from a sticker placedunder the electric motor, see

figure to the right.

Installation

ROTATION

25


STEP 3 Unloaded pump at longer intervalsRun for a period at no load condition until system is stable and control is established. Checking of theoil level may be needed due to parts of the system having been filled with fluid. Check all interlocks. Check for unusual noises or vibrations. Check that the specified pressure level for charge pressure at the PAC is maintained in accor-

dance with the values stated on the hydraulic diagram in the attached technical documentation.These pressure levels are preset at the factory and there is normally no need to readjust.

Check for leakage points. Stop the electric motor. Correct any faults discovered in the points above. Check all connections, screws etc. and tighten if necessary. Restart when finished.

STEP 4 Loaded hydraulic systemThe hydraulic system can be loaded when the hydraulic system function is satisfactory in unloadedrunning condition. Gradually increase load pressure until proper operation is obtained. It may be necessary, at this point, to make adjustments to flow, ramp rates, etc. Cycle the system until normal operating temperature is reached.

STEP 5 Checking Check for unusual noises or vibrations. Check the function of the safety equipment. Check temperature in tank and closed loop. Check also that the cooler control is stable. If not,

investigate water supply, controls, air cooler, etc. Check for leakage points. Check that the pump compensator pressure control and pressure switches (optional) are set at

levels appropriate to the specific drive. Upon delivery, these pressure levels are set at the levelsspecified by the customer and normally no readjustment will be necessary. The values arestated in the technical documentation. System compensator can easily be checked by closing aball valve on the high pressure leg and stroking the pump until the pressure is showing on thegauge.

The working pressure must be checked to ensure that they correspond to the specified values.

STEP 6 Stop the electric motor Correct any faults discovered while performing the points of Step 5. Check the filter indicator. It is not unusual to change elements on commissioning as the system

is cleaning the dirt particles out. When changing filter elements carefully follow the instructions(section 5.3 Filter change) to prevent introduction of dirt into the system. If there is still dirt inthe system, additional flushing is necessary in order to prevent premature failure of systemcomponents.

Check all connections, screws etc. and tighten if necessary. Remove waste fluid, scrap cabling, etc. to keep the area in and around the unit clean.

Check fluid level in the tank

Installation


26

View from the back View from the back Front view

P6S, P7S, P11S & P14S P24S & P30S

Charge pressure and Pump compensator pressure level are set before the PAC leaves the factory andconsequently there is normally no need for readjustment. Always check the pressure levels in techni-cal documentation. Professional service personnel familiar with the functions and risks in-volved with the pump must perform setting of pressures on the pump(s). The pressures shall beset during operation and with the system at operating temperature. Note that pressures can changewith different viscosity.

1. Charge pressure adjustment: Remove acorn nut, loosen lock nut and adjust pressure with a5/32" size Allen key. Clockwise adjustment will increase the pressure. The charge pressure (onthe charge pressure gauge) shall be within the following limits: 218 psi (15 bar) for P6S/ P7S &P11S/P14S & P24S and 261 psi (18 bar) for P30S.

If other charge pressures are to be set, contact Hgglunds Drives representative for consultation.

2. When charge pressure is set: Tighten lock nut and return acorn nut. Note in the logbook orother technical documentation.

3. If the main pressure levels are to be increased: Make sure that the piping and machinestructure can take higher pressure/higher torque delivered from the hydraulic motor.

4. Compensator pressure adjustment: Dead head the pump, then activate or move the inputsignal to the control so that pressure increases in the high pressure closed circuit to the pres-sure limiter setting. The pressure limiter setting is reached when the pressure stops increasingand remains steady at a given pressure level. (As shown on the gauges)

The pressure limiter setting for both A- and B-side is set on the compensator valve.

Remove acorn nut, loosen lock nut and adjust pressures with a 5/32" size Allen key, until the desiredpressure level is established. Clockwise rotation of the adjustment screw will increase the pressure.5. When main pressures are set: Tighten lock nut and return acorn nut. Note the new pressure

level in logbook or technical documentation.

Working in high pressure areascould be dangerous in case ofunforeseen failures.

4.13 Pump settings and adjustmentsDenison Gold Cup pump

Installation

COMPENSATORVALVE

CHARGE PRESSUREADJUSTMENT

CHARGE PRESSUREADJUSTMENT

DANGER!

27


Daily checks, first week aftercommissioning Fluid leaks. Fluid level in the tank. Operating temperature. System pressure. System performance and general condition. Unusual noises. Contamination indicators on the filters.Pre-start checks (also daily) Fluid leaks. Fluid level in the tank. Is the suction valve open? Contamination indicator on the filters.

5. PREVENTIVE MAINTENANCE5.1 Maintenance logWe recommend that a maintenance log be kept to record service/maintenance/repair, addition andalteration of the equipment. Each note, observation or comment should be dated.

5.2 Maintenance chartThe maintenance of hydraulic systems is designed to prevent failure of the system and to keep thesystem running efficiently according to specification. The specific procedures will depend on thenature of the equipment, the environment it is working in and the duty cycle, keeping in mind theconsequences of a breakdown. To optimize the maintenance intervals a Life Cycle Cost (LCC) analy-sis is recommended. Follow the safety precautions during the checkups (section 1.1 Safety Precau-tions).

Maintenance

Frequent checks Unusual vibrations. Unusual noises. Fluid leaks. Fluid level in the tank. Is the unit relatively clean? Air flow paths

unrestricted? Pressure levels normal - stable? Actuator speeds normal - stable? Operating temperature. Is the drive running smoothly? Contamination indicators on the filters.


28

5.3 Filter changeSingle filter1. Stop the operation and electric motor.2. Remove the filter bowl and change filter cartridge.It is very important during the mounting not to expose the new cartridge to any dirt, thereforekeep it in the plastic cover as long as possible.Check the O-ring and the backup ring for damage, change parts if necessary.3. Mount the filter bowl. Tighten by hand to stop and back off 1/8th of a turn.Note! When removing a filter element take some time to inspect and look for unusual contaminationwithin the pleats. Contact your Hgglunds Drives office for advice.

=Inspection=Replacement

*If the contamination indicator is tripped out, the filtersmust be changed immediately, and the oil examined.

Scheduled maintenancePlanned maintenance at specific time intervals, including the following checks and actions: All points listed under frequent checks. Check all pressure levels. Check for stable temperature levels around the system. Drain water and sludge from the tank at the drain tap. Check the electric motor. Check the function of monitoring equipment/switches, etc. Clean areas where dirt is building up.

Note: never use a high pressure washing system to clean inside the power unit Check the cables. Check accumulators (optional) for correct pre-charge. Check drain line flows and drain line oil condition. Check the hoses, couplings and pump(s), with regards to cracks, leaks and condition. Check the shaft coupling through the inspection hole. Warning, rotating parts inside the

inspection hole. Check the flow of cooling water. Check that the insulation inside the cabinet (especially on hood) is fixed. Check that the doors and cover of the power unit are not damaged.

Maintenance

Air inlet

Air breather on tank Hydraulic fluid

Accumulator(s)(optional)

After the first 100 working hours *After 3 months or 500 working hours *Once every 6 months * Once every 24 months

Oil Filters

Absolute maximum intervals for major inspection and replacement

29


Vent screws

Different hydraulic fluids are affected differently- consult the manufacturer.

Pressureequalizerlever

Switchinglever

In thispositionyou canchange

thiselement

There are dangers associ-ated with hydraulic fluid.

Store used hydraulic fluidand contaminated filterelements for proper dis-posal.

The fluid may be hot if thecooling is insufficient.

Duplex filter1. Press in the pressure-equalizing lever on the underside of the switching lever and hold it, see

figure below.2. Withdraw the catch knob, turn over and engage the switching lever on the other side.3. Loosen the vent screw, only on the side where the filter is to be changed, (see picture below) 2-

3 turns.4. Remove the filter bowl and change filter cartridge.It is very important during the mounting not to expose the cartridge to any dirt, therefore keepit in the plastic cover as long as possible.Check the O-ring and the backup ring for damage. Change parts if necessary.5. Mount the filter bowl. Tighten by hand to stop and back off 1/8th of a turn.6. Refill the filter by pressing the equalizing lever and hold it there until the vent screw bore is

bubble free.7. Tighten the vent screw. Check the filter for leaks by pressing in the equalizing lever again.

5.4 Inspection of hydraulic fluidWe recommend that the hydraulic fluid be analyzed once every 6 months. The analysis should coverviscosity, oxidation, water content, additives and fouling. In the vast majority of cases, your oil supplierwill perform an analysis that will reveal the condition of the hydraulic fluid and can recommend suitableactions. If the analysis reveals that the properties of the hydraulic fluid are not fulfilling the require-ments (section 2.3 Requirements for hydraulic fluid cleanliness) it should no longer be used, but bechanged or cleaned immediately. Refill fluid according to instructions (section 4.12.2 Filling up thesystem with hydraulic fluid).

Maintenance

CAUTION!


30

5.5 Lubrication of electric motorLubricate electric motors larger than 30 HP1. Clean the grease nipples.2. Grease the electric motor with a grease gun.GreaseWhen re-greasing, use only special ball bearing grease with the following properties: Good quality lithium base or lithium complex grease. Base oil viscosity 476-667 SSU at 104 F (100-140 cSt at 40 C). Consistency NLGI grades 2 or 3. Temperature range -22 F - +248 F (-30 C - +120 C), continuously.Grease with the right properties is available from all the major lubricant manufacturers. If the type ofgrease is changed and compatibility is uncertain, lubricate several times at short intervals in order todisplace the old grease.

Air inlet for electrical motorCheck that the air inlets on the cabinet hood and on the electric motor are not clogged by dirt and thatair can easily pass.

Check the warning labelon the grease cartridge. Frame

sizeElectric motor

HP (kW)Lubrication

intervalsVolume of

grease

286 30 (22) 1.0 cu. in.40 (30)50 (37)60 (45)75 (56)

100 (75)125 (93)150 (112)200 (149)250 (186)300 (224)350 (261)400 (298)

5011 450 (336)

Lubrication schedule for electric motor (60 Hz)

2.5 cu. in.

1.5 cu. in.

check data

404-449 509

324-3656 to 12 months

6 months

3 months

5.6 Air breather changeRefer to maintenance chart (section 5.2 Maintenance chart) for recommended replacement inter-vals.

1. Clean around the area where the air breather is located.2. Unscrew the breather and make sure no foreign material has entered the tank.3. Thread on a new air breather.

GREASENIPPLES

Maintenance

CAUTION!

31


5.8 Power unit out of servicePeriods out of commissioningClean and empty the cooling system (water side) before periods of rest (especially if the cooling wateris not totally clean). If the PAC is to be out of service for more than three months, the hydraulic systemmust be protected internally against rust.This can be done in the following manner: Use hydraulic fluid that is consistent with fluid types used at your location, which has rust pre-

venting additives. Use additives which give protection against rust for up to about a year. After this, the equipment

should be run at intervals to maintain a protective film on the internal surfaces of componentsand oil lines, thus providing protection against corrosion.

If any parts of the system are disconnected, note that open fittings must be protected by plugsor covers to prevent entrance of any dirt particles.

Re commissioningBefore the drive is restarted after a long idle period, a check should be made as to whether theinstructions supplied for the original commissioning still apply. Moreover, the following measuresshould be observed.

Remove preservative solution and any signs of contamination. Follow the procedure for initial start-up (section 4.12.3 Initial start-up procedure).6. CORRECTIVE MAINTENANCE6.1 CommonBefore removing any hydraulic/electric components, disconnect the power unit. Ensure that no energyis accumulated in the system and the power is disconnected from the electric motor. Follow recom-mended safety procedures.

Before disassembly Troubleshoot the PAC and perform appropriate tests. Clean all assemblies and components, take all precautions necessary to prevent dirt entering

the system. Disassembly may only be done by professional service personnel.

5.7 Cleaning of Air-Oil coolerCleaning of air fins The easiest way to clean the air fins is by using compressed air or rinsing with water. Fouling can be dealt with using a degreasing agent and a high-pressure washing system. When

using a high pressure washing system point the jet carefully parallel to the air fins.

Follow the safety precautions on the container of the cleaning agent used.Disconnect the power unit before disconnecting the Water-oil/Air-oil cooler.Make sure that electric power is cut off before cleaning! Cleaning agentand waste water from rinsing should not be disposed of in nature.

Maintenance

WARNING!


32

Always use all four lifting points when lifting the electricmotor/pump unit.

Never use the lifting ears on the electric motor to lift thecomplete electric motor/pump unit.

Use only lifting equipment adapted to the weight (section 4.2Lifting methods and weights).

Do not stand underneath hanging load Take center of gravity into consideration during lifting.

Disassembly Label all parts, and protect precision or machined surfaces. Inspect all parts during disassembly for wear or damage. If hydraulic fluid is to be drained and reused, make sure that drain containers are clean and

covered when not in use. Clean all metal parts using a suitable solvent prior to reassembly, set aside on a clean and lint

free cloth to drain.Reassembly Lubricate with system hydraulic fluid. Replace all seals, gaskets and o-rings with new items of the correct size. Ensure complete sealing at pipe connections. Refill hydraulic fluid according to recommendations (section 4.12.2 Filling up the system with

hydraulic fluid).6.2 Change of hydraulic pump/electric motor assemblyThe most common method to change the pump is to lift the complete electric motor/pump unit andthen remove the pump.The electric motor and pump are assembled into a unit and mounted on the motor support plateattached to the frame via shock mounts.

1. Remove top cover and sound baffle: Item 1 and 2 (section 4.5 Mounting of electric motor).2. Release the motor support plate: Release the motor support plate from the frame.3. Secure lifting equipment: Adapt lifting equipment in the four holes in the corners of the motor

support plate.4. Lift the electric motor/pump unit: Be careful and take the weight and center of gravity into

consideration. Never let the electric motor/pump stand on the charge pump.5. Assemble: Assemble in reverse order according to point 1 to 4.

Corrective Maintenance

DANGER!

33


6.3 TroubleshootingTroubleshooting

Problem Probable cause ActionMain voltage to electric motor lacking

Look for the cause in the electric power supply network

Suction valve closed Open suction line valve, verify switch function

Not enough oil in reservoir Verify reservoir oil level and switch functionReservoir temperature above set limit Verify reservoir temp switch function

Look for the cause in the electric power supply networkExamine the control system in the power unit. If the control system has tripped, determine the reason

No servo pressureNo control current to electro hydraulic stroker control. Examine the control function or electronic control card

Coupling pump/electric motor defect

Check through the inspection hole in the bellhousing

Wrong direction of rotation of hydraulic pump Check direction of rotation

Load is too largeCheck that load pressure is not too high so that pressure override reduces pump delivery

Suction line not open Open suction line valveCharge pressure too low or non-existent Check that charge pressure is correct

Pump/Motor baseplate shipping bolts still installed Remove shipping bolts

Air leaks and pump cavitating

Examine the suction line to charge pump for air leaks. Test by pouring oil over pipe joints while listening for changes in noise in the pump

Air filter in tank clogged Change filterWorn elastomer element in the shaft coupling Change elastomer element

Wrong direction of rotation Reverse direction of rotationHigh oil temperature in closed circuit

No oil exchange from closed loop

Check charge pressure and shuttle valve setting

Control voltage lacking

Power Unit does not start

Power unit fails to deliver oil flow

Unwanted noise


34

7. DISPOSING OF POWER UNITWhen the complete PAC or a single component is worn out, it should be disposed of as soon aspossible. Used hydraulic fluid, material exposed to hydraulic fluid and grease may cause damage onthe environment and should be disposed of according to prevailing local regulations.

Check that the power unit is completely disconnected. The components may contain accumulated energy. Take fire hazards into consideration during dismantling. The accumulator (optional) must be empty and discharged.

Troubleshooting

Problem Probable cause Action

Power unit fails to deliver oil Perform previously described actions

No command signal to pump

Verify input signal to amplifier card and output signal to electrohydraulic pump control

Pump/Motor coupling not installed properly

Verify that pump and electric motor coupling and insert are installed and tightened properly

Pump compensator valve is not closed Replace pump compensator valve

Compare with our oil recommendationsCheck the oil temperature, and the cooling circuit

Abrasive material circulating through pump with the hydraulic fluid

Check filters and change if necessary. Check that changing is performed at prescribed intervals

Air in the hydraulic system and Pump cavitating

Locate and remedy the air system leak and purge air from the system

Content of water in hydraulic fluid too high Inspect hydraulic fluid, change oil

Check flow of cooling water, water temperature, cooler, water valve and water filter or air cooler (optional)If air cooler is clean, inspect cooler fins and remove any obstructions

Internal leakage in pump Change or repair pumpToo small an amount of replacement oil in hydraulic system

Check that charge pump delivers sufficient flushing oil

Charge pressure is out of adjustment

Adjust according to values on hydraulic circuit diagram

No pressure in system

Excessive wear

High oil temperature

Poor cooling capacity

Viscosity too low

DANGER!

AM32

6-1A

199

9 P

rinte

r : Pr

ecis

ion

Prin

ting

1999

HGGLUNDS DRIVES INC.2275 INTERNATIONAL STREETCOLUMBUS, OHIO 43228 USA

Phone: (614) 527-7400 Fax: (614) 527-7401www.hagglunds.com

Contents1. GENERAL 1.1 Safety precautions 1.2 Operating principle 2. TECHNICAL DATA 2.1 Operating conditions 2.2 Cooling water 2.3 Requirements for hydraulic fluid cleanliness 2.4 Choice of hydraulic fluid 2.5 Power unit monitoring 3. HANDLING OF THE PACKED POWER UNIT 3.1 Storage of the packed power unit 3.2 Lifting the packed power unit 4. INSTALLATION 4.1 Installation directions 4.2 Lifting methods and weights 4.3 Positioning the power unit 4.4 Mounting of the cabinet feet 4.5 Mounting of electric motor 4.6 Mounting of air-oil cooler and cabinet ventilation 4.7 Mounting of top cover 4.8 Hydraulic connections 4.9 Electric connections 4.10 Pipe work 4.11 Extra filtration before start up 4.12 Commissioning 4.12.1 Prior to commissioning 4.12.2 Filling up the system with hydraulic fluid 4.12.3 Initial start up procedure 4.13 Pump settings and adjustments 5. PREVENTIVE MAINTENANCE 5.1 Maintenance log 5.2 Maintenance chart 5.3 Filter change 5.4 Inspection of hydraulic fluid 5.5 Lubrication of electric motor 5.6 Air breather change 5.7 Cleaning of Air-Oil cooler 5.8 Power unit out of service 6. CORRECTIVE MAINTENANCE 6.1 Common 6.2 Change of hydraulic pump/electric motor assembly 6.3 Troubleshooting 7. DISPOSING OF POWER UNIT

I&M manual

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