RE 07 900/04.

91

Assembly, Commissioning and Service of Hydraulic Systems

RE 07 900/04.91
Replaces: 01.83

1.

General

1.1. Long service life and functional reliability of hydraulic systems and their components are dependent on correct maintenance. Ensure fault-free operation by taking note of: the special installation and operating instructions for the components the technical data contained in the data sheet We would also like to draw your attention to: the VDI Guidelines, Commissioning and Service of Hydraulic Systems, VDI/3027 Hydraulic Systems DIN 24 346 and ISO 4413

Please note: viscosity operating temperature range type of seals on components used

3.

Commissioning
When assembly has been carried out correctly, we may now proceed with commissioning and functional test.

3.1 Preparation for Trial Run Tank cleaned? Pipelines cleaned and correctly fitted? Couplings, flanges, tightened? Pipelines and components correctly connected in line with installation drawings or circuit diagram? Pressure accumulators charged with nitrogen? It is recommended that the gas charge is noted on the accumulator itself (e. g. by a label) and in the circuit diagram, so that a comparatory check may be made later if required. Prime mover and pump correctly assembled and aligned? Prime mover correctly connected? Filter of specified pore size? Specified oil filled up to maximum oil level? 3.2 Trial Run Any personnel not required should leave the danger zone! Only personnel from the machine manufacturer and possibly maintenance and operating personnel should be present. Are shut-off valves fully open? Does the direction of rotation of the prime mover match that of the pump? Switch on briefly and test. check position of directional valves and if necessary move into required position. Set control valves to by-pass. Open pump suction valves if necessary fill pump housing with oil. If pilot pump is fitted, start up. 1) Start main pump, move out of zero position and listen for noise. Swivel pump out a little, approx 5 1) Bleed system Carefully loosen fitting or bleed screws at high point in the system. When the escaping hydraulic fluid is free of air bubbles, the filling process is complete. Re-tighten fittings. Flush system, if possible by short-circuiting the serviced units. Continue flushing unit the filters remain clean; check filter!
1

2.

Assembly Rules
Cleanliness: of the environment of power units, pipe connections, components (e. g. pickling may be necessary if pipes have been welded or hot-bent)

2.1. Preperation of Assembly

of hydraulic fluids Watch out for contamination, dampness; dirt from the environment must not be allowed to enter the tanks. Fill oil tanks only via a filter preferably via system filters or portable filter stations with fine filters. protective internal paint coatings, if used, must be resistant to the hydraulic fluid to be used. of stock parts Storage of parts which have not been filled or threated with anti-corrosion fluid can lead to the build-up of resin. Dissolve resin and renew lubricating film. Are all parts to hand?

Is there any transport damage? 2.2. Carrying out Assembly Make use of lifting rings and transport equipment Do not use force, in order to prevent radial forces and tension on pipelines and components. Ensure that pipelines are firmly secured. Do not use hemp and putty as sealing materials, as these can lead to contamination and thus to malfunctions. In order to avoid external leakage, observe the installation instructions of the pipe fittings' manufacturer. We recommend the use of fittings with flexible seals. Make sure hose lines are correctly laid. Rubbing and abutting of the lines must be avoided. Availability of correct fluids (DIN 24 318, 51 524, ISO VG DIN 51 519; for fire-resistant fluids DIN 24 317), selected according to system requirements.

) As far as is possible with the built-on control devices, otherwise start at full displacement volume. Run internal combustion engines at idling speed.

1/2

RE 07 900/04.91

Check function of system without load; if possible, operate by hand. Cold test the electro-hydraulic controls. When operating temperature has been reached, test system under load. Gradually increase pressure. Check monitoring and measuring devices. Listen for noise. Check oil level, top up. Check setting of pressure relief valves by loading or braking the system. check for leakage. Switch off drive. Tighten all fittings, even if there is no evidence of leakage. Warning: tighten only when the system is not under pressure. Check oil level. Full functional test of the system. Compare measured values with the permissible and/or required data (pressure, speed, setting of other control components). Jerky movements indicate the presence of air in the system. By swivelling the pump briefly to one or both sides with the serviced units in the loaded or braked condition, certain air pockets can be eliminated. The system is completely bled when all functions can be carried out smoothly and continuously and there is no foaming on the surface of the oil. In practice it has been found that foaming should have ceased 1 hour after start up at the latest. Check temperature. Switch off drive. Remove filter elements (secondary and main flow filters) and inspect for residue. Clean filter elements, replace paper cartridges. If further contamination is found, an additional flushing is necessary in order to prevent premature failure of system components. All settings should be laid down in an acceptance certificate.

Daily during the first week. After one week the filters should be cleaned as necessary. Service suction filters. Suction filters required particularly careful servicing. After the initial running-in time they should be checked and if necessary cleaned at least once a week. 4.4. Service system fluid Servicing is dependent on serveral operating factors oil level (e. g. water in oil, severely aged oil) operating temperature volume of oil Drain and renew when in warm opeating condition. Severely aged or contaminated fluid cannot be improved by topping up with fresh fluid. Use filter when filling, with mesh width of 0.06 mm or alternatively and better fill via system filter. Take laboratory samples of system fluid and have inspected for particle type, size and quantity; document findings. 4.5. Check pressure accumulators for charging pressure; while doing so, there must be no pressure on the oil side of the accumulator. 4.6. Measure operating temperature. Rising operating temperature is an indication of increasing friction and leakage. 4.7. Leakages in the pipe system Apart from loss of oil, lekages can endanger concrete floors and components, particularly with underfloor piping. 4.8. Check main and pilot pressure At weekly intervals Note any pressure corrections in service book Frequent re-adjustment indicates wear at the pressure relief valve.

4. Servicing
4.1. Prepare service book It is recommended that a service book is prepared, in which it is laid down which particular parts must be checked. 4.2. Check fluid level continuously during commissioning daily after commissioning thereafter weekly 4.3. Check filters Check and if necessary clean every 2 to 3 hours during commissioning.

Mannesmann Rexroth AG D-97813 Lohr am Main Jahnstrae 3-5 D-97816 Lohr am Main Telefon 0 93 52 / 18-0 Telefax 0 93 52 / 18-10 40 Telex 6 89 418-0

Mannesmann Rexroth Limited Cromwell Road, St. Neots, Huntingdon, Cambs. PE19 2ES Tel: (01480) 476041 Fax: (01480) 219052

2/2

The specified data is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract. All rights reserved Subject to revision