Operating Instructions for

Hydraulic Power Unit

8-40100001.00205

PINTSCH BUBENZER GmbH

Friedrichshttenstr. 1
57540 Kirchen-Wehbach
Tel.: +49-2741 - 9488 - 0
Fax: +49-2741 - 9488 -44
GERMANY
www.pintschbubenzer.de
e-Mail: info@pintschbubenzer.de

PB-8-40100001.00205-0813-01/1

Operating Manual
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Table of contents
1 Safety regulations.................................................................................... 3
1.1

Symbols in this manual ......................................................................................... 3

1.2

Warnings ............................................................................................................... 4

2 Power unit ................................................................................................ 6

2.1

Introduction ........................................................................................................... 6

2.2

Warranty ................................................................................................................ 6

2.3

Limitation of liability ............................................................................................... 6

2.4

Instructions and information for and obligations of the operator ............................ 7

2.5

Power Unit ............................................................................................................. 8

2.6

Technical Data ...................................................................................................... 8

2.7

State of shipment ................................................................................................ 10

3 Setup ....................................................................................................... 11
3.1

Preliminary Work ................................................................................................. 11

3.2

Hydraulic connection ........................................................................................... 11

3.3

Bleed installation ................................................................................................. 12

3.4

Electrical connection ........................................................................................... 12

4 Operation of the hydraulic power system ........................................... 14

4.1

Release (open) the rail clamp hydraulically ......................................................... 14

4.2

Set the rail clamp................................................................................................. 14

4.3

Manual release .................................................................................................... 14

4.4

Actuate magnetic valve manually ........................................................................ 15

5 Maintenance ........................................................................................... 16
5.1

Regular maintenance tasks ................................................................................. 16

5.2

Oil change ........................................................................................................... 16

5.3

Replace solenoid valve ....................................................................................... 17

6 Putting out of service and disposal ..................................................... 18

7 Spare parts ............................................................................................. 19
8 Appendix ................................................................................................ 20

Operating Manual
8-40100001.00205
1 Safety regulations
1.1

Symbols in this manual

The following symbols / pictographs are used throughout this manual to point out dangers and
information.

Danger for health and life.

Danger of damage to or destruction of the installation or parts of the installation.

Danger for health and life due to electrical shock!

Warning of hot surfaces! Danger of burning!

Warning of rotating machine parts!

Warning of moving parts! Danger of squeezing!

Warning of possible pollution and dangers to the environment

Additional important information

There may be other specific warning symbols/ pictographs used to point out dangers more
precisely in certain situations.

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1.2

Warnings

Note: warnings and other security rules are presented like this throughout the manual:

All safety advises are marked by Symbols and frames!

Symbol / Pictograph

Description

The power unit / brake may only be used in the way described in chapter 2.5 Description and
proper use. The safety of your brake / brake-system depends on proper and regular inspection
and maintenance. Study the manual before starting the installation. If in doubt, please dont
hesitate to contact our service-department or your local retailer.
Important!
The power unit is part of an essential safety device.
Any misuse or insufficient handling or maintenance endangers life!

Also study the following manuals and Regulations:

Operating manual of the installation
Operating manual of the brake
Safety precautions of the installation
Valid Safety regulations
Before starting any work with the brake:
Warning!
A sudden startup of the installation endangers the life of the maintenance
personnel! Secure the drive and the installation against any accidental
movement before starting any work!

Dont use any mechanical devices to block the brake.

Ensure that the drive is disconnected from the electrical power supply.
Ensure that the brake is disconnected from the electrical power supply.
Any electrical work is only to be done by a trained electrician.
Use only genuine PINTSCH BUBENZER spare-parts.
Ensure that the brake is set to its proper values according to the manual after finishing any
work!
Danger of crushing
When working on the power unit, heavy tools are used. Particular attention
should therefore be paid to possible crushing points when: Using tools,
fitting and removing the brake, accessories or spare parts.

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Secure dismounted parts!

Due to weight and shape the components of the power unit may cause
heavy injuries when dropped. When working on the power unit / brake,
secure all dismounted parts against falling!

Do not disassemble the power unit completely!

The POWER UNIT must never be disassembled further than described in
the manual!

Safety distance
A safety distance must be maintained to all hazardous zones to ensure
safety of personnel and prevention of damage to the power unit.

Avoid negligent behaviour

Refrain from any actions that could affect the safety of the brake. Always
take measures against imminent dangers for life and health or against the
safety of the brake before starting any work on the power unit!

The standard common safety rules and regulations must also be observed under the pressure of
time. Accidents cannot be reversed. Work with care!
Before carrying out any work on the brake, measures must be taken against any dangers to the life
and health of persons and damage to the brake:
Only closed shoes in a perfect condition must be worn. Open sandals, damaged or unsuitable
shoes must not be worn.
Closed, tight-fitting working clothes must be worn. Wide work jackets and wide sleeves can be
dangerous.
Long hair must be tied back.

Work must only be carried out on the brake when:

All dangerous movements have stopped
Accidental and unexpected operation of the brake is made impossible by suitable measures
If the brake is loaded, other safety devices provide a braking and holding function.
Important!
Ensure that the power unit is set to its proper values according to the
manual after finishing any work!

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2 Power unit
2.1

Introduction

This manual has been written to the best of our knowledge. It is intended to familiarize the
operation and maintenance personnel with the function, the handling, the maintenance and the
safety regulations of the product. Furthermore these instructions should make sure that trained
and qualified personnel is able to handle the product according to its designated use. However
the manual cant cover all the possible circumstances at the place of operation. If you have any
questions concerning the product or this manual, please contact PINTSCH BUBENZER quoting
the type and serial number of product as given on the typeplate.
Copyright: The reprinting and duplication of all this technical documentation or extracts from it is except for internal requirements in connection with the operation of the device - permitted only with
the approval thereto in writing of PINTSCH BUBENZER GmbH. Permitting third parties to inspect
the device as described is prohibited. Similarly prohibited is the handing over of the device to third
parties and its replication.

2.2

Warranty

The warranty and its duration depend on the contract. For details on the suppliers warranty please
refer to the terms of the contract. Any warranty- or liability-claims are excluded in case they occur
because of one or more of the following conditions:
Non-designated use of the power unit.
Improper handling, setup, operation and maintenance of the brake by the operating company.
Neglection of the regulations and notes in this manual concerning transport, setting up,
operation and maintenance of the brake.
Improper maintenance and repairs of the power unit.
Improper monitoring of components, which are prone to wear.
Catastrophes, external objects and forces and force majeure.
Changes at the brake without approval of PINTSCH BUBENZER.
The information in this manual has been checked thoroughly. Nevertheless we cant accept liability
for errors.

2.3

Limitation of liability

All the technical information, data and instructions on or for the operating and maintenance of the
product as contained in these operating instructions are up to date at the time of printing and are
given to the best of our knowledge and with account being taken of our experience and findings up
to the present time.
We undertake no liability for losses and operational disruptions which come about as a result of
operating errors, non-observation of these operating instructions or unprofessional repairs. We
draw explicit attention to the fact that only original spare parts and original accessories have been
checked and approved by us.
Every form of liability is excluded for the use of spare parts and accessories that are not original
ones.

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Conversions and changes of every form to the brake are not permitted for reasons of safety and
any such conversions and changes made render liability for any loss/damage resulting there from
to be excluded.
We are liable for any errors of omission or commission for which we are responsible within the
framework of the warranty obligations entered into in the main contract whereby the advancing of
further claims is excluded. The advancing of claims for damages - regardless of the legal
foundation on which they are based - is excluded.

2.4

Instructions and information for and obligations of the operator

The operating instructions represent an important component of the product. Thus, for example, if
the product is passed on to a third party as a component of a system, then these operating
instructions are to be passed on to this third party as operator of this system. The operator of the
system containing the product is to ensure that these operating instructions are available to his
operating personnel at all times!
In order to ensure that the health and safety of the operating personnel is not endangered as well
as to ensure the proper working of the device, the operator is obliged to instruct his personnel on
the safe and proper operating, maintaining and servicing of the device as well as on how the
device should be operated in the proper manner. In this connection the relevant supervision and
notifying obligations are to be observed and any special operational circumstances taken account
of!
Our customer service department is at your disposal should you require technical information on
any of PINTSCH BUBENZER GmbH's products and how to use these correctly. See below for the
address and telephone number.
Should you have any questions of this device, please contact our customer service department.

PINTSCH BUBENZER GmbH

Werk Kirchen
Friedrichshttenstr. 1
57548 Kirchen-Wehbach
GERMANY

PINTSCH BUBENZER GmbH

Plant Dinslaken
Hnxer Str. 149
46537 Dinslaken
GERMANY

Tel.: +49-2741 - 9488 - 0

Fax: +49-2741 - 9488 -44

Tel. +49 (0)2064 602 8

Fax +49 (0)2064 602 515

E-Mail: info@pintschbubenzer.de
E-Mail: info@pintschbubenzer.de
Internet: www.pintschbubenzer.de
Internet: www.pintschbubenzer.de
Amtsgericht Montabaur, HRB 5590
Geschftsfhrer: Markus E. Topp, Stefan Krger

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2.5

Power Unit

The hydraulic power unit 8-40100001.00203 is designed and set to supply rail clamps type
PINTSCH BUBENZER BSZ according to the conditions described in your order. Please also refer
to the designated use of the rail clamp. The rail clamp is released (opened) by the hydraulic power
unit and set by spring force. In emergency situations the rail clamp can be released by a hand
pump lever. This power unit is not suited for the use in areas with explosion hazards and is not
certified acc. to Atex!

The function is described in section 4

Any other use or any further change of the power unit is strictly forbidden!
Ignoring the regulations for the designated use and /or the instructions for
setup and maintenance endangers life and leads to the loss of any
warranty by the manufacturer!

2.6

Technical Data
Hydraulic diagram
Assembly drawing
Wiring diagram

3845108
3651749
120-2075

Compare technical data with type plate of the unit. (Control voltage of the valves and motor
voltage)
Rail clamps to supply
Oil tank volume:
Hydraulic Oil:
Power
Volume flow Q :
Min. Operating pressure:
Max. Operating pressure:
Motor voltage :
Control voltage :
Direction of Pump
Duty cycle of motor

1 x BSZ
2,2 l
ISO VG 2268
2.2 kW at 50 Hz
6.3 l/min at 50 Hz
250 bar
270 bar
230 V AC
400 V, 50 Hz +/- 10%
460 V, 50 Hz +/- 10%
Right
S3 intermittent operation 10%;
Short time operation 3min

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13
K
19

6
31

10

16

37

14

30

Fig. 1:

Pos.
K
5
6
10
13
14

Item
Terminal box
Filler
Oil level gauge
2/2-way seated valve
Pressure gauge
Pressure switch

Pos.
16
19
30
31
37

Item
Handpump
Pressure limiting valve
Temperature sensor
Oil level sensor
Pressure limiting valve

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2.7

State of shipment
Important!
The hydraulic power unit must always be moved with proper lifting
devices!
Danger of injury!

The unit is shipped ready for use, without oil filling.

The power unit needs to be installed as described in chapter 3 (see below).
The Operating pressure is pre-set by PINTSCH BUBENZER.
These settings must not be altered!

Keep rail clamps and power units dustproof and waterproof together with drying material during
the storage and/or transportation period.
Protect the rail clamps against external damage for the complete storage-/transport period.
To avoid condensation inside the units, piping etc. the hydraulic power units must not be stored
outdoors.
Pipe connections and connections on manifolds should be provided with threaded plugs.
Carry out commissioning of a long-term stored hydraulic power unit by specialists.
Store hydraulic power units completely dustproof if they are not directly used after
manufacturing.
Fill up the tank with hydraulic fluid if the power units are not directly used after manufacturing.

In case of additional painting, do NOT contaminate:

Pistons and seals.
Electrical components.
Signs or plates
Moving parts

10

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3 Setup
Danger!
A sudden startup of the installation endangers the life of the maintenance
personnel! Secure the drive and the installation against any accidental
movement before starting any work!

3.1

Preliminary Work
Important!
Contamination of the hydraulic oil may endanger the brake function! The
brake, the power unit and all tubing and hoses have to be cleaned / flushed
inside and bled BEFORE the brake is connected!

3.2

The hydraulic power unit is usually shipped readily mounted and connected to the rail clamp. If
this is not the case (e.g. spare parts delivery):
Mount the hydraulic unit according to the drawing of the rail clamp.
In case any tubing is higher than the rail clamp(s) and the power unit, install an additional
bleeder valve (not included in the scope of supply) at the highest point of the tubing.

Hydraulic connection
Attention:
The hydraulic tasks may only be executed by person trained in this field!

Connect hydraulic power unit and rail clamp according to diagram 3845108.
The connections between hydraulic power unit and rail clamps have to be executed in a way
that metal chippings and dirt cannot get into the tubing.
Arrange all parts so the rail clamp can still be properly reached.
In case any tubing are higher than the rail clamp(s) and the power unit, install an additional
bleeder valve (not included in the scope of supply) at the highest point of the tubing
Fill in approximately 2.2 litres of absolutely clean (min. 10 micron) hydraulic oil of the correct
viscosity grade ISO VG 1068. Refer to section 2.4
In case the temperature class changes make sure to fill in the correct oil (refer to appendix).
Ensure that the necessary operating-pressure is available and isnt exceeded. The maximum
operating pressure is contained in the operating manual of the rail clamp.

11

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3.3

Bleed installation
Important!
Air bulbs inside the hydraulic system endanger the correct function of the
brake. The brake, the hydraulic power unit and the tubing has to be bled
before the start up.

3.4

The rail clamps and the complete tubing have to be bled!

The bleeding of the rail clamp is explained in the manual of the rail clamp.

Electrical connection
Danger!
The applied electrical voltages are dangerous to life!
The electrical connection and all other electrical tasks must only be done
by a trained electrician!

The hydraulic power system has to be connected according to wiring diagram 120-2075.
The limit switch of the rail clamp has to be connected according to wiring diagram 120-2075.
Check function.

12

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4 Operation of the hydraulic power system
4.1

Release (open) the rail clamp hydraulically

Insure that shutoff valve (29) is open!
Energize pump motor and the directional seat valve (10) simultaneously.
The hydraulic fluid picked up by the pump goes directly into the cylinder and releases the rail
clamp.
When the operating pressure has been reached, pressure switch (14) switches off pump motor.
The check valve (17.1) keeps the rail clamp open.
Pressure can be checked at the manometer (13)

4.2

Set the rail clamp

Switch-off the control voltage of the directional seat valve (20.1) to reach the idle position.
The rail clamp sets by spring force, the hydraulic fluid is led back to the tank

4.3

Manual release
Danger!
When using the manual release no other safety device is active!
When the brake is released to quick, the load accelerates uncontrolled!
Release brake slowly and watch the load!

Screw in knurled screw (10.5) at 2/2 way seated valve (10) clockwise.
Attach extension lever (16.1) to hand pump lever (16).
Operate hand pump (16) until the rail clamp is released.
Check at pressure gauge (13).
After finishing all tasks:
o Store lever (16.1) safely in its place.
10.5
o Reopen magnetic valve (10.5).

Fig. 2:

14

13

16

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4.4

Actuate magnetic valve manually

In case the magnetic valve (10) is jammed it may be opened
manually
Screw in knurled screw (10.5) at 2/2 way seated valve (10.3)
clockwise.

Fig. 3:

15

10.3

10.5

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5 Maintenance
Danger!
A sudden startup of the installation endangers the life of the maintenance
personnel! Secure the drive and the installation against any accidental
movement before starting any work!

Warning:
The power unit may be pressurized.
Make sure the Installation is not pressurized! Check at the manometer!

Danger!
The applied electrical voltages are dangerous to life!
The electrical connection and all other electrical tasks must only be done
by a trained electrician!

5.1

Regular maintenance tasks

Check every 450 operating hours or monthly (Brakes not used for dynamic braking):
Oil level
Leakages at tubing and hoses
Leakages at connections
Operating pressure of the hydraulic power unit
Function of the power unit/brake system.
Check the hydraulic power unit outside the regular inspection intervals if:
Prolonged braking times or -distances appear.
Extreme operating conditions appear:
After a longer period of rail clamp
-standstill or drive standstill.
Any leaks appear.
An Emergency stop occurred.

5.2

Oil change
Take care that the hydraulic fluids, lubricants and other used substances
as well as oil-soiled parts are disposed environmental friendly and in
compliance with the corresponding laws and regulations!
Electronic scrap has to be disposed separately.

First change 3 months after initial operation

After that once a year or after 2.000 operating hours
Attach a hose to the-connector (32).
Open drain valve (32) and let oil flow into proper container.
Drain the complete system.
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If part of the tubing is lower than the hydraulic power unit, this
area also has to be drained.
Close drain valve
Remove hose.
Refill oil according to chapter 3.2
Bleed the system according to chapter 3.3

32

Fig. 4:

5.3

Replace solenoid valve

Replace plug (10.1):

Unscrew mounting screw
Pull out plug (10.1).
Unscrew electric connection.
Carefully leverage baseplate out of plug.
Connect new plug electrically.
Heed correct control voltage.
Pull out malfunctioning plug (10.1).
Remount new plug.
Check function.
In case the Valve does still not work properly although the plug has been replaced:
Replace magnetic coil (10.3).
Dismount plug (10.1).
The hexagon screw (10.6) must not be loosened.
Unscrew magnet cap (10.4).
Pull off coil body (10.3) with seal.
Check seals for damages.
Check all parts for cleanliness.
Mount new coil (10.3) with seal.
Remount magnet cap (10.4)
Check function.
Replace cartridge (10.2):
Dismount coil (10.3).
Screw out cartridge (10.2) at hexagon (10.6).
Carefully do not jam!
Clean thread.
Screw in new cartridge (10.2).
Tighten cartridge with torque wrench to a nominal
torque of 25 Nm (10.6).
Carefully do not jam!
Remount valve unit completely.
Check function.
Fig. 5:

17

10.1

10.6

10.2

10.3

10.4

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6 Putting out of service and disposal
When the power unit is put out of service, the following instructions have to be heeded, to help
avoiding dangers to life, material and environment:
The power unit must only be put out of service and disposed by trained and qualified personnel.
Always heed the applying laws and regulations!

Important!
Because of the weight of the power unit always use proper lifting devices
and transport the brake using the lifting ore!
Danger of injury!

Warning!
A sudden startup of the installation endangers the life of the working
personnel! Secure the drive and the installation against any accidental
movement before starting any work!

Danger!
The applied electrical voltages are dangerous to life!
The electrical connection and all other electrical tasks must only be done
by a trained electrician!

Caution!
Make sure the system is not pressurized!
Danger of injury!

Take care that the hydraulic fluids, lubricants and other used substances
as well as oil-soiled parts are disposed environmental friendly and in
compliance with the corresponding laws and regulations!
Electronic scrap has to be disposed separately.

18

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7 Spare parts
Notice!
The use of spare parts, not meant for this brake, can lead to a malfunction
of the brake or damage the brake!
Only use original PINTSCH BUBENZER spare parts!!
Important!
In case of ordering, please indicate the type and the serial no. of the brake /
power unit which is located on the type plate of the power unit!

Pos.
1.1
5
6
7
8
10
10.1
12
13
14
16
16.1
17.1
19
30
31
37

Typ
Type
ltank
Oil tank
Belftungsfilter
Air breather and filter cap assembly
Niveau-/ (Temperatur)anzeige
Oil sight glass (with thermometer)
Zahnradpumpe / Radialkolbenpumpe
Gear type pump / Radial piston type pump
Saugsieb mir Gehuse
Suction strainer
2/2 Wegesitzventil
2/2-Directional seated valve
2/2 Wegesitzventil
2/2-Directional seated valve
Motor
Motor
Glyz. Manometer
Pressure Gauge
Druckschalter
Pressure switch
Handpumpe
Handpump
Handpumpenbettigung /
Extension Lever
Rckschlagventil
Check valve
Druckbegrenzungsventil
Pressure limiting valve
Temperature sensor
Temperatursensor
lstandssensor
Fluid level sensor
Druckbegrenzungsventil
Pressure limiting valve

19

Daten
Data
OEL-BEH 162xrd166 VN=04 L FSK H
pulverb. / 3091493
Belueftungsfilter HP0
TSF/38/N /
284567
FSA-127-1.X/- / 12/700036
Zahnradp. 4,75ccm CA 3-Port-linksdreh.
3037482
CA-CO 350m
3147384
WSM06020V-01M-C-N-230AG
3147384
MU kompl. M18x1,5 SO1166 h= 47,6mm
WSM06020V-01M-C-N-24DG
E-Motor CO3Ph-2,20-230/400V-50-4 /
3045996
HN60-01-A63/400/G 1/4B*
0161-441-14-1-001/100-400 bar* /
6007277
PAM-V 20 (PAM0142004)
3640525
20x30x600 (PAM0290000) / 3537767
RVM06020-01-C-N-0.5
316992
DB4E-01X-250V
716143
TS-L70/X/12 FSK
3252766
FSK-127-2.5/O/-/12
3070285
DB4E-01X-350V /
716003

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8 Appendix
Always consider the existing temperature ranges before selecting an oil.

Reference temperature
ISO 3448 DIN 51519

Guide lines for selection

VG10, VG15: Systems intended for short time operation or use in the open or for clamping
devices. Systems intended for continuous operation (for use in the open, operation in winter)

VG22, VG32: General application (for use in the open, operation in summer only)

VG46, VG68 : Systems in tropical conditions at ambient temperatures up to 40C or closed

rooms (temperature during start not lower than 20C)

20