INSTRUCTION MANUAL

ORDERNR.;422444/0004 engineering

I
Hydraudyne Cylinders b.v.
DATE: 1999 mannesmann
REV.: 1/10.03.2000 Rexroth
Boxtel, The Netherlands
PAGE: 1

HYDRAULIC CYLINDER
for
HYTOP B.V.
CUTTER DREDGER

CUSHIONING CYLINDER
YOUR ORDERNR. 9921.27/34859

Any correspondence concerning the operation or repair of the cylinder, or orders for spare parts,
should be addressed to:

HYDRAUDYNE CYLINDERS B.V.

Postbus 32
5280/V\ BOXTEL
THE NETHERLANDS
Telephone :+31 411 651951*
Telecopier:+31 411 674125

* Please confirm all telephone calls in writing, by facsimile.

 INSTRUCTION MANUAL
ORDERNR.;422444/0004 •Pl engmeenng
Hydraudyne Cylinders b.v.
DATE: 1999 'jjmannesmann
REV.: 1/10.03.2000
Boxtel, The Netherlands
PAGE: 2
• Rexroth

CONTENTS

Section Description Page

1. Installation 3

2. Operation 3

3, Maintenance 4

4. Storage 4

Parts list 6

Attachment:

Assembly drawing: 3.055.909.A1

 INSTRUCTION MANUAL
ORDERNR.:422444/0004 •91 engineering
Hydraudyne Cylinders b.v.
DATE: 1999 ^limannesmann
REV.: 1/10.03.2000
Boxtel, The Netherlands
PAGE: 3
• Rexroth

1. INSTALLATION

If the cylinder has been in storage for a long period (> 2 months), it should be
tested for proper operation before installation. This can save unnecessary
dismantling and reassembly to fix any necessary repairs.
If the cylinder is not provided with suitable lifting lugs, it should be lifted with
broad lifting slings. If lifting lugs are provided, however, these should be
utilized as much as possible during installation, using load rated shackles.
Throughout the installation, no dirt should be allowed to enter the hydraulic
system. The connection ports should therefore be properly covered and sealed.
Care must also be taken, so that the piston rod can't become damaged.
The cylinder should be installed free of tension, so that the guides, for example,
are not put under extra strain, which would shorten the life of these guides. In
case of a pulling cylinder, make sure that no pushing force can occur in the
piston rod.
The pipes and/or hoses should be attached to the cylinder without tension. They
should be connected to the cylinder by means of good quality couplings. Before
the pipes are connected, they should be carefully cleaned and pickled.

2. OPERATION

Before the cylinder can be connected to the pipework, it must be well rinsed
out. The cylinder must not be connected to the pipework at this stage.
The hydraulic system should be filled with the working medium, using a filter
provided with a filter element having a micron rating mesh of £ 60 |jm.
The pipework must be rinsed out until the oil has a cleanliness class 8 to NAS
1638. The rinsing should be carried out with a pressure filter with micron rating
of 10 pm. After this, the cylinder can be connected to the pipework.
For good operation and a minimum noise level, the cylinder should be properly
bled of air. This can be done by using air bleed valves installed in the cylinder or
in the pipe- work. If no such valves are present, the connections with the
cylinder can be slightly loosened. When the oil leaking out is free of air bubbles
and/or no longer foams, the cylinder has been bled and the connections can be
tightened again.
If oil other than mineral oil is to be used, Hydraudyne Cylinders B.V. should be
consulted first, unless the type of oil in question was agreed when the cylinder
was commissioned.
 INSTRUCTION MANUAL
ORDERNR.:422444/0004 •Ipl engineering
Hydraudyne Cylinders b.v.
DATE: 1999 liimanriesmarin
REV.: 1/10.03.2000 H Rexroth
Boxtel, The Netherlands
PAGE: 4

3. MAINTENANCE

Generally speaking, once hydraulic cylinders are in operation, they need very
little or no maintenance. After a new system has been started up, periodic
checks will be necessary during the initial period to see that the cylinder is
working properly and that there is no leakage of oil. The rod should also be
checked for any running marks which could indicate the presence of dirt in the
system. Furthermore, the oil level in the system should be checked regularly.
Temperatures between -20 and +70 °C have no adverse effect on the operation
of the cylinder.
Oil filters incorporated into the system should be regularly cleaned in the early
stages of operation. Initially this should be every 100 hours, later, once a month
and after that only when the oil is renewed or as experience dictates. The
necessity for renewing the oil will depend on the circumstances in which it is
used, the condition of the oil, and the size of the system. Note that dirty or
degraded oil should never be mixed with new oil. The oil should thus be
completely renewed throughout the system.
If the cylinder is subject to heavy or pushing loads, any pivots or centers of rota-
tion or grease spaces provided with a grease nipple, should be greased regularly
with a grease such as Shell Rhodina 2, or equivalent.
With heavy pushing loads, it is advisable to ensure that pivots or centers of
rotation are checked fairly regularly.

A/.B.: Any maintenance free bearings which have been installed must not be
greased under any circumstances^.

4. STORAGE

If the cylinder needs to be stored temporarily before installation or for a longer

period as spare cylinder, the following points should be observed:
The cylinder should be stored in dry conditions and under normal climatic cir-
cumstances. The humidity should be under 70%. The storage area should be free
of corrosive materials and vapors.
If the cylinder is being stored as a spare cylinder, it should be treated with
protective oil. Cylinders which are later t o work with mineral oil as hydraulic
medium: These should be filled for 80% with the company's usual oil with the
addition of 2% Shell VSI concentrate 8235 or the equivalent of another brand.
Before using the oil, it is recommended to drain it and fill it with new oil, since,
depending on the additives present in the oil, it may have become acidic as a
result of the addition of the VSI concentrate,
 INSTRUCTION MANUAL
ORDERNR.:422444/0004 • p i engineering
Hydraudyne Cylinders b.v.
DATE: 1999 'urr\ar)r)esmann
REV.: 1/10.03.2000
Boxtel, The Netherlands • Rexroth
PAGE: 5

Cylinders which are later to work with a water/glycol mixture as medium: These
should be filled for 80% with the user's usual medium. If Erifon 818
(manufacturer: Marston Bentley Ltd.) is used no further additives are necessary.
For other water/glycol mixtures, the manufacturer should be consulted as t o
whether a special additive ('Vapor Space Inhibitor') is required. At the same
time, inquiry should be made as to the proportions to be used for the mixture
and whether these can be maintained when the cylinder is put into operation.
Cylinders which are later to work with synthetic oil: In such cases, it will be
necessary to consult the manufacturer of the oil in question about what should
be used to protect against corrosion and about the conditions of use. The
protective oil will work best if the cylinder has been in operation for a short
time before storage.
If poorly combustible liquids such as chlorinated or unchlorinated phosphate
esters or types of glycol are used, the cylinder must be cleaned out and rinsed.
The seals which are normally used are unaffected by these liquids, however.
The cylinder should be stored horizontally on two supports and turned between
45° and 180° twice a year. Short cylinders should be stored vertically if possible.
If a cylinder has been in storage for more than three years, depending upon the
type of seals, it is either advisable or necessary to replace the seals before use.
Grease any remaining unprotected parts, such as fitting surfaces or joining faces
with Shell Ensis F or G, or equivalent (which is suitable for storage at a longer
period). Parts of the rod which come out of the cylinder must be wrapped with a
greasy paper for corrosion protection and must be packed also in a material
which gives a mechanical protection.
Wrap or pack any ball bearings or other bearings in a greasy paper.
If there are any bronze dust removers present, remove these and store them
separately.
If the cylinder is to be stored for a long period (more than two or three months),
the connection ports should be plugged with good quality plugs and flanges
must be provided with 0-rings.
 INSTRUCTION MANUAL
ORDERNR.:422444/0004 engineenng

I
Hydraudyne Cylinders b.v.
DATE: 1999 manr)esmann
REV.: 1/10.03.2000 Rexroth
Boxtel, The Netherlands
PAGE: 6

PARTS LIST
Drawing nc . assembly :3.055.909.A1

Pos Num- Name Material DIN Dimensions Cert.

nr. ber and/or and/or EN10204
Manufacturer Drawing nr.

0130 1 Cyl.head S355J2G3 10025 3.036.212.A2 3.1B

1550* 1 Wiper ring Polyester/Hallite RD220xRD240x18
1551* 1 Wiper ring Busak&Shamban WES302200/Z62N
1720* 1 Rod seal Busak&Shamban RSZH1302200/Z80N
1740* 1 Rod seal Busak&Shamban RSZH130220/Z52N
1800*2 Guidingstrip Luytex C380/ Busak&Shamban RD220xRD225x25
1850* 1 O-ring NBRSO^'Shore 234,30x7,00
1860* 1 Back-up ring PTFE 250,0x238.3x3,0
1970 32 Cyl.head screw 12.9 912 M16X180
3090 1 Piston rod S355J2G3 10025 3.052.233.A2 3.1B
3330 1 Piston S355J2G3 10025 3.036.214.A2 3.IB
3520 1 Ring XSCrNiMo 17.12.2 3.053.309.A2
4010 2 Spherical bearing ELGES 648 GE110UK-2RS
4080 4 Locking ring SEEGER 472 160x4
4490 1 Cyl.pin ST 7979D RD10M5x24
4495 1 Cyl.pin ST 3,001.183.A4
4500 1 Screw 45H 913 M12X12
4520* 1 Guidingstrip Luytex C380/ Busak&Shamban RD240xRD235x25
4650 1 Screw 12.9 IS07379 M8x10f9x16
4660* 1 O-ring NBR90"Shore 221,84x3,53
4670 1 Cyl.pin ST 7979D RD6M6x20
4680 1 Plug ST VSTI-1/8"-ED
5010 1 Cylinder shell 5355J2G3 10025 3.052.234.A1 3.1B
6080 1 Minimess VOSS R y*"

TYPE: CYOCMPS/240/220/60B10/B1KLUKWAN

*= Recommended Spare parts

NB:(S355J2G3/EN10025=ST52.3N/DIN17100)
 DESCRIPTION CHK
1400 KAS 1030. SO WAS 50, tSS WAS 135. DO-aHS WAS UK
MOUNTING ANGLE 0' aEARINGS TYPE \M WAS QO
ADOeO ™ S 3530, *650. J660, 4570 AND JSBO

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FOR INFORMATION ONLY
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HINIHESS
\ AIRBLEEQ

R 1 ^
TYPE :
A
CYOCMP5/0240/Q220/00060B10/B1KLUKHAN
MODE OF OPERATING
SINGLE ACTING PUSHING
aOHE 240 mn)
RODDIAMETER 220 min
STROKE LENGTH
OESIGNPRESSURE FULL BORE
60
25
A mm
MPa
ANNULUS 25 MPa
TEST PRESSURE FULL BORE 30 MPa
ANNULUS 30 MPa
MAX. PUSHING-FORCE 950 kN
MAX. PULLING-FOflCE N.A kN
ENERGY TO BE FULL BORE N.A
CUSHIONED ANNULUS N.A
MAX.SPEED MOVING 'OUT' rnm/s
MOVING "IN" mm/s
MIN.SPEED MOVING "OUT" mm/s
MOVING 'IN' mm/s
HYDRAULIC MEDIUM MINERAL OIL
MOVING FREQUENCY /rain
MOUNTING ANGLE WITH HORIZONTAL
DESIGN TEMPERATURE -20 / +70 •c
LATERAL FORCES
tS5 THE AIRBLEEO POSITION HAS TO BE ON
THE UPPER-SIDE OF THE BUILT-IN
CYLINDER
SURFACE CONDITION
m SPHERICAL BEARING
ELGES GE-110-UK-gflS
BORE: HONED
{2x) A ROD : CERAMAX

A CYLINDER BOX FILLED KITH OIL EXXON NUTO H6fl ISO VG68 + 2X VSI
PRESERVATION:
SHOTBLAST SA 2.5 ISO-8501-01
1 COAT SIGMACQVER PRIMER 50 um
o . INTERMEDIATE COAT URI
. T O P COAT um
'B" TOTAL DRY FILM THICKNESS D.F.T. 50 um

REL. FOR PHQO •ATE ASSEMBLY DRAWING

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CHECKEO PASN 18-02-1998
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