Name: He. INTEGRAL HYDRAULIK Datum / date 03.04.2008 Anderungsdatum / revision date : Anlagen + Systeme Gerateliste zu Schaltplan / part lists for : 49.159 HSLM 630/45 ‘Song Thao RM Pos. Stck T-Nr. Zeichnung-Nr. Benennung ‘Typenbezeichnung Lieferant Pice No. Drawing-No. Denominacién Type Supplier 1 24777 699-1060-010-048 Gerateschrank / hydraulic cabinet Nennvolumen 630 | Integral Hydraulik 2 11982 411-1319-014-031 Innenzahnradp. / internal gear pump ——-PT4-31,5 Integral Hydraulik 24 17269 424-2295-048-032 Kupplung / coupling R42.48-32 KTR 12196 350-1061-514-027 Pumpentréiger / bell housing PK350/10/19 KTR 3 24966 E-Motor / electric motor m. KL 15KW/;380V;50Hz;1500min-1;1P55;ISO F/B ABB 12038 100-2417-025-250 Manometer / pressure gauge MG 100/2508, Integral Hydraulik 12215 004-2453-212-200 Me®schlauch / hose $100-AC-AC-0200 Hydrotechnik 411973, 001-1332-009-019 Blockkugelhahn / shutoff valve BHG V400.312-1 Bohmer 12577 001-1332-009-020 Blockkugelhahn / shutoff valve BHG V315.320-1 Bohmer 12216 001-1332-009-034 Kugelhahn / shutoff valve Nr.90 025 04 3/4" AS 13023. 001-1332-009-022 Kugelhahn / shutoff valve Nr.90 025 16 11/2" AS 13293 001-2459-009-185 Kompensator / bellow expansion joint 7160 OOS-TI DN 11/2" PN10 IWKA 6.4 14684 352-1330-012-640 62 11267 351-1330-012-640 63 11267 351-1330-012-640 12050 912-1012-022-001 64 11728 302-1330-013-640 65 12327 301-1330-013-640 TA 20493 551-1340-044-000 12231 001-1305-009-038 17897 001-1312-009-359 12332 001-1342-009-031 2h eee nee een nee aanaaa Druckbegrenzungsv. / pressure relief valve DBE-6S-210/210 B, bauteilgepriift Druckbegrenzungsv. / pressure relief valve DBE-6S-210/160 Druckbegrenzungsv. / pressure relief valve DBE 6S-210/140 Steuerblock / manifold (zu Pos.6.1;6.2;6.3) Druckbegrenzungsv. / pressure relief valve DBG-6S-210/210 B, bauteilgepriift Druckbegrenzungsv. / pressure relief valve DBG-6S-210/160 Wegeventil / directional valve Betriebsanzeige / power light Verkettungsblock / manifold 2/2-Wege-Sitzventil-Patrone / valve W4A-10M000-AC230/2 Nr: 3124016 mit LED gelb 240V EC5434P NG10 EMDV-10N-C2-0-240A (zu Pos.7.1) ~ Seite / pagelpagina 1 — Integral Hydraulik Integral Hydraulik Integral Hydraulik Bongartz Integral Hydraulik Integral Hydraulik Bosch Rexroth Integral Hydraulik Euro Fluid IMAVName: He. INTEGRAL HYDRAULIK Datum / date 03.04.2008 Anderungsdatum / revision date Anlagen + Systeme Gerateliste zu Schaltplan / part lists for: 49.159 HSLM 630/45 Song Thao RM Pos. Stck T-Nr. Zeichnung-Nr. Benennung Typenbezeichnung Lieferant Pice No. Drawing-No. Denominacién Type Supplier 3 12231 001-1305-009-038 Betriebsanzeige / power light Nr: 3124016 mit LED gelb 240V Integral Hydraulik 1 20233 001-1312-009-381 Steuerblock / manifold MS-2292-IM/240AG IMAV 2 128332 001-1342-009-031 2/2-Wege-SitzventilPatrone / valve EMDV-10N-C2-0-240 imav 2 12231 001-1305-009-038 Betriebsanzeige / power light Nr: 3124016 mit LED gelb 240V Integral Hydraulik 2 13420 001-1335-009-034 Ventilgehause / manifold 2LH-10A-B04 (G1/2) (zu Pos. 7.3; 7.10) IMAV a4 1 12485 020-1531-014-014 Riickschlagventil/ check valve RHD20-PS nach LOESCHE-Datenblatt Integral Hydraulik 92 1 17899 020-1531-034-001 Riickschlagventil / check valve RHD20-PS 3 bar n. LOESCHE-Datenbl. Integral Hydraulik 93-10 2 18844 016-1531-014-016 Rlickschlagventil / check valve RHV16-PSR-ED n. LOESCHE-Datenbl. Integral Hydraulik 18,2-5-6 3 12335 001-1334-009-045 Drosselventil / flow restrictor NFCV-10N-K-0 Integral Hydr. 18.10 ° 1 12188 018-1334-034-022 Drosselventil/ flow restrictor FT1254/2-4/2 Integral Hydraulik 19 1 12056 001-1327-009-456 Beliiftungsfilter / air breather Pi0145Mic Mahle 20 1 16365 001-1327-009-578 Druckfilter/ filter unit Pi 30025-012 Mahle 1 16368 001-1327-009-579 Filterelement / filter element Pi 24025 DN Sm-x16 (zu Pos.20) Mahle 23 1 15587 001-1305-009-535 Niveauschalter/ zero overlap SSM.1.B5.300.5 Engler 25 1 Dreifachtaster / switch / palpador 26 1 Klemmenkasten / terminal box Rose 27 2 12155 001-1305-009-385 Heizstab / heating element 62";800mm lang:900W:;380V;50Hz Helios 28. 1 16577 001-1305-009-568 Widerstandsthermometer / WBV10; R1/2"; Pt100 Klasse A Grillo electric resistance thermometer ~ Seite / page/pagina 2 -- (649159_de_enXLS.on gezeichnet eae ‘Ohne Verkteit Growing without 700 S f eI ct ar | = = LOESCHE i A | TR Ras TOW Zz 7 | (049-1462-013-159) ees = oo | | INTEGRAL HYDRAULIK 649.159 | Anlagen + Systeme 4, Lise eee ekeionereseae seen eee YORK CABNET Tamia oa awINTEGRAL HYDRAULIK Anlagen + Systeme General operating instructions for installation, com- missioning and maintenance of hydraulic systems INTEGRAL HYDRAULIK GmbH & Co KG. Tol: 40 (oynts4 4131-0 Page 112 Fax: +49 (0}215¢ 4181-50 a Hanns Marin Scheyer St 20 Postfach 50.0203 web: wa ntogral-hyrautlede 70.2006 7677 Wich 47870 Wich eMail info@integrahyeraulk.deINTEGRAL HYDRAULIK Gonerl operating instructions fe instalation, com- Anlagen + Systeme missioning and maintenance of hydraulic ayetoms 1 General 3 5 Dangerwarnings 11 1.4 Conventions 3 5.1 General " 2 Installation 3 52 Dangers " 2.4 Preparing for installation 3 5.21 from the hydraulic medium 11 241 Eretion ste 3 5.22 Fire risk " 24.2 Cleanness 3 523 Toxicly " 2.2 Routing pipes and hoses 3 524 Temperature " 22.1 Peunions a 525 Environment hazard " 222 Welded pipes a 52.6 Risk from kinetic energy " 2.2.3 Hose connections 4 5.2.7 Displacement of oxygen " 3° Inilalcommissioning 5 828 Conseavrce of inademite 34 General s 5.2.9 Unintended movements caused by 3.2 Preparations forthe trial run 5 pressure energy ti 32.1. Filing with hydraulic tid 5 5.2.10 Failure of controls 1 3.2.2 Purging the hydraulic system «6 5.2.11 trom accumulated energy 11 33° Tealrun 6 5.2.12 Failure ol components 12 + Starting the system 6 5.2.13 Special warnings on hydraulic Accumulator systems 12 3.3.2 Increasing to operating pressure 7 5.2.14 Directives, regulations, technical mistakes made during res 12 7 4 Servicing 7 4.4 Inspection 7 42. Maintenance a 42.1 Safety measures 9 422 Cleaning the system 9 4.23 Maintenance ofthe hydraulic tid 9 4.2.4 Maintenance to the piping system 9 425 Maintenance of -—hydraulic accumulators: 10 4.2.6 Maintenance of other system components 10 43° Repairs 10 4.4 General overhaul of the system 10 INTEGRAL HYDRAULIK GmbH & Co KG peek otal tiated et a) Page 22 +449 (0}2154 431-50, A Hanns-Marto-Scheyer-Sr, 20 Postach 50 02 09 were integra nya de 70-2008 47877 Wich 47670 Wilich e-Nalt info@iniegral-hycraulicdeINTEGRAL HYDRAULIK Aniagen + Systeme General operating instructions fo installation, com ‘miseioning and maintenance of hydraulic eystome 1 General ‘The service life and economical, functional opera- tion of hydraulic systems depends to a great ex- tent on correct handling. Certain rules therefore have to be heeded during installation, commis- sioning and maintenance. These include: * the operating instructions and all additional documentation ‘+ the special operating instructions for the com- ponents. Attention should also be paid to the following do- cuments: + DIN 24946 Hydraulic systems * DIN ISO 4413 General rules relating to hy- raulc systems. 1.1 Conventions ‘The following signs and symbols are used to draw attention to important information and possible hazards. [Ere B sew Draws attention to useful informa tion Draws attention to dangers for persons, material, machines and the environment 2 Installation Installation in general and of the piping systems in particular should only be carried out by corre- spondingly trained, qualified staff. All necessary technical documentation including these operating instructions must be present at the erection site before starting installation. 2.1 Preparing for installation ‘© Check that the hydraulic system is complete including all components supplied as loose parts. © Check the hydraulic system and all compo- nents for any signs of possible transport dam- age. ‘+ Use the lifting eyelet bolts and transport de- vices provided on the hydraulic system 2.1.1 Erection site [i] Ambien conto: Ambient temperatures: -10 10+ 40°C Allow sufficient space for operating, mainte- nance and servicing work. Ensure that there is adequate ventilation around the hydraulic system to warrant sufficient heat dissipation. Provide coolers if necessary. ‘The floor at the erection site must be flat and have a sufficient load rating. Fastening possibil- ties should be provided it necessary. 2.1.2 Cleanness ‘Caution! Ensure that the site is absolutely clean during the installation process, Caution! Even when connections are ‘opened only brietly, they should be cavered with provisional protection caps. ‘+ The hydraulic system and all components must be kept clean, and should be cleaned if necessary. ‘+The hydraulic fluid must not be contaminated with dirt particles, other fluids or moisture. * Components with corrosion protection must be de-preserved by suitable means (2.9. de- greasing) before installation. + Any plugs used to seal connections of the hydraulic system should only be removed im- mediately before connection. + When sealing threads of the fittings with liquid sealant, ensure that the thread itself is left clear. If this is not the case, hardened sealant particies can contaminate the system. 2.2 Routing pipes and hoses Pipes must consist of seamless precision steel pipes made of St 354 or St. 37.4 as per DIN 2391/6. Corresponding stainless steel hydraulic pipes can also be used. + The pipes, hoses and fittings used for the system must correspond to the pressure stage for which the system is rated. INTEGRAL HYDRAULIK GmbH & Co KG Hanns-Martn-SehlayerStr. 20 47677 Witch Postfach 50 02.09, 47870 Wilich Tol: 449 (0}2184 4131-0 Page itz Fax +49 (0)2184 4131-50 __a ob: wwintagral-hyérauk. do 702006 e-Mail info@itegral-hycraulk.deINTEGRAL HYDRAULIK Anlagen + Systeme * Tho pipe diameters are to be selected accord- ing to the volume flow so as not to exceed the tolerable flow velocities. = maximum flow velocities | [DIN ISO 4413) Intake pipe 1.2 mis Discharge pipe Sms Retum pipe 4 mls +” Pipe bends are fo be produced using a suit- able bending device. The pipe cross section ‘must not be constricted by bending. * Pipes shortened to the required length must, be neatly deburred and cleaned. Heat-ireated pipes must be descaled and cleaned by me- chanical means. This is particularly important after weicing, ‘+ The pipes should be routed short and straight, wherever possible. * Ensure that the pipes are routed and fastened without any tension, providing sutficlent pipe holders [Maximum spacing between pipe holders [DIN ISO 4413) Pipe outer diameter (mm) |Spacing between pipe: hoiders st0 {1 > 10 and <25 15: > 25 and <50 2 > 50 3 Co 2.2.4 Pipe unions Possible pipe union systems include for example cutting ring unions, flanged unions or welding nipple (welding cone) unions. + Select the pipe unions according to the pres- sure stage and ambient conditions (ambient ‘General operating instructions for installation, com= ‘issloning and maintenance of hydraulic systems * We recommend pipe unions with resilient seal Caution! Do notuse hemp, putty or Teflon tape to seal unions! Correctly fited pipe unions are Impervious! 2.2.2 Welded pipes 22.2.1 Welding procedure The first layer of every weld is produced using inert gas welding according to DIN 1910 page 4 (IG ~ tungsten inert gas welding), with forming gas flowing trough tre welded pipe. Subsequont layers in every weld may be produced by manual arc welding. ‘+ Remove any loose impurities before fiting the Individual pipe sections, * Use mechanical methods to clean accessible welds. 2.2.2.2 Plekling After welding, pickle the pipes in circulation tech- nique, bypassing the control and functional ele- ments. Then drain the pickling fluid completely from the pipes. Pipe sections which can be dis- mantled can also be piskled in a pickling bath, * After pickling, neutralise the complete piping system. + Drain the complete piping system again after neutralisation. To drain the pipes, they must be routed with a ‘corresponding gradient and suitable drain ele- ments, =] Immediately after draining the pipes, they should be oiled or rinsing should begin, La) Caution! The accumulated fluids must be dis- posed of correctly according to the valid regula- tions. 2.2.3 Hose connections ‘Special attention must be paid to the hose con- nections because of their special safety signifi cance. Caution! Hose pipes must be fited correctly temperature, vibrations, etc.). and carefully. * Always comply with the installation instruc- tions given by the pipe union manufacturer. INTEGRAL HYDRAULIK GmbH & Co KG Tale 49 (yied aia1-9 Faye itz Fac +49 (0)2154 4'31-50 A Hanne Martin-Schiayer-Str. 20, Postiach 600209 web: wirmintegraFhysraulk.de 706-2008 47877 Wiles 47670 Wich eNall: info@integral-nyraulk deINTEGRAL HYDRAULIK Anlagen + Systeme General operating instructions for installation, com- missioning and maintenance of hydraulic systems AN ‘Caution! Damaged hoses must never be used. + Hoses must not be exposed to tensile stress. * Hoses must not be twisted round their longi- tudinal axis. ‘+The bending radii must never be smaller than those specified by the manufacturer, + Hoses must be fitted so as not to chafe on other parts. Hoses are subject to material fatigue. Comply with the manufacturers instructions regarding sence lite. [=] 3 Initial commissioning Once the installation work has been completed properly, the hydraulic system can be commis- sioned. 3.1 General Hydraulic systems should only be commissioned by correspondingly trained skilled staff, in the presence of responsible staff from the machine ‘manutacturer and staff from the machine operator. * Circuit diagrams, component lists and data sheets of the fitted components and measur- ing instruments must be available. * Initial commissioning must be cartied out with all due care and attention, * tis advisable to draw up an initial commis- sioning report. 3.2 Preparations for the trial run Checking the installation process: * Is the tank completely free of impurities? * Are the pipe and hose lines neatly and cor- rectly fitted? ‘+ Are all unions and flanges tightened (impervi- ous)? * Before commissioning the system, gas-filed hhycraulic accumulators must be brought to the correct precfiling pressure (nitrogen is used as gas medium, unless stated otherwise). Check the position of the venting and stop valves according to the circuit diagram. Caution! Always comply with the manutac- turer's instructions wien ‘filing, fiting and main- taining the pressure accumulator. Caution! Always comply with the direc- tives/regulationsules for pressure accumula- tors valid at the erection site. * Check that the voltage and currént values stated on the electric motors and the electro- hydraulic parts comply with the power supply. * After connecting the electric motor, check that it tums in the right direction by switching on brietly Caution! if the pump runs for more than one second in the wrong direction, it can run dry and cause major damage. 3.2.1. Filling with hydraulic fluid The pressure medium in a hydraulic system has to full a whole series of properties to guarantee reliable operation in te long run. Itis advisable to consulta renowned of manufacturer when making the choice. Hydraulic oils contain may additional substances, for example with corrosion inhibiting and wear reducing properties. They must comply with DIN 51524. When topping up with operating fluid, always use the same operating fuid that is already filed in the system. This should also be ‘observed when using mineral oils complying with DIN 51524, Part | or Part Il. These ails can also differ in terms of additives and base ols. Caution! When using operating fuids in class HFA, HFC and HED, never mix diferent makes because these ‘tulds cannot replace all the properties of mineral oils. They may also be incompatible with gaskets, seals and coatings. We therefore urgently advise you to consult the manufacturer. LY Lastiont Moats, environment compte fiuids (bio olls) in slass HEPG, HETG and HES should also be avoided, so’ that here again, consultation is urgently advised. [i] Guarantee, cae for any damage incurred by Using fluids of the same type but trom different ‘manufacturers mey possibly be rejected. Manufacturers of hydraulic fiuids usually reject any responsibility when additives from other manufacturers have been mixed in with the fluid, ‘The same also applies to the manufacturers of hydraulic machinery and equipment. ‘+ Always handle hydraulic fluid with great care. INTEGRAL HYDRAULIK GmbH & Co KG Hanns Martn-Schlyer-Sr, 20 $7877 Witch Postfach 50.02.08 447870 Wit Tol: +49, (012186 4131-0 sit2 Fax: 449 (012184 4131-60 A web: wiwrintogral-rydrauik.de 70-2006 e-Mait info@integral-hycrausk.deINTEGRAL HYDRAULIK Anlagen + Systeme ‘= Ensure in particular that only certified fluids are used and that these are absolutely clean. * Special care is required when taking oll from a barrel. Always check that the barrel contents are free of any impurities such as rust or con- densation, * Before filing the medium into the system, ensure that the container is free of corrosion and impurities. Caution! The medium is normally fled into the system using the filer neck; always use a fine filter Where possible, use a pumping unit with fine fiter to fil the system. a AA Cation in some case, merauc pumps ans motors must be backed |e, pre-fllad with hydraulic uid (comply with the corresponding operating instructions fr pumps/motors). 3.2.2 Purging the hydraulic system Before starting the system up at full speed and full working pressure, firstly all parts must be purged thoroughly. As far as possible, use the same fluid for this purpose which will be subsequently be Used for normal operation. * For the purging process, bridge the consumer connections using sections of hose, and re- place parculary sensitive components with purge plates. Caution! When using a purge fui, this must be compatible withthe hydraulic fluid, ‘The advantage of using the hydraulic fluid di rectly for purging is thatthe fluid can remain in the system which has now been cleaned. A change of oll at this point could introduce more impurities into the tank. | + If the system pump has to be used for the purging process, always ensure that this only pumps clean fluid and operates with a low working pressure. Caution! Ensure that the hydraulic fluid being returned tothe tank from the system is fitered. I the existing return fiters are used for this pur- pose, new fiter elements must be fited after ‘every purge cycle. General operating instructions fr installation, com- missioning and maintenance of hydraulle systems When there are long fines to the consumers, It may be appropriate to use a separate purging Unit. This has @ far higher volume tlow than Present in normal operation so that the corre- sponding turbulence in the pipes accelerate the procedure of loosening any possible impurities, with a shorter purge cycle. =| © During initial commissioning, the fluid level drops because the oil is distributed along the pipes through the entire system. Caution! For this reason, hydraulic fluid must be topped up immediately. [] During subsequent operation the id ievel also AL} has to be checked at regular intervals. It must ‘not fall below the marked level 3.3. Trial run ‘The trial run should only be carried out by trained, aualified skilled staff. Only the required staff from the system manufacturer, maintenance staff or system operators should be allowed in the imme- diate vicinity of the system. The hydraulic system should be adjusted so that the pump can start up depressurised, Caution! Before starting the system, depressur- ise all pressure valves (pressure limit. ing/reducing and controling valves) including the pump pressure controllers. The only excep- tion are load soalod pressure limiting valves. 3.3.1. Starting the system + Note whether the hydraulic pumps/motors are pre-fled with hydraulic fluid (refer to the cor- Tesponding pump/motor operating instruc- tions). * Switch the electric motor brielly on and off again straight away, checking the direction in which the pump turns. Also pay attention to any unusual noises. + If the pump turns in the correct direction and no unusual noises can be heard, switch the electric motor on finally ‘+ If there Is no automatic venting, loosen the union on the discharge side of the pump or open the venting valves to make it easier for the pump to start up and so that air can es- cape better from the system * Run the moving parts of the system under low pressure to allow the air to escape. Continue doing so until the movements are smooth INTEGRAL HYDRAULIK GmbH & Co KG. Postfach 50 02 09, 47670 Witch Hanne-Marin-SehiayerStr, 20 47871 Wich Tol: +49 (0)2184 4191-0 Page 612 Fac 448 (9)2184 4131-50 A web: wm intogral-bycrauik.de 70-2006 Mall: info@intogral-nydrauth.deINTEGRAL HYDRAULIK Anlagen + Systeme without any jolts and the liquid discharged at the venting connections is completely free of bubbles. ‘+ Now seal all venting openings and proceed with a frst leak test, ‘© Check the oil level in the tank once again. [i] Now let be system run ora wi at tow pros sure. This Is the last cleaning process before running the pump under full load, on condition that oll flows through th fiters of the system. 3.3.2. Increasing to operating pressure ‘After completing all points stated under 3.3.1 and bringing the system to operating pressure, at least 40°C, now slowly increase the pressure in the system until it reaches operating/nominal pres- sure, checking the pressure level constantly on the pressure gauge. [1] When the system is equioned win a pressue- controlled pump and additional pressure limiting valve, the pressure at the pressure limiting valve should be set to at least 20 bar more than the ump pressure. + Constantty monitor the control and measuring instruments during this tial run. ‘* Monitor in particular the fluid level in the tank. ‘Top up with hydraulic fluid if necessary. ‘+ As soon as the system has reached its normal operating temperature, once again check all Pipe unions and holders. Caution! Oniy tighten the unions and flanges after the system is depressurised, ‘+ Check the pump and motor housing tempera- tures, they should not exceed 70°C. * Change the fitter element more frequently during the start-up phase than during subse- quent operation. * Record the time values, temperatures and all other important information for future mainte- nance of the hydraulic system 3.4 Frequent mistakes made du- ring commissioning Many mistakes are made during initial commis- sioning by inadequately trained staff. The follow- ing section incicates the most frequent mistakes made during initial commissioning. ‘+ Inadequate cleanness during installation. General operating instructions for installation, com- ‘missioning and maintenance of hydraulic systoms * Inadequate purging of the complete system + Topping up with unfitered hydraulic fui. + No control of the fluid level in the tank, no topping up to compensate for liquid losses. + Inadequate venting of the system, indicated for example by jersing drives. ‘+ Adjusting the pressure limiting valves with an inadequate pressure difference to the operat- ing pressure so that the closing hysteresis is not observed. ‘+ Hydraulic pumps and motors are not filled with hydraulic fluid before starting the system. ‘+ Unusual noises in the pump are ignored. Pos- sible reason: cavitation from air in the intake ‘low (leaking intake pipe, air in the hydraulic fluid). ‘+ Adjusting spindles are not secured with lock ‘us or sealed with lead. + No records are kept of set values, no default values are availabe. 4 Servicing Hycraullo systems and controls supplied by INTEGRAL HYDRAULIK offer all design prerequi sites to guarantee long, troublefree operation. However, servicing of these top quality systems must not be neglected. Servicing is organised in various different basic measures according to DIN 31051. These include inspection, maintenance and repairs. 4.1 Inspection According to DIN 31051, inspection consists of measures to ascertain and assess the current status of a specific unit, ‘Accordingly, it makes sense to work through a list of the various specific inspection points for the Particular system. important points to be featured in an inspection list are featured below. © Check the oil levelin the oil tank. When the fluid level is too low, this normaly indicates losses from outer leaks. After major ‘maintenance work, the fluid level can stil fal slowly after a certain period of time when the system vents aulomaticaly. Too much fluid in the tank indicates that higher system compo- nents have run emply dufing standstill periods because air has penetrated the system, i INTEGRAL HYDRAULIK GmbH & Co KG Hanns Martn-Sehayer ir. 20 47877 Wien 47870 Witch Postfach 50 02.09, Tol: +49 (o)ats4 ag1-0 Page 712 Fac +49 (0)2154 4191-50 A web: worwintegra-hycrautk.de 70-2006 eMall: inlo@iniograbtyerauth.deINTEGRAL HYDRAULIK Anlagen + Systeme Visual pipes/hoses, unions, flanges, pumps/motors, cylinders, control units, oil tanks) | INTEGRAL HYDRAULIK GmbH & Co KG Hanns Marin Schayer-St. 20 47877 Witch inspection for leaks (tighiness of Caution! Oniy retighten unions and flanges when the system has been depressurised. Check the hoses and pipes for chafe marks, other signs of damage and correct fastening Caution! Damaged pipes and hoses must be replaced immediately. Check the hoses. Caution! Check hoses regulary to ensure that they are safe for operation. Hoses are subject to material fatigue, with a limited service life (gen- erally 6 years, including 2 years shelf Ife), Check the fluid temperature during operation, ‘An increase in fuid temperature can have the following causes: + The heat exchanger is not working property (coiled surface, falled ventlator, inadequate or interupted water circuit, cooling water in- take temperature too high, heat exchanger ‘logged up). ‘+ Heat dissipation of the fluid system, pipe system and hydraulic components. has ‘been reduced by dirt deposits ‘+ Inner leaks of individual components have Increased, pressure limiting valves are tig- gered already by low pressure. ‘+ The system is operated outside the permit- ted ata ‘Check the heat exchanger. + Airfoil heat exchanger: particularly at ‘operating sites with high dust levels, heat dissipation decreases quickly because of dust deposits on the surface of the heat ex- cchanger. If the cooling air then also con- tains oii mist from outer leaks, this can Quickly prevent heat cissipation + Waterioil neat exchanger: the cooling Water must be so clean that heat trans- mission is not pravanted by insulating coats of deposits. This is particularly important hen the operating fluid temperature is kept constant by throtting the cooling water 60 that there are no high water velocities to rinse out deposits. Its important to ensure that heat exchangers cannot run dry either (of water or of operating fuid with anly par- tial areas available for heat transmission, Check the system pressures. Go ral operating instructions for installation, com- mmissioning and maintenance of hydraulic systoms * Check the appearance of the hydraulic fui. [=| The condition of the hydraulic fluid is of special lmportance. As described by the so-called chain reaction of abrasion, every dint paricie which is ‘ot removed generates additonal particles, i.e. the number of particles increases at a growing rate, Visual inspection can only provide a rough ap- praisal of the state of the fluid; laboratory tests are always preferable. The following signs indi- ‘cate that the fluc isin poor condition: + milky turbidity ‘© looks darkerthan when filed in + smells of burt ol + deposits on the bottom of the tank. ‘+ Check the fier soling indicators of the pres- sute return filters. Also check the venting filter for soiling, * Check the pump and motor housing tempera- tures. ‘© Check for any unusual noises. | + When pressure limiting valves open, a hissing Sourd can be heard. Any rating or whisting incicates. damage in the limiting valves or pressure reducing valves. + Oylinders can make ating or creaking noises. This can indicate worn guides, con- straits (2.9. seized roker bearings), unsult able operatirg fide ee + Pump noises get louder with increasing pressure (ths also applies to oll motors). ‘This can indeate erosion or cavitation damage near ne control surace o increas- ing backiash in the displacement elements oF incipient roller bearing damage. Un- pleasantly loud noises trom pumps regard- Toss of the pressure load indicate too much nogatve pressure in the intake (r fed) Pipe. + Check the system output and drive speeds. * Visual inspection of electric leads, motors, control elements, solenoid valves, ‘sensors, Pressure switches, ‘+ Visual inspection cf hydraulic accumulators. 4.2 DIN 3 Maintenance 1051 understands maintenance as meas- ures to delay degeneration of the existing wear reserves in the corresponding unit In practice, there is often a fuzzy interface be- 7870 Wiics Postfach 50 02 09 tween inspection and maintenance. Faults ascer- tained during inspection must be remedied imme- Tol: +49 (o)ats4 4131-0 Page a/t2 Fac 449 (0}2166 4131-50 A web: wnwintogra-hycrauk.de 70-2006 ‘eMail info@integral-nydrautideINTEGRAL HYDRAULIK Anlagen + Systeme diately during maintenance. The key maintenance work is listed below. 4.21 Safety measures All due care and attention is required when start ing up or maintaining the system. The following points should be given special attention. © Accumulators must be depressurised com- pletely on the fluid side when removing corre- sponding pipes. + Loads which could fall down uncontrolled or make unexpected movements when disman- ting the hydraulic drive or when fiting the pipes must be supported or wedged accord- ingly. + Before starting any work to the plant, ensure that the electricity has been switched off and ‘secured to prevent it being switched on again (possibly removing the main fuse). 4.2.2 Cleaning the system Hydraulic systems must be cleaned on the outside from time to time: + to make it easier to find leaks; © to avoid dit from being entrained into the system when topping up with operating fluid; * to prevent dirt from the system when changing fiter elements; * to prevent dirt particles from scoring the piston rods of hydraulic cylinders; ‘+ to ensure that the rated heat dissipation is not reduced or completely prevented. Caution! Always make sure when cleaning the ‘system components that no cleaning fluid can penetrate into the hydraulic system. 4.2.3 Maintenance of the hydraulic fluid ‘The service ife of the hydraulic fluid depends to a great extent on its care. Parameters affecting the service life include above all the average operat- ing temperature (high temperatures accelerate aging noticeably), soiling and incorporation of water. Mixing different kinds of fluid can also cause harmful reactions (gumming, clogging). General operating instructions for instalation, com- missioning and maintenance of hydraulle systoms hydraulic uid Always comply with the following rules: ‘+ Take reguiar oil samples to examine particle type, size and quently + When changing the hycraulic fluid (this should be carried out ai regular intervals, at least every twelve months), please comply with the following points: © Drain the hydraulic fluid completely while still warm and dispose of correctly and properly. © Clean the tark if necessary. © Al fiter elements must be replaced eve- Ty time that the hydraulic fluid is changed. © Only fill the system with new hydraulic fluid using suitable fiers with a fitration rate correspending at least to that of the installed system fiters (see also 3.2.1) © Vent the hydraulic system after recom- missioning LR Saiont Never nc tere here fs * Check the filter regularly. Change the filter ‘elements of the corresponding filter at the lat- est when the soiling displays have been acti- vated. 4.2.4 Maintenance to the piping sys- tem '* Check the piping system for any leaks. Corre- sponding measures must be taken when leaks are detected Caution! The piping system must be depressur- \sed before carrying out any tightening or seal- ing work, T]]_ beaks to points sealed with soft gaskets (O- LILI rings, shaped gaskets) cannot be eliminated by tightening. in this case, replacing the sealing elements is the only way to repair the leak. ‘+ Check that the pipes are fastened securely at the fastening points. + Check hose pipes for any chafe marks and check hose fittings for leaks. Caution! Damaged hoses must be replaced immediately. Caution! The condition of the hydraulic fuld cannot be improved by topping up with new INTEGRAL HYDRAULIK GmbH & Co KG Tok: +49 (0)2154 4191-0 Hanns-Martn-SchiayerSr. 20 47877 Wich Posttach 5002 09 47870 Wilich| Fax: +49 (0)2184 4131-50 web: wwwintegral-hydraulk de eMal: Inio@intagralnydauldeINTEGRAL HYDRAULIK Anlagen + Systeme General operating instructions for installation, com- miseloning and maintenance of hydraulle systems 4.2.5 Maintenance of hydraulic accu- mulators ‘As a general rule, hydraulic accumulators are essentially ree of maintenance. MS, Sten Wo to tycraue accumulators must not be carried out unti the accumulator has ‘been depressurised completely. LY Sate Ne weld, soktering or mechanical working of any kind must be carried out on the hydraulic accumulator. A, Dame Inappropriate repairs to hyraule accumulators can cause accidents with drastic consequences to persons and property. Possible maintenance work includes: ‘+ checking the gas filing pressure; ‘checking the safety devices and fittings; ‘© checking thatthe accumulator is held/attached correctly. “| me Please refer to the: Instructions issued by the corresponding manufacturer for the exact pro- ‘cadure involved in maintenance of the hydraulle accumulator. 4.26 Maintenance of other system components . * Check the pressure settings and correct as required. Records must be kept of any neces- sary corrections. (Repeated adjustments of the pressure valves indicate increasing wear in the valve) + Check correct functioning of monitoring ele- ments such as pressure gauges, pressure switches, level indicators, ete. Check that the control elements function pro- erly. 4.3 Repairs Repairs include measures to restore a specific Unit to its correctly functioning condition. Succsssful repairs presume that the repair staff have a sound working knowledge about the struc- ture and operation of the system and its compo nents. Together with availability of the key meas- uring/diagnosis instruments, this is prerequisite for effective, systematic troubleshooting. The key points to be observed when making re- pairs are as follows: ‘*Allnecessary documents should be available. + The main measuring instruments should be available: © Thermometer © Pressure gauge © Multimeter © Stopwatch + Attention must be paid to the greatest possi- ble cleanness. ‘+ Defect units should be repaired on site as far as possible. + Allopened parts sould not be exposed to the elements for longer than absolutely neces- sary. 4.4 General overhaul of the sys- tem When after several ysars of operations, routine maintenance and inspections indicate that the system performance ro longer complies with the specified normal values, the hydraulic units should Undergo a thorough general overhaul. Itis advisable for a gereral overhaul to be carried ‘out by the manufacturer who offers the necessary ‘equipment and experience. ‘As a general rule: * A general overhaul offers the opportunity for really thorough cleaning of all units, particu- larly inside the tank + Itis advisable to use a flat plastic scraper for Cleaning fiat surfaces. The use of cloths could leave behind fibres which would cause con- siderable disruptions. * Its advisable to raplace all gaskets because these can no longer warrant a perfect seal af- ter the hardening effects of several years in operation. + Attention must also be paid to worn, porous hoses, + When recommissioning the hydraulic units, the same attentior must be given to the cor- responding regulations. In any case special care is required to ensure that the units are absolutely clean on the inside. INTEGRAL HYDRAULIK GmbH & Co KG Hanns-Marin-Schleyer-Stt. 20 47877 Win Posttach 50 02 08 47870 Wie Tol: 949 (92186 4191-0 Page 10712 Fax: +49 (0)2156 4191-50 A web: wwurintogral-hydrauli.de 10-2006 Inio@ntegrabindrautk.deINTEGRAL HYDRAULIK Anlagen + Systeme 5 Danger warnings 5.1 General Hydraulic components and complete hydraulic systems are produced by Integral Hydraulkac- cording to acknowledged engineering rules and are considered safe when used for their proper purpose and maintained accordingly. On the other hand, hydraulic components and systems pose dangers. which can cause injuries to persons andior damage to property when due care and attention is neglected 5.2 Dangers 5.2.1 from the hydraulic medium The chemical properties of the hydraulic medium ose a danger even when not pressurised, let along the damage which can be caused by its inherent energy when pressurised. 5.2.2 Fire risk The normally used mineral oil is inflammable both in liquid form and in particular as ol/air mist. It is therefore important to prevent oil leaks and to avoid any naked lights and the presence of hot parts (also during transport). Appropriate warning signs should be affixed to the system. 5.2.3 Toxicity Although hydraulic media are not explicitly classi- fied as toxic, any kind of inhalation and longer skin ‘contact should be avoided. Replace contaminated Glothing as soon as possible. Clean any areas of the skin which have had contact with the medium. 5.24 Temperature Leaking hydraulic fluid at high temperatures can cause scalding injuries. Cooling should be pro- vided if there are grounds to suspect that the me- dium is developing excessive temperatures. 5.2.5 Environment hazard Hydraulic fluid leaking outside can contaminate the soil, groundwater and other waters. Outside leaks should therefore be prevented by drip trays or suitable solutions. If necessary, the use of envi- Tonment-compatible hydraulic fluids ("bio oils") should be considered particularly for mobile appli- cations. General operating instructions for installation, com- ‘miseioning and maintenance of hydraulic systems 5.2.6 Risk from kinetic energy ‘When there is a drastic pressure gradient, leaking jets of fluid can be extremely dangerous (dril- ing/injecting effect or cutting effect). Prevention in this case entails dimensioning all components, pipe connections, unions etc. correctly, tightening all unions correctly, fastening all components safely, complying wih the prescribed welding methods and providing reliable pressure limiting devices, also taking account of dynamic influ- ences. 5.2.7 Displacement of oxygen ‘This hazard is only possible when the gas side of larger hydraulic accumulators filed with nitrogen is discharged in confined unvented rooms. If this is unavoidable, measures should be taken to al- low for corresponding ventilation. 5.2.8 Consequence of compatibility inadequate Inadequate compatibiity of the hydraulic tiuids with gaskets, bellows, membranes, coats of paint etc. can cause leaks resulting in the dangers de- scribed above or render the whole system inoper- able. Itis therefore important only to use hydraulic fluids recommended by the manufacturer. The manufacturer should be consulted when using ‘other media or in the case of unusual operating conditions (e.g. very low temperatures). 5.2.9 Unintended movements caused by pressure energy Unintentional movements of working units are possible along the lines of unexpected operating movements and also parts or components flying off as a result of loosened or burst connections. 5.2.10 Failure of controls Failing controls shoukd not cause unintentional movements. When the controls fail, any danger- ous movements should be stopped or not acti- vated in the first place (fail-safe concept). If this is rot the case, other ferms of protection must be provided, e.g. soreens, barriers erected, etc. 5.2.11 from accumulated energy Hydraulic systems with accumulated effect (tubes, hydraulic accumulator} accumulate energy which can stil cause dangerous movements even after fallure of the primary energy. It is important to check whether the system can be automatically INTEGRAL HYDRAULIK GmbH & Co KG. Hanne Martin-Shleyer St. 20 47977 Wiles Postlach 50 02 08 87870 Witch Tek: +40 (02184 4191-0 Page 11/12 Fa: +49 (02184 4191-50 A web: wmintagrabhycraulk.de 10-2006 oMalt info@intogralyerautk.deINTEGRAL HYDRAULIK General operating instructions for installation, com- Anlagen* Systeme ‘missioning and taintenance of hydraulle systems depressurised on failure of the primary energy. It not, for example in the case of accumulator- supported tensioning devices, then a clear danger warning must be provided. 5.2.12 Failure of components Parts or components can be caused to fly off when connections burst, tear, come undone, work loose or open etc. This canbe caused by static overloads, and even more probably by dynamic vibration loads. Finally, damage can also be caused by outer forces. 5.2.13 Special warnings on hydraulic accumulator systems In Germany, hydraulic accumulators are deemed to be pressure vessels and therefore come under the pressure vessel ordinance and technical rules for pressure vessels. Initial commissioning can only take place after the hydraulic accumulator has undergone acceptance testing by an inde- pendent expert or expert on behalf of the owner. For further details, reference is made to the corre- ‘sponding regulations and our brochure publication number 15-08: 5.2.14 Directives, regulations, techni- cal rules Here is a small selection of publications and regu: lations dealing with safety: + Council Directive dated 14 June 1989 for harmonisation of the legal regulations of the Member States referring to machines. * Pressure Vessel Ordinance (DruckbehV) da- ted 27.02.1980 in the latest valid version (cur- rently 4.96) + Technical Rules for Pressure Vessels (TRB) in the latest valid version. + 150.4413 Hydraulic fluid power- General rules for the application to transmission and control systems, + DIN EN 982 (corresponds to EN 982) Safely requirements for fluid power systems and their components — Hydraulics. + DIN 26 552 Accumulators in hydraulic sys- tems (with supplement sheet). INTEGRAL HYDRAULIK GmbH & Co KG Fla agers Oletos Hat Page 122 Fox: 449 (0}2154 4131-50 A Hanns-Marin-Sehlayer-Str. 20, Positach 600209 web: worm tegralnyraulk de 70-2006 47877 Witch 47870 Wich eMail Info@integrabiycrautk.deHydraulic oil INTEGRAL HYDRAULIK ‘ recommendations Anlagen + Systeme se arte! working concitions we recommend usage of HL and HLP Hydraulic ols (on Mineral ol basis). In specal cases Fee GURY and HVLP olls with same viscosity may be used. Please contact us if you wish to use HE-Liuide (HERG, HETG and HEES oils) or HFC (not easily nfarimable water ~ Glycole mixture). rhe Sequence ofthe listed suppliers is alphabetical and therefore no standard of value. We would also lke to indicate that the lists not complete and that we cannot guarantee for i's context. Please take natics that some liquids cover a wide range of viscosity and therefore are only mentioned once (e.9, 32-68). 3) normally Hydraulic Oil acc. to DIN 51824 part 1 normally Hydraulic Oil acc. to DIN 51524 part 2 normally Hydraulic Oil acc. to DIN 51524 part 3 Sheet 1 of 2 “tke ® or but detergent veas . vGs8 Glorabeent |=) HL (mineral ol) [ 2) HEPG (eyabkarasis) ayn, (minerloi) |e) HEPG jpohgynavbasey Seog | HLPS, (rivera) | F)HETG (ogaubIe ol) |E}HPL Imnecteh | HneTe oree ce order) 6) BVLES Kminerai ot) | g) HEES (synth. ester) |<) HVLP {minerelol) | a) HEES ley, cota. QHLPOY Krineratof | R)HEC (watergyea!) | @)HLPD {mineatoi) | hy HFG. twataroyoo) ARAL 2) Aral Viam UF 46 @) Aral Vitam BAF 45 2) Aral Vitam UF @8 ) Aral Viam GF 46 ©) Aral Vitam GF 63 6) Atal Vtam HF 48 8) Aral Vitam EHE «3 6) Aral Vitara VF 68 ‘Aral Vitam VE 46 6) Aral Vitam OF 46 1) Aral Mental 48 6) Aral Vitam 8 68 BeCHEM 2) Hyciostar UWF < 2) Ryaosiar UWF 68 ) Stari. 48 8) UWS Hyeraule 32 2) StaroiNe. 68 6) Staroi HV 46 9) Hycrosta HEP 43 Star HVI 68 0) Hycostar HEP 68 1) Slarol H-LPD <6 hy Hydrostar HY 48 @) StarolH-LPD 68 P 2) BP Energol HL 48 b) BP Energol HUPAHM 48 |) Biohyd <6 1) BP Energol HLP HM 08 ©) Barran HV 46 9} Biohye SE 48, ¢) Barren HV 68, 9) Biohyd SE 68 @) BP Energol HLPO 4s | hy Enersyn SFC 16 9) BP Energol HLPD 68 CASTROL | a) Magna 46 3) Magna 68 ©) Hyspin as 4 1 Garelube HYG 32 5) Hyspin AW 63 1) Careube HG 68 Hyspin SP 46 Hyspin SP 68 2) Hyspin AWHM 4; 9) Castrol Produkt 65/13 |e) Hyspin AWM 63 9} Castel Produkt 695/14 Careibe HES 48 Caretioe HES 58 0) Vario HOX 48 1) Anal WG 4 }) Vario HOX 45 ydrauiko! HLP.O 48 Se Hydraulic HLP-0 68 F DEA 3) Astron HL 46 ) Econa PG «6 3) Aston HU 68 D) Aston HLP 45 1) (Econa R32) b) Astron HUP 68 Astron X HLP 45 ‘Aston X HLP 6a ©) Astron KVL 46 1) Econa & 48 ©) Astron HVLP 68 ‘tion X HVLP 46 ©) Acts HLPD 48 hy) Tecto HF-C 46 5 0) Acts HLPD 68 ‘Actis XHLPO 46 ‘Acts XHLPO 68 Tien EP 48 “en EP 63 a 3) ELF POLYTELIS 68 2) ELF POLYTELIS 6 D) ELFOUNA 6a ‘ELF XTO $9031 3) ELFOLNA 4 ELFOLNA DS 62 ELFOLNA DS 45 ELFOLNA SP 68 ELFOLNA SP 46 ©) HYDRELF DS 68 6) HXORELE B10 ©) HYORELF Ds 46 DELFOLNAHLPOS8 | NPYRELE HFC 48 0) ELFOLNA HLPO 45 ELFOLNA HMO 68 ELFOLNA Ho 48 ESS0 2) TERESSO 46 ©) Hydraulkel PGKs__[a) TERESSO GS 1b) NUTO Has. 1 Hydraulic PFL by NUTO Hes Hiydraulke! HUP 46 Hydraulic HLP 63 ©) UNIS N45 9) Hydrauikel HE 46 ©) UNWVIS N 68 @) HLPD-OEL 48 }d) HLPO-OEL 63 FINA 2) CIRKAN 48 |=) Hyaeauikai Daosi-a6 |) CIRKAN es b) HYORAN 48 4 BIOHYORANRS28 |b) HYORAN68 ©) HYDRAN KV 45 9) BIOHYORAN SE 38 [c) HYDRANHVe8 19) BIOHYDRAN TMP 68 1) HYDRAN HLP.0 45 BIOHYDRAN TWP 45 Hiydeaulka! 03033, @) HYDRAN HLP.0 68 INTEGRAL HYDRAULIK GmbH & Co. KG Telefon (02154) 4131-0 A Hanns-MartinSchleyer-Str.20 Postfach 600209 Fax (02184) 4131-50 Caress ATBTT Wilich 47870 Wilich E-Mail info@intearal-hydravlik.de are Web winw.integra-hydrauik.deINTEGRAL HYDRAULIK Hydraulic oil Anlagen + Systeme recommendations Sheet 2 of 2 veas ves Of company |2) LY, (mineral oi) | e)HEPG (polygiykol-basis) |) HL (mineral of) | e) HEPG (polyglykol basis) (alphabetical |b) HLP” (mineral ol) |1)HETG (vegetable ol) — |b) HLP (mineral ol) | f)HETG (vegetable ol) order) ¢) HVLP® (mineral ol) | g) HEES (synth. ester) ©) HVLP (mineral oi) | g) HES (eymth. ester) 3) LPO" (mineral oil) h)HFC (wateriglyool) 9) HLPD (mineral of) h)HFC (waterigiycol) Fina 3) CIRKAN 48 =) Hydeaulkal 03031-45 | a) CIRKAN GB b) HYORAN 48 D BIOHYORANRS 38 |) HYORANG S)HYDRANHV45 |g) BIOHYORANSE 38 |e) HYDRANHVE8 |g) BIOHYORAN TMP-68 8) HYORANHLP.0.45 | SIOHYORAN TMP 48 Hydrauika! 03033 4) HYORAN HLP.O 68 Mineraiéi- fa) HL (Mineralst) |e) HEPG (Polygiykolbesis) | a) HL (Minerale) ‘¢) HEPG (Polyglykolbasis} firma b)HLP? — (Minersitl) |) HETG (Pflanzendl) b)HLP (Minerala) ) HETG (Pfianzenol) Hersteller [c) HVLP” (Mineraiat) | 9) HEES (synth. Ester). =|.c) HVLP (Minerals) g) HEES (synth. Ester) @)HLPD — (Mineralsi) | h) HFC (WassedGiykol) *| d) HLPD (Mineralé) A)HFC (Wasser/Glyko!) FUCHS _[o)RENOLNDTA4S |e) RENOLINPO 4S 2) RENOLIN DTA 68 B)RENOLINBIS VG.4e |) PLANTOHYDASN |) RENOLIN2OVGSS | PLANTOHYO EEN RENOLIN ZAF 463 RENOLIN ZAF 62.8 e)RENOLINMIR 46MC |e) PLANTOHYD 46S |<) RENOLINUR 2M | g) PLANTOHYD 68S RENOLINZAF 46MC_|" PLANTOHYD Supers |” RENOLN ZAP OMG 4) RENOLIN MR 18 VG 4e|b) Hyarotherm 46 M1 ) RENOLIN MR 20/6 68, RENOLIN D 15.VG48 | Hycrotherm 45 NFS RENOLIN ZAF 68 RENOLIN ZAF 460 MOBIL |) vaste Oi Medium 2) DTE Oi Heavy Mesum OTE O Medium Vacira Oi Heavy Medi ) Mobi OTE 25, f) Mobi EAL 226 H ) Mobi OTE 26 c)MebIOTE 5M |g) Mobil EAL Syndroulc «=| ¢) Mebi OTE 16 M Hydraulic O8 UF 48 Je) Hydeautkar HPD 48 | ty Hyronuid UT 6) Hydra LPO 8 Nywae FR 200 Fluid OEsT [ay yerauarnL a8 2) Hyaroukel AL 68 D)HydraulcalHiP 4s |) GOHY-FLUDHV2: |b) HydraumalHLP es |p aI HY-FLUID VER €) Hycraulk@lHV148 |g) BIO SyntheticH¥O 43. |e) HydraulkslHviée |g) BIO Syetnal HYD 68 4) Hysraula! 46 00 6) Hyarautxo|68 OD PANOLIN | 8)Panain nol iSO 48 3) Panelinindol1SO 68 5) Panolin HLP ISO 48 2) Panoln HLP 150 68 6) Pan. HLP Universal27 |.) PanotinHLP Synth 4s |} Pancin GP's5 6) Pancin HLP Synth 68 @) Panalin HLP-01S0 46 4) Panain HUP-D IS 68 PETROFER |) [sohbde VG 4st | e) Symaubaa 4s 3) sole VE 68 L D)lsokibie V6 48 {) Tebolaric 32 ») lslubre Ve 68 )lsoWurie VG 45 HV |g) Envolubrie HE 48 6) Iscubrie VG 8B HV |g) Emvlubic HE 68 Sisohibic VG 450 | hy Una-Sate 620 }isohvore V8.0 | Ulva Safe 360 ‘QUAKER 1) GREENSAVE N20 9) GREENSAVE N40 A QUINTOLUBRIC 730 SHELL |) Morina 146 @) Shell Fuid 80 46 b) Shek Totus O145 |) Shei Naturale HF-R |b) Shen Tetus 0168 ¢) Shel Telus 017045. |g) Shel Naturelle HF-E 43 4) Shell Netuebe HF-E 62 4) Shel Telus 01.0045 |) 2) Shot Telus 01 068 ‘STUART @)ISOCORE «6 6) ISOCOR HF 40 4) SOCOR HF 68 F)HYOROGOR co 44 TEBIOL 9) Forahya HVS 1) Forahya Hv 62 4) Estey HE 46 TRIGOL |) Tob 72 3) Webel 773 b) bol 943 AW 45 Trib! 943 AW 68 WISURA | 2) Dynex 46 3) Dynex 68 ®) Tempo 46 1) Hydroma NAT 40 b) Tempo 68 6) Hygroma 45 9) Hycrofuid SE 46 ) Hysroma 68 Jo) HLPD 48 3) HLPO 68 INTEGRAL HYDRAULIK GmbH & Co. KG Telefon (02154) 4131-0 ' Hanns-Martin-Schieyer-Str.20 Postfach 500209 Fex (02154) 4131-50 i A ATBT7 Wilich 47870 Wilich E-Mall_info@intearal-hydravic aDDaae Web — wwww.integral-hydraulik.de 01-012-05/04EINTEGRAL HYDRAULIK Internal Gear Pumps Anlagen + Systeme 2.0 System Trochocentric 175 bar (250 176 Umin Integral Hydraulik internal gear pumps have the following features: Low noise level ‘The special Trochocentric gear profile virtually eliminates the trapped volume between the gear tips of the pinion and the root of the gearing on the ring gear. This ensures very quiet running of the pump with low put sation. The design reduces gear tooth pressure to a minimum promoting long life. High power handling The long sealing zone between suction and pressure produces high volumetric efficiency. The small outside diameter of the ring gear and the large volume provided for the pinion minimises mechanical losses. The small number of teeth, wide gearing and large flow cross sectional area ensures low filling resistance and Promotes good suction behaviour, . Compactness The long sealing zone of the crescent and small tooth difference between pinion and ring gear ensures that the maximum displacement is achieved thereby keeping size small. Casing parts are few due to the method of fitting the bearings into the pump housing. Single and double pumps are available. INTEGRAL HYDRAULIK GmbH & Co. KG Telefon (02154) 4131-0 onne-Marin-Schoyer-St. 20 Postiach 500209 Fax (02184) 413150 P ic 47870 Wil Mail inte ra oi rove i e 19-007-09/04E Web — www.integral-hydraulikdeCS Characteristics Operating pressure Continuous pressure +: 175 bar (250 bar on request) Peak pressure + 200 bar (300 bar) (Bs max. oF 10 % of duty cycle) : Suction conditions min 06 bar absolute : max 05 bar Delivery 7,5 — 176 Vmin (1600 rpm) Effective displacement 15 — 12 cmilrey Speed 1 see size table Fluid temperature range Oto 70°C Viscosity range + 20 to 300 mms (cSt) Recommended filtration + 25um absolute {Suction fer not requitec) Size table a Detivery* Speed rpm Type Size min aa | max Order code Pr2- 5 75 211 - 1919 - 014 - 005 PT2- 63 a4 211 - 1919 - 014 - 006 Pr2- 8 _ 12 or | oe 211 - 1819 - 014 - 008 PT2- 10 6 211 - 1919 - 014-010 PTS. 125 187 311 - 1819- 014-012 PT3- 16 24 311 - 1319- 014-016 PT3- 20 : 30 Sr S11 - 1919-014 PTS. 25 375 311 - 1919 - 014-025 PT4- 318 472 3000 411 - 1919 - 014-031 PT4= 40 4 C 800 | 2800 411 - 1919 - 014- 040 PT 4- 50 75 | 2500 411 - 1319 - 014 - 050 PTS- 63 6 2200 511 - 1919 - 014 - 063 PTS- 80 : 110 0 | 2400 511 - 1919 - 024- 080 PTS- 100 188 2100 Bt - 1919 - 024-100 PTS - 125 176 1800 B11 - 1919 - 024-125 “The qucted dalvrioe and efecive GapiaSarants ao al a pump pressure of 100 barat 1800 rom and 08 mas wscoaly INTEGRAL HYDRAULIKsg Characteristic curves (measured at 1500 rpm, viscosity 36 mm#/s and cil temperature 50°C) PT 2-5 PT 2-63 we ® 0 a. 3 © min 8 8 28 ‘ a 18 : . & ° «0 @ wis 0 owiehe Pump Pressure p Pump Pressure p- PT 2-8 PT 2-10 2 wo wo © tin 3 3 2» 5 5 2 : 2 a 5 8 6 ame 3 2 2 ° o@ o@ ° © @ wm wise 0 wa) ore bw Pump Pressure p Pump Pressure p ~ PT 3 - 12,5, PT3 - 16 ® wn » a a. © tmin BR © Yimin 3 = » a & = a e & g 3 g z a 8 a 8 oe ae 8 o Ly. 5 : é i Fa ow im WOT 00 0 wie Pump Pressure p Pump Pressure p 2 piso at wo e PT3 - 25 o o Umin BR O bmin 3 > 2 2 & 5B § g 2 5 : Fe 5 5 5 ° (é ° oo wm wor bw rr Pump Pressure p Fump Pressure p er PT4-315 ' fie a PT 4-40 T woo A © tin 3 2 & Pw a § | 2 2 + 5 5 a x Lj» 5 om wie ow 0 wa ew Pump Pressure p Pump Pressure p INTEGRAL HYDRAULIKPT 4-50 Fy amt nin * a ” Eg o T a g« to § 8 a +t sZ t 0 it, oa OTS bar Pump Pressure p PTS-63 PTs-80 = 0 160 — min a Vin + : a i 3 © 1 i= 3 Q 3 é > 5 g Be ite 8 © p° § 2 T i ao a 15 i « i » 2 | a 1g iJ, 0] am e078 bat 0 ia) 0017S bar Pump Pressure p wo PT 5 - 100 w in & 0 Delivery Q 8 ito 0 8 10180775 bar Pump Pressure p hw Power consumed P. Power consumed P ‘Sound pressure (measured in quiet room) » ; | + B © i a i ae - ' . Pump pressure p _ INTEGRAL HYDRAULIKDimensions Lege RS es it Cy 1. f = Wi ma a fe ame Ses Pe ese ae a es a fess Poe pa Peet wore al pee ee F eestor e he heel lw te ete pete tee zl z i z cs 5 es vs 2 eal : oS a a = : E fas a 5 a fe te 5 a H 16 aT s 41 i a z = A t a a a fs ‘ a a : d ; i fe ria 5 5 fe c e = : o = a = i fF ; ; A om : 5 a a Weight kg | 24 [25 [ 26 [28 | 49 [52] 85 | 60 | 29 434 | 139 | 222 | 239 | 256 [ 278 Sea eames nc Sanat seer [eae feats tase | See ares eat peata ceed eon Pipe flanges NC (O-ring and screws Included) SAEGv2_| v2 | 96 | 14 | 16 | 14 |M 8] 19| 58] 46) c3 | 17,5) sees {atte wets ete eee seer Tt Le es wat tea leas SAE.G 1 V1 12] 44 | ta | 25 | 56 [oral 26 | 9a) re] 70 [oa] tes saece 12 bot [aor [wale fast tae ey f saz@o [a [eo [as er [7 [elo 1) ronda | om Trae | [seca [a ss | once [Here weet 29x35 ‘On 1819-014 100 . SAEG2 56,7 x35. 011 - 1319-014 - 200 a a INTEGRAL HYDRAULIKGeneral purpose aluminum motors M2AA 160-200 Dimension drawings Foot- and flange-mounted motor; IM B35 (IM 2001), IM 2002 3 era eel | Le rs ot i aa = IM B35 (IM 2001), IM 2002 Moir A AA AB AG AE BY 8B BA BB EC GCA G# GBD A DB Do ieo* 25466 S10«SIO—«10 «10 ase SS OHS BS WS TSS TS aD Mee eos 279 65S HHO 310 210 261 B7B 5B BIS BF T1855 14S 75 4B MGM 180% 279 65S G40 B10 210 BA 7B 5B 316 Ba 121 2eG5 1825 25 4B lS OMG moos 318 GF © GBD 950 ID 267 ONS 88 BES 8s a3 BIB te”) aS gO 2007 _318_6 300 _360_210_267 905 98 365 98 193 298 200008592202 Molor EA” EG EH OF OFA G GA GB GC HHA HS HO HD HE KL site ck oT yooe 10 HHA M0 51S 27 3S 180 20 HS 90 tS to" 110 698 -BB A410. 4S 51S 27 5 10 20 SDH Seas sn a ee ee ee a es gon 0 _g0 42 28 16 10 49 59 2735s OHS 18 7a Moor LA 8 LG MON OP OST UB UB VA WB VG ODE: 160" 8 a wos 2 5235 300 20 s50 19 5 ZMMO MIs 89 m0 795 1945 1715 wo 20 74 900 250 350 19 § © 2M4O MIE G9 210 79S 1945 1715, 209 2 8015 380 a00 400 18 © © ZMK MIB 109 210 7S 1948 1715 zoo” _20_ e220 e215 50 200400 195 MMO MIS 109210798 1905 1718 “ganas ® Kosteu openings. BB, SOB wag. Hed Lt Coa w02 3 Mai Dae isos tM DiSH 190K8 Ey 255" Smo Fra ison bat Ft Rois ® Shoulder of shat extension and contac cute cf fange ae nthe sam pane Nop? 380M 100 Meg not ace. oe 160 L, 180, 200 LA'B rt aos. 0 IEC. Above table gives the main dimensions in mm, For detalled drawings please see our webpages ‘ynnwabb.com/motorsacrives' or contact us, eo ‘ABB LV Motors / Cat. BU/ Low Voltage General Purpose Motors / Aluminum GB 12-2004General purpose aluminum motors Technical data for totally enclosed squirrel @® cage three phase motors IP 55 —IC 411 — Insulation class F, temperature rise class B Moment Sound Eff Power Current Efi Power Current ofinerta pressure Oupst Motor ype Speed ciency factory Speed scloney factory. eth GDF Weight level kw imine omg A nmin Soop Riga? kg BIA) 1500 r/min = 4-poles 380 V 50 Hz 415 50 Hz 7 saa 90 a a a a 18 MAA TOOLA 1490854 08K 321450 86.1. 072-31 Da 22 MAA 100LG 142068 980 “as Wed ‘569 ova 48 ome 25 Ba 3 IAA 112MA (45567208165 455 e7#8 080 61 0018 3456 4 MOKA V1aM gS B79 OFT BOSS aad OTT 8 oe 55 MAMA 1228 1460889 OM 1111400 80.1 08s 1030008485 1s MAA. 92M 480 B08 ORT 147 480 G03 os7 3S OM | Ba. Be n MOA 160M = 400«O1.1. 089-225 470 O18 082 20S OST 18 WOK 160k MSS ots ORK GO tH8S ane SOB 28” OMe | 108 62 185 MAA 100M = 1405 O17 085 96 T470 oz? md MST a Wona too aes 607 008 a2 p09 ook as ms ter es 30 WOAA 200MLB 1470” 631 085 58 1475 995 084 54 04 208 69 a MAA 2258MA THIS BAe Ok 72 Mon gaa Oat 8s OTIS Be 6 MOA 225SMB 1475 940 085 85 = 148094281220 5% ee a ae a ee 78 MOA 200SMA 1475. O45 O87 199-1400 9h@ 098-128-8380 0 MOAR peosme 1470 080 asd tes ters “051 987 Stes Oss) 4088 1500 r/min = 4-poles 380,V 50 Hz 415 V 50 Hz a a e 04s = MOVA 7188 ©1980 75:1 080 1412 1400 740 072 12 090080 85 45, os MV Te Moo U7r "OTT mo ¥6A nse dB ogo eB 085 MaVA_ soc 1400 781 O81 23 1430 784 068 265 noted 11 50 at tava wo Te ee ee ee 195 7 MAA SOL 1980 7a8 089 44 1400 795 975 498 00043 16 50 229 MOAR 808 11900704 085 {5A 4400 Bog 5a ae | doods 47s 50 ‘MGA 100LC 1410" 60.0 0g2 88 1420 620975 87 ~ c009 25 60 55 8 WGKA tA. 41S BRS OMB KT RG BSS Oye OTT tI BA 88 82 MOAA 192MBA 1445880 O87 184 aus 88ST «188K Dian ae nats, a2 oer ee) gage Tea oe a Cooks Be 8 yes > MOAA 160OLB 1440893 085 97 45D OS HSS 1S 30) oaR “tots ies “ee (085 sn Hao 927 nee 55 | ages fer 68 a7 MGA 200MLB 1475939 085 711475 933 0m @7 098 205 69 488 WoaR zoomine : fe Sa Samm 88 58 MOAA 2255MC 1475 943 004 105 1400 O46 082 99D 85 TS 9 > Maka 288M OF : j 058 Bsa 66 8 MOAA 2505MB 1475045 087 198 1480 O4.8 086128088 SOE Recalculation factors Recalculation factors for current at rated voltages other than 400 V 50 He. Rated voltage at 50 Hz and motor wound for Recalculation factor Rated vollage at 50 Hz and motor wound for" Recalculation factor mov 1.82 500 0.80 230 74 es0v ost a15v 0.96 690 0.58 §D sco. ers/ ca. 84 /on Vtage Sona Pues Mare /Atmrum Go 1208 F(sou ewan ‘cor saya no) rset euros Bat -snto vores eee srepresay se oN ‘toys Be eunuromrcor esa 0p open wey ‘oyeedo eset png ea om pono aay Como ae pen oe eoNEN eaL ‘Aupwen te10u99"4 1ue4> Buoys eranon soront'9 Superedg'e ‘swuowexibew uowuosra s woneneisurz eoueuomrert'y tes2u99"t swwaweg 10811 fenuew oueuayueus pue uoperedo ‘uopel/eisuy oon aay er 18 SoBenBue spo on soot A, rouse awa oesastong mh cig ‘etoana Kom a 30> papsp wey oe erations 8a na ao go apne ie one ise snes {a umm re zy oaae98 oH Ps asa a pa) SNe ONG SP ‘quuojueg jo uoqese90q 93 aavSor| et Se oe as | ose stares om ge | se ‘ergad wom eu porns Bape Sse oe oe | oe epee sey equa oa pose ved oe | @| or] on a] 8) a) oi & w]e | a @] &] fo] oe @] el al @ ty] or | emma] ov | one ent | noe | Foe new, | mg veng | womieeg | ummaniy wa suey ogei 0 pc wd Oe ug v pais ose ee a SEL ‘sumo duvong na eseeey sunt pee ‘wounbny rae se Ye ye ounomue ep a “premuncp on sop eM Unto BUENO KEM ‘rou ued edgy 91 ojo poe se pe ppreneusyproasapvootmnepns aga Weidnbo mpm eeumpo Uaqe odie ele) “roe ane Sonn Aas)p ou eu any scan oes ‘eoj ou pu pes x usonag nis nu 4 eee ‘sens wopepunog “yoda Saep “rote oper es eaayoua pam sooo saoipepanicom aaron au sige evmtar jose ouleeu eo es edt erepea onevodsuel. ‘meter Bupicoo re pain oa em ns ‘yeouo uondeoee (Ouey) eop08 on Sugg seep e240 S88 BY eID WoReHEIEEL tenon tern sc eNO‘voneouany pue eousuenier, souruoturen > Sunessdo'e fo ym psoUg 9,3) ‘ar douo soa suum ou sensoeop eee wonseuuegsary stoge 0 0 Hey 28 some on0n outs sees ‘Hon woneEPaNT wer ouPa=NpUT Se]aU] BI Ts] C asa paneaiano] ue ser 2 eve 02000) a ee ee eaieuproye tnen ea . we 5560 sno1p uso} xsi in peo pa ara Pa — | wAutoonn see esp 0 0508 vost] seastanoap| eas care Fara se 90 moves sBueeai| eT —riamiterts coat oes ops seevsetenr| NesvauapanesDuLN apap] jo eSupaN la veo| ‘Wom wots a) E01) __. padre wedop we uegoous 0209 suogauans oy sda _ ee Pe Pe a ees Joram baie payne innos oor oo ‘ites ova 26a ~ [us pean ser pas | ‘a peerO| apps aa an ca oe ‘nyui] essen ‘oo ox svi ashy] wianows| ‘eur pec edad am toad page a pepumy oq ru Buoy aro ps 9ae8 ew NaN ‘ue Buneows oqnon son sean cen] ‘oy som aay Ratau et Peco sss pasos ugauoys unypoe ay vowed vom aa ‘1 vue rood dst orp SNe OSyeMp N89 OUP SEMAN HEL = __ ie puna] am sole ons yee 201 2oou ag wo 28 eas scruno wm om pe Sop | rareoyoon mney ee oo G|_swn eoye%0 ‘ae SORT W RLS Saray TEED “Sa a BeTbEpY ua or 21 on 2296 4 290194050 309.901 uoy ‘Fivear peor Ba| a 0 ose |_ sunt me 0 see oad 6 ee (0d oL.ivHi| ‘asnvo| __a1anoul| {bute enssrd prose one ea no eso ‘10n91 2810N, ‘sqowoynbos jowewuowaug 's dou yes pager qo pais oq am rou Sapa sarcopis np saps ‘au puna quo suns ayods bh Supuynoy444-3 Bourdon Tube Pressure Gauge eect eee ets Model 213.53, with Liquid Filling and Stainless Steel Case 1 Intended for adverse service conditions where pulsating cr vibration exists 1 Suitable for all gaseous and liquid media that will not obstruct the pressure system or attack copper alloy Parts 1 Hydraulics 1 Compressors. 1 Shipbutcing industry 1% Vibration and shook resistant 1 Especially sturdy design | NS 63, 100 approved by German Lloyd and Gosstandart 1 Scale ranges up to 0... 1000 bar Description Design EN 837-1 Nominal size 40, 50, 68 and 100 mm ‘Accuracy class. NS 40: 25 NS 50, 63: 1.6 NS 100: 1.0 Scale range NS40,50: 0.1 upto 0. 600 ber NS 63, 100: 0.0.8 upto 0... 1000 bar or other equivalent units of pressure or vacuum WKA Data Shoat PMC2.12 Bourdon Tube Pressure Gauge Model 213.53, ‘radial connection Working pressure NS 40, 50, 63: Steady: % of scale range Fluctuating: 2% of scale range: Short ime: full scale range NS 100: Steady: full scale range Fluctuating: 0.9 x tll scale range Short time: 1.3 x full scale range Operating Temperature Ambient NS 40,50, 63: 0... 60°C NS 100: 20... 460°C Medium: +60 °C maximum ‘Temperature effect When temperature ofthe pressure element deviates from reference temperature (+20 °C) max, #0.4 96/10 K of the span Ingress protection IP 65 (EN 60 829 /1EC 529) : Page tot2 WIKAI Hhron otyourbusinesPressure connection Material: Cu-alloy LLawer mount (LM), cenire back mount (CBM) or lower back mount (LBM) NS 40: G%B, 14mm fats, NS 50, 63:6 %B, 14 mm flats NS 100: 6% 8, 22 mm flats Pressure oloment NS 40, 60, 63: < 60 bar S60 bar NS 100: Ciraloy, C-type, soft soldered Cu-alloy, helical type, soft soldered Cunalloy, C-type, soft soldered :, stainless steel 316L, helical type, brazed Dial NS 40, 50, 63: white plastic, with pointer stop pin NS 100: \hite aluminium with black lettering Pointer NS 40, 50, 63: black plastic NS 100: black aluminium, Dimensions in mm. Ba ih ean 071008 ‘Ordering information Pressure gauge model / Nominal size / Scale range / Size of connection / Optional extras required Window Clear plastic case Natural finish stainless steel, wit pressure relief in case top (O-Ring seal between case and entry stem anges <0... 16 bar with case venting provision Bezel ring ‘Tiangular bezel, oll formed, glossy fnish stainless steet Liquid fing Glycerine 99,7 % Optional extras NS 50, 63: stainless steel pressure system (model 233.53) | NS 100: zero point adjustment in front 1 Medium temperature to 100 °C with special soft solder 1 Ambient temperature ~40 ... +80 °C: silicon oil filing 1 S-hole panel mounting flange, stainless steel, back entry only (not NS 40) 18 S-hole surtace mounting flance, stainless steel (not NS 40) "5 With clamp (back entry only) +100 mr lower back ‘pressure entry (LBM) ‘Secs in ert cn att peat a eng ee of ng ‘einen yop th mows peat ay ba mpaenby owt shaker ‘Wkk Data Snoct Puig 12 07/2008 [wikal] \WIKA Alexander Wiegand GmbH & Co. KG ‘Aexander Wiegand-Strabe 30 83911 Klingenberg/Germany Phone (+49) 93 72/132-0 Fax (40) 39 72/182-406 EMail infoBwika.de rile.BOJHIMIEIRG SY ‘ Block: Hochdruck-Kugelhahn mit Gewindeanschiu8 Block type high prasoure ball vale with threaded ports Robinet monobioc haute pression a bolsseuu sphargue, raccords males ou femolleg Jen [ON | Normalaustarungen bar [mm | Standara versions | Exéeutons standards | yet wpa Gerause | 150-500 4-28 | seam stan! Body ‘Steet Sigel [Corps Acer Acior Kuget | 150-500 [a-2s | stant, scans, | Bat harverchromt|hartverehromt | Bite Steet Stoet | { hard chromed {hard chromed | ‘Acie, \Aclen | | ‘rom. cur ehromé cur Dichtungen | 150-800 [4-25 | Polyamid | Tefion [Seas } ints (© Der Schattaritt geht zum | Tferumfang. (© Bei Kugethshnen mit Dich- {unger aus Tetlon werden im | | NormatallO-Ringa aue Viton singebeat | 6 Sonderaustonrungen aut Ratose: © Tenandiaisincder | | © at vas wth talon sols Srearmaly delvores wih wenn Special designs upon reauest | | (© Lamanette est comprise | | ansiaurason. | © Les obinets a bolssaau | ‘Spherique avec ois tetlon, ‘ont prévus normaremant avec Joints torque en viton © Exécutions spéciaies sur 1 { ‘Auch loferoar mit ‘TUv-BautelrKennzeichen. ‘Algo availabe with ‘WV piace partmark, ‘Aussi wrable avee Bestel-Ne. und Typ bitte angeben. Please quate order-no, andtyp. Mentonnerrtérence elie sp, ‘marquage comoosant TY yet Typ2 BHG V500.104/... 6BHG ‘IN 2389 sole etre psoas Se vss EaRactonccomsanvins EN ow azeavn uo week sm sere Miaka Pi nebo Anachiuart im | w| A [swe Sen peat | Type de moconioment a mee SERS hon 3 le/a]g/ 3] 8 - AA Forcompressiontitia, with = 12 |e [ml] 8) oF | Sismereta 2 elalal al a | aero 2 ei) lie) 8 | 33 | ase 2 Sees) a] e iG Bsa ie| 2 | 2 2 = aigisle) ss 2. incor z elgig) i] jeff orcomemeesentae. a 3 |r| ao) 3 | oe {tga = elelg a | meaaeereaee = 21818) 8) 38 = = Far Rohererechradbung chmare Rae, OIN2363 288 Forcomprssion ting, aasgenes | saseel LE nasties iia ‘Sar 3 30 30 [Ff Rear sorta, 2368 500 | 380 Pourraccors avec cine 200 | 280 LE bin z3ss' sere ouce ste | Wie Re 250" | 480 ‘Rachatchtend, matiachen = T ‘Rasengewinds, OINTS 3 2 Fat seating mete = = 230 300 = aS 0 Sa 400 SSSRRRT a Fat seaing 88> 828 8 8 a8: _ai ens, DIN'SO.228"1 "Get wetwort mit vec Stance, OS 2007 Wer Autengewice, ‘ANSUIASMES 1204 FT male tread, ANSIAGMED 03 ‘lacie WPT, ANSIasies 209 BSP orale trond A Sin so aaa P Taraudoge,winwont iE Gnisoren cn eo| 12 |_2i | eva vonszas Wehinnengpwinge, ANSU/ASHED 204 NPT fate tread, Kt EE ansragues van P Traucnge ner [> Ansiagie i201 SBSS8S | SE8EBSE8 | 22888888 ageseees | agaaness | aagausss | sassasss |agssaeee | aagauess | saeaaees |aasneses BI9B8RR8| SIRBRENE | eaERE RSE | aaTaRRE: Biganeas|sieaesas suee26as [saeazeee sueeenas |Ruasesss | see: BBsaseos | BB * Druckatufe dr Robrorehraubung. anol excued noma pipe pressure Yeulles ous eprtrd le péeson nominle dy tube. 93 | ia veonoe 38 | Bie vernon 85 | Bua Vaooste 42 | she varsemo too 2 | 21 | Bho VatseesINTEGRAL HYDRAULIK Anlagen + Systeme Ball valve Ball valve PN 40 Ball valve PN 40 with level with level Both ends female threads full flow Female/male thread full flow .. Housing: Yellow brass, MS 8, Housing: Yellow brass, MS 58, ~ nickel-plated nickel-plated Ball: Yellow brass, MS 58 Ball: Yellow brass, MS 58 O-ring: viton O-ring: viton Washer: PTFE ( teflon) Washer: PTFE ( teflon) Dimension: Order Ne Dimension: Order No.: 14" 90 025 01 1/4" 90 02510 3/8" 90 025 02 3/8" 90 025 11 1/2" 90 025 03 12" 90 025 12 a4" 90 025 04 3/4" 90 025 13 " 90025 05 1" 90 025 14 11/4" 90 025 06 11/4" 9002515 412" 9002507 11/2" 90 025 16 2 90 025 08 a 90 02517 212" 90 025 09 s 90 025 19 PN 25 bar Verschluschrauben ON rit Innensechskcant og INTEGRAL HYDRAULIK GmbH & Co. KG Telefon (02184) 4131-0 Hanns-Martin-Schleyer-Str,20 Postfach 500209 Fax (02154) 4131-50 E 47877 Witich 47870 Wilich E-Mail info@intearal-hvdraullkde Web —_www.integral-hycraulik.de 932-412-0903INTEGRAL HYDRAULIK Pressure Relief Valve eee icenne 6.1 With TV Test Certificate NG 6 6.4 Direct Operated Pou = 315 bar Qnee = 80 Vmin Design Function Pressure relief valves are The pressure relief valve meets the designed as seat valves requirements of "AD-Merkblatt A2" and is with cushion piston. The officially approvea tor the satety seat valve provides a of hydraulic accumulators. The drainless sealing between valve has been type tested by TOV the pressure port and can be supplied with TOV test and the return port below certificate upon request. the adjusted setting Safety valves with TOV certificate pressure. The cushion are reconmended if the built-in piston prevents uncon- valves cannot be positioned to trolled oscillations of respond and there is no separate the poppet when opened. test bench available. The pressure Due to inproved strea is set by the manufacturer in stages Vining the valve achieves of 10 bar. Higher pressure settings high Flow rates. are avoided by means of a seal, how- ever it is possible to relieve the hydraulic accumulator when the pump is turned off. The valve is available as screw in type DBE 6 or as threaded connection type DBG 6. Cartridge A Type DBE 6 { Threaded Connection Type DBG6 617 180 28 INTEGRAL HYDRAULIK GmbH & Co. KG Felefon (02484) 4134-0 F Kenns-Marin-Scheyer-tr.20 Postfach 500209 Fax 02184) 4191-50 - 47877 Wilich 47870 Wich EMail info@intecrabn 3 Web — www.integral-hydraulik.de eeINTEGRAL HYDRAULIK Anlagen + Systeme Ordering Code DBE — 6K —210/ 160 B Ly B_ Cypectestea) TUv (Tov-Test-cert ification) Cartridge type E Mounting type factory setting of Threaded connection type G ‘the response pressure according to the table max. Pressure | 50 bar Handknob K | Adjustment setting 125 bar Scew S 210 bar 318 bar Ordering No. Standard Types The third figure of the ordering No. is a 3 instead of 2 for valves with TOV certificate ordering Ho, rae Setting |ftisne | TOV: component Screw-in Valve DBE = § Pipe Connection Valve 086 - 6 jin bar mark operated by operated by operated by ‘operated by Pin Pa urn] ‘hand knob ‘inner hexagon hand knob | inner hexagon =| »|m mm ®| & | Beonar, 03 Siternar, 222 | ss2-son-or2-29|52-s00-o2- 10) se t80-019-t0| 02 -160-018- 10 o| 6 fe | 8 | @ ‘om @| © “0m 2| 8 en e| 8 an bd 8 | supers, 5590 | aso. 1390. o12- 420 | s60-1900-012- 440 302 - 1330-013 - 420 | 302 - 1390-013 - 440, | @ forca m | @ ero | @ oi 135, 60 60.125 | =) @ sim e| 8 e100 | ie | 3 or =| 3 ord Wo | & | Svaemse, doar | 252 s200-ov2-ea 52-1500 -012-640| sa 1590 018-20] s02- 000-019-640 ®| o e100 | o 270 m/e fom zo | on210 ma wa 20 20 j xe Fa m| |_ =| _ | = 20 | | Berne. e20| o2- 10-012 az0| 2-150 -o12-840| 021500019 -ca| 2-180-010-80 m = = = i a Fy as a : Sealing Set: Ordering No. 351-1330-019-009 Housing for Flange mounting and sandwich mounting with mounting surface AS as per DIN 24340 is avatlable. Please see Data Sheet 30-00109-846 for dinension drawings. Valves with VITOM sea1s available upon request. eaeangan vba, '30-100-08/00 aAre DUnAL Fo eRAULI, Anlagen * Systeme Technical Data Pressure setting range Port P : up to 315 bar Port T : up to 50 bar Reconmended flow : see characteristics Temperature range : =20 to +70°C. Viscosity range 12 to 300 mm’/s (cSt) Recommended filtration : 25 ym abs. Characteristics (for 50°C oil temperature and 36 cSt viscosity) Threaded Connection max. relief setting 50 bar sax. relief setting 125 bar ver ver 2 Sa et a ay 2° = £ in : Ef [ras atnisstbte Mow wax. adnissible flow — ° Q 8 dO Unin ° o a 0 «© # | is Ba 1) pre ne ie ea 9 vetght ab. 1,8 kg g a fe 22 Is ge 3 I 2 =| 4) preanaresgeuge fe fhned- G18 eee own oe ps g : | 3 / 3 1 2 1 q | i eo \ 11.4 presur-gauge ine (loses) @ 14 O-Ring 9.28 x 178 Weight ab. 1,8 kg INTEGRAL HYDRAULIKINTEGRAL HYDRAULIK Directional Control Valve Anlagen + Systeme NG 10 Typ: Design ‘Spool valve (five chambers system)” ae Mounting type ‘Subplate, NG 10-1SO 4401 W4A-10M000-AC230/2 | Mounting position | as desired | ‘Ambient temperature _|-20...+50°C Qimax. : 100 min Fluid: Mineral-oil basied| hydraulic-fluids DIN/ISO (others on request) p max : 315 bar Viscosity 10..500 mm?/s Fluid temperature Seal quality Viton (standard) FPM -20...480°C. (Perbunan NBR -25..+80°O) MW vt CASHIERS Fitraton Contamination sso 10, according to NAS 1688 to be achioved with filter 8, = 75 551-1340-044-000 Operating pressure Port P; A, B: 15 and 7: 160 bar Power rating ‘A0280-50/60 O25x4.5 Co] S282 INTEGRAL HYORAULIK GmbH & Co. KG Telefon ( (02184) 4131-0 Hanns-Martin-Schleyer-St. 20 Postfach 600200 Fax (02484) 413160 H 47877 Wilich 47870 Witich E-Mail info@intearalnvdrauik.de ——__ Web wwaintegra-hydraulk.de +40-600-08/0512 way, 2 pos. sol. valve, poppet (normally EMDV-10.-C2- closed) Symbol: 4.2-5-6 43-40 Nom. pressure: 350 bar Nominal flow: 60 l/min. | 4. HYDRAULIK GMBH TMAV-Hyarauilk Gmblt Brelte Strasse 10, 1D-40670 Meerbusch (Osterath) ‘Telefon +49 (0)2159 - 9188.0, “Telefax +49 (0)2159 - 4242 E-mail: info@imav.com Internet: hito://wvw.imav.com. CS-210-101-00 HEX 27mm (torque cartridge: 48 - 54 Nm) cavity c-10-2 data-sheet no. 1K100-109-00 ap. Ap-Q-charactaristic INF 7/14 we Rar Goro) a ga oe eat ter hy a 2 Tt 0 Tenn2 way, 2 pos. sol. valve, poppet (normally closed) EMDV-10.-C2-0- HYDRAU a TA nK GMBM INAV-Hydraullk GmbH Brelte Strasse 10 i 0-40670 Meerbusch (Osterath) Ordering exampl Telefon +49 (0)2159 = 9188.0 EMDV -10N-C2- 0 -0240 G Telefax +49 (0)2159 - 4242 Poe gy see el nina. A B GoD Fl CS-210-101-00 Model code: design F] power supply solenoid valve Ga’DIN 43650 connector, other poppet type valve connectors see data sheet no.: CS-010- 900-00 pilot operated [B] size and seating ON = Buna (NBR) 10V = Viton (FPM) (C] symbol function mode C2 = normally closed construction 0 = screw-in valve voltage DC current: 0120 = 12v DC 24D = 24V DC AC current: 120A = 120V AC 240A = 240V AC other voltage on request Technical Data: nominal pressure: 350 bar nominal flow: 60 min weight: 0.86 kg temperature range: — -40°C to 120°C fluids: hydraulic oll as per DIN 51524 T1 (ISO TC 131) max. leakage: 5 drops/min at 22 99 % [Sm-L. 3m > 99% ans g fig. a a7] & i fig. 1a | | | i MAHLE Fitersysteme GmbH Bereich ndustietiter ‘Schleifoschuweg 45 0-74613 Ohringen P.O. Box 1309 D-74603 Otringen +49 79 41 67.0 {149 79.41 67-429 Incemes waw.mahle.com Email ub2Industrieemahie.com ‘Subject to technical alteration! ‘opticnal contamination indicator fig. 4 jena] clamp ‘connection according to DIN 24857 T2 {6x screw MSx16 and sealing contained 40 8 s— 5 Pousseor4 ce 10.2003MAHLE e 0 Industrial Filtration Medium Pressure Filter Pi 3000 (Operating pressure 200/316 ber, Nominal size up to 400 ‘according DIN 24550 Efficient fitors for modern hydraulic systoms Quality fiers, easy to service 1m Modilar design principle 1m Equipped with highly effcient Sm-x filer elements 1m Compact design 1m Bralued oloments por 150 16880, 1m Minimal pressure drop i= High dit holding capacty and ferential pressure stabil pro- 1m optcafelectrcallectronic contamination control viding optimal element sevice fe tm Threaded connection Worldwide distribution190 mais 25" 3 mms SE) fg si | Es we | Fy ee Zz oy eZ ; , [min]. P/30006 Sm-x Vimin} —-P?30010 Sm-x V[vmin} z PW py a l7 ss Le Pi30004Sm-x vst V[imin} P1306 Sm-xvst V[Vmin} —_—P/30010 Sm-x vst Peal , = 9 se 5 Viumin) P3025. Sm-x Vivmin) —-P30040 Sm-x 4p [bar) Ap [bar] fi Ay eked Vivmin} y Bes Ze Ze Pig0016:Smxvst V{vmin] —PI30025Sm-xvst V[Vmin} ——PI30040.Sm-xvst —_V [Vmin] 7 | RES y= diferent! pressure A p bar] = flow rate V Win} Medium Pressure Filter Pi 3000 | 2= patie ia (um) ‘determined by multipass test ('SO 16888) calibration accorsing te ISO 11171 (NIST) seer pel Sex 3 yy 200 See 8 RS ae See 10g sae See 18 gOS sae Sen AD nae cpt tt ao ‘measured according to ISO 16889 (rukipass test) ‘Sexy elements with 4p 210 bar Smavet 3 Bye 2200 Smxvst 6 pr) 2200 Smaxvst 10 Pye 2200 Smxvet 16 Bev) 2200 Smavst 25 Base) 2200 pt 20 bar diferent Pressure MAHL fier and fer elements are manufactured respectively, tested in accordance with the following international stendords Norm Designation DINis0 2041 yaa Nid power ite mens; veticaton of ealapee/bust reditance DIN 1s0-2942| ydralc fui power tte elements; verification of fabrication itegry [pI iso 2049) Fiycrauic Rul power fiter elements; vercation of material compatlty wih fds [DIv1s0 2025; Hydraulic Rud powor fitr elements; method for end load test DIN igo 2904] Hycrauli uid pow itr elements; verification of flow fatigue charactrision 1503668 . Hydra hid power fiers; evaluation of pressure drop verse flow characteristics iSOAoFTat Fatigue pressure testing of metal containing envelopes in hydraulc fhid applications SO 76888 Hyrule Rul power fiers; multipass method for evaluation ration performance of efter element remy t Mediuni Pressure Fiter Pi 3000 T 3Example for ordering fers: [i Housing design 2: Fitoroloment [V= t00Wrin and elsarical contamination indicator [Smoxvetd Type: Pi s0010-015 Type: Pi 71010 DN Sm vet 3 Order rime: 78208084 [Order number: 78227480 ° ° @ : © | with bypass | with bypass | with bypass ° with, | valveand | valve and | valve and ° with Nominal size| Order Indicator | indicator | optical | electical | with optical | lectrical NG Wein. | -number ||... Type cavity | cavity | indicator _| indicator | indicator | indicator rraz0rees [Pi a0004-010 ° [reabrso4 =~ |[Prsqooeot1 7367386 [Piaoooe-o12 [ras04208 _|Pi30004-019 razovese _ |Piaooo+o14 rezo7e4s _[Pis0004-016 i7e207961 [Pi30006-010 rezo7ere | Pra0006-014 re207se7 _[Pia0008-o12 [resoazta _[Pia0006-070 [re209001 [Pi 30006-074 Frezoaots __|P130006-016 rez0803s | P130010-010 razoeo4s —_[Pis0010-017 fraz0a0s0 | Pis00t0-o12 [resosz22 _|PIs0070-013 [rezoso7s —_|Pis00t0-014 [rez0s0e4 [PI 30010-016 [78208100 | P130016-010 reans118 __[Prsoove-014 7a208128 | Prs0016-012 re2s0e7a __[Pra0016-013 7206142 [Pra00%6-014 [rezostse _|P1a00%6-016 [rezoste7 __|P130025-010 7ez08i75 _|P130025-011 reaneies [Pi s0025-012 rezsese [Pi s0025-013 rreaoeece —_|Pis0025-014 rezoset7 [Pi s0025.016 79208226 _|Pis0040-010 jrezoes3 | P130080-014 rezne201 | Pis0040-012 7259006 | Pi20040-013 razn6o66 | Pis0040-014 frezoea74 [Pi s0040-015 ‘Wn iter wth non bypaas configuration is selected ha Colapso pressure oT the element may not be emeeded, “Type Pl 30004 Fi 20010 have an operating pressure of 315 bares pressure of 410 bar. Medium PressiireFiter Pi 3000 TNominal size ‘Ord: Collapse pressure | Filter surace NG tung umber Type Ftor matoriat oar] [oma rezso829 PI2t004ONSmx3 __[Smx3 lars rre90889 PI22004DNSmx6___[Sm«6 lars 77925674 P123004 DN Smx10___|Smx 10 20 lars 260007 PI24004 DN Sex 16 [Sex 16 lars ag [Tazo Fi25004 DN Smx25 [Sx 25 ars [re2teors IPL71004 DN Smxvst’__[Smox vat 3 ro 7960166 P172008 ON Smaxvet® _[Smoxvet6 as, frreases4 [PI73004 DN Six vat 10_|Sroxvet 10 210 faas razs6087 [PI74004 DN Smox vet 16 _|Smox vet 16 [aes raai6005 [PI7S004 DN Sox vat 26 _|Sr-x vet 25 as >. [rgesoae0 PIZI006 ONStixS ___[Smx'3 leas },fryeeoe67 PI22005 ON Smx6 [Smee ess 7725566. PI23008 DN Sax 10" [Sime 10 20 eas 1 [reeoaa, [Pr2scos ON Smx16 __[smax 16 as vy (resosee: }P125006 DN Srmx 25___|Smx 25 eas reniat37 IPLT1006 ON Smox vet [Smoxvatd 780) 77860749 PIT2008 ON Smaxvat 8 [Smox vet 6 780) 7925662, PLT3008 ON Smox vet 10 _|Smox vet 10 210 [reo Taxis P174006 ON Smox vat 16 _[Sm-x vat 16 [780 7a2i6152 175006 ON Sav vat 28 _|Smox vst 25 [reo reazraTe PI21010DNSmx3__[Smx3 1375) [7resoa7s: [Piza010DNSm

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