Crane model Crane Serial No : HS 01068-1069-1070/19

AT 7 NE1 HPU Serial No

Year of Production
: HS C0261-C0262-C0263/19
: 2019
Document title

USE AND MAINTENANCE MANUAL

for
HYDRAULIC POWER PACK
HS.MARINE S.r.l.
00 03/06/2019 Final S. Forni Rapacchi
Rev. no. Issue date Rev. Description Issued by. Inspection. sign. App. sign.
Serial number: Package title:

HS C0261/19 HPU model 11 kW – 380V/50Hz

HS C0262/19
HS C0263/19
for CRANE model AT 7 NE1
Customer name /address : Space for Status Code Sticker
STATUS 1
1 Complete version

2 Provisional :-
interface information

MOLUTION., LTD - Công ty TNHH 3 For information only

Molution Date:
_________________________________________
Add. : 14D Nam Thong 2D, Nam Thong 2- Manufacturer Name / Address :
S19, Quarter 6, Tan Phu Ward, District 7,
Ho Chi Minh City, Vietnam.
Địa chỉ : 14D Nam Thông 2D, Khu Nam
Thông 2-S19, Khu phố 6, Phường Tân Phú, Quận 7,
Thành phố Hồ Chí Minh HS.MARINE S.r.l.
Via G. Marconi , n° 33 - Loc.Commessaggio Inferiore ,
Tel : 0285 411 2266 46018 SABBIONETA ( MN )- ITALY
Phone +39-0375-254819/Fax +39- 0375-255049
Fax : 0285 411 1136 e.mail: info@hsmarine.net
www.hsmarine.net
Additional Note : Order number: Order data:

HSMarine-SBI-2019-02 15/01/2019
Date: HS.MARINE document code Supplier Version.:
number:
____________________________ Ver. 00/ En
Signature 904.004

_____________________________

2
CONTENTS
GENERAL INFORMATION

1) OPERATION……………………………………………………………. Pag.04
1.1 STARTING THE POWERPACK ………………………………………………….Pag.04
1.2 OPERATION’S ANOMALIES …………………………………………… Pag.06
1.3a CAUSES OF POLLUTION OF THE HYDRAULIC FLUID …………………….. Pag.08
1.3b CAUSES OF PRESENCE OF WATER IN THE FLUID …………………….. Pag.09

1.3c CAUSES OF AIR BELLS IN THE FLUID ………………………………… Pag.09

1.3d CAUSES OF THE PRESENCE OF SURFACE FOAM IN THE FLUID ……… Pag.10
1.3e CAUSES OF EXCESSIVE EXTERNAL LEAK …………………………………. Pag.10
1.3f CAUSES OF FLUID OVERHEATING ……………………………………. Pag.11

2) MAINTENANCE ……………………………………………………….. Pag.12

2.1 GENERAL MAINTENANCE ……………………………………………. Pag.12

2.1a HYDRAULIC FLUID MAINTENANCE ………………………………….. Pag.13

2.1b OIL FILTER MAINTENANCE …………………………………………... Pag.13

2.1c AIR FILTER MAINTENANCE …………………………………………... Pag.14

2.1d OTHER MAINTENANCE POINTS ………………………………………. Pag.14

3) DISPOSAL PROCEDURES …………………………………………… Pag.15

4) WARRANTY …………………………………………………………… Pag.16

5) OIL TABLE …………………………………………………………….. Pag.17

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GENERAL INFORMATION

 Requesting servicing 

Supporting staff to install and start the power pack will have to be requested at least two
weeks before the date of intervention.

 Ordering spare parts 

All spare parts have to be ordered from an authorised distributor only.

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1) OPERATION

1.1 STARTING THE POWERPACK

 After connecting the hydraulic plant according to the drawing and verifying that all actuators are fully
disconnected from the components they must handle, carry out the following operations:
 Fill the tank with new oil, if possible by using a transfer power pack equipped with a filter whose
filtering level is similar to the one recommended for the plant.
 Fill the pump and engine (pistons –blades etc.) casings with clean oil (same operation as with filling).
 Reset all safety and pressure valves
 Connect to electric motor
 Verify correct direction of rotation (start and stop by means of the main switch until the correct
direction is verified).
 Switch the electric motor on for approximately 2/3 sec. Then stop. Repeat the operation 5-6 times
while checking the gauge mounted in the delivery piping (it must display zero pressure. Verify the
connectors and leaking pipes, the noise of the pump and check the aspect of the hydraulic fluid taking
into account the specification included in Table N. 1.
 Operating the engine only, make the oil flow within the plant for at least 5 minutes (oil pressure zero
bars).
 Then manually operate the valves checking individual actuators so as to fill the pippin’s and the
actuators themselves.
 If the actuators do not budge owing to internal friction, handle the pressure valves controlling them
(read values on the gauges)
 Operate actuators for some time especially if the are on line and double-effect gauges, to bleed air.
 Check the oil level again and top up if necessary
 Calibrate pressure valves manually. Remember that pressure is created by the resistance the actuators
must overcome to work. Carefully comply with the hydraulic scheme.
 To calibrate many actuators, connecting them to the components they must handle if necessary,
therefore the definitive calibration will have to be carried out later, when the machine is connected.
 To simulate the maximum load (calibration pressure), the actuators must be subject to a load greater
than the maximum operating load.
 After carrying out the calibration, operate the loadless plant (actuators must not be operative) for
approximately 30 minutes.

5
 After tests, replace the filter cartridge checking the pollution level.
 Verify the following items again:

 Possible oil leaks

 Oil level
 Noise of loadless pump under pressure
 Oil status
 Temperature of external components and tank
 Operating pressure
 After carrying out these checks, the automatic cycle can be started according to the electric scheme.
 Always monitor plant temperature and pressure.
 Remember that hot oil under pressure is dangerous. Do not stay in the area of operations and do not
handle connectors, pippin’s and components if the plant has not yet been stopped and fully pressure
released.
 Further information available from our Technical office.

6
1.2 OPERATING ANOMALIES

THE ELECTRIC ENGINE DOES NOT START

HYDRAULIC PLANT

A) Air or oil emulsion present in the circuit, foam in the tank:

1 – The oil level in the tank is too low, the suction pipe is not submerged therefore the pump
pumps air and oil at the same time.
2 – Holes or fissuring along suction pipe or faulty pump seal gaskets, letting air come
through.

B) The pump supplies no oil:

1 – The pump is not primed.
2 – The oil level is too low.
3 – Excessively viscous oil.
4 – Broken pump shaft or driving joints.

C) The pump supplies no pressure:

1 The pump supplies no oil.
2 Pressure adjustment device not calibrated.
3 Pressure adjustment device remains open.
4 Oil leaks between circuit and tank
5 Worn out pump.

D) Pump noise:
1 – Air bells in the circuit.
2 – Excessively viscous oil, causing cavitation when suction takes place.
3– Wearing out of the driving joint between pump and engine
4 – Worn out pump.

7
E) Capacity and pressure fluctuations:
1 – Capacity adjusting devices flawed or badly set.
2 – Air in the circuit.
3 – Safety valves instability.

F) Oil overheating:
1 – Pump operating at excessive pressure
2 – The pump is worn out and internal leak take place
3 – Excessive leaks through the components
4 – Insufficient heat loss capacity in the exchanger.
5 – Excessively viscous oil.
6 – Constant overloading.

G) Leaks from gaskets:

1 – Abrasive material in the oil.
2 – Shaving or other external material in the oil
3 – Excessive operating pressure
4 – Adjustment flaw, flawed couplings.

H) The pump overloads the engine:

1 – Higher speed than specified.
2 – Excessive pressure value
3 – Clogged delivery pippin’s.
4 – The characteristics of the engine are unsuitable for the pressure and delivery demands.

I) Valve noise:
1 – Cursor is worn out.

L) Insufficient speed:
1 – Insufficient capacity (lowered pump performance).
2 – Low pressure.
3 – Excessive demand from other circuit components.

8
1.3a CAUSES OF POLLUTION IN THE HYDRAULIC FLUID

Solid impurity in the oil is the main cause for failures in hydraulic plants. It may cause
unforced damage; however it often leads to a constant wearing entailing a performance
reduction and damage that must be repaired.
If the fluid analysis reveals a remarkable pollution, the following causes may be considered:
- Careless cleaning and washing of the plant, or the machine was not cleaned before starting
up and after repairing it.
- Transport and storage in dirty, unsuitable places.
- Oil was not replaced.
- Dirty maintenance equipment.
- Missing filter cartridges, insufficient filtering level, clogged or faulty filters – clog gauges
missing or not considered.
- Insufficient outlet filter on the oil tank.
- Oil tank not sealed (piping connection or cleaning hatches not sealed, etc. )
- Metal or gasket particles coming from pumps, valve engines or cylinders.
- Rust particles coming from the tank cover
- Dirty leaking in through flawed gaskets (through the cylinder scraper ring).
- Leaked oil out was reintroduced into the system.

9
 1.3b CAUSES OF THE PRESENCE OF WATER IN THE HYDRAULIC
FLUID

The presence of water in the fluid causes wearing, pollution and corrosion in the plant,
modifying the oil characteristics and damaging the plant.
Causes of the presence of water in the fluid may be the following:

- Cutting fluid containing water leaking in.

- Rain or cleaning water leaking in.
- Condensation water following temperature variation and/or fluctuation of the oil volume
inside the tank.
- The regular drainage of sedimentation water inside the tank was not carried out.

1.3c CAUSES OF AIR IN THE HYDRAULIC FLUID

Air balls in the fluid may cause noise (cavitation), wrong movements and may damage the
plant. The following conditions may favour the creation and presence of air balls in the oil:

- Not suitable or dirty fluid.

- Undersized or wrongly built tank (reduced pause time, whirling in the return oil that is
reintroduced into the circulation).
- Depression areas are not air-proof (for example in the suction pippin’s, pumps, throttling
valves).
- Air balls may emerge if the pressure drops (for example owing to loops in the hoses and
pippin’s).
- Insufficient plant bleeding (during start-up, after repairing).
- The mesh of the filters is too thick or clogged before suction pippin’s.

10
1.3d CAUSES OF SURFACE FOAM IN THE HYDRAULIC FLUID

The presence of surface foam may cause the intake of foam through the pump or the spilling
of foam from the tank. The following conditions may cause excessive surface foam:
- Excessively dirt oil (dirt, water, oil by-products, protection products, solvents etc.).
- Errors in manufacturing of the tank.
- Excessive re-circulation speed.
- Splash plate not working or missing.
- Age

1.3e CAUSES OF EXCESSIVE EXTERNAL LEAKS

Leaks often require greater topping up of oil than required for oil replacement. Leaks are
expensive: e.g. 50 leaking areas leaking one oil drop every 5 seconds cause an annual loss of
approximately 10,000 litres of oil, not to speak of environmental pollution. The main causes
for leaks are the following:
- Piping connections not sealed.
- Insufficient checks and maintenance of the plant
- Cylinder and shaft gaskets are flawed.
- Difficult access to piping connections (thus hampering the search for and the elimination
of possible leaks).
- Hoses are flawed.
- Gaskets are not protected (for example scraper rings, bellows, sheet metal cover) against
dirt or metal shaving.

11
1.3f CAUSES OF OVERHEATING OF THE HYDRAULIC FLUID

As a rule the oil temperature inside the tank should not exceed 60° C in fixed plants and 70° C
in mobile plants. Excessively high oil temperatures shorter shorten the life of the fluid,
gaskets and hoses life, favouring the creation of residues and increasing wearing.
The causes of overheating include the following:
- Excessive capacity of pumps (excessive throttling).
- Undersized or flawed tanks.
- The cooler is missing, too small, badly set, dirty or its by-pass valve is open.
- Pippins are too small (small diameter).
- Maximum pressure valves were not calibrated correctly, they are dirty or flawed; the
pressure controller (pressure cut) was calibrated for a higher value than the safety valve.
- External thermal influence (sun, ovens, high external temperature, insufficient
refrigerating air).
- Air present in the oil (heat from compression).
- Excessively low oil level.
- Metal or pump gaskets, valves, engines or cylinders wearing out.
- Incorrect viscosity of the fluid may cause overheating involving not only the tank but also
the power pack.

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2) MAINTENANCE

2.1 GENERAL MAINTENANCE

HYDRAULIC PLANT
Hydraulic components generally do not need any special maintenance. Checks are to be
directed to fluid and filters.
Eliminating all process residues and impurity coming from the erosion of relative movement
components from the fluid is necessary.
Special care should be dedicated to the temperature, which has not to exceed 60°- 70° C.
During operation, the oil must be checked and replaced according to regular intervals
depending on operating conditions of the machine.
Considering a control subject to regular operating conditions, the following norms are to be
complied with as regards oil change and filtering:
- After the first 100 working hours verify that filters are clean and replace them if
necessary.
- Each 3000/5000 working hours in normal conditions, replace the full oil load.
Norms to be followed in such operations are the following:
- Never clean with cotton cloth or ragged cloth
- Unload the system, clean or change filters and carefully clean the tank if necessary.
- Fill the system with new oil.
- Operate load less machine, for minimum 30 minutes, making sure that oil circulates
everywhere.
- Cleaning the external core of the heat exchanger is paramount to the good performance of
the system. Remove all deposit before each start-up is.
All checks must be repeated regularly, especially regarding temperature, whose rising of
causes a very rapid deterioration of mechanic components and gaskets.
The fluid level is to be checked more frequently.
Noise is to be checked carefully, since it is the best sign of imminent or existing failures.

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2.1a MAINTENANCE OF HYDRAULIC FLUID

- If necessary top-up the fluid by using of a filter with the same filtering capacity (10 
absolute) of the operating filters.
- After a long not-operating period, drain possible condensation before starting up.
- Carry out additional filtering by a portable filtering device.
- Replace the not regular checked fluid every 1000-5000 operating hours, or at least once a
year after lab check. It is necessary to replace fluid according to shorter intervals if the plant
is subject to high temperatures.
- Also consider summer and winter operating conditions if the fluid does not cover both
temperature ranges so as to ensure optimum viscosity.
- Clean tanks every time the oil is replaced.
- Pour new oil only through a filter. The filtering capacity (10  in absolute terms) needs to
correspond to that of the operating filters. Portable electronic pumping and filtering devices
may also be used.

2.1b MAINTENANCE OF OIL FILTER

- Always replace the filter cartridge after starting up. The use of paper cartridges is
recommended for starting, since they can be cut and allow a precise analyse of the
cleanliness of the plant. If you have any doubt flux the plant.
- Regarding filters not periodically checked, replace every 500 operating hours. Paper
cartridges may not be cleaned, metal mesh filters may be cleaned only partially and have to
be sent to the manufacturer for this operation.
- Regarding filters undergoing automatic checks, cartridges must be replaced immediately at
the first warning sign and with hot plant.
- Analyse dirty cartridges; if pollution anomalies are spotted, identify causes. Checks must
always be carried out according to shorter intervals. You have any doubt, flux the plant.
- Filter cartridges must be stored in their original packing.

14
2.1c MAINTENANCE OF AIR FILTER

- Generally carry out maintenance along with oil maintenance.

- Particularly dusty and humid environments may require shorter intervals or a different
positioning of the group.
- The filtering capacity must correspond to the one of the oil filter.

2.1d OTHER MAINTENANCE POINTS

- Replace worn out components (gaskets, hoses).

- Points to be lubricated manually according provisions are: articulated shafts and clutch
connections.

REMARKS:

- Condensation in the tank causes an increase of the oil level; therefore the gauge displays
incorrect data.
- Note the oil type used to fill the tank on a plate.
- The leaked out oil is always dirty and must never be reintroduced into the tank.
- If the plant is repaired or modified, flux it, if necessary along with checking the filter
cartridges before starting up.
- During long distance and or maritime transport and temporary storage, unites must be
protected.
- Hydraulic plants, already started up, must be protected from corrosion if they do not
operate for long periods.
- At the time of start-up, protective products must be carefully eliminated ad all check and
maintenance intervals must be halved.

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3) DIPOSAL AND DISMISSAL PROCEDURE

INTRODUCTION
The machine is not polluting or dangerous for the environment; however during the
installation, maintenance and dismissal phases is produced waste, which in case of
incorrect disposition, may damage environment.
MAXIMUM ENVIRONMENTAL PROTECTION MUST BE STRIVED FOR.

USED MINERAL AND SYNTHETIC OILS

This is special waste to be sent directly or indirectly to the dedicated consortium.

DETERIORATED OR OBSOLETE MACHINES AND EQUIPMENT

This is special waste to be dismissed according to typology.

16
4) WARRANTY

HS.MARINE guarantees good manufacturing and quality of its Power-pack for 12 months
starting from the date of delivery to the installing staff.

During this period HS.MARINE commits itself (without any additional charge) to repair or
replace flawed components in its seat, without taking on responsibility for refunding indirect or
direct damages.

After examining the flawed components, that will have to be delivered carriage paid to its seat in
Italy , HS.MARINE is exclusively entitled to acknowledge or cancel warranty.

All necessary transfer, transport, labour costs for assembling and disassembling the power pack
are always customers’ duties.

WARRANTY IS CANCELLED if, during the after mentioned period, the products are:
- Stored in an unsuitable environment
- Repaired or modified by staff not authorised by HS.MARINE;
- Used or subjected to maintenance not complying with norms set by HS.MARINE;
- Overloaded or used for different tasks from those for which they were supplied;
- Warranty is cancelled if the customer is defaulting for any reason.

17
18
5) TABLE OF MINERAL OILS
Hydraulic fluids on a mineral oil basis for axial piston units

Table of mineral oils included in groups HLP(HM) and HVLP

to DIN 51524 , parts 2 and 3

ISO -
Viscosity VG 22 VG 32 VG 46 VG 68 VG 100
class

Maker HLP HVLP HLP HVLP HLP HVLP HLP HLP

ADDINOL Hydraulikòl Hydraulikòl Hydraulikòl Hydraulikòl Hydraulikòl

HLP 22 HLP32 HLP 46 HLP 68 HLP 100

Hydraulikòl Hydraulikòl Hydraulikòl

HVLP 32 HVLP 46 HVLP 68

AGIP OSO 22 OSO 32 OSO 46 OSO 68 OSO 100

ARNICA 22 ARNICA 32 ARNICA 46 ARNICA 68

ARAL Aral Aral Aral Aral Aral

Vitam Vitam Vitam Vitam Vitam
GF 22 GF 32 GF 46 GF 68 GF 100
Aral Aral
Vitam Vitam
HF 32 HF 46

AVIA AVILUB AVILUB AVILUB AVILUB AVILUB

RSL 22 RSL 32 RSL 46 RSL 68 RSL 100
AVILUB AVILUB AVILUB
HVI 32 HVI 46 Avia Fluid HVI 68
ZAD 46

BP Energol Energoi Energoi Energoi Energoi

HLP 22 HLP 32 HLP 46 HLP 68 HLP 100
Bartran Bartran Bartran
HV 32 HV 46 HV 68

CASTROL HYSPIN HYSPIN HYSPIN HYSPIN HYSPIN

AWS 22 AWS 32 AWS 46 AWS68 AWS 100
HYSPIN HYSPIN HYSPIN
AWH 32 AWH 46 AWH 68

COFRAN Cofraline Cofraline Cofraline Cofraline Cofraline

extra 22 S 32 S extra 46 S extra 68 S extra 100 S
Hydrolíne Hydroline Hydroline
Equigrade Equigrade Equigrade
32 46 68
Speziale 32 Speziale 68

DEA Astron Astron Astron Astron Astron

HLP 22 HLP 32 HLP 46 HLP 68 HLP100
Astron Z Astron Z Astron Z
HLP 32 HLP 46 HLP 68

19
Hydraulic fluids on a mineral oil basis for axial piston units

ISO -
Viscosity VG 22 VG 32 VG 46 VG 68 VG 100
class

Maker HLP HVLP HLP HVLP HLP HVLP HLP HLP

MOBIL Mobil Mobil Mobil Mobil Mobil

DTE 22 DTE 24 DTE 25 DTE 26 DTE 27

Mobil Mobil Mobil Mobil

Hydraulic Hydraulic Hydraulic Hydraulic
Oil Light Oil Medium Oil Heavy Oil Heavy
Medium
Mobil Mobil Mobil
DTE 13 DTE15 DTE 16

SHELL Shell Tellus Shell Tellus Shell Tellus Shell Tellus Shell Tellus
OI 22 OI 32 OI 46 OI 68 OI 100

Shell Hydrol Shell Hydrol Shell Hydrol Shell HydrolS hell Hydrol
DO 22 DO 32 DO 46 DO 68 DO 100
Shell Tellus Shell Tellus Shell Tellus
OI T 32 OI T 46 OI T 68

Shell Hydrol Shell Hydrol Shell Hydrol

HV 46 HV 46 HV 46

TOTAL Azolla Azolla Azolla Azolla Azolla

ZS 22 ZS 32 ZS 46 ZS 68 ZS 100
Equivis Equivis Equivis
ZS 32 ZS 46 ZS 68

TRIBOL Tribol 771 Tribol 772 Tribol 773 Tribol 775

Tribol ET Tribol ET Tribol ET

1140-32 1140-46 1140-68

Tribol Tribol Tribol Tribol

943 AW 22 943 AW 32 943 AW 46 943 AW 68

VERKOL Vesta Vesta Vesta Vesta Vesta

HLP 22 HLP 32 HLP 46 HLP 68 HLP 100
Vesta Vesta Vesta
HV 32 HV 46 HV 68

WINTERS- WIOLAN WIOLAN WIOLAN WIOLAN WIOLAN

HALL HS 22 HS 32 HS 46 HS 68 HS 100

WIOLAN WIOLAN WIOLAN WIOLAN WIOLAN

HX 22 HX 32 HX 46 HX 68 HX 100
WIOLAN WIOLAN WIOLAN
HV 32 HV 46 HV 68

SAE- SAE SAE SAE SAE SAE SAE

Motor Oils 5 W 10 W 10 W 30 10 W 30 20 W 20 30

20
Recommend Hydraulic oil specifications

We recommend to use the same oil utilised on the crane.

The crane is supplied with hydraulic oil type AGIP ARNICA 46, if not otherwise specified.

This is the only oil we authorise as it recorded the best results in a number of tests we performed.

Use the same make and type of oil when changing the oil.

! Do not mix oils of different types and characteristics, as this might cause abnormalities in
the hydraulic system and lead to component failure.

ATTENTION

If you cannot obtain AGIP ARNICA 46 hydraulic oil and are compelled to use another type of oil, it must
nevertheless comply with the following specifications:

Density at 15C 0.875 kg/l

Flash Point 210C

Pour point -38C

Kinematics Viscosity at 40C 46 mm2/s

100C 9 mm2/s

Viscosity index 175

! Contact the manufacturer if oils of other types and characteristics are to be used.

OBSERVER

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 HS.MARINE S.r.l.
Via G. Marconi , n° 33 - Loc.Commessaggio Inferiore ,
46018 SABBIONETA ( MN )- ITALY
Phone +39-0375-254819/Fax +39- 0375-255049
e.mail: info@hsmarine.net

www.hsmarine.net

22