140 - 210 bar > 210 bar 9 8 20/18/15 19/17/14 12 15 m 6 -- 12 m Pressure < 140 bar NAS 1638 Class 10 ISO 4406 Class 21/19/16 Ratio x = 75 25 40 m InstallationNotes Some general considerations should be made on the hydraulic system, in which the pump is to be fitted. Special attention should be given to hydraulic system design and assembly, especially to the intake, delivery and return pipes and position of system parts; valves, filters, tanks, heat exchangers and accumulators. Proper safety devices and reliable instruments to avoid fluid turbulence, especially in return pipe to the tank, and prevent air, water and foreign bodies from entering into the system are very important. It is also very important to equip the hydraulic system with a proper filtration unit. Before starting the system on a continuous basis, take some simple precautions: Check that the direction of rotation of the pump is correct with the drive shaft rotation. Check for proper alignment of pump shaft and motor shaft; it is necessary that the connection does not induce axial or radial loads. Protect drive shaft seal during pump painting. Check if contact area between seal ring and shaft is clean; dust could provoke quicker wear and leakage. Remove all dirt, chips and all foreign bodies from flanges that connect inlet and delivery ports. Ensure that intake and return pipes are always below fluid level and as far from each other as possible. Install the pump below head, if possible. Fill the pump with fluid, and turn it by hand. On first startup, set pressure limiting valves at minimum level possible. Avoid lower rotation speed than minimum allowed with pressure higher than P1. Do not start the system at low temperatures under load condi t ions or af ter long stops. Always avoid or l imi t load start ing to ensure longer pump l i fe. Start the system for a few minutes and turn on all components; bleed air from circuit to ensure correct filling. Check fluid level in the tank after loading all components. Gradually increase pressure, continuously check fluid and moving parts temperature, check rotation speed until you reach set operating values that shall be within the limits indicated in this catalogue. Cleaning and Filtering The System Most early failures of pumps are due to contaminated fluids. The extreme reduction of the tolerances required in the design of the pumps and therefore their operation with minimum clearances, are heavily influenced by contaminated fluid. Particles circulating in the fluid act as abrasive agents, damaging the surfaces they touch and increasing the quantity of contaminant. For this reason, ensure that system is perfectly clean during startup and keep it clean for this whole operating life. Necessary checks to limit contamination should be performed at regular intervals. Preventive maintenance is better than breakdownmaintenance! Preventive actions include: proper cleaning of the system during assembly, deburring, eliminating the welding scum and fluid filtering before filling up. Contamination level of system fluid should not exceed class 18/ 15 (ref. ISO 4406). Even fresh fluids might exceed this contamination level; therefore always pre-filter the fluid when filling up or topping up the system. Fit a proper tank; its capacity should be proportional to the volume displaced by the pump in one workingminute. Fluid contamination level check and correction during operation can be obtained through filters that retain the particles in the fluid. Two parameters tell which filter is most suitable: absolute filtering power and filtering ratio. Low absolute filtering power and high filtering ratio for small particles help ensure good filtration. It is then very important to limit not only maximum dimensions, but also the number of smaller particles that pass through the filter. It goes without saying that with an operating pressure increase and according to the system sophistication degree, filtering should become more and more efficient. The filtering system shall always ensure contamination levels do not exceed the values indicated below. Hydraulic Fluids Use mineral oil based hydraulic fluids that have good anti-wear, anti-foaming (rapid de-aeration), antioxidant, anti-corrosion and lubricating proprieties. Fluids should also comply with DIN 51525 and VDMA 24317 standards and get through 11 stage of FZG test. For the standard models, the temperature of the fluid should be between -20°C and +85°C. Fluid kinematic viscosity ranges are as follows: Minimum (short periods) 10mm²/s Maximum (cold start) 1000 mm²/s Recommended viscosity range 15 - 90 mm²/s Cast Iron Gear Pumps & Motors Installation Notes 2 #DriveLineHarmony www.jbj.co.uk/cast-iron-pumps-motors.html
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