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Installation and

Maintenance Manual
PAC

Installation and Maintenance Manual, Power Unit PAC

Preface

Preface
Hgglunds Drives is one of the worlds leading manufacturers of low speed,
high torque and heavy-duty hydraulic drive systems. We supply a durable
drive system that will work under the toughest conditions with a minimum
level of maintenance requirements. We have industrial and marine customers all over the world. They know that when they seek solutions, support or
service, they can trust Hgglunds Drives to be there. The Hgglunds Drives
main office and manufacturing plant is located in Mellansel, Sweden. In
addition, there are sales and service offices in 40 countries worldwide.

Our high quality drive systems are based upon our unique hydraulic piston
motors, which were developed through experience accumulated over 30
years in marine and industrial areas. Today this ongoing development work
has resulted in our PAC power unit product line. This is what powers our
drive systems. New, as well as established technical solutions contribute to
the creation of this product. The most desirable features and operating
reliability have been designed into this power unit, PAC.

This manual provides necessary information for installation and maintenance


of the PAC. In order to find particular information, just search for the applicable section as listed in the table of contents. However, changes in the
equipment may occur. Therefore, we reserve the right to introduce amendments in the manual, as we deem necessary without notice or obligations.

Before starting the installation and/or maintenance, the manual must be


read and thoroughly understood in all respects. All involved personnel shall
read and acknowledge the safety precautions that are stated in section 1.1.

Original AM326-1A 1999

The content in this manual is subject to change without notice or


obligation. Therefore, information contained herein should always
be confirmed with Hgglunds Drives or its representatives.

Installation and Maintenance Manual, Power Unit PAC

Contents

Contents
1. GENERAL ........................................................................................................................ 4
1.1 Safety precautions ........................................................................................................................4
1.2 Operating principle ........................................................................................................................6

2. TECHNICAL DATA ........................................................................................................... 7


2.1 Operating conditions .....................................................................................................................7
2.2 Cooling water ................................................................................................................................7
2.3 Requirements for hydraulic fluid cleanliness .................................................................................7
2.4 Choice of hydraulic fluid ................................................................................................................8
2.5 Power unit monitoring ...................................................................................................................9

3. HANDLING OF THE PACKED POWER UNIT ............................................................... 10


3.1 Storage of the packed power unit ...............................................................................................10
3.2 Lifting the packed power unit ......................................................................................................10

4. INSTALLATION .............................................................................................................. 11
4.1 Installation directions ..................................................................................................................11
4.2 Lifting methods and weights .......................................................................................................13
4.3 Positioning the power unit ...........................................................................................................14
4.4 Mounting of the cabinet feet ........................................................................................................14
4.5 Mounting of electric motor...........................................................................................................15
4.6 Mounting of air-oil cooler and cabinet ventilation ........................................................................16
4.7 Mounting of top cover..................................................................................................................17
4.8 Hydraulic connections .................................................................................................................17
4.9 Electric connections ....................................................................................................................18
4.10 Pipe work ..................................................................................................................................18
4.11 Extra filtration before start up ....................................................................................................21

4.12 Commissioning ........................................................................................................ 22


4.12.1 Prior to commissioning ...........................................................................................................22
4.12.2 Filling up the system with hydraulic fluid ................................................................................22
4.12.3 Initial start up procedure ........................................................................................................24
4.13 Pump settings and adjustments ................................................................................................26

5. PREVENTIVE MAINTENANCE ..................................................................................... 27


5.1 Maintenance log ..........................................................................................................................27
5.2 Maintenance chart ......................................................................................................................27
5.3 Filter change ...............................................................................................................................28
5.4 Inspection of hydraulic fluid .........................................................................................................29
5.5 Lubrication of electric motor ........................................................................................................30
5.6 Air breather change ....................................................................................................................30
5.7 Cleaning of Air-Oil cooler ............................................................................................................31
5.8 Power unit out of service .............................................................................................................31

6. CORRECTIVE MAINTENANCE .................................................................................... 31


6.1 Common .....................................................................................................................................31
6.2 Change of hydraulic pump/electric motor assembly ...................................................................32
6.3 Troubleshooting ...........................................................................................................................33

7. DISPOSING OF POWER UNIT ...................................................................................... 34

General

Installation and Maintenance Manual, Power Unit PAC

1. GENERAL
1.1 Safety precautions
It is of extreme importance that the safety precautions are always followed. If you are unsure about
anything, please contact your nearest Hgglunds Drives representative for advice.

Warning signs
In this manual, you will find the following signs, which indicate a potential hazard that can or will cause
personal injury or substantial property damage. There are three levels of hazard classification:

DANGER is used to indicate the presence of a hazard, which will


cause severe personal injury, death, or substantial property damage
if the warning is ignored.

DANGER

WARNING is used to indicate the presence of a hazard, which can


cause severe personal injury, death, or substantial property damage
if the warning is ignored.

WARNING

CAUTION is used to indicate the presence of a hazard, which will or


can cause minor personal injury or property damage if the warning is
ignored.

CAUTION

General
Limit access to the equipment only to authorized personnel. Only perform measures on the PAC when
you are completely familiar with the function of the power unit (including the control system) as well as
the complete drive.
Service and repair of the electrical, hydraulic, and the mechanical functions require professional service personnel who are aware of risks involved.
Safety equipment necessary for the prevention of accidents during the mounting and maintenance
must be used in accordance with the regulations prevailing in the local country.

Installation and Maintenance Manual, Power Unit PAC

General

Prior to troubleshooting

Use the order code and other attached technical documentation to identify the features of your
unique power unit and system.
Read the attached technical documentation (this manual included) and make yourself familiar
with the PAC (control system included) as well as the complete drive.
Use safety equipment like hard hat, protective goggles, safety shoes and hearing protection.
Always ensure that there is no accumulated energy in the system prior to maintenance.
Ensure that all electric power is off and locked out.
Ensure that there is no entrapped pressure in the hydraulic system.
Ensure that no pressure will enter the hydraulic system in the power unit via the hydraulic motor,
for example loads on the shaft or winch drum.
If the hydraulic system is used for lift devices such as elevators, winches, etc., these should be
secured, or in the rest position (hanging load).
Ensure that all accumulators are discharged.

Electricity supply
Safety equipment necessary for the prevention of accidents must be provided in accordance with the
regulations prevailing in the local country.
All electrical supply levels shall be within the limits that the equipment is constructed for, see technical
documentation and maximum rating plates.

Mounting
Carefully follow the instructions and be aware of the large weights and forces involved during lifting.
Incorrect mounting and setting of electrical, hydraulic and the mechanical components can cause
personal injury or property damage.

Before starting up
Before starting up new, rebuilt or serviced drive systems, all accessories and safety arrangement
functions need to be checked and tested.

Maintenance and service


Follow the maintenance intervals for your specific PAC or the maximum intervals on the maintenance
chart (section 5.2 Maintenance Chart) and keep a maintenance log. Regular and correct maintenance is necessary for reliable and safe operation.
Only use spare parts recommended and supplied by the Hgglunds Drives organization.

Hydraulic fluid
Be aware that most hydraulic fluids can cause personal injury and severe damage to the environment.
Check the caution sign on the container or consult the supplier. Used hydraulic fluid can contain
noxious contaminates. We recommend using the service of a professional oil company for supply and
disposal of used fluids. Never dump hydraulic fluid into water drainage or water supplies.

Bell housing
Note that there are rotating parts inside the bell housing during operation. Be careful during inspection
through the inspection hole. Replace inspection cover when finished.

Hot surfaces
Temperatures in the hydraulic system above 158 F (70 C) will create hot surfaces.

Emergency situations
Emergency shutdown: It has to be possible to turn off the electric power during an emergency situation. Only use a fire extinguisher that is approved for use on both oil products and electric equipment.
5

Operating Principle

Installation and Maintenance Manual, Power Unit PAC

1.2 Operating principle


Main components
1. Hydraulic pump
2. Drain valve
3. Sight glass
4. Charge pressure gauge
5. Servo pressure gauge
6. Main pressure gauge B port
7. Main pressure gauge A port
8. Air breather
9. Drain filter
10. Return filter
11. Electric motor
12. Filter switch
13. Suction valve limit switch
14. Charge pressure switch
15. Electrohydraulic stroker
16. Oil heater
17. Terminal box
18. Oil Cooler
19. Temperature switch
20. Level switch

18
20
19

17
11
7
5
4
6
13
9
12
15

8
6
4
5
7
3
12
14
15
10
16

10
1

13

Note: Changes from the picture and main


components table above may occur.

Function
The function of the power unit is to provide the hydraulic motor(s) (or other hydraulic systems) with the
required flow of oil and pressure at the right time. All included parts are assembled in one (or more)
compact cabinet(s). The PAC has one or more pumps driven by one or more electric motors. The
main pump is an axial piston pump with variable displacement for closed loop systems. The electric
motor is totally enclosed fan cooled. Two different control systems are available.

Control systems available


Spider: A small, compact and configurable control system. It can health monitor the power unit
and can control one or two pumps with three preprogrammed functions:

The PAC is a very flexible product with a wide range


of options. This makes it possible to select a standard power unit to fulfill the features needed in
many different applications. This installation and
maintenance manual is intended to cover all standard options. It may not cover all details on special power units, which differ from the standard
PAC concept.

Basic, for most of our drives can be configured for speed feedback control and power
limitation.
Shredder, for shredder applications.
Synchro, for friction and synchronized drives.

MCA: For special control functions, normally based


on PLC and control cards.

Note: It is also possible to control the PAC from


external control systems provided by the customer.

CAUTION

It is important to check the


other attached technical
documentation to identify
the features of your unique
power unit.

Installation and Maintenance Manual, Power Unit PAC

Technical Data

2. TECHNICAL DATA
2.1 Operating conditions
The standard PAC unit is designed for the conditions listed below. If the requirements are outside of
the conditions listed below, contact your Hgglunds Drives representative with your specific requirements for special design considerations.
Ambient temperature: Minimum 32 F (0 C) to a maximum 85 F (30 C).
Altitude: Maximum 3,300 feet (1000 m).
Classified Location: Unit is designed for a standard location. Units can be built for use in
classified hazardous locations. Contact your Hgglunds Drives representative for more details.

2.2 Cooling water


The cooling system is primarily designed to operate with clean water.
When there are particles in the water, larger than 0.02 in. (0.5 mm), a water filter must be used.
It is important to:

Maintain the water filter (if any) in a correct way, this is to get the required flow of water through
the water oil cooler.
Ensure you have the required flow, pressure and temperature of the cooling water (see attached
technical documentation).
Check the temperature in the hydraulic system, according to the maintenance intervals for your
specific power unit or the maximum intervals on the maintenance chart.
Clean the cooling system if the temperature in the hydraulic system is above the specified limits.
Clean and empty the cooling system (waterside) before periods of inactivity (especially if the
cooling water is not totally clean).
If cooling capacity is too low, the service life of hydraulic motor, the main
components in power unit, and the hydraulic fluid will be reduced.

2.3 Requirements for hydraulic fluid cleanliness


The PAC is equipped with filters on the drain and return line(s). In order to obtain rated service life it is
important to follow recommendations concerning cleanliness levels and maintenance requirements.

Cleanliness recommendations

The system must be flushed before start up (section 4.12 Flushing before start up).
When filling the tank with hydraulic fluid it is important to fill through the quick connection (section 4.13.2 Filling up the system with hydraulic fluid).
The particle contamination level in the system should not exceed ISO/DIS 4406 16/13 (NAS
1638, class 7).
The water content shall be <0.1% and in individual applications with high demands for service
life, <0.05%.
Always use filter elements recommended and supplied by the Hgglunds Drives organization.
The hydraulic fluid should be analyzed according to the special maintenance intervals for your
specific PAC or the maximum intervals on the maintenance chart (section 5.2 Maintenance
Chart). You should be particularly careful when removing equipment for repairs or maintenance
so that dirt cannot enter the system. Components should be cleaned and free of dirt prior to
disassembly.
Do not re use hydraulic fluid that has leaked out.
7

Technical Data

Installation and Maintenance Manual, Power Unit PAC

2.4 Choice of hydraulic fluid


The power unit is primarily designed to operate on conventional petroleum based hydraulic fluids.
Consultation with an Hgglunds Drives service representative is recommended when choosing your
hydraulic fluid.
The hydraulic fluid has to fulfill the following requirements:
Have FZG (90) fail stage minimum 11 described in IP 334 (DIN 51354).
Contain inhibitors to prevent oxidation, corrosion and foaming.
Have a viscosity within the prescribed interval for both PAC (see below) and hydraulic motor at
operating temperature (measured in the motor case).
Have a water content of <0.1% and in individual applications with high demands for service life,
<0.05%.
For other hydraulic fluids, please contact your Hgglunds Drives representative when:
You may need other seals within the pump and other components.
The service life, maximum pressure and maximum speed for the pumps may be reduced.

Viscosity limits
Recommended

RECOMMENDED VISCOSITY
at operating temperature 40150 cSt (187-720 SSU)

100 VI

Viscosity index VI For operation with large


temperature difference

150 VI

Minimum continuous

20 cSt (98 SSU)

Maximum continuous

150 cSt (720 SSU)

Maximum intermittent

Viscosity n

At cold start the maximum


permissible viscosity is 1600
cSt (7400 SSU) run with low
pressure and low flow.

40 cSt (187 SSU)

Minimum intermittent

1600 cSt (7400 SSU)

Temperature F (measured in the motor case)


50

100

150

200

150

720

Recommended
viscosity

100

40

187

Viscosity n SSU

Viscosity n cSt

1000

VG 100
VG 46

VG 150
VG 68

10
0

10

20

30

40

50

60

70

80

90

100

Temperature C (measured in the motor case)

!
WARNING

Check caution sign on container or consult the supplier.


Avoid prolonged contact of hydraulic fluid with your skin.
Use services of a professional oil supplier for disposal of used fluids,
and filter elements.
Never dump hydraulic fluid into drainage or water supplies.
Clean hydraulic fluid spills from floors immediately to prevent injury.
8

Installation and Maintenance Manual, Power Unit PAC

Technical Data

2.5 Power unit monitoring


If the monitoring function is not included in a control system supplied with the PAC, the following
function must be fulfilled in the system.

MONITORING SWITCHES

EXTERNAL FUNCTIONS

POWER UNIT
Maximum oil
Temperature switch

1
Minimum oil
Temperature switch

1
Minimum oil
level switch

1
Closed suction

STOP HYDRAULIC MOTOR

line switch

1
Low charge
pressure switch

1s

0s

Time delay off

0s 0.5s
5s

STOP ELECTRIC MOTOR

Time delay on

&

0s

Time delay on
Electric motor started

Warning oil
temperature switch

1
Low oil
level switch

1
Return filter
switch

Drain filter
switch

High pressure
switch

Time delay off

0s

5s

WARNING INDICATION

Time delay off

0s

5s

Time delay off

0s

5s

The monitoring of the power unit switches are grouped in two levels according to the above logic
diagram.
The warning indication is to inform about a problem in the PAC but does not need an immediate action.
The alarm indicates a need for stopping the pump. The stop sequence is to first stop the hydraulic
motor without ramp, by setting the pump swash angle to zero. Furthermore, after a short delay stop
the electric motor.
The low charge pressure switch must be interlocked during stop and start-up of the electric motor, to
avoid alarm and give the pump time to build up the charge pressure after start.

Technical Data

Installation and Maintenance Manual, Power Unit PAC

3. HANDLING OF THE PACKED POWER UNIT


3.1 Storage of the packed power unit
At delivery, the hydraulic components are protected internally by an oil film (containing rust preventing
additives). This provides sufficient protection for indoor storage in air conditioned premises for up to
12 months.
The PAC and included parts should be stored indoors, in dry, vibration free and dust free conditions. It
should not be stored for more than three months in non-air conditioned premises. (That also includes
parts belonging to the power unit that are delivered separately).
Place the power unit where it will not be exposed to direct sunlight or extreme cold to avoid condensation.
If storage time exceeds the above mentioned limits, then the power
unit must be operated so that the hydraulic system is lubricated with
new fluid. (section 5.8 Power unit out of service)

3.2 Lifting the packed power unit

The packed power unit is labeled with center of gravity and weight.
Normally the power unit package is designed for forklift truck
handling.
Center of gravity label

!
CAUTION

Center of gravity is high, see label on the power unit.


Avoid rapid acceleration, deceleration and turns while
moving the equipment.
Position the forks according to the instructions below.

Lifting with fork lift

The absolute minimum required fork length is 51.2 in. (1300 mm).
The minimum distance between the forks is 31.5 in. (800 mm) for a 2 door PAC and 43.3 in.
(1100 mm) for a 3 door power unit.
Position forks with regards to the center of gravity.

Parts that are delivered separately

The package is always labeled with the weight.


Packages on shipping skids are designed for forklift truck handling only.
Some other packages may be lifted with a lifting crane, always check the label on the package.

!
DANGER

Do not stand underneath hanging load.


Use only lifting equipment adapted to the weight on the
label of the package.

10

Installation and Maintenance Manual, Power Unit PAC

Installation

4. INSTALLATION
4.1 Installation directions
If the PAC is to work properly, it must be installed in accordance with these instructions. The conditions
the unit will operate in must be taken into consideration.
Improper installation, not following the instructions in this manual and in the attached technical documentation, may affect the function and/or the service life of the power unit. It is important that the
safety precautions mentioned in this manual are always followed.

In order to achieve air circulation requirements, you should never


place the power unit directly against a wall or similar obstruction. If
this is the case then contact your Hgglunds Drives representative.

H1

PAC 200D/400D/600/800

H1

PAC 100/200/300/400

A2

B1

B2
H2

H2

B2

A1

B1

A3

Cabinet Size
Type
Dimension

1
PAC 100
PAC 200

PAC 400D

PAC 400

PAC 200D

PAC 300

PAC 600

5
PAC 800

H1

89 in. (2261mm)

89 in. (2261mm)

99 in. (2515mm)

99 in. (2515mm)

H2

1/2 in. (13mm)

1/2 in. (13mm)

1/2 in. (13mm)

1/2 in. (13mm)

3 in. (76mm)

B1

55 1/8 in. (1400mm)

80 3/4 in. (2051mm)

66 in. (1676mm)

105 in. (2667mm)

121 3/4 in. (3092mm)

B2

51 1/8 in. (1299mm)

76 in. (1949mm)

62 in. (1575mm)

100 in. (2540mm)

117 3/4 in. (2991mm)

A1

39 3/8 in. (1000mm)

39 3/8 in. (1000mm)

53 1/4 in. (1353mm)

53 1/4 in. (1353mm)

53 1/4 in. (1353mm)

A2

35 3/8 in. (899mm)

35 3/8 in. (899mm)

49 1/4 in. (1251mm)

48 1/2 in. (1232mm)

48 1/4 in. (2526mm)

A3

82 5/8 in. (2099mm)

82 5/8 in. (2099mm)

81 1/2 in. (2070mm)

81 1/2 in. (2070mm) 103 1/4 in. (2623mm)

5/8-13 UNC

5/8-13 UNC

5/8-13 UNC

11

5/8-13 UNC

106 1/2 in. (2705mm)

5/8-13 UNC

Installation and Maintenance Manual, Power Unit PAC

Installation

Placing the power unit


Take into consideration the following when placing the PAC unit:

Place on a firm level foundation to avoid vibrations.


To ease maintenance and service (section 4.3 Positioning the power unit).
Protect from weather, airborne sprays, heavy contamination and radiated heat.
To ensure proper ventilation for cooling purposes and for the electric motor and air-oil cooler.
To minimize pipe runs.

Clamp each pipe in the pipe run separately and attach it to a firm foundation to avoid vibration. The
main connections from the PAC must always be fitted to the piping with hoses.

!
CAUTION

If air-oil cooler is mounted at a location other than on


the power unit, beware that the cooler will start without notice and has sharp edges.

OIL

OIL

OIL

OIL

OUT

IN

OUT

IN

REMOVE SIDE PANELS

When units are installed side by side, the side panels must be removed.
This makes it possible to perform service on the power unit.

12

Installation

Installation and Maintenance Manual, Power Unit PAC

4.2 Lifting methods and weights

Electric Motor
Power HP (kW) Weight* lb (kg)
30 (22)

The total weight of the power unit is stamped


on the rating plate located on the Junction box
door inside the cabinet.

365 (165)

40 (30)

490 (222)

50 (37)

560 (254)

60 (45)

800 (363)

75 (56)

Lifting with ropes and/or chains

840 (380)

100 (75)

1160 (526)

125 (93)

1540 (698)

150 (112)

1730 (785)

Lifting with fork lift

200 (149)

1750 (794)

250 (186)

1925 (873)

300 (224)

2500 (1134)

350 (261)

2650 (1202)

400 (298)

3500 (1587)

450 (336)

4300 (1950)

Lift the PAC with no top cover on, maximum lifting angle 90.

The absolute minimum required fork length is 51.2 in. (1300 mm).
The minimum distance between the forks is 31.5 in. (800 mm) for a 2
door power unit and 43.3 in. (1100 mm) for a 3 door power unit.
Position forks with regards to the center of gravity.

*This is the weight for a


standard electrical motor,
more accurate weight for
a specific motor can be
found on the rating plate.

Denison Pumps
Model
P6S

Weight lb (kg)
335 (152)

P7S

753 (342)

P30S
A

484 (220)

P24S

484 (220)

P14S

335 (152)

P11S

786 (357)

Air-Oil Cooler
Size

Weight lb (kg)

AOVH-30

Always use all four lifting points when


lifting the power unit.

190 (86)

AOVH-40

350 (159)

!
DANGER

221 (100)
296 (134)

AOL-1600

AOL-950
AOL-1200

355 (161)

Do not stand underneath a hanging load.


Use only lifting equipment adapted to the weight of the power unit
(check rating plate inside the cabinet).
Center of gravity is high, see label on cabinet.
Do not lift the power unit with hydraulic fluid in the tank, or with the
front bar disassembled.

13

Installation and Maintenance Manual, Power Unit PAC

Installation

4.3 Positioning the power unit


The following minimum space must be left around the PAC, to ensure proper ventilation and provide
sufficient working space for easier maintenance. Heavier maintenance such as changing the pump/
motor assembly will demand larger working space.
The PACs may not be installed side by side without the facing side panels being removed.
It is important that all pipes for both water and hydraulics are mounted properly to allow for sufficient
working space for maintenance.

PAC 100/200/300/400

PAC 200D/400D/600/800

FLOOR OUTLINE WITH AIR COOLER

FLOOR OUTLINE WITH AIR COOLER

8 [203mm]

8 [203mm]
FLOOR OUTLINE WITHOUT AIR COOLER

FLOOR OUTLINE WITHOUT AIR COOLER

32 [813mm]

32 [813mm]

36 [914mm]

32 [813mm]
32 [813mm]

32 [813mm]

40 [1016mm]
40 [1016mm]

REF. FLOOR OUTLINE


DISTANCES SHOWN ARE MINIMUM

REF. FLOOR OUTLINE


DISTANCES SHOWN ARE MINIMUM

4.4 Mounting of the cabinet feet


The cabinet feet (optional) minimizes the vibrations and makes it easier to level the PAC. They are
delivered separately within the cabinet and have to be mounted according to the following instructions:

WARNING

14

1
2

Be careful while mounting the


cabinet feet. Follow the safety
precautions in section Lifting
methods and weights

1-1 1 ADJUSTABLE
2

1. Mount the cabinet feet before filling hydraulic fluid in the tank.
2. Mount the cabinet feet before installing the electric motor(s), if they are delivered separately or
supplied by the customer.
3. Lift the power unit according to instructions in this manual (section 3.2 Lifting the packed power
unit). Be sure to follow the safety precautions.
4. Mount the cabinet feet according to the drawing below.
5. Level the PAC by the adjusting screws.

Installation

Installation and Maintenance Manual, Power Unit PAC

4.5 Mounting of electric motor


In certain cases the electric motor(s) are delivered separately. The following instructions are applicable for these cases only.

1. Remove the top cover from the power unit


Loosen the screws that keep the top cover on the frame. Mount lifting eyebolts in their holes on the
corners of the top cover, and lift the top cover away. If range of lift is insufficient, front panel and front
beam of the power unit can be removed.

2. Remove the sound baffle


Take the sound baffle off and put it in a place where it cannot be damaged. When putting back, the
insulation material must be turned upwards.

3. Unpack the electric motor(s)


Unpack the electric motor and check it for external damage. Also, check that all rating plate data is the
same as in the attached technical documentation.

4. Check the shaft coupling(s)


Check that the axial shaft coupling clearance is in conformance with the coupling manufacturer specifications.

5. Lift the electric motor


First, use the top mounted lifting ear and lift to position the electric motor vertically. Then lift with all
lifting ears. Never let the electric motor stand on the shaft coupling.
Two different types of lifting equipment may be needed in order to lift the electric motor.

6. Mount the electric motor in the power unit


Lift the electric motor into the PAC. It is important that it is hanging perpendicular. Fit the shaft
coupling through inspection hole into the nylon star coupling without causing any damage to it. The
connection box on the electric motor must be positioned as shown in the picture on page 6 (section 1.2
Operating principle). Lower motor to a position approximately 0.2 in. (5 mm) above bell housing.
Place greased bolts in the holes and tighten by hand.

7. Tighten bolts to the bell housing


Inspect that there is an axial clearance on the shaft coupling through the inspection hole in the bell
housing, and then tighten the attached bolts to the bell housing.

8. Assemble top cover and sound baffle


Assemble in reverse order according to point 1 and 2.
When the top of the electric motor is below the sound baffle, a piece of thin sheet aluminum must be
formed into a cylinder or a hexagon and be placed over the fan cover. It must be secured to the heat
shield by way of rivets to allow the electric motor to draw in cooling air from the area above the heat
shield (the area where the cooling air inlet is located).
The hole in the sound baffle must be located straight above the electric motor and be slightly smaller
than the cross section of the fan cover.
For connection of electric motor refer to page 18 (section 4.9 Electric connections).

DANGER

Do not stand underneath a hanging load.


Use all lifting ears when the electric motor is hanging free.
Use only lifting equipment adapted to the weight on the rating plate.
No hands/fingers between electric motor and bell housing during assembly.
15

Installation

Installation and Maintenance Manual, Power Unit PAC

4.6 Mounting of air-oil cooler and cabinet ventilation


Normally the air-oil cooler is delivered separately and is to be mounted on the power unit. The following instructions are applicable for these cases only. (Changes may occur from the drawing and/or
technical documentation.)

Mount brackets with attached screws (in the drilled holes) on the PAC according to the installation drawing in attached technical documentation.
Lift up air-oil cooler. Never lift with the electric motor.
Mount the air-oil cooler on the brackets with the attached screws.
Check that all screws are properly tightened.
Connect the attached hydraulic hoses. Note that Oil In at the power unit shall be connected to
Oil Out at the air-oil cooler and vice versa. The coupling protections must be kept on until final
assembly to avoid the entrance of dirt.
For electric connections, couplings and hoses, see respective section.
Air-oil cooler must always be connected with flexible hoses.
1 1/4" JIC 37 FLARE

1 1/4" JIC 37 FLARE

RECOMMENDED ELECTRICAL
PENETRATION

RECOMMENDED ELECTRICAL
PENETRATION

OIL

OIL

OIL

OIL

OUT

IN

OUT

IN

AIR
FLOW

AIR
FLOW

RUBBER FLAP
A

RUBBER FLAP

1 1/4" SAE

1 1/4" SAE

Note: There must be an opening in the lower


edge of the rubber flap, to allow the cooling air
from the electric motor fan to exit.

DANGER

Beware of airborne particles in


the outgoing air flow
If the air-oil cooler becomes
loose it can cause severe personal injury.

Dimensions in (mm)
Cabinet size

Power unit

Cooler ports
A

Motor drain port

PAC 100/200

PAC 200D

PAC 300/400

59 3/8" (1508) 54 5/8" (1387)

PAC 400D/600

62 5/8" (1591) 57 7/8" (1470)

PAC 800

74 3/8" (1889) 69 3/8" (1762) 82 3/4" (2102) 17 5/8" (448) 10 1/2" (267)

48 5/8" (1235) 43 7/8" (1114) 71 1/2" (1816) 15 1/4" (387)

Cooler Connections
OIL IN & OIL OUT

5" (127)
1 1/4" JIC 37 male flare

75 1/2" (1918) 19 3/8" (492)

16

6" (152)
1 1/2" JIC 37 male flare

Installation and Maintenance Manual, Power Unit PAC

Installation

4.7 Mounting of top cover


If the power unit is placed outdoors, the top cover should be sealed using sealing strip. Do not use
glue to seal the top cover! It is recommended that you place the unit so the air intake is turned away
from dusty environments.

NO GLUE!

4.8 Hydraulic connections


During mounting of the hydraulic connections the following points must be kept in mind:

The coupling protections must be kept on until final assembly.


It is important that all pipes are properly mounted to allow for sufficient working space for maintenance of the PAC.
Always use hoses to connect pump with piping.
Professional service personnel aware of risks involved must perform all measurements in the hydraulic system. Be especially cautious when connecting the A and B connections (high pressure).

Denison Pump
Main A & B
Size
Connections *
P6/P7
P11/P14
P24/P30

!
DANGER

Threaded holes **
Thread

1 1/2"

5/8-11 UNC

2"

Depth

3/4-10 UNC

Do not make any


measures or perform
maintenance if the
hydraulic system is
pressurized.

*SAE-flange J 518, code 62, 414


bar (6000 psi) 90 connections
have to be used.

1.06 in. (27 mm)

Cabinet
size
1
2
3
4
5

17

** 4 screws needed/connection,
preferably with Grade 8 cap
head bolts.

Power Unit

Dimension connection
Drain line
Flushing

PAC 100/200
PAC 200D
1 1/4" SAE
1" SAE female
PAC 300/400
code 61 flange
PAC 400D/600
PAC 800

Installation and Maintenance Manual, Power Unit PAC

Installation

4.9 Electric connections


Safety precautions

All electric equipment is intended to be installed and used by qualified personnel who are familiar with relevant safety requirements.
Safety equipment necessary for the prevention of accidents at the mounting and operating site
must be provided in accordance with the regulations prevailing in the local country.
Grounding shall be carried out according to local regulations before the electric equipment is
connected to the main voltage.
All electrical supply levels must be within the limits that the equipment is constructed for, see
technical documentation and maximum rating plate.

Junction box
Connect the cables on the screw terminals inside the junction box. Make the connections according to
the electrical drawing in the attached technical documentation.

Air-oil cooler
The voltage and connection are stamped on the rating plate. Connect the electric motor to the electrical supply. Check direction of rotation, see air stream arrow in section 4.6.

Electric motor
Major voltage connection according to designation on the rating plate.

4.10 Pipe work

Installation of electrical equipment must in most


countries be installed by licensed electricians
(reference local laws and regulations).

DANGER
When sizing hoses and hydraulic piping between the motor and the power unit, a safety factor of at
least 4 times the maximum system pressure should be used for the tensile strength. Keep in mind that
the equipment may be readjusted to higher pressure in duty. Pressure losses in the pipe system
should generally be kept to a minimum but there are exceptions in certain applications. Contact a
Hgglunds Drives service representative for more information.

Hydraulic pipes
The hydraulic pipes should be of high-grade steel as per ISO 3304, DIN 2391/C or ANSI/B93.4.

Pressure test
A pressure test to 1 1/2 times the maximum working pressure should be performed on the main lines
to check for possible leakage.
Pressure tests on the main lines are best carried out using a hydraulic hand pump.

Hoses
To avoid damage caused by vibrations it is important that the PAC and the motor be connected to
pipes by means of hoses.
The hoses must be short and have the smallest possible diameter in order to obtain a small compression volume. Nevertheless, allowance must be made for the minimum permissible bending radius
according to the data provided by the supplier of the hose. Allowance must also be made for the flow
velocities listed under Pipe sizes.

Pipe flushing
The piping system must be flushed with an adequately sized flushing pump prior to starting up the
PAC unit to remove contamination introduced during assembly and/or welding. Please contact a
Hgglunds Drives service representative for proper cleaning and flushing procedure.
18

Installation

Installation and Maintenance Manual, Power Unit PAC

Pipe sizes
It is important that lines between the main connections of the motor and PAC are as short as possible.
This gives the following advantages:
1. Small compression volume in the hydraulic system.
This is particularly important in hydraulic systems with large and rapid load variations, and in
drives, where high speed accuracy is essential.
2. Small power losses in the hydraulic system.
3. Lower installation costs in that smaller pipe sizes and shorter pipe lengths can be used.
For a normal hydraulic system, the total pressure drop in the pressure and return line must
not be more than 5 percent of the normal working pressure.
The following flow rates are recommended values and should not be exceeded:
Main lines 15 ft/s (4.5 m/s)

Drain lines 5 ft/s (1.0 m/s)

4. Lower noise level.


In certain systems, where very small compression volumes are required, higher flow rates
are acceptable with possible increase in noise. Contact Hgglunds Drives representative in
these specific cases.
When dimensioning hose and pipe lengths between the drain connections of the motor and the PAC,
keep in mind that the total pressure drop to the drain connections of the motor must not exceed 14.5
PSI (1 bar). The pressure drop through the PAC is 7.25 PSI (0.5 bar).

Pipe couplings
It is essential that a tight and pressure rated coupling is chosen.
The following types of coupling are recommended:

Non-welded couplings are preferred


Non welded couplings provide the most clean piping installation as compared to a welded pipe system.

Welded couplings (socket or butt type)


When using welded couplings, the pipes should be machined, normalized, and pickled. The pipes
must then be brushed, rinsed internally and blown clean before flushing.

Pipe coupling
Type collar coupling as per SAE J 514.

Pipe clamps
Pipes should be clamped with uniformly spaced clamps.
The distance between the clamps may not exceed 6 ft (2 m) for pipes with outside diameters between
1/2 in. (15 mm) and 1 1/2 in. (38 mm). The distance between the clamps may not exceed 9 ft (3m) for
pipes with outside diameters greater than 1 1/2 in. (38 mm).
In addition, the pipes must be clamped immediately before and after a bend. The pipes must be
clamped immediately before transition to a hose as well.
The pipe clamps shall be secured to a stable and non-vibrating surface such as concrete structure.
The pipe clamps must be of a type permitting a certain amount of axial and radial motion in the
clamped joint and have good vibration-absorbing properties.

19

Installation and Maintenance Manual, Power Unit PAC

Installation

Storage of included components


The included components must be stored in the same way as the power unit (section 3.1 Storage of
the packed power unit). Notice that the packing must not be removed during storage.

!
DANGER

Do not work on the pipe system if the hydraulic system is pressurized.


Use necessary safety equipment during installation of the pipe system.
Usual safety requirements for each step must be followed.

Handling of fittings
Inspect the sealing surfaces on the couplings visually before mounting. It must be free of any damages such as scores and cracks. Handle the couplings with care. If you drop the coupling or it has
nicks on it inspect it visually. Check that the sealing (if any) is in its right position, free from cracks and
that it is saturated with oil.
The protection and packing on the fittings must be kept on until final assembly.

Flange fittings

Clamps

The screws must be tightened crosswise.

The normal distance between clamps:

JIC-fittings (SAE J514, ISO 8434)

Pipe diameter less than 1 in. (25.4 mm)


space clamps 60-80 in. (1524-2032 mm)
apart.
Pipe diameter greater than 1 in. (25.4 mm)
space clamps 80-100 in. (2032-2540 mm)
apart.
The pipes must be clamped immediately before
as well as after a bend and immediately before
transition to a hose.

Tighten fittings by hand, then tighten 1/4 to 1/2


turn more using an appropriate wrench. Do not
over tighten the fittings.
Use correct size tools, fittings can be damaged
and difficult to remove.
Be aware that all fittings may expand because of
heat and vibrations. All fittings must be checked
and retightened.

Welded fittings
Contact your Hgglunds Drives representative.

Correct

Mounting of hoses
Ensure that hoses are not stressed or twisted on
installation, to prevent premature failure. Bend
radius should conform to manufacturer recommendations.

Pressure tests
Pressure tests should always take place before
flushing in order to release contamination by
stresses introduced by the pressure. The main
lines must be pressure and leakage tested to a
static pressure of 1 1/2 times the maximum expected system pressure (not above bursting pressure). The hydraulic motor and power unit must
be disconnected or protected by closed valves
during the pressure tests.

Incorrect

Cleaning
The pipes and hoses should be pre-cleaned, inspected and sealed by the supplier. If the pipes
are field bent and installed the overall system must
be flushed to reach the required cleanliness level.

20

Installation

Installation and Maintenance Manual, Power Unit PAC

Example of a pipe installation which


is convenient and could easily be
sound insulated

4.11 Extra filtration before start up

HYDRAULIC MOTOR

A pressure filter and check valve has to be connected to the main line at the power unit. This
filter is connected on the return side of the drive
pump.

Hoses
connected
together

Recommended filtration degree 10 = 75 or better.

Flow Direction

The size of the filter should be matched to that of


the pump concerned, so that the pressure drop
across the filter is not excessive and that the maximum pressure/flow ratings for the filter is not exceeded.

Filter
Check valve

The main lines should be connected together at


the motor enabling the entire system to be filtered,
see the figure to the right.
The maximum flow from the power unit should be
filtered through the main circuit for at least two
hours on small installations and considerably
longer on larger ones.

POWER UNIT

Use extreme caution to ensure pump is stroked in


synchronization with free flow direction of check
valve.

Use a check valve sized for the oil flow.


When using the main pump the maximum
pressure should be reduced.

21

Installation and Maintenance Manual, Power Unit PAC

Installation

4.12 Commissioning
4.12.1 Prior to commissioning

Read and understand this complete manual and the other attached technical documentation.
Visually check the whole system for signs of damage, incorrect circuitry, security of foundations,
and that the degree of filtration of the filters are according to the data in the technical documentation.
Check that the coupling between the electric motor and pump is properly mounted.
Check that the pre charge pressure in the accumulator (optional) is in accordance with the
technical documentation.

Cleanliness

The hydraulic system must be flushed and thoroughly cleaned on the inside.
If you are uncertain about the cleanliness of the system, it must be checked prior to filling with
oil.

Pipe work

Are the couplings properly tightened?


Is the pipe work properly cleaned?
Is the pipe work mounted free of stress?
Are the lines in accordance with installation drawing/piping plan?

Electrical System

Check that electric motor(s) and control system and other electrical components are connected
to the correct voltages.
Check the function of electrical components and monitoring system manually. Instruments that
cannot be actuated can be checked for correct wiring and possibly operated manually. Level
switch and indication should be checked when filling the tank.

4.12.2 Filling up the system with hydraulic fluid


Before filling

Check that the correct type and quality of


hydraulic fluid is used. Do not mix different
types of hydraulic fluid without first checking
with manufacturers.
Check that the barrel with hydraulic fluid and
tank/hoses are not contaminated with water
or other substances.
Follow instructions for handling of couplings
and hoses (section 4.10 Pipework).
Plug the drain connection D (motor) to
prevent non filtered fluid being filled into the
hydraulic motor case, when filling the system
the first time.
Fill the pump case with filtered hydraulic oil
through the D1 port on the pump. When
finished filling the pump case, replace the
plug/hose connected to the D1 port.

'D1' DRAIN
PORT

22

Installation

Installation and Maintenance Manual, Power Unit PAC

Filling
Use a fluid filling pump unit, which has a filter with a filter rating of 10 microns, or better.
New fluid is normally not filtered and will introduce dirt into the system, the
fluid must therefore always be filled through a filter. Never pour hydraulic
fluid into the tank through the air breather filter.
Always pump the fluid in through the quick connection that is marked appropriately. The quick connection is a completely rustproof quick release coupling, see figure below. The fluid filled into the system
will be filtered through the drain filter for better results.
The tank must be filled with oil to 0.79 in. (20 mm) below the maximum level on the visual level gauge
on tank before starting for the first time.
Check the function of the level switch and indication during filling up of the tank.

ON FILL HOSE

System is full when


hydraulic fluid is at 5/8
up into the sight glass

ON POWER UNIT

RETURN FILTER

OIL FILL
CONNECTION
PUMP/MOTOR CASE
DRAIN FILTER

OIL HEATER

After filling the system with fluid, open the drain line and reconnect the drain line from the hydraulic motor.

!
WARNING

Check caution sign on container and the warnings (section 2.4 Choice
of hydraulic fluid).
Avoid prolonged contact of hydraulic fluid with your skin.
Clean hydraulic fluid spills from floors immediately to prevent personal
injury.
23

Installation and Maintenance Manual, Power Unit PAC

Installation

4.12.3 Initial start up procedure


Important Note!

Make sure the driven system and driven machine is ready to run, warn all personnel in the area
that start up is in progress.
Follow safety precautions in this manual (section 1.1 Safety precautions).
Never operate the power unit with defective instruments or control elements.
Keep flammable materials away from the power unit.
During start-up period, the hydraulic system will be filtered to remove dirt particles, therefore
keep an eye on the filter indicator during the entire start up procedure.

On cold start up, the filters may indicate bypass. After a few minutes of operating, press down the
visual indicator to reset. If the indicators will not reset after system has reached operating temperature, filter element must be inspected and changed.

STEP 1

Immediately before starting

Check fluid level in the tank and refill to about 0.79 in. (20 mm) below maximum level at visual
level gauge on tank (section 4.12.2 Filling up the system with hydraulic fluid).
Check if any components need filling with clean hydraulic fluid, such as the pump case and
motor case.
Check safety equipment.
Check that all the prescribed steps (section 4.12.1 Prior to commissioning) have been carried
out.
Make sure that all valves on the suction, pressure and inlet side of the pump, as well as any
valves on drain lines, are open.
Check that cooling water is connected and turned on if a water-oil cooler is used.

For adjustments and settings on the control system (if any) see separate instruction in attached technical documentation.

STEP 2

Start with unloaded pump at short intervals

Starting of the PAC shall be carried out with a completely unloaded pump in short intervals.

When the hydraulic fluid is cold, some restarts may be needed in order to raise the charge
pressure.
Check that the charge pressure corresponds with data and settings on attached technical documentation.
If OK, the pump may be allowed to come on stroke and introduce flow into the unloaded hydraulic system.
Flow and pressure should be limited until lines are purged of air.

Check that the charge pressure is still OK.

Immediately make sure that the


pump has the correct direction
of rotation. Otherwise, the
pump will be damaged. The
correct direction of rotation is
evident from a sticker placed
under the electric motor, see
figure to the right.

ROTATION

24

Installation

Installation and Maintenance Manual, Power Unit PAC

STEP 3

Unloaded pump at longer intervals

Run for a period at no load condition until system is stable and control is established. Checking of the
oil level may be needed due to parts of the system having been filled with fluid.

Check all interlocks.


Check fluid level in the tank
Check for unusual noises or vibrations.
Check that the specified pressure level for charge pressure at the PAC is maintained in accordance with the values stated on the hydraulic diagram in the attached technical documentation.
These pressure levels are preset at the factory and there is normally no need to readjust.
Check for leakage points.
Stop the electric motor.
Correct any faults discovered in the points above.
Check all connections, screws etc. and tighten if necessary.
Restart when finished.

STEP 4

Loaded hydraulic system

The hydraulic system can be loaded when the hydraulic system function is satisfactory in unloaded
running condition.

Gradually increase load pressure until proper operation is obtained.


It may be necessary, at this point, to make adjustments to flow, ramp rates, etc.
Cycle the system until normal operating temperature is reached.

STEP 5

Check for unusual noises or vibrations.


Check the function of the safety equipment.
Check temperature in tank and closed loop. Check also that the cooler control is stable. If not,
investigate water supply, controls, air cooler, etc.
Check for leakage points.
Check that the pump compensator pressure control and pressure switches (optional) are set at
levels appropriate to the specific drive. Upon delivery, these pressure levels are set at the levels
specified by the customer and normally no readjustment will be necessary. The values are
stated in the technical documentation. System compensator can easily be checked by closing a
ball valve on the high pressure leg and stroking the pump until the pressure is showing on the
gauge.
The working pressure must be checked to ensure that they correspond to the specified values.

STEP 6

Checking

Stop the electric motor

Correct any faults discovered while performing the points of Step 5.


Check the filter indicator. It is not unusual to change elements on commissioning as the system
is cleaning the dirt particles out. When changing filter elements carefully follow the instructions
(section 5.3 Filter change) to prevent introduction of dirt into the system. If there is still dirt in
the system, additional flushing is necessary in order to prevent premature failure of system
components.
Check all connections, screws etc. and tighten if necessary.
Remove waste fluid, scrap cabling, etc. to keep the area in and around the unit clean.

25

Installation

Installation and Maintenance Manual, Power Unit PAC

4.13 Pump settings and adjustments


Denison Gold Cup pump

!
DANGER

P6S, P7S, P11S & P14S

Working in high pressure areas


could be dangerous in case of
unforeseen failures.

P24S & P30S

CHARGE PRESSURE
ADJUSTMENT
COMPENSATOR
VALVE

CHARGE PRESSURE
ADJUSTMENT

View from the back

View from the back

Front view

Charge pressure and Pump compensator pressure level are set before the PAC leaves the factory and
consequently there is normally no need for readjustment. Always check the pressure levels in technical documentation. Professional service personnel familiar with the functions and risks involved with the pump must perform setting of pressures on the pump(s). The pressures shall be
set during operation and with the system at operating temperature. Note that pressures can change
with different viscosity.
1. Charge pressure adjustment: Remove acorn nut, loosen lock nut and adjust pressure with a
5/32" size Allen key. Clockwise adjustment will increase the pressure. The charge pressure (on
the charge pressure gauge) shall be within the following limits: 218 psi (15 bar) for P6S/ P7S &
P11S/P14S & P24S and 261 psi (18 bar) for P30S.
If other charge pressures are to be set, contact Hgglunds Drives representative for consultation.

2. When charge pressure is set: Tighten lock nut and return acorn nut. Note in the logbook or
other technical documentation.
3. If the main pressure levels are to be increased: Make sure that the piping and machine
structure can take higher pressure/higher torque delivered from the hydraulic motor.
4. Compensator pressure adjustment: Dead head the pump, then activate or move the input
signal to the control so that pressure increases in the high pressure closed circuit to the pressure limiter setting. The pressure limiter setting is reached when the pressure stops increasing
and remains steady at a given pressure level. (As shown on the gauges)
The pressure limiter setting for both A- and B-side is set on the compensator valve.

Remove acorn nut, loosen lock nut and adjust pressures with a 5/32" size Allen key, until the desired
pressure level is established. Clockwise rotation of the adjustment screw will increase the pressure.
5. When main pressures are set: Tighten lock nut and return acorn nut. Note the new pressure
level in logbook or technical documentation.
26

Installation and Maintenance Manual, Power Unit PAC

Maintenance

5. PREVENTIVE MAINTENANCE
5.1 Maintenance log
We recommend that a maintenance log be kept to record service/maintenance/repair, addition and
alteration of the equipment. Each note, observation or comment should be dated.

5.2 Maintenance chart


The maintenance of hydraulic systems is designed to prevent failure of the system and to keep the
system running efficiently according to specification. The specific procedures will depend on the
nature of the equipment, the environment it is working in and the duty cycle, keeping in mind the
consequences of a breakdown. To optimize the maintenance intervals a Life Cycle Cost (LCC) analysis is recommended. Follow the safety precautions during the checkups (section 1.1 Safety Precautions).

Daily checks, first week after


commissioning

Fluid leaks.
Fluid level in the tank.
Operating temperature.
System pressure.
System performance and general condition.
Unusual noises.
Contamination indicators on the filters.

Pre-start checks

Frequent checks

(also daily)

Fluid leaks.
Fluid level in the tank.
Is the suction valve open?
Contamination indicator on the filters.

27

Unusual vibrations.
Unusual noises.
Fluid leaks.
Fluid level in the tank.
Is the unit relatively clean? Air flow paths
unrestricted?
Pressure levels normal - stable?
Actuator speeds normal - stable?
Operating temperature.
Is the drive running smoothly?
Contamination indicators on the filters.

Maintenance

Installation and Maintenance Manual, Power Unit PAC

Scheduled maintenance
Planned maintenance at specific time intervals, including the following checks and actions:

All points listed under frequent checks.


Check all pressure levels.
Check for stable temperature levels around the system.
Drain water and sludge from the tank at the drain tap.
Check the electric motor.
Check the function of monitoring equipment/switches, etc.
Clean areas where dirt is building up.
Note: never use a high pressure washing system to clean inside the power unit
Check the cables.
Check accumulators (optional) for correct pre-charge.
Check drain line flows and drain line oil condition.
Check the hoses, couplings and pump(s), with regards to cracks, leaks and condition.
Check the shaft coupling through the inspection hole. Warning, rotating parts inside the
inspection hole.
Check the flow of cooling water.
Check that the insulation inside the cabinet (especially on hood) is fixed.
Check that the doors and cover of the power unit are not damaged.
Absolute maximum intervals for major inspection and replacement
Air
Air breather
Oil
Accumulator(s)
Hydraulic fluid
(optional)
inlet Filters
on tank
After the first 100 working hours
After 3 months or 500 working hours
Once every 6 months
Once every 24 months

*
*
*

*If the contamination indicator is tripped out, the filters


must be changed immediately, and the oil examined.

=Inspection
=Replacement

5.3 Filter change


Single filter
1. Stop the operation and electric motor.
2. Remove the filter bowl and change filter cartridge.
It is very important during the mounting not to expose the new cartridge to any dirt, therefore
keep it in the plastic cover as long as possible.
Check the O-ring and the backup ring for damage, change parts if necessary.
3. Mount the filter bowl. Tighten by hand to stop and back off 1/8th of a turn.
Note! When removing a filter element take some time to inspect and look for unusual contamination
within the pleats. Contact your Hgglunds Drives office for advice.

28

Installation and Maintenance Manual, Power Unit PAC

Maintenance

Duplex filter
1. Press in the pressure-equalizing lever on the underside of the switching lever and hold it, see
figure below.
2. Withdraw the catch knob, turn over and engage the switching lever on the other side.
3. Loosen the vent screw, only on the side where the filter is to be changed, (see picture below) 23 turns.
4. Remove the filter bowl and change filter cartridge.
It is very important during the mounting not to expose the cartridge to any dirt, therefore keep
it in the plastic cover as long as possible.
Check the O-ring and the backup ring for damage. Change parts if necessary.
5. Mount the filter bowl. Tighten by hand to stop and back off 1/8th of a turn.
6. Refill the filter by pressing the equalizing lever and hold it there until the vent screw bore is
bubble free.
7. Tighten the vent screw. Check the filter for leaks by pressing in the equalizing lever again.

5.4 Inspection of hydraulic fluid


We recommend that the hydraulic fluid be analyzed once every 6 months. The analysis should cover
viscosity, oxidation, water content, additives and fouling. In the vast majority of cases, your oil supplier
will perform an analysis that will reveal the condition of the hydraulic fluid and can recommend suitable
actions. If the analysis reveals that the properties of the hydraulic fluid are not fulfilling the requirements (section 2.3 Requirements for hydraulic fluid cleanliness) it should no longer be used, but be
changed or cleaned immediately. Refill fluid according to instructions (section 4.12.2 Filling up the
system with hydraulic fluid).
Vent screws

CAUTION

Pressure
equalizer
lever

There are dangers associated with hydraulic fluid.


Store used hydraulic fluid
and contaminated filter
elements for proper disposal.
The fluid may be hot if the
cooling is insufficient.

In this
position
you can
change
this
element

Switching
lever

Different hydraulic fluids are affected differently


- consult the manufacturer.

29

Installation and Maintenance Manual, Power Unit PAC

Maintenance

5.5 Lubrication of electric motor


Lubricate electric motors larger than 30 HP
1. Clean the grease nipples.
2. Grease the electric motor with a grease gun.

Grease
When re-greasing, use only special ball bearing grease with the following properties:
Good quality lithium base or lithium complex grease.
Base oil viscosity 476-667 SSU at 104 F (100-140 cSt at 40 C).
Consistency NLGI grades 2 or 3.
Temperature range -22 F - +248 F (-30 C - +120 C), continuously.
Grease with the right properties is available from all the major lubricant manufacturers. If the type of
grease is changed and compatibility is uncertain, lubricate several times at short intervals in order to
displace the old grease.

Air inlet for electrical motor


Check that the air inlets on the cabinet hood and on the electric motor are not clogged by dirt and that
air can easily pass.

Lubrication schedule for electric motor (60 Hz)

Check the warning label


on the grease cartridge.

Frame
size

Electric motor
HP (kW)

286

CAUTION

Lubrication
intervals

30 (22)

Volume of
grease
1.0 cu. in.

40 (30)
50 (37)

6 to 12 months

324-365

1.5 cu. in.


60 (45)
75 (56)
100 (75)
125 (93)
150 (112)
200 (149)

6 months

2.5 cu. in.

3 months

404-449
509

GREASE
NIPPLES

check data

250 (186)
300 (224)
350 (261)
400 (298)

5011

450 (336)

5.6 Air breather change


Refer to maintenance chart (section 5.2 Maintenance chart) for recommended replacement intervals.
1. Clean around the area where the air breather is located.
2. Unscrew the breather and make sure no foreign material has entered the tank.
3. Thread on a new air breather.

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Installation and Maintenance Manual, Power Unit PAC

Maintenance

5.7 Cleaning of Air-Oil cooler


Cleaning of air fins

The easiest way to clean the air fins is by using compressed air or rinsing with water.
Fouling can be dealt with using a degreasing agent and a high-pressure washing system. When
using a high pressure washing system point the jet carefully parallel to the air fins.

!
WARNING

Follow the safety precautions on the container of the cleaning agent used.
Disconnect the power unit before disconnecting the Water-oil/Air-oil cooler.
Make sure that electric power is cut off before cleaning! Cleaning agent
and waste water from rinsing should not be disposed of in nature.

5.8 Power unit out of service


Periods out of commissioning
Clean and empty the cooling system (water side) before periods of rest (especially if the cooling water
is not totally clean). If the PAC is to be out of service for more than three months, the hydraulic system
must be protected internally against rust.
This can be done in the following manner:
Use hydraulic fluid that is consistent with fluid types used at your location, which has rust preventing additives.
Use additives which give protection against rust for up to about a year. After this, the equipment
should be run at intervals to maintain a protective film on the internal surfaces of components
and oil lines, thus providing protection against corrosion.
If any parts of the system are disconnected, note that open fittings must be protected by plugs
or covers to prevent entrance of any dirt particles.

Re commissioning
Before the drive is restarted after a long idle period, a check should be made as to whether the
instructions supplied for the original commissioning still apply. Moreover, the following measures
should be observed.

Remove preservative solution and any signs of contamination.


Follow the procedure for initial start-up (section 4.12.3 Initial start-up procedure).

6. CORRECTIVE MAINTENANCE
6.1 Common
Before removing any hydraulic/electric components, disconnect the power unit. Ensure that no energy
is accumulated in the system and the power is disconnected from the electric motor. Follow recommended safety procedures.

Before disassembly

Troubleshoot the PAC and perform appropriate tests.


Clean all assemblies and components, take all precautions necessary to prevent dirt entering
the system.
Disassembly may only be done by professional service personnel.

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Installation and Maintenance Manual, Power Unit PAC

Corrective Maintenance

Disassembly

Label all parts, and protect precision or machined surfaces.


Inspect all parts during disassembly for wear or damage.
If hydraulic fluid is to be drained and reused, make sure that drain containers are clean and
covered when not in use.
Clean all metal parts using a suitable solvent prior to reassembly, set aside on a clean and lint
free cloth to drain.

Reassembly

Lubricate with system hydraulic fluid.


Replace all seals, gaskets and o-rings with new items of the correct size.
Ensure complete sealing at pipe connections.
Refill hydraulic fluid according to recommendations (section 4.12.2 Filling up the system with
hydraulic fluid).

6.2 Change of hydraulic pump/electric motor assembly


The most common method to change the pump is to lift the complete electric motor/pump unit and
then remove the pump.
The electric motor and pump are assembled into a unit and mounted on the motor support plate
attached to the frame via shock mounts.
1. Remove top cover and sound baffle: Item 1 and 2 (section 4.5 Mounting of electric motor).
2. Release the motor support plate: Release the motor support plate from the frame.
3. Secure lifting equipment: Adapt lifting equipment in the four holes in the corners of the motor
support plate.
4. Lift the electric motor/pump unit: Be careful and take the weight and center of gravity into
consideration. Never let the electric motor/pump stand on the charge pump.
5. Assemble: Assemble in reverse order according to point 1 to 4.

!
DANGER

Always use all four lifting points when lifting the electric
motor/pump unit.
Never use the lifting ears on the electric motor to lift the
complete electric motor/pump unit.
Use only lifting equipment adapted to the weight (section 4.2
Lifting methods and weights).
Do not stand underneath hanging load
Take center of gravity into consideration during lifting.

32

Installation and Maintenance Manual, Power Unit PAC

Troubleshooting

6.3 Troubleshooting

Problem

Probable cause

Action

Main voltage to electric


motor lacking

Look for the cause in the electric power


supply network
Open suction line valve, verify switch
function
Verify reservoir oil level and switch
function

Suction valve closed


Not enough oil in reservoir
Power Unit does not start

Reservoir temperature
above set limit

Control voltage lacking

No servo pressure
Coupling pump/electric
Power unit fails to deliver oil motor defect
flow
Wrong direction of rotation
of hydraulic pump

Verify reservoir temp switch function


Look for the cause in the electric power
supply network
Examine the control system in the power
unit. If the control system has tripped,
determine the reason
No control current to electro hydraulic
stroker control. Examine the control
function or electronic control card
Check through the inspection hole in the
bellhousing
Check direction of rotation
Check that load pressure is not too high
so that pressure override reduces pump
delivery
Open suction line valve

Load is too large

Suction line not open


Charge pressure too low or
Check that charge pressure is correct
non-existent
Pump/Motor baseplate
Remove shipping bolts
shipping bolts still installed
Unwanted noise

High oil temperature in


closed circuit

Air leaks and pump


cavitating
Air filter in tank clogged
Worn elastomer element in
the shaft coupling
Wrong direction of rotation
No oil exchange from closed
loop

33

Examine the suction line to charge pump


for air leaks. Test by pouring oil over pipe
joints while listening for changes in noise
in the pump
Change filter
Change elastomer element
Reverse direction of rotation
Check charge pressure and shuttle valve
setting

Installation and Maintenance Manual, Power Unit PAC

Troubleshooting

Problem

Probable cause

Action

Power unit fails to deliver oil Perform previously described actions


No command signal to
pump
No pressure in system
Pump/Motor coupling not
installed properly

Excessive wear

High oil temperature

Verify input signal to amplifier card and


output signal to electrohydraulic pump
control
Verify that pump and electric motor
coupling and insert are installed and
tightened properly

Pump compensator valve is


Replace pump compensator valve
not closed
Compare with our oil recommendations
Viscosity too low
Check the oil temperature, and the
cooling circuit
Abrasive material circulating Check filters and change if necessary.
Check that changing is performed at
through pump with the
prescribed intervals
hydraulic fluid
Air in the hydraulic system Locate and remedy the air system leak
and Pump cavitating
and purge air from the system
Content of water in
Inspect hydraulic fluid, change oil
hydraulic fluid too high
Check flow of cooling water, water
temperature, cooler, water valve and
Poor cooling capacity
water filter or air cooler (optional)
If air cooler is clean, inspect cooler fins
and remove any obstructions
Internal leakage in pump
Change or repair pump
Too small an amount of
Check that charge pump delivers sufficient
replacement oil in hydraulic
flushing oil
system
Charge pressure is out of
Adjust according to values on hydraulic
adjustment
circuit diagram

7. DISPOSING OF POWER UNIT


When the complete PAC or a single component is worn out, it should be disposed of as soon as
possible. Used hydraulic fluid, material exposed to hydraulic fluid and grease may cause damage on
the environment and should be disposed of according to prevailing local regulations.

DANGER

Check that the power unit is completely disconnected.


The components may contain accumulated energy.
Take fire hazards into consideration during dismantling.
The accumulator (optional) must be empty and discharged.
34

AM326-1A 1999 Printer : Precision Printing 1999

HGGLUNDS DRIVES INC.


2275 INTERNATIONAL STREET
COLUMBUS, OHIO 43228 USA
Phone: (614) 527-7400 Fax: (614) 527-7401
www.hagglunds.com