7 семестр (Бормотов А) / 1man_bw_l23_30_chn_23_30_instruktsiya_po_ekspluatatsii_1 / MAN-BW L23-30 H Vol-1 (Instruction)+

Please note:

The numbers refer to the plate items in section 520.

Fig 1 Hydraulic tools.

08028-0D/H5250/94.08.12

08028-0D/H5250/94.08.12

Starting position

Related procedure

General

Warning: The hand lever pump is not equipped with a pressure relief valve.

Never use the pump without a mounted manometer. Always pay attention to the given pressure of the connected pressure consumers. Do never exceed this pressure or the max. pressure of the hand lever pump.

Important: Except for hydraulic oil, never use different liquids such as petrol, water, diesel oil, alcohol or brake liquid, since these can lead to damages or even to destruction of the pump and/or the parts connected with it. Choose a place of assembling and operation where the pump can always stand safe and firm on a horizontal plain. There should always be sufficient space for operating the pump.

Never handle the pump lever with oiled hands and never use hand lever extensions. Never expose the pump to great heat, fire or extreme coldness, since this leads to damages or even destruction. Protect the pump from falling objects and avoid hard blows or pushes.

Attention - Danger to life

Check the manometer of the pump for the needed hydraulic pressure, given by an authorized person, not to be exceeded. Make sure that the pressure you want to generate is also admissible for all connection parts.

All pressure connections and connecting elements have to be clean and undamaged. High-pressure connections from the pump to the tools have to be established correctly prior to any pressurization. Disregard leads to danger to life. Please see working card 520-01.06.

Attention - Danger on injuries

Loads being lifted by the pump may never be held by the pump valves alone. Use additional non-return valves or safety relief valves and secure the load by sufficient support against falling.

Initial Start-up and Venting

In general and venting

Please make sure that all parts of the pump, especially the manometer and the pressure port, are in a perfect condition. Defect parts are to be exchanged against new ones immediately.

Turn the carrying handle with counter-clockwise rotation out of his fixing. Then turn it into the hand lever of the pump against the stopping face.

Attention: If the carrying handle is not srewed-in into the hand lever, it can cause injuries while using the pump.

Open the oil filler cap and check the oil level. If neccessary, fill up the tank with hydraulic oil according to IS0 VG 32. Never overfill the tank. Close the oil filler cap.

Open the tank breather with the square wrench (included in the scope of supply) by about one turn. Now loosen the breather screw at the pump on the left side on the pump housing with an allen key SW 2,5 by about one turn. Close the depressurization valve tightly. Seal the nipple on the pump with a hose and pump at the hand lever until oil flows out of the breather screw bladder-free. Only then are you allowed to close the breather screw. The pump is now vented and ready for operation.

After each operation and for the transport, close the tank breather in order to avoid the hydraulic oil’s running out.

Pressurization

-Open the tank breather with the square wrench approx. one turn.

Remark: The pump is only to be operated with open tank breather.

-Close the depressurization valve at the pump when turning clockwise by handoperation.

08028-0D/H5250/94.08.12

08028-0D/H5250/94.08.12

Remark: The depressurization valve is designed for manual operation. The use of any tools at the depressurization valve could cause damages of the valve or the valve seat.

-Pump at the hand lever until the wanted pressure is achieved. Check the pressurization at the manometer and take care of possible leakages.

Remark: The pump works with two stages. The change from the first stage to the second stage happens automatical at a system pressure of about 30 bar.

Attention: The pump is not equipped with an internal pressure relief valve. The use of a manometer and the control of the system pressure during pressurization is indispensable.

Attention: Do not stand directly over the moving line of the pump lever. Under arising circumstances the lever can “hit back”. To avoid accidents stand sideways the pump.

Attention - High-pressure hydraulic

On principle, tihen leakages occur during the pressurization, immediately release the hydraulic pressure and seal the leakage or renew defect parts.

Depressurization

-Open the depressurization valve slowly by a turn to the left.

-Make sure that the hydraulic pressure at the manometer has been completely released. Consider the returning time of the hydraulic oil.

Adjustment of change-over pressure from stage 1 to stage 2

In exeptional case, it can be useful to adjust the change-over pressure from stage 1 to stage 2 (factory adjusted at approx. 30 bar).

Below of the pressure relief valve is an adjusting screw with inner hexagon (wrench size 10 mm). Turning out counter-clockwisely the adjusting screw minimizes the change-over pressure, turning in clockwise maximizes the change-over pressure.

Attention: Inside of the adjusting screw is another grub screw with inner hexagon (wrench size 4 mm) to limit the stroke of the change-over piston inside of the pump block. It is absolutely necessary, to screw out the grub screw approx. 2 times before turning the adjusting screw!

The regulation of the adjusting screw follows gradually in approx. 10° - steps. After everv adjusting step the grub screw is to screw in until it fits closely and approx. a l/4 turn to loosen.

Check by carefully pumping if the change-over pressure wanted has been reached. If necessary, repeat the procedure as described above.

General

Analysis and Correction of Malfunction

Correction of malfunctions

In case of malfunctions at the pump, the following points are to help you with the analysis of the problem and correcting it yourself.

For this, uncouple or unscrew all consumer and highpressure hoses from the pump.

If the problem cannot be solved, please contact MAN B&W Diesel Holeby.

Pressure Port

The pressure port of the pump is produced according to our customers’ wishes. In addition, there is a variety of possibilities to connect the pump with one or more pressure consumers.

Attention - Danger to life

Prior to the pump’ s start-up please make sure that, no matter which pressure port you chose, all connection elements are in a perfect condition. Convince yourself of the fact that these are correctly connected and suitable for the necessary pressure.

Attention - High-pressure hydraulic

On principle, when leakages occur during the pressurization, immediately release the hydraulic pressure and seal the leakane or renew defect parts.

Maintenance and Storage

The pump should be lubricated frequently at the movable parts. Protect it from contamination because dirt in the oil or in the pressure port can lead to the pump’ s failure. A dry storage avoids the steel parts’ getting rusty.

The storage and transport of the pump should always be done in a horizontal position. Thus, you avoid a possibly necessary venting of the pump during its start-up.

For checking the oil level, please open the depressurization valve and let the oil completely flow back into the tank. Open the oil filler cap and fill up hydraulic oil according to IS0 VG 32, if neccessary. Do not overcharge the tank. Close the oil filler cap.

The use of the pump in a dirty area requires a regular oil change. Fill the pump with clean hydraulic oil and lubricate all moving parts (hinges) regulary.

08028-0D/H5250/94.08.12

08028-0D/H5250/94.08.12

1) The hydraulic jacks require no maintenance except replacement of defective sealing rings, each of which consists of an o-ring and a back-up ring fitted in ring grooves in the piston and cylinder.

The piston and cylinder are easily separated by taking out the bleed screw and pressing the parts apart by means of working air.

Work.

air

Fig 1.

Make sure that there are no marks or scratches on the sliding surfaces of the parts. The presence of metal particles will damage the sealing rings.

2) The sealing rings are to be fitted with the o-rings nearest to the pressure chamber and with the back-up rings away from the pressure chamber.

Compression tool

Fig 2.

Fit the sealing rings and lubricate with clean lub. oil. The piston and cylinder are pressed together by means of the tool supplied. See that the rings do not get stuck between the piston and cylinder.

Pressure Testing of Hoses

To avoid working accidents caused by emission of pressure oil from the hydraulic hoses, the hoses should be pressure tested at 1200 bar once a year.

Note: During the pressure testing the hoses must be covered carefully.

08028-0D/H5250/94.08.12

08028-0D/H5250/94.08.12

L23/30H

Description:

Hand tools:

Starting position:

Related procedure:

1)Before the nuts are screwed on, the threads and the contact faces should be greased with copaslip or similar, the tightening torques being based on a coefficient of fiction in the threads.

2)The nuts should fit easily on the thread, and it should be checked that they bear on the entire contact face.

3)In the case of new nuts and studs, tighten and loosen the nuts 2 or 3 times so that the thread may assume its difinite shape, thus obviating the risk of loose nuts.

4)Nuts secured with a split pin are tightened to the stated torque and then to the next split-pin hole.

5)The following instructions apply to the use and maintenance of the torque spanner.

Torque Spanner

6) The handle of the torque spanner is provided with a scale indicating the torque at which the spanner can be set.

7)For setting the spanner at the torque required, there is a ball on a small arm at the end of the handle.

8)When pulling the ball with the arm outwards, a small crank handle is formed.

A spring-loaded slide in the handle provided with a mark which, when turning the crank handle, can be set at the required torque on the scale.

The torque spanner functions are as follows:

9)The above-mentioned spring activates a pawl system in the handle, and when using the spanner, this pawl system will be released when the pre-set torque has been reached, at which moment a small jerk is felt in the spanner and a small click is heard.

10)The torque spanner must not be used for torque higher than those stamped on it, and it must not be damaged by hammering on it or the like.

08028-0D/H5250/94.08.12