Installation and Commissioning Instructions
Fluids
For selecting appropriate fluids, please refer to the following chapter, which provides detailed information on recommended oil types. The fluids used must comply with DIN 51524, parts 1 and 2. For other fluid types, additional instructions must be followed, particularly regarding compatibility with sealing materials.
Commissioning
Start-up should only be performed by qualified Automotive Lift Repair Tampa Florida professionals. It is essential to follow the specific instructions provided by both the manufacturer and component producers. Ensure that the hydraulic diagram, parts list, and control system flow chart are available. The desired pressure settings for all pressure valves should be indicated in the hydraulic diagram.
Start-Up Safety Guidelines
Before initiating the start-up, the entire hydraulic system must be thoroughly inspected by experts. Pay close attention to the following:
– Proper installation of pipes and clamping
– Correct connection of pressure and return pipes
– Accurate connection of pilot pressure lines
– Proper assembly of hydraulic components
– Correct connection of the power unit, manifolds, cylinders, and hydraulic motors
– Proper electrical connections
– Ensure that all hydraulic equipment and components driven by hydraulics are securely mounted for safe operation
Before start-up, specialists must take necessary precautions to safeguard individuals and system components. The start-up process should be executed with care, adhering to all safety regulations.
Filling
Before adding hydraulic fluid to the tank, inspect the tank’s interior for cleanliness and clean it if required. Use a fine filter when filling to ensure the fluid reaches the necessary cleanliness standard. Special filling equipment or return line filters are ideal for this task. The appropriate oil type will be marked on a sign near the filling opening.
Flushing
After filling the Automotive Lift Repair Tampa Florida reservoir, we recommend flushing the hydraulic system, allowing the fluid to circulate multiple times through the tank. Before flushing, remove servo-valves and proportional valves and replace them with flushing plates to prevent contamination-related damage. System start-up should only occur after the required cleanliness level and operating temperature have been reached.
For large or centralized oil stations, flush long pipelines by short-circuiting the pressure and return lines. This prevents contaminants from entering pilot valves or drives like cylinders and hydraulic motors. Coordination of these measures should be integrated into the Automotive Lift Repair Tampa Florida system’s design phase.
Electrical Connections
Ensure the correct current and voltage types are available:
– Motor: Verify the current matches the E-motor’s type plate.
– Solenoids: Confirm the current type (AC or DC) and the voltage are correct by checking device labels.
– Plugs: Electrical connections must adhere to technical standards and use appropriate plugs.
– Grounding: All power units, system components, and individually mounted devices must be properly grounded.
Pumps and Devices
Before start-up, the Automotive Lift Repair Tampa Florida pump case must be filled with clean hydraulic fluid to lubricate the bearings. Follow the specific start-up instructions for pumps and other hydraulic or electric components.
For initial start-up, it’s beneficial to set the pump pressure low. For variable displacement pumps, set the pressure compensator to approximately 15-20 bar, and for fixed displacement pumps, adjust the pressure limiting valve accordingly.
Servicing and Maintenance Guidelines
Pressure Valves
When servicing pressure valves, always begin with the minimum pressure setting according to the machine’s function. After finalizing the pressure, record it on the measuring location plate. Accumulator safety valves, which are design-tested and preset, are the exception to this procedure.
Pressure Unloading Valves
To adjust pressure unloading valves, follow the pressure settings in the hydraulic schematic. Pay close attention to the start-up instructions specific to these valves.
Throttle Valves
Adjust each drive (cylinders, etc.) gradually using the throttle or flow control valves until the desired speed or stroke time is achieved.
Directional Valves
Use the Automotive Lift Repair Tampa Florida electric control system to select the appropriate direction for electrically operated valves. If manual override of the solenoid is needed, use the correct tool.
Proportional Valves
Start proportional pressure flow and DC valves with a low electrical command signal.
Automotive Lift Repair Tampa Florida Hydraulic Accumulators
For systems with hydraulic accumulators, verify or fill the gas pre-load level to the correct amount. Appropriate testing and filling equipment must be used, and only nitrogen should be used to fill the accumulators for safety reasons. The pre-load level, coordinated with the working pressure, is indicated in the hydraulic schematic. Generally, the gas pre-load level is calculated as:
Gas Pre-Load = Minimum Working Pressure x 0.9
Once testing or filling is complete, the accumulator can be brought into the system via a ball valve.
Switching On
Initially, the Automotive Lift Repair Tampa Florida motor should be switched on briefly and then off to verify the rotation direction. The correct direction is indicated by an arrow on the pump housing. If the direction is wrong, reverse the e-motor polarity. The pump is started by short on-off cycles. After about one minute of operation, the working pressure can be adjusted to its nominal value. Always prioritize the pump manufacturer’s start-up instructions over general guidelines.
Air Bleeding
Air in the hydraulic system is undesirable as it negatively affects system control. Proper air bleeding is crucial during the first start-up, oil changes, or after opening lines and valves. Run all functions at no load and low pressure, ensuring full cylinder stroke. Vent the system at its highest point by slightly loosening a fitting to release trapped air. Once the oil stops foaming, retighten the fitting. If venting screws are provided on the cylinder, use them to vent air while ensuring the cylinder completes several full strokes. Check and refill the tank oil level after venting.
Filter
The performance and lifespan of pumps and hydraulic devices heavily depend on fluid cleanliness. Dirt is the primary enemy of hydraulic systems and originates from three main sources:
1. Contamination during installation
2. Contamination during operation
3. Environmental impurities
The appropriate filtering method is determined during system planning based on the required cleanliness level. Pressure or return line filtration, as well as additional bypass filtration, is used as necessary. For non-critical systems, a return line filter with β25 ≥ 75 (25 µm) is typically used to prevent tank contamination and ensure the pump only intakes clean oil.