INSTALLATION AND MAINTENANCE MANUAL

FOR

SMD

15 Kw Zone 2 Deck Cart HPU

SMD Ref C1485

PFP Ref: 5741259

CONTENTS

1 Introduction

2 Storage Recommendation

3 Safety

4 Filling the System

5 Flushing Before Start Up

6 Commissioning

7 Starting

8 Trouble Shooting Guide (Charts 1 to 5)

9 General Maintenance

10 Technical Information

a) Oil Grade
b) Technical Data Sheets
c) Parts List
d) Power Unit General Arrangement
e) Circuit Diagram
1 INTRODUCTION

The purpose of this manual is to give skilled personnel an in depth understanding

of the operation of the hydraulic system.

The manual also provides:-

a) Information on the procedures to be followed for setting up the

system.

b) Comprehensive faultfinding charts.

c) Safety warnings where necessary.

To ensure reliable operation of the system it is essential that the cleanliness and
temperature of the hydraulic fluid is maintained as specified in the manual (see
section II b).

Your attention is drawn to the importance of ensuring that all operator’s are
aware of the need to report any fault immediately and that action to remedy the
fault must be carried out without delay.

Your attention is also drawn to the following safety warnings:-

a) When carrying out any work on the system where either inadvertent
movement would cause injury to personnel or damage to the equipment,
or when removing any hydraulic component the electric motor starter must
be locked off.

b) When carrying out any work mechanisms, slides or weights MUST be

mechanically restrained from moving.

The hydraulic and/or electrical control equipment referred to in this manual was
manufactured by:-

Primary Fluid Power Ltd

Caddick Road
Knowsley Industrial Park
Liverpool
L34 9HP
2. STORAGE RECOMMENDATIONS

On delivery, the hydraulic components of the power unit are protected internally
by means of an oil film. This affords sufficient protection for indoor storage in
temperature controlled premises for up to 12 months.

If the power unit is stored for longer periods, the power unit must be operated so
that the hydraulic system is lubricated with new oil.

3 SAFETY

When starting or servicing any machinery always take every reasonable safety
precaution.

Securely prop or wedge slides or weights that could fall or move when hydraulic
power or pipe work is removed.

Removing any main electrical fuses, removes risks during servicing.

4 FILLING THE SYSTEM

The cleaner a system is when it is put into service the greater will be the life
expectancy of the parts liable to wear.

The hydraulic fluid is the life blood of your system – treat it with the respect it
deserves. Ensure that you have the correct fluid and that it is clean.

When transferring fluid from the barrel to the system every possible precaution
should be taken to prevent dirt entering the system. Start off by cleaning around
the end of the oil barrel before removing the bung. See that the tank filler entry
and equipment to be used for the fluid transfer are scrupulously clean. Wherever
practical the transfer of fluid is best accomplished by using a portable pumping
unit incorporating a filter. This system is fitted with a self seal coupling to allow
oil to be pumped into the oil reservoir via the return line filter.
5 FLUSHING BEFORE START UP

Flush all parts of the system thoroughly before putting the equipment into
service.

Ideally, flushing should be carried out with the same type of fluid that is to be
used in service and if possible a flushing pump should be used which will create
fluid velocities higher than those which would normally be present in the system.

In a newly built system, no matter how carefully constructed, most of the dirt will
be in the pipework and during the process of flushing this out, temporary bridging
loops must be used at the actuator ends and sensitive valves should be replaced
by bridging plates so that the contamination is not flushed into these units. It is
advisable that temporary flushing filters are installed in the bridging loops to
speed up the flushing process.

If the power unit pump has to be used for the flushing operation, make sure that it
pumps only clean fluid and operates at low pressure. If the system fluid is used
for flushing, once the system is clean there is no need to change the fluid again
as this could introduce additional contamination into the reservoir.

During flushing ensure that the clean-up filters are not by-passing and after
flushing fit new elements to the system filters.

6 COMMISSIONING

Prior to starting-up

• Check the fluid level in the reservoir.

• If there are shut off valves in the system, check that these valves are in a
position that is safe and correct for start up.
Make sure that the machine is safe to start and that personnel are clear of
possible hazard areas.

Drawings:
• Item list PLH5741259
• Hydraulic circuit 5741259C1
• General arrangement of the Power Unit is shown on drawing 5741259G1
• Electrical drawing ES100722-R3
• Power unit lift drawing 5741259G2-C1485
Filtration

To ensure a long and trouble free life it is essential that clean oil is circulated
through the system. The level of contamination is determined by the, Filters
fitted to the system, and the Air Breather.

Return and Pressure Filtration

The Filters incorporate a by-pass valve, which opens should the filter element
become blocked. The filter has a disposable element which has a rating of 7
Micrometre Absolute. See parts list for elements fitted. The condition of the
element is monitored by a visual indicator.

Air Breather

The Air Breather is located on the top of the reservoir. It has a micron 3 micron
rating suitable for the system. The breather has no by-pass and is a disposable
item. In the event of the breather becoming blocked it may cause the pump to
cavitate when there is a nett outflow of fluid from the reservoir.

Alarms

Alarms may be fitted to the power unit to send an appropriate signal to the alarm
annunciator panel, as follows:

Low Oil Level

Level Switches are fitted to the power unit which give an alarm signal should the
oil level in reservoir: Reservoir capacity 200 litres.
a. Low oil level warning. (60 litres below full position)
b. Low oil level shutdown. (100 litres below full position)
The reservoir is fitted with an oil level gauge to monitor the fluid level.

Pump suction limit switches

The suction stop valves have a sleeve to allow locking in the open position. Do
not close this valve with the pump running as this will damage the pump.

Temperature

A visual temperature gauge is fitted to monitor the fluid in the oil reservoir.
The fluid temperature should never exceed 65 deg C.
There are 2 temperature switches set at 55 deg C for warning and 65 deg C for
shutdown.
 Electrical control panel lights and push buttons

Top row left to right

1, Control on indication – white light

2, Low oil level warning – amber light
3, Low oil level shutdown – red light
4, Hot oil warning – amber light
5, Hot oil trip - red
6, Motor running – green light
7, Motor tripped – red light
8, Motor ACH on – blue light
9, Hot oil panel – red light

Second row left to right

1, Hours run meter

Third row left to right

1, Motor start button – Green button

2, Motor stop button – Red button
3, Emergency stop reset – Blue button

Bottom row

1, Emergency stop button – red mushroom

Pendant buttons top to bottom (Top is cable entry)

1, Energency stop – red mushroom

2, Energise solenoid “A” – white
3, Energise solenoid “B” – yellow
7 STARTING

System with fixed delivery pump

This section applies when a new pump or electric motor has been fitted.

Ensure that there is sufficient fluid in the reservoir.

Turn the adjusting screw of the Relief Valve fully anti-clockwise to ensure that no
pressure will be generated in the system.

Check the rotation of the Electric Motor by bliping the electric motor starter. The
correct direction of the motor is shown on the motor fan case. Clockwise rotation
viewed from the motor fan end.

Set System Relief Pressure:

Ensure that the rotation of the Electric Motor is correct.

Start the Electric Motor

To set the system pressure one of the solenoids needs energising by the
pendant push button or manual overide in the end of the solenoid.
Turn the adjusting screw of the Relief Valve clockwise until resistance is felt.
Continue turning clockwise observing the Pressure Gauge until the pressure
reaches the maximum safe working pressure of the system. Lock up the
adjusting screw and replace the protective cap.

The relief valve is now set up

8 TROUBLESHOOTING GUIDE

Chart 1

EXCESSIVE NOISE

A B C
PUMP NOISY MOTOR NOISY RELIEF VALVE

Cavitation Coupling misaligned Setting too low or too close to

1. 1. 1.
another valve setting
Remedy: a Remedy: c
. Remedy: d

Air in fluid Motor or coupling worn or Worn poppet and seat

2. 2. damaged 2.
Remedy: b Remedy: e
Remedy: b

Coupling Misaligned
3.
Remedy: c

4. Pump worn or
damaged

Remedy: e

Remedies:

a. Any or all of the following. b. Any or all of the following: c. Align unit and check condition of
seals, bearings and coupling.
Replace dirty filters: wash Tighten leaking connections;
strainers in solvent compatible fill reservoir to proper level d. Install pressure gauge and adjust
with system fluid: clean clogged (with rare exception all return to correct pressure.
inlet line; clean or replace lines should be below fluid
reservoir breather vent; change level in reservoir); bleed air e. Overhaul or replace.
system fluid; change to proper from seal replace pump shaft
pump drive motor speed; seal (and shaft if worn at seal
overhaul or replace supercharge journal).
pump; fluid may be too cold.
 Chart 2
EXCESSIVE HEAT

A B C D

RELIEF VALVE
PUMP HEATED MOTOR HEATED HEATED FLUID HEATED

Fluid heated Fluid heated System pressure

1. 1. 1. 1. too high. 1.
Remedy: See Remedy: See Remedy: See
Column D Column D Column D Remedy: d

Cavitation Relief or unloading Valve setting incorrect Unloading valve set

2. 2. valve set too high 2. 2. too high
Remedy: a
Remedy: d Remedy: d Remedy: d

Air in Fluid Excessive load Fluid or low supply

3. 3. 3. Worn or damaged 3.
valve
Remedy: b Remedy: c Remedy: f
Remedy: e

Relief or unloading Worn or damaged Incorrect fluid

4. valve set too high 4. motor 4. viscosity

Remedy: d Remedy: e Remedy: f

Excessive load Faulty fluid cooling

5. 5.
system
Remedy: c
Remedy: g

6. Worn or damaged 6. Worn pump, valve

pump
motor cylinder or
Remedy: e other component

Remedy: e
Remedies:

a. Any or all of the following: c. Align unit and check condition of g. Clean cooler and/or cooler strainer;
seals and bearings; locate and replace cooler control valve; repair
Replace dirty filters; clean clogged correct mechanical binding; check or replace cooler.
inlet line; clean or replace for work load in excess of circuit
breather vent: change system fluid:
change to proper pump drive motor d. Install pressure gauge and adjust to
speed; overhaul or replace correct pressure (keep at least 125
supercharge pump. PSI difference between valve settings).

b. Any or all of the following: e. Overhaul or replace.

Tighten leaking connections; fill f. Change filters and also system fluid
reservoir to proper level (with rare if improper viscosity; fill reservoir to
exception all return lines should be proper level.
below fluid level in reservoir); bleed
air from system; replace pump shaft
seal (and shaft if worn at seal journal).
Chart 3
INCORRECT FLOW

A B C
NO FLOW LOW FLOW EXCESSIVE FLOW

Pump not receiving fluid Flow control set too low Flow control set too high
1. 1. 1.
Remedy: a Remedy: d Remedy: d

2. Pump drive motor not 2. Relief or unloading 2. Yoke actuating device

operating. valve set too low inoperative (variable
displacement pumps)
Remedy: e Pump no receiving fluid
Remedy: e

Pump to drive coupling Flow by-passing thru Improper size pump used
3. sheared 3. partially open valve 3. for replacement

Remedy: c Remedy: e or f Remedy: h

Pump drive motor turning in External leak in system

4. wrong direction 4.
Remedy: b
Remedy: g

Directional control set in

5. wrong position
Remedy: f

6. Entire flow passing over

relief valve
Remedy: d

Damaged Pump
7.
Remedy: c

8. Improperly assembled
pump

Remedy: e

Remedies:

a. Any or all of the following: c. Check for damaged pump or pump f. Check position of manually operated
drive, replace and align coupling. controls; check electrical circuit on
Replace dirty filters; clean clogged solenoid operated controls; repair or
Inlet line, clean or replace reservoir d. Adjust replace pilot pressure pump.
breather vent; fill reservoir to proper
level; overhaul or replace e. Overhaul or replace. g. Reverse rotation.
supercharge pump.
h. Replace with correct unit.
b. Tighten leaking connections.
 Chart 4
INCORRECT PRESSURE

A B C D

ERRATIC EXCESSIVE
NO PRESSURE LOW PRESSURE PRESSURE PRESSURE

1. No flow 1. Pressure relief path 1. Air in fluid 1. Pressure reducing

exists relief or unloading
Remedy: See Chart 3, Remedy: b valve misadjusted
column A Remedy: See Chart 3,
Column A and B Remedy: d

2. Pressure reducing 2. Worn relief valve 2. Pressure reducing

valve set too low relief or unloading
Remedy: e valve worn or
Remedy: d damaged.

Remedy: e

3. Pressure reducing 3. Contamination in fluid

valve damaged 3.
Remedy: a
Remedy: c

Damaged pump, motor Accumulator defective

4. or cylinder 4. or has lost charge
Remedy: e Remedy: e

Worn pump, motor or

5. cylinder.

Remedy: e

Remedies:

a. Replace dirty filters and system fluid.

b. Tighten leaking connections (fill reservoir

to proper level and bleed air from system).

c. Replace.

d. Adjust.

e. Overhaul or replace.
 Chart 5
FAULTY OPERATION

A B C D

ERRATIC EXCESSIVE SPEED

NO MOVEMENT SLOW MOVEMENT MOVEMENT OR MOVEMENT

1. No flow or pressure 1. Low flow 1. Erratic pressure 1. Excessive flow

Remedy: See Chart III Remedy: See Chart 3, Remedy: See Chart IV Remedy: See Chart 3

Limited or sequence Air in Fluid Over-riding work load

2. 2. Fluid viscosity too high 2. 2.
device (mechanical,
electrical or hydraulic ) Remedy: a Remedy: See Chart I Remedy: h
inoperative or
misadjusted.
Remedy: e

3. Mechanical bind 3. Insufficient control 3. No lubrication of

pressure for valves 3. machine ways or
Remedy: b linkage
Remedy: See Chart 4
Remedy: See Chart 4

Worn or damaged No lubrication of Worn or damaged

4. 4. 4.
cylinder or motor machine ways or cylinder or motor
linkage
Remedy: e Remedy: e
Remedy: g

5. Worn or damaged or
motor

Remedy: e

Remedies:

a. Fluid may be too cold or should be c. Adjust, repair or replace. f. Lubricate.

changed to clean fluid of correct
viscosity. d. Clean and adjust or replace; check g. Adjust, repair or replace counterbalance
condition of system fluid and filters. valve.
b. Locate bind and repair.
e. Overhaul or replace.
9 GENERAL MAINTENANCE

Provided all adjustments are correctly set initially, and routine maintenance
procedures observed; the system should be capable of running continuously for
long periods of time without further adjustment.

The main cause of failure in any hydraulic systems is due to foreign matter
contaminating the oil. Every care has been taken to minimise the ingress of dirt,
either air borne of from the oil.

However, some self generated contamination is inevitable due to erosion and

wear within the hydraulic components. Particular emphasis should be given
therefore to observing recommendations on filter element changes.

Degradation could take place rapidly if the unit is allowed to run continuously at
excessively high temperatures. Running at high temperatures will cause seal
deterioration, the lubricity of the oil will be affected and efficiencies impaired.
Careful checks should be made therefore to ensure that sufficient cooling is
always available.

Important

ANY WORK OTHER THAN VISUAL CHECKS SHOULD BE CARRIED OUT

WITH POWER UNITS STOPPED. IF IT IS NECESSARY TO RUN THE UNIT
TO MAKE ADJUSTMENTS ENSURE THAT PERSONNEL ARE CLEAR OF ALL
MOVING PARTS.

A Daily Checks

Carry out visual inspection of all pipe work joints to ensure no leaks.

Visually check all flexible hoses to ensure no frettage is taking place due
to hoses rubbing on adjacent parts.

B Check oil level in reservoir using gauge. Top-up if necessary. Use only
recommended fluid from clean containers. There should be no oil loss if
system is tight.

C Check oil temperature. It should not exceed 65° degrees C

D Check filter clogging indicators. If ‘filter blocked’ indicates, stop machine

at next available opportunity and replace suspect filter element.

E After first 100 hours operation.

F Change all filter elements.

G Take oil sample from sampling point and send to laboratory for analysis.
Since all systems are different it is impossible to establish fixed times for
filter element changes. An analysis of oil condition at regular intervals
over a 12 month period will enable an element change schedule on a time
basis to be established.

H Ensure all mountings are secure.

I Carry out random checks on pipe work joints, testing for tightness. If
loose fittings are discovered it will be necessary too systematically check
all joints in the system.

J After first 500 hours operation.

K Repeat procedure as in E.

L Every 1000 hours.

M Repeat procedure as in E.

NOTE

Oil sampling (G) should be necessary after first 1000 hours or until element
replacement schedule is established.

N Check that pumps are operating satisfactorily.

O Every 5000 hours.

P Repeat procedure as in L.

Q Drain oil from reservoir and visually inspect. If sludge has accumulated in
the tank it will be necessary to remove the lid and thoroughly clean out
reservoir.

R Re-assemble reservoir and refill with new oil. Flush system .

S Every 10,000 hours.

T Repeat procedure as in O.

U Check drive couplings and replace if necessary.

V All flexible hoses should be replaced.

W Every 20, 000 hours
X Repeat procedure as in S.

NOTE

As a general rule unless otherwise specified in maintenance instructions it is not

advisable to strip hydraulic pumps or valves for inspection unless there is a
definite fault. Mating surfaces, seals, etc., once disturbed can be difficult to re-
assembly and extreme care is necessary to avoid further contamination of the
system. If in doubt consult your hydraulic specialist.
10 TECHNICAL INFORMATION

a) Selection of Oil Grade

The Power Unit is primarily designed to operate on conventional petroleum

based hydraulic fluids.
The hydraulic fluid can be chosen in consultation with an oil supplier.

The following table is an indication of the temperature extremes between which

the viscosity grades can be used to remain within start-up and running viscosity
range recommendations.

Viscosity
Grade Start up Start Up Start Up Running Running
@40° C 860 cSt 220 cSt 110 cSt 54 cSt Max. 13 cSt Min.
32 cSt -12°C 6°C 14°C 27°C 62°C
46 cSt -6°C 12°C 22°C 34°C 71°C
68 cSt 0°C 19°C 29°C 42°C 81°C

- Check caution sign on container or consult the supplier.

- Avoid contact of long duration with the skin.
- Use services of a professional oil supplier for disposal or used fluids, and filter
elements. .
- Never dump hydraulic fluid into drainages or water courses.
- Avoid contamination of hydraulic fluids on floors, it involves a great risk to slip
and fall.
Parts List PLH5741259

Customer: SMD LTD C1485 Order Number 166555 PAINT SIGNAL RED RAL3001
Originator: MICHAEL DEAN Date 13/02/2014
Approved By: Issue 1
Issued By: RJ Sheet No. 1 OF 4
Item Qty Description Product No. Supplier Ord No. Req Ack Rec Remarks
ZONE 2 HPU
1 1 15KW ELECTRIC MOTOR 415-3-50 & 440/480-3-60 5079776 WEG
4 POLE TEFV FOOT AND FLANGE MOUNTED
FITTED WITH 110 VOLT ANTI-CONDENSATION HEATERS
FITTED WITH THERMISTORS IP56 PROTECTION
ZONE 2 (CE Ex II 3G EExnA II T3)
2 1 GEAR PUMP P124-1" GEAR WIDTH P124A085D1ZA10-55+ATEX 5080535 HYDRA-PERM
3 1 CAST IRON BELLHOUSING PG350/06/04-00 5079806 KTR
4 1 DRIVE COUPLING R42.42-22.22F.GG.98sh + ATEX 5079807 KTR
5 1 OPEN BASE FRAME C/W BUND 5083471 PFP
6 1 200 LITRE OIL RESERVOIR (WORKING VOLUME) 5081507 PFP
7 1 RETURN LINE FILTER HH6420F24KNTB1YF15 5058244 PALL
1 VISUAL INDICATOR RC778NZ090H 5019964 PALL
8 2 MAGNETIC DRAIN PLUGS TMA12 5077190 HARRIER
2 OIL LEVEL GAUGES LG10T 5015223 PFP
11 1 AIR BREATHER HC0293SEE5 5007650 PALL
12 1 DUAL OIL LEVEL FLOAT SWITCH T/LL70-2 5080477 FOZMULA
1" BSP HEADER, NITROPHYLL FLOATS, 2 AMP REED RATING,
IP67 STAINLESS STEEL HEADER AND TUBE
SWITCHES SET AT 300M/M AND 400M/M
BOTH SWITCHES NORMALLY OPEN
13 1 SUCTION STOP VALVE 11/4" BSP 8103025 5057082 ISIS
15 1 TANK DRAIN VALVE BV12B 5001861 PFP
16 1 SPECIAL MANIFOLD 19714 WITH SAE FL RETURN PORT 5079675 DREELSIDE
Parts List PLH5741259

Customer: SMD LTD C1485 Order Number 166555

Originator: MICHAEL DEAN Date 13/02/2014
Approved By: Issue 1
Issued By: RJ Sheet No. 2 OF 4
Item Qty Description Product No. Supplier Ord No. Req Ack Rec Remarks
17 2 CHECK VALVE CXDA-XEN 5064162 SUN
18 1 RELIEF VALVE RPEC-KWN 5079680 SUN
1 LOCK NUT 990-999-018 5065690 SUN
19 1 PRESSURE FILTER HH4610S20KNSB1 DR PLUG 5058243 PALL
1 VISUAL INDICATOR RC778NZ090H 5019964 PALL
21 1 DIRECTIONAL VALVE DHA-0710-M-24VDC 5066776 ATOS
22 1 DUAL FLOW CONTROL METER OUT NCEB-KCN-GBZ/S 5079681 SUN
23 3 TEST POINTS SMK20-G1/4"-PC 5023723 STAUFF
24 1 TEST CONNECTOR SMD20-G1/4" 5023713 STAUFF
25 1 PRESSURE GAUGE 63 M/M DIAMETER RANGE 0-400 BAR 5015545 PFP
26 1 ELECTRICAL CONTROL CABINET (ZONE 2) 15KW ES100722 5083381 ELEC SAFE
27 1 PENDANT 07-3513-10P74P4N81 5067564 PARM. GRAH.
28 1 FILL POINT SELF SEAL COUPLING ANV 3/4" MALE 84003 5019498 ISIS
1 FILL POINT SELF SEAL COUPLING ANV 3/4" FEMALE 84103 5019497 ISIS
1 DUST CAP TMA34 5082068 ISIS
1 DUST CAP TFA34 5025591 ISIS
29 1 RETURN HOSE 1" BORE R2AT 15 METRES LONG PFP
RETURN HOSE DIRECTLY BACK TO TANK
30 1 FLAT FACE COUPLING 3/4" FEMALE F.FL13 3/4" BSP 5079679 ISIS
31 1 DUST CAP TM2FI12 5077093 ISIS
32 2 PRESSURE HOSE 1/2" BORE R2AT 15 METRES LONG PFP
33 2 FLAT FACE COUPLING 1/2" FEMALE F.FL9 1/2" BSP 5079678 ISIS
34 2 DUST CAP TMF38 5077094 ISIS
Parts List PLH5741259

Customer: SMD LTD C1485 Order Number 166555

Originator: MICHAEL DEAN Date 13/02/2014
Approved By: Issue 1
Issued By: RJ Sheet No. 3 OF 4
Item Qty Description Product No. Supplier Ord No. Req Ack Rec Remarks
35 1 TEMPERATURE GAUGE BH226 5065692 BRIT ROT
1 POCKET TW001 (NO STAND OFF REQUIRED) 5065967 BRIT ROT
1 SHOT BLAST AND PAINT 2 PACK EPOXY 3 COAT SYSTEM 5080295 NL WILLIAMS
SMD INSTRUCTION 019 SYSTEM 2
1 MAIN FRAME TO BE TESTED TO DNV 2.7-3 5080263 LLOYDS
36 1 GRP GRATING COVER TO DRAWING 5724195D1 5079925 GRATING CO
37 10 "M" TYPE CLIPS 5068776 GRATING CO
38 1 SET OF IDENTIFICATION LABELS
1 WIRE ELECTRICAL CABINET MOTOR AND SWITCHES 5080177 PFP
41 4 DECK MOUNTING BRACKET TO DRAWING AA7853-1 5079901 PFP
1 ZYLON COATING OF MANIFOLDS 5081950 SURF. TECH
42 1 LIFT SET RATED FOR 2 TONNE DNV 2.7-1 5081891 EAST&DICK
2 THERMOSTATS 060L310466 KPS79 5068217 DANFOSS
2 POCKET 060L327166 5068218 DANFOSS
2 GASKET SET 060L036666 5068219 DANFOSS
1 50 METRES POWER SUPPLY CABLE 6M/M 4 CORE BLACK 5078677 CABLE SERV
SPEC 6584TQ6
1 GLANDS (TO BE FITTED BY CUSTOMER) 32M/M A2F EXD/E 5078672 CMP
1 LOAD TEST LABEL AB2493 5080231 LEWIS HOWE
1 HPU LABEL AA7905 5081503 LEWIS HOWE
Parts List PLH5741259

Customer: SMD LTD C1485 Order Number 166555

Originator: MICHAEL DEAN Date 13/02/2014
Approved By: Issue 1
Issued By: RJ Sheet No. 4 OF 4
Item Qty Description Product No. Supplier Ord No. Req Ack Rec Remarks
44 1 WATER OIL COOLER FG080-3877-1 5004241 BOWMAN

45 1 COOLER MOUNTING BRACKET 5738609F1 5084709 LASER

46 1 SAE FILTER INTERFACE PLATE 5083470 PFP

4 1 COOLER INLET HOSE PFP

1-3000 SAE 45 x DIN 30s 90

5 1 COOLER OUTLET HOSE PFP

1-3000SAE ST. x DIN 30s 90

6 1 BOLT KIT PFP

 34
PORT SIZES
33 C4, C5 - 1/2" BSP
C7 - 3/4" BSP
32 R1 -3/4" BSP
23.1 23.2 R2 - 1" BSP
EXTENT OF POWER UNIT C3 C4 C5 C6 C7

31.1 22 17.2

A B

21 FILL POINT
P T C8

17.1 28
27
24 26

19b 19a
PENDANT ELECTRICAL PANEL
18
25 23
C2
16
??

C1 C9

WATER OUT
1 1/4" 30 31

WATER IN 44
1 1/4"

29
12
35 LPM @ 60 HZ

T1 T2 7b 7a LV1
11
43.1 43.2
R1 R2

RESERVOIR
9.1
250 LITRES

1 2 6

9.2
15KW
1800 rpm 35 8.1 8.2
460v 3ph 60Hz 3
15KW 4
1500rpm
415v 3ph 50Hz

SMD REF IA2700

13
15
ISSUE CKD.BY REVISION BY DATE TOLERANCES DRAWN P.T./M.D
SURFACE FINISH
A THIS DRAWING IS THE PROPERTY OF
(EXCEPT WHERE OTHERWISE STATED)
PRIMARY FLUID POWER ROUGH MACHINE FABRICATION DIMS. +OR- 1.0 mm. CHECKED
MARKS VISIBLE MACHINING DIMS. +OR- O.2 mm.
IT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT. IT MUST NOT ANGLE DIMS. +OR- O.5 DEGREES DATE MARCH 2014
BE LOANED, COPIED, REPRODUCED OR COMMUNICATED EITHER SMOOTH MACHINE
MARKS JUST VISIBLE
WHOLLY OR IN PART TO A THIRD PARTY WITHOUT THEIR WRITTEN THIRD ANGLE TITLE DRG. NO. ISSUE
HYDRAULIC CIRCUIT 15KW POWER UNIT
PERMISSION AND MUST NOT BE USED FOR ANY PURPOSE DETRIMENTAL FINE SMOOTH MACHINE PROJECTION
TO THE INTERESTS OF THE AFOREMENTIONED COMPANY. MARKS NOT VISIBLE SMD - C1485 - ZONE 2 5741259C1 A
SCALE @ SIZE A1
 1
2" BSP
PUMP OUTLET
4 HOLES Ø14 FILL POINT
50HZ 29 LPM

200
60HZ 35 LPM

150
C4 C3
44 C8

MAXIMUM WORKING PRESSURE 210 BAR C7 C5 C6

45

POWER PACK PROTECTION IP56 46 90 3

4" BSP
43.1 43.2 12 6 11 7 1
RESERVOIR VOLUME 200L 230 2" BSP
WATER OUT
FLOAT SWITCHES SET TO 300mm & 400mm FROM TOP OF MOUNTING BOSS
SEA FIXING DETAIL PORT CONNECTIONS
ESTIMATED WEIGHT WITHOUT OIL 1030 KG POWER UNIT
ESTIMATED WEIGHT WITH OIL 1250 KG 4 OFF

LOAD FRAME TEST DNV 2.7-3

2 POINT LIFT PROOF LOAD TEST FACTOR = 1.5 x MGW SEA FIXING COMPONETS AS KIT
LIFTING LUGS 23 MM HOLE DIAMETER X 25 THICK 4 OFF
36 WATER IN R2 - 1" BSP
RETURN 4 H0LES Ø14 THRO'
MOTION 38mm GRP GRATING
200 20
30 140
FULL LOAD CURRENT (415V) 28A 142

50
FULL LOAD CURRENT (460V) 27.9A R5 TYP
STARTING CURRENT (STAR DELTA) 2 X F.L.C.

230
20
200
SUPPLY POWER

142
130
415V 50Hz - 23 KVA
460V 60 Hz - 26 KVA SMD DRAWING AD6111-0

1515
1115 739 C OF G WITH OIL 544 C OF G WITH OIL

21
26 28 22 19

FILL POINT

25

23.?
C8 C4 C3 16
C7 C5 C6 17 23.?
R1 - 3/4" BSP
RETURN 18

9.1
1360

9.2
587 C OF G WITH OIL

35

13

EARTHING BOSS
C/W M12 BRASS BOLT
DRAIN VALVE & 2 FLAT WASHERS
2 3 1 5 8.1 15 8.2
EARTHING BOSS
4 SMD REF IA2700
C/W M12 BRASS BOLT ISSUE CKD.BY REVISION BY DATE
& 2 FLAT WASHERS
TOLERANCES DRAWN P.T.
SURFACE FINISH
THIS DRAWING IS THE PROPERTY OF
(EXCEPT WHERE OTHERWISE STATED)
PRIMARY FLUID POWER ROUGH MACHINE FABRICATION DIMS. +OR- 1.0 mm. CHECKED S.G.
MARKS VISIBLE MACHINING DIMS. +OR- O.2 mm.
IT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT. IT MUST NOT ANGLE DIMS. +OR- O.5 DEGREES DATE APRIL 2013 Fluid Power
BE LOANED, COPIED, REPRODUCED OR COMMUNICATED EITHER SMOOTH MACHINE
MARKS JUST VISIBLE
WHOLLY OR IN PART TO A THIRD PARTY WITHOUT THEIR WRITTEN THIRD ANGLE TITLE DRG. NO. ISSUE
PERMISSION AND MUST NOT BE USED FOR ANY PURPOSE DETRIMENTAL FINE SMOOTH MACHINE PROJECTION 15KW POWER UNIT GENERAL ARRANGEMENT
TO THE INTERESTS OF THE AFOREMENTIONED COMPANY. MARKS NOT VISIBLE S.M.D. - C1485 - ZONE 2 57341259G1 A
SCALE 1:5 @ SIZE A0
REFERENCE DOCUMENTS
DRAWING 5741259G1 - 15KW POWER UNIT G.A.
LIFT SET 7314/8 - 4 WIRE ROPE SLING SET

NOTES:
1. WEIGHT WITHOUT OIL 1030KG
WEIGHT WITH OIL 1250KG
2. LOAD FRAME TEST DNV 2.7-3
POINT LIFT PROOF LOAD TEST FACTOR = 1.5 x MGW
3. INSPECT LIFT POINTS AND RIGGING BEFORE EACH USE
4. IF IN DOUBT ASK.

2347

1360

587 C OF G WITH OIL

739 C OF G WITH OIL 544 C OF G WITH OIL

1515 1115

SMD REF IA2700

ISSUE CKD.BY REVISION BY DATE TOLERANCES DRAWN P.T.
SURFACE FINISH
THIS DRAWING IS THE PROPERTY OF
(EXCEPT WHERE OTHERWISE STATED)
PRIMARY FLUID POWER ROUGH MACHINE FABRICATION DIMS. +OR- 1.0 mm. CHECKED S.G.
MARKS VISIBLE MACHINING DIMS. +OR- O.2 mm.
IT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT. IT MUST NOT ANGLE DIMS. +OR- O.5 DEGREES DATE APRIL 2013 Fluid Power
BE LOANED, COPIED, REPRODUCED OR COMMUNICATED EITHER SMOOTH MACHINE
MARKS JUST VISIBLE
WHOLLY OR IN PART TO A THIRD PARTY WITHOUT THEIR WRITTEN THIRD ANGLE TITLE DRG. NO. ISSUE
PERMISSION AND MUST NOT BE USED FOR ANY PURPOSE DETRIMENTAL FINE SMOOTH MACHINE PROJECTION 15KW POWER UNIT LIFTING DRAWING
TO THE INTERESTS OF THE AFOREMENTIONED COMPANY. MARKS NOT VISIBLE S.M.D. - C1485 5741259G2 A
SCALE 1:5 @ SIZE A0
 N .1. WILLIAMS
G ROUP
l/estside Industrial Estate
Jackson Street
st. Helens
M erseyside
Primary Fluid Power Ltd WAg 3AT
Caddick Road
Knowsley Business Park

vl o- Knowsley
Merseyside
134 gHP

Ap.|l2014

CERTTFTCATE oF CoNFoHMTTY

Dear Sirs,

NLW Job Rel.: 041418223PF

PFP Order No.: 5378588
Mark lD.: C1485MD

We hereby confirm that the following free issue items associated with the aforementioned
order number(s) have been processed in accordance with your advised specilication.

Item(s): Frame x 4
Tank x 4
Lidx4

Specification

1. Shotblast SA 2.5 BS EN ISO 8501-1(2007) 857079:PartAl (1989)

2. Zinc Bich Primer.........-........ .............60pm DFT
3. Hi-Build Epoxy Coating..... ..............220pm DFT
4. Acrylic Urethane.............. .................50pm DFT

Controlling Specs.: Norsok M501

lssue: Rev.6, February 2013
Coatings System No.: 1 (Pre-Qualified)

Minimum DFT: 330pm

Finish Colour: RAL 3002
Delivery Note: 044176

Paint Supplied: lnternational Paints Ltd, Stoneygate Lane, Felling, Gateshead, Tyne & Wear,
I NEl O OJY

Yours faithlully,

&:cr*.U---,.
I Jack.S.Bromilow
Ouality Assurance
for NL Williams Group Ltd

1U
E
Website:
26526 Fax: +44 l0)1744 22551
Telephone: +44 10)1744
wwwsafetysurfacing uk.com Email: enquiries@safetysurfacing

Co, Registration No. I t 36318

uk com
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 LbvdsBritishrsstinsltd
LLOYDS
BBITISH
MAGNETIC PARTICLE INSPECTION REPORT
Customer: PRIMARY FLUID PoWER LTD Report No.: 238371/NDT/001
Rig: N/A Job No.: 238371
Location: KNOWSLEY IND PARK, MERSEYSIDE W.O. No.:
.u. t\to.: cJ rt 4uJ
Description: L|FT|NG FRAME ldentification No.:
c,t268MD

Material: STEEL Surface Condition:CLEAN&DR\ C

/Ueldinq Process: Test Temoerature:A|\4B|ENT "C
/Uelder lD: Illumination: 600 Lux
)rawing No.: Examination Dale 28l13l I 4

MAGNETIC PARTICLE TEST

Equipment Serial No Test Weioht Magnetizing process: cor(inuous.l_11 Residudl_l
l\4agnetizing current:
Y6 YOKE LBry1 4.5 KG
Atternatinolll Hafwavel-l oi,*l--l
Consumables TvDe Batch No. L4agnetizing coirl_l Prods YokelX I

/y'hite Contrast Paint J &A 121103 l/ethod: Permanent lvlasnet:

3lack Maqnetic lnk 130206 lndicator:
lilagnetic Field Burmah Castrol Strip
l/Vet Fluorescent N/A N/A Intensitv:
Blacklioht N/A
)rv Powder N/A Demaqnetization: Yes No

Specification: BS EN tSO 9934.2001

fechnique: lvlagnetic Particles: or.vl--l w*l-il
Cther: visiblel- Flror""""ntl---l
Scope of Work: MPI CARRIED OUT TO TOP LIFTING LUG WELDS ON FRAME C1268MD

, 2\
lnspection Result:
NO INDICATIONS FOUND ,

Qualification: Clients Rep.: Position:

PCN Level ll Sign:

Date:

238371.001 - PRIMARY FLUID MPI.xls

 JOHN TEIRE & COMPANY LTD
180 RIMROSE ROAD, BOOTLE, MERSEYSIDE, L2O4QS
TEL: 0151-944-1027 F^x:0151-922-6739

REPOR.T OF THOROUGH EXAMINATION OF LIFTING EQUIPMENT

THIS REPORT COMPLIES WiTH THE REOUIREI\IENTS OF THE LIFTING OPERATIONS AND LIFTING EQUlPMENT

DATE OF EXAM: 07/03i 2014 DATE OF REPORTT 0710312014 DATE OF LAST EXAM: FIRST EXAIV]

LATEST DATE FOR NEXT EXAM; 6 NiIONTHS FRONI ABOVE ORDER NO; 5378231

SWL OETAIL OF ANY DEFECT

I.D. NOS DESCRIPTION (TONNES) WHICH IS OR MAY BECOME
A DANGER TO PERSONS

1 OFF 4 LEG SLING SET TO DNV SPEC

MASTERLINK AT TOP FITTED WITH '18MI\,4 2 TONNES
7314I DIA 6X36 IWRC X 1.25 METRE LEGS @0-45 NONE
TERMINATING WITH THIMBLE EYES WITH DEGREES
FLEIVIISH EYE SPLICE AND STEEL TAPER
FERRULES TERI\,4INATING WITH 3/4' ALLOY
SAFETY BOW SHACKLES

Particulars of any repair, renewal or alteration required to Was the examination carried out
remedy the defect identified above: N/A
'1. Prior to new delivery YES
2. Within an interval of 6 months NO
3. within an interval of 12 months NO

ls defect an immediate danqer to persons; N/A lf "NO" date bv which it could be a danqer: N/A

Details of anv test completed as part of examination: NiA

Name of inspector making this report: ls this equipment safe to operate: YES
BILL CAIRNS

Name of person authenticating report: Signed:

MICHAEL WINTER
 DOCNO: l0l -5.I

a7 rlrT.fr"[y GENERAL
TEST CERTIFICATE
ISSUE: I
DATE:
PAGE:
0l/11102
t OF I

Customer: Soil Machine Dl,namics Limited, Turbinia Works, Dar.y Bank,

Wallsend, T1,ne & Wear, NE28 6UZ

Customer Order Number: 166555

P.F.P Job Number: 5'741259 Certificate Number: 5'741259/l

Description: 15KW 250 Litre Deck Cart Power Unit C1485MD

Te,qt-e AUied Out

Pressure and Function Test of Hydraulic Power Unit

Electric Motor Serial Number: 102045584'/
Note Test carried out at 50HZ

Pump Flow 28.8 LPM @ 0 Bar

Relief Valve set to 210 Bar

Sling Set: 7314 / 8

Witnessed By Name Position Sisnature

Primary Fluid Power: M Dean Project Engineering

Customer:

Inspection Authority:

Date: 30 April20l4
 DOC NO: 101-5.1
ISSUE:
?7,,ry"ary GENERAL
TEST CERTIFICATE DATE:
PAGE:
I
01llll02
I OF I

Customer: Soil Machine Dynamics Limited, Turbinia Works, Dary Bank,

Wallsend, Tyme & Wear, NE28 6UZ

Customer Order Number: 166555

P.F.P Job Number: 5741259 Certificate Numbe( 5741259/2

Description: l5KW 250 Litre Deck Cart Power Unit - C l485MD

leel ce,r,rie,C''q''!*

Noise Test ofHydraulic Power Unit

Noise Readings taken at 1 metre from floor level and
I Metre from Power Unit

Test Besullc

Pump Pressure 0 Bar Pump Flow 28.8 LPM

Maximum Level 75.0 Db Minimum Level 72.0 Db

Pump Pressure 210 Bar Pump Flow 0 LPM (Across Relief Valve)
Maximum Level 82.0 Db Minimum Level 75.0 Db

Witnessed By Name Position Sigrature

Primary Fluid Power: M Dean Project Engineering

Customer:

Inspection Authority:

Date: 30 April2014
 DOC NO: 101-5.1
GENERAL ISSUE: I
rr.g_ty TEST CERTIFICATE DATE:
PAGE:
0lll ll02
I OF I

Customer: Soil Machine Dynamics Limited, Turbinia Works, Dary Bank,

Wallsend, Tyne & Wear, NE28 6UZ

Customer Order Number: 166555

P.F.P Job Number: 5741259 Certificate Numben 574125913

Description: 15KW 250 Litre Deck Cafi Power Unit CI485MD

Test Carried Out

Cleanliness Test ofHydraulic Power Unit

Witressed Bv Name Position Signature

Primary Fluid Power: M Dean Project Engineering

Customer:

Inspection Authority:

Date: 30 April2014
 FACTORY ACCEPTANCE TEST FOR 15KW HYDRAULIC DECK CART POWER UNIT FOR S.M.D.
PFP JOB NO. 5741259
PU IDENTIFICATION 5741259
SMD ORDER NO. '166555
SMD JOB NO. c148sMD

WITNESS
ID ITEM/FUNCTION PROCEDURE COMMENTS
PFP SMD
1 DII\,lENSIONAL CHECK O/A, LIFT LUGS, DECK MOUNTS, MD
2 CHECK MOTOR CHECK LABEL 1sKW 440-3-60 4 POLE MD
NOTE TEST CARRIED OUT WITH 415V-3PH-sOHZ
NOTE CALCULATED PUMP FLOWS WILL BE 20% [,4ORE THAN TEST RESULTS
3 RECORD I\,1OTOR SERIAL NO REAO LABEL SERtAL NO. 1020455847 MD
4 BELLHOUSING CHECK FOR DRAIN HOLE MD
5 TEST EOUIP, FITTED FIT FLOW I\iIETER MD
6 HYD CONNECTJONS CHECK HOSES AND FITTINGS MD
7 OPEN SUCTION BALL VALVE MD
I BACK OFF RELIEF VALVE TURN ANTI-CLOCKWISE I\,1INIMUM SETTING MD
9 JOG START MOIOR CHECK ROTATION CLOCKWISE MD
10 START MOTOR RUN UNDER NO LOAD MD
11 MOTOR LOAD RECORD AMPS 13.3 AMPS MD
12 OPERATE PENDANT CONTROL MD
13 PUMP FLOW READ FLOW IIIETER UNLOADED 28,8 LPM MD
14 CLOSE BALL VALVE FLOW WILL GO ACROSS R V FLOW WILL GO TO ZERO MD
15 SET RELIEF VALVE SCREW IN SLOWLY SET TO 210 BAR MD
MOTOR LOAD RECORD AI\,1PS 26.4 AMPS MD
17 OPEN BALL VALVE MD
18 OPERATE PENDANT CONTROL MD
19 PUMP FLOW YOU WILL READ NO FLOW ONLY ONE OUTLET MD
20 PUMP PRESSURE READ GAUGE SHOULD BE 210 BAR MD

21 OIL CLEANLINESS TAKE SAI!1PLE CLEANLINESS LEVEL NAS 6 MD

22 BASIC CHECK OF ELECTRICAL CONTROL BOX MD

23 MOTOR START PRESS START BUTTON MD
24 MOTOR STOP PRESS STOP BUTTON MD
25 MOTOR START PRESS START BUTTON MD
EMERGENCY STOP PRESS EI\,lERGENCY STOP MD
27 MOTOR START PRESS START BUTTON MD
2A PENDANT EMERGENCY STOP PRESS EIV]ERGENCY STOP MD
29 MOTOR SHOI.JLD NOTE START WHILE EIUERGENCY STOP BUTTON IS DEPRESSED MD
30 PRESSURE FILTER BLOCKED I\,,IANUAL INDICATION MD
31 RETURN FILTER BLOCKED MANUAL INDICATION MD
LEVEL SWITCH CHECK DRAIN TANK MD
33 LOW OIL WARNING DRAIN TANK LEVEL SWITCH IS SET TO 3OO MD
34 LOW OIL SHUTDOWN DRAIN TANK LEVEL SWITCH IS SET TO 4OO MD
35 LOAD TEST CERTIFICATE VISUAL CHECK MD
MPI REPORT VISUAL CHECK MD
37 CERT, OF CONFORMITY - PAINT VISUAL CHECK MD
3B TEMP SWITCH WARNING VIEW LAMP 55 DEG C MD
TEMP SWITCH SHUTDOWN SWIICHES I\,IOTOR OFF 65 DEG C MD
40 CORROSION PROTECTION VALVOLINE TECTYL ON ALL AREAS MD