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SERVO-HYDRAULICS

Technical documentation
Start-up of hydraulic system
SUPPLEMENT TO OPERATING MANUAL - SERVO-HYDRAULICS

Technical documentation: actuator units

Lever

Connecting cable

Connection P
(marked red)

Proportional magnets

Connection T
(marked blue) Single actuator units
as extension

4-fold actuator unit

General parameters
Design Actuating piston with mechanical transmission to a lever with integrated hydro-
mechanical closed-loop control circuit.
4-fold actuator unit as basic module, comprising 4 actuators and connection for
hydraulic hoses.
Single actuator unit, suitable for flange mounting on 4-fold actuator unit (or as
autonomous unit on adapter plate); in this way, the 4-fold module can be extended as
required (max. number: 6) by mounting single actuator units on top of each other.
By flanging single actuator units to an adapter plate, it is also possible to construct
actuator units containing more than 4 actuators.
Mounting On 4-fold actuator unit using four M8 screws (supplied) or on adapter plate using
two M8 screws
Mounting position Any
Force 500 N (18 bar)
800 N (30 bar)
Mass 4-fold actuator unit : 12.5 kg
Single actuator unit : 3 kg
Ambient temperature range -25°C ..... +50°C

Hydraulic parameters
Operating pressure
Temperature of pressure medium
Viscosity range
Oil consumption
Leakage oil
Filtration absolute
Hydraulic connections
max. 30bar Standard 18 bar
max. 60°C
2
10 .... 200 mm /s
3
5.9 cm per stroke and actuator unit
approx. 0.12 l/min per actuator unit
1 mm
Connection P (red) Screw coupling 8-L (DIN2353)
Connection T (blue) Screw coupling 10-L (DIN 2353)

Page 1
Electrical parameters (magnet)
Nominal voltage 12 V= (VDC) 24 V= (VDC)
Nominal current IN 1800 mA 900 mA
Nominal output approx. 22 W approx. 22 W
Resistor R20 5.6 W 21.2 W
Duty cycle 100 % 100 %
Electrical connection "Junior Timer" plug
Cable (included in extension kit) "Junior Timer" socket; 2.5 m long
Degree of protection IP 65

Accessories
Extension kit (compl. kit) 1 kit per actuator unit = 4-fold actuator unit = 4 kits
containing: · 1 threaded rod M8 x 200
· 2 nuts M8 · 1 ball cup
· 1 fork head · 1 welding plate

Adapter plate For connecting one or more single actuator units

containing: · 4 locking screws · 2 fastening screws M8
· 2 connecting screw couplings (hydraulics)

Connection kit For connecting hydraulic supply to actuator unit

Hydraulic system For supplying the actuator unit (see data sheet)
Duty type = standard; independent of main hydraulic circuit, thus ensuring a
constant, high-quality supply to the actuator unit
Pressure supply module For supplying the actuator unit (see data sheet) from the main hydraulic circuit;
there may be a loss of performance and risk of contamination, however.
Emergency stop valve For interrupting the main hydraulic supply

Stroke extension 97
90
800 80
The lever can be extended according to mm
700 Force at 30
Kraft bei 30 bar
bar 70
mm
the desired stroke (please note that
Extension in in

this reduces the force). 600 60

Verlängerung
in NN
Kraft in

500 50
Force

400 40
Example:
300 30
200 20
Desired stroke: 20 mm
100 Kraft bei
Force at 18 bar 10
Extension = 43 mm
Force at 18 bar = 320 N 0 0
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

Force at 30 bar = 480 N

Hub ininmm
Stroke mm

The reduction of the lifting force is negligible, however, as the required stroke extension depends on the transmission ratio of
the linkage at the main valve.

(Force x displacement = 100 %)

Page 2
Dimensions
256

165
P T

180 40,4 R 1/4"

R 1/4"
mit 129
with
Verschraubung
screw coupling
(T = 10L; P = 8L)
(T = 10L; P = 8L)

View from the bottom

129
12

85
4 x M8/12

Assembly of the rods and securing of the ball connection

Welding plate

Fork head with

safety bow
Threaded rod

Ball socket secured

Counter nuts

Ball socket safety device Ball socket safety device

open closed

Page 3
Technical documents: hydraulic unit

Motor cable

Electric motor

Return filter

Tank connection T
Pressure setting device (marked blue) 10L

Flushing connection Pressure connection P

(locked) (marked red) 8L
Magnetic valve Measuring connection
(locked) R 1/4"

Tank

General parameters
Design Compact, factory-assembled unit.
The interconnection allows energy-saving control which minimizes
power losses.
Mounting position Vertical:
Tank always at the bottom
Horizontal:
Advantage: filter at the top to prevent oil escaping during filter changes.
The oil filler neck has a vent and must always be at the highest point
(if necessary, the tank can be rotated accordingly).
Mounting At the bottom using two M8 screws (supplied) or at the side

Technical data, hydraulic

Oil capacity about 4 - 5 l hydraulic oil,
minimum quality ISO 32 with viscosity index > 160 (e.g. AeroShell Fluid 71)
Volumetric capacity 2.5 l/min
2
Viscosity range 10 ... 200 mm /s
Pressure 18 bar (standard pre-setting) max. 30 bar
Return filter 10 m
Hydraulic connections Pressure connection P (red) Screw coupling 8L, DIN 2353
Tank connection T (blue) Screw coupling 10L, DIN 2353
Flushing connection (sealed) Screw coupling 10L, DIN 2353
sealed
Measuring connection R 1/4" (sealed)

Page 4
Technical data, electrical
Voltage (motor & valve) 24 V 12 V
Power consumption of motor 250 W 250 W
Nominal current of motor 12.5 A 25 A
Power consumption of valve 19 W 19 W
Duty cycle (motor & valve) 100 % 100 %
Degree of protection min. IP 55 min. IP 55
Valve connecting cable 2.5 m long, with "Junior Timer" plug
Motor connecting cable 2.5 m long, blue= - , brown= + , or according to identification on cable
Attention!
If the cables are incorrectly connected, the sense of rotation of the motor
(clockwise in relation to the motor axle) will be wrong, which can soon lead
to the destruction of the pump !
Ambient temperature range -25°C ... +50°C
Oil temperature max. 60 °C

Hydraulic circuit diagram MP P T S

18 - 30 bar

1,5 bar

Page 5
Dimensions

Einfüll-
Filling and& ventilating
Belüftungsanschluss
connection
ø ~180

ø 180
~220

1
8
0
~
1
0
0

B 220 135
~500 160

A ~270

130

80
P
T
MP

2 x M8
S

Ansicht
View A/B A/B
(Befestigung)
(fixing)

Assembly and start-up

The hydraulic unit is mounted using the fastening screws and connected to the actuator unit by means of hoses.

Prior to start-up: · Fill the unit with oil

about 4 - 5 l hydraulic oil, minimum quality ISO 32 with viscosity index > 160
(e.g. AeroShell Fluid 71)
· Check the sense of rotation
· Vent the entire system according to the venting instructions

Maintenance
The hydraulic unit is largely maintenance-free.
The electrical and hydraulic connecting elements should be checked periodically, however, and tightened/refastened as
necessary.

The filter should be changed after every 500 operating hours.

Attention!
A dirty filter can lead to the destruction of the entire hydraulic unit!

Oil changes: You should change the oil after every 1000 operating hours or at least once a year.
Hydraulic oil, minimum quality ISO 32 with viscosity index > 160 (e.g. AeroShell Fluid 71)

Page 6
Connecting diagram

Actuator unit(s)
T (10-L)
Fixing 4 x M8 marked blue
Main valve

P (8-L)
marked red

Proportional Proportional
magnet(s) magnet(s)

P T
Welding plate

P (8-L) T (10-L)
marked red marked blue

Small unit
from main pump

Page 7
Technical documents: supply unit

Pressure filter Connection S

(measuring connection)
Connection T
(marked blue) Connection PM

Connection P Tank connection T1

(marked red)

Magnetic valve

Pressure setting device

Connection PR (covered)

General parameters
Design Compact hydraulic module for supplying the actuator unit from the
normal hydraulic circuit of the truck.
With integrated pressurisation and filtration of the supply oil for the
actuator unit. The pressurized oil is made to circulate without pressure
by a solenoid valve in order to minimize power losses.
Mounting position Any
The filter should face vertically downwards in order to prevent the oil from escaping
while changing the filter.
Mounting At the bottom using two M8 screws (supplied) or at the side
Option If necessary, an emergency stop valve (unpressurized circulation of entire
main system) can be flange-mounted directly to the unit.

Technical data, hydraulic

Flow rate Actuator unit supply Main circuit
approx. 4 l/min approx. 90 l
Pressure 18 bar (standard), max. 30 bar max. 300 bar
2
Viscosity range 10 ... 200 mm /s
Filtration Supply circuit 10 m; the main circuit is not filtered, but it is advisable to do so
using a main filter according to the specifications of the crane manufacturer.

Hydraulic connections
Actuator unit supply
Main circuit
Leakage oil connection
Oil temperature
Pressure connection P (red) Screw coupling 8L, DIN 2353
Tank connection T (blue) Screw connection 10L, DIN 2353
Flushing connection S (sealed) Screw connection 10L, DIN 2353
measuring connection also sealed
Pump connection PM R 3/4" internal
Pressure transfer tube PR R 3/4" internal
Leakage oil T1 R 3/8" internal
The latter should be introduced into the tank without pressure where possible
in order to avoid unnecessary power losses, although it can be connected to
the normal return tube
max. 60°C

Page 8
Technical data, electrical
Valve voltage 24 V 12 V
Valve power consumption 19 W 19 W
Duty cycle of valve 100 % 100 %
Degree of protection min. IP 55 min. IP 55
Valve connecting cable 2.5 m long, with "Junior Timer" plug
Ambient temperature range -25°C ... +50°C

Hydraulic circuit diagram

P
18 - 30 bar
T1 T

M3
M1
M2
PM PR

Connecting diagram

Actuator unit(s)

Fixing 4 x M8
T (10-L) Main valve
marked blue

P (8-L)
marked red

Proportional Proportional
magnet(s) magnet(s)
P T
Welding
plate

Supply unit P (8-L) marked red

T (10-L) marked blue

PR (3/4")

from main pump

If possible, lead directly in the tank
PM (R3/4") T1 (3/8") in a depressurized way
(reduced power loss)

Page 9
Dimensions
70
70

10
10

10
1
0
4 x M8

770
0

R 3/8"

189
T T1

1
8
9
P
PM

103
S PM PR

63.5

1
0
3
80
8
0

6
3
.5
PR

R 3/4"
R 3/4" 90
90 259
259

Assembly and start-up

The supply module is mounted using the fastening screws and connected to the actuator unit by means of hoses.
Prior to start-up, the entire system must be vented according to the venting instructions

Maintenance
The supply module is largely maintenance-free.

The electrical and hydraulic connecting elements should be checked periodically, however, and tightened/refastened as
necessary.

The filter should be changed after every 500 operating hours.

Attention! A dirty filter will block the supply to the actuator unit!

Oil changes:
The oil should be changed after every 1000 operating hours or at least once a year.
Hydraulic oil, minimum quality ISO 32 with viscosity index > 160 (e.g. AeroShell Fluid 71)

Page 10
Operating instructions - start-up of hydraulic system

Venting (with supply module)

Before the system can be put into operation, it has to be vented.

For this purpose, remove the hose from connection T on the supply module and connect it to connection S.
This is done in the following order:

1. Switch off the main drive (hydraulic pump).

2. Disconnect the linkage from the actuator units.
3. Remove the sealing plug from connection S.
4. Remove the hose from connection T
and attach it to connection S.
5. Mount the sealing plug on connection T
Sealing plug Tank hose T
ATTENTION:
on connection T (marked blue)
Failure to mount the sealing plug will
on connection S
cause oil to escape!
6. Remove the plug from the supply module.
7. Switch on the main drive (hydraulic pump). Tank hose T1
8. Put the radio system into operation. Plug
removed
9. Actuate each actuating cylinder in each
direction by radio for one minute,
beginning with the cylinder furthest from
the oil connections.
Since there is no power available, you will only see a slight movement or none at all!
It is helpful to actuate the relevant actuator unit manually at the same time.
10. Undo the vent screw of the built-in valve (do not remove) and wait until
bubble-free oil emerges, then re-tighten.
11. Switch off the main drive (hydraulic pump).
12. Swap hose from connection S to connection T.
13. Seal connection S.
14. Insert plug and engage linkage.
The system can now be put into operation.

If the system is not sufficiently vented, the following effects may occur:
! Vibration or "stuttering" of the system
! Poor controllability
In this case, it may be necessary to repeat the venting procedure.

CHANGING THE OIL FILTER PRESSURE SETTING

1. Every 100 operating hours (or approx. half-yearly).

2. Thereafter, every 500 operating hours (or yearly).

Standard 18 bar

Page 11
Operating instructions - start-up of hydraulic system

Venting (with electric pump)

Before the system can be put into operation, it has to be vented.

For this purpose, remove the hose from connection P on the hydraulic unit and connect it to connection S.

This is done in the following order:

1. Disconnect the system from the power supply (motor of unit should not be running).
2. Disconnect the linkage from the actuator units.
3. Remove the sealing plug from connection S.
4. Remove the hose from connection P
and attach it to connection S.
5. Mount the sealing plug on connection P.
ATTENTION: Failure to mount the sealing plug
will cause oil to escape under pressure!
6. Put the radio system into operation so that the unit starts up. T

7. Actuate each actuating cylinder in each direction

by radio for one minute. S
P
Since there is no power available, you will only see
a slight movement or noneat all!
It is helpful to actuate the relevant actuator unit
manually at the same time.
8. Disconnect the system from the power supply again.
9. Swap hose from connection S to connection P. Pressure hose Pressure Sealing plug
(marked red) gauge on
10. Seal connection S.
on connection S connection connection P
The system can now be put into operation.

If the system is not sufficiently vented, the following effects may occur:
! Vibration or "stuttering" of the system
! Poor controllability
In this case, it may be necessary to repeat the venting procedure.

CHANGING THE OIL FILTER PRESSURE SETTING

1. Every 100 operating hours (or approx. half-yearly). Standard 18 bar

2. Thereafter, every 500 operating hours (or yearly).

Technische Unterlagen - Inbetriebnahme Servohydraulik, englisch

Teile-Nr.: 3.150.1077 · Technische Änderungen vorbehalten. Stand 10.06
We reserve the right to alter specifications without notice. Edition 10.06

Page 12 NBB Controls + Components AG · Otto-Hahn-Str. 3-5 · DE-75248 Ölbronn-Dürrn · Tel.: 0 72 37/ 9 99-0 · Fax: 0 72 37/ 9 99-199