MANUAL FOR

HYDRAULIC SYSTEM
JJ 27.03.01-01
K2/403/F68/A1.Y/11/S251/V1/N01
B1840
Rev. 0

1/21

Declaration of incorporation of machinery component

The Machinery Directive 2006/42/EC Annex II B

Representative
Company:
Address:
Postal code/city:
Country:
Telephone:
Fax:
Web:
Mail:

AVN Hydraulik A/S

Dalager 5
2605 Brndby
Denmark
+45 70 20 04 11
+45 43 24 55 05
www.avn.dk
Avn.hydraulik@avn.dk

Machine:
Type:
Serial no:
Year:

Pump Unit B1840

K2/403/F68/A1.Y/11/S251/V1/N01

Person authorised to hand over the

technical dossier:
Michael Lindberg
Dalager 5
2605 Brndby
Denmark

2001

The above machine has been manufactured in accordance with the Machinery Directive i.e.
Council Directive 2006/42/EC of 17 May 2006 on the harmonisation of the laws of the Member
States relating to machinery. The following health and safety requirements in Appendix 1 have
been complied with VSSK: 1.5.3.
Manufactured in accordance with the following EC Directives:
Pressure equipment directive 97/23/EC (PED)
The Low Voltage Directive, i.e. Council Directive 2006/95/EC of 12 December 2006 on the
harmonisation of the laws of Member States relating to electrical equipment designed for use
within certain voltage limits.
The EMC Directive, i.e. Council Directive 2004/108/EC of 15 December 2004 on the
approximation of the laws of the Member States relating to electromagnetic compatibility.
The machinery component must not be used until the finished machine into which it is to be
incorporated has been tested for compatibility and found to comply with all relevant health and
safety requirements as set out in 2006/42/EC and other relevant directives.

Title: Managing DirectorName: Michael Lindberg

Date: 09 June 2015

Signature:

2/21

Instructions for hydraulic systems

Thank you for choosing an AVN oil supply unit!

1. INTENDED USE
Hydraulics for linear and rotary motions.

2. GENERELT INTRODUCTION
In order to obtain safe and optimal function and maximum working life of the oil supply
unit, the following instructions for installation, commissioning, operation and maintenance
should be read and followed very carefully.
Before leaving AVN manufacturing site the oil supply unit was tested and adjusted to its
defined parameters.

3. COMMISSIONING
Pump station and components should be installed in a manner that renders inspection
and maintenance possible. Also consider routine checks of temperature, pressure, fluid
level, maintenance indicators, clearance for filling and draining oil as well as filter element
change outs.
The pump station are to be installed on a flat base. Installation and assembly may only be
performed by personnel train in commissioning of hydraulic systems.
Hydraulic pipes and hoses that are mounted to the unit must be rated for the system
pressures. These are indicated on the hydraulic diagram.
To maximize the lifespan of hydraulic hoses, minimize temperature variations, cold/hot
radiation, bends, sunlight and dusty atmosphere.
Furthermore, there should be provision for sufficient ventilation of the pump station.
Directional control valves can be placed in any position. However, vertically mounted
spool valves with spools facing down increases their reaction time, so horizontal
installation is recommended.
Pressure valves should either be mounted vertically with their control handle/screw
facing upwards or horizontally. Other control- and regulation components can
usually be installed in any position. Please crosscheck corresponding data sheet.
Pumps and motors shall be provided with pipelines according to manufacturers
instructions. Maximum and minimum pressures in the suction line shall not exceed
the values given by the manufacturer. Drain lines shall end under minimum oil level
in the reservoir and have a dimension that keeps the pump/motor housing pressure
below its maximum.
The connection of the drain line shall be made in such manner that the pump/motor
housing is always filled with oil.
All mounting surfaces shall be smooth and plane, so that valve- and pump
housings can be tightened without adverse internal tensions.
Mounting bolts are tightened equally with torque wrench.
Piston pumps must be filled with oil before starting.

3/21

Pipe work are to be carried out by trained personnel in accordance with drawings
and specifications. Use as few fittings as possible, avoid sharp angles and bends
and keep the pipe lengths as short as possible. Clean all pipes and fittings before
installation. If uncertain, please consult one of AVNs technicians.
After cleaning, all welding, soldering and other interference with the system are to
be strictly avoided.

To reduce noise, pipes should always be hung in specially designed pipe clamps.
Mount hydraulic hoses between hydraulic pipes and fixed parts

For detailed information concerning noise and other data refer to the attached test
report.
Hydraulic fluid. Usually it is not mechanical parts that limit a system's life, but too
little, too dirty or incorrect oil. Correct type of oil must be used along with
continuous monitoring of filtration, temperature and oil level in the tank.
If the system is fitted with accumulators, these must be depressurized when
checking the oil level.
By providing your oil company the systems start-up and operating conditions, one
can get information about the correct type of oil
AVN Hydraulik A/S recommends a mineral hydraulic oil with viscosity 16-46 cst.
such as. Uno-X Rando 32 or 46, or similar.
If you want to use a different oil type or viscosity AVN Hydraulic must be consulted.
Failure to comply will void the warranty, including claims for consequential
damages.
If the unit are to work with "fire-resistant fluids", whether in the case of aqueous or
synthetic fluids, AVN Hydraulic must be consulted. Eg. all components must be
fitted with seals that are resistant to the liquid, and one must ensure that the tank
interior paint cannot degrade. Further, pipe sizes should probably be different due
to the fluids changed density or viscosity, and there may be special requirements
with regards to maintenance.

Working with hydraulic oils requires the use of safety glasses and chemical
resistant gloves

4. DECOMMISSIONING
Depressurize the system. Be especially careful that any accumulators are
depressurized. Working components (cylinders and motors) as well as pipework is
emptied for oil or isolated so that the oil does not spill out.

5. TRANSPORT
The pump unit must be emptied of oil before shipping.
Tank or frame can be fitted with lifting eyes, these are only intended for lifting subcomponents and must not be used to lift the grouped entity.

4/21

6. START UP
Prior to starting, check the following:
The tank and pipes are clean before filling with fluid. (Possibly flush the system)
The components are connected correctly according to the hydraulic diagram
The prescribed liquid type and purity is used
The liquid filling is done through a filter that minimum corresponds to the units
degree of filtration.
The alignment between motor and pump is in order. It might have been
unbalanced during transport
The voltage and frequency is correct
The direction of rotation of the drive motor is properly
Any. accumulator is pre-filled with nitrogen (N2) to the correct pressure
Any. gears, piston pumps or piston motors are filled with liquid to ensure their
internal lubrication

7. STARTING UP
In cases where there are special requirements for the units purity, flush the system
with a separate pump-filter system capable of attaining oil speeds in the pipes of
approx. 15 m / sec.
Usually the system is started without load. Pressure relief valves are set as low as
possible, but do not touch pressure valves at any accumulator, which are preset.
The system is checked for any loose fittings and leaks and runs at low pressure
until the air is removed from the oil. The tank re-filled with oil, equivalent to the
amount obtained in the piping and cylinders, and the pressure is then gradually
increased.

If the system is fitted with accumulators they must be relieved when checking the oil level
Pressure relief valves set taking account of indications of the suppliers'. When the
system is running satisfactory, set pressure switches, level switches, thermostats,
etc. Pressures, temperature, time setting and other data is recorded and noted (eg.
on the hydraulic diagram), as this may have an impact on later adjustment.
After a short time of operation, check the temperature of bearings, bushings and
fluid. These temperatures must not exceed normal operating temperature.
Any additional tensioning and adjustment are made, and final settings are secured
against unintentional adjustments.

8. MAINTENANCE
Already in the planning stage, one should think of the maintenance. By mounting
test points and isolation/drain valves in appropriate places one can facilitate
troubleshooting and perhaps replace defective parts and clean/change filters
without emptying the system of liquid.
The frequency of preventive maintenance is a matter of experience, depending on
operating conditions. It is recommended to prepare a maintenance log for the unit,
if necessary in cooperation with the supplier.

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After first start-up inspections are to be made with only few hours apart.
The hydraulic pump station must be inspected daily, including control of filter
warning lights / mechanical dirt indicators
If the filter warning light activates the system must be stopped as soon as possible,
and a serviceman must be called.
At a minimum, check the system for leaks, abnormal temperatures, excessive
noise and oil levels daily.
Alignment between axles are controlled, as well as any need for retightening of
bolts and nuts. Operations are recorded in the maintenance protocol. It is
economical to use filters with contamination indicator, so that the filter element is
only changed out when dirty. Particles in a dirty element can tell a lot about any.
start of wear of the different components.
Oil change depends on the operating conditions and agreed best with the oil
supplier. Take an oil sample of the liquid according to instructions, and let its
chemical status and degree of pollution be analyzed. AVN Hydraulik offers
assistance with particle analysis.
As a rule of thumb, it is recommended to change the filters every 800 hours of
operation, alternatively 6 months and to change the oil every 1600 hours or
alternatively 12 months.
Service is carried out the first time after 40-60 hours. Failure to comply will void
your warranty.
Maintenance should be done by qualified and trained personnel, so that the
maximum safety is reached.
If in doubt Please always contact AVN Hydraulik A/S
During maintenance, repair and cleaning of the hydraulic system, supply isolating
devices must always be open.
It must be ensured that the entire system is depressurized before disassembly, and
there must always be special precaution made when working on hydraulic systems

Repair, adjustment and service of the hydraulic system may only be performed by
trained personnel who can service hydraulic systems. For additional instructions in
this matter, please refer to the user manuals for individual components.

Before screens and other protections in front of moving parts are removed, the
machine's power supply isolator be opened and locked

9. STORAGE
Should the unit or components be stored more than 3 months prior to installation /
commissioning, it must be preserved - parts must be stored in a dry place without
the possibility of attack by corrosive substances and/or vapors, and filled with a
preservative fluid.

10. PERSONAL SAFETY EQUIPMENT

When working on the hydraulic system the power supply separation must always
be open and locked

6/21

For your safety use the following personal safety equipment when working in the area of
the oil supply unit.

Helmet

Wear helmet when moving and/or lifting the oil supply

unit or larger elements within it.

Earmuffs

Wear earmuffs when working near the oil supply unit in

operation.

Safety glasses

Wear safety glasses when working near the oil supply unit,
especially when handling oil and cleaning agents.

Gloves

Wear gloves when working with the oil supply unit in,
especially when handling oil and cleaning agents.

Safety boots

Wear safety boots when moving and/or lifting the oil

supply unit, or larger elements within it.

AVN Hydraulik A/S

Dalager 5
DK-2605 Brndby
Denmark
Phone:
+45 70 20 04 11
Fax:
+45 43 24 55 05
Web:
www.avn.dk
Mail:
avn.hydraulik@avn.dk

7/21

8/21

Nummer
241010
241035
241113
241158
241365
89155
99930
241367
241410
241535
241552
241520
431050
431500
221999
211400
184400
1400
1810
222200
223000
19110

Beskrivelse
F68FLANGE+KOBLING
A1YMANIFOLD30120BAR
TANKTYPES251(2,5LPLAST)
MONTAGESTFORPLASTTANK12,5
BLOKNO1G386001000
MALINGBLOKA1.Y+N03+MOTOR
MONTRTIMEN01TILPRESSOSTAT
BLOKN03CETOP3P(G386002020
PUMPEKODE111,1CCM
SUGEFILTERFR37115L/MIN
RETURRRS02/09LODRETMONT.
SUGERRS02V/03V/09/31/140
HED5OP12X/100K14/PRESSOSTAT
STIKZ14FORHED5/HED8
M4X45UNBRAKOSKRUE91212.9
TOGN.FT2901/4"MANO.HANE
MANOMETER630160BAR1/4"N
ARONMAGNETV.AD3E16EM
ARONMAGNETV.AD3E02CMJ3
M5X30UNBRACOSKRUE912.12.9
M5X80UNBRAKOSKRUE91212.9
ARONMODULVENTILAM3UD/T5BA
LSTLEVERET
104450 OILC.084101030220SNKEB/VENTI
IPILOTDELMONTERESA8MED
MMDYSE
259240 A08RLWDX3/8"LIGEINDSKRUNI
221871 232309BLNDE0,45MMM8RUSTF
KUNSTYKLISTE:
DVL30/16200SSRODPAAFSTO
DVL50/30460SSRODPAAFSTO

Antalpr.
1
1
1
1
1
1
1
2
1
1
1
1
1
1
4
1
1
1
1
4
4
1
0
1
0
0
1
1
0
1
1

9/21

Enhedskod Position
STK
3
STK
5
STK
6
STK
STK
7
STK
TIM.
STK
9
STK
2
STK
1
STK
STK
STK
8
STK
08A
STK
STK
10
STK
11
STK
12
STK
13
STK
STK
STK
17
STK

STK
STK
PCS
PCS

16

16A
16B
14
15

Manifold
A1 Y Manifold 30-120 Bar
AVN no.: 241035

rev. 0
Dalager 5
Suensonsvej 14

DK-2605 Brndby
DK-8600 Silkeborg

Fax +45 4324 5505

Fax +45 8722 8100

E-mail: avn.hydraulik@avn.dk
Web: www.avn.dk

10/21

 +45 70 20 04 11

Side
10.241037

Element for CETOP parallel connection N03

AVN no.: 241367

Replacement O-ring: OR14,0x1,78

AVN # = 310550

rev. 0
Dalager 5
Bergsesvej 14

DK-2605 Brndby
DK-8600 Silkeborg

Fax 43 24 55 05
Cvr 31 58 61 35

Email: avn.hydraulik@avn.dk
Internetadresse: www.avn.dk

11/21

+45 70 20 04 11

Side
10.241367.1

AVN HYDRAULIK A-S

Dalager 5
Suensonsvej 14

DK-2605 Brndby
DK-8600 Silkeborg

Hydro-Electrical Switch Type

Type HED 5 OP 1-2X/100 Z14

Fax +45 43 24 55 05 E-mail avn.hydraulik@avn.dk

Fax +45 87 22 81 00 Internetadresse www.avn.dk
12/21

+45 70 20 04 11

Page
12.431050.1

AVN HYDRAULIK A-S

Dalager 5
Suensonsvej 14

DK-2605 Brndby
DK-8600 Silkeborg

Hydro-Electrical Switch Type

Type HED 5 OP 1-2X/100 Z14

Fax +45 43 24 55 05 E-mail avn.hydraulik@avn.dk

Fax +45 87 22 81 00 Internetadresse www.avn.dk
13/21

+45 70 20 04 11

Page
12.431050.2

Gauge isolator FT290

AVN no.: 211400

rev. 3
Dalager 5
Bergsesvej 14

DK-2605 Brndby
DK-8600 Silkeborg

Fax 43 24 55 05
Cvr 31 58 61 35

Email: avn.hydraulik@avn.dk
Internetadresse: www.avn.dk

14/21

+45 70 20 04 11

Side
7.211400

Pressure gauge 63, 0-160bar 1/4

AVN no.: 184400

rev. 0
Dalager 5
Bergsesvej 14

DK-2605 Brndby
DK-8600 Silkeborg

Fax 43 24 55 05
Cvr 31 58 61 35

Email: avn.hydraulik@avn.dk
Internetadresse: www.avn.dk

15/21

+45 70 20 04 11

Side
12.184400.1

Directional controlvalve AD3

CETOP 3/NG6

ARON

Order code:
AD Directional valve
3

CETOP 3 / NG6

Type og operator (see table 1)

**

Spool type (see table 5)

Mounting type (see table 2)

Voltage (see table 3)

**

Variants

Serial no.

Data:
Valve type

Spool valve

Max. flow

60 l/min

Max. Pressure port P/A/B

320 bar

Max. Pressure port T

160 bar

rev. 1.0
Dalager 5
Suensonsvej 14

DK-2605 Brndby
DK-8600 Silkeborg

Fax +45 4324 5505

Fax +45 8722 8100

E-mail: avn.hydraulik@avn.dk
Web: www.avn.dk

16/21

 +45 70 20 04 11

Page
7.1.1

Directional controlvalve AD3

ARON
Table 3 Voltage

Table 1 Type of operator

E = Electrical
M = Mechanical
D = Direct mechanical
O = Hydraulic
P = Pneumatic
L = Lever operation

AC Voltage

Rated power

A = 24V / 50 Hz

57 VA

J = 115V / 50 Hz - 120V / 60 Hz
Y = 230V / 50 Hz - 240V / 60 Hz

52 VA
55 VA

DC Voltage

Rated power

L = 12 VDC
M = 24 VDC

Table 2 Mounting

30 W
30 W

C
D*
E
* = with lock

Table 5
Two solenoids C mounting spool
Spool

Symbol

One solenoid E mounting spool

Transient position

Spool

01

01

02

02

03

03

04

04

Symbol

Transient position

16

Two solenoids D mounting spool

Spool

Symbol

Transient position

20
21

Only the most common types is shown. In case you need information concerning other types,
please do not hesitate to contact our sales department or visit our website.
Dalager 5
Suensonsvej 14

DK-2605 Brndby
DK-8600 Silkeborg

Fax +45 4324 5505

Fax +45 8722 8100

E-mail: avn.hydraulik@avn.dk
Web: www.avn.dk

17/21

 +45 70 20 04 11

rev. 1.0
Page
7.1.2

Directional control valves

CETOP 3 / NG6

Aron

rev. 0
Dalager 5
Suensonsvej 14

DK-2605 Brndby
DK-8600 Silkeborg

Fax +45 4324 5505

Fax +45 8722 8100

E-mail: avn.hydraulik@avn.dk
Web: www.avn.dk

18/21

 +45 70 20 04 11

Page
7.1.3

Solenoid valve CETOP3 4/3

AVNno.:1810
Solenoid operated type AD 3E 02C M J3 24 VDC

Specifications

rev. 0
Dalager 5
Bergsesvej 14

DK-2605 Brndby
DK-8600 Silkeborg

Fax 43 24 55 05
Cvr 31 58 61 35

Email: avn.hydraulik@avn.dk
Internetadresse: www.avn.dk

19/21

+45 70 20 04 11

Side
7.1810.1

Solenoid valve CETOP3 4/3

AVNno.:1810

rev. 0
Dalager 5
Bergsesvej 14

DK-2605 Brndby
DK-8600 Silkeborg

Fax 43 24 55 05
Cvr 31 58 61 35

Email: avn.hydraulik@avn.dk
Internetadresse: www.avn.dk

20/21

+45 70 20 04 11

Side
7.1810.2

Solenoid valve CETOP3 4/3

AVNno.:1810

Solenoid D15 for CETOP 3

D15 Direct current solenoid specifications

rev. 0
Dalager 5
Bergsesvej 14

DK-2605 Brndby
DK-8600 Silkeborg

Fax 43 24 55 05
Cvr 31 58 61 35

Email: avn.hydraulik@avn.dk
Internetadresse: www.avn.dk

21/21

+45 70 20 04 11

Side
7.1810.3