400 Hydraulic system for steering

thruster
Flushing Specification for Hydraulic Systems with
Variable Displacement Pump

Preliminary Notes
These instructions are to provide information and Given that SCHOTTEL propulsion systems are subject
guidance to all persons involved in the initial start−up, to further development, we reserve the right to carry out
operation and maintenance of SCHOTTEL propulsion technical modifications.
systems. Please make sure that these instructions are
read, understood and carefully observed. Important instructions relevant to technical and
operational safety are identified by the following
These instructions are to be made available to all symbols:
persons carrying out work on the propulsion systems.
We shall not accept liability for any damages or ! WARNING
malfunctions resulting from non−observance of these
instructions. Indicates working and operating methods that are to be
It is a prerequisite that all users are familiar with the strictly observed to prevent any risk to personal safety.
propulsion systems and have been informed about the
possible dangers associated with their use.
Only trained and qualified personnel are permitted to
! CAUTION

carry out work on the propulsion systems. Indicates working and operating methods that are to be
strictly observed to prevent damage to or destruction of
References to illustrations contained in the text are materials.
written in brackets, e.g. (1/3). The first number refers to
the illustration number in the manual; the second
number is the item number in the illustration. NOTE
All illustrations are schematic diagrams and do not Indicates specific features of the working process
make any claim to completeness. which are to be observed.
Any technical modification to SCHOTTEL propulsion
systems to be performed by non−SCHOTTEL
personnel requires written authorisation.
i INFORMATION
However, this does not include any of the modifications Application instructions and information.
or control settings described in our instructions.
When carrying out any work on SCHOTTEL propulsion
systems, always observe the safety and environmental
protection regulations as well as the applicable laws in
force in the relevant country of operation.

These instructions have been written with the utmost care and attention to detail.
Should you require any further information, please contact:
SCHOTTEL GmbH
Mainzer Straße 99
56322 Spay, Germany
Phone +49 (0) 2628 610
Fax +49 (0) 2628 61300
E−mail info@schottel.de

en STD−Ro Flushing Specification for Hydraulic Systems with Variable Displacement Pump 07/3151 1100933 1/ 3
Hydraulic oil used in the operation of a variable
displacement pump in a closed hydraulic system has to ! CAUTION
be absolutely pure. For this reason, the hydraulic
system is to be flushed before commissioning and after The hydraulic system is to be installed according to
maintenance and repair work has been carried out. SCHOTTEL Specification 1099237.
Two flushing procedures are required to attain the
necessary purity level.

Flushing Procedure 1
1
Tools:
D Pressure filter (10m) with check valve (2 x)
D Flushing unit with pump

! CAUTION
Variable displacement pumps and hydraulic motors
must not be rinsed in flushing procedure 1.

2
1. Disconnect the variable displacement pump (1/4)
from the flushing circuit.
2. Connect the flushing unit (1/3).
3. Disconnect the hydraulic motors (1/1) from the
10  10 
flushing circuit.
4. Install the pressure filter with check valve (1/2) in
the flushing circuit in accordance with figure 1.
3
! CAUTION
It is crucial that the minimum flushing time is observed!
The minimum flushing time can be calculated as
follows:
t = V/Q x 5
V = tank volume [ l ], Q = feed quantity of pump [l/min] 4
t = minimum flushing time [ h ]

5. Initiate the flushing procedure with a continuous

volume flow.

NOTE
The results of the oil samples are to be documented.

Figure 1

2/ 3 STD−Ro Flushing Specification for Hydraulic Systems with Variable Displacement Pump 07/3151 1100933 en
6. Take oil samples during the flushing procedure.
7. Continue the flushing procedure until a purity level
complying with ISO 4406 20/18/15 is attained or
better.
8. Remove the flushing unit.
9. Connect the hydraulic motors.
10. Connect the variable displacement pump.

NOTE
Leave the pressure filter in the flushing circuit for
flushing procedure 2.

Once flushing procedure 1 has finished, the entire

hydraulic system is to be flushed in flushing
procedure 2 during commissioning.

2
Flushing Procedure 2

1. Carry out commissioning.

10  10 

! CAUTION
During commissioning, a minimum flushing time of 30
minutes is to be upheld.

2. Remove the pressure filter (2/2) after

commissioning.

3. Reconnect the system according to the Hydraulic

Circuit Diagram.
3

Figure 2

en STD−Ro Flushing Specification for Hydraulic Systems with Variable Displacement Pump 07/3151 1100933 3/ 3
 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

10 11 12 Biegeradius min. R=500mm

Bending radius min. R=500mm 13 14 41,43 40 40 42,43
428
M M
95,5 305,9
15,43 9,43
-4Y2 -4Y1

X1 X2

15,9 17

42-26,5 tief
deep
L
3,4
L
S
c.c.w.

206
A
Z S
178

MH
PS
18

MA

165,1
Y

470

224,5
K K

33
MB
T2

206

613
Fa B
32
34

30-26,5 tief
55

deep
J J
-2S5
65 22
max. Druckschalter 4x 21
max. pressure switch

19
-2S4

H 224,5 H

27 26 2 3,4 16,43
230,5

30 24 25 26 26 23,43 6 7 8
-2S2
Z1:1
20 min. Druckschalter
Biegeradius min. R=350mm
Bending radius min. R=350mm 7,4
min. pressure switch
G G

Biegeradius min. R=^420mm W50x2x30x24x9g

Bending radius min. R=420mm DIN5480
22,43 21 35-21,5 tief
deep
209

37 38,43 36 304,9

F F

Biegeradius min. R=350mm

1 2 5 35 6 7 8

107
60
M16
Bending radius min. R=350mm

12

E E

36
Konserviert mit TECTYL Nr. 846 - ID-Nr. 1039098
To conserve with TECTYL Nr. 846 - ID-Nr. 1039098
11
X1 55
a

30-26,5 tief
deep
D D
Handnotbetätigung
Manual emergency operation
R
Einstellung der Druckschalter gemäß Hy-Plan!
Adjustment of pressure switches see Hy-diagram!

Ersatzfilterelement ID-Nr: 1125807

889 spare filter element ID-No: 1125807
Schneidringe mit Kabelband ID Nr. 1007832
X2 b an der Verschraubung befestigt.
C
Cutting ring with cabel strap ID Nr. 1007832 C
on the relevant fitting to fasten.

Anstrich gemaess Anstrich-Spezifikation ID-Nr. 1099071-2

RAL Farbton siehe Auftrag
painting acc. to painting specification id-no. 1099071-2
Welle gegen Beschädigung geschützt! 833,5 RAL color see order
Shaft protected against demage!
Schlauchleitungen vor dem Grundieren zwischen
den Einbindungen abgeklebt.
Hose lines between the binds before
38 39,43 36 28 29 priming masked with tape.
B Hy-Antriebsstation gut zugänglich und belüftet installiert. B
Max. Umgebungstemperatur 45°C.
Hy-power pack has to be installed accessible and ventilated.
L
3 4 7 8 9 10 14 15 16 17
Max ambient temperature 45°C.
N T I A
O N F IDE
1139
C
Dieser Entwurf ist geistiges Eigentum Schutzvermerk CAD-ZEICHNUNG Typ: H 1212
1 2 1 2 1 der SCHOTTEL GmbH DIN ISO 16016 beachten Manuelle Aenderung verboten !
1 1

-2S2 3
-2S4 3
-2S5 2
Werkstueckkanten
DIN ISO 13715
Projektionsmethode 1
DIN ISO 128
Allgemeintoleranz DIN ISO 2768-mK
Schweisskonstr. DIN EN ISO 13920-C
Massstab: 1:2 Gewicht: 47.56 kg
-0.3 Tolerierung DIN ISO 8015 Werkstoff:
+0.8
Oberflaechenangaben DIN EN ISO 1302 Rohteil-Nr.:
-4Y1 -4Y2 Datum Name Modell-Nr.:
Hydraulik Hydraulik Hydraulik Bearb. 02.02.2012 FahrC Benennung:
A A
Filter
druck
verschmutzt
Druck
max Steuerventil Steuerventil
Gepr. 08.02.2012 ScherrW
AV 10.02.2012 KensyC
HY-Pumpe kpl.
min Norm 16.02.2012 MalewskiD A4VG180L-DIN/W50-D30/42/35-280
HY-Pump Unit
min hydr. oil max
Abt.
Zeichnungs-Nr. Index: 000 Format
filter hydr. oil SCHOTTEL GmbH
hydr. oil
pressure clogged pressure steering valve steering valve 000 0000 02.02.2012
Zust. Aenderung Datum
FahrC
Name Urspr.:
Mainzer Strasse 99
D-56322 Spay/Rhein 1189104
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 0
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1

6 5 7 5 X2 1 2 X2 5 6

12 43
F F

1 21 1 1 1

Schaltpunkt
13 -2S1 3
-2S3 2

level switch 18,39

5
5 20,44 Hydraulik
niveau
Hydraulik
Temperatur
min max

629
693

19,44

ca.43
hydr. oil hydr. oil

ca.226
560

E level temperature E
min max

400,24
25
42-22,5 tief
deep

230
230

4 29

8,9 553 180 180 26

27
D D

46,47 633 414

27 4
30 31 474
4
509
2

16 6,45 15,44 10 51 14 33,34,35 11 31 30 31

2 4
17 1
191
89 89
191
51
C
35-21,5 tief Schwerpunkt C
deep 5
18 center
Hy-Antriebsstation gut zugaenglich und belueftet installieren.
Max. Umgebungstemperatur 45°C
1 22 3
Install hydraulic drive station in an easily accessible and well ventilated place.
23,24 Max. ambient temperature 45°

23 Ventil- und Schaltereinstellung gemaess Hy-Plan, siehe Auftrag.

160

1 Set valves and switches according to Hydraulic Circuit Diagram, see order.
Kühlwasseraustritt G1 1/4" Kühlwassereintritt G1 1/4"
Cooling water outlet G1 1/4" Cooling water inlet G1 1/4" Endanstrich gemaess SCHOTTEL Anstrichspezifikation Ident-Nr. 1099071 auftragen
rot markiert blau markiert RAL‐Ton siehe Auftrag
5 markd blue
marked red Apply final paint acc. to SCHOTTEL Paint Specifications ID-No. 1099071
B
39 3
10 Refer to order for RAL colour
B
130
25,14

5 -2S1 3 1 Aufkleben mit ID Nr.: 1040106 L

vorbehandelt mit Reiniger ID Nr.: 1034072 E N TIA
F ID
40
To stick on with ID Nr.: 1040106
after handel with ID Nr.: 1034072 CON
2 Dieser Entwurf ist geistiges Eigentum Schutzvermerk CAD-ZEICHNUNG Typ: H 2020
37,38
der SCHOTTEL GmbH DIN ISO 16016 beachten Manuelle Aenderung verboten !
Werkstueckkanten Projektionsmethode 1 Allgemeintoleranz DIN ISO 2768-mK Massstab: 1:5 Gewicht: 115.78 kg
DIN ISO 13715 DIN ISO 128-30 Schweisskonstr. DIN EN ISO 13920-CF
-0.3 Tolerierung DIN EN ISO 8015 Werkstoff:
+0.8
200 200 Oberflaechenangaben DIN EN ISO 1302
Name
Rohteil-Nr.:
Datum Modell-Nr.:

3,4
Bearb. 08.02.2012 FahrC Benennung:
A 767 A
005 14/1969 16.07.2014 KollmannK
Gepr. 06.06.2012 ScherrW
AV 06.06.2012 KensyC
HY-Oelbehaelter kpl. NG 100
Zweikammer-EMK712-Temp.schalter
18 17 16 24 23 48,49 004 13/1873
003
002
13/0702
12/2923
09.07.2013
14.03.2013
13.11.2012
FahrC
FahrC
FahrC
Norm 23.07.2014 MalewskiD
Abt. TKS Hydro-oil tank cpl. NG 100
Zeichnungs-Nr. Index: 005 Format
SCHOTTEL GmbH

5 -2S3
001
000
12/2318
0000
06.09.2012
08.02.2012
Zust. Aenderung Datum
FahrC
FahrC
Name
Mainzer Strasse 99
D-56322 Spay/Rhein

Urspr.: 1122106
1188962
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 2
8 7 6 5 4 3 2 1