Internal Gear Pump / Drive QT, QX, QXV, QXM series. Operating manual. Bucher Hydraulics GmbH Industriestrasse 1 D Klettgau

Internal Gear Pump / Drive QT, QX, QXV, QXM series Operating manual Bucher Hydraulics GmbH Industriestrasse 1 D-79771 Klettgau 410.10.00.00 / VPZ / 07.2005 Operating manuel 100-I-000014-E-00 Observe protection notice according to ISO 16016. Subject to changes. 1 / 26

Table of contents Table of contents 1 About this document... 4 1.1 Valid scope... 4 1.2 Target groups... 4 1.3 Other applicable documents... 4 1.4 Warning labels and symbols... 5 1.5 Series... 5 2 Security... 6 2.1 Intended use... 6 2.2 General safety instructions... 6 2.2.1 Product safety... 6 2.2.2 Operator's obligations... 7 2.2.3 Duties of the operating staff... 7 2.3 Special hazards... 7 2.3.1 Potentially explosive areas... 7 2.3.2 Hazardous pumped liquids... 7 3 Layout and function... 8 3.1 Labels... 8 3.1.1 Type plate... 8 3.1.2 Pump type code... 8 3.2 Construction... 9 4 Transport, storage and disposal... 11 4.1 Transport... 11 4.1.1 Unpacking and inspection on delivery... 11 4.1.2 Lifting... 11 4.2 Preservation... 12 4.3 Storage... 12 4.4 Remove the preservative... 12 4.5 Disposal... 12 5 Setup and connection... 13 5.1 Preparing the installation... 13 5.1.1 Check the environment... 13 5.1.2 Prepare the installation site... 13 5.1.3 Remove the preservative... 13 5.1.4 Choose orientation for the installation... 13 5.2 Assembly... 13 5.3 Planning the piping... 14 5.3.1 Avoid contamination of the piping... 14 5.3.2 Lay out supports and flange connections... 14 5.3.3 Specify nominal diameters... 14 5.3.4 Specify pipe lengths... 14 5.3.5 Optimise cross-section and bends... 14 5.3.6 Arrange for safety and monitoring devices (recommended)... 14 5.4 Connecting the pipes... 15 5.4.1 Install the suction pipe... 15 5.4.2 Install the pressure pipe... 15 5.4.3 Check that pipe connections are stress-free... 15 5.5 Install any additional functions... 15 5.5.1 Install connection for leaking oil... 15 5.5.2 Install cooling/heating... 15 5.6 Connect the electrics... 15 5.6.1 Connect the motor... 15 5.6.2 Check the direction of rotation... 15 6 Operation... 16 6.1 Preparations for the initial start-up... 16 6.1.1 Identify the pump type... 16 6.1.2 Cool or heat the pumped liquid... 16 6.1.3 Fill the system... 16 6.1.4 Check the connection for leaking oil... 16 6.2 Start-up... 16 6.2.1 Switch-on... 16 6.2.2 Switch-off... 17 6.3 Interrupting operation... 17 6.4 Returning to operation... 17 7 Maintenance... 18 7.1 Inspections... 18 7.2 Maintenance... 18 7.2.1 Antifriction bearing... 18 7.2.2 Replace radial shaft seal ring... 19 7.3 Returning the pump to the manufacturer... 19 7.4 Assembly... 19 7.5 Ordering replacement parts... 19 8 Disturbance recovery... 20 8.1 QT, QX, QXV pumps... 20 8.2 QXM (drive)... 22 9 Appendix... 24 9.1 Technical specifications... 24 9.1.1 Ambient conditions... 24 9.1.2 Noise pressure level... 24 9.1.3 Tightening torque for cover/flange... 24 9.1.4 Pumped liquid... 24 9.1.5 Viscosity... 24 9.1.6 Contamination class... 25 9.1.7 Run-in cycle... 25 9.1.8 Flow speed... 26 9.1.9 Pump input pressure... 26 9.1.10 Preservative... 26 9.1.11 Cleaning agents... 26 9.2 Spare parts... 26 2/26 100-I-000014-E-00 / 07.2005

Table of contents List of figures List of tables Fig. 1 Type plate (example)... 8 Fig. 2 Pump type code (example)... 8 Fig. 3 QX low pressure pump (pressure range 1)... 9 Fig. 4 QX low pressure pump (pressure range 2)... 9 Fig. 5 QX high pressure pump (pressure range 3)... 10 Fig. 6 Fastening the lifting gear to the pump... 11 Fig. 7 Run-in cycle QT/QX/QXM overall run-in time 10 minutes... 25 Fig. 8 Run-in cycle QXV overall run-in time 21 minutes... 25 Tab. 1 Target groups and their duties... 4 Tab. 2 Other applicable documents and their purpose... 4 Tab. 3 Warning labels and consequences of disregarding them... 5 Tab. 4 Symbols and their meaning... 5 Tab. 5 Series and function... 5 Tab. 6 Special versions (extract)... 8 Tab. 7 Action to be taken for operational interruptions... 17 Tab. 8 Actions to be taken after prolonged shutdown periods... 17 Tab. 9 Assignment of fault numbers QT, QX, QXV pumps... 20 Tab. 10 Fault table QT, QX, QXV pumps... 21 Tab. 11 Assignment of fault numbers - QXM (drive)... 22 Tab. 12 Fault table QXM (drive)... 23 Tab. 13 Ambient conditions... 24 Tab. 14 Tightening torque for cover/flange... 24 Tab. 15 Pumped liquid by group... 24 Tab. 16 Categories of pumped liquids... 24 Tab. 17 Viscosity... 24 Tab. 18 Contamination class... 25 Tab. 19 Flow speed (recommended)... 26 Tab. 20 Pump input pressure (absolute) - minimum... 26 Tab. 21 Pump input pressure (absolute) - maximum... 26 Tab. 22 Spare parts... 26 100-I-000014-E-00 / 07.2005 3/26

About this document 1 About this document 1.1 Valid scope In this manual, all series, even the QXM drive, will be generally called pumps. This manual is part of the pump, applies to all of the pump series mentioned above, describes safe and appropriate operation during all operating phases. 1.2 Target groups Target group Operating company Qualified staff, fitter Duty Keep this manual available where the device is used, including for later use. Ensure that personnel read and follow the instructions in this manual and the other applicable documents, especially all safety information and warnings. Observe any additional rules and regulations referring to the installation. Read, observe and follow this manual and the other applicable documents, especially all safety information and warnings. Tab. 1 Target groups and their duties 1.3 Other applicable documents Document ATEX additional instructions 100-I-000015-.. Technical description Installation and commissioning for internal gear pumps and motors, series QX, QXM, QXV, QT and QR 410.10.00.00 Purpose Only when operated in potentially explosive areas Brochure and confirmation of order with technical details and operating limits Brief introduction (supplied with every pump) Tab. 2 Other applicable documents and their purpose 4/26 100-I-000014-E-00 / 07.2005

About this document 1.4 Warning labels and symbols Warning label Risk level Consequences of disregard DANGER WARNING Immediate acute risk Potential acute risk Potentially hazardous situation Potentially hazardous situation Fatal injury, grievous bodily harm Fatal injury, grievous bodily harm Minor bodily harm Material damage Tab. 3 Symbol Warning labels and consequences of disregarding them Meaning Safety warning sign Take note of all information highlighted by the safety warning sign and follow the instructions to avoid injury or death. Instruction 1., 2.,... Multiple step instructions Precondition Cross reference Information, note Tab. 4 Symbols and their meaning 1.5 Series Pump series Function QT Internal gear pump 1) QX Internal gear pump 1) QXV Internal gear pump for low viscosity liquids 1) QXM Internal gear drive 1) Tab. 5 Series and function 1) called pump in the following 100-I-000014-E-00 / 07.2005 5/26

Security 2 Security The manufacturer does not accept any liability for damage resulting from disregard of the entire documentation. 2.1 Intended use Only use the pump to pump the agreed liquids ( Technical description). Maintain operating limits and size-dependent minimum flow rate. Do not allow to run dry. Damage occurs within a few seconds. Make certain that the pump is never commissioned and never operated without a pumped liquid. Avoid cavitation: Maintain minimum pressure at pump input ( 9.1.9 Pump input pressure, Page 26). Avoid overheating: Maintain permissible values of pressure, temperature, speed of rotation and on-time. Avoid damage to motor: Do not open the pressure release valve beyond the agreed operating point. Do not exceed the allowed number of motor switch-ons per hour ( Manufacturer's specifications). Consult with the manufacturer about any other use of the pump. 2.2 General safety instructions Take note of the following instructions before carrying out any work. 2.2.1 Product safety The pump has been constructed using the latest technology and accepted technical safety rules. Nevertheless, operation of the pump can involve risk to life and health of the user or of third parties, or risk of damage to the pump and other property. Only operate the pump if it is in perfect technical condition; only use it as intended, staying aware of safety and risks, and adhering to the instructions in this manual. Keep this manual and all other applicable documents complete, legible and accessible to staff at all times. Refrain from any procedures that would endanger staff or third parties. Should there be any safety-relevant fault, deactivate the pump immediately and have the fault corrected by responsible personnel. In addition to the entire documentation for the product, always comply with statutory or other safety and accidentprevention rules as well as with the applicable standards and guidelines in the country where the pump is operated. Prevention of obvious misuse (examples) Observe the operating limits of the pump regarding temperature, pressure, flow rate and speed of rotation ( Technical description). 6/26 100-I-000014-E-00 / 07.2005

Security 2.2.2 Operator's obligations Safety-conscious operation Only operate the pump if it is in perfect technical condition; only use it as intended, staying aware of safety and risks, and adhering to the instructions in this manual. Ensure that the following are observed and monitored: adherence to intended use, statutory or other safety and accident-prevention rules, safety regulations governing the handling of hazardous substances, applicable standards and guidelines in the country where the pump is operated. Make protective equipment available. Staff qualifications Make certain that all personnel tasked with work on the pump have read and understood this manual and all other applicable documents, especially the safety, maintenance and repair instructions, before they begin the job. Organize responsibilities, who is in charge of any specific duty and how personnel is supervised. Ensure that all work is carried out by specialist technicians only: fitting, repair and maintenance work, work on the pump electrical system. Make certain that trainee personnel may only work on the pump when supervised by a specialist technician. Safety installations Provide the following safety installations and verify their integrity: for hot and moving parts: on-site protection against accidental contact with the pump, if electrostatic charging is possible: fit appropriate earthing. 2.2.3 Duties of the operating staff Observe and keep legible all instructions given on the pump, e.g. the arrow indicating the direction of rotation and the markings for fluid connections. Do not remove the protection against accidental contact for hot, cold and moving parts during operation. Use protective equipment if necessary. Carry out work on the pump only while the pump is not running. Isolate the motor from its supply voltage and keep it locked in that state while carrying out any fitting or maintenance work. Mount the safety installations on the pump according to regulations after completion of work on the pump. 2.3 Special hazards 2.3.1 Potentially explosive areas ( ATEX additional instructions). 2.3.2 Hazardous pumped liquids Observe the safety regulations for the handling of hazardous substances when working with hazardous pumped liquids (e.g. hot, flammable, explosive, poisonous or potentially harmful). Use protective equipment when carrying out any work on the pump. Warranty Obtain the manufacturer's approval prior to carrying out any modification, repair or alterations during the warranty period. Only use original parts or parts that have been approved by the manufacturer. 100-I-000014-E-00 / 07.2005 7/26

Layout and function 3 Layout and function 3.1 Labels 3.1.2 Pump type code 3.1.1 Type plate QX 5 3-040 R 0 9 Type 1 1 2 P d bar 2 3 4 V g cm 3/U 3 5 Nr. 4 6 MADE IN GERMANY Fig. 1 Type plate (example) 1 Pump type 2 Constant pressure [bar] 3 Geometrical displacement/delivery/swallowing [cm 3 /rev.] 4 Serial number Fig. 2 Pump type code (example) 1 Pump series 2 Size 3 Pressure range 4 Displacement/delivery/swallowing [cm 3 /rev.] 5 Direction of rotation (R=clockwise, L=anticlockwise, N=both) 6 Special version (optional) The following table shows an extract from possible special versions. Number 06 Characteristic Separate connection for leaking oil QX 2-5 G 1/4" QX 6 G 3/8" QX 8 G 1/2" 09 FPM (Viton) sealing material 12 2 hole fixing flange according to ISO 3019/2 (metric) 14 Operating temperature up to 160 C 29 Hydraulic liquid HFB and HFC, size 2-5 66 4 hole fixing flange according to ISO 3019/2 (metric) 83 2. vacuum connection for QX 61 SAE 2" QX 81 SAE 2.5" 86 Hydraulic liquid HFB and HFC, size 6+8 165 169 Tab. 6 Special versions (extract) 8/26 100-I-000014-E-00 / 07.2005

Layout and function 3.2 Construction x-x 7 6 6 x P 1 2 3 4 x 5 S Fig. 3 QX low pressure pump (pressure range 1) 1 Pump shaft 2 Flange with radial shaft seal rings 3 Antifriction bearing 4 Gear wheels 5 Gear wheel housing 6 Plain bearing 7 Housing x-x 7 6 x 6 P 1 2 3 4 5 x S Fig. 4 QX low pressure pump (pressure range 2) 1 Pump shaft 2 Flange with radial shaft seal rings 3 Antifriction bearing 4 Gear wheels 5 Gear wheel housing 6 Plain bearing 7 Housing 100-I-000014-E-00 / 07.2005 9/26

Layout and function x-x 9 7 8 7 6 x P 1 2 3 4 5 x S Fig. 5 QX high pressure pump (pressure range 3) 1 Pump shaft 2 Flange with radial shaft seal rings 3 Antifriction bearing 4 Gear wheels 5 Connection for leaking oil (optional) 6 Gear wheel housing 2 7 Plain bearing 8 Gear wheel housing 1 9 Housing 10 / 26 100-I-000014-E-00 / 07.2005

Transport, storage and disposal 4 Transport, storage and disposal 4.1 Transport 4.1.2 Lifting Weight ( Technical description). 4.1.1 Unpacking and inspection on delivery 1. Unpack the pump on delivery and inspect for transport damage. 2. Report any transport damage to the manufacturer without delay. 3. Dispose of packaging material according to local regulations. DANGER Death or crushed limbs caused by falling loads! Use lifting gear appropriate for the total weight to be lifted. Fasten the lifting gear as shown in the illustrations below. Do not stand under suspended loads. 1 Fig. 6 Fastening the lifting gear to the pump 1. If only one thread is available for eye bolt, put the second sling around the end of the pump. 2. Lift the pump properly. 100-I-000014-E-00 / 07.2005 11 / 26

Transport, storage and disposal 4.2 Preservation Only necessary when storing. 4.4 Remove the preservative Only necessary for pumps which have been preserved for storage. Material damage due to improper storage! Preserve the pump properly inside and out for storage. 1. Select preservative according to the type and duration of storage ( 9.1.10 Preservative, Page 26). 2. Use the preservative as specified by the manufacturer. 3. Apply the preservative to all bare metal surfaces inside and out. 4.3 Storage Material damage due to inappropriate storage! Preserve and store the pump properly. 1. Seal all openings with blank flanges, blind plugs or plastic covers. 2. Make certain that the storage room meets the following conditions: dry frost-free vibration-free 3. Turn shaft once a month. 4. Make certain that the shaft and the bearing change their rotational position in the process. WARNING Danger of poisoning due to preservative and cleaning agent in the vicinity of foodstuffs or drinking water! Only use cleaning agents compatible with the pumped liquid ( 9.1.11 Cleaning agents, Page 26). Completely remove any preservative. Damage to seals through incorrect cleaning agent! Ensure that the cleaning agent does not attack the seals. 1. Select the cleaning agent according to the area of use. ( 9.1.11 Cleaning agents, Page 26). 2. Dispose of preservative according to local regulations. 4.5 Disposal Plastic parts can be contaminated by poisonous or radioactive pumped media to such an extent that cleaning will be insufficient. WARNING Risk of poisoning and environmental damage caused by pumped liquid or oil! Use protective equipment when carrying out any work on the pump. Prior to disposal of the pump: Collect pumped liquid and oil or grease which drain out and dispose of separately according to local regulations. Neutralise residues of pumped liquid in the pump. Remove the preservative ( 4.4 Remove the preservative, Page 12). Dismount plastic parts and dispose of the parts according to local regulations. Dispose of pump according to local regulations. 12 / 26 100-I-000014-E-00 / 07.2005

Setup and connection 5 Setup and connection For pumps in potentially explosive areas ( ATEX additional instructions 100-I-000015-..). Material damage caused by dirt! Do not remove transport protection until immediately before installing the pump. Do not remove covers and transport and sealing covers until just before connecting the piping to the pump. 5.1 Preparing the installation 5.1.1 Check the environment 1. Make certain that the required environmental conditions are met ( 9.1.1 Ambient conditions, Page 24). 2. For installations > 1000 m above sea level, consult with the manufacturer. 5.1.2 Prepare the installation site Make certain that the installation site meets the following conditions: pump is freely accessible from all sides, sufficient space for installation/removal of the pipes and for maintenance and repair work, especially for the removal and installation of the pump and the motor, pump not exposed to external vibrations (damage to bearings), frost protection. 5.1.3 Remove the preservative If the pump is to be commissioned directly after installation and connection: Remove any preservative before installation ( 4.4 Remove the preservative, Page 12). 5.1.4 Choose orientation for the installation The crescent seal internal-gear pump can be operated in any orientation. 5.2 Assembly Note the brief introduction supplied ( Installation and commissioning for crescent seal internal-gear pumps and motors, series QX, QXM, QXV, QT and QR). Material damage caused by knocks and blows! Do not cant the coupling halves when sliding on. Do not knock or hit any component of the pump. Material damage by recoil force of the coupling! Connect the shaft and the motor with < 0.2 mm misalignment. Material damage due to axial forces! Only operate the pump with direct drive and elastic coupling. 1. Use coupling with H7 tolerance on the coupling bore. 2. Apply a very thin film of molybdenum disulphide (e.g. Molykote) on the pump and motor shaft ends. 3. Insert fitting keys. 4. Without mounting device: Remove rubber buffers and heat coupling halves to approx. 100 C. 5. Slide on the pump-side and motor-side coupling halves until the shaft ends and the coupling centre are flush with each other. Keep the specified distance between the coupling halves ( Assembly instructions for the coupling). 6. Tighten the grub screws on both coupling halves. Freely choose orientation for the installation. 100-I-000014-E-00 / 07.2005 13 / 26

Setup and connection 5.3 Planning the piping Use flexible piping (recommended). For fixed piping use seamless precision steel piping to DIN 2391 (recommended). 5.3.1 Avoid contamination of the piping Materialdamageduetoimpuritiesinthepump! Make certain that no impurities can get into the pump. 1. Clean all piping components and armatures prior to assembly. 2. Ensure that no flange gaskets are protruding inwards. 3. Remove blank flanges, plugs, protective films and/or protective paints from the flanges. 5.3.2 Lay out supports and flange connections Material damage due to excessive force and torque from piping to pump! Minimise pipe forces and take every possible operating condition into account: cold/warm empty/full unpressurised/pressurised shift in position of flanges Ensure that pipe can slide freely in the supports and will not seize up through corrosion. 5.3.6 Arrange for safety and monitoring devices (recommended) Avoid contamination 1. Note permissible contamination ( 9.1.6 Contamination class, Page 25). 2. Integrate filter into the suction pipe. 3. To monitor contamination, fit a differential manometer with a contact manometer. Avoid excessive pressure Fit a pressure-relief valve. Avoid overheating Enable a temperature monitor to turn the pump off. Avoid reverse operation Install a non-return valve between the pressure joint and the stop valve to ensure that the liquid will not flow back whenthepumpisswitchedoff. Provide for isolating and shut-off devices for the pipes For maintenance and repair work Fit stop valves before and after the pump. Enable measurement of the operating conditions 1. For pressure measurements, fit manometers before and after the pump. 2. Provide for motor torque measurements. 3. Provide for pump temperature measurements. 5.3.3 Specify nominal diameters Keep flow resistance in pipes as low as possible. 1. Set the nominal diameters to correspond to the size and to the pipe flanges. 2. Note the maximum flow speeds ( 9.1.8 Flow speed, Page 26). 5.3.4 Specify pipe lengths Set the maximum length of pipe network according to pressure at pump input ( 9.1.9 Pump input pressure, Page 26). 5.3.5 Optimise cross-section and bends 1. Avoid bends with radius of less than 1.5 times the pipe diameter. 2. Avoid abrupt changes of cross-section in the pipe network. 14 / 26 100-I-000014-E-00 / 07.2005

Setup and connection 5.4 Connecting the pipes Damage due to impurities in the pump! Ensure that no impurities can get into the pump. 5.4.1 Install the suction pipe 1. Remove transport and sealing covers from the pump. 2. Avoid air pockets: Run pipes with a continuous slope up to the pump. 3. Ensure that no gaskets protrude inwards. 4. For hydraulic systems: Connect the suction pipe to the tank a few cm below the minimum liquid level. 5.4.2 Install the pressure pipe 1. Remove transport and sealing covers from the pump. 2. Fit the pressure pipe. 3. Ensure that no gaskets protrude inwards. 5.4.3 Check that pipe connections are stress-free Pipe installed and cooled down 1. Separate the connecting flanges of the pipes from the pump. 2. Check that pipes can move freely in all directions they might be expected to expand. 3. Make certain that the flange surfaces are parallel. 4. Reconnect the pipe flanges to the pump. 5.5 Install any additional functions 5.5.1 Install connection for leaking oil With QXV/QXM, to recycle leaks back into the pumped liquid circuit. With QX/QT, this is only possible if the pump is ordered accordingly. 5.6 Connect the electrics DANGER Risk of fatal injury through electric shock! Have all electrical work carried out by qualified electricians only. DANGER Risk of fatal injury due to rotating parts! When carrying out any fitting or maintenance work, isolate the motor from its supply voltage and keep it locked in that state. 5.6.1 Connect the motor Follow the manufacturer's instructions. 1. Connect the motor according to the circuit diagram. 2. Ensure that the electrical energy does not present any risk. 3. Install an EMERGENCY OFF switch. 5.6.2 Check the direction of rotation Damage caused by running dry! Decouple the motor from the pump. As default setting, the pump rotates clockwise. Anti-clockwise is also possible. 1. Switch motor on and immediately off again. 2. Check that the motor's direction of rotation corresponds to the arrow showing the direction of rotation on the pump. 3. If the direction of rotation is different: swap two phases. 4. Recouple the motor to the pump. Damage caused by overheating! Collect leaking oil < 1.5 bar absolute in tank. Ensure that connection dimensions for leaking oil are adequate and take the shortest route to the tank. Install connection for leaking oil with screw in fitting on the pump. 5.5.2 Install cooling/heating Recommended for the ideal temperature of the pumped liquid ( 9.1.1 Ambient conditions, Page 24). 1. Choose heating or cooling as your environment dictates. 2. Install the connections and then install the cooling/heating as specified by the manufacturer. 100-I-000014-E-00 / 07.2005 15 / 26

Operation 6 Operation For pumps in potentially explosive areas ( ATEX additional instructions 100-I-000015-..). 6.1 Preparations for the initial start-up 6.1.1 Identify the pump type Identify the pump type ( Technical description). 6.1.2 Cool or heat the pumped liquid For cooling or heating liquid ensure: adequate quantity required parameters 6.1.3 Fill the system WARNING Risk of injury and poisoning due to hazardous pumped liquids! Safely collect any leaking pumped liquid and dispose of it in accordance with environmental rules and requirements. Material damage due to incorrect or contaminated pumped liquid! Use approved pumped liquid ( 9.1.4 Pumped liquid, Page 24). Note permissible viscosity ( 9.1.5 Viscosity, Page 24). Note permissible contamination ( 9.1.6 Contamination class, Page 25). Damage caused by running dry! Make certain that the pump is properly filled. When operating pump: Ensure minimum liquid level in tank. 1. Fill the pump and the suction pipe with pumped liquid. Fill the pump and suction pipe with pumped liquid by turning the pump by hand or by pulsing the drive (recommended). 2. Switch motor on and pressurise pumped liquid with 20 bar (consult manufacturer for higher pressure). 3. Ensure that no joints or connections leak. 6.1.4 Check the connection for leaking oil Collect leaking oil with < 1.5 bar absolute in a tank. 6.2 Start-up 6.2.1 Switch-on The pump is correctly installed and connected The motor is correctly installed and connected All connections are stress-free and leak-free All safety installations have been fitted and tested for integrity The pump has been correctly prepared, filled and bled DANGER Risk of injury due to running pump! Do not touch the running pump. Do not carry out any work on the running pump. Allow the pump to cool down completely before starting any work on it. DANGER Risk of injury and poisoning caused by pumped liquid spraying out! Use protective equipment when carrying out any work on the pump. Damage caused by running dry! Make certain that the pump is properly filled. Ensure minimum liquid level in tank. Damage through cavitation! To bleed the pump operate pressure free. Only pressurise pumped liquid that has been completely bled. Damage caused by temperature shock! Ensure that the temperature difference between the pump and the pumped liquid is < 25 C. 1. Note run-in cycle ( 9.1.7 Run-in cycle, Page 25). 2. Switch on the motor and check that it runs smoothly. 3. After the first start, switch the pump off and wait until there are no more air pockets in the pumped liquid. 4. Switch motor on and pressurise pumped liquid with 20 bar (consult manufacturer for higher pressure). 5. After the initial stress caused by pressure and operating temperature, check that the pump is not leaking. 6. Increase the pressure as specified in the run-in cycle. 16 / 26 100-I-000014-E-00 / 07.2005

Operation 7. After the initial stress caused by pressure and operating temperature, check that the pump is not leaking. 6.2.2 Switch-off The pressure-side valve is closed (recommended) WARNING Risk of injury caused by hot pump parts! Use protective equipment when carrying out any work on the pump. 1. Switch the control to circulate to the tank. 2. Switch off the motor. 3. Check all fixing bolts and tighten if necessary. 6.3 Interrupting operation WARNING 6.4 Returning to operation 1. After shutdowns, take the following actions before restarting the pump: Shutdown duration Action > 6 months Return QXV pumps to manufacturer. Other pumps: Replace shaft seal with repair kit ( 9.2 Spare parts, Page 26). >2years Tab. 8 Return pumps to manufacturer. Actions to be taken after prolonged shutdown periods 2. Carry out all steps as for the initial start-up ( 6.2 Start-up, Page 16). Risk of injury and poisoning due to hazardous pumped liquids! Safely collect any leaking pumped liquid and dispose of it in accordance with environmental rules and requirements. Carry out the following measures when operation is interrupted: Pump is emptied disassembled Action Close stop valves on both sides of pump. Isolate the motor from its power supply and secure against unauthorized switch-on. put into storage Tab. 7 Pump preserve ( 4.2 Preservation, Page 12). store ( 4.3 Storage, Page 12). Action to be taken for operational interruptions 100-I-000014-E-00 / 07.2005 17 / 26

Maintenance 7 Maintenance For pumps in potentially explosive areas ( ATEX additional instructions 100-I-000015-..). Trained service technicians are available for fitting and repair jobs. 7.1 Inspections The inspection intervals depend on the load placed on the pump. 7.2 Maintenance DANGER Risk of injury due to running pump! Do not touch the running pump. Do not carry out any work on the running pump. When carrying out any fitting or maintenance work, isolate the motor from its supply voltage and keep it locked in that state. DANGER Risk of injury due to running pump! Do not touch the running pump. Do not carry out any work on the running pump. WARNING Risk of injury and poisoning due to hazardous pumped liquids! Use protective equipment when carrying out any work on the pump. 1. Check at appropriate intervals: compliance with minimum flow rate normal operating conditions unchanged for hydraulic systems: check liquid level in tank and check hydraulic liquid for viscosity, ageing and contamination coupling alignment and condition of elastic elements 2. For trouble-free operation, always ensure the following: no dry running no leaks no cavitation suction-side gate valves open unobstructed and clean filters sufficient supply pressure no unusual running noises and vibrations no excessive leakage at the shaft seal proper functioning of auxiliary operating systems DANGER Risk of fatal injury through electric shock! Have all electrical work carried out by qualified electricians only. WARNING Risk of injury and poisoning due to hazardous or hot pumped liquids! Use protective equipment when carrying out any work on the pump. Allow the pump to cool down completely before commencing any work. Make certain that the pump is unpressurised. Empty the pump, safely collect the pumped liquid and dispose of it in accordance with environmental rules and requirements. Damage due to disassembly of the pump! Do not take the pump to pieces. Return faulty pumps to the manufacturer ( 7.3 Returning the pump to the manufacturer, Page 19). For QT, QX and QXM pumps, only the repair set can be replaced ( 9.2 Spare parts, Page 26). 7.2.1 Antifriction bearing Faulty antifriction bearings increase noise levels, torque or temperature. Return pumps with faulty bearings to the manufacturer ( 7.3 Returning the pump to the manufacturer, Page 19). 18 / 26 100-I-000014-E-00 / 07.2005

Maintenance 7.2.2 Replace radial shaft seal ring Replace cover/flange with faulty radial shaft seal ring with repair set ( 9.2 Spare parts, Page 26). 1. Remove pump from system. 2. Remove fitting key from pump shaft. 3. Remove cheese head bolts from cover/flange. 4. Pull off cover/flange with old radial shaft seal ring from shaft. 5. Grease pump shaft. 6. Slide repair set onto shaft and fix in place with cheese head bolts. 7. Fit fitting key into pump shaft. 7.3 Returning the pump to the manufacturer Pump is unpressurised Pump is completely empty Electrical connections are isolated and the motor is secured against switch-on Pump has cooled down Coupling guard has been removed For couplings with a spacer: Spacer has been removed Auxiliary operating systems are shut down, unpressurised and emptied Manometer connections, manometer and fixtures have been removed 1. Flush the pump and decontaminate if hazardous liquid has been pumped. 2. Return the complete pump (not disassembled) to the manufacturer. 7.4 Assembly 1. Keep to specified torque ( Technical description). 2. Fit the pump into the system ( 5 Setup and connection, Page 13). 7.5 Ordering replacement parts For trouble-free replacement in case of any damage we recommend keeping replacement pumps or spare parts available on site ( 9.2 Spare parts, Page 26). To order spare parts keep the pump type ready ( type plate). 100-I-000014-E-00 / 07.2005 19 / 26

Disturbance recovery 8 Disturbance recovery 8.1 QT, QX, QXV pumps For faults that do not appear in the following table or faults that cannot be traced back to the suggested causes, please consult with the manufacturer. Possible faults are identified by a fault number in the table below. Use this number to find cause and remedy in the troubleshooting list. Fault Number Pump not pumping 1 Pumping rate insufficient 2 Pumping rate excessive 3 Pumping pressure insufficient 4 Pumping pressure excessive 5 Pump running roughly 6 Roller bearing temperatures too high 7 Pump leaking 8 Motor power uptake excessive 9 Tab. 9 Assignment of fault numbers QT, QX, QXV pumps Fault number 1 2 3 4 5 6 7 8 9 Cause Remedy X Transport and sealing cover not removed Remove transport and sealing cover. If damage caused by running dry, return to the manufacturer. X Supply/suction line and/or pressure line closed by valve Open the valve. X Liquid level in the tank < minimum Top up the pumped liquid. X Coupling destroyed Replace the coupling. X Suction pipe too short Lengthen suction pipe. X X X Suction pipe leaking Tighten bolts on pipes or flanges. Seal thread. X X X Motor speed insufficient Compare required rotational speed of motor with type plate on pump. Replace motor if necessary. Increase motor speed, if speed control available. X X Supply/suction pipe not fully opened Open the armature. X X Faulty control Repair control. X X Burst pipe underneath tank lid Replace pipe. X X X X Supply/suction pipe, pump or suction strainer blocked or encrusted X X X Supply/suction pipe cross-section too narrow Clean supply/suction pipes, pump or suction strainer. Increase cross-section. 20 / 26 100-I-000014-E-00 / 07.2005

Disturbance recovery Fault number 1 2 3 4 5 6 7 8 9 Cause Remedy X X X Hydraulic components of the pump dirty, clotted or encrusted X X Supply/suction pipe and pump not bled properly or not filled up completely Return pump to manufacturer. Clean the components. Fill up pump and/or piping completely and bleed them. X X Supply/suction line contains air pockets Install armature for bleeding. Correct piping layout. X X X X Air sucked in Seal source of malfunction. X X X X Excessive amount of gas: pump is cavitating X X X Viscosity or density of the pumped liquid outside the specified range for the pump X X X Temperature of pumped liquid too high: pump is cavitating X X X Pressure-side armature not opened sufficiently Consult with manufacturer. Consult with manufacturer. Increase supply pressure. Lower temperature. Inquire with manufacturer. Open pressure-side armature. X X X X Pressure pipe blocked Clean pressure pipe. X X X X Pump rotating the wrong way Swap any two phases at the motor. X X X X Pump components worn Return pump to manufacturer. X X X X X Motor speed excessive Compare required rotational speed of motor with type plate on pump. Replace motor if necessary. Reduce motor speed with speed control, if available. X X X Faulty antifriction bearing in pump Return pump to manufacturer. X X Faulty antifriction bearing in motor Replace antifriction bearing. X Connecting bolts not tightened correctly Tighten connecting bolts. X Worn radial shaft seal ring Return QXV pumps to manufacturer. Other pumps: replace shaft seal with repair kit ( 9.2 Spare parts, Page 26). X Faulty housing seal Return pump to manufacturer. X X X X Pump distorted Check pipe connections and pump fixings. X Worn coupling Replace the coupling. X X X X Motor running on 2 phases Check fuse and replace it if necessary. Tab. 10 Fault table QT, QX, QXV pumps Check cable connections and insulation. 100-I-000014-E-00 / 07.2005 21 / 26

Disturbance recovery 8.2 QXM (drive) For faults that do not appear in the following table or faults that cannot be traced back to the suggested causes, please consult with the manufacturer. Possible faults are identified by a fault number in the table below. Use this number to find the cause and remedy in the troubleshooting list. Fault Drivedoesnotstart 1 Drive rotates too slowly 2 Drive rotates too quickly 3 Insufficient torque 4 Insufficient power delivered 5 Driveisleaking 6 Tab. 11 Number Assignment of fault numbers - QXM (drive) 22 / 26 100-I-000014-E-00 / 07.2005

Disturbance recovery Fault number 1 2 3 4 5 6 Cause Remedy X Transport and sealing cover not removed Remove transport and sealing cover. X Supply and/or pressure line closed by valve Open valve. X Coupling destroyed Replace coupling. If damage caused by running dry, return to the manufacturer. X X X Rotational speed too low or start up torque too high Compare required rotational speed of drive with type plate. Replace motor if necessary. Increase motor speed, if speed control available. X X Supply/drain pipe not fully opened Open armature. X X Faulty control Repair control. X X X X Supply/drain pipe, drive blocked or encrusted Clean supply/drain pipe, drive. X X X Supply/drain pipe cross-section too narrow Increase cross-section. X X X Hydraulic components of the pump dirty, clotted or encrusted Return drive to manufacturer. X X X X Excessive amount of gas Consult with manufacturer. X X Viscosity or density of the pumped liquid outside the specified range for the drive Consult with manufacturer. X X X Temperature of pumped liquid too high Lower temperature. Inquire with manufacturer. X X X X Drive rotates in wrong direction Exchange connections for supply and drain pipes. X X X Pump components worn Return pump to manufacturer. X X X Excessive supply Compare required rotational speed of drive with type plate. Replace motor if necessary. Reduce supply. Reduce motor speed with speed control, if available. X Drive distorted Check pipe connections and drive fixings. X Worn coupling Replace coupling. Tab. 12 Fault table QXM (drive) 100-I-000014-E-00 / 07.2005 23 / 26

Appendix 9 Appendix 9.1 Technical specifications Further technical details ( Technical description). 9.1.1 Ambient conditions Consult with the manufacturer about operation under other ambient conditions. Temperature [ C] 1) 20 to +80 ideal +30 to +50 Relative humidity [%] permissible longterm shortterm Installation height above sea level [m] 85 100 1000 Tab. 13 Ambient conditions 1) depends on permissible viscosity, amongst other things 2) consult with the manufacturer for higher installation 9.1.4 Pumped liquid HLP and HFC For series QT, QX, QXM, QXV QT, QX, QXM 9.1.2 Noise pressure level For exact details on noise pressure level ( Technical description). Pumped liquid (group) Max. load [N/mm 2 ] 3) Temperature [ C] HLP 1) 30 80 HFC 2) 30 50 Tab. 15 Pumped liquid by group 1) hydraulic oils to DIN 51524, part 2 2) low flammability hydraulic liquid to DIN 51502 3) recommended by Brugger DIN 51347-2 Precondition Pumped liquid corresponds to permissible viscosity Pump/motor is a special version Other pumped liquids For series Pumped liquid 9.1.3 Tightening torque for cover/flange Repair set Pump type Tightening torque [Nm] QX, QXM QX2 10 ± 2 QX3 20 ± 2 QX4 40 ± 5 QX5 80 ± 10 QX6 160 ± 10 QT, QX, QXM QXV Tab. 16 Mineral oils/synthetic liquids Turbine oils/biologically degradable oils Low viscosity mineral oils Fuels Low flammability liquid (HFA) Calibrating liquids (for test rigs) amongst others Categories of pumped liquids QT Tab. 14 QX8 320 ± 20 QT2 10 ± 2 QT3 10 ± 2 QT4 10 ± 2 QT5 20 ± 2 QT6 20 ± 2 QT8 20 ± 2 Tightening torque for cover/flange 9.1.5 Viscosity For series Viscosity [mm 2 /s] QT 20 300 QX, QXM 10 300 QXV 0.8 10 Tab. 17 Viscosity 24 / 26 100-I-000014-E-00 / 07.2005

Appendix 9.1.6 Contamination class For series Class to NAS 1638 to ISO 4406 QT, QX, QXM 9 20/18/15 QXV 8 19/17/14 Tab. 18 Contamination class 9.1.7 Run-in cycle y 100 1s 2s 3s 1s 2s 3s 120s 100s 1s 2s 3s 50 120s 0 140s 20s 1 2 3 4 5 6 7 30s 10s 8 9 10 11 x 1s 2s 2s 3s 3s 3s 5s Fig. 7 Run-in cycle QT/QX/QXM overall run-in time 10 minutes x time [min] y working pressure [%] y 1s 2s 3s 100 1s 2s 3s 240s 1s 2s 3s 240s 50 240s 0 280s 20s 30s 14s 2 4 6 8 10 12 14 16 18 20 22 x 1s 2s 2s 3s 3s 3s 5s Fig. 8 Run-in cycle QXV overall run-in time 21 minutes x time [min] y working pressure [%] 100-I-000014-E-00 / 07.2005 25 / 26

Appendix 9.1.8 Flow speed QT, QX, QXV pumps QXM (drive) Suction pipe [m/s] Pressure pipe [m/s] P1 [m/s] P2 [m/s] 1.8 7.0 7.0 7.0 Tab. 19 Flow speed (recommended) 9.1.9 Pump input pressure If in doubt ask manufacturer about pump input pressure. Minimum [bar] 1) Start phase Long-term Mineral oil HFC Low viscosity 0.6 0.85 0.90 0.90 Tab. 20 Pump input pressure (absolute) - minimum 1) Depending on size and pumped liquid Maximum [bar] Standard version Special version 1.5 > 1.5 1) Tab. 21 Pump input pressure (absolute) - maximum 1) for QT and QX series external connection for leaking oil required 9.1.10 Preservative High quality, mineral oil to DIN 51517 CL 46 or to ISO 3448 VG46(recommended) 9.1.11 Cleaning agents Benzine, wax solvents, diesel, petrol, alkaline cleaners 9.2 Spare parts Type of drive Repair set Version QT QT Cover complete with radial shaft seal ring, spacer disc and O-ring QX QXM QX Flange complete with radial shaft seal ring, spacer disc and O-ring QXV Tab. 22 Spare parts Leaky pumps must be returned to the factory ( 7.3 Returning the pump to the manufacturer, Page 19). 26 / 26 100-I-000014-E-00 / 07.2005