Eaton Hydrowa User manual

Instruction manual
Specialized in Custom Built hydraulic cylinders
Hydrowa™ cylinders
Release 8 – October, 2011

General information
Eaton Industries B.V. Eindhoven
Eaton Industries B.V. was founded in 1980 as a small machinery plant named
Hydrowa. More and more the core business of this plant shifted from
manufacturing machine parts to the production of hydraulic cylinders. Eaton
acquired Hydrowa B.V. in 2000 from the American IMC group. Previously the
Danish Sophus Berendsen corporation sold Hydrowa B.V. in 1998 to IMC after
10 years being owner of Hydrowa B.V..
In September 2006 the name Eaton Hydrowa changed name to Eaton
Industries BV. Hydrowa is now the brand name for the cylinders.
Eaton Industries B.V. main operation is the production of special custom build
hydraulic cylinders. To support customers needs, the repair and service unit
initiates repair and service activities on (own/competitors) cylinders.
Our core business implies engineering-to-order; we tailor our products to
customer needs and wishes. The custom products, we manufacture, can have
all imaginary dimensions and specifications. Eaton Industries can supply
cylinders with bore diameters up to Ø 1500 mm and the stroke length up to
22,000 mm.
Contact information Eaton Industries (Netherlands) B.V. :
Eaton Fluid Power
Hydraulics Operations
Eaton Industries (Netherlands) B.V.
Hoppenkuil 6, 5626 DD Eindhoven
P.O. Box 9707, 5602 LS Eindhoven
The Netherlands
Tel.: [phone]
Fax.: [phone]
E-mail: [e-mail]
Website: www.eatonindustries.nl

Instruction Manual
Page 2
Index
1 Type code cylinder ________________________________________________ 3
2 Symbols ________________________________________________________ 4
3 Precaution ______________________________________________________ 5
3.1 Instructions before operating ____________________________________ 5
3.2 Conditions ___________________________________________________ 5
3.3 Safety aspects hydraulic system__________________________________ 5
3.4 Warnings ____________________________________________________ 5
4 Lifting instructions_________________________________________________ 6
4.1 Who is allowed to lift cylinders ___________________________________ 6
4.2 Personal protection ____________________________________________ 6
4.3 General lifting procedure________________________________________ 6
4.4 Lifting eyes for lifting cylinders ___________________________________ 7
5 Storage manual __________________________________________________ 8
5.1 Personal protection ____________________________________________ 8
5.2 Basic activities before and during storage __________________________ 8
5.2.1 Basic activities ____________________________________________ 8
5.2.2 Preservation______________________________________________ 8
5.2.3 Storage checklist __________________________________________ 9
6 Installation manual _______________________________________________ 10
6.1 Personal protection ___________________________________________ 10
6.2 How to remove protection material _______________________________ 10
6.3 Step by step installation guide __________________________________ 10
6.4 Installation of accessories______________________________________ 11
6.5 Filling the cylinder with oil and release air from the cylinder ___________ 12
7 User guide _____________________________________________________ 13
7.1 Warnings ___________________________________________________ 13
7.2 Who is allowed to operate a cylinder _____________________________ 13
7.3 Personal protection ___________________________________________ 13
7.4 How to operate a cylinder ______________________________________ 13
7.5 General information about accessories ___________________________ 13
7.6 How to use manifold blocks and valves ___________________________ 14
8 Maintenance manual _____________________________________________ 15
8.1 Checklists __________________________________________________ 15
8.2 Maintenance description for basic parts ___________________________ 15
8.3 Oil maintenance _____________________________________________ 16
9 Service manual__________________________________________________ 17
9.1 Troubleshooting list of most common malfunctions __________________ 17
9.2 Contact data Eaton Industries B.V._______________________________ 19
9.3 Preparation for transportation ___________________________________ 19
Appendix A – Maintenance / Inspection log _______________________________ 20

Instruction Manual
Page 3
1 Type code cylinder
1
HYPOS is an integrated stroke-measuring system

Instruction Manual
Page 4
2 Symbols
Safety helmet
Ear protection
Safety glasses
Safety boots
Safety gloves
General warning or important note
Warning this material contains corrosive substances
Do not expose to open fire

Instruction Manual
Page 5
3 Precaution
3.1 Instructions before operating
Before installing, handling, removing or starting to work with a
cylinder read this manual first. Make sure the appropriate personal
protection equipment is used at all time. Only qualified personnel
should be allowed to operate a cylinder.
Eaton Industries is not responsible for damaged property, injuries or any other
kind of damage occurred during the use of cylinders by third parties.
3.2 Conditions
Make sure the cylinders are used in the environmental conditions that are
suitable for the cylinders. Eaton industries will not guarantee that cylinders will
properly function in different conditions then they are made for. Also the lifetime
of the cylinder will be decreased when it is used in different environmental
conditions.
3.3 Safety aspects hydraulic system
Cylinders connected to a hydraulic system must comply with NEN-EN-ISO 4413
and NEN-EN 982. The system must take safety aspects into account.
3.4 Warnings
Never expose cylinders or cylinder components to any kind of open
fire!
Do not expose the cylinder or cylinder components to a
temperature above 70°C unless you have approval of Eaton
Industries BV to use the cylinder in environmental conditions with
temperatures above 70°C
Some hydraulic oil types contain corrosive substances!
Do not drill any holes in the cylinders!
Do not weld anything on cylinders. If some extra mounting spot or
anything else has to be welded on the cylinder contact Eaton
industries at Eindhoven.
Warning signs that might be attached to the cylinder (when applicable):

Instruction Manual
Page 6
4 Lifting instructions
4.1 Who is allowed to lift cylinders
Only qualified personnel shall lift cylinders.
4.2 Personal protection
Use the normal appropriate personal protection when lifting cylinders:
4.3 General lifting procedure
Lifting gear
Use appropriate and certified lifting slings for lifting cylinders. Do not use steel
slings, chains or cables to lift cylinders. Steel slings can damage the paintwork
that may result in corrosion on the surface of the cylinder that will reduce the
lifetime of the cylinder.
Do NOT use damaged or worn nylon slings or other damaged lifting
equipment.
Unless otherwise specified, do not fix cables or chains to wooden
support blocks. The blocks could break and cause personal injury,
damage the cylinders or damage property.
This instruction must be studied by the lifting personnel. Hoisting must be done
by qualified personnel, using certified equipment. Hoisting equipment should
have enough lifting capacity and be able to do the job.
Moving the load
When moving the load make sure if there is nobody working near the moving
crane or load. If so warn the crew before moving the load in their direction.
Make sure nothing is blocking the route of the moving load. Under no
circumstances may anyone ride the hook or load. Directional movement should
be made smoothly and deliberately. Avoid rapid movements in any direction.
Do not exceed the rated load capacity of the crane, hoist, chain,
cable, slings, or other component.

Instruction Manual
Page 7
4.4 Lifting eyes for lifting cylinders
Most of the bigger cylinders made by Eaton Industries have special hoisting
eyes mounted at the cylinder itself. Always use these eyes when lifting
cylinders. If it isn’t possible to use the hoisting eyes when mounting the cylinder
in its construction, use the normal procedure of lifting heavy loads.

Instruction Manual
Page 8
5 Storage manual
5.1 Personal protection
5.2 Basic activities before and during storage
5.2.1 Basic activities
The below mentioned storage and maintenance activities need to be executed
and recorded properly in the inspection & maintenance log (document FOR-
004 – Maintenance & Inspection Log see appendix A) in order to benefit Eaton
warranty policy. For some specific application or circumstances additional
instructions can be defined and communicated by Eaton. These additional
instructions do not replace the general instructions in this manual, but are
additional. In appendix A is shown an example how to fill in the inspection and
maintenance log.
5.2.2 Preservation
- Preferably the cylinder should be filled 100% with oil
- Other option is to fill the cylinder with nitrogen pressure (~ 10 bar)
or a combination of both.
- During transportation and lifting of the cylinder the piston rod
should always be fully retracted and must remain retracted during storage.
- Always protect the extended part of the piston rod. There are several ways
to protect a piston rod from environmental threats. Greasing, oiling or
waxing are some of the ways to protect the piston rod. Another way to
protect the piston rod is wrapping with a Denso-system. Eaton can advise
which system can be used and how to apply this system.
- Blind the connection ports of the cylinder with steel plugs or blind flanges
(SAE) to prevent the cylinder from entering contamination and make sure
that the cylinder is air tight.
- Rod eyes and bottom eyes should be protected with cover-plates or equal.
Trunnion should be covered by protection-bushings, protection-plates,
Lamiflex
®
or equal.
- Oil, grease or wax (Rust-Ban 397 or equivalent, suitable for the
environment) all blank surfaces (steel parts).
- Preferably the cylinders should be stored in vertical position. If not possible
store the cylinders in horizontal position, free from stresses and/or loads.
- The cylinders should be stored in a closed building with a constant
temperature between –10°C and +40°C. Sudden fluctuations in
temperature can damage the cylinder.
- The environment where the cylinder is stored should be dry, out of direct
sunlight, damp and erosive material. The relative humidity of the storage
area should preferably not exceed 70% RH.