Parker Calzoni MR Series Manual

INSTALLATION AND MAINTENANCE
MANUAL
Hydraulic Motors Type
MR – MRE – MRA
MRD – MRDE – MRDA
MRV – MRVE – MRVA
MRT – MRTE – MRTF – MRTA
ATEX INCLUDED
03/2006

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1 – GENERAL INFORMATION....................................................................................................................................4
1.1 –PURPOSE OF THIS MANUAL.....................................................................................................................................4
1.2 –GENERAL SAFETY WARNINGS ................................................................................................................................4
1.3 -SYMBOLS.................................................................................................................................................................6
1.4 –NOTES ABOUT ATEX STANDARDS .........................................................................................................................7
1.5 -ADDITIONAL DOCUMENTATION...............................................................................................................................7
1.6 -IDENTIFYING THE MOTOR ........................................................................................................................................7
1.7 –TECHNICAL SUPPORT REQUEST ..............................................................................................................................8
1.8 –MANUFACTURER RESPONSIBILITY..........................................................................................................................9
2 –TECHNICAL INFORMATION .............................................................................................................................10
2.1 –MOTOR DESCRIPTION ...........................................................................................................................................10
2.2 –CONFORMITY TO STANDARDS ...............................................................................................................................14
2.3 –OPERATING FLUIDS...............................................................................................................................................16
2.3.1 –Working viscosity range................................................................................................................................16
2.3.2 –Extreme Conditions.......................................................................................................................................16
2.3.3 –Choosing the type of fluid according to the operating temperature .............................................................16
2.3.4 –Types of fluids allowed .................................................................................................................................17
2.3.5 –Fluid filtration ..............................................................................................................................................18
2.3.6 –Mixing different oils......................................................................................................................................19
2.4 –PUMP OPERATION:BOOST PRESSURE REQUIREMENTS...........................................................................................20
3 –HANDLING AND STORAGE................................................................................................................................21
3.1 –SUPPLY CONDITIONS.............................................................................................................................................21
3.2 -TRANSPORTATION .................................................................................................................................................23
3.3 -STORAGE ...............................................................................................................................................................23
3.4 –PACKING REMOVAL........................................................................................................................................23
3.5 –CONTENTS CONTROL ............................................................................................................................................24
3.6 -HANDLING.............................................................................................................................................................25
3.6.1 –Handling of Motor Types MR –MRE –MRA / MRD –MRDE –MRDA / MRV –MRVE –MRVA............25
3.6.2 –Handling of Motor Types MRT –MRTE –MTF –MRTA ............................................................................27
4 -INSTALLATION......................................................................................................................................................28
4.1 –APPLYING THE MOTOR TO THE SYSTEM................................................................................................................28
4.2 –HYDRAULIC CONNECTIONS...................................................................................................................................30
4.2.1 –Main Inlet Hoses Connections......................................................................................................................30
4.2.2 –Drain Line Connections................................................................................................................................30
4.3 -FLUSHING..............................................................................................................................................................32

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4.4 –DISPLACEMENT CHANGE CONNECTIONS FOR MOTOR TYPES MRD/MRDE/MRDA –MRV/MRVE/MRVA..36
5 -USE.............................................................................................................................................................................37
5.1 –PRE START UP CONTROLS......................................................................................................................................37
5.2 –MOTOR CASE OIL FILLING....................................................................................................................................38
5.3 –START UP..............................................................................................................................................................39
5.4 –“CHECK LIST”FOR USAGE IN PRESENCE OF EXPLOSIVE HAZARDOUS ATMOSPHERE (DIRECTIVE “ATEX” 94/9/CE)
......................................................................................................................................................................................40
6 -MAINTENANCE ......................................................................................................................................................41
6.1 –HYDRAULIC SYSTEM PERIODIC MAINTENANCE .....................................................................................................41
6.2 –MOTOR MAINTENANCE.........................................................................................................................................42
6.2.1 –Filters Cleaning Process ..............................................................................................................................42
6.2.2 –Operating Fluid Change...............................................................................................................................42
6.2.3 -Viscosity.........................................................................................................................................................42
6.2.4 -Oxidation.......................................................................................................................................................42
6.2.5 –Water Presence.............................................................................................................................................42
6.2.6 –Degree of contamination...............................................................................................................................43
6.3 -EMPTYING .............................................................................................................................................................43
7 –REPAIR AND SERVICE.........................................................................................................................................44
7.1 –GENERAL INFORMATION.......................................................................................................................................44
7.2 -MALFUNCTIONS:TROUBLE-SHOOTING..................................................................................................................44
7.3 –WARRANTY CONDITIONS......................................................................................................................................46
8 -SCRAPPING..............................................................................................................................................................48
8.1 –SHUT-DOWN AND DISMANTLING ...........................................................................................................................48
8.1.1 –Safety Warnings............................................................................................................................................48
8.1.2 -Instructions....................................................................................................................................................48
9 –DATA COLLECTION FORMAT..........................................................................................................................49
10 -CONTACTS.............................................................................................................................................................50

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1 – General Information
This section must be read before consulting the rest of the
documentation and before undertaking any kind of activity
with the machinery.
This section is required reading for anyone assigned to
interact with the machinery for all kind of purposes
(transportation, installation, running, maintenance, etc.).
1.1 – Purpose of this Manual
The purpose of this manual is to inform about the general rules to be followed for the correct use of the
radial piston hydraulic motors type:
1. MR/MRE/MRA (fixed displacement motor –single pistons row)
2. MRT/MRTE/MRTF/MRTA (fixed displacement motor –multiple pistons row)
3. MRD/MRDE/MRDA (dual displacement motor –single pistons row)
4. MRV/MRVE/MRVA (variable displacement motor –single pistons row)
All essential information of interest for users as well as designers are available in the “Technical Catalogue”
dedicated to each above listed motor range; while in the present manual
you can find the procedures to be followed for:
Handling & Storage
Installation
Use and Maintenance
Repairs and Service
Scrapping
This manual also provides important information concerning the safety of the people assigned to the
assembly, use and maintenance of the radial piston motors; consequently, it is necessary that this manual is
carefully read and the indications here reported strictly followed.
In case this manual gets lost or damaged, a replacement copy can be required directly to Parker Calzoni
s.r.l. by using the present manual code: RCOe2100/09/05.
1.2 – General Safety Warnings
When using industrial machinery and systems, one must be aware that moving parts (both linear and
rotary), high-voltage electrical parts, any high-temperature parts, etc. may cause serious harm to people
and propriety.

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Those responsible for system security must ensure that:
all improper use and operations are avoided;
the safety devices are not removed or tampered with;
maintenance operations are regularly performed;
all precautions, individual protection, etc. required by safety regulations and legislation valid in the
user’s country are duly adopted (see EEC directives 89/686/CEE and 89/656/CEE)
only original spares are used, especially for components that perform a safety function.
For this purpose, it is essential that:
this documentation is filed, by a duly assigned person, in a suitable location so that to be always
accessible for consultation, and always in good condition.
only adequately trained personnel are assigned to the machinery.
The “Machine Directive” (89/392/CEE and subsequent changes) defines “OPERATOR” the person(s) assigned
to install, operate, ad just, maintain, clean, repair and handle a machinery.
To better define the degree of preparation, field of operation and level of responsibility of the “OPERATORS”
in this manual we define the following terms:
OPERATOR
Person who does not necessarily have a strong technical background, trained to run
the machine in ordinary production regarding: start-up, stop at the end of the shift,
simple maintenance operations (cleaning, etc.).
MAINTENACE TECHNICIAN (mechanical or electrical)
Qualified Technician assigned to the more complex operations of installations,
maintenance, repairs, etc. within his/her specific field of competence (mechanical or
electrical.)
It is essential to make sure that the assigned operators have read and well understood the manual sections
of their own competence. In particular:
the OPERATOR must consult the sections relevant to “General Information” and
“Use”.
The MAINTENANCE TECHNICIAN assigned to installation, maintenance, repair, etc.
must consult all sections of this manual.

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1.3 - Symbols
In this documentation special symbols are used to highlight in each instance possible hazardous conditions
for people and/or property:
SERIOUS danger: LIFE-THREATENING to people.
People harm and product damage danger.
Danger of damage, even serious, to the product.
Particularly Important Technical Information: not to be neglected.
Danger of contamination.
Danger deriving from fluids under pressure.
Compulsory usage of protective goggles.
Compulsory hands protection.
Centre of gravity.
Do not store in a damp environment.
Compulsory usage of special lifting equipment.

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1.4 – Notes about ATEX Standards
In this manual there are notes concerning the usage of radial piston Calzoni motors in potential explosive
hazardous zones classified by the Directive 94/9/CE. These notes are identified by using the symbols below:
The information provided in correspondence of these symbols are relevant only to
machinery operating in conformity to the Directive “ATEX” 94/9/CE.
The operations recalled by these symbols must be performed by qualified personnel
with specific skills and competence about safety requirements in potential explosive
hazardous zones.
Not to follow the indications identified by these symbols can lead to serious dangers to
people and environment safety; moreover not to follow these indications can lead to
the motor not to comply with the Directive requirements.
1.5 -Additional Documentation
Along with the present manual, upon request, the following additional documentation can be provided for
each product:
Exploded View
Spare Parts List
Overall Dimensions Drawing (the overall dimensions for each standard motor type can also be found
in the “Technical Catalogue” relevant to each motor series).
Your documentation request can be addressed to Parker Calzoni s.r.l.
1.6 - Identifying the motor
A metal plate is located on the motor rotary valve housing where you can find the complete code that
describes the configuration of the unit (as per the “technical catalogue”) and the maximum continuous
working pressure.
In addition, a serial number is punched on the rotary valve housing of each motor; the motor serial number
consists of 5 digits or one letter and 4 digits.
For a correct motor identification you must refer to both serial number and motor
code. You must refer to these data in case of spare parts, information as well as
service requests.
For motor code interpretation, pls. refer to the motor “technical catalogue”.

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Motors destined to operate in explosive hazardous zones classified according to Directive 94/9/CE can be
recognised thanks to a special plate you can find on the motor rotary valve housing in addition to the one
that indicates the motor code. The special plate is as below:
This identifying plate has to be kept in conditions so that all data on it can always be clearly read;
consequently, a periodic cleaning of the plate is required.
1.7 – Technical Support Request
Any kind of technical support request has to be addressed to one of the Parker Hannifin Sales Company or
directly to Parker Calzoni s.r.l. by communicating the data you can find on the motor metal plate, the motor
serial number, the approximate number of service hours of the unit and the kind of failure experienced.1.
1Pls. See “Data collection format”
Metal Plate with
complete motor code
SERIAL NUMBER

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1.8 – Manufacturer Responsibility
The manufacturer declines any responsibility in case of:
use of the product not according to the safety regulations and legislation valid in the user’s country;
use of the product in operating conditions not allowed according to the product technical
documentation;
improper installation: the instructions given in this manual are not followed or not properly followed;
hydraulic system problems;
modification or manumission of the product;
operations executed by personnel not properly trained or not assigned to such a kind of operations.
The safety of the product depends upon the strict observation of the indications given in this manual; in
particular, it is necessary:
to always operate within allowed product working operating conditions2
to always perform an accurate ordinary maintenance activity;
to assign the inspection activity as well as maintenance activity to duly trained personnel;
to only use original spares;
to always use the product according to the indications you find in this manual.
The instructions of this manual are in addition and do not replace the obligations we
are required to comply with in accordance to the currently valid safety regulations and
legislations.
2Pls. refer to the “Technical Catalogue” of the unit in usage.

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2 – Technical Information
This section is dedicated to a general introduction to the machinery. The products this macula refers to are
radial piston hydraulic motors whose series are:
1. MR/MRE/MRA (fixed displacement motors –single pistons row)
2. MRT/MRTE/MRTF/MRTA (fixed displacement motors– multiple pistons row)
3. MRD/MRDE/MRDA (dual displacement motors –single pistons row)
4. MRV/MRVE/MRVA (variable displacement motors –single pistons row)
The motors are used to convert the energy generated by working fluid pressure into kinetic energy of a
rotating shaft. The motor provides a torque proportional to the feeding hydraulic pressure and a speed
proportional to the feeding flow rate from the system pump.
The hydraulic radial piston motors object of this manual fall into the range of “Low Speed High Torque”
(LSHT) motors.
One fundamental feature of these motors is the capability to develop a very high starting torque, able to win
high resistant torque and start up the system.
This information represents an initial approach to become familiar with the products object of this manual;
more specific and detailed information on various topics is contained sections to follow.
2.1 – Motor Description
Parker Calzoni motors are the result of an original design aimed to obtain extremely high performances. The
radial driving system consists of telescopic cylinders (1) working against the spherical eccentric cam of the
rotating shaft on one side (2) and against the spherical caps (3) of the cylinder heads (4) on the other side.
The force is transmitted to the rotating shaft directly by means of a pressurised column of hydraulic fluid (a)
without any intermediate connecting rods, pistons, pads and pins; this feature leads to high mechanical
efficiency, thanks to the minimization of friction, and to the reduction of the moving parts wear.
The sealing surfaces of the pistons on shaft and cylinder head caps are perfectly spherical; the sealing surfaces
retain their circular cross section when stressed by pressure so that there is no alteration in the sealing
geometry.The usage of dedicated coating on the motor shaft reduces the friction and prevents any kind of
seizure of the motor’s internal components.
Since the force is transmitted directly toward the centre of the rotating shaft without connecting rods, there is
no transverse component of the thrust (side load) which means no out of round wear of the pistons.
The Parker Calzoni driving system design allows the realisation of motors with limited weight and overall
dimensions.
The timing system is realised by means of a frontal rotary valve (5), that rotates between two fixed plates (6-7),
connected to the main rotating shaft by means of a driving shaft (8).
This timing system design is hydraulically balanced and self compensated for wear and temperature variation.

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Motor Type MR/MRE/MRA – fixed displacement, single pistons row
Motor Type MRT/MRTE/MRTF/MRTA – fixed displacement, multiple pistons row

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Motor Type MRD/MRDE/MRDA – dual displacement motor, single pistons row
Motor Type MRV/MRVE/MRVA – variable displacement motor, single pistons row
For the motor type MRD/MRDE/MRDA the change of displacement is accomplished by having the eccentric
cam (2) free to radial move: the radial movement of the eccentric cam is controlled by means of hydraulic
cylinders (12) located inside the shaft. It is possible to choose maximum and minimum displacement values
within the maximum range allowed by means of spacers. The piloting cylinders are operated by means of a
rotating intake (9). Motor displacement can be changed during the motor operation, from maximum
displacement to minimum displacement, as well as from minimum displacement to maximum displacement
with no need to stop the motor operation.

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The eccentric cam radial move in the variable motors type MRV/MRVE/MRVA is controlled by means of a
counter check valve (11) located inside the rotating shaft. This valve pilots the movement of the
displacement change system cylinders (12): with this solution it is possible to obtain whatever value of
displacement within the maximum range allowed by means of a continuous variation of the position of the
eccentric cam (2).
The usage of Parker Calzoni motors is made very flexible by means of electronic and hydraulic regulation
circuits; moreover, these solutions lead to efficiency increase and performances improvement of the machine
the motors are installed on.
Thanks to these design peculiarities, Parker Calzoni motors grant high mechanical and volumetric efficiency
values, even at very low speed and high operating pressure, as well as in starting torque condition; these
performances do not worsen during the motor service life, granting the reliability for which this motor brand
is well known.
According to the application’s request, the motor can be provided in different configurations. To widen the
motors’ flexibility PARKER CALZONI provides a series of accessories and options (for all information
concerning the technical and dimensions characteristics pls. refer to the correspondent “technical
catalogue“).

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2.2 – Conformity to standards
Parker Calzoni motors can be provided in conformity to the essential safety requirements according to the
Directive ATEX 94/9/CE as per the specifications here below:
The motors, if destined to operate in potential explosive hazardous atmosphere, are designed and
realised in conformity to the Safety Essential Requirements (RES) of Annex II of Directive “ATEX”
94/9/CE. The Directive provides the following classification:
Group II, category 2, operation in gaseous and dustyenvironment zone 1 and 21;
Group II, category 3, operation in gaseous and dustyenvironment zone 2 e 22;
Group I, category M2, operation inside mines;
Maximum surface temperature: class of temperature T4
SAFETY SPECIFICATIONS FOR MOTORS IN CONFORMITY TO DIRECTIVE 94/9/CE
the motor must be connected to ground by means of the dedicated threaded hole identified by
means of the symbol ( ) –pls. refer to the picture here below;
only mineral oil with in flammability degree higher than 185°C can be used;
motor seals must be in VITON®;
motor must be always flushed in whatever operating condition (pls. refer to the section
“Flushing”);
the motor must be equipped with a system to detect the oil level inside the motor case: motor
case must be always full of oil (pls. refer to the section “Flushing”);
no creeping metal elements external to the motor are allowed;
plastic parts that might accumulate electrostatic charges are not allowed; their presence is
accepted if shielded.
for installations in zones 21 and 22 the user has to adopt a scheduled periodic cleaning plan of
the machinery surface and recesses so that to prevent more than 5 mm thickness dusts
deposits.
Before servicing motors that operate in potential explosive hazardous atmosphere, the assigned
personnel must deactivate the inlet feeding putting the motor in “out of service” condition; attention
has to be paid to any situation that might lead to the undesired re start up of the motor or to the
undesired and not predicted movement of motor’s parts.
All additional environmental safety regulations must be undertaken (i.e. degassing process & residual
dust cleaning process of the atmosphere)
It is forbidden to use a motor not designed and realised in conformity to the dedicated standards in
potential explosive hazardous zones or where the usage of anti-deflagration components is required.

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2.3 – Operating Fluids
The viscosity, quality and cleanliness of the operating fluid are decisive factors in determining the reliability,
performances and life time of a hydraulic component.
2.3.1 – Working viscosity range
The motor maximum life time and performances are achieved within the recommended viscosity range. For
applications exceeding this range we recommend that you contact Parker Calzoni s.r.l.
Vrec. = recommended operating viscosity 30....50 mm2/s
This viscosity is referred at the same time to the temperature of the fluid entering the motor and to the
temperature of the fluid inside the motor housing (case temperature).
2.3.2 – Extreme Conditions
The following limitations are applied:
Vmin.abs. = 10 mm2/s for instants in case of emergency, with a maximum case fluid temperature
of 80°C
Vmin. = 18 mm2/s with reduced torque and maximum supplied power performances
Vmax. = 1000 mm2/s during “cold” start up
2.3.3 – Choosing the type of fluid according to the operating temperature
The motor operating temperature is defined as the higher between that of the inlet feeding fluid entering
the motor and that of the fluid inside the motor case (case temperature).
Temperature must never exceed 80°C anywhere in the system.
It is recommended that you choose the viscosity of the fluid based on the maximum operating temperature
so that to make the motor operate within the recommended viscosity range.

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If these viscosity requirements cannot be met due to extreme operating parameters or high environment
temperature, motor case flushing is strictly recommended in order to operate within the viscosity limits.
Should it be absolutely necessary to use a viscosity exceeding the recommended range, pls. first contact
Parker Calzoni s.r.l.
2.3.4 – Types of fluids allowed
HLP oils according to standard DIN 51 524 part 2 (with wear-proof, oxidation-proof and corrosion-proof
additives) and part 3 (with a high viscosity index, suitable for applications subject to broad operating
temperature variations) are recommended.
The use of water-based fluids is allowed only with motors specifically designed; the motor performances get
reduced according to the class the oil belongs to: HFA, HFB orHFC (pls. contact Parker Calzoni s.r.l. about
the usage of motors on water based fluids).
The use of synthetic fluids (type HFD) is allowed with motors supplied with seals in FPM material (pls.
contact Parker Calzoni s.r.l. about the usage of motors on synthetic fluids).
Seals in FPM material are necessary for HFD/U fluids only if expressly indicated by the fluid manufacturer.
The use of synthetic fluids (typo HFD) does not imply any motor performances reduction.
Three families of biodegradable fluids are currently available in the market:
1. Vegetable-based fluids HETG
2. Polyglycol-based synthetic fluids HEPG
3. Ester-based synthetic fluids HEE
At the present time very little practical experience and information has been gathered with regard to the
possible performances and aging characteristics of the various fluids belonging to the HETG class. In case of
working pressure exceeding 200 bar, the generation of sludge is a side effect of the use of a fluid belonging
to this class. As a consequence the fluid has to be frequently monitored and an operating temperature below
45°C is recommended.
HEPG fluids have excellent working characteristics thanks to their usual high viscosity.
For information concerning HEE fluids you can refer to the operating parameters of the HLP oils.
AS FOR MINERAL BASED FLUIDS, BIODEGRADABLE FLUIDS
MUST BE DISPOSED OF IN ACCORDANCE TO CURRENT
REGULATIONS.

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It is compulsory to us only oils whose inflammable degree is higher than 185°C in case
the motor
is destined to be used in potential explosive hazardous atmosphere
(Directive“ATEX” 94/9/CE).
FLAMMABLE AND SELF-EXTINGUISHING FLUIDS
Fluid characteristics
Class Type of fluid Water content (% in weight)
HFA
HFB
HFC
HFD
HFD/R
HFD/S
HFD/T
HFD/U
Oil-water emulsion
Water-oil emulsion
Water-based solution (mostly with glycol)
Synthetic fluids (water free)
Fluid based on phosphorous esters
Fluid based on chlorinated hydrocarbons
Fluid based on phosphorous esters & chlorinated
hydrocarbons
Other compositions
95 – 98
>40
35 – 55
0 – 0.1
Motor application limitations
Temperature (°C)Class Pressure
(bar)
(% nom.
pressure)
Speed
(r.p.m.)
(% max.
speed)
Power
(kW)
(% max.
power)
Maximum Ideal
HFA
HFB
HFC
HFD
50
80
60
100
50
80
60
100
25
60
30
100
50
60
60
80
40
45
45
50
Note: For HFD/U fluids FPM seals must be used only if required by the fluid
manufacturer.
2.3.5 – Fluid filtration
To ensure a smooth and reliable motor operation, the fluid must comply with to one of the following
filtration classes:
1. class 9 according to NAS 1638
2. class 6 according to SAE, ASTM, AIA
3. class 20/17/16 according to ISO 4406:1999

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To ensure a long motor life time class 8 according to NAS 1638 is recommended: it is
attainable by using ßx = 100 filtration quotient.
In case the above listed filtration classes cannot be respected, pls. contact Parker
Calzoni s.r.l.
2.3.6 – Mixing different oils
Mixing oils of different brands or different oils of the same brand may lead to the formation of sediment and
sludge. Consequently a rapid, irreversible deterioration of the system is induced.

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2.4 – Pump Operation: boost pressure requirements
In case the motor is used as a pump or driven by the load (even for short time) it is necessary to ensure an
adequate boost pressure to the inlet line.
The diagrams relevant to the minimum boost pressure required by the motor when working as a pump can
be found in the “Technical Catalogue”of the series the motor belongs to.
The hydraulic circuit has to be built so that to protect the motor from insufficient
boosts pressure. The two circuits below are just general examples to how to solve the
problem.
Open Loop Circuit Closed Loop Circuit