HIGH PRESSURE COOLANT SYSTEM FOR STAR MACHINES

MODEL NJ1750-E

MAINTENANCE MANUAL WITH PARTS

LIST AND ELECTRICAL DIAGRAM

For parts or service contact your distributor or your local Star dealer
 Totally Integrated
Automation Portal

Main [OB1]
Main Properties
General
Name Main Number 1 Type OB
Language LAD Numbering automatic
Information
Title "Main Program Sweep Author Comment
(Cycle)"
Family Version 0.1 User-defined
ID

Name Data type Default value

Input
Initial_Call Bool
Remanence Bool
Temp
Constant

Network 1:

"IEC_TIMERS_
%I0.0
DATA".TIMER_0
"INPUT_1"
TON
Time
"IEC_TIMERS_
%I0.1 DATA".TIMER_0.
"INPUT_2" PT

%I0.2
"INPUT_3" "IEC_TIMERS_
DATA".TIMER_1
TOF
Time
%I0.3 "IEC_TIMERS_
"INPUT_4" DATA".TIMER_1.
PT

%I0.4
"INPUT_5"

%I0.5
"INPUT_6"

%I0.6
"INPUT_7"

%I0.7
"INPUT_8"
 Totally Integrated
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Network 2:

"IEC_TIMERS_
DATA".TIMER_0. %Q1.0
Q "K1"

Network 3:

"IEC_TIMERS_
%I0.0
DATA".TIMER_2
"INPUT_1"
TOF
Time
"IEC_TIMERS_
DATA".TIMER_2.
PT

Network 4:

"IEC_TIMERS_
%I0.1
DATA".TIMER_3
"INPUT_2"
TOF
Time
"IEC_TIMERS_
DATA".TIMER_3.
PT

Network 5:

%I0.2 "IEC_TIMERS_
DATA".TIMER_4
"INPUT_3"
TOF
Time
"IEC_TIMERS_
DATA".TIMER_4.
PT

Network 6:
 Totally Integrated
Automation Portal

"IEC_TIMERS_
%I0.3
DATA".TIMER_5
"INPUT_4"
TOF
Time
"IEC_TIMERS_
DATA".TIMER_5.
PT

Network 7:

%I0.4 "IEC_TIMERS_
DATA".TIMER_6
"INPUT_5"
TOF
Time
"IEC_TIMERS_
DATA".TIMER_6.
PT

Network 8:

%I0.5 "IEC_TIMERS_
DATA".TIMER_7
"INPUT_6"
TOF
Time
"IEC_TIMERS_
DATA".TIMER_7.
PT

Network 9:

"IEC_TIMERS_
%I0.6
DATA".TIMER_8
"INPUT_7"
TOF
Time
"IEC_TIMERS_
DATA".TIMER_8.
PT

Network 10:
 Totally Integrated
Automation Portal

"IEC_TIMERS_
%I0.7
DATA".TIMER_9
"INPUT_8"
TOF
Time
"IEC_TIMERS_
DATA".TIMER_9.
PT

Network 11:

"IEC_TIMERS_
DATA".TIMER_2. %Q0.0
Q "SOL_1"

Network 12:

"IEC_TIMERS_
DATA".TIMER_3. %Q0.1
Q "SOL_2"

Network 13:

"IEC_TIMERS_
DATA".TIMER_4. %Q0.2
Q "SOL_3"

Network 14:

"IEC_TIMERS_
DATA".TIMER_5. %Q0.3
Q "SOL_4"

Network 15:
 Totally Integrated
Automation Portal

"IEC_TIMERS_
DATA".TIMER_6. %Q0.4
Q "SOL_5"

Network 16:

"IEC_TIMERS_
DATA".TIMER_7. %Q0.5
Q "SOL_6"

Network 17:

"IEC_TIMERS_
DATA".TIMER_8. %Q0.6
Q "SOL_7"

Network 18:

"IEC_TIMERS_
DATA".TIMER_9. %Q0.7
Q "SOL_8"

Network 19:

Network 19:

%I0.0 %I0.1 %I0.2 %I0.3 %I0.4 %I0.5 %I0.6

"INPUT_1" "INPUT_2" "INPUT_3" "INPUT_4" "INPUT_5" "INPUT_6" "INPUT_7"
1

"IEC_TIMERS_ %I4.1 %M2.0

%I0.7 DATA".TIMER_1. "Q1.0_OR_K1_ "K1_ABNORMAL_
"INPUT_8" Q HEALTH_SIGNAL" SIGNAL"
1

Network 20:
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%I4.0 %M2.0 %Q1.1

%M1.2 "OVERLOAD_ "K1_ABNORMAL_ "PLC_HEALTH_
"AlwaysTRUE" INPUT" SIGNAL" OUTPUT"
 Totally Integrated
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IEC_TIMERS_DATA [DB1]
IEC_TIMERS_DATA Properties
General
Name IEC_TIMERS_DATA Number 1 Type DB
Language DB Numbering automatic
Information
Title Author Comment
Family Version 0.1 User-defined
ID

Name Data type Start value Retain

Static
TIMER_0 IEC_TIMER True
ST Time T#0ms True
PT Time T#500ms True
ET Time T#0ms True
RU Bool false True
IN Bool false True
Q Bool false True
TIMER_1 IEC_TIMER True
ST Time T#0ms True
PT Time T#2500ms True
ET Time T#0ms True
RU Bool false True
IN Bool false True
Q Bool false True
TIMER_2 IEC_TIMER True
ST Time T#0ms True
PT Time T#2000ms True
ET Time T#0ms True
RU Bool false True
IN Bool false True
Q Bool false True
TIMER_3 IEC_TIMER True
ST Time T#0ms True
PT Time T#2000ms True
ET Time T#0ms True
RU Bool false True
IN Bool false True
Q Bool false True
TIMER_4 IEC_TIMER True
ST Time T#0ms True
PT Time T#2000ms True
ET Time T#0ms True
RU Bool false True
IN Bool false True
 Totally Integrated
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Name Data type Start value Retain

Q Bool false True
TIMER_5 IEC_TIMER True
ST Time T#0ms True
PT Time T#2000ms True
ET Time T#0ms True
RU Bool false True
IN Bool false True
Q Bool false True
TIMER_6 IEC_TIMER True
ST Time T#0ms True
PT Time T#2000ms True
ET Time T#0ms True
RU Bool false True
IN Bool false True
Q Bool false True
TIMER_7 IEC_TIMER True
ST Time T#0ms True
PT Time T#2000ms True
ET Time T#0ms True
RU Bool false True
IN Bool false True
Q Bool false True
TIMER_8 IEC_TIMER True
ST Time T#0ms True
PT Time T#2000ms True
ET Time T#0ms True
RU Bool false True
IN Bool false True
Q Bool false True
TIMER_9 IEC_TIMER True
ST Time T#0ms True
PT Time T#2000ms True
ET Time T#0ms True
RU Bool false True
IN Bool false True
Q Bool false True
 Totally Integrated
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Default tag table [70]

PLC tags
PLC tags
Name Data type Address Retain
System_Byte Byte %MB1 False
FirstScan Bool %M1.0 False
DiagStatusUpdate Bool %M1.1 False
AlwaysTRUE Bool %M1.2 False
AlwaysFALSE Bool %M1.3 False
Clock_Byte Byte %MB0 False
Clock_10Hz Bool %M0.0 False
Clock_5Hz Bool %M0.1 False
Clock_2.5Hz Bool %M0.2 False
Clock_2Hz Bool %M0.3 False
Clock_1.25Hz Bool %M0.4 False
Clock_1Hz Bool %M0.5 False
Clock_0.625Hz Bool %M0.6 False
Clock_0.5Hz Bool %M0.7 False
INPUT_1 Bool %I0.0 False
INPUT_2 Bool %I0.1 False
INPUT_3 Bool %I0.2 False
INPUT_4 Bool %I0.3 False
INPUT_5 Bool %I0.4 False
INPUT_6 Bool %I0.5 False
INPUT_7 Bool %I0.6 False
INPUT_8 Bool %I0.7 False
SPARE_DIG_INPUT_I1.0 Bool %I1.0 False
SPARE_DIG_INPUT_I1.1 Bool %I1.1 False
SPARE_DIG_INPUT_I1.2 Bool %I1.2 False
SPARE_DIG_INPUT_I1.3 Bool %I1.3 False
SPARE_DIG_INPUT_I1.4 Bool %I1.4 False
SPARE_DIG_INPUT_I1.5 Bool %I1.5 False
OVERLOAD_INPUT Bool %I4.0 False
Q1.0_OR_K1_HEALTH_SIGNAL Bool %I4.1 False
SOL_1 Bool %Q0.0 False
SOL_2 Bool %Q0.1 False
SOL_3 Bool %Q0.2 False
SOL_4 Bool %Q0.3 False
Totally Integrated
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Name Data type Address Retain

SOL_5 Bool %Q0.4 False
SOL_6 Bool %Q0.5 False
SOL_7 Bool %Q0.6 False
SOL_8 Bool %Q0.7 False
K1 Bool %Q1.0 False
PLC_HEALTH_OUTPUT Bool %Q1.1 False
SPARE_DIG_OUTPUT_Q4.0 Bool %Q4.0 False
SPARE_DIG_OUTPUT_Q4.1 Bool %Q4.1 False
K1_ABNORMAL_SIGNAL Bool %M2.0 False
 Totally Integrated
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Default tag table [70]

User constants
User constants
Name Data type Value
INDEX PART # DESCRIPTION
1 610003 3/4 NPT STREET (BRASS)
2 610013 3/4"M NPT X 1" BARB
3 510005 FILTER, FLAT BASE
4 610014 3/4"M NPT X 3/4" BARB
5 610016 1/4 M X F GAUGE COCK
6 610015 1/4 M COMP. 90 (FOR PLASTIC HOSE 1/4")
7 610021 -30~30 PSI GAUGE BACK M. (LIQ FILLED)
8 610018 3/4" BALL VALVE
9 610004 3/4X2.5L NIPPLE
10 910001 NJ1750 ENCLOSURE
ELECTRICAL BOX -PLEASE, REFER TO
11 990001
ELECTRICAL DIAGRAM SECTION FOR PARTS
12 210021 LEVELING PADS, CASTERS
13 510001 5HP MOTOR 1760 RPM
14 710004 LOVEJOY COUPLING L095 1-1/8 X 1/4
15 710005 LOVEJOY SPIDER
16 710003 LOVEJOY COUPLING L095 5/8 X 5/32
17 710002 MOTOR TO PUMP ADDAPTER 1960
18 610001 5/8 O'RING X 1/2JIC MXM 90
19 510002 8 GPM GEAR PUMP
20 610002 3/4 O'RING X 3/4 NPT STREET 90
21 610005 3/4 NPT.F X 1" BARB
22 610020 0~2000 PSI GAUGE BOTTOM M. (LIQ FILLED)
23 610006 1/2 O'RING
1/2" O RING PLUG
24 610011 1/2" NPT M X 3/4 BARB (BRASS)
25 710001 RELIEF VALVE
26 610007 3/8 O'RING PLUG
27 610010 1/2 O'RING M X 1/2 JIC F SWIVEL
28 510003 MANIFOLD BLOCK (MAIN)
29 880001 VALVE
30 880002 COIL
31 880003 CONNECTOR
32 610009 1/2" O'RING M X 1/2" JIC M STR
33 610008 1/2" O'RING.M X 1/2"JIC M 90
34 510004 MANIFOLD BLOCK (EXPANSION)
 F
F

E E

D D

C C

B B

UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN

NEW ENGLAND TOOL CORP.
TOLERANCES:
FRACTIONAL CHECKED TITLE:
A ANGULAR: MACH BEND
ENG APPR. A
TWO PLACE DECIMAL
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS
THREE PLACE DECIMAL

INTERPRET GEOMETRIC
MFG APPR.

Q.A.
ASSEMBLY
NEW ENGLAND TOOL CORP. TOLERANCING PER:
DRAWING IS THE SOLE PROPERTY OF
8 THOMPSON RD. UNIT #10 NEW ENGLAND TOOL CORPORATION. ANY MATERIAL
COMMENTS:

EAST WINDSOR , CT 06088 SIZE DWG. NO. REV

REPRODUCTION IN PART OR AS A WHOLE
TEL. 860-627-7833
FAX 860-627-7849
WITHOUT THE WRITTEN PERMISSION OF
NEW ENGLAND TOOL CORPORATION IS
PROHIBITED.
NEXT ASSY USED ON
FINISH
C NJ1750
APPLICATION DO NOT SCALE DRAWING SCALE: 1:1 WEIGHT: SHEET 1 OF 6
8 7 6 5 4 3 2 1
 F
F

6
5
1
E E

1
4
2
D D

7
1
C C

8
B B

3
9

UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN

NEW ENGLAND TOOL CORP.
TOLERANCES:
FRACTIONAL CHECKED TITLE:
A ANGULAR: MACH BEND
ENG APPR. A
FILTER ASSEMBLY
TWO PLACE DECIMAL
THREE PLACE DECIMAL MFG APPR.
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS INTERPRET GEOMETRIC Q.A.
NEW ENGLAND TOOL CORP. TOLERANCING PER:
DRAWING IS THE SOLE PROPERTY OF
8 THOMPSON RD. UNIT #10 NEW ENGLAND TOOL CORPORATION. ANY MATERIAL
COMMENTS:

EAST WINDSOR , CT 06088 SIZE DWG. NO. REV

REPRODUCTION IN PART OR AS A WHOLE
TEL. 860-627-7833
FAX 860-627-7849
WITHOUT THE WRITTEN PERMISSION OF
NEW ENGLAND TOOL CORPORATION IS
PROHIBITED.
NEXT ASSY USED ON
FINISH
C NJ1750
APPLICATION DO NOT SCALE DRAWING SCALE: 1:1 WEIGHT: SHEET 2 OF 6
8 7 6 5 4 3 2 1
 F
F

10
11

E E

D D

C C

B B

12

UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN

NEW ENGLAND TOOL CORP.
TOLERANCES:
FRACTIONAL CHECKED TITLE:
A ANGULAR: MACH BEND
ENG APPR. A
TWO PLACE DECIMAL
PROPRIETARY AND CONFIDENTIAL
THREE PLACE DECIMAL MFG APPR. HOUSING ASSEMBLY
THE INFORMATION CONTAINED IN THIS INTERPRET GEOMETRIC Q.A.
NEW ENGLAND TOOL CORP. TOLERANCING PER:
DRAWING IS THE SOLE PROPERTY OF
8 THOMPSON RD. UNIT #10 NEW ENGLAND TOOL CORPORATION. ANY MATERIAL
COMMENTS:

EAST WINDSOR , CT 06088 SIZE DWG. NO. REV

REPRODUCTION IN PART OR AS A WHOLE
TEL. 860-627-7833
FAX 860-627-7849
WITHOUT THE WRITTEN PERMISSION OF
NEW ENGLAND TOOL CORPORATION IS
PROHIBITED.
NEXT ASSY USED ON
FINISH
C NJ1750
APPLICATION DO NOT SCALE DRAWING SCALE: 1:1 WEIGHT: SHEET 3 OF 6
8 7 6 5 4 3 2 1
 F
F

13
14
15
E E

16 17

20
D D

21

C C

9
B
1 B

18 19

UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN

NEW ENGLAND TOOL CORP.
TOLERANCES:
FRACTIONAL CHECKED TITLE:
A ANGULAR: MACH BEND
ENG APPR. A
PROPRIETARY AND CONFIDENTIAL
TWO PLACE DECIMAL
THREE PLACE DECIMAL MFG APPR. MOTOR ASSEMBLY
THE INFORMATION CONTAINED IN THIS INTERPRET GEOMETRIC Q.A.
NEW ENGLAND TOOL CORP. TOLERANCING PER:
DRAWING IS THE SOLE PROPERTY OF
8 THOMPSON RD. UNIT #10 NEW ENGLAND TOOL CORPORATION. ANY MATERIAL
COMMENTS:

EAST WINDSOR , CT 06088 SIZE DWG. NO. REV

REPRODUCTION IN PART OR AS A WHOLE
TEL. 860-627-7833
FAX 860-627-7849
WITHOUT THE WRITTEN PERMISSION OF
NEW ENGLAND TOOL CORPORATION IS
PROHIBITED.
NEXT ASSY USED ON
FINISH
C NJ1750
APPLICATION DO NOT SCALE DRAWING SCALE: 1:1 WEIGHT: SHEET 4 OF 6
8 7 6 5 4 3 2 1
 F
F

30
22

26
E E

29

23
D
31 D

28

24

34
C C

B B

27 32
26
25 33
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN

NEW ENGLAND TOOL CORP.
TOLERANCES:
FRACTIONAL CHECKED TITLE:
A ANGULAR: MACH BEND A

8 - VALVE
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL MFG APPR.
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS INTERPRET GEOMETRIC Q.A.
NEW ENGLAND TOOL CORP. TOLERANCING PER:
DRAWING IS THE SOLE PROPERTY OF
8 THOMPSON RD. UNIT #10 NEW ENGLAND TOOL CORPORATION. ANY MATERIAL
COMMENTS:

EAST WINDSOR , CT 06088 SIZE DWG. NO. REV

REPRODUCTION IN PART OR AS A WHOLE
TEL. 860-627-7833
FAX 860-627-7849
WITHOUT THE WRITTEN PERMISSION OF
NEW ENGLAND TOOL CORPORATION IS
PROHIBITED.
NEXT ASSY USED ON
FINISH
C NJ1750
APPLICATION DO NOT SCALE DRAWING SCALE: 1:1 WEIGHT: SHEET 5 OF 6
8 7 6 5 4 3 2 1
 F
F

22

E E

31 30

26
D
23
D

24

29
C 25 C

B B

33
28
26 UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN

NEW ENGLAND TOOL CORP.
TOLERANCES:
FRACTIONAL CHECKED TITLE:
A

4 - VALVE
ANGULAR: MACH BEND A
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL MFG APPR.
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS INTERPRET GEOMETRIC Q.A.
NEW ENGLAND TOOL CORP. TOLERANCING PER:
DRAWING IS THE SOLE PROPERTY OF
8 THOMPSON RD. UNIT #10 NEW ENGLAND TOOL CORPORATION. ANY MATERIAL
COMMENTS:

EAST WINDSOR , CT 06088 SIZE DWG. NO. REV

REPRODUCTION IN PART OR AS A WHOLE
TEL. 860-627-7833
FAX 860-627-7849
WITHOUT THE WRITTEN PERMISSION OF
NEW ENGLAND TOOL CORPORATION IS
PROHIBITED.
NEXT ASSY USED ON
FINISH
C NJ1750
APPLICATION DO NOT SCALE DRAWING SCALE: 1:1 WEIGHT: SHEET 6 OF 6
8 7 6 5 4 3 2 1
 SAFETY INSTRUCTIONS
- Make sure electrical power is disconnected before servicing pressure pump or electrical
cabinet

- Do not move high pressure pump while it is powered on

- For maintenance purposes use parts provided or recommended by New England Tool
Corporation

- In case of emergency press the E-STOP (EMERGENCY STOP) button on the CNC
machine and disconnect power by shutting OFF Main circuit breaker (CB1) on the high
pressure pump

- Allow qualified personnel to handle and service high pressure pump system

- Make sure high pressure pump is not making any erratic (unusual) noise during
operation, inspect for any signs of any leakage around pump area

- Inspect hydraulic hoses for tightness and leaks, and Make sure that filter vessel cover is
latched and secure
- Take extra preclusion if you run high pressure pump and machine unattended, fire hazard
may exist during operation of the machine and pump, especially if you are in process
machining materials such as Magnesium, Titanium, etc…

- We recommend installing fire extinguisher system inside machine, especially if machine

is running unattended

- High pressure pump system is not provided with coolant flow switch, we rely on machine
coolant protection to insure pump is not running dry without coolant oil or fluid

- Always insure there is enough oil in the machine oil reservoir and high pressure pump
filter vessel, refill oil tank as necessery

- Prevent oil or water to come in contact with electrical equipment

- Under no circumstances do not come in the way of high pressure coolant streams

- Never install shut-off valves between the pump and discharge pressure regulator, or in the
regulator bypass line
 MAINTENANCE SCHEDULE

Daily
Check the pressure difference between input and output gauges on the filter body. (part #
610021) Pressure difference should not be greater than 5 PSI while the unit is in
operation. Under no circumstances output gauge should read negative pressure (vacuum)
as that condition might cause pump to fail. Either, pressure difference or negative
pressure is a sign that filter bag needs to be changed. Always use 5 micron bag filter as
coarser filter will let unwanted particles pass through and damage the pump. Make sure
to clean the filter vessel nicely before installing the new filter bag. When putting the new
bag filter in, make sure that it is seated all the way down and that no cutting chips can
pass through on the side of it. Make sure that filter lid is latched properly. Open the bleed
valve on the top of the filter vessel (part# 610016). Do not start the pump unless filter
vessel is full of oil and there is solid stream of coolant coming out of bleeder line through
¼” clear hose back to the machine oil tank. This will help us keep the air pockets out of
our hydraulic system.

Weekly
Clean the main coolant tank on machine tool side and remove all the chips form it. Dirty
tank full of chips will cause filter to clog more often. This may vary from application to
application. When cutting aluminum, you may find that filter bag clogs faster than when
running stainless steel. Also, three shifts operation will require you to replace filter and
clean the main tank more often.

Special Notes:
-During the operation of the pump unit, make sure that oil based coolant does not create a
lot of foam. Contact your coolant supply company to get an additive that prevents
foaming. Check and fill the machine tool reservoir as needed.
-When turning the unit on frequently in your program, (more than 3 times per minute)
change your program such that you open up another line and than turn off the previous
one with interval of at least 2 seconds between. This will keep the pump running
constantly. Frequent starting and stopping puts unnecessary load on the unit.
-Pay extra attention to the level of oil in the pump head. Running the pump unit with no
hydraulic oil in it will cause pump to fail.
 Electrical maintenance recommendations to our customers:

Preventive maintenance is the key for successful operation of our high pressure pump system. All
electrical components have life expectancy, and should be inspected periodically, especially
contactors, overload relays, PLC unit, power supply etc. The proper use of our system will determine
how long some of the components will last, and excessive use of high pressure system will result in
failure of some of our electrical componets.
Contactors are useful in commercial and industrial applications, particularly for controlling large
lighting loads and motors. One of their hallmarks is reliability. However, like any other device, they
are not infallible. For example, an IEC-rated contactor may run a motor that draws 7.5A at full load.
In that duty, it should last for 3600 mechanical cycles per hour maximum,10000000 lifetime
mechanical cycles and about 3,000,000 lifetime contacts. But, if you used it for consistent jogging
and opening and closing contacts very frequently, you'd have to replace it after just a few thousand
operations.
A contactor really has only two basic parts: the contacts and the coil. The coil energizes the
contactor, moving the contacts into position. The contacts transmit the current from the source to the
load. Heat can destroy either of them, so take a good look at both.
Contacts will overheat if they transmit too much current, if they do not close quickly and firmly, or if
they open too frequently. Any of these situations will cause significant deterioration of the contact
surface and the shape of that surface. Erratic operation and failure will be quick. To check the
contacts, just look at them. Some minor pitting as well as a black oxide coating is normal, but severe
pitting or any melting or deforming of the contact surface is a sure sign of misapplication. Replace
contacts with such symptoms.
Coils can overheat if operating voltages are too low or too high; if the contacts fail to open or close
because of dirt or misalignment; or if they have suffered physical damage or experienced an
electrical short. Coil insulation degrades quickly when it gets too hot. When it degrades, it will short
out (and blow a fuse) or just open and stop operating.
To check a coil, stick an ohmmeter across the coil leads. Infinite resistance means the coil is open. A
shorted coil will usually register significant resistance, like a good coil. If you happen to have a
matching contactor nearby, compare the two coils. The shorted coil will usually have significantly
higher or lower resistance than the good one. If the difference is significant, replace it. Replacing the
contacts or coil often means replacing the whole contactor. But no matter what you replace,
compare the NEMA or IEC rating with the job the contactor will really be doing. If you match it to the
application, it should last a long time.
PLC unit Siemens Digital 24VDC Solid state PLC outputs don’t have any ratings listed for lifetime
mechanical cycles or lifetime contacts (they should last forever as long as output current does not
exceed 0.75A , but if PLC is used for excessive switching , contact can be burned, and we
recommend PLC should be replaced after 3 years. On PLC Siemens Relay Expansion module (if
used) lifetime expectancy in normal application should be 1,000000 mechanical cycles, and 100000
lifetime contacts at full load (2A), however excessive use and frequent switching may result in output
contact being burned or stuck closed or open, and we recommend replacement of PLC expansion
module after 3 years.
Releco C10 control Relay has 1200 mechanical cycles per hour maximum, 10,000000 lifetime
mechanical cycles, 100,000 lifetime contacts at full load (10A) . Replace as necessary.
Replace circuit breakers if you discover any signs of contacts being burned, but severe pitting or any
melting or deforming of the contact surface is a sure sign of misapplication.
 MANUAL

FOR HYDRAULIC GEAR PUMPS OPERATION

It is necessary the following conditions to be kept, in order a good operation and

reliability of the gear pumps made by us to be insured:

Working liquid:
Hydraulic oils with viscosity from 20 up to 200 mm2/s ( cSt). Recommended oil
viscosity 50...100 mm 2/s ( cSt) at 40°C. A viscosity to 385 mm2/s is possible at starting.
It is not admissible different oils marks to be mixed, because it is possible a decrease of
their oiliness ability to follow. The working oil is subject to change. The period of using
depends on the working conditions and it is determined by the consumer. At oil change it
is necessary the tank and the filters to be cleaned.
Temperature - from 253°K to 353°K (-20°C to +80°C).
Recommended filtration degree - 25 µm and better.
Rotation frequency - from 750 tr/min to maximum values for the relevant kind of
pump.

Rotation direction:
"Clockwise" or "Anticlockwise" as you look against pump shaft - according to the
arrow marked on the front cover. A wrong turn is not allowable and it is lead to getting the
semering that tighten the driving shaft out.

Flow direction — inlet and outlet:

According to the body /rear cover/ marking. Usually, the bigger opening is the
suction one

Suction pressure:
The suction pipe of the pumps has to ensure a stable suck without air penetration.
The allowable suction under pressure is 0,203 bar / vacuum/. An above pressure more
than 0,5 bar toward the atmospheric pressure /1,5 bar absolute pressure/ is not
admissible.
 Shaft loading:
Radial and axial powers on the shaft are not allowable — just a torque.

Pump drive:
The drive is direct with elastic or other couplings, that ensure self-adjustment of the
leading gear in radial direction more than 0,25 mm. The non-axiality of the driving shaft
and the leading shaft of the pump mustn't exceed 0,1mm. Belt and chain drive, as well as
vibrations and unbalance of the drive are not allowed.

Pipes:
Suction pipe — it has to be hermetic, with small length and the diameter to be large
enough to ensure under pressure up to the allowable and oil speeds - 0,6...1 m/s.
If a filter on the inlet is available, it has to be with enough traffic capacity, in order
not to aggravate the sucking /see Suction Pressure/
Pressure pipe — it has to be with small length and as minimum number curved
sections and transitions. If there are vibrations between the pump and the motor /for
example, an internal - combustion engine or vibrations in the hydraulic system/, it is
obligatory a rubber pipe /hose/ to be used.
Allowable speeds of the oil - 2...5 m/s.

Tank:
The volume and the construction of the tank depend on working conditions. For the

pump it is necessary the suction and the return pipes to be mounted in such a way that

the returning oil not to be sucked immediately, i.e. they have to be maximum distant one

of another. Their ends have to be cut under angle less than 45° and directed in opposite

sides, as the return pipe has to be on 100 mm higher than the suction one. The last has

to be mounted at least 50 mm above the bottom, in order not to suck the settled

contaminations. In order to avoid foam making, all the pipes have to be dipped at least

50 mm under the lowest admissible oil level.

 Mounting:
It is obligatory the pumps to be centered to the relative diameter of the front cover.

Call your attention to the correct connection of the suction and pressure pipes, as well as

to the rotation direction /the arrow/.

Starting operation:
It is necessary the correct mounting to be checked. The pump can be set in motion,

but without loading /on idle stroke /, when the suction pipe and the pump are filled with

oil. This is necessary to ensure bearings lubrication and air exhaustion. When all the

system is full with oil, the pressure is increasing gradually to the necessary working

pressure. The exceeding of the maximum working pressure for the relevant pump type is

inadmissible.

The pumps delivered by us are developed and checked for flow rate and pressure.

They can start work immediately at observing the requirements of this manual.
 Possible faults:

Possible fault Reason Action

1. Shortage of - non-observance of the mounting conditions Check and repair of

displacement and - an effect of radial and axial forces the coupling
pressure on the shaft of the pump, caused by incorrect
coupling Checking the oil
- insufficient filling with oil viscosity and refuel
- disrupted vacuum at the inlet with new oil
- oil viscosity under the allowable one

2. Noise and vibrations - non-observed mounting conditions, Check and repair the
- insufficient filling with oil suction pipe
- suck of air

3. Injured or torn seal -contaminations came under the seal Cleaning and change
the seal

4. Sticking of the - highly polluted oil

bearings - availability of hard fragments more than the
allowable filtration precision
- incorrect mounting
- pressure exceeding more than the Change the pump
allowable one
- low oil viscosity
- air sucking

The pump can be considered as unserviceable, if it cannot reach the displacement and
pressure, under observing all the conditions of this manual and under room
temperature of the oil. This pump during 2...3 minutes of work heats to a temperature
that is unbearable for the palm of the hand.
 STANDARD SPECIFICATIONS NJ1750‐E
Max. Output pressure 69 bar
Number of output lines 4 (8 optional)
Flow rate @ 69 bar 25 l/min
Motor 3 kW
Weight 236 kg
Power requirements 3 phase 400 V
Type of coolant Oil only
Type of pump Gear
Control type Siemens