KTR PIK - Oil cooler Operating/Mounting Instructions

KTR PIK - Oil cooler is a connecting element between electric motor and hydraulic pump. It features an integrated oil-air cooler for efficient temperature management. The PIK is designed for use in various hydraulic systems, ensuring reliable and optimal performance.

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KTR Kupplungstechnik
GmbH
D-48407 Rheine
PIK - oil cooler
Mounting Instructions
KTR-N
sheet:
edition:
41028 E
1
5
The PIK is a connecting element between electro motor and hydraulik pump in combination with an
oil - air cooler.
General Hints
Please read through these mounting instructions carefully before you assemble the PIK. Please pay
special attention to the safety instructions!
The mounting instructions are part of your product. Please keep them carefully and close to the PIK.
The copyright for these mounting instructions remains with KTR Kupplungstechnik GmbH.
Safety and Advice Hints
STOP
DANGER!
Danger of injury to persons.
!
CAUTION!
Damages on the machine possible.
ATTENTION!
Pointing to important items.
General Hints to Danger
STOP
DANGER!
With assembly and disassembly of the PIK’s it has to be made sure that the entire
drive train is protected against unintentional engagement. You can be seriously
hurt by rotating parts. Please make absolutely sure to read through and observe
the following safety instructions.
• All operations on and with the PIK have to be performed taking into account &quot;safety first&quot;.
• Please make sure to disengage the power pack before you perform your work at the PIK.
• Protect the power pack against unintentional engagement, e. g. by providing hints at the place of
engagement or removing the fuse for current supply.
• Do not touch the operation area of the machine as long as it is in operation.
• Please protect the rotating drive parts against unintentional touch. Please provide for the necessary
protection devices and caps.
Proper Use
You may only assemble and disassemble the PIK if you
• have carefully read through the mounting instructions and understood them
• and if you are authorized and have proper skills
The PIK ring may only be used in accordance with the technical data (see hydraulic components
catalogue). Unauthorized modifications on the PIK design are not admissible. We do not take any
warranty for resulting damages. To further develop the product we reserve the right for technical
modifications.
The PIK described in here corresponds to the technical status at the time of printing of these mounting
instructions.
Schutzvermerk
ISO 16016 beachten.
Gezeichnet:
Gepr&uuml;ft:
16.10.06 Sha/Wy
16.10.06 Sha
Ersatz f&uuml;r:
Ersetzt durch:
KTR Kupplungstechnik
GmbH
D-48407 Rheine
KTR-N
sheet:
edition:
PIK - oil cooler
Mounting Instructions
41028 E
2
5
The PIK is generally supplied ready for assembly.
Components of PIK
Component
Quantity
1
1
2
1)
3
1)
4
1
2)
1
2
Designation
PIK (bellhousing with
integrated cooler)
fan wheel
PIK feet
damping rod
1) Delivery only on customer&acute;s request.
2) Quantity = 1 set (1 set consists of 4 feet incl. cap screws)
picture 1: PIK
Hints concerning the PIK
•
The max. permissible operating pressure for the installed heat exchanger is 15 bar.
!
•
ATTENTION!
The sense of rotation of the engine is right - from the pump shaft!
Please see diagrams 1 to 8 regarding the permissible oil quantity flowing through and the pressure
difference. If the max. permissible quantities flow through, please make sure that there is a free
flowing-through of the cooler output line in order to avoid peak pressures.
•
CAUTION!
Peak pressures must be avoided.
The permanent operating pressure should not exceed 10 bar during static
operation and be max. 6 bar in case of pulsating dynamical load. In case of
dynamical load peak pressures of more than 10 bar must be avoided.
ATTENTION!
Please consult with our Engineering Department in case of quantities flowing
through which are higher than indicated in these diagrams.
The position to assemble the PIK oil cooler is optional.
!
CAUTION!
Please make sure that there is free space approx. 10 cm in front of and behind
of the air input and air output. The performance of the PIK is increased by the
natural flow direction of warm air if the air output is on the top.
The fixing threads of the PIK feet are respectively arranged.
Schutzvermerk
ISO 16016 beachten.
Gezeichnet:
Gepr&uuml;ft:
16.10.06 Sha/Wy
16.10.06 Sha
Ersatz f&uuml;r:
Ersetzt durch:
KTR Kupplungstechnik
GmbH
D-48407 Rheine
KTR-N
sheet:
edition:
PIK - oil cooler
Mounting Instructions
41028 E
3
5
Design of the PIK system
picture 2: system arrangement
Assembly / Starting the PIK
•
The PIK (bellhousing with integrated cooler) is put onto the engine centering / pump centering and
screwed.
•
The screw length must be selected in a way that at least the total length of the thread in the
bellhousing is used.
The tightening torques TA are indicated in the following table 1 for assembly PIK with electro motor
and table 2 for assembly PIK with pump.
Table 1:
cap screw
DIN EN ISO 4762 1)
tightening torque 2)
M8
M10
M12
M16
M20
25 Nm
49 Nm
86 Nm
210 Nm
410 Nm
Table 2:
cap screw
DIN EN ISO 4762
tightening torque
1)
M5
M6
M8
M10
M12
M16
M20
3 Nm
5 Nm
13 Nm
25 Nm
40 Nm
100 Nm
190 Nm
1) min. property class 8.8
2) tightening torques of the property class 8.8
•
ATTENTION!
The screws must be generally used with Loctite, Omnifit 230M or comparable
adhesives for securing.
The connection for cooler input or output is optional.
!
CAUTION!
When the oil connection ducts are assembled or disassembled you have to hold
up hexagonally.
The max. tightening torque is 40 Nm.
Schutzvermerk
ISO 16016 beachten.
Gezeichnet:
Gepr&uuml;ft:
16.10.06 Sha/Wy
16.10.06 Sha
Ersatz f&uuml;r:
Ersetzt durch:
KTR Kupplungstechnik
GmbH
D-48407 Rheine
PIK - oil cooler
Mounting Instructions
KTR-N
sheet:
edition:
41028 E
4
5
Assembly / Starting the PIK
Continuation:
•
You generally need fixing threads to fix the PIK feet.
The nylon stoppers in the threads must be removed before the assembly.
Hexagon socket screws acc. to DIN EN ISO 4762 must be used.
The tightening torque TA of the screws to the PIK is indicated in table 1.
•
Fixing threads are generally planned to fix the tank (type V1).
The nylon stoppers in the threads must be removed before the assembly.
The screw tightening torques of the screws from the tank cover to the PIK are indicated in table 1.
!
•
CAUTION!
The oil connection pieces must show to the direction of the engine (The heat
exchanger can be turned if V1 is used)!
The fan wheel must be pushed onto the engine shaft until the stop and secured against axial
displacement.
Safety device against axial displacement:
Fan wheel with radial safety device:
The screw tightening torques for the assembly of the fan
wheel are shown in table 2 (see picture 3).
picture 3: fan wheel with radial safety device
•
The mounting instructions for the respective coupling type are generally valid for the assembly of
the coupling. The dimensions for the assembly of the coupling hubs are shown on the drawing of
the respective engine-pump combination.
•
The DT damping ring can only be used in the variation DT.../2.
Before the assembly the nylon caps in the threads must be removed.
Hexagon socket screws acc. to DIN EN ISO 4762 must be used.
The DT damping ring must be screwed with the PIK. Please make sure that the hexagon socket
screws are plugged into the DT damping ring through the cylinder bores and screwed into the PIK
housing.
The tightening torques of the screws from the DT damping ring to the PIK housing are mentioned
in table 1.
Schutzvermerk
ISO 16016 beachten.
Gezeichnet:
Gepr&uuml;ft:
16.10.06 Sha/Wy
16.10.06 Sha
Ersatz f&uuml;r:
Ersetzt durch:
KTR Kupplungstechnik
GmbH
D-48407 Rheine
PIK - oil cooler
Mounting Instructions
KTR-N
sheet:
edition:
41028 E
5
5
Assembly / Starting the PIK
Continuation:
•
Position of the PIK oil cooler in the hydraulics circle
The PIK oil cooler must be the last element in the oil circulation in order to avoid pressure. Filter
units (also designs with „by-pass“ valve) must be positioned in front of the PIK oil cooler since
sudden changes of the volume flow lead to short-term peak torques which are not compensated by
sludge valves.
•
Operating temperature
CAUTION!
Before the initial operation please make sure that the max. oil temperature of
+80 &deg;C is not exceeded.
!
Maintenance Hints
The PIK oil coolers are maintenance-free in many points. Due to the vacuum principle and the
respective airflow dirts can be easily recognized from the outside and can be cleaned from the outside
without having to disassemble the heat exchanger (e. g. with a vacuum cleaner). By reason of the
even surface of the types the housing be easily cleaned from the outside.
Technical Data
Performance of the fan with 1500 1/min.
PIK 200 =
PIK 250 =
25 W
40 W
PIK 300 =
PIK 350 =
125 W
230 W
Cooling effect PK [KW] depending on volume flow Pressure difference p [bar] depending on volume
and temperature difference between oil intake
flow and viscosity of hydraulic fluid.
and air intake.
Speed of fan 1500 1/min.
PIK 200
PIK 200
cooling effect PK [KW]
1,0
∆T=50K
0,9
pressure difference p [bar]
1,6
0,8
∆T=40K
0,7
γ=100mm2/s
1,4
1,2
0,6
∆T=30K
γ=80mm2/s
γ=60mm2/s
γ=40mm2/s
1,0
0,8
0,5
∆T=20K
0,4
0,6
0,4
0,3
0,2
0,2
0,0
0
0,1
2
4
6
8
10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
volume flow Q [L/min]
0,0
0
2
4
6
8
10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
volume flow Q [L/min]
diagramme 1
Schutzvermerk
ISO 16016 beachten.
Gezeichnet:
Gepr&uuml;ft:
diagramme 2
16.10.06 Sha/Wy
16.10.06 Sha
Ersatz f&uuml;r:
Ersetzt durch:
KTR Kupplungstechnik
GmbH
D-48407 Rheine
KTR-N
sheet:
edition:
PIK - oil cooler
Mounting Instructions
41028 E
6
5
Technical Data
Continuation:
Cooling effect PK [KW] depending on volume flow Pressure difference p [bar] depending on volume
and temperature difference between oil intake
flow and viscosity of hydraulic fluid.
and air intake.
Speed of fan 1500 1/min.
PIK 250
PIK 250
cooling effect PK [KW]
2,0
∆T=50K
1,8
pressure difference p [bar]
1,6
1,6
∆T=40K
1,4
γ=100mm2/s
1,4
γ=80mm2/s
γ=60mm2/s
γ=40mm2/s
1,2
∆T=30K
1,2
1,0
0,8
1,0
∆T=20K
0,8
0,6
0,4
0,6
0,2
0,4
0,0
0
0,2
2
4
6
8
10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
volume flow Q [L/min]
0,0
0
2
4
6
8
10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
volume flow Q [L/min]
diagramme 3
diagramme 4
PIK 300
PIK 300
cooling effect PK [KW]
3,0
∆T=50K
pressure difference p [bar]
γ=100mm2/s
2,5
2,5
∆T=40K
2,0
∆T=30K
1,5
∆T=20K
1,0
γ=80mm2/s
γ=60mm2/s
γ=40mm2/s
2,0
1,5
1,0
0,5
0,5
0,0
0
0,0
0
5
10
15
20
25
30
35
40
45
50
55
5
10
15
20
25
30
35
40
45
50
55
60
volume flow Q [L/min]
60
volume flow Q [L/min]
diagramme 5
diagramme 6
PIK 350
PIK 350
cooling effect PK [KW]
6
∆T=50K
pressure difference p [bar]
∆T=40K
3,5
∆T=30K
2,5
∆T=20K
1,5
4
5
γ=100mm2/s
3
4
γ=80mm2/s
γ=60mm2/s
γ=40mm2/s
2
3
2
1
0,5
1
0
0
0
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
5
10
15
20
25
30
35
40
45
50
volume flow Q [L/min]
diagramme 7
Schutzvermerk
ISO 16016 beachten.
Gezeichnet:
Gepr&uuml;ft:
diagramme 8
16.10.06 Sha/Wy
16.10.06 Sha
55
volume flow Q [L/min]
Ersatz f&uuml;r:
Ersetzt durch:
60
65
70
75
80
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Key features

Oil-air cooler
Electric motor to hydraulic pump connection
Adjustable oil flow direction
Fan wheel with radial safety device
Maintenance-free design
Max. operating pressure: 15 bar

Frequently asked questions

The PIK oil coolers are maintenance-free. Due to the vacuum principle and airflow, dirt can be cleaned from the outside without disassembling the heat exchanger.

Before initial operation, ensure the max. oil temperature does not exceed +80 °C.

The PIK oil cooler should be the last element in the oil circulation to avoid pressure buildup. Filter units should be positioned in front of the PIK.

The maximum tightening torque for the PIK oil cooler is 40 Nm.

Use hexagon socket screws according to DIN EN ISO 4762. The tightening torques are specified in the manual.