DYNA Z 6, Z16

Refill of Oil including Dismantling and Mounting of the necessary Parts as well as
Checking of all Pull-off and Extraction testers
Issue for sales representatives and authorized calibration stations

Service Manual & Repair Guide

This document is part of the ASPO Service & Repair set for Dyna and describes the procedure
how to adjust, repair and calibrate the instruments.
Key Words: Pull-off-tester, Repair, Service, Calibration, Upgrade, Manual, ASPO

Document Number :
Document Revision:
Revision Date:
Document State:
Author:

345.11
01
31-Oct-2008
released
Rudolf Bhend

Company:

Proceq SA
Bahnstrasse 23
CH-8603 Schwerzenbach
Switzerland

Classification:

for internal use only

Doc: 345.11

Rev: 01

Copyright 2011, Proceq SA, CH-8603 Schwerzenbach

Filename: 20081031 Service & Repair Guide Dyna 345.11

rudolf.bhend@proceq.com

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Table of Contents

1
2
3
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
5

Doc:

Scope and Application

Aim of Instructions
Means for the Refill
Description of the Checking and Refill with Oil
Preparation and Repairs
Refill with Oil, Pump in vertical Position
Assembling and first Testing of Instrument
Refill with Oil, Pump in inclined Position
Final Checks
Figures
Control of Path Measuring Device
Applying Documents

Rev: 01

Copyright 2011, Proceq SA, CH-8603 Schwerzenbach

Filename: 20081031 Service & Repair Guide Dyna 345.11

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Dyna Z Refill, Dismantling and Mounting

Service Manual & Repair Guide

Scope and Application

The instructions are valid for:
Pull off testers DYNA Z16, DYNA Z16E, DYNA Z6, DYNA Z6E and
Extraction testers DYNA Z16S, DYNA Z16SE, DYNA Z16 Fs, DYNA Z6S, DYNA Z6SE and DYNA
Z6Fs.

Aim of Instructions
With this instructions an air bubble free refill with oil of the instrument and a proper exchange of parts
shall be achieved, thus the functioning for the next operation period is guaranteed.

Means for the Refill

-

Vice to retain the instrument

25 ml syringe with needle (64)
Hydraulic oil Rhodosil oil 47 V 300 and Rhodosil oil 47 V 100,
mixed one to one, amount necessary up to 150ml
- Calibration device same as used for the calibration of the DYNA Z instrument
- Operation instructions of the pull-off, respectively of the extraction testers
In the following chapters all the names and numbers in brackets used for the parts are identical with
the ones used in the operation instructions, except the numbers 50 onwards for parts shown in figures
1, 2 and 3 on page 5 and 6 only.

4
4.1

Description of the Checking and Refill with Oil

Preparations and Repairs
Prepare the calibration unit like for the calibration (e.g. set the load pacer to 0.100 kN/s)
Perform a visual checking of all parts including manometer/display unit, especially inner part of the
coupling (15), draw bolt (7) and in case of the extraction tester also the fitting ring (6) and if
available the intermediate coupling (17).
Check the proper working of the hydraulic pump by turning the crank (12) clockwise and
anticlockwise. Leave the pump at the start position.
All damaged parts must be replaced.
Check the oil level as explained in the operation instructions under Maintenance, Storage and
Care, thus especially if excessive oil spots are seen. Leave the pump at the end position.
Dismantle the draw spindle (14) and the wheel (13) (wheel (13.1) and handles (13.2) in case of the
extraction tester). For instruments from DYNATEST dismantle additionally the guide parts on the
soffit of the slab, figure 1, Pos. 50, 51 und 52, so the piston (4) becomes visible. Remove the crank
(12) of the pump.

Clamp the instrument with one of the legs (protect it with a cloth) in the vice to have the hydraulic
pump body (3) in a vertical position (see figure 2), remove the interlocking/vent screw (63) and the
vent screw (66). Unscrew the vent screw (61) at the Manometer (2) /pressure sensor (8) by two to
three turns.

In case the oil level is insufficient:

- Remove the remaining oil in the system by pressing on the piston (4) several times. The oil
escapes via the vent screw (66) opening.
- Dismantle the piston (4) and replace all O-rings. Apply the special grease around the complete
surface of the O-ring and in the groove prior the placing of the new O-ring and after placing
again around the O-ring.
- Mount the piston (4).
- In case the leak is between the device plate (5) and the support for the manometer (2) /
electronic sensor cell (8) replace the respective O-rings accordingly.

Doc: 345.11

Rev: 01

Copyright 2011, Proceq SA, CH-8603 Schwerzenbach

Filename: 20081031 Service & Repair Guide Dyna 345.11

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Dyna Z Refill, Dismantling and Mounting

4.2

Service Manual & Repair Guide

Refill with Oil, Pump in vertical Position

Turn the pump rod (62) anticlockwise back to the start position and check the position of the piston
(4) at the soffit of the device plate (5).The lower edge of the piston (4) must be 1.0 to 1.5 mm higher
as the soffit of the device plate (5). If necessary move the piston (4) manually to the right position.

Refill the oil via the opening of the interlocking vent screw (63) using a syringe with needle (64).
Constantly refill oil to keep a constant oil level (see figure 2) until the top level is reached. Some of the
old oil may escape via the vent screw (66) opening.

Close vent screw (66). Insert interlocking/vent screw (63) and remove excess oil with cloth. Close vent
screw (61) of manometer (2) / pressure sensor (8).

For information: In case of new instruments with LEO1 manometer or if a new manometer must be
installed, the lower part of the manometer is filled with oil by means of the syringe (64). The
manometer (2) is mounted and the vent screw (61) inserted simultaneously.

4.3

Assembling and first Testing of Instrument

In case the pin (to prevent the turning of the draw spindle (14)) is loose or even removed install it and
lock it with a centre punch and a hammer.

Mount the draw spindle (14), the wheel (13), ((13.1) in case of the extraction tester) and the crank
(12).

Fix the instrument on the calibration unit.

Load instrument up to the nominal load with the load rate of 100 N/s (as set in the calibration unit) by
turning the pump crank (12) at the speed that the flow bar follows the pace maker on the display of the
calibration unit with the same speed.

Leave the instrument loaded for about two minutes. The load will decrease, at the beginning faster
towards the end slower. The drop of load after two minutes may be up to 10 % of the nominal load.
Increase load again up to the nominal load and leave the instrument for another five to seven minutes.
With this the whole hydraulic systems gets stabilized.

Turn pump crank (12) anticlockwise back to the start position.

4.4

Refill with Oil, Pump in inclined Position

Clamp the instrument with one of the legs (protect it with a cloth) in the vice with the vent screw (66) of
the plate on the top (see figure 3).

Undo vent screw (66) on the device plate (5).

Exit the oil slightly by pushing carefully onto the piston (4), check at the vent screw (66) opening if any
air bubbles are trapped in the oil, if necessary remove some oil by pressing several times smoothly
onto the piston (4).

Fill up emerging hollows immediately with oil from the syringe (64) with immersed needle through the
vent screw (66) opening (see figure 3).

Leave the instrument open. Repeat the procedure of the previous two points after approx. five
minutes. Fix the vent screw (66). Only little oil should come out.

Check the start position of the piston (4) at the soffit of the device plate (5).The lower edge of the
piston (4) must be 1.0 to 1.5 mm higher as the soffit of the device plate (5).

Turn pump crank (12) clockwise to the end position and check the position of the lower piston edge. It
must be 4.5 to 5.0 mm higher as the start position. Turn back the pump crank (12) anticlockwise to the
start position and check again the position.
The instrument may has to be removed from the vice for easy turning of the crank (12) and clamed
again as shown in figure 3.

In case the positions of the piston (4) are correct, continue with chapter 4.5 Final check.

In case the positions of the piston (4) are not correct:

Doc: 345.11

Rev: 01

Copyright 2011, Proceq SA, CH-8603 Schwerzenbach

Filename: 20081031 Service & Repair Guide Dyna 345.11

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Dyna Z Refill, Dismantling and Mounting

Service Manual & Repair Guide

Exit the air left in the oil by turning the pump rod (62) clockwise and unscrewing the vent screw
(66) simultaneously. The air will escape as bubbles at the opening of the vent screw (66).
Refill the oil using a syringe (64) with immersed needle and by simultaneously turning the pump
rod (62) anticlockwise, thus the pump piston in the pump body is pulled back and the oil sucked
in. Constantly refill oil to keep a constant oil level.
If necessary unscrew also the vent screw (61) of the manometer (2) / pressure sensor (8) and fill
up emerging hollows immediately with oil from the syringe (64) with immersed needle at the
opening of the vent screw (61).
Fix vent screw (66) and possibly the vent screw (61). Only few oil should come out.
4.5

Final Checks
Fix the instrument on the calibration unit.
Load instrument up to 100% with the load rate of 100 N/s (as set in the calibration unit) by turning
the pump crank (12) at the speed that the flow bar follows the pace maker on the display of the
calibration unit with the same speed.
Leave the instrument loaded for about two minutes. The load will decrease, at the beginning
faster towards the end slower.

In case the drop is not more then 4% of the nominal load continue as follows:

For DYNATEST-Instruments mount the guide parts pos. 50, 51 und 52 (see figure 1)
Calibrate the instrument as explained in the instructions AW 345.05, respectively AW 345.13.
For the model DYNA Z . Fs continue with chapter 4.7 Control of the Path Measuring Device
on page 6/6.

In case the drop is more then 4% of the nominal load continue as follows:

Clamp the instrument with one of the legs (protect it with a cloth) in the vice with the vent screw
(66) of the plate on the top (see figure 3)
Exit the air left in the oil by turning the pump rod (62) clockwise and unscrewing the vent screw
(66) simultaneously. The air will escape as bubbles at the opening of the vent screw (66).
Refill the oil using a syringe (64) with immersed needle (4) and by simultaneously turning the
pump rod (2) anticlockwise, thus the pump piston in the pump body is pulled back and the oil
sucked in. Constantly refill oil to keep a constant oil level.
If necessary open also the vent screw (61) of the manometer (2) / pressure sensor (8) and fill up
emerging hollows immediately with oil from the syringe (64) with immersed needle at the
opening of the vent screw (61).
Fix vent screw (56) and possibly the vent screw (61). Only few oil should come out
Repeat the loading of the instrument, i.e. go back to the first point of this chapter 4.5.

Doc: 345.11

Rev: 01

Copyright 2011, Proceq SA, CH-8603 Schwerzenbach

Filename: 20081031 Service & Repair Guide Dyna 345.11

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Dyna Z Refill, Dismantling and Mounting

4.6

Service Manual & Repair Guide

Figures

Wheel (13.1)
Handle(13.2)
Piston (4)
O-rings
Device plate (5)
Guide parts (50),(51), (52)
(For DYNATEST instruments only)

Vertical section through DYNA Z S

Figure 1

Interlocking/Vent Screw, (63)

Pressure sensor /
El. measuring cell
(8)
with vent screw
(61)

Syringe with needle (64)

Pump body (3)

Device plate (5)

Pump rod (62)

Figure 2

Doc: 345.11

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Copyright 2011, Proceq SA, CH-8603 Schwerzenbach

Filename: 20081031 Service & Repair Guide Dyna 345.11

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Dyna Z Refill, Dismantling and Mounting

Service Manual & Repair Guide

Syringe
with needle (64)

Vent Screw (66)

Pump body (3)

Piston (4)

Figure 3

4.7

Control of Path Measuring Device

The position of the path measuring device is checked as follows:
Turn the pump rod clockwise up to the end position of the pump piston inside of the pump body
Check if the finger of the path measuring device is touching the stop

If yes, instrument is functional, if not

Adjust the head piece of the finger accordingly

Calibrate the instrument as explained in the instructions AW 345.05.

Applying Documents
-

Doc: 345.11

Assembling drawings:
DYNA Z 16

4 124 561

DYNA Z 16 S

4 124 637

DYNA Z 16 analogue

4 124 636

DYNA Z 6

4 124 682

DYNA Z 6 S

4 124 683

DYNA Z 16 E

4 124 561

DYNA Z 16 SE

4 124 637

DYNA Z 16 Fs

4 124 637 4 124 627

DYNA Z 6E

4 124 682

DYNA Z 6 SE

4 124 683

DYNA Z 6 Fs

4 124 683 4 124 627

Operation instructions for the DYNA Z-Instruments

Rev: 01

Copyright 2011, Proceq SA, CH-8603 Schwerzenbach

Filename: 20081031 Service & Repair Guide Dyna 345.11

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