碎煤机液压站使用说明书SY8

SY8型碎煤机液压站SY8HYORAULICSTATIONOFCOALCRUSHER使用说明书OPERATIONALINSTRUCTION山西电力设备厂SHANXIELECTRICPOWEREQUIPMENTFACTORYSY8型碎煤机液压站使用说明书1目录型号意义2用途2技术规格2结构与工作原理3操作和保养3故障及排除方法4附液压系统图5SY8型碎煤机液压站使用说明书2型号意义液压站“液”汉语拼音首字母碎煤机“碎”汉语拼音首字母额定流量整数部分数据用途SY8型碎煤机液压站为HCS系列环锤式碎煤机的配套产品。主要用于驱动该机的液压缸，以启闭前后机盖，便于碎煤机的检修。本液压站也可用于其他机械设备的检修或需要承重的场合。技术规格液压站的液压系统参数及驱动油缸性能分别见表和表表1液压系统参数项目单位数据项目单位数据油泵型号流量压力L/MINBARCBFA10CFL819785电动机型号功率转速电压KWR/MINVY100L6V115940380系统流量压力L/MINBAR6825625油箱有效容积L6010溢流阀调节范围工作标压BARBAR7014075液压油牌号用量KG30机械油5095表2驱动油缸性能810碎煤机型号HCSZ100HCSZ200HCSZ300HCSZ500HCSZ700HCSCHCSC6HCSZ600HCSZ800SPM14系列SPM16系列HCSC12系统图油缸组号油缸内径活塞杆径MMMM5028633580451005512570作用面积推出端拉回端CM2CM219641348311721175027343778545391122728423SY8型碎煤机液压站使用说明书3进程推力TFKN14914592382337314307949148117677517单缸驱动力回程拉力TFKN10310116516162152105337330256351594结构与工作原理液压站由吸油口滤油器、齿轮油泵、溢流阀、手动换向阀、单向节流阀、胶管总成，快速接头，压力表及开关、油管、油箱、空气滤清器等元件组成。交流电动机通过爪形联轴器带动齿轮泵旋转，压力油进入溢流阀由压力表显示标定压力，M型换向阀实现执行元件（油缸）的进程和回程的油路换向。单向节流阀以节流调速改变工作速度。回油路的油液及溢流阀的余油汇集后经连接块的溢流口流回油箱。5操作和保养51根据液压系统图及表2，按照所要驱动的碎煤机液压缸，将快速接头体及尼龙垫圈与油缸的接头相联接。并且检查管路各接头是否可靠。52检查油泵电机的转向是否正确。从轴头方向观察应为顺时针方向旋转。53起动前油箱油面应位于油标的上端。起动后油面应处于油标中可视位置。若从油标中看不到油面时应补充油，见下图。54缓缓转动电机（或反复起动电机），使泵的排出管卸载，排出泵体内及管路中的空气。55电机停转后重新起动时，需间隔一分钟方可进行。56调整溢流阀的压力到75BAR,若需要更高的工作压力时，可作相应的调整，但不允许超过140BAR。57工作油的粘度为1738厘斯（255E），推荐采用30机油。58正常油温为1060，当起动时油温低于0，要对工作油预热，待油温升至5方可进行。59从空气滤清器向油箱内注渍，其滤网的过滤精度主为120目/寸。510应定期取样检查工作油的颜色、透明度、沉淀物及气味等，若油变质或严重污染，应及时更换。一般每一年应更换一次。SY8型碎煤机液压站使用说明书46故障及排除方法序号故障性质产生原因排除方法1油泵排油，但达不到工作压力1溢流阀动作不良2油压回路无负荷3系统漏油1拆卸阀体检查修复2检查油路加负荷3检查管道制止泄漏2有压力但不排油或者容积效率下降1泵内密封件损坏2吸入异物在滑动部分产生异常摩擦1与制造厂联系进行修理2进行检查排除异物3噪声过大1吸入管太细2吸油口滤油器堵塞3吸入管或其他部位吸入空气4油箱内有气泡5油箱内油面过低6泵的安装基础刚性不足7转速和压力超出规定值8联轴器噪声大1更换较大内径的油管2清洗3向吸入管注油找出不良处4检查回油路防止发生气泡5加油到规定油面6提高安装基础刚度7检查转速、压力及油路8检查联轴器有无损伤或错位过大4油泵发热1容积效率不良，泵内进入空气2轴承磨损3油粘度过高，润滑不良油污严重1排除空气，提高容积效率2更换新轴承3更换新油SY8型碎煤机液压站使用说明书57附液压系统图SY8型碎煤机液压站使用说明书6性能参数项目单位数据额定流量L/MIN819标定压力BAR75功率KW15转速R/MIN940液压用油30机油油箱加油量L601012EF125空气滤清器Q66L/MIN,滤面80CM2,精度09MM1温州轻纺机械厂11JB195777卡套式压力表管接头G6M14151上海液压附件厂10Y60压力表P0160BAR1阳泉仪表厂9Q/ZB27577快速接头（两端开闭）DG10MM,P320BAR,Q40L/MIN2上海液压附件厂8JB188577胶管总成A型扣压式，133000，P200BAR2上海液压附件厂7LDFL10C单向节流阀DG10MM,P140BAR,Q25L/MIN2榆次液压件厂634SMB10HT手动换向阀DG10MM,P315BAR,Q40L/MIN1上海液压件一厂5YFB10HY1溢流阀DG10MM,P70210BAR,Q40L/MIN14CBFA10CFL齿轮油泵P140BAR,N1800R/MIN,Q1127ML/R1榆次液压件厂3Y100L6（V1）电动机N15KW,N940R/MIN,U380V12WU6380J吸油口滤清器DG25MM，Q63L，精度80UM1上海高行液压件厂1SY83油箱箱内4924124951序号代号名称规格数量备注SY8型碎煤机液压站SY8SM液压系统图使用说明书山西电力设备厂SY8型碎煤机液压站使用说明书7OPERATINGINSTRUCTIONSFORTYPESY8HYORAULICSTATIONOFCOALCRUSHERSY8型碎煤机液压站使用说明书8SHANXIPOWEREQUIPMENTPLANTSY8型碎煤机液压站使用说明书91DESIGNATIONOFTYPEAREASFOLLOWSSY8RATEFLOWSHOWNININTEGRALPARTINITIALLETTEROFCHINESEPHONETICALPHABETFORHYDRAULICSTATIONINITIALLETTEROFCHINESEPHONETICALPHABETFORCOALCRUSHER2APPLICATIONSTYPESY8HYDRAULICSTATIONOFCOALCRUSHERISAMATCHEDPRODUCTOFTHEHCSSERIESRINGHAMMERCOALCRUSHERITISUSEDTOACTUATETHEHYDRAULICCYLINDERSTOOPENANDCLOSETHEFRONTANDREARMACHINECOVERSANDRESETTHESCREENDECKFRAMESOASTOBECONVENIENTFORINSPECTIONANDREPAIROFTHECOALCRUSHERTHISHYDRAULICSTATIONCANBEALSOUSEDFORINSPECTIONANDREPAIROFOTHEREQUIPMENTORWHEREWEIGHTSARENECESSARYTOBESUPPORTED3TECHNICALSPECIFICATIONSTECHNICALPARAMETERSOFTHEHYDRAULICSYSTEMOFTHEHYDRAULICSTATIONANDPERFORMANCEOFTHEACTIVATINGCYLINDERSARESHOWNSEPARATELYINTABLE1ANDTABLE2TABLE1TECHNICALPARAMETERSOFHYDRAULICSYSTEMITEMSUNITDATAITEMSUNITDATAHYDRAULICPUMPTYPEFLOWPRESSUREL/MINMPACBFA10CFL819785ELECTRICMOTORTYPEPOWERSPEEDVOLTAGEKWR/MINVY100L6V115940400SYSTEMFLOWPRESSUREL/MINMPA6825625EFFECTIVETANKAREAL6010RELIEFVALVEPRESSUREREGULATINGSCOPENOMINALOPERATINGPRESSUREMPAMPA71475HYDRAULICOILGRADEOILQUANTITYUSEDKG30MACHINEOIL5795SY8型碎煤机液压站使用说明书10TABLE2PERFORMANCEOFACTIVATINGCYLINDERSTYPESOFCOALCRUSHERSHCSZ300HCSP400HCSQ700HCSC6HCSC81012CYLINDERSETNOINTHEHYDRAULICCIRCUITDIAGRAMINNERDIAMETERSOFHYDRAULICCYLINDERSPISTONRODDIAMETERSMMMM633580451005512570ACTIONAREAPUSHINGENDPULLINGENDCM2CM2311721175027343778545391122728423PUSHONADVANCINGSTROKETFKN2382337314307949148117677517ACTUATINGFORCEOFSINGLECYLINDERPULLONRETURNINGSTROKETFKN16516162152105337330256351594CONSTRUCTIONANDWORKINGPRINCIPLETHEHYDRAULICSTATIONISCONSISTEDOFSUCTIONFILTER,GEARPUMP,RELIEFVALVE,HANDOPERATEDDIRECTIONALVALVE,ONEWAYTHROTTLEVALVE,HOSEASSEMBLY,QUICKRELEASECOUPLINGSPRESSUREMETERSANDSWITCHES,OILPIPES,OILTANKAIRFILTERS,ETCWHENTHEGEARPUMPISROTATEDBYAACELECTRICMOTORTHROUGHACLAWCOUPLING,THEPRESSUREOILISBROUGHTINTOARELIEFVALVEWHERETHENORMALPRESSUREISINDICATEDBYAPRESSUREMETERATYPEMDIRECTIONALVALVEISUSEDFORCHANGINGTHEDIRECTIONSOFACTUATORSHYDRAULICCYLINDERSFORTHEIRADVANCINGANDRETURNINGSTROKESTHEONEWAYTHROTTLEVALVECANCHANGETHEWORKINGSPEEDBYMEANSOFRESTRICTIONSPEEDREGULATIONTHEOILINTHERETURNLINEANDREMAININGOILINTHERELIEFVALVESHALLBECOLLECTEDANDRETURNEDTOTHEOILTANKTHROUGHTHEDISCHARGINGOPENING5OPERATIONANDMAINTENANCE51INACCORDANCEWITHTHEHYDRAULICSYSTEMDIAGRAMANDTABLE2ANDTHECONSTRUCTIONOFTHEHYDRAULICCYLINDERSFORACTUATINGTHECOALCRUSHER,THEQUICKRELEASECOUPLINGSANDNYLONWASHERSSHALLBECONNECTEDTOTHECONNECTIONSOFTHEHYDRAULICCYLINDERSANDTHECOUPLINGSOFTHELINESHALLBECHECKEDFORTHEIRRELIABILITY52THEELECTRICMOTORFORHYDRAULICPUMPSHALLBEINSPECTEDFORITSCORRECTROTATINGDIRECTIONVIEWFROMTHESHAFTEND,THEMOTORSHALLBEROTATEDCLOCKWISE53BEFORESTARTINGTHEOILLEVELOFTHETANKSHALLBEOVERTHEOILGAUGEAFTERSTARTINGTHEOILLEVELSHALLBEINTHEOILGAUGEATAVISIBLEOPPOSITIONWHENTHEOILLEVELCANNOTBEFOUNDFROMTHEOILGAUGE,OILSHALLBESUPPLEMENTEDINTHETANK,ASSHOWNINTHEFOLLOWINGFIGURESY8型碎煤机液压站使用说明书1154THEELECTRICMOTORSHALLBESLOWLYROTATEDORTHEMOTORISSTARTEDREPEATEDLYTOUNLOADTHEDISCHARGINGPIPELINESOASTOREMOVEAIRINTHEPUMPBODYANDTHEPIPELINE55WHENTHEELECTRICMOTORISRESTARTEDAFTERITSTOPS,ITSHALLBECARRIEDOUTAFTERONEMINUTEINTERVAL56THEPRESSUREOFRELIEFVALVESHALLBEADJUSTEDTO75MPA,WHENTHEMOREHIGHPRESSURESAREREQUIRED,APPROPRIATEADJUSTMENTSHALLBEMADEITISNOWALLOWEDTOEXCEED14MPA57THEVISCOSITYOFTHEWORKINGOILSHALLBEFROM17CENTISTOKETO38CENTISTOKE255E30MACHINEOILISRECOMMENDEDTOUSE58THENORMALOILTEMPERATURESHALLBEFROM10TO60WHENOILTEMPERATUREISBELOW0ATSTARTING,THEWORKINGOILSHALLBEWARMEDUPTHEMACHINESHALLBESTARTEDWHENOILTEMPERATUREREACH559OILSHALLBEFILLEDTOTHEOILTANKFROMAIRFILTER,INWHICHTHESTRAINERHASAFILTRATIONSIZEOF120MESHES/INCH510THEWORKINGOILSHALLBECHECKEDATREGULARINTERVALSFORITSCOLOUR,TRANSPARENCY,SETTLINGMATERIAL,SMELLANDSOONIFTHEOILISDETERIORATEDORPOLLUTEDBADLY,ITSHALLBECHANGEDINTIMEASARULE,OILSHALLBECHANGEDONCEAYEAROILLEVELL1L/25MMUPDOWNSY8型碎煤机液压站使用说明书126MALFUNCTIONSANDELIMINATIONSERNOMALFUNCTIONSCAUSESELIMINATION1ALTHOUGHTHEOILPUMPISDISCHARGED,BUTTHEOPERATINGPRESSURECANNOTBEMET1THERELIEFVALVEISOPERATEDIMPROPERLY2THEREARENOLOADINTHEHYDRAULICCIRCUIT3OILLEAKAGEAREFOUNDINTHESYSTEM1THEVALVEBODYSHALLBEDISMOUNTEDFORINSPECTIONANDREPAIR2THEHYDRAULICCIRCUITSHALLBEINSPECTEDANDLOADED3THEPIPELINESHALLBEINSPECTEDTOPREVENTFROMLEAKAGE2THEREAREPRESSUREINTHEPUMPBUTOILCANNOTBEDISCHARGEDORTHEVOLUMEEFFICIENCYISCUTDOWN1THESEALINGSINTHEPUMPMAYBEDAMAGED2SUCKEDINFOREIGNMATERIALPRODUCEABNORMALFRICTIONINTHESLIDINGPART1THEMANUFACTURERSSHALLBEBROUGHTINTOCONTACTFORREPAIR2INSPECTIONSHALLBECARRIEDOUTTOELIMINATEFOREIGNMATERIAL3EXCESSIVENOISEAREFOUND1THESUCTIONLINEISTOOTHIN2THEFILTERATTHESUCTIONINLETISBLOCKED3AIRARESUCKEDINTHESUCTIONLINEOROTHERPARTS4THEREAREAIRBUBBLESINTHEOILTANK5THEOILLEVELISTOOLOWINTHEOILTANK6THEINSTALLATIONFOUNDATIONISSHORTOFRIGIDNESS7THESPEEDANDPRESSUREEXCEEDTHESPECIFIEDVALUES8THEREISABIGNOISEATTHECOUPLING1THEOILPIPEORHOSEWITHBIGGERDIAMETERSSHALLBEREPLACED2CLEANINGANDWASHINGSHALLBECARRIEDOUT3THESUCTIONLINESHALLBEFILLEDWITHOILTOFINDTHEIMPROPERPOSITIONS4THERETURNOILLINESHALLBEINSPECTEDTOPREVENTFROMPRODUCINGBUBBLES5OILSHALLBEFILLEDTOTHESPECIFIEDLEVEL6THERIGIDNESSOFTHEINSTALLINGFOUNDATIONSHALLBEIMPROVED7THESPEED,PRESSUREANDOILCIRCUITSHALLBEINSPECTED8THECOUPLINGSHALLBECHECKEDFORDAMAGEOREXCESSIVEMISALIGNMENT4HEATINGISPRODUCEDINTHEOILPUMP1THEVOLUMEEFFICIENCYISIMPROPERORAIRENTERINTOTHEPUMP2THEBEARINGISWORN3VISCOSITYOFOILISTOOHIGH,LUBRICATIONISIMPROPERANDOILISPOLLUTEDBADLY1AIRSHALLBEEXHAUSTEDANDVOLUMEEFFICIENCYSHALLBEIMPROVED2NEWBEARINGSHALLBEREPLACED3OILSHALLBECHANGEDORREPLACEDSY8型碎煤机液压站使用说明书13PERFORMANCEACTUATINGCYLINDERSETSITEMSUNITDATATYPEOFCOALCRUSHERNUMBEROFHYDRAULICCYLINDERSETSASSEMBLYDRAWINGNOOFHYDRAULICCYLINDERSRATEFLOWL/MIN819HCSZ300HCSQ300100000NORMALPRESSUREMPA75HCSP400HCSP700HCSQ7000100POWERKW15HCSC6HCSC692SPEEDR/MIN940HCSC8HCSC8090000HYDRAULICOIL30MACHINEOILHCSC12HCSC12110000TANKFILLINGCAPACITYL6010NOTESFRONTCOVERCYLINDERREARCOVERCYLINDERTHEHYDRAULICSTATIONDRIVINGSHALLBEPROVIDEDACCORDI