电动荷花状抓斗.doc

MAINTENANCE INSTRUCTION 维修指南 HU 3.06.0626 En HU 3.06.0626 中文版 PAGE 第 1 页，共 42 页 FILE 文件： MAINTENANCE INSTRUCTION 维修指南 KCI Konecranes Plc DEPT./HANDLED BY: 部门/ 编制： CHC/ J. Rikknen APPROVED BY: 批准： CHD/ T. Glad DATE: 日期： 08.04.2004 SOFTW./VERS. 软件/版本 Word 97/Vertex Word 97/Vertex LANG. 语种： En 英语 ISSUE 发行： 0 0 1 OPERATING MANUAL FOR MOTOR OPERATED ORANGE-PEEL GRAB, WGR80-1 电动荷花状抓斗(WGR80-1 型)使用说明书 TABLE OF CONTENTS目录 1SPECIFICATION OF GRAB WGR80-12 1.1Dimensions 尺寸.2 1.2Technical main data 主要技术数据2 1.3Operating data 操作数据.2 1.4Electric motor data 电动马达数据2 1.5Hydraulic data 液压数据.3 1.6Mechanical data 机械性能数据.3 2DESCRIPTION AND GENERAL SURVEY 概述.5 2.1Construction 结构5 2.2Function of hydraulic system 液压系统功能.6 2.3Measuring points 测量点8 2.4Hydraulic diagram 液压流程图10 2.5Control block 控制模块.11 2.6Function of electrical system 电气系统功能12 3OPERATING INSTRUCTIONS 操作指南.13 3.1Putting into operation 进入操作13 3.2Maintenance items.14 3.3Information for operation 有关操作的说明16 3.4Shut-down 关机17 3.5Transportation 装运.17 4MAINTENANCE 维修.17 4.1Hydraulic fluid change 液压油更换19 4.2Lubrication instructions 润滑指南20 4.3Electric motor 电动马达21 4.4Control block 控制模块22 4.5Hydraulic power unit 液压动力装置.22 4.6Pump 油泵.22 4.7Hydraulic cylinders 液压缸22 MAINTENANCE INSTRUCTION 维修指南 HU 3.06.0626 En HU 3.06.0626 中文版 PAGE 第 2 页，共 42 页 FILE 文件： MAINTENANCE INSTRUCTION 维修指南 KCI Konecranes Plc DEPT./HANDLED BY: 部门/ 编制： CHC/ J. Rikknen APPROVED BY: 批准： CHD/ T. Glad DATE: 日期： 08.04.2004 SOFTW./VERS. 软件/版本 Word 97/Vertex Word 97/Vertex LANG. 语种： En 英语 ISSUE 发行： 0 0 2 4.8Jaws 抓爪.23 4.8.1The welds of jaw 抓爪的焊接26 4.9Balancing beam 平衡梁.26 5TROUBLE SHOOTING 故障排除27 6SPARE PARTS 备件.32 1SPECIFICATION OF GRAB WGR80-1 WGR80-1 型抓斗技术说明 1.1Dimensions 尺寸 1.Main dimensions according to figure 1. 主要尺寸数据见图 1。 1.2Technical main data 主要技术数据 1.Dead weight (Incl. hydr. fluid) _6200 kg 总重量（包括液压油） _6200 kg 2.Grab volume _8 m 抓斗体积_8 m 3.Number of jaws _7 pcs 抓爪数量_7 件 4.Design of jaw _closed 抓爪设计_闭合 5.Max. jaw tip force of closed grab _38 kN 抓斗闭合时爪尖最大抓力 _38 kN 1.3Operating data 操作数据 1.Closing time _15 sec 闭合时间_15 sec 2.Opening time _18 sec 开启时间_18 sec 3.Control system _Directional valve 控制系统_导向阀 1.4Electric motor data 电动马达数据 1.Output power _37 kW 输出功率_37 kW 2.Duty type _S3-40 % 任务类型_S3-40 % 3.Protection class _IP55 保护级别_IP55 MAINTENANCE INSTRUCTION 维修指南 HU 3.06.0626 En HU 3.06.0626 中文版 PAGE 第 3 页，共 42 页 FILE 文件： MAINTENANCE INSTRUCTION 维修指南 KCI Konecranes Plc DEPT./HANDLED BY: 部门/ 编制： CHC/ J. Rikknen APPROVED BY: 批准： CHD/ T. Glad DATE: 日期： 08.04.2004 SOFTW./VERS. 软件/版本 Word 97/Vertex Word 97/Vertex LANG. 语种： En 英语 ISSUE 发行： 0 0 3 4.Insulation class _IEC-H 绝缘级别_IEC-H 5.Rotating speed_1500 RPM 旋转速度_1500 转/min 6.Power supply _3380 V; 50 Hz 电源 _3380 V; 50 Hz 7.Design and mounting arrangement _IEC-V1 设计及安装要求 _IEC-V1 1.5Hydraulic data 液压数据 1.Pump type _Helical gear pump 油泵型号_螺旋齿轮泵 2.Rated pressure_250 bar 额定压力_250 bar 3.Control valves_Special valve block 控制阀_专制闸阀 4.Cylinder design pressure _250 bar 液压缸设计压力 _250 bar 5.Grab operating pressure _200 bar 折斗工作压力 _200 bar 6.Fluid volume flow _120 LPM 液压油流量 _120 升/min 7.Tank capacity (max. fluid level) _250 liters 油箱容量（最大液面） _250 升 8.Fluid filter element type _Replaceable 10 Mic 液压油滤芯类型 _10 片可更换型 1.6Mechanical data 机械性能数据 1.Frame material_S355J2G3 横梁材料_S355J2G3 2.Jaw material_Welded high tensile steel plate 抓爪材料_焊接的高抗拉钢板 3.Jaw bearing and tip material _Extremely wear-resistant steel 抓爪轴承和爪尖材料_高耐磨钢 4.Axles _AISI8620 芯轴 _AISI8620 5.Cylinder fixing bearings _Spherical plain bearing steel to steel 液压缸固定轴承 _关节轴承钢对钢 6.Cylinder piston rod surface _Hard chromium plating, 20-30 m 液压缸活塞杆表面_镀铬硬化厚度 20-30 m MAINTENANCE INSTRUCTION 维修指南 HU 3.06.0626 En HU 3.06.0626 中文版 PAGE 第 4 页，共 42 页 FILE 文件： MAINTENANCE INSTRUCTION 维修指南 KCI Konecranes Plc DEPT./HANDLED BY: 部门/ 编制： CHC/ J. Rikknen APPROVED BY: 批准： CHD/ T. Glad DATE: 日期： 08.04.2004 SOFTW./VERS. 软件/版本 Word 97/Vertex Word 97/Vertex LANG. 语种： En 英语 ISSUE 发行： 0 0 4 Figure 1. Main dimensions 图 1 . 主要尺寸数据 MAINTENANCE INSTRUCTION 维修指南 HU 3.06.0626 En HU 3.06.0626 中文版 PAGE 第 5 页，共 42 页 FILE 文件： MAINTENANCE INSTRUCTION 维修指南 KCI Konecranes Plc DEPT./HANDLED BY: 部门/ 编制： CHC/ J. Rikknen APPROVED BY: 批准： CHD/ T. Glad DATE: 日期： 08.04.2004 SOFTW./VERS. 软件/版本 Word 97/Vertex Word 97/Vertex LANG. 语种： En 英语 ISSUE 发行： 0 0 5 2DESCRIPTION AND GENERAL SURVEY 概述 2.1Construction 结构 The KCI orange peel motor grab is constructed as follows: KCI 荷花状马达抓斗结构如下图所示： Figure 2. Principal parts 图 2. 主要另部件 The jaws that serve to pick up waste are fixed by means of pins to the frame. The pins also serve as pivot points for the jaws. The pivot points of the jaws are manufactured from wear-resistant material. 能爪起废物的抓爪用销钉固定在斗框上，销钉同时也作为抓爪的转动中心点，它们用耐磨材料制成。 上盖 内装电动马达 内装控制模块 内装透气塞 液压缸 耦合器（钟罩状壳内） 螺旋齿轮泵（油箱内） 提升链 平衡梁 电源及控制电缆 内装电子箱 液压缸保护罩 油箱 基座 抓爪 爪尖 MAINTENANCE INSTRUCTION 维修指南 HU 3.06.0626 En HU 3.06.0626 中文版 PAGE 第 6 页，共 42 页 FILE 文件： MAINTENANCE INSTRUCTION 维修指南 KCI Konecranes Plc DEPT./HANDLED BY: 部门/ 编制： CHC/ J. Rikknen APPROVED BY: 批准： CHD/ T. Glad DATE: 日期： 08.04.2004 SOFTW./VERS. 软件/版本 Word 97/Vertex Word 97/Vertex LANG. 语种： En 英语 ISSUE 发行： 0 0 6 The hydraulic pump motor is mounted vertically and as a complete assembly in the frame, which also serves a protective function. The lower section of the frame is designed to serve as a fluid tank as well. The hydraulic power unit consists of an electric motor, a spur gear pump and a control valve block. The hydraulic power unit can be removed completely from the grab by removing the mounting bolts. The low mounting position of the hydraulic unit within the grab makes a low grab profile possible and favorable center of gravity. 液压泵马达作为一个完整组件垂直地安装在斗框上，同时也有保护作用的功能。斗框的下半部同时 也是油箱。液压动力装置由一个电动马达、一个直齿齿轮泵及一个控制阀模块组成。只要卸下固定 螺栓，可以将液压动力装置从抓斗上折下。液压装置放在抓斗下部得到一个抓斗低位配置及最好的 重力中心。 The fixing points for the hydraulic cylinders are positioned at the frame and at the jaws. The jaws are opened and closed by retracting or extending the piston rods respectively. The piston rods are hard chrome plated. The control valve block is connected to the hydraulic cylinders by means of hydraulic hoses. The hydraulic cylinders are protected against mechanical damage. 液压缸的固定点处在斗框及抓爪上。通过控制活塞杆的来回运动，就可以开启或闭合抓爪。活塞杆 经渡铬硬化。控制阀模块用液压管连接到液压缸上。液压缸应作保护，避免机械损坏。 Power is supplied to the electric motor via a rubber-coated cable and a plug unit. A strain relief feature is installed to protect the plug unit from damage. The plug is provided with a protective cover. 动力通过橡胶绝缘涂层电缆和插头供给电动马达。插头具有应变释放功能，能有效防止机械损坏。 插头还同时提供保护盖。 The grab is suspended with the balancing beam, which can swing 45 to two directions at the same time. There are two small holes for lifting chains on a plate of the balancing beam. A cover plate of the frame is mounted by bolts. 抓斗悬挂平衡梁上， 能够同时在两个方向上旋转 45。平衡梁的横板上有个小孔供提升链通行。斗 框的盖板用螺栓连接固定。 All component groups and parts are manufactured from high-quality materials and are designed for easy interchangeability. 所有另部件都是用高质量材料制成，且设计成具有互换性。 2.2Function of hydraulic system 液压系统功能 Hydraulic diagram is presented in section 2-4. The locations of hydraulic components in valve block are also shown in section 2-5. 液压的流程图由 2.4 节给出。液压部件在阀控模块的位置由 2.5 节给出。 MAINTENANCE INSTRUCTION 维修指南 HU 3.06.0626 En HU 3.06.0626 中文版 PAGE 第 7 页，共 42 页 FILE 文件： MAINTENANCE INSTRUCTION 维修指南 KCI Konecranes Plc DEPT./HANDLED BY: 部门/ 编制： CHC/ J. Rikknen APPROVED BY: 批准： CHD/ T. Glad DATE: 日期： 08.04.2004 SOFTW./VERS. 软件/版本 Word 97/Vertex Word 97/Vertex LANG. 语种： En 英语 ISSUE 发行： 0 0 7 The type of the hydraulic system is so called open circulation with directional valve. Electric motor runs constantly during normal operation, but it will stop automatically in 30 seconds, if no open/close command is given (PLC setting). This system decreases number of motor start-ups and thus prevents high starting current damaging components. Hydraulic system automatically switches to free flow circulation in both directions. Thus no extra heat is produced. Observe! Directional valve controlled grab cant be operated without PLC-control command from crane. 液压系统的类型属于称之为带导向阀的开放和循环型。电动马达在正常工作状态下持续运转，但如 果无开通/关闭的指令时， 它将在 30 秒内自动停止（程序逻辑控制设置）。这种系统减少了机器启 动时马达的数量，因而有效地防止了启动时的大电流对部件的损坏。液压系统能在两个方向上自动 地转换到自由流动循环状态。这样就不会产生过多的热量。 注意：由导向阀控制的抓斗如没有从起 重机给出的 PLC 控制指令则不能工作。 Free-flow circulation 自由流动循环 Valve 阀1416.116.220 Position 位置Open 开Closed 关Closed 关12 When the electric motor is running the hydraulic pump pumps fluid to point P in diagram. Valves 14, 16.1, 16.2 and 20 are in normal positions. Pressure opens the pressure-sensing valve no. 15 and the fluid flows through it back to the tank T3. Cylinders keep their positions because counterbalance valves 18 and 19 and also check valves 17.1 and 17.2 are closed. 当电动马达驱动液压泵将油泵入流程图中的 P 点时，阀门 14, 16.1, 16.2 和 20 处在正常位置。 压力 打开压敏阀门 15， 液压油通过它流回油箱 T3。液压缸保持它们的位置，这是因为平衡阀 18 和 19 平以及截止阀 17.1 和 17.2 都有关闭着。 Opening 打开 Valve 阀1416.116.220 Position 位置Closed 关Closed 关Open 开12 The hydraulic fluid flows through valve 16.2 via point B to the rod side of the cylinder. Pressure also opens the counter balance valve 18 and thus allows return flow from cylinder piston side via point A to the tank T3. When cylinder reaches the end position, increased pressure opens pressure control valve 13 and the system switches to free flow circulation. 液压油流过阀 16.2 的 B 点到达液压缸杆。压力打开平衡阀 18，这样使得回流由液压缸活塞的 A 点 流到油箱 T3。当液压缸到达终端位置时，压力增加将打开控制阀 13 ，系统将转换到自由流动循环 状态。 MAINTENANCE INSTRUCTION 维修指南 HU 3.06.0626 En HU 3.06.0626 中文版 PAGE 第 8 页，共 42 页 FILE 文件： MAINTENANCE INSTRUCTION 维修指南 KCI Konecranes Plc DEPT./HANDLED BY: 部门/ 编制： CHC/ J. Rikknen APPROVED BY: 批准： CHD/ T. Glad DATE: 日期： 08.04.2004 SOFTW./VERS. 软件/版本 Word 97/Vertex Word 97/Vertex LANG. 语种： En 英语 ISSUE 发行： 0 0 8 Closing 关闭 Valve 阀1416.116.220 Position 位置Closed 关Open 开Closed 关32 The hydraulic fluid flows through valve 16.1 via point A to the piston side of the cylinders. Pressure also opens the counter balance valve 19 and thus allows return flow from rod side of cylinders via point B to the tank T3. When cylinders reach the end positions, or when compressing the waste, increased pressure opens pressure control valve 13, and the system switches to free flow circulation. Check valve 17.1 that it keeps high pressure in piston side of cylinders. Also valve 19 closes and locks the position of cylinders. 液压油经阀 16.1 的 A 点流到液压缸活塞周围。压力打开平衡阀 19， 允许回流从液压缸活塞周围的 B 点流回到油箱 T3。当液压缸到达端点位置时，或压缩废油时，压力增加将打开控制阀 13，系统将 转换到自由流动循环。截止阀 17.1 将使液压缸的活塞周围保持高压力。此时阀门 19 关闭并锁紧液 压缸的位置。 Recharging 增压 When waste compresses, the hydraulic system switches to free flow circulation. When waste collapses, the pressure in cylinder decreases. In order to prevent waste from falling, the system recharges itself. This happens when pressure control valve 13 detects decreased pressure and closes. Thus also pressure sensing valve 15 closes and the fluid flows through valve 16.1 to the piston side of the cylinders. 当废油压缩，使液压系统转换到自由流动循环。当废油跌落，液压缸内的压力降低。为防止废油跌 落，系统自身增压。当压力控制阀 13 关闭并检测到压力降低时，这种情况会出现。这样， 压敏阀 15 也关闭，液压油通过阀 16.1 流回到液压缸的活塞 周围。 2.3Measuring points 测量点 The hydraulic system is equipped with three pressure measuring points. Those are labeled as PMP, PMA and PMB in hydraulic diagram. 液压系统带有三个测量点，在流程图中标明为 PMP，PMA 和 PMB PMP = pump pressure PMP 指泵压 PMA= pressure in cylinder piston side line PMA 指液压缸活塞周围的压力 PMB = pressure in cylinder rod side line PMB 指液压缸杆周围的压力。 MAINTENANCE INSTRUCTION 维修指南 HU 3.06.0626 En HU 3.06.0626 中文版 PAGE 第 9 页，共 42 页 FILE 文件： MAINTENANCE INSTRUCTION 维修指南 KCI Konecranes Plc DEPT./HANDLED BY: 部门/ 编制： CHC/ J. Rikknen APPROVED BY: 批准： CHD/ T. Glad DATE: 日期： 08.04.2004 SOFTW./VERS. 软件/版本 Word 97/Vertex Word 97/Vertex LANG. 语种： En 英语 ISSUE 发行： 0 0 9 Pressure in PMP and PMA can be measured from connectors which locate in frame of the grab. Pressure meter equipped with hose and required connector is delivered with the grab. See also section 4 maintenance. PMP 和 PMA 的压力可通过位于抓斗框的接点进行测量。带有连接管和接点的压力表随抓斗同时提 供。参见第 4 节 维修。 MAINTENANCE INSTRUCTION 维修指南 HU 3.06.0626 En HU 3.06.0626 中文版 PAGE 第 10 页，共 42 页 FILE 文件： MAINTENANCE INSTRUCTION 维修指南 KCI Konecranes Plc DEPT./HANDLED BY: 部门/ 编制： CHC/ J. Rikknen APPROVED BY: 批准： CHD/ T. Glad DATE: 日期： 08.04.2004 SOFTW./VERS. 软件/版本 Word 97/Vertex Word 97/Vertex LANG. 语种： En 英语 ISSUE 发行： 0 0 10 2.4Hydraulic diagram 液压流程图 Figure 3. Hydraulic diagram 图 3 液压流程图 T3 MAINTENANCE INSTRUCTION 维修指南 HU 3.06.0626 En HU 3.06.0626 中文版 PAGE 第 11 页，共 42 页 FILE 文件： MAINTENANCE INSTRUCTION 维修指南 KCI Konecranes Plc DEPT./HANDLED BY: 部门/ 编制： CHC/ J. Rikknen APPROVED BY: 批准： CHD/ T. Glad DATE: 日期： 08.04.2004 SOFTW./VERS. 软件/版本 Word 97/Vertex Word 97/Vertex LANG. 语种： En 英语 ISSUE 发行： 0 0 11 2.5Control block 控制模块 Figure 4. Control block 图 4 控制模块 MAINTENANCE INSTRUCTION 维修指南 HU 3.06.0626 En HU 3.06.0626 中文版 PAGE 第 12 页，共 42 页 FILE 文件： MAINTENANCE INSTRUCTION 维修指南 KCI Konecranes Plc DEPT./HANDLED BY: 部门/ 编制： CHC/ J. Rikknen APPROVED BY: 批准： CHD/ T. Glad DATE: 日期： 08.04.2004 SOFTW./VERS. 软件/版本 Word 97/Vertex Word 97/Vertex LANG. 语种： En 英语 ISSUE 发行： 0 0 12 2.6Function of electrical system 电气系统功能 See figures 17 and 18. 参见图 17 和 18。 The PLC, which controls the grab, has been located in a cubicle on the trolley, on the bridge or on the building itself. The PLC reads the control request (open or close) given by the crane driver. The command is forwarded to the grab via data cable. Command from PLC controls electrically controlled valves M-Y1M-Y4. 控制抓斗的 PLC 设在吊车的控制室中，控制室可在横跨桥或在厂房中。PLC 读取由吊车司机发出的 控制请求（打开或关闭）。指令由数据通讯电缆转到抓斗。由 PLC 发出的指令控制阀门 M-Y1 到 M-Y4. Open command controls the valves M-Y1 and M-Y3。 打开指令控制阀门 M-Y1 到 M-Y3。 Close command controls the valves M-Y1, M-Y2 and M-Y4. 关闭指令控制阀门 M-Y1，M-Y2 和 M-Y4。 When a request to stop closing or opening movement, the PLC detects the corresponding command is removed. 当清求停止打开或关闭行动时，PLC 检测到相关的指令并焦虑执行。 To avoid frequent motor starts the PLC does not stop the motor immediately after last stop command. Instead the PLC keeps motor running and waits for new control requests. The running period of the motor is determined by a PLC- parameter. Typically it will be 20100 seconds. 为防止马达多次启动，PLC 在最后一个停止指令执行后并不立即停止马达。而是保持马达继续运转， 等候新的控制请求。继续运转时间由 PLC 参数仪决定，一般为 20 到 100 秒。 When the PLC detects a control request and the motor is not running, the corresponding command is delayed until the motor has reached its nominal speed of rotation. This is to protect the motor against overload. Delay time is determined by a PLC- parameter. 如 PLC 检测到请求而马达不运转时，则相关的指令会延迟，直到马达达到它的正常运转速度。这样 可防止马达过载。延迟时间由 PLC 参数仪决定。 The electric components of the grab are mounted in a cubicle located on side of the frame. Cubicle is protected against mechanical shocks. 抓斗的电气元件安置在斗框一侧的控制室中。控制室被保护防止机械撞击。 Tilting limit switch prevents the closing and opening commands, when the grab is tilted more than 45. To continue the operation the grab has to be lifted up from the waste pile. MAINTENANCE INSTRUCTION 维修指南 HU 3.06.0626 En HU 3.06.0626 中文版 PAGE 第 13 页，共 42 页 FILE 文件： MAINTENANCE INSTRUCTION 维修指南 KCI Konecranes Plc DEPT./HANDLED BY: 部门/ 编制： CHC/ J. Rikknen APPROVED BY: 批准： CHD/ T. Glad DATE: 日期： 08.04.2004 SOFTW./VERS. 软件/版本 Word 97/Vertex Word 97/Vertex LANG. 语种： En 英语 ISSUE 发行： 0 0 13 当抓斗倾斜超过 45时，倾斜限位开关将阻止打开或关闭指令。要继续工作，抓斗必须从物料堆中 提起。 Oil temperature limit switch and oil limit switch stop the hydraulics if the set value is reached. The oil has to be left cooled off or added. This is to protect pump and other hydraulic components. 油温限位开关及油限位开关将在设定值达到后停止液压操作。此时应将油冷却或加入新油。这样可 保护油泵及其它元件。 3OPERATING INSTRUCTIONS 操作指南 3.1Putting into operation 进入操作 Initial start-up 启动机器 Connect the power supply cable to the grab. If the electric motor rotates in the wrong direction, disconnect the cable and interchange terminal leads. If the plug outlet is not hooked up, connect it according to the wiring plan. 接通抓斗电源电线。如电动马达转动方向有错，断开电线并改变接线端子。如电源插座没有紧 固，按接线要求予以纠正。 Check the hydraulic fluid level. Replace fluid that may have been lost during transportation of the grab. 检查液压油液面，抓斗运输过程中如有油漏失，应予以加补充。 Relieve tension in the power cable. It must not exert any tension on the plug outlet. 放松电源电线，在电源插座上不得有任何收紧情况。 Before a trial run first observe items 3.2 and 3.3. 试运行前，请注意 3.2 节和 3.3 节的要求。 3.2Maintenance items ItemMaintenance interval DailyWeeklyMonthly QuarterlyAnnuallyNote / action Mechanical: -BearingsCheckCheck wearing.Wave jaw hardly CheckCheck wearing.See section 4.8 LubricateSee section 4.2 -ScrewsCheckTightness -Axle holders CheckCondition -JawsCheckCheck welds.See section 4.8.1 -GeneralCheck Mechanical damages Hydraulic: -Hydraulic oil CheckCheck oil