取料机-液压说明书.pdf

CQGQ50 25 取料机料耙液压系统 CQGQ50 25 取料机料耙液压系统 安装使用维护说明书 大连力科技术工程有限公司 2011 年年 3 月月 本企业通过 ISO9001 认证 桥式刮板取料机液压控制系统使用维护说明书 大连力科技术工程有限公司 中国 大连 1 本液压系统是为 CQGQ50 25 取料机配套的 1 液压系统技术内容 1 1 桥式刮板取料机液压系统主要技术参数 1 1 1 料耙控制工作压力 12Mpa 1 1 2 油泵最大排量 69ml r 1 1 3 电机功率 22Kw 1 1 4 油缸规格 料耙油缸 缸径 140mm 杆径 100mm 行程 3800mm 1 1 5 使用液压油 冬季 低温液压油 YC N32 其它季节 抗磨液压油 YB N46 1 1 6 油箱容积 800 升 1 2 相关技术图纸 1 2 1 液压系统工作原理 参见 CQGQ50 25 取料机液压系统原理图 1 2 2 液压系统附件 风冷却器 过滤器 压力表 温度检测仪 液位计等 1 2 3 安装平面图 详见 CQGQ50 25 取料机液压系统安装平面图布置图 1 2 4 电气原理图 详见 CQGQ50 25 取料机液压系统电气原理图 2 液压系统的安装 调试及维护 2 液压系统的安装 调试及维护 2 1 液压系统的安装 2 1 1 安装前的技术准备工作 2 1 1 1 技术资料的准备与熟悉 液压系统原理图 电气原理图 安装平面布置图及清单等图纸和资料都 应准备齐全 以便工程技术人员对具体内容和技术要逐项熟悉与研究 2 1 1 2 物资准备 桥式刮板取料机液压控制系统使用维护说明书 大连力科技术工程有限公司 中国 大连 2 按照液压系统原理图及清单 核对液压件的数量 确认所有液压件的质 量状况 2 1 1 3 质量检查 安装前应检查各液压元件及部件应完好无损 液压元件所附带的密封件 应完整无缺并确认密封件保管期限 液压管道 管接头 软管均应清洁干净 在连接时不得有赃物进入设备及元件内 2 1 1 4 液压元件的拆洗与测试 液压元件在运输或库存期间易侵入污染物和锈蚀 新的液压元件内部也 有可能残留未清除尽的污物 确认未被污染的液压元件可不拆洗 但需进行 性能检测 质量检验 若性能 质量有问题要与生产厂联系解决 2 1 2 液压管道安装 液压管道安装是液压设备安装的一项主要工程 2 1 3 液压系统的清洗 液压系统安装完毕后 在试车前必须对管道 流道等进行循环清洗 液 压系统的正常使用对清洁度的要求是很严格的 首先保证液压管路 管接头 阀组及油箱清洁干净 其次保证所用的液压油达到清洁度的要求 2 2 液压系统的调试 2 2 1 调试准备工作 由液压技术工程师牵头 组织相关技术人员认真熟悉液压系统工作原 理 设计意图和设计要求 有关调试设备及工具准备齐全 研究掌握液压设 备的工况条件和负载特性 2 2 2 调试方法与步骤 桥式刮板取料机液压控制系统使用维护说明书 大连力科技术工程有限公司 中国 大连 3 2 2 2 1 确认液压系统净化符合标准后 向油箱加入规定的介质 加入介质 时一定要过滤 滤芯的精度要符合要求 2 2 2 2 在检查整个系统安装无误后 方可进行调试 2 2 2 3 空运行 将溢流阀的压力调节旋扭松开 各电磁铁断电 然后使电 机接通电源 点动电机 检查电机转向是否正确 如果正确 可连续接通电 源 此时油泵排出的液压油经溢流阀卸荷回油箱 2 2 2 4 压力调试 调节溢流阀调压旋扭 使压力逐级升高 达到调定压力 后保持一段时间 检查整个系统有无泄漏 如果有泄漏 及时处理 2 2 2 5 试运行 按动 左行 或 右行 按扭 调节料耙油缸使之达到要 求 2 2 2 6 调试注意事项 不准在执行元件运动状态下调节系统的工作压力 2 3 液压系统的使用维护 2 3 1 液压系统的使用保养要求 2 3 1 1 使用维护要求 压力阀 节流阀调节到所要求数值时 应将调节螺钉紧固牢靠 防止松 动 注意油质变化 定期抽样化验 及时净化处理或更换新油液 液压系统 的油温按要求的范围进行控制 所有电控柜 液压站等不得敞开使用 以免 积污 定期检查冷却器工作性能 经常检查管件接头 法兰盘等的固定状况 发现松动及时紧固 高压软管 密封件要定期更换 一般为二年左右 主要 液压元件定期进行性能测定 并定期更换维修 2 3 1 2 操作保养规程 操作者必须熟悉本设备所用的主要液压元件的作用 熟悉液压系统工作 桥式刮板取料机液压控制系统使用维护说明书 大连力科技术工程有限公司 中国 大连 4 原理 掌握系统工作程序 操作者要经常监视液压系统工作状况 特别是工 作压力和执行机构的运行速度 液压系统启动前 应检查电磁阀和所有运动 机构是否处于原始状态 油箱油位是否正常 操作者不准损坏电气系统的互 锁装置 不准用手推动电控阀 操作者不准私自调节或更换主要液压元件 液压系统出现故障时 应立即报告维修部门或系统生产厂 对故障原因进行 分析 并尽快予以排除 液压设备应经常保持清洁 防止各种污染物进入油 箱 2 3 2 定期维护内容与要求 2 3 2 1 定期紧固 对高中压设备 其管接头 法兰盘 液压缸紧固螺钉和压盖螺钉 活塞 杆止推或工作台止推调节螺钉 行程开关和档块固定螺钉等 应当每个月紧 固一次 低压液压系统可以三个月紧固一次 紧固时 拧紧力要均匀 并应 达到规定的拧紧力矩 2 3 2 2 定期检查或更换密封件 在正常的周期内 一般为二年更换一次或在停机大修时 所有密封件都 要更换新件 2 3 2 3 定期清洗或更换液压件 清洗周期 液压缸每隔一年清洗一次 其他液压设备应根据实际情况确 定 磨损严重 疲劳严重的液压元件要及时更换新件 2 3 2 4 定期清洗油箱与管道 油箱一般半年清洗一次 对油路板 软管 可拆的管道应拆下来清洗 桥式刮板取料机液压控制系统使用维护说明书 大连力科技术工程有限公司 中国 大连 5 清洗周期应根据液压设备工作环境和污染情况而定 2 3 2 5 定期更换滤芯 滤油器的滤芯必须经常更换 3 备件清单 油泵 PVV4 1X 069RA15LMC 1 件 比例换向阀 4WRZ16W6 150 7X 6EG24N9ETK4 M 1 件 比例放大板 VT VSPA2 1 2X V0 T1 1 件 放大板支架 VT3002 2X 48F 1 件 电磁溢流阀 DBW20B2 5X 315 UEG24N9K4 1 件 电磁换向阀 4WE6J6X EG24N9K4 1 件 单向节流阀 Z2FS6 2 4X 2QV 1 件 板式单向阀 RVP20 10 1 件 风冷却器 OKA EL6S 40 3 0 D M A 1 400V 50Hz 1 件 滤油器 RFA 630X20F C 1 件 滤芯 FAX 630 x20 5 件 压力表 SPG063 0 40MPa R M14X1 5 F 1 件 液控单向阀 SL20PA2 4X 1 件 料耙油缸密封组件 140 100 3 件 液位计 YWZ 400T 1 件 温度计 WSSX 411 1 L 400mm 0 100 1 件 液位控制继电器 YKJD24 400 1 件 放油球阀 Q11F 16 DN25 1 件 桥式刮板取料机液压控制系统使用维护说明书 大连力科技术工程有限公司 中国 大连 6 测压接头 PPT 3 3 件 测压软管 HFH2 P1 3 P 1 0 1 根 空气滤清器 QUQ2 5 10X2 0 1 件 蝶阀 D41 1 6 DN65 1 件 联轴器 NL7 YA48X90 YA31 75X60 1 件 减震喉 KXT DN65 1 件 油缸胶管 32 2000 JB1885 77 单 90 0 4 根 油缸胶管 32 4300 JB1885 77 单 90 0 4 根 高压胶管 32 400 JB1885 77 单 90 0 1 根 高压胶管 38 800 JB1885 77 A 型单 90 1 根 高压胶管 38 800 JB1885 77 A 型双 90 安装角 0 1 根 1 Hydraulic Systems for CQGQ50 25 Reclaimer Specifications of Installation Operation and Maintenance Dalian Like Technology Co Ltd ISO9001 approved 2 This hydraulic systems are designed for the CQGQ50 25 reclaimer 1 Technical information 1 1 hydraulic system of stock rake and tighten mechanism 1 1 1 Main technical parameters 1 1 1 1 Stock rake working pressure 12Mpa 1 1 1 2 Maximum pump discharge 69ml r 1 1 1 3 Motor power 22Kw 1 1 1 4 Dimensions of stock rake cylinder Cylinder diameter 140mm Pole diameter 100mm Cylinder stroke 3800mm 1 1 1 6 Using of hydraulic oil Anti wear hydraulic oil YB N46 1 1 1 7 Capacity of oil tank 800L 1 1 2 Drawings concerned 1 1 2 1 Operating principle For details see Functional Diagram of hydraulic system of CQGQ50 25 reclaimer 1 1 2 2 Accessories air cooler filter pressure gauge temperature detector liquid level meter and etc 1 1 2 3 Plan sketch of installation For details see Plan sketch of installation and lay out of hydraulic system of CQGQ50 25 reclaimer 1 1 2 4 Electric principle graph For details see Electric Principle Graph of hydraulic system of CQGQ50 25 reclaimer 2 Installation debugging and maintenance of hydraulic systems 2 1 Installation 2 1 1 Technological preparation for installation 2 1 1 1 Preparation of technical data Functional Diagram Electric Principle Graph Plan sketch of installation and lay out and others drawings and data concerned are prepared well The engineers and technicians shall carefully read and well know the details of them 2 1 1 2 Preparation of materials 3 Check the quantity and confirm the quality of all hydraulic parts according to the Functional Diagram and others concerned 2 1 1 3 Quality inspection Check all hydraulic components and parts for defects before installation The sealing pats of hydraulic components should not be any defect The hydraulic pipes pipe joints and soft tubes should be clean During connecting no dirty things are allowed into the equipment and components 2 1 1 4 Unpick wash and debug the hydraulic components The hydraulic components are easily dirtied and rusted during transportation or storage There are possible remaining dirty things in the new hydraulic components Unstained components can be free of unpicking and washing but performance test and quality inspection are required If problems are founded in performance or quality contact the manufacturer for settlement 2 1 2 Installation of hydraulic pipe Installation of hydraulic pipe is a major process of that of hydraulic equipment 2 1 3 Cleaning of hydraulic pipe After installation the pipelines and fluid channels shall be cleaned circularly before trial run The requirement of hydraulic equipment for the cleaning degree is very high especially for the hydraulic pipelines pipe joints valve blocks and oil tank Further the cleaning degree of the used hydraulic oil should be qualified 2 2 Preparation for debugging Under the leadership and instructions of hydraulic engineer relative technicians should be familiar with the working principle design purpose and design specifications of the hydraulic systems appropriate equipments and tools necessary for debugging should be prepared well the operating conditions and load properties of the hydraulic systems should also be well known 2 2 2 Debugging method and process 2 2 2 1 After confirming the cleaning degree of hydraulic system is qualified add regulated mediator in the oil tank The mediator must be filtered and the precision of filter element should be qualified too 2 2 2 2 Debugging can start after confirming the whole system is well installed 4 2 2 2 3 Dry running release pressure control knob of overflow valve switch off all electric magnets switch on motor and check it for smooth running If the motor runs well continuously keep the power on and the hydraulic oil discharged by oil pump returns to the oil tank through overflow value 2 2 2 4 Pressure debugging raise the pressure gradually by turning the pressure control knob of overflow valve keeps the pressure at the regulated line and check the whole system for leak Any leak should be corrected immediately 2 2 2 5 Try to run turn on the motor to drive the pump to run press the button of Left or Right to make the stock rake oil cylinder meet the requirement 2 2 2 6 Debugging precautions Don t adjust the working pressure of system when the components are running 2 3 Use and maintenance of hydraulic system 2 3 1 Requirements for use and maintenance of hydraulic system 2 3 1 1 Requirements for use and maintenance When pressure valve and governing valve is adjusted to the regulated value fasten the adjusting screw for fear of loosening pay attention to the change of oiliness make spot sampling test periodically and clean or replace the old oil the oil temperature of the hydraulic system should be control within the regulated scope never use the electric control cabinet or hydraulic station when they re open for fear of dirt retention check the performance of cooler periodically often check pipe joints and flange for loosening hi pressure soft tube and sealing parts should be replaced periodically generally once every 2 years the performance of main hydraulic components should be tested maintained and replaced periodically 2 3 1 2 Procedure of operation and maintenance The operator must be familiar with the functions of main hydraulic components the working principle of hydraulic system and working procedure of system the operator should often monitor the performance of the system especially the running speed of pressure and running speed of the mechanism before starting the system check the electron magnetic valve and all running mechanism are in original status and the level of oil in oil tank is correct the operator shouldn t damage the interlock of the electric system or push electric control valve by hand the operator 5 shouldn t adjust or replace the main hydraulic component without approval and if something is wrong with the hydraulic system report the maintenance or manufacturer immediately for settlement the hydraulic equipment should be kept clean all along to prevent contaminant coming into the oil tank 2 3 2 Periodical maintenance and requirement 2 3 2 1 Periodical fastening The fastening screws in medium and hi pressure equipment pipe joint flange and hydraulic cylinder the capping screws the adjusting screws in piston rod and work bench and the fixing screws in stroke switch and limit stop should be fastened once a month Those of low pressure hydraulic system can be fastened once every 3 months The fastening force should be even and meets the regulated screwing moment 2 3 2 2 Periodical check and replacement of sealing parts During normal period all the sealing parts are replaced once every 2 years or during heavy maintenance 2 3 2 3 Periodical cleaning or replacement of hydraulic components Cleaning period the hydraulic cylinder is cleaned once 2 years and others upon actual conditions The badly wearing and tired hydraulic components should be replaced with new ones timely 2 3 2 4 Periodical cleaning of oil tank and pipeline The oil tank should be cleaned once half a year the oil way board soft tube and removable pipes should be disassembled for cleaning The cleaning period depends on the operational environment and contamination conditions of the hydraulic equipment 2 3 2 5 Periodical replaceme