泵站使用说明(英汉双语).doc

液 压 泵 站Hydraulic Pump Station使用说明书Operating Manual 郑州新华能气动液压设备有限公司ZHENGZHOU XINHUANENG HYDRAULICS CO., LTD目 录Contents一 主要技术参数(1). Main Technical Parameters . (1)二 安全使用注意事项(2). Safe Application and Precautions. (2)三 使用说明(2). Direction for Use. (2)四 调试运行(3). Commissioning and Operation. (3)五 维护与保养(3). Maintenance and Care. (3)六 常见故障及排除(7) . Common Failures and Solutions (7)七 液压系统原理图 (10). Hydraulic System Principle Diagram. (10)八 液压系统外观图 (11). Appearance View of Hydraulic System. (11)九 电气原理图 (12). Electric Circuit Diagram (12)十 易损件明细表 (13). Wearing Parts List (13)十一 维护检修记录 (14). Maintenance Records (14)一 安 全 使 用. Main Technical Parameters1 工作人员必须仔细阅读本说明书，掌握本设备的使用方法及工作原理，了解本泵站各部结构及功能，方能操作。 The operating staffs can operate only after read this manual carefully to master the usage method and operating principles and understand the structures and functions of all parts of this pump.2 检查泵站现状及完好状态，检查各仪表，调节旋钮及按钮等是否在运输过程中损坏，当泵站出现异常声音和故障时要切断电源终止工作，排除故障，严禁超技术范围使用。Check the present situation of the pump station and make sure it is in good condition. Check whether all instruments, adjusting knob and push buttons are damaged during the transportation. If there is abnormal noise or fault, cut off the power supply to remove faults. Application beyond technical scope is forbidden. 3 泵站工作电压380V，220V或24V控制，电气故障应由电工检测排除，严禁非专业人员擅自处理。系统压力出厂调试时已进行设定，未经生产主管允许不得乱动各调压、调速旋钮。The working voltage of pump station is 380V, with 200V or -24V control. The electrical faults shall be removed by electrician detection, and non-specialized person is not allowed to do so without permission. The system pressure was set during ex-factory debugging. Without permission of production supervisor, it is not allowed to tamper with pressure regulating and speed regulating knobs.二 注 意 事 项. Precautions 1 工作油使用温度不要超过65。The application temperature of working oil shall not exceed 65.2 防止污染，污染物会使油液加速氧化。Prevent pollution damage; otherwise, the pollutant will accelerate oxidation of fluid oil. 3 避免水分混入油液，水分会使油液乳化。Prevent water mixing in the fluid oil; otherwise, the water will emulsify it. 4 要控制油压机器及配管之漏油，定期检查其紧固情况。Prevent the oil hydraulic press and its pipes from oil leakage and make regular inspection on its fastening. 5 工作油应定期检查，夏天用HM46#，冬天用HM32#。The working oil shall be inspected on a regular basis, using HM46# in summer and HM32# in winter. 6 已经开始劣化的油液，补充新油并不能延长寿命。应予全部更换。其他有关问题请参阅说明书。For the fluid oil which starts degradation, replenishing fresh oil can not extend it life, and it shall be replaced. For information about other problems, see the manual. 三 警 告 Caution 1 严禁电机转向错误！No running electric motor in wrong director!2 严禁使用电压不符或缺相运行！No working voltage unconformity or absence-phase operation!3 使用前必须将油加至液位计2/3位置！Before using, the oil shall be added to the 2/3 point of the liquid level gauge.4 严禁随意调整各油压元件旋钮！No regulating oil pressure knobs at discretion. 5 严禁将泵站倒置，非专业人员切勿拆卸维修！No inversion of pump station. Non-specialized person shall not dismantle it for maintenance. 使 用 说 明Use Direction 一、 安装. Installation 1、 油箱尽可能安装在通风良好、温差较小、空气中粉尘较少的平面上， 油箱地脚与地基接触良好，以免系统工作时发生振动 The oil tank shall be installed on a surface with excellent ventilation, small temperature difference and little dust in air. 2、 安装时需注意留有足够的维修空间 During installation, enough service clearance shall be left.3、 过滤器、蓄能器等经常维护、检修的元件，需安装在易于维修的位置Filter, accumulator and other components requiring frequent maintenance and overhaul shall be installed at the positions easy for maintenance. 4、 对于冷却器需注意水质、水量、水温和防冻。For the cooler, attention shall be paid to the quality, amount, and temperature of the water as well as freeze protection. 5、 油箱清洗干净后向油箱内注入NL46或NM46抗磨液压油，油面应加至可视液位计2/3处 After the oil tank is cleaned up, NL46 or NM46 aitiwear hydraulic oil shall be injected into it, and the oil surface shall reach the 2/3 point of the graphic liquid level gauge. 6、 带有蓄能器的泵站应远离热源，禁止在蓄能器上进行焊接、铆接、敲击或机加工 The pump station with accumulator shall keep far away from heat. Welding, riveting, striking or machine work on the accumulator are prohibited. 7、 泵站与设备之间硬管连接时一定要用管夹将管路固定，以免油压冲击使管路振动。软管连接要注意胶管的余量及其与设备的摩擦问题，必要时用套弹簧或支架等方法将胶管防护起来，并保证合理的弯曲半径During the hard pipe connection between pump station and equipment, the pipe duct shall be fixed with pipe clamp for fear that the oil pressure impact might vibrate the pipe. As for hose connection, attention shall be paid to the allowance of rubber hose and friction between it and equipment. If necessary, protect the rubber by covering spring or bracket and ensure reasonable bend radius. 8、 装配管道时需注意管道的热胀、冷缩，管道接头处的漏油与空气吸入，管道支架的间隔一般为2m，不同管径应选择合适的管夹距离While assembling the pipe, attention shall be paid to the expansion caused by heat and contraction caused by cold of the pipe, the oil leak and air aspiration at the pipe joints. The interval between brackets shall be generally 2m and distance between pipe clamps shall vary from pipe diameters. 9、 在管道的高点要设置排气装置，在低点要设置放油装置 Air exhausting device shall be set at the high point of the pipe and jettison gear at the low point. 10、 要仔细清除管道中的焊接熔渣、切割铁屑等杂物，并进行充分的清洗和酸洗 Welding cinder, scrap iron and other sundries shall be removed carefully by washing and acid treatment. 11、 清洗液应采用与工作液体性质相同的油液，加入加强溶解力及防腐蚀等的添加剂Cleaning liquid shall adopt the oil liquid of the same character as the working fluid. Additive for strengthening solvency and corrosion protection shall be added. 12、 清洗时在排油回路中设置过滤器（精度10um）,以检测清洗效果，清洗时采用尽可能大的流速，清洗压力-3Mpa,清洗完毕应仔细清除在管道、油箱壁上附着的清洗液 During cleaning, a filter (with the accuracy of 10um) shall be set in the oil discharge circuit to check the cleaning effect, and the flow rate shall be as great as possible with a cleaning pressure of -3Mpa. After the cleaning is complete, the cleaning liquid attached to the pipe wall or oil tank shall be removed carefully. 二、 启动时的注意事项. Matters Needing Attention When Start液压装置首次运行时，由于油液还没有充分到达每个地方，各运动部件没有跑合，所以烧坏液压泵、漏油等事故很容易发生，必须慎重对待During the first run of the hydraulic units, since the oil liquid has not completely reached every position and the moving elements are not running-in, burning-out and oil leak of hydraulic pump likely to occur, which shall be treated cautiously. 1、 启动前必须仔细阅读使用说明书，充分了解设备及液压装置的结构及动作情况 Before start, shall carefully read the operating manual to fully understand the structure and action of the equipments and hydraulic devices. 2、 检查各联接部位是否正确。检查电源电压与工作电压是否一致Check whether the joints are correct and whether the supply voltage is consistent with the working voltage. 3、 将溢流阀调至低压卸荷状态（卸荷溢流阀除外）。Adjust the overflow valve to the low-voltage unloading condition (expect the unloading overflow valve). 4、 用手转动联轴器应转动灵活。The shaft joint shall rotate flexibly when turned by hand. 5、 点动油泵检查油泵转向是否正确。Inch the oil pump to check whether its rotary direction is correct. 6、 油温低于10以下时，油泵应连续点动几次后方可进入正常运行When the oil temperature is lower than 10, the oil pump shall enter normal running after several inching. 7、 油泵正常运转后，检查油泵管道是否漏油。After the oil pump run normally, check whether there is oil leak on the pipe of the oil pump.8、 在油泵正常运转的状态下，油温应保持在3550之间 油温最高不得超过60，需要时可利用加热器或冷却器调节温度。Under the normal operation of oil pump, the oil temperature shall be kept between 35 and 50, not higher than 60. The temperature can be regulated with heater or cooler as necessary. 9、 如果系统所配管线很长或油缸很大时，在油泵第一次启动后应及时向油箱中补油并观察油位的变化。If the pipeline of the system is long or the oil cylinder is large, after the first start, shall add oil into oil tank and observe the change of oil level. 10、系统用油必须保持清洁，不得将空气吸入系统。The system shall be kept clean with oil and air aspiration into system is not allowed. 11、将溢流阀手轮顺时针旋转，压力将升高，反之将降低。将溢流阀调至系统的工作压力，然后将螺母锁紧，溢流阀的调定压力不得超过系统最高压力。Turn the overflow valve hand wheel clockwise, the pressure will increase; conversely, it will fall. Regulate the overflow valve to the working pressure of the system, and then lock the nut. The set pressure of the overflow shall not exceed the highest pressure of the system. 13、 减压阀同上。Pressure-reducing valve is same as above. 三、 1 操作方法及日常检查. 1. Operating Method and Routine Inspection 1、 逆时针旋转压力表开关将其打开。Turn the pressure meter switch counterclockwise to open it. 2、 逆时针旋转溢流阀手轮，使液压系统处于卸荷状态。Turn the hand wheel of the overflow valve counterclockwise to keep the hydraulic system at the unloading state. 3、 油泵及电机运转正常后，空载运行分钟。After the normal operation, the oil pump and electric motor shall run for 5 minutes idle. 4、 顺时针旋转溢流阀手轮，逐级升压至使用压力。Turn the hand wheel of the overflow valve clockwise to increase pressure progressively to the application pressure. 5、 检查各联接部位是否有泄漏。Check whether there is leakage at any joint. 6、 以上操作完成并且正常后，可按工作要求进入工作。After the above operations are completed normally, the system can be put in working order in accordance with working requirement. 2 日常检查部位有以下几个方面2. The points needing routine inspection including the following aspects: 7、 油箱中的油量和油温 Amount and temperature of the oil in the oil tank8、 各密封部位、管接头等处的漏油情况 The oil leak at all sealing points and pipe joints and so on 9、 溢流阀的压力调节旋钮等主要部位的螺钉有无松动 Whether the pressure regulation knob of the overflow valves and other key parts are loose10、 各部位的温度 Temperature at all parts. 11、 过滤器的堵塞情况 Blockage of filter 12、 压力表等指示装置是否异常 Whether the indicating devices such as pressure meter is abnormal. 13、 电磁阀动作时的响声，电磁线圈的温度 Noise when the electromagnetic valve acts, and the temperature of electromagnetic coil. 四、维护与保养.Maintenance and Care即使是很好的液压设备，如果只使用而不注意维护保养，就会发生故障，而不得不停机检修。因此，日常的保养和检查就显得尤为重要。此外，保养还能使设备处于良好的性能状态，可以延长设备的使用寿命。Without maintenance or care, after a period of use, even the hydraulic equipments of high quality will break and have to be stopped for overhaul. Therefore, it is particularly important to carry out routine maintenance and inspection.1、 冬季室内油温未达到25时，不准开始顺序动作，夏季油温高于60时，要注意系统的工作状况，并通知维修人员进行处理。In winter, when the oil temperature indoor is lower than 25, it is not allowed to start serial action; in summer, when the oil temperature is higher than 60, attention shall be paid to the working condition of the system and the maintenance personnel shall treat it after on short notice. 2、 停机四小时以上的设备，应先使泵空载运转五分钟，再起动执行机构工作。For the equipment in halt for more than 4 hours, the execute machine shall be started after a five-minute no-load running of pump.3、 各种液压元件未经主管部门同意，任何人不准私自调节或拆换。Without permission of department in charge, anyone is not allowed to regulate or dismantle or replace any hydraulic component. 4、 当液压系统出现故障时，不准擅自乱动，应立即通知维修部门分析原因并排除。When the hydraulic system breaks down, it is not allowed to tamper with it, and the maintenance department shall be immediately informed to analyze the causes and remove the fault. 5、 初次使用液压系统半年更换一次液压油，以后每一年更换一次液压油。For the first use of hydraulic system, the hydraulic oil shall be replaced every half a year; afterwards, the hydraulic oil shall be replaced once a year. 6、 定期对液压系统的元件、辅件进行检查。定期检查内容及方法见后面：五.6项 Carry out regular inspection on the components and auxiliaries of the hydraulic system, and the approaches for regular inspection are shown below in section (6). 五 常见故障及排除方法. Common Failures and Solutions 、 液压泵1. Hydraulic pump故障Failure原 因Cause排除方法Solution泵不出油Inactive pump传动泵的电机转向错误Wrong rotation of transmission pump motor立即停止、更正电机方向Stop immediately and correct the direction of the motor泵没有转动No rotation of pump检查联轴器No rotation of pump油箱内的液面太低Too low liquid surface inside the tank.加入适量的液压油Add suitable amount of hydraulic oil吸油管或过滤器堵塞Blocked oil suction pipe or filter清洗过滤器及吸油管、去除杂物Wash them to remove debris从吸油管吸入空气Air intaken from oil suction pipe检查何处漏气，并修理Check for air leakage and repair油泵转速太低Too low oil pump rotation speed提高转速Increase the speed油液粘度太高Too high oil viscosity使用推荐的液压油Use the recommended hydraulic oil泵轴折断Pump shaft fracture修理泵、确认转数、压力是否超规轴心是否对准Repair the pump and check for the super-normal number of revolution and pressure and for the alignment of axle center吸入管堵塞Suction pipe blocked检查吸入管路Check the suction pipe吸油过滤器容量不足Under capacity of oil absorption filter更换大于泵排量2倍以上Use a pump with two times output for replacement叶片不能滑出The blade cant slide out.修理泵Repair the pump泵不升压Pump without boos因上述原因油泵不出油Inactive pump because of the above causes按上述方法进行处理According to the above method for processing溢流阀调定压力太低Too low overflow valve set pressure调整溢流阀的压力Adjust the overflow valve pressure溢流阀阀座被杂物卡死Overflow valve seat jammed清除溢流阀阀座上的杂物Remove the debris from the overflow valve seat系统中有泄漏Oil leakage in the system对系统进行顺次试验检查Test and check the system in succession系统中的油自由流回油箱Oil in the system flows back to the tank检查系统中的各处截止阀是否关闭，换向阀是否在正常位置Check the shutoff valves of the system for close-down and reversing valve for normal position端盖未能拧紧End cover not screw-down紧固螺钉Fastening the screws泵内泄Internal leakage of pump更换Change it into a new one漏油Oil leakage油的粘度太低Too low oil viscosity检查并更换液压油Check and change the hydraulic oil密封圈损坏Failure of sealing rings检查并更换密封圈Check and change the sealing rings动作不良 Poor operation 起动时或寒冷时动作不良Poor operation when starting or cold油液粘度太高，更换合适的液压油The oil viscosity is too high, replace with appropriate hydraulic oil随温度上升，速度下降Speed decreases as temperature rises泵的压力低，阀、缸内泄大并检查速度控制的节流分路The pressure of pump is low; the leakage in the valve and cylinder is too much. Check the speed controlled throttling shunt.跳动Move up and down油量不足，混入空气，密封圈压的太紧，并排除之The oil is not enough with air and the sealing rings are crowded too tight. Solve them.速度低时速度不稳The speed is instability at low speed.节流阀开度太小，节流口损伤，排除或更换液压油Throttle valve opening is too small, throttles mouth is damaged. Solve it and change hydraulic oil.泵有噪音Pump with noises泵有噪音Pump with noises油箱过滤器堵塞Blocked tank filter清洗过滤器Wash the filter在双联泵时吸入管错误Suction pipe error in double pump修理配管Repair piping吸油管吸入空气Air intaken from oil suction pipe认真检查，堵漏Check carefully and make leak stoppage吸油管部分堵塞Suction pipe partially blocked清除杂物使其通畅Remove sundry to make it smooth泵的端盖螺钉太松The end cover screw of pump is too loose拧紧螺钉直至噪音停止Tighten the screws up until the noise stopped超出规定转数Beyond the specified number of rotation检查转数Check it超出规定压力Beyond the specified pressure检查压力Check it泵破损Pump damaged更换泵Change the pump配油盘有杂物堵塞Oil distribution casing jammed借助说明书拆卸并清除脏物Disassembly and remove the debris according to instruction manual油中有气泡There are bubbles in the oil.检查回油管出口是否没入油中，加长回油管Check whether the oil return pipe outlet is immergeed in the oil or not and extend it.油的粘度太高Too high oil viscosity选用合适的液压油Use proper hydraulic oil内部泄漏过大Too much internal leakage检查阀、缸的泄漏情况Check the valve and cylinder for leakage工作压力太高Too high work pressure检查压力表及溢流阀灵敏度Check the sensitivity of pressure gauge and overflow valve散热不良Poor heat emission检查油路是否短路，冷却器通油状况是否正常Check the hydraulic system for short circuit and oil cooler for normal operation卸荷回路动作不良Poor relief circuit operation检查电气回路、电磁阀、先导回路、卸载阀回路是否正常Check the electric circuits, electromagnetic valve, pilot loop and unloading valve loop for normal operation油量不足The oil is not enough.加油至适量Add oil to suitable amount、 换向阀2. Reversing valve 故障Failure原 因Cause排 除 方 法Solutions操纵阀不能动作Control valvecant operate阀被堵塞Valve blocked拆开清洗Demount and clean阀体变形Valve body deformation重新安装，使螺钉压紧力均匀Reinstall and make screws compressing force uniform弹簧折断（有中位的阀）Spring broken-off（valve with meso-position）更换弹簧Change the spring操纵压力不够（电液阀）Insufficient operation pressure（electro-hydraulic valve）操纵压力必须大于0.35MPa。中间位置卸荷式，请在回油路设置单向阀以产生背压Operation pressure must be more than 0.35 MPa. When off-loading at mid position, please set one-way valve in the outlet oil line to produce back pressure电磁阀线圈烧坏Electromag-neticvalvecoilsburnout电磁铁损坏Electromagnet failure更换电磁铁Change the electromagnet电压太低Too low voltage调整电压在额定电压的10%以内Adjust the voltage within 10% of the rated voltage换向压力超过规定Supernormal reversing pressure降低压力Reduce the pressure换向流量超过规定Supernormal reversing flow换通径更大的阀Change it into a valve with bigger diameter回油孔有背压Oil return hole with back pressure检查背压是否在规定范围之内Checkup whether the back pressure is within the specified range or not粉尘阻滞阀运动The operation of the valve is retarded by dust.拆卸清洗Demount and wash因弹簧折断无法Because of the spring fracture更换弹簧Change the spring复位Reset松开螺栓交替上紧Loosen bolts and tighten them up alternately阀芯不动或迟缓Fixed or delayed valve core检查电气系统Check up the electric system电气系统不良负荷电压错误Poor electrical system Load voltage error检查电压，使用适当电磁线圈Check up the voltage and use proper magnet coil液控阀不动作Hydraulic controlled valves do not operate.液控压力不足Insufficient hydraulic controlled pressure提高压力或加背压阀Reinforce the pressure or enhance counterbalance valve阀芯胶着Valve cor