碎煤機(jī)液壓站使用說明書SY8

SY8型碎煤機(jī)液壓站SY8HYORAULICSTATIONOFCOALCRUSHER使用說明書OPERATIONALINSTRUCTION山西電力設(shè)備廠SHANXIELECTRICPOWEREQUIPMENTFACTORY目錄１.型號(hào)意義………………2２.用途………………………2３.技術(shù)規(guī)格…………………2４.結(jié)構(gòu)與工作原理…………………………3５.操作和保養(yǎng)………………3６.故障及排除方法…………………………4７.附：液壓系統(tǒng)圖…………………………5１型號(hào)意義ＳＹ８液壓站液壓站“液”漢語拼音首字母碎煤機(jī)“碎”漢語拼音首字母額定流量整數(shù)部分?jǐn)?shù)據(jù)２用途SY8型碎煤機(jī)液壓站為HCS系列環(huán)錘式碎煤機(jī)配套產(chǎn)品。主要用于驅(qū)動(dòng)該機(jī)液壓缸，以啟閉前后機(jī)蓋，便于碎煤機(jī)檢修。本液壓站也可用于其余機(jī)械設(shè)備檢修或需要承重場(chǎng)所。３技術(shù)規(guī)格液壓站液壓系統(tǒng)參數(shù)及驅(qū)動(dòng)油缸性能分別見表１和表２表1液壓系統(tǒng)參數(shù)項(xiàng)目單位數(shù)據(jù)項(xiàng)目單位數(shù)據(jù)油泵型號(hào)流量壓力L/minbarCB-FA10C-FL8.1978.5電動(dòng)機(jī)型號(hào)功率轉(zhuǎn)速電壓KWr/minVY100L-6(V1)1.5940380系統(tǒng)流量壓力L/minbar6.82562.5油箱有效容積L60±10溢流閥調(diào)整范圍工作標(biāo)壓barbar70~14075液壓油牌號(hào)用量kg30#機(jī)械油50±9.5表2驅(qū)動(dòng)油缸性能碎煤機(jī)型號(hào)HCSZ-100HCSZ-200HCSZ-300HCSZ-500HCSZ-700HCSCHCSC6HCSZ-600HCSZ-800SPM-14系列SPM-16系列HCSC81012系統(tǒng)圖油缸組號(hào)油缸內(nèi)徑活塞桿徑mmmmⅠ5028Ⅰ6335Ⅰ8045ⅠⅡ10055ⅠⅡ12570作用面積推出端拉回端cm2cm219.6413.4831.1721.1750.2734.3778.5453.91122.7284.23單缸驅(qū)動(dòng)力進(jìn)程推力tfKN1.4914.592.3823.373.1430.794.9148.117.6775.17回程拉力tfKN1.0310.11.6516.162.1521.053.3733.025.6351.59結(jié)構(gòu)與工作原理液壓站由吸油口濾油器、齒輪油泵、溢流閥、手動(dòng)換向閥、單向節(jié)流閥、膠管總成，快速接頭，壓力表及開關(guān)、油管、油箱、空氣濾清器等元件組成。交流電動(dòng)機(jī)經(jīng)過爪形聯(lián)軸器帶動(dòng)齒輪泵旋轉(zhuǎn)，壓力油進(jìn)入溢流閥由壓力表顯示標(biāo)定壓力，M型換向閥實(shí)現(xiàn)執(zhí)行元件（油缸）進(jìn)程和回程油路換向。單向節(jié)流閥以節(jié)流調(diào)速改變工作速度。回油路油液及溢流閥余油聚集后經(jīng)連接塊溢流口流回油箱。操作和保養(yǎng)依照液壓系統(tǒng)圖及表2，按照所要驅(qū)動(dòng)碎煤機(jī)液壓缸，將快速接頭體Ⅰ及尼龍墊圈與油缸接頭相聯(lián)接。而且檢驗(yàn)管路各接頭是否可靠。檢驗(yàn)油泵電機(jī)轉(zhuǎn)向是否正確。從軸頭方向觀察應(yīng)為順時(shí)針方向旋轉(zhuǎn)。起動(dòng)前油箱油面應(yīng)位于油標(biāo)上端。起動(dòng)后油面應(yīng)處于油標(biāo)中可視位置。若從油標(biāo)中看不到油面時(shí)應(yīng)補(bǔ)充油，見下列圖。緩緩轉(zhuǎn)動(dòng)電機(jī)（或重復(fù)起動(dòng)電機(jī)），使泵排出管卸載，排出泵體內(nèi)及管路中空氣。電機(jī)停轉(zhuǎn)后重新起動(dòng)時(shí)，需間隔一分鐘方可進(jìn)行。調(diào)整溢流閥壓力到75bar,若需要更高工作壓力時(shí)，可作對(duì)應(yīng)調(diào)整，但不允許超出140bar。工作油粘度為1738厘斯（2.55°E），推薦采取30#機(jī)油。正常油溫為1060℃，當(dāng)起動(dòng)時(shí)油溫低于0℃，要對(duì)工作油預(yù)熱，待油溫升至5℃方可進(jìn)行。從空氣濾清器向油箱內(nèi)注漬，其濾網(wǎng)過濾精度主為120目/寸。應(yīng)定時(shí)取樣檢驗(yàn)工作油顏色、透明度、沉淀物及氣味等，若油變質(zhì)或嚴(yán)重污染，應(yīng)及時(shí)更換。通常每一年應(yīng)更換一次。故障及排除方法序號(hào)故障性質(zhì)產(chǎn)生原因排除方法1油泵排油，但達(dá)不到工作壓力溢流閥動(dòng)作不良油壓回路無負(fù)荷系統(tǒng)漏油拆卸閥體檢驗(yàn)修復(fù)檢驗(yàn)油路加負(fù)荷檢驗(yàn)管道阻止泄漏2有壓力但不排油或者容積效率下降泵內(nèi)密封件損壞吸入異物在滑動(dòng)部分產(chǎn)生異常摩擦與制造廠聯(lián)絡(luò)進(jìn)行修理進(jìn)行檢驗(yàn)排除異物3噪聲過大吸入管太細(xì)吸油口濾油器堵塞吸入管或其余部位吸入空氣油箱內(nèi)有氣泡油箱內(nèi)油面過低泵安裝基礎(chǔ)剛性不足轉(zhuǎn)速和壓力超出要求值聯(lián)軸器噪聲大更換較大內(nèi)徑油管清洗向吸入管注油找出不良處檢驗(yàn)回油路預(yù)防發(fā)生氣泡加油到要求油面提升安裝基礎(chǔ)剛度檢驗(yàn)轉(zhuǎn)速、壓力及油路檢驗(yàn)聯(lián)軸器有沒有損傷或錯(cuò)位過大4油泵發(fā)燒容積效率不良，泵內(nèi)進(jìn)入空氣軸承磨損油粘度過高，潤滑不良油污嚴(yán)重排除空氣，提升容積效率更換新軸承更換新油附：液壓系統(tǒng)圖ⅠⅡ性能參數(shù)項(xiàng)目單位數(shù)據(jù)額定流量L/min8.19標(biāo)定壓力bar75功率KW1.5轉(zhuǎn)速r/min940液壓用油30#機(jī)油油箱加油量L60±1012EF1-25空氣濾清器Q=66L/min,濾面80cm2,精度0.9mm1溫州輕紡機(jī)械廠11JB1957-77卡套式壓力表管接頭G6M14*1.51上海液壓附件廠10Y-60壓力表P=0~160bar1陽泉儀表廠9Q/ZB275-77快速接頭（兩端開閉）Dg=10mm,P=320bar,Q=40L/min2上海液壓附件廠8JB1885-77膠管總成A型扣壓式，13Ⅱ-3000，P=200bar2上海液壓附件廠7LDF-L10c單向節(jié)流閥Dg=10mm,P=140bar,Q=25L/min2榆次液壓件廠634SM-B10H-T手動(dòng)換向閥Dg=10mm,P=315bar,Q=40L/min1上海液壓件一廠5YF-B10H-y1溢流閥Dg=10mm,P=70~210bar,Q=40L/min14CB-FA10c-FL齒輪油泵P=140bar,n=1800r/min,q=11.27ml/r1榆次液壓件廠3Y100L-6（V1）電動(dòng)機(jī)N=1.5KW,n=940r/min,U=380V12WU-63*80-J吸油口濾清器Dg=25mm，Q=63L，精度80um1上海高行液壓件廠1SY8.3油箱箱內(nèi)492*412*4951序號(hào)代號(hào)名稱規(guī)格數(shù)量備注SY8型碎煤機(jī)液壓站SY8-SM使用說明書液壓系統(tǒng)圖山西電力設(shè)備廠OPERATINGINSTRUCTIONSFORTYPESY8HYORAULICSTATIONOFCOALCRUSHERSHANXIPOWEREQUIPMENTPLANT

1.Designationoftypeareasfollows:SY8RateflowshowninintegralpartInitialletterofChinesephoneticalphabetforHydraulicStationInitialletterofChinesephoneticalphabetforcoalcrusher2.ApplicationsTypeSY8hydraulicstationofcoalcrusherisamatchedproductoftheHCSseriesringhammercoalcrusher.Itisusedtoactuatethehydrauliccylinderstoopenandclosethefrontandrearmachinecoversandresetthescreendeckframesoastobeconvenientforinspectionandrepairofthecoalcrusher.Thishydraulicstationcanbealsousedforinspectionandrepairofotherequipmentorwhereweightsarenecessarytobesupported.3.TechnicalspecificationsTechnicalparametersofthehydraulicsystemofthehydraulicstationandperformanceoftheactivatingcylindersareshownseparatelyinTable1andTable2.Table1TechnicalParametersofHydraulicSystemItemsUnitDataItemsUnitDataHydraulicpumpTypeFlowPressureL/minMPaCB-FA10C-FL8.197.85ElectricmotorTypePowerSpeedVoltageKWr/minVY100L-6(V1)1.5940400SystemFlowPressureL/minMPa6.8256.25EffectivetankareaL60±10ReliefvalvePressureregulatingscopeNominaloperatingpressureMPaMPa7～147.5HydraulicoilGradeOilquantityusedkg#30machineoil57±9.5

Table2PerformanceofActivatingcylindersTypesofcoalcrushersHCSZ-300HCSP-400HCSQ-700HCSC6HCSC81012CylindersetNhehydrauliccircuitdiagramInnerdiametersofhydrauliccylindersPistonroddiametersmmmmⅠ6335Ⅰ8045ⅠⅡ10055ⅠⅡ12570ActionareaPushingendPullingendcm2cm231.1721.1750.2734.3778.5453.91122.7284.23ActuatingforceofsinglecylinderPushonadvancingstroketfKN2.3823.373.1430.794.9148.117.6775.17PullonreturningstroketfKN1.6516.162.1521.053.3733.025.6351.594.ConstructionandworkingprincipleThehydraulicstationisconsistedofsuctionfilter,gearpump,reliefvalve,handoperateddirectionalvalve,one-waythrottlevalve,hoseassembly,quick-releasecouplingspressuremetersandswitches,oilpipes,oiltankairfilters,etc.WhenthegearpumpisrotatedbyaACelectricmotorthroughaclawcoupling,thepressureoilisbroughtintoareliefvalvewherethenormalpressureisindicatedbyapressuremeter.AtypeMdirectionalvalveisusedforchangingthedirectionsofactuators(hydrauliccylinders)fortheiradvancingandreturningstrokes.Theone-waythrottlevalvecanchangetheworkingspeedbymeansofrestrictionspeedregulation.Theoilinthereturnlineandremainingoilinthereliefvalveshallbecollectedandreturnedtotheoiltankthroughthedischargingopening.5.Operationandmaintenance5.1InaccordancewiththehydraulicsystemdiagramandTable2andtheconstructionofthehydrauliccylindersforactuatingthecoalcrusher,thequick-releasecouplingsⅠandnylonwashersshallbeconnectedtotheconnectionsofthehydrauliccylindersandthecouplingsofthelineshallbecheckedfortheirreliability.5.2Theelectricmotorforhydraulicpumpshallbeinspectedforitscorrectrotatingdirection.Viewfromtheshaftend,themotorshallberotatedclockwise.5.3Beforestartingtheoillevelofthetankshallbeovertheoilgauge.Afterstartingtheoillevelshallbeintheoilgaugeatavisibleopposition.Whentheoillevelcannotbefoundfromtheoilgauge,oilshallbesupplementedinthetank,asshowninthefollowingfigure.OillevelOillevelL1=L/2±5mmUpDown5.4Theelectricmotorshallbeslowlyrotated(orthemotorisstartedrepeatedly)tounloadthedischargingpipelinesoastoremoveairinthepumpbodyandthepipeline.5.5Whentheelectricmotorisre-startedafteritstops,itshallbecarriedoutafteroneminuteinterval.5.6Thepressureofreliefvalveshallbeadjustedto7.5MPa,whenthemorehighpressuresarerequired,appropriateadjustmentshallbemade.Itisnowallowedtoexceed14MPa.5.7Theviscosityoftheworkingoilshallbefrom17centistoketo38centistoke(2.5～5°E)#30machineoilisrecommendedtouse.5.8Thenormaloiltemperatureshallbefrom10℃to60℃.Whenoiltemperatureisbelow0℃atstarting,theworkingoilshallbewarmedup.Themachineshallbestartedwhenoiltemperaturereach5℃.5.9Oilshallbefilledtotheoiltankfromairfilter,inwhichthestrainerhasafiltrationsizeof120meshes/inch.5.10Theworkingoilshallbecheckedatregularintervalsforitscolour,transparency,settlingmaterial,smellandsoon.Iftheoilisdeterioratedorpollutedbadly,itshallbechangedintime.Asarule,oilshallbechangedonceayear.

6.MalfunctionsandeliminationSer.No.MalfunctionsCausesElimination1Althoughtheoilpumpisdischarged,buttheoperatingpressurecannotbemet1.Thereliefvalveisoperatedimproperly.2.Therearenoloadinthehydrauliccircuit.3.Oilleakagearefoundinthesystem1.Thevalvebodyshallbedismountedforinspectionandrepair.2.Thehydrauliccircuitshallbeinspectedandloaded.3.Thepipelineshallbeinspectedtopreventfromleakage.2Therearepressureinthepumpbutoilcannotbedischargedorthevolumeefficiencyiscutdown.1.Thesealingsinthepumpmaybedamaged.2.Sucked-inforeignmaterialproduceabnormalfrictionintheslidingpart.1.Themanufacturersshallbebroughtintocontactforrepair.2.Inspectionshallbecarriedouttoeliminateforeignmaterial.3Excessivenoisearefound1.Thesuctionlineistoothin.2.Thefilteratthesuctioninletisblocked.3.Airaresuckedinthesuctionlineorotherparts.4.Thereareairbubblesintheoiltank.5.Theoillevelistoolowintheoiltank.6.Theinstallationfoundationisshortofrigidness.7.Thespeedandpressureexceedthespecifiedvalues.8.Thereisabignoiseatthecoupling.1.Theoilpipeorhosewithbiggerdiametersshallbereplaced.2.Cleaningandwashingshallbecarriedout.3.Thesuctionlineshallbefilledwithoiltofindtheimproperpositions.4.Thereturnoillineshallbeinspectedtopreventfromproducingbubbles.5.Oilshallbefilledtothespecifiedlevel.6.Therigidnessoftheinstallingfoundationshallbeimproved.7.Thespeed,pressureandoilcircuitshallbeinspected.8.Thecouplingshallbecheckedfordamageorexcessivemisalignment.4Heatingisproducedintheoilpump1.Thevolumeefficiencyisimproperorairenterintothepump.2.Thebearingisworn.3.Viscosityofoilistoohigh,lubricationisimproperandoilispollutedbadly.1.Airshallbeexhaustedandvolumeefficiencyshallbeimproved.2.Newbearingshallbereplaced.3.Oilshallbechangedorreplaced.

PerformanceActuatingcylindersetsItemsUnitDataTypeofcoalcrusherNumberofhydrauliccylindersetsAssemblydrawingNo.ofhydrauliccylindersRateflowL/min8.19HCSZ-300ⅠHCSQ-300-10.00.00NormalPressureMpa7.5HCSP-400HCSP-700HCSQ-700-01-00PowerKW1.5HCSC6ⅠⅡHCSC6.9(2)Speedr/min940HCSC8ⅠⅡHCSC8-09.00.00HydraulicOil#30machineoilHCSC12HCSC12-11.00.00TankfillingCapacityL60±10Notes:Ⅰ-FrontcovercylinderⅡ-RearcovercylinderThehydraulicst