碎煤机液压站使用说明书SY8

1、SY8型碎煤机液压站使用说明书SY8型碎煤机液压站SY8 HYORAULIC STATION OF COAL CRUSHER 使用说明书OPERATIONAL INSTRUCTION山西电力设备厂SHANXI ELECTRIC POWER EQUIPMENT FACTORY 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5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

2、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/minbarCB-FA10C-FL8.1978.5电动机型号功率转速电压KWr/minVY100L-6(V1)1.5940380系统流量压力L/minbar6.82562.5油箱有效容积L60±10溢流阀调节范围工作标压barbar7014075液压油牌号用量kg30#机械油50±9.5表2 驱动油缸性能碎煤机型号HCSZ-100HCSZ-200HCSZ-300HCSZ-500HCSZ-700HCSCHCSC6HCSZ-600H

3、CSZ-800SPM-14系列SPM-16系列HCSC81012系统图油缸组号油缸内径活塞杆径mmmm502863358045 10055 12570作用面积推出端拉回端cm2cm219.6413.4831.1721.1750.2734.3778.5453.91122.7284.23单缸驱动力进程推力tfKN1.4914.592.3823.373.1430.794.9148.117.6775.17回程拉力tfKN1.0310.11.6516.162.1521.053.3733.025.6351.594 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

4、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5.1 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。5.2 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。5.3 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

5、。5.4 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。5.5 电机停转后重新起动时，需间隔一分钟方可进行。5.6 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14 0bar。5.7 工作油的粘度为1738厘斯（2.55°E），推荐采用30#机油。5.8 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。5.9 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。5.10 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。6

6、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

7、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7 附：液压系统图 性能参数项目单位数据额定流量L/min8.19标定压力bar75功率KW1.5转速r/min940液压用油30#机油油箱加油量L60±1012EF1-25空气滤清器Q=66L/min,滤面80cm2,精度0.9mm1温州轻纺机械厂11JB1957-77卡套式压力表管接头G6 M14*1.51上海液压附件厂10Y-60压力表P=0160bar1阳泉仪表厂9Q/ZB275-77快速接头

8、（两端开闭）Dg=10mm,P=320bar,Q=40L/min2上海液压附件厂8JB1885-77胶管总成A型扣压式，13-3000，P=200bar2上海液压附件厂7LDF-L10c单向节流阀Dg=10mm,P=140bar,Q=25L/min2榆次液压件厂634SM-B10H-T手动换向阀Dg=10mm,P=315bar,Q=40L/min1上海液压件一厂5YF-B10H-y1溢流阀Dg=10mm,P=70210bar,Q=40L/min14CB-FA10c-FL齿轮油泵P=140bar,n=1800r/min,q=11.27ml/r1榆次液压件厂3Y100L-6（V1）电动机N=1.5

9、KW,n=940r/min,U=380V12WU-63*80-J吸油口滤清器Dg=25mm，Q=63L，精度80um1上海高行液压件厂1SY8.3油箱箱内492*412*4951序号代号名称规格数量备注SY8型碎煤机液压站SY8-SM使用说明书液压系统图山西电力设备厂OPERATING INSTRUCTIONSFORTYPE SY8 HYORAULIC STATION OF COAL CRUSHERSHANXI POWER EQUIPMENT PLANT 1. Designation of type are as follows: S Y 8 Rate flow shown in integr

10、al part Initial letter of Chinese phonetic alphabet for Hydraulic Station Initial letter of Chinese phonetic alphabet for coal crusher 2. Applications Type SY8 hydraulic station of coal crusher is a matched product of the HCS series ring hammer coal crusher. It is used to actuate the hydraulic cylin

11、ders to open and close the front and rear machine covers and reset the screen deck frame so as to be convenient for inspection and repair of the coal crusher. This hydraulic station can be also used for inspection and repair of other equipment or where weights are necessary to be supported. 3. Techn

12、ical specifications Technical parameters of the hydraulic system of the hydraulic station and performance of the activating cylinders are shown separately in Table 1 and Table 2.Table 1 Technical Parameters of Hydraulic SystemItemsUnitDataItemsUnitDataHydraulic pumpTypeFlowPressureL/minMPaCB-FA10C-F

13、L8.197.85Electric motorTypePowerSpeedVoltageKWr/minVY100L-6(V1)1.5940400SystemFlowPressureL/minMPa6.8256.25Effective tank areaL60±10Relief valvePressure regulating scopeNominal operating pressure MPaMPa7147.5Hydraulic oilGradeOil quantity usedkg#30 machine oil57±9.5Table 2 Performance of A

14、ctivating cylindersTypes of coal crushersHCSZ-300HCSP-400HCSQ-700HCSC6HCSC81012Cylinder set No. in the hydraulic circuit diagramInner diameters of hydraulic cylindersPiston rod diametersmmmm63358045 10055 12570Action areaPushing endPulling endcm2cm231.1721.1750.2734.3778.5453.91122.7284.23Actuating

15、force of single cylinderPush on advancing stroketfKN2.3823.373.1430.794.9148.117.6775.17Pull on returning stroketfKN1.6516.162.1521.053.3733.025.6351.59 4. Construction and working principle The hydraulic station is consisted of suction filter, gear pump, relief valve, hand operated directional valv

16、e, one-way throttle valve, hose assembly, quick-release couplings pressure meters and switches, oil pipes, oil tank air filters, etc. When the gear pump is rotated by a AC electric motor through a claw coupling, the pressure oil is brought into a relief valve where the normal pressure is indicated b

17、y a pressure meter. A type M directional valve is used for changing the directions of actuators (hydraulic cylinders) for their advancing and returning strokes. The one-way throttle valve can change the working speed by means of restriction speed regulation. The oil in the return line and remaining

18、oil in the relief valve shall be collected and returned to the oil tank through the discharging opening. 5. Operation and maintenance 5.1 In accordance with the hydraulic system diagram and Table 2 and the construction of the hydraulic cylinders for actuating the coal crusher, the quick-release coup

19、lings and nylon washers shall be connected to the connections of the hydraulic cylinders and the couplings of the line shall be checked for their reliability. 5.2 The electric motor for hydraulic pump shall be inspected for its correct rotating direction. View from the shaft end, the motor shall be

20、rotated clockwise. 5.3 Before starting the oil level of the tank shall be over the oil gauge. After starting the oil level shall be in the oil gauge at a visible opposition. When the oil level can not be found from the oil gauge, oil shall be supplemented in the tank, as shown in the following figur

21、e. Oil levelL1=L/2±5mmUpDown 5.4 The electric motor shall be slowly rotated (or the motor is started repeatedly) to unload the discharging pipe line so as to remove air in the pump body and the pipe line. 5.5 When the electric motor is re-started after it stops, it shall be carried out after on

22、e minute interval. 5.6 The pressure of relief valve shall be adjusted to 7.5MPa, when the more high pressures are required, appropriate adjustment shall be made. It is now allowed to exceed 14 MPa. 5.7 The viscosity of the working oil shall be from 17 centistoke to 38 centistoke (2.55°E) #30 ma

23、chine oil is recommended to use. 5.8 The normal oil temperature shall be from 10 to 60. When oil temperature is below 0 at starting, the working oil shall be warmed up. The machine shall be started when oil temperature reach 5. 5.9 Oil shall be filled to the oil tank from air filter, in which the st

24、rainer has a filtration size of 120 meshes/inch. 5.10 The working oil shall be checked at regular intervals for its colour, transparency, settling material, smell and so on. If the oil is deteriorated or polluted badly, it shall be changed in time. As a rule, oil shall be changed once a year. 6. Mal

25、functions and eliminationSer.No.MalfunctionsCausesElimination1Although the oil pump is discharged, but the operating pressure can not be met1. The relief valve is operated improperly.2. There are no load in the hydraulic circuit.3. Oil leakage are found in the system1. The valve body shall be dismou

26、nted for inspection and repair.2. The hydraulic circuit shall be inspected and loaded.3. The pipe line shall be inspected to prevent from leakage.2There are pressure in the pump but oil can not be discharged or the volume efficiency is cut down.1. The sealings in the pump may be damaged.2. Sucked-in

27、 foreign material produce abnormal friction in the sliding part.1. The manufacturers shall be brought into contact for repair.2. Inspection shall be carried out to eliminate foreign material.3Excessive noise are found1. The suction line is too thin.2. The filter at the suction inlet is blocked.3. Ai

28、r are sucked in the suction line or other parts.4. There are air bubbles in the oil tank.5. The oil level is too low in the oil tank.6. The installation foundation is short of rigidness.7. The speed and pressure exceed the specified values.8. There is a big noise at the coupling.1. The oil pipe or h

29、ose with bigger diameters shall be replaced.2. Cleaning and washing shall be carried out.3. The suction line shall be filled with oil to find the improper positions.4. The return oil line shall be inspected to prevent from producing bubbles.5. Oil shall be filled to the specified level.6. The rigidn

30、ess of the installing foundation shall be improved.7. The speed, pressure and oil circuit shall be inspected.8. The coupling shall be checked for damage or excessive misalignment.4Heating is produced in the oil pump1. The volume efficiency is improper or air enter into the pump.2. The bearing is wor

31、n.3. Viscosity of oil is too high, lubrication is improper and oil is polluted badly.1. Air shall be exhausted and volume efficiency shall be improved.2. New bearing shall be replaced.3. Oil shall be changed or replaced.PerformanceActuating cylinder setsItemsUnitDataType of coal crusherNumber of hyd

32、raulic cylinder setsAssembly drawing No. of hydraulic cylindersRate flowL/min8.19HCSZ-300HCSQ-300-10.00.00NormalPressureMpa7.5HCSP-400HCSP-700HCSQ-700-01-00PowerKW1.5HCSC6HCSC6.9(2)Speedr/min940HCSC8HCSC8-09.00.00HydraulicOil#30machine oilHCSC12HCSC12-11.00.00Tank filling CapacityL60±10Notes: -Front cover cylinder -Rear cover cylinder The hydraulic station driving shall be provided accord