MGKZ125稀油站中英文使用手冊(cè)

1、稀油站使用手冊(cè)LUBRICATING STATION型號(hào)：MGKZ-125北京中冶邁克液壓有限責(zé)任公司BEIJING MECC HYDRAULIC目 錄安全說(shuō)明.正確使用.說(shuō)明.型號(hào)說(shuō)明.概述.工作原理.技術(shù)參數(shù).安裝.泵的安裝.電氣接線.操作規(guī)程.投入運(yùn)行.用于潤(rùn)滑時(shí)的投入運(yùn)行.壓力調(diào)節(jié).流量調(diào)節(jié).保養(yǎng)與維修.故障診斷.機(jī)參數(shù)表.附件：外形尺寸圖.電用戶手冊(cè)前言l 本用戶手冊(cè)是用來(lái)讓用戶熟悉元件/潤(rùn)滑系統(tǒng)并正確使用該系統(tǒng)。必須在元件/潤(rùn)滑系統(tǒng)使用的現(xiàn)場(chǎng)配備該手冊(cè)。必須讓所有負(fù)責(zé)該元件/潤(rùn)滑系統(tǒng)的人員閱讀和使用該手冊(cè)，如從事以下作業(yè)的人員：l 操作，包括運(yùn)行過(guò)程中的調(diào)節(jié)、故障診斷等、生產(chǎn)廢物的

2、清除、維護(hù)、加工材料的處理等。l 維護(hù) （檢查和維修）以及/更換l 運(yùn)輸 按包裝箱上的要求及示意圖l 對(duì)于那些看不懂英文資料的人員，在其運(yùn)行本設(shè)備 相關(guān)作業(yè)前，該元件/潤(rùn)滑系統(tǒng)的用戶必須告知其本 手冊(cè)內(nèi)容，特別是安全說(shuō)明。l 操作規(guī)程包括有關(guān)本元件/潤(rùn)滑系統(tǒng)安全、正確和經(jīng)濟(jì)運(yùn)行的重要信息。仔細(xì)閱讀這些內(nèi)容將有助于避免危險(xiǎn)的發(fā)生。降低維修成本并縮短檢修所造成的停工期。提高元件/潤(rùn)滑系統(tǒng)的可靠性并延長(zhǎng)其使用壽命。必須遵守關(guān)于事故預(yù)防及環(huán)境保護(hù)的相關(guān)國(guó)家法律法規(guī)中的規(guī)定。安全說(shuō)明l 操作規(guī)程中包含了在元件/潤(rùn)滑裝置在安裝、運(yùn) 人員資格認(rèn)定和培訓(xùn) 行或服務(wù)中所必須遵守的基本要求。因此，操作工人和專業(yè)人

3、士/用戶在安裝和運(yùn)行設(shè)備前，絕對(duì)有必要閱讀本操作規(guī)程。操作規(guī)程必須一直放在機(jī)器/系統(tǒng)所安裝的現(xiàn)場(chǎng)。l 必須閱讀這一關(guān)于安全的主要章節(jié)中所包含的所有基本安全說(shuō)明以及其他主要章節(jié)所給出的特殊安全說(shuō)明。操作規(guī)程中的危險(xiǎn)標(biāo)識(shí)標(biāo)準(zhǔn)DIN 4844-W9規(guī)定的安全標(biāo)識(shí)符號(hào)l 上述符號(hào)表示若不遵守操作規(guī)程中的該條規(guī)定，可能會(huì)人身傷害。標(biāo)準(zhǔn)DIN 4844-W9規(guī)定的安全標(biāo)識(shí)符號(hào)l 該符號(hào)表示帶電。CAUTIONl 該符號(hào)表示警告，若不遵守該安全說(shuō)明可能會(huì)導(dǎo)致機(jī)器損壞或故障。l 必須注意那些標(biāo)識(shí)在設(shè)備上的警告內(nèi)容，且必須保持這些警告內(nèi)容清晰可讀。l 負(fù)責(zé)操作、維護(hù)、檢查和安全的人員必須有資格擔(dān)任這些工作。l

4、用戶必須正確的管理操作人員所負(fù)責(zé)的責(zé)任和監(jiān)督區(qū)域。l 如果這些人沒(méi)有掌握所必須的技能，那么他們就需要接受適當(dāng)?shù)呐嘤?xùn)和指導(dǎo)。如果有必要，這一工作可由制造商/設(shè)備供應(yīng)商代表機(jī)器使用者開(kāi)展。l 此外，用戶必須確保操作人員完全理解了本操作規(guī)程的內(nèi)容。因?yàn)闆](méi)有閱讀安全規(guī)程所導(dǎo)致的危險(xiǎn)l 沒(méi)有注意安全警告將可能導(dǎo)致設(shè)備和環(huán)境的損壞以及/或人身傷害。l 沒(méi)有閱讀安全注釋可能會(huì)導(dǎo)致設(shè)備損壞的所有索賠權(quán)的喪失。l 作為舉例，我們?cè)谙旅媪谐隽艘恍┮驗(yàn)闆](méi)有認(rèn)真閱讀警告而可能帶來(lái)的危險(xiǎn)：機(jī)器/系統(tǒng)無(wú)法實(shí)現(xiàn)重要功能的故障無(wú)法進(jìn)行特定的維護(hù)與維修方法由于電、機(jī)械和化學(xué)影響所帶來(lái)的人身傷害由于有害物質(zhì)的泄露而造成對(duì)環(huán)境的危

5、害具備安全意識(shí)的工作必須遵守本操作規(guī)程中所給出的安全說(shuō)明。為避免造成事故而制定的現(xiàn)行國(guó)家法律法規(guī)。任何工作和工廠規(guī)章制度和事故預(yù)防措施。用戶/操作人員安全說(shuō)明l 如果熱的/冷的機(jī)械部件可能存在危險(xiǎn)，那么客戶必須防止意外接觸情況。l 在機(jī)器運(yùn)行時(shí)，不得卸開(kāi)運(yùn)行部件的保護(hù)裝置。l 對(duì)有害物質(zhì)泄露的處理不得對(duì)環(huán)境和人員造成傷害。必須遵守法律的要求。l 因電流所造成的其他危險(xiǎn)。維護(hù)、檢查和安裝工作的安全說(shuō)明l 用戶必須確認(rèn)由已完整閱讀本操作規(guī)程的得到授權(quán)的有資格的專業(yè)人員執(zhí)行所有維護(hù)、檢查和安裝工作。l 機(jī)械運(yùn)行時(shí)絕不要對(duì)機(jī)器進(jìn)行任何次類(lèi)操作。遵守本操作規(guī)程中所描述的關(guān)閉機(jī)器的所有要求。l 在完成清潔

6、程序后立刻重新組裝所有安全和保護(hù)設(shè)備。清潔泵和泵組中傳送有害物質(zhì)的部分。根據(jù)適用的政府法律法規(guī)執(zhí)行有害物質(zhì)的處理。在運(yùn)行泵/泵組前，確保已滿足“運(yùn)行”部分中所給出的所有要求。未經(jīng)授權(quán)的改裝和部件制造l 只有在得到制造商允許的情況下，才能對(duì)機(jī)器進(jìn)行改造和改裝。只有得到制造商認(rèn)可的原廠部件和附件能夠確保安全運(yùn)行。l 如果使用了其他部件，制造商將不對(duì)所帶來(lái)的后果負(fù)任何責(zé)任。不允許的運(yùn)行方式l 我們只保證在符合“正確使用”部分中提給出的要求下的操作中產(chǎn)品操作安全。不得超過(guò)技術(shù)數(shù)據(jù)中所列出的最大額定值。l 由于電壓?jiǎn)栴}，禁止在東南亞國(guó)家使用本產(chǎn)品，如需使用，得通過(guò)廠家確認(rèn)更改電機(jī)電壓后方可使用。正確使用

7、l MGKZ-*型稀油潤(rùn)滑站是專為減速箱齒輪、傳動(dòng)軸承等稀油潤(rùn)滑設(shè)計(jì)的。l 不得超出技術(shù)參數(shù)中所提到的最大額定值，特別是高壓不得超出320bar的工作壓力，低壓不得超出8bar的最大工作壓力。l 正常工作溫度在400C500C內(nèi)，不得長(zhǎng)時(shí)間低溫或高溫的情況下運(yùn)行。l MGKZ-*型稀油潤(rùn)滑站有多種型號(hào)可供選擇，適于多個(gè)領(lǐng)域的應(yīng)用，如：鋼鐵行業(yè)設(shè)備輸送設(shè)備建材機(jī)械，橡膠塑料行業(yè)設(shè)備l 任何其他的應(yīng)用都不符合本規(guī)范，且我們將不對(duì)其他應(yīng)用的損失索賠作保證和責(zé)任承擔(dān)。 說(shuō) 明型號(hào)說(shuō)明：l 整個(gè)稀油站型號(hào)上的編碼進(jìn)行定義型號(hào)編碼舉例：MGKZ-125-*-*-* 其中MGKZ表示為高低壓稀油站，后面的1

8、25表示低壓流量，后面的星號(hào)的值為高壓泵的流量。如果低壓出口與高壓出口的數(shù)量超出一個(gè)時(shí)只需要在后面注明，前面是低壓出口數(shù)量，后面是高壓出口數(shù)量。注：如有其他特殊要求請(qǐng)?jiān)谟嗀浨霸敿?xì)說(shuō)明，無(wú)其他說(shuō)明則按標(biāo)準(zhǔn)配置生產(chǎn)設(shè)備。該述：l 我們MGKZ-125型稀油站主要適用于稀油循環(huán)潤(rùn)滑系統(tǒng)，它向減速機(jī)、齒輪座等摩擦部位供送潤(rùn)滑油。我公司生產(chǎn)的稀油站不僅符合Q/ZB355-77重機(jī)標(biāo)準(zhǔn)，其性能均優(yōu)級(jí)于原重機(jī)標(biāo)準(zhǔn)的稀油站。尤其是儀表盤(pán)、電控柜內(nèi)的主要元器件質(zhì)量和性能優(yōu)于原重機(jī)標(biāo)準(zhǔn)的稀油站。l 該稀油站工作介質(zhì)的粘度等級(jí)為N22N320工業(yè)潤(rùn)滑油，本油站通常安裝在主機(jī)附近的地下油庫(kù)內(nèi)或地平面。 工作原理MGK

9、Z-125型高低稀油站由油箱、低壓油泵裝置、高壓泵裝置、過(guò)濾器（雙筒網(wǎng)式油濾器）、列管式油冷卻器、儀表裝置、管道、閥門(mén)等組成。MGKZ-125型稀油站為整體式小型高低壓稀油站。本高低壓稀油站MGKZ-125工作時(shí)，油液由低壓齒輪泵從油箱吸出，經(jīng)單向閥、雙筒網(wǎng)式油濾器、列管式油冷卻器直接送到設(shè)備的潤(rùn)滑點(diǎn)。油站的低壓泵裝置的最高工作壓力為0.4MPa，最低工作壓力為0.1MPa。根據(jù)潤(rùn)滑點(diǎn)的要求，通過(guò)調(diào)節(jié)安全閥確定使用壓力，當(dāng)油站工作壓力超過(guò)安全閥的調(diào)定壓力時(shí)，安全閥打開(kāi)，多余的油液流回油箱；同時(shí)由高壓泵從油箱吸出油液，經(jīng)單向閥、分流裝置直接送到設(shè)備的潤(rùn)滑點(diǎn)，油站的高壓泵裝置的最高工作壓力為31.

10、5MPa，當(dāng)壓力達(dá)到31.5MPa時(shí)安全閥打開(kāi)，從而使設(shè)備的最高壓力不超過(guò)最高壓力31.5MPa的值。稀油站的結(jié)構(gòu)有如下特點(diǎn)：l 稀油站設(shè)有兩臺(tái)低壓油泵，一用一備，正常情況下工作泵運(yùn)行，當(dāng)系統(tǒng)壓力低于0.1MPa時(shí)，備用泵開(kāi)始工作，保證向主機(jī)供送潤(rùn)滑油。l 稀油站設(shè)有兩臺(tái)高壓油泵，一用一備，正常情況下工作泵運(yùn)行，當(dāng)系統(tǒng)壓力低于3MPa時(shí)，備用泵開(kāi)始工作，保證向主機(jī)供送潤(rùn)滑油。l 采用雙筒網(wǎng)式濾油器，該濾油器有兩組過(guò)濾濾芯，一組工作，一組備用。當(dāng)工作濾芯壓差超過(guò)0.05MPa需更換時(shí)，人工調(diào)整轉(zhuǎn)換閥使備用濾芯工作，同時(shí)更換原工作濾芯。此種濾油器結(jié)構(gòu)緊湊、不設(shè)旁路、更換方便。l 回油口設(shè)有磁性過(guò)濾

11、裝置，可將回油中的細(xì)小鐵磁物質(zhì)吸附過(guò)濾，保證油液的清潔度。l 儀表盤(pán)定位安裝在稀油站正面左上方，兩只耐震壓力表可直接觀察油站出口油壓及油泵油壓；壓力變送器控制油站出油口油壓并實(shí)現(xiàn)對(duì)油站的自控與監(jiān)控；E+H壓差發(fā)訊器用來(lái)檢測(cè)雙筒網(wǎng)式濾油器的壓差。l 電控箱（不在供貨范圍內(nèi)）可實(shí)現(xiàn)自動(dòng)控制及機(jī)旁操作，低壓油泵正常工作時(shí)，一臺(tái)工作，一臺(tái)備用，由于低壓油泵或設(shè)備原因造成系統(tǒng)壓力下降到調(diào)定值時(shí)，通過(guò)壓力變送器控制，備用泵自動(dòng)啟動(dòng)替代原工作泵工作，原工作泵待工作壓正常后停泵（其延時(shí)時(shí)間根據(jù)現(xiàn)場(chǎng)情況決定）。當(dāng)壓力繼續(xù)下降到另一調(diào)定值0.05MPa時(shí)，發(fā)出事故報(bào)警并命令主機(jī)停機(jī)。油站出油口裝有熱電阻對(duì)出口油溫

12、進(jìn)行控制，當(dāng)油溫>45時(shí)，冷卻水閥接通；當(dāng)油溫>60時(shí)，主機(jī)停機(jī)并報(bào)警。當(dāng)油箱油溫低于17時(shí)，接通電加熱器，當(dāng)油溫升至40時(shí)，自動(dòng)切斷加熱器。l 油站采用隔離式加熱方式，電加熱器采用帶護(hù)套式的加熱器，避免了直接加熱時(shí)因局部加熱測(cè)試過(guò)高使?jié)櫥妥冑|(zhì)而影響潤(rùn)滑油的性能。稀油站的系統(tǒng)原理圖及外形圖詳見(jiàn)聯(lián)附圖。安裝、調(diào)試及試運(yùn)轉(zhuǎn)l 整體式稀油站安放在地面上，無(wú)須地腳堅(jiān)固。l 接管前，先將管子酸洗、除銹、中和，再用凈水沖洗，最后用壓縮空氣吹干。l 整體式稀油站已在制造廠進(jìn)行性能試驗(yàn)。幫在現(xiàn)場(chǎng)安放平衡，即可連接出油管、回油管、水管等，現(xiàn)場(chǎng)安裝完畢后，用濾油車(chē)過(guò)濾加油，經(jīng)試運(yùn)轉(zhuǎn)正常后即可投入工作

13、。操作規(guī)程l 根據(jù)工藝要求如工作油溫低于17時(shí)，開(kāi)啟電加熱器交油加熱。l 將雙筒網(wǎng)式濾油器的換向閥定位在其中一個(gè)過(guò)濾濾芯工作位置上，打開(kāi)稀油站相應(yīng)的油、水閥門(mén)和壓力表開(kāi)關(guān)，檢查油冷卻器螺栓是否松動(dòng)。l 在主機(jī)開(kāi)機(jī)前先開(kāi)啟稀油站工作油泵，待系統(tǒng)工作壓力正常后，再啟動(dòng)主機(jī)，主機(jī)停機(jī)后才可停泵。l 稀油站開(kāi)機(jī)前，應(yīng)先啟動(dòng)油泵電機(jī)，觀察電動(dòng)機(jī)轉(zhuǎn)動(dòng)方向是否正確。l 啟動(dòng)油泵后，根據(jù)壓力表檢查事先設(shè)定的高壓值0.4MPa、低壓值0.1MPa、超低壓值0.05MPa、是否正確如需調(diào)整用編程器重新設(shè)定，并檢查壓力變送器安裝是否牢固。l 稀油站工作中如因油溫、油壓、油位牌不正常位置時(shí)，則有相應(yīng)的信號(hào)燈亮或音響報(bào)

14、警。并對(duì)報(bào)警部位作必要處理。l 稀油站在工作中應(yīng)經(jīng)常觀察儀表盤(pán)上的壓力表，當(dāng)壓力表壓差超過(guò)0.05MPa時(shí)，即應(yīng)更換濾芯。維護(hù)保養(yǎng)及注意事項(xiàng)l 油泵軸密封圈要經(jīng)常檢查，如有泄漏或損壞時(shí)，要立即更換。l 油冷卻器必須根據(jù)水質(zhì)情況，每5至10個(gè)月進(jìn)行一次內(nèi)部檢查與清洗。l 雙筒網(wǎng)式濾油器，每三個(gè)月拆洗一次，去除內(nèi)部淤存污垢，并根據(jù)密封善予以更換。l 磁過(guò)濾器每三個(gè)月清洗一次。l 油站管路及連接部位不得有滲漏現(xiàn)象。l 定期檢查控制批示儀表的可靠性，定期進(jìn)行鑒定，適當(dāng)調(diào)整或更換。l 定期檢查油箱的油質(zhì)，及時(shí)進(jìn)行更換和補(bǔ)充潤(rùn)滑油，保持適當(dāng)油位。l 注意檢視油箱內(nèi)最低油位處，如發(fā)現(xiàn)有水，則應(yīng)打開(kāi)油箱下部?jī)?/p>

15、閥門(mén)將水放出。各組元件使用和維護(hù)方法詳見(jiàn)有關(guān)的說(shuō)明書(shū)。潤(rùn)滑系統(tǒng)檢查方法如下常規(guī)故障評(píng)估表：序號(hào)故障現(xiàn)象可能原因采取措施1油溫過(guò)高冷卻器堵或結(jié)垢，油箱油液太少，安全閥壓力設(shè)定太低，溫控儀誤動(dòng)作啟動(dòng)加熱器，液壓泵站通風(fēng)不好，過(guò)濾器堵油液經(jīng)旁路走，電磁水閥有損壞，水冷卻過(guò)濾器中有臟物。清洗過(guò)濾器，加油，調(diào)整安全閥設(shè)定壓力，更換溫控儀，改善通風(fēng)，清洗過(guò)濾器，更換電磁水閥。2其他部件發(fā)生泄漏油中含臟物，油溫過(guò)高密封老化，密封在組裝時(shí)有損壞，螺紋接頭松動(dòng)。更換油液，更換密封，擰緊螺紋接頭。3壓力波動(dòng)油中混入空氣造成不均勻運(yùn)動(dòng)，齒輪泵發(fā)生磨損或損壞，軸向柱塞泵安全閥發(fā)生損壞。排除空氣，對(duì)泵進(jìn)行修理或更換，將

16、安全閥更換或修理。4泵的不正常運(yùn)行噪音油中混入空氣（形成氣泡），齒輪泵或電機(jī)的緊固螺栓松動(dòng)，油箱內(nèi)的油位過(guò)低，油溫過(guò)低。檢查管網(wǎng)有無(wú)漏氣，將螺栓擰緊，檢查有無(wú)漏油重新加油，檢查溫控系統(tǒng)、加熱系統(tǒng)、冷卻系統(tǒng)。5其他異常噪音液壓管網(wǎng)的緊固件已松動(dòng)，潤(rùn)滑系統(tǒng)出現(xiàn)壓力沖動(dòng)。檢查緊固件是否損壞或松動(dòng)，檢查感應(yīng)塊固定情況。6建不起壓力系統(tǒng)壓力上不來(lái)，回程或推程壓力上不來(lái)。檢查系統(tǒng)安全閥、泵的安全閥（注：關(guān)掉相應(yīng)的回油路的X截止閥），檢查管路上相應(yīng)的安全閥。維修工作注意事項(xiàng)：l 全部維護(hù)工作應(yīng)作有檢查表，并按表中規(guī)定的內(nèi)容進(jìn)行，將檢查結(jié)果歸檔。l 將檢查、維護(hù)以及修理過(guò)程中發(fā)現(xiàn)的問(wèn)題記錄在檢查表中。l 如果

17、檢查中發(fā)現(xiàn)某些零部件需要更換，應(yīng)確保及時(shí)將相關(guān)的備件備齊。l 如果維護(hù)工作需要將系統(tǒng)拆開(kāi)，則應(yīng)確保周?chē)h(huán)境特別清潔，溢漏的潤(rùn)滑油絕對(duì)不能再使用。l 除對(duì)具體部件進(jìn)行檢查外，維護(hù)和修理工作還應(yīng)包括對(duì)潤(rùn)滑油、潤(rùn)滑管道連接件擰緊、泄漏、泵站工作噪音和潤(rùn)滑油溫度的檢查。潤(rùn)滑油：l 對(duì)潤(rùn)滑油的要求：只能使用規(guī)定的潤(rùn)滑油，產(chǎn)地和質(zhì)量不同的液壓油不能混合在一起用，泄漏的潤(rùn)滑油不可以重新使用，必須確保使用的潤(rùn)滑油滿足系統(tǒng)清潔度的要求（本系統(tǒng)所采用的是潤(rùn)滑油#320，用戶現(xiàn)場(chǎng)需備潤(rùn)滑油57桶，油廠家可以根據(jù)用戶自己確定）。l 液壓油首次使用更換周期為六-八個(gè)月，以后正常周期為一年，具體時(shí)間根據(jù)現(xiàn)場(chǎng)觀察油液定。l

18、 影響潤(rùn)滑油質(zhì)量的因素：來(lái)自周?chē)h(huán)境的贓物（在灌裝或泄漏時(shí)進(jìn)入的碎肖，密封材料、塵土和空氣中的水氣），運(yùn)行過(guò)程中形成的贓物（潤(rùn)滑油因本身老化而形成的贓物，以及機(jī)件因摩擦而掉下的金屬末和鐵銹等）；水會(huì)使油乳化，可明顯呈乳白色，增加油老化速度，老化物會(huì)增加磨損、阻塞、粘堵、生銹。l 潤(rùn)滑油檢查：對(duì)液壓油進(jìn)行經(jīng)常性檢查是必要的，因?yàn)槿绻臀坏陀谧畹陀臀唬敲从偷墓ぷ鳒囟葘⑸?，并發(fā)生空氣混入，最壞的情況是油流中斷，所有上述情況都有可能造成工作元件的損壞；臟物和化學(xué)變化（老化），會(huì)使液壓油在使用過(guò)程中變質(zhì)，如果臟物和油的老化超過(guò)一定的限定值，那么必須將油更換，換油太遲會(huì)增大系統(tǒng)發(fā)生故障的可能性。l 日

19、常檢查：油液顏色、溫度，系統(tǒng)壓力，泵、電機(jī)聲音，系統(tǒng)有無(wú)漏油，泵的溫度。換油注意事項(xiàng)：l 抽出使用過(guò)的油：確保系統(tǒng)處于停機(jī)狀態(tài)，潤(rùn)滑油使用濾油小車(chē)通過(guò)油箱上的空氣過(guò)濾器連接法蘭口抽出，抽完后打開(kāi)放油閥將剩余的油排出去。l 清洗管網(wǎng)：用少量的新油清洗管網(wǎng)，此過(guò)程使用濾油小車(chē)來(lái)完成。l 清洗油箱：將油箱內(nèi)部徹底清理干凈，將油箱上的檢查蓋拆開(kāi)即可進(jìn)行油箱內(nèi)部的清理；不得使用纖維材料清理油箱，一般出廠前已清理過(guò)，換潤(rùn)滑油時(shí)可用新油沖一下油箱，油箱用濾油機(jī)進(jìn)行加油。不得使用溶劑清理油箱，因?yàn)闅堄嗟娜軇?huì)加速液壓油老化，根據(jù)情況更換濾芯，濾油小車(chē)在使用前必須清洗干凈。試車(chē)運(yùn)行的準(zhǔn)備管道： l 充分的沖洗：

20、雜質(zhì)的等級(jí)20級(jí)以內(nèi)NAS1638；管夾應(yīng)準(zhǔn)備充分：通常在直管路上，間隔1000MM-2000MM，當(dāng)管道振動(dòng)較大或彎曲點(diǎn)過(guò)多的情況下，管夾間距盡可能小一些；應(yīng)有足夠的耐壓力：是工作壓力的1.25-1.5倍。電氣： l 確定電機(jī)的運(yùn)轉(zhuǎn)方向：一般參照潤(rùn)滑泵頂部銘牌上箭頭方向和潤(rùn)滑設(shè)備的裝配圖檢查電機(jī)的運(yùn)轉(zhuǎn)方向。特殊要求應(yīng)先斷開(kāi)電機(jī)和油泵之間的連軸器，然后然電機(jī)單獨(dú)運(yùn)行以確定電機(jī)的旋轉(zhuǎn)方向l 電器元件的導(dǎo)電性實(shí)驗(yàn)：檢查電路和電器元件的一致性，給每一個(gè)電器元件單獨(dú)通電以確定磁體是否按動(dòng)作執(zhí)行。原理圖元件注釋：稀油站外形結(jié)構(gòu)圖：壓力調(diào)節(jié)：l 在調(diào)試時(shí)，首先把所有安全閥的壓力設(shè)定值調(diào)到最小，確定好電機(jī)轉(zhuǎn)

21、向后，正常啟動(dòng)電機(jī)，把油路出口的截止閥或蝶閥關(guān)閉，然后慢慢旋轉(zhuǎn)溢流閥的調(diào)壓旋鈕，按順時(shí)針?lè)较?；同時(shí)目光注意著儀表盤(pán)上相應(yīng)的壓力表，直到表針指到參數(shù)表內(nèi)所提供的數(shù)值時(shí)鎖緊旋鈕；此時(shí)壓力調(diào)整完畢，最后停止電機(jī)再重復(fù)啟動(dòng)幾次待確認(rèn)壓力值設(shè)定無(wú)誤的情況下把所有閥門(mén)按正常工作時(shí)打開(kāi)。流量調(diào)節(jié)：l 在調(diào)試時(shí)，注意出口處相應(yīng)的壓力表，調(diào)整各個(gè)出口處的節(jié)流閥；盡量使同等功能的出油口的壓力相等。技術(shù)參數(shù)：低壓流量：125 L/min 低壓壓力：0.4MPa電機(jī)參數(shù)：5.5Kw 480V 60HZ高壓流量：20 L/min 高壓壓力：31.5 MPa電機(jī)參數(shù)：18. 5Kw 480V 60HZ油箱容積：2 m3冷

22、卻面積：17 m2 冷卻水耗量：14.4 m3/h過(guò)濾面積：13 m2 過(guò)濾精度：80umLUBRICATION STATIONOPERATION MANUALMGKZ-125BEIJING MECC HYDRAULIC Co., Ltd. ContentSafety instruction.usage.instruction.model instruction.abstract.working principletechnique parameter.installation.pump installation.electric connection.operation rule.press

23、ure adjustment.flow missioning.malfunction .parameter list.annex: outlet dimension.PrefaceThe manual tells customers how to right operate the lubrication system and components, and this manual is indispensable at site. All relative operators should read carefully before operating. Oper

24、ators who do not understand English should be told the dialed information about the manual, esp the safety part. Reading the manual carefully will help to avoid kinds of dangers happening, reduce the cost of maintenance, shorten the downtime and prolong the service time.Follow the interrelated natio

25、nal laws and regulations on environment protection and accident prevention.Safety instructionThe manual includes how to install, transport and service for components and lubrication system. Therefore, operator and user must read this manual before operating this system. Put this manual at job site.D

26、anger SignalStandard: DIN 4844-W9 l If dont follow operation rule, it may cause human hurt.Standard: DIN 4844-W9 l With electric CAUTIONl This signal means warning. If dont follow this manual, it may damage equipments or cause malfunction.l Pay special attention on the warning detail. Keep this caut

27、ion readable. Personnel qualifying and training l Personnel who charge operation, maintenance, checking and safety must have qualified cognizance.l If the person doesnt master the operation skills, they have to be trained. l Otherwise, user must make sure that the operator knows how to operate this

28、station after reading this manual. Damage caused if dont read this manuall If dont pay attention for the safety warning, it may cause equipment damaged or human hurt.l If dont read this manual, user may lost the claim right if equipment is damaged. l If dont read this manual, the damages may be as f

29、ollows:Equipment/ system cant achieve the preset function. Preset maintenance and repairing cant be done. Electric, mechanics and chemistry may cause human hurt. Detrimental substance leakage may cause environment pollution.Operator must have safety sense. They have to follow :safety instruction in

30、this manual, national laws and regulations on accident prevention, other relative plants rules. User/operator safety instruction l Hot/cold mechanical parts may have danger. User must pay special attention to it. l When the station is working, dont unload the protection unit. l When dealing with the

31、 leaked detrimental substance, dont pollute environment and human.l Electric current may cause other danger. Maintenance, inspection and installation safety instructionl User must confirm that the cognizance operator do the work of maintenance, checking and installation.l Operate the equipment norma

32、lly when it is running. Follow the requirement in the manual. l After cleaning the piping and reservoir, re-assembly safety and protection equipment. Clear out foreign substance in pump unit. Unauthorized refit and manufactureDo not refit or change the machines and components except getting confirma

33、tion from the manufacturer, and all changed components and accessories must apply to running safely.If use other components which are not confirmed by manufacturer, manufacturer will be not responsible for any result.Unallowed running waysWe just guarantee safety under the right operation.Forbid usi

34、ng the station in southeast countries because of the different voltage, if it has to be used, motor and voltage should be properly changed, meanwhile, the manufacturer should confirm it.right useMGKZ*#lubrication station is specially designed for reducer gear and bearing.Do not surpass the rated val

35、ue, and the rated value is from 8bar to 320bar. Working temperature is from 40 to 50. It does not apply to running in high and low temperatures for a long time.MGKZ-*# type lubrication station has a lot model to choose. The station is used in many industries, such as: iron& steel industry, trans

36、port, building, and plastic. If the user doesnt operate the station as the manual, the manufacturer doesnt have any responsibility to claim. InstructionModel instruction：l Meanings of signalsample：MGKZ-125-*- MGKZ presents for lubrication station, 125presents LP flow rate, * *presents HP flow rate.

37、The last two presents outlet number. The first presents LP outlet number. The last presents the HP outlet number. Note: If you have special requirement, you must point out before placing the order.。Abstract：l TBJ-125 type lubrication station is used in circulation hydraulic system. It can supply lub

38、rication oil to the friction part. This station is designed according to Heavy Machine Q/ZB355-77 standard. Its performance is better than other heavy machine standard lubrication station. Especially gauge panel and main parts of electric panel are better than others. l Viscosity of working medium i

39、s N22N320，this station is mounted under / on ground near the main frame.。Working PrincipleMGKZ-125 type lubrication station contains reservoir, LP pump unit, HP pump unit, oil filter, cooler, gauge unit, piping and valves. This station is a complete, mini type lubrication system. When it is working,

40、 LP pump sucks oil from reservoir via check valve, oil filter and cooler. Then oil is transmitted to the lubrication point. For the LP pump unit, max. working pressure is 0.4 MPa, min. working pressure is 0.1MPa. Adjust safe valve to set pressure. If pressure is higher than rated pressure, safe valv

41、e is open, redundant oil flows back to reservoir. At the same time HP pump sucks oil from reservoir via check valve, divider. Then oil is transmitted to the lubrication point. For the HP pump unit, max. working pressure is 31.5MPa. If the pressure is higher than 31.5 MPa, safe valve is open.Lubricat

42、ion station has following characters:l This station has 2 LP pumps, one on duty, one standby. In normal, one pump works. If the pressure is lower than 0.1MPa, the standby pump begins to work.l This station has 2 HP pumps, one on duty, one standby. In normal, one pump works. If the pressure is lower

43、than 3 MPa, the standby pump begins to work.l This station uses double tube filter. This filter has 2 elements, one on duty, one standby. If the differential pressure is higher than 0.05MPa, change directional valve to the standby element by hand. Then change the working element. l Magnetic filter u

44、nit is mounted at the return line. This filter unit can absorb mini ferromagnetic substance to assure the oil cleanness.l Instrument panel is mounted on the up left-hand of front side. Two pressure gauges can read outlet pressure and pump pressure. Pressure transmitter controls the pressure on the o

45、utlet line. E+H differential pressure sensor checks pressure difference on the oil filter.l This station is heated separately. This heater has a sleeve to prevent from changing the oil quality if oil is heated partly. Schematic drawing and outlet drawing see attachment. Installation, maintenance and

46、 commissioning The station is installed on the ground. Do not need anchor bolts.l Before connecting pipes, pickling, rust-removal and neutralization must be done. Use water to flush and compressed air to blow.l Performance test has to be done before ex work. Piping connection can be done after reach

47、ing the job site. After installation, use filter unit to filter. The station can be run after commissioning well. Operation Rulel If oil temperature is lower than 17, open heater to heat.l Place directional valve in the place which is the element working area. Open corresponding valve switch and pre

48、ssure gauge switch. Check whether bolts of cooler are loose. l Drive working pump. Open mainframe after pressure is steady. Working pump stops after mainframe stops.l Drive working pump to check motors rotary direction.l After driving pump, check whether set pressure value is right, such as, max. pr

49、essure is 0.4 MPa, min. pressure is 0.1MPa, ultra-low pressure is 0.05MPa. If it is not right, adjust it again. Check whether pressure transmitter is tight.l If oil temperature, pressure or level indicator is not right, corresponding signal lamp will be bright or alarming. Deal with the malfunction.

50、l Visual check the pressure gauge. If the pressure value is over 0.05MPa, change element in time. Maintenance and Commissioningl Check and flush oil cooler every 510months.l Check seal gasket periodically. If there is leakage or damage, change it in time.l Disassembly and flush oil filter every 3 mo

51、nths. Eliminate inner contaminant and change element.l Flush magnetic filter every 3 months.l No leakage on piping and connection part.l Check gauges reliability. Adjust and change termly.l Check oil quality periodically. Change and refill lubrication oil. This method can keep oil on a certain level

52、. l Visual check the lowest oil level. If there is water, open drain valve which is on the bottom of the reservoir. Drain out water. Check ruleMalfunction and trouble-shooting：itemdescriptionreasonTrouble-shooting1Oil temperature higher than set valueCooler is clogged. Little oil in reservoir. Press

53、ure value is not high enough. Open heater by mistake. Dont vent well for hydraulic station. Oil flows by-pass. Solenoid water valve is damaged. Foreign substance is in the cooler. Rinse filter. Fill in oil. Adjust safe valve to set pressure value. Change temperature controller. Let it vent well. Clean filter. Change solenoid water valve. 2Leakage on other partsOil mixes foreign substance. Oil temperature is higher. Seal washer is ageing. Seal washer is damage when assembling. Bolts is loose. Change oil. Change seal washer. Tighten bolts. 3P