SY8型碎煤機(jī)液壓站SY8HYORAULICSTATIONOFCOALCRUSHER使用說(shuō)明書(shū)OPERATIONALINSTRUCTION山西電力設(shè)備廠SHANXIELECTRICPOWEREQUIPMENTFACTORYSY8型碎煤機(jī)液壓站使用說(shuō)明書(shū)1目錄型號(hào)意義2用途2技術(shù)規(guī)格2結(jié)構(gòu)與工作原理3操作和保養(yǎng)3故障及排除方法4附液壓系統(tǒng)圖5SY8型碎煤機(jī)液壓站使用說(shuō)明書(shū)2型號(hào)意義液壓站“液”漢語(yǔ)拼音首字母碎煤機(jī)“碎”漢語(yǔ)拼音首字母額定流量整數(shù)部分?jǐn)?shù)據(jù)用途SY8型碎煤機(jī)液壓站為HCS系列環(huán)錘式碎煤機(jī)的配套產(chǎn)品。主要用于驅(qū)動(dòng)該機(jī)的液壓缸，以啟閉前后機(jī)蓋，便于碎煤機(jī)的檢修。本液壓站也可用于其他機(jī)械設(shè)備的檢修或需要承重的場(chǎng)合。技術(shù)規(guī)格液壓站的液壓系統(tǒng)參數(shù)及驅(qū)動(dòng)油缸性能分別見(jiàn)表和表表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/MINBARCBFA10CFL819785電動(dòng)機(jī)型號(hào)功率轉(zhuǎn)速電壓KWR/MINVY100L6V115940380系統(tǒng)流量壓力L/MINBAR6825625油箱有效容積L6010溢流閥調(diào)節(jié)范圍工作標(biāo)壓BARBAR7014075液壓油牌號(hào)用量KG30機(jī)械油5095表2驅(qū)動(dòng)油缸性能810碎煤機(jī)型號(hào)HCSZ100HCSZ200HCSZ300HCSZ500HCSZ700HCSCHCSC6HCSZ600HCSZ800SPM14系列SPM16系列HCSC12系統(tǒng)圖油缸組號(hào)油缸內(nèi)徑活塞桿徑MMMM5028633580451005512570作用面積推出端拉回端CM2CM219641348311721175027343778545391122728423SY8型碎煤機(jī)液壓站使用說(shuō)明書(shū)3進(jìn)程推力TFKN14914592382337314307949148117677517單缸驅(qū)動(dòng)力回程拉力TFKN10310116516162152105337330256351594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(kāi)關(guān)、油管、油箱、空氣濾清器等元件組成。交流電動(dòng)機(jī)通過(guò)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）的進(jìn)程和回程的油路換向。單向節(jié)流閥以節(jié)流調(diào)速改變工作速度。回油路的油液及溢流閥的余油匯集后經(jīng)連接塊的溢流口流回油箱。5操作和保養(yǎng)51根據(jù)液壓系統(tǒng)圖及表2，按照所要驅(qū)動(dòng)的碎煤機(jī)液壓缸，將快速接頭體及尼龍墊圈與油缸的接頭相聯(lián)接。并且檢查管路各接頭是否可靠。52檢查油泵電機(jī)的轉(zhuǎn)向是否正確。從軸頭方向觀察應(yīng)為順時(shí)針?lè)较蛐D(zhuǎn)。53起動(dòng)前油箱油面應(yīng)位于油標(biāo)的上端。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(jiàn)下圖。54緩緩轉(zhuǎn)動(dòng)電機(jī)（或反復(fù)起動(dòng)電機(jī)），使泵的排出管卸載，排出泵體內(nèi)及管路中的空氣。55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。56調(diào)整溢流閥的壓力到75BAR,若需要更高的工作壓力時(shí)，可作相應(yīng)的調(diào)整，但不允許超過(guò)140BAR。57工作油的粘度為1738厘斯（255E），推薦采用30機(jī)油。58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。59從空氣濾清器向油箱內(nèi)注漬，其濾網(wǎng)的過(guò)濾精度主為120目/寸。510應(yīng)定期取樣檢查工作油的顏色、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。一般每一年應(yīng)更換一次。SY8型碎煤機(jī)液壓站使用說(shuō)明書(shū)46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1溢流閥動(dòng)作不良2油壓回路無(wú)負(fù)荷3系統(tǒng)漏油1拆卸閥體檢查修復(fù)2檢查油路加負(fù)荷3檢查管道制止泄漏2有壓力但不排油或者容積效率下降1泵內(nèi)密封件損壞2吸入異物在滑動(dòng)部分產(chǎn)生異常摩擦1與制造廠聯(lián)系進(jìn)行修理2進(jìn)行檢查排除異物3噪聲過(guò)大1吸入管太細(xì)2吸油口濾油器堵塞3吸入管或其他部位吸入空氣4油箱內(nèi)有氣泡5油箱內(nèi)油面過(guò)低6泵的安裝基礎(chǔ)剛性不足7轉(zhuǎn)速和壓力超出規(guī)定值8聯(lián)軸器噪聲大1更換較大內(nèi)徑的油管2清洗3向吸入管注油找出不良處4檢查回油路防止發(fā)生氣泡5加油到規(guī)定油面6提高安裝基礎(chǔ)剛度7檢查轉(zhuǎn)速、壓力及油路8檢查聯(lián)軸器有無(wú)損傷或錯(cuò)位過(guò)大4油泵發(fā)熱1容積效率不良，泵內(nèi)進(jìn)入空氣2軸承磨損3油粘度過(guò)高，潤(rùn)滑不良油污嚴(yán)重1排除空氣，提高容積效率2更換新軸承3更換新油SY8型碎煤機(jī)液壓站使用說(shuō)明書(shū)57附液壓系統(tǒng)圖SY8型碎煤機(jī)液壓站使用說(shuō)明書(shū)6性能參數(shù)項(xiàng)目單位數(shù)據(jù)額定流量L/MIN819標(biāo)定壓力BAR75功率KW15轉(zhuǎn)速R/MIN940液壓用油30機(jī)油油箱加油量L601012EF125空氣濾清器Q66L/MIN,濾面80CM2,精度09MM1溫州輕紡機(jī)械廠11JB195777卡套式壓力表管接頭G6M14151上海液壓附件廠10Y60壓力表P0160BAR1陽(yáng)泉儀表廠9Q/ZB27577快速接頭（兩端開(kāi)閉）DG10MM,P320BAR,Q40L/MIN2上海液壓附件廠8JB188577膠管總成A型扣壓式，133000，P200BAR2上海液壓附件廠7LDFL10C單向節(jié)流閥DG10MM,P140BAR,Q25L/MIN2榆次液壓件廠634SMB10HT手動(dòng)換向閥DG10MM,P315BAR,Q40L/MIN1上海液壓件一廠5YFB10HY1溢流閥DG10MM,P70210BAR,Q40L/MIN14CBFA10CFL齒輪油泵P140BAR,N1800R/MIN,Q1127ML/R1榆次液壓件廠3Y100L6（V1）電動(dòng)機(jī)N15KW,N940R/MIN,U380V12WU6380J吸油口濾清器DG25MM，Q63L，精度80UM1上海高行液壓件廠1SY83油箱箱內(nèi)4924124951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SY8SM液壓系統(tǒng)圖使用說(shuō)明書(shū)山西電力設(shè)備廠SY8型碎煤機(jī)液壓站使用說(shuō)明書(shū)7OPERATINGINSTRUCTIONSFORTYPESY8HYORAULICSTATIONOFCOALCRUSHERSY8型碎煤機(jī)液壓站使用說(shuō)明書(shū)8SHANXIPOWEREQUIPMENTPLANTSY8型碎煤機(jī)液壓站使用說(shuō)明書(shū)91DESIGNATIONOFTYPEAREASFOLLOWSSY8RATEFLOWSHOWNININTEGRALPARTINITIALLETTEROFCHINESEPHONETICALPHABETFORHYDRAULICSTATIONINITIALLETTEROFCHINESEPHONETICALPHABETFORCOALCRUSHER2APPLICATIONSTYPESY8HYDRAULICSTATIONOFCOALCRUSHERISAMATCHEDPRODUCTOFTHEHCSSERIESRINGHAMMERCOALCRUSHERITISUSEDTOACTUATETHEHYDRAULICCYLINDERSTOOPENANDCLOSETHEFRONTANDREARMACHINECOVERSANDRESETTHESCREENDECKFRAMESOASTOBECONVENIENTFORINSPECTIONANDREPAIROFTHECOALCRUSHERTHISHYDRAULICSTATIONCANBEALSOUSEDFORINSPECTIONANDREPAIROFOTHEREQUIPMENTORWHEREWEIGHTSARENECESSARYTOBESUPPORTED3TECHNICALSPECIFICATIONSTECHNICALPARAMETERSOFTHEHYDRAULICSYSTEMOFTHEHYDRAULICSTATIONANDPERFORMANCEOFTHEACTIVATINGCYLINDERSARESHOWNSEPARATELYINTABLE1ANDTABLE2TABLE1TECHNICALPARAMETERSOFHYDRAULICSYSTEMITEMSUNITDATAITEMSUNITDATAHYDRAULICPUMPTYPEFLOWPRESSUREL/MINMPACBFA10CFL819785ELECTRICMOTORTYPEPOWERSPEEDVOLTAGEKWR/MINVY100L6V115940400SYSTEMFLOWPRESSUREL/MINMPA6825625EFFECTIVETANKAREAL6010RELIEFVALVEPRESSUREREGULATINGSCOPENOMINALOPERATINGPRESSUREMPAMPA71475HYDRAULICOILGRADEOILQUANTITYUSEDKG30MACHINEOIL5795SY8型碎煤機(jī)液壓站使用說(shuō)明書(shū)10TABLE2PERFORMANCEOFACTIVATINGCYLINDERSTYPESOFCOALCRUSHERSHCSZ300HCSP400HCSQ700HCSC6HCSC81012CYLINDERSETNOINTHEHYDRAULICCIRCUITDIAGRAMINNERDIAMETERSOFHYDRAULICCYLINDERSPISTONRODDIAMETERSMMMM633580451005512570ACTIONAREAPUSHINGENDPULLINGENDCM2CM2311721175027343778545391122728423PUSHONADVANCINGSTROKETFKN2382337314307949148117677517ACTUATINGFORCEOFSINGLECYLINDERPULLONRETURNINGSTROKETFKN16516162152105337330256351594CONSTRUCTIONANDWORKINGPRINCIPLETHEHYDRAULICSTATIONISCONSISTEDOFSUCTIONFILTER,GEARPUMP,RELIEFVALVE,HANDOPERATEDDIRECTIONALVALVE,ONEWAYTHROTTLEVALVE,HOSEASSEMBLY,QUICKRELEASECOUPLINGSPRESSUREMETERSANDSWITCHES,OILPIPES,OILTANKAIRFILTERS,ETCWHENTHEGEARPUMPISROTATEDBYAACELECTRICMOTORTHROUGHACLAWCOUPLING,THEPRESSUREOILISBROUGHTINTOARELIEFVALVEWHERETHENORMALPRESSUREISINDICATEDBYAPRESSUREMETERATYPEMDIRECTIONALVALVEISUSEDFORCHANGINGTHEDIRECTIONSOFACTUATORSHYDRAULICCYLINDERSFORTHEIRADVANCINGANDRETURNINGSTROKESTHEONEWAYTHROTTLEVALVECANCHANGETHEWORKINGSPEEDBYMEANSOFRESTRICTIONSPEEDREGULATIONTHEOILINTHERETURNLINEANDREMAININGOILINTHERELIEFVALVESHALLBECOLLECTEDANDRETURNEDTOTHEOILTANKTHROUGHTHEDISCHARGINGOPENING5OPERATIONANDMAINTENANCE51INACCORDANCEWITHTHEHYDRAULICSYSTEMDIAGRAMANDTABLE2ANDTHECONSTRUCTIONOFTHEHYDRAULICCYLINDERSFORACTUATINGTHECOALCRUSHER,THEQUICKRELEASECOUPLINGSANDNYLONWASHERSSHALLBECONNECTEDTOTHECONNECTIONSOFTHEHYDRAULICCYLINDERSANDTHECOUPLINGSOFTHELINESHALLBECHECKEDFORTHEIRRELIABILITY52THEELECTRICMOTORFORHYDRAULICPUMPSHALLBEINSPECTEDFORITSCORRECTROTATINGDIRECTIONVIEWFROMTHESHAFTEND,THEMOTORSHALLBEROTATEDCLOCKWISE53BEFORESTARTINGTHEOILLEVELOFTHETANKSHALLBEOVERTHEOILGAUGEAFTERSTARTINGTHEOILLEVELSHALLBEINTHEOILGAUGEATAVISIBLEOPPOSITIONWHENTHEOILLEVELCANNOTBEFOUNDFROMTHEOILGAUGE,OILSHALLBESUPPLEMENTEDINTHETANK,ASSHOWNINTHEFOLLOWINGFIGURESY8型碎煤機(jī)液壓站使用說(shuō)明書(shū)1154THEELECTRICMOTORSHALLBESLOWLYROTATEDORTHEMOTORISSTARTEDREPEATEDLYTOUNLOADTHEDISCHARGINGPIPELINESOASTOREMOVEAIRINTHEPUMPBODYANDTHEPIPELINE55WHENTHEELECTRICMOTORISRESTARTEDAFTERITSTOPS,ITSHALLBECARRIEDOUTAFTERONEMINUTEINTERVAL56THEPRESSUREOFRELIEFVALVESHALLBEADJUSTEDTO75MPA,WHENTHEMOREHIGHPRESSURESAREREQUIRED,APPROPRIATEADJUSTMENTSHALLBEMADEITISNOWALLOWEDTOEXCEED14MPA57THEVISCOSITYOFTHEWORKINGOILSHALLBEFROM17CENTISTOKETO38CENTISTOKE255E30MACHINEOILISRECOMMENDEDTOUSE58THENORMALOILTEMPERATURESHALLBEFROM10TO60WHENOILTEMPERATUREISBELOW0ATSTARTING,THEWORKINGOILSHALLBEWARMEDUPTHEMACHINESHALLBESTARTEDWHENOILTEMPERATUREREACH559OILSHALLBEFILLEDTOTHEOILTANKFROMAIRFILTER,INWHICHTHESTRAINERHASAFILTRATIONSIZEOF120MESHES/INCH510THEWORKINGOILSHALLBECHECKEDATREGULARINTERVALSFORITSCOLOUR,TRANSPARENCY,SETTLINGMATERIAL,SMELLANDSOONIFTHEOILISDETERIORATEDORPOLLUTEDBADLY,ITSHALLBECHANGEDINTIMEASARULE,OILSHALLBECHANGEDONCEAYEAROILLEVELL1L/25MMUPDOWNSY8型碎煤機(jī)液壓站使用說(shuō)明書(shū)126MALFUNCTIONSANDELIMINATIONSERNOMALFUNCTIONSCAUSESELIMINATION1ALTHOUGHTHEOILPUMPISDISCHARGED,BUTTHEOPERATINGPRESSURECANNOTBEMET1THERELIEFVALVEISOPERATEDIMPROPERLY2THEREARENOLOADINTHEHYDRAULICCIRCUIT3OILLEAKAGEAREFOUNDINTHESYSTEM1THEVALVEBODYSHALLBEDISMOUNTEDFORINSPECTIONANDREPAIR2THEHYDRAULICCIRCUITSHALLBEINSPECTEDANDLOADED3THEPIPELINESHALLBEINSPECTEDTOPREVENTFROMLEAKAGE2THEREAREPRESSUREINTHEPUMPBUTOILCANNOTBEDISCHARGEDORTHEVOLUMEEFFICIENCYISCUTDOWN1THESEALINGSINTHEPUMPMAYBEDAMAGED2SUCKEDINFOREIGNMATERIALPRODUCEABNORMALFRICTIONINTHESLIDINGPART1THEMANUFACTURERSSHALLBEBROUGHTINTOCONTACTFORREPAIR2INSPECTIONSHALLBECARRIEDOUTTOELIMINATEFOREIGNMATERIAL3EXCESSIVENOISEAREFOUND1THESUCTIONLINEISTOOTHIN2THEFILTERATTHESUCTIONINLETISBLOCKED3AIRARESUCKEDINTHESUCTIONLINEOROTHERPARTS4THEREAREAIRBUBBLESINTHEOILTANK5THEOILLEVELISTOOLOWINTHEOILTANK6THEINSTALLATIONFOUNDATIONISSHORTOFRIGIDNESS7THESPEEDANDPRESSUREEXCEEDTHESPECIFIEDVALUES8THEREISABIGNOISEATTHECOUPLING1THEOILPIPEORHOSEWITHBIGGERDIAMETERSSHALLBEREPLACED2CLEANINGANDWASHINGSHALLBECARRIEDOUT3THESUCTIONLINESHALLBEFILLEDWITHOILTOFINDTHEIMPROPERPOSITIONS4THERETURNOILLINESHALLBEINSPECTEDTOPREVENTFROMPRODUCINGBUBBLES5OILSHALLBEFILLEDTOTHESPECIFIEDLEVEL6THERIGIDNESSOFTHEINSTALLINGFOUNDATIONSHALLBEIMPROVED7THESPEED,PRESSUREANDOILCIRCUITSHALLBEINSPECTED8THECOUPLINGSHALLBECHECKEDFORDAMAGEOREXCESSIVEMISALIGNMENT4HEATINGISPRODUCEDINTHEOILPUMP1THEVOLUMEEFFICIENCYISIMPROPERORAIRENTERINTOTHEPUMP2THEBEARINGISWORN3VISCOSITYOFOILISTOOHIGH,LUBRICATIONISIMPROPERANDOILISPOLLUTEDBADLY1AIRSHALLBEEXHAUSTEDANDVOLUMEEFFICIENCYSHALLBEIMPROVED2NEWBEARINGSHALLBEREPLACED3OILSHALLBECHANGEDORREPLACEDSY8型碎煤機(jī)液壓站使用說(shuō)明書(shū)13PERFORMANCEACTUATINGCYLINDERSETSITEMSUNITDATATYPEOFCOALCRUSHERNUMBEROFHYDRAULICCYLINDERSETSASSEMBLYDRAWINGNOOFHYDRAULICCYLINDERSRATEFLOWL/MIN819HCSZ300HCSQ300100000NORMALPRESSUREMPA75HCSP400HCSP700HCSQ7000100POWERKW15HCSC6HCSC692SPEEDR/MIN940HCSC8HCSC8090000HYDRAULICOIL30MACHINEOILHCSC12HCSC12110000TANKFILLINGCAPACITYL6010NOTESFRONTCOVERCYLINDERREARCOVERCYLINDERTHEHYDRAULICSTATIONDRIVINGSHALLBEPROVIDEDACCORDI