machine maintence
纪检干部-无政府
General
W
ARNING
Maintenance work carried out on the machine by
untrained, unskilled and unauthorized personnel
can
lead to serious injury andor machine
damage as well as rendering all warranty claims
void.
Work on the machine must only be
performed by adequately trainedand qualifies
personnel.
The following safety
instruction must be adhered to:
• Always
switch off the machine, when you perform setting
and maintenance operations as well as
repairs,
unless it is absolutely necessary that the machine
is operating.
• Secure the machine
against being unintentionally switched on if you
are performing maintenance
operations on the
disconnected machine.
• If you remove
safety devices (when performing setting and
maintenance operations or repairs) or
disconnect them, make sure, they are in place
and are functioning properly before you release
the
machine for further operation.
•
When you carry out setting and maintenance
operations or repairs, block – if necessary – the
access to
the working area.
• Before
carrying out work on the electrical system you
must switch off the machine at the main switch
and secure it against being unintentionally
switched on again:
– Disconnect the machine
(switch off all circuit breakers of main machine
switch).
– Secure machine against being
switched on.
– Carry out a voltage free check.
• Work on servo drives:
After
switching servo drives off wait at least five
minutes to allow intermediate circuit to
discharge.
Before commencing work the actual
voltage in the intermediate circuit must be
measured with a
suitable instrument and be
smaller than 42V DC, to prevent potential danger.
The extinguishing of the
operational LED is no
indicator that the circuit is free of voltage.
Never disconnect the electrical leads on the serve
drives while
they are live. Electric arcing
can occur and cause damage to persons and
terminals.
• Always enlist a second
person for work on current-carrying parts that
can, in an emergency, cur off
the power
supply.
• Always use tools appropriate
for the job, e.g. insulated tools when working on
the electrical equipment
of the machine.
• Use only genuine parts or spare parts and
operating material approved by Yizumi.
•
Please observe the prescribed maintenance and
service intervals.
1 |
Page
Preventive maintenance
schedule
Observing the schedule
recommended below will prevent malfunctions and
repair, and prolong
equipment lifetime. See
Section 3.6 for the list of recommended
lubricants.
VG 46
Every 10 000
working hours
Yearly
Bi-yearly
Quarterly
Monthly
Weekly
The operating hours are indicated on the
“Product and Quality” page.
The position
numbers in the table below correspond to those in
the illustration.
Daily checks
-
Short inspection before start of work.
- Check
the rear gate safety function.
- Check the
function of emergency stop button, startstop
button, purge shield
- Check whether the
thermocouples and heaters are secured.
- Check
if any unusual operation, vibration or sound is
not detected from machine. It does
operate
normally.
EP-2
EP-2
EP-2
#
460 #460 EP-2
2 | Page
Duration
Weekly
Weekly
Pos.
Description Comments
1 Clean surface, remove
any dust, lubricants,
plastic purge. Remove
any objects.
2 Open all ventilation fan
filters and clean If air filters are
with
compressed air (see instruction 3.4.1).
contaminated by oil,
replace them
3 Apply
lubrication oil to supporting sliders.
Use
oil viscosity # 460. See the list of
recommended oil and lubrication grades
3.2.3.
5 Check lubrication grease
container level,
refill if required. See
instruction 3.2.2.
4 Lubricate screw bearing
with lubrication
bell, one turn per week.
Apply more
lubrication if required according
to
instruction 3.2.1.
5 Check and refill
toggle lubrication grease
tank according to
instruction 3.2.2. Use
grease viscosity #02.
9 Check hydraulic oil level and refill if
required.
6 Clean and lubricate moving
platen bushes.
(8 nipples). Avoid
overfilling. See
instruction 3.2.4.
1
Clean surfaces.
9 Change paper oil filter
according to
instruction 3.3.1.
7 Check
oil in injection unit base 3.2.5.
7 Remove
dust and plastic purge, refill oil in
injection unit base.
8 Check and tighten
clamping mechanism
screws.
9 Clean oil
tank, tank filters, change paper
filter and
replace hydraulic oil #VG46. See
3.2.6.
If
machine is equipped with accumulators,
replace
high pressure filter element. See
3.3.2.
Weekly
Weekly
Monthly
Monthly
Monthly
3 Monthly
6 Monthly
6
Monthly
6 Monthly
Annually
Annually
10,000 hours
3 | Page
Check oil temperature on the controller screen on
a monthly basis to avoid oil cooler
contamination.
On machines
equipped with air oil cooling system, clean the
oil cooler with compressed air.
On
machines equipped with mixed cooling system
(water, air type), clean the oil cooler
with
compressed air, Check water cooler and clean if
required.
On machines with water
cooling only, check the temperature for
abnormalities and clean
the cooler if
required.
Check the position, level,
and anti-vibration pad tightening at the lowest
frequency of half
a year.
Do not
use the following chemicals and other similar
chemicals for cleaning machine
surfaces as
they are too aggressive: Glycol, Acetone,
Methanol, and Ethane.
SAFETY INSTRUCTIONS
The safety devices must be inspected
regularly
o After each mould change
o At
the start of the shift
o Once a week with
continuous operation
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1. LUBRICATION
1.1 Lubricating
Point on Clamping Unit
1
2 3
5
1
6
4
All
lubricating points on the clamping unit, apart
from the mould height adjusting mechanism (ring
gear and
adjusting nuts) are lubricated via
the automatic central lubrication system.
Item
1
2
3
4
5
6
Lubrication point
Mould height adjustment
nuts
Toggle lever mechanism
Guides of
moving clamping platen
Number
4
22
4
Interval
(cycles)
Every 3
months
150-300
150-300
Every 3
months
150-300
150-300
Lubricant
Grease
Lubrication
oil
Lubrication
oil
Grease
Lubrication
oil
Lubrication
oil
Service
Manual
greasing
Central
Lubrication
Central
Lubrication
Manual greasing
Central
Lubrication
Central
Lubrication
Guides of the columns in the platen for 4
mould height adjustment
Guides shoes on
the moving clamping
platen
Guides shoes of
tail clamping platen 2
4
5 | Page
1.2
Lubrication Points on Injection Unit
2
Item
1
Lubrication
point
Guides of injection platen
1
Number
4
Interval
(cycles)
Every
half
months
Grease Manual
greasing
Lubricant Service
2 Plasticizing
house for the bearing 2 Every 3
months
Grease Manual greasing
6
| Page
2.
Recommended oil and
lubricant grade
Hydraulic oil
Brand Type
EXXON TERESSO 46NUTOH 46
MOBIL DTE 25
SHELL TELLUS 46
BP
ENERGOL HLP 46
TEXACO RANDO OIL HD46
NIHON
SEKIYU SUPER HYRANDO 46
Lubrication
grease for toggle and bearings
Brand Type
IDEMITSU BEARING LUBRICATION EP No.1
IDEMITSU EPONEX No.1
MOBIL MOBILUX EP-1
ESSO BEACON EP-1
ESSO LITHTAN No. 1
SHELL ALVANIA EP R1
Lubrication oil
for slider shoes
Brand Type
IDEMITSU
DAPHNE MECHINCAL 460
IDEMITSU DAPHNE ETERNITY
OIL B 460
MOBIL MOBILUX EP 460
ESSO
MOBILITH SHC 460
SHELL OMALA 460
Lubrication oil for Injection unit base
Brand Type
IDEMITSU DAPHNE MECHINCAL 460
IDEMITSU DAPHNE ETERNITY OIL B 460
MOBIL
MOBILUX EP 460
ESSO MOBILITH SHC 460
SHELL
OMALA 460
7 | Page
3. Automatic central
lubrication
Add lubricating oil to the
specified level and make daily inspection before
operation.
Inspection content:
1.
Check the level of lubrication oil, if the level
is lower than “LOW LINE”, please fill
lubrication oil till the level reach to “MAX
LINE”;
2. Check the lubrication pressure
during the machine is lubricating, if the
lubrication pressure is
not reach to “green
area”, you need to check:
a. Whether the
lubrication pump is working normally.
b.
Whether some part of lubrication circuit is
leakage.
c. Whether the parameter setting is
abnormal.
8 | Page
3.2.4 Lubrication of
movable platen bushes
The bushes
lubrication points location are
indicated
by the arrows. The same set of points
are
located on the other side.
Stop
the machine.
Connect grease
lubricator to moving platens.
nipples to
apply grease.
When refilling
the grease, make sure the grease
is not
squeezed out.
9 | Page
If the
grease is squeezed out, check the seals
condition.
Lubricate the moving
platen bushings at least
every three months to
ensure its smooth
movement.
Each
of the moving platens has four lubrication
points.
!!!! When refilling
the grease, do not overfill.
Use grease with
viscosity #02.
See the list of recommended
oil and lubrication grades 3.6.0
SAFETY
INSTRUCTIONS
Do not lubricate when machine
is in
operation.
Abide by the rules of
safe handling of
lubrication materials.
3.2.5 Lubrication of injection unit
base
Stop the machine.
Open the protective
cover.
Check level and condition of both oil
refill openings. If necessary refill or
change oil.
Close protective cover
Oil level inside injection unit base
opening should not exceed 2mm
from the
base surface.
Injection unit part
Injection unit base
Oil level
Base
surface
Injection unit base
Protective
cover
Important! Do not allow water leakage
into oil container
See the list of recommended
oil and lubrication grades 3.6.0.
SAFETY INSTRUCTIONS
Do
not refill when machine is in operation.
Abide by the rules of safe handling of
lubrication materials.
10 | Page
3.2.6 Hydraulic oil change
First change: Change hydraulic oil when
machine reaches 2,000 hours of operation.
Next
change: Change hydraulic oil after every
10,000 hours of operation.
Stop
the machine and switch off power.
Pump out all the hydraulic oil from the oil
tank.
Clean the interior of
the oil tank.
Replace the
paper oil cleaner element. (See 3.3.1)
Clean the tank oil filter (see 3.3.3).
Replace high pressure oil filter
(see 3.3.2) only for machines with accumulator.
11 | Page
Refill the hydraulic
oil.
Check oil level.
Start the oil
pump.
Run under no load condition for at
least one hour before operating the machine.
SAFETY INSTRUCTIONS
Abide by the rules
of safe handling of
lubrication materials.
3.3 Oil filter replacement and
cleaning
3.3.1 Paper oil filter
replacement
When the contamination
indicator
pointer is in the red zone,
replace
paper element.
Turn the power off and wait until the
pressure gauge value reaches zero.
Loosen the “T” screw and remove the cap.
Use the security belt to pull the filter
element off
the housing. If needed, rotate the
filter element to
loosen it from the housing.
In case the security belt is broken,
use pliers to pull
the filter element little
by little from inside out.
T-screw
The cap
Contamination indicator
Load new filter element until it reaches the
bottom
of the housing. Reposition the
sealing “U” ring
sequentially.
Place the cap and tighten the “T”
screw, making
sure the sealing ring for the
screw is in place
before tightening the
screw.
12 |
Page
SAFETY INSTRUCTIONS
Switch off
the machine before replacing filter
element.
Abide by the rules of safe handling of
lubrication materials.
3.3.3 Oil
tank filters cleaning
Before
cleaning the filter, stop the machine and switch
off power supply.
Open tank cover.
Pump out the hydraulic oil from the oil
tank.
Remove the filter by turning it
clockwise. (Oil filter is located inside the oil
storage tank at the pump absorbing position.)
Use a nylon brush to wash the filter
with gasoline or kerosene.
Clean out
with compressed air.
Install the
cleaned filter.
Important! Do not
use steel brush to avoid damaging the filter.
13 | Page
SAFETY INSTRUCTIONS
Switch off the machine before replacing filter
element.
Abide by the rules of safe
handling of
lubrication materials.
3.4 Air filter and coolers cleaning
3.4.1 Electrical cabinet air filter
cleaning
Switch off machine
power then remove
air filter cover.
Take out
filter element.
Use compressed air or vacuum cleaner for
filter cleaning.
If filter element is oiled or damaged,
it has to be replaced with a new one.
14 | Page
SAFETY INSTRUCTIONS
When cleaning
filter, beware of dust.
Do not inhale.
3.4.3 Water oil cooler cleaning
Before cleaning, stop the machine and close
cooling water flow.
Water out
Water in
15 | Page
1 – Rear cover
4
– Cooler body
7 – Front Wall
10 –
Fixture
2 – “O” Ring
5 – Barrier
8
– “O” Ring
11 – Base
3 – Rear wall
6 – Cooling
Pipes
9 – Front Wall
12 – Fixing screws
Unscrew fixing screws (pos.12) on both
sides.
Open the covers.
Use
a nylon brush or pipe cleaner to clean the cooling
pipe (pos.6)
inside. An acid agent of 0, 6
%-0, 8% can also be applied.
Before
assembling, check “O” rings condition (pos.2,
pos8).
Close the covers and fix them
with the screws.
SAFETY INSTRUCTIONS
Switch off the machine and cooling water
supply before cleaning.
Abide by the
rules of safe handling of acid
agents.
机型
60t
90t
120t
160t
200t
260t
320t
400t
480t
560t
650t
800t
1100t
1400t
1800t
2200t
平行度允许范围
合模力为零（mm)
0.15
0.2
0.2
0.24
0.24
0.32
0.32
0.35
0.35
0.35
0.4
0.4
0.45
0.45
0.5
0.5
合模力最大
(mm)
0.1
0.1
0.1
0.12
≥0.08
0.12
0.16
0.16
0.16
0.16
0.16
0.2
0.2
0.2
0.45-0.60
0.2
0.2
0.2
≥0.20
≤0.10
≥0.15
0.25-0.45 ≤0.08
≥0.12
0.15-0.25 ≤0.07
调模螺母间隙
mm
螺杆跳动允许
值
mm
螺杆间隙
(最小处）mm
≥0.05
16 | Page
3.5
Hydraulic system maintenance
3.5.1
Accumulator maintenance
Any intervention,
maintenance, repair must be carried out by a
Qualified and trained personnel.
1.
Gas Valve (for charging)
2. Bladder
3.
Shell
4. Nitrogen 70bar.
5. Poppet valve
6. Hydraulic Oil
(1)
For accumulators 10 to 50 liters
* These parts
are supplied as a kit with Instructions.
Item
Spare parts
1
2
3
4
6
5
5
1 Bladder kit
2* Bladder
assembly
3* Gas valve assembly
4 Gas valve
cap
5 Fluid port assemblies
6* Anti
extrusion ring
7* Drain plug with seal (1)
8* Seal kit
17 | Page
SAFETY INSTRUCTIONS
• Switch off the power supply and release the
pressure.
• Any repair or maintenance work
shall only be
conducted by a certified
professional.
3.5.2 Sliding shoe
pressure adjustment
Sliding shoe pressure
has to be adjusted to prevent damage of tie bars
and moving platen bushes.
Before pressure
adjustment check Teflon plate condition under
slider shoes. !!!
(The Teflon plate is located
under the slider shoe. Its width should not be
less than 2mm. The gap between the
support and
slider shoe should exceed 0.5mm. If it is less,
replace the Teflon plate.)
Make sure the
manometer indicates pressure changes while the
machine is in operation.
The indications
should fluctuate from 20 to 50 Bar.
If a
small-size mould is used, the indications should
not exceed 20 Bar.
If a large-size mould is
used, indications should not exceed 50 Bars.
Pressure is configured with
adjusting
screw.
Ease the fixing nut.
Adjusting screw
and
fixing nut
To
increase the pressure, rotate the
Manometer
screw clockwise.
Pressure
outlet
To decrease
it, rotate
18 | Page
counterclockwise.
After configuration, open and close the
mould
to make sure the pressure is
adjusted
properly.
Tighten the fixing nut.
SAFETY INSTRUCTIONS
Do not fully unscrew
the adjusting bolt.
3.5.3 Low
pressure clamping adjustment
Hydraulic
distributor of the clamping system has the option
to configure the low pressure (LP)
high limit
using the adjusting knob (1). This is required to
protect the mould from damages.
Mechanical
adjustment allows limiting the maximum clamping
pressure in the L-P area.
After pressure
adjustment, Screen settings pressure parameter
values cannot exceed the
mechanically set
limits.
SAFETY INSTRUCTIONS
Do not fully unscrew
the adjusting bolt.
19 | Page
3.5.4 Mold close back pressure
adjustment
Hydraulic distributor of the
clamping system has the option to configure
clamping back pressure
using the adjusting
knob (2). This ensures smooth acceleration and
deceleration of the mould
during clamping.
Mechanical adjustment allows limiting the
acceleration and deceleration time.
SAFETY
INSTRUCTIONS
Do not fully unscrew the
adjusting bolt.
20 | Page
3.5.5 Mold open back pressure
adjustment
Hydraulic distributor of the
clamping system has the option to configure
opening back pressure
using the adjusting knob
(3). This ensures smooth acceleration and
deceleration of the mould
during opening.
Mechanical adjustment allows limiting the
acceleration and deceleration time.
SAFETY
INSTRUCTIONS
Do not fully unscrew the
adjusting bolt.
21 | Page
3.5.6 Hydraulic safety devices checking
Hydraulic safety valve checking is executed as
follows:
Turn on the machine and start
the pump.
Check that the mould moves
forward and backward
smoothly.
Press the hydraulic safety valve.
Press
the “Mould Close” button. The pressure
should
increase while the mould remains static if
the
valve functions properly.
Unblock the
safety valve.
If the machine’s tonnage
exceeds 600 ton, check all
the hydraulic
safety devices on the rear and front
side.
To prevent accidents, check the hydraulic
valve condition regularly.
22 | Page
SAFETY
INSTRUCTIONS
Be careful when checking the
devices.