MGKZ-125稀油站中英文使用手冊

1、稀油站使用手冊LUBRICATING STATION型號：MGKZ-125北京中冶邁克液壓有限責(zé)任公司BEIJING MECC HYDRAULIC目 錄安全說明.正確使用.說明.型號說明.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.用于潤滑時的投入運(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.電用戶手冊前言l 本用戶手冊是用來讓用戶熟悉元件/潤滑系統(tǒng)并正確使用該系統(tǒng)。必須在元件/潤滑系統(tǒng)使用的現(xiàn)場配備該手冊。必須讓所有負(fù)責(zé)該元件/潤滑系統(tǒng)的人員閱讀和使用該手冊，如從事以下作業(yè)的人員：l 操作，包括運(yùn)行過程中的調(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/潤滑系統(tǒng)的用戶必須告知其本 手冊內(nèi)容，特別是安全說明。l 操作規(guī)程包括有關(guān)本元件/潤滑系統(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/潤滑系統(tǒng)的可靠性并延長其使用壽命。必須遵守關(guān)于事故預(yù)防及環(huán)境保護(hù)的相關(guān)國家法律法規(guī)中的規(guī)定。安全說明l 操作規(guī)程中包含了在元件/潤滑裝置在安裝、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。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明以及其他主要章節(jié)所給出的特殊安全說明。操作規(guī)程中的危險標(biāo)識標(biāo)準(zhǔn)DIN 4844-W9規(guī)定的安全標(biāo)識符號l 上述符號表示若不遵守操作規(guī)程中的該條規(guī)定，可能會人身傷害。標(biāo)準(zhǔn)DIN 4844-W9規(guī)定的安全標(biāo)識符號l 該符號表示帶電。CAUTIONl 該符號表示警告，若不遵守該安全說明可能會導(dǎo)致機(jī)器損壞或故障。l 必須注意那些標(biāo)識在設(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]有閱讀安全規(guī)程所導(dǎo)致的危險l 沒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 沒有閱讀安全注釋可能會導(dǎo)致設(shè)備損壞的所有索賠權(quán)的喪失。l 作為舉例，我們在下面列出了一些因?yàn)闆]有認(rèn)真閱讀警告而可能帶來的危險：機(jī)器/系統(tǒng)無法實(shí)現(xiàn)重要功能的故障無法進(jìn)行特定的維護(hù)與維修方法由于電、機(jī)械和化學(xué)影響所帶來的人身傷害由于有害物質(zhì)的泄露而造成對環(huán)境的危

5、害具備安全意識的工作必須遵守本操作規(guī)程中所給出的安全說明。為避免造成事故而制定的現(xiàn)行國家法律法規(guī)。任何工作和工廠規(guī)章制度和事故預(yù)防措施。用戶/操作人員安全說明l 如果熱的/冷的機(jī)械部件可能存在危險，那么客戶必須防止意外接觸情況。l 在機(jī)器運(yùn)行時，不得卸開運(yùn)行部件的保護(hù)裝置。l 對有害物質(zhì)泄露的處理不得對環(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。維護(hù)、檢查和安裝工作的安全說明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)行時絕不要對機(jī)器進(jìn)行任何次類操作。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，制造商將不對所帶來的后果負(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。不得超過技術(shù)數(shù)據(jù)中所列出的最大額定值。l 由于電壓問題，禁止在東南亞國家使用本產(chǎn)品，如需使用，得通過廠家確認(rèn)更改電機(jī)電壓后方可使用。正確使用

7、l MGKZ-*型稀油潤滑站是專為減速箱齒輪、傳動軸承等稀油潤滑設(shè)計的。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)，不得長時間低溫或高溫的情況下運(yùn)行。l MGKZ-*型稀油潤滑站有多種型號可供選擇，適于多個領(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，且我們將不對其他應(yīng)用的損失索賠作保證和責(zé)任承擔(dān)。 說 明型號說明：l 整個稀油站型號上的編碼進(jìn)行定義型號編碼舉例：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)量超出一個時只需要在后面注明，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在訂貨前詳細(xì)說明，無其他說明則按標(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)潤滑系統(tǒng)，它向減速機(jī)、齒輪座等摩擦部位供送潤滑油。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)級于原重機(jī)標(biāo)準(zhǔn)的稀油站。尤其是儀表盤、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)的粘度等級為N22N320工業(yè)潤滑油，本油站通常安裝在主機(jī)附近的地下油庫內(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，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)潤滑點(diǎn)的要求，通過調(diào)節(jié)安全閥確定使用壓力，當(dāng)油站工作壓力超過安全閥的調(diào)定壓力時，安全閥打開，多余的油液流回油箱；同時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)備的潤滑點(diǎn)，油站的高壓泵裝置的最高工作壓力為MPa

10、，當(dāng)壓力達(dá)到MPa時安全閥打開，從而使設(shè)備的最高壓力不超過最高壓力MPa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，備用泵開始工作，保證向主機(jī)供送潤滑油。l 稀油站設(shè)有兩臺高壓油泵，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，備用泵開始工作，保證向主機(jī)供送潤滑油。l 采用雙筒網(wǎng)式濾油器，該濾油器有兩組過濾濾芯，一組工作，一組備用。當(dāng)工作濾芯壓差超過0.05MPa需更換時，人工調(diào)整轉(zhuǎn)換閥使備用濾芯工作，同時更換原工作濾芯。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)有磁性過濾裝置，可將回油中的細(xì)小鐵

11、磁物質(zhì)吸附過濾，保證油液的清潔度。l 儀表盤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)對油站的自控與監(jiān)控；E+H壓差發(fā)訊器用來檢測雙筒網(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)自動控制及機(jī)旁操作，低壓油泵正常工作時，一臺工作，一臺備用，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，通過壓力變送器控制，備用泵自動啟動替代原工作泵工作，原工作泵待工作壓正常后停泵（其延時時間根據(jù)現(xiàn)場情況決定）。當(dāng)壓力繼續(xù)下降到另一調(diào)定值0.05MPa時，發(fā)出事故報警并命令主機(jī)停機(jī)。油站出油口裝有熱電阻對出口油溫進(jìn)行控制，當(dāng)油溫>

12、45時，冷卻水閥接通；當(dāng)油溫>60時，主機(jī)停機(jī)并報警。當(dāng)油箱油溫低于17時，接通電加熱器，當(dāng)油溫升至40時，自動切斷加熱器。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，避免了直接加熱時因局部加熱測試過高使?jié)櫥妥冑|(zhì)而影響潤滑油的性能。稀油站的系統(tǒng)原理圖及外形圖詳見聯(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，無須地腳堅固。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)場安放平衡，即可連接出油管、回油管、水管等，現(xiàn)場安裝完畢后，用濾油車過濾加油，經(jīng)試運(yùn)轉(zhuǎn)正常后即可投入工作。操作規(guī)程l 根據(jù)工藝要

13、求如工作油溫低于17時，開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過濾濾芯工作位置上，打開稀油站相應(yīng)的油、水閥門和壓力表開關(guān)，檢查油冷卻器螺栓是否松動。l 在主機(jī)開機(jī)前先開啟稀油站工作油泵，待系統(tǒng)工作壓力正常后，再啟動主機(jī)，主機(jī)停機(jī)后才可停泵。l 稀油站開機(jī)前，應(yīng)先啟動油泵電機(jī)，觀察電動機(jī)轉(zhuǎn)動方向是否正確。l 啟動油泵后，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，則有相應(yīng)的信號燈亮或音響報警。并對報警部位作必要處

14、理。l 稀油站在工作中應(yīng)經(jīng)常觀察儀表盤上的壓力表，當(dāng)壓力表壓差超過0.05MPa時，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，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 磁過濾器每三個月清洗一次。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)，及時進(jìn)行更換和補(bǔ)充潤滑油，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)打開油箱下部兩閥門將水放出。各組元件使

15、用和維護(hù)方法詳見有關(guān)的說明書。潤滑系統(tǒng)檢查方法如下常規(guī)故障評估表：序號故障現(xiàn)象可能原因采取措施1油溫過高冷卻器堵或結(jié)垢，油箱油液太少，安全閥壓力設(shè)定太低，溫控儀誤動作啟動加熱器，液壓泵站通風(fēng)不好，過濾器堵油液經(jīng)旁路走，電磁水閥有損壞，水冷卻過濾器中有臟物。清洗過濾器，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，油溫過高密封老化，密封在組裝時有損壞，螺紋接頭松動。更換油液，更換密封，擰緊螺紋接頭。3壓力波動油中混入空氣造成不均勻運(yùn)動，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，對泵進(jìn)行修理或更換，將安全閥更換或修理。4泵的

16、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，油箱內(nèi)的油位過低，油溫過低。檢查管網(wǎng)有無漏氣，將螺栓擰緊，檢查有無漏油重新加油，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，潤滑系統(tǒng)出現(xiàn)壓力沖動。檢查緊固件是否損壞或松動，檢查感應(yīng)塊固定情況。6建不起壓力系統(tǒng)壓力上不來，回程或推程壓力上不來。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)以及修理過程中發(fā)現(xiàn)的問題記錄在檢查表中。l 如果檢查中發(fā)現(xiàn)某些零部件需要

17、更換，應(yīng)確保及時將相關(guān)的備件備齊。l 如果維護(hù)工作需要將系統(tǒng)拆開，則應(yīng)確保周圍環(huán)境特別清潔，溢漏的潤滑油絕對不能再使用。l 除對具體部件進(jìn)行檢查外，維護(hù)和修理工作還應(yīng)包括對潤滑油、潤滑管道連接件擰緊、泄漏、泵站工作噪音和潤滑油溫度的檢查。潤滑油：l 對潤滑油的要求：只能使用規(guī)定的潤滑油，產(chǎn)地和質(zhì)量不同的液壓油不能混合在一起用，泄漏的潤滑油不可以重新使用，必須確保使用的潤滑油滿足系統(tǒng)清潔度的要求（本系統(tǒng)所采用的是潤滑油#320，用戶現(xiàn)場需備潤滑油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月，以后正常周期為一年，具體時間根據(jù)現(xiàn)場觀察油液定。l 影響潤滑油質(zhì)量的因素：

18、來自周圍環(huán)境的贓物（在灌裝或泄漏時進(jìn)入的碎肖，密封材料、塵土和空氣中的水氣），運(yùn)行過程中形成的贓物（潤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）；水會使油乳化，可明顯呈乳白色，增加油老化速度，老化物會增加磨損、阻塞、粘堵、生銹。l 潤滑油檢查：對液壓油進(jìn)行經(jīng)常性檢查是必要的，因?yàn)槿绻臀坏陀谧畹陀臀?，那么油的工作溫度將升高，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），會使液壓油在使用過程中變質(zhì)，如果臟物和油的老化超過一定的限定值，那么必須將油更換，換油太遲會增大系統(tǒng)發(fā)生故障的可能性。l 日常檢查：油液顏色、溫度，

19、系統(tǒng)壓力，泵、電機(jī)聲音，系統(tǒng)有無漏油，泵的溫度。換油注意事項(xiàng)：l 抽出使用過的油：確保系統(tǒng)處于停機(jī)狀態(tài)，潤滑油使用濾油小車通過油箱上的空氣過濾器連接法蘭口抽出，抽完后打開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)，此過程使用濾油小車來完成。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，換潤滑油時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铀僖簤河屠匣?，根?jù)情況更換濾芯，濾油小車在使用前必須清洗干凈。試車運(yùn)行的準(zhǔn)備管道： l 充分的沖洗：雜質(zhì)的等級20級以內(nèi)NA

20、S1638；管夾應(yīng)準(zhǔn)備充分：通常在直管路上，間隔1000MM-2000MM，當(dāng)管道振動較大或彎曲點(diǎn)過多的情況下，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：一般參照潤滑泵頂部銘牌上箭頭方向和潤滑設(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，給每一個電器元件單獨(dú)通電以確定磁體是否按動作執(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，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)向后，正常啟動電機(jī)，把油

21、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，按順時針方向；同時目光注意著儀表盤上相應(yīng)的壓力表，直到表針指到參數(shù)表內(nèi)所提供的數(shù)值時鎖緊旋鈕；此時壓力調(diào)整完畢，最后停止電機(jī)再重復(fù)啟動幾次待確認(rèn)壓力值設(shè)定無誤的情況下把所有閥門按正常工作時打開。流量調(diào)節(jié)：l 在調(diào)試時，注意出口處相應(yīng)的壓力表，調(diào)整各個出口處的節(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：電機(jī)參數(shù)：5.5Kw 480V 60HZ高壓流量：20 L/min MPa電機(jī)參數(shù)：18. 5Kw 480V 60HZ油箱容積：2 m3冷卻面積：17 m2 m3/h過濾面積：13 m2 過濾精

22、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.pressure adjustment.flow missi

23、oning.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. Operators who do not understand English sho

24、uld 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 national laws and regulations on environment

25、 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.Danger SignalStandard: DIN 4844-W9 l If

26、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 caution readable. Personnel qualifying and

27、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 station after reading this manual. Dama

28、ge 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 follows:Equipment/ system cant achieve t

29、he 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 this manual, national laws and regulati

30、ons 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 leaked detrimental substance, dont pol

31、lute 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 normally when it is running. Follow the requ

32、irement 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 confirmation from the manufacturer, and all cha

33、nged 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 using the station in southeast countries b

34、ecause 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 value, and the rated value is from 8bar to

35、 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, transport, building, and plastic. If the use

36、r 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. The last two presents outlet number. Th

37、e 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 lubrication oil to the friction part. This

38、 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 is N22N320，this station is mounted under

39、 / 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, LP pump sucks oil from reservoir via c

40、heck 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 valve is open, redundant oil flows back to

41、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 MPa. If the pressure is higher than MPa, safe valve is open.Lubrication station has following characters:l This stat

42、ion 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 than 3 MPa, the standby pump begins to work.l Th

43、is 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 unit is mounted at the return line. This filter u

44、nit 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 outlet line. E+H differential pressure sensor che

45、cks 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 commissioning The station is installed on the g

46、round. 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 reaching the job site. After installation, use filter

47、 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 pressure gauge switch. Check whether bolts of coole

48、r 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. pressure is 0.4 MPa, min. pressure is 0.1MPa, ultr

49、a-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.l Visual check the pressure gauge. If the pressu

50、re 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 months. Eliminate inner contaminant and change ele

51、ment.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. l Visual check the lowest oil level. If there

52、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. Pressure value is not high enough. Open heater by mis

53、take. 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. 3Pressure vibrationOil and air mixes to cause mov