TABLE OF CONTENTS

1. INSTALLATION1 1.1TRANSPORTATION1 1.2 TOOLS3 1.3 INSTALLATION.3

1.3.1 PREPARATION FOR INSTALLATION3 1.3.2 INSTALLATION PROCEDURE3

1.4 UTILITY REQUIREMENT4 1.4.1 ELECTRICAL REQUIREMENT4 1.4.2 OIL REQUIREMENT..4

1.5 ENVIRONMENTAL REQUIREMENTS5 2. THEORY OF OPERATION6

2.1 GENERAL ..6 2.2 OVERVIEW7

2.2.1ADJUSTMENT OF THE PRESS.7 2.2.2 STROKE ADJUSTMENT..8 2.2.3 MANUAL OPERATION.9 2.2.4 AUTOMATIC OPERATION..9 2.2.5 AUTO-RETURN OPERATION ..9 2.2.6 ASSEMBLY OF DIES AND DIE ADAPTERS 10 2.2.7 PROCEDURE OF DIES AND DIE ADAPTERS INSTALLATION.....11

2.3 SYSTEM STARTUP...22 2.4 EMERGENCY STOP..23

2.4.1 EMERGENCY STOP BUTTONS LOCATION...23 2.4.2 RESTARTING THE SYSTEM AFTER AN EMERGENCY ST23

2.5 POWER DOWN PROCEDURE23 2.6 TECHNICAL DATA ..24

2.6.1 C-TYPE HYDRAULIC CLAMPING PRESS MACHINE...24 2.6.2 TWO COLUMN HYDRAULIC CLAMPING PRESS MAC.25

APPENDIX ASPLICING TABLE FOR ALUMINUM FERRULE EN 13411-3 (DIN 3093)..26 APPENDIX B : SPLICING TABLE FOR FLEMISH EYE STEEL SLEEVES..28 APPENDIX C : OIL RECOMMENDATION..29

3 NSTRUCTIONS OF MAINTENANCE...30

3.1 GENERAL...30 3.2 ELECTRICAL SAFETY.....30

3.2.2 ELECTRICAL SAFETY GUIDELINES....30 3.3 RECOMMENDED MAINTENANCE SCHEDULE.....31 3.4 HYDRAULIC OIL REPLACEMENT...33

3.4.1 OIL CHANGE.....33 3.4.2 CONDITION OF THE HYDRAULIC OIL....33

3.4.3 RECOMMENDATION OF OIL.33 3.4.4 PROCEDURES FOR OIL CHANGE.....33

3.5 SAFETY DURING MAINTENANCE...35 4 TROUBLESHOOTING...36

1. INSTALLATION This chapter provides system specifications and facility requirements. These subjects will be addressed in the following sections:

z Transportation of the machine z Tools z Procedure for installation z Utility requirements z Environmental requirements

The following environmental and utility requirements are necessary for warranty validation and will help to ensure the performance quality and reliability of the machine. 1.1 TRANSPORTATION

The WIROP Hydraulic Clamping Press Machine weighs at least 500 kgs (WP-4000 can weigh as much as 36 Tons). Please handle with extreme care. 2-Column Hydraulic Clamping Press has to be fastened directly to the floor of a container by wire ropes with wood blocks as sleepers under the machine due to its size and weight. C-type Hydraulic Clamping Press will lie on the pallet and will be covered with wooden box. They have to be handled differently. Please read the following notes before attempting to transport or move the system. z When moving WIROP press out of the container, please use forkliftpicture 1-1or

overhead cranepicture 1-2.

picture 1-1 picture 1-2

1

Holes for Forks

z The capacity of the crane or forklift has to be able to sustain 1.33 times minimum the weight of machine.

z When using the forklift, put the forks into the bottom holes of the press to prevent unbalance or tipping the load falling down.(see picture 1-1)

z The weight of the hydraulic clamping press machine for every model is as follows:

Model WT-40C WT-80C WP-150C WP-300H WP-300C WP-600H WP-600C

Weight 500 kgs 800 kgs 850 kgs 1490 kgs 1800 kgs 3155 kgs 5400 kgs

Model WP-1000 WP-1250 WP-1500 WP-2000 WP-3000 WP-4000

Weight 7500 kgs 8500 kgs 11000 kgs 18500 kgs 28000 kgs 36000 kgs

z The crane or forklift operator has to be certified by local government to perform the job.

2

1.2 TOOLS The following tools and supplies may be necessary for transporting, unpacking, and installing the machine. 1. A forklift or crane with the loading of 1.33 times minimum the weight of machine. 2. Screw gun for removing the crate or wooden box. 3. Hard hat goggles and steel-toe working shoes for the operators. 1.3 INSTALLATION 1.3.1 PREPARATION FOR INSTALLATION The hydraulic fluid applied in our series of machines are heavy-duty hydraulic oil with class AW (grade no.: 68 AW) or as equal ( ref .Appendix C at bottom page 29) Volumes of hydraulic oil for each model are as follows:

Model WT-40C WT-80C WP-150C WP-300C WP-600C Qty 50 L 105 L 110 L 140 L 300 L Model WP-1000 WP-1250 WP-1500 WP-2000 WP-3000 WP-4000 Qty 650 L 750 L 800 L 1200 L 3200 L 3200 L

1.3.2 INSTALLATION PROCEDURE Do not start the machine without oil. 1. Secure the system from vibration on the base. 2. Fill the hydraulic oil tank with specified hydraulic oil and make sure the oil level is in the level observer window. Inside the gauge, it also shows the oil temperature.picture 1-3

picture 1-3 3

3. Have qualified engineer check the electrical connections,do not energize the system before this is completed. 1.4 UTILITY REQUIREMENT 1.4.1 OIL REQUIREMENT Only specific hydraulic oils are allowed to apply on the machine due to ensure good sealing and operating conditions. The reliability of the machine depends on the quality of the hydraulic oil used. For this PRESS installation we would like to recommend hydraulic oil of the class AW (grade no.: 68 AW) or as equal. 1.4.2 ELECTRICAL REQUIREMENT Our hydraulic clamping press machine has different power specifications for various voltages level. For example, we offer 220V for Taiwan, 415V for Singapore and 380V for European Community. Make sure voltage matches your power supply. Turn on the main breaker and circuit breakers in the control box.see picture 1-4 After connection, turn on the power, start the motor on and shut off immediately to check the motor direction.see picture 1-5If it does not match the direction shown ,switch any 2 power wires of the 3 phases.

picture 1-4

4

PLC

Main breaker

Circuit breakers

Overload relay

picture 1-5

1.5 ENVIRONMENTAL REQUIREMENTS

1. Temperature: -5 ~ 40 when temperature is over 65149a cooling system is recommendedCheck the temperature from the oil gauge.picture 1-3

2. Humidity: under 95%

5

Direction

2. THEORY OF OPERATION 2.1 GENERAL Instruction The hydraulic clamping press machine is to be used for clamping sleeves, ferrules, sockets or stopper for wire rope. The sleeves, ferrules, sockets or stoppers are made of aluminum, copper , steel or stainless steel. Any other material should be checked by authorized personal before using. The machine could cause a fatal accident if not properly used. The manufacturers recommendation for proper swaging of sleeves, sockets, ferrules and stoppers or buttons must be adhered to. These recommendations (e.g. EN 13411-3 etc.) must be known to the qualified operator. Never put hands in between the dies or die holders. Do not put things i.e. tools , sleeves in the operating area of the machine. 1. Main power switch

2. Pump stop button 3.Down buttonsame Foot Level Down 4. Power lamp

5. Pump start button

6. Up button (same Foot Level UP)

7. Stroke adjustment switch(Timer)

8. E-stop button

9. Operative selection switch with key

10. Pressure setting knob

11. Electric Hazard W.L

12. Bar key to open the control box

13. Pressure gauge

Picture 2-2

6

Foot Level Switch

picture 2-3

Pressure setting knob

picture 2-4

2.2 OVERVIEW 2.2.1 ADJUSTMENT OF THE PRESS Before adjusting the presses there are some items the operator should inspect. 1. The pressure setting handlepicture 2-4must be adjusted to the required level for each

specific application. (refer the dial of pressure setting)By turning the setting handle. 2. The required pressure may exceed the working pressure level by 10. 3. Do not fully extend the piston without the dies in the press. 4. Do not move the piston to the most with out inserted swaging dies. 5. Damaged swaging dies are not to be inserted.

7

6. You will have to use swaging dies delivered or approved by the manufacturer or distributor only.

7. All parts of the PRESS must be checked for safety by authorized supervisor at least once a year.

8. In case of changing of location, it is necessary to interrupt the electric circuit. 9. The CE Machinery Directive would loose its status of conformity if the control circuit or

original design is changed. 10. Any arbitrary alteration would releases the manufacturer from his warranty obligation. Any

arbitrary alteration of the original design would endanger the operator and also damage the machine.

STROKE ADJUSTMENT By switching the electronic TIMER(No.7of picture 2-2), the stroke of the piston can be adjusted. (The opening width between the swaging dies can be adjusted by the timer. )Please dont adjust the timer to enter the red zone. After setting the press, the hydraulic clamping press machine is able to operate either manually or automatically. 2.2.2 MANUAL OPERATION:(engage the foot switch to get movement) 1. Turn to manual position MANU ( picture 2-2, No.9) 2. Adjust the pressure to appropriate level by using force adjust handle.( picture 2-2, No.10) 3. Insert the swaging dies. 4. This item 5 has been added. 5. Grease the swaging dies socket and or sleeves. 6. Start the pump motor is started by pushing the button MOTOR ON 7. Insert the fitting to be swaged into the chosen die cavity dead centre. 8. The stated pressure force is indicated (in kg/cm2) at the manometer( picture 2-2, No.13) . 9. To keep touching foot switch DOWN or button DOWN ( picture 2-2, No.3) to

downward the piston until it is possible to take off the rope without any problems. 10. With this adjustment of the Force (pressure) setting handle( picture 2-2, No.10), for

different size of rope. 11. After finishing a series, it is absolutely necessary to retract the pressure force setting handle

to low level( 10 on Fig 2-2).

8

2.2.3 AUTOMATIC OPERATION It means One touch UP to move upward and automatically return to the set position. Before the first automatic operation can be effective, it is necessary to try out for the required pressure force on a manual operation process. 1. Turn the switch onto position (AUTO) ( picture 2-2, No.9)by the key switch. 2. Adjust the required pressure force by means of Force (pressure) setting handle indicator.

( picture 2-2, No.10) 3. Adjust the return stroke by adjusting the Stoke adjustment switch.( picture 2-2, No.7) 4. Grease the swaging die and the sleeves. 5. Start the closing process by one touch to the foot switch. ( picture 2-2, No.6)The cylinder

will go up to reach the set pressure and return automatically to the position set by theStoke adjustment timer ( picture 2-2, No.7)

6. In case of emergency ,touch the emergency stop button( picture 2-2, No.8) to shut down the power.(To re-start the machine, turn the emergency stop button clockwise. Then re-start the motor.)

2.2.4 AUTO-RETURN OPERATION (A.R.) 1. Turn the switch onto position (A.R.) ( No.9)by the key switch. 2. Adjust the required pressure force by means of Pressure Setting Knob indicator. ( No.10) 3. Adjust the return stroke by adjusting the Stoke adjustment switch.( No.7) 4. Grease the swaging die and the sleeves. 5. Keep touching foot switch UP or button "UP"( No.6) .The cylinder will go up to reach the set pressure 6. When release foot switch UP or button "UP"( No.6) .The cylinder will be reversed. 7. In case of emergency ,touch the emergency stop button( No.8) to shut down the power. (To re-start the machine, turn the emergency stop button clockwise. Then re-start the motor.) 2.2.5 CHANGING DIES The change of the swaging dies requires a total attention in to avoid any hurts and damages.Fpr the processing of rope clamps you must use corresponding sets of swaging dies depending on rope diameter and construction.For DN3093(EN13411-3)Al. Ferrules ref. Appendix AFor Flemish eye steel sleeves ref. Appendix B Before installation dies and die adapters. 1. Turn the selector switch tomanual position.( picture 2-2, No.9) 2. Release the pressure handle by counter-clockwise to the low pressure level. 3.To install dies and die adapters refer 2.2.6 Assembly of dies and die adapters and 2.2.7

Procedure of dies and die adapters installation.

9

2.2.6 Assembly of dies and die adapters Wirop Standard Dies block dimensions

Type Dimension

S 80mmx78mm M 100mmx78mm A 156mmx110mm B 220mmx150mm C 250mmx200mm D 300mmx230mm

10

Fig2-3

Fig2-3-1

11

Fig2-3-2

Fig2-3-3

12

2.2.6 Procedure of dies and die adapters installation

Use a die hanger or magnet lifting device to

lift the die.

picture 2-3 1.1

Put the lower die on the die platform.

picture 2-3 1.2

13

Die hanger

Die platform

Put the upper die on top of the lower die.

picture 2-3 1.3

Move the lower die holder to the

level of the bottom of the lower die.

(picture 2-3 1.4

14

Make sure that the die guides are not in the way of the die block when inserting the die block into the holder, this will prevent the dies colliding with the guide and causing harm to the dies and possible injury to the installer.

picture 2-3 1.5

Use manual mode to move the dies

up to just about reach the top. The dies should now be able to slide

over guide and into their proper position.

Close the dies slightly but not enough to allow easy movement to adjust them to there final position.

Tighten the fixing bolts.

picture 2-3 1.6

15

Slot

Guide

Fixing bolts

gap

Install the lower die adapter (C/D)

onto the die holder.

picture 2-3 1.7

Put the lower die (c type) on the die platform.

Put the upper die on top of lower die. Set the upper die adapter on the upper

die.

picture 2-3 1.8

16

(C/D) die adapter

Move the piston to level the lower die

holder to the level of the lower die. Push the dies and die adapters partially

onto the die holder. Caution

Take care that the die adaptyer. does not collide with the guide when moving the piston up.

picture 2-3 1.9

Use Manual move the dies up to

just about reach the top. The dies should now be able to

slide over the guide and into their proper position.

Close the dies as close as possible but still allow a movement for fixing the dies.

* Tighten the fixing bolts.

picture 2-3 1.10

17

Guide

Slot

Fixing bolts

Put the lower die adapter (B/C

or A/C) or the die holder with die adapter.

picture 2-3 1.11

Place the upper die (B type or C

type) on top of the lower die using a die hanger or magnet lifting device.

Place the upper die adapter on top of the upper die.

picture 2-3 1.12

18

Move the lower die holder so the dies and adaptors can be pushed partially onto the die holder.

CautionMake sure the upper die adapters do not collide the guide.

Use Manual move the piston up to let the upper die adapter just about reach the top.

The upper adapter should now able to slide over the guide into its proper position.

Close the dies and adapters as close as possible by Manaul method and then fix the bolts in place.

picture 2-3 1.13

When changing smaller dies, no need to move out the die adapters. Just change the dies, the die adapters remain on the die holders.

picture 2-3 1.14

19

gap

Changing smaller dies place

upper and lower die on die platform.

picture 2-3 1.15

Move the piston to bring the

lower die holder to the level of the bottom die.

picture 2-3 1.16

20

Leave a gap between the

dies and the die adapters bigger than the button.

Caution: Take care that the die does not collide with the button when moving the piston up.

picture 2-3 1.17

Push the dies side holes to

the buttons. Tighten the fixing bolts.

picture 2-3 1.18

21

Fixing bolts

2.3 SYSTEM STARTUP The operator must strictly observe the regulations of the safety authorities. The following points are to be especially observed during working at the PRESS due to safety: 1. Only skilled and qualified workers are allowed to operate at the PRESS. 2. If a new operator is going ti be swaging, it is mandatory that they be trained by a qualified

operator, This training to include the possible dangers of operating the press and the proper techniques of swaging and inspection of the finished swaged product.

3. The operator must always observe attentively all cycles of operation. 4. The operator must wear the necessary safety clothing and shoes. 5. When the PRESS runs, unauthorized persons are not allowed to be present at the danger

area. 6. The danger area of the PRESS must be marked black / yellow. 7. In the danger area of the PRESS foreign materials (parts of the body, tools, etc.) are not

allowed. Every time when shift begins, following performance checks will have to be effected after

starting the machine: a) Perfect function of emergency-stop circuit. b) Perfect function of Force(pressure) setting. c) Perfect reverse/ forward of the piston. d) Failures or irregularities during the machine operation have to be reported to a the

competent foreman or operator. The machine must be locked out or stopped until the irregularity has been eliminated and the foreman or competent operator has given permission to proceed.

e) In case that the Irregularity cannot be eliminated by specialist on site, it will be necessary to inform the competent after sale- service:

Wirop Industrial Co., LTD. 806,Fong-Pin 1st Rd., Kaohsiung Hsien ,Taiwan TEL: +886-07-7019369 ,FAX:+886-07-7019623

E-mail: wirop@wirop.com.tw

22

2.4 Emergency Stop 2.4.1 EMERGENCY STOP BUTTON LOCATION In case of emergency, push the button to shut down the power of the machine.picture 2-2 No.8 2.4.2 RESTARTING THE SYSTEM AFTER AN EMERGENCY STOP

a) Push the emergency stop button and turn the button clockwise. b) Push pump start button to start the machine.

2.5 POWER DOWN PROCEDURE

a) Push pump stop button.picture 2-2 No.2 b) Turn off the power. picture 2-2 No.1

23

2.6 TECHNICAL DATA 2.6.1 C-TYPE HYDRAULIC CLAMPING PRESS MACHINE

Model Technical data

WT-40C WT-80C WP-150C WP-300C WP-600C

Column 1 1 1 1 1 Max. pressure capacity (T) 46 89 147 315 605 Max. wire rope Dia.(mm) Al.ferrnles one stage 8 10 16 26 36

Power supply (HP) 5 7.5 5 7.5 15 Max. current

(A)380V/220V 8.6/15 12.7/22 8.6/15 12.7/22 26/45

Max. oil pressure (bar) 230 270 300 300 300 Max. piston stroke (mm) 50 55 55 70 85 Unloaded speed (mm/s) 7.14 6.2 25.4 11.7 13.2 Loaded speed (mm/s) 7.14 6.2 3.6 1.7 2.3

Reversing speed (mm/s) 10 7.3 33.9 14.5 16.9 Foot switch + + + + +

Auto/ Manu selection + + + + + Operation height 1100 1150 1130 1240 1340

Dimension L x W x H (mm)

600x800 x1430

600x900 x1700

1000x560 x 1600

1200x600 x1800

1530x750 2150

Approx. weight (kg) 500 800 850 2200 5400

24

2.6.2 TWO COLUMN HYDRAULIC CLAMPING PRESS MACHINE Model Technical data

WP-1000 (2)

WP-1250(2)

WP-1500 (2)

WP-2000 (2)

WP-3000 (2)

WP-4000(2)

Column 2 2 2 2 2 2 Max. pressure capacity (T) 1051 1318 1500 2029 3057 4100

Max. wire rope Dia.(mm) Al.ferrules one stage 48 54 64 68 78

94

Power supply (HP) 20 25 25 30 75 75

Max. current (A) 380V/220V

34.7/60 37/75 37/75 46/80 70/120 70/120

Max. oil pressure (bar) 300 300 300 300 300 300

Max. piston stroke (mm) 100 110 130 160 200 260

Unloaded speed (mm/s) 9.8 8.1 8.8 8.9 8 6

Loaded speed (mm/s) 1.9 1.2 1.35 1.8 4.8/1.4 3.2/1.05

Reversing speed (mm/s) 12.5 10.1 12.2 11 10 7.5

Foot switch + + + + + +

Auto/Manu selection + + + + + +

Operation height 1150 1220 1250 1560

Dimension L x W x H (mm)

2000x950 x1950

2200x1050x2100

2350x1035x 2250

2700x1340 x 2350

2100x1750 x3110

2300x1750x3110

Approx. weight (kg) 7500 8500 11000 18500 28000 36000

25

Appendix A : Splicing table for Aluminum ferrule EN 13411-3 (DIN 3093) Selection of the correct Aluminum ferrule is to take account of: Measured rope diameter Rope type (and core) Nominal metallic cross-sectional area factor of the rope. Case1 For single layer round strand ropes with fiber core and cable-laid ropes having a metallic cross-sectional area factor C of least 0.283,a ferrule having a size number equivalent to the nominal rope diameter is to be selected from Table A.2. Case2 For single layer round strand ropes with metallic core and for rotation-resistant round strand ropes having a metallic cross-sectional area factor up to 0.487,a ferrule having the next larger size number than the nominal rope diameter is to be selected from TABLE A.2 Case3 For single layer round strand ropes with metallic core and for rotation-resistant round strand ropes and parallel closed round strand ropes having a metallic cross-sectional area factor greater than 0.487 and up to 0.613 the ferrule is to be selected from Table A.2. Case4 For spiral strand rope having a metallic cross-sectional area factor of at least 0.613, ferrules are to be selected having two size numbers larger than the nominal rope diameter, see table A.2. Two ferrules spaced two rope having two rope diameters apart are to be used per termination. After pressing a space is to be maintained between the ferrules.

26

Ferrule size number and die No. Case 1 Case 2 Case 3 Case 4 Rope diameter

Nominal Measured

From to

Single layer round

strand ropes with FC

and cable laid ropes C0.283

Single layer round

strand ropes with

IWRC and

rotation-resistant

round strand ropes C0.487

Single layer round

strand ropes with IWRC

rotation-resistant ropes

and parallel-closed ropes 0.487C0.613

Spiral strands

2 ferrules C0.613

2.5 2.5 2.7 2.5 3 - - 3 2.8 3.2 3 3.5 - -

3.5 3.3 3.7 3.5 4 - - 4 3.8 4.3 4 4.5 - 5

4.5 4.4 4.8 4.5 5 - 6 5 4.9 5.4 5 6 - 6.5

5.5 5.9 - 6 6 6.4

6 6.5 7

7

6.5 6.5 6.9 6.5 7 8 8 7 7 7.4 7 8 9 9

7.5 7.9 9 8 8 8.4

8 9 10

10

8.5 8.9 10 9 9 9.5

9 10 11

11

9.6 9.9 11 10 10 10.5

10 11 12

12

10.6 10.9 12 11 11 11.6

11 12 13

13

11.7 11.9 13 12 12 12.6

12 13 14

14

12.7 12.9 14 13 13 13.7

13 14 16

16

13.8 13.9 16 14 14 14.7

14 16 18

18

14.8 15.9 18 16 16 19.8

16 18 20

20

16.9 17.9 20 18 18 18.9

18 20 22

22

19 19.9 22 20 20 21

20 22 24

24

21.1 21.9 24 22 22 23.1

22 24 26

26

23.2 23.9 26 24 24 25.2

24 26 28

28

Ferrule size number(see A.6) Case 1 Case 2 Case 3 Case 4 Rope diameter

Nominal Measured

From to

Single layer round

strand ropes with

FC and cable laid ropes C

0.283

Single layer round

strand ropes with

IWRC and

rotation-resistant

round strand ropes C0.487

Single layer round

strand ropes with

IWRC

rotation-resistant ropes

and parallel-closed ropes 0.487C

0.613

Spiral strands

2 ferrules C0.613

25.3 25.9 28 26 26 27.3

26 28 30

30

27.4 27.9 30 28 28 29.4

28 30 32

32

29.5 29.9 32 30 30 31.5

30 32 36

34

31.6 31.9 34 32 32 33.6

32 34 36

36

33.7 33.9 36 34 34 35.7

34 36 38

36

35.8 35.9 38 36 36 37.8

36 38 40

40

37.9 37.9 40 38 38 39.9

38 40 44

44

40 40 42 40 44 48 48 42.1 43.2 48 48 44 44 46.2

44 48 52 52

46.3 47.9 52 52 46 48 50.4

48 52 56 56

50.5 51.9 56 52 52 54.6

52

56 60

60

54.7 55.9 - - 56 56 58.8

56 60 - -

58.9 59.9 - - - 60 60 63

60 - - -

27

Appendix B : Splicing table for Flemish eye steel sleeves

FOR WIRE ROPE SIZEinch MAX.AFTER SWAGE DIMENSIONSinch

1/4 0.57 5/16 0.57 3/8 0.57 7/16 1.01 1/2 1.01 9/16 1.24 5/8 1.24 3/4 1.46 7/8 1.68 1 1.93

1-1/8 2.13 1-1/4 2.32 1-3/8 2.52 1-1/2 2.71 1-3/4 3.1

2 3.56 2-1/4 4.12 2-1/2 4.5 2-3/4 4.7

3 4.96 3-1/4 5.37 3-1/2 5.77 3-3/4 6.23

4 6.69 4-1/2 7.45

5 8.28 6 9.93

28

Appendix C : Oil Recommendation

in closed rooms

Temperature below 5C

in closed rooms

Temperature above 5C

Symbol acc. to DIN 51502 HLP

46

HLP

68

AGIP OSO 46

AGIP OSO 68

Aral Vitam GF 46,

Aral Vitam DE 46

Aral Vitam GF 68,

Aral Vitam DE 68

BP Energol HLP 46,

BP Energol HLP-D 46

BP Auto Hydraulic Oel 46

BP Energol HLP 68,

BP Energol HLP-D 68

CASTROL Hyspin AWS 46

CASTROL Hyspin AWS 68

ELF Olna 46,

Hydrelf 46

ELF Olna 68,

Hydrelf 68

NUTO H 46

NUTO H 68

FANAL Salvo MWS 46

FANAL Salvo MWS 68

FINA Hydran 46

FINA Hydran 68

Mobil D.T.E. 25

Mobil D.T.E. 26

Shell Tellus Oel 46

Shell Tellus Oel 68

Rando oil HD B-46,

Hydraulic Oil HDW 46

Rando Oil HD C-68,

Hydraulic Oil HDW 68

29

3 .Instructions of Maintenance Normal Maintenance Measures: The Machine should be cleaned at regular intervals depending on mush it is used. It is especially important to keep them clean for the die holders, die adapters dies. We would recommend cleaning the die holders, die adapters and dies before and after using.

3.1 GENERAL The hydraulic press machine should run trouble free when properly maintained. The recommended maintenance schedule for the machine depends on location and measures of operation. Preventative maintenance is described in this section, as is the correct handling of all parts affected by maintenance work. Only qualified technicians are allowed to perform maintenance and service work. Little errors may cause unexpected outcome and result in expensive service charges.

3.2 ELECTRICAL SAFETY 3.2.1 General electrical hazards High voltage risks are present in the system but are not accessible unless the protective covers are removed without putting them back. Only trained qualified electrical personnel who have a complete understanding of the electrical system are allowed to perform electrical maintenance or service on the press machine. It is the responsibility of every operator to acknowledge the High Voltage Risks which may exist in each component and to be aware that circuits may be wired incorrectly or may not agree with prints.

3.2.2 Electrical safety guidelines There are references to levels of Hot Work (level of electrical hazard) in this chapter. The levels are defined as follows:

Type 1: The equipment is fully de-energized. Type 2: The equipment is energized. Live circuits are covered or insulated. Type 3: The equipment is energized. Live circuits are exposed and accidental

contact is possible. Potential exposures are less than 30 volts RMS, 42.2 volts peak, 240 volt-amps, and 20 Joules The following are the minimum safety precautions that must be followed when servicing high voltage sections of equipment.

1. Assume that all components and parts are grounded and that all circuits are energized, until confirmed otherwise. Do not trust safety equipment to work in every instance.

30

2. De-energize the power source when servicing high voltage components. Use appropriate test equipment to verify that circuits de-energized. If any potential exists in the circuit, use appropriate discharge equipment to drain off the charge.

3. Use only one hand at a time, and keep the other hand free so that no direct path to ground across your body exists. Use your right hand if possible so that the path to ground avoids the heart region. Always work in the protective position; allow space for maneuvering or escape.

4. If at any time there is a question about any wiring or any sensation of electrical shock (tingle) from discharged circuits, check again to verify that the power source is de-energized and all charges have been drained.

5. Always wear non-metallic safety glasses when servicing electrical components. Safety glasses provide protection against debris and prevent injury in the event of a mechanical failure of a device. Metal-framed glasses increase the possibility of electrical if they contact an energized electrical circuit and can damage equipment if dropped into an energized circuit.

6. Personnel who service high-voltage electrical equipment should not wear metallic jewelry. Jewelry increases the possibility of electrocution and could also become entangled with machine parts or shirt-circuit equipment.

7. Use non-metallic and/or insulated tools when servicing high-voltage equipment. Do not use test equipment unless it is rated for the expected voltages.

8. Never touch a conductor, energized or not, if it can be avoided. Do not become part of an electrical circuit. Increase body resistance by increasing distance or insulation.

9. Troubleshoot with the high voltage system energized only if it is absolutely required. 10. Beware of capacitive charges which may exist long after power is removed from a machine.

Always allow at least five minutes after disconnecting the electrical supply before servicing the system to allow capacitive charges to discharge.

11. Apply ground straps to all potential points only after all voltage and charge have been removed from the equipment.

12. Always wear clean, dry, properly-fit clothing and shoes to increase skin resistance and provide physical protection.

3.3 Recommended maintenance schedule 1. Daily: The oil level check has to be effected on piston position run in, if necessary suitable hydraulic oil must be refilled up to the upper mark. Normally, the oil lever is between lower and higher mark. (a) During the operation it is necessary to check the temperature of oil occasionally. The working temperature of the oil should not exceed 65 . Sudden raises in temperature are emergency

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signals and it will be absolutely necessary to stop the machine at once for investigation. (b) Check the function of buttons and switches on the control panel.

2. Monthly: (a) Check of all visible pipe fittings in view of density (leakage of oil). Leaking piping fittings must be tightened under depressurized conditions. 3. After 2000 working hours or 18 months : (Depended on which one arrive first) (a) Replace hydraulic oil. 4 .Cleaning Outer oil filter: Whenever after ruing 5 minutes, to check the indicator on outer oil filter. If it indicates on YELLOW or RED area, the oil filer requires cleaning. Please follow the procedure to clean.

4-1 Release 4 bolts of the outer oil filer

4-2 Release the cover of oil filter

4-3 Take out the cover of outer oil filter

4-4 Take out spring

4-5 Take out oil filter

4-6 To clean oil filter by air and cleaner.

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3.4 . Hydraulic oil replacement 3.4.1 Oil change The first oil change is effected immediately after commissioning. Further oil changes will be necessary alter approx. 18 months. However, it must be guaranteed that the operation temperature is not higher than 65 and that the oil filters are regularly cleaning. A corresponding maintenance of oil and regular checks will prolong the intervals of change. 3.4.2 Condition of the hydraulic oil The maturing of oil is depending on the several working conditions such as temperature, environment dirt, working pressure, humidity, etc. The degree of maturing and with that the usability could be found out by a simple visual check. 3.4.3 Recommendation of oil a) Disposal

The disposal hydraulic oil must be drained and properly handled in conformity with local environmental codes and regulations.

b) Attention You must strictly observe that the hydraulic oil cannot intrude into the food chain.

3.4.4 Procedures for oil change

Power-off procedure a) Wait for at least 5 minutes. b) Use wrench to open oil drain plug c) After draining the hydraulic oil, open the cover of hand hole. d) Use clean clothes to clean the oil tank oil filers and clean the oil filters inside

(ref.Dwg.No.B-B-WPH600C-1 item 5 and 6 and 4-6) e) After cleaning the oil tank, close the oil drain plug and the cover of hand hole. f) To open the oil filling cap and refill with new hydraulic oil.

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3.5 Safety during maintenance

1. Always carry out adjustment, maintenance and inspection work at the scheduled times.

2. Inform the operating personnel that maintenance and repair work is to be carried out. 3. When carrying out any maintenance, repair or inspection work, always disconnect the

press machine from any voltage sources and secure the main switch so that it cant be activated.

4. Check that any screws that have been undone are properly tightened when the machine is reassembled.

5. When the maintenance work is completed, check that the safety devices are operating correctly.

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4.TROUBLESHOOTING

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Trouble Trouble shooting

1. Over-loaded result

in motor stopping

1.Open the control panel

2.Re-set the over-load relay Q1 (refer Dwg.No : B-B-WPE600C-1-04)

3.Restart the machine

4. If the over-load relay trip when you restart the machine. Check

whether your main powers voltage is the same as machines

specification.

2. You can start pump

but cant press up and

down

(Push UP and

DOWN button. The

lamps do not lighten

1. Open the control panel

2. To check whether CB2 and CB3 trip (refer Dwg.No : B-B-WPE600C-1-04)

3. You can start pump

but cant press up and

down

(Push UP and

DOWN button. The

lamps lighten)

1. Open the control panel

2. To check KR1 (for UP) and KR2,KR3 (for DOWN) are in normal

conditions. (refer Dwg.No : B-B-WPE600C-1-04)

3. If KR1 ,KR2 and KR3 are in normal condition. To check the direction

valve DSHG-06-3C60 (refer Dwg.No.: B-B-WPH600C-1. No.4) whether

solenoid valves are burn out or jammed.

4. Losing Pressure.

1.Check whether relief valve RVP-10 painted RED loosen

(refer Dwg.No.: B-B-WPH600C-1. No.10 RED)

2.Check whether High pressure pump IGH-3F-16-R-20 (refer Dwg.No.:

B-B-WPH600C-1. No.5) is out of order.

5. Speed become

lower (in abnormal

condition)

1. Check whether Low pressure pump 150T-75+(IG3F)-FR (refer Dwg.No.:

B-B-WPH600C-1. No.6) is out of order

2. To clean and check LOGIC CARTRIDGE VALVE LE-16B (refer Dwg.No.:

B-B-WPH600C-1. No.7) and COUNTERBALANCE VALVE CB11A33IL (refer

Dwg.No.: B-B-WPH600C-1. No.15)

6. After long time

using, the oil system

make the noise.

To change the hydraulic oil and clean the oil filler