Hydraulic parts installation requirements and commissioning and test run

Installation requirements for hydraulic parts:

I. Hydraulic pump/motor Installation Requirements:

1. Install according to the provisions and requirements of the design drawings;

2, hydraulic pump shaft and transmission mechanism shaft rotation direction must be the required direction of the pump;

3. The coaxiality of the pump shaft and the transmission mechanism shall be within 0.1mm, and the tilt Angle shall not be greater than 1°. When installing shaft joint, it is best not to knock, so as not to damage parts such as hydraulic pump rotor, installation should be correct and firm.

4, fastening hydraulic pump, transmission mechanism of the foot screw, screw stress should be uniform and firm and reliable.

5, when turning the coupling by hand, the hydraulic pump transmission should feel easy, no stuck or abnormal phenomenon, and then can be matched with pipe.

Ii. Hydraulic cylinder Installation Requirements:

1. Install according to the provisions and requirements of the design drawings;

2, the hydraulic cylinder piston rod to drive the moving mechanism to move to achieve flexible and light, in the whole stroke of any local no stuck phenomenon;

3. Before installation, the assembly quality of the hydraulic cylinder itself should be strictly checked. Only after the assembly quality of the hydraulic cylinder is qualified can it be placed on the equipment.

Three, hydraulic valve installation requirements:

Valve components are installed in the form of pipe type, plate type, superposition type and plug type. Different forms of installation methods and requirements are also different, the common requirements are as follows:

1, the installation should check the record of various hydraulic valve test conditions, and whether there is abnormal.

2, check the flatness of the plate valve joint surface and the groove processing size and quality of the installation seals, if there are defects should be repaired or replaced.

3. Installation shall be carried out according to the provisions and requirements of the design drawings.

4. When installing the valve, pay attention to the position of inlet, outlet, return, control, drain and other oil ports. It is strictly prohibited to install wrongly. The reversing valve is well installed horizontally.

5, pay attention to the quality of the installation, the seal quality should be carefully checked, do not install wrong, to avoid damage in the installation; When the fastening screw is tightened, the force should be even. The material and processing quality of the screw should be paid attention to for the high-voltage element. The screws that do not meet the requirements are not allowed to be used.

6, pay attention to cleaning during installation, do not wear gloves for installation, do not use fiber products to wipe the installation joint surface (installation plate plane and valve plate plane), to prevent fiber dirt into the valve.

7. Check the following items after the valve is installed:

8. Push the reversing valve slide valve by hand to achieve a flexible, correct and in place reset;

9. The adjusting screw of the pressure regulating valve should be in a relaxed state;

10, the regulating hand wheel of the speed regulating valve should be in the state of small opening throttle;

11. Make the position of the reversing valve spool in the position state shown in the schematic diagram;

12. Check whether the oil hole that should be blocked (if remote control is not used for the relief valve) is blocked, and whether the oil port of the connecting oil pipe is connected, and ensure that the connection between the oil pipe and the oil port is tight and reliable.

Iv. Cleaning of hydraulic system:

1 cleaning requirements:

1. Clean the environment and the site first;

2. The cleaning fluid should use special cleaning oil with low viscosity (or turbine oil with a viscosity of 20CST at 38°C), and have the ability to dissolve rubber. When possible, the cleaning oil can be heated to 50-80°C;

3. Replace the working filter element with a washing filter element before washing, and replace the working filter element with a working filter element after washing;

4. Disconnect the oil cylinder or hydraulic motor from the pipe before flushing, connect the oil inlet pipe and the oil return pipe with the hose, and connect the oil cylinder or hydraulic motor with the pipe after passing flushing;

5. The skin capsule accumulator can be filled with nitrogen, etc.;

6. Oil according to the oil brand specified in the equipment operation manual. The oil must be filtered and cleaned.

7. After cleaning, the cleaning oil must be drained as far as possible to avoid mixing the cleaning oil with the new oil, which will cause deterioration of the hydraulic oil and affect its service life;

8. After cleaning, clean the inside of the oil tank. After checking to meet the requirements, remove the newly added cleaning loop and restore the pipeline to the system specified in the design. Pay attention to clean when disassembling and assembling, and install and connect relevant components and pipe fittings firmly and reliably.

9, flushing inspection: hydraulic transmission system particle count method is not lower than G; When using visual method, check the filter element of the oil filter after continuous filtration for 1h, and there should be no visible pollutants. Table 5 and table 6 respectively show the number of particles containing solid pollutants per 100ml of oil as indicated by the interval number corresponding to the pollution level of pipeline flushing and each interval number.

The pressure test of the system shall be carried out after the pipeline flushing is qualified, the system is formed after installation, and the system is run empty. Note: Pressure test, commissioning and test run of K=103M=1064 hydraulic system

I. Pressure test

1. The working medium specified by the system shall be used for empty operation. When the working medium is added to the tank, it shall be filtered and the filtering precision shall be no less than the filtering precision specified by the system design;

2. Before empty operation, remove the tubing of the oil port of the hydraulic pump and the oil leakage port (if any), and fill the oil into the oil inlet of the pump according to the rotation direction. Turn the coupling by hand until the oil outlet of the pump is free of bubbles. Connect the pump inlet pipe and fill the inlet pipe if possible. In addition, the hydraulic motor and the pump with the drain port should be filled with oil into the shell through the leak port.

3. In the case of empty operation, the servo valve, proportional valve, hydraulic cylinder and hydraulic motor in the system shall be isolated from the circulation loop with short-circuit transition plate. The accumulator, pressure sensor and pressure relay shall be disassembled and replaced by screw plugging to make these components escape from the circulation loop;

4, empty operation, must loosen the relief valve regulating screw, so that the control pressure can maintain the oil circulation to overcome the pipeline resistance at the lowest value, if there is a throttle valve, pressure relief valve, it should be adjusted to the maximum opening; Turn on the power, inching the hydraulic pump motor to check whether the power is connected wrong, and then continuously inching the motor to extend the starting process. If the pressure rises sharply during the starting process, it is necessary to check the cause of overflow valve failure, and then continue inching the motor until normal operation is ruled out;

5. Pay close attention to the variation of pressure difference before and after the filter during empty operation. If the pressure difference increases, the filter element should be replaced or washed at any time;

6. The oil temperature of empty operation should be within the normal operating oil temperature range;

7. The inspection standard for oil contamination in empty operation is the same as that for pipeline flushing.

Ii. Pressure test:

The pressure test shall be carried out after the system is qualified in empty operation, and the specific provisions in the above empty operation shall be observed

1. Test pressure of the system: For the system with working pressure lower than 16Mpa, the test pressure is 1.5 times of the working pressure; For the system whose working pressure is higher than 16Mpa, the test pressure is 1.25 times of the working pressure.

2. The test pressure should be increased step by step, and the pressure should be stabilized for 2-3min at each level of increase. After reaching the test pressure, the pressure should be maintained for 10min, and then lowered to the working pressure for a comprehensive inspection.

3. During the pressure test, if any fault needs to be dealt with, the pressure must be relieved first; If welds need to be rewelded, the pipe must be removed and the oil shall be cleaned before welding;

4. During the pressure test, the pipe shall not be pummeled and open fire shall not be carried out at the same time within 5m of the test area;

5. Fill in the System Pressure Test Record after the test.

3. Commissioning and test run: Generally, system commissioning should be carried out in the order of hydraulic pump commissioning and system commissioning (including pressure and flow, that is, speed commissioning of the actuator). Various commissioning projects are carried out by part to the whole system item by item.