1、MAINTENANCE INSTRUCTION维修指南HU 3.06.0626 EnHU 3.06.0626 中文版PAGE第 1 页，共 42 页FILE文件：MAINTENANCEINSTRUCTION维修指南KCI Konecranes Plc DEPT./HANDLED BY:部门/ 编制：CHC/J. RikknenAPPROVED BY:批准：CHD/T. GladDATE:日期：08.04.2004SOFTW./VERS.软件/版本Word 97/VertexWord 97/VertexLANG.语种：En英语ISSUE 发行：001OPERATING MANUAL FOR MO
2、TOR OPERATED ORANGE-PEEL GRAB, WGR80-1电动荷花状抓斗(WGR80-1 型)使用说明书TABLE OF CONTENTS目录1 SPECIFICATION OF GRAB WGR80-121.1 Dimensions 尺寸 .21.2 Technical main data 主要技术数据 21.3 Operating data 操作数据 .21.4 Electric motor data 电动马达数据 21.5 Hydraulic data 液压数据 .31.6 Mechanical data 机械性能数据 .32 DESCRIPTION AND GENER
3、AL SURVEY 概述 .52.1 Construction 结构 52.2 Function of hydraulic system 液压系统功能 .62.3 Measuring points 测量点 82.4 Hydraulic diagram 液压流程图 102.5 Control block 控制模块 .112.6 Function of electrical system 电气系统功能 123 OPERATING INSTRUCTIONS 操作指南 .133.1 Putting into operation 进入操作 133.2 Maintenance items .143.3 I
4、nformation for operation 有关操作的说明 163.4 Shut-down 关机 173.5 Transportation 装运 .174 MAINTENANCE 维修 .174.1 Hydraulic fluid change 液压油更换 194.2 Lubrication instructions 润滑指南 204.3 Electric motor 电动马达 214.4 Control block 控制模块 224.5 Hydraulic power unit 液压动力装置 .224.6 Pump 油泵 .224.7 Hydraulic cylinders 液压缸 2
5、2MAINTENANCE INSTRUCTION维修指南HU 3.06.0626 EnHU 3.06.0626 中文版PAGE第 2 页，共 42 页FILE文件：MAINTENANCEINSTRUCTION维修指南KCI Konecranes Plc DEPT./HANDLED BY:部门/ 编制：CHC/J. RikknenAPPROVED BY:批准：CHD/T. GladDATE:日期：08.04.2004SOFTW./VERS.软件/版本Word 97/VertexWord 97/VertexLANG.语种：En英语ISSUE 发行：0024.8 Jaws 抓爪 .234.8.1 T
6、he welds of jaw 抓爪的焊接 264.9 Balancing beam 平衡梁 .265 TROUBLE SHOOTING 故障排除 276 SPARE PARTS 备件 .321 SPECIFICATION OF GRAB WGR80-1WGR80-1 型抓斗技术说明1.1 Dimensions 尺寸 1. Main dimensions according to figure 1.主要尺寸数据见图 1。1.2 Technical main data 主要技术数据 1. Dead weight (Incl. hydr. fluid) _6200 kg总重量（包括液压油） _62
7、00 kg2. Grab volume _8 m抓斗体积 _8 m3. Number of jaws _7 pcs抓爪数量 _7 件4. Design of jaw _closed抓爪设计 _闭合5. Max. jaw tip force of closed grab _38 kN抓斗闭合时爪尖最大抓力 _38 kN1.3 Operating data 操作数据1. Closing time _15 sec闭合时间 _15 sec2. Opening time _18 sec开启时间 _18 sec3. Control system _Directional valve控制系统 _导向阀1.4
8、 Electric motor data 电动马达数据1. Output power _37 kW输出功率 _37 kW2. Duty type _S3-40 %任务类型 _S3-40 %3. Protection class _IP55保护级别 _IP55MAINTENANCE INSTRUCTION维修指南HU 3.06.0626 EnHU 3.06.0626 中文版PAGE第 3 页，共 42 页FILE文件：MAINTENANCEINSTRUCTION维修指南KCI Konecranes Plc DEPT./HANDLED BY:部门/ 编制：CHC/J. RikknenAPPROVE
9、D BY:批准：CHD/T. GladDATE:日期：08.04.2004SOFTW./VERS.软件/版本Word 97/VertexWord 97/VertexLANG.语种：En英语ISSUE 发行：0034. Insulation class _IEC-H绝缘级别 _IEC-H5. Rotating speed_1500 RPM旋转速度 _1500 转/min6. Power supply _3380 V; 50 Hz电源 _3380 V; 50 Hz7. Design and mounting arrangement _IEC-V1设计及安装要求 _IEC-V11.5 Hydraul
10、ic data 液压数据1. Pump type _Helical gear pump油泵型号 _螺旋齿轮泵2. Rated pressure_250 bar额定压力 _250 bar3. Control valves_Special valve block控制阀 _专制闸阀4. Cylinder design pressure _250 bar液压缸设计压力 _250 bar5. Grab operating pressure _200 bar折斗工作压力 _200 bar6. Fluid volume flow _120 LPM液压油流量 _120 升/min7. Tank capacit
11、y (max. fluid level) _250 liters油箱容量（最大液面） _250 升8. Fluid filter element type _Replaceable 10 Mic液压油滤芯类型 _10 片可更换型 1.6 Mechanical data 机械性能数据1. Frame material_S355J2G3横梁材料 _S355J2G32. Jaw material_Welded high tensile steel plate抓爪材料 _焊接的高抗拉钢板3. Jaw bearing and tip material _Extremely wear-resistant
12、steel抓爪轴承和爪尖材料 _高耐磨钢4. Axles _AISI8620芯轴 _AISI86205. Cylinder fixing bearings _Spherical plain bearing steel to steel液压缸固定轴承 _关节轴承钢对钢6. Cylinder piston rod surface _Hard chromium plating, 20-30 m液压缸活塞杆表面 _镀铬硬化厚度 20-30 mMAINTENANCE INSTRUCTION维修指南HU 3.06.0626 EnHU 3.06.0626 中文版PAGE第 4 页，共 42 页FILE文件：
13、MAINTENANCEINSTRUCTION维修指南KCI Konecranes Plc DEPT./HANDLED BY:部门/ 编制：CHC/J. RikknenAPPROVED BY:批准：CHD/T. GladDATE:日期：08.04.2004SOFTW./VERS.软件/版本Word 97/VertexWord 97/VertexLANG.语种：En英语ISSUE 发行：004Figure 1. Main dimensions 图 1 . 主要尺寸数据MAINTENANCE INSTRUCTION维修指南HU 3.06.0626 EnHU 3.06.0626 中文版PAGE第 5
14、页，共 42 页FILE文件：MAINTENANCEINSTRUCTION维修指南KCI Konecranes Plc DEPT./HANDLED BY:部门/ 编制：CHC/J. RikknenAPPROVED BY:批准：CHD/T. GladDATE:日期：08.04.2004SOFTW./VERS.软件/版本Word 97/VertexWord 97/VertexLANG.语种：En英语ISSUE 发行：0052 DESCRIPTION AND GENERAL SURVEY概述2.1 Construction 结构The KCI orange peel motor grab is co
15、nstructed as follows:KCI 荷花状马达抓斗结构如下图所示：Figure 2. Principal parts 图 2. 主要另部件The jaws that serve to pick up waste are fixed by means of pins to the frame. The pins also serve as pivot points for the jaws. The pivot points of the jaws are manufactured from wear-resistant material.能爪起废物的抓爪用销钉固定在斗框上，销钉同
16、时也作为抓爪的转动中心点，它们用耐磨材料制成。上盖内装电动马达内装控制模块内装透气塞液压缸耦合器（钟罩状壳内）螺旋齿轮泵（油箱内）提升链平衡梁电源及控制电缆内装电子箱液压缸保护罩油箱基座抓爪爪尖MAINTENANCE INSTRUCTION维修指南HU 3.06.0626 EnHU 3.06.0626 中文版PAGE第 6 页，共 42 页FILE文件：MAINTENANCEINSTRUCTION维修指南KCI Konecranes Plc DEPT./HANDLED BY:部门/ 编制：CHC/J. RikknenAPPROVED BY:批准：CHD/T. GladDATE:日期：08.04
17、.2004SOFTW./VERS.软件/版本Word 97/VertexWord 97/VertexLANG.语种：En英语ISSUE 发行：006The hydraulic pump motor is mounted vertically and as a complete assembly in the frame, which also serves a protective function. The lower section of the frame is designed to serve as a fluid tank as well. The hydraulic power
18、unit consists of an electric motor, a spur gear pump and a control valve block. The hydraulic power unit can be removed completely from the grab by removing the mounting bolts. The low mounting position of the hydraulic unit within the grab makes a low grab profile possible and favorable center of g
19、ravity.液压泵马达作为一个完整组件垂直地安装在斗框上，同时也有保护作用的功能。斗框的下半部同时也是油箱。液压动力装置由一个电动马达、一个直齿齿轮泵及一个控制阀模块组成。只要卸下固定螺栓，可以将液压动力装置从抓斗上折下。液压装置放在抓斗下部得到一个抓斗低位配置及最好的重力中心。The fixing points for the hydraulic cylinders are positioned at the frame and at the jaws. The jaws are opened and closed by retracting or extending the piston
20、 rods respectively. The piston rods are hard chrome plated. The control valve block is connected to the hydraulic cylinders by means of hydraulic hoses. The hydraulic cylinders are protected against mechanical damage.液压缸的固定点处在斗框及抓爪上。通过控制活塞杆的来回运动，就可以开启或闭合抓爪。活塞杆经渡铬硬化。控制阀模块用液压管连接到液压缸上。液压缸应作保护，避免机械损坏。Po
21、wer is supplied to the electric motor via a rubber-coated cable and a plug unit. A strain relief feature is installed to protect the plug unit from damage. The plug is provided with a protective cover. 动力通过橡胶绝缘涂层电缆和插头供给电动马达。插头具有应变释放功能，能有效防止机械损坏。插头还同时提供保护盖。The grab is suspended with the balancing bea
22、m, which can swing 45 to two directions at the same time. There are two small holes for lifting chains on a plate of the balancing beam. A cover plate of the frame is mounted by bolts. 抓斗悬挂平衡梁上， 能够同时在两个方向上旋转 45。平衡梁的横板上有个小孔供提升链通行。斗框的盖板用螺栓连接固定。All component groups and parts are manufactured from high-
23、quality materials and are designed for easy interchangeability. 所有另部件都是用高质量材料制成，且设计成具有互换性。2.2 Function of hydraulic system 液压系统功能Hydraulic diagram is presented in section 2-4. The locations of hydraulic components in valve block are also shown in section 2-5.液压的流程图由 2.4 节给出。液压部件在阀控模块的位置由 2.5 节给出。MAI
24、NTENANCE INSTRUCTION维修指南HU 3.06.0626 EnHU 3.06.0626 中文版PAGE第 7 页，共 42 页FILE文件：MAINTENANCEINSTRUCTION维修指南KCI Konecranes Plc DEPT./HANDLED BY:部门/ 编制：CHC/J. RikknenAPPROVED BY:批准：CHD/T. GladDATE:日期：08.04.2004SOFTW./VERS.软件/版本Word 97/VertexWord 97/VertexLANG.语种：En英语ISSUE 发行：007The type of the hydraulic
25、system is so called open circulation with directional valve. Electric motor runs constantly during normal operation, but it will stop automatically in 30 seconds, if no open/close command is given (PLC setting). This system decreases number of motor start-ups and thus prevents high starting current
26、damaging components. Hydraulic system automatically switches to free flow circulation in both directions. Thus no extra heat is produced. Observe! Directional valve controlled grab cant be operated without PLC-control command from crane.液压系统的类型属于称之为带导向阀的开放和循环型。电动马达在正常工作状态下持续运转，但如果无开通/关闭的指令时， 它将在 30
27、秒内自动停止（程序逻辑控制设置）。这种系统减少了机器启动时马达的数量，因而有效地防止了启动时的大电流对部件的损坏。液压系统能在两个方向上自动地转换到自由流动循环状态。这样就不会产生过多的热量。 注意：由导向阀控制的抓斗如没有从起重机给出的 PLC 控制指令则不能工作。Free-flow circulation 自由流动循环Valve 阀 14 16.1 16.2 20Position 位置 Open 开 Closed 关 Closed 关 12When the electric motor is running the hydraulic pump pumps fluid to point P
28、 in diagram. Valves 14, 16.1, 16.2 and 20 are in normal positions. Pressure opens the pressure-sensing valve no. 15 and the fluid flows through it back to the tank T3. Cylinders keep their positions because counterbalance valves 18 and 19 and also check valves 17.1 and 17.2 are closed.当电动马达驱动液压泵将油泵入
29、流程图中的 P 点时，阀门 14, 16.1, 16.2 和 20 处在正常位置。 压力打开压敏阀门 15， 液压油通过它流回油箱 T3。液压缸保持它们的位置，这是因为平衡阀 18 和 19平以及截止阀 17.1 和 17.2 都有关闭着。Opening 打开Valve 阀 14 16.1 16.2 20Position 位置 Closed 关 Closed 关 Open 开 12The hydraulic fluid flows through valve 16.2 via point B to the rod side of the cylinder. Pressure also open
30、s the counter balance valve 18 and thus allows return flow from cylinder piston side via point A to the tank T3. When cylinder reaches the end position, increased pressure opens pressure control valve 13 and the system switches to free flow circulation.液压油流过阀 16.2 的 B 点到达液压缸杆。压力打开平衡阀 18，这样使得回流由液压缸活塞
31、的 A 点流到油箱 T3。当液压缸到达终端位置时，压力增加将打开控制阀 13 ，系统将转换到自由流动循环状态。MAINTENANCE INSTRUCTION维修指南HU 3.06.0626 EnHU 3.06.0626 中文版PAGE第 8 页，共 42 页FILE文件：MAINTENANCEINSTRUCTION维修指南KCI Konecranes Plc DEPT./HANDLED BY:部门/ 编制：CHC/J. RikknenAPPROVED BY:批准：CHD/T. GladDATE:日期：08.04.2004SOFTW./VERS.软件/版本Word 97/VertexWord 9
32、7/VertexLANG.语种：En英语ISSUE 发行：008Closing 关闭Valve 阀 14 16.1 16.2 20Position 位置 Closed 关 Open 开 Closed 关 32The hydraulic fluid flows through valve 16.1 via point A to the piston side of the cylinders. Pressure also opens the counter balance valve 19 and thus allows return flow from rod side of cylinder
33、s via point B to the tank T3. When cylinders reach the end positions, or when compressing the waste, increased pressure opens pressure control valve 13, and the system switches to free flow circulation. Check valve 17.1 that it keeps high pressure in piston side of cylinders. Also valve 19 closes an
34、d locks the position of cylinders. 液压油经阀 16.1 的 A 点流到液压缸活塞周围。压力打开平衡阀 19， 允许回流从液压缸活塞周围的B 点流回到油箱 T3。当液压缸到达端点位置时，或压缩废油时，压力增加将打开控制阀 13，系统将转换到自由流动循环。截止阀 17.1 将使液压缸的活塞周围保持高压力。此时阀门 19 关闭并锁紧液压缸的位置。Recharging 增压When waste compresses, the hydraulic system switches to free flow circulation. When waste collapse
35、s, the pressure in cylinder decreases. In order to prevent waste from falling, the system recharges itself. This happens when pressure control valve 13 detects decreased pressure and closes. Thus also pressure sensing valve 15 closes and the fluid flows through valve 16.1 to the piston side of the c
36、ylinders.当废油压缩，使液压系统转换到自由流动循环。当废油跌落，液压缸内的压力降低。为防止废油跌落，系统自身增压。当压力控制阀 13 关闭并检测到压力降低时，这种情况会出现。这样， 压敏阀15 也关闭，液压油通过阀 16.1 流回到液压缸的活塞 周围。2.3 Measuring points 测量点The hydraulic system is equipped with three pressure measuring points. Those are labeled as PMP, PMA and PMB in hydraulic diagram. 液压系统带有三个测量点，在流程
37、图中标明为 PMP，PMA 和 PMBPMP = pump pressure PMP 指泵压PMA= pressure in cylinder piston side line PMA 指液压缸活塞周围的压力PMB = pressure in cylinder rod side linePMB 指液压缸杆周围的压力。MAINTENANCE INSTRUCTION维修指南HU 3.06.0626 EnHU 3.06.0626 中文版PAGE第 9 页，共 42 页FILE文件：MAINTENANCEINSTRUCTION维修指南KCI Konecranes Plc DEPT./HANDLED B
38、Y:部门/ 编制：CHC/J. RikknenAPPROVED BY:批准：CHD/T. GladDATE:日期：08.04.2004SOFTW./VERS.软件/版本Word 97/VertexWord 97/VertexLANG.语种：En英语ISSUE 发行：009Pressure in PMP and PMA can be measured from connectors which locate in frame of the grab. Pressure meter equipped with hose and required connector is delivered wit
39、h the grab. See also section 4 maintenance.PMP 和 PMA 的压力可通过位于抓斗框的接点进行测量。带有连接管和接点的压力表随抓斗同时提供。参见第 4 节 维修。MAINTENANCE INSTRUCTION维修指南HU 3.06.0626 EnHU 3.06.0626 中文版PAGE第 10 页，共 42 页FILE文件：MAINTENANCEINSTRUCTION维修指南KCI Konecranes Plc DEPT./HANDLED BY:部门/ 编制：CHC/J. RikknenAPPROVED BY:批准：CHD/T. GladDATE:日
40、期：08.04.2004SOFTW./VERS.软件/版本Word 97/VertexWord 97/VertexLANG.语种：En英语ISSUE 发行：00102.4 Hydraulic diagram 液压流程图Figure 3. Hydraulic diagram 图 3 液压流程图T3MAINTENANCE INSTRUCTION维修指南HU 3.06.0626 EnHU 3.06.0626 中文版PAGE第 11 页，共 42 页FILE文件：MAINTENANCEINSTRUCTION维修指南KCI Konecranes Plc DEPT./HANDLED BY:部门/ 编制：C
41、HC/J. RikknenAPPROVED BY:批准：CHD/T. GladDATE:日期：08.04.2004SOFTW./VERS.软件/版本Word 97/VertexWord 97/VertexLANG.语种：En英语ISSUE 发行：00112.5 Control block 控制模块Figure 4. Control block 图 4 控制模块MAINTENANCE INSTRUCTION维修指南HU 3.06.0626 EnHU 3.06.0626 中文版PAGE第 12 页，共 42 页FILE文件：MAINTENANCEINSTRUCTION维修指南KCI Konecra
42、nes Plc DEPT./HANDLED BY:部门/ 编制：CHC/J. RikknenAPPROVED BY:批准：CHD/T. GladDATE:日期：08.04.2004SOFTW./VERS.软件/版本Word 97/VertexWord 97/VertexLANG.语种：En英语ISSUE 发行：00122.6 Function of electrical system 电气系统功能See figures 17 and 18. 参见图 17 和 18。The PLC, which controls the grab, has been located in a cubicle o
43、n the trolley, on the bridge or on the building itself. The PLC reads the control request (open or close) given by the crane driver. The command is forwarded to the grab via data cable. Command from PLC controls electrically controlled valves M-Y1M-Y4.控制抓斗的 PLC 设在吊车的控制室中，控制室可在横跨桥或在厂房中。PLC 读取由吊车司机发出的
44、控制请求（打开或关闭）。指令由数据通讯电缆转到抓斗。由 PLC 发出的指令控制阀门 M-Y1 到M-Y4.Open command controls the valves M-Y1 and M-Y3。打开指令控制阀门 M-Y1 到 M-Y3。Close command controls the valves M-Y1, M-Y2 and M-Y4.关闭指令控制阀门 M-Y1，M-Y2 和 M-Y4。When a request to stop closing or opening movement, the PLC detects the corresponding command is removed.当清求停止打开或关闭行动时，PLC 检测到相关的指令并焦虑执行。To avoid frequent motor starts the PL
