Second, the hydraulic system 1, die casting machine should put an end to the use of deteriorated, thickened and deposited hydraulic oil. When replacing hydraulic oil, don't mix old and new hydraulic oil, and be sure to install the tank cover after each oil change, as shown in Figure 4. 2, the new machine should be replaced after 500 hours of operation, and then every 2000 hours of operation. Clean the filter element every time the hydraulic oil is changed: remove the filter element, immerse it in clean diesel oil, clean it with a steel brush, and then blow it clean with compressed air, as shown in Figure 5. 3. When removing any high-pressure parts, such as hydraulic valves and oil pipes, there may be residual pressure inside, so when loosening the screws, loosen them slowly. Only when the residual pressure is eliminated can all screws be loosened, as shown in Figure 6. 4. Check fittings such as oil pipe joint and oil valve mounting screw once every six months, and tighten them in time to prevent leakage or air from entering the hydraulic system, as shown in Figure 7. 5. The relief valve, proportional pressure valve and pressure reducing valve on the oil circuit board should be adjusted by professionals. Pay attention to tighten the nut after adjusting the relief valve and pressure reducing valve, so as to avoid changing the adjusted pressure during the operation of the machine, as shown in Figure 8. 6. Be sure to check the indicator on the filter. When the indicator pointer is normal in the green area, it is slightly blocked in the yellow area and seriously blocked in the red area, as shown in Figure 9. When the pointer enters the yellow area, the filter element must be cleaned. For cleaning methods, please refer to Article (2). 7. The motor should be cleaned and overhauled once every six months. Under normal circumstances, bearings should be replaced with grease once every six months. If the grease used for rolling bearings does not harden, the service life can be extended. If the oil turns black, there are water drops or dirt on the oil surface, and the oil becomes hard, it should be replaced in time. When the motor is in use, foreign objects should be prevented from entering the machine body to prevent the air duct from being blocked. Once the above-mentioned abnormal situation is found, it should be stopped in time, as shown in figure 10. 8. Requirements for nitrogen pressure inspection (1) Observe whether there is any leakage of nitrogen within three days before the operation of the new machine to prevent the internal damage of the nitrogen bottle during transportation. (2) Check for the first time after one week of operation, every other week for the next two months, and every two months thereafter. When the pressure is insufficient, nitrogen should be filled. (3) The method of checking the nitrogen pressure is as follows: turn off the motor, reset the emergency stop button, loosen the stop valve to unload, and observe the representation values of the booster oil pressure and the second gear oil pressure. When the oil pressure drops to zero, the nitrogen pressure values of the two groups of accumulators are the nitrogen pressure of the booster accumulator and the nitrogen pressure of the quick injection accumulator respectively. Each nitrogen pressure must meet the specified value in the machine operation manual. For example, in DCC400 horizontal cold chamber die casting machine, the nitrogen pressure of quick injection accumulator is 90- 100bar, and the nitrogen pressure of booster accumulator is 80-90bar, as shown in figure 1 1. 9. If the hydraulic valve fails because the valve core is blocked by foreign matter, remove the valve core, clean it with diesel oil (or soak it in clean hydraulic oil), and then blow the foreign matter with compressed air, as shown in figure 12. Note: Generally speaking, it is not allowed to remove the valve core, and it can only be removed if the oil valve has been blocked by foreign objects. 10. When disassembling the hydraulic components related to the accumulator, the shut-off valve should be opened first, and it can only be disassembled after all the high-pressure oil in the accumulator is unloaded, otherwise the danger of high-pressure oil injection will occur, as shown in figure 13. 1 1. Before leaving the factory, all the oil valves of the machine have been adjusted. According to the needs of die casting products, the "injection working pressure" and "pressurization working pressure" and the flow of each reversing valve can be adjusted, and the rest involves system pressure, flow proportional control and safety pressure. Arbitrary adjustment is not allowed. 12. The high-quality hydraulic oil (1) system should be used for flushing the die casting machine, and it should be replaced according to the specified procedures. There is not much water stain and gum, and there is no black oil like asphalt at the bottom of the fuel tank. As long as the capacity of the fuel tank is 1/3- 1/2 of the new oil, the purpose is to wash away the old oil and leave no or less old oil. 2) If you don't change all the oil, just add some new oil, the system doesn't need to be flushed, but pay attention to whether the new oil is the same brand and viscosity of the anti-wear hydraulic oil from the same supplier. Otherwise, the mixing experiment should be done, and the methods are as follows: put half of the new oil and half of the old oil into the container respectively; In addition, put 1/3 new oil and 2/3 old oil into another container, keep it at a constant temperature of 70-80℃ for 24 hours, and carefully observe whether there is turbidity or precipitation. If not, you can use it. (2) Filling new oil The new oil filling amount of the die casting machine is related to the model, and the specific filling amount is according to the requirements of the machine instruction manual. (3) Test run: After adding new oil, test run with no load for 10- 15 minutes, and then run normally with load after the temperature and pressure are normal. Iii. Electrical part (1) Main motor 1. After starting the motor for the first time or replacing the motor control circuit, first determine whether the motor turns correctly, so as not to damage the motor. The specific method is: click the motor start button, and observe the motor turn from the fan blade at the back of the motor. The motor should rotate clockwise. Otherwise, the power supply needs to be cut off, and the three-phase line of the power supply on the terminal in the main electrical box is arbitrarily replaced with two phases. Click the motor button again until the steering is correct, as shown in figure 14. 2. Start the motor with Y/△, and don't do other operations before the motor start indicator lights up, as shown in figure 15. 3. Before the commissioning of the new machine, first check that all electrical lines should be well connected, requiring no short circuit, no open circuit, no missing installation and no looseness. When the power supply is turned on, the position of the induction switch and the limit switch are accurate and their functions are good, as shown in Figure 16. (2) Electrical control box 1. Electrical control box is the key part of electrical maintenance, so the use and management of electrical box should be strengthened at ordinary times. After opening the electrical box for maintenance or setting parameters, lock the door of the electrical box in time. Non-professionals are not allowed to open the electric box at will, press the control button in the electric box or set relevant parameters on the control panel, as shown in figure 17. 3. Clean the electric box every three months to keep the inside of the electric box dry and tidy. Wires, metal products, magnetic substances or flammable materials cannot be stored in the electrical box to ensure air circulation and good heat dissipation conditions in the electrical box, as shown in figure 19. 4. During routine maintenance inside the electric box, the wiring should be neat, the wire number should meet the technical requirements, and the redundant wires should be cut off. It is absolutely forbidden to connect wires at will or store long exposed wires inside the electric box. After maintenance, cover the trunking cover in time and lock the door of the electric box, as shown in Figure 20. 5. All terminals in the electrical box are fastened once every six months to prevent poor contact or loose discharge, such as contactor input and output terminals and power input terminals. For terminals with high current, use special tools to press the lug, and smooth the conductive part of the lug, such as the motor terminal, as shown in Figure 2 1. 6. In case of power failure, please turn off the main switch of the external power supply of the machine, the power switch in the electric box, the air switch and the power switch on the operation panel to prevent the circuit elements from being damaged or having an accident, as shown in Figure 22. (3) External line maintenance 1. Check the external wires of the machine every day to ensure that they are intact and securely tied. If the power cord sheath is damaged, it should be replaced in time, as shown in Figure 23. 2. During routine maintenance, it is forbidden to walk the line randomly. The wiring should be standardized, the line type should meet the use requirements, and the line number should be consistent with the electrical main box, and it is not allowed to be changed or lost at will, as shown in Figure 24. (4) External signal device 1 maintenance. Check and maintain limit switches (made in Kyrgyzstan) and induction switches once a month. Requirements: the limit switch (made in Kyrgyzstan) and the induction switch are sensitive, the mounting screws are not loose, and dust, oil stains and magnetic substances on their surfaces are wiped, as shown in Figure 6-25. 1- adjustable (mode) thick limit switch 2- adjustable (mode) thin limit switch 3- on (mode) terminal induction switch 4- on (mode) fast-turn slow induction switch 5- lock (mode) low-voltage induction switch 6- lock (mode) high-voltage induction switch 7- lock (mode) terminal induction switch 8- 0- lock type Kloc-0/2- Ejection Limit Switch 108 Joint (Die) Part 1 and Elbow (Machine Hinge) are the key parts of the joint system, and the screws of Elbow (Machine Hinge) should be retightened once every two months, as shown in Figure 27. 2. Check the sliding bearing (copper company) and sealing ring (dust seal) of the movable seat plate regularly, and replace them in time if they are worn, as shown in Figure 28. 3. The sliding foot adjustment of the movable seat plate should be moderate. Too tight will lead to premature wear of steel plates and elbows. Too loose or too tight will lead to the deformation or wear of the pull rod, resulting in abnormal opening and closing (mold) action, as shown in Figure 29. 4. The speed of die setting (die setting) should be slow, and appropriate pressure and flow should be set. Mold opening (mold closing) must be carried out after mold opening (mold closing), otherwise the thread of the pull rod or adjusting nut will be damaged, as shown in Figure 30. 5. When installing the mold, it is best to stay in the middle of the template. Eccentric setting will lead to uneven stress and easy to wear the elbow in advance, as shown in Figure 3 1. 6. Before installing the fastening bolt (die screw) of the die, the T-groove and the assembly hole should be cleaned to avoid screwing the bolt into the screw hole forcibly and damaging the thread, as shown in Figure 32. 7. When installing the mold, the machine should choose the "manual" operation mode, as shown in Figure 33. 8. On the premise of satisfying production, the locking (die) force should be smaller. Working under the maximum locking force for a long time will accelerate the wear of the elbow, as shown in Figure 34.
Verb (abbreviation of verb) injection part 1. Before the machine leaves the factory, make sure that the coaxiality between the fuel injection chamber and the fuel injection piston rod is within the required value, and then check the fuel injection center every 1 year, as shown in Figure 35. 2. In the process of injection, if slag inclusion is found in the product, the reason should be checked in time and the slag inclusion should be cleaned up, as shown in Figure 36. 3. In the process of injection, if the movement resistance of the punch increases, the speed slows down, or even liquid splashes out from the gate, the punch and the injection chamber (barrel) should be inspected in time and the worn punch should be replaced, as shown in Figure 37. 4. Pay attention to check the cooling water system of the punching machine to ensure that there is no water leakage, as shown in Figure 38. The intransitive verb lubricates parts 1. Lubricate all grease nipples of the whole machine once a month. Lithium-based grease and molybdenum disulfide grease are generally selected. Be careful not to inject too much grease into the sliding bearing of the movable seat plate to prevent the dust seal from slipping out of the hole, as shown in Figure 39. 2. Before operating the machine every day, the lubricating pump should supply oil to the lubricating system, and it is never allowed to start the machine without lubrication. Elbow lubrication is usually divided into manual lubrication and automatic lubrication, as shown in Figure 40. Manual lubrication: Before starting, manually operate the lubricating pump for 2-3 times to ensure that all lubricating points are filled with lubricating oil. Automatic lubrication: after the process parameters are set, the time interval of automatic lubrication is controlled by computer. 3. Check the lubrication pipes of elbow lubrication system and punch lubrication system every week, and require each lubrication pipe to have enough lubricating oil to ensure the smooth flow of lubricating oil pipes. If the lubricating oil pipe joint is loose or falls off, it should be handled in time, as shown in Figure 4 1. 4. If the contour adjustment (mold) device is lubricated with grease, it should be filled once a month. Before filling, clean the surface of adjusting (die) nut and screw motion pair, and the contact surface between gland and nut, sprocket or gear transmission pair, and then apply grease evenly, as shown in Figure 42. 5. The guide rod of ejection hydraulic cylinder should be lubricated with grease once every 3 months, and the oiler should be cleaned before oiling. When using the ejector dual hydraulic cylinder, attention should be paid to the cleanliness of the piston rod, as shown in Figure 43. 6. If the sliding seat and steel plate are lubricated with grease, they should be lubricated once a month. Before filling, remove the sliding foot of the movable seat plate, clean it with clean diesel oil, wipe off the dust and sundries on the surface of the steel plate, then install the sliding foot of the movable seat plate, inject an appropriate amount of grease into the oil groove of the sliding foot with an oil gun, and coat a thin layer of oil on the steel plate, as shown in Figure 44. 7. Choose lubricating oil reasonably. Don't mix several brands of oil to ensure that the lubricating oil is not polluted. Don't use deteriorated lubricating oil. High quality lubricating oil can make the die casting machine run smoothly; Prevent the friction surface from being scratched, and ensure that the machine parts are not rusted and corroded; Reduce the loss of lubricant. 8. The injection punch should be lubricated with high-quality lubricating oil or lubricant. 7. The cooling system is 1. Each connecting water pipe of the cooling system should be overhauled once a year to observe whether there is corrosion or water leakage, otherwise it should be repaired or replaced in time, as shown in Figure 45. 2. The cooling water of the machine should be purified fresh water, the river water should be filtered by the water tower, and the filtering device of the water tower should be cleaned with chemicals once every six months, as shown in Figure 46. 3. After the cooler works for half a year, the surface area of the tube wall becomes dirty and the heat exchange performance decreases. The covers at both ends of the cooler should be removed and the scale should be cleaned with copper bars, as shown in Figure 47. 4. Ensure that the hydraulic oil temperature does not exceed 55℃ when the machine works continuously, and the working oil temperature is not lower than 15℃ when it works at low temperature, as shown in Figure 48. Eight. Hot working system (1) injection chamber and punch 1, controlling the temperature of aluminum alloy liquid at 620-680℃ and magnesium alloy liquid at 650-680℃. If the material temperature is too high, it will accelerate the wear and corrosion of punch (hammer head) and injection chamber (cylinder), as shown in Figure 49. 3. Add the punch lubricant regularly to ensure the lubrication effect of the punch. Do not use hydraulic oil and engine oil instead of punch lubricant, as shown in Figure 5 1. 4. Before injection, preheat the injection chamber and punch. For a small die casting machine, the simple method is to pour an appropriate amount of alloy solution into the pressure chamber in the closed (die) state, start the machine and push it out before the hammer after solidification, and repeat it for 2-3 times, as shown in the figure.