Hydraulic Power Pack
The Power pack consists of an oil reservoir, a pump driven by an electric motor, filters pressure gauges and valves to control the flow or pressure of oil. It is designed to be used in a harsh foundry environment and should provide years of service if properly maintained. That’s why we wish you should go through the following general instructions to ensure satisfactory running of the hydraulic system power pack supplied by us with the equipment.
1. Clean the oil tank thoroughly before first filling.
2. Oil level should be maintained. If oil level is less, it may cause damage to the pumps.
3. Clean the suction strainer ls every week It is advised to use suction strainer’s in hydraulic system.
4. Clean the power pack daily to keep away from dust and iron particles.
5. Use only fine cloth to clean the hydraulic system components.
6. Filter the oil after first 100 hours of working and clean the tank
7. Filter the oil every 500 Hours of working and clean the tank.
8. Change the complete oil after 7000 hours of working
9. After any maintenance, all the openings are to be plugged properly.
10. Do not refill the leaked oil.
11. Stop external leakage, if any, immediately.
12. Use correct grade of hydraulic oil. Do not mix different grade/make.
CAUTION :- Mixing of water and dust in oil may cause SERIOUS DAMAGE to the pumps and components.
Now we are sure, if the above instructions are followed religiously, the hydraulic system Power Pack will be working to your satisfaction. However for further details please go through the subsequent pages and follow the instructions as the need arises.
(1.A) :- UNPACKING & HANDLING
If the hydraulic system is supplied in the wooden case, then remove the top and side covers of the wooden case in which package is crated. Remove the unit carefully from the bottom plank of the case. Ensure that the package has not suffered any damage during transport/ handling. Avoid storing of packages and loose supply items for long periods as oil film during testing would vanish and thereby lay open the unit to adverse effects of surrounding environment. This generally lowers the life of the equipment
(1.B) :- INSTALLATION& COMMISSIONING OF THE POWER PACK UNIT
Before installation is carried out,ensure that the Power pack have not suffered any damage because of storage conditions.
Install the hydraulic power pack unit in a location away from radiant heat and direct traffic, and protected from temperature extremes.
All piping or tubing should be clean and fro of scale, chips and dirt. Care should be taken at each joint to ensure that the pipe or tube is burr free and that no sealing compound flows in to the pipe.
During erection ensure that pipe outlets,filling aperture etc. on the equipment remain closed unit the final installation of the connection pipelines or until filing of the tanks respectively. For thee purpose plastic plugs or caps should be employed but never use make shift stoppers of fabric or paper loath should.
Before commissioning, clean power pack with a piece of dry cloth. Cotton waste or wet c never be used. Lift the Power pack by hoist and clean its bottom with cloth to remove the sand particles. Place the ( hydraulic system ) power pack on foundation as per power pack layout drawings.
Allow enough space around the unit so that maintenance can be easily carried out.
INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR AIR & HYDRAULIC CYLINDERS
(1.C) :- OIL TANK
If the additional oil tank is required with the hydraulic power pack, then were commend that the inside surfaces of the tank should be painted with an oil resistant paint. Before painting, the internal walls should be meticulously cleaned from welding scale, rolling scale and rust.
(1.D) :- INSTALLATION OF OTHER UNITS
unit not supplied along with Power packs are to be fixed in position before bringing the unit into Heat exchangers (if any),etc. is to be kept in a well-ventilated area. Accumulators, if any, he requirements of the accumulator manufacturer to the per – Units not suppl are to be filled in accordance with t charge required by the system.
(1.E) :- CONNECTIONS
The hydraulic system diagram supplied with the furnace equipment specifies that size of steel hydraulic tubing, which should be used to connect the hydraulic power unit to the furnace.
Should flexible hoses in addition to those supplied on the equipment be required;only breaded,nylon reinforced hoses for intraline furnace and steel in forced hoses for steel shell furnace suitable of the pressure of the system can be used.
CAUTION :- Over tightening of hose and tube coupling nuts will cause thread and seal damage resulting in fitting leakage. Torque values are for threads lubricated with oil, anti-seize compound, petroleum, or general purpose grease, as applicable.
Be careful when tightening pipe fittings. Over tightening causes distortion, cracking and leaks.
(1.F) :- OPERATING INSTRUCTIONS
(1.F.1) PREPARATION FOR INITIAL OPERATION
Following points must be considered before starting your power pack in initial condition.
1. Be tore starting the driving motor it must be made certain that oil reservoir, pumps, valves hydraulic cylinders, hydraulic motors and all other loose supply components, pipes and fittings are properly cleaned and inter connected correctly with suitable and correct size of pipe lines.
2. Filter and oil the Hydraulic oil in the reservoir up to the maximum level Indicated.
3. Check the level of the unit in respective planes. Also check the alignment of ( hydraulic system ) pump and electric motor.
4. Check and tighten all the fittings and joints provided in the hydraulic systems.
5. Unscrew and adjust relief valve at lowest pressure setting. Also adjust various pressure control valves/flow control valves/pressure switch/directional control valves, suitably for initial starting (if provided)
6. Loosen the bleeding screws wherever provided.
7. Ensure that water flow is available to the cooler in case a water cooled cooler is incorporated in the circuit.
8. Connect electrical supply to the motor and also to electrically operated solenoid valves through proper isolators, limit switches and relay as per electric circuit diagram (if any).
9. In case a shut off valve is provided between tank and ( hydraulic system ) pump suction line the same must be.