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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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Fig2-3
Fig2-3-1
11
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Fig2-3-2
Fig2-3-3
12
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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: [email protected]
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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
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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
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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
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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
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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
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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
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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
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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
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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.
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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
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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
36
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