Manual Maq Llenado Aceite Hidraulico

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JRJZJRJZJRJZJRJZ----V05PV05PV05PV05P

Power-Steering Fluid Filling Machine

Operating Instruction

JINAN CJIERUI ELECTRIC CO.,LTD. OF CHINAAdress:No.56 General Road in Jinan, Shandong province Post Code:250108

Tel: 0531-88266622 General Phone

Fax: 0531-88772200 0531-81206707

E-mail: [email protected] Web Site: www.cjierui.com


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JRJZ vacuum filling instruction page 2

Company Introduction

JINAN JIERUI ELECTRIC CO., LTD. OF CHINA, that is JINAN

CJIERUI ELECTRIC CO., LTD, which integrates design and development,

manufacture, installation and sales services as one. This manufacture has higher

competitive in intelligence professional electromechanical equipment in China.

Also it is certified high-tech enterprises in Shandong Province.

JINAN JIERUI ELECTRIC CO., LTD. was established in October 1995

and its register fund was one million yuan; JINAN CJIERUI ELECTRIC CO.,

LTD. was established in June, 2003 and its register fund was five million yuan.

The enterprise is located No.56 in General Road of Jinan city and covers 8700

. In 2010 the company's income of annual sales was more than 80 million

yuan, with an annual taxes was more than 6 million yuan, and fixed assets was

50 million yuan, and current assets was over 38 million; The company has

maintained a 40% average annual growth since it was founded.

At present, the numbers of employees are 156 persons, 53 technical

engineers who have rich experience in the application of vacuum technology,

automatic control, gas and liquid transmission technology, electro-hydraulic

integration technology and other fields professionals. CJIERUI ELECTRIC

CO., LTD. establishes expedite communication and business contacts with

well-known domestic and foreign enterprises and institutions such as the U.S.

GRACO. Germany BURKERT, LEYBOLD, WILO, Britain SPIRAX likelihood,

Sweden ORION, Shandong University, Harbin Institute of Electrical and

Mechanical College, Tianjin Industrial University of Technology and so on.

From 1999 to 2001, JIERUI ELECTRIC CO., LTD. made the first

completely automatic power steering vacuum filling machine of China

proprietary intellectual property rights with China First Automobile Group and

the Chinese Automobile Research institute, which supplied prologue of the

automobile assembly line to high, fine, excellent on mechanical and electrical


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JIERUI Products Brief

Standard Products

JRJZ-V series Vacuum Filling products

JRBJ series Intelligence Industrial Identification products

JRBJ series Intelligence Industrial Gelatinizing products

JRJZ-N series Quantitative Filling products

JRJZ-S Concentrated Fluid Transportation system

JRJZ-H series Lubricant Coating system

JRJL series Hermetic Leak Detectors

JR-XX series information gathering of production lines,

monitoring system.

Non-standard products

Industrial non-standard equipment, engineering and construction solutions

consulting, design, production, services on site

Automobile assembly line specialized non-standard work, clamp, and

automation solutions

Various production lines specialized non-standard equipment, automation

solutions

Various production lines used to retrofit, manufacture and sale solutions in

China with imported equipment

Special Notice: CJIERUI, JIERUI ELECTRIC, JIERUI etc. relating

brand, mark, trademark are CJIERUIS register brand, its property and

ownership governed by CJIERUI ELECTRIC CO., LTD., and protected by the

relevant laws and regulations.


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CJIERUI Sales Services Introduction

CJIERUI ELECTRIC CO., LTD. not only provides high-class products, but

also provides top-notch service for customers from various levels; during

pre-market, performance, sale provides elaborate technical services and

meticulous, effective, comprehensive communication with customers to ensure

that manufacturers of products are to customers and themselves satisfaction. As

for sold products, we grant whatever is requested and reply whatever is asked

and overall track, in order to pursuit dual-perfect of products quality and

technical services.

Service Concept

Sincerity, specialty, prompt, careful

Service support

After-sales service department directly is responsible for customers and the

general manager, with implementing Initial Consultation system to ensure that

the service got an effective response;

Perfect services database, the maturity clients, equipment archives, digital and

network management, which effectively coordinate the relevant departments,

and to ensure timely and accuracy;

InInInIn Nationwide distribute after-sales service Office and to ensure service

response timely and efficiency;

The 24-hour direct dial service hotline and complaint hotline, inspect and

supervise services to ensure customers satisfaction

Serviceteam

Make a good use of talents and establish a high standard, high quality, efficient

service team, and use a full service system;

Specialty engineers president over replying technical problems from

customers.

The leader, technical deputy and professional maintenance staff of the

company regularly or irregularly visit customers;


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We set permanent office in FAW (Changchun), DFAC (Shiyan), Chongqing,

Suzhou, etc. area, specialty personnel are responsible for after sales service.

Service promise

All the sold equipments are used for warranty within one year and lifetime

maintenance.

We can guide installation on-site according to the needs of its customers and

ensure the correct installation of equipment;

To ensure that users have qualified personnel to operate and maintain with

systematic operation training.

Receipt of a notice should be given treatment response within one hour.

Service personnel serve on-site with the average area 12-hour and special area

within 24 hours

Make a customer archives to provide regular visit.


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Introduction of other area agencies

Office in China First Automobile Group

Address: FAW factory No. 665, 38 blocks

Tel: 0431-5986108 13944179631

Office in DFAC Group

Address: Dongfeng Group office, Shiyan city

Tel: 0719-8264988 13617195365

Office in Chongqing

Office in Suzhou

Office in Tianjin


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Caution before using

Safety Note

Misuse Equipment hazardous:

The equipment used exclusively for professional use and avoid misusing of

equipment.

Please read carefully manual equipment instructions and all components

instructions, warning etc before using.

No moving or changing equipments.

All the equipment parameters are set before leaving factory, and

non-professionals avoid amending.

Before changing parameters, please record original parameters.

Check and maintain the equipments daily, and replace the worn components

immediately.

Fire and Explosion hazardous

The equipment is the three-phase 4-wire 380V AC power equipment, which

should be grounded line before using, solidly and reliably connect to the safety

standards protection grounded line after electricity switched on. No smoking in the working area.

Keep well ventilation of equipments.

If accidents occur, please immediately shut down, until maintain equipment

to normal before the boot.

Spraying hazardous

1. Avoid any part of the body close the pipeline system components during


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operations and maintenance.

2. Do not use hands and any other part of the body to prevent the leakage.

3. Please carefully check equipment pipeline and connecting whether to be

normal, when you find the worn parts and replace them immediately. When

maintaining equipments, you must keep the pressure relief.

Personal Safety

1. Working uniform: Workers must wear protective uniform, do not

wear earrings, bracelets, necklace and other jewelry ornaments!

2. Protective gloves: Workers must wear protective gloves to prevent

danger.

3. Protective glasses: Workers must wear protective glasses to protect

their eyes from harming!

4. Safety boots: Workers are required to wear protective boots!


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JRJZ-V05P Power-Steering fluid filling machine

Operating Instruction

CONTENTS

1 Equipment Overview------------------------------------------------------------------------------------1

1.1THE INTERNAL PIPELINE: ---------------------------------------------------------------------------- 1

1.2ELECTRIC CONTROL SYSTEM -----------------------------------------------------------------------3

1.3PNEUMATIC CONTROL UNIT------------------------------------------------------------------------5

1.4FILLING GUN AND MOVING PIPE: ------------------------------------------------------------------- 5

2 Principal of Working ------------------------------------------------------------------------------------ 6

3 Main Technical Index ----------------------------------------------------------------------------------- 7

4 Vacuum Filling Equipment Operation Process ------------------------------------------------------ 7

4.1PREPARATION-----------------------------------------------------------------------------------------8

4.2EVACUATION -----------------------------------------------------------------------------------------8

4.3CONSTANT PRESSURE,LEAKAGE CHECK ----------------------------------------------------------8

4.4RE-EVACUATION -------------------------------------------------------------------------------------9

4.5FILLING PROCESS ------------------------------------------------------------------------------------9

4.6SUCTION PROCESS -----------------------------------------------------------------------------------9

4.7 COMPLETE ------------------------------------------------------------------------------------------9

4.8SUCTION AGAINST DROP ----------------------------------------------------------------------------9

4.9SYSTEM SUPPLY --------------------------------------------------------------------------------------9

5. Operating-------------------------------------------------------------------------------------------------9

5.1START/STOP OPERATING SYSTEM ------------------------------------------------------------------9

5.2SYSTEM PARAMETERS SET ----------------------------------------------------------------------- 10

5.3VACUUM FILLING OPERATION-------------------------------------------------------------------- 13

5.4SYSTEM MONITOR --------------------------------------------------------------------------------- 16

5.5MANUAL DEBUGGING----------------------------------------------------------------------------- 17

5.6DATE QUERY FUNCTION -------------------------------------------------------------------------- 18

5.7WARNING RELATING OPERATIONS --------------------------------------------------------------- 19

6 Faults and Remedy ------------------------------------------------------------------------------------ 20

7 Maintenance and Repair ------------------------------------------------------------------------------ 237.1SYSTEM MAINTENANCE DAILY ------------------------------------------------------------------ 23

7.2SYSTEM REPAIR : ----------------------------------------------------------------------------------- 26

Annex one------------------------------------------------------------------------------------------------- 27

Key part list ----------------------------------------------------------------------------------------------- 29

Spare list--------------------------------------------------------------------------------------------------- 30


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1.1.1.1. Equipment Overview

JRJZ-V05P Power-steering fluid

vacuum filling machine is JINAN

CJIERUI ELECTRIC CO., LTD

catering for the needs of auto

Power-steering fluid in production

Line, which has designed and

manufactured a new type of

mechanical-electrical integration,

special vacuum quantitative filling

equipment.

Fig 1.1.1

JRJZ V05P Power-Steering fluid vacuum filling machine can synchronous detect

power steering fluid pipeline system pressure reliably and deals with statistics about

the filling volume, vacuum and pressure data parameters when filling powering

steering oil. It provides reliable quality assurance for production management andperformance testing.

The general overview of JRJZ V05P Power-Steering fluid vacuum filling

machine is shown as fig 1.1.1, including tube pipe, electric control system,

Pneumatic control system, filling gun and moving system etc.

1.1.1.1.1111The internal pipeline:The internal pipeline:The internal pipeline:The internal pipeline:

The internal pipeline and components of the equipment as shown in Figure 1.1.3,

internal piping system consists of vacuum tube fill pipe, suction pipe and fluid tube

and so on. The symbol of pipelines indicated in Figure 1.1.2.

Vacuum pipeline

Exhaust pipes

Compressed air

Fluid Pipeline

Suction line

Fig 1.1.2


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1) Vacuum systemmainly is used for vacuuming with imported vacuum pump in

shortest time, which consists of vacuum pump, vacuum tank, water and air

separated tank, vacuum sensor, vacuum pressure gauge , The control and

adjustment valves with visual position control. Use SV25B pump as vacuum

pump to complete system vacuuming.

2) Filling System: system filled using constant-current electric gear pump and

shorten fluctuations time in the pipeline system under pressure and can more

accurately reflect filling pressure. Regulating pressure by fluid regulate valve.

Mainly consists of the storage tank, filling pump, regulator valve, flow meter,

filters, pressure sensor, pressure gauges, the control and adjustment valves with

visual position control.

3) Supply System: Two road parallel pipeline supplies, automatic switching, flow

switches control barrels and make judgment more quickly. While use of time for

two determinants. Mainly consists of supply pump, flow switch, filters, the

control and adjustment valves with visual position control.

4) The suction system: the main function is used for adjusting level and suckingresidual liquid pipeline to the reservoir, and control pressure in the tank through

pressure switch and use vacuum pump to make a negative pressure in the

reservoir and using pressure gap suck liquid to fuel tank. Mainly consists of The

control and adjustment valves with visual position control.


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Fig 1.1.31.2 Electric control system

Mainly consists of control panel and switch board.

1.2.1.Control panel

JRJZ V05P Power-Steering fluid vacuum filling machine operating system

consists of information system and switch/indicator control panel, color LCD display

and panel indicator etc., there is a three-colors indicator at the top of cabinet.

System control panel consists of switch control panel and switch indicator

panel.(fig 1.2.1 ).

Vacuum pump

Filling pump

Supply pump

Storage tank

Flow switch

Flow meter Fluid Valve


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Fig 1.2.1 switch /indicator control panel

When vacuum filling equipment is running and instructed by indicator light in

addition to color LCD display relevant data to ensure that operators in remote monitor

the state of filling.

Switches control panel is composed ofEmergency stopPower onwith

lightPower stopManual/AutoStartStopSupplyReset.

Switching indicator panels is composed of ReadyFirst vacuumVacuum

leakPost vacuumFillingSuctionOver.

Type selection button is composed of High lowType 1Type 2Type

3Type 4Type 5.1.2.2. Electric board

It is the main electric control circuit. There are PLC, A/D module, minitype

breakers, motor protection switch, mini-type relay, contacters, switch power and

connection ends etc inside the electric cabinet. PLC can make operation for system

logic, to control the action of each component and ensure the normal working of

system. The A/D module shall translate the analogue of transducers (vacuum, pressure)

into digital and transport them to PLC,PLC shall make compare according to all

parameters and programs in the system, thereby, to control the filling system and

vacuum sestem; The mini-type breaker can be used for manual switch during


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maintenance and commissioning ,and the overcurrent protection for each loop during

normal running; The motor protection switch mainly is used for the overcurrent and

undervoltage for each pump motor; The mini-type relay can complete the logistic

enforcement assisting the touchers.

1.31.31.31.3Pneumatic Control Unit

1.3.1 the main function of the device provides an effective source of compressed air,

after compressed air comes into the equipment, firstly gas processing unit (triplet)

filter, lubrication etc., then gas sources will be available to provide to the aerodynamic

components, the sol valve control through PLC to achieve pneumatic control functions.

As shown in Figure 1.3.1, Mainly consists of : Service unit with shut-off valve for

pressure regulation, filter and water Separator, the discreteness of solenoid

valves, valve block, and bypass;

Fig 1.3.1

1.41.41.41.4Filling gun and moving pipe:

The following features:

A. Gun and the main pipeline joints connecting rapid routing and coated with

plastic covers.

B. The gun head is designed with anti-leak, after filling finish; there is no leakage

when plucking gun head.

C. Gun is set with start and stop button and indicator lighters. The green button


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means start and the red button means stop.

D. Gun head cooperated with oil tank are connected with pneumatic clamping

type.

E. Filling oil gun is seated the right part of equipment for operators use, which is

made from aluminum (not including handle), the part of easy-worn connected with

oil tank is considered intension, durability and corrosive resistance.

F. Gun head cooperated with the oil tank, oil tank mouth is without deformation

or injury, and the body without interference.

G. The moving pipe is hanged by moving arm, facilitating the operation .

2222 Principal of Working

JRJZ-V05P Power-Steering fluid vacuum filling machine is composed of fluid

control, pneumatic control and electric control three parts: Fluid control mainly

real-time check and quantitative controls fluid filling and system vacuum pressure;

pneumatic control part mainly finishes the fluid valve supplying pilot gas and controls

filling gun clamping; electrical control system mainly finishes system process control

and testing, also deal with process parameters data, preservation, the system running

monitoring, data display and failure alarm, etc.

JRJZ series common vacuum filling equipment working principle is based filled

system with vacuum check, vacuum filling, and suction of filling line and purification

etc. process technology integration of intelligent control. And complete vacuum, check

and fill process with higher operating rhythms.

Vacuum process of JRJZ V05P Power-Steering fluid vacuum filling machine,including low vacuum and then high vacuum stage; while suction process, including

suction, ventilation, etc. several stages. Filling process of quantitative vacuum filling

equipment consists of preparation, vacuuming and leakage detection, re-evacuation,

filling, suction and completing, etc. several sequential process.

Refer to system diagram, see the attached figure.


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3 Main Technical Index1)Technical Parameters

system vacuum value (filling gun mouth): 2mbar

Filling speed : 115L/min adjustable( free speed of opened container).

filling pressure: 1-4 bar adjustable

filling accuracy: level height2mm

Filling cycle : 120s/vehicle

Equipment shape dimensions: lengthwidthheight:17008001800mm

2)working environment

gas source: 5-7bar

power: Three-phase 380V10% 50Hz

environment temperature: -545

Environment humidity: 95%

Noise 72dB

4444 Vacuum Filling Equipment Operation ProcessThe process of Vacuum Filling Equipment consists of preparation, evacuation,

leakage check, re-evacuation, filling process, suction and complete .


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4.14.14.14.1 Preparation

After power on, then system shall enter into working state.

4.24.24.24.2 Evacuation

When first evacuation, vacuum pump M1 runs, vacuum pressure holding valve

V501 and gun vacuum valve V522 opens, a few seconds later, vacuum sensor V504.1

opens, until preset time.

4.34.34.34.3 Constant pressure, leakage check

No process content

1 Preparation Electrified equipment with self-check enter preparation

2

Gun automatic

clamping Press the green button on the gun, seal complete

3 EvacuationBig leakage checking

If failure to withdraw from filling cycle, sound and light alarm

4

Constant

pressure, leakage

check

Small leakage checking

If failure to withdraw from filling cycle, sound and light alarm

5 Re-evacuation Gun head reach the lowest vacuum 2mbar

6 Pressure fillingConstant pressure filling, pressure, flow and time triple control. If

failure to withdraw from filling cycle, sound and light alarm

7 Keep pressure Make the filling pressure constant to ensure fill up

8 Suction process Inflatable, and suction to complete level treatment

9 Filling complete State initialization, sound and light alarm

10Pneumatic

loosenedpress red button on the gun and unclamp

11Manual

extraction gunsSuction and anti-leakage


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After first evacuation, vacuum pressure holding valve V501 closes, system

begins leakage checking, until preset time.

4.4 Re-evacuation

Generally, system enters into re-evacuation process after leakage checking, and

opens vacuum pressure holding valve V501 again. The re-evacuation is to repeat

evacuation process, until preset time.

4.5 Filling process

When filling, filling pump M2 runs, and gun filing valve V521 and filling valve

V502 act, meantimes, tank breath valve V507 acts to accelerate filling process, until

preset pressure.

4.6 Suction process

After filling, the oil in pipeline shall be sucked back into tank. During this

process, tank vacuum valve V512 acts and tank shall be vacuumized by vacuum pump,

meantimes, suction valve V521 and blowing valve V509 acts, until preset time.

4.7 Complete

After suction, the whole filling process ends, system shall give indication signal

for s few seconds.

4.8 Suction against drop

Then, press stop button, tank vacuum valve V512 shall act again to suction

against drop until preset time or after gun returns into its house. The suction against

time can be set on man-machine interface.

4.9 System supply

Auto supply mode, supply valve V510 or V511 acts to supply oil into tank.

5. Operating

5.1 Start/stop Operating System

5.1.1 Power On:

Connect with the main powerunder the control panel of the JRJZ-V05P

Power-Steering fluid vacuum filling machine ; Push the power onbutton in the


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control panel The indication light shines and the touch screen enters the original

interface(fig 5.1.1)

Fig5.1.1 system original interface

5.1.25.1.25.1.25.1.2 Power off Operation: Shut off the compressed air supply valve in the mechanics

cabinet.

5.2 System Parameters Set

System parameters set is completed on the touch screen.

5.2.1 Selection of Working Mode

Switch the manual / automaticswitch to manual location on the control panel,

system enters manual mode; If switching the switch to automatic location, the system

enters automatic work mode.

5.2.25.2.25.2.25.2.2 Operating Parameters Set

NNNNoticeoticeoticeotice This element must be operated by professional operator or authorized

personals of our company, no other personnel changes at will!

1Technic Parameters Set

In figure 5.1.1 window, press "Parameter set" System accesses (Figure 5.2.1),

after inputting the process password (system default password 1), press ENT andsystem firstly enters current parameter set interface (Figure 5.2.2), in which you can

set parameters as fig 5.2.2 shown.


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Fig 5.2.1 password input

Fig 5.2.2 current parameter set

List 5.2.1

No. Parameter name unit Meaning Set value

1 Rough vacuum time SThe time to check whether there is big

leakage in vacuum pipe and break pipe.

2 Rough vacuum value MbarThe vacuum limit value for rough

vacuum process

3 Fine vacuum time S The time to check whether there issmall leakage in vacuum pipe and break

pipe.

4 Fine vacuum value mbarThe vacuum limit value for farther

vacuum process


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5Vacuum leakage

checking time SVacuum leakage checking time

6Vacuum checking

valuembar

Checking whether there is small

leakage

7 Re-evacuation time S Time time for second vacuum process

8 Filling pressure Bar The pressure value for full filling

9 Filling volume L The max filling volume

10 Filling tolerance L The filling volume range

11The shortest filling

times The shortest filling time

12 Max time S The longest filling time

13 Pressure keep time SPressure keep time after filling to

ensure filling full.

14 Suction time S Time of suction process

15 Barrel empty time S The time to check barrel empty.

16Suction against drop

timeS

Suction against drop time after taking

gun form filling point.

2System parameter set

The system parameter is the measure parameter to ensure the system filling

precision.Input system parameter password (system default password 1) in the

interface shown as fig 5.2.1, press ENT key and system enters system parameter set

interface (fig 5.2.3). user can modify the measure parameter, also can set new

password.


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Fig 5.2.3 system parameter set interface

AAAAttention: the system parameters have been set right,ttention: the system parameters have been set right,ttention: the system parameters have been set right,ttention: the system parameters have been set right, do not change them withoutdo not change them withoutdo not change them withoutdo not change them without

professional person.professional person.professional person.professional person.

5.35.35.35.3Vacuum Filling Operation

5.3.1Automatic Filling

1First, switchmanual / automaticswitch to the automatic position on the panel,

filling equipment enters preparation state, preparation indicator lights on. .

2On the monitor interface, select needed vehicle type.

3Take the gun from bracket and point to the filled pot, push the green FILLING

button on the top of the gun or press the remote control locking button, the three

claws in the gun clamps the lip of the pot and the entire vacuum filling cycle

starts as follow. The indication lamps will indicate the each process; the whole

cycle is going on automatically without person.

ReadyFirst vacuumVacuum leakPost vacuumFillingSuctionOver

4Filling completed, press the stop button, claws loosened, and system back suction

against drop until the suction preset time or gun back into the gun bracket.

5Filling gun back into the gun bracket.


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5.3.25.3.25.3.25.3.2Manual Filling

Firstswitch the manual/automaticswitch to the manual position ,the system

enters to the manual work mode, the preparation indicator lights on..

Step execution

Each time pressing the filling button, system shall enter into ReadyFirst vacuum

Vacuum leakPost vacuum FillingSuctionOver step by step. You can get the

changing and result of each parameter during every process, to make the fault judge

more easy and full. Generally, in normal produce line, for user we do not recommend

this mode.

NNNNote:ote:ote:ote:

a) System shall sync-output fault alarm with the indicator on panel when fault.

b) With automatic mode filling, if pressfilling stop key on the gun or the stop

button on the operation panel, system stops current operation, and then return the

initial state.

c) During filling process, operators can observe the current fill volume, the current

pressure and current va0cuum degree by system monitor interface. Detailed

monitoring interface see 5.4.

d) Any filling state, users can adjust filling pressure by the filling pipeline regulating

valve RF1 to regulate the speed of the filling.

5.3.35.3.35.3.35.3.3Supply fluid to tank by hand

1First, switch manual / automatic switch to the manual position on the panel,

filling equipment enters manual state.

2Pressmanual supplybutton on the panel, supply indicator lights are on, supply

fluid valve open, the system begins supplying oil to the storage tank from. to fill the

required level, again press on the panelmanual supplybutton, and stop supplying.

Note:Note:Note:Note: DuringDuringDuringDuring manualmanualmanualmanual supplysupplysupplysupply,,,, untiluntiluntiluntil systemsystemsystemsystem setsetsetset thethethethe highhighhighhigh level,level,level,level, you need notyou need notyou need notyou need not presspresspresspress

manualmanualmanualmanual supplysupplysupplysupplybuttonbuttonbuttonbutton , the system will automatically stop, the system will automatically stop, the system will automatically stop, the system will automatically stop susususupplying.pplying.pplying.pplying.

5.3.45.3.45.3.45.3.4Automatically supply fluid to tank

System monitors the level of the fluid in the storage tank by the fluid level switch.

When the storage tank level reaches the low level, system will automatically open the


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valve V510or V511to supply, when reach to high level, the system automatically stop

supplying, supply valve closed.

5.3.55.3.55.3.55.3.5 State Indicator Instructions

Three-color Lamps indicator

1) A red warning light constant on indicated system with malfunction, when checking

generally electricity or equipment preparation state. This warning, system does not

start filling operations. Mainly in the following circumstances lit :

A. Gas source is smaller than set the smallest pressure, which is to protect

pneumatic valve dependable motion.

B. The Trip situation of filling pump, vacuum pump motor protector.C. The liquid level is too low or too high.

2) A red warning light frequent flashes indicates filling process with failure, in this

case, you can choose complete mandatory or restoration re-operation. Mainly in

the following circumstances:

A. Filling time exceeds longest filling time set.

B. When evacuation, do not vacuum the largest leak vacuum degree in set time,the system reckons there is big leakage.

C. During leakage check, find leakage greater than the set.

D. When filling, the pipe-distance exceed journey.

3) A yellow light constant on shows system with problem, need to solve with manual

intervention, mainly in the following circumstances:

A. Filters plug, regardless of supply filters or filling filters

B. When complete filling, the actual filling volume is less than the preset least

filling volume.

C. When the edge of oil drum empty.

2) The green light is on expressed filling, extinguishing indicates completing.

Sound warning : the following two situations :

A. After filling completed, the buzzer will call a period of time to remind the

operator complete filling. 1HZ frequency, time out or press the "stop" button

on the gun to stop.

B. System with malfunction, with a red light for state instructions, buzzer


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frequency 5HZ, until troubleshooting or by pressing the "alarm reset" button.

5.45.45.45.4 System Monitor

Systems with real-time monitoring function, users can fully understand equipment

current work state by this picture.

Touch "system monitor in the initial interface 5.1.1, you can access to the main

monitor window of system (Figure 5.4.1), also, you can access this window by

touching system monitor on any window. The operators can observe the current

filling volume, the current cycle time, the current pressure and the current vacuum

value and the current parameters of the changes by this interface etc.

Fig 5.4.1 system monitor interface

On system monitor interface, press next page button, to enter pipeline monitor

interface, shown as fig 5.4.2. ON this interface, you can observe current filling state,

filling pressure and vacuum degree expressly.


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Fig 5.4.2 pipeline monitor interface

The warm interface can appear automatically for any fault of equipment. On the

monitor interface, press warm button, system can also access warm information

interface, in which interface, user can find warm time and fault content.

Fig 5.4.3 warm information interface

5.55.55.55.5 Manual Debugging

The function reserves the use of super administrator. During the system adjusting

or failure checking, divorcing from any PLC mode control, easy to operate and judge

the valve operation more directly on the man-machine interface. But professionalpersonnel are needed to complete, otherwise you can not properly handled the valve

interlocked relationship and brought the unexpected failure. This function absolutely is


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used cautiously.

In 5.1.1 window after input manual debugging password,(system default

password 1)) press the ENT key, the system enters manually debugging window

(Figure 5.5.1), users can manually debugging in this window, "the manual debugging"

functions for system service/ maintenance, an online debugging functions of the main

system components individually, or a combination check.

Fig 5.5.1 manual debugging window

5.65.65.65.6 Date Query Function

Data query function is about statistics about the total filling volume and time of

filling, users can access this function window for data inquiries.

5.6.1 In any interface, select "Data Query", the system accesses data query interface(fig 5.6.1). in this interface, you can query the last time of filling time, vacuum value,

filling quantity and the whole process time.


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Fig 5.6.1 data query window

5.5.5.5.7777Warning Relating Operations

1During systems operation, before operators carry out the next phase of the

operation or change the setting, must complete ongoing operation, or will result

in system disorder or system failures.

2 In all touch-screen interfaces "return" buttons are return the initial interface.

3In case of emergencies, you can beat emergency stop on the panel,

equipment stop.

Unless an emergency situation, you can not pressemergency stop button,

frequently use emergency stop button to stop power would affect some

components of life, even damage some electrical components.


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6666 Faults and Remedy

The system has fault diagnosis and alarm instructions function. In any working

state, failure, the alarm buzzers ring with failure, while red indicator light on of the top

three-color, the operator can query the current buzz content on the screen, the specific

alarm Table see 6.1.

When alarm interface appears, pressalarm reseton the panel to cancel

alarm ,users can handle relating alarm by alarm picture. If fault does not be removed in

time, alarm interface shall trip again after one minute(can be set)

Table 6.1 detailed alarm items and treatment

alarm content reason treatment

level too low alarmLevel switches or supplypump may be damaged

1check level switch

2adjust infusion pump and filter

level too high alarmlevel switch may be

damaged or infusion speed

too fast

1check level switch

2adjust throttle valve of infusion

pressure shortage

alarm

pressure switch may be

damaged or Under voltage

gas supply circuit

1check pressure switch

2Check pressure of the gas supply loopwhether to be enough

filling pump alarm

load may be too large or

system power failure1protective switch current set whether tobe too small

2check system load whether to be too

large

3 check system distribution electricity

circuit

vacuum pump alarm

load may be too large or

system power failure1protective switch current set whether to

be too small2check system load whether to be too

large

3 check system distribution electricitycircuit

big leakage alarm

Seal system not well, filling

head unclamp, pipeline

leakage, or large leakage

check parameter set too

small

1remove filling head and clamp

2check system pipeline whether to be leak

3adjust large leakage parameters

small leakage alarm

pipeline with small leakage

or small leakage parameters

set too small

1choose compel filling or cancel filling

2check system pipeline


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3 adjust system small leakage checkparameters

drum empty alarmfilter damage

pipeline unsmooth

1check filter

2check clean pipeline

filter alarmfilter damage

pipeline unsmooth

1check filter

2check clean pipeline

filling overtime alarm

set filling volume too

large

filling pipeline leak

1 check set filling volume and

filling protective

2check and maintain pipelie

Note: any of the foregoing alarm, according to the screen prompts for the

corresponding inspection and operation. If that does not succeed, please contact with

the manufacturers.

Equipment Common Faults and Remedy:

Vacuum failure (large leakage and small leakage alarm).

1)Seal damage, check seal loop of gun muzzle whether to damage or not, if

damaged, replace new seal loop;

2)vacuum pump failure, initiate vacuum pump, check vacuum pump whether to

normally operate or not, if normally operated, block gunpoint by hand and

directly vacuum, and then observe vacuum gauge whether it is below 20mbar

or not, if not reach, denoting that pipeline is leaking or vacuum pump

performance decline.

3)Car assembly loops or oil drum leaks, if such testing can vacuum below 20mar,

denoting circuit assembly or oil drum leaks;

Press filling without action.

1) Check gas source on site and observe triplet of the equipment to have

compressed air or not.

2) Press the button to observe input dot of the PLC corresponding button

whether it is light, if not light denoting button damage.

3) If light on to observe input dot of the PLC corresponding button whether it

is light, if not light denoting PLC or the internal process with problem.

4) Observation stop button corresponding PLC lights and whether it is


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lighting, lighting denoting button damage.

5) After obviating power issues, observe output dot corresponding fluid valve

whether to correctly open or not, if not open, pull out the windpipe to

check whether ventilate or not, ventilation denoting fluid valve damage;

6) Not ventilating, measure the corresponding sol valve whether to have 24V

power input or not, if no inputting, denoting PLC solenoid valve

connecting line with problem. If inputting, and solenoid valve without

action, denoting solenoid valve with failure. When you can remove the

windpipe, repeatedly open and close solenoid valve by the manual button,

to see whether to resume normally or not, if ineffective, denoting solenoid

valve damage;

Filling process without vacuuming

1) Observe this process whether to activate the vacuum air pump or not, if not

starting, check whether contactor Pick-up and whether the thermal

protection switch is Takeoff;

2) Pump starts normally, observe vacuum valve of this process whether toopen or not, if not opening, connect 2.6

3) Valve open normally without filling, showing that the pneumatic control

valve of filling gun did not open, and check the corresponding sol valve

whether it is normal, if work normally, when press corresponding sol valve

manual switch a minute then loose and repeated operation, then observe

whether to fill normally or not.

During filling process, evacuation without filling

1) Observe this process whether to activate the filling pump or not, if not

starting, check whether contactor is Pick-up and whether the thermal

protection switch is Takeoff;

2) Pump starts normally, and observe filling valve of this process whether to

open or not, if not opening, connect 2.6.Valve open normally without

filling, showing that the pneumatic control valve of filling gun did not

open, and check the corresponding sol valve whether it is normal or not, if

work normally, when press corresponding sol valve manual switch a


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minute then loose and repeated operation, then observe whether to fill

normally or not.

Filling Inadequate

1) During vacuum observations, vacuum instrumentation shows whether to reach

20mbar around or not, if not reaching, denoting vacuum failure, refer to 1.

2) If not evacuation, observe set value of pressure display gauge or "filling

pressure stable time" and "suction time of PLC parameters set value whether

to be changed or not, if altered, revises original setting values.

3) If no changed, observe pressure gauge pressure of filling pipeline whether is

above the two kilograms during filling, if not, gently shake regulating valve to

reach above two kilograms of pressure and adjust pressure until filling pressure

satisfied;

Level Failure (Level too low, Level too high alarm)

1) If level below lowest limit, firstly observe liquid pipelines whether to have power

steering fluid or not.

2) Pipeline has no problem, observe four level reference point of the PLC whether it isnormal, if not normal, denoting Level Meter or connectors with problem, test

connections and troubleshooting Level Meter

3) If input point is correct to observe whether the fluid valve open, if not openning,

connect 2.6)

4) If level is above level higher limitobserve four level reference point of the PLC

whether it is normal, if not normal, denoting Level Meter or connectors withproblem, test connections and troubleshooting Level Meter

5) If output point is normal to observe whether the fluid valve is opened, if openning,

connect 2.6)

7777 Maintenance and Repair

7.17.17.17.1 System Maintenance Daily

System Pipeline Maintenance: check equipment pipelines daily and tie-in whether

to leak or not, and ensure that equipment is clean and tidy. Carrying out


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maintenance every three months with cleaning dust and check whether pipeline

and circuit are normal.

Vacuum Pump Maintenance:

1) Check vacuum oil daily, if necessary you must check oil volume and top up it.

Suggestion: you should always keep oil level be in the middle of oil level observing

window.

2) Change vacuum oil immediately and you must replace vacuum pump oil in follow

circumstances during using equipment.

a)The equipment has been used more than three-five month.

b)Observe that oil color becomes darkle, deep and dirty.c)The viscidity of oil becomes thick or rare.

d)The oil has become compound of oil and water.

e)There are mass solid deposits.

f) The system cant reach the normal vacuum value.

g)The equipment has already filled more than 5000 vehicles.

Tool required: Allen key 8mmOil changing must be done with a switched off and still warm pump.

Open the oil drain plug and let run out the used oil into an appropriate container.

Refasten the oil drain plug when oil runs slower, start up the pump briefly (10

sec. max) and switch off immediately. Reopen the oil drain plug and drain the

rest of the oil. Before refastening the oil drain plug, inspect the O-ring and if

necessary replace it. Open the oil fill plug and pour in clean oil; refasten the oil

fill plug.

Cleaning the filter:

A wire-mesh filter is located in the intake port of the pump to act as a dirt trap for

impurities. It should be kept clean in order to avoid reduction of the pumping speed.

For this purpose, remove the dirt trap from the intake port and rinse it in a suitable

vessel using a solvent. Then thoroughly dry it with compressed air. If the dirt trap is

defective, replace it. The cleaning intervals depend on requirements.

1) If the limit pressure of pump is affected because any air or fluid melted into oil,

you can run pump for 30min to exhaust under the condition of gas ballast valve


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opened and inlet closed.

2) If vacuum pump has been set aside for one year, the oil must be replaced

before it is used again.

3) The open times of pump cant exceed six to avoid motor over loading.

4) The vacuum pump oil must be LEYBOLD oil. The damaged due to other oil

doesnt be included in warranty.

System checks vacuum value and flux parameters every half year and makes

them optimization.

You should keep fingers clean, slightly touch and press, forbid touching with

finger nail during using of various operation keyboards equipped in the

equipment system (especially LCD touching screen keyboard).

Electric Maintenance: regularly inspect whether connection terminal line

loosens and whether the relay contacts badly and every valve plug contacts

badly in order to ensure signal reliably input and output.

Maintaining Filter: Check whether supply filter and filling pipe filter are

blocked every month and clean filter sieve. Filter should be rinsed andchanged when system fault for filter is blocked during normally using.

Filling gun maintenance: Seal ring of filling nozzle is easy-damageable and

you should check regularly every month. If damaged you should replace it

immediately.

Moving system maintenance: you should regularly fill the lubricant oil for

mobile arm parts every year..

Maintenance of gas disposal unit

1) Oil level of oil tank should keep between upper limit and lower limit, if

shortage you should supply oil immediately. Use viscosity 2.5~7E lubricant

and 22 engineer oil is recommended.

2) Filter adopted with manually drainage device should advert to drain and keep

level below level sign, at least drain once every shift.

The equipment should be deposited in the circumstance of room temperature

and good ventilation to avoid rain or exposing in sun. Please keep equipment

upright for transportation or storage.


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Ensure that power supply and gas source are switched off you can carry out

various maintenance.

7.2 System repair :

Fluid control circuit maintenance: every fluid valve can open by manual in the

fluid control circuit, during maintenance if you want to operate a valve, you

can press white point in the sol valve by manual, and check and maintain the

relevant pipelines, you can operate sol valve by manual only on the power off

conditions.

Electric loop maintenance: Total system logic controls are in the PLC control,

after checking trapezium and knowing the logic relation, and then observe

each input and output state in the PLC to confirm interior logic with failure

or exterior connector and valve or its perform components problem. During

maintenance process you can refer to system theory chart and electric control

chart.


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Annex one

Two conjoined / triple-use (compressed air source processor) instruction (for

reference only difference between models)

Installation

1Blow the pipeline by compressed air before installation.

2Triplet required install vertical, and water cup and oil cup are adown, but

pressure relief valve knob install up or adown.

3Arrowhead direction refers to air compress direction, pay attention to it when

installation.

Environment

1Avoid exposure in the sun

2As a result of water cup and oil cup are made from creosote; Avoid using in

circumstances containing the following chemistry: compound oil, thinner,

chloroethylene, kerosene, acid or aroma hydrocarbon.

Operation

1The filter should advert to release water with drainage manually, level not

exceed level symbol, at least set water once every number of runs

2When adjusting pressure, firstly pull the knob, right rotate with pressure

ascending and left rotate with pressure descending, and then push the knob and

clock on the adjusted pressure.

3The oil level of oil tank should keep between upper limit and lower limit, oil

deficiency, supply oil prompt. use mucosity 2.57E lubricate, we commend

use number 22 steamer oil.

4The minimum air flux in the normally operating should content the minimum

flux request of oil tank.

5Cup and cup removed should be operated without pressure.

1Clutch shield cover by hands, press orientation device and rotate right or

left 45 by thumb, make the arrowhead of orientation device versus the


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arrowhead of valve and pull adown to remove.

2Some models can directly tweak down.

6Oil tank can fill oil with stop gas or non stop gas, fill oil step as follows:

1Usually directly fill by opening oil stuff.

2Some model: a. open the block of oil tank and dropt air of cup b. tweak

down oil cupc. add the cup proper oild. tweak up oil cupe. tweak

up stuff.

Maintenance:

Abstersion of cup and sieve should choose litmusless scour, after washing with

rinsing and cool.


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Key part list

No. Name Type Manufacturer

1 Vane vacuum pump SV25BGermany

LEYBOLD

2 Vacuum sensor PTX610 DRUCK

3 Pressure sensor A-10 Germany WIKA

4 Flow sensor OV-10

5 Fluid valve TYPE2000 G1/2Germany

BURKERT

6 Fluid valve E290 ASCO

7 Filling pump TOP-2MY400-210HBM Japan NIPPON

8 Supply pump TOP-2MY400-220HBM Japan NIPPON

9 PLC 1766-L32BWA AB

10 Extend module 1762-IQ16 AB

11 A/D module 1762-OW16 AB

12 Touch screen 2711P-T6C20A AB

13 Sol valve VQZ115-5G-C6 Japan SMC

14Air processing unit

(Triplet )AC30-03 Japan SMC

15 Pressure gauge 0-1.6MPa Shanghai China

16 Electric components SCHNEIDER

17 Flow switch FB21-020GK BANNA

18 Level switch steel Beijing china

19 Ripple pipe jacket AD42.5 Germany FLEX

20 Fluid filter G1/2 Haideke

21 Storage tank 50L cjierui

22 Cabinet J812C-01 china

23 Moving arm JR010 cjierui


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24 Air-condition LA-03B Leibo

25 Filling gun J812C-03 cjierui

26 Balancer 1.5-3Kg Aotu

Spare list

No. Name Type Manufacturer Mark

1 Button on panel XB2B SCHNEIDER

2 Button on gun 49112red greem American ICW

3Fluid valve

TYPE2000BURKERT

4 Sol valve VQZ11155G-C6 SMC

5 Seal hoop KF25 LEYBOLD

6 Oil of vacuum pump GS77 LEYBOLD

7 seal J782A-03.01-07 cjierui

8 Filter core 1/2 Haideke

Documents

Manual Maq Llenado Aceite Hidraulico