60010 assembly checks (2)(aner).doc

Fagor Arrasate Koop. E.

CHECKS TO BE MADE

IN FAGOR ARRASATE

CHECKS :

* MECHANICALS x* ELÉCTRICALS

* HYDROPNEUMATICS AND LUBRICATION

Correct ó No apply

Project : 60010(29025)Customer : SHANGHAI GENERAL MOTORS

Machine : TLE4-2000-

Prepared by : Signature : Date ::

22/02/2011

ASSEMBLY CHECKS 2/17

Checks: GEOMETRICAL MOTOR-FLYWHEEL

MEASUREMENTMEASUREMENT

APPARATUSMEASUREMENT INSTRUCTIONS

SPECIFIEDVALUE

ACTUALVALUE

Distance between flywheel and motor pulley (dimension A according to drawing)

Vernier calliper

Using a ruler resting on the flywheel take the distance indicated in the drawing as dimension A

1 116 mm. ___113__ mm.

Parallelism between wheel and motor pulley (dimension A in accordance with drawing)

Vernier calliper

Using a ruler resting on the flywheel take the distance indicated in the drawing as dimension A, in the three points.

Maximum difference between points A 1,2,3: 0.5 mm

___0.5__ mm.

CHECKED BY : CHECK DATE : APPROVAL :

FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02


Checks: GEOMETRICAL – CROWN



SPECIFIEDVALUE

ACTUALVALUE

Total play between shaft and bushing on connecting rod heads

External micrometer or comparison

gauge

With the connecting rod fitted to the eccentric wheel, measure the play between the shaft and bushing, inserting the gauge along the whole length

Total play

A

0,475-0,80 mm.

B

0,24-0-40 mm.

C

0,165-0,30 mm.

D

0,165-0,30 mm.

A Eccentric 1

Front ___0.75__ mm.

_________ mm.

Back

__0.65__ mm.

_________ mm.

A Eccentric 2

Front

__0.70__ mm.

_________ mm.

Back

___0.45__ mm.

_________ mm.

B Eccentric 1

Front

___0.30 _ mm.

Back

___0.25__ mm.

B Excentri.2

Front

___0.25__ mm.

Back

___0.25__ mm.

C Eccentric1

Front

___0.20__ mm.

Back

___0.20__ mm.

C Eccentric2

Front

___0.20__ mm.

Back

___0.25__ mm.

D Eccentric1

Front

___0.23__ mm.

Back

___0.22__ mm.

D Eccentric2

Front

___0.195_ mm.

Back

___0.25__ mm.

FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02




SPECIFIEDVALUE

ACTUALVALUE

Play in the bottom rod External micrometer or comparison

gauge

Measure the clearance between the shaft

1 and Bushing 2 0,165-0,30 mm.

Connecting rod 1

___0.24___ mm.

Connecting rod 2

___0.21__ mm.

Connecting rod 3

___0.22__ mm.

Connecting rod 4

___0.23__ mm.

Lateral play in connecting rod articulations

Gauges Measure the lateral play between ruder bar and connecting rod. The value is the sum of both values

0,5

5 mm.

Connecting rod 1

___5.20__ mm.

Connecting rod 2

___4.40__ mm.

Connecting rod 3

___4.55__ mm.

Connecting rod 4

___4.35__ mm.

Lateral play in lever articulations

Gauges Measure the lateral play between swing lever and lever. The value is the sum of both values

0,5

5 mm.

Lever 1

___5.10__ mm.

Lever 2

___4.55__ mm.

Lever 3

___4.40__ mm.

Lever 4

___4.34__ mm.


FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02




SPECIFIEDVALUE

ACTUALVALUE

Lateral play between connecting rod bushing and ruder bar

NOTE: Mark the eccentric and connecting rods with corresponding number

Gauges Measure the play side on each side between the bushing and the eccentric projection an the stop parts. The value reflected will be the sum of the two

0,5

5 mm.

Ruder bar 1:

__5.10___ mm.

Ruder bar 2:

___5.50__ mm.

Ruder bar 3:

___5.25__ mm.

Ruder bar 4:

___5.20__ mm.


FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02




SPECIFIEDVALUE

ACTUALVALUE

Total play between shaft and bushing in the seats of intermediate and eccentric shafts

Comparison gauge or gauges

With the shafts fitted in the crown measure the play between shaft and bushing, inserting the gauge along the whole length

Total play

Shaft 1

_0,28-0,45_ mm.

Shaft 2

_0,28-0,45_ mm.

Shaft 3

_0,24-0,40_ mm.

Shaft 4

_0,165-0,30 mm.

Total play

Shaft 1

Front

__0.33___ mm.

Back

___0.31__ mm.

Shaft 2

Front

___0.31__ mm.

Back

___0.28__ mm.

Shaft 3

Front

__0.30__ mm.

Center

___0.30__ mm.

Back

___0.30__ mm.

Shaft 4

Front

___0.28__ mm.

Back

___0.25__ mm.


FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02


KINEMATIC CHAIN

ASSEMBLY CHEKING OF ECCENTRIC GEAR IN CROWN

With the eccentric gears in B.D.C. check the alignment of gear center with eccentric center and gear tooth reference

CORRECT

Left √

Right √


FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02




SPECIFIEDVALUE

ACTUALVALUE

Play between the flanks of the teeth in the eccentric wheel drive gear

Comparison gauge

Apply the probe to the flank of one of the pinion teeth. Keeping the wheel still, move the pinion in both rotation directions and observe the deviation of the comparison gauge needle

P10,48-0,64mm.

P20,60-0,80mm.

P30,60-0,80mm.

P40,60-0,80mm.

P1_0.27__ mm.

P2_______ mm.

P3__0.62_ mm.

P4__0.9__ mm.

Parallelism between the flanks of the teeht in the eccentric wheel drive gear

Coat the pinion teeth which drive the eccentric wheels with a coating of minium. Turn the eccentric wheels one turn and visually check the contact along the length of the tooth

CORRECT √


FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02




SPECIFIEDVALUE

ACTUALVALUE

MICROINCH

Play between the flanks of the teeth in the microinch wheel drive gear

Comparison gauge

Apply the probe to the flank of one of the pinion teeth. Keeping the wheel still, move the pinion in both rotation directions and observe the deviation of the comparison gauge needle

P20,20-0,30 mm. P__0.30__ mm.

Parallelism between the flanks of the teeht in the microinch wheel drive gear

Impregnate the pinion teeth with a thin even layer of minium and activate the unit in the direction of rotation until the wheel completes one rotation. Check the contact between the teeth

CORRECT √

Jump in fast shaft Support and comparison

gauge

Place comparison gauge support on flywheel support (mushroom) and rotate the shaft one turn.

Record the maximum difference shown on the gauge

Max. dif.

0,10 mm. ___0.02__ mm.

Concentricity between fast shaft and flywheel support (mushroom)

With the shaft in a fixed position, measure the distance between the support and the shaft at four points, as shown in the diagram.

Record the difference between the opposite points: 1-2 and 3-4

Máx. dif.

0,20 mm. 1-2__0.15_ mm.

3-4__0.08__ mm.


FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02


FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02


Checks: GEOMETRICAL – COUNTERBALANCER

ABSENCE OF AIR LEAKAGE

Checking instructions:

Instal a distance tube or similar (see dwg.), of a length that guarantees a safety distance (dimension “A”) of 100 mm.

Fit to counterbalancer chamber, air at the working pressure indicated in the drawing through the pressure regulator. Once reached the pressure, close the air feed and check after 30 minutes that the pressure has not descended more than 10%.

CORRECT

COUNTERBALANCER Nº 1 .................... √

COUNTERBALANCER Nº 2 .................... √

COUNTERBALANCER Nº 3 ....................

COUNTERBALANCER Nº 4 ....................


FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02


Checks: LOCKING SCREWS/NUTS

Inspection of the locking of screws and nuts ( N.A. 24-08i )

Crown:

Screws/nuts that need to be lock with locking liquid(LOCTITE) ....................

Screws/nuts that need to be lock with steel wire ...........................................

Self-locking nuts..............................................................................................

Locking washers ............................................................................................

Slide :

Screws/nuts that need to be lock with locking liquid(LOCTITE) ....................

Screws/nuts that need to be lock with steel wire ...........................................

Self-locking nuts..............................................................................................

Locking washers ............................................................................................

CORRECTO

Connecting fittings of oil pipes

After tightening all the connecting fittings for the lubrication of the head bolts, paint adjusting signals according to drawing..................................................


FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02

REGISTRATION MARKS :

Tight Loose


Checks: GEOMETRICAL - SLIDE



SPECIFIEDVALUE

ACTUALVALUE

Play between the flanks of the teeth in worm mechanisms for slide adjustment

Comparison gauge

Insert the worm into the crown, supported on bushing 1 and 2 which replace the bearings. Apply the probe to one of the ends of the worm and keeping the crown still, move the worm axially. Observe the displacement on the gauge

0.22 – 0.70 mm

Nº1 Front left

___0.27__ mm

Nº2 Back left

___0.30__ mm

Nº3 Back right

___0.25__ mm

Nº4 Front right

___0.35__ mm

Surface contact between the flanks of the worm and crown teeth for slide adjustment

Coat the worm screw with a thin, even coating of minium and activate it manually at a constant speed in both rotation directions until the crown completes one turn. Check the contact between the teeth

l. 50% or more of effective width of tooth

t. 20% or more in the direction of the tooth depth

Nº1 Front left

l___65___ %

t___40___ %

Nº2 Back left

l___80___ %

t___60___ %

Nº3 Back right

l___70___ %

t___50___ %

Nº4 Front right

l___46___ %

t____63___ %

FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02




SPECIFIEDVALUE

ACTUALVALUE

Lateral play of adjustment mechanism crown in its housing

Gauges Measure the play between the top cover and the crown (before putting any pressure in the hydraulic cylinder)

Pressure 160 kg/cm2

h=0,07 - 0,12 mm.

H+h=0,15-0,25mm

Nº1 Front left

_________ mm

Nº2 Back left

___0.15___ mm

Nº3 Back right

_________ mm

Nº4 Front right

_________ mm

Nº1 Front left

_________ mm

Nº2 Back left

___0.26__ mm

Nº3 Back right

_________ mm

Nº4 Front right

_________ mm

Lateral play between nut and piston

Comparison gauge

Put pressure into the hydraulic cylinder and check with the comparison gauge the measurement difference with the nut rested on the piston and with the nut pulling upto the top

FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02




SPECIFIEDVALUE

ACTUALVALUE

Total play in the connection. Nut plus screw

Comparison gauge

Place the comparison gauge on the connection screw and locate the needle on the casing. Use a crane to establish the connection play, pulling up on the screw. The comparison gauge will indicate the total play

0,43 – 0,65 mm Nº1 Front left

_________ mm

Nº2 Back left

___0.59__ mm

Nº3 Back right

_________ mm

Nº4 Front right

_________ mm

Anti-overload system hydraulic cylinder stroke

Vernier calliper

Measure the distance L before and after putting oil in the hydraulic cylinder and note down the difference between the two readings

0,5025 mm

(Difference between the four connections not more than 0,30 mm)

Nº1 Front left

_________ mm

Nº2 Back left

_________ mm

Nº3 Back right

_________ mm

Nº4 Front right

_________ mm

Check that the mechanism operates easily to adjust the slide by manually turning the worm

Front right

Back left

Front left

Back right

FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02


- No leakage in connection chamber – Load pressure 320 kg/cm2

.After 4 hours check no leakage of oil in hydraulic cylinder

Front right

Back left

Front left

Back right

NOTE: The right, left, front and back positions mentioned in the slide checks are taken looking at the press from the front

Check that the oil collection tank of lubrication is clean


FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02


Checks: GEOMETRICAL – BASE- HYDRAULIC CUSHION

These checks are in the final control book.

Checks: GENERAL – MOVING BOLSTER

Keep the wheels turning at no load for 30' and check:

- Sound level < 80 dB (A) and correct operation......................................

- No heating up. Acceptable tº: 20ºC over the ambient temperature ........

Check alignment and parallelism of moving bolster wheels. Specified value 0,2 mm.

- Wheels for introduction into press:

Alignment............................................................................

Parallelism ..........................................................................

Check that the distance between the wheels of the moving bolster comply with the measurements specified on the drawing

- Wheels for introduction into press...........................................................

- Wheels for side evacuation ....................................................................

Checking of height equality of wheels

Place a straight edge as in drawing and check the equality in thefour wheels

- Wheels for introduction into press...........................................................

BOLSTER

1

2


FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02

60010 assembly checks (2)(aner).doc

Documents

connecting rod bushing

rod articulations gauges

b eccentric

rod heads external micrometer

eccentric wheel

swing lever

lever articulations

ruder bar note