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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
ASSEMBLY CHECKS 3/17
Checks: GEOMETRICAL – CROWN
MEASUREMENTMEASUREMENT
APPARATUSMEASUREMENT INSTRUCTIONS
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
ASSEMBLY CHECKS 4/17
MEASUREMENTMEASUREMENT
APPARATUSMEASUREMENT INSTRUCTIONS
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.
CHECKED BY : CHECK DATE : APPROVAL :
FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02
ASSEMBLY CHECKS 5/17
MEASUREMENTMEASUREMENT
APPARATUSMEASUREMENT INSTRUCTIONS
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.
CHECKED BY : CHECK DATE : APPROVAL :
FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02
ASSEMBLY CHECKS 6/17
MEASUREMENTMEASUREMENT
APPARATUSMEASUREMENT INSTRUCTIONS
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.
CHECKED BY : CHECK DATE : APPROVAL :
FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02
ASSEMBLY CHECKS 7/17
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 √
CHECKED BY : CHECK DATE : APPROVAL :
FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02
ASSEMBLY CHECKS 8/17
MEASUREMENTMEASUREMENT
APPARATUSMEASUREMENT INSTRUCTIONS
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 √
CHECKED BY : CHECK DATE : APPROVAL :
FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02
ASSEMBLY CHECKS 9/17
MEASUREMENTMEASUREMENT
APPARATUSMEASUREMENT INSTRUCTIONS
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.
CHECKED BY : CHECK DATE : APPROVAL :
FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02
ASSEMBLY CHECKS 10/17
FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02
ASSEMBLY CHECKS 11/17
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 ....................
CHECKED BY : CHECK DATE : APPROVAL :
FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02
ASSEMBLY CHECKS 12/17
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..................................................
CHECKED BY : CHECK DATE : APPROVAL :
FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02
REGISTRATION MARKS :
Tight Loose
ASSEMBLY CHECKS 13/17
Checks: GEOMETRICAL - SLIDE
MEASUREMENTMEASUREMENT
APPARATUSMEASUREMENT INSTRUCTIONS
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
ASSEMBLY CHECKS 14/17
MEASUREMENTMEASUREMENT
APPARATUSMEASUREMENT INSTRUCTIONS
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
ASSEMBLY CHECKS 15/17
MEASUREMENTMEASUREMENT
APPARATUSMEASUREMENT INSTRUCTIONS
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
ASSEMBLY CHECKS 16/17
- 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
CHECKED BY : CHECK DATE : APPROVAL :
FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02
ASSEMBLY CHECKS 17/17
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
CHECKED BY : CHECK DATE : APPROVAL :
FSG 7.3.5-2 Proyect:60010(29025) Ed.: 11-02