Q91Y-1250T Heavy Scrap Hydraulic Shear Technical ...

Technical Documents of Jiangyin Tianfu Technology Co., Ltd.

Q91Y-1250T Heavy Scrap Hydraulic

Shear

Technical Instructions

Jiangyin Tianfu Technology Co.,Ltd.

NOV 2019


Catalogue

0. Company Profile ......................................................................................................................... 1

1. Summary ...................................................................................................................................... 2

1.1 Machine Synopsis ............................................................................................................... 2

1.2 Design Basis ........................................................................................................................ 3

1.3 Requirements for Public Facilities ...................................................................................... 3

2. Technical Specifications of Q91Y-1250T Scrap Hydraulic Shear and Matching Equipment4

2.1 Equipment Composition and Function Description ............................................................ 4

2.2 Electrical Control System ................................................................................................... 6

2.3 Hydraulic System ................................................................................................................ 7

2.4 Technical Specifications ...................................................................................................... 8

3. Scope of Supply ........................................................................................................................... 9

3.1 Supply Scope of Scrap Hydraulic Shearing Machine ......................................................... 9

3.2 Technical Requirements and Material of Key Components ................................................ 9

3.3 List of Equipment suppliers ................................................................................................ 9

3.4 Equipment Split Delivery Table ........................................................................................ 11

3.5 Describe of Equipment Junction Point .............................................................................. 12

3.6 Equipment Composition and Requirements(Single SET) ................................................. 13

4. Technical Norms of Scrap Hydraulic Shearing ...................................................................... 14

4.1 General Requirements ....................................................................................................... 14

4.2 Structural Requirements .................................................................................................... 15

4.3 Requirements for Distribution Equipment ........................................................................ 15

4.4 Special Requirements For Hydraulic Scrap Shear and Its Affiliated Systems .................. 15

4.5 Main Inspection and Test Items ..................................................................................... 15

5. Data Delivery List ..................................................................................................................... 17

6. Design Inspections ..................................................................................................................... 19

7. Instructions for anticorrosive coating of equipment .............................................................. 19

8. The Excluded Items of the Bidders. ......................................................................................... 20

9. After-sale Service Commitments .............................................................................................. 20

9.1 Quality Performance of the Equipment ............................................................................. 20

9.2 Pre-sale Service ................................................................................................................. 20

9.3 Quality Assurance 、Personnel Training and After-sale Service ..................................... 21

10. Installation of Heavy Scrap Shear ......................................................................................... 21

11. Maintenance of Heavy Scrap Shear ....................................................................................... 24

11.1 Safety Operation .............................................................................................................. 24

11.2 Daily Maintenance .......................................................................................................... 24

11.3 Weekly Maintenance ....................................................................................................... 25

11.4 Annual Maintenance ........................................................................................................ 25

11.5 Overhaul and Maintenance .............................................................................................. 25

11.6 Blade Changing and Blade Clearance ............................................................................. 25

12. Safe Operation Regulations .................................................................................................... 26

13. Schematic Diagram of Equipment Foundation Layout ....................................................... 27


1

0. Company Profile

Jiangyin Tianfu Technology Co,.ltd is located in Jiangyin City,which ranks the

National Powerful Country Top100 in Yangtze River Delta zone.It is an enterprise

specializing in manufacturing large-medium sized hydraulic equipment.It is the

domestic large-scale production base of hydraulic scrap baler and hydraulic metal

shear.After 20 years’ development,the company has grown to be a renowned

enterprise in junk-recycle industry.The products are widely used in resources

recycling industry,waste recycling industry and recycling economy industry and so

on,and have been highly praised by the customers.

It is capable of producing over 3000 sets of large-medium sized hydraulic

equipment yearly.The company has a powerful ,high-caliber and young research team

with great innovation capacity,and has founded Postdoctoral research station by

working with He Hefei Polytechnic University .According to customers’

requirement,the company produces customized models to meet different manufacture

demands.Recently,by its own R&D,over 10 new models come through every year,all

get national patent.

The company was named as＂National Important High-Tech Enterprise in Torch

Plan ＂，＂ Jiangsu High-Tech Enterprise ＂ , ＂ National standardization AAA

Enterprise＂ ,＂ Jiangsu Innovation Enterprise ＂ ,＂ Jiangsu Private Technology

Enterprise ＂ .It is ＂ Quality and reputation guaranteed model unit ＂ , ＂ Key

promotion unit＂of China light product quality safeguard center.

Tianfu brand hydraulic equipment are sold to more than 70 countries in

Europe,Africa,Southeast Asia,such as USA,Japan,Russia,India,Brazil etc.

Each set of machine in Tianfu is strictly manufactured according to the quality

management system standard of ISO9001:2008 and CE.

Tianfu Technology upholds the business philosophy of "not seeking to deliberately

enlarge the company's scale, but striving to make each equipment fine and strong",

and achieves the service goal of "creating high-quality products for customers" with

first-class skills and attitude.


2

1. Summary

1.1 Machine Synopsis

Q91Y-1250T scrap steel hydraulic shearing machine is a model


3

developed with the world's advanced vertical scrap steel shearing machine

as the prototype. It uses the world-class technology and components to

manufacture products. Its structure, technical parameters and

performance have reached the world-class level.

As the first equipment for large-scale scrap steel processing, this

machine can cut various kinds of scrap steel, billet, metal structural

parts, etc. It provides high-quality furnace burden for metallurgical

industry, and is an important processing equipment for metallurgical

industry and large-scale metal recovery industry.

1.2 Design Basis

The hydraulic scrap shear is designed and manufactured according to the relevant

technical terms stipulated in the bidding documents and contract documents, as well

as the relevant national technical standards. The followings are the technical

specifications and technical standards mainly referred to in the design:

《机械设计手册》第五版北京化学工业出版社 2007

GB/T3766-2001 液压系统通用技术

GB5226.1-2002 机械安全机械电气设备第一部分通用技术条件

GB/T7935-2005 液压元件通用技术

In the design process, we perform according to the provisions of the bidding

documents, and the technical parameters, indicators and technical requirements

confirmed by the buyer.The productivity indicators are based on a large number of

process experiments and design experience of similar products.

1.3 Requirements for Public Facilities

External Environmental Requirements:

Power Supply:Three-phase alternating current,Voltage380V（±10%）,Frequency

50HZ（±2%）

Hydraulic working medium:No.46 Anti-wear Hydraulic Oil

Below 2000 meters above sea level

-15℃≤Ambient Temperature≤40℃

Humidity:Relative humidity does not exceed 90% at ambient temperature (+20

C);Relative humidity does not exceed 50% at ambient temperature (+40 C)

Water Source 1: tap water, water flow 10L/min, 0-0.3mpa, non-continuous water

for cooling and replenishment

Total power of equipment:480KW

The rated total current is about 960 A, and the main oil pump motor has frequent

short-term overload in the working process, which makes the maximum

instantaneous total current of the whole machine reach 1050 A, and the rated

current of the total power supply switch in the switchgear of this machine is


4

1000A.

2. Technical Specifications of Q91Y-1250T Scrap

Hydraulic Shear and Matching Equipment

2.1 Equipment Composition and Function Description

The electrical system of the shearing machine consists of the main oil pump

motor, the control oil pump motor, the cooling system motor, the oil heater, the

electric control cabinet, the control console, the proximity switch controlling the

stroke of each oil cylinder, the laser displacement sensor and the transmitter, the

pressure sensor controlling the pressure of each oil cylinder, the oil level switch

detecting the oil height, the temperature sensor detecting the oil temperature and the

wires connecting each part,the cable box and the laying system of the line.

It mainly consists of the following components:

①Main Body of the Door Shear

It consists of gantry frame, pressing slider, pressing cylinder, pressing

wear-resisting plate, shearing slider, cutting cylinder and shearing wear-resisting

plate.The pressing assembly composed of the pressing slider and the pressing oil

cylinder is installed in the sliding groove formed by the gantry structure, and moves

up and down under the action of the pressing oil cylinder, thus completing the

material pressing at the outlet of the shearing material box.The shearing assembly is

composed of shearing slider and shearing cylinder. They are installed in the sliding

groove of gantry structure and move up and down under the action of shearing

cylinder. The shearing material with the same shearing growth is pushed out by the

feeding head of shearing tank. The contact surface between slider and chute is

equipped with replaceable wear-resistant strip or liner, which can be replaced after

wear to prolong service life. In addition, two side pressure cylinders are installed on

the side of the gantry shears for lateral extrusion, so as to cut the social material into

the furnace material that meets the specifications.

Integral welded scissors slider, not easy to deform, strong and durable

The cutting edge track is set in the adjustable V-shaped guide rail, which

canaccurately transfer the shear force.

Large inner diameter cylinder with sufficient output force to relieve pressure of

hydraulic system

②Feeding Bed

It is composed of a feeding box, a feeding press head, a feeding cylinder, etc.The

material box is welded by various profiles and sheets. It is the frame of the shearing

material box. It is used to undertake materials and install the feeding head.The feeding

pressure head moves in the feeding tank under the action of the feeding cylinder for

shearing.The feeding length can be adjusted according to the burden requirement.

Cylinder feeding, stable feeding

Laser Ranging Transmitter Replaces Traditional Proximity Switch for Accurate

Ranging


5

Thick and durable material

③Electrical System

The electric system consists of the main circuit of the motor, the starting and

stopping control circuit of the motor and the input and output control circuit of the

PLC.

Digital stepless display and precise control

The stepless setting of various displacement parameters can be accomplished

by the touch screen of the console.

④Hydraulic Power System

The hydraulic power system is composed of hydraulic tank, hydraulic pump

station, valve station and hydraulic pipeline system. It is the central control system of

the main engine. According to functional logic, different pipelines are connected

together. Its function is to provide energy for the operation of shearing cylinder,

pressure cylinder, side pressure cylinder, feeding cylinder, pressure head cylinder and

other executing parts.

The tank level can be observed locally or displayed on the operating table.

Oil Temperature Protection

⑤Hydraulic Pipeline System

The hydraulic system consists of hydraulic oil tank, hydraulic pump station, valve

station and hydraulic pipeline system. It is the central control system of the main

engine.

Precision piping for hydraulic piping

Factory Standardized Flange, Easy and Fast Installation

⑥Cooling System

The working hydraulic oil of the machine is cooled by an automatic circulating

water cooling system.

The equipment of automatic circulating water cooling system consists of oil pump

and motor, plate heat exchanger, pipeline pump and motor, fan cooling circulating

water tower, pipeline and connecting flange.

When the oil temperature of the automatic circulating water cooling system of

working hydraulic oil reaches 50 C, the temperature sensor installed on the tank tank

controls the automatic start-up operation of the circulating water cooling device.

When the oil temperature decreases by 25 C, the operation of the circulating water

cooling system stops.

Fast cooling speed and good cooling effect

Low Water Loss and Low Operating Cost

⑦Lubricating System

The lubrication mode of heavy scrap shears is the fully automatic centralized

lubrication mode of thin oil lubrication on the running friction surface between the

sliding seat of scissors and the upper press head.

⑧ Key Technologies of The Host Machining

By adopting floating boring, rolling or honing technology, the surface

roughness and shape and size tolerance of the inner hole of the cylinder are

effectively guaranteed.


6

Welding technology is mature, stress is removed after welding and then

processed as a whole, the dimension accuracy is more accurate.

Material and Manufacturing Technology of Scissor Slider

Dimension Guarantee of Installation Position of each Cylinder

Heat treatment process for key components

2.2 Electrical Control System

The electric control cabinet centralizes all the main control devices. All the

operating devices of the machine are centralized on the control panel, including all

the operation buttons, touch screen and alarm.

The electric control system of this machine is equipped with Mitsubishi series

PLC program controller, switching module, analog module, and a variety of sensors.

Logical control of solenoid valve, pressure and displacement control of cylinder,

monitoring control of oil temperature and oil level, signal display and alarm are

realized. The touch screen is used to set various parameters and monitor the running

status of each cylinder of the machine.

The electrical control of the machine refuses to have Schneider general power

switch with rated current of 1000A, which is used as short circuit protection for the

whole electrical equipment. The closing and opening operations are all electric

operation, which can be controlled by the operation button on the cabinet and the

operation button on the console. Each motor is short-circuit and overload protected

by circuit breaker and thermal relay. Starting mode of oil pump motor is star

triangle. Starting mode of each motor is interlocked, that is, when one motor is not

started, another motor will not start at the same time, thus reducing the impact of

motor starting current on the grid. When each motor trips or overloads, it will give

an alarm signal. The fault information can be seen on the touch screen for staff to

check and repair.

The control system of the shearing machine integrates the fabrication and

laying of an electric control cabinet group, a control console, each tap box and the

cylinder stroke transmission device of the main engine, the electric circuit laying of

the power department and the installation and laying of the interconnection control

circuit of each part.

Electrical control cabinet group: A. Inlet power cabinet, which provides

protection for the whole low-voltage system of the shears, adopts Schneider's

intelligent frame circuit breaker. The circuit breaker is in three-dimensional

arrangement, the contact system and the operating mechanism are all installed on

the iron frame. There are "split" and "close" instructions and manual "split" and

"close" buttons. Circuit breakers are equipped with shunt trippers and under-voltage

trippers. The circuit breaker is safe and reliable in use, with high cost performance

and stable power supply to the equipment. B. Power cabinet, bearing the control of

oil pump motor set, clear and reasonable layout is the basis of design, simple and

clear circuit to create more convenience for later maintenance, components using

Schneider brand, according to motor power size, select suitable circuit breaker,

contactor, and corresponding overload protection, overcurrent protection device,


7

more reliable to ensure the operation of equipment. C. Core unit PLC cabinet, using

Mitsubishi FX3U series PLC, with excellent quality, reasonable design and

long-term continuous production is our purpose. High-performance PLC with high

speed, capacity, performance and powerful function is conducive to real-time grasp

of the operation status of equipment.

Operator centralizes all specific operations and signal feedback, integrates

motor start-stop, automatic/manual real-time switching, automatic control of

equipment, automatic control of ancillary equipment, automatic control of operation,

automatic control of hydraulic station, management control and other functions.

When the automatic control system can not run automatically because of external

conditions, it also has the function of manual control to ensure the stable operation

of equipment under the condition of manual control.

2.3 Hydraulic System

The hydraulic station made by our company has the characteristics of

environmental protection, low noise, small occupied area, no oil pollution,

convenient installation and moving machine. The following picture:


8

2.4 Technical Specifications

1 Shearing

cylinder

Push

force 4000KN Quantity 3 sets

model YG450/320 Stroke 1150mm

2 Press

cylinder

Push



3 Side cylinder

Push



4 Pressure Indoor Size 8000×2000×1100 MM

5 Scissors length 2000MM

6 Shearing frequency 2-3 Times/minute

7 System maximum force 25MPa

8 Power 270 KW`

9 Motor

model Y225M-4 Power 45KW

Nominal

Speed 1480 rpm Quantity 6 sets

10 Oil pump

model A4VSO 250 Nominal

Pressure 31.5 MPa

Nominal

Outflow 250 ml/r Quantity 6 sets

11 Machine price 350000USD


9

3. Scope of Supply

3.1 Supply Scope of Scrap Hydraulic Shearing Machine

Equipment supply: 2 sets

序号

Serial Number

供货范围

Scope of Supply

数量（台/套）

Quantity

(table/set)

备注

Remarks

1 门剪主机体

The main body of door scissors 1

2 料床 Feeding bed 1

3 电气系统

Electrical System 1

4 液压动力系统

Hydraulic Power System 1

5 液压管路系统

Hydraulic Pipeline System 1

6 润滑系统 Lubricating System 1

7 冷却系统 Cooling System 1

8 专用工具 Special Tools 1

9 随机文件 The attachment 1

设备总装示意图、液压及电气

原理图、基础图、合格证书

General Assembly Drawing,

Hydraulic and Electrical

Principle Drawing, Basic

Drawing, Qualification

Certificate of Equipment

3.2 Technical Requirements and Material ofKey Components

部件名称

Part Name

材质

Material Quality

处理方式及要求

Handling methods and requirements

备注

Remarks

刀片 Blade 6CrW2Si 淬火 HRC48-52，消耗件

Quenched HRC48-52,Consumables

耗材

Consumables

过滤滤芯

Filter Cartridge

纸质

Paper Quality

耗材

Consumables

3.3 List of Equipment suppliers

设备名称

Equipment Name

供货商

Supplier

备注

Remarks

柱塞变量泵 Plunger variable pump 佛山市科达液压

Foshan Kodak Hydraulic Pressure

液压阀门（先导控制阀、单向阀等）

Hydraulic valves (pilot control REXROTH


10

valves, one-way valves, etc.)

电机 Motor 泰州泰达电机

Taizhou Teda Motor

Supplier Profile:

REXROTH is a wholly foreign-owned enterprise and a leading global expert in

transmission and control.Rexroth provides personalized solutions for customers in the

fields of industrial and factory automation, walking machinery, and renewable

energy.At present, as the common choice of more than 500,000 customers worldwide,

Rexroth is constantly providing customers with high-quality electronic control,

hydraulic, pneumatic and Mechatronic components and systems.In more than 80

countries around the world, Rexroth has become a reliable partner for local customers

to help them produce safer and more efficient machinery and equipment, thus

committed to the rational use of natural resources.

Foshan Keda Hydraulic Machinery Co., Ltd. is a hydraulic company affiliated

to "Guangdong Kodak Electrical and Mechanical Co., Ltd. (Stock Code 600499)".

The company is committed to the research, development and design and manufacture

of high-end KD-A4VSO series variable piston pumps.There is a group of professional

knowledge and practical experience of the talent team, 10 years of maintenance and

remanufacturing Germany A4VSO pump more than 5000.At the beginning of the

company's establishment, the development path was "mass maintenance→technical

analysis→replacement by piece →operation inspection →whole pump manufacture→

improvement and innovation".At the beginning of 2005, A4VSO180, 250 and 355

pumps were manufactured successfully and applied in batches. They are one of the

first-class ceramic press manufacturers in China. They have passed strict testing and

qualified as "strategic suppliers".Kodak Hydraulic is a long-term joint partner of the

world's three major ceramics manufacturers, providing variable displacement pumps

for many well-known domestic manufacturers of hydraulic pumping stations.The

company's existing factory area is 40,000 square meters, and the modern standard

factory building is more than 25,000 square meters. Has a perfect quality assurance

system, through the ISO 9001 quality management system certification. There are

dozens of advanced equipment such as MAZAK high precision vertical and

horizontal CNC machining center and CNC boring and milling machine in Japan,

which realize one clamping and automatic forming. Closed and constant temperature

dust-free oil pump assembly workshop 1500 square meters, with 300 KW and 75 KW

domestic advanced computer control, proportional automatic loading, automatic

generation of functional curve factory test bench. The company produces KD-A4VSO

series 40, 71, 125, 180, 250, 300, 355, 370, 500ml/r variable piston pumps, which are

widely used in iron and steel metallurgy, forging, ceramics, refractory, railway shield,

water conservancy and hydropower, engineering machinery, petrochemical industry,

ship, military industry and other industries.

Taizhou Teda Motor Co., Ltd. is a company with rich experience in production

and design, a complete set of production equipment, strict process flow, process

discipline, perfect testing system, all kinds of excellent processing equipment and

testing equipment. Enterprises now employ more than 100 employees, 15 engineers


11

and technicians, and research institutes, colleges and universities have good

cooperative relations. Can undertake the development of special specifications of

motor and dispatch products required by users. The company covers an area of about

10,000 square meters, with an annual output value of more than 50 million yuan. Its

products are well sold all over the country, and are exported to Southeast Asia, Europe

and other countries and regions, and are well received by the vast number of users.

3.4 Equipment Split Delivery Table

项目序

号

Item

Number

设备名称

Equipment

Name

数量

Quantit

y

基本数据

Basic Data

基本设计

Basic

Design

详细设

计

Detailed

Design

安装

Install

现场调试

Field

Debuggin

g

供货

Suppl

y

1

设备本体

Equipment

Ontology

1set S S S S S S

2

液压系统

Hydraulic

System

1set S S S S S S

3

液压管路

Hydraulic

Pipeline

1set S S S S S S

4

冷却系统

Cooling

System

1set S S S S S S

5

润滑系统

Lubricating

System

1set S S S S S S

6

电气系统

Electrical

System

1set S S S S S S

7

专用工具

Special

Tools

1set S S S S S S

8

基础和建筑

物

Foundation

and

Buildings

S S B B B B


12

9

地脚螺栓、

预埋件

Anchor

bolts,

Embedded

parts

S S B B B B

10

油液介质

The Oil

Medium

S -- -- -- -- B

11

安装调试

Installation

and

Debugging

S S S S S S

Note: Abbreviation Definition: B - Bidder Responsible, S - Bidder Responsible,

S/B - Bidder Responsible / Bidder Assistance

3.5 Describe of Equipment Junction Point

Design Junction Point:

(1) The bidder is responsible for the design of scrap steel hydraulic shears and the

design of equipment installation drawings (including loads).

(2) The tenderer is responsible for site planning and design, and the construction

drawings of equipment and infrastructure (including power supply, water supply,

lighting, ventilation, grounding, lightning protection, noise reduction, drainage, etc.).

Making Junctions:

(1) The bidder is responsible for the production of equipment within the scope of

supply.

(2)The tendering party shall be responsible for the foundation construction of the site,

the construction of supporting equipment and the production of the embedded parts of

the foundation.

Water Junctions:

Water source points in the installation drawings of equipment foundation

provided by bidders. The tenderer is responsible for setting up water sources.


13

Electric Junctions:

The tenderer shall lead the low voltage to the low voltage power supply cabinet

of the engine room, which has the condition of power supply and closing.

Medium used in equipment (hydraulic oil, lubricating oil):

The tendering party shall provide for itself.

3.6 Equipment Composition and Requirements(Single SET)

序号

Serial

Numbe

r

部件名称

Part Name

规格型号

Specifications

数量

Quantity

生产厂家

Manufacture

1 加料箱部件

Feeding Box Components 8000x2000x1400 1set

江阴天福科技

Jiangyin Tianfu Technology

1.1 加料箱

Feeding Box 1set

江阴天福科技


1.2 液压马达部件

Hydraulic Motor Components 1set

江阴天福科技


1.3 其余附件

Other Accessories 1set

江阴天福科技


2

重废剪主机

Main Engine of Heavy Scrap

Shearing

1set 江阴天福科技


2.1

重废剪压料头部件

Pressing Head Component of

Heavy Scrap Shearing

1set 江阴天福科技


2.2 剪切油缸

Shear Cylinder YG500/340-1100 3

江阴天福科技


2.3 压料油缸

Pressure Cylinder YG320/220-1470 2

江阴天福科技


2.4 侧压油缸

Lateral Pressure Cylinder YG220/160-250 2

江阴天福科技


2.5 推料油缸

Pusher Cylinder YG200/150-7950 2

江阴天福科技


3 液压系统 1set 江阴天福科技


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4. Technical Norms of Scrap Hydraulic Shearing

4.1General Requirements

The equipment has complete function, advanced technology, and can meet

personal safety and labor protection conditions.

All equipments are designed and manufactured correctly. Under normal

working conditions, Jun can operate safely and continuously without excessive

stress, vibration, temperature rise, wear, corrosion and aging.

The materials and components (or components) used should meet the

requirements of relevant specifications, and should be new and high quality, and

can meet the requirements of local environmental conditions.

Hydraulic System Jiangyin Tianfu Technology

3.1 电动机

Motor YE3-225M-4 10

泰州泰达电机

Taizhou Teda Motor

3.2 液压泵

Hydraulic Pump A4V250 10

佛山科达

Foshan Koda

3.3

液压阀门（先导控制阀、单向

阀等）

Hydraulic valves (pilot control

valves, one-way valves, etc.)

组件

Component 1set DINGSI

3.4 水冷散热、加热系统

Water Cooling,Heating System 1set

国内知名品牌

Famous Brands in China

3.5 液压油箱箱体

Hydraulic Tank Body

江阴天福科技


3.6 液压管路系统

Hydraulic Pipeline System 1set

江阴天福科技


3.7 进油过滤系统

Oil Intake Filtration System 1set

国内知名品牌

Famous Brands in China

3.8 其余配件

Other Accessories

4 电气控制系统

Electric Control System 1set

4.1 主要电气元器件

Main Electrical Components 1 ZHENGTAI

4.2 PLC 1 三菱

Mitsubishi


15

The parts or components used should have good interchangeability.

4.2Structural Requirements

The structure of the equipment is convenient for daily maintenance (such as

refueling, tightening, etc.). The parts of the equipment adopt advanced and

reliable manufacturing technology, and have good surface geometry and

suitable tolerance coordination.

The lubrication part is well sealed and no oil leakage is allowed.

4.3 Requirements for Distribution Equipment

Outsourcing matching selection of domestic and foreign first-line brands,

energy-saving advanced products, and production license and production

inspection certificate, Hubei Lidi foreign purchased components and materials

to test, and its quality, performance is responsible.

Parts that are easy to wear, corrode, age or need to be adjusted, inspected or

replaced should be provided with spare parts, and can be easily disassembled,

replaced and repaired.

4.4Special Requirements For Hydraulic Scrap Shear and Its

Affiliated Systems

Hydraulic systems and components must be cleaned before assembling.

After assembling, they should be sealed well, without impact and leakage.

Generally, the temperature rise of the tank is not higher than the ambient

temperature of 30℃, but the temperature of the tank must not exceed 60℃.

Generally, it should be controlled in the range of 30℃~60℃.

Hydraulic working medium: No. 46 anti-wear hydraulic oil.

4.5 Main Inspection and Test Items

序号

Serial Number 检查项目 Inspection Items

检查结果

Inspection Result

备注

Remarks

1 联结螺栓是否存在松动

Is there loosening of connection bolt

2 是否有漏油漆点 Are there any paint leaks

3 安全标识是否设置

Whether the security identity is set

4 润滑点检查是否有润滑油

Lubrication Point Check for Lubrication Oil

5 油泵是否加入引油

Whether to add oil diversion to oil pump or not

Checklist after installation:

Trial operation stage:


16

序号

Serial

Number

部件 Component 检查项目 Inspection Items

检查内容

Inspection

Contents

备注

Remark

1 送料压头

Feeding Press Head

运行正常 Running Normally

运行平稳 Running Smoothly

2 上压料压头

Upper Press Head



3 侧压压头

Side Press Head



4 剪切

Shearing

运行正常，平稳

Running Normally and Smoothly

剪切次数 2-3次/分钟

Shearing Frequency 2-3times/min

Preparation for material feeding and production (this is prepared by the tenderer):

调试前准备项目 Preparation Project before Commissioning

序号

Serial

Number

项目 Item 内容 Content 要求 Requirement 备注

Remark

1 原料

Raw Material

直径≤220mm的圆钢

剪切尺寸≤190x190mm的方钢

剪切尺寸≤130x900mm的钢板

Round steel with diameter

less than 220mm

Square steel with shear

size less than 190x190mm

Steel plate with shear size

less than 130x900mm

Non-shearing dangerous or

explosive; inflammable

and explosive substances

(including containers

containing such

substances, such as

shells, peroxides,

metal propellants, etc.);

containers containing

flammable liquids and

gases; wire ropes, nets;

special steel, hardened

steel

2

正常生产所需

人

Personnel

required for

熟练的操作员

Skilled Operator

1名/台

One person/

one machine

单班制（操作员必须进行专

业培训上岗）

Single shift system

(operators must be trained


17

normal

production

professionally)

原材料上料设备操作员

Raw Material Feeding

Equipment Operator

若干 Some

根据上料设备实际需求

According to the actual

demand of feeding

equipment

安全生产巡视员

Safety Inspector

至少一名

At least one

按实际需求 According to

actual demand

3

上料设备

Feeding

Equipment

抓钢机、吸盘或其他上料设备

Grabber, sucker or other

feeding equipment

确保每小时大于 30

吨的上料量

Ensure that the

feeding volume is

greater than 30

tons per hour

4 电源

Power Supply

低压电源（电源线需铺设至控

制柜） Low Voltage Power

Supply (Power Wire to be

laid to Control Cabinet)

低压 380V/50HZ

耗电总功率 370Kw/

套剪断机。

Low Voltage

380V/50HZ

The total power

consumption is

370Kw/shearing

machine.

5 水源 Source

of water

冷却塔处水源 Water source

at cooling tower 10L/min

6

动力系统用

For power

system

抗磨液压油 L-HM-46

Anti-wear Hydraulic Oil

L-HM-46

23000L/台

23000L/one machine

预估

Estimate

Feed Production

No-load Test

The working pressure of the hydraulic system is set to 10 MPa, and the running

time of the machine is not less than 4 hours, of which the continuous running time is

not less than 2 hours.

After no-load operation of the equipment has no problem, it will enter the stage

of loading operation. The materials and auxiliary equipment prepared in the early

stage will be transferred to the site, and the loading operation stage can be carried out

by feeding.

5. DataDelivery List

序号

Serial

Number

资料内容

Data Content

提交时间

Submission Time

备注

Remark

1 废钢液压剪断机总图（包括平面图、立面合同签订后一周内电子版 dwg


18

图、基础图）General Drawing of Scrap

Hydraulic Shear (including Plane

Drawing, Elevation Drawing and

Foundation Drawing)

Within a week of

signing the

contract

和 PDF文件格

式各一套

Electronic

version of

DWG and PDF

file format

each set

2 电气原理图 Electrical schematic

diagram

随机发货 Random

Delivery

3

液压系统原理图（含元件清单）

Schematic diagram of hydraulic system

(including list of components)

随机发货 Random

Delivery

4

装配安装图、易损件图纸 Assembly and

installation drawings, vulnerable

parts drawings

随机发货 Random

Delivery

一式三份

Triplicate 5

安装、运行、维护使用说明书

Installation, operation and

maintenance instructions

随机发货 Random

Delivery

6

装箱单及随机和推荐备品备件清单

Packing list and random and

recommended spare parts list

随机发货 Random

Delivery

7 产品合格证（一份 )Product

Qualification Certificate (1 copies)

随机发货 Random

Delivery

8

工厂试验报告及质量合格出厂报告

Factory Test Report and Qualified

Exit Report

随机发货 Random

Delivery

一式三份

Triplicate

9

设备安装施工技术方案、检测、调试方案

等 Installation and construction

technology scheme, testing and

debugging scheme of equipment, etc.

随机发货 Random

Delivery


19

6. Design Inspections

Design Scope, Design Liaison, Design Review and Joint Design of Bidders and

Bidders

设计范围

Design Scope

投标方责任

Liability of Bidder

招标方责任

Liability of

Tenderee

联合设计

Joint Design

设备本体Device Ontology △

液压系统Hydraulic System △

液压管路System Pipeline △

冷却系统Cooling System △

润滑系统

Lubrication System

△

电气系统Electric System △

布局方案设计

Layout Scheme Design

△

基础设计Basic Design △

基础施工图设计

Design of Foundation

Construction Drawing

△

On the 10th day after the entry into force of the contract, the basic design shall be

examined and liaised.

Bidder Design Liaison Person

Bidder:Jiangyin Tianfu Technology Co.,Ltd.

Contacts:Haibin Hu

Telephone:15961663285

Add:No.80,jianshe Road,Industry Concentrated Zone,Yunting town,jiangyin City

Fax:+86-510-86158378

E-mail:[email protected]

7. Instructions for anticorrosivecoating of equipment

(1)The quality requirements of anti-rust and paint shall be implemented in accordance

with 《钢结构、管道涂装技术规程》YB/T9256 and《重型机械通用技术条件第 12 部分：

涂装》JB/T5000.12.

(2)Machinery Color

序号设备名称涂漆色彩（国标）


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Serial Number Equipment Name Painting Color(National Standard)

色卡号码

Color Card Number 颜色 Color

1 一般机械

General Machinery

深蓝

Dark Blue

2 电动机 Motor GSB05-1426-2001 PB05 海蓝

PB05 Sea Blue

3

安装在设备上的扶手

Handrails mounted on

equipment

Y07 中黄

Medium Yellow

8. The Excluded Items of the Bidders.

Design and manufacture of equipment not included in the scope of supply by

bidders;

Design and Construction of Construction Drawings Excluding All Equipment

Foundation;

Excluding energy media and lubricating oil for equipment motor vehicles;

Excluding the fabrication of embedded parts for equipment foundation.

Bidders shall strictly perform their duties and obligations in accordance with bidding

documents and contracts.

9. After-sale Service Commitments

After-sale Service and Product Manufacturing Commitments

In order to better serve the vast number of enterprises and work together to

promote the development of China's scrap steel industry, Jiangyin Tianfu provides

pre-sale technical advice, equipment selection and overall solutions to ensure the

quality, performance, delivery time, service guarantee and technical support,

maintenance and technical training of equipment during and outside the warranty

period from the systematic selection planning. The following plans and

commitments:

9.1 Quality Performance of the Equipment

Our company has been certified by ISO 9001 international quality system, and

promises that the quality of equipment produced and sold will meet the technical

agreement requirements in the contract, and the relevant environmental protection

indicators will meet the requirements of national standards. Our company is

responsible for the design, manufacture, installation, commissioning and

acceptance of the whole system. The relevant behavior conforms to the current

industry standards in China.

9.2 Pre-sale Service

9.2.1 The Commissioner will introduce the implementation standards of


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domestic industrial waste disposal for users, introduce the characteristics and general

situation of our products, and provide decision-making materials for users to select

high-quality and low-cost products.

9.2.2 Provide technical solutions, send specialized technical personnel, business

personnel for technical exchanges, business presentation. May organize your

company personnel to come to the factory to inspect the instruction. During the whole

bidding process, we will provide timely product performance, characteristics,

schematic design drawings and various parameters to actively cooperate with your

company in selecting satisfactory product manufacturers.

9.3 Quality Assurance 、Personnel Training and After-sale Service

(1) Equipment warranty: The free warranty period of the equipment is 12 months

from the date of passing the acceptance and acceptance. During the warranty period,

Party B shall be responsible for the free repair or replacement of the equipment in

case of damage caused by design, material, process or structural errors.

(2) Personnel training: Our company's relevant technical personnel conduct

theoretical training to users in order to understand the working principle and nature of

the equipment structure and eliminate general failures; after debugging of the

equipment, on-site practical training will be conducted to provide guidance and

demonstration to users, so as to achieve the ability of practical routine operation,

disassembly and assembly of parts, and elimination of general failures.

(3)After-sales service (for domestic): Party B must provide solutions within 8

hours after receiving the fax repair notice from Party A; if it confirms the need for

dispatch, it must arrive at the scene in 72 hours. During the warranty period, Party B

shall provide the fragile spare parts and list to Party A for urgent replacement.

(4)After-sales service (for foreign countries): If the equipment fails, the user

needs to provide us with photos of the equipment failures, after confirmation, we can

give the maintenance plan. If the failure is not serious, we can contact the user

through the network or telephone to guide its maintenance; if the failure is serious, we

need our personnel to go to the site to repair, then the corresponding travel expenses

(including road and working hours) will be borne by Party B.

(5)After-sales Service Institutions

Our company has a after-sales service office, the main contact personnel are as

follows:

联系人 Contacts 汪志强 Zhiqiang Wang

联系电话 Mobile 13626239226

售后服务处电话

After-sale Service

Department Telephone

0510-86010821

10. Installation of HeavyScrap Shear

1. According to the basic data in the basic map of heavy and waste shear provided by us, users

can design and build a good foundation according to the actual geological conditions of

their production site.


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According to the basic embedding drawings provided by us, the users should

make the embedding parts by themselves and bury them together when building

the foundation.

2.According to the instructions for the use of heavy and waste shears provided by

us, the adjusting pad drawings are made by the users themselves, and the quantity can

be determined according to the actual situation of the foundation.

(1)Install Program:

A. Installation procedure of main engine (installation sequence of majorcomponents)

(dismantling and transportation status according to main body part):

Installation of Foundation and Facilities→Main Body→Scissor Slider

Seat→Guide Rail Adjustment Block→Adjustment Block→Location Block→Fixed

Location Block→Bearing Seat→Shearing Oil Cylinder→Pressure Cylinder→Side

Pressure Cylinder Bearing→Side Pressure Head→Side Pressure Cylinder→Safety

Protection Bar.

B. Installation Procedure of Feeding Bed (Installation Sequence of Major Parts):

Installation of Foundation and Facilities→Feeding Bed→Connect to Host

Body→Install feeding cylinder and its support and connect with feeding slider.

C. Installation Procedure for Power System and Electrical System (Main Parts

Installation Sequence):

Fuel tank→oil return filter→oil pump motor station→heat exchanger→cooling

tower→ large valve block bracket→large valve block→ electrical control cabinet→

heavy waste shear operation table.

D. Hydraulic pipeline and circuit connection:

Each dismantled pipeline is connected with each other according to the position

and direction shown in the general machine drawing. The high-pressure circuit is

welded with thick-walled seamless steel pipe and flange, and the low-pressure oil

return circuit is welded with fluid-conveyed steel pipe and flange.

The lubrication system is composed of thin steel pipe and pipe joint, which are

connected to scissors sliding seat and pressing head according to position.

The pipeline between heat exchanger and cooling tower is PVC pipeline and PVC

flange thermal adhesive, which can be connected with each other.

(2)The required lifting equipment capacity for installation:

A. Hoisting weight of main engine

Total body weight: about 95000kg

(excluding side cylinders, side press head and supports)

B. Lifting weight of other parts:

Material bed about 28000kg

Hydraulic Station about 22000kg (NO Hydraulic Oil for work)

Electrical control cabinet about 1200kg

Side Pressure Cylinder about 1240kg (2x620)

Side pressure head and support about 3310kg (2x1655)

C. Lifting Equipment:

According to the transportation conditions in the user's area, if the main body is

transported as a whole, the lifting capacity of the lifting equipment required is not less


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than 120 tons.

Lifting equipment capacity for material bed and hydraulic station installation is

not less than 40 tons.

The capacity of hoisting equipment required for installation of other parts is not

less than 10 tons.

(3)Installation Notes:

A. After signing the formal contract, the user can get a complete set of technical data

for the installation of foundation and facilities.

B. When installing and disassembling hydraulic equipment, its interior must be kept

clean and not wiped with cotton yarn.

C. Installation surface of each hydraulic component shall not have defects such as

component deformation and valve core stuck.

D. All fastening threads should be tightened evenly.

The tightening torque of the main fastening threads is (Unit: N. m)

8.8 levelM16 200

10.9 level M16 270

8.8 level M20 390

10.9 level M20 530

8.8 level M24 670

10.9 level M24 910

8.8 level M30 1330

10.9 level M30 1810

12.9 level M30 2320

8.8 level M36 2310

12.9 level M48 6250

The above is for reference in installation.

Among them, 8.8 level is used for the connection between general parts, 10.9 grade

is mainly used for the connection between the flange of the cylinder head and the

bottom of the cylinder and the installation of the cylinder.

E. Sealing fillers such as fibers and putty should not be used, because these materials

will cause pollution and work failure.

F. Pipeline must be cleaned before assembly, and acid cleaning is recommended to

remove dust, rust and chips from the inner wall of the pipe. Do not wipe the inner

wall of the pipe with cotton yarn during cleaning.

G. When installing the tubing, the tubing shall be free from distortion and other

deformation to prevent oil leakage at the joint of the tubing.

H. When installing the cylinder, it is necessary to ensure that there is no residual

radial stress in the piston rod of the cylinder, so as to avoid working failure and

premature wear.

İ. Installation of electrical equipment must pay attention to the following situations.

Voltage fluctuation of solenoid valves and pressure switches should not exceed (+5%)

under continuous use, and grounding should be reliable.

(4)Installation Accuracy of HeavyScrap Shear:

The installation accuracy of heavy scrap shears mainly concentrates on three parts:


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main body, material bed and clearance between upper and lower scissors.

A. Main Body Installation Accuracy

Horizontal plane of front, rear and left sides should be leveled to less than

0.5/1000mm.

B. Installation Accuracy of Feeding Bed

The clearance between the front end of the bed and the main body fitting surface is

less than 0.05 mm; the left and right level of the bed bottom is less than 0.5 mm, and

the level before and after the bed is adjusted to less than 0.3 mm.

C. Clearance between upper and lower blades

The clearance between upper blade and lower blade of heavy waste scissors is

generally adjusted to 0.35-0.85 mm. (Installation structure of guide rail of scissors

slide seat and upper and lower blades of fuselage can be seen in figs. 9, 10 and 11 of

the appendix)

11. Maintenance of HeavyScrap Shear

11.1 Safety Operation

1.1 No one is allowed to enter the computer room or operating room without

permission.

1.2 No ineligible person is allowed to operate the machine.

1.3 All staff members should consciously abide by the rules and regulations of the

machine to prevent accidents.

1.4 After pressing the emergency stop button, the key control switch is still on.

1.5 At the end of the work, the pressure head and scissors sliding seat should be

lowered to the lowest position, the feeding slider should be returned to the position,

and the cover should be closed in place. To ensure safety.

11.2 Daily Maintenance

(1) Check oil level in main tank and Lubricating Tank.

(2) Check oil temperature in main tank.

(3) Check the pressure of hydraulic system.

Maximum working pressure 35 MPa.

(4) Check leakage of cylinder and pipeline.

(5) Check the distance between the induction limit switch and the moving parts

controlled by it, and pay attention to removing the dry flexible objects, such as

scrap steel sheets, which may fall into it.

(6) Check and confirm that the upper and lower blades are firmly installed.

(7) Check blade usage and wear. (Users can judge by the blade edge wear inspection

chart, as shown in Figure 12 attached)

(8) Check and confirm that the scissors sliding seat is unimpeded in its motion range.

(9) Check to make sure that the moving parts are not stuck by waste materials.

(10) Check and confirm that the sliding guide of scissors is in good lubrication

condition.

(11) Check whether the guide rail of the tool pad and scissors sliding seat is firmly


25

installed and damaged, and update it in time if necessary.

(12) Check whether the parts of the head cylinder, feeding cylinder, rotating

movement part of the head and feeding slider are normal or not.

(13) Check whether the feed bed head cylinder stroke control transmitter and

induction switch are normal.

(14) During operation, the operator should always pay attention to the system pressure

displayed by the pressure gauge on the console. The maximum pressure should

not exceed 35 MPa.

(15) Before each shift of heavy scrap shear is operated, proper amount of dilute

lubricant shall be injected into the oil cup of the rotating moving part of the cover

shaft and the connecting part between the cover cylinder and the cover.

11.3 Weekly Maintenance

(1) Check the oil filter and clean it if necessary.

(2) Check whether the position of pump, valve and cylinder is correct. If

translocation occurs, it should be corrected in time.

(3) Check the reliability of each important thread connection and tighten it again if

necessary. For example, the connection between heavy waste shear frame and

material bed, the connection between scissors slide seat, pressing head and piston

rod, the connection between cylinder head flange and bottom and cylinder body,

the connection between left and right guide rail and frame.

11.4 Annual Maintenance

11.4.1 Adding new lubricants to motor shaft bearings according to the lubrication

charts and tables in Volume 2.

11.4.2 Check the degree of contamination of hydraulic oil and its anti-wear ability.

11.4.3 Clean the air filter on the main tank and add hydraulic oil.

11.4.4 Check the oil filter and observe the sediment in the filter. When there are more

black objects, check the cylinder seals and replace them if necessary.

11.5 Overhaul and Maintenance

Check the wear and repair condition of the machine. If necessary, the user can

contact the manufacturer and the manufacturer can complete the work.

11.6 Blade Changing and Blade Clearance

11.6.1In one of the following cases, the blade must be replaced or the blade must be

replaced:

a. The edge of the blade caved badly.

b. Excessive wear of cutting edge makes it difficult to adjust the clearance between

upper and lower blades.

c. After each edge has been used and bluntly ground, new blades must be replaced.

It must be noted that excessive wear of blade edges can cause the danger of

beingstuck while the machine is running. Once this happens, the shear slider, the left

and right guide rail seat, and even the whole heavy scrap shear frame will be seriously


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damaged.

11.6.2 Replacement of blades or edges shall be carried out in the following order:

a. Manually raise the pressure head and scissors sliding seat, locate the position of

safety pin, insert safety pin, and light the safety pin signal on the console。

b. Cut off the power switch。

c. Place the "Maintenance in progress, no startup" language warning board in the

position of the console.

d. Remove blade。

e. Check whether the insert bolt, positioning sleeve and tool pad are damaged. The

protruding parts and burrs of the tool pad should be thoroughly removed. The

damaged parts must be replaced.

f. When the blade edge is replaced, the protrusions on each side of the blade must be

thoroughly removed

g. When installing the blade, tighten the nut gently, confirm that the blade is installed

correctly, then tighten the nut reliably.

h. Manual operation makes the shearing slider and pressing slider rise successively。

i. Safety pins for pull-out scissors sliding seat and pressing head.

Special Note:

There are six upper and lower blades used in the waste shears with the same structure

and size, which can be interchanged.

11.6.3Inspection of clearance between upper and lower blades

a. The minimum clearance between upper and lower blades shall not be less than

0.5mm, and the maximum clearance shall be determined by the thickness and density

of the material to be sheared after the action of the pressing slider, generally not less

than 1 mm.

b. Gap measurement should be taken at several positions of the blade's entire width.

c. While checking the clearance of the blade, the clearance between the slide seat of

scissors and the left and right guide seat should also be checked.

d. Adjustment of clearance between upper and lower blades.

e. If necessary, please contact the manufacturer of heavy scrap shears.

12. Safe Operation Regulations

In addition to abiding by local laws and regulations and the rules and regulations of

the enterprise, equipment operation, maintenance and management personnel should

pay attention to the following matters:

The operator must operate the machine or monitor the work of the machine

in the operating room.

When the operator leaves the operating room, he must shut down and lock

the console.

When the operator comes out of the operating room, he should contact the

operator of the loading crane at least visually, preferably with a dialog machine.

Operating rooms and computer rooms must be closed during non-working

hours.

No unauthorized person shall enter the operating room or machine room.


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When the machine works, the unrelated personnel are not allowed to enter

the work site at will, let alone stay on the site. When someone (such as an agreed

visitor) is in a dangerous position on the site, the machine must stop or partially stop

working, including the loading crane.

The power supply voltage of each pressure switch and induction switch is

24V. Please pay attention to safety during loading and unloading. The grounding part

should keep good grounding.

After the replacement of blades or other operations are completed, the safety

pins of the sliding seat and the pressing head of scissors must be pulled out

completely. Otherwise, when the machine is restarted, the safety pins are in danger of

being cut off.

Once the hydraulic system leaks, it must be repaired immediately.

After pressing any emergency stop button, if you want to restart the machine,

you must reset the pressing emergency stop button.

When the machine works at night, it should provide completely non-glaring

lighting system.

It is strictly forbidden to have open fire near hydraulic devices.

Only those who can comply with safe operating procedures can access and

operate the machine.

The feeding height of the machine bin should be less than the feeding height

of the bin (less than 1400 mm).

The length of each feeding of the machine bin shall be less than 8000mm.

13. Schematic Diagram of Equipment Foundation

Layout


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Q91Y-1250T Heavy Scrap Hydraulic Shear Technical ...

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Transcript of Q91Y-1250T Heavy Scrap Hydraulic Shear Technical ...