Manual Maq Llenado Aceite Hidraulico

JRJZ JRJZ JRJZ JRJZ- -- -V05P V05P V05P V05P
Power-Steering Fluid Filling Machine

Operating Instruction

JINAN CJIERUI ELECTRIC CO.,LTD. OF CHINA
Adress:No.56 General Road in Jinan, Shandong province Post Code:250108
Tel: 0531-88266622 General Phone
Fax: 0531-88772200 0531-81206707
E-mail: cjierui@cjierui.com Web Site: www.cjierui.com
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

numerical control equipment domestically; And it seized the domestic and
foreign markets rapidly in afterwards several years.
Currently, the brand of JIERUI and CJIERUI vacuum filling equipment,
quantitative filling equipment and automobile assembly line of mechanical and
electrical equipment have occupied more than 60% market share in domestic
market. In Volkswagen, Hongqi, FAW, DFAC, Chery, Chang'an, Great Wall
Changfeng, HuaTai, KIA, Nissan and other famous auto company's product line
to replace the imported equipment, and successfully exported to Russia,
Vietnam and other foreign markets. It received customers recognization at
home and abroad as a stable quality, excellent cost performance and improved
customer service system.
When consolidating the existing products and markets, CJIERUI
ELECTRIC CO., LTD. always sticks to technology and quality as top of the
enterprise development, continuously improves products system and explores,
develops new products; gradually transfers to non-standard industry. In 2006 the
company successfully developed hermetic leak detection, attack started, Helium
recycling etc. a series of automatic electrical and mechanical equipment for
Emerson Group, and quality of products transcended the Emerson Group of the
United States suppliers, and successfully exported to the Vietnamese company
of Emerson Group. At present, the company has already established business tie
with foreign-funded enterprise of the Yangtze River Delta, Pearl River Delta and
the Bohai - rim areas and successfully operates a large number of non-standard
equipment items.
The concept of JIERUI ELECTRIC CO., LTD. is "integrity, dedication,
efficiency, innovation". The company adheres to the people-oriented,
market-oriented, innovative technology standpoint, and reliable products quality
management system to provide our customers with high performance and low
cost of products and first-class technical services, which will become best
Intelligent electromechanical equipment suppliers in China.


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.

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;
In In In In 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
Service team
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;

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.


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


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

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!


JRJZ-V05P Power-Steering fluid filling machine
Operating Instruction
CONTENTS

1 Equipment Overview------------------------------------------------------------------------------------ 1
1.1THE INTERNAL PIPELINE: ---------------------------------------------------------------------------- 1
1.2 ELECTRIC CONTROL SYSTEM ----------------------------------------------------------------------- 3
1.3 PNEUMATIC CONTROL UNIT------------------------------------------------------------------------ 5
1.4 FILLING GUN AND MOVING PIPE: ------------------------------------------------------------------- 5
2 Principal of Working ------------------------------------------------------------------------------------ 6
3 Main Technical Index ----------------------------------------------------------------------------------- 7
4 Vacuum Filling Equipment Operation Process ------------------------------------------------------ 7
4.1 PREPARATION----------------------------------------------------------------------------------------- 8
4.2 EVACUATION ----------------------------------------------------------------------------------------- 8
4.3 CONSTANT PRESSURE, LEAKAGE CHECK ---------------------------------------------------------- 8
4.4 RE-EVACUATION ------------------------------------------------------------------------------------- 9
4.5 FILLING PROCESS ------------------------------------------------------------------------------------ 9
4.6 SUCTION PROCESS ----------------------------------------------------------------------------------- 9
4.7 COMPLETE ------------------------------------------------------------------------------------------ 9
4.8 SUCTION AGAINST DROP ---------------------------------------------------------------------------- 9
4.9 SYSTEM SUPPLY-------------------------------------------------------------------------------------- 9
5. Operating------------------------------------------------------------------------------------------------- 9
5.1 START/STOP OPERATING SYSTEM------------------------------------------------------------------ 9
5.2 SYSTEM PARAMETERS SET ----------------------------------------------------------------------- 10
5.3 VACUUM FILLING OPERATION-------------------------------------------------------------------- 13
5.4 SYSTEM MONITOR--------------------------------------------------------------------------------- 16
5.5 MANUAL DEBUGGING----------------------------------------------------------------------------- 17
5.6 DATE QUERY FUNCTION -------------------------------------------------------------------------- 18
5.7 WARNING RELATING OPERATIONS--------------------------------------------------------------- 19
6 Faults and Remedy ------------------------------------------------------------------------------------ 20
7 Maintenance and Repair ------------------------------------------------------------------------------ 23
7.1 SYSTEM MAINTENANCE DAILY ------------------------------------------------------------------ 23
7.2 SYSTEM REPAIR : ----------------------------------------------------------------------------------- 26
Annex one------------------------------------------------------------------------------------------------- 27
Key part list ----------------------------------------------------------------------------------------------- 29
Spare list--------------------------------------------------------------------------------------------------- 30

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 and
performance 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. 1.1 11 1The 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

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 sucking
residual 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.

Fig 1.1.3
1.2 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

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

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.
1.3 1.3 1.3 1.3 Pneumatic 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
1.4 1.4 1.4 1.4 Filling 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

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 .
2 22 2 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.


3 Main Technical Index
1) 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
4 44 4 Vacuum Filling Equipment Operation Process
The process of Vacuum Filling Equipment consists of preparation, evacuation,
leakage check, re-evacuation, filling process, suction and complete .

4.1 4.1 4.1 4.1 Preparation
After power on, then system shall enter into working state.
4.2 4.2 4.2 4.2 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.
4.3 4.3 4.3 4.3 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 Evacuation
Big 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 filling
Constant 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
10
Pneumatic
loosened
press red button on the gun and unclamp
11
Manual
extraction guns
Suction and anti-leakage

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

control panel The indication light shines and the touch screen enters the original
interface(fig 5.1.1)

Fig5.1.1 system original interface
5.1.2 5.1.2 5.1.2 5.1.2 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.
5.2.2 5.2.2 5.2.2 5.2.2 Operating Parameters Set
N NN Notice otice otice otice 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 and
system firstly enters current parameter set interface (Figure 5.2.2), in which you can
set parameters as fig 5.2.2 shown.

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 S
The time to check whether there is big
leakage in vacuum pipe and break pipe.

2
Rough vacuum value Mbar
The vacuum limit value for rough
vacuum process

3
Fine vacuum time S
The time to check whether there is
small leakage in vacuum pipe and break
pipe.

4
Fine vacuum value mbar
The vacuum limit value for farther
vacuum process


5
Vacuum leakage
checking time
S
Vacuum leakage checking time

6
Vacuum checking
value
mbar
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
11
The shortest filling
time
s The shortest filling time
12 Max time S The longest filling time
13 Pressure keep time S
Pressure 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.
16
Suction against drop
time
S
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.


Fig 5.2.3 system parameter set interface

A AA Attention: 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 without do not change them without do not change them without do not change them without
professional person. professional person. professional person. professional person.

5.3 5.3 5.3 5.3 Vacuum 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 vacuum FillingSuctionOver
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.


5.3.2 5.3.2 5.3.2 5.3.2 Manual 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.
N NN Note: 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.
5.3.3 5.3.3 5.3.3 5.3.3 Supply 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: During During During During manual manual manual manual supply supply supply supply, , , , until until until until system system system system set set set set the the the the high high high high level, level, level, level, you need not you need not you need not you need not press press press press
manual manual manual manual supply supply supply supply button button button button , the system will automatically stop , the system will automatically stop , the system will automatically stop , the system will automatically stop su su su supplying. pplying. pplying. pplying.
5.3.4 5.3.4 5.3.4 5.3.4 Automatically 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

valve V510or V511to supply, when reach to high level, the system automatically stop
supplying, supply valve closed.
5.3.5 5.3.5 5.3.5 5.3.5 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

frequency 5HZ, until troubleshooting or by pressing the "alarm reset" button.
5.4 5.4 5.4 5.4 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.


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
5.5 5.5 5.5 5.5 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 professional
personnel are needed to complete, otherwise you can not properly handled the valve
interlocked relationship and brought the unexpected failure. This function absolutely is

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
5.6 5.6 5.6 5.6 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.

Fig 5.6.1 data query window

5. 5. 5. 5.7 77 7 Warning Relating Operations
1 During 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.
3 In 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.


6 66 6 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 reset on 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 alarm
Level switches or supply
pump may be damaged
1check level switch
2adjust infusion pump and filter
level too high alarm
level 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 loop
whether to be enough
filling pump alarm
load may be too large or
system power failure
1protective switch current set whether to
be 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 failure
1protective switch current set whether to
be too small
2check system load whether to be too
large
3 check system distribution electricity
circuit
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

3 adjust system small leakage check
parameters
drum empty alarm
filter damage
pipeline unsmooth
1check filter
2check clean pipeline
filter alarm
filter 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

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 to
open 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

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 is
normal, 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 with
problem, 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)

7 77 7 Maintenance and Repair
7.1 7.1 7.1 7.1 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

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 8mm
Oil 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

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 and
changed 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.

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.


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

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 cup c. add the cup proper oil d. tweak up oil cupe. tweak
up stuff.
Maintenance:
Abstersion of cup and sieve should choose litmusless scour, after washing with
rinsing and cool.


Key part list
No. Name Type Manufacturer
1 Vane vacuum pump SV25B
Germany
LEYBOLD

2 Vacuum sensor PTX610 DRUCK
3 Pressure sensor A-10 Germany WIKA
4 Flow sensor OV-10
5 Fluid valve TYPE2000 G1/2
Germany
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
14
Air 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

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

3 Fluid valve
TYPE2000
BURKERT

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

Manual Maq Llenado Aceite Hidraulico

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Power-Steering Fluid Filling Machine

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