Fervi P001/75 User manual

USE AND
MAINTENANCE MANUAL
Pressa manuale idraulica e pneumatica
Art. P001/75
TRANSLATION OF THE ORIGINAL INSTRUCTIONS
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PREFACE
P
lease ensure you have read this manual before operation
TRANSLATION OF THE ORIGINAL INSTRUCTIONS
It is compulsory to read this instruction manual before starting operation. The guarantee that
the machine will function and perform properly is strictly depe
ndent upon the application of all
the instructions contained in this manual.
Operator Qualifications
The workers responsible for the use of this machine must have all the necessary
information and instruction and should be given adequate training in
relation to safety
regarding:
a)
Conditions of use for the equipment;
b)
Foreseeable abnormal situations, pursuant to Article 73 of Legislative Decree
81/08.
We guarantee the Machine complies with the specifications and technical instructions
described in th
e Manual on the date of issuance and listed herein; On the other hand,
the machine may also be subject to important technical changes in the future, without
the Manual being updated.
Therefore, contact FERVI for information about modifications that may hav
e been
implemented.
REV. 1
September 2013
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CONTENTS
1
INTRODUCTION
................................
................................
........................
5
1.1
Preface
................................
................................
................................
..........................
6
2
SAFETY WARNINGS
................................
................................
..................
7
2.1
General safety rules for machine equipment
................................
................................
.
7
2.2
Safety regulations for hydraulic pres
ses
................................
................................
.......
8
2.3
Technical support
................................
................................
................................
..........
8
2.4
Other provisions
................................
................................
................................
...........
8
3
TECHNICAL
SPECIFICATIONS
................................
................................
...
9
4
DESCRIPTION OF THE M
ACHINE
................................
...............................
9
4.1
Main parts of the machine
................................
................................
...........................
10
4.2
Identification plate
................................
................................
................................
.....
11
4.3
Warning pictograms
................................
................................
................................
....
12
5
MACHINE SAFETY DEVIC
ES
................................
................................
.....
13
6
IMPROPER USES AND PR
ECAUTIONS
................................
......................
14
7
TRANSPORTING, LIFTIN
G AND DISPLACEMENT
................................
......
15
8
ASSEMBLY AN
D COMMISSIONING
................................
..........................
16
8.1
General warnings
................................
................................
................................
........
16
8.2
Unpacking instructions
................................
................................
...............................
16
8.3
Press assembly
................................
................................
................................
...........
17
8.4
Press installation
................................
................................
................................
........
19
8.5
Preliminary testing
................................
................................
................................
.....
19
9
MACHINE OPERATION
................................
................................
.............
20
9.1
Adjusting table height
................................
................................
................................
.
2
0
9.2
Manual pressing work
................................
................................
................................
.
21
9.3
Removing air from the circuit
................................
................................
......................
22
9.4
Pressing work with pneumatic energy
................................
................................
........
23
9.5
Pressur
e release
................................
................................
................................
.........
23
10
MAINTENANCE
................................
................................
.....................
24
10.1
Routine maintenance
................................
................................
...............................
24
11
TR
OUBLESHOOTING COMMON
PROBLEMS
................................
............
26
12
REPLACEMENT PARTS
................................
................................
...........
27
13
HYDRAULIC CIRCUIT DI
AGRAM
................................
............................
29
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1
INTRO
DUCTION
This manual is considered an integral part of the machine it was attached to at the time of
purchase.
The manufacturer holds all ownership to material and intellectual property of this manual;
any disclosure or copying, even partial, of this publi
cation without prior written consent is
forbidden.
The purpose of this manual is to provide the knowledge necessary for the use and
maintenance of the machine
Pressa manuale idraulica e pneumatica
Art. P001/75
and
create a sense of responsibility and an understanding of the capabilities and limitations of the
means entrusted to the operator.
As the machine is entrusted to experienced and skilled operators, the
following machine must
be perfectly known by the operator if you want it to be used safely and effectively.
Operators must be properly trained and prepared, so make sure that this manual is read and
consulted by the staff responsible for commissioning, op
eration and maintenance of the
Pressa manuale idraulica e pneumatica
. This is to make all operations the safest and
most effective possible for those who carry out these tasks.
Therefore, it is imperati
ve to strictly comply with the requirements in this manual, a
necessary condition for safe and satisfactory operation of the machine.
Before starting operation, installation and use of the
Pressa manuale idraulica e
pneumatica
, authorized staff must therefore:

read this technical document carefully;

know which protections and safety devices are available on the machines, their location
and how they work.
The buyer is responsible for ensuring that users
are properly trained, that they are aware of
all the information and instructions in this document and that they are aware of the potential
risks of operating the
Pressa manuale idraulica e pneumatica
.
The manufacturer waives any and all responsibility for damage to people and/or
things caused by non
-
observance of the instructions in this manual.
The
Pressa manuale idraulica e pneumatica
has been de
signed and built with mechanical
guards and safety devices designed to protect the operator/user from possible injury. It is
strictly forbidden to modify or remove guards, safety devices and caution labels. If this must
be done (for example, for cleaning o
r repair), make sure that no one can use the machine.
Modifications to the machines carried out by the user must be considered their sole
responsibility, therefore the manufacturer declines all responsibility for any damage
caused to persons and/or prope
rty resulting from maintenance performed by
unqualified personnel and in a manner different from the operating procedures
shown below.
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G
RAPHIC REPRESENTATIO
N OF SAFETY
,
OPERATIONAL AND RISK
WARNINGS
The following boxes are designed to attract the attenti
on of the reader / user for the
proper
and
safe
use of the machine:
Pay Attention
This highlights behavioural rules to prevent damage to the machine and/or the occurrence of
dangerous situations.
Residual Risks
This highlights the presence of dang
ers that cause residual risks to which the operator must
pay attention in order to avoid injury or damage to property.
1.1
Preface
For safe and easy operation of the
Pressa manuale idraulica e pneumatica
,
this manual
must be read carefully in order to acquire the necessary knowledge. In other words,
durability and performance are strictly dependent on how it is used.
Even if already familiar with the
Pre
ssa manuale idraulica e pneumatica
, it is necessary
to follow the instructions contained herein, in addition to the general precautions to be
observed while working.

Acquire full knowledge of the machine.
Read this manual carefully to understand: operation
, safety devices and all necessary
precautions. All this is to allow safe use of the machine.

Wear appropriate clothing for the job.
The operator must wear appropriate clothing to prevent the occurrence of unforeseen
accidents.

Maintain the machine with ca
re.
Using the Machine
The machine must only be used by qualified personnel trained to use the machine by
authorized personnel.
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2
SAFETY WARNINGS
2.1
General safety rules for machine equipment
Risks associated with using the machine
DO NOT underestimat
e the risks associated with using the machine and concentrate on the
work in progress.
Risks associated with using the machine
Despite the implementation of all the safety devices for safe use of the machine, it is
necessary to take note of all the re
quirements for the prevention of accidents reported in
various parts of this manual.
Risks related to Using the Machine
Every person who is responsible for the use and maintenance of the machine should have first
read the instruction manual, particul
arly the chapter on safety information.
It is recommended that the plant safety manager get written confirmation of the above.
Risks associated with using the machine

During all work phases with the machine, you should proceed with great caution in
or
der to avoid damage to persons, to the property or to the machine itself.

Please only use the machine for its envisaged uses.

Don't tamper with the safety devices equipping the machine.
Risks associated with using the machine
Before starting any work
on the machine, the operator must wear the appropriate personal
protective equipment (PPE) such as gloves and eye protection.
1.
Always check the efficiency and integrity of the machine.
2.
Do not use the machine in an enclosed or poorly ventilated area, or in
the presence of a
flammable and/or explosive atmosphere. Do not use the machine in damp and/or wet
locations, or those exposed to rain or humidity.
3.
Before starting the machine, get used to ensuring that no remaining maintenance and
service keys are insert
ed.
4.
Keep the workplace tidy and free from obstruction; disorder causes accidents.
5.
Make sure that your work environment is forbidden to children, strangers and animals.
6.
Do not perform tasks on the machine other than those for which it was designed. Only
use
the machine in the manner in which it was intended, as described in this instruction
manual.
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7.
Work without disturbances.
8.
Work areas must be well lit.
9.
Always wear eye protection and protective gloves while working. If dust is produced,
use the appropriate m
asks.
10.
Wear appropriate clothing. Loose clothing, dangling jewellery, long hair, etc.., can get
caught in the moving parts, causing irreparable injury.
11.
Replace worn and/or damaged parts, check that the guards and protection devices work
properly before oper
ating. If necessary, have the machine checked by the service
support personnel. Use only original spare parts.
12.
Do not use the machine in areas with a risk of fire and/or explosion.
13.
It is recommended that users of this publication, for maintenance and repai
r, have a
basic knowledge of the mechanical principles and procedures inherent in repair
technique.
14.
The company safety officer is required to make sure that machine operators
have read and understood this manual in its entirety.
15.
The company safety manager
is responsible for monitoring the company's risk
status according to Legislative Decree no. 81/08.
2.2
Safety regulations for hydraulic presses
Compression and impact

The operation of lifting loads
ALWAYS
entails a risk related to the possibility of the l
oad
falling, even if handled properly.

There is
NO
"intrinsic" means of safety, just as there is
NO
worker who, while careful,
can "always" avoid an accident. DO NOT underestimate the risks associated with using
the machine and concentrate on the work in
progress.
2.3
Technical support
For any problems or concerns, please contact, without hesitation the Technical Support
Department of your dealer, who has competent and specialised staff, specific equipment and
spare parts.
2.4
Other provisions
I
T IS FORBIDDEN TO
TAMPER WITH SAFETY D
EVICES
Check the presence and integrity of protections and the proper functioning of safety devices
before starting operation.
If any defect is encountered do not use the machine!
It is absolutely forbidden, therefore, to modify or
remove the guards, safety
devices, labels and information plates.
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3
TECHNICAL SPECIFICAT
IONS
Description (unit of measurement)
Art. P001 / 75
Capacity (kN / t)
750 / 75
Dimensions (W x D x H) (mm)
1450 x 800 x 1940
Plunger diameter (mm)
78
Piston strok
e (mm)
250
Air intake pressure (MPa)
0.6
–
0.85
Hydraulic pressure (MPa)
59.92
Empty mass (kg)
435
4
DESCRIPTION OF THE M
ACHINE
The
M
ANUAL
H
YDRAULIC
P
RESS
Art. P001/75
is a machine designed for pressing objects
made of metal or similar materials; for exa
mple, for the assembly of mechanical units, press
fitting bearings or pulleys on shafts, etc.
Other types of use, or the extension of use beyond that envisaged, does not
correspond to the designation attributed by the manufacturer, and therefore the
latter
cannot accept any responsibility for any damage resulting therefrom.
Compression and impact

The press was designed and manufactured for a specific use, different uses and non
-
compliance with the technical parameters established by the Manufacturer may
constitute dangerous conditions for the operator.

This, with particular reference to the size, shape and materials of the pressed pieces.
The hydraulic
-
pneumatic press consists of:

Steel frame and load bearing columns;

Movable pallet carrier with a sy
stem using steel cables with a manual winch

Hydraulic cylinder with movable piston (plunger);

Manually or pneumatically operated pump, pressure gauge and other components of
the hydraulic circuit.
The press must be used exclusively on flat, not tilted and
appropriately hard and resistant
supporting surfaces capable of supporting weights such as industrial shed floors.
Moreover, it should be protected from weather, wind and humidity, and from the risk of fire
and explosions.
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4.1
Main parts of the machine
Figure
1
-
Overview of the Machine
1
Pressure gauge
7
Compressed air line
2
Hydraulic piston (plunger)
8
Pallet carrier displacement winch
3
Supporting beam (column)
9
Support pins with cotter pin
4
Ta
ble
10
Support posts
5
Hydraulic pump
11
Support feet
6
Pump levers
12
Lower beam
1
2
3
4
5
6
7
8
9
10
11
12
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4.2
Identification plate
On the press, on the front of the supporting beam, there is the identification plate illustrated
below:
Figure
2
–
Identification plate
M
AXIMUM CAPACITY VALU
E
The labels specify the
maximum capacity
(under standard conditions).
This value indicates the maximum pressing force the machine can exert.

P001/75:
Maximum pressing force (capacity)
750 kN (75,
000 kg approx.)
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4.3
Warning pictograms
There are several warning pictograms attached to the machine.
Figure
3
–
Warning pictograms.
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5
MACHINE SAFETY DEVIC
ES
The main safety devices of the press include:

The suppo
rt spring of the plunger;

Table and bed plate locking pins.
The Press has a
spring
inserted inside the cylinder which
supports the plunger, preventing accidental falling due to
gravity.
It also has the important function of returning the plunger
to the r
est position when the pressure in the hydraulic
circuit is "discharged" being a single
-
acting hydraulic
cylinder.
The press is also equipped with pallet carrier and pressing
plate
locking pins
supplied with cotter pins. After adjusting
the height of the p
allet carrier, the steel pins hold it in a
stable secure position. There are two pins for each side of
the pallet carrier.
Figure
4
–
Locking pins.
Use of PPE
In any case, ALWAYS use appropriate personal protective equipment
such as:

crush resistant gloves;

overalls or aprons;

safety shoes.
Figure
5
-
Personal Protective Equipment.
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6
IMPROPER USES AND PR
ECAUTIONS
The following actions, which obviously cannot cover the entire range of possib
le "misuse" of
the machines are
strictly forbidden.
IT IS STRICTLY FORBIDDEN !!

To compress springs or other similar objects;

To compress objects without resting them correctly on the press;

To compress irregular shaped objects that may slip out;

To ke
ep hands or other parts of the body in the pressing area during the descent of the
piston;

To use the manual press without it being properly secured to the floor;

To use the press on yielding surfaces and in any case with insufficient strength to
support t
he load;

To leave the manual press unattended when it is loaded (with the circuit under
pressure);

To exceed the pressing force (capacity) and/or the maximum pressure indicated on the
label;

To move the table while the press is loaded (with the circuit und
er pressure);

To allow untrained personnel to operate the manual press;

To operate the manual press if you are not psycho
-
physically fit;

To operate the manual press without due care;

To use the manual press other than for its intended use;

To operate the
manual press under unforeseen environmental conditions;

To operate the manual press in insufficient light.
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7
TRANSPORTING, LIFTIN
G AND DISPLACEMENT
Displacement for the purpose of transporting the
M
ANUAL
H
YDRAULIC
P
RESS
must be carried
out using suitable
lifting equipment.
The Press Art P001/75 is partially assembled and all the components are inside a wooden box
for a total weight of 460 kg.
Transportation requires industrial vehicles such as trucks, lorries etc.
Compression

Lifting the presses requi
res equipment with a capacity of at least 600 kg.

Do not use makeshift equipment and do not attempt to lift manually.

Do not move the press when there are people within the operating range of lifting
equipment.
If the press has to be moved after assembly
, it is necessary:
1.
To remove the mounting bolts from the floor.
2.
Use a forklift truck, inserting the forks as described in
the figure on the side or pass the harness straps
under the upper beam, on either side of the hydraulic
cylinder.
3.
To lift the press s
moothly without jolting.
Figure
6
-
Lifting the press
after assembly.
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8
ASSEMBLY AND COMMISS
IONING
8.1
General warnings
The following chapters are the core of the manual, as they contain
the real operating instructions on how
to install, operate and
maintain the Pneumatic Manual Hydraulic Press.
The safety information in the preceding pages must be read and
understood before learning the operating procedures.
Given the difficulty and importance of machine assembly and
commiss
ioning, poor execution thereof may lead to serious safety
risks for exposed persons both at this stage and during
subsequent operation.
Figure
7
–
Packaging
conditions.
8.2
Unpacking instructions
The press is supplied in a wo
oden box.
Before disposing of the packaging, ensure all machine parts (eg screws), the owner's manual
and other documentation have been removed.
Standard packaging
Packaging materials (plastic bags, polystyrene foam, etc.) must not be left within reach
of
children as these are potentially dangerous.
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8.3
Press assembly
To assemble the press, follow these steps:
1.
Unscrew the two M12 bolts that connect the pallet carrier to the body of the press,
used to make it easier to transport.
2.
Connect the base
section (Ref. 01 in the figure) to the left
and right side supports (Ref. 03 in the figure) following the
sequence of using a screw (Ref. 02 in the figure), a washer
(Ref. 06 in the figure), a spring lock washer (Ref. 05 in the
figure) and a nut (Ref. 04 i
n the figure).
Figure
8
–
Side supports
installation.
3.
Assemble the pressure gauge (Ref. 43 in the figure) by
screwing it clockwise into the appropriate housing (Ref. 32
in the figure). Tighten the nut as securely as possible
(Ref.
44 in the figure) to prevent leakage from the circuit.
Figure
9
–
Pressure gauge
installation.
4.
Assembling the pump unit: connect the pump unit (Ref. 57 in the
figure) to the support plate (Ref. 49 in the figure) with
three
screws (Ref. 51 in the figure) and the same number of spring
lock washers (Ref. 50 in the figure) and tighten securely.
Figure
10
–
Pump
unit positioning.
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Assembly of the connecting pipes:

Pipe 1: Remove the cap fro
m the connecting
pipe (Ref. 58 in the figure) and then insert the
O
-
ring (Ref. 45 in the figure). In the
meantime, remove the cap from the cylinder
unit (Ref. 37 in the figure) and attach the
connecting pipe (Ref. 58 in the figure)
tightening securely to p
revent leakage.

Pipe 2: Connect the O
-
ring (Ref. 45 in the
figure) to the pressure gauge (Ref. 43 in the
figure) and then attach it to the connecting
pipe (Ref. 59 in the figure) tightening
securely.
Then install the two levers in their appropriate
housing
, screwing in the locking bolts.
Figure
11
–
Installing the
connecting pipes.
Air outlet valve
Before proceeding with the assembly open the air vent valve inside the cylinder (Ref. 61)
5.
Move the manual winch (Ref. 11 in th
e figure)
into position next to the machine and connect it
to the bracket (Ref. 34 in the figure) using the
screws (Ref. 02 in the figure), washers (Ref. 06
in the figure), spring lock washers (Ref. 05 in
the figure) and the nut (Ref. 04 in the figure).
Ti
ghten securely to avoid any possible
loosening.
Figure
12
–
Manual winch
installation.
Parts list
Refer to the parts list and its technical drawings to verify the presence of all the parts
necessary for the proper assembly o
f the machine.
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8.4
Press installation
Loss of stability / Fall
Choose a press assembly position such that:

the area is sheltered from weather and moisture;

the surface is perfectly flat, non
-
slip and non
-
deformable, with an appropriate load
capacity for
the weight of the machine;

a work area free of obstacles and barriers can be fitted out around the machine;

It is positioned in a well lit area.
Proceed as follows to fasten the press to the ground:
1.
Fasten the base support brackets to the floor in a st
able and secure position, using the
fastening holes on the brackets themselves. Use appropriate fastening devices such as
bolts, dowels, etc.
2.
Securely tighten the mounting bolts / grips.
8.5
Preliminary testing
Before using the press, it is necessary and esse
ntial to carry out a preliminary test in its place
of operation.
The test includes:

a general visual inspection of the machine to ensure there are no worn parts and/or
damage on the equipment itself, and that all components have been assembled
correctly;

checking the stability of the press;

testing machine operation by running a few complete cycles (for the whole stroke of
the pressing piston) free of load.

a verification that the vertical displacement of the pallet carrier functions properly.
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9
MACHINE OP
ERATION
9.1
Adjusting table height
Loss of stability / Fall

Move the table vertically only when the machine is free of load (hydraulic circuit not
under pressure).

Ensure no one has limbs or body parts under the table to avoid crushing.
Protective glov
es
Always wear suitable protective gloves while moving the table vertically.
Place the table and pressing plate at the required height depending on the size of the
workpiece as follows:
1.
Unload the table, removing all wedges and pressing plates.
2.
Use the
manual winch to slightly lift the pallet and therefore remove weight from the
four support pins.
Crushing
Do not attempt to operate the winch with your hands near the teeth of the winch itself.
Always use the handle.
3.
Remove the cotter pin from the l
ocking pins
and pull them out one by one from their
housing being careful not to destabilize the
pallet carrier.
Figure
13
-
Winch and pins.
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