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JRJZJRJZJRJZJRJZ----V06PV06PV06PV06P Brake 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: [email protected] Web Site: www.cjierui.com

JRJZ-V vacuum filling machine instruction

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 field’s 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 CJIERUI’S 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-V06P Brake fluid filling machine

Operating Instruction

CONTENTS

1. EQUIPMENT OVERVIEW---------------------------------------------------------------------------1

1.1 CONSTITUTION AND FUNCTION OF EQUIPMENT ----------------------------------------------1 1.2 CONTROL PANEL: ---------------------------------------------------------------------------------3 1.3 PNEUMATIC CONTROL UNIT:--------------------------------------------------------------------4 1.4 THE ELECTRIC CONTROL SYSTEM： -----------------------------------------------------------4 1.5 FILLING GUN AND ITS HOUSE GROUP: ----------------------------------------------------------5

2. PRINCIPAL OF WORKING--------------------------------------------------------------------------5

3. MAIN TECHNICAL INDEX -------------------------------------------------------------------------6

4. VACUUM FILLING EQUIPMENT OPERATION PROCESS----------------------------------7

4.1 PREPARATION-----------------------------------------------------------------------------------------7 4.2 EVACUATION -----------------------------------------------------------------------------------------7 4.3 LEAKAGE CHECK-------------------------------------------------------------------------------------8 4.4 RE-EVACUATION -------------------------------------------------------------------------------------8 4.5 FILLING PROCESS------------------------------------------------------------------------------------8 4.6 SUCTION PROCESS-----------------------------------------------------------------------------------8 4.7 COMPLETE--------------------------------------------------------------------------------------------8 4.8 SUCTION AGAINST DROP----------------------------------------------------------------------------8 4.9 SYSTEM SUPPLY--------------------------------------------------------------------------------------8

5. OPERATION --------------------------------------------------------------------------------------------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 FUNCTION------------------------------------------------------------------------------------ 18 5.7 WARNING RELATING OPERATIONS--------------------------------------------------------------- 19

6 FAULTS AND REMEDY ---------------------------------------------------------------------------- 20

7 MAINTENANCE AND REPAIR ------------------------------------------------------------------- 24

7.1 SYSTEM MAINTENANCE DAILY ------------------------------------------------------------------ 24 7.2 SYSTEM MAINTENANCE:-------------------------------------------------------------------------- 26

ANNEX ONE TWO CONJOINED / TRIPLE-USE (COMPRESSED AIR SOURCE PROCESSOR) INSTRUCTION----------------------------------------------------------------------- 27

ANNEX TWO MAIN COMPONENTS LIST------------------------------------------------------- 29

JRJZ-V vacuum filling machine instruction 1

1. Equipment Overview

JRJZ-V06P brake fluid filling machine

is for the needs of auto brake fluid in

production Line, designed and

manufactured by WUHU CHERY

EQUIPMENT CO., LTD, as

a new type of mechanical-electrical

integration, special vacuum quantitative

filling equipment.

Fig 1.1.1

JRJZ-V06P Brake fluid filling machine can synchronous detect brake fluid

pipeline system pressure reliably and deal 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.

1.1 Constitution and Function of Equipment

1.1.1 The internal pipeline and components of the equipment is 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 Red

Exhaust pipes Yellow

Compressed air Orange

Fluid Pipeline White

Suction line Blue

1) Vacuum System: mainly for vacuum, realize high vacuum effect within little

time by import vacuum pump, including vacuum pump, vacuum sensor and


control and adjustment valves with visual position control etc. D30C vacuum

pump is used mainly for find vacuum.

2) Filling system: system completes filling by constant current electric pump ,

which can shorten the fluctuate time in pipeline during pressure holding process

and can give the filling pressure more exactly. Adjust pressure with fluid valve.

This system consists of the storage tank, filling pump, regulator valve, flow

meter, pressure sensor, pressure meter and control and adjustment valves with

visual position control etc.

Fig 1.1.3 inter pipe

3) Supply system: Two roads for supply, automatics switch, and decide supply by

time delay. This system consists of supply pump and control and adjustment

valves with visual position control etc.

4) Suction system: the main function is to adjust fluid level and suction fluid

remained in pipeline to storage tank after filling complete. The pressure in

tank is controlled by pressure switch. Make tank in vacuum state by D16B.DOT

Vacuum pump D30C

Vacuum pump D16B

Filling tank

Storage tank

Fluid valve


vacuum pump, so system can suction fluid into tank due to pressure difference.

This system consists of control and adjustment valves with visual position

control etc.

1.2 Control panel:

The main operating control panel, Operator can make man-machine

conversation on control panel.

Main operating control panel mainly consists of switch indication control panel,

process indication lamp panel and touch screen. 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 of 【Emergency stop】、【Power on】（with

light）、【Power stop】、【Manual/Auto】、【Start】、【Stop】、【Supply】、【Reset】、

【1-ABS-0】.

Switching indicator panels is composed of “Ready→First vacuum→Vacuum

leak→Post vacuum→Filling→Suction→Over”.

Type selection button is composed of【High low】、【Type 1】、【Type 2】、【Type

3】、【Type 4】、【Type 5】.

Fig 1.1.4


1.3 Pneumatic Control Unit:

Located on the left door of cabinet, the main function is to provide an effective

source of compressed air. Before compressed air coming into the equipment, firstly

processes unit (triplet) filter, lubrication etc., and then gas sources will be available to

provide to the aerodynamic components. Control the sol valves by PLC to achieve

pneumatic control functions. Mainly consists of solenoid valve group, valve board,

air disposal unit (triplet), and regulator etc.

Fig 1.1.5

1.4 The electric control system：

The main electric control loop. Inside electric cabinet there are PLC, A/D module,

mini breaker, motor protective switches, mini relay, contactor, switch electric source,

connection terminal etc. PLC shall make logic operation of whole system to assistant

each control component action to ensure normal working of system. A/D module

shall translate the simulation signal of each sensor（pressure, vacuum） into digital

and input them to PLC, then PLC shall compare every parameter and program to

control filling system and vacuum system. Mini breaker can be used for manual

switch under debugging mode, and protect each loop form over current under normal

mode. Motor protection switch mainly protects each pump motor form over current


and under voltage. Mini relay complete logic operation with contactor.

1.5 Filling gun and its house group:

1.5.1 Gun and the main pipeline joints connecting rapid routing and coated with

plastic covers.

1.5.2 The gun head is designed with anti-leak, after filling finishes; there is no

leakage when plucking gun head.

1.5.3Gun is set with start and stop button and indicator lighters. Green button if for

filling and red button is for stop.

1.5.4Gun head cooperated with oil tank are connected with pneumatic clamping type.

1.5.5Filling oil gun is seated right side of equipment for 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.

1.5.6 Gun head cooperated with the oil tank, oil tank mouth is without deformation or

injury, and the body without interference.

2. Principal of Working

JRJZ-V06P brake 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 Antifreeze filling and system vacuum pressure;

pneumatic control part mainly finishes the fluid valve supplying pilot gas supply and

controls filling gun clamping; electrical control system mainly finishes system

process control and testing, also deal with process parameters data, preservation and

the system 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,

checking and filling process with higher operating rhythms.

Vacuum process of JRJZ - V06P Brake 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

� Max system vacuum capability（filling gun head）：：1mbar under temperature

25℃

� Max displacement of vacuum pump:：30 m3 /h more than 400mabr under

temperature 25℃

� Filling mode ：in-line

� Filling medium: brake fluid

� filling pressure: 1－10bar，adjustable

� filling speed：1－15L/ min , adjustable

� filling accuracy：level±2mm

� Filling cycle : ≤120s/vehicle

� moving pipe length：8m

� moving mode：moving arm

� supply mode：two pails auto exchange

� Equipment shape dimensions: length×width×height 1700×800×1600mm

2) working environment

� gas source:6.5bar（静态）;

� power: three-phase 380V±10% 50Hz±1％；

� power consumption：3.5KW；

� environment temperature:－5～45℃；Environment humidity：55～99%；

� noise：70db;


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 Preparation

After power on, then system shall enter into working state.

4.2 Evacuation

When first evacuation, vacuum pump M1 runs, vacuum pressure holding valve

No Process Content

1 Preparation Electrified, equipment enters preparation after self-check

2

Automatically

clamp 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

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

loosening Press red button on the gun and unclamp

11 Manually

take guns Suction against drop.


V601and gun vacuum valve V622 opens, a few seconds later, vacuum sensor

V604.1 opens, until preset time.

4.3 Leakage check

After first evacuation, vacuum pressure holding valve V601 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 V601 again. The re-evacuation is to repeat

evacuation process, until preset time.

4.5 Filling process

When filling, filling pump M3 runs, and gun filing valve V621 and filling valve

V602 act, filling process start until preset pressure. Then keep to preset times, the

filling process ends.

4.6 Suction process

After filling, the oil in pipeline shall be sucked back into tank. During this process,

Tank vacuum valve V612 opens, the vacuum air pump D16B.DOT start to

evacuation for tank. suction valve V603, gun suction valve V621 and blowing

valve V509 act, 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, vacuum pump M2 runs. The system opens tank vacuum

valve V612 again, suction valve V603 acts 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. See details in fig 5.2.2.

4.9 System supply

During the system supply process, supply valve V610or V611 acts and use the


negative pressure in tank to supply oil into tank.

5. Operation

Check Before Power On

1. Check the pipeline and joints whether to leak and damage or not, if so, please

replace or repair them immediately.

2. Check the gas source valve whether to open or not, whether gas supply range

is within the scope of（0.5－0.6Mpa）or not。

3. Check whether the vacuum pump oil is within the indicator line, if inadequate,

please add immediately.

4. Observe the vacuum pump oil color whether to become pale or not, verify the

use of time and replace vacuum pump oil immediately.

5. Check the contact line whether to peel or not and repair immediately.

6. Check supply oil mix whether to insert on line within the oil drum or not. .

7. Check emergency stop button whether to pluck off or not and make

emergency stop button at spring state.

5.1 Start/stop Operating System

5.1.1 Power On:

Connect with the main power of the JRJZ-V06P brake fluid filling machine ;

Push the 【power on】button 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 Power off Operation: Shut off the main electric source switch and main air

valve.

5.2 5.2 5.2 5.2 System Parameters Set

System parameters set is completed on the touch screen.

5.2.1 Selection of Working Mode

Switch the 【manual / automatic】switch 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 Operating Parameters Set

NNNNote: this item must be operated by professional persote: this item must be operated by professional persote: this item must be operated by professional persote: this item must be operated by professional person or authorized person by on or authorized person by on or authorized person by on or authorized person by

our our our our company, strictly prohibit other pcompany, strictly prohibit other pcompany, strictly prohibit other pcompany, strictly prohibit other person amend.erson amend.erson amend.erson amend.

1)Technical Parameters Set

In figure 5.1.1 window, press "Parameter set" to access the interface shown as

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 each control parameters of vacuum filling process; press DOWN to enter

“Technics parameter two(fig 5.2.3)”.


Fig 5.2.1 password input interface

Fig 5.2.2 Technics parameter set interface


1

Fig 5.2.3 technics set interface 2

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.

2) System parameter set

System parameters are for system measurement to ensure the filling accuracy.

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

5.2.4 ). User can modify the measure parameter, also can set new password.

Fig 5.2.3 system parameter set interface

NNNNote : before delivery, system parameters have been set right, do not amend ote : before delivery, system parameters have been set right, do not amend ote : before delivery, system parameters have been set right, do not amend ote : before delivery, system parameters have been set right, do not amend

them .them .them .them .

5.3 5.3 5.3 5.3 Vacuum Filling Operation

5.3.15.3.15.3.15.3.1 Automatic Filling

1. First, switch【manual / automatic】switch to the automatic position on the panel,

filling equipment enters preparation state, preparation indicator lights on.


2. on monitor interface, select vehicle type.

3. Take 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:

Ready→First vacuum→Vacuum leak→Post vacuum→ Filling→Suction→Over

4. After filling, press stop button to unclamp claws, then system starts suction

against drop until preset time or gun returns into its house.

5. Put the gun into its house.

5.3.2 5.3.2 5.3.2 5.3.2 Manual Filling

1. First，switch the 【manual/automatic】switch to the “manual” position ,the

system enters to the manual work mode, the “preparation” indicator lights on..

Each time pressing the filling button, system shall enter into evacuation, leakage

checking, re-evacuation, filling, suction 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.

Ready→First vacuum→Vacuum leak→Post vacuum→ Filling→Suction→Over

� NNNNote ote ote ote ：：：：

a) System shall sync-output fault alarm with the indicator on panel when fault.

b) With automatic mode filling, if press【filling 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 vacuum 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 Supply fluid to tank by hand

1. First, switch 【manual / automatic】 switch to the manual position on the panel,


filling equipment enters manual state.

2. Press【manual supply】button 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 panel【manual supply】button, and stop

supplying.

Note: Note: Note: Note: DuringDuringDuringDuring manual manual manual manual supplysupplysupplysupply, , , , until until until until systemsystemsystemsystem 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 presspresspresspress

【【【【manual manual manual manual supplysupplysupplysupply】】】】buttonbuttonbuttonbutton , the system will automatically stop , the system will automatically stop , the system will automatically stop , the system will automatically stop supplying.supplying.supplying.supplying.

5.3.45.3.45.3.45.3.4 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 SV10or SV11 to supply with level alarm interface( see

details in 6 fault and remedy), when reach to high level, the system automatically

stop supplying, supply valve closed.

5.3.55.3.55.3.55.3.5 State Indicator Instructions

1. 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 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 indicating 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, you can 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.

2. 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 System Monitor

Systems with real-time monitoring function, users can fully understand

equipment current work state by this picture.

Touch "system monitor” in any interface, you can access to the main monitor

window of system (Figure 5.4.1), press the “pipe monitor” to the pipe monitor

interface (fig 5.4.2). The operators can observe the current filling volume, the current

cycle time, the current pressure and the current vacuum value and the current filling

state.


Fig 5.4.1main system monitor interface

Fig 5.4.1 system pipe monitor interface

5.5 5.5 5.5 5.5 Manual Debugging

Only super manager can operate this function. When system debugging and fault

judge, under this mode, you can operate pump and valves directly on man-machine

interface without PLC control, which makes judge and operation more easily. But this

must be completed by very professional person, otherwise, it can bring unexpected

fault with wrong interlocking of pump and valves. This function must be used

usefully.


In 5.1.1 window after input “manual debugging password”, 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 Date 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 the main menu select "Data Query", the system accesses data query interface

(fig 5.6.1).


Fig 5.6.1 data query window

User can press “ clear” to clear filling times and filling quantity manually.

Note: The data will not automatically clear and only manually cleared.

5.7 5.7 5.7 5.7 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.

（4） For any system fault alarm , you can press【alarm reset】button to cancel alarm.

Unless an emergency situation, you can not press【emergency stop】 button,

frequently use 【emergency stop】 button to stop power would affect some

components of life, even damage some electrical components.


6666 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, press【alarm reset】on the panel to cancel alarm.

Repairing equipment must be made under stopped state. Only after all alarms

have been eliminated, equipment can be started. Do not repair equipment with

electric.

Table 6.1 detailed alarm items and treatment

alarm content reason treatment

level too low

alarm

Level switches may be

damaged or infusion pump

damage

1、check level switch

2、adjust infusion pump and filter

level too high

alarm

level switch may be

damaged or infusion speed

too fast


2、adjust throttle valve of infusion

pressure shortage

alarm

pressure switch may be

damaged or Under voltage

gas supply circuit

1、check pressure switch

2、Check pressure of the gas supply loop

whether to be enough

filling pump

alarm

load may be too large or

system power failure

1、protective switch current set whether to

be too small

2、check 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

1、protective switch current set whether to

be too small

2、check 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

1、remove filling head and clamp

2、check system pipeline whether to be leak

3、adjust large leakage parameters

small leakage

alarm

pipeline with small leakage

or small leakage parameters

set too small

1、choose compel filling or cancel filling

2、check system pipeline

3、 adjust system small leakage check

parameters

drum empty

alarm

level switch damage

drum empty


2、change drum prompt

filter alarm filter damage

pipeline unsmooth

1、check filter

2、check clean pipeline

filling overtime

alarm

set filling volume too large

filling pipeline leak

1、check set filling volume and filling

protective

2、check 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 :

1. 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: start vacuum pump and check vacuum pump whether

to normally operate or not, if normally operate, 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;

2. Press filling without action.

1) Check gas source on site and observe triplet of the equipment whether 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 stops 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;

3. Filling process without vacuuming

1) Observe this process whether to activate the vacuum air 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 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.

4. 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 or not 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.

5. Filling Inadequate

1) During evacuation 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, revise 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;

6. Level Failure (Level too low, Level too high alarm)

1) If level is 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 is opened, if not

opening, connect 2.6)


4) If level is above level higher limit；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

If output point is normal to observe whether the fluid valve is opened, if opening,

connect 2.6

7 Maintenance and Repair

7.1 System Maintenance Daily

1. 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.

2. 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) Normally, system shall first check vacuum oil level after turn on, and shall

open SV11 valve to supply with shortage. However, operator also should

check oil level every day one time, to avoid vacuum pump being damaged

and affecting filling with oil shortage due to system failure.

3) 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 one month.

b) Observe that oil color has becoming white.

c) The equipment has already filled more than 7000 vehicles.

d) Changing oil type: LEBOLD N62

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.

4) 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.

5) 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.

6) If vacuum pump has been set aside for one year, the oil must be replaced

before it is used again.

7) The open times of pump can’t exceed six to avoid motor over loading.

8) The vacuum pump oil must be LEYBOLD oil. The damaged due to other oil

doesn’t be included in warranty.

3. System Maintenance:

System checks vacuum value and flux parameters every half year and makes

them optimization.

4. 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).

5. 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.

6. 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.

7. 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.

8. Moving system maintenance: you should regularly fill the lubricant oil for mobile

arm parts every year.

9. 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 2.5~7°E 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.

10. Maintaining air desiccator:

1) You should change desiccant in the drier every four years, when changing you

just remove four screws of below cover and unfix connect pipe.

Desiccant type: modified aluminum:A5

2) Carrying out maintenance every four months and cleaning dust and checking

whether gas pipeline and electric line are normal.

11. Ensure that power supply and gas source are switched off you can carry out

various maintenance.

12. you can know the detailed content on the main parts instructions.

7.2 System Maintenance:

1. Fluid control circuit maintenance: every fluid valve can open manual in the

fluid control circuit, during maintenance if you want to operate a valve, you

can press white point in the sol valve manually, and check and maintain the

relevant pipelines, you can operate manually sol valve only on the power off

conditions.

2. Electric loop maintenance: Total system logic controls are in the PLC control,

after checking trapezium and know the logic relation, observe each input and

output state in the “PLC”, confirm that interior logic failure, or exterior

connector and valve or its perform components problem, 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)

一、 Installation

1、Blow the pipeline by compressed air before installation.

2、Triplet required install vertical, and water cup and oil cup are adown, but

pressure relief valve knob install up or adown.

3、Arrowhead direction refers to air compress direction, pay attention to it when

installation.

二、 Environment

1、Avoid exposure in the sun。

2、As 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.

三、 Operation

1、The filter should advert to release water with drainage manually, level does not

exceed level symbol, at least set water once every number of runs

2、When 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.

3、The oil level of oil tank should keep between upper limit and lower limit, oil

deficiency, supply oil prompt. use mucosity 2.5～7ºE lubricate, we commend

use number 22 steamer oil.

4、The minimum air flux in the normally operating should content the minimum

flux request of oil tank.

5、Cup and cup cover removed should be operated without pressure.

（1）Clutch shield cover by hands and press orientation device and rotate right


or left 45º by thumb, and then make the arrowhead of orientation device

versus the arrowhead of valve and pull adown to remove.

（2）Some models can directly tweak down.

6、Oil tank can fill oil with stop gas or non stop gas, fill oil step as follows:

（1）Usually directly fill by opening oil stuff.

（2）Some 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 cup→e. tweak

up stuff.

四、 Maintenance:

Abstersion of cup and sieve should choose litmusless scour, after washing with rinsing and cool.


Annex two

Main Components List

NO Name Type Manufactures Mark

1 Vacuum pump D16B.DOT Germany

LEYBOLD

2 Vacuum pump D30C Germany

LEYBOLD

3 Vacuum sensor PTX610 DURCK

4 Pressure sensor A-10 WIKA

5 Flow sensor 8030 Germany

BURKERT

6 Fluid valve G1/2 Germany

BURKERT

7 Filling pump TOP-2MY400-206HBM Japan NIPPON

8 Vacuum pressure

siwtch ZSE30-01-25-ML SMC

9 Pressure meter with

switch

GP46-10-01L5 SMC

10 PLC 1766-L32BWA AB

11 I/O extending unit 1762-IQ16 AB

12 A/D extending unit 1762-OW16 AB

13 Air dryer KGA-250 YSC

14 Touch screen 2711P-T6C20A AB

15 Triple AC30-03 SMC

16 Pressure meter Y60 Shanghai

17 Electric components SCHNEIDER


18 Fluid hose 10X12 fluorine Japan DMZ

19 Ripple pipe jacket AD42.5 nylon Germany FLEX

20 Fluid filter 500目,150目 Haideke

21 Supply oil

combination Self-made

22 Storage tank 50Lstainless steel China

23 Cabinet 1700X800X1800 China

24 Air-condition LA-03-H Leibo

25 Mobile arm JR010 Self-made

26 Balancer 1.5-3KG Aotuo

27 Filling gun J812D-03 Self-made

SSSSpare list pare list pare list pare list

NO Name Type Manufactures

1 Button on panel XB2B SCHNEIDER

2 Button on gun 49112 American ICW

3 Fluid valve TYPE2000 BURKERT

4 Sol valve VQZ1115 SMC

5 Seal toop KF25 LEYBOLD

6 Filter core G1/2

manual maq llenado liga freno

Documents

yuan jinan cjierui electric

electrical equipment

quantitative filling

imported equipment

general road of jinan

china adress

foreign markets

automobile group