Preface
The molds and blades of the hydraulic ironworker are the core wearable components of the equipment. Their integrity, fitting accuracy, and operating status directly determine machining precision, production stability, operating efficiency, and overall equipment service life.Standardized, periodic inspection and maintenance effectively reduce mold wear, equipment failure, oil leakage, pressure relief, and workpiece scrap. This document establishes a four-level standardized maintenance system covering daily, weekly, monthly, semi-annual, and annual cycles. By clarifying key lubrication points and mandatory prohibitions, it forms a fully implementable, traceable, and reusable standard operating procedure (SOP) for industrial ironworker equipment.
1. Daily Maintenance Specifications (Per Shift / Mandatory)
1.1 Pre-start Static Inspection
Perform pre-startup checks to ensure safety and equipment integrity, including:
Hydraulic System: Check oil levels; fill with the same oil type, avoiding mixing.
Components: Verify that all molds and blades are securely fastened, with no cracks or damage.
Alignment: Visually check that the punch and die align properly; avoid frequent gap adjustments.
Cleanliness: Remove debris from the workbench, molds, and blades.
Safety & Power: Test safety devices (emergency stop, guards) and ensure stable power supply with intact, properly functioning circuit protection.
Lubrication: Perform initial lubrication for all core components, adhering to the principles outlined in section 5.2.
1.2 Dynamic Operation Monitoring
Continuously monitor the equipment during operation to detect faults early. Core monitoring areas include:
Noise & Function: Monitor the hydraulic and transmission systems for abnormal noise, stopping immediately if any occurs.
Temperature Control: Only check temperatures while the machine is shut down. Ensure the motor stays under 70°C (158°F) and the hydraulic oil operates between 35°C–60°C (95°F–140°F). For cold starts (oil <15°C/59°F), perform a no-load warm-up until the temperature rises above 20°C (68°F). Halt operation if the oil exceeds 65°C (149°F).
System Integrity: Ensure no leaks occur in the hydraulic circuit, joints, or cylinders.
Load Management: Never exceed the machine's rated capacity to avoid damage to components.
1.3 Shutdown and Cleaning
After operation, secure the equipment to ensure longevity and safety:
Pressure Management: Use the pressure release button to reduce hydraulic pressure and verify that the gauge reads zero.
Power & Shutdown: Cut the power securely after the system stops and the mechanism resets.
Maintenance: Thoroughly clean the machine, removing all debris and materials.
Protection: Apply rust-preventative oil to the mold and punch surfaces.
2. Weekly Maintenance
Perform in-depth weekly checks to ensure sustained performance:
Lubrication: Re-lubricate sliding surfaces, guides, and joints to prevent wear.
Clearance & Calibration: Check the alignment and gap of all shears and dies, adjusting to standard specifications.
Fasteners: Check and tighten all critical bolts on the tool rest and motor.
System Maintenance: Clean the cooler and ventilation components to maintain optimal performance.
3. Monthly System Inspection
Perform a comprehensive monthly inspection covering the entire machine:
System Integrity: Inspect the entire hydraulic circuit for potential leaks and seal failures.
Electronics & Safety: Test all electrical connections and safety limit switches for proper function.
Performance Verification: Check that all hydraulic controls, valves, and cylinders function without lag or failure.
Environmental Care: Clean all components around the hydraulic unit and keep the working area free from debris.
4. Semi-annual / Annual In-depth Overhaul Maintenance
Perform a comprehensive whole-machine deep overhaul semi-annually or annually.
MANDATORY SAFETY WARNING & LOTO PROTOCOL:
Before performing any disassembly, inspection, or maintenance, operators must strictly execute the Lockout/Tagout (LOTO) procedure: completely shut down the main power supply, lock the isolation switch with a personal safety padlock, and tag it out to prevent accidental re-energization. Subsequently, press the pressure relief button to completely release all residual pressure from the hydraulic system and accumulator, and verify that the pressure gauge reads absolute zero.
Focus on replacing wear parts, calibrating systems, and eliminating hidden risks:
Hydraulic Oil & Tank Care: Drain old hydraulic oil completely and clean all sludge, sediments, and impurities from the tank interior. Use only high-pressure anti-wear hydraulic oil: HM32/HM46 for winter/low-temperature environments (low viscosity for cold-start fluidity) or HM68 for summer/high-temperature environments (high viscosity for high-load stability). Prohibitions: Never use HL rust/oxidation oils lacking anti-wear properties. Never mix different brands or viscosity grades. EHS Compliance: All drained waste hydraulic oil, contaminated filters, and oily cleaning rags must be stored in specialized leak-proof containers and handed over to certified local hazardous waste recycling organizations for compliant disposal.
Filter Replacement: Replace the hydraulic oil filter to prevent system pressure drops, sluggish operation, or pump burnout caused by clogs.
Clearance & Pressure Calibration: Inspect and adjust shear blade clearances and punch-and-die fit. Calibrate system working pressure to ensure it remains within factory limits; overpressure operation is strictly prohibited.
Seal Restoration: Inspect all oil seals and O-rings; replace aged, hardened, or deformed seals immediately to eliminate oil leaks and pressure drops.
Electrical System Tuning: Tighten all electrical terminals, inspect contactors and relays, and replace any burnt or degraded components to ensure electrical safety.
5. Core Lubrication Positions & Standard Principles
5.1 Key Lubrication Points & Specified Lubricants
Apply the designated industrial-grade lubricants strictly to the following high-frequency moving and high-wear components:
Tool rest sliding guide rails: Apply premium slideway oil (ISO VG 68 or equivalent) to maintain a persistent oil film under heavy loads.
Punch guide sleeves: Apply heavy-duty lithium-based grease (NLGI No. 2 or equivalent) to prevent scoring during high-speed vertical strokes.
Transmission connecting rods and pin shaft joints: Lubricate with extreme pressure lithium or molybdenum disulfide grease (NLGI No. 2) to handle high impact.
Rear material stop moving guide rails: Apply standard slideway oil (ISO VG 68) for smooth positioning adjustment.
Pressure feeding mechanism sliding contact surfaces: Apply a thin layer of lithium grease (NLGI No. 2) to ensure smooth feeding friction.
Notching station rams and guide rails: Apply high-viscosity slideway oil (ISO VG 68) to resist high shearing stress.
5.2 Lubrication Principles
Strictly implement the rule of filling small amounts of lubricant frequently and refueling on demand. One-time large-dose oil filling is prohibited to prevent oil overflow, dust accumulation, scaling, and contamination of workpieces or equipment. Maintain a clean, uniform oil film with minimal friction.
6. Mandatory Operation Prohibitions
To ensure personnel safety, preserve mold integrity, and prevent catastrophic equipment failures, operators must strictly obey the following prohibitions. Unauthorized deviations will lead to accountability for resulting damage or incidents:
Overload Prohibitions: Never punch or shear steel plates/profiles exceeding the machine's rated thickness capacity.
Material Restrictions: Never process high-hardness materials (e.g., quenched steel, cast iron, hard alloys) to prevent mold chipping, fracture, or impact damage.
Live-Line Restrictions: Never adjust molds, disassemble components, or enter blade/punch hazard zones while the hydraulic system is under pressure.
Fault Prohibitions: Never run the equipment during oil shortages, excessive oil temperatures (>65°C/149°F), or active system faults.
Pressure Restrictions: Never bypass factory settings to increase hydraulic working pressure, preventing pipe bursts or structural frame deformation.
Stacking Restrictions: Never shear overlapping/stacked sheet metal or directly trim rough-edged plates, preventing uneven stress, mold offset, and workpiece scrap.
