перевод
FORLOAD
Telescopic Loader
Operation & Maintenance Manual
PREFACE
Thank you for selecting our Telescopic Loader.
This manual is prepared for the operator, the serviceman and the technician in order to provide necessary information about safety performance, structure, operation, maintenance and control of wheel loader.
This manual provides the correct guide for operation and maintenance. Please read it carefully before operating.
Please keep this manual in the cabin to make it at hand at any time. If it is lost, please purchase a new one.
Correct operation, regular maintenance and sufficient lubrication are very important to ensuring safety and good condition of the machine. Failure to do so may cause serious problem to machine itself or human life.
Owing to the rapid development of technology and our continual improvement of products, the information contained in this manual may be changed without notice.
For improving our product and service, customers are kindly requested to give us comments and suggestion after reading this manual.
Оглавление
CHAPTER II STRUCTURAL PRINCIPLE OF THE MAJOR COMPONENTS AND MAINTENANCE 2
1. Hydraulic torque converter - Transmission (Figure 2-2) 3
2. Drive hydraulic system (Figure2-5) 8
IV. The working hydraulic system 20
1. The brake master cylinder 29
5. Multi-functional unloading valve: 34
VI. For device and the frame 36
3. Lighting and signaling systems 42
CHAPTER III THE DRIVING AND OPERATION 43
I. Instrumentation and control equipment 43
II. A new car to go together 44
1. Inspection and preparation before moving: 46
CHAPTER IV TECHNICAL MAINTENANCE 52
I. Loaders water, oil grade and drain table 52
1. routine maintenance (daily) 52
2. Weekly technical maintenance 54
3. The monthly technical maintenance 54
4. Quarterly technical maintenance 54
5. Technical maintenance every six months 55
6. An annual technical maintenance 55
CHAPTER V COMMON FAULTS AND EXCLUSION METHOD 56
V. The working hydraulic system 58
CHAPTER VI THE TRANSPORT AND STORAGE 60
CHAPTER I USES AND FEATURES
I Uses and Features
This Telescopic Loader for road construction, urban construction, environmental sanitation, coal, gravel yard, small and medium sized civil engineering, railway stations, terminals, freight yards, warehouses and other places, mainly used to shovel loading or recultivation, gravel, coal, slag, garbage and other loose materials, tractor trucks with 3-5 tons with the loading and unloading of materials, but also for bulldozers, shovel digging, Calibrating, heap, lifting, towing and other operations.
This machine has the following features:
1. Using hydraulic mechanical transmission, can make full use of engine power, according to the size of the external resistance Promise speed automatic, while avoiding the engine due to the sudden increase of external load flame, can absorb and eliminate the external load on the engine vibration and shock, thereby protecting the transmission and engine, increase machine life, so that machine easy to operate, comfortable, with high economic and production efficiency
2. Using the central articulated frame and load-sensing full hydraulic steering gear, turning the front and rear tracks overlap, turning radius is small, easy operation in narrow space, manipulating light and flexible, safe and reliable, and compact structure, easy maintenance
3. Using four-wheel drive, low-voltage wide-base off-road tires, swing rear axle, has a good off-road performance, through performance, and greater traction.
4. Wheel hydraulic brake system caliper disc brake, braking force big, safe and reliable.
5. All enclosed elastic support cab, seats with adjustable and vibration reduction features, driving comfort and broad vision.
CHAPTER II STRUCTURAL PRINCIPLE OF THE MAJOR COMPONENTS AND MAINTENANCE
I. Engine System
It mostly include engine, radiator, air filter, muffler, diesel tank and accelerator.
1. Engine
This engine’s structure, specifications, use and maintain please see the product descriptions.
2. Air filter
This machine’s air filter is a bipolar type air filter paper air filter, which uses the blades do not spin Liu coarse filter and automatic dust rubber dust bag, can automatically dust, rain and snow to have a more ideal for the separation effect. Large area of the main filter filter paper, air resistance is low, filtration efficiency, dust storage capacity, so that the maintenance cycle is long, long service life. Its security filter can be further broken ugly primary filter to protect the engine accidentally, without causing cylinder liner, piston ring wear and tear of early.
The use of air filters every 50 hours should be shutdown and maintenance time, remove the main filter cleaning with compressed air from the inside to the outside, or tapping the cover for maintenance, to prohibit oil, water, clean filter. The main filter damaged or normal use after one year, to be replaced, rubber dust bag vertically downward, is strictly prohibited without the rubber dust bag to work under conditions.
3. Radiator
Radiator assembly from water radiator, transmission oil cooler and engine oil radiator, namely pairs of recycled water, transmission oil, motor oil for hair forced cooling.
Radiator not have leakage, water radiators should be added rain, river water and other soft water, the ambient temperature is low after work every day should be a net cooling water discharge to prevent Frost Crack body, water tank and other components. External radiator to keep clean and maintain the smooth flow of internal heat in order to good effect.
4. Diesel tank
Diesel fuel tank is located in the bottom left side of the cab, Oil mouth work 50 hours per filter should be cleaned once.
II. Transmission
The torque converter drive system by, power shift transmissions, drive shafts, drive bridges formed.
Can be seen from (Figure 2-1), the engine power output increased through the torque converter torque transmission to the gearbox. Power transmission through the multi-stage gear to slow down, by different gears have different transmission of, respectively, the output of different speed in different directions, resulting in forward I, II files; back I, II file.
As the ground uneven, oscillating rear axle and steering and other reasons, so that the location of transmission before and after the bridge and the relative change, thus adopting universal gear. Namely, the output power transmission through universal joints and expansion joint with the drive shaft, transmission to the front and rear axle.
Spread before and after the bridge by the main reduction gear to reduce speed and power to change the direction of rotation (to the left and right drive shaft rotation into the front and rear axle rotation). The differential reached the round side of reducer to drive the wheels turning.
1. Hydraulic torque converter - Transmission (Figure 2-2)
Hydraulic torque converter and gearbox two people linked together by bolt, pump wheel (1) with the pump wheel cover (2) stroke connection with a closed bolt body. It is one end of the connecting plate and the engine flywheel through elastic (3) bolt on the other side that the pump wheel supported by bearings in the idler pulley seat (6), in this closed body, equipped with a turbine (4) and idler pulley (5).
(Figure 2-1) Schematic diagram of transmission system
1 diesel; 2 hydraulic torque converter; 3 transmission; 4 hand brake; 5 wheels; 6 wheel reducer; 7 differential; 8 driving axle; 9 the main transmission; 10 drive shaft;
(Figure 2-2) Hydraulic torque converter - Transmission
1 pump wheel; 2 pump wheel covers; 3 flexible connecting plate; 4 turbine; 5 idler pulley; 6 idler pulley blocks; 7 pump wheel hub; 8, 31 driving gear; 9 forward gear piston; 10, 12, 14, 16, 18, 22, 28, 29 Gear; 11 the piston back live stalls; 13, 30 clutch housing; 15 shell; 17 the output shaft; 19 block oil board; 20 oil seal; 21 intermediate shaft; 23 second gear piston; 24, 27 clutch shaft assembly; 25 dual-gear; 26 a stall piston; 32 turbine shaft;
Turbine by Involute spline shaft connected with the turbine. Idler pulley (5) by involute spline connected with the guide pulley blocks, idler pulley blocks (6) with screws fixed to the torque converter housing. Driven variable speed pump and the working device of the driving gear pump (8) through the involute spline connected with the pump wheel, driving gear (8) led passive gear, and then drive through the spline sets of variable-speed pumps and pump working equipment. Transmission of the driving gear (31), through the involute spline shaft with the turbine (32) connected to the body with forward low clutch gearbox shaft assembly (27) and regression grade clutch shaft assembly (24); clutch from the Dynamic Friction involute spline through the respective sets of the clutch hub body (30) and (13) on the inner spline. Active friction plate clutch involute spline through the respective sets of gear (10), (28) (12) on. Gear (26) by Involute Spline installed on the output shaft (17), the gear (16) and (18) coincide.
Works (Figure 2-3)
(Figure 2-3) Transmission torque converter transmission diagram
Power coming from the engine through the flexible connecting plate torque converter pump wheel drive rotation (in conjunction in the pump gear wheel Z14 through Z15 may be the work of pumps and variable speed drive pumps), the engine’s mechanical energy is converted to pump the liquid round function, so that highspeed impact of liquid in the turbine blades, so that regardless of rotation, so that the kinetic energy of the liquid then converted into mechanical energy, and transport out through the turbine shaft, the liquid outflow from the turbine into the idler pulley, when the outflow of liquid from the turbine when the blade runner down to change the direction of the impact of guide pulley, the working fluid to the guide pulley in order to force, As the guide pulley fixed and the guide wheel to the working fluid to the size of equal and opposite reaction, the working fluid to be counter-productive to return to the role of torque in the turbine, the turbine at this time received a pump wheel torque and reaction torque idler pulley together, This torque converter will play a larger role in torque.
When the variable-speed joystick and change are in the middle of the joystick (ie, gap), although the gear associated with the turbine and the Z2/Z3 coincide with the Z1, but not with the clutch, gear (Z2/Z3) idling, coming from the turbine shaft power could not be exported, so cars do not stop moving.
When the reversing lever in the forward position, variable-speed joystick for low-profile position, rotate the pressure oil (12— 14 kg / cm2) into the transmission control valve, control valve out of the pressure from the oil by pipeline, or to resist the advance side cover, from the clutch hub body axis of the central hole into the oil-Road clutch piston, piston under pressure in a move to make progress, low-speed two clutch master, slave friction plate combination. From the input gear (Z1) input power, through the gear (Z2, Z6, Z7, Z8, Z9, Z10, Z11) pass the output shaft, drive around the rotation axis, and then through the front and rear drive axle- driven rotation of the wheels to achieve forward a File.
When the reversing lever for forward position, variable-speed joystick for high-end position, the same as with a file. Pressure oil into the clutch piston to move forward, high-speed two clutch master, slave friction plate combination of power through the gears (Z1, Z2, Z4, Z5, Z8, Z9, Z10, Z11) to the output shaft, so that rotation around the axis of rotation, and through the front and rear drive axle-driven rotation of the wheels to achieve forward second gear.
Back a file, two files to achieve the same process and forward files are no longer detail, period of rotation line as follows:
Back a file by the Z1, Z3, back clutch, Z5, Z4, low-speed clutch, Z6, Z7, Z8, Z9, Z10, Z11 front and rear shaft drive transmission output shaft rotation, through the front and rear drive axles, drive the wheels turning, to achieve regression a file.
Back two files: The Z1, Z3, back clutch, high-speed clutch, Z8, Z9, Z11 and drive around the oil to pass the output shaft rotation, through the front and rear drive axles driven rotation of the wheels to achieve backward second gear.
Clutch structure and working principle:
(Figure 2-4) Shift clutch structure
1 active gear; 2 active tablets; 3 driven films; 4 passive hubs; 5 piston; 6 spring; 7 shaft; 6, 11 card ring; 9 bearing plate; 10 pressure plate; 12, 13 seal ring;
Transmission is equipped with a four shift clutch, that is, forward block, to the Tui Dang, a file, second gear clutch. Four clutch structure and working principle is the same, (Figure 2-4) shows the structure of the clutch shift map for the wet clutch shifting, multi-plate clutch. Active film (2) and slave-chip (3) of each four, active gear (1) Outer Spline active hub for the clutch, with two bearings supporting the shaft (7), the active foreign spline gear and active tablets (2) to connect the inner spline can also be done in its axial movement, Driven tablets (3) and passive foreign Spline Hub (4), connecting the inner spline can also be done in its axial movement, springs (6) one end of the resist piston (5), the left side of face, the other side of through the spring support plate (9) and clasp (8) supported in the axis (7), when the pressure shaft into the piston through the oil path A (5) The right side oil chamber, the piston will overcome the spring force left, all the active pressed tablets and slave films, clutch combination of transmission power
2. Drive hydraulic system (Figure2-5)
Installed in the torque converter in the gearbox at the top of the shell on the change gear pump (12), through the filter (3) from the gearbox oil at the end to oil-absorbing, from the gear pump output pressure of the oil through the oil filter (11) into the main pressure regulating valve (6). Oil Pressure Regulating Valve into two routes out of the way to the speed control valve (5) (oil pressure 1.2~1.4MPa); another pass through the main relief valve into the hydraulic torque converter (1) (oil pressure 0.6~0.7MPa). Came out from the torque converter (hydraulic 0.2~0.28MPa), through the oil cooler (4) into the clutch hub body in order to lubricate bearings, gears or clutch friction plate cooling. Last reflow gearbox, the working transmission oil temperature is generally 90°C - 95°C, the maximum instantaneous temperature should not exceed 120°C, or to stop the cooling
Here are the main components of the system structure and working principle.
(Figure 2-5) Torque Converter - Transmission oil system schematic diagram
(Figure 2-6) Transmission Control Valve
a. (Figure2-6) Transmission Control Valve
Transmission Control Valve from the speed valve, valve, and shutoff valve that is composed of body. Speed valve stem from the speed (2), spring (9) and steel ball (10), with pulling velocity stem (2) allows for a file transmission, respectively, neutral gear and second gear.
Valve from the valve rod (3), spring (4) and ball composition, pull valve rod (3), respectively, allows for forward transmission gear, the neutral gear and post-Tuidang.
Valve and speed, a combination of valves can be achieved forward a file and two files, one file and two files back. For example, when the pull-out valve rod (3), from the main pressure regulating valve to the pressure of the oil into the valve through a hole flowing into the transmission forward clutch, the pressure oil promote the piston, so that the clutch master, slave friction plate with, gearbox mount forward gear. When the speed of valve stem is in a file or two files location, the pressure oil from the b-hole back into the gearbox clutch, the oil pressure push the piston to the clutch master slave chip integrated, gearbox mount to the Tui Dang. Then when the rate of stem a file or two files in the location, speed to achieve a reversal of a file or two files back.
Shut-off valves: shut-off valves by the control valve assembly, spool (6), spring (5). When the loader does not step on the normal brake pedal travel, the shut-off valve in the middle position, the next step when the driver when the brake pedal from the brake system pressure on the oil control valve into the oil chamber to promote piston (8), piston push ejector to spool (6) Sports, compression spring (5). At this point cut off the valve spool, the valve clutch gearbox oil Qu Wang Tao (a or b-hole) cut, so that forward or backward clutch, no transmission power. This will not only help loaders braking, but also will be installed in the loader shovel all the power for work unit.
b. (Figure 2-7) main pressure regulating valve
Mainly by the main relief valve body (1), spool (6), Spring (7,8), or relief valve of the ball valve (10), conical spring (9) etc., the pressure from the gear pump Oil flows through the main pressure regulating valve A transmission control valve chamber, when the A cavity when the fluid pressure exceeds 1.1 MPa to overcome the spring (7, 8) of the forces promoting the spool (6) down to open the B cavity. After oil into the hydraulic torque converter in the B cavity. When the oil pressure chamber B exceeds 0.4 MPa, the ball valve (10) to open the excess fuel back to mailbox.
3. Driving axle
Loader for the full-bridge driver, that is, both front axle or rear axle drive axle. Before and after the bridge is the main drive in the difference between the spiral bevel gear pair in a different direction. The main rotating front axle spiral bevel gears for the L, the right-hand rear axle.
Drive axle structure (as shown in Figure 2-8): mainly by the bridge off the main reducer that differential assembly, axle, wheel side reducer etc... Off the bridge installed on the frame, the frame came to bear the load and pass it to the wheels, the car shell is the main reduction gear, axle, wheel side supporting the installation of speed reducer body, the main reducer is a spiral bevel gear reducer, transmission of torque transmitted from the rotation axis or movement. Differential is the ruler of two cone-shaped gear axle (5), cross-axis (10) and four cone-shaped ruler differential gear (4), left Differential Case (2, 6) etc. It left two wheels of different speed differential roles played, and final drive axle torque or movement to pass the right and left full-floating axle, axle (12), respectively at both ends through the spline and semi - shaft gear (5) and wheel-side of the sun gear reducer (19) connected. Therefore, the main transmission axle from coming through the differential torque and motion passed on gear reducer, speed reducer for the wheel-side single-stage planetary gear rotation, internal gear ring (18) mounted on the bridge by Spline shell (13) at the end, and with the nut fixed, and therefore within the ring gear and axle housing does not rotate together.
(Figure 2-7) Diagram the main relief valve
1 valve body; 2 flexible pin; 3 block; 4, 5, O-ring; 6 spool; 7,8 Spring; 9 conical springs; 10 ball valve; 11 valve seat; 12 adjustment screw; 13 nut;
(Figure 2-8) Drive Axle chart
1 the main reducer shell; 2 the differential left shell; 3 Driving Bevel Gear; 4 differential gear; 5 axle gear; 6 differential; 7 the earth's axis gear mat; 8 planetary gear pad; 9 bolts; 10 differential gear axis (cross-axis); 11 driven bevel gear; 12 axle; 13 Bridge Shell; 14 brake; 15 wheel rim; 16 tire; 17 wheel hub; 18 Gear; 19 the sun wheel; 20 planet carrier; 21 brake disc; 22 planetary gear ;23 needle; 24 planetary axle;
With the sun wheel (19) and internal ring gear (18) at the same time and in the three planetary gear teeth (22), from the planetary gear shaft (24) weeks to have to installed in the planet carrier fabric (20), the planetary gear (22) and planetary Axle (24) fitted between the roller (23) in order to reduce friction, planetary frame (20) through the stud and the wheel hub (17) connected.
(Figure 2-9)
1 Differential Case; 2 differential gear axis (cross-axis); 3 differential gear; 4 axle gear; 5 axle; 6 the sun wheel; 7 planetary gear; 8 wheel hub; 9 Gear; 10 driven bevel gear; 11 Bevel Gear; 12 drive shaft; 13 Wheel;
Working principle (as shown in Figure 2-9): Shaft (12) through the spiral bevel gear (11), drive driven bevel gear (10); torque has been reached on the driven bevel gear, this torque with the Driven bevel gear loaded into one of the left Differential Case (1) to a cross shaft (2) re-installed in the cross axis through the four differential bevel gear (3), reached the left and right two and a half cone shaft gear (4) on. If the speed of time left and right wheels are equal (that is, to face the axle axis moment resistance equal), then the differential gear and axle gears does not produce the relative movement. Like the left and right wheel is linked by a shaft, but when the vehicle turns, or uneven on the road, take the left and right wheel speed is not at the same time (that is, to face the left and right axle axis resistance torque different, the difference is greater than the required differential gear rotation Images), differential gears rotate around its own axis, so that the speed of about two different play differential roles. Power through the axle (5) delivered to the wheel-side reducer, when the sun wheel drive axle (6) rotation, with the sun wheel of the three planetary gear meshing (7) would rotate around its axis, But also because of planetary gear and internal ring gear (9) relative to mating, then roll up, including Gear, internal gear ring fixed to the axle housing due to can not rotate, so the planet, it will be fixed on the wheel hub through (8) on the planet Axle driving the wheel hub (8), together with the wheels (13) together produced along the ring gear revolution, leaving loader driving. As the wheel speed is much smaller than the sun-gear speed, and thus play a reduced speed, increased torque effect.
Drive axle adjustment and maintenance according to the following requirements:
a. Main from the East side of spiral bevel gear tooth gap of 0.20-0.34mm, the variation shall not exceed 0.15mm, tooth gap can be adjusted differential nut;
b. The axle differential gears and planetary gears meshing clearance of 0.20-0.30mm, assembled should ensure that their hands can be rotation of light, non-catching phenomenon;
c. Driven bevel gear bearing clearance at both ends of the adjustment nut by turning the differential, so that the axial gap maintained at between 0.10-0.15mm;
d. Lord, driven spiral bevel gear tooth contact area, should ensure that the direction along the tooth length was 60%, along the 18 direction of 50% of high tooth contact with the tooth surface should be the central location and close to little-endian;
e. Between the wheel-side through the deceleration bearing lock nut to adjust the turning space for the 0.10-0.15mm, planet carrier should turn freely, without catching phenomenon;
f. The main transmission and the wheel-side Reducer work 1200 hours or so every time when the replacement of lubricating oil, should be based on the different regional and seasonal selection of the appropriate grades of lubricants.
4. Drive shaft
Mainly by the drive shaft universal joints, expansion joints and driveshafts, etc., universal joint cross from the universal (1), card ring (2), Needle (3), cross-axis (6), universal joint casing fork (8) etc. (see Figure 2-10), the main role is to pass changes in the angle of torque and rotation, expansion joint is a pair consisting of internal and external spline shaft, which allows the total length of a flexible shaft, However, the spline shaft length should ensure that the work in a variety of circumstances, that is, no roof torn off and not die, drive shaft pipe is made of rolled steel round tube, is used to transfer torque and rotation.
Shaft adjustment and maintenance should be noted that
a. Spline shaft with the cross-axis must be provision for periodic filling grease
b. Shaft bolts should be inspections in the maintenance of car fastening;
c. Drive shaft universal joints at both ends of the fork in the same plane, and marked with the arrow mark indicating, in the demolition or repair should be careful not misplaced.
III. Steering systems
Loader steering and working installations of pump diversion system. Mainly by the load-sensing steering system hydraulic steering gear, priority valve, steering cylinders, tubing, and work to share the work of the hydraulic system tanks, pumps and other components, (Figure 2-11) Schematic diagram of its work.
(Figure 2-10) Universal joint shaft
1, 12 Yokes; 2 card rings; 3 needles; 4 sleeves; 5 blankets seals; 6 cross-axis; 7 butter mouth; 8 universal joint fork tube; 9 dust cover; 10 drive shaft tube; 11 Yokes;
The pressure of the oil from the pump leading to the first priority valve, regardless of load pressure on small, high and low speed the steering wheel, steering priority valve to give priority to the allocation of traffic, to ensure sufficient oil supply shift, so that turning movements smooth and reliable, and the rest can all supply in Hydraulic system, thereby eliminating the asphalt turned to oil as a result of excessive power loss, increase system efficiency.
Steering into the pipe on the road to install a one-way valve to prevent backflow of people turning steering oil tank, causing the steering wheel thugs, when the steering wheel left when the oil flowing through the load-sensing hydraulic steering gear into a small cavity and the left steering cylinder the right steering cylinder large cavity, so that loaders turn left; when the steering wheel, right turn, the oil through load-sensing steering into the left turn to a small cavity and the left steering cylinder large cavity, so that loaders turn left, if the wheels encounter obstacles or when the steering cylinder in the hydraulic system on the limit position of more than 12Mpa, fixed import and export of the oil port in the steering-side surface of the overflow valve can guarantee unloading, oil flowing back into the mailbox, to prevent system overload.
IV. The working hydraulic system
loader hydraulic system mainly by the gear pump, priority valve, multi-valve, boom cylinder, dump tank, working fuel tanks and pipeline components (see Figure 2-12)
Pressure oil from the gear pump via priority valve to a multiway valve, through the manipulation of the corresponding slide valve to oil transported to the boom cylinder or dump tanks, working device does not work, the oil through the multi-channel valve of the Middle Road and the oil filter back to the oil-mail.
The main components within the system are described below:
1. Multi-way valve (Figure 2-13) of the valve slice multi-way valve, mainly by the safety valve (1), into the oil valve (2), dump valve (3), moving arm valve (4) and oil return valve (5), etc... Dump, boom valve series-parallel connection between the use of asphalt.
(Figure 2-11) Steering hydraulic system diagram
1 tank; 2 pump; 3 the priority valve; 4 load-sensing steering; 5 overflow safety valve; 6 Steering Cylinder;
(Figure 2-12) Working hydraulic system diagram
1 dump tank; 2 Lift Cylinder; 3 distribution valves; 4 oil filter; 5 tank;
(Figure 2-13) ZL20E-04T.QW multi-valve assembly structure diagram
1 safety valve; 2 into the oil body; 3 dump valve; 4 Boom Valves; 5 return oil valve; 6 slide valve; 7 sleeve; 8 the main spool; 9, 13 Spring; 10 valve seat; 11 pilot spool; 12 valve; 14 adjusting screw; 15 over the oil fill valve; 16 one-way valve;
Dump valve for spring return of the three-position valve, which has Po, P, 0 and A, B cavity. Stem in the middle of the chamber when the Po through 0 (see section AA), and stem flow back into the middle of the oil Road mailbox. When the valve stem moves, the stem is cut off the middle of the oil Road, multi-way valve hydraulic imports increased, Po-cavity high-pressure oil will be open one-way valve (16) into two P cavity, and then enter into the working tank A or B, back from the working oil tank directly into the 0 back to the fuel tank cavity.
The machine working device upgrade the boom of a process, the need to dump fuel tank automatic elongation, or four-bar linkage of the campaign will have difficulty in turning this dump valve is equipped with a valve structure with two identical overload fill valve, to prevent an overload, and the other to the system make up the oil, avoid creating a vacuum.
Ball valve boom turned to a four-position valve position, its structure and working principle and the dump valve is similar to the difference is just one more slide valves A, B, and 0-cavity all-pass cavity of the floating position of
Safety valve for the pilot-operated relief valve, also known as variable damping safety valve. The main spool (8) in the weak spring (9) and hydraulic effects, the pressed in the sleeve (7), the sleeve also pressed in the valve seat (10), they are common in the valve A working oil chamber or to return to the oil chamber 0 separated. A hydraulic chamber when it is set over pressure valve, pilot spool (11) to open, oil flows through the slide valve (6), the center hole, due to the role of small resistance, so that a cavity slightly lower than the A-cavity hydraulic oil pressure, differential pressure slide valve that is in this spring under the action of Customer Service (9) role shifted to the right, in-line with the pilot valve try to be, when A-cavity hydraulic force of the slide valve directly passed to the pilot valve to open further large, On the other hand, due to the pilot valve when the center of the slide valve hole blocked, the oil can only be through the slide valve spool the gap with the main flow of the damping effect of this gap than the slide valve of the damping role of the large central hole, so a hydraulic chamber rapidly decreased, the sleeve will be in the A cavity with a cavity under pressure to open quickly.
Under normal operating conditions, A cavity-cavity hydraulic oil pressure is higher than 0, the sleeve, the main spool and the slide valve have been pressed in the seat, when the A cavity below the 0 hydraulic oil pressure chamber, the sleeve, the main spool and the spool valve will be the same as a normal one-way valve, in which open under pressure from the 0 to the A-cavity fill oil chamber.
2. cylinder (Figure 2-14): loader structure and principle of all the tanks is basically the same, is a double-acting single rod piston cylinders, mainly by the cylinder head (1), cylinder (4), Pistons (2), piston rod (5) and seals so on. When the pressure of the oil through the valve into a multi-channel oil-Road, the oil promote the piston shift to the right. Piston to the right of oil flow back through the b oil Road, tanks, piston rod out at this time. By the same token, b into the oil when the oil path, a oil-Road back to oil, piston left, the piston rod retracted, due to the piston rod and the piston are linked, so the oil pressure to the piston on both sides of the role of the different sizes in the same Oil under the action of the piston of the force left by the great.
3. the gear pump (Figure 2-15): the work of hydraulic system and steering gear pump hydraulic system to share CBG2063, the use of work pressure 16Mpa, flow 1201/Min (pump speed of 1900r/min).
The pump is a fixed part of the axial clearance of the external gear pump, the overall structure as the three combined, between the gear face and the side, there is a certain degree of axial clearance, the gear diameter and the pump body bore a certain degree of path to the gap, mainly by the former pump before (4), after the pump cover (9), pump (7), driving gear (3), driven gear (14) etc...
(Figure 2-14) Boom, Bucket Cylinder Schematic
1 cylinder head; 2 piston; 3 Y-ring; 4 cylinder; 5 piston rod; 6 guide sleeve; 7 earrings; 8 joint bearing;
(Figure 2-15) The gear pump Schematic
1 side; 2 Circlips; 3 active gear; 4 the former pump cover; 5 since the tight seals; 6 O-ring; 7 pump; 8 O-ring; 9. after the pump cover; 10 O-ring; 11 bolt; 12 cylindrical pin; 13 roller bearings; 14 driven gear
Pump at work driving gear rotated, so that the oil pump chamber volume increases, the formation of partial vacuum between the two gears, oil pressure in the atmosphere into the pump’s oil-absorbing chamber. Between the two gear oil, was closed by side and the pump cavity, with the gear will rotate out of oil into the oil chamber, pump out the oil in the cavity at one end, due to continuous rotation gears meshing with each other, so that the oil cavity volume, there have been extrusion reduced the oil out of the oil from the mouth to drain out the formation of oil pressure under load.
In the course of oil pump, hydraulic oil flows through the axial clearance into the lubrication of bearings. Flow to the Small End of the oil seal ring through before and after the oil pump cover Road and side of the hole flow back to oil-absorbing chamber. In order to reduce leakage within the pump to maintain the pressure needed to improve the volumetric efficiency of the pump in the drive gear at both ends with sealing ring. Under the action of the hydraulic oil, so that seal ring around the big end of the pump cover in the face close to the ring plane, so that it seals. Sealing ring gear clearance hole and take the initiative to drain oil, because the gap control, to produce a greater pressure drop, therefore reducing the amount of leakage, and eliminate the axial force to ensure the pumps work. , In the pump or pump cover junction with 0-shaped ring is to prevent external leakage, the bearings are equipped with a small ring, in order to prevent leakage, the former pump cover is equipped with self-energizing seal is to prevent the inhalation of air and leakage, and seal with Circlips limit axial movement.
V. The brake system
(Figure 2-16) Schematic diagram of brake system
1 disc brake; 2 air compressor; 3 unloading valve; 4 pressure gauge; 5 afterburner device; 6 reservoir pump; 7 release valve; 8 the brake master cylinder; 9 the brake light switch;
Loader braking system including the foot brake and hand brake system, two independent braking systems. Foot braking system uses four-wheel disc brakes gas cap oil (see Figure 2-16), mainly by the brake master cylinder, afterburner device, composed of disc brakes, brake, foot pedal, pump storage within the The compressed gas directly into the afterburner device through the brake master cylinder to promote the brake fluid into the disc brake of the brake wheel cylinders, thereby creating a braking effect, while the brake master cylinder high-pressure gas into the variable distribution valves shut-off valve piston, the promotion of slide valve down, cut off valve to go forward or backward clutch oil line. So that the main clutch friction plate driven the rapid separation, power was cut, and front and rear axles are not driven so fast and reliable braking. Hand brake system for the driver to leave the vehicle or at the ramp on the parking available, use of external-beam-type parking brake drum hand brake.
Here are the system’s main components:
1. The brake master cylinder
Structure, as shown in (Figure 2-17), the following functions:
When the brake pedal to relax when the piston 5 in the return spring 4 under the action of being pushed to the highest position, the piston face and under the intake valve 6 between the 2 mm gap, pass through the afterburner pump into the valve orifice C center bore similarities with the atmosphere, while the intake valve 6 under the action of the intake valve spring off, this time in a relaxed state of brakes.
When the driver depresses the brake pedal, through the ejector spring balance to exert some pressure, thus promoting the piston moving down, closing the opening in the channel between C and atmospheric, and moved into the top 6 valve, compressed air through the orifice A, the intake valves and orifice C input afterburner pump, resulting in brake. Air flow, see (Figure 2-17).
In the braking state, the orifice C output pressure and a smooth pedal force is proportional to 3, through a balance spring to achieve. When the pedal force is constant, ejector spring tension imposed on the balance, then balance the spring is compressed, the piston upward until the intake valve closed, this time on the pressure force acting on the piston and the pedal pressure imposed on the balance of spring in a state of equilibrium, the output air pressure orifice C for a constant air pressure. 'When the pedal to exert increased pressure on the balance of the spring, when the piston down again, re-open the intake valve, when the piston chamber under pressure to a certain value, the force acting on the piston and the pedal pressure imposed on the balance of spring-phase balanced, the intake valve is once more closed, while the output of air pressure orifice C while maintaining a constant and higher pressure than the original. In other words, the pressure orifice c output while maintaining a constant and higher pressure than the original.
(Figure 2-17) The brake master cylinder
1 pedal; 2 mandrel; 3 balance spring; 4 piston; 5 intake valve;
In other words, the output pressure orifice C and balance spring is proportional to the amount of compression deformation, that is, with the brake pedal board is proportional to the itinerary.
2. The hand brake
Use of external beam-type hand-drum brakes, brake gearbox output shaft, slope on the road to vehicles parking purposes. The hand brake by wire rope is connected with the hand brake lever. Brake by hand brake lever pull rope, so that friction plate to hold fast, pressed the brake hub braking effect on the resulting. Contact brake, hand brake lever back in situ, eliminating tension, friction plate under the action of the spring back, so that separate the friction plate and brake hub.
3. Caliper disc brake
(Figure 2-18)
Caliper disc brake from the inside of the clamp (2), external clamp (5), friction plate (12), Pistons (9) and brake disc (1), etc... Brake disc bolt fixed to the wheel hub, the internal and external clamp with four bolts to connect as a whole, symmetrically arranged on the outer brake disc distance. Brake caliper by four bolts on a flange fixed to the axle, brake disc has been caught in the brake caliper in two between the brake lining, brake friction plate is used hot forming process, the lining system and the cylinder floor riveting, adhesion formed, it adopted two orientation axes hanging brake caliper mounted on the shell, and may be axial movement along the pin.
Both internal and external pliers hydraulic brake wheel cylinders of the pump, in which the two pistons installed. Cylinder wall has opened a trapezoidal cross-section of the ring groove, which loaded rectangular cross-section of the rubber seals, and then point out the small ring groove with dust cover to prevent contamination into the surface of sliding. Brake Wheel Cylinder, including between the two forceps into the hole. Brake Wheel Cylinder may apply to the two at the same time into the oil. Wheel Cylinder Brake Caliper outside between the two there is a through-hole, two pipelines will be their inside and outside the inner and outer clamp 2 Cylinder connectivity.
(Figure 2-18) Caliper disc brake
1 brake disc; 2 internal clamp; 3, 4, fastening screw nut; 5 outer clamp; 6, Pin; 7, dust cover; 8 O-ring; 9 piston; 10 gas discharge nozzle; 11 rubber cap; 12 friction plate; 13 washers; 14 drain plug; 16, 20 hollow screw; 17, 23 washer; 18, 19 bolt washers;
Brake, the brake oil is pressed into the inner and outer clamp in the four Wheel Cylinder, piston oil under pressure, move brake discs, so promoting the disc brake friction plate pressed together with the wheels slow down or stop. At this point the edge of a rectangular rubber ring piston friction due to the role of edges, resulting in small amount of elastic deformation, as shown in (Figure 2-19). Lift the brake, the piston ring by the elastic deformation of the rectangular back position. Although the rectangular seal edge deformation is very small, but generally not able to avoid the brake disc when braking friction plate clamped back arising from frictional resistance.
(Figure 2-19) Brake caliper piston seals in the work of the
a) braking situations
b) the lifting of braking
4. Air compressor:
The compressor is a single-cylinder piston for diesel engine accessories, see instruction manual.
5. Multi-functional unloading valve:
Structure, as shown in (Figure 2-20), the following functions:
Oil-water separation of roles: the impact of valve-type oil water separation within the structure, so that compressed air in the oil-water separation of dirt out of the dump the dump in the dirt inside and automatically discharged into the atmosphere, to prevent oil pollution and corrosion of brake pipes, the system dynamic room in the rubber brake components, parts, causing traffic trouble. Same time, because the moisture in compressed air was discharged because of frozen pipes will not be affected by the winter driving safety.
(Figure 2-20) Multi-functional unloading valve
1 unloading spring; 2 unloading delay piston body; 3 exhaust piston Aprons; 4 exhaust piston; 5 under the unloading valve cover; 6 dirt piled up plate; 7 under the unloading valve cover seal; 8 unloading valve body; 9 exhaust check valve; 10 exhaust check valve spring; 11 unloading valve cover; 12 Spring; 13 adjustment screw; 14 insulator; 15 filter cover; 16 Plate;
Compressor unloading: When the valve to achieve the desired pressure (0.8Mpa), the valve piece exhaust valve opens automatically, so that storage pump and air compressor gas line break, storage pump keep the pressure constant, while the air compressor in the work-load stress-free state. Thereby reducing the power consumption, while the temperature of air compressor is also decreased, to extend the life of the air compressor and belt. When the pressure of less than 0.7Mpa, the unloading valve can automatically restore to the inflatable pump storage.
Improve the system of sealing: This valve has a one-way valves microglia, when the air machine stops working, they can attempt to stop the reservoir pump high-pressure air return, still remain a day and night air way pressure (0.4Mpa) above. Meanwhile, emergency air compressor in the transient fault, since there is such a one-way valve backstop role, not because of pressure within the storage pump caused by the sudden disappearance of an accident.
Foot brake system uses Note:
1. Afterburner device of mineral oil storage cup filling nature of moving fluid, brake fluid was found to be insufficient time to add oil storage cup covered with small holes should be interlinked with the atmosphere.
2. Hydraulic system, mixed with gas will affect the braking performance, replacement parts, and after going to the exhaust cleaning system. As follows:
a. Remove hydraulic lines, fuel storage cups, filling mouth, mouth, etc. of the fouling deflated;
b. oil storage rooms, full of brake fluid;
c. In the deflated deflated by mouth set into a transparent tube, tube placed by the other side of the oil dish, to collect the discharged oil;
d. Pine open air nozzle, continuous riding under the brake pedal until it routed to the liquid column until no air bubbles. Tightened up and deflated and then release the brake pedal mouth. Deflated when the liquid oil storage room below the set value, it is necessary to add a timely manner so as to avoid the air to re-enter the system.
VI. For device and the frame
1. The working unit
The machine working device mainly by the bucket, rod, boom, beams, rocker etc., shown in Figure 2-21. Bucket organizations to adopt "Z"-shaped reversal, single-arm, single-rod structure, characterized by unloading distance, the rise of force, bucket on the turn angle are large bucket pan is good, easy-to-fill bucket, Lifting the process of material not easily spilled. Highest position when the discharge, and then directly down to the lowest position boom, the bucket will be automatically in a shovel into the state. Boom a single board structure, the back-end supporting the previous frame, the front-end bucket attached, central cylinder connected with the boom, when the telescopic cylinder when the boom to boom around its back-end pin rotation, Achieve the bucket raised or lowered. Central rocker arm connected with the movement, when the telescopic cylinder when the switch to the Big Dipper, so that one arm around the rotation between the points of support, through the rod connected to bucket up and down rotation, with the boom and vehicle upgrades advance and retreat, to complete a variety of jobs. Bucket with teeth for the flat-bed type, bucket tooth fixed with studs on the main cutting edge, the bucket teeth can be replaced after wear and tear. As the main cutting edge of serious wear and tear, can be cut to replace.
Working device with forklifts and boom, bucket and rod, rod and rocker arm, rocker arm and boom, boom with the frame, moving tanks and rocker arm with the hinge point with the oil tanks and so, the assembly of gap in the 0.18 -0.34mm between the work occur between the pin and bushing wear. Such as the gap of more than 0.6-0.7 in need of replacement bushing or pin.
2. Frame
Frame of the entire machine to install all the parts to connect the matrix. Mainly by the front frame and rear frame is composed of two, after the same time, with a sub-frame chassis, shown in Figure (2-22). Before and after the frame with the hinge pin hinge formed. Front frame seat in the former bridge, while the above arrangement to work device. Through the sub-frame after frame associated with the rear axle, engine, torque converter, gearbox, steering control mechanism installed in the above, Deng Jun, through the steering mechanism so that the frame before and after the relative rotation around the hinge axis to achieve steering, rear frame and sub-frame with the hinge pin connection. Sub-frame can swing up and down around the center hinge pin 12°, so that machine, when traveling on the bumpy road, still has a good stability.
(Figure 2-21) Working device
(Figure 2-22) Schematic diagram of the frame
1 the former frame; 2 after the frame; 3 sub-frame;
VII. Electrical system
This machine uses electrical system voltage 24V DC, in-line system, negative Datie.
Electrical systems include power supply parts, starting systems, lighting and signaling systems. (Figure 2-23) Schematic diagram of the electrical system
1. Power supply parts
Power supply parts, including batteries, generators, voltage regulator, ammeter, etc... Battery-6Q-75 type, rated capacity of 75Ah, voltage of 12V, 2 batteries in series to use, negative Datie, output rated voltage of 24V.
Silicon Rectifier generators JF2314Y type, rated voltage 28V, rated power of 350W, with the FT211-type voltage regulator supporting the use of. Load generators in parallel with the battery-powered, high-speed operation when the engine when the generator in addition to the load power, the same time, battery charge, charging voltage is controlled by the voltage regulator.
Ammeter is used to detect the battery charge and discharge conditions, the pointer swing to the (+) that the charge put to the (-) indicates discharge.
2. Starting system
QD251A-type starter motor as direct current string of excited, voltage 24V, power of 3. 7KW. With the electromagnetic device and a one-way ball clutch engagement in order to prevent high-speed diesel engine operation after starting the armature resulting damage.
When the power through the starter switch connected with the electromagnetic coil, due to the electromagnetic coil core role will be inhaled through the leverage to drive gear wheel meshing with the points, while connected to starter circuit, so that the rotation starter drives the flywheel turning. When the starting switch off when the electromagnetic coil power supply is cut off, magnetic loss, core iron back to bits, so that drive gear and flywheel ring gear from the same time, disconnect the starting circuit.
Figure 2-19: Illustrative Diagram For Loader Electric System
3. Lighting and signaling systems
Lighting systems include front and rear headlights, small lights, ceiling lights, instrument lights, turn indicator, anti-fog and so on. Signaling system, including speakers, front and rear turn lights, brake lights, flasher, sensor plug and instrument lights.
Electrical system Note:
1. Inspected once a week, and the proportion of the value of battery liquid level. Liquid level should be above the plate is about 10~15mm, surface low can be added to add a small amount of distilled water. Electro-hydraulic ratio not be less than 1.205 in summer and winter of noteless than 1.245, normal range: 1.25-1.26, 1.28-1.29 in winter.
2. Usually should regularly check wiring connector is loose, and kept clean, and timely replacement of damaged joints and broken wires, in order to ensure the normal charging generator, but also check and adjust the generator level of the fan belt tension
3. End of the day or stop for maintenance should be a total disconnect power switch
4. Winter quickly in order to ensure a reliable engine start, glow plug right into the cylinder with the air heated 10-20 seconds.
5. Battery starter motor installation location as close as possible to shorten the length of connecting wire to prevent the pressure drop is too large, the biggest pressure drop are generally not more than 1 volt, connect flat wire with 35 mm low-voltage wires.
6. Rectifier generator maintenance, must not be allowed to use on the way to check ignition power generation, to prevent burnout rectifier components
7. Voltage regulator is a precision electrical appliances in general do not arbitrarily disassemble to adjust. When necessary, special equipment examine and adjust, shut down immediately after the key switch off the circuit to prevent battery discharge to the magnetic field coils, resulting in battery power loss, affecting the next electrification.
8. Starter motor when the current is large due to operation of each start-up time shall not exceed 10 seconds, if we start a row, the gap is not less than 2 minutes, and the starting row number should not exceed 10 times, so as to avoid damage to starter motor and battery.
9. The engine flywheel and the starter motor is not completely stopped rotating, it can not start again, bonding, or may damage the starter motor gear and gear ring.
10. In the engine running, you can not cut off the power switch, because the circuit between the generator and the battery to cut off the damaged generator.
CHAPTER III THE DRIVING AND OPERATION
I. Instrumentation and control equipment
The machine of all control devices and instrumentation as shown in Figure 3-1. The control switch, gauges, lights and control handle movement and function in Table 3-1. Shown in the chart before and after, left, Friends of the direction of the provisions are subject to the machine direction
The work of cultivating the habit of always look at the instrument panel and timely to note any unusual circumstances.
(Figure 3-1) Loader operating mechanism and instrumentation
II. A new car to go together
To extend the life of loaders, new car should be carried out before use to go co-pilot, so that all parts of the friction parts to running-in. This provision also applies to post-loaders after overhaul.
New car to go test period of not less than 32 hours, walking together in the period, the speed gradually from low to high growth rate, loading weight (or traction total weight) may not exceed 70% of the common load and to shovel fitted loose material is appropriate and take the empty co-commissioning and commissioning of suboperations commissioning two steps.
1. Empty for the commissioning of about 8 hours, the steps are:
(1) The method according to the provisions of diesel engine start, the first low-speed interval run for five minutes and then gradually increased to a maximum speed of operation of 10 minutes;
(2) Operation working device joystick boom and bucket joystick, so that boom to upgrade, down, tipping bucket, and close the Big Dipper, about 10-minutes;
(3) Empty running, after the first low-speed high-speed, forward, backward running various stalls are conducted jointly.
2. Empty after the end of commissioning to check the following items:
(1) Comprehensive inspection departments bolts, nuts fastening the situation. Especially the cylinder head bolts, exhaust pipe bolts and front and rear drive axle fixed bolts, wheel rim nut, shaft connecting bolt, etc.;
(2) The adequacy of the fan belt tight or too loose;
(3) Engine, torque converter, gearbox, drive bridges parts are no unusual sounds;
(4) Working hydraulic system, transmission hydraulic system, engine lubrication refrigeration systems, braking systems, engine cooling water circulation system and so whether the oil spill, leakage phenomenon;
(5) The shift is flexible, agile and reliable brake it;
(6) The meter reading is normal;
(7) Of the joystick, throttle rod connection is appropriate or loose;
(8) Whether the process was working device movement jammed phenomenon;
(9) Electrical Systems ministries connection, meter, light signals and generating charging is normal.
3. Operating commissioning inspection and maintenance of the above-mentioned after. To gradually increase the load during operation, action can not be too drastic and too fast and pay attention to observing the different materials in the loader shovel loading capacity. Job commissioning process should also check the commissioning required inspection items.
4. Walking together after the expiry of the following tasks:
(1) The replacement of engine oil, and diesel oil filter cleaning;
(2) Replacement of converter, gearbox and hydraulic system in the oil, and cleaning the filter;
(3) The replacement of the hydraulic system in the oil, and cleaning the filter;
(4) Cleaning before and after the bridge and the wheel-side final drive speed reducer, and replaced with new oil;
(5) Exclusion period found that the failure to go together.
III. Driving and operation
In the driving operation of this machine before, it should read this manual and the engine instruction manual to ensure that the performance of this machine structure and operating methods, technology, maintenance and repair activities have a clear understanding of familiarity with each of joystick position and role of the instrument in order to ensure that the safe.
Driving and operation
1. Inspection and preparation before moving:
(1) To add a little cooling water tank;
(2) Check the engine oil is sufficient;
(3) Check the transmission and working hydraulic system oil is adequate;
(4) To add a little engine oil
(5) Check the tire pressure is adequate, wheel rim nut is loose;
(6) The lubrication of parts to add a little oil or grease
2. Note
(1) Added to diesel fuel must be clean, diesel grades should comply with the prescribed quality requirements;
(2) Gearbox, hydraulic torque converter used in hydraulic drive shaft, the working hydraulic system used in hydraulic oil must be clean and meet grade requirements;
(3) Required regular maintenance and lubrication;
(4) After starting the engine to carry out air moving forward, until the water temperature reached 55°C after the line started moving;
(5) Loader running on the road, because the foot brake at the same time, can cut off the forward or backward clutch oil line, so do not have to brake before the gear lever placed in neutral gear;
(6) When the manipulation of moving arm and turn the Big Dipper to the need position, should be placed in the middle of the joystick;
(7) Diesel engine water temperature reaches 55°C, oil temperature reaches 45°C, allowed full-load operation. When operating the engine water temperature should not exceed 90°C, oil temperature should not exceed 95°C, torque converter oil temperature does not exceed 120 °C;
(8) Shall not be raised to the highest position of the transport bucket materials, delivery of materials should maintain a steady arm and hinge point from the ground 310 mm, in order to maintain a stable driving.
3. Starting
(1) A master switch on the power;
(2) Variable speed joystick and the joystick placed in the middle of working equipment, hand-brake lever on the brake position;
(3) Gates gates into the key switch clockwise to connect position;
(4) Under the accelerator pedal tread half of toggle start switch to the "start" position you can start, a start-up time should not exceed a maximum of 15 seconds, if during this period, the engine failed to start, should be stopped after 2 minutes for the first second start. Such as continuous four or five starter failures and identify the cause of the malfunction should be examined, removed, may continue to start;
(5) After the start, and gradually increase the throttle, so that the engine in the 1200-1400 rev / min speed under the warm-up and pay attention to the instructions of the engine instrumentation is in the normal range;
(6) Winter starting problems, the cooling water will be released, plus a hot water or boiled water re-start, the engine lubricating system when necessary, to add the word 70-80 °C in winter oil re-start, start, they should observe the engine oil pressure, appropriate controls throttle to prevent the bush-burning.
4. Driving and operating
After starting the engine idling warm about 5 minutes later, when the water temperature and oil temperature reached 45 °C or above, a variety of instruments directed at the normal state and the engine running sound, smoke is normal, may release the hand brake mounted file it started to travel.
(1) shovel loaded
II stall speed of the front loader to sail windrow in order to insert the material piles I stall speed, this time working device into the middle of the joystick are, if it is a hard flat concrete floor, then the boom stick into the middle of both position, if it is a hard flat concrete floor, then the boom joystick can be pushed in front, "floating" position, so close to facing the bucket near the piles. Throttle control should be appropriate, that is, to ensure sufficient insertion force, not to make too much wheel spin, so as not to shorten tire life. Loader shovel material tends to be used the following methods:
a. A shovel digging method (see Figure 3-2a), loaders straight forward, so that bucket before the cutting edge along the windrow at the bottom of insertion, insertion depth is about the Big Dipper at the end of its length, loader halt and then use the switch to the Big Dipper fuel tank filled with flip up bucket to bucket.
b. Sub-shovel method (see Figure 3-2b), this approach is that to insert a shovel and upgrade, which is mainly used shovels dug into hard materials.
c. Mining Law (see Figure 3-2c), bucket stacker into 1 / 3 of the Big Dipper at the end of length, loader halt to enhance boom, this method is used to tap the mound.
d. With the shovel method (see Figure 3-2d), loaders move forward into the bucket is not a large stockpile depth (approximately 0.2- 0.5 at the end of the length of the Big Dipper), the loader to move forward at the same time, upward turn transfer bucket or carrying arm (see Figure 3-2c).
Note that the inertia may not be high-speed lane to the windrow dash, spade store items, the speed should be less than 4 km / hr.
(2) Transit
Bucket full throttle and then decreased, working to re-pull lever "neutral" position, hung back a file out of piles. If the transport distance is longer, need to be upgraded to the transport position bucket and then driving to make the machine even a good stability. If the consignment is expected in the vicinity of the truck, you can continue to lift out to the appropriate height of up unloading.
(3) Discharge
a. Boom Bucket give rise to higher than the carriages, while I speed loader in order to close to the railway carriage;
b. When the bucket higher than the rear compartment and enter the unloading area, the switch to the Big Dipper joystick slowly pushed forward to the "next turn" position, so stop lifting boom, bucket in the material began to flow out;
c. Depresses the brake pedal to stop the car and continue to flip bucket until it is expected to unload the empty, such as fighting within the adhesive material, may be pulling back and forth Bucket joystick, bucket shake a few times, so that material falling;
(Figure 3-2) Loader shovel method of materials
(Figure 3-3) Loader practices
d. Tipping joystick pulled "Flip" position, Shoulong bucket, changing to the rod placed in the "back" position, release the brakes, loaders back out, retreat to leave the carriages, the down boom for the next load action.
Note:
Discharge, the bucket will not move to more than the necessary height, the material should be as evenly mounted inside the car.
(4) Working mode:
Loader and dump truck with the job, its most widely used operating in the following ways (see Figure 3-3).
a. "I"-shaped working method (see Figure 3-3a) dump truck back and forth parallel to the face to move forward and backward, loaders perpendicular to face forward and backward. Loader forklift truck filled, the straight line back some distance from the loader back process, and to give rise to uninstall the bucket position, dump truck and loader back to the perpendicular to the appropriate location, in the forklift
unloading, the dump truck forward some distance, advancing towards windrow loader shovel loading of materials, for the next cycle of work.
b. "V"-shaped working method (see Figure 3-3b) dump truck into a 60 ° angle with the face. Loader bucket filled after the U-turn back the course of 60 , so that perpendicular to the dump truck loader.
Raise sail dump truck and then unloaded. Loader dump truck unloaded and then turn around and sail away from the stockpile, a job the next cycle.
c. "L"-shaped working method (see Figure 3-3c) dump truck perpendicular to the face, shovel loaders loaded materials, the back and turn around 90°, and then towards dump truck, loader no-load back turned 90 ° to sail to stockpile for the next cycle of a job.
5. Parking and flameout
(1) Reduce the engine speed, and depresses the brake pedal, you can stop;
(2) The shift lever placed in neutral gear position;
(3) Release the brake pedal, tighten hand brake lever;
(4) The operation of the engine idle speed 3-5 minutes so that the ministries uniform cooling;
(5) Working device affixed to the flat to the ground, the handles are placed in the middle position;
(6) Filed flame bolt, so that the engine flameout, it will turn off plug-refoulement in situ;
(7) Pull out the gates key, pull down the overall power switch and lock the doors;
(8) Winter park, it should promptly release valve open all screw let go all the water cooling system, such as water antifreeze and Canada do not need to release;
(9) Temperature to -20°C ~ -30°C, it should remove the battery, moved into the warm house to avoid Frost Crack.
IV. Security Note:
1. The driver must have a full driving license, familiar with the machine manual and engine specifications, and in accordance with the provisions of which the use, repair, maintenance;
2. Boom bucket to stand on the next strictly prohibited;
3. Turns must be slow to ban U-turn and slam the brakes, no high-speed driving in the rain and snow, and pay attention to avoid turning on the slope;
4. Strictly prohibited when the engine flameout downhill, steering, hydraulic steering failure thick to avoid accidents;
5. After the bucket load shall not exceed the transport location of high-speed traffic;
6. Loading the goods are not allowed when the focus of bias;
7. Does not allow work overload traffic;
8. In addition to tightening handbrake parking ramp, the wheels with a triangular wooden mat well;
9. Loaders shall not be parked near a fire;
10. Meter readings and pay attention to whether it is normal
CHAPTER IV TECHNICAL MAINTENANCE
Loader work environment is more difficult, the mechanical vibration or due to the strong collision, so that the machine parts easier to loose or damaged. In order to ensure the normal operation of loaders, extend service life and take preventive measures to reduce the loss of regular users of the machine’s technical maintenance to keep it in good technical condition. This chapter introduces the addition to the engine other than the part of the technical maintenance, technical maintenance of the engine with the engine, follow random instructions for use.
I. Loaders water, oil grade and drain table
II. Tire maintenance:
1. Installation, within the tire, wheel rim and the liner band, lock ring must be complete good, clean, wheel rim, lock ring should be pre-painted steel anti-rust paint, does not allow flying edge, burr, scratches and other defects to prevent damage within the tire.
2. Maintaining proper tire pressure: tire pressure is too large, the canvas and rubber matrix by the expansion force is too large, easy to break. On the contrary, tire pressure is too small, so that sidewall bending too much and make, the tire and the wheel rim between the relative sliding, resulting in increased wear and tear.
3. The correct assignment is an important factor in improving tire life. Under normal circumstances prohibit brakes, emergency start-up and high-speed cornering, try to avoid slipping phenomenon during operation.
4. Tire to avoid oils, chemicals (pH, etc.), paint and other contacts.
5. The machine used tires should be transposed after a certain time, before and after the crossbar switch
6. If long-term parking, the machine should be lifted, so that tire off the ground, and avoid direct sunlight.
III Regular maintenance
1. routine maintenance (daily)
before moving off, came back after the daily maintenance
(1) Check the radiator water, fuel tank and fuel tank work, gearbox oil, brake master cylinder brake fluid volume, the oil level must be added to the provisions of positions. The Department is to add a little grease lubrication;
(2) Check tire pressure and shape;
(3) Check whether the manipulation of flexible, reliable, and braking reliability, signal equipment is intact;
(4) Whether the abnormal engine noise after launch, the instrument is normal;
(5) Whether the various parts of oil spills, leaking place;
(6) Gearbox, torque converter, oil pump, front and rear bridges whether overheating;
(7) Check whether the loosening and loss of fasteners and screw them tight and filled;
(8) Winter operation returned, should pay attention to the engine and water drainage (except when added antifreeze).
2. Weekly technical maintenance
(some work 50 hours later)
In addition to routine maintenance, the need for more of the following maintenance:
(1) The entire vehicle injection pressure of all butter, grease the mouth;
(2) Fastening bolts drive shaft, drive axle bolts, tire nuts and other fasteners
(3) The clean air filter, diesel filter and the gearbox, the working fuel tanks and hydraulic system oil filter;
(4) Check the brake rod in hand, foot brake pedal, shift lever, throttle pedal travel is the gap and meet the requirements, which do not meet should be adjusted;
(5) Check the battery electrolyte within the height and the proportion of liquid, such as the lack of proportion and the charge should be adjusted;
(6) Check the bucket, boom, rocker ministries are nondestructive crack Songkuang phenomenon.
3. The monthly technical maintenance
(about 200 hours of work later)
In addition to daily, weekly technical maintenance, the need to add the following items;
(1) Check the drive axle, wheel side gear reducer oil level, added the provisions of the oil level;
(2) Check the hand brake, foot brake wear, and adjust the clearance;
(3) Check the steering parts of space and be adjusted.
4. Quarterly technical maintenance
(about 600 hours of work later)
In addition to daily, weekly, monthly technical and maintenance projects, need to add the following items:
(1) According to the seasonal change to replace appropriate grade of fuel, oil, gear oil, grease, etc.;
(2) Check the Multi-way valve, all kinds of tank leakage, if the working device sinking serious repairs should be excluded;
(3) Check whether the brake master cylinder sleeves for damage.
5. Technical maintenance every six months
(about 1200 hours of work later)
In addition to daily, weekly, monthly, quarterly technical maintenance projects, need to add the following items;
(1) The replacement of all fuel, oil, transmission oil, hydraulic oil, gear oil, brake oil, and to pipe, tubing, filter and so clean, and then purified by adding the new oil;
(2) Take apart and wash brake master cylinder, brake wheel cylinders, check the braking effect and whether it back bit sensitive;
(3) Examine and adjust the main driving spiral bevel gear pair meshing prints and space, and adjust to the specified scope;
(4) Check the torque converter, gearbox, and steering the use of performance, if necessary, the disintegration of inspection.
6. An annual technical maintenance
(about 2400 hours of work later)
(1) Drive axle and the wheel side of the main transmission reducer decomposition of inspection, replacement of wearing parts;
(2) Gearbox, torque converter disintegration of inspection, replacement of wearing parts;
(3) Steering priority valve disintegration of inspection;
(4) The dissolution tank inspection, replacement of seals;
(5) Check front and rear frame, the working parts of deformation and damage equipment, and correct distortion, repair damaged parts;
(6) Of the shaft the disintegration of inspection, cleaning oil change;
(7) Engine in accordance with its instructions for use. according to the provisions of
CHAPTER V COMMON FAULTS AND EXCLUSION METHOD
In order to facilitate users to understand and to exclude the general failure loader now introduce some common symptoms, possible causes and elimination methods, the diesel engine fault and troubleshooting, see engine manual
I. The whole
II. Transmission
III. Steering systems
IV. The brake system
V. The working hydraulic system
VI. Electrical system
CHAPTER VI THE TRANSPORT AND STORAGE
I. The transport loader
1. Self-transport for short distance travel on their own should be followed by "new motor vehicle to go together, " the provisions of, and pay attention to speed should not exceed 20 km/h, torque converter oil temperature should not exceed 110°C, the engine temperature, oil temperature can not be Chao Guo 95°C, the engine oil pressure normal way to discover if the temperature is too high, oil pressure is not normal, it should stop cooling or maintenance.
2. Traction traction transport transportation was slow, but not enough security can only damage the engine or hydraulic drive system does not work when used as an emergency from time to time, traction to the front and rear axles when the drive shaft gearbox apart to avoid damage to transmission box and shift clutch, the car should the driver to manipulate the direction of traction speed to 5 km/h or so is appropriate.
3. Long-distance transport long-distance transport by rail, car and shipments, in addition shall comply with the relevant provisions of the transportation sector, we must also do the following preparatory work;
a. Before and after each wheel chock with a triangular solid, front and rear is best to use thick wire rope, or fixed, to prevent rolling;
b. Tighten parking brake lever, and put flat rear compartment on the bucket;
c. Disconnect the power main switch, all kinds of joysticks on the gap position, locked the door;
d. Winter or sent to the cold region, should put the engine cooling water inside the net.
II. The storage loader
After operating the loader need long-term storage. The following provisions should be kept.
1. Check points in different parts of the fuel oil, add a little clean grease;
2. Batteries should be taken off, should be kept dry inside the house, a monthly charge;
3. The machine put up, so that tire vacant;
4. Every air operation starting in January once;
5. Will be deposited in the Treasury or the shed loaders, such as the application of waterproof cloth carefully kept open cover;
6. Release of cooling water;
7. Will be pulling up to the brake hand brake lever position
8. The working device to manipulate the joystick slowly several times to remove residual pressure inside the cylinder, and tubing on the interval after, the gear lever placed in neutral gear.
Comments
Post a Comment