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Use, maintenance and common fault treatment of side discharge loader
Release time:
2023-01-03
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Use, maintenance and common fault treatment of side discharge loader
Use of (I) side dump loaders
1. Preparation before homework
(1) Voltage check: When using 1140V voltage (motor Y-shaped wiring), the power supply cable should not be smallAt 25mm³; At 660V (motor △ connection), it shall not be less than 35 mm³. The machine works under rated conditions.During operation, the voltage change measured at the inlet side of the explosion-proof switch box shall be within ± 10% of the rated value.
(2) Cable inspection: check whether the cable suspension is reliable before starting the machine, and the cable should always be maintained when the machine is workingIn the sagging state, the cable shall not bear additional tension. The cable can be suspended with random tape.Set, can also be manually pulled, available soft rope belt, one end tied to the cable sheath, the other end tied to a wooden handle,Hear in the hand. The cable shall not be dragged and rubbed on the roadway floor.
(3) Motor inspection: test the steering of the motor. Seen from the rear of the motor, the motor fan should rotate clockwise;When the direction is opposite, stop the machine immediately and change the direction by changing the bit sequence of the commutation line.
(4) Inspection of the whole machine: check whether the parts of the machine are damaged and abnormal sound, and check whether the hoses can beBy fixing, whether the hose skin and the frame, bucket, bucket arm, oil cylinder and other components are rubbed and squeezed.
(5) Track inspection: check the tension of the two tracks. The crawler is in the support chain wheel and the guide wheel (or drive chain.Wheel) sag between 15~30mm.
(6) Brake inspection: test the braking performance on flat ground and adjust in time if any problem is found.
(7) Leakage check: check the hose joints, hydraulic component seals and oil plugs for oil leakage.
(8) Check whether the bolt pre-tightening force of each part is loose or not.
(9) The driver should use the handrail to get on the machine from the left side of the machine. It is strictly forbidden to pull the multi-way valve operating handle horizontally.Do not step on the hydraulic tubing.
(10) The driver should sit correctly, pay attention, and hold the operating handles on both sides with his left and right hands,According to the different operation process of the machine, take good care of the front and rear supporting equipment, personnel and cables.
(11) The driver can operate after confirming that there are no people and other machines and tools in the front and back and on both sides, and pressing the warning bellMove the machine. Before loading rock, the roadway in the operating range of the machine should be cleaned up, the bucket should be leveled and pushed flat.Remove obstructions. In case of unblasted protruding rocks on the base plate, blasting method or pneumatic pick shall be used to remove them. FootwearThe belt is not allowed to cross obstacles higher than 20cm.
(12) When loading, the side unloading oil cylinder must be reset, and the lifting oil cylinder and the bucket oil cylinder are adjusted through the working mechanism.Full bucket shoveling angle.
(13) When loading rock, there must be a special person to monitor the cable. The person is located 5m away from the machine with a whistle,A shutdown signal is issued immediately when a problem is found.
(14) After the machine bucket is shoveled into a certain depth, the bucket is turned over in time and moderately by pulling the bucket cylinder to lift the bucket.The filling coefficient of the high bucket reduces the load of the machine in time.
(15) When the machine encounters large scattered rocks during walking, stop the machine and move the scattered rocks away; the machine is strictly prohibited.Crawlers rolled over large rocks. When the operation is blocked, the handle should be quickly restored to the neutral position to avoid the overflow of the system.Hot.
(16) Reduce the number of frequent starting and inching. Do not pull the handle back and forth to avoid pressure shock.Machine start, stop to be accurate, stable, under normal circumstances, and strive to complete a loading and unloading cycle action, machineThe device advances and retreats once.
(17) Avoid unnecessary turns and sharp turns as much as possible, and avoid twisting, shaking from side to side, andForklift collision. The walking track of the machine should be gentle and smooth.
(18) The driver should operate calmly, hand posture should be correct, push forward and pull backward with soft strength and smooth direction,The timing is appropriate, the operation pays attention to accumulate experience, and grasps the word "degree.
(19) The driver must first confirm that there are no people and no other machines and tools on the front and rear sides, and give a clear notice to the assistant driver.The mobile machine can only be operated after the alarm. The driver should be skilled in loading and unloading, so that "three accurate, four noteItaly, five strictly prohibited, six do not pack ".
Three accurate: bucket landing, unloading (must try to reduce the height of the bucket, after unloading the bucket must beTo reset) and pull the cylinder to move smoothly and accurately.
Four attention: pay attention to the surrounding personnel; pay attention not to collide with the bracket; pay attention to the machine not to press the cable; pay attention to the rock pileAn unexploded explosive detonator.
Five is strictly prohibited: it is strictly prohibited to dig ditches with a bucket; it is strictly prohibited to push or pull heavy objects and tramcars forward after the bucket stands on its side;It is strictly prohibited to use a bucket to collide with large rocks that have not been blasted; it is strictly prohibited to use a side dump machine to frequently dump rocks when there is no mine truck; whenWhen the bucket is lifted without reliable support, it is strictly prohibited to work under the bucket.6. No loading: no loading of gangue larger than 80cm; No loading when the machine is ill; No loading when the unloading distance is more than 10m;Do not install it when there is no illumination; do not install it when there is no monitoring cable; do not install it if the top and support are unsafe.
(20) When the machine encounters large scattered rocks during walking, stop the machine and remove the scattered rocks; the machine is strictly prohibited.The crawler rolled over large rocks. When the operation is blocked, the multi-way valve handle should be quickly restored to the neutral position to avoid hydraulic pressure.System overflow heating.
(21) In case of shotcrete operation, the machine shall be withdrawn from the operation area and covered with shed cloth to preventDust. Before blasting, the machine should be withdrawn 50m away from the working face and the bucket should be lifted to prevent lighting and operating valves.The pole was destroyed by the collapsed stones (the exit distance can be stipulated by the mine safety department, and the principle of not damaging the machine is taken as the principle).
(22) The driver must be calm when emergency stop is required under special circumstances (such as the operation valve cannot be reset).There is an oil pump motor button and a remote power control button on the operation panel directly in front of the driver. Press any buttonCan be forced to stop.
(23) After the operation is completed, the machine exits the working face to a safe place to park, the bucket falls to the ground, and the oil pump motor is stopped,When each handle is reset to zero position, the master shall stop the switch handle at zero position and stop the main power supply. If necessary, use sleepers, etc. as baffles,Protect the front lighting lamp to avoid collapse during blasting.
(24) Check all parts of the machine, clean (flush) the outer surface of the motor, multi-way valve, crawler frame,Mud and sand dirt on the cylinder piston rod. Conscientiously implement the shift system and fill in the work diary.
(25) Shutdown procedures.
① Laydown the bucket and stop the machine horizontally. When working on a slope, you shouldFirst, place the machine in an oblique horizontal state relative to the roadway (the bucket faces the side of the roadway), and then use the pre-prepared specialPad the crawler with wedge-shaped block. ② Power off, release system pressure (working mechanism hydraulic system through operationway reversing valve pressure relief).
(26) Restart the program.
① Find out the location and cause of the system failure; ② If the failure is handled or moreWhen changing components, the system is polluted, and local or system cleaning should be carried out. ③ Confirm again that the components and hydraulic connection are positiveIt is correct and the electrical connection is correct; ④ Adjust the adjustable components to a safe state; ⑤ Check the fuel tankLiquid level, appropriate oil replenishment; ⑥ Alarm, notify all personnel present to start the machine soon; ⑦ Start the system, one by oneGradually increase the external load; ⑧ Bleed as required, operate the reversing valve to extend the piston rod of the oil cylinder and retract it several timesThe oil cylinder does not crawl and there is no lag in operation, and then re-tighten the bleed screw plug.
(27) Emergency shutdown procedures.
① In case of emergency or sudden power failure, use this procedure; ② SystemDo not panic when the movement fails (especially when sports car on a slope), but lower the bucket quickly until undercover.State, the rock loading machine will stop due to increased resistance; or pull the walking handle to make the whole machine stop close to the side of the side.The car, but the angle between the machine and the roadway gang is not easy to be too large, otherwise there will be a danger of overturning; ③ In case of sudden power failure,Operate the triple valve and the bucket falls under the action of gravity until it is close to the ground.
(II) maintenance and common fault handling
1. Debugging
(1) If necessary, re-adjust the hydraulic system pressure of the rock loader (the system pressure has been set at the factory,If the machine does not appear abnormal phenomenon, generally do not change the set pressure value). Pressure of relief valve of working mechanismThe force setting value is 16MPa.
(2) Hydraulic system pressure adjustment method: the bucket arm lift cylinder or pull bucket cylinder telescopic to the limit overflowposition, open the pressure gauge switch and adjust the overflow valve on the multi-way valve until the pressure shown on the pressure gauge is16MPa. Pressure regulation of the hydraulic system of the traveling mechanism: the bucket can be pushed against the gangue pile, and the traveling reversing valve can be adjusted.The overflow valve of the, read the overflow pressure 21MPa on the pressure gauge.
Note: The pressure setting value of the overflow valve on the multi-way valve has generally been adjusted during the factory test.Pressure adjustment should be careful to prevent excessive pressure damage to the system.
(3) Adjustment of caterpillar overhang. Inject butter into the tensioning cylinder through a high-pressure grease gun (tensioning shoebelt) or unscrew the one-way valve seat to release the butter (loosen the track), between the track support sprocket and the guide wheel sprocketThe sagging amount should be controlled within the range of 15~20mm.
(4) Brake adjustment. During the test run, the rock loader will be driven into the slope of the working face less than 16 °, stopped, andThe lower slip is not more than 10 mm/s, and the balance brake valve needs to be adjusted. Adjustment method: in the shutdown state,Adjust the adjustment screw of the balance brake valve with the Allen wrench, and turn it clockwise for 1/4 turns (pay attention to the balance of the twoThe brake valve needs to be adjusted at the same time), and then the climbing test is done until the slip requirement is met.
2. Routine maintenance of the machine
(1) The machine should be cleaned (washed) every shift to remove the accumulated gangue and cement mortar (pay special attention to cleaningexcept for gangue and mortar at the heat sink and foot brake of the walking motor).
(2) There are 11 pin shafts on the working mechanism that need to be filled with lubricating oil at least once a week. The specific location is2 upper and lower pin shafts of side unloading cylinder, 4 upper and lower pin shafts of bucket arm, 1 main pin of side unloading cylinder, up and down of bucket pulling cylinder2 pin shafts, 2 pin shafts on the upper part of the lifting cylinder. It is permitted to pour lubricating oil directly into the hinge gap with an oil can.
(3) Timely remove foreign matters such as gangue, steel drill and wire rope squeezed into the crawler.
(4) Timely tighten loose track shoe bolts and structural connecting bolts, and immediately change those that cannot be tightened.Change.
(5) The reducer bleed plug is blocked when leaving the factory. When the reducer has a high temperature rise, it can be rotated.The lower plug opens the vent hole.
(6) Open the air filter, insert a clean slender iron wire into the oil tank, check the hydraulic oil level,The liquid level should not be lower than 2/3 of the tank height.
(7) Check whether each pipe joint leaks oil. Check whether the sealing ring of the hose connector is damaged and whether the U-shaped clamp isShedding off.
(8) Check whether the hoses are squeezed or worn.
(9) Check the tightening of the low pressure pipe clamps and the binding of the hoses.
(10) Hoses or seals shall not be removed and replaced in harsh environments, with oil leakage or after removal and replacement,Do the tank level check again.
3. Daily maintenance of electrical system
(1) The machine shall not be parked in the place where there is water in the roadway.
(2) The insulation and withstand voltage of the system should be checked at least once a month before use.
(3) Check and adjust the opening distance and three-phase synchronization of the vacuum contactor contacts.
(4) Check whether the protection function of the electronic thermal relay and the inherent safety circuit are normal.
(5) Check and tighten the thread ends. The active mechanism of the conductive part of the vacuum contactor is regularly filled with graphiteGrease (or molybdenum dioxide), add lubricating oil to other movable parts.
(6) Check the button every month, apply anti-rust oil on the button rod and the explosion-proof surface.
(7) Check the explosion-proof surface of the electric cabinet and apply antirust oil regularly (monthly) according to relevant regulations.
(8) Check the fastening of bolts on the electric cabinet and motor, and the fastening of cable inlet and outlet wires (eachmonth).
(9) Check whether the electrical components and terminals in the electric cabinet are loose and whether the locking mechanism acts correctly.Regular and flexible; Check each button, clean the inside and apply appropriate anti-rust oil on the button rod and explosion-proof surface (monthly).
4. Precautions for hydraulic system
(1) When there is pressure in the system, do not loosen the joints, remove the fastening threads and any hydraulic components:After the pump stops, the working mechanism should be unloaded, and the bucket and bucket seat should be reliably padded; the machine should be parked horizontally,Avoid the presence of pressure in the travel motor system; after checking and confirming that there is no pressure, the element in the system can be removed.pieces.
(2) When repairing the hydraulic system on site and on the ground, be sure to ensure a clean environment and prohibit pollutants from enteringin the hydraulic system. Before loosening each connection, scrub the surface of the component or connector and apply it after removal.The specified plug immediately seals the opening. The removal of hydraulic components must not wear gloves, do not scrub with silk floss. ToSystem refueling must go through the oil filter.
(3) The oil pipe shall be replaced immediately after it is damaged, and the newly replaced soft and hard pipes shall meet the requirements of the system pressure. NewBefore the installation of the hose, it is necessary to use compressed air to blow off the dirt on the inner wall and check that the nozzle is free of burrs. Hard metal pipePickling shall be carried out. Immediately plug the tubing with the corresponding cap after cleaning.
(4) Refueling: Only clean special sealed containers are allowed to store hydraulic oil, which should be passed during ground maintenance.The oil filter must fill the machine at the construction site through the top return oil filter on the auxiliary oil tank of the machine.Oil, clean the oil filling port and hose with a clean, lint-free cloth before filling. Note: When refuelingThe liquid level shall be controlled to a moderate height according to the requirements of this operation procedure.
(5) Replacement of components: The model of the replaced components must be correct. When replacing the components,Seals should be prepared in advance, the original old seals must be replaced, not secondary use. Threaded fastenersTo tighten evenly and one by one, do not make individual bolts stressed too much, causing deformation of components, adjustable components,If the constant power change point of the variable pump, the safety liquid flow valve on the multi-way valve should be reset.
5. Hydraulic system inspection and maintenance
(1) Liquid level inspection: low liquid level will cause damage to the suction of the oil pump, and each shift should use the auxiliary oil tankThe oil needle checks the height of the liquid level and replenish oil in time.
(2) Oil temperature inspection: The maximum allowable working temperature of oil flow is 70 ℃. When the temperature is too high, it will accelerateThe aging of the oil, the life of the seals and hydraulic parts will be significantly shortened, the leakage will increase, and the system efficiency will be low,Therefore, attention should be paid to the detection of oil temperature changes. If the oil temperature rises suddenly, stop the machine immediately to check the oil sample or component work.Condition.
(3) Oil quality inspection: visual observation can be used to preliminarily judge whether the oil is aging and deteriorated.
Dark color: caused by oxides in the oil, due to overheating, incomplete oil change, or mixed with other oilsLiquid.
Emulsification: The contaminant is water or foam due to water or air intrusion.
Water-liquid stratification: the contaminant is water, which is caused by water immersion or humid cold air entering the oil tank for condensation.into water droplets.
Bubble: The contaminant is air, which is caused by low liquid level or air leakage in the suction pipe.
Suspended or sediment: the pollutants are solid particles due to oil aging and abrasion.Oil emits tar smell: it indicates serious aging and is caused by fever.
(4) Oil change: Under good management, the oil in the machine must be replaced once a year.
(5) Filter inspection: Each shift should check the filter, and the oil temperature should reach the normal working temperatureCheck at 45 ℃ ~ 55 ℃; if the oil filtration resistance is still too high at this time (indicating that the gauge needle is in the red area)The filter element should be replaced, and the old filter element cannot be used again.
(6) The scale on the inner wall of the cooler shall be cleaned with a special cleaning agent every six months.
(7) Inspection cycle: each shift (liquid level, oil temperature, filter, noise, pressure, leakage, brake);Monthly (liquid level, oil temperature, filter, pressure, leakage, noise); every six months (cooler, oilsample.
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