Chapteri Use 、 Product Features And The Main Performance Parameters [PDF]

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ChapterI Use 、 product features and the main performance parameters 1、use and product features Loader cars develop and manufacturing is according to the JG/T91-2000 standards, the cars are suitable for the construction sites,cement and precast factory,lime kiln,the battlefield and other bulk materials handling and stacking ,and also can be used for large-scale farms garbage removal. A、The cars use articulated frame,full hydraulic power steering.easy operation,radius of gyration is small,narrow space in operation,the completion of a large loader can't be done. B、The machine structure is simple, easy maintenance, most parts with domestic standards, common parts, reliable, well-resourced parts. C、The machine working device is hydraulic control, high efficiency, save a lot of labor force. 2、main performance parameters Item Type Rated loading quantity(kg) Rated bucket capacity(m³) The whole quantity(kg) Engine type Rated power(kw) Rated speed (r/min) Dump heights(mm) Distance of discharge(mm) Boom rise time(s) Boom fill time(s) Discharge time(s) Min.swerve radii(mm) Overall size (l×w×h)

ZL-908

ZL-910

ZL-912

ZL-915

ZL-916

ZL-920

ZL-928

ZL-930

ZL-932

800

1000

1200

1500

1600

2000

2000

2200

2400

0.3

0.45

0.5

0.5-0.6

0.7-0.9

1.0

0.9-1.05

0.9-1.1

1.2

2150

2150

3000

3280

3580

5500

5600

5700

6000

Chang chaiL24

Chang chaiL28

QC480G 485

485

490

41024105

41004105

41054108

4108z

17.6

20

26

35

38

51

55

52、60

74.9

2200

2200

2400

2200

2200

2200

2200

2400

2400

2700

2700

2700

2880

3300

3100

3600

3600

750

750

750

800

850

≥860

≥860

≥860

≥860

6

5

5

5

6

5

5

5

5

4.5

4

4

4

4

3

3

3

3

1

1

1

1

1

3.5

-

-

-

3500

4200

4500

4600

4650

≤3700

≤3700

≤3700

≤3700

4260×1520

4260×1520

4400×1620

4950×1600

4950×1600

5470×1700

5470×1880

5850×1880

5850×2200

×2200

×2200

×2300

×2550

×2650

×2680

×2700

×2700

×3000

1

2900/ 3160

ChapterII

Structure of the main components and

installation adjustment

1、Engine system Mainly includes the engine, air filter, muffler, and throttle control systems. A、Engine On the diesel engine structure, performance parameters, use and technical maintenance instructions, see immediately brought about by the use of diesel engines. B、Filter: Filter the air of dust and other magazines, improve cylinder, piston life. C、Muffler: To reduce the noise diesel engine scheduled to reduce environmental impact.

Picture2-1 ZL15Loader car view picture 1、bucket 2、handling block 3、tire 4、drive axle 5、shaft 6、frame 7、minor shifter 8、main shifter 9、hood 10、seat 11、Driving shed 12、Steering 13、Electrical and Lighting 14、Multi-way valve 15、Hose 16、Glass 17、Arm Lift Cylinder 18、Arm 19、Bucket Cylinder 20、Rocker 21、Bar 2、Rotation System

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A、The engine through the triangle connecting belt and clutch to achieve power transmission capabilities. Triangle tape tight or too loose to be fit, too loose will make a serious skid tape, plus poly V-belt early wear and tear, shortening their service life; tight tape and other relevant parts would force too much, resulting in damage. V-belt in the use frequently affected by tension-compression deformation, resulting in relaxation and, therefore, should be periodically adjust belt tightness. Adjusting belt tension along the rack through the engine before and after the move to achieve. （1）Release the engine support plate and rack connected to four connecting bolt; （2）Adjusted so that the engine thrust bolt move forward or backward along the rack; （3）In the middle of each V-belt 49 Newton force to impose its sagging amount of 10-15 mm, the belt tensioning degree of the right triangle; （4）The four fixed bolts fastening the engine. Important notes (1)In use to prevent the tape dip oil, mud and water, often tape-round slot of the dirt removed, so as not to reduce the friction coefficient. （2）Not free to use adhesive tape to reduce the number of replacement can not be used to replace the old and new into a group different from the triangular tape of different lengths (4 tape length difference of less than 5 mm). 2、Clutch Loader clutch for the two-piece, dry, often bonding friction. Clutch is used to pass or cut off the engine power, and the protective role of transmission. The temporary separation clutch, hanging files and allows a smooth shift loader, smooth clutch engagement can ensure a smooth start-loaders. 1、Frame Mainly by the active part of the clutch and driven parts, parts and other components to manipulate the composition, as shown in Figure 2-2.

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Picture 2-2

clutch

1、Tape Wheel 2、DISC 3、Active Disk 4、Tape Wheel Cover 5、Bearing 60204 Bearing Caps

8、Spring

6、Nut M16 7、

9、Bearing 60206 (four-wheel drive 60207) 10、Circlip 11、Platen 12、

Adjustment Screw 13、Pin 14、Separation lever drive 688,909) 16、Separation Claw

15、Separation of bearings 688,808 (four-wheel

17、Bearing Caps

18、Separation Claw

Does not allow the clutch friction surfaces contaminated with oil, if oil-stained with kerosene should be cleaned, dried after the assembly to use, otherwise it would cause the clutch slip and accelerate the wear and tear.

Picture2-3

Coupling operating mechanism schematic drawing

(20-30mm /Pedal free travel) 1、 clutch pedal 2, return spring 3, drive shaft 4, clutch rod 5, fastening nut 6, rod connector 7, the clutch wheel tape 2、 Clutch Adjustment The process of clutch in use, spare parts continue to wear and deformation, especially the driven plate wear, so that separation lever to reduce the gap separating bearing face, so that three separate levers head not in the same plane, and may even make the head and separate separation lever bearing cross-section contact, resulting in incomplete or slipping clutch such phenomena, it is necessary to adjust the clutch on a regular basis. In the pedal back to places where the separation and separation of bars bearing a part of the gap end 3-bit 0.5 0.2 mm, see Figure 2-3 three separate ends of lever 3 (with separate bearing contact locations), must ensure that the same rotating the plane if they do not meet the requirements, by adjusting the screw 5 on the adjustment nut 4. As the driven clutch plate friction plate wear and clutch pedal free travel will be reduced accordingly. If we do not adjust, but also make the clutch slip speed up the friction plate wear and tear, which is in use should also be adjusted periodically. By adjusting the working length of the rod 4 may be the freedom to change the pedal travel, pedal free travel and normal bits 20-30 mm. After adjustment loaded pin, cotter pin and tighten nut firmly fixed.

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3、 Clutch Bearing Lubrication Clutch Release Bearings and bearing 5,9 is a clutch assembly when Grease. Clutch Release Bearings only have a corresponding movement of separation, using an infrequent basis, usually without the need to increase separation of the external bearing grease. 1000 hours at work or use were found bearing a sound only when it will be removed to check the separation of bearings, wash into the heat melting Na-grease, until the infiltration full bearing until grease cooling out, wipe the outer surface of , and then loading to use. The remaining two rolling bearings 5,9 at 1000 hours when the filling grease maintenance, careful not to make too much. 4、 Transmission Variable-speed gearbox in part by the main and sub-transmission combined into six forward and one back files, transmission line, shown in Figure 2-4.

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picture2-4 ZL05、06Shaft diagram 5. Gland 10.Ⅱ.Ⅲ.Ⅳ Shaft left bearing cap 12.Ⅱ~Ⅵ Axis dial file fork 13. Ⅱ. Ⅲ.Ⅳ.Ⅵ .File slider 14. Ⅱ.ⅤRod slider 15. Vice-shift fork 17. Slider to the left cover 19. Vice-speed slider 23. Gland 26. BallФ10 27. Spring 29. Interlocking round pin 31. Slider to the right cover 32. Rolling 30633. Circlip 34. ⅠShaft gear 36. Ⅰ Shaft 37. Bearing sleeve seat 39. Rolling 1.2205 40. Ⅰ Shaft 41. Vice-speed low-speed gear 43. Sleeve 44. Vice-speed high-speed gear 45. KeysA8×35 46. Circlip 47. Rolling 1,220,648. Rolling 1,230,5 49.Ⅳ shaft sleeve 50. reduction pinion 51. ⅣShaft 52. Ⅱ.ⅤFile sliding gear 53. Ⅰ.Ⅲ.Ⅳ.Ⅵ.Stall sliding gear 54.Ⅱ.Ⅲ.Ⅳ Axle right bearing cap 55. Rolling 307 56.Ⅴ Shaft 57. Reducer gear 58.Ⅰ.ⅢFile gear 59.Ⅳ.Ⅵ Files Gear 60. Ⅱ.ⅤFile gear 61. ⅢShaft 62. Vice-speed sliding gear 67. Gearbox 68. Pad 69. Oil Plug Ⅰaxis right end of the extended transmission, and clutch driven plate connected with the spline sliding gear in a fixed Z1 axis, the gear Z2, Z3, respectively gearbox high, low driving gear, they are separated by sets of fixed-mounted No. Ⅱ shaft, the gear teeth Z2 and Z1 often sliding gear Z4, Z5.Ⅰ.Ⅲfiles sliding gear Z11, are related to the main transmission shaft Ⅱ through the sliding spline connection. Manipulation of the main transmission main gearbox sliding gear Z9.Z10.Z11; Vice-shifter control high-low sliding gearZ4.Z5.

Picture 2-5 Schematic diagram of four-wheel drive transmission gearbox

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1. Shaft gear (20 teeth) 2. High-speed gear (28 teeth) 3. Low speed gear (18 teeth) 4. To pay transmission slipping gear (17 teeth. Union 27 teeth) 5. Reverse gear (22 teeth) 6. 2. Fourth gear gear (33 teeth) 7. 1. third gear gear (18 teeth) 8. gear shaft (15 teeth) 9. 2. Fourth gear sliding gear (17 teeth) 10. 1. 3 reverse slip Gear (20 teeth 25 teeth together) 11. Reducers Gear (49 teeth) Note: The five-axis seal35×58×6 To achieve the sliding gear transmission box location, set up the main transmission and sub transmission two joysticks. Manipulation of the primary. Vice stick shift, you can toggle the corresponding slip gear, get to use the stalls. Vice-speed high. Lower two positions. There are two main speed forward and one back position. Vice-speed hang low, the main variable hanging file access Ⅰ .Ⅱ file, deputy high speed link, the main variable hanging file access Ⅲ.Ⅳ file. 2、Differential ZL05.ZL06 differential assembly, see 2-6 from two separate radial ball bearings (6011) by axle support on the gearbox casing on. Differential Case 1. Differential on the cylindrical shell 7 and the driven gear 8 together with strong bolts, that differential entourage moving cylindrical shell with the rotary gear reducer. 4 differential planetary gear differential housing on the two loaded differential cross shaft 5 with the two axle shaft gear teeth corresponding to 4 kg, while the axle gear and the axle shaft via the spline connection.

Picture2-6

Differential

1. Differential under the shell 2. Differential gear 3. Differential gear gasket 4. Axle gear 5. Cross-axis 6. Axle gear gasket seven. Differential cover body 8. Cylinder driven theory 9. Bearing 6011 When the straight-line loader for the exercise, by the driven cylindrical gear reducer to power through the differential housing. Differential gear shafts,

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planetary gears, axle gears passed to the left and right axle; when the loader turning a corner, As the two rear wheel by ground-based resistance to different, and therefore planetary gear differential in the accompanying transfer of public housing, it is also around the differential gear rotation, so that the left and right axle turn generate the speed loader turning smoothly. 3、Locking mechanism To make an accurate position of the slider, and does not auto-dislocation, set the slider locking mechanism, shown in Figure 2-6. The machine uses spring-ball type locking mechanism, ball 2 in the spring under the effect of an embedded slider 3 positioning slot, so that the slider can not easily slip. Only manipulate the gear lever to exert a certain power of the slider, the ball will move after the compression spring, when the slider 4 will lead slip through the fork sliding gear to complete the work Guadang or extracts files.

Picture 2-7 Locking mechanism 1. Spring 2. Ball 3. Slider 4. Fork 5. Gearbox 4、Interlocking institutions In order to ensure that only put up a stall, but only when Guadang only in the gap, the two main speed slider to set the interlock between the institutions, shown in Figure 2-8, using the lock pin city, interlocking bodies, namely, 7.8 bar between the two flowers into a lock pin 2. When one of a smooth move, relying on the slider back to the cylindrical surface gap position, the other slider is possible slip and lock does not move slider, which play an interlocking role as insurance.

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Picture2-8Interlocking institutions 1. Slider cover 2. Interlocking round lock 3. Gearbox 4. 1. 3. 4. 6 files Fork 5. Vice-speed slider 6. Vice-speed Fork 7. two Five-speed slider 5、Gearbox lubrication and adjustment 1. Gearbox gears, bearings and the other moving parts, relying on running gear splash oil lubrication, oil level is too low will affect the reliability of lubrication, oil level is too high will increase the fluid resistance to temperature, or oil spill. ZL05.06 filling gear oil should be about 5 kg, four-wheel drive transmission should bear about 3 kilograms, when the transmission oil is dirty (with 500 hours) should be promptly replaced. 2. Department of cylindrical gear gearbox gears, the gap does not require adjustment, when the gears and bearings gap is too large or damaged should be replaced. Axial clearance can be separated by paper pad and cover to adjust the axle differential gears and planetary gear gap is too large, should be replaced gear or gasket. 3、shaUniversal joint cross shaft are oiling Tsui, each working 150 hours should inject lubricating grease.

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Picture2-9 shaft 1. Axle tube assembly 2. Sheathing fastening ring 3. Spline jacket 4. Oil cup M65. Casing fork 6. Casing fork blocking cover 7. Cross-axis clasp 8. Cross shaft assembly (Beijing 130 ) 9.M10 × 1 nut 10. spring washers 1011. flange fork 12. bolts

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ZL

Transmission Contact Size Chart

1. ZL-type forward pass is a manual gear box mechanical control gear box, which hardened process technology used in all gears, gear wear resistance, impact resistance was significantly higher than other similar products, so that the product has easy to operate long life and high safety factor. 2. The product of the rated transmission power 44KW, apply to ZL15 Loader, its transmission power. 3. Main specifications and technical parameters Input Speed

2200r/min

Output torque

200N/m

Center Distance

474mm

Lubricant volume

16kg

Stall speed ratio

Ⅰ

Ⅱ

Ⅲ

R

16.96

6.22

3.51

7.71

Net weight

167kg

4, the installation size and input methods 1. Gear box installation dimensions diagram (Figure 1) 2. Cabinet assembly diagram (Figure 2) 5. Gear Box Installation When the product connecting with the engine, you must ensure that connected two axes coaxial degree of not more than 0.15mm, connect the base to ensure sufficient strength and adjustable, so that equipment, safe operation. 6. Gear would like to experiment Test sets to simulate installation of gear box testing, testing, pre-open the gear box oil cap, into the lubricating oil, according to technical parameters of fuel. Correct upon inspection, will be placed in neutral gear position gear box handle, driving. Idling for 2-3 minutes, stopping Guadang level-grinding to observe the operation, such as work normally installed to use.

11

Assembly diagram

12

7. Three packs of the scope of The following conditions of the three guarantees: 1. Gearbox shell cracks caused by leakage. 2. Driveshaft cracked and broken. 3. Gear box in normal use, resulting in broken shaft. Playing gear. Shell rupture. Not be implemented the following three bags, but the implementation of reasonable charges Repair: 1. Because of the use. Maintenance. Improper maintenance, resulting in early wear and failure; such as poor handling in transit, after purchase damage. Conditions of use beyond the scope of product specification requirements. Speeding overload use. Fails to product specification requirements for running-in operation. overhaul. adjustments. fastening, internal combustion engines mismatch. use of non-conformity of the fuel, etc.; 2. Because of self-modification. Self-correction. Disassembly product specification does not permit self-correction. Demolition of parts and components caused by failure; 3. No three packs of certificates or no valid invoices, purchase products they could not prove that they belong to three packs of the life of the product; 4. Three bags of documents or invoices the product specifications and requirements of three bags of model type does not match the product specifications, or altered; 5. After the failure, no damage to keep the status quo, or without obtaining permission from sellers. Mender agreed to dispose of the cause of the malfunction so that right can not make technical appraisal; 6. Because of the driver. Operator did not obtain a driver's training in accordance with law. Operational failures caused by the certificate; 7. Due to damage caused by force majeure. Special Note: 1. Three packs of valid votes from the development of the date of shipment, net of business due to take three packs of the occupation and the lack of maintenance repairer repair parts for repairs of time. Three packs of the life of the product failures that, with three packs of certificate processing invoices and repair. Replacement. Return. 2. Three bags is valid for 3 months. The three bags of the ultimate right to interpret owned by the Company.

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Box Parts Schedule

NO.

Parts Name

Amount/set

NO.

Parts Name

Amount/set

1

Transmission Case

1

23

Reverse shaft

1

2

Gear stick

1

24

Brake Hub

1

3

Shifter

1

25

Brake Disc

1

4

FORK

2

26

Brake Disc Block

1

5

Fork shaft

2

27

Oil discharge bolt

1

6

Gearbox cover

1

28

208 Bearing

2

7

A shaft gear

1

29

Axis Cover

1

8

307 Bearing

10

30

Axis

1

9

35×58×12SEAL

1

31

Then the output tray

1

10

An axis

1

32

Large reduction gear

1

11

Connect Set

1

33

Four-axis

1

12

Shaft

1

34

A small reduction gear

1

13

Box attached

1

35

Reverse pinion

1

14

Linkers cover

1

36

A file gears

1

15

Side Cover

1

37

2-axis

1

16

2-axis gear

1

38

A reverse sliding gear

1

17

23 files sliding

1

39

Cover

6

18

Third axil

1

40

Fork Cover

1

19

Third gear

1

41

38×58×12SEAL

2

20

files Gear

1

42

Then disc

1

21

Fourth gear

1

43

brake hub

22

Reverse Gear

1

44

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ZL16-ZL20 Series Power Shift Transmission 1. Features: ZL-type fixed-axis power-shift gearbox for wheel loader and its deformation ZL15.ZL16.ZL18.ZL20 products. YJ240B.YJ265.YJ280 type with torque converter match. Can be within a certain range with the external load automatically change the size of changes in the transport speed and torque, so that the engine is always at the maximum power to work and do not turn off. The machine has a compact structure, easy manipulation, shift smooth, reliable, long life. 2. Main technical parameters Item

Value

Unit

Rated Input Speed

2500

R/min

Rated input power

44-60

KW

Torque Limit Input

550

N.M

Supporting torque converter model

YJ240B、YJ265、YJ280

Hydraulic speed control

1.2~1.5

Mpa

Oil Pressure

0.15~0.3

Mpa

ForwardⅠfile

2.16

Transmissi

ForwardⅡfile

0.77

on ratio

Back Ⅰfile

2.21

Back Ⅱfile

0.78518

weightQ

180-260

15

kg

ZL16-ZL20

series of power-shift gearbox

16

Torque Converter 1. Features: YJ240B.YJ280.YJ265

series

hydraulic

torque

converter

is

a

single-phase

single-stage radial turbine components, torque converter 3, which has advanced structure. Reliable work. Easy-to-reasonable matching the characteristics of the host, and the use of easy maintenance. Is currently made ZL16 type. ZL18 type. ZL20 Loader ideal matching gear. 2. Main technical parameters:

Item

Value

Unit

Rated Input Speed

2200

R/min

Rated input power

45-60

KW

Nominal

23.50

N.M

condition

22.54

N.M

Zero speed torqueMBg0

condition

And efficient working Nominal torqueMBg0

Zero speed condition variable moment coefficientK0

3.13

Maximum efficiency K0

0.817

Effective zone width ηmax

1.86

WeightQ

135-185

17

KG

4. Drive Axle Drive axle in active and passive gears have been carried out by exposure standard matching, therefore, can be adjusted long-term use is not only in replacement of defective parts or parts to wear and tear due to moving only when we need to make adjustments to the original bridge. Adjustments should pay attention to the following:

Picture 1. Axle bolt

2.

Wheel

hub

3.

2-10 drive axle Brake

drum 4.

Horseshoe

(Beijing

130)

5.

49×100.49×102Seal 6. Lock the mother 7. Bearings 75118. Tire bolt 9. Bearings 781.31

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thousand. Brake Cylinder (Beijing 130) 11 . release valve 12. driveshaft access plate 13. nut 14. Bearing 27309 15. 27,522.2959016 bearings. Main vertebral gear 17. 29,590.2952218 bearings. Axle gear 19. Planetary gear 20. Passive bevel gear 1. Take the initiative to gear bearing gap within the bearing from the driving gear behind the seat cover to adjust the pedestal, and after adjustment should be no space and they can freely rotate. 2. Main. Passive gear gear tooth gap in active gear flange around the radius 45MM measured, its displacement (arc length) should be between 0.2 ~ 0.6mm. 3. After every 100 hours of driving, check the drive axle of oil. The correct oil filling port side of not less than the lower edge of 10mm, if necessary, to add, for every 300 hours of driving, they should replace the gear oil, this machine should be added on the 18th hyperbola gear oil. 4. Every 100 hours of driving, it should be replaced once a round of shells bearing grease, adjust bearing preload degrees to the right so far. 5. Brake System Braking 1.ZL05.ZL06 loader for mechanical braking. In use, and other components due to friction plate wear and deformation will lead to increased or generated by braking stroke brake bias, affecting braking performance, when brakes should be timely adjusted in order to ensure driving safety. 1. To adjust the length of the two brake rod (Figure 2-11) can change the size of the brake pedal air travel, and can synchronize brake brakes around. Brake rod will allow air travel to reduce short-rotation; rotation length can increase air travel. 3 locking nut should be loosened to adjust to adjust well after the lock.

Picture 2-11Brake Adjustment 1. Brake 2. Brake rod 3. Locking nut

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Picture 2-12 Axle assembly 1. Nut M142. Double-headed bolt M14×60 3. Elastic pad 4. Nut M16 5. Elastic pad 6. Double-headed bolt M16×607. Brake hub 8. Bearing gland 9. Paper pad 10. Seal 52×751×211. Bearings 21012. Card spring 13. Plate 14. brake shoe 15. eccentric shaft 16. axle casing 17. elastic pad 18. nut M1619. lock the mother 20. locking pieces 21. lock the mother 22. bushing 23. brake Convex Shaft 24. brake shoe recoil spring 25. Shaft 2. To adjust the position of eccentric shaft 15 (Figure 2-12), can change the brake shoes and brake drum friction plate friction surface contact prints, so that even wear of the friction film. Adjustments will be paving the rear axle loader, release the nut 18 (Figure 2-12), with the wrench rotating eccentric shaft, while rotating hand wheel, when the brake shoes and brake drum contact resistance will be felt, and then and then slightly eccentric axial rotating in the opposite direction until the wheels turning until the resistance disappears. Finally, the locking nut to prevent rotation. Four-wheel drive loader traffic using BJ130 hydraulic brake system, brake, brake pedal full stroke 160mm, free travel for the 8-10mm, when the brake pedal is too low should be found to check: 1. Pipes leak. 2. Shoe and drum gap is too large. 3. Whether there are air channels. There is no work 200 hours to check brake shoe wear and tear. When the shoe to wear to make the pedal stroke is too large, we must adjust the shoe and the gap between

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the drum, the process is as follows: (1) jack up the wheel to be adjusted. 1. In the bottom of the back of the brake to find eccentric wheel bolts, rotating eccentric wheel bolts, until the shoe and drum contact, and then relax eccentric wheel bolts, until the freedom of rotation and the friction shoe and drum until they are no longer. Note: The adjustment does not allow rotation and removal of brake shoe sales support. 2. When the brake pipe in there air, and replaced with new brake fluid, as well as storage tanks dry bottom, add the brake fluid when the brake pipes and pumps will need to put air in the net, its methods are as follows: (1) the brake pedal several times under the continuous step, release to give up valves, air release pipe, tighten valve, release the brake pedal, so to repeat several times, until the asphalt air row last. (2) abandon the process, we need to keep the lowering of oil storage tanks continued to add brake fluid, not be allowed to dry at the end of storage tanks, all to give up after the brake fluid should be to add a little, the machine should be added "912" brake oil brake pedal free travel from the brake master cylinder to adjust the putter. 2. Tire processing Tires. Wheel rim, such as improper handling tire to explode. Wheel rim will be broken, resulting in serious casualties. For safety reasons, should note the following points:

Because the tire rim of the disassembly. Maintenance and repair needs of special equipment and technology, all point to ask tire repair professional maintenance staff to operate. •Using the specified tire, and inflated to the provisions of the pressure. •When inflated, inflatable tubes should be fixed to the valve on the tube card and to prohibit any person to work area. Air should continue to check the tire pressure to prevent the inflation pressure is too high. •Rim, such as fixed properly, while inflating the tire rim may have burst. To ensure

21

safety, the tire should be inflated around the work area to set up a fence. When inflated, the staff should stand on the side of the tire tread, while the ban stood side tires. •Tire pressure drops velocity anomaly or anomalies Rim devices are the tire rim sign of a problem. This case, to ask tire repair station for maintenance professionals. •After the high-speed exercise or heavy work, to adjust the tire pressure. •Prohibit the installation of the tire rim on the heating or welding. Tire near the fire source is strictly prohibited. Summer job, tire pressure should not be too high. •Precursor loading front wheels and rear wheel drive loader for the modular structure of the tube. Primary volume and sub-volumes by 9 M12 bolt connection. Inflatable tires is fastening bolts must be checked before. •Demolition Tires Tire gas must be put in net. Otherwise, there rim burst, causing casualties, such as the illegal operation of your own risk. Tire inflation pressure: nominal pressure 3MPA 6. Working Device Hydraulic System (A) The working device is a bucket. Bar. Boom. Crossbar. Rocker so on. The machine features: hand with force, received fighting a larger perspective, material loaded much more lift without scattering material, operation and high efficiency. (B) Work by the gear pump hydraulic system. Priority valve. Load-sensing steering. Multi-channel valve. Tank. Tubing. E-mail form. The machine features: turn priority, smooth and reliable. Pressure oil pump shaft from the first leading to the priority valve, regardless of load size, the steering wheel high and low speed. Priority valve to give priority to steering the allocation of fuel to ensure the oil supply shortage of steering, so that turning movements smooth and reliable, and the rest to the working hydraulic system, thereby eliminating excess oil due to oil line shift caused by power loss, increased system efficiency.

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Chapter III of the electrical equipment Single-cylinder machine electrical systems use AC voltage 12 V, four-cylinder machine is 24 volts, negative ground system.

1. front and rear headlights 2. Turn signal 3. Accumulator 4. Fuse box 5. Power Switch 6. Pairs of file switch 7. Turning switch 8. Power Table 9. Starter switch 10. Generator 11. Electric starter 12. Starting Ji Electrical 13. adjuster 14. horn button 15. flasher 16. loudspeaker 17. temperature Table 18. Oil Pressure Gauge 1. Battery Battery model single-cylinder machine N120-12V, four-cylinder machines for the N140-24V, its function is when the engine starts, the power supply to start the motor, but the engine work, if the generator voltage is lower than the battery voltage , then the power supply to the machine to the battery charger to save some energy. In use Note: 1. Always keep charging state, such as the long unused, should be charging at least once a month. 2. Frequently check the electrolyte fluid level, liquid level should be 10-15 mm above the plate, less than distilled water when you can add. If satisfied that the electrolyte Lou sprinkle losses, accounting for 1.28 should be added to the electrolyte. 3. Should always check whether the battery vent plug, remove the external soil and stolen goods, wipe spilled electrolyte and electrodes coated with thin layer of calcium-based grease to prevent corrosion. 4. Shall not be excessive use of the engine. 5. Battery should be fastened in order to damage from vibration.

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2. Generator and Regulator 1. Alternator: Generators have marked "armature". "Magnetic field" the word, and a two terminal marked "ground" indication of the grounding screw. They should be marked with the relay regulator have the same text on the terminal connections, "ground" screw on the regulator and the relay, "ground" screw connected. Generators at both ends with bolts on the bracket fixed to the generator; another one generator shoring, used to adjust the three-legged belt tensioner degrees. 2. Relay regulator: Relay regulator by the interceptors. Regulator. Limiter composed of three devices. Regulators on the relay marked "armature". "Magnetic." 2 terminal and a grounding screw. "Armature". "Magnetic field" and the base side of the grounding screw terminal on the generator should be the corresponding terminal and grounding screw connected. "Battery" terminal access Ammeter "-" was terminal, ammeter of the "+" terminal and the battery's "-" was attached pole. Regulator was found not working or use of 1000 hours, they need a skilled electrician to adjust. 3. Starter Its use are: the supply of power from the battery to starter-generator, starter gear for mobile is based on the electromagnetic drive, and with a one-way roller clutch, to prevent the starter armature with high-speed rotation after starting the engine damage. 4. Other 1. Fuse box: When the circuit fails, the current overload, the fuse can automatically fuse, thereby ensuring the electrical equipment completely work. There are four stalls fuse box fuse assembly, the file uses and operating current in the table below: File Numb

1

2

3

4

Uses

General Fuse

Charging circuit

Headlights.Taillight

Turnlights

Operating Current (Amps)

30

20

60

6

If the circuit is not found in normal circumstances, should immediately check the fuse box in the corresponding fuse is blown, according to other files have been blown fuse, check the components to be protected. After troubleshooting, disconnect the fuse board, Bakai dynamic loading head, the upper end of spare fuses removed the fuse panel of about 60 mm, tight around the head in fixed equipment, the subsequent pull back to move loaded head, and then insert the fuse box mounted fuse board to its original location in. 2. Ammeter Ammeter to indicate the battery charge. Discharge current, when the generator to the battery charging, the pointer inclines towards "+"; the other hand, for the "-", no current flows through, it means zero. 3. Electric Lock: Insert key Keyhole, the right call, in addition to everything except the electric starter electrical power connected. And then right away, starter connected to the power, start the engine. In order to protect the starter motor, requiring the engine

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start immediately after the electric locking keys allocated to the left. 4. Gates: gates control the entire electrical system, parking, should the power off to avoid battery discharge. Chapter IV

driving

Driving and operating prior to conducting operations, should be familiar with the structure of loaders. Technical maintenance. Operating methods in order to ensure the safety of exercise and work to improve life expectancy and productivity of the loader. During driving and task performance should pay attention to the following safety issues. 1. The driver must be rules of the road. Mechanical structure. How-to-peer learning, and read the instruction manual. 2. In addition to driving the exercise room, not allowed to ride anywhere in personnel. 3. And pay attention to the reaction meter ministries working condition. 4. When operating strictly prohibited under the moving arm and bucket moving. 5. Engine flameout should be immediately stopped to prevent the steering failure causing the accident. 1. All new vehicles to go The units used in the new car must be carried out commissioning, through the operation of the new car is not fully operational shall not be used. Commissioning the machine can be running-in of the friction parts. To avoid the failure, thus ensuring a reliable loader to work to extend the period of use. This rule also been overhauled for use in the loader. Sub-empty car commissioning commissioning commissioning and operation of two-step. 2, empty commissioning (about 8h) 1. Methods: (1) The prescribed method of starting diesel engine, the first 5min after starting to medium-speed idle (non-linked files). And then gradually accelerate to maximum speed, running 10min. (2) operation working device joystick boom and bucket joystick, so that boom to upgrade, down, tipping bucket, and close the Big Dipper. Is about to 10min. (3) mounted forward file. Tuidang later. Empty exercise. After the first vulgar high-speed, uniform arrangement of each stall. 2. Check items: (1) comprehensive inspection of ministries bolts. Nut fastening the situation. Especially the cylinder head bolts, exhaust pipe bolts and front and rear drive axle bolts, wheel nuts, transmission shaft connecting bolts. (2) engine. Gearbox. Drive Bridge parts are no unusual sounds. (3) the hydraulic system and gearbox. Engine lubrication system, braking system, engine cooling systems, whether the oil spill. Leakage phenomenon. (4) The meter reading is normal. (5) The shift is flexible, sensitive and reliable braking it. (6) The working device moves the phenomenon of whether the process was stuck. (7) Check the electrical work. 3. Operating test run (about 20h) 1. According to operational control methods work, added material should be gradually

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increased. 2. Operating commissioning process, in addition to check the empty commissioning inspection items, but also observed in different materials in the loader shovel loading capacity. 3. In walking together during the loading and unloading load shall not exceed 70% of the common load. 4. In the period of walking together in order to shovel loading loose material is appropriate. Action shall not be excessive. Too fast. 4. Loader use (A) Precautions for use 1. Added to pure diesel, diesel label should comply with the prescribed quality requirements. 2. Working device used in hydraulic system hydraulic oil must be clean. 3. According to the provisions of regular maintenance and lubrication. 4. After starting the engine to carry out air operations until the water temperature reached 55°C and then start the exercise. 5. When the boom control switch to the Big Dipper and the need to reach location, should set an intermediate position joystick. 6. Shall not be raised to the highest position of the transport bucket materials, materials should be kept in special delivery from the hopper on the ground in order to 300mm, in order to maintain stability in the exercise. 7. Lift arm, the hopper must be closed flat, or tanks and rocker damage your own risk. (B) empty travel 1. Starting Inspections before moving to make sure departments are normal after starting the engine. Should be placed before starting the joystick neutral position, and then insert the key gates, and rotate one position clockwise direction, connected to power, riding under the throttle, and then start the engine. In case of low temperature in winter, when the cooling water should be released, plus a hot water or boiled water start. Start, they should observe the engine oil pressure, appropriate controls throttle to prevent the engine bush-burning. A start-up time for the 5-15s, still can not start if it is over time, it should stop, wait a minute for a second time after the start. If more than three consecutive still unable to start, should check the reason for re-start troubleshooting. 2. Start with the traffic After starting the engine throttle speed should be further carried out in the warm-up, and pay close attention to oil pressure gauge instructions. At the same time check the engine and other systems are all normal. Ministries are normal, it will rise to the transport bucket position; first hanging forward file, the next step the accelerator pedal slowly, you can continue straight ahead loader, and then depending on the operating conditions of roads and the speed you need to choose the appropriate file bit and throttle for driving and operation. 3. Parking and flameout Engine shut down, should idle running 2-3min, in order to ministries uniform cooling.

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Winter, after stopping the engine put in time draining valve, put the net in all the water cooling system to prevent the mechanical Frost Crack. When the water temperature to -20°C-30°C, the batteries should be removed, so as to avoid moving into Nuanshi Frost Crack. Also, pay attention to parking bungalow on the ground before the bucket, turn off the power. (C) operations to manipulate Operation with the driver to manipulate the number of degree of operation, different levels of drivers are familiar with the operation of different method of operation. Method of loading and unloading operations described below, for reference only. Comrades in the use of aircraft operation in the practice of operating on their own grasp of continuous improvement and summary method of operation to improve the loading and unloading operations of production and machine life. Operation to clear the area before, filling potholes and other damage to eradicate Chienshih tires and obstacles impede the operation. 1. Shovel loading operations (1) the speed of file being windrow forward boom next pitch on the ground under the shovel about 250mm, Bucket part of the bottom plane parallel with the ground (which can also move forward, putting down his bucket edge). (2) at a distance of about 1-1.5m windrow Department, to lay down their boom. Bucket, so that the blade grounding bucket, and bucket at the end with the ground plane into a 3-7° corner cut into the windrow. (3) depresses the accelerator to the feed bucket full cut pile, and intermittently controlled bucket Bucket and boom raise up to fill up the Big Dipper. (4) When turned on the bucket after bucket filled to boom elevated to the appropriate height, and then let the boom joystick back to the middle. (5) Xiewan material, put the hopper back, and then down the arm. 2. Transport operations 1) full bucket, release the throttle, so that engine speed reduced, hang back files, and then slowly increase the throttle, the loading machine to withdraw piles. (2) sail material discharge points, or truck. Ruoyin road is too soft or non-flat space, can not be used or by-distance trucks to assist in the 500m or less, in the heading for unloading point, the bucket into the transport position, is strictly prohibited U-turn or braking in order to ensure transport security. steady. (3) If the tires skid will reduce tire life, so jobs should avoid skidding tires.

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Chapter V

Technical maintenance

The car loader work condition working conditions are bad, frequently in not the smooth job location travel and the work, various part easy to receive the intense vibration or the collision, causes the machine part to become less crowded or the damage. Thus for guaranteed the charger the good performance, the normal work, the extension service life, besides must be familiar with the machine various section constructions, but also needs according to the request periodic inspection machine technical condition, and carries on the technical maintenance earnestly. The this chapter main introduction besides the engine the partial technical maintenance, the engine technical maintenance please refer to the engine instruction booklet to carry on. 一、Car loader oil used and lubrication matters needing attention １、When replenishment fuel oil, hydraulic fluid, lubricating oil and lubricant, should the oil injection tool, the vessel as well as the oil injection spot scours cleanly, prevented the moisture, the sludge, the sundry goods enter in the oil used. ２、When replenishment each kind of oil class, must cause the machine to be in the horizontal position.Besides attaches the oil level indicating device to be possible to carry on the observation, overflows generally by the oil plug up to.The gear box oil dipstick covers in the speed change. ３、When replenishment each kind of oil class, should put the dirty oil only, pours into clear wash oil Yu Yuan to work the oil level, in the idling situation, causes the engine to revolve several minutes, after stops the revolution, puts the clear wash oil only, again joins the clean fresh oil, after if the oil viscosity may slightly heat up beforehand too greatly dilutes carries on the replenishment again. ４、In the low temperature or under the high temperature different working condition, should according to the actual situation and the operation requirements, replacement power oil and the lubricating oil type. 二、Car loader oil used type (Sees the table 5--1to show) Project Model

ZL series car loader

Fuel oil tank

Summer (above 10 10℃)-10#Diesel oil

oil sump

Summer (above 10 ℃ )CC40,WinterCC30Diesel engine lubricating oil

gear box, driving axle

18#Hyperbolic curve gear oil

hydraulic fluid tank

Winter46 、 Summer68Anti-rubs the hydraulic fluid (international oil)

various oil injections ju

Combination calcium base lubricating oil

brake fluid

Add "912"synthesis brake fluid

28

℃

)0#,Winter

(under

三、Lubrication The correct lubrication may reduce the machine greatly the friction drag and the components attrition, thus lengthens the machine the life. When lubrication please note the forecited oil used matters needing attention, the lubricating oil please do act according to the Table 5-1 regulations to select.The engine lubrication please press the engine instruction booklet to stipulate carries on. 四、Routine maintenance Routine maintenance after each class of work, and in the revolution carries on, its content are not many, the time is short, but is extremely important to the normal work and the reduced accident.The routine maintenance prime task is: 1、 The work before and after machine appears externally the part maintenance to be neat. 2、 Whether there is inspects the fastener to become less crowded with the loss, and screws tight and makes up neat. 3、 Whether there is does various spots part damage. 4、 Inspects each lubrication place whether replenishes the lubricating oil. 5、 Inspects all fuel tanks (fuel oil tank, work fuel tank, applies the brake total pump), the oil level must replenish. 6、 Whether the engine cooling water does replenish. 7、 Whether there is does the inspection electrical system wire connection loosen, the accumulator cell electric quantity is whether enough. 8、 Inspects various measuring appliances good, whether the light bulb integrity. 9、 The inspection operates respectively is whether nimble, is reliable. 10、 Whether there is after the start inspects the oil leak, the water leakage situation, whether there is not normal sound. 11、 The experiment applies the brake whether reliably, changes whether nimbly. 五、Periodic maintenance (一)After each week technical maintenance (works approximately 50h) Besides routine maintenance project, but also must carry on as follows the project. 1、Inspects footboard traveling schedule which the foot applies the brake whether conforms to the requirement, if it does not Tallying to adjust. 2、Fastens the before and after drive shaft connecting bolt, the driving axle connecting bolt, the tire nut. 3、Inspection accumulator cell Shan Genei liquid level highly with specific gravity of electrolyte (15℃; when proportion is 1.24-1.27), the following foot supplements the distilled water and the charge. 4、Presses the note calcium base lubricant to the lubricator fitting. (二)After each month of technical maintenance (approximately 200 hours) Except every day, each week technical maintenance project outside, but also must supplement the following item： 1、Survey tire pressure.If insufficient should give to restore vital energy.

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2、Clean fuel oil, hydraulic fluid filter. 3、Inspection braking system whether there is oil leak or damage. 4、Inspects and screws tight the wheel hub bolt, the brake disc and the bearing cap bolt. (三)After each quarter technical maintenance (approximately 600 hours) 1、Inspects the multitandem valve, each kind of cylinder leak situation, if has causes the work equipment drop phenomenon seriously, then should repair the elimination. 2、Whether there is the inspection applies the brake the total pump leather cup to damage. 3、The inspection wheel hub bearing gap, and causes outside the brake disc the end beat to be smaller than 0.2mm. （四）The technical maintenance (approximately works after every half year for 1200 hours) Except every day, each week, each month of, each quarter technical maintenance project outside, but also must supplement the following item: １、Replaces the complete oil duct system oil used, the hydraulic system oil used, the gear box, around the bridge gear oil and the brake fluid and so on.And cleans and so on pipeline, drill tubing, filter is clean, then pours into the fresh oil which the process purifies. ２、Takes apart and washes applies the brake the total pump, the inspection brake effect. ３、Around inspection bridge, master drive gear meshing situation, if host, driven awl tooth gear clearance oversized, then should give to adjust in 0.2-0.34mm. ４、The inspection work installment and do the rack, whether there is distort, the welded joint break phenomenon.

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Chapter VI Name

Breakdown phenomenon

reason analysis

elimination method

please refer to the diesel engine instruction booklet

一、Engine 1、When joint slips

1 、 The footboard free stroke excessively small 2、pressure spring weak 3、friction disk surface has the greasy dirt 4 、 friction disk attrition to exceed the time limit

Readjusting Replacement pressure Spring Wash Rechange friction risk

2、when joint tremble

１、Spline attrition oversized ２、Each tie bolt becomes less crowded ３、The rubbing surface has the fat ４ 、 The separation release lever adjustment is not uniform

Exchange clutch shaft or the cap of shaft Tight Wash Renew to adjust

3 、 The coupling not easy to separate

1 、 Footboard free stroke Readjust oversized Readjust ２、Separates the release lever to adjust improper

1、Sends the sound

１、The gear attrition exceeds, the tooth lateral clearance oversized ２、bearing attrition exceeds ３、each fastening screw loose ４、lubricating oil insufficient ５ 、 gear and the axis spline wears excessively

二、Clutch

三、 transmission

General breakdown and reason analysis

2、Often shifting gear

Replace gearshift

Replacementbearig fastening Supplement lubricatig oil gearshift or axis

1、Dials forks the axis retaining The replacement spring spring weak or the defeat 2、dials forks the axis locating replacement dials forks the axis slot attrition to exceed gearshift or the axis 3 、 inside and outside spline attrition

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四、Driving axle

五、Steering system

3 、 Shifts gears goes not

The tooth gear teeth end bumps the wool

Repairs the gearshift

deburring

or

the

1 、 nimbly when to have the sound

1 、 The host reduction gear linking not good

Adjustment either change bevel gear

2、bearing attrition exceeds or the loose 3、gear attrition exceeds

replacement bearing or adjustment gearshift

2 、 The driving axle applies the brake when sends the sound

1、Brake shield plate curving

Repair either replacement

2、drag friction burr rivet loose 3、brake drum damage

repair repair or replacement

3 、 brake the vehicle runs

1、The brake shoe surface has The clean the oil readjusts 2、gap adjustment is not good causes the barometric pressure to 3、 when the tire pressure does be consistent not gather the standard

4 、 applies the brake not to work

１ 、 The brake drum and the Readjusts brake shoe gap adjustment improper Readjusts or the replacement ２、Has the greasy dirt ３ 、 The drag friction burr replacement attrition exceeds

１、The steering wheel １、The worm bearing adjuster Readjusts free rotational impluse has axial flees moves Readjusts or the replacement increases suddenly ２、Worm bearing adjuster and trundle backlash oversized replacement ３ 、 The fall attachment attrition exceeds or the breakage ２ 、 The rotation gear is not nimble

１、The lubrication is not good The apply oil ２ 、 Various ball ends adjust readjusts improper

１ 、 Moves the arm lifting capacity insufficiency or the extension fights the strength to be insufficient

１ 、 The safety valve adjustment does not work as the system pressure is low２、 Oil suction pipe and oil-filter pipes jamming ３ 、 Oil pump, cylinder, pipeline internal leakage ４ 、 The multitandem valve

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１、According to rating regulating system working pressure ２、The clean trades the oil ３ 、 Replaces the oil pump, and according to the nature subsidence quantity inspection system leak-proof quality ４、Replaces the multitandem valve

六 、 Hydraulic system braking system

七、Electrical

wears excessively, the valve lever and the valve chest tolerance clearance surpasses the stipulation ２ 、 The system operating performance reduces or is unstable

１、Power oil deterioration ２、Foreign matter blind off a line ３ 、 Oil filter jamming or damage ４、In the system has the air

３ 、 After moves the arm lifting to sink voluntarily

１、Moves in the arm cylinder 1 、 Takes apart for overhaul the leak the oil cylinder, replaces the seal packing collar 2、 Takes apart for overhaul or the 2 、 Multitandem valve valve replacement lever gap oversized

4、The oil temperature excessively is high

1 、 The heavy load operating time has grown 2、Oil mass insufficiency

5 、 After the steering wheel returns to the position to continue to change

1、In the diverter returns to the 1、Takes apart for overhaul replaces position reed damage the reed 2 、 Matches between the oil 2、Disassembles the diverter repair jacket and the oil or fuel distribution axis the deactivation or matches between the oil jacket and the valve chest the deactivation

6 、 The foot braking force is insufficient

1、Brake minute pump oil leak 2、In the brake hydraulic circuit has the air 3 、 Applies the brake the total pump leather cup damage 4 、 Applies the brake the total oil pumping fluid to be insufficient 5、The throwout lever traveling schedule adjusts improper 6、The brake lining plate wears down to the limit

1 、 Replacement minute pump oil seal 2、Deaerate

1 、 Accumulator cell plate

1 、 Desulphurization processing or

1 、 But the engine

33

１、Replacement power oil ２、Clean oil duct system and fuel tank ３、Clean or replacement ４、Whether there is inspects the oil system to leak air

1、Engine off rest or reduced load 2 、 Refuels to the stipulation oil level

3、Replacement leather cup 4、Refueling

5、Adjustment traveling schedule 6 、 Replaces the new brake lining plate

system

normal the accumulator cell does not charge or the charging rate is low

curing 2 、 Generator leather belt pine or damage 3、The wiring jail, the contact is not good 4 、 Regulator adjustment not when or has the damage

replaces the pole plate 2、Readjusts or the replacement 3、Inspects and eliminates it 4、Readjusts or the repair

2 、 The capacity of storage battery is insufficient

1 、 The specific gravity of electrolyte or the liquid level excessively are low 2 、 Between the pole plate short-circuits 3、Pole plate curing 4、The wire contact is not good 5 、 The wire contact not good pole plate active material falls off

1、 Readjusts the proportion or the increase electrolyte 2、Elimination settling, replacement electrolyte 3 、 Desulphurization processing or replaces the pole plate 4、Inspects and eliminates it 5、Replaces the pole plate

3、The generator does not generate electricity

1 、 Residual magnetism vanishing 2 、 The field coil return route breaks 3 、 The commutator contact is not good 4 、 The electronics brush catches not nimbly 5、Armature turn-to-turn short circuit

According to the generator original polarity, meets with the accumulator cell in the field coil both sides and puts through

34

with 0 or the 00th sandpaper polish revision electronics brush size, the regulating spring pressure inspects and repairs

Certificate Model No. Diesel

Model No. Origin

Frame Number The date of manufacture

The product passed the test to allow the factory

Quality Supervision

Inspection Division inspector：

Date

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