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Operation manual of 80 type slag raking machine

Article source: admin popularity: Time of publication: April 18, 2020 09:11

Foreword
 
Dear users
This series of vertical claw digging loader (common name: slag raking machine) is designed according to the mining and loading of iron ore, lead-zinc mine, molybdenum ore, phosphate ore and other ores in China. It is suitable for mine tunnels or roadways of 2m × 2M and is used for excavation and loading operation of national defense, mining, railway, water conservancy, hydropower and other engineering construction departments. It has the advantages of high power (29.5kw), low fuel consumption, low power and time saving, and fast loading speed. The hydraulic and electrical components are all made of domestic famous brand products with reliable performance. In particular, the use of dual power, electricity, oil is very convenient, because of good performance, high efficiency, can effectively load all kinds of slag in caves, hills, suitable for non coal gas mines.
This manual introduces in detail the use, maintenance and adjustment methods of the vertical claw excavator loader, and also introduces the relevant structure and working principle. It is hoped that the operators and maintenance personnel can operate and use correctly and maintain in time according to the requirements of the manual.
For the use and maintenance of diesel engine, please refer to the operation manual of diesel engine.
With the enterprise's technological innovation and various needs of users, the product performance structure will continue to improve and improve. In addition to the revision when we re issue, the contents described in this manual may be different from the actual structure, and some parameters may be different from the actual parameters. Please state the model and purchase date when repairing and purchasing the parts, and ask the users to understand.
Constantly improve the quality of products, to meet the needs of users is our goal. We sincerely hope that users can put forward improvement opinions on the use, repair and maintenance of this product and inform our factory in order to further improve the product quality and better meet the needs of our customers.
Thank you for using our products!


Chapter 1 Structure and performance of the whole machine
1、 Structure diagram of the whole machine. (attached figure)
2、 Main technical parameters of vertical claw excavator loader.

Product model Z ZWY-80T
Loading capacity (m3 / h) 50~80
Excavation height (mm) two thousand and eight hundred
Excavation distance (from shovel opening) (mm) one thousand and four hundred
Excavation width (mm) two thousand and eight hundred
Unloading distance (mm) 800 ~ 1700 (can be lengthened)
Unloading height (mm) 1200-1700 (heightening)
Total motor power (kw) twenty-nine point five
Maximum material passing area (width × height) (mm) (can be increased) 800×700
Maximum rotation angle (°) ±60
Driving speed (km / h) 1.3-25
Minimum turning radius (mm) five thousand and eight hundred
Climbing capacity (°) ≤25
Adapt to roadway slope (°) ≤10
Ground clearance (mm) two hundred
Applicable section (mm) ≥2200×2400
Shape (length × width × height) (mm) 5500×1700×1900
Total weight (T) four point eight
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 



















Chapter II safety rules

The vertical claw excavator loader mostly works in the roadway, tunnel and mining working face. The operator should carefully read the operation manual before starting the machine, and be familiar with the relevant provisions on mine safety requirements and risk prevention.
1. When the locomotive adopts electric motor, the operator should separate the release clutch on the coaxial line of diesel engine motor. A leakage protector matching with the motor shall be installed at the power access terminal. After power on, the electric pen should be used to test whether there is leakage. If there is leakage, cut off the power supply immediately, and ask experienced electrical maintenance personnel to check and deal with it. Staff must wear safety helmet, insulating shoes and gloves to keep the power switch box dry.
2. Before starting the diesel engine or motor, check whether the indicator light and instrument are normal, whether the variable speed control lever and panel switch are in neutral position. Before walking or on the road, the brake, steering, bucket, slag picking and slag transportation tests shall be carried out, and the start-up can be started only after the adjustment is normal.
3. Operators should be familiar with the lighting clarity of construction site and tunnel and ground changes, and understand the setting of underground water, electricity and steam pipelines on the construction site, and work carefully in the above places. When there is a high-voltage line near the construction site, a safe distance should be kept between the working device and the high-voltage line. It is necessary to check whether there is any hidden danger of collapse above and in front of the machine working face, so as to ensure the safety of operation.
4. The horizontal hard ground must be selected for parking the machine, and all operating handles should be placed in the middle position. Turn off the engine at low speed gradually and turn off the ignition switch 5 minutes before starting. When the temperature is lower than zero, the engine cooling water should be drained and the battery power switch should be turned off.
5. It is strictly forbidden to stand under the bucket arm, within the radius of rotation, in the transport trough and under the transport trough.
 
Chapter 3 operation and use
1、 New machine running in instructions:
1. New running in period:
The service life of the vertical claw excavator loader has a great relationship with the initial use. The running in process of the engine's walking part and the hydraulic system has a running in process. In order to improve the service life of the machine, the following operation regulations should be strictly observed in the initial use of the new machine (50 hours of excavation operation)
1) Preparation before running in:
(1) Check the connection and installation of all parts of the machine.
(2) Whether the accessories are complete.
(3) Whether there is any damage.
(4) Check whether all pipe joints of the oil circuit are loose and leak.
(5) Check whether the tire pressure is normal.
(6) Check the brake condition of the whole vehicle.
(7) Check whether the motor, diesel engine, hydraulic pump and hydraulic motor are abnormal.
(8) Add fuel and hydraulic oil as required and check the brake fluid.
(9) Check battery electrolyte and battery wiring.
2) Running in content
The running in load is 70% ~ 80% of the rated value, and the diesel engine speed shall not be lower than 1200 rpm. Running in includes digging, transporting, walking and climbing.
2. Requirements after running in:
(1) Change the lubricating oil of diesel engine and drive axle and hydraulic oil of hydraulic system, clean the oil tank, clean the filter, replace the lubricating oil and hydraulic oil after sedimentation, and check the brake fluid.
(2) Carry out a first level maintenance (see the contents of the first level maintenance).
(3) Replace the hydraulic oil after working for 500 hours.
2、 Instructions for use of new machine:
1. Check the following items before starting the engine:
(1) Fuel volume of fuel tank, hydraulic tank and drive axle.
Warning: during the working process, the oil temperature is very high, do not touch it to avoid scalding.
(2) Engine oil level.
(3) Whether the steering and connection are loose.
(4) Tire pressure.
(5) Is there any foreign matter in the electric cabinet( Internal voltage three hundred and eighty Fu, danger!
(6) Whether the switches on the console are in the middle position.
2. Check the following items after the engine is started
(1) Whether the panel indicator light is on and whether the function switches of the panel are normal.
(2) Are hydraulic system, engine system, brake system and electrical system available Oil leakage and leakage (test the machine shell with electric pen) water leakage
3. Pay attention to the following items when driving and digging
(1) Whether each operating handle is flexible and stuck. Check the cause and eliminate it.
(2) During the operation, check and listen to the engine or motor, shipping system, electrical system, hydraulic system for abnormal sound and odor.
4. During the working interval and after the shift:
(1) Check all parts for oil leakage.
(2) Check whether the frame, motor, diesel engine, hydraulic pump and radiator are loose.
(3) Eliminate problems in the process of work.
(4) Turn the switches on the console to the middle position.
(5) Pull down the electric control box and battery switch.
(6) After winter operation, the cooling water of the engine should be drained when the roadheader is stored.
3、 Driving and operation
The correct driving and operation is very important to improve the working efficiency, reduce the fuel and ensure that the backhoe loader is in good working condition. At the same time, it can effectively extend the service life of the machine.
(1) Diesel engine operation
1. Diesel engine starting
(1) Before starting, check whether the fuel, lubricating oil and cooling water are sufficient, and whether the hydraulic system and brake system of the engine have water leakage, air leakage, oil leakage and other abnormal phenomena. The above anomalies were excluded.
(2) Put the shift lever in the neutral position.
(3) Put the throttle lever in the middle position.
With the high speed of the flywheel, the engine can be turned on quickly by turning on the power supply of the engine. When the engine starts, turn the switch back to the original position to avoid damaging the engine gear.
Note: 1) each start should not exceed fifteen If it can not be started once, it should be started once two Minutes before starting to protect the starter and battery.
② Do not start the engine at high speed.
If it can not be started for three consecutive times, find out the cause and remove the fault. After the engine is started, the electric lock switch should be placed in the generating position. Move the charging switch towards the battery.
(4) When it is difficult to start in cold winter, the engine can be preheated by adding hot water or other preheating methods.
2. Excavator loader walking and working start
(1) After the engine is started, keep the medium speed and stable operation. When the system pressure is normal, you can start or start digging operation.
(2) Try to avoid parking on the slope. When it is necessary to stop, the skid should be added under the wheel to prevent the loader from sliding.
Danger: when reversing backward, make sure that there are no people or obstacles behind.
3. Safe operation
(1) When the vertical claw excavator loader is driven to the excavation site, put the gear shift lever into neutral, and then adjust the seat position.
(2) Before operation, the car body shall be placed as stable as possible.
(3) The operator must place the bucket on the ground or in the front of the body regardless of the length of time when leaving the machine.
(4) Up and down slope shall not exceed the maximum allowable climbing gradient of the machine.
(5) The bucket shall not be lifted, lowered and rotated rapidly to avoid damage to the machine.
(6) When moving the machine, the working device should be retracted, and the working device should be in the middle position.
(7) In general, when the road conditions are poor, you should drive carefully for the safety of you and others.
Warning: if it is necessary to operate the operating device control lever while the machine is running, stop the machine before operating the operating device control lever.
(2) Motor operation
1. Turn the release clutch between the diesel engine and the motor to the separation position to separate the diesel engine and the motor.
2. After installing the leakage protector at the power access end, connect the three-phase power supply, and use the electric pen to check that there is no leakage on the body before starting the motor. The working device can be operated after the power motor and hydraulic oil radiator motor operate normally. The operation method is the same as above.
3. Avoid damage to power supply by tire and working device during operation.
 
Chapter 4 maintenance and lubrication
The regular maintenance of the vertical claw excavator loader can effectively prevent the premature damage of parts, avoid the occurrence of unnecessary faults, prolong the service life of the machine and improve the economic benefits of users.
The operator shall change the oil according to the time interval specified in the manual, and use lubricating oil, fuel oil and hydraulic oil that meet the requirements.
Warning: check the oil quantity and change the oil according to the following regulations:
·Stop the roadheader loader on level ground and turn off the engine or motor.
·Refuel after the engine or motor is shut down.
·Smoking and all open flames are prohibited in the refueling area.
·Please keep clean when changing engine oil and hydraulic oil.
·Keep the surroundings clean when removing the connector or plug.
1、 Daily maintenance (once a day or every shift)
Routine maintenance and lubrication are the main methods.
1. Remove the soil and oil on the surface of the parts and components of the roadheader.
2. Check whether the fasteners of the fuselage are loose and fasten the loose parts.
3. Check and adjust the tightness of V-belt.
4. Check whether the fuel, hydraulic oil, brake fluid and water are sufficient and whether there is leakage, and timely supplement.
Danger: when checking the leakage of the hydraulic pipeline, the maintenance work of the hydraulic pipeline can be carried out only after the working device is lowered to the ground, the engine is turned off, or the pressure in the system is released.
5. Check whether the electric control box and electric circuit are abnormal or damaged.
6. Check that the steering is flexible.
7. Check whether the hydraulic cylinder can stretch and retract freely, whether the cylinder rod has slip mark, whether the oil pipe and joint have leakage phenomenon, if any, find out the reason in time and eliminate it.
8. Check whether the engine and motor start and run normally.
9. Check the tire pressure and inflate it in time.
10. Check whether the pin shaft parts are flexible, and add lubricating oil to the oil cup, pin shaft and points.
2、 First level maintenance (once a week)
The primary maintenance is mainly lubrication and fastening.
1. Complete the daily maintenance.
2. Check the bolt connection parts, and tighten them if they are loose.
3. Check the engine, drive axle and oil level, and supplement to the specified level if it is insufficient.
4. Check and adjust the tightness and parallelism of scraper conveyor chain, and check the operation of roller sprocket.
5. Check the spring pin and spring pin of each spring cup.
6. Check the dirt level of the engine air filter, remove the accumulated dust, and check the hose fastening clips.
7. Check the free stroke of pedal and steering gear, and adjust if necessary.
3、 Secondary maintenance (once a month)
1. Complete the first level maintenance.
2. For the first time, replace the hydraulic oil and clean the hydraulic oil tank and hydraulic pipeline thoroughly. When changing the hydraulic oil, check the dirty degree of the hydraulic oil and decide to filter and replace the hydraulic oil. Clean the oil suction filter screen and filter element.
Danger: direct contact with high temperature hydraulic oil and connected parts is strictly prohibited.
3. Check the wear of the cylinder seal.
4. Clean the diesel engine oil filter and crankcase, and change the oil and oil filter element.
5. According to the requirements of the diesel engine manual, complete the engine maintenance items.
6. Check the pull in condition of each contactor in the electric control box.
7. Check and adjust the steering wheel toe in.
4、 Three level maintenance (half a year)
Three level maintenance, eliminate hidden dangers, comprehensive maintenance
1. Complete the first and second level maintenance.
2. According to the diesel engine instruction manual to carry on the comprehensive maintenance and the maintenance to the diesel engine.
3. The steering gear and drive axle are disassembled, cleaned and adjusted according to the service conditions. Replace the damaged parts.
4. Clean and lubricate each direction joint of transmission shaft.
5. Replace the oil suction screen, hydraulic oil and filter element.
6. Clean hydraulic components such as multi-channel directional valve, oil tank and oil pipe.
7. Dismantle and inspect the rotating parts of the working part, and timely replace the pin shaft and bushing.
8. Clean the electric control box, check the insulation of the circuit, and replace the damaged electrical components.
5、 Seasonal maintenance
When the temperature is lower than 0 ℃ in winter, add winter oil to the fuel, lubrication and hydraulic systems [see Appendix 1]. When the temperature is higher than 20 ℃ in summer, replace the corresponding oil. When it is not used for a long time, the hydraulic oil, fuel oil and cooling water should be drained.
6、 Storage technology maintenance
1. Three level maintenance should be done before storage, so that the roadheader loader is in a good technical state.
2. Drain fuel and cooling water.
3. Apply anti rust oil or grease to the parts easy to rust.
4. Remove the battery for full charging and storage.
Danger: ① it is forbidden to dismantle the battery when the engine is running, otherwise it will burn out the instrument and even cause fire.
② Wear protective gloves and safety glasses when handling batteries.
③ Battery electrolyte is flammable and explosive, and sparks and open fire are strictly prohibited around.  
 
Chapter 5 common faults and troubleshooting of hydraulic system


Fault phenomenon Cause of failure Exclusion method
Hydraulic system does not work 1. The oil in the oil tank is insufficient, the oil is dirty and there is air in the oil pipe.
2. The oil outlet filter screen in the oil tank is blocked.
3. The safety valve of multiple directional valve is worn.
4. The oil pump does not absorb oil.
5. The filter screen of oil filter is blocked.
1. Add enough oil and tighten the coupling at both ends of the oil inlet pipe of the oil pump; replace the oil inlet pipe, filter or replace the hydraulic oil.
2. Clean the filter screen.
Replace the safety valve.
4. If the oil pump is damaged, replace it.
5. Clean the filter screen of oil filter.
Oil cylinder crawls or does not move 1. There is not enough oil in the oil tank, and there is air or dirty oil in the system.
2. The viscosity of hydraulic oil is too high or too low.
3. Internal leakage of oil cylinder.
4. Wear of multiple directional valve.
1. Add enough oil, remove air or change oil.
 
2. Check the oil viscosity.
3. Replace the inner sealing ring of oil cylinder.
4. Check the damage of multi-way directional valve.
The operation of multi-channel directional valve is not working well 1. The valve rod is stuck.
2. The valve rod is damaged.
3. The return spring fails.
1. Clean the stuck valve core, filter or replace the hydraulic oil.
2. Repair and replace the damaged parts.
3. Replace the spring.
The motor doesn't turn 1. The chain scraper is stuck.
2. The hydraulic system has insufficient oil supply and pressure.
3. The oil temperature is too high or too low.
4. The bearing of sprocket end cover is damaged.
5. The roller bearing under the transport groove is damaged.
1. Remove the stuck materials.
2. Check the system pressure or flow.
3. Check the working condition of radiator or change the hydraulic oil.
4. Replace the bearing.
Replace the bearing 5.
The working oil temperature is too high (over 80 ° or too fast temperature rise) 1. The working hours of the day are too long.
2. There is not enough oil in the oil tank.
3. The oil pump is worn.
4. The radiator has too much dust.
5. The hydraulic oil is too thick or too thin.
1. Stop working for a period of time.
2. Add enough oil.
3. Replace the oil pump
4. Remove dust.
5. Change the hydraulic oil.

Chapter 6 Appendix 1: use of oil
 

Serial number Filling position ambient temperature Specifications Standard code
one burn
oil
box
20℃ 10 light diesel GB252-2000
Above 4 ℃ No.0 light diesel oil
-Above 5 ℃ -10 light diesel
-Above 15 ~ - 5 ℃ -20 light diesel
two hydraulic pressure
tank
summer Lm-46 antiwear hydraulic oil GB7631.2-1987
winter Lm-32 antiwear hydraulic oil
three Drive axle
transmission case
summer 22 × hypoid gear oil SY1102-60S
winter 18 × hypoid gear oil
four launch
engine oil
summer See engine description  
winter See engine description
five braking     Synthetic brake fluid
six other Lithium grease    

 
Chapter VII after sales service regulations

1、 Product use, maintenance technical guidance services
1. When the products are delivered to users, the maintenance personnel (or agents) of our factory must conduct a comprehensive inspection on the sold products, verify the "operation manual" and "product certificate" and "user information card" of the random items one by one, and handle the handover procedures, and explain the maintenance methods and precautions of the products carefully.
2. After the products are sold, during the warranty period, our service personnel (or agents) will visit the site from time to time to understand the use and maintenance of the products, and provide on-site technical consulting services.

2、 Details of warranty service
1. During the warranty period, if the user uses and maintains the product correctly according to the "operation manual" and the operation manual of diesel engine and other main accessories, if the product fails to work normally due to the quality problems of design, manufacturing, debugging, assembly and materials, the warranty service shall be provided. During the repair process, the user shall provide convenience and coordination.
2. The warranty service should focus on repair. In principle, the replacement of spare parts should be identified by the customer service department of our factory. If it is really a quality problem and has no repair value, it can be replaced. The old parts should be returned to our factory.
3. The warranty period is three months from the date of delivery.

3、 Service scope without warranty  
1. Failure caused by improper use and maintenance not in accordance with the "operation manual"; failure caused by overload use of operating conditions beyond the scope specified in the "operation manual"; damage of bucket teeth and other accessories caused by crushing ore with bucket or bucket teeth; failure caused by changing the design structure of products before leaving the factory.
2. Failure caused by user's unauthorized increase of system pressure.
3. Failure caused by using accessories not approved by our factory.
4. After the fault occurs, it is unable to make technical identification of the fault cause due to self disposal without the consent of our factory.
5. The loss caused by the expansion of the fault, the indirect loss and the loss caused by force majeure.
6. Failure caused by untrained drivers and operators or failure to operate according to regulations.
7. Electrical components, circuit wires, meters, rubber parts, sealing rings, filter screen, bolts, shaft sleeves, bearings, springs, pull rods and other vulnerable parts are not guaranteed or compensated (for others, please refer to the details and time limit of Three Guarantees).
8. Our company will not be liable for the indirect costs incurred in the warranty process due to quality failure, such as oil, low value consumables, transportation, hoisting and other expenses.
9. If the product exceeds the warranty period, if the user has difficulties in maintenance, our company will try our best to provide good service and assist the user to deal with it according to the paid service regulations.
 

Keywords: 80 type mining slag raking machine, slag raking machine operation manual, mining slag raking machine said

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