ZL15装载机的使用说明书_(1) (修复的).doc

24ZL15型装载机说 明 书系别：工程机械系班级：13筑机323姓名：余浩学号：33 目 录第一章 用途、性能及注意事项3第二章 技术性能和参数一、 整机主要性能及参数4二、 工作装置液压系统5第三章 装载机检查与调整 一、 发动机（详见柴油机说明书）6 二、 离合器11 三、 传动轴13 四、 驱动桥14 五、 制动系15 六、 工作装置液压系统16第四章 电器设备 一、 蓄电池17 二、 发电机与调节器18 三、 起动机19 四、 其他20第五章 驾驶操作 一、 新车走合21 二、 空车试运转22 三、 作业试运转22 四、 装载机的使用23第六章 技术保养第七章 一般故障及原因分析23第一章 用途、性能及注意事项ZL12型装载机是单斗、前卸、铰接、轮胎式装载机，是本公司根据用户要求，参考和吸收国内外同类机型的结构特点和先进技术，与专业院校结合，开发设计的小型工程机械。ZL12 loader is fixed shovel turns, the front discharge, hinged, wheeled loaders, is the company in accordance with user requirements, reference and absorbing advanced technology and structure of similar models at home and abroad, combined with the professional institutions, development and design of small construction machinery.ZL12型装载机具有以下结构特点：1、 单摇臂Z型反转机构，实现特大掘起力；Onez-shapedrockerarmmechanism,super largebreakoutforce2、 名牌发动机，前、后桥驱动-双桥驱动，动力强劲； Famousengine,frontandrear axledrive-dualdrive,powerful3、 改进型液压过滤系统，确保油路运行可靠；improvedhydraulicfilteringsystemtoensurereliableoperationofoil;4、 柴油机后置，液压转向，操作简单灵活；Rear-mountedengine,hydraulicsteering,operationissimpleandflexible5、 铰接式车架，转弯半径小。Articulatedframe,smallturningradius.它具有设计合理、结构紧凑、操纵灵活、维修方便等优点。其各项性能指标均达到国家标准。Itfeaturesreasonabledesign,compact,flexible,convenientmaintenanceand so on.Theperformanceindicatorsareuptonational standards.它广泛适用于建筑工程、市政工程、城乡园林、石灰窑、沙场、水泥厂、石料厂、预制厂等施工场所，特别适用于在狭窄的场地装载散装物料的场所及与载重汽车、拖拉机、农用运输车、建筑机械（混砂机，搅拌机）等配套使用，能大大提高工作效率。本装载机的主要零部件均采用名牌厂家产品，互换性好，质量可靠，配件资源充足。Itiswidelyusedinconstruction,civilengineering,urban and ruralgarden,lime kiln,onthebattlefield,cement,stone,precastplants,constructionsites,especiallysuitableinnarrowgroundplaceofbulkmaterialsandtrucks,buses,tractors,agriculturalvehicles,constructionmachinery(mixer,mixer)andotherancillaryuses,cangreatlyimproveefficiency.Themaincomponentsaretheloaderadoptsfamousbrandproductmanufacturers,interchangeability,thequalityisreliable,partsresources.注意事项1、 本装载机驾驶员须经专门训练、并熟读本说明书。Theloaderdrivermust betrained,andreadthemanual.2、 新车必须按规定进行磨合运转后方可投入正常工作。Newcarsmustoperateasprovisionstoadjusttherearcan beput intowork.3、 使用规定的柴油、液压油和润滑油，并在加油前进行充分地沉淀和过滤。Provisions on the use of diesel oil, hydraulic oil and lubricants, and fully sedimentation and filtration before refueling.4、 不准用高速档起步，以免损坏离合器和其他传动件。Do notusethehighgearstarts,so as not todamagetheclutchandtransmissionparts.5、 下坡时不宜高速行驶，禁止空档滑坡。 Hillwould not be suitable forhighspeeds,bannedfreelandslide.6、 寒冷季节地区装载机停车不用时，应放尽发动机水箱中的冷却水，以免冻裂。Loaderparkingincoldseasonswhennotinuse,draintheenginecooling waterinthewater tank,so as to avoidFrostcrack. 第二章 技术性能与参数一、整机主要性能和参数1额定装料质量（kg）Theratingfeedsthequality15002额定斗容量（m3） Ratedbucketcapacity0.53最大卸料高度（mm） Themaximumwholesalechargeat 26004最大卸料高度时的卸料距离（mm）Maximumunloadingheightofdischargefrom10505举升时间(S) Liftingtime 66下降时间(S) Falltime 37翻斗时间(S) Skiptime 1.58行驶速度：Speed 低速档Low speedI (km/h) 5高速档RapidIV (km/h)259最小转变半径Minimum turning radius (m)4.210外形尺寸（长x宽x高）Overalldimensions(lengthxwidthxheight)（mm）5200x1690x240011铲斗宽度Bucketwidth（mm）160012轴距Wheelbase（mm）201013轮距Track width（mm）133014最小离地间隙Minimumgroundclearance（mm）20015整机质量Operating weight（kg）330016柴油机型号Diesel enginemodel48517标定功率Ratedpower（kw）2618额定转速Ratedspeed（r/min）220019起动方式Startmode12V直流电机驱动DCmotordrive二、液压系统主要性能和参数 1油泵：型号CB-Fc40额定压力（MPa）16公称排量ml/r402多路换向阀型号ZL15额定压力（MPa）25公称流量(L/min)63最大流量（L/min）803优先阀型号YXL-F160L-N第三章：装载机的检查与调整本装载机在出厂前各部位均已调整至最佳状态，客户在使用新机时无需调整。待工作一段时间后一些部位可作适当的调整，具体调整方法如下：Loader in the factory parts are adjusted to an optimal state, customers using the new machine without adjustment. After working for a while some appropriate adjustments can be made, make detailed adjustments are as follows:一、发动机Engine：详见柴油机说明书As shown inthediesel enginemanual二、离合器Clutch：1离合器踏板自由行程的调整Adjustment of the clutch pedal free play为保证离合器在传递动力时不打滑，离合器分离轴承与分离杠杆之间应保持一定间隙，具体反应到踏板上应有25-30毫米的自由行程距离。使用过程中，由于磨擦片磨损,分离杠杆与分离轴承之间的间隙将逐渐减少，甚至消失。因此必须定期检查和调整踏板的自由行程。In order to guarantee in power transmission, the clutch does not slip, clutch release bearings with a certain gap between lever and concrete responses to the pedal free travel distance of 25-30 mm. During use, due to friction and wear, clearance between lever and release bearing will be gradually reduced or even eliminated. Therefore must be checked regularly and adjusted the pedal free travel.自由行程调整是改变离合器拉杆的长度来实现的，放长离合器拉杆，踏板自由行程便减少，缩短离合器拉杆，自由行程增大。Freestrokeadjustmentisaccomplishedbychangingthelengthoftheclutchlever,andlengthenclutchleverpedalfreetravelisreduced,reducedclutchleverfreeplayincreases.2离合器分离杠杆位置的调整Adjustmentoftheclutchleverposition离合器的三个分离杠杆端面应在同一平面内，彼此相差不超过0.15毫米。用转动调节螺栓的方法进行调整。Three clutch lever end face should be in the same plane, and vary no more than 0.15 mm. Turn the adjusting bolt adjust method.三、传动轴Drive shaft：装载机有四个万向节，与BJ130汽车万向节通用，万向节十字轴上有注油嘴，每工作150小时应注润滑油脂。LoadersigewantosectionBJ130automobilecardanuniversal,universaljointshaftontheinjectionnozzle,shouldpourthelubricatinggreaseevery150hours.四、驱动桥Driveaxle：主、被动齿轮已按接触区标准进行选配，因此，可长期使用不应进行调整，只有在更换损坏零件或因零件磨损而移动时，方需进行调整。调整时应注意以下几项：Activeandpassivegearcontactzonematchingthecriteria,socanlong-termuseshouldbeadjustedonlywhenthereplacementofthedamagedpartsorpartsworn,needtobeadjusted.Adjustmentsshouldpay attentionto thefollowingitems:（1） 主动齿轮的轴承间隙：由主动齿轮上的轴承内圈背后的垫座来调整，调整后应该没有间隙而又能自由转动。Piniongearbearingclearance:frombehindtheinnerringof thebearingonthepiniongeartoadjustthepedestal,thereshould benogapaftertheadjustmentandcanturnfreely.（2） 主、被动齿轮的齿侧间隙：在主动齿轮的法兰盘半径45mm的周围上测时，其位移（弧长）应在0.2-0.4mm之间.Activeandpassivegeartoothbacklash:inandaroundtheradiusof thegearflange45mmwhenloggingon,thedisplacement(ARClength)should bebetween0.2-0.4mm.（3） 每行驶100小时后，检查驱动桥油面，正确的油面高度为不低于加油口下缘10mm，否则要添加。每行驶300小时后,应更换齿轮油,本机应加18号双曲线齿轮油。Afterevery100hours,checkthetransaxleoillevel,correctoillevelshouldnotbelessthanunderthefilleredge10MM,ifyouwanttoadd.Afterevery300hours,youshouldreplacethegearoil,native18thhypoidgearoilshould beadded.（4） 每行驶100小时后，应更换一次轮壳轴承润滑脂，调整轴承预紧度到合适为止。Afterevery100hours,youshouldreplacethewheelbearinggrease,bearingpreloadadjustmenttofit.五、制动系Brakesystem本机制动采用BJ130液压制动系统，制动踏板全行程160mm，自由行程为8-10mm，当发现制动踏板太低时应检查：ThismechanismusesBJ130hydraulicbrakesystems,brakepedalstroke160mm,thefreetripto8-10MM,whenthebrakepedalis toolow,youshouldcheck:（1） 管道是否漏油。thepipelineleaksoil（2） 蹄片与鼓的间隙是否过大。shoeanddrumgapistoolarge.（3） 管路中是否有空气。whetherthereisairinthepipes.每工作200小时，应检查制动蹄片的磨损。当蹄片磨损到使踏板行程过大时，必须调整蹄片和鼓之间的间隙，其过程如下：Every 200 hours, you should check the wear of the brake shoes. When the shoe wear to the pedal stroke is too large, must adjust the clearance between the shoes and drums, the process is as follows:1、顶起需调整的车轮。Adjustmentwheel.2、在制动底板的背面找到偏心轮螺栓，转动偏心轮螺栓，直到蹄片与鼓接触，然后放松偏心轮螺栓，直到车轮自由转动并且蹄片与鼓不再磨擦时为止。Find cam bolts on the back of the brake plate, turn eccentric bolts until the foot contact with the drum, then relax the eccentric bolt until the wheel turn freely and friction shoes and the drum is no longer the time.在更换制动液以及贮油壶干底后添加新制动液时，需要将制动管路及泵中空气放净。其方法如下:Replacementofbrakefluidandoilstoragepotsatthebottomandaddnewbrakefluid,needtoputairinthebrakelinesandpumpclean.Themethodis as follows:1、 将制动踏板连续地踏下数次，松开放气阀，放出管内空气，旋紧气阀，松开制动踏板。如此重复数次，直到油路内空气排完为止。The brake pedal to press a few times in a row, loose open air valve, releasing air and tighten the valve and release the brake pedal. Repeat several times until the air in the circuit have been exhausted.2、放气过程中要随着贮油壶油面降低而不断添加制动液,不能让贮油壶干底，全部放气完毕后，应把制动液加足。本机应加“912”刹车油。制动踏板的自由行程由制动总泵推杆来调整。Put gas in the process of with the Oiler oil to reduce storage and adding brake fluid and not let oil storage pots dry bottom, after completion of all gas, you should add plenty of brake fluid. This machine should be 912 brake fluid.Brake pedal free travel from the brake master cylinder push rod adjustment.六、工作装置液压系统Workingdeviceofhydraulicsystem工作装置液压系统是由齿轮泵、多路换向阀、优先阀、动臂油缸、翻斗油缸、转向油缸、工作油箱及油管等组成。压力油从齿轮泵经优先阀、多路换向阀，通过操纵相应的滑阀把油液输送到各油缸。工作装置不工作时，油液经多路换向阀的中间油道回油箱。Working device of hydraulic system is made up of gear pumps, multi-valve, priority valve, cylinder, tipping bucket, to the fuel tank, the fuel tank and the fuel tank tubing and other components. Pressure oil gear pumps with priority valves, directional valves, by operating the corresponding sliding valve sends oil into each cylinder. Device is not working, oil hydraulic multi-way directional valve oil back in the middle of the tank.第四章 电器设备ZL15电器系统采用直流电压12伏，负极接地制。ZL15 electricalsystemwithDCvoltage12v,negativegroundsystem.一、蓄电池Battery蓄电池型号为6-QA-120，它的功用上是发动机起动时，供电给起动电动机；当发动机正常工作时，若发电机的电压低于蓄电池的电压时，则供电给用电设备；若发电机的电压高于蓄电池的电压时，则发电机向蓄电池充电，以储存一部分电能。Battery type for 6-QA-120, its function is on when the engine is started, to supply power to starter motor when the engine is working properly, if the generator voltage is lower than the batterys voltage, then the power supply to electrical equipment; if the generator voltage is higher than the batterys voltage, the generator to charge batteries to store part of the electric energy.在使用中应注意：Inuseshould benoted:1、 经常保持充电状态，如长期不用，每月最少应充电一次。Keepthechargingstatus,corrode,chargingat leastonce amonth.2、 经常检查电解液液面高度，液面应高出极板10-15毫米，不足时可添加蒸馏水。如确因电解液漏洒损失时，则应加比重为1.28的电解液。Alwayschecktheelectrolyteliquidlevelheight,liquidlevelshould beabovetheplate10-15mm,mustbesufficienttoadddistilled water.Ifspillduetoelectrolyteloss,youshouldadd1.28oftheelectrolyte.3、 应经常检查蓄电池通气孔是否堵塞，如若堵塞，应及时清除外部泥土和脏物，擦净溢出的电解液，并在电极上涂以薄层钙基润滑脂以防腐蚀。Shouldalwayscheckthebatteryventsareunblocked,ifblocked,should befreeofexteriordirtanddirt,wipethespilledelectrolyteandelectrodescoatedwithathinlayerofcalciumbasegreaseto avoidcorrosion.4、 不得频繁使用起动机。Notfrequentlyusedstarter.5、 蓄电池应紧固,以免受震动而损坏。Batteryshould besecuredtoavoidvibrationdamage.二、发电机与调节器Generatorandregulator1、硅整流发电机：Siliconrectifyinggenerator:发电机上标有 “+”、“F”两个接线柱和一个 “”接地钉。它们应与继电调节器上标有相同文字的接线柱连接。Generatorismarkedwith+andftwoterminalsanda-groundingstuds.Theyshould beidenticaltorelaycontrollerismarkedwiththetextterminalconnection.发电机两端用螺栓固定在发电机支架上；另有一个发电机撑脚，用来调整三角皮带张紧度。Generatorendsboltedtothealternatorbracket;theotherleghasagenerator,used toadjustthebelttension.2、 继电调节器Relaycontroller继电调节器是由截流器、调压器、限流器三个装置所有组成。继电调节器上标有“+”、“F”二个接线柱和一个“”接地螺钉，“+”、“F”接线柱应与发电机上相应的接线柱相连。蓄电池的“+”接线柱与电流表“”极相连，电流表的“+”极接线柱与电锁的一档相连。Relay controller is by closure, voltage regulator, limiting three devices all components. Relay controller is marked with + and f two terminals and a - grounding screw, +, and f terminals should be connected to the corresponding terminal on the generator.Batterys + Terminal and ammeter - connected ammeter + pole with one of the electric lock connected to terminals.发现调节器工作不正常或使用1000小时后，需要有熟练的电工进行调整。Regulatorisnotworkingproperlyorafter1000hoursofusageisfound,youneedtoadjustaskilledelectrician.三、起动机Starter它的用途是由蓄电池供给电源来起动发动机。起动机齿轮的转动是以电磁驱动，并带有单向滚柱式离合器，能防止起动机电枢随起动后的发动机高速旋转而损坏。Itsuseissuppliedbythebatterypowertostarttheengine.Startergearrotationisbasedonelectromagneticactuation,withone-wayrollerclutch,whichcanpreventtheStarterarmaturewithhigh-speedrotationandafterstartingtheenginedamage.四、其他Other1、电流表Ammeter电流表用以蓄电池的充、放电电流显示，当发动机向蓄电池充电时，指针偏向“+”；反之则为指向“-”极；无电流通过则为指零。Ammeters used to display battery charge and discharge currents, when the engine to charge batteries, pointer deflection + and vice versa is to point to the - pole; no current through it to mean zero.2、电锁 Electriclock电锁控制整个电气系统，钥匙插入锁孔后，向右转一档时，所有电器的电源接通；向右转二档，起动机起动。为了保护启动马达，要求在发动机起动后，立即将电锁松开，钥匙自动复位至一档位置。Electric lock control your entire electrical system, insert the key into the lock hole, turn right one notch, all electrical power on; turn to second gear, starter motor starter. In order to protect the starter motor, asked after the engine start, the electric lock release immediately, key auto reset to the first gear position.第五章 驾驶操作在进行驾驶与操纵作业之前，应熟悉装载机的结构、技术保养、操作方法等，才能保证安全行驶与作业，提高装载机的寿命与生产率。Before driving and manipulation in the job should become familiar with the structure, technical, maintenance and operational methods of the loader to ensure safe driving and work, improving the life and productivity of loaders.在进行驾驶与作业操作时应注意以下安全事项：Whentheyaredrivingjobactionshouldbeawareof thefollowingsecurityconsiderations:1、 驾驶员必须经过交通规则、机械结构、操作方法等的学习，并阅读使用说明。Drivers must be the rules, learn mechanical structures, methods of operation, and read the instructions for use.2、 行驶时除驾驶室内，任何地方不许乘坐人员。Apart fromamovingcab,anywherenotonstaff.3、 随时注意仪表所反应的各种工作状态。Always checkinstrumentsreflectavariety ofworkingconditions.4、 作业时严禁人员在动臂和铲斗下走动。Operationspersonnelis prohibitedundertheboomandbucket.5、 发动机熄火时立即停车，以防转向失灵造成事故。Enginestopimmediately,incasetheSteeringmalfunctioncausedtheaccident.一、 新车走合Newcarco1、 使用单位在新车使用时，必须进行试运转，未经试运转的新车不得正式作业使用。Use the unit when used on new cars, and commissioning must be carried out, without commissioning new car may not be used on official work.2、 试运转能使机器各磨擦部位进行磨合。避免故障，从而保证装载机可靠地工作。Commissioning can make the rubbing parts of the machine to adjust. Avoiding failure, thus ensuring the loader to work reliably.3、 本规定同样适用于经过大修后的装载机。Theseprovisions shallalsoapplyaftertheoverhaul, theloader.4、 新车试运转分空车试运转和作业试运转二步进行。New car test run carried out in empty car set-up and operation commissioning the second step.二、 空车试运转Theemptytest run（约8h）1、方法Method按规定的方法起动柴油机，起动后低速空转（不挂档）5min以上，然后逐渐加速到最高转速运转10min。In accordance with the prescribed method for starting diesel engines, after starting low speed idle (without gear) 5min above, and then gradually accelerate to maximum speed 10min.操作工作装置动臂操纵杆和翻斗纵杆，使动臂提升、下降，铲斗倾翻和收斗，约进行10 min。OperationleveranddumpverticalRoddeviceboom,jiblifting,descending,tippingthebucketandtakeabout10min.挂上前进档、后退档、空车行驶。先低速后高速，每档位均匀安排。Hung forward and backward gears, driving empty cars. Low speed high speed after each stall evenly arranged.2、检查项目Inspectionitems全面检查各部位螺栓、螺母紧固情况。特别是气缸盖螺栓、排气管螺栓及前后驱动桥固定螺栓、轮辋螺母、传动轴连接螺栓等均应检查一次。Comprehensive check each part of the bolt and nut fastening. In particular cylinder head bolts and exhaust pipe bolt and rear driving axle rim fixing bolt, nut, shaft connections bolts should be checked again.检查变速箱的油位。Checkthegearboxoillevel.发动机、变速箱、驱动桥等部件有无异常声响。Componentssuch asengine,transmission,driveaxlehasnoabnormalnoises.工作装置液压系统、变速箱、发动机的润滑系统、制动系统、发动机的水冷系统等有无漏油、漏水现象。Workingdeviceofhydraulicsystems,transmissions,enginelubricationsystem,brakingsystem,enginecoolingsystemsthere arenospillsandleakagephenomenon.各仪表读数是否正常。Themeterreadingsarenormal.转向是否灵活，制动是否灵敏可靠。Steeringisflexible,brakesaresensitiveandreliable.工作装置动作过程中有无卡滞现象。Deviceseizure-freemovementoflabor.检查电器的工作情况。Checktheelectricalwork.三、 作业试运转Operationscommissioning（约20 h）1、 按作业操纵方法进行作业，装料量应逐渐增加。Jobsbyjobcontrolmethods,chargeamountshouldgraduallyincrease.2、 作业试转过程，除检查空车试运转的检查项目外，还要，观察装载机在不同物料中的铲装能力。Job trial process, in addition to check for empty test run checked items, but also, observe loader loading capacity in different materials.3、 在走和期内装载重量不得超过额定载重的70%，行驶速度不得超过最高速度的70%。Andbuilt-in load must not exceed the rated load capacity of 70%travelspeedshall not exceed the maximum speed of 70%.4、 在走和期内以铲装疏松物料为宜，动作不得过猛过急。Andinperiodinloadingunconsolidatedmaterialisappropriate,nottoohardtoo fast.四、 装载机的使用Loaderused（一） 使用注意事项Notetheuseof1、 加添的柴油必须清洁，柴油标号应符合规定的质量要求。Adddieselmustbeclean,dieselgradeshallmeetthespecifiedqualityrequirements.2、 工作装置液压系统使用的液压油必须清洁。Workingdeviceofhydraulicsystemofhydraulicoilusedmust beclean.3、 按规定进行定期保养和润滑。Requiredforregularmaintenanceandlubrication.4、 发动机启动后，进行空运转，待水温达到55后再起步行驶。Aftertheenginestarts,idlerunninguntilthewatertemperaturereaches55degrees Celsiusandstartdrivingagain.5、 当操纵动臂与转斗达到需要位置后，应将操纵杆置于中间位置。When you manipulate the boom and bucket come up to the required position, lever should be placed in the middle position.6、 不得将铲斗提升到最高位置运输物料，运载物料时应保持料斗底面离地300mm，以保持稳定行驶。Bucket may not be promoted to the top position, transport material, which carries the material should be kept away from the hopper to the base 300mm in order to maintain stability.(二)、空车行驶Emptydrive1起动Starting进行出车前检查，确认各部均属于正常后进行起动发动机。Checkbeforedri