As a heavy machine, loaded with dozens of tons of electric cymbals, although it is a kind of reinforced iron bone, but it also has a delicate time, if we do not pay attention to maintenance at all important stages, then the future may be in the high maintenance cost It will be very painful.
First, do some "don't" in the baby life of the loader:
1. Do not overload, the working load during the running-in period should not exceed 60% of the rated working load, and prevent overheating caused by long-term continuous operation;
2. Do not drive the vehicle, check the dashboard, motor oil and seal. Fill the lubrication points with grease every shift;
3, don't let the car dirty, tighten the parts often;
4. Don't ignore maintenance;
5. Do not leave the operation manual aside.
Second, the infant period of the loader
Loader infant period is also known as the new machine break-in period.
We usually see a very interesting phenomenon: if it is a car, especially a private car, people often care about the use of the new car during the running-in period. They dare not drive fast and dare not drive far. Poor running-in affects future performance, but the loader does not receive such care.
The first 60 hours after the loader leaves the factory is the break-in period, but for this big guy who works after buying it, it is people's concern to seize the time and make money. Since it is a new machine, it must not be used very hard. Anyway, there is a period of repair. As a result, the machine is often overloaded, and early failures occur frequently. With a lot of confusion, the service life of the machine is greatly reduced.
In fact, what we have to understand is that the new machine has rough surfaces due to the parts and other components just started, and the concave and convex parts rub against each other during the operation of the machine. The metal debris that is rubbed off participates in the continued friction, so the parts in this period are easy to wear If it is overloaded at this time, it is easy to cause damage to components and early failure. In addition, the newly assembled parts have a small gap, and it is not easy for the lubricating oil to form a uniform protective layer on the surface of the parts, resulting in wear and tear, and in serious cases, surface scratches. Coupled with various differences in the shape, size, material, and assembly of new parts, there will always be deformation and looseness during the operation of the machine.
In addition, many people never buy the new machine and never read the manual. Based on experience, it is easy to ignore some important precautions and operating rules. Under such operation, the machine will of course be injured.
III. The young and middle age of the loader
This is the stage where the machine plays its most important role. Although all parts have come out of the running-in period and the lubrication coordination is in place, it can not increase the workload without restraint. In fact, more attention has been given to the online maintenance and repair time. Table, here is for you to broadcast this timetable again.
every day
1. Check for oil, water, gas leakage and overheating of machine parts;
2. Check the level of diesel engine oil, coolant and hydraulic oil;
3. Check tire pressure and damage;
4. Check the instrument and lighting;
5. Press butter at each hinge point.
Every 50 hours
1. Check and tighten the front and rear drive shaft bolts;
2. Check the gearbox oil level;
3. Check and adjust the amount of foot brake and hand brake, brake booster oil;
4. Check the throttle control and variable speed control system.
Every 100 hours
1. Change the transmission oil (after every 600 hours), clean the oil pan filter;
2. Change the engine oil (after every 600 hours);
3. Check the liquid level of the battery, and apply Vaseline to the battery terminal;
4. Check the tightening of the rim, brake disc bolt and bridge bolt;
5. Check the tightening of each tightening bolt.
Every 200 hours
1. Check the oil level of the front and rear axles;
2. Clean the air filter (replace the filter if necessary);
3. Cleaning oil, diesel and transmission oil filters;
4. The measured tire pressure is 0.27 ~ 0.31Mpa;
5. Check the working device, whether the welds of the front and rear frames are cracked;
6. Check the tightness of the generator and fan belt.
Every 600 hours
1. Replace the front and rear axle gear oil (after every 1000 hours);
2. Cleaning the oil filter of the diesel tank;
3. Remove the pollutants on the surface of the water tank and radiator;
4. Replace the engine oil, replace the oil and diesel oil filter;
5. Replace the transmission oil and oil filter;
6. Check the engine valve clearance.
Every 1200 hours
1. Replace the hydraulic oil, clean or replace the oil filter, and clean the oil tank;
2. Check the operation of the engine;
3. Check the working condition of the hydraulic system;
4. Check the performance of the steering system;
5. Check the performance of the brake system and replace the brake fluid.
Every 2400 hours
1. Check and repair the engine according to the engine manual;
2. Dismantle the gearbox and torque converter;
3. Perform disassembly inspection on the front and rear axles;
4. Check the welding seams of various parts of the whole machine.
Fourth, the life of the loader is extended
The depreciation period of the loader is 10 years, but after 5,000 hours of use, various problems will occur. Therefore, in addition to maintenance during young adults, more attention should be paid to the method of extending the life of the loader after 5000 hours.
1) Reduce the invisible wear caused by the environmental climate to the loader
This is to reduce the impact of environmental factors on its service life. Since most construction machinery is open-air operation, the operation site often changes, so the temperature and temperature of the work site have a great influence. For long-term fixed operation machinery, there must be a parking lot (shed) or a cover, and maintenance measures using wooden support pads to reduce the invisible wear caused by sun, rain and rust. Many construction units ignore the impact of the environment on the use of machinery (the ambient temperature is too low, and it can also have catastrophic consequences for the machine). Failure to take appropriate protective measures or adaptation measures will result in reduced mechanical performance, shortened service life and even accidents.
2) Adhere to the "two fixed and three guaranteed" system
Set up, set up, pack and use, pack and store, pack and maintain, load the operator to do "three understandings" (understand the structure, understand the principles, understand the performance), "four meetings" (will be used, will be maintained, will be inspected, general faults will be eliminated ). Proper use of loader, strict implementation of safety technology operation procedures, implementation of target cost management of mechanical equipment, economic benefits of operators and hooking of loader use fees (such as fuel costs, maintenance costs, maintenance costs, materials, tools, etc.) Passive daily maintenance equipment for active daily maintenance.
3) Low-cost rapid repair method
The "low-cost rapid repair method" proposed by the machinery industry is also an effective method to extend the service life of machinery. In addition to mechanical design, maintenance design is also used to improve the maintainability of the machine. The following methods can also be used for maintenance practice:
4) Adopt advanced mechanical testing and other auxiliary maintenance methods
Mechanical maintenance work is an important part of prolonging the service life of machinery. Through reasonable maintenance methods, the service life of construction machinery can be effectively extended. According to statistics of relevant data, the use of advanced condition monitoring methods can reduce maintenance costs by 25% to 50%, failure rate by 75%, and machine life.
5) Regular maintenance of the loader is the key to extending the life
"Ministry of Communications Road Maintenance Machinery Warranty Regulations" has clear regulations on the maintenance of loader. However, when the construction period is tight and the tasks are heavy, many construction units often neglect the maintenance work. It is believed that the machine is operating normally and there is no malfunction and there is no need to stop maintenance. This masks the hidden dangers of future mechanical accidents. Because maintenance can eliminate mechanical hazards, if it is not maintained in time, it will often cause serious failures of mechanical equipment and even cause personal injuries. This will increase maintenance costs and delay construction time.
First of all, using advanced brush plating and adhesive repair technology can also repair faulty parts quickly and economically. Such as wear-resistant surfacing, sprayed diamond plating, magnetic plating, laser plating, etc.
Second, the machine is not only a tool for us to make money. We should like these big guys. For example, we care about children, pay attention to maintenance and use each stage of life correctly, which can save our maintenance costs and save us time and energy for work.
Third, it is the replacement of parts. Many parts on construction machinery, such as bulldozers, crawler pins of excavators, and cylinder liners of diesel engines, are often subjected to unidirectional loads during operation. If they are not replaced correctly, it will cause uneven wear. Balance the position of load components to make them wear, and then extend the service life.
