装载机岗位操作手册.docx

装载机岗位操作手册.docx

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装载机岗位操作手册

水泥事业部中央控制室

车队司机岗位操作手册

编制:

王义明

审批：

赵永梅

批准：

张明

文件编号：

MXSN-SN-ZK-01

一、司机岗位职责·····················································4

二、适应范围························································4

三、岗位作业规程·····················································4

四、装载机安全作业操作规程···········································4

五、装载机使用中的注意事项···········································5

六、装载机作业方法···················································6

6.1铲装作业························································6

6.1.1作业准备····················································6

9.1.2作业过程····················································6

6.2铲装方法························································6

9.2.1一次铲装法··················································6

6.2.2配合铲装法··················································6

6.3装载机与运输车辆配合的作业方案·································6

6.3.1、V型作业方法···············································6

6.3.2、I型作业方法···············································7

6.3.3、L型作业方法···············································7

6.3.4、T型作业方法···············································7

6.4搬运工作························································7

6.5推运作业························································7

6.6整地作业························································7

6.6.1撒土作业···················································7

6.6.2粗平整·····················································7

6.6.3精平整·····················································7

6.7挖掘作业·····················································7

6.7.1铲进作业···················································7

6.7.2挖土作业···················································7

6.8牵引作业························································8

七、装载机的停车·························································8

八、卫生环保职责·························································8

九、装载机的定期保养和润滑···············································8

9.1日常检查保养······················································8

9.1.1每班启动发动机前应检查的部位··································8

9.1.2每班启动发动机后应检查的部位··································9

9.1.3作业运行中的检查··············································9

9.2定期维护保养······················································9

9.2.1每50工作小时的维·············································9

9.2.2每100工作小时的维护··········································9

9.2.3每250工作小时的维护··········································9

9.2.4每500工作小时的维护··········································9

9.2.5每1000工作小时的维护·········································10

9.2.6每2000工作小时的维护·········································10

十、装载机的常见故障及排除···············································11

10.1传动系统·························································11

㈠各档变速压力均低·················································11

㈡某个档变速压力底·················································11

㈢变矩器油温过高···················································11

㈣发动机高转速车开不动·············································11

㈤驱动力不足·······················································11

㈥变速箱油位增高···················································11

10.2制动系统························································11

㈠脚制动力不足····················································11

㈡刹车后挂不上档（变速压力表不指示）·······························12

㈢停车制动器不能正常松开··········································12

㈣听车后空气罐压力迅速下降（30分钟气压下降超过0.1MPa）············12

㈤刹车气压表压力上升缓慢··········································12

㈥紧急及停车制动力不足············································12

10.3工作液压系统····················································12

㈠动臂提升力不足或转斗提升力不足··································12

㈡发动机高转速时，转斗或动臂提升缓慢······························12

10.4转向液压系统····················································12

㈠转向费力························································12

㈡车子转向不平稳··················································13

㈢车子左右转向都慢················································13

㈣车子一边转向快一边转向慢········································13

㈤转动方向盘车子不转向············································13

㈥司机不操作车子自传··············································13

㈦司机不操作方向盘自传············································13

㈧车子高速运转时转向太快··········································13

㈨转向泵噪音大，转向缸动作缓慢···································13

10.5电气系统·························································13

㈠发电机不发电或发出电压低·········································13

㈡发电机过热·······················································13

㈢蓄电池不充电或充电电流过小······································14

㈣蓄电池充电电流长时间过大········································14

㈤电传感仪表无指示················································14

㈥发动机无法启动或启动困难········································14

㈦发电机不熄火····················································14

㈧灯具不亮························································14

㈨仪表指示至最大量程··············································14

十一、成本质量控制····················································15

11.1装载机节油的管理················································15

11.3车辆加油管理···················································15

11.4开展修旧利废活动················································15

11.5实行定人定车管理················································15

一、司机岗位职责

1.1熟悉车辆工作原理、机械常识，交通规则。

1.2自觉遵守交通法规和安全操作规程，严格执行车辆日常保养制度。

1.3驾驶所属车辆完成生产任务。

负责各条生产线上料、堆场均化平整、物料倒运等工作。

1.4听从中控值班主任的统一调动，保证各生产岗位上的正常运行；除水泥事业部中控室和车队长以外，其他任何人没有权利随便调车。

1.5每位司机严格执行定人定车制度，不准乱用他人车辆。

对所属车辆经常要主动进行维护、保养。

1.6对发生故障的车辆应及时向车队申报，小故障自己负责排除，大故障应提出维修方案并配合修理工实施维修。

1.7认真完成值班长与车队长零时安排的工作任务。

1.8认真学习岗位知识，努力提高技术水平，加强服务质量。

二、适用范围

适用于蒙西水泥事业部中央控制室车队司机。

三、岗位作业规程

3.1上班必须在45分钟前到中控值班主任室签到，正点后必须到达现场。

3.2司机上料时，必须按值班主任的规定和比例上料；并与上料工配合完成上料任务；无故不得上错或耽误上料。

3.3自觉干好工作范围内的活，不得故意拖延工作时间或出工不出力。

3.4司机在交接班时，各岗位料仓必须上满，堆场必须平整好；熟料库必须倒空；并同时向下一班司机交代上料情况和生产程序。

3.5值班车辆的活动范围为水泥事业部生产线，加油、修理或别的事情要离开作业现场，必须向值班主任、班长请假。

3.6每班值班车辆要为下一班司机加好燃油，保证生产正常运行。

3.7车辆在修理期间，司机必须一人在场负责配件的领用，并监督车辆的维修质量。

四、装载机安全作业操作规程

4.1所有本部门岗位工必须经过岗前三级（质技部、水泥事业部、工段）安全、消防培训并经考试合格后方可上岗；

4.2装载机驾驶员必须经过专业操作培训，熟悉装载机的结构、性能及工作原理，经考试合格后，持证方可操作装载机。

4.3车辆在厂区内行走时，最高时速不得超过每小时10公里；不得超速行驶欺行霸道；对其它车辆要互相避让安全通过。

4.4车辆在运行时，除装载机驾驶室内动臂与前车架之间，铲斗、机盖及其它任何部位一律不准乘坐人。

4.5严禁酒后上岗，或将车辆交于非驾驶员驾驶。

4.6车辆在作业现场必须要注意该现场其它工作人员的安全，设备的安全，前进后退时一定要环顾四周有无车辆行人通过；并和所装卸车辆保持一定的安全距离。

4.5司机在各岗位上一定要和放料工配合好，上料时要鸣喇叭并下车查看篦子上是否有人，确认无人方可上料。

4.6所有司机必须时刻注意安全意识，在执行各种工作任务时，该任务存在有不安全因素的司机有权拒绝不干并向上级反映。

4.7车辆使用时，司机必须认真检查各油位和冷却水及各机械连接部件的情况；经常检查并紧固各种螺丝螺母；防止车辆的早期磨损和损坏；把事故处理在萌芽状态。

4.8装载机行驶时，铲斗应保持在运输位置，即斗底与地面相距约400mm。

应避免急加速、急转弯、急刹车和锯齿形行车等，以保证装载机能稳定行驶。

4.9装载机在下坡时，严禁关闭发动机脱档滑行。

否则，将会导致液压转向失灵，造成重大行车事故。

4.10装载机在进行装卸物料时，严禁在物料偏向一侧或铲斗举至最高位置时运输物料，以确保稳定，保证装载机安全行驶。

4.11装载机取货前，车体前后应成直线，对正并靠近货堆，同时将铲斗平行接触地面，然后进行取货。

4.12取货时要根据物料的阻力，选用适当的档位和速度，铲斗插入货堆后，提升动臂，同时把铲斗向后收，车体继续前进。

4.13装载机作业时应遵守以下“六不准”：

①不准用高速档取货；

②不准边转向边取货；

③不准升高铲斗行驶；

④不准在斜坡路面上横向行驶；

⑤不准铲斗偏重行驶；

⑤不准在升起的铲斗下面站人或进行检修。

五、装载机使用中的注意事项

6.1进行出车前的检查工作，确认各部位正常后，检查各操纵手柄是否置于中间，若停机放置的时间较长，应先用手油泵向燃油系统中注燃油，并旋松喷油泵上的放气螺钉，以排空燃油系统中的气体。

起动时，打开钥匙开关，接通总电源，按下起动钥匙旋转即可起动。

若首次起动失败，须等待2～5钟后再作第二次起动，如三次不能起动时，应停止起动，找出原因，排除故障后再行起动。

每次起动时间不得超过12秒。

6.2发动机起动后，应在600～750r/min的转速下进行暖机，并密切注意各仪表的读数，特别是柴油机机油压力表的读数，其数值应大于0.05MPa。

当气压表的读数大于0.44MPa后，方可出车。

6.3发动机起动后，检查装载机各部位是否正常，将动臂提升至运输位置；松开手制动，踩下制动踏板，轻轻操纵变速操纵杆，将操纵杆挂在选定的档位；松开脚制动踏板，缓慢踩下油门踏板，使装载机逐渐加速。

待水温达到75℃后，才能全负荷作业。

6.4装载机在同方向行驶时换挡不必停车，也不必踩制动踏板；但若改变行驶方向，则一定要在停车后换挡。

6.5装载机在坡道上行驶或作业时，选择阀应置于不切断位置（适用于有选择阀的装载机），因制动时变速箱仍有动力输出，一旦制动解除能迅速起步，以保证装载机运行平稳；否则，若选择阀置于切断位置，踩下制动踏板，变速箱的油路被切断，从而使变速箱无动力输出，装载机停车后再次起步就会出现溜坡和不稳定的现象。

6.6在操纵转斗油缸操纵杆时，当转斗置于合适位置，松开操纵手柄，操纵杆可自动回位；但当操纵动臂油缸操纵杆时，当动臂举升（或下降）到所需位置后，应将操纵杆置于中间，因动臂操纵杆没有自动回位的功能。

6.7装载机在作业过程中，发动机的水温不得超过95℃，变矩器的油温不得超过115℃。

若由于长时间重载作业，油、水温超过允许值时应停车冷却。

6.8若装载机在运行中发动机突然熄火，应立即踩下制动踏板，因此时转向油泵已停止工作，故不能转动转向机实施转向。

6.9在行驶中严禁高速行车！

高速行驶会对安全造成威胁。

装载机下坡行驶时，应轻踩制动踏板，并保持发动机在运行状态。

严禁关机溜坡！

6.10对于装载机的各零部件应按规定进行定期的保养和润滑。

6.11装载机变速箱—变矩器中使用的液力传动油、液压系统中使用的液压油必须清洁并符合规定要求。

六、装载机作业方法

6.1铲装作业

6.1.1作业准备

清理作业场地，填平凹坑，铲除尖石等易于损坏装载机轮胎和妨碍装载机作业的障碍物。

铲装作业时，行驶速度应降至4km/h以下。

6.1.2作业过程

装载机的作业循环包括以下四个过程：

①装载机以一档驶向料堆，在距料堆约1～1.5m处，放下动臂、转动铲斗，使铲斗刀刃接地，铲斗斗底与地平面成3°～7°的夹角，然后低速插入料堆。

②装载机以全力插入料堆，并间断地操纵铲斗转动和动臂上升，直至装满铲斗，然后把铲斗上翻、将动臂提升至运输位置。

③装载机装满后退，驶向卸料点或运输车辆，同时提升动臂至卸载高度将物料卸下。

若物料粘积在铲斗上，可来回搬动转斗操纵手柄，撞击撞块，使粘积在铲斗上的物料弹振脱落。

④空车退回，同时将动臂下降至运输位置，装载机返回至装料堆进行下一个工作循环。

6.2铲装方法

不同的铲装方法对作业阻力和铲斗的装满程度有很大影响，工作时应根据铲装的物料种类（容重、粒度大小等）、料堆高度等选用不同的铲装方法。

6.2.1一次铲装法

一次铲装法，装载机直线前进，铲斗刀刃插入料堆，直至铲斗后臂与料堆接触，装载机停止前进，铲斗转至装满位置，然后提升动臂至运输高度（铲斗下铰点离地面高度约400mm左右）。

一次铲装法是最简单的铲装作业方法。

对驾驶员操作水平要求不高。

但其作业阻力大，需要把铲斗插入料堆很深，因而常要求装载机有比较大的插入力，同时需要很大的功率来克服铲斗上翻时的阻力。

用来铲装松散物料，如煤、砂、焦炭等。

6.2.2配合铲装法

装载机在前进的同时，配合以转斗或动臂提升的动作进行铲装作业。

它可又细分为两种方法：

a.当铲斗插入料堆不大的深度（约为0.2～0.5斗深）时，在装载机前进的同时，间断地操作铲斗上翻，并配合动臂提升，直至装满铲斗。

b.装载机在前进的同时，配合以动臂提升，在斗刃离开料堆后，铲斗转至运输状态。

此方法又称为“挖掘机”铲装法。

采用配合铲装方法，铲斗不需要插入很深，特别是采用前一种配合铲装法，靠插入运动与铲斗转动、提升运动相配合，使插入阻力大大减小（其阻力一般为一次铲装法的1/2～1/3），并且铲斗也容易装满，是一种比较有效的作业方法，但要求驾驶员具有较高的操作水平。

6.3装载机与运输车辆配合的作业方案

装载机与运输车辆相配合的作业方案一般有V型作业法、I型作业法、L型作业法和T型作业法。

6.3.1、V型作业方法

运输车辆与装载机驶向料堆的方向成60°夹角停放，装载机在料堆装载后，倒车后退3～5m左右，然后用转向油缸使铰接车架折腰35°左右，再前进驶往运输车辆卸载。

这种方案可保证得到最少的工作循环时间，作业效率较高。

6.3.2、I型作业方法

运输车辆平行于工作面适时地往复前进与后退，装载机则穿梭般地垂直于工作面直线前进与后退进行作业，所以这种作业方法也叫穿梭作业法。

I型作业方式省去了装载机的调车时间，但增加了运输车辆前进与后退的次数，因此采用这种作业方式，装载机的作业循环时间，取决于装载机和其配合作业的运输车辆的驾驶的操作技术熟练程度，并要求车队连续运输与之配合，才能取得较高的作业效率。

6.3.3、L型作业方法

运输车辆垂直于工作面，装载机铲装物料后，倒退并调转90°角；然后向前驶向运输车辆卸载，空载的装载机后退调转90°角，然后向前驶向料堆，进行下一次铲装。

这种作业方式在运距较小，而作业场合比较宽广时，装载机可同时与两台运输车辆配合工作。

6.3.4、T型作业方法

运输车辆平行于工作面，但距离工作面较远，装载机铲装物料后，倒退并调转90°角；然后再向相反方向调转90°角驶向运输车辆卸料。

6.4搬运工作

在以下情况下，可采用装载机自行搬运：

6.4.1路面过软，未经平整的场地，不能用载重汽车的。

6.4.2搬运距离在500m以内，用载重汽车浪费时间。

搬运的车速根据搬运距离和路面条件决定，为使搬运时安全稳定和具有良好的视线，应上转铲斗到极限位置并保持动臂下铰点距地面400mm左右。

6.5推运作业

如果将铲斗作为推土刮板时，可以进行填平作业。

此时铲斗内装满沙土，使其对地面保持水平状态，踩下油门踏板使铲斗向前推进，推进中发现阻碍装载机前进时，可稍稍提升动臂继续前进，铲装动臂升降时，操纵杆应放在浮动位置，不可扳倒上升或下降任一固定位置，以保证推运作业的顺利进行。

6.6整地作业

利用铲斗斗尖和刀板可进行撒土、平地、打基础等整地作业，

6.6.1撒土作业

用铲斗铲进砂土，装载机后退行驶，并使铲斗前倾10°～15°度角，将砂土均匀播撒。

6.6.2粗平整

使铲斗完全前倾，将铲斗的斗尖与地面接触，进行低速后退，平整土地。

6.6.3精平整

将铲斗内装满砂土并与地面保持水平状态接地。

将动臂操纵杆放在“浮动”的位置上，装载机缓慢后退行驶。

6.7挖掘作业

挖掘作业是装载机停止或在前进中将铲斗插入砂土、岩石等堆积物进行装载铲运的作业，挖掘