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Operation and Maintenance Training Courseware Of Wheel Loader 4 March 2011

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Title: PRES FORMAT Author: Volvo Employee Last modified by: CN06413 Created Date: 8/18/1997 6:12:36 PM Document presentation format: A4 (210x297 ) – PowerPoint PPT presentation

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Title: Operation and Maintenance Training Courseware Of Wheel Loader 4 March 2011


1
Operation and Maintenance Training Courseware Of
Wheel Loader 4 March 2011
2
Main Content
  • Suitable Group
  • Training Objectives
  • Contents
  • Evaluation Topics

3
Suitable Group
This course is suitable for key accounts and
loader drivers. It also applies to service
technicians at service stations.
4
Main Content
  • Suitable Group
  • Training Objectives
  • Contents
  • Evaluation Topics

5
Training Objectives
1. This training course is expected to have 8
hours. 2. After training of this course,
students should master the following main
knowledge points (1)Operation and maintenance
safety of loader (2)Content and steps of proper
operation and maintenance of loader (3)Operating
methods (4)Regulations of mandatory service
6
Contents
Safety Precautions
1
1
Operation
2
Maintenance
3
Service
4
7
Introduction
  • 1. This teaching material is mainly to guide
    users to correctly operate and maintain the
    machine, to ensure good operation of the machine.
  • 2. Before operating the machine, users must
    carefully read related content in Operation and
    Maintenance Manual, and execute strictly
    according to the relevant provisions.
  • 3. In construction process relevant state laws
    and regulations and management regulations must
    be followed.

8
Safety Precautions
  • 1. Only personnel who have received special
    training or related operation qualification can
    operate the machine.

9
Safety Precautions
  • 2. Operator shall be in good condition.

10
Safety Precautions
  • 3. When the view is limited, specially-assigned
    person must be responsible for directing, and
    ensure that all the people understand the
    gestures and signals.

11
Safety Precautions
  • 4. Operator shall ensure that all the safety
    equipments of the machine are in good condition
    and operated in accordance with regulations .

12
Safety Precautions
  • 5. Selection of working conditions for the
    machine. Client shall select different working
    devices according to working conditions.
    Otherwise, service life of the machine will be
    reduced, and man-machine potential safety hazard
    will be increased.

Mine, quarry and other working conditions
Best configuration rock bucket
Reduce service life!
Firm Durable!
13
??? Bigger bucket 2.2/2.5m3
???? Snow removal device
????? 4 in 1 bucket 1.8m3
8
1
7
??? Rock bucket 1.5m3
??? Log grapple
???! attachment
2
6
5
3
??? Side dump bucket1.4m3
4
??? Grass grapple
?? Pallet fork
14
Contents
Safety Precautions
1
1
Operation
2
Maintenance
3
Service
4
15
Operation
Inspection before Starting
1
1
Starting
2
Inspection after Starting
3
Operation
4
16
Inspection before Starting
  • 1. Oil Level of Engine
  • Oil amount of engine(Oil inspection scale when
    the loader is leveled and stationary )

17
Inspection before Starting
  • Level of Hydraulic Oil
  • Inspection Conditions
  • ? The loader shall be stopped on flat and firm
    ground for operation.
  • ? When speed control is at neutral position,
    start the machine, take up the bucket, step on
    the gas and lift the lifting arm to the top
    position. With bucket flat mechanism, lean
    forward the bucket to flat position. And then
    slowly drop lifting arm in idling until it lands
    on the ground. Lay flat the bucket. Place the
    control rod at middle position. Finally flameout
    timely.

18
Inspection before Starting
  • 2. Level of Hydraulic Oil
  • Inspection Conditions
  • ? Lifting arm shall drop slowly at idle speed
    with moderate movement. The time shall be between
    10 to 15 seconds. Timing starts when lifting arm
    begins to automatically drop until the bucket
    lands.
  • ? Wait for at least 3 minutes or more after
    flameout. And then observe and record level of
    the hydraulic oil.

19
Inspection before Starting
2. Level of Hydraulic Oil
Product Model Level of Hydraulic Oil(scale)
LG933 35
LG918/ LG936L/LG938L/LG946/LG952/ LG952H/LG953/LG953L 68
LG956L/ LG958L/ LG959/ LG968/ LG969/ LG979 1012
20
(No Transcript)
21
Inspection before Starting
  • 3. Brake Fluid

Oil amount shall be about ¾(three-quarter) of the
oil cup.
22
Inspection before Starting
  • 4. Coolant Liquid(Antifreeze) in Radiator(Water
    Box)
  • ! Warning
  • ? Normally, don't open cover of radiator . At
    operating temperature,the engine coolant is hot
    and under pressure. Steam can cause personal
    injury.
  • ? Amount of water must be inspected after the
    engine cools.

Radiator is filled with water or antifreeze
solution
23
Inspection before Starting
  • 5. Lubricating oil adding of hinged parts

24
Inspection before Starting
  • 6. Whether there is leakage on joints, pumps,
    valves, steering tear, braking system and other
    parts of hydraulic pipes. Find and handle
    problems in time

25
Inspection before Starting
  • 7. Color of electric eye of storage battery

Color of Electric Eye Electric Quantity
Electric quantity is above 65. Normal
Electric quantity is below 65 . Charging is needed
Overcharge. Replaced with new parts.
26
Inspection before Starting
  • 8. Check air pressure of tires
  • Front wheel0.3330.353MPa
  • Back wheel0.2750.294 MPa

27
Inspection before Starting
Failures caused by tire pressure abnormity
1. Measuring Method Measure after tire
temperature reduces to normal temperature. 2.
Application in Failure Diagnosis Abnormal
wear of patterns in the center of tires is caused
by improper air pressure.
28
Failures caused by tire pressure abnormity
Inspection before Starting
  • Symptom 1 Serious wear in the middle of tire
    crown.
  • ReasonUse reasonExcessive air pressure and
    driving lead to reduction of grounding area of
    tire crown, increasing of local load and
    intensifying of abrasion.

29
Inspection before Starting
Failures caused by tire pressure abnormity
  • Symptom 2Burst on the crow has the shape of Y, X
    or /.
  • Reason Use reasonHigh-speed running, emergency
    braking or impact stress concentration after
    meeting with barriers under excessive air
    pressure or excessive load will cause burst.

30
Inspection before Starting
Failures caused by tire pressure abnormity
  • Symptom 3Severe wear of tire shoulder at two
    sides of tire crown
  • ReasonUse reason Pressure is too low, so
    grounding area of tire shoulder increases, load
    on tire shoulder increases, and wear is
    intensified.

31
Inspection before Starting
Failures caused by tire pressure abnormity
  • Symptom 4Severe corrosion of tire crown
  • ReasonUse reason Front axle tires and rear axle
    tires are not filled with air according to the
    rules. Gravity centre of the machine is close to
    the front axle. Front axle tires have big
    deformation due to squeezing. Tires on the same
    axle skid, which causes corrosion.

32
Starting
Inspection before Starting
1
1
Starting
2
Inspection after Starting
3
Operation
4
33
Starting
  • Start the engine after ensuring that gear 0FF
    is used, hydraulic operation handle is on 0FF
    position and electric switch is on.
  • Caution
  • 1.After the engine starts, let the key go
    immediately. Starting switch will automatically
    "return
  • 2. Each starting time of the engine shall not
    exceed 10 seconds
  • 3. Interval between 2 starting shall not be less
    than 2 minutes. If the engine can not be started
    for 3 times, please stop the machine for
    inspection. The engine shall be started again
    after troubleshooting

34
Starting
  • 4. Do not speed up suddenly during preheating
    stage of the engine
  • 5. Engine is not allowed to be idling or operate
    at high speed for more than 20 minutes. Some load
    shall be exerted from time to time to allow the
    engine to operate at middle speed
  • 6. The accelerator pedal shall be stepped on
    slowly with constant speed. It is forbidden to
    power over
  • 7. After the vehicle starts, the engine shall be
    idling 3 to 5 minutes (preheating). Full load
    operation is not allowed until the oil
    temperature of engine increases

35
Starting
Inspection before Starting
1
1
Starting
2
Inspection after Starting
3
Operation
4
36
Inspection after Starting
  • 1. Check the level of transmission oil in
    gearbox
  • When the engine is idling, oil inspection
    plug of gearbox can let out transmission oil

37
Inspection after Starting
  • 2. Whether oil pressure indicating light is off
    after the engine starts
  • (Low pressure warning when the light is on. In
    addition, there are brake pressure alarm lamp,
    charge lamp, etc)

Alarm Lamp
38
Inspection after Starting
Lubricating Oil Pressure Range of Engine
Weichai-SitaierIdle speed is between 0.1 and 0.25MPa.
Weichai-Deutz Idle speed is between 0.12 and 0.6MPa.
YuchaiIdle speed 0.1MPa
SC CAT121 Idle speed 0.062MPa
CumminsIdle speed 0.069MPa
39
Inspection after Starting
Water Thermometer
  • 3. Water Thermometer
  • When indicator is in green area (temperature is
    between 60 and 98?).

If water temperature of the engine enters red
area, the machine shall be stopped for inspection.
40
Inspection after Starting
  • 4. Gearbox Pressure Gauge Indicator of gearbox
    oil pressure gauge is between
  • 1.1 and 1.5MPa(green area)

Gearbox Pressure Gauge
41
Inspection after Starting
Air Pressure Gauge
  • 5. Air Pressure Gauge
  • Indicator of brake air pressure gauge
  • is between 0.45 and 0.784 MPa(green area.
  • The alarm lamp will be on when air
  • pressure is below 0.4MPa. Frictionbrake begins
    to skid.

Do not operate the machine. You can drive after
inspection and troubleshooting).
42
Inspection after Starting
Oil Temperature Gauge of Torque Converter
  • 6. Oil Temperature Gauge of Torque Converter
  • When indicator of oil temperature gauge is in
    green area (temperature is between 60 and 110?),
    the oil temperature is normal.

If the indicator is in red area, please stop the
machine for inspection.
43
Warning!!
  • If the above instruments have the said abnormal
    symptoms, do not operate the machine. Please
    immediately notify SDLG authorized dealers or
    SDLG. The machine can be operated after
    inspection and troubleshooting.

44
Inspection after Starting
  • 7. Engine
  • Normal operation. Idling, sound and smoke
    discharge dont have abnormality.

45
Inspection after Starting
  • 8. Steering
  • Left and right steering are flexible and in
    place in idle state. No heavy steering, delay,
    wag motion, abnormal noise, line deflection,
    rotation or idling. Check steering stop block.
    When steering is in place, stop block shall be
    able to effectively contact (if equipped with
    hydraulic limit products, turning limit valve
    shall touch limit plunger first).

Warning! ?When the vehicle is at high speed,
sudden steering or steering on abrupt slope are
dangerous. ?If the vehicle suddenly flameouts
while running, steering is not allowed. Do not
flameout when running on hillside, because it is
very dangerous. If the vehicle flameouts, stop
the vehicle at safe place immediately.
46
Inspection after Starting
  • 9. Braking Flexibility

Service braking is flexible and reliable
Parking braking is reliable
1/5Gradient
47
Inspection after Starting
  • Gear Handle

Gears are flexible to operate
Warning! When the vehicle is running at high
speed, sudden shifting is not allowed. You shall
brake and slow down before shifting.
48
Inspection after Starting
  • Control Handle

Light and stable to control. No blocking or
adhesion
Warning! Do not drop the heavy load bucket from
floating position
49
Starting
Inspection before Starting
1
1
Starting
2
Inspection after Starting
3
Operation
4
50
Operation
Operation Precautions
1
1
Operation Method
2
False Operation Case
3
51
Operation Precautions
X
  • 1. Irrelevant personnel are not allowed to
    enter the cab or other parts of the wheel loader!

X
52
Operation Precautions
  • 2. When the loader conducts excavation or
    loading work, the loader shall be straight to the
    front. Front and back frame shall not have
    angle

53
Operation Precautions
  • 3. Do not insert stockpile with high-speed
    inertia of the loader. Straightly cut with
    driving force of the loader

54
Operation Precautions
  • 4. Machine configuration doesnt comfort to
    operation conditions
  • (For example, shovel rocks with standard bucket
    improperly)

X
55
Operation Precautions
  • 5. Driver loads with full loading when the
    vehicle is running and swing arm is held high

56
Operation Precautions
  • 6. Drive operates with unbalanced loading(shovel
    hard materials with a corner of the bucket)

X
57
Operation Precautions
  • 7. The driver operates with overload, so that
    back wheel sometimes turns up
  • NoteStress on single axle is forbidden.

X
58
Operation Precautions
  • 8. When shoveling materials, after bucket of
    loader is inserted into material pile, the
    driver lift the swing arm instead of folding the
    bucket but directly

59
Operation Precautions
  • 9. The loader operates in water(In a short time
    water shall not flood vent of the driving axle.
    Water surface shall not be over the driving axle
    or reach the lowest point of flange oil seal).

60
Operation Precautions
  • 10. Do not excavate or knock objects with bucket
    at high position, in order to avoid bending of
    oil cylinder of swing arm.

X
61
Operation Precautions
  • 11. When the bucket reaches its limit, do not
    continue to pull control handle.
  • ? Unloading shall be slow with constant speed.
    Do not unload all the materials at one time.
  • ? After unloading, take back the bucket or
    partly take back the bucket before lifting the
    swing arm, in order to avoid cylinder pulling.

62
Operation Precautions
  • 12. Transport height of the bucket
  • ? 400-500mm above the ground
  • ? Try to lower on the slope.

63
Operation Precautions
  • 13. Operation at the edge of the cliff
  • ? Reduce speed in advance!
  • ? Pour out a pile first. And then push the first
    pile with the second one.

64
Operation Precautions
  • 14. Operation on the slope
  • ? Drive slowly when the vehicle goes down slope.
    Coasting with engine off is not allowed
  • ? Drive back when going down slope with heavy
    things in the bucket
  • ? Lower centre of gravity when going up slope
  • ? Steering is forbidden when the working device
    is lifted!

65
Operation Precautions
  • 15. Modification without consent of SDLG is
    prohibited
  • 16. Dropping heavy-load swing arm from floating
    position is prohibited
  • 17. Do not steer away from materials after the
    bucket is inserted into materials
  • 18. Gear 2 operation is prohibited.

66
Operation
Operation Precautions
1
1
2
Operation Method
False Operation Case
3
67
Operation Method
  • 1. Shoveling Operation

One-time shoveling method Cooperating
shoveling method
68
Operation Method
  • 2. Rock and earthwork operation
  • ? To shovel rocks, the bucket shall have a
    downward inclination
  • ? To shovel earthwork, the bucket shall be put
    down horizontally and inserted straightly to the
    material pile
  • ? When the bucket is inserted into the material
    pile, swing arm shall be lifted, in order that
    the bucket will not be inserted too deep.
  • ? By lifting the swing arm, tires will generate
    enough traction.

Rock Material Piling
69
Operation Method
  • 3. Land leveling operation
  • ?After the bucket is filled with materials, the
    vehicle shall move back and scatter materials in
    the bucket little by little.
  • ?When leveling the ground, the bucket shall be
    placed on the ground. Drive back with control
    handle of working device at floating position.

70
Operation Method
  • 4. Excavation Operation
  • ?And then take back the bucket while going forward

71
Operation Method
  • 5. Cross loading and unloading
  • ?The loader shall face the material pile. After
    the bucket is full of materials, the loader will
    move back. And then dump truck is allowed to move
    to the place between the loader and material
    pile. This loading method has the shortest
    cycling time.

72
Operation Method
  • 6. V-shaped loading and unloading
  • ?Set position for dump truck. It shall have and
    angle of about 60 degrees with backward direction
    of the loader. After the bucket is filled with
    materials, the loader returns, proceeds at an
    angle, and runs to the dump truck. The smaller
    the v-shaped angle during operation of loader is,
    the higher working efficiency is.

73
Operation
Operation Precautions
1
1
2
Operation Method
False Operation Case
3
74
False Operation Case
  • 1. Front axle break and working device deforms.

75
False Operation Case
  • 2. On muddy track
  • Be careful of sudden turn.

76
False Operation Case
  • 3. Cliff operation
  • Drive carefully

77
Contents
Safety Precautions
1
1
Operation
2
Maintenance
3
Service
4
78
Maintenance (take LG953 for example)
The product uses 30 operation and 70
maintenance. Proper maintenance can greatly
reduce friction of machine and wear of parts,
keep the machine run normally, and extend service
life of the machine. (example)
79
Maintenance
Detailed Security Rules and Regulations
1
Maintenance Guidelines
1
2
Daily Maintenance
3
Regulations and Content of Mandatory Service
4
Examples of Mandatory Service
5
Negative Case of Improper Maintenance
6
80
Detailed Security Rules and Regulations
1. Hang security identifier

Maintenance Mark
  • When maintaining machine, maintenance mark shall
    be posted on the steering wheel with name of
    maintenance personnel, date and time on it
  • Except the person who posted the mark, anybody
    else shall not pick off this mark
  • The person who posted the mark shall keep start
    key.

Operation is prohibited
81
Detailed Security Rules and Regulations
2. Detailed Security Rules and Regulations ?
Operate on solid and flat road. ? Working
device shall be close to the ground. Lay the
bucket flat. ? All the control rods shall be
in the middle position. ? Pull the parking
brake lever. ? Stop dogs shall be placed in
front of and behind tires. ? Lock the front
and back frame with frame locking rod. ? Pay
attention to high-temperature oil and
high-temperature cooling water. Prevent burns.
82
Detailed Security Rules and Regulations
3. Safe Welding ? Turn off the engine start
switch and remove cables of storage battery. ?
The distance between welding area and
grounding cables is within 1m. ? Avoid
welding near seal ring and bearing. ? Don't
weld pipes with oil.
83
Maintenance
Detailed Security Rules and Regulations
1
Maintenance Guidelines
1
2
Daily Maintenance
3
Regulations and Content of Mandatory Service
4
Examples of Mandatory Service
5
6
Negative Case of Improper Maintenance
84
Maintenance Guidelines
1. Use the maintenance package provided by Lingong
?Filter and seals Sealer, O-shaped seal ring,
junk ring and filter ?Special oil
products Hydraulic transmission oil, gear oil
and anti-wear hydraulic oil ?Special fittings
Ensure reliable
85
Maintenance Guidelines
2. Using guidelines of engine oil and fuel ?
Do not mix oil with different brands together ?
Clean or replace related oil filter when
replacing the oil ? Add oil according to
specified amount ? Distinguish number of
fuel according to ambient temperature when
replacing fuel ? Dont remove fuel
preliminary filter when adding fuel ?
Remove air in the pipes after replacing oil
filter.
86
Maintenance Guidelines
3. Maintenance guidelines of coolant ?
Produce scale under high temperature with clean
soft water, well water or spring ? If the
engine is overheated, coolant shall not be added.
It shall be added after the engine gets cool ?
If liquid surface of coolant is too low,
overheating of engine and correction of cooling
system will be caused. ? When the ambient
temperature is below 0?, antifreeze solution
shall be added into coolant.
87
Maintenance Guidelines
4. Maintenance guidelines of electric system ?
Check tightness and damage of fan belt of
generator ? Check color change of
electric eye of storage battery. ? Keep
electric system dry. Avoid waters corrosion to
electric system.
88
Maintenance
Detailed Security Rules and Regulations
1
Maintenance Guidelines
1
2
Daily Maintenance
3
Regulations and Content of Mandatory Service
4
Examples of Mandatory Service
5
Negative Case of Improper Maintenance
6
89
Daily Maintenance
1. Running-in period of new vehicle 8 hours
for new vehicle. Arrange running in uniformly for
3 gears. Speed shall be from low to high. ?
During running-in period, mainly shovel loosen
materials. 70 of rated load shall not be
exceeded. It is better to shovel loosen
materials. Too much force shall not be used. ?
Regularly check temperature of gearbox, torque
converter, drive axle, wheels, brake disc and
brake drum. And find out reasons for
overheating. ? Check fastening of bolts and
nuts.
90
Check the followings after empty commissioning
  • ? Whether bolts and nuts are loosened at joints.
  • ? Whether rotating parts have abnormal noise.
  • ? Whether readings of meters are normal.
  • ? Whether systems have leakage.
  • ? Whether steering and braking are flexible and
    reliable.
  • ? Whether working device operates normally.
  • ? Tightness of fan belt.
  • ? Whether control rods are flexible and reliable.
  • ? Check storage battery and tighten wiring
    terminals.
  • ? Whether sealing parts have leakage.
  • ? Open water drain valve of air storage tank to
    drain water.

91
Daily Maintenance
  • 2. Maintenance every 10 hours (day)
  • Check sealing of hydraulic, steering and braking
    system of working device.
  • Check reliability and flexibility of braking.
  • Check whether circuit of electrical system and
    electrical elements are normal.
  • Check oil level in fuel tank and water level in
    water box.
  • Add lubricating grease for fan shaft of diesel
    engine, hinge points of front and back frame,
    transmission shaft, hinge points of back axle
    swing and hinge points of working device.
  • Check whether there is something else abnormal.
  • Maintain diesel engine strictly according to
    requirements in Maintenance Manual of Diesel
    Engine.

92
Daily Maintenance
  • 3 . Maintenance every 50 hours (week)
  • Simultaneously conducted with maintenance every
    10 hours.
  • Check oil level of gearbox, hydraulic oil tank
    and brake booster pump.
  • Check and fasten connecting bolts of transmission
    shafts.
  • Check and fasten connecting bolts of wheel rim
    and brake caliper.
  • Check and fasten connecting bolts of bucket
    teeth.
  • Check and lubricate throttle control, parking
    brake and shifting control system.

93
Daily Maintenance
  • In addition, add the following maintenance for
    the first 50 hours
  • Check and clean vent of gearbox. Check and clean
    torque converter-oil filter core of oil channel
    system of gearbox.
  • Check whether hydraulic system has leakage. Check
    and clean vent of hydraulic oil tank. Check and
    clean oil return filter core of hydraulic oil
    tank.
  • Check whether brake system has leakage. Clean
    filter screen of oil cup on booster pump. Clean
    the vent. Check brake fluid and add when there is
    lack.

94
Daily Maintenance
  • 4. Maintenance every 250 hours (month)
  • Simultaneously conducted with maintenance every
    10 hours and maintenance every 50 hours.
  • Check storage battery. Clean the surface and
    wiring terminal. Smear a thin layer of vaseline.
  • Check whether connecting bolts on working device
    and front and back frame are loosened. Check
    whether weld joints have crack.
  • Check whether joints of front and back axle,
    diesel engine, gearbox and frame are loosened.
  • Measure pressure of tires. Front wheel shall be
    0.333-0.353MPa. Back wheel shall be
    0.275-0.294MPa.
  • Open water drain valve of gas holder to drain
    water.

95

Daily Maintenance
  • In addition, add the following maintenance for
    the first 250 hours
  • Check and clean vent of gearbox. Clean bottom
    shell of gearbox. Replace oil filter core at
    bottom of gearbox. Replace torque converter-oil
    filter core of oil channel system of gearbox.
    Replace oil in gearbox.
  • Replace gear oil of front and back axle.
  • Check whether brake system has leakage. Clean
    filter screen of oil cup on booster pump. Clean
    the vent. Check brake fluid and add when there is
    lack.

96
Daily Maintenance
  • 5. Maintenance every 500 hours (quarter)
  • Simultaneously conducted with maintenance every
    10 hours, maintenance every 50 hours and
    maintenance every 250 hours.
  • Check and adjust brake clearance of manual brake
    system.
  • Check wear of brake disc and friction plate of
    foot brake system. Replace when necessary.

97
Daily Maintenance
  • In addition, add the following maintenance for
    the first 500 hours
  • Check whether hydraulic system has leakage.
    Check and clean vent of hydraulic oil tank.
    Replace oil return filter core of hydraulic oil
    tank. Check level and cleanness of hydraulic oil.
    Filter when recourses are available, add when
    there is lack, and replace when neccesary.
  • Check whether brake system has leakage. Clean
    filter screen of oil cup on booster pump. Clean
    the vent. Replace brake fluid.

98
Daily Maintenance
  • 6. Maintenance every 1000 hours (half a year)
  • Simultaneously conducted with maintenance every
    10 hours, maintenance every 50 hours, maintenance
    every 250 hours and maintenance every 500 hours.
  • Clean bottom shell of gearbox. Clean the vents.
    Replace oil filter core at bottom of gearbox.
    Replace torque converter-oil filter core of oil
    channel system of gearbox. Replace oil in
    gearbox.
  • Replace gear oil of front and back axle.
  • Check and clean filter screen of oil cup on
    booster pump. Clean the vent. Replace brake
    fluid.
  • Check whether hydraulic system has leakage. Check
    and clean vents of hydraulic oil tank. Clean
    hydraulic oil tank. Replace oil absorption filter
    and oil return filter core of hydraulic oil tank.
    Replace hydraulic oil.
  • Check clearance and wear between axis pin and
    cover of hinge joints.

99
Daily Maintenance
  • 7. Maintenance every 2000 hours (a year)
  • Simultaneously conducted with maintenance every
    10 hours, maintenance every 50 hours, maintenance
    every 250 hours, maintenance every 500 hours
    and maintenance every 1000 hours.
  • Check performance of torque converter, gearbox,
    front and back axle differential mechanism, and
    hub reduction gear.
  • By measuring natural settlement of hydraulic oil
    cylinder, check sealing of multiple unit valve
    and hydraulic oil cylinder. Measure working
    pressure of the system.
  • Check welding and stress parts of rim. And
    correct deformed parts.

100
Daily Maintenance
  • The above provisions are for basic requirements
    under normal use. Maintenance shall be conducted
    according to the earlier time cycle in the above
    two time requirements. If working conditions are
    bad, users shall reduce maintenance period and
    increase maintenance frequency according to the
    actual needs,.
  • Gas holder must be replaced after it is used for
    3 years.

101
Maintenance
Detailed Security Rules and Regulations
1
Maintenance Guidelines
1
2
Daily Maintenance
3
Regulations and Content of Mandatory Service
4
Examples of Mandatory Service
5
6
Negative Case of Improper Maintenance
102
1. Content of 3 Mandatory Services of Loader
Number of times of maintenance Number of times of maintenance The first time The second time The third time
Maintenance Hours Maintenance Hours 50100h 500600h 10001200h
Maintenance Date Maintenance Date About 10 days About 2 months About 5 months
Must be replaced Gear oil v v
Must be replaced Gear oil of drive axle (front and back) v v v
Must be replaced Brake fluid of booster pump v v
Must be replaced Hydraulic oil in hydraulic system v
Must be replaced Oil return (absorption) filter of hydraulic oil tank v v
Must be replaced Oil absorption filter of gearbox v v v
Must be replaced Hydraulic transmission oil filter v v v
Must be replaced Seal Ring 1053.1 v v
Must be replaced Seal Ring 514.2 v v
Check liquid surface or add Gear oil v v v
Check liquid surface or add Hydraulic oil v v v
Check liquid surface or add Brake fluid of booster pump v v v
Check liquid surface or add Cooling liquid in water box v v v
103
Content of 3 Mandatory Services of Loader
(Continued)
Number of times of maintenance Number of times of maintenance The first time The second time The third time
Maintenance Hours Maintenance Hours 50100 h 500600h 10001200h
Maintenance Date Maintenance Date About 10 days About 2 months About 5 months
Check, adjust or fasten Connecting bolt of transmission shaft v v v
Check, adjust or fasten Connecting bolt of rim v v v
Check, adjust or fasten Connecting bolt of brake caliper v v v
Check, adjust or fasten Connecting bolt of bucket lip v v v
Check, adjust or fasten Connecting bolt of front and back axle v v
Check, adjust or fasten Connecting bolt of diesel engine (with support and frame) v v
Check, adjust or fasten Connecting bolt between gearbox and frame v v
Check, adjust or fasten Connecting bolt of all parts of working device v v
Check, adjust or fasten Brake clearance of manual brake system v v
104
Content of 3 Mandatory Services of Loader
(Continued)
Number of times of maintenance Number of times of maintenance The first time The second time The third time
Maintenance Hours Maintenance Hours 50100 h 500600h 10001200h
Maintenance Date Maintenance Date About 10 days About 2 months About 5 months
Check and test Sealing and status of working device hydraulic system v v v
Check and test Sealing and status of steering hydraulic system v v v
Check and test Sealing and status of foot brake system v v v
Check and test Wear of brake disc and brake pad of foot brake system v v
Check and test Clearance and wear between axis pin and cover of hinge joints v
Check and test Circuit and electric elements of electric system v v v
Check and test Air pressure of front wheel(0.333-0.353MPa) v v
Check and test Air pressure of back wheel(0.275-0.294MPa) v v
Check and test Draining of gas holder(guide user to drain on time) v v v
Check and test Performance of torque converter, gearbox, front and back axle differential mechanism and hub reduction gear v
Check and test Working pressure of working device hydraulic system v
Check and test Working pressure of steering hydraulic system v
Check and test Welding and stress parts of rim. And correct deformed parts v
105
Content of 3 Mandatory Services of Loader
(Continued)
Number of times of maintenance Number of times of maintenance The first time The second time The third time
Maintenance Hours Maintenance Hours 50100 h 500600h 10001200h
Maintenance Date Maintenance Date About 10 days About 2 months About 5 months
Check lubrication Transmission shaft v v v
Check lubrication Hinge joints of back axle swing v v v
Check lubrication Hinge joints of front and back frame v v v
Check lubrication Hinge joints of working device v v v
Check lubrication Fan shaft of diesel engine v v v
Check cleaning Vent of gearbox v v v
Check cleaning Vent of hydraulic oil tank and fuel tank v v v
Check cleaning Filter screen on oil cup of booster pump v v v
Check cleaning Vent of booster pump v v v
Check cleaning A thin layer of vaseline on the surface of storage battery, terminal and surface of terminal v v
Strict implementation According to requirements in Diesel Engine Maintenance Manual, maintain diesel engine v v v
Strict implementation Maintain according to requirements of ZF axle and box v v v
106
2. SDLG Loader Oil Recommendation List
Type Recommended Type and Standard Refueling Amount Part Using Oil
Oil of engine Ambient temperature-15 CD 15W/40 GB11122-1997 Ambient temperature lt-15 CD 5W/20 GB11122-1997 20L Engine
Oil of torque converter No. 6 Hydraulic Transmission Oil Q/SH018.44.03-1994 45L Torque converter and gearbox
Gear oil SAE 85W-90 GL-5 Gear Oil GB13895-1992 32L Axle main transmission and wheel reduction
Hydraulic oil Ambient temperature -5 L-HM46 Hydraulic Oil Ambient temperature -30L-HV46 Hydraulic Oil 200L Hydraulic oil tank
Engine fuel Minimum air temperature4? No. 0 Light Diesel Oil GB252-1994 Minimum air temperature-5? -No. 10 Light Diesel Oil GB252-1994 Minimum air temperature-14? -No. 20 Light Diesel Oil GB252-1994 Minimum air temperature-29? -No. 35 Light Diesel Oil GB252-1994 300L Fuel tank
Brake fluid Mobil Brake Fluid DOT3 GB12981-2003 4L Brake oil cup
Lubricating grease No. 2 or No. 3 Lithium Lubricating Grease GB7324-1994 2.8kg Axis pin on hinge joints of working device
Antifreeze solution Glycol Engine Antifreeze solution SH0521-1992 Radiator
107
Maintenance
Detailed Security Rules and Regulations
1
Maintenance Guidelines
1
2
Daily Maintenance
3
Regulations and Content of Mandatory Service
4
Examples of Mandatory Service
5
6
Negative Case of Improper Maintenance
108
1. Engine System-Air Filter
? Mail filter core can be cleaned for 6 times at
most before replacing. Security filter core is
disposable ? After cleaning, if maintenance
indicator is still red, security filter core must
be replaced ? If filter is broken, it shall be
replaced ? Interval for filter replacing depends
on operation environment. The worse the
environment is, the more frequent replacing is.
109
Cleaning and Inspection Method of Main Filter
Core 1)Mechanical cleaning Lean on soft and
clean surface of object. Clap the end of main
filter. 2)Clean with compressed air ? Blow the
filter clean along wrinkles from inside to
outside ? Use clean and dry compressed air not
higher than 500kp ? Minimum distance between
nozzle and filter shall be 3 to 5 cm. 3)Check
filter ? Check the filter with light ? The
filter must be replaced if it has small hole,
scratch, crack or other damages ? Auxiliary
filter must be replaced with replacing main
filter ? After the main filter has been
replaced or cleaned, if the indicating light of
the filter is on, auxiliary filter is blocked.
110
Engine System-Replace Engine Oil
Replacing steps 1)Replace oil when the vehicle
is hot 2)Stop the vehicle on flat and hard
ground. Tires shall be fixed with
cleat 3)Prepare container for waste oil(above 50
liters) 4)Twist off the drain bolt to discharge
oil in the engine completely 5)Fill new oil
through oil filler 6)Special engine oil must be
used.
111
Replace engine oil filter Engine oil filter is
disposable product, which shall be replaced when
replacing oil.
Replacing steps 1) Remove With special
disassembling tools of engine oil filter 2) Fill
the filter with new oil. Amount of engine oil is
about 5 liters. It can ensure fast lubrication
after starting. 3) Smear oil on seal packing.
Screw up the filter until seal packing just
contacts with the seal surface. And then screw up
for ½ round. 4) After installation, the engine
must idle run for at least 1 minute. And check
leakage.
112
Engine System-Turbocharger
Caution ?The turbocharger operates under high
temperature. Therefore, be careful in
maintenance. ?Do not speed up immediately after
starting the engine. ?The engine shall idle run
for 5 minutes before flameout. ?.Parking at high
speed will damage the turbocharger. ?If there is
vibration noise or the turbocharger has vibration
noise, the turbocharger must be repaired or
replaced.
113
Engine System-Belt Tensioning
Water pump and fan belt Check the belt every 250
hours or when belt has large noise. Correct
method of belt tensioning Press the belt with a
force of 10kg after tensioning. Fluctuation is
from 5 to 8mm. If over 15mm, please adjust
tension wheel or replace with new belt.
114
2. Fuel System Maintenance
1)Clean fuel tank regularly Open plug and drain
disc at the bottom of oil tank and discharge all
the sediment.
2)Replace fuel filter ? When fuel used meets the
specified requirements, replace fuel filter every
1000 hours. ? When fuel used contains mover than
0.5 of sulphur and more than 0.01 of water or
sediment, replacing interval of fuel filter shall
be half. ? Filter is disposable product. It
cannot be washed and has to be replaced.
3)Discharge accumulated water in oil-water
separator regularly (through water drain valve)
Oil-water separator
115
2)Replace Hydraulic Oil
Replacing steps ? Keep the bucket flat and drop
the swing arm to the ground completely ? Remove
pedal on upper part of oil tank ? Unscrew air
changing filter to release pressure in oil
tank ? Remove oil adding filter ? Put the
container under drain plug ?Remove drain cock to
discharge wasted oil ? Reassemble after washing
oil filters ? Remove drain disc. Clean and
reassemble ? Fill the vehicle with oil and put
on the protective cover ? Check oil level with
eyes.
Oil replacing cycle 1200 hours
116
3)Clean and Replace Filter
A Oil adding filter core BAir changing
filter COil return filter core
? Wash hydraulic oil return filter core after
using it for 250 hours for the first time. After
that wash it every 600 hours ? When replacing
oil return filter core, open respirator to
release internal pressure of oil tank first ?
After replacing, the engine shall idle run for
several minutes to remove air in oil channels ?
Lift the swing arm and turn over the bucket to
discharge air in the system ? Respirator shall
be washed frequently and replaced when necessary
in dusty environment.
117
4. Gearbox System
Replacing steps ? Replace oil for hot vehicle.
Machine shall be laid flat. ? Twist on the drain
plug and discharge old oil completely ? Clean
oil filter and oil absorption screen ? Add
qualified oil product until oil can overflow from
oil inspection valve.
A Oil inspection valve BOil absorption screen
(inside) COil filter DDrain plug
118
5. Cooling System Maintenance
Steps to replace coolant ? Remove dirt on
radiator with compressed air from inside to
outside ? Open water drain valve on torque
converter oil cooling and discharge
coolant ? Pour though filler with clean running
water ? Start the engine and idle running for 10
minutes ? Flameout, discharge water and add
qualified coolant ? Idle running of the engine
shall last for about 5 minutes ? Flameout and
add coolant to mouth of water box ? Twist on
the cover of water box ? Coolant with different
models shall not be mixed!
119
?Maintenance Example
6. Electric System-Storage Battery
  • Connection of storage battery
  • ? Check whether poles of storage batter are clean
    and fastened
  • ? Positive and negative terminals of storage
    battery shall not be connected improperly, or
    rectifier of generator will be damaged.
  • Electric welding
  • Turn off engine start switch and remove cables on
    storage battery.
  • ? The distance between welding area and
    grounding cables is within 1m.
  • ? Avoid welding near seal ring and bearing.
  • ? Don't weld pipes with oil.

120
  • 7. Storage
  • ? Storage battery Regularly check. Start once a
    month. Each time shall not be less than 20
    minutes. Storage battery shall be removed,
    separately stored and charged regularly if it is
    stored for over 3 months or in cold area.

121
  • 7. Storage
  • ? Lubricating grease shall be put on exposed
    coating, steel, finished surface, etc, to prevent
    corrosion. Dirt on exposed coating of oil
    cylinder shall be removed in the next operation.

122
  • 7. Storage
  • ? Cooling water in water tank shall be completely
    discharged, including water drain valve of engine
    and torque converter oil cooler. Or replace with
    antifreeze solution.

123
  • 7. Storage
  • ?Tires shall keep air pressure.
  • Front wheel0.3330.353MPa
  • Back wheel0.2750.294 MPa
  • Air pressure of 18-level tires shall increase by
    0.05 MPa

124
Maintenance
Detailed Security Rules and Regulations
1
Maintenance Guidelines
1
2
Daily Maintenance
3
Regulations and Content of Mandatory Service
4
Examples of Mandatory Service
5
Negative Case of Improper Maintenance
6
125
Case 1. Lack of oil and wear of axis pin
126
Case 2. Water accumulated in tank and poor braking
127
Case 3. Oil is used improperly. Filter is broken.
Oil channels are blocked.
128
Case 4. Antifreeze solution is not used in
winter. Forget to drop water. The machine has
frost cracking
129
Case 5. Oil filling is not enough. Wear of axis
pin
130
Case 6. Misuse accelerates wear
131
Contents
Safety Precautions
1
1
Operation
2
Maintenance
3
Service
4
132
Domestic Network
More than 200 sales agents and over 180 Lingong
service stations.
  • North
  • Northeast
  • East
  • South-central
  • West

133
Overseas Network
134
Service
  • ?Service Concept and Purpose
  • ?Service Concept
  • ?Service Purpose

Create Value and Improve Brand
Attention to Details Beyond Expectation
135
Service
  • ?Warranty Period
  • See warranty period of products sold out by
    dealers who have signed distribution agreement
    with SDLG in the following table (which is the
    earlier)

Since the date of b/l Since the date of selling by dealers Since the date when equipment starts working See warranty scope and content in warrant certificate
24 months 18 months 2000 months See warranty scope and content in warrant certificate
Note 1. If agreed by the Parties, special agreement shall prevail. 2. Date of b/l refers to the date when ship owner issued on B/L. 3. This warrant policy is applicable to products delivered by Lingong since Jan 1st 2011. Note 1. If agreed by the Parties, special agreement shall prevail. 2. Date of b/l refers to the date when ship owner issued on B/L. 3. This warrant policy is applicable to products delivered by Lingong since Jan 1st 2011. Note 1. If agreed by the Parties, special agreement shall prevail. 2. Date of b/l refers to the date when ship owner issued on B/L. 3. This warrant policy is applicable to products delivered by Lingong since Jan 1st 2011. Note 1. If agreed by the Parties, special agreement shall prevail. 2. Date of b/l refers to the date when ship owner issued on B/L. 3. This warrant policy is applicable to products delivered by Lingong since Jan 1st 2011.
136
Service
  • ?Mandatory Service Subvention Standard
  • Lingong products sold out by dealers must have
    50-to-100-hour, 500-to-600-hour, and
    1000-to-1200-hours mandatory services within
    warranty period according to the requirement of
    warrant certificate.

Subvention Standard of 3 Mandatory Services
Provided by Lingong
Product Type Dealer Service Capacity Level Subvention Standard(USD/unit/time) Dealer Service Capacity Level Subvention Standard(USD/unit/time) Dealer Service Capacity Level Subvention Standard(USD/unit/time)
Product Type Class A Class B Class C
Loader and other machine products 400 350 300
This policy is applicable to products delivered by Lingong from Jan 1st 2011 to Dec 31st 2011. This policy is applicable to products delivered by Lingong from Jan 1st 2011 to Dec 31st 2011. This policy is applicable to products delivered by Lingong from Jan 1st 2011 to Dec 31st 2011. This policy is applicable to products delivered by Lingong from Jan 1st 2011 to Dec 31st 2011.
137
4S Franchise Store
4S Franchise Store is the most basic construction
requirement of SDLG to terminal store. The
one-stop service of machine sales, spare parts
supply, technical service and information
feedback is realized.
138
Flow Maintenance Shop
Door-to-door service is faster!
139
Powerful Accessory Center
140
Reliability In Action!
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