Operation and Maintenance Training Courseware Of Wheel Loader 4 March 2011.
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Transcript of Operation and Maintenance Training Courseware Of Wheel Loader 4 March 2011.
Operation and Maintenance Training Courseware Of Wheel Loader
4 March 2011
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 2
Main Content
Evaluation Topics
Suitable Group
Contents
Training Objectives
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 3
Suitable Group
This course is suitable for key accounts and loader drivers.
It also applies to service technicians at service stations.
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 4
Main Content
Evaluation Topics
Suitable Group
Contents
Training Objectives
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 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
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Safety Precautions
Operation
Maintenance
Service
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Contents
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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.
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Safety Precautions
1. Only personnel who have received special training or related operation qualification
can operate the machine.
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Safety Precautions
2. Operator shall be in good condition.
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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.
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Safety Precautions
4. Operator shall ensure that all the safety equipments of the machine are in good condition and
operated in accordance with regulations .
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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.
Reduce service life !
Firm Durable !
Mine, quarry and other working conditions
Best configuration: rock bucket
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 13
多用途!attachment
岩石斗Rock bucket
1.5m3
侧卸斗Side dump
bucket1.4m3
加大斗Bigger bucket
2.2/2.5m3
夹木叉Log
grapple
抓草叉Grass
grapple
除雪装置Snow
removal device
1
2
3
平叉Pallet fork
6
7
54
8
多功能铲斗4 in 1 bucket 1.8m3
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Safety Precautions
Operation
Maintenance
Service
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Contents
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Inspection before Starting
Starting
Inspection after Starting
Operation
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Operation
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Inspection before Starting
1. Oil Level of Engine
Oil amount of engine(Oil inspection scale when the loader is leveled and
stationary )
“L” Scale --Dangerous
“H”Scale --Stationary and Full
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2. Level of Hydraulic Oil
Inspection Conditions
① The loader shall be stopped on flat and firm ground for
operation.
② 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.
Inspection before Starting
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2. Level of Hydraulic Oil
Inspection Conditions:
③ 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.
④ Wait for at least 3 minutes or more after
flameout. And then observe and record level of
the hydraulic oil.
Inspection before Starting
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Product ModelLevel of Hydraulic Oil
( scale)
LG933 3 ~ 5
LG918/ LG936L/LG938L/LG946/LG952/
LG952H/LG953/LG953L6 ~ 8
LG956L/ LG958L/ LG959/ LG968/ LG969/ LG979 10 ~ 12
2. Level of Hydraulic Oil
Inspection before Starting
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LG933L
LG953
LG956L
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3. Brake Fluid
Oil amount shall be
about ¾ ( three-quarte
r ) of the oil cup.
Inspection before Starting
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4. Coolant Liquid(Antifreeze) in Radiator
( Water Box )
! Warning
① Normally, don't open cover of radiator .
At operating temperature,the engine
coolant is hot and under pressure.
Steam can cause personal injury.
② Amount of water must be inspected
after the engine cools. Radiator is filled with water or antifreeze solution
Inspection before Starting
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5. Lubricating oil adding of hinged parts
Inspection before Starting
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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
Inspection before Starting
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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.
Inspection before Starting
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8. Check air pressure of tires
Front wheel : 0.333~0.353MPa
Back wheel : 0.275~0.294 MPa
Inspection before Starting
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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.
Inspection before Starting
Failures caused by tire pressure abnormity
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Failures caused by tire pressure abnormity
Symptom 1 : Serious wear in
the middle of tire crown.
Reason : Use reason :
Excessive air pressure and
driving lead to reduction of
grounding area of tire crown,
increasing of local load and
intensifying of abrasion.
Inspection before Starting
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Symptom 2 : Burst on the crow has
the shape of Y, X or / .
Reason : Use reason : High-speed
running, emergency braking or impact
stress concentration after meeting with
barriers under excessive air pressure or
excessive load will cause burst.
Failures caused by tire pressure abnormity
Inspection before Starting
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Symptom 3 : Severe wear of tire shoulder at two sides of tire
crown
Reason : Use reason : Pressure is too low, so grounding
area of tire shoulder increases, load on tire shoulder
increases, and wear is intensified.
Failures caused by tire pressure abnormity
Inspection before Starting
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Symptom 4 : Severe corrosion of tire crown
Reason : Use 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.
Failures caused by tire pressure abnormity
Inspection before Starting
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Inspection before Starting
Starting
Inspection after Starting
Operation
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Starting
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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;
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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
Starting
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Inspection before Starting
Starting
Inspection after Starting
Operation
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Starting
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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
Oil overflows from oil
inspection plug
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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
Inspection after Starting
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Weichai-Sitaier : Idle speed is between 0.1 and 0.25MPa.
Weichai-Deutz : Idle speed is between 0.12 and 0.6MPa.
Yuchai : Idle speed ≥0.1MPa
SC CAT121 : Idle speed ≥0.062MPa
Cummins : Idle speed ≥0.069MPa
Lubricating Oil Pressure Range of Engine
Inspection after Starting
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 39
3. Water Thermometer
When indicator is in green area
(temperature is between 60 and 98℃ ) .
Water Thermomete
r
Inspection after Starting
If water temperature of the engine enters red area, the machine shall be stopped for inspection.
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 40
4. Gearbox Pressure Gauge Indicator of
gearbox oil pressure gauge is
between
1.1 and 1.5MPa ( green area )
Gearbox Pressure Gauge
Inspection after Starting
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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.
Inspection after Starting Air Pressure Gauge
Do not operate the machine. You can drive after inspection and troubleshooting).
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 42
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.
Oil Temperature Gauge of Torque
Converter
Inspection after Starting
If the indicator is in red area, please stop the machine for inspection.
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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.
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7. Engine
Normal operation. Idling, sound
and smoke discharge don’t have
abnormality.
Inspection after Starting
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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).
Inspection after Starting
Warning !①When the vehicle is at high speed, sudden steering or
steering on abrupt slope are dangerous.
② 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.
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9. Braking Flexibility
Service braking is flexible and reliable
Parking braking is reliable
Inspection after Starting
1/5Gradient
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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.
Inspection after Starting
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Control Handle
Light and stable to control. No blocking
or adhesion
Warning !Do not drop the heavy load bucket from floating position
Inspection after Starting
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Inspection before Starting
Starting
Inspection after Starting
Operation
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Starting
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Operation Precautions
Operation Method
False Operation Case
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Operation
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Operation Precautions
1. Irrelevant personnel are not
allowed to enter the cab or other
parts of the wheel loader!
X
X
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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;
Operation Precautions
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3. Do not insert
stockpile with high-
speed inertia of the
loader. Straightly cut
with driving force of
the loader;
Operation Precautions
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4. Machine configuration
doesn’t comfort to
operation conditions
( For example, shovel
rocks with standard
bucket improperly ) ;
X
Operation Precautions
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5. Driver loads with full loading
when the vehicle is running and
swing arm is held high;
Operation Precautions
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6. Drive operates with
unbalanced
loading ( shovel hard
materials with a corner
of the bucket ) ; X
Operation Precautions
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7. The driver operates
with overload, so that
back wheel sometimes
turns up;
Note : Stress on single
axle is forbidden.
X
Operation Precautions
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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;
Operation Precautions
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 59
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 ) .
X
Operation Precautions
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10. Do not excavate or knock objects with bucket at high position, in
order to avoid bending of oil cylinder of swing arm.
X
Operation Precautions
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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.
First
after
After
slow
Operation Precautions
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12. Transport height of the bucket:
★ 400 - 500mm above the ground
★ Try to lower on the slope.
Operation Precautions
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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.
Operation Precautions
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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!
Operation Precautions
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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.
Operation Precautions
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Operation Precautions
Operation Method
False Operation Case
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Operation
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Operation Method
1. Shoveling Operation
One-time shoveling method
Cooperating shoveling method
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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.
Operation Method
Rock Material Piling
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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.
Operation Method
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4. Excavation Operation
★And then take back the bucket while going forward
0~10°0~10°
10-30cm10-30cm
Operation Method
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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.
Operation Method
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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.
Operation Method
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Operation Precautions
Operation Method
False Operation Case
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Operation
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1. Front axle break and
working device deforms.
X
False Operation Case
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2. On muddy track
Be careful of sudden turn.
False Operation Case
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3. Cliff operation
Drive carefully
False Operation Case
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Safety Precautions
Operation
Maintenance
Service
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Contents
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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)
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Detailed Security Rules and Regulations
Maintenance Guidelines
Daily Maintenance
Regulations and Content of
Mandatory Service
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Maintenance
55
66
Examples of Mandatory Service
Negative Case of Improper Maintenance
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• 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.
1. Hang security identifier
Detailed Security Rules and Regulations
Maintenance Mark
Operation is prohibited
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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.
Detailed Security Rules and Regulations
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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.
Detailed Security Rules and Regulations
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Detailed Security Rules and Regulations
Maintenance Guidelines
Daily Maintenance
Regulations and Content of
Mandatory Service
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Maintenance
55
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Examples of Mandatory Service
Negative Case of Improper Maintenance
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◎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
1. Use the maintenance package provided
by Lingong
Maintenance Guidelines
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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;
● Don’t remove fuel preliminary filter when adding fuel;
● Remove air in the pipes after replacing oil filter.
Maintenance Guidelines
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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.
Maintenance Guidelines
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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 water’s corrosion to
electric system.
Maintenance Guidelines
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Detailed Security Rules and Regulations
Maintenance Guidelines
Daily Maintenance
Regulations and Content of
Mandatory Service
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Maintenance
55
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Examples of Mandatory Service
Negative Case of Improper Maintenance
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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.
Daily Maintenance
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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.
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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.
Daily Maintenance
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 92
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.
Daily Maintenance
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 93
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.
Daily Maintenance
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 94
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.
Daily Maintenance
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 95
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.
Daily Maintenance
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 96
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.
Daily Maintenance
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 97
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.
Daily Maintenance
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 98
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.
Daily Maintenance
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 99
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.
Daily Maintenance
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 100
• 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.
Daily Maintenance
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 101
11
Detailed Security Rules and Regulations
Maintenance Guidelines
Daily Maintenance
Regulations and Content of
Mandatory Service
11
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44
Maintenance
55
66
Examples of Mandatory Service
Negative Case of Improper Maintenance
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 102
Number of times of maintenance The first time The second time The third time
Maintenance Hours50 ~ 100h
500 ~ 600h 1000 ~ 1200h
Maintenance Date About 10 days About 2 monthsAbout 5 months
Must be replaced
Gear oil √ √
Gear oil of drive axle (front and back) √ √ √
Brake fluid of booster pump √ √
Hydraulic oil in hydraulic system √
Oil return (absorption) filter of hydraulic oil tank
√ √
Oil absorption filter of gearbox √ √ √
Hydraulic transmission oil filter √ √ √
Seal Ring 105*3.1 √ √
Seal Ring 51*4.2 √ √
Check liquid surface or add
Gear oil √ √ √
Hydraulic oil √ √ √
Brake fluid of booster pump √ √ √
Cooling liquid in water box √ √ √
1. Content of 3 Mandatory Services of Loader
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 103
Number of times of maintenance The first time The second time The third time
Maintenance Hours 50 ~ 100 h 500 ~ 600h 1000 ~ 1200h
Maintenance Date About 10 days About 2 months About 5 months
Check, adjust or fasten
Connecting bolt of transmission shaft √ √ √
Connecting bolt of rim √ √ √
Connecting bolt of brake caliper √ √ √
Connecting bolt of bucket lip √ √ √
Connecting bolt of front and back axle √ √
Connecting bolt of diesel engine (with support and frame)
√ √
Connecting bolt between gearbox and frame √ √
Connecting bolt of all parts of working device √ √
Brake clearance of manual brake system √ √
Content of 3 Mandatory Services of Loader (Continued)
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 104
Number of times of maintenance The first time The second time The third time
Maintenance Hours 50 ~ 100 h 500 ~ 600h 1000 ~ 1200h
Maintenance Date About 10 days About 2 months About 5 months
Check and test
Sealing and status of working device hydraulic system √ √ √
Sealing and status of steering hydraulic system √ √ √
Sealing and status of foot brake system √ √ √
Wear of brake disc and brake pad of foot brake system √ √
Clearance and wear between axis pin and cover of hinge joints
√
Circuit and electric elements of electric system √ √ √
Air pressure of front wheel ( 0.333-0.353MPa ) √ √
Air pressure of back wheel ( 0.275-0.294MPa ) √ √
Draining of gas holder ( guide user to drain on time ) √ √ √
Performance of torque converter, gearbox, front and back axle differential mechanism and hub reduction gear
√
Working pressure of working device hydraulic system √
Working pressure of steering hydraulic system √
Welding and stress parts of rim. And correct deformed parts √
Content of 3 Mandatory Services of Loader (Continued)
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 105
Number of times of maintenance The first time The second time The third time
Maintenance Hours 50 ~ 100 h 500 ~ 600h 1000 ~ 1200h
Maintenance Date About 10 days About 2 monthsAbout 5 months
Check lubricatio
n
Transmission shaft √ √ √
Hinge joints of back axle swing √ √ √
Hinge joints of front and back frame √ √ √
Hinge joints of working device √ √ √
Fan shaft of diesel engine √ √ √
Check cleaning
Vent of gearbox √ √ √
Vent of hydraulic oil tank and fuel tank √ √ √
Filter screen on oil cup of booster pump √ √ √
Vent of booster pump √ √ √
A thin layer of vaseline on the surface of storage battery, terminal and surface of terminal
√ √
Strict implementation
According to requirements in Diesel Engine Maintenance Manual, maintain diesel engine
√ √ √
Maintain according to requirements of ZF axle and box √ √ √
Content of 3 Mandatory Services of Loader (Continued)
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 106
Type Recommended Type and StandardRefueling
AmountPart Using Oil
Oil of engineAmbient temperature≥-15° CD 15W/40 GB11122-1997Ambient temperature < -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 32LAxle main transmission and wheel reduction
Hydraulic oilAmbient temperature ≥-5° L-HM46 Hydraulic Oil Ambient temperature ≥-30°L-HV46 Hydraulic Oil
200L Hydraulic oil tank
Engine fuel
Minimum air temperature≥4 No. 0 L℃ ight Diesel Oil GB252-1994 Minimum air temperature≥-5 -No. 10 L℃ ight Diesel Oil GB252-1994Minimum air temperature≥-14 -No. 20 L℃ ight Diesel Oil GB252-1994Minimum air temperature≥-29 -No. 35 L℃ ight 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 2.8kgAxis pin on hinge joints of working device
Antifreeze solution
Glycol Engine Antifreeze solution SH0521-1992 Radiator
2. SDLG Loader Oil Recommendation List
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 107
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Maintenance Guidelines
Daily Maintenance
Regulations and Content of
Mandatory Service
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Maintenance
55
66Examples of Mandatory Service
Negative Case of Improper Maintenance
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 108
◎ 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.
1. Engine System-Air Filter
Maintenance
indicatorMail filter core Security filter core
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 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.
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 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.
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 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.
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 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.
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 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.
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 114
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.
Oil-water
separator
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.
3 ) Discharge accumulated water in oil-water separator regularly (through water drain valve)
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 115
2 ) Replace Hydraulic Oil
Oil replacing cycle: 1200 hours
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.
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 116
B
3 ) Clean and Replace FilterA: Oil adding filter core
B : Air changing filter
C : Oil return filter coreB
A
C
A
C
◎ 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.
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 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.
B
A
C
D
A: Oil inspection valve
B : Oil absorption screen
(inside)
C : Oil filter
D : Drain plug
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 118
5. Cooling System MaintenanceSteps 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 !
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 119
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.
★Maintenance Example
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 120
7. Storage
① 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.
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 121
7. Storage
② 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.
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 122
7. Storage
③ 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.
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 123
7. Storage
④Tires shall keep air pressure.
Front wheel : 0.333~0.353MPa
Back wheel : 0.275~0.294 MPa
Air pressure of 18-level tires
shall increase by 0.05 MPa
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 124
11
Detailed Security Rules and Regulations
Maintenance Guidelines
Daily Maintenance
Regulations and Content of
Mandatory Service
11
22
33
44
Maintenance
55
66
Examples of Mandatory Service
Negative Case of Improper Maintenance
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 125
Case 1. Lack of oil and wear of axis pin
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 126
Case 2. Water accumulated in tank and poor braking
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 127
Case 3. Oil is used improperly. Filter is broken. Oil channels are blocked.
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 128
Case 4. Antifreeze solution is not used in winter. Forget to drop water. The machine has frost cracking
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 129
Case 5. Oil filling is not enough. Wear of axis pin
Oil mouths paste
death
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 130
Case 6. Misuse accelerates wear
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 131
11
Safety Precautions
Operation
Maintenance
Service
11
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Contents
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 132
• North
• Northeast• East
• South-central
• West
More than 200 sales agents and over 180 Lingong service stations.
Domestic Network
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 133
Overseas Network
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 134
Service
★Service Concept and Purpose
◆ Service Concept
◆ Service Purpose
Create Value and Improve Brand
Attention to Details Beyond
Expectation
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 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
certificate24 months 18 months 2000 months
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.
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 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 TypeDealer Service Capacity Level Subvention
Standard ( USD/unit/time)
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.
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 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.
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 138
Flow Maintenance Shop Door-to-door service is faster!
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 139
Powerful Accessory Center
RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 140
Reliability In Action!