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


Suitable Group

This course is suitable for key accounts and loader drivers.

It also applies to service technicians at service stations.


Main Content

Evaluation Topics

Suitable Group

Contents

Training Objectives


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


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.


Safety Precautions

1. Only personnel who have received special training or related operation qualification

can operate the machine.


Safety Precautions

2. Operator shall be in good condition.


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.


Safety Precautions

4. Operator shall ensure that all the safety equipments of the machine are in good condition and

operated in accordance with regulations .


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


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


11

Inspection before Starting

Starting

Inspection after Starting

Operation

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Operation



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


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 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.



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




LG933L

LG953

LG956L


3. Brake Fluid

Oil amount shall be

about ¾ （ three-quarte

r ） of the oil cup.



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



5. Lubricating oil adding of hinged parts



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



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.



8. Check air pressure of tires

Front wheel ： 0.333~0.353MPa

Back wheel ： 0.275~0.294 MPa



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.


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.



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.




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.




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.




11


Starting


Operation

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Starting


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;


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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Starting


Operation

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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


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



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



3. Water Thermometer

When indicator is in green area

(temperature is between 60 and 98℃ ） .

Water Thermomete

r


If water temperature of the engine enters red area, the machine shall be stopped for inspection.


4. Gearbox Pressure Gauge Indicator of

gearbox oil pressure gauge is

between

1.1 and 1.5MPa （ green area ）

Gearbox 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.

Inspection after Starting Air Pressure Gauge

Do not operate the machine. You can drive after inspection and troubleshooting).


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


If the indicator is in red area, please stop the machine for inspection.


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.


7. Engine

Normal operation. Idling, sound

and smoke discharge don’t have

abnormality.



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 ！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.


9. Braking Flexibility

Service braking is flexible and reliable

Parking braking is reliable


1/5Gradient


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.



Control Handle

Light and stable to control. No blocking

or adhesion

Warning ！Do not drop the heavy load bucket from floating position



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Starting


Operation

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Starting


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Operation Precautions

Operation Method

False Operation Case

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Operation



1. Irrelevant personnel are not

allowed to enter the cab or other

parts of the wheel loader!

X

X


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;



3. Do not insert

stockpile with high-

speed inertia of the

loader. Straightly cut

with driving force of

the loader;



4. Machine configuration

doesn’t comfort to

operation conditions

（ For example, shovel

rocks with standard

bucket improperly ） ;

X



5. Driver loads with full loading

when the vehicle is running and

swing arm is held high;



6. Drive operates with

unbalanced

loading （ shovel hard

materials with a corner

of the bucket ） ; X



7. The driver operates

with overload, so that

back wheel sometimes

turns up;

Note ： Stress on single

axle is forbidden.

X



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;



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



10. Do not excavate or knock objects with bucket at high position, in

order to avoid bending of oil cylinder of swing arm.

X



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



12. Transport height of the bucket:

★ 400 － 500mm above the ground

★ Try to lower on the slope.



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.



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!



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.



11


Operation Method


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Operation


Operation Method

1. Shoveling Operation

One-time shoveling method

Cooperating shoveling 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.

Operation Method

Rock Material Piling


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


4. Excavation Operation

★And then take back the bucket while going forward

0~10°0~10°

10-30cm10-30cm

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.

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.

Operation Method


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Operation Method


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Operation


1. Front axle break and

working device deforms.

X



2. On muddy track

Be careful of sudden turn.



3. Cliff operation

Drive carefully



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Safety Precautions

Operation

Maintenance

Service

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Contents


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)


11

Detailed Security Rules and Regulations

Maintenance Guidelines

Daily Maintenance

Regulations and Content of

Mandatory Service

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Maintenance

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Examples of Mandatory Service

Negative Case of Improper Maintenance


• 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


Maintenance Mark

Operation is prohibited


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.



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.



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Daily Maintenance


Mandatory Service

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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



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.



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.



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.



11



Daily Maintenance


Mandatory Service

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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


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.


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


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


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


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


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


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


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


6. Maintenance every 1000 hours (half a year)

Simultaneously conducted with maintenance every 10 hours, maintenance every 50 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


7. Maintenance every 2000 hours (a year)

• Simultaneously conducted with maintenance every 10 hours,

maintenance every 50 hours, maintenance every 250 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


• 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


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Daily Maintenance


Mandatory Service

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Maintenance

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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



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)




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 　　 √





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 √ √ √



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


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Daily Maintenance


Mandatory Service

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Maintenance

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66Examples of Mandatory Service



◎ 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


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.


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.


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.


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.


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.


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)


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.


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.


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


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 ！


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


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.


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.


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.


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


11



Daily Maintenance


Mandatory Service

11

22

33

44

Maintenance

55

66




Case 1. Lack of oil and wear of axis pin


Case 2. Water accumulated in tank and poor braking


Case 3. Oil is used improperly. Filter is broken. Oil channels are blocked.


Case 4. Antifreeze solution is not used in winter. Forget to drop water. The machine has frost cracking


Case 5. Oil filling is not enough. Wear of axis pin

Oil mouths paste

death


Case 6. Misuse accelerates wear


11

Safety Precautions

Operation

Maintenance

Service

11

22

33

44

Contents


• North

• Northeast• East

• South-central

• West

More than 200 sales agents and over 180 Lingong service stations.

Domestic Network


Overseas Network


Service

★Service Concept and Purpose

◆ Service Concept

◆ Service Purpose

Create Value and Improve Brand

Attention to Details Beyond

Expectation


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.


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.


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.


Flow Maintenance Shop Door-to-door service is faster!


Powerful Accessory Center


Reliability In Action!

Documents

Operation and Maintenance Training Courseware Of Wheel Loader 4 March 2011