04维护保养要点Maintenance point.pdf

8/17/2019 04 Maintenance point.pdf

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维护保养要点

Maintenance point


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注意 Attention

在维护保养前按以要求停放机器

Park the machine as follows before maintenance:1、把机器停放在平坦的地面上

Park the machine on flat ground.

2、把铲斗下降放到地面上Lower the bucket onto ground.


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注意 Attention

3.发动机在怠速状态下运转3分钟

Set the engine speed to idling speed and run it for 3 minutes.4.使启动开关在关的位置并拔下钥匙

Turn the start switch to OFF position and take off the key

5.使先导控制杆处于锁定的位置

Push the pilot control lever to LOCK position.

6.在右手操作杆上挂“禁止操作”标示牌

Attach a “DO NOT OPERATE” tag to right hand control lever if the

machine is not operated.


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Kinds of oil

plantsquantity Oil brand/Specification Circumstance temperature

2# MSO2 lithium based grease★ -20～40℃（-4～104°F）

Mobile EP2 -20～40℃（-4～104°F）lubricate According to

require

Shell EP2 or RO2 -20～40℃（-4～104°F）

Mobile 1#（5W-40）（ API CG-4） -20～20℃（-4～68°F）

Mobile 1300（15W-40）（ API CG-4） -10～40℃（14～104°F）

Shell 10W-30（ API CG-4） -20～35℃（-4～95°F）Engine oil 25L

Shell 15W-40（ API CG-4）★ -10～40℃（14～104°F）

ASTM D975 NO.1★ -20～0℃（-4～32°F）Fuel 412L

ASTM D975 NO.2 -10～40℃（14～104°F）

Coolant 30SHELL antifreeze(100％ primary) and water

42:58

-30～40℃（-22～104°F）

Gear oil According to

require

SAE85W-140（ API GL4）-Swing reduction

SAE85W-90（ API GL4）-Travel reduction-20～40℃（-4～104°F）

ISO VG 32 -20～20℃（-4～68°F）

ISO VG 46★-20～40℃（-4～104°F）Hydraulic oil

Tank: 230L

System :330LISO VG 68 -10～40℃（14～104°F）

1.The Recommended oil

Note: " ★ " used by the manufacturer after the machine is newly produced


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1.推荐用油

The Recommended oil.

2.主要保养项目及位置

Main maintenance item and locatoin .

3.保养周期Maintenance Intervals.

4.各系统的保养点

Maintenance point of every system.4.1柴油机系统

Diesel engine system

4.2回转和行走减速机

Swing and Travel Reductions

目录Table of contents


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柴油精滤滤芯

Fuel fine-fil ter

油水分离器滤芯

Oil-water separator

filter

机油滤清器滤芯

Engine oil filter

先导滤清器滤芯

Pilot

filter

检查液压油位：每天检查

Check hydraulic oil level：

daily check

（打开右后侧门视图

The view of afteropen the right

door ）

燃油提升泵

Upgrade pumpof fuel


Main maintenance item and location

打开右侧门站在地上可以检查维护的项目

Open the right door may be check and maintenance on the ground

柴油粗滤滤芯

Fuel prefilter

柴油箱放水阀：每天

或

8小时

The water drainbalve of fuel tank:

everyday or every 8

hour


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（打开左后侧门视图

The view of after open

the back-left door ）

打开左后侧门站在地上可以检查维护的项目

Open the back-left door may be check and maintenance on the ground

电锁开关

Ignition switch




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张紧装置打黄油

Add lubrication to track tension device




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3.保养周期

Maintenance Intervals

3.1 8小时或每天Every 8 Hours or Every Day Service

3.2 50小时或每周

Every 50 Hours or Every Week Service

3.3 100小时或两周

Every 100 Hours or Two Week Service

3.4 250小时或每月

Every 250 Hours or Every Month Service

3.5 500小时或3个月

Every 500 Hours or Three Months Service

3.6 1000小时或6个月

Every 1000 Hours or Six Months Service3.7 2000小时或每年

Every 2000 Hours or Every Year Service



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3.1.1检查发动机油位

Check the oil level of the Engine.3.1.2检查冷却液液位

Check coolant level.

3.1.3检查液压油位Check hydraulic oil level.

3.1.4燃料箱水及污物排放

Drain any water and trash from the fuel tank.3.1.5燃油预滤器水及污物排放

Clean the fuel pre-filter, fuel filter and trash.

3.1.6检查空调制冷剂泄漏Check the refrigerant for leakage.

3.1 8小时或每天

Every 8 Hours or Every Day Service


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3.1.1 检查发动机油位Check the oil level of the Engine

OK

注意：为避免烫伤，在高温时不要检查发动机油

Attention: In order to avoid scalds , do notinspect when engine oil is high temperature.


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3.1.2 检查冷却液液位Check coolant level

注意：当发动机冷却液下降到50度以下，缓慢的旋开水箱盖以释放压

力，这样可以避免高温水蒸气喷出和烫伤。

Attention: After the engine coolant temperature drops down to 50℃ ,slowly screw out the water radiator cap to release pressure in order to

avoid scalded by high temperature vapor or splashing coolant.

检查液位


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3.1.3 检查液压油位Check hydraulic oil level

OK

在检查前按如停放机器

Park the machine as follow before check

3 1 4 燃料箱水及污物排放


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3.1.4 燃料箱水及污物排放Drain any water and trash from the fuel tank

3 1 5 燃油预滤器水及污物排放


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3.1.5 燃油预滤器水及污物排放Clean the fuel pre-filter, fuel filter and trash

3 1 6 检查空调制冷剂泄漏


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3.1.6 检查空调制冷剂泄漏Check the refrigerant for leakage

Under normal working

condition, refrigerantcan be viewed through

the sight glass. An even

and stable refrigerant

flow indicates that therefrigerant capacity is

normal. If bubbles are

found in the refrigerant,

then replenishrefrigerant because that

indicates a refrigerant

leakage in the system.

目录


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3.保养周期


3.1 8小时或每天Every 8 Hours or Every Day Service



3.3 100小时或两周Every 100 Hours or Two Week Service



3.5 500小时或3个月


3.6 1000小时或6个月




3 2 50小时或每周


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3.2.1润滑（打黄油）动臂销。

Lubricate the boom pin.

3.2.2润滑（打黄油）动臂液压缸底销。

Lubricate the bottom pin of boom cylinder .

3.2.3润滑（打黄油）斗杆、铲斗和连杆连接销。

Lubricate the arm, bucket and linkage pin.

3.2.4检查和调整履带的下垂。Check and adjust the track.

3.2.5清扫空气滤清器外部过滤零件。

Clean the air filter.

3.2 50小时或每周Every 50 Hours or Every Week Service

3 2 1 润滑（打黄油）动臂销


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3.2.1 润滑（打黄油）动臂销Lubricate the boom pin

动臂销boom pin

3 2 2 润滑（打黄油）动臂液压缸底销


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3.2.2 润滑（打黄油）动臂液压缸底销Lubricate the bottom pin of boom cylinder

动臂缸底销The bottom pin of

boom cylinder

3 2 3 润滑（打黄油）斗杆铲斗和连杆连接销


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3.2.3 润滑（打黄油）斗杆、铲斗和连杆连接销Lubricate the arm, bucket and linkage pin

润滑点Lubricate Point


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3 2 4 检查和调整履带的下垂


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Measure the distance

(2)Measure the distance from thebottom of track frame and the

back of track shoe.

CLG922LC：270 to 350mm。

3.2.4 检查和调整履带的下垂Check and adjust the track

3 2 4 检查和调整履带的下垂


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(3)To tension the track, firstly turn the grease fitting

to the convenient position, and then connect thegrease gun. Add grease till the tension within the

recommended limit.

(4)To loosen the track, turn the valve

counterclockwise and slowly. When valve is

loosened for 1 to 1.5 circles, the grease will flow outfrom grease outlet. If the grease does not flow out

smoothly, lift the track above ground, slowly rotate

the track.

3.2.4 检查和调整履带的下垂Check and adjust the track

3 2 5 清扫空气滤清器外部过滤零件


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3.2.5 清扫空气滤清器外部过滤零件Clean the air filter

用手拍

Pat with yourhands

用压缩空气由里面往外吹Blowing from the

inside out with

compressed air

粉尘很多

A lot of dust

注意：

意：

如果气体中有粉

果气体中有粉

尘，将会导致气缸的磨损

，将会导致气缸的磨损

Caution:Caution:If If the air hasthe air hasthe dust, will createsthe dust, will creates

the cylinder wear the cylinder wear


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3 3 100小时或两周


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3.3.1润滑（打黄油）动臂和斗杆连接销。

Lubricate the boom and arm pivot pin.

3.3.2润滑（打黄油）斗杆液压缸活塞杆销和缸底销。

Lubricate the piston pin and bottom pin of arm cylinder.

3.3.3润滑（打黄油）铲斗液压缸底销。

Lubricate the bottom pin of bucket cylinder.

3.3.4润滑（打黄油）动臂液压缸活塞杆销。

Lubricate the piston pin of boom cylinder .

3.3.5检查和调整风扇皮带张力。

Check and adjust belt tension of fan.

3.3.6检查调整压缩机皮带的张力。

Check and adjust belt tension of compressor.


3 3 1 润滑（打黄油）动臂和斗杆连接销


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3.3.1 润滑（打黄油）动臂和斗杆连接销Lubricate the boom and arm pivot pin

润滑点

Lubricate point

3 3 2 润滑（打黄油）斗杆液压缸活塞杆销和缸底销


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3.3.2 润滑（打黄油）斗杆液压缸活塞杆销和缸底销Lubricate the piston pin and bottom pin of arm cylinder

活塞销The piston pin

缸体销The bottom pin

3.3.3 润滑（打黄油）铲斗液压缸底销


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3.3.3 润滑（打黄油）铲斗液压缸底销Lubricate the bottom pin of bucket cylinder

活塞销The piston pin

缸体销The bottom pin

3 3 4 润滑（打黄油）动臂液压缸活塞杆销


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3.3.4 润滑（打黄油）动臂液压缸活塞杆销Lubricate the piston pin of boom cylinder

动臂缸活塞杆销the piston pin of

boom cylinder

3.3.5 检查和调整风扇皮带张力


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3 3 5 检查和调整风扇皮带张力Check and adjust belt tension of fan

Slack fan belt could cause inappropriatebattery charging, engine heating and

quick and abnormal wear. But overtightened fan belt also will cause bearingand belt damaged.

9.5-12.7mm (the maximum deformation

by hand )

3.3.6 检查调整压缩机皮带的张力


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检查调整压缩机皮带的张力

Check and adjust belt tension of compressor

Slack fan belt could cause air conditionrefrigeration capacity fall

5-10mm (the maximum deformation byhand )

目录


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3.保养周期









3.5 500小时或3个月


3.6 1000小时或6个月






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3.4.1检查回转减速机齿轮油油位。

Check the swing reduction gear oil.

3.4.2检查行走减速机齿轮油油位。

Check the travel reduction gear oil.

3.4.3检查螺栓和螺母的张紧扭矩。

Check the tightening torque of bolts and nuts.

3.4.4更换发动机油。Replace the engine oil.

3.4.5更换润滑油滤清器。

Replace the engine oil filter.

3.4.6更换燃油粗滤器。

Replace the primary fuel filter.

3.4.7更换燃油滤清器。

Replace the fuel filter.3.4.8清洁新风、内回风滤网。

Clean the fresh air filter and recirculating air filter of the cab.


3.4.1检查回转减速机齿轮油油位Ch k th i d ti il


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Check the swing reduction gear oil

Take out dipstick, the oil level should reach the position

between L and H. If the oil level is below L, then open oil fill

cap to replenish gear oil.

加油oil fill油标

Oil dipstick

OK

润滑油口Port for lubricating oil

3.4.2 检查行走减速机齿轮油油位


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Check the travel reduction gear oil

(1)Move the machine slowly until oil level plug is located to level mark.

(2)Unscrew air exhaust plug slowly to release pressure after the gear oil cools

down completely.(3)Unscrew plug to check oil level. The oil should be below the oil level mark.

放油螺堵Oil drain plug

油位线Oil level mark

加油

Refill oil

3.4.3 检查螺栓和螺母的张紧扭矩


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Check the tightening torque of bolts and nuts

If there is any looseness, tighten to the specified torque.

Replace the bolts and nuts with new one of same quality orhigher quality.

Use torque wrench to check and tighten bolts and nuts.

Ensure the threads are clean when mounting or replacing. Apply lubricant to bolts and nuts to maintain their frictional

coefficients.

If the bolts on the counterweight are loose, contact your

dealer or service center.

3.4.3 检查螺栓和螺母的张紧扭矩


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bolt of sprocket 305N.mtrack shoe bolt 750N.m

Counterweight

bolt 1850N.m

swing reductiongear bolt 600N.m

bolt of revolving frame and

swing bearing 800N.m

Check the tightening torque of bolts and nuts

3.4.4 更换发动机油Replace the engine oil


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Replace the engine oil

Drain OilThe oil drain valve

Attention: In order to avoid scalds , do not replace whenengine oil is high temperature.

3.4.5 更换润滑油滤清器


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Replace the engine oil filter

Engine oil filter

3.4.6 更换燃油粗滤器


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Replace the primary fuel filter

The primary fuel filter

3.4.7 更换燃油滤清器R f f


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Replace the fuel filter

The fuel filter

3.4.8 清洁新风、内回风滤网


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Clean the fresh air filter and recirculating air filter of the cab

空调外滤芯

the fresh air filter

目录T bl f t t


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3.保养周期









3.5 500小时或3个月


3.6 1000小时或6个月

Every 1000 Hours or Six Months Service

3.7 2000小时或每年


Table of contents

3.5 500小时或3个月Every 500 Hours or Three Months Service


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3.5.1 润滑（打黄油）回转轴承。

Lubricate the swing bearing.

3.5.2 润滑（打黄油）回转内部齿轮。

Lubricate the swing gear.

3.5.3 清扫散热器组外部。Clean the surface of radiator group.

3.5.4 更换空气滤清器外部和内部过滤零件。

Replace the external and internal components of air filter.

3.5.5 清扫空调冷凝器外部

Clean the surface of the condenser.


3.5.1 润滑（打黄油）回转轴承L b i t th i b i


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Lubricate the swing bearing

Check the lubricant on the gear, lubricant must properly flow on

the surface of gears. If need, refill about 0.5 kg lubricant.

NOTICE: Do not fill too much grease.

The swing bearing Lubricate Cover

3.5.2 润滑（打黄油）回转内部齿轮Lubricate the swing gear


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Lubricate the swing gear

Remove cover near the swivel joint at the bottom of the swing

gear compartment. Refilling capacity for the grease is about 4 kg.

Lubricate the swing gear Lubricate Drain Cover

3.5.3 清扫散热器组外部Clean the surface of radiator group


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Clean the surface of radiator group

Use pressure air to clean radiator or oil cooler

clean

If the surface of radiator

group is very dirty, thewater and oil temperature

will overheat.

NO PRESSURE

WASHERS ALLOWED!!

3.5.4 更换空气滤清器外部和内部过滤零件Replace the external and internal components of air filter


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Replace the external and internal components of air filter

外滤芯External filter

内滤芯Internal filter

3.5.5 清扫空调冷凝器外部Clean the surface of the condenser


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Clean the surface of the condenser

clean



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3.保养周期










3.6 1000小时或6个月


3.7 2000小时或每年


Table of contents

3.6 1000小时或6个月Every 1000 Hours or Six Months Service


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3.6.1 更换燃油输送泵过滤器

Replace the fuel lift pump filter.

3.6.2 更换回转减速机齿轮油。（500小时第一次更换）

Replace the swing reduction gear oil.(500 hours replace for

the first time )

3.6.3 更换行走减速机齿轮油。（500小时第一次更换）

Replace the travel reduction gear oil.(500 hours replace for

the first time )

3.6.4 更换先导油滤清器。

Replace the pilot oil filter.3.6.5 更换液压箱回油滤。

Replace the hydraulic oil return filter.

3.6.6 润滑（打黄油）回转减速机轴承

Lubricate the bearing of swing reduction gear.


3.6.1 更换燃油输送泵过滤器Replace the fuel lift pump filter


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Replace the fuel lift pump filter

燃油输送泵过滤器The fuel lift pump filter

3.6.2 更换回转减速机齿轮油。（500小时第一次更换）Replace the swing reduction gear oil (500 hours replace for the first time )


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Replace the swing reduction gear oil.(500 hours replace for the first time )

润滑油口Port for lubricating oil

放油螺堵Drain Oil plug

3.6.3 更换行走减速机齿轮油。（500小时第一次更换）Replace the travel reduction gear oil (500 hours replace for the first time )


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Replace the travel reduction gear oil.(500 hours replace for the first time )

放油螺堵

Oil drain plug

放油

Drain oil

加油

Refill oil

3.6.4 更换先导油滤清器Replace the pilot oil filter


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Cleaning housing internalReplace the pilot oil filter pilot oil filter

3.6.5 更换液压箱回油滤Replace the hydraulic oil return filter


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Replace the hydraulic oil return filter

(1) Slowly loosen the breather cap counterclockwise to release pressure,

then open the cap carefully

(2) Secure cover with hand to overcome the spring force when removingthe last two bolts. Open the cover.

(3) Remove spring and return filter.

(4) Replace with a new return filter.

(5) Install spring, cover and o-ring.

3.6.6 润滑（打黄油）回转减速机轴承Lubricate the bearing of swing reduction gear


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Lubricate the bearing of swing reduction gear

润滑点

Lubricate point



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3.保养周期






3.3 100小时或两周

Every 100 Hours or Two Week Service




3.6 1000小时或6个月


3.7 2000小时或每年


3.7 2000小时或每年Every 2000 Hours or Every Year Service


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3.7.1 更换液压油

Replace the hydraulic oil.

3.7.2 更换吸油滤清器。

Replace the suction oil filter of hydraulic oil tank.

3.7.3 更换冷却液和清洗散热器内部。

Replace the coolant and clean the internal surface of

radiator.

y y

3.7.1 更换液压油Replace the hydraulic oil


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p y

（1）Swing the revolving frame to 90 °to park the machine on

a flat ground.

（2）Retract the arm cylinder and extend the bucket cylindercompletely to lock the machine.

（3）Lower the bucket onto ground. 。

（4）Shut down the engine and take out the key.

（5）Push the pilot shutoff lever to LOCK position.



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（6）Clean the top of hydraulic tank to prevent dust coming into

the hydraulic oil system.

（7）Slowly loosen the breather cap counterclockwise to release

pressure, then open the cap carefully..

（8）Open the hydraulic tank cover.

（9）Clean the oil outlet of hydraulic tank and unscrew oil drain

plug to drain oil. Collect the oil with container.

p y



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（10）Remove suction filter and rod group.

（11）Clean the internal surface of suction filter and hydraulic oil tank.

Take out the screen to wash. If it needs to replace with a new

filter, install the new filter onto the rod.

（12）Install suction filter and rod group. Ensure the filter is fixed tocorrect position.

p y



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（13）Wash the hydraulic oil tank with clean hydraulic oil. Wipe it with

clean and dry towel. Install and tighten the oil drain plug.

（14）Refill hydraulic oil to the position between low and high mark.

（15）Install the hydraulic oil cover. Ensure the suction filter and rod

are fixed to correct position.



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（16）Unscrew the air exhaust plug from the top of the pump. Fill oil to

the pump through the plug mouth and then install the air

exhaust plug.

（17）Start the engine and run it at idle speed. Put a “DO NOT

OPERATE” tag to the pilot shutoff lever. Make sure the pilot

shutoff lever is at LOCK position.

（18）Loosen the breather cap to release the air until the oil flows out

of the mouth. Tighten the cap.



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（19）Run the engine at a speed of 1200 rpm. Operate the control

lever slowly for about 15 minutes to exhaust the air in the system.

（20）Retract the arm cylinder and extend the bucket cylinder

completely to lock the machine.

（21）Lower the bucket onto ground.


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3.7.2 更换吸油滤清器Replace the suction oil filter of hydraulic oil tank


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3.7.3 更换冷却液和清洗散热器内部Replace the coolant and clean the internal surface of radiator


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（1）Slowly screw out the water radiator filler cap to release

pressure after the coolant temperature is below 50 ℃ .

（2）Open the water release valve at the bottom of the radiator,

drain out the coolant of the engine and collect with a container.

（3） After draining out coolant of the engine, close the water release

valve at the bottom of the water radiator.

Drain the Coolant Fill Coolant



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（4）Check all water lines and clamps of cooling system for damage,

replace if necessary. Check water radiator for leakage, damage

and piled-up trashes, clean and repair if necessary.（5）Replenish cleanser which is mixed with water and sodium carbonate

into the cooling system of the engine, its proportion is 0.5 kilograms of

sodium carbonate with 23 liters of water. The level should reach normal

level of the engine and keep stable within 10 minutes.



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（6）Keep the water radiator filler cap open, start the engine, when the

coolant temperature is over 80 ℃ , run the engine for 5 minutes again.

（7）Stop the engine, drain out cleanser.（8）Replenish clean water into cooling system of the engine till it reaches

normal level and is kept stasble within 10 minutes. keep the water

radiator filler cap open, start the engine, when the coolant temperature

is over 80 ℃ , run the engine for 5 minutes again.


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4.1柴油机系统 Diesel engine system期间（小时）Interval(hours)

零部件 Component

数量

Quantit

y 8 50 100 250 500 1000 2000


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80★★★ The first service time ※ Shorten the time of maintenance

y

检查 Check 11．发动机油 Engine oil

更换 Replace 25L ★★★

2．润滑油滤清器The engine oil filter 更换 Replace 1 ★★★

3．燃料箱水及污物排放 Drain any water and trash from

the fuel tank.

１

排放 Drain 14．燃油预滤器 Fuel pre-filter.

更换 Replace 1 ★★★

5．更换燃油滤清器 Replace fuel filter 2 ★★★

清扫 Clean 16．空气滤清器外部组件 The externalcomponents of air filter 更换 Replace 1

7．空气滤清器内部组件 The internal

components of air filter

更换 Replace 1

8．检查冷却液液位 Check coolant level 1

9．检查和调整皮带张力 Check and adjust belt tension offan

1

30L10．更换冷却液 Replace the coolant

清扫散热器内部 Clean the internal surface of radiator 一年或者2000个操作小时


11．清扫散热器组外部 Clean the surface of radiatorgroup 1 ※1

4.1柴油机系统 Diesel engine system


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Check coolant level—everyday or 8 hours

When the engine is cooling, the water in radiator must be full.

Check and adjust fan tension (from B series diesel engine operation and

maintenance mannual)

Key point: loose fan drive belt may cause lack of battery charging, engine

heating and abnormal and rapid wear of belt. While the belt is too tight,

may cause the damage of bearing and drive belt



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Antirust :

When change coolant water, add about 0.58L（0.15 gallon）

antirust, while using antifreeze, antirust is not available any more.

Antifreeze:

If the temperature is forecast down to below 0 ℃ (32 degreesFahrenheit), please add a mixture of antifreeze and softened

water into the coolant system. If antifreeze you have bought

including ratio instruction, please follow the instructions andmake the mixtures according to the local minimum temperature.

The following table lists the proportion of SHELL stock

temperature for ratio of antifreeze and mixture for the reference.



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83

Antifreeze ratio table:

the proportion of SHELL antifreeze and water

The ratio of antifreeze The ratio of water Condensing point

30% 70% -15℃

34% 66% -20℃39% 61% -25℃

41.8% 58.2% -30℃

45% 55% -35℃



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84

Clean the outer part of radiator---per 500 hours

1． Open side entrance and engine hood .

2． Use the compressed air or water to clean or wash the radiator and oil coolant .

Cleaning mouths are

on and under the

shroud , you can usethe compressed air or

water to clean or wash

the inner part of core

4.2 回转和行走减速机

Swing and Travel Reduction


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周期（小时） Intervals(Hours)部件components

数量quantity

8 50 100 250 500 1000 2000Oil level

check

— 1．回转减速机

Swing

Reductions replace 3.4L ★★

★

Oil level

check

— 2．行走减速机

Travel

Reductions replace 5.5L×2 ★★

★

★★★ 第一次服务时间

The first service time

Documents

04维护保养要点Maintenance point.pdf