车辆维修保养手册

2005-24 Trail 20” Container Handling Vehicle MANUAL FOR MAINTENANCE/REPAIRH U N A N Z O O M L I O N S P E C I A L V E H I C L E C O.,LT D.December 2006CONTENTSChapter 1 Maintenance and V ehicle Care 2 Chapter 2 Normal Problems and Troubleshooting 12 Chapter 3 Transportation and Storage 131Chapter 1 Maintenance and Vehicle Care1 Concepts1.1 Introduction of Palletized Loading VehicleThe self loading vehicle is a machine for either fork lifting, loading, excavating and drawing. Through different tools we may fulfill various needs.It’s excellent for its performance, stability and security.1.2 Maintenance and Vehicle CareThe purpose of maintenance is for normal use of the equipments, ensuring normally functioning of them and guaranteeing the working life of the machine.1.2.1 OverhaulOverhaul is heavy repair as scheduled. After 5 years since exit-factory, or when the machine’s main performances are lower than 95% of the standard values, overhaul becomes necessary, that means we need to check and repair the overall vehicle completely.1.2.1 Mid-scale RepairMid-scale repair is also as scheduled. Users should, according to the failure mechanism when the self loading vehicle malfunction occurs during the operation, find out the problems. Mid-scale repair is performed once every two years. Also when we encounter the troubles that regular repair and maintenance cannot solve, it’s time to consider mid-scale repair.1.2.3 Minor RepairMinor repair is actually daily maintenance.2. Purpose and General Requirements2.1 PurposeThe purpose of maintenance and vehicle care is to prevent, find out as early as possible and eliminate the problems of the PLS (palletized loading system), ensure it works well, improve its performance and economic profit.2.2 General Requirements1. Before we perform maintenance, we need a plan, including the items to be maintained, key aspect, schedule, task assignment, requirements, evaluation, team leader and corresponding methods.2. The maintenance technicians must be familiar with the basic structure, principle of work and technical performance of the spare parts.3. The maintenance technicians must observe operation regulations and technical safety rules.24. Normally during maintenance we do not dismantle the parts. If it is necessary we must remember its original place and try not to displace its installation place.5. Keep the records, including the abnormity, troubleshooting, etc.3. Organization of Maintenance3.1 Overhaul OrganizationIt includes overhaul reason analysis, period, team members, site, tools and instruments, budget, effect to be expected and the plan.3.2 Mid-scale Repair OrganizationIt includes the name and type of the products to be repaired, the reason analysis, period, team members, site, tools and instruments, budget, effect to be expected and the plan.3.3 Minor Repair OrganizationIt includes team establishment, tools and sources preparation and keeping records.4. Contents of Maintenance4.1 For the maintenance of engine and chassis, please read the manufacturers’ manuals: the WD615 Series Diesel Manual for Use and Maintenance, and the Shanqi Steyr Truck Manual for Use and Maintenance.4.1.1 Lubrication and Hydraulic OilTransmissionLubrication Part Capacity Recommendation Package No.Oil Pump Drive Shaft’s Universal Joint 50g #2 General Lithium BaseGrease (GB7324-1994)Self-loading MechanismLubrication Part Capacity Recommendation Package No.Lifting cylinder pin roll 50g #2 General Lithium Base Grease (GB7324-1994)Lifting arm jointed shaft 50g #2 General Lithium Base Grease (GB7324-1994)Hook arm jointed shaft 50g #2 General Lithium Base Grease (GB7324-1994)Jointed shaft of hook arm oil cylinder 50g#2 General Lithium Base Grease(GB7324-1994)Hook 80g #2 General Lithium Base Grease (GB7324-1994)3H Frame:Lubrication Part Capacity Recommendation Package No.Telescoping pipe’s out arm 伸缩管外臂100g#2 General Lithium BaseGrease (GB7324-1994)Hub splines 20g #2 General Lithium Base Grease (GB7324-1994)Auxiliary FrameLubrication Part Capacity Recommendation Package No.Support platform 100g #2 General Lithium Base Grease (GB7324-1994)Support contact roller 20g #2 General Lithium Base Grease (GB7324-1994)Rear Support (Container’s guiding mechanism)Lubrication Part Capacity Recommendation Package No.Turning pin roll 30g #2 General Lithium Base Grease (GB7324-1994)Support link joint 200g #2 General Lithium Base Grease (GB7324-1994)H frame’s accessory holder 随车装置Lubrication Part Capacity Recommendation Package No.Cylinder pin roll 20g #2 General Lithium Base Grease (GB7324-1994)Joint pin roll 10g #2 General Lithium Base Grease (GB7324-1994)HydraulicLubrication Part Capacity Recommendation Package No. Hydraulic oil tank 250L L-HV32(GB/T7631.2-1987)Please use the recommended grease. When filling, no need to use the grease which is easy to be blended. Grease analysisDuring repair or maintenance, you may need to get a grease sample from a part for analysis.4Fig 4-1: Lubrication Points of PLSNote: ★ means lubricating by oil gun, ※ means brushing.4.1.2 Oil Filter CoresOil Filter CoresName Type Qty. Manufacturer No.Scavenge oil filter of hydraulic oil tank 0330R010BN3HC 1 HYDAC fromGermany4.1.3 Repair Cycle A=Adjust; N=NeatC=Check; R=Replace G=Grease; V=V ent After50 h.Oneday or10 h.50 h. 250 h.Oneyearor 500h.Oneyearor1000h.2000h.4000h.TransmissionCoupling shaft of oil pump G G 〈〈〈〈〈Connection of oil pump C 〈〈〈〈〈〈Self-loading MechanismJoint of pin roll G 〈〈〈〈〈Lifting and hook arm G 〈〈〈〈〈Hook wearing C C 〈〈〈〈〈H Frame5Telescoping casing G 〈〈〈〈〈Turning pin C 〈〈〈〈〈Rear supportLink joint C 〈〈〈〈〈〈Twist lock C 〈〈〈〈〈Auxiliary FrameFrame structure C 〈〈〈〈〈Connecting bolt C 〈〈〈〈〈〈HydraulicHydraulic oil level C 〈〈〈〈〈Hydraulic Oil Filter Cores R R 〈〈〈〈Balance V alve C C 〈〈〈〈Hydraulic oil V 〈〈〈Filter shell cover (hydraulic oilR 〈〈〈tank)Hydraulic operation speed C** 〈〈〈Hose and flexible hose conditions C C** 〈〈〈Hydraulic cylinder conditionsC C** 〈〈〈(leakage, shaft)Hydraulic circuit output C** 〈〈Hydraulic oil tank N** 〈〈4.1.4 Maintenance for Every Day or Every Ten Hours4.1.4.1 Connection of oil pumpCheck the oil pump connection and transmission shaft connection every day.4.1.4.2 Link jointCheck the link joint’s connection every day to see it’s reliable, adjust the link joint where appropriate.4.1.4.3 Frame connectionCheck the frame’s connecting bolts to see if they are loose every day we start a day’s work or end a day. If it’s loose then it’s required to tighten it or replace it with the bolt which strength shall not be lower than the original strength.4.1.5 Maintenance for Every 50 Hours4.1.5.1 Greasing the self-loading mechanismIf the vehicle runs for less than 50 hours, then every week you need the following maintenance.6In the dusty or oxidation-affected working conditions, maintenance needs to be added to once every ten hours or every day. After cleaning, grease the following locations and remove the excessive part.For the greasing parts, please see Table 6.1.1 and the Lubrication Points Diagram.4.1.5.2 Check Hydraulic Oil LevelPark the vehicle to a flat ground, retract the self-loading mechanism and shut off the motor.1.Check the hydraulic level meter, if it is right, the level should be 5cm lower than the highest point.2.If necessary we need more oil.3.Take off the air filter cover, add oil through the adding nozzle.4.Clean the oil tank bottom, add oil by means of clean hopper.5.Since cooling is dependent on the oil flow in the oil tank, the hydraulic oil should be kept at the highest oil level.4.1.6 Maintenance for Every 250 Hours4.1.7 Maintenance for Every 500 Hours4.1.7.1 Hydraulic Oil Filter Core Replacement1.Park the vehicle on flat ground, release the pressure of the hydraulic circuit (swing the hydraulic control rod).2.Clean the outside of filter cores to avoid the static hydraulic circuit is polluted.3.Put a container below the hydraulic oil filter and then unscrew the filter.4.Replace with new filter core, remember the original position, turn 90 degree and then lock it.4.1.7.2 Balance valve check1.Maintenance is required after the initial 50 hours, after that, every 500 hours we need to perform it once. Park the truck on flat ground, use the park brake, and then turn to free shift.2.Balance valve functionThe balance valve is used to protect the user from any possible pipe explosion in case of hydraulic pressure decrease or wrong operation.During this type of check, non-technicians should stay away from the site.If after the engine has stopped, the hydraulic system still works, we need to replace or repair the balance valve. If the balance valve is damaged, then do not move the vehicle.3.Check the hydraulic operationLifting circuitAccording to the operation manual, operate the lifting circuit, the lifting arm should be able to stay at any position. If the operating handle is in the middle but the lifting arm cannot be stopped, then the balance valve or oil cylinder should be repaired or replaced.7Hook arm circuitAccording to the operation manual, operate the hook arm circuit, the hook arm should be able to stay at any position. If the operating handle is in the middle but the hook arm cannot be stopped, then the balance valve or oil cylinder should be repaired or replaced.Stabilizer circuitAccording to the operation manual, operate the stabilizer circuit, it should be able to stay at any position. If the operating handle is in the middle but the stabilizer cannot be stopped, then the balance valve or oil cylinder should be repaired or replaced.H frame’s accessory holder circuitAccording to the operation manual, operate the H frame‘s accessory holder circuit, the drive cylinder should be able to stay at any position. If the operating handle is in the middle but the drive cylinder cannot be stopped, then the balance valve or oil cylinder should be repaired or replaced.4.1.8 Maintenance for Every 1000 Hours4.1.8.1 Hydraulic Oil and Filter Core Replacement1.Park the vehicle to a flat ground, retract the self-loading mechanism.Before any maintenance, make sure the cylinder and hydraulic oil tank’s sucking-nozzle are clean.2.Oil ventPut a container below the oil vent plug and then unscrew the plug.Take away the oil-adding nozzle cover 2, make sure oil is complete vented.Dispose the scavenge oil in an environment-friendly way.3.Clean the filter netTake away the filter coverUse compressed air to clean the filter core’s net. Check the net, if necessary, replace it.Refit the filter net and cover, make sure the sealing elements are in the right positions.4.Adding oilWash and screw the outlet plug (screw torque moment 29-39Nm).Add oil using air filter.Before filling, clean the oil tank’s bottom first, then use a cleaner container and hopper.Observe the oil level of the oil dip rod 5 (E6/4), the oil level should 5cm above the rod’s top. Check if there is any leakage of the cylinder.Replace it with a new air filter.回油滤清器Suction returnline filter空气滤清器Air filter油箱箱体Oil tank吸油滤清器Suction filter连接螺栓Connecting bolt4.1.9 Irregular Maintenance4.1.9.1 Wheel ReplacementWhen the vehicle needs its wheel to be replaced on roads, remember that:1.It is suggested to use a hydraulic jack and safe support;2.Try to park the truck on flat and solid ground.3.Start the alarming light;4.Fix the vehicle by letting the axles opposite to the to-be-replaced wheel side be duplex balanced.5.Loose the bolts on the wheel to be replaced.6.Put the jack below the lighting axle, as close as possible to the wheel, then adjust the jack.7.Raise the wheel until it leaves the ground, then put safe supports below the axle.pletely loose the nuts and take out wheel.9.Repeat it and remove the wheel.10.Put on a new wheel.11.Put on the nuts back manually. If necessary, add grease.12.Take away safe supports Low down the vehicle using jack.13.Tighten the wheel’s nuts using a wrench.4.1.10.2 Trailer of the Loading VehicleIf the loading vehicle is trailed, the speed should be lower than 25km/h.Shift the fwd rod to free.Release park brake.Start the alarming light;If the engine is not started, the steering and braking systems should not be started either. Operate slowly (steering, braking), avoid sudden move.4.1.10.4 Loading vehicle transported on platform1.Before loading the vehicle, ensure all the safety instructions about the platform have been observed. The driver should know the dimension and weight of the truck. Ensure the platform’s dimension and load capacity are sufficient to transport the vehicle, and you need to check the contact surface pressure acceptable by the platform. Check the area on the platform that can support the vehicle. If the mechanical engine is equipped with turbine, the exhaust outlet must be sealed to avoid it runs without being lubricated.92.Transporting on PlatformBlock the platform wheel;Fix loading slope plate (as long as possible)Get the vehicle to the platform.Park the truck on the platform.3.FixingFixing wheel-stop blocks in front of and behind the wheels on the platform.It is forbidden to fix such blocks behind the front wheels and the two sides of the rear wheels. Use sufficient ropes to fix the vehicle on the platform, and lock it on the frame.Tension the ropes.Loading V ehicle Transported by PlatformChapter 2 Normal Problems and TroubleshootingIf any failure occurs during the 2005-24 Trail Handling 20ft Container V ehicle’s operation, it shall be comprehensively inspected and analyzed to find out the reasons and take proper measures to eliminate the failure. General failures and troubleshooting method are listed as follows.General failures and trouble shooting methodsS. N.Failure Reasons Trouble shooting method1 Oil circuitleakageConnector loosenedSealing ring brokenPipe brokenFasten the connectorReplace the sealing ringWeld up or replace the pipe2 Oil pressure iscannot increaseThe oil tank’s oil level is too low,the sucking pipe is blocked.Regulating valve set pressure toolowLack of oil vent in the oil pumpPressure pipeline is connectedwith the return line, or the elementleakage is too largeOil pump damaged or leakage toolargeAdd more oil or check the sucking pipeAdjust the regulating valveCheck the diesel engine’s rotation speedand make calibrationCheck the oil circuit, in particular thevalvesCheck the oil pumps or replace them3 Serious oilcircuit noiseSerious oil circuit noiseOil temperature too lowPipe and element not fastenedOne-way valve or elements failedOil filter jammedLack of oil in the tankRepeat the operation and try to eliminatethe gas inside, check the oil pump’ssucking pipe, no leakageHeat the oil with low-speed pump orreplace the oilFasten itAdjust or repair itClean the filterAdding oil4 Oil too hot Inside leakage too largePressure too highWorking temperature too highBalance valve failureCheck the elementsAdjust the regulating valvePark the vehicle and let it cool downCheck and repair the balance valve5 The oil pressuremeter’s needlepointer does notmoveThe shimmy damper failedThe pressure meter is damaged orthe inlet oil circuit is jammedCheck and repairCheck and repair6 Pressure toohigh or vibrationoccurring inboomtelescopingDamped hole on the balance valvejammedToo large friction on the fixed orflexible parts, or jammedsomewhereClean the balance valveCheck and repair7 Pressure toohigh or vibrationoccurring inboom loweringAir inside the cylinderDamped hole on the balance valvejammedPerform lifting-lowing for a few timewithout loads, to get rid of air, add oil,clean the balance valve.Chapter 3 Transportation and Storage1 TransportThe 2005-24 Trail Handling 20ft Container V ehicle may runs on roads, or perform long-distance transportation using train or other vehicles. During transportation, block the wheels at the front and rear, fix it with ropes, and also use necessary rain-proof covers.There are no specific requirements for railway transportation. Tie the chassis according to the railway rules. During railway transportation, we need to put the vehicle on the platform lorry longitudinally and symmetrically. The H frame should be totally retracted. It’s forbidden to load those off-size goods such as container and shelter.2. StorageProperly store those equipments which are not planned to be used within 3 months. For the Trail Handling 20ft Container V ehicle which are to be stored, we need to perform technical check first, ensure it is technically sound. Make sure the equipments will not be affected by rust during storage, they should be good enough to be put into use immediately once it is taken out of storage.For storage of the chassis, please follow the rules in the Manual of Use and Maintenance for Shanqi Steyr Truck.Requirements for 2005-24 Trail Handling 20ft Container V ehicle’s Upper Part Storage:1. Let the lifting arm be at the position of driving2. Use dry compressed air to blow away the dust (or manually removing it), clean the machine’s oil dirt.3. The mechanisms’ lubrication positions need to be lubricated/greased as required.4. To the non-coated surfaces we need to use lithium base grease.5. The tyres must be inflated according to the regulations, use cushion timber to support the truck’s beam to let the tyre leave the ground.6. The Trail Handling 20ft Container V ehicle is suggested to be stored in garage, if it has to be outside, then use water resistant cloth.7. During storage, if there is water coming in, the machine needs to be prevented from rusting.。