2005-24 Trail 20” Container Handling Vehicle MANUAL FOR MAINTENANCE/REPAIR
H 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 2006
CONTENTS
Chapter 1 Maintenance and V ehicle Care    2 Chapter 2 Normal Problems and Troubleshooting 12 Chapter 3 Transportation and Storage 13
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Chapter 1 Maintenance and Vehicle Care
1 Concepts
1.1 Introduction of Palletized Loading Vehicle
The 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.
同学聚会主持词
1.2 Maintenance and Vehicle Care
The 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 Overhaul
Overhaul 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 Repair
Mid-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 Repair
Minor repair is actually daily maintenance.
2. Purpose and General Requirements
2.1 Purpose
The 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 Requirements
1. 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.小学运动会加油稿
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4. 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 Maintenance
3.1 Overhaul Organization
It includes overhaul reason analysis, period, team members, site, tools and instruments, budget, effect to be expected and the plan.
3.2 Mid-scale Repair Organization
It 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 Organization
It includes team establishment, tools and sources preparation and keeping records.
4. Contents of Maintenance
4.1 For the maintenance of engine and chassis, please read the manufacturers’ manuals: the WD61
5 Series Diesel Manual for Use and Maintenance, and the Shanqi Steyr Truck Manual for Use and Maintenance.
4.1.1 Lubrication and Hydraulic Oil
Transmission
Lubrication Part Capacity Recommendation Package No.
Oil Pump Drive Shaft’s Universal Joint 50g #2 General Lithium Base
Grease (GB7324-1994)
Self-loading Mechanism
Lubrication 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)
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H Frame:
Lubrication Part Capacity Recommendation Package No.
Telescoping pipe’s out arm 伸缩管外臂100g
#2 General Lithium Base
Grease (GB7324-1994)
Hub splines 20g #2 General Lithium Base Grease (GB7324-1994)
Auxiliary Frame
Lubrication 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)南海位置
Rear Support (Container’s guiding mechanism)
Lubrication Part Capacity Recommendation Package No.
Turning pin roll 30g #2 General Lithium Base Grease (GB7324-1994)申军谊资料
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)
Hydraulic
Lubrication 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 analysis
During repair or maintenance, you may need to get a grease sample from a part for analysis.
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Fig 4-1: Lubrication Points of PLS
Note: ★ means lubricating by oil gun, ※ means brushing.
繁衍后代的意思4.1.2 Oil Filter Cores
Oil Filter Cores
Name Type Qty. Manufacturer No.
Scavenge oil filter of hydraulic oil tank 0330R010BN3HC    1 HYDAC from
Germany
4.1.3 Repair Cycle A=Adjust; N=Neat
C=Check; R=Replace G=Grease; V=V ent After
50 h.
One
day or
10 h.
50 h. 250 h.
One
year
or 500
h.
One
year
or
1000
h.
2000
h.
4000
h.
Transmission金泰熙和rain
Coupling shaft of oil pump G G 〈〈〈〈〈Connection of oil pump    C 〈〈〈〈〈〈Self-loading Mechanism
Joint of pin roll G 〈〈〈〈〈Lifting and hook arm G 〈〈〈〈〈Hook wearing    C    C 〈〈〈〈〈H Frame
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