Maintenance

SD200/SD200-3 Wheel loader

Sep, 2021
Service engineering Part
DISD
Mantenance
Symbol Description

The following are the standard symbols used in the “Lubrication and Service Chart” on the next page.

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Mantenance
Service Intervals
See the Operation and Maintenance Manual for details.
V : Maintenance and refill
: Cleaning
: Replacing on every interval
F : First-time exchange only
Note: In case of digging in water, be sure to
apply lubricant to the front pins before and
after operating. Transmission oil must be of
the same viscosity as grade the engine oil.

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Mantenance
10 Hours (Daily Service)
Check Engine Oil Level
(Note: When checking the oil level using the dipstick, always remove and wipe it clean before making final level
check.)

1. Check the engine oil level every day before starting up the engine.
2. Remove the engine oil dipstick. The oil level must be between the “LOW” and “FULL” marks.
Note: If the oil level is above the “HIGH” mark on the dipstick, the oil must be drained until it reaches
an appropriate level.
3. To add oil, remove the engine oil fill cap.

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Mantenance
10 Hours (Daily Service)
Check Transmission Oil Level
(Note: When checking the oil level using the dipstick, always remove and wipe it clean before making final level check.)

Two people are needed to perform this procedure.

1. Park the vehicle on horizontal road, and run the engine.
2. Open the oil filler of transmission to check the oil level.
3. The oil filler has an oil dipstick. Check the engine with the same method.

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Mantenance
10 Hours (Daily Service)
Check Hydraulic Oil Level

1. Move the machine to a level area and stop the engine.

2. Apply the parking brake.
3. Lower the bucket or attachment to the ground.
4. Check the sight gauge that is attached to the hydraulic tank. The oil level must be visible in the red centered circle
marked on the sight gauge.
5. To add hydraulic oil,if the oil level is under the required mark.
6. Remove the upper cover from the hydraulic oil tank and add oil until its lever reaches the top of the sight gauge.

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Mantenance
10 Hours (Daily Service)
Check for Leaks in Hydraulic System

During daily walk-around checks, check if any signs of leakage are found at the hoses, piping, fittings, cylinders,
or hydraulic motors. If any are found, determine the source of the leakage and fix it.

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Mantenance
10 Hours (Daily Service)
Check Coolant Level

Check sight gauge (1) that is attached to the radiator. The coolant level must be visible in the red centered circle
marked on the gauge. To add coolant, remove fill cap (2) of the radiator and add coolant to the appropriate level
observed on sight gauge (1). If the ambient temperature is below the freezing point, see “Antifreeze
Concentration Chart” below for antifreeze protection. Using the chart, calculate the proper mix of antifreeze and
water for the expected temperature.

Note: If the breather holes in the cap are clogged, a vacuum may form in the tank preventing the normal fuel flow
into the engine. Keep the fuel cap holes clean.

Antifreeze Concentration Chart

Ambient Temperature Cooling Water Antifreeze

-20℃ 67% 33%

-25℃ 60% 40%

-30℃ 56% 44%

-40℃ 50% 50%

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Mantenance
50 Hours (Weekly Service)
Grease (Front Attachment, Steering Cylinder, and Upper and Lower Center Pins)

Note: Perform all daily service checks.

Grease the fittings on a daily basis, or every 10 hours, for the first 100 hours of operation to comply with new
machine break-in requirements. After that, greasing must be done every 50 hours. If the bucket is being used in
water, grease the fittings immediately after the machine gets out of water.

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Mantenance
50 Hours (Weekly Service)
Clean Exterior of Radiator, Oil Cooler, and Air Conditioner Condenser

Dust and dirt on the fins of radiator, oil cooler, and transmission coolermay greatly reduce their cooling
performance. Use compressed air, water, and steam to clean the fins on the radiator, oil cooler, and transmission
cooler.

Note
1. In case of operation on an extremely dusty site, clean the fins every 50 hours. On other regular work sites,
clean the fins every 500 hours.

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Mantenance
50 Hours (Weekly Service)
Clean Outer Filter of Air Cleaner

Note
1. Clean the outer filter every 50 hours / Weeks of operation (Do not clean the inner filter).
2. If the air cleaner clogging warning lamp on the gauge panel has turned “ON,” the air cleaner must be serviced.
3. If the machine operates under severely dusty conditions, the service interval must be shortened.
4. Replace the outer filter after cleaning 4 times or every 500 hours / 3 months of operation.

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Mantenance
250 Hours
Change Engine Oil and Filter
Note: Change the engine oil and filter after first 50 hours of operating a new machine and every 500 hours
thereafter.
1. Position a large container under the engine. Loosen the drain bolt(1)and drain all engine oil. Tighten the drain
valve.
2. Replace the engine oil filter(2). The engine oil filter is a spin-on type. Remove and discard the filter.
3. Install a new filter. Apply a small amount of oil around the filter gasket. Screw the filter onto the head by
hand until the gasket contacts the head, and then turn the filter another 3/4–1 turn by a filter wrench.
4. Fill the engine with correct oil through the oil fill port（3）.
5. Start the engine and check the engine oil pressure indicator.
6. Stop the engine. Check for signs of leaks at the filter. Check the oil level again using the dipstick.

1 3
2

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Mantenance
250 Hours
Change Engine Oil and Filter

Oil Grade Oil Capacity Checking interval First /Change interval

Engine oil /15W—40 14L Daily 50h/250h

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Mantenance
500 Hours
Change Fuel Filter

Warning: Before you replace the filter, wait for the engine to cool down. Be careful of fire hazards. Do not smoke.
1. Locate the fuel filter inside the engine compartment.
2. Position a small container under the fuel filter. Drain the filter by opening the drain valve at the bottom of the
filter.
3. Screw out the fuel filter from the head assembly. Discard the fuel filter.
4. After cleaning the filter head, install a new fuel filter. Screw the filter onto the head until the gasket contacts
the head, and then turn the filter another 1/3–1/2 turn.
5. Start the engine. After the engine has run for a couple of minutes, stop the engine and check for leaks.

Loosen

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Mantenance
500 Hours
Change Air Filter

Warning: Before you replace the filter, wait for the engine to cool down.

1. Remove access cover by loosening latches

2. Remove the outer &inner filter from the housing.
3. Clean the inside of the air cleaner body, Do not use compressed air
4. Install the air filter and cover properly.

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Mantenance
500 Hours
Drain and Change Transmission Oil and Filter

Note: The transmission oil and filter must be changed after first 100 hours of operation to comply with new
machine break-in requirements. After the first change, the oil and filter must be changed every 500 hours.
1. Start up the machine and drive it until the transmission oil heats up
to 82°C–93°C (180°F–200°F). Park the machine on a level area.
2. Place the transmission lever in NEUTRAL. Apply the parking brake.
Stop the engine. Secure the tires with blocks.
3. Remove the drain plug. Drain all transmission oil into a receptacle.
Clean the drain plug.
4. Install the drain plug into the transmission.
5. Remove the bolt with l wrentch from filter housing cover and take
out filter element.then clean the filter housing
6. Install the new filter element into the housing and install the bolt.
7. Fill the transmission with oil through the oil supply pipe until the oil
level reaches the low mark on the dipstick.
8. Start the engine. Leave the engine at idle for two minutes.then stop
the engine to check the level.the oil lever must reach the high mark
on the dipstick.
9. Check the filter for leaks while the engine is running

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Mantenance
500 Hours
Change Transmission Oil Filter Element

1. Screw out element cover (1). Dispose of the oil in the Hosing(5).
2. Remove O-ring (4) and filter (2).
3. Use a nonflammable, nontoxic solvent to clean out Housing (5).
4. Insert a new filter (2) into Housing (5). Install a new O-ring (4).
5. Screw cover (1) onto housing (5).

Oil Grade Oil Capacity First Maintenance Time Change interval

Engine oil / 15W-40 35L 100h 500h 17
Mantenance
500 Hours
Change Brake fluid

1. Park the vehicle on horizontal road.

2. Release the break pedal,lossen the air breather bolt of F/R brake caliper to drain the brake oil.tighten
the bolt after finished
3. Open the cover of brake pump and fill new oil.
4. Ensure that the oil level is just above the filter screen
Attention:
Air discharging job should be done after filling the oil.

Oil Grade Oil Capacity Checking interval Change interval

Brake fluid / Dot3 1L daily(10 hours) 500h
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Mantenance
1000 Hours
Change Hydraulic System Pilot Filter

Note: Change the engine oil and filter after first 250 hours of operating a new machine and every 1000hours
thereafter.

1. Vent the hydraulic oil tank.

2. Screw out element cover (5). Dispose of the oil in the cover.
3. Remove O-ring (3) and filter (4).
4. Use a nonflammable, nontoxic solvent to clean out cover (5).
5. Insert a new filter (4) into cover (5). Install a new O-ring (3).
6. Screw cover (5) onto filter head (1).

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Mantenance
1000 Hours

Change Hydraulic Return Filter

Note: Replace hydraulic return filter after first 250 hours of operation or rebuild and every 1,000 hours thereafter.

1. Clean the filter cover and its surrounding area on the

tank.
2. Remove the bolts from the cover.
3. Lift the cover open and take the O-ring out of the tank.
Remove the control spring, which is seated beneath the
cover.
4. Remove the valve and filter from the tank.
5. Clean the underside of the cover.
6. Install a new element and valve into the tank. Press the
element down onto its base until the top of the element
is placed approximately 3 mm below the tank edge.
7. Install a new O-ring on the cover. Install the spring on
the element.
8. Mount the cover over the element. Tighten the bolts on
the cover.
9. Tighten the breather cap onto the tank.

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Mantenance
1000 Hours

Change Axle Differential and Planetary Oil

Note: Change the Axle oil at first 100 hours of operating a new machine and every 1000hours thereafter.

1. Position the machine on a firm, level ground.

2. Clean the areas around the drain plugs on both ends of
the axle. Remove the plugs and drain oil into a suitable
container.
3. Clean the area around level plug (1) and drain plug (2)
on the differential. Remove level plug (1) and drain plug
(2). Drain oil into a suitable container.
4. Install drain plug (1) on the differential and tighten it.
Install the drain plugs on both ends of the axle and
tighten them.
5. Fill oil through the level plug hole on the differential until
the oil level is even with the bottom of the plug hole.
Check the oil level in the differential once again. Add oil
if necessary. If the oil level is appropriate at the level
plug hole, install and tighten the level plug. 1
6. Fill oil through the level plug hole on the hub until the oil
level is even with the bottom of the plug hole.
7. Repeat the steps above with the other axle.
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Mantenance
2000 Hours
Change Radiator Coolant
1. Open the radiator cap slowly to allow any pressure to escape.
2. Place a container under the radiator and open the drain valve.
3. Fill the cooling system with a flushing solution.
4. Run the engine at low idle until the coolant temperature gauge indicator reaches “BLUE ZONE.” Run the
engine for another ten minutes.
5. Wait until the engine cools down.
6. Drain the flushing fluid and fill the system with water.
7. Run the engine again until the water completely circulates.
8. Once the engine has cooled down, drain the water and fill the system with a proper antifreeze mix for the
ambient temperature.
9. Run the engine without the radiator cap installed so that all air may be vent out of the system. Fill the
radiator until the water lever reaches the neck.
10. Drain and fill the radiator coolant recovery tank.

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Mantenance
2000 Hours
Change Hydraulic Oil

1. Raise the boom to the maximum height. Tilt the bucket back as far as possible and stop the engine.
2. Put an oil catch container under the hydraulic tank drain plug. Remove the hydraulic oil tank cover. Remove
the drain plug from the bottom of the tank. Drain all hydraulic oil.
3. Without starting the engine, operate the controls to dump the bucket. And then lower the boom. This will
drain oil out of the boom and bucket cylinders.
4. Replace the Hydraulic return Filter”
5. Install the tank drain plug. Refill the tank through the hydraulic oil cover opening. Install new return filter and
bolt down the cover.

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