RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD. 1 Test Tools and Application...

RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD. 1

Test Tools and Application

Shandong Lingong

Import and Export Corp.: Training Room

2011


Abstract

1. Safety Instructions

2. Test Tools and Application Notes

3. Application of Test Tools on Loaders

4. Test Tools Manual


Abstract






1.1 Operators shall understand and abide by the existing national and local

safety regulations.

1.2 Most accidents are due to the failure to abide by the operation or

maintenance instructions. To avoid accidents, please read, understand and

stick to all the warnings and notes in the maintenance manual and on the

machines.

Main Contents of Safety Instructions:

1.Safety Instructions

When debugging and maintaining the hydraulic system of the loader, please note the followings:


1.3 Take care during the test so as to avoid hurting yourself or others.

1.4 Flame out the engine first and put down the movable arm through the

control of a handler. Do not adjust the pressure of the hydraulic system

until it is unloaded.

Note: Do not adjust pressure directly when finding the pressure is lower

than the normal one during the process of pressure measurement,

because it is extremely possible to result in the over-pressure of the

system which may cause the danger.





1.5 During the test, a notice board of “No Operation” must be hung on the

operation handler or a special caretaker must be assigned for tendering

the machine so as to avoid a danger incurred from an improper operation

by non-test persons.

1.6 Since it is impossible to foresee all the potential dangers, the instructions

in the Manual and on the machine could not include all the safety

precautions. If adopting un-recommended steps or operations, please

keep yourself and others safe as well as prevent the machine from

damaging. When not sure about the safety of some steps, please contact

with our company. Our company is not liable for those incidents caused

by improper handling, which indeed should be responsible by the users

and operators.



Abstract






2.1 Test Tool Kit

2.Test Tools and Application Notes

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No. Code NameSpecification

and ModelApplication

1 6900000436Disposable Packing

BoxPacking Box

2 4030000369Manometer

213.53.063/60G1/40—6MPa

Measure pilot pressure and transmission pressure

3 4030000370Manometer

213.53.063/400G1/40—40MPa

Measure system pressure (working / steering)

4 4030000368Test Hose

SMS20/M1/4-3000ACompatible with a manometer

5 6430000379 Manometer 213.53.063/600G1/4Measure the vibration pressure of a roller

2.2.1 Test Tools and Application



No. Code NameSpecification


6 6430000205Tyre Pressure

Gauge0—0.6MPa Measure the pressure of a tyre

7 6430000423Joint of Tyre

Pressure Gauge　 Compatible with a tyre

pressure gauge

8 6430000204Infrared Radiation

Thermometer Infrared Radiation

Thermometer Noncontact –type infrared radiation thermometer

9 6430000206 Multimeter 　 Measure various electronic components and circuits

10 6430000203 Battery Tester HBV200Measure the voltage and discharge of a battery




No.

Code NameSpecification


11 6410004204 Test Joint smk20-m14*1.5-PE smk20-m14*1.5-PECompatible with the manometer

12 6410003035 Test Joint smk20-m14*1.5-pc smk20-m14*1.5-pcCompatible with the manometer

13 4120002381 Test Joint smk20-G1/4-pc smk20-G1/4-pcCompatible with the manometer

14 6430000556 Tachometer DT-207LMeasure the rotational speed of the engine or related components

Note:The actual location of test joints and manometers in the kits might be different from that in

the picture. Please select carefully so as to avoid mistakes.




Abstract






3. Application of Test Tools on Loader

3.1 Manometer

3.2 Battery Tester

3.3 Multimeter

3.4 Infrared Radiation Thermometer

3.5 Tachometer

3.5 Barometer


3.1 Application of Manometer

Test Specification for Manometer:

3.1.1 Keep clean during the test and prevent dirt into the hydraulic system.

3.1.2 Clean the test hose coupling when switching one test medium to

another so as to prevent the oil from contamination.

3.1.3 Use the suitable manometer strictly in accordance with requirements.

3.1.4 Ensure the safety during the test.



3.2 Pressure Test of Working Hydraulic System (using the manometer with range of 0—40 MPa)

Pressure Type

Model Rated Pressure

Pressure of Working Hydraulic System

LG918 、 LG956L 、 LG958L 17.5MPa

LG933L 、 LG936L 、 LG938L 、 LG952L 、 LG946L 16.0MPa

40F 12.5MPa

LG953 、 LG968 18.0MPa



3.3 Working Hydraulic System Test

1. Use the manometer with the range of 0—40 MPa to test the pressure of the working hydraulic

system on the loader. The engine is running at the rated rotational speed with the hydraulic oil

temperature of between 60 ℃--90 ℃. When connected with the manometer, the engine must

be off and the hydraulic system might contain some pressure.

2. When large chamber and small chambers of boom cylinder, large and small chambers of dump

cylinder or other working units are applied with load, the pressure measured could be thought

as the pressure of the working hydraulic system. The pressure of these ports could also be

thought as similar to the pressure of the working hydraulic system (except the small chamber

of the dump cylinder).

3. Samples for pressure test of the below models will be made below. Test pressure ports have

been respectively marked:

（ 1 ） LG918 (2) LG933L (3) LG936L （ 4 ） LG946 （ 5 ） LG952H （ 6 ） LG952

（ 7 ） LG953 （ 8 ） LG953L （ 9 ） LG956L （ 10 ） LG958L （ 11 ） LG968



3.4.1 Pressure Test Port of LG918(with pilot passages) Working Hydraulic System

Pressure Test Port

Multiple unit Valve



3.4.2 Pressure Test Port of LG918 Working Hydraulic System (Pressure Test Sample)

LG918 Test Result

Test Jointsmk20-m14*1.5-PE



3.4.3 Pressure Test Port of LG933L Working Hydraulic System

Inlet Pipe of Multiple unit Valve

Pressure Test Port




Pressure Test Port

Multiple unit Valve




Pressure Test Port

Multiple unit Valve



Pressure Test Port

3.4.6 Pressure Test Port of LG952H/LG952 Working Hydraulic System

Inlet Block of Multiple unit Valve

Multiple unit Valve



3.4.7 Pressure Test Port of LG953L/LG953 Working Hydraulic System

Pressure Test Port

Multiple unit Valve



3.4.7 Pressure Test Port of LG956L/LG958 Working Hydraulic System

Pressure Test Port

Multiple unit Valve



3.4.8 Pressure Test Port of LG968 Working Hydraulic System

Pressure Test Port

Inlet Block of Multiple unit Valve



3.5.1 Pressure Test of Steering System (Using the manometer with range of 0—40 MPa)

Pressure Type

ModelPressure Value

MPa

Pressure of Steering System

LG953 、 LG918 、 LG933L 、 LG938L 、 LG952L 、 LG968

14.0

LG936L 12

LG956L 、 LG979L 、 LG958L 16



Test Methods:

1. Use the manometer with the range of 0--40 MPa to test the pressure of the working

hydraulic system on the loader. The engine is running at the rated rotational speed with

the hydraulic oil temperature of 60 ℃--90 ℃. When connected with manometer, the

engine must be off and the hydraulic system might contain some pressure; after stating

the loader, turn the steering to a limit location of one side, the value shown on the

manometer is the pressure of the steering system.

2. Samples for pressure test of the below models will be made below. Test pressure ports

have been respectively marked:

(1)LG956L(2)LG936L(3)LG933L4)LG918(5)LG936L(6)LG946(7)LG968

(8)LG9952(9)LG952L(10)LG953(11)LG953L Pressure Test Port of Steering System

Note: During the test, the tester shall keep away from coupling part of the loader to ensure the personal safety!



3.5.2 Pressure Test Port of LG933L/LG918 (Mechanically Operated Hydraulic System) Steering System

Pressure Test Port

Steering valve



3.5.3 Pressure Test of LG936L Steering System (sample)

Pressure Test Port

Priority Valve

Test Joints smk20-m14*1.5-PE



3.5.4 Pressure Test Port of LG946L Steering System

Pressure Test Port

Priority Valve



3.5.5 Pressure Test Port of LG952H /LG952/LG953L/LG953 Steering System

Steering Cylinder

Pressure Test Port



3.5.6 Pressure Test of LG956L/LG958L Steering System

Inlet Pipe B of Steering

Cylinder

Inlet Pipe A of Steering

Cylinder

Test Jointsmk20-m14*1.5-PE

Pressure Test Port

Test Result



3.5.7 Pressure Test Port of LG968/LG946L Steering System

Pressure Test Port

Flow Amplifier Valve




4.1 Battery Tester

4.2 Multimeter


4.4 Tachometer

4.5 Manometer


4.1 Battery Tester

For testing capacity and effective discharging of various batteries so as

to judge whether the batteries are good or bad.

4.1.1 Structural Features ：The product consists of a DC voltmeter, a load resistance, circuits, a switch, a

shell of imported steel, copper plated clamps and so forth. The panel can show

the capacity status of the battery.

4.1.2 Technical Parameter:

Test Range: The rated voltage is 6 V and 12 V, and when the rated capacity is

32—500 A, the discharging current is 100—120.

HBV200 Battery Tester Manual：


• Indication Forms ： indicating by colors and words.

• Measuring Methods ： manual instantaneous contact type, no more than 5

seconds in respect of the time of each test.

• Meter Accuracy: Class 2.0 Meter, with the capacity range of 0—16 V, the

outgoing products are all meeting the standards of the enterprise. (Q/ILPW-02-98).

The off-load voltage shall be tested before the test of the battery. When the off-load

voltage ≥12.4 V, the battery test could be done; otherwise, the battery shall be

charged first before the test. The time of charging shall not be over 10 seconds.

HBV200 Battery Tester Manual:

4.1 Battery Tester


4.1.3 Test Preparation:

The test shall be conducted in an airy place. The operator must not smoke

and no naked light is allowed around. Clean the test end of the battery and

check whether the shell of the battery is cracked or broken.

4.1.4 Methods of Battery Test:

Firstly, make sure the pointer is at the zero position of the dial scale, and if

not, operate the zero rotation device in the cover hole to adjust the

position.

Then put the test clamp on the terminal of the battery. The indicator lamp is

on when it is the positive pole. The test can be conducted no matter it is

positive or negative. But when the lamp is off, you should check whether

the clamp position is correct.

Press the load switch until the pointer goes steady. The time should not be

over 10 seconds.

4.1 Battery Tester


4.1.5 Battery Analysis:

See the pointer. When it is in the green zone, the battery is good; while in

red zone, low; and in yellow zone, weak.

please see the back side details for the time of discharging test and

voltage.

4.1.6 Charging System Test:

Connect with the tester with the same methods of battery test

• Start the engine to put it at the working temperature

• The rotational speed will reach 1200—1500 revolutions/min. Keep the

engine clean and the load switch off.

4.1 Battery Tester


• Readings: the readings in the red zone shows there is a problem in the charging

system and the battery would be lack of charging. If the pointer is in OK zone

(green zone), it means the charging system is fine and the charging works.

4.1.7 Test the insulation of battery:

• Put the red rubber clamp with wires of the battery tester on the positive end of

the battery. Note: the black rubber clamp with wires must not be used so as to

prevent a danger.

• Insert the test bar with wires into the jack at the lower part of the tester so as to

test the insulation of the battery grid by grid. If any grid shows no signal (keep

contacted when testing), it means the battery is insulated.

• Normally, the voltage of one grid is 2 V, which means the battery is in a good

status.

4.1 Battery Tester


4.1.8 Notices:

The battery tester must not be exposed in rain or snow.

• No fire is allowed around the battery. Do not drop any mental tools on the

battery to prevent any potential sparks, short circuit or other faults and even

explosions incurred from hereunder. When testing a single grid, the red

clamp should be clipped on the positive pole and the test bar into the jack.

• Do not use the tester which is damaged.

4.1 Battery Tester


Battery Test Analysis

4.1.9 Battery Analysis----read ten seconds after discharging

Load Test Battery Status

OK (Green Zone)The battery status is good. Check the status of the charging system on the vehicle (see the instructions)

NO ( Yellow Zone)

but the pointer is steady

Off-capacity, might be caused by:

1.Battery Defect

2.Part is short of electricity, need of charging

NO ( Red Zone)

But the pointer keeps down

Battery might has defects (if the single grid fails). Under this condition, a simple test can be made. Loosen the load switch to observe the pointer. If the voltage restores to 12 V quickly, there is probably defect in the battery; if the voltage restore slowly, it might be over-discharged.

4.1 Battery Tester


Battery Test Analysis

4.1.10 Influence of Temperature

Temperature of Battery 20 0 -15 -25 ℃ ℃ ℃ ℃

Judging Voltage V0 V0~0.2V V0~0.5V V0~0.9V

4.1 Battery Tester


4.1.11 Battery Tester （ Sample）

Load Switch

4.1 Battery Tester


4.2.1 Overview

MY-65 is a handheld 4 ½ digital multimeter with high accuracy and stable

performance. The circuit design of the entire device is characterized in the

integrated circuit and dual integral A / D converter as well as full-

functional overload protections. It could be used to test DC and AC

voltage, DC and AC current, resistance, capacitance, diode, frequency,

intact or break of circuit and so forth.

4.2.2 Features

• 10 functions with 32 measuring ranges

• LCD display, word height of 22mm

• Out of range shows “1”

• Full range overload protections

• Automatic cut-off of power supply

• Working temperature: 0℃ ～ 40℃

Measuring Methods:

4.2 Multimeter


• Range of storing temperature ： -10℃～ 50℃

• Low battery display: Battery symbol on the top-left of LCD

• Dimensions: 189*91*31.5mm

Technical Parameters:

Accuracy: ± (% readings + number of words)

Ambient Temperature: 23 ±5℃ ℃

Relative Humidity: no higher than 75%

Measuring Methods:

4.2 Multimeter


Range Resolution Accuracy

200mV 0.01mV ±(0.05%+5)

2V 0.1mV ±(0.1%+5)

20V 1mV ±(0.1%+5)

200V 10mV ±(0.1%+5)

1000V 0.1V ±(0.15%+5)

4.2.3 DC Voltage

Input Resistance: 10 MΩof various ranges

Overload Protection: 200 mV range is effective value for DC 250 V or AC 250 V.

The others are for 700 V or peak value for 1000 V.

Measuring Methods:

4.2 Multimeter


Range Resolution Accuracy （ 50~60Hz） Accuracy （ 40~400Hz）

2V 0.1mV ±(0.5%+15) ±(1.0%+15)

20V 1mV ±(0.8%+15) ±(1%+50)

200V 10mV ±(0.8%+15) ±(1%+50)

700V 0.1V ±(1.0%+15) ±(1.2%+50)

4.2.4 AC Voltage:

Input Resistance ： 2MΩ of various ranges.

Overload Protections ： All ranges are effective values for 700 V or peak Value

for 1000 V.

Display: Average ( transformed to sine waves)

Measuring Methods:

4.2 Multimeter



2mA 0.1μA ±(0.5%+10)

20mA 1μA ±(0.5%+10)

200mA 10μA ±(0.8%+10)

20A 1mA ±(2.0%+20)

4.2.5 DC Current:

Overload Protection: 200mA/250V fuse （ 20A range is out of protection of fuse ）Maximum Input Current: 10 A continuous, 20 A should not keep longer than 15

Seconds.

Measuring Methods:

4.2 Multimeter



2mA 0.1μA ±(0.8%+20)

20mA 1μA ±(0.8%+20)

200mA 10μA ±(1.2%+20)

20A 1mA ±(2.5%+50)

4.2.6 AC Current:

Overload Protection: 200mA/250V fuse （ 20A range is out of protection of fuse ）Maximum Input Current: 10 A continuous, 20 A should not keep longer than 15

Seconds.

Range of Frequency: 40 Hz—400 Hz

Display: Average ( transformed to sine wave)

Measuring Methods:

4.2 Multimeter



200Ω 0.01Ω ±(0.5%+10)

2kΩ 0.1Ω ±(0.5%+5)

20kΩ 1Ω ±(0.5%+5)

200kΩ 10Ω ±(0.5%+5)

2MΩ 100Ω ±(0.5%+5)

20MΩ 1kΩ ±(0.5%+5)

200MΩ 10kΩ ± 【 5.0% （ reading-1000 ） +20 】

4.2.7 Resistance:

Overload Protection: Effective value of 250 AC current

Note: In Level 200 MΩ, the meter probe is short. The display of 1000 words is normal and it

should be deducted from the reading.

Measuring Methods:

4.2 Multimeter



2000pF 0.1pF ±(4.0%+20)

20nF 1pF ±(4.0%+20)

200nF 10pF ±(4.0%+20)

2μF 100pF ±(4.0%+20)

20μF 1nF ±(4.0%+20)

4.2.8 Capacitance:

Measuring Methods:

4.2 Multimeter


Range Instructions

♬ When the tested resistance is below 70 Ω, the inside beeper would start beeping.

4.2.9 Frequency:

Input Voltage Range: 200 mV—10V effective value

Overload Protection: 250 V AC effective value


20kHz 1Hz ±(1.5%+15)

4.2.10 Audio On-off

Measuring Methods:

4.2 Multimeter


Voltage Measuring:

(A) Insert black meter probe into COM jack and red one into VO or VOHz jack.

(B) Put rotational function switch in DCV range to test DCV (Put rotational

function switch in ACV range to test ACV). Estimate the maximum range of

tested voltage and select a proper range. And then put an electro probe

parallel connected with the two ends of the targeted circuit. The multimeter

would then show the voltage value and the polarity of the end connected

with the red probe.

Measuring Methods:

4.2 Multimeter


Measuring Current:

(A) Insert the black probe into COM jack. When the targeted current is under 200

MA, insert the red probe into MA jack. When the targeted current is between

200 MA—20 A, insert the red one into 20 A jack.

(B) Put the rotational function switch at the current file of DCV. Estimate the

maximum of the tested current and select a proper range. And then put the

electro probe serially connected with the two ends of targeted circuit.

4.2 Multimeter


Measuring Resistance:

(A) Insert the black probe into COM jack while the red one into VO or VOHz

jack.

(B) Turn the rotational function switch to 0 position, select a proper range,

and then connects the probes with a lead foot of the resistance in

parallel. Read the readings from the display screen.

(C) If the display screen still shows I during the measurement, it means

higher range should be adopted.

4.2 Multimeter


4.2.11 Sample of Multimeter Usage

Testing the rated voltage of a power generator

4.2 Multimeter


4.3.1 Main Technical Parameters4.3.2 Operating Instructions4.3.3 Cautions4.3.4 Maintenance4.3.5 Usage of Infrared Radiation Thermometer (sample)

Infrared Radiation Thermometer Manual



(1) Laser Aiming Guide

(2) ℃ / Convertor℉

(3) Resolution: 0.1℃

(4) Storage Temperature-21℃～50℃

(5) Time of Measurement0.8S

(6) Distance Coefficient Ratio 12:1

4.3.1 Main Technical Parameters:

Warning:Do not point laser at eyes directly or to any reflective surface!

(7) Preset Emissivity: 0.95

(8) Power Supply: 9 V

(9) Battery Life: About 12 hours

(10) Accuracy: ±2% or ±2℃

(11) Working Temperature: 0 --50℃ ℃



(1) Start-up— Press the “ Measurement” key and the device will start up to self-check, self-

measure and display the temperature.

(2) Measurement — Point the probe at a target and press “ Measurement” key to conduct

single test, or press it to conduct successive tests (Note: the time of pressing the

“Measurement” key should not be less than 0.8 seconds)

(3) Shut-down—The device will shut down automatically after 15 seconds of no operation

conducted at the start-up status

(4) Auxiliary function—Press the “ C” key to make temperature displayed in form of “ ”. ℃

Press the “ F” key to make temperature displayed in form of “℉”. Pressing the

“Backlight” key can turn on / off the backlight. And the “ Laser” key can open / close the

laser aiming.

The infrared radiation thermometer is small and easy to use. It can read the surface

temperature of a object in one second after the aiming to the targeted and pressing of “

Measurement”. It could measure the temperatures of hot, dangerous, accessible objects

without contact.

4.3.2 Follow the below instructions when using the thermometer:



(1) It might take 30 minutes to adjust when the ambient temperature changes a lot.

When the ambient temperature changes a lot, it will influence the accuracy of the

thermometer. When the thermometer is moved from one place to another which

has a quite different temperature, the accuracy will be lowered temporarily. And

thus, in order to get better and more accurate results, it should wait for some time

before measuring when the temperature changes a lot.

(2) Most organic materials and surfaces that are painted or oxidized may have a

emissivity of 0.95, and thus the preset emissivity in the thermometer is 0.95. A

metal surfaces that is bright or polished would lead to the inaccuracy of the

reading during the measurement. The solution is to use black tapes or paint to

cover the metal surface and measure the temperature of the tapes when it is equal

to that of the metal surface.

4.3.3 Cautions:



4.3.4 Maintenance:

Lens Cleaning Method:

Rinse out granules with clean compressed air and use a soft brush to brush

the dirt. And then use wet cotton balls to scrub ( cotton balls can be wetted by

water).

Notice: Do not use detergent to clean lens!

(3) The infrared radiation thermometer is small and easy to use. It can read the

surface temperature of a object in one second after the aiming to the

targeted and pressing of “ Measurement”. It could measure the

temperatures of hot, dangerous, accessible objects without contact.

Special Cautions: Do not point laser at eyes directly or to any

reflective surface so as to avoid harming to human body!



4.3.5 Usage of Infrared Radiation Thermometer (sample)

Laser illuminating Point

Temperature Display

Keys on the thermometer



4.4.1 Non-contacting Measurement：

Method of Use:

(1) Paste a reflective tape on the test axis or movable components like a disk and a pulley.

If the targeted device is too reflective, apply some dark paint to ensure the reliability of

results.

(2) Press the power switch for some seconds and observe the display of the screen to

check whether the rotational component shows changes in accordance with rotational

speed. If the light beam hits the target, the top part of screen will flash the speed. If no

speed flashes, it means the light beam misses the target (readjust the light beam).

(3) After observation, loosen the switch before the tachometer gets off from the testing

place so as to keep readings.

(4) The display of the last reading could last 5 minutes. Pressing the storage key once can

extend 5 minutes and it is allowed to be pressed many times.

4.4 Tachometer


4.4.2 Tachometer

Reflective TapesTesting the rotational speed of engine

4.4 Tachometer


(1) Test Methods: Test when the vehicle should be off and the temperature

of the tyres should be down to the normal values.

(2) Application in Fault Judging: Abnormal wears of the treads on the middle

part of the tyres might be caused by over-pressure; High-temperature,

tyre-shoulder separation or burst of the tyres might be caused by low-

pressure or over-load.

(3) Standard Pressure:

Front Tyre: 0.333—0.353 MPa

Back Tyre: 0.275—0.294 Mpa

Remarks: for the tyres of eighteen layers, the pressures should be

respectively added 0.05 MPa based on the above values.

4.5.1 Tyre Pressure Gauge：

4.5 Tyre Pressure Gauge


4.5.2 Pressure Guage

Tyre Pressure Gauge—Test front tyre pressure of LG956L

4.5 Tyre Pressure Gauge


THE ENDTHE ENDTHE ENDTHE ENDCorporate vision

To be a most satisfied and most recommendable brand in China’s construction machinery industry

Corporate missionTo provide reliable product and service making customers get

persistent return with maximum value through consistent innovation

Date post:	17-Jan-2016
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