Operating procedures for maintenance and

repair of mechanical equipment

第一章 safe operation

Article 1 Always park the machine on a hard, level

surface, shut off the engine, and remove the key before
performing maintenance work.
Article 2 If the maintenance process requires the
engine to run, at least two maintenance personnel are
required to follow the following rules: One of them must
stay in the cab at all times, keep in touch with the other
maintenance personnel, and be ready to turn off the engine
at any time when necessary.
Article 3 Carry out maintenance Be sure to wear work
clothes when doing nursing work. Avoid wearing rings,
watches, ties, silk scarves, open jackets, loose clothing,
etc. Failure to do so creates a risk of personal injury
from becoming entangled or pulled in.
Article 4 When carrying out maintenance work,
especially when working under the machine, the "DO NOT
START" warning sign should be hung on the control panel in
a conspicuous place.
The fifth It is strictly forbidden to start the
equipment with "do not start" or similar warning signs.
Article 6strictIt is forbidden to repair and maintain
the equipment when the equipment is not well supported.
Article 7Protective gloves should be worn when
searching for leaks.
eighth It is strictly forbidden to insert tools or
other objects into the running fan or drive belt, which
will cause damage to the components and objects to fly out.
Special care must be taken when disassembling grease
nipples or high pressure valve parts to prevent parts from
flying out during operation and causing injury.
Article 9Avoid maintenance work on ramps. If it is
necessary to work on a slope, in addition to using the
machine brake, the machine must be fixed with a skid or
wedge block, and the operation can only be started under
the premise of ensuring safety.
Article 10Smoking is strictly prohibited when
approaching or handling oil or other flammable and
explosive items.
Article 11When working at heights, safety belts or
lifelines must be fastened; when disassembling or
installing parts, first secure the parts and tools to
prevent falling.
Article 12Do not incinerate or puncture pressure
vessels.

Chapter 2 Preparations before Maintenance Operations

Article 13 Maintenance site preparation

 Before carrying out maintenance work, choose a flat,
spacious, sunny and well-ventilated site. Remove oil and
water stains in the working area, and cover the smooth
surface with a layer of coarse sand or other non-slip
substances. If you can't keep clean and tidy, it will
affect the maintenance effect.
Article 15Check the tools and equipment used for
maintenance to ensure that they are in safe and effective
use.
Article 16Carry out maintenance work on the machine as
required clean.
(1) General rules to be followed for cleaning the
machine:
Remove oil, fuel, dust and other dirt from the machine
before starting maintenance work.
Use a lint-free cloth when cleaning the machine. Do
not clean the machine with flammable liquids or aggressive
cleaning products.
Do not clean the machine with steam jets during the
first two months of machine initialization (or after
repainting).
(2)Preparation before cleaning the machine with a high-
pressure cleaner such as water or steam jet:
Lubricate all bearing points, bolted connections and
flanged bearings to prevent water or steam from entering
the bearing points.
Cover or glue closed all openings that cannot allow
water or steam to enter for safety or functional reasons,
such as electric motors, electrical components, control
boxes, plug connections, air filters, etc.
Ensure that the fire warning system of the engine
compartment temperature sensor and the fire extinguisher
are not exposed to hot cleaning products during cleaning
operations. Otherwise the fire extinguisher may activate.
(3)When cleaning the machine with a high-pressure
cleaner with steam or hot water, the following requirements
must be observed:
The nozzle must be no closer than 20 inches (50cm)
from the surface to be cleaned.
The water temperature should not exceed 60°c
(140°F).
Limit the maximum water pressure to 80 bar (80kg/cm2).
(4)Use only neutral detergents when using washer
fluids, such as common car wash diluted at 2% or 3%
maximum.
(5)All protective coverings should be completely
removed after washing the machine.
(6) Check all fuel, engine oil and hydraulic lines for
leaks, loose connections, abrasions and damage.
(7)Correct any defects found immediately.
(8)Lubricate all bearing points, bolted connections
and flanged bearings to exclude any water or cleaning
products that may have entered.

third chapter Maintenance work

Article 17All aspects of maintenance operations must

attach great importance to cleaning and pollution
prevention, especially to prevent dust and sand from
polluting the hydraulic system, lubrication system, fuel
system, and cooling system of the machine.
Article 18Before opening the pipeline interface of a
certain part of the machine for maintenance work, it should
be confirmed that the weather and environment will not
adversely affect the quality of maintenance work. When
maintenance operations must be carried out in harsh weather
environments, necessary enclosure measures should be taken
according to site conditions to ensure the quality of
maintenance operations.
Article 19After cleaning the pipeline interface of a
certain part of the machine, the closed port cannot be
installed immediately, and it should be quickly sealed and
protected with plastic wrap to avoid being polluted by dust
and sand.
Article 20Cleaning of parts
(1) Selection of cleaning fluid:
Gasoline is mainly used to clean grease, dirt and
generally adhered mechanical impurities, and is suitable
for cleaning more precise parts.
The use of kerosene and diesel oil is similar to that
of gasoline, but the cleaning ability is not as good as
that of gasoline, and it dries slowly after cleaning, but
it is safer than gasoline.
Chemical cleaning fluid, also known as emulsifier
cleaning fluid, has good cleaning ability for grease and
water-soluble dirt.
(2) Precautions when cleaning
 For rubber products, such as sealing rings and other
parts, it is strictly forbidden to wash with gasoline to
prevent swelling and deformation, but to use alcohol or
cleaning fluid for cleaning.
When cleaning the parts, you can use cotton yarn or a
lint-free cloth to wipe according to the parts with
different precision. Rolling bearings cannot be cleaned
with cotton yarn to prevent cotton yarn ends from entering
the bearing and affecting the assembly quality of the
bearing.
After cleaning, the parts should be assembled after
wiping off the oil to prevent the dirty oil from affecting
the assembly quality. At the same time, the cleaned parts
should not be placed for too long (the parts that are not
assembled should be kept in a safe place) to prevent dirt
and dust from contaminating the parts.
The cleaning of parts can be divided into one-time
cleaning and secondary cleaning. After the parts are
cleaned for the first time, check whether there are bumps
and scratches on the mating surface, whether there are
burrs on the teeth and corners of the gears, and whether
the threads are damaged. The burrs and slightly damaged
parts of the parts should be trimmed. When trimming, you
can use oil stone, scraper, gauze, and fine file to remove
thorns and trim, but care should be taken not to damage the
parts. The parts after inspection and repair should be
cleaned again.
Article 21 Operating specifications for high
temperature, high pressure, high altitude and hoisting
operations
(1)To prevent burns from splashing hot water or steam
when checking or draining coolant, wait for the water to
cool enough to touch the radiator cap with your hands
before starting work. Even if the coolant has cooled,
loosen the cap slowly before unscrewing it to release
pressure inside the radiator.
(2)To prevent burns from hot oil splashes or contact
with hot parts when checking or draining the oil, wait for
the oil to cool to a temperature where you can touch the
cap or plug with your hands before starting operations.
Even if the oil has cooled down, slowly loosen the cap or
plug before unscrewing it.
(3) When disassembling the high-pressure oil pipe of
the hydraulic system, the pressure in the hydraulic system
should be released first, and then the vent hole of the
hydraulic oil tank should be opened to release the internal
pressure of the hydraulic oil tank. Finally, slowly
disassemble the hydraulic oil pipe to release the residual
pressure in the oil pipe.
(4) Before working at heights, check whether the seat
belt has an annual inspection mark, and carefully check the
hidden dangers of the seat belt by the operator himself.
When working at heights, fasten the seat belt and ensure
safety before proceeding. The excavator should go up and
down in a "three-point" way, and jumping up and down is
strictly prohibited.
(5) Before hoisting, check whether there is an annual
inspection mark on the sling and wire rope, and carefully
check whether there are any hidden dangers. It is necessary
to wait for the hoisted object to be safely placed on the
ground before performing other operations. It is strictly
forbidden to work under and around the hoisted object.
Article 22 Battery electrolyte contains sulfuric acid,
and batteries produce flammable hydrogen gas that can
explode. Misuse can result in serious injury or fire. For
this, the following requirements must be observed:
(1)Always wear safety glasses and rubber gloves when
working on batteries.
(2)Do not smoke or use open flames around batteries.
(3)Before working on the battery, turn the starter
switch to the "OFF" position.
(4)Do not allow tools or other metal objects to come
into contact with the battery terminals. Do not leave tools
or other metal objects around the battery.
(5)When removing the battery, wait for about a minute
after turning off the engine start switch, always remove
the negative terminal (ground side) first, and always
connect the positive terminal first and ground last when
installing the battery. Verify that all battery terminals
are securely connected.
(6) FinishedThen tighten the battery cover.
(7)If acid is accidentally ingested, drink plenty of
water or milk, eggs or vegetable oil and seek medical
attention immediately.
(8) If sulfuric acid splashes into your eyes,
immediately rinse with plenty of water and seek medical
treatment immediately.
 Article 23 Starting the engine with the auxiliary
cable
When it is necessary to use the auxiliary cable to
start the machine, the operation should be carried out in
strict accordance with the following procedures. Wrong
operation may cause the battery to explode and cause
injury.
(1) Always wear safety goggles and rubber gloves when
starting the engine with the auxiliary cable.
(2) Before connecting the normal machine and the
faulty machine with auxiliary cables, check to ensure that
the normal machine and the faulty machine use the same
battery voltage.
(3) Before connecting the auxiliary cable, turn the
start switches of both the normal machine and the faulty
machine to the "OFF" position. Otherwise, the machine may
move when the power is turned on.
(4) When installing the auxiliary cable, be sure to
connect the positive cable first.
(5) Parallel connection of the auxiliary starting
battery and the machine battery: the positive pole is
connected to the positive pole, and the negative pole is
connected to the negative pole.
(6) When removing the auxiliary cable, remove the
negative cable (ground side) first. When removing the
auxiliary cable, be careful not to allow the auxiliary
cable clips to touch each other or the machine.
NOTE: When starting with the auxiliary cable, it must
be operated by two workers at the same time (one sitting on
the driver's seat and the other next to the battery). When
starting another machine, the two machines are not allowed
to touch.
Article 24 Welding work
(1) When the paint is heated by welding, soldering or
using a gas torch, it will produce harmful gas, so the
paint must be removed before welding or heating.
(2) Choose to carry out the paint removal operation
outdoors or in a well-ventilated place.
(3) If sandpaper and grinding wheels are used to
remove the paint, please wear a qualified respirator to
prevent inhalation of dust.
(4) If a solvent or paint remover is used to remove
the paint, wash the paint remover with soap and water after
removing the paint. Wait at least 15 minutes for solvents
to evaporate before soldering or heating, and remove
solvent or paint remover containers and other flammable
items from work area.
(5) Electric welders are required to work with a
certificate, and operation without a certificate is
strictly prohibited.
(6) Protective equipment must be worn before work.
(7) Electric welding equipment must ensure good
insulation and safe grounding.
(8) When oxygen welding equipment is used, the oxygen
and acetylene cylinders should be more than 10 meters away
from the cutting and welding operation point or the open
flame point.
(9) It is forbidden to store flammable and explosive
materials in the welding site.
(10) The electric welding operation must be stopped
immediately when it is raining in the open-air operation.
If the indoor operation is found to be leaking and wet, the
electric welding operation is also strictly prohibited.
When working in a container or a small place, someone
should supervise to prevent accidents.
(11) When welding the machine, in order to prevent
damage to electronic devices and bearings, while strictly
implementing the relevant welding process requirements,
please follow the steps below for welding:
Shut off the engine and remove the key.
Remove the negative cable from the battery. Never use
the grounding point of electrical parts (ECM or ECM sensor)
or electronic parts as the grounding point of the welding
machine.
Use the ground wire clamp of the electric welding
machine to clamp the components to be welded, and the clamp
point should be as close to the welding position as
possible to ensure that the welding current is far away
from critical components, such as drive train bearings,
hydraulic components, electrical components, etc.
Prevent the debris generated during the welding
process from splashing into the electrical cabinet and
causing short-circuit faults.
Weld the materials together using standard welding
procedures.
When welding near the oil tank, the oil in the oil
tank must be drained and dried, otherwise it may catch fire
during welding and cause an explosion accident.
Never weld near plastic, rubber materials, or the
poisonous fumes generated when heating these materials will
be a hazard to personnel.
After the operation is over, check the welding work
site for any abnormal conditions, then cut off the power
supply and extinguish the fire. Check the tool materials
and store them properly.
Chapter 4 Acceptance of Maintenance Operations
Article 25 After the maintenance operation is
completed, the person in charge of the maintenance
operation shall notify the equipment operator to prepare
for the test run and acceptance.
Article 26 Before the test run, the person in charge
of the maintenance operation and the equipment operator
should jointly conduct a comprehensive inspection of the
equipment according to the "Operation and Maintenance
Manual" of the equipment, and confirm that the oil level of
each part of the machine and the firmness of the connecting
parts meet the requirements before the test run .
Article 27 The designated equipment operator shall
make preparations before starting the machine.
Article 28 The person in charge of maintenance
operations shall warn all maintenance personnel and notify
the equipment operator to start the engine after confirming
safety.
Article 29 Operate the machine according to the
"Operation and Maintenance Manual" of the equipment, and
carefully check whether the operation status of each part
of the machine is normal. If abnormal noise, leakage or
other abnormal phenomena are found during the operation of
the machine, it should be stopped immediately for
inspection, and the test run will be carried out after the
inspection and repair are completed.
Article 30 After the test run, sort out the records of
the maintenance operation: the list of personnel involved
in this maintenance operation, the time when the
maintenance operation started, the job content, the test
run record of the machine after the operation is completed,
and the completion time of the maintenance operation and so
on. The person in charge of maintenance operations and the
person in charge of cooperating operations should jointly
sign and confirm the filing.
Chapter 5 Maintenance Operation Site Cleanup
Article 32 The maintenance personnel should carefully
count the tools and parts after the operation, and store
them properly in order to avoid forgetting them at the
operation site.
Article 33 Clean up the garbage and sundries on the
site, and take back the operation warning signs.
Article 35 Take the waste oil of the machine back to
the maintenance center for unified storage and disposal in
the container. Dumping on the spot is strictly prohibited
to cause environmental pollution.