The usage and maintenance techniques of loading machinery during the running-in period

After leaving the factory, a loader is generally required to have a running-in period of about 60 hours (some call it the running-in period), which is stipulated based on the technical characteristics of the loader in its initial use.

The running-in period is an important link to ensure the normal operation of the loader, reduce the failure rate and extend its service life. However, at present, some users ignore the special technical requirements during the running-in period of new machines due to a lack of common sense in using loaders, tight schedules, or the desire to gain profits as soon as possible. Some users even think that since the manufacturer has a warranty period, if the machine breaks down, the manufacturer will be responsible for the repair. As a result, during the running-in period, the machine is used beyond its capacity for a long time, leading to frequent early failures of the machine. This not only affects the normal use of the machine and shortens its service life, but also hinders the progress of the project due to the damage of the machine. Therefore, the application and maintenance of the running-in period of loaders should be given full attention.

I. Characteristics of the Break-in Period

1. Fast wear rate

Due to the influence of factors such as the processing, assembly and adjustment of new machine parts, the friction surfaces are rough, the contact area of the mating surfaces is small, and the pressure-bearing conditions on the surfaces are uneven. During the operation of the machine, the protruding and recessed parts on the surface of the components interlock and rub against each other. The metal debris worn off then acts as an abrasive and continues to participate in the friction, further accelerating the wear of the mating surfaces of the components. Therefore, during the running-in period, it is easy to cause wear of components (especially the mating surfaces), and the wear rate is fast. At this point, if the operation is overloaded, it may lead to damage of components and cause early failure.

2. Poor lubrication

Due to the small fit clearance of the newly assembled components and the difficulty in ensuring the uniformity of the fit clearance due to assembly and other reasons, the lubricating oil (grease) is not easy to form a uniform oil film on the friction surface to prevent wear. This reduces the lubrication efficiency and causes premature abnormal wear of the machine parts. In severe cases, it may cause scratches or seizing on the precisely fitted friction surfaces, leading to malfunctions.

3. Loosening occurs

Newly processed and assembled components have deviations in geometric shape and mating dimensions. During the initial stage of use, due to the influence of alternating loads such as impact and vibration, as well as factors like heat and deformation, along with rapid wear and other reasons, the originally tight components are prone to loosening.

4. Leakage occurs

Due to the loosening of machine parts, vibration and the influence of machine heating, leakage may occur at the sealing surfaces and pipe joints of the machine. Some casting and processing defects are difficult to detect during assembly and debugging, but they are exposed due to the vibration and shock during operation, manifesting as oil (water) leakage. Therefore, leakage is prone to occur during the running-in period.

5. There are many operational errors

Due to insufficient understanding of the structure and performance of the machine (especially for new operators), it is easy to cause malfunctions or even mechanical accidents due to operational errors.

Ii. Application and Maintenance during the Running-in Period

1. As construction machinery is a special type of vehicle, operators should receive training and guidance from the manufacturer, have a thorough understanding of the machine's structure and performance, and acquire certain operation and maintenance experience before operating the machine. The "Product Operation and Maintenance Manual" provided by the manufacturer is an essential document for operators to operate the equipment. Before operating the machine, it is necessary to read the "Operation and Maintenance Manual" first and operate and maintain it as required.

2. Pay attention to the working load during the running-in period. The working load during the running-in period should not exceed 60% of the rated working load, and an appropriate workload should be arranged to prevent overheating caused by continuous operation of the machine for a long time.

3. Pay close attention to frequently observing the indications of all instruments. If any abnormality occurs, stop the machine immediately to eliminate it. Cease operation until the cause is identified and the fault is eliminated.

4. Pay attention to frequently checking the levels and qualities of lubricating oil, hydraulic oil, coolant, brake fluid and fuel (water), and also pay attention to checking the sealing performance of the entire machine. If excessive oil and water shortage is found during the inspection, the cause should be analyzed. At the same time, the lubrication of each lubrication point should be strengthened. It is recommended that during the running-in period, grease be added to the lubrication points every shift (except for special requirements).

5. Keep the machine clean and adjust and tighten loose parts in time to prevent accelerated wear of parts or loss of parts due to looseness.

After the running-in period is over, mandatory maintenance should be carried out on the machine, including thorough inspection and adjustment. At the same time, attention should be paid to the replacement of the oil.

In conclusion, the requirements for the use and maintenance of loaders during the running-in period can be summarized as: strengthening training, reducing load, paying attention to inspection, and enhancing lubrication. As long as you attach importance to and carry out maintenance and upkeep of the loader during the running-in period as required, the occurrence of early faults can be reduced, the service life can be prolonged, the operation efficiency can be improved, and the machine can bring you more benefits.