LGMG H1840 User manual

Maintenance Manual
H1840
Telescopic handler
LINGONG HEAVY MACHINERY CO., LTD.
△
! WARNING
Before operation and maintenance, the
drivers and maintenance personnel are
required to read this manual thoroughly.
Otherwise, fatal accident may occur.
This manual shall be kept properly for
future reference by the personnel
concerned.

Telescopic handler
Maintenance Manual
880*1230 mm Sextodecimo 8 sheets
Second edition, September 2022 First print, September 2022
Lingong Heavy Machinery Co., Ltd.
Add.: 12F, Building 3, Lushang Olympic City, No. 9777, Jingshi Road, Lixia District, Jinan
City, Shandong Province, China
Tel.: [phone] Technical service hotline: [phone]
Fax: [phone] Parts sales hotline: [phone]
Website: www.lgmg.com.cn

Maintenance Manual of Telescopic Handler
I
Foreword
Thanks for purchasing the telescopic handler produced by Lingong Heavy Machinery Co., Ltd. This
machine is designed according to EN 1459-1:2017+A1:2020. This manual introduces the maintenance
of the telescopic handler for safety guidelines and correct operation and maintenance of the machine.
How to get the best out of your machine is a goal we pursue together with you, and it depends to a large
extent on how familiar you are with the machine and how carefully and thoroughly it is maintained. We
sincerely hope that you will read through this manual before starting and operating the machine for the
first time and before repairing and maintaining the machine, and that you will master the operation and
maintenance described therein.
The illustrations and descriptions in this manual are correct at the time of publication, but due to the
continuous improvement of the structure and performance of our products, the design as well as
operation and maintenance instructions of the product may be subject to change without notice. For the
latest information of the machine or any question about this manual, please consult us.
This manual applies to telescopic handlers. Users should strictly follow the maintenance interval in the
maintenance schedule to maintain the machine.
This manual should always be kept at the specified location so that it can be read at any time. This
manual is an integral part of the machine and should be handed over when ownership or use of the
machine is transferred. If the manual is lost, damaged or illegible, please replace it promptly!
This manual is the property of Lingong Heavy Machinery Co., Ltd., and may not be duplicated or
reprinted without our written permission.
△
! WARNING
Only the personnel who have been professionally trained and qualified are
allowed to operate and maintain the machine.
Incorrect operation, maintenance and repair are dangerous and may lead to
personal injury or death.
Before operation or maintenance, please read this manual thoroughly.
Otherwise, do not operate, maintain or repair this machine.

Maintenance Manual of Telescopic Handler
II
Please load the machine in strict accordance with the rating; otherwise all
the consequences arising from overloading or unauthorized modification
will be borne by the user.
The operation instructions and precautions in this manual apply only to the
intended use of the machine. If the machine is used for an operation that is
out of the specification herein but not prohibited, always make sure that this
operation will not cause personal injury to yourself or others.
Please operate the machine in strict accordance with the safety
requirements in the manual. The user is responsible for all consequences
caused by non-compliance with the safety requirements of the machine.

Maintenance Manual of Telescopic Handler
III
Safety Notices
The operator shall understand and abide by the current national and local safety regulations. If such
regulations are not available, the safety instructions in this manual shall prevail.
Most accidents are caused by failure to obey operation and maintenance specifications of the machine.
To avoid unnecessary accident, please read and follow all warnings and precautions in this manual and
on the machine before operation or maintenance.
Considering the fact that not all possible hazards are foreseeable, it is impossible for safety notices in
this manual and on the machine to cover all safety precautions. If it is necessary to take steps and
operations not recommended herein, always protect the safety of yourself and others, and keep the
machine from any damage. If the safety of some operations remains uncertain, please consult us or
dealers.
The operation and maintenance precautions referred to herein apply only to the intended use of this
machine. If the machine is to be used for other purposes than those listed herein, it is the user or
operator instead of us that shall take the safety liabilities therefrom.
In no case shall any operations expressively prohibited herein be performed.
For the purpose of this manual, the following signal words are applied to identify safety instructions:
△
!DANGER - Indicating any existing dangers that, if not avoided, will cause
serious injury or even death, and also serious machine damage.
△
!WARNING - Indicating any potential dangers that, if not avoided, may cause
death or serious injury, and also serious machine damage.
△
!CAUTION - Indicating situations that, if not avoided, may cause minor or
moderate injury, and also machine damage or shortened machine service life.

Maintenance Manual of Telescopic Handler
IV
Contents
Foreword...............................................................................................................................I
Safety Notices.....................................................................................................................III
Contents ............................................................................................................................ IV
Chapter 1 Maintenance........................................................................................................1
1.1 Checking the safety manual ....................................................................................3
1.2 Checking the labels and signs.................................................................................3
1.3 Checking for damaged, loose or missing parts........................................................3
1.4 Daily or every 8 h.....................................................................................................4
1.5 Every 50 h or weekly ...............................................................................................7
1.6 Every 250 h .............................................................................................................9
1.7 Every 500 h ...........................................................................................................13
1.8 Every 1000 h .........................................................................................................18
1.9 Every 1500 h .........................................................................................................21
1.10 Every 2000 h .......................................................................................................21
1.11 Appendix..............................................................................................................26

Maintenance Manual of Telescopic Handler
1
Chapter 1 Maintenance

Maintenance Manual of Telescopic Handler
2

Maintenance Manual of Telescopic Handler
3
1.1 Checking the safety
manual
It is essential to keep the operation and
maintenance manuals in good condition to
achieve safe operation of the equipment. If the
manual is illegible or missing, the safety and
operation information necessary for safe running
cannot be provided.
1) Confirm that the Operation Manual and the
Maintenance Manual are kept intact in the
cab.
2) Check that every page of the manual is
legible and intact.
3) Put the manual in the cab after use.
△
! To replace any manual, please
contact the service personnel of LGMG.
1.2 Checking the labels and
signs
It is essential to keep all safety and description
labels and signs in good condition to achieve safe
operation of the equipment. Labels are used to
remind the operation and maintenance personnel
of potential hazards during operation of the
equipment and provide operation and
maintenance information for users. Illegible labels
cannot remind the maintenance personnel of
procedures or hazards and may also lead to
unsafe operation.
Check whether all labels are in proper positions
with reference to the label section in this manual
and based on the label menu and description.
Check the legibility and condition of all labels, and
replace the damaged or illegible labels promptly if
any.
△
! To replace the labels, please
contact the service personnel of LGMG.
1.3 Checking for damaged,
loose or missing parts
This procedure shall be implemented once every
8h or every day.
It is essential to check the equipment condition
regularly to achieve safe operation and superior
performance of the equipment. Incorrect
positioning or maintenance and part damage,
looseness or loss may lead to unsafe operation.
1) Check the equipment for damage, incorrect
installation or part loss, including:
Electrical component, wire and cable
Hydraulic hose, connector, valve block
and hydraulic cylinder
Fuel tank and hydraulic tank
Boom chains and sliders
Tires and hubs
Engine and its relevant parts
Limit switch and horn
Nuts, bolts and other fasteners
Outrigger mechanism
Brake pedal and parking brake
Indicator light and alarm
Drive shaft

Maintenance Manual of Telescopic Handler
4
Inspect the entire machine to check:
the welds or structural parts for cracks
the chassis for deformation or open weld
the machine for dent or damage
that all structural parts and other key
components are intact and all relevant
fasteners and pins are installed in
correct positions and tightened
Regular maintenance
In a working environment where is extremely cold,
dusty or humid, more frequent lubrication and
maintenance than that is specified in "Regular
Maintenance" is required. During maintenance,
the maintenance items listed in the original
requirements shall be carried out repeatedly.
For example, when carrying out maintenance
items for 250 working hours, the maintenance
items for 50 working hours or weekly and every 8
working hours or daily shall be carried out at the
same time.
During maintenance, the engine shall be stopped,
the machine shall be parked on a level ground,
the gear selector shall be set to N gear, the
parking brake handle shall be pulled up, and the
padding block shall be placed under the tires to
prevent the machine from moving.
1.4 Daily or every 8 h
1.4.1 Checking the engine oil level
Insufficient or excessive oil will cause engine
damage. The oil level can be checked only when
the engine is placed horizontally and shut down. If
the engine is hot, shut it down and check the oil
level after 10 minutes so that the engine oil can
be discharged into the oil pan. If the engine is
cold, check the oil level immediately.
1. Pull out the oil dipstick and wipe it with a clean
cloth, re-insert it into the engine oil level port to
the end, and then pull it out for inspection. The oil
level should be between the "L" mark and the "H"
mark of the oil dipstick.
2. If the oil level is below the "L" scale, please add
oil. If the oil level is above the "H" mark, unscrew
the drain plug at the bottom of the oil pan to
discharge some oil.
△
! CAUTION: Too much or too little
engine oil will cause engine damage.
1.4.2 Checking the coolant level
H1840 is used as an example. For other model,
please refer to this picture:
Check the coolant level every 8 hours or
everyday (whichever comes first).

Maintenance Manual of Telescopic Handler
5
1. Place the telescopic handler on the horizontal
ground, stop the engine and wait till it is cool.
2. The coolant level shall not be lower than the
middle position of the sight hole (1).
3. If necessary, add coolant through the filler (2).
△
! In order to avoid the risk of
scalding, wait until the engine is cool
enough before removing the cooling
circuit filler cap 2.
1.4.3 Checking the fuel level
Check every 8 hours or every day (whichever
comes first).
Check the fuel level via the fuel level gauge on
the instrument panel.
Keep the fuel tank full to minimize any
condensation due to atmospheric conditions.
△
! CAUTION: Adding should be
always carried out before the diesel in
the diesel tank is used up, or, the engine
will stall and the diesel at the bottom of
the diesel tank will contain more water
and impurities, which will affect the
normal operation of the engine.
△
! CAUTION: The fuel shall be
selected according to the lowest local
temperature when the machine is in use.
1.4.4 Draining water from the fuel
filter
Drain it every 8 hours or every day (whichever
comes first).
△
! Explosion and fire hazard. Engine
fuel is combustible. Check the location
of the equipment. This step shall be
performed in open and well-ventilated
areas away from heaters, sparks, flames,
and burning tobacco. Aconforming fire
extinguisher should be placed in an
easily accessible place.
△
! This step shall be performed when
the engine is shut down.
1
2

Maintenance Manual of Telescopic Handler
6
1) Place the container under the drain valve.
2) Install a suitable tube on the connector (2),
then open the drain valve (1) to drain the liquid
from the filter and close the drain valve
immediately when the clean fuel is drained.
3) Wipe away the spilled fuel oil.
1.4.5 Checking the tire pressure
and wheel nut torque
Drain it every 8 hours or every day (whichever
comes first).
Check the tire for cuts, protrusions, wear, etc.
Check and adjust the tire pressure if necessary:
Model
Speed
(km/h)
Single tire
load (Kg)
Tire
pressure
(kpa)
H1840
40
5600
500
Tightening torque of wheel nut:
Model
Front axle
Rear axle
H1840
780-880N.m
780-880N.m
△
! CAUTION: Check whether the air
hose is properly connected to the tire
valve before inflation and keep a certain
distance from everyone during inflation.
1.4.6 Checking the hydraulic oil
level
Check every 8 hours or every day (whichever
comes first).
When checking the hydraulic oil level, park the
handler on a flat ground. The hydraulic oil level for
storage shall be not less than 1/2 of the level
meter .
1.4.7 Checking the DEF level
Check every 8 hours or every day (whichever
comes first).
Stop the engine, park the machine on a level
ground, set the gear selector to N gear, pull up
the parking brake handle, and chock the tire to
prevent the machine from moving.
Check the DEF level.

Maintenance Manual of Telescopic Handler
7
1.5 Every 50 h or weekly
1.5.1 Cleaning radiator
Clean and flush the cooling system before the
recommended maintenance interval if the
following conditions occur:
The engine overheats frequently.
Coolant foaming was observed.
The oil has entered the cooling system and
the coolant is contaminated.
The diesel fuel has entered the cooling
system and the coolant is contaminated.
△
! CAUTION:
Cleaning radiator should always be
carried out when the engine is shut
down.
△
! CAUTION:
If the operation isn’t performed carefully,
the radiator core will be prone to
damage.
1. Clean the radiator through blowing from the air
outlet side of the radiator with compressed air.
2. Clean the inside of the radiator with a soft cloth.
1.5.2 Checking washer fluid level
H1840 is used as an example. For other model,
please refer to this picture:
Check weekly or every 50 hours (whichever
comes first).
1) Remove protective cover.
2) Check the level in the water tank (1).
3) If necessary, add washer fluid by filler (2).
1.5.3 Cleaning the cab A/C filter
H1840 is used as an example. For other model,
please refer to this picture:
A. Cab outer filter element
1) Remove the protective cover.
1
2
1

Maintenance Manual of Telescopic Handler
8
2) Take out the A/C filter element (1) and clean
it with compressed air. If the filter element is
damaged, replace it.
3) Install the filter element (1) and housing.
B. Cab inner filter element
1) Remove the shield.
2) Take out the A/C filter element and clean it
with compressed air. If the filter element is
damaged, please replace it.
3) Install the filter element and the shield.
1.5.4 Checking the transmission
fluid
No.
Description
1
Oil filler/oil dipstick
2
Oil outlet
3
Breather
1. Stop the engine, park the machine on a level
ground, set the gear selector to N gear, pull up
the parking brake handle, and chock the tire to
prevent the machine from moving.
2. Carefully clean the breather (5) and
surrounding area.
3. Unscrew the oil dipstick (1), wipe it with a cloth,
insert it back to the original place, and pull it
out again to check the oil stain. The oil level
shall be between the maximum and minimum
limits on the oil dipstick (hot range or cold
range). If the oil level is above the maximum of
the hot/cold range, drain the oil and if the level
is below the minimum, add the oil according to
the standard.
△
! CAUTION: High/low transmission
fluid level will cause damage to
the transmission. Please keep the

Maintenance Manual of Telescopic Handler
9
transmission fluid level in the correct
position.
△
! CAUTION: During the process of
checking the transmission fluid level
and replacing the transmission fluid,
pay attention to cleanliness to avoid
entering of dirt into the transmission
system and damaging the transmission.
1.6 Every 250 h
1.6.1 Replacing cab A/C filter
Change every 250 hours.
H1840 is used as an example. For other model,
please refer to this picture:
A. Replace the cab outer filter element
1) Remove the protective cover.
2) Take out the A/C filter element and replace
with a new filter element (1).
3) Install the protective cover.
B. Replace the cab inner filter element
1）Remove the shield.
2）Take out the A/C filter element and replace it
with a new one.
3）Install the protective cover.
1.6.2 Check the drive axle final
drive and wheel reducer oil level
△
! CAUTION: Before the operation,
the engine shall be stopped, the vehicle
shall be parked on a level surface, the
parking brake handle shall be pulled up,
and the tire shall be blocked to prevent
the machine from moving.
△
! CAUTION: To discharge, fill and
check the oil level, the drive axle must
be horizontal and mounted on the
vehicle.
Check the reducer oil level every 250 hours or
quarterly. Improper reducer oil level will lead to
equipment performance degradation, and
continuous use will lead to component damage.
Check the oil level of the final drive
1

Maintenance Manual of Telescopic Handler
10
1. Carefully clean the breather (3) and
surrounding area.
2. Check the oil level: remove the oil filler plug (1)
and check whether the oil level is at the lower
edge of the filler. Otherwise, add oil and
tighten the plug.
Check drive axle wheel reducer oil
1. Turn the wheel so that the plug (4) is in the
highest position and unscrew it to some extent
to release the possible pressure.
2. Turn the wheel so that the plug (4) is in the
horizontal position, remove the plug to check
whether the oil level is at the lower edge of the
oil filler , otherwise add oil and tighten the plug.
1.6.3 Checking transfer box oil
level
No.
Description
1
Oil filler
2
Oil outlet
3
Breather
Check the transfer box oil level
1. Stop the engine, park the machine on a level
ground, set the gear selector to N gear, turn off
the engine, pull up the parking brake handle,
and chock the tire to prevent the vehicle from
moving.
2. Remove the oil filler plug (1), and check
whether the level is at the lower edge of the oil
filler. Otherwise, fill the oil to the specified
position and install the plug (1).
1.6.4 Checking boom chain
Cleaning and lubricating boom chain

Maintenance Manual of Telescopic Handler
11
1) Raise the outrigger and keep the boom level.
2) Fully extend the boom.
3) Wipe the chain outside the boom with a clean
lint-free cloth, and then check carefully of any
wear.
4) Brush the chain with a hard nylon brush and
clean diesel fuel to remove any foreign matter.
5) Brush the chain with a paint brush soaked in
cleaning diesel fuel and blow dry it with
compressed air.
6) Lubricate the chain with lubricant, extend and
retract the boom several times to check the
performance of the chain.
Check chain tension
1) Fully extend the boom and retract the boom
by 200 mm.
2) Measure the distance between the bottom of
the chain and the top of the boom with a ruler.
The distance of the two same chain must be
consistent.
3) Boom 1: The distance shall be between 97
mm and 117 mm, and if necessary, adjust it
with tensioner 2. Loosen lock nut 3 and
tighten nut 4 until the desired distance is
reached. Retighten the lock nut 3 while
limiting the nut 4.
4) Boom 2: The distance shall be between 65
mm and 85 mm. If necessary, adjust with
tensioner 5. Loosen lock nut 6 and tighten nut
7 until the desired distance is reached.
Retighten the lock nut 6 while limiting the nut
7.
△
! CAUTION: If the Chain is too long
to adjust the tension, replace it in pairs.
If one of the chain is damaged, the two
1
2
1
2
2
3
4
5
7
6

Maintenance Manual of Telescopic Handler
12
chains shall also be replaced together.
1.6.5 Lubricating boom slider
Carry it out every 10 hours for the first 50 hours
and every 250 hours thereafter.
1) Raise the outrigger.
2) Extend the boom as much as possible.
3) Apply grease evenly around the boom with a
brush (molybdenum disulfide is
recommended).
4) Remove excess grease and retract the
boom.
1.6.6 Checking hydraulic oil
1) This inspection should be carried out every
250 hours or quarterly (whichever comes
first).
Collect a hydraulic oil sample, place it in a
transparent container, and visually inspect
the hydraulic oil as follows:
Color: the oil shall be transparent and appear
in light honey color.
Appearance: the oil shall be clear, not cloudy,
and free of particles, foreign matters or other
contaminants.
Check the hydraulic oil through the smell (the
heat can be smelled, but there is no "burnt"
smell) or the friction between the fingers
(there shall be a sticky feeling, no rough
feeling of any particles). If all hydraulic oil
pass the above inspection, continue to
service at predetermined intervals. If the
hydraulic oil does not comply with any of the
above inspections, the hydraulic oil must be
tested or replaced.
2) Replacement or testing of hydraulic oil is
critical to the performance and service life of
the equipment. Contaminated hydraulic oil
may affect equipment performance, and
continuous use will cause equipment
damage. For harsh working environment, the
inspection should be carried out more
frequently.
3) Before replacing the hydraulic oil, the oil stain
separator can be used to test whether it is
necessary.
4) If the hydraulic oil has not been replaced for
two years, it shall be tested quarterly. If it fails
to pass the test, replace the hydraulic oil.
Note: when replacing the hydraulic oil, it is
recommended to replace all hydraulic filters at the
same time.

Maintenance Manual of Telescopic Handler
13
1.7 Every 500 h
1.7.1 Replacing engine oil and oil
filter
First 50 hours, and then change it every 500
hours or every half a year (whichever comes
first).
△
! Do not work on the running
engine!
No smoking and open fire!
Be careful when handling high
temperature engine oil. Risk of burns!
△
! When working on the oil system,
pay attention to the cleanliness of the
outer surface. Carefully clean all areas
involved. Dry the wet parts with
compressed air.
△
! Please abide by the oil safety
provisions and local regulations.
Dispose of spilled oil and filter elements
as specified. Ensure that waste oil
doesn't drip to the ground.
Draining engine oil
1) Warm up the engine
2) Place the engine horizontally.
3) Shut down the engine.
4) Place a container under the oil drain plug.
5) Unscrew the oil drain plug (1) and drain the
old oil.
6) Install a new seal ring (2) on the oil drain plug,
screw the oil drain plug in and tighten it.
Torque of drain plug: 24N.m.
Note: If a drain valve is installed, unscrew the
drain valve to drain the oil.
Replacing the oil filter
△
! CAUTION: Each time the oil is
changed, the oil filter element should
also be replaced.
1. Clean the area near the oil filter mounting seat.
2. Remove the cover (1) from the filter housing

Maintenance Manual of Telescopic Handler
14
(4).
3. Remove the filter element (3) from the cover
(1).
4. Remove the seal ring (2) from the cover (1).
5. Install a new seal ring (2) on cover (1). Install a
new filter (3) to cover (1). Install the cover (1) and
filter (3) to cover (4).
6. Torque of cover (1):24N.m.
△
! CAUTION: Excessive mechanical
tightening may damage the thread or
damage the seal of the oil filter element.
Adding oil
1) Add oil through the oil filler (1).
2) Wait a few minutes for oil to flow into the oil
pan.
3) Warm up the engine and run it at low speed
for 3 minutes to check the drain plug and the
filter for leakage.
4) Turn off the engine, wait a few minutes,
check the oil level and refill if necessary.
1.7.2 Replacing primary fuel filter
element
Replace every 500 hours or every six
months (whichever comes first).
△
! Engine must be turned off!
No smoking and open fire!
Be careful when handling hot fuel!
△
! Do not loosen the fuel injection
pipeline or high pressure fuel pipeline
while the engine is running.
△
! Carefully clean all areas involved.
Dry the wet parts with compressed air.
△
! Please observe safety regulations
on fuel and relevant local laws and
regulations. Dispose of spilled fuel and
filter elements according to regulations.
Fuel must not leak to the ground.
△
! After the operation on the fuel
system is completed, bleed the system,
conduct a trial run and check the
tightness.
△
! Explosion and fire hazard. Engine
fuel is combustible. Check the location
of the machine. This step shall be