PREFACE

This operation and maintenance manual is specially written to give the user a
general idea of how to operate maintenance and manage the LW520 Wheel Loader.
Information on performance, operation, construction, maintenance and adjustment of
the LW520 loader is briefly given in this manual for the reference of operators,
maintainers and technical administrators.
Due to continuous improvements on the structure and performance of our
machines, the user should note that there may be a little difference between the
contents of this manual and the latest products of our factory.
Any remarks concerning the operation and design of this loader or on this manual
will be much appreciated. Please inform us at any time so that we may make further
improvements on the quality of the products and serve the user better.

CONTENTS

Chapter 1 Applications & main performance and parameter ……………………2

1.1 Applications …………………………………………………………………………2
1.2 Main performance and parameter………………………………………………2
1.3 Standard installs ……………………………………………………………………2
Chapter 2 Operation and function ………………………………………………………5
2.1 Controlling mechanism and instruments ……………………………………5
2.2 Break-in of a new loader ………………………………………………………6
2.3 Operation of the machine ………………………………………………………7
2.4 Lubrication of the machine ……………………………………………………13
Chapter 3 Main assembly structure and its maintenance ………………………14
3.1 Diesel engine ……………………………………………………………………………14
 3.2 Torque converter & transmission ………………………………………………14
3.3 Drive axles ………………………………………………………………………………26
3.4 Transmission shaft ……………………………………………………………………27
3.5 Brake system ……………………………………………………………………………28
3.6 Hydraulic system ……………………………………………………………………32
3.7 Steering system …………………………………………………………………………38
3.8 Gearchange system ……………………………………………………………………41
3.9 Implement ………………………………………………………………………………42
3.10 Chassis ………………………………………………………………………………42
3.11 Air conditioning system ………………………………………………………43
3.12 Electrical and instrument system …………………………………………43
Chapter 4 Periodical maintenance ……………………………………………………44
4.1 General description ………………………………………………………47
4.2 Attention-getting items ………………………………………………………47
4.3 Periodical maintenance ………………………………………………………48
Chapter 5 Probable malfunction and remedy ………………………………………50
5.1 Torque converter & transmission ………………………………………………50
5.2 Brake system ……………………………………………………………………………51
5.3 Hydraulic system ……………………………………………………………………52
5.4 Steering system ……………………………………………………………………… 53
Chapter 6 Safety Items …………………………………………………………………… 56
Chapter 7 General Notices of Safety ……………………………………………………… 58
Chapter 8 Operating Precautions Safety……………………………………………………60
Chapter 9 Precautions for maintenance……………………………………………………64
Chapter 10 Safety Items in Operating Wheel Loader………………………………………66
10.1 General notices of safety ……………………………………………66
10.2 Precautions before starting the engine ……………………………68
10.3 Precautions after starting the engine and working ……………69
10.4 Vehicle parking …………………………………………………………………71
10.5 Precaution in the Process of Maintenance……………………………72
10.6 Operating when machine is lifting and transporting…………………74
Sketch map of principal dimensions

1
 Sketch map of transmission system
CHAPTER 1 APPLICATION & MAIN PERFORMANCE AND PARAMETER
1.1 Applications
This machine is a larger version of the wheel loaders that are used mainly in
loading and unloading loose materials. It is suitable for loading and unloading,
bulldozing, lifting, towing and other operations in mine fields, building
construction sites, road construction projects, steel and iron works etc. It is a
multi-purpose and highly efficient construction machine.
1.2 Main performance and parameter
Bucket capacity 3m3
Rating loading capacity 5000kg
Arm lifting time (under rating load) 7s
Bucket forward tilting time (empty) 2.5s
Traveling speed:
Forward 1st gear 0～10km/h
Forward 2nd gear 0～34km/h
Reverse gear 0～13km/h
Maximum traction (be fully loaded) 155KN
Maximum gradeability 30°
Minimum turning radius:
Outside of rear whee1 5745mm
Outside of bucket 6675mm
Dimensions:
Overall length (bucket on ground) 7785mm
Overall width (outside of wheel) 2820mm
Bucket width 3000mm
Overall height (top of cab) 3500mm
Wheelbase 3200mm
Tread 2200mm
Minimum ground clearance 450mm
Maximum dumping height (dumping reach 1050mm) 3205mm
Total weight (cab included) 16500kg
Seat of driver: locate in the front of rear frame
1.3 Standard scheme
1.3.1 Diesel engine
Model: WD615.61AG26/X6130G27
Structure: Water cooling in-line 4-cycle direct injection
Number of cylinders: 6
Cylinder’s inner diameter and stroke: 126×130mm
Piston displacement: 9.726L
Compression ratio: 15.5
Rated output: 162kW /2200rpm (hour rating)
Maximum torque: 845N·m
Minimum specific fuel consumption 210g／kw·h
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 Fuel oil: No. 0 or -20 light diesel oi1
Regulator: 　　　　　　　　　　　　　　RFD
Fan Diameter:　　　　　　　　　　　　　　　Φ670/Φ700
1.3.2 Transmission system
Torque converter
Type Dual-turbine type
Sta1l torque ratio K=4
Cooling mode Pressure oil circulation cooling
Oil pressure of torque converter inlet 0.58MPa
Oi1 pressure of torque converter outlet 0.28～0.45MPa
Transmission
Type Planetary, hydrau1ic power shift
Gears Two forwards and one reverse
Speed charging pump (gear pump)
Revs 2200rpm
Rate of flow 120L/min
Working pressure 1.1～1.5MPa
Differential gear
Type Spira1 bevel gear
Reduction ratio 5.286:1
Final drive
Type Spur planetary gear
Reduction ratio 4.4:1
Axles and wheels
Drive type All wheels
Tire 23.5-25
Tire pressure 0.28～0.3MPa
1.3.3 Brake System
Service brake: Air-assisted hydraulic-disk type brake on 4 wheels
Diameter of disk Φ＝460mm
Diameter of hydraulic cylinder Φ＝75mm
Friction lining size(length×width×thickness) 182×72×15mm
Parking brake internal-expanding dual-shoe brake
Diameter of brake drums 305mm
Lining size (length ×width ×thickness) 325×76×6.5mm
Air pressure of brake system 0.6～0.8MPa
1.3.4 Steering system
Type Articulated frame, full-hydraulic steering
Number of steering cylinders-bore ×stroke 2-Φ90×399mm
Steering pump CBG2080
Steering gear BZZ1-1000
Working pressure of system 14MPa
Turing angle 38 degrees to each direction
1.3.5 Implement
Number of arm cylinders-bore ×stroke 2-Φ160×755
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 Number of bucket tilting cylinder- bore ×stroke 1-Φ180×591
Distribution valve Dual-spool type
Operation pump CBG3160
Revs 2200rpm
Rate of flow 104～352L/min
System pressure 16.5MPa
Implement arrangement single rocker arm reversing 6-bar linkage
1.3.6 Electrical and instrument system
System voltage 24 volt
Batteries Model 2-6-Q-195
Lighting system voltage 24 volt
Engine starting voltage 24 volt (electric motor)
1.3.7 Oil capacity
Fuel tank 278L
Hydraulic system 278L
Engine crankcase 42L
Transmission 45L
Axles (differential and planetary system) 40L
Front and rear boosters 3.5L
1.3.8 Air conditioning system
Heat flow
Operation medium Cooling water for diesel engine
Cooling flow
Operation medium Freon 12(F-12)
Cooling capacity 4.2kJ/h
System voltage 24 volt

CHAPTER 2 OPERATION AND FUNCTION

In order to operate the machine safely and reliably, the operation and functions
should be thoroughly understood before using the loader.
2.1 Controlling mechanism and instruments
The location of controlling mechanism and instruments are shown in fig 2-1, 2-2
and 2-3.

4
2.2 Break-in of a new loader
During the course of break-in that lasts 60 hours, the operation and maintenance
such as followings should be paid enough attention to.
1. The followings must be done after break-in a new loader for 8 hours.
(1)Check the fastening of all the bolts and nuts, especially the bolts for cylinder
covers, exhaust pipe, front and rear axles, connecting transmission shaft, and
nuts for rims.
(2)Clean coarse and fine oil filter and fuel oil filter.
(3)Check the tightness of the fan belt.
(4)Check the proportion and the reserve of the electrolyte in the storage battery,
and tighten the terminals of the storage battery.
5
 (5)Check the oil quantity of the gear box.
(6)Check the seals of hydraulic system, air pressure system, brake system and
air conditioning system.
(7)Check all the connection of control lever and throttle links.
(8)Check all the connection of electric system, the condition of power supply
and light illumination and steering signals.
2. Break-in with forward 2nd gear and reverse gear.
3. During the break-in, loading and unloading is not allowed to exceed 70% of
the rating load capacity.
4. Pay attention to the lubricating condition of the loader, renew or fill the oil
and grease according to requirement.
5. Pay close attention to the temperature for gear box, torque converter, front
and rear axles, hubs, brake disk and brake drum. If overheated, find the cause and
remedy.
6. Check all the bolts and nuts.
7. During the course of break-in, it is appropriate to shovel loose material. Too
abrupt and hasty action is forbidden.
8. The following maintenance should be done after accomplishing the break-in.
(1)Check the filter screen of the gear box oil sump, renew the oil.
(2)Renew the engine oil.
2.3 Operation of the machine
2.3.1 Points for attention during operation.
1. The diesel oil must be precipitated for at least 72 hours before filling. The
name of diesel oil should accord with the requirement.
2. The hydraulic transmission oil filled in the torque converter-transmission and
the hydraulic oil filled in hydraulic system should be clean.
3. Periodical maintenance and lubrication should be carried out according to the
regulation.
4. The engine should be kept idling until water temperature reaches 55℃ and air
pressure reaches 0.35MPa before the loader traveling.
5. The engine should be preheated to above 30 ～40℃with hot water or steam
before starting, when the weather temperature is under 5℃.
6. It is unnecessary to stop traveling or to apply service brake for gear shifting.
When change the speed from low to high, first release the accelerator pedal, and
simultaneously, shift the gear, and then press the accelerator pedal to bring the output
shaft of the transmission to rotate with the speed of transmission shaft. Otherwise,
press the accelerator pedal directly to shift the gear.
7. It is unnecessary to shift the gearchange into neutral gear position when the
service brake applies.
8. The control levers should be shifted into the neutral position when the arm
and the bucket are set to the required position.
9. The loader should be stopped before reversing.
10. It is until the temperature of the cooling water has reached 55℃ and the
temperature of the engine oil has reaches 45℃ that the loader is permitted to work in
fully loaded condition. During operation, the temperature of the cooling water should
6
not exceed 90℃, and the temperature of the engine oil should not exceed 110℃. If
the oil temperature exceeds 110℃, the machine should be stopped to cool down.
11. To assure traveling stably when transporting materials, the distance between
ground and the underside hinge joint of arm should be 450mm. Lifting the bucket to
tiptop is forbidden when transporting materials.
12. The power of the engine such as model X6130G27 will be decrease with the
increase in altitude, ambient temperature and relative humidity. Therefore, the user
need refer to the power correction table included in the operation manual to acquire
the actual power output of the engine under the local condition, so as to ensure the
correct use of the loader before operating the machine. The output of model
WD615.6AG26 diesel is hardly affected by the environment.
13. In order to protect the parts, the emergency and parking brake should not be
applied while traveling except in emergency.
14. In case the engine can not start under trouble or other condition and the
loader ought to be towed by another vehicle, it is necessary to affranchise the parking
brake firstly.
Warning: the loader is deprived of both power steering and brake function at that
time.
2.3.2 Checkups and maintenances before and after operation.
Checkups before operation
1. Engine, electric appliances and instruments
(1) Check water level in the radiator.
(2) Check fuel level in the fuel tank.
(3) Check engine oil level in the engine oil sump.
(4) Check all pipes and other parts for leakage.
(5) Check wire connection of the batteries.
2. Chassis
(1) Check the hydraulic oil level.
(2) Check the hydraulic oil pipes and other parts for leakage.
(3) Check the working reliability of the service brake and emergency brake.
(4) Check all the control levers to see if they work perfectly and are set to
neutral position.
(5) Check the air pressure of the tires.
3. After the engine start
(1) Observe the readings on all instruments to see if their indications are
normal.
(2) Check all the lighting installations, turning signal lamps, horn,
windshield wiper and brake lamps.
(3) Operate the implements mechanisms and check the operating condition.
(4) Listen attentively to the sound of the engine at low speed to determine
its working condition.
(5) Trial run on each gear.
4. Checkups and maintenances after work (everyday)
(1) Check fuel level.
(2) Check level and cleanness of engine oil. If oil level is too high or the
7
 oil become thin, find out the cause and remedy the trouble.
(3) Check all the oil, water and air pipelines for leakage.
(4) Check the fixation of the transmission, torque converter, hydraulic oil
pump, steering gear, front and rare axle, and check whether these
components are overheated.
(5) Check the tightness of the bolts, studs and nuts of the wheels and
transmission draft, and check the fixation of all the pins.
(6) Check if the implement mechanism is in good condition.
(7) Check the outside appearance and air pressure of the tires.
(8) Drain out the cooling water when the temperature of the weather is
below 5℃.
(9) Fill grease into greasing points.
2.3.3 Start, stop and operate the machine
1. Start
After the “checkups before operation” has been carried out and all the parts are
in good order, the engine can be started.
Before start, set the gearchange and the control levers of implement in their
neutral position. Inserting the key to switch on the power, and then press the
accelerator pedal slightly, and then turn the starting switch.
The starting switch should be turned on for 5 seconds once only (continuous
operation of the switch should not exceed 15 seconds). The switch should be
released immediately if it is fail to start. Wait for one minute then start again.
If the failures are more than 4 times, find out the trouble and remedy it, and
then start again.
The engine should run at the speed of 600～750 rpm for a while to make the
engine warm and check the indications of the instruments especially the
engine oil manometer. At the same time, check the engine and the other
systems for irregularities.
Release the parking brake and shift gear to run after the air pressure reached to
0.3～0.35MPa.
2. Stop
Before stopping run the engine at a speed of 800 ～ 1000 rpm for several
minutes to enable the parts of engine cool down evenly. The bucket should be
lowered on the ground flatwise, then turn off the power and apply the parking
brake. All the water drain cocks of the engine should be opened to drain off
the water in the cooling system soon after the engine stops in winter.
However, there is not need draining off the water if anti-freezers have been
added. The storage batteries should be removed and placed in a warm room
when the air temperature falls below -30℃ to avoid cold cracking.
3. Operate the implement
Preparative for operation
(1) The traveling speed for shovel loading materials should be below 1km/h.
(2) Clean up the operation ground, fill-in the pits, remove sharp rocks and other
obstacles that may damage the tyre or hinder the operation of the loader.
4. Operation modes
8
 There are two modes of loading and unloading generally.
As shown in fig 2-4(a), the distance between loader and lorry is ten meters, the
lorry stops when the loader is working. The working efficiency is higher.
Combination operation of the loader and the lorries, as shown in fig 2-4(b), is a
fairly appropriate mode for continuous hauling by a lorry team.
5. Shoveling operation
(1) Drive the loader towards the stock pile in 1 st gear, with the underside hinge
joint of arm 300mm off the ground and the bucket bottom parallel to the
ground, as shown in fig 2-5(a).
(2) At a distance of one meter in front of the stock pile, lower the arm and let the
bottom of the bucket touch the ground and cut into the

stock pile, as shown in fig 2-5(b).

(3) Press down the accelerator pedal to force the bucket cutting into the stock
pile with full power. If the resistance is too strong, the combined
shovel-loading mode should be applied, that is to say, the loading of
materials is done by titling up the bucket and raising the arm
simultaneously at intervals until the bucket is fully filled.
(4) After filling the bucket, raise the arm to the required height, and set the arm
control lever to the neutral position, as shown in fig 2-6(c).

9
Fig 2-5 Shoveling operation Fig 2-6 Dumping operation
6. Transporting operation
The loader is used for hauling under the following condition.
(1) For the ground is too soft or the field not leveled, it is too hard to transport
with lorry.
(2) The hauling distance is less than 500 meters. It is cost waste time to
transport with lorry.
The transporting speed is determined by the distance and ground condition. In
order to keep safety, stability and good visibility during hauling, the bucket
should be turned upward to its extreme position and keep the underside hinge
joint of arm 450 mm from the ground.
7. Dumping operation
When dumping materials into lorries or stock yards, first raise the arm to height
so that when the bucket is titled, it will not collide the lorry body or stock pile.
Then push forward the bucket control lever to tilt the bucket forward and
dump. Bumping of materials should be done slowly so as to minimize the
impaction on the lorry.
If materials stick on the bucket, control the stick back and forth to shake the
bucket, as shown in fig 2-6.
After dumping, draw the bucket control lever to its rear extreme position; push
the arm control lever to the declining position to prepare for the next cycle of
the operation.
8. Bulldozing operation
(1) Lay the bucket flat on the ground.
(2) Pedal the accelerator and bulldoze forward. When the vehicle is hindered
during the bulldozing operation, lift the arm slightly and continue the
action. The control lever should not be shifted to either of the two
extreme positions but between them while lifting or lowering the
arm, as shown in fig 2-7.

10
 Fig 2-7 Bulldozing operation Fig 2-8 Scraping operation
9. Scraping operation
(1) Tilt the bucket to utmost position, and let the bucket blade contact the
ground.
(2) When the loader is used for scraping hard surface, the arm control lever
should be set to the floating position, and for soft surface, it should be
shifted to the neutral position.
(3) Engage the reverse gear and use the bucket blade to even the ground, as
shown in fig 2-8.
10. Towing operation
Hitch on a 20-ton trailer for material transportation.
(1) Hitch the trailer to the drag pin hard.
(2) Shift the implement to the transportation position.
(3) Drive the vehicle slowly when starting and stopping. Before driving down a
slope, be sure that the brake is ok. When the road is very steep, equip
the trailer with brake to ensure safety.
2.4 Lubrication of the machine
Proper lubrication will greatly reduce the friction and wear of the machine parts.
1. Points of attention
(1) Clean the oilers and the lubrication points.
(2) Put the machine in a level position to check the oil level.
(3) Add oil to the front and rear axle through fillers at the left and right
wheel hubs, until the oil flows out from the oil level plug hole of the axle
castings.
(4) Add oil to the transmission, until the oil flows out from the oil level
petcock. Start the engine and run for 5 minutes, then check the oil level
again after filling oil first time.
(5) It is forbidden that combines or interchanges different kinds of oil,
otherwise, it may cause the ageing of rubber parts and wear on
components.
2. Kinds and brands of lubricant are listed in the following table.
Name of oil
Type of oil Position of use
Summer Winter

11
 Roller bearing, sliding
Lithium-base grease No. 2 No. 1
bearing and hinged parts

Implement hydraulic
Hydraulic oil L-HM46 L-HM32
system, steering system
Hydraulic Torque converter,
No.8
transmission oil transmission
Engine oil 40CD 5W/30CD Diesel engine

Fuel oil No. 0 or No. -10 No. -35 Diesel engine

Gear oil 85W/90 Front and rear axle

Synthetic brake fluid LG3 Brake system

CHAPTER 3 MAIN ASSEMBLY STRUCTURE AND ITS MAINTENANCE

3.1 Diesel engine
LW520 wheel loader may install two types of diesel engine, one is
WD615.61AG26, and the other is X6150G27. To operate and maintain the engine,
refer to the relevant operation manual.
3.1.1 Cooling system
The cooling system is composed of water tank, radiator for cooling the torque
converter-transmission oil and an air hood. This unit is fixed on the radiator bracket
and rear frame. The water inlet on the top of the radiator is connected to the outlet
elbow of thermostat of the engine, and the water outlet at the bottom of the radiator is
connected to the oil cooler inlet elbow, and the oil cooler outlet elbow is connected to
the water pump of the engine.
3.1.2 Throttle control system
The throttle control system consists of accelerator pedal, flexible shaft and so on,
and connects with throttle pull plate. The stop screw is used for limiting the
maximum opening of the throttle. When assembling, adjust high or short according to
condition.
3.1.3 Stopping device
The stopping device is a stay wire connecting to the engine stop lever with the
wire tube fixed to the casting of the fuel pump. The stopping button locates at the
lower right side of the operator’s seat, and when the button is pulled out the engine
will stop.
3.1.4 Fuel tank
The fuel tank is laid at the lower right side of cab and is fixed to the frame with
four bolts. The capacity of the fuel tank is 278 liters. The hydraulic air filter is on the
top of the tank and a draining plug is at the bottom. The liquid level meter is placed at
the flank of the tank.
3.2 Torque converter & transmission
Torque converter & transmission is composed of torque converter and
12
transmission.
3.2.1 Torque converter
1. Feature
The LW520 wheel loader is equipped with a dual-turbine hydraulic torque
converter between the engine and the transmission for transmitting power with the
following advantages.
(1) The torque converter can adjust the output and rotate speed automatically
that means the loader can change the traveling speed and traction to adapt the
various road conditions and operation modes automatically.
The torque converter is a stepless transmission, can provide a smooth drive
when the vehicle accelerates from start to maximum speed of a gear. The
acceleration performance is better than the normal.
The torque converter can decrease the speed of the loader and increase the
traction without gear shifting automatically while the loader is running across
a slope or obstacles. Thus, the vehicle will be able to run and an appropriate
speed to overcome the obstacle. When external resistance decreases, the
speed of the vehicle will increase automatically.
In the same way, when the loader cut into the material pile at high speed, the
torque converter can change the speed and traction automatically to assure
the cut-in.
Having the above superiority, the loader can be operated at a higher average
speed and a shorter working circle, which results in higher productivity.
(2) Having two turbines, the torque converter can perform the function of an
automatic transmission with two gear ratios. For this reason, the
configuration of the transmission is more compact with a lower cost.
(3) Due to the high torque conversion ratio and the wide high efficiency range,
the engine can be operated more effectively to develop traction force and
travel speed, which results in good economy.
(4) Since power is transmitted by hydraulic oil instead of mechanical connection,
the oil absorb the shock or impact between the input and output shafts to
protect the diesel engine and the transmission. Accordingly, the longevity of
the loader is protracted and the cost and the workload of maintenance are
reduced. And the engine cannot be stalled even by a sudden increase of
externa1 load, thus the oil pumps wi1l work continuously and this ensures
safe and reliable operation of the vehic1e.
(5) Due to above features, the driver’s labor intensity is greatly lessened, and the
vehicle is more comfortable to operate.
2. Operation principle
As shown in fig 3.2-1, the torque converter consists of four basic parts: the
impeller B, the turbines T1 and T2, and stator D. The cavity formed by these parts is
filled with oil. Impeller B is driven directly by the engine, turns at engine speed n B
and converts the engine power into hydro-dynamic energy to force the oil in the
cavity flow from impeller B to the turbines T1 and T2 where its dynamic energy is
absorbed as torque delivered to the overdrive clutch via gears Z 1 and Z3; and the oil
pressure causes turbines T1 and T2 to rotate at speed nT1 and nT2 respectively. The
13
circulation of oil in the converter is shown by arrow in the fig. The turbine T 2 then
redirects the oil back toward the impeller B. Stator D is the reaction member and is
interposed between turbine T2 and impeller B to change the direction of oil flow so
that it enters the impeller in the same direction as the impeller is rotating. Due to the
design of the wheels blades, the oil flows that go in and out each wheel have different
track and direction respectively. Because of nB is equal the engine speed and nT1 and
nT2 is changing according to external load, the speed and direction of the oil flow are
changing continually. So the torque coming from the impeller and the torque
directing by the stator are both changing. As a result, the sum of the torque (positive)
coming from impeller and the torque (positive or negative) coming from stator which
is acquired by the turbines is changing. When the torque that coming from stator is
positive, the torque of output shaft increases and vice versa. Thus the torque
transferred through the converter is changed, and the stator is necessary for the
transformation of torque.
The flow of oil in turbine T2 moves from the periphery toward the hub. The
torque developed by the fluid force is delivered through gear pair Z 3 and Z4 to the
output shaft of the torque converter. Turbine T2 transmits the engine power to the
output shaft principally under light load and high speed condition. The oil passes the
blades of turbine T1 in axial direction. Turbine T1 transmits torque when the load
demand is his and vehicle speed is lower. Under such conditions, the overdrive clutch
locks gear Z2 to gear Z4 by the wedge action of the rollers, so that the torque from
turbine T1 can be transferred to the output shaft and combines with that of turbine T 2.
In the overdrive clutch, as shown in fig 3.2-1, the roller under the action of the spring
is held between the peripheries of the cam, which is connected to gear Z 1, and the
inside of the hub of gear Z2. When the vehicle is at high speed and the load demand is
low, gear Z4 together with the cam runs faster than gear Z2, the roller rotates in
direction “A” and gear Z2 spins freely. Thus, the torque is delivered by turbine T 2 to
the output shaft. As the load demand increases and gear Z 4 is rotating slower than
gear Z2, the roller rotates in direction “B” and the overdrive clutch locks gears Z 2 and
Z4 together by the wedge action of rollers. Thus, the torque delivered by each turbine
is combined with the other, and both turbines deliver the combined torque to the
output shaft. The overdrive clutch is engaged or disengaged automatically according
to the variation of vehicle speed and load demand.

14
 Fig 3.2-1 Operation principle of torque converter
1. Diesel engine 2. Flywheel 3. Cam Ring gear
5. Spring 6. Roller 7. Overdrive clutch
8. Output draft 9. Working cavity 10. Casing
3. Structure
The left half and the K and H views of fig 3.2-2 show the structure of the torque
converter. The converter housing 13 is connected at the left end to the engine
flywheel housing and at the right end to the housing 4, and on the contact surfaces of
both ends are placed gaskets 21 and 9 respectively. The pump impeller 16 and pump
cover 25 are connected with bolts. The flexible plates 28 are bolted to the engine
flywheel 22 and the pump cover, so that the pump impeller is driven at engine speed.
The turbine set is composed of first turbine 18 and second turbine l9. The first turbine
is fixed to the turbine cover 23 by roll-pins l7 and riveted to the hub 26. The two
turbines are splined respectively to the first turbine drive gear 5 and the second
turbine drive gear 8, which are co-axial and rotating independently. The sleeve 10 is
fixed to the converter housing 13 and supports the pump impeller on bearing. The
stator 27 and spacer 15 are splined to the sleeve and constrained by a circlip put in the
groove at the end of the sleeve. Gear l4 is fixed to the pump impeller l6. This gear
drives the oil pump, and when tows starting, wheel torque is transmitted to the engine
through this gear. A seal ring 12 is placed between gear l4 and sleeve l0, and some oil
will leak out from the converter during operation, but oil pressure will not reduce.
The seal rings 7 and l1 are used in the same way as seal ring l2. Brass ring 6 is a
spacer ring placed between gear 5 and 8 to let them rotate at different speeds.
Spring 36 in the overdrive clutch, as seen in the H view of the drawing, are
installed between flanges of the cover plate 37 and lugs of the roller cage 38. Under
the action of the springs, the rollers 35 are in contact with the inside surface of the
hub of gear 40 and the face of cam 39. Gear 40 and cam 39 rotate in same direction.
When the former is faster than the latter, the clutch engages and when the latter is
faster than the former, the clutch is released.
15
 Pressure regulation valve 32 controls the inlet oil pressure of the torque
converter, and the back-pressure regulation valve 33 controls the pressure of the
lubricating oil.
4. Interior oil passage
The pressure oil from the charging pump 1 enters the torque converter from port
“A” (shown in K view) and flows through port “D” and channel “E”, passing through
the converter pump hub bearing, around the spacer ring 15, and then enters the cavity
of the converter, to fill it continually. Excess oil from the space “G” flows between
sleeve 10 and second turbine drive gear shaft, as indicated by letter “F”, and leaves
the converter housing 13 through port “B” as shown in the K view.
3.2.2 Transmission
1. General description
The planetary type hydraulic-operated transmission used in the ZL50F can
provide two forward speeds and one reverse speed. Its advantages are simplicity,

Fig 3.2-2 Torque Converter-Transmission

l. Charging pump 2. Gasket 3. Oil pump driven gear shaft 4. Housing 5. 1st turbine drive gear 6. brass ring
7. Seal ring 8.2nd turbine drive gear 9. Gasket l0. Sleeve
ll. Seal ring l2. Seal ring l3. Converter housing 14. Oil pump drive gear l6. Pump impeller 17. Roll pins
16
l8. 1st turbine l9. 2nd turbine 20. Locking washer 21. Paper gasket
22. flywheel 23.Turbine cover 24. Rivets 25. Pump cover 26. Turbine hub
27.stator 28. Flexible plates 29. Oil temperature gauge connection 30. Pipe connection 3l. plug
32. Pressure regulator valve 33. Back-pressure regulation valve 34. pipe connection 35. Rollers 36. Springs
37. Cover plate 38. Roller cage 39. Cam 40. 1st turbine driven gear 41.2nd turbine driven gear shaft
42. Bearing 43.Bolt 44.Sun gear 45. Reverse planet pinions 46. Reverse planet carrier
47.1st gear planet pinions 48. Reverse ring gear 49. Front and rear axle connection pull rod
50. Front and rear axle connection shifting fork 51. Rear output shaft 52. Sliding sleeve 53. Output shaft gear 54.
Front output shaft 55. Middle cover 58. Cylindrical pin 57.lntermediate shaft output gear
58. 1st-gear planet pinion spindles 59. Disk spring 60. End cover 6l. Ball bearing 31l 62. Direct-gear shaft
64. Direct-gear cylinder 65. Direct-gear piston 67. Bolts 68. Direct-gear friction clutch
69. Direct-gear drive plate 70. Direct-gear connecting flange 71. 1st=gear planet carrier 72. 1st-gear cylinder 73.
1st-gear piston 74. 1st-gear ring gear 75. 1st-gear friction clutch 76. Spring 77. Springs guide pins
78. Reverse gear friction clutch 79. Reverse gear piston 80. Duplex pump 81. Steering oil pump
compactness, high rigidity, high driving efficiency, simple and reliable controlling,
and longer service life.
The transmission is mainly composed of the housing, overdrive clutch, planetary
assemblies, friction clutches and pistons, changing oil pump hydraulic control valves,
oil strainer, shafts and gears.
The function of the transmission is to transmit the engine torque, and to change
the driving direction and speed of the vehicle. The charging pump sucks the oil from
transmission casing through filter and feeds it into control valve; operator can use the
control lever to feed pressure oil into selected chamber then to shift the transmission
according to his demand. When road condition is severe, use shifting fork and sleeve,
to connect rear output shaft to front output shaft to implement four-wheel drive.
2. Structure and operation principle
(1)The planetary assemblies are shown in fig 3.2-2. There are two planetary
assemblies in this transmission for the reverse gear and the 1st gear. The
p1anetary gear set is mainly composed of the planet carrier, planet pinions,
planet spindles, internal ring gear and sun gear. The planet pinions are carried
on the planet carrier, and are in mesh both with the sun gear and the ring gear.
The driving plates of the 1st-gear friction clutch 75 are splined to the 1st-gear
ring gear 74, the driving plates of the reverse gear clutch 78 are splined to the
reverse planet carrier 48. When the control valve is shifted to 1st gear, the 1st-
gear ring gear 74 is locked by the 1st-gear clutch 75. The sun gear 44 drives
the planet pinions 47 to rotate round their own axes, causing the pinions
together with the 1st-gear planet carrier 71 to revolve about the axis of sun
gear 44. Therefore, power is transmitted through the planet carrier to the
output shaft. When the control valve is shifted to the reverse gear, the reverse
planet carrier 46 is locked and there is no planetary motion. The sun gear 44
drives the reverse planet pinions 45 , which in turn drives the reverse ring gear
48 to rotate in opposite direction to that of the sun gear , and the power is
output from the gear set by the reverse ring gear 48.
In the reverse planetary assembly, the friction clutch brakes the reverse carrier
46, and the power is output through the reverse ring gear 48. But in the 1st-
17
 gear, the friction clutch brakes the 1st-gear ring gear, and the power is output
through the 1st-gear planet carrier 71. Therefore, the direction of torque that
output through the two assemblies is opposite. It must point out that when
reverse, 1st-gear friction plate clutch is released, the planet gear and ring gear
is in idle and power is only transmitted by the carrier 71.
(2) The transmission control valve, as shown in fig 3.2-3, includes the pressure
regulator valve, cut-off valve, distributing valve, compensating valve and
pump body.

Fig 3.2-3 Transmission control valve

1. Pressure regulating valve rod 2. Spring 3. Spring 4. Pressure regulating ring
5. Sliding piston 6. Gasket 7. Spring 8. Cut-off valve spool
9. Plunger 10. Air valve rod 11. Air valve body 12. Distributing valve
13. Balls 14. Spring 15. One-way throttle valve 16. Spring
17. Leather cup a. Reverse gear b. Neutral gear c. 1st-gear d. 2nd-gear
Principle of the control valve
①Pressure regulator valve: As shown in fig 3.2-3, the regulator valve 1 is held
in balanced position by spring 2 and the other end of the spring acts on the
sliding piston 5. The piston compresses spring 3 also. Cavity C is the oil line
inlet of the control valve, and it connects with cavity A through an orifice of
rod 1. Cavity B is interlinked with the oil tank and cavity D is interlinked with
the torque converter. After the engine is started, oil from charging pump flows
into the pressure regulator valve 1 through cavity C, and then the oil channel
F, the cut-off valve 8 and the oil channel T to the distributing valve 12. At the
same time oil from cavity C passes through the orifice of valve rod 1 to cavity
A and pushes valve 1 to the right. Thus, the cavity D is opened, a portion of
the oil from the charging pump flows to the torque converter. The oil in
channel T also passes through channel P into the cavity E of the compensating
valve, and the oil pressure acts against the piston 5 pushing it to the left.
When the spring force balances the oil pressure, the pressure is regulated.
When the system oil pressure rises and exceeds the specified value, piston 5
18
 continually move to the left and is restricted by pressure regulating ring 4.
The oil pressure in cavity A is increased, the oil pushes the regulator valve to
the right, When port B is opened, a portion of oil from cavity C returns to the
oil tank and the oil pressure will decrease so that the system pressure
maintains at the specified range. And then, the regulator valve 1 move left
again and port B is closed. Therefore, the pressure regulator valve is able to
regulate the pressure and also act as a safety valve.
②Distributing valve: As shown in fig 3.2-3, the distributing va1ve 12 is held in
position by spring 14 and detent balls 13. The movement of the distributing
valve can engage the 1st-gear, 2nd-gear and reverse gear. The port M, L and J
are connected to the cylinders of the 1st, 2nd and reverse gear respectively,
and port N, K and H are separately connected to oil tank. Cavities U, V and W
are interlinked with oil channel T.
When the distributing valve is shifted to the 1st-gear position, pressure oil
flows from cavity V to port M, and through which oil is directed to the 1st-
gear cylinder and its pressure applies the clutch. At this time, the inlet port L
and J are blocked.
The gear position and the corresponding oil inlets and outlets are list in the
following table:
Gear position Oil inlet Oil outlet
st
1 -gear M N
nd
2 -gear L K
Reverse gear J H
When the distributing valve is shifted to the 2nd-gear, oil in cavity U flows to
port L and actuates the 2nd-gear clutch. At this time, ports M and J are
blocked
When the distributing valve is shifted to the reverse gear, oil from cavity W
flows to port J and its pressure applies the reverse gear c1utch. At this time,
the oil inlets M and L are blocked.
③ The sliding piston: As shown in fig 3.2-3, the sliding piston provides more rapid
and smoother engagement of the friction clutch. At the right side of this
piston, cavity E of the valve is connected to channel T through orifice Y and
also the one-way valve 15, When the distributing valve is shifted to one of the
clutch positions, oil from channel T flows to the connected clutch cylinder. It
is obvious that there is a pressure drop in channel T, and therefore, not only
the oil from the pressure regulating valve flows through channel T into the
cylinder, but also the pressure oil from cavity E supplies to that cylinder
through the one-way valve 15 and channels P and T in sequence. Because of
the combined oil flow, the clutch cylinder is filled quickly and oil pressure in
the cylinder and channel T is increased rapidly. Thus, the compensation piston
serves to accelerate the engaging of the clutch. If the cylinder is continually to
be filled with oi1, the c1utch will be filled with oil and suddenly engaged and
it wil1 result in shock. However, as the oil from cavity E flows to the cylinder,
the pressure at E is reduced so that both piston 5 and the pressure regulator

19
 valve move to the right. When the clutch cylinder is filled sufficiently with
oil, pressure in channel T again rises, causing the oil to be fed back to “E”
through channel P and past orifice Y, at this time. The one-way valve 15 is
blocked. As a result, oil pressure at the passages increase more slowly, and the
engaging of the clutch is smoother, After the engagement of the clutch, the
pressure at channel T and the pressure at cavity E are then balanced, and the
latter is filled again with pressure oil for the next gear shifting process.
3. Power path in the transmission (refer to fig 3.2-2)
2nd-gear or direct gear: When the distributing valve of the transmission control
valve is shifted to the 2nd-gear position, pressure oil from the control valve is
directed to the 2nd gear cylinder 64 via the oil inlet at housing 4 pushing the
direct-gear piston 65 to the left and engaging the clutch plates 68. Since the
direct-gear drive plate 69, direct gear cylinder 64 and intermediate shaft
output gear 57 are connected together with bolts 67 and the pins 56 are fixed
onto the direct-gear drive plate 69. Therefore, the power transmitted from the
2nd turbine drive gear shaft 41 is transferred through sun gear 44, direct-gear
shaft 62, via clutch 68 and pins 56 to the direct-gear drive plate 69. From
here, power is then transmitted through gear 57 to the front output shaft 54 to
achieve a high speed forward drive. The path is: 2nd turbine drive gear shaft 41
→Sun gear 44 → Direct-gear
shaft 62 → Direct-gear friction clutch 68 → Direct-gear drive plate 69 →
Bolt 67 → Direct-gear cylinder 64 → Intermediate shaft output
gear 57 → Output shaft gear 53 → Front output shaft 54
1st-gear: When the distributing valve of the control valve is set to the 1st-gear, pressure
oil flows from the control valve through oil port at housing 4 into cylinder 72
of the 1st-gear, and pushed the 1st-gear piston 73 to the left, to engage the 1 st-
gear clutch 75. As this clutch now holds the ring gear 74 stationary, the power
path is through the sun gear 44, 1 st-gear planet carrier 70 which is bolted to
the carrier 71. Power is thus transmitted to the direct-gear drive plate 69 since
flange 70 and plate 69 are connected by spline. The rotating direction of the
direct gear is the same as the 2nd-gear.
The path is: 2nd turbine drive gear shaft 41 → Sun gear 44 → 1st-gear planet
pinions 47 → 1st-gear planet carrier 71 → Direct-gear connecting
flange 70 → Direct-gear drive plate 69 → Bolt 67 →Direct-gear
cylinder 64 → Intermediate shaft output gear 57 → Output shaft
gear 53 → Front output shaft 54
Reverse gear: When the distributing valve of the transmission control level is set
to the reverse gear position, the pressure oil from the control valve flow,
through the reverse oil port at housing 4 to the reverse gear cylinder pushing
the reverse gear piston 79 to the right, engaging the reverse gear clutch 78.
The engaged clutch locks the reverse planet carrier 46 so that sun gear 44
drives the reverse gear pinions 45 which in turn, drives the reverse ring gear
48 which is attached to the carrier 71 of the 1 st-gear planetary assembly,
power from the reverse ting gear is transmitted to the 1st-gear planet carrier.
The direction of rotation of the 1st-gear planet carrier is reversed, thus,
20
 backward drive is achieved.
The path is: 2nd turbine drive gear shaft 41 → Sun gear 44 → Reverse planet
pinions 45 → Reverse ring gear 48 →1st-gear planet carrier 71
→Direct-gear connecting flange 70 → Direct-gear drive plate 69
→ Bolt 67 →Direct-gear cylinder 64 → Intermediate shaft output
gear 57 → Output shaft gear 53 → Front output shaft 54
3.2.3 Torque converter-transmission hydraulic system
The heat that generates during operation of the torque converter transmission is carried
by force circulating oil and dissipated at the oil cooler. The hydraulic system is shown
in fig 3.2-4.
The charging pump 4 draws the oil from oil sump 1 through strainer 2 and
flexible hose 3, and pumps it to oil filter 6 through a hole being dril1ed in the sump

Fig 3.2-4 Torque converter-transmission hydraulic system

1. Oil sump 2. Oil strainer 3. Hose 4. Charging pump
5. Hose 6. Oil filter 7. Hose 8. Pressure regulator valve
9. Clutch cut-off valve 10. Distributing valve 11. Direct-gear cylinder
12. 1st-gear cylinder 13. Reverse gear cylinder 14. Air valve
15. One-way valve 16. Compensating piston 17. Oil pipe
18. Pressure regulating valve 19. torque converter 20. Hose 21. Oil cooler
22. Hose 23. Back-pressure regulating valve 24. Overdrive clutch a. Air inlet
housing and flexible hose 5, then to the hose 7 and sends it to the transmission control
valve. Oil filter 6 incorporates a by-pass valve which opens at 0.08-0.12MPa. The by-
pass valve opens to allow the oil to by pass the filter when the filter element is
clogged and resistance exceeds the normal pressure range. The pressure oil separates
into two routes when goes out the control valve. Along one route, oil f1ows to the
pressure regulator valve 8 (1.1-1.5MPa), clutch out-off valve 9 and the distributing
valve 10. According to the various positions of the distributing valve 10, oil flows to
21
the 1st, 2nd or reverse gear cylinder through the oil passages D, B or A respectively.
Structure and operating principles of the transmission control valve are detailed in the
section “Structure and operating principles of Transmission” in this manual. Along
the other route, the oil flows to torque converter l9 through pipe 17 in the housing
wall, and then flows to the oil cooler 21 through flexible hose 20 and then returns to
the transmission through flexible hose 22. The coo1ed oil then flow back to port J,
shown in fig. 3.2-3, on the torque converter housing 13 to lubricate the overdrive
clutch and the planetary assemblies and then returns to sump 1. Pressure regu1ator
valve 18 controls the torque converter inlet oil pressure at 0.56MPa, outlet pressure at
0.28-0.45MPa. Back-pressure regulator valve 23 controls the lubrication oil pressure
at 0.1-0.2Mpa, when this value exceeded the valve will open to release the pressure.
3.3 Drive axles
3.3.1 General description
There are one front axle and one rear axle in a wheel loader. The front and the
rear are same except that the spiral angles of their drive spiral bevel gears have
opposite direction: the front one is the left-hand, while the other is right-hand. To
increase the traction force and traveling performance, LW520 equips with two axles
driving.
3.3.2 Structure and principle
The axle consists of the axle housing, drive gear and pinion, differential, shafts,
hub reduction gear set, and wheel assembly, as shown in fig 3.3-1.
The housing of axle, supporting all the loads of the vehicle, is fixed on the
frame. At the same time, the housing of axle is the setting foundation of drive gear
and pinion, differential, the axle shaft and hub reduction gear set.
The main drive, as a speed reducer transmitting the torque and changing the
direction of motion, consists of one single pair of spiral bevel gears.
The differential is composed of two differential side gears, differential pinion
cross, four planetary common bevel gears, left and right halves of the differential
casing. The differential permits left and right wheels to rotate at different speed, and
transmits power from the drive gear to the axle draft.
The axle drafts are full floating, and transmit power to the final drives.
The final drive is sun-and-planet gear. The ring gear is fixed to the wheel
supporting shaft at the end of the axle housing, and the planet carrier is connected to
the wheel hub. Motion of the ax1e shaft is transmitted to the planetary set through the
sun gear, which is mounted on the end of the shaft. The function of this mechanism is
to reduce the rotate speed and increase the output torque, to fit the requirement of
working speed.

22
 Fig 3.1-1 Drive axle
1. Main drive 2. Bolt 3. Vent pipe 4. Stud 5. Axle shaft
6. Disk brake 7. Oil seal 8. Wheel supporting shaft 9. circlip
10. Bearing 11. Dustproof hood 12. Brake disk 13. Wheel hub
14. Tyre 15. Rim ring 16. Check ring 17. Rim nuts
18. planet carrier 19. Ring gear 20. Check ring 21. Planet pinion
22. Shim 23. Planet pinion shaft 24. Ball 25. Needle roller
26. Cover 27. Circlip 28. Sun gear 29. Gasket 30. Round nut
31. Bearing 32. Bolt 33. Plug 34. Rim
Tyre and rim assembly is the main travel part. Model 23.5-25 tyre is used on the
loader. It is of low pressure and wide base type with lower ground pressure, suitable
for cross-country traveling and has good adhesion.
3.4 Transmission shaft
The transmission shaft transmits the power from the transmission to the drive
axles.
The front transmission draft is a reformed version of STYLE Truck transmission
draft and the rear one is a reformed version of DONFENG Truck transmission draft.
3.5 Brake system
3.5.1 General description
The brake system of LW520 loader consists of service brake system and
emergency/parking brake system.
1. Service brake system.
This system is used to control general travel speed and break the vehicle
with air-hydraulic clamp brakes in all four wheels. It provides the advantage
of smooth braking safety reliability, compacted structure, easy maintenance
and the better recuperative character under wet condition.
2. Emergency/parking brake system
This system is used for parking. Sometimes, this system and the service
system may be use together to deal with the emergency.
3.5.2 Structure and principle
The principle of the brake system is shown in fig 3.5.1.

23
 (1) The compressed air produced by the air compressor 1 first flows into
automatic drainage and pressure regulator 2, then into the air tank 3. When
braking, the compressed air flows into air-hydraulic booster 7 through foot
brake valve 6 and presses brake liquid. The piston and plate are pushed
toward the brake disk to brake the disk by the brake fluid.
(2) Emergency/parking brake system should be used when the service brake
system is out of order or when the loader parks.
3.5.3 Principle of main components
1. Automatic drainage and pressure regulator is shown in fig 3.5-2. The function
of this valve is to separate oil, water and other impurity in compressed air
coming from the air compressor. The valve will cool and limit the pressure of
compressed air to protect the air circuit as a safety valve and can be used to
inflate the tyre also.

Fig 3.5-2 Automatic drainage and pressure regulator

Principle: The compressed air from air compressor flows into chamber C
through inlet B, then pass through strainer a and check valve f to the outlet D
and charges into air tank. When the pressure of tank reaches a certain value,
the compressed air in chamber E pushes diaphragm d to open inlet valve e,
the air then flows into chamber F, pushes down the piston f and opens the
24
 lower vent valve g to exhaust the compressed air in chamber C together with
condensed water and impurity in the lower portion of chamber C, through
vent port G into atmosphere. If the pressure is reduced in air tank, the inlet
valve e and vent valve g are closed in turn under the operation of spring. The
pressure regulator continues to charge air into tank.
When inflating tyres, unscrew the cap P and connect an air hose. Piston rod h is
pressed by the hose and blocks the path of outlet and compressed air flows
entirely into the tyre through the center hole in piston rod. If the inflating
pressure exceeds 0.98MPa, the relief valve R will open and air will exhaust
from hole m.
After the loader has been working for 1000 hours, maintenance of the valve
is necessary. Dismantle the nether half, clean the screen a, and then lubricates
the moving surface between piston f and upper portion with proper amount of
grease after cleaning. The entire maintenance is necessary after the loader has
been working for 5000 hours.
Warnings: The pressure control valve is adjusted properly before delivery, further
adjustment is forbidden.
2. Foot brake valve is shown in fig 3.5-3.

Fig 3.5-3 Foot brake valve

1. Air tank 2. Drain valve 3. Front brake chamber
4. Rear brake chamber 5. Push rod 6. Balancing rod
7. Balancing piston 8. vent 9. inlet valve 10. Balancing spring
The function of foot brake valve is to switch of and cut off the compressed air
circuit to the booster.
Principle: When braking, press down push rod 5 which in turn, via balance rod 6
pushes down both balancing piston 7 of the two chambers to close vent
valves 8 and open inlet valve 9. The compressed air from air tank is input
chamber V through valve 9 and flows into front and rear brake chamber
through both vent port respectively. The air pressure of chamber V is to
balance the force that balancing pod exerts the spring a. In balanced condition
the vent valve is closed, the air pressure at vent port corresponds with push
rod force, change the push rod pressure, then the new balanced air pressure
can be obtained at vent port. The value of output air pressure P 2 changes
along with the push rod force F.
25
When releasing brake, the operation process is opposite to braking process. The
compressed air in both vent port is exhausted into atmosphere through vent
valve 8 and bleeding port D respectively.
Warnings: The rubber dustproof hood on the top of brake valve must be kept in
good condition and the inner chamber of brake valve must be cleaned
periodically. Apply proper amount of 1ight lubricant on the surface of piston
to maintain its smooth motion. The rubber drumhead should be kept
complete.
3. Air-hydraulic booster is shown in fig 3.5-4.

Fig 3.5-4 Air-hydraulic booster

1. Screw joint 2. Piston 3. Y-shaped seal ring 4. Felt ring
5. Spring 6. Lock ring 7. Thrust washer 8. Leather ring
9. End cover 10. Filler plug 11. Packing 12. Strainer
13. piston 14. Leather cup 15. Spring 16. Return oil valve
A. Return oil port B. Compensating port
The function of air-hydraulic booster is to convert the air pressure into
hydraulic pressure and enlarge the pressure. The booster consists of air
cylinder and hydraulic master cylinder. When air pressure reaches 0.68-
0.7MPa, the hydraulic pressure is 10MPa.
Principle: When brake is applied, the compressed air pushes piston 2 to overcome
the resistance of spring 5 and move to the right. The piston 2 and push rod
push the piston 13 to right, so a high pressure generates in the hydraulic
master cylinder. The pressure oil opens the small flapper on the return valve
16 and enters brake cylinder to activate the brake.
When the brake is released, the compressed air turns back to the air tank via the
screw joint 1. The piston 2 and 13 return to theirs original position under the
action of spring. The brake liquid in the brake turns back to the booster
through the return oil valve 16. If the brake liquid is too much, it will flow to
the oil-holder via the compensating port B. If the pedal is released too fast,
the brake liquid can not return back to the hydraulic master cylinder in time,
there will be a meiobar in the cylinder. The brake liquid in the oil-holder will
compensate the cylinder via return oil port A and six small holes on the head
of the piston 13 around the leather cup 14 under atmospheric pressure. Thus,
the brake will be more powerful when applying second time.
26
 In order to keep air from immerging the system via the screw joint or leather cup,
return oil valve 16 has a small valve which can keep the pressure of the
hydraulic path when it was closed.
4. Clamp-disk brakeis shown in fig 3.5-5.

Fig 3.5-5 Clamp-disk brake

1. Inner clamp 2. O-ring 3. Dust ring 4. Friction plate 5. Piston
6. Outer clamp 7. Brake disk 8. Pipe connection 9. Air bleeder
The function of clamp-disk brake is to create friction, which brakes the wheels,
between the plates and the brake disk.
Principle: When brake is applied, pressure oil from the booster flows into clamp
and pushes piston 5 carrying friction plates 4 which press on brake disk.
Since the clamp is fixed on the wheel hub, and brake disk rotates with the
hub, the friction force between friction plates and brake disk will stop the
wheel rotation. When the brake is released, the piston 5 returns to its original
position under the action of seal ring 2. When friction plates are worn, the
gap between plates and brake disk is increased; the force of oil overcomes the
friction force between piston and seal ring and moves the piston relatively, so
that the seal ring deformation is resiled to compensate the gap.
The friction plate should be replaced when worn down to the bottom of the
longitudinal grooves.
3.6 Hydraulic system
The main components of the hydraulic system of implement include the
operation pump, distributing valve, arm cylinders, bucket tilting cylinder, oil tank and
oil pipe, etc. The principle of the hydraulic system of implement is shown in fig 3.6-
1.

27
 Fig 3.6-1 Principle diagram of implement hydraulic system
1. Arm cylinder 2. Bucket tilting cylinder 3. Distributing valve
4. Operation pump 5. Coarse filter 6. Oil tank 7. Fine filter
Distributing valve
The distributing valve, as shown in fig 3.6-2, is a single-piece two-spool valve,
consisting of a bucket directional control valve, an arm directional control valve and
a safety valve. Series-parallel internal passages are employed between the two
directional control valves. The function of the valve is to control the moving direction
of the tilting cylinder and the arm cylinder by changing the flow direction of the
hydraulic fluid, or to set the bucket or the arm to a certain position to meet the needs
of various operational movements.
The bucket tilting valve is a three-position valve and is able to control the three
movements of forward tilting, back tilting and hold. The arm directional control valve
is a four-position valve and is able to control the raising, hold, lowering and floating
movements of the arms. The spring 4l in the arm return valve 42 presses the steel
balls 40 towards both ends against the V-shaped groove on the inside wall of detent
sleeve 44. Therefore, it is possible to detain the arm valve stem in any one of the four
working positions. The safety valve controls the pressure of the system and when the
pressure exceeds l7MPa, it opens to allow the oil to return to the tank, protecting the
system from damage. The side opening P of the distributing valve connecting to the
operation pump is the oil inlet. The upper opening (as shown in S-S view in fig 3.6-2)
connecting to the oil tank is the oil return port. Cavities A and B are respectively
connected to the front and rear chambers of the bucket tilting cylinder and cavities C
and D are relatively connected to the upper and lower chambers of the arm cylinders.
The seven oil grooves in the valve casing 14 are symmetrically arranged side to side.
The load relieve oil channel at the neutral position is of a three groove construction,
so that

28
 Fig 3.6-2 Distributing valve
1. Cotter pin 2. Waster 3. Round shouldered pin 4. O-ring 5. Spring seat
7. Retainer ring 9. YX type seal ring 10. Check valve 11. Bolt 12. Nut 13. Washer 14. Valve
casing 15. Bucket tilting spool 16. Arm spool 17. main valve sleeve
18. Main valve spool 19. Main valve spring 20. Pilot valve seat 21. O-ring
22. Pilot valve 23. Spring set 24. O-ring 25. Pilot valve spring 26. Pilot valve case
27. Pressure adjusting screw 28. Nut 29. Washer 30. Locknut 31. Spring seat
32. Return spring 33. Spring seat 34. Positioning seat 35. Tilting return sleeve
36. Seal 37. Shim 38. Washer 39. Detent spring 40. Steel ball 41. Spring
42. Arm return sleeve 43. Spring seat 44. Detent seat 45. Bolt 46. Washer 47. O-ring
48. Screw plug 49. Screw plug 50. O-ring 51. Bolt 52. O-ring 53. Screw plug
56. Sleeve 57. Dustproof ring
hydraulic motivity may be eliminated when changing direction and the oi1 return
resistance is reduced.
Two check valves 10 are mounted on the two ends of the bucket ti1ting slide valve,
and are respectively pressed tightly against the valve seats by spring 39. There is
another check valve mounted on the left end of the arm slide valve l6 and pressed
tightly against the valve seat by a spring. The use of the check valve is to prevent the
pressure oil to flow back to the tank when changing direction, therefore, overcoming
the phenomenon of “nodding” of the working mechanism during operation.
Moreover, the back pressure produced by the returning oil will also stabilize the work
of the system.
(1) The working principle of distributing valve
29
1 Neutral position ( blocked position)
The oil circuit on both the bucket tilting and the arm cylinders are locked and the
latter stop at a certain position. The oil coming from the pump now flows
into the tank through inlet P, then Ⅱ, Ⅲ, Ⅳ and Ⅴ to the return opening and
then through the return piping to the oil tank. The safety valves are shut and
the system makes idle circulations.
2 Bucket back tilting (up turning)
Move the bucket tilting slide valve to the right. The pressure oil flows into the
valve bore from oil channel I in the valve case, pushes open the check valve,
and then flows into oil channel B, which is connected to the rear chamber of
the bucket tilting cylinder. The oil then flows through a pipeline to the rear
chamber of the bucket tilting cylinder, allowing the piston rod to extend and
tilting the bucket backwards.
The return oil coming from the front chamber of the cylinder enters the valve
bore through channel A to open the check valve, and flows into channel W to
return to the oil tank.
3 Bucket forward tilting (down turning)
Move the bucket slide valve to the left. The pressure oi1 flows from the valve
case into oil channel Ⅲ and then the valve bore, and pushes open the check
valve. The oil from the valve bore enters oil channel A which connects to
the front chamber of the bucket tilting cylinder, drawing back the piston rod
to tilt the bucket forward.
The check valve is opened by the returning oil from the cylinder rear chamber
and oil enters the valve bore from channe1 B which connects to the cylinder
rear chamber and flows into the oil return to channel I then turn back to the
oil tank.
4 Arm raising
Move the arm slide valve to the right. The pressure oil goes through channel
Ⅳ in the valve casing to the valve bore, opens the check valve, then enters
channel D which connects to the arm cylinder lower chamber and flows into
it to extend the piston rod and raise the arms.
The returning oil from the arm cylinder upper chamber returns to channel C
in the distributing valve casing, flows through the passage via the center of
the valve spool to the valve bore and then goes back to the tank through
channel Ⅳ.
5 Arm lowering
Move the arm slide valve to the left. The pressure oil enters into the valve
bore and the center passage of the valve spool through the upper channel Ⅴ
then flows out and reaches channel C which connects to the upper chamber
of the arm cylinder. Thus the piston draw back and the arms lower down.
The oil in the cylinder lower chamber passes through the pipeline and
returns to channel D in the distributing valve casing. After entering the valve
bore and opening the check valve, the oil flows into channel Ⅰ through the
valve bore and then returns to the tank.
6 Arm floating
30
 When the arm slide valve is in floating position, the oil from pump flows
back to the oil tank through the neutral unloading groove and channel Ⅵ.
The upper and lower chambers of the arm cylinders connects with the oil
return channel through oil channels C and D respectively, and then the holes
on the valve spool. An unpressurized idle circulation is formed in the
system. The cylinders are in the free floating state caused by the action of
the implement weight and the ground.
(2) Safety valve
The safety valve which regulates the system pressure is incorporated of the
distributing valve as shown in fig 3.6-2. It is a pilot-operated valve consisting
of two parts: the main valve and the pilot valve. The opening and closing of
the main valve is controlled by the pilot valve. When the pressure of the
system is below the compression of spring 25, and not enough to open the
pilot valve 22, the conic valve is closed and no oil flows through the circular
damping orifice a at the center of main valve spool l8, so that the pressures at
both sides of the spool 18 are equal. Under the action of the main valve spring
19 and the differential pressure causing by the differential area between the
left side and the right side of spool 18, the spool keeps standing at the right
position. So the bypass channel between pressure cavity P and return oil
cavity Ⅰin the valve casing is closed.
When the system pressure increases enough to overcome the force of the spring
and open the pilot valve 22, a small portion of pressure oil flows to the return
oil cavity Ⅰ through the damping orifice a. Due to the action of the damping
orifice, a differential pressure creates, and the oil pressure on the right side of
the spool is lower than that on the left. When the force produced by this
differential pressure exceeds the force of spring 19, it pushes the spool to the
left to open the valve, and a large amount of pressure oil flows back to the oil
tank through the by-pass channel H, so that a protection against overload is
obtained. The working pressure of the system at this time should be 17MPa.
When the system pressure is below 17MPa, the pilot valve closes to stop oil
flowing through the orifice a and the differential pressure disappears. The
spool returns to its original position and closes the oil return opening.
The system pressure achieves by adjusting the adjusting screw 27 which changes
the compression of spring 26 with.
Double-action safety valve for front and rear chambers
The double-action safety valves are assemblies of a differential type safety valve
and a check valve, and its structure is shown in fig 3.6-3 and fig 3.6-4.
The valves are bolted on the distributing valve. Their ports A and C connect to
distributing channels for front and rear chamber of bucket tilting cylinder
respectively. Ports B and D connect to oil return channels. They provide overload
protection and oil replenishment effects on the front and rear chambers of the bucket
tilting cylinder. The safety valves are set at 19.5MPa for the rear chamber and l0MPa
for the front chamber. When the pressure in the front chamber of the bucket tilting
cylinder exceeds 10MPa or that in the rear chamber exceeds 19.5MPa during
operation, it overcomes the force of spring, opens sliding spool 7 and oil flows back
31
to the tank. At this time the, check valve 5 is closed under the oil pressure. When the
bucket tilts forward and rapidly dumps the load, because there is not enough time for
the distributing valve to provide enough oil to fill the vacuum formed in the front
chamber, oil in the oil tank opens the check valve 8 under atmospheric pressure and
replenishes the front chamber of the tilting cylinder, thus preventing the phenomenon
of “cavitations” and assuring the normal operation of the system. So that, for cleaning
the material in bucket, the impact between bucket and limit block is allowed.

Fig 3.6-3 Rear chamber double-action safety valve Fig 3.6-4 Front chamber double-action safety valve
1. Screwed cover 2. Pressure adjusting screw 3. Nut 4. Copper washer
5. Spring 6. Valve case 7. Spool 8. Check valve spool 9. Spring
10. To rear chamber of tilting 11. To return circuit 12. To front chamber of tilting
Another function of the double-action safety valve is that when the bucket is
tilted to the extreme forward position and the arms are to be raised, due to the
uncoordinated movement of the working mechanism linkage, the piston rod of the
bucket tilting cylinder will be forced outwards and the pressure of the front chamber
is increased. The front double-action safety valve overflows under overload and the
rear double-action safety valve replenishes oil to the vacuum. On the contrary when
the arms descend with the bucket tilted to its backmost limit, the piston rod retracts,
and the pressure in the rear cavity increases and forms a vacuum in the front chamber.
The oil from the oil tank now forces the check valve of the front double-action safety
valve to open and replenish. Thus, the double-action safety valve solves the
interference of implement, stables the system and safeguards the components.
3.7 Steering system
Full-hydraulic steering is adopted on this machine. Large displacement steering
gear is applied in this system. The principle of the steering system is shown in fig
3.7-1 “Principle diagram of steering system”.

32
 Fig 3.7-1 Principle diagram of steering system
1. Steering cylinder 2. Model FKAR valve 3. Model BZZⅠ-1000A steering gear
4.Gear pump 5. Coarse filter 6. Oil tank 7. Fine filter
3.7.1 Full-hydraulic steering gear (as shown in fig 2.7-2)
Principle: Model BZZ-1000 full-hydraulic steering gear is a cycloidal rotary
valve type steering gear consisting mainly of a servo-valve and a pair of meshed
cycloidal wheels. It features maneuverability, feather touch steering,

Fig 3.7-2 Full-hydraulic steering gear

1. Coupler 2. Rear cover 3. Case 4. Spring 5. Yoke
6. Valve sleeve 7. Spacer disk 8. Connecting axle 9. Rotor
10. Front cover 11. Valve spool 12. Steel ball 13. Stator
reliable operation, compact design, ease in installation and capability of
implementing manual steering when the engine stops. In operation, the steering
wheel is connected to the steering gear through the steering shaft. The steering
gear is mounted together with model FKA valve block which includes a
bidirectional damping valve, an overflow valve and a check valve. The overflow
valve, situated between the inlet port and the return port, limits the maximum
pressure of the steering gear in order to protect the steering system. This valve
33
 assures load-relief when steering cylinders reach their end positions. The
function of the damping valve is to prevent high pressure in the hydraulic system
caused by external shock on the wheels and to protect the hoses and other
mechanisms from damage. The check valve prevents vehicle skewing caused by
high pressure oil passing through the steering gear in the reverse direction when
Overpressure in cylinder side exceeding the pump pressure. It also prevents air
from entering the pump during manual steering.
3.7.2 Steering pump
The steering pump in this machine is Model CBG2080 gear pump. It is a fixed
axle clearance and externally meshed type gear pump of 3-piece construction with
left rotated and single key. The clearance between the end face of the gear and the
side plate is fixed. The radial clearance between the gear circumference and the pump
case is fixed also.

Fig 3.7-3 Steering pump

1. Flat key 2. Retainer ring 3. Seal ring 4. Front cover
5. Seal ring 6. Bearing 7. Cylinder pin 8. O-ring
9. Side plate 10. Pump case 11. Drive gear 12. Retainer ring
13. Seal ring 14. Rear cover 15. Bolt 16. Driven gear
3.7.3 Steering cylinder
The steering cylinders are of single stage, double action and single piston rod
type, as shown in fig 3.7-4. The end of piston rod connects to the rear frame and the
other end to the front frame. The piston rod chamber of the left cylinder connects to
the large chamber of the right steering cylinder via a hose and the large chamber of
the left cylinder connects to the piston chamber of the right steering cylinder. When
steering is applying, the piston moves to-and-for under the oil pressure, which drives
the front and rear frame to rotate relatively.

34
 Fig 3.7-4 Steering cylinder
1. Guide ring 2. Guide sleeve 3. Cylinder body 4. Piston rod 5. Piston
6. Composite seal ring for bores 7. Support ring 8. Knuckle bearing
3.8 Gearchange system
The function of the gearchange system is to control the transmission control
valve, then to change the driving direction and speed of the vehicle.
The gearchange system is composed of shift lever, upper linkage, coupling,
1ower linkage and column, as shown in fig 3.8-1.

1. Gearchange lever 2. upper linkage 3. Coupling

4. Column 5. Lowering linkage
The transmission valve includes four, corresponding to reverse, neutral, 1st-gear
and 2nd gear.
3.9 Implement
The implement of the loader is composed of four main components: the bucket,
lifting arms, draw-bar and rocker arm, as shown in fig 3.9-1.

35
 Fig 3.9-1 The implement mechanism
1. Bucket 2. Draw-bar 3. Rocker arm 4. Lifting arm
5. Seal 6. Sleeve 7. Pin 8. Wearable plank
The lifting arms are supported on the front frame by their rear ends. They form a
Z-bar linkage together with the rocker arm, the draw-bar and the bucket. The lifting
or lowering of this linkage is actuated by the extension or retraction of the lifting
cylinders. In this linkage system, a single rocker arm is used, which is mounted on
the cross beam.
With the lifting arms staying in any position and under the actuation of the
bucket-tilting cylinder via the linkage, the bucket can be rotated forward or backward
around its lower pivot. When the tilting cylinder is locked and the arms are lifted or
descended under the actuation of the lifting cylinders, the angle between the bucket
bottom plane and the ground level can be held in a relatively constant range so that
the material in the bucket will not spill.
The bucket is the equipment to cut, collect, transport and dump material. The
standard (universal) bucket of this loader is for loading materials of density ranging
between l.4 and 2.0 ton/m3 (e.g. sand, gravel, loose soil and etc.). The standard bucket
is equipped with teeth making of highly wear-resistant alloy, which can be replaced
when worn out. The cutting edge of the bucket is also pile-up welded with wear-
resistant alloy.
The pins in all pivots of the implement mechanism are dust-sealed, as shown in
fig 3.9-1, which may extend the service life of the pins and the sleeves. All pins
should be lubricated every 50 work-hours to ensure their normal condition.
The implement mechanism should be inspected for fracture at the welds and
deformation periodically. Repair in time if any abnormality occurs.
3.10 Chassis
The chassis of the loader consists of front frame, rear frame, pivot pin and the
sub-frame, as shown in fig 3.10-1.

36
 Front frame and rear frame are the base of the loader and the support of all the
components. They are connected together by pivot pins. The upper pin is mounted in
knuckle bearing and the lower one, in radial roller thrust bearing. The front and rear
frames can swing relatively within an angle of 38°. The sub-frame is mounted under
the rear frame and is connected to the rear drive axle housing, allowing a vertical
swing of 11°. So the loader may operate on uneven ground with all four wheels on
the ground, assuring good stability. The connection between the sub-frame and the
rear frame is mounted on slide bearings.
The bearings between front and rear frames and those between the sub-frame and
the rear frame should be lubricated every 50 work hours to ensure normal operation.
3. 11 Air conditioning system
Air conditioning system is an optional scheme. It features cab pressure
regulation, air filtering, and cooling or heating air supply. The cooling capacity
ensures that the temperature inside is lower 5 to 7℃than outside in summer; The
heating capacity ensures that the temperature inside is ranging from l5 to 28℃ in
winter. The loader is suitable to operate in the northern and southern parts of China
and in dusty environment. A regulation panel is mounted on the cover of evaporator
behind the driver's seat for adjustment of cooling, heating or ventilation.
Please refer to separate instruction manual of the air conditioner for its
construction and operation principle.
3.12 Electrical and instrument system
3.12.1 General description
The electric system of the loader consists of power supply circuit, starting
circuit, and lighting circuit. All circuits are single-lined with the negative of 24 volts
supply grounded to the chassis of the loader. The principle diagram of the electric
system is shown in fig 3.12-1 and the wiring diagram in fig 3.12-2.

37
 Fig

3.12-1 Electric system principle diagram

The function of the power supply circuit is to provide electric power for the
starting circuit and the lighting circuit. The batteries are charged when the engine is
working on the rails. So the circuit can supply power when the engine is working at a
low speed or when there appears a peak load on the circuit.
The function of the starting circuit is to start the engine through driving the
flywheel of the engine.
3.12.2 Structure and principle
1. Power supply circuit: This circuit consists of the batteries and the power relay.
When starting the engine, turn the key to activate the power relay, the normal open
contact of which closes the battery circuit and power is supplied to all circuits.
2. Starting circuit: This circuit consists of the starter and the starting relay.
The working principle: Insert the key into the preheat start switch JK406 and turn
the key 20° clockwise to position“Ⅰ” before starting the engine. Here electric current
passes through “BR” of JK406 and the coil of the power relay JD231 to the negative
of the batteries. The contact of JD23l is closed by the magnetic force creating by the
coil of JD231. The contact makes that the negative of the two series-connected
batteries closes the circuit via the pole “48” and the contact “47” of the power relay.
When starting the engine, turn the key further clockwise 20° to position Ⅱ of switch
JK406. The contact of JQ1A is closed for the magnetic force which is created by the
circuit that electric current passes through JK406 B to JK408 R 2 then to JQ1A coil to
JD195 to the ground. Thus, the current of starter relay winding passes through wire

38
 solenoidactuatingcoil  starterfield  atarterarmatrue
32-contact of JQ1A-  holdingcoil
 -the ground. The

combined magnetic force of both coils pulls the core which in turn pushes the
coupling via the yoke to engage the drive gear with the flywheel. The other end of the
core pushes at the same time he disk contact Q to close the armature circuit and an
large current passes through thick wire 51 – contact Q – starter field – starter
armature – ground. The starter rotates to drive the crankshaft of the engine.
During starting operation, the holding coil is functioning for normal starting
operation for the solenoid actuation coil is of malfunction for the both ends is under
the same tension while the disk contact Q is closed. With the engine has been
starting, the key on JK406 returns to position Ⅰ, terminal R2 is cut off, relay JQ1A is
not energized and its N. O. contact opens. A portion of the main current passes
through actuating coil - holding coil - ground. Since the winding directions of the two
coils are the same while the currents passing by them are in opposite directions, the
magnetic forces produced cancel each other. The core is demagnetized and returns
instantly to its original position and the starting is accomplished.

A branch of the current at terminal 32 passes through regulator FT221 to coil S1a
then to the ground. The magnetic force created by coil S 1a closes the contact of the
circuit relay that makes the alternator establish its voltage rapidly.
To stop the loader, turn the key in switch JK406 counterclockwise 20° back to
position “0”, the power relay JD231 is not energized. Its N. O. contact opens to cut
off the power supply.
3.12.3 Points to be noticed
1. Storage battery
Two model 6-Q-195 starting batteries, each of rated voltage 12V and capacity
195 ampere-hours are connected in series on the loader. The operating voltage is 24V.
Cautions in the usage of the batteries
39
 ①The connection between the wire terminals and the battery poles should be
tightly secured.
②Keep the battery top clean and dry. Filler plugs should be tightened with their
vent unobstructed.
③Check electrolyte level and density regularly. Fill in distilled water when level
is low. Never fill with sulfuric acid. The electrolyte density should be adjusted
according to local temperature.
④Check the discharge status of the battery regularly. Batteries should not be
discharged for over 50%. Full charge should always be maintained especially
in winter to avoid freezing of the electrolyte owing to reduced density.
⑤The charging current should not exceed 20A during operation.
⑥For stoppage over half a month, the batteries must be fully charged before
storage, and charged monthly during storage with a current of 9A for 6 to 8
hours to prevent damage of the batteries.
2. The starter
The starter used in this loader is model QD214-4 pole, series excitation DC motor,
with rated voltage 24V, maximum output power 6.6kw and maximum torque 58.
8N·m.The starter is equipped with a drive gear meshing organ. The rotation is
clockwise viewed from the driving end.
Cautions in the usage of the starter
1 The operating duration of the starter should not exceed 15 seconds. If the
starter is to be used twice, the time interval between two starting operations
should be more than 1 minutes.
② Never turn the preheat start key again until the engine and the starter stop
completely. Otherwise, shock between flywheel gear ring and the drive gear
may result.
2 When starting in winter, the oil supply cup for preheat should be kept full to
avoid burning of the preheater.
④ Release the preheat- start key immediately after starting. If starting can not
be accomplished after several consecutive attempts, inspect and remedy the
trouble before trying again.
CHAPTER 4 PERIODICAL MAINTENANCE
4.1 General description
Kept technical maintenance strictly will extend the service life of the machine.
Troubles can be located in early stage to reduce down-time and save repair cost.
Please observe the schedule specified in this chapter and carry out inspection and
maintenance accordingly. The schedule may be advanced when operating in adverse
environment and under unfavorable conditions. Lubricating locations are shown in
Fig 4-1.
4.2 Attention-getting items
When applying lubricants, specified type should be used in order to reduce part
wear and extend service life. If restricted by local conditions, substitutes of the
similar.

40
 Fig 4-1 Lubrication diagram of the loader
1. Grease 2. Engine oil 3. Brake fluid
4. Gear oil 5. Hydraulic oil 6. Torque converter oil
The loader should be in a level position when lubricating.
The lubricating tools and the lubricating part should be cleaned when
lubricating.
Lubricating oil in use should be maintained steady for a certain period of time to
deposit and then use the upper portion of clean oil.
The used oil should be drained when changing oil. Fill in with flushing oil and
run the engine and all moving parts for several minutes. Drain the flushing oil after
stopping the engine and fill in with fresh oil and then run the engine for several
minutes, recruit the fresh oil to the stipulate level.
For grease lubrication, apply grease until it is pressed out at the grease cup.
Under extremely low or high temperature, use lubricants according to actual
operating conditions for replacement.
4.3 Periodical maintenance
Periodical maintenance is classified into 50, 200, 600 and 1200 hours intervals.
1. Every 50 hours
(1) Tighten the bolts on the front and rear transmission shafts.
(2) Check the oil content of the brake booster.
(3) Check the oil level of the transmission.
(4) Inspect and lubricate the throttle control, emergency brake and gearchange
system.
(5) Add grease to the grease points on the fan shaft, front and rear vehicle frame
hinges, transmission shafts and sub-frame.
2. Every 200 hours
(1) Check the tightness of the wheel rim bolts and brake disk bolts.
(2) Check the oil level of the front and rear axle.
(3) Clean the air filter.
41
 (4) Clean the engine oil filter, fuel filter and the hydraulic transmission oil filter.
(5) Measure the tyre pressure. The tyre pressure should be 0. 3MPa.
(6) Check the electrolyte level, add electrolyte to the storage batteries and clean
their surfaces. Smear a thin coat of vaseline on the terminals.
(7) Inspect the various load-bearing welds and fixing bolts of the working
mechanism, front and rear vehicle frame and sub-frame for cracks or
looseness.
3. Every 600 hours
(1) Check the cleanliness of the transmission oil. If impurities are found in the oil
change the oil and wash the oil strainer at the same time.
(2) Tighten the connecting bolts that fix the front and rear axle to the frames.
(3) Inspect and adjust the emergency and parking brake.
(4) Inspect the steering gear. Adjust if necessary.
(5) Replace engine oil.
4. Every 1200 hours
(1) Change the front and rear axle gear oil.
(2) Clean the oil strainer and the oil tank bottom of the working mechanism
hydraulic system and change the oil.
(3) Clean and inspect the brake booster. Inspect the conditions of the sealing
elements and springs. Change the brake fluid. prop up the vehicle frame, turn
the wheels and check the sensibility of the brake.
(4) Clean the diesel fuel filter of oil tank.
(5) Inspect the working condition of the torque converter, transmission and steering
gear. If necessary, dismantle and inspect the parts.
(6) Inspect the sealing condition of the distributing valve and the working
mechanism cylinders by checking the sinkage of the working cylinders.
Measure the working pressure of the system, which should be 17MPa. If the
sinkage exceeds the specified amount, dismantle and inspect the cylinders or
the distributing valve.
(7) Inspect the working mechanisms and vehicle frame to see if there are cracks on
the welds. Inspect the tightness of the bolts and nuts on these parts.
(8) Inspect the welds on the wheel rims and condition of load-bearing locations.
CHAPTER 5 PROBABLE MALFUNCTION AND REMEDY
5.1 Transmission system
Serial
Trouble Cause Remedy
number
Ⅰ Gear 1. Low oil level in the 1. Replenish oil to specified oil
shifting transmission oil sump level
pressure of 2. Main oil line leakage 2. Inspect main oil line for leaks
all gears are 3. Transmission oil strainer 3. Wash or replace oil strainer
all low clogged 4. Dismantle to inspect or replace
4. defective oil pump the pump
5. Improper adjustment of the 5. Readjust according to the
pressure regulating valve instruction

42
 6. Weak or broken pressure 6. Replace the spring of the
regulator valve spring regulator valve
7. Jamming of pressure regulator 7. Dismantle to inspect and
valve or piston eliminate the jamming
1. Seal ring for that gear is 1. Replace seal ring
Gear
damaged.
shifting
2. Seal ring on that oil line is 2. Replace seal ring
Ⅱ pressure on
damaged.
a certain
3. Oil passage to that gear is 3. Find the leakage and repair
gear is low
leaking
1.Transmission oil level is too low 1. Replenish oil to specified oil
2.Transmission oil level is too high level.
3.Low gear shifting pressure and 2. Drain oil to specified oil level
Torque
clutch plates slipping 3. Refer to Ⅰand Ⅱ
converter oil
Ⅲ 4.Clogging of the torque converter 4. Clean or replace oil cooler
temperature
oil cooler
is too high
5.Too long continuous operation of 5. Stop vehicle to cool down
the torque converter under
heavy load
Engine runs 1. Gear not engaged 1. Again shift to the desired
at full speed position, or readjust gear
Ⅳ but vehicle 2. Pressure regulator valve spring shifting control lever system
fails to is broken 2. Replace the spring
travel 3. Refer to 1. 2. 3.and 4. of Ⅰ 3. Refer to 1.2.3.and 4. of Ⅰ
1.Gear shifting pressure is low 1. Refer to ⅠandⅡ
2. Refer to Ⅲ
2.Converter oil temperature is too
high 3.Dismantle and inspect the torque
3.Damage of the torque converter converter, replace the impeller
Inadequate
Ⅴ impeller 4. Dismantle and inspect the
drive force
4.Damage of the overdrive clutch overdrive clutch, replace the
damaged parts.
5.Inadequate output power of the 5. Check the engine
engine
Rising of 1. Oil leaks on the steering pump 1. Replace oil seal on the steering
the shaft end. pump shaft end
Ⅵ
transmission 2. Oil leaks on the pump of the 2. replace oil seal on the pump of
oil level implement mechanism the implement mechanism
5.2 Brake system
Serial
Trouble Cause Remedy
number
Ⅰ Inadequate 1. leakage of the cylinder on the 1. Replace the rectangular
force of clamp shaped seal ring
service 2. Presence of air in the brake 2. Bleed the air
brake hydraulic pipeline 3. Inspect the automatic drainage

43
 3. Air pressure is too low and pressure regulator, air
tank and pipeline for leakage
4. Wear of the booster leather cup 4. Replace the leather cup
5. Oil leakage to friction lining 5. Inspect or replace wheel hub
from the wheel hub ring
6. Friction lining worn down to 6. Replace friction lining
the limit
1. Incorrect position of the brake 1. Readjust the position of the
control valve push lever, piston push lever, inspect or replace
rod jammed, valve return the spring of brake valve,
Brake fails
spring ineffective or broken inspect the brake valve piston
Ⅱ to release
rod and drum diaphragm.
properly
2. Booster not working properly 2. Inspect the booster
3. The brake piston of the 3. Inspect or replace the
cylinder unable to return rectangular shaped seal ring
Air tank 1. Brake valve gate jammed by 1. Apply the brake several times
pressure foreign matters or damaged continuously to blow the dirt
decrease away or replace the valve
rapidly after 2. Loose pipe joint or cracking of 2. Tighten the connection or
stopping the the brake fluid pipe replace the brake fluid pipeline
Ⅲ
vehicle(air 3. Leaks on the air tank check 3. Inspect the cause of leakage,
pressure valve or pressure controller replace check valve if necessary
decrease
exceeding
0.1MPa)
1. Loose the pipe joint 1. Tighten the connection
2. Abnormal operation of the 2. Inspect the operation of the
compressor compressor
3. oil draining screw plug on the 3. Tighten the plug
Braking air
oil water is loose 4. Inspect and clean the inside of
pressure
Ⅳ 4. Brake control valve gate or the valve, find out the leak
indication
diaphragm and repair
rises slowly
5. Clogging of the pressure 5. Clean the air vent, inspect the
controller air vent of leakage check valve and drum
of the check valve and drum diaphragm, and repair.
diaphragm
Inadequate 1. The clearance between the 1.Readjust according to
brake force brake drum and friction lining specification
of the is too large 2. Clean the frication lining
Ⅴ
emergency/ 2. The friction lining smeared by
parking oil
brake
5.3 Hydraulic system
Serial Trouble Cause Remedy

44
number
Inadequate 1. Worn cylinder oil seals 1. Replace the oil seals
raising force 2. Serious wear of the 2. Dismantle, inspect and repair
of the arms distributing valve, fitting to achieve the specified
or clearance between valve spool clearance or replace the valve
inadequate and valve case exceed the 3. Check for leakage in line and
bucket specified value repair
tilting force 3. Oil line leakage 4. Replace the operation pump
Ⅰ
4. Serious interior oil leaking of
the operation pump 5. Adjust the working pressure
5. Improper adjustment of the of the system to specified
safety valve, system pressure value
too low 6. Clean the filter and change the
6. Clogged oil suction pipe and oil
oil strainer
Bucket tilting 1. Refer to Ⅰ 1. Refer to Ⅰ
and arm 2. The double-action safety 2. Dismantle and inspect the
lifting are valves are blocked double-action safety valve
Ⅱ slow when
the engine
run at full
speed
5.4 Steering system
Serial
Trouble Cause Remedy
number
1.Slowly steering is
Inadequate oil supply of Check the steering
laborsaving, but fast is
the steering pump pump
strenuous
Purge air in the
Presence of air in steering steering system and
2. Bubbles in oil and
system, inadequate oil in check the suction pipe
irregular noise, cylinders
oil tank , oil viscosity is of steering pump for
move is uncertainty
Ⅰ too high leakage, add specified
strenuous oil to specified level
steering 1.Foreign matters 1.Check strainer for
between spool and seat damage
of safety valve, pressure
3.Steering is lighter at no
cannot be established 2.Clean the foreign
load or low load but heavier
due to untightness matters from the
at heavy load
2.Adjusting crew loosen, spool and the seat
pressure stetting then readjust on the
changed test bench

45
 1.Steering wheel does not
return to central position
where the pressure drop
increase
2.Evident increase in
pressure pulsation, even
the steering wheel cannot
rotate
3. Steering wheel turns itself
or swings left and right
4.Vehicle skewing, or
steering cylinders not
reacting or slow in reacting
to the motion of steering
Ⅱmalfuncti
wheel
on in
steering
5.Steering wheel does not
return to neutral position
itself, increased pressure
drop in neutral position,
steering gear not discharge
when steering wheel stop
turning
Oil leakage from the
copulae of valve body,
1. Damaged seal ring
Ⅲ spacer, stator and rear cover,
2. Foreign matters in the 2. Clean it
others the seams between overflow
valve cover and steering
gear
Spring in steering gear
Replace
broken
Pin broken or deformed,
Replace pin or
notch on connecting shaft
connecting shaft
broken or deformed
Misplacement of rotor
and connecting shaft, Dismantle and replace
return spring broken, the spring and
jamming of valve sleeve, reassemble
spool or body
Defective double-action
safety valve, front and
rear wheels not aligned,
too much difference in air Check the double-
pressure of right and left action safety valve and
tyres, Serious internal relative accessory
leakage in one cylinder, other
defective sealing in the
neutral position of
steering circuit
1.Non-concentric
1.Dismantle, check
assembly of the steering
and reassemble
column and the steering
valve spool
2.Steering shaft rubbing
2.Adjust
against steering valve
spool axially
3.Excessive resistance on
3.Reassemble after
steering column when
grinding
turning
4.Replace spring plates
4.spring plates broken
1. Replace the rings
seams
46
 Chapter 6 Safety Items
Warnings
Please read and get familiar with all the safety items to prevent casualty
accidents.
This section includes safety items of optional equipment and accessories.
Warning Prompt
There are several safety signs on the machine. This section describes safety
signs where they are pasted and hidden perils. Please spend some time to get familiar
with these them.
In order to make sure that you can read all safety signs, replace or clean them
with cloth, soapsuds if the words or graphs on them are not illegible. Detergents,
gasoline, etc should not be used.
If any safety sign is damaged, lost or becomes illegible after cleaning, it is a
must to replace it. If any part with a safety sign is replaced, make sure the new safety
sign is pasted on the corresponding part for replacement.
Warnings before start
Wrong driving and maintenance may cause casualty accidents.
It is required to read carefully the operation manual and relevant safety items
prior to driving and maintenance. All operations shall be as per regulations.
The operation manual shall be accessible for a driver in cab. Please contact the
World dealers for the updated operation manual.
Warnings concerning safe lock lever
Please lower the operation machine down the ground and place the safety lock
buckle (right side of driver seat) on the fixed locking position before leaving the cab
so that accidents resulting in the unconscious misoperation of the control lever can be
prevented when the mechanical control level is not fixed.
Mechanical jerks or driver’s unconscious operations are potential to cause
serious injuries.
Warnings raising in reversing
Before starting the vehicle or the operation machine,
Beep to cause attentions of peoples around.
Confirm that nobody is in the vehicle and around.
Ask help when necessary, especially while reversing.
It is imperative to comply with the requirements above even with reversing horn
and rear reflector.

47
No entry
It is prohibited to enter the vehicle turning scope when operations are in process.
Otherwise it may cause casualty accidents.

Safety items concerning frame lock

While delivering or lifting, the vehicle body may suddenly turn back if the frame
lock is not fixed.
The turn-back may cause people around to be seriously injured or lose life.
It is imperative to use the fixed link of frame lock while the vehicle body is
delivering or lifting.
It is required to use the fixed link of frame lock as required in servicing.

Chapter 7 General Notices of Safety

Safety principle
Only the personnel who have been specially trained and approved can operate
and maintain the machine.
All the safety regulations, preventive measures and instructions should be
observed during operating and maintaining the machine.
48
 When working with the other operators and the people who are in charge of
directing the traffic in the work site, make sure that all the gesture signals are
understood by them.
Safety devices
Make sure that all the hoods and covers are in the right positions and repair the
damaged parts immediately.
Use the safety devices such as safety joysticks correctly.
Disassembly of any safety device is prohibited and the safety devices should
maintain good working conditions.
Safety joystick → refer to “Parking the machine”.
Incorrect operation of any safety device could result in serious personal injuries
or death.
Unauthorized modification
Any modification not authorized by World Group could cause dangers.
Before modification, consult World Group. It will not be responsible for any
injuries or damage caused by any unauthorized modification.
Rules to be followed when maintaining and repairing machine
Contact the machine only when all the parts are shut down completely

Prevention of crush or cut injury

Do not insert your hands, arms or other parts of the body into or between the
moving parts such as between the attachment and the oil cylinder or the bodywork
and the attachment etc. When the machine is working, the gap between the moving
parts could be changed, which may cause serious damage or injuries.

Precautions for accessories

You should read relevant contents about the accessories in the User Manual and
this manual before
installing or using the optional accessories.
49
 Do not use the accessories not approved by World Group, otherwise it may
cause safety problems and affect normal operation and service life of the machine.
World Group would not be responsible for any injury, accident or mechanical
failure caused by using unapproved accessories.

Chapter 8 Operating Precautions

Before starting engine
Check if there is any abnormal condition around that may cause hazards
before starting the vehicle.
Check the landform and the soil texture to choose the best working method.
If working on a road, there must be someone in charge of directing traffic.
And the roadPadding blocks should be placed in order to ensure the safety of traffic
and pedestrians.
If working in a place where underground facilities, such as water pipes, gas
pipelines, high voltage cables etc. are laid, the relevant company in charge should be
contacted in order to avoid any damage.
If working in water or through a sandy dike, the ground quality, water depth and
flow rate should be inspected.
Make sure not to exceed the permitted water depth
In operator cab
Never place any tool or spare part in the operator cab randomly as they could
damage joysticks or switches. They should always be kept in the tool box in the
vehicle at any time.
Keep no oil, grease and other dirt on the floor, pedal and handrail in the operator
cab.
In operating machine
While start
Walk around the vehicle prior to getting up the vehicle and check that there are
50
not anybody and other obstacles.
Do not start the engine if it is found that a warning mark is hanged on the control
lever.
It is allowed to start the engine only after the driver sits well.
Do not let anyone enter the cab and other places of the vehicle except for the
driver.
For the vehicle equipped with the reverse warning buzzer, make sure that the
buzzer can work normally.
Inspections in reversing
Before operating the machine or equipment, it is required to carry out the
follows:
Beep to cause attentions of peoples around.
Confirm that nobody is around the vehicle, especially in the rear area.
Ask someone check that everything is ok when necessary, especially while the
vehicle drives reversely.
Ask someone direct the traffic on site if the vehicle drives in the dangerous area
or the field of vision is very tough.

Safety inspection
Check and ensure the frame lock is in the neutral position before driving or
operating the vehicle.
Notices in travelling
The bucket shall be on height of 40-50 cm off from the ground when it travels in
the level road.
The loader shall travel at low speed and keep stable in turning while travelling in
the rough road.
Do not turn suddenly.
The steering wheel cannot work if the engine stops in travelling, which is very
dangerous, requiring a sudden brake to stop the loader.
Precautions during operating
Do not get too close to the edge of a cliff edge.
When building up a dam or shoving soil, or pouring down soil near a cliff, first
pour down one stack and then push the first one with the second one.
Do not bump a tip lorry or the side of a dug canal with the bucket.
The load would be reduced suddenly when the loaded stuff are pushed off a cliff
or when the vehicle arrives at the top of a slope. In this condition the speed would be
increased suddenly so it must be decelerated.
51
 Do not load windward to prevent dust.
Ensure there is none in the working area when loading the tip lorry. Reduce
surge as much as possible.
Ensuring a clear vision
When working in dark, the working and roof lights should be installed and the
illumination facility should be established in the working site if necessary.
Stop working when the vision is poor, such as foggy, snowy or rainy days. Do
not work until the weather gets better to ensure safe working.
Be careful to operate in snow
When performing construction on the road covered with snow or ice, only a
little slope could cause the vehicle in the danger of slipping to the edge. Therefore,
drive slowly to avoid starting, turning or braking suddenly.
Specially be careful when shoving snow on a road as the road shoulder and other
things buried in snow can not be seen.
Tire chains should be installed when traveling on the road covered with snow.
Do not brake suddenly and lower down the bucket to the ground before stopping
when traveling on the hillside covered with snow.
The loading work varies greatly with different kinds of snow. Therefore the load
should be reduced and try not let the vehicle slide. Do not crash the attachment
Be especially careful to work in the place with limited height, such as in a
tunnel, under a bridge or cable, or in a garage. Do not crash the attachment.
Do not crash the attachment
Be especially careful to work in the place with limited height, such as in a
tunnel, under a bridge or cable, or in a garage. Do not crash the attachment.
Breaking ,methods
Do not step foot on the brake pedal unless it is necessary.
Do not repeat breaking unless it is necessary.
Brake with the engine (the gearbox cannot be placed in the neutral position) and
always step on the brake pedal when traveling downhill.
Working on soft ground
Do not work in the places close to a cliff, crag and trench. If they collapse, you
and the vehicle will fall down or overturn, resulting in a series of injuries and death.
Remember the carrying capacity of these places would be decreased after storms.
The soil nearby a trench is relatively loose and could collapse due to the weight
and vibration of the vehicle.
The fallen object protection system (FOPS) should be installed when working in
the places with fallen gravels or other small objects.
Working in the dangerous places with fallen stones or possibility of vehicle
overturning danger is forbidden.
Vehicle parking
Park the vehicle on flat ground if all possible. If you have to park it on a slope,
the wheels should be secured with wood blocks to prevent it from sliding.
When parking on a road, be careful with other vehicles, banners and guardrails.
Do not obstruct the traffic.
Ensure the passing vehicles and pedestrians could see the skid-steer loader
52
clearly with the guardrails, signs, banners, lights and other necessary symbols.
The attachment should be lowered down to the ground completely and the safety
joystick should be in the locked position. Then stop the engine and lock all the
devices with a security lock.
Shipping
When shipping the loader with a trailer, follow the regulations on the lengths,
widths and heights of goods in each country and region and comply with all
applicable laws.
The lengths, widths and heights of goods should be considered when determining
shipping routes.

Chapter 9 Precautions for maintenance

Working under vehicle
Before maintaining the vehicle or performing service under it, place all the
movable attachments on
the ground or to their lowest positions.
Must secure the tires with blocks.
Never work under a vehicle not securely supported.

53
Rotating fans and belts
Do not get close to the rotating parts and be careful not to get hung by other
articles.
If your body or any tool contacts the blades of fan, they may be cut off or flied.
Therefore, do not
contact any rotating part.

Precautions when machine is travelling or stopping

Keep certain distance when machine is travelling, othewise it might cause
accidents.

When the loader stops, don’t stay under the boom and bucket.

54
Operating when chassis is lifted
When operating with the chassis lifted, lock the front and rear frames with the
frame locks and place the joystick in the middle position. Then lock the joystick with
the safety lock and lock out the attachment and chassis.
When lifting the vehicle with a jack, fill up the wheels on the other side with
wooden blocks. Place blocks to fix the position after the vehicle is blocked.
Maintaining tires
It requires special tools and techniques to remove, repair and install the tires. Please go to the specified
service stations for repairing.

Chapter 10 Safety Items in Operating Wheel Loader

1.General notices of safety

1.1 Before using the wheel loader, operator or relevant personnel shall read the
instruction carefully and do what it stipulated. Otherwise major injury or unnecessary
damage will be caused.

1.1.1 Only the personnel who have been specially trained and approved can operate
and maintain the machine.

1.1.2 All the safety regulations, preventive measures and instructions should be
observed during operating and maintaining the machine.

1.2 Operator shall dress conform to the safety requirements, wearing necessary
protection equipment.

1.2.1 Avoid dressing loose clothes and wearing jewelries. Do not have long loose
hairs as they could be snagged by the joysticks and moving parts, causing
serious personal injuries and death.

55
1.2.2 Don’t wear clothes with oil stain, in case to cause fire.

1.2.3 Wear helmets, safety goggles, masks or gloves as well as safety shoes during
operating and maintaining the machine, in order to prevent the splashed metal
chips or other tiny particles from injuring you.

1.3 When working in a small or dangerous area, the warning sign is necessary.

1.4 Working after the operator got drunk or overwrought is absolutely prohibited.

1.5 If the operator who don’t fell well or take some medicine might causing sleep
can’t operate the wheel loader.

1.6 When maintaining or inspecting in the articulation area,”anti-rotation rod” has to

be installed, in order to prevent injury because of the rotaion of front and rear
frame.

1.7 Up and down wheel loader in stairs when it’s stable. Don’t jump down the wheel
loader when it’s travelling.

1.8 Don’t grab any operating rob when up and down wheel loader.

1.9 When refilling and inspecting the fuel or coolant, shuting down the engine first
and prohibit smoking. Make sure the cover of fuel tank is closed. And the fuel
and engine oil have to be put in some place which can’t be accessed without
permission, in order to make sure its safety.

1.10 If the boom has to be lifted when maintaining, it has to be make the lifted boom
stable and make sure it won’t fall down during maintaining.

1.11 The machine can’t be modified without permission. If it’s needed, then
confirmed with relevant department of our company. It will not be responsible
for any injuries and damage caused by any unauthorized modification.

1.12 When working with the other operators and the people who are in charge of
directing the traffic in the working site, make sure that all the gesture signals are
undersood by them.

1.13 When the operator left the cabin, the door and windows have to be locked. In
order to cause the personal injury around the machine because of wrong
operation by other people.

1.14 The working devices should be lowered all the way down to the ground when
left the wheel loader. Then the engine should be shut down and all the devices
should be locked.

56
1.15 When maintaining and repairing machine, all the parts have to be shut down
completely.

1.16 The key should always be with the operator. The engine should be shut down
and the key shall be pulled out before maintenance and repairing.

1.17 Before removing the cover of radiator, the engine should be shut down and let
the radiator cool down; after slowly loosening the cover and releasing the high
pressure gas inside, it can be removed in order not to cause any injury.

1.18 The hydraulic liquid might spray out when removing the cover of hydraulic
tank. Slowly loosen the cover to release the pressure first before removing it.

1.19 Do not insert your hands, arms or other parts of the body into or between the
moving parts such as between the attachment and the oil cylinder or the
bodywork and the attachment etc. When the machine is working, the gap
between the moving parts could be changed, which may cause serious damage
or injuries.

1.20 When working in the site with asbestos dust, shall wear protecive masks and
work back to the wind direction in order not to cause any health problem.

1.21 The machine has to equip an effective fire extinguisher, and know how to use it
when there is a fire.

1.22 When maintaining and repairing the loader, please change the spare parts and oil
strictly according to the instruction book and spare parts catalogue. Otherwise
our company is not responsible for any safety problem occurred due to that.

2. Precautions before starting the engine

2.1 Check if there is any abnormal condition around that may cause hazards before
starting the vehicle.

2.1.1 Inspect to make sure when starting the engine, no one is under the wheel loader
or near its working site, in order not to injure other people.

2.1.2 If working on a road, there must be someone in charge of directing traffic. And
the road padding blocks should be placed in order to ensure the safety of traffic
and pedestrians.

2.1.3 If working in a place where underground facilities, such as water pipes, gas
pipelines, high voltage cables etc. are laid, the relevant company in charge
should be contacted in order to avoid any damage.

57
2.1.4 If working in water or through a sandy dike, the ground quality, water depth and
flow rate should be inspected. Make sure not to exceed the permitted water
depth.

2.2 Preventing fire

2.1.1 Completely remove the wood chips, scrap of paper and other flammables on the
engine box, which may cause fire.

2.2.2 Check if there is any leak in the fuel, lubricant and hydraulic system. Fix all
leaks and get rid of all excess oil or flammable liquid.

2.2.3 Do not operate the vehicle near any flame.

2.3 Never place any tool or spare part in the operator cab randomly as they could
damage or break the joysticks or switches. They should always be kept in the
tool box in the vehicle at any time.

2.4 Inspect to make sure all the lamps are normal. Especially the turning and braking
lamps.

2.5 Before starting the engine, the joystick has to be in neutral position.

2.6 Before starting the engine, the brake lever has to be in stopping position.

2.7 It is allowed to start the engine only after the driver sits well.

2.8 Do not start then engine if it’s found that a warning mark is hanged on the control
lever.

2.9 Do not let anyone enter the driving line of the vehicle.

2.10 It’s better starting the engine in places with good ventilation. If inside of the
room, put the exhuasting passage outside of the room, because too much engine
emission might cause people to death.

3. Precautions after starting the engine and working

3.1 Before traveling, clean the blocks on the road, especially the iron block and
ditches, to prevent breaking the tire.

3.2 Adjust the rear mirror, and make sure the operator has the best vision.

3.3 Make sure the horn, reversing sign lamp, buzzer and other safety devices are in
normal condition.

58
3.4 When it’s about to travel or inspecting the flexibility of turning, you should press
the horn first and then warn the surrounding people about safety.

3.5, Inspect the joystick, pedal and steering wheel before traveling. Make sure they
are all in normal condition and then start to work. Especially inspect the turning
and braking system.

3.6 Make sure no one is near the wheel loader, especially in the reversing area. If
working in a poor vision site and dangerous area, there should be someone
guiding the operation.

3.7 Overloaded working is prohibited. Because it might cause personal injury or

machine damage.

3.8 Travel in slow speed when the loader is heavy loading and dischaging. Do not
turning or braking suddenly, in order to prevent overturning, and cause personal
injury and property loss.

3.9 When traveling in ramp, keep the bucket close to(about 200mm-300mm off from)
the ground. It is required to quickly lower the bucket down to the ground at
emergency, stopping the loader or preventing it from turning over.

3.10 Do not turn in ramp or traverse the ramp. It’s allowable to carry out there
operations in the level ground.

3.11 Do not travel up and down in the grass, places with fallen leaves, or wet steel
plate where it is easy to make the vehicle skid. The vehicle shall travel at very
low speed along the slope edge.

3.12 The driver shall depress the brake and lower the bucket down in case the engine
halts in ramp. Then use the parking brake. When the vehicle is travelling with
loading, travel forward uphill and reverse downhill.

3.13 Avoid the tires slide when working and just two wheels on the ground, in order
to reduce the abrasion and damage of the spare parts.

3.14 Do not get too close to the edge of a cliff edge.

3.15 Stop working when the vision is poor, such as foggy, snowy or rainy days. Do
not work until the weather gets better to ensure safe working. Tire chains should
be installed when traveling on the road covered with snow.

3.16 When working in dark, the working and roof lights should be installed and the
illumination facility should be established in the working site if necessary.

59
3.17 Be especially careful to work in the place with limited height, such as in a
tunnel, under a bridge or cable, or in a garage. Do not crash the attachment.

3.18 When dragging, no one is allowed to enter into the area between towing vehicle
and the vehicle to be towed when they are connected. Keep safe distance
between people and machine to prevent accident because of the damage of
towing device.

4. Vehicle parking

4.1 Park the vehicle on flat ground without danger of failing and slide, at the same
time, low the device down to the ground completely. If you have to park it on a
slope, the wheels should be secured with wood blocks to prevent it from sliding.
After the engine shut down, it’s necessary to pull the control handle of the work
device to ensure that various of hydraulic cylinder in the state of no pressure.
When the vehicle on a slope, the tires should be placed well to prevent them
from sliding.

4.2 Put the shifting lever and working operation lever and other levers in the neutral
position.

4.3 Take away the key of frame lock and then shut down the master switch, finally
close the windows and doors.

4.4 Never stop near flame and high temperature places in case of explosion and
accident.

4.5 Make sure no person stand in the front of tires when inflating the tire by gas
storage tank, in case of explosion and damage.

5. Precaution in the Process of Maintenance

5.1 Park the vehicle on hard and flat ground, and shut down the engine before
checking and performing maintenance. Make the brake system on the state of
brake, gearbox and work manipulation in neutral position, shut down frame lock
and the vehicle’s doors.

5.1.1 Control levers and switches in the cab can not be operated randomly, they are
only can be used by professional person and trained person in case of hurting
people around the machine.

5.1.2 In the process of maintenance, warning signboard should be placed around the
vehicles in order to tell other people not to operate the machine to ensure the
safety.

60
5.1.3 Only the professional personnel are permitted to maintain and repair the
vehicle.

5.1.4 If someoneelse starts the engine or operates the joystick when you are
maintaining or lubricating the vehicle, it may cause your injury or death..

5.2 Person who perform maintenance work should extremely be careful and do not
touch any moving parts like air fan, leather belt and transmission shaft.

5.3 Use tools that are proper to do the work. It is harmful to use broken, poor quality,
defective or temporarily substituted tools.

5.4 Before maintaining the vehicle or performing service under it, place all the
movable attachments on the ground or to their lowest positions and must secure
the tires with blocks in case of damage.

5.5 When inspecting or maintaining the vehicle with the attachment raised, reliably
uphold the raised moving arm so as to prevent the attachment from falling down.
Furthermore, place the attachment joystick in the middle position and lock it
with the safety lock in case of any damage.

5.6 Precautions for handling high pressure hose, do not forget there is pressure in the
oil pipe all the time, before releasing the internal pressure, do not perform
maintenance and checking in case of injury or damage. Do not use any high
pressure pipes and rubbers in case of causing oil leakage, it may bring injury and
damage.

5.7 When repairing the electrical system or using welding, you should disconnect the
negative pole of storage battery to cut off the power.

5.8 Must check the machine before and after working everyday in order to ensure the
safety of working.

5.8.1 Check whether working lamps and indicators are broken and check whether the
electrical, gas and oil line are getting old and broken.

5.8.2 Check whether the dust in air filter of engine is effecting the air inlet.

5.8.3 Check whether the connection bolts are loose or falling off.

5.8.4 Check whether pins and connection bolts are loose.

5.8.5 Check the tire’s pressure, the tires need to be charged to the specified
pressure( front wheel:0.30-0.32MPa, rear-wheel: 0.28-0.30MPa). Check whether
the bolts in tires are loose.

61
5.8.6 Check whether there is the situation of leakage of oil, water, electricity and gas.

5.8.7 Check the cooling water volume, oil amount in the engine sump,breaking oil
amount. When checking the water volume and oil amount, you should stop the
engine, and check or refill them when the engine and cooler are cooling down.

5.8.8 Refill the grease to nozzles.

5.8.9 Check the situation of break pad and check whether they are need to be
changed.

5.8.10 When disassembling or installing the storage battery: check the positive and
negative poles, tighten the cover of storage battery reliably, when
disconnecting it, the negative or ground pole should be removed first.

5.8.11 Avoid the metal devices connecting with battery poles, in order not to cause
short-circuit.

5.8.12 At the moment when the vehicle stops, the cooling water in the engine and the
oil in every part are all at high temperature and with high pressure. Under this
condition, if the covers are removed to check the machine or exchange some
parts, it may bring some injury and damage. So you should wait for them
cooling down before performing check and maintenance.

5.9 When repairing the frame parts and using welding, you should emphasis on
fireproofing.

5.10 Keep the vehicle clean and tidy all the time. Oil or grease overflow can be
dangerous, so as scattered tools or broken parts because they may trip you down
or injure you.

5.11 It requires special tools and techniques to remove, repair and install the tires.
Please go to the specified service station for repairing.
5.12 Do not pour down waste oil into drainages or rivers. Make sure put the discharged
oil into a vessel, never just pour down on the ground in case of any injury or
damage.
6. Operating when machine is lifting and transporting
6.1 When the machine is lifting, engine should be shut down first, place the joystick
and hand brake system in the middle position, and then lock the front and rear
frame using the shutoff rod.
6.2 When lifting the vehicle with a machine, fill up the wheels on the other side with
wood blocks, place blocks to fix the position after the vehicle is blocked.

62