Operation Manual

Wheel Loader

CAEL
 Preface
Thanks for selecting and purchasing our product. Before using the
product, please read the operation manual carefully. The manual will help
you to operate the products correctly. It shows the products’ performance,
technical parameter, the use and the maintenance of the products, and the
matters needed attention. Thanks for your trust and support!
 Contents
Chapter 1 Use, Performance, and Cautions 1
Chapter 2 The Technical Performance and Parameters 2
2.1 Machine Performance and Parameters 2
2.2 The Hydraulic System 3
Chapter 3 The Security and Warning Sign 4
Chapter 4 Inspect and Adjust 5
4.1 The Engine: Please see diesel manual 5
4.2 Clutch 5
4.3 Triangle Belt Loose And Tight Adjustment 5
4.4, Transmission Shaft 6
4.5 Drive Axle 6
4.6 The Braking System 6
4.7 The Hydraulic System. 7
Chapter 5 Electrical Equipment 9
5.1 The Battery 9
5.2 Alternator and Regulator 10
5.3 The Electric Starter 10
5.4 Other: 10
Chapter 6 Driving Operation 12
6.1 Operate Mechanism and Appliance Arrangement Schematic Drawing 12
6.2 A New Loader Commissioning 13
6.3 Empty Commissioning 13
6.4 Operating Test 13
6.5 Driving Operation 14
Chapter 7 Technical Maintenance 16
7.1 Oil and Lubrication Notes 16
7.2 The Type of Loader oil 16
7.3 Lubricates 17
7.4 Routine Maintenance 18
7.5 Regular Maintenance 18
7.6 Technical Maintenance of Each quarter. 19
Chapter 8 General and the Reasons for Failure Analysis 20
Chapter 9 Replacement Parts List 24
Chapter 10 Notes 25
1.Users Notice 25
2. Safe Driving Matters Needing Attention 25
Chapter 11 Some of Classic Operation for Loader 26
Chapter 1 Use, Performance, and Cautions

ZL912 wheel loader is a kind of wheel loader with single bucket ,articulated and hydraulic
unloading. It has been developed and designed in accordance with user requirements, reference
models after absorption of domestic and similar structural features and advanced technology. The
machine has been widely used in construction and field building.

ZL912 wheel loader has the following characteristics:

1, Single-arm Z-reversal structure, to achieve the max breakout force;
2. Use of articulated frame, small ,mobile and flexible turning radius .
3, The branded engine, front + rear axle drive, and robust power.
4, Improved hydraulic filtration system to ensure reliable circuit operation;
5, Rear diesel engine, hydraulic steering, simple and flexible operation
The machine is reasonable in design, compact in structure, flexible in manipulation, and easy to
maintenance.
It is widely used in the construction, municipal engineering, urban and rural gardens, lime, sand,
cement factories, mines and other enterprises and institutions and departments, in particular, apply
to the narrow space for the loading operation of sand and construction machinery (mixer sand
machine, mixer) . The main components of the loader are used brand-name manufacturer’s
products, interchangeability of good, reliable, well-resourced parts.

Warning!
1. The driver shall be specially trained and read the operation manual before operation.
2. New machine shall be operated without loads before working in fields .
3. Check engine oil level. Fill in diesel oil, engine oil, hydraulic oil and lubricate the joints.
4. To avoid damage coupling & other transmission parts, it is prohibited to start at high speed gear.
5. High speed or neutral gear driving shall be prohibited during going-down of slope.
6. In the cold-weather area, when the machine is not used, cooling water shall be drained out of
water tank, so as to avoid freezing and cracking.

The specifications may alter at any time due to continuous improvement of the design and
requirements of different users.

1
Chapter 2 The Technical Performance and Parameters

2.1 Machine Performance and Parameters

Model ZL912
Rated Load 1200 kg
2.2 Operating Mass 3700 kg
Bucket Capacity 1 m3
The Bucket Width 1800 mm
Overall Performance
Dumping Height 3200 mm
Dumping Reach 900 mm
Max. Grade Ability 30%
Max. Breakout Force 40 KN
Wheelbase 2300 mm
Tread 1390 mm
Dimensions Mini Turning Radius 3500 mm
Mini. Ground Clearance 270 mm
Overall Size (LxWxH) 6150 x1850 x 2800 mm
Brand YUNNEI
Model YN27
Rated Power /Speed 42 kW /2400 r/min
Engine Equipped Max.Torque 140 N.m
Bore x Stroke 90mm x105 mm
Displacement 2.7 L
Type 4-Cylinder,In-line,Naturally-aspired,Water-cooled
Torque Converter YJ265
Gearbox Type Counter-shaft , Power-shift
Transmission Gear Shift 2F+2R
& Drive System Max. Travel Speed 35 km/h
Drive Model 4 x4
Axle Isuzu Reduction Axle
Displacement of Work Pump 50 mL/r
Hydraulic System Displacement of Walk Pump 18 mL/r
Working Pressure 16 MPa
Service Brake Oil Brake
Brake&Tyre Parking Brake Drum-type Shoe Brake
Tyre Size 20.5/70-16
Hydraulic System

Model CBFC50
Gear pump
2
 Rated pressure（MPa） 16
Nominal Displacement 50 ml/r
Speed 2500 r/min
Model ZL15.2
Rated pressure (MPa) 16
Multi-way valve
Rated flow (L/min) 63
Max flow (L/min) 80

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Chapter 3 The Security and Warning Sign

Despite numerous security precautions, there are still some potential danger. Necessary security
warning signs shall be pasted on the machine as follows:

Figure 1 security caution label

Figure 2. reversing warning label

Figure 3 security caution label

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Chapter 4 Inspect and Adjust

All components of the loader have been tested and adjusted to the best condition before delivery. It
is unnecessary for the operator to make adjustment. Only after a period of working time, some of
the components shall be appropriately adjusted by the methods as follows:

4.1 The engine: Please see Diesel Manual

4.2 Clutch:

1. Adjustment of Free Stroke of Clutch Pedal

To ensure the clutch no slipping during power transmission, 25-30 mm free stroke for clutch pedal
shall keep between disengaging bearing and disengaging lever. During operations, the gap between
disengaging lever and its bearing decreases gradually and even vanish. Therefore, the pedal’s free
stroke shall be checked and adjusted periodically.
The adjustment of free stroke is achieved by the alteration of the length of clutch pull rod.
Lengthen the pull rod and the free stroke of pedal reduce; Shorten the pull rod and the free stroke
increases.
2. Adjustment of the position of Clutch Disengaging Lever
The lower edges of 3 pieces release lever and the disengaging bearing shall be contacted with each
other during operation. The gap of them shall not be over 0.15 mm. It can be adjusted by
fasten/unfasten the screws.
Disengage swiftly and contact smoothly when operating clutch. Smash is prohibited when joining
clutch.
4.3 Triangle Belt Loose and Tight Adjustment
1, Generator Belt's Adjustment (Figure 4)

The generator belt's adjustment is changed generator's position to realize, Loosens lock nut which is
on the generator adjusting yoke, Changes generator's position on the Scaffold , the loose and tight of
the belt is moderate, then tight the lock nut.
Figure 4

, t

4.4 Transmission Shaft

The loader has four universal joints, compatible with those of BJ130 automobile. There is an inject
nipple on the cross axle. It should be added with lubricating grease once every 150 working hours

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When assembling or disassembling the transmission shaft, the relative position of the two edge of
flange cross shall be well noted, and kept in same surface. Any time shall attentions on tightness of
the bolts on the two edge contact flange of the transmission shaft.

4.5 Drive Axle

Contact area of drive gear and driven gear shall in accordance with criteria. Therefore, it can be
used for long-term and without adjusted. Adjustment is required only when replacement of
defective parts or moving wear and tear parts.
Pay attention to the following items when adjusting:
(1) Drive gear's bearing clearance: It is obtained by adjusting the thickness of drive gear inner
bearing race's mat. No gap on shaft-direction and free rotation is required after adjustment.
(2) Clearance of tooth side of Drive gear and driven gear: measures the clearance around radius
45mm of drive gear’s flange plate, its displacement (arc length) should between 0.2-0.6mm. Inspect
contact face with tintage method, trace shall be not less than tooth depth and tooth length by 40%,
and is in slight intendancy to small edge. The joggle clearance and contact face are rectified by
adjusted by the thickness of the race's mat and the adjustment nut of the two side trigger differential
carrier.
(3) After driving for 100 hours every time, check driving axle oil level. The correct oil level is not
less than oil filler lower level 10mm, when necessary, it should be added, After driving for 300
hours , the gear oil should be replaced. This loader should apply No. 18th hyperbolic curve gear oil.
(4) After driving for 100 hours every time, please replace shell bearing grease by one time. adjust
bearing preload until a suitable degree.

4.6 The Braking System:

The machine uses BJ130 hydraulic brake system with 160mm brake pedal full stroke and 8-10mm
free stroke. Check when the brake pedal is too low.
(1) Whether pipeline oil leak.
(2) Whether the gap between the shoe and drum is oversized or not.
(3) Whether there is air in pipeline or not.
After working for 200 hours every time, inspect the brake shoe attrition. When shoe wear down to
the oversize of pedal travel, adjust the gap between the shoe and drum, the method is as follows:
(1) Prop up the wheels which need to be adjusted.
(2) Find the eccentric bolt in the back of brake shield plate, rotate the eccentric bolt until the shoe
contact the drum, then, relax the eccentric bolt until wheel freely rotate and the shoe and the drum
no longer rubbed.
Drain the air out of the brake pipes and cylinders when replace brake fluid and fill in new brake
fluid in case no oil in storage pot. Its method is as follows:

(a) Step on the brake pedal continuously several times, loosen the bleeder valve, drain the air out of
pipe, tighten up the air valve, and then loosen the brake pedal. Repeat several times until there is no
air in the oil tubes.
(b) During air deflation, please supplement brake liquid continuously with the lowering of oil
storage tank level. No oil in storage tank is prohibited. Replenish the brake liquid after all air are
drained out. The loader shall use No. 912 brake oil.
Brake pedal’s free stroke is adjusted by the push rod of master brake cylinder.

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4.7 The Hydraulic System (Details see Figure 5)

Hydraulic System is composed by the gear pumps, .multi-way valve, privilege valve, dumping
cylinder, steering cylinder, fuel tank and oil pipes.
Pressure oil flows from the gear pump to hydraulic cylinder through the manipulation of relative
slide-valve of multi-way valve. When device does not work, the oil flows back to the oil tank
through the middle oil pipe of multi-way valve.
Hydraulic system's use and maintenance should pay attention to the following several points:
1st, the oil in fuel tank must pass through strict filters, not only check and clean oil filter frequently,
but also maintains the normal level.
2nd, Normally please replace the oil when the working time accumulates about 1200 hours. For
interrupted use, replace the oil about a half year or one year every time according to specific
conditions.
3rd, when hydraulic system start, please drain away air and prevent the air to enter the hydraulic
system again.
4th, do not allow to adjust hydraulic system's working pressure at will.
5th, During the hydraulic system steady work, pay attention to the working condition and sound of
hydraulic system various parts, so that prompt trouble clearing.

7
 Figure 5
1,hydraulic tank 2. filter net 3.gear pump 4. privilege valve 5.unloading cylinder
6 lifting cylinder 7. Multi-way valve 8. steering cylinder 9. commutator 10. cooler

8
Chapter 5 Electrical Equipment

ZL-20 type loader’s electrical system use voltage of 24 AC volts, negative earth system. Its
electrical schematic diagram see Figure 6.
5.1 The Battery

Accumulator model is 2pcs 6-QA-80 .Its function is to supply electricity to starting motor when
start-up the engine. When the engine is in normal working, if the generator voltage is lower than the
battery voltage, it supply electricity to electrical appliances; if generator voltage is higher than the
battery voltage, then the generator discharge the circuit to the battery to store electrical energy .

Figure 6.

Attentions in Work.
1. Keep in charging state. Charge once per month at least in case of no use for long time.

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2. Check regularly the electrolyte liquid level. The liquid level should be 10-15 mm higher than the
pole plate, and supplement distilled water in case of insufficiency. When certain electrolyte leaks or
sprinkles, should add the electrolytes with proportion of1.28.
3. Check the battery vent plug regularly. Remove the external soil and dirt, clean the spilled
electrolyte, and electrodes should be coated with thin layer of calcium-based grease to prevent
corrosion.
4. Battery should be fastened against vibration damaged.

5.2 Alternator and Regulator

1. Alternator:
Alternator has two wire connecting pole marked “+” and " F ". They shall be connected
respectively with the same marked connecting pole on rectification regulator.

Alternator both ends fixed with bolts on the alternator bracket; another alternator bolster feet,
adjust the belt triangle for the elasticity degree.
2. Relay Regulator
Relay regulator is composed by the circuit-intercepting device, voltage regulator, circuit limiter.
Relay Regulator has two wire connecting poles marked "+"," F " and “-“ ground bolt. "+"," F"
terminal should be connected with the same superscript marked terminal on the alternator .
Battery "+" terminal connect with Ampere meter "-" terminal. The Ampere meter "+" terminal
should connect with electric locking first gear.

In case abnormal work of regulator found or after 1000 working hours, the skilled electrician is
needed to make the adjustment.

5.3 The Electric Starter

Its application is to supply power from the battery to start the engine. The rotation of starter’s gears
is driven by the electromagnetic drive and with a unidirectional roller clutch, to prevent the starter’s
armature to be damaged after starting engine at revolving high speed.
The use time of the starter shall not surpass 15 seconds continuously. Two starting time interval is
not less 45 seconds. In case several failure in starting, please check out the reason.

5.4 Others
1. The Ampere Meter
The Ampere meter display for current charge and discharge. when charge current to the battery
from the alternator , the bias indicates to "+"; contrariwise the bias indicates to "-". when no current
the bias indicates to "0"

2.Electricity Lock

The electricity locks control entire electrical system. After the key insertion locking hole, turn one
gear toward right, and all electric appliance's power source connection; Turn two gear toward right,
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the generator starts. Loosen the electric lock at once and the key return automatic to first gear
position, so as to protect starting motor.
3, the vehicles equipped with headlights, front and back turn signal lights, front and back fog lights
and driving light，the specification of the lights as follow：
Item Description Quantity Specification
1 headlights 1 12V 55W
2 front and back turn signal lights 4
3 fog lights 4 12V 10W
4 driving light 2 12V 5/10W

Chapter 6 Driving Operation

Before driving and operating, the driver should be familiar with the structure, technical
maintenance, operation methods and so on, in order to ensure safe driving and operation, extend the
life of loader and productivity.
During driving and operating, should pay attention to the following safety matters:
1.The driver must learn traffic rules, the mechanical structure, methods of operation, and read the
operating instruction carefully.
2. When traveling, no place is permitted for personnel riding except the cabin
3. Alert at any time by the reaction of the appearance about the work of departments.
4. During operation, people is prohibited to moving under bucket.
5. When switch off the engine, stop and park the loader to prevent accidents caused by steering
failure.

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6.1 Operate Mechanism and Appliance Arrangement Schematic Drawing (Figure 7)

Figure 7

6.2 A New Loader Commissioning

1.To use the new loader, commissioning must be carried out. Any new loader without
commissioning shall not be used on formal working.
2.Commissioning of machines can run the friction parts, to avoid breakdowns and ensure reliable
steady work.
3.This provision also applies to overhauled loader.
4.The commissioning of new loader includes 2 steps, namely, empty commissioning and operating
test.

6.3 Empty Commissioning (about 8h)

1. Methods

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(1) By the method of starting the diesel engine, after the initial start-up with idling low speed
working about 5min (not put into gear ), then gradually speed up to the highest speed for 10mins.
(2)Control the tipping rod, to make the bucket roll-over and withdraw. The time goes about 10
minutes.
(3) Put the forward gear, then reverse gear, empty run. At first low-speed ,then high-speed, uniform
arrangement of each running.
2.Inspection Items
(1) Overall check various bolt, nut tight situation. Especially the cylinder cover bolts. , Exhaust
pipes bolts , front and rear drive axle fixed bolts, ring rim nuts, transmission shaft bolts.
(2) Inspect gear box's oil level.
(3) check whether the parts of engine, gearbox and driven axle have abnormal voice.
(4) check whether the hydraulic systems, gearbox, engine lubrication systems, braking systems,
engine cooling system leak oil or water .
(5) All instrument readings are normal or not.
(6) Steering flexible or not, braking sensitive and reliable or not.
(7)During working, devices is jammed or not . (8) Inspect electrical work.
6.4 Operating Test (about 20 h)

1. Operate according to the operation method, and gradually increase of the quantity of feeds.
2. During operation test, not only to check the empty commissioning projects, but also observe
loading capacity with different materials.
3. During running-in, load capacity shall not surpass 70% of the rated load, the driving speed shall
not surpass 70% of the maximum speed.

6.5 Driving Operation

(A) Caution:
1. The diesel added must be pure, diesel labeling requirements should be consistent with quality
requirements.
2. The hydraulic oil used in the hydraulic system of work devices must be clean.
3. Make regular maintenance and lubrication as per regulation
4. Keep the engine at idle rotation after started. Start running when the water temperature reached
55 ℃
5. When the bucket reaches the required location, the control handle should be put in the middle
position
6. It is prohibited to transport material while the bucket reach the highest position. Delivery of
materials should be kept the bottom of bucket with ground clearance of 300 mm in order to
maintain the stability of traveling.

B）Drive with Empty Load

1. Starting
Carry out pre-trip inspection to confirm that all the parts are normal , then start the engine. Before
starting , all the joystick should be placed in the neutral position ,then insert the key to the electric
switch and rotate one position clockwise, connect power, tread the accelerator, and then start the
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engine. In case of low temperature in winter, the cooling water should be released, and add some
hot water or boiling water to start. During start-up, should observe the oil press of engine,
adaptively control throttle to prevent the bush-burning of engine.
One start-up time costs 5-15S. If it can’t be stared over time, it should be stopped until a minute
after starting for the second time. If engine can not be started for more than three times , should
check the reasons and start again.
2. Start with the drive
After starting, the engine should be warmed up at speed of middle gear and pay close attention to
the direction of oil pressure gauge. At the same time, check whether diesel engines and other
systems are all normal. All the parts are right, then rise bucket to the transport position. First put
lever at forward gear, slowly treads the accelerator pedal, you can travel loader now, and then
choose a suitable gear to drive according to the circumstance of roads and your work.
3. Parking and off
Run idle for 2-3 minutes before the stop of engine, so as to make all the parts cool. In winter, after
parking, duly screw the release valve of engine, drain out all the water in cooling system to prevent
the frost crack of parts . When the water temperature to -20 ℃ -30 ℃, the battery should be
removed, and put in the warm room so as to avoid frost crack.
In addition, withdraw the bucket of loader onto ground and shut off the electricity before parking.
(C) Operations to manipulate
Operating control is related to operation proficiency of the driver. Drivers of different proficiency
have different operating practices. Grasp voluntarily in the operating practice, improves and sum up
operating procedure unceasingly, raises the production efficiency and machine's life.
Before operation ,should clear the ground and fill the pits, eradicate the hard stone to prevent
damage of tires .
1.Loading operation
① When go forward to the piled material with Ⅰgear, the ground clearance of the hinged point under
the moving arm should be about 250 mm, Bucket bottom should be parallel with the ground
② At 1-1.5m away from the piled material , lay down the moving arm to adjust the bucket so that
the blade of bucket can touch ground. The bucket bottom and ground angle at 3-7 º then shovel the
material piled.
③Steps on the accelerator to cause the bucket be close to the material pile, continuously operate the
bucket and move the arm until full load.
④After fully loading, the shovel upturn and the moving arm lift to the suitable altitude, then lets the
control handle of moving arm return to the middle position.
⑤Loosens the accelerator, causes the engine to reduce the speed, hangs up reverse gears, slowly
increase the accelerator, the loader withdraws from the material pile.
⑥ Drive to the dump place, or transport vehicles. If the ground too soft, without preparation of soil,
can not assist with truck or the transport distance is about 500m , and the loader need drive to the
dump place, the bucket must lift to the transport position, in order to ensure transportation safety.
2nd, loading operation
Scoop the sandy soil, rock, ore to loads the truck, the freight vehicle, container.
3rd, Preparation of soil operation
Use the angle between the scoop tip and the bottom, may scatters the earth, smoothly, lay ground
and so on.
The preparation of soil work ensure the vehicles backlash to carry on by all means must. when carry
on do march forward in the preparation of soil work situation, please maintain scoop's front rake for
0-10°.
4th, Bulldozes operations
Earth-moving scraper will be used as a bucket, you can achieve the bulldozing operation. At this
point in bucket filled with sand to maintain the level of the ground state of operation.

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5th, Hauling operations
inserts the traction rope in the rear part hauling ear , may realize hauling work.

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 Chapter 7 Technical Maintenance

The operating work environment of dumper are more worse, often operation on bumpy road
construction site, the part are vulnerable by strong vibration or impact, will cause machine parts
loose or damaged, in order to ensure the dumper is in good performance, the normal operation,
extend service life, not only be familiar with the various parts structure of the machine, but also
required regular inspect the technical state of machinery and technical maintenance seriously. In
addition to this chapter introduces many the technology maintenance of parts except the engine,
engine maintenance please refer the engine instruction.

7.1 Oil and lubrication Notes

1. Add fuel, hydraulic oil, lubricating oil and grease, should clean the inject oil tools, container and
oil scrub to prevent water, mud, debris into the oil being.
2. Add variety of oils, it is important to make the machine in a horizontal position. Besides attaches
the oil level indicating device to be possible to carry on the observation, up to generally overflows
by the oil plug. The gear box oil dipstick on the covers of gear box.
3. When add lubricating oil, should put out the dirty oil , inject the clear wash oil to the right oil
level, in the empty load situation, make the engine to work several minutes, then stopping work,
puts out the wash oil , then inject clean oil, if the oil is too viscosity, may heat up slightly
beforehand too greatly or dilutes, then inject.
4. Under the different working conditions, should use the different viscosity, the trademark oil,
please strictly carry on according to Table 8-1.

7.2 The type of loader oil (see table 8 - 1 shown)

Item model
Fuel tank Summer (10 ℃ above) No. 0 diesel, in winter (10 ℃ below) No.
10 diesel.
Oil Pan Summer (10℃ above) CC40, winter CC30 diesel engine
lubricating oil
transmission gear box, 18 # hyperbola gear oil
drive axle bridge
hydraulic oil container Winter No.46, Summer No.68 anti-wear hydraulic oil
(International oil)
Various grease nipple Combination calcium base lubricating oil

Brake oil plus "912" synthetic brake fluid

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7.3 Lubricates

The correct lubrication can reduce machine's friction and the components attrition greatly, thus
lengthens machine's life. when lubricate please note the fore-mentioned oil used instruction, the
lubricating oil please select according to the Table 8-1.
Engine's lubrication please base on the engine instruction booklet stipulate to carries on.

Pre-and back – Twin bridge filling-up area Transmission shaft lubrication filling-up area

Brake oil area Hydraulic oil area

Latter swings lubrication filling-up area Front transmission shaft: lubrication area

Hinge lubrication points filling-up area Hydraulic pump lubrication filling-up area

7.4 Routine Maintenance

The routine maintenance carries on each class of work , it is very important to avoid to the
minimum accidents in normal work. The routine maintenance's prime task is as follow:
1. Pre and after operation of the machine, outside parts of the machine should keep clean.
2. Check whether the loosening of fasteners or missing, and filled and tightened.
3. Check whether the mechanical parts damage or not.
4. Check whether increase full of lubricating oil for each lubricating part.

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5. Inspection of all fuel tanks (fuel tank, working fuel tanks, brake pot), oil level must be up to the
mustard .
6. Check the engine cooling water is adequate.
7. Check the electrical system to see if any loose on wire connections and battery power is
adequate.
8. Check appearance , light is complete, good.
9. Check whether the manipulation flexible and reliable or not.
10. After starting ,check oil leakage, water leakage, and abnormal noises.
11. Test the reliability of the braking, steering is flexible or not.

7.5 Regular Maintenance

(A)The technical maintenance of each week (about 50h after work)

besides routine maintenance project, but also needs to carry on as follows.
1. Inspect whether the brake pedal's traveling schedule does meet the requirement, if not , should
adjust to tally.
2. Fasten the front and rear drive shaft connecting bolts, drive axle connecting bolt, nut tire.
3. Inspect the battery to a single cell level within the height and the proportion of electro-hydraulic
(15℃ when proportion is 1.24-1.27), if insufficiency , add the distilled water and charge current.
4. Inject the calcium-based grease to the nozzles
(B) The technical maintenance of each month (after about 200h)
In addition to daily, weekly technical maintenance, but also to add the following items:
1. Survey tire pressure. Tire's standard inflation pressure is 0.3Mpa. if insufficient should fill.
2. Clean the filter of fuel, hydraulic oil. 3. Check the brake system whether there is oil leak or
damage.
4. Inspect and fasten wheel bolts, brake disc and the bearing cap bolts.

7.6 Technical Maintenance of Each Quarter (after about 600h).

1. Inspects the multi-way valve, each kind of cylinder's leak situation, if has causes the work
equipment drop phenomenon seriously, should be repaired and elimination.
2. Inspect whether there is a damage on the brake total pump leather cup.
3.Adjust the bush bearing gap, and make the outside ending beat brake disc is smaller than 0.20mm
(C) technical maintenance every six months (after about 1200h)
In addition to daily, weekly, monthly, quarterly technical maintenance of the project, but also added
the following items:
1. Replace all the fuel and oil circuit system, hydraulic system oil, gearbox, the front and rear bridge
and the brake oil, gear oil. And clean pipes, tube, filter, etc., and then pour into the new oil after
purification.
2.Take apart and wash brake master cylinder, check the braking effect.

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3. Inspect front and back the bridge, the main transmission gear meshing, the victims, the driven
bevel gear of the gear gap is too large, should be adjusted to within 0.2-0.34mm.
4.The work installment and rack, whether there is distort, the welded joint break or not..

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 Chapter 8 General and Reasons for Failure Analysis

ITEM Fault Phenomenon Cause Analysis Trouble solving

First, the engine See Diesel Manual
1.Footboard free stroke too
1.Adjust
small
2. The pressure spring weak 2.Replace pressure it
1．joint slips 3. There is greasy dirt on the
3.Clean
friction piece surface
4. Friction wear and tear
4.Replace it
excessive
1.Replace the clutch
1.The spline wear excessive
shaft or axis
Second, clutch 2. The bolts fastening
2.Wrap fastens
2．when joint Loosening
trembles 3. There is fat on rubbing
3.Clean
surface
4. The separation lever to
4.Adjust
adjust inequality
1. Footboard free stroke
1.Adjust
3. the coupling is not oversized
easy to separate 2.The separation lever to adjust
2.Adjust
inequality
1.The gear attrition exceeds the
time limit, tooth's lateral 1.Replace it
clearance oversized
2. Bearing attrition to exceed
2.Replace it
the time limit
1.noise of sound 3.The bolts fastening
3.Wrap fasten
Loosening
4.The lubricating oil
4.Added
Third, insufficient
transmission 5.Gear and the axis spline
5.Replace gear or shaft
gearbox wears excessive
1. Dials the fork axis retaining
1.Replace it
spring weak or no effect
2.jump profile 2．Dial the fork axis located
2.Replace it
frequently. groove exceed wearing
3. Internal and external spline
3.Replace axis or gear
wear and tear
3．Shift is not
1. Gear-side touch hair 1.Replace it
flexible
1. The main reduction gear
1．Noise when 1.Adjust or replace it
4.driving bridge meshing point bad
driving
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 2. Bearing wear exceeds or
2.Adjust or replace it
loose
3. Gear attrition to exceed 3.Replace it
1. Brake boot plate curving 1.Repair or replace
2. Brake friction burr rivet
2．Noise when brake 2.Repair
loose
3.Brake drum damage 3.Repair or replace
1. There is oil on Brake shoe
1.Clean
surface
3. Deviation of vehicle
braking 2．Gap adjustment improper 2.Adjust
3. Sub-standard tire pressure 3.Adjust
1. Brake drum brake shoe and
Adjusts
gap improper adjustment
4.brake is not flexible 2．Greasy dirt 2.Clean
3．Brake friction burr wear to
3.Replace
exceed.
1. the steering wheel
1.Readjust shunt valve,
idle run light, the 1.Oil supply inadequate
priority valve
quick extension sinks
Fifth, steering 2.Readjust priority
2. Turned weak 2.Working Oil pressure low
system valve, overflow valve
3. the rotation steering
3.The air is in the system or the 3.Deaerate or makes up
wheel cylinder is
oil mass is insufficient the oil charge
motionless
1.Adjust the presses
1. Pressure relief valve adjust rating according to the
improper, system pressure low system working
pressure
2. Oil suction pipe and the oil
2.Clean or replace
filter pluged
1.Lifing arm or 3.Replace oil pump, and
dumper force according to normal
3. Gear pump, cylinder, pipe
insufficiency subsidence quantity
internal leakage
checkout system
Six, Brake System leak-proof
,Hydraulic System
4．Multi-way valve wear and
tear excessive, stem and valve 4.Replace multitandem
clearance should exceed the valve
prescribed
1. Working oil deterioration 1. Replace.
2. Cleaning oil duct
2. the operating 2. Pipe blockage
system and fuel tank
system performance
3. Oil filter jamed or damaged 3. Clean or replace
fall or unstable
4.Inspect the oil system
4.there is air in the system
to leak air

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 1.Takes apart to repair
1. Moves arm cylinder internal
the cylinder, replace
3. after lifting the arm, leakage
seal packing collar
sinks voluntarily
2. Multitandem valve lever gap 2.Take apart to repair or
oversized to replace
1.Load operating time 1. Stop or reduce the
the oil temperature is excessively long load.
excessively high 2.Refuel to stipulation
2. Oil mass insufficient
oil level
1. In the diverter returns to the 1.Take apart to repair or
position reed to damage replace
5. after the steering 2．Match between the oil
wheel returns to the jacket and the oil or fuel
position, continues to distribution axis the 2.Disassemble the
change deactivation or matches diverter to repair
between the oil jacket and the
valve chest deactivation
1. Brake to divide pump oil
1. Replace
leak
2.there is air in Brake hydraulic
2. Deaerate
circuit
3.Brake the total pump leather
3.Replace
6．the foot braking cup to damage
force is insufficient 4.Brake total oil pumping fluid
4．Refuel
insufficient
5．Push stroke adjustment 5.Adjust traveling
Improper schedule
6. Brake friction piece wears
6.Replace
limit
1.Desulphurization
1. Battery plate vulcanize processing, or replace
1. the engine is pole plate
normal, but the 2. Generator belt too loose or
2. Adjusts or replaces
accumulator cell does damaged
not charge or the 3. Inspect and
3.Wiring is not strong, bad
charging rate is low Elimination
4. Regulator improperly
4.Adjusts or repairs
adjusted or damaged
Seven electrical
systems 1.To re-adjust the
1. The Electrolyte proportion or
proportion or adding
liquid level excessively low
electrolyte
2.Elimination of
2. the capacity of 2. Pole plate short-circuit sediment, replacing
storage battery is electrolyte
insufficient 3.Desulfurization
3. Pole plate vulcanize process or replace the
plate
4. Wire connection is bad 4. Inspect and
Elimination
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 5. Pole plate active material 5.Replacement pole
Shedding plate
1, according to the
1. Remanence disappears original polarity
generators, batteries
2, connected to both
2. The magnetic field coil
ends of the magnetic
circuit fault
field coil,
3. the generator does
3, Use No. 0 or No. 00
not generate electricity 3. Commutator bad contact
sandpaper or polishing
4. amend the brush size,
4. Not flexible brush jammed adjust the spring
pressure
5. Armature turn-to-turn short 5. Inspects and repairs
circuit

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 Chapter 9 Replacement Parts List

Loader replacement parts list as follow：

No. Item Installs Position Fitting specification

Driving axle driving bevel gear
47x84x9.5
Oil seal Flange connection
Driving axle ring shell SD115x140x14

Single-row radial
Clutch release bearing barrel 688991
Thrust ball bearing

Clutch B1372
Triangle belt
Hydraulic pump B1000

Diesel filter net

Hydraulic filter net

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 Chapter 10 Notes
1.Users notice

1st, user notice

1, the user when buys machine, must receive the instruction booklet, the certificate, three packages
of certificates.
2, the operator before operating this aircraft, must read the instruction for use in detail, should carry
on the operation, the debugging and the maintenance according to the instruction booklet in request.
3rd, This hydraulic system of the loader does not permit to adjust the pressure at will.
2nd, Safe Driving Matters Needing Attention

1st The driver must pass the specialized training, otherwise are not allowed to operate
2nd Prohibits driving after drinking alcohol strictly, when operation the attention must concentrate,
does not permit to eating , smoking, chatting when driving.
Second, safe driving Attention
3rd, before driving, connected electricity and inspects each kind of signal, the flare, the measuring
appliance and the instrument light complete good and working steady; Then inspection oil, the
water, the electricity circuit route, the drivers, steering drive axle, the load bearing system
components completely complete, only then starting engine.
4th.When operating, don’t put your foot on the pedal switch board constantly, so as not to
accidentally step on the switch, causing accident.
5th, when loading, the bucket, under the arm to refuse to staying, the stowage not to permit the
imbalance, the overload, forbids the bucket to overhigh the delivers position to move with high
speed, refuses the extreme turning, in the travel to refuse the personnel to jumps down, when curve
must decelerate.
6th , unloading material, does not permit the material center of gravity imbalance, also beside does
not allow the bulk material to stretch out the vehicle to help.
7th, In winter starting engine refuses to baking the engine. by fire. After starting, the engine must
the idle operation for 5~10 minutes, when the water temperature, the oil temperature rise the rating,
only then to working

Chapter 11 Some of Classic Operation for Loader

First: The loader operator was tight heel arrived in the cab floor when the loader are working, feet
and the accelerator pedal to maintain the parallel, playful underground fuel pedal pressure.

Second: loader in operation, keep the throttle stabilize all the time. As the general operation of
state, the throttle opening around 70% is appropriate.

Third: When the loader are working, the driver's foot should separate with the brake pedal, and
keep the foot on the cab floor, prohibit step on the brake pedal all the time. The loader frequently
works in uneven work site, if the foot always steps on the brake pedal, the loader body always up
and down moves will cause driver happen to step on the brake pedal. In normal circumstances, must

25
use control the situation by which the accelerator decelerates and to shift gears. In this way, to avoid
frequent braking system caused by overheating, but also for the speed loader quick.

Four: When car loader work, specially when the shovel digs the work, should in the accelerator
stable situation, move with the circulation lifts fights control handle's method with the extension to
cause the scoop shovel full material. Lifted fights with the extension operates bar's circulation to
move is said “industrious”. This process is important, This process was very important for the oil
consumption.

Five: Uses when the car loader must make scoop's raising to be very good with the turn over
coordination. The normal process of the loader bucket digs :
1, the bucket keep flat in the ground, drives to the material to pile steadily. When the bucket parallel
shovels the material piles and encounter fierce resistance ( hits an obstruction) , it should be follow
the principle as: first raises the arm, then turn the bucket . This may avoid that the bucket base hit
the obstruction effectively, and show the max breakout force of the loader.
Six :
1, Prohibit to make the loader's tire to slip. In the loader operation, if hits the encounter fierce
resistance, and step the acceleration pedal continuously, it will be occur the tires skidding
phenomenon. This phenomenon is usually caused by incorrect operation due to the driver, so that it
will be caused more fuel consumption and further damage the tire.
2, Prohibit to make the loader's rear tyre tilt, due to the rise of the loader force, when the driver
operates the loader, such as bucket the raw soil and stone material mountain, if the operation is not
correct ,it is easily to present two trailing wheels to turn upwards the lift-off the phenomenon. This
tilt movements landing inertia will cause bucket blade plate fracture, bucket deformation;
When the rear tyre turns upwards very high, it is easy to cause the front and rear frame
isostructuralism welding place dehiscence, even plate break and so on.
3. Prohibit to make the loader's. The bucket digs the ordinary material, the loader may work with II
gear, Prohibit to impact to the material with II gear orientation to bucket the materials. The correct
method , turn to I gear when the bucket approach the material, and go on finishing completes
process

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