Omm LW300KN

Foreword
This manual mainly offers you some problems occurring when normal operating and maintenance to
the loader, also proposes some effective suggestions to solve these problems, which can help you make use
of the machine safely and effectively. Before operation, reading and comprehending the manual is a must.
Should often keep the manual nearby the machine for the personnel operating the loader to consult and
read. If the manual is lost or made dirty unable to read, please get in touch with us (XCMG Construction
Machinery Co., Ltd., that爷s XCMG) or our distributors appointed. If the machine is sold, please give this
manual attached with the machine to the new user.
This manual includes the following contents: safety, use and main technical performance
specifications, operation and maintenance, common trouble shootings. Because of continue improvement in
design and different requirements of customer to dispose of the machine, the contents, norms, diagrams and
other contents in this manual may be altered at any time, while these alteration will influence the
maintenance to the machine. So you should master the intact newest documents about the machine before
operating. To get the latest information of the machine or answers of any inquiry to the manual, please
consult us (XCMG) or our distributors appointed.
As you know, we can not predict every working environment being with danger, some warnings in the
manual and on the product may be not mentioned. Other situations influencing safety operation may be
reflected by means of the safety symbols on the machine, insurance requirement and local regulations
stipulated in province or local place. If we do not offer you special recommendation about a certain tool,
procedure, working method or operating technology, you should pay more attention to safety of yourself or
others when operating. Because we can爷t t work with you to control directly running, operation, check,
lubricating and maintenance to the machine, so you must take some effective measures for your safety.
As for the detail information to other machine key components, please see the relative manuals
respectively.
Warning Signs for Safety Precautions
This safety warning sign show you the very important information about the safety! When
you see the sign in this manual, please read the item beside the sign and obey with the
item strictly, and inform it to other people. Ignorance to safety warning can cause serious
injuries and casualties.
LW300KN 英文操保手册 1
CONTENTS
1. Operation
1.1 The Use of the New Loader 1-01
1.2 Application Purpose of the Machine 1-02
1.3 Component Names and Decals 1-03

1.4 Safety Signs and Theirs Position 1-06
1.5 Instruments and Controls 1-08
1.6 Operation Regulations 1-11

1.7 Working Method 1-29
1.8 Oil and Water Supplying 1-35
2. Lubrication, Maintenance and Repair

2.1 General Principle of Maintenance 2-01
2.2 Lubricating the Machine 2-03
2.3 Maintaining to the Machine 2-10
2.4 Lubrication and Maintenance 2-18

2.5 Structural Principle and Maintenance Precautions 2-29
2.6 Trouble Shootings 2-43
2.7 Replacement of the Key Parts 2-48
3. Transportation , Storage and Protection

3.1 Safe Transportation 3-01
3.2 Storage and Protection 3-04
4. Technical Specifications
4.1 Technical Specifications 4-01
4.2 Overall Dimensions 4-04
Operation
1.1 The Use of the New Loader
1.1 The Use of the New Loader

1.1.1 Notices
This machine has already been checked and adjusted completely before selling. However, if it works under
the atrocious environment at the beginning the service life of the machine may be shortened obviously. So
it is necessary to carry out a run-in to the machine at the first 50 operating hours and pay attention to
maintaining service.
Please obey with the following regulations during the run-in period:
荫 After starting the loader, idle the machine for 5 minutes to get it warmed up.
荫 It is forbidden to accelerate the engine suddenly during pre-warming up process.
荫 Avoid of emergent driving, sudden turnaround and unnecessary emergent braking.
荫 Check and repair the machine according to regulations.
1.1.2 Study the Safety Items

荫 Study the loader manual and concerned documents, understand them completely.
荫 Be familiar with all operating levers, indicating meters and alarming devices.
荫 Identify warning signs and safety signs, which can remind you the dangerous conditions.
荫 Obey with and take good care of all the safety signs that are pasted on the machine, replace the
defaced one and replenish the lost one.
1.1.3 Learn the Checking Method

荫 Many safety and protecting devices are installed on the machine, such as seat belt, lamp, protecting
fence, ladder and extinguisher and so on, ensure them under the controllable condition.
荫 Check if tyres are wore out or damaged or not. Check if all tyre air pressures are normal or not. Don爷t
operate the loader if some tyre air pressure are insufficient.
荫 If the lock bar of steering pin is installed, please keep it in ready condition. The locked machine can爷t
be turned.
1.1.4 Be Familiar With Your Machine

荫 Be familiar with functions of every controlling device, meter and pedal. Clear grease out from operating
levers, pedals and handles to avoid of sliding.
荫 Clear sundries out from the cab, and keep the cab ground clear.
荫 Don爷t leave any thing that you must take with you.
1.1.5 Running-In of the Machine

荫 Although the loader has been checked and adjusted, but if it is used in a bad operating environment at
the beginning, the service life of it should be shortened. Please apply running-in operation for 50 hours
at initial stage.
荫 After starting, idle the machine for 5 minutes.
荫 It is forbidden to accelerate the engine suddenly during warming up process.
1-01
1.2 Application Purpose of the Machine
荫 Avoid of sudden startup, sudden accelerating and steering and sudden braking, except in emergency
case.
荫 During running in period, every gear should be engaged equally in time.
荫 During run-in period, it is better to load the bucket with loose materials and avoid of rude operation.
The loading capacity should not exceed 70% of its rated capacity and the driving speed should not
exceed 70% of the rated maximum speed.
荫 Pay attention to the lubricating state of the machine, and replace or inject the lubricant according to
prescribed schedule.
荫 Check the tightness of every bolt and nut.
荫 After 10 hours of running in period, the following operations should be carried out:
吟 Check the tightness of every bolt and nut overall, especially, the cylinder head bolt of diesel engine,
fixing bolts on engine, gearbox and front & rear axle, hub nuts, and the connecting bolts of the
transmission shaft etc. All the above mentioned bolts should be checked.
吟 Clean the rough engine oil filter, fine engine oil filter and fuel filter.
吟 Check the tightness of fan belt, generator belts and belts on air-conditioner compressor.
吟 Check the status of the battery electrolyte and tighten the joints of the battery.
吟 Check the oil level in the transmission system.
吟 Check the airproof status of the hydraulic system and braking system.
吟 Check if every control lever and accelerator lever are well connected and tightened.
吟 Check the temperature and connection of every component in the electric system, and check the
generator performance, illumination lamps and steering lamps.
1.2 Application Purpose of the Machine

This loader is of a construction machinery with a single bucket, front dumping, articulated frame and wheel
type. It can be widely used in construction worksites, port wharfs, stations and storage areas for loading or
short -distance transporting loose materials such as mud, sand, coal and dust. Also it can be applied in
towing, ground leveling, stacking and piling. All of these application make it become a high-efficient and
multi-function construction machinery.
荫 Applied with articulated frame, with the articulating center being placed in the middle of the two
wheelbases, and small steering radius, so the loader is very maneuverable and suitable for narrow
places.
荫 Applied with hydraulic mechanical transmission, so the power of the engine can be fully used, and the
torque can be increased, so as to obtain a bigger drawing force. Meanwhile, the loader adopt variable
infinitively speed, which can effectively protect the transmission system and the engine.
荫 With the full hydraulic steering and power shift and hydraulic operating system, it is flexible, steady
and reliable to operate the machine.
荫 Having the low-pressure & wide -base tyres and the swing rear axle, the loader has a good off-road
performance, so it can travel and work freely on rough terrains..
1-02
8 LW300KN 英文操保手册
1.3 Component Names and Decals
荫 Elevation : 臆3000mm
荫 Ambient temperature : -15益~40益
荫 Water-wading depth : 臆500mm
荫 Overloading.
荫 Hanging a cable on bucket teethes to lift heavy object.
荫 Excavating at the over-head position of the loader.
This loader is a common purpose machine, so it is not suitable to the environment that is easy to burn and
explode or has powder and poisonous air.
1.3.1 Component Name
Rear lamp
Top lamp
Air filter
Front lamp & steering lamp Exhausting pipe
Boom Hood
Rocker
Bucket Steering lamp
Counterweight
battery box
Fuel
Splash Hydraulic Drive tank
fender oil tank axle
Figure 1-1 Overall figure and component name
1-03
1-04
1.3.2 Decals and Number

翌 Decal of the loader (figure 1-3)
The decal is pinned on the front frame which shows the loader type, product number, producing date and
manufacturer name.
翌 The signs of XCMG are located below the cab and on left side of cab.
翌 Frame number is impressed on the left side of rear frame and outlined with black line.
This decal may vary along with the actual configuration

Figure 1-3 Decal of the loader
翌 Decal of engine (Figure 1-4)
It is pinned on the engine
Figure 1-4 Decal of engine

翌 Every main component also has its decal which shows the product type, number and manufacturer and
so on.
CAUTION Please obey with those signs warnings which are painted on the loader.
翌 If these signs and decals get tore off or unreadable, please get a new one available on the machine.
1-05
1.4 Safety Signs and Theirs Position

There are some safety signs pasted on the loader. Please read all the safety signs and obey with them. The
positions of safety signs are shown in the Figure 1-5.
Take good care of these safety signs, replace the damaged one and replenish the lost one in time. If one
component of the loader with safety sign on it has to be replaced, please paste a new safety sign on the
new component.
Use clothing and suds to rinse the dirty signs. It is not allowed to use and gasoline to rinse the dirty signs.
3
2
4
1
6 5
Figure 1-5 Pasting positions of safety signs
1-06
1.4.1 Don爷t stand under the raised working 1.4.4 Back the machine
equipment. The signs are pasted on the two It is located on the counterweight.
sides of lifting arms.
Figure 1-9
1.4.5 Sign for Hydraulic Oil

Being located on the outside of hydraulic oil tank.
Figure 1-6
1.4.2 Don爷t enter this working area.
The sign is pasted on the articulation joint of
the front and rear frame.
Figure 1-10
1.4.6 Sign for Fuel

On the filling pipe of fuel tank. Being located at
the fuel-filling plug of the fuel tank.
Figure 1-7
1.4.3 Anti-freezer
It is located on the two sides of hood.
Figure 1-11
当气温低于 0益时如不使用防冻液袁
停车后应将柴油机散热器尧油冷却
器及管路中的水放尽袁否则冻裂发
动机机体袁散热器或油冷却器等遥
WHEN THE TEMPERATURE BELOW 0益袁
AFTER PARKING THE LOADER袁 PLEASE
DRAIN THE ENGINE RADIATOR OIL
COOLER AND WATER PIPE, IF THE
WATER HAS NOT BEEN ADDED ANTI -
FREEZER袁 IT WILL FREEZE THE ENGINE
RADIATOR AND OIL COOLER CRACK.
Figure 1-8
1-07
1.5 Instruments and Controls

1.5.1 Composition of Control System
Figure 1-12 Composition of Instruments and Controls

1尧Brake pedal 2尧Shift operating handle 3尧Spare position 4尧Voltage meter 5尧Air pressure meter
6尧Tachometer 7尧Water temperature meter 8尧Fuel level meter 9尧Oil temperature meter of torque
converter 10尧Spare position 11尧Switch of rotary alarm 12尧Switch of fan 13尧Accelerator pedal
14尧Switch of steering lamp 15尧Boom control lever 16尧Tilt control lever 17尧Switch of front lamp
18尧Switch of rear lamp 19尧Switch of ceil lamp 20尧Switch of wiper 21尧Signal of danger
22尧Switch of aether 23尧Spare position 24尧Hand brake lever 25尧Switch of Air-conditioner
1-08
1.5.2 Function Explanations
No Name Function Note

Brake the machine when trample down the ped
1 Brake pedal
al.
Shift operating Push it forward to get reverse gear and neutral
2
handle gear, push it furthermore to get gear I and II.
3
4 Voltage meter It can display the voltage of battery.

Air pressure The normal pressure is 686 耀
5 It can display the braking air pressure.
meter 784KPa.
It can display the engine speed and total work
6 Tachometer
ing time.
Water tempera It can display the temperature of engine cooling Stop the machine if the temper
7
ture meter water. ature exceed 100益.
8 Fuel level meter It can display the fuel level.
Stop the machine if the temper
Oil temperature
It can display the oil temperature of torque ature exceed 110益, run the en
9 meter of torque
converter. gine at low speed to make it
converter
cooled down.
10 Spare switch
Switch of rotary
11 It is used to control the rotary alarm.
alarm
12 Switch of fan It is used to control the fan.
Accelerator ped
13 It can control the oil input to engine.
al
Move it forward to turn on the
Switch of steer left steering lamp and move it
14 It is used to control the steering lamp.
ing lamp backward to turn on the right
steering lamp.
Pull back the lever to raise the lifting arms and
push it forward to lower it down and push it fur
Boom control
15 thermore to get floating position. When it being
lever
put in middle position, the lifting arm remains
motionless.
When the lever be pushed forward, the bucket
will tilt. When the lever be pulled backward, the
16 Tilt control lever
bucket will be retracted. When the lever be put
at neutral gear, the bucket remain motionless.
Switch of front
17 It is used to control the front lamp.
lamp
Switch of rear
18 It is used to control the rear lamp.
lamp
1-09
No Name Function Note
19 Switch of ceil lamp It is used to control the indoor top lamp.
20 Switch of wiper It is used to control the wiper
21 Signal of danger It flashes to give out warning.
22 Switch of aether It is used to control the aether injection.
23 Spare position
Raise up the lever to brake and put down it to re
24 Hand brake lever
lease the brake.
Switch of air -condi It is used to control the air -conditioner and the
25
tioner indoor temperature.
1.5.3 Gear-Shifting Operation (Figure 1-13 & 1-14)
Forward II gear
Forward I gear
Neutral gear
Reverse gear
Figure 1-13 Gear position Figure 1-14 Actual photo of Gear-Shifting handle
1.5.4 Operation Of Working Apparatus (Figure 1-15 & 1-16)
Floating
Dropping
Neutral
Raising
Tilt forward
Neutral
Tilt backward
Figure 1-15 Positions of control levers Figure 1-16 Actual photo of control levers
1-10
1.6 Operation Regulations
1.5.5 Parking Brake (Figure 1-7)
Figure 1-17 Positions of Control lever
1.5.7 Seat Adjustment ( Figure 1-18 )
Figure 1-18 Seat ( Double-way, with cushion )

1.6.1 Safety Rules
A. Safety rules
荫 Don爷t operate the loader if you feel uncomfortable or take
medicines or drink alcohol. Operating the loader with bad
health may injure others or yourself.
荫 When you work together with other people, please make
them understand the gesture language. Figure 1-19
1-11
荫 When operating or maintaining the loader, please take

safety guards.
荫 When operating or maintaining the loader, please wear
safety hat which is made up of hard material, safety
glasses, safety shoes, glistening coat, veil, earplugs and
gloves. When scattering metal scrapes or cleaning the
debris from air filter by hammer or compressed air, please
wear safety glasses, hard hat and thick gloves. Figure 1-20
荫 Don爷t wear loose clothing as loose clothing can be easily
enwinded in control levers or moving parts to cause
casualty.
荫 Don爷t wear greasy clothing which can incur burning.
荫 Compressed air can injure people. Please wear veil,
protective clothing and safety shoes when using the
compressed air to clean something. The maximum pressure
of compressed air should not exceed 0.3Mpa.
荫 Check if the safety guards are normal or not before putting
them into use. Figure 1-21
Any unauthorized restructuring to this loader can result danger or casualty. Before restructuring the loader,
please consult with XCMG Construction Machinery Co., Ltd.. (XCMG) or authorized agent. Manufacturer
should not be responsible for the damages caused by unauthorized restructuring.
1.6.2 Safety Operation
荫 Only the authorized technician can operate and maintain the

loader.
荫 When operating or maintaining the machine, please obey
with all safety regulations and notices.
荫 Read the Operator爷s Manual of the loader, study the
structure, maintenance and operation of the loader, and be
familiar with all buttons, handles and meters. Figure 1-22
荫 Please understand all regulations about operation, get

known all the signals which are used in working process. If
there are some grease on the operating area, please wipe it
out immediately because it can result slippery.
Figure 1-23
1-12
Before and after machine operation, please check every system.

Check if all safety protecting methods are in safe condition or
not. Check if all tyres are wore out or not, and theirs air
pressures are normal or not. Breakdowns and accidents should
occur if you neglect oil leakages, water leakages, deformations,
looseness and abnormal noise. So please check the loader
frequently.
Figure 1-24
荫 Before operator leaving the seat, please lock the control levers and pull out the handle of parking
brake. Careless touching on unlocked operating levers can cause accidents.
荫 When you leave the loader, please lay the working apparatus on ground and lock the control levers,
then stop the engine. Lock all devices by keys. Take keys along with you always.
荫 Inspect the ladder and handrail before and after getting on

and off the loader. Wipe away oil, lubricant and sludge that
are on the ladder or handrail.
荫 Don爷t jump on or off from the loader. Never getting on or off
the loader when the loader is moving.
荫 When getting on or off the loader, please face to the loader,
grip the handrail and step on the ladder and ensure your
body is stable. Figure 1-25
荫 Don爷t grip any control levers when you getting on or off the
loader.
荫 Don爷t get on and off the loader from the rear ladder or tyres.
荫 Don爷t climb up and down the loader carrying with tools or other materials, please use ropes to hoist the
tools or other materials.
Fuel and lubricant used by loader are combustible materials, so it is dangerous when fire approaching the
loader.
Keep fuel and lubricant far away from fire.
荫 Stop the engine when injecting fuel. Smoking and fire are
forbidden during oil injecting process.
荫 Screw up all caps of oil tanks.
荫 Use marked vessels to hold combustible liquid, and put them
on a fixed place. Unconcerned people is disallowed to use it.
荫 Move combustible material away from the loader surface,
ensure that no greasy cloth or combustible material exists on
the loader surface. Figure 1-26
1-13
荫 Don爷t weld or incise the pipes containing combustible

liquid. Before welding or incising pipes, please use non -
combustible liquid to clean the pipes.
荫 When the loader is working, keep the exhauster of muffler
far away from combustible materials, such as withered grass
or waste paper and so on.
荫 Choose the parking place carefully and keep hot parts of the
loader far away from combustible materials.
Figure 1-27
荫 Prevent pipes and hoses from leaking. Replace the damaged

pipes and hoses. Use the pipes and hoses which have been
repaired or cleaned.
荫 Battery can produce out explosive gas, so don爷t let smoking
and fire approach the battery. Maintain the batteries
according to Operator爷s Manual strictly.
Figure 1-28
荫 When checking the dark area, don爷t use fire to lighten the
area.
Figure 1-29
荫 Front -located working apparatus may obstruct the visual

field of operator. When the bucket is filled with load, weight
is concentrated on two front wheels of the loader, so take
stability into consideration when driving on a road.
荫 Fog, flappy soot and sand can obstruct the visual field of
operator.
荫 Investigate the working place in advance, watch the road
condition, keep vigilance against to obstacles, sludge, snow
and cave. Figure 1-30
1-14
荫 Before driving on speedway and public road, please refer to

Operator爷s Manual in advance and obey with local traffic
rules. Don爷t incur traffic jam and be quickly when getting
through a crossing.
荫 Understand all operating regulations and signals, operator
must know the meaning of every signal and sign at the first
glance.
Figure 1-31
Take steps according to following items if injure or fire accident

has occurred.
荫 You must prepare a fire extinguisher and know how to use
it.
荫 First-aid kit must be prepared on the working place. Refresh
the first-aid kit with new medicines.
荫 You must know how to save yourself when fire accident
Figure 1-32
occurring or you have been injured.
荫 Some useful telephone numbers must be pasted on a obvious
place, such as telephone number of doctors or hospitals, ensure all people know these telephone
numbers and know the communicating method.
荫 Any part of your body should never get into working area of moving parts of the loader. Along with the
movement of working equipment, the space of linkage devices will increase or decrease, approaching to
this area can result injuring. If it is necessary to enter into the space that between moving parts, please
stop the engine and lock the working equipment.
Figure 1-33
1-15
荫 Support the loader reliably and firmly when you have to

work under the machine. Don爷t rely on the cylinder to
support the loader. Accessory may fall down if controlling
device moves or pipes leak oil.
荫 Don爷t adjust anything when the loader or the engine is
running.
荫 Evade away from all rotating parts and working parts.
荫 Ensure that no sundries exist in laminas of fan. Rotating
Figure 1-34
laminas of fan can eject out or break the sundries which
exist in the fan.
荫 It is dangerous to check the engine when the engine is running, avoid of doing that.
荫 Aether is a poisonous and combustible material.

荫 Inhaling into or contacting with the aether can injure you.
荫 Good ventilating must be provided to the place where aether
is used.
荫 Don爷t smoke when replacing the aether.
荫 Guard against fire when using aether.
荫 Don爷t put the aether cylinder on a living area or in the cab.
荫 Put the aether cylinder on a shadowy place.
荫 Put the abandoned cylinder on a safe place, don爷t bake Figure 1-35
something on it and bore some holes on it.
荫 Keep the aether cylinder far away from unconcerned people.
荫 When installing and using a accessory, please read the manual which is about to the accessory.
荫 Don爷t use the accessories that are unauthorized by XCMG Construction Machinery Co., Ltd. or its
agent. The unauthorized accessories can cause dangers and tamper with the normal operation.
荫 XCMG Construction Machinery Co., Ltd. should not be responsible for the damages and accidents
caused by using the unauthorized accessories.
1.6.3 Safe Starting
Operator must wear protecting dresses according to actual

condition. Protecting dresses include safety hat, safety clothing,
safety shoes, safety glasses, gloves and respirator.
Figure 1-36
1-16
荫 Investigate the surrounding environment of working place before starting operation. Keep guard against
abnormal conditions that can result dangerous accidents.
荫 Be familiar with the terrain and ground condition of the working place, choose the safest working
method.
荫 Make the ground of working place more firm and level before starting operation. If the working place is
sandy, please sprinkle some water on the ground before working.
荫 When working on a public road, please assign a man as traffic director, or set fence around the working
place and set up some notices which show 野No entrance 冶.
荫 Ensure good and effective ventilation before you working
indoors, avoid of toxicosis resulted from waste gas.
荫 Some water pipes, gas pipes and electrical cables may be
buried under the ground, please take notices of the burring
positions and avoid of damaging these pipes.
荫 Before working in a shallow water or passing through a sandy
bank, please inspect the water floor and water depth and
velocity of stream. Prevent the driving axle contacting with
Figure 1-37
water. Cleanout and check lubricating holes after working.
Check the loader before every daily work, perform daily

maintenance insistently. Treat abnormal condition seriously, repair breakdown immediately and report to
managing personnel.
荫 Take notice to oil leakage, water leakage, looseness of bolts,
abnormal sound and lost of parts.
荫 Ensure that the lock bar has been disengaged.
荫 Check the oil level of cooling liquid and fuel and oil in
engine sump, check that air filters are blocked or not.
荫 Ensure that all illuminating devices and lamps are normal,
repair the abnormal one
荫 Ensure that all meters and gauges are normal, put operating
levers at theirs right positions. Figure 1-38
荫 Clean the cab windows and clean all lamps to get a good
visual field.
荫 For get a good visual field, turn rear -view mirrors to a proper angle. Replace the damaged glass of
rear-view mirror.
荫 Don爷t leave tools or parts around the operator爷s seat. Vibrations can make these tools or parts fall
down to damage operating levers or switches.
荫 Adjust the angle of seat until operator feel comfortable, and ensure safety belt and its fixing are
reliable. Replace the safety belt which has been used for 3 years.
荫 Ensure the fire extinguisher is normal.
荫 Clear grease and sludge away from handrail, ladder and shoes to avoid of sliding.
1-17
荫 Before getting on the loader, ensure that no one stay in or surround the loader. Ask unconcerned people
keeping distance away from the loader, then start the loader.
荫 Don爷t start the engine if control lever is pasted on a tab which shows 野No operation冶.
荫 At first, sit down on the seat and adjust it until you feel comfortable. Take on the safety belt.
荫 Be familiar with all alarm devices and meters and operating devices.
荫 Ensure that the parking brake has been released and all operating levers have been put at theirs
neutral position.
荫 Sound the bugle to remind surrounding people getting away.
荫 Start the engine according to Operator爷s Manual.
荫 The engine should be started only when the operator remain
in cab. Starting the engine by making the start motor
shortcut is forbidden, this operation not only can damage the
electrical system, but also is a dangerous job.
荫 Refer to Operator爷s Manual in advance before using aether
cooling starting device. Keep guard to fire because the
aether is combustible material. Figure 1-39
荫 Aether is forbidden to be used when plug-shape pre-warmer
has been installed on the engine.
Inspect the loader according to following items after the loader has been started and before working.
荫 If abnormal sound or vibrations occur while the engine is running, it means that the loader has
troubles, please resolve the troubles and report to managing personnel.
荫 Check the speed controlling of engine under the condition of neutral gear.
荫 Pay attentions on all meters and apparatus and alarm lamps, ensure that they can work normally and
remain in regulated range.
荫 Try operating on all operating levers and ensure that they
are flexible.
荫 Try the gear -shifting lever to feel that the gear position is
right or not.
荫 Inspect the braking pedal and accelerograph pedal, and
inspect that the steering is sensitive or not under the
condition of low speed.
荫 Ensure the reverse alarm is normal.
荫 Ensure that the hand braking has been disengaged.
Figure 1-40
1-18
1.6.4 Safe Driving
荫 Keep a right operating habit to ensure safety.

荫 Sound the bugle before starting the loader, start the loader
after everything is confirmed normal..
荫 Ensure that no one or no obstacle is near the loader.
Figure 1-41
荫 Don爷t stretch your arms or legs out of the cab, it can incur
injure. Don爷t put your arms or feet on operating devices.
Figure 1-42
荫 Devote your mind to operation because momentary neglect

can result tragedy. Attend to surrounding people and sound
the bugle to alarm them.
Figure 1-43
荫 Don爷t drive the loader with the doors and windows are open,
but fixed door or window is not restricted by this regulation.
Figure 1-44
1-19
荫 The loader is not a man carrier, so hitchhiking is disallowed.

荫 Using the bucket to carry people or as working platform is
very dangerous.
Figure 1-45
荫 Please obey with traffic rules when driving the loader on a

public road, don爷t incur traffic jam, and get through the
crossing quickly.
荫 Drive the loader with courtesy when driving on a public
road, keep distance away from other vehicles.
Emergent braking may cause injuring !

It is very dangerous to shift between
DANGER forward and reverse gear when the
loader driving with high speed. Figure 1-46
荫 It is dangerous to drive the loader with the bucket being

highly raised and full of load. When transporting some load,
please choose a suitable speed and keep the bucket away
from the ground 500~600mm, so the center of gravity of the
loader can be lowered and the stability can be ensured.
Figure 1-47
The load would not exceed the limit of the rated load. Avoid of
overloading. XCMG Construction Machinery Co., Ltd.. should
not be responsible for the injuring or damaging to people and
machine caused by overload.
Figure 1-48
1-20
荫 Avoid of hurry driving, emergent braking, hurry turning and

bypassing when transporting load.
荫 It is dangerous to operate the working equipment impetuous鄄
ly. Impetuous action of working apparatus can throw out the
load or overturn the loader.
Figure 1-49
荫 Be familiar with the performance of the loader and choose

the right speed according to actual condition. Determine the
most suitable route and working method and get cooperating
people known that.
Figure 1-50
荫 Drive the loader slowly to make the loader in a controllable

condition.
荫 Speedy driving, hurry turning or emergent braking is forbid鄄
den when the loader drives on a bumpy road or a slope.
荫 It is hard to control the steering wheel when the loader
drives on a uneven terrain or a messy road, so take great
care to prevent overturning.
Figure 1-51
荫 Run the engine smoothly, and don爷t turn the loader when it
is running with high speed.
Figure 1-52
1-21
荫 When the visibility is limited, the speed should be reduced.

Sound the bugle to remind surrounding people and avoid of
savage operation.
Figure 1-53
荫 Bad weather, such as: flying sand, thick fog and heavy rain,
can weaken or invalidate the visibility, so reduce the speed
and sound the bugle.
荫 When loading a large size goods, be careful of lifting, mov鄄
ing and shifting gears. Be sure that no one enter into the
working area, and a guider is necessary.
Figure 1-54
荫 Misconception to the distances and terrain may occur in the

night, so keep a proper speed that suitable to the surround鄄
ing illuminating.
荫 Turn on the front lamps and top lamps when working at
night.
Figure 1-55
荫 When passing a place with many obstacles such as the roof

and the porch of the buildings, do not get the machine col鄄
lided with these obstacles.
荫 Lower the speed when driving or steering in a limited areas.
Be sure that there is no obstacle around it.
荫 When the road condition is bad, operate the machine care鄄
fully, and avoid of losing the stability.
Figure 1-56
1-22
荫 Do not work alone in the dangerous places. Investigate the

road conditions, intensity of bridge and the topography of
the worksite in advance.
荫 Take notices to sinking of wheels and braking performance
when driving in a marsh and loose ground.
荫 Don爷t make the bottom of driving axle contact with water
when working in shallow water and swamp area.
荫 Avoiding of traveling too close to the overhangs and deep Figure 1-57
ditches. There is a hazard that the weight and the vibration
of the machine will make the soil to collapse, and the
machine may fall or overturn.
荫 When working in a dangerous place which has the hazard of
falling rocks or overturning, start the protection devices
(FOPS&ROPS).
荫 When working continuously in rainy weather, working
condition may be changed by rain, so take great care.
When working on the place where earthquake or blast has
happened, please take more care.
荫 When working on a snowy ground, reduce the loading
Figure 1-58
volume and take notices to skidding.
荫 Travelling sideways or turning on a slope is very dangerous,

don爷t try this operating.
荫 Don爷t swerve on a slope. Swerving only can be performed on
a flat ground. Lower the speed and reduce the turning angle
when working on hilltop, bank and slope.
荫 Getting up or down a slopes is preferred rather than passing
through an alleyway or pavement.
荫 Choose a proper speed gear before getting down a slope, and
don爷t shift speed on the process of getting down a slope.
荫 The gravity centre of the loader will be concentrated on fore Figure 1-59
wheels or rear wheels when driving on a slope, so please
take more care and avoid of emergent braking.
荫 When driving on a slope, a bank or a hillside, make the
bucket near the ground and keep a distance of 20 -30cm
away from ground. If emergent case occur, please drop the
bucket to ground which can help the loader to stop and
prevent it from overturning.
荫 When driving on a slope with full load
* Use the gear 玉
* Keep the loader forwards when driving uphill and
backwards when driving downhill. Figure 1-60
* Don爷t swerve
1-23
荫 If i t is necessary to brake the loader while the loader is

downhill, trample down the braking pedal without cutting off
the power. Do not put the gear-shifting lever on the neural
position. When the speed is faster than the rated speed,
trample the braking pedal to reduce the speed.
荫 If the engine stops working when the loader driving on a
slope, please trample down the braking pedal completely
and drop the bucket to ground, then apply parking brake to
fix the loader. Figure 1-61
荫 If the gradient of the slope is less than 15毅, repeat the above
procedure and put operating levers at theirs neutral position,
then start the engine again.
To prevent accidents, even if the loader has been equipped with

reverse alarm and rear -view mirrors, obeying with following
rules is necessary before moving the machine and the working
equipment.
荫 Sound the bugle to remind surrounding people.
荫 Ensure that no one is surrounding the loader. Especially Figure 1-62
check the area that behind the loader for the sake of this
area is invisible to the operator爷s position.
荫 Some one should be designated to guide the transportation when operating on a dangerous place or a
place with poor visibility.
荫 No one can enter into the driving area or turnaround area without allowance.
荫 Don爷 t change the driving direction when the loader driving
at high speed.
1.6.5 Safety
荫 When operating the loader, operator must sit on the seat and
take the safety belt. The loader should always be in
controllable condition.
Figure 1-63
荫 The operation to handles must be correct.
Figure 1-64
1-24
荫 Repair the breakdown at once if the breakdown occur, and

listen the abnormal sound to distinguish the reasons of
breakdown. Don爷t repair the part that is in working..
Figure 1-65
荫 Do not overload. Performance that is beyond the capability of

the loader is extremely dangerous. It is very dangerous to
disobey the instructions when operating. Please investigate
the load weight in advance to avoid of overload. XCMG
should not be responsible for the damages and injures
caused by overload.
Figure 1-66
荫 Dashing with high speed is equal to suicide. Dashing not

only can damage the loader but also can injure the operator.
Never try doing it.
Figure 1-67
荫 The loader should be aligned vertically to the heap to be

loaded. If handling the heap from an oblique direction, the
loader may be unbalanced.
Figure 1-68
1-25
荫 Investigate the surrounding condition in advance before

starting operation.
荫 Check the ground condition before passing through a tunnel
or over a bridge.
荫 When working in heavy windy weather, operate the loader
favourably with the wind.
荫 Be careful when the load must be lifted to the highest
position. Lifting the load to high position is dangerous
Figure 1-69
because it make the loader unbalanced, so move the loader
slowly and take notices when tilting the bucket forward.
荫 When a truck cooperating with the loader, avoid of the

bucket colliding with the truck. No one can stand under the
bucket and don爷t hang the bucket over the cab of the truck.
Figure 1-70
荫 Before traversing the loader, please observe the behind area

carefully.
荫 Stop working when the visibility is weakened by smoking,

heavy fog and flay dust. Please prepare illuminating devices
if the working place is dark.
Figure 1-71
荫 When working at night, please notice the following items.
a. Ensure that sufficient illuminating devices have been
prepared.
b. Ensure that all working lamps of the loader can work
normally.
c. You will easily have a wrong impression to the distance
and height of objects at night.
d. When working at night, please stop the loader to inspect
its condition frequently and check the surrounding condition.
荫 Before passing over a bridge or other constructions, please
ensure that it has enough solidity to support the loader.
Figure 1-71
1-26
荫 The loader is a special purpose machine. Don爷t use the head

or any part of the working equipment to scratch, move or
push something.
Figure 1-73
荫 Unconcerned people should not be permitted entering into

working area. As the working mechanisms of the loader
move up and down, and the loader itself also move around,
so it is forbidden to enter into the working area of the work鄄
ing equipment. If the machine can爷t work, please fix the
working equipment firmly at first.
Figure 1-74
荫 When working near a cliff or a place which is easy to col鄄

lapse, please operate the loader with the safest method and
assign a guider to help you.
Figure 1-75
荫 When dumping soil or stone from a higher place, the safety

of the dumping place should be considered.
荫 When the material is near the cliff or the loader is near the
top of a slope, the speed of the loader will increase abruptly
as the load being dumped, so remember to decelerate the
loader.
荫 When embanking or shoving and dumping near a cliff, you
should make one heap and then use the second heap to push
the first one. Figure 1-76
1-27
C. Ensure the ventilation before operating indoor.

荫 If some operation have to be done in a enclosed room or in a
place which has poor ventilating, the windows must be opened
for ventilation. If the opening of windows still can爷t provide
enough ventilating, fans are necessary.
Figure 1-77
荫 Prepare several fire extinguishers before working inside a

enclosed room, and bear in mind its location and using method..
Figure 1-78
D. Keep far away from dangerous place

荫 If the air released from the muffler is ejected to combustible
material or the exhauster is near to them, fire will be easily
lighted. So when you are near the combustible or dangerous
material such as oil, cotton, paper, withered grass or chemical
substance, special attentions must be paid.
Figure 1-79
Keep far away from high voltage lines

荫 Don爷 make the machine contacted with high voltage lines. Even if nearing the high voltage line also
can cause electrical shock. Keep a safe distance from high voltage line according to following table.
Voltage The minimal safety distance
100耀200V 2m 7ft
Low voltage
6,600V 2m 7ft
22,000V 3m 10ft
66,000V 4m 14ft
154,000V 5m 17ft
High voltage
187,000V 6m 20ft
275,000V 7m 23ft
500,000V 11m 36ft
1-28
1.7 Working Method
荫 Do the following jobs well to prevent accidents

翌 If the risk of contacting with electrical cables is obvious, please consult with local electrical department
before working.
翌 Take on rubber shoes and rubber gloves. Put a rubber pad on the operator爷s seat. Prevent any part of
your body from contacting with the metal chassis.
翌 Assign a guider to remind you when the loader getting near the electrical cables.
翌 Operator should not leave the cab if the working equipment has contacted with electrical cables.
翌 No one can be permitted to get near the loader when working near the high voltage line.
翌 Know the voltage of high voltage line from electrical department before working.
1.6.6 Safe Parking

荫 Choose a place as flat as possible to park the loader, drop the working equipment down onto the
ground.
荫 Don爷t park the loader on a slope. If parking the loader on a slope is unavoidable, the gradient of the
slope should not exceed 1/5, at the same time, use wedges to fix wheels, then drop the working
apparatus down onto the ground.
荫 If the loader is in trouble or has to be parked on a place in which the traffic is heavy, please set fence,
signal flags or warning poles around the loader. Take some methods to make other vehicles see the
loader clearly. The loader and fence and signal flags should not jam the traffic.
荫 Dump all load out before stopping the loader, drop the working equipment to ground and lock all
operating levers, pull up the parking brake and put it at braking position. Lock all devices and take out
keys. When getting down the loader, please face to the machine while getting down and keep your body
stable. Jumping down from the loader is forbidden.
荫 Don爷t get on the loader while it is running.
1.6.7 Precautions For Cold Weather

荫 After working, please clear ice, snow, water or sludge away from wires, sockets, switches and sensors or
theirs surfaces. If you do not clear these, it will be froze and make your machine fail to work in next
operation.
荫 Warm-up your loader completely before working. If the loader has not been warmed-up completely, it
will react slowly and may result accident.
荫 Operate every operating lever to make hydraulic oil circulate in hydraulic system and get warmed,
therefore the loader can work ably.
荫 If the electrolyte of battery has iced, don爷t charge electricity to battery. Don爷t use another electrical
source to start the engine, as this performance is dangerous because it can make battery to fire.
荫 When charging electricity or using other electrical source to start the engine, make sure that the
electrolyte has thawed out and check out if there is any leakage on it before starting.
1.7 Working Method

1.7.1 Excavating Performance
Excavating performance is to insert the bucket into material heap and load or shove.
1-29
1.7 Working Method
Excavating performance includes shoving and digging.
When performing excavation, make the two sides of bucket bear load
CAUTION evenly, only one side of the bucket bearing load is forbidden.
Keep the bucket parallel with ground. Apply low-speed gear to drive the loader and get
close with the heap of load, insert the bucket into
heap of load.
Raise the lifting arms and operate the bucket Keep the bucket tilting backwards to its
control lever to make it tilt back for 2-3 times to maximum limit, and raise it 400 -500mm above
fully load material to be loaded. the ground.
A. Shoving Operation
Keep the bucket parallel with the ground while driving the loader, insert the bucket into heap fully, raise
the lifting arms and reverse the loader. Operate the bucket 2-3 times to make it tilt backward.
Besides, when it is hard to insert into a material heap, shake the bucket by moving the tilt lever back and
forth to fill up the bucket.
If the wheel skids, please reduce the force that is applied on the
CAUTION accelerator pedal and the load, avoid of forcible operation.
1-30
1.7 Working Method
Drive the loader to fill the material into bucket

Keep the bucket tilt forwards a little.
(cutting depth can be adjusted by controlling the
handles of lifting arm and bucket ).
Raise the lifting arm and keep the bucket tilting Keep the bucket tilting backward to its maximum
backwards. limit, and keep it away from the ground 40cm.
B. Digging operation
The proper inclining angle of the bucket is 0~10毅.
Drive the loader with a low speed, raise the lifting arm after the bucket inserting into 10 ~30cm, at the
same time tilt the bucket backward. The less the bucket digs, the easier the loader does.
1.7.2 Load Performance

When loading sand, rocks or ores into truck or container, please choose a high efficient working method.
Determine the working method according to actual condition, the working method includes the cooperation
of loader and truck or only the loader.
Clear the gravels and stones away from the ground by bucket, which can
CAUTION prevent wheels from damaging and the road surface frequently.
V-type cycling operation I-type cycling operation
Pay attention on the road surface when transporting, choose a speed that
will not make loaded material splash out and lower the bucket when
CAUTION driving.
1-31
1.7 Working Method
A. Dig and load on a flat ground

Keep the bucket tilt forwards a little, operate the lifting arms and bucket to adjust the digging depth while
driving the loader. Special attention should be paid when the terrain varies.
Following operation must be performed according to 野shoving operation冶.
L-type cycling operation T-type cycling operation
B. Working in combination with transporting vehicle

The method has, as shown in above figures, four types. Choose a working method of shortest cycling time.
The above-mentioned method is to use the machine for continuous shovelling, transporting and dumping.
This method is suitable to the transporting distance of 30~100m in normal condition.
1.7.3 Ground Preparation

By the angle formed by bucket cutting edge and the ground, the loader can perform soil scattering, ground
levelling and foundation laying.
When performing the ground preparing, the machine must be driven

backward.
If it is a must to prepare the ground while the loader is forward moving,
CAUTION
please keep the forward tilting angle within 0毅~10毅.
Soil scattering
Load sand or soil into bucket, then tilt the bucket forward to 10毅~15毅 and scatter the sand or soil evenly
while the loader is moving backwards.
1-32
1.7 Working Method
1.7.4 Soil Pushing

The bucket can be used as a scraping plate to level up the ground.
At this time, fill the bucket with sand or soil and keep it parallel with ground, then perform levelling up.
Coarse levelling
Tilt the bucket forward completely, keep the bucket teeth contacting with ground and reverse the loader at
a low speed to make the ground levelling.
Fine levelling
Fill the bucket with sand or soil and keep it contacting with ground horizontally. Put the handle of the
lifting arms at 野float冶 position, then reverse the loader slowly.
When working on a hard ground, put the handle of the lifting arms at 野float冶 position, make the bucket
stick to ground and scrape the ground clearly.
During the machine operation as above -mentioned, the water

temperature of engine should not be over 90益, oil temperature of torque
converter should not be over 110益, oil pressure of braking should not be
CAUTION
lower than 0.44Mpa. Otherwise, stop working immediately and figure out
the problem reason.
1.7.5 Snow Sweeping

Please pay special attentions on following items.
Although the snow sweeping is similar to common loading performance, but the snowy road is a special
condition which can result skidding or the steering wheel out of control.
Avoid of hurry driving, emergent braking, rapid turning , and operate the loader with care.
Notices of snow sweeping
荫 Ensure the safety when fog weakening your visual field.
荫 Take notices to those objects buried under the snow.
荫 Know the positions of ditches and curb.
荫 Anti-skid chains must be installed on 4 wheels.
1-33
1.7 Working Method
1.7.6 Towing Performance

Raise up the towing pin which is located at the counterweight and thread towing cable through it, then put
the towing pin down.
The towing cable should be threaded firmly.

CAUTION
The braking device of the vehicle which is to be towed can function normally, otherwise don爷t attempt to
tow it.
Figure 1-81 The photo of towing pin located in counterweight
Notices to towing performance

荫 When towing a break-down loader in short distance, please obey with the following instructions. The
speed should not exceed 2km/h, move the break-down loader to a safe place to repair it. This method
can only be used in emergent case. Please use a truck to move the break-down loader for the long-
distance transportation.
荫 Necessary security protection should be made for the towing vehicle, and try to prevent any injury
happening on operators caused due to the failure of towing cable and towing link.
荫 It is forbidden to operate the vehicle unless the operator can control the steering and braking of the
vehicle to be towed.
荫 Before towing a loader, please check the condition of towing cable and towing link, ensuring that they
have enough intensity. The strength of the towing cable must be 5 times to the weight of the loader.
Towing cable can also be used to draw the loader that is trapped in sludge or on a slope.
1-34
1.8 Oil and Water Supplying
荫 Chains can not be used as towing cable because it may break and cause casualty. Assign a observer on
a safe place who can stop the towing performance if the towing cable breaks or gets loose.
荫 Terminate the towing performance when the towed vehicle can move by itself.
荫 The minimum towing angle must be ensured, which should not be over 30毅.
荫 Hurry towing can break the towing cable, so it is suggested to apply slow and smooth towing.
荫 Under the normal condition, the size of the towing vehicle should be same with that of the loader to be
towed, and the towing vehicle should also be of proper braking performance, sufficient power and
weight to meet the demands in terms of towing slope and towing distance.
荫 When towing a break-down loader downhill a slope, a larger vehicle should be needed and follow after
the loader, so as to prevent the break-down loader from rolling.
荫 Towing force should vary according to different terrain condition. If the terrain condition is level and
smooth, the needed towing force is small. If the terrain condition is bad, the towing force is large.
荫 If the machine engine is still running, the break-down loader only can be moved for a short distance
just under special case, while the machine爷s power system and steering system also can be operated.
Bear in mind that the machine can only be towed for a short distance, e.g., tow the machine out of mud
trap or tow it onto a road edge.
荫 Before towing, keep the direction of the loader in line with the towing direction.
A improper towing method or bad steel cable can result casualty or damage, so obey with following
items.
吟 The towing vehicle and towed machine must be installed with ROPS & FOPS.
吟 Choose the high quality steel cable, and please wear gloves when dealing with steel cable.
吟 Before cooperating with other workers, discuss with them and determine the signals that will be
used.
吟 If the engine and braking systems of the break-down loader gets troubles, please consult with their
manufacturer for repairing them.
吟 It is dangerous to tow a loader on a slope.
吟 The steel cable to be used for towing should be strong enough to tow the break-down machine. No
one should stay between the towing machine and the towed machine.
吟 Keep the hook of the towed machine be in alignment with the towing machine.
吟 Don爷t stand astride on towing cables by two feet.

1.8.1 Notices
荫 All oil must be pure and be sedimented for 72 hours. The cleanness of the hydraulic system should
1-35
reach to 18/15 ( GB/T14039-93 ) or NAS10 ( American Standard ), otherwise it may make bucket
falland cause excessive abrasion to the pump.
荫 Oil injector and related parts must be clean and prevent water or dirt getting into oil.
荫 Keep the loader in a level condition when checking the oil quantity.
荫 Under different ambient temperature, use oil with different viscosity and trademark, please observe with
the relative instructions.
荫 Different kinds of oil can not be mixed or substituted together, otherwise it may cause rubber elements
aging and early abrasion.
荫 Check any oil leakage in the system after oil injecting.
Avoid of scalds when checking or replacing the oil and cooling liquid.
CAUTION
1.8.2 Injecting Method

A. Inject oil to hydraulic oil tank
荫 Oil checking:
Check the oil level in hydraulic oil tank Bear it in mind that oil level must be above the middle scale of
the oil-dipstick. When necessary, please replenish it with the new oil.
When checking oil level, the bucket should be placed on the ground
CAUTION horizontally and the engine should be stopped.
荫 Replacing with new oil according to following procedure:

吟 Raise the lifting arms to the utmost high position and then stop the engine. Lifting arms will drop down
and bucket will overturn by theirs own weight, so cylinder oil should be discharged out completely.
吟 Open the oil-drainage plug to discharge dirty oil when the oil is still warm.
吟 Remove away the flange cover and clean the injecting hole and filters. Replace the damaged oil filter.
吟 Inject new oil through oil-filling plug till it reaches to the middle scale of the oil-dipstick. It is
forbidden to inject new oil directly without the oil filter.
吟 After injecting the new oil, run the engine with low speed and operate the working apparatus several
times to bleed out air from the system, at this time, oil level may drop a little, so please check the oil
level again, replenish new oil if it is necessary.
Drain out the water and debris that are deposited in the oil tank from drainage plug.
1-36
B. Fill fuel to fuel tank

荫 Check of the fuel level
There is a level indicator on the fuel tank, keep the fuel level always above the 2/3 of the lower scale.
荫 Draining debris
Drain out water and debris that are deposited in the oil tank from draining plug. At the same time, clean
the fuel-filling plug and oil filter. For the damaged filter, please replace with a new one.
C. Fill braking oil

There are two oil cups on the booster pump.
荫 Checking the braking oil level

Check the braking oil level. The height between oil surface and oil -filling plug should be 15 ~25mm.
Replenish with new oil when necessary.
荫 Replacing with new oil

Replace all the braking oil according to lubricating schedule, at the same time, clean the oil cup and
replace the filter.
If air getting into braking hydraulic system, the braking performance should be effected negatively. So it is
needed to bleed out air after replacing braking oil. Oil drainage should be in the follow steps:
吟 Clean the hydraulic pipes, braking oil cups, oil-filling plug and exhaust nozzle.
吟 Fill braking liquid to its oil cup.
吟 Start the engine, then stop it after braking pressure reaches 0.68~0.7Mpa.
吟 Sleeve the exhaust nozzle with a transparent hose, with one end of the transparent hose into the oil cup.
吟 Release all exhaust nozzles for bleed out air, and trample down the braking pedal several times till
there is no bubbles ejecting out from exhaust nozzle. Screw up the exhaust nozzle and disengage the
braking pedal. When bleeding out air, please replenish in time braking liquid to the oil cup, so as to
avoid air getting into pipe system.
吟 After the air has been bleeded out completely, fill in oil to desired level.
Oil of different brands should not be mixed together. Mineral oil should
CAUTION not be used as braking liquid.
1-37
D. Oil filling to the transmission system

Fill oil into transmission system through oil pipe. Check its oil level according to Gearbox Manual.
E. Filling oil to both front & rear axle

荫 Checking oil
Screw off the oil filling plug and check the oil level. If the oil surface is near the plug, it is enough,
replenish new oil when oil level is insufficient.

吟 Drain out the used oil from the draining plugs on hub reduction and main reduction areas. It is better
to drain out oil while the machine still being warm.
吟 Screw off the oil-filling plugs on main reducer and hub reducer to fill up with new oil till there is oil
flowing out from both the oil filling plug of the main reducer and the watching-hole of the hub reducer.
(The arrow direction on the hub should face downward, and the watching-hole is located at the arrow
end).
吟 Finally, screw up the oil filling plug.
F. Fill oil to engine

荫 Checking the oil level
吟 Pull out the oil-dipstick and clean its end, insert it into oil again, then pull it out to check.
吟 The oil level is right if the oil surface lies between upper and lower scale of the dipstick. If the oil level
is bellow the lower scale, then replenish it with new oil till it arrives at the upper scale.
吟 Checking oil level can only be implemented before working or after the engine stops running for 15
minutes.
吟 Check the cleanness of the oil again. If it is found that the oil is over polluted, replace it completely
with the new oil.

吟 Drain out the used oil from oil-draining plug of the oil pan, then fill up new oil via the oil filling hole
till the oil level reaches to the upper scale.
吟 Run the engine with low speed, then stop it to check the oil level. Replenish with more new oil if the
oil level is insufficient.
吟 The oil level should not be over the upper scale.
吟 The replacement for the engine oil should only be done while the engine still being hot.
G. Fill cooling water

荫 Water filling up
吟 If the temperature of engine water is too high, firstly check the water quantity in the radiator. Replenish
water if water level is insufficient. At the same time, check if the radiator gets blocked or not and if the
hoses get worn out or not. Be sure to put the radiator cover tightly to prevent cooling water evaporating.
1-38
吟 Replacement for the cooling water should only be done while the radiator is cold. Firstly open the
radiator cover, then open the draining valve to drain off the cooling water.
吟 Start the engine after finishing the cooling water replacement for making the water level drop a little.
Then stop the engine and replenish cooling water again if necessary.
吟 Fill the radiator full with cooling water, then run the engine with high speed to make the cooling water
circulate inside the radiator. Fill more cooling water while the engine is running. At the same time,
drain out the cooling water from draining valve until the clean cooling water flow out from the draining
valve.
Don爷t open the radiator cover when the engine is running or the engine
CAUTION stopped just a moment ago. The ejecting of hot water is very dangerous.
荫 If it is necessary to open the cover, please cover it with a cloth.
荫 Cautions:
吟 Rain water, tap water or precipitated river water can be used as cooling water. Well water can also be
used as cooling water.
吟 When the ambient temperature is lower than 0益, please add anti-freezing agent into cooling water to
prevent water getting frozen.
吟 If the loader is stored for a long time and without anti -freezer, please drain out all cooling water
completely.
吟 Cooling water that is with anti -freezer does not need to be drained out. But the high quality anti -
freezer should be used.
吟 In a extreme hot weather with temperature up to more than 30益, engine is easy to get overheated, so
parking place must be a shady place.
吟 To prolong the service life of the engine, make the engine run with low speed for 5 minutes at the end
of daily work. Stop the engine after the water temperature becoming cooled.
吟 The freezing point of anti -freezing agent should be 10益 lower than the lowest temperature of the
ambient temperature.
吟 The anti-freezing agent should be replaced every year.
1-39
1.8.3 Oil Type and Brand (Table 1-3冤
No. Description Oil Specification Loader Type Application (on machines)
100益 12.5耀16.3
CF-4 15W-40 Standard
100益 9.3耀12.5
1 Diesel oil
CH-4 15W- 40 Cummins 100益 12.5耀16.3
CH-4 5W/ 50 Alpine Type 100益 16.3耀21.9
Summer 0#,10#
Standard
Winter -10#,-35#
2 Diesel
50# Alpine Type
85W/90 GL-5 Standard

3 Gear oil
75W/90 GL-5 Alpine Type
100益<6.1曰
Summer L-HM46
40益 41.4耀50.6
Standard
100益<5;
4 Hydraulic oil Winter L-HM32
40益 28.8耀35.2
30# Alpine Type 50益 32.26
6# hydraulic transmission oil Summer 100益 5.0耀7.0

5 Transmission oil
8# hydraulic transmission oil Winter 100益 7.0耀9.0
-40益 <1500
6 Brake liquid 719 Synthesized braking liquid 50益逸4.2
100益逸1.5
7 Anti-freezing agent -45# Alpine Type
8 Lubricating grease 3#
1-40
Lubrication , Maintenance and
Repair
2.1 General Principle of Maintenance

2.1.1 Warning Label
荫 When the operator is maintaining or refueling the machine, starting engine or operating the joystick by
other persons may cause severe injury or death to the operator.
荫 Post a warning label on the joystick in the cab to show that service and maintenance are being done to
the machine. If necessary, post the warning labels around the machine.
2.1.2 Common knowledge
荫 The operator and the service people should be trained and get relative professional certification. The
persons who have nothing with the inspection and maintenances are not allowed to enter in the working
areas. You can appoint the special person to guard the areas.
荫 You should repair the loader according to the this manual. If you do not know how to repair the loader,
you should ask help from manufacturer.
荫 Repairing procedures should be programmed in advance.
When the loader is to be repaired or its parts to be
dismantled, assign a service foreman who is in charge of the
service work on site, and do the service work in the order as
programmed..
荫 The operator should wear a safety hat, protection suit with
the wristbands and trouser -legs tightened. Sometimes
according to the maintenance work scope, safety glasses,
gloves and mask should also be worn. Figure 2-1
荫 Please use the proper tools and do not use the broken and
inferior tools.
荫 To avoid the accident, you should always lower down all the
working apparatus. Stop the engine, engage the hand brake
and place the chock under the wheels when you repairing the
loader.
荫 Pay attention the decals. The most important points are
decaled on the loader and they must be followed strictly. If
the decals are peeled off or polluted, new ones must be
Figure 2-2
attached or clean them.
荫 Before repairing the loader, you should post a warning tab-
野Operation is forbidden冶 or other similar sign in the cab to
alarm others not to touch any handle in cab. If you do not do
this, it is very dangerous for the service man and himself.
荫 Appoint a director for assembly or disassembly the
accessories.
荫 Fuel and oil is dangerous. Fuel, oil, grease and linoleum are
not allowed to be exposed to any fire and flame.
Figure 2-3
2-01
荫 No smoking when adding oil and doing inspection work.

荫 Put the accessories taken down from the loader in a safe
place, and make sure these accessories will not disappear.
Make rails beside the working areas and hang a sign to
forbid irrespective people get close.
PSTROL
Figure 2-4
荫 Forbid any irrespective people to enter into the working

areas.
荫 Keep the working area clean and orderly. Do not get oil and
grease scattering to all over the working areas. Avoid firing
and slipping.
Figure 2-5
荫 When checking or maintaining the machine, the frames

should be locked by a locking bar.
Figure 2-6
荫 When you jack up one side of the machine, don爷t allow

other person to get into the other side of the machine.
荫 Before jacking up the loader, block the other side wheels by
wedges. After jacking up the loader, please put cushion
under it.
Figure 2-7
2-02
2.2 Lubricating the Machine
荫 Don爷t reconstruct the machine on the site.

Never reconstruct the loader on site which may affect the
functions , safety and strength of the loader or its bucket.
Figure 2-8
荫 Prepare the extinguisher before working inside a building,

and get familiar with where it is located and how to use it.
Figure 2-9
2.2.1 Parts to Be Lubricated and Lubricating Schedule.
2-03
2.2.2 Recommended Lubricant And Oil ( See the Table 1-3 )

2.2.3 Instructions to Be Followed When Refilling Fuel and Lubricating Oil
Fuel, lubricating oil, hydraulic oil, anti-freezing addition and braking oil could be flammable with fire
or flame, so following points must be obeyed:
荫 Stop the engine when refilling fuel or lubricating oil.
荫 Smoking is definitely prohibited.
荫 Clean away the leaked fuel, lubricating oil, hydraulic oil, anti-freezing agent and braking oil.
荫 All the tank covers for fuel, lubricating oil, hydraulic oil, anti-freezing agent and braking oil must be
securely fastened.
荫 Refill the fuel, lubricating oil, hydraulic oil, anti -freezing addition and braking oil in the place with
good ventilation.
B. Precautions
荫 Oil is required to be cleaned. The diesel oil must be deposited for some time.
荫 Oil injector and oil-filling area must be clean. Prevent contaminated water entering into oil.
荫 When checking oil quantity, the machine must be kept in a level state.
荫 Under different ambient temperature, please use oil with different viscosity and trademark. Please
strictly adhere to the relative instruction in this manual.
荫 Different type of oil can't be mixed and substituted together. Otherwise it may cause rubber components
aging and early wearing-out.
荫 After filling oil or changing oil, please check if there are any oil leakage.
C. Inject oil to the hydraulic tank
荫 Checking oil level:
Check the oil dipstick in oil tank. The oil surface should be kept above the middle scale of dipstick. When
oil level is not enough, please replenish with oil.
When checking oil level, the bucket should be positioned on the ground in
CAUTION level state, and the engine stops running.
荫 Replacing with new oil according to following steps

吟 Raise the lifting arm to its highest position. Then stop the engine. Lower the lifting arm and tilt bucket
downwards with their own weight, so as to let oil inside hydraulic cylinder flow out completely.
吟 When the oil being still warm, loosen the drainage plug under the hydraulic oil tank to discharge used
oil.
吟 Remove away the flange cover, and clean the oil filling plug and oil filter. Also replace the oil filter
when it get broken.
吟 Replenish with new oil till oil surface till it reaches the middle scale of oil dipstick. It is now allowed
to fill in new oil directly via oil filling plug without the help of oil filter.
吟 After filling in new oil, start the engine and let it run at low speed, and operate every control handles
several times, so as to bleed out air from the working system. Afterwards, maybe the oil level will get
2-04
lower slightly, so it is necessary to check the oil level again ( above the middle scale of dipstick). If
necessary, refill in with more new oil.
荫 Discharging contaminated remains
The contaminated remains and water inside the oil tank could be discharged from the drainage plug.
D. Inject fuel to fuel tank
荫 Checking fuel level
Inject new fuel to the fuel tank when the fuel level drops down to the lower scale.
荫 Discharging contaminated remains
Drain off water and contaminated remains inside the tank from the drainage flange at the bottom of the
tank. And then clean the fuel filling plug and fuel filter. Replace the filter if it gets worn.
E. Refill the braking oil
There are two braking oil cups ( which are located on the boosting pumps on the right side of machine
frame.)
荫 Checking oil level
Check the braking oil level. The height between the oil surface and oil filling plug should be 15-25mm.
When there is not enough oil , replenish it with new oil.
Completely replace the braking oil according to the interval schedule for lubricating. When replacing
braking oil, clean the oil cups and replace the oil filter.
If air penetrating into braking hydraulic system, it will affect negatively the machine braking performance.
So it is needed to bleed out air from the system according to following steps:
翌 Clean the hydraulic pipelines, braking oil cups, drainage plug and air-discharging plug.
翌 Fill up the oil cup with braking oil liquid.
翌 Start up the engine, and shut it off after the air pressure reading being up to 0.68-0.7MPa.
翌 Fit a hyaline hose on the air-draining plug, leaving the other end of the hose in the oil cup.
翌 Loosen all the air-draining plugs, and repeatedly step on the braking pedal several times, and then step
it down fully till the oil liquid without any bulb flowing out. After that, tighten the air-draining plug,
and release the braking pedal. During the air bleeding, replenish braking oil to oil cup in time, so as to
prevent air entering into circuit system again.
翌 After finishing air bleeding, fill in braking oil to the level as required.
Don爷t mix different type of oil together. And it is either not allowed to use
CAUTION mineral oil as braking oil.
If it is necessary to use different type braking liquid, please discharge the old braking liquid completely
and use the new braking liquid clean the braking system.
F. Inject new oil to the torque converter and transmission system
The torque converter and transmission system both use the same transmission oil, which must be checked
2-05
and replaced periodically .

荫 Oil level checking
Open the oil-drainage plug of the gearbox.
If there is any oil flowing out from the oil-drainage plug immediately after the oil-drainage plug is un鄄
screwed, it means that there is too much transmission oil in gearbox. Then what you need to do is to keep
the oil-drainage plug open till there is even no oil flowing out, which shows the oil level inside gearbox is
ok. However, if there is no oil flowing after the oil-drainage plug is unscrewed, it means oil level inside
the gearbox is not enough. Then you need to replenish with new transmission oil till there is oil flowing out
from the oil-drainage plug.
Oil level checking for the gearbox should only be done after the engine having been started.
荫 Oil replacing
In addition to the regular oil-change as scheduled, the transmission oil should also be totally changed if
finding the oil quality getting deteriorated or mixed with other oil.
When changing the transmission oil, drain out the used transmission oil via the oil-pan. After that, fill in
new oil via the oil-filling plug. Then start the engine and let it run at low speed for bleeding air out the
transmission system. After finishing air-bleeding, you will find the oil level gets lower a little bit, so you
need to replenish with more oil.
G. Fill oil to front and rear driving axle
荫 Oil level checking
Screw off the oil-filling plug and check the oil level, if the oil level is near the plug, it is ok, otherwise,
replenish with new oil.
荫 Oil replacing
Drain out the used oil from the oil-drainage plugs on both the main reducer and hub reducer respectively.
Screw off oil-filling plugs on the left and right hubs and main reducers. Inject with new oil till there is oil
flowing out from the oil filling plug and oil-level observation hole (at this time, the arrow on the hub re鄄
ducer should face downwards).
H. Fill engine oil
荫 Oil Level checking
Take out the engine oil dipstick and clean it, then reinsert in again into engine oil pan, and pull it out to
check the oil level.
If the oil level stays between the upper and lower marks of the dipstick, it is to say that the level is cor鄄
rect. Replenish new oil if the level is lower than the lower mark till it reaches to the upper mark.
Level checking should be done before machine operation or 15 minutes after the its engine stops.
After level checking, the oil pollution and mixed debris should also be checked. If oil is over polluted , it
must be replaced totally with new oil.
荫 Oil replacing
Drain the used oil through the oil-drainage plug on the oil sump, and then inject new oil through the oil-
filling plug till the oil level reaches to the upper mark of oil dipstick.
2-06
Start the engine and let it run at a low speed for a while, then stop the engine to check the level again, If
oil level is not sufficient, please replenish with new oil .
The oil level should not exceed the upper mark.
Engine oil should only be replaced while the engine is still warm.
I. Fill the cooling water
荫 Cooling water replenishing
If the water temperature becomes too high, firstly check the water level that is inside the radiator .
At the same time, you must also check if the holes of the radiator element get clogged or hoses get burst.
The cover of radiator should be fastened to avoid vaporization.
荫 Water replacing
The cooling water must be replaced only when the radiator is cold. Open the water tank cover, and then
open the drainage-cap at the bottom of the radiator, the water can then be drained out.
After replacing cooling water , start the engine to make the water level drop a little . Then stop the engine
to refill the water again.
When inner cleaning needs to be performed for the radiator, firstly fill the radiator fully with water and run
the engine at a high speed to make the water circulate. Drain the water again through the drainage-cap.
Keep the engine running at idle speed, while injecting the radiator with fresh water till clean water flows
out from the drainage-cap.
When the engine just stops or keep running, never open the radiator cover. High temperature water will
burst out to burn you.
翌 If it is necessary to open the radiator, cover it with a cloth and then screw it off slowly to open.
荫 Notes
吟 Rain water, city water and precipitated river water can be used as cooling water .Well water can be
used only after being softened.
吟 When the ambient temperature is below 0益 , anti -freezing agent should be injected into the cooling
water to protect the cooling system .
吟 If no anti-freezing agent is added , all the cooling water should be drained out through the drainage
valve to protect them from cracking.
吟 It is no need to drain out cooling water after anti -freezing agent has been used. High quality anti -
freezing agent should be used .
吟 In summer, when the ambient temperature exceeds 30益, the engine is easy to get overheated. So it is
better to park your machine in a shadowed place.
吟 In order to prolong the service life of the engine, at the end of daily work firstly keep the engine run at
a low speed for about 5 minutes till the water gets cool, and then stop the engine.
2-07
2.2.4 Lubrication Points And Oil Filling Points
Lubrication points of front transmission shaft
Lubrication points of rear transmission

shaft
Lubrication points of front transmission shaft
Oil-filling point of braking oil to rear axle Oil-filling point of braking oil to front axle
2-08
Hydraulic oil-filling position Fuel-filling position
Lubrication point of working attachment Lubrication point of gearbox
Engine oil dipstick Engine oil-filling position
2-09
2.3 Maintaining to the Machine

2.3.1 Common Operation and Instructions
A. Cleaning
荫 Clean the machine before doing any service and maintenance, so as to prevent dirt getting into the
machine.
荫 If the machine is dirty when doing service and maintenance,
it is not easy to find problems and may cause dirt spatter
into eyes or may have the danger of sliding or hurting due to
greasy dirt on the machine.
荫 While cleaning the machine, use the cleaning -addition
which is not flammable.
荫 When cleaning the inside part of machine, should lock the
control handles by locking -device to prevent the working
mechanism moving. And get the braking system be engaged. Figure 2-10
荫 When cleaning the machine, wear anti -slip shoes to avoid
slipping on wet ground. When using the high pressure water
to wash the machine, please wear the protection clothes.
荫 Don爷t splash out water directly on the electric component (e.
g: sensor, and sockets and plugs ). If water gets into the
electric system, it can cause breakdown.
荫 When cleaning the filter elements with compressed air, wear
the protection clothes and safe glasses.
Figure 2-11
B. Illumination
荫 When checking the fuel, lubricant, electrolyte of the storage battery or cleanser of window glass, it is
required to use the illuminator which is of exploding-proof. Otherwise, there is a danger of explosion.
荫 If the operator works at a dark place without lighting, there is a danger of injury. So lighting should be
equipped.
荫 Even if in the dark, it is not allowed to use lighter or fire to light. There is a danger of fire. Explosion
may occur when gas emitted from the storage battery meets with the fire.
荫 When taking the machine as a lighting power source, please follow the instructions in this manual.
2-10
C. Work in an enclosed room

荫 The exhausted gas of engine is poisonous and if you have to
work in a closed room, you must use the ventilation devices. If
you have not installed the ventilation devices, you should open
door and windows.
Figure 2-12
D. Working under the machine

荫 Stop the loader on a smooth ground, and put down all the
working mechanism on the ground before working under the
loader.
荫 Block the wheels with chocks.
荫 It is very dangerous to work under the loader which is only
supported by working mechanism.
荫 Never work under the loader which is with poor supporter.
Figure 2-13
E. Working on the top of the machine

荫 When carrying our maintenance on the top of machine, ensure the foothold is clean and there are no
barrier obey with the following instructions for preventing falling down.
翌 There are no sprinkled lubricating grease and lubricant on the machine.
翌 Don爷t leave tools everywhere.
翌 Pay attention on the paces while walking on the machine.
荫 Don爷t jump off from the machine directly. When getting on or off the machine, please face toward the
machine, and use the ladder and handrail
荫 Use the protecting device under the special circumstance.
荫 The top of the engine hood is smooth and slippery, so no people will be allowed to stand on it.
荫 Standing on the top of tyre is dangerous, so never stand on the tyres.
荫 When cleaning the front glasses of the cab, you should stand on the splash fender of front frame.
F. Servicing the machine while the engine is running

In order to avoid injury and accident, don爷t carry out
maintenance work for the running engine. If maintenance has to
be carried out while the engine is running, follow the following
instructions:
荫 Appoint a man sitting on driver爷s seat and get ready to stop
the engine at any time.
荫 Don爷t touch exhausting pipe or high temperature parts, such
Figure 2-14
as end tube, muffler, etc. so as to avoid scalding.
2-11
荫 When working close to a rotating part, there is the risk to be rolled inside by rotating parts, so special
care should be given.
荫 Don爷t touch any control handle. If it is necessary to operate a control handle, firstly make a alarming to
other people and ask them to leave.
荫 Never touch the rotating leafs of the fan or the fan belt as it is very dangerous.
荫 Don爷t adjust the part that you do not understand.
G. Don爷t leave anything falling into the machine

荫 When opening the cover or oil-filling hole for repairing, care should be taken not to drop anything into
the machine. If anything has fell into the machine, it may cause breakdown, you must take it out.
荫 Unnecessary tools and parts should not exist in your pockets when maintaining the machine.
H. Heavy objects
荫 While using the hammer, wear the protective glasses, security helmet and protective clothes. And a
stick of copper cushion is needed between the hammer and the parts to be struck.
荫 If using a hammer to hit a hard part such as pin or bearing, there will be the risk that crashes may
enter into eyes, so special care should be given.
荫 Use tools and heavy objects carefully and avoid them falling down.
I. Repair by welding
Welding must be taken by skillful workers at places with proper equipment. Gas, fire or electric shock can
be produced when welding. So it is disallowed for unqualified persons to carry out the operation. The
following instructions must be obeyed while welding:
荫 The end of battery should be disconnected in order to prevent the battery from exploding .
荫 Disconnect the clip connection of the computer control panel of the transmission (which is placed in the
control box right side of the driver爷s seat in the cab) to prevent burning the panel when welding; After
finishing repairing, insert back the clip connector of control panel properly according to the
requirement, otherwise you can爷t start or run the machine.
荫 Clear paints from welding place in order to prevent the
production of the pernicious gas.
荫 Burnable vapor and spark may be produced when welding on
or near the hydraulic equipment or pipelines, which may
cause fire, so welding in above mentioned places should be
forbidden.
荫 If sparks caused by welding drop on rubber hose, electric
wire or pressure pipeline directly, these tubes may burst
suddenly, the insulating cover of the electric wire will be Figure 2-15
damaged, so please use fender to guard these pipes.
荫 When welding near tyre, special attention should be paid
because it may explode.
2-12
荫 When welding, protective clothes should be wore.

荫 The ventilation of the welding place should be well prepared.
荫 Clear up all inflammable material, and fire extinguisher
should be supplied at the site.
Figure 2-16
2.3.2 Checking and Maintaining to Every System
A. Inspection and service for the cooling system
荫 When just finishing work, the hydraulic oil temperature, the oil and water temperature in engine and
radiator are very high and still have pressure. At this moment, any attempt to open oil tank, radiator,
drain oil or water, or change the filter may be severely burnt. Wait till the temperature fall down and
observe the required program when doing the above operation.
荫 To prevent splashing hot oil, turn off the engine, cool the hot water and open slowly to release the
pressure. When checking the temperature, put your hand close to the front of water radiator, check the
air temperature. But pay attention not to touch the radiator.
荫 For preventing hot oils from splashing out , stop the engine and let oil get cooled. And slowly open the
cover of hot oil tank cover to release its pressure. When checking if the oil temperature has been cold
or not, get your hand near the front of radiator for hydraulic oil and torque converter oil. And check air
temperature. Don爷t touch the radiator.
荫 Don爷t touch the engine body or muffler, exhaust tail tube and relay when the machine is still hot, and
avoid being scalded.
荫 Don爷t remove the engine oil temperature sensor, water temperature sensor, torque converter sensor and
air-conditioner tubes so as not to get scaled.
Figure 2-17
荫 Cooling system contain alkaline material, so pay attention to not to have the cooling system touch your
skin and eyes.
荫 When replacing coolant liquid, engine oil, transmission oil and oil filters, etc, use the proper container
to hold these oil liquid. The disposing to waste liquid should be conformed with the local rules and
regulations.
2-13
荫 When you need to remove the air -conditioner tubes, remember not to expose the tubes to fire and
flame. Otherwise it will cause injury due to poisonous gas.
B. Inspection and service for hydraulic system

荫 Before making any inspection and service for hydraulic system, securely lock the hydraulic cylinders
and other hydraulic devices. Have the hydraulic oil get cool, then release all the pressure from the
hydraulic system.
荫 Don爷t bend or hit the high -pressure pipelines. And never mount the tubes and hoses that are bent
abnormally or already broken on the machine.
荫 If some tubes or hoses which are used for fuel circuit, lubricating oil circuit and hydraulic system
circuit become loose or broken, get them fixed. Leakage may also cause fire, please repair it or make
replacement.
荫 Please check carefully all the tubes and hoses, and tighten all the connection fittings with torque as
required. When making inspection for any oil leakage, use a clean piece of plate or paper board to
make such inspection rather than by means of hand, since the liquid pressure from leaking point will
cause severe health injury, even if the leaking point is very small, like a needle eye, the leakage
pressure can strike through your skin. If oil liquid splashes onto your skin, seek help from the
competent surgeon to treat the case within several hours. And replacement should be made if following
cases are found:
吟 Connecting fittings be broken or leakages appear.
吟 The external coating of hoses are worn out or cracked and their reinforcing wires are exposed.
吟 Hoses get bulged at some particular locations.
吟 Hoses get obviously twisted or deformed due to pressing.
吟 The hose reinforcing wires get extending out.
吟 End is connected wrongly.
荫 Make sure that all pipelines clamping, protection and insulating plates are correctly mounted, so as to
prevent shocking and conflicting with other parts.
荫 When replacing coolant liquid, engine oil, transmission oil and oil filters, etc, use the proper container
to hold these oil liquid. The disposing to waste liquid should be conformed with the local rules and
regulations concerning environmental protection.
C. Air reservior
Discharge the water from air reservoir every day, especially in winter. Ensure that the water draining valve
is closed before starting the machine.
D. Electrical system
Only the qualified technician can service the electrical system.
When you adjust the out-sourcing electrical power, please connect the grounding -line at last to prevent
generating sparkle around the battery, which, otherwise, could result exploding. Bear it in mind that
2-14
the grounding-line is connected from the end of the regulator to that of the starter.
E. Engine hood
Don爷t service the non-mental engine hood willingly. The dust produced by polishing the hood can cause
exploding, and the dust is injurious to your health.
F. Rejected staffs
Please obey with following instructions to prevent the pollution.
荫 Don爷t pour the rejected oil liquid into rivers and sewer network.
荫 The drained oil must be placed in a container rather than pouring it directly onto the ground.
荫 Please respect the local relative laws and regulations when disposing the the harmful and poisonous
materials, for instance: lubricant, fuel, cooling liquid, battery and so on.
G援Fire prevention
荫 When refilling fuel, it is a must to stop the engine. And during refilling fuel, it is prohibited to smoke
or expose to fire or flame.
荫 The storage for fuel, grease and other combustible staffs should be kept far away fire.
荫 Clean away all the combustible staffs, such as: fuel, lubricating oil and other foreign articles built-up
on the machine. And make sure there is no any oily cloth or other combustible material existing.
荫 There will be some explosive gas producing near the battery, so never get it near to fire or flame.
Strictly follow the relative instructions to maintain and use the battery.
荫 When parking the machine, care should be taken to select the suitable parking location and its
surrounding environment. And special attention should be
paid to ensure that there is no withered grass, used paper
and other combustible material near the muffler of the
machine.
荫 Check if there is any leakage of fuel, engine oil and
hydraulic oil. If it is in case, replace the broken hoses. And
only after cleaning and fixing the problems, you can make
another attempt to drive the machine again.
荫 Check if the electrical wires get broken or failed. If finding
any damage, replace it with a new one. Figure 2-18
荫 When cleaning the components, use the non -combustible
cleaning solvent. Don爷t use the petroleum oil or other combustible liquid for cleaning.
荫 Don爷t make any welding or fire -cutting on the pipelines or tanks which contain combustible liquid.
Before you make any welding or cutting, clean the pipeline first with non-combustible cleaning solvent,
then make welding and cutting.
荫 The ether is a kind of combustible material, so avoid it exposing to fire or flame. When using it, strictly
follow relative instructions.
2-15
荫 Prior to making any service and repairing, check if the

fire -extinguisher is proper or not. Know the storage
location of the fire-extinguisher and first-aid kit.
荫 When it is needed to check the dark area on the
machine, don't use flame or fire to lighten this area.
H. Maintenance for battery Figure 2-19

This battery is made by Johnson Controls, Inc..
荫Open the battery box to check the surface of battery. Ensure that no acid get out and no crack and dirty.
荫Check the battery condition:
要 Green: it means the battery is full.
要要
要 Black: it means the battery is need charging.
要要
要 White: it means the battery is must to be replaced.
要要
荫 Remove the dirty from battery surface.
荫 Clean the pole
荫 Check the fastener.
The battery electrolyte contains sulphuric acid and can produces hydrogen, so incorrect handling for the
battery will cause serious injury and fire risk, therefore, the following points must be obeyed:
荫 Never get the lighted cigarette or flame close to the battery.
荫 When you have to touch the battery during working, you ought to wear safety glasses and rubber gloves.
荫 If the electrolyte is splashed onto your clothes or skin, rinse
it off with plenty of fresh water immediately.
荫 If the battery electrolyte is splashed into eyes, it will cause
blindness. In this case, rinse the eyes with plenty of fresh
water and go to hospital right away.
荫 If you drink the electrolyte carelessly, then you must drink
a lot of water, milk, fresh egg or vegetable oil, and get help
from doctors or go to hospital immediately.
荫 Before operating about the battery, remember to stop the
Figure 2-20
engine.
荫 Avoid the touching of metal staffs ( e.g: tools), which could cause short circuit to positive pole ( +) and
negative pole (-) of the battery.
荫 When installing the battery, fix the positive pole (+) first; when dismounting the battery, disconnect the
negative pole (-) first.
荫 When disassembling or installing the battery, firstly check which pole is positive pole and which is
negative pole, then tighten it with screws. If the electrolyte level reaches near 野 lower冶, then refill
stilled water till it reaches 野 upper冶 level.
荫 When cleaning the top surface of the battery, use a piece of cloth to wipe it. Never use petroleum oil
and other organic solvent and cleaning solvent.
2-16
荫 Tighten the top cover of the battery.

荫 If the electrolyte has been frozen, don爷t recharge the battery
and start the engine with other power source either, otherwise
it is very dangerous and will cause battery gets fire. When
charging the battery or starting the engine with other power
source, melt the battery electrolyte first before attempting to
start the engine, and you also need to check if there is any
leakage. Figure 2-21
荫 Remove the battery from the machine before recharging the
battery.
荫 When repairing the electric system or doing welding on the machine, it is needed to remove the
negative pole (-) of the battery to prevent the current flowing.
When recharging the battery, if handle the battery incorrectly, then there is the risk of battery explosion.
So the procedure for recharging the battery should be in line with required process and instruction, and
also obey the following points.
荫 Recharging for the battery should be done in a place with good ventilation. Take out its top cover, by
doing so hydrogen scattering and explosion can be prevented.
荫 Set the recharging voltage according to the voltage requirement for the battery to be recharged. If the
recharging voltage is wrongly set, then it will cause the recharger getting too hot or fire and also
possibly explosion.
荫 Connect the positive (+ ) clamping -terminal of the recharger with positive pole (+ ), and negative
terminal (-) with negative pole (-). And fasten their connection.
荫 If the recharging ratio is less than 1/10, then you have to make rapid-recharging and set it within the
battery爷s rated capacity. If the recharging current is too much, then it may cause electrolyte leakage or
evaporation, which will possibly cause fire or explosion.
Don爷t dispose the rejected battery willingly everywhere if it could not be used due to aging or
deterioriation. Also, don爷t pour its acid liquid willingly everywhere, as the acid liquid may bring serious
damage to people爷s health and animals or bad pollution to the surrounding environment.
荫 If the tyres explode, the explosion itself will throw the wheel hub, tyres, driving axle and other
components 500m or more far away from the machine. And explosion and its partials will cause server
damage and healthy injury, so the tyres pressure must be maintained at normal pressure range. Never
inflate the tyres beyond its rated pressure range.
荫 During traveling, the heat produced due to high-speed machine traveling will cause the tyres pressure
arising to some extent, which is the normal case, please don爷t attempt to reduce the tyres pressure.
2-17
2.4 Lubrication and Maintenance
What you should do is to reduce the machine traveling speed

or just stop the machine to have the tyres cooling down.
However, if the machine keeps moving at very high speed
continuously, which will cause the tyres being overheated,
then tyres explosion will be led, so attention should be given.
荫 When adjusting tyre pressure, keep away from the tyre as far
as possible. And you should always stand at the back of the
tyre.
Figure 2-22
荫 It it prohibited to inflate the tyres with combustible gas. It is
recommended to use dry Nitrogen . If the tyres have already been filled with air, you can also use
Nitrogen for pressure adjustment purpose, and Nitrogen can be well mixed with air. Inflating tyres with
Nitrogen can possibly reduce the risk of tyres explosion, since Nitrogen doesn爷t help combust but can
prevent the rubber oxidation and deterioration and avoid rust for wheel hubs.
荫 In order to avoid tyres being over inflated, it is necessary to have proper tools to be used for inflating
tyres with Nitrogen and relative training on how to use these kind of tools.
荫 Check tyres and wheel hub. Don爷t operate the loader when the tyre pressure is very low. And also
check if there are any cracks or deformation on the tyres.
荫 Check the mounting screws and bolts on the wheels to see
if they are securely fastened as required by the
manufacturer.
荫 During checking the wheels, don爷t make any access to the
steering wheels, both in the front and in the back. Such
checking should be done from the wheel sides. When you
need to remove one of the wheel, other wheels should be
blocked with wedges.
荫 When performing welding near a wheels, special care Figure 2-23
should be given because the tyre wheel may cause

explosion,
荫 Repairing the tyres and wheel hubs is a dangerous job.
Only the trained and competent personnel can make
inspection and maintenance to tyres and wheel hubs with
the help of proper tools and correct procedures.
荫 When replacing a tyre, make sure the tyre to be used is
correct. All tyres should be same in terms of specification Figure 2-24
data and texture.

The maintenance is very important to the loader . It is a wrong idea that the maintenance is unnecessary
as long as the loader can work normally. The right maintenance not only can prolong the service life of the
loader , but also can find the trouble early , so the repairing time and cost should be saved.
2-18
2.4.1 Checking and Maintaining Before and After Working

A. Checking before working
荫 Water level of the radiator.
荫 Oil levels inside the sump of the engine.
荫 Oil levels inside the fuel tank, hydraulic reservoir and transmission.
荫 Seal of each oil hose, water hose, water hose, air hose and their connectors.
荫 Connections of the batteries.
荫 Reliability of service brake and park brake.
荫 Flexibility of each control lever and shift them into their neutrals.
荫 Inflation of each type.
荫 Fastening of the rim bolts, axle bolts and other screws.
B Checking and maintaining after the working
荫 Check the fuel level.
荫 Oil level and cleanness of the oil sump. If the oil is found over-leveled and diluted, cause should be
found out and cleared.
荫 Leakage from each hose and their connectors.
荫 Fastening, sealing and overheating of transmission, torque converter, hydraulic pump, steering devices,
axles and brake clippers.
荫 Fastening of all the pins and bolts on wheel rims and transmitting shafts.
荫 Empty the radiator when the environmental temperature is below 0益(except with antifreeze).
荫 Check if the brake liquid is enough or not .
荫 Clean the oil-water separator and drain the water in the air tank.
荫 Lubricate each grease point as required in the time schedule.
Reasonable inspections and maintenance are necessary to your loader. Be careful not to cause any accident
or hurt yourself. If something abnormal is found during your inspection, mark it first and fix it after all the
checking items.
When inspection is carried out with the bucket highly raised, make sure that it cannot fall down.
Fire is strictly forbidden when checking or maintaining. No smoking is permitted and fire extinguisher must
be at hand.
2.4.2 Periodical Checking And Repairing

Time schedule for periodical maintenance
Inspection and service schedule for engine ( Table 2-1 )
Inspection and service schedule for electrical system ( Table 2-2 )
Inspection and service schedule for steering system ( Table 2-3 )
Inspection and service schedule for transferring device ( Table 2-4 )
Inspection and service schedule for working device ( Table 2-5 )
Inspection and service schedule for braking system ( Table 2-6 )
Inspection and service schedule for miscellaneous items ( Table 2-7 )
2-19
2-20
2-21
2-22
2-23
2-24
2.4.3 Periodical Maintenance

The proper lubricating and maintain can ensure the normal operation and prolong the machine service life,
so the time and cost of repair can be reduced.
The periodical maintenance is divided into six time modes: 50hrs, 100hrs, 250hrs, 500hrs, 1000hrs,
2000hrs.
荫 Fasten the connecting bolts of front and rear transmitting shaft .

荫 Check the oil level in braking booster.
荫 Check the oil level of transmission.
荫 Check the oil level of front and rear axle.
荫 Check the engine oil level and fill the oil if necessary.
荫 Check the accelerator control hand brake and gear-shifting performance.
荫 Inject grease to fan shaft , chassis articulating pins, transmission shaft, rear axle supports and steering
pins.
荫 For draining sediments and mixed water from fuel , loosen the drainage plug that is at the bottom of
fuel tank.
荫 Check the hydraulic oil level.
荫 Clean the oil filling filter of fuel tank.

荫 Replace the gearbox oil firstly.
荫 Check if the mounting bolts for wheel rims and braking disc are securely fastened.
荫 Engine air gap : check and adjust
荫 Adjust the tension of fan belt. Press the central point between engine pulley and fan pulley with about
6kg force. The normal tension flexibility of the belt is about 10mm. After adjusting, mounting bolts
should be tightly fastened.
荫 Measure the inflation pressure of tyres.
The inflating pressure of tyres should be measured before starting the machine.
Tyre pressure: Front tyres: 0.32~0.35MPa Rear tyres: 0.28~0.30MPa
The following maintenance should be performed only after the first 250 working hours.
荫 Fuel filter : replace the filter core
荫 Transmission oil filter : replace the filter core
荫 Clean the filters of oil filter and fuel filter and transmission filter.
荫 Fill the battery liquid and clean its surface , apply some Vaseline on its connector..
荫 Check if the working mechanism, frame, weld and fixing bolts get loose or cracked. And fasten the nuts
on wheel rims.
荫 Lubrication : Inject grease to the bucket pin, bucket link pin, boom pin, rocker pin, tilt cylinder pin,
raising cylinder pin, lift arm pin, steering cylinder pin .
2-25
荫 Replace the oil of transmission system and clean the filter for oil-pan.
荫 Fasten the bolts that connect the axles and frame.
荫 Check and adjust the hand brake clearance.
荫 Replace the diesel oil.
荫 Lubrication : Inject grease to the main transmission shaft, front and rear transmission shaft.
荫 Check the wear status of the disc braking device.
绎If the wear of braking cushion exceeds its maximum limit, the ineffective braking is very dangerous .
Please take more frequent checking as the braking cushion gets worn to its limit.
荫 Replace the hydraulic oil, clean the hydraulic oil filter and clean the breath hole of the transmission
system & torque converter.
荫 Clean and check the braking booster, replace the braking oil, and check the performance of the braking
system.
荫 Clean the diesel oil filter.
荫 Lubrication : Inject grease to the articulation pin , front and rear transmission shaft , main transmission
shaft and park braking clamp, etc. .
荫 Adjust the impeller gap of the turbo charger and fasten the mounting bolts on the turbo charger.
荫 Check and repair the engine according to the Engine Manual.

荫 Check and repair the transmission system and torque converter
荫 Dismantle and check the axle, axle differential and rim reducer .
荫 Dismantle and check the steering device and steering valve and adjust the steering angles.
荫 Check the sealing status and system pressure of the multi-way valve cylinder and working cylinder by
visibly checking how much the working cylinder has dropped down. If the cylinder has dropped down
one time beyond the designed value, then you need to dismount the cylinder and valves to figure out
cause.
荫 Check if the cracks occur on working apparatus and welded parts. And check if the nuts and bolts are
securely fastened.
荫 Check the welding position on rim and correct any deformation.
荫 Replace the gear oil in front and rear axle.
2.4.4 Checking And Maintaining To Machine Component
2-26
The detailed checking method and maintenance to this engine are listed in the manual along with the
engine.
荫 Battery
吟 The batteries should be kept clean. As the tops or terminals of batteries are easily polluted, and that
will be the main reason of electricity escaping, so they must be cleaned frequently.
吟 When assembling electrode terminals , grind them first and then clamp fast.
吟 Before you inspecting the electrical system, be sure to disconnect the negative terminal (- ) of the
batteries first.
吟 As explosive gas may release out surrounding the batteries, flame is forbidden to be held near them.
荫 Wires and fuses
吟 Always pay attention to the connections and protecting peel of wires and the clamping of the fuses.
吟 If one line works abnormally, the fuse of this line should first be checked.
吟 If the fuse is to be replaced , causes should be found out , and then check the lamp bulbs and
disconnection.
吟 Fuses are located at upright corner of the cab and under the left side of the instrument panel .
吟 The capacity (ampere ) on the bulb and clamp must also be checked.
荫 Lamps and instruments
吟 Check the function of each lamp switch.
吟 Dirt on lamps must be cleaned away
吟 Press the horn button to check the sound.
吟 If the pointer of meters stay in green area, it is normal.
荫 Fully hydraulic steering unit has been adopted in this type of loader . When the loader works correctly,
driving direction can be changed by a slight turning of the steering wheel . When you feel hard to steer,
do not turn the steering wheel rudely, stop the loader for checking. Operation can be resumed after the
trouble has been eliminated.
荫 Don爷t turn the steering wheel before starting the machine.
荫 Don爷t forcefully turn the steering wheel in case it gets hard to turn it.
荫 After 2000 working hours, the steering valve should be dismantled for inspection and steering angle be
corrected. When internal or external leakage happens to the steering cylinders, inspection is necessary
and seals should be replaced.
荫 After 2000 working hours, the gearbox, torque converter , main drive and hub reducers of the driving
axles should be dismantled for inspection and washing . Pay attention to abnormal noises from the
transmission system during operation.
荫 Transmission pipe-line filter
When replacing the filter element, first release the dirt and debris out, and then take off the cover to
2-27
change the filter element with a new one. Afterwards, replace the cover.
荫 Transmission shaft Check if the mounting screws and the spline are securely fastened. And also check
if there is any vibration at the driving shaft.
When dismantling and reassembling the shafts , pay attention to the relative positions of the universal
joint yokes at the two ends , and the arrows should be kept in alignment.
荫 Wheels
Check the tyres inflation pressure and also check the tyres surface to see their wear status and to see if
there is any metal partials embedded in tyres. And the mounting nuts on wheel rims should also be
checked. Such checking should be done while the machine is cold. Normally the tyre inflation pressure
should be a little bit lower when machine operating in sandy area than that when machine operating in
hard-ground areas
Check if the locking ring is disengaged or not. Special attentions must be

CAUTION paid when inflating tyres.
荫 After 2000 hours , check the welding seams on wheel rims and also check the parts which are loaded.
If there is any deformation case, please correct it.
荫 After 2000 hours , the natural subsidence of the working mechanism should be checked. Raise the
main booms up to their utmost limit while the machine bucket is empty. Then stop the engine, be sure
descending length of the lift-cylinders should not be beyond 65mm within 15 minutes.
荫 If the descending volume is too much (over 65mm), check the sealing performance for distribution value
and lift cylinders and measure the system working pressure.
荫 Disc brake
Check the wear status for the brake friction plate and carry out air-bleeding for the system periodically.
荫 Checking to the brake friction plates
Screw off the screw pin and remove the plate cover. The friction plate can then be taken out . There are
3 ditches on the plate, which shows how much the plates are worn. If the ditches become disappeared,
the plate has to be replaced.
荫 Air-bleeding
Air trapped into the system will affect the machine braking performance. After finishing parts
replacement or system cleaning, bear in mind to bleed air out from the braking system.
When making air bleeding, take a piece of transparent hose and insert its one end into the air nozzle
while the other end is put into an oil container. Release the nozzle and trample down the braking pedal
several times continuously till there is any oil liquid coming out without bubbles. Afterwards fasten the
nozzle and then release the braking pedal.
荫 Brake pedal
The performance for braking pedal can only be checked while the machine is traveling. And also
figure out if the braking performance is only acting on one side.
2-28
2.5 Structural Principle and Maintenance Precautions
Check the pedal clearance after the pedal has been trampled down, movement to its front end must be
of the clearance of 13 to 23mm.
荫 Booster pump
After working for 2000 hours , the booster pump should be dismantled and thoroughly serviced.
荫 Parking brake
Engage the hand brake and check if the loader is under braking condition. If the braking performance
is not good or abnormal phenomena appears, please find out the reason and eliminate it. The frictional
lining and braking drum must be checked .
荫 After 2000 hours operation, the whole loader must be visually checked . Pay attention to damages ,
deformations, cracking , welding peelings and other shortcomings which can hinder normal operation ,
especially the working apparatus and wheels.
荫 After 2000 hours, check the fastening of each screw and nut on the loader . Fasten it if necessary.
Special attentions should be paid to the rim nuts and screws on the suspending parts. Check the sealing
of each hose connection , engine, radiator and transmission system for oil or water leakage.
荫 If leakage is hard to be found , stop the engine and clean the part that is to be checked , then restart
the engine.

This loader is composed of engine, transmission system, steering system, braking system, frame, working
device, hydraulic operation system, cab and electrical equipment and so on.
2.5.1 Engine
The engine is composed of diesel, air filter, exhausting pipe, cooling system and pipes and so on. Service
and maintain the engine according to 野Engine Manual冶 that attached to the engine.
窑 If the machine is to be transported for a long distance or parked for a long time in cold weather and its
cooling liquid has not been filled with anti -freezing agent, please open the drainage plug of diesel
engine, water pump, engine oil cooler, lower chamber of water tank and oil cooler of torque converter to
discharge all water. Doing so in this way can prevent above-mentioned parts from being damaged due to
water freezing.
窑 If there is some oil mixed in the cooling liquid or some water in the engine爷s oil cup, besides checking
the engine itself, please also check if the filters for both water tank and engine oil get cracked.
窑Also needing to be checked is the fastening of the bots on the engine fan.
窑 The rain water, tap water and pellucid river water can be used as cooling water. The well water, which
contains much mineral material in water, should not be used directly as cooling water, as the mineral
material might produce incrustation scale in engine爷s water chamber, the result of which is the poor
cooling performance for the engine. So, it is not highly recommended to use well water; or you can use it
only after it is softened. In the circumstance of machine application under extremely cold area or in
winter, please fill anti-freezing agent into the cooling water to prevent cooling water getting frozen.
2-29
2.5.2 Transmission System

The transmission system is composed of hydraulic torque converter, gearbox, oil pipes, transmission shaft,
front and rear driving axle and wheels. (Figure 2-25)
Torque
converter Working Disc brake
oil pump oil pump
Single-stage turbo
torque converter
Steering oil
pump
Diesel engine
Rimdeceleration
Tyre
Hand brake
Emergent
brake
Figure 2-25
Proper running for torque converter and gearbox is very critical to the machine performance, therefore,
correct and regular maintenance to the torque converter and gearbox must be done strictly according to
what is stated in this manual.
荫 The maintaining before driving Preparation work and maintenance before machine driving
Before having the gearbox running, it is a must to firstly check oil level inside the gearbox. If finding oil
level is not enough, please replenish with fresh gear oil with correct type and spec. In case it is an initial
time to fill the gearbox with oil, you must take the radiator, filter and its pipelines into consideration,
which means those parts also must be full with gear oil as well. Therefore, the oil filling volume for the
initial time is always more than that to be needed during the regular maintenance procedure. Checking oil
level in gearbox should be done only when the Neutral-gear being engaged, engine running at idle speed
and gear oil inside the gearbox being at ambient temperature.
Please check the gearbox oil level at right side of the gearbox itself.
荫 Machine driving and gear-shifting
Before starting the engine, it is a must to place the hand-lever at Neutral position.
Just for the sake of safety, the parking brake should be engaged before starting the engine, so that the
2-30
machine itself doesn爷t move together with starting of the engine. After the engine being started and before
the machine driving, please firstly disengage the parking brake, and then move the hand -lever at your
desired gear, then drive the machine forward slowly.
Every time you stop the machine, please get the parking brake engaged, otherwise the machine will still
move under a certain traction force generated by engine before the engine itself totally stops.
While the machine driving, you also need to disengage the parking brake, otherwise oil temperature inside
the gearbox will rise very high and parking brake will also get very high temperature very soon, as the
machine torque converter produces very large power output during the machine driving with gear-shifting
lever being engaged.
Put all the control handles at theirs neutral position before starting engine.
CAUTION
荫 Temporary parking and stop

In case of stopping the machine, you need to place the control handle at Neutral position, then immediately
raise up the hand brake to get the machine braked. As there is no rigid link between the machine engine
and the output shaft of torque converter, therefore, if in the circumstance of parking a machine onto a slope
( both upward or downward) and operator needing to leave the machine unattended, then it is highly
recommended to block the machine wheels with wedges or wood blocks besides already having the hand
brake engaged, so as to prevent the machine from slipping from the slope.
Also, in case of parking a machine for a long term on a flat area, then it is also required to block the
machine wheels with wedges or stones, just for the sake of accident prevention and machine safety.
After the machine stops, please don爷t let its engine and torque converter run for long time at idle speed.
荫 Oil temperature and oil pressure
Oil temperature in torque converter: On operation panel there is a temperature gauge to monitor oil
temperature for the torque converter, so please keep close watch at the temperature gauge, which should
always read normally the range of 80益耀110益, but this range of temperature readings could rise to 120益
at its maximum within short time when the machine is loaded with heavy duty, which is acceptable within
a short period of time.
The oil temperature of torque converter oil should not exceed 120益. Stop and check the machine for oil
leakage if the temperature exceeds 120益 . At the same time, if the oil temperature can drop to normal
temperature quickly under the circumstance of the engine running speed being at 1200 耀1500 r/min and
the gearbox being engaged at Neutral gear for 2 -3 minutes, it means the transmission works well.
Otherwise, stop the machine and find out the trouble reason and eliminate it before you attempt to restart it
again.
Oil pressure for gear-shifting:
The oil pressure for gear shifting should be always normally at the range of 1.08耀1.47Mpa. So if it is found
that oil pressure drops below the minimum pressure when a certain gear is engaged and the clutch is also
engaged, then it shows something goes wrong, then you must figure out the reason why the oil pressure
goes down and eliminate the trouble. The oil pressure failure for the clutch is much related with oil
leakage from the oil pump and blockage of the oil distribution valve. If the oil pressure drops too low, it
2-31
will cause the clutch to slide or to be worn very fast, which finally will result severe damage to the clutch,
as the clutch discs gets overheated due to constant sliding.
Oil pressure for the torque converter is already set up at the time of machine ex-work, with input pressure
of 0.30耀0.45Mpa and output pressure 0.20耀0.30Mpa.
荫 Oil Replacing
The oil liquid used on this machine must be periodically replaced at a certain interval according to what is
relatively stated in this manual. In case of needing to replace the oil liquid for the machine, please park
the machine onto a flat piece of ground, then start the engine to get the oil temperature inside the gearbox
rise up to 60益, then afterwards, unscrew off the oil-drainage plugs on the gearbox and radiator for empty鄄
ing the used oil out the gearbox and radiator respectively. After finishing oil draining, clean the plugs and
area around the plugs, then re-mount the plugs onto their original location together with the new sealing-
ring, afterwards, replace the oil filter and fill the gearbox and radiator with fresh gear oil up to desired
level.
You need to empty oil from not only from the gearbox but also from the
CAUTION torque converter and radiator as well.
After the initial 100 working hours, it is a must to do the first -time oil
replacement for the machine. Then afterwards, every 1000 working hours
CAUTION
or every year, it is necessary to replace the oil liquid once a time at least.
During the regularly scheduled maintenance and service to the machine, if it is found there is any signs of
oil quality deteriorating or mixing with other foreign materials, then it is required to check, clean and re鄄
place with the fresh oil.
The transmission shaft for front and rear driving axle is connected with a universal joint by bolts. Such
structure is featured in easy dismantling and reliable performance.
The transmission shaft has been dynamically balanced, so when dismantling the transmission shaft, please
take a notice to the relative position of universal joint, which is that the universal yokes at the two sides of
the transmission shaft should be placed in the same plane, so please assemble the universal yoke in the
way as indicated by the arrow.
The universal joint assembly should be mounted together with the transmission shaft in such way that it
can rotate freely without any blockage after being connected with transmission shaft. And also bear it in
mind not to willingly increase or decrease the rolling-needle inside the roller bearing.
Fill lubricating grease into the rolling-needle bearing of universal joint as scheduled.
Bolts used on the transmission shaft is of alloy steel, which should not be replaced by other material-made
bolts, so please don爷t use different bolts to hold the transmission shaft.
The driving axles has both front and rear driving axle, with main difference on the rotation speed of their
2-32
gear. Gears inside the front axle rotate to left, while gears inside the rear axle rotate to right.
For the purpose of increasing traction power, the machine adopts 4-wheel drive system.
The driving axle is composed of axle casing, main reducer (including its differential), axle shaft and hub
reducer.
The axle casing is fixed on the frame, which bears the load from the machine frame and transfers it to
wheels, it also is the casing for main reducer, axle shaft and hub reducer.
The main driver is one stage spiral bevel gear reducer, and it mainly is used to increase the torque of the
transmission system, lower the transmission and change the driving direction.
Differential is a planetary gear couple which is consisted of two bevel axle shaft gears, spider, four bevel
pinion gears and left and right differential cage . It differentiates the speed for the left and right wheel and
transfers the torque of the main transmission and movement to the hub reducer.
The left and right side shaft is of full floating type, which can transfer the torque from main transmission to
rim decelerator.
Semi-shafts on both left and right is of fully floating type, which function to transfer power and movement
generated from the driving axle and differential to the hub reducer.
Hub reducer is a planetary gear transmission mechanism. With its inner gear ring fixed on hub bearing,
planetary gear and hub rotating together. Function of the hub reducer is to increase the torque of driving
system and reduce the speed of transmission.
Tyres and rims are the main driving device . With the low-pressure wide-base cross-country tyres (23.5-
25), the loader has a good off-road performance.
2.5.3 Braking System

Braking system is used for speed controlling or parking on the flatland or slope.
This loader has two braking systems .
This braking system is used to control speed in normal traveling, with advantages of being smooth and safe.
The system adopts dry-type air-over-oil braking system, which is featured in reliability, safety, easy main鄄
tenance and simplified structure. The system can automatically offset wear for braking plates, with nice ra鄄
diation performance and long service life and none noise.
This system should be used after the loader stops on a slope or a flat ground.
荫Check the braking performance
Braking performance is directly related to your safety and working efficiency , you must check if the brake
system works very well. After repairing it, the brake distance must less than 15 meters when the loader
runs at speed of 32km/h on straight and dry road. The loader must appear brake quickly without deviation
after you lightly step on pedal when the loader runs at speed of 32km/h.
荫Maintain the braking system
CLEAN: It is a must to clean it so as to make it work well.
CHECK: It is a must to check brake system if it leaks, all joints get loose, oil level is normal, oil pipes are
straightway and rubber parts are aged.
2-33
2.5.4 Hydraulic System

The hydraulic system of LW300KN loader includes working hydraulic system and steering hydraulic
system.
Working Hydraulic System (Common type)

Working hydraulic system of the loader is used to control the movement of lift arms and bucket. It mainly
is composed of working pump, hydraulic control valve, double-function safety valve, lift cylinder, tilt, oil
tank and pipes and so on.
If the direction-changing valves of lifting arms and tilt cylinder all are in neutral position, high pressure
oil in oil pump returns back to oil tank, then the front and rear chambers of lifting arm cylinders and tilt
cylinders will all close, so the lifting arms and bucket will be kept at original position. Direction-changing
valve of lifting arm cylinder can be used to control the lifting arms and direction-changing valve of tilt
cylinder can be used to control the bucket. Double-effect safety valves are installed in the front and rear
chamber of the tilt cylinder, it can resolve the disharmony of working mechanism.
Working Hydraulic System (Lead operation)
The hydraulically activated working system of the machine is functioning to control the movement of main
boom and bucket, which is mainly consisted of pump, multi-way valve, pilot valve, check-valve, selector
valve and energy accumulator, safety valve, boom cylinder, bucket cylinder, oil tank and oil lines.
The pilot valve can control bucket -control -lever and boom -control -lever. The bucket -control -lever is
designed with three position, saying specifically at: front tilting, neutral and back tilting; while, the boom-
control -lever is designed with four working positions, saying at: raising, neutral, lowering and floating
position. A solenoid valve is set for regulating the positions for raising, floating and back-tilting.
When the control lever being put at neutral gear, the slide valve remains at its starting-position and the oil
chamber closes. At this time, the control port is linked with oil returning chamber and the multi-way valve
is at its neutral position.
When pressing down the control lever, the measuring spring will push the measuring valve downward to
cut off the oil way that connects with the control chamber and the oil returning chamber. At the same time,
the oil inlet chamber is connected with oil controlling chamber, then the pilot oil will reach to the another
side of the multi-way valve and make it move, by which to realize the steering performance.
At the same time, the oil pressure from the oil chamber also acts onto the measuring valve and be in
balance to the measuring spring force, that is to say: when the control lever is maintained at a certain
position, then the measuring spring also keeps at a constant force and the oil chamber also has the
constant pressure, which is similarly functioning as a constant-flow valve. The valve travel is proportional
to the angle of pilot-valve control lever, through which to realize the proportional pilot control.
When moving the pilot control lever to have the bucket be at its fully raised position or have it fully
retracted, then the magnetic force generated from the wiring will position the control lever at such position
and lock the pilot-control valve till the bucket is raised to desired position or at its limit angle, then the
bucket爷s limit switch will be disconnected electrically, which results to have the wiring being powered off
and have the spring acts, under which to restore the control lever to its neutral position.
When moving the control lever to have the bucket lowering down till it coming to 野 floating 野 position, the
pilot valve will be locked, as at this position there is no position locking made by wiring magnetic force.
2-34
Then, oil pressure at valve port gets increased, which opens the valve and releases the oil pressure to oil
tank. As long as pulling up the control lever, the spring will act to restore the control -lever back to its
neutral position.
For on-spot checking, the hydraulic system of working mechanism can be checked by means of raising or
lowering lifting arms, tilting the bucket, releasing pressure from distribution valve and safety valve and
descending the lifting arms.
荫 Check the highest pressure of the system
Screw off the plug on the oil tube of the hydraulic control valve and fix a 25Mpa pressure gauge, then lift
the arm to horizontal position, have the engine and hydraulic oil be their working temperature and keep
the engine running at rated speed. Operate the bucket control lever to tilt it backward till the pressure
reaches to its maximum which will be 16MPa. If it is not the case, please adjust the safety valve of the
hydraulic control valve.
荫 Check and adjust the pressure of the double-effect safety valve
吟 Checking and adjustment for big chamber safety valve of tilt cylinder.
Screw off the plug on tube of the tilt cylinder big chamber, and fix a 25Mpa pressure gauge, then raise the
lift arm to the highest position. Have engine and hydraulic oil be their normal working temperature and
keep the engine running at idle speed. Tilt the bucket to its most front position, then lower the lift arm. At
this time, the pressure reading will be 17.5 Mpa. If it is not the case, please adjust it.
吟 Checking and adjustment for small chamber safety valve of tilt cylinder.
Screw off the plug on the tube of the tilt cylinder爷s front chamber, and fix a 16Mpa pressure gauge, then
raise the lift arm to its horizontal position. Have engine and hydraulic oil be at their working normal
temperature and keep engine running at idle speed. Tilt the bucket to its most front position, then raise the
lift arm. At this time, the pressure reading of the pressure gauge should be 8Mpa . If it is not the case,
please adjust it.
The function of the steering system is to control the direction of the loader爷s traveling , which can make
the loader travel in direct line and change the direction flexible on steering.
荫 This system is featured in the following points:
Priority of oil distribution is given to the steering system, regardless the load burden that machine carries
or the speed that steering wheel turns, which ensures the steering system to be more smooth and reliable in
terms of its operation and performance.
Oil pumped out from the pump, on the one hand, is distributed to the steering system; while, on the other
hand, part of it will flow into other working system. Such way of oil distribution serves to efficiently pre鄄
vent oil power loss that possibly happens due to too much oil distribution to the steering system, therefore,
the machine production efficiency can be greatly improved.
荫 Working principle
Steering gear and steering cylinder consist of a position control system, displacement of steering cylinder
piston rod is in directly proportional to angle displacement of steering gear spool. Cycloid motor inside of
2-35
the steering gear is a metering device (working as oil pump at extinction steering), it transfers the oil liquid
volume distributed to the steering cylinder into angle displacement of the steering gear valve sleeve, the
relative angle displacement of spool decides opening area of oil distribution window. The higher speed
steering wheel rotates, the bigger angle displacement would be; when the steering wheel stops turning,
angle displacement becomes zero and oil distribution window closed, as the feedback control is
implemented. Return spring makes the valve sleeve cross dead zone to center with the spool. Additionally
the steering gear has a function of flow rate amplification, when steering rapidly, the variable orifice on
valve sleeve opens up allowing some oil liquid to enter into steering cylinder through it in order to fasten
steering speed. Priority valve is a uniform pressure dropping component, no matter how loads and supply
oil flow rates change, the priority valve is able to sustain pressure difference at both ends inside the
steering gear to ensure flow rate needed by steering gear.
荫 Hydraulic oil in the system must be kept clean. In case the ration of filter is larger than 75, the
accuracy of oil-suction filter should be over 400um, the accuracy of oil-return filter should be over 50um.
荫 Hydraulic oil must be checked at regular interval. If the oil cleaning degree is under 10 stage
(ISO4406-19/16) according to NAS1638 chart, the oil must be filtrated or renewed. After 1200 hours of
the loader operation, the oil must be changed and new oil should be filled according to the following
procedures:
吟 Lift the arms to their utmost height, and then stop the engine. Tilt the bucket and lower the lifting arms
by their own weight to discharge the oil that is inside the cylinder thoroughly.
吟 When the oil is still warm, screw off the plug at the bottom of the tank to discharge out the debris.
吟 Screw off the plug of the oil tank and cylinder hose to discharge out the dirty oil. Afterwards clean the
tank and filter by kerosene (or diesel).
吟 After replenishing new oil, let the engine run at a low speed and operate the working apparatus to
bleed air from the system.
荫 When dismantling the hydraulic element, keep working place tidy and clean to prevent dust, dirt,
debris dropping into the hydraulic elements .
荫 To install the hydraulic elements after finishing maintenance, please check the former rubber , oil-seal
and O-ring . Replace the bad elements that damage the seal .
荫 When dismantling the hydraulic elements, don爷t strike or hammer the elements .
2.5.5 Electrical System

The function of electrical system is to start the engine and provide electricity to illumination lamps, gauges,
electrical controls and other auxiliary apparatus, etc. for ensuring safe driving and operation of the
machine. The electrical system is consisted of those parts such as: battery re -charging, engine starting,
illumination, monitor lamps and other auxiliary elements, with system voltage of DC24V and negative-pole
being grounded.
Battery re-charging: Consisting of battery, generator and adjuster. Please pay attention to following points:
荫Battery
There are two batteries in series, with negative pole ( 野 – 野) of the first battery being linked with the
2-36
positive pole ( 野+冶) of the second battery, while the negative pole ( 野-冶) of the second one being grounded.
The positive pole (野-冶) of the first battery is connected with the main power switch, so as long as the main
power switch is turned on, then the battery provides power to the machine.
If the battery can work soundly, you don爷t need to remove the battery for charging or discharging the bat鄄
tery, as it can re-charged by itself during its working procedure. Only in the case of none-working for long
term, the battery should be removed off from the machine and get it charged once time every month at
least.
It is necessary to check the battery electrolyte level once time at least at interval of every 10要15 days in
winter season and every 5要6 days in summer, and it needs to check the battery appearance condition and
keep it clean.
Never put anything metal staffs onto the battery, otherwise it will cause the battery to be shorted. After the
battery being mounted inside its compartment, it must be well secured to prevent it from being damaged
due to severe shock during the machine driving or operation. And also keep the battery terminal connec鄄
tors and wirings be firmly fastened.
荫Generator
The generator is driven by a motor. In case the battery having insufficient power, it will be charged by the
generator.
For details of the generator, please see Engine Manual.
荫Adjustor
It is used for adjusting the output voltage and current volume from the generator, by which to achieve the
stable output voltage from the generator.
荫 Starter
The starter assembly is consisted of ignition button, main power switch and starting motor. When starting
the machine, put the ignition button at 野ON冶 position, then the main power switch is turned on; afterwards,
move the ignition button to 野 START冶 position to engage the starting motor for starting the engine. Bear it
in mind that time for starting the engine should not be over 10 seconds. If you fails to start the engine in
one time, then you have to wait at least 3 minutes before you try to another attempt to re-start it again. It
is strictly prohibited to start the engine while it has not completely stopped yet.
It is kindly recommended, in order to make sure your machine engine could be safely started, to make the
following checking:
要check the electrical wiring of the engine to see if they get loose or tear off;
要要
要要
要check the battery status to see if it can work properly;
要check the oil input to the engine system.
要要
荫 Illumination and signal lamps
There are several lamps mounted on the machine, including: front overhead lamp, rear overhead lamp, op鄄
eration lamp, front steering lamp, rear steering lamp, instrument lamps and braking lamp, etc. Following
table lists out the bulbs size for those lamps ( Table 2-9)
2-37
No Description Q爷ty Bulbs spec.
1 Front overheard lamps 4 24V 55/50W
2 Rear overhead lamps and operation lamps 2 24V 70W
3 Front and rear steering lamps 4 24V 21W
4 Rear steering lamps and braking lamps 2 24V 10/21W
5 Rear lamps 2 24V 21W
6 Top lamp 1 24V 5W
7 Gauge lamps 5 24V 2W
8 Front small lamps 2 24V 10W
荫 Operation monitoring gauges
Function of operation monitoring gauges: to display and feed the operator the critical data of a working
wheel loader, so that the operator could know and keep in-time monitoring to the machine performance,
and take necessary measure timely in case of any unintentional accident happening, so as to avoid any
human injury or machine damages and to maintain the machine be in good order.
There are in total 6 monitoring gauges on the machine, they are respectively: engine water temperature
gauge, braking air pressure gauge, voltmeter, torque converter oil temperature gauge, fuel meter, engine
hour meter. All of these gauges ( meters) have 野red爷 settings and 野green冶 settings, with the 野green冶
settings area meaning the sound working setting data. If the meter ( gauge) points at 野 red冶 area, it shows
there is something wrong with the machine or there is potential trouble, so please stop the machine and
eliminate possible trouble. Only after all the monitoring gauges point at 野green冶 area can you drive and
operate the machine again, otherwise, it will cause severe human casualty or machine damage. This is very
important!
荫 Diagram of electrical system
2-38
2-39
2.5.6 Air-conditioner system

A. Air conditioner structure and its working system
The air conditioner system fitted on the machine can be used for heating and cooling performance.
For details of the air conditioner structure and its working system, please refer to the Air -Conditioner
Manual supplied together with the machine.
Inlet of hot water
Evaporator Compressor
IOutlet of hot water
Condensor
Liquid
tank
Fig. 2-26 Principle of Air-conditioner

1. Control valve 2. Hot water tube 3. Evaporator assembly ( including control board, heat exchanger,
blower and valves 4. Hose ( from evaporator to compressor) 5. Compressor 6. Belt 7. Hose ( from
compressor to condenser) 8. Condenser assembly ( including condenser fan) 9. Hose ( from condenser to
water tank) 10. Water tank 11. Hose ( from water tank to evaporator )
荫 Only the professional technician can repair the air-conditioner.

荫In case of needing to check and repair any part on the machine, you need to park the machine onto a
flat ground, and keep the transmission lever at Neutral position, have the braking system engaged, and
keep unconcerned people away from the repair site or working area.
荫Contacting with freezer can cause injury, so please wear eyes protector and other safety guards to protect
the eyes and skin from being hurt by exposed cooling liquid. Take special care when touching any ma鄄
chine parts, especially the parts with high temperature or any moving parts.
荫 No matter if or not the engine is running, the air conditioner system is always with pressure, so never
try to heat the cooling -agent system. In case of needing to empty the air conditioner system, it is a
must to wear eye-protector, even if the pressure gauge reads at zero. It is kindly required to dismount
the air conditioner parts with much care, even with protective measures being taken.
2-40
荫Smoking, flame and fire are extremely not allowed at the repair site for air conditioner, as the cooling-
agent inside the air conditioner will produce a kind of poisonous air when it is getting near the heating
source, so sucking in such poisonous air will cause severe human casualty or even death.
荫 The air conditioner can be started only after the machine engine being started. After the engine totally
stops, switch off the air conditioner power, so as to save the machine power.
荫 For soundly operating the air conditioner system, it is highly recommended to use 野High冶 -gear for
cooling performance.
荫In case of none use of air-conditioner for a long period of time in spring, autumn or in winter, it is a
must to have the air conditioner run for 5 minutes every two week at least, so as to prevent the air con鄄
ditioner parts from getting rusty due to long-term none-running.
荫 In case of needing to replenish cooling agent to the air conditioner, please select and use the proper
cooling agent as stated in the Air Conditioner Manual. Never try to mix two different kinds of cooling
agent together on the air conditioner.
荫 Sufficient and scheduled maintenance to the air conditioner is critically important for maintaining sound
and reliable, prolonged service-life of the air conditioner. So scheduled maintenance to air conditioner
is very necessary and needed. ( for details, please see table 2要10)
Maintenance Interval
Maintenance Items Checking Methods Every Every Every Every Every
Day Week Month Quarter Year
Cooling agent Check the flowing condition through

吟
status the watching hole.
Check the hoses for any signs of
吟
Cooling cracks or damages. .
system
Pipes Check that if each joint leaks or not. 吟
Check that if each clamp is loose or
吟
damage or not.
Replace the cooling oil ( please use
Cooling oil the oil with correct brand as stated in 吟
the manual.).
Compressor
Belt Check the tension and wear of belt. 吟
Compressor
Check the bracket is reliable or not. 吟
bracket
Check to see if it is clean and good
Condenser core 吟
or not.
Face side of Check if there is any foreign debris
Condenser 吟
condenser on the front side.
Condenser bracket Check to see if the bracket get loose
吟
or not.
2-41
Maintenance Interval
Maintenance Items Checking Methods Every Every Every Every Every
Day Week Month Quarter Year
Evaporator bracket Check that it is damaged or not. 吟

Inlet of cycling Check that if the ventilation is good
Evaporator wind 吟
or not.
Check to see if the motor can work
Blow motor 吟
properly.
Coupler Check the coupler is ok or not. 吟
Electrical Electromagne-tic
Check that if it can work properly. 吟
system clutch
Control switch Check that if it can work properly. 吟
2.5.7 Heating System
heater switch
water pump engine
Engine provides the heating source and the circulating water in engine is connected to the radiator. There
is a fan blowing heating wind into cab, which will improve the operator爷s operating environment.
B. Notes: Before using the heating system, run the engine for a while till the water temperature reaches to
70益, then start the heater. When the ambient temperature drops down to 0益, discharge water out from the
pipes and radiator to avoid water being frozen. If the water has been injected with anti-freezer, there is no
need to discharge water.
2-42
2.6 Trouble Shootings

2.6.1 Engine System
Phenomena of
Reasons of breakdown Remedies
breakdown
1.Gear has not been engaged. 1.Engage the gear .
2.The oil amount in transmission

system is not enough. 2.Replenish oil to regulated amount.
Engine is running but
3.Transmitting oil pump is damaged
machine can爷t drive . and the pressure gauge has no 3.Replace or repair the oil pump.
indication.
4. Check if the torque converter has
4. Trouble occurs in torque converter.
leakage or is damaged.
1.Valve pressure is adjusted
1.Adjust it to regulated value .
improperly .
2.Clutch has serious oil leakage 2.Replce the oil seal and its bracket .
Oil pressure for gear - 3. Gear -shifting valve restores to its 3.Check the valve return spring and if
original position there is any debris in the cavity .
shifting is too low
4.Leakage from oil circuit 4.Fasten the tubes.
5.Oil pump fails to work. 5.Replace the oil pump.
6.Oil filter is blocked. 6.Clean the oil filter.
1.Oil pressure for gear-shifting is low 1.See the above text .

Gear-shifting could not
2.Transmission pipeline is clogged . 2.Dismantle and dredge it .
be engaged.
3.Clutch has serious oil leakage. 3.See above text .
1.Oil in the transmission system is

1.Replenish the oil .
insufficient .
2.Oil pressure for gear-shifting is too
2.See above text .
low .
3.Braking system is adjusted
improperly, the brake clamp couldn爷t 3.Check and adjust it .
The driving force is be disengaged.
insufficient 4.When the oil temperature is over
4.The temperature in torque converter
100益 , please stop the machine and
is too high.
check it .
5.The driving and driven clutch plates 5.Dismantle , clean and replace the
do not engage correctly . plate .
6.The rotating speed of the engine is 6.Check and adjust the rotating speed.
slow.
2-43
Phenomena of
Reasons of breakdown Remedies
breakdown
1.Oil is insufficient . 1.Replenish oil .
The gearbox and torque
2.Check and repair the clutch and
converter get 2.Clutch slips . adjust its pressure .
overheated.
3.Working time is too long . 3.Stop working to cool the machine .
Gear shifting is
1.Arrangement of gear is wrong. 1.Readjust and repair it .
disordered
2.6.2 Steering System
Breakdown Phenomena Reasons of breakdown Remedies
1.Oil supplying to oil pump is 1.Repair or replace the oil

insufficient. pump.
2.Too muck pressure loss on the 2.Redesign the pipe -line, and
pipe that connects the pilot select the spring with high
It is easy when turning valve and steering-wheel. vigidity.
steering -wheel slowly
and hard when turning 3.Valve core of pilot valve is 3.Eliminate the clogging
it quickly. phenomena or replace the pilot
clogged.
valve.
4. Turn the steering wheel to its
4.There is some air in the pipe
limit and then turn it even
that is between pilot valve and
further, so the safety valve is
steering-wheel.
open to bleed air.
It is hard to The steering wheel is 1.The pressure setting of safety 1.Readjust the pressure of
steering. easy to turn in case valve in pilot valve is too low. safety valve.
the machine is without
load while it is hard to 2.Eliminate the clogging
2.The valve core is clogged or
turn in case the problem or replace the safety
the inner leakage is severe.
machine is with load. valve.
It is hard to turn the 1.Replenish with new steel ball
steering wheel and 1.The check -valve ( being of if the steel ball gets lost. If
steering cylinder has steel ball) fails to work. there is any foreign gets into
no action. the valve, clean it.
There is some foam in 1. There is some air in the 1.Bleed air from system and
the oil. steering system. check the oil suction line.
1.Replenish with new oil or
It is heavy to make 1.Oil amount is insufficient and
replace with the low viscosity
steering. the oil viscosity is too high.
oil.
2-44
Breakdown Phenomena Reasons of breakdown Remedies
The steering wheel can not

return back to its neutral
position. And there is 1.Replace the damaged
1.Spring is broken.
increasing pressure loss spring.
while steering wheel being at
its neutral position.
There is so much vibration
1.Pin is broken or deformed or
on the steering -wheel that 1.Replace the pin or link
there is cracking or deformation
you even could not turn the shaft.
problem at the link shaft.
Steering wheel steering-wheel.
fails to work. Wrong oil -circuit for the
steering system. And the 1.Wrong installation of the
1.Assemble it again.
steering wheel turns by itself rotator and the link shaft.
or swings.
Machine driving direction is
not in alignment or the 1.The dual -way overload valve
steering cylinder doesn爷t fails to work (the steel ball gets 1.Clean the double -
move or maybe slowly moves blocked or its spring can爷t work direction overload valve.
when you turning the properly).
steering wheel.
1.Steering column is not in
eccentric with valve core.
Pressure at the neutral
Steering wheel 2.The steering column and the Resolve the breakdown
position increases. The
can爷t restore valve core are deadly engaged. correspondingly to its
steering mechanism can't
to its original
release its load when steering 3.Resistance to steering column reason.
position
wheel stops turning. is too much.
4.Spring plate is broken.
When performing power

steering, operator can爷t feel
the steering limit while the
Manual The radial or axial clearance
steering cylinder is already Replace the couple of
steering is between the stator and rotor is
at its maximum limit. stator and rotor.
impossible too great.
definitely. When you turn the
steering wheel, the cylinder
has no reaction.
2-45
2.6.3 Electrical System
Breakdown phenomena Reasons of breakdown Remedies
1.The battery is damaged or not be

1.Replace the battery or charge it fully.
charged fully.
2.Switch is damaged. 2.Repair or replace the switch.

It is hard to start the
engine or the engine 3.Starting motor is damaged. 3.Repair or replace the starting motor.
can爷t be started at all.
4.Poor wires connection. 4.Check and repair the starting wires.
5.Fuel oil way or the air way has
5.Check the fuel oil way or air way.
breakdown.
1.The starting key can爷t restore to its
1.Repair or replace the starting key.
original position.
Starting motor is always 2.The electrical contactor for starting
burnt down frequently. motor could not be well disengaged 2.Repair or clean the contactor.
due to somehow adhension.
3.Starting circuit has shortcut. 3.Check and repair the starting circuit.
1.Wire gets loose or shed off. 1.Check or repair the wire.

Meter indication is 2.Sensor is damaged. 2.Replace the sensor.
abnormal.
3.Replace the damaged meter with the
3.Meter is damaged.
same type one.
1.Check the circuit and make the
1.WIre gets loose or shed off.
connection reliable.
Buzzer gives sound 2.Braking air pressure is too low. 2.Check the air-way.
ceaselessly.
3.Buzzer is damaged. 3.Repair or replace the buzzer.
4.Pressure sensor is damaged. 4.Replace the pressure sensor.
1.The fuse is broken. 1.Replace the fuse.
Lamp can not be 野ON冶. 2.Bulb filament is burnt down. 2.Replace the bulb.
3.Connecting wire gets loose or shed
3.Repair the connecting wire.
off.
1.Some wires get broken or loose. 1.Connect wire properly.
2.Fuse is broken. 2.Replace the fuse.

Generator can爷t be re- 3.Diode is brunt down. 3.Replace the diode.
charged.
4.Electrical brush is blocked or the 4.Repair the electrical brush and the
slip ring is poorly connected. slip ring.
5.Circuit of stator and rotor is broken
5.Replace the generator.
or shortcut.
2-46
2.6.4 Braking System
Breakdown phenomena Breakdown reasons Remedies
1.There is oil leakage from braking 1.Replace the seal ring.

plates.
2.There is air in braking hydraulic 2.Bleed air out.
circuit.
3.Low braking air pressure. 3.Chek air-compressor, oil-water
Foot -braking pressure separator, safety valve and sealing
is insufficient. performance.
4.Pressure booster gets worn. 4.Check the pressure booster casing.
5.Oil leaks onto braking plates from 5.check or replace the hub sealing ring.
hub.
6.Braking plates wear out totally. 6.Replace the braking plates.
1.Braking valve is wrongly positioned. 1.Check or replace the braking valve.

The braking system And the piston rod is blocked and the
spring fails to work or just is broken.
could not be
2.Pressure-booster works defectively. 2.Check or replace pressure booster.
disengaged. 3.Pump piston could not restore to its 3.Check or replace the sealing ring.
original position.
Braking oil pressure 1.Poor sealing for pneumatic system. 1.Check and repair the pneumatic
gauge shows the system.
2.Air compressor can爷t work well. 2.check the air compressor.
pressure reading 3.Oil -drainage plug of the oil -water 3.Re-tighten the plug.
increases slowly. separator is not firmly tightened.
2.6.5 Hydraulic System
1. Oil sealing ring for cylinders wears 1. Replace the oil sealing ring.
out or gets broken.
2. Dismount the valve, and check and
2. The distribution valve wears too
repair it, so as to have its clearance be
much, and the valve clearance is out
up to desired value. Or just replace the
of its acceptable limit.
distribution valve with a new one.
Insufficient power for
3. There is oil leakage from hydraulic 3. Figure out where oil leaks, and
raising the main boom, oil circuit. eliminate the oil leakage problem.
or insufficient power for
4. Severe inner oil leakage in the oil 4. Replace the oil pump.
tilting bucket. pump.
5. Wrong adjustment for the safety 5. Reset the system pressure to desired
valve, which causes the problem of value.
low system pressure.
6. The oil suction pipe and oil filter 6. Clean the oil filter and change oil.
get blocked.
2-47
2.7 Replacement of the Key Parts
When the engine 1. Please see details in No. (1) of this 1. Please see details in No. (1) of this
rotates at high speed, section. section.
the bucket or main 2. The safety valve gets blocked 2. Dismount and check the safety valve.
boom raises quite slow. deadly.
Hydraulic gets Hydraulic oil and transmission oil

oil Replace the oil sealing ring, clean the
come together due to over -wearing oil filter, and check to see if the oil -
mixed with transmission
and aging of the sealing ring for oil suction pipe -lines get deformed or
oil. pump. cracked.

荫 Customers must service the loader periodically to ensure the safety. Those parts which are listed in the
following list are important to your safety and should be replaced according to schedule
荫 Those parts will get aged and wore out along with working time increasing, it is hard to judge the
condition of those parts, so replace those key parts periodically without regarding if they are normal or
not.
荫 Repair or replace the damaged part right away without regarding to the schedule.
荫 When replacing a hose, please replace the O-ring and seal cushion at the same time.
荫 For replacing those key parts correctly, it is better to consult with XCMG or its agent.
Key Parts Replacement List
No Key parts to be replaced periodically Quantity Replacing schedule
1 Filter of oil-suction circuit of hydraulic oil tank 2
2 Filter of oil-return circuit of hydraulic tank 1

Every half a year or 1000 hours
3 Filter of oil-suction circuit of fuel tank 1
(whichever comes first).
4 Oil-filling filter for hydraulic tank 1
5 Fuel-filling filter for fuel tank 1
6 Fuel hose (fuel tank---fore-hand filter of diesel) 1
7 Fuel hose (fore-hand filter of diesel---oil pump) 1
8 Fuel hose (fuel pump---diesel filter) 1

Every 2 years or 4000 hours
9 Fuel hose (diesel filter---high pressure pump) 1
(whichever comes first).
10 Fuel-return hose 1
11 Hose (torque converter---radiator) 1
12 Hose (radiator---torque converter) 1
2-48
No Key parts to be replaced periodically Quantity Replacing schedule
13 Steering cylinder seals 2
14 Hose (valve block---air cylinder) 1
15 Hose (air cylinder---foot brake) 2

Every 2 years or 4000 hours
16 Hose (foot brake---booster pump) 3 (whichever comes first).
17 Hose (foot brake---check valve ) 1
18 Hose (check valve---braking cylinder) 1
Note: this table is only for reference.
2-49
Transportation, Storage and
Protection
3.1 Safe Transportation

3.1.1 Load or Unload the Machine
荫 Before loading the machine onto a carrier, clear the ice or snow from the carrier to avoid of slippery.
荫 If the loader should be transported to a cold area, ensure that its cooling system has good anti-freezing
ability.
荫 Wedge the towing vehicle or locomotive before lifting the loader.
荫 There is always a potential risk of danger during loading and unloading the machine, so special care
should be given. During loading and unloading the machine,
run the engine at low speed.
荫 Moving the machine should be done on the hard ground, and
the machine should be kept at a safe distance from road
side.
荫 When loading or unloading the machine to or from a carrier
vehicle, you must be sure that the wheels of vehicles are
securely positioned, not moving. And put a wedge under the
slope plate. Figure 3-1
荫 Use those slope plates which have enough strength, length
and width, so that it can be sure the slope plates are strong
and safe enough to load or unload the machine. The angle
between the slope plates and ground should not be larger
than 15毅 . And the gap between slope plates should be in
accordance with the wheel base of the machine to be loaded
or unloaded.
荫 Make sure the slope plates are securely fastened and have
same height. Figure 3-2
荫 Make sure the slope plates are free of grease, oil, ice and
other loosing material. And also remove away the dirt from the machine wheels.
荫 Never make steering on the slope plates. But if the steering has to be done, at first get the machine off
from the slope plates. After steering, you can drive the machine onto the slope plates again.
荫 Perform following jobs after loading the machine

吟 After loading the machine onto a carrier, lock the articulation of front and rear frame.
吟 Drop the bucket down on the deck of carrier and put the gear-shift lever at neutral position.
吟 Engage the parking brake.
吟 Stop the engine and pull out the key.
吟 Move all hydraulic controlling lever to release pressure.
吟 Lock the door of cab and take all safety measures.
吟 Wedge all wheels of the loader.
吟 Prepare enough ropes to prevent the loader from skidding during transporting.
吟 Cover the exhausting nozzle.
3-01

3.1.2 Hoist or put down the machine

荫 When the loader has to be moved into a ship or other place, please use the lifting lugs which is located
on front and rear frame.
Figure 3-3 Locking pole of steering
荫 The improper hoisting to the loader can result injury and damage to people and the machine, therefore
before hoisting the loader, please lock the frame to prevent the machine from turning. (figure 3-3)
荫 Retract the locking bar when the hoisting performance finished.
吟 Sketch map for hoisting the loader.
Figure 3-4
When hoisting the loader, the rope only can pass through the lifting lugs.
3-02

Prevent hydraulic pipes from being damaged.

When lifting the loader, make sure that there is nobody standing under
CAUTION
the lifted machine.
NOTE: The operating weight should vary according to different working devices.
吟 Please select those ropes and lifting devices which have enough solidity. Keep the loader horizontal in
the hoisting process.
吟 The girder of hoisting device must has enough width to avoid colliding with the loader.
吟 Take the length, width, height and weight into consideration.
吟 Every loader has lifting lugs, there are two lugs on the rear part of the loader and two on the front part
of the loader. Ropes can be threaded through them.
Figure 3-5 Lifting hook of fore frame
Figure 3-6 Lifting hook of rear frame
3-03

3.2 Storage and Protection
3.1.3 Transporting the Loader on a Public Road

荫 When transporting this loader, please obey with those laws which regulate the weight, height, width and
length.
荫 Determine the transporting route with regarding to the weight, height, width and length of the machine.
荫 Before passing through a bridge or a building, please ensure in advance that its strength can support
the weight of the machine. Obey with traffic rules when driving on a public road.
荫 If the loader has to be dismantled for the purpose of being transported, please consult with
manufacturer or its agent.

3.2.1 Daily Parking
荫 Park the loader on a place, with its bucket resting on the ground horizontally. Try your best to park the
loader on a dry place, and avoid of moisture. If the machine has to be kept outside, a shelter cloth must
be used to cover it.
荫 Turn the ignition switch to 野OFF冶 position, take out the key and keep it in a safe place.
荫 After the ignition key being pulled out. Operate slowly the control levers of the working devices for 2 to
3 times, so as to release the remained pressure inside the cylinders and hoses, and then leave them at
their neutral positions.
荫 Place the gear-shifting lever at neutral position, and the parking brake must be engaged.
荫 Lock the front and rear chassis with the lock bar.
荫 Lock all the parts that have locking key. Pull out the keys and keep them safely.
荫 In winter or cold weather (when the ambient temperature below 0益 ), anti-freezing addition must be
applied into the cooling water. Cooling water must be drained out completely for those machines
without anti -freezing addition in the cooling system, so that the engine can be protected from being
cracked by ice.
3.2.2 Long Time Storage

The storing period for the machine includes short-term storing and long-term storing. For short-term, the
storing period should not exceed two months. Over more than two months must be taken as a long-term
storing. The parking place for storing should be sheltered, ventilated and dry and without any corrosive
substances or gas.
Before storing
If a wheel loader needs to be stored for a long time, take the following measures:
荫 Clean the machine thoroughly, have it be dry and store it in dry storage house. If the machine has to be
stored under open air , then it should be stored on the concrete ground where it is easy to drain off
water, and cover it with canvas.
3-04

荫 Before storing it, fill up the fuel tank, add grease and change hydraulic oil.
荫 Coat the piston which extends out from hydraulic
cylinders with grease.
荫 Dismount the negative pole of battery and close the
battery box cover. Or remove the battery from the
machine and store it separately.
荫 If the air temperature falls down below 0益, add anti-
freezing addition into cooling water of the radiator.
荫 Put on the security lock and then lock the bucket,
control lever for working arms and articulation
locking-bar. Afterwards, engage the parking brake.
Figure 3-7
When the loader needs to be stored within one month,
except those mentioned measures in the Daily Parking, the following procedures must be noted:
荫 Start and drive the machine every week, and operate its working device to let it be ready for work at
any time.
When the loader needs to be stored over one month, except those mentioned in Daily Parking, the
following procedures must also be noted.
荫 Check all the oil levels and lubricating points to see if the oil being in the level as required.
荫 Considering the raining season, try your best to park the machine on a hard ground of a higher place.
荫 The battery must be removed. Although the machine is indoor stored, if it is too hot or damp, the
battery must be dismounted to get it stored in a better place, and charge it once a week.
荫 Parts which moisture can easily get in (such as: ventilating device and air filter) should be covered with
a clothes.
荫 The inflating pressure of the tyres must be standard. Check the wear and damage status of the tyres.
荫 In order to release the heavy load on the tyres, it is better to jack up the machine to let it be in floating
state. If the loader can爷t not be jacked up, the inflation of the tyres must be checked every two weeks
to ensure the tyre pressure.
荫 Restore the machine into ready -work condition each week. Start the engine and let it warm up, and
then move the machine back and forth a little bit.
荫 If you think it is necessary to activate the working device, before you do it, the grease on the cylinder
rods must be cleaned away. And after such attempt, apply grease to cylinder rods again.
3-05

3.2.3 After A Long Time Storage

荫 Move away all the protecting coverings.
荫 Clean away the anti-rust grease on the exposed parts.
荫 Drain out the oil that is inside the engine, gear box
and driving axle, and then wash them and refill with new
oil.
荫 Drain out the debris and water from hydraulic oil tank
and fuel tank.
荫 Dismantle the pneumatic cylinder of the engine, and
lubricate the valve and rocker shaft. And check the Figure 3-8
performance of each valve.
荫 Fill the radiator with cooling water to the standard level.
荫 Charge the battery again and connect it to the wires.
荫 Adjust the inflation pressure of the tyres in accordance with the road condition.
荫 Follow the checking procedures before operating.
荫 Warm up the engine.
3.2.4 Storage of Other Parts

Obey with following instructions when storing the tyres.
荫 Being as a general principle, the tyres must be stored in warehouse. Anybody without prior approval
should not enter into the warehouse. If tyres have to be stored outdoors, please settle a protecting fence
surrounding the storing area. Notes which show 野No Entrance冶 should be settled.
荫 Tyres should be stored in dry and clean area, otherwise moisture will speed up the oxidation of the
tyres and oil or polluted dirt will make tyres corroded more quickly. When storing tyres, you should
consider, as much as possible, sheltering and heat-insulation, and avoid air ventilation. The tyres under
storing should be covered with canvas, plastic or other covering staffs. Incorrect storage for tyres will
seriously affect their quality and service life.
荫 Put tyres on the flat ground vertically, and fix them by means of wedges, so as to prevent them falling
down even if it touched by somebody disapproved. If a tyre is placed on the ground by its side, then it
may be pressed flat, which ,being as a result, will worsen
its quality. The tyres under storage should be turned once
every month. ( turn 90毅).
荫 If wheel tyre is to fall down, get away from it, since the Wedge
tyres of construction machinery are very heavy, and any

attempt to hold it by hand will incur serious injury.
3-06

Technical Specifications

4.1 Technical Specifications
Overall dimensions
Overall 1ength (bucket on the ground) 7250 mm
Bucket width 2470 mm
Overall height 3290 mm
Wheel base 2900 mm
Tread 1850 mm
Min. ground clearance 370 mm
Specification
Rated capacity 3000 kg
Bucket volume 1.8 m3
Operating weight 10.6 t
Traveling speeds ()
玉 13 km/h
域 36 km/h
Reverse 玉 16 km/h
Max. tractive force 100 KN
Max. climbing gradient 28毅
Max. dumping angle 45毅
Max. dumping height 2930 mm
Dumping reach 1000 mm
Overturn angle of bucket
The lowest position 43毅
The highest position 57毅
Bucket automatic leveling function yes
Max. Breakout force 130 KN
Total cycling time 10 S
Min. Turning radius
Outside of the bucket 5170 mm
Turning angle of the frames 38依1 o
Oscillating angle of the rear axle 依12 o
4-01

Engine Rated Power Rated Speed Maximum Torque

YC6J125Z-T22 92 2000 510/1300~1500
Transmission system
Torque converter
Model YJSW315-4F
Type 1 stage, 4-elements, double turbo
Cyclic diameter 315 mm
Conversion coefficient K=4.458
Cooling method Oil cooling-pressure circulating type
Oil inlet pressure 0.3~0.45Mpa
Oil outlet pressure 0.2~0.3Mpa
(2).Transmission
Model 2BS315A(D)III
Type Planetary, hydraulic shift
Gear number 2 forward and 1 reverse
玉 2.155 1.557
域 0.578
Transmission working oil pressure 1.08-1.47MPa
Displacement of transmission oil pump 57 ml/r
Front and rear axle

Speed ratio 5.286
Hub reducer
Type One stage-planetary deceleration
Speed ratio 3.882
Tyres
Tyre specification 17.5-25
Inflating pressure Fore tyre: 0.32-0.35 MPa
Rear tyre: 0.28-0.30 MPa
4-02

Braking system
Foot brake Oil disc braking on 4 wheels
Braking air pressure 784-833 KPa
Hand brake Clamp disc brake
Steering system
System pressure 14 MPa
Max turning angle 依38o
Hydraulic system of the working device

System pressure 16 MPa
Oil liquid volume

Fuel (diesel) 180 L
Lubricating oil of engine 20 L
T/M & T/C oil 32 L
Hydraulic reservoir 170 L
Axle (transmission and rim decelerator) 25 L
4-03

4.2 Overall Dimension
4.2 Overall Dimension
Overall Figure of LW300KN Wheel Loader
4-04

Omm LW300KN

Uploaded by

Copyright:

Available Formats

Omm LW300KN

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Omm LW300KN

Uploaded by

Copyright:

Available Formats

Foreword

Warning Signs for Safety Precautions

1.3 Component Names and Decals 1-03

1.6 Operation Regulations 1-11

2. Lubrication, Maintenance and Repair

2.4 Lubrication and Maintenance 2-18

2.7 Replacement of the Key Parts 2-48

3. Transportation , Storage and Protection

1.1 The Use of the New Loader

1.1.2 Study the Safety Items

1.1.3 Learn the Checking Method

1.1.4 Be Familiar With Your Machine

1.1.5 Running-In of the Machine

1.2 Application Purpose of the Machine

Figure 1-1 Overall figure and component name

1.3.2 Decals and Number

This decal may vary along with the actual configuration

Figure 1-4 Decal of engine

1.4 Safety Signs and Theirs Position

Figure 1-5 Pasting positions of safety signs

1.4.5 Sign for Hydraulic Oil

1.4.6 Sign for Fuel

1.5 Instruments and Controls

Figure 1-12 Composition of Instruments and Controls

1.5.2 Function Explanations

No Name Function Note

4 Voltage meter It can display the voltage of battery.

No Name Function Note

19 Switch of ceil lamp It is used to control the indoor top lamp.

20 Switch of wiper It is used to control the wiper

21 Signal of danger It flashes to give out warning.

22 Switch of aether It is used to control the aether injection.

1.5.3 Gear-Shifting Operation (Figure 1-13 & 1-14)

1.5.4 Operation Of Working Apparatus (Figure 1-15 & 1-16)

1.5.5 Parking Brake (Figure 1-7)

Figure 1-17 Positions of Control lever

1.5.7 Seat Adjustment ( Figure 1-18 )

Figure 1-18 Seat ( Double-way, with cushion )

1.6 Operation Regulations

荫 When operating or maintaining the loader, please take

荫 Only the authorized technician can operate and maintain the

荫 Please understand all regulations about operation, get

Before and after machine operation, please check every system.

荫 Inspect the ladder and handrail before and after getting on

荫 Don爷t weld or incise the pipes containing combustible

荫 Prevent pipes and hoses from leaking. Replace the damaged

荫 Front -located working apparatus may obstruct the visual

荫 Before driving on speedway and public road, please refer to

Take steps according to following items if injure or fire accident

荫 Support the loader reliably and firmly when you have to

荫 Aether is a poisonous and combustible material.

Operator must wear protecting dresses according to actual

Check the loader before every daily work, perform daily

1.6.4 Safe Driving

荫 Keep a right operating habit to ensure safety.

荫 Devote your mind to operation because momentary neglect

荫 The loader is not a man carrier, so hitchhiking is disallowed.

荫 Please obey with traffic rules when driving the loader on a

Emergent braking may cause injuring !