ChapterI Use 、 product features and the main performance

parameters
1、use and product features

Loader cars develop and manufacturing is according to the JG/T91-2000 standards, the

cars are suitable for the construction sites,cement and precast factory,lime kiln,the

battlefield and other bulk materials handling and stacking ,and also can be used for

large-scale farms garbage removal.

A、The cars use articulated frame,full hydraulic power steering.easy operation,radius

of gyration is small,narrow space in operation,the completion of a large loader can't be done.

B、The machine structure is simple, easy maintenance, most parts with domestic standards,

common parts, reliable, well-resourced parts.

C、The machine working device is hydraulic control, high efficiency, save a lot of labor force.
2、main performance parameters
Item
ZL-908 ZL-910 ZL-912 ZL-915 ZL-916 ZL-920 ZL-928 ZL-930 ZL-932
Type
Rated loading
800 1000 1200 1500 1600 2000 2000 2200 2400
quantity(kg)
Rated bucket
0.3 0.45 0.5 0.5-0.6 0.7-0.9 1.0 0.9-1.05 0.9-1.1 1.2
capacity(m³)
The whole
2150 2150 3000 3280 3580 5500 5600 5700 6000
quantity(kg)
Engine type Chang Chang QC480G 4102- 4100- 4105-
485 490 4108z
chaiL24 chaiL28 485 4105 4105 4108
Rated
17.6 20 26 35 38 51 55 52、60 74.9
power(kw)
Rated speed
2200 2200 2400 2200 2200 2200 2200 2400 2400
(r/min)
Dump 2900/
2700 2700 2700 2880 3300 3100 3600 3600
heights(mm) 3160
Distance of
750 750 750 800 850 ≥860 ≥860 ≥860 ≥860
discharge(mm)
Boom rise
6 5 5 5 6 5 5 5 5
time(s)
Boom fill
4.5 4 4 4 4 3 3 3 3
time(s)
Discharge
1 1 1 1 1 3.5 - - -
time(s)
Min.swerve
3500 4200 4500 4600 4650 ≤3700 ≤3700 ≤3700 ≤3700
radii(mm)
Overall size 4260×1520 4260×1520 4400×1620 4950×1600 4950×1600 5470×1700 5470×1880 5850×1880 5850×2200
(l×w×h) ×2200 ×2200 ×2300 ×2550 ×2650 ×2680 ×2700 ×2700 ×3000

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 ChapterII Structure of the main components and installation adjustment
1、Engine system
Mainly includes the engine, air filter, muffler, and throttle control systems.
A、Engine
On the diesel engine structure, performance parameters, use and technical maintenance
instructions, see immediately brought about by the use of diesel engines.
B、Filter: Filter the air of dust and other magazines, improve cylinder, piston life.
C、Muffler: To reduce the noise diesel engine scheduled to reduce environmental impact.

Picture2-1 ZL15Loader car view picture

1、bucket 2、handling block 3、tire 4、drive axle 5、shaft 6、frame 7、minor shifter
8、main shifter 9、hood 10、seat 11、Driving shed 12、Steering 13、Electrical and
Lighting 14、Multi-way valve 15、Hose 16、Glass 17、Arm Lift Cylinder 18、Arm
19、Bucket Cylinder 20、Rocker 21、Bar
2、Rotation System

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A、The engine through the triangle connecting belt and clutch to achieve power
transmission capabilities. Triangle tape tight or too loose to be fit, too loose will
make a serious skid tape, plus poly V-belt early wear and tear, shortening their
service life; tight tape and other relevant parts would force too much, resulting
in damage. V-belt in the use frequently affected by tension-compression deformation,
resulting in relaxation and, therefore, should be periodically adjust belt tightness.
Adjusting belt tension along the rack through the engine before and after the move
to achieve.
（1）Release the engine support plate and rack connected to four connecting bolt;
（2）Adjusted so that the engine thrust bolt move forward or backward along the rack;
（3）In the middle of each V-belt 49 Newton force to impose its sagging amount of
10-15 mm, the belt tensioning degree of the right triangle;
（4）The four fixed bolts fastening the engine.
Important notes
(1)In use to prevent the tape dip oil, mud and water, often tape-round slot of the
dirt removed, so as not to reduce the friction coefficient.
（2）Not free to use adhesive tape to reduce the number of replacement can not be
used to replace the old and new into a group different from the triangular tape of
different lengths (4 tape length difference of less than 5 mm).
2、Clutch
Loader clutch for the two-piece, dry, often bonding friction. Clutch is used to
pass or cut off the engine power, and the protective role of transmission. The
temporary separation clutch, hanging files and allows a smooth shift loader, smooth
clutch engagement can ensure a smooth start-loaders.
1、Frame
Mainly by the active part of the clutch and driven parts, parts and other
components to manipulate the composition, as shown in Figure 2-2.

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 Picture 2-2 clutch
1、Tape Wheel 2、DISC 3、Active Disk 4、Tape Wheel Cover 5、Bearing 60204 6、Nut M16 7、
Bearing Caps 8、Spring 9、Bearing 60206 (four-wheel drive 60207) 10、Circlip 11、Platen 12、
Adjustment Screw 13、Pin 14、Separation lever 15、Separation of bearings 688,808 (four-wheel
drive 688,909) 16、Separation Claw 17、Bearing Caps 18、Separation Claw

Does not allow the clutch friction surfaces contaminated with oil, if oil-stained
with kerosene should be cleaned, dried after the assembly to use, otherwise it would
cause the clutch slip and accelerate the wear and tear.

Picture2-3 Coupling operating mechanism schematic drawing

(20-30mm /Pedal free travel)

1、 clutch pedal 2, return spring 3, drive shaft 4, clutch rod 5, fastening nut 6,
rod connector 7, the clutch wheel tape
2、 Clutch Adjustment

The process of clutch in use, spare parts continue to wear and deformation,
especially the driven plate wear, so that separation lever to reduce the gap separating
bearing face, so that three separate levers head not in the same plane, and may even
make the head and separate separation lever bearing cross-section contact, resulting
in incomplete or slipping clutch such phenomena, it is necessary to adjust the clutch
on a regular basis.
In the pedal back to places where the separation and separation of bars bearing
a part of the gap end 3-bit 0.5 0.2 mm, see Figure 2-3 three separate ends of lever
3 (with separate bearing contact locations), must ensure that the same rotating the
plane if they do not meet the requirements, by adjusting the screw 5 on the adjustment
nut 4.
As the driven clutch plate friction plate wear and clutch pedal free travel will
be reduced accordingly. If we do not adjust, but also make the clutch slip speed up
the friction plate wear and tear, which is in use should also be adjusted periodically.
By adjusting the working length of the rod 4 may be the freedom to change the pedal
travel, pedal free travel and normal bits 20-30 mm. After adjustment loaded pin, cotter
pin and tighten nut firmly fixed.

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 3、 Clutch Bearing Lubrication

Clutch Release Bearings and bearing 5,9 is a clutch assembly when Grease.
Clutch Release Bearings only have a corresponding movement of separation, using
an infrequent basis, usually without the need to increase separation of the external
bearing grease. 1000 hours at work or use were found bearing a sound only when it
will be removed to check the separation of bearings, wash into the heat melting
Na-grease, until the infiltration full bearing until grease cooling out, wipe the
outer surface of , and then loading to use. The remaining two rolling bearings 5,9
at 1000 hours when the filling grease maintenance, careful not to make too much.

4、 Transmission

Variable-speed gearbox in part by the main and sub-transmission combined into

six forward and one back files, transmission line, shown in Figure 2-4.

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 picture2-4 ZL05、06Shaft diagram

5. Gland 10.Ⅱ.Ⅲ.Ⅳ Shaft left bearing cap 12.Ⅱ~Ⅵ Axis dial file fork 13. Ⅱ.
Ⅲ.Ⅳ.Ⅵ .File slider 14. Ⅱ.ⅤRod slider 15. Vice-shift fork 17. Slider to the left
cover 19. Vice-speed slider 23. Gland 26. BallФ10 27. Spring 29. Interlocking round
pin 31. Slider to the right cover 32. Rolling 30633. Circlip 34. ⅠShaft gear 36.
Ⅰ Shaft 37. Bearing sleeve seat 39. Rolling 1.2205 40. Ⅰ Shaft 41. Vice-speed
low-speed gear 43. Sleeve 44. Vice-speed high-speed gear 45. KeysA8×35 46. Circlip
47. Rolling 1,220,648. Rolling 1,230,5 49.Ⅳ shaft sleeve 50. reduction pinion 51.
ⅣShaft 52. Ⅱ.ⅤFile sliding gear 53. Ⅰ.Ⅲ.Ⅳ.Ⅵ.Stall sliding gear 54.Ⅱ.Ⅲ.Ⅳ
Axle right bearing cap 55. Rolling 307 56.Ⅴ Shaft 57. Reducer gear 58.Ⅰ.ⅢFile gear
59.Ⅳ.Ⅵ Files Gear 60. Ⅱ.ⅤFile gear 61. ⅢShaft 62. Vice-speed sliding gear 67.
Gearbox 68. Pad 69. Oil Plug

Ⅰaxis right end of the extended transmission, and clutch driven plate connected
with the spline sliding gear in a fixed Z1 axis, the gear Z2, Z3, respectively gearbox
high, low driving gear, they are separated by sets of fixed-mounted No. Ⅱ shaft,
the gear teeth Z2 and Z1 often sliding gear Z4, Z5.Ⅰ.Ⅲfiles sliding gear Z11, are related
to the main transmission shaft Ⅱ through the sliding spline connection. Manipulation
of the main transmission main gearbox sliding gear Z9.Z10.Z11; Vice-shifter control
high-low sliding gearZ4.Z5.

Picture 2-5 Schematic diagram of four-wheel drive transmission gearbox

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1. Shaft gear (20 teeth) 2. High-speed gear (28 teeth) 3. Low speed gear (18 teeth)
4. To pay transmission slipping gear (17 teeth. Union 27 teeth) 5. Reverse gear (22
teeth) 6. 2. Fourth gear gear (33 teeth) 7. 1. third gear gear (18 teeth) 8. gear
shaft (15 teeth) 9. 2. Fourth gear sliding gear (17 teeth) 10. 1. 3 reverse slip Gear
(20 teeth 25 teeth together) 11. Reducers Gear (49 teeth) Note: The five-axis
seal35×58×6

To achieve the sliding gear transmission box location, set up the main transmission
and sub transmission two joysticks. Manipulation of the primary. Vice stick shift,
you can toggle the corresponding slip gear, get to use the stalls. Vice-speed high.
Lower two positions.

There are two main speed forward and one back position. Vice-speed hang low, the
main variable hanging file access Ⅰ .Ⅱ file, deputy high speed link, the main
variable hanging file access Ⅲ.Ⅳ file.

2、Differential

ZL05.ZL06 differential assembly, see 2-6 from two separate radial ball bearings
(6011) by axle support on the gearbox casing on. Differential Case 1. Differential
on the cylindrical shell 7 and the driven gear 8 together with strong bolts, that
differential entourage moving cylindrical shell with the rotary gear reducer. 4
differential planetary gear differential housing on the two loaded differential cross
shaft 5 with the two axle shaft gear teeth corresponding to 4 kg, while the axle gear
and the axle shaft via the spline connection.

Picture2-6 Differential

1. Differential under the shell 2. Differential gear 3. Differential gear gasket 4.

Axle gear 5. Cross-axis 6. Axle gear gasket seven. Differential cover body 8. Cylinder
driven theory 9. Bearing 6011

When the straight-line loader for the exercise, by the driven cylindrical gear
reducer to power through the differential housing. Differential gear shafts,

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planetary gears, axle gears passed to the left and right axle; when the loader turning
a corner, As the two rear wheel by ground-based resistance to different, and therefore
planetary gear differential in the accompanying transfer of public housing, it is
also around the differential gear rotation, so that the left and right axle turn
generate the speed loader turning smoothly.

3、Locking mechanism

To make an accurate position of the slider, and does not auto-dislocation, set
the slider locking mechanism, shown in Figure 2-6. The machine uses spring-ball type
locking mechanism, ball 2 in the spring under the effect of an embedded slider 3
positioning slot, so that the slider can not easily slip. Only manipulate the gear
lever to exert a certain power of the slider, the ball will move after the compression
spring, when the slider 4 will lead slip through the fork sliding gear to complete
the work Guadang or extracts files.

Picture 2-7 Locking mechanism

1. Spring 2. Ball 3. Slider 4. Fork 5. Gearbox

4、Interlocking institutions

In order to ensure that only put up a stall, but only when Guadang only in the
gap, the two main speed slider to set the interlock between the institutions, shown
in Figure 2-8, using the lock pin city, interlocking bodies, namely, 7.8 bar between
the two flowers into a lock pin 2. When one of a smooth move, relying on the slider
back to the cylindrical surface gap position, the other slider is possible slip and
lock does not move slider, which play an interlocking role as insurance.

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 Picture2-8Interlocking institutions

1. Slider cover 2. Interlocking round lock 3. Gearbox 4. 1. 3. 4. 6 files Fork 5.

Vice-speed slider 6. Vice-speed Fork 7. two Five-speed slider

5、Gearbox lubrication and adjustment

1. Gearbox gears, bearings and the other moving parts, relying on running gear splash
oil lubrication, oil level is too low will affect the reliability of lubrication,
oil level is too high will increase the fluid resistance to temperature, or oil spill.
ZL05.06 filling gear oil should be about 5 kg, four-wheel drive transmission should
bear about 3 kilograms, when the transmission oil is dirty (with 500 hours) should
be promptly replaced.

2. Department of cylindrical gear gearbox gears, the gap does not require adjustment,
when the gears and bearings gap is too large or damaged should be replaced. Axial
clearance can be separated by paper pad and cover to adjust the axle differential
gears and planetary gear gap is too large, should be replaced gear or gasket.

3、shaUniversal joint cross shaft are oiling Tsui, each working 150 hours should inject
lubricating grease.

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 Picture2-9 shaft

1. Axle tube assembly 2. Sheathing fastening ring 3. Spline jacket 4. Oil cup M65.
Casing fork 6. Casing fork blocking cover 7. Cross-axis clasp 8. Cross shaft
assembly (Beijing 130 ) 9.M10 × 1 nut 10. spring washers 1011. flange fork 12.
bolts

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 ZL Transmission Contact Size Chart

1. ZL-type forward pass is a manual gear box mechanical control gear box, which
hardened process technology used in all gears, gear wear resistance, impact resistance
was significantly higher than other similar products, so that the product has easy
to operate long life and high safety factor.

2. The product of the rated transmission power 44KW, apply to ZL15 Loader, its
transmission power.

3. Main specifications and technical parameters

Input Speed 2200r/min

Output torque 200N/m
Center Distance 474mm
Lubricant volume 16kg
Ⅰ Ⅱ Ⅲ R
Stall speed ratio
16.96 6.22 3.51 7.71
Net weight 167kg

4, the installation size and input methods

1. Gear box installation dimensions diagram (Figure 1)

2. Cabinet assembly diagram (Figure 2)

5. Gear Box Installation

When the product connecting with the engine, you must ensure that connected two
axes coaxial degree of not more than 0.15mm, connect the base to ensure sufficient
strength and adjustable, so that equipment, safe operation.

6. Gear would like to experiment

Test sets to simulate installation of gear box testing, testing, pre-open the
gear box oil cap, into the lubricating oil, according to technical parameters of fuel.
Correct upon inspection, will be placed in neutral gear position gear box handle,
driving. Idling for 2-3 minutes, stopping Guadang level-grinding to observe the
operation, such as work normally installed to use.

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Assembly diagram

12
7. Three packs of the scope of
The following conditions of the three guarantees:
1. Gearbox shell cracks caused by leakage.
2. Driveshaft cracked and broken.
3. Gear box in normal use, resulting in broken shaft. Playing gear. Shell rupture.
Not be implemented the following three bags, but the implementation of reasonable
charges Repair:
1. Because of the use. Maintenance. Improper maintenance, resulting in early wear
and failure; such as poor handling in transit, after purchase damage. Conditions of
use beyond the scope of product specification requirements. Speeding overload use.
Fails to product specification requirements for running-in operation. overhaul.
adjustments. fastening, internal combustion engines mismatch. use of non-conformity
of the fuel, etc.;
2. Because of self-modification. Self-correction. Disassembly product specification
does not permit self-correction. Demolition of parts and components caused by failure;
3. No three packs of certificates or no valid invoices, purchase products they could
not prove that they belong to three packs of the life of the product;
4. Three bags of documents or invoices the product specifications and requirements
of three bags of model type does not match the product specifications, or altered;
5. After the failure, no damage to keep the status quo, or without obtaining permission
from sellers. Mender agreed to dispose of the cause of the malfunction so that right
can not make technical appraisal;
6. Because of the driver. Operator did not obtain a driver's training in accordance
with law. Operational failures caused by the certificate;
7. Due to damage caused by force majeure.
Special Note:
1. Three packs of valid votes from the development of the date of shipment, net of
business due to take three packs of the occupation and the lack of maintenance repairer
repair parts for repairs of time. Three packs of the life of the product failures
that, with three packs of certificate processing invoices and repair. Replacement.
Return.
2. Three bags is valid for 3 months.
The three bags of the ultimate right to interpret owned by the Company.

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 Box Parts Schedule

NO. Parts Name Amount/set NO. Parts Name Amount/set

1 Transmission Case 1 23 Reverse shaft 1
2 Gear stick 1 24 Brake Hub 1
3 Shifter 1 25 Brake Disc 1
4 FORK 2 26 Brake Disc Block 1
5 Fork shaft 2 27 Oil discharge bolt 1
6 Gearbox cover 1 28 208 Bearing 2
7 A shaft gear 1 29 Axis Cover 1
8 307 Bearing 10 30 Axis 1
9 35×58×12SEAL 1 31 Then the output tray 1
10 An axis 1 32 Large reduction gear 1
11 Connect Set 1 33 Four-axis 1
12 Shaft 1 34 A small reduction gear 1
13 Box attached 1 35 Reverse pinion 1
14 Linkers cover 1 36 A file gears 1
15 Side Cover 1 37 2-axis 1
16 2-axis gear 1 38 A reverse sliding gear 1
17 23 files sliding 1 39 Cover 6
18 Third axil 1 40 Fork Cover 1
19 Third gear 1 41 38×58×12SEAL 2
20 files Gear 1 42 Then disc 1
21 Fourth gear 1 43 brake hub
22 Reverse Gear 1 44

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 ZL16-ZL20 Series
Power Shift Transmission
1. Features:
ZL-type fixed-axis power-shift gearbox for wheel loader and its deformation
ZL15.ZL16.ZL18.ZL20 products. YJ240B.YJ265.YJ280 type with torque converter match.
Can be within a certain range with the external load automatically change the size
of changes in the transport speed and torque, so that the engine is always at the
maximum power to work and do not turn off. The machine has a compact structure, easy
manipulation, shift smooth, reliable, long life.
2. Main technical parameters
Item Value Unit
Rated Input Speed 2500 R/min
Rated input power 44-60 KW
Torque Limit Input 550 N.M
Supporting torque converter model YJ240B、YJ265、YJ280
Hydraulic speed control 1.2~1.5 Mpa
Oil Pressure 0.15~0.3 Mpa
ForwardⅠfile 2.16
Transmissi ForwardⅡfile 0.77
on ratio Back Ⅰfile 2.21
Back Ⅱfile 0.78518
weightQ 180-260 kg

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ZL16-ZL20 series of power-shift gearbox

16
 Torque Converter

1. Features:

YJ240B.YJ280.YJ265 series hydraulic torque converter is a single-phase

single-stage radial turbine components, torque converter 3, which has advanced

structure. Reliable work. Easy-to-reasonable matching the characteristics of the host,

and the use of easy maintenance.

Is currently made ZL16 type. ZL18 type. ZL20 Loader ideal matching gear.

2. Main technical parameters:

Item Value Unit

Rated Input Speed 2200 R/min

Rated input power 45-60 KW

Zero speed condition Nominal
torqueMBg0 23.50 N.M

And efficient working condition

Nominal torqueMBg0 22.54 N.M

Zero speed condition variable moment

coefficientK0 3.13

Maximum efficiency K0 0.817

Effective zone width ηmax 1.86

WeightQ 135-185 KG

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4. Drive Axle
Drive axle in active and passive gears have been carried out by exposure standard
matching, therefore, can be adjusted long-term use is not only in replacement of
defective parts or parts to wear and tear due to moving only when we need to make
adjustments to the original bridge. Adjustments should pay attention to the following:

Picture 2-10 drive axle

1. Axle bolt 2. Wheel hub 3. Brake drum 4. Horseshoe (Beijing 130) 5.

49×100.49×102Seal 6. Lock the mother 7. Bearings 75118. Tire bolt 9. Bearings 781.31

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thousand. Brake Cylinder (Beijing 130) 11 . release valve 12. driveshaft access plate
13. nut 14. Bearing 27309 15. 27,522.2959016 bearings. Main vertebral gear 17.
29,590.2952218 bearings. Axle gear 19. Planetary gear 20. Passive bevel gear

1. Take the initiative to gear bearing gap within the bearing from the driving gear
behind the seat cover to adjust the pedestal, and after adjustment should be no space
and they can freely rotate.
2. Main. Passive gear gear tooth gap in active gear flange around the radius 45MM
measured, its displacement (arc length) should be between 0.2 ~ 0.6mm.
3. After every 100 hours of driving, check the drive axle of oil. The correct oil
filling port side of not less than the lower edge of 10mm, if necessary, to add, for
every 300 hours of driving, they should replace the gear oil, this machine should
be added on the 18th hyperbola gear oil.
4. Every 100 hours of driving, it should be replaced once a round of shells bearing
grease, adjust bearing preload degrees to the right so far.
5. Brake System
Braking 1.ZL05.ZL06 loader for mechanical braking.
In use, and other components due to friction plate wear and deformation will lead
to increased or generated by braking stroke brake bias, affecting braking performance,
when brakes should be timely adjusted in order to ensure driving safety.
1. To adjust the length of the two brake rod (Figure 2-11) can change the size of
the brake pedal air travel, and can synchronize brake brakes around. Brake rod will
allow air travel to reduce short-rotation; rotation length can increase air travel.
3 locking nut should be loosened to adjust to adjust well after the lock.

Picture 2-11Brake Adjustment

1. Brake 2. Brake rod 3. Locking nut

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 Picture 2-12 Axle assembly

1. Nut M142. Double-headed bolt M14×60 3. Elastic pad 4. Nut M16 5. Elastic pad 6.
Double-headed bolt M16×607. Brake hub 8. Bearing gland 9. Paper pad 10. Seal
52×751×211. Bearings 21012. Card spring 13. Plate 14. brake shoe 15. eccentric shaft
16. axle casing 17. elastic pad 18. nut M1619. lock the mother 20. locking pieces
21. lock the mother 22. bushing 23. brake Convex Shaft 24. brake shoe recoil spring
25. Shaft

2. To adjust the position of eccentric shaft 15 (Figure 2-12), can change the brake
shoes and brake drum friction plate friction surface contact prints, so that even
wear of the friction film. Adjustments will be paving the rear axle loader, release
the nut 18 (Figure 2-12), with the wrench rotating eccentric shaft, while rotating
hand wheel, when the brake shoes and brake drum contact resistance will be felt, and
then and then slightly eccentric axial rotating in the opposite direction until the
wheels turning until the resistance disappears. Finally, the locking nut to prevent
rotation.

Four-wheel drive loader traffic using BJ130 hydraulic brake system, brake, brake pedal
full stroke 160mm, free travel for the 8-10mm, when the brake pedal is too low should
be found to check:
1. Pipes leak.
2. Shoe and drum gap is too large.
3. Whether there are air channels.
There is no work 200 hours to check brake shoe wear and tear. When the shoe to wear
to make the pedal stroke is too large, we must adjust the shoe and the gap between

20
the drum, the process is as follows:
(1) jack up the wheel to be adjusted.
1. In the bottom of the back of the brake to find eccentric wheel bolts, rotating
eccentric wheel bolts, until the shoe and drum contact, and then relax eccentric wheel
bolts, until the freedom of rotation and the friction shoe and drum until they are
no longer.
Note: The adjustment does not allow rotation and removal of brake shoe sales support.
2. When the brake pipe in there air, and replaced with new brake fluid, as well as
storage tanks dry bottom, add the brake fluid when the brake pipes and pumps will
need to put air in the net, its methods are as follows:
(1) the brake pedal several times under the continuous step, release to give up valves,
air release pipe, tighten valve, release the brake pedal, so to repeat several times,
until the asphalt air row last.
(2) abandon the process, we need to keep the lowering of oil storage tanks continued
to add brake fluid, not be allowed to dry at the end of storage tanks, all to give
up after the brake fluid should be to add a little, the machine should be added "912"
brake oil brake pedal free travel from the brake master cylinder to adjust the putter.
2. Tire processing
Tires. Wheel rim, such as improper handling tire to explode. Wheel rim will be broken,
resulting in serious casualties. For safety reasons, should note the following points:

Because the tire rim of the disassembly. Maintenance and repair needs of
special equipment and technology, all point to ask tire repair professional
maintenance staff to operate.
•Using the specified tire, and inflated to the provisions of the pressure.
•When inflated, inflatable tubes should be fixed to the valve on the tube card and
to prohibit any person to work area.
Air should continue to check the tire pressure to prevent the inflation pressure is
too high.
•Rim, such as fixed properly, while inflating the tire rim may have burst. To ensure

21
safety, the tire should be inflated around the work area to set up a fence. When
inflated, the staff should stand on the side of the tire tread, while the ban stood
side tires.
•Tire pressure drops velocity anomaly or anomalies Rim devices are the tire rim sign
of a problem. This case, to ask tire repair station for maintenance professionals.

•After the high-speed exercise or heavy work, to adjust the tire pressure.
•Prohibit the installation of the tire rim on the heating or welding. Tire near the
fire source is strictly prohibited. Summer job, tire pressure should not be too high.
•Precursor loading front wheels and rear wheel drive loader for the modular structure
of the tube. Primary volume and sub-volumes by 9 M12 bolt connection. Inflatable tires
is fastening bolts must be checked before. •Demolition Tires Tire gas must be put in
net. Otherwise, there rim burst, causing casualties, such as the illegal operation
of your own risk.
Tire inflation pressure: nominal pressure 3MPA
6. Working Device Hydraulic System
(A) The working device is a bucket. Bar. Boom. Crossbar. Rocker so on. The machine
features: hand with force, received fighting a larger perspective, material loaded
much more lift without scattering material, operation and high efficiency.
(B) Work by the gear pump hydraulic system. Priority valve. Load-sensing steering.
Multi-channel valve. Tank. Tubing. E-mail form. The machine features: turn priority,
smooth and reliable. Pressure oil pump shaft from the first leading to the priority
valve, regardless of load size, the steering wheel high and low speed. Priority valve
to give priority to steering the allocation of fuel to ensure the oil supply shortage
of steering, so that turning movements smooth and reliable, and the rest to the working
hydraulic system, thereby eliminating excess oil due to oil line shift caused by power
loss, increased system efficiency.

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 Chapter III of the electrical equipment

Single-cylinder machine electrical systems use AC voltage 12 V, four-cylinder machine

is 24 volts, negative ground system.

1. front and rear headlights 2. Turn signal 3. Accumulator 4. Fuse box 5. Power Switch
6. Pairs of file switch 7. Turning switch 8. Power Table 9. Starter switch 10. Generator
11. Electric starter 12. Starting Ji Electrical 13. adjuster 14. horn button 15.
flasher 16. loudspeaker 17. temperature Table 18. Oil Pressure Gauge

1. Battery
Battery model single-cylinder machine N120-12V, four-cylinder machines for the
N140-24V, its function is when the engine starts, the power supply to start the motor,
but the engine work, if the generator voltage is lower than the battery voltage ,
then the power supply to the machine to the battery charger to save some energy.
In use Note:
1. Always keep charging state, such as the long unused, should be charging at least
once a month.
2. Frequently check the electrolyte fluid level, liquid level should be 10-15 mm above
the plate, less than distilled water when you can add. If satisfied that the
electrolyte Lou sprinkle losses, accounting for 1.28 should be added to the
electrolyte.
3. Should always check whether the battery vent plug, remove the external soil and
stolen goods, wipe spilled electrolyte and electrodes coated with thin layer of
calcium-based grease to prevent corrosion.
4. Shall not be excessive use of the engine.
5. Battery should be fastened in order to damage from vibration.

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 2. Generator and Regulator
1. Alternator:
Generators have marked "armature". "Magnetic field" the word, and a two terminal
marked "ground" indication of the grounding screw. They should be marked with the
relay regulator have the same text on the terminal connections, "ground" screw on
the regulator and the relay, "ground" screw connected.
Generators at both ends with bolts on the bracket fixed to the generator; another
one generator shoring, used to adjust the three-legged belt tensioner degrees.
2. Relay regulator:
Relay regulator by the interceptors. Regulator. Limiter composed of three devices.
Regulators on the relay marked "armature". "Magnetic." 2 terminal and a grounding
screw. "Armature". "Magnetic field" and the base side of the grounding screw terminal
on the generator should be the corresponding terminal and grounding screw connected.
"Battery" terminal access Ammeter "-" was terminal, ammeter of the "+" terminal and
the battery's "-" was attached pole.
Regulator was found not working or use of 1000 hours, they need a skilled electrician
to adjust.
3. Starter
Its use are: the supply of power from the battery to starter-generator, starter
gear for mobile is based on the electromagnetic drive, and with a one-way roller clutch,
to prevent the starter armature with high-speed rotation after starting the engine
damage.
4. Other
1. Fuse box:
When the circuit fails, the current overload, the fuse can automatically fuse,
thereby ensuring the electrical equipment completely work. There are four stalls fuse
box fuse assembly, the file uses and operating current in the table below:

File Numb 1 2 3 4

Uses General Fuse Charging circuit Headlights.Taillight Turnlights

Operating 30 20 60 6
Current (Amps)

If the circuit is not found in normal circumstances, should immediately check the
fuse box in the corresponding fuse is blown, according to other files have been blown
fuse, check the components to be protected. After troubleshooting, disconnect the
fuse board, Bakai dynamic loading head, the upper end of spare fuses removed the fuse
panel of about 60 mm, tight around the head in fixed equipment, the subsequent pull
back to move loaded head, and then insert the fuse box mounted fuse board to its
original location in.
2. Ammeter
Ammeter to indicate the battery charge. Discharge current, when the generator to the
battery charging, the pointer inclines towards "+"; the other hand, for the "-", no
current flows through, it means zero.
3. Electric Lock:
Insert key Keyhole, the right call, in addition to everything except the electric
starter electrical power connected. And then right away, starter connected to the
power, start the engine. In order to protect the starter motor, requiring the engine

24
start immediately after the electric locking keys allocated to the left.
4. Gates: gates control the entire electrical system, parking, should the power off
to avoid battery discharge.

Chapter IV driving

Driving and operating prior to conducting operations, should be familiar with the
structure of loaders. Technical maintenance. Operating methods in order to ensure
the safety of exercise and work to improve life expectancy and productivity of the
loader.
During driving and task performance should pay attention to the following safety
issues.
1. The driver must be rules of the road. Mechanical structure. How-to-peer learning,
and read the instruction manual.
2. In addition to driving the exercise room, not allowed to ride anywhere in personnel.
3. And pay attention to the reaction meter ministries working condition.
4. When operating strictly prohibited under the moving arm and bucket moving.
5. Engine flameout should be immediately stopped to prevent the steering failure
causing the accident.
1. All new vehicles to go
The units used in the new car must be carried out commissioning, through the operation
of the new car is not fully operational shall not be used.
Commissioning the machine can be running-in of the friction parts. To avoid the failure,
thus ensuring a reliable loader to work to extend the period of use.
This rule also been overhauled for use in the loader.
Sub-empty car commissioning commissioning commissioning and operation of two-step.
2, empty commissioning (about 8h)

1. Methods:
(1) The prescribed method of starting diesel engine, the first 5min after starting
to medium-speed idle (non-linked files). And then gradually accelerate to maximum
speed, running 10min.
(2) operation working device joystick boom and bucket joystick, so that boom to upgrade,
down, tipping bucket, and close the Big Dipper. Is about to 10min.
(3) mounted forward file. Tuidang later. Empty exercise. After the first vulgar
high-speed, uniform arrangement of each stall.
2. Check items:
(1) comprehensive inspection of ministries bolts. Nut fastening the situation.
Especially the cylinder head bolts, exhaust pipe bolts and front and rear drive axle
bolts, wheel nuts, transmission shaft connecting bolts.
(2) engine. Gearbox. Drive Bridge parts are no unusual sounds.
(3) the hydraulic system and gearbox. Engine lubrication system, braking system,
engine cooling systems, whether the oil spill. Leakage phenomenon.
(4) The meter reading is normal.
(5) The shift is flexible, sensitive and reliable braking it.
(6) The working device moves the phenomenon of whether the process was stuck.
(7) Check the electrical work.
3. Operating test run (about 20h)
1. According to operational control methods work, added material should be gradually

25
increased.
2. Operating commissioning process, in addition to check the empty commissioning
inspection items, but also observed in different materials in the loader shovel
loading capacity.
3. In walking together during the loading and unloading load shall not exceed 70%
of the common load.
4. In the period of walking together in order to shovel loading loose material is
appropriate. Action shall not be excessive. Too fast.
4. Loader use
(A) Precautions for use
1. Added to pure diesel, diesel label should comply with the prescribed quality
requirements.
2. Working device used in hydraulic system hydraulic oil must be clean.
3. According to the provisions of regular maintenance and lubrication.
4. After starting the engine to carry out air operations until the water temperature
reached 55°C and then start the exercise.
5. When the boom control switch to the Big Dipper and the need to reach location,
should set an intermediate position joystick.
6. Shall not be raised to the highest position of the transport bucket materials,
materials should be kept in special delivery from the hopper on the ground in order
to 300mm, in order to maintain stability in the exercise.
7. Lift arm, the hopper must be closed flat, or tanks and rocker damage your own risk.

(B) empty travel

1. Starting
Inspections before moving to make sure departments are normal after starting the
engine. Should be placed before starting the joystick neutral position, and then
insert the key gates, and rotate one position clockwise direction, connected to power,
riding under the throttle, and then start the engine. In case of low temperature in
winter, when the cooling water should be released, plus a hot water or boiled water
start. Start, they should observe the engine oil pressure, appropriate controls
throttle to prevent the engine bush-burning.
A start-up time for the 5-15s, still can not start if it is over time, it should
stop, wait a minute for a second time after the start. If more than three consecutive
still unable to start, should check the reason for re-start troubleshooting.
2. Start with the traffic
After starting the engine throttle speed should be further carried out in the
warm-up, and pay close attention to oil pressure gauge instructions. At the same time
check the engine and other systems are all normal. Ministries are normal, it will
rise to the transport bucket position; first hanging forward file, the next step the
accelerator pedal slowly, you can continue straight ahead loader, and then depending
on the operating conditions of roads and the speed you need to choose the appropriate
file bit and throttle for driving and operation.
3. Parking and flameout
Engine shut down, should idle running 2-3min, in order to ministries uniform
cooling.

26
 Winter, after stopping the engine put in time draining valve, put the net in all
the water cooling system to prevent the mechanical Frost Crack. When the water
temperature to -20°C-30°C, the batteries should be removed, so as to avoid moving
into Nuanshi Frost Crack.
Also, pay attention to parking bungalow on the ground before the bucket, turn off
the power.
(C) operations to manipulate
Operation with the driver to manipulate the number of degree of operation,
different levels of drivers are familiar with the operation of different method of
operation. Method of loading and unloading operations described below, for reference
only. Comrades in the use of aircraft operation in the practice of operating on their
own grasp of continuous improvement and summary method of operation to improve the
loading and unloading operations of production and machine life.
Operation to clear the area before, filling potholes and other damage to eradicate
Chienshih tires and obstacles impede the operation.
1. Shovel loading operations
(1) the speed of file being windrow forward boom next pitch on the ground under the
shovel about 250mm, Bucket part of the bottom plane parallel with the ground (which
can also move forward, putting down his bucket edge).
(2) at a distance of about 1-1.5m windrow Department, to lay down their boom. Bucket,
so that the blade grounding bucket, and bucket at the end with the ground plane into
a 3-7° corner cut into the windrow.
(3) depresses the accelerator to the feed bucket full cut pile, and intermittently
controlled bucket Bucket and boom raise up to fill up the Big Dipper.
(4) When turned on the bucket after bucket filled to boom elevated to the appropriate
height, and then let the boom joystick back to the middle.
(5) Xiewan material, put the hopper back, and then down the arm.
2. Transport operations

1) full bucket, release the throttle, so that engine speed reduced, hang back files,
and then slowly increase the throttle, the loading machine to withdraw piles.
(2) sail material discharge points, or truck. Ruoyin road is too soft or non-flat
space, can not be used or by-distance trucks to assist in the 500m or less, in the
heading for unloading point, the bucket into the transport position, is strictly
prohibited U-turn or braking in order to ensure transport security. steady.
(3) If the tires skid will reduce tire life, so jobs should avoid skidding tires.

27
 Chapter V Technical maintenance
The car loader work condition working conditions are bad, frequently in not
the smooth job location travel and the work, various part easy to receive the intense
vibration or the collision, causes the machine part to become less crowded or the
damage. Thus for guaranteed the charger the good performance, the normal work, the
extension service life, besides must be familiar with the machine various section
constructions, but also needs according to the request periodic inspection machine
technical condition, and carries on the technical maintenance earnestly. The this
chapter main introduction besides the engine the partial technical maintenance, the
engine technical maintenance please refer to the engine instruction booklet to carry
on.
一、Car loader oil used and lubrication matters needing attention
１、When replenishment fuel oil, hydraulic fluid, lubricating oil and lubricant,
should the oil injection tool, the vessel as well as the oil injection spot scours
cleanly, prevented the moisture, the sludge, the sundry goods enter in the oil used.
２、When replenishment each kind of oil class, must cause the machine to be in the
horizontal position.Besides attaches the oil level indicating device to be possible
to carry on the observation, overflows generally by the oil plug up to.The gear box
oil dipstick covers in the speed change.
３、When replenishment each kind of oil class, should put the dirty oil only, pours
into clear wash oil Yu Yuan to work the oil level, in the idling situation, causes
the engine to revolve several minutes, after stops the revolution, puts the clear
wash oil only, again joins the clean fresh oil, after if the oil viscosity may slightly
heat up beforehand too greatly dilutes carries on the replenishment again.
４、In the low temperature or under the high temperature different working condition,
should according to the actual situation and the operation requirements, replacement
power oil and the lubricating oil type.
二、Car loader oil used type (Sees the table 5--1to show)
Project ZL series car loader
Model
Fuel oil tank Summer (above 10 ℃ )0#,Winter (under
10℃)-10#Diesel oil
oil sump Summer (above 10 ℃ )CC40,WinterCC30Diesel engine
lubricating oil
gear box, driving axle 18#Hyperbolic curve gear oil

hydraulic fluid tank Winter46 、 Summer68Anti-rubs the hydraulic fluid

(international oil)
various oil injections ju Combination calcium base lubricating oil

brake fluid Add "912"synthesis brake fluid

28
三、Lubrication
The correct lubrication may reduce the machine greatly the friction drag and the
components attrition, thus lengthens the machine the life.
When lubrication please note the forecited oil used matters needing attention,
the lubricating oil please do act according to the Table 5-1 regulations to select.The
engine lubrication please press the engine instruction booklet to stipulate carries
on.
四、Routine maintenance
Routine maintenance after each class of work, and in the revolution carries on,
its content are not many, the time is short, but is extremely important to the normal
work and the reduced accident.The routine maintenance prime task is:
1、 The work before and after machine appears externally the part maintenance to be
neat.
2、 Whether there is inspects the fastener to become less crowded with the loss, and
screws tight and makes up neat.
3、 Whether there is does various spots part damage.
4、 Inspects each lubrication place whether replenishes the lubricating oil.
5、 Inspects all fuel tanks (fuel oil tank, work fuel tank, applies the brake total
pump), the oil level must replenish.
6、 Whether the engine cooling water does replenish.
7、 Whether there is does the inspection electrical system wire connection loosen,
the accumulator cell electric quantity is whether enough.
8、 Inspects various measuring appliances good, whether the light bulb integrity.
9、 The inspection operates respectively is whether nimble, is reliable.
10、 Whether there is after the start inspects the oil leak, the water leakage
situation, whether there is not normal sound.
11、 The experiment applies the brake whether reliably, changes whether nimbly.
五、Periodic maintenance
(一)After each week technical maintenance (works approximately 50h)
Besides routine maintenance project, but also must carry on as follows the project.
1、Inspects footboard traveling schedule which the foot applies the brake whether
conforms to the requirement, if it does not Tallying to adjust.
2、Fastens the before and after drive shaft connecting bolt, the driving axle
connecting bolt, the tire nut.
3、Inspection accumulator cell Shan Genei liquid level highly with specific gravity
of electrolyte (15℃; when proportion is 1.24-1.27), the following foot supplements
the distilled water and the charge.
4、Presses the note calcium base lubricant to the lubricator fitting.
(二)After each month of technical maintenance (approximately 200 hours)
Except every day, each week technical maintenance project outside, but also must
supplement the following item：
1、Survey tire pressure.If insufficient should give to restore vital energy.

29
2、Clean fuel oil, hydraulic fluid filter.
3、Inspection braking system whether there is oil leak or damage.
4、Inspects and screws tight the wheel hub bolt, the brake disc and the bearing cap
bolt.
(三)After each quarter technical maintenance (approximately 600 hours)
1、Inspects the multitandem valve, each kind of cylinder leak situation, if has causes
the work equipment drop phenomenon seriously, then should repair the elimination.
2、Whether there is the inspection applies the brake the total pump leather cup to
damage.
3、The inspection wheel hub bearing gap, and causes outside the brake disc the end
beat to be smaller than 0.2mm.
（四）The technical maintenance (approximately works after every half year for 1200
hours)
Except every day, each week, each month of, each quarter technical maintenance project
outside, but also must supplement the following item:
１、Replaces the complete oil duct system oil used, the hydraulic system oil used,
the gear box, around the bridge gear oil and the brake fluid and so on.And cleans
and so on pipeline, drill tubing, filter is clean, then pours into the fresh oil which
the process purifies.
２、Takes apart and washes applies the brake the total pump, the inspection brake
effect.
３、Around inspection bridge, master drive gear meshing situation, if host, driven
awl tooth gear clearance oversized, then should give to adjust in 0.2-0.34mm.
４、The inspection work installment and do the rack, whether there is distort, the
welded joint break phenomenon.

30
 Chapter VI General breakdown and reason analysis

Name Breakdown reason analysis elimination method

phenomenon
一、Engine please refer to the diesel engine
instruction booklet
1、When joint slips 1 、 The footboard free stroke Readjusting
excessively small Replacement pressure Spring
2、pressure spring weak Wash
3、friction disk surface has the Rechange friction risk
greasy dirt
4 、 friction disk attrition to
exceed the time limit
2、when joint tremble １、Spline attrition oversized Exchange clutch shaft or the cap of
２、Each tie bolt becomes less shaft
二、Clutch
crowded Tight
３、The rubbing surface has the Wash
fat Renew to adjust
４ 、 The separation release
lever adjustment is not uniform
3 、 The coupling not 1 、 Footboard free stroke Readjust
easy to separate oversized Readjust
２、Separates the release lever
to adjust improper
1、Sends the sound １、The gear attrition exceeds, Replace gearshift
the tooth lateral clearance
oversized
２、bearing attrition exceeds Replacementbearig
３、each fastening screw loose fastening
４、lubricating oil insufficient Supplement lubricatig oil
５ 、 gear and the axis spline gearshift or axis
三、 wears excessively
transmission 2、Often shifting gear 1、Dials forks the axis retaining The replacement spring
spring weak or the defeat
2、dials forks the axis locating replacement dials forks the axis
slot attrition to exceed gearshift or the axis
3 、 inside and outside spline
attrition

31
 3 、 Shifts gears goes The tooth gear teeth end bumps Repairs the deburring or the
not the wool gearshift

1 、 nimbly when to 1 、 The host reduction gear
have the sound linking not good
2、bearing attrition exceeds or
the loose
3、gear attrition exceeds
Adjustment either change bevel
gear
replacement bearing or adjustment
gearshift

2 、 The driving axle 1、Brake shield plate curving Repair either replacement
applies the brake when 2、drag friction burr rivet loose repair
sends the sound 3、brake drum damage repair or replacement
四、Driving
3 、 brake the vehicle 1、The brake shoe surface has The clean
axle
runs the oil
readjusts
2、gap adjustment is not good
causes the barometric pressure to
3、 when the tire pressure does
be consistent
not gather the standard
4 、 applies the brake １ 、 The brake drum and the Readjusts
not to work brake shoe gap adjustment
improper
２、Has the greasy dirt Readjusts or the replacement
３ 、 The drag friction burr replacement
attrition exceeds
１、The steering wheel １、The worm bearing adjuster Readjusts
free rotational impluse has axial flees moves
Readjusts or the replacement
increases suddenly ２、Worm bearing adjuster and
trundle backlash oversized
replacement
五、Steering ３ 、 The fall attachment
system attrition exceeds or the
breakage
２ 、 The rotation gear １、The lubrication is not good The apply oil
is not nimble ２ 、 Various ball ends adjust readjusts
improper
１ 、 Moves the arm １ 、 The safety valve １、According to rating regulating
lifting capacity adjustment does not work as system working pressure
insufficiency or the the system pressure is low２、 ２、The clean trades the oil
extension fights the Oil suction pipe and oil-filter ３ 、 Replaces the oil pump, and
strength to be pipes jamming according to the nature subsidence
insufficient ３ 、 Oil pump, cylinder, quantity inspection system
pipeline internal leakage leak-proof quality
４ 、 The multitandem valve ４、Replaces the multitandem valve

32
 wears excessively, the valve
lever and the valve chest
六 、 tolerance clearance surpasses
Hydraulic the stipulation
system ２ 、 The system １、Power oil deterioration
braking operating performance ２、Foreign matter blind off a
system reduces or is unstable line
３ 、 Oil filter jamming or
damage
４、In the system has the air
１、Replacement power oil
２、Clean oil duct system and fuel
tank
３、Clean or replacement
４、Whether there is inspects the oil
system to leak air

３ 、 After moves the １、Moves in the arm cylinder 1 、 Takes apart for overhaul the
arm lifting to sink leak the oil cylinder, replaces the seal packing
voluntarily collar
2、 Takes apart for overhaul or the
2 、 Multitandem valve valve replacement
lever gap oversized
4、The oil temperature 1 、 The heavy load operating 1、Engine off rest or reduced load
excessively is high time has grown 2 、 Refuels to the stipulation oil
2、Oil mass insufficiency level
5 、 After the steering 1、In the diverter returns to the 1、Takes apart for overhaul replaces
wheel returns to the position reed damage the reed
position to continue to 2 、 Matches between the oil 2、Disassembles the diverter repair
change jacket and the oil or fuel
distribution axis the
deactivation or matches
between the oil jacket and the
valve chest the deactivation
6 、 The foot braking 1、Brake minute pump oil leak 1 、 Replacement minute pump oil
force is insufficient 2、In the brake hydraulic circuit seal
has the air 2、Deaerate
3 、 Applies the brake the total
pump leather cup damage 3、Replacement leather cup
4 、 Applies the brake the total
oil pumping fluid to be 4、Refueling
insufficient
5、The throwout lever traveling
schedule adjusts improper 5、Adjustment traveling schedule
6、The brake lining plate wears
down to the limit 6 、 Replaces the new brake lining
plate
七、Electrical 1 、 But the engine 1 、 Accumulator cell plate 1 、 Desulphurization processing or

33
system normal the curing
accumulator cell does 2 、 Generator leather belt pine
not charge or the or damage
charging rate is low 3、The wiring jail, the contact
is not good
4 、 Regulator adjustment not
when or has the damage
2 、 The capacity of 1 、 The specific gravity of
storage battery is electrolyte or the liquid level
insufficient excessively are low
2 、 Between the pole plate
short-circuits
3、Pole plate curing
4、The wire contact is not good
5 、 The wire contact not good
pole plate active material falls
off
3、The generator does 1 、 Residual magnetism
not generate electricity vanishing
2 、 The field coil return route
breaks
3 、 The commutator contact is
not good
4 、 The electronics brush
catches not nimbly
5、Armature turn-to-turn short
circuit
34
replaces the pole plate
2、Readjusts or the replacement
3、Inspects and eliminates it
4、Readjusts or the repair
1、 Readjusts the proportion or the
increase electrolyte
2、Elimination settling, replacement
electrolyte
3 、 Desulphurization processing or
replaces the pole plate
4、Inspects and eliminates it
5、Replaces the pole plate
According to the generator original
polarity, meets with the
accumulator cell in the field coil
both sides and puts through
with 0 or the 00th sandpaper
polish
revision electronics brush size, the
regulating spring pressure
inspects and repairs
 Certificate

Model

No.

Diesel Model

No.

Origin

Frame Number

The date of manufacture

The product passed the test to allow the factory

Quality Supervision Inspection Division inspector：

Date

35