Z5GNV

ZL50GN Wheel Loader

Operator’s Manual

XCMG Construction Machinery Co., Ltd.

 Foreword
Most accidents occurred during the operations, maintenances, and repairs of the machine are caused by the

failure to abide by the basic safety regulations or precautions.

The operator must be fully aware of the potential hazards, including personal factors that may influence the
safety, and remain vigilant. They shall accept necessary training to learn the skills and tools required for
correct operation.
Incorrect operation, maintenance or repair of the machine may cause hazards or even personal
injury!
This manual is an important part of the machine ， which shows you the useful information regarding:
machine components and its operation, safety, service, maintenance, troubleshooting and technical
specifications. This manual can help you operate machines smoothly, safely and efficiently.
Please read carefully and understand completely this manual content before using, maintaining and
repairing the machine, especially those information about safety precautions. Please operate this
machine according to this manual strictly.
The operator of the machine must keep this manual within his reach, and the service people of this machine
also must be familiar with and understand this manual content.
The safety precautions and safety warnings are provided in this manual and on this product. The negligence
of these safety warnings will probably lead to personal injuries or death to yourself or other personnel.
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.

Warning sign for safety Explanation

If you pay no attention to any danger risk, casualty or serious injury will
DANGER occur.

If you pay no attention to any danger risk, casualty or serious injury may
WARNING occur.

If you pay no attention to any danger risk, injury to people or damage to

CAUTION equipment may occur.
If this manual gets lost or become dirty, please get a new one from XCMG CONSTRUCTION
MACHINERY CO., LTD. or its authorized agent. If you re-sell the machine to others, please hand over this
manual to the new machine user.

Declaration from The Manufacturer

◆ Only the trained and authorized people can operate and service this equipment.
◆ Operator and relative people must wear necessary safety protection staffs and take necessary safety
measurement.
◆ Don’t take any operation that is forbidden in this manual under any condition.
◆ Manufacturer can’t predict all the working environment in which latent danger exists and operation that
may cause danger. If you do the operation that is not mentioned in this manual, please ensure that this
operation will not damage to the operator, other people and this equipment. If you can’t ensure safety of
such operation, please stop working and consult with XCMG CONSTRUCTION MACHINERY CO.,
LTD. or its authorized agent.
◆ The manufacturer will not be responsible for the casualty, injury and damage caused by using this
equipment beyond this equipment purpose and regulations of operator’s manual.
◆ The accessories licensed by our company or our designated distributors shall be used. The use of
unlicensed accessories may cause safety problems and affect the normal operation and service life of the
machine. XCMG Construction Machinery Co., Ltd. assumes no liability for the damages, accidents and
machine breakdown caused by the use of unlicensed accessories.
◆ The unauthorized restructuring to the machine can cause danger, and manufacturer will not be
responsible for the damages caused by unauthorized restructuring.
◆ Some details shown in the pictures or diagrams in this manual or some optional components listed may
be different from your machine. Other components that are irrelevant to the instructions may have been
removed from the pictures or diagrams to facilitate illustration;
◆ This manual may not include the changes made to the machine due to the improvements and upgrades
of the product design. This may result in the inconsistency between this manual and the machine
purchased and influence the maintenance of the machine. Read and study this manual carefully and
compare with the machine;
◆ For further information about the machine or if you have any questions about this manual, please
consult our company or the machine distributor.
◆ Observe the national and local laws and regulations during the operation, maintenance and repair of this
machine.

Before driving on public roads, please check to see if the machine meets the
requirements of the local laws and regulations for road travel and obtain the road
CAUTION
travel permission of relevant managerial departments.
In order to ensure the accuracy of spare parts album, this machine is not equipped with a printed spare parts
album. To learn more about the information of its spare parts, please record the 17-digit product code in the
“PIN Code” of the machine sign on the right side of the front frame.

Your Machine PIN Code:

Please use a computer that can access the Internet, enter the following url in the Internet Explorer, then input
your machine PIN Code in the opened webpage, you can inquire the spare parts information of your
machine:
http:// 58.218.196.206:8088
 Table of Contents
1. Safety...........................................................................................................................................................1
1.1. Safety Signs And Theirs Position................................................................................................3
1.1.1. Paste Position Sketch of Safety Sign.............................................................................. 3
1.1.2. Safety Sign Instructions.................................................................................................. 4
1.1.3. Fire Extinguish................................................................................................................ 7
1.2. General safety information..........................................................................................................7
1.2.1. Safety Rules.................................................................................................................... 7
1.2.2. Safety guard.................................................................................................................... 7
1.2.3. Fire-prevention................................................................................................................8
1.2.4. Fire extinguisher and first-aid kit....................................................................................9
1.2.5. Fire safety........................................................................................................................9
1.3. Safe operaiton............................................................................................................................10
1.3.1. Be familiar with your machine..................................................................................... 10
1.3.2. Safe Starting.................................................................................................................. 11
1.3.3. Safe Driving.................................................................................................................. 14
1.3.4. Safety.............................................................................................................................19
1.3.5. Safe Parking.................................................................................................................. 22
1.3.6. Precautions for cold weather.........................................................................................22
1.4. General principle of maintenance............................................................................................. 23
1.4.1. Warning Label...............................................................................................................23
1.4.2. General maintenance requirements...............................................................................23
1.4.3. Maintaining to the machine.......................................................................................... 25
1.4.4. Maintenance of components and matters needing attention........................................ 28

2......................................................................................................................................................... Operation1
2.1. Component Names And Decals.................................................................................................. 4
2.2. Cab instrument and operating devices........................................................................................ 4
2.2.1. Cab interior layout.......................................................................................................... 4
2.2.2. Function descriptions of cab instrument and operating devices.....................................7
2.2.3. Usages of the operating devices....................................................................................10
2.2.4. Adjustment and usage of the seats................................................................................ 11
2.2.5. Standby exit...................................................................................................................12
2.2.6. Circuit breaker of storage battery................................................................................. 12
2.3. The Use Of The New Loader....................................................................................................12
2.3.1. Notices...........................................................................................................................12
2.3.2. Study The Safety Items................................................................................................. 13
2.3.3. Learn The Checking Method........................................................................................ 13
2.3.4. Be Familiar With Your Machine................................................................................... 13
2.3.5. Running-in of the machine............................................................................................13
2.4. In case of using the machine under the condition of mining area, tough mountain area, space
restricted area or the area with large slope, please be kindly noted of the followings.........................14
2.5. Before start................................................................................................................................ 15
 2.5.1. Daily checking.............................................................................................................. 15
2.5.2. Unlocking of frame steering lock................................................................................. 15
2.5.3. Getting on/off the machine........................................................................................... 16
2.5.4. Adjustment of exterior rearview mirror........................................................................16
2.6. Start the engine..........................................................................................................................17
2.6.1. Engine and Warm up Period......................................................................................... 17
2.7. Drive the machine..................................................................................................................... 18
2.7.1. Forward/backward starting drive.................................................................................. 18
2.7.2. Switch gears.................................................................................................................. 19
2.7.3. Steer the machine.......................................................................................................... 19
2.7.4. Braking of machine.......................................................................................................19
2.8. Parking of machine................................................................................................................... 20
2.8.1. Engine Stopping............................................................................................................20
2.9. Leave the machine.....................................................................................................................21
2.10. Working Method....................................................................................................................... 21
2.10.1. Forbidden Operation..................................................................................................... 21
2.10.2. Excavating Performance............................................................................................... 22
2.10.3. Load performance......................................................................................................... 23
2.10.4. Ground preparation....................................................................................................... 24
2.10.5. Snow Sweeping.............................................................................................................25
2.10.6. Towing performance..................................................................................................... 25
2.11. Hoist and Transport................................................................................................................... 26
2.11.1. Hoist or put down the machine..................................................................................... 26
2.11.2. Transporting the loader on a public road...................................................................... 27
2.11.3. Loading/unloading of machine..................................................................................... 28
2.11.4. After loading the machine.............................................................................................28
2.12. Storage.......................................................................................................................................29
2.12.1. Before Storing............................................................................................................... 29
2.12.2. Short-time storage......................................................................................................... 29
2.12.3. Long Time Storage........................................................................................................29
2.12.4. After an Extended Storage Time...................................................................................29
2.12.5. Storage of tires.............................................................................................................. 30

3. Maintenance............................................................................................................................................ 1
3.1.1. Recommended Lubricant And Oil.................................................................................. 3
3.1.2. Special recommendation “XUG specialized oil”........................................................... 4
3.1.3. Applicable air temperature for different oil product grades........................................... 4
3.1. Parts to be lubricated and lubricating schedule.......................................................................... 5
3.2. Periodic Maintenance and Service Cycles..................................................................................6
3.2.1. Periodic Maintenance and Service Instructions..............................................................6
3.2.2. Maintenance and service every 10h/day.........................................................................6
3.2.3. Maintenance and service every 50h/week...................................................................... 6
3.2.4. Maintenance and service every 100h/2 weeks............................................................... 7
3.2.5. Maintenance and service every 250h/month.................................................................. 7
 3.2.6. Maintenance and service every 500h/2 months..............................................................7
3.2.7. Maintenance and service every 600h..............................................................................8
3.2.8. Maintenance and service every 1000h/6 months............................................................8
3.2.9. Maintenance and service every 2000h/year....................................................................8
3.3. Inspection and adding of oil........................................................................................................8
3.3.1. Notes about the oils.........................................................................................................8
3.3.2. Fuel oil............................................................................................................................ 9
3.3.3. Hydraulic oil..................................................................................................................10
3.3.4. Brake fluid.....................................................................................................................11
3.3.5. Gearbox oil....................................................................................................................12
3.3.6. Drive axle oil.................................................................................................................13
3.3.7. Engine oil...................................................................................................................... 14
3.3.8. Engine cooling liquid....................................................................................................15
3.4. Checking and Maintaining Components...................................................................................17
3.4.1. Electrical system........................................................................................................... 17
3.4.2. Maintenance for battery................................................................................................ 17
3.4.3. Recharging.................................................................................................................... 18
3.4.4. Drive Unit......................................................................................................................18
3.4.5. Maintenance for Tyres.................................................................................................. 18
3.4.6. Working device............................................................................................................. 19
3.4.7. Braking system..............................................................................................................19
3.4.8. Air reservior.................................................................................................................. 20
3.4.9. Air-conditioner (optional)............................................................................................. 20
3.4.10. Others............................................................................................................................ 22
3.5. Trouble and shootings............................................................................................................... 22
3.5.1. Power System................................................................................................................22
3.5.2. Steering System.............................................................................................................23
3.5.3. Electrical System...........................................................................................................25
3.5.4. Braking System............................................................................................................. 25
3.5.5. Working hydraulic system............................................................................................ 27
3.6. Replacement of the key parts....................................................................................................27

4. Product Information................................................................................................................................1
4.1. Purpose............................................................................................................................................ 3
4.1.1. Performance features.......................................................................................................3
4.1.2. Requirements For The Working Environment:.............................................................. 3
4.2. Decals And Number........................................................................................................................ 3
4.2.1. Product Nameplate..........................................................................................................3
4.2.2. Engine nameplate............................................................................................................4
4.2.3. Other nameplates.............................................................................................................4
4.3. Overall dimensions of machine (standard configuration).............................................................. 5
4.4. Main technical specification (standard configuration)................................................................... 6
4.4.1. Overall dimensions......................................................................................................... 6
4.4.2. Performance Parameters................................................................................................. 6
 4.5. Main technical specifications of non-standard attachments........................................................... 8
4.5.1. Specification of optional linkage systems and double-circuit attachments for standard
boom 8
4.5.2. Specification of optional linkage systems and double-circuit attachments for small
high-dumping boom........................................................................................................................ 8
4.5.3. Specification of optional linkage systems and double-circuit attachments for large
high-dumping boom........................................................................................................................ 9
4.5.4. Specification of optional triple-circuit attachments for standard boom.........................9
4.6. Electric Schematic Diagram..........................................................................................................10
4.6.1. Weichai + planetary transmission + dry axle................................................................10
4.6.2. Shangchai + planetary transmission + dry axle............................................................ 14
4.6.3. Shangchai + MYF200 electronic control transmission + dry axle...............................18
4.7. Hydraulic Schematic Diagram...................................................................................................... 22
4.7.1. Planetary transmission + dry axle + constant displacement pump...............................22
4.7.2. MYF200 transmission + dry axle + constant displacement pump............................... 24

5. Appendix................................................................................................................................................. 1
5.1. List of maintenance parts............................................................................................................ 3
5.1.1. List of Maintenance Parts for Standard Configuration (Weichai WD10 series engine,
planetary transmission, and dry axle)............................................................................................. 3
5.1.2. List of Maintenance Parts for Standard Configuration (Shangchai SC11CB220G2B1
series engine, planetary transmission, and dry axle)...................................................................... 4
5.1.3. List of Maintenance Parts for Standard Configuration (Shangchai SC11CB220G2B1
series engine, MYF200 electronic control transmission, and dry axle)......................................... 5
5.2. Introduction of spare parts center............................................................................................... 7
1. Safety

1
 Table of contents
1. Safety.......................................................................................................................................................................1
1.1. Safety Signs And Theirs Position............................................................................................................... 3
1.1.1. Paste Position Sketch of Safety Sign..............................................................................................3
1.1.2. Safety Sign Instructions..................................................................................................................4
1.1.3. Fire Extinguish................................................................................................................................7
1.2. General safety information......................................................................................................................... 7
1.2.1. Safety Rules.................................................................................................................................... 7
1.2.2. Safety guard.................................................................................................................................... 7
1.2.3. Fire-prevention................................................................................................................................8
1.2.4. Fire extinguisher and first-aid kit................................................................................................... 9
1.2.5. Fire safety........................................................................................................................................9
1.3. Safe operaiton........................................................................................................................................... 10
1.3.1. Be familiar with your machine..................................................................................................... 10
1.3.2. Safe Starting..................................................................................................................................11
1.3.3. Safe Driving.................................................................................................................................. 14
1.3.4. Safety............................................................................................................................................ 19
1.3.5. Safe Parking.................................................................................................................................. 22
1.3.6. Precautions for cold weather........................................................................................................ 22
1.4. General principle of maintenance.............................................................................................................23
1.4.1. Warning Label...............................................................................................................................23
1.4.2. General maintenance requirements.............................................................................................. 23
1.4.3. Maintaining to the machine.......................................................................................................... 25
1.4.4. Maintenance of components and matters needing attention........................................................ 28

2
1.1. 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.

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.

1.1.1. Paste Position Sketch of Safety Sign

Water tank

One piece each in left and right

symmetric positions

Shroud

Figure 1-1 Paste Position Sketch of Safety Sign

3
The label declarations are as follows:
1—Keep away from lift arm and bucket (Figure 1-2)2—Do not enter into the articulated area, risk of
crushing (Figure 1-3)
3—Fill in the antifreeze(Figure 1-4) 4—Do not get close to the moving parts with your
hands. (Figure 1-5)
5—Do not get close to the machine, beware of 6—Electric shock hazard safety sign (Figure 1-7)
reversing.(Figure 1-6)
7—Hand braking warning (Figure 1-8) 8—Warning of mechanical handbrake (Figure 1- 9)
9—Shut down the engine and remove the key before 10—Read the Use and Maintenance Manual(Figure
maintenance and service.(Figure 1-10) 1-11)
11—Breather sign（Figure 1- 12）

1.1.2. Safety Sign Instructions

Figure 1-3 Do not enter into the articulated

area, risk of crushing
Figure 1-2 Keep away from lift arm and bucket Danger: Nobody shall stand here. Please
keep a safety distance with the machine.
Danger: Keep a safety distance away from the machine.
Crushing may cause serious injuries.
Nobody shall stand in the area while the life arm is lowering or
hoisting, otherwise it may cause serious injuries.

4
 Figure 1-4 Fill in the antifreeze
Figure 1-5 Do not get close to the moving
Warning: Do not mix the engine coolant, or it may cause
parts with your hands.
damages to the machine.
Danger: Do not open or remove the safety

guard while the engine is working.

Figure 1-6 Do not get close to the machine, beware of

reversing
Danger: Keep a safety distance with the machine to Figure 1-7 Electric shock hazard safety
prevent the injuries caused by reversing. sign
Danger: Keep away from the high-voltage
cable during working to prevent the injuries
caused by electric shock.

Figure 1-8 Hand braking warning Figure 1- 9 Warning of mechanical

Warning: Do not drive when the machine alarms for handbrake
insufficient brake air pressure! Otherwise accidents may occur. Warning: Release the handbrake

5
 handle before driving. Pull up the
handbrake handle during parking.

Figure 1-10 Shut down the engine and remove the key Figure 1-11 Read the Use and Maintenance
before maintenance and service Manual
Warning: Shut down the engine and remove the key Warning: Do not operate the machine
before maintenance and service! Otherwise accidents may before reading and understanding the contents
occur due to incorrect operation. of this manual, especially those related to safety.

Figure 1- 12 Breather sign

Caution: Please clean the filter element weekly to ensure
system cleanliness.

6
1.1.3. Fire Extinguish

● Fire extinguisher shall be equipped on the machine as an

additional safety precaution.
● Be familiar with the usages of the fire extinguisher,
inspect and maintain it regularly and follow the advices on
the instruction plate.
● The machine reserves a mount bracket for 4kg fire Figure 1-13 Fire extinguisher bracket position
extinguisher on the cab floor behind the left seat. The fire
extinguisher is an optional part and users can use their
own or buy from our spare parts center. (Figure 1-13)

1.2. General safety information

1.2.1. Safety Rules

● Only the trained people can operate and maintain the

machine.
● Don’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.
● When you work together with other people, please make
them understand the gesture language.

1.2.2. Safety guard

● When operating or maintaining the loader, please take safety

guards.
● 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. Figure 1- 14
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- 14)
● Don’t wear loose clothing as loose clothing can be easily
enwinded in control levers or moving parts to cause casualty.
● Don’t wear greasy clothing which can incur burning.
● Wear goggles or a mask on work sites with liquefied natural
gas. It is suggested to wear cotton protective clothes that are
easy to take off and heat insulating gloves. Wear long
trousers that can cover the openings of the footwear uppers
and do not roll up the trouser legs. There should be no iron Figure 1- 15

7
 nails on the shoe bottoms, in order to prevent the body from
being hurt by the spilled liquid. (Figure 1- 15)
● Check if the safety guards are normal or not before putting
them into use.

1.2.3. Fire-prevention

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.(Figure 1- 16)
● Screw up all caps of oil tanks.
● Use marked vessels to hold combustible liquid, and put them
on a fixed place. Unconcerned people is disallowed to use it. Figure 1- 16
● Move combustible material away from the loader surface,
ensure that no greasy cloth or combustible material exists on
the loader surface.
● Don’t weld or incise the pipes containing combustible liquid.
Before welding or incising pipes, please use
non-combustible liquid to clean the pipes.
● When the loader is working, keep the exhauster of muffler Figure 1- 17
far away from combustible materials, such as withered grass
or waste paper and so on. (Figure 1- 17)
● Choose the parking place carefully and keep hot parts of the
loader far away from combustible materials.
● Prevent pipes and hoses from leaking. Replace the damaged
pipes and hoses. Use the pipes and hoses which have been
repaired or cleaned. (Figure 1- 18)

Figure 1- 18
● Battery can produce out explosive gas, so don’t let smoking
and fire approach the battery. Maintain the batteries
according to Operator’s Manual strictly.
● When checking the dark area, don’t use fire to lighten the
area. (Figure 1- 19)
Figure 1- 19

8
1.2.4. Fire extinguisher and first-aid kit

Take steps according to following items if injure or fire accident

has occurred.
● You must prepare a fire extinguisher and know how to use it.
● First-aid kit must be prepared on the working place. Refresh
the first-aid kit with new medicines. (Figure 1- 20)
● Some useful telephone numbers must be pasted on a obvious
place, such as telephone number of doctors or hospitals, Figure 1- 20
ensure all people know these telephone numbers and know
the communicating method.
● You must know how to save yourself when fire accident
occurring or you have been injured.

1.2.5. Fire safety

If you find that your machine has caught a fire, the safety of you and the other people on the site is the most
important. The following actions can be taken if only they will not put you and the other people in danger.
Evaluate the risk of personal injury at all times and keep a safe distance from the machine when you feel
dangerous.
 If you cannot do anything, please switch off the machine before you leave.

 Move the machine away from inflammables, such as gas stations, buildings, garbage dumps, coverings and

woods;

 Lower all the implements and switch off the engine as soon as possible. If the engine is still running, it will

continue to cause a fire. The damage of any hose connected to the engine or pump may cause a fire.

 If possible, turn the battery circuit breaker to the off (O) position. Switching off the battery will eliminate the

ignition source in case of electrical short circuit. If the electric wire is damaged by the fire and causes a short

circuit, switching off the battery will eliminate the secondary ignition source.

 Please inform the emergency personnel of the fire situation and your address.

 Use the onboard fire distinguisher according to the following procedure:

（1） Pull out the safety pin;
（2） Aim the nozzle of the fire distinguisher at the root of the flame;
（3） Press the handle to release the fire extinguishing agent;
（4） Sweep from one side to the other side of the root of the flame with the fire extinguisher until the fire
is extinguished.
 If the flame is out of control, pay attention to the following hazards:
（1） The tyre of the tyred loader has an explosion hazard when it is burning;
（2） An explosion may throw hot explosion fragments and debris far away;
（3） The oil tank, accumulator, hoses and hose joints may blow out in a fire and sprinkle the fuel and
9
 explosion fragments to a very large area;
（4） Please remember that, almost all the fluids in the machine are flammable, including coolant and
hydraulic oil. Plastics, rubber, fabrics and the resin in the glass mats are also flammable.

1.3. Safe operaiton

1.3.1. Be familiar with your machine

● Only the authorized technician can operate and maintain the

loader.
● When operating or maintaining the machine, please obey with all
safety regulations and notices.
● Read the Operator’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- 21)
● When installing and using a accessory, please read the manual Figure 1- 21
which is about to the accessory.
Don’t use the accessories that are unauthorized by Xuzhou Construction Machinery
Group Inc or its agent. The unauthorized accessories can cause dangers and tamper
Warning with the normal operation. Xuzhou Construction Machinery Group Inc should not
be responsible for the damages and accidents caused by using the unauthorized
accessories.
● 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- 22)

Figure 1- 22
● 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-
23) Figure 1- 23

10
B. Guard against crushing or incising injuring
● 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 Figure 1- 24
engine and lock the working equipment. (Figure 1- 24)
● Support the loader reliably and firmly when you have to work
under the machine. Don’t rely on the cylinder to support the
loader. Accessory may fall down if controlling device moves or
pipes leak oil.
● Don’t adjust anything when the loader or the engine is running.
● Evade away from all rotating parts and working parts. (Figure 1-
25)
● Ensure that no sundries exist in laminas of fan. Rotating laminas Figure 1- 25
of fan can eject out or break the sundries which exist in the fan.
● It is dangerous to check the engine when the engine is running,
avoid of doing that.

1.3.2. Safe Starting

A. Driver’s clothing
The driver shall select the required personal protective articles
depending on the operation needs. For instance, the driver shall wear
the safety helmet, work clothing with contracted sleeve and leg
openings, safety shoes, safety goggles, and gloves and mask. (Figure
1- 26)

Figure 1- 26
B. Investigate the surrounding environment of working place
before starting operation. (Figure 1- 27)
● Investigate the surrounding environment of working place before
starting operation. Keep guard against abnormal conditions that
can result dangerous accidents.
● Be familiar with the terrain and ground condition of the working
place, choose the safest working method.
● 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.
● When working on a public road, please assign a man as traffic Figure 1- 27
director, or set fence around the working place and set up some
notices which show “No entrance”.
● Ensure good and effective ventilation before you working
indoors, avoid of toxicosis resulted from waste gas.
● Some water pipes, gas pipes and electrical cables may be buried
11
 under the ground, please take notices of the burring positions and
avoid of damaging these pipes.
● 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 water.
Cleanout and check lubricating holes after working.
C. Check the loader before starting it
Check the loader before every daily work, perform daily maintenance
insistently. Treat abnormal condition seriously, repair breakdown
immediately and report to managing personnel.
● Take notice to oil leakage, water leakage, looseness of
bolts, abnormal sound and lost of parts.
● Ensure that the lock bar has been disengaged.
Figure 1- 28
● Clean the cab windows and clean all lamps to get a good
visual field.
● For get a good visual field, turn rear-view mirrors to a proper
angle. Replace the damaged glass of rear-view mirror.（Figure 1-
28)
D. Get on and off the loader
● 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.
● Don’t jump on or off from the loader. Never getting on or off the
loader when the loader is moving. (Figure 1- 29)
● 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.
● Don’t grip any control levers when you getting on or off the Figure 1- 29
loader.
● Don’t get on and off the loader from the rear ladder or tyres.
● Don’t climb up and down the loader carrying with tools or other
materials, please use ropes to hoist the tools or other materials.
E. When the operator leaves the seat
● When the operator rises from the seat, be sure to pull down the
pilot lock to avoid moving the working device and causing an
accident due to the accidental touch of the operating lever.
● Before leaving the machine, ensure to pull up the parking brake
handle to braking position, shift all joysticks to neutral position,
stop the engine, and lock all devices by key. Always carry the key
with you.

12
 Special care shall be taken when standing or walking on the platforms on both
sides of the cab. Grasp the handrail to avoid falling.

CAUTION Do not place the parts and tools around the operating elements in the cab!
This is because vibration may be produced during running and operation and
these stuff may damage the operating elements or switches; or may lead to the
maloperation or movement of the pedal and cause an accident.
F. Start the loader
● 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.
● Don’t start the engine if control lever is pasted on a tab which
shows “No operation”.
● At first, sit down on the seat and adjust it until you feel
comfortable. Take on the safety belt.
● Sound the bugle to remind surrounding people getting away.
(Figure 1- 30)
● Start the engine according to Operator’s Manual. Figure 1- 30
● 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.
● Refer to Operator’s Manual in advance before using aether
cooling starting device. Keep guard to fire because the aether is
combustible material.
● Aether is forbidden to be used when plug-shape pre-warmer has
been installed on the engine.
G. Checking after the loader has been started
Inspect the loader according to following items after the loader has
been started and before working. (Figure 1- 31)
● 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.
● Check the speed controlling of engine under the condition of
neutral gear. Figure 1- 31
● Pay attentions on all meters and apparatus and alarm lamps,
ensure that they can work normally and remain in regulated
range.
● Ensure that the hand braking has been disengaged.
● Try operating on all operating levers and ensure that they are
flexible.
● Try the gear-shifting lever to feel that the gear position is right or
not.
● Inspect the braking pedal and accelerograph pedal, and inspect
that the steering is sensitive or not under the condition of low
speed.
● Ensure the reverse alarm is normal.

13
1.3.3. Safe Driving

A. Ensure safety for yourself and others

● Keep a right operating habit to ensure safety.
● Sound the bugle before starting the loader, start the loader after
everything is confirmed normal.
● Ensure that no one or no obstacle is near the loader. (Figure 1- 32)

Figure 1- 32
● Don’t stretch your arms or legs out of the cab, it can incur injure.
Don’t put your arms or feet on operating devices. (Figure 1- 33)

Figure 1- 33
● Devote your mind to operation because momentary neglect can
result tragedy. Attend to surrounding people and sound the bugle
to alarm them. (Figure 1- 34)

Figure 1- 34
● Don’t drive the loader with the doors and windows are open, but
fixed door or window is not restricted by this regulation. (Figure
1- 35)

Figure 1- 35
● The loader is not a man carrier, so hitchhiking is disallowed.
● Using the bucket to carry people or as working platform is very
dangerous. (Figure 1- 36)

Figure 1- 36

14
B. Road driving
● 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. (Figure 1- 37)
● Fog, flappy soot and sand can obstruct the visual field of operator.
● Investigate the working place in advance, watch the road
condition, keep vigilance against to obstacles, sludge, snow and Figure 1- 37
cave.
● Please obey with traffic rules when driving the loader on a public
road, don’t incur traffic jam, and get through the crossing quickly.
● Drive the loader with courtesy when driving on a public road, keep
distance away from other vehicles.
● Before driving on speedway and public road, please refer to
Operator’s Manual in advance and obey with local traffic rules.
Don’t incur traffic jam and be quickly when getting through a
crossing. (Figure 1- 38)
● Understand all operating regulations and signals, operator must
know the meaning of every signal and sign at the first glance.

Figure 1- 38
Emergent braking may cause injuring!
DANGER It is very dangerous to shift between forward and reverse gear when the loader driving
with high speed.

C. Transporting with full load

● 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- 39)

Figure 1- 39
● 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- 40)

Figure 1- 40

15
● Avoid of hurry driving, emergent braking, hurry turning and bypassing
when transporting load. It is dangerous to operate the working
equipment impetuously. Impetuous action of working apparatus can
throw out the load or overturn the loader. (Figure 1- 41)

Figure 1- 41
D. Over-speed is forbidden
● 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- 42)

Figure 1- 42
● Drive the loader slowly to make the loader in a controllable condition.
● Speedy driving, hurry turning or emergent braking is forbidden when
the loader drives on a bumpy road or a slope.
● 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- 43)

Figure 1- 43
● Run the engine smoothly, and don’t turn the loader when it is running
with high speed. (Figure 1- 44)

Figure 1- 44
E. Keep good visibility
● When the visibility is limited, the speed should be reduced. Sound the
bugle to remind surrounding people and avoid of savage operation.
(Figure 1- 45)
● 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.
Figure 1- 45

16
● When loading a large size goods, be careful of lifting, moving and
shifting gears. Be sure that no one enter into the working area, and a
guider is necessary. (Figure 1- 46)

Figure 1- 46
● Misconception to the distances and terrain may occur in the night, so
keep a proper speed that suitable to the surrounding illuminating.
● Turn on the front lamps and top lamps when working at night. (Figure
1- 47)

Figure 1- 47
F. Obstacles
● When passing a place with many obstacles such as the roof and the
porch of the buildings, do not get the machine collided with these
obstacles.
● Lower the speed when driving or steering in a limited areas. Be sure
that there is no obstacle around it.
● When the road condition is bad, operate the machine carefully, and Figure 1- 48
avoid of losing the stability.(Figure 1- 48)
G. When traveling under severe condition
● Do not work alone in the dangerous places. Investigate the road
conditions, intensity of bridge and the topography of the worksite in
advance.(Figure 1- 49)
● Take notices to sinking of wheels and braking performance when
driving in a marsh and loose ground.
● Don’t make the bottom of driving axle contact with water when Figure 1- 49
working in shallow water and swamp area.
● Avoiding of traveling too close to the overhangs and deep 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.
● When working in a dangerous place which has the hazard of falling
rocks or overturning, start the protection devices (FOPS&ROPS).
● 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.
● When working on a snowy ground, reduce the loading volume and
take notices to skidding.
● Travelling sideways or turning on a slope is very dangerous, don’t try
this operating. (Figure 1- 50) Figure 1- 50

17
H. Driving on a Slope
● Don’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. (Figure 1- 51)
● Getting up or down a slopes is preferred rather than passing through an
alleyway or pavement.
● Choose a proper speed gear before getting down a slope, and don’t
Figure 1- 51
shift speed on the process of getting down a slope.
● The gravity centre of the loader will be concentrated on fore wheels or
rear wheels when driving on a slope, so please take more care and
avoid of emergent braking.
● 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.
● When driving on a slope with full load (Figure 1- 52)
△ Use the gear Ⅰ
Figure 1- 52
△ Keep the loader forwards when driving uphill and backwards when
driving downhill.
△ Don’t swerve
● If it 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.
● 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- 53
● If the gradient of the slope is less than 15º, repeat the above procedure
and put operating levers at theirs neutral position, then start the engine
again. (Figure 1- 53)
I. Take notices when swerving the loader.
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.
● Sound the bugle to remind surrounding people.
● Ensure that no one is surrounding the loader. Especially check the area
that behind the loader for the sake of this area is invisible to the
operator’s position.（Figure 1- 54）
● Some one should be designated to guide the transportation when Figure 1- 54
operating on a dangerous place or a place with poor visibility.
● No one can enter into the driving area or turnaround area without
allowance.
● Don’ t change the driving direction when the loader driving at high
speed.

18
1.3.4. Safety

A. Keep a good operating habit

● 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- 55)

Figure 1- 55
● The operation to handles must be correct. (Figure 1- 56)

Figure 1- 56
● Repair the breakdown at once if the breakdown occur, and listen
the abnormal sound to distinguish the reasons of breakdown.
Don’t repair the part that is in working. (Figure 1- 57)

Figure 1- 57
Overload operation is very dangerous and may cause mechanical or personal
DANGER injury!
● The loaded weight must not exceed the specified value of “rated
working load” indicated on the product label of the complete
machine. Overload operation is very dangerous and may cause the
rear wheels to leave the ground or even cause the machine to turn
over. Therefore, confirm the loaded weight in advance to avoid
overloading. XCMG Construction Machinery Co., Ltd. assumes
no liability for the mechanical or personal injury caused by Figure 1- 58
overload operation. (Figure 1- 58)
● 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- 59)

Figure 1- 59
● 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- 60)
● Investigate the surrounding condition in advance before starting
operation.
● Check the ground condition before passing through a tunnel or
over a bridge. Figure 1- 60

19
● When working in heavy windy weather, operate the loader
favourably with the wind.
● Be careful when the load must be lifted to the highest position.
Lifting the load to high position is dangerous because it make the
loader unbalanced, so move the loader slowly and take notices
when tilting the bucket forward. (Figure 1- 61)
Figure 1- 61
● When a truck cooperating with the loader, avoid of the bucket
colliding with the truck. No one can stand under the bucket and
don’t hang the bucket over the cab of the truck. (Figure 1- 62)

Figure 1- 62
● 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- 63)
● 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. Figure 1- 63
d. When working at night, please stop the loader to inspect its
condition frequently and check the surrounding condition.
● Before passing over a bridge or other constructions, please ensure
that it has enough solidity to support the loader. (Figure 1- 64)

Figure 1- 64
● The loader is a special purpose machine. Don’t use the head or
any part of the working equipment to scratch, move or push
something. (Figure 1- 65)

Figure 1- 65
B. Take notices to surrounding environment
● 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 working
equipment. If the machine can’t work, please fix the working
equipment firmly at first. (Figure 1- 66) Figure 1- 66

20
● When working near a cliff or a place which is easy to collapse,
please operate the loader with the safest method and assign a
guider to help you.(Figure 1- 67)

Figure 1- 67
● When dumping soil or stone from a higher place, the safety of the
dumping place should be considered.
● 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.
● 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- 68) Figure 1- 68
C. Ensure the ventilation before operating indoor
● 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’t provide enough
ventilating, fans are necessary. (Figure 1- 69)

Figure 1- 69
● Prepare several fire extinguishers before working inside a
enclosed room, and bear in mind its location and using method.
(Figure 1- 70)

Figure 1- 70
D. Keep far away from dangerous place
● 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- 71)

Figure 1- 71
E. Keep far away from high voltage lines
● Don’ 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.

21
Table 1-2
Voltage The minimal safety distance
Low voltage 100～200V 2m 7ft
6,600V 2m 7ft
22,000V 3m 10ft
66,000V 4m 14ft
High voltage 154,000V 5m 17ft
187,000V 6m 20ft
275,000V 7m 23ft
500,000V 11m 36ft
Do the following jobs well to prevent accidents
☆ If the risk of contacting with electrical cables is obvious, please consult with local electrical department before
working.
☆ Take on rubber shoes and rubber gloves. Put a rubber pad on the operator’s seat. Prevent any part of your body
from contacting with the metal chassis.
☆ Assign a guider to remind you when the loader getting near the electrical cables.
☆ Operator should not leave the cab if the working equipment has contacted with electrical cables.
☆ No one can be permitted to get near the loader when working near the high voltage line.
☆ Know the voltage of high voltage line from electrical department before working.

1.3.5. Safe Parking

● Choose a place as flat as possible to park the loader, drop the working equipment down onto the ground.
● Don’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.
● 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.
● 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.
● Don’t get on the loader while it is running.
● In a extreme hot weather with temperature up to more than 30℃, engine is easy to get overheated, so parking
place must be a shady place.
● 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.
● When the vehicle is parked for a long time, put the cathode switch of the power supply to the “O” position to
turn off the power supply of the complete vehicle and prevent low battery.

1.3.6. Precautions for cold weather

● 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.
● Warm-up your loader completely before working. If the loader has not been warmed-up completely, it will
22
 react slowly and may result accident.
● Operate every operating lever to make hydraulic oil circulate in hydraulic system and get warmed, therefore
the loader can work ably.
● If the electrolyte of battery has iced, don’t charge electricity to battery. Don’t use another electrical source to
start the engine, as this performance is dangerous because it can make battery to fire.
● 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.

1.4. General principle of maintenance

1.4.1. Warning Label

● 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.
● 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.

1.4.2. General maintenance requirements

● 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.
● You should repair the loader according to the this manual. If you
Figure 1- 72
do not know how to repair the loader, you should ask help from
manufacturer.
● 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.
● 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 1- 72）
● Please use the proper tools and do not use the broken and inferior
tools.
● 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.
（Figure 1- 73）
Figure 1- 73

23
● 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 attached or clean them.
● Before repairing the loader, you should post a warning
tab—“Operation is forbidden” 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.（Figure 1- Figure 1- 74
74）
● Appoint a director for assembly or disassembly the accessories.
● Fuel and oil is dangerous. Fuel, oil, grease and linoleum are not
allowed to be exposed to any fire and flame.
● No smoking when adding oil and doing inspection work.（Figure
1- 75）

Figure 1- 75
● 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.
● Forbid any irrevspective people to enter into the working areas.
● Keep the working area clean and orderly. Do not get oil and
grease scattering to all over the working areas. Avoid firing and Figure 1- 76
slipping.（Figure 1- 76）
● When checking or maintaining the machine, the frames should be
locked by a locking bar.（Figure 1- 77）

Figure 1- 77
● When the bucket is being raised, dismantle down the safety
bracket and lock it to the piston rod of lifting arm cylinder which
can prevent the lifting arm cylinder from withdrawing.
● Put the operating lever at neutral position and lock it with locking
system.（Figure 1- 78）

Figure 1- 78
● Don’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 1- 79)

Figure 1- 79
● Prepare the extinguisher before working inside a building, and
get familiar with where it is located and how to use it. (Figure 1-
80)

24
 Figure 1- 80

1.4.3. Maintaining to the machine

A. Cleaning
● Clean the machine before doing any service and maintenance, so
as to prevent dirt getting into the machine.
● 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.（Figure 1- 81）
● While cleaning the machine, use the cleaning-addition which is
not flammable. Figure 1- 81
● 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.
● 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.
● Don'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.
● When cleaning the filter elements with compressed air, wear the Figure 1- 82
protection clothes and safe glasses.（Figure 1- 82）

B. Support to the working mechanism

● When the bucket is being raised, dismantle down the safety
bracket and lock it to the piston rod of lifting arm cylinder which
can prevent the lifting arm cylinder from withdrawing.
● Put the operating lever at neutral position and lock it with locking
system.
C. Illumination
● 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.
● If the operator works at a dark place without lighting, there is a
danger of injury. So lighting should be equipped.
● 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.
● When taking the machine as a lighting power source, please
follow the instructions in this manual.

25
D. Work in an enclosed room
● 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 1- 83）
Figure 1- 83
E. Working under the machine
● Stop the loader on a smooth ground, and put down all the
working mechanism on the ground before working under the
loader.
● Block the wheels with chocks.
● It is very dangerous to work under the loader which is only
supported by working mechanism.
● Never work under the loader which is with poor supporter.
Figure 1- 84
（Figure 1- 84）

F. Working on the top of the machine

● 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.
△ There are no sprinkled lubricating grease and lubricant on the
machine.
△ Don't leave tools everywhere.
△ Pay attention on the paces while walking on the machine.
● Don'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
● Use the protecting device under the special circumstance.
● The top of the engine hood is smooth and slippery, so no people
will be allowed to stand on it.
● Standing on the top of tyre is dangerous, so never stand on the
tyres.
● When cleaning the front glasses of the cab, you should stand on
the splash fender of front frame.
G. Servicing the machine while the engine is running
In order to avoid injury and accident, don’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:
● Appoint a man sitting on driver’s seat and get ready to stop the
engine at any time.
● Don't touch exhausting pipe or high temperature parts, such as
end tube, muffler, etc. so as to avoid scalding.
● When working close to a rotating part, there is the risk to be
Figure 1- 85
rolled inside by rotating parts, so special care should be given.
● Don’t touch any control handle. If it is necessary to operate a
control handle, firstly make a alarming to other people and ask
26
 them to leave.
● Never touch the rotating leafs of the fan or the fan belt as it is
very dangerous. (Figure 1- 85)
● Don't adjust the part that you do not understand.
H. Don't leave anything falling into the machine
● 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.
● Unnecessary tools and parts should not exist in your pockets
when maintaining the machine.
I. Heavy objects
● 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.
● 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.
● Use tools and heavy objects carefully and avoid them falling
down.
J. 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 end of battery should be disconnected in order to prevent the
battery from exploding.
● Disconnect the clip connection of the computer control panel of
the transmission (which is placed in the control box right side of
the driver’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't start or run the machine.
● Ensure to unplug all connectors from the engine ECU to prevent
the high current from damaging the circuit board. Cover the ECU
slot by sheath to prevent the ingress of particles and welding
spark. Do not touch the ECU pins by hand.
● Clear paints from welding place in order to prevent the
production of the pernicious gas.
● 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.
● 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 damaged, so please
use fender to guard these pipes. Figure 1- 86
● When welding near tyre, special attention should be paid because

27
 it may explode. (Figure 1- 86)
● When welding, protective clothes should be wore.
● The ventilation of the welding place should be well prepared.
(Figure 1- 87)
● Clear up all inflammable material, and fire extinguisher should be
supplied at the site.
● Do not make renovations that may influence the performance,
strength and safety of the machine and the operating device. Figure 1- 87
K. Natters needing attention during fueling or oil change
● The oil must be clean and contaminant free.
● Oil injector and related parts must be clean and prevent water or
dirt getting into oil.
● Keep the loader in a level condition when checking the oil
quantity.
● Under different ambient temperature, use oil with different
viscosity and trademark, please observe with the relative
instructions.
● Different kinds of oil can not be mixed or substituted together
● During oil change, the corresponding filter must be changed.
● Check any oil leakage in the system after oil injecting.

CAUTION Avoid of scalds when checking or replacing the oil and cooling liquid.

L. Rejected staffs
Please obey with following instructions to prevent the pollution.
● Don’t pour the rejected oil liquid into rivers and sewer network.
● The drained oil must be placed in a container rather than pouring
it directly onto the ground.
● 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.

1.4.4. Maintenance of components and matters needing attention

A. Cooling system
● 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.（Figure 1- 88）
● To prevent splashing hot oil, turn off the engine, cool the hot
water and open slowly to release the pressure. When checking the Figure 1- 88
temperature, put your hand close to the front of water radiator,
check the air temperature. But pay attention not to touch the

28
 radiator.
● 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’t touch the radiator.
● Don’t touch the engine body or muffler, exhaust tail tube and
relay when the machine is still hot, and avoid being scalded.
（Figure 1- 89）
● Don’t remove the engine oil temperature sensor, water
temperature sensor, torque converter sensor and air-conditioner Figure 1- 89
tubes so as not to get scaled.
● Cooling system contain alkaline material, so pay attention to not
to have the cooling system touch your skin and eyes.
● 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. Hydraulic system
● 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.
● Don’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.
● 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.
● 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:
△ Connecting fittings be broken or leakages appear.
△ The external coating of hoses are worn out or cracked and their
reinforcing wires are exposed.
△ Hoses get bulged at some particular locations.
△ Hoses get obviously twisted or deformed due to pressing.
△ The hose reinforcing wires get extending out.
△ End is connected wrongly.
29
● Make sure that all pipelines clamping, protection and insulating
plates are correctly mounted, so as to prevent shocking and
conflicting with other parts.
● 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. Steering device
● 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.
● Don’t turn the steering wheel when the engine has not been
started.
● Let the steering wheel changes along with the terrain varies.

D. Electrical system
● Only the qualified technician can service the electrical system.
● When adjusting the external power supply, please attach the
ground cable at last in order not to produce sparks around the
battery and cause an explosion. Please note that the ground cable
is from the regulator end to the starter end.
● Adjust the key of starter before service the electrical system.
● Before repairing the electrical system, remove the negative (-) Figure 1- 90
electrode of the battery to prevent the flowing of current.（Figure
1- 90）
E. Battery
● This battery is free of maintenance.
● Before operating about the battery, remember to stop the engine.
● 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:
 Never get the lighted cigarette or flame close to the battery.
（Figure 1- 91）
 When you have to touch the battery during working, you ought to Figure 1- 91
wear safety glasses and rubber gloves.
 If the electrolyte is splashed onto your clothes or skin, rinse it off
with plenty of fresh water immediately.
 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.
 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.
 Avoid the touching of metal staffs (e.g: tools), which could cause
short circuit to positive pole (+) and negative pole (  ) of the
battery.

30
 When installing the battery, fix the positive pole (+) first.
 When dismounting the battery, disconnect the negative pole (  )
first.
 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.
F. Dispose the waste battery
● When the battery cannot used due to electrode ageing, do not
discard it careless or pour the acid liquor anywhere, otherwise it
may hurt yourself or the surrounding people or animals and
pollute the environment. Used batteries shall be sent to the waste
recycling department for disposal.

G. Tyres
 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.（Figure 1- 92）
 During traveling, the heat produced due to high-speed machine
Figure 1- 92
traveling will cause the tyres pressure arising to some extent,
which is the normal case, please don’t attempt to reduce the tyres
pressure. 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.
Check the lock ring of the wheel to see if it has fallen off. Pay attention to it
CAUTION during inflation.

 When adjusting tyre pressure, keep away from the tyre as far as
possible. And you should always stand at the back of the tyre.
 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’t help combust but can prevent the rubber
oxidation and deterioration and avoid rust for wheel hubs.
 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. Figure 1- 93
 Check tyres and wheel hub. Don’t operate the loader when the
tyre pressure is very low. And also check if there are any cracks

31
 or deformation on the tyres.
 Check the mounting screws and bolts on the wheels to see if they
are securely fastened as required by the manufacturer.
 During checking the wheels, don’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.
（Figure 1- 93）。
 When performing welding near a wheels, special care should be
given because the tyre wheel may cause explosion, 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.
 When replacing a tyre, make sure the tyre to be used is correct.
All tyres should be same in terms of specification data and
texture.
H. Air reservoir
● The air reservoir must be replaced after 3 years.

32
2. Operation

1
 Table of contents
2. Operation.........................................................................................................................................................1
2.1. Component Names And Decals.................................................................................................................. 4
2.2. Cab instrument and operating devices........................................................................................................4
2.2.1. Cab interior layout.......................................................................................................................... 4
2.2.2. Function descriptions of cab instrument and operating devices.................................................... 7
2.2.3. Usages of the operating devices................................................................................................... 10
2.2.4. Adjustment and usage of the seats................................................................................................11
2.2.5. Standby exit.................................................................................................................................. 12
2.2.6. Circuit breaker of storage battery................................................................................................. 12
2.3. The Use Of The New Loader....................................................................................................................12
2.3.1. Notices.......................................................................................................................................... 12
2.3.2. Study The Safety Items.................................................................................................................13
2.3.3. Learn The Checking Method........................................................................................................ 13
2.3.4. Be Familiar With Your Machine...................................................................................................13
2.3.5. Running-in of the machine........................................................................................................... 13
2.4. In case of using the machine under the condition of mining area, tough mountain area, space restricted
area or the area with large slope, please be kindly noted of the followings.........................................................14
2.5. Before start................................................................................................................................................15
2.5.1. Daily checking.............................................................................................................................. 15
2.5.2. Unlocking of frame steering lock................................................................................................. 15
2.5.3. Getting on/off the machine........................................................................................................... 16
2.5.4. Adjustment of exterior rearview mirror....................................................................................... 16
2.6. Start the engine......................................................................................................................................... 17
2.6.1. Engine and Warm up Period......................................................................................................... 17
2.7. Drive the machine..................................................................................................................................... 18
2.7.1. Forward/backward starting drive..................................................................................................18
2.7.2. Switch gears.................................................................................................................................. 19
2.7.3. Steer the machine..........................................................................................................................19
2.7.4. Braking of machine.......................................................................................................................19
2.8. Parking of machine................................................................................................................................... 20
2.8.1. Engine Stopping............................................................................................................................20
2.9. Leave the machine.................................................................................................................................... 21
2.10. Working Method................................................................................................................................... 21
2.10.1. Forbidden Operation..................................................................................................................... 21
2.10.2. Excavating Performance...............................................................................................................22
2.10.3. Load performance......................................................................................................................... 23
2.10.4. Ground preparation....................................................................................................................... 24
2.10.5. Snow Sweeping.............................................................................................................................25
2.10.6. Towing performance..................................................................................................................... 25
2.11. Hoist and Transport...................................................................................................................................26
2.11.1. Hoist or put down the machine.....................................................................................................26
2.11.2. Transporting the loader on a public road......................................................................................27
2.11.3. Loading/unloading of machine.....................................................................................................28
2.11.4. After loading the machine............................................................................................................ 28
2.12. Storage.................................................................................................................................................. 29
2
2.12.1. Before Storing...............................................................................................................................29
2.12.2. Short-time storage.........................................................................................................................29
2.12.3. Long Time Storage....................................................................................................................... 29
2.12.4. After an Extended Storage Time.................................................................................................. 29
2.12.5. Storage of tires.............................................................................................................................. 30

3
The descriptions in this part are provided for the reference of the new operators and for the verification of
experienced operators.
This part contains the descriptions in terms of instruments, switches, machine controls, accessory controls,
transportation, and traction information.
The diagrams contained in this part can guide the operator to understand the correct procedures for the checking,
start, operations, and stop of the machine. The operation skills described in this manual are the basic operation
skills. Following the operator’s further understanding about the machine and machine functions, the operation skills
and techniques will be improved accordingly.

2.1. Component Names And Decals

Figure 2-1 Overall figure and component name

2.2. Cab instrument and operating devices

2.2.1. Cab interior layout

4
1. Combination instrument 2. Key switch 3. Horn button 4. Ryoma combination
switch (Headlight,
high/low beam and turn
lamp)
5. Sprinkler 6. Emergency switch 7. Front working light switch 8. Rear working light
switch
9. Hood rear working light 10. Front wiper switch 11. Hand brake controller 12. Power socket
switch
13. Reserved 14. Controller 15. Starter relay / Flameout 16. Power switch
relay
17. Transmission control 18. Centralized control box 19. Radio 20. Fan
unit
21. Rotating warning lamp 22. Rotary warning lamp 23. Rear wiper switch 24. Gear control
switch
25. Brake pedal 26. Accelerator pedal 27. A/C switch
Note: Note: The parts 13, 19, 21, and 22 are optional parts, part 14 is optional as needed, and part 17 is installed in
electric cabinet
Figure 2-2 Cab interior layout

5
Figure 2-3 Rocker Switches (The numbers in this diagram are consistent with those in Figure 2-2)

Figure 2- 4 Combination instrument

6
2.2.2. Function descriptions of cab instrument and operating devices

2.2.2.1. Function descriptions of cab instrument and operating devices (table 2-1)
(The numbers are consistent with those in Figure 2-2 and Figure 2-3.)
No. Name Action and function Remarks
Tachometer(G1) It indicates the real-time speed of engine
Air pressure meter
Displays brake air pressure.
(G2)
Water temperature
Combination Indicate the engine coolant temperature.
gauge(G3)
1 instrument(Fi
Voltmeter(G4) Indicate the engine oil pressure.
gure 2- 4)
Oil temperature
Battery voltage
gauge (G5)
It indicates battery charging status, parking brake
Warning lamp
status, and low brake air pressure.
It controls the power-on of whole vehicle and the
2 Key Switch
start of engine.
3 Horn button Press to sound the horn.
It controls the high beam, low beam, turn signal
4 Ryoma combination switch
lamp, and marker lamp.
Store the water used by windscreen wiper
5 Sprinkler
sprayer
It controls the turn-on of four turn signal lamps
6 Emergency switch
in event of emergency stop of the vehicle.
Control the turn-on and turn-off of the front
7 Front working lamp switch
working lamp.
Control the turn-on and turn-off of the rear
8 Rear working lamp switch
working lamp.
9 Engine hood rear lamp Switch used to control the engine hood rear lamp
10 Front wiper switch Control the front wiper.
Pull up the handle to apply the brake and push
11 Hand brake controller
down the handle to release the brake
It functions for installation of cigarette lighter or
12 Power socket
functions as power socket
It can be used to provide the vehicle positioning
13 Reserved Optional
and send the vehicle information.
It realizes the functions such as independent heat
14 Controller Optional
dissipation.
15 Starter relay/flameout relay It controls the start and stop of the engine.
16 Power switch It controls the power-on of the vehicle.
Installed at the
It controls the function realization of choice of
17 Transmission control unit
transmission. electric
cabinet
18 Electric central control box It incorporates the fuses and relays for the whole
7
 vehicle and controls the power supply of the
whole vehicle.
19 Radio Optional

20 Fan

21 Rotary warning lamp It plays the safety warning role. Optional

Optional,
22 Rotary alarm lamp switch Control the rotary alarm lamp matched with
part 21.
23 Rear wiper switch Control the rear wiper.
Push forward to engage 1st and 2nd forward gears,
Planetary
pull backward to engage reverse gear, and hold
gearbox
in neutral to engage neutral gear.
24 Shifting lever
Pull/push the joystick horizontal to change the
MYF200
traveling direction, namely forward (F), neutral
transmission
(N), and reverse (R).
25 Brake pedal Depress the pedal to apply the brake.
It controls the engine fuel supply amount, the
26 Accelerator pedal
engine speed, and other working status.
It controls the air output volume and
27 A/C switch
temperature.

Table 2-2 Description of working statuses of signal indicator lamps (power-on status) and buttons on
combination instrument (See Figure 2-4)
No. Name Symbol Color Note (On status of indicator lamp)
The turn signal lamp switch is shifted
1 Left turn signal Green
to left turn.
The turn signal lamp switch is shifted
2 Right turn signal Green
to right turn.

3 Charging indicator Red Charging status

The warning lamp turns on when the

4 Low brake air pressure Red
air pressure is ≤4bar or ≥8bar.
The engine oil pressure is ≤1 bar or
5 Low engine oil pressure Red
≥6bar for 5S.

6 Parking brake Red The handbrake is not released.

7 Axle oil temperature Red Optional

Optional
8 Preheating Red
Warm-up status from cold start.

9 Engine coolant temperature Red The coolant temperature is ≥100ºC.

10 Low fuel level warning Yellow The fuel level is ≤1/8.

8
 Low transmission oil pressure
11 Low transmission oil pressure Red
warning
The transmission oil temperature is
12 Transmission oil temperature Red
≥120ºC.

13 Air filter blockage Red Optional

14 Buzzer mute Red A warning tone is muted.

15 Reserved TBD TBD Optional

16 Reserved TBD TBD Optional

17 Reserved TBD TBD Optional

18 Engine maintenance Red Optional

19 Reserved TBD TBD Optional

20 Waiting for start Red

21 Reserved TBD TBD Optional

22 Power cutoff Yellow Optional

In event of serious trouble code in

23 Engine stop indicator Red
engine or transmission. Optional
24 Reserved TBD TBD Optional
1. “Press and hold” means to press
and hold a button for >=3s and
“press” means to press and hold the
button for ≤3s. Press and hold to
25 Multi-functional button
mute the warning tone and press and
hold again to unmute. After the
re-ignition, the warning tone will be
restored.

9
2.2.3. Usages of the operating devices

2.2.3.1. Shift control

Forward II
F
Forward I

Neutral gear

Reverse gear R

Figure 2- 5 Diagram of planetary gearbox Figure 2- 6 Real photo of planetary gearbox

Push forward: Forward gear
Push down to Rotate to Pull backward: Reverse gear
operate KD shift gear. Neutral position: Neutral gear
gear.

Figure 2- 7 Diagram of MYF200 transmission

Figure 2- 8 Real photo of MYF200 transmission

The MYF200 transmission is equipped with neutral start protection function,

Caution namely the engine can be started only when the transmission is in neutral gear.
2.2.3.2. Working device controls (Figure 2-9 and
2-10)
Float
Drop

Rear-tipping Neutral Forerakea

position

Lift

Fornt

Left Right
Figure 2-10 Picture of real products

Rear

Figure 2- 9 Schematics of control lever at different positions

10
2.2.3.3. Parking brake (emergency brake) (Figure
2-11 and 2-12) Parking brake button

Brake

Loosen

Figure 2-12 Picture of real products

Figure 2-11 Schematics of parking brake

2.2.4. Adjustment and usage of the seats

Adjust the handle D to move the seat longitudinally and adjust the handle F to move both control box and seat
longitudinally.

Armrest angle adjustment

handwheel (A)

Backrest elevation height

adjustment handwheel (G)

Backrest angle adjustment

handwheel (B)

Seat height adjustment

handwheel (C)

Longitudinal adjustment
handle (D)

Shock absorber rigidity

adjustment handle (E)

Longitudinal adjustment
handle (F)

Figure 2- 13 Seat adjustment

11
2.2.5. Standby exit

The right window of the cab can be used as standby exit. The
window can be opened only from inside of cab.
Push the handle 1 of lock to unlock and push the window to
the full-open position. (Figure 2- 14)

Figure 2- 14 Standby exit

2.2.6. Circuit breaker of storage battery

Open the battery cover on the left side of counter weight, and
the circuit breaker of battery is located in front of the
battery.(Figure 2- 15)
I---ON. To energize the electrical system, the circuit breaker
must be switched to “ON” position before starting the engine.
O---OFF. To cut off the electrical system, anticlockwise rotate
handle of the circuit breaker to “OFF” position.
The circuit breaker of storage battery performs functions
different with those the start switch of the engine. To cut off
the power supply of the whole electrical system, please switch
the circuit breaker of the battery to “OFF” position. If only Figure 2-15 Circuit breaker of storage battery
the starting key switch is switched off, the battery still
connects to the electrical system.
Please switch the circuit breaker of the battery to “OFF”
position while maintaining and servicing the electrical system
or other machine parts.
Never switch the circuit breaker of the battery to “OFF” position while the engine
Caution is working. Otherwise it may lead to serious damages to the electrical system.

2.3. The Use Of The New Loader

2.3.1. Notices

12
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:
● After starting the loader, idle the machine for 5 minutes to get it warmed up.
● It is forbidden to accelerate the engine suddenly during pre-warming up process.
● Avoid of emergent driving, sudden turnaround and unnecessary emergent braking.
● Check and repair the machine according to regulations.

2.3.2. Study The Safety Items

● Study the loader manual and concerned documents, understand them completely.
● Be familiar with all operating levers, indicating meters and alarming devices.
● Identify warning signs and safety signs, which can remind you the dangerous conditions.
● 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.

2.3.3. Learn The Checking Method

● 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.
● Check if tyres are wore out or damaged or not. Check if all tyre air pressures are normal or not. Don’t operate
the loader if some tyre air pressure are insufficient.
● If the lock bar of steering pin is installed, please keep it in ready condition. The locked machine can’t be
turned.

2.3.4. Be Familiar With Your Machine

● Be familiar with functions of every controlling device, meter and pedal. Clear grease out from operating levers,
pedals and handles to avoid of sliding.
● Clear sundries out from the cab, and keep the cab ground clear.

2.3.5. Running-in of the machine

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.
● After starting, idle the machine for 5 minutes
● It is forbidden to accelerate the engine suddenly during warming up process.
● Avoid of sudden startup, sudden accelerating and steering and sudden braking, except in emergency case.
● During running in period, every gear should be engaged equally in time.
● 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.
● Pay attention to the lubricating state of the machine, and replace or inject the lubricant according to prescribed
13
 schedule.
● Pay attention to the temperature of transmission, torque converter, front and rear axle, wheel hub and brake
drum. If overheating occurs, please find out the reason and resolve the problem.
● Check the tightness of every bolt and nut.
● After 10 hours of running in period, the following operations should be carried out:
a. 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.
b. Clean the rough engine oil filter, fine engine oil filter and fuel filter.
c. Check the tightness of fan belt, generator belts and belts on air-conditioner compressor.
d. Check the status of the battery electrolyte and tighten the joints of the battery.
e. Check the oil level in the transmission system.
f. Check the airproof status of the hydraulic system and braking system.
g. Check if every control lever and accelerator lever are well connected and tightened.
h. Check the temperature and connection of every component in the electric system, and check the generator
performance, illumination lamps and steering lamps.

2.4. In case of using the machine under the condition of mining area,
tough mountain area, space restricted area or the area with large

slope, please be kindly noted of the followings

● Tire-protection chains are highly recommended.

● It is severely prohibited to have the braking system not fully applied for long time for the purpose of lowing
driving speed.
● Please install and use a water-sprinkling device for cooling down braking plates.
● If it is impossible to install and use a water-sprinkling device to cool down the braking plates, then it is also a
must to get the braking plates cool down somehow every certain interval.
● Please bleed air out the braking plates, replenish or change braking oil regularly if necessary, according to the
braking performance.

14
2.5. Before start

2.5.1. Daily checking

● To prolong the life of the machine to the maximum

degree, fulfill the all-round daily checking before
starting the engine. Figure 2- 16
● Check the surrounding and bottom area of the machine.
Check for presence of loose bolt, accumulated waste,
oil/coolant leakage, and broken or worn part.
Note: Closely observe for presence of leakage. Upon
detection of any leakage, find out and solve the leakage
source. If the leakage is detected or suspected, check the
oil level more frequently.
● Check the statuses of machine and hydraulic parts.
● Check the battery status and turn the battery cutoff
switch to on position (I).
● When necessary, adjust the inflation pressure.
● Check all oil levels, coolant level, and fuel level.
● Remove all accumulated waste and chippings. Before
operating the machine, fulfill all necessary repair works.
● Ensure that all covers and shields are securely installed.
● Adjust the rearview mirrors of machine to appropriate
angle.
● As per the maintenance specification, add lubricant to
lubricating points that require daily maintenance. (Figure
2- 16)

2.5.2. Unlocking of frame steering lock

● Before the operation of the machine, separate the frame

steering locking lever (1) from the front frame.
● Move the frame steering locking lever to unlocking
position and install the pin (2). (Figure 2- 17)

Figure 2- 17

15
2.5.3. Getting on/off the machine

● Get on or off the machine only by the areas with

footplates and/or handrails. Sweep clean the footplates
and handrails before getting on the machine. Check the
footplates and handrails. Fulfill all necessary repair
works.
● To get on or off the machine, face towards the machine
and keep three-point contact with footplates and
handrails. (Figure 2- 18)
Note: The three-point contact can be two feet and one hand or Figure 2- 18 Example for typical method of
one foot and two hands. getting on/off machine
● Do not get on a moving machine. It’s prohibited to get
off from a moving machine. It’s prohibited to jump off
the machine.
● Do not carry any tool or article while getting on or off
the machine. Pull the equipment onto the platform by a
rope.
● It’s prohibited to use any joystick as handrail while
getting on or off the cab.
2.5.4. Adjustment of exterior rearview
mirror
The rearview mirrors can provide an additional visual field
around the machine. Keep the rearview mirrors clean and
under good working status. Adjust all rearview mirrors at the
Figure 2- 19 Adjustment of exterior rearview
start of every work shift or at the change of operator.
mirror
In addition, it’s recommended to clean up the working site to
minimize the danger arising from the visual field problem.
Before the operations, please adjust the left and right exterior
rearview mirrors of the cab as necessary, in order to ensure
that at least 1m areas on both sides of the machine can be
observed from the operator's position. In addition, a backward
visual field of as large as possible shall be provided. (Figure
2- 19)

16
2.6. Start the engine
● Adjust the seat to the ideal position after buckling up.
● More the steering column to the ideal position.
● Place the shift level to the position of neutral position.
● Join with the parking brake.
● More all operating lever to the central position.
● Inspect whether no people or obstacle appear in the circulating area before starting the engine; then honk the
horn and start the engine.
● The gas exhausted is poisonous; and pay the special attention to ensure the nice ventilation when starting the
engine in the closed space.
● Start the engine by turning the start key switch of the engine to the position START; and release the start
switch key when the engine is started.

The engine shall be started again after 1min if it is not started within 5-10s and cannot
started again if it is not started in consecutive three times, and the reason shall be found
NOTE out.
The turbocharger may be damaged if the engine fails to run at low speed before the oil
pressure gauge indicates that the oil pressure is enough.
2.6.1. Engine and Warm up Period
● The engine can be started after 3s when the whole machine is powered on or upon self inspection of the
instrument (the process of powering on or self inspection, which takes longer time, shall prevail).
● After starting the loader, idle the machine for 5 minutes to get it warmed up. DO NOT accelerate the engine
suddenly during the warm up process.
● Observe the indicator lamp and the instrument frequently during operations; stop the machine for inspection
if the abnormal information displayed cannot be removed.
● The machine can be warmed up by the hydraulic oil if the operating lever of the bucket is remained at the
closed position in short run (10s and below); in this way the hydraulic oil can achieve the safety pressure and
the engine can be warmed up by the hydraulic oil more quickly.
● Operate all operating levers in the circulating way so that the hydraulic oil can flow through all hydraulic oil
cylinders and all hydraulic oil pipes in the circulating way.
● Observe and comply with the following suggestions when rotating the engine at low speed to warm up.
 The engine shall be warmed up for about 15min when the temperature is higher than 0℃.
 The engine shall be warmed up for about 30min when the temperature is less than 0℃.
 The warm-up time may be longer if the temperature is at below -20℃. Moreover, the more warm-up time
may be needed if the hydraulic action is slow.
● The whole machine should not run at low revolving speed in presence of low load for a long time; or the
machine may be easily trapped in phenomena, such as oil expelling.
● The machine shall be allowed to run at full load only when the temperature of the outlet water is higher than
60℃ and the temperature of the engine oil is higher than 50℃. Moreover, the load and the revolving speed
shall be increased gradually, and the sudden increase and sudden unloading of the load shall be avoided as far
as possible.

17
 The engine shall run at low speed until the alarm indicator lamp of the engine oil
pressure is turned off; the engine shall be stopped if the alarm indicator lamp cannot be
NOTE
turned off within 10s and can be started again after finding out the reason; or the engine
may be damaged.

2.7. Drive the machine

2.7.1. Forward/backward starting
drive
● Ensure no miscellaneous personnel appears on the
vehicle or around the machine before driving.
● Overturn the bucket to the maximum backward
inclination if needed and elevate the transportation Figure 2- 20
position from the swing arm to the place at the bottom of
the bucket which is about 40cm far from the floor.
● Put on the brake pedal and operate the gear shift lever to
the forward I gear or the reverse gear I. (Figure 2- 20)

18
● Put down the manual brake button and release parking
brake. (Figure 2- 21)
● Hit the accelerator gradually after releasing the brake
pedal to allow the machine to drive forward or
backward.

2.7.2. Switch gears

● Hit the accelerator appropriately when switch over the
gears in accordance with the speed to avoid excessive
impact of the transmission system; therefore, the service
life of the machine and the comfort during driving can be Figure 2- 21
improved.
● It is not necessary to stop the machine or hit the
accelerator when switching over the forward gears
during driving. Further, release the accelerator once
when switching over to the high-speed gear from the
low-speed gear, and operate the gear shift lever to the
corresponding gear and continue driving by hitting the
accelerator at the same time. Moreover, reduce the speed
gradually and appropriately and switch over the gears
after release the accelerator first when switching over to
the low-speed gear from the high-speed gear.
● To improve the driving comfort and prolong life of drive
parts, stop the machine completely before changing the
driving direction (from forward gear to reverse gear or
vice versa).

2.7.3. Steer the machine

● The vehicle can be steered by rotating the steering wheel
toward the direction to be changed during driving.

Do not change the direction suddenly or on the steep slope when driving at high
Warning speed.
The vehicle shall not be allowed to change the direction when the engine is stopped.

2.7.4. Braking of machine

● If the braking of the machine is required during driving, release the accelerator pedal and depress the brake
pedal appropriately depending on the emergency degree to slow down the machine, till the machine comes to
a complete stop.
● Do not depress/release the brake pedal repeatedly in a frequent manner, unless it’s absolutely necessary.

19
2.8. Parking of machine
● Park the machine on a level surface. If it is necessary to park on a grade, block the wheels.
● Apply the service brakes in order to stop the machine.
● Move the transmission control to the NEUTRAL position.
● Engage the parking brake.
● Lower the work tool to the ground and apply slight downward pressure.
It’s prohibited to brake the machine by parking brake during traveling, unless the
service brake is damaged.
Warning While driving down a slope, it’s prohibited to stop the engine or shift the gearshift
joystick to neutral gear.

2.8.1. Engine Stopping

Cool down the engine with reference to the following procedure, in order to prevent the oil coking due to
over-high temperature of turbocharger housing (if equipped).
● The engine shall run 5min at low and idle speed when the machine is stopped; in this way, the part which is
too hot in the engine can be cooled gradually.
● The start switch key of the engine shall be switched over to the position OFF and shall be drawn out.

Do not stop the engine immediately after the machine has been operated under load.
NOTE
This can cause overheating and accelerated wear of engine components.

20
2.9. Leave the machine

● The ladder and the handrail must be used when taking off the vehicle; and people shall hold the ladder and
handrail with two hands when facing the machine. Moreover, ensure that no impurity is left on the ladder
before leaving the vehicle.
● Inspect whether no fragment is left in the engine room; and clean the fragments and all kinds of papers in
order to prevent fire.
● Clear up all combustible fragments to reduce the potential risk of fire and discard the fragments properly.
● Inspect the oil surface and cleanness condition of the bottom housing of the engine oil; find out the reason if
the oil level is too high and the oil is being thinning gradually and eliminate the problem.
● Inspect whether the oil pipe, the water pipe, the gas pipe and all kinds of accessories are subjected to
penetration and leakage.
● Inspect the fixation and sealing condition of the gearbox, the torque converter, the hydraulic oil pump and the
front and rear axles, and check whether excessive heating occurs.
● Inspect whether the bolts of the rim, the bolts of the transmission shaft and all pin shafts are loosened.
● Discharge the cooling water (except the moment when the antifreezing solution is added) when the
temperature is less than 0℃.
● Check brake system for sufficient brake fluid.
● Drain the oil dirt and deposited water from oil-water separator combination valve and drain the water from
air reservoir.
● People can leave the machine after switching over the storage battery circuit breaker to the off-position (O)
when the machine will not run for more than 24h.
● Close all covers, lock all parts having locks, draw out the keys and keep them carefully.

2.10. Working Method

2.10.1. Forbidden Operation

● Overloading.
● Only one side of the loader bears the load.
● Digging the hard material.
● Hanging a cable on bucket teethes to lift heavy object.
● Excavating at the over-head position of the loader.
● Restructuring the machine without authorization.
The failure to operate as per the specification will probably lead to machine damage or
personal injury/death, for which XCMG Construction Machinery Co., Ltd. will not be
Warning
liable.

21
2.10.2. Excavating Performance

The excavating procedure is to insert the bucket into material heap and load or shove. Excavating procedures
include shoving and digging.

When performing excavation, make the two sides of bucket bear load evenly, only one
CAUTION side of the bucket bearing load is forbidden.
If the wheel skids, please reduce the force that is applied on the accelerator pedal and
CAUTION the load, avoid of forcible operation.
A. Shoving operation
● Keep the bucket parallel with ground. (Figure 2- 22)

Figure 2- 22
● Apply low-speed gear to drive the loader and get close
with the heap of load, insert the bucket into heap of load.
(Figure 2- 23)

Figure 2- 23
● Raise the lifting arms and operate the bucket control
lever to make it tilt back for 2-3 times to fully load
material to be loaded.
● If the bucket is difficult to pierce into the material pile,
operate the bucket end in proportion of forward tilting 1
→ backward tilting 2 while ensuring that the wheels are Figure 2- 24
free of slip. (Figure 2- 24)
● Keep the bucket tilting backwards to its maximum limit,
and raise it 40cm above the ground. (Transportation
status) (Figure 2- 25)

Figure 2- 25
B. Digging operation
● Place the bucket onto the ground while maintaining it
under slightly forward tilting position with respect to the
ground. It’s preferable that the forward tilting angle of
the bucket is within approximately 0~10º.
● Drive the machine forward at low speed to pierce the Figure 2- 26
bucket gradually into the ground. (Figure 2- 26)

22
● Depending on the hardness of the ground soil, when the
teeth of the bucket are pierced into the ground for
10~30cm, slightly lift the boom on one hand and slightly
tilt backward the bucket on the other hand to shovel the
material continuously. (Adjust the digging depth by
boom and bucket joysticks) (Figure 2- 27) Figure 2- 27
● When the material in the bucket is sufficient, lift the
boom and tilt backward the bucket to fully load the
material. (Figure 2- 28)

Figure 2- 28
● Keep the bucket tilting backward to its maximum limit,
and keep it away from the ground 40cm. (Figure 2- 29)

Figure 2- 29

2.10.3. 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 prevent wheels
from damaging and the road surface frequently.
CAUTION Pay attention on the road surface when transporting, choose a speed that will not make
loaded material splash out and lower the bucket when driving.
● If the loading position and the dumping position of the
loader form one angle, adopt the operation mode of
reversing and adjusting angle after loading and dumping
of material. (Figure 2- 30)

Figure 2- 30 V-type cycling operation

● If the loading position and the dumping position are in
same direction, adopt the operation mode of reversing
the loader linearly after loading of material, waiting for
the transport vehicle to take position, forwarding the
loader linearly to dump the material, and reversing the
loader linearly and driving away the transport vehicle.
(Figure 2- 31) Figure 2- 31 I-type cycling operation

23
● If the loading position is perpendicular to the dumping
position, adopt the operation mode of loading the
material, making a turn, and reversing the loader and
then making a turn, forwarding to the position
perpendicular to the loading position, and dumping the
material. (Figure 2- 32)
Figure 2- 32 L-type cycling operation
● If the loading position is opposite direction to the
dumping position, adopt the operation mode of loading
the material, making a turn, and reversing the loader and
then making a turn, forwarding to the position reverse to
the loading position, and dumping the material. (Figure
2- 33)
Figure 2- 33 T-type cycling operation

2.10.4. 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, please keep
the forward tilting angle within 0º~5º.
During the machine operation as above-mentioned, the water temperature of engine
CAUTION should not be over 100℃, oil temperature of torque converter should not be over
80-110℃, oil pressure of braking should not be lower than 0.4Mpa. Otherwise, stop
working immediately and figure out the problem reason.
A. Soil scattering
● Load sand or soil into bucket, then tilt the bucket
forward to 10º~15º and scatter the sand or soil evenly
while the loader is moving backwards. (Figure 2- 34)

Figure 2- 34
B. Soil Pushing
● Fully load the bucket with soil, keep it horizontal, place
it onto the ground, and forward slowly for operation.
● For bulldozing on a hard ground, shift the boom joystick
to “Float” position so that the bucket bulldozes
thoroughly the soil in close contact with the ground.
(Figure 2- 35) Figure 2- 35

24
C. 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.
D. Fine levelling
● Fill the bucket with sand or soil and keep it contacting
with ground horizontally. Put the handle of the lifting Figure 2- 36
arms at “float” position, then reverse the loader slowly.
(Figure 2- 36)

2.10.5. Snow Sweeping

Use a bucket without teeth, place it horizontally onto the

ground, and adopt the operation mode similar to the “soil
Figure 2- 37
digging” to remove the snow. (Figure 2- 37)
Notices of snow sweeping
 Ensure the safety when fog weakening your visual field.
 Take notices to those objects buried under the snow.
 Know the positions of ditches and curb.
 Anti-skid chains must be installed on 4 wheels
 For large area snow removal operation, it’s
recommended to use a more effective snow plough.
On a slip ground, please operate slowly and carefully and avoid the sudden forwarding,
Notice stop, and turn, in order to prevent the slip of wheels and the difficult control of
direction.
Figure 2- 38

2.10.6. Towing performance

● Connect the towing rope reliably to the object to be towed.

● Lift the traction pin on the rear ballast of the machine and insert the towing rope.
● Lower the traction pin in place.
● Slowly drive forward the machine for towing operation.
The towing cable should be threaded firmly.
CAUTION The braking device of the vehicle which is to be towed can function normally, otherwise
don’t attempt to tow it.

2.10.6.1. Notices to towing performance

● 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.
● 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.

25
● It is forbidden to operate the vehicle unless the operator can control the steering and braking of the vehicle to
be towed.
● 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.
● 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.
● Terminate the towing performance when the towed vehicle can move by itself.
● The minimum towing angle must be ensured, which should not be over 30º.
● Hurry towing can break the towing cable, so it is suggested to apply slow and smooth towing.
● 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.
● 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.
● 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.
● 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’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.
● 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.
△ The towing vehicle and towed machine must be installed with ROPS&FOPS.
△ Choose the high quality steel cable, and please wear gloves when dealing with steel cable.
△ Before cooperating with other workers, discuss with them and determine the signals that will be used.
△ If the engine and braking systems of the break-down loader gets troubles, please consult with their
manufacturer for repairing them.
△ It is dangerous to tow a loader on a slope.
△ 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.
△ Keep the hook of the towed machine be in alignment with the towing machine.
△ Don’t stand astride on towing cables by two feet.

2.11. Hoist and Transport

2.11.1. Hoist or put down the machine

● When the loader has to be moved into a ship or other

place, please use the lifting lugs which is located on
Figure 2- 39 Diagram for locking of frame
front and rear frame.
steering locking rod
● Lock the front and rear frames by locking rod
integrally against swing before hoisting. (Figure 2- 39)

26
● Refer to hoisting diagram of complete machine. (Figure
2- 40)
● The operating mass varies depending on specific
working device.

Figure 2- 40 Hoisting diagram of complete

machine

● 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
2- 41 and Figure 2- 42)
● Please select those ropes and lifting devices which
have enough solidity. Keep the loader horizontal in the
hoisting process.
● The girder of hoisting device must has enough width Figure 2- 41 Hoisting hook of front chassis
to avoid colliding with the loader.
● Take the length, width, height and weight into
consideration.
● Before hoisting the loader, please lock the frame to
prevent the machine from turning.

Figure 2- 42 Hoisting hook of rear chassis

When hoisting the loader, the rope only can pass through the lifting lugs.
Prevent hydraulic pipes from being damaged.
Danger When lifting the loader, make sure that there is nobody standing under the lifted
machine.
● At completion of hoisting, ensure to restore the
locking rod to disengaged position before
operations. (Figure 2- 43)

Figure 2- 43 Diagram for disengaged of frame steering

locking rod

2.11.2. Transporting the loader on a public road

● The wheel loader is a non-road vehicle and is unsuitable for long-distance driving. Transport the loader by
transport vehicle for long-distance site transfer.
● When transporting this loader, please obey with those laws which regulate the weight, height, width and
length.

27
● Determine the transporting route with regarding to the weight, height, width and length of the machine.
● 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.
● If the loader has to be dismantled for the purpose of being transported, please consult with manufacturer or its
agent.

2.11.3. Loading/unloading of machine

● Before loading the machine, remove the snow/ice and other easily
slip substance from the deck of transport vehicle to prevent the slip
of machine during loading and transport.
● To transport the machine to a cold region, ensure that the cooling
system has good anti-freeze performance.
● There is always a potential danger during the loading and
unloading of the machine. The extreme care shall be taken. During
loading/unloading of the machine, run the engine at low speed and Figure 2- 44
drive the machine at low speed.
● The loading and unloading of the machine shall be conducted on
solid and level ground, keeping a safe distance from the edge of the
road.
● During the loading and unloading of the machine, ensure to fix the
wheels of the transport vehicle to prevent it from movement and
place the cushion blocks beneath the ramps. (Figure 2- 44)
● Use the inclined boards of sufficient strength and length to provide
ramps for safe loading and unloading. The angle between ramps
and the ground shall not exceed 15º. The distance between ramps
shall be compatible to the wheel tread of the machine.
● Ensure that the ramps are securely fixed and are under consistent
height on two sides.
● It’s prohibited to make a turn on the ramps. When necessary, drive
the machine away from the ramps and adjust the direction before Figure 2- 45
re-driving onto the ramps. (Figure 2- 45)
● Keep the ramp surfaces clean, without lubricant, oil, ice, or loose
material.
● Before loading the machine, remove the dirt from machine tires.

2.11.4. After loading the machine

● After loading the loader, engage the frame steering locking device to place front and rear frames at
appropriate position.
● Lower the bucket onto the deck of transport vehicle and place the gearshift joystick in neutral position.
● Apply the parking brake.
● Stop the engine and withdraw the starter key.
● Move all hydraulic control joysticks to relieve the pressure.
● Lock the cab doors and take all safety protection measures.

28
● Shift the indicator rod of battery cutoff switch to off position (O).
● Install tie-downs at different locations and place stop blocks for front and rear wheels.
● Ensure that the equipment and tools on the machine are complete and a sufficient number of ropes is used to
prevent the movement of loader during transportation.

2.12. 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. If a wheel
loader needs to be stored for a long time, take the following measures.

2.12.1. Before Storing

● 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.
● Before storing it, fill up the fuel tank, add grease and change hydraulic oil.
● Put on the security lock and then lock the bucket, control lever for working arms and articulation locking-bar.
Afterwards, engage the parking brake.
● The parking place for storing should be sheltered, ventilated and dry and without any corrosive substances or
gas.

2.12.2. Short-time storage

● Drive the machine once a week and at the same operate the working device to keep the machine under
ready-for-use status.

2.12.3. Long Time Storage

● 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.
● Parts which moisture can easily get in (such as: ventilating device and air filter) should be covered with a
clothes.
● The inflating pressure of the tyres must be standard. Check the wear and damage status of the tyres.
● 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’t not be jacked up, the inflation of the tyres must be checked every two weeks to ensure the tyre
pressure.
● 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.
● 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.

2.12.4. After an Extended Storage Time

29
● Remove all protecting coverings.
● Clean up the anti-rust grease on the exposed parts.
● Drain engine oil, gear box, and driving axle, and then wash them and refill with new oil.
● Drain out the debris and water from hydraulic oil tank and fuel tank.
● Charge the battery again and connect it to the wires.
● Adjust the inflation pressure of the tires in accordance with the road condition.
● Follow the checking procedures before operating.
● Warm up the engine.

2.12.5. Storage of tires

● 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 “No Entrance” should be settled.
● 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.
● Put tyres on the flat ground vertically, and fix them by means of wedges (figure 2-46) , so as to prevent them
falling down 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)

Wedge

Figure 2- 46
If wheel tyre is to fall down, get away from it, since the tyres of construction machinery
Warning are very heavy, and any attempt to hold it by hand will incur serious injury.

30
3.Maintenance

1
 Table of contents
3. Maintenance............................................................................................................................................................ 1
3.1.1. Recommended Lubricant And Oil..................................................................................................3
3.1.2. Special recommendation “XUG specialized oil”........................................................................... 4
3.1.3. Applicable air temperature for different oil product grades...........................................................4
3.1. Parts to be lubricated and lubricating schedule.......................................................................................... 5
3.2. Periodic Maintenance and Service Cycles..................................................................................................6
3.2.1. Periodic Maintenance and Service Instructions............................................................................. 6
3.2.2. Maintenance and service every 10h/day.........................................................................................6
3.2.3. Maintenance and service every 50h/week......................................................................................6
3.2.4. Maintenance and service every 100h/2 weeks............................................................................... 7
3.2.5. Maintenance and service every 250h/month.................................................................................. 7
3.2.6. Maintenance and service every 500h/2 months............................................................................. 7
3.2.7. Maintenance and service every 600h............................................................................................. 8
3.2.8. Maintenance and service every 1000h/6 months........................................................................... 8
3.2.9. Maintenance and service every 2000h/year................................................................................... 8
3.3. Inspection and adding of oil....................................................................................................................... 8
3.3.1. Notes about the oils........................................................................................................................ 8
3.3.2. Fuel oil............................................................................................................................................ 9
3.3.3. Hydraulic oil................................................................................................................................. 10
3.3.4. Brake fluid.....................................................................................................................................11
3.3.5. Gearbox oil................................................................................................................................... 12
3.3.6. Drive axle oil................................................................................................................................ 13
3.3.7. Engine oil...................................................................................................................................... 14
3.3.8. Engine cooling liquid....................................................................................................................15
3.4. Checking and Maintaining Components.................................................................................................. 17
3.4.1. Electrical system........................................................................................................................... 17
3.4.2. Maintenance for battery................................................................................................................17
3.4.3. Recharging.................................................................................................................................... 18
3.4.4. Drive Unit..................................................................................................................................... 18
3.4.5. Maintenance for Tyres.................................................................................................................. 18
3.4.6. Working device............................................................................................................................. 19
3.4.7. Braking system............................................................................................................................. 19
3.4.8. Air reservior.................................................................................................................................. 20
3.4.9. Air-conditioner (optional).............................................................................................................20
3.4.10. Others............................................................................................................................................22
3.5. Trouble and shootings...............................................................................................................................22
3.5.1. Power System............................................................................................................................... 22
3.5.2. Steering System............................................................................................................................ 23
3.5.3. Electrical System.......................................................................................................................... 25
3.5.4. Braking System.............................................................................................................................25
3.5.5. Working hydraulic system............................................................................................................ 26
3.6. Replacement of the key parts....................................................................................................................27

2
 3.1.1. Recommended Lubricant And Oil
Table 3- 1
Fuelling
Categories Names and designations Fuel quantity Notes
parts
0# light diesel oil Summer
Fuel -10# light diesel oil 300L Fuel tank Winter
-35# light diesel oil Extremely cold areas
Depending Weichai engine and Shangchai
CF-4 15W/40 heavy diesel
on specific engine
Engine oil
Engine oil engine
sump
CH-4 5W/40 heavy diesel configuration Winter and extremely cold areas
①

8# hydraulic drive oil

ZL50
45 L planetary Oil for cold
Including oil
8D hydraulic drive oil transmission temperature
for
Transmission regions(<-35℃)
transmission,
oil
8# hydraulic drive oil oil radiator,
ZF and pipeline
58 L Oil for cold
transmission
8D hydraulic drive oil temperature
regions (<-35℃)

L-HML46 hydraulic oil Conventional oil

Hydraulic oil 200 L Hydraulic
Oil used for extremely cold areas
L-HS32 hydraulic oil oil tank
(<-30℃)
GL-5 85W/90 Main drive Summer and winter
of the drive
Gear oil 2×27 L axle and Oil used for extremely cold areas
GL-5 75W/90
wheel-sided (<-30℃)
reducer
Pin rolls of working devices, pin rolls on front
Lubricating 2# extreme pressure and rear frames, universal joint pin and spline of
2.5kg
grease lithium-based lubricating grease all transmission shafts, the fan and pump joints
of the engine, and etc.
DOT4/HZY4 motor vehicle
Brake fluid 3kg Brake oil cup Dry-type drive axle
brake fluid

Antifreeze - No. 45 antifreeze About 45L Cooling system

3
 3.1.2. Special recommendation “XUG specialized oil”
Table 3- 2
Part Name
SN. Type No.
Chinese Name English Name

HYDRAULIC OIL FOR L-HML46 822537935

1 徐工专用液压油 LOADER GRADER MOTOR
SOIL STABILIZER SERRIES L-HS32 822537887

3 HIGH HYDRAULIC 6# 839901336

徐工专用高级液力传
4 RANSMISSION OIL FOR 8# 822502306
动油
5 XCMG 8D 822537936
VEHICLE HEAVY LOAD
7 GL-5 85W/90 822501215
GEAR OIL XCMG
徐工专用齿轮油
8 VEHICLE GEAR OIL XCMG GL-5 75W/90 822501189

CF-4 15W/40 822501230

9 徐工专用柴油机油 DIESEL OIL XCMG
CH-4 5W/40 822502587
10 徐工专用锂基脂 GREASE FOR XCMG 2# 822500105
11 徐工专用刹车油 BRAKE OIL FOR XCMG DOT4/HZY4 822538032

12 防冻液 ANTIFREEZE -45# 839903738

Notes:
①During the replacement of engine oil, the required volume of the diesel engine oil is 20L for Weichai
WD10G220E23/WD10G220E21 series and is 28L for Shangchai SC11CB220G2 engine. The oil trademark is as
below:
Conventional oil: CH-4 15W/40 heavy diesel or engine oil above the level;
Oil used for winter or extremely cold areas: CH-4 5W/40 heavy diesel.

Bleed the air from the axle brakes after the replacement with new axle or after the repair works related to the axle
brake pipeline.
* The above is for reference only, please select specific oil products according to the usage and maintenance
manual of the engine, gearbox and drive axles and in principle, lower-grade oil can be replaced with higher-grade
oil.
* Under special circumstances, select the oil products according to local air temperature environment or consult to
the factory.

3.1.3. Applicable air temperature for different oil product grades

Table 3- 3
Applicable Air Notes
Type Oil Grades
Temperature (℃)
Fuel 10# light diesel oil ≥12 GB 252
5#light diesel oil ≥8
0# light diesel oil ≥4
-10# light diesel oil ≥-5

4
 -20# light diesel oil ≥-14
-35# light diesel oil ≥-29
-50# light diesel oil ≥-44
Engine Oil Viscosity Grade 15W/40 heavy diesel -20~+40 GB 11122
Viscosity Grade 10W/40 heavy diesel -25~+40
Viscosity Grade 5W/40 heavy diesel -30~+40
Viscosity Grade 10W/30 heavy diesel -25~+30
Viscosity Grade 5W/30 heavy diesel -30~+30

3.1. Parts to be lubricated and lubricating schedule

Figure 3- 1

5
3.2. Periodic Maintenance and Service Cycles

3.2.1. Periodic Maintenance and Service Instructions

● Be sure to read and understand all safety information, warnings and instructions before carrying out
operation or maintenance measures.
● The user shall be responsible for the maintenance. During the maintenance, properly use or adjust all
the lubricating oil, oil and fluid, and oil filter and replace the normally worn or aging parts.
● Failure to comply with the proper periodic maintenance and service cycles and steps may lead to
degradation of performance and/or acceleration of parts wear.
● The maintenance and service cycles listed in this Manual is determined by general working time,
operating conditions and operating time totalizer or calendar (day, week or month), whichever occurs
first. Poor working conditions like dusty or damp environment will need more frequent lubrication and
maintenance than the required intervals.
● Periodic maintenance and service cycles is classified into 10, 50, 100, 250, 500, 1000, 2000 hours.
● During maintenance and service, all the maintenance items listed in the original requirements shall be carried
out repeatedly. For example, while performing the maintenance and service every 250h (month), the user shall
also carry out all the items listed in every 100h (2 weeks), 50h (week) and 10h (day) maintenance at the same
time.
● If the machine is used less frequently and is still far from the corresponding hours of using in the same
calendar period, at least the following provisions shall be complied with:
 Items listed in working period between 10h to 100h shall be conducted every 3 months.
 Items listed in working period between 250h to 500h shall be conducted every 6 months.
 Items listed in working period between 1000h to 2000h shall be conducted every year.

3.2.2. Maintenance and service every 10h/day

● Check the coolant level of radiator panel, and fill it up if necessary.
● Check the fuel and engine oil level, and fill it up if necessary.
● Check the brake fluid level in oil cup, and fill it up if necessary.
● Check the hydraulic fluid level, and fill it up if necessary.
● Check the operational performance of parking brake and service brake for normal condition.
● Check the movement of steering cylinder and steering wheel.
● Check the accelerator control and transmission control for reliability and flexibility.
● Open the discharge valve of the air reservoir to empty its water.
● Check the electrical system wiring and electrical components for normal operation.
● Apply grease to all lubrication points at working device and sway bracket pin according to instructions
identified on lubrication diagram.
● Check the hydraulic and brake system pipelines for leakage.
● Visually inspect all systems for abnormities and leakage.

3.2.3. Maintenance and service every 50h/week

● Conduct the maintenance and service every 10h at the same time
● Release the drain plug at the bottom of fuel tank to drain deposit and water.
● Check and fasten the attachment bolts of front and rear drive shaft.
6
● Check the transmission fluid level, and fill it up if necessary.
● Apply grease to all lubrication points at drive shaft, center pin, cab and steering pin etc., according to
instructions identified on lubrication diagram.
● Clean the filter element of breather at fuel tank, transmission and driving cylinder.
● If air conditioner is used, clean its strainer.
In addition, the followings shall be conducted for the first 50h:
● Replace engine oil (except for Shangchai engine)

3.2.4. Maintenance and service every 100h/2 weeks

● Conduct the maintenance and service every 10h and 50h at the same time
● Check the oil level of front and rear axle, and fill it up if necessary.
● Clean the air filter element.
● Clean the fueling filter of the fuel tank.
● Check and fasten the fixing bolts of rim and brake disc.
● Check the tire pressure (tire pressure under cold condition: front tire 0.38~0.40MPa, and rear tire
0.32~0.34MPa), inflate the tire if necessary.
In addition, the followings shall be conducted for the first 100h:
● Replace transmission fluid and transmission filter.
● Replace engine oil and oil filter element (Applicable Shangchai engine)

3.2.5. Maintenance and service every 250h/month

● Conduct the maintenance and service every 10h, 50h and 100h at the same time
● Adjust the fan belt tensity: depress one point between the generator pulley and fan belt with fingers (about 10
kg force), the tensioning deflection of normal belts shall be about 10-12 mm. Tighten the screw bolt and nut
firmly after adjustment.
● Replace engine oil.
● Replace engine oil element.
● Replace fuel filter element.
● Replace fuel preliminary filter element.
● Replace fuel fine filter element.
● Fasten the attachment bolts for front and rear axle, engine, transmission and frame.
● If air conditioner is used, clean its strainer.
In addition, the followings shall be conducted for the first 250h:
● Replace gear oil of front and rear axle.

3.2.6. Maintenance and service every 500h/2 months

● Conduct the maintenance and service every 10h, 50h, 100h and 250h at the same time
● Replace suction filter cotton of air conditioner.
● Replace breather filter element of hydraulic fluid tank.
● Check the wear conditions of the disc brake friction plates, replace if necessary.
● Check the fastening condition of the disc brake.
● Check the wear conditions of parking brake.
● Check the fastening condition of parking brake.
● Check and adjust the hand brake clearance.
● Check and fasten the attachment bolts for front and rear axle, engine, transmission and frame.
In addition, the followings shall be conducted for the first 500h:
● Replace the hydraulic return oil filter.
7
 3.2.7. Maintenance and service every 600h
● Conduct the maintenance and service every 10h, 50h and 100h at the same time
● Replace the planetary transmission oil, and clean the oil sump and oil filter.

3.2.8. Maintenance and service every 1000h/6 months

● Conduct the maintenance and service every 10h, 50h, 100h, 250h and 500h at the same time
● Replace the countershaft transmission oil and transmission oil filter element and clean the oil sump.
● Replace the oil filling strainer of the fuel tank.
● Replace the oil suction element of the fuel tank.
● Replace the gear oil of front and rear axle.
● Clean the fuel tank.
● Replace the brake booster oil.
● Check the clearance and wear conditions between every hinged joint and the cover.
● Replace the hydraulic return oil filter.

3.2.9. Maintenance and service every 2000h/year

● Conduct the maintenance and service every 10h, 50h, 100h, 250h, 500h and 1000h at the same time
● Replace the hydraulic oil, and clean the fuel tank and return oil filter.
● Replace the coolant liquid of radiator panel.
● Check the functional performance of the engine, transmission, front and rear axles.
● Carry out inspection of steering engine and steering valve under disassembled condition and calibrate the
steering angle.
● Check the leakproofness of the multi-way valve and operating fuel tank and measure the system working
pressure by testing the natural declining quantity of the operating fuel tank. If the declining quantity exceeds
up to double the specified value, carry out inspection of the fuel tank and distribution valve under
disassembled condition.
● Check the welding seams of the working devices and different frame parts for cracks and also check the
fastening condition of bolts and nuts.
● Check the weld seam and all forced parts of the rim and calibrate the deformation if any.
When the contents of this manual do not conform to the specialized operation
Caution instructions of parts and components which come with the machine, the specialized
operation instructions shall prevail.

3.3. Inspection and adding of oil

3.3.1. Notes about the oils

● Pay attention to fire because the fuel oil, the lubricant, the hydraulic oil and the antifreezing solution can be
fired by the open flame.
● Smoking and fire shall be prohibited in the area having oil.
● The places for adding or storing the fuel oil, the lubricant, the hydraulic oil and the antifreezing solution shall
be ventilated well.
● The covers of the containers for packing all fuel oil, lubricant, hydraulic oil and antifreezing solution shall be
screwed up tightly.
● The fuel oil, the oil of the torque converter, the hydraulic oil and all kinds of lubricants must be pure and in
8
 line with the quality requirements specified.
● The tools for filling the oil, the containers and the filling holes shall be wiped up in order to prevent the water
contaminants from entering into the oil.
● The engine shall be stopped when filling the fuel oil or the lubricant.
● The overflowing fuel oil, the lubricant, the hydraulic oil and the antifreezing solution shall be wiped up
immediately.
● The oils of different viscosities shall be taken in different ambient temperature; please use the oils in strict
accordance with the oil trademark mentioned.
● The liquid shall be packaged by the appropriate containers when replacing the parts, such as the cooling liquid,
the engine oil, the gearbox oil and the filter.
● The treatment of the wastewater shall be in line with the local laws and regulations for environment protection.
● Inspect whether oil leakage appears after refueling and replacement of the oil.
● If not otherwise specified, the machine shall be stopped on the flat floor when inspecting the oil level and
replacing the oil; and the bucket shall be placed on the floor flatwise, and the engine shall be stopped.
● The oil may be at high temperature; therefore the operators shall wear the protective equipments when
discharging the sundries and replacing the oil and operate carefully in order to protect the operators from
injuries.

3.3.2. Fuel oil

3.3.2.1. Inspect the oil level
● Method 1: open the power key switch if the LCD display Fuel gauge
screen of the instrument panel is equipped with the fuel
gauge, wherein the pointer of the fuel gauge should be
remained at the scale of 1/8
Figure 3- 2 Fuel gauge (optional) on instrumental
panel
● Method 2: the fuel oil shall be filled if the oil level
indicator is installed at the right corner of the fuel oil
tank and the level of the fuel oil is reduced to the
minimum oil level of the lower oil level indicator.(Figure
3- 3)

Figure 3-3 oil level indicator of the fuel oil tank

3.3.2.2. Discharge the sundries
● Discharge the water and the sundries accumulated in the
oil tank from the oil drainage flange at the bottom.
(Figure 3- 4)

Figure 3-4 Oil drainage flange of the fuel oil tank

9
● Unscrew the filling cover of the diesel tank and take out
and wash the filter element. (Figure 3- 5)

Figure 3-5 Filling strainer of the fuel oil tank

3.3.3. Hydraulic oil

3.3.3.1. Requirements to oil quality

Pollution grade of particles in hydraulic oil:—/20/17
The replacement interval of the hydraulic oil is 2,000h or 1
year, whichever comes first.

Oil refilling port

3.3.3.2. Complement oils Oil return filter
element cover plate
● Inspect the oil level indicator of the working oil tank,
wherein the oil level shall be remained at the place near Oil return filter
element
Ventilator filter
the middle scale of the oil level indicator; please element

complement the oil if the oil level is lower than the

bottom level of the oil level indicator, and the hydraulic
oil shall be complemented by means of the oil
complementing hole on the cover plate of the return oil
filter. (Figure 3-6)

Oil drainage plug

Figure 3-6 Filling hole and the oil level indicator

of the hydraulic oil tank

3.3.3.3. Replace the oil

● Clean the sundries in the bucket.
● Elevate the swing arm to the maximum height and incline the bucket maximally; and shut down the engine.
● Unscrew the oil drainage plug at the bottom of the oil tank when the oil is warm and discharge the sump oil.
● Operate the bucket control lever and overturn the bucket downward to the maximum position gradually by
virtue of the gravity; then operate the control lever of the swing arm to make the swing arm fall gradually and
discharge the oil in the cylinder completely.
● Dismantle the cover plate of the return oil filter and fill the hydraulic oil. (Figure 3-6)
● Fill the new oil from the return oil filter to the position specified in the middle of the oil level indicator; and
the oil cannot be filled into the oil tank directly after removing the oil hole filter.

10
● Start the engine and run it at idle speed; operate the swing arm gradually to elevate, wherein the
receiving/unloading of the bucket shall be implemented for 2-3 times respectively; then discharge the air in
the system by keeping the engine run at idle speed for 5min.
● Place the bucket on the floor flatwise and shut down the engine; and inspect the level of the hydraulic oil and
complement the oil to the position specified again.
Operations to the machine shall be implemented in accordance with
relevant safety specifications when replacing the oil; and pay attention to
Warning safety. Moreover, the hydraulic oil cannot be filled by dismantling the
breathing apparatus.
3.3.3.4. Discharge the sundries
● Inspect and discharge the water and settlements accumulated at the lower part of the oil tank every 1000h;
and the water and settlements accumulated can be discharged from the oil drainage plug at the bottom when
the whole machine is stopped for 2h.(Figure 3-6)
The nut on the top end of the breathing apparatus shall be unscrewed when
dismantling the hydraulic pipeline or connector connecting with the oil tank; and the
Notice compressed air in the oil tank shall be discharged completely by pressing the exhaust
valve; then the hydraulic pipeline or connector can be dismantled.
3.3.4. Brake fluid
● The brake fluid is contained in two brake fluid cups
(located in right stand, as shown in Figure 3-7).

3.3.4.1. Inspect the oil level

● Visually observe the brake fluid level. The height from
Figure 3- 7 Brake fluid cup
the level to the oil port shall be 15~25mm. Timely add if
insufficient.
It’s prohibited to mix the brake fluids of different trademarks or use a mineral oil as
Notice brake fluid.
3.3.4.2. Replacement with new brake fluid Bleeder
valve of
● Shift the gearshift joystick to neutral gear and apply the booster
parking brake.
● Remove the deposited dirt from the brake pipeline, fluid
reservoir, filler port, and bleeder valve of booster, and
bleeder valve of wheel caliper disc brake.
● Prepare an appropriate container, disassemble the
connecting nut between brake oil pipeline and brake
caliper, and drain the used brake fluid into the container.
● Clean the brake fluid cups and brake pipelines and then
Figure 3- 8
reinstall securely.
● Top up the brake fluid into the brake fluid cups.
● Start the engine, run the engine till the reading of brake
pressure gauge reaches 0.6-0.7MPa, and then stop the
engine.
● Attach one end of a transparent air bleeding pipe to the
air bleeder valve and place the other end into the oil

11
 container. (Figure 3-8)
● Loosen completely bleeder valve to bleed the air, depress
the brake pedal repeatedly for several times, and then
depress and hold the brake pedal, till no air bubble
overflows from the bleeder valve.
● Tighten the bleeder valve and release the brake pedal.
● While bleeding the air, observe the level in the brake
fluid cups and timely add the brake fluid to prevent the
re-ingress of air into the pipeline system.
● Add brake fluid to the fluid cups to the specified level.
3.3.5. Gearbox oil
The torque converter and the gearbox shall share the hydraulic pressure transmission oil to implement circulation,
and the oil mass shall be inspected strictly and replaced regularly.
3.3.5.1. Inspect the oil level
● Place the machine on the level ground, put the stop dogs
at the front and rear tires, put the gear shift lever in the
neutral position and pull up the parking brake;
● Start engine, make it in idle running for several minutes
and then shut down it.
● Open the oil checking plug above the filler port side of
Oil checking plug
the transmission. If the oil flows out slowly, it indicates
that the oil level is appropriate. If there is no oil flowing Figure 3- 9
out, add the transmission oil.(Figure 3- 9)
3.3.5.2. Replace the oil
● Place the machine on the level ground, put the stop dogs
Oil drainage plug
at the front and rear tires, put the gear shift lever in the
neutral position and pull up the parking brake;
● Start engine, make it in idle running for several minutes Figure 3- 10
and then shut down it.
● Open the drain plug on the bottom of the side of
gearbox, and use a vessel to hold it.(Figure 3- 10)
● Change the filter element of gearbox;
● After the oil is exhausted, clean up the greasy dirt around
the oil outlet of gearbox, clean out the sundries attached
on the drain plug, and re-twine the appropriate raw
material on the plug screw according to the screwing
direction of thread and then install it in the original
place.(Figure 3- 11)

Figure 3- 11

12
● Open the oil filler of gearbox on the side of rear frame,
inject the transmission oil according to the stipulated
code and volume, and then screw on the filler cap;
● Start the engine, make it in idle running for 5 minutes
and then re-examine the oil level of gearbox.(Figure 3-
12)

Figure 3- 12
3.3.6. Drive axle oil
3.3.6.1. Inspect the oil level
● Unscrew the main driving (examination) oil filler plug
on the axle housing. If the oil level is lower than the plug
outlet, it is appropriate; if it is not, the oil needs to be
supplied.(Figure 3- 13)
Figure 3- 13
3.3.6.2. Replace the oil
● Drive the machine on the level ground slowly, and make
the drain plug on the end face of wheel side of the front
drive axle in the lowest position.(Figure 3- 14)
● Shut down the engine, put the gear shift lever in the
neutral position and press the parking brake;
● Unscrew the drain plugs on the center bottom of axle
housing of the front drive axle and on the end faces of
sides of the two wheels to discharge the oil, and use a
vessel to hold it.
● After the oil is exhausted, screw on the drain plug on the
center bottom of axle housing of the front drive axle.
● Start the engine, pull up the parking brake, drive the
machine slowly, and make the arrow of the end face of
the wheel side of the front drive axle to point to the
direction of right below, and then shut down the engine,
put the gear shift lever in the neutral position, and last
press the parking brake;
● Unscrew the main driving (examination) oil filler plug Figure 3- 14
on the axle housing of the front drive axle and the plug
of view hole on the end of arrow of wheel side of both
end faces.
● Inject the new oil from the place of oil filler plug of
wheel side (examination) and oil filler plug of main drive
(examination) until the moment that the oil overflows
from the oil filler of main drive in the axle housing and

13
 the oil overflows from the view hole wheel side.
● Screw the five spout plugs mentioned above.
● Change the gear oil of rear drive axle according to the
above process.
3.3.7. Engine oil
3.3.7.1. Inspect the oil level
● Drive the machine on the level ground, shut down the
engine, put the gear shift lever in the neutral position and
press the parking brake.
● Pull out the dipstick on the side of engine body, infix its
head and then infix its whole body, and last pull out it for
examination.(Figure 3- 15)

Figure 3- 15
● The engine oil level shall be within the markings of
“FULL” and “ADD” on the stationary side of the oil
dipstick. if the oil level is too low, more oil shall be
added.(Figure 3- 16)
● Inspect whether the oil is polluted and whether there are
some sundries in the oil. If the oil is polluted excessively,
the oil shall be changed.

Figure 3- 16
The time to check the oil level must be before operation or after 15 minutes when the
Notice engine is shut down.
3.3.7.2. Replace the oil
● Place the machine on the level ground, put the stop dogs
at the front and rear tires, put the gear shift lever in the
neutral position and pull up the parking brake. If the
engine is not heated, start the engine and make it in idle
running, and when the oil temperature reaches to 20℃ to
40℃, shut down the engine.
● Open the drain plug of engine oil at the right front of fuel
tank of the engine, discharge the oil and use a vessel to
hold it.(Figure 3- 17)
● Change the oil filter.
● After the oil is exhausted, screw the drain plug.
● Inject the new stipulated oil from the oil filler on the left
posterior of engine. Figure 3- 17 Drain outlet of engine oil
● Start the engine keep it ticking over, and check whether

14
 the oil filter and drain plug leak.
● After about 15 minutes when shutting down the engine,
make the oil to flow circularly and sufficiently, and
re-check the oil level of engine.
3.3.8. Engine cooling liquid
3.3.8.1. Inspect oil level
● When the water temperature of engine is too high, firstly
check the cooling liquid level. If it is not enough, more
cooling liquid shall be added. At the same time, check
whether the radiator core is blocked and whether the tube
is damaged.
● Place the machine on the level ground, put the gear shift
lever in the neutral position, press the parking brake and
Figure 3- 18
shut down the engine. If the water temperature of engine
is high, wait the water temperature to drop to below
50℃.
● Observe the liquid level of expansion tank, which shall
be near the midline. If it not enough, more water shall be
added.
● Open the radiator cap from the view hole at the rear top
of the engine cover, and the cooling liquid level shall Figure 3- 19
reach to the bottom of filling neck of water tank of the
radiator; and complement the cooling liquid if it is not
enough. (Figure 3-18, Figure 3-19)
● After checking, fasten down the radiator cap to prevent
the cooling liquid from evaporating.

The radiator cap shall not be opened when the engine stops just for a moment or it is
running, if not, the hyper-thermal cooling liquid will spewing out and it is very dangerous.
Warning When opening the radiator cap, it shall be covered with a piece of cloth and shall be
opened slowly.

3.3.8.2. Change of antifreezing solution and

Fuel tank
internal clean of radiator
● Operate the engine for 1 to 1.5 hours under normal water
temperature (at least 85°C).
● Place the machine on the level ground, put the gear shift
lever in the neutral position, pull on the parking brake,
shut down the engine, and wait the water temperature to
drop to below 50℃.
● Firstly open the radiator cap, then switch on the water
drain valve on the bottom, and last switch off the water
drain valve after all antifreezing solution is Figure 3- 20
discharged.(Figure 3- 20)

15
● Fill the clean water into the cooling system to be the
normal water level.
● Start the engine, speed up the engine gradually, and
continue to make the engine in idle running for 5
minutes under the condition that the water temperature is
over 85°C.
● Shut down the engine, and discharge the cooling water
after the water temperature is below 50°C. If the
discharged water is still dirty, it shall be continued to
Figure 3- 21
wash until the clean water is discharged. Switch off the
water drain valve after all water is discharged.(Figure 3-
21)
● Fill antifreezing solution until the cooling liquid level
reaches to the bottom of filling neck of water tank (or
expansion tank) of the radiator.
● Start the engine, make the liquid level drops slightly, and
then shut down the engine and re-supply the antifreezing
solution.

Don’t use the detergent with corrosivity for the cooling system, or the aluminium
units will be damaged.
Warning The cooling liquid is poisonous, so it shall be avoided from touching children and
pets. If the cooling liquid is not continued to be used any more, is shall be treated
according to the local environmental protection regulations.

3.3.8.3. Notes
● The antifreezing solution is required to be the cooling liquid for the machine. When the machine leaves from
the factory, the antifreezing solution has been filled into the radiator. When the machine is operated under
normal conditions, the antifreezing solution is required. Don’t use rainwater, tap water or river water to
replace it, or the diesel engine or radiator will be damaged prematurely.
● When the temperature is under 0℃, the antifreezing solution may not be discharged. If under the urgent
situation, the antifreezing solution must be replaced with the ordinary water temporarily, all water drain
valves must be switched on to discharge all cooling water and to prevent the machine from being frosted
cracking.
● When the temperature is over 30℃, the engine shall be placed in the shady and cool place because it is easy
to overheat.
● After operation, in order to prolong the service life of engine, the engine must be operated at low speed for 5
minutes and shall be stopped after the water temperature drops.

16
3.4. Checking and Maintaining Components

3.4.1. Electrical system

● Only the qualified technician can service the electrical system.
● When adjusting the external power supply, please attach the
ground cable at last in order not to produce sparks around the
battery and cause an explosion. Please note that the ground
cable is from the regulator end to the starter end.
● Adjust the key of starter before service the electrical system.
● Before repairing the electrical system, remove the negative (-) Figure 3- 22
electrode of the battery to prevent the flowing of current.(Figure
3- 22)
● Electric circuits and fuses
 Check the circuit connectors for presence of looseness, check wire rubber insulations for presence of damage,
and check the fuses for secure and tight assembling. In event of dysfunction of any circuit, firstly check the
fuse of the circuit for burnout. During replacement of fuse, ensure to find out the burnout cause of the fuse
and further check for bulb burnout and circuit damage.
 The fuses are located within the cab. During replacement, please notice the capacities (amperes) on the fuse
tubes and clamps.
● Lamps and instruments
 Check the switches of all lamps for normal functioning. Thoroughly remove the dirt from the lamps.
 Press the horn button to check for normal sounding of horn.
 The pointers of the instruments shall be within green zone under normal status.
3.4.2. Maintenance for battery

● This battery is free of maintenance.

● Before operating about the battery, remember to stop the engine.
● Never get the lighted cigarette or flame close to the
battery.(Figure 3- 23)
● Open the battery compartment and check the battery surface.
Ensure that no electrolyte leaks out and there is no signs of
crack, strike and pollution.
● Check the working status of the battery ( there is an indicator Figure 3- 23
light on the battery):
-GREEN: meaning that the battery energy sufficient, and it can be
used normally.
-BLACK: meaning that the battery needs to be charged.
-WHITE: meaning that the battery has to be discarded as junk and be
replaced.
● Clean the battery compartment and the battery surface.
● Clean the electrodes of battery.
● Check the fastening for the battery.
● Avoid the touching of metal staffs (e.g: tools), which could cause short circuit to positive pole ( +) and
negative pole () of the battery.
● When installing the battery, fix the positive pole (+) first; when dismounting the battery, disconnect the
17
 negative pole () first.
● 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.
● Tighten the top cover of the battery.
3.4.3. Recharging

● 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.
● 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.
● 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.
● Connect the positive (+) clamping-terminal of the recharger with positive pole (+), and negative terminal ()
with negative pole (). And fasten their connection.
● If the recharging ratio is less than 1/10, then you have to make rapid-recharging and set it within the battery’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.
3.4.4. Drive Unit
● Break down the torque converter, transmission, drive axle main drive, and wheel reducer for checking after
2,000 working hours of the machine. During cleaning, check the drive system for presence of abnormal
“splash” or "creak" sound.
● During the replacement of this filter element, drain the internal impurities and oil dirt, disassemble the filter,
take out the filter element, replace with new filter element, and assemble the upper cover.
● Drive shaft
 Check the mounting bolts of connectors for looseness, check the vibration status of the shaft end, and check
spline part for looseness.
 During the disassembling and assembling of the drive shaft, notice the relative position of the universal joints
on two ends and ensure the aligned arrows during assembling.
● Wheels
 Check the tire inflation pressure as well as the tires surface for wear status.Look for any metal partials
embedded in tires. Check the mounting nuts on the wheel rims. Checking should be done while the machine
is cold. Normally the tire inflation pressure should be a little bit lower when machine operating in a sandy
area than when machine operating on hard-ground.
 After 2000 hours, check the welding seams on wheel rims and also check the parts which are loaded. Correct
any deformation that may occur to the case.
3.4.5. Maintenance for Tyres

● 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.
● 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’t attempt to reduce the tyres pressure. What you should
do is to reduce the machine traveling speed or just stop the machine to have the tyres cooling down. However,
18
 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.

Check if the locking ring is disengaged or not.

CAUTION
● When adjusting tyre pressure, keep away from the tyre
as far as possible. And you should always stand at the
back of the tyre.
● 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 Figure 3- 24
possibly reduce the risk of tyres explosion, since
Nitrogen doesn’t help combust but can prevent the
rubber oxidation and deterioration and avoid rust for
wheel hubs.
● 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.
● Check tyres and wheel hub. Don’t operate the loader
when the tyre pressure is very low. And also check if
there are any cracks or deformation on the tyres.
● Check the mounting screws and bolts on the wheels to
see if they are securely fastened as required by the
manufacturer.
● During checking the wheels, don’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.(Figure 3- 24)。
3.4.6. Working device

● 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. 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.
3.4.7. Braking system

● Disc brake: Check the wear status for the brake friction plate and carry out air-bleeding for the system
periodically.
● 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.
● Brake pedal:

19
 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.
 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.
● Booster pump: After working for 2000 hours , the booster pump should be dismantled and thoroughly
serviced.
● 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.
● Breather of afterburner cylinder: Turn on the cover of afterburner cylinder breather every week (should be
every day in dusty environment of long time operation). Take the filter element out for cleaning to avoid
danger of brake failure.
3.4.8. 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.
If the brake pad is worn to the maximum limit, the ineffective braking will be really
Notice dangerous. When the wear of the brake pad is closing to the limit, check the brake
pad more frequently.
3.4.9. Air-conditioner (optional)

● Only the professional technician can repair the air-conditioner.

● 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.
● 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 machine parts,
especially the parts with high temperature or any moving parts.
● 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.
● 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.
● 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.
● For soundly operating the air conditioner system, it is highly recommended to use “High”-gear for cooling
performance.
● 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 conditioner parts
from getting rusty due to long-term none-running.
● 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.
● During using the air conditioner, you should keep the cab doors and windows closed.

20
● During using the air conditioner, try not to always keep the temperature regulator at the maximum cooling
application while with fan blowing at low speed, otherwise, it will cause the evaporator to be frosted.
● Park the machine on a shadowy place in summer for avoiding the direct sunlight.
● Before running the air conditioner for heating performance, you should firstly let the engine run for a while.
Only after the engine water rises to 80℃ can you switch on the hot water valve and switch on the air
conditioner blower. If the ambient temperature is below 0℃, drain off the water inside the hose and radiator
to prevent water freezing, but water with anti-freezing agent inside the water tank is exceptional.
Maintenance
● 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 3-4)
Table 3- 4
Maintenance Interval
Maintenance Items Checking Methods Every Every Every Every Every
Day Week Month Quarter Year
Cooling agent Check the flowing condition
△
status through the watching hole.
Check the hoses for any
△
Cooling signs of cracks or damages. .
system Check that if each joint leaks
Pipes △
or not.
Check that if each clamp is
△
loose or damage or not.
Replace the cooling oil
(please use the oil with
Cooling oil △
correct brand as stated in the
manual.).
Compressor
Check the tension and wear
Belt △
of belt.
Compressor Check the bracket is reliable
△
bracket or not.
Check to see if it is clean
Condenser core △
and good or not.
Face side of Check if there is any foreign
Condenser △
condenser debris on the front side.
Condenser Check to see if the bracket
△
bracket get loose or not.
Evaporator Check that it is damaged or
△
bracket not.
Inlet of cycling Check that if the ventilation
Evaporator △
wind is good or not.
Check to see if the motor
Blow motor △
can work properly.
Check the coupler is ok or
Coupler △
Electrical not.
system Electromagne-tic Check that if it can work
△
clutch properly.

21
 Check that if it can work
Control switch △
properly.
3.4.10. Others
● 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.
● 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.
If leakage is hard to be found, stop the engine and clean the part that is to be checked, then restart the engine.

3.5. Trouble and shootings

3.5.1. Power System

Table 3- 5
Trouble Symptom Causes Remedies

1、 Gear has not been engaged.

1． Engage the gear.
2、 The oil amount in transmission system is
2． Replenish oil to regulated amount.
Engine is running but not enough.
3． Replace or repair the oil pump.
machine can’t drive . 3、 Transmitting oil pump is damaged and the
4． Check if the torque converter has
pressure gauge has no indication.
leakage or is damaged.
4、 Trouble occurs in torque converter.
1、 Valve pressure is adjusted improperly 1、 Adjust it to regulated value
2、 Clutch has serious oil leakage 2、 Replce the oil seal and its bracket .
Oil pressure for 3、 Gear-shifting valve restores to its original 3、 Check the valve return spring and if
gear-shifting is too position there is any debris in the cavity
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 Trouble No. 2.
Gear-shifting could
2、 Transmission pipeline is clogged . 2、 Dismantle and dredge it .
not be engaged.
3、 Clutch has serious oil leakage. 3、 See Trouble No. 2.
1、 Oil in the transmission system is
1、 Replenish the oil.
insufficient .
2、 See Trouble No. 2.
2、 Oil pressure for gear-shifting is too low .
3、 Check and adjust it .
3、 Braking system is adjusted improperly,
4、 When the oil temperature is over
The driving force is the brake clamp couldn’t be disengaged.
100℃, please stop the machine and
insufficient. 4、 The temperature in torque converter is too
check it .
high.
5、 Dismantle , clean and replace the
5、 The driving and driven clutch plates do
plate.
not engage correctly .
6、Check and adjust the rotating speed.
6、 The rotating speed of the engine is slow.
The gearbox and 1、 Oil is insufficient . 1、 Replenish oil.
torque converter get 2、 Clutch slips 2、 Check and repair the clutch and
22
overheated. 3、 Working time is too long. adjust its pressure.
3、Stop working to cool the machine.
Gear shifting is
1. Arrangement of gear is wrong. 1. Readjust and repair it .
disordered
3.5.2. Steering System
Table 3- 6
Trouble Symptom Causes Remedies
1. It is quite hard to make steering. Oil temperature being too low. Try to operate it again after oil
Wrong connection for oil temperature warming up.
pipelines of pilot-control oil Re-connect the oil pipelines correctly as
circuit. required.
Oil pipelines of pilot-control oil Clean the oil pipelines of pilot-control oil
circuit being blocked. circuit.
Pilot-control oil pressure being Adjust the overflow valve pressure, as
too low. required.
The mounting bolts on Turn the bolts to make them get loose a
fully-hydraulic steering little bit.
mechanism being fastened too
tight.
2.The steering wheel can still rotate There is something wrong with Check and make repairing for steering
after the machine steers to its max. steering limitation mechanism. limitation mechanism.
limitation.
3.Steering being unstable. The function of oil flow-control Check, repair or replace the flow-control
valve being unstable. valve.
4.Steering to left and right is quite Improper adjustment for the Adjust the spring pad correctly.
slow. spring of oil flow-control valve. Check, repair or replace the steering
Insufficient oil flow for steering pump.
pump. Adjust the pilot-control pressure or
The valve bar of flow change the spring.
amplifying valve does not move
to the end.
5.Steering to one side is quite quick The pads pieces, on both ends Adjust the pads pieces correctly as
and to other side is low. of the valve bar for oil flow required.
amplifying valve, are not
correct.
6.When steering resistant force is Very serious oil leakage from Check, repair or replace the sealing ring.
low, steering is all right, but when the valve seat of overflow valve Check, repair or replace the valve and
resistant force getting large, for main oil circuit. sealing ring.
steering gets slow( to both left and Very serious oil leakage from Adjust the steering system pressure.
right sides). shuttle valve.
Too low pressure for steering
system.
7.When steering resistance force is Different leakage between two
Check and repair or replace spherical
low, steering is all right, but when ends of spherical judgment
judgment valve and replace seal ring.
steering resistance gets large, it is valve

23
quick to make steering to one side
and slow to other side.
8.When turning the machine, the Oil flow-control valve doesn’t Check, repair or replace the oil
machine doesn’t make steering. work. flow-control valve.
Something wrong with Check and repair the overflow valve of
overflow valve of pilot-control pilot-control oil circuit.
oil circuit. Check and repair the overflow valve of
Something wrong with main oil circuit.
overflow valve of main oil
circuit.
9.The machine makes steering by The valve bar of flow Check, repair the valve bar and restore the
itself even without being operated amplifying valve could not spring to its original position.
by the operator. restore to its neutral position. Get the bolts a little bit loose.
The mounting bolts for flow Get the bolts a little bit loose.
amplifying valve are fastened Check, repair and replace the valve bar.
too tight.
The bolts on the cover of flow
amplifying valve are fastened
too tight.
Improper configuration for the
valve bar and its socket.
10.The steering-wheel turns by The valves set of hydraulic Clean away the foreign bodies.
itself even without being operated steering system is blocked. Replace the spring discs.
by the operator. The spring discs of the steering
system being broken.
11.The steering gets very quick The oil flow-control valve Adjust the valve pads as requested.
when the machine is traveling at being improperly adjusted. Check, repair or replace the valve bar.
high speed. The valve bar of oil flow Clean or replace the valve bar.
amplifying valve can’t move
freely.
The sockets for both ends of
valve bar of oil flow amplifying
valve being blocked or being
wrong position.
12.Loud sound from steering pump, There is air inside the steering Improve the sealing status of steering
and steering cylinder piston moving oil circuit. pump.
slowly. The steering pump gets worn Check, repair or replace the steering
down, with insufficient oil flow. pump.
Oil viscosity being thin. Change the hydraulic oil, as required.
Insufficient hydraulic oil level. Replenish with new oil, as instructed.
Pressure for overflow valve of Re-adjust the pressure value for overflow
main oil circuit is adjusted too valve.
low. Check and repair the hydraulic cylinder or
Serious oil leakage from replace the sealing ring.
steering cylinder.

24
 3.5.3. Electrical System
Table 3- 7
Trouble Symptom Causes 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.
3. Starting motor is damaged. 3. Repair or replace the starting motor.
It is hard to start the engine or
4. Poor wires connection. 4. Check and repair the starting wires.
the engine can’t be started at
5. Fuel oil way or the air way has 5. Check the fuel oil way or air way.
all.
breakdown.
6. The shift lever is not in neutral
6. Put the lever at neutral gear.
gear.
7. The fuse is broken. 7. Replace the fuse.
1. The starting key can’t restore to 1. Repair or replace the starting key.
its original position.
2. The electrical contactor for 2.Repair or clean the contactor.
Starting motor is always burnt
starting motor could not be well
down frequently.
disengaged due to somehow
adhension.
3. Starting circuit has shortcut. 3. Check and repair the starting circuit.
Wrong display of gauges 1. The wire connection gets loose 1. Fasten the wire connection.
or disconnected. 2. Replace the sensor.
2. The sensor being broken. 3. Replace the gauges.
3. Gauges being broken.
Warning buzzer keeps 1. The warning buzzer for 1. Please see the instruction manual of
sounding. monitoring gauge keeps the monitoring gauge.
sounding. 2. Check the braking loop.
2. Low braking Pressure. 3. Replace the air pressure sensor.
3. The air pressure sensor being 4. keep the pilot wire insulated.
broken.
4. The wire connection for the
warning buzzer being
short-circuit.
The bulbs don’t light. 1. The fuse is broken. 1. Replace the fuse.
2. The bulb is broken. 2. Change the bulb.
3. The wire connection gets 3. Fasten the wire connection.
disconnected.
The generator doesn’t work, or 1. The wire connection for the 1. Retighten the wire connection.
its current is too little or too engine gets loose. 2. Adjust the tension of the pulley belt.
much. 2. The pulley belt gets too loose. 3. Replace the generator.
3. The regulator or the generator
being broken.

3.5.4. Braking System

3.5.4.1. Air-assisted hydraulic brake
25
Table 3- 8
Trouble Symptom Causes Remedies
1、 Replace the seal ring.
2、 Bleed air out.
1、 There is oil leakage from braking plates.
3、 Chek air-compressor, oil-water
2、 There is air in braking hydraulic circuit.
Foot-braking separator, safety valve and sealing
3、 Low braking air pressure.
pressure is performance.
4、 Pressure booster gets worn.
insufficient. 4、 Replace the pressure booster
5、 Oil leaks onto braking plates from hub.
5、 Check or replace the hub sealing
6、 Braking plates wear out totally.
ring.
6、 Replace the braking plates.
1、 Braking valve is wrongly positioned .And the
piston rod is blocked and the spring fails to
The braking 1、 Check or replace the braking valve.
work or just is broken.
system could not 2、 Check or replace pressure booster.
2、 Pressure-booster works defectively.
be disengaged. 3、 Check or replace the sealing ring.
3、 Pump piston could not restore to its original
position.
Braking oil
1、 Poor sealing for pneumatic system. 1、 Check and repair the pneumatic
pressure gauge
2、 Air compressor can’t work well. system.
shows the
3、 Oil-drainage plug of the oil-water separator is 2、 Ccheck the air compressor.
pressure reading
not firmly tightened. 3、 Re-tighten the plug.
increases slowly.
There is not 1、 The gap between the braking drum and
1、 Make re-adjustment
enough power for braking plate is too large
2、 Clean the braking plate
hand brake. 2、 There is some oil on the braking plate.
3.5.4.2. Full hydraulic brake
Table 3- 9
Trouble Symptom Causes Remedies
1. There is still air inside the braking 1. Discharge the air
hydraulic pipelines. 2. Adjust it to 17.5MPa.
2. The adjusted pressure is too low
Foot-braking pressure is 3. The nitrogen pressure of accumulator is 3. Fill the nitrogen until the pressure
insufficient. too low. reach to 5MPa
4. The lead pump is damaged. 4. Repair or replace the pump.
5. The braking discs have been worn out 5. Replace the braking disc or oil seal.
or braking oil chamber leaks oil.
1. The position of braking valve rod is 1. Repair or replace the bake valve.
wrong, the piston rod is jammed or the
The braking device can’t
returning spring breaks down. 2. Replace the returning spring.
be disengaged soundly.
2. The returning spring of rim brake fail to
work.
1. Too much clearance between the 1. Make re-adjustment.
There is not enough
braking drum and braking discs. 2. Clean the braking discs.
power for hand brake.
2. There is oil on the braking discs.
3.5.5. Working hydraulic system

26
Table 3- 10
Trouble Symptom Causes Remedies
Insufficient power for 1. Oil sealing ring for cylinders wears out or gets
1. Replace the oil sealing ring.
raising the main boom, or broken. 2. Dismount the valve, and check
insufficient power for 2. The distribution valve wears too much, and the
and repair it, so as to have its
tilting bucket. valve clearance is out of its acceptable limit.
clearance be up to desired value,
3. There is oil leakage from hydraulic oil circuit.
or just replace the distribution
4. Severe inner oil leakage in the oil pump. valve with a new one.
5. Wrong adjustment for the safety valve, which
3. Figure out where oil leaks, and
causes the problem of low system pressure. eliminate the oil leakage problem.
6. The oil suction pipe and oil filter get blocked.
4. Replace the oil pump.
5. Reset the system pressure to
desired value.
6. Clean the oil filter and change
oil.
When the engine rotates 1. Please see details in No. (1) of this section. 1. Please see details in No. (1) of
at high speed, the bucket 2. The safety valve gets blocked deadly. this section.
or main boom raises quite 2. Dismount and check the
slow. safety valve.
Hydraulic oil gets mixed Hydraulic oil and transmission oil come together Replace the oil sealing ring, clean
with transmission oil. due to over-wearing and aging of the sealing ring the oil filter, and check to see if
for oil pump. the oil-suction pipe-lines get
deformed or cracked.

3.6. Replacement of the key parts

● 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
● 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.
● Repair or replace the damaged part right away without regarding to the schedule.
● When replacing a hose, please replace the O-ring and seal cushion at the same time.
● For replacing those key parts correctly, it is better to consult with XCMG or its agent. table 3- 11。

Table 3- 11 Key Parts Replacement List

Brake system
No. Key parts that need to be replaced periodically Quantity Replacement period
1 Hose(Oil-water separator combination valve――air 1
cylinder)
2 Hose(air cylinder---foot brake) 1
3 Hose(foot brake---booster pump) 1
4 Hose(Booster pump――Front axle) 1
Every two years or 4000
5 Hose(Booster pump――Rear axle) 1
hours (whichever is earlier)
6 Hose(foot brake――Hand brake) 2
7 Hose(Hand brake――Handbrake booster cylinder) 2
8 Hose(Hand brake――Power cutoff cylinder (when equipped 2
with planetary transmission)
9 Hose(Rear axle brake pipe) 2
27
 10 Air cylinder 1 Every three years
Note: Refer to Parts Catalog for the detailed list of materials.

Steering system
No. Key parts that need to be replaced periodically Quantity Replacement period
1 Hose(Steering device L/R――Left/right limit valve) 2
2 Hose(Left limit valve――Flow amplifying valve) 1
3 Hose(Right limit valve――Flow amplifying valve) 1
4 Hose(Pilot pump――Steering device P) 1
5 Hose(Steering device T――Limit valve T) 1
Every two years or 4000
6 Hose(Flow amplifying valve――Left steering cylinder) 1
hours (whichever is earlier)
7 Hose(Flow amplifying valve――Right steering cylinder) 1
8 Hose(Left steering cylinder――Right steering cylinder) 2
9 Hose(Left limit valveT――Right limit valveT) 1
10 Hose(Left limit valveT――hydraulic oil tank) 1
11 Hose(Steering pump――Flow amplifying valve) 1
Note: Refer to Parts Catalog for the detailed list of materials.

28
4. Product Information

1
 Table of contents
4. Product Information...................................................................................................................................... 1

4.1. Purpose...................................................................................................................................................3

4.1.1. Performance features......................................................................................................................3

4.1.2. Requirements For The Working Environment:..............................................................................3

4.2. Decals And Number...............................................................................................................................3

4.2.1. Product Nameplate......................................................................................................................... 3

4.2.2. Engine nameplate........................................................................................................................... 4

4.2.3. Other nameplates............................................................................................................................4

4.3. Overall dimensions of machine (standard configuration)......................................................................5

4.4. Main technical specification (standard configuration).......................................................................... 6

4.4.1. Overall dimensions.........................................................................................................................6

4.4.2. Performance Parameters.................................................................................................................6

4.5. Main technical specifications of non-standard attachments.................................................................. 8

4.5.1. Specification of optional linkage systems and double-circuit attachments for standard boom..... 8

4.5.2. Specification of optional linkage systems and double-circuit attachments for small
high-dumping boom...................................................................................................................................... 8

4.5.3. Specification of optional linkage systems and double-circuit attachments for large
high-dumping boom...................................................................................................................................... 9

4.5.4. Specification of optional triple-circuit attachments for standard boom.........................................9

4.6. Electric Schematic Diagram................................................................................................................ 10

4.6.1. Weichai + planetary transmission + dry axle............................................................................... 10

4.6.2. Shangchai + planetary transmission + dry axle............................................................................14

4.6.3. Shangchai + MYF200 electronic control transmission + dry axle...............................................18

4.7. Hydraulic Schematic Diagram.............................................................................................................22

4.7.1. Planetary transmission + dry axle + constant displacement pump.............................................. 22

4.7.2. MYF200 transmission + dry axle + constant displacement pump...............................................24

2
4.1. Purpose

4.1.1. Performance features

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.
This machine can be also equipped with other attachments to fulfill the corresponding specific operation.

4.1.2. Requirements For The Working Environment:

● Elevation:≤4000m
● Ambient temperature: -15℃～40℃

Note: This machine is a common purpose construction machinery, so it is not can be used in easy
burning, easy explosive, high dusty or poisonous environment.

4.2. Decals And Number

4.2.1. Product Nameplate

It’s fixed on the right vertical plate of

the front frame to indicate the
information including product model,
main parameters, product identification Figure 4- 1 Location of Product Nameplate
number, manufacture year, and
manufacturer.(Figure4- 1 and Figure
4-2)
For easy reference, please record the
code after the “Product identification
number (PIN)” in this nameplate to the
corresponding end place of the
Foreword of this manual.

Figure 4- 2 Example of Machine Nameplate (The

information varies depending on specific model)

3
4.2.2. Engine nameplate

It’s fixed on the right side of the engine

block to indicate the information
including engine parameters, emission,
and manufacturer. Figure 4- 3

Figure 4- 3 Location of Engine Nameplate

4.2.3. Other nameplates

On various main parts of the machine, the information including product type, manufacture number, and
manufacturer code is indicated by nameplate or stamping.

4
4.3. Overall dimensions of machine (standard configuration)

Figure 4-4 Diagram for Overall Dimensions of Machine under Standard Configuration

5
4.4. Main technical specification (standard configuration)

4.4.1. Overall dimensions

Parameter Name Parameter Values (mm) Notes

The bucket is put flat on the
Overall length 8225
ground.
Machine width 2850 Outside the wheels
Bucket width 3016
Overall height 3515 Cab roof
Axle base 3300
Wheel base 2250
Minimum ground clearance 440

4.4.2. Performance Parameters

Parameter Name Parameter Values (mm) Notes

Rated working load 5000kg
Standard bucket capacity 3 m3
Operating weight 17300±300kg
Forward/Reverse I Gear 11.5/16.5km/h Planetary
Maximum Forward II Gear 38km/h transmission
designed ForwardⅠ/Ⅱ/Ⅲ/ⅣGear 6.5/11/24/38 MYF200 electronic
speed control
ReverseⅠ/Ⅱ/Ⅲ/ⅣGear 6.5/11/24/38 transmission
Maximum grade ability 30°
Unloading angel 45°
Highest Primary bucket
Unloading Unloading height ≥3100mm
cutting-board
Position
Primary bucket
Unloading distance ≥1100mm
cutting-board
Bucket digging force 170 kN
The bucket is
Maximum digging depth 46mm
placed flat.
Boom lifting time ≤6

Total cycling time ≤10.5s

Minimum Outside of bucket 6910mm

turning
radius Tire center 5925mm

Machine steering angle ±38°

6
 Tire specification 23.5-25

Tire Front wheel 0.38~0.40MPa

inflation
pressure Rear wheel 0.32~0.34MPa

Note: The operating weight is Note: The operating weight is for the standard machine in the following condition:
appropriate amount of all kinds of lubricant, full tank of fuel, and an operator with a weight of 75kg.

7
4.5. Main technical specifications of non-standard attachments

4.5.1. Specification of optional linkage systems and double-circuit attachments for

standard boom

Parameter
No. Item (standard boom) 3.5 Sliding
2.5 bucket 2.8 bucket 4.0 bucket 4.5 bucket
bucket forks
1 Dumping reach (mm) 1110 1050 1210 1210 1250 1760
2 Dumping height (mm) 3100 3140 2980 2980 2950 3210
3 Dumping angle º 45 45 45 45 45 26
4 Breakout force 170 186 155 155 150 —
5 Bucket width (mm) 3000 3016 3016 3016 3170 2500
6 Rated load (kg) 5000 5000 5000 5000 5000 4500
Gross machine weight
7 17736 17280 17500 17730 17630 17080
(kg)
Overall machine length
8 8310 8165 8245 8245 8255 8455
(mm)

4.5.2. Specification of optional linkage systems and double-circuit attachments for

small high-dumping boom

Item(small Parameter
No.
high-dumping boom) 2.5 bucket 2.8 bucket 3.0 bucket 3.5 bucket 4.0 bucket 4.5 bucket
1 Dumping reach (mm) 1180 1130 1180 1300 1300 1330
2 Dumping height (mm) 3500 3550 3500 3390 3390 3360
3 Dumping angle º 41 41 41 41 41 41
4 Breakout force 158 166 156 148 146 140
5 Bucket width (mm) 3000 3016 3016 3016 3016 3170
6 Rated load (kg) 5000 5000 5000 5000 5000 5000
Gross machine weight 17900 17425 17465 17665 17890 17795
7
(kg)
Overall machine length 8665 8515 8575 8590 8590 8600
8
(mm)

8
4.5.3. Specification of optional linkage systems and double-circuit attachments for
large high-dumping boom

No. Item(Large high-dumping Parameter

boom) 2.5 bucket 2.8 bucket 3.0 bucket 3.5 bucket 4.0 bucket
1 Dumping reach (mm) 1210 1140 1190 1300 1300
2 Dumping height (mm) 3730 3780 3730 3620 3620
3 Dumping angle º 43 43 43 43 43
4 Breakout force 169 186 175 150 148
5 Bucket width (mm) 3000 3016 3016 3016 3016
6 Rated load (kg) 4500 4500 4500 4500 4500
7 Gross machine weight (kg) 18423 18155 18195 18395 18525
8 Overall machine length 8935 8785 8845 8865 8865
(mm)

4.5.4. Specification of optional triple-circuit attachments for standard boom

Parameter
Staggere Staggere
Item (standard V-shaped Interchangeable
No. Paired d clamp d clamp V-shaped Bale Snow
boom) clamp staggered
clamp (split (split clamp grab plough
for ports clamp
type) type)
Holding circle
1 1000 430 100 450 850 1470 130 /
diameter (mm)
Dumping
2 1820 1845 1660 1845 1900 2050 1730 /
reach (mm)
Dumping
3 3160 3230 3120 3230 3000 3200 3150 /
height (mm)
Dumping
4 30 30 30 30 35 20 30 /
angle º
Attachment
5 2198 2356 2458 2356 1900 2580 2500 3800
width (mm)
Rated load
6 5000 5000 5000 5000 5000 4500 5000
(kg)
Gross machine
7 17630 17593 17500 17873 17673 18235 17400 18235
weight (kg)
Overall
8 machine 8575 8525 8425 8525 8725 8710 8465 8580
length (mm)

9
4.6. Electric Schematic Diagram

4.6.1. Weichai + planetary transmission + dry axle

Figure 4- 5

10
Figure 4- 6
11
Figure 4- 7

12
Figure 4- 8
13
4.6.2. Shangchai + planetary transmission + dry axle

Figure 4- 9

14
Figure 4- 10

15
Figure 4- 11
16
Figure 4- 12

17
4.6.3. Shangchai + MYF200 electronic control transmission + dry axle

Figure 4- 13

18
Figure 4- 14
19
Figure 4- 15
20
Figure 4- 16
21
4.7. Hydraulic Schematic Diagram

4.7.1. Planetary transmission + dry axle + constant displacement pump

Figure 4- 16 Double-Circuit

22
Figure 4- 17 Triple-Circuit

23
4.7.2. MYF200 transmission + dry axle + constant displacement pump

Figure 4-18 Double-Circuit

24
Figure 4-18 Triple-Circuit

25
5. Appendix

1
 Table of contents
5. Appendix....................................................................................................................................................1
5.1. List of maintenance parts...............................................................................................................3
5.1.1. List of Maintenance Parts for Standard Configuration (Weichai WD10 series engine,
planetary transmission, and dry axle)................................................................................................3
5.1.2. List of Maintenance Parts for Standard Configuration (Shangchai SC11CB220G2B1
series engine, planetary transmission, and dry axle).........................................................................4
5.1.3. List of Maintenance Parts for Standard Configuration (Shangchai SC11CB220G2B1
series engine, MYF200 electronic control transmission, and dry axle)............................................5
5.2. Introduction of spare parts center..................................................................................................7

2
5.1. List of maintenance parts
5.1.1. List of Maintenance Parts for Standard Configuration (Weichai WD10 series engine, planetary transmission, and

dry axle)
Code of
No. Description of material Quantity Remark
material
Clean when the air filter maintenance indicator turns red and
1 860131611 612600114993 Air fine filter 1
replace after 5 cleaning cycles
2 860133763 1000602934 Engine oil filter element 2 50 hours for the first time and per 250 hours later
Change it per 250 hours or per 1 month, and the earlier expired
860118457 1000588583 Fuel filter element 1
time shall prevail.
3
Change it per 250 hours or per 1 month, and the earlier expired
860119766 1000424916 Fuel filter element 1
time shall prevail. (water cold filter element)
Change it per 250 hours or per 1 month, and the earlier expired
4 860133745 1000422382 Fuel fine filter element 2
time shall prevail.
For planetary transmission, 100h for the first time and afterwards
5 860125403 ZL40.3.200C Torque converter filter 1
once every 600h.
6 803086817 ZPAG2X Hydraulic oil tank ventilator filter element 1 Change per 500 hours

7 803164329 XGHL7-700×10 Hydraulic oil return filter 1 500 hours for the first time and per 1000 hours later
Change it per 1000 hours or per 6 months, and the earlier expired
8 803164217 Fuel tank filler filter screen 1
time shall prevail.
Change it per 1000 hours or per 6 months, and the earlier expired
9 803164228 WU-16X100-J Fuel tank suction filter element 1
time shall prevail.
10 800987420 XG-1201014 Booster cylinder air filter element 1 Clean once every 50h or weekly.

11 803588719 1001330509 Air return filter screen 1 Clean once every 250h or monthly.

12 803588207 1001203946 A/C suction filter cotton 1 Change it per 500 hours or per 2 months
13 803588203 1001156572 A/C filter screen 1 Clean once every 50h or weekly.
14 822502297 CF-4 15W-40 diesel engine oil (summer) 20L 50 hours for the first time and per 250 hours later
CH-4 5W-40 Diesel engine oil(For winter and low
15 822502587 20L 50 hours for the first time and per 250 hours later
temperature regions)
3
 16 839901336 6# hydraulic drive oil(Summer) 45L 100 hours for the first time and per 600 hours later
8# hydraulic drive oil(Winter and low temperature
17 822502306 45L 100 hours for the first time and per 600 hours later
regions)
8D hydraulic drive oil(Extremely low temperature
18 822537936 45L 100 hours for the first time and per 600 hours later
regions)
85W 90 GL-5 Heavy-duty gear oil(Summer and
19 822501215 2×27L 250 hours for the first time and per 1000 hours later
winter)
75W 90 GL-5 Heavy-duty gear oil (low temperature
20 822501189 2×27L 250 hours for the first time and per 1000 hours later
regions)
Fixed volume, replace once every 2,000h or yearly (whichever
21 822537935 L-HML46 hydraulic oil
comes first).
200L
Fixed volume in extremely low temperature regions, replace once
22 822537887 L-HS32 hydraulic oil
every 2,000h or yearly (whichever comes first).

5.1.2. List of Maintenance Parts for Standard Configuration (Shangchai SC11CB220G2B1 series engine, planetary

transmission, and dry axle)

Code of
No. Description of material Quantity Remark
material
Clean when the air filter maintenance indicator turns red and
1 860113056 2640x-2 Air fine filter 1
replace after 5 cleaning cycles
2 860109878 D17-002-02+b Engine oil filter element 2 100 hours for the first time and per 250 hours later
Change it per 250 hours or per 1 month, and the earlier expired
3 860113017 D638-002-02 Fuel fine filter 1
time shall prevail.
Change it per 250 hours or per 1 month, and the earlier expired
4 860125383 D00-305-03+a Water filter(Fuel strainer) 1
time shall prevail.
For planetary transmission, 100h for the first time and afterwards
5 860125403 ZL40.3.200C Torque converter filter 1
once every 600h.
ZPAG2X Hydraulic oil tank ventilator filter
6 803086817 1 Change per 500 hours
element
7 803164329 XGHL7-700×10 Hydraulic oil return filter 1 500 hours for the first time and per 1000 hours later
Change it per 1000 hours or per 6 months, and the earlier expired
8 803164217 Fuel tank filler filter screen 1
time shall prevail.
Change it per 1000 hours or per 6 months, and the earlier expired
9 803164228 WU-16X100-J Fuel tank suction filter element 1
time shall prevail.
4
 10 800987420 XG-1201014 Booster cylinder air filter element 1 Clean once every 50h or weekly.
11 803588719 1001330509 Air return filter screen 1 Clean once every 250h or monthly.
12 803588207 1001203946 A/C suction filter cotton 1 Change it per 500 hours or per 2 months
13 803588203 1001156572 A/C filter screen 1 Clean once every 50h or weekly.
14 822502297 CF-4 15W-40 Diesel engine oil(Summer) 28L 50 hours for the first time and per 250 hours later
CH-4 5W-40 Diesel engine oil(Winter and low
15 822502587 28L 50 hours for the first time and per 250 hours later
temperature regions)
16 839901336 6# hydraulic drive oil(Summer) 45L 100 hours for the first time and per 600 hours later
8# hydraulic drive oil(Winter and low temperature
17 822502306 45L 100 hours for the first time and per 600 hours later
regions)
8D hydraulic drive oil(Extremely low temperature
18 822537936 45L 100 hours for the first time and per 600 hours later
regions)
19 822501215 85W 90 GL-5 Heavy-duty gear oil(Summer and winter) 2×27L 250 hours for the first time and per 1000 hours later
75W 90 GL-5 Heavy-duty gear oil (low temperature
20 822501189 2×27L 250 hours for the first time and per 1000 hours later
regions)
Fixed volume, replace once every 2,000h or yearly (whichever
21 822537935 L-HML46 hydraulic oil
comes first).
200L
Fixed volume in extremely low temperature regions, replace once
22 822537887 L-HS32 hydraulic oil
every 2,000h or yearly (whichever comes first).

5.1.3. List of Maintenance Parts for Standard Configuration (Shangchai SC11CB220G2B1 series engine, MYF200

electronic control transmission, and dry axle)

Code of
No. Description of material Quantity Remark
material
Clean when the air filter maintenance indicator turns red and
1 860113056 2640x-2 Air fine filter 1
replace after 5 cleaning cycles
2 860109878 D17-002-02+b Engine oil filter element 2 100 hours for the first time and per 250 hours later
Change it per 250 hours or per 1 month, and the earlier expired
3 860113017 D638-002-02 Fuel fine filter 1
time shall prevail.

5
 Change it per 250 hours or per 1 month, and the earlier expired
4 860125383 D00-305-03+a Engine fuel strainer 1
time shall prevail.
For MYF transmission, 100h for the first time and afterwards once
5 860126438 PYQ-142 Filter element 1
every 1000h.
6 803086817 ZPAG2X Hydraulic oil tank ventilator filter element 1 Change per 500 hours
7 803164329 XGHL7-700×10 Hydraulic oil return filter 1 500 hours for the first time and per 1000 hours later
Change it per 1000 hours or per 6 months, and the earlier expired
8 803164217 XCXZX-LW7701 Fuel tank filler filter screen 1
time shall prevail.
9 803164228 WU-16X100-J Fuel tank suction filter element 1 Change it per 1000 hours or per 6 months
10 800987420 XG-1201014 Booster cylinder air filter element 1 Clean once every 50h or weekly.
11 803588719 1001330509 Air return filter screen 1 Clean once every 250h or monthly.
12 803588207 1001203946 A/C suction filter cotton 1 Change it per 500 hours or per 2 months
13 803588203 1001156572 A/C filter screen 1 Clean once every 50h or weekly.
14 822502297 CF-4 15W-40 Diesel engine oil(Summer) 28L 50 hours for the first time and per 250 hours later
CH-4 5W-40 Diesel engine oil(Winter and low
15 822502587 28L 50 hours for the first time and per 250 hours later
temperature regions)
16 839901336 6# hydraulic drive oil(Summer) 45L 100 hours for the first time and per 600 hours later
8# hydraulic drive oil(Winter and low temperature
17 822502306 45L 100 hours for the first time and per 600 hours later
regions)
8D hydraulic drive oil(Extremely low temperature
18 822537936 45L 100 hours for the first time and per 600 hours later
regions)
19 822501215 85W 90 GL-5 Heavy-duty gear oil(Summer and winter) 2×27L 250 hours for the first time and per 1000 hours later
75W 90 GL-5 Heavy-duty gear oil (low temperature
20 822501189 2×27L 250 hours for the first time and per 1000 hours later
regions)
Fixed volume, replace once every 2,000h or yearly (whichever
21 822537935 L-HML46 hydraulic oil
comes first).
200L
Fixed volume in extremely low temperature regions, replace once
22 822537887 L-HS32 hydraulic oil
every 2,000h or yearly (whichever comes first).

6
5.2. Introduction of spare parts center
The Spare Parts Center of XCMG Construction Machinery Co., Ltd. is the responsible sales department for all types of
product spare parts under various business units and is full-time responsible for the sales and management of spare parts for
the products, including XCMG loaders, forklift loaders, skid-steer loaders, and backhoe loaders, both home and abroad. All
spare parts under operations of this center are of genuine XCMG parts or genuine imported parts. At present, with a storage
area of more than 10,000m2, this center stores more than 20,000 types of spare parts equivalent to a value of RMB
50,000,000.
This center is currently located at the intersection between Xuzhou-Shangqiu Road and West 3rd Ring Road (No. 58,
Kuangshan West Road, Xuzhou, Jiangsu, China). With first-class storage conditions, advanced SAP computer information
management system, complete sales supply, storage, and shipping system, and experienced spare parts engineer team, this
center can also provide the technical consultation, training and guidance, and operation planning of spare parts to the
customers in addition to the supply of spare parts to the customers both home and abroad.

Exterior of Spare Parts Center Warehouse Interior of Spare Parts Center

First-Class Quality

Special Package of Spare Parts Special Mark of Spare Parts